Ford Fusion Hybrid Workshop Repair and Service Manual

2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid
Workshop Manual
Quick Links
Introduction
Master DTC Chart
Specifications
Metrics
Torque Wrench Adapter Formulas
Acronyms
Alphabetical Index
Table of Contents
1: General Information
00: Service Information
2: Chassis
04: Suspension
05: Driveline
06: Brake System
11: Steering System
3: Powertrain
03: Engine
07: Automatic Transmission
08: Manual Transmission, Clutch and Transfer Case
09: Exhaust System
10: Fuel System
4: Electrical
12: Climate Control System
13: Instrumentation and Warning Systems
14: Battery and Charging System
15: Audio Systems
17: Lighting
18: Electrical Distribution
19: Electronic Feature Group
5: Body and Paint
01: Body
02: Frame and Mounting
SECTION 100-00: Service
Information
2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop
Manual
DESCRIPTION AND OPERATION Procedure revision date: 04/30/2012
Symbols Glossary
Symbols are used inside the graphics and in the text area to enhance the information.
Movement Symbols
Movement symbols provide detailed information to a required component movement. These component
movements can be rotational or 1-3 dimensional movements.
Item Description
1 Minor component movement clockwise or counterclockwise
2 Major component movement clockwise or counterclockwise
3 Component movement to the left, right, up, or down
4 Component movement towards or away
5 3 dimensional component movement
6 2 dimensional component movement
7 3 dimensional component rotation
8 3 dimensional component cycling
Turn Symbols
Turn symbols are used to provide further information on the direction or angle of component turns.
2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop Manual
Symbols Glossary 1
Item Description
1 Turn the component clockwise through 45
2 Turn the component counterclockwise through 45
7 Turn the component clockwise through 2 complete turns
8 Turn the component counterclockwise through 2 complete turns
Steering Wheel Symbols
Steering wheel symbols are used to provide further information to a required steering wheel position or
steering column lock status.
Symbols Glossary 2
Item 1 Steering wheel in straight ahead position
2 Steering column locked
3 Steering column unlocked
4 Rotate steering wheel 90 left from center
5 Rotate steering wheel 90 right from center
6 Turn steering wheel fully counterclockwise to stop
7 Turn steering wheel fully clockwise to stop
Body Types
Body type symbols are used to identify different body configurations.
Symbols Glossary 3
Item Description
1 3, 4, 5-door body style
2 Wagon body style
3 Sport Utility Vehicle (SUV) body style
4 Coupe body style
5 Convertible body style
6 Van body style
7 3, 4, 5-door body style - Top View
8 Wagon body style - Top View
9 Underbody view
10 Right-hand drive (RHD) vehicle
11 Left-hand drive (LHD) vehicle
Gearshift Lever Position Symbols
Gearshift lever position symbols are used to show the gear position required for the procedure.
Symbols Glossary 4
Item Description
1 Set the selector lever to the park (P) position
2 Set the selector lever to the reverse (R) position
3 Set the selector lever to the neutral (N) position
4 Set the selector lever to the drive (D) position
5 Set the selector lever with manual shift option to the drive (D) position
6 Set the selector lever with manual shift option to the manual (M) position
7 Set the selector lever with manual shift option to the shift down (-) position
8 Set the selector lever with manual shift option to the shift up (+) position
9 Set the manual shift lever to the neutral (N) position
10 Set the manual shift lever to indicated gear position (all possible gears shown here)
Screwdriver Symbols
The screwdriver symbols are used to indicate which screwdriver bit is required for the procedure step.
Symbols Glossary 5
Item Description
1 Screwdriver
2 Phillips or cross-bladed screwdriver
3 Flat-bladed screwdriver
4 Hexagonal or Allen screwdriver
5 TORX screwdriver
Plier Symbols
The plier symbols are used to indicate which plier is required for the procedure step.
Symbols Glossary 6
Item Description
1 Combination pliers
2 Side cutter pliers
3 Internal snap-ring pliers
4 External snap-ring pliers
5 Hose clamping pliers
6 Locking pliers
7 Long or Needle-nosed pliers
Drilling and Threading Tool Symbols
The drilling or threading tool symbols are used to indicate which type and size drill, thread-cutting device, or
file is required for the procedure.
Symbols Glossary 7
Item Description
1 Drill bit with a specified diameter
2 Hole saw with a specified diameter
3 Stepped drill bit using a specified step diameter
4 Tap with a specified diameter
5 Die with a specified diameter
6 File or de-burring tool for circular holes
7 File or de-burring tool
Cutting Tool Symbols
The cutting tool symbols are used to indicate which type of cutting tool is used for the procedure.
Symbols Glossary 8
Item Description
1 Box-cutter or cutting knife
2 Pneumatic body saw
3 Scissors
4 Grinder
5 Jig saw
6 Plasma cutter
7 Sanding block or paper
8 Drill through the indicated number of body layers with the specified diameter drill bit
9 Drill through the indicated number of body layers with an appropriate size drill bit
10 Drill through first body layer with the specified diameter drill bit
11 Drill through first body layer with an appropriate size drill bit
12 Wire brush
Apply Chemicals, Lubricants, or Clamping Load Symbols
The apply chemicals, lubricants or clamping load symbols are used to direct the application of chemicals,
lubricants, or loads for the procedure.
Symbols Glossary 9
Item Description
1 Apply a bead from the specified tube
2 Apply a bead from the specified cartridge
3 Apply the specified chemical with a brush
4 Apply the specified clamping load to the specified component
5 Apply the specified diameter bead from the specified tube
6 Apply the specified diameter bead from the specified cartridge
7 Apply the specified chemical with a roller
8 Apply hot glue to the specified component
9 Apply the specified amount of fluid
10 Apply the fluid
11 Clean the specified component with the specified material
12 Apply a broken bead of the specified diameter
13 Apply the specified chemical with a spray can
14 Apply the specified lubricant to the specified component
15 Spot weld the specified component
16 Apply a continuous line of weld to the specified component
17 Apply the fluid with a syringe
18 Extract the fluid with a syringe
Measurement Symbols
Symbols Glossary 10
The measurement symbols are used to show which measurement will be made at a specified point.
Item Description
1 Measure the amperage using a digital multimeter
2 Measure the voltage using a digital multimeter
3 Measure the resistance using a digital multimeter
4 Measure the length or distance
5 Check that the specified pressure is available using a suitable pressure gauge
6 Measure the pressure at the specified port using a suitable pressure gauge
7 Measure the time with a stopwatch
8 Wait for the indicating amount of time
9 The minimum temperature for the specified task
10 The maximum temperature for the specified task
11 The allowable temperature range for the specified task
12 The required temperature for the task
13 Measure for the specified movement
14 Measure for movement not to exceed specified amount
15 Measure for the miniumum-specified movement
General Equipment Symbols
The general equipment symbols specify which general equipment is used to carry out the procedure.
Symbols Glossary 11
Item Description
1 Hot air gun
2 Soldering iron
3 Putty knife or scraper
4 Awl or scriber
5 Hold-down or securing strap
6 File with specified size
7 Center punch
8 Marker
9 Metal Inert Gas (MIG) welder
10 Hose clamp
11 Trim tool
12 Shop vacuum
13 Strap wrench
14 Wedge
15 Pin punch
Material Symbols
The material symbols are used to indicate where to use the specified material.
Symbols Glossary 12
Item Description
1 Remove or install a pop-rivet
2 Apply tape to specified area
3 Remove or install a cable tie
Miscellaneous Symbols
These symbols provide miscellaneous information required for the procedure.
Item Description
Symbols Glossary 13
1 Turn Ignition off
2 Turn Ignition on (run position)
3 This procedure requires the specified number of technicians
4 Respirator or self-contained breathing apparatus
5 Prohibited action used in combination with another symbol
6 Do not use power tools
7 Visual inspection
8 Noise check
9 Dispose the specified component
10 Dispose the specified component
11 Set engine speed to the specified RPM
12 Firmly apply the parking brake
13 Fully release the parking brake
14 Special disposal required
15 Visually inspect using a mirror
16 Area or component must be dry
Mandatory Protective Equipment
The protective equipment symbols indicate required safety equipment to avoid or reduce health and safety
risks.
Item Description
1 Wear protective gloves
2 Wear face shield
3 Wear safety goggles
Symbols Glossary 14
4 Wear ear protection
5 Wear safety goggles and ear protection
6 Wear a respirator
Prohibition Symbols - Health, Safety, and Component Care
The prohibition symbols are used to prohibit specified actions to avoid safety hazards or component damage.
Item Description
1 Prohibited action used in combination with another symbol
2 No open flames
3 No smoking
4 No water
5 Do not touch
6 Do not switch
7 No grinding
Warning Symbols - Health and Safety Warnings or Component Care
The warning symbols are used to avoid hazardous conditions and to avoid component damage.
Symbols Glossary 15
Item Description
1 Hazardous voltage or Electrical shock or Electrocution danger
2 Fire hazard or highly flammable
3 Burn hazard or hot surface
4 Device has automatic start-up
5 Toxic
6 Explosive material
7 Battery hazard
8 Corrosive material
9 Lifting hazard
10 Hand crush or force from above hazard
11 Cutting of fingers or hand hazard
12 Pressure hazard
13 Invisible laser radiation. Do not view directly with optical instruments (magnifiers). Class 1M laser
product.
System Diagram Symbols
The symbols provide Information about networks or wiring.
Symbols Glossary 16
Item Description
1 Medium Speed Controller Area Network
2 High Speed Controller Area Network
3 Local Interconnect Network
4 Wires cross but are not connected
Symbols Glossary 17
Symbols Glossary 18
Information
Manual
Using This Manual
Introduction
This manual describes and directs repair procedures for this vehicle model year. It includes diagnostics for all
vehicle systems except driveability and emission control. Refer to the separate Powertrain Control/Emissions
Diagnosis (PC/ED) manual for driveability and emission control diagnostics.
Information is organized into groups, with sections that have subsections dividing them.
Warnings, Notices, and Notes in This Manual
Warnings provide information to avoid personal injury and to make sure service actions on critical safety
systems are performed correctly.
Notices provide information to avoid damage to the vehicle or a component.
Notes provide information critical for a complete and effective repair.
Warnings that apply to an entire system or workshop manual section are located in section 100-00 Description
and Operation Safety Warnings .
Warnings, Notices, or Notes that apply to an entire procedure will be placed at the beginning of the procedure.
Warnings, Notices, or Notes that apply to a single step are placed at the beginning of the step. Those that
apply to a group of steps will be placed at the first step requiring it.
Vehicle and Engine Orientation Identifiers
LH and RH vehicle designations are oriented from the driver's seat position looking forward. LH and RH
engine designations are oriented from the flywheel position looking towards the crankshaft pulley.
How to Use Diagnostic Information
DTC and Symptom Charts
Module DTC Charts are used to begin and direct the diagnosis of a DTC. Symptom Charts contain concern
symptoms and direct solutions either in the chart or in a linked Diagnostic Routine. Both DTC and Symptom
Charts may provide the solution within the chart, or provide a link to the appropriate Diagnostic Routine.
In some sections, the Symptom Chart is preceded by a Preliminary Inspection which must be followed prior to
using the Symptom Chart
Using Module DTC Charts
This Workshop Manual contains diagnostics for DTCs set by vehicle modules. Driveability and emission
DTCs are covered in the separate Powertrain Control/Emissions Diagnosis (PC/ED) manual. If a PCM-set
DTC is not listed in the Workshop Manual, it is serviced in the Powertrain Control/Emissions Diagnosis
(PC/ED) manual.
Using This Manual 19
DTC diagnostics are found in both on-line and printed publications and are used as follows:
On-line publications: Using the left side menu, click on the Master DTC Chart link to view the
vehicle module DTC charts. Each module has a chart with links or in-chart solutions for all DTCs
diagnosed in the Workshop Manual.

Printed publications: Use the DTC index in the rear of the book.
Diagnostic Methods
Diagnostic Methods provides information to support diagnosing Ford vehicles. Diagnostic strategies,
diagnostic tool support information, and advanced circuit testing methods are included. REFER to Diagnostic
Methods .
Diagnostic Routines
Diagnostic Routines provide information to determine the root cause of concerns addressed in either a DTC
Chart or Symptom Chart. Each Diagnostic Routine contains:
Diagnostic Overview
Wiring Diagram References (as applicable)
Normal Operation and Fault Conditions
Visual Inspection and Diagnostic Pre-checks

Tool Table (as applicable)
Material Table (as applicable)
Pinpoint Test Steps
Component Tests
Component Tests are used to separately analyze a single common component in a system. The test will
determine if the part is functioning correctly.
Mechanical Procedures Such As Removal and Installation
Reuse Of Fasteners, Seals, Or Gaskets
The following is a list of assumptions made in the reuse of fasteners, seals, or gaskets.
Seals and gaskets must be replaced unless otherwise specified.
Standard fasteners are reused unless otherwise specified.
Fasteners with self-locking features must be replaced unless otherwise noted. Reminder text may or
may not be included with the procedure step. Examples of fastener coatings or fasteners with
mechanical locking (with the locking features highlighted yellow) are shown in illustration 1.

Torque to yield bolts (bolts with more than one stage of tightening torque and a final torque angle
specification) must be discarded and new torque to yield bolts installed unless otherwise stated within
the procedure.

Illustration 1 - self-locking coatings or locking feature are highlighted yellow
Illustration 1 - self-locking coatings or locking feature are highlighted yellow 20
Graphics
Illustrations in this manual may be used to replace written step instructions. Color-coding (see color scheme in
this document) is used to communicate the required step action or actions. Service action icons (see Symbols
Glossary ) are used to add additional information regarding the required action.
The color scheme in a step graphic (an illustration used in removal or installation steps) indicates
servicing information as follows:
Fasteners (including panel retainers) or electrical connectors - Magenta (Purple)
Target component that is to be removed - Blue
Components that must be removed prior to the target component shown in blue - Brown or
Green

Components placed aside for access, but not removed; highlighted areas such as inspection
areas, adjustments or measurements - Yellow

Essential Special Service Tools (ESSTs) and other tools - Pale Blue
Chemical or Sealer apply areas - Alternating blue and white dashes (see illustration 4)
Sectioned or cut-away areas - Red
Remaining components - Grey

Callouts in graphics indicate removal (or tightening) order, or identify individual instructions in substeps of
the same number (such as different torque values).
Arrows containing x numbers (Illustration 2) indicate the number of identical fasteners or connectors to be
removed or installed in the graphic.
In Illustration 2, two identical fasteners are indicated by the x2 arrow, with another arrow illustrating a third
fastener of a different type. Because the different fasteners require different torques, callouts are used to
identify those two torque values in the associated step text. The hose clamp is another fastener to be removed.
The yellow coloring of the hose indicates it is to be moved aside (not removed).
The following written steps would be necessary if the illustration did not have color coding:
Remove the engine oil pipe fastener at the engine connection. 1.
Remove the two engine oil pipe fasteners from the turbocharger and remove the pipe. 2.
Remove the air inlet hose from the turbocharger and position aside. 3.
Illustration 2
Hidden fasteners, such as panel retainers, are identified in the illustration by a magenta disc. An inset detail
view illustrating the fastener type may be included (Illustration 3).
Illustration 2 21
Illustration 3 - Note motion arrow at panel bottom; it indicates to lift panel up, then move inward to remove
Symbols
Symbols may be used inside graphics or in the text area to communicate service actions. The following
examples demonstrate the use of some of these symbols. REFER to Symbols Glossary for a complete symbols
list with explanations.
In the Illustration 4 example, service action symbols are shown as used to direct the application of sealer,
lubricant, weight, tape or cleaning detergent to a component. In this example a bead diameter of "xx"
millimeters is prescribed. The blue and white dashes indicate where the material is applied.
Illustration 4
Illustration 5 is an example of location symbols used to show the location of a component tem within the
vehicle.
Illustration 5
Illustration 6 shows how gearshift lever or selector lever position symbols may be used to indicate the
gearshift lever or selector lever position required. The required Essential Special Service Tool to align the
shift mechanism is shown in pale blue and identified by ESST number.
Illustration 6
Illustration 3 - Note motion arrow at panel bottom; it indicates to lift panel up, then move inward to remove 22
Callouts or arrows may be used to identify components for supporting special information, such as a required
sequence or to indicate a number of identical components. Illustration 7 shows a removal order in the top
graphic and the bottom graphic indicates 12 identical bolts.
Illustration 7
Standard tool symbols direct the use of standard tools to perform a service action, such as the cutting of carpet
shown in Illustration 8. Tool symbols may include dimensional values (for example, a drill with a specified
diameter).
Illustration 8
Illustration 6 23
Illustration 8 24
Information
Manual
Safety Warnings
Heating, Ventilation and Air Conditioning Safety Warnings
WARNING: Take the following precautions when repairing an air conditioning system containing
R-134a:
Always wear safety goggles.
Avoid contact with liquid refrigerant R-134a. R-134a vaporizes at approximately -25C (-13F) under
atmospheric pressure and will freeze skin tissue.

Never allow refrigerant R-134a gas to escape in quantity in an occupied space. It will displace the
oxygen needed to support life.

Never use a torch in an atmosphere containing R-134a gas. R-134a is non-toxic at all normal
conditions, but it decomposes when exposed to high temperatures such as a torch flame. During
decomposition it releases irritating and toxic gasses (as described in the Material Safety Data Sheet
from the manufacturer). Decomposition products are hydrofluoric acid, carbon dioxide and water.

Failure to follow these instructions may result in serious personal injury.
WARNING: Before disconnecting any heater water hoses, shut OFF the engine and wait until
engine is fully cool. Failure to comply with this warning may result in serious injury or burns from hot
liquid escaping from the engine cooling system.
WARNING: Use extreme care and observe all safety and service precautions related to the use of
refrigerants as outlined on refrigerant tank and on recovery and charging equipment. Failure to follow
these instructions may result in serious personal injury.
Battery System Service Warnings
WARNING: Always disconnect the battery ground cable at the battery before disconnecting the
starter motor battery terminal lead. If a tool is shorted at the starter motor battery terminal, the tool
can quickly heat enough to cause a skin burn. Failure to follow this instruction may result in serious
personal injury.
WARNING: Before carrying out maintenance on the starting system, disconnect the battery ground
cable from the frame to completely isolate the starter from the dual frame-mounted batteries. Failure to
follow this instruction may result in serious personal injury.
WARNING: Batteries contain sulfuric acid and produce explosive gases. Work in a well-ventilated
area. Do not allow the battery to come in contact with flames, sparks or burning substances. Avoid
contact with skin, eyes or clothing. Shield eyes when working near the battery to protect against
possible splashing of acid solution. In case of acid contact with skin or eyes, flush immediately with
water for a minimum of 15 minutes, then get prompt medical attention. If acid is swallowed, call a
physician immediately. Failure to follow these instructions may result in serious personal injury.
WARNING: Always lift a plastic-cased battery with a battery carrier or with hands on opposite
corners. Excessive pressure on the battery end walls may cause acid to flow through the vent caps,
resulting in personal injury and/or damage to the vehicle or battery.
Safety Warnings 25
WARNING: Do not get underneath the frame-mounted battery when disconnecting or connecting
the auxiliary battery safety straps. The battery is heavy and could fall. Failure to follow this instruction
may result in serious personal injury.
WARNING: Battery posts, terminals and related accessories contain lead and lead components.
Wash hands after handling. Failure to follow these instructions may result in serious personal injury.
Brake System Service Warnings
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions will
help prevent system contamination, brake component damage and the risk of serious personal injury.
WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or
friction components. Remove dust using government-approved techniques. Friction component dust
may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if
dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure
may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or
may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure
to follow these instructions may result in serious personal injury.
WARNING: Remove air pressure from the air brake system prior to servicing the system.
Attempting to service the air brake system while it is under pneumatic pressure may result in serious
injury from unexpected hose whip, component movement or component propulsion.
WARNING: Always install new brake shoes or pads at both ends of an axle to reduce the possibility
of brakes pulling vehicle to one side. Failure to follow this instruction may result in uneven braking and
serious personal injury.
Body and Frame Service Warnings
WARNING: Always refer to Material Safety Data Sheet (MSDS) when handling chemicals and wear
protective equipment as directed. Examples may include but are not limited to respirators and
chemically resistant gloves. Failure to follow these instructions may result in serious personal injury.
WARNING: Always wear protective equipment including eye protection with side shields, and a
dust mask when sanding or grinding. Failure to follow these instructions may result in serious personal
injury.
WARNING: On vehicles equipped with Safety Canopy options, prior to carrying out any
sectioning repairs near the roof line or sail panel areas of the vehicle, remove the Safety Canopy
module and related components. Failure to comply may result in accidental deployment or damage to
the Safety Canopy. Refer to Section 501-20B . Failure to follow these instructions may result in
serious injury to technician or vehicle occupant(s).
WARNING: Do not cut or grind body side components within 50 mm (1.96 in) of restraint
anchoring points. Welding within 50 mm (1.96 in) of restraint anchoring points may result in incorrect
operation of restraint devices. For additional restraints anchoring location information, refer to Section
501-20A and Section 501-20B . Failure to follow these instructions may result in serious injury to
vehicle occupant(s).
WARNING: Do not carry out body side sectioning repairs in areas of laser welds. Factory laser
Safety Warnings 26
welds cannot be duplicated with conventional welding equipment and structural integrity may be
compromised. Failure to follow this instruction may result in serious injury to vehicle occupant(s).
WARNING: Do not carry out body side sectioning repairs in areas of door hinge or striker
anchoring points. Welding within 50 mm (1.96 in) of door hinge or striker locations may compromise
structural integrity during a collision. Failure to follow these instructions may result in serious injury to
WARNING: Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes
and skin. Always use protection such as a welder's helmet with dark-colored filter lenses of the correct
density. Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest
shade providing adequate visibility are recommended. It is strongly recommended that persons
working in the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow
WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the
impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to
the original production configuration. A new RCM and sensors must be installed whether or not the air
bags have deployed. Failure to follow these instructions may result in serious personal injury or death
in a crash.
WARNING: Do not permanently remove the trailer hitch. The trailer hitch is an integral part of the
vehicle frame. Always reinstall the hitch before delivery of the vehicle to the customer. Failure to follow
this instruction may compromise vehicle crash integrity and increase the risk of personal injury in a
rear end collision.
WARNING: Collision damage repair must conform to the instructions contained in this workshop
manual. Replacement components must be new, genuine Ford Motor Company parts. Recycled,
salvaged, aftermarket or reconditioned parts (including body parts, wheels or safety restraint
components) are not authorized by Ford.
Departure from the instructions provided in this manual, including alternate repair methods or the use
of substitute components, risks compromising crash safety. Failure to follow these instructions may
adversely affect structural integrity and crash safety performance, which could result in serious
personal injury to vehicle occupants in a crash.
Engine Cooling System Service Warnings
WARNING: Always allow the engine to cool before opening the cooling system. Do not unscrew the
coolant pressure relief cap when the engine is operating or the cooling system is hot. The cooling system
is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly.
Fuel System Service Warnings
WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components,
relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains
under high pressure, even when the engine is not running. Failure to follow this instruction may result
in serious personal injury.
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working
on or near any fuel-related component. Highly flammable mixtures are always present and may be
Safety Warnings 27
ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Clean all fuel residue from the engine compartment. If not removed, fuel residue may
ignite when the engine is returned to operation. Failure to follow this instruction may result in serious
personal injury.
WARNING: Contact with exposed fuel injector wiring, if energized, may result in electric shock.
Use care when working on or around energized fuel injector wiring. Fuel injector wiring supplies high
voltage to operate the fuel injectors. Failure to follow this instruction may result in serious personal
injury.
WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio
equipment of any type when working on or near any fuel-related component. Highly flammable
mixtures are always present and may be ignited. Failure to follow these instructions may result in
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always
present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the
event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources.
WARNING: Remove the fuel filler cap slowly. The fuel system may be under pressure. If the fuel
filler cap is venting vapor or if you hear a hissing sound, wait until it stops before completely removing
the fuel filler cap. Otherwise, fuel may spray out. Failure to follow these instructions may result in
WARNING: Do not work on the fuel system until the pressure has been released and the engine has
cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel
may cause cuts and contact with hot fuel may cause burns. Failure to follow these instructions may
result in serious personal injury.
WARNING: Avoid contact with fuel during a visual inspection for fuel leaks with the engine
running. Do not work on the fuel system until the pressure has been released and the engine has cooled.
Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause
cuts and contact with hot fuel may cause burns. Failure to follow these instructions may result in
General Service Warnings
WARNING: Never get underneath a vehicle that is supported only by a jack. The jack could
unintentionally lower. Always support vehicle with floor stands. Failure to follow these instructions
WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction
WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber
and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may
Safety Warnings 28
WARNING: Carefully read cautionary information on product label. For emergency medical
information seek medical advice. In the USA or Canada on Ford/Motorcraft products call:
1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if
available. Failure to follow these instructions may result in serious personal injury.
WARNING: Use tools, not fingers, to hold flagnuts. Flagnuts may slip or spin unexpectedly when
removing fasteners. Failure to follow this instruction may result in injured fingers.
WARNING: Keep solvents away from ignition sources. Solvents may be flammable and can ignite or
explode if not handled correctly. Failure to follow this instruction may result in serious personal injury.
WARNING: Place a shop towel between the hands and the exterior mirror glass for protection in
case of glass breakage during mirror service. Failure to follow this instruction may result in serious
personal injury.
WARNING: Use only a type-D fire extinguisher to extinguish magnesium fires. Never attempt to use
a type-A, -B, -C extinguisher, or water, as these items are ineffective and may accelerate a magnesium
fire. Failure to follow these instructions may result in serious personal injury.
WARNING: Only raise the vehicle when positioned on a hard, level surface. Attempting to raise the
vehicle on an uneven or soft surface may result in vehicle slipping or falling from the jack or jackstand.
Failure to follow this instruction may result in serious personal injury.
WARNING: Identify the correct jacking points by locating the triangle stamped into the uni-body
sheet metal or vehicle frame. Raising a vehicle in any other location may result in vehicle shifting or
falling. Failure to follow this instruction may result in serious personal injury.
WARNING: Install only FCC-approved radio transmitting equipment. See your authorized radio
dealer for the correct transmitter. Use of incorrect transmitting equipment may cause the vehicle to
malfunction or stall, resulting in loss of power brake and power steering assist. Failure to follow these
instructions may result in serious personal injury to vehicle occupant(s).
WARNING: Vehicle may have multiple drive wheels. Do not use engine to power the driveline
unless all drive wheels are elevated off the ground. Drive wheels in contact with ground could cause
unexpected vehicle movement. Failure to follow this instruction may result in serious personal injury.
WARNING: Do not operate the engine with the hood open until the fan blade has been examined for
possible cracks and separation. A damaged fan can separate during operation. Failure to follow this
instruction may result in serious personal injury.
WARNING: Do not stand in line with or near the engine cooling fan blade when revving the engine.
A damaged fan can separate during operation. Failure to follow this instruction may result in serious
personal injury.
WARNING: When jacking or lifting the vehicle, block all wheels remaining on the ground. Set the
parking brake if the rear wheels will remain on the ground. These actions help prevent unintended
vehicle movement. Failure to follow these instructions may result in serious personal injury.
WARNING: Turn OFF the ignition switch for a minimum of 5 minutes before removing
high-voltage cables. High-voltage cables and wiring are orange in color. The nominal high-voltage
traction battery voltage (HVTB) is 330 V DC. Failure to follow these instructions may result in serious
personal injury or death.
WARNING: Vehicles with engine auto start-stop technology may start automatically with the
Safety Warnings 29
ignition on. Make sure the ignition is off when servicing or working in close proximity to rotating
engine parts. Failure to follow this instruction may result in serious personal injury.
WARNING: Wear high-voltage insulated safety gloves and a face shield when working with
high-voltage batteries or cables. The high-voltage insulated safety gloves should be of the appropriate
safety and protection rating. Inspect the gloves before use and always wear them with the leather outer
glove. Any hole in the rubber insulating glove is a potential entry point for high-voltage. Failure to
follow these instructions may result in serious personal injury or death.
WARNING: Depower the high-voltage traction battery (HVTB) before carrying out any removal or
installation procedures affecting the high-voltage battery system. Failure to follow this instruction may
result in serious personal injury or death.
WARNING: Secure the torque converter in the transmission during removal or installation. The
torque converter is heavy and may result in injury if it falls out of the transmission. Failure to follow
this instruction may result in serious personal injury.
WARNING: When using compressed air, never let air pressure exceed 172 kPa (25 psi) and always
wear safety glasses. Compressed air may cause foreign material or parts to become airborne. Failure to
WARNING: Wear protective gloves when handling components or parts that have pointed or sharp
edges. Failure to follow this instruction may result in serious personal injury.
WARNING: Turn off (disable) the power running boards (if equipped) before jacking, lifting or
placing any object under the vehicle. Never place your hand between the power running board and the
vehicle. Extended power running boards will retract when doors are closed. Failure to follow these
instructions may result in serious personal injury.
WARNING: Disconnect the window regulator motor connector before working inside the vehicle
doors. Service actions inside the door (such as door latch, handle or lock cylinder service) or operating
the remote keyless entry (RKE) fob may activate the windows on vehicles equipped with global
open/close. Serious injury to hands or arms may occur if a window motor is activated during service.
Safety Restraints Service Warnings
WARNING: Anytime the Safety Canopy or side air curtain module has deployed, a new headliner
and new A-, B- and C-pillar upper trim panels and attaching hardware must be installed. Remove any
other damaged components and hardware and install new components and hardware as needed.
Failure to follow these instructions may result in the Safety Canopy or side air curtain module
deploying incorrectly and increases the risk of serious personal injury or death in a crash.
WARNING: Deploy all supplemental restraint system (SRS) devices (air bags, pretensioners, load
limiters, etc.) outdoo with all personnel at least 9 meters (30 feet) away to make sure of personal safety.
Due to the loud report which occurs when an SRS device is deployed, hearing protection is required.
WARNING: The fire suppression system backup power supply must be depleted before lifting the
vehicle or when repairing or replacing any of the following:
Fire suppression system components
Components located near the fire suppression manual switch
Safety Warnings 30
Fuel tank and components located near the fuel tank
Rear axle and components located near the rear axle
To deplete the backup power supply, disconnect the battery and wait at least 1 minute. Be sure to disconnect
all auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in
in a crash.
WARNING: Never disassemble or tamper with seat belt deployable components, including
pretensioners, load limiters and inflators. Never back probe deployable device electrical connectors.
Tampering or back probing may cause an accidental deployment and result in personal injury or
death.
WARNING: Never probe the electrical connectors on airbag, Safety Canopy or side air curtain
assemblies. Failure to follow this instruction may result in the accidental deployment of these
assemblies, which increases the risk of serious personal injury or death.
WARNING: Never put any type of fastener or tie strap around any part of a Safety Canopy
module, side air curtain module or interior trim panel. This will prevent the Safety Canopy or side air
curtain module from deploying correctly. Failure to follow this instruction may increase the risk of
serious personal injury or death in a crash.
WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor
(if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation,
which increases the risk of personal injury or death in a crash.
WARNING: Always carry or place a live Safety Canopy, or side air curtain module, with the
module and tear seam pointed away from your body. Failure to follow this instruction may result in
serious personal injury or death in the event of an accidental deployment.
WARNING: Always deplete the backup power supply before repairing or installing any new front
or side air bag supplemental restraint system (SRS) component and before servicing, removing,
installing, adjusting or striking components near the front or side impact sensors or the restraints
control module (RCM). Nearby components include doors, instrument panel, console, door latches,
strikers, seats and hood latches. Refer to the Description and Operation portion of Section 501-20B for
location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the
battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power
supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death
in the event of an accidental deployment.
WARNING: Do not paint any airbag trim covers or deployment doors. Paint may cause the airbag
to deploy incorrectly. Failure to follow this instruction may increase the risk of serious personal injury
or death in a crash.
Safety Warnings 31
Tire and Wheel Service Warnings
WARNING: Replacement wheels must be equivalent to the original equipment wheels in:
load carrying capacity.
diameter, width and offset.
pilot hole and bolt circle.
Combined load carrying capacity of replacement wheels for a given axle, must be equal to or greater than that
axle's gross axle weight rating (GAWR) identified on the vehicle's Safety Compliance Certification label. All
other specifications should be evaluated by measurement of both the original wheel and the replacement
wheel. If specifications are not equivalent, the safety and handling of the vehicle may be degraded, which may
result in serious injury to the vehicle occupant(s).
WARNING: Never inflate a tire that has been run flat without first removing the tire from the wheel
to inspect for damage. A damaged tire can fail during inflation. Failure to follow this instruction may
WARNING: Do not hit the wheel or tire with a metallic hammer. This action may damage the wheel
or tire, resulting in tire or wheel failure. Failure to follow this instruction may result in serious personal
injury to the technician or vehicle occupant(s).
WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material
present on the mounting surface of the wheel and the mounting surface of the wheel hub, brake drum
or brake disc. Make sure that any fasteners that attach the rotor to the hub are secured so they do not
interfere with the mounting surfaces of the wheel. Failure to follow these instructions when installing
wheels may result in the wheel nuts loosening and the wheel coming off while the vehicle is in motion,
which could result in loss of control, leading to serious injury or death to vehicle occupant(s).
WARNING: Inflating tires to pressures that exceed maximum tire inflation rating on tire sidewall
may result in tire failure and serious personal injury to the technician or vehicle occupant(s).
WARNING: Only use replacement tires that are the same size, load index, speed rating and type
(such as P-metric versus LT-metric or all-season versus all-terrain) as those originally provided by
Ford. The recommended tire and wheel size may be found on either the Safety Compliance
Certification Label or the Tire Label, which is located on the B-pillar or edge of the driver's door. If the
information is not found on these labels, consult a Ford dealer. Use of any tire or wheel not
recommended by Ford can affect the safety and performance of the vehicle, which could result in an
increased risk of loss of vehicle control, vehicle rollover, personal injury and death. Additionally, the
use of non-recommended tires and wheels could cause steering, suspension, axle or transfer case/power
transfer unit failure.
WARNING: Do not mount tube-type tires on tubeless wheels or tubeless tires on tube-type wheels.
Incorrect combinations could result in tire separation from wheel and may result in serious injury to
WARNING: Cracked wheels can be dangerous. Deflate tires on cracked wheels prior to removal of
wheels from the vehicle. Failure to follow this instruction may result in serious personal injury.
WARNING: Retighten wheel nuts within 160 km (100 mi) after a wheel is reinstalled. Wheels can
loosen after initial tightening. Failure to follow this instruction may result in serious injury to vehicle
occupant(s).
WARNING: Retighten wheel nuts within 160 km (100 mi) after a wheel is reinstalled. For dual rear
Safety Warnings 32
wheel (DRW) only, a second retightening is required within 800 km (500 mi). Wheels can loosen after
initial tightening. Failure to follow this instruction may result in serious injury to vehicle occupant(s).
WARNING: Always match the tire size to the wheel size during assembly. Incorrect matching can
result in tire bead damage or tire separation from the wheel. Failure to follow this instruction may
result in serious personal injury to technician or vehicle occupant(s).
WARNING: Keep eyes away from valve stem when deflating tires. Reduce air pressure in tire as
much as possible by pushing in valve core plunger prior to removing the core. Escaping air can carry
particles that can injure the eyes. Failure to follow these instructions may result in serious personal
injury.
WARNING: Never use wheels different than the original equipment. Additionally, never use wheel
nuts different than the original equipment. Failure to follow these instructions may result in damage to
the wheel or mounting system. This damage could cause the wheel to come off while the vehicle is being
driven, which could result in serious personal injury or death to vehicle occupant(s).
WARNING: Do not weld or peen wheels. A wheel needing such repairs must have a new wheel
installed. Failure to follow these instructions may result in wheel failure and serious personal injury.
WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous
chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush
immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of
the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the
correct procedures for hazardous material disposal. Failure to follow these instructions may result in
Safety Warnings 33
Information
Manual
Diagnostic Methods
WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in
Section 100-00 . Failure to follow this instruction may result in serious personal injury.
Effective Diagnostic Techniques
The following diagnostic process is critical for consistently successful diagnoses. Random methods work
inconsistently and often lead to multiple repairs and the accompanying frustration.
Understand and verify the symptom .
Understanding a symptom requires understanding normal operation.
Duplicate the concern. Re-create the same conditions that demonstrated the original concern
(road testing may be necessary).

Determine the responsible system .
Gather data, such as a visual inspection and an OASIS report.
Perform system tests, such as pressure tests or DTC retrieval.

Identify the responsible component .
Test the suspect component and related parts.

Determine the root cause
Examine related components (wiring faults, misalignments, incorrect adjustments) that may
be the actual cause or may have caused the component failure.

Repair all related faults to avoid repeat failures.
Verify the repair has corrected the concern (and not created any new ones) using the identical
conditions that demonstrated the original concern.

Diagnostic Scan Tool Testing
Network Test
Performing a network test is always recommended for analysis of electronic system concerns. Always solve
network issues before addressing individual symptoms or DTCs.
Recommended Practice: REFER to Symptom Chart in Section 418-00 to diagnose a network outage or no
response from an individual module (or modules).
DTC Retrieval
Generally, a good diagnostic strategy is to resolve all on-demand codes related to the system concern.
Retrieving all continuous DTCs can also be beneficial to understand historic issues or issues outside of the
suspect system that may be affecting your concern. On-demand testing should be done to ensure the fault
represented by a continuous DTC is still present.
Continuous Memory Diagnostic Trouble Codes (CMDTCs)
Modules that produce diagnostic trouble codes have a program that evaluates system conditions, normally
while the vehicle or system is in use. Module inputs can be checked for values indicating an electrical fault
with the monitoring circuit or component. Module outputs can be monitored for correct function. Codes are
stored when predefined limits are exceeded and retained even if the ignition is turned off (generally
DTC-retention is for 40+ ignition cycles). Not all continuous codes have a matching on-demand code - and
Diagnostic Methods 34
vice versa; this varies with different modules. For example, some network communication codes are
continuous only. It is important to note that the presence of a continuous DTC does not guarantee that the
fault currently exists.
Ford On-Demand DTCs
Ford Motor Company modules have a unique feature that performs a special diagnostic program at the request
of the technician (using a scan tool). This "On-demand" diagnostic program can exercise system outputs not
normally running when the car is parked and record observed faults. These diagnostic codes are
communicated to the scan tool; they are not recorded in module memory. An on-demand test is an effective
tool for evaluating real input and output conditions during module activity - activity that might not normally
be occurring during service bay conditions. For example, an air suspension module on-demand test can run
the compressor, vent the system, and observe the report from the height sensor even when the car is already at
correct trim height and not requiring height adjustment.
Network Communication DTCs
Network DTCs (U-prefix codes) are often a result of intermittent concerns such as damaged wiring or low
battery voltage occurrences. Additionally, vehicle repair procedures (such as module reprogramming or
diagnostics with modules disconnected) often set network DTCs. Replacing a module to resolve a network
DTC is unlikely to resolve the concern. To prevent recurrence of intermittent network concerns, inspect all
network wiring, especially in-line and module connectors; test the vehicle battery.
Recommended practice: Clear the DTC and retest. If the DTC repeats, test the vehicle communication
network.
DTC Nomenclature (SAE J2012 and ISO 14229)
Many modules use 5-character DTCs followed by a 2-character failure-type code. The failure-type
(sometimes called "fault byte") digits provide information about specific fault conditions such as opens or
shorts to ground. Continuous memory DTCs have an additional 2-character DTC status code suffix to assist in
determining DTC history.
Integrated Diagnostic System (IDS) Scan Tool Usage
If The IDS Scan Tool Does Not Communicate With The Vehicle
The IDS scan tool first attempts to communicate with the PCM. After establishing communication with the
PCM, the scan tool then attempts to communicate with all other modules on the vehicle.
Verify the scan tool operation with a known good vehicle. 1.
Verify the ignition is ON. 2.
If an IDS session cannot be established with the vehicle ( IDS may state "No communication can be
established with the PCM"):
Choose "NO" when the scan tool prompts to retry communication.
Enter either a PCM part number, tear tag, or calibration number to identify the vehicle and
start a session.
The PCM part number can be determined from OASIS -- choose "HVBoM" from the
OASIS page and search for the PCM part number

The PCM part number and 4-character tear tag are printed on the PCM label.

Establish a session based on the PCM information (above).
3.
Using the tool box menu, run the network test.
Determine if all modules on the network are unresponsive or if only the PCM does not
communicate.

Recommended practice: REFER to Symptom Chart in Section 418-00 to diagnose the
network outage or no response from the PCM.

4.
Measuring Automotive Circuits
Wiring Pin (Terminal) Fit And The Use Of Rotunda Flex Probes
To avoid wiring pin (terminal) damage, Rotunda Flex Probes NUD105-R025D must be used to
connect test equipment or jumper wires to pins (terminals).

Male to female pin (terminal) fit is critical for connection reliability.
Pin (terminal) fit may be checked by using the mating pin (terminal) to test for normal
separation force (a damaged pin or terminal will have very low separation force from the
mating pin or terminal)

Correctly checking the separation force of small pins (terminals) may require removal of the
connector terminal guide/retainer if it adds drag to the pin (terminal) insertion or removal

Replace damaged connectors or pins (terminals).
Use the Wiring Diagram connector view (cell 150) to identify the correct replacement
connector with pigtail.

Use the Wire Harness Terminal Repair Guide to identify and order the correct replacement
pin and pigtail. Available through Ford Dealers, REFER to FMC dealer website, or REFER to
www.fcs.dealersonnection.com/wire .

Checking Power-Providing Circuits
Measuring a power wire with the intended load disconnected using a DMM will only find open
circuits (open fuse or wire).

Recommended practice: Circuits carrying approximately 200-1000 mA* may be loaded with the
specified test light SGT27000. Measure circuit voltage with a DMM while the test light is connected
and illuminated. A reduction in the voltage present during test-light-loading indicates excessive
circuit resistance.

Recommended practice: Circuits carrying more than one ampere* should be loaded with a device
requiring similar current (e.g., a headlamp bulb may be effective). A reduction in the voltage present
during loading indicates excessive resistance.

*Circuit current is matched to wire gauge/size; Examples:
Conductor sizes of 24 gauge (.5 mm) or smaller are generally used to carry approximately 1
ampere (1000 mA) or less. Use of the test light to load these circuits is appropriate.

Conductor sizes of 20 gauge (.8 mm) or larger are generally used to carry approximately 5
amperes (5000 mA) or more. Match the substitute load (measure substitute load current first
as necessary) to this current level.

Checking Ground-Providing Circuits
The best method of checking ground circuits is to measure the circuit voltage drop during component
operation (or attempted operation).

An ohmmeter may be accurately used if the battery has been disconnected.
Recommended practice: Expect less than 2 ohms for most small diameter (18 gauge and smaller)
wires.

Ohmmeter low-resistance resolution (approximately 0.1 ohm) limits its use to circuits carrying less
than approximately 5 amperes (this is due to the fact that very small resistances, undetectable by a
DMM , cause significant voltage loss in higher current circuits).

DMM ohmmeter readings are easily corrupted by the normal voltage present (battery connected) in
many ground circuits.
Recommended practice: Reverse the leads and check for changes in the measurement.
Reversing the DMM lead connections should never change the resistance measurement
(unless the circuit contains a semi-conductor). Measurement (non-semi-conductor)
differences when leads are interchanged at the test points indicate invalid test results. The
presence of voltage corrupts the reading, and causes the meter reading to change when the
leads are reversed.

Checking Circuit Continuity
Recommended practice: Expect less than 2 ohms of resistance for most wires.
Ohmmeter low-resistance resolution (approximately 0.1 ohm) limits its use to circuits carrying less
than approximately 5 amperes. This is due to the fact that very small resistances, below the resolution
of a DMM , cause significant voltage loss in higher current circuits.

The DMM applies a small amount of voltage to the circuit or component to calculate resistance. As a
result, DMM ohmmeters are very sensitive to any level of voltage present. Voltage present in the
circuit will corrupt the DMM reading.

Checking For Unintended Continuity (Shorts) To Other Circuits
A DMM ohmmeter may be used to detect undesired circuit connections to:
Ground
Other unpowered circuits

Recommended practice: Expect greater than 10,000 ohms of resistance between two separate
circuits; the best result is an open circuit DMM indication (no detected resistance).

Shorts to voltage are checked with a DMM voltmeter
Recommended practice: Turn ignition on (with battery connected) and measure the circuit for any
voltage present (none should be present)

Checking Circuits By Back-Probing A Connector
Back-probing should be performed only when directed by a service manual diagnostic routine. Never
back-probe safety restraint deployable devices such as airbags or belt pretensioners. Back-probing is a
testing method of last resort and should only be employed where a diagnostic step requires a circuit to
be tested under actual operating conditions. Back-probing is a risky testing method due to the
uncertainty of the probe connection and the possibility of damaging terminals.

Do not force test leads or other probes into connectors. Adequate care must be exercised to avoid
connector terminal damage while ensuring that good electrical contact is made with the circuit or
terminal. Failure to follow these instructions may cause damage to wiring, terminals, or connectors
and subsequent electrical faults.
Use Rotunda Back-Probe Pins POMA6411 to assist in making a good test connection and to
prevent connector or terminal damage during back-probing.

Do not test for the presence of voltage at a single point where zero volts is a possible result (you
cannot tell the difference between a bad probe contact and a zero volt result).

Do not test for continuity/opens (using a DMM ohmmeter) between two points (you cannot tell the
difference between bad probe contacts and an open circuit).

Back-probing may be used where the circuit must be analyzed with the voltage-drop method (if the
circuit carries greater than 5 amperes and no other means of testing will definitively eliminate circuit
resistance as a possible fault). A zero-volt result indicates incorrect test conditions (no current flow)
or bad back-probe connections.

Occasionally, module failure mode behavior will change the operation of a circuit when it is opened
for testing. Back-probing is an acceptable remedy for these testing dilemmas.

Circuit Analysis Using Jumper Wires (Creating Substitute Circuits)
Jumper wires may be employed for circuit analysis.
Cautions:
Always use fused jumper wires - the recommended universal-testing jumper wire fuse is 2-5
amperes; larger fuse ratings should be used only in special circumstances.

Use flex probes or equivalent to prevent connector terminal damage (flex probes are not
intended to carry higher currents necessary to operate motors such as a cooling fan or blower
motor).

Follow workshop manual testing directions when using jumper wireso avoid component or
harness damage due to incorrect jumper connections.

Never repair a circuit by adding a new wire in parallel to the old one (overlaying the circuit)
without fully understanding what caused the circuit to fail. Always find, examine, and repair
the fault to correct the root cause and to repair any adjacent wiring that has been damaged.

Checking Modules
Generally, module failure rate is very low and therefore replacement modules usually do not resolve
the root cause. Incorrect replacement of a module is often the result of inadequate testing.
Understand the correct module function.
Make sure programmable parameters are set correctly for the function in question (see the list
in Section 418-01 ).

Resolve DTCs first - as directed by Diagnostic Routines.
Test all inputs, both hard-wired and networked.
Test outputs (see "Checking module switching circuits" below).
Check applicable TSBs for module software changes (flash programming).

Checking module switching circuits.
Using the scan tool module-output command function (e.g., IDS Output State Control) to
activate components is a fast way to confirm an output is capable of being switched on by the
module. Testing that reveals normal module-output function confirms the need to analyze the
module inputs.

Don't apply ground or power directly to module-switched components with jumper wes
(unless directed by a workshop manual procedure), as the component can be damaged by a
direct connection to ground/power.

SECTION 100-01: Identification
Codes
Manual
Identification Codes
Vehicle Identification Number (VIN)
Vehicle Identification Number (VIN) Tag Locator
The Vehicle Identification Number (VIN) is a 17-digit combination of letters and numbers. The VIN is
stamped on a metal tab riveted on the instrument panel, top upper left of the dash. The VIN is also found on
the Vehicle Certification (VC) label.
If the VIN plate requires replacement, authorized dealers must contact their respective regional office.
Item Description
1 World Manufacturer Identifier (WMI)
2 Restraint system type
3 Vehicle line and series type
4 Engine type
5 Check digit
6 Model year
7 Assembly plant
8 Production sequence number
Identification Codes 39
World Manufacturer Identifier (WMI)
The first 3 VIN positions are the World Manufacturer Identifier (WMI).
3FA - Ford, Mexico, passenger car
3LN - Lincoln, Mexico, passenger car
Restraint System Type
The fourth VIN position identifies the vehicle restraint system used.
D - Active safety belts, all positions with driver, front passenger air bags and driver side knee bolster
H - Active safety belts, all positions, driver and front passenger air bags and driver and front
passenger side impact air bags

Vehicle Line and Series Type
VIN positions 5 through 7 indicate the vehicle line and series type.
L2G - Lincoln, Front Wheel Drive (FWD)
L2J - Lincoln, All-Wheel Drive (AWD)
L2L - Lincoln, Hybrid FWD
P0C - Ford, SEL, AWD
P0D - Ford, Sport, AWD
P0G - Ford, S, FWD
P0H - Ford, SE, FWD
P0J - Ford, SEL, FWD
P0L - Ford, Hybrid SEL, FWD
Engine Type
The eighth VIN position is the engine type (displacement and number of cylinders).
3 - ATK-CVC, 2.5L, 4-valve Gas/Electric (Hybrid)
A - 2.5L, Dual Overhead Camshaft (DOHC), 4-cylinder, Duratec
C - 3.5L, DOHC , V6
G - 3.0L, Overhead Camshaft (OHC), V6, Duratec
More specific engine information can be found on the engine tag. For additional information, refer to Section
303-01A , Section 303-01B , Section 303-01C or Section 303-01D .
Check Digit
The ninth VIN position is a government-assigned, computer-generated check digit.
Model Year
The tenth VIN position is the model year code.
C - 2012
Assembly Plant
The eleventh VIN position is the assembly plant code.
R - Hermosillo Assembly (Hermosillo, Mexico)
World Manufacturer Identifier (WMI) 40
Build Sequence
VIN positions 12 through 17 are an alphanumeric code for the vehicle build sequence. This is also the vehicle
serial and warranty number. These 6 characters are also found on the engine block and transmission.
100001-599999 - Ford
600001-999999 - Lincoln
Vehicle Certification (VC) Codes
Vehicle Certification (VC) Label Locator
The upper portion of the Vehicle Certification (VC) label contains the manufacturer's name, the month and
year of manufacture, the certification statement and the Vehicle Identification Number (VIN). It also includes
Gross Vehicle Weight Rating (GVWR). The VC label is located on the LH door jamb.
If a vehicle requires replacement of the VC label and is 4 years old or less, an authorized dealer must submit
the VIN to their respective regional office. The regional office will submit a web form to the assembly plant
for the replacement label. Once the label has been printed, a representative from the regional office will
deliver the label to the dealer and witness installation on the vehicle. If a vehicle is more than 4 years old and
requires a replacement label, the dealer must submit a request to the Department of Motor Vehicles.
Item Description
Build Sequence 41
1 Exterior paint code
2 Region code
3 District Special Order (DSO)
4 Interior trim code
5 Tape/paint stripe code
6 Radio code
7 Axle code
8 Transmission code
9 Spring code
10 Powertrain calibration information
Exterior Paint
Exterior paint codes may be listed as a 2-part code. The first set of characters identify the primary body color.
The second set of characters (if applicable) identify the vehicle accent or 2-tone body color. All colors are
base coat/clear coat.
Exterior Color Codes
HT - Cinnamon
JY - Ginger Ale
JZ - Crystal Champagne
R2 - Red Candy Tint
SZ - Blue Flame
UA - Ebony
UG - White Platinum (tri-coat)
UJ - Sterling Gray Metallic
UN - Steel Blue
UX - Ingot Silver Metallic
WS - White Suede (tri-coat)
Interior Trim
Interior trim codes are listed as a 2-part code. The first character identifies the interior trim type. The second
character identifies the interior trim color.
Interior Trim Type
A - Perforated leather/SOHO grain le- F-appearance cloth, Ford
D - B-cloth, Ford
F - Verona leather, Ford
L - Hero perforated leather, Lincoln
M - Perforated leather, Lincoln
T - E-cloth, Ford
V - Variation perforated leather, Ford
Z - Premium perforated leather, Lincoln
Interior Trim Color
B - Blue, Ford
C - Camel, Ford
G - Ginger, Ford
H - Cashmere, Lincoln
L - Medium Light Stone, Ford
Vehicle Certification (VC) Label Locator 42
R - Red, Ford
S - Light Camel, Lincoln
W - Charcoal Black, Ford/Lincoln
Tape/Paint Stripe
Tape and paint stripe codes do not apply.
Radio Type
Radio type codes are as follows:
B - AM/FM stereo, in-dash 6-disc CD changer, MP3 and clock
F - AM/FM stereo, CD player, MP3 and clock
N - AM/FM stereo, in-dash single disc CD changer with navigation system
Axle Ratio Codes
The axle ratios are:
25 - 2.57 - Ford
30 - 3.06 - Ford
32 - 3.21 - Ford
33 - 3.33 - Ford, Lincoln
43 - 4.39 - Ford
Transmission Type
Transmission type codes are as follows:
6 - 6-speed manual transmission (Mazda G6M) - Ford
B - 6-speed automatic transmission (Aisin F21) - Ford, Lincoln
H - Continuously Variable Transaxle (CVT) - Ford Hybrid, Lincoln Hybrid
W - 6-speed automatic transmission (6F) - Ford
Refer to the transmission tag information in Section 307-01A Section 307-01B , Section 307-01C or Section
308-00 .
Spring Code
Spring codes are listed as a 2-part code. The first 2 characters identify the front springs. Characters 3 and 4
identify the rear springs. Front spring base part number is 5310, rear spring base part number is 5560.
Powertrain Calibration Information
NOTE: Powertrain calibration information is limited to a maximum of 5 characters per line on the Vehicle
Certification (VC) label. Because of this, calibration identification consisting of more than 5 characters will
Interior Trim 43
wrap to the second line on the VC label.
Powertrain calibration information is printed in the lower right corner of the VC label. Only base calibration
information is printed. Revision levels will not appear, however, they can be obtained through a scan tool
using the most current software revision.
Powertrain Calibration Information
Item Description
1 Model year (model year in which calibration strategy was first introduced)
2 Vehicle code
3 Transmission code
4 Unique calibration (designates different hardware to similar vehicles). Example: tires and drive ratios
5 Fleet code (describes fleet to which the vehicle belongs). Example: 6 - Evaporative Emission (EVAP)
6 Certification region (lead region where multiple regions are included in one calibration). Example: A -
U.S. federal
7 Revision level (will advance as revns occur). Not printed on label
Model Year
7 - 2007
8 - 2008
9 - 2009
A - 2010
B - 2011
C - 2012
Vehicle Line
DE - Ford, Lincoln
Transmission
1 - Automatic transmission
2 - Manual transmission
Unique Calibration
The Emissions/Corporate Average Fuel Economy/Carbon Dioxide Compliance Department is responsible for
assigning these calibration numbers. Unique calibration identifications are assigned to cover similar vehicles
to differentiate tires, drive configurations, final drive ratios and other calibration-significant factors.
These 2 characters are chosen by the analyst to provide identifiable information unique to each calibration.
For example, using the number 2 to denote a 2-valve engine versus using the number 4 to denote a 4-valve
engine, offers an easily identifiable difference.
Spring Code 44
Fleet Code
0 - Certification (U.S. 4K, final sale in export markets)
1 - Heavy duty gas engine/Dyno
2 - Fast-Automobile Manufacturers' Association, U.S.
3 - Alternative Durability Protocol, U.S.
4 - Not assigned
5 - Not assigned
6 - Evaporative Emission (EVAP)
7 - Mileage accumulation, aging endurance durability
8 - On-Board Diagnostic (OBD)
9 - Not assigned
Certification Region
5 - U.S. 50 states
A - U.S. federal, including altitude, may include Canada and/or Mexico
B - U.S. California, includes U.S. green states
C - Canada
D - China
E - European Community (Austria, Belgium, Denmark, Finland, France, Germany, Greece, Ireland,
Italy, Luxembourg, Netherlands, Portugal, Spain, Sweden, United Kingdom)

F - Extended Estonia, Hungary, Norway, Poland, Romania, Russian Federation, Slovakia, Slovenia,
Switzerland, Yugoslavia)

G - Gulf Cooperative Council (Bahrain, Kuwait, Oman, Qatar, Saudi Arabia, United Arab Emirates)
H - Hong Kong
J - Japan
K - Korea
L - Malaysia
M - Mexico
N - New Zealand
P - Australia
Q - South America (Brazil)
S - Singapore
T - Taiwan
U - South America (unleaded fuel)
V - Vietnam
X - Rest Of World (ROW)
Y - Military
Z - Israel
Revision Level (not printed on label)
91-99 - Hardware calibration levels
01-04 - Preliminary levels
00 - Job 1 production (initial calibration)
05-09 - Pre-job 1 revisions to calibrations
10-89 - Post-job 1 revisions to calibrations
0B - Durability test level
BD - OBD intermediate level (pre-05)
Unique Calibration 45
Unique Calibration 46
SECTION 100-02: Jacking and Lifting
Workshop Manual
Jacking and Lifting
WARNING: When jacking or lifting the vehicle, block all wheels remaining on the ground. Set the
parking brake if the rear wheels will remain on the ground. These actions help prevent unintended
vehicle movement. Failure to follow these instructions may result in serious personal injury.
WARNING: Never get underneath a vehicle that is supported only by a jack. The jack could
unintentionally lower. Always support vehicle with floor stands. Failure to follow these instructions
WARNING: Only raise the vehicle when positioned on a hard, level surface. Attempting to raise the
vehicle on an uneven or soft surface may result in vehicle slipping or falling from the jack or jackstand.
WARNING: Position the hoist lift arms as shown in the illustration. Incorrect positioning could
result in vehicle slipping or falling from the hoist. Failure to follow this instruction may result in serious
personal injury.
NOTICE: The jack provided with the vehicle is intended to be used in an emergency for changing a
deflated tire. To avoid damage to the vehicle, never use the jack to hoist the vehicle for any other
purpose.
NOTICE: To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on lift
without first checking for possible interference, or damage may occur.
NOTICE: Damage to the suspension, exhaust or steering linkage components may occur if care is not
exercised when positioning the hoist adapters prior to lifting the vehicle.
NOTICE: To prevent possible damage to the Sport package trim when lifting with a hoist, position the
hoist pad on the pinch weld as indicated.
Jacking and Lifting Points
Jacking and Lifting 47
Lifting Points - Front
Lifting Points - Rear
Lifting Points - Front 48
SECTION 100-03: Maintenance
Schedule
Manual
Maintenance Schedules - Gasoline Engines
For Maintenance Schedule information, refer to the Scheduled Maintenance Guide chapter in the Owner's
Guide.
Also available at:
www.motorcraftservice.com and select Owner Guides.
Lifting Points - Rear 49
SECTION 100-03: Maintenance
Schedule
Manual
Maintenance Schedules - Hybrid
For Maintenance Schedule Information, refer to the Scheduled Maintenance Guide chapter in the Owner's
Guide.
Also available at:
www.motorcraftservice.com and select Owner Guides.
Maintenance Schedules - Gasoline Engines 50
SECTION 100-04: Noise, Vibration and Harshness
Workshop Manual
Noise, Vibration and Harshness (NVH)
Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling,
that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue
where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a
firmer than usual response from the suspension system. NVH is a term used to describe these conditions,
which result in varying degrees of dissatisfaction. Although a certain level of NVH caused by road and
environmental conditions is normal, this section is designed to aid in the diagnosis, testing and repair of NVH
symptoms.
Acceptable NVH
All internal combustion engines and drivelines produce some noise and vibration; operating in a real world
environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these
to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when
actually the sounds are normal for the vehicle type. As a technician, it is very important to be familiar with
vehicle features and know how they relate to NVH symptoms and their diagnosis. For example, if the vehicle
has automatic overdrive, it is important to test drive the vehicle both in and out of overdrive mode.
Glossary of Terms
Amplitude
The quantity or amount of energy produced by a vibrating component (G-force). An extreme vibration has a
high amplitude. A mild vibration has a low amplitude. See Intensity.
Boom
Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming.
Buffet/Buffeting
Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass.
Buzz
A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a
high-frequency vibration. Vibration feels similar to an electric razor.
Chatter
A pronounced series of rapidly repeating rattling or clicking sounds.
Chirp
A short-duration, high-pitched noise associated with a slipping drive belt.
Maintenance Schedules - Hybrid 51
Chuckle
A repetitious, low-pitched sound. A loud chuckle is usually described as a knock.
Click
A sharp, brief, non-resonant sound, similar to actuating a ball point pen.
Clonk
A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as
hammering.
Clunk/Driveline Clunk
A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or
decelerating abruptly. Also described as a thunk.
Conductor
The components that carry (transmit) a vibration frequency from the originator to the reactor.
Cycles Per Second
Cycles per second. Same as hertz (Hz).
Cracks
A mid-frequency sound, related to squeak. Sound varies with temperature conditions.
Creak
A metallic squeak.
Cycle
The process of a vibrating component going through a complete range of motion and returning to the starting
point.
Decibel (dB)
A unit of measurement, referring to sound pressure level, abbreviated dB.
Drone
A low-frequency, steady sound, like a freezer compressor. Also described as a moan.
Drumming
A cycling, low-frequency, rhythmic noise often accompanied by a sensation of pressure on the ear drums.
Also described as a low rumble, boom or rolling thunder.
Flutter
Mid to high intermittent sound due to air flow. Similar to a flag flapping in the wind.
Chuckle 52
Frequency
The rate at which a cycle occurs within a given time.
G-force
The additional load or weight produced in an object during acceleration. When measuring the level or
amplitude of a vibration without sound, the unit G is added to associate the force of the vibration to gravity.
This is similar to measuring the weight of an object, which is also a function of gravity.
Gravelly Feel
A grinding or growl in a component, similar to the feel experienced when driving on gravel.
Grind
An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood.
Hertz (Hz)
A unit of measure used to describe noise and vibration concerns expressed in cycles per second.
Hiss
Steady, high-frequency noise. Vacuum leak sound.
Hoot
A steady, low-frequency tone, sounds like blowing over a long neck bottle.
Howl
A mid-range frequency noise between drumming and whine. Also described as a hum.
Hum
Mid-frequency steady sound, like a small fan motor. Also described as a howl.
Intensity
The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher
the sound's amplitude, the higher the intensity and vice versa. See Amplitude.
Knock
A heavy, loud, repetitious sound, like a knock on the door.
Moan
A constant, low-frequency tone. Also described as a hum.
Ping
A short-duration, high-frequency sound, which has a slight echo.
Frequency 53
Pitch
The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice
versa.
Pumping Feel
A slow, pulsing movement.
Rattle
A random and momentary or short-duration noise.
Reactor
The component, or part, that receives a vibration from an originator and conductor and reacts to the vibration
by moving.
Roughness
A medium-frequency vibration. A slightly higher frequency than a shake. This type of vibration is usually
related to drivetrain components.
Rustling
Intermittent sound of varying frequency, sounds similar to shuffling through leaves.
Shake
A low-frequency vibration, usually with visible component movement. Usually relates to tires, wheels, brake
drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as
a shimmy or wobble.
Shimmy
An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft
rotation. Also described as waddle.
Shudder
A low-frequency vibration that is felt through the steering wheel or seat during light brake application.
Slap
A resonance from flat surfaces, such as safety belt webbing or door trim panels.
Squeak
A high-pitched transient sound, similar to rubbing fingers against a clean window.
Squeal
A long-duration, high-pitched noise.
Pitch 54
Tap
A light, rhythmic or intermittent hammering sound, similar to tapping a pencil on a table edge.
Thump
A dull beat caused by 2 items striking together.
Tick
A rhythmic tap, similar to a clock noise.
Tip-In Moan
A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph).
Transient
A noise or vibration that is momentary, a short duration.
Vibration
Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and
down.
Whine
A constant, high-pitched noise. Also described as a screech.
Whistle
High-pitched noise with a very narrow frequency band. Examples of whistle noises are a turbocharger or air
flow around an antenna.
Wind Noise
Any noise caused by air movement in, out or around the vehicle.
Tap 55
Wind Noise 56
SECTION 100-04: Noise, Vibration and
Harshness
Workshop Manual
DIAGNOSIS AND TESTING Procedure revision date: 06/03/2011
Noise, Vibration and Harshness (NVH)
Special Tool(s)
Electronic Vibration Analyzer (EVA)
100-F027 (014-00344) or equivalent
EngineEAR
107-R2100 or equivalent
EngineEAR/ChassisEAR
Mastertech Series MTS 4000 Driveline
Balance and NVH Analyzer (Vetronix)
257-00018 or equivalent
Squeak and Rattle Repair Kit
164-R4900
Ultrasonic Leak Detector
Diagnostic Theory
The shortest route to an accurate diagnosis results from:
system knowledge, including comparison with a known good system.
system history, including repair history and usage patterns.
condition history, especially any relationship to repairs or sudden change.
knowledge of possible sources.
using a systematic diagnostic method that divides the system into related areas.
The diagnosis and correction of NVH symptoms requires:
a road or system test to determine the exact nature of the symptom.
an analysis of the possible causes.
testing to verify the cause.
repairing any symptoms found.
a road test or system test to make sure the cause has been corrected or brought back to within an
acceptable range.

Diagnostic Procedure Overview
Qualifying the symptom by the particular sensation present can help narrow down the cause. Always use the
Noise, Vibration and Harshness (NVH) 57
"symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the
problem into related areas to correct the customer concern.
Verify the "symptom".
Determine which "system(s)" can cause the "symptom" using the diagnostic tools described in this
section.

After determining the possible "system(s)", refer to the appropriate section in this manual to identify
the worn or damaged "components".

After identifying the "components", identify the "cause" of the failure.
Tools and Techniques
The diagnostic tools allow for a systematic collection of information that is necessary to accurately diagnose
and repair NVH problems. Remember that the vibrating source component (originator) may only generate a
small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another
receiving component (reactor), due to contact with other components (transfer path). For the best results, carry
out the test as follows:
Test drive the vehicle with the vibration sensor inside the vehicle. a.
Place the sensor in the vehicle according to feel.
If the condition is felt through the steering wheel, the source is most likely in the front of the
vehicle.

A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive
axle or rear wheels and tires.

b.
Record the readings. Also note when the condition begins, when it reaches maximum intensity and if
it tends to diminish above/below a certain speed.
If a vibration symptom is vehicle speed related, the tire and wheel rpm/frequency and
driveshaft frequency should be calculated.

If a vibration symptom is engine speed related, the engine, engine accessory and engine firing
frequencies should be calculated.

Frequencies with an amplitude reading of 0.06 Gs or less are barely perceptible NVH levels.
No corrective action is necessary.

c.
Place the vibration sensor on or near the suspect area outside the vehicle. d.
Continue the road test, driving the vehicle at the speed the symptom occurs and take another reading. e.
Compare the readings.
A match in frequency indicates the problem component or area.
An unmatched test could indicate the symptom is caused by the engine, torque converter or
engine accessory. Use the diagnostic tools in the rpm mode and check if symptom is rpm
related.

f.
The following diagnostic tools and techniques can be used separately or in conjunction with each other to aid
in the diagnosis of NVH symptoms. They are listed in order of preference for ease in their use for locating
these symptoms.
NVH Analyzer (Vetronix)
The Mastertech Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix) and the MTS 4100
NVH analyzers are tools to aid in the identification and isolation of a noise, vibration or harshness symptom
in a vehicle. They measure noise and vibration data and compare it with data obtained from the vehicle's PCM
as well as vehicle variants that were entered by the user such as pulley size, axle ratio and tire size in order to
provide possible sources. The Mastertech Series MTS 4000 Driveline Balance and NVH Analyzer
(Vetronix) and the MTS 4100 have the following characteristics:
Interface with the vehicle's computer system
NVH Analyzer (Vetronix) 58
Support and store vibration data input from 1 or 2 accelerometers
Support and store noise data input from 2 microphones
Provide a photo-tachometer for operation of the driveshaft balancing function
Provide a strobe output capable of driving a standard timing light
Contain a real-time clock circuit that provides time and date information which is used for tagging test
data

Have the capability to print to an external printer and interface with a PC
Can be powered from a variety of power sources: cigarette lighter, AC power or the internal battery
pack

The Mastertech Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix) and the MTS 4100
NVH analyzers have 4 main operating modes. The first is for vibion diagnosis. This mode measures data from
1 or 2 accelerometers simultaneously while obtaining data from the vehicle. Then it carries out a frequency
analysis on the accelerometer information and compares the vibration frequencies with the frequencies
associated with various rotating components within the vehicle. The data can be presented in 4 different
display modes: principle component, bar chart, frequency spectrum or waterfall. All display mode formats
contain the same common elements, such as amplitude.
The second is for noise diagnosis. This mode measures noise from 1 or 2 microphones simultaneously. All
noise measurements are in decibels (dBs). All frequency bands used for noise measurements are the same as
for the vibration measurements, up to 1,000 Hz.
The third is driveshaft balancing. Driveshaft balancing is done using 1 or 2 accelerometers and a
photo-tachometer. The accelerometers measure the vibration at both ends of the driveshaft, while the
photo-tachometer measures the rotation speed and position reference. Refer to Section 205-00 .
The fourth is the strobe. A strobe or standard timing light can be connected to an analyzer, to provide a means
for measuring rotation speed. The strobe function is used for isolating the source of a vibration.
Electronic Vibration Analyzer (EVA)
The Electronic Vibration Analyzer (EVA) is a hand-held electronic scan tool which will assist in locating the
source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for
testing purposes. The unit displays the 3 most common vibration frequencies and their corresponding
amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude)
of each vibration being displayed and its relative G-force. The keypad is arranged to make the EVA simple to
program and use. Some of the functions include the ability to average readings as well as record, play back
and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating
components such as a driveshaft or engine accessories.
Item Description
1 Electronic Vibration Analyzer (EVA) screen
2 Frequency mode displayed in rpm or Hz
3 Active sensor input (A or B)
4 Current active mode
Electronic Vibration Analyzer (EVA) 59
5 G-force indicators or the strongest frequencies in descending strength of each vibration
6 Strength of each vibration
7 Frequency in rpm/Hz of each vibration
Record the readings taken with the diagnostic tool.
Frequencies should be read in the "average" mode.
Frequencies have a range of plus or minus 2 Hz. A reading of 10 Hz can be displayed as an 8 Hz
through 12 Hz.

Vibrate Software
Vibrate Software (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the
source of unacceptable vibrations. The engine's crankshaft is the point of reference for vibration diagnosis.
Every rotating component will have an angular velocity that is faster, slower or the same as the engine's
crankshaft. Vibrate Software calculates the angular velocity of each component and graphically represents
these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how
Vibrate Software helps diagnose a vibration symptom:
Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire,
driveshaft and engine vibrations.

Print a Vibration Worksheet graph. The printed graph is to be used during the road test.
Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration
frequency rpm and the engine rpm on the worksheet graph. The point on the graph where the
vibration frequency rpm reading and the engine rpm reading intersect indicates the specific
component group causing the symptom.
A frequency measurement tool capable of measuring vibration frequency and engine rpm will
be needed.

Provides graphics of diagnostic procedures to aid in testing components.
Reed Tachometer
The Reed tachometer is a hand-held vibration sensor which will assist in locating the source of unacceptable
vibrations. The vibration sensor can be placed anywhere in the vehicle fosting purposes. The Reed tachometer
contains several reeds that are tuned to vibrate or resonate at different frequencies ranging from 10 to 80 Hz or
600 to 4,800 rpm. Though the Reed tachometer is able to measure multiple frequencies, it does not measure
amplitude.
Sirometer
The Sirometer measures frequency in hertz and rpm. To use the Sirometer, place it on any vibrating
component and slowly scroll the wire out by turning the knob. As the length of wire changes, so does its
natural frequency. Find the length of wire that vibrates with the highest amplitude. This frequency will match
that of the vibrating component. Read the frequency for that length of wire.
Combination EngineEAR/ChassisEAR
An electronic listening device used to quickly identify noise and the location under the chassis while the
vehicle is being road tested. The ChassisEARs can identify the noise and location of damaged/worn wheel
bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings.
Vibrate Software 60
EngineEAR Basic Unit
An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of
damaged/worn bearings in generators, coolant pumps, A/C compressors and power steering pumps. They are
also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise.
The EngineEAR has a sensing tip, amplifier and headphones. The directional sensing tip is used to listen to
the various components. Point the sensing tip at the suspect component and adjust the volume with the
amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations,
generated by or passing through, the component. Various volume levels can reveal different sounds.
Mechanic's Stethoscope
A mechanic's stethoscope is an inexpensive tool for locating noises in engines and other moving parts. It can
be used to help diagnose piston slap, worn gears, faulty valves, coolant pump failure, damaged gaskets,
defective bearings and body squeaks.
Squeak and Rattle Repair Kit
The Squeak and Rattle Repair Kit (Rotunda tool number 164-R4900) contains lubricants and self-adhesive
materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the
following materials:
PVC (soft foam) tape
Urethane (hard foam) tape
Flocked (black fuzzy) tape
UHMW (frosted) tape
Squeak and rattle oil tube
Squeak and rattle grease tube
Ultrasonic Leak Detector
The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is
weatherstripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative
emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the
ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the
vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is
approached, a beeping sound is produced which increases in both speed and frequency.
Write-Up Job Aid
To assist the service advisor and the technician, a Write-Up Job Aid used during the interview process is
included with this material. The Write-Up Job Aid serves as a place to record all important symptom
information.
EngineEAR Basic Unit 61
1: Customer Interview
The diagnostic process starts with the customer interview. The service advisor must obtain as much
information as possible about the symptom and take a test drive with the customer. There are many ways a
customer will describe NVH symptoms and this will help minimize confusion arising from descriptive
language differences. It is important that the symptom is correctly interpreted and the customer descriptions
are recorded. During the interview, complete the write-up job aid and ask the following questions:
When was it first noticed?
Did it appear suddenly or gradually?
Did any abnormal occurrence coincide with or precede its appearance?
Use the information gained from the customer to accurately begin the diagnostic process.
2: Pre-Drive Check
It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the
vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle.
The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything
that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle
on the road.
3: Preparing for the Road Test
Observe the following when preparing for the road test:
Review the information recorded on the write-up job aid. It is important to know the specific
symptom the customer has with the vehicle.

Do not be misled by the reported location of the noise/vibration. The cause can actually be some
Ultrasonic Leak Detector 62
distance away.
Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal
testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in
which the condition occurs.

While observing that they are not related to the symptom, eliminate the following:
If possible, lower the radio antenna in order to minimize turbulence.
Identify anything that could potentially make noise or be a source of wind noise.
Inspect the vehicle for add-on items that create vibration/noise.
Turn off the radio and the heating and cooling system blower.

The engine speed is an important factor in arriving at a final conclusion. Therefore, connect a
diagnostic tool, Vetronix, or an accurate tachometer to the engine, even if the vehicle has a
tachometer. This will make sure of an exact engine speed reading.

4: Verify the Customer Concern
Verify the customer concern by carrying out a road test, an engine run-up test or both.
The decision to carry out a road test, an engine run-up test or both depends on the type of NVH symptom. A
road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A Drive
Engine Run-Up (DERU) or a Neutral Engine Run-Up (NERU) test identifies noises and vibrations relating to
engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests,
however, they will eliminate many possibilities if carried out correctly.
5: Road Test
NOTE: It may be necessary to have the customer ride along or drive the vehicle to point out the symptom.
During the road test, take into consideration the customer's driving habits and the driving conditions. The
customer's concern just may be an acceptable operating condition for that vehicle.
The following is a brief overview of each test in the order in which it appears. A review of this information
helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After
reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this
process.
The Slow Acceleration Test is normally the first test to carry out when identifying an NVH symptom,
especially when a road test with the customer is not possible.

The Heavy Acceleration Test helps to determine if the symptom is torque-related.
The Neutral Coast Down Speed Test helps to determine if the symptom is vehicle speed-related.
The Downshift Speed Test helps to determine if the symptom is engine speed-related.
The Steering Input Test helps to determine how the wheel bearings and other suspension components
contribute to a vehicle speed-related symptom.

The Brake Test helps to identify vibrations or noise that are brake related.
The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy
surface.

The Engine Run-Up Tests consist of the Neutral Engine Run-Up (NERU) Test and the Drive Engine
Run-Up (DERU) Load Test. These tests help to determine if the symptom is engine speed-related.

The Neutral Engine Run-Up (NERU) Test is used as a follow-up test to the Downshift Speed Test
when the symptom occurs at idle.

The Drive Engine Run-Up (DERU) Load Test helps to identify vibration/noise sensitive to engine
load or torque. It also helps to reproduce engine speed-related symptoms that cannot be duplicated
when carrying out the Neutral Engine Run-Up (NERU) Test or the Neutral Coast Down Test.

The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related
symptoms.
The Vehicle Cold Soak Procedure helps to identify symptoms occurring during initial start-up and
when an extended time lapse occurs between vehicle usage.

Slow Acceleration Test
To carry out this test, proceed as follows:
Slowly accelerate to the speed where the reported symptom occurs. Note the vehicle speed, the engine
rpm and, if possible, determine the vibration frequency.

Attempt to identify from what part of the vehicle the symptom is coming.
Attempt to identify the source of the symptom.
If the source of the symptom has been identified as a result of this test, proceed to the appropriate
section for further diagnosis and repair. If the source has not been identified, continue with the road
test.

Heavy Acceleration Test
Accelerate hard from 0-64 km/h (0-40 mph).
Decelerate in a lower gear.
The symptom is torque-related if duplicated while carrying out this test.
test.

Neutral Coast Down Speed Test
Drive at a higher rate of speed than where the symptom occurred when carrying out the Slow
Acceleration Test.

Place the transmission in NEUTRAL and coast down past the speed where the symptom occurs.
The symptom is vehicle speed-related if duplicated while carrying out this test. This eliminates the
engine and the torque converter as sources.

If the symptom was not duplicated while carrying out this test, carry out the Downshift Speed Test to
verify if the symptom is engine speed related.

test.

Downshift Speed Test
Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test.
Drive at the engine rpm where the symptom occurs.
The symptom is engine speed related if duplicated while carrying out this test. This eliminates the
tires, wheels, brakes and the suspension components as sources.

If necessary, repeat this test using other gears and NEUTRAL to verify the results.
test.

Steering Input Test
Drive at the speed where the symptom occurs, while making sweeping turns in both directions.
If the symptom goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of
Four-Wheel Drive (4WD) applications), and tire tread wear are all possible sources.

test.

Brake Test
With the brake released, accelerate the vehicle. While coasting (brake pedal released) to a stop in
NEUTRAL, note any abnormal rate of deceleration. Abnormal deceleration could indicate a parking
brake or service brake that is not fully releasing.

Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light
braking applications.

Accelerate to 89-97 km/h (55-60 mph). Moderately apply the brakes and slow the vehicle to a stop.
A brake vibration can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard
upon brake application and should diminish when the brake is released. For vehicles with separate
park brake shoes, noise or vibration from the parking brake system will not be affected by applying
the hydraulic brakes. On these systems, the parking brake system requires inspection if a parking
brake concern is suspected.

brake section(s) for further diagnosis and repair. If the source has not been identified, continue with
the road test.

Road Test Over Bumps
Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is
coming from the front or the back and the left or the right side of the vehicle.

test.

Neutral Engine Run-Up (NERU) Test
Install a tachometer.
Increase the engine rpm up from an idle to approximately 4,000 rpm while in PARK on Front Wheel
Drive (FWD) vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the
engine rpm and, if possible, determine the vibration frequency.

Attempt to identify what part of the vehicle the symptom is coming from.
Attempt to identify the source of the symptom.
test.

Drive Engine Run-Up (DERU) Load Test
WARNING: Block all wheels, set the parking brake and firmly apply the service brake to reduce the
risk of vehicle movement during this procedure. Failure to follow these instructions may result in
NOTICE: Do not carry out the Engine Load Test for more than 5 seconds or damage to the
transmission or transaxle may result.
Block the front and rear wheels.
Apply the parking brake and the service brake.
Install a tachometer.
Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to
approximately 2,000 rpm. Note the engine rpm and, if possible, determine the vibration frequency.

Repeat the test in REVERSE.
If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or
transaxle mounts.

If the symptom is definitely engine speed-related, carry out the Engine Accessory Test to narrow
down the source.

test.

Engine Accessory Test
NOTICE: Limit engine running time to one minute or less with belts removed or serious engine damage
will result.
NOTE: Use a frequency measurement tool to pinpoint accessory vibrations. A listening device, such as an
EngineEAR, will also help to identify noises from specific accessories.
Remove the accessory drive belt(s).
Increase the engine rpm to where the symptom occurs.
If the vibration/noise is duplicated when carrying out this test, the belt(s) and accessories are not
sources.

If the vibration/noise was not duplicated when carrying out this test, install the accessory belt(s), one
at a time, to locate the source.

test.

Vehicle Cold Soak Procedure
To carry out this procedure, proceed as follows:
Test preparations include matching customer conditions (if known). If not known, document the test
conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to
3 minutes.

Park the vehicle where testing will occur. The vehicle must remain at or below the symptom
temperature (if known) for 6-8 hours.

Before starting the engine, conduct a visual inspection under the hood.
Turn the key on, but do not start the engine. Listen for the fuel pump, ABS and air suspension system
noises.

Start the engine.
Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the
general location of the vibration/noise. Then, search for a more precise location by using a
stethoscope or EngineEAR.

test.

Classify NVH Symptom
For NVH concerns, it is necessary to classify the customer's concern into one of the 3 categories: noise,
vibration or harshness. The reason for this is that a customer concern may consist of a combination of
symptoms involving noise and vibration, or vibration and harshness. In cases where there are combination
symptoms, determine which diagnostic path to follow: noise, vibration or harshness. For example, if a
customer has a concern involving a noise and a vibration, and it is determined that it is vehicle speed-related,
follow the vibration diagnostic path.
Noise Symptoms
Once a symptom is classified as a noise, the particular conditions under which the noise occurs need to be
identified. These conditions are identified and verified during the road test. For example, a noise may only
occur while turning. The next step is to determine which systems on the vehicle are related to that condition.
In this case, the steering system and wheel/tire system may be suspect. After identifying possible systems, a
preliminary inspection of these systems should be done. If the source of noise is still unidentified, use a
listening device (such as the ChassisEAR) to pinpoint the source. Once the source has been identified,
determine if this source is related to the suspected system previously identified. If it is related, then complete
the repair to resolve the customer concern. If it is unrelated, then it is possible that the source of the noise is a
reactor to a noise being transmitted through a transfer path. If this is the case, repairing the reactor will not
resolve the customer concern. The transfer path must be identified and a determination made if the noise is
normal, but accentuated by the transfer path (conductor), or if the originator is the fault causing excessive
noise to transfer to another component through a conductor. There is a relationship between systems identified
as related to conditions and the noise transfer path. In some cases, the condition under which the noise occurs
has nothing to do with the identified source. This relationship is important in the diagnosis of noise concerns.
It is the first clue that the identified source of noise might be a reactor and that further investigation is needed
to diagnose a possible noise transfer path concern. Based on the results from the road test, make a
determination of which action in the symptom chart to take first.
Vibration Symptoms
Most vibrations consist of movements back and forth or up and down that repeat. Every time the vibrating
component goes through its complete range of motion and returns to the starting point is called a cycle. The
rate at which these cycles occur within a given time is called the frequency. Frequency is measured in cycles
per second or Hertz (Hz). One cycle per second equals one Hz. Once the frequency of a vibration is known,
calculations can be done to determine the system that is the source of the concern.
Order of Vibration
The order of a vibration refers to how often the vibration is present in one revolution of the component. For
example, a vibration that is present once each revolution of a component would be a first order vibration. A
vibration present twice each revolution of the component would be a second order vibration. Vibration orders
do not have to be whole numbers, they can have decimal values such as 1.5 order vibration or 3.08 order
vibration.
The concept of order of vibration is important to remember when the measured frequency of a vibration does
not seem to match the frequency calculations of any of the likely systems or components. As the order
increases, the frequency of the vibration will also increase by a multiple of that number.
For example, vibration may be present where the frequency is measured at 14 Hz. After doing the necessary
calculations it is determined the first order tire and wheel frequency is 7 Hz and the first order driveshaft
frequency is 22 Hz. Based on this information if can be determined the vibration is most likely a second order
tire and wheel vibration: 7 Hz (first order tire and wheel frequency) multiplied by 2 (second order) equals 14
Hz (second order tire and wheel frequency).
Relationship of Vibration Frequency to Order of Vibration
After carrying out the road test as described in this section, the vibration was determined to be either
vehicle-speed related or engine-speed related. That determination will identify the vibration frequency
calculations that should be done.
Vibration Type Calculate
Vehicle-speed related Tire-speed vibration frequency
Driveshaft-speed vibration frequency
Engine-speed related Engine vibration frequency
Engine accessory vibration frequency
Engine firing vibration frequency
In calculating and using frequency readings, it is important to remember the direct relationship between Hz
and rpm. One Hz is equal to 60 rpm. This is easy to remember; think of Hz as cycles per second. There are 60
seconds in a minute, therefore multiply Hz reading by 60 to get rpm. Conversely, divide rpm by 60 to get Hz.
Use the Frequency and RPM Calculations Worksheet to calculate system/component frequencies. The
worksheet provides the necessary steps to determine each system/component group frequency.
Frequency Calculations
Calculating Tire and Wheel Frequency
For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and
wheel rpm and frequency by carrying out the following:
Measure the diameter of the tire.
Record the speed at which the vibration occurs.
Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency
Chart.

If the vehicle speed is not listed, calculate the tire and wheel frequency as follows:
Divide the vehicle speed at which the vibration occurs by 16 km/h (10 mph). Multiply that
number by the 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide
that number by 60.

For example, if calculating the frequency based on vehicle speed in km/h for a 64 km/h
vibration with 835 mm tires, divide 64 km/h by 16 km/h = 4. Multiply 4 by 105 rpm = 420.
Divide 420 by 60 seconds = 7 Hz at 64 km/h.

If calculating the frequency based on vehicle speed in mph for a 40 mph vibration with 33
inch tires, divide 40 mph by 10 mph = 4. Multiply 4 by 105 rpm = 420. Divide 420 by 60
seconds = 7 Hz at 40 mph.

The calculated frequency of 7 Hz is the first order tire and wheel vibration; the second order
tire and wheel vibration would be twice this number at 14 Hz; the third order tire and wheel
vibration would be 21 Hz; and so on.

Tire Speed and Frequency Chart
Tire Diameter Tire RPM/Hz Tire RPM/Hz Tire RPM/Hz Tire RPM/Hz
mm (in) @ 16 km/h (10 mph) @ 80 km/h (50 mph) @ 97 km/h (60 mph) @ 113 km/h
(70 mph)
483 (19) 182 910/15 1,092/18 1,274/21
508 (20) 173 865/14 1,038/17 1,211/20
533 (21) 165 825/14 990/16 1,155/19
560 (22) 158 790/13 948/16 1,106/18
585 (23) 151 755/13 906/15 1,057/18
610 (24) 145 725/12 870/14 1,015/17
635 (25) 139 695/12 834/14 973/16
660 (26) 134 670/11 804/13 938/16
685 (27) 129 645/11 774/13 903/15
710 (28) 124 620/10 744/12 868/14
735 (29) 119 595/10 714/12 833/14
760 (30) 115 575/10 690/11 805/13
785 (31) 111 555/9 666/11 777/13
810 (32) 108 540/9 648/11 756/13
835 (33) 105 525/9 630/10 735/12
864 (34) 102 510/8 612/10 714/12
Calculating Driveshaft Frequency
Knowing the tire and wheel frequency allows for easy calculation of driveshaft frequency. The driveshaft
drives the tires through the rear axle. Therefore, to determine driveshaft frequency, multiply tire and wheel
frequency by the ratio of the rear axle. Calculate driveshaft frequency by performing the following steps:
Obtain the axle ratio of the vehicle. Suppose the vehicle has a vibration problem at 64 km/h (40 mph)
and a rear axle ratio of 2.93:1.

Multiply the tire and wheel frequency of 7 Hz (calculated previously) with the rear axle ratio of
2.93:1. This results in a driveshaft frequency of 21 Hz at a vehicle speed of 64 km/h (40 mph).

The calculated frequency of 21 Hz is the first order driveshaft frequency; the second order frequency of the
driveshaft is twice this number, or 42 Hz; and so on.
Calculating Engine Frequency
Use the engine rpm where the vibration symptom occurs to determine engine frequency. Calculate engine
frequency by dividing the engine rpm by 60 (the number of seconds in a minute). For example, if the
corresponding engine rpm of a vibration concern on a vehicle is 2,400 rpm, the resulting engine frequency is
40 Hz. Therefore, a 40 Hz vibration is a first order engine vibration. For purposes of vibration diagnosis, the
engine also includes the torque converter and exhaust system.
Calculating Engine Accessory Frequency
Belt-driven engine accessories often produce vibrations at different frequencies than the engine itself. This is
because the drive ratio created by the different size pulleys causes them to rotate at different speeds.
Determining engine accessory frequency is comparable to calculating driveshaft frequency.
Calculate engine accessory frequency by performing the following steps:
Determine the size ratio factor between the accessory pulley and the crankshaft pulley. For example,
if the diameter of the crankshaft pulley is 6 inches and the accessory pulley diameter is 2 inches, the
accessory pulley rotates 3 times for every crankshaft rotation (6 divided by 2).

Multiply the engine rpm where the vibration condition occurs by the number of times the accessory
pulley is rotating per crankshaft revolution. For example, if the engine rpm is 2,400 rpm, the
accessory is rotating at 7,200 rpm (2,400 rpm multiplied by 3).

Divide the accessory rpm by 60 (the number of seconds in a minute). In this example, the engine
accessory frequency is 120 Hz (7,200 divided by 60).

Calculating Engine Firing Frequency
Engine firing frequency is a term used to describe the pulses an engine creates from the firing of the cylinders.
Engine firing frequency depends on how many cylinders an engine has. The number of times an engine fires a
cylinder with each crankshaft revolution is equal to one-half the number of cylinders. A 4-cylinder engine
fires 2 cylinders with each crankshaft revolution. Two revolutions of the crankshaft fire all 4 cylinders. A
6-cylinder engine fires 3 cylinders with each crankshaft revolution. An 8-cylinder engine fires 4 cylinders for
each crankshaft revolution.
Calculate engine firing frequency by performing the following steps:
Multiply the engine rpm where the vibration symptom occurs by the number of cylinders fired with
each crankshaft revolution. For example, a vehicle with a 6-cylinder engine experiences a vibration
concern at 2,400 rpm. The engine is firing the cylinders at 7,200 times per minute (3 multiplied by
2,400).

Divide this number by 60 (the number of seconds in a minute) to obtain the engine firing frequency.
In this example, the engine firing frequency is 120 Hz (7,200 divided by 60) at 2,400 rpm.

Frequency and RPM Calculations Worksheet
Harshness Symptoms
Harshness is customer perception which gives the impression of no isolation from the tire/wheel and
suspension system. Harshness may be caused by road conditions, temperature changes, component damage
and/or incorrect customer modifications on original components/specifications. Customers usually experience
harshness when the vehicle is driving over bumps or potholes and in cold weather conditions. Harshness can
also be experienced with excessive tire pressure, sporty tires, heavy-duty springs and shocks, or other vehicle
modifications. Some aftermarket tires, even with the correct size, may change vehicle behavior and produce
customer concerns. The first step in diagnosing a harshness concern is to determine if the concern was
experienced only in certain specific operating conditions, such as large potholes or extremely cold weather. In
these cases, harshness should be considered normal. A known good vehicle can be driven under the same
conditions and the rides can be compared to determine whether the concern is normal or vehicle specific. The
second step is to check tire pressure and make sure it was set within vehicle specifications. The third step is to
inspect for aftermarket or modified components and determine if they are the cause of the harshness
complaint. If the harshness concern persists after the above steps, it is possible that some components are
damaged. Based on the results from the road test, make a determination of which action in the symptom chart
to take first.
NVH Symptom Chart Categories
A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. Use
the symptom and possible system categories as follows:
Identify the operating condition that the vehicle is exhibiting.
Match the operating condition to the symptom.
Verify the symptom.
Calculate the frequency and order of the symptom.
Identify which category or system(s) could cause the symptom.
Refer to the section indicated to identify and diagnose the symptom or confirm that the system is not
the source of the condition.

Use the diagnostic instructions in this section along with the necessary listed tools to identify the vibration
order and to isolate the symptom and the possible systems associated with that symptom. Then based on the
results from the road test, make a determination of which action in the symptom chart to take first. Since it is
possible any one of multiple systems may be the cause of the symptom, it may be necessary to use a process
of elimination type diagnostic approach to pinpoint the concern. Refer to the section(s) indicated to identify
and isolate the cause or rule that system out as being the causal system for the symptom.
Vehicle-Speed Related Vibrations
NOTE: Any assembly that is out of balance will only cause a first order vibration, it will not cause a higher
order vibration.
When a vehicle-speed related vibration is present, both tire-speed related vibration and driveshaft-speed
related vibration calculations should be carried out.
Symptom Chart - Tire-Speed Related Vibrations
Symptom Chart - Tire-Speed Related Vibrations
Symptom Chart - Driveshaft-Speed Related Vibrations
Symptom Chart - Driveshaft-Speed Related Vibrations
order vibration.
ConditionPossible SourcesAction
First order driveshaft vibration
Driveshaft <
REFER to Section 205-00 .
Rear drive axle/differential
Second order driveshaft vibration
U-joint
Output shaft bushing in transmission/transaxle
Refer to the appropriate section in Group 307 for the procedure. Refer to the appropriate section in
Group 308 for the procedure. GO to the Symptom Chart in the appropriate section.

Third order driveshaft vibration
Rear drive axle/differential
Symptom Chart - Engine-Speed Related Vibrations
Symptom Chart - Engine-Speed Related Vibrations
NOTE: When an engine-speed related vibration is present, engine, engine accessory and engine firing
calculations should be carried out.
order vibration.
NOTE: Some engine-speed related vibrations are normal though they should not be felt in the passenger
compartment.
0.5 order engine vibration
Engine
First through sixth order engine vibration
Engine
Transmission/transaxle

Engine mounts
Transmission/transaxle mounts

Exhaust system
Belt driven accessory speed vibration
Engine pulley
Coolant pump
Generator
A/C compressor
REFER to Section 412-00A .
Power steering pump
REFER to Section 211-00B .
Vacuum pump
Accessory drive belt
Symptom Chart - Noise, Air Leaks or Water Leaks
Symptom Chart - Noise, Air Leaks or Water Leaks
Symptom Chart - Harshness
Symptom Chart - Harshness
SECTION 501-00: Body System - Genal
Information
Workshop Manual
SPECIFICATIONS Procedure revision date: 06/03/2011
Material
Item Specification Fill
Capacity
3MTM Strip Caulk - Black
051135-08578
WSB-M4G32-C -
Seam Sealer
TA-2
- -
Clear Silicone Rubber
TA-32
ESB-M4G92-A -
Silicone Gasket and Sealant
TA-30
WSE-M4G323-A4 -
Silicone Spray Lubricant
XL-6
ESR-M13P4-A -
Trim and Weatherstrip
Adhesive
TA-14-A
- -
SECTION 501-00: Body System - General
Information
Workshop Manual
Insulation
Insulation is used as a sound-deadener to reduce exterior road and powertrain noises from the interior of the
vehicle. Mastic insulators are also used as insulation. For information on the location of the mastic insulators,
refer to Section 501-35 . 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- and D-pillar sections.
behind the rear quarter trim panel.
It has heat-bondable mastic deadeners for improved NVH characteristics.
&nbspP>
Insulation 77
Information
Workshop Manual
Body Sealer Types And Applications
Seam Sealer
Seam Sealer TA-2 or equivalent:
is a heavy-bodied, non-sag adhesive/sealer for use on standing cosmetic seams, truck bed seams,
tooled door skin seams and floor pans.

can be used on water leaks and noise concerns.
Clear Silicone Rubber TA-32 or equivalent meeting Ford Specification ESB-M4G92-A:
does not run.
is fast drying.
remains semi-elastic.
can be used for sealing water leaks, noise concerns, remounting trim and repairing torn
weatherstripping.

Silicone Gasket and Sealant TA-30 or equivalent meeting Ford specification WSE-M4G323-A4:
is a form-in-place gasket and multi-purpose adhesive/sealant.
is a room temperature curing silicone rubber.
Caulking Cord
3MTM Strip Caulk-Black 051135-08578 or equivalent meeting Ford specification WSB-M4G32-C:
is a heavy-bodied, plastic base with a filler.
is commonly known as perma-gum.
is used on spot-weld holes and between surfaces not sealed with a gasket.
Weatherstrip Adhesive
Trim and Weatherstrip Adhesive TA-14-A or equivalent:
is a quick drying, strong adhesive designed to hold weatherstripping onto all body panels and
surrounding metal.

Silicone Lubricant
Silicone Spray Lubricant XL-6 or equivalent meeting d specification ESR-M13P4-A:
is used to keep the door and the window weatherstrip pliable and soft.
makes the door easier to close.
retards weatherstrip squeaks.
retards weatherstrip wear.
Body Sealer Types And Applications 78
helps retain door window alignment by reducing friction between the glass frame and the rubber
weatherstrip.

should not be used prior to painting.
Body Sealer Types And Applications 79
Information
Workshop Manual
Body System
Material
Item Specification
Seam Sealer
TA-2
-
TA-30
WSE-M4G323-A4
Inspection and Verification
Dust and Water Leaks
Most dust and water leaks occur due to missing or mis-installed body sealer or components. The source of the
leak is detected by:
pressurizing the vehicle and testing with soapy water.
Locate and tape off the body vents.
Turn the blower motor on the high position.
Turn the air recurculation to the off mode.
Close the windows and doors.
Open the hood and spray soapy water along body seams and grommete sure to test the areas
arround the A-pillar at the fender and the hood hinge area.

Check for bubbles.

inspecting for a dust pattern or water path near and above the area in question.
removing any trim or carpet in the general area of the leak.
road testing or water-hose testing the vehicle.
placing a bright light under the vehicle, removing any necessary trim or carpet and inspecting the
interior of the body at joints and weld lines.

Wind Noise
Most wind noise leaks occur at the corners of the windows or in the doors. Wind noise is detected by driving
the vehicle at highway speeds or at speeds as specified by the customer. The vehicle should be driven in 4
different directions, with all the windows CLOSED, the radio OFF and the A/C blower motor OFF.
Squeak and Rattle
Squeak and rattle noises are generally caused by loose parts, contact or relative movement between 2 surfaces
or loose wires and connectors. The source of the noise can be detected by stopping movement of the suspect
part by hand or by using dampening or low friction materials.
Symptom Chart - NVH
Body System 80
Symptom Chart - NVH
NOTE: NVH symptoms should be identified using the diagnostic tools that are available. For a list of these
tools, an explanation of their uses and a glossary of common terms, refer to Section 100-04 . Since it is
possible that any one of multiple systems may be the cause of a symptom, it may bcessary to use a process of
elimination type of diagnostic approach to pinpoint the responsible system. If this is not the causal system for
the symptom, refer back to Section 100-04 for the next likely system and continue diagnosis.
Draft/wind noise and water leak around door perimeter
Loose fit seal
PINCH seal carrier to improve retention on seal flange.
Seal installed incorrectly
REINSTALL the seal.
Door misaligned
REALIGN the door. CHECK door gaps and fit in door opening and ADJUST as necessary. REFER to
Section 501-03 .

Scuff plate installed incorrectly
REINSTALL the scuff plate.
Seal or seal pushpins damaged
INSTALL a new seal/pushpins.
Sheet metal joints in door or door opening
SEAL leaks with silicone gasket and sealant.
Draft/wind noise and water leak around glass run
Door glass misaligned
ADJUST door glass.
Glass run installed incorrectly
REINSTALL glass run.
Leak path behind glass run
INSTALL foam rope behind glass run.
Glass run channel spread wide
PINCH glass run channel to reduce size of opening.
Body System 81
Glass run damaged
INSTALL a new glass run.
Draft/wind noise and water leak at inner belt line
Belt line seal installed incorrectly on flange
ADJUST seal. (Do not bend the flange.)
No contact with side glass
ADJUST door glass.
No contact with glass runs at both ends of belt line seal
ADJUST belt line seal or ADD foam at seal ends.
Belt line seal damaged
INSTALL a new seal.
Draft/wind noise and water leak at outer belt line
Belt line seal installed incorrectly on flange (no glass contact)
ADJUST seal.
Belt line seal does not contact the glass
ADJUST door glass.
No contact with glass runs at both ends of belt line seal
ADJUST belt line seal or ADD foam at seal ends.
Belt line seal damaged
INSTALL a new seal.
Draft/wind noise at inner door handle/speaker opening
Hole in weathershield
SEAL hole with suitable tape.
Weathershield misaligned
REALIGN weathershield. INSTALL a new weathershield if pressure sensitive adhesive fails.
Exterior door handle seal misaligned/damaged
REALIGN or INSTALL a new seal as necessary. REFER to Section 501-14 .
Body System 82
Speaker or speaker seal missing or damaged
INSTALL a new door speaker.
Draft/wind noise and water leaks at floor pan and grommets
Missing or damaged plugs/grommets
CHECK plugs/grommets for correct installation or damage. INSTALL new plugs/grommets if
necessary.

Road noise
Missing mastic insulators
CHECK for missing mastic insulators. REFER to Section 501-35 .
Missing body insulators
CHECK for missing body insulators.
Rattles in body/doors and instrument panel
Loose wires/cables
CHECK that all wires/cables are correctly routed and inserted in correct retainers.
Loose objects/components in door wells, pillars quarter trim panels
CHECK doors by carefully striking underside of doors with a rubber mallet while listening for rattles
in doors and pillars. REMOVE or TIGHTEN loose objects/components.

Buzz from instrument panel components
IDENTIFY which components of the instrument panel are buzzing. SECURE/FASTEN components
as necessary, ADD foam or felt as needed if rattle persists.

Door drain holes collecting water
Holes clogged with mud or road tar
CLEAN drain holes of foreign material with a punch or screwdriver. CHECK drain holes regularly.
Wind noise from exterior rear view mirror
Exterior mirror housing misaligned
REALIGN with edges shingled to airflow, with no gaps.
Mirror sail gasket folded/misaligned
REINSTALL with gasket unfolded and aligned correctly.
Mirror housing trim cap installed incorrectly
Body System 83
REINSTALL with edges shingled to airflow.
Air leak through mirror housing hinge
Fully ENGAGE mirror into its operating position. USE foam to block air path through hinge.
Inner sail trim installed incorrectly
REINSTALL sail trim. ADJUST door trim.
Inner sail gasket/barrier installed incorrectly
REINSTALL trim cover with gasket/barrier aligned correctly.
Air path through wiring bundle/fastener access holes
BLOCK air path(s) with foam/tape.
Exposed fastener access hole on mirror housing/sail
INSTALL a new cap if missing.
Rattle/vibration from exterior rear view mirror
Mirror glass adjustment screws loose
REMOVE mirror glass and TIGHTEN mirror glass adjustment motor screws. REFER to Section
501-09 .

Mirror mounting nuts loose
TIGHTEN mirror mounting nuts. REFER to Section 501-09 .
Aftermarket air deflector/stone shields
If possible, REMOVE aftermarket air deflector/stone shield, then ROAD TEST vehicle. If concern is
no longer present, ADVISE customer that aftermarket component was causing concern.

Draft/wind noise and water leak around perimeter of all fixed glass
Gaps in the sealant bead
APPLY approved sealant.
Air traveling up windshield molding along A-pillar
INSTALL foam rope full length of the A-pillar.
Gaps in sealant bead of windshield/rear glass
RESEAL windshield/rear glass. REFER to Section 501-11 .
Windshield/rear glass misaligned or not installed correctly
Body System 84
REINSTALL windshield/rear glass. REFER to Section 501-11 .
Rear hood seal at base of windshield misaligned/damaged
REALIGN or INSTALL a new seal as necessary.
Draft noise at cowl
Cowl seal misaligned/damaged
REALIGN or INSTALL a new seal as necessary.
Draft/water leak or noise from roof opening panel
Roof opening panel/components
REFER to Section 501-17 for diagnosis.
Wind noise created by airflow over or behind body panels
Fender splash shield misaligned
REALIGN fender splash shield.
Body panel misaligned (exposed edge)
REALIGN appropriate body panel.
Hood misaligned (front margin)
CHECK hood gaps and fit. ADJUST hood as necessary.
Front grille edge noise
APPLY foam in hollow areas behind louvers.
Wind noise created by grille opening panel
Grille relationship to leading edge on hood
If possible, ADJUST grille opening panel forward to eliminate wind noise.
Sharp edges due to material imperfections
REMOVE sharp edges (no damage to visible surface).
Wind noise from air extractor (body vent)
Air extractor housing seated incorrectly
REINSTALL air extractor housing.
Air extractor housing or flaps damaged
Body System 85
INSTALL a new air extractor.
Wind noise from bug shield/exterior windshield sun visor
Turbulence created by location and shape
DETERMINE if an OEM part or aftermarket. If aftermarket ADVISE customer accordingly. If OEM,
VERIFY correctly installed. If noise is abnormal, REPAIR or INSTALL new as required.

Body System 86
SECTION 501-02: Front End Body Panels
Workshop Manual
Torque Specifications
Description Nm lb-ft lb-in
A/C line retaining bolt 6 - 53
Fender lower bolts 9 - 80
Fender rear lower bolt 9 - 80
Fender rear upper bolt 9 - 80
Fender support brace bolts 9 - 80
Fender upper bolts 9 - 80
Fender upper rear inner bolt 5 - 44
Hood hinge-to-body bolts 22 16 -
Hood hinge-to-hood bolts 22 16 -
Hood latch bolts 12 - 106
Hood striker bolts 12 - 106
Radiator grille support bolts - 106
Windshield washer reservoir retaining bolt 7 - 62
Wiper mounting arm and pivot shaft assembly bolts 5 - 44
Wiper pivot arm nuts 20 - 177
Body System 87
Workshop Manual
REMOVAL AND INSTALLATION Procedure revision date: 06/03/2011
Front End Body Panels - Exploded View
Item Part Number Description
1 W706805 Splash shield screw (4 required)
2 W712196 Splash shield pin-type retainer (10
required)
3 5416034 RH/ 5416035
LH
Splash shield
4 W505421 Fender lower bolts
5 W505421 Fender support brace bolt
6 W505421 Fender rear lower bolt
7 W505421 Fender rear upper bolt
8 W505421 Fender upper rear inner bolt
9 W505421 Fender upper bolt (3 required)
10 16005 RH/ 16006 LH Fender
11 16E132 RH/ 16E133 LH Fender baffle
12 16A023 RH/ 16A024 LH Fender support brace
For additional information, refer to the procedures in this section. 1.
Front End Body Panels - Exploded View 88
Front End Body Panels - Exploded View 89
Workshop Manual
Fender
Removal and Installation
All vehicles
Remove the front fender splash shield. For additional information, refer to Fender Splash Shield in
this section.
1.
Remove the fender baffle. 2.
Remove the upper rear inner fender bolt.
To install, tighten to 5 Nm (44 lb-in).
3.
Remove the 2 lower fender bolts.
4.
Fusion only
Remove the side turn signal lamp. For additional information, refer to Section 417-01 . 5.
All vehicles
NOTE: The front door must be open to gain access to the rear fender bolt.
Remove the upper rear fender bolt.
6.
Remove the bumper cover bracket from the front fender.
Remove the screw. 1.
Remove the bolt. 2.
Pull outward to release the clip. 3.
7.
Fender 90
NOTE: Two bolts are required for Fusion and Milan, one bolt is required for MKZ.
Remove the fender support brace bolt.
8.
Remove the pushpin from the front fender to headlamp. 9.
Remove the upper rear inner fender bolt.
10.
Remove the 3 upper fender bolts and the front fender.
11.
To install, reverse the removal procedure. 12.
Fender 91
Fender 92
Workshop Manual
Fender Splash Shield
Remove the fender splash shield screws. 1.
Remove the 11 fender splash shield pin-type retainers. 2.
Remove the fender splash shield. 3.
Fender Splash Shield 93
Workshop Manual
Cowl Panel Grille
1 W520403-S Wiper pivot arm nuts (2 required)
2 17526 Wiper pivot arm
3 17526 Wiper pivot arm
4 W701121-S Cowl panel grille bolt (2 required)
5 1502316-A Pin-type retainer (4 required)
6 W709919 Cowl panel retaining clip (2 required)
7 5402010 Upper cowl panel grille
8 W701121 Wiper mounting arm and pivot shaft assembly bolt (2
required)
9 17508 Wiper mounting arm and pivot shaft assembly
10 W707717 Cowl panel center brace bolt (3 required)
11 54022A06 Cowl panel center brace
12 W707717 Lower cowl panel grille bolt (10 required)
13 5402000-A Lower cowl panel grille
Upper cowl panel grille
Remove the 2 wiper pivot arms nuts.
1.
Remove the LH and RH wiper pivot arms. 2.
Remove the 4 pin-type retainers from the upper cowl panel grille. 3.
Cowl Panel Grille 94
Remove the 2 bolts from the upper cowl panel grille.
4.
Remove the 2 retaining clips and the upper cowl panel grille. 5.
3.5L only
Insert a flat-blade screwdriver behind the power steering reservoir. 6.
Push the retainer rearward to remove the power steering reservoir and position the power steering
reservoir aside.
7.
Remove the 2 brake fluid reservoir retainers and position the brake fluid reservoir aside.
8.
Hybrid only
Insert a flat-blade screwdriver behind the high voltage junction box. 9.
Push the retainer rearward to remove the high voltage junction box and position the high voltage
junction box aside.
10.
Remove the 2 brake fluid reservoir bolts and position the brake fluid reservoir aside.
11.
Lower cowl panel grille
Remove the wiper mounting arm and wiper pivot shaft assembly in the following sequence.
Disconnect the electrical connector. 1.
Remove the 2 bolts.
2.
12.
Remove the 3 bolts and the lower cowl panel center brace.
13.
Remove the 10 lower cowl panel grille bolts.
14.
Remove the lower cowl panel grille. 15.
To install, reverse the removal procedure.
Adjust the pivot arms. For additional information, refer to Section 501-16 .
16.
Workshop Manual
Radiator Grille Support
1 16138 Radiator grille support
2 W505425 Radiator grille support bolt (2 required)
3 8311 LH/ 8310 RH Air deflector
4 - Air deflector pushpin (2 required)
5 8327 Lower air deflector
6 N807389 Lower air deflector scrivet (4 required)
7 5416826 Hood prop rod
8 16700 Hood latch
9 N808727 Hood latch bolt (2 required)
10 16916 Hood release cable
With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .
1.
NOTE: Applies to 3.5L engines only.
Remove the Air Cleaner (ACL) outlet pipe and ACL assembly. For additional information, refer to
Section 303-12C .
2.
Disconnect the hood security switch electrical connector. 3.
Remove the windshield washer reservoir retaining bolt.
4.
Radiator Grille Support 98
Remove the A/C line retaining bolt. 5.
Remove the front headlamps. For additional information, refer to Section 417-01 . 6.
NOTE: This step is necessary to relieve stress from the radiator grille support prior to removal.
Using a suitable hood prop tool, prop and support the hood. Latch the vehicle hood prop rod into
position on the radiator grille support.
7.
Remove the front bumper. For additional information, refer to Section 501-19 . 8.
Remove the front impact severity sensor and release the harness clip. For additional information, refer
to Section 501-20B .
9.
Disconnect the ambient air temperature sensor electrical connector and harness clip. Position the
harness aside.
10.
Disconnect the hood latch release cable from the latch assembly. 11.
Remove the hood latch bolts.
12.
Remove the cooling module retaining clip screws and release the clips. 13.
Remove the radiator grille support bolts (3 each side) and remove the support.
14.
Transfer all necessary components.
15.
SECTION 501-03: Body Closures
Manual
Door check arm-to-body bolt 25 18 -
Door check arm-to-door nuts 12 - 106
Door hinge-to-body bolts 25 18 -
Door hinge-to-door bolts 30 22 -
Door latch striker plate bolts 22 16 -
Luggage compartment lid hinge-to-body bolts 25 18 -
Luggage compartment lid hinge-to-luggage compartment lid nuts 25 18 -
Luggage compartment lid striker plate bolts 22 16 -
SECTION 501-03: Body Closures 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop Manual
GENERAL PROCEDURES Procedure revision date: 06/03/2011
Door Alignment - Front
All alignments
Remove the door latch striker plate. 1.
Front door in and out, up and down alignment
Loosen, but do not remove, the front door hinge-to-front door fasteners enough to allow door
alignment.
2.
Front door fore, aft and tilt alignment
Remove the front fender. For additional information, refer to Section 501-02 . 3.
Loosen, but do not remove, the upper front door hinge-to-body fasteners enough to allow door
alignment.
4.
Loosen, but do not remove, the lower front door hinge-to-body fasteners enough to allow door
alignment.
5.
All alignments
Adjust the door. For additional information, refer to Section 501-35 . 6.
Tighten the door fasteners.
Tighten the front door hinge-to-front door bolts to 30 Nm (22 lb-ft).
Tighten the front door hinge-to-body bolts to 25 Nm (18 lb-ft).
7.
Front door fore, aft and tilt alignment
Install the front fender. For additional information, refer to Section 501-02 . 8.
All alignments
Install and adjust the door striker as necessary. For additional information, refer to Section 501-35 .
Tighten the door latch striker plate bolts to 22 Nm (16 lb-ft).
9.
Door Alignment - Front 101
Door Alignment - Front 102
Door Alignment - Rear
All alignments
Remove the door latch striker plate. 1.
Rear door in and out, up and down alignment
Loosen, but do not remove, the rear door hinge-to-rear door fasteners enough to allow door alignment. 2.
Rear door fore, aft and tilt alignment
Position aside the B-pillar panel. 3.
Loosen, but do not remove, the upper rear door hinge-to-body fasteners enough to allow door
alignment.
4.
Loosen, but do not remove, the lower rear door hinge-to-body fasteners enough to allow door
alignment.
5.
All alignments
Adjust the door. For additional information, refer to Section 501-35 . 6.
Tighten the door fasteners.
Tighten the rear door hinge-to-rear door bolts to 30 Nm (22 lb-ft).
Tighten the rear door hinge-to-body bolts to 25 Nm (18 lb-ft).
7.
Rear door fore, aft and tilt alignment
Install the B-pillar trim panel. 8.
All alignments
Install and adjust the door striker as necessary. For additional information, refer to Section 501-35 .
Tighten the door latch striker plate bolts to 22 Nm (16 lb-ft).
9.
Door Alignment - Rear 103
Door Alignment - Rear 104
Luggage Compartment Lid Alignment
Remove the luggage compartment lid struts. 1.
Loosen the 4 luggage compartment lid hinge-to-body bolts. 2.
Adjust the luggage compartment lid as necessary.
For additional information, refer to Section 501-35 .
3.
Tighten the 4 luggage compartment lid hinge-to-body bolts.
Tighten to 25 Nm (18 lb-ft).
4.
Install the luggage compartment lid struts. 5.
Luggage Compartment Lid Alignment 105
Striker Adjustment
NOTE: Before adjusting the door latch striker plate, verify that the door can be closed easily and fits tightly.
Loosen the door latch striker bolts. 1.
Reposition the door latch striker plate from side-to-side or up and down as necessary. 2.
Tighten the door latch striker plate bolts.
3.
Check the adjustment of the door. For additional information, refer to Section 501-35 .
Repeat the procedure as necessary.
4.
Striker Adjustment 106
Manual
REMOVAL AND
INSTALLATION
Procedure revision date: 06/03/2011
Door
NOTE: Front door shown, rear door similar.
1 W711119 Hinge-to-door bolts
2 W506023 Hinge-to-body bolts
3 5422800 Upper hinge
4 5422810 Lower hinge
5 5420124 Front door
Remove the door check arm-to-body bolt.
To install, tighten to 25 Nm (18 lb-ft).
1.
NOTICE: To avoid damaging the door, this step requires an assistant.
NOTE: To minimize the possibility of cross threading, hand start all fasteners during the installation.
Mark the position of each hinge and remove the hinge-to-door bolts.
2.
Remove the front door. 3.
If necessary, align the door. For additional information, refer to Door Alignment - Front or
Door Alignment - Rear in this section.

4.
Door 107
Door 108
Manual
REMOVAL AND
INSTALLATION
Door Check Arm
1 5423552 Door check arm
2 W520111 Door check arm-to-door nuts
3 - Door check arm-to-check arm bracket (part of
5423552)
4 - Door check arm bracket (part of 5423552)
5 W707375 Door check arm-to-body bolt
Remove the door trim panel. For additional information, refer to Section 501-05 . 1.
Remove the door check arm-to-body bolt.
2.
Remove the door check arm-to-door nuts.
3.
Door Check Arm 109
Door Check Arm 110
Manual
REMOVAL AND
INSTALLATION
Luggage Compartment Lid
1 N811478-S Hinge-to-luggage compartment lid nut (4
required)
2 W503931 Hinge-to-body bolt (4 required)
3 42700 RH/ 42701
LH
Luggage compartment lid hinge
4 54406A10 Luggage compartment lid assist strut (RH/LH)
5 W712985 Luggage compartment bumper (2 required)
6 40110 Luggage compartment lid
Luggage Compartment Lid Trim Panel
Item
Part
Number Description
Luggage Compartment Lid 111
2 W706635 Luggage compartment lid trim panel pin-type retainer
(10 required)
3 45594 Luggage compartment lid trim panel
Open the luggage compartment lid. 1.
Remove the luggage compartment lid trim panel and pin-type retainers. 2.
Disconnect the electrical connectors and remove the wiring harness clips from the luggage
compartment lid.
3.
Remove the luggage compartment lid lift struts. 4.
With the help of an assistant, remove the hinge-to-luggage compartment lid nuts.
5.
With the help of an assistant, remove the luggage compartment lid. 6.
Adjust the luggage compartment lid as necessary. For additional information, refer to Luggage
Compartment Lid Alignment in this section.
8.
Luggage Compartment Lid Trim Panel 112
SECTION 501-05: Interior Trim and Ornamentation
Workshop Manual
Assist handle bolts 5 - 44
Child seat tether anchor bolts 22 16 -
D-ring bolt 40 30 -
SECTION 501-05: Interior Trim and
Ornamentation
Workshop Manual
Interior Trim - Exploded View
1 03598 RH/
03599 LH
A-pillar trim panel
2 13208 RH/
13209 LH
Front door scuff plate (with Inertia Fuel Shutoff
(IFS) switch emblem shown, others similar)
3 13228 RH/
13229 LH
Rear door scuff plate
4 24346 RH/
24347 LH
B-pillar lower trim panel
5 672A40A B-pillar trim panel screw cover
6 W705604 B-pillar trim panel screw
7 24356 RH/
24357 LH
B-pillar upper trim panel
8 672A40B C-pillar trim panel screw cover
9 W705604 C-pillar trim panel screw
10 52018 RH/
52019 LH
C-pillar trim panel
11 - Scuff plate trim panel - front, lighted outer clip (part
of 5413208) (2 required)
12 5413208 Scuff plate trim panel - front, lighted outer
Interior Trim - Exploded View 115
&nnbsp;
Interior Trim - Exploded View 116
Ornamentation
Workshop Manual
A-Pillar Trim Panel
NOTE: The A-pillar trim panel is a one-time-use. If removed, a new A-pillar trim panel must be installed.
NOTE: When removing the A-pillar trim panel, use a gentle side-to-side rocking motion to free the
clip from the trim panel.
Remove the A-pillar trim panel and the clip from the sheet metal.
1.
Align attachment clips to the holes and snap the new A-pillar trim panel in place.
2.
A-Pillar Trim Panel 117
Ornamentation
Workshop Manual
B-Pillar Trim Panel
Position the front seats in the full forward position. 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 D-ring bolt.
2.
Position the front and rear door weatherstrips aside. 3.
Remove the front door scuff plate trim panel. For additional information, refer to Scuff Plate Trim
Panel - Front in this section.
4.
Remove the rear door scuff plate trim panel. For additional information, refer to Scuff Plate Trim
Panel - Rear in this section.
5.
Remove the lower B-pillar trim panel.
Lift the lower area of the lower B-pillar trim panel and pull inward toward the center of the
vehicle.

Slide the lower B-pillar trim panel down to disengage it from the upper B-pillar trim panel.
6.
Remove the upper B-pillar trim panel.
Remove the screw cover.
Remove the screw.
Remove the push-pin with the B-pillar trim panel.
7.
B-Pillar Trim Panel 118
B-Pillar Trim Panel 119
Ornamentation
Workshop Manual
C-Pillar Trim Panel
Position the rear door weatherstrip aside. 1.
Remove the screw cover. 2.
Remove the screw. 3.
Remove the C-pillar trim panel. 4.
C-Pillar Trim Panel 120
Ornamentation
Workshop Manual
Door Trim Panel - Front
Fusion
NOTE: RH shown, LH similar.
1 047A74 Front door inside handle bezel screw cover
2 W505153 Front door inside handle bezel screw
3 54266B Front door inside handle bezel
4 14529B Front door window switch
5 W707745 Front door trim panel upper screw
6 22621 LH/ 22620 RH Front door inside handle screw cover
7 W505942 Front door inside handle screw
8 22621 LH/ 22620 RH Front door inside handle bezel
9 W709494 Front door trim panel center screw
10 W706476 Front door trim panel lower screw
11 5423942 Front door trim panel
12 17K709 Front door trim sail panel
MKZ
NOTE: LH shown, RH similar.
Door Trim Panel - Front 121
1 5423942 Front door trim panel
2 5424057 Front door inside handle escutcheon screw cover
3 W505942 Front door inside handle escutcheon screw
4 W707745 Front door trim panel upper screw
5 W712297 Front door trim panel center screw
6 14529 Front door trim panel multiswitch
7 14524 Front door trim panel multiswitch bezel
8 17K709 Front door trim panel sail panel
9 W707745 Front door trim panel lower screw
All vehicles
Remove the front door inside handle screw cover. 1.
Remove the front door inside handle screw. 2.
Fusion
Remove the front door inside handle bezel screw cover. 3.
Remove the front door inside handle bezel screw. 4.
Remove the front door inside handle bezel.
Lift upward on the rear of the front door inside handle bezel.
Disconnect the electrical connector.
5.
All vehicles
Remove the front door trim panel upper screw. 6.
Remove the front door trim panel lower screw. 7.
Remove the front door trim panel center screw.
Fusion is located behind the inside door handle bezel.
MKZ is located above the map pocket.
8.
MKZ 122
NOTE: The back of the front door trim panel shown with the location of the pin-type retainers.
Remove the front door trim panel.
Pull the front door trim panel outward to release the pin-type retainers.
9.
MKZ 123
Ornamentation
Workshop Manual
Door Trim Panel - Rear
Fusion
1 047A74 Rear door inside handle bezel screw cover
2 W505153 Rear door inside handle bezel screw
3 54266 Rear door inside handle bezel
4 14529 Rear door window switch
5 W707745 Rear door trim panel upper screw
6 22620 RH/ 22621 LH Rear door handle screw cover
7 W505942 Rear door handle screw
8 5427406 Rear door trim panel
MKZ
Door Trim Panel - Rear 124
1 5427406 Rear trim panel
2 5424056 Rear door inside handle escutcheon bolt cover
3 W505942 Rear door inside handle escutcheon bolt
4 W707745 Rear door trim panel upper screw
5 W712297 Rear door trim panel lower screw
6 14529 Rear door trim panel switch
All vehicles
Remove the rear door inside handle bolt cover. 1.
Remove the upper rear door inside handle bolt. 2.
Fusion
Remove the rear door handle screw cover. 3.
Remove the rear door handle screw. 4.
Remove the rear door inside handle bezel.
Lift upward on the rear of the rear door inside handle bezel.
5.
All vehicles
Remove the rear door trim panel upper screw. 6.
MKZ
Remove the rear door trim panel lower screw. 7.
All vehicles
NOTE: The back of the rear door trim panel shown with the location of the rear door trim panel
pin-type retainers indicated.
Remove the rear door trim panel.
8.
MKZ 125
Pull the rear door trim panel outward to release the rear door trim panel pin-type retainers.
MKZ 126
Ornamentation
Workshop Manual
Headliner
NOTE: Headliner with moonroof shown, headliner without moonroof similar.
1 W504265 Assist handle bolt (2 required)
2 31406B RH/ 31407B LH Rear assist handle
3 W504265 Assist handle bolt (2 required)
4 31406A RH/ 31407A LH Front assist handle
5 W505003 Sun visor screw (2 required)
6 04104 RH/ 04105 LH Sun visor
7 W505003 Sun visor arm clip screw
8 04132 Sun visor arm clip
9 519A70 Overhead console
10 W709571 Pushpin retainer (2 required)
11 51916 Headliner
Remove the driver seat and rear seat cushion. For additional information, refer to Section 501-10 . 1.
Position the passenger seat fully rearward and recline fully. 2.
Open the assist handle covers.
Remove the bolts and remove the handles.

3.
Headliner 127
Remove the A-pillar trim panels. For additional information, refer to A-Pillar Trim Panel in this
section.
4.
Disconnect the wire harness connector and the 2 pushpins. 5.
If equipped, remove the rain sensor cover.
Pull the rain sensor cover outward off the windshield.
6.
If equipped, disconnect the rain sensor electrical connector. 7.
If equipped, disconnect the automatic dimming rear view mirror and compass electrical connectors. 8.
Remove the B-pillar trim panels. For additional information, refer to B-Pillar Trim Panel in this
section.
9.
Remove the C-pillar trim panels. For additional information, refer to C-Pillar Trim Panel in this
section.
10.
Remove the overhead console.
11.
Remove the sun visor clips. 12.
NOTE: The sun visor wiring is secured to the headliner and cannot be separated in vehicle. 13.
Headliner 128
Remove the 4 sun visor screws and lower the sunvisors.
Remove the 2 headliner pushpin retainers at the rear. 14.
If equipped, position the headliner forward to gain access to disconnect the roof opening panel motor
electrical connector.
15.
NOTICE: To avoid damaging the headliner, an assistant is required to support the sun visors
for this step.
Remove the headliner through the LH rear door.
16.
NOTE: Obtain the 3M Duramix 4747 Super Fast Adhesive commercially. The 3M Duramix 4747
Super Fast Adhesive is a 2-part adhesive in a 50 ml dual-tube applicator. Depending on the size of the
headliner and optional wire harness(es), the purchase of two to five 50 ml tubes is suggested.
If installing a new headliner, transfer the wire harness in the following sequence:
Using a suitable marking tool, mark the new headliner with the routing and exit points of the
wire harness from the original headliner.
1.
Carefully remove the wire harness from the original headliner. 2.
NOTICE: Make sure not to damage the wire harness when cutting the excess adhesive
from the wire harness.
Cut and remove any excess adhesive from the wire harness.
3.
Position the wire harness onto the new headliner and check that the harness has enough length
to be connected to the body/roof connectors. Apply tape to temporarily hold the wire harness
in that position on the headliner.
4.
NOTE: The 3M Duramix 4747 Super Fast Adhesive will set in 20 seconds. Continually make
sure that the wire harness is routed correctly when applying the adhesive.
Apply the 3M Duramix 4747 Super Fast Adhesive in the same location as the factory
installed adhesive along the full length of the wire harness-to-headliner to avoid any NVH
concern(s).
5.
Transfer all necessary components. 6.
17.
Headliner 129
Headliner 130
Ornamentation
Workshop Manual
Parcel Shelf
NOTE: Fusion shown, MKZ and Hybrid similar.
1 W706635 Parcel shelf pushpin (2 required)
2 63874 Parcel shelf seat back latch cover (2 required)
3 46668 Parcel shelf
Remove the C-pillar trim panels. For additional information, refer to C-Pillar Trim Panel in this
section.
1.
Remove the rear seat bolsters. For additional information, refer to Section 501-10 . 2.
Fold the rear seats down. 3.
Pull the seat back latch covers forward and remove from the vehicle. 4.
Remove the high mounted stoplamp. For additional information, refer to Section 417-01 . 5.
Remove the 2 pushpins. 6.
Thread the seat belts through the guides. 7.
Parcel Shelf 131
Parcel Shelf 132
Ornamentation
Workshop Manual
Scuff Plate Trim Panel - Front
NOTE: On the MKZ, there is an outer lighted scuff plate. For additional information, refer to Scuff Plate
Trim Panel - Front, Lighted Outer .
Pull the front inboard section of the scuff plate trim panel outward to release the 1 retaining clip. 1.
NOTE: The 3 retaining clips must stay attached to the door weather strip and pinch weld.
Lift the scuff plate trim panel straight up to release the scuff plate trim panel from the 3 retaining
clips.
2.
Align the scuff plate trim panel into the clips and snap into place.
3.
Scuff Plate Trim Panel - Front 133
Ornamentation
Workshop Manual
Scuff Plate Trim Panel - Front, Lighted Outer
NOTE: The front lighter outer scuff plate is only available on the MKZ.
Remove the front door scuff plate. For additional information, refer to Scuff Plate Trim Panel - Front
in this section.
1.
Remove the B-pillar lower trim panel. For additional information, refer to B-Pillar Trim Panel in this
section.
2.
Disconnect the scuff plate trim panel electrical connector located behind the lower B-pillar trim panel. 3.
NOTICE: To avoid damage to the scuff plate trim panel, remove any retaining clips from the
body and attach them to the scuff plate trim panel before installing.
Remove the front, lighted outer scuff plate trim panel by lifting straight up and releasing the 2
retaining clips from the body.
4.
Align the retaining clips to the body and snap in place.
5.
Scuff Plate Trim Panel - Front, Lighted Outer 134
Ornamentation
Workshop Manual
Scuff Plate Trim Panel - Rear
NOTE: The 2 retaining clips must stay attached to the door weather strip and pinch weld.
Lift the rear scuff plate trim panel straight up to release the rear scuff plate trim panel from the 2
retaining clips.
1.
Align the rear scuff plate trim panel into the clips and snap into place.
2.
Scuff Plate Trim Panel - Rear 135
SECTION 501-08: Exterior Trim and
Ornamentation
Workshop Manual
Description Nm lb-in
Luggage compartment lid applique nuts 5 44
Spoiler-to-luggage compartment lid nuts 6 53
Scuff Plate Trim Panel - Rear 136
Ornamentation
Workshop Manual
Radiator Grille - MKZ
1 N802539 Upper radiator air deflector J-clip (4
required)
2 8A164 Upper radiator air deflector
3 W706805 Upper radiator grille screws (6
required)
4 8150-B LH/ 8150-A RH Upper radiator grille
5 17C831 Front bumper cover
6 17K946-A LH/ 17K947-A
RH
Fog lamp bezel trim
7 17K946-B LH/ 17K947-B
RH
Fog lamp bezels
8 8B262 Badge
9 8150-C Lower center radiator grille
10 8150-D Lower center radiator grille
moulding
11 W706805 Front bumper cover valance screw
(6 required)
12 W711035 Front bumper cover valance
pin-type retainer (9 required)
13 N802539 Front bumper cover valance J-clip
(6 required)
14 17B635 Front bumper cover valance
Radiator Grille - MKZ 137
All radiator grilles
Section 501-19 .
Upper radiator grille
Remove the 6 upper radiator grille screws. 2.
Remove the upper radiator deflector. 3.
Remove the upper radiator grille. 4.
Lower radiator grille
Pull outward to remove the lower radiator grille moulding. 5.
Remove the lower center radiator grille.
Remove the lower center radiator grille from the clips on the bumper cover.
Remove the lower center radiator grille from the bumper cover.
6.
All radiator grilles
Radiator Grille - MKZ 138
Ornamentation
Workshop Manual
Radiator Grille - Fusion
1 50980 Pin-type retainer (4 required)
2 8150-A Upper radiator grille
3 W707501 Center radiator grille nuts (2 required)
4 W707501 Lower radiator grille nuts (2 required)
5 W707501 Badge nut (2 required)
6 8A164 Radiator grille reinforcement
7 8150-B Center radiator grille
8 8B262 Badge
9 8150-C Lower radiator grille
11 17K946-J LH/
17K947-J RH
Fog lamp bezel moulding
12 17K946-F LH/
17K947-F RH
Fog lamp bezel
13 17K945 Lower bumper grille moulding
14 8150-D Lower bumper grille
15 - Lower bumper grille moulding clip (9
required) (part of 17K945)
Upper radiator grille
Remove th pin-type retainers. 1.
Press the tabs to release the upper radiator grille from the radiator grille reinforcement and remove the
upper radiator grille.
2.
Center and lower radiator and lower bumper grilles
Remove the front bumper cover. For additional information, refer to Section 501-19 . 3.
Radiator Grille - Fusion 139
Center and lower radiator grilles
Press the tabs to release the radiator grille reinforcement and remove the radiator grille
reinforcements.
4.
Center radiator grille
Remove the center radiator grille nuts. 5.
Remove the center radiator grille. 6.
Lower radiator grille
Remove the lower radiator grille nuts. 7.
Remove the lower radiator grille. 8.
Lower bumper grille
Remove the lower bumper grille moulding clips. 9.
Remove the lower bumper grille moulding. 10.
Press the tabs to release the lower bumper grille from the front bumper cover. 11.
Remove the lower bumper grille from the bumper cover. 12.
All vehicles
Radiator Grille - Fusion 140
Ornamentation
Workshop Manual
Spoiler
Fusion
1 40602 Spoiler
2 N621926-S Spoiler nut (4 required)
4 - Spoiler pin-type retainer (2 required) (part of 40602)
Open the luggage compartment lid. 1.
If equipped, disconnect the spoiler electrical connector. 2.
Remove the spoiler-to-luggage compartment lid nuts.
3.
NOTE: The spoiler is attached to the luggage compartment lid with double-sided tape. New tape
must be installed during installation.
Position a piano wire, or equivalent tool, between the spoiler and the luggage compartment lid.
4.
Cut the double-sided tape. 5.
NOTE: There are 2 pin-type retainers on the bottom of the spoiler. If the pin-type retainers break during
removal, a new spoiler must be installed.
Slide a suitable tool between the luggage compartment lid and the spoiler at each end until contact is
made with the pin-type retainers. Push in the pin-type retainer and pull up on the spoiler to release the
spoiler from the luggage compartment lid.
6.
Spoiler 141
Remove the spoiler. 7.
NOTE: Clean the mounting surfaces of the luggage compartment lid and the spoiler prior to
installing. Press along the front edge of the spoiler after securing the fasteners to make sure of correct
tape adhesion.
8.
Fusion 142
Ornamentation
Workshop Manual
Applique - Luggage Compartment Lid
Item
Part
Number Description
1 42509 Luggage compartment lid applique
2 - Luggage compartment lid applique pin-type retainer
(part of 42509)
3 W709764 Luggage compartment lid applique nut (4 required)
4 W706635 Luggage compartment lid trim panel pin-type retainer
(12 required)
5 45594 Luggage compartment lid trim panel
Remove the luggage compartment lid trim panel pin-type retainers. 1.
Remove the luggage compartment lid trim panel. 2.
Disconnect the luggage compartment lid applique electrical connectors. 3.
Remove the luggage compartment lid applique nuts.
4.
Remove the luggage compartment lid applique.
Squeeze the tabs on the luggage compartment lid applique pin-type retainer to release it from
the luggage compartment lid.

5.
To install, reverse the removal procedurei> 6.
Applique - Luggage Compartment Lid 143
Applique - Luggage Compartment Lid 144
Ornamentation
Workshop Manual
Beltline Moulding - Front Door
1 - Front door beltline moulding screw (part of 21453)
2 21453 Front door beltline moulding
Remove the front door beltline moulding screw. 1.
Starting at the rear of the moulding, pull upward to release the moulding from the door. 2.
Pull rearward to remove the beltline moulding. 3.
Beltline Moulding - Front Door 145
Beltline Moulding - Front Door 146
Ornamentation
Workshop Manual
Beltline Moulding - Rear Door
1 - Rear door beltline moulding screw (part of 25597)
2 25597 Rear door beltline moulding
Remove the beltline moulding screw. 1.
Starting at the front of the moulding, pull upward to release it from the door. 2.
Pull forward to release the beltline moulding from the quarter window trim. 3.
Beltline Moulding - Rear Door 147
Beltline Moulding - Rear Door 148
Ornamentation
Workshop Manual
Rocker Panel Moulding
1 - Rocker panel moulding lower clip (5 required) (part
of 10154 LH/ 10155 RH)
2 10154 LH/
10155 RH
Rocker panel moulding
3 W505421 Rocker panel moulding pin-type retainer
4 - Rocker panel moulding upper clip (8 required) (part
of 10154 LH/ 10155 RH)
Remove the rocker panel pin-type retainer. 1.
Pull downward on the rocker panel lower clip flanges to release them from the body. 2.
Pull outward on the rocker panel moulding to release the rocker panel upper clips from the body. 3.
Rocker Panel Moulding 149
SECTION 501-09: Rear View Mirrors
Workshop Manual
Exterior mirror mounting nuts 8 71
SECTION 501-09: Rear View
Mirrors
Manual
Rear View Mirrors
The main components of the exterior rear view mirrors are:
Exterior mirror control switch
Exterior mirror cover
Exterior mirror glass
Exterior mirror glass adjustment motors
Exterior mirror plastic housing
Exterior mirror glass with blind spot monitoring indicator (optional)
Heated exterior mirror glass (optional)
LH exterior auto-dimming mirror glass (optional)
Memory exterior mirrors (optional)
Puddle lamps (optional)
For information on the puddles lamps, refer to Section 417-01 .
For information on the blind spot monitoring system, refer to Section 419-04 .
Exterior Mirrors
Heated Exterior Mirrors
The power exterior rear view mirrors are available with a heated mirror glass feature, which heats the mirror
glass to remove frost, snow, ice and condensation. The rear window defrost switch controls the operation of
the heated exterior rear view mirrors. The heated exterior mirrors should be warm to the touch after 4 minutes
of operation.
Memory Exterior Mirrors
The memory mirror function recalls the preferred positioning of the LH and RH exterior mirror glass. The
preferred positioning of the LH exterior mirror glass is retained in the Driver Door Module (DDM) memory,
while the preferred positioning of the RH exterior mirror glass is retained in the Driver Seat Module (DSM)
memory. The memory mirror function is activated by the door mounted switches or the Remote Keyless Entry
(RKE) transmitter. When a memory position is recalled by the operator, the LH and RH exterior mirror glass
will automatically adjust to the preferred position. The DDM and DSM are capable of setting a DTC for the
memory mirror system when a system concern exists. For information on the DDM , refer to Section 501-14 .
For information on the DSM and Memory Position Programming, refer to Section 501-10 .
LH Auto-Dimming Mirror
The LH exterior mirror may be equipped with an auto-dimming feature. This feature automatically reduces
the glare caused by headlamps reflecting in the mirror. To provide increased visibility when backing up, the
LH exterior mirror will automatically return to a high reflectance mode whenever the vehicle is in REVERSE.
Interior Mirror
The vehicle can be equipped with one of the following interior rear view mirrors:
Rear View Mirrors 152
Interior rear view mirror
Interior auto-dimming rear view mirror with compass (optional)
Interior auto-dimming rear view mirror with compass and video display (optional)
Interior Rear View Mirror
The interior rear view mirror consists of a mirror glass and housing. The interior rear view mirror mounts to
an interior rear view mirror bracket at the upper center of the windshield glass. The interior rear view mirror
can be adjusted left, right, up and down using the 2 pivot points on the support arm. The interior rear view
mirror can be adjusted from a day position to a night position to reduce unwanted glare caused by headlamps
reflecting in the mirror. Adjusting the interior rear view mirror day/night tab, located at the bottom of the
interior rear view mirror, rearward will adjust the interior mirror to the night position. Adjusting the interior
rear view mirror day/night tab forward will adjust the interior mirror to the day position.
Interior Auto-Dimming Rear View Mirror
The interior rear view mirror may be equipped with an auto-dimming feature. The interior auto-dimming rear
view mirror feature automatically reduces the glare caused by headlamps reflecting in the interior rear view
mirror. The auto-dimming feature is activated when the ignition is in the RUN or ACC position. The interior
auto-dimming rear view mirror adjusts the reflectance level of the interior rear view mirror glass to eliminate
unwanted glare. The reflectance level of the mirror glass is variable and depends on the amount of rear glare
in relation to ambient light conditions in front of the interior mirror. When the forward sensor detects daytime
conditions, the rearward sensor is inactive and the interior rear view mirror stays in a high reflectance mode.
When the forward sensor detects nighttime conditions, the rearward sensor is active and detects glare from the
headlights of vehicles approaching from the rear or other glare-producing light sources. To provide increased
visibility when backing up, the interior rear view mirror will automatically return to a high reflectance mode
whenever the gear selector is in REVERSE.
On vehicles equipped with a compass, the interior rear view mirror will be equipped with an integrated
compass module. For compass information, calibration or diagnostics, refer to Section 413-01 .
On vehicles equipped with a rear-mounted object detection camera, a video image will be displayed on the LH
side of the interior rear view mirror glass when the gear selector is in REVERSE. For information on the
rear-mounted object detection system, refer to Section 413-13 .
LH Auto-Dimming Mirror 153
Interior Auto-Dimming Rear View Mirror 154
Mirrors
Manual
Rear View Mirrors - Exterior
Special Tool(s)
Fluke 77-IV Digital Multimeter
FLU77-4 or equivalent
Vehicle Communication Module (VCM)
and Integrated Diagnostic System (IDS)
software with appropriate hardware, or
equivalent scan tool
Principles of Operation
The movement of the LH and RH exterior mirror glass is controlled by the exterior mirror control switch and
the LH and RH exterior mirror motors. Adjusting the exterior mirror switch to the LH or RH position
determines which exterior mirror motor will be controlled. The exterior mirror control switch logic is the
selected movement request from the exterior mirror control switch. When the exterior mirror control switch is
adjusted to the left, right, up or down position, the exterior mirror control switch will supply voltage and
ground to the selected exterior mirror motor to move the exterior mirror glass to the desired position.
Only vehicles equipped with memory exterior rear view mirrors are capable of setting DTCs.
The exterior mirrors use a jumper harness between the vehicle wireness connector and the exterior mirror
motor. The exterior mirror jumper harness is integral to the exterior mirror. If a concern with the exterior
mirror jumper harness exists and cannot be repaired, a new exterior mirror must be installed.
Heated Exterior Mirror
The rear window defrost switch controls the operation of the heated exterior mirror glass. The heated exterior
mirror glass only operates when the rear window defrost system is ON. The heated exterior mirror glass
power is supplied by the rear window defrost relay through Smart Junction Box (SJB) fuse 9 (10A), which
isolates the heated exterior mirror system from the rear window defrost system in the event of a concern. The
heated exterior mirrors should be warm to the touch after 4 minutes of operation.
LH Auto-Dimming Mirror
The interior auto-dimming rear view mirror controls the reflectance level of the LH exterior mirror to
eliminate unwanted glare. The reflectance level of the mirror glass is variable and depends on the amount of
rear glare in relation to ambient light conditions in front of the interior mirror. To provide increased visibility
when backing up, the interior rear view mirror glass and LH exterior mirror glass will automatically return to
a high reflectance mode whenever the gear selector is in REVERSE.
For information and diagnostics, refer to Rear View Mirrors - Interior in this section.
Memory Exterior Mirror
Rear View Mirrors - Exterior 155
The memory mirror function recalls the preferred positioning of the exterior mirror motors when the gear
selector is in PARK or NEUTRAL and the door mounted switches or Remote Keyless Entry (RKE)
transmitter are activated.
Each exterior mirromotor is equipped with a potentiometer, which the Driver Door Module (DDM) and
Driver Seat Module (DSM) use to monitor the position of the mirrors. The DDM constantly tracks LH mirror
motor position. The DSM constantly tracks RH mirror motor position. When a mirror motor position is stored
in memory by the operator, the module will retain this position in memory for future recall. The position of
the mirror motors are stored within the DDM and DSM memory as long as the modules retain power. When a
memory position is recalled by the operator, the DDM and DSM will power the exterior mirror motors
simultaneously and monitor the potentiometer circuits. When the stored memory position is reached, the
DDM and DSM will remove power from the exterior mirror motors. If the exterior mirror control switch is
operated during a memory recall, the DDM and DSM will stop the memory recall and respond to the exterior
mirror control switch command.
For information on the DDM , refer to Section 501-14 .
For information on the DSM and Memory Position Programming, refer to Section 501-10 .
Puddle Lamps
The exterior mirrors may be equipped with puddle lamps, which will illuminate when the interior lights are
turned on by opening a door or by pressing the unlock button on the remote transmitter, if equipped. For
information on the mirror-mounted puddle lamps, refer to Section 417-01 .
Verify the customer concern. 1.
Visually inspect for obvious signs of mechanical or electrical damage:
Visual Inspection Chart
Mechanical Electrical
Exterior mirror
Exterior mirror
control switch

Smart Junction Box (SJB) fuse 12
(7.5A)

Power Distribution Box (PDB) fuse 38
(10A)

Circuitry
Driver Door Module (DDM)
Driver Seat Module (DSM)
Exterior mirror motor
Exterior mirror
Loose or corroded connections
Bent pins
2.
If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step.
3.
NOTE: Make sure to use the latest scan tool software release.
If the cause is not visually evident, connect the scan tool to the Data Link Connector (DLC).
4.
NOTE: The Vehicle Communication Module (VCM) LED prove out confirms power and ground
from the DLC are provided to the VCM .
If the scan tool does not communicate with the VCM :
check the VCM connection to the vehicle.
check the scan tool connection to the VCM .
refer to Section 418-00 , No Power To The Scan Tool, to diagnose no power to the scan tool.
5.
If the scan tool does not communicate with the vehicle:
verify the ignition key is in the ON position.
verify the scan tool operation with a known good vehicle.
refer to Section 418-00 to diagnose no response from the DDM or the DSM .
6.
Carry out the network test.
If the scan tool responds with no communication for one or more modules, refer to Section
418-00 .

If the network test passes, retrieve and record continuous memory DTCs.
7.
Clear the continuous DTCs and carry out the self-test diagnostics for the DDM and DSM . 8.
If the DTCs retrieved are related to the concern, go to Driver Door Module (DDM) DTC Chart or
Driver Seat Module (DSM) DTC Chart. For all other DTCs, refer to Section 419-10 .
9.
If no DTCs related to the concern are retrieved, GO to Symptom Chart - Exterior Mirrors or GO to
Symptom Chart - NVH .
10.
DTC Charts
Driver Door Module (DDM) DTC Chart
DTC Description Action
B1667 Mirror Driver Up/Down Motor Stalled GO to Pinpoint Test D .
B1668 Mirror Driver Right/Left Motor Stalled GO to Pinpoint Test D .
B1733 Mirror Driver Vertical Switch Circuit Failure GO to Pinpoint Test D .
B1737 Mirror Driver Horizontal Switch Circuit Failure GO to Pinpoint Test D .
B1741 Mirror Passenger Vertical Switch Circuit Failure GO to Pinpoint Test D .
B1745 Mirror Passenger Horizontal Switch Circuit Failure GO to Pinpoint Test D .
B2223 Driver Mirror Drive Circuit Failure GO to Pinpoint Test D .
B2320 Driver Mirror Horizontal Feedback Potentiometer Circuit Failure GO to Pinpoint Test D .
B2322 Driver Mirror Horizontal Feedback Potentiometer Circuit Short to
Battery
GO to Pinpoint Test D .
B2324 Driver Mirror Vertical Feedback Potentiometer Circuit Failure GO to Pinpoint Test D .
B2326 Driver Mirror Vertical Feedback Potentiometer Circuit Short to
Battery
All other
DTCs
- REFER to Section
501-14 .
Driver Seat Module (DSM) DTC Chart
B1669 Mirror Passenger Up/Down Motor Stalled GO to Pinpoint Test D .
B1670 Mirror Passenger Right/Left Motor Stalled GO to Pinpoint Test D .
B2224 /TD> Passenger Mirror Drive Circuit Failure GO to Pinpoint Test D .
B2312 Passenger Mirror Horizontal Feedback Potentiometer Circuit
Failure
B2314 Passenger Mirror Horizontal Feedback Potentiometer Circuit Short
to Battery
B2316 Passenger Mirror Vertical Feedback Potentiometer Circuit Failure GO to Pinpoint Test D .
B2318 Passenger Mirror Vertical Feedback Potentiometer Circuit Short to
Battery
All other
DTCs
- REFER to Section
501-10 .
Symptom Chart - Exterior Mirrors
Symptom Chart - Exterior Mirrors
Symptom Chart - NVH
Symptom Chart - NVH
possible any one of multiple systems may be the cause of a symptom, it may be necessary to use a process of
Exterior mirror vibrates/loose
Exterior mirror mounting nuts loose
TIGHTEN the exterior mirror mounting nuts to the specified value located in the Torque
Specifications table.

Exterior mirror glass loose
PRESS the center of the exterior mirror glass up, down, left and right to make sure that the exterior
mirror glasss seated correctly. If the exterior mirror glass is still loose, REMOVE the exterior mirror

glass and INSPECT the exterior mirror backing plate for damage. If the exterior mirror backing plate
is damaged, INSTALL a new exterior mirror glass. REFER to Exterior Mirror Glass in this section.
Aftermarket air deflector/stone shields
If possible, REMOVE aftermarket air deflector/stone shield, then ROAD TEST the vehicle. If
concern is no longer present, ADVISE customer that aftermarket components were causing undesired
vibration.

Wind noise
Foam gasket between the exterior mirror and door frame is missing or damaged
VERIFY that the foam gasket is present and in good condition. If necessary, REPOSITION the foam
gasket between the exterior mirror and door frame.

Exterior mirror is not correctly fitted to the door
VERIFY that there are no gaps between the exterior mirror and the door. If necessary, LOOSEN the
exterior mirror nuts and REPOSITION the exterior mirror.

VERIFY that the exterior mirror cover is not loose or broken. If necessary, INSTALL a new exterior
mirror cover. REFER to Exterior Mirror Cover in this section.

Pinpoint Tests
Pinpoint Test A: The Mirrors are Inoperative - Non-Memory Mirrors
Refer to Wiring Diagrams Cell 124 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Power Mirrors for
schematic and connector information.
Normal Operation
Under normal operation, the exterior mirror control switch receives power through circuit SBP12 (GN/RD)
and ground through circuit GD126 (BK/WH). The exterior mirror control switch uses circuit CPM23 (GY) as
the common circuit for both exterior mirror motor up/down and right/left movement.
This pinpoint test is intended to diagnose the following:
Fuse
Wiring, terminals or connectors
Exteor mirror control switch
PINPOINT TEST A: THE MIRRORS ARE INOPERATIVE - NON-MEMORY MIRRORS
Test Step Result / Action to Take
A1 CHECK THE VOLTAGE TO THE EXTERIOR
MIRROR CONTROL SWITCH
Normal Operation 159
Ignition OFF.
Disconnect: Exterior Mirror Control Switch
C527.

Measure the voltage between exterior mirror
control switch C527-3, circuit SBP12 (GN/RD),
harness side and ground.

Is the voltage greater than 10 volts?
Yes
GO to A2 .
No
VERIFY Smart Junction Box (SJB) fuse 12
(7.5A) is OK. If OK, REPAIR the circuit. If
not OK, REFER to the Wiring Diagrams
manual to identify the possible causes of the
circuit short. TEST the system for normal
operation.
A2 CHECK GROUND TO THE EXTERIOR
Measure the resistance between exterior mirror
control switch C527-1, circuit GD126 (BK/WH),

Is the resistance less than 5 ohms?
Yes
GO to A3 .
No
REPAIR the circuit. TEST the system for
normal operation.
A3 CHECK CIRCUIT CPM23 (GY) FOR A
SHORT TO VOLTAGE
Ignition ON.
control switch C527-6, circuit CPM23 (GY),

Is any voltage present?
Yes
normal operation.
No
GO to A4 .
A4 CHECK CIRCUIT CPM23 (GY) FOR A
SHORT TO GROUND
PINPOINT TEST A: THE MIRRORS ARE INOPERATIVE - NON-MEMORY MIRRORS 160
Ignition OFF.
Measure the resistance between exterior mirror
control switch C527-6, circuit CPM23 (GY),

Is the resistance greater than 10,000 ohms?
Yes
GO to A5 .
No
normal operation.
A5 CHECK CIRCUIT CPM23 (GY) FOR AN
OPEN
Disconnect: LH Exterior Mirror C516 (without
heated mirrors) or C517 (with heated mirrors).

Without heated mirrors: Measure the
resistance between exterior mirror control switch
C527-6, circuit CPM23 (GY), harness side and
LH exterior mirror C516-2, circuit CPM23 (GY),
harness side.

With heated mirrors: Measure the resistance
between exterior mirror control switch C527-6,
circuit CPM23 (GY), harness side and LH
exterior mirror C517-2, circuit CPM23 (GY),
harness side.

Yes
INSTALL a new exterior mirror control
switch. REFER to Exterior Mirror Control
Switch in this section. TEST the system for
normal operation.
No
normal operation.
Pinpoint Test B: A Single Mirror is Inoperative - Non-Memory Mirrors
PINPOINT TEST A: THE MIRRORS ARE INOPERATIVE - NON-MEMORY MIRRORS 161
Normal Operation
Under normal operation, the exterior mirror control switch uses circuit CPM23 (GY) as the common circuit
for both exterior mirror down/up and left/right movement.
Exterior mirror
PINPOINT TEST B: A SINGLE MIRROR IS INOPERATIVE - NON-MEMORY MIRRORS
B1 CHECK THE LH MIRROR
OPERATION
Operate the LH exterior mirror using
the exterior mirror control switch.

Does the LH exterior mirror
operate?

Yes
GO to B2 .
No
GO to B4 .
B2 CHECK THE EXTERIOR MIRROR
CONTROL SWITCH
Ignition OFF.
Disconnect: Exterior Mirror Control
Switch C527.

Carry out the Exterior Mirror Control
Switch component test.
Refer to Wiring Diagrams Cell 149 (
Fusion/MKZ , Fusion Hybrid/MKZ
Hybrid ) for component testing.

Did the exterior mirror control
switch pass the component test?

Yes
GO to B3 .
No
INSTALL a new exterior mirror control switch. REFER
to Exterior Mirror Control Switch in this section. TEST
the system for normal operation.
B3 CHECK CIRCUIT CPM23 (GY)
FOR AN OPEN
Disconnect: RH Exterior Mirror
C622 (without heated mirrors) or
C625 (with heated mirrors).

Without heated mirror: Measure
the resistance between exterior mirror
control switch C527-6, circuit
CPM23 (GY), harness side and RH
exterior mirror C622-2, circuit
CPM23 (GY), harness side.

Yes
CHECK the RH exterior mirror jumper harness between
the vehicle harness and the exterior mirror motor for open
circuits and damaged or pushed-out pins. If the jumper
harness is not OK, REPAIR the jumper harness. If the
jumper harness cannot be repaired, INSTALL a new RH
exterior mirror. REFER to Exterior Mirror in this section.
If the jumper harness is OK, INSTALL a new exterior
mirror motor. REFER to Exterior Mirror Motor in this
section. TEST the system for normal operation.
With heated mirror: Measure the
resistance between exterior mirror
CPM23 (GY), harness side and RH

No
REPAIR the circuit. TEST the system for normal
operation.
B4 CHECK THE EXTERIOR MIRROR
CONTROL SWITCH
Ignition OFF.
Disconnect: Exterior Mirror Control
Switch C527.

Carry out the Exterior Mirror Control

Did the exterior mirror control
switch pass the component test?

Yes
GO to B5 .
No
INSTALL a new exterior mirror control switch. REFER
to Exterior Mirror Control Switch in this section. TEST
B5 CHECK CIRCUIT CPM23 (GY)
FOR AN OPEN
Disconnect: LH Exterior Mirror
C516 (without heated mirrors) or
C517 (with heated mirrors).

Without heated mirror: Measure
the resistance between exterior mirror
CPM23 (GY), harness side and LH

Yes
CHECK the LH exterior mirror jumper harness between
the vehicle harness and the exterior mirror motor for open
circuits and damaged or pushed-out pins. If the jumper
harness is not OK, REPAIR the jumper harness. If the
jumper harness cannot be repaired, INSTALL a new LH
exterior mirror. REFER to Exterior Mirror in this section.
If the jumper harness is OK, INSTALL a new exterior
mirror motor. REFER to Exterior Mirror Motor in this
No
PINPOINT TEST B: A SINGLE MIRROR IS INOPERATIVE - NON-MEMORY MIRRORS 163
With heated mirror: Measure the
resistance between exterior mirror
CPM23 (GY), harness side and LH

operation.
Pinpoint Test C: A Single Mirror Does Not Operate Correctly - Non-Memory Mirrors
Normal Operation
Under normal operation, the exterior mirror control switch uses circuits CPM16 (BN/BU), CPM17 (BU/GN),
CPM20 (BN/WH), CPM21 (YE/VT) and CPM23 (GY) to control the exterior mirror motor movement. The
exterior mirror switch controls the LH exterior mirror motor movement by switching voltage and ground to
circuits CPM16 (BN/BU), CPM17 (BU/GN) and CPM23 (GY). The exterior mirror switch controls the RH
exterior mirror motor movement by switching voltage and ground to circuits CPM20 (BN/WH), CPM21
(YE/VT) and CPM23 (GY).
Mirror Movement
When the LH/RH exterior mirror motor receives ground through circuit CPM16 (BN/BU)/CPM20
(BN/WH) and power through circuit CPM23 (GY), the LH/RH exterior mirror motor will operate
rightward.

When the LH/RH exterior mirror motor receives power through circuit CPM16 (BN/BU)/CPM20
(BN/WH) and ground through circuit CPM23 (GY), the LH/RH exterior mirror motor will operate
leftward.

When the LH/RH exterior mirror motor receives ground through circuit CPM17 (BU/GN)/CPM21
(YE/VT) and power through circuit CPM23 (GY), the LH/RH exterior mirror motor will operate
upward.

When the LH/RH exterior mirror motor receives power through circuit CPM17 (BU/GN)/CPM21
(YE/VT) and ground through circuit CPM23 (GY), the LH/RH exterior mirror motor will operate
downward.

Exterior mirror
PINPOINT TEST C: A SINGLE MIRROR DOES NOT OPERATE CORRECTLY - NON-MEMORY MIRRORS
C1 CHECK THE MIRROR
MOVEMENT (RIGHT/LEFT)
Operate the RH and LH exterior
mirrors in the right and left
direction using the exterior mirror
control switch.

Do the exterior mirrors move
left and right?

Yes
GO to C2 .
No
GO to C3 .
C2 CHECK THE MIRROR
MOVEMENT (DOWN/UP)
Operate the RH and LH exterior
mirrors in the down and up
direction using the exterior mirror
control switch.

Do the exterior mirrors move
up and down?

Yes
The system is operating correctly at this time. The concern
may have been caused by a loose or corroded connector.
TEST the system for normal operation.
No
GO to C4 .
C3 CHECK THE VOLTAGE TO
THE INOPERATIVE MIRROR
Ignition OFF.
Disconnect: Inoperative LH
Exterior Mirror C516 (without
heated mirrors) or C517 (with
heated mirrors).

Disconnect: Inoperative RH
heated mirrors).

NOTE: Position the exterior
mirror control switch to the LH or
RH position.

Without heated mirrors: While
operating the exterior mirror
control switch in the LEFT
position, measure the voltage
between ground and exterior
mirror:

LH: C516-3, circuit
CPM16 (BN/BU),
harness side.

Yes
CHECK the RH or LH exterior mirror jumper harness
between the vehicle harness and the exterior mirror motor for
open circuits and damaged or pushed-out pins. If the jumper
harness is not OK, REPAIR the jumper harness. If the jumper
harness cannot be repaired, INSTALL a new RH or LH
exterior mirror. REFER to Exterior Mirror in this section. If
the jumper harness is OK, INSTALL a new RH or LH
exterior mirror motor. REFER to Exterior Mirror Motor in
this section. TEST the system for normal operation.
No
GO to C5 .
PINPOINT TEST C: A SINGLE MIRROR DOES NOT OPERATE CORRECTLY - NON-MEMORY MIRRORS 165
RH: C622-3, circuit
CPM20 (BN/WH),
harness side.

RH position.

With heated mirrors: While
control switch in the LEFT
mirror:

LH: C517-3, circuit
CPM16 (BN/BU),
harness side.

RH: C625-3, circuit
CPM20 (BN/WH),
harness side.

Is the voltage greater than 10
volts?

C4 CHECK THE VOLTAGE TO
THE INOPERATIVE MIRROR
Ignition OFF.
Disconnect: Inoperative LH
heated mirrors).

Disconnect: Inoperative RH
heated mirrors).

RH position.

Without heated mirrors: While
control switch in the DOWN
mirror:

LH: C516-1, circuit
CPM17 (BU/GN),
harness side.

Yes
CHECK the RH or LH exterior mirror jumper harness
between the vehicle harness and the exterior mirror motor for
open circuits and damaged or pushed-out pins. If the jumper
harness is not OK, REPAIR the jumper harness. If the jumper
harness cannot be repaired, INSTALL a new RH or LH
exterior mirror. REFER to Exterior Mirror in this section. If
the jumper harness is OK, INSTALL a new RH or LH
exterior mirror motor. REFER to Exterior Mirror Motor in
this section. TEST the system for normal operation.
No
GO to C6 .
RH: C622-1, circuit
CPM21 (YE/VT), harness
side.

RH position.

With heated mirrors: While
control switch in the DOWN
mirror:

LH: C517-1, circuit
CPM17 (BU/GN),
harness side.

RH: C625-1, circuit
CPM21 (YE/VT), harness
side.

volts?

C5 CHECK CIRCUIT CPM16
(BN/BU) OR CPM20 (BN/WH) FOR
AN OPEN
Disconnect: Exterior Mirror
Control Switch C527.

Inoperative LH mirror:
Measure the resistance between
exterior mirror control switch
C527-8, circuit CPM16 (BN/BU),
harness side and LH exterior
mirror:

without heated mirror:
C516-3, circuit CPM16
(BN/BU), harness side.

with heated mirror:
(BN/BU), harness side.

Yes
INSTALL a new exterior mirror control switch. REFER to
Exterior Mirror Control Switch in this section. TEST the
system for normal operation.
No
REPAIR the circuit. TEST the system for normal operation.
Inoperative RH mirror:
(BN/WH), harness side and RH
exterior mirror:

(BN/WH), harness side.

with heated mirror:

Is the resistance less than 5
ohms?

C6 CHECK CIRCUIT CPM17
(BU/GN) OR CPM21 (YE/VT) FOR
AN OPEN
Disconnect: Exterior Mirror

Inoperative LH mirror:
C527-5, circuit CPM17 (BU/GN),
harness side and LH exterior
mirror:

(BU/GN), harness side.

with heated mirror:
(BU/GN), harness side.

Yes
INSTALL a new exterior mirror control switch. REFER to
Exterior Mirror Control Switch in this section. TEST the
No
REPAIR the circuit. TEST the system for normal operation.
Inoperative RH mirror:
C527-2, circuit CPM21 (YE/VT),
harness side and RH exterior
mirror:

(YE/VT), harness side.

with heated mirror:

ohms?

Pinpoint Test D: The Memory Mirror is Inoperative
Normal Operation
Under normal operation, the exterior mirror control switch receives power from circuit SBP12 (GN/RD) and
ground from circuit GD126 (BK/WH). The exterior mirror control switch uses circuits CPM16 (BN/BU),
CPM17 (BU/GN), CPM20 (BN/WH), CPM21 (YE/VT) and CPM23 (GY) to send input signals to the Driver
Door Module (DDM). The DDM controls the LH exterior mirror motor movement by supplying the
appropriate power and ground to circuits CPM27 (GY/BU), CPM28 (BU/BN) and CPM29 (GN). The DDM
communicates with the Driver Seat Module (DSM) through the Medium Speed Controller Area Network
(MS-CAN) whenever the DDM receives an input signal from the exterior mirror control switch for the RH
mirror. The DSM controls the RH exterior mirror motor movement by supplying the appropriate power and
ground to circuits CPM31 (YE/GY), CPM33 (WH/VT) and CPM34 (WH/BN).
The memory mirror system uses feedback potentiometers, located in the LH and RH exterior mirror motors, in
order to track the movement and position of the LH and RH exterior mirror motors. The DDM supplies the
LH exterior mirror feedback potentiometer reference voltage through circuit LPM30 (GY/VT) and ground
through circuit RPM30 (YE). The DSM supplies the RH exterior mirror feedback potentiometer reference
voltage through circuit LPM30 (GY/VT) and ground through circuit RPM30 (YE). The DDM receives
feedback from the LH exterior mirror feedback potentiometer through left/right circuit VPM35 (YE/BU) and
up/down circuit VPM36 (BN/YE). The DSM receives feedback from the RH exterior mirror feedback
potentiometer through left/right circuit VPM37 (BU/OG) and up/down circuit VPM38 (BN/GN).
DTC Description Fault Trigger Conditions
B1667 Mirror Driver Up/Down Motor Stalled
Incorrect mirror motor position reported to the DDM
during On-Demand Self Test.
B1668 Mirror Driver Right/Left Motor Stalled
Incorrect mirror motor position reported to the DDM
B1669 Mirror Passenger Up/Down Motor
Stalled

Incorrect mirror motor position reported to the DSM
B1670 Mirror Passenger Right/Left Motor
Stalled

Incorrect mirror motor position reported to the DSM
B1733 Mirror Driver Vertical Switch Circuit
Failure

Mirror switch failure detected by the DDM when
switch is activated.
B1737 Mirror Driver Horizontal Switch
Circuit Failure

B1741 Mirror Passenger Vertical Switch
Circuit Failure

B1745 Mirror Passenger Horizontal Switch
Circuit Failure

B2223 Mirror Driver Drive Circuit Failure
Short to ground or battery.
B2224 Mirror Passenger Drive Circuit Failure
Short to ground or battery.
B2312 Mirror Passenger Horizontal Feedback
Potentiometer Circuit Failure

Open or short to ground.
B2314 Mirror Passenger Horizontal Feedback
Potentiometer Circuit Short to Battery

Short to battery.
B2316 Mirror Passenger Vertical Feedback

B2318 Mirror Passenger Vertical Feedback

Short to battery.
B2320 Mirror Driver Horizontal Feedback

Short to battery.
B2322 Mirror Driver Horizontal Feedback

B2324 Mirror Driver Vertical Feedback


Short to battery.
Fuse
DDM
DSM
Exterior mirror
PINPOINT TEST D: THE MEMORY MIRROR IS INOPERATIVE
D1 RETRIEVE THE DTCs FROM THE DSM
AND DDM
Use the recorded DSM and DDM DTCs from
the continuous and on-demand self tests.

Are DTCs retrieved?
Yes
If DTC B1733, B1737, B1741 or B1745 -
CARRY OUT the Exterior Mirror Control
Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ) for
component testing.
If the switch tests OK, GO to D11 . If DTC
B1667 or B1668 - If other DTCs are present,
DIAGNOSE them first. If no other DTCs are
present, INSPECT the LH exterior mirror motor
for foreign material, damage or a binding
condition. If no condition is found, GO to D12 .
If DTC B1669 or B1670 - If other DTCs are
present, DIAGNOSE them first. If no other
DTCs are present, INSPECT the RH exterior
mirror motor for foreign material, damage or a
binding condition. If no condition is found, GO
to D14 . If DTC B2223, GO to D16 . If DTC
B2224, GO to D19 . If DTC B2312, B2316,
B2320 or B2324, GO to D22 . If DTC B2314,
B2318, B2322 or B2326, GO to D26 .
No
GO to D2 .
PINPOINT TEST D: THE MEMORY MIRROR IS INOPERATIVE 171
D2 CHECK THE OPERATION OF THE
EXTERIOR MIRRORS FROM THE EXTERIOR
Operate the mirrors using the exterior mirror
control switch.

Do the mirrors operate momentarily using
the exterior mirror control switch?

Yes
GO to D8 .
No
GO to D3 .
D3 CHECK THE EXTERIOR MIRROR
CONTROL SWITCH
Ignition OFF.
C527.

Carry out the Exterior Mirror Control Switch
component test.
Fusion/MKZ , Fusion Hybrid/MKZ Hybrid )
for component testing.

Did the exterior mirror control switch pass
the component test?

Yes
GO to D4 .
No
INSTALL a new exterior mirror control switch.
REFER to Exterior Mirror Control Switch in this
D4 CHECK CIRCUIT SBP12 (GN/RD) FOR
VOLTAGE
Ignition ON.
control switch C527-3, circuit SBP12
(GN/RD), harness side and ground.

Yes
GO to D5 .
No
(7.5A) is OK. If OK, REPAIR the circuit. If not
OK, REFER to the Wiring Diagrams manual to
identify the possible causes of the circuit short.
D5 CHECK CIRCUIT GD126 (BK/WH) FOR AN
OPEN
Ignition OFF.
Measure the resistance between exterior
mirror control switch C527-1, circuit GD126
(BK/WH), harness side and ground.

Yes
GO to D6 .
No
operation.
D6 CHECK CIRCUITS CPM16 (BN/BU), CPM17
(BU/GN), CPM20 (BN/WH), CPM21 (YE/VT)
AND CPM23 (GY) FOR A SHORT TO GROUND
Disconnect: DDM C568B.
Measure the resistance between ground and
exterior mirror control switch:

harness side.

harness side.

C527-6, circuit CPM23 (GY), harness
side.

C527-7, circuit CPM20 (BN/WH),
harness side.

harness side.

Are the resistances greater than 10,000
ohms?

Yes
GO to D7 .
No
REPAIR the circuit(s). TEST the system for
normal operation.
D7 CHECK CIRCUITS CPM16 (BN/BU), CPM17
(BU/GN), CPM20 (BN/WH), CPM21 (YE/VT)
AND CPM23 (GY) FOR AN OPEN
Measure the resistance between exterior
mirror control switch C527, harness side and
DDM C568A, harness side using the
following chart:

Exterior Mirror
Control Switch Circuit DDM
C527-2 CPM21
(YE/VT)
C568A-7
C527-5 CPM17
(BU/GN)
C568A-9
Yes
GO to D29 .
No
normal operation.
C527-6 CPM23 (GY) C568A-11
C527-7 CPM20
(BN/WH)
C568A-8
C527-8 CPM16
(BN/BU)
C568A-10
Are the resistances less than 5 ohms?
D8 CHECK CIRCUIT RPM30 (YE) FOR A
SHORT TO VOLTAGE
Ignition OFF.
Disconnect: Inoperative LH Mirror: DDM
C568A and DDM C568B.

Disconnect: Inoperative RH Mirror: DSM
C3299C and C3299D.

Ignition ON.
Inoperative LH mirror: Measure the voltage
between DDM C568B-21, circuit RPM30
(YE), harness side and ground.

Inoperative RH mirror: Measure the voltage
between DSM C3299D-11, circuit RPM30

Yes
operation.
No
GO to D9 .
D9 CHECK CIRCUIT LPM30 (GY/VT) FOR
SHORT TO GROUND
Ignition OFF.
Disconnect: Inoperative Exterior Mirror C522
(LH) or C626 (RH).

Inoperative LH mirror: Measure the
resistance between DDM C568B-9, circuit
LPM30 (GY/VT), harness side and ground.

Inoperative RH mirror: Measure the
resistance between DSM C3299D-1, circuit
LPM30 (GY/VT), harness side and ground.

Yes
GO to D10 .
No
operation.
D10 CHECK CIRCUITS RPM30 (YE) AND
LPM30 (GY/VT) FOR AN OPEN
Inoperative LH mirror: Measure the
resistance between LH exterior mirror C522,
harness side, DDM C568A, harness side and
DDM C568B, harness side using the following
chart:

LH Exterior
Mirror Circuit DDM
C522-16 RPM30 (YE) C568B-21
C522-13 LPM30
(GY/VT)
C568B-9
Yes
CHECK the LH or RH exterior mirror jumper
harness between the vehicle harness and the
exterior mirror motors for open or shorted
circuits and damaged or pushed-out pins. If the
jumper harness is not OK, REPAIR the jumper
harness. If the jumper harness cannot be
repaired, INSTALL a new LH or RH exterior
mirror. REFER to Exterior Mirror in this section.
If the jumper harness is OK, INSTALL a new
LH or RH exterior mirror motor. REFER to
Exterior Mirror Motor in this section. TEST the
No
normal operation.
Inoperative RH mirror: Measure the
resistance between RH exterior mirror C626,
harness side and DSM C3299C, harness side
using the following chart:

RH Exterior
Mirror Circuit DSM
C626-13 LPM30
(GY/VT)
C3299D-1
C626-16 RPM30 (YE) C3299D-11
D11 CHECK CIRCUITS CPM16 (BN/BU),
CPM17 (BU/GN), CPM20 (BN/WH), CPM21
(YE/VT) AND CPM23 (GY) FOR A SHORT TO
VOLTAGE
Ignition OFF.
C527.

Ignition ON.
Measure the voltage between ground and
exterior mirror control switch:

harness side.

harness side.

C527-6, circuit CPM23 (GY), harness
side.

C527-7, circuit CPM20 (BN/WH),
harness side.

harness side.

Yes
REPAIR the circuit(s). CLEAR the DTCs. TEST
No
GO to D29 .
D12 CHECK THE EXTERIOR MIRROR FOR
VOLTAGE FROM THE DDM
Ignition OFF.
Disconnect: LH Exterior Mirror C522.
Ignition ON.
Enter the following diagnostic mode on the
scan tool: DDM DataLogger.

DTC B1667: Measure the voltage between
LH exterior mirror C522-1, circuit CPM29
(GN), harness side and ground while toggling
the LH exterior mirror DDM PID DR_UP to
ON; and between LH exterior mirror C522-2,
circuit CPM27 (GY/BU), harness side and
ground while toggling the LH exterior mirror
DDM PID DR_DOWN to ON.

LH exterior mirror C522-3, circuit CPM27
(GY/BU), harness side and ground while
toggling the LH exterior mirror DDM PID
DR_LEFT to ON; and between LH exterior
mirror C522-4, circuit CPM28 (BU/BN),
harness side and ground while toggling the LH
exterior mirror DDM PID DR_RIGHT to ON.

Yes
CHECK the LH exterior mirror jumper harness
between the vehicle harness and the exterior
mirror motor for shorted and open circuits and
damaged or pushed-out pins. If the jumper
harness is not OK, REPAIR the jumper harness.
If the jumper harness cannot be repaired,
INSTALL a new LH exterior mirror. REFER to
Exterior Mirror in this section. If the jumper
harness is OK, INSTALL a new LH exterior
mirror motor. REFER to Exterior Mirror Motor
in this section. CLEAR the DTCs. TEST the
No
GO to D13 .
Do the voltages momentarily change from 0
volt to greater than 10 volts when the active
command is toggled ON?

D13 CHECK CIRCUITS CPM27 (GY/BU),
CPM28 (BU/BN) AND CPM29 (GN) FOR AN
OPEN
Ignition OFF.
DTC B1667: Measure the resistance between
LH exterior mirror C522, harness side and
chart:

LH Exterior
Mirror Circuit DDM
C522-1 CPM29 (GN) C568B-4
C522-2 CPM27
(GY/BU)
C568B-2
LH exterior mirror C522, harness side and
chart:

LH Exterior
Mirror Circuit DDM
C522-3 CPM27
(GY/BU)
C568B-2
C522-4 CPM28
(BU/BN)
C568B-5
Yes
GO to D29 .
No
D14 CHECK THE EXTERIOR MIRROR FOR
VOLTAGE FROM THE DSM
Ignition OFF.
Disconnect: RH Exterior Mirror C626.
Ignition ON.
scan tool: DSM DataLogger.

RH exterior mirror C626-1, circuit CPM34
(WH/BN), harness side and ground while
toggling the RH exterior mirror DSM PID
PR_UP to ON; and between RH exterior
mirror C626-2, circuit CPM31 (YE/GY),
harness side and ground while toggling the RH
exterior mirror DSM PID PR_DOWN to ON.

RH exterior mirror C626-3, circuit CPM31
(YE/GY), harness side and ground while
toggling the RH exterior mirror DSM PID
PR_LEFT to ON; and between RH exterior
mirror C626-4, circuit CPM33 (WH/VT),
harness side and ground while toggling the RH
exterior mirror DSM PID PR_RIGHT to ON.

Do the voltages momentarily change from 0
volt to greater than 10 volts when the active
command is toggled ON?

Yes
CHECK the RH exterior mirror jumper harness
mirror motor for shorted and open circuits and
INSTALL a new RH exterior mirror. REFER to
Exterior Mirror in this section. If the jumper
harness is OK, INSTALL a new RH exterior
mirror motor. REFER to Exterior Mirror Motor
in this section. CLEAR the DTCs. TEST the
No
GO to D15 .
D15 CHECK CIRCUITS CPM31 (YE/GY),
CPM33 (WH/VT) AND CPM34 (WH/BN) FOR AN
OPEN
Ignition OFF.
Disconnect: DSM C3299D.
RH exterior mirror C626, harness side and
DSM C3299D, harness side using the
following chart:

RH Exterior
Mirror Circuit DSM
C626-1 CPM34
(WH/BN)
C3299D-7
C626-2 CPM31
(YE/GY)
C3299D-8
RH exterior mirror C626, harness side and
DSM C3299D, harness side using the
following chart:

RH Exterior
Mirror Circuit DSM
C626-3 CPM31
(YE/GY)
C3299D-8
C626-4 CPM33
(WH/VT)
C3299D-6
Yes
GO to D28 .
No
D16 CHECK CIRCUITS CPM27, CPM28
(BU/BN) AND CPM29 (GN) FOR A SHORT TO
VOLTAGE
Ignition OFF.
Ignition ON.
DDM :

C568B-5, circuit CPM28 (BU/BN),
harness side.

C568B-4, circuit CPM29 (GN),
harness side.

C568B-2, circuit CPM27 (GY/BU),
harness side.

Yes
No
GO to D17 .
D17 CHECK CIRCUITS CPM27 (GY/BU),
CPM28 (BU/BN) AND CPM29 (GN) FOR A
SHORT TO GROUND
Ignition OFF.
DDM :

harness side.

harness side.

harness side.

ohms?

Yes
GO to D29 .
No
GO to D18 .
D18 CHECK THE LH EXTERIOR MIRROR
FOR A SHORT TO GROUND
DDM :

harness side.

harness side.

harness side.

ohms?

Yes
mirror motor for shorted circuits and damaged or
pushed-out pins. If the jumper harness is not OK,
REPAIR the jumper harness. If the jumper
harness cannot be repaired, INSTALL a new LH
exterior mirror. REFER to Exterior Mirror in this
section. If the jumper harness is OK, INSTALL a
new LH exterior mirror motor. REFER to
Exterior Mirror Motor in this section. CLEAR
the DTCs. TEST the system for normal
operation.
No
CPM33 (WH/VT) AND CPM34 (WH/BN) FOR A
SHORT TO VOLTAGE
Ignition OFF.
Disconnect: DSM C3299D.
Ignition ON.
DSM :

C3299D-7, circuit CPM34 (WH/BN),
harness side.

C3299D-8, circuit CPM31 (YE/GY),
harness side.

C3299D-6, circuit CPM33 (WH/VT),
harness side.

Yes
No
GO to D20 .
CPM33 (WH/VT) AND CPM34 (WH/BN) FOR A
SHORT TO GROUND
Ignition OFF.
DSM :

harness side.

Yes
GO to D28 .
No
GO to D21 .
harness side.

harness side.

ohms?

D21 CHECK THE RH EXTERIOR MIRROR
DSM :

harness side.

harness side.

harness side.

ohms?

Yes
CHECK the RH exterior mirror jumper harness
mirror motor for shorted circuits and damaged or
REPAIR the jumper harness. If the jumper
harness cannot be repaired, INSTALL a new RH
exterior mirror. REFER to Exterior Mirror in this
section. If the jumper harness is OK, INSTALL a
new RH exterior mirror motor. REFER to
Exterior Mirror Motor in this section. CLEAR
operation.
No
D22 CHECK THE LH AND RH EXTERIOR
MIRRORS
Ignition OFF.
Disconnect: DTC B2312 or B2316: DSM
C3299D.

Disconnect: DTC B2320 or B2324: DDM
C568A.

DTC B2312 or B2316: Measure the resistance
between ground and DSM :

DTC B2312: C3299D-15, circuit
VPM37 (BU/OG), harness side.

VPM38 (BN/GN), harness side.

Yes
GO to D24 .
No
GO to D23 .
between ground and DDM :

DTC B2320: C568A-2, circuit
VPM35 (YE/BU), harness side.

VPM36 (BN/YE), harness side.

D23 CHECK CIRCUITS VPM35 (YE/BU),
VPM36 (BN/YE), VPM37 (BU/OG) AND VPM38
(BN/GN) FOR A SHORT TO GROUND
Disconnect: DTC B2312 or B2316: RH
Exterior Mirror C625.

Disconnect: DTC B2320 or B2324: LH







Yes
CHECK the RH or LH exterior mirror jumper
exterior mirror motor for shorted circuits and
INSTALL a new RH or LH exterior mirror.
REFER to Exterior Mirror in this section. If the
jumper harness is OK, INSTALL a new RH or
LH exterior mirror motor. REFER to Exterior
Mirror Motor in this section. CLEAR the DTCs.
No
D24 CHECK THE RH AND LH EXTERIOR
MIRRORS FOR AN INTERNAL OPEN
between DSM C3299D-15, circuit VPM37
(BU/OG), harness side and C3299D-14,
circuit VPM38 (BN/GN), harness side.

between DDM C568A-2, circuit VPM35
(YE/BU), harness side and C568A-1, circuit

Yes
For DTC B2312 or B2316, GO to D28 . For
DTC B2320 or B2324, GO to D29 .
No
GO to D25 .
D25 CHECK CIRCUITS VPM35 (YE/BU),
VPM36 (BN/YE), VPM37 (BU/OG) AND VPM38
(BN/GN) FOR AN OPEN


between RH exterior mirror C626, harness
side and DSM C3299D, harness side using the
following chart:

Yes
DTC
RH
Exterior
Mirror Circuit DSM
B2312 C626-15 VPM37
(BU/OG)
C3299D-15
B2316 C626-14 VPM38
(BN/GN)
C3299D-14
between LH exterior mirror C522, harness
side and DDM C568A, harness side using the
following chart:

DTC
RH Exterior
Mirror Circuit DSM
B2312 C522-15 VPM35
(YE/BU)
C568A-2
B2316 C522-14 VPM36
(BN/YE)
C568A-1
No
MIRRORS
Ignition OFF.
Disconnect: DTC B2314 or B2318: DSM
C3299D.

Disconnect: DTC B2322 or B2326: DDM
C568A.

Ignition ON.
DTC B2314 or B2318: Measure the voltage

Yes
GO to D27 .
No
For DTC B2314 or B2318, GO to D28 . For
DTC B2322 or B2326, GO to D29 .





MIRRORS
Ignition OFF.






Yes
No


D28 CHECK THE DSM FOR CORRECT
OPERATION
Disconnect all DSM connectors.
Check for:
corrosion.
pushed-out pins.
Connect all DSM connectors and make sure
they seat correctly.

Operate the system and verify the concern is
still present.

Is the concern still present?
Yes
INSTALL a new DSM . REFER to Section
501-10 . CLEAR the DTCs. REPEAT the
self-test.
No
The system is operating correctly at this time.
Concern may have been caused by a loose or
corroded connector. CLEAR the DTCs.
REPEAT the self-test.
D29 CHECK THE DDM FOR CORRECT
OPERATION
Disconnect all DDM connectors.
Check for:
corrosion.
pushed-out pins.
Connect all DDM connectors and make sure

still present.

Yes
INSTALL a new DDM . REFER to Section
501-14 . CLEAR the DTCs. REPEAT the
self-test.
No
Pinpoint Test E: The Heated Exterior Mirror is Inoperative
Refer to Wiring Diagrams Cell 56 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Heated Windows for
Normal Operation
Under normal operation, the LH and RH exterior mirror glass receives power from Power Distribution Box
(PDB) fuse 38 (10A) and through circuit CBB38 (GY/BU), when the rear window defrost system is on.
Ground is supplied to the LH heated exterior mirror glass through circuit GD126 (BK/WH) and to the RH
heated exterior mirror glass through circuit GD139 (BK/YE).
Fuse
Exterior mirror
PINPOINT TEST E: THE HEATED EXTERIOR MIRROR IS INOPERATIVE
E1 CHECK THE OPERATION OF THE
REAR WINDOW DEFROST SYSTEM
Ignition ON.
Press the rear window defrost switch to
the ON position.

Place a hand on the rear window to verify
that the rear window heats up.

Does the rear window defrost system
operate?

Yes
GO to E2 .
No
REFER to Section 501-11 to diagnose the rear
window defrost system.
E2 CHECK THE VOLTAGE TO THE
EXTERIOR MIRRORS
Ignition OFF.
Disconnect: LH Exterior Mirror C517
(without memory mirrors)/C522 (with
memory mirrors) or RH Exterior Mirror
C625 (without memory mirrors)/C626
(with memory mirrors).

Ignition ON.
Press the rear window defrost switch to
the ON position.

Without memory mirrors: Measure the
voltage between ground and inoperative
exterior mirror:

LH: C517-5, circuit CBB38
(GY/BU), harness side.

RH: C625-5, circuit CBB38
(GY/BU0), harness side.

With memory mirrors: Measure the
voltage between ground and inoperative
exterior mirror:

LH: C522-6, circuit CBB38
(BU/OG), harness side.

Yes
GO to E3 .
No
VERIFY that PDB fuse 38 (10A) is OK. If OK,
REPAIR the circuit. If not OK, REFER to the Wiring
Diagrams manual to identify the possible causes of
the circuit short. TEST the system for normal
operation.
PINPOINT TEST E: THE HEATED EXTERIOR MIRROR IS INOPERATIVE 189
RH: C626-6, circuit CBB38
(GY/BU), harness side.

E3 CHECK THE EXTERIOR REAR VIEW
MIRROR GROUND CIRCUIT FOR AN
OPEN
Ignition OFF.
Without memory mirrors: Measure the
resistance between ground and
inoperative exterior mirror:

LH: C517-6, circuit GD126
(BK/WH), harness side.

RH: C625-6, circuit GD139
(BK/YE), harness side.

With memory mirrors: Measure the
resistance between ground and
inoperative exterior mirror:

LH: C522-7, circuit GD126
(BK/WH), harness side.

RH: C626-7, circuit GD139

Yes
CHECK the LH or RH exterior mirror jumper harness
between the vehicle harness and the exterior mirror
glass for open circuits and damaged or pushed-out
pins. If the jumper harness is not OK, REPAIR the
jumper harness. If the jumper harness cannot be
repaired, INSTALL a new LH or RH exterior mirror.
jumper harness is OK, INSTALL a new LH or RH
exterior mirror glass. REFER to Exterior Mirror Glass
in this section. TEST the system for normal operation.
No
operation.
Mirrors
Manual
Rear View Mirrors - Interior
Special Tool(s)
Interior Auto-Dimming Rear View Mirror
The interior auto-dimming rear view mirror automatically reduces the glare caused by headlamps reflecting in
the interior rear view mirror. Voltage is supplied to the interior auto-dimming mirror when the ignition is in
RUN or ACC. The auto-dimming feature is disabled when the vehicle is in REVERSE.
The interior auto-dimming rear view mirror has 2 photoelectric sensors, forward facing and rearward facing
sensors, that detect forward and rearward light conditions. Based on these inputs, the automatic dimming
feature adjusts the reflectance level of the interior rear view mirror glass to eliminate unwanted glare. The
reflectance level of the mirror glass is variable and depends on the amount of rear glare in relation to ambient
light conditions in front of the interior mirror.
When the forward facing sensor detects daytime conditions, the rearward facing sensor is inactive and the
mirror stays in a high reflectance mode. When the forward facing sensor detects nighttime conditions, the
rearward facing sensor is active and detects glare from the headlights of vehicles approaching from the rear, or
other glare producing light sources. To provide increased visibility when backing up, the interior rear view
and LH exterior mirror automaticallturns to a high reflectance mode whenever the vehicle is in REVERSE.
If the forward or rearward sensors are blocked, the automatic dimming interior mirror might not work
correctly.
Visually inspect for obvious signs of mechanical or electrical damage:
Interior rear
view mirror
(15A)

Circuitry
LH exterior mirror glass
LH exterior mirror
2.
Rear View Mirrors - Interior 192
Interior auto-dimming rear view
mirror

3.
If the concern is not visually evident, verify the symptom and GO to Symptom Chart - Interior Mirror
or GO to Symptom Chart - NVH .
4.
Symptom Chart - Interior Mirror
Symptom Chart - Interior Mirror
Symptom Chart - NVH
Symptom Chart - NVH
NOT> NVH symptoms should be identified using the diagnostic tools that are available. For a list of
these tools, an explanation of their uses and a glossary of common terms, refer to Section 100-04 . Since
it is possible any one of multiple systems may be the cause of a symptom, it may be necessary to use a
process of elimination type of diagnostic approach to pinpoint the responsible system. If this is not the
causal system for the symptom, refer back to Section 100-04 for the next likely system and continue
diagnosis.
The interior mirror loose/vibrates
Interior mirror mounting loose
If the mirror is still on the windshield do not remove. ATTEMPT to fully seat the mirror first (use
Rear View Mirror Installer Tool for non-auto-dimming mirror). If the mirror is still loose or vibrates,
REMOVE and REINSTALL the mirror. REFER to Interior Rear View Mirror in this section. If the
condition still exists, INSTALL a new mirror.

Pinpoint Tests
Pinpoint Test F: The Auto-Dimming Mirror Does Not Operate Correctly
Rear View Mirrors - Interior 193
Normal Operation
Under normal operation the interior auto-dimming mirror receives voltage from the Smart Junction Box
(SJB). The interior auto-dimming mirror contains 2 photoelectric sensors: one in the front of the interior rear
view mirror and one mounted on the glass side of the mirror. If the sensors are blocked, the LH exterior mirror
and auto-dimming feature may not operate correctly. Always verify both sensors are not physically blocked
before attempting to diagnose auto-dimming mirror concerns. Whenever the gear selector lever is placed in
REVERSE, the interior auto-dimming mirror temporarily disables the auto-dimming feature. The
auto-dimming feature is enabled again when the gear selector lever is moved out of REVERSE.
Fuse
Interior auto-dimming mirror
LH exterior mirror auto-dimming glass
LH exterior auto-dimming mirror (if equipped)
PINPOINT TEST F: THE AUTO-DIMMING MIRROR DOES NOT OPERATE CORRECTLY
NOTICE: Use the correct probe adapter(s) from the Flex Probe Kit when making measurements.
Failure to use the correct probe adapter(s) may damage the connector.
NOTE: If the Transmission Range (TR) sensor is malfunctioning and the backup lamps are on all the time or
do not turn on, the auto-dimming interior mirror will not darken or return to normal view.
F1 CHECK THE OPERATION OF THE
BACKUP LAMPS
Ignition ON.
Move the selector lever through the entire
range.

Do the backup lamps illuminate and
only in REVERSE?

Yes
MKZ only: If the LH exterior mirror only is always
dim, REPAIR circuit LRD12 (BU/GY) for a short to
voltage. TEST the system for normal operation.
MKZ only: If the LH exterior mirror only does not
dim correctly, GO to F10 . MKZ only: If the interior
mirror only does not dim correctly and the LH
exterior mirror does dim correctly, INSTALL a new
interior mirror, REFER to Interior Rear View Mirror
in this section. TEST the system for normal
operation. MKZ only: If the LH exterior mirror and
interior mirror does not dim correctly, GO to F2 .
Fusion only: If the interior mirror does not operate
correctly, GO to F2 .
No
REFER to Section 417-01 to diagnose the backup
lamps.
F2 VERIFY THAT THE FORWARD AND
REARWARD FACING SENSORS ARE NOT
BLOCKED
Visually verify that the forward and
rearward facing sensors are not blocked.

Yes
If possible, REMOVE the blockage. TEST the system
for normal operation. If the blockage cannot be
Sources of blockage can include:
stickers, window decals or tags.
fold-down screens for TVs or
DVD players.

non-OEM window tinting.
Were either of the sensors blocked?
removed, ADVISE the customer of the correct
operation of the interior auto-dimming mirror.
No
GO to F3 .
INTERIOR AUTO-DIMMING MIRROR -
DAYLIGHT CONDITIONS
Ignition ON.
Without video display: Use a bright
lamp to simultaneously illuminate the
forward-facing sensor and the
rearward-facing sensor. The mirror should
adjust to a high reflectance mode (mirror
will be clear).

With video display: Use a bright lamp to
simultaneously illuminate the
forward-facing sensor and the
rearward-facing sensor. The mirror should
adjust to a high reflectance mode (mirror
will be clear).

Does the mirror adjust to the high
reflectance (clear) mode?

Yes
GO to F4 .
No
INSTALL a new interior mirror. REFER to Interior
Rear View Mirror in this section. TEST the system
for normal operation.
NIGHTTIME CONDITIONS WITH GLARE
Ignition ON.
Without video display: Simulate
nighttime conditions with glare:

NOTE: Covering the sensor with
a finger or hand is not adequate.
Yes
GO to F5 .
No
GO to F7 .
PINPOINT TEST F: THE AUTO-DIMMING MIRROR DOES NOT OPERATE CORRECTLY 195
Cover the forward-facing sensor
with black electrical tape or other
dark material.

Illuminate the rearward-facing
sensor. The mirror should darken
to a lower reflectance mode.

With video
display: Simulate nighttime conditions
with glare:
dark material.


Did the mirror darken to a lower
reflectance (darker) mode?

NIGHTTIME CONDITIONS WITHOUT
GLARE
Ignition ON.
Without video display: Simulate
nighttime conditions without glare:

Cover the rearward-facing sensor.
The mirror should adjust to e high
reflectance mode.

Yes
GO to F6 .
No
GO to F7 .
With video display: Simulate nighttime
conditions without glare:

Cover the rearward-facing sensor.
The mirror should adjust to the
high reflectance mode.

Did the mirror adjust to the high
reflectance (clear) mode?

NIGHTTIME CONDITIONS WITH THE
VEHICLE IN REVERSE
Ignition ON.
Without video display: Simulate nighttime
conditions with glare:

NOTE: Covering the sensor with a finger
or hand is not adequate.
Cover the forward-facing sensor with
black electrical tape or other dark
material.

Illuminate the rearward-facing sensor.
With video display: Simulate nighttime
conditions with glare:

Yes
The system is operating normally at this time.
REVIEW operation of the interior auto-dimming
mirror feature with the customer.
No
GO to F7 .
NOTE: Covering the sensor with a finger
or hand is not adequate.
Cover the forward-facing sensor with
black electrical tape or other dark
material.

Illuminate the rearward-facing sensor.
Select REVERSE.
Did the mirror adjust to a high reflectance
(clear) mode?

F7 CHECK THE VOLTAGE TO THE
INTERIOR MIRROR
Ignition OFF.
Disconnect: Interior Mirror C911 or
C9039 (with video display).

Ignition ON.
Measure the voltage between ground and:
Without video display , interior
auto-dimming mirror C911-1,
circuit CBP41 (BU), harness side.

With video display , interior
auto-dimming mirror C9039-1,
circuit CBP41 (BU), harness side.

Yes
GO to F8 .
No
VERIFY SJB fuse 41 (15A) is OK. If OK, REPAIR
the circuit. If not OK, REFER to the Wiring
Diagrams manual to identify the possible causes of
the circuit short. TEST the system for normal
operation.
F8 CHECK THE GROUND TO THE
INTERIOR MIRROR
Ignition OFF.
Without video display: Measure the
resistance between interior auto-dimming
mirror C911-4, circuit GD139 (BK/YE),

Yes
GO to F9 .
No
operation.
With video display: Measure the
resistance between interior auto-dimming
mirror C9039-3, circuit GD139 (BK/YE),

F9 CHECK REVERSE INPUT CIRCUIT
Ignition ON.
Select REVERSE.
Without video display: Measure the
voltage between interior auto-dimming
mirror C911-3, circuit CLS10 (GN/BN),

With video display: Measure the voltage
between interior auto-dimming mirror
C9039-2, circuit CLS10 (GN/BN),

Yes
INSTALL a new interior auto-dimming mirror.
REFER to Interior Rear View Mirror in this section.
No
operation.
F10 CHECK CIRCUIT LRD12 (BU/GY)
FOR VOLTAGE
Ignition OFF.
Ignition ON.
Simulate nighttime conditions with glare:
dark material.


Measure the voltage between LH exterior
mirror C522-9, circuit LRD12 (BU/GY),

Is the voltage greater than 1 volt?
Yes
GO to F11 .
No
GO to F13 .
F11 CHECK CIRCUIT RRD12 (BN) FOR
GROUND
Measure the resistance between LH
exterior mirror C522-8, circuit RRD12
(BN), harness side and ground.

Yes
GO to F12 .
No
between the vehicle harness and the exterior mirror
glass for shorted or open circuits and damaged or
REPAIR the jumper harness. If the jumper harness
cannot be repaired, INSTALL a new LH exterior
mirror. REFER to Exterior Mirror in this section. If
the jumper harness is OK, INSTALL a new LH
Is the resistance greater than 10,000
ohms?

exterior mirror glass. REFER to Exterior Mirror
Glass in this section. TEST the system for normal
operation.
F12 CHECK CIRCUIT RRD12 (BN) FOR
AN OPEN
Ignition OFF.
Disconnect: Interior Mirror C911.
exterior mirror C522-8, circuit RRD12
(BN), harness side and interior
auto-dimming mirror C911-15, circuit
RRD12 (BN), harness side.

Yes
INSTALL new interior mirror. REFER to Interior
No
operation.
FOR AN OPEN
Ignition OFF.
Disconnect: Interior Mirror C911.
exterior mirror C522-9, circuit LRD12
(BU/GY), harness side and interior
auto-dimming mirror C911-11, circuit
LRD12 (BU/GY), harness side.

Yes
GO to F14 .
No
operation.
Measure the resistance between ground
and interior auto-dimming mirror
C911-11, circuit LRD12 (BU/GY),
harness side.

ohms?

Yes
INSTALL new interior mirror. REFER to Interior
No
operation.
Mirrors
Manual
Exterior Mirrors - Exploded View
Exterior mirror with Blind Spot Information System (BLIS)
NOTE: LH exterior mirror shown, RH exterior mirror similar.
1 17K707 Exterior mirror glass
2 - Exterior mirror motor screw (part of
17D696)
3 17D696 Exterior mirror motor
4 17682 RH/ 17683 LH Exterior mirror
5 17D742 RH/ 17D743
LH
6 N621906 Exterior mirror nut (3 required)
Exterior mirror with integrated spotter mirror
NOTE: LH exterior mirror shown, RH exterior mirror similar.
Exterior Mirrors - Exploded View 203
1 17K707 Exterior mirror glass>
2 - Exterior mirror motor screw (part of
17D696)
3 17D696 Exterior mirror motor
4 17682 RH/ 17683 LH Exterior mirror housing
5 17D743 LH/ 17D742
RH
6 N621906 Exterior mirror nut (3 required)
Exterior mirror with integrated spotter mirror 204
Mirrors
Manual
Exterior Mirror
Remove the front door trim panel. For additional information, refer to Section 501-05 . 1.
Remove the front door sail panel.
If equipped, disconnect the speaker electrical connector.
2.
Disconnect the exterior mirror electrical connector. 3.
Remove the 3 exterior mirror nuts and the exterior mirror.
4.
Exterior Mirror 205
Exterior Mirror 206
Mirrors
Manual
Exterior Mirror Glass
Removal
Vehicles with Blind Spot Information System (BLIS)
Position the exterior mirror glass in the full down position. 1.
WARNING: Place a shop towel between the hands and the exterior mirror glass for protection in
case of glass breakage during mirror service. Failure to follow this instruction may result in serious
personal injury.
Pull the upper edge of the exterior mirror glass outward and then upward to release the locking tabs
from the exterior mirror motor.
2.
Disconnect the electrical connectors from the exterior mirror glass. 3.
Vehicles with integrated spotter mirror
Position the exterior mirror glass to the full upward and inboard position and insert a thin, flat-blade
screwdriver.
4.
WARNING: Place a shop towel between the hands and the exterior mirror glass for
protection in case of glass breakage during mirror service. Failure to follow this instruction may
NOTE: LH mirror and motor removed from the housing and viewed from the back to show location
of clips and placement of screwdriver.
Using the thin, flat-blade screwdriver, remove the exterior mirror glass by releasing the tabs. Starting
at the lower outboard side of the mirror and continuing to the lower inboard side.
5.
Exterior Mirror Glass 207
If equipped, disconnect the electrical connectors and remove the exterior mirror glass. 6.
Installation
Vehicles with Blind Spot Information System (BLIS)
If equipped, connect the electrical connectors to the exterior mirror glass. 1.
Install the lower exterior mirror glass onto the exterior mirror motor. 2.
Position the exterior glass upward. 3.
NOTE: An audible click will be heard during installation.
Place a hand against the back of the exterior mirror and a hand flat against the upper exterior mirror
glass and press the exterior mirror glass into the upper exterior mirror motor retainers.
4.
Vehicles with integrated spotter mirror
If equipped, connect the electrical connectors. 5.
Position the exterior mirror glass onto the exterior mirror motor.
6.
NOTE: An audible click will be heard during installation.
Firmly press the exterior mirror glass until it snaps onto the exterior mirror motor.
7.
Rotate the exterior mirror glass in all directions after the installation to make sure that all of the
exterior mirror glass retaining clips are completely fastened.
8.
Mirrors
Manual
Exterior Mirror Motor
NOTE: Exterior mirror with Blind Spot Information System (BLIS) shown, exterior mirror with integrated
spotter mirror similar.
Removethe exterior mirror glass. For additional information, refer to Exterior Mirror Glass in this
section.
1.
Remove the exterior mirror motor screw. 2.
Use a flat-blade screwdriver and remove the exterior mirror motor from the 3 mounting clips.
Disconnect the electrical connector(s).
3.
Exterior Mirror Motor 210
Exterior Mirror Motor 211
Mirrors
Manual
Exterior Mirror Cover
Remove the exterior mirror glass. For additional information, refer to Exterior Mirror Glass in this
section.
1.
NOTE: Exterior mirror with Blind Spot Information System (BLIS) shown, exterior mirror without
BLIS similar.
Depress the 3 tabs and remove the exterior mirror cover.
2.
Exterior Mirror Cover 212
Mirrors
Manual
Exterior Mirror Control Switch
Fusion
1 W505153 Window control switch screw
2 22635 Window control switch bezel
3 17B676 Exterior mirror control switch
MKZ
1 14631 Exterior mirror electrical connector
2 17K709 Front door trim sail panel
3 17B676 Exterior mirror control switch
Fusion
Exterior Mirror Control Switch 213
Remove the window control switch bezel in the following sequence.
Remove the window control switch screw. 1.
Pull upward and remove the control switch bezel. 2.
Disconnect the electrical connectors. 3.
1.
MKZ
Pull outward to remove the front door trim sail panel and disconnect the electrical connector. 3.
All vehicles
NOTE: Fusion shown, MKZ similar.
Remove the exterior mirror control switch.
Depress the 2 locking tabs.
4.
MKZ 214
Mirrors
Manual
Interior Rear View Mirror
Special Tool(s)
Installer, Rear View Mirror
501-025 (T94P-17700-AH)
Mirror Remover
501-D118A
Installer, Rear View Mirror
501-191
Mirror Remover
501-190
Mirror Identification
1 - Mirror type 1
2 - Mirror type 2
3 - Mirror type 3
4 - Mirror type 4
Interior Rear View Mirror 215
Removal
Mirror Type 1
NOTICE: The windshield must be at room temperature. Otherwise, damage to the windshield glass
may occur.
NOTE: Click here to view a video version of this procedure.
If equipped. 1.
2.
NOTICE: Make sure the Mirror Remover is fully insertthe interior rear view mirror mount
access hole. Otherwise, damage to the windshield glass may occur.
3.
Mirror Identification 216
Using a closed hand, bump the adjustment handle of the Mirror Remover to slide the mirror upward
on the mirror mount.
4.
5.
Mirror Type 2
6.
Mirror Type 3
7.
8.
9.
Mirror Type 4
10.
11.
NOTICE: To prevent damage to the mirror or base, rotate the mirror base with hands only do
not use tools.
NOTICE: To prevent damage to the mirror wiring, do not rotate the mirror head beyond 180
degrees.
12.
Installation
Mirror Type 1
NOTE: Click here to view a video version of this procedure.
Slide the interior rear view mirror mount over the windshield bracket from the top. 1.
NOTE: An audible click will be heard as the mirror fully seats. 2.
If equipped. 3.
If equipped with compass module, check the compass zone and calibration. Refer to General
Procedures in Section 413-01 or Section 419-11.
4.
Mirror Type 2
5.
If equipped with a compass module which requires calibration, check the compass zone adjustment
and calibration. Refer to General Procedures in Section 413-01 or Section 419-11.
6.
Mirror Type 3
Mirror Type 4
If a new mirror has been installed, download the IPM-A configuration information from the
scan tool to the new IPM-A .

If a new mirror has been installed, perform camera alignment using a scan tool.
8.
SECTION 501-10: Seating 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop Manual
Front Seat
Cushion Thermo-Electric Device (TED) assembly nuts 6 - 53
Occupant Classification System (OCS) rail-to-seat track bolts 25 18 -
Power recliner motor bolt 6 - 53
Power seat track horizontal drive unit bolts 28 21 -
Recliner-to-backrest frame bolts 55 41 -
Recliner-to-cushion frame bolts 55 41 -
Safety belt anchor bracket nuts 36 27 -
Safety belt buckle bolt 40 30 -
Safety belt buckle bracket nuts 36 27 -
Safety belt retractor belt anchor bolt 40 30 -
Seat position sensor bolt 6 - 53
Seat riser bolts 25 18 -
Seat-to-floor bolts
a
- - -
Seat track-to-cushion frame nuts 36 27 -
Side air bag-to-backrest frame nuts 8 - 71
Rear Seat
Armrest pivot bolts 10 - 89
Armrest bracket-to-backrest bolts 10 - 89
Backrest latch release handle bracket nuts 9 - 80
Backrest latch nuts 48 35 -
Backrest-to-floor bolts 47 35 -
Side bolster bolt 11 -
SECTION 501-10: Seating
Manual
Seats
Front Seats
Each front seat can be equipped with the following serviceable items and systems:
Power or manual seat track
Backrest recliners
Heated or climate controlled seat system
Driver memory seat
Power or manual lumbar
Seat side air bags
Occupant Classification System (OCS) system on front passenger seat
For a detailed list of front seat serviceable parts, refer to Seat - Exploded View, Front in this section.
Driver Memory Seat
When equipped with the memory option, the seat is controlled by the Driver Seat Module (DSM).
The system contains the following serviceable components:
DSM , mounted to the seat track
Memory SET switch, located on the driver door
Power seat track
Seat control switch
Heated Seat System
Seat heater mats located in the seat cushion and backrest
Heated seat module, mounted to the bottom of the front passenger seat track
Heated seat buttons, located on the HVAC module (without navigation) or on the Front Controls
Interface Module (FCIM) (with navigation)

Heated seat indicators, located on the heated seat button
HVAC module (with navigation)
The FCIM and HVAC module operate the heated seat system independently from other systems. Upon
pressing a heated seat button, the heated seat module will cycle off, high, low and off. Both indicators
illuminate in high, the lower indicator illuminates in low and neither will be illuminated when off.
If the ignition source is turned off, the heated seat module will enter an off state and will not return to on until
the heated seat control button is once again pressed with the ignition in RUN. The heated seat module does
not time out.
Climate Controlled Seat System
Seats 224
Thermo-Electric Device (TED) and blower assembly within each front seat cushion and backrest
TED and blower assembly (for cushion TED filter, turn to the left to remove) (backrest TED filter is
not serviceable but can be removed)
Cushion and backrest manifolds
Cushion and backrest foam pads
Cushion and backrest trim covers
Climate controlled seat buttons, located on the FCIM
Dual Climate Controlled Seat Module (DCSM), mounted to the bottom of the front passenger seat
cushion

HVAC module
Backrest Recliners
All backrest recliners are serviced with the backrest frame.
Seat Side Air Bags
The driver and front passenger seat side air bags are standard equipment attached to the front seat backrest
frame. If a seat side air bag deployment has occurred, or for more information, refer to Section 501-20B .
Occupant Classification System (OCS) System
The OCS system is standard equipment on all front passenger seats. For diagnosing or servicing the OCS
system, refer to Section 501-20B .
Rear Seats
The rear seats contain the following serviceable parts and systems:
60/40 split folding backrest
Fold-down armrest that may be equipped with cup holders
A latch attached to the package tray sheet metal for each backrest
Backrest latch release handles, located in the luggage compartment (non-hybrid vehicles only)
For a detailed list of rear seat serviceable parts, refer to Seat - Exploded View, Rear in this section.
Non-Hybrid Vehicle
The center tunnel is higher on an All-Wheel Drive (AWD) vehicle, creating the need for a shorter cushion
foam pad. Make sure when installing a new cushion foam pad, the correct part is being installed.
Hybrid Vehicle
The cushion has a 2-piece foam pad to allow for traction battery ventilation. Make sure when installing a new
cushion the correct hard and soft foam pads are being installed.
Seats 225
/body>
Seats 226
Seats
Special Tool(s)
Flex Probe Kit
NUD105-R025D or equivalent
Medium Speed Controller Area Network (MS-CAN)
This vehicle utilizes a communication system called a Medium Speed Controller Area Network (MS-CAN).
When diagnosing the memory seat, heated seats or climate controlled seats, use a Vehicle Communication
Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent
scan tool with the latest software update with the capability of communicating over the MS-CAN bus.
Driver and Passenger Power Seats Without Memory
The 10-way power seat control feature moves the seat in 10 possible directions: the seat can be moved
forward or backward and the front and back of the cushion can be moved up and down independently. The
backrest of the seat can be moved forward and backward, and the lumbar can be moved in and out. All 10
positions are controlled by one switch. The power seat feature operates independent of the ignition position.
The 8-way power seat control feature moves the seat in 8 possible directions. It is like the 10-way power seat,
less power lumbar.
The 4-way power seat control feature moves the seat in 4 possible directions: the seat can be moved forward
or backward and the backrest of the seat can be moved forward and backward.
The power seat motors are hardwired to the seat control switch. The circuits are normally at ground through
the seat control switch. An individual circuit is switched to voltage when a specific adjustment position is
selected.
Power Driver Seat With Memory
NOTE: Verify good battery condition before diagnosing the memory seat system. Poor battery condition may
interfere with memory seat operation, even if vehicle starting is possible.
Seats 227
NOTE: A memory recall in progress does not prohibit the initiation of another memory recall; the most
recently requested memory recall will be executed.
The driver power memory seat is controlled by the Driver Seat Module (DSM). The memory seat feature
allows the driver to program a personalized seat position that can be recalled using the memory switch or a
Remote Keyless Entry (RKE) transmitter. There are 2 memory settings possible. The 2 settings consist of 8
possible directions: the seat can be moved forward or backward and the front and back of the cushion can be
moved up and down independently. The backrest of the seat can be moved forward and backward. Adjustable
lumbar is not a memory option. The power seat feature operates independent of the ignition position.
The driver seat control switch provides voltage to the DSM when activated. The NEUTRAL position of the
driver seat control switch position is a ground state through the seat control switch contacts. A voltage input
causes the DSM to power the appropriate motor until the input is removed. Ground is the normal state of the
motor circuits through the DSM and is not switched to control the motors. The DSM internally switches the
appropriate circuit from ground to voltage for operating the motors.
As the seat is adjusted, the DSM constantly monitors the motor position sensors to record the current seat
position. The DSM will remove voltage from the motor upon termination of the seat control switch input or if
the DSM does not see movement from the motor by monitoring the position sensor.
The DSM communicates DTCs and other information using the MS-CAN communication bus. It should be
noted for diagnostics that because Controller Area Network (CAN) bus communication is more robust and
reliable than other methods, it may be possible to have limited module communication with one of the CAN
bus circuits disconnected or shorted to ground. Refer to Section 418-00 for information concerning MS-CAN
bus communication.
For information on programming memory positions or recalling a stored memory position, refer to Memory
Position Programming in this section. For information on RKE transmitter programming, refer to Section
501-14 .
The DSM is located under the driver seat. To install a new DSM , refer to Driver Seat Module (DSM) in this
section. Programmable Module Installation (PMI) must be carried out when installing a new DSM . Refer to
Section 418-01 .
This section only diagnoses concerns specific to the memory seat. To diagnose a memory exterior mirror
concern, refer to Section 501-09 .
Easy Exit/Easy Entry
The easy entry/easy exit feature is a function of the DSM that moves the driver seat backwards about 50.8 mm
(2 in) when the ignition key is removed from the ignition. The DSM receives a key out command over the
MS-CAN communication network and powers the driver seat rearward. This function will not operate if the
seat is less than the 50.8 mm (2 in) travel distance to the end of the track or the function has been disabled.
The DSM will also cancel this operation if a valid input command is received from the driver seat control
switch, memory SET switch or exterior mirror control switch.
The DSM will record the current seat position before powering the seat for an easy exit function. This
recorded position will be used to return the seat to this position on the easy entry operation. During easy entry
operation, the seat is returned to the position previous to the easy exit operation. Easy entry operation will be
cancelled if a valid input command from the seat control switch, memory SET switch or exterior mirror
control switch is received by the DSM .
The easy entry/easy exit feature can be enabled/disabled using a scan tool. When enabled, the feature becomes
Seats 228
a user accessible item on the message center allowing the user to turn the feature on and off. Refer to the
Owner's Literature or Section 413-01 for information on the message center.
Heated Seats
When equipped with navigation, heated seat request and indicator messages are communicated between the
Front Controls Interface Module (FCIM) and HVAC module over the Controller Area Network (CAN),
otherwise, heated seat request and indicator messages are always communicated between the HVAC module
and heated seat module.
The engine must be running for the heated seat system to operate and it does not time out. The heated seat
module supplies voltage to the heater mats. The heated seat module regulates seat temperature by monitoring
a thermostat located in the cushion heater mat.
The heated seat module does not report DTCs and does not communicate on the communication network. If a
fault is detected, the module will disable the affected seat(s) and indicator(s). After the fault is corrected, the
heated seat module needs to be reset by cycling the ignition.
The heated seat module control circuits are monitored by the HVAC module and will set a DTC if a circuit
fault is detected. Refer to the HVAC Module DTC Chart.
Climate Controlled Seat System
NOTICE: Avoid applying voltage directly to a Thermo-Electric Device (TED) for testing its operation.
Doing so may cause damage to the TED .
NOTE: When installing a new Dual Climate Controlled Seat Module (DCSM), it is necessary to carry out
Programmable Module Installation (PMI). Refer to Section 418-01 .
The driver and front passenger climate controlled seats are independently controlled by the DCSM . The
climate controlled seat system only operates with the engine running, however, if using a scan tool to
command the DCSM , diagnostic testing can be carried out with the ignition ON and engine OFF. The DCSM
receives voltage from the Battery Junction Box (BJB) on DCSM C3265A pins E and F. If one pin does not
receive voltage, both seats will remain operational because the voltage supply circuits are internally connected
in the DCSM .
If a fault is detected, only the affected seat will be disabled. If the system shuts down, cycling the ignition
OFF and then ON again will reset the DCSM to function until the DTC resets.
The 4 buttons (identified with seat icons), located on the FCIM , activate each seat system setting and
illuminate indicators on each button to indicate the operating mode, 3 indicators for HIGH, 2 indicators for
MED or 1 indicator for LOW. The push-buttons with the blue seat icon operate the seat cooling mode and the
push-buttons with the red seat icon operate the seat heating mode.
The climate controlled seat button commands are communicated from the FCIM over the MS-CAN to the
HVAC module and then to the DCSM . Upon receiving a command, the DCSM then communicates indicator
illumination commands back to the HVAC module which then commands the FCIM to turn the indicators on
or off. The climate controlled seat system can only operate if all 3 modules are communicating correctly on
the CAN .
Each cushion and backrest is equipped with a Thermo-Electric Device (TED) assembly that includes a seat
blower (fan motor, serviced as an assembly with the TED ). Applying voltage polarity to the TED in one
Seats 229
direction, causes it to heat. Applying voltage polarity in the opposite direction causes the TED to cool. Cabin
air is drawn through the blower and distributed to each of the TED modules located in the seat cushion and
backrest. The TEDs then heat or cool the incoming air depending on the control switch settings. The air is
then directed into the manifold where it is distributed along the surface of the cushion and backrest of the seat.
Once the system is activated, the DCSM controls the heating/cooling modes and the blower speed dependant
on the settings.
The temperature differences between the individual heated and cooled settings is minimal. For example, it is
difficult to distinguish between LOW COOL and MEDIUM COOL settings. Measuring seat temperature at
different settings is possible by monitoring the DCSM PIDs using the scan tool.
The climate controlled seats can be commanded using the scan tool to verify both module communication on
the MS-CAN bus and operation of the DCSM . This method may be useful for isolating a control switch
concern. It should also be noted that because CAN bus communication is more robust and reliable than other
methods, it may be possible to have limited module communication with one of the CAN bus circuits
disconnected or shorted to ground. Refer to Section 418-00 for information concerning CAN bus
communication.
Heating Characteristics
NOTE: The presence of overtemperature faults (DTCs B2729, B2730, B272A and B272B) can be induced by
incorrect operation of the climate controlled seat system after an initial heat setting has been attained. If a heat
setting is repeatedly turned OFF and ON in an attempt to increase the seat temperature, an overtemperature
condition can result and the DTCs will be set.
In the LOW setting, the DCSM is set to maintain TED temperature at approximately 46C (115F).
In the MEDIUM setting, the DCSM is set to maintain TED temperature at approximately 60C
(140F).

In the HIGH setting, the DCSM is set to maintain TED temperature at approximately 65C (149F).
When heating, the DCSM will vary the speed of the fans and the TED duty cycle in order to reach and
maintain the temperature determined by the switch setting.

Engine must be running over 3 and seat heating does not time out.
Cooling Characteristics
In cool mode, the TED circuits of a given seat are wired in series internally in the DCSM .
In cool mode, the TED can remove up to 8C (14F) from the ambient air temperature entering the
system.

When cooling, the DCSM maintains constant speed of the fans and constant TED supply voltage
(duty cycle) in open loop cool mode.

Engine must be running over 350 rpm and seat cooling does not time out.
The climate controlled seat system is deactivated by one of the following actions:
Selecting the HVAC module setting to manual OFF.
Turning the vehicle OFF.
Climate Controlled Seat System Recovery Mode
NOTE: The presence of overtemperature faults (DTCs B2729, B2730, B272A and B272B) can be induced by
incorrect operation of the climate controlled seat system after an initial heat setting has been attained. If a heat
Seats 230
setting is repeatedly turned OFF and ON in an attempt to increase the seat temperature or repeatedly toggled
between heat and cool modesan overtemperature condition can result and the DTCs will be set.
If the temperature at one of the TEDs falls below 5C (41F), the DCSM will shut down the TEDs and initiate
system recovery mode. If the temperature continues to drop below 2C (36F), the DCSM will shut down the
affected seat operation.
If the temperature at one of the TEDs rises above 110C (230F) in the heat mode or 65C (149F) in the cool
mode for more than 4 seconds, the DCSM will record an overtemperature DTC, remove voltage from the
TEDs and go into recovery mode (blower only) for 30 seconds to cool down the TEDs . The same will occur
if a temperature difference of 60C (108F) or greater is seen between the backrest and cushion TEDs on
either front seat. The DCSM will continue to monitor the TEDs while in recovery mode. If the temperature of
the TEDs does not drop to 105C (221F) in the heat mode or 60C (140F) in the cool mode after 30
seconds, the system will continue to cool the TEDs in recovery mode for up to 5 minutes. If the TEDs cool
down at any time after 30 seconds, but before 5 minutes (checked at 4-second intervals), the system will
operate as normal. An overtemperature DTC will still be recorded even if the system recovers and is operating
normally. Recovery mode is more likely to occur during extreme cabin temperatures with significant seat back
sunload. If the system does not recover within 30 seconds in heat mode or within 5 minutes in cool mode, the
DCSM will disable that seat (fault mode) and remain off until the ignition is cycled. Also, if the DCSM
detects temperature differentfault twice during the same ignition cycle, it will shutdown. When a fault causes
a shutdown, the climate controlled seat indicators will turn off for the affected seat and that seat will not be
operational until the next key cycle.
Visually inspect for obvious signs of mechanical and electrical damage. 2.
Switch(es)
Seat tracks obstructed or damaged
Lumbar assembly damaged
Recliner assembly damaged (backrest frame)
Thermo-Electric Device (TED) assembly filter dirty
(cushion or backrest)

Battery Junction Box (BJB) fuse(s):
12 (30A MKZ) (climate
controlled seats)

31 (30A) (passenger power
seat)

32 (30A) (driver power seat
or driver memory seat)

Smart Junction Box (SJB) fuse(s):
12 (7.5A) (driver memory
seat)

18 (20A Fusion) (heated
seat module)

35 (10A Fusion) (heated
seat module)

Wiring harness
Seat control switch(es)
Seats 231
Power seat motor (seat track)
Memory SET switch
Seat cushion heater
Seat backrest heater
Lumbar control switch
Power lumbar motor
TED assembly (cushion or backrest)
Power recliner motor
Dual Climate Controlled Seat
Module (DCSM)

Front Controls Interface Module
(FCIM)

Heated seat module
HVAC module
NOTE: The Smart Junction Box (SJB) may also be identified as the Generic Electronic Module (GEM).
3.
If the concern is with the power seat (non-memory seat) or heated seat and the cause is not visually
evident, verify the symptom and GO to Symptom Chart .
4.
If the concern is with the memory seat or climate controlled seat and the cause is not visually evident,
connect the scan tool to the Data Link Connector (DLC).
5.
NOTE: The VCM LED prove out confirms power and ground from the DLC are provided to the
VCM .
6.
refer to Section 418-00 to diagnose no response from the PCM.
7.
418-00 .

If the network test passes, retrieve and record CMDTCs .
8.
Clear the continuous DTCs and carry out the self-test diagnostics for the Driver Seat Module (DSM),
Driver Door Module (DDM), DCSM , FCIM and HVAC module.
9.
Seats 232
If the DTCs retrieved are related to the concern, go to Driver Seat Module (DSM) DTC Chart, Dual
Climate Controlled Seat Module (DCSM) DTC Chart, HVAC Module DTC Chart or Driver Door
Module (DDM) DTC Chart. For all other DTCs, refer to Section 419-10 .
10.
If no DTCs related to the concern are retrieved, GO to Symptom Chart . 11.
DTC Charts
B1534 Memory 1 Switch Circuit Short To Ground GO to Pinpoint Test M .
B1538 Memory 2 Switch Circuit Short To Ground GO to Pinpoint Test M .
All Other DTCs - REFER to the DTC Chart in Section 501-14 .
Driver Seat Module (DSM) DTC Chart
B106E Solid State Driver Disabled due
to Short Circuit
GO to Pinpoint Test B .
B106F Module Disabled Due to
External Fault
B1317 Battery Voltage High GO to Pinpoint Test AV .
B1318 Battery Voltage Low GO to Pinpoint Test AW .
B1663 Seat Driver Front Up/Down
Motor Stalled
If the motor does not operate, GO to Pinpoint Test L . If the motor
operates, GO to Pinpoint Test M .
B1664 Seat Driver Rear Up/Down
Motor Stalled
B1665 Seat Driver Forward/Backward
Motor Stalled
B1666 Seat Driver Recline Motor
Stalled
B1669 Mirror Passenger Up/Down
Motor Stalled
Section 501-09 .
B1670 Mirror Passenger Right/Left
Motor Stalled
Section 501-09 .
B1703 Seat Driver Recline Forward
Switch Circuit Short To Battery
GO to Pinpoint Test L .
B1707 Seat Driver Recline Rearward
Switch Circuit Short To Battery
B1711 Seat Driver Front Up Switch
Circuit Short To Battery
B1715 Seat Driver Front Down Switch
Seats 233
B1719 Seat Driver Forward Switch
B1723 Seat Driver Rearward Switch
B1727 Seat Driver Rear Up Switch
B1731 Seat Driver Rear Down Switch
B1952 Seat Rear Up/Down Position
Feedback Circuit Short To
Battery
GO to Pinpoint Test M .
B1953 Seat Rear Up/Down Position
Ground
B1956 Seat Front Up/Down Position
Battery
B1957 Seat Front Up/Down Position
Ground
B1960 Seat Recline
Forward/Backward Position
Battery
B1961 Seat Recline
Forward/Backward Position
Ground
B1964 Seat Horizontal
Forward/Rearward Position
Battery
B1965 Seat Horizontal
Forward/Rearward Position
Ground
B2143 NVM (Non Volatile Memory)
Failure
CARRY OUT Programmable Module Installation (PMI) on the
DSM . REFER to Section 418-01 . CLEAR DTCs. CYCLE the
ignition and RETEST the system. If DTC B2143 is retrieved again,
INSTALL a new DSM . REFER to Driver Seat Module (DSM) in
this section.
B2224 Passenger Mirror Drive Circuit
Failure
Section 501-09 .
B2312 Passenger Mirror Horizontal
Feedback Potentiometer Circuit
Failure
Section 501-09 .
B2314 Passenger Mirror Horizontal
Short to Battery
Section 501-09 .
B2316 Section 501-09 .
Seats 234
Passenger Mirror Vertical
Failure
B2318 Passenger Mirror Vertical
Short to Battery
Section 501-09 .
B2477 Module Configuration Failure REFER to Section 418-01 .
U0140 Lost Communication With
Body Control Module (GEM)
GO to Pinpoint Test AX .
U0155 Lost Communication With
Instrument Panel Cluster (IC)
Control Module
GO to Pinpoint Test AY .
U2050 No Application Present REFER to Section 418-01 .
Dual Climate Controlled Seat Module (DCSM) DTC Chart
B103B Thermoelectric Driver
Overcurrent Low
GO to Pinpoint Test W .
B103C Thermoelectric Driver Open
Load
GO to Pinpoint Test X .
B103D Blower Driver Overtemperature GO to Pinpoint Test Y .
B1111 Driver Thermal Electric Device
Control Overtemperature Fault
B1113 Passenger Thermal Electric
Device Control Overtemperature
Fault
GO to Pinpoint Test Z .
B111B Passenger Thermoelectric Driver
Overcurrent Low
B111C Passenger Thermoelectric Driver
Open Load
GO to Pinpoint Test AA .
B111D Passenger Blower Driver
Overtemperature
GO to Pinpoint Test AB .
B1342 ECU is Faulted INSTALL a new Dual Climate Controlled Seat Module (DCSM).
REFER to Dual Climate Controlled Seat Module (DCSM) in this
section.
B19A1 Passenger Seat Cushion Blower
Speed Short to Battery
GO to Pinpoint Test AC .
B19A2 Passenger Seat Back Blower
GO to Pinpoint Test AD .
B19A3 Driver Seat Cushion Blower
GO to Pinpoint Test AE .
B19A4 Driver Seat Back Blower Speed
Short to Battery
GO to Pinpoint Test AF .
B19A5 Passenger Seat Cushion Blower GO to Pinpoint Test AG .
Seats 235
Speed Short to Ground
B19A6 Passenger Seat Back Blower
GO to Pinpoint Test AH .
B19A7 Driver Seat Cushion Blower
GO to Pinpoint Test AI .
B19A8 Driver Seat Back Blower Speed
Short to Ground
GO to Pinpoint Test AJ .
B2477 Module Configuration Failure NOTE: This DTC indicates PMI has not been done to a newly
installed module or configuration data has been lost.
CARRY OUT Programmable Module Installation (PMI) on the
DCSM . REFER to Section 418-01 . REPEAT the self-test. If PMI
is successful, the DTC will not be present.
B2486 Climate Control Seat Module
Voltage Out of Range
GO to Pinpoint Test AK .
B2729 Cushion Over-Temp Detected
(Driver)
GO to Pinpoint Test AL .
B272A Passenger Cushion Over-Temp
Detected
GO to Pinpoint Test AM .
B272B Passenger Back Over-Temp
Detected
GO to Pinpoint Test AN .
B272C Driver Differential Temperature
Fault
GO to Pinpoint Test AO .
B272D Passenger Differential
Temperature Fault
GO to Pinpoint Test AP .
B272E Driver Ignition Run/Blower
Circuit Short to Ground (this
DTC sets for an open or short to
voltage)
GO to Pinpoint Test AQ .
B272F Passenger Ignition Run/Blower
Circuit Short to Ground (this
DTC sets for an open or short to
voltage)
GO to Pinpoint Test AR .
B2730 Back Over-Temp Detected
(Driver)
GO to Pinpoint Test AS .
U2050 No Application Present INSTALL a new DCSM . REFER to Dual Climate Controlled Seat
Module (DCSM) in this section. REPEAT the self-test.
HVAC Module DTC Chart
NOTE: This module utilizes a 5-character DTC followed by a 2-character failure type code. The failure type
code provides information about specific fault conditions such as opens or shorts to ground. Continuous
Memory Diagnostic Trouble Codes (CMDTCs) have an additional 2-character DTC status code suffix to
assist in determining DTC history.
NOTE: Some PCM DTCs may inhibit A/C operation. If any PCM DTCs are retrieved, diagnose those first.
Refer to the PCM DTC Chart.
Seats 236
DTC Description Action to Take
B1030:12 Left Front Seat Heater: Circuit Short To
Battery
GO to Pinpoint Test R .
B1030:14 Left Front Seat Heater: Circuit Short To
Ground Or Open
B1032:12 Right Front Seat Heater: Circuit Short To
Battery
GO to Pinpoint Test S .
B1032:14 Right Front Seat Heater: Circuit Short To
Ground Or Open
All Other
DTCs
- REFER to the DTC Chart in Section 412-00A or
Section 412-00B .
Symptom Chart
Symptom Chart
Pinpoint Tests
NOTICE: Use the correct probe adapter(s) from the Flex Probe Kit when taking measurements. Failure
to use the correct probe adapter(s) may damage the connector.
NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection and
verification before proceeding with the pinpoint test.
Refer to Inspection and Verification, Driver Seat Module (DSM) DTC Chart, Driver Door Module (DDM)
DTC Chart, Dual Climate Controlled Seat Module (DCSM) DTC Chart, HVAC Module DTC Chart and the
Symptom Chart for direction to the appropriate pinpoint test.
Pinpoint Test A: The Power Seat is Inoperative - Driver, Without Memory
Refer to Wiring Diagrams Cell 120 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Power Seats for schematic
and connector information.
Normal Operation
The driver seat control switch is supplied voltage and ground. When the driver seat control switch is activated,
voltage and ground is supplied to the applicable seat track motor to move the seat to the desired position.
There are 3 seat track motors that combine to move the seat cushion horizontally (forward/rearward) and
vertically (front up/down and rear up/down). If a new motor on the seat track needs to be installed, it is
necessary to install an entire seat track assembly. There is an additional motor in the seat recliner mechanism
to move the seat backrest forward and rearward.
Fuse
Seat control switch
PINPOINT TEST A: THE POWER SEAT IS INOPERATIVE - DRIVER, WITHOUT MEMORY
NOTE: If a seat equipped with a seat mounted side air bag is being serviced, the Supplemental Restraint
System (SRS) must be depowered. Refer to Section 501-20B .
NOTE: The air bag warning lamp illuminates when the Restraints Control Module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate an SRS fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
A1 CHECK FOR VOLTAGE TO THE SEAT
CONTROL SWITCH
Ignition OFF.
Depower the SRS . Refer to Supplemental Restraint
System (SRS) Depowering and Repowering in the
General Procedures portion of Section 501-20B .

Disconnect: Driver Seat Side Air Bag C327.
Disconnect: Driver Seat Control Switch C360.
WARNING: Make sure no one is in the
vehicle and there is nothing blocking or placed in
front of any air bag module when the battery is
connected. Failure to follow these instructions
may result in serious personal injury in the event
of an accidental deployment.

Connect the battery ground cable. Refer to Section
414-01 .

Measure the voltage between driver seat control
switch C360-5, circuit SBB32 (VT/RD), harness side
and ground.

Yes
GO to A2 .
No
VERIFY Battery Junction Box (BJB) fuse
32 (30A) is OK. If OK, REPAIR the
circuit. If not OK, REFER to the Wiring
Diagrams manual to identify the possible
causes of the circuit short. TEST the
DISCONNECT the battery ground cable.
CONNECT driver seat side air bag module
C327. REPOWER the SRS . REFER to
Section 501-20B .
A2 CHECK FOR GROUND TO THE SEAT
CONTROL SWITCH
Measure the resistance between driver seat control
switch C360-3, circuit GD126 (BK/WH), harness
side and ground.

Yes
INSTALL a new driver seat control
switch. REFER to Seat Control Switch in
this section. TEST the system for normal
operation.
Section 501-20B .
PINPOINT TEST A: THE POWER SEAT IS INOPERATIVE - DRIVER, WITHOUT MEMORY 238
No
normal operation.
Section 501-20B .
Pinpoint Test B: DTCs B106E and B106F
Normal Operation
The Driver Seat Module (DSM) controls the output of several vehicle systems by means of solid state drivers.
When an overload occurs on any of these drivers, a DTC is set. The module also tracks the number of
repetitive faults on each of these circuits. The module compares this number of overloads to 3 progressive
thresholds established for each circuit. If the 3 thresholds have not been exceeded, then the DTC of the
affected circuit can be cleared by eliminating the fault, then clearing the DTCs and running the self-test. At
the point that each of the first 2 thresholds are exceeded, B106E is set along with the DTC relating to the
affected circuit. Once the final threshold has been exceeded, the affected output is permanently disabled, and
B106F is set along with B1342, at which time the DSM must be replaced.
DTC B106E (Solid State Driver Disabled Due To Short Circuit) - sets when the DSM has disabled a
circuit due to a repetitive fault causing a circuit overload. A corresponding DTC for the circuit in
question is also set.

DTC B106F (Module Disabled Due to External Fault) - sets when one or more output functions are
permanently disabled due to a repetitive circuit overload fault. DTC B106F is set with DTC B1342.
When DTC B106F is present, a new DSM must be installed after the fault condition has been
corrected.

Output circuit short to ground or voltage
DSM
PINPOINT TEST B: DTCs B106E, B106F
NOTICE: If DTC B106F is present, the fault condition mbe corrected prior to installing a new DSM .
Failure to correct the fault condition first may cause damage to the new DSM , resulting in a repeat
repair.
B1 REVIEW THE DTCs
Review the DTCs from the
DSM self-test.

Yes
CORRECT the cause of any other DTCs present. When the other
DTCs are corrected, INSTALL a new DSM . REFER to Driver
Seat Module (DSM) in this section. TEST the system for normal
Are DTCs B106F and
B1342 present?
operation.
No
GO to B2 .
B2 REPAIR OTHER DTCs
Repair the cause of any
DTCs present, other than
DTC B106E. Refer to DTC
Charts in this section.

Clear the DTCs.
Carry out the DSM self-test.
Is DTC B106E still
present?

Yes
The fault causing the output state to be disabled is still present.
REPAIR the cause of the concern. CLEAR the DTCs. REPEAT the
self-test.
No
The system is operating correctly at this time. The concern was
caused by a fault in one of the output circuits.
Pinpoint Test C: The Power Seat is Inoperative - MKZ, Passenger
Normal Operation
The passengeseat control switch is supplied voltage and ground. When the passenger seat control switch is
activated, voltage and ground is supplied to the applicable seat track motor to move the seat to the desired
position. There are 3 seat track motors that combine to move the seat cushion horizontally (forward/rearward)
and vertically (front up/down and rear up/down). If a new motor on the seat track needs to be installed, it is
Fuse
Seat control switch
PINPOINT TEST C: THE POWER SEAT IS INOPERATIVE - MKZ, PASSENGER
C1 CHECK FOR VOLTAGE TO THE SEAT CONTROL
SWITCH
PINPOINT TEST B: DTCs B106E, B106F 240
Ignition OFF.

Disconnect: Passenger Seat Side Air Bag Module
C313.

Disconnect: Passenger Seat Control Switch C3190.
WARNING: Make sure no one is in the vehicle
and there is nothing blocking or placed in front of
any air bag module when the battery is connected.
Failure to follow these instructions may result in
serious personal injury in the event of an accidental
deployment.

414-01 .

Measure the voltage between passenger seat control
switch C3190-5, circuit SBB31 (WH/RD), harness side
and ground.

Yes
GO to C2 .
No
31 (30A) is OK. If OK, REPAIR the circuit.
If not OK, REFER to the Wiring Diagrams
operation.
CONNECT passenger seat side air bag
module C313. REPOWER the SRS . REFER
C2 CHECK FOR GROUND TO THE SEAT CONTROL
SWITCH
Measure the resistance between passenger seat control
switch C3190-3, circuit GD126 (BK/WH), harness side
and ground.

Yes
INSTALL a new passenger seat control
operation.
No
normal operation.
Pinpoint Test D: The Power Seat is Inoperative - Fusion, Passenger
PINPOINT TEST C: THE POWER SEAT IS INOPERATIVE - MKZ, PASSENGER 241
Normal Operation
The passenger seat control switch is supplied voltage and ground. When the passenger seat control switch is
activated, voltage and ground is supplied to the seat track motor to move the seat to the desired position. The
seat track motor moves the seat cushion horizontally (forward/rearward). If a new motor on the seat track
needs to be installed, it is necessary to install an entire seat track assembly. There is an additional motor in the
seat recliner mechanism to move the seat backrest forward and rearward.
This pinpoint test is intended to dgnose the following:
Fuse
Seat control switch
PINPOINT TEST D: THE POWER SEAT IS INOPERATIVE - FUSION, PASSENGER
D1 CHECK FOR VOLTAGE AT THE SEAT
CONTROL SWITCH
Ignition OFF.

Disconnect: Passenger Seat Side Air Bag C313.

414-01 .

Measure the voltage between passenger seat control
switch C330-5, circuit SBB31 (WH/RD), harness
side and ground.

Yes
GO to D2 .
No
module C313. REPOWER the SRS .
D2 CHECK FOR GROUND TO THE SEAT
CONTROL SWITCH
Measure the resistance between passenger seat
control switch C330-3, circuit GD139 (BK/YE),

Yes
INSTALL a new passenger seat control
operation.
No
normal operation.
Pinpoint Test E: The Power Seat Moves But is Loose
Normal Operation
Power seat movement should be smooth and the seat cushion should not rock during or after operation.
Loose fastening hardware
Seat track
PINPOINT TEST E: THE POWER SEAT MOVES BUT IS LOOSE
E1 CHECK THE FASTENING
HARDWARE
Inspect for loose mounting hardware
on the seat.

Are the seat fasteners tight?
Yes
IDENTIFY the cause and REPAIR as necessary. TEST
No
TIGHTEN all fastening hardware to specification. TEST
PINPOINT TEST D: THE POWER SEAT IS INOPERATIVE - FUSION, PASSENGER 243
Pinpoint Test F: The Power Seat Moves But is Noisy
Normal Operation
The power seat should move quietly during operation. Some noise is acceptable.
Seat track
Seat track component
Object obstructing seat movement
PINPOINT TEST F: THE POWER SEAT MOVES BUT IS NOISY
F1 CHECK THE TRACK ALIGNMENT
Check the alignment of the track to the
floor and the track to the seat.

Is the seat track aligned correctly?
Yes
IDENTIFY the cause and REPAIR as necessary. TEST
No
ALIGN the track to the seat and the floor. TEST the
Pinpoint Test G: The Power Seat Does Not Make Full Travel
Normal Operation
The power seat should travel fully horizontal (forward/rearward) and vertical (front up/down and rear
up/down).
Obstruction
Seat track
PINPOINT TEST G: THE POWER SEAT DOES NOT MAKE FULL TRAVEL
PINPOINT TEST E: THE POWER SEAT MOVES BUT IS LOOSE 244
G1 CHECK FOR AN OBSTRUCTION IN
THE SEAT TRACK
Ignition OFF.
Remove the seat. Refer to Seat - Front
in this section.

Check the seat track for any
obstructions.

Is the seat track clear of
obstructions?

Yes
IDENTIFY the cause and REPAIR as necessary.
REPOWER the SRS . REFER to Section 501-20B .
No
REMOVE the obstruction(s). INSTALL the seat.
Pinpoint Test H: The Power Seat Does Not Move Horizontally/Vertically/Recline - Driver
Normal Operation
The driver seat control switch is supplied voltage and ground. When the driver seat control switch is activated,
voltage and ground is supplied to the applicable seat track motor to move the seat to the desired position.
There are 3 seat track motors that combine to move the seat cushion horizontally (forward/rearward) and
vertically (front up/down and rear up/down). If a new motor on the seat track needs to be installed, it is
Seat control switch
Seat track
Seat recliner motor
PINPOINT TEST H: THE POWER SEAT DOES NOT MOVE HORIZONTALLY/VERTICALLY/RECLINE - DRIVER
H1 CHECK THE HORIZONTAL MOTOR FOR CORRECT
OPERATION
Operate the driver power seat forward and rearward.
Does the seat move horizontally?
Yes
GO to H2 .
No
PINPOINT TEST G: THE POWER SEAT DOES NOT MAKE FULL TRAVEL 245
GO to H3 .
H2 CHECK THE RECLINER MOTOR FOR CORRECT
OPERATION
Recline the driver backrest forward and rearward.
Does the seat backrest recline forward and rearward?
Yes
GO to H6 .
No
GO to H13 .
H3 CHECK VOLTAGE TO THE DRIVER SEAT
HORIZONTAL MOTOR
Ignition OFF.
Depower the SRS . Refer to Supplemental Restraint System
(SRS) Depowering and Repowering in the General
Procedures portion of Section 501-20B .

Disconnect: Driver Seat Motor C357.
WARNING: Make sure no one is in the vehicle and
there is nothing blocking or placed in front of any air
bag module when the battery is connected. Failure to
follow these instructions may result in serious personal
injury in the event of an accidental deployment.

Connect the battery ground cable. Refer to Section 414-01 .
NOTE: During the following step, the voltage being
measured changes polarity dependent upon which direction
the seat control switch is activated.

Measure the voltage between driver seat motor C357-6,
circuit CPS23 (GN/VT), harness side and C357-3, circuit
CPS22 (BN), harness side, while operating the seat control
switch horizontal adjust forward and rearward.

Is the voltage greater than 10 volts when the seat control
switch is operated and 0 volt in the rest position?

Yes
INSTALL a new driver seat track
assembly. REFER to Seat Track in
this section. TEST the system for
normal operation.
DISCONNECT the battery ground
cable. CONNECT driver seat side
air bag module C327. REPOWER
the SRS . REFER to Section
501-20B .
No
GO to H4 .
H4 CHECK HORIZONTAL MOTOR CIRCUIT FOR AN
OPEN AND SHORT TO GROUND
Measure the resistance between:
driver seat control switch C360-9, circuit CPS23
(GN/VT), harness side and driver seat motor
C357-6, circuit CPS23 (GN/VT), harness side.

(GN/VT), harness side and ground.

Yes
GO to H5 .
No
REPAIR the circuit. TEST the
PINPOINT TEST H: THE POWER SEAT DOES NOT MOVE HORIZONTALLY/VERTICALLY/RECLINE - DRIVER 246
Is the resistance less than 5 ohms between the driver
seat motor and the driver seat control switch; and
greater than 10,000 ohms between the driver seat
control switch and ground?

501-20B .
H5 CHECK HORIZONTAL MOTOR CIRCUIT FOR AN
(BN), harness side and driver seat motor C357-3,
circuit CPS23 (GN/VT), harness side.

(BN), harness side and ground.


Yes
switch. REFER to Seat Control
Switch in this section. TEST the
501-20B .
No
501-20B .
H6 DETERMINE THE SEAT HEIGHT ADJUST FAILURE
Operate the front and rear seat height adjustments.
Does the seat front and rear height adjust up and down?
Yes
If only front height adjust operates,
GO to H7 .
If only rear height adjust operates,
GO to H10 .
No
501-20B .
H7 CHECK VOLTAGE TO THE DRIVER SEAT REAR
HEIGHT MOTOR
Ignition OFF.

Disconnect: Driver Seat Motor C357.


circuit CPS27 (BU/BN), harness side and C357-4, circuit
CPS26 (YE/BU), harness side, while operating the seat
control switch rear height adjust up and down.


Yes
normal operation.
501-20B .
No
GO to H8 .
H8 CHECK REAR HEIGHT MOTOR CIRCUIT FOR AN
(BU/BN), harness side and driver seat motor
C357-1, circuit CPS27 (BU/BN), harness side.

(BU/BN), harness side and ground.

Yes
GO to H9 .
No
501-20B .

H9 CHECK REAR HEIGHT MOTOR CIRCUIT FOR AN
(YE/BU), harness side and driver seat motor
C357-4, circuit CPS26 (YE/BU), harness side.

(YE/BU), harness side and ground.


Yes
501-20B .
No
501-20B .
H10 CHECK VOLTAGE TO THE DRIVER SEAT FRONT
HEIGHT MOTOR
Ignition OFF.

Disconnect: Driver Seat Motor C357 .


circuit CPS25 (WH/VT), harness side and C357-5, circuit
CPS24 (GY), harness side, while operating the seat control
switch front height adjust up and down.

Yes
normal operation.
501-20B .
No
GO to H11 .

H11 CHECK FRONT HEIGHT MOTOR CIRCUIT FOR AN
(WH/VT), harness side and driver seat motor
C357-2, circuit CPS25 (WH/VT), harness side.

(WH/VT), harness side and ground.


Yes
GO to H12 .
No
501-20B .
H12 CHECK FRONT HEIGHT MOTOR CIRCUIT FOR AN
OPEN AND A SHORT TO GROUND
(GY) harness side, and driver seat motor C357-5,
circuit CPS24 (GY), harness side.

(GY), harness side and ground.


Yes
501-20B .
No
501-20B .
H13 CHECK VOLTAGE TO THE DRIVER SEAT
RECLINER MOTOR
Ignition OFF.

Disconnect: Driver Seat Recliner Motor C3187.


Measure the voltage between driver seat recliner motor
C3187-1, circuit CPS29 (WH/BN), harness side and
C3187-5, circuit CPS30 (VT/BN), harness side, while
operating the seat control switch recline adjust forward and
rearward.


Yes
INSTALL a new driver seat
recliner motor. REFER to Seat
Recliner Motor in this section.
TEST the system for normal
operation.
501-20B .
No
GO to H14 .
H14 CHECK RECLINER MOTOR CIRCUIT FOR AN
(WH/BN), harness side and driver seat recliner
motor C3187-1, circuit CPS29 (WH/BN), harness
side.

(WH/BN), harness side and ground.

Yes
GO to H15 .
No
501-20B .
seat recliner motor and the driver seat control switch;
and greater than 10,000 ohms between the driver seat

H15 CHECK RECLINER MOTOR CIRCUIT FOR AN
(VT/BN) harness side, and driver seat recliner
motor C3187-5, circuit CPS30 (VT/BN), harness
side.

(VT/BN), harness side and ground.

seat recliner motor and the driver seat control switch;
and greater than 10,000 ohms between the seat control
switch and ground?

Yes
501-20B .
No
501-20B .
Pinpoint Test J: The Power Seat Does Not Move Horizontally/Vertically/Recline - MKZ, Passenger
Normal Operation
activated, voltage and ground is supplied to the applicable seat track motor to move the seat to the desired
position. There are 3 seat track motors that combine to move the seat cushion horizontally (forward/rearward)
and vertically (front up/down and rear up/down). If a new motor on the seat track needs to be installed, it is
Seat control switch
Seat track
Seat recliner motor
PINPOINT TEST J: THE POWER SEAT DOES NOT MOVE HORIZONTALLY/VERTICALLY/RECLINE - MKZ,
PASSENGER
J1 CHECK THE HORIZONTAL MOTOR FOR CORRECT
OPERATION
Operate the passenger power seat forward and rearward.
Yes
GO to J2 .
No
GO to J3 .
J2 CHECK THE RECLINER MOTOR FOR CORRECT
OPERATION
Recline the passenger backrest forward and rearward.
Does the seat backrest recline forward and rearward?
Yes
GO to J6 .
No
GO to J13 .
J3 CHECK VOLTAGE TO THE PASSENGER SEAT
HORIZONTAL MOTOR
Ignition OFF.
Depower the SRS . Refer to Supplemental Restraint System (SRS)
Depowering and Repowering in the General Procedures portion of
Section 501-20B .

Disconnect: Passenger Seat Side Air Bag Module C313.
Disconnect: Passenger Seat Motor C3015.
WARNING: Make sure no one is in the vehicle and there is
nothing blocking or placed in front of any air bag module when
the battery is connected. Failure to follow these instructions
may result in serious personal injury in the event of an
accidental deployment.

NOTE: During the following step, the voltage being measured
changes polarity dependent upon which direction the seat control

Measure the voltage between passenger seat motor C3015-6, circuit
CPS38 (GN/BU), harness side and C3015-3, circuit CPS33 (WH),
harness side, while operating the seat control switch horizontal
adjust forward and rearward.

Yes
INSTALL a new passenger
seat track assembly.
REFER to Seat Track in
this section. TEST the
system for normal
operation.
DISCONNECT the battery
ground cable. CONNECT
passenger seat side air bag
module C313. REPOWER
the SRS . REFER to
Section 501-20B .
No
GO to J4 .
PINPOINT TEST J: THE POWER SEAT DOES NOT MOVE HORIZONTALLY/VERTICALLY/RECLINE - MKZ, PASSENGER 253
Is the voltage greater than 10 volts when the seat control switch
is operated and 0 volt in the rest position?

J4 CHECK HORIZONTAL MOTOR CIRCUIT FOR AN OPEN
AND SHORT TO GROUND
passenger seat control switch C3190-9, circuit CPS38
(GN/BU), harness side and passenger seat motor C3015-6,
circuit CPS38 (GN/BU), harness side.

(GN/BU), harness side and ground.

Is the resistance less than 5 ohms between the passenger seat
motor and the passenger seat control switch; and greater than
10,000 ohms between the passenger seat control switch and
ground?

Yes
GO to J5 .
No
REPAIR the circuit. TEST
the system for normal
operation.
the SRS . REFER to
Section 501-20B .
J5 CHECK HORIZONTAL MOTOR CIRCUIT FOR AN OPEN
AND SHORT TO GROUND
(WH), harness side and passenger seat motor C3015-3,
circuit CPS33 (WH), harness side.

(WH), harness side and ground.


Yes
seat control switch. REFER
to Seat Control Switch in
system for normal
operation.
the SRS . REFER to
Section 501-20B .
No
ground? operation.
the SRS . REFER to
Section 501-20B .
J6 DETERMINE THE SEAT HEIGHT ADJUST FAILURE
Operate the front and rear seat height adjustments.
Does the seat front and rear height adjust up and down?
Yes
If only front height adjust
operates, GO to J7 .
If only rear height adjust
operates, GO to J10 .
No
system for normal
operation.
the SRS . REFER to
Section 501-20B .
J7 CHECK VOLTAGE TO THE PASSENGER SEAT REAR
HEIGHT MOTOR
Ignition OFF.
Section 501-20B .



CPS37 (WH/BU), harness side and C3015-4, circuit CPS36
(YE/GY), harness side, while operating the seat control switch rear
height adjust up and down.

Yes
system for normal
operation.
the SRS . REFER to
Section 501-20B .
No
GO to J8 .

J8 CHECK REAR HEIGHT MOTOR CIRCUIT FOR AN OPEN
AND SHORT TO GROUND
(WH/BU), harness side and passenger seat motor C3015-1,
circuit CPS37 (WH/BU), harness side.

(WH/BU), harness side and ground.

ground?

Yes
GO to J9 .
No
operation.
the SRS . REFER to
Section 501-20B .
J9 CHECK REAR HEIGHT MOTOR CIRCUIT FOR AN OPEN
AND SHORT TO GROUND
(YE/GY), harness side and passenger seat motor C3015-4,
circuit CPS36 (YE/GY), harness side.

(YE/GY), harness side and ground.


Yes
system for normal
operation.
the SRS . REFER to
Section 501-20B .
No
ground? operation.
the SRS . REFER to
Section 501-20B .
J10 CHECK VOLTAGE TO THE PASSENGER SEAT FRONT
HEIGHT MOTOR
Ignition OFF.
Section 501-20B .



CPS35 (VT/GN), harness side and C3015-5, circuit CPS34
(GY/BU), while operating the seat control switch front height adjust
up and down.


Yes
system for normal
operation.
the SRS . REFER to
Section 501-20B .
No
GO to J11 .
J11 CHECK FRONT HEIGHT MOTOR CIRCUIT FOR AN OPEN
AND SHORT TO GROUND
(VT/GN), harness side and passenger seat motor C3015-2,
circuit CPS35 (VT/GN), harness side.

(VT/GN), harness side and ground.

Yes
GO to J12 .
No
operation.
ground?

the SRS . REFER to
Section 501-20B .
J12 CHECK FRONT HEIGHT MOTOR CIRCUIT FOR AN OPEN
AND SHORT TO GROUND
(GY/BU) harness side, and passenger seat motor C3015-5,
circuit CPS34 (GY/BU), harness side.

(GY/BU), harness side and ground.

ground?

Yes
system for normal
operation.
the SRS . REFER to
Section 501-20B .
No
operation.
the SRS . REFER to
Section 501-20B .
J13 CHECK VOLTAGE TO THE PASSENGER SEAT RECLINER
MOTOR
Ignition OFF.
Section 501-20B .

Disconnect: Passenger Seat Recliner Motor C3189.

Yes
seat recliner motor. REFER
to Seat Recliner Motor in
system for normal
operation.
the SRS . REFER to

Measure the voltage between passenger seat recliner motor
C3189-1, circuit CPS39 (GY/YE), harness side and C3189-5,
circuit CPS40 (VT/GY), harness side, while operating the seat
control switch recline adjust forward and rearward.


Section 501-20B .
No
GO to J14 .
J14 CHECK RECLINER MOTOR CIRCUIT FOR AN OPEN AND
SHORT TO GROUND
(GY/YE), harness side and passenger seat recliner motor
C3189-1, circuit CPS39 (GY/YE), harness side.

(GY/YE), harness side and ground.

recliner motor and the passenger seat control switch; and
greater than 10,000 ohms between the passenger seat control
switch and ground?

Yes
GO to J15 .
No
operation.
the SRS . REFER to
Section 501-20B .
J15 CHECK RECLINER MOTOR CIRCUIT FOR AN OPEN AND
SHORT TO GROUND
(VT/GY) harness side, and passenger seat recliner motor
C3189-5, circuit CPS40 (VT/GY), harness side.

(VT/GY), harness side and ground.

Yes
system for normal
operation.
greater than 10,000 ohms between the seat control switch and
ground?

the SRS . REFER to
Section 501-20B .
No
operation.
the SRS . REFER to
Section 501-20B .
Pinpoint Test K: The Power Seat Does Not Move Horizontally/Recline - Fusion, Passenger
Normal Operation
activated, voltage and ground is supplied to the seat track motor to move the seat to the desired position. The
seat track motor moves the seat cushion horizontally (forward/rearward). If a new motor on the seat track
needs to be installed, it is necessary to install an entire seat track assembly. There is an additional motor in the
seat recliner mechanism to move the seat backrest forward and rearward.
Wing, terminals or connectors
Seat control switch
Seat track
PINPOINT TEST K: THE POWER SEAT DOES NOT MOVE HORIZONTALLY/RECLINE - FUSION, PASSENGER
K1 CHECK THE HORIZONTAL MOTOR FOR CORRECT
OPERATION
Operate the passenger power seat forward and rearward.
Yes
GO to K5 .
No
GO to K2 .
K2 CHECK VOLTAGE TO THE PASSENGER SEAT
HORIZONTAL MOTOR
Ignition OFF.
Section 501-20B .

Disconnect: Passenger Seat Horizontal Motor C332.


CPS38 (GN/BU), harness side and C332-2, circuit CPS33 (WH),
harness side, while operating the seat control switch horizontal
adjust forward and rearward.

is toggled in both directions and 0 volt in the rest position?

Yes
system for normal
operation.
the SRS . REFER to
Section 501-20B .
No
GO to K3 .
K3 CHECK THE HORIZONTAL MOTOR CIRCUIT FOR AN
passenger seat control switch C330-4, circuit CPS33 (WH),
harness side and passenger seat horizontal motor C332-2,
circuit CPS33 (WH), harness side.

passenger seat control switch C330-4, circuit CPS33 (WH),

Yes
GO to K4 .
No
operation.
the SRS . REFER to
Section 501-20B .
PINPOINT TEST K: THE POWER SEAT DOES NOT MOVE HORIZONTALLY/RECLINE - FUSION, PASSENGER 261
horizontal motor and the passenger seat control switch; and
switch and ground?

K4 CHECK THE HORIZONTAL MOTOR CIRCUIT FOR AN
(GN/BU), harness side and passenger seat horizontal motor
C332-1, circuit CPS38 (GN/BU), harness side.


horizontal motor and the passenger seat control switch; and
switch and ground?

Yes
system for normal
operation.
the SRS . REFER to
Section 501-20B .
No
operation.
the SRS . REFER to
Section 501-20B .
K5 CHECK VOLTAGE TO THE PASSENGER SEAT RECLINER
MOTOR
Ignition OFF.
Section 501-20B .

Disconnect: Passenger Seat Recliner Motor C3189.

Yes
seat recliner motor. REFER
to Seat Recliner Motor in
system for normal
operation.
the SRS . REFER to

Measure the voltage between passenger seat recliner motor
C3189-1, circuit CPS39 (GY/YE), harness side and C3189-5,
circuit CPS40 (VT/GY), harness side, while operating the seat
control switch recline adjust forward and rearward.


Section 501-20B .
No
GO to K6 .
K6 CHECK RECLINER MOTOR CIRCUIT FOR AN OPEN AND
SHORT TO GROUND
(GY/YE), harness side and passenger seat recliner motor
C3189-1, circuit CPS39 (GY/YE), harness side.

(GY/YE), harness side and ground.

switch and ground?

Yes
GO to K7 .
No
operation.
the SRS . REFER to
Section 501-20B .
K7 CHECK RECLINER MOTOR CIRCUIT FOR AN OPEN AND
SHORT TO GROUND
(VT/GY) harness side, and passenger seat recliner motor
C3189-5, circuit CPS40 (VT/GY), harness side.

(VT/GY), harness side and ground.

Yes
system for normal
operation.
greater than 10,000 ohms between the seat control switch and
ground?

the SRS . REFER to
Section 501-20B .
No
operation.
the SRS . REFER to
Section 501-20B .
Pinpoint Test L: The Memory Seat is Inoperative/Does Not Operate Correctly - Does Not Operate
Horizontally/Vertically/Recline
Refer to Wiring Diagrams Cell 123 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Memory Seats for
Refer to Wiring Diagrams Cell 149 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Component Testing for
component testing.
Normal Operation
When activated, the seat control switch supplies voltage and ground to the applicable Driver Seat Module
(DSM) inputs. The DSM then supplies voltage and ground to the appropriate seat track motor or seat recliner
motor to move the seat in the desired direction. There are 3 seat track motors that combine to move the seat
horizontally (forward/backward) and vertically (front up/down and rear up/down). The seat recliner
mechanism uses a single motor to pivot the seat backrest forward and backward.
Each motor in the memory power seat track and power recliner contains a Hall-effect position sensor. The
DSM supplies a signal supply circuit to each position sensor and a shared reference signal return circuit. Each
position sensor sends a signal voltage back to the DSM used to monitor the position of the power seat and seat
backrest. The DSM uses this information to return the seat to a stored pre-programmed position when pressing
the memory SET switch or a Remote Keyless Entry (RKE) transmitter. Refer to Principles of Operation in
this section or the Owner's Literature for information on programming the DSM for storing memory seat
positions.
The following pinpoint test diagnoses a memory seat that does not operate in one or more directions when
using the seat control switch. If the memory seat moves in all directions using the seat control switch, GO to
Pinpoint Test M .
B1342 - ECU is
Faulted

If a programming error is detected, the DTC is set.
B1663 - Seat Driver
Front Up/Down
Motor Stalled

B1664 - Seat Driver
Rear Up/Down
Motor Stalled

B1665 - Seat Driver
Forward/Backward
Motor Stalled

During self-test, the DSM attempts to operate the appropriate seat track motor
and uses the motor's position sensor to monitor movement. If no motor
movement is sensed, the DTC is set. The DSM will retry motor operation on
the next activation of the seat control switch. If no movement continues to be
monitored after 250 milliseconds, the DSM disables the output.
B1666 - Seat Driver
Recline Motor
Stalled

During self-test, the DSM attempts to operate the recliner motor and uses the
recliner motor position sensor to monitor movement. If no motor movement is
sensed, the DTC is set. The DSM will retry motor operation on the next
activation of the seat control switch. If no motor movement is still monitored
after 250 millisthe DSM disables the output.
B1703 - Seat Driver
Recline Forward
Switch Circuit Short
to Battery

B1707 - Seat Driver
Recline Rearward
Switch Circuit Short
to Battery

If voltage is sensed on the switch input circuit during the DSM Self Test, the
DTC is set. If voltage is sensed on the input circuit for greater than 2 minutes,
the DTC is set as continuous. With the DTC set, any input signal on the circuit
is ignored.
B1711 - Seat Driver
Front Up Switch
Circuit Short to
Battery

B1715 - Seat Driver
Front Down Switch
Circuit Short to
Battery

is ignored.
B1719 - Seat Driver
Forward Switch
Circuit Short to
Battery

B1723 - Seat Driver
Rearward Switch
Circuit Short to
Battery

the DTC is nuous. With the DTC set, any input signal on the circuit is ignored.
B1727 - Seat Driver
Rear Up Switch
Circuit Short to
Battery

B1731 - Seat Driver
Rear Down Switch
Circuit Short to
Battery

is ignored.
Fuse
Seat control switch
Seat track
Seat recliner motor
DSM
PINPOINT TEST L: THE MEMORY SEAT IS INOPERATIVE/DOES NOT OPERATE CORRECTLY - DOES NOT
OPERATE HORIZONTALLY/VERTICALLY/RECLINE
L1 CHECK THE TCM
TRANSMISSION RANGE (TR) PID
Ignition ON.
Enter the following diagnostic
mode on the scan tool:
DataLogger - TCM - PID: TR.

Operate the transmission gear
selector in all positions while
monitoring the TCM PID TR
states.

Do the PID states agree with
the selected positions?

Yes
GO to L2 .
No
To diagna transmission gear selector (PRNDL) status concern,
REFER to Section 307-01A , Section 307-01B or Section
307-01C .
L2 CHECK THE DSM IGNITION
SWITCH STATUS (IGN_SW) PID
DataLogger - DSM - PID:
IGN_SW.

Cycle the ignition in all
positions while monitoring the
DSM PID states.

the selected positions?

Yes
GO to L3 .
No
To diagnose an ignition status concern, REFER to Section
211-05 .
L3 RETRIEVE THE DSM DTCs
Operate the memory seat and
memory exterior mirrors in all

Yes
If DTCs B1663, B1664, B1665 and B1666 are all retrieved, GO
to L12 .
PINPOINT TEST L: THE MEMORY SEAT IS INOPERATIVE/DOES NOT OPERATE CORRECTLY - DOES NOT OPERATE HORIZONTALLY/VERTICALLY/RECLINE 266
directions through the full
range of travel.
Place the memory seat and
memory exterior mirrors in
central travel positions.

mode on the scan tool: Self
Test - DSM .

Are any DTCs retrieved?
If DTC B1663, GO to L22 .
If DTC B1342, INSTALL a new DSM . REFER to Driver Seat
Module (DSM) in this section. REPEAT the self-test. CLEAR
the DTCs.
For any other DSM DTCs, REFER to the Driver Seat Module
(DSM) DTC Chart.
No
GO to L4 .
L4 CHECK THE DSM SEAT
CONTROL SWITCH PIDs
DataLogger - DSM - PIDs.

Driver Power Seat
Front Up/Down
Switch (SFNT_SW)

Driver Power Seat
Forward/Backward
Switch (SFWD_SW)

Driver Power Seat
Rear Up/Down Switch
(SREARSW)

Driver Power Seat
Recline Switch Status
(SRCL_SW)

Operate the seat control switch
in all positions and monitor the

Yes
GO to L11 .
No
VERIFY Smart Junction Box (SJB) fuse 12 (7.5A) is OK.
If SJB fuse 12 (7.5A) fails while operating the seat control
switch, DISCONNECT the seat control switch C3297 and GO to
L9 .
If SJB fuse 12 (7.5A) is OK, GO to L5 .
DSM seat control switch PIDs.
the switch positions?

L5 CHECK THE SEAT
CONTROL SWITCH
Remove the seat control
switch. Refer to Seat Control
Switch in this section.

Check the seat control switch.
Refer to Wiring Diagrams Cell
149 ( Fusion/MKZ , Fusion
Hybrid/MKZ Hybrid ),
Component Testing for
component testing.

Is the seat control switch
OK?

Yes
GO to L6 .
No
INSTALL a new seat control switch. REFER to Seat Control
Switch in this section. REPEAT the self-test. CLEAR the DTCs.
L6 CHECK FOR VOLTAGE TO
THE SEAT CONTROL SWITCH
Ignition OFF.
Depower the SRS . Refer to
Supplemental Restraint System
(SRS) Depowering and
Repowering in the General
Procedures portion of Section
501-20B .

Disconnect: Driver Seat Side
Air Bag C327.

WARNING: Make sure
no one is in the vehicle and
there is nothing blocking or
placed in front of any air bag
module when the battery is
connected. Failure to follow
these instructions may result
in serious personal injury in
the event of an accidental
deployment.

Connect the battery ground
cable. Refer to Section 414-01
.

Measure the voltage between
seat control switch C3297-5,
circuit SBP12 (GN/RD),

Yes
GO to L7 .
No
VERIFY SJB fuse 12 (7.5A) is OK. If OK, REPAIR the circuit.
If not OK, REFER to the Wiring Diagrams manual to identify
the possible causes of the circuit short. REPEAT the self-test.
CLEAR the DTCs.
CONNECT driver seat side air bag module C327. REPOWER
the SRS . REFER to Section 501-20B .
volts?

L7 CHECK FOR GROUND TO
THE SEAT CONTROL SWITCH
Measure the resistance
between seat control switch
C3297-3, circuit GD126
(BK/WH), harness side and
ground.

ohms?

Yes
GO to L8 .
No
REPAIR the circuit. REPEAT the self-test. CLEAR the DTCs.
DISCONNECT the battery ground cable. CONNECT driver seat
side air bag module C327. REPOWER the SRS . REFER to
Section 501-20B .
L8 CHECK CIRCUITS
BETWEEN THE SEAT CONTROL
SWITCH AND DSM FOR A
SHORT TO VOLTAGE
Disconnect: DSM C3299B.
Ignition ON.
seat control switch C3297,
harness side and ground using
the following chart:

Connector Circuit
C3297-9 CPS06 (GN/WH)
C3297-4 CPS01 (GN/BU)
C3297-2 CPS03 (VT/GY)
C3297-6 CPS02 (GY/YE)
C3297-11 CPS07 (GY/BN)
C3297-8 CPS08 (VT/OG)
C3297-12 CPS04 (YE/OG)
Yes
REPAIR the circuit(s). REPEAT the self-test. CLEAR the
DTCs.
Section 501-20B .
No
GO to L9 .
C3297-1 CPS05 (BU/WH)
Is voltage present on any
circuits?

L9 CHECK CIRCUITS
SWITCH AND DSM FOR A
SHORT TO GROUND
Ignition OFF.
501-20B .

Air Bag C327.

Disconnect: Driver Seat

WARNING: Make sure
deployment.

.

C3297 pins, harness side and
ground using the following
chart:

Connector Circuit
C3297-9 CPS06 (GN/WH)
Yes
GO to L10 .
No
DTCs.
Section 501-20B .
C3297-4 CPS01 (GN/BU)
C3297-2 CPS03 (VT/GY)
C3297-6 CPS02 (GY/YE)
C3297-11 CPS07 (GY/BN)
C3297-8 CPS08 (VT/OG)
C3297-12 CPS04 (YE/OG)
C3297-1 CPS05 (BU/WH)
Are the resistances greater
than 10,000 ohms?

L10 CHECK CIRCUITS
SWITCH AND DSM FOR AN
OPEN
C3297, harness side and DSM
C3299B pins, harness side

Seat
Control
Switch
Connector Circuit
DSM
Connector
C3297-9 CPS06
(GN/WH)
C3299B-15
C3297-4 CPS01
(GN/BU)
C3299B-16
C3297-2 CPS03
(VT/GY)
C3299B-18
C3297-6 CPS02
(GY/YE)
C3299B-6
C3297-11 CPS07
(GY/BN)
C3299B-19
C3297-8 CPS08
(VT/OG)
C3299B-7
C3297-12 CPS04
(YE/OG)
C3299B-5
Yes
INSTALL a new DSM . REFER to Driver Seat Module (DSM)
in this section. REPEAT the self-test. CLEAR the DTCs.
Section 501-20B .
No
DTCs.
Section 501-20B .
C3297-1 CPS05
(BU/WH)
C3299B-17
Are the resistances less than
5 ohms?

L11 CHECK SEAT TRACK
OPERATION USING DSM SEAT
TRACK MOTOR PIDs

Front Motor Up
(FRONT_UP)

Front Motor Down
(FRONT_DWN)

Rear Motor Up
(REAR_UP)

Rear Motor Down
(REAR_DWN)

Horizontal Motor
Forward
(HORZ_FWD)

Horizontal Motor
Backward
(HORZ_BWD)

Recline Motor
Backward
(RECL_BWD)

Recline Motor
Forward
(RECL_FWD)

Toggle the DSM active
commands ON and OFF while
monitoring the seat movement.

Does the driver seat operate
correctly?

Yes
The condition may be intermittent. CHECK for causes of an
intermittent concern, particularly the pins and terminals of
electrical connectors that were disconnected. Do not install any
new components at this time. Components should only be
installed when directed to do so in the pinpoint test. REPAIR
any intermittent wiring, terminal or connector concerns found.
REPEAT the self-test. CLEAR the DTCs.
Section 501-20B .
No
If no seat movement, GO to L12 .
If no front vertical seat movement, GO to L22 .
If no rear vertical seat movement, GO to L25 .
If no horizontal seat movement, GO to L28 .
If no recline seat movement, GO to L31 .
L12 CHECK FOR VOLTAGE TO
THE DSM
Ignition OFF.
501-20B .

Air Bag C327.

Disconnect: DSM C3299A .
WARNING: Make sure
deployment.

.

DSM C3299A-1, circuit
SBB32 (VT/RD), harness side
and ground.

volts?

Yes
GO to L13 .
No
VERIFY Battery Junction Box (BJB) fuse 32 (30A) is OK. If
OK, REPAIR the circuit. If not OK, REFER to the Wiring
Diagrams manual to identify the possible causes of the circuit
short. REPEAT the self-test. CLEAR the DTCs.
Section 501-20B .
L13 CHECK FOR GROUND TO
THE DSM
between:

DSM C3299A-2,
circuit GD126
(BK/WH), harness side
and ground.

DSM C3299B-24,
circuit GD126
(BK/WH), harness side
and ground.

Yes
GO to L14 .
No
Section 501-20B .
ohms?

L14 CHECK THE FRONT
HEIGHT MOTOR CIRCUITS FOR
A SHORT TO GROUND
between:

DSM C3299B-23,
circuit CPS25
(WH/VT), harness side
and ground.

DSM C3299B-11,
circuit CPS24 (GY),
harness side and
ground.

than 10,000 ohms?

Yes
GO to L16 .
No
GO to L15 .
L15 CHECK THE FRONT
A SHORT TO GROUND
Disconnect: Power Seat Motor
C357.

between:

DSM C3299B-23,
circuit CPS25
and ground.

DSM C3299B-11,
circuit CPS24 (GY),
harness side and
ground.

Yes
INSTALL a new driver seat track assembly. REFER to Seat
Track in this section. REPEAT the self-test. CLEAR the DTCs.
Section 501-20B .
No
DTCs.
than 10,000 ohms?

Section 501-20B .
L16 CHECK THE REAR HEIGHT
MOTOR CIRCUITS FOR A
SHORT TO GROUND
between:

DSM C3299B-22,
circuit CPS27
(BU/BN), harness side
and ground.

DSM C3299B-10,
circuit CPS26
(YE/BU), harness side
and ground.

than 10,000 ohms?

Yes
GO to L18 .
No
GO to L17 .
SHORT TO GROUND
C357.

between:

DSM C3299B-22,
circuit CPS27
and ground.

DSM C3299B-10,
circuit CPS26
and ground.

Yes
Section 501-20B .
No
DTCs.
Section 501-20B .
than 10,000 ohms?

L18 CHECK THE HORIZONTAL
SHORT TO GROUND
between:

DSM C3299B-9,
circuit CPS23
(GN/VT), harness side
and ground.

DSM C3299B-12,
circuit CPS22 (BN),
harness side and
ground.

than 10,000 ohms?

Yes
GO to L20 .
No
GO to L19 .
SHORT TO GROUND
C357.

between:

DSM C3299B-9,
circuit CPS23
and ground.

DSM C3299B-12,
circuit CPS22 (BN),
harness side and
ground.

Yes
Section 501-20B .
No
DTCs.
Section 501-20B .
than 10,000 ohms?

L20 CHECK THE RECLINER
SHORT TO GROUND
between:

DSM C3299B-13,
circuit CPS29
(WH/BN), harness side
and ground.

DSM C3299B-21,
circuit CPS30
(VT/BN), harness side
and ground.

than 10,000 ohms?

Yes
Section 501-20B .
No
GO to L21 .
SHORT TO GROUND
Disconnect: Driver Power Seat
Recliner Motor C3187.

between:

DSM C3299B-13,
circuit CPS29
and ground.

DSM C3299B-21,
circuit CPS30
and ground.

Yes
INSTALL a new driver seat recliner motor. REFER to Seat
Recliner Motor in this section. REPEAT the self-test. CLEAR
the DTCs.
Section 501-20B .
No
DTCs.
Section 501-20B .
than 10,000 ohms?

L22 CHECK FOR VOLTAGE AT
THE FRONT HEIGHT MOTOR
USING DSM SEAT TRACK
MOTOR PIDs
Ignition OFF.
501-20B .

Air Bag C327.

C357.

WARNING: Make sure
deployment.

.

Ignition ON.

Front Motor Up
(FRONT_UP)

Front Motor Down
(FRONT_DWN)

power seat motor C357-2,
circuit CPS25 (WH/VT) and
C357-5, circuit CPS24 (GY),
harness side while toggling
DSM active commands
FRONT_UP and
FRONT_DWN, ON and OFF.

Yes
Section 501-20B .
No
GO to L23 .
volts when command ON in
both directions and 0 volt
when commanded OFF?

L23 CHECK THE FRONT
A SHORT TO VOLTAGE
Ignition ON.
Measure the voltage between:
DSM C3299B-23,
circuit CPS25
and ground.

DSM C3299B-11,
circuit CPS24 (GY),
harness side and
ground.

Is voltage present on either
circuit?

Yes
DTCs.
Section 501-20B .
No
GO to L24 .
L24 CHECK THE FRONT
AN OPEN
between:

DSM C3299B-23,
circuit CPS25
and power seat motor
C357-2, circuit CPS25
(WH/VT), harness
side.

DSM C3299B-11,
circuit CPS24 (GY),

Yes
Section 501-20B .
No
DTCs.
harness side and power
seat motor C357-5,
circuit CPS24 (GY),
harness side.
5 ohms?

Section 501-20B .
L25 CHECK VOLTAGE AT THE
REAR HEIGHT MOTOR USING
DSM SEAT TRACK MOTOR PIDs
Ignition OFF.
501-20B .

Air Bag C327.

C357.

WARNING: Make sure
deployment.

.

Ignition ON.

Rear Motor Up
(REAR_UP)

Rear Motor Down
(REAR_DWN)

circuit CPS27 (BU/BN),

Yes
Section 501-20B .
No
GO to L26 .
harness side and C357-4,
circuit CPS26 (YE/BU),
harness side while toggling
DSM active commands
REAR_UP and REAR_DWN,
ON and OFF.
when commanded OFF?

SHORT TO VOLTAGE
Ignition ON.
DSM C3299B-22,
circuit CPS27
and ground.

DSM C3299B-10,
circuit CPS26
and ground.

circuit?

Yes
DTCs.
Section 501-20B .
No
GO to L27 .
MOTOR CIRCUITS FOR AN
OPEN
Ignition OFF.
between:

DSM C3299B-22,
circuit CPS27
(BU/BN), harness side.

DSM C3299B-10,
circuit CPS26
and rear height power
seat motor C357-4,
circuit CPS26
(YE/BU), harness side.

5 ohms?

Yes
Section 501-20B .
No
DTCs. DISCONNECT the battery ground cable. CONNECT
driver seat side air bag module C327. REPOWER the SRS .
HORIZONTAL MOTOR USING
DSM SEAT TRACK MOTOR PIDs
Ignition OFF.
501-20B .

Air Bag C327.

C357.

WARNING: Make sure
deployment.


Yes
Section 501-20B .
No
GO to L29 .
.
Ignition ON.

Horizontal Motor
Forward
(HORZ_FWD)

Horizontal Motor
Backward
(HORZ_BWD)

circuit CPS22 (BN) and
(GN/VT), harness side while
toggling DSM active
commands HORZ_FWD and
HORZ_BWD, ON and OFF.

when commanded OFF?

SHORT TO VOLTAGE
Ignition ON.
DSM C3299B-9,
circuit CPS23
and ground.

DSM C3299B-12,
circuit CPS22 (BN),
harness side and
ground.

Yes
DTCs.
Section 501-20B .
No
GO to L30 .
circuit?

OPEN
Ignition OFF.
between:

DSM C3299B-9,
circuit CPS23
(GN/VT), harness side.

DSM C3299B-12,
circuit CPS22 (BN),
harness side and
horizontal power seat
motor C357-3, circuit
CPS22 (BN), harness
side.

5 ohms?

Yes
Section 501-20B .
No
DTCs.
Section 501-20B .
RECLINER MOTOR USING DSM
RECLINER MOTOR PIDs
Ignition OFF.
501-20B .

Air Bag C327.

Yes
INSTALL a new driver seat recliner motor. REFER to
ref="SCS~us~en~file=SCS1A014.HTM~gen~ref.HTM" >Seat
Recliner Motor in this section. REPEAT the self-test. CLEAR
the DTCs.
Section 501-20B .
No
Disconnect: Driver Seat Power
Recliner Motor C3187.

WARNING: Make sure
deployment.

.

Ignition ON.
DataLogger - DSM - PIDs .

Recline Motor
Forward
(RECL_FWD)

Recline Motor
Backward
(RECL_BWD)

driver seat power recliner
motor C3187-1, circuit CPS29
(WH/BN) and C3187-5, circuit
CPS30 (VT/BN), harness side
while toggling the DSM
commands ON and OFF.

volts when commanded ON
in both directions and 0 volt
when commanded OFF?

GO to L32 .
L32 CHECK RECLINER MOTOR
CIRCUITS FOR A SHORT TO
VOLTAGE
Ignition ON.
DSM C3299B-13,
circuit CPS29
and ground.

DSM C3299B-21,
circuit CPS30
and ground.

circuit?

Yes
DTCs.
Section 501-20B .
No
GO to L33 .
OPEN
Ignition OFF.
between:

DSM C3299B-13,
circuit CPS29
and recliner power seat
CPS29 (WH/BN),
harness side.

DSM C3229B-21,
circuit CPS30
and recliner power seat
CPS30 (VT/BN),
harness side.

5 ohms?

Yes
Section 501-20B .
No
DTCs.
Section 501-20B .
Pinpoint Test M: The Memory Seat Does Not Operate Correctly - Does Not Operate Using the Memory
SET Switch
schematic and connector information. /p>
Normal Operation
Each motor in the memory seat track and recliner mechanism contains a Hall-effect position sensor. The
Driver Seat Module (DSM) supplies a shared signal return feed circuit to each sensor. Each position sensor
sends a signal pulse back to the DSM on the sensor feed circuit to monitor the position of the power seat and
seat backrest. The DSM stores the sensor position data when a SET command is received and uses this
information to return the seat to the stored position when a recall command is received.
When the memory SET switch button 1 or 2 is pressed, a ground signal is supplied to the Driver Door Module
(DDM). The DDM communicates a memory SET command to the DSM on the Medium Speed Controller
Area Network (MS-CAN). The DSM then supplies voltage and ground to the power seat track motors and
power recliner motor to move the seat to the stored position. For information on programming memory
positions or recalling a stored memory position, refer to Memory Position Programming in this section.
The following pinpoint test diagnoses a memory seat that does not operate correctly using the memory SET
switch. If the memory seat does not move in all directions using the seat control switch, GO to Pinpoint Test
L .
B1342 - ECU is
Faulted

If a programming error is detected, the DTC is set.
B1534 - Memory 1
Switch Circuit Short to
Ground

B1538 - Memory 2
Switch Circuit Short to
Ground

If a short to ground is sensed on the switch input circuit during the DDM
Self Test, the DTC is set. If activity is sensed on the input circuit for greater
than 2 minutes, the DTC is set as continuous. With the DTC set, any input
signal on the circuit is ignored.
B1663 - Seat Driver
Front Up/Down Motor
Stalled

B1664 - Seat Driver
Rear Up/Down Motor
Stalled

B1665 - Seat Driver
Forward/Backward
Motor Stalled

During self-test the DSM attempts to operate the appropriate seat track
motor and uses the motor's position sensor to monitor movement. If no
motor movement is sensed, the DTC is set. The DSM will retry motor
operation on the next activation of the seat control switch. If no movement
continues to be monitored after 250 milliseconds, the DSM disables the
output.
B1666 - Seat Driver
Recline Motor Stalled

During self-test the DSM attempts to operate the recliner motor and uses the
recliner motor position sensor to monitor movement. If no motor movement
is sensed, the DTC is set. The DSM will retry motor operation on the next
activation of the seat control switch. If no motor movement is still monitored
after 250 milliseconds, the DSM disables the output.
B1952 - Seat Rear
Up/Down Position
Feedback Circuit Short
to Battery

B1956 - Seat Front
Up/Down Position
to Battery

B1960 - Seat Recline
Forward/Backward
Position Feedback
Circuit Short to Battery

B1964 - Seat
Horizontal Forard
Position Feedback

If a short to voltage or an open condition is present on the affected motor's
position sensor (Hall effect) feedback circuit, the DTC is set. After a DTC is
set, a memory recall is not possible but the seat control switch can operate
the associated motor in 1-second increments.
B1953 - Seat Rear
Up/Down Position
to Ground

B1957 - Seat Front
Up/Down Position
to Ground

B1961 - Seat Recline
Forward/Backward
Position Feedback
Circuit Short to Ground

B1965 - Seat
Horizontal
Forward/Rearward
Position Feedback

If a short to ground condition is present on the affected motor's position
sensor (Hall effect) feedback circuit, the DTC is set. After a DTC is set, a
memory recall is not possible but the seat control switch can operate the
associated motor in 1-second increments.
Memory SET switch
Missing status information - MS-CAN communication bus messages:
ignition switch status
gear selector position

Memory power seat track
Seat recliner motor
DDM
DSM
PINPOINT TEST M: THE MEMORY SEAT DOES NOCORRECTLY - DOES NOT OPERATE USING THE MEMORY SET
SWITCH
PINPOINT TEST M: THE MEMORY SEAT DOES NOCORRECTLY - DOES NOT OPERATE USING THE MEMORY SET SWITCH 288
M1 CHECK TCM TRANSMISSION RANGE (TR) PID
Ignition ON.
Enter the following diagnostic mode on the scan tool:
DataLogger - TCM - PIDs: TR.

Operate the transmission gear selector in all positions while
monitoring the TCM PID TR states.

Do the PID states agree with the selected positions?
Yes
GO to M2 .
No
To diagnose a transmission gear
selector (PRNDL) status concern,
REFER to Section 307-01A ,
Section 307-01B or Section
307-01C .
M2 CHECK DSM IGNITION SWITCH STATUS (IGN_SW)
PID
DataLogger - DSM - PID: IGN_SW.

Cycle the ignition in all positions while monitoring the DSM
PID states.

Do the PID states agree with the selected positions?
Yes
GO to M3 .
No
To diagnose an ignition status
concern, REFER to Section 211-05
.
M3 RETRIEVE THE DTCs
Operate the memory seat and memory exterior mirrors in all
directions through the full range of travel.

Place the memory seat and memory exterior mirrors in
central travel positions.

Enter the following diagnostic mode on the scan tool: Self
Test - DSM .

Test - DDM .

Are any DTCs retrieved during the DDM Self Tests?
Yes
If one or both of the following
DDM DTCs are retrieved; B1534
or B1538, GO to M5 .
If DTCs B1952, B1956, B1960
and B1964 are all retrieved, GO to
M10 .
If DTCs B1953, B1957, B1961
and B1965 are all retrieved, GO to
M10 .
If DTC B1663, GO to M11 .
If DTC B1342, INSTALL a new
DSM . REFER to Driver Seat
Module (DSM) in this section.
REPEAT the self-test. CLEAR the
DTCs.
No
GO to M4 .
M4 CHECK THE DSM MEMORY SET SWITCH PID
STATES

Memory 1 recall switch status
Memory 2 recall switch status
While activating the memory switch recall 1 and recall 2
buttons, monitor the DDM memory SET switch PID states.

Do the PID states agree with the switch button positions?
Yes
GO to M10 .
No
GO to M5 .
M5 CHECK THE MEMORY SET SWITCH
Ignition OFF.
Disconnect: Memory SET Switch C503.
Measure the resistance between memory SET switch pins,
component side, while pressing the indicated buttons using
the following chart and illustration:

Switch Button Pins Ohms
Memory Switch 1 7 and 2 Less
than 20
Memory Switch 2 3 and 2 Less
than 20
Yes
GO to M6 .
No
INSTALL a new memory SET
switch. REFER to Memory Set
Switch in this section. REPEAT
the self-test. CLEAR the DTCs.
Is the memory SET switch OK?
M6 CHECK MEMORY SET GROUND CIRCUIT FOR AN
OPEN
Measure the resistance between memory SET switch
C503-2, circuit GD126 (BK/WH), harness side and ground.

Yes
GO to M7 .
No
REPAIR the circuit. REPEAT the
self-test. CLEAR the DTCs.
M7 CHECK MEMORY SET CIRCUITS FOR A SHORT TO
VOLTAGE
Ignition ON.
Measure the voltage between memory SET switch C503,
harness side and ground using the following chart:

Connector Circuit
C503-7 CPS15 (VT/WH)
C503-3 CPS16 (YE)
Is voltage present on any circuits?
Yes
REPAIR the circuit(s). REPEAT
No
GO to M8 .
M8 CHECK MEMORY SET CIRCUITS FOR A SHORT TO
GROUND
Ignition OFF.
Measure the resistance between memory SET switch C503,

Connector Circuit
C503-7 CPS15 (VT/WH)
C503-3 CPS16 (YE)
Are the resistances greater than 10,000 ohms?
Yes
GO to M9 .
No
M9 CHECK MEMORY SET CIRCUITS FOR AN OPEN
Measure the resistance between memory SET switch C503
pins and DDM C568B pins using the following chart:

Memory SET switch
connector Circuit
DDM
connector
C503-7 CPS15
(VT/WH)
C568B-16
C503-3 CPS16 (YE) C568B-17
Yes
INSTALL a new DDM . REFER
to Section 501-14 . REPEAT the
No
M10 CHECK DSM SENSOR PIDs

Driver Power Seat Front Up/Down Sense
(SFNT_MT)

Driver Power Seat Forward/Backward Sense
(SFWD_MT)

Yes
INSTALL a new DSM . REFER to
Driver Seat Module (DSM) in this
section. REPEAT the self-test.
CLEAR the DTCs.
No
Driver Power Seat Rear Up/Down Sense
(SREARMT)

Driver Power Seat Recline Sense (SRCL_MT)
NOTE: If the DSM detects a fault while carrying out this
step, the associated motor may operate in one-second
intervals.

Using the switch, operate the memory seat in all directions
through the full range of travel while monitoring the DSM
PIDs.

Does each PID indicate the sensor is operational
throughout each motor's full range of travel?

If the PID indicates driver seat
front vertical position sensor is not
present, GO to M11 .
If the PID indicates driver seat rear
vertical position sensor is not
horizontal position sensor is not
recline position sensor is not
M11 CHECK THE FRONT HEIGHT SENSOR CIRCUITS
FOR A SHORT TO VOLTAGE
Ignition OFF.

Disconnect: DSM C3299B .
Disconnect: Memory Seat Position Sensor C358.
there is nothing blocking or placed in front of any air bag
module when the battery is connected. Failure to follow
these instructions may result in serious personal injury

Ignition ON.
memory seat position sensor C358-2, circuit VPS10
(BU/GN), harness side and ground.

memory seat position sensor 358-5, circuit RPS13
(GN/OG), harness side and ground.

Is voltage present on either circuit?
Yes
501-20B .
No
GO to M12 .
Ignition OFF.


Yes
GO to M13 .
No
501-20B .
FOR AN OPEN
(BU/GN), harness side and DSM C3299B-4, circuit
VPS10 (BU/GN), harness side.

(GN/OG), harness side and DSM C3299B-8, circuit
RPS13 (GN/OG), harness side.

Yes
this section. REPEAT the self-test.
CLEAR the DTCs.
501-20B .
No
501-20B .
M14 CHECK THE REAR HEIGHT SENSOR CIRCUITS
Ignition OFF.

Disconnect: Memory Seat Position Sensor C358.

Yes
501-20B .
No
GO to M15 .
(GN/BN), harness side and ground.

driver seat position sensor C358-4, circuit RPS13

Ignition OFF.

memory seat position sensor C358-4, circuit RPS13

Yes
GO to M16 .
No
501-20B .
FOR AN OPEN
memory position sensor C358-1, circuit VPS11
(GN/BN), harness side and DSM C3299B-3, circuit
VPS11 (GN/BN), harness side.


Yes
CLEAR the DTCs.
501-20B .
No
REPAIR the circuit(s) in question.
DTCs.
501-20B .
M17 CHECK THE HORIZONTAL SENSOR CIRCUITS FOR
A SHORT TO VOLTAGE
Ignition OFF.

Disconnect: Memory Seat Position Sensor C358 .

Ignition ON.
(BN/BU), harness side and ground.


Yes
501-20B .
No
GO to M18 .
A SHORT TO GROUND
Ignition OFF.


Yes
GO to M19 .
No
501-20B .
AN OPEN
(BN/BU), harness side and DSM C3299B-14, circuit
VPS09 (BN/BU), harness side.


Yes
CLEAR the DTCs.
501-20B .
No
501-20B .
M20 CHECK THE RECLINER SENSOR CIRCUITS FOR A
SHORT TO VOLTAGE
Ignition OFF.

Disconnect: Driver Seat Recliner Motor C3187.

driver seat recliner motor C3187-2, circuit RPS13

driver seat recliner motor C3187-4, circuit VPS12
(GY/OG), harness side and ground.

Yes
501-20B .
No
GO to M21 .
M21 CHECK THE RECLINER SENSOR CIRCUITS FOR A
SHORT TO GROUND
Ignition OFF.

(GY/OG), harness side and ground.

Yes
GO to M22 .
No
501-20B .
M22 CHECK THE RECLINER SENSOR CIRCUITS FOR AN
OPEN

(GY/OG), harness side and DSM C3299B-20,
circuit VPS12 (GY/OG), harness side.

Yes
INSTALL a new driver seat
recliner motor. REFER to Seat
Recliner Motor in this section.
DTCs.
501-20B .
No
501-20B .
Pinpoint Test N: Easy Exit/Easy Entry is Inoperative/Does Not Operate Correctly
Normal Operation
The Driver Seat Module (DSM) receives a key out command over the Medium Speed Controller Area
Network (MS-CAN) and powers the driver seat rearward about 50.8 mm (2 in).
Key-in-ignition warning switch
Instrument Panel Cluster (IPC) module
DSM
PINPOINT TEST N: EASY EXIT/EASY ENTRY IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
N1 CHECK POWER SEAT OPERATION
Ignition ON.
Check the message center to verify the easy entry/easy
exit feature is enabled.

The easy entry/easy exit feature can be
enabled/disabled using a scan tool in module
programming. When enabled, the feature
becomes a user accessible item on the message
center allowing the user to turn the feature on
and off. Refer to the Owner's Literature or
Section 413-01 for information on the message
center.

Operate the seat fully forward and rearward with the
switch to verify the power seat track is OK.

Does the power seat operate forward and rearward
correctly?

Yes
GO to N2 .
No
REFER to the Symptom Chart for
diagnosis of inoperative driver power
seat horizontal movement.
N2 CHECK EASY EXIT OPERATION
Position the driver seat at least 50.8 mm (2 in) from the
rear stop point.

Ignition OFF.
Remove the key from the ignition.
Does the seat move rearward approximately 50.8
mm (2 in)?

Yes
GO to N5 .
No
GO to N3 .
N3 CHECK THE GEM / SJB IGNITION SWITCH
POSITION (IGN_SW) PID STATES
Ignition ON.
DataLogger - GEM - PID: IGN_SW.

Monitor the GEM PID states with the ignition key in
and with the key removed.

Do the PID states agree with the key positions?
Yes
GO to N4 .
No
To diagnose the key-in-ignition warning
switch fault, REFER to Section 413-01 .
N4 CHECK DSM DTCs
Self Test - DSM .

Are any DSM DTCs present?
Yes
REFER to the Driver Seat Module
(DSM) DTC Chart for DSM DTC
diagnosis.
No
section. REPEAT the self-test. CLEAR
the DTCs.
N5 CHECK THE EASY ENTRY OPERATION
Insert the ignition key.
Does the driver power seat move forward
approximately 50.8 mm (2 in)?

Yes
The system is operating correctly at this
time. RETEST the system for
intermittent operation. If no fault is
found, INSTRUCT the customer on the
correct operation of the system.
No
section. REPEAT the self-test. CLEAR
the DTCs.
Pinpoint Test O: The Power Lumbar is Inoperative - Driver
Normal Operation
The seat control switch is supplied battery voltage and ground. When the lumbar button (part of seat control
switch) is pressed, voltage and ground are supplied to the power lumbar motor to move the lumbar mechanism
in or out.
Seat control switch
Power lumbar motor assembly
PINPOINT TEST O: THE POWER LUMBAR IS INOPERATIVE - DRIVER
PINPOINT TEST N: EASY EXIT/EASY ENTRY IS INOPERATIVE/DOES NOT OPERATE CORRECTLY 300
O1 CHECK FOR VOLTAGE TO THE SEAT
CONTROL SWITCH
Ignition OFF.
Depower the SRS . Refer to Supplemental
Restraint System (SRS) Depowering and
Repowering in the General Procedures portion of
Section 501-20B .

Disconnect: Seat Control Switch C3297 (MKZ)
or C360 (Fusion).

vehicle and there is nothing blocking or placed
in front of any air bag module when the
battery is connected. Failure to follow these
instructions may result in serious personal
injury in the event of an accidental
deployment.

Connect the battery ground cable. Refer to
Section 414-01 .

Measure the voltage between seat control switch
and ground.

For Fusion, measure the voltage between
seat control switch C360-5, circuit
SBB32 (VT/RD), harness side and
ground.

For MKZ, measure the voltage between
seat control switch C3297-5, circuit
SBP12 (GN/RD), harness side and
ground.

Yes
GO to O2 .
No
(7.5A) (MKZ) or Battery Junction Box (BJB)
fuse 32 (30A) (Fusion) is OK. If OK, REPAIR
the circuit. If not OK, REFER to the Wiring
causes of the circuit short. TEST the system
Section 501-20B .
O2 CHECK FOR GROUND AT THE SEAT
CONTROL SWITCH
Measure the resistance between seat control
switch and ground.

For Fusion, measure the resistance
between seat control switch C360-3,
circuit GD126 (BK/WH), harness side
and ground.

For MKZ, measure the resistance
between seat control switch C3297-3,
circuit GD126 (BK/WH), harness side
and ground.

Yes
GO to O3 .
No
normal operation.
Section 501-20B .
PINPOINT TEST O: THE POWER LUMBAR IS INOPERATIVE - DRIVER 301
O3 CHECK VOLTAGE TO THE LUMBAR
MOTOR
Connect: Seat Control Switch C3297 (MKZ) or
C360 (Fusion).

Disconnect: Power Lumbar Motor C3215.
NOTE: During the following step, the voltage
being measured changes polarity dependent upon
which direction the seat control switch is
activated.

Measure the voltage between power lumbar
motor C3215-1, circuit CPS18 (BN/GN), harness
side and power lumbar motor C3215-2, circuit
CPS19 (GY/VT), harness side.

Operate the seat control switch in both
directions.

Is the voltage greater than 10 volts when the
seat control switch is operated and 0 volt in
the rest position?

Yes
INSTALL a new power lumbar assembly.
REFER to Lumbar Assembly in this section.
Section 501-20B .
No
GO to O4 .
O4 CHECK THE LUMBAR MOTOR CIRCUITS
Disconnect: Seat Control Switch C3297 (MKZ)
or C360 (Fusion).

seat control switch C3297-7 (MKZ) or
C360-7 (Fusion), circuit CPS18
(BN/GN), harness side and ground.

(GY/VT), harness side and ground.

Yes
GO to O5 .
No
normal operation.
Section 501-20B .
PINPOINT TEST O: THE POWER LUMBAR IS INOPERATIVE - DRIVER 302
Are the resistances greater than 10,000 ohms.
O5 CHECK THE LUMBAR MOTOR CIRCUITS
FOR AN OPEN
(BN/GN), harness side and power
lumbar motor C3215-1, circuit CPS18
(BN/GN), harness side.

(GY/VT), harness side and power
lumbar motor C3215-2, circuit CPS19
(GY/VT), harness side.

Yes
INSTALL a new seat control switch. REFER
to Seat Control Switch in this section. TEST
Section 501-20B .
No
normal operation.
Section 501-20B .
Pinpoint Test P: The Power Lumbar is Inoperative - Passenger
Normal Operation
The seat control switch is supplied battery voltage and ground. When the lumbar button (part of seat control
switch) is pressed, voltage and ground are supplied to the power lumbar motor to move the lumbar mechanism
in or out.
Seat control switch
Power lumbar motor assembly
PINPOINT TEST P: THE POWER LUMBAR IS INOPERATIVE - PASSENGER
b>NOTE: If a seat equipped with a seat mounted side air bag is being serviced, the Supplemental Restraint
P1 CHECK FOR VOLTAGE TO THE SEAT
CONTROL SWITCH
Ignition OFF.

C313.

Disconnect: Seat Control Switch C3190.

414-01 .

Measure the voltage between seat control switch
C3190-5, circuit SBB31 (WH/RD), harness side and
ground.

Yes
GO to P2 .
No
P2 CHECK FOR GROUND TO THE SEAT
CONTROL SWITCH
Measure the resistance between seat control switch
C3190-3, circuit GD126 (BK/WH), harness side and
ground.

Yes
GO to P3 .
No
normal operation.
PINPOINT TEST P: THE POWER LUMBAR IS INOPERATIVE - PASSENGER 304
P3 CHECK FOR VOLTAGE TO THE LUMBAR
MOTOR
Connect: Seat Control Switch C3190.
Disconnect: Power Lumbar Motor C3216.
measured changes polarity dependent upon which
direction the seat control switch is activated.

Measure the voltage between power lumbar motor
C3216-1, circuit CPS20 (VT), harness side and
power lumbar motor C3216-2, circuit CPS21
(WH/OG), harness side.

Operate the seat control switch in both directions.
Is the voltage greater than 10 volts when the seat
control switch is operated and 0 volt in the rest
position?

Yes
INSTALL a new power lumbar assembly.
REFER to Lumbar Assembly in this
section. TEST the system for normal
operation.
No
GO to P4 .
P4 CHECK THE LUMBAR MOTOR CIRCUITS FOR
A SHORT TO GROUND
Disconnect: Seat Control Switch C3190.
seat control switch C3190-7, circuit CPS20
(VT), harness side and ground.

(WH/OG), harness side and ground.

Are the resistances greater than 10,000 ohms.
Yes
GO to P5 .
No
REPAIR the circuit(s). TEST the system
P5 CHECK THE LUMBAR MOTOR CIRCUITS FOR
AN OPEN
PINPOINT TEST P: THE POWER LUMBAR IS INOPERATIVE - PASSENGER 305
(VT), harness side and power lumbar motor
C3215-1, circuit CPS20 (VT), harness side.

(WH/OG), harness side and power lumbar
motor C3215-2, circuit CPS21 (WH/OG),
harness side.

Yes
INSTALL a new seat control switch.
REFER to Seat Control Switch in this
operation.
No
normal operation.
Pinpoint Test Q: The Heated Seats are Inoperative - Driver and Front Passenger
Refer to Wiring Diagrams Cell 119 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Climate Controlled Seats
for schematic and connector information.
Normal Operation
The engine must be running for the heated seat system to operate. When the driver or passenger heated seat
button is pressed, a momentary ground signal is sent on the driver or passenger request circuit to turn the
heated seat system on or off. The heated seat module monitors temperature sensors contained within the
cushion heater mats. The temperature sensors share the same return circuit to the heated seat module. If the
temperature sensor return circuit opens (resistance greater than 300,000 ohms), the heated seat module will
disable the outputs to both seats.
The Front Controls Interface Module (FCIM) (with navigation), HVAC module and heated seat module must
be communicating correctly for the system to operate correctly. PIDs are available to check heated seat switch
operation in the FCIM (with navigation) and HVAC module (with and without navigation).
Normal heat cycle may require several minutes to initially warm the seat. The seat should be occupied to
correctly test for normal operation. Temperature measuring devices do not provide an accurate method for
testing heated seat operation as surface temperatures are subject to human and environmental characteristics.
Correct testing requires heater mat resistance measurements which have tight tolerances affecting the length
of time for the heater mats to reach maximum operating temperature.
The heated seat module does not report DTCs. If a fault is detected, the module will disable the affected
seat(s) and indicator(s). After the fault is corrected, the heated seat module needs to be reset by cycling the
ignition.
Fuse(s)
Medium Speed Controller Area Network (MS-CAN) fault
FCIM (if equipped)
Heated seat module
HVAC module
PINPOINT TEST Q: THE HEATED SEATS ARE INOPERATIVE - DRIVER AND FRONT PASSENGER
and the ignition switch is ON. This is normal operation andoes not indicate an SRS fault.
Q1 CHECK HEATED SEAT OPERATION
Ignition OFF.
Start the engine.
Verify both heated seats do not heat.
Does either heated seat operate?
Yes
GO to Symptom Chart to diagnose the
heated seat is inoperative/does not operate
correctly - driver or the heated seat is
inoperative/does not operate correctly -
passenger.
No
GO to Q2 .
Q2 CHECK HEATED SEAT INDICATOR
ILLUMINATION
Ignition OFF.
Start the engine.
Verify system indicator illumion.
When pressing and releasing each heated seat
button individually, does any heated seat
indicator illuminate or flash and then turn off?

Yes
GO to Q7 .
No
For vehicles with navigation, GO to Q3 .
For vehicles without navigation, GO to Q4 .
Q3 RETRIEVE THE FCIM DTCs
Enter the following diagnostic mode on the scan
tool: Self Test - FCIM .

Are any FCIM DTCs retrieved?
Q4 RETRIEVE THE HVAC MODULE DTCs
tool: Self Test - HVAC Module.

Are any HVAC module DTCs retrieved?
Yes
For any HVAC module DTCs, REFER to
the HVAC Module DTC Chart in this
section.
No
For vehicles with navigation, GO to Q5 .
For vehicles without navigation, GO to Q6 .
Q5 MONITOR THE FCIM PIDs AND CHECK
INPUTS
PINPOINT TEST Q: THE HEATED SEATS ARE INOPERATIVE - DRIVER AND FRONT PASSENGER 307
tool: DataLogger - FCIM - PIDs.

Driver Heated Seat
(CC_SW_D_HSEATS)

Passenger Heated Seat
(CC_SW_P_HSEATS)

Monitor the FCIM PIDs while individually
pushing the driver and passenger heated seat
buttons.

Do the PID values agree with the switch button
positions?

Yes
GO to Q6 .
No
INSTALL a new FCIM . REFER to Section
415-00 < TEST the system for normal
operation.
Q6 MONITOR THE HVAC MODULE PIDs AND
CHECK INPUTS
tool: DataLogger - HVAC Module - PIDs.

Driver Heated Seat
(CC_SW_D_HSEATS)

(CC_SW_P_HSEATS)

Monitor HVAC module PIDs while individually
pushing the driver and passenger heated seat
buttons.

positions?

Yes
The fault is intermittent, CHECK for causes
of the intermittent fault. INSPECT the
connectors, terminals and wiring.
ATTEMPT to recreate the fault by flexing
the wire harness and operating the system.
CHECK the electrical connectors for
corrosion, poor pin contact or pushed-out
pins. REPAIR any intermittent concerns
found and TIGHTEN any loose connector
pins. REPEAT the self-test. CLEAR the
DTCs. CHECK the system for normal
operation.
No
INSTALL a new HVAC module. REFER to
Section 412-01 . TEST the system for
normal operation.
Q7 CHECK VOLTAGE TO THE HEATED SEAT
MODULE
Ignition OFF.
Repowering in the General Procedurestion of
Section 501-20B .

C313.

Disconnect: Heated Seat Module C3304B.
in front of any air bag module when the battery
is connected. Failure to follow these instructions
may result in serious personal injury in the
event of an accidental deployment.

414-01 .

Ignition ON.
Yes
GO to Q8 .
No
VERIFY Smart Junction Box (SJB) fuses 18
(20A) and 35 (10A) are OK. If OK,
REPAIR the affected circuit. If not OK,
REFER to the Wiring Diagrams manual to
identify the possible causes of the circuit
short. TEST the system for normal
operation.
module C313.
REPOWER the SRS . REFER to Section
501-20B .
heated seat module C3304B-1, circuit
SBP18 (YE/RD), harness side and ground.

CBP35 (YE/GY), harness side and ground.

Are the voltages greater than 10 volts?
Q8 CHECK THE HEATED SEAT MODULE
GROUND CIRCUIT FOR AN OPEN
Ignition OFF.
Measure the resistance between heated seat module
C3304B-5, circuit GD139 (BK/YE), harness side
and ground.

Yes
GO to Q9 .
No
normal operation.
module C313.
501-20B .
Q9 CHECK HEATED SEAT MODULE SENSOR
RETURN CIRCUIT FOR AN OPEN
Disconnect: Heated Seat Module C3304A.
Disconnect: Passenger Seat Cushion Heater C334.
C3304A-12, circuit RHS05 (YE/VT), harness side
and passenger seat cushion heater C334-4, circuit
RHS05 (YE/VT), harness side.

Yes
INSTALL a new heated seat module.
REFER to Heated Seat Module in this
operation.
module C313.
501-20B .
No
normal operation.
module C313.
501-20B .
Pinpoint Test R: The Heated Seat is Inoperative - Driver
Refer to Wiring Dgrams Cell 119 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Climate Controlled Seats for
Normal Operation
The heated seat module receives battery voltage. The HVAC module supplies a momentary ground signal to
the heated seat module to request the system on/off. The heated seat module supplies voltage to the heater
mats. The heated seat module monitors the heater mat temperature sensor. If the temperature sensor circuits
open, the heated seat module will disable output voltage to the heater mat. The heated seat module control
circuits are monitored by the HVAC module and will set a DTC if a circuit fault is detected.
DTC B1030:12 (Left Front Seat Heater: Circuit Short To Battery) - If the driver seat control circuit
from the HVAC module to the heated seat module is shorted to voltage, the DTC is set in the HVAC
module.

DTC B1030:14 (Left Front Seat Heater: Circuit Short To Ground or Open) - If the driver seat control
circuit from the HVAC module to the heated seat module is shorted to ground or open, the DTC is set
in the HVAC module.

Heater feed circuit short to battery, ground or open
Sensor circuit short to battery, ground or open
Heated seat switch stuck closed to ground
Heater mat
Heated seat module
HVAC module
FCIM (if equipped)
PINPOINT TEST R: THE HEATED SEAT IS INOPERATIVE - DRIVER
R1 CHECK HEATED SEAT OPERATION
Start the engine.
Verify the passenger heated seat is
operational.

Is the passenger heated seat
operational?

Yes
GO to R2 .
No
GO to Symptom Chart to diagnose the heated seats
are inoperative - driver and front passenger or the
heated seat is inoperative/ds not operate correctly -
passenger.
R2 CHECK HEATED SEAT INDICATOR
ILLUMINATION
Verify system indicator illumination.
Do the driver heated seat indicators
illuminate or flash and then turn off?

Yes
GO to R7 .
No
Vehicles with navigation, GO to R3 .
Vehicles without navigation, GO to R4 .
R3 RETRIEVE THE FCIM DTCs
Enter the following diagnostic mode on
the scan tool: Self Test - FCIM .

Yes
For all FCIM DTCs, REFER to the Master DTC
Chart in Section 415-00 .
No
GO to R4 .
R4 RETRIEVE THE HVAC MODULE DTCs
the scan tool: Self Test - HVAC Module.

Are any HVAC module DTCs
retrieved?

Yes
If DTC B1030:12, GO to R18 .
If DTC B1030:14, GO to R19 .
For any other HVAC module DTCs, REFER to the
HVAC Module DTC Chart in this section.
No
For vehicles with navigation, GO to R5 .
For vehicles without navigation, GO to R6 .
R5 MONITOR THE DRIVER HEATED
SEAT (CC_SW_D_HSEATS) PID AND
CHECK INPUTS
the scan tool: DataLogger - FCIM - PIDs:
CC_SW_D_HSEATS.

Yes
GO to R6 .
No
INSTALL a new FCIM . REFER to Section 415-00 .
PINPOINT TEST R: THE HEATED SEAT IS INOPERATIVE - DRIVER 311
Monitor the FCIM PID while pushing the
driver heated seat button.

Do the PID states agree with the switch
button positions?

R6 MONITOR THE DRIVER HEATED
SEAT (CC_SW_D_HSEATS) PID AND
CHECK INPUTS
the scan tool: DataLogger - HVAC
Module - PIDs: CC_SW_D_HSEATS.

Monitor the HVAC module PID while
pushing the driver heated seat button.

Do the PID values agree with the switch
button positions?

Yes
The fault is intermittent, CHECK for causes of the
intermittent fault. INSPECT the connectors,
terminals and wiring. ATTEMPT to recreate the fault
by flexing the wire harness and operating the system.
CHECK the electrical connectors for corrosion, poor
pin contact or pushed-out pins. REPAIR any
intermittent concerns found and TIGHTEN any loose
connector pins. REPEAT the self-test. CLEAR the
DTCs. CHECK the system for normal operation.
No
INSTALL a new HVAC module. REFER to Section
412-01 . TEST the system for normal operation.
R7 CHECK FOR VOLTAGE TO THE
HEATED SEAT MODULE
Ignition OFF.
Repowering in the General Procedures
portion of Section 501-20B .

Disconnect: Driver Seat Side Air Bag
Module C327.

Disconnect: Passenger Seat Side Air Bag
Module C313.

WARNING: Make sure no one is in
the vehicle and there is nothing blocking
or placed in front of any air bag module
when the battery is connected. Failure
to follow these instructions may result
in serious personal injury in the event of
an accidental deployment.

Section 414-01 .

Measure the voltage between heated seat
module C3304B-1, circuit SBP18
(YE/RD) harness side and ground.

Yes
GO to R8 .
No
operation.
CONNECT driver seat side air bag module C327.
CONNECT passenger seat side air bag module
C313. REPOWER the SRS . REFER to Section
501-20B .
R8 CHECK THE TEMPERATURE SENSOR
OUTPUT CIRCUIT FOR A SHORT TO
VOLTAGE
Disconnect: Driver Seat Cushion Heater
Mat C364.

Ignition ON.
module C3304A-3, circuit VHS26 (VT),

Yes
REPAIR the circuit. GO to R11 to check the
temperature sensor for damage. If OK, TEST the
system for normal operation. If not OK, INSTALL a
new driver seat cushion heater mat. REFER to Seat
Cushion Cover - Front in this section.
501-20B .
No
GO t R9 .
R9 CHECK THE TEMPERATURE SENSOR
OUTPUT CIRCUIT FOR AN OPEN AND
SHORT TO GROUND
Ignition OFF.
heated seat module C3304A-3,
circuit VHS26 (VT), harness side
and rear seat cushion heater mat
C364-3, circuit VHS26 (VT),
harness side.

heated seat module C3304A-3,
circuit VHS26 (VT), harness side
and ground.

Is the resistance less than 5 ohms
between C3304A-3 and C364-3, and

Yes
GO to R10 .
No
operation.
501-20B .
greater than 10,000 ohms between
C3304A-3 and ground?
R10 CHECK THE TEMPERATURE
SENSOR RETURN CIRCUIT FOR AN OPEN
Measure the resistance between heated
seat module C3304A-12, circuit RHS05
(YE/VT), harness side and driver seat
cushion heater mat C364-4, circuit RHS05

Yes
GO to R11 .
No
operation.
501-20B .
R11 CHECK THE TEMPERATURE
SENSOR FOR AN OPEN
Measure the resistance between rear
heated seat cushion C364 pin 3 and pin 4,
component side.

Is the resistance between 300 ohms and
300,000 ohms?

Yes
GO to R12 .
No
INSTALL a new cushion heater mat. REFER to Seat
Cushion Cover - Front in this section. TEST the
501-20B .
R12 CHECK THE HEATER MAT OUTPUT
CIRCUIT FOR A SHORT TO VOLTAGE
Ignition ON.
module C3304B-4, circuit CHS02

Yes
operation.
501-20B .
No
GO to R13 .
R13 CHECK THE HEATER MAT OUTPUT
CIRCUIT FOR AN OPEN AND SHORT TO
GROUND
Ignition OFF.
heated seat module C3304B-4,
circuit CHS02 (YE/BU), harness
side and cushion heater mat
C364-1, circuit CHS02 (YE/BU),
harness side.

heated seat module C3304B-4,
circuit CHS02 (YE/BU), harness
side and ground.

between C3304B-4 and C364-1, and
greater than 10,000 ohms between
C3304B-4 and ground?

Yes
GO to R14 .
No
operation.
501-20B .
R14 CHECK THE HEATER MAT
RESISTANCE
Connect: Driver Seat Backrest Heater Mat
C365.

Connect: Driver Seat Cushion Heater Mat
C364.

seat module C3304B-4, circuit CHS02

Yes
GO to R21 .
No
GO to R15 .
Is the resistance between 1.2 and 4.0
ohms?

R15 CHECK THE CUSHION HEATER MAT
FOR AN OPEN
Disconnect: Driver Seat Cushion Heater
Mat C364.

Measure the resistance between driver seat
cushion heater mat C364 pins 1 and 2,
component side.

ohms?

Yes
GO to R16 .
No
INSTALL a new driver seat cushion heater mat.
REFER to Seat Cushion Cover - Front in this
501-20B .
R16 CHECK THE CIRCUIT BETWEEN
THE CUSHION HEATER MAT AND
BACKREST HEATER MAT FOR AN OPEN
AND SHORT TO GROUND
Disconnect: Driver Seat Backrest Heater
Mat C365.

seat cushion heater mat C364-2,
circuit CHS11 (VT/GN), harness
side and seat backrest heater mat
C365-1, circuit CHS11 (VT/GN),
harness side.

seat cushion heater mat C364-2,
circuit CHS11 (VT/GN), harness
side and ground.

Is the resistance less than 0.5 ohm?
Yes
GO to R17 .
No
operation.
501-20B .
R17 CHECK THE BACKREST HEATER
MAT FOR AN OPEN
Measure the resistance between driver seat
backrest heater mat C365 pins 1 and 2,
component side.

ohms?

Yes
REPAIR circuit GD126 (BK/WH) for an open.
501-20B .
No
INSTALL a new driver seat backrest heater mat.
501-20B .
R18 CHECK HEATED SEAT MODULE
SWITCH INPUT CIRCUIT FOR SHORT TO
VOLTAGE
Ignition OFF.

Module C313.

Disconnect: HVAC Module C2356A.

Section 414-01 .

Ignition ON.
module C3304A-2, circuit CHS29

Yes
operation.
501-20B .
No
501-20B .
R19 CHECK THE HEATED SEAT
MODULE SWITCH INPUT CIRCUIT FOR
AN OPEN
Ignition OFF.

Module C313.


Section 414-01 .

seat module C3304A-2, circuit CHS29
(WH/BU), harness side and HVAC
(WH/BU), harness side.

Yes
GO to R20 .
No
operation.
501-20B .
R20 CHECK THE HEATED SEAT
MODULE SWITCH INPUT CIRCUIT FOR A
SHORT TO GROUND
seat module C3304A-2, circuit CHS29

ohms?

Yes
INSTALL a new heated seat module. REFER to
Heated Seat Module in this section. TEST the system
501-20B .
No
operation.
501-20B .
R21 CHECK THE HVAC MODULE
OUTPUT
Connect: Heated Seat Module C3304A
and C3304B.

Ignition ON.
NOTE: The following measurement must
be taken by back-probing heated seat
module C3304A.

NOTE: Voltage on circuit CHS29
(WH/BU) should drop momentarily when
the driver heated seat control button is
pressed.

(WH/BU), harness side and ground by
back-probing heated seat module
connector. Press the driver heated seat
button on the HVAC module and note the
voltage.

Is the voltage greater than 10 volts
before pressing the driver heated seat
control button, then momentarily drops
when the heated seat control button is
pressed?

Yes
INSTALL a new heated seat module. REFER to
Heated Seat Module in this section. TEST the system
501-20B .
No
If voltage is greater than 10 volts but did not drop
when the driver heated seat button was pressed,
If voltage is less than 10 volts, INSTALL a new
heated seat module. REFER to Heated Seat Module
operation.
501-20B .
Pinpoint Test S: The Heated Seat is Inoperative - Passenger
Normal Operation
Theeated seat module receives battery voltage. The HVAC module supplies a momentary ground signal to the
heated seat module to request the system on/off. The heated seat module supplies voltage to the heater mats.
The heated seat module monitors the heater mat temperature sensor. If the temperature sensor circuits open,
the heated seat module will disable output voltage to the heater mat. The heated seat module control circuits
are monitored by the HVAC module and will set a DTC if a circuit fault is detected.
DTC B1032:12 (Right Front Seat Heater: Circuit Short To Battery) - If the passenger seat control
circuit from the HVAC module to the heated seat module is shorted to voltage, the DTC is set in the
HVAC module.

DTC B1032:14 (Right Front Seat Heater: Circuit Short To Ground or Open) - If the passenger seat
control circuit from the HVAC module to the heated seat module is shorted to ground or open, the
DTC is set in the HVAC module.

This pinpoint test is intended to diagnose the follo:
Heater feed circuit short to battery, ground or open
Sensor circuit short to battery, ground or open
Heated seat switch stuck closed to ground
Heater mat
Heated seat module
HVAC module
FCIM (if equipped)
PINPOINT TEST S: THE HEATED SEAT IS INOPERATIVE - PASSENGER
S1 CHECK HEATED SEAT OPERATION
Ignition OFF. Start the engine.
Verify the driver heated seat is operational.
Is the driver heated seat operational?
Yes
GO to S2 .
No
GO to Symptom Chart to diagnose the
heated seats are inoperative - driver and
front passenger or the heated seat is
driver.
S2 CHECK HEATED SEAT INDICATOR
ILLUMINATION
Do the passenger heated seat indicators
illuminate or flash and then turn off?

Yes
GO to S7 .
No
Vehicles with navigation, GO to S3 .
Vehicles without navigation, GO to S4 .
S3 RETRIEVE THE FCIM DTCs
tool: Self Test - FCIM .

Yes
For all FCIM DTCs, REFER to the Master
DTC Chart in Section 415-00 .
No
GO to S4 .
S4 RETRIEVE THE HVAC MODULE DTCs
tool: Self Test - HVAC Module.

Are any HVAC module DTCs retrieved?
Yes
If DTC B1032:12, GO to S18 .
If DTC B1032:14, GO to S19 .
For any other HVAC module DTCs, REFER
to the HVAC Module DTC Chart in this
section.
No
For vehicles with navigation, GO to S5 .
For vehicles without navigation, GO to S6 .
S5 MONITOR THE PASSENGER HEATED SEAT
(CC_SW_P_HSEATS)ID AND CHECK INPUTS
tool: DataLogger - FCIM - PIDs:
CC_SW_P_HSEATS.

Monitor the FCIM PID while pushing the
passenger heated seat button.

Do the PID states agree with the switch button
positions?

Yes
GO to S6 .
No
INSTALL a new FCIM . REFER to Section
415-00 . TEST the system for normal
operation.
S6 MONITOR THE PASSENGER HEATED SEAT
(CC_SW_P_HSEATS) PID AND CHECK INPUTS
PINPOINT TEST S: THE HEATED SEAT IS INOPERATIVE - PASSENGER 321
tool: DataLogger - HVAC Module - PIDs:
CC_SW_P_HSEATS.

Monitor the HVAC module PID while pushing the
passenger heatedtton.

positions?

Yes
The fault is intermittent, CHECK for causes
of the intermittent fault. INSPECT the
connectors, terminals and wiring.
ATTEMPT to recreate the fault by flexing
the wire harness and operating the system.
CHECK the electrical connectors for
corrosion, poor pin contact or pushed-out
pins. REPAIR any intermittent concerns
found and TIGHTEN any loose connector
pins. REPEAT the self-test. CLEAR the
DTCs. CHECK the system for normal
operation.
No
normal operation.
S7 CHECK FOR VOLTAGE TO THE HEATED
SEAT MODULE
Ignition OFF.
Section 501-20B .

C313.


414-01 .

Measure the voltage between heated seat module
C3304B-3, circuit SBP18 (YE/RD), harness side
and ground.

Yes
GO to S8 .
No
normal operation.
S8 CHECK THE TEMPERATURE SENSOR
OUTPUT CIRCUIT FOR A SHORT TO VOLTAGE
Disconnect: Passenger Seat Cushion Heater Mat
C334.

Ignition ON.
C3304A-9, circuit VHS27 (WH/OG), harness side
and ground.

Yes
REPAIR the circuit. GO to S11 to check the
temperature sensor for damage. If OK,
TEST the system for normal operation. If
not OK, INSTALL a new driver seat
cushion heater mat. REFER to Seat Cushion
Cover - Front in this section.
No
GO to S9 .
OUTPUT CIRCUIT FOR AN OPEN AND SHORT TO
GROUND
Ignition OFF.
heated seat module C3304A-9, circuit
VHS27 (WH/OG), harness side and seat
cushion heater mat C334-3, circuit VHS27

heated seat module C3304A-9, circuit
VHS27 (WH/OG), harness side and
ground.

Is the resistance less than 5 ohms between
C3304A-9 and C334-3, and greater than 10,000
ohms between C3304A-9 and ground?

Yes
GO to S10 .
No
normal operation.
C3304A-12, circuit RHS05 (YE/VT), harness side
and passenger seat cushion heater mat C334-4,
circuit RHS05 (YE/VT), harness side.

Yes
GO to S11 .
No
normal operation.
S11 CHECK TEMPERATURE SENSOR FOR AN
OPEN
Measure the resistance between rear heated seat
cushion C334 pin 3 and pin 4, component side.

Is the resistance between 300 ohms and 300,000
ohms?

Yes
GO to S12 .
No
INSTALL a new cushion heater mat.
REFER to Seat Cushion Cover - Front in
operation.
S12 CHECK THE HEATER MAT OUTPUT
Ignition ON.
C3304B-6, circuit CHS07 (GY/BU), harness side
and ground.

Yes
normal operation.
COECT passenger seat side air bag module
Section 501-20B .
No
GO to S13 .
S13 CHECK CUSHION HEATER MAT OUTPUT
CIRCUIT FOR AN OPEN AND SHORT TO
GROUND
Ignition OFF.
CHS07 (GY/BU), harness side and
passenger seat cushion heater mat C334-1,
circuit CHS07 (GY/BU), harness side.

Yes
GO to S14 .
No
normal operation.
CHS07 (GY/BU), harness side and
ground.

Is the resistance less than 5 ohms between
C3304B-6 and C334-1, and greater than 10,000
ohms between C3304B-6 and ground?

S14 CHECK THE HEATER MAT RESISTANCE
Connect: Passenger Seat Backrest Heater Mat
C335.

Connect: Passenger Seat Cushion Heater Mat
C334.

C3304B-6, circuit CHS07 (GY/BU), harness side
and ground.

Is the resistance between 1.2 and 4.0 ohms?
Yes
GO to S21 .
No
GO to S15 .
S15 CHECK THE CUSHION HEATER MAT FOR
AN OPEN
Disconnect: Passenger Seat Cushion Heater Mat
C334.

cushion heater mat C334 pins 1 and 2, component
side.

Yes
GO to S16 .
No
INSTALL a new driver seat cushion heater
mat. REFER to Seat Cushion Cover - Front
n this section. TEST the system for normal
operation.
S16 CHECK THE CIRCUIT BETWEEN THE
CUSHION HEATER MAT AND BACKREST
HEATER MAT FOR AN OPEN AND SHORT TO
GROUND
Disconnect: Passenger Seat Backrest Heater Mat
C335.

seat cushion heater mat C334-2, circuit
CHS12 (YE/GN), harness side and seat
backrest heater mat C335-1, circuit CHS12
(YE/GN), harness side.

seat cushion heater mat C334-2, circuit
CHS12 (YE/GN), harness side and ground.

Is the resistance less than 0.5 ohm?
Yes
GO to S17 .
No
normal operation.
S17 CHECK BACKREST HEATER MAT FOR AN
OPEN
backrest heater mat C335 pins 1 and 2, component
side.

Yes
REPAIR circuit GD139 (BK/YE) for an
open. TEST the system for normal
operation.
No
INSTALL a new passenger seat backrest
heater mat. TEST the system for normal
operation.
S18 CHECK HEATED SEAT MODULE SWITCH
INPUT CIRCUIT FOR SHORT TO VOLTAGE
Ignition OFF.
Section 501-20B .

Yes
normal operation.
C313.


414-01 .

Ignition ON.
C3304A-8, circuit CHS30 (GY/YE), harness side
and ground.

No
normal operation.
S19 CHECK THE HEATED SEAT MODULE
SWITCH INPUT CIRCUIT FOR AN OPEN
Ignition OFF.
Section 501-20B .

C313.


414-01 .

and HVAC module C2356A-4, circuit CHS30
(GY/YE), harness side.

Yes
GO to S20 .
No
normal operation.
S20 CHECK THE HEATED SEAT MODULE
SWITCH INPUT CIRCUIT FOR A SHORT TO
GROUND
and ground.

Yes
operation.
No
normal operation.
S21 CHECK THE HVAC MODULE OUTPUT
Connect: Heated Seat Module C3304A and
C3304B.

Ignition ON.
NOTE: The following measurement must be taken
by back-probing heated seat module C3304A.

NOTE: Voltage on circuit CHS30 (GY/YE)
should drop momentarily when the passenger
heated seat control button is pressed.

Measure the voltage between passenger heated seat
module C3304A-8, circuit CHS30 (GY/YE),
harness side and ground by back-probing the
heated seat module connector. Press the passenger
heated seat button on the HVAC module and note
the voltage.

Yes
operation.
No
If voltage is greater than 10 volts but did not
drop when the passenger heated seat button
was pressed, INSTALL a new HVAC
module. REFER to Section 412-01 . TEST
Is the voltage greater than 10 volts before
pressing the passenger heated seat control
button, then momentarily drops when the
heated seat control button is pressed?

If voltage is less than 10 volts, INSTALL a
new heated seat module. REFER to Heated
Seat Module in this section. TEST the
Pinpoint Test T: The Heated Seat Does Not Operate Correctly - Seat Does Heat But the Heated Seat
Indicator Does Not Illuminate When Pressed
Rer to Wiring Diagrams Cell 119 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Climate Controlled Seats for
Normal Operation
When the heated seat module is commanded ON, voltage is supplied from the heated seat module to the
HVAC module on the low/high heat mode indicator circuits. When voltage is not supplied from the heated
seat module, none of the indicators illuminate.
Heated seat module
HVAC module
Front Controls Interface Module (FCIM)
PINPOINT TEST T: THE HEATED SEAT DOES NOT OPERATE CORRECTLY - SEAT DOES HEAT BUT THE
HEATED SEAT INDICATOR DOES NOT ILLUMINATE WHEN PRESSED
T1 CHECK INDICATOR CIRCUITS FOR A SHORT TO
GROUND
Ignition OFF.

Disconnect: HVAC Module C2356B.
Yes
GO to T2 .
No
REPAIR the circuit(s). TEST the
For driver seat, measure the resistance between:
HVAC module C2356B-7, circuit CHS04
(YE/GY), harness side and ground.

(VT/BN), harness side and ground.

For passenger seat, measure the resistance between:
HVAC module C2356B-4, circuit CHS09 (GY),

HVAC module C2356B-5, circuit CHS14 (GN),

cable. CONNECT passenger seat
side air bag module C313.
REPOWER the SRS . REFER to
Section 501-20B .
T2 CHECK INDICATOR CIRCUITS FOR AN OPEN
For driver seat, measure the resistance between:
(YE/GY), harness side and heated seat module
C3304A-4, circuit CHS04 (YE/GY), harness side.

(VT/BN), harness side and heated seat module
C3304A-5, circuit CHS13 (VT/BN), harness side.

For passenger seat, measure the resistance between:
HVAC module C2356B-4, circuit CHS09 (GY),
harness side and heated seat module C3304A-10,
circuit CHS09 (GY), harness side.

HVAC module C2356B-5, circuit CHS14 (GN),
harness side and heated seat module C3304A-11,
circuit CHS14 (GN), harness side.

Yes
For driver seat, GO to T3 .
For passenger seat, GO to T4 .
No
Section 501-20B .
PINPOINT TEST T: THE HEATED SEAT DOES NOT OPERATE CORRECTLY - SEAT DOES HEAT BUT THEHEATED SEAT INDICATOR DOES NOT ILLUMINATE WHEN PRESSED 330
T3 CHECK THE HEATED SEAT MODULE INDICATOR
CIRCUIT OUTPUT
Connect: HVAC Module C2356B.
Connect: Heated Seat Module C3304A.
Start the engine.
NOTE: The following measurement must be taken by
back-probing heated seat module C3304A.

NOTE: There should be no voltage on circuit CHS04
(YE/GY) when the driver seat side of the heated seat
module is off. When the heated seat module is commanded
on, voltage on circuit CHS04 (YE/GY) should drop
momentarily each time the driver heated seat control button
is pressed.

C3304A-4, circuit CHS04 (YE/GY), harness side and
ground by back-probing heated seat module C3304A-4.
Press the driver heated seat control button and note the
voltage.

Is there less than 1 volt when the heated seat module is
off and greater than 10 volts when the driver heated seat
module is in low or high mode?

Yes
For vehicles without navigation,
INSTALL a new HVAC module.
For vehicles with navigation,
INSTALL a new FCIM . REFER to
Section 415-00 .
operation.
cable.
CONNECT passenger seat side air
bag module C313.
Section 501-20B .
No
INSTALL a new heated seat
module. REFER to Heated Seat
Module in this section.
operation.
cable.
bag module C313.
Section 501-20B .
T4 CHECK THE HEATED SEAT MODULE INDICATOR
CIRCUIT OUTPUT
PINPOINT TEST T: THE HEATED SEAT DOES NOT OPERATE CORRECTLY - SEAT DOES HEAT BUT THEHEATED SEAT INDICATOR DOES NOT ILLUMINATE WHEN PRESSED 331
Connect: HVAC Module C2356B.
Connect: Heated Seat Module C3304A.
Start the engine.
NOTE: The following measurement must be taken by
back-probing heated seat module C3304A.

NOTE: There should be no voltage on circuit CHS09 (GY)
when the passenger seat side of the heated seat module is
off. When the heated seat module is commanded on,
voltage on circuit CHS09 (GY) should drop momentarily
each time the passenger heated seat control button is
pressed.

C3304A-10, circuit CHS09 (GY), harness side and ground
by back-probing heated seat module C3304A-10. Press the
passenger heated seat control button and note the voltage.

Is there less than 1 volt when the heated seat module is
off and greater than 10 volts when the driver heated seat
module is in low or high mode?

Yes
For vehicles without navigation,
For vehicles with navigation,
Section 415-00 .
operation.
cable.
bag module C313.
Section 501-20B .
No
INSTALL a new heated seat
module. REFER to Heated Seat
operation.
cable.
bag module C313.
Section 501-20B .
Pinpoint Test U: All Climate Controlled Seats Are Inoperative - Switch Indicators May or May Not
Illuminate
Normal Operation
The Dual Climate Controlled Seat Module (DCSM) is supplied voltage at all times, but the climate controlled
seat system only operates with the engine running. The system can be operated with the ignition ON engine
OFF by using a scan tool to bypass the climate controlled seat buttons on the touchscreen interface. When
commanding a heat or cool mode operation in this manner, it only operates in 15-second intervals. Both
voltage supply circuits are spliced together internal to the DCSM , so if one circuit becomes open, both seats
can still be operated. However, if a fault occurs setting a DTC specific to either climate controlled seat, only
the affected seat is disabled by the DCSM .
Climate controlled seat button commands are communicated from the Front Controls Interface Module
(FCIM) over the Medium Speed Controller Area Network (MS-CAN) to the HVAC module and then to the
DCSM . Upon receiving a command, the DCSM then communicates indicator illumination commands back to
the HVAC module which then commands the FCIM to turn the indicators on or off. No direct connection
exists between the FCIM , HVAC module and DCSM . The climate controlled seat system can only operate if
all 3 modules are communicating correctly on the Controller Area Network (CAN).
Fuse
MS-CAN
FCIM
HVAC module
DCSM
PINPOINT TEST U: ALL CLIMATE CONTROLLED SEATS ARE INOPERATIVE - SWITCH INDICATORS MAY OR
MAY NOT ILLUMINATE
NOTICE: When taking measurements at Dual Climate Controlled Seat Module (DCSM) harness
connectors, do not insert the electrical probes into the female connector pins. Inserting the probes into
connector pins can cause intermittent or open electrical connections after reassembly resulting in
Diagnostic Trouble Codes (DTCs) and system failure. Touching the tip of these connector pins is
recommended instead.
U1 VERIFY CLIMATE
CONTROLLED SEAT
BLOWER OPERATION
Ignition OFF.
Remove the driver and
front passenger cushion
Thermo-Electric Device
(TED) filters to verify
blower operation.

Turn the filters
to the left
(counterclockwise)
and remove.

Start the engine.
Operate climate
controlled seat buttons
while verifying both
blowers operate.

Does either blower
operate?

Yes
If only one blower operates,
GO to Symptom Chart to
diagnose a single climate
controlled seat is inoperative.
If both blowers operate, GO
to U5 .
No
GO to U2 .
U2 VERIFY CLIMATE
CONTROLLED SEAT
INDICATOR
ILLUMINATION
Ignition OFF.
Yes
GO to U5 .
PINPOINT TEST U: ALL CLIMATE CONTROLLED SEATS ARE INOPERATIVE - SWITCH INDICATORS MAY OR MAY NOT ILLUMINATE 333
Start the engine.
Verify system indicator
illumination.

Does any climate
controlled seat
indicator illuminate or
flash and then turn
off?

No
GO to U3 .
U3 CHECK THE FCIM
FOR DTCs
Ignition In ACC.
Enter the following
diagnostic mode on the
scan tool: Self Test -
FCIM .

Are any DTCs
retrieved?

Yes
REFER to the Master DTC
No
GO to U4 .
U4 CHECK THE HVAC
MODULE FOR DTCs
Enter the following
HVAC module.

Are any DTCs
retrieved?

Yes
REFER to the Master DTC
Chart in Section 412-00A or
Section 412-00B .
No
GO to U6 .
U5 CHECK THE DCSM
FOR DTCs
Enter the following
DCSM .

Are any DTCs
present?

Yes
GO to the Dual Climate
Controlled Seat Module
(DCSM) DTC Chart in this
section.
No
CHECK for causes of the
intermittent fault. INSPECT
the connectors, terminals and
wiring. ATTEMPT to
recreate the fault by flexing
the wire harness and
operating the system.
CHECK the electrical
connectors for corrosion,
poor pin contact or
pushed-out pins. REPAIR
any intermittent concerns
found and TIGHTEN any
loose DCSM connector pins.
If no intermittent concerns
are found, CARRY OUT the
Component Test -
Thermo-Electric Device
(TED) Cooling Performance
in this section for both seats.
U6 MONITOR THE FCIM
PIDs AND CHECK INPUTS
Enter the
following
diagnostic mode
on the scan tool:
DataLogger -
FCIM - PIDs.

Driver
Cooled
Seat
(CC_SW_D_CL_S)

Driver
Heated
Seat
(CC_SW_D_HSEATS)

Passenger
Cooled
Seat
(CC_SW_P_CL_S)

Passenger
Heated
Seat
(CC_SW_P_HSEATS)

Monitor the FCIM
PIDs while
individually
pushing driver and
passenger climate
controlled seat
switch buttons.

Do the PID
values agree with
the switch
positions?

Yes
GO to U7 .
No
INSTALL a
new FCIM .
REFER to
Section
415-00 .
TEST the
system for
normal
operation.
U7 MONITOR THE HVAC
MODULE PIDs AND
CHECK INPUTS
Enter the following
diagnostic mode he
scan tool: DataLogger -
HVAC module - PIDs.

Driver Cooled
Seat
(CC_SW_D_CL_S)

Driver Heated
Seat
(CC_SW_D_HSEATS)

Yes
GO to U8 .
No
INSTALL a new HVAC
module. REFER to Section
412-01 . TEST the system
Passenger
Cooled Seat
(CC_SW_P_CL_S)

Passenger
Heated Seat
(CC_SW_P_HSEATS)

Monitor the HVAC
module PIDs while
individually pushing
driver and passenger
climate controlled seat
switch buttons.

Do the PID values
agree with the switch
positions?

U8 CHECK DCSM USING
ACTIVE COMMANDS
Enter the following
DCSM - PIDs.

Seat Cushion
Thermal
Electric Device
Temperature
(CSHTEMP)

Seat Back
Thermal
Electric Device
Temperature
(BK_TEMP)

Climate-conSeat
Heat Command
(TED_HEAT_D)

Passenger
Cushion
Thermal
Electric Device
(TED)
Temperature
(PCSHTMP)

Passenger Back
TED
Temperature
(PBKTMP)

Passenger TED
Heat Mode
(TED_HEAT_P)

NOTE: The DCSM
active commands
TED_HEAT_D (driver
seat) and
TED_HEAT_P

Yes
CHECK for causes of the
intermittent fault. INSPECT
the connectors, terminals and
wiring. ATTEMPT to
recreate the fault by flexing
the wire harness and
operating the system.
CHECK the electrical
connectors for corrosion,
poor pin contact or
pushed-out pins. REPAIR
any intermittent concerns
found and TIGHTEN any
loose HVAC module
connector pins. REPEAT the
self-test. CHECK the system
No
INSTALL a new DCSM .
REFER to Dual Climate
(DCSM) in this section.
CLEAR the DTCs.
(passenger seat) are
limited to 15 seconds in
the ON state, then turn
OFF.
Operate the climate
controlled seats using
active commands while
monitoring the
appropriate PIDs.

When the
command is in
process, the
TED
temperature
PIDs on the
seat being
commanded
should
momentarily
increase. If no
temperature
increase is
noted, remove
the cushion
blower filter
and repeat the
active
command while
physically
monitoring the
cushion blower
for fan
movement.

Do the PID states or
cushion blower
movement indicate
climate controlled seat
operation?

Pinpoint Test V: A Single Climate Controlled Seat is Inoperative - Switch Indicators May or May Not
Illuminate
Normal Operation
Climate controlled seat button commands are communicated from the Front Controls Interface Module
(FCIM) over the Medium Speed Controller Area Network (MS-CAN) to the HVAC module and then to the
DCSM . Upon receiving a command, the DCSM then communicates indicator illumination commands back to
the HVAC module which then commands the FCIM to turn the indicators on or off. No direct connection
exists between the FCIM , HVAC module and DCSM . The climate controlled seat system can only operate if
all 3 modules are communicating correctly on the Controller Area Network (CAN).
MS-CAN
FCIM
HVAC module
DCSM
PINPOINT TEST V: A SINGLE CLIMATE CONTROLLED SEAT IS INOPERATIVE - SWITCH INDICATORS MAY OR
MAY NOT ILLUMINATE
V1 VERIFY CLIMATE CONTROLLED
SEAT BLOWER OPERATION
Ignition OFF.
Remove the driver and front passenger
cushion TED filters to verify blower
operation.

Turn the filter to the left
(counterclockwise) and remove.

Start the engine.
Operate climate controlled seat buttons
while verifying both blowers operate.

Are all climate controlled seats
inoperative?

Yes
GO to Symptom Chart to diagnose all climate
controlled seats are inoperative.
No
If both blowers operate, GO to V3 .
If only one blower operates, GO to V2 .
V2 VERIFY CLIMATE CONTROLLED
SEAT INDICATOR ILLUMINATION
Ignition OFF.
Start the engine.
Does any climate controlled seat
indicator illuminate or flash and then
turn off?

Yes
GO to V3 .
No
GO to V4 .
V3 CHECK THE DCSM FOR DTCs
PINPOINT TEST V: A SINGLE CLIMATE CONTROLLED SEAT IS INOPERATIVE - SWITCH INDICATORS MAY OR MAY NOT ILLUMINATE 338
Ignition In ACC.
the scan tool: Self Test - DCSM .

Are any DTCs present?
Yes
GO to the Dual Climate Controlled Seat Module
(DCSM) DTC Chart in this section.
No
GO to V8 .
V4 CHECK THE FCIM FOR DTCs
the scan tool: Self Test - FCIM .

Yes
REFER to the Master DTC Chart in Section 415-00 .
No
GO to V5 .
V5 CHECK THE HVAC MODULE FOR
DTCs
the scan tool: Self Test - HVAC module.

Yes
REFER to the Master DTC Chart in Section 412-00A
or Section 412-00B .
No
GO to V6 .
V6 MONITOR THE FCIM PIDs AND
CHECK INPUTS
the scan tool: DataLogger - FCIM -
PIDs.

Driver Cooled Seat
(CC_SW_D_CL_S)

Driver Heated Seat
(CC_SW_D_HSEATS)

Passenger Cooled Seat
(CC_SW_P_CL_S)

(CC_SW_P_HSEATS)

Monitor the FCIM PIDs while
individually pushing the affected driver
or passenger climate controlled seat
switch buttons.

Do the PID values agree with the
switch positions?

Yes
GO to V7 .
No
INSTALL a new FCIM . REFER to Section 41 . TEST
V7 MONITOR THE HVAC MODULE PIDs
AND CHECK INPUTS
the scan tool: DataLogger - HVAC
module - PIDs.

Driver Cooled Seat
(CC_SW_D_CL_S)

Driver Heated Seat
(CC_SW_D_HSEATS)

Passenger Cooled Seat
(CC_SW_P_CL_S)

Yes
GO to V8 .
No
(CC_SW_P_HSEATS)

Monitor the HVAC module PIDs while
individually pushing the affected driver
or passenger climate controlled seat
switch buttons.

Do the PID values agree with the
switch positions?

V8 CHECK DCSM USING ACTIVE
COMMANDS
the scan tool: DataLogger - DCSM -
PIDs.

Seat Cushion Thermal Electric
Device Temperature
(CSHTEMP)

Seat Back Thermal Electric
Device Temperature
(BK_TEMP)

Climate-controlled Seat Heat
Command (TED_HEAT_D)

Passenger Cushion Thermal
Electric Device (TED)
Temperature (PCSHTMP)

Passenger Back TED
Temperature (PBKTMP)

Passenger TED Heat Mode
(TED_HEAT_P)

NOTE: The DCSM active commands
TED_HEAT_D (driver seat) and
TED_HEAT_P (passenger seat) are
limited to 15 seconds in the ON state,
then turn OFF.

Operate the affected climate controlled
seat using active commands while
monitoring the appropriate PIDs.

When the command is in
process, the TED temperature
PIDs on the affected seat being
commanded should momentarily
increase. If no temperature
increase is noted, remove the
cushion blower filter and repeat
the active command while
physically monitoring the
cushion blower for fan
movement.

Do the PID states or cushion blower
movement indicate climate controlled
seat operation?

Yes
CHECK for causes of the intermittent fault. INSPECT
the connectors, terminals and wiring. ATTEMPT to
recreate the fault by flexing the wire harness and
operating the system. CHECK the electrical
connectors for corrosion, poor pin contact or
pushed-out pins. REPAIR any intermittent concerns
found and TIGHTEN any loose HVAC module
connector pins. REPEAT the self-test. CHECK the
If no intermittent concerns are found, CARRY T the
Component Test - Thermo-Electric Device (TED)
Cooling Performance in this section for both seats.
No
INSTALL a new DCSM . REFER to Dual Climate
Controlled Seat Module (DCSM) in this section.
Pinpoint Test W: DTCs B103B and B1111
Normal Operation
The Dual Climate Controlled Seat Module (DCSM) is supplied volta at all times, but the climate controlled
The seat cushion is equipped with a Thermo-Electric Device (TED) assembly that includes a seat blower (fan
motor, serviced as an assembly with the TED ). Similarly, the seat backrest is also equipped with its own TED
assembly with blower. Cabin air is drawn through the blower and distributed to each of the TED modules
located in the seat cushion and backrest. The TEDs then heat or cool the air. The air is then directed into the
foam pad and manifold where it is distributed along the surface of the cushion and backrest of the seat. Once
the system is activated, the DCSM uses a set of flexible algorithms to control the heating/cooling modes and
the blower speed dependant on the HVAC module seat switch settings.
DTC B103B (Thermo-Electric Driver Overcurrent Low) - If DCSM outputs to the driver seat backrest
or cushion TED (circuit pin G, H, J or K at the DCSM connector) or any components within these
circuit loops are shorted to ground or a TED resistance of less than 0.9 ohm is sensed, the DCSM will
shut down the driver seat system and set this DTC.

DTC B1111 (Driver Thermo-Electric Device Control Overtemperature Fault) - If the DCSM TED
driver integrated circuit temperature exceeds 175C (347F), the DCSM will shut down the driver seat
system and set this DTC.

TED assembly
DCSM
PINPOINT TEST W: DTCs B103B AND B1111
W1 CHECK TED CIRCUITS FOR A SHORT TO
GROUND
Ignition OFF.

C313.

Disconnect: DCSM C3305A.
Measure the resistance between DCSM C3305A,

Connector Circuit
C3305A-G CHS02 (YE/BU)
C3305A-H RHS02 (BU/OG)
C3305A-J CHS01 (GY/VT)
C3305A-K RHS01 (WH/VT)
Yes
GO to W2 .
No
If the resistance of C3305A-G, circuit
CHS02 (YE/BU) and/or C3305A-H,
circuit RHS02 (BU/OG) to ground is
not greater than 10,000 ohms, GO to
W6 .
If the resistance of C3305A-J, circuit
CHS01 (GY/VT) and/or C3305A-K,
circuit RHS01 (WH/VT) to ground is
not greater than 10,000 ohms, GO to
W7 .
W2 CHECK TED CIRCUITS FOR A SHORT TO
VOLTAGE
deployment.

414-01 .

Ignition ON.
Measure the voltage between DCSM C3305A, harness
side and ground using the following chart:

Connector Circuit
Yes
If voltage is present at C3305A-G and/or
C3305A-H, GO to W8 .
If voltage is present at C3305A-J and/or
C3305A-K, GO to W9 .
No
GO to W3 .
PINPOINT TEST W: DTCs B103B AND B1111 342
W3 CHECK THE RESISTANCE OF THE TED AND
WIRING
Ignition OFF.
DCSM C3305A-G, circuit CHS02 (YE/BU),
harness side and DCSM C3305A-H, circuit
RHS02 (BU/OG), harness side.

DCSM C3305A-J, circuit CHS01 (GY/VT),
harness side and C3305A-K, circuit RHS01
(WH/VT), harness side.

Are the resistances between 0.9 and 10 ohms?
Yes
INSTALL a new DCSM . REFER to
Dual Climate Controlled Seat Module
(DCSM) in this section. REPEAT the
cable. CONNECT driver seat side air
bag module C327. CONNECT
passenger seat side air bag module
Section 501-20B .
No
If the resistance between DCSM
C3305A-G and C3305A-H is not
between 0.9 and 10 ohms, GO to W5 .
If the resistance between DCSM
C3305A-J and C3305A-K is not
between 0.9 and 10 ohms, GO to W4 .
W4 CHECK THE BACKREST TED RESISTANCE
Disconnect: Backrest TED C3310.
Measure the resistance between backrest TED C3310
pin 1 and pin 3, component side.

Is the resistance between 0.9 and 10 ohms?
Yes
REPAIR circuit CHS01 (GY/VT) or
RHS01 (WH/VT) for an open. REPEAT
Section 501-20B .
No
INSTALL a new backrest TED . REFER
to Seat Backrest Thermo-Electric
Device in this section. REPEAT the
Section 501-20B .
W5 CHECK THE CUSHION TED RESISTANCE
Disconnect: Cushion TED C3300.
Measure the resistance between cushion TED C3300
pin 1 and pin 3, component side.

Yes
REPAIR circuit CHS02 (YE/BU) or
RHS02 (BU/OG) for an open. REPEAT
Section 501-20B .
No
INSTALL a new cushion TED . REFER
to Seat Cushion Thermo-Electric Device
in this section. REPEAT the self-test.
CLEAR the DTCs.
Section 501-20B .
W6 CHECK CUSHION TED CIRCUITS FOR A SHORT
TO GROUND

DCSM C3305A-H, circuit RHS02 (BU/OG),

Yes
CLEAR the DTCs.
Section 501-20B .
No
REPAIR the circuit(s). REPEAT the
Section 501-20B .
W7 CHECK BACKREST TED CIRCUITS FOR A
SHORT TO GROUND

DCSM C3305A-K, circuit RHS01 (WH/VT),

Yes
Section 501-20B .
No
Section 501-20B .
W8 CHECK CUSHION TED CIRCUITS FOR A SHORT
TO VOLTAGE
Ignition ON.

DCSM C3305A-H, circuit RHS02 (BU/OG),

Yes
Section 501-20B .
No
CLEAR the DTCs.
Section 501-20B .
W9 CHECK BACKREST TED CIRCUITS FOR A
SHORT TO VOLTAGE
Ignition ON.

DCSM C3305A-K, circuit RHS01 (WH/VT),

Yes
Section 501-20B .
No
Section 501-20B .
Pinpoint Test X: DTC B103C
Normal Operation
DTC B103C (Thermo-Electric Driver Open Load) - If DCSM outputs to the driver seat backrest or
cushion TED (circuit pins G, H, J or K at the DCSM connector) or any components within these
circuit loops are open, disconnected or a TED resistance greater than 90 kohms is sensed, the DCSM
continues normal operation and sets this DTC.

TED assembly
DCSM
PINPOINT TEST X: DTC B103C
X1 CHECK TED CIRCUITS FOR AN OPEN
Ignition OFF.
(SRS) Depowering and Repowering in the General Procedures

Measure the resistance between DCSM C3305A, harness side
and cushion TED C3300, harness side; and between DCSM
C3305A, harness side and backrest TED C3310, harness side

DCSM Connector Circuit TED Connector
C3305A-G CHS02 (YE/BU) C3300-1
C3305A-H RHS02 (BU/OG) C3300-3
C3305A-J CHS01 (GY/VT) C3310-1
C3305A-K RHS01 (WH/VT) C3310-3
Yes
GO to X2 .
No
REPAIR the circuit(s).
REPEAT the self-test. CLEAR
the DTCs.
driver seat side air bag module
C327. CONNECT passenger
seat side air bag module C313.
REPOWER the SRS . REFER
PINPOINT TEST X: DTC B103C 347
X2 CHECK TED CIRCUITS FOR A SHORT TO VOLTAGE
WARNING: Make sure no one is in the vehicle and there
is nothing blocking or placed in front of any air bag module
when the battery is connected. Failure to follow these
instructions may result in serious personal injury in the

Ignition ON.
Measure the voltage between DCSM C3305A, harness side and
ground using the following chart:

Connector Circuit
Yes
the DTCs.
No
GO to X3 .
X3 CHECK THE BACKREST AND CUSHION TED
RESISTANCE
Ignition OFF.
backrest TED C3310 pin 1 and pin 3, component side.
cushion TED C3310 pin 1 and pin 3, component side.
Yes
the DTCs.
PINPOINT TEST X: DTC B103C 348
No
If backrest TED resistance is
not between 0.9 and 10 ohms,
INSTALL a new backrest
TED . REFER to Seat
Backrest Thermo-Electric
Device in this section.
the DTCs.
If cushion TED resistance is
INSTALL a new cushion TED
. REFER to Seat Cushion
Thermo-Electric Device in this
CLEAR the DTCs.
Pinpoint Test Y: DTC B103D
Normal Operation
DTC B103D (Blower Driver Overtemperature) - If the DCSM outputs to the driver seat blower or any
components within these circuit loops are shorted to ground or cause an excessive current draw, the
DCSM will overheat, shut down the driver seat system and set this DTC.

TED assembly
DCSM
PINPOINT TEST Y: DTC B103D
NOTE: If a seat equipped with a seat mounted side air bag being serviced, the Supplemental Restraint System
(SRS) must be depowered. Refer to Section 501-20B .
Y1 CHECK THE BLOWER MOTOR FEED CIRCUIT
Ignition OFF.

Disconnect: Driver Seat Side Air Bag Module C327.
C313.

Disconnect: DCSM C3305C.
Measure the resistance between DCSM C3305C-16,
circuit CHS03 (GN/BN), harness side and ground.

Yes
GO to Y2 .
No
REPAIR the circuit. REPEAT the self-test.
C327. CONNECT passenger seat side air
bag module C313. REPOWER the SRS .
PINPOINT TEST Y: DTC B103D 350
Y2 CHECK FOR A SHORT BETWEEN THE
BLOWER MOTOR FEED AND GROUND CIRCUITS
circuit RHS03 (GY/OG), harness side and
C3305C-16, circuit CHS03 (GN/BN), harness side.

Yes
GO to Y3 .
No
REPAIR the circuits. REPEAT the
Y3 CHECK THE BACKREST AND CUSHION
BLOWER MOTOR RESISTANCE
NOTE: The ohmmeter must be connected with the
positive lead to pin 2 and the negative lead to pin 4
when measuring. Ohmmeter leads incorrectly
connected will result in false readings and lead to
incorrect identification of components that are not
faulty.

backrest TED C3310 pin 2 and pin 4,
component side.

cushion TED C3300 pin 2 and pin 4,
component side.

Are the resistances between 4,000 and 10,000
ohms?

Yes
INSTALL a new DCSM . REFER to Dual
Climate Controlled Seat Module (DCSM)
CLEAR the DTCs.
No
If cushion TED resistance is not between
4,000 and 10,000 ohms, INSTALL a new
cushion TED . REFER to Seat Cushion
Thermo-Electric Device in this section.
If backrest TED resistance is not between
backrest TED . REFER to Seat Backrest
PINPOINT TEST Y: DTC B103D 351
Pinpoint Test Z: DTCs B1113 and B111B
Normal Operation
DTC B1113 (Passenger Thermo-Electric Device Control Overtemperature Fault) - If the DCSM TED
driver integrated circuit temperature exceeds 175C (347F), the DCSM will shut down the passenger
seat system and set this DTC.

DTC B111B (Passenger Thermo-Electric Driver Overcurrent Low) - If DCSM outputs to the
passenger seat backrest or cus TED (circuit pins A, B, C or D at the DCSM connector) or any
components within these circuit loops are shorted to ground or a TED resistance of less than 0.9 ohm
is sensed, the DCSM will shut down the passenger seat system and set this DTC.

TED assembly
DCSM
PINPOINT TEST Z: DTCs B1113 AND B111B
Z1 CHECK THE TED CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Section 501-20B .

Measure the resistance between DCSM C3305A, harness side and

Connector Circuit
C3305A-A CHS07 (GY/BU)
C3305A-B RHS07 (BU)
C3305A-C CHS06 (BU/BN)
C3305A-D RHS06 (WH)
Yes
GO to Z2 .
No
If the resistance between
C3305A-A and/or
C3305A-B to ground is not
greater than 10,000 ohms,
GO to Z6 .
C3305A-C and/or
C3305A-D to ground is not
greater than 10,000 ohms,
GO to Z7 .
Z2 CHECK THE TED CIRCUITS FOR A SHORT TO VOLTAGE

Ignition ON.

Connector Circuit
Yes
If voltage is present at
C3305A-A and/or
C3305A-B, GO to Z8 .
If voltage is present at
C3305A-C and/or
C3305A-D, GO to Z9 .
No
GO to Z3 .
PINPOINT TEST Z: DTCs B1113 AND B111B 353
C3305A-B RHS07 (BU)
C3305A-D RHS06 (WH)
Z3 CHECK THE RESISTANCE OF THE TED AND WIRING
Ignition OFF.
DCSM C3305A-A, circuit CHS07 (GY/BU), harness side
and DCSM C3305A-B, circuit RHS07 (BU), harness side.

DCSM C3305A-C, circuit CHS06 (BU/BN), harness side
and C3305A-D, circuit RHS06 (WH), harness side.

Yes
CLEAR the DTCs.
the SRS . REFER to
Section 501-20B .
No
DCSM C3305A-A and
C3305A-B is not between
0.9 and 10 ohms, GO to Z5
.
DCSM C3305A-C and
C3305A-D is not between
0.9 and 10 ohms, GO to Z4
.
Z4 CHECK THE BACKREST TED RESISTANCE
Measure the resistance between backrest TED C3311 pin 1 and pin
3, component side.

Yes
REPAIR circuit CHS06
(BU/BN) or RHS06 (WH)
for an open. REPEAT the
self-test. CLEAR the
DTCs.
the SRS . REFER to
Section 501-20B .
No
TED . REFER to Seat
CLEAR the DTCs.
the SRS . REFER to
Section 501-20B .
Z5 CHECK THE CUSHION TED RESISTANCE
Measure the resistance between cushion TED C3303 pin 1 and pin
3, component side.

Yes
REPAIR circuit CHS07
(GY/BU) or RHS07 (BU)
for an open. REPEAT the
self-test. CLEAR the
DTCs.
the SRS . REFER to
Section 501-20B .
No
INSTALL a new cushion
TED . REFER to Seat
Cushion Thermo-Electric
CLEAR the DTCs.
the SRS . REFER to
Section 501-20B .
Z6 CHECK THE CUSHION TED CIRCUITS FOR A SHORT TO
GROUND
and ground.

DCSM C3305A-B, circuit RHS07 (BU), harness side and
ground.

Yes
TED . REFER to Seat
CLEAR the DTCs.
the SRS . REFER to
Section 501-20B .
No
CLEAR the DTCs.
the SRS . REFER to
Section 501-20B .
Z7 CHECK THE BACKREST TED CIRCUITS FOR A SHORT TO
GROUND
and ground.

DCSM C3305A-D, circuit RHS06 (WH), harness side and
ground.

Yes
TED . REFER to Seat
CLEAR the DTCs.
the SRS . REFER to
Section 501-20B .
No
CLEAR the DTCs.
the SRS . REFER to
Section 501-20B .
Z8 CHECK THE CUSHION TED CIRCUITS FOR A SHORT TO
VOLTAGE
Ignition ON.
and ground.

DCSM C3305A-B, circuit RHS07 (BU), harness side and
ground.

Yes
CLEAR the DTCs.
the SRS . REFER to
Section 501-20B .
No
TED . REFER to Seat
CLEAR the DTCs.
the SRS . REFER to
Section 501-20B .
Z9 CHECK THE BACKREST TED CIRCUITS FOR A SHORT TO
VOLTAGE
Ignition ON.
and ground.

DCSM C3305A-D, circuit RHS06 (WH), harness side and
ground.

Yes
CLEAR the DTCs.
the SRS . REFER to
Section 501-20B .
No
TED . REFER to Seat
CLEAR the DTCs.
the SRS . REFER to
Section 501-20B .
Pinpoint Test AA: DTC B111C
Normal Operation
DTC B111C (Passenger Thermo-Electric Driver Open Load) - If DCSM outputs to the passenger seat
backrest or cushion TED (circuit pins A, B, C or D at the DCSM connector) or any components
within these circuit loops are open, disconnected or a TED resistance greater than 90 kohms is sensed,
the DCSM continues normal operation and sets this DTC.

TED assembly
DCSM
PINPOINT TEST AA: DTC B111C
AA1 CHECK THE TED CIRCUITS FOR AN OPEN
Ignition OFF.

Measure the resistance between DCSM C3305A, harness side
and cushion TED C3303, harness side; and between DCSM
C3305A, harness side and backrest TED C3311, harness side

DCSM Connector Circuit TED Connector
C3305A-A CHS07 (GY/BU) C3303-1
C3305A-B RHS07 (BU) C3303-3
C3305A-C CHS06 (BU/BN) C3311-1
C3305A-D RHS06 (WH) C3311-3
Yes
GO to AA2 .
No
the DTCs.
module C313. REPOWER the
SRS . REFER to Section
501-20B .
AA2 CHECK THE TED CIRCUITS FOR A SHORT TO
VOLTAGE

Ignition ON.

Connector Circuit
Yes
the DTCs.
501-20B .
No
GO to AA3 .
PINPOINT TEST AA: DTC B111C 359
C3305A-B RHS07 (BU)
C3305A-D RHS06 (WH)
AA3 CHECK THE BACKREST AND CUSHION TED
RESISTANCE
Ignition OFF.
backrest TED C3311 pin 1 and pin 3, component side.
cushion TED C3311 pin 1 and pin 3, component side.
Yes
the DTCs.
501-20B .
No
If backrest TED resistance is
TED . REFER to Seat
the DTCs.
If cushion TED resistance is
INSTALL a new cushion TED
. REFER to Seat Cushion
CLEAR the DTCs.
PINPOINT TEST AA: DTC B111C 360
501-20B .
Pinpoint Test AB: DTC B111D
Normal Operation
DTC B111D (Passenger Blower Driver Overtemperature) - If the DCSM outputs to the passenger seat
blower or any components within these circuit loops are shorted to ground or cause an excessive
current draw, the DCSM will overheat, shut down the passenger seat system and set this DTC.

TED assembly
DCSM
PINPOINT TEST AB: DTC B111D
AB1 CHECK THE BLOWER MOTOR FEED
CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.

circuit CHS08 (BN/YE), harness side and ground.

Yes
GO to AB2 .
No
AB2 CHECK FOR A SHORT BETWEEN THE
BLOWER MOTOR FEED AND GROUND CIRCUITS
circuit RHS08 (VT/WH), harness side and
C3305C-8, circuit CHS08 (BN/YE), harness side.

Yes
GO to AB3 .
No
AB3 CHECK THE BACKREST CUSHION BLOWER
MOTOR RESISTANCE
NOTE: The ohmmeter must be connected with the
connected will result in false readings and lead to
faulty.

cushion TED C3303 pin 2 and pin 4,
component side.

Yes
Climate Controlled Seat Module (DCSM)
CLEAR the DTCs.
PINPOINT TEST AB: DTC B111D 362
backrest TED C3311 pin 2 and pin 4,
component side.

Are the resistances between 4,000 and 10,000
ohms?

No
If cushion TED resistance is not between
If backrest TED resistance is not between
backrest TED . REFER to Seat Backrest
Pinpoint Test AC: DTC B19A1
Normal Operation
The Dual Climate Controlled Seat Module (DCSM) supplies voltage and ground to the passenger seat cushion
Thermo-Electric Device (TED). The DCSM also sends a speed control voltage signal to the TED to control
blower speed.
DTC B19A1 (Passenger Seat Cushion Blower Speed Short to Battery) - If the passenger seat cushion
blower speed circuit is shorted to voltage, the DCSM will shut down the passenger seat system and set
this DTC.

TED and blower assembly
DCSM
PINPOINT TEST AC: DTC B19A1
NOTE: If a seat equipped with a seat mounted side air bag is being rviced, the Supplemental Restraint
AC1 CHECK THE CUSHION TED BLOWER MOTOR
SPEED CONTROL CIRCUIT FOR A SHORT TO VOLTAGE
Ignition OFF.


Ignition ON.
Measure the voltage between C3305C-3, circuit VHS23

Yes
GO to AC2 .
No
GO to AC3 .
Measure the voltage between DCSM C3305C-3, circuit
VHS23 (BN/BU), harness side and ground.

Yes
cable.
bag module C313.
Section 501-20B .
No
GO to AC3 .
SPEED CONTROL AND BLOWER MOTOR FEED
CIRCUITS FOR A SHORT TOGETHER
PINPOINT TEST AC: DTC B19A1 364
Ignition OFF.
Measure the resistance between DCSM C3305C-3, circuit
VHS23 (BN/BU), harness side and C3305C-8, circuit
CHS08 (BN/YE), harness side.

Yes
GO to AC4 .
No
cable.
bag module C313.
Section 501-20B .
AC4 CHECK THE CUSHION TED RESISTANCE FOR AN
INTERNAL SHORT
Measure the resistance between cushion TED C3303 pin 2
and pin 7, component side.

Is the resistance greater than 2,000,000 ohms?
Yes
INSTALL a new DCSM . REFER
to Dual Climate Controlled Seat
Module (DCSM) in this section.
DTCs.
cable.
bag module C313.
Section 501-20B .
No
INSTALL a new cushion TED .
REFER to Seat Cushion
CLEAR the DTCs.
Section 501-20B .
Pinpoint Test AD: DTC B19A2
PINPOINT TEST AC: DTC B19A1 365
Normal Operation
The Dual Climate Controlled Seat Module (DCSM) supplies voltage and ground to the passenger seat
backrest Thermo-Electric Device (TED). The DCSM also sends a speed control voltage signal to the TED to
control blower speed.
DTC B19A2 (Passenger Seat Back Blower Speed Short to Battery) - If the passenger seat backrest
blower speed circuit is shorted to voltage, the DCSM will shut down the passenger seat system and set
this DTC.

DCSM
PINPOINT TEST AD: DTC B19A2
AD1 CHECK THE BACKREST TED BLOWER MOTOR
Ignition OFF.


Ignition ON.
(BU/WH), harness side and ground.

Yes
GO to AD2 .
No
GO to AD3 .
VHS21 (BU/WH), harness side and ground.

Yes
cable.
bag module C313.
Section 501-20B .
No
GO to AD3 .
Ignition OFF.
VHS21 (BU/WH), harness side and C3305C-8, circuit
CHS08 (BN/YE), harness side.

Yes
GO to AD4 .
No
cable.
bag module C313.
Section 501-20B .
AD4 CHECK THE BACKREST TED RESISTANCE FOR
AN INTERNAL SHORT
PINPOINT TEST AD: DTC B19A2 367
Measure the resistance between backrest TED C3311 pin 2

Yes
DTCs.
cable.
bag module C313.
Section 501-20B .
No
INSTALL a new backrest TED .
REFER to Seat Backrest
CLEAR the DTCs.
Section 501-20B .
Pinpoint Test AE: DTC B19A3
Normal Operation
The Dual Climate Controlled Seat Module (DCSM) supplies voltage and ground to the driver seat cushion
blower speed.
DTC B19A3 (Driver Seat Cushion Blower Speed Short to Battery) - If the driver seat cushion blower
speed circuit is shorted to voltage, the DCSM will shut down the driver seat system and set this DTC.

DCSM
PINPOINT TEST AE: DTC B19A3
AE1 CHECK THE CUSHION TED BLOWER MOTOR
Ignition OFF.


Ignition ON.

Yes
GO to AE2 .
No
GO to AE3 .
PINPOINT TEST AE: DTC B19A3 369

Yes
cable.
CONNECT driver seat side air bag
module C327 and passenger seat
Section 501-20B .
No
GO to AE3 .
Ignition OFF.
VHS18 (BN/GN), harness side and C3305C-16, circuit
CHS03 (GN/BN), harness side.

Yes
GO to AE4 .
No
cable.
Section 501-20B .
AE4 CHECK THE CUSHION TED RESISTANCE FOR AN
INTERNAL SHORT
Measure the resistance between cushion TED C3300 pin 2

Yes
DTCs.
cable.
Section 501-20B .
PINPOINT TEST AE: DTC B19A3 370
No
CLEAR the DTCs.
Section 501-20B .
Pinpoint Test AF: DTC B19A4
Normal Operation
The Dual Climate Controlled Seat Module (DCSM) supplies voltage and ground to the driver seat backrest
blower speed.
DTC B19A4 (Driver Seat Back Blower Speed Short to Battery) - If the driver seat backrest blower
speed circuit is shorted to voltage, the DCSM will shut down the driver seat system and set this DTC.

DCSM
PINPOINT TEST AF: DTC B19A4
and the ignitn switch is ON. This is normal operation and does not indicate an SRS fault.
AF1 CHECK THE BACKREST TED BLOWER MOTOR
Ignition OFF.


Ignition ON.

Yes
GO to AF2 .
No
GO to AF3 .

Yes
cable.
Section 501-20B .
No
GO to AF3 .
PINPOINT TEST AF: DTC B19A4 372
Ignition OFF.
VHS16 (BU/GN), harness side and C3305c-16, circuit
CHS03 (GN/BN), harness side.

Yes
GO to AF4 .
No
cable.
Section 501-20B .
AF4 CHECK THE BACKREST TED RESISTANCE FOR
AN INTERNAL SHORT
Measure the resistance between backrest TED C3310 pin 2

Yes
DTCs.
cable.
Section 501-20B .
No
INSTALL a new backrest TED .
REFER to Seat Backrest
CLEAR the DTCs.
Section 501-20B .
Pinpoint Test AG: DTC B19A5
PINPOINT TEST AF: DTC B19A4 373
Normal Operation
The Dual Climate Controlled Seat Module (DCSM) supplies voltage and ground to the passenger seat cushion
blower speed.
DTC B19A5 (Passenger Seat Cushion Blower Speed Short to Ground) - If the passenger seat cushion
blower speed circuit is shted to ground, the DCSM will shut down the passenger seat system and set
this DTC.

DCSM
PINPOINT TEST AG: DTC B19A5
AG1 CHECK THE CUSHION TED BLOWER
MOTOR SPEED CONTROL CIRCUIT FOR A
SHORT TO GROUND
Ignition OFF.

circuit VHS23 (BN/BU), harness side and ground.

Yes
GO to AG2 .
No
CLEAR the DTCs.
module C313.
501-20B .
AG2 CHECK THE CUSHION TED BLOWER
MOTOR SPEED CONTROL AND BLOWER MOTOR
GROUND CIRCUITS FOR A SHORT TOGETHER
circuit VHS23 (BN/BU), harness side and
C3305C-7, circuit RHS08 (VT/WH), harness side.

Yes
INSTALL a new cushion TED . REFER to
Seat Cushion Thermo-Electric Device in
this section. REPEAT the self-test. CLEAR
the DTCs.
module C313.
501-20B .
No
REPAIR the circuits. REPEAT the self-test.
CLEAR the DTCs.
module C313.
501-20B .
Pinpoint Test AH: DTC B19A6
Normal Operation
The Dual Climate Controlled Seat Module (DCSM) supplies voltage and ground to the passenger seat
backrest Thermo-Electric Device (TED). The DCSM also sends a speed control voltage signal to the TED to
control blower speed.
DTC B19A6 (Passenger Seat Back Blower Speed Short to Ground) - If the passenger seat backrest
blower speed circuit is shorted to ground, the DCSM will shut down the passenger seat system and set
this DTC.

PINPOINT TEST AG: DTC B19A5 375
DCSM
PINPOINT TEST AH: DTC B19A6
AH1 CHECK THE BACKREST TED BLOWER
SPEED CONTROL CIRCUIT FOR A SHORT TO
GROUND
Ignition OFF.

circuit VHS21 (BU/WH), harness side and ground.

Yes
GO to AH2 .
No
CLEAR the DTCs.
module C313.
501-20B .
AH2 CHECK THE BACKREST TED BLOWER
circuit VHS21 (BU/WH), harness side and
C3305C-7, circuit RHS08 (VT/WH), harness side.

Yes
INSTALL a new backrest TED . REFER to
Seat Backrest Thermo-Electric Device in
the DTCs.
module C313.
501-20B .
No
CLEAR the DTCs.
module C313.
501-20B .
Pinpoint Test AI: DTC B19A7
Normal Operation
The Dual Climate Controlled Seat Module (DCSM) supplies voltage and ground to the driver seat cushion
blower speed.
DTC B19A7 (Driver Seat Cushion Blower Speed Short to Ground) - If the driver seat cushion blower
speed circuit is shorted to ground, the DCSM will shut down the driver seat system and set this DTC.

DCSM
PINPOINT TEST AI: DTC B19A7
Diagnostic Trouble Codes (DTCsand system failure. Touching the tip of these connector pins is
PINPOINT TEST AH: DTC B19A6 377
AI1 CHECK THE CUSHION TED BLOWER MOTOR
SPEED CONTROL CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.

VHS18 (BN/GN), harness side and ground.

Yes
GO to AI2 .
No
module C327.
bag module C313.
Section 501-20B .
AI2 CHECK THE CUSHION TED BLOWER MOTOR
SPEED CONTROL AND BLOWER MOTOR GROUND
VHS18 (BN/GN), harness side and C3305C-15, circuit
RHS03 (GY/OG), harness side.

Yes
CLEAR the DTCs.
cable.
module C327.
bag module C313.
Section 501-20B .
PINPOINT TEST AI: DTC B19A7 378
No
module C327.
bag module C313.
Section 501-20B .
Pinpoint Test AJ: DTC B19A8
Normal Operation
The Dual Climate Controlled Seat Module (DCSM) supplies voltage and ground to the driver seat backrest
blower speed.
DTC B19A8 (Driver Seat Back Blower Speed Short to Ground) - If the driver seat backrest blower
speed circuit is shorted to ground, the DCSM will shut down the driver seat system and set this DTC.

DCSM
PINPOINT TEST AJ: DTC B19A8
AJ1 CHECK THE BACKREST TED BLOWER
MOTOR SPEED CONTROL CIRCUIT FOR A
SHORT TO GROUND
Ignition OFF.

Measure the resistance between DCSM
C3305C-12, circuit VHS16 (BU/GN), harness side
and ground.

Yes
GO to AJ2 .
No
CLEAR the DTCs.
C327.
module C313.
501-20B .
AJ2 CHECK THE BACKREST TED BLOWER
C3305C-12, circuit VHS16 (BU/GN), harness side
and C3305C-15, circuit RHS03 (GY/OG), harness
side.

Yes
Seat Backrest Thermo-Electric Device in
the DTCs.
C327.
module C313.
501-20B .
No
CLEAR the DTCs.
C327.
PINPOINT TEST AJ: DTC B19A8 380
module C313.
501-20B .
Pinpoint Test AK: DTC B2486
Normal Operation
The Dual Climate Controlled Seat Module (DCSM) monitors the input voltage for correct operation. If the
DCSM detects input voltage below 10 volts or above 15 volts, it will store DTC B2486 in memory. If DTC
B2486 is set, the DCSM enters a standby mode and suspends the system outputs for the operation of both
seats until system voltage between 10 and 15 volts is restored and a climate controlled seat switch button is
selected on.
DTC B2486 (Climate Control Seat Module Voltage Out of Range) - If the DCSM detects voltage
below 10 volts or greater than 15 volts, the DTC is set.

DCSM
PINPOINT TEST AK: DTC B2486
NOTE: DTC B1676 can be set if the vehicle has been recently jump started, the battery has been recently
charged or the battery has been discharged. The battery may become discharged due to excessive load(s) on
the charging system from aftermarket accessories or if the battery has been left unattended with the
accessories on.
AK1 RETRIEVE ALL CMDTCs IN ALL MODULES
Ignition ON.
Yes
REFER to Section 414-00 to diagnose
the charging system.
Self Test - ALL CMDTCs .

Is DTC B2486 or B1676 present in one or more
modules AND P0563, P0620, P0625, P0626 or
P065B retrieved from the PCM?

No
GO to AK2 .
AK2 CHECK THE BATTERY CONDITION
NOTE: DTC B1676 can be set if the vehicle has been
recently jump started, the battery has been recently
charged or the battery has been discharged. The battery
may become discharged due to excessive load(s) on
the charging system from aftermarket accessories or if
the battery has been left unattended with the
accessories on.
Ignition OFF.
Carry out the Battery Condition Test. Refer to Section
414-01 .

Did the battery pass the condition test?
Yes
If the battery passed the condition test,
but required a recharge, REFER to
Section 414-00 to diagnose the charging
system. CLEAR all Continuous Memory
Diagnostic Trouble Codes (CMDTCs).
If the battery passed the condition test
and did not require a recharge, GO to
AK3 .
No
INSTALL a new battery. CLEAR all
CMDTCs . TEST the system for normal
operation.
AK3 CHECK THE CHARGING SYSTEM VOLTAGE
NOTE: Do not allow the engine speed to increase
above 2,000 rpm while performing this step or the
generator may self excite and result in default charging
system output voltage. If engine speed goes above
2,000 rpm, shut the vehicle OFF and restart the engine
before performing this step.
Start the engine.
Measure voltage of the battery with and without a load
on the charging system as follows:

Turn off all accessories and run the engine at
1,500 rpm for a minimum of 2 minutes while
measuring battery voltage.

Turn on headlights and HVAC fan on high and
run engine at 1,500 rpm for a minimum of 2
minutes while measuring battery voltage.

Are the voltages between 13 and 15.2 volts?
Yes
GO to AK4 .
No
REFER to Section 414-00 to diagnose
the charging system. CLEAR all
operation.
AK4 CHECK VOLTAGE TO THE DCSM
PINPOINT TEST AK: DTC B2486 382
Ignition OFF.

deployment.

414-01 .

Ignition ON.
DCSM C3305A-E, circuit SBB12 (GN/RD),

DCSM C3305A-F, circuit SBB12 (GN/RD),

Yes
GO to AK5 .
No
VERIFY BJB fuse 12 (30A) is OK. If
OK, REPAIR the circuit in question. If
manual to identify possible causes of the
circuit short. CLEAR all CMDTCs .
cable. CONNECT passenger seat side
air bag module C313. REPOWER the
SRS . REFER to Section 501-20B .
AK5 CHECK THE DCSM GROUND CIRCUIT FOR AN
OPEN
Ignition OFF.
Measure the resistance between DCSM C3305A-M,
circuit GD139 (BK/YE), harness side and ground.

Repeat this measurement while wiggling the harness.
Yes
GO to AK6 .
No
REPAIR the circuit. CLEAR all
CMDTCs . REPEAT the self-test.
AK6 CHECK FOR CORRECT DCSM OPERATION
Check the harness and component side connectors for
the following:

corrosion.
damaged pins.
Yes
(DCSM) in this section. CLEAR all
CMDTCs . REPEAT the self-test.
PINPOINT TEST AK: DTC B2486 383
pushed-out pins.
Connect: DCSM C3305A.
Make sure the DCSM connector is seated correctly.
Start the engine.
Operate the climate controlled seats and verify system
operation.

Self Test - DCSM .

Is DTC B1317 or B1318 still present?
No
time. The concern may have been caused
by a loose or corroded connector.
CLEAR all CMDTCs . REPEAT the
self-test.
Pinpoint Test AL: DTC B2729
Normal Operation
The Dual Climate Controlled Seat Module (DCSM) monitors seat cushion temperature while it supplies
voltage and ground to both blower motors. The DCSM also supplies a variable voltage signal to control the
blower speed. Cabin air enters the blower through a filter attached to the Thermo-Electric Device (TED)
housing. Conditioned air exits the TED and flows through a manifold attached to the foam pad.
DTC B2729 (Cushion Over-Temp Detected) - In the heating mode, if the driver seat cushion TED
temperature exceeds 85C (185F) for more than 34 seconds, the TED is disconnected or the duct is
blocked, the DCSM will shut down the driver seat system and set this DTC.

DTC B2729 (Cushion Over-Temp Detected) - In the cooling mode, if the driver seat cushion TED
temperature exceeds 70C (158F) for more than 34 seconds, the TED is disconnected or the duct is
blocked, the DCSM will shut down the driver seat system and set this DTC.

Restricted cushion TED filter
Crushed or restricted climate controlled seat manifold
Cushion TED assembly
PINPOINT TEST AL: DTC B2729
Diagnostic Trouble Codes (DTCs) and systeilure. Touching the tip of these connector pins is
NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is
removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before
releasing the vehicle to the customer.
AL1 CHECK THE DCSM FOR ON-DEMAND DTCs
Start the vehicle and set the driver seat to HIGH heat.
Self Test - DCSM .

Was DTC B2729 retrieved on-demand during the
self-test?

Yes
GO to AL2 .
No
GO to AL5 .
AL2 CHECK THE DRIVER SEAT CUSHION TED
THERMISTOR CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.

Disconnect: Driver Seat Side Air Bag C327 and
Passenger Seat Side Air Bag C313.

Disconnect: DCSM C3305B.
Disconnect: Driver Seat Cushion TED C3300.
deployment.

414-01 .

DCSM C3305B-7, circuit VHS26 (VT), harness
side and ground.

DCSM C3305B-8, circuit RHS05 (YE/VT),

Yes
GO to AL3 .
No
REPAIR the circuit(s). CLEAR the
DTCs. REPEAT the self-test.
bag module C327 and passenger seat
Section 501-20B .
THERMISTOR AND WIRING
PINPOINT TEST AL: DTC B2729 385
Connect: Driver Seat Cushion TED C3300.
Measure the resistance between DCSM C3305B-7,
circuit VHS26 (VT), harness side and DCSM
C3305B-8, circuit RHS05 (YE/VT), harness side. Note
the ambient temperature and refer to the following table.

Temperature Resistance
0-10C (32-50F) 2,782-1,663 ohms
10-20C (50-68F) 1,837-1,140 ohms
20-30C (68-86F) 1,260-806 ohms
893-570 ohms
40-50C (104-122F) 630-428 ohms
Is the resistance within the limits indicated?
Yes
GO to AL18 .
No
GO to AL4 .
THERMISTOR
Measure the resistance between driver seat cushion TED
C3300 pin 5 and pin 8, component side. Note the
ambient temperature and refer to the following table.

0-10C (32-50F) 2,782-1,663 ohms
10-20C (50-68F) 1,837-1,140 ohms
20-30C (68-86F) 1,260-806 ohms
30-40C (86-104F) 893-570 ohms
40-50C (104-122F) 630-428 ohms
Yes
REPAIR circuit VHS26 (VT) or
RHS05 (YE/VT) for an open or high
resistance. CLEAR the DTCs.
Section 501-20B .
No
INSTALL a new driver seat cushion
TED . REFER to Seat Cushion
CLEAR the DTCs. REPEAT the
self-test.
Section 501-20B .
AL5 CONFIRM THE FAULT WHILE MONITORING
THE DCSM SEAT BACK THERMAL ELECTRIC
DEVICE TEMPERATURE (BK_TEMP) AND SEAT
CUSHION THERMAL ELECTRIC DEVICE
TEMPERATURE (CSHTEMP) PIDs
Set the driver seat to OFF.
Clear DTCs - DCSM .

DataLogger - DCSM .

Monitor the DCSM PIDs BK_TEMP and CSHTEMP.
NOTE: A crushed seat cushion foam pad or a crushed
climate controlled seat manifold may be the cause of the
fault making it necessary to occupy the seat to recreate
and identify the fault.

Attempt to recreate the fault. Start the vehicle and set
the driver seat to HIGH heat for at least 15 minutes
while occupying the seat.

Do the PIDs increase incrementally (gradually) and
stay within 15C (27F) of each other?

Yes
Fault not present at this time. Fault
may have been set due to a past failure,
incorrect use of the climate controlled
seat system by repeated switching
between heat and cool modes or due to
excessive passenger compartment
temperature. CLEAR the DTCs.
No
If the CSHTEMP PID increases
incrementally and is greater than 15C
(27F) of the BK_TEMP PID, GO to
AL6 .
If the CSHTEMP PID increases
quickly (temperature "jumps" and does
not increase incrementally) and is
greater than 15C (27F) of the
BK_TEMP PID, GO to AL16 .
AL6 COMPARE OPERATION OF THE DRIVER AND
PASSENGER SEATS
With the engine running, set both front seats to HIGH
cool.

Note the airflow exhausting from the driver seat cushion
TED and compare it to the airflow exhausting from the
passenger seat cushion TED .

Carry out a wiggle test of the wire harnesses between
the DCSM and the driver seat cushion TED while
monitoring blower operation of the TED . The blower
should operate consistently and not change speeds

Is the airflow exhausting from the driver seat
cushion TED comparable to the airflow exhausting
from the passenger seat cushion TED with no change
in operation when carrying out the wiggle test?

Yes
GO to AL7 .
No
If the airflow exhausting from the
driver seat cushion TED is not
comparable to the airflow exhausting
from the passenger seat cushion TED ,
GO to AL8 .
If the driver seat cushion TED blower
operation changed while carrying out
the wiggle test, IDENTIFY and
REPAIR the wiring fault. CLEAR the
AL7 COMPARE OPERATION OF THE DRIVER AND
PASSENGER SEATS WHILE OCCUPIED
Note the airflow exhausting from the driver seat cushion
TED with the driver seat occupied and compare it to the
airflow exhausting from the passenger seat cushion TED
with the passenger seat occupied.

from the passenger seat cushion TED ?

Yes
GO to AL16 .
No
foam pad and/or climate controlled seat
manifold. CLEAR the DTCs. REPEAT
the self-test.
AL8 CHECK THE DRIVER SEAT CUSHION BLOWER
FOR AN OBSTRUCTION OR RESTRICTED FILTER
Ignition OFF.
Inspect the blower of the driver seat cushion TED
assembly for an obstruction or for a restricted filter.

Is the blower obstructed or the filter restricted?
Yes
REMOVE the obstruction or
INSTALL a new filter. CLEAR the
No
GO to AL9 .
SPEED CONTROL CIRCUIT FOR AN OPEN


deployment.

414-01 .

circuit VHS18 (BN/GN), harness side and driver seat
cushion TED C3300-7, circuit VHS18 (BN/GN),
harness side.

Yes
GO to AL10 .
No
REPAIR the circuit. CLEAR the
Section 501-20B .
Ignition ON.
Measure the voltage between DCSM C3305C-15,
circuit RHS03 (GY/OG), harness side and ground.

Yes
Section 501-20B .
No
GO to AL11 .
Ignition OFF.

Yes
GO to AL12 .
No
Section 501-20B .
CIRCUITS FOR AN OPEN
DCSM C3305C-16, circuit CHS03 (GN/BN),
harness side and driver seat cushion TED
C3300-2, circuit CHS03 (GN/BN), harness side.

DCSM C3305C-15, circuit RHS03 (GY/OG),
harness side and driver seat cushion TED
C3300-4, circuit RHS03 (GY/OG), harness side.

Yes
GO to AL13 .
No
Section 501-20B .
RESISTANCE
NOTICE: The ohmmeter must be connected with the
connected results in false readings and leads to
damaged.

C3300 pin 2 and pin 4, component side.

Is the resistance between 4,000 ohms and 10,000
ohms?

Yes
GO to AL14 .
No
self-test.
Section 501-20B .
SPEED CONTROL RESISTANCE
damaged.


Is the resistance between 240K ohms and 400K
ohms?

Yes
GO to AL15 .
No
self-test.
Section 501-20B .
INSTALLATION AND FOR CRUSHED SEAT CUSHION
Ignition OFF.
Remove the driver seat. Refer to Seat - Front in this
section.

Remove the driver seat cushion cover. Refer to Seat

Inspect the driver seat cushion for the following:
Is the driver seat cushion TED correctly
installed?

Yes
INSTALL the driver seat cushion
cover and seat and GO to AL18 .
No
CORRECTLY install the driver seat
cushion TED or INSTALL a new
driver seat cushion foam pad and/or
climate controlled seat manifold.
Is the driver seat cushion seat cushion foam pad
crushed or restricted?

Is the driver seat cushion climate controlled seat
manifold crushed or restricted?

Is the driver seat cushion TED correctly installed
and are there no signs of damage to the foam pad
and manifold?

CONNECT the battery ground cable.
REFER to Section 414-01 . CLEAR
the DTCs. REPEAT the self-test.
Section 501-20B .
Ignition OFF.


deployment.

414-01 .

circuit VHS26 (VT), harness side and C3305B-8 circuit
RHS05 (YE/VT), harness side. Note the ambient
temperature and refer to the following table.

0-10C (32-50F) 2,782-1,663 ohms
10-20C (50-68F) 1,837-1,140 ohms
20-30C (68-86F) 1,260-806 ohms
30-40C (86-104F) 893-570 ohms
40-50C (104-122F) 630-428 ohms
Yes
GO to AL18 .
No
GO to AL17 .
THERMISTOR
C3300 pin 5 and pin 8, component side. Note the

0-10C (32-50F) 2,782-1,663 ohms
10-20C (50-68F) 1,837-1,140 ohms
20-30C (68-86F) 1,260-806 ohms
893-570 ohms
40-50C (104-122F) 630-428 ohms
Yes
REPAIR circuit VHS26 (VT) or
RHS05 (YE/VT) for an open or high
Section 501-20B .
No
INSTALL a new TED . REFER to Seat
Cushion Thermo-Electric Device in
this section. CLEAR the DTCs. AT the
self-test.
Section 501-20B .
HEATING/COOLING CIRCUITRY CURRENT DRAW
Connect: All DCSM , TED and body harness-to-seat
harness connectors.

NOTICE: It may be necessary to open the seat wire
harness conduit to allow placing the inductive
current probe around the circuit as described in the
following step. Care must be taken when opening up
the wire harness so as not to damage any wiring or
connectors. Do not damage any wiring or induce
stress on any wiring or connectors. Close up the wire
harness once repairs to the seat are complete.

NOTE: Use a commercially available inductive current
probe (such as Electronic Specialties Current
Probe/Multimeter 685 or a Fluke I410 [used with a
digital multimeter]) or the low current probe from the
Vehicle Measurement Module available for use with
Integrated Diagnostic System (IDS). If these are
unavailable, the inductive current probe feature from a
battery tester may be substituted.

Place an inductive current probe around circuit CHS02
(YE/BU) near DCSM C3305A-G and monitor the

Yes
GO to AL19 .
No
self-test.
Section 501-20B .
current draw.
Is the current draw less than 11 amps?
AL19 CHECK RESISTANCE OF THE DRIVER SEAT
CUSHION TED AND WIRING
Ignition OFF.
Measure the resistance between DCSM C3305A-G
circuit CHS02 (YE/BU), harness side and C3305A-H,
circuit RHS02 (BU/OG), harness side.

Yes
GO to AL21 .
No
GO to AL20 .
AL20 CHECK THE RESISTANCE OF THE DRIVER
SEAT CUSHION TED

Yes
REPAIR circuit CHS02 (YE/BU) or
RHS02 (BU/OG) for an open or high
Section 501-20B .
No
self-test.
Section 501-20B .
AL21 CHECK FOR CORRECT DCSM OPERATION
Inspect the DCSM and driver seat cushion TED harness
and component side connectors and the body
harness-to-seat harness connectors for:

corrosion
damaged pins
pushed-out pins
Connect: All DCSM , TED and Body Harness-to-Seat
Harness Connectors.

Make sure the connectors are seated correctly.
Start the engine.
Clear DTCs - DCSM .

Attempt to recreate the fault. With the engine still
running set the driver seat to HIGH heat for at least 15
minutes.

Yes
self-test. TEST the system for normal
operation.
Section 501-20B .
No
The system is operating correctly at
this time. The concern may have been
caused by a loose or corroded
connector.
Section 501-20B .
Pinpoint Test AM: DTC B272A
Normal Operation
The Dual Climate Controlled Seat Module (DCSM) monitors seat cushion temperature while it supplies
DTC B272A (Passenger Cushion Over-Temp Detected) - In the cooling mode, if the passenger seat
cushion TED temperature exceeds 70C (158F) for more than 34 seconds, the TED is disconnected
or the duct is blocked, the DCSM will shut down the passenger seat system and set this DTC.

DTC B272A (Passenger Cushion Over-Temp Detected) - In the heating mode, if the passenger seat
cushion TED temperature exceeds 85C (185F) for more than 34 seconds, the TED is disconnected

Restricted cushion TED filter
Cushion TED assembly
PINPOINT TEST AM: DTC B272A
removed and tgnition is ON.
AM1 CHECK THE DCSM FOR ON-DEMAND DTCs
Start the vehicle and set the passenger seat to HIGH
heat.

Self Test - DCSM .

Was DTC B272A retrieved on-demand during the
self-test?

Yes
GO to AM2 .
No
GO to AM5 .
AM2 CHECK THE PASSENGER SEAT CUSHION TED
Ignition OFF.

Disconnect: Passenger Seat Cushion TED C3303.
deployment.

414-01 .

DCSM C3305B-2, circuit VHS27 (WH/OG),

DCSM C3305B-3, circuit RHS10 (BU/OG),

Yes
GO to AM3 .
No
air bag module C313.
Section 501-20B .
PINPOINT TEST AM: DTC B272A 395
Connect: Passenger Seat Cushion TED C3303.
circuit VHS27 (WH/OG), harness side and DCSM
C3305B-3, circuit RHS10 (BU/OG), harness side. Note

0-10C (32-50F) 2,782-1,663 ohms
10-20C (50-68F) 1,837-1,140 ohms
20-30C (68-86F) 1,260-806 ohms
30-40C (86-104F) 893-570 ohms
40-50C (104-122F) 630-428 ohms
Yes
GO to AM18 .
No
GO to AM4 .
THERMISTOR
Measure the resistance between passenger seat cushion
TED C3303 pin 5 and pin 8, component side. Note the

0-10C (32-50F) 2,782-1,663 ohms
10-20C (50-68F) 1,837-1,140 ohms
20-30C (68-86F) 1,260-806 ohms
Yes
REPAIR circuit VHS27 (WH/OG) or
Section 501-20B .
No
30-40C (86-104F) 893-570 ohms
40-50C (104-122F) 630-428 ohms
INSTALL a new passenger seat
self-test.
Section 501-20B .
AM5 CONFIRM THE FAULT WHILE MONITORING
DEVICE TEMPERATURE (PBKTEMP) AND SEAT
TEMPERATURE (PCSHTEMP) PIDs
Set the passenger seat to OFF.
Clear DTCs - DCSM .

DataLogger - DCSM .

Monitor the DCSM PIDs PBKTEMP and PCSHTEMP.
NOTE: A crushed seat cushion foam pad or a crushed

Attempt to recreate the fault. Start the vehicle and set
the passenger seat to HIGH heat for at least 15 minutes
while occupying the seat.


Yes
excessive passenger compartment
No
If the PCSHTEMP PID increases
(27F) of the PBKTEMP PID, GO to
AM6 .
If the PCSHTEMP PID increases
PBKTEMP PID, GO to AM16 .
cool.

Note the airflow exhausting from the passenger seat
cushion TED and compare it to the airflow exhausting
from the driver seat cushion TED .

the DCSM and the passenger seat cushion TED while

Is the airflow exhausting from the passenger seat
from the driver seat cushion TED with no change in

Yes
GO to AM7 .
No
passenger seat cushion TED is not
from the driver seat cushion TED , GO
to AM8 .
If the passenger seat cushion TED
blower operation changed while
carrying out the wiggle test,
operation when carrying out the wiggle test? IDENTIFY and REPAIR the wiring
fault. CLEAR the DTCs. REPEAT the
self-test.
AM7 COMPARE OPERATION OF THE DRIVER AND
cushion TED with the passenger seat occupied and
compare it to the airflow exhausting from the driver seat
cushion TED with the driver seat occupied.

Is the airflow exhausting from the passenger seat
from the driver seat cushion TED ?

Yes
GO to AM16 .
No
cushion foam pad and/or climate
controlled seat manifold. CLEAR the
AM8 CHECK THE PASSENGER SEAT CUSHION
BLOWER FOR AN OBSTRUCTION OR RESTRICTED
FILTER
Ignition OFF.
Inspect the blower of the passenger seat cushion TED

Yes
No
GO to AM9 .
BLOWER SPEED CONTROL CIRCUIT FOR AN OPEN

Disconnect: DCSM 3305C.
deployment.

414-01 .

circuit VHS23 (BN/BU), harness side and passenger
seat cushion TED C3303-7, circuit VHS23 (BN/BU),
harness side.

Yes
GO to AM10 .
No
Section 501-20B .
BLOWER CIRCUIT FOR A SHORT TO VOLTAGE
Ignition ON.
RHS08 (VT/WH), harness side and ground.

Yes
Section 501-20B .
No
GO to AM11 .
BLOWER CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
circuit CHS08 (BN/YE), harness side and ground.

Yes
GO to AM12 .
No
Section 501-20B .
BLOWER CIRCUITS FOR AN OPEN
DCSM C3305C-8, circuit CHS08 (BN/YE),
harness side and passenger seat cushion TED
C3303-2, circuit CHS08 (BN/YE), harness side.

DCSM C3305C-7, circuit RHS08 (VT/WH),
harness side and passenger seat cushion TED
C3303-4, circuit RHS08 (VT/WH), harness
side.

Yes
GO to AM13 .
No
Section 501-20B .
BLOWER RESISTANCE
damaged.

TED C3303 pin 2 and pin 4, component side.

ohms?

Yes
GO to AM14 .
No
self-test.
Section 501-20B .
BLOWER SPEED CONTROL RESISTANCE
damaged.


Yes
GO to AM15 .
No
self-test.
Section 501-20B .
ohms?

INSTALLATION AND FOR CRUSHED SEAT CUSHION
Ignition OFF.
Remove the passenger seat. Refer to Seat - Front in this
section.

Remove the passenger seat cushion cover. Refer to Seat

Inspect the passenger seat cushion for the following:
Is the passenger seat cushion TED correctly
installed?

Is the passenger seat cushion seat cushion foam
pad crushed or restricted?

Is the passenger seat cushion climate controlled
seat manifold crushed or restricted?

Is the passenger seat cushion TED correctly installed
and are there no signs of damage to foam pad and
manifold?

Yes
INSTALL the passenger seat cushion
cover and seat and GO to AM18 .
No
CORRECTLY install the passenger
seat cushion TED or INSTALL a new
passenger seat cushion foam pad
and/or climate controlled seat
manifold. CONNECT the battery
ground cable. REFER to Section
414-01 . CLEAR the DTCs. REPEAT
the self-test.
Section 501-20B .
Ignition OFF.

deployment.

414-01 .

circuit VHS27 (WH/OG), harness side and C3305B-3
circuit RHS10 (BU/OG), harness side. Note the ambient

0-10C (32-50F) 2,782-1,663 ohms
10-20C (50-68F) 1,837-1,140 ohms
Yes
GO to AM18 .
No
GO to AM17 .
20-30C (68-86F) 1,260-806 ohms
30-40C (86-104F) 893-570 ohms
40-50C (104-122F) 630-428 ohms
THERMISTOR

0-10C (32-50F) 2,782-1,663 ohms
10-20C (50-68F) 1,837-1,140 ohms
20-30C (68-86F) 1,260-806 ohms
30-40C (86-104F) 893-570 ohms
40-50C (104-122F) 630-428 ohms
Is the resisin the limits indicated?
Yes
REPAIR circuit VHS27 (WH/OG) or
Section 501-20B .
No
INSTALL a new TED . REFER to Seat
Cushion Thermo-Electric Device in
this section. CLEAR the DTCs.
Section 501-20B .
Harness Connectors.


Yes
GO to AM19 .
No
self-test.

(GY/BU) near DCSM C3305A-A and monitor the
current draw.

Start the vehicle and set the passenger seat to HIGH
heat.

Section 501-20B .
AM19 CHECK RESISTANCE OF THE PASSENGER
SEAT CUSHION TED AND WIRING
Ignition OFF.
Disconnect: DCSM 3305A.
Measure the resistance between DCSM C3305A-A
circuit CHS07 (GY/BU), harness side and C3305A-B,
circuit RHS07 (BU), harness side.

Yes
GO to AM21 .
No
GO to AM20 .
AM20 CHECK THE RESISTANCE OF THE
PASSENGER SEAT CUSHION TED

Yes
REPAIR circuit CHS07 (GY/BU) or
RHS07 (BU) for an open or high
Section 501-20B .
No
self-test.
Section 501-20B .
AM21 CHECK FOR CORRECT DCSM OPERATION
Inspect the DCSM and passenger seat cushion TED
harness and component side connectors and the body

corrosion
damaged pins
pushed-out pins
Harness Connectors.

Start the engine.
Clear DTCs - DCSM .

running set the passenger seat to HIGH heat for at least
15 minutes.

Yes
operation.
Section 501-20B .
No
connector.
Section 501-20B .
Pinpoint Test AN: DTC B272B
Normal Operation
The Dual Climate Controlled Seat Module (DCSM) monitors seat backrest temperature while it supplies
DTC B272B (Passenger Back Over-Temp Detected) - In the cooling mode, if the passenger seat
backrest TED temperature exceeds 70C (158F) for more than 34 seconds, the TED is disconnected

DTC B272B (Passenger Back Over-Temp Detected) - In the heating mode, if the passenger seat
backrest TED temperature exceeds 85C (185F) for more than 34 seconds, the TED is disconnected
or the duct is blocked, the DCSM will shut down the passenger seat system and set this DTC. This
pinpoint test is intended to diagnose the following:

Restricted backrest TED filter
Backrest TED assembly
PINPOINT TEST AN: DTC B272B
AN1 CHECK THE DCSM FOR ON-DEMAND
DTCs
Start the vehicle and set the passenger seat to
HIGH heat.

tool: Self Test - DCSM .

Was DTC B272B retrieved on-demand during
the self-test?

Yes
GO to AN2 .
No
GO to AN5 .
AN2 CHECK THE PASSENGER SEAT
BACKREST TED THERMISTOR CIRCUITS FOR A
SHORT TO GROUND
Ignition OFF.
Section 501-20B .

Disconnect: Passenger Seat Backrest TED C3311.

Yes
GO to AN3 .
No
REPAIR the circuit(s). CLEAR the DTCs.
module C313.
501-20B .
PINPOINT TEST AN: DTC B272B 405
deployment.
Section 414-01 .

DCSM C3305B-4, circuit VHS36

DCSM C3305B-5, circuit RHS20

BACKREST TED THERMISTOR AND WIRING
Connect: Passenger Seat Backrest TED C3311.
C3305B-4, circuit VHS36 (YE/BU), harness side
and DCSM C3305B-5, circuit RHS20 (GN/BU),
harness side. Note the ambient temperature and
refer to the following table.

0-10C (32-50F) 2,782-1,663 ohms
10-20C (50-68F) 1,837-1,140 ohms
20-30C (68-86F) 1,260-806 ohms
30-40C (86-104F) 893-570 ohms
40-50C (104-122F) 630-428 ohms
Yes
GO to AN18 .
No
GO to AN4 .
BACKREST TED THERMISTOR
backrest TED C3311 pin 5 and pin 8, component
side. Note the ambient temperature and refer to
the following table.

0-10C (32-50F) 2,782-1,663 ohms
10-20C (50-68F) 1,837-1,140 ohms
20-30C (68-86F) 1,260-806 ohms
30-40C (86-104F) 893-570 ohms
40-50C (104-122F) 630-428 ohms
Yes
REPAIR circuit VHS36 (YE/BU) or RHS20
(GN/BU) for an open or high resistance.
CLEAR the DTCs. REPEAT the self-test.
module C313.
501-20B .
No
TED . REFER to Seat Backrest
module C313.
501-20B .
AN5 CONFIRM THE FAULT WHILE
MONITORING THE DCSM SEAT BACK
THERMAL ELECTRIC DEVICE TEMPERATURE
(PBKTEMP) AND SEAT CUSHION THERMAL
ELECTRIC DEVICE TEMPERATURE
(PCSHTEMP) PIDs
tool: Clear DTCs - DCSM .

tool: DataLogger - DCSM .

Monitor the DCSM PIDs PBKTEMP and
PCSHTEMP.

NOTE: A crushed seat backrest foam pad or a
crushed climate controlled seat manifold may be
the cause of the fault making it necessary to
occupy the seat to recreate and identify the fault.

Attempt to recreate the fault. Start the vehicle and
set the passenger seat to HIGH heat for at least 15
minutes while occupying the seat.

Do the PIDs increase incrementally (gradually)
and stay within 15C (27F) of each other?

Yes
Fault not present at this time. Fault mahave
been set due to a past failure, incorrect use of
the climate controlled seat system by
repeated switching between heat and cool
modes or due to excessive passenger
compartment temperature. CLEAR the
No
If the PBKTEMP PID increases
incrementally and is greater than 15C (27F)
of the PCSHTEMP PID, GO to AN6 .
If the PBKTEMP PID increases quickly
(temperature "jumps" and does not increase
incrementally) and is greater than 15C
(27F) of the PCSHTEMP PID, GO to AN16
.
AN6 COMPARE OPERATION OF THE DRIVER
AND PASSENGER SEATS
With the engine running, set both front seats to
HIGH cool.

Note the airflow exhausting from the passenger
seat backrest TED and compare it to the airflow
exhausting from the driver seat backrest TED .

Carry out a wiggle test of the wire harnesses
between the DCSM and the passenger seat
backrest TED while monitoring blower operation
of the TED . The blower should operate
consistently and not change speeds

Is the airflow exhausting from the passenger
seat backrest TED comparable to the airflow
exhausting from the driver seat backrest TED
with no change in operation when carrying out
the wiggle test?

Yes
GO to AN7 .
No
If the airflow exhausting from the passenger
seat backrest TED is not comparable to the
airflow exhausting from the driver seat
backrest TED , GO to AN8 .
If the passenger seat backrest TED blower
operation changed while carrying out the
wiggle test, IDENTIFY and REPAIR the
wiring fault. CLEAR the DTCs. REPEAT the
self-test.
AN7 COMPARE OPERATION OF THE DRIVER
AND PASSENGER SEATS WHILE OCCUPIED
Note the airflow exhausting from the passenger
seat backrest TED with the passenger seat
occupied and compare it to the airflow exhausting
from the driver seat backrest TED with the driver
seat occupied.

Is the airflow exhausting from the passenger
seat backrest TED comparable to the airflow
exhausting from the driver seat backrest TED
?

Yes
GO to AN16 .
No
foam pad and/or climate controlled seat
manifold. CLEAR the DTCs. REPEAT the
self-test.
BACKREST BLOWER FOR AN OBSTRUCTION
OR RESTRICTED FILTER
Ignition OFF.
Inspect the blower of the passenger seat backrest
TED assembly for an obstruction or for a
restricted filter.

Is the blower obstructed or the filter
restricted?

Yes
REMOVE the obstruction or INSTALL a
new filter. CLEAR the DTCs. REPEAT the
self-test.
No
GO to AN9 .
BACKREST BLOWER SPEED CONTROL
CIRCUIT FOR AN OPEN
Section 501-20B .


Yes
GO to AN10 .
No
REPAIR the circuit. CLEAR the DTCs.
module C313.
501-20B .
deployment.
Section 414-01 .

C3305C-4, circuit VHS21 (BU/WH), harness side
and passenger seat backrest TED C3311-7, circuit
VHS21 (BU/WH), harness side.

BACKREST BLOWER CIRCUIT FOR A SHORT
TO VOLTAGE
Ignition ON.
Measure the voltage between DCSM C3305C-7,
circuit RHS08 (VT/WH), harness side and
ground.

Yes
module C313.
501-20B .
No
GO to AN11 .
BACKREST BLOWER CIRCUIT FOR A SHORT
TO GROUND
Ignition OFF.
C3305C-8, circuit CHS08 (BN/YE), harness side
and ground.

Yes
GO to AN12 .
No
module C313.
501-20B .
BACKREST BLOWER CIRCUITS FOR AN OPEN
DCSM C3305C-8, circuit CHS08
(BN/YE), harness side and passenger seat
backrest TED C3311-2, circuit CHS08
(BN/YE), harness side.

DCSM C3305C-7, circuit RHS08
(VT/WH), harness side and passenger
seat backrest TED C3311-4, circuit
RHS08 (VT/WH), harness side.

Yes
GO to AN13 .
No
REPAIR the circuit(s). CLEAR the DTCs.
module C313.
501-20B .
BACKREST BLOWER RESISTANCE
NOTICE: The ohmmeter must be connected
with the positive lead to pin 2 and the negative
lead to pin 4 when measuring. Ohmmeter leads
incorrectly connected results in false readings
and leads to incorrect identification of
components that are not damaged.

side.

Is the resistance between 4,000 ohms and
10,000 ohms?

Yes
GO to AN14 .
No
module C313.
501-20B .
BACKREST BLOWER SPEED CONTROL
RESISTANCE
NOTICE: The ohmmeter must be connected
with the positive lead to pin 7 and the negative
lead to pin 4 when measuring. Ohmmeter leads
incorrectly connected results in false readings
and leads to incorrect identification of
components that are not damaged.

side.

ohms?

Yes
GO to AN15 .
No
module C313.
501-20B .
BACKREST TED INSTALLATION AND FOR
CRUSHED SEAT BACKREST
Ignition OFF.
Remove the passenger seat. Refer to Seat - Front
in this section.

Remove the passenger seat backrest cover. Refer
to Seat Backrest Cover - Front in this section.

Inspect the passenger seat backrest for the
following:

Is the passenger seat backrest TED
correctly installed?

Is the passenger seat backrest foam pad

Is the passenger seat backrest climate
controlled seat manifold crushed or
restricted?

Is the passenger seat backrest TED correctly
installed and are there no signs of damage to
the foam pad and manifold?

Yes
INSTALL the passenger seat backrest cover
and seat and GO to AN18 .
No
CORRECTLY install the passenger seat
backrest TED or INSTALL a new passenger
seat backrest foam pad and/or climate
controlled seat manifold. CONNECT the
battery nd cable. REFER to Section 414-01 .
module C313.
501-20B .
BACKREST TED THERMISTOR AND WIRING
Ignition OFF.
Section 501-20B .

1,260-806 ohms
deployment.

Section 414-01 .

C3305B-4, circuit VHS36 (YE/BU), harness side
and C3305B-5 circuit RHS20 (GN/BU), harness
side. Note the ambient temperature and refer to
the following table.

0-10C (32-50F) 2,782-1,663
ohms
10-20C (50-68F) 1,837-1,140
ohms
30-40C (86-104F) 893-570 ohms
40-50C (104-122F) 630-428 ohms
Yes
GO to AN18 .
No
GO to AN17 . AN17 CHECK THE PASSENGER SEAT BACKREST TED THERMISTOR
Measure the resistance between passenger seat backrest TED C3315 and pin 8, component side. Note

0-10C (32-50F) 2,782-1,663 ohms
10-20C (50-68F) 1,837-1,140 ohms
20-30C (68-86F) 1,260-806 ohms
30-40C (86-104F) 893-570 ohms
40-50C (104-122F) 630-428 ohms
Yes
REPAIR circuit VHS36 (YE/BU) or RHS20 (GN/BU) for an open or high resistance. CLEAR the DTCs.
DISCONNECT the battery ground cable. CONNECT passenger seat side air bag module C313.
No
INSTALL a new TED . REFER to Seat Backrest Thermo-Electric Device in this section. CLEAR the DTCs.
REPOWER the SRS . REFER to Section 501-20B . AN18 CHECK THE PASSENGER SEAT
BACKREST TED HEATING/COOLING CIRCUITRY CURRENT DRAW
Connect: All DCSM , TED and Body Harness-to-Seat Harness Connectors.
NOTICE: It may be necessary to open the seat wire harness conduit to allow placing the
inductive current probe around the circuit as described in the following step. Care must be
taken when opening up the wire harness so as not to damage any wiring or connectors. Do not
damage any wiring or induce stress on any wiring or connectors. Close up the wire harness once
repairs to the seat are complete.

NOTE: Use a commercially available inductive current probe (such as Electronic Specialties Current
Probe/Multimeter 685 or a Fluke I410 [used with a digital multimeter]) or the low current probe from
the Vehicle Measurement Module available for use with Integrated Diagnostic System (IDS). If these
are unavailable, the inductive current probe feature from a battery tester may be substituted.

Place an inductive current probe around circuit CHS06 (BU/BN) near DCSM C3305A-C and monitor
the current draw.

Start the vehicle and set the passenger seat to HIGH heat.
Yes
GO to AN19 .
No
INSTALL a new passenger seat backrest TED . REFER to Seat Backrest Thermo-Electric Device in this
section. CLEAR the DTCs. REPEAT the self-test.
REPOWER the SRS . REFER to Section 501-20B . AN19 CHECK RESISTANCE OF THE
PASSENGER SEAT BACKREST TED AND WIRING
Ignition OFF.
Measure the resistance between DCSM C3305A-C circuit CHS06 (BU/BN), harness side and
C3305A-D, circuit RHS06 (WH), harness side.

Yes
GO to AN21 .
No
GO to AN20 . AN20 CHECK THE RESISTANCE OF THE PASSENGER SEAT BACKREST TED
Measure the resistance between passenger seat backrest TED C3311 pin 1 and pin 3, component side.
Yes
REPAIR circuit CHS06 (BU/BN) or RHS06 (WH) for an open or high resistance. CLEAR the DTCs.
No
INSTALL a new passenger seat backrest TED . REFER to Seat Backrest Thermo-Electric Device in this
REPOWER the SRS . REFER to Section 501-20B . AN21 CHECK FOR CORRECT DCSM
OPERATION
Inspect the DCSM and passenger seat backrest TED harness and component side connectors and the
body harness-to-seat harness connectors for:

corrosion
damaged pins
pushed-out pins
Connect: All DCSM , TED and Body Harness-to-Seat Harness Connectors.
Start the engine.
Enter the following diagnostic mode on the scan tool: Clear DTCs - DCSM .
Attempt to recreate the fault. With the engine still running set the passenger seat to HIGH heat for at
least 15 minutes.

Yes
INSTALL a new DCSM . REFER to Dual Climate Controlled Seat Module (DCSM) in this section. REPEAT
the self-test. TEST the system for normal operation.
No
The system is operating correctly at this time. The concern may have been caused by a loose or corroded
connector.
Pinpoint Test AO: DTC B272C
Normal Operation
commanding a heat or cool mode operation in this manner, the climate controlled seat system only operates in
15-second intervals. Both voltage supply circuits are spliced together internal to the DCSM , so if one circuit
becomes open, both seats can still be operated. However, if a fault occurs setting a DTC specific to either
climate controlled seat, only the affected seat is disabled by the DCSM .
A differential fault occurs when the cushion and backrest TEDs on an affected seat are reporting very
different temperatures to the DCSM . This may result from an airflow restriction or a circuit fault of either
TED area. If a TED and manifold is clear of obstruction and is operational, the other TED and circuitry on the
seat should be checked. It is important to note that a TED with a higher temperature may be operating
correctly and not the area of concern. The other TED may be indicating a much lower temperature, causing
the DTC to set.
DTC B272C (Driver Differential Temperature Fault) - If there is a temperature differential between
the driver backrest and cushion TED of 60C (108F) or more for more than 4 seconds, the TED is
disconnected or the duct is blocked, this DTC will set. When this happens the first time in a key cycle,
the DCSM puts the driver seat system into recovery mode (see principles of operation). If the system
is able to recover, it will function nory. If the system is able to recover and it occurs a second time in
the same key cycle, the DCSM will shut down the driver seat system.

Restricted cushion or backrest TED filter
Crushed or restricted cushion or backrest foam pad
Crushed or restricted cushion or backrest climate controlled seat manifold
Cushion or backrest TED assembly
DCSM
PINPOINT TEST AO: DTC B272C
AO1 CHECK FOR DCSM DTCs
scan tool: Self Test - DCSM .

Was DTC B2729 or B2730 retrieved?
Yes
For DTC B2729, GO to Pinpoint Test AL . For
DTC B2730, GO to Pinpoint Test AS .
No
GO to AO2 .
AO2 MONITOR THE TED TEMPERATURE
PIDs
scan tool: DataLogger - DCSM - PIDs.

Yes
GO to AO3 .
PINPOINT TEST AO: DTC B272C 416
Passenger Cushion Thermal Electric
Device (TED) Temperature
(PCSHTMP)

Passenger Back TED Temperature
(PBKTMP)

Seat cushion thermal electric device
temperature (CSHTEMP)

Seat back thermal electric device
temperature (BK_TEMP)

NOTE: Make sure the temperature of the
climate controlled seats has stabilized before
monitoring the PIDs. Not allowing stabilization
can cause incorrect readings and lead to
incorrect identification of components that are
not faulty.

Monitor TED temperature PIDs with the
climate controlled seats OFF. Compare the PID
values of the driver seat to those of the front
passenger seat, this can help identify if there is
a concern with the driver seat cushir backrest
PID value readings.

Are both driver seat TED temperature PIDs
within 10C (18F) of the ambient
temperature?

No
If the driver seat cushion PID varies 10C
(18F) or more from ambient temperature, GO
to AO16 .
If the driver seat backrest PID varies 10C
(18F) or more from ambient temperature, GO
to AO32 .
AO3 CONFIRM THE FAULT IS IN THE SEAT
CUSHION OR THE BACKREST
Ignition OFF.
Ignition ON.
NOTE: A crushed seat cushion foam pad or a
crushed climate controlled seat manifold may
be the cause of the fault. It may be necessary to
sit on the seat or place something of reasonable
size and weight on the seat to recreate the fault.

NOTE: If at shuts down before a 15-minute
heat cycle has timed-out, carry out the DCSM
self-test and go to the Dual Climate Controlled
Seat Module (DCSM) DTC Chart to continue
diagnostics.

After cycling the ignition and with the engine
running, set the driver seat to high heat (3
indicators illuminated on HVAC module).
Allow the seat to heat for at least 15 minutes
while monitoring the TED temperature PIDs of
the driver seat. If necessary, when the seat
times-out after 15 minutes, set the driver seat to
high heat once again.

Do the driver seat cushion TED and
backrest TED PIDs vary more than 60C
(108F) from each other?

Yes
If the driver seat cushion PID is 60C (108F)
hotter than the backrest PID, GO to AO5 .
If the driver seat backrest PID is 60C (108F)
hotter than the cushion PID, GO to AO20 .
No
GO to AO4 .
AO4 CHECK THE TEDs COOLING
PERFORMANCE
Check the TEDs cooling performance on the
affected seat. Refer to Component Test -
Thermo-Electric Device (TED) Cooling
Performance in this section.

Did the TEDs pass the component test?
Yes
The DTC may have been set by extreme cabin
temperatures or excessive sunload on the seat
causing the system to enter recovery mode.
Occupant size and weight characteristics can
also be a factor. CLEAR the DTCs. REPEAT
the self-test. TEST the system for normal
operation. If a concern cannot be found or
duplicated, RETURN the vehicle to the
customer.
No
CHECK the affected seat cushion or backrest
for correct installation of the climate controlled
seat components ( TED , manifold, plenum, air
ducts and foam pad). CHECK for airflow
restrictions ( TED inlets and outlets, TED
-to-manifold or plenum connections, filters and
ducts) and REPAIR as needed. CHECK for an
intermittent wiring fault. REPAIR as needed.
AO5 CHECK FOR CORRECT TED
INSTALLATION AND FOR CRUSHED FOAM
Ignition OFF.
Remove the seat. Refer to Seat - Front in this
section.

Remove the seat cushion trim cover. Refer to
Seat Cushion Cover - Front in this section.

Inspect the seat cushion for the following:
Is the cushion blower obstructed?
Is the blower filter restricted or
plugged?

Is the TED correctly installed?
Is the seat cushion foam pad crushed or
restricted?

Is the climate controlled seat manifold crushed
or restricted?

Is the TED correctly installed and the foam pad
and manifold OK?

Yes
GO to AO6 .
No
CORRECTLY install the cushion TED or
INSTALL a new seat cushion foam pad and/or
climate controlled seat manifold. REPEAT the
501-20B .
AO6 CHECK THE BACKREST TED GROUND
Ignition OFF.
Position the driver seat in the vehicle and
connect the seat-to-floor connectors.

Disconnect: Driver Seat Side Air Bag Module
C327.

Module C313.

Yes
CLEAR the DTCs.
C327. CONNECT passenger seat side air bag
module C313. REPOWER the SRS . REFER to
Section 501-20B .
vehicle and there is nothing blocking or
placed in front of any air bag module when
the battery is connected. Failure to follow
these instructions may result in serious
personal injury in the event of an accidental
deployment.

Section 414-01 .

Ignition ON.
Measure the voltage between DCSM
C3305A-K, circuit RHS01 (WH/VT), harness
side and ground.

No
GO to AO7 .
AO7 CHECK THE BACKREST TED FEED
Ignition OFF.
C3305A-J, circuit CHS01 (GY/VT), harness
side and ground.

Yes
GO to AO8 .
No
CLEAR the DTCs.
Section 501-20B .
AO8 CHECK THE RESISTANCE OF THE
BACKREST TED AND WIRING
C3305A-J, circuit CHS01 (GY/VT), harness
side and DCSM C3305A-K, circuit RHS01

Yes
GO to AO10 .
No
GO to AO9 .
BACKREST TED
Measure the resistance between backrest TED

Yes
REPAIR circuit CHS01 (GY/VT) or RHS01
(WH/VT) for an open. REPEAT the self-test.
CLEAR the DTCs.
Section 501-20B .
No
INSTALL a new backrest TED . REFER to Seat
Backrest Thermo-Electric Device in this
section. REPEAT the self-test. CLEAR the
DTCs.
Section 501-20B .
AO10 CHECK THE BLOWER MOTOR FEED
AND SPEED CONTROL CIRCUITS FOR A
SHORT TO VOLTAGE
Ignition ON.

DCSM C3305C-11, circuit VHS18

Yes
GO to AO11 .
No
REPAIR the circuit(s). REPEAT the self-test.
CLEAR the DTCs.
Section 501-20B .
SHORT TO GROUND
Ignition OFF.


ohms?

Yes
GO to AO12 .
No
CLEAR the DTCs.
Section 501-20B .
AO12 CHECK THE BLOWER MOTOR AND
WIRING
NOTE: The ohmmeter must be connected with
the positive lead to DCSM C3305C-16, circuit
CHS03 (GN/BN) and the negative lead to
DCSM C3305C-15, circuit RHS03 (GY/OG)
connected will result in false readings and lead
to incorrect identification of components that
are not faulty.

C3305C-16, circuit CHS03 (GN/BN), harness
side and DCSM C3305C-15, circuit RHS03
(GY/OG), harness side.

Is the resistance between 4,000 and 10,000
ohms?

Yes
GO to AO14 .
No
GO to AO13 .
AO13 CHECK THE BLOWER MOTOR
RESISTANCE
the positive lead to pin 2 and the negative lead
to pin 4 when measuring. Ohmmeter leads
incorrectly connected will result in false
readings and lead to incorrect identification of
components that are not faulty.

Measure the resistance between cushion TED

ohms?

Yes
CLEAR the DTCs.
Section 501-20B .
No
INSTALL a new cushion TED . REFER to Seat
Cushion Thermo-Electric Device in this section.
Section 501-20B .
AO14 CHECK THE BLOWER MOTOR SPEED
CONTROL AND CIRCUIT RESISTANCE
the positive lead to C3305C-11, circuit VHS18
(BN/GN), harness side and the negative lead to
C3305C-15, circuit RHS03 (GY/OG), harness
side when measuring. Ohmmeter leads

C3305C-11, circuit VHS18 (BN/GN), harness

Is the resistance between 240 kohms and 4
megohms?

Yes
GO to AO16 .
No
GO to AO15 .
CONTROL RESISTANCE


megohms?

Yes
CLEAR the DTCs.
Section 501-20B .
No
Section 501-20B .
AO16 CHECK THE THERMISTOR FEED
Ignition OFF.
Repowering in the General Procedures portion
of Section 501-20B .

C327.

Module C313.

deployment.

Section 414-01 .

Ignition ON.
C3305B-7, circuit VHS26 (VT), harness side
and ground.

Yes
CLEAR the DTCs.
Section 501-20B .
No
GO to AO17 .
Ignition OFF.
and ground.

Yes
GO to AO18 .
No
CLEAR the DTCs.
Section 501-20B .
AO18 CHECK THE TED THERMISTOR AND
WIRING RESISTANCE AT THE DCSM
and DCSM C3305B-8, circuit RHS05
(YE/VT), harness side. Note the ambient
temperature and compare result to the
following table:

0-10C (32-50F) 2,782-1,663 ohms
10-20C (50-68F) 1,837-1,140 ohms
20-30C (68-86F) 1,260-806 ohms
30-40C (86-104F) 893-570 ohms
40-50C (104-122F) 630-428 ohms
Yes
Climate Controlled Seat Module (DCSM) in
this section. REPEAT the self-test. CLEAR the
DTCs.
Section 501-20B .
No
GO to AO19 .
AO19 CHECK THE TED THERMISTOR
RESISTANCE
pin 5 and pin 8, component side. Note the
ambient temperature and compare result to the
following table:

0-10C (32-50F) 2,782-1,663 ohms
10-20C (50-68F) 1,837-1,140 ohms
20-30C (68-86F) 1,260-806 ohms
30-40C (86-104F) 893-570 ohms
40-50C (104-122F) 630-428 ohms
Yes
CLEAR the DTCs.
No
Section 501-20B .
AO20 CHECK FOR CORRECT TED
INSTALLATION AND FOR CRUSHED FOAM
Ignition OFF.
Remove the seat. Refer to Seat - Front in this
section.

Remove the seat backrest trim cover. Refer to
Seat Backrest - Front in this section.

Inspect the seat backrest for the following:
Is the backrest blower obstructed?
Is the blower filter restricted or
plugged?

Is the TED correctly installed?
Is the seat backrest foam pad crushed
or restricted?

Yes
GO to AO21 .
No
CORRECTLY install the backrest TED or
INSTALL a new seat backrest foam pad and/or
climate controlled seat manifold. REPEAT the
501-20B .
Is the climate controlled seat manifold

Is the TED correctly installed and the foam
pad and manifold OK?

AO21 CHECK THE CUSHION TED GROUND
Ignition OFF.
Position the driver seat in the vehicle and
connect the seat-to-floor connectors.


Module C313.

deployment.

Section 414-01 .

Ignition ON.
C3305A-H, circuit RHS02 (BU/OG), harness
side and ground.

Yes
CLEAR the DTCs.
Section 501-20B .
No
GO to AO22 .
AO22 CHECK THE CUSHION TED FEED
Ignition OFF.
C3305A-G, circuit CHS02 (YE/BU), harness
side and ground.

Yes
GO to AO23 .
No
CLEAR the DTCs.
Section 501-20B .
CUSHION TED AND WIRING
C3305A-G circuit CHS02 (YE/BU), harness
side and DCSM C3305A-H, circuit RHS02

Yes
GO to AO25 .
No
GO to AO24 .
AO24 CHECK THE CUSHION TED
RESISTANCE

Yes
REPAIR circuit CHS02 (YE/BU) or RHS02
(BU/OG) for an open. REPEAT the self-test.
CLEAR the DTCs.
Section 501-20B .
No
Section 501-20B .
SHORT TO VOLTAGE
Ignition ON.


Yes
CLEAR the DTCs.
Section 501-20B .
No
GO to AO26 .
SPEED CONTROL FEED CIRCUITS FOR A
SHORT TO GROUND
Ignition OFF.


ohms?

Yes
GO to AO27 .
No
CLEAR the DTCs.
Section 501-20B .
WIRING RESISTANCE
the positive lead to DCSM C3305C-16, circuit
CHS03 (GN/BN) and the negative lead to
DCSM C3305C-15, circuit RHS03 (GY/OG)
connected will result in false readings and lead
to incorrect identification of components that
are not faulty.

C3305C-16, circuit CHS03 (GN/BN), harness

Yes
GO to AO29 .
No
GO to AO28 .
ohms?

AO28 CHECK THE BLOWER MOTOR
RESISTANCE


ohms?

Yes
CLEAR the DTCs.
Section 501-20B .
No
DTCs.
Section 501-20B .
CONTROL AND CIRCUIT RESISTANCE
the positive lead to C3305C-12, circuit VHS16
(BU/GN), harness side and the negative lead to
C3305C-15, circuit RHS03 (GY/OG), harness
side when measuring. Ohmmeter leads

C3305C-12, circuit VHS16 (BU/GN), harness

Yes
GO to AO31 .
No
GO to AO30 .
megohms?

CONTROL RESISTANCE


megohms?

Yes
CLEAR the DTCs.
Section 501-20B .
No
DTCs.
Section 501-20B .
Ignition ON.
C3305B-9, circuit VHS35 (VT/OG), harness
side and ground.

Yes
CLEAR the DTCs.
Section 501-20B .
No
GO to AO32 .
Ignition OFF.

C327.

Module C313.

side and ground.

Yes
GO to AO33 .
No
CLEAR the DTCs.
Section 501-20B .
AO33 CHECK THE TED THERMISTOR AND
WIRING RESISTANCE
side and DCSM C3305B-10, circuit RHS15
(GY/BN), harness side. Note the ambient
temperature and compare result to the
following table:

0-10C (32-50F) 2,782-1,663 ohms
10-20C (50-68F) 1,837-1,140 ohms
20-30C (68-86F) 1,260-806 ohms
30-40C (86-104F) 893-570 ohms
40-50C (104-122F) 630-428 ohms
Yes
Climate Controlled Seat Module (DCSM) in
this section. REPEAT the self-test. CLEAR the
Section 501-20B .
No
GO to AO34 .
AO34 CHECK THE TED THERMISTOR
RESISTANCE
pin 5 and pin 8, component side. Note the
ambient temperature and compare result to the
following table:

0-10C (32-50F) 2,782-1,663 ohms
10-20C (50-68F) 1,837-1,140 ohms
20-30C (68-86F) 1,260-806 ohms
30-40C (86-104F) 893-570 ohms
40-50C (104-122F) 630-428 ohms
Yes
CLEAR the DTCs.
Section 501-20B .
No
Pinpoint Test AP: DTC B272D
Normal Operation
commanding a heat or cool mode operation in this manner, the climate controlled seat system only operates in
15-second intervals. Both voltage supply circuits are spliced together internal to the DCSM , so if one circuit
becomes open, both seats can still be operated. However, if a fault occurs setting a DTC specific to either
climate controlled seat, only the affected seat is disabled by the DCSM .
A differential fault occurs when the cushion and backrest TEDs on an affected seat are reporting very
different temperatures to the DCSM . This may result from an airflow restriction or a circuit fault of either
TED area. If a TED and manifold is clear of obstruction and is operational, the other TED and circuitry on the
seat should be checked. It is important to note that a TED with a higher temperature may be operating
correctly and not the area of concern. The other TED may be indicating a much lower temperature, causing
the DTC to set.
DTC B272D (Passenger Differential Temperature Fault) - If there is a temperature differential
between the passenger backrest and cushion TED of 60C (108F) or more for more than 4 seconds,
the TED is disconnected or the duct is blocked, this DTC will set. When this happens the first time in
a key cycle, the DCSM puts the passenger seat system into recovery mode (see Principles of
Operation). If the system is able to recover, it will function normally. If the system is able to recover
and it occurs a second time in the same key cycle, the DCSM will shut down the passenger seat
system.

Restricted cushion or backrest TED filter
Crushed or restricted cushion or backrest foam pad
Crushed or restricted cushion or backrest climate controlled seat manifold
Cushion or backrest TED assembly
DCSM
PINPOINT TEST AP: DTC B272D
AP1 CHECK THE DCSM FOR
DTCs
mode on the scan tool: Self Test
- DCSM .

Was DTC B272A or B272B
retrieved?

Yes
For DTC B272A, GO to Pinpoint Test AM . For DTC B272B,
GO to Pinpoint Test AN .
No
GO to AP2 .
AP2 MONITOR THE TED
TEMPERATURE PIDs
PINPOINT TEST AP: DTC B272D 433
l>
Enter the following diagnostic mode
on the scan tool: DataLogger - DCSM
- PIDs.

Passenger cushion thermal
electric device (TED)
temperature (PCSHTMP)

Passenger back TED temperature
(PBKTMP)

Seat cushion thermal electric
device temperature (CSHTEMP)

Seat back thermal electric device
temperature (BK_TEMP)

NOTE: Make sure the temperature of
the climate controlled seats has
stabilized before monitoring the PIDs.
Not allowing stabilization can cause
incorrect readings and lead to incorrect
identification of components that are
not faulty.

Monitor the TED temperature PIDs
with the climate controlled seats OFF.
Compare the PIDs of the front
passenger seat to those of the driver
seat, this can help identify if there is a
concern with the front passenger seat
cushion or backrest PID readings.

Are both front passenger seat TED
temperature PIDs within 10C
(18F) of the ambient temperature?

Yes
GO to AP3 .
No
If the front passenger seat cushion PID varies 10C (18F) or
more from ambient temperature, GO to AP16 .
If the front passenger seat backrest PID varies 10C (18F) or
more from ambient temperature, GO to AP32 .
AP3 CONFIRM THE FAULT IS IN
THE SEAT CUSHION OR
BACKREST TED
Ignition OFF.
Ignition ON.
NOTE: A crushed seat cushion
foam pad or a crushed climate
controlled seat manifold may be
the cause of the fault. It may be
necessary to sit on the seat or
place something of reasonable
size and weight on the seat to
recreate the fault.

NOTE: If the seat shuts down
before a 15-minute heat cycle
has timed-out, carry out the
DCSM self-test and go to the
Dual Climate Controlled Seat
Module (DCSM) DTC Chart to
continue diagnostics.

Yes
If the front passenger seat cushion PID is 60C (108F) hotter
than the backrest PID, GO to AP5 .
If the front passenger seat backrest PID is 60C (108F) hotter
than the cushion PID, GO to AP20 .
No
GO to AP4 .
After cycling the ignition and
with the engine running, set the
driver seat to high heat (3
indicators illuminated on HVAC
module). Allow the seat to heat
for at least 15 minutes while
monitoring the TED temperature
PIDs of the driver seat. If
necessary, when the seat
times-out after 15 minutes, set
the driver seat to high heat once
again.

Do the driver seat cushion
TED and backrest TED PIDs
vary more than 60C (108F)
from each other?

AP4 CHECK THE TEDs COOLING
PERFORMANCE
Check TEDs cooling
performance on the affected seat.
Refer to Component Test -
Thermo-Electric Device (TED)
Cooling Performance in this
section.

Did the TEDs pass the
component test?

Yes
The DTC may have been set by extreme cabin temperatures or
excessive sunload on the seat causing the system to enter
recovery mode. Occupant size and weight characteristics can
also be a factor. CLEAR the DTCs. REPEAT the self-test.
TEST the system for normal operation. If a concern cannot be
found or duplicated, RETURN the vehicle to the customer.
No
CHECK the affected seat cushion or backrest for correct
installation of the climate controlled seat components ( TED ,
manifold, plenum, air ducts and foam pad). CHECK for
airflow restrictions ( TED inlets and outlets, TED -to-manifold
or plenum connections, filters and ducts) and REPAIR as
needed. CHECK for an intermittent wiring fault. REPAIR as
needed. REPEAT the self-test. CLEAR the DTCs.
AP5 CHECK FOR CORRECT TED
INSTALLATION AND FOR
CRUSHED FOAM
Ignition OFF.
Remove the seat. Refer to Seat -
Front in this section.

Remove the seat cushion trim
cover. Refer to Seat Cushion
Cover - Front in this section.

Inspect the seat cushion for the
following:

Is the cushion blower
obstructed?

Is the blower filter
restricted or plugged?

Is the TED correctly
installed?

Yes
GO to AP6 .
No
Correctly INSTALL the cushion TED or INSTALL a new seat
cushion foam pad and/or climate controlled seat manifold.
DISCONNECT the battery ground cable. REPOWER the SRS
. REFER to Section 501-20B .
Is the seat cushion foam
pad crushed or
restricted?

Is the climate controlled
seat manifold crushed or
restricted?

Is the TED correctly installed
and the foam pad and manifold
OK?

AP6 CHECK THE BACKREST TED
GROUND CIRCUIT FOR A SHORT
TO VOLTAGE
Ignition OFF.
Position the front passenger seat
in the vehicle and connect the
seat-to-floor connectors.

501-20B .

Disconnect: Passenger Seat Side
Air Bag C313.

WARNING: Make sure no
one is in the vehicle and there
is nothing blocking or placed in
front of any air bag module
when the battery is connected.
Failure to follow these
instructions may result in
serious personal injury in the
event of an accidental
deployment.

cable. Refer to Section 414-01 .

Ignition ON.
DCSM C3305A-D, circuit
RHS06 (WH), harness side and
ground.

Yes
DISCONNECT the battery ground cable. CONNECT
passenger seat side air bag module C313. REPOWER the SRS
No
GO to AP7 .
AP7 CHECK THE BACKREST TED
FEED CIRCUIT FOR A SHORT TO
GROUND
Ignition OFF.
DCSM C3305A-C, circuit
CHS06 (BU/BN), harness side
and ground.

Is the resistance greater than
10,000 ohms?

Yes
GO to AP8 .
No
AP8 CHECK THE RESISTANCE
OF THE BACKREST TED AND
WIRING
DCSM C3305A-C, circuit
CHS06 (BU/BN), harness side
and DCSM C3305A-D, circuit
RHS06 (WH), harness side.

Is the resistance between 0.9
and 10 ohms?

Yes
GO to AP10 .
No
GO to AP9 .
AP9 CHECK THE RESISTANCE
OF THE BACKREST TED
Disconnect: Backrest TED
C3311.

backrest TED C3311 pin 1 and
pin 3, component side.

Yes
REPAIR circuit CHS06 (BU/BN) or RHS06 (WH) for an
open. REPEAT the self-test. CLEAR the DTCs.
No
INSTALL a new backrest TED . REFER to Seat Backrest
and 10 ohms?

Thermo-Electric Device in this section. REPEAT the self-test.
CLEAR the DTCs.
AP10 CHECK THE BLOWER
MOTOR FEED AND SPEED
CONTROL CIRCUITS FOR A
SHORT TO VOLTAGE
Ignition ON.
DCSM C3305C-8,
circuit CHS08 (BN/YE),

DCSM C3305C-3,
circuit VHS23 (BN/BU),

circuit?

Yes
DTCs.
No
GO to AP11 .
SHORT TO GROUND
Ignition OFF.
DCSM C3305C-8,

DCSM C3305C-3,
circuit VHS23 (BN/BU),

Yes
GO to AP12 .
No
DTCs.
than 10,000 ohms?

MOTOR AND WIRING
RESISTANCE
NOTE: The ohmmeter must be
connected with the positive lead
to DCSM C3305C-8, circuit
CHS08 (BN/YE) and the
negative lead to DCSM
C3305C-7, circuit RHS08
(VT/WH) when measuring.
Ohmmeter leads incorrectly
connected will result in false
readings and lead to incorrect
identification of components that
are not faulty.

DCSM C3305C-8, circuit
CHS08 (BN/YE), harness side
and DCSM C3305C-7, circuit

Is the resistance between 4,000
and 10,000 ohms?

Yes
GO to AP14 .
No
GO to AP13 .
MOTOR RESISTANCE
Disconnect: Cushion TED
C3303.

to pin 2 and the negative lead to
pin 4 when measuring.

Yes
DTCs.
No
INSTALL a new cushion TED . REFER to Seat Cushion
are not faulty.
cushion TED C3303 pin 2 and

and 10,000 ohms?

CLEAR the DTCs.
MOTOR SPEED CONTROL AND
CIRCUIT RESISTANCE
to C3305C-3, circuit VHS23
(BN/BU), harness side and the
negative lead to C3305C-7,
circuit RHS08 (VT/WH),
harness side when measuring.
are not faulty.

VHS23 (BN/BU), harness side

Is the resistance between 240
kohms and 4 megohms?

Yes
GO to AP16 .
No
GO to AP15 .
MOTOR SPEED CONTROL
RESISTANCE
C3303.

are not faulty.



Yes
DTCs.
No
CLEAR the DTCs.
AP16 CHECK THE THERMISTOR
VOLTAGE
Ignition OFF.
501-20B .

Air Bag C313.

deployment.


Ignition ON.
Yes
No
GO to AP17 .
DCSM C3305B-2, circuit
VHS27 (WH/OG), harness side
and ground.

GROUND
Ignition OFF.
and ground.

10,000 ohms?

Yes
GO to AP18 .
No
AND WIRING RESISTANCE
and DCSM C3305B-3, circuit
RHS10 (BU/OG), harness side.
Note the ambient temperature
and compare result to the
following table:

0-10C
(32-50F)
2,782-1,663
ohms
Yes
INSTALL a new DCSM . REFER to Dual Climate Controlled
Seat Module (DCSM) in this section. REPEAT the self-test.
CLEAR the DTCs.
passenger seat side air bag module C313. REPOWER
theitle="Supplemental Restraint System" class="popup"
onmouseover="this.className='popupnounderline';"
onmouseout="this.className='popup';">SRS . REFER to
Section 501-20B .
No
GO to AP19 .
10-20C
(50-68F)
1,837-1,140
ohms
20-30C
(68-86F)
1,260-806
ohms
30-40C
(86-104F)
893-570 ohms
40-50C
(104-122F)
630-428 ohms
Is the resistance within the
limits indicated?

RESISTANCE
C3303.

cushion TED pin 5 and pin 8,
component side. Note the
ambient temperature and
compare result to the following
table:

0-10C
(32-50F)
2,782-1,663
ohms
10-20C
(50-68F)
1,837-1,140
ohms
20-30C
(68-86F)
1,260-806
30-40C
(86-104F)
893-570 ohms
40-50C
(104-122F)
630-428 ohms
Yes
DTCs.
No
CLEAR the DTCs.
DISCONNthe battery ground cable. CONNECT passenger
seat side air bag module C313. REPOWER the SRS . REFER
limits indicated?

AP20 CHECK FOR CORRECT TED
INSTALLATION AND FOR
CRUSHED FOAM
Ignition OFF.
Remove the seat. Refer to Seat -

Remove the seat backrest trim
cover. Refer to Seat Backrest -

Inspect the seat backrest for the
following:

Is the backrest blower
obstructed?

Is the blower filter
restricted or plugged?

Is the TED correctly
installed?

Is the seat backrest foam
pad crushed or
restricted?

Is the climate controlled
seat manifold crushed or
restricted?

Is the TED correctly installed
and the foam pad and manifold
OK?

Yes
GO to AP21 .
No
Correctly INSTALL the backrest TED or INSTALL a new
seat backrest foam pad and/or climate controlled seat
manifold. REPEAT the self-test. CLEAR the DTCs.
DISCONNECT the battery ground cable. REPOWER the SRS
AP21 CHECK THE CUSHION TED
GROUND CIRCUIT FOR A SHORT
TO VOLTAGE
Ignition OFF.
Position the front passenger seat
in the vehicle and connect the
seat-to-floor connectors.

501-20B .

Air Bag C313.

Yes
No
GO to AP22 .
deployment.


Ignition ON.
DCSM C3305A-B, circuit
RHS07 (BU), harness side and
ground.

GROUND
Ignition OFF.
DCSM C3305A-A, circuit
CHS07 (GY/BU), harness side
and ground.

10,000 ohms?

Yes
GO to AP23 .
No
AND WIRING RESISTANCE
DCSM C3305A-A circuit
CHS07 (GY/BU), harness side
and DCSM C3305A-B, circuit
RHS07 (BU), harness side.

and 10 ohms?

Yes
GO to AP25 .
No
GO to AP24 .
RESISTANCE
C3303.


and 10 ohms?

Yes
REPAIR circuit CHS07 (GY/BU) or RHS07 (BU) for an
open. REPEAT the self-test. CLEAR the DTCs.
No
CLEAR the DTCs.
SHORT TO VOLTAGE
Ignition ON.
DCSM C3305C-8,

DCSM C3305C-4,
circuit VHS21
(BU/WH), harness side
and ground.

Yes
DTCs.
No
GO to AP26 .
circuit?

SHORT TO GROUND
Ignition OFF.
DCSM C3305C-8,

DCSM C3305C-4,
circuit VHS21
(BU/WH), harness side
and ground.

than 10,000 ohms?

Yes
GO to AP27 .
No
DTCs.
MOTOR AND WIRING
RESISTANCE
to DCSM C3305C-8, circuit
CHS08 (BN/YE) and the
negative lead to DCSM
C3305C-7, circuit RHS08
(VT/WH) when measuring.
are not faulty.

CHS08 (BN/YE), harness side

Yes
GO to AP29 .
No
GO to AP28 .
and 10,000 ohms?

MOTOR RESISTANCE
C3311.

are not faulty.


and 10,000 ohms?

Yes
DTCs.
No
CLEAR the DTCs.
MOTOR GROUND CIRCUIT TO
BLOWER MOTOR SPEED
CONTROL CIRCUIT RESISTANCE
to C3305C-4, circuit VHS21
(BU/WH), harness side and the
negative lead to C3305C-7,
circuit RHS08 (VT/WH),
harness side when measuring.

Yes
GO to AP31 .
No
GO to AP30 .
are not faulty.
VHS21 (BU/WH), harness side


MOTOR SPEED CONTROL
RESISTANCE
C3311.

are not faulty.



Yes
DTCs.
No
CLEAR the DTCs.
VOLTAGE
Ignition ON.
VHS36 (YE/BU), harness side
and ground.

Yes
No
GO to AP32 .
GROUND
Ignition OFF.
501-20B .

Air Bag Module C313.

and ground.

10,000 ohms?

Yes
GO to AP33 .
No
AND WIRING RESISTANCE AT
THE DCSM
and DCSM C3305B-5, circuit
RHS20 (GN/BU), harness side.
Note the ambient temperature
and compare result to the
following table:

0-10C
(32-50F)
2,782-1,663
ohms
10-20C
(50-68F)
1,837-1,140
ohms
20-30C
(68-86F)
1,260-806
ohms
30-40C
(86-104F)
893-570 ohms
40-50C
(104-122F)
630-428 ohms
limits indicated?

Yes
INSTALL a new DCSM . REFER to Dual Climate Controlled
Seat Module (DCSM) in this section. REPEAT the self-test.
CLEAR the DTCs.
No
GO to AP34 .
AP34 CHECK THE TED
THERMISTOR RESISTANCE
C3311.

backrest TED pin 5 and pin 8,
component side. Note the
ambient temperature and
compare result to the following
table:

Yes
DTCs.
No
CLEAR the DTCs.
0-10C
(32-50F)
2,782-1,663
ohms
10-20C
(50-68F)
20-30C
(68-86F)
1,260-806
ohms
30-40C
(86-104F)
893-570
ohms
40-50C
(104-122F)
630-428
ohms
limits indicated?

Pinpoint Test AQ: DTC B272E
NOTE: This DTC sets for an open or short to voltage. See DTC setting description below.
Normal Operation
The driver climate controlled seat blowers are located within the backrest and cushion Thermo-Electric
Devices (TEDs). The Dual Climate Controlled Seat Module (DCSM) supplies voltage and ground to both
blowers. The blowers are independently controlled by separate speed control circuits from the DCSM .
DTC B272E (Driver Ignition Run/Blower Circuit Short to Ground [this DTC sets for an open or short
to voltage]) - If either the blower voltage supply or return circuits are open (to both cushion and
backrest blowers) or shorted to voltage, the DTC is set and after 4-6 seconds the DCSM disables
outputs to the driver seat. The DTC will also set if the blower voltage supply or return circuit is open
to only one blower when DCSM supply voltage is less than 12 volts.

HVAC module
Backrest or cushion TED
DCSM
PINPOINT TEST AQ: DTC B272E
connectors, do not insert the electrical probes into the male connector pins. Inserting the probes into
AQ1 CHECK THE TED BLOWER MOTOR CIRCUITS FOR A
SHORT TO VOLTAGE
Ignition OFF.

Disconnect: Driver Seat Side Air Bag C327 and Passenger Seat
Side Air Bag C313.


Ignition ON.
Measure the voltage between DCSM C3305C, harness side and
ground using the following chart.

DCSM Connector Circuit
C3305C-16 CHS03 (GN/BN)
C3305C-15 RHS03 (GY/OG)
Yes
the DTCs.
C327 and passenger seat side
No
GO to AQ2 .
AQ2 CHECK THE TED BLOWER MOTOR CIRCUITS FOR
AN OPEN
PINPOINT TEST AQ: DTC B272E 453
Ignition OFF.
Measure the resistance between DCSM C3305C, harness side
and cushion TED C3300, harness side using the following chart.

DCSM
Connector Circuit
Cushion TED
Connector
C3305C-16 CHS03
(GN/BN)
C3300-2
C3305C-15 RHS03
(GY/OG)
C3300-4
Yes
GO to AQ3 .
No
the DTCs.
air bag module C313
AQ3 CHECK THE RESISTANCE OF THE CUSHION AND
BACKREST TED BLOWER MOTORS
NOTE: The ohmmeter must be connected with the positive lead
to pin 2 and the negative lead to pin 4 when measuring.
Ohmmeter leads incorrectly connected will result in false
readings and lead to incorrect identification of components that
are not faulty.

cushion TED C3300 pins 2 and 4, component side.
backrest TED C3310 pins 2 and 4, component side.
Are the resistances between 4,000 and 10,000 ohms?
Yes
the DTCs.
No
If the cushion TED resistance
is not between 4,000 and
10,000 ohms, INSTALL a new
cushion TED . REFER to Seat
the DTCs.
If backrest the TED resistance
PINPOINT TEST AQ: DTC B272E 454
backrest TED . REFER to Seat
the DTCs.
Pinpoint Test AR: DTC B272F
Normal Operation
The passenger climate controlled seat blowers are located within the backrest and cushion Thermo-Electric
Devices (TEDs). The Dual Climate Controlled Seat Module (DCSM) supplies voltage to both blowers on
circuit CHS08 (BN/YE) and ground to both blowers on circuit RHS08 (VT/WH). The blowers are
independently controlled by separate speed control circuits from the DCSM .
DTC B272F (Passenger Ignition Run/Blower Circuit Short to Ground [this DTC sets for an open or
short to voltage]) - If either the blower voltage supply or return circuits are open (to both cushion and
backrest blowers) or shorted to voltage, the DTC is set and after 4-6 seconds the DCSM disables
outputs to the passenger seat. The DTC will also set if the blower voltage supply or return circuit is
open to only one blower when DCSM supply voltage is less than 12 volts.

HVAC module
Backrest or cushion TED
DCSM
PINPOINT TEST AR: DTC B272F
connector pins can causintermittent or open electrical connections after reassembly resulting in
AR1 CHECK THE TED BLOWER MOTOR CIRCUITS FOR A
SHORT TO VOLTAGE
Ignition OFF.


Ignition ON.
Measure the voltage between DCSM C3305C, harness side and

DCSM Connector Circuit
C3305C-8 CHS08 (BN/YE)
C3305C-7 RHS08 (VT/WH)
Yes
the DTCs.
module C313.
No
GO to AR2 .
AR2 CHECK THE TED BLOWER MOTOR CIRCUITS FOR AN
OPEN
Ignition OFF.
Measure the resistance between DCSM C3305C, harness side
and cushion TED C3300, harness side using the following chart.

Yes
GO to AR3 .
No
the DTCs.
PINPOINT TEST AR: DTC B272F 456
DCSM
Connector Circuit
Cushion TED
Connector
C3305C-8 CHS08 (BN/YE) C3303-2
C3305C-7 RHS08
(VT/WH)
C3303-4
module C313.
AR3 CHECK THE RESISTANCE OF THE CUSHION AND
BACKREST TED BLOWER MOTORS
NOTE: The ohmmeter must be connected with the positive lead
to pin 2 and the negative lead to pin 4 when measuring.
Ohmmeter leads incorrectly connected will result in false
readings and lead to incorrect identification of components that
are not faulty.

cushion TED C3303 pins 2 and 4, component side.
backrest TED C3311 pins 2 and 4, component side.
Are the resistances between 4,000 and 10,000 ohms?
Yes
the DTCs.
module C313.
No
If the cushion TED resistance
cushion TED . REFER to Seat
the DTCs.
If backrest the TED resistance
backrest TED . REFER to Seat
the DTCs.
PINPOINT TEST AR: DTC B272F 457
module C313.
Pinpoint Test AS: DTC B2730
Normal Operation
The Dual Climate Controlled Seat Module (DCSM) monitors seat backrest temperature while it supplies
DTC B2730 (Back Over-Temp Detected) - If the driver seat backrest TED temperature exceeds 85C
(185F) in cool mode or 70C (158F) in heat mode for more than 34 seconds the DCSM will shut
down the driver seat system and set.

Restricted backrest TED filter
Backrest TED assembly
PINPOINT TEST AS: DTC B2730
NOTE: The air bag warning indicator illuminates when the correct Restraintsol Module (RCM) fuse is
AS1 CHECK THE DCSM FOR ON-DEMAND DTCs
Self Test - DCSM .

Was DTC B2730 retrieved on-demand during the
self-test?

Yes
GO to AS2 .
No
GO to AS5 .
AS2 CHECK THE DRIVER SEAT BACKREST TED
Ignition OFF.


Disconnect: Driver Seat Backrest TED C3310.
deployment.

414-01 .

DCSM C3305B-9, circuit VHS35 (VT/OG),

DCSM C3305B-10, circuit RHS15 (GY/BN),

Yes
GO to AS3 .
No
Section 501-20B .
Connect: Driver Seat Backrest TED C3310.
circuit VHS35 (VT/OG), harness side and DCSM
C3305B-10, circuit RHS15 (GY/BN), harness side. Note

0-10C (32-50F) 2,782-1,663 ohms
10-20C (50-68F) 1,837-1,140 ohms
20-30C (68-86F) 1,260-806 ohms
30-40C (86-104F) 893-570 ohms
40-50C (104-122F) 630-428 ohms
Yes
GO to AS18 .
No
GO to AS4 .
PINPOINT TEST AS: DTC B2730 459
THERMISTOR
Measure the resistance between driver seat backrest

0-10C (32-50F) 2,782-1,663 ohms
10-20C (50-68F) 1,837-1,140 ohms
20-30C (68-86F) 1,260-806 ohms
30-40C (86-104F) 893-570 ohms
40-50C (104-122F) 630-428 ohms
Yes
REPAIR circuit VHS35 (VT/OG) or
RHS15 (GY/BN) for an open or high
Section 501-20B .
INSTALL a new driver seat backrest
self-test.
Section 501-20B .
AS5 CONFIRM THE FAULT WHILE MONITORING
DEVICE TEMPERATURE (BK_TEMP) AND SEAT
TEMPERATURE (CSHTEMP) PIDs
Clear DTCs - DCSM .

DataLogger - DCSM .

Monitor the DCSM PIDs BK_TEMP and CSHTEMP.
NOTE: A crushed seat backrest foam pad or a crushed

Yes
excessive driver compartment
Attempt to recreate the fault. Start the vehicle and set the
driver seat to HIGH heat for at least 15 minutes while
occupying the seat.


No
If the BK_TEMP PID increases
(27F) of the CSHTEMP PID, GO to
AS6 .
If the BK_TEMP PID increases
CSHTEMP PID, GO to AS16 .
AS6 COMPARE OPERATION OF THE DRIVER AND
PASSENGER SEATS
cool.

Note the airflow exhausting from the driver seat
backrest TED and compare it to the airflow exhausting
from the passenger seat backrest TED .

the DCSM and the driver seat backrest TED while

backrest TED comparable to the airflow exhausting
from the passenger seat backrest TED with no
change in operation when carrying out the wiggle
test?

Yes
GO to AS7 .
No
driver seat backrest TED is not
from the driver seat backrest TED , GO
to AS8 .
If the passenger seat backrest TED
blower operation changed while
carrying out the wiggle test,
IDENTIFY and REPAIR the wiring
fault. CLEAR the DTCs. REPEAT the
self-test.
AS7 COMPARE OPERATION OF THE DRIVER AND
backrest TED with the driver seat occupied and compare
it to the airflow exhausting from the passenger seat
backrest TED with the passenger seat occupied.

backrest TED comparable to the airflow exhausting
from the passenger seat backrest TED ?

Yes
GO to AS16 .
No
foam pad and/or climate controlled
seat manifold. CLEAR the DTCs.
AS8 CHECK THE DRIVER SEAT BACKREST
BLOWER FOR AN OBSTRUCTION OR RESTRICTED
FILTER
Ignition OFF.
Inspect the blower of the driver seat backrest TED

Yes
No
GO to AS9 .
BLOWER SPEED CONTROL CIRCUIT FOR AN OPEN


deployment.

414-01 .

circuit VHS16 (BU/GN), harness side and driver seat
backrest TED C3310-7, circuit VHS16 (BU/GN),
harness side.

Yes
GO to AS10 .
No
Section 501-20B .
BLOWER CIRCUIT FOR A SHORT TO VOLTAGE
Ignition ON.
RHS03 (GY/OG), harness side and ground.

Yes
Section 501-20B .
No
GO to AS11 .
BLOWER CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.

Yes
GO to AS12 .
No
Section 501-20B .
BLOWER CIRCUITS FOR AN OPEN
DCSM C3305C-16, circuit CHS03 (GN/BN),
harness side and driver seat backrest TED
C3310-2, circuit CHS03 (GN/BN), harness side.

DCSM C3305C-15, circuit RHS03 (GY/OG),
harness side and driver seat backrest TED
C3310-4, circuit RHS03 (GY/OG), harness side.

Yes
GO to AS13 .
No
Section 501-20B .
BLOWER RESISTANCE
damaged.


Yes
GO to AS14 .
No
self-test.
Section 501-20B .
ohms?

BLOWER SPEED CONTROL RESISTANCE
damaged.


ohms?

Yes
GO to AS15 .
No
self-test.
Section 501-20B .
INSTALLATION AND FOR CRUSHED SEAT
BACKREST
Ignition OFF.
Remove the driver seat. Refer to Seat - Front in this
section.

Remove the driver seat backrest cover. Refer to Seat
Backrest Cover - Front in this section.

Inspect the driver seat backrest for the following:
Is the driver seat backrest TED correctly
installed?

Is the driver seat backresam pad crushed or
restricted?

Is the driver seat backrest climate controlled seat
manifold crushed or restricted?

Is the driver seat backrest TED correctly installed
and are there no signs of damage to the foam pad
and manifold?

Yes
INSTALL the driver seat backrest
cover and seat and GO to AS18 .
No
CORRECTLY install the driver seat
backrest TED or INSTALL a new
driver seat backrest foam pad and/or
climate controlled seat manifold.
CONNECT the battery ground cable.
REFER to Section 414-01 . CLEAR
Section 501-20B .
Ignition OFF.


deployment.

414-01 .

circuit VHS35 (VT/OG), harness side and C3305B-10
circuit RHS15 (GY/BN), harness side. Note the ambient

0-10C (32-50F) 2,782-1,663 ohms
10-20C (50-68F) 1,837-1,140 ohms
20-30C (68-86F) 1,260-806 ohms
30-40C (86-104F) 893-570 ohms
40-50C (104-122F) 630-428 ohms
Yes
GO to AS18 .
No
GO to AS17 .
THERMISTOR

Yes
REPAIR circuit VHS35 (VT/OG) or
RHS15 (GY/BN) for an open or high
0-10C (32-50F) 2,782-1,663 ohms
10-20C (50-68F) 1,837-1,140 ohms
20-30C (68-86F) 1,260-806 ohms
30-40C (86-104F) 893-570 ohms
630-428 ohms
Section 501-20B .
No
INSTALL a new TED . REFER to
Seat Backrest Thermo-Electric Device
in this section. CLEAR the DTCs.
bag module C7 and passenger seat side
Section 501-20B .
Harness Connectors.



(GY/VT) near DCSM C3305A-J and monitor the current
draw.

Yes
GO to AS19 .
No
self-test.
Section 501-20B .
AS19 CHECK RESISTANCE OF THE DRIVER SEAT
BACKREST TED AND WIRING
Ignition OFF.
Measure the resistance between DCSM C3305A-J
circuit CHS01 (GY/VT), harness side and C3305A-K,
circuit RHS01 (WH/VT), harness side.

Yes
GO to AS21 .
No
GO to AS20 .
AS20 CHECK THE RESISTANCE OF THE DRIVER
SEAT BACKREST TED

Yes
REPAIR circuit CHS01 (GY/VT) or
RHS01 (WH/VT) for an open or high
Section 501-20B .
No
self-test.
Section 501-20B .
AS21 CHECK FOR CORRECT DCSM OPERATION
Inspect the DCSM and driver seat backrest TED harness
and component side connectors and the body

corrosion
damaged pins
pushed-out pins
Yes
operation.
Harness Connectors.

Start the engine.
Clear DTCs - DCSM .

running set the driver seat to HIGH heat for at least 15
minutes.

Section 501-20B .
No
connector.
Section 501-20B .
Pinpoint Test AT: DTC U0140
Refer to Wiring Diagrams Cell 14 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Module Communications
Network for schematic and connector information.
Normal Operation
The Driver Seat Module (DSM) and the Smart Junction Box (SJB) communicate using the Medium Speed
Controller Area Network (MS-CAN). Messages are exchanged between the modules on the MS-CAN for the
purposes of determining what functions are being carried out.
DTC U0140 (Lost Communication With Body Control Module (GEM)) - set by the DSM whenever it
has lost communication to the SJB for 15 seconds or longer as long as the module voltage is between
10 and 15 volts.

Module communication
DSM
SJB
PINPOINT TEST AT: DTC U0140
AT1 VERIFY CUSTOMER CONCERN
Ignition ON.
Verify there is an observable symptom present.
Is an observable symptom present?
Yes
GO to AT2 .
No
The system is operating normally at this
time. The DTC may have been set due
to high network traffic or an
intermittent fault condition.
AT2 CHECK THE COMMUNICATION NETWORK
Ignition ON.
Network Test.

Does the SJB pass the network test?
Yes
GO to AT3 .
No
AT3 RETRIEVE THE RECORDED DTCs FROM THE
SELF-TEST
Check for recorded DSM DTCs from the self-test.
Is DTC B1317 or DTC B1318 recorded?
Yes
No
GO to AT4 .
AT4 RECHECK THE DSM DTCs
NOTE: If new modules were installed prior to the DTC
being set, the module configuration may be incorrectly
set during Programmable Module Installation (PMI) or
the PMI may not have been carried out.
Clear the DTCs. Repeat the DSM self-test.
Is DTC U0140 still present?
Yes
GO to AT5 .
No
time. The DTC may have been set due
to high network traffic or an
intermittent fault condition.
AT5 CHECK FOR DTC U0140/U0140:00 SET IN OTHER
MODULES
Clear all DTCs.
Ignition OFF.
Ignition ON.
Wait 10 seconds.
Self-Test.

Retrieve the continuous memory DTCs from all
modules.

Is DTC U0140/U0140:00 set in other modules?
Yes
INSTALL a new SJB . REFER to
Section 419-10 .
No
section.
Pinpoint Test AU: DTC U0155
Normal Operation
The Driver Seat Module (DSM) and the Instrument Panel Cluster (IPC) communicate using the Medium
Speed Controller Area Network (MS-CAN). Messages are exchanged between the modules on the MS-CAN
for the purposes of determining what functions are being carried out.
DTC U0155 (Lost Communication with Instrument Panel Cluster (IC) Control Module) - set by the
DSM if ignition status message is present, the DSM supply voltage is greater than 10.5 volts, the

PINPOINT TEST AT: DTC U0140 469
ignition must be in the on position for a minimum of 5 seconds and if messages are missing for 15
seconds or longer from the IPC over the MS-CAN .
DSM
IPC
PINPOINT TEST AU: DTC U0155
AU1 VERIFY CUSTOMER CONCERN
Ignition ON.
Yes
GO to AU2 .
No
The system is operating normally
at this time. The DTC may have
been set due to high network
traffic or an intermittent fault
condition.
AU2 CHECK THE COMMUNICATION NETWORK
Network Test.

Does the IPC pass the network test?
Yes
GO to AU3 .
No
AU3 RETRIEVE THE RECORDED DTCs FROM THE
SELF-TEST
Is DTC B1317 or B1318 recorded?
Yes
No
GO to AU4 .
AU4 RECHECK THE DSM DTCs
NOTE: If new modules were installed prior to the DTC being
set, the module configuration may be incorrectly set during
Programmable Module Installation (PMI) or the PMI may not
have been carried out.
Yes
GO to AU5 .
No
The system is operating correctly
condition.
AU5 CHECK FOR DTC U0155/U0155:00 SET IN OTHER
MODULES
Clear all DTCs.
Ignition OFF.
Yes
INSTALL a new IPC . REFER to
Section 413-01 .
Ignition ON.
Wait 10 seconds.
Self-Test.

Retrieve the continuous memory DTCs from all modules.
No
INSTALL a new DSM . REFER
to Driver Seat Module (DSM) in
this section.
Pinpoint Test AV: DTC B1317
Normal Operation
The Driver Seat Module (DSM) monitors the voltage from the battery to determine if it goes above or below
specific thresholds.
DTC B1317 (Battery Voltage High) - a continuous memory or on-demand DTC that sets when the
DSM detects battery voltage above 15.5 volts on circuit SBB32.

Charging system concern
DSM
PINPOINT TEST AV: DTC B1317
NOTE: DTC B1317 may be stored in the module memory due to previous battery charging or vehicle jump
starting events.
AV1 CHECK FOR DTC B1317, B1676
OR P0563 SET IN OTHER MODULES
Ignition ON.
on the scan tool: Retrieve All
CMDTCs Self-Test.

Retrieve the continuous memory
DTCs from all modules.

Is DTC B1317, B1676 or P0563
(PCM) set in more than one
module?

Yes
REFER to Section 414-00 to diagnose an overcharging
condition.
No
GO to AV2 .
AV2 CHECK THE BATTERY
VOLTAGE
Turn off all interior/exterior lights
and accessories.

Start and run the engine at
approximately 2,000 rpm for 3

Yes
condition.
No
PINPOINT TEST AU: DTC U0155 471
minutes while monitoring the battery
voltage.
Does the battery voltage rise to 15.5
volts or higher?

GO to AV3 .
AV3 RECHECK FOR DTC B1317
Turn the engine off.
Ignition ON.
on the scan tool: DSM Self-Test.

Clear the continuous memory DTCs.
Carry out the DSM self-test.
Is DTC B1317 present?
Yes
INSTALL a new DSM . REFER to Driver Seat Module
(DSM) in this section. TEST the system for normal
operation.
No
The system is operating normally at this time. The DTC
may have been set previously during battery charging or
while jump starting the vehicle.
Pinpoint Test AW: DTC B1318
Refer to Wiring Diagrams Cell 13 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Power Distribution/SJB for
Normal Operation
The Driver Seat Module (DSM) monitors the voltage from the battery to determine if it goes above or below
DTC B1318 (Battery Voltage Low) - a continuous memory or on-demand DTC that sets when the
DSM detects battery voltage below 10 volts on circuit SBB32.

High circuit resistance
DSM
PINPOINT TEST AW: DTC B1318
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Failure to disconnect the battery when instructed will result in false resistce readings. Refer to Section
414-01 .
AW1 RECHECK THE DSM DTCs
Ignition ON.
scan tool: DSM Self-Test.

Is DTC B1318 still present?
Yes
GO to AW2 .
No
The system is operating normally at this time. The
DTC may have been set previously during battery
PINPOINT TEST AV: DTC B1317 472
charging or while jump starting the vehicle.
AW2 CHECK FOR CHARGING SYSTEM
DTCs IN THE PCM
scan tool: PCM Self-Test.

Retrieve the continuous memory DTCs
from the PCM.

Is DTC P0620, P0625, P0626 or P065B
set in the PCM?

Yes
No
GO to AW3 .
AW3 CHECK THE BATTERY CONDITION
AND STATE OF CHARGE
Ignition OFF.
Check the battery condition and verify the
battery is fully charged. Refer to Section
414-01 .

Is the battery OK and fully charged?
Yes
GO to AW4 .
No
AW4 CHECK THE DSM VOLTAGE SUPPLY
Measure and record the voltage at the
battery.

Disconnect: DSM C3299a.
Ignition ON.
Measure the voltage between the DSM
C3299a-1, circuit SBB32 (VT/RD), harness
side and ground.

Is the voltage within 0.2 volt of the
recorded battery voltage?

Yes
GO to AW5 .
No
REPAIR the circuit for high resistance. CLEAR the
AW5 CHECK THE DSM GROUND
CIRCUITS
Ignition OFF.
Disconnect: Negative Battery Cable.
Disconnect: DSM C3299b.
Measure the resistance between the DSM
C3299a-2, circuit GD126 (BK/WH),

Yes
CONNECT the negative battery cable. GO to AW6
.
No
REPAIR the circuit for high resistance. CONNECT
the negative battery cable. TEST the system for
normal operation.
PINPOINT TEST AW: DTC B1318 473
Measure the resistance between the DSM
C3299b-24, circuit GD126 (BK/WH),

AW6 CHECK FOR CORRECT DSM
OPERATION
Disconnect the DSM connectors.
Check for:
corrosion
damaged pins
pushed-out pins
Connect the DSM connectors and make
sure they seat correctly.

Operate the system and verify the concern
is still present.

Yes
INSTALL a new DSM . REFER to Driver Seat
Module (DSM) in this section. TEST the system for
normal operation.
No
The system is operating correctly at this time. The
concern may have been caused by a loose or
corroded connector.
Pinpoint Test AX: DTC U0140
Normal Operation
The Driver Seat Module (DSM) and the Smart Junction Box (SJB) communicate using the Medium Speed
DTC U0140 (Lost Communication With Body Control Module (GEM)) - set by the DSM whenever it
has lost communication to the SJB for 15 seconds or longer as long as the module voltage is between
10 and 15 volts.

DSM
SJB
PINPOINT TEST AX: DTC U0140
AX1 VERIFY CUSTOMER CONCERN
Ignition ON.
Yes
GO to AX2 .
No
condition.
AX2 CHECK THE COMMUNICATION NETWORK
Ignition ON.
Network Test.

Yes
GO to AX3 .
No
AX3 RETRIEVE THE RECORDED DTCs FROM THE
SELF-TEST
Yes
For DTC B1317, GO to Pinpoint
Test AV .
Test AW .
No
GO to AX4 .
AX4 RECHECK THE DSM DTCs
Yes
GO to AX5 .
No
condition.
AX5 CHECK FOR DTC U0140/U0140:00 SET IN OTHER
MODULES
Clear all DTCs.
Ignition OFF.
Ignition ON.
Wait 10 seconds.
Yes
Section 419-10 .
No
PINPOINT TEST AX: DTC U0140 475
Self-Test.

this section.
Pinpoint Test AY: DTC U0155
Normal Operation
The Driver Seat Module (DSM) and the Instrument Panel Cluster (IPC) communicate using the Medium
Speed Controller Area Network (MS-CAN). Messages are exchanged between the modules on the MS-CAN
for the purposes of determining what functions are being carried out.
DTC U0155 (Lost Communication with Instrument Panel Cluster (IC) Control Module) - set by the
DSM if ignition status message is present, the DSM supply voltage is greater than 10.5 volts, the
ignition must be in the on position for a minimum of 5 seconds and if messages are missing for 15
seconds or longer from the IPC over the MS-CAN .

Modu communication
DSM
IPC
PINPOINT TEST AY: DTC U0155
AY1 VERIFY CUSTOMER CONCERN
Ignition ON.
Yes
GO to AY2 .
No
condition.
AY2 CHECK THE COMMUNICATION NETWORK
Network Test.

Does the IPC pass the network test?
Yes
GO to AY3 .
No
AY3 RETRIEVE THE RECORDED DTCs FROM THE
SELF-TEST
Yes
Is DTC B1317 or B1318 recorded? Test AV .
Test AW .
No
GO to AY4 .
AY4 RECHECK THE DSM DTCs
Yes
GO to AY5 .
No
condition.
AY5 CHECK FOR DTC U0155/U0155:00 SET IN OTHER
MODULES
Clear all DTCs.
Ignition OFF.
Ignition ON.
Wait 10 seconds.
Self-Test.

Yes
INSTALL a new IPC . REFER to
Section 413-01 .
No
this section.
Component Test
Component Testing - Thermo-Electric Device (TED) Cooling Performance
NOTE: This test is intended to check the cooling mode performance of an operational climate controlled seat
backrest or cushion Thermo-Electric Device (TED) and verify it is cooling inlet air at the TED (ambient cabin
air) between 6-8C (10-14F).
NOTE: Make sure the vehicle is out of direct sunlight and is in an area with a stable air temperature when
testing the climate controlled seat system.
NOTE: For correct temperature measurements, the seat being tested should be occupied.
EntataLogger and monitor the following Dual Climate Controlled Seat Module (DCSM) PIDs:
CSHTEMP (Seat cushion thermal electric device temperature)
BK_TEMP (Seat back thermal electric device temperature)
PCSHTMP (Passenger Cushion Thermal Electric Device [TED] Temperature)
PBKTMP (Passenger Back TED Temperature)
DCCSMOD (Driver State Seat Mode)
PCCSMOD (Passenger State Seat Mode)
1.
Any initial PID value of greater than 205C (401F) or less than 2C (36F) indicates a system
hardware failure. Do not proceed with this test. GO to Symptom Chart or Dual Climate Controlled
2.
PINPOINT TEST AY: DTC U0155 477
Seat Module (DCSM) DTC Chart for diagnosis.
NOTE: Typical backrest and cushion TED shown, others similar.
Gain access to the seat backrest and cushion TEDs and use a suitable thermo-couple temperature
measuring device to monitor the air inlet temperature.
Access the backrest TED .
Release the backrest trim cover J-clips at the sides and bottom.
Pull out at the bottod detach the 2 lower hard back panel pin-type retainers.
Position the backrest trim cover aside.

Place the temperature probe near each TEDs air filter.
3.
NOTE: The engine must be running to operate the climate controlled seat system and carry out this
test.
Operate system in high cool mode and measure the temperature at the cushion TED filter using the
thermo-couple device.
Obtain and record the air inlet temperature at the TED .
4.
Use a scan tool to measure the cushion TED PID temperature and record the value.
Monitor the MODE PID and verify the system is operating. If during testing the PID value
changes to Blower Only state, the system has entered into recovery mode and voltage to the
TEDs is disabled. If this occurs, the seat has failed the test. Do not continue. Return to the
diagnostic routine.

5.
Subtract the cushion TED PID temperature from the cushion air inlet temperature and record the
temperature difference value.
6.
Continue to operate the system in high cool mode and use the thermo-couple device to measure the
temperature at the backrest TED filter.
Obtain and record the air inlet temperature at the TED .
Secure the temperature probe at the backrest TED air filter and close the backrest trim
cover before measuring.

7.
Use a scan tool to measure the backrest TED PID temperature and record the value.
Monitor the MODE PID and verify the system is operating. If during testing the PID value
changes to Blower Only state, the system has entered into recovery mode and voltage to the
TEDs is disabled. If this occurs, the seat has failed the test. Do not continue. Return to the

8.
diagnostic routine.
Subtract the backrest TED PID temperature from the backrest air inlet temperature and record the
value.
9.
Compare the cushion and backrest calculated temperature values. Both values should be between
6-8C (10.8-14.4F) and approximately equal (1C [1.8F]).
10.
If the calculated temperature values are not within these specifications, check the climate controlled
seat components for air duct or filter restrictions, blockages, duct or electrical disconnections and for
incorrect assembly. Repair as needed. If OK, carry out the DCSM self-test and if any DTC is
retrieved, go to Dual Climate Controlled Seat Module (DCSM) DTC Chart for diagnostic direction.
Return to the diagnostic routine.
11.
Heated Seat Module Reset
NOTE: This heated seat module is used on 2 different systems. These systems use 2 different on/off switches,
the single momentary switch and the dual momentary switch. A new heated seat module is programmed to
function for a single momentary switch.
The single momentary switch provides a ground signal to the heated seat module on one circuit. This cycles
the system high, low and off.
The dual momentary switch provides a ground to the heated seat module on 2 different circuits. Toggling the
dual momentary switch to one side cycles the system low and off. Toggling the switch to the other side cycles
the system high and off.
When a new heated seat module is installed on a system with a dual momentary switch and the module
receives a ground signal from the low circuit of that switch, the module is then programmed to function for a
dual momentary switch. Now the heated seat module will expect to see ground signals on 2 different circuits
to cycle the system high/off and low/off.
Once the heated seat module is programmed for use with dual momentary switches, the heated seat module
cannot be used with a single momentary switch heated seat system until the following reset procedure is
carried out.
Back probe and short both high switch inputs to ground. 1.
Turn the ignition ON. 2.
Wait for heated seat switch LEDs to start flashing. 3.
Disconnect both grounds as soon as the heated seat switch LEDs start flashing. 4.
The LEDs will flash a total of 5 times when the module is reset.
Wait for the LEDs to stop flashing and the system should work correctly.
5.
If the system does not work correctly, carry out the Heated Seat Module Reset steps again. Otherwise,
refer to the Symptom Chart in the Seats portion of this section.
6.
Heated Seat Module Reset 480
Heated Seat Module Reset 481
Memory Position Programming
Programming Memory Positions
NOTE: Memory positions can be stored at any time.
Place the vehicle ignition to ON. 1.
NOTE: To program the Remote Keyless Entry (RKE) transmitter, refer to Section 501-14 .
To set memory position(s), move the memory driver seat, memory exterior mirrors (if equipped),
memory adjustable pedals (if equipped) and memory steering column (if equipped) to the preferred
position using the appropriate switch(es).
2.
NOTE: Input from the driver seat control switch, exterior mirror control switch (if equipped),
steering column control switch (if equipped) and adjustable pedal control switch (if equipped) during
memory programming will abort the operation.
NOTE: If other tones or chimes are being produced, the memory save tone will not be heard because
it is one of the lowest priorities.
Press and hold a memory button (1 or 2) until a tone is heard (1.5 seconds). When the tone is heard,
the memory programming is complete.
3.
Repeat the previous steps to program another memory position. 4.
Recalling a Stored Memory Position
NOTE: A memory recall can be initiated only if the vehicle is in PARK or NEUTRAL gear and the ignition
is not in START. A memory recall in progress will not be affected by placing the ignition in START or by
moving the gearshift lever out of PARK or NEUTRAL.
NOTE: Input from the driver seat control switch, memory SET switch, adjustable pedal control switch (if
equipped), exterior mirror control switch (if equipped) or steering column control switch (if equipped) during
a memory recall will abort the memory recall.
The driver can recall the desired memory driver seat, memory exterior mirror (if equipped), memory
adjustable pedal (if equipped) and memory steering column (if equipped) positions by depressing
either memory SET switch button 1 or 2. Depressing memory SET switch button 1 will initiate a
recall of the positions stored for Memory 1. Depressing memory SET switch button 2 will initiate a
recall of the positions stored for Memory 2.
1.
Memory Position Programming 482
Memory Position Programming 483
Seat Latch Adjustment - Rear
Remove the parcel shelf. For additional information, refer to Section 501-05 . 1.
Loosen the 2 rear seat backrest latch nuts. Adjust the latch position as necessary for good backrest fit
and latch closure when upright.
2.
Install the parcel shelf. For additional information, refer to Section 501-05 . 3.
Seat Latch Adjustment - Rear 484
Manual
REMOVAL AND
INSTALLATION
Seat - Front
Special Tool(s)
NOTE: Passenger seat shown, driver seat similar.
NOTE: The seat track-to-floor bolts must be tightened in the sequence described in this procedure.
1 621A44 Safety belt retractor belt anchor bolt cover
(part of 62184) (passenger only)
2 W505274 Safety belt retractor belt anchor bolt
(passenger only)
3 - Safety belt retractor belt anchor (part of
611B08) (passenger only)
4 61748 (passenger)/
61749 (driver)
Seat-to-floor bolt cover (4 required)
Seat - Front 485
5 W707858 Seat-to-floor bolt (4 required)
6 /td> Electrical connectors (part of 14A698)
7 - Front seat assembly
Removal
WARNING: Never probe the electrical connectors on air bag, Safety Canopy or side air curtain
modules. Failure to follow this instruction may result in the accidental deployment of these modules,
which increases the risk of serious personal injury or death.
removed and the ignition switch is ON.
Passenger seat
Remove the safety belt retractor belt anchor bolt cover from the cushion side shield to access the
safety belt anchor bolt.
If equipped with power seats, position the seat track downward to access the safety belt
retractor anchor bolt.

1.
Remove the bolt and separate the safety belt anchor from the seat. 2.
All seats
Push the release buttons on the head restraint guides and remove the head restraint. 3.
Position the seat to gain access to all 4 seat-to-floor bolts.
If equipped with power seats, fully raise the seat to aid seat service.
4.
Depower the S . For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering in the General Procedures portion of Section 501-20B .
5.
Remove the 4 seat track-to-floor bolt covers and bolts. 6.
Lift the seat to disengage 2 locator pins from the floor and tip the seat to access the electrical
connectors.
7.
WARNING: Use care when handling the front passenger seat and track assembly. Dropping
the assembly, placing excessive weight on or sitting on a front passenger seat that is not secured
in the vehicle may result in damaged seat components. Failure to follow these instructions may
result in incorrect operation of the occupant classification system (OCS) and increases the risk
of serious personal injury or death in a crash.
Disconnect the seat harness electrical connectors and remove the seat.
Slide and disengage the side air bag module electrical connector locking clip, release the tab
and disconnect the side air bag module electrical connector.

NOTICE: Use care when disconnecting the seat harness electrical connector. Excessive
force on the assurance lever can break the connector mounting.
Disconnect the seat harness electrical connector.

8.
Seat - Front 486
Release the locking tab and rotate the assurance lever fully to disengage the seat
harness electrical connector.

Slightly tip the connector away and disconnect.
Installation
WARNING: Make sure the front passenger seat is correctly installed and fastened to the vehicle. Do
not force the alignment to the floorpan mounting holes. If the seat does not align to the floorpan
mounting holes, repair the seat or floorpan as needed. Failure to follow these instructions may result in
incorrect operation of the occupant classification system (OCS) and increase the risk of serious
personal injury or death in a crash.
WARNING: After any crash, inspect the front passenger seat-to-floorpan mounting area for
deformation and restore to its original condition, if deformed. Correct alignment of the occupant
classification system (OCS) sensor rails to the seat and floorpan is critical for correct OCS operation.
Incorrect operation of the OCS increases the risk of serious personal injury or death in a crash.
Manual seats
Align both seat track rails to be flush with the rear edge of the seat track base to synchronize. 1.
All seats
Position the seat in the vehicle. 2.
Tip the seat and connect the electrical connectors.
Connect the seat harness electrical connector.
Make sure the electrical connector assurance lever is in the fully released position.
Tip the body harness connector into the seat connector and partially insert.
Rotate the assurance lever while pushing the connectors together until the handle is
locked.

Connect the side air bag module electrical connector, then slide and engage the side air bag
electrical connector locking clip.

3.
Align the 2 forward seat mounting locators to the guide holes in the floor and position the seat in
place.
4.
NOTE: Make sure the safety belt webbing is not twisted and the safety belts and buckles are
accessible to the occupants.
Install the seat-to-floor bolts by hand and tighten in the following sequence.
Tighten to 47 Nm (35 lb-ft). 1.
5.
Seat - Front 487
Install the 4 seat-to-floor bolt covers. 6.
Repower the SRS . If a passenger seat has been serviced, do not prove out the SRS at this time.
For additional information, refer to Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures portion of Section 501-20B .
7.
Install the head restraint. 8.
Passenger seat
NOTE: If equipped with power seats, position the passenger seat track downward for safety belt
retractor belt anchor and bolt installation.
Position the safety belt retractor belt anchor to the seat and install the bolt.
9.
Install the safety belt retractor belt anchor bolt cover. 10.
Carry out the Occupant Classification System (OCS) System Reset. For additional information, refer
to the General Procedures portion of Section 501-20B .
11.
Seat - Front 488
Seat - Front 489
Manual
REMOVAL AND
INSTALLATION
Seat - Exploded View, Front
Front Seat Backrest
NOTE: Driver backrest shown, passenger backrest similar.
1 611A08 Head restraint
2 610A16 Head restraint guide (master)
3 610A18 Head restraint guide (slave)
4 14D696 Backrest heater mat (if equipped)
5 19N550 Backrest manifold, climate controlled seat
(if equipped)
6 64811 Backrest foam pad
7 W500632 Recliner-to-cushion frame bolt (4 required)
8 61018 Backrest frame (with manual recliner) (if
equipped)
9 608A15 Backrest frame (with power recliner) (if
equipped)
10 - Spring clip, recliner handle (part of 61199)
(if equipped)
11 61199 Handle, recliner (if equipped)
12 611D11 Side air bag module
13 N620480 Nut, side air bag (2 required)
14
Seat - Exploded View, Front 490
14K155 td>Wiring
harness, side air bag (if
equipped)
15 65500 Lumbar assembly, power (if equipped)
16 64842 Lumbar assembly, static (if equipped)
17 65500 Lumbar assembly, manual (if equipped)
18 610C01 Manual lumbar control (if equipped)
19 W715704 Rivet, manual lumbar control (2 required)
(if equipped)
20 14C693 Wiring harness, power seat backrest (if
equipped)
21 613A68 Recliner torque shaft
22 W790022 Bolt, recliner motor (if equipped)
23 14547 Recliner motor (if equipped)
24 - Pal nut, recliner torque shaft (2 required)
25 64646 Upper support spring
26 W712476 Rivet, climate controlled seat
Thermo-Electric Device (TED) (3
required) (if equipped)
27 19N550 TED assembly (if equipped)
28 18D583 Bracket, TED assembly (if equipped)
29 W790002 Pin-type retainer
30 18D507 Exhaust duct, climate controlled seat TED
assembly (if equipped)
31 - Tie strap
32 - Filter, climate controlled seat TED
assembly (part of 19N550) (if equipped)
33 64417 Backrest trim cover
Driver Seat Cushion
NOTE: Power seat track shown, manual seat track similar.
Front Seat Backrest 491
Item
Part
Number Description
1 63101 Cushion frame
2 - Bolt, safety belt buckle (part of 61203)
3 61203 Safety belt buckle
4 610D09 Safety belt buckle bracket
5 W520113 Nut, safety belt buckle bracket-to-seat track (2 required)
6 W505256 Bolt, seat position sensor (part of 61203) (driver only)
7 14B416 Seat position sensor (driver only)
8 N620480 Nut, cushion Thermo-Electric Device (TED) (3
9 19N550
10 19E880 Cushion TED filter (if equipped)
11 61711 Seat track
12 W520113 Seat track-to-cushion frame nut (4 required)
13 610E34 Electrical bracket
14 - Pop rivets (4 required)
15 14C708 Driver Seat Module (DSM) (if equipped)
16 62622 Manual lumbar control knob (if equipped)
17 14711 Seat control switch knob (if equipped)
18 14711 Power recline switch knob (if equipped)
19 14711 Power lumbar switch knob (if equipped)
20 14A701 Seat control switch (if equipped)
21 62187 Cushion side shield
22 14A699 Driver seat wire harness
23 632A23 Cushion foam pad
24 -
Driver Seat Cushion 492
Cushion manifold, climate controlled seat (part of
632A23) (if equipped)
25 - Cushion insert (part of 632A23) (if equipped)
26 14D696 Cushion heater mat (if equipped)
27 62900 Cushion trim co
28 61753 Manual height adjust handle (if equipped)
29 W711217 Screw, manual height adjust handle (if equipped)
30 62768 Cover, manual height adjust handle (if equipped)
Passenger Seat Cushion
Item
Part
Number Description
2 61710 Seat track
10 610D08 Safety belt anchor bracket
11 W520113 Nut, safety belt anchor bracket (2 required)
12 19N550 Cushion Thermo-Electric Device (TED) (if equipped)
Passenger Seat Cushion 493
14 N620480 Nut, cushion TED (3 required) (if equipped)
15 W790002 Scrivet
16 W520113 Nut, safety belt buckle bracket (2 required)
21 - Cushion manifold, climate controlled seat (part of
24 62900 Cushion trim cover
Power Seat Track - Passenger
Item Description
1 61710 Seat track
2 14A698 Passenger seat wire harness
3 W712479 Occupant Classification System (OCS) rail-to-seat track
bolts (8 required)
4 61708 Outboard OCS weight sensor assembly
5 14A577 Outboard OCS wire harness
6 61912 Rear outboard seat riser
7 61912 Front outboard seat riser
8 61709 Inboard OCS weight sensor assembly
Power Seat Track - Passenger 494
9 14A578 Inboard OCS wire harness
10 61913 Rear inboard seat riser
11 61913 Front inboard seat riser
12 W712479 Seat riser-to-seat track bolts (6 required)
14 31134/31147 Pop rivet (4 required)
15 14B422 Occupant Classification System Module (OCSM)
16 31134/31147 Pop rivets (quantity varies with seat option)
17 14C724 Heated seat module (if equipped)
18 14C724 Dual Climate Controlled Seat Module (DCSM) (if
equipped)
Manual
REMOVAL AND
INSTALLATION
Head Restraint Guide Sleeve
Removal
NOTE: Typical head restraint guide sleeve shown, others similar.
Push in on the 2 head restraint guide sleeve release buttons and remove the head restraint. 1.
Obtain a flat-head screwdriver with a width of 4 mm (0.157 in) to 7 mm (0.275 in) and a thickness of
approximately 1 mm (0.039 in).
2.
Align the screwdriver to the middle of the head restraint guide sleeve release button. 3.
Position the screwdriver between the head restraint guide sleeve neck and backrest trim cover and
foam pad.
4.
Position the screwdriver at a 45-degree angle. 5.
NOTE: For retainer clarity, backrest trim cover and foam pad are removed.
Push the screwdriver in, bending the lock feature on the head restraint guide sleeve in.
6.
Head Restraint Guide Sleeve 496
While bending the lock feature in, push down on the screwdriver handle, prying the head restraint
guide sleeve up and disengaging it from the backrest frame crossmember.
7.
Remove the head restraint guide sleeve.
Discard the head restraint guide sleeve.
8.
Repeat these steps for the head restraint guide sleeve on the opposite side. 9.
Installation
NOTICE: Always install new head restraint guide sleeves. Difficult adjustment of the head restraint
may occur. Failure to follow these instructions may result in component failure.
NOTICE: The head restraint guide sleeves are not interchangeable. Failure to install the correct head
restraint guide sleeve at the correct position may result in component failure.
Make sure the holes in the backrest foam pad and backrest trim cover are aligned to the holes in the
backrest frame.
1.
Install the head restraint guide sleeve with the large button and wide key on the LH side of the seat. 2.
Install the head restraint guide sleeve with the small button and thin key on the RH side of the seat. 3.
NOTICE: Do not attempt to seat the head restraint guide sleeve by hand. This may result in
excessive head restraint adjustment efforts and permanent damage to the head restraint guide
sleeve.
To allow the head restraint guide sleeve to slide freely through the backrest foam pad and backrest
trim cover, twist the head restraint guide sleeve while pushing it into the backrest frame hole as far as
it will go with hand pressure.
4.
NOTICE: Striking effort should not result in any type of damage or distortion to the head
restraint guide sleeve. If a head restraint guide sleeve is damaged, install a new one.
Using a non-marring mallet, strike the top of the head restraint guide sleeve with moderate force,
seating it in the backrest frame.
Striking effort must be hard enough to snap the head restraint guide sleeve retainer in place in
the backrest frame.

5.
Inspect the head restraint guide sleeve.
Pull the head restraint guide sleeve out by hand, making sure it is locked in place. If the head
restraint guide sleeve can be removed by hand, repeat the installation procedure. If the head
restraint guide sleeve can be removed again after installing a second time, install a new head
restraint guide sleeve.

6.
Repeat these steps for the head restraint guide sleeve on the opposite side. 7.
After installation of 2 new head restraint guide sleeves, install the head restraint in the following
sequence.
Position the head restraint rods to the head restraint guide sleeve holes. 1.
Push the head restraint down, guiding the rods into the head restraint guide sleeve holes. 2.
Make sure the head restraint adjusts without excessive effort and locks in place. 3.
8.
Manual
REMOVAL AND
INSTALLATION
Seat Backrest - Front
NOTICE: Do not reinstall the cushion side shield or side shield retainers after removal. These are
one-time-use items that become damaged during removal and may not remain attached if reinstalled.
Install a new side shield during seat assembly (includes new retainers attached).
All seats
Remove the front seat. For additional information, refer to Seat - Front in this section. 1.
Remove the manual height adjust handle, if equipped.
Remove the height adjust handle cover.
Remove the 2 screws and height adjust handle.
2.
Remove the spring clip and manual recliner handle, if equipped. 3.
Remove the manual lumbar control knob, if equipped.
Adjust the manual lumbar to the full relaxed position.
Pull outward and remove the manual lumbar knob.
4.
Seat Backrest - Front 500
Manual
REMOVAL AND
INSTALLATION
Seat Backrest Cover - Front
WARNING: Front seat backrest trim covers installed on seats equipped with seat side air bags
cannot be repaired. A new trim cover must be installed. Cleaning is permissible. Failure to follow these
instructions may result in the seat side air bag module deploying incorrectly and increase the risk of
Remove the front seat backrest. For additional information, refer to Seat Backrest - Front in this
section.
1.
Remove the 2 head restraint guide sleeves. For additional information, refer to Head Restraint Guide
Sleeve in this section.
2.
Detach the 2 pin-type retainers and trim cover flaps from the recliners. 3.
Disengage the backrest cover lower J-strips. 4.
NOTICE: Use care when separating the backrest cover from the hook-and-loop strip, or the
hook-and-loop strip can be torn from the backrest foam pad.
Invert the backrest cover up the backrest, remove all rows of hog rings (if equipped) from the front of
the backrest trim cover and separate the hook-and-loop strips.
5.
Remove the backrest cover rear upper hog rings.
To install, make sure the climate controlled seat backrest manifold is correctly aligned to the
foam pad, if equipped.

6.
Separate any remaining hook-and-loop strips, invert up and remove the backrest cover. 7.
Seat Backrest Cover - Front 501
Seat Backrest Cover - Front 502
Manual
REMOVAL AND
INSTALLATION
Seat Cushion Cover - Front
section.
1.
NOTE: Trim cover J-clip configurations vary with seat option.
Release all the remaining J-clips attaching the trim cover to the cushion frame.
2.
NOTICE: Use care when separating the seat cushion trim cover from the hook-and-loop strip,
or the hook-and-loop strip can be torn from the cushion foam pad.
Release the hook-and-loop strips, remove the hog rings (if equipped), separate the cushion trim cover
from the cushion foam pad and remove.
3.
Seat Cushion Cover - Front 503
Manual
REMOVAL AND
INSTALLATION
Seat Track
All seats
section.
1.
Passenger seat with failed horizontal motor
To remove the Occupant Classification System (OCS) weight sensor assemblies, remove the 2 seat
track horizontal drive unit bolts. This will allow the power seat tracks to move manually for access to
the 8 OCS weight sensor assembly bolts.
2.
Passenger seat receiving a new seat track
Remove the inboard and outboard OCS weight sensor assemblies. For additional information, refer to
Occupant Classification System (OCS) in Section 501-20B .
3.
Power seat
If equipped, disconnect the seat control switch and remove the cushion side shield. 4.
Heated seat
NOTE: Passenger seat shown, driver seat similar.
Disconnect the cushion heater mat electrical connector.
5.
All seats
Detach the hook-and-loop strips from around the safety belt buckle assembly. 6.
Seat Track 504
Detach all wiring harness pin-type retainers from the cushion frame. 7.
Release the cushion trim cover J-clips and remove the seat cushion foam pad and cushion trim cover. 8.
Climate controlled seat
NOTICE: Inspect the climate controlled seat cushion manifold and foam pad for crush or
obstruction. Before installation, repair as needed.
NOTE: Covering the Thermo-Electric Device (TED) openings is recommended to prevent foreign
material from entering the TED .
Disconnect the TED assembly electrical connector.
9.
All seats
Remove the 4 cushion frame-to-seat track nuts and separate the cushion frame and seat track.
10.
Detach any remaining wiring harness retainers attached to the cushion frame and remove the seat
track.
11.
Seat Track 505
Manual
REMOVAL AND
INSTALLATION
Seat Recliner Motor
Removal
NOTE: The manual recliners and power recliners are serviced as part of the backrest frame.
section.
1.
4.
Remove the one-way push clip on the RH side of the power recliner. Slide the recliner shaft out from
the LH side of the seat enough to clear the RH recliner and power recline motor.
5.
Disconnect the electrical connector, remove the screw and the power recline motor. 6.
Installation
NOTICE: Avoid rotating the recliner shaft until the recliner is fully installed or the recliners
will not be synchronized.
Install the recliner motor in the following sequence:
Position the recliner shaft through the recliner motor and RH recliner. 1.
Install a new one-way push clip onto the recliner shaft at the RH recliner. 2.
Slightly turn the recliner motor to align the bolt hole with the hole in the RH recliner and
install the recliner motor bolt.
Tighten to 6 Nm (53 lb-in).
3.
Connect the recliner motor electrical connecto 4.
1.
Roll the backrest trim cover down, attach the hook-and-loop strips, install new hog rings (if equipped)
and attach the backrest cover lower J-strips.
2.
Attach the 2 pin-type retainers and trim cover flaps to the recliners. 3.
Seat Recliner Motor 506
Install the front seat backrest. For additional information, refer to Seat Backrest - Front in this section. 4.
Seat Recliner Motor 507
Manual
REMOVAL AND
INSTALLATION
Lumbar Assembly
All vehicles
section.
1.
Vehicles with climate controlled seats
2.
All vehicles
5.
Vehicles with climate controlled seats
Remove the rear upper hog rings attaching the trim cover to the backrest frame and remove the trim
cover.
6.
Remove the foam pad from the backrest frame.
If equipped with climate controlled seats, remove the hog rings from the upper support spring.
If equipped with heated seats, detach the pin-type retainer and backrest heater mat wiring
harness from the backrest frame.

7.
All vehicles
Release the 2 lumbar spring clips from the backrest frame and remove the lumbar.
Route out the manual lumbar cable, if equipped.
Note the routing of the lumbar cable for installation.

Disconnect the electrical connector from the power lumbar motor, if equipped.
8.
Lumbar Assembly 508
Lumbar Assembly 509
Manual
REMOVAL AND
INSTALLATION
Seat Backrest Thermo-Electric Device
NOTE: The backrest Thermo-Electric Device (TED) filter is detachable from the TED assembly housing and
can be replaced without TED removal.
section.
1.
2.
5.
Remove the rear upper hog rings and trim cover. 6.
NOTICE: Inspect the climate controlled seat backrest manifold for crush and obstruction
before installation. If damaged, install a new backrest manifold.
If necessary, remove the climate controlled seat backrest manifold from the foam pad.
To install, align the backrest manifold and insert into the valleys of the foam pad.
Check for correct fit between the manifold, foam pad and TED assembly, to make
sure there is no air flow obstruction or cushion crush.

7.
Remove the hog rings from the upper support spring and remove the foam pad. 8.
Seat Backrest Thermo-Electric Device 510
Disconnect the backrest TED assembly electrical connector and detach the wiring harness retainers. 9.
Remove the TED exhaust duct.
Cut and remove the tie strap.
During installation, install a new tie strap.

Remove the pin-type retainer and separate the exhaust duct from the TED .
10.
Disconnect the backrest upper support spring from the backrest frame and remove the spring support
with the TED attached.
11.
If necessary, detach the backrest TED filter from the TED . 12.
NOTE: Note the TED position on the support spring for installation.
Separate the TED from the upper backrest support spring.
13.
NOTICE: Cover the Thermo-Electric Device (TED) openings before removing any rivets to
prevent foreign material from entering the TED .
Remove the 3 rivets and bracket from the TED .
14.
Manual
REMOVAL AND
INSTALLATION
Seat Cushion Thermo-Electric Device
NOTE: The cushion Thermo-Electric Device (TED) filter is detachable from the TED assembly housing from
underneath the seat cushion.
Remove the front seat. For additional information, refer to Seat - Front in this section.
Fully raise the seat before depowering the Supplemental Restraint System (SRS) to aid
cushion TED assembly access.

1.
Disconnect the TED electrical connector. 2.
NOTICE: Inspect the climate controlled seat cushion manifold and foam pad for crush or
obstruction. Before installation, repair as needed. Failure to do so may cause the climate control
to work inefficiently.
Remove the 3 nuts and TED assembly from the cushion frame.
To install, check for correct fit between the cushion manifold, foam pad and TED assembly,
to make sure there is no airflow obstruction, cushion crush or foreign material.

3.
Seat Cushion Thermo-Electric Device 513
Seat Cushion Thermo-Electric Device 514
Manual
REMOVAL AND
INSTALLATION
Dual Climate Controlled Seat Module (DCSM)
Special Tool(s)
Removal
NOTE: When installing a new Dual Climate Controlled Seat Module (DCSM), it is necessary to carry out the
Programmable Module Installation (PMI) procedure. For additional information, refer to Section 418-01 .
Before removing the DCSM , carry out the appropriate steps in the Programmable Module Installation
(PMI) procedure. For additional information, refer to Section 418-01 .
1.
Remove the front passenger seat. For additional information, refer to Seat - Front in this section. 2.
Remove the DCSM from the cushion electrical bracket.
Release the locking wedges and disconnect the 3 DCSM electrical connectors.
Remove the 2 rivets and DCSM .
3.
Installation
Install the DCSM to the seat.
Position the DCSM to the electrical bracket and install 2 new rivets.
Connect the 3 DCSM electrical connectors and locking wedges.
1.
Install the front seat. For additional information, refer to Seat - Front in this section. 2.
After installing the DCSM , carry out the appropriate steps in the Programmable Module Installation
(PMI) procedure. For additional information, refer to Section 418-01 .
3.
Dual Climate Controlled Seat Module (DCSM) 515
Dual Climate Controlled Seat Module (DCSM) 516
Manual
REMOVAL AND
INSTALLATION
Heated Seat Module
Remove the front passenger seat. For additional information, refer to Seat - Front in this section. 1.
Remove the heated seat module from the cushion electrical bracket.
Disconnect the 2 heated seat module electrical connectors.
Remove the rivet and heated seat module.
2.
Heated Seat Module 517
Manual
REMOVAL AND
INSTALLATION
Special Tool(s)
1 - Driver Seat Module (DSM) rivets (2 required)
2 - DSM electrical connectors (part of 14A699)
3 13C789 DSM
NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges,
damage may result.
NOTE: Prior to the removal of the module, it is necessary to upload the module configuration information to
the appropriate scan tool. This information needs to be downloaded into the new module once installed. For
additional information, refer to Section 418-01 .
NOTE: This step is necessary only if the Driver Seat Module (DSM) is being replaced.
Upload the module configuration information from the DSM into the scan tool. For additional
information, refer to Section 41 .
1.
Driver Seat Module (DSM) 518
Remove the driver seat. For additional information, refer to Section 501-10 . 2.
Drill out the 2 rivets. 3.
Disconnect the 4 electrical connectors and remove the DSM . 4.
NOTE: If the DSM was not replaced, this substep is not necessary.
Download the DSM configuration from the scan tool into the new DSM . For additional
information, refer to Section 418-01 .

5.
Driver Seat Module (DSM) 519
Manual
REMOVAL AND
INSTALLATION
Seat Control Switch
NOTICE: Do not reinstall the cushion side shield or side shield retainers after removal. These are
one-time-use items that become damaged during removal and may not remain attached if reinstalled.
Install a new side shield during seat assembly (includes new retainers attached).
Remove the front seat. For additional information, refer to Seat - Front in this section. 1.
Remove the spring clip and manual recliner handle, if equipped. 2.
Pull and remove the manual lumbar control knob and seat control switch button(s), if equipped. 3.
Remove and discard the cushion side shield and one-time-use retainers.
Pull out on the side and rear of the cushion side shield and release the retainers.
Separate the wire harness from the cushion side shield.
1.
Remove the side shield and any remaining side shield retainers from the seat and discard.
For installation, install a new cushion side shield (includes new retainers attached).
2.
4.
Disconnect the seat control switch, release the cushion side shield retainers and remove the seat
control switch.
5.
Seat Control Switch 520
Seat Control Switch 521
Manual
REMOVAL AND
INSTALLATION
Memory Set Switch
Release the memory SET switch bezel tab at the top and separate from the door panel. 1.
Disconnect the electrical connector, release the 4 tabs and remove the memory SET switch. 2.
Memory Set Switch 522
Manual
REMOVAL AND
INSTALLATION
Seat - Exploded View, Rear
Rear Seat Backrest, 60 Percent
1 611A08 Head restraints (1 each required)
2 66716 Striker cover
3 610A18 Head restraint guide sleeves (without button) (2
required)
4 610A16 Head restraint guide sleeves (with button) (2 required)
5 - Armrest bracket-to-backrest bolts (4 required)
6 613A39 Backrest frame
7 047A74 Rubber insert, armrest cup holder
8 13562 Armrest cup holder
9 67210 Armrest bracket
10 W790023 Armrest pivot bolt (2 required)
11 613B44 Armrest pivot bushing (2 required)
12 67112 Armrest assembly
3 610A18 Head restraint guide sleeve (without button)
Seat - Exploded View, Rear 523
4 610A16 Head restraint guide sleeve (with button)
Rear Seat Cushion, Non-Hybrid
1 63804 Cushion cover
Rear Seat Cushion, Hybrid
1 63804 Cushion cover
3 63160 Hard foam
4 638A52 Grille
5 - Screw (5 required) (part of 638A52)
Rear Seat Backrest, 40 Percent 524
Rear Seat Cushion, Hybrid 525
Manual
REMOVAL AND
INSTALLATION
Seat Backrest - Rear
1 - Backrest assembly
2 W707858 Backrest-to-floor bolt (4 required)
1 - Backrest assembly
2 W707858 Backrest-to-floor bolt (4 required)
Removal
NOTE: If the center safety belt retractor locks and the safety belt webbing prevents the 60 percent backrest
from lowering, raise the backrest upward to release the safety belt retractor and belt webbing.
Seat Backrest - Rear 526
All vehicles
Remove the rear seat cushion. For additional information, refer to Seat Cushion - Rear in this section. 1.
Remove the 2 forward backrest-to-floor bolts from the affected rear seat backrest. 2.
Non-Hybrid vehicles
Open the trunk, pull the release handle under the quarter panel and fold the affected backrest down. 3.
Hybrid vehicles
Fold the affected backrest down.
Between the High Voltage Traction Battery (HVTB) and the sheet metal, locate the seat
backrest latch release lever.

Push the release lever toward the outboard side of the vehicle and fold the backrest down.
4.
All vehicles
Remove the 2 rearward backrest-to-floor bolts from the affected rear seat backrest.
Position aside the floor trim cover behind the backrest to gain access to the rearward
backrest-to-floor bolts.

5.
Raise the rear seat backrest and hinge assembly above the 2 locator pins on the floor and remove the
backrest.
6.
Installation
Position the rear seat backrest pivot assembly to the 2 locator pins on the floor.
Make sure the rear seat safety belt webbing is positioned in front of the backst assembly for
installation and is not positioned underneath the backrest pivot assembly.

1.
Install the 2 rearward backrest-to-floor bolts.
2.
Position the backrest upright and install the 2 forward backrest-to-floor bolts.
3.
Check backrest latch and latch release operation.
Raise the backrest and check for good backrest fit and latch closure when upright.
If necessary, adjust the rear seat latch. For additional information, refer to Seat Latch
Adjustment - Rear in the General Procedures portion of this section.

4.
Manual
REMOVAL AND
INSTALLATION
Seat Backrest Cover - Rear, 40 Percent
All vehicles
Remove the 40 percent rear seat backrest. For additional information, refer to Seat Backrest - Rear in
this section.
1.
NOTE: Typical head restraint shown.
While lifting up on the head restraint, push in the hole, push in the button and remove the head
restraint.
2.
Release 4 tabs (2 shown) and remove the striker cover. 3.
Release the backrest cover from around the striker opening. 4.
NOTE: The head restraint guide sleeves are keyed and will not interchange. Install the head restraint
guide sleeve with the button on the LH side.

Seat Backrest Cover - Rear, 40 Percent 529
Squeeze the ends of the head restraint guide sleeves together and remove.
Hybrid vehicle
Remove 2 pin-type retainers and the duct end seal. 6.
All vehicles
Separate the backrest cover.
Disengage the lower J-strips.
Slide the heat deflector out from between the backrest frame and backrest
cover, if equipped.

1.
Disengage the 2 J-clips. 2.
Disengage the backrest cover clip and unwrap the backrest cover from around the
backrest frame.
3.
7.
NOTICE: Use care when separating the backrest cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn from the backrest foam pad.
Remove the backrest cover.
Invert the backrest cover, separate the hook-and-loop strips and remove all rows of
hog rings working up the backrest.

8.
Manual
REMOVAL AND
INSTALLATION
Seat Backrest Cover - Rear, 60 Percent
All vehicles
this section.
1.
restraint.
Repeat for the other head restraint.
2.
Release 4 tabs (2 shown) and remove the striker cover. 3.
Hybrid vehicle
All vehicles
Slide the heat deflector out from between the backrest frame and backrest cover, if
equipped.

1.
Disengage the backrest cover clip and unwrap the backrest cover from around the backrest
frame.
3.
Remove 2 pin-type retainers. 4.
6.
Separate 4 pin-type retainers attaching the armrest pocket cover to the backrest frame. 7.
Remove the 4 armrest-to-backrest bolts and armrest assembly.
For installation, adjust the armrest horizontally as needed for good fit.
8.
Disengage 2 clips in the armrest pocket. 9.
10.
Invert the backrest cover up as far as it will go.
Separate the hook-and-loop strips and remove all rows of hog rings working up the backrest.
NOTE: The head restraint guide sleeves are keyed and will not interchange. Install the head restraint
guide sleeve with the button on the LH side.
Under the backrest foam pad, squeeze the ends of the head restraint guide sleeves together and
remove.
11.
Remove the backrest cover. 12.
Manual
REMOVAL AND
INSTALLATION
Seat Armrest - Rear
All vehicles
this section.
1.
Hybrid vehicle
Remove the 2 pin-type retainers and the duct end seal. 2.
All vehicles
Separate the 4 pin-type retainers attaching the armrest pocket cover to the backrest frame. 3.
Remove the armrest assembly.
2.
4.
Disassemble the armrest assembly in the following sequence.
Remove the cup holder rubber insert. 1.
Remove 2 pin-type retainers and the cup holder. 2.
Remove 2 armrest pivot bolts and armrest bracket.
3.
Release the armrest cover clip, invert and remove. 4.
5.
Seat Armrest - Rear 535
Seat Armrest - Rear 536
Manual
REMOVAL AND
INSTALLATION
Seat Backrest Latch - Rear
NOTE: LH side shown, RH side similar.
Item
Part
Number Description
1 613D61 Backrest latch assembly
2 W520103 Backrest latch nut (2 required)
3 601L60 Latch release cable assembly
4 624A94 Latch release handle bracket (non-hybrid vehicles)
5 W520101 Latch release handle bracket nuts (2 required)
(non-hybrid vehicles)
Removal
All vehicles
Remove the parcel shelf from the rear of the vehicle to access the rear backrest latch nuts. For
1.
NOTE: Make sure the affected backrest is released.
Access the luggage compartment, detach the trim pin-type retainer and position the trim aside.
2.
Non-hybrid vehicles
Seat Backrest Latch - Rear 537
Re the 2 nuts and detach the latch release handle bracket. 3.
Detach the 2 pin-type retainers and latch cable assembly.
Note the cable routing for installation.
4.
Detach the release cable from the latch and remove. 5.
All vehicles
Remove the backrest latch.
Remove the 2 nuts and backrest latch.
6.
Installation
Non-hybrid vehicles
Attach the release cable to the latch. 1.
Route the release cable, position the release handle and bracket to the 2 studs and install the 2 nuts.
Install the 2 release cable pin-type retainers.
Position the trim and install the pin-type retainer.
2.
All vehicles
Position the latch and install the nuts.
Adjust the latch. For additional information, refer to Seat Latch Adjustment - Rear in the
General Procedures portion of this section.

3.
Install the parcel shelf. For additional information, refer to Section 501- . 4.
Seat Backrest Latch - Rear 538
Manual
REMOVAL AND
INSTALLATION
Seat Cushion - Rear
NOTE: Backrest pad and frame removed for clarity.
Item
Part
Number Description
1 - Cushion assembly
2 624A14 Cushion latch (2 required)
3 - Cushion rear retainer (2 required, part of rear seat
backrest)
NOTICE: Do not force the latches or cushion to release. Applying excessive force to release the
rear seat cushion latches can damage them.
NOTICE: Make sure the 2 rear cushion latches are fully disengaged before raising the seat
cushion to avoid damaging the latches.
From under the front of the cushion assembly, push each of the 2 seat cushion latch release levers to
the left of the vehicle. Lift up at the front and release the front of the cushion assembly.
1.
NOTICE: The Hybrid Electric Vehicle (HEV) seat cushion can be easily damaged if not
removed correctly. Do not attempt to removet cushion without disengaging the wires in the
hard foam from the backrest frame hooks. Failure to follow this instruction can pull the wires
out of the hard foam.
2.
Seat Cushion - Rear 539
Release the rear of the seat cushion in the following sequence.
Push the cushion assembly back as far as possible. 1.
Lift up at the rear outboard ends of the cushion assembly, disengaging the wires in the
cushion from the wire retainer hooks of the backrest assembly.
2.
Pull the cushion assembly forward and remove. 3.
Make sure the wires in the cushion are engaged to the wire retainer hooks of the backrest
assembly on each side.

3.
Seat Cushion - Rear 540
Manual
REMOVAL AND
INSTALLATION
Seat Cushion Cover - Rear
If equipped, remove 5 screws and the grille. 2.
If equipped, remove the hog rings retaining the cushion cover wire to the cushion foam pad wire and
the draw strings to the cover wires.
3.
If equipped, separate the cushion cover retainers attached to the hard foam. 4.
Invert the cushion cover. 5.
NOTICE: Use care when separating the cushion cover from the hook-and-loop strip, or the
hook-and-loop strip can be torn from the cushion foam pad.
Remove the hog rings (if equipped), separate the hook-and-loop strips and remove the cushion cover.
6.
To install, reverse the removal proced 7.
Seat Cushion Cover - Rear 541
Seat Cushion Cover - Rear 542
Manual
REMOVAL AND
INSTALLATION
Seat Bolster - Rear
1 W710330 Bolster bolt
2 - Bolster latch
3 66893 Rear seat side bolster
Removal
NOTICE: Do not apply excessive forward force to the side bolsters or damage may occur.
Remove the bolt from the affected side bolster. 2.
For non-hybrid vehicles, open the trunk, pull the release handle under the quarter panel and fold the
affected seat backrest down.
3.
For hybrid vehicle, fold the affected backrest down.
Between the High Voltage Traction Battery (HVTB) and the sheet metal, locate the seat
backrest latch release lever.

Push the release lever toward the outboard side of the vehicle and fold the backrest down
4.
Seat Bolster - Rear 543
If removing the LH side bolster, fashion a tool for releasing the LH side bolster as shown. 5.
NOTE: The latch release tabs are accessible through a small service notch located on the rear inboard
edge of each side bolster (behind the bolster trim cover sew seam).
Locate the service notch behind the rear inboard edge of the affected side bolster to access the latch
release tab.
6.
NOTICE: Do not force the latch or side bolster to release. Applying excessive force can damage
the latch.
NOTE: Latch shown with bolster removed for clarity.
To remove the LH side bolster, use a hooked pick or fashion a hooked tool to pull the latch release
toward the RH side of the vehicle and release the side bolster.
7.
NOTICE: Do not force the latch or side bolster to release. Applying excessive force can damage
the latch.
NOTE: Latch shown with bolster removed for clarity.
To remove the RH side bolster, use a flat-blade screwdriver to push the latch release toward the RH
side of the vehicle and release the side bolster.
8.
With the affected bolster latch released, pull the side bolster forward and remove. 9.
Installation
Position the side bolster, align and insert to the latch.
1.
Align the bolt holes and install the side bolster bolt.
2.
Install the rear seat cushion. Refer to Seat Cushion - Rear in this section. 3.
>
Manual
DISASSEMBLY AND ASSEMBLY Procedure revision date: 06/03/2011
Seat Backrest - Front
NOTE: Driver backrest shown, passenger backrest similar.
Item
Part
Number Description
2 610A16 Head restraint guide (master)
3 610A18 Head restraint guide (slave)
4 14D696 Backrest heater mat (if equipped)
5 19N550 Backrest manifold, climate controlled seat (if equipped)
7 W500632 Recliner-to-cushion frame bolt (4 required)
8 61018 Backrest frame (with manual recliner) (if equipped)
9 608A15 Backrest frame (with power recliner) (if equipped)
10 - Spring clip, recliner handle (part of 61199) (if equipped)
11 61199 Handle, recliner (if equipped)
12 611D11 Side air bag module (if equipped)
13 N620480 Nut, side air bag bracket (2 required) (if equipped)
14 14K155 Wiringss, side air bag (if equipped)
15 65500 Lumbar assembly, power (if equipped)
16 64842 Lumbar assembly, static (if equipped)
17 65500 Lumbar assembly, manual (if equipped)
18 610C01 Manual lumbar control (if equipped)
19 W715704 Rivet, manual lumbar control (2 required) (if equipped)
20 14C693 Wiring harness, power seat backrest (if equipped)
21 613A68 Recliner torque shaft
22 W790022 Bolt, recliner motor (if equipped)
23 14547 Recliner motor (if equipped)
24 - Pal nut, recliner torque shaft (2 required)
25 64646 Upper support spring
26 W712476 Rivet, climate controlled seat Thermo-Electric Device
(TED) (3 required) (if equipped)
27 19N550 TED assembly (if equipped)
28 18D583 Bracket, TED assembly (if equipped)
29 W790002 Pin-type retainer
30 18D507 Exhaust duct, climate controlled seat TED assembly (if
equipped)
31 - Tie strap
32 - Filter, climate controlled seat TED assembly (part of
19N550) (if equipped)
Disassembly
WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim
cover/tear seam pointed away from the body. Do not set a live air bag module down with the
deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in
serious personal injury in the event of an accidental deployment.
WARNING: If the seat side air bag cover has been damaged or separated from its mounting, or if
the air bag material has been exposed, install a new seat side air bag module. Never try to repair the
seat side air bag module. Failure to follow these instructions may result in the seat side air bag
deploying incorrectly, which increases the risk of serious personal injury or death in a crash.
cannot be repaired. A new trim cover must be installed. Cleaning is permissible. Failure to follow these
NOTE: If a side air bag deployment took place, a new seat backrest foam pad, backrest trim cover and side
air bag module and nuts must be installed. A new seat backrest frame should be installed if necessary.
NOTE: The manual recliners and power recliners are serviced as part of the backrest frame.
All seats
section.
1.
Remove and discard th2 head restraint guide sleeves. For additional information, refer to Head
Restraint Guide Sleeve in this section.
2.
Detach the 2 pin-type retainers and trim cover flaps from the recliners, if equipped. 3.
Disengage the backrest cover lower J-strips, separate the hook-and-loop strips and invert the trim
cover up as far as it will go.
4.
If equipped, remove all rows of hog rings from the backrest trim cover and separate the
hook-and-loop strips while inverting the trim cover up the backrest.
5.
Remove the backrest cover rear upper hog rings. 6.
Remove the backrest cover. 7.
If equipped, detach the pin-type retainer and backrest heater mat wiring harness from the backrest
frame.
8.
Separate the backrest foam pad from the backrest frame.
If equipped with climate controlled seats, remove the hog rings from the upper support spring.
Remove the backrest heater mat (if equipped) or the backrest climate controlled seat manifold
(if equipped) from the foam pad.

9.
Remove the backrest climate controlled seat manifold from the foam pad. 10.
If a new heater mat is needed, carefully peel and remove the backrest heater mat from the backrest
foam pad.
It is acceptable for a thin layer of foam to peel away with the old heater mat. The new heater
mat will adhere to the foam pad, but if foam tearing occurs or if any pieces of foam are
removed, install a new foam pad.

11.
Release the 2 lumbar spring clips from the backrest frame and remove the lumbar assembly.
Route out the lumbar cable from the backrest frame, if equipped.
Note the routing of the lumbar cable for installation.

Disconnect the electrical connector from the power lumbar motor, if equipped.
12.
Disconnect the Thermo-Electric Device (TED) assembly electrical connector and detach the wiring
harness retainers.
13.
Remove the TED exhaust duct.
Cut and remove the tie strap.
Remove the retainer and separate the exhaust duct from the TED .
14.
Disconnect the backrest upper support spring from the backrest frame and remove the spring support
with the TED attached.
Use an appropriate tool and separate the TED from the upper backrest support spring.
Note the TED position on the support spring for installation.

15.
Seat with power recliner
Remove the one-way push clip on the RH side of the power recliner. Slide the recliner shaft out from
the LH side of the seat enough to clear the RH recliner and power recline motor.
16.
Disconnect the electrical connector, remove the bolt and the power recline motor. 17.
All seats
NOTE: Note the side air bag module wire harness routing for assembly.
Release the side air bag module wire harness pin-type retainers and remove the side air bag module
wiring harness from the backrest frame.
18.
Remove and discard the 2 side air bag module nuts.
Pull outward on the side air bag module until the studs clear the backrest frame.
19.
Detach any pin-type retainers, route out and remove the backrest wiring harness, if equipped. 20.
Assembly
All seats
Route and install the backrest wiring harness, if removed. 1.
WARNING: If the seat side air bag cover has been damaged or separated from its mounting,
or if the air bag material has been exposed, install a new seat side air bag module. Never try to
repair the seat side air bag module. Failure to follow these instructions may result in the seat
side air bag deploying incorrectly, which increases the risk of serious personal injury or death
in a crash.
WARNING: Inspect the seat side air bag module and mounting surfaces for any damage or
foreign material before installing the seat side air bag module. If any damage is found, install
new components. If any foreign material is found, remove it. Failure to follow these instructions
may result in the seat side air bag module deploying incorrectly and increase the risk of serious
Position the side air bag module to the backrest frame and install 2 new nuts.
2.
Install the side air bag wiring harness.
Route the side air bag wiring harness to the backrest frame as noted in disassembly and install
the pushpin-type retainers.

3.
Connect the side air bag module electrical connector and then slide and engage the side air bag
electrical connector locking clip.
4.
Seat with power recliner
NOTE: The recliners are synchronized. Do not rotate the recliner shaft until fully installed.
Install the recliner motor in the following sequence.
Position the recliner shaft through the recliner motor and RH recliner. 1.
Install a new one-way push clip onto the recliner shaft at the RH recliner. 2.
Slightly turn the recliner motor to align the bolt hole with the hole in the RH recliner and
install the recliner motor bolt.
3.
Connect the recliner motor electrical connector. 4.
5.
NOTICE: Before assembly, inspect the climate controlled seat components for damage, crush,
obstruction and foreign material and repair as needed.
Install the upper support spring and TED assembly to the backrest frame.
Attach the TED and bracket to the backrest upper support spring as noted in disassembly.
6.
Connect the exhaust duct to the TED and install a new tie strap. 7.
Connect the TED electrical connector. 8.
All seats
Attach the lumbar assembly spring clips and install the lumbar assembly to the backrest frame.
If manual lumbar, route the lumbar cable to the backrest as noted in disassembly.
If power lumbar, connect the power lumbar motor electrical connector.
9.
Position the backrest foam pad to the backrest frame. 10.
NOTICE: Do not install a used heater mat to any foam pad. It will not adhere correctly causing
it to bunch up and may cause system failure.
If installing a new heater mat, attach the backrest heater mat to the backrest foam pad.
Remove the paper backing from the adhesive strips.
Align the heater mat to the foam pad and apply it to the foam making sure it lays flat, without
wrinkles and is tucked into the valleys of the foam pad.

11.
obstruction and foreign material and repair as needed.
Align the backrest manifold and insert into the valleys of the foam pad.
Check for correct fit between the manifold, foam pad and TED assembly, to make sure there
is no air flow obstruction or cushion crush.

12.
Install new hog rings to the upper support spring and foam pad. 13.
All seats
Position the backrest trim cover to the backrest frame and foam pad and install new rear upper hog
rings to the backrest frame.
14.
Roll the backrest trim cover downward and attach the hook-and-loop strips.
If removed, install new hog rings as noted during disassembly.
15.
Attach the backrest cover lower J-strips. 16.
Install 2 new head restraint guide sleeves. For additional information, refer to Head Restraint Guide
17.
Install the 2 pin-type retainers and trim cover flaps to the recliners, if equipped. 18.
Install the front seat backrest. For additional information, refer to Seat Backrest - Front in this section. 19.
Manual
Seat Cushion - Front
Driver Seat Cushion
Item
Part
Number Description
5 W520113 Nut, safety belt buckle bracket-to-seat track (2 required)
6 W505256 Bolt, seat position sensor (part of 61203) (driver only)
7 14B416 Seat position sensor (driver only)
8 N620480 Nut, cushion Thermo-Electric Device (TED) (3
9 19N550 Cushion TED , climate controlled seat (if equipped)
11 61711
14 - Pop rivets (4 required)
15 14C708 Driver Seat Module (DSM) (if equipped)
Seat Cushion - Front 554
22 14A699 Driver seat wire harness
28 61753 Manual height adjust handle (if equipped)
29 W711217 Screw, manual height adjust handle (if equipped)
30 62768 Cover, manual height adjust handle (if equipped)
Passenger Seat Cushion
Item
Part
Number Description
2 61710 Seat track
10 610D08 Safety belt anchor bracket
11 W520113 Nut, safety belt anchor bracket (2 required)
12 19N550 Cushion Thermo-Electric Device (TED) (if equipped)
14 N620480 Nut, cushion TED (3 required) (if equipped)
15 W790002 Scrivet
16 W520113 Nut, safety belt buckle bracket (2 required)
Driver Seat Cushion 555
Power Seat Track - Passenger
1 61710 Seat track
2 14A698 Passenger seat wire harness
3 W712479 Occupant Classification System (OCS) rail-to-seat
track bolts (8 required)
4 61708 Outboard OCS> weight sensor assembly
5 14A577 Outboard OCS wire harness
6 61912 Rear outboard seat riser
7 61912 Front outboard seat riser
8 61709 Inboard OCS weight sensor assembly
9 14A578 Inboard OCS wire harness
10 61913 Rear inboard seat riser
11 61913 Front inboard seat riser
12 W712479 Seat riser-to-seat track bolts (6 required)
14 31134/31147 Pop rivet (4 required)
16 31134/31147 Pop rivets (quantity varies with seat option)
Passenger Seat Cushion 556
17 14C724 Heated seat module (if equipped)
18 14C724 Dual Climate Controlled Seat Module (DCSM) (if
equipped)
Disassembly and Assembly
All seats
Remove the seat. For additional information, refer to Seat - Front in this section. 1.
Remove the seat track. For additional information, refer to Seat Track in this section. 2.
NOTICE: Use care when separating the seat cushion trim cover from the hook-and-loop strip,
or the hook-and-loop strip can be torn from the cushion foam pad.
Release the hook-and-loop strips, remove the hog rings, if equipped and separate the cushion trim
cover from the cushion foam pad.
3.
Heated seat
If a new heater mat is needed, carefully peel and remove the cushion heater mat from the cushion
foam pad and route the wire harness through the cushion foam pad opening.
It is acceptable for a thin layer of foam to peel away with the old heater mat. The new heater
mat will adhere to the foam pad, but if foam tearing occurs or if any pieces of foam are
removed, install a new foam pad.

For installation, peel away the paper from the adhesive strips, align and apply the new heater
mat to the cushion foam pad being sure to tuck the heater mat into the foam pad creases.
The heater mat must lay flat on the foam pad with no wrinkles.

4.
obstruction and foreign material. Repair as needed.
If necessary, remove the cushion manifold from the foam pad.
For installation, align the cushion manifold and insert into the valleys of the foam pad.
Check for correct fit between the manifold, foam pad and cushion Thermo-Electric
Device (TED) assembly, to make sure there is no airflow obstruction or cushion
crush.

5.
NOTE: Covering the TED openings is recommended to prevent foreign material from entering the
TED .
Remove the 3 nuts and cushion TED assembly from the cushion frame.
For installation, check for correct fit between the cushion manifold, foam pad and cushion
TED assembly, to make sure there is no air flow obstruction, cushion crush or foreign
material.

6.
All seats
Remove the recliner cable, if equipped. 7.
To assemble, reverse the disassembly procedure. 8.
Manual
Seat Backrest - Rear, 60 Percent
1 611A08 Head restraints (1 each required)
3 610A18 Head restraint guide sleeves (without button) (2
required)
4 610A16 Head restraint guide sleeves (with button) (2 required)
5 - Armrest bracket-to-backrest bolts (4 required)
7 047A74 Rubber insert, armrest cup holder
8 13562 Armrest cup holder
9 67210 Armrest bracket
10 W790023 Armrest pivot bolt (2 required)
11 613B44 Armrest pivot bushing (2 required)
12 67112 Armrest assembly
All vehicles
Remove the 60 percent rear seat backrest. ditional information, refer to Seat Backrest - Rear in this
section.
1.
restraint.
Repeat for the other head restraint.
2.
Seat Backrest - Rear, 60 Percent 559
Release the 4 tabs (2 shown) and remove the striker cover. 3.
Hybrid vehicle
All vehicles
equipped.

1.
From in the opening, disengage the backrest cover clip and unwrap the backrest cover from
around the backrest frame.
3.
6.
Remove the 2 pin-type retainers. 4.
Separate the 4 pin-type retainers attaching the armrest pocket cover to the backrest frame. 7.
8.
Disassemble the armrest assembly in the following sequence.
Remove the cup holder rubber insert. 1.
Remove the 2 pin-type retainers and cup holder. 2.
Remove 2 armrest pivot bolts and armrest bracket.
3.
9.
Disengage 2 backrest cover clips in the armrest pocket. 10.
Invert the backrest cover up as far as it will go.
Separate the hook-and-loop strips and remove all rows of hog rings working up the backrest.
11.
NOTE: The head restraint guide sleeves are keyed and will not interchange. To assemble, install the
head restraint guide sleeve with the button on the LH side.
Under the backrest foam pad, squeeze the ends of the head restraint guide sleeves together and
remove.
12.
Remove the backrest cover and foam pad from the backrest frame. 13.
Manual
Seat Backrest - Rear, 40 Percent
3 610A18 Head restraint guide sleeve (without button)
4 610A16 Head restraint guide sleeve (with button)
All vehicles
this section.
1.
restraint.
2.
Release the 4 tabs (2 shown) and remove the striker cover. 3.
Hybrid vehicle
Remove the 2 pin-type retainers and duct end seal. 5.
All vehicles
equipped.

1.
From in the opening, disengage the backrest cover clip and unwrap the backrest cover from
around the backrest frame.
3.
6.
NOTE: The head restraint guide sleeves are keyed and will not interchange. To assemble, install the
head restraint guide sleeve with the button on the LH side.
Squeeze the ends of the head restraint guide sleeves together and remove.
7.
Remove the backrest cover.
Invert the backrest cover, separate the hook-and-loop strips and remove all rows of hog rings
working up the backrest.

8.
Remove the foam pad from the backrest frame. 9.
SECTION 501-11: Glass, Frames and Mechanisms
Workshop Manual
Material
Capacity
Dow Urethane Adhesive
BetasealTM Express
- -
Dow Urethane One Step Glass
Primer
BetaprimeTM 5500 / 5500A /
5500SA
- -
Motorcraft Lacquer Touch-Up
Paint (match color to exterior grid
wire)
PMP-19500-XXXXX
ESR-M2P100-C -
Permatex Quick GridTM Rear
Window Defogger Repair Kit
15067
- -
Sika Urethane Adhesive
Sika Tack ASAP
- -
Sika Urethane Metal and Glass
Primer
Sika 206 G+P
- -
Motorcraft Ultra-Clear Spray
Glass Cleaner
ZC-23
ESR-M14P5-A -
General Specifications
Item Specification
Terminal Kit - Back Glass 4F1Z-14421-AA -
Front and rear interior door handle bolt 8 71
Front door module bolts 11 97
Front window glass clamp bolts 6 53 gn="left">Rear door module bolts 11 97
Rear window glass clamp bolt 6 53
SECTION 501-11: Glass, Frames and Mechanisms
Workshop Manual
Glass, Frames and Mechanisms
The glass, frames and mechanisms consist of:
accessory delay relay.
door window regulator motors.
Front Controls Interface Module (FCIM).
front door glass top run.
front door window glass.
HVAC module.
rear door window glass.
rear window defrost grid.
rear window defrost relay.
rear window glass.
rear fixed window glass.
rear window regulator and motor - run and brackets.
SJB .
window control switches.
window regulators.
windshield glass.
The glass, frames and mechanisms include:
standard plastic and laminate safety glass.
windshield glass which is bonded to the opening flange with a urethane adhesive.
NOTE: All vehicles are equipped with one-touch up/down feature on the LH front window. All MKZ and
some Fusion vehicles are equipped with one-touch up/down feature for both LH and RH front windows.
The window regulator control switch:
is located on each door trim panel.
may be used to manually raise or lower all windows from the left front window control switch or the
individual side window from the corresponding individual door switch.

can lock out rear window control switches when the lock-out switch on the left front window control
switch is turned on.

The accessory delay relay, located in the SJB , provides power for the operation of the power windows. The
accessory delay feature is active when the ignition switch is in the RUN or the ACC position, or when the
ignition switch is changed from RUN or ACC to the OFF/LOCK position and the LF and RF doors are closed.
Global Open (If Equipped)
NOTE: All MKZ and some Fusion are equipped with the global open feature. Only Fusion vehicles equipped
with RH front one-touch up/down have the global open feature.
Glass, Frames and Mechanisms 568
NOTE: The global open feature may be enabled/disabled via scan tool or in some cases modified by the
customer following a procedure listed in the vehicle Oer's Literature. For a complete list of available
programmable parameters, refer to the Module Configuration and Parameter Chart in Section 418-01 .
The SJB sends a signal on the global open circuit, to both front door window motors and the roof opening
panel motor, to open or close the windows based on a signal received from the Remote Keyless Entry (RKE)
transmitter. If the accessory delay relay is active, the global open feature will not operate.
Rear Window Defrost
For MKZ, the rear window defrost switch is integral to the FCIM . For Fusion, the rear window defrost switch
is integral to the HVAC module or FCIM if equipped with navigation system. When the rear window defrost
switch is pressed, the HVAC module will activate the rear window defrost relay. When the rear window
defrost relay is activated, the rear window defrost grid will be energized.
SECTION 501-11: Glass, Frames and
Mechanisms
Workshop Manual
Glass, Frames and Mechanisms
Special Tool(s)
Flex Probe Kit
Test Light
SGT27000 or equivalent 250-300 mA
incandescent bulb test lamp
Front Power Window Control - One-Touch Up/Down
some Fusion vehicles are equipped with one-touch up/down feature for both LH and RH front windows. LH
and RH one-touch up/down functionality is identical.
NOTE: The front window motor must be de-initialized, then initialized whenever:
the front window motor is removed from the window regulator drum housing.
a new window regulator is installed.
a new window glass is installed.
a new top run is installed.
grease or lubricants are applied to the window regulator or glass run.
Each door window motor is a 6-pin motor with integral electronics and must be initialized whenever a new
window motor has been installed. Initialization is required to learn the full UP position and the profile of the
glass as it travels through the glass channel. Once initialized, obstacle detection is enabled. When mechanical
repairs have been carried out on the window regulator or glass run, the window motor must be de-initialized,
and then initialized. The window control switch sends 2 separate signals to the window motor: up and down.
When the window control switch is pressed to the first detent position, a 12-volt signal is sent to the window
motor to request an up or down operation. When auto up or auto down is requested (switch pressed to the
second detent position), the window control switch provides a 12-volt signal on both the up and down line
simultaneously. During an auto up or auto down request, the window motor determines intended window
direction by the signal first received. If the window control switch is pressed too quickly to the second detent
position (less than 5 milliseconds of time between first detent signal and second detent signal), the window
motor will not be able to determine the intended direction request and will not operate until the window
control switch is relsed and pressed again. The up and down contacts are floating within the window control
switch when the switch is in the neutral position. The up and down feeds to the window motor are all low
current.
When the window motor is operating in auto up or auto down mode, movement of the window can be stopped
by pressing the switch to any position (up, down, auto up, auto down). The window control switch must be
released before the window will move again.
If there is an open in the window control switch or the associated wiring, the related function will become
inoperative. If the up contact of the switch or the associated wiring develops an open circuit, the window will
only operate in the down direction. If the down contact of the switch or the associated wiring develops an
open circuit, the window will only operate in the up direction.
A new window motor will not operate in one-touch up mode, and the bounce-back feature will be disabled
prior to initialization. If the switch is actuated to the AUTO UP or AUTO DOWN position and released,
window movement will stop when the up or down contact in the window control switch is released. If the
window motor is removed from the window regulator drum housing, or if a new window motor is installed, it
must be initialized. Refer to Window Motor Initialization in this section.
The window motor will automatically adjust to system changes throughout its life: changes in seal drag and
slight changes in the full OPEN position will occur and will be automatically compensated for. Once
initialized, the window motor will soft stall into the upper and lower positions contributing to extended
durability of the system. If the window does not seal completely in the full UP position (very small gaps/non
bounce-back events only), the window switch can be actuated to the UP position and the window will be
energized for a fraction of a second to fully seal and this new position will be learned.
Passenger windows may be raised or lowered using the LH front window control switch or the corresponding
passenger window control switch. Rear passenger window control switches receive power when the accessory
delay relay is active and the LH front window lock switch is in the UNLOCK position. When the LH front
window lock switch is in the LOCK position, the rear passenger windows will not operate.
Bounce-Back
The window motor has a bounce-back feature. If an obstacle has been detected in the window opening as the
window glass is moving upward, the window motor will automatically reverse direction and move the glass
toward the bounce-back position (in both up and one-touch up modes). If an obstruction occurs between 4 mm
(0.15 in) and 200 mm (7.87 in) of window opening, the bounce-back position will be 250 mm (9.84 in) of
window opening. If an obstruction occurs at a position greater than 200 mm (7.87 in) of window opening, the
bounce-back position will be 50 mm (1.96 in) below where the obstruction occurred.
Security Override
To override a bounce-back condition (to overcome the resistance of ice on the window or seals for example),
within 2 seconds after the window reaches the bounce-back position, pull and hold the window control switch.
The window will travel up with no bounce-back or pinch protection. If the window control switch is released
before the window is fully closed, the window will stop. If the ignition switch is turned to OFF or START
(without delayed accessory power), the window motor will stop.
Global Open (if equipped)
customer following a procedure listed in the vehicle Owner's Literature. For a complete list of available
If equipped, when the unlock button of the Remote Keyless Entry (RKE) transmitter is held for 2 seconds, the
global open feature activates. The SJB sends a signal to activate the one-touch down operation of both front
windows. The global open feature does not operate if the delay accessory is active.
Delayed Accessory Power
The SJB activates the accessory delay relay whenever the ignition switch is in the RUN or the ACC position,
or when the ignition switch is changed from RUN or ACC to the off/lock position and the LH and RH front
doors are closed. When energized, the accessory delay relay supplies voltage to the power window system.
The SJB will deactivate the delayed accessory feature when:
the LF door is ajar and the ignition switch is in the off/lock or key-out position.
the RF door is ajar and the ignition switch is in the off/lock or key-out position.
ten minutes have elapsed since the ignition switch was changed from ACC or RUN to the off/lock
position.

Rear Window Defrost
For MKZ the rear window defrost switch is integral to the Front Controls Interface Module (FCIM). For
Fusion, the rear window defrost switch is integral to the HVAC module or the FCIM if equipped with
navigation system. When the rear window defrost switch is pressed, the HVAC module will activate the rear
window defrost relay located in the Battery Junction Box (BJB). When the rear window defrost relay is active,
the rear window defrost grid will be energized.
The HVAC module will deactivate the rear window defrost relay when one of the following conditions is met:
The rear window defrost switch is pressed when the feature is active
Ignition switch state is changed from RUN to OFF/LOCK
The 10-minute timer completes
Visually inspect for obvious signs of mechanical or electrical damage.
Door window regulator
and motor

Door glass run
Door window glass
Loose, corroded connectors
Circuitry
Window control switch
Battery Junction Box (BJB) fuse 6 (40A)
Smart Junction Box (SJB) circuit breaker 47
(30A)

SJB fuse(s):
1 (30A)
4 (30A)
17 (20A)
41 (15A)

2.
45 (5A)
Accessory delay relay
Rear window defrost relay
Circuit breaker
Rear window defrost grid
3.
4.
5.
verify the ignition is in the ON position.
refer to Section 418-00 to diagnose no response from the SJB or HVAC module.
6.
418-00 .

If the network test passes, retrieve and record Continuous Memory Diagnostic Trouble Codes
(CMDTCs).

7.
Clear the CMDTCs and carry out the self-test diagnostics for the SJB . 8.
If the DTCs retrieved are related to the concern, go to Smart Junction Box (SJB) DTC Chart or
HVAC Module DTC Chart. For all other DTCs, refer to Section 419-10 .
9.
DTC Charts
Smart Junction Box (SJB) DTC Chart
B1302 Accessory Delay Relay Coil Circuit Failure If the accessory delay is always on, GO to
Pinpoint Test Q .
If the accessory delay is inoperative, GO to
Pinpoint Test P .
B1304 Accessory Delay Relay Coil Circuit Short
to Battery
GO to Pinpoint Test P .
B2947 Global Opening/Closing Circuit Open GO to Pinpoint Test K .
B2949 Global Opening/Closing Circuit Short to
Battery
GO to Pinpoint Test K .
All Other
DTCs
- REFER to the Master DTC Chart in Section
419-10 .
code provides information about specific fault conditions such as opens or shorts to ground. CMDTCs have an
additional 2-character DTC status code suffix to assist in determining DTC history.
HVAC Module DTC Chart
B1C83:12 Rear Defog Relay: Circuit Short to
Battery
For MKZ, GO to Pinpoint Test L .
For Fusion, GO to Pinpoint Test N .
B1C83:14 Rear Defog Relay: Circuit Short to
Ground or Open
If the rear window does not defrost, GO to Pinpoint
Test L (MKZ) or GO to Pinpoint Test N (Fusion).
If the rear window defrost does not turn off, GO to
Pinpoint Test M (MKZ) or GO to Pinpoint Test O
(Fusion).
All other DTCs - REFER to the Master DTC Chart in Section 412-00A
Symptom Chart
Symptom Chart
All power windows are inoperative -
Fusion

Circuit breaker
Wiring, terminals or
connectors

GO
to
Pinpoint
Test
B .

All passenger power windows are
inoperative - Fusion, LH and RH rear
connectors

GO
to
Pinpoint
Test
C .

A single power window is inoperative -
MKZ, LH front
Fuse(s) GO
to

connectors

Power window motor
SJB
Pinpoint
.
Fusion, LH front
connectors

Power window motor
SJB
GO
to
Pinpoint
Test
E .

MKZ, RH front
Fuse
connectors

Power window motor
GO
to
Pinpoint
Test
F .

A Single Power Window is Inoperative -
Fusion, RH Front (RH Front Window is
Equipped With One-Touch Up/Down)
Fuse
connectors

Power window motor
GO
to
Pinpoint
Test
G .

MKZ, LH or RH rear
Fuse
connectors

Power window motor
GO
to
Pinpoint
Test
H .

Fusion, RH front, LH or RH rear
connectors

Power window motor
GO
to
Pinpoint
Test I
.

The one-touch up/down feature is
inoperative
connectors

Power window motor
Power window motor not
initialized

Battery power was lost
while LH or RH front
power window motor
was operating

GO
to
Pinpoint
Test J
.

The global open function is
if equipped
Remote Keyless Entry
(RKE) transmitters

connectors

SJB
GO
to
Pinpoint
Test
K .

Power window motor(s)
not initialized

The defrost system is inoperative - MKZ Fuse(s)
Rear window defrost
relay

connectors

Antenna module
HVAC module
Front Controls Interface
Module (FCIM)

GO
to
Pinpoint
Test
L .

The defrost system will not shut off
automatically - MKZ
Rear window defrost
relay

connectors

HVAC module
/td>
GO
to
Pinpoint
Test
M .

The defrost system is inoperative -
Fusion
Fuse(s)
Rear window defrost
relay

connectors

HVAC module
FCIM (if equipped with
navigation system)

GO
to
Pinpoint
Test
N .

The defrost system will not shut off
automatically - Fusion
Rear window defrost
relay

connectors

HVAC module
GO
to
Pinpoint
Test
O .

The delayed accessory is inoperative SJB GO
to
Pinpoint
Test
P .

The delayed accessory does not turn off Accessory delay relay
connectors

SJB
GO
to
Pinpoint
Test
Q .

Pinpoint Tests
Pinpoint Test A: All Passenger Power Windows are Inoperative - MKZ, LH and RH Rear
Refer to Wiring Diagrams Cell 100 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Power Windows for
Normal Operation
Under normal operation, the accessory delay relay supplies voltage to the master window control switch.
When the master window lockout control switch is in the UNLOCK position, voltage is supplied to the LH
and RH rear window control switches. The master window control switch supplies the ground circuit for
passenger rear window operation.
Circuit breaker
PINPOINT TEST A: ALL PASSENGER POWER WINDOWS ARE INOPERATIVE - MKZ, LH AND RH REAR
NOTE: Before performing this pinpoint test, make sure the master window lockout control switch is in the
UNLOCK position.
A1 CHECK FOR VOLTAGE TO MASTER WINDOW
CONTROL SWITCH
Disconnect: Master Window Control Switch C535B.
Ignition ON.
Measurthe voltage between master window control
switch C535B-3, circuit CBP47 (GN/BU), harness
side and ground.

Yes
GO to A2 .
No
VERIFY SJB circuit breaker 47 (30A) is
OK. If OK, REPAIR the circuit. TEST the
If not OK, REFER to the Wiring
A2 CHECK THE MASTER WINDOW CONTROL
SWITCH GROUND CIRCUIT
Ignition OFF.
Measure the resistance between master window
control switch C535B-6, circuit GD126 (BK/WH),

Yes
GO to A3 .
No
normal operation.
A3 CHECK THE MASTER WINDOW CONTROL
SWITCH
Carry out the master window control switch
component test.
Refer to Wiring Diagrams Cell 149 ( Fusion/MKZ ,
Fusion Hybrid/MKZ Hybrid ) for component testing.

Did the master window control switch pass the
component test?

Yes
REPAIR circuit CPW14 (VT/WH) for an
operation.
No
INSTALL a new master window control
switch. REFER to Window Control
Switch in this section. TEST the system
Pinpoint Test B: All Power Windows are Inoperative - Fusion
Normal Operation
Under normal operation, the accessory delay relay supplies voltage to the master window control switch. The
master window control switch supplies the ground circuit for passenger rear window operation. On vehicles
not equipped with RH front window one-touch up/down feature, this ground circuit is shared with the LH
front window motor.
Accessory lay relay
Circuit breaker
PINPOINT TEST B: ALL POWER WINDOWS ARE INOPERATIVE - FUSION
PINPOINT TEST A: ALL PASSENGER POWER WINDOWS ARE INOPERATIVE - MKZ, LH AND RH REAR 578
B1 CHECK FOR VOLTAGE TO MASTER
WINDOW CONTROL SWITCH
Disconnect: Master Window Control
Switch C535A (if RH front window is
equipped with one-touch up/down) or
C537A (if RH front window is not
equipped with one-touch up/down).

Ignition ON.
Measure the voltage between master
window control switch C535A-3 or
C537A-2, circuit CBP47 (GN/BU), harness
side and ground.

Yes
For vehicles not equipped with RH front window
one-touch up/down feature, GO to B2 . For vehicles
equipped with RH front window one-touch up/down
feature, INSTALL a new master window control
switch. REFER to Window Control Switch in this
No
VERIFY SJB circuit breaker 47 (30A) is OK. If
OK, GO to Pinpoint Test O to diagnose the
accessory delay relay circuit.
If not OK, REFER to the Wiring Diagrams manual
to identify the possible causes of the circuit short.
B2 CHECK THE MASTER WINDOW
CONTROL SWITCH GROUND CIRCUIT
FOR AN OPEN
Ignition OFF.
Switch C537B.

Measure the resistance between master
window control switch C537B-7, circuit
GD126 (BK/WH), harness side and
ground.

Yes
INSTALL a new master window control switch.
REFER to Window Control Switch in this section.
No
operation.
Pinpoint Test C: All Passenger Power Windows are Inoperative - Fusion, LH and RH Rear
PINPOINT TEST B: ALL POWER WINDOWS ARE INOPERATIVE - FUSION 579
Normal Operation
Under normal operation, the accessory delay relay supplies voltage to the master window control switch.
When the master window lockout control switch is in the UNLOCK position, voltage is supplied to the LH
and RH rear window control switches. The master window control switch supplies the ground circuit for
passenger rear window operation.
l type="disc">This pinpoint test is intended to diagnose the following:
PINPOINT TEST C: ALL PASSENGER POWER WINDOWS ARE INOPERATIVE - FUSION, LH AND RH REAR
C1 CHECK THE REAR PASSENGER WINDOW
OPERATION FROM THE MASTER WINDOW
CONTROL SWITCH
Ignition ON.
Attempt to operate the rear passenger windows from the
master window control switch.

Do the rear passenger windows operate from the
master window control switch?

Yes
GO to C3 .
No
GO to C2 .
C2 CHECK THE MASTER WINDOW CONTROL
SWITCH GROUND CIRCUIT FOR AN OPEN
Ignition OFF.
Disconnect: Master Window Control Switch C535B (if
RH front window is equippedith one-touch up/down) or
C537B (if RH front window is not equipped with
one-touch up/down).

Measure the resistance between master window control
switch C535B-6 or C537B-7, circuit GD126 (BK/WH),

Yes
INSTALL a new master window
control switch. REFER to Window
Control Switch in this section. TEST
No
REPAIR the circuit. TEST the system
C3 CHECK THE MASTER WINDOW CONTROL
SWITCH
Yes
REPAIR circuit CPW14 (VT/WH) for
Carry out the master window control switch component
test.

component test?

an open. TEST the system for normal
operation.
No
INSTALL a new master window
control switch. REFER to Window
Pinpoint Test D: A Single Power Window is Inoperative - MKZ, LH Front
NOTE: A new LH front power window motor will not operate in one-touch up mode until initialized. Refer
to Window Motor Initialization in this section.
Normal Operation
Under normal operation, voltage is supplied to the master window control switch from the accessory delay
relay. The LH front power window motor has dedicated high current power and ground circuits. When the
master window control switch is activated, a low current voltage signal is supplied to the LH front power
window motor which causes the window to move upward or downward.
Fuse(s)
Power window motor
PINPOINT TEST D: A SINGLE POWER WINDOW IS INOPERATIVE - MKZ, LH FRONT
D1 CHECK THE POWER TO THE MASTER
Disconnect: Master Window Control Switch
C535A.

Igtion ON.
Measure the voltage between master window
control switch C535A-3, circuit CBP41 (BU),

Yes
GO to D2 .
No
(15A) is OK. If OK, REPAIR the circuit. If
circuit short. DE-INITIALIZE then
INITIALIZE the front window motor. REFER
to Window Motor Initialization in this
operation.
PINPOINT TEST C: ALL PASSENGER POWER WINDOWS ARE INOPERATIVE - FUSION, LH AND RH REAR 581
D2 CHECK THE VOLTAGE TO THE POWER
WINDOW MOTOR
Ignition OFF.
Disconnect: LH Front Power Window Motor
C540.

Measure the voltage between LH front power
window motor C540-4, circuit SBP01 (RD),

Yes
GO to D3 .
No
VERIFY SJB fuse 1 (30A) is OK. If OK,
REPAIR the circuit. If not OK, REFER to the
Wiring Diagrams manual to identify the
possible causes of the circuit short.
DE-INITIALIZE, then INITIALIZE the LH
front window motor. REFER to Window
Motor Initialization in this section. TEST the
D3 CHECK THE LH FRONT POWER WINDOW
MOTOR GROUND CIRCUIT FOR AN OPEN
Measure the resistance between LH front power
window motor C540-3, circuit GD126 (BK/WH),

Yes
GO to D4 .
No
REPAIR the circuit. DE-INITIALIZE then
INITIALIZE the LH front window motor.
REFER to Window Motor Initialization in
operation.
D4 CHECK THE MASTER WINDOW CONTROL
SWITCH-TO-LH FRONT POWER WINDOW
MOTOR CIRCUITS FOR AN OPEN
window motor C540-1, circuit CPW10 (YE/VT),
harness side and master window control switch
C535A-8, circuit CPW10 (YE/VT), harness side.

Yes
GO to D5 .
No
REPAIR circuit CPW10 (YE/VT) or CPW11
(BU/GY) for an open. DE-INITIALIZE then
PINPOINT TEST D: A SINGLE POWER WINDOW IS INOPERATIVE - MKZ, LH FRONT 582
window motor C540-6, circuit CPW11 (BU/GY),
C535A-4, circuit CPW11 (BU/GY), harness side.

operation.
D5 CHECK THE MASTER WINDOW CONTROL
SWITCH
component test.
component testing.

component test?

Yes
INSTALL a new LH front power window
motor. REFER to Window Regulator and
Motor - Front Door in this section.
INITIALIZE the LH front power window
motor. REFER to Window Motor
Initialization in this section. TEST the system
No
switch. REFER to Window Control Switch in
this section. DE-INITIALIZE, then
Initialization in this section. TEST the system
Pinpoint Test E: A Single Power Window is Inoperative - Fusion, LH Front
NOTE: A new LH front power window motor will not operate in one-touch up mode until initialized. Refer
PINPOINT TEST D: A SINGLE POWER WINDOW IS INOPERATIVE - MKZ, LH FRONT 583
Normal Operation
Under normal operation, voltage is supied to the master window control switch from the accessory delay
relay. The LH front power window motor has dedicated high current power and ground circuits. When the
master window control switch is activated, a low current voltage signal is supplied to the LH front power
window motor which causes the window to move upward or downward.
Fuse
Power window motor
PINPOINT TEST E: A SINGLE POWER WINDOW IS INOPERATIVE - FUSION, LH FRONT
E1 CHECK THE VOLTAGE TO THE POWER
WINDOW MOTOR
Ignition OFF.
C540.

Measure the voltage between LH front power
window motor C540-4, circuit SBP01 (RD),

Yes
GO to E2 .
No
(30A) is OK. If OK, REPAIR the circuit. If
circuit short. DE-INITIALIZE, then
operation.
E2 CHECK THE LH FRONT POWER WINDOW
MOTOR GROUND CIRCUIT FOR AN OPEN
Ignition OFF.
window motor C540-3, circuit GD126 (BK/WH),

Yes
GO to E3 .
No
operation.
E3 CHECK THE MASTER WINDOW CONTROL
SWITCH-TO-LH FRONT POWER WINDOW
MOTOR CIRCUITS FOR AN OPEN
Disconnect: LH Front Window Control Switch
C535A (if RH front window is equipped with
one-touch up/down) or C537A (if RH front
window is not equipped with one-touch up/down).

window motor C540-1, circuit CPW10 (YE/VT),
C535A-7 or C537A-1, circuit CPW10 (YE/VT),
harness side.

window motor C540-6, circuit CPW11 (BU/GY),
C535A-3 or C537A-5, circuit CPW11 (BU/GY),
harness side.

Yes
GO to E4 .
No
Initialization in this section. TEST the
E4 CHECK THE MASTER WINDOW CONTROL
SWITCH
component test.
Refer to Wiring Diagrams Cell 149 ( Fusion/MKZ
, Fusion Hybrid/MKZ Hybrid ) for component

Yes
PINPOINT TEST E: A SINGLE POWER WINDOW IS INOPERATIVE - FUSION, LH FRONT 585
testing.
component test?

No
switch. REFER to Window Control Switch
in this section. DE-INITIALIZE, then
Pinpoint Test F: A Single Power Window is Inoperative - MKZ, RH Front
NOTE: A new RH front power window motor will not operate in one-touch up mode until initialized. Refer
Normal Operation
Under normal operation, the accessory delay relay supplies voltage to the master window control switch and
the RH front window control switch. The RH front power window motor has dedicated high current power
and ground circuits. When the master window control switch or RH front window control switch is activated,
a low current voltage signal is supplied to the RH front power window motor which causes the window to
move upward or downward.
Fuse(s)
Power window motor
PINPOINT TEST F: A SINGLE POWER WINDOW IS INOPERATIVE - MKZ, RH FRONT
F1 CHECK THE RH FRONT POWER
WINDOW OPERATION FROM THE
MASTER WINDOW CONTROL SWITCH
Attempt to operate the RH front window
using the master window control switch.

Does the RH window operate when
using the master window control
switch?

Yes
GO to F7 .
No
GO to F2 .
F2 CHECK THE POWER TO THE
Switch C535A.

Ignition ON.
Measure the voltage between master
window control switch C535A-3, circuit
CBP41 (BU), harness side and ground.

Yes
GO to F3 .
No
VERIFY Smart Junction Box (SJB) fuse 41 (15A) is
OK. If OK, REPAIR the circuit. If not OK, REFER to
the Wiring Diagrams manual to identify the possible
causes of the circuit short. DE-INITIALIZE, then
INITIALIZE the front power window motor. REFER
to Window Motor Initialization in this section. TEST
POWER WINDOW MOTOR
Ignition OFF.
Disconnect: RH Front Power Window
Motor C623.

Measure the voltage between RH front
power window motor C623-4, circuit
ground.

Yes
GO to F4 .
No
VERIFY SJB fuse 4 (30A) is OK. If OK, REPAIR the
circuit. DE-INITIALIZE then INITIALIZE the RH
front power window motor.
If not OK, REFER to the Wiring Diagrams manual to
identify the possible causes of the circuit short. REFER
F4 CHECK THE RH FRONT POWER
WINDOW MOTOR GROUND CIRCUIT
FOR AN OPEN
Measure the resistance between RH
front power window motor C623-3,
circuit GD139 (BK/YE), harness side
and ground.

Yes
GO to F5 .
No
INITIALIZE the RH front power window motor.
REFER to Window Motor Initialization in this section.
PINPOINT TEST F: A SINGLE POWER WINDOW IS INOPERATIVE - MKZ, RH FRONT 587
F5 CHECK THE MASTER WINDOW
CONTROL SWITCH-TO-RH FRONT
POWER WINDOW MOTOR CIRCUITS
FOR AN OPEN
front window power window motor
C623-1, circuit CPW12 (GN/OG),
harness side and master window control
switch C535A-2, circuit CPW12
(GN/OG), harness side.

circuit CPW13 (BN/YE), harness side
and master window control switch
C535A-6, circuit CPW13 (BN/YE),
harness side.

Yes
GO to F6 .
No
CONTROL SWITCH
Carry out the master window control
switch component test.

Yes
INSTALL a new RH front power window motor.
REFER to Window Regulator and Motor - Front Door
in this section. INITIALIZE the RH front power
window motor. REFER to Window Motor
Initialization in this section. TEST the system for
normal operation.
Did the master window control switch
pass the component test?

No
F7 CHECK FOR VOLTAGE TO THE RH
FRONT WINDOW CONTROL SWITCH
Disconnect: RH Front Window Control
Switch C624.

Ignition ON.
window control switch C624-2, circuit

Yes
GO to F8 .
No
operation.
WINDOW CONTROL SWITCH CIRCUITS
FOR AN OPEN
Ignition OFF.
Switch C535A.

CPW12 (GN/OG), harness side and RH
front window control switch C624-5,
circuit CPW12 (GN/OG), harness side.

CPW13 (BN/YE), harness side and RH

Yes
INSTALL a new RH front window control switch.
No
operation.
circuit CPW13 (BN/YE), harness side.
Pinpoint Test G: A Single Power Window is Inoperative - Fusion, RH Front (RH Front Window is
Equipped With One-Touch Up/Down)
NOTE: A new RH front power window motor will not operate in one-touch up mode until initialized. Refer
Normal Operation
Under normal operation, the accessory delay relay supplies voltage to the master window control switch and
the RH front window control switch. The RH front power window motor has dedicated high current power
and ground circuits. When the master window control switch or RH front window control switch is activated,
a low current voltage signal is supplied to the RH front power window motor which causes the window to
move upward or downward.
Fuse(s)
Power window motor
PINPOINT TEST G: A SINGLE POWER WINDOW IS INOPERATIVE - FUSION, RH FRONT (RH FRONT WINDOW IS
EQUIPPED WITH ONE-TOUCH UP/DOWN)
Failure to use the correct probe adapter(s) may damage e connector.
G1 CHECK THE RH FRONT POWER
WINDOW OPERATION FROM THE
Attempt to operate the RH front window
using the master window control switch.

Does the RH window operate when
using the master window control
switch?

Yes
GO to G6 .
No
GO to G2 .
G2 CHECK THE VOLTAGE TO THE
POWER WINDOW MOTOR
Ignition OFF.
Disconnect: RH Front Power Window
Motor C623.

power window motor C623-4, circuit
ground.

Yes
GO to G3 .
No
VERIFY SJB fuse 4 (30A) is OK. If OK, REPAIR the
circuit. DE-INITIALIZE then INITIALIZE the RH
front power window motor.
If not OK, REFER to the Wiring Diagrams manual to
identify the possible causes of the circuit short. REFER
G3 CHECK THE RH FRONT POWER
WINDOW MOTOR GROUND CIRCUIT
FOR AN OPEN
circuit GD139 (BK/YE), harness side
and ground.

Yes
GO to G4 .
No
G4 CHECK THE MASTER WINDOW
POWER WINDOW MOTOR CIRCUITS
FOR AN OPEN
Switch C535A.

front window power window motor
C623-1, circuit CPW12 (GN/OG),
harness side and master window control
switch C535A-2, circuit CPW12
(GN/OG), harness side.

Yes
GO to G5 .
No
PINPOINT TEST G: A SINGLE POWER WINDOW IS INOPERATIVE - FUSION, RH FRONT (RH FRONT WINDOW ISEQUIPPED WITH ONE-TOUCH UP/DOWN) 591
circuit CPW13 (BN/YE), harness side
and master window control switch
C535A-6, circuit CPW13 (BN/YE),
harness side.

CONTROL SWITCH
Carry out the master window control
switch component test.

Did the master window control switch

Yes
INSTALL a new RH front power window motor.
REFER to Window Regulator and Motor - Front Door
in this section. INITIALIZE the RH front power
window motor. REFER to Window Motor
normal operation.
No
TEST the system for normal opation.
G6 CHECK FOR VOLTAGE TO THE RH
FRONT WINDOW CONTROL SWITCH
Disconnect: RH Front Window Control
Switch C624.

Ignition ON.
window control switch C624-5, circuit

Yes
GO to G7 .
No
VERIFY Smart Junction Box (SJB) fuse 41 (15A) is
OK. If OK, REPAIR the circuit. If not OK, REFER to
the Wiring Diagrams manual to identify the possible
causes of the circuit short. DE-INITIALIZE, then
INITIALIZE the front power window motor. REFER
WINDOW CONTROL SWITCH CIRCUITS
FOR AN OPEN
Ignition OFF.
Switch C535A.

CPW12 (GN/OG), harness side and RH
circuit CPW12 (GN/OG), harness side.

CPW13 (BN/YE), harness side and RH
circuit CPW13 (BN/YE), harness side.

Yes
INSTALL a new RH front window control switch.
No
operation.
Pinpoint Test H: A Single Power Window is Inoperative - MKZ, LH or RH Rear
Normal Operation
The LH and RH rear window control switches receive voltage from the master window control switch when
the window lockout switch is set to the UNLOCK position. Ground is also provided to the LH and RH rear
window control switches from the master window control switch. The LH and RH rear window control
switches transfer power and ground to their respective rear window motors. Window direction is controlled by
reversing polarity of the voltage and ground circuits being supplied to the window motor.
When operating the LH or RH rear window from the master window control switch, voltage and ground is
sent from the LH front window control switch through the normally closed contacts within the LH or RH rear
window control switch to operate the LH or RH rear window. Window direction is controlled by reversing
polarity of the voltage and ground circuits being supplied to the window motor.
Power window motor
PINPOINT TEST H: A SINGLE POWER WINDOW IS INOPERATIVE - MKZ, LH OR RH REAR
H1 CHECK THE VOLTAGE TO THE LH OR RH REAR WINDOW
CONTROL SWITCH
Disconnect: Inoperative Rear Window Control Switch C701 (LH)
or C819 (RH).

Ignition ON.
NOTE: Set the master window control lockout switch to the
UNLOCK position.

Measure the voltage between the inoperative rear window
connector and ground:

for the RH rear window control switch, measure the voltage
between RH rear window control switch C819-3, circuit
CPW14 (VT/WH), harness side and ground.

for the LH rear window control switch, measure the voltage
between C701-3, circuit CPW14 (VT/WH), harness side
and ground.

Yes
GO to H2 .
No
operation.
H2 CHECK THE GROUNDS TO THE INOPERATIVE REAR
Ignition OFF.
Measure the resistance between the inoperative window control
switch and ground:

for the RH rear window control switch, measure the
resistance between RH rear window control switch C819-1,
circuit CPW17 (BN/GN), harness side and ground; and
CPW18 (GY/VT), harness side and ground.

for the LH rear window control switch, measure the
resistance between LH rear window control switch C701-1,
circuit CPW15 (YE), harness side and ground; and between
LH rear window control switch C701-6, circuit CPW16
(BU/OG), harness side and ground.

Yes
GO to H4 .
No
GO to H3 .
H3 CHECK THE CIRCUITS TO THE INOPERATIVE REAR
WINDOW CONTROL SWITCH FOR AN OPEN
Ignition OFF.
Disconnect: LH Front Window Control Switch C535B.
For an inoperative LH rear power window, measure the resistance
between master window control switch C535B-1, circuit CPW15
(YE) and LH rear window control switch C701-1, circuit CPW15
(YE), harness side; and between master window control switch
C535B-2, circuit CPW16 (BU/OG) and LH rear window control
switch C701-6, circuit CPW16 (BU/OG), harness side.

For an inoperative RH rear power window, measure the resistance
between master window control switch C535B-7, circuit CPW17
(BN/GN) and RH window control switch C819-1, circuit CPW17
(BN/GN), harness side; and between master window control switch

Yes
INSTALL a new master
window control switch.
REFER to Window Control
Switch in this section.
TEST the system for
normal operation.
No
REPAIR the circuit(s) for
an open. TEST the system
PINPOINT TEST H: A SINGLE POWER WINDOW IS INOPERATIVE - MKZ, LH OR RH REAR 595
C535B-8, circuit CPW18 (GY/VT) and RH rear window control
switch C819-6, circuit CPW18 (GY/VT), harness side.
H4 CHECK THE INOPERATIVE WINDOW CONTROL SWITCH
Connect: Master Window Control Switch C535B.
Ignition ON.
For an inoperative LH rear window, connect a fused jumper wire
between LH rear window control switch C701-2, circuit CPW21
(BN), harness side and LH rear window control switch C701-3,
circuit CPW14 (VT/WH), harness side; and between LH rear
window control switch C701-5, circuit CPW22 (GN/VT), harness
side and LH rear window control switch C701-6, circuit CPW16
(BU/OG), harness side. The LH rear window should operate in the
downward direction.

For an inoperative RH rear window, connect a fused jumper wire
between RH rear window control switch C819-2, circuit CPW23
(GY), harness side and RH rear window control switch C819-3,
circuit CPW14 (VT/WH), harness side; and between RH rear
window control switch C819-5, circuit CPW24 (WH/VT), harness
side and RH rear window control switch C819-6, circuit CPW18
(GY/VT), harness side. The RH rear window should operate in the
downward direction.

circuit CPW15 (YE), harness side; and between LH rear window
control switch C701-5, circuit CPW22 (GN/VT), harness side and

Yes
window control switch or
RH rear window control
switch. REFER to Window
Control Switch in this
section. TEST the system
No
GO to H5 .
LH rear window control switch C701-3, circuit CPW14 (VT/WH),
harness side. The LH rear window should operate in the upward
direction.
circuit CPW17 (BN/GN), harness side; and between RH rear
(VT/WH), harness side. The RH rear window should operate in the
upward direction.

Did the inoperative window operate correctly?
H5 CHECK THE POWER WINDOW MOTOR CIRCUITS
Ignition OFF.
Disconnect: Inoperative Rear Window Motor C703 (LH) or C803
(RH).

For an inoperative LH rear window, measure the resistance between
LH rear window control switch C701-5, circuit CPW22 (GN/VT),
harness side and LH rear window motor C703-1, circuit CPW22
(GN/VT), harness side.

For an inoperative RH rear window, measure the resistance
(WH/VT), harness side and RH rear window motor C803-1, circuit
CPW24 (WH/VT), harness side.

LH rear window control switch C701-2, circuit CPW21 (BN),
harness side and LH rear window motor C703-2, circuit CPW21
(BN), harness side.

For an inoperative RH rear window, measure the resistance
(GY), harness side and RH rear window motor C803-2, circuit
CPW23 (GY), harness side.

Yes
INSTALL a new LH or RH
rear window motor. REFER
to Window Regulator
Motor in this section. TEST
operation.
No
operation.
Pinpoint Test I: A Single Power Window is Inoperative - Fusion, RH Front, LH or RH Rear
NOTE: To diagnose an inoperative RH front window that is equipped with one-touch up/down feature, GO to
Pinpoint Test G .
Refer to Wiring Diagrams Cell 100 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ),ower Windows for
Normal Operation
The RH front window control switch receives voltage from the accessory delay relay. The LH and RH rear
window control switches receive voltage from the LH front window control switch when the window lock
switch is set to the UNLOCK position. Ground is provided to the RH front, LH rear and RH rear window
control switches from the LH front window control switch. Each window control switch transfers voltage and
ground to their respective window motors. Window direction is controlled by reversing polarity of the voltage
and ground circuits being supplied to the window motor.
Power window motor
PINPOINT TEST I: A SINGLE POWER WINDOW IS INOPERATIVE - FUSION, RH FRONT, LH OR RH REAR
I1 CHECK THE VOLTAGE TO THE RH FRONT, LH REAR OR RH
REAR WINDOW CONTROL SWITCH
Disconnect: Inoperative Rear Window Control Switch C604 (RH
front), C701 (LH rear) or C819 (RH rear).

Ignition ON.
NOTE: Set the master window control lockout switch to the
UNLOCK position.

Measure the voltage between the inoperative window connector and
ground:

for the RH front window control switch, measure the voltage
between RH front window control switch C604-3, circuit

Yes
GO to I2 .
No
For RH front window,
REPAIR circuit CBP47
(GN/BU) for an open.
TEST the system for
normal operation.
CBP47 (GN/BU), harness side and ground.
for t RH rear window control switch, measure the voltage
CPW14 (VT/WH), harness side and ground.

for the LH rear window control switch, measure the voltage
between C701-3, circuit CPW14 (VT/WH), harness side and
ground.

For LH or RH rear
window, REPAIR circuit
CPW14 (VT/WH) for an
open. TEST the system for
normal operation.
I2 CHECK THE GROUNDS TO THE INOPERATIVE REAR
Ignition OFF.
Measure the resistance between the inoperative window control
switch and ground:

for the RH front window control switch, measure the
resistance between RH front window control switch C604-1,
circuit CPW12 (GN/OG), harness side and ground; and
between RH front window control switch C604-6, circuit
CPW13 (GY/RD), harness side and ground.

for the RH rear window control switch, measure the
resistance between RH rear window control switch C819-1,
circuit CPW17 (BN/GN), harness side and ground; and
CPW18 (GY/VT), harness side and ground.

for the LH rear window control switch, measure the
resistance between LH rear window control switch C701-1,
circuit CPW15 (YE), harness side and ground; and between
LH rear window control switch C701-6, circuit CPW16
(BU/OG), harness side and ground.

Yes
GO to I4 .
No
GO to I3 .
I3 CHECK THE CIRCUITS TO THE INOPERATIVE REAR
WINDOW CONTROL SWITCH FOR AN OPEN
PINPOINT TEST I: A SINGLE POWER WINDOW IS INOPERATIVE - FUSION, RH FRONT, LH OR RH REAR 599
Ignition OFF.
Disconnect: LH Front Window Control Switch C537A, C535B (if
RH front window is equipped with one-touch up/down) or C537B (if
RH front window is not equipped with one-touch up/down).

Measure the resistance between the master window control switch
and the inoperative window control switch:

For an inoperative RH front power window, measure the
resistance between master window control switch C537A-4,
circuit CPW12 (GN/OG) and RH front window control
switch C604-1, circuit CPW12 (GN/OG), harness side; and
between master window control switch C537A-8, circuit
CPW13 (GY/RD) and RH front window control switch
C604-6, circuit CPW13 (GY/RD), harness side.

For an inoperative LH rear power window, measure the
resistance between master window control switch C535B-1
or C537B-1, circuit CPW15 (YE) and LH rear window
control switch C701-1, circuit CPW15 (YE), harness side;
and between master window control switch C535B-2 or
C537B-5, circuit CPW16 (BU/OG) and LH rear window
control switch C701-6, circuit CPW16 (BU/OG), harness
side.

For an inoperative RH rear power window, measure the
resistance between master window control switch C535B-7
or C537B-4, circuit CPW17 (BN/GN) and RH window
control switch C819-1, circuit CPW17 (BN/GN), harness
side; and between master window control switch C535B-8 or
C537B-8, circuit CPW18 (GY/VT) and RH rear window
control switch C819-6, circuit CPW18 (GY/VT), harness
side.

Yes
REFER to Window
No
REPAIR the circuit(s) for
an open. TEST the system
I4 CHECK THE INOPERATIVE WINDOW CONTROL SWITCH
Ignition ON.
For an inoperative RH front window, connect a fused jumper wire
between RH front window control switch C604-2, circuit CPW19
(VT), harness side and RH front window control switch C604-3,
circuit CBP47 (GN/BU), harness side; and between RH front
window control switch C604-5, circuit CPW20 (YE/BK), harness
side and RH front window control switch C604-6, circuit CPW13
(GY/RD), harness side. The RH front window should operate in the
downward direction.

circuit CPW14 (VT/WH), harness side; and between LH rear

Yes
INSTALL a new RH
front, LH or RH rear
REFER to Window
No
GO to I5 .
window control switch C701-5, circuit CPW22 (GN/VT), harness
side and LH rear window control switch C701-6, circuit CPW16
(BU/OG), harness side. The LH rear window should operate in the
downward direction.
circuit CPW14 (VT/WH), harness side; and between RH rear
(GY/VT), harness side. The RH rear window should operate in the
downward direction.

For an inoperative RH front window, connect a fused jumper wire
between RH front window control switch C604-2, circuit CPW19
(VT), harness side and RH front window control switch C604-1,
circuit CPW12 (GN/OG), harness side; and between RH front
window control switch C604-5, circuit CPW20 (YE/BK), harness
side and RH front window control switch C604-3, circuit CBP47
(GN/BU), harness side. The RH front window should operate in the
upward direction.

circuit CPW15 (YE), harness side; and between LH rear window
control switch C701-5, circuit CPW22 (GN/VT), harness side and
LH rear window control switch C701-3, circuit CPW14 (VT/WH),
harness side. The LH rear window should operate in the upward
direction.

circuit CPW17 (BN/GN), harness side; and between RH rear window
control switch C819-5, circuit CPW24 (WH/VT), harness side and
RH rear window control switch C819-3, circuit CPW14 (VT/WH),
harness side. The RH rear window should operate in the upward
direction.

Did the inoperative window operate correctly?
I5 CHECK THE POWER WINDOW MOTOR CIRCUITS
Ignition OFF.
Disconnect: Inoperative Power Window Motor C608 (RH front),
C703 (LH rear) or C803 (RH rear).

For an inoperative RH front window, measure the resistance between
RH front window control switch C604-2, circuit CPW19 (VT),
harness side and RH front power window motor C608-2, circuit
CPW19 (VT), harness side.

LH rear window control switch C701-2, circuit CPW21 (BN),
harness side and LH rear power window motor C703-2, circuit
CPW21 (BN), harness side.

For an inoperative RH rear window, measure the resistance between
RH rear window control switch C819-2, circuit CPW23 (GY),
harness side and RH rear power window motor C803-2, circuit
CPW23 (GY), harness side.

For an inoperative RH front window, measure the resistance between
RH front window control switch C604-5, circuit CPW20 (YE/BK),
harness side and RH front power window motor C608-1, circuit
CPW20 (YE/BK), harness side.

LH rear window control switch C701-5, circuit CPW22 (GN/VT),
harness side and LH rear power window motor C703-1, circuit
CPW22 (GN/VT), harness side.

For an inoperative RH rear window, measure the resistance between
RH rear window control switch C819-5, circuit CPW24 (WH/VT),
harness side and RH rear power window motor C803-2, circuit
CPW24 (WH/VT), harness side.

Yes
INSTALL a new RH
front, LH or RH rear
power window motor.
REFER to Window
Regulator Motor in this
No
operation.
Pinpoint Test J: The One-Touch Up/Down Feature is Inoperative
some Fusion vehicles are equipped with one-touch up/down feature for both LH and RH front windows.
NOTE: A new LH or RH front power window motor will not operate in one-touch up or one-touch down
mode until initialized. Refer to Window Motor Initialization in this section.
Normal Operation
During normal operation, when the window control switch is pressed to the second detent position to request
an auto up or auto down operation, the window control switch provides a 12-volt signal on both the up and
down line simultaneously. During an auto up or auto down request, the window motor determines intended
window direction by the signal first received (first detent position). If the window control switch is pressed
too quickly to the second detent position (less than 5 milliseconds of time between first detent signal and
second detent signal), the window motor will not be able to determine the intended direction request and will
not operate until the window control switch is released and pressed again.
B(+) power lost during LH or RH front window operation
Power window motor not initialized
Power window motor
PINPOINT TEST J: THE ONE-TOUCH UP/DOWN FEATURE IS INOPERATIVE
J1 CHECK FOR POWER (B+) LOSS DURING
LH OR RH FRONT POWER WINDOW
OPERATION
Verify if power (B+) was lost during LH or RH
front window operation.

Was power (B+) lost while the LH or RH
front window was in operation?

Yes
RAISE the LH or RH front window to the fully
CLOSED position. VERIFY the window glass
stalls into the upper header seal. The front
window should function normally. TEST the
No
GO to J2 .
J2 DE-INITIALIZE, THEN INITIALIZE THE
FRONT POWER WINDOW MOTOR
De-initialize the front power window motor,
then carry out the front power window motor
initialization procedure. Refer to Window
Motor Initialization in this section.

Is the one-touch up/down feature operating
correctly?

Yes
The front power window motor lost
initialization.
No
For LH window, GO to J3 . For RH window,
GO to J4 .
J3 CHECK THE MASTER WINDOW CONTROL
SWITCH
Ignition OFF.
C535A and C535B (MKZ or Fusion if RH front
window is equipped with one-touch up/down)
or C537A and C537B (Fusion if RH front
window is not equipped with one-touch
up/down).

component test.

Did the master window switch pass the
component test?

Yes
motor. REFER to Window Regulator Motor in
operation.
No
switch. REFER to Window Control Switch in
operation.
J4 CHECK THE LH AND RH FRONT WINDOW
CONTROL SWITCH
Ignition OFF.
C535A and C535B.

Disconnect: RH Front Window Control Switch
C624.

component test and the RH front window
control switch component test.

Did both the master window control switch
and RH front window switch pass the
component tests?

Yes
INSTALL a new RH front power window
motor. REFER to Window Regulator Motor in
operation.
No
INSTALL a new master window control switch
or RH front window control switch. REFER to
Window Control Switch in this section. TEST
Pinpoint Test K: The Global Open Function is Inoperative/Does Not Operate Correctly - If Equipped
PINPOINT TEST J: THE ONE-TOUCH UP/DOWN FEATURE IS INOPERATIVE 604
Normal Operation
When the unlock button of the Remote Keyless Entry (RKE) transmitter is held for 2 seconds, the global open
activates. The Smart Junction Box (SJB) sends a signal to the LH and RH front power window motors to
activate the one-touch down operation of both front windows.
The global open feature does not operate if the accessory delay relay is active.
DTC B2947 (Global Opening/Closing Circuit Open) - sets when the SJB detects the global open
circuit is open or shorted to ground.

DTC B2949 (Global Opening/Closing Circuit Short to Battery) - sets when the SJB detects the global
open circuit is shorted to voltage.

RKE transmitters
SJB
Power window motors not initialized
PINPOINT TEST K: THE GLOBAL OPEN FUNCTION IS INOPERATIVE/DOES NOT OPERATE CORRECTLY - IF
EQUIPPED
Failuuse the correct probe adapter(s) may damage the connector.
NOTE: The global open feature must be enabled and one-touch up/down must be operational for the global
open function to operate correctly. Make sure the global open feature is enabled and one-touch up/down is
operational before proceeding with this diagnostic.
K1 CHECK THE DTCs
Refer to the results from the previous SJB
self-test.

Was DTC B2947 or B2949 retrieved?
Yes
For B2949, GO to K2 .
For B2947, GO to K5 .
No
GO to K7 .
K2 CHECK THE GLOBAL OPEN CIRCUIT FOR
A SHORT TO VOLTAGE
Ignition OFF.
Disconnect: SJB C2280C.
Ignition ON.
Measure the voltage between SJB C2280C-10,
circuit CPW01 (BN/BU), harness side and
ground.

Yes
GO to K3 .
No
GO to K9 .
A SHORT TO VOLTAGE
C540.

ground.

Yes
GO to K4 .
No
Initialization in this section. CLEAR the
DTCs. REPEAT the self-test. TEST the
A SHORT TO VOLTAGE
Disconnect: RH Front Power Window Motor C62
ground.

Yes
INITIALIZE the LH and RH front window
motors. REFER to Window Motor
No
INSTALL a new RH front power window
INITIALIZE the RH front power window
motor. REFER to Window Motor Initializaon
in this section. CLEAR the DTCs. REPEAT
the self-test. TEST the system for normal
PINPOINT TEST K: THE GLOBAL OPEN FUNCTION IS INOPERATIVE/DOES NOT OPERATE CORRECTLY - IFEQUIPPED 606
operation.
AN OPEN
Ignition OFF.
C540.

Disconnect: RH Front Power Window Motor
C623.

Measure the resistance between SJB C2280C-10,
circuit CPW01 (BN/BU), harness side and LH
front power window motor C540-2, circuit
CPW01 (BN/BU), harness side; and between SJB
C2280C-10, circuit CPW01 (BN/BU), harness
side and RH front power window motor C623-2,
circuit CPW01 (BN/BU), harness side.

Yes
GO to K6 .
No
INITIALIZE the LH and RH front power
window motors. REFER to Window Motor
A SHORT TO GROUND
Measure the resistance between SJB C2280C-10,
ground.

Yes
GO to K9 .
No
INITIALIZE the LH and RH front power
window motors. REFER to Window Motor
K7 CHECK THE RKE TRANSMITTER
OPERATION
Operate the RKE lock/unlock function using all
of the RKE transmitters.

Does the RKE lock/unlock function operate
correctly with at least one of the RKE
transmitters?

Yes
GO to K8 .
No
REFER to Section 501-14 to continue
diagnosis of the RKE system. CLEAR the
PINPOINT TEST K: THE GLOBAL OPEN FUNCTION IS INOPERATIVE/DOES NOT OPERATE CORRECTLY - IFEQUIPPED 607
K8 CHECK THE RKE TRANSMITTERS GLOBAL
OPEN OPERATION
Operate the global open function using all of the
RKE transmitters.

Does the global open function operate correctly
with at least one of the RKE transmitters?

Yes
PROVIDE new RKE transmitters. REFER to
Section 501-14 . TEST the system for normal
operation.
No
GO to K9 .
K9 CHECK THE SJB FOR CORRECT
OPERATION
Disconnect all of the SJB connectors.
Check for:
corrosion.
pushed-out pins.
Connect all of the SJB connectors and make sure

Operate the system and verify the concern is still
present.

Yes
INSTALL a new SJB . REFER to Section
419-10 . REPEAT the self-test. TEST the
No
The concern may have been caused by a
loose or corroded connector. CLEAR the
Pinpoint Test L: The Defrost System is Inoperative - MKZ
Refer to Wiring Diagrams Cell 56 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Heated Window for
Normal Operation
When the engine is running and the defrost switch (integral to the Front Controls Interface Module (FCIM)) is
pressed, the FCIM sends the defrost request message to the HVAC module over the Controller Area Network
(CAN). When the request is received, the HVAC module activates the rear window defrost relay which
supplies voltage through the antenna module to the rear window defrost grid.
DTC B1C83:12 (Rear Defog Relay: Circuit Short to Battery) - sets when the HVAC module detects a
short to voltage on the rear window defrost relay control circuit.

DTC B1C83:14 (Rear Defog Relay: Circuit Short to Ground or Open) - sets when the HVAC module
detects an open or short to ground on the rear window defrost relay control circuit.

Fuse(s)
Rear wi defrost relay
HVAC module
FCIM
Antenna module
PINPOINT TEST L: THE DEFROST SYSTEM IS INOPERATIVE - MKZ
L1 CHECK FOR VOLTAGE TO THE REAR WINDOW
DEFROST GRID
Disconnect: Antenna Module C4194B.
Start the engine.
Activate the rear defrost switch and measure the voltage
between antenna module C4194B-1, circuit CRD06
(BN/YE), harness side and ground.

Yes
INSPECT antenna module jumper
harness and rear window defrost grid
ground circuit for damage and
REPAIR as necessary. If jumper
harness and defrost grid ground wire
are OK, INSTALL a new antenna
module. TEST the system for normal
operation.
No
GO to L2 .
L2 CHECK FOR VOLTAGE TO THE REAR WINDOW
DEFROST RELAY
Ignition OFF.
Disconnect: Rear Window Defrost Relay.
Ignition ON.
Measure the voltage between rear window defrost relay
socket pin 86 and ground; and between rear window
defrost relay socket pin 30 and ground.

Is the voltage greater than 10 volts for both
measurements?

Yes
GO to L3 .
No
VERIFY Battery Junction Box (BJB)
fuse 6 (40A) and Smart Junction Box
(SJB) fuse 45 (5A) are OK. If OK,
Diagrams manual to identify the
L3 CHECK THE HVAC MODULE
PINPOINT TEST L: THE DEFROST SYSTEM IS INOPERATIVE - MKZ 609
NOTICE: The following step uses a test light to
simulate normal circuit loads. Use only the test light
recommended in the Special Tools table at the
beginning of this section or equivalent. To avoid
connector terminal damage, use the Flex Probe Kit for
the test light probe connection to the vehicle. Do not
use the test light probe directly on any connector.
Start the engine.
Activate the rear window defrost switch.
Connect a 12-volt incandescent test light between rear
window defrost relay socket pin 85, circuit CH122
(WH/OG) and rear window defrost relay socket pin 86.

Does the test light illuminate?
Yes
GO to L4 .
No
GO to L5 .
L4 CHECK THE REAR WINDOW DEFROST RELAY
Carry out the rear window defrost relay component test.

Did the rear window defrost relay pass the component
test?

Yes
REPAIR open in circuit CRD06
(BN/YE). CLEAR the DTCs. TEST
No
INSTALL a new rear window
defrost relay. CLEAR the DTCs.
operation.
L5 CHECK THE REAR WINDOW DEFROST SWITCH
(CC_SW_R_DEF) PID
Ignition ON.
DataLogger - FCIM .

Monitor the FCIM CC_SW_R_DEF PID while pressing
and releasing the rear window defrost switch.

Does the PID agree with the rear window defrost
switch status?

Yes
GO to L6 .
No
Section 415-00 . CLEAR the DTCs.
operation.
PINPOINT TEST L: THE DEFROST SYSTEM IS INOPERATIVE - MKZ 610
L6 CHECK THE REAR WINDOW DEFROST RELAY
CONTROL CIRCUIT FOR AN OPEN
Ignition OFF.
Measure the resistance between rear window defrost relay
socket pin 85, circuit CH122 (WH/OG), harness side and
HVAC module C2356A-12, circuit CH122 (WH/OG),
harness side.

Yes
GO to L7 .
No
L7 CHECK FOR CORRECT HVAC MODULE
OPERATION
Disconnect all HVAC module electrical connectors.
Check for:
corrosion.
pushed-out pins.
Connect all HVAC module electrical connectors and make

Operate the system and verify the concern is still present.
Yes
REFER to Section 412-01 . TEST
No
this time. Concern may have been
connector. TEST the system for
normal operation.
Pinpoint Test M: The Defrost System Will Not Shut Off Automatically - MKZ
Normal Operation
When the engine is running and the defrost switch (integral to the Front Controls Interface Module (FCIM)) is
pressed, the FCIM sends the defrost request message to the HVAC module over the Controller Area Network
(CAN). When the request is received, the HVAC module activates the rear window defrost relay which
supplies voltage through the antenna module to the rear window defrost grid.

HVAC module
PINPOINT TEST M: THE DEFROST SYSTEM WILL NOT SHUT OFF AUTOMATICALLY - MKZ
M1 CHECK THE REAR WINDOW DEFROST GRID POWER
CIRCUIT FOR A SHORT TO VOLTA
Disconnect: Antenna Module C4194B.
Ignition ON.
Measure the voltage between antenna module C4194B-1, circuit
CRD06 (BN/YE), harness side and ground.

Yes
REPAIR circuit CRD06
(BN/YE) for a short to
voltage. TEST the system for
normal operation.
No
GO to M2 .
M2 CHECK THE HVAC MODULE OUTPUT
Start the engine.
NOTICE: The following step uses a test light to simulate
normal circuit loads. Use only the test light recommended in
the Special Tools table at the beginning of this section or
equivalent. To avoid connector terminal damage, use the Flex
Probe Kit for the test light probe connection to the vehicle. Do
not use the test light probe directly on any connector.

Connect a 12-volt incandescent test light between rear window
defrost relay socket pin 85, circuit CH122 (WH/OG) and rear
window defrost relay socket pin 86.

Yes
GO to M3 .
No
INSTALL a new rear
window defrost relay. TEST
operation.
PINPOINT TEST M: THE DEFROST SYSTEM WILL NOT SHUT OFF AUTOMATICALLY - MKZ612
M3 CHECK THE REAR WINDOW DEFROST RELAY
CONTROL CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Measure the resistance between rear window defrost relay socket
pin 85, circuit CH122 (WH/OG) and ground.

Yes
GO to M4 .
No
REPAIR short to ground in
circuit CH122 (WH/OG).
operation.
M4 CHECK FOR CORRECT HVAC MODULE OPERATION
Disconnect all HVAC module connectors.
Check for:
corrosion.
pushed-out pins.
Connect all HVAC module connectors and make sure they seat
correctly.

Yes
INSTALL a new HVAC
412-01 . TEST the system for
normal operation.
No
The system is operating
correctly at this time.
Concern may have been
connector. TEST the system
PINPOINT TEST M: THE DEFROST SYSTEM WILL NOT SHUT OFF AUTOMATICALLY - MKZ613
Pinpoint Test N: The Defrost System is Inoperative - Fusion
Normal Operation
When the engine is running and the defrost switch (integral to the HVAC module or Front Controls Interface
Module (FCIM), if equipped with navigation system) is pressed, the HVAC module activates the rear window
defrost relay by grounding the relay coil. For vehicles equipped with navigation system, the FCIM sends the
defrost request message to the HVAC module over the Controller Area Network (CAN). When the defrost
relay is activated, voltage is supplied from the relay to the rear window defrost grid.
DTC B1C83:12 (Rear Defog Relay: Circuit Short to Battery) - sets when the HVAC module detects a
short to voltage on the rear window defrost relay control circuit.


Fuse
HVAC module
FCIM
PINPOINT TEST N: THE DEFROST SYSTEM IS INOPERATIVE - FUSION
NOTICE: Use the correct probe adapter(s) from the Flex Probe Kit when making measurements. F to
use the correct probe adapter(s) may damage the connector.
N1 CHECK FOR VOLTAGE TO THE REAR WINDOW
DEFROST GRID
Disconnect: Rear Window Defrost Grid Power.
Start the engine.
Activate the rear defrost switch and measure the voltage between
rear window defrost grid power C402A-1, circuit CRD06
(BN/YE), harness side and ground.

Yes
GO to N2 .
No
GO to N3 .
N2 CHECK THE REAR WINDOW DEFROST GRID GROUND
Ignition OFF.
Disconnect: Rear Window Defrost Grid Ground C402B.
Measure the resistance between rear window defrost grid ground
C402B-1, circuit GD147 (BK/VT) and ground.

Yes
CARRY OUT the Grid Wire
Test in this section. REPAIR
the rear window defrost grid
or INSTALL a new rear
window glass. REFER to
Window Grid Wire Repair in
No
operation.
N3 CHECK THE VOLTAGE SUPPLY TO THE REAR WINDOW
DEFROST RELAY
Ignition OFF.
Ignition ON.
Measure the voltage between rear window defrost relay socket pin
86 and ground; and between rear window defrost relay socket pin
30 and ground.

Is the voltage greater than 10 volts for both measurements?
Yes
GO to N4 .
No
VERIFY Battery Junction
Box (BJB) fuse 6 (40A) and
Smart Junction Box (SJB)
fuse 45 (5A) are OK. If OK,
operation.
If not OK, REFER to the
Wiring Diagrams manual to
identify the possible causes
of the circuit short. REPAIR
the circuit. TEST the system
N4 CHECK THE HVAC MODULE
Start the engine.
Yes
GO to N5 .
No
If equipped with navigation
system, GO to N6 . If not
equipped with navigation
system, GO to N7 .
PINPOINT TEST N: THE DEFROST SYSTEM IS INOPERATIVE - FUSION 615
Activate the rear window defrost switch.

N5 CHECK THE REAR WINDOW DEFROST RELAY
Carry out the rear window defrost relay component test.
Refer to Wiring Diagrams Cell 149 ( Fusion/MKZ , Fusion
Hybrid/MKZ Hybrid ) for component testing.

Did the rear window defrost relay pass the component test?
Yes
REPAIR open in circuit
CRD06 (BN/YE). CLEAR
the DTCs. TEST the system
No
INSTALL a new rear
window defrost relay.
CLEAR the DTCs. TEST the
N6 CHECK THE REAR WINDOW DEFROST SWITCH
(CC_SW_R_DEF) PID
Ignition ON.
Enter the following diagnostic mode on the scan tool: DataLogger
- FCIM .

Monitor the FCIM CC_SW_R_DEF PID while pressing and
releasing the rear window defrost switch.

Does the PID agree with the rear window defrost switch
status?

Yes
GO to N7 .
No
INSTALL a new FCIM .
CLEAR the DTCs. TEST the
N7 CHECK THE REAR WINDOW DEFROST RELAY CONTROL
CIRCUIT FOR AN OPEN
PINPOINT TEST N: THE DEFROST SYSTEM IS INOPERATIVE - FUSION 616
Ignition OFF.
Disconnect: HVAC Module - Electronic Manual Temperature
Control (EMTC) C2357A or HVAC Module - Dual Automatic
Temperature Control (DATC) C2356A.

pin 85, circuit CH122 (WH/OG), harness side and HVAC module
- EMTC C2357A-12 or HVAC Module - DATC C2356A-12,
circuit CH122 (WH/OG), harness side.

Yes
GO to N8 .
No
operation.
Disconnect all HVAC module electrical connectors.
Check for:
corrosion.
pushed-out pins.
Connect all HVAC module electrical connectors and make sure

Yes
INSTALL a new HVAC
412-01 . TEST the system
No
caused by a loose or
corroded connector. TEST
operation.
Pinpoint Test O: The Defrost System Will Not Shut Off Automatically - Fusion
Normal Operation
When the engine is running and the defrost switch (integral to the HVAC module or Front Controls Interface
Module (FCIM), if equipped with navigation system) is pressed, the HVAC module activates the rear window
defrost relay by grounding the relay coil. For vehicles equipped with navigation system, the FCIM sends the
defrost request message to the HVAC module over the Controller Area Network (CAN). When the defrost
relay is activated, voltage is supplied from the relay to the rear window defrost grid.

HVAC module
PINPOINT TEST O: THE DEFROST SYSTEM WILL NOT SHUT OFF AUTOMATICALLY - FUSION
O1 CHECK THE REAR WINDOW DEFROST GRID POWER
Disconnect: Rear Window Defrost Grid Power C402A.
Ignition ON.
Measure the voltage between rear window defrost grid power
C402A-1, circuit CRD06 (BN/YE), harness side and ground.

Yes
REPAIR circuit CRD06
(BN/YE) for a short to
voltage. TEST the system for
normal operation.
No
GO to O2 .
O2 CHECK THE REAR WINDOW DEFROST RELAY
Start the engine.


Yes
GO to O3 .
No
INSTALL a new rear
window defrost relay. TEST
operation.
PINPOINT TEST O: THE DEFROST SYSTEM WILL NOT SHUT OFF AUTOMATICALLY - FUSION 618
O3 CHECK THE REAR WINDOW DEFROST RELAY
Ignition OFF.
Disconnect: HVAC Module - Electronic Manual Temperature
Control (EMTC) C2357A or HVAC Module - Dual Automatic
Temperature Control (DATC) C2356A.

Start the engine.
pin 85, circuit CH122 (WH/OG), harness side and ground.

Yes
GO to O4 .
No
REPAIR short to ground in
circuit CH122 (WH/OG).
operation.
O4 CHECK FOR CORRECT HVAC MODULE OPERATION
Disconnect all HVAC module connectors.
Check for:
corrosion.
pushed-out pins.
Connect all HVAC module connectors and make sure they seat
correctly.

Yes
INSTALL a new HVAC
normal operation.
No
PINPOINT TEST O: THE DEFROST SYSTEM WILL NOT SHUT OFF AUTOMATICALLY - FUSION 619
Pinpoint Test P: The Delayed Accessory is Inoperative
Normal Operation
The accessory delay relay is located in the Smart Junction Box (SJB). When the ignition is turned ON, the
SJB activates the accessory delay relay, which provides power to the master window control switch. The
delayed accessory feature remains active for 10 minutes after the ignition is turned OFF or until either front
door is opened.
DTC B1302 (Accessory Delay Relay Coil Circuit Failure) - sets when the SJB detects an open or
short to ground on the accessory delay relay control circuit.

DTC B1304 (Accessory Delay Relay Coil Circuit Short to Battery) - Sets when the SJB detects a
short to voltage on the accessory delay relay control circuit.

Circuit breaker
SJB
PINPOINT TEST P: THE DELAYED ASORY IS INOPERATIVE
P1 CHECK THE DOOR AJAR SWITCH
OPERATION
Open and close the front doors. Verify the interior
lights turn on when the doors are open, and off when
the doors are closed.

Do the interior lights operate normally?
Yes
GO to P2 .
No
REFER to Section 417-02 to diagnose the
interior lighting and door ajar switches.
P2 CHECK THE ACCESSORY DELAY RELAY
Disconnect: Accessory Delay Relay.
Carry out the accessory delay relay component test.

Did the delayed accessory relay pass the
component test?

Yes
VERIFY SJB fuse 41 (15A) (MKZ only)
and circuit breaker 47 (30A) are OK. If
OK, GO to P3 .
causes of the circuit short. REPAIR the
circuit. TEST the system for normal
operation.
No
INSTALL a new accessory delay relay.
P3 CHECK THE MASTER WINDOW CONTROL
SWITCH POWER CIRCUIT FOR AN OPEN
Ignition OFF.
Disconnect: SJB C2280D.
Disconnect: Master Window Control Switch C537A
(Fusion, if RH front window is not equipped with
one-touch up/down) or C535B (MKZ and/or Fusion
if RH front window is equipped with one-touch
up/down).

Measure the resistance between master window
control switch C537A-2 or C535B-3 , circuit CBP47
(GN/BU), harness side and SJB C2280D-32, circuit
CBP47 (GN/BU), harness side.

Yes
GO to P4 .
No
normal operation.
P4 CHECK FOR CORRECT SJB OPERATION
Disconnect all SJB connectors.
Check for:
corrosion.
pushed-out pins.
Connect all SJB connectors and make sure they seat
correctly.

present.

Yes
operation.
No
time. Concern may have been caused by a
loose or corroded connector. CLEAR the
Pinpoint Test Q: The Delayed Accessory Does Not Turn Off
Normal Operation
The accessory delay relay is located in the Smart Junction Box (SJB). When the ignition is turned ON, the
SJB activates the accessory delay relay, which provides power to the master window control switch. The
PINPOINT TEST P: THE DELAYED ASORY IS INOPERATIVE 621
delayed accessory feature remains active for 10 minutes after the ignition is turned OFF or until either front
door is opened.
DTC B1302 (Accessory Delay Relay Coil Circuit Failure) - sets when the SJB detects an open or
short to ground on the accessory delay relay control circuit.

Wiring, terminals or connections
SJB
PINPOINT TEST Q: THE DELAYED ACCESSORY DOES NOT TURN OFF
Q1 CHECK FOR STUCK/STICKING
ACCESSORY DELAY RELAY
Disconnect:
Delayed
Accessory
Relay.

Do the
power
windows
still
operate?

Yes
GO
to
Q3 .
No
GO
to
Q2 .
Q2 CHECK THE ACCESSORY
DELAY RELAY
Carry out the accessory delay relay
component test.
Refer to Wiring Diagrams Cell 149
( Fusion/MKZ , Fusion
Hybrid/MKZ Hybrid ) for
component testing.

Did the accessory delay relay

Yes
GO to Q4 .
No
INSTALL a new accessory delay
relay. TEST the system for normal
operation.
Q3 CHECK THE MASTER WINDOW
CONTROL SWITCH POWER
CIRCUIT FOR A SHORT TO
VOLTAGE
Ignition OFF.
Ignition ON.
C2280D-32, circuit CBP47

Yes
REPAIR circuit CBP47 (GN/BU) for
a short to voltage. TEST the system
No
GO to Q4 .
Q4 CHECK FOR CORRECT SJB
OPERATION
Disconnect all SJB connectors.
Check for:
corrosion.
pushed-out pins.
Connect all SJB connectors and
make sure they seat correctly.

Operate the system and verify the
concern is still present.

Yes
normal operation.
No
connector. CLEAR the DTCs.
REPEAT the self-test. TEST the
Component Test
Grid Wire Test
Using a bright lamp inside the vehicle, inspect the wire grid from the outside. A broken grid wire
appears as a brown spot.
1.
Run the engine at idle. Set the rear window defrost switch to ON. The indicator light should
illuminate.
2.
Working inside the vehicle with a voltmeter, contact the broad, red-brown stripes of the back glass
window grid (positive lead to B+ side and negative lead to ground side). The meter should read 10-13
volts. A lower voltage reading may indicate a loose grid connection.
3.
Contact a good ground point with the negative lead of the meter. The voltage reading should not
change. If the voltage increases, this indicates a loose ground connection. A voltage reading of less
than 10 volts indicates a loose B+ side connection.
4.
With the negative lead of the meter grounded, touch each grid line of the rear window defrost glass at
its midpoint with the positive lead. A reading of approximately 6 volts indicates the line is good. A
reading of 0 volt indicates the line is broken between the midpoint and the B+ side of the grid line. A
reading of 12 volts indicates the circuit is broken between the midpoint of the grid line and ground.
5.
Pinpointing the exact position of the break can be accomplished (if the voltmeter reads 0 volt when
the midpoint of the grid line is touched with the positive lead of the voltmeter) by moving the positive
lead of the voltmeter toward the B+ side of the grid line and touching the grid line until the voltmeter
reads 12 volts. If the voltmeter reads 12 volts when the midpoint of the grid line is touched with the
positive lead of the voltmeter, simply move the positive lead of the voltmeter toward the ground
connection of the grid line and touch the grid line until the voltmeter reads 0 volt.
6.
PINPOINT TEST Q: THE DELAYED ACCESSORY DOES NOT TURN OFF 623
PINPOINT TEST Q: THE DELAYED ACCESSORY DOES NOT TURN OFF 624
Mechanisms
Workshop Manual
Window Grid Wire Repair
General Equipment
Polypropylene Film Fine Line Tape (Commercially
available)
Material
Item Specification
Motorcraft Lacquer Touch-Up
Paint (match color to exterior grid
wire)
PMP-19500-XXXXX
ESR-M2P100-C
Permatex Quick GridTM Rear
Window Defogger Repair Kit
15067
-
Motorcraft Ultra-Clear Spray
Glass Cleaner
ZC-23
ESR-M14P5-A
NOTE: The grid line material is not embedded into the glass, but is baked to the glass surface and
consequently can be scraped off. An undamaged grid line will have small ridges that project above the surface
of the glass and can easily be felt when running a fingernail across them. Grid lines that have been "razor
bladed" will feel smooth when a fingernail is dragged across the affected area. Inoperative lines may appear to
the eye to be undamaged due to residue remaining on the glass and will require diagnosis with a voltmeter or
12V test lamp. For additional information, refer to Diagnosis and Testing in this section.
Bring the vehicle up to a room temperature of at least 16C (60F) or above. 1.
NOTICE: Do not use scrapers, sharp instruments or abrasive window cleaners on the interior
surface of the rear window glass as this may cause damage to the grid lines.
Clean the entire grid line repair area with glass cleaner and 0000 steel wool to remove all dirt, wax,
grease, oil or other foreign material.
2.
Mark the location of the grid break on the exterior of the rear window glass. 3.
Using a polypropylene film fine line tape, mask the area directly above and below the grid break
extending the tape 26 mm (1.02 in) beyond the concern area in both directions. The break area should
4.
Window Grid Wire Repair 625
be at the cef the mask.
NOTE: If the brown layer is not broken or missing, apply only the silver grid repair compound to the
break. If both the brown and silver layers of the grid are broken or missing, apply a coating of the
lacquer touch up paint across the break in the grid line prior to applying the rear window defroster
repair compound. Do not overlap the silver grid line with the paint. Several applications may be
necessary to achieve a color match.
NOTE: Allow at least 5 minutes of drying time between applications for the touch up paint or the
silver repair coating. Applying fewer coats or not allowing adequate drying time between coats will
produce repaired resistance that is greater than OEM resistance, resulting in poor defrost performance
and excessive localized heating.
Apply the repair coating to the grid break area in several smooth, continuous strokes. Extend the
silver repair coating at least 6.35 mm (0.25 in) on both sides of the break area.
Apply a minimum of 6 applications of the grid repair compound.
5.
NOTE: The repair coating air-dries in approximately one minute and can be energized after 5
minutes. Optimum adhesion occurs after approximately 24 hours.
Allow the repair area to dry completely and remove the mask.
6.
NOTICE: Be careful not to damage the grid line with the razor blade. If this occurs, additional
repair may be necessary.
Remove any excess repair compound above or below the grid line with a razor blade.
7.
NOTE: The interior side of the grid lines are not painted, but due to the silver tarnishing will tend to
change the grid to a gold or brown color. The repair area will be bright silver and will also tarnish
over time to match the rest of the grid.
Test the system for normal operation.
8.
Mechanisms
Workshop Manual
Lead Terminal Repair
General Equipment
Terminal Kit - Back Glass 4F1Z-14421-AA
Material
Item Specification
Motorcraft Ultra-Clear Spray Glass
Cleaner
ZC-23
ESR-M14P5-A
Bring the vehicle up to room temperature of at least 16C (60F) or above. 1.
NOTE: The new terminal will cover the original terminal location, but it must be placed so that the
terminal conductive areas will be placed on a good conductive base.
Clean the bus bar in the area to be repaired with steel wool (000 to 0000 grade), and then with glass
cleaner to remove all dirt, wax, grease, oil or other foreign material.
2.
NOTICE: Do not use any type of flame torch or flame-heated soldering gun for this procedure.
Use of these tools provide inadequate heat generation at the tip and the exhaust heat can cause
damage to plastic trim parts in the area. Use only an electric soldering gun with 100 watts or
more of power. Before using the soldering gun, be sure to melt a small amount of rosin core
solder to the tip. The solder will assist in achieving better heat transfer from the soldering gun
tip to the new terminal.
NOTE: Depending on the original terminal location, and whether the terminal is covered by pillar
trim, will determine where to locate the new terminal. Some grid line bus bars may only allow the
placement of the terminal above or below the original tab location due to space limitations. Fst
vehicle applications, the replacement tab location will cover the original tab location, but still allow
the replacement tab to attach to the bus bar on good conductive material.
Place the replacement terminal type A over the original tab location, making sure the conductive areas
of the terminal will be on a good conductive area. Do not place the terminal tab foot on the original
location, which does not have conductive material.
3.
Hold the terminal in place with an item such as a regular lead pencil at a 90 degree angle from the
terminal. (Holding at other than a 90 degree angle may allow the terminal to slip when the solder
4.
Lead Terminal Repair 628
liquefies.)
NOTE: The new terminal has pre-applied solder, flux and temperature-sensitive paint. The paint
provides a visual indication when the terminal has reached the correct temperature to melt solder on
the terminal. When the correct temperature is achieved, the temperature paint will liquefy and change
color.
Place the soldering gun tip on the top of the terminal, but not on the painted areas of the tab. Energize
the soldering gun and watch for the painted area of the terminal to liquefy and change color. The paint
should liquefy in approximately 25-45 seconds after heating. As soon as the paint color completely
changes on either side of the terminal, de-energize the soldering gun and continue to hold the terminal
in place with the soldering gun and pencil for an additional 30 seconds.
5.
Remove the soldering gun and pencil from the terminal. The terminal should be allowed to cool for
another 2 minutes before the wiring lead is attached to the terminal.
6.
Attach the electrical lead connection to this terminal, turn on the heated rear window and verify the
operation.
7.
Lead Terminal Repair 629
Mechanisms
Workshop Manual
Window Motor Initialization
NOTE: Initialization is required to learn both the full UP and full DOWN positions of the glass as it travels
through the glass channel. Once initialized, obstacle detection is enabled.
NOTE: The front window motor must be de-initialized, then initialized whenever:
the front window motor is removed from the window regulator drum housing.
a new window regulator is installed.
a new window glass is installed.
a new top run is installed.
grease or lubricants are applied to the window regulator or glass run.
NOTE: Install and tighten all window components to specification before carrying out the initialization
procedure.
NOTE: A new (original factory setting) or de-initialized window motor will not operate in one-touch up
mode until initialized. If a new front window motor has been installed, proceed to the initialization procedure.
NOTE: Excessive bounce-back (window reverses direction with no obstructions present) may indicate that a
de-initialization procedure may need to be performed.
De-Initialization procedure
Turn the ignition key ON. 1.
Operate the window control switch in one-touch up mode and remove power from the window motor
while the window is moving by one of the following methods:
Disconnect the vehicle battery cable while the window is moving . 1.
Disconnect the window motor connector while the window is moving . 2.
Remove the LH or RH front window motor fuse while the window is moving . 3.
2.
This will de-initialize the window motor and reset the window motor to its original factory settings. 3.
Reconnect the battery cable, window motor connector or window motor fuse before proceeding to the
initialization procedure.
4.
Initialization procedure
WARNING: Keep objects and body parts clear of the glass panel when carrying out the
initialization procedure. During the initialization procedure, the glass panel closes with high force and
cannot detect objects in its path. Failure to follow this instruction may result in serious personal injury.
NOTE: The front window must be in the full OPEN position for this procedure to operate correctly.
NOTE: If the initialization procedure is only partially completed, the front window motor will remain
de-initialized and will not operate in one-touch up mode.
Turn the ignition key ON. 5.
Window Motor Initialization 630
Press and hold the window control switch until the window glass stalls for 2 seconds into the glass top
run and release the switch.
6.
Pull and hold the window control switch until the window glass stalls for 2 seconds at the bottom of
its travel and release the switch.
7.
Test for correct window operation by carrying out the one-touch up feature. If the window does not
operate correctly, carefully repeat this procedure.
8.
Window Motor Initialization 631
Mechanisms
Workshop Manual
Glass Reseal - Windshield
Material
Item Specification
BetasealTM Express
-
Sika Tack ASAP
-
Cleaner
ZC-23
ESR-M14P5-A
Remove the cowl panel grille. For additional information, refer to Section 501-02 . 1.
Remove the LH and RH A-pillar trim panels. For additional information, refer to Section 501-05 . 2.
Remove the LH and RH sun visors. 3.
If equipped, remove the overhead console. 4.
If equipped, disconnect the automatic-dimming rear view mirror electrical connector. 5.
If equipped, disconnect the rain sensor electrical connector. 6.
Remove the LH and RH assist handles. 7.
Lower the front portion of the headliner and block with a suitable material. 8.
Clean the edge formed by the existing urethane adhesive and the glass on the inside at the top and sides and
outside on the bottom of the windshield with glass cleaner.

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
adhesive with less effort and a continuous bead.
NOTE: Make sure there are no gaps in the urethane adhesive bead.
Apply urethane adhesive over the top of the existing urethane adhesive.
11.
Glass Reseal - Windshield 632
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.
NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air or water
leaks.
After the urethane adhesive has cured, check the windshield seal for air or water leaks through the
urethane adhesive bead and add urethane adhesive as necessary.
12.
Position the front portion of the headliner. 13.
Install the LH and RH assist handles. 14.
If equipped, connect the rain sensor electrical connector. 15.
If equipped, connect the automatic-dimming rear view mirror electrical connector. 16.
If equipped, install the overhead console. 17.
Install the LH and RH sun visors. 18.
Install the LH and RH A-pillar trim panels. For additional information, refer to Section 501-05 . 19.
Install the cowl panel grille. For additional information, refer to Section 501-02 . 20.
Clean the interior and exterior windshield glass with glass cleaner. 21.
Glass Reseal - Windshield 633
Mechanisms
Workshop Manual
Glass Reseal - Rear
Material
Item Specification
BetasealTM Express
-
Sika Tack ASAP
-
Cleaner
ZC-23
ESR-M14P5-A
Remove the C-pillar trim panel and parcel shelf, and lower the headliner. For additional information,
refer to Section 501-05 .
1.
Disconnect the rear window glass electrical connectors. 2.
Clean the interior and exterior of the windshield glass surface with glass cleaner. 3.
NOTE: Use either a high ratio, electric or battery-operated caulk gun that applies the urethane
adhesive with less effort and continuous bead.
NOTE: Make sure there are no gaps in the urethane adhesive bead.
Apply the urethane adhesive over the top of the existing uresive.
Apply the urethane adhesive to the top and sides of the rear glass from the interior of the
vehicle.

Apply the urethane adhesive to the bottom of the rear glass from the exterior of the vehicle.
5.
leaks.
After the urethane adhesive cures, check the rear glass seal for air or water leaks through the urethane
adhesive bead and add urethane adhesive as necessary.
6.
Connect the rear window glass electrical connectors. 7.
Glass Reseal - Rear 634
Install the headliner, parcel shelf and C-pillar trim panels. For additional information, refer to Section
501-05 .
8.
Glass Reseal - Rear 635
Mechanisms
Workshop Manual
Glass, Frames and Mechanisms - Exploded View, Front Door
1 5402010 Wiring harness cover plate
2 378377-S Access hole plug
3 5423201 LH/ 5423200 RH Window regulator
4 W505966-S Window motor screw (3 required)
5 5423395 LH/ 5423394 RH Window motor
6 14489 Window motor electrical connector
7 14A464 Door latch electrical connector
8 14A464 Keypad latch electrical connector
9 W505421-S Door module bolt (10 required)
10 W706476 Interior door handle bolt
11 - Wiring harness retainer
12 5421457 LH/ 5421456 RH Interior door window glass belt moulding
13 5421411 LH/ 5425712 RH Front door window glass
14 5421597 LH/ 5421596 RH Door window glass top run
15 378377-S Window glass clamp bolt (2 requir/td>
Glass, Frames and Mechanisms - Exploded View, Front Door 636
Glass, Frames and Mechanisms - Exploded View, Front Door 637
Mechanisms
Workshop Manual
Window Glass - Front Door
NOTE: All vehicles are equipped with a one-touch up/down feature for the LH front window. All MKZ and
some Fusion vehicles are equipped with a one-touch up/down feature for the LH and RH front windows. The
LH and RH one-touch up/down functionality is identical.
NOTE: The front window motor must be de-initialized, then initialized whenever the LH front or RH front (if
equipped with one-touch up/down functionality) window motor is removed from the window regulator drum
housing, a new window regulator is installed, a new window glass is installed, a new top run is installed or for
any operation in which grease or lubricants are applied to the window regulator or glass run.
Remove the wiring harness cover plate and the access hole plug. 2.
NOTE: If the window regulator motor is inoperative, remove it. For additional information, refer to
Window Regulator Motor in this section.
Lower the window until the glass clamp bolts can be accessed through the access holes.
3.
Loosen the B-pillar front door window glass clamp bolt.
4.
Loosen the A-pillar front door window glass clamp bolt.
5.
Window Glass - Front Door 638
Tape the window in position, then lower the window regulator downward until it reaches the stops at
the bottom of the regulator tracks.
6.
Lift the window glass out of the door. 7.
If equipped with one-touch up/down functionality, initialize the window motor. For additional
information, refer to Window Motor Initialization in this section.

8.
Window Glass - Front Door 639
Mechanisms
Workshop Manual
Window Regulator Motor
Disconnect the window motor electrical connector. 2.
Secure the glass in position with tape. 3.
Remove the 3 window motor screws. 4.
Remove the window motor. 5.

6.
Window Regulator Motor 640
Window Regulator Motor 641
Mechanisms
Workshop Manual
Window Regulator and Motor - Front Door
NOTE: If installing the original front window motor (if equipped with one-touch up/down
functionality), it must be de-initialized. For additional information, refer to Window Motor
Initialization in this section.
Remove the door trim panel. For additional information, refer to Section 501-05 .
1.
Remove the wiring harness cover plate and the access hole plug. 2.
NOTE: If the window regulator motor is inoperative, remove it. For additional information, refer to
Window Regulator Motor in this section.
Lower the window enough to access the window glass clamp bolts through the access holes.
3.
Loosen the B-pillar window glass clamp bolt and disconnect the door latch cable retainers.
4.
Loosen the A-pillar window glass clamp bolt.
5.
Window Regulator and Motor - Front Door 642
Tape the window in position, then lower the window regulator until it is approximately 55 mm (2.165
in) above the bottom of the regulator tracks.
6.
Remove the front door speaker. For additional information, refer to Section 415-00 . 7.
Remove the interior door handle bolt and position the door handle aside. 8.
Disconnect the wiring harness retainers. 9.
Disconnect the door latch electrical connector. 10.
If equipped, disconnect the keyless entry keypad and door lock electrical connector and release from
the bracket.
11.
If equipped, disconnect the power mirror electrical connector. 12.
Remove the 10 door module bolts and the window regulator motor electrical connector.
13.
Remove the front door module. If installing a new door module, transfer parts as necessary. 14.

15.
Mechanisms
Workshop Manual
Door Glass Top Run - Front
Remove the front door window glass. For additional information, refer to Window Glass - Front Door
in this section.
1.
Remove the front door window glass inner weatherstrip. 2.
Remove the front door glass top run. 3.

4.
Door Glass Top Run - Front 645
Door Glass Top Run - Front 646
Mechanisms
Workshop Manual
Glass, Frames and Mechanisms - Exploded View, Rear Door
1 378377 Access hole plugs
2 14489 Electrical connector
3 W505966-S Screw (3 required)
4 5423395 LH/ 5423394 RH Window regulator motor
5 5402010 Wiring harness cover plate
6 - Clip
7 5427001 LH/ 5427000 RH Window regulator
8 - Interior door handle bolt
9 5425861 LH/ 5425860 RH Interior door window glass belt
moulding
10 W505421-S Door module bolt (10 required)
11 14A464 Rear door latch electrical
connector
12 - Wiring harness retainer
13 54235A89 LH/ 54235A88 RH Rear door module
14 W651013-S Access hole plug
15 W506410-S Window regulator glass clamp
bolt (2 required)
N811106-S Upper C-pillar rear glass run bolt
17 5429905 LH/ 5429904 RH Rear door fixed glass
weatherstrip
18 5426871 LH/ 5426870 RH Rear door fixed glass
19 5425767 LH/ 5425766 RH Rear door glass top run
20 5425713 LH/ 5425712 RH Rear door window glass
21 5425796 Rear door quarter glass window
guide
Glass, Frames and Mechanisms - Exploded View, Rear Door 647
Glass, Frames and Mechanisms - Exploded View, Rear Door 648
Mechanisms
Workshop Manual
Window Glass - Rear Door
Remove the rear door fixed window glass. For additional information, refer to Window Glass - Rear
Door, Fixed in this section.
1.
Remove the top run. 2.
Remove the rear window glass. 3.
Window Glass - Rear Door 649
Mechanisms
Workshop Manual
Window Regulator and Motor - Rear Door
Remove the rear door trim panel. For additional information, refer to Section 501-05 . 1.
Remove the access hole plugs. 2.
NOTE: If the door window regulator motor is inoperative, remove it. For additional information,
refer to Window Regulator Motor in this section.
Lower the window until the glass clamp bolts are accessible through the access hole plugs, then
loosen the glass clamp bolts.
3.
Tape the window in position, then lower the window regulator downward until it reaches the stops at
the bottom of the regulator tracks.
4.
Remove the door speaker. For additional information, refer to Section 415-00 . 5.
Remove the interior door handle screw and position the door handle aside. 6.
Disconnect the wiring harness retainers. 7.
Window Regulator and Motor - Rear Door 650
Remove the wiring harness cover plate and disconnect the 2 door latch cable retainers. 8.
Remove the 10 door module bolts.
9.
Disconnect the door latch electrical connector. 10.
Remove the rear door module assembly. If installing a new door module, transfer parts as necessary. 11.
Mechanisms
Workshop Manual
Door Glass Run and Bracket - Rear
Remove the rear door fixed window glass. For additional information, refer to Window Glass - Rear
Door, Fixed in this section.
1.
Carefully position the glass aside, then remove the rear door glass top run. 2.
Door Glass Run and Bracket - Rear 653
Mechanisms
Workshop Manual
Window Control Switch
Fusion
NOTE: LH front shown, all others similar.
1 W703268 Screw
2 54266 Window control switch bezel
3 - Electrical connector (3 required)
4 14529 Window control switch
MKZ - Front Door
NOTE: LH front shown.
Window Control Switch 654
2 - Electrical connectors (2 required)
MKZ - Rear Door
NOTE: RH rear shown.
1 - Electrical connector
Fusion
Remove the access cover and the screw. 1.
Using an appropriate non-marring trim tool, pry the rear of the switch bezel upward and then shift the
switch assembly rearward to disengage the front locking tab.
2.
MKZ
NOTE: For LH front window control switch assembly only, the rear retaining clip is located
off-center towards the outside of the vehicle.
Using an appropriate non-marring trim tool, pry the rear of the switch bezel upward to disengage the
retaining clip, then shift the switch assembly rearward to disengage the front locking tab.
3.
All Vehicles
MKZ - Front Door 655
Disconnect the electrical connector(s). 4.
Remove the window control switch. 5.
MKZ - Rear Door 656
Mechanisms
Workshop Manual
Window Glass - Rear
Special Tool(s)
Deluxe Windshield Removal Tool
The Pumper
Material
Item Specification
BetasealTM Express
-
Dow Urethane One Step Glass Primer
5500SA
-
Sika Tack ASAP
-
Primer
Sika 206 G+P
-
Cleaner
ZC-23
ESR-M14P5-A
1 5442006 Rear window glass
2 - Moulding
Removal
Window Glass - Rear 657
NOTE: If the rear window glass is being removed to repair a dust/water leak, remove and reinstall the
existing rear window glass.
Remove the C-pillar trim panel and parcel shelf, and lower the headliner. For additional information,
1.
Disconnect the 2 rear window defrost electrical connectors. 2.
Before cutting the urethane adhesive, remove dirt and other foreign material from the rear window
pinchweld area.
Use a clean shop towel or oil-free, compressed air.
3.
Lubricate the urethane adhesive with water to aid the Deluxe Windshield Removal Tool when cutting. 4.
WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this
WARNING: Wear protective gloves when handling components or parts that have pointed or
sharp edges. Failure to follow this instruction may result in serious personal injury.
NOTICE: To avoid rust formation, use extreme care not to scratch the paint or primer or
otherwise damage the pinchweld during glass removal.
NOTE: Insert the blade into the Deluxe Windshield Removal Tool so that the flat side is against the
glass. This will leave the entire urethane adhesive bead on the pinchweld and allow a dry fit of the
replacement rear window glass.
NOTE: Support the rear window glass to prevent the glass from dropping while cutting the urethane
adhesive.
Insert the Deluxe Windshield Removal Tool at the upper center of the rear window glass and work
toward the bottom corners.
5.
Using The Pumper, distance the rear window glass from the body. 6.
Insert the Deluxe Windshield Removal Tool into the bottom of the urethane adhesive and cut from
corner to corner.
7.
Carefully remove the rear window glass from the vehicle and place on a stable work surface. 8.
Installation
Dry-fit the rear window glass on the existing urethane adhesive bead on the pinch weld.
Position the glass on the pinch weld.
Center the glass in the opening.
Make alignment marks with tape or non-staining grease pencil on the rear window glass and
the body.

1.
After the dry-fit alignment, remove the glass from the body opening and place on a stable work
surface with the interior side of the glass facing upward.
2.
WARNING: Repair any corrosion found on the pinch weld. The pinch weld is a structural
component of the vehicle. Corrosion left unrepaired may reduce the structural integrity of the
vehicle. Failure to follow this instruction may result in serious injury to vehicle occupant(s).
NOTE: Avoid scratching the pinch weld. Repair all minor scratches or exposed metal on the pinch
weld following manufacturer's instructions. Use the same brand pinch weld primer, glass primer and
urethane adhesive.
Using an appropriate tool, trim the urethane adhesive leaving a 1-2 mm (0.04-0.08 in) base of original
equipment urethane adhesive on the pinchweld.
3.
Using a clean shop towel, brush or oil-free, compressed air, clean the pinch weld area around the
existing urethane adhesive. Remove any foreign material or water that may have entered during glass
removal.
4.
If reinstalling the same rear window glass, remove the remaining urethane adhesive from the glass
leaving a thin layer to bond with the new urethane adhesive bead.
5.
Clean the inside of the new rear window glass surface with glass cleaner. 6.
NOTE: Be sure to use the same brand and cure-rate products for the urethane adhesive and glass
primer. Do not mix different brands of urethane adhesive and glass primer. Refer to the Material
Chart in this procedure.
If installing a new rear window glass, apply glass primer according to manufacturer's instructions.
Allow at least 6 minutes to dry.
7.
NOTE: The rear window glass must be positioned within 10 minutes of applying the urethane
adhesive.
Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld,
starting and ending at the bottom of the rear window glass near the center, making sure there are no
gaps in the bead.
9.
WARNING: Do not drive vehicle until the urethane adhesive seal has cured. Follow
urethane adhesive manufacturer's curing directions. Inadequate or incorrect curing of the
urethane adhesive seal will adversely affect glass retention. Failure to follow these instructions
may result in serious injury to vehicle occupant(s).
NOTICE: Before positioning the rear window glass, open vehicle windows to prevent the air
pressure of closing doors from affecting the urethane adhesive bond.
Using the alignment marks made previously, position the rear window glass on the pinch weld.
10.
leaks.
After the urethane adhesive has cured, check the rear window glass seal for air or water leaks through
the urethane adhesive bead and add urethane adhesive as necessary.
11.
Install the headliner, parcel shelf and C-pillar trim panels. For additional information, refer to Section
501-05 .
12.
Connect the LH and RH heated rear window electrical connector. 13.
Mechanisms
Workshop Manual
Window Glass - Rear Door, Fixed
Lower the rear window. 1.
Remove the rear door inner trim panel. Refer to Section 501-05 . 2.
Remove the inner beltline weatherstrip. 3.
Remove the screw and the outer beltline weatherstrip. 4.
Position the rear window glass run aside. 5.
Remove the access hole plug. 6.
Remove the rear quarter glass window guide bolt and screw. 7.
Window Glass - Rear Door, Fixed 662
Remove the rear quarter glass window guide. 8.
Remove the rear door fixed window glass. 9.
Mechanisms
Workshop Manual
Windshield Glass
Special Tool(s)
Deluxe Windshield Removal Tool
The Pumper
Material
Item Specification
BetasealTM Express
-
Dow Urethane One Step Glass Primer
5500SA
-
Sika Tack ASAP
-
Primer
Sika 206 G+P
-
Cleaner
ZC-23
ESR-M14P5-A
1 - Moulding
2 5403100 Windshield
Removal
Windshield Glass 665
NOTE: If the windshield glass is being removed to repair a dust/water leak, remove and reinstall the existing
windshield glass.
Remove the A-pillar trim panels. For additional information, refer to Section 501-05 . 1.
Remove the sun visors. 2.
Remove the interior mirror. For additional information, refer to Section 501-09 . 3.
If equipped, remove the rain sensor. For additional information, refer to Section 501-16 . 4.
Partially lower the front portion of the headliner near the windshield header and block with suitable
material. For additional information, refer to Section 501-05 .
5.
Before cutting the urethane adhesive, remove dirt and other foreign material from the windshield
pinchweld area.
Use a clean shop towel or oil-free, compressed air.
7.
NOTE: Refer to manufacturer's instructions before using the Deluxe Windshield Removal Tool.
Lubricate the urethane adhesive with water to aid the Deluxe Windshield Removal Tool when cutting.
8.
WARNING: Wear protective gloves when handling components or parts that have pointed
or sharp edges. Failure to follow this instruction may result in serious personal injury.
NOTICE: To avoid rust formation, use extreme care not to scratch the paint or primer or
otherwise damage the pinchweld during glass removal.
NOTE: Insert the blade into the Deluxe Windshield Removal Tool so that the flat side is against the
glass. This will leave the entire urethane adhesive bead on the pinchweld and allow a dry fit of the
replacement windshield glass.
NOTE: Support the windshield glass to prevent the glass from dropping while cutting the urethane
adhesive.
Insert the Deluxe Windshield Removal Tool at the upper center of the windshield glass and work
toward the bottom corners.
9.
Using The Pumper, distance the windshield glass from the body. 10.
Insert the Deluxe Windshield Removal Tool into the bottom of the urethane adhesive and cut from
corner to corner.
11.
Carefully remove the windshield glass from the vehicle and place on a stable work surface. 12.
Installation
Dry-fit the windshield glass on the existing urethane adhesive bead on the pinch weld.
Position the windshield glass on the pinch weld.
Center the glass in the opening.
Adjust the windshield glass stop blocks (if equipped) as needed for best fit.
Make alignment marks with tape or non-staining grease pencil (preferably at the windshield
glass stop blocks) on the windshield glass and the body.

1.
After the dry-fit alignment, remove the glass from the body opening and place on a stable work
surface with the interior side of the glass facing upward.
2.
WARNING: Repair any corrosion found on the pinch weld. The pinch weld is a structural
component of the vehicle. Corrosion left unrepaired may reduce the structural integrity of the
vehicle. Failure to follow this instruction may result in serious injury to vehicle occupant(s).
NOTE: Avoid scratching the pinch weld. Repair all minor scratches or exposed metal on the pinch
weld following manufacturer's instructions. Use the same brand pinch weld primer, glass primer and
urethane adhesive.
Using an appropriate tool, trim the urethane adhesive leaving a 1-2 mm (0.04-0.08 in) base of original
equipment urethane adhesive on the pinchweld.
3.
Using a clean shop towel, brush or oil-free, compressed air, clean the pinch weld area around the
existing urethane adhesive. Remove any foreign material or water that may have entered during glass
removal.
4.
If reinstalling the same windshield glass, remove the remaining urethane adhesive from the glass
leaving a thin layer to bond with the new urethane adhesive bead.
5.
Clean the inside of the windshield glass surface with glass cleaner.
Make sure to thoroughly clean the surface of the blackened border area where the urethane
adhesive will be applied.

6.
NOTE: Be sure to use the same brand and cure-rate products for the urethane adhesive and glass
primer. Do not mix different brands of urethane adhesive and glass primer. Refer to the Material
Chart in this procedure.
If installing a new windshield glass, apply glass primer according to manufacturer's instructions.
Allow at least 6 minutes to dry.
7.
NOTE: The windshield glass must be positioned within 10 minutes of applying the urethane
adhesive.
Apply a uniform bead of urethane adhesive on top of the existing trimmed urethane adhesive bead on
the pinch weld, starting and ending at the bottom of the windshield glass near the center, making sure
there are no gaps in the bead.
9.
WARNING: Do not drive vehicle until the urethane adhesive seal has cured. Follow
urethane adhesive manufacturer's curing directions. Inadequate or incorrect curing of the
urethane adhesive seal will adversely affect glass retention. Failure to follow these instructions
may result in serious injury to vehicle occupant(s).
NOTICE: Before positioning the windshield glass, open vehicle windows to prevent the air
pressure of closing doors from affecting the urethane adhesive bond.
Using the alignment marks made previously, position the windshield glass on the pinch weld.
10.
leaks.
After the urethane adhesive has cured, check the windshield glass seal for air or water leaks through
the urethane adhesive bead and add urethane adhesive as necessary.
11.
Install the headliner. For additional information, refer to Section 501-05 . 13.
If equipped, install the rain sensor. For additional information, refer to Section 501-16 . 14.
Install the interior mirror. For additional information, refer to Section 501-09 . 15.
Install the sun visors. 16.
Install the A-pillar trim panels. For additional information, refer to Section 501-05 . 17.
SECTION 501-12: Instrument Panel and Console
Workshop Manual
Center instrument panel finish panel screws 3 - 27
Glove compartment dampener screws 2 - 18
Hood release handle screws 3 - 27
Instrument Cluster (IC) opening bolts 23 17 -
Instrument panel center support bolts 20 - 177
Instrument panel lower bolts 8 - 71
Instrument panel side bolts 23 17 -
Steering column shaft bolt 20 177
Upper storage compartment screws 3 - 27
Upper storage compartment tether nut 6 - 53
Wire harness screws 3 - 27
SECTION 501-12: Instrument Panel and
Console
Workshop Manual
Instrument Panel - Exploded View
Fusion
1 04480 RH/ 04481 LH Instrument panel side finish panel
2 04320 Instrument panel
3 - Instrument cluster finish panel retaining clip
(part of 044D70) (2 required)
4 044D70 Instrument cluster finish panel
5 W707628 Instrument cluster finish panel screw (2
required)
6 W701834 Instrument Cluster (IC) opening bolt (2
required)
7 - Upper storage compartment tether (part of
13594)
8 045G34 Upper storage compartment mat
9 W505253 Upper storage compartment screw (2
required)
10 13549 Upper storage compartment
11 - Upper storage compartment retaining clip
(part of 13594) (4 required)
12 N811479 Instrument panel center support bolt (3
required)
13 - Upper storage compartment tether nut
14
Instrument Panel - Exploded View 671
Steering column
opening trim panel
15 N808453 Steering column opening trim panel screw (2
required)
16 - Steering column opening trim panel retaining
clip (4 required)
17 W701834 Instrument panel side bolt (3 required)
18 W708268 Instrument panel lower bolt (2 required)
MKZ
1 04320 Instrument panel
2 - LH instrument panel finish panel clip (part of
044A91) (2 required)
3 044A91 LH instrument panel finish panel
4 044D70 Instrument cluster finish panel
5 W707628 Instrument cluster finish panel screw (2 required)
6 - Instrument cluster finish panel screw cover (part of
044D70) (2 required)
7 - Instrument cluster finish panel retaining clip (part of
044D70) (3 required)
8 - Center instrument panel finish panel retaining clip
(part of 04302) (3 required)
9 04302 Center instrument panel el
10 W707628 Center instrument panel finish panel screw (3
required)
Fusion 672
11 04480 RH/
04481 LH
Instrument panel side finish panel
12 - Instrument panel finish moulding retaining clip
(part of 044A90) (8 required)
13 W707607 Instrument panel finish moulding screw (4 required)
14 044A90 Instrument panel finish moulding
15 W701834 Instrument Cluster (IC) opening bolt (2 required)
16 14401 Instrument panel harness connector
17 N811479 Instrument panel center support bolt (3 required)
18 011201 Steering column opening trim panel
19 N808453 Steering column opening trim panel screw (2
required)
20 - Steering column opening trim panel retaining clip
(4 required)
21 W701834 Instrument panel side bolt (3 required)
22 W708268 Instrument panel lower bolt (2 required)
Glove Compartment
060T10 Glove compartment
2 - Glove compartment damper clip (part
of 06102)
3 06010 Glove compartment mini-bin (Fusion
only)
4 N804693 Glove compartment damper screw (2
required)
5 06102 Glove compartment damper
MKZ 673
Glove Compartment 674
Console
Workshop Manual
Instrument Panel
Remove the steering wheel. For additional information, refer to Section 211-04 . 1.
Remove the floor console. For additional information, refer to Console - Floor, Fusion or Console -
Floor, MKZ in this section.
2.
Remove the selector lever or the gearshift lever. For additional information, refer to Section 307-05A
3.
Remove the LH and RH instrument panel side finish panels.
Pull the sides of the instrument panel side finish panels away from the instrument panel to
release the retaining tabs.

4.
Remove the LH and RH weatherstrips from the front door openings near the instrument panel. 5.
Remove the LH and RH A-pillar trim panels. For additional information, refer to Section 501-05 . 6.
Remove the LH and RH lower cowl panels. For additional information, refer to Interior Trim - Exploded
View in Section 501-05 .
If equipped, remove the RH lower instrument panel insulator. 8.
Disconnect the 2 electrical connectors located at the LH lower cowl. 9.
Disconnect the small gray and the black electrical connectors from the Smart Junction Box (SJB). 10.
Remove the 2 screws and position the hood release handle aside. 11.
Instrument Panel 675
Disconnect the bulkhead electrical connector and the antenna cable located at the RH lor cowl. If
equipped, disconnect the satellite antenna.
12.
Fully lower the glove compartment door and disconnect the 2 A/C electrical connectors. 13.
Disconnect the electrical connector and the 2 wire harness retainers located on the floor between the
front seats.
14.
Remove the 2 nuts and position the steering column pinch bolt cover aside. 15.
Remove and discard the steering column shaft bolt.
To install, use a new steering column shaft bolt and tighten to 20 Nm (177 lb-in).
16.
NOTE: Index-mark the steering column shaft position to the steering gear for reference during
installation.
Detach the upper steering column shaft from the steering column.
17.
Disconnect the in-vehicle temperature sensor aspirator hose from the heater core and evaporator core
housing, if equipped, in the following sequence.
Separate the aspirator hose retaining clips away from the heater core and evaporator core
housing.
1.
Pull the aspirator hose away from the heater core and evaporator core housing. 2.
18.
Remove the Instrument Cluster (IC). For additional information, refer to Section 413-01 . 19.
Through the IC opening, remove the 2 IC opening bolts.
20.
Remove the 3 instrument panel center support bolts.
21.
Remove the LH and RH instrument panel lower bolts from the outer sides of the instrument panel.
22.
NOTICE: To avoid damaging the instrument panel, the aid of an assistant is required to carry
out this step.
NOTICE: Make sure that all electrical connectors and wiring are not hindered before removing
the instrument panel or damage to the components may occur.
Remove the instrument panel.
Through the instrument panel side finish panel openings, remove the 3 instrument panel side
bolts.

23.
NOTICE: To avoid damaging the instrument panel, the aid of an assistant is required when
positioning the instrument panel to the vehicle.
NOTICE: Make sure that all electrical connectors and wiring are correctly routed when
installing the instrument panel or damage to the components may occur.
24.
Console
Workshop Manual
Instrument Panel Upper Section
Fusion - Front View
Item
Part
Number Description
1 W505253 Instrument panel front screw (3 required)
2 14401 Center instrument panel finish panel electrical
connector(s)
3 - Center instrument panel finish panel retaining clip (part
of 011201) (6 required)
4 011201 Center instrument panel finish panel
5 W707628 Center instrument panel finish panel screw (2 required)
6 W505253 LH duct support screw
MKZ - Front View
Instrument Panel Upper Section 679
1 W505253 Instrument panel front screw (6
required)
2 046A76 In-vehicle temperature sensor
3 04338 LH switch assembly
14401
LH switch assembly electrical
connector
Rear View
NOTE: MKZ shown, Fusion similar.
MKZ - Front View 680
1 04320 Instrument panel upper section
2 04545 In-vehicle cross beam
3 14401 Data Link Connector (DLC)
4 W707607 Instrument panel rear screw (6 required)
5 W707607 Wire harness screws (3 required)
All vehicles
Remove the center instrument panel finish panel. For additional information, refer to Instrument Panel
Finish Panel - Center in this section.
1.
NOTICE: To avoid damaging the in-vehicle cross beam or the instrument panel upper section,
spread a suitable covering over the bench on which to place the instrument panel when removed
from the vehicle.
NOTE: Place the instrument panel on the bench upside-down.
Remove the instrument panel. For additional infortion, refer to Instrument Panel in this section.
2.
Remove the passenger air bag. For additional information, refer to Section 501-20B . 3.
Remove the audio unit. For additional information, refer to Section 415-00 . 4.
Remove the Front Display Interface Module (FDIM), if equipped. For additional information, refer to
Section 415-00 .
5.
Disconnect the Data Link Connector (DLC) from the lower LH instrument panel.
Press the retainer clip toward the center of the connector and push the connector towards the
back of the instrument panel.

6.
Remove the headlamp switch. For additional information, refer to Section 417-01 . 7.
Rear View 681
Fusion
Through the headlamp switch opening, remove the LH duct support screw. 8.
Through the Instrument Cluster (IC) opening, remove the 2 instrument panel front screws. 9.
Remove the HVAC module, if equipped. For additional information, refer to Section 412-01 . 10.
Through the audio unit opening, remove the instrument panel front screw. 11.
MKZ
Remove LH switch assembly in the following sequence.
Press the 4 switch retainer clips toward the center of the switch and push the switch forward
toward the front of the instrument panel upper section.
1.
Disconnect the electrical connectors and remove the switch assembly. 2.
12.
Remove the RH register. For additional information, refer to Section 412-01 . 13.
Through the LH and RH register openings, remove the 2 instrument panel front screws. 14.
Through the IC opening, remove the 2 instrument panel front screws. 15.
Through the audio unit opening, remove the 2 instrument panel front screws. 16.
Remove the in-vehicle temperature sensor. For additional information, refer to Section 412-01 . 17.
All vehicles
Remove the 6 instrument panel rear screws. 18.
Remove the 3 wire harness screws from the rear of the instrument panel upper section and disconnect
wire harness retainers as necessary.
19.
NOTE: Position the instrument panel upper section away from the in-vehicle cross beam to access
the instrument panel speaker electrical connector.
If equipped, disconnect the instrument panel speaker.
20.
NOTICE: To avoid damaging the instrument panel upper section, the aid of an assistant is
required to carry out this step.
Remove the in-vehicle cross beam from the instrument panel upper section.
21.
Transfer parts from the instrument panel upper section as necessary.
22.
Rear View 682
Rear View 683
Console
Workshop Manual
Instrument Cluster Finish Panel - Fusion
Remove the 2 instrument cluster finish panel screws. 1.
Remove the instrument cluster finish panel.
Pull the instrument cluster finish panel toward the rear of the vehicle to release the retaining
clips.

Detach the in-vehicle temperature sensor, if equipped.
2.
Instrument Cluster Finish Panel - Fusion 684
Console
Workshop Manual
Instrument Cluster Finish Panel - MKZ
Release the 2 instrument cluster finish panel screws covers and remove the 2 instrument cluster finish
panel screws.
1.
Remove the steering wheel. For additional information, refer to Section 211-04 . 2.
Remove the multifunction switch. For additional information, refer to Section 211-05 . 3.
Remove the LH instrument panel finish panel.
Pull the LH instrument panel finish panel toward the rear of the vehicle to release the
retaining clips.

4.
Remove the instrument cluster finish panel.
Pull the instrument cluster finish panel toward the rear of the vehicle to release the retaining
clips.

5.
If replacing the instrument cluster finish panel, remove the 2 register screws and transfer the
register.

Make sure to align the LH instrument panel finish panel retaining clips to the retaining clip
holes in the instrument panel.

6.
Instrument Cluster Finish Panel - MKZ 685
Console
Workshop Manual
Instrument Panel Finish Panel - Center
MKZ
Remove the instrument cluster finish panel. For additional information, refer to Instrument Cluster
Finish Panel - MKZ in this section.
1.
Remove the instrument panel finish moulding in the following sequence.
Remove the 4 instrument panel finish moulding screws. 1.
Pull the instrument panel finish moulding toward the rear of the vehicle to release the
retaining clips.
2.
2.
NOTE: Center instrument panel finish panel with navigation shown, center instrument panel finish
panel without navigation similar.
Remove the 3 center instrument panel finish panel screws.
3.
Remove the center instrument panel finish panel.
Pull the center instrument panel finish panel toward the rear of the vehicle to release the
retaining clips.

4.
Fusion
NOTICE: When prying on a component, a non-marring tool must be used or damage to the component
may occur.
Pull the parking brake handle upward. 5.
If equipped with anatic transmission, place the selector lever in the NEUTRAL position and remove
the selector lever trim ring.
Using a non-marring tool, pry upward to release the retaining clips.
6.
Remove the floor console finish panel in the following sequence.
Using a non-marring tool, pry upward to release the retaining clips. 1.
Disconnect the electrical connectors, if equipped. 2.
7.
Remove the utility tray in the following sequence.
Using a non-marring tool, pry upward to release the retaining clips. 1.
Disconnect the audio jack connector, if equipped. 3.
8.
Instrument Panel Finish Panel - Center 686
Remove the upper storage compartment. For additional information, refer to Storage Compartment -
Upper in this section.
9.
Remove the 2 center instrument panel finish panel screws. 10.
Remove the center instrument panel finish panel.
Pull the center instrument panel finish panel toward the rear of the vehicle to release the
retaining clips.

Disconnect the electrical connector(s).
11.
All vehicles
Instrument Panel Finish Panel - Center 687
Console
Workshop Manual
Storage Compartment - Upper
NOTE: Steering column shroud removed to show clarity.
Remove the upper storage compartment tether nut.
1.
Remove the upper storage compartment mat and the 2 upper storage compartment screws. 2.
Remove the upper storage compartment in the following sequence.
Pull the upper storage compartment toward the rear of the vehicle to release the 5 retaining
clips.
1.
Disconnect the electrical connector, if equipped. 2.
3.
Storage Compartment - Upper 688
Console
Workshop Manual
Console - Floor, Fusion
Item
Part
Number Description
1 14401 Power point connectors
2 - Utility tray (part of 011202)
3 045A76 Floor console finish panel
4 061A16 Selector lever trim ring
5 - Utility tray retaining clip (part of 045A76) (2 required)
6 W709955 Floor console screws (4 required)
7 14401 Bulkhead electrical connector
8 - Floor console finish panel retaining clip (part of
9 672A40 Floor console screw cover (2 required)
10 W711401 Floor console front screw (2 required)
11 011202 Floor console
12 14401 Ambient light electrical connector
13 W711401 Floor console rear screw (2 required)
NOTICE: When prying on a component, a non-marring tool must be used or damage to the component
may occur.
Position the front seats rearward. 2.
Pull the parking brake handle upward. 3.
Console - Floor, Fusion 689
If equipped with an automatic transmission, remove the selector lever trim ring.
4.
If equipped with a manual transmission, remove the gearshift knob by turning in a counterclockwise
direction.
5.
Open the storage compartment door and remove the floor console finish panel.
Disconnect the electrical connectors, if equipped.
6.
Remove the utility tray.
Disconnect the audio jack connector, if equipped.
7.
Remove the 2 floor console screw covers. 8.
Remove the 2 floor console front screws. 9.
Disconnect the power point and bulkhead electrical connectors. Detach the electrical connector
pin-type retainer.
10.
NOTICE: To prevent damage to the instrument panel, place the selector lever in NEUTRAL
and pull the console towards the rear of the vehicle when removing the console.
Remove the 4 floor console screws, place the selector lever in NEUTRAL, pull the console towards
the rear of the vehicle and remove the floor console.
11.
Console - Floor, Fusion 690
Console
Workshop Manual
Console - Floor, MKZ
Item
Part
Number Description
1 - LH floor console finish moulding retaining clip (part of
2 - RH floor console finish moulding retaining clip (part of
3 061A16 Floor console finish moulding
4 1181081 Floor console lower trim panel
5 045A76 Floor console finish panel
6 - RH floor console lower trim panel retaining clip (part of
1181081) (7 required)
7 W709955 Floor console front screw (4 required)
8 14401 Bulkhead electrical connector
9 W711401 Floor console rear screw (2 required)
10 04620 Floor console
11 - LH floor console lower trim panel retaining clip (part of
1181081) (7 required)
Apply the parking brake. 1.
Place the selector lever in the NEUTRAL position. 2.
Position the front seats to the full rearward and downwa. 3.
Console - Floor, MKZ 691
Pull the middle and rear of the LH and RH floor console lower trim panels outward to release the
retaining clips.
4.
NOTICE: Damage to the floor console upper trim panels may occur if cardboard is not used to
remove the floor console lower trim panels.
Position a piece of cardboard between the LH and RH floor console lower trim panels and the floor
console.
5.
Remove the LH floor console lower trim panel and cardboard simultaneously. 6.
Remove the RH floor console lower trim panel and cardboard simultaneously. 7.
Position the front seats forward. 8.
Remove the 2 floor console rear screws. 9.
Position the front seats rearward. 10.
Open the storage compartment lid, remove the LH and RH floor console finish mouldings.
Lift upward on the floor console finish mouldings to release the retaining clips.
11.
Remove the selector lever knob. For additional information, refer to Section 307-05A . 12.
NOTICE: Use a non-marring tool to pry on the component. Failure to will cause damage to the
component.
Remove the floor console finish panel in the following sequence:
With a non-marring tool, pry upward on the right rear portion of the floor console finish panel
to release the 2 retaining clips.
1.
With a non-marring tool, pry upward on the front sides of the floor console finish panel to
release the 4 retaining clips.
2.
If equipped, disconnect the electrical connectors. 3.
Slide the park brake handle boot away from the park brake handle. 4.
13.
Remove the 4 floor console front screws. 14.
Disconnect the floor console bulkhead and front in-line electrical connectors. 15.
Disconnect the floor console power point connector and detach the 2 wire harness pin-type retainers. 16.
Remove the floor console. 17.
Console
Workshop Manual
Console - Overhead
Open the overhead console compartment door. 1.
From inside the compartment, remove the 2 screws. 2.
Disconnect the electrical connectors.
3.
Console - Overhead 694
Console
Workshop Manual
Power Point
Special Tool(s)
Remover, Power Point Socket
Removal
NOTE: Power point cover may differ depending on location.
Open the power point cover. 1.
Install the Power Point Socket Remover in one of the power point socket slots. 2.
Position the Power Point Socket Remover so that it engages in the adjacent slot. 3.
Using the Power Point Socket Remover, pull the power point socket out of the retainer. 4.
Installation
Connect the electrical connector. 1.
Power Point 695
Slide the power point socket into the retainer. 2.
Power Point 696
SECTION 501-14: Handles, Locks, Latches and
Entry Systems
Workshop Manual
Material
Capacity
Multi-Purpose Grease
XG-4 and/or XL-5
ESB-M1C93-B -
Penetrating and Lock Lubricant
(US); Penetrating Fluid (Canada)
XL-1 (US); CXC-51-A (Canada)
- -
Door latch bolts 8 - 71
Door latch striker bolts 25 18 -
Exterior door handle reinforcement bolt 6 53 -
Hood latch bolts 12 - 106
Hood latch striker bolts 12 - 106
Interior door handle bolt 11 - 97
Luggage compartment lid latch nuts 9 - 80
Luggage compartment lid striker bolts 12 - 106
Secondary hood latch release handle bolt 12 - 106
Power Point 697
SECTION 501-14: Handles, Locks, Latches and Entry
Systems
2012 Fusion, MKZ, Fusion Hybrid, MKZ
Hybrid Workshop Manual
Handles, Locks, Latches and Entry Systems
NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM).
Hood Latch
The hood latch consists of the following components:
Hood latch release handle and cable
Hood latch
Secondary hood latch release handle and cable (MKZ)
Front Door
The front door consists of the following components:
Door ajar switch (part of the front door latch)
Door lock cylinder (driver door only)
Exterior front door handle
Exterior front door handle reinforcement
Front door latch
Front door lock actuator (part of the front door latch)
Interior door handle actuating cable
Interior door handle
Keyless entry keypad (if equipped)
Rear Door
The rear door consists of the following components:
Door ajar switch (part of the rear door latch)
Exterior rear door handle
Exterior rear door handle reinforcement
Interior door handle actuating cable (part of the rear door latch)
Interior door handle
Rear door latch
Rear door lock actuator (part of the rear door latch)
Luggage Compartment Lid
The luggage compartment lid consists of the following components:
Luggage compartment lid latch
Luggage compartment lid lock cylinder
Luggage compartment lid release switch (next to headlamp switch)
Lock cylinder actuating cable (part of the luggage compartment lid latch)
Mechanical emergency release cable and handle (part of the luggage compartment lid latch)
Power Lock/Unlock
Handles, Locks, Latches and Entry Systems 698
The power lock/unlock feature requests all of the vehicle doors locked or unlocked upon a customer request
from either door lock control switch in the vehicle. The power door locking system functions independently of
ignition status or vehicle speed.
Autolock
NOTE: The autolock feature is not available on vehicles equipped with a manual transaxle.
The autolock feature locks all the doors when the following conditions are met:
All the doors are closed
The ignition switch is in the ON position
The vehicle is shifted into any gear, putting the vehicle in motion
The vehicle attains a speed greater than 20 km/h (12 mph)
The autolock feature repeats when:
any door is opened then closed with the ignition in the ON position.
the vehicle speed is 15 km/h (9 mph) or slower.
the vehicle attains a speed greater than 20 km/h (12 mph).
The autolock feature can be enabled/disabled, refer to Autolock and Auto-Unlock Programming in this section
for programming information.
Auto-Unlock
NOTE: The doors will not auto-unlock if the vehicle has been electronically locked before the driver door is
opened.
NOTE: The auto-unlock feature comes disabled from the factory on vehicles equipped with a manual
transaxle, but can be enabled.
The auto-unlock feature unlocks all the doors when the following conditions are met:
The ignition is in the ON position
The vehicle has been in motion at a speed greater than 20 km/h (12 mph)
The vehicle then comes to a stop
The ignition is switched to the OFF or ACC position
And the driver door is opened within 10 minutes of the ignition being switched to the LOCK or ACC
position

The auto-unlock feature can be enabled/disabled independently of autolock. Refer to Autolock and
Auto-Unlock Programming in this section for programming information.
Smart Unlock
The smart unlock feature prevents the doors from locking with the key in the ignition lock cylinder. When the
SJB receives a lock command from a door lock control switch (only), and the key is in the ignition lock
cylinder with one of the front doors open, the SJB commands the doors to unlock.
The vehicle can still be locked with the ignition key in the ignition cylinder by locking the doors with the push
button rods, the door lock cylinder or a Remote Keyless Entry (RKE) command from an Integrated Keyhead
Transmitter (IKT) or the keyless entry keypad (if equipped).
Remote Keyless Entry (RKE)
The RKE system uses an Integrated Keyhead Transmitter (IKT). The IKT incorporates both the Passive
Anti-Theft System (PATS) functions and the RKE transmitter functions in a single device.
The RKE transmitter is programmed automatically during PATS key programming. During PATS key
programming, the Instrument Panel Cluster (IPC) obtains the Transmitter Identification Code (TIC) from the
IKT and sends the TIC data over the Medium Speed Controller Area Network (MS-CAN) to the SJB .
The SJB accepts programming of up to 4 IKTs . In addition to the IKTs , 4 conventional keyfobs can also be
programmed to the vehicle if requested by the customer. For information on programming the IKTs , refer to
Key Programming Using Two Programmed Keys or Integrated Keyhead Transmitter (IKT) Key Programming
Using Diagnostic Equipment in Section 419-01B or Section 419-01C . For information on programming the
conventional keyfobs, refer to Remote Keyless Entry (RKE) Transmitter Programming in this section.
The IKT carries out the following functions:
Unlocks the driver door
Unlocks all doors
Locks all doors
Releases the luggage compartment lid latch
Arms/disarms the perimeter alarm
Activates/deactivates the panic alarm
Commands the interior lamps on (when unlocking) and off (when locking)
Provides a long flash of the turn signals when UNLOCK is pressed (late vehicles only)
Recalls the memory seat position associated with a particular remote entry device (when enabled)
(MKZ)

Sounds the horn once when LOCK is pressed twice within 3 seconds, and the doors are closed
Sounds the horn twice when LOCK is pressed twice within 3 seconds, and any door is ajar
The IKT has a normal operating range of 10 m (33 ft).
Remote Keyless Entry (RKE) Lock/Unlock Control - Unlock
The RKE feature provides lock/unlock functions independently of key position, vehicle speed, or transmission
position. The RKE feature provides a stepped (if enabled) process for unlocking the doors. Upon receipt of the
first request for unlocking the doors, the RKE control feature requests the SJB to unlock the driver door only.
If another unlock request is received within 3 seconds of the first, the RKE feature requests the SJB to unlock
all the doors. This feature can be configured to one-step unlock, so that all the doors unlock on the first press
of the unlock button. Refer to Stepped Unlock Programming in this section for programming information.
Remote Keyless Entry (RKE) Lock/Unlock Control - Lock
The RKE feature requests that all the doors be locked when the lock button is pressed. On any press of the
lock button with all doors closed, the SJB provides one flash of the turn signals. If any door is ajar, no flash
occurs. As soon as the last door is closed, the SJB provides the flash of the turn signals. If 2 presses of the
lock button are received within 3 seconds, the horn chirps once and the turn signals flash twice to indicate that
all the doors are closed and locked. If any door is ajar when the second lock request is received within 3
seconds of the first, the RKE transmitter feature requests the SJB chirp the horn twice without flashing the
turn signals to indicate it locked all the doors but one or more doors are ajar. When the key is in the ON or
START position, the turn signal flashes and horn chirp confirmations do not occur.
Remote Keyless Entry (RKE) Luggage Compartment Lid Release
The RKE feature provides luggage compartment lid release function independently of key position. The
luggage compartment lid release button must be pressed twice within 3 seconds for the luggage compartment
lid to release.
Panic Alarm
The panic alarm feature provides audible and visual alarms which are evident from the exterior of the vehicle.
The panic alarm feature requests that the turn signals are flashed and the horn sounds until deactivation. The
flashing of the outputs occurs simultaneously. Activation of the panic alarm is accomplished by pressing the
panic button on an Integrated Keyhead Transmitter (IKT) whenever the key is in the OFF position. At all
other times this feature is disabled. Deactivation of an active PANIC alarm is accomplished by any of the
following actions:
a second press of the IKT panic button
the key is switched out of the OFF position
a period of 2 minutes and 45 seconds has elapsed since the initial activation
Keyless Entry Keypad
The keyless entry keypad carries out the following functions:
Unlocks the driver door
Unlocks all the doors
Locks all doors
Enables/disables auto-unlocking
Enables/disables autolocking
Arms/disarms the perimeter alarm
Recalls the memory seat position associated with a particular customer key code (when enabled)
Releases the luggage compartment lid latch
Programs/erases the customer key code(s)
Illuminates the keyless entry keypad lamp and issues illuminated entry on/off requests
The keypad feature operates independently of key position status, vehicle speed, or transmission position.
When a keypad button is pressed, the keypad buttons illuminate to provide better visibility. If the lock all
doors command is entered or 5 seconds have elapsed since the last button press, the illumination is turned off.
Each vehicle equipped with a keypad is programmed with a 5-digit factory set entry code. This code is
provided to the customer through a wallet card in the Owner's Literature. In addition, this code is available
through a scan tool and is also printed on the SJB label. When entering codes each digit must be entered
within 5 seconds of the previous button press. In addition to the factory set code, 3 personal codes can also be
programmed. For additional information on programming the personal keypad codes, refer to Keyless Entry
Keypad Code Programming in this section.
Locking the Doors with the Keyless Entry Keypad System
It is not necessary to enter the factory set or personal code prior to locking all doors. To lock all doors, press
the 7/8 and 9/0 controls at the same time.
Unlocking the Doors with the Keyless Entry Keypad System
To unlock the driver door (if stepped unlock is disabled), enter either the factory set code or a personal code;
each digit must be pressed within 5 seconds of the prior digit. The interior lamps illuminate.
To unlock all doors, enter either the factory set code or a personal code (driver door unlocks) and press the 3/4
button within 5 seconds. This feature can be changed to 1-step unlock, so that all the doors unlock on receipt
of the factory set or personal code. Refer to Stepped Unlock Programming in this section for programming
information.
To open the luggage compartment, enter the factory set code or a personal code (driver door unlocks) and
press the 5/6 button within 5 seconds.
Anti-Scan Feature
To provide added security, the keypad is disabled for 1 minute after 35 button presses without a valid entry
code being entered. The keypad flashes during this 1-minute mode with all functionality disabled except for
7/8 and 9/0 still being allowed to lock the vehicle.
Anti-Scan is turned off after 1 minute of keypad inactivity.
Entry Systems
Workshop Manual
Handles, Locks, Latches and Entry Systems
Special Tool(s)
Flex Probe Kit
NUD105-R025D
Material
Item Specification
XG-4 and/or XL-5
ESB-M1C93-B
Penetrating and Lock Lubricant (US);
Penetrating Fluid (Canada)
-
NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM).
The SJB receives inputs and delivers outputs to many of the electronically controlled features of the vehicle.
The SJB constantly monitors the system under its control and reports a concern in the form of a DTC.
Power Door Locks - Fusion
Regardless of the key position, the SJB is supplied voltage at all times. When the SJB receives a signal from
the Remote Keyless Entry (RKE) transmitter, the keyless entry keypad, or the door lock control switches, the
SJB supplies a ground signal to the appropriate lock or unlock relay. The ground signal closes the relay which
supplies voltage to the door lock actuators. The door lock actuators then actuate to a lock or unlock position.
Power Door Locks - MKZ
The SJB controls all of the passenger door lock actuators and receives input from the passenger door lock
control switch. The Driver Door Module (DDM) controls only the driver door lock actuatoreceives input from
the driver door lock control switch. The 2 modules communicate the lock or unlock commands through the
Medium Speed Controller Area Network (MS-CAN).
The SJB and the DDM are supplied voltage at all times. When the SJB receives a signal from the Remote
Keyless Entry (RKE) transmitter, the keyless entry keypad, or the RH door lock control switch, the SJB sends
a command to the DDM through the MS-CAN , and a ground signal to the lock and unlock relays. When the
LH door lock control switch is pressed, the DDM receives the lock or unlock signal. The DDM sends a
request through the MS-CAN to the SJB to lock or unlock the passenger doors. The SJB then responds to the
DDM request, authorizing a lock or unlock of the driver door by the DDM . The DDM then supplies voltage
and ground to the driver door lock actuator based on the lock or unlock request. The ground signal in the SJB
closes the relay which supplies voltage to the remaining door lock actuators. The remaining door lock
actuators then actuate to a lock or unlock position determined by the relay.
Luggage Compartment Lid Release
NOTE: When using the Integrated Keyhead Transmitter (IKT), 2 presses (within 3 seconds) of the luggage
compartment lid release button are required to release the luggage compartment lid.
The luggage compartment lid release system is inhibited when the vehicle speed exceeds 8 km/h (5 mph). The
luggage compartment lid latch releases the luggage compartment lid when the customer requests it be opened
using either the IKT , the keyless entry keypad, or the luggage compartment lid release switch. When the SJB
receives a signal to release the luggage compartment lid, the SJB supplies voltage to the luggage compartment
lid latch. The luggage compartment lid latch then actuates to release the luggage compartment lid.
The SJB interprets radio frequency signals from the Remote Keyless Entry (RKE) transmitters. The SJB
requests the illuminated entry feature to turn the interior lamps on when an unlock command is received. If a
lock command is received, the illuminated entry feature turns off.
The RKE transmitter supplies a signal to the SJB when any button is pressed. The SJB then supplies voltage
to the appropriate door lock actuator(s) to lock or unlock the doors. The RKE transmitter can also be used to
release the luggage compartment lid or activate the panic alarm. On MKZ, the RKE transmitter also causes
the SJB to send an MS-CAN message to the Driver Seat Module (DSM) to activate all memory features to the
positions associated with the RKE transmitter being used.
The keyless entry keypad is hardwired to the SJB . The SJB interprets the inputs from the keyless entry
keypad and then controls the associated operation. The keyless entry keypad is illuminated for 5 seconds
when any button is pressed. The SJB requests the illuminated entry feature to turn the interior lamps on when
a valid entry code is received. If a lock all doors code is entered, the illuminated entry feature turns off.
NOTE: The keyless entry keypad does not lock the doors if the driver door is ajar.
The keyless entry keypad supplies a signal to the SJB when the buttons are pressed. The SJB then supplies
voltage to the appropriate door lock actuator(s) to lock or unlock the doors. The keyless entry keypad can also
be used to release the luggage compartment lid. On MKZ, the keyless entry keypad also causes the SJB to
send an MS-CAN message to the Driver Seat Module (DSM) to activate all memory features to the positions
associated with the personal entry code entered on the keypad.
Visually inspect for obvious signs of mechanical or electrical damage. 2.
Binding latch
mechanisms

Door handles
Door striker adjustment
Hood latch
Luggage compartment
lid latch

Misaligned door
Smart Junction Box (SJB) fuse(s)
5 (10A)
17 (20A)

Door lock control switch
Luggage compartment lid release
switch

Keyless entry keypad
transmitter

SJB
3.
4.
NOTE: The Vehicle Communication Module (VCM) LED prove-out confirms power and ground
Check the VCM connection to the vehicle.
Check the scan tool connection to the VCM .
Refer to Section 418-00 , No Power To The Scan Tool, to diagnose no power to the scan tool.
5.
Verify the ignition key is in the ON position.
Verify the scan tool operation with a known good vehicle.
Refer to Section 418-00 to diagnose no response from the PCM.
6.
418-00 .

If the network test passes, retrieve and record the continuous memory DTCs.
7.
Clear the continuous DTCs and carry out the self-test diagnostics for the SJB , Driver Door Module
(DDM) and the Instrument Panel Cluster (IPC).
8.
If the DTCs retrieved are related to the concern, go to DTC Charts. For all other DTCs, refer to the
Diagnostic Trouble Code (DTC) Chart in Section 419-10 .
9.
If no DTCs related to the concern are retrieved, GO to Symptom Chart - Electrical . 10.
DTC Charts
B106E Solid State Driver Disabled Due
to Short Circuit
B106F Module Disabled Due to
External Fault
B1317 Battery Voltage High GO to Pinpoint Test AB .
B1318 Battery Voltage Low GO to Pinpoint Test AC .
B1342 ECU is Faulted CLEAR the DTCs. REPEAT the self-test. If DTC B1342 is
retrieved again, INSTALL a new Driver Door Module (DDM).
REFER to Driver Door Module (DDM) in this section. TEST the
B1534 Memory 1 Switch Circuit Short
to Ground
B1538 Memory 2 Switch Circuit Short
to Ground
B1667 Mirror Driver Up/Down Motor
Stalled
B1668 Mirror Driver Right/Left Motor
Stalled
B1733 Mirror Driver Vertical Switch
Circuit Failure
B1737 Mirror Driver Horizontal Switch
Circuit Failure
B1741 Mirror Passenger Vertical
Switch Circuit Failure
B1745 Mirror Passenger Horizontal
Switch Circuit Failure
B2223 Mirror Driver Drive Circuit
Failure
B2320 Mirror Driver Horizontal
Failure
B2322 Mirror Driver Horizontal
Short To Battery
Potentiometer Circuit Short To
Battery
B2477 Module Configuration Failure REFER to Section 418-01 .
B2574 Drivers Door LOCK Switch
Short to Ground
GO to Pinpoint Test H .
B2575 GO to Pinpoint Test H .
Drivers Door UNLOCK Switch
Short to Ground
U0140 Lost Communication With Body
Control Module (GEM)
U2050 No Application Present REFER to Section 418-01 .
Instrument Panel Cluster (IPC) DTC Chart
NOTE: This module utilizes a 5-character DTC followed by a 2-character failure-type code. The failure-type
code provides information about specific fault conditions such as opens, or shorts to ground. Continuous
memory DTCs have an additional 2-character DTC status code suffix to assist in determining DTC history.
B109E:42 Remote Keyless
Entry: General
Memory Failure
The Smart Junction Box (SJB) limit of 4 integrated keys is reached.
PROGRAM a maximum of 4 integrated keys. REFER to programming
keys using diagnostic equipment in Section 419-01B or Section 419-01C .
Entry: Not
Programmed
Entry: Signal Invalid
All other
DTCs
- REFER to the Diagnostic Trouble Code (DTC) Chart in Section 419-10 .
B1138 Memory Full The SJB limit of 4 integrated keys is reached. PROGRAM a maximum
of 4 integrated keys. REFER to programming keys using diagnostic
equipment in Section 419-01B or Section 419-01C . CLEAR the DTCs.
B1139 Invalid Transmitter
Identification Code
B1624 Lamp Keypad Output
Open Circuit
B1626 Lamp Keypad Output
Short Circuit To Ground
B2276 Less Than 2
Transmitters
Programmed
PROGRAM all of the customer's Integrated Keyhead Transmitters
(IKTs) (minimum of 2). REFER to Section 419-01B or Section 419-01C
. TEST the system for normal operation.
B2425 Remote Keyless Entry
Out of Synchronization
B2667 Liftglass Release Switch
Circuit Failure
GO to Pinpoint Test I .
B2A25 Trim Panel Lock Switch
Circuit Failure
B2A26 Keypad Switch Circuit
Failure
GO to Pinpoint Test J .
All other
DTCs
- REFER to the Diagnostic Trouble Code (DTC) Chart in Section 419-10 .
Symptom Chart
Symptom Chart - Electrical
Symptom Chart - Mechanical
Pinpoint Tests
Pinpoint Test A: All Door Locks Are Inoperative
Refer to Wiring Diagrams Cell 110 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Power Door Locks for
Normal Operation - MKZ
The Smart Junction Box (SJB) supplies voltage and ground to all the passenger door lock actuators by
controlling the lock all and unlock all relays. The Driver Door Module (DDM) supplies voltage and ground
only to the driver door lock actuator. The SJB receives inputs from the RH door lock control switch, keyless
entry keypad, and the Remote Keyless Entry (RKE) transmitter. The DDM only receives input from the LH
door lock control switch. Both modules share the information obtained from the inputs over the Medium
Speed Controller Area Network (MS-CAN). Upon a lock request, the SJB supplies voltage on the passenger
door lock circuit and ground on the passenger door unlock circuit, and the DDM supplies voltage on the driver
door lock circuit and ground on the driver door unlock circuit. Upon an unlock request, the voltage and
ground are reversed on the previously listed circuits. When the door lock and unlock relays are not energized
they are connected to ground. A dedicated SJB ground circuit is provided only for the lock and unlock relays.
Fusion
The SJB supplies voltage to the lock all relay, the unlock driver door relay or unlock all relay based upon
input from the door lock control switches, the RKE transmitter, or the keyless entry keypad. Upon a lock
request, the SJB supplies voltage on the all door lock circuit and ground on the driver and passenger door lock
circuits. Upon an unlock request, the voltage and ground are reversed on the previously listed circuits. When
the door lock and unlock relays are not energized they are connected to ground. A dedicated SJB ground
circuit is provided only for the lock and unlock relays.
Fuse
Wiring, terminals, or connectors
Luggage compartment lid release solenoid (part of the luggage compartment lid latch)
Normal Operation - MKZ 708
SJB
PINPOINT TEST A: ALL DOOR LOCKS ARE INOPERATIVE
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to
Section 414-01 .
A1 VERIFY THE OPERATION OF BOTH DOOR
LOCK CONTROL SWITCHES
Press the lock and unlock button on both door lock
control switches while observing the door lock
operation.

Are the door locks inoperative from both switches?
Yes
For MKZ, multiple failures exist if all
locks are inoperative. CHECK the
symptom(s) and GO to Symptom Chart -
Electrical .
For Fusion and Milan, GO to A2 .
No
A2 VERIFY ALL DOOR LOCKS ARE INOPERATIVE
Press the lock and unlock buttons from a door lock
control switch while observing the door locks.

Are all the door locks inoperative from both switch
positions (lock and unlock)?

Yes
VERIFY the SJB fuse 17 (20A) is OK. If
OK, GO to A3 .
If not OK, GO to A5 .
No
GO to Symptom Chart - Electrical .
A3 CHECK THE ALL LOCK CIRCUIT FOR AN
OPEN
Disconnect: LH Front Door Latch C525 .
Disconnect: SJB C228d .
Measure the resistance between the SJB C2280d-6,
circuit CPL11 (GY/BN), harness side and the LH
front door latch C525-2, circuit CPL11 (GY/BN),
harness side.

Yes
GO to A4 .
No
REPAIR circuit CPL11 (GY/BN) for an
operation.
Fusion 709
A4 CHECK THE POWER DOOR LOCK RELAY
Ignition OFF.
Disconnect: Negative Battery Cable .
Measure the resistance between the SJB C2280d-7,
circuit GD126 (BK/WH), harness side and ground.

Yes
GO to A8 .
No
REPAIR circuit GD126 (BK/WH) for an
operation.
A5 CHECK THE LUGGAGE COMPARTMENT LID
RELEASE OUTPUT CIRCUIT FOR A SHORT TO
GROUND
Install a new SJB fuse 17 (20A).
Operate the luggage compartment lid release by
pressing the luggage compartment lid release switch.

Is the SJB fuse 17 (20A) OK?
Yes
GO to A7 .
No
GO to A6 .
A6 CHECK THE LUGGAGE COMPARTMENT LID
RELEASE SOLENOID
Disconnect: Luggage Compartment Lid Release
Solenoid C429 .

Operate the luggage compartment lid release by
pressing the luggage compartment lid release switch.

Yes
INSTALL a new luggage compartment
lid latch. REFER to Luggage
Compartment Lid Latch in this section.
No
REPAIR circuit CPL59 (BN/BU) for a
short to ground. TEST the system for
normal operation.
A7 CHECK THE ALL LOCK CIRCUIT FOR A
SHORT TO GROUND
Operate the door lock actuators by pressing LOCK on
the door lock control switch.

Yes
REPAIR circuit CPL51 (BU/GN) or
CPL52 (VT/GY) for a short to ground.
No
REPAIR circuit CPL11 (GY/BN) for a
short to ground. TEST the system for
normal operation.
A8 CHECK FOR CORRECT SJB OPERATION
Disconnect all the SJB connectors.
Yes
PINPOINT TEST A: ALL DOOR LOCKS ARE INOPERATIVE 710
Check for:
corrosion
damaged pins
pushed-out pins
Connect all the SJB connectors and make sure they
seat correctly.

present.

normal operation.
No
Pinpoint Test B: A Single/More Than One Door Lock Is Inoperative - Fusion
Normal Operation
The SJB supplies voltage to the lock all relay, the unlock driver door relay or unlock all relay based upon
input from the door lock control switches, the RKE transmitter, or the keyless entry keypad. Upon a lock
request, the SJB supplies voltage on the all door lock circuit and ground on the driver and passenger door lock
circuits. Upon an unlock request, the voltage and ground are reversed on the previously listed circuits. When
the door lock and unlock relays are not energized they are connected to ground. A dedicated SJB ground
circuit is provided only for the lock and unlock relays.
Door lock actuator (part of the door latch)
SJB
PINPOINT TEST B: A SINGLE/MORE THAN ONE DOOR LOCK IS INOPERATIVE - FUSION
B1 CHECK THE OPERATION FROM THE INTERIOR
DOOR HANDLE
Open the door using the interior door handle.
Does the interior door handle operate normally?
Yes
GO to B2 .
No
GO to Pinpoint Test U .
B2 CHECK THE LOCK LEVER OPERATION
Operate the door lock lever while observing for any
binding.

Is the door lock lever binding?
Yes
INSPECT the interior door handle and
door latch for binding. REPAIR as
necessary. TEST thsystem for normal
operation.
No
GO to B3 .
B3 CHECK THE ALL LOCK CIRCUIT FOR VOLTAGE
Ignition OFF.
Disconnect: Inoperative Door Lock Actuator .
NOTE: The SJB only supplies voltage to the actuator
momentarily. It is important to monitor the meter while
pressing the door lock control switch.

While pressing the door lock control switch in the
LOCK position, measure the voltage between the
inoperative door lock actuator, harness side and ground
as follows:

Inoperative Door Lock
Actuator Connector-Pin Circuit
LH front C525-2 CPL11
(GY/BN)
RH front C603-2 CPL11
(GY/BN)
LH rear C704-2 CPL11
(GY/BN)
RH rear C804-2 CPL11
(GY/BN)
Is the voltage momentarily greater than 10 volts?
Yes
GO to B4 .
No
REPAIR circuit CPL11 (GY/BN) for
operation.
B4 CHECK THE UNLOCK CIRCUITS FOR VOLTAGE
momentarily. It is important to monitor the meter while
pressing the door lock control switch.

While pressing the door lock control switch in the
UNLOCK position, measure the voltage between the
inoperative door lock actuator, harness side and ground
as follows:

Connector-Pin Circuit
Yes
INSTALL a new door latch for the
door lock actuator in question. REFER
to Front Door Latch or Rear Door
Latch in this section. TEST the system
No
GO to B5 .
PINPOINT TEST B: A SINGLE/MORE THAN ONE DOOR LOCK IS INOPERATIVE - FUSION 712
Actuator
LH front C525-10 CPL51
(BU/GN)
RH front C603-10 CPL52
(VT/GY)
LH rear C704-10 CPL52
(VT/GY)
RH rear C804-10 CPL52
(VT/GY)
B5 CHECK THE UNLOCK CIRCUITS FOR AN OPEN
Measure the resistance between the inoperative door
lock actuator, harness side and the SJB , harness side as
follows:

Actuator
Connector-Pin
SJB
LH front C525-10 C2280d-28 CPL51
(BU/GN)
RH front C603-10 C2280d-27 CPL52
(VT/GY)
LH rear C704-10 C2280d-27 CPL52
(VT/GY)
RH rear C804-10 C2280d-27 CPL52
(VT/GY)
Yes
GO to B6 .
No
REPAIR the circuit in question for an
operation.
PINPOINT TEST B: A SINGLE/MORE THAN ONE DOOR LOCK IS INOPERATIVE - FUSION 713
B6 CHECK FOR CORRECT SJB OPERATION
Check for:
corrosion
damaged pins
pushed-out pins
Connect all the SJB connectors and make sure they seat
correctly.

Yes
normal operation.
No
connector.
Pinpoint Test C: A Single/More Than One Door Lock Is Inoperative - MKZ
Normal Operation
The Smart Junction Box (SJB) supplies voltage and ground to all the passenger door lock actuators by
controlling the lock all and unlock all relays. The Driver Door Module (DDM) supplies voltage and ground
only to the driver door lock actuator. The SJB receives inputs from the RH door lock control switch, keyless
entry keypad, and the Remote Keyless Entry (RKE) transmitter. The DDM only receives input from the LH
door lock control switch. Both modules share the information obtained from the inputs over the Medium
Speed Controller Area Network (MS-CAN). Up a lock request, the SJB supplies voltage on the passenger
door lock circuit and ground on the passenger door unlock circuit, and the DDM supplies voltage on the driver
door lock circuit and ground on the driver door unlock circuit. Upon an unlock request, the voltage and
ground are reversed on the previously listed circuits. When the door lock and unlock relays are not energized
they are connected to ground. A dedicated SJB ground circuit is provided only for the lock and unlock relays.
Fuse
Door lock actuator (part of the door latch)
Luggage compartment lid release solenoid (part of the luggage compartment latch)
DDM
SJB
PINPOINT TEST C: A SINGLE/MORE THAN ONE DOOR LOCK IS INOPERATIVE - MKZ
Section 414-01 .
C1 CHECK THE OPERATION FROM THE INTERIOR DOOR
HANDLE
Open the door using the interior door handle.
Does the interior door handle operate normally?
Yes
GO to C2 .
No
C2 CHECK THE LOCK LEVER OPERATION
Operate the door lock lever while observing for any binding.
Is the door lock lever binding?
Yes
INSPECT the interior door
handle and door latch for
binding. REPAIR as
necessary. TEST the system
No
GO to C3 .
C3 CHECK FOR COMMUNICATION WITH THE DDM AND
SJB
Enter the following diagnostic mode on the scan tool: Network
Test .

Does the SJB or DDM fail the network test?
Yes
No
GO to C4 .
C4 CHECK THE PASSENGER DOOR LOCKS
Ignition OFF.
Operate the door locks from the passenger door lock control
switch.

Are all of the passenger door locks inoperative?
Yes
VERIFY the SJB fuse 17
(20A) is OK. If OK, GO to C5
.
If not OK, GO to C8 .
No
GO to C11 .
C5 CHECK THE POWER DOOR LOCK RELAY GROUND
CIRCUIT FOR AN OPEN
Ignition OFF.
Measure the resistance between the SJB C2280d-7, circuit
GD126 (BK/WH), harness side and ground.

Yes
GO to C6 .
No
REPAIR circuit GD126
(BK/WH) for an open. TEST
operation.
C6 CHECK THE LOCK CIRCUIT FOR AN OPEN
PINPOINT TEST C: A SINGLE/MORE THAN ONE DOOR LOCK IS INOPERATIVE - MKZ 715
Disconnect: RH Front Door Latch C603 .
Measure the resistance between the RH front door latch C603-2,
circuit CPL11 (GY/BN), harness side and the SJB C2280d-6,
circuit CPL11 (GY/BN), harness side.

Yes
GO to C7 .
No
REPAIR circuit CPL11
(GY/BN) for an open. TEST
operation.
C7 CHECK THE UNLOCK CIRCUIT FOR AN OPEN
Measure the resistance between the RH front door latch
C603-10, circuit CPL52 (VT/GY), harness side and the SJB
C2280d-27, circuit CPL52 (VT/GY), harness side.

Yes
GO to C19 .
No
(VT/GY) for an open. TEST
operation.
C8 CHECK THE LUGGAGE COMPARTMENT LID RELEASE
OUTPUT CIRCUIT FOR A SHORT TO GROUND
Operate the luggage compartment lid release by pressing the
luggage compartment lid release switch.

Yes
GO to C10 .
No
GO to C9 .
C9 CHECK THE LUGGAGE COMPARTMENT LID RELEASE
SOLENOID
Disconnect: Luggage Compartment Lid Release Solenoid C429 .
Operate the luggage compartment lid release by pressing the
luggage compartment lid release switch.

Yes
INSTALL a new luggage
compartment lid latch. REFER
to Luggage Compartment Lid
Latch in this section.
No
(BN/BU) for a short to
ground. TEST the system for
normal operation.
C10 CHECK THE LOCK CIRCUIT FOR A SHORT TO
GROUND
Operate the door lock actuators by pressing LOCK on the
passenger door lock control switch.

Yes
(VT/GY) for a short to
normal operation.
No
(GY/BN) for a short to
normal operation.
C11 CHECK THE DRIVER DOOR LOCK
Check to see if the driver door lock is the inoperative lock.
Is the driver door lock inoperative?
Yes
GO to C12 .
No
GO to C16 .
C12 CHECK THE DRIVER DOOR LOCK CIRCUIT FOR
VOLTAGE
Disconnect: LH Front Door Latch C525 .
NOTE: The DDM only supplies voltage to the actuator
momentarily. It is important to monitor the meter while pressing

While pressing the door lock control switch in the LOCK
position, measure the voltage between the LH front door latch
C525-2, circuit CPL02 (VT/GN), harness side and ground.

Yes
GO to C13 .
No
GO to C14 .
C13 CHECK THE DRIVER UNLOCK CIRCUIT FOR
VOLTAGE
NOTE: The DDM only supplies voltage to the actuator

While pressing the door lock control switch in the UNLOCK
position, measure the voltage between the LH front door latch
C525-10, circuit CPL51 (BU/GN), harness side and ground.

Yes
INSTALL a new driver door
latch. REFER to Front Door
Latch in this section. TEST
operation.
No
GO to C15 .
C14 CHECK THE DRIVER LOCK CIRCUIT FOR AN OPEN OR
A SHORT TO GROUND
Disconnect: DDM C568b .
Measure the resistance between the LH front door latch C525-2,
circuit CPL02 (VT/GN), harness side and the DDM C568b-11,
circuit CPL02 (VT/GN), harness side; and between the LH front
door latch C525-2, circuit CPL02 (VT/GN), harness side and
ground.

Is the resistance less than 5 ohms between the LH front door
latch and the DDM , and greater than 10,000 ohms between
the LH front door latch and ground?

Yes
GO to C15 .
No
(VT/GN). TEST the system
C15 CHECK THE DRIVER UNLOCK CIRCUIT FOR AN OPEN
OR A SHORT TO GROUND
Disconnect: DDM C568b .
Measure the resistance between the LH front door latch
C525-10, circuit CPL51 (BU/GN), harness side and the DDM
C568b-10, circuit CPL51 (BU/GN), harness side; and between
the LH front door latch C525-10, circuit CPL51 (BU/GN),

Is the resistance less than 5 ohms between the LH front door
latch and the DDM , and greater than 10,000 ohms between
the LH front door latch and ground?

Yes
GO to C18 .
No
(BU/GN). TEST the system
C16 CHECK THE PASSENGER LOCK CIRCUIT FOR
VOLTAGE
Disconnect: Suspect Door Latch .

While pressing the door lock control switch in the LOCK
position, measure the voltage between the suspect door latch and
ground as follows:

Door Latch Connector-Pin Circuit
C603-2 (RH front) CPL11
(GY/BN)
C704-2 (LH rear) CPL11
(GY/BN)
C804-2 (RH rear) CPL11
(GY/BN)
Yes
GO to C17 .
No
(GY/BN) for an open. TEST
operation.
C17 CHECK THE PASSENGER UNLOCK CIRCUIT FOR
VOLTAGE

While pressing the door lock control switch in the UNLOCK
position, measure the voltage between the suspect door latch and
ground as follows:

Door Latch Connector-Pin Circuit
C603-10 (RH front) CPL52 (VT/GY)
C704-10 (LH rear) CPL52 (VT/GY)
C804-10 (RH rear) CPL52 (VT/GY)
Yes
INSTALL a new door latch
for the door lock actuator in
question. REFER to Front
Door Latch or Rear Door
Latch in this section. TEST
operation.
No
(VT/GY) for an open. TEST
operation.
C18 CHECK FOR CORRECT DDM OPERATION
Disconnect all the DDM connectors.
Check for:
corrosion
damaged pins
pushed-out pins
Connect all the DDM connectors and make sure they seat
correctly.

Yes
INSTALL a new DDM .
REFER to Driver Door
Module (DDM) in this section.
operation.
No
correctly at this time. The
concern may have been caused
by a loose or corroded
C19 CHECK FOR CORRECT SJB OPERATION
Check for:
corrosion
damaged pins
pushed-out pins
correctly.

Yes
INSTALL a new SJB .
operation.
No
concern may have been caused
by a loose or corroded
connector.
Pinpoint Test D: All Door Locks Are Inoperative From One Switch - Fusion
Normal Operation
The Smart Junction Box (SJB) sends voltage signals to the door lock control switches through the lock and
unlock input circuits. When the lock or unlock switch is pressed, the corresponding voltage signal is routed to
ground, signalling the SJB to lock or unlock the doors. The door lock control switches have a dedicated
ground circuit.
PINPOINT TEST D: ALL DOOR LOCKS ARE INOPERATIVE FROM ONE SWITCH - FUSION
D1 CHECK THE DOOR LOCK CONTROL
SWITCH
Disconnect: Inoperative Door Lock
Control Switch .

Carry out the door lock control switch
component test.

Is the door lock control switch OK?
Yes
REPAIR circuit GD126 (BK/WH) or GD139
(BK/YE) for an open. TEST the system for normal
operation.
No
INSTALL a new door lock control switch. REFER to
Door Lock Control Switch . TEST the system for
normal operation.
Pinpoint Test E: All Door Locks Are Inoperative From One Switch - MKZ
Normal Operation
The Smart Junction Box (SJB) sends voltage signals to the passenger door lock control switch through the
lock and unlock input circuits. When the lock or unlock switch is pressed, the corresponding voltage signal is
routed to ground, signalling the SJB to lock or unlock the passenger doors and send a lock or unlock
command to the Driver Door Module (DDM) over the Medium Speed Controller Area Network (MS-CAN).
The DDM sends voltage signals to the driver door lock control switch through the lock and unlock input
circuits. When the lock or unlock switch is pressed, the corresponding voltage signal is routed to ground,
signalling the DDM to lock or unlock the driver door and send a lock or unlock command to the SJB over the
MS-CAN .
The door lock control switches have a dedicated ground circuit.
DDM
SJB
PINPOINT TEST E: ALL DOOR LOCKS ARE INOPERATIVE FROM ONE SWITCH - MKZ
PINPOINT TEST D: ALL DOOR LOCKS ARE INOPERATIVE FROM ONE SWITCH - FUSION 721
Section 414-01 .
E1 CHECK THE RECORDED SJB AND DDM
DTCsROM THE SELF-TEST
Check the recorded results from the SJB and
DDM self-test.

Yes
REFER to DTC Charts in this section.
No
GO to E2 .
E2 CHECK THE DRIVER DOOR LOCK
CONTROL SWITCH
Check to see if the driver door lock control
switch is the inoperative switch.

Is the driver door lock control switch
inoperative?

Yes
GO to E3 .
No
GO to E4 .
E3 CHECK THE DRIVER DOOR SWITCH
Disconnect: Driver Door Lock Control Switch
C505 .

Measure the resistance between the driver door
lock control switch C505-4, circuit GD126
(BK/WH), harness side and ground.

Yes
GO to E5 .
No
REPAIR circuit GD126 (BK/WH) for an open.
E4 CHECK THE PASSENGER SWITCH
Disconnect: Passenger Door Lock Control
Switch C605 .

Measure the resistance between the passenger
door lock control switch C605-4, circuit
GD139 (BK/YE), harness side and ground.

Yes
GO to E5 .
No
REPAIR circuit GD139 (BK/YE) for an open.
PINPOINT TEST E: ALL DOOR LOCKS ARE INOPERATIVE FROM ONE SWITCH - MKZ 722
E5 CHECK THE SUSPECT DOOR LOCK
CONTROL SWITCH FOR CORRECT
OPERATION
Carry out the door lock control switch
component test.

Yes
For an inoperative driver door lock control
switch, GO to E6 .
For an inoperative passenger door lock control
switch, GO to E7 .
No
INSTALL a new door lock control switch.
REFER to Door Lock Control Switch in this
E6 CHECK THE DDM FOR CORRECT
OPERATION
Check for:
corrosion
damaged pins
pushed-out pins
Connect all the DDM connectors and make

still present.

Yes
INSTALL a new DDM . REFER to Driver Door
Module (DDM) in this section. TEST the system
No
The concern may have been caused by a loose or
corroded connector. TEST the system for
normal operation.
E7 CHECK THE SJB FOR CORRECT
OPERATION
Check for:
corrosion
damaged pins
pushed-out pins
Connect all the SJB connectors and make sure

still present.

Yes
No
corroded connector.
Pinpoint Test F: The Door Lock Switches Operate Only One Way - Fusion
PINPOINT TEST E: ALL DOOR LOCKS ARE INOPERATIVE FROM ONE SWITCH - MKZ 723
Normal Operation
The Smart Junction Box (SJB) sends voltage signals to the door lock control switches through the lock and
unlock input circuits. When the lock or unlock switch is pressed, the corresponding voltage signal is routed to
ground, signalling the SJB to lock or unlock the doors. The door lock control switches have a dedicated
ground circuit.
SJB
PINPOINT TEST F: THE DOOR LOCK SWITCHES OPERATE ONLY ONE WAY - FUSION
F1 RETRIEVE THE RECORDED SJB DTCs FROM THE
SELF-TEST
Check for recorded SJB DTCs from the self-test.
Are any DTCs recorded?
Yes
For DTC B2A25, GO to
Pinpoint Test H .
For all other SJB DTCs,
REFER to DTC Charts in
this section.
No
GO to F2 .
F2 VERIFY THE OPERATION OF BOTH DOOR LOCK CONTROL
SWITCHES
Ignition OFF.
Press the lock and unlock button of both door lock control switches
while observing the door lock operation.

Do the door locks operate only one way from both switches?
Yes
GO to F4 .
No
GO to F3 .
F3 CHECK THE LOCK INPUT OR UNLOCK INPUT CIRCUIT
FOR AN OPEN (SINGLE SWITCH INOPERATIVE)
Disconnect: Suspect Door Lock Control Switch .
Unlock the doors from the working door lock control switch.
Observe the door locks while connecting a fused jumper wire
between the LH door lock control switch C505-1, circuit CPK19
(BU/GN), harness side and the LH door lock control switch C505-4,
circuit GD126 (BK/WH), harness side; or between the RH door lock
control switch C605-1, circuit CPK19 (BU/GN), harness side and the
RH door lock control switch C605-4, circuit GD139 (BK/YE),

Yes
INSTALL a new door
lock control switch.
REFER to Door Lock
No
harness side.
Remove the jumper wire.
Observe the door locks while connecting a fused jumper wire
between the LH door lock control switch C505-3, circuit CPK23
(YE/VT), harness side and the LH door lock control switch C505-4,
circuit GD126 (BK/WH), harness side; or between the RH door lock
control switch C605-3, circuit CPK23 (YE/VT), harness side and the
RH door lock control switch C605-4, circuit GD139 (BK/YE),
harness side.

Do the doors lock and unlock with the jumper wire?
REPAIR the input circuit
in question. TEST the
system for normal
operation.
F4 CHECK THE LOCK INPUT OR THE UNLOCK INPUT
CIRCUIT FOR AN OPEN (BOTH SWITCHES INOPERATIVE)
Disconnect: LH Door Lock Control Switch C505 .
Disconnect: SJB C2280c .
If the doors do not lock, measure the resistance between the SJB
C2280c-17, circuit CPK19 (BU/GN), harness side and the LH door
lock control switch C505-1, circuit CPK19 (BU/GN), harness side.

If the doors do not unlock, measure the resistance between the SJB
C2280c-4, circuit CPK23 (YE/VT), harness side and the LH door
lock control switch C505-3, circuit CPK23 (YE/VT), harness side.

Yes
GO to F5 .
No
REPAIR the circuit in
question. TEST the system
PINPOINT TEST F: THE DOOR LOCK SWITCHES OPERATE ONLY ONE WAY - FUSION 725
F5 CHECK FOR CORRECT SJB OPERATION
Check for:
corrosion
damaged pins
pushed-out pins
Connect all the SJB connectors and make sure they seat correctly.
Yes
INSTALL a new SJB .
REFER to Section 419-10
. TEST the system for
normal operation.
No
concern may have been
corroded connector.
Pinpoint Test G: The Door Lock Switches Operate Only One Way - MKZ
Normal Operation
The DDM sends voltage signals to the driver door lockontrol switch through the lock and unlock input
MS-CAN .
DDM
SJB
PINPOINT TEST G: THE DOOR LOCK SWITCHES OPERATE ONLY ONE WAY - MKZ
G1 RETRIEVE THE RECORDED DDM AND SJB DTCs
FROM BH THE SELF-TESTS
Check for recorded DDM and SJB DTCs from the
self-tests.

Yes
For DDM DTC B2574 or B2575 and
SJB DTC B2A25, GO to Pinpoint
Test H .
For all other DTCs, REFER to DTC
Charts in this section.
No
GO to G2 .
G2 CHECK THE SUSPECT DOOR LOCK CONTROL
SWITCH FOR CORRECT OPERATION
Disconnect: Inoperative Door Lock Control Switch .
Carry out the door lock control switch component test.

Yes
If the driver door lock control switch
was the switch tested, GO to G3 .
If the passenger door lock control
switch was the switch tested, GO to
G4 .
No
INSTALL a new door lock control
switch. REFER to Door Lock Control
G3 CHECK THE DRIVER LOCK AND UNLOCK INPUT
CIRCUITS FOR AN OPEN AT THE DDM
Ignition OFF.
Disconnect: DDM C568a .
If the doors do not lock, measure the resistance between
the DDM C568a-5, circuit CPL42 (GY/YE), harness side
and the LH door lock control switch C505-1, circuit
CPL42 (GY/YE), harness side.

If the doors do not unlock, measure the resistance
Yes
GO to G5 .
No
REPAIR the circuit in question for an
operation.
PINPOINT TEST G: THE DOOR LOCK SWITCHES OPERATE ONLY ONE WAY - MKZ 727
between the DDM C568a-6, circuit CPL43 (VT/GY),
harness side and the LH door lock control switch C505-3,
circuit CPL43 (VT/GY), harness side.
G4 CHECK THE PASSENGER LOCK AND UNLOCK
INPUT CIRCUITS FOR AN OPEN AT THE SJB
Ignition OFF.
If the doors do not lock, measure the resistance between
the SJB C2280c-17, circuit CPK19 (BU/GN), harness
side and the RH door lock control switch C605-1, circuit
CPK19 (BU/GN), harness side.

If the doors do not unlock, measure the resistance
between the SJB C2280c-4, circuit CPK23 (YE/VT),
harness side and the RH door lock control switch C605-3,
circuit CPK23 (YE/VT), harness side.

Yes
GO to G6 .
No
REPAIR the circuit in question.
operation.
G5 CHECK FOR CORRECT DDM OPERATION
Check for:
corrosion
damaged pins
pushed-out pins
Yes
INSTALL a new DDM . REFER to
Driver Door Module (DDM) in this
operation.
PINPOINT TEST G: THE DOOR LOCK SWITCHES OPERATE ONLY ONE WAY - MKZ 728
correctly.

No
connector.
G6 CHECK FOR CORRECT SJB OPERATION
Check for:
corrosion
damaged pins
pushed-out pins
correctly.

Yes
normal operation.
No
connector.
Pinpoint Test H: DTC B2A25, B2574, Or B2575
Normal Operation - MKZ
The DDM sends voltage signals to the driver door lock control switch through the lock and unlock input
MS-CAN .
Fusion
The SJB sends voltage signals to both door lock control switches through the lock and unlock input circuits.
When the lock or unlock switch is pressed, the corresponding voltage signal is routed to ground, signalling the
SJB to lock or unlock the doors. The door lock control switches have a dedicated ground circuit.
DTC B2574 (Drivers Door LOCK Switch Short to Ground) - a continuous and on-demand DTC that
sets when the DDM detects a short to ground on the lock input circuit. This code will also set if the
driver door lock control switch is pressed for longer than 2 minutes.

DTC B2575 (Drivers Door UNLOCK Switch Short to Ground) - a continuous and on-demand DTC
that sets when the DDM detects a short to ground on the unlock circuit. This code will also set if the
driver door lock control switch is pressed for longer than 2 minutes.

DTC B2A25 (Trim Panel Lock Switch Circuit Failure) - an on-demand DTC that sets when the SJB
detects a short to ground from the lock or unlock request input circuits. This DTC may also set if
either of the door lock control switches are pressed for longer than 2 minutes.

Normal Operation - MKZ 729
DDM
SJB
PINPOINT TEST H: DTC B2A25, B2574, OR B2575
H1 CHECK THE RECORDED SJB DTCs FROM THE
SELST
Check the recorded results from the SJB self-test.
Is DTC B2A25 present?
Yes
GO to H2 .
No
For DTCs B2574 or B2575, GO to
H5 .
H2 CHECK THE RH DOOR LOCK CONTROL SWITCH
Disconnect: RH Door Lock Control Switch C605 .
Repeat the SJB self-test.
Is DTC B2A25 retrieved again?
Yes
For Fusion and Milan, LEAVE the
switch disconnected. GO to H3 .
For MKZ, LEAVE the switch
disconnected. GO to H4 .
No
INSTALL a new RH door lock
control switch. REFER to Door Lock
H3 CHECK THE LH DOOR LOCK CONTROL SWITCH -
FUSION
Repeat the SJB self-test.
Is DTC B2A25 retrieved again?
Yes
LEAVE the switch disconnected. GO
to H4 .
No
INSTALL a new LH door lock
Control Switch in this section.EST
H4 CHECK THE SJB LOCK INPUT CIRCUIT OR THE
UNLOCK INPUT CIRCUIT FOR A SHORT TO GROUND
Fusion 730
Ignition OFF.
Measure the resistance between the RH door lock control
switch C605-1, circuit CPK19 (BU/GN), harness side and
ground; and between the RH door lock control switch
C605-3, circuit CPK23 (YE/VT), harness side and
ground.

Yes
GO to H8 .
No
self-test.
H5 CHECK THE LH DOOR LOCK CONTROL SWITCH -
MKZ
Repeat the DDM self-test.
Is DTC B2574 or B2575 retrieved?
Yes
LEAVE the switch disconnected. GO
to H6 .
No
INSTALL a new LH door lock
H6 CHECK THE DDM LOCK INPUT CIRCUIT OR THE
UNLOCK INPUT CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Disconnect: DDM C568a .
Measure the resistance between the LH door lock control
switch C505-1, circuit CPL42 (GY/YE), harness side and
ground; and between the LH door lock control switch
C505-3, circuit CPL43 (VT/GY), harness side and
ground.

Yes
GO to H7 .
No
self-test.
H7 CHECK FOR CORRECT DDM OPERATION
Check for:
Yes
INSTALL a new DDM . REFER to
Driver Door Module (DDM) in this
PINPOINT TEST H: DTC B2A25, B2574, OR B2575 731
corrosion
damaged pins
pushed-out pins
correctly.

operation.
No
this time. The concern may have
been caused by a loose or corroded
connector.
H8 CHECK FOR CORRECT SJB OPERATION
Check for:
corrosion
damaged pins
pushed-out pins
correctly.

Yes
normal operation.
No
connector.
Pinpoint Test I: The Luggage Compartment Lid Release Is Inoperative/Does Not Operate Correctly
Refer to Wiring Diagrams Cell 113 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Luggage Compartment
Lid Release for schematic and connector information.
Normal Operation
When the Smart Junction Box (SJB) receives an open request from the luggage compartment lid switch, a
Remote Keyless Entry (RKE) transmitter or the keyless entry keypad (if equipped), the SJB supplies voltage
to the luggage compartment lid latch which releases the latch. The luggage compartment lid latch has a
dedicated ground circuit.
The SJB sends a voltage signal to the luggage compartment lid release switch through the input circuit. When
the luggage compartment lid release switch is pressed, the voltage signal is routed to ground, signalling the
SJB to release the luggage compartment lid. The luggage compartment lid release switch has a dedicated
ground circuit.
DTC B2667 (Liftglass Release Switch Circuit Failure) - an on-demand DTC that sets if the SJB
detects a short to ground on the luggage compartment lid release switch input circuit. This code also
sets if the luggage compartment lid release request is detected for longer than 2 minutes.

Luggage compartment lid release switch
Luggage compartment lid latch
SJB
PINPOINT TEST I: THE LUGGAGE COMPARTMENT LID RELEASE IS INOPERATIVE/DOES NOT OPERATE
CORRECTLY
Section 414-01 .
I1 CHECK THE DOOR LOCK OPERATION
Lock and unlock the doors using a door lock control switch.
Do the passenger door locks operate?
Yes
GO to I2 .
No
For Fusion, GO to Pinpoint Test
A .
For MKZ, GO to Pinpoint Test C
.
I2 CARRY OUT THE SJB LUGGAGE COMPARTMENT LID
RELEASE ACTIVE COMMAND USING THE SCAN TOOL
Enter the following diagnostic mode on the scan tool: SJB
DataLogger .

Select the SJB PID (LIFTGLASS_R) and active command the
luggage compartment lid to release.

Does the luggage compartment lid release?
Yes
GO to I3 .
No
GO to I7 .
I3 CHECK THE LUGGAGE COMPARTMENT LID RELEASE
SWITCH
Disconnect: Luggage Compartment Lid Release Switch
C2269 .

Connect a fused jumper wire between the luggage
compartment lid release switch C2269-6, circuit CPL60
(BN/YE), harness side and the luggage compartment lid
release switch C2269-2, circuit GD116 (BK/VT), harness
side.

Does the luggage compartment lid release?
Yes
compartment lid release switch.
REFER to Luggage
Compartment Lid Release
No
GO to I4 .
PINPOINT TEST I: THE LUGGAGE COMPARTMENT LID RELEASE IS INOPERATIVE/DOES NOT OPERATE CORRECTLY 733
Ignition OFF.
Measure the resistance between the luggage compartment lid
release switch C2269-2, circuit GD116 (BK/VT), harness side
and ground.

Yes
GO to I5 .
No
REPAIR circuit GD116 (BK/VT)
for an open. TEST the system for
normal operation.
SWITCH INPUT CIRCUIT FOR A SHORT TO GROUND
release switch C2269-6, circuit CPL60 (BN/YE), harness side
and ground.

Yes
GO to I6 .
No
REPAIR circuit CPL60 (BN/YE)
for a short to ground. CLEAR the
INPUT CIRCUIT FOR AN OPEN
switch C2269-6, circuit CPL60 (BN/YE), harness side and the
SJB C2280c-20, circuit CPL60 (BN/YE), harness side.

Yes
GO to I12 .
No
REPAIR circuit CPL60 (BN/YE)
normal operation.
OUTPUT CIRCUIT FOR VOLTAGE
Disconnect: Luggage Compartment Lid Latch C429 .
Ignition ON.
NOTE: Do not operate the luggage compartment lid release
while carrying out this test.

Measure the voltage between the luggage compartment lid
latch C429-3, circuit CPL59 (BN/BU), harness side and
ground.

Yes
GO to I8 .
No
GO to I9 .
OUTPUT CIRCUIT FOR A SHORT TO VOLTAGE
Ignition OFF.
Ignition ON.
Measure the voltage between the luggage compartment lid
ground.

Yes
REPAIR circuit CPL59 (BN/BU)
for a short to voltage. TEST the
No
GO to I12 .
I9 CHECK FOR VOLTAGE TO THE LUGGAGE
COMPARTMENT LID RELEASE SOLENOID
Unlock the doors with a door lock control switch.
NOTE: The SJB only supplies voltage to the luggage
compartment lid release solenoid momentarily. It is important
to monitor the meter while pressing the luggage compartment
lid release switch.

While pressing the luggage compartment lid release switch,
measure the voltage between the luggage compartment lid
ground.

Yes
GO to I11 .
No
GO to I10 .
I10 CHECK THE LUGGAGE COMPARTMENT LID
RELEASE OUTPUT CIRCUIT FOR AN OPEN
Ignition OFF.
Measure the resistance between the SJB C2280d-31, circuit
CPL59 (BN/BU), harness side and the luggage compartment
lid latch C429-3, circuit CPL59 (BN/BU), harness side.

Yes
GO to I12 .
No
REPAIR circuit CPL59 (BN/BU)
normal operation.
I11 CHECK THE LUGGAGE COMPARTMENT LID LATCH
Ignition OFF.
latch C429-4, circuit GD171 (BK/GY), harness side and
ground.

Yes
compartment lid latch. REFER to
Luggage Compartment Lid Latch
in this section. TEST the system
No
(BK/GY) for an open. TEST the
I12 CHECK FOR CORRECT SJB OPERATION
Check for:
corrosion
damaged pins
pushed-out pins
Yes
INSTALL a new SJB . REFER
to Section 419-10 . TEST the
No
correctly.

at this time. The concern may
have been caused by a loose or
corroded connector.
Pinpoint Test J: The Doors Do Not Lock/Unlock Using The Keyless Entry Keypad
Refer to Wiring Diagrams Cell 117 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Remote Keyless Entry and
Alarm for schematic and connector information.
Normal Operation
The Smart Junction Box (SJB) monitors for a ground signal on the keyless entry keypad signal input circuits.
When an individual keypad button is pressed, an individual or combination of the input circuits is routed to
ground. The SJB then determines which button was pressed based on which circuit(s) are grounded. The
keypad has a dedicated ground circuit. Once the SJB determines that the 5-digit personal entry code, or the
factory set 5-digit entry code has been entered on the keypad, the SJB then energizes the driver door unlock
relay to unlock the driver door.
To unlock all the doors, the 3/4 button must be pressed within 5 seconds of the 5-digit code being entered.
To release the luggage compartment lid, the 5/6 button must be pressed within 5 seconds of the 5-digit code
being entered.
To lock all the doors, the 5-digit code does not need to be entered. Press the 7/8 and 9/0 buttons at the same
time.
DTC B2A26 (Keypad Switch Circuit Failure) - an on-demand DTC that sets when the SJB detects a
short to ground on any of the keyless entry keypad input circuits.

SJB
PINPOINT TEST J: THE DOORS DO NOT LOCK/UNLOCK USING THE KEYLESS ENTRY KEYPAD
Section 414-01 .
J1 CHECK THE SJB KEYCODE PID
DataLogger .

Observe the SJB PID (KEYCODE). Read and record the
5-digit factory set entry code.

Yes
The system is operating as
designed. INFORM the customer of
the correct system operation.
Enter the 5-digit factory set entry code on the keyless entry
keypad, then press the 3/4 button.

Do the doors unlock?
No
GO to J2 .
J2 RETRIEVE THE RECORDED SJB DTCs FROM THE
SELF-TEST
Check for recorded SJB DTCs from the self-test.
Is DTC B2A26 recorded?
Yes
GO to J3 .
No
GO to J5 .
J3 REPEAT THE SJB SELF-TEST
Disconnect: Keyless Entry Keypad C530 .
Clear the DTCs, then repeat the SJB self-test.
Is DTC B2A26 recorded?
Yes
GO to J4 .
No
INSTALL a new keyless entry
keypad. REFER to Keyless Entry
Keypad in this section. CLEAR the
J4 CHECK THE KEYPAD INPUT CIRCUITS FOR A
SHORT TO GROUND
Ignition OFF.
Measure the resistance between the keypad, harness side
and ground as follows:

Keypad Connector-Pin Circuit
C530-7 CPK29 (GY/BU)
C530-5 CPK30 (VT/GN)
C530-1 CPK31 (YE/GN)
Yes
GO to J10 .
No
self-test.
J5 CHECK THE SJB KEY_PAD PID
DataLogger .

Press each keyless entry keypad button while observing the
SJB PID (KEY_PAD).

Does the PID display the correct values?
Yes
GO to J10 .
No
GO to J6 .
PINPOINT TEST J: THE DOORS DO NOT LOCK/UNLOCK USING THE KEYLESS ENTRY KEYPAD 738
J6 CHECK THE KEYPAD GROUND CIRCUIT FOR AN
OPEN
Ignition OFF.
Measure the resistance between the keyless entry keypad
C530-2, circuit GD126 (BK/WH), harness side and ground.

Yes
GO to J7 .
No
J7 CHECK THE KEYLESS ENTRY KEYPAD
Connect: Negative Battery Cable .
Connect a fused jumper wire between the keyless entry
keypad harness side, while monitoring the SJB PID
(KEY_PAD) as follows:

Keyless Entry
Keypad
Connector-Pin/
Circuit
Keyless Entry
Keypad
Connector-Pin/
Circuit
SJB PID
(KEY_PAD)
Value
C530-7
CPK29 (GY/BU)
C530-2
GD126 (BK/WH)
1/2
C530-5
CPK30 (VT/GN)
C530-2
GD126 (BK/WH)
7/8
C530-1
CPK31 (YE/GN)
C530-2
GD126 (BK/WH)
9/0
Does the PID display the correct values?
Yes
INSTALL a new keyless entry
keypad. REFER to Keyless Entry
Keypad in this section.
No
GO to J8 .
J8 CHECK THE KEYPAD INPUT CIRCUITS FOR AN
OPEN
Measure the resistance between the SJB , harness side and
the keyless entry keypad, harness side as follows:

SJB
Connector-Pin
C2280c-5 CPK29
(GY/BU)
C530-7
C2280c-18 CPK30
(VT/GN)
C530-5
C2280c-6 CPK31
(YE/GN)
C530-1
Yes
GO to J9 .
No
REPAIR the circuit in question for
an open. TEST the system for
normal operation.
J9 CHECK THE KEYPAD INPUT CIRCUITS FOR A
SHORT TO EACH OTHER
Measure the resistance between the keypad, harness side as
follows:

Keypad
Connector-Pin Circuits
Keypad
Connector-Pin
and CPK30
(VT/GN)
C530-5
and CPK31
(YE/GN)
C530-1
C530-5 CPK30 (VT/GN)
and CPK31
(YE/GN)
C530-1
Yes
GO to J10 .
No
operation.
J10 CHECK FOR CORRECT SJB OPERATION
Check for:
corrosion
damaged pins
pushed-out pins
correctly.

Yes
Section 419-10 . TEST the system
No
connector.
Pinpoint Test K: The Keyless Entry Keypad Illumination Is Inoperative/Does Not Operate Correctly
Refer to Wiring Diagrams Cell 117 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Remote Keyless Entry and
Alarm for schematic and connector information.
Normal Operation
When any keypad button is pressed the Smart Junction Box (SJB) sends voltage to the keyless entry keypad
LEDs on the illumination circuit to assist the driver in entering an access code at night. The keyless entry
keypad has a separate ground circuit for the LEDs.
DTC B1624 (Lamp Keypad Output Open Circuit) - a continuous and on-demand DTC that sets when
the SJB detects the keyless entry keypad illumination output or ground circuit is open, or the
illumination output circuit is shorted to voltage.

DTC B1626 (Lamp Keypad Output Short Circuit To Ground) - an on-demand DTC that sets when the
SJB detects the keyless entry keypad illumination output circuit is shorted to ground.

SJB
PINPOINT TEST K: THE KEYLESS ENTRY KEYPAD ILLUMINATION IS INOPERATIVE/DOES NOT OPERATE
CORRECTLY
NOTICE: Use the correct probapter(s) when making measurements. Failure to use the correct probe
adapter(s) may damage the connector.
Section 414-01 .
K1 CHECK THE KEYLESS ENTRY KEYPAD
OPERATION
Press the 7/8 and 9/0 buttons simultaneously on the
keyless entry keypad.

Do all of the doors lock?
Yes
GO to K2 .
No
K2 CHECK THE RECORDED SJB DTCs FROM THE
SELF-TEST
Check the recorded results from the SJB self-test.
Yes
GO to K3 .
No
GO to K5 .
K3 CHECK THE KEYLESS ENTRY KEYPAD FOR A
SHORT TO GROUND
Clear the DTCs, then repeat the SJB self-test.
Is DTC B1626 recorded?
Yes
GO to K4 .
No
INSTALL a new keyless entry keypad.
REFER to Keyless Entry Keypad in
normal operation.
K4 CHECK THE KEYPAD ILLUMINATION OUTPUT
Ignition OFF.
C530-6, circuit CPK28 (WH/GN), harness side and
ground.

Yes
GO to K11 .
No
REPAIR circuit CPK28 (WH/GN) for
a short to ground. CLEAR the DTCs.
K5 CHECK THE KEYLESS ENTRY KEYPAD
ILLUMINATION
Ignition OFF.
Check the keyless entry keypad illumination.
Is the keyless entry keypad illumination always on?
Yes
GO to K6 .
No
GO to K7 .
PINPOINT TEST K: THE KEYLESS ENTRY KEYPAD ILLUMINATION IS INOPERATIVE/DOES NOT OPERATECORRECTLY 742
Ignition ON.
Observe the keypad illumination.
Is the keypad still illuminated?
Yes
a short to voltage. TEST the system for
normal operation.
No
GO to K11 .
CIRCUIT FOR REFERENCE VOLTAGE
NOTE: The SJB sends out a constant reference voltage
on circuit CPK28 (WH/GN) for its own circuit
diagnostics. This voltage is 10 volts +/- 1 volt.
Measure the voltage between the keyless entry keypad
ground.

Are 10 volts (+/- 1 volt) present?
Yes
GO to K9 .
No
GO to K8 .
CIRCUIT FOR AN OPEN
C530-6, circuit CPK28 (WH/GN), harness side and the
SJB C2280c-11, circuit CPK28 (WH/GN), harness side.

Yes
GO to K11 .
No
operation.
K9 CHECK FOR SJB OUTPUT
PINPOINT TEST K: THE KEYLESS ENTRY KEYPAD ILLUMINATION IS INOPERATIVE/DOES NOT OPERATECORRECTLY 743
Measure the voltage between the keyless entry keypad
ground while active commanding the SJB PID
(KY_PAD_LMP) ON.

Yes
GO to K10 .
No
GO to K11 .
K10 CHECK THE KEYPAD ILLUMINATION GROUND
CIRCUIT FOR AN OPEN
C530-3, circuit GD126 (BK/WH), harness side and
ground.

Yes
INSTALL a new keyless entry keypad.
REFER to Keyless Entry Keypad in
normal operation.
No
K11 CHECK FOR CORRECT SJB OPERATION
Check for:
corrosion
damaged pins
pushed-out pins
correctly.

present.

Yes
normal operation.
No
connector.
Pinpoint Test L: The Remote Keyless Entry (RKE) Transmitter Is Inoperative
Normal Operation
Remote locking and unlocking of the doors, releasing the luggage compartment lid, and activating the panic
alarm is accomplished by the Smart Junction Box (SJB) receiving a command message from the RKE
Integrated Keyhead Transmitter (IKT). The IKTs and SJB also utilize a rolling code to prevent the code from
being "captured" by a code grabber. The system advances the counter in the RKE transmitter and SJB every
time an IKT button is pressed.
DTC B1139 (Invalid Transmitter Identification Code) - a continuous DTC that sets when the SJB
detects an invalid Transmitter Identification Code (TIC) from an IKT .

DTC B2425 (Remote Keyless Entry Out of Synchronization) - a continuous DTC that sets when the
SJB detects the rolling counter received from an RKE transmitter is 1,024 times greater than the
rolling counter stored in the module.

B109E:86 (Remote Keyless Entry: Signal Invalid) - a continuous DTC that sets when the Instrument
Panel Cluster (IPC) detects an invalid TIC from an IKT .

IKT
IKT battery
IKT button pressed a substantial amount of times while outside the range of the vehicle
IKT programming
SJB
PINPOINT TEST L: THE RKE TRANSMITTER IS INOPERATIVE
NOTE: All IKT transmitters mu be present to begin diagnosis of the RKE system.
NOTE: Aftermarket or dealer-installed systems may adversely affect the RKE system operation. These
systems should be disconnected before diagnosing any RKE concerns.
L1 CHECK FOR THE CORRECT RKE
TRANSMITTERS
NOTE: Make sure the IKTs are those
provided with the OEM system and not
from an aftermarket system, or a
dealer-installed system that may have been
installed on the vehicle.

Check that the correct IKTs are used with
the vehicle. Compare the IKTs with the one
shown in the Description and Operation
portion of this section.

Are all the correct IKTs present?
Yes
GO to L2 .
No
The system cannot be tested without the correct
IKTs . INFORM the customer that all the correct
IKTs must be present to proceed with diagnosis of
the system.
L2 CHECK THE RECORDED SJB AND IPC
DTCs FROM THE SELF-TEST
Check the recorded results from the SJB
and IPC self-test.

Is DTC B2425 or DTC B109E:86
recorded?

Yes
For DTC B2425, GO to L3 .
For DTC B109E:86, GO to Pinpoint Test R .
No
GO to L4 .
L3 RESYNCHRONIZE THE INOPERATIVE
IKT
PINPOINT TEST L: THE RKE TRANSMITTER IS INOPERATIVE 745
Ignition OFF.
Ignition ON.
Leave the IKT key in the ON position for a
minimum of 6 seconds.

Ignition OFF.
Press any button on the IKT .
Does the IKT operate?
Yes
The system is OK. CLEAR the DTCs. REPEAT
the self-test.
No
GO to L4 .
L4 MAKE SURE THE RKE TRANSMITTER
SIGNAL IS BEING RECEIVED
scan tool: SJB DataLogger .

Press lock and unlock on the IKT while
observing the SJB PIDs (TIC_LAST) and
(TNSMT_CMD).

Does the TIC and RKE command show
up on the scan tool screen when a button
is pressed?

Yes
GO to L5 .
No
GO to L6 .
L5 CHECK IF THE RKE TRANSMITTERS
ARE PROGRAMMED

Press a button on the IKT and compare the
SJB PID (TIC_LAST) with the PIDs
(TIC_1, 2, 3, 4, 7, 8, 9, or 10).

Does the TIC displayed match any of the
TICs stored in memory?

Yes
GO to L8 .
No
PROGRAM the inoperative IKT individually or
PROGRAM all the IKTs . REFER to Section
419-01B for the programming procedures. If all the
IKTs are to be programmed, INFORM the
customer that any IKTs not present need to be
programmed. TEST the system for normal
operation.
L6 CHECK THE IKT BATTERY
Using a thin coin, open the IKT .
Do not clean off any grease from the battery
terminals on the back surface of the circuit
board.

Verify the correct battery is used (CR2032).
Remove the IKT battery and measure the
voltage.

Is the voltage greater than 2.5 volts?
Yes
GO to L7 .
No
INSTALL a new battery (make sure the battery is
seated correctly). DO NOT reprogram the IKT
(weak or dead batteries do not erase TICs from
memory). TEST the system for normal operation.
L7 CHECK FOR NORMAL OPERATION
WITH A KNOWN GOOD IKT

Use the customer's second IKT , or a known
good RKE transmitter that is correct for the
vehicle, press a button on the IKT while
observing the SJB PID (TIC_LAST).

Does the TIC show up on the scan tool
when a button is pressed?

Yes
REPLACE the inoperative IKT and PROGRAM
the inoperative IKT individually or PROGRAM all
the IKTs . REFER to Section 419-01B for the
programming procedures. If all the IKTs are to be
programmed, INFORM the customer that any IKTs
not present need to be programmed. TEST the
PINPOINT TEST L: THE RKE TRANSMITTER IS INOPERATIVE 746
No
GO to L8 .
L8 CHECK FOR CORRECT SJB
OPERATION
Check for:
corrosion
damaged pins
pushed-out pins
Connect all the SJB connectors and make

still present.

Yes
INSTALL a new SJB . REFER to Section 419-10 .
No
corroded connector.
Pinpoint Test M: An Individual Button/Feature Is Inoperative From The Remote Keyless Entry (RKE)
Transmitter
Normal Operation
When any Integrated Keyhead Transmitter (IKT) button is pressed, the SJB receives and processes the
command to provide the appropriate output.
Door locks
Horn system
Luggage compartment lid release
Turn signal system
IKT
PINPOINT TEST M: AN INDIVIDUAL BUTTON/FEATURE IS INOPERATIVE FROM THE RKE TRANSMITTER
NOTE: The panic feature will only operate when the key is in the OFF or LOCK positions.
M1 VERIFY THE DOOR LOCK
OPERATION
Press the lock and unlock
button on the driver door
lock control switch while
observing the door lock
operation.

Do the door locks operate
correctly?

Yes
GO to M2 .
No
M2 VERIFY THE HORN
OPERATION
Enter the following
diagnostic mode on the scan
tool: SJB DataLogger .

Select the SJB PID (HORN)
and active command the
horn on.

Does the horn sound when
commanded on?

Yes
GO to M3 .
No
M3 VERIFY THE HAZARD
LAMP OPERATION
Place the hazard switch in
the ON position.

Do the hazard lamps
operate correctly?

Yes
GO to M4 .
No
M4 VERIFY THE LUGGAGE
COMPARTMENT LID
RELEASE OPERATION
Press the luggage
compartment lid release
button, located next to the
headlamp switch.

Does the luggage
compartment lid release?

Yes
REPLACE the inoperative IKT and PROGRAM the IKT
individually or PROGRAM all the IKTs . REFER to Section
419-01B for the programming procedures. If all the IKTs are to be
programmed, INFORM the customer that any IKTs not present
need to be programmed. TEST the system for normal operation.
No
Pinpoint Test N: The Remote Keyless Entry (RKE) Transmitter Has Poor Range Performance
Normal Operation
The RKE transmitter sends a radio signal to the Smart Junction Box (SJB) based on the user selected RKE
transmitter button. The SJB then carries out the selected action.
IKT
IKT battery
Aftermarket systems
High power devices
TV/radio transmission towers
SJB
PINPOINT TEST N: THE RKE TRANSMITTER HAS POOR RANGE PERFORMANCE
NOTE: All RKE transmitters must be present to begin diagnosis of the RKE system.
NOTE: Aftermarket or dealer-installed systems may adversely affect RKE system operation. These systems
should be disconnected before diagnosing any RKE concerns.
PINPOINT TEST M: AN INDIVIDUAL BUTTON/FEATURE IS INOPERATIVE FROM THE RKE TRANSMITTER 748
N1 CHECK FOR THE CORRECT RKE
TRANSMITTERS
NOTE: Make sure the RKE transmitters
are those provided with the OEM system
and not from an aftermarket system or a
dealer-installed system.

Check that the correct RKE transmitters
are used with the vehicle.

Are all the correct RKE transmitters
present?

Yes
GO to N2 .
No
The system cannot be tested without the correct RKE
transmitters. INFORM the customer that all the
correct RKE transmitters must be present to proceed
with diagnosis of the system.
N2 CHECK ALL THE RKE
TRANSMITTERS FOR POOR RANGE
PERFORMANCE
NOTE: The 10 m (33 ft) measurement of
range is not the standard but is a
guideline that clearly indicates a vehicle
is experiencing normal range
performance.
Check all the RKE transmitters for poor
range performance (less than 10 m [33
ft]).

Do all RKE transmitters experience
poor range?

Yes
GO to N4 .
No
GO to N3 .
N3 CHECK THE IKT BATTERY
Using a thin coin, open the IKT .
Do not clean off any grease from the
battery terminals on the back surface of
the circuit board.

Verify the correct battery is used
(CR2032).

Remove the IKT battery and measure the
voltage.

Yes
REPLACE the inoperative IKT and PROGRAM the
IKT individually or PROGRAM all the IKTs .
REFER to Section 419-01B for the programming
procedures. If all the IKTs are to be programmed,
INFORM the customer that any IKTs not present
need to be programmed. TEST the system for normal
operation.
No
INSTALL a new battery (make sure the battery is
seated correctly). DO NOT reprogram the IKT (weak
or dead batteries do not erase Transmitter
Identification Codes (TICs) from memory). TEST the
N4 CHECK THE LOCATION OF THE
VEHICLE AND THE APPROACH ANGLES
AROUND THE VEHICLE
Make sure the poor performance is
consistent in nature and is not from one
approaching angle.

The RKE transmitter range performance
may be degraded in certain locations. For

Yes
GO to N5 .
No
The system is operating correctly at this time. TEST
PINPOINT TEST N: THE RKE TRANSMITTER HAS POOR RANGE PERFORMANCE 749
example, if the vehicle is within 0.8 km
(0.5 miles) of high-power devices or
radio/TV towers, the operating distance
of the RKE transmitters may be reduced.
Is the poor range performance
consistent around the vehicle?

N5 CHECK FOR CORRECT SJB
OPERATION
Check for:
corrosion
damaged pins
pushed-out pins


Yes
No
concern may have been caused by a loose or corroded
connector.
Pinpoint Test O: The Autolock Does Not Operate Correctly
Normal Operation
The Smart Junction Box (SJB) energizes the lock relay based upon input from the ajar switches, the
Transmission Range (TR) sensor, and the vehicle speed signal. The SJB locks the doors when the following
conditions are met:
The ignition switch is in the ON position
The vehicle is shifted into any gear putting the vehicle in motion
The vehicle attains a speed greater than 20 km/h (12 mph)
Ignition switch
Door ajar switches
Vehicle speed signal
TR sensor
SJB
PINPOINT TEST O: THE AUTOLOCK DOES NOT OPERATE CORRECTLY
O1 CHECK THE AUTOLOCKS
CONFIGURATION
Check to see if the autolocks are enabled. Refer
Yes
GO to O2 .
to Autolock and Auto-Unlock Programming in
this section.
Are the autolocks enabled?
No
ENABLE the autolocks. REFER to Autolock
and Auto-Unlock Programming in this
operation.
O2 CHECK THE COURTESY LAMP
OPERATION
Open and close each door while observing the
courtesy lamp operation.

Do the courtesy lamps operate correctly?
Yes
GO to O3 .
No
O3 CHECK THE SJB IGNITION STATUS PID
Ignition ON.
tool: SJB DataLogger .

Monitor the SJB PID (IGN_R_ECU).
Does the ignition status PID indicate ON?
Yes
GO to O4 .
No
diagnosis of the ignition switch.
O4 CHECK THE VEHICLE SPEED OPERATION
Check the operation of the speedometer.
Does the speedometer operate correctly?
Yes
GO to O5 .
No
O5 RETRIEVE THE RECORDED SJB DTCs
FROM THE CONTINUOUS SELF-TESTS
Check for recorded SJB DTCs from the
continuous self-tests.

Is DTC U0155 recorded?
Yes
No
GO to O6 .
O6 CHECK FOR CORRECT SJB OPERATION
Check for:
corrosion
damaged pins
pushed-out pins

present.

Yes
operation.
No
The concern may have been caused by a loose
or corroded connector.
Pinpoint Test P: The Auto-Unlock Does Not Operate Correctly
PINPOINT TEST O: THE AUTOLOCK DOES NOT OPERATE CORRECTLY 751
Normal Operation
The Smart Junction Box (SJB) energizes the unlock relay based upon input from the ajar switches and the
vehicle speed signal. The SJB unlocks the doors when the following conditions are met:
The vehicle speed has exceeded 20 km/h (12 mph) then dropped to 0 km/h (0 mph) (vehicle stopped).
The key is turned to the OFF or ACCY position.
The LH front door is opened within 10 minutes of the key being turned to the OFF or ACCY position.
Door ajar switches
Ignition switch
Vehicle speed signal
SJB
PINPOINT TEST P: THE AUTO-UNLOCK DOES NOT OPERATE CORRECTLY
P1 CHECK THE AUTO-UNLOCK
CONFIGURATION
Check if the auto-unlock is enabled.
Refer to Autolock and Auto-Unlock
Programming in this section.

Is auto-unlock enabled?
Yes
GO to P2 .
No
ENABLE auto-unlock. REFER to Autolock and
Auto-Unlock Programming in this section. TEST the
P2 CHECK THE COURTESY LAMP
OPERATION
Open and close each door while
observing the courtesy lamp operation.

Do the courtesy lamps operate
correctly?

Yes
GO to P3 .
No
P3 CHECK THE SJB IGNITION STATUS
PID
Ignition ON.
the scan tool: SJB DataLogger .

Monitor the SJB PID (IGN_R_ECU).
Does the ignition status PID indicate
ON?

Yes
GO to P4 .
No
REFER to Section 211-05 to continue diagnosis of the
ignition switch.
P4 CHECK THE VEHICLE SPEED
OPERATION
Check the operation of the speedometer.
Does the speedometer operate
correctly?

Yes
GO to P5 .
No
P5 CHECK FOR CORRECT SJB
OPERATION
Check for:
corrosion
damaged pins
pushed-out pins


Yes
No
connector.
Pinpoint Test Q: The Smart Unlock Does Not Operate Correctly
Normal Operation
The Smart Junction Box (SJB) commands all doors to unlock based on input from the key-in-ignition switch
and door ajar signal. The feature helps prevent the keys from being locked in the vehicle by unlocking the
doors if the key is in the ignition and either front door is ajar.
The vehicle can still be locked with the key in the ignition, by using the manual lock rod, a key in the door
lock cylinder, keyless entry keypad, or the LOCK button on an Integrated Keyhead Transmitter (IKT).
LH front door ajar switch
RH front door ajar switch
Key-in-ignition switch
SJB
PINPOINT TEST Q: THE SMART UNLOCK DOES NOT OPERATE CORRECTLY
Q1 CHECK THE COURTESY LAMP
OPERATION
Open and close each door while
checking the courtesy lamp
operation.

Do the courtesy lamps operate
correctly?

Yes
GO to Q2 .
No
Q2 CHECK THE KEY-IN-IGNITION
CHIME
Insert the key in the ignition switch.
Open the driver door.
Does the key-in-ignition chime
operate correctly?

Yes
GO to Q3 .
No
PINPOINT TEST P: THE AUTO-UNLOCK DOES NOT OPERATE CORRECTLY 753
Q3 CHECK FOR CORRECT SJB
OPERATION
Check for:
corrosion
damaged pins
pushed-out pins
Connect all the SJB connectors and


Yes
INSTALL a new SJB . REFER to Section 419-10 . TEST
No
Pinpoint Test R: B109E:51
Normal Operation
When an Integrated Keyhead Transmitter (IKT) key is programmed, the Remote Keyless Entry (RKE)
Transmitter Identification Code (TIC) data from the key is received by the Instrument Panel Cluster (IPC).
The IPC then sends the TIC data to the Smart Junction Box (SJB) over the Medium Speed Controller Area
Network (MS-CAN). The SJB stores the TIC data in memory and sends an acknowledgement back to the IPC
that the TIC data was successfully programmed.
DTC B109E:51 (Remote Keyless Entry: Not Programmed) - a continuous DTC that sets when the
IPC sends the RKE TIC data to the SJB over the MS-CAN , and it does not receive a response from
the SJB that the TIC data has been stored.

IKT programming
MS-CAN
SJB
PINPOINT TEST R: DTC B109E:51
R1 CHECK FOR THE CORRECT RKE
TRANSMITTERS
NOTE: Make sure the IKTs are those provided
with the OEM system and not from an
aftermarket system, or a dealer-installed system
that may have been installed on the vehicle.

Check that the correct IKTs are used with the
vehicle.

Are all the correct IKTs present?
Yes
GO to R2 .
No
The system cannot be tested without the
correct IKTs . INFORM the customer that all
the correct IKTs must be present to proceed
with diagnosis of the system.
R2 CHECK FOR COMMUNICATION WITH THE
IPC AND SJB
PINPOINT TEST Q: THE SMART UNLOCK DOES NOT OPERATE CORRECTLY 754
tool: Network Test .

Does the IPC or SJB fail the network test?
Yes
No
GO to R3 .
R3 REPROGRAM THE IKT KEYS
Erase and program all of the IKT keys using the
scan tool method. Refer to Section 419-01B .

Erase all IPC DTCs.
tool: IPC Self-Test .

Is DTC B109E:51 retrieved again?
Yes
GO to R5 .
No
GO to R4 .
R4 CHECK THE OPERATION OF THE RKE
TRANSMITTER
Press any button on the suspect IKT key.
Does the RKE transmitter operate?
Yes
The system is operating normally. The
concern may have been caused by an
improperly programmed IKT key.
No
R5 CHECK FOR CORRECT SJB OPERATION
Check for:
corrosion
damaged pins
pushed-out pins

present.

Yes
operation.
No
Pinpoint Test S: Hard To Open/Close Door From Either Door Handle
Normal Operation
The door latch can be actuated from the interior or exterior door handle. When actuated, the door latch
releases and allows the door to open. If the door latch or the door hinges have insufficient lubrication or if the
striker or door are misaligned, it causes extra force to be used when opening or closing the door.
Door alignment
Door hinges
Striker adjustment
Door latch
PINPOINT TEST R: DTC B109E:51 755
PINPOINT TEST S: HARD TO OPEN/CLOSE DOOR FROM EITHER DOOR HANDLE
S1 CHECK THE LATCH OPERATION
FROM BOTH DOOR HANDLES
Open and close the door using both the
interior and exterior door handles.

Does the door open normally from
one of the door handles?

Yes
If the door is difficult/does not open from the exterior
door handle, GO to Pinpoint Test T .
If the door is difficult/does not open from the interior
door handle, GO to Pinpoint Test U .
No
If the door does not operate correctly from both door
handles, GO to S2 .
Open the door.
Using a screwdriver, fully close the
latch (2 clicks).

Verify that the latch releases easily
while pulling on the interior/exterior
door handle.

Does the latch release easily?
Yes
GO to S4 .
No
GO to S3 .
AFTER LUBRICATION
Lubricate the door latch. Refer to Latch
Lubrication in this section.

latch (2 clicks).

Verify that the latch releases easily
while pulling on the interior/exterior
door handle.

Yes
The concern was caused by an insufficiently lubricated
door latch.
No
INSTALL a new door latch. REFER to Front Door
Latch or Rear Door Latch in this section. TEST the
PINPOINT TEST S: HARD TO OPEN/CLOSE DOOR FROM EITHER DOOR HANDLE 756
Does the latch release easily?
S4 CHECK THE STRIKER
ADJUSTMENT
Check the adjustment of the striker.
Refer to Section 501-03 .

Is the striker adjusted correctly?
Yes
GO to S5 .
No
ADJUST the striker as necessary. TEST the system for
normal operation.
S5 CHECK THE DOOR ALIGNMENT
Check the alignment of the door. Refer
to Section 501-03 .

Is the door aligned correctly?
Yes
LUBRICATE the door hinges. TEST the system for
normal operation.
No
ADJUST the door as necessary. TEST the system for
normal operation.
Pinpoint Test T: A Door Is Difficult/Does Not Open From The Exterior Door Handle
Normal Operation
The exterior door handle is connected to the door latch with an actuating rod. When the exterior door handle is
pulled it causes the actuating rod to push down on the latch lever. When the latch lever is moved, the door
latch releases, allowing the door to open.
Broken or binding linkage
Exterior door handle reinforcement
Door latch
PINPOINT TEST T: A DOOR IS DIFFICULT/DOES NOT OPEN FROM THE EXTERIOR DOOR HANDLE
T1 CHECK THE LATCH
OPERATION FROM BOTH DOOR
HANDLES
Open and close the door using
both the interior and exterior door
handles.

Does the door open normally
from one of the door handles?

Yes
If the door is difficult/does not open from only the exterior
door handle, GO to T2 .
No
handles, GO to Pinpoint Test S .
T2 CHECK THE EXTERIOR DOOR
HANDLE REINFORCEMENT
Remove the door window
regulator and motor assembly.

Open the clip and disconnect the
exterior door handle actuating rod.

Pull and release the exterior door
handle

Does the exterior door handle
operate correctly?

Yes
GO to T3 .
No
INSTALL a new exterior door handle reinforcement.
REFER to Door Handle Reinforcement - Exterior, Front or
Door Handle Reinforcement - Exterior, Rear in this section.
TEST the systor normal operation.
T3 CHECK THE EXTERIOR DOOR
HANDLE AND LINKAGE
OPERATION
Operate the exterior door handle
while observing the linkage.

Are any of the exterior door
handle components or linkages
binding or broken?

Yes
REPAIR as necessary. TEST the system for normal
operation.
No
INSTALL a new door latch. REFER to Front Door Latch or
Rear Door Latch in this section. TEST the system for normal
operation.
Pinpoint Test U: A Door Is Difficult/Does Not Open From The Interior Door Handle
Normal Operation
The interior door handle is connected to the door latch by an actuating cable. When the interior door handle is
pulled it causes the cable to pull on the latch lever. When the latch lever is moved, the door latch releases,
allowing the door to open.
Broken or binding cable/linkage
Door latch
PINPOINT TEST U: A DOOR IS DIFFICULT/DOES NOT OPEN FROM THE INTERIOR DOOR HANDLE
U1 CHECK THE LATCH OPERATION
FROM BOTH DOOR HANDLES
Yes
If the door is difficult/does not open from only the
PINPOINT TEST T: A DOOR IS DIFFICULT/DOES NOT OPEN FROM THE EXTERIOR DOOR HANDLE 758
For the rear doors, make sure the child
lock is in the unlock position.

Open and close the door using both the
interior and exterior door handles.

Does the door open normally from
one of the door handles?

interior door handle, GO to U2 .
No
handles, GO to Pinpoint Test S .
U2 CHECK THE INTERIOR DOOR
HANDLE AND CABLE/LINKAGE
OPERATION
Remove the door trim panel. Refer to
Section 501-05 .

Operate the interior door handle while
observing the cable/linkage.

Are any of the interior door handle
components or cable/linkages
binding or broken?

Yes
operation.
No
Pinpoint Test V: Exterior Door Release Handle Sticks
Normal Operation
The exterior door handle is connected to the door latch with an actuating rod. When the exterior door handle is
pulled it causes the actuating rod to push down on the latch lever. When the latch lever is moved, the door
latch releases, allowing the door to open. The handle has a return spring to make sure the handle returns to a
closed position.
Binding linkage
Broken handle return spring
Door latch
PINPOINT TEST V: EXTERIOR DOOR RELEASE HANDLE STICKS
V1 CHECK FOR A BROKEN
RETURN SPRING
Remove the door window
regulator and motor assembly.

Open the clip and disconnect the
exterior door handle actuating rod.

Yes
GO to V2 .
No
INSTALL a new exterior door handle reinforcement.
REFER to Door Handle Reinforcement - Exterior, Front or
Door Handle Reinforcement - Extr, Rear in this section.
PINPOINT TEST U: A DOOR IS DIFFICULT/DOES NOT OPEN FROM THE INTERIOR DOOR HANDLE 759
Pull and release the exterior door
handle

Does the exterior door handle
return to a closed position once
released?

V2 CHECK THE EXTERIOR DOOR
HANDLE AND LINKAGE
OPERATION
Operate the exterior door handle
while observing the linkage.

Are any of the exterior door
handle components or linkages
binding?

Yes
operation.
No
INSTALL a new door latch. REFER to Front Door Latch or
Rear Door Latch in this section. TEST the system for normal
operation.
Pinpoint Test W: Interior Door Release Handle Sticks
Normal Operation
The interior door handle is connected to the door latch by an actuating cable. When the interior door handle is
pulled it causes the cable to pull on the latch lever. When the latch lever is moved, the door latch releases,
allowing the door to open. The handle has a return spring to make sure the handle returns to a closed position.
Binding cable
Broken handle return spring
Door latch
PINPOINT TEST W: INTERIOR DOOR RELEASE HANDLE STICKS
W1 CHECK FOR A BROKEN RETURN
SPRING
Remove the interior door handle. Refer to
Interior Door Handle in this section.

Pull and release the interior door handle
Does the interior door handle return to
a closed position once released?

Yes
GO to W2 .
No
INSTALL a new interior door handle. REFER to
Interior Door Handle in this section. TEST the system
PINPOINT TEST V: EXTERIOR DOOR RELEASE HANDLE STICKS 760
W2 CHECK THE INTERIOR DOOR
HANDLE CABLE OPERATION
Remove the door latch release cable.
Refer to Door Latch Release Cable in this
section.

Observe the door latch release cable for
any damage or binding.

Is the door latch release cable OK?
Yes
No
operation.
Pinpoint Test X: Squeak/Rattle/Chucking Noise From Door
Door alignment
Striker adjustment
Door latch
PINPOINT TEST X: SQUEAK/RATTLE/CHUCKING NOISE FROM DOOR
X1 CHECK FOR ANY LOOSE
COMPONENTS
Remove the door trim panel. Refer to
Section 501-05 .

Inspect inside the door for any loose
components.

Are there any loose components
inside the door?

Yes
operation.
No
GO to X2 .
X2 CHECK THE STRIKER
ADJUSTMENT
Check the adjustment of the striker.

Is the striker adjusted correctly?
Yes
GO to X3 .
No
ADJUST the striker as necessary. TEST the system for
normal operation.
X3 CHECK THE DOOR ALIGNMENT
Check the alignment of the door.

Is the door aligned correctly?
Yes
GO to X4 .
No
ADJUST the door as necessary. TEST the system for
normal operation.
X4 CHECK THE LATCH OPERATION
AFTER LUBRICATION
PINPOINT TEST W: INTERIOR DOOR RELEASE HANDLE STICKS 761
Lubricate the door latch. Refer to
Latch Lubrication in this section.

latch (2 clicks).

Operate the door latch and listen for
the noise.

Is the original noise still present
after the latch is lubricated?

Yes
INSTALL a new door latch. REFER to Front Door Latch
or Rear Door Latch in this section. TEST the system for
normal operation.
No
The concern was caused by an insufficiently lubricated
door latch.
Pinpoint Test Y: Manual Door Lock Cylinder Inoperative
Normal Operation
The door lock cylinder is connected to the door latch via a lock rod and can be used to manually lock/unlock a
door.
Bent or binding lock rod and lever
Door lock cylinder
Door latch
PINPOINT TEST Y: MANUAL DOOR LOCK CYLINDER INOPERATIVE
Y1 CHECK THE LOCK
CYLINDER OPERATION AFTER
LUBRICATION
Spray a lock lubricant such as
Motorcraft XL-1 into the lock
cylinder opening for a couple
seconds.

Operate the door lock cylinder
with the key.

Does the door lock and
unlock using the door lock
cylinder?

Yes
The concern was caused by an insufficiently lubricated lock
cylinder. Spray a multi-purpose grease such as Motorcraft XL-5
into the lock cylinder for a couple seconds to provide long term
lubrication.
No
GO to Y2 .
Y2 CHECK THE DOOR LOCK
CYLINDER
PINPOINT TEST X: SQUEAK/RATTLE/CHUCKING NOISE FROM DOOR 762
Remove the door lock cylinder.
Refer to Door Lock Cylinder in
this section.

with the key.

Does the door lock cylinder
rotate freely to both lock and
unlock positions?

Yes
GO to Y3 .
No
INSTALL a new door lock cylinder. REFER to Door Lock
Cylinder in this section. TEST the system for normal operation.
Y3 CHECK THE DOOR LOCK
CYLINDER LINKAGE
while observing the rod and
lever.

Is the door lock cylinder rod
and lever bent or binding?

Yes
REPAIR as necessary. TEST the system for normal operation.
No
INSTALL a new door latch. REFER to Front Door Latch in this
Pinpoint Test Z: Ignition Key Cannot Be Returned To OFF Position
Refer to Wiring Diagrams Cell 37 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Shift Interlock for
Normal Operation
The ignition switch contains a key removal inhibit solenoid. The solenoid prevents the ignition lock cylinder
from being turned to lock and the key removed any time the transmission selector lever is in any position
except park (automatic transaxle only). The inhibit solenoid receives voltage at all times from the Smart
Junction Box (SJB) fuse 27 (20A). When the transmission selector lever is in any gear except park, the
selector switch closes, which supplies ground to the solenoid.
Transmission selector lever
Binding steering column components
Ignition lock cylinder
Ignition switch
PINPOINT TEST Z: IGNITION KEY CANNOT BE RETURNED TO OFF POSITION
Z1 CHECK FOR AN ENERGIZED KEY
REMOVAL INHIBIT SOLENOID
Remove the SJB fuse 27 (20A).
Attempt to turn the ignition key to the run
position and then back to the lock position and
remove the key.

Does the ignition lock cylinder turn to the lock
position and can the key be removed?

Yes
diagnosis of the key removal inhibit solenoid
system.
No
GO to Z2 .
PINPOINT TEST Y: MANUAL DOOR LOCK CYLINDER INOPERATIVE 763
Z2 CHECK THE IGNITION LOCK CYLINDER
FOR BINDING
Remove the ignition lock cylinder. Refer to
Ignition Lock Cylinder in this section.

Rotate the ignition lock cylinder through all
positions using the key.

Does the ignition lock cylinder freely rotate
through all positions and can the key be
removed from the lock cylinder?

Yes
diagnosis of the steering column for any
binding steering column components or
ignition switch.
No
INSTALL a new ignition lock cylinder.
REFER to Ignition Lock Cylinder in this
operation.
Pinpoint Test AA: DTCs B106E, B106F
Normal Operation
When a repetitive fault causing a circuit overload is detected on certain output circuits, the Driver Door
Module (DDM) disables the circuit by removing voltage, or ground, to the affected circuit. The circuit
remains disabled until the fault is corrected and an on-demand self-test is run. When the on-demand self-test
has been run after all faults have been corrected, any DTCs related to the fault are cleared.
DTC B106E (Solid State Driver Disabled Due to Short Circuit) - a continuous DTC that sets when the
DDM has disabled a circuit due to a repetitive fault causing a circuit overload. For a complete list of
corresponding DTCs, refer to Principles of Operation in this section.

DTC B106F (Module Disabled Due to External Fault) - a continuous DTC that sets when one or more
output functions are permanently disabled due to a repetitive circuit overload fault. DTC B106F is set
with DTC B106E. When DTC B106F is present, the DDM must be replaced after the fault condition
has been corrected.

Output circuit short to ground or voltage
DDM
PINPOINT TEST AA: DTCs B106E, B106F
NOTICE: If DTC B106F is present and the DDM is to be replaced, the fault condition must be
corrected first. Failure to correct the fault condition first may cause damage to the new DDM , resulting
in a repeat repair.
AA1 REVIEW THE
DTCs
Review the DTCs
from the DDM
self-test.

Is only DTC B106F
present?

Yes
INSTALL a new DDM . REFER to Driver Door Module (DDM) in this
No
CORRECT any DTCs present other than DTC B106E (DTC B106F may
PINPOINT TEST Z: IGNITION KEY CANNOT BE RETURNED TO OFF POSITION 764
also be present). REFER to DTC Charts in this section. After the repair,
GO to AA2 .
AA2 CARRY OUT THE
DDM SELF-TEST
Carry out the DDM
self-test.

Is only DTC B106F
present?

Yes
INSTALL a new DDM . REFER to Driver Door Module (DDM) in this
No
The system is operating correctly at this time. The concern was caused by a
fault in one of the output circuits, which is no longer present.
Pinpoint Test AB: DTC B1317
Normal Operation
The Driver Door Module (DDM) monitors the voltage from the battery to determine if it goes above or below
specific thresholds and sets DTC B1317 in continuous memory and on-demand if the DDM detects high
battery voltage above 15.5 volts on circuit SBP12.
DTC B1317 (Battery Voltage High) - a continuous memory or on-demand DTC that sets when the
DDM detects battery voltage above 15.5 volts on circuit SBP12.

Charging system concern
DDM
PINPOINT TEST AB: DTC B1317
NOTE: DTC B1317 may be stored in the module memory due to previous battery charging or vehicle jump
starting events.
AB1 CHECK FOR DTC B1317, B1676
OR P0563 SET IN OTHER MODULES
Ignition ON.
Enter the following diagnostic me on
the scan tool: (All CMDTCs)
Self-Test.

Retrieve the continuous memory
DTCs from all modules.

Is DTC B1317, B1676 or P0563
(PCM) set in more than one
module?

Yes
condition.
No
GO to AB2 .
PINPOINT TEST AA: DTCs B106E, B106F 765
AB2 CHECK THE BATTERY
VOLTAGE
Turn off all interior/exterior lights
and accessories.

Start and run the engine at
approximately 2,000 rpm for 3
minutes while monitoring the battery
voltage.

Does the battery voltage rise to 15.5
volts or higher?

Yes
condition.
No
GO to AB3 .
AB3 RECHECK FOR DTC B1317
Turn the engine off.
Ignition ON.
on the scan tool: DDM Self-Test.

Clear the continuous memory DTCs.
Carry out the DDM self-test.
Yes
INSTALL a new DDM . REFER to Driver Door Module
(DDM) in this section. TEST the system for normal
operation.
No
The system is operating normally at this time. The DTC
may have been set previously during battery charging or
while jump starting the vehicle.
Pinpoint Test AC: DTC B1318
Normal Operation
The Driver Door Module (DDM) monitors the voltage from the battery to determine if it goes above or below
DTC B1318 (Battery Voltage Low) - a continuous memory or on-demand DTC that sets when the
DDM detects battery voltage below 10 volts on circuit SBP12.

High circuit resistance
DDM
PINPOINT TEST AC: DTC B1318
Section 414-01 .
PINPOINT TEST AB: DTC B1317 766
AC1 RECHECK THE DDM DTCs
Ignition ON.
tool: DDM Self-Test.

Clear the DTCs. Repeat the DDM self-test.
Is DTC B1318 still present?
Yes
GO to AC2 .
No
The DTC may have been set previously
during battery charging or while jump starting
the vehicle.
AC2 CHECK FOR CHARGING SYSTEM DTCs IN
THE PCM
tool: PCM Self-Test.

Retrieve the continuous memory DTCs from the
PCM.

Is DTC P0620, P0625, P0626 or P065B set in
the PCM?

Yes
No
GO to AC3 .
AC3 CHECK THE BATTERY CONDITION AND
STATE OF CHARGE
Ignition OFF.
Check the battery condition and verify the battery
is fully charged. Refer to Section 414-01 .

Is the battery OK and fully charged?
Yes
GO to AC4 .
No
AC4 CHECK THE DDM VOLTAGE SUPPLY
Measure and record the voltage at the battery.
Disconnect: DDM C568b.
Ignition ON.
Measure the voltage between the DDM C568b-1,
circuit SBP12 (GN/RD), harness side and ground.

Is the voltage within 0.2 volt of the recorded
battery voltage?

Yes
GO to AC5 .
No
REPAIR the circuit for high resistance.
AC5 CHECK THE DDM GROUND CIRCUIT
Ignition OFF.
Disconnect: Negative Battery Cable.
Measure the resistance between the DDM
C568b-24, circuit GD126 (BK/WH), harness side
and ground.

Yes
GO to AC6 .
No
REPAIR the circuit for high resistance. TEST
PINPOINT TEST AC: DTC B1318 767
AC6 CHECK FOR CORRECT DDM OPERATION
Connect: Negative Battery Cable.
Disconnect the DDM connectors.
Check for:
corrosion
damaged pins
pushed-out pins
Connect the DDM connectors and make sure they
seat correctly.

present.

Yes
INSTALL a new DDM . REFER to Driver
Door Module (DDM) in this section. TEST
No
Pinpoint Test AD: DTC U0140
Normal Operation
The Driver Door Module (DDM) and the Smart Junction Box (SJB) communicate using the Medium Speed
DTC U0140 (Lost Communication With Body Control Module (GEM)) - set by the DDM whenever
it has lost communication to the SJB for 15 seconds or longer as long as the module voltage is
between 10 and 15 volts.

DDM
SJB
PINPOINT TEST AD: DTC U0140
AD1 VERIFY CUSTOMER CONCERN
Ignition ON.
Yes
GO to AD2 .
rify there is an observable symptom present.
Is an observable symptom present? No
condition.
AD2 CHECK THE COMMUNICATION NETWORK
Ignition ON.
Network Test.

Yes
GO to AD3 .
No
AD3 RETRIEVE THE RECORDED DTCs FROM THE
SELF-TEST
Check for recorded DDM DTCs from the self-test.
Yes
Test AB .
Test AC .
No
GO to AD4 .
AD4 RECHECK THE DDM DTCs
Clear the DTCs. Repeat the DDM self-test.
Yes
GO to AD5 .
No
condition.
AD5 CHECK FOR DTC U0140/U0140:00 SET IN OTHER
MODULES
Clear all DTCs.
Ignition OFF.
Ignition ON.
Wait 10 seconds.
Self-Test.

Yes
Section 419-10 .
No
INSTALL a new DDM . REFER
to Driver Door Module (DDM)
in this section.
PINPOINT TEST AD: DTC U0140 769
PINPOINT TEST AD: DTC U0140 770
Entry Systems
Workshop Manual
Remote Keyless Entry (RKE) Transmitter Programming
NOTE: This procedure is for programming conventional keyfobs only. The Remote Keyless Entry (RKE)
transmitter of the Integrated Keyhead Transmitter (IKT) is programmed automatically during the Passive
Anti-Theft System (PATS) programming. For additional information, refer to Key Programming Using Two
Programmed Keys or Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment
in Section 419-01B to program the IKT .
NOTE: All RKE transmitters must be programmed at the same time.
NOTE: Do not apply the brake pedal during this sequencing, as doing so ends the sequence and the
transmitters will not be programmed.
Electronically unlock the door locks using the door lock control switch. 1.
Cycle the ignition switch from the OFF to the RUN position 8 times in rapid succession (within 10
seconds), with the eighth turn ending in RUN. If the module successfully enters program mode, it
locks and then unlocks all the doors.
2.
NOTE: If no action is taken within 20 seconds after a transmitter has been programmed, the
programming sequence ends (the doors lock and unlock to confirm that programming is complete).
Within 20 seconds, press any button on the RKE transmitter to be programmed. The doors lock and
then unlock to confirm that each RKE transmitter is programmed. Repeat this step for each RKE
transmitter.
3.
Exiting the programming mode is accomplished if one of the following occurs:
The key transitions to the OFF position.
20 seconds have passed since entering programming mode or since the last RKE transmitter
was programmed.

The maximum number (4) of RKE transmitters have been programmed.
4.
Check the operation of the RKE transmitter. If the door locks do not respond for the programmed
RKE transmitter(s), wait several seconds and press the button again. If the door locks still fail to
respond, refer to Handles, Locks, Latches and Entry Systems in this section. (Make sure that no more
than the maximum number of RKE transmitters are attempted to be programmed.)
5.
Remote Keyless Entry (RKE) Transmitter Programming 771
Remote Keyless Entry (RKE) Transmitter Programming 772
Entry Systems
Workshop Manual
Keyless Entry Keypad Code Programming
Programming a Personal Entry Code and Keypad Association to Memory Features (If Equipped)
NOTE: The system allows 3 personal codes to be programmed.
NOTE: Multiple personal codes can be programmed in one step. When programming multiple codes in one
step, each code must be programmed by entering each button within 5 seconds of each other. If 5 seconds
elapse between any button press, programming mode is exited.
NOTE: If only a single personal code is desired or unable to program multiple codes in one step, each
personal code can be programmed individually by repeating Steps 1-5 for each code desired.
Enter the factory set 5-digit keyless entry keypad code. 1.
Within 5 seconds, press the 1/2 button on the keypad to activate the programming mode. 2.
Enter the new personal 5-digit keyless entry keypad code. Each number must be entered within 5
seconds of each other.
3.
After entering the new personal code, press a 6th button to program each new code.
Pressing 1/2 stores the first personal code (if equipped with memory, this code is associated
with driver 1 settings).

Pressing 3/4 stores the second personal code (if equipped with memory, this code is
associated with driver 2 settings).

Pressing 5/6, 7/8 or 9/0 stores the third personal code, but does not associate the code with a
memory setting.

4.
The door locks lock and unlock to confirm the new code is programmed. 5.
Erasing a Personal Entry Code
Enter the factory set 5-digit keyless entry keypad code. 1.
Within 5 seconds, press the 1/2 button on the keypad and release. 2.
Within 5 seconds, press and hold the 1/2 button for 2 seconds. 3.
All personal codes are now erased and only the factory set 5-digit code works. 4.
Keyless Entry Keypad Code Programming 773
Keyless Entry Keypad Code Programming 774
Entry Systems
Workshop Manual
Remote Memory Activation
Position the driver seat and exterior mirror(s) to the desired positions. 1.
Press and hold either memory button (1 or 2) for 5 seconds. A tone will be heard after 1-1/2 seconds
when the memory store is done. Continue to hold until a second tone is heard after 5 seconds.
2.
Within 3 seconds, press the LOCK button on the Remote Keyless Entry (RKE) transmitter. 3.
If a second memory setting is desired, repeat the procedure with the second RKE transmitter. 4.
Remote Memory Activation 775
Entry Systems
Workshop Manual
Remote Memory Deactivation
Press and hold either memory button (1 or 2) for 5 seconds. A tone will be heard after 1-1/2 seconds
when the memory store is done. Continue to hold until a second tone is heard after 5 seconds.
1.
Within 3 seconds, press the UNLOCK button on the Remote Keyless Entry (RKE) transmitter. 2.
If a second memory setting is desired to be deactivated, repeat the procedure with the second RKE
transmitter.
3.
Remote Memory Deactivation 776
Entry Systems
Workshop Manual
Autolock and Auto-Unlock Programming
Programming the Autolock Feature Using the Door Lock Control Switch
NOTE: The autolock feature can be enabled or disabled independently of the auto-unlock feature.
NOTE: Make sure that the vehicle's perimeter alarm is not armed, the key is in the OFF position and the
doors are closed.
NOTE: The following steps must be carried out within 30 seconds or the procedure will need to be repeated.
If the procedure needs to be repeated, wait 30 seconds between programming sessions.
Turn the ignition key from the OFF to the RUN position. 1.
Press the unlock button on the door lock control switch 3 times. 2.
Turn the ignition key from the RUN to the OFF position. 3.
Turn the ignition key to the RUN position. The horn chirps one time to indicate that programming
mode is entered.
5.
To enable/disable the autolock feature, press the unlock button on the door lock control switch then
the lock button. The horn chirps once if the autolocks are disabled or twice (one short chirp followed
by a long chirp) if the autolocks are enabled.
6.
Turn the ignition key to the OFF position. The horn chirps once to signal that the programming is
complete.
7.
Programming the Autolock Feature Using the Keyless Entry Keypad
NOTE: The autolock feature can be enabled or disabled independently of the auto-unlock feature.
doors are closed.
Turn the ignition key to the OFF position. 1.
Close all of the doors. 2.
Enter the factory set 5 digit entry code. 3.
Autolock and Auto-Unlock Programming 777
Press and hold the 3/4 button. While holding the 3/4 button, press the 7/8 button. 4.
Release the 7/8 button. 5.
Release the 3/4 button. The horn chirps once if the autolocks are disabled, or chirps once followed by
a honk if the autolocks are enabled.
6.
Programming the Auto-Unlock Feature Using the Door Lock Control Switch
NOTE: The auto-unlock feature is disabled from the factory on vehicles equipped with a manual transaxle,
but can be enabled.
NOTE: The auto-unlock feature can be enabled or disabled independently of the autolock feature.
doors are closed.
Turn the ignition key from the OFF to the RUN position. 1.
Press the unlock button on the door unlock control switch 3 times. 2.
Turn the ignition key from the RUN to the OFF position. 3.
Turn the ignition key to the RUN position. The horn chirps one time to indicate that programming
mode is entered.
5.
To enable/disable the auto-unlock feature, press the lock button on the door lock control switch then
the unlock button. The horn chirps once if auto-unlock is disabled or twice (one short chirp followed
by a long chirp) if auto-unlock is enabled.
6.
Turn the ignition key to the OFF position. The horn chirps once to signal that the programming is
complete.
7.
Programming the Auto-Unlock Feature Using the Keyless Entry Keypad
NOTE: The auto-unlock feature is disabled from the factory on vehicles equipped with a manual transaxle,
but can be enabled.
NOTE: The auto-unlock feature can be enabled or disabled independently of the autolock feature.
doors are closed.
Turn the ignition key to the OFF position. 1.
Close all of the doors. 2.
Enter the factory set 5 digit entry code. 3.
Press and hold the 3/4 button. While holding the 3/4 button, press and release the 7/8 button. While
still holding the 3/4 button, press and release the 7/8 button a second time.
4.
Release the 3/4 button. The horn chirps once if auto-unlock is disabled, or chirps once followed by a
honk if auto-unlock is enabled.
5.
Entry Systems
Workshop Manual
Stepped Unlock Programming
With the ignition switch in the OFF position, press the LOCK and UNLOCK buttons on the Remote
Keyless Entry (RKE) transmitter simultaneously for 4 seconds.
The turn signals flash twice to indicate the mode change.
1.
Repeat Step 1 to enable/disable the stepped unlocking feature. 2.
Stepped Unlock Programming 780
Entry Systems
Workshop Manual
Latch Lubrication
Material
Item Specification
XG-4 and/or XL-5
ESB-M1C93-B
Open the door. 1.
Using a screwdriver, fully close the latch (2 clicks). 2.
Spray the multi-purpose grease into the opening on the door latch for approximately 5 seconds. 3.
Open the latch using either the interior or exterior door handle. 4.
Open and close the door several times to circulate the lubricant inside the latch. 5.
Wipe off any excess grease. 6.
Latch Lubrication 781
Latch Lubrication 782
Entry Systems
Workshop Manual
Hood Latch
Fusion
1 N808727-S307 Hood latch bolts (2 required)
2 16700 Hood latch
3 16916 Hood latch release cable
4 N807658-S307 Hood latch striker bolts (2 required)
5 16K689 Hood latch striker
MKZ
1 N808727-S307 Hood latch bolts (2 required)
2 16700 Hood latch
Hood Latch 783
4 16916 Secondary hood latch release cable
5 N807658-S307 Hood latch striker bolts (2 required)
6 16K689 Hood latch striker
Remove the 6 (Fusion)/2 (MKZ) radiator grille pin-type retainers and the 4 radiator grille bolts. 1.
For MKZ, disconnect the secondary hood latch release cable from the hood latch. 2.
NOTE: Pull up on the radiator grille to gain access to the hood latch.
NOTE: Mark the hood latch position prior to removal of the hood latch bolts.
Remove the 2 hood latch bolts and position the hood latch aside.
3.
Disconnect the hood latch release cable and remove the hood latch. 4.
MKZ 784
Entry Systems
Workshop Manual
Hood Latch Release Handle
1 - Hood latch release handle bolts (2 required)
2 16916 Hood latch release handle
Hood Latch Release Cable Routing
Remove the hood latch. For additional information, refer to Hood Latch in this section. 1.
Remove the LH fender splash shield. For additional information, refer to Section 501-02 . 2.
Release the 2 hood latch release cable locators from the radiator grille opening panel reinforcement. 3.
Disconnect the hood latch release cable from the LH fender opening, open the 2 hood latch release
cable locators and position the cable aside.
4.
Hood Latch Release Handle 785
Release the hood latch release cable locator from the wiring harness. 5.
Remove the Smart Junction Box (SJB). For additionalnformation, refer to Section 419-10 . 6.
Remove the 2 hood latch release handle bolts. 7.
Remove the hood latch release handle and cable assembly. 8.
Hood Latch Release Cable Routing 786
Entry Systems
Workshop Manual
Hood Latch Release Handle - Secondary
1 N808727-S307 Secondary hood latch release handle bolt
2 16916 Secondary hood latch release handle and cable
Remove the 2 radiator grille pin-type retainers and the 4 radiator grille bolts. 1.
NOTE: Pull up on the radiator grille to gain access to the hood latch.
Disconnect the secondary hood latch release cable from the hood latch.
2.
Remove the secondary hood latch release handle bolt.
3.
Hood Latch Release Handle - Secondary 787
Hood Latch Release Handle - Secondary 788
Entry Systems
Workshop Manual
Front Door Handles, Locks and Latches - Exploded View
1 5421991 Door lock cylinder (driver door only)
2 5426685/ 5426684 Exterior front door handle reinforcement
(LH/RH)
3 5422135 Front door lock cylinder actuating rod (driver
door only)
4 5422153/ 5422152 Exterior door handle actuating rod (LH/RH)
5 54221A00 Interior door handle actuating cable
6 5422601/ 5422600 Interior door handle (LH/RH)
7 5421813/ 5421812 Front door latch (LH/RH)
8 - Door latch carrier (LH/RH)
9 W705830-S901 Front door latch bolts (3 required)
10 - Grommet
11 54218A14/
5422088
Exterior door handle bezel (LH/RH)
12 5422404 Exterior front door handle
13 - Grommet
14 14A626 Keyless entry keypad
15 W711379-S900 Striker bolts d)
16 5422008 Striker
Front Door Handles, Locks and Latches - Exploded View 789
Front Door Handles, Locks and Latches - Exploded View 790
Entry Systems
Workshop Manual
Rear Door Handles, Locks and Latches - Exploded View
1 5426685/ 5426684 Exterior rear door handle reinforcement
(LH/RH)
2 5426597/ 5426596 Exterior door handle actuating rod (LH/RH)
3 - Door latch carrier
4 5422601/ 5422600 Interior rear door handle (LH/RH)
5 54221A01/
54221A00
Door latch release cable (LH/RH)
6 5426413/ 5426412 Rear door latch (LH/RH)
7 W705830-S901 Door latch bolts (3 required)
8 - Grommet
9 5422088 Exterior door handle bezel
10 5422404 Exterior door handle
11 W710881-S900 Striker bolts (2 required)
12 5422008 Striker
Rear Door Handles, Locks and Latches - Exploded View 791
Rear Door Handles, Locks and Latches - Exploded View 792
Entry Systems
Workshop Manual
Interior Door Handle
NOTE: LH front door shown, other doors similar.
1 W709494-S438 Interior door handle bolt
2 5422601/ 5422600 Interior door handle (LH/RH)
3 54221A00 Interior door handle release cable
Remove the interior door handle bolt.
2.
Disconnect the interior door handle release cable and remove the interior door handle. 3.
Interior Door Handle 793
Interior Door Handle 794
Entry Systems
Workshop Manual
Exterior Door Handle
NOTE: LH front door shown, other doors similar.
1 - Grommet
2 - Exterior door handle bezel retaining screw
3 54218A14/
5422088
Exterior door handle bezel (with key hole/without
key hole)
4 5422404 Exterior door handle
Remove the grommet from the rear of the door. 1.
Loosen, but do not remove the exterior door handle bezel retaining screw and remove the exterior
door handle bezel.
2.
NOTE: Pull the exterior door handle outward and to the rear to release it from the exterior door
handle reinforcement.
Remove the exterior door handle.
3.
Exterior Door Handle 795
Exterior Door Handle 796
Entry Systems
Workshop Manual
Front Door Latch
Remove the front door window regulator and motor. For additional information, refer to Section
501-11 .
1.
Remove the exterior door handle. For additional information, refer to Exterior Door Handle in this
section.
2.
Loosen the exterior door handle reinforcement bolt.
To install, tighten to 6 Nm (53 lb-in)
3.
Slide the exterior front door handle reinforcement to the front of the vehicle and push inside the door. 4.
Remove the 3 front door latch bolts.
5.
Remove the complete latch, carrier, and handle reinforcement assembly from the door. 6.
Open the clip and disconnect the exterior front door handle actuating rod. 7.
If required, disconnect the front door lock cylinder actuating rod. 8.
Remove the 2 screws and remove the front door latch from the carrier. 9.
Front Door Latch 797
Front Door Latch 798
Entry Systems
Workshop Manual
Door Handle Reinforcement - Exterior, Front
501-11 .
1.
section.
2.
To install, tighten to 6 Nm (53 lb-in)
3.
5.
Open the clip and disconnect the exterior front doondle actuating rod. 7.
If required, disconnect the front door lock cylinder actuating rod. 8.
Remove the screw and remove the front exterior door handle reinforcement from the carrier. 9.
Door Handle Reinforcement - Exterior, Front 799
Door Handle Reinforcement - Exterior, Front 800
Entry Systems
Workshop Manual
Rear Door Latch
Remove the rear door window regulator and motor. For additional information, refer to Section
501-11 .
1.
section.
2.
Position the rear door window glass at the top of the door. 3.
4.
Slide the exterior rear door handle reinforcement to the front of the vehicle and push inside the door. 5.
Remove the 3 rear door latch bolts.
6.
Open the clip and disconnect the exterior rear door handle actuating rod. 8.
Remove the 2 screws and remove the rear door latch from the carrier. 9.
Rear Door Latch 801
Rear Door Latch 802
Entry Systems
Workshop Manual
Door Handle Reinforcement - Exterior, Rear
Remove the rear door window regulator and motor. For additional information, refer to Section
501-11 .
1.
section.
2.
Position the rear door window glass at the top of the door. 3.
4.
Slide the exterior rear door handle reinforcement to the front of the vehicle and push inside the door. 5.
Remove the 3 rear door latch bolts.
6.
Remove the complete latch, carrier, and handle reinforcement assembly from the d 7.
Open the clip and disconnect the exterior rear door handle actuating rod. 8.
Remove the screw and remove the rear exterior door handle reinforcement from the carrier. 9.
Door Handle Reinforcement - Exterior, Rear 803
Door Handle Reinforcement - Exterior, Rear 804
Entry Systems
Workshop Manual
Door Latch Release Cable
NOTE: LH front shown, other doors similar.
Item
Part
Number Description
1 - Door latch, carrier, and exterior door handle
reinforcement assembly
2 54221A00 Door latch release cable
Remove the door window regulator and motor. For additional information, refer to Section 501-11 . 1.
section.
2.
On the rear doors, position the door window glass at the top of the door. 3.
4.
Slide the exterior door handle reinforcement to the front of the vehicle and push inside the door. 5.
Remove the 3 door latch bolts.
6.
Remove the release cable from the latch.
Slide the cable housing off the latch.
Unhook the cable from the latch lever.
8.
Door Latch Release Cable 805
Door Latch Release Cable 806
Entry Systems
Workshop Manual
Luggage Compartment Lid Latch
1 - Luggage compartment lid lock cylinder actuating
cable (part of 5443200)
2 - Luggage compartment lid latch electrical connector
(part of 13A412)
3 W705760-S424 Luggage compartment lid latch nuts (3 required)
4 5443200 Luggage compartment lid latch
5 - Luggage compartment striker bolts (2 required)
6 5443252 Luggage compartment striker
Remove the 10 pin-type retainers and the luggage compartment lid trim panel. 1.
Disconnect the luggage compartment lid lock cylinder actuating cable from the luggage compartment
lid lock cylinder.
2.
Disconnect the electrical connector from the luggage compartment lid latch. 3.
Remove the 3 nuts and the luggage compartment lid latch.
4.
Luggage Compartment Lid Latch 807
Luggage Compartment Lid Latch 808
Entry Systems
Workshop Manual
Ignition Lock Cylinder
1 3511 Steering column lock module
2 11582 Ignition lock cylinder
NOTE: For non-functional ignition lock cylinders, the steering column lock module has to be replaced. For
Remove the Passive Anti-Theft System (PATS) transceiver. For additional information, refer to
Section 419-01B or Section 419-01C .
1.
Turn the ignition key to the ACC position. 2.
Using a suitable tool, press the ignition lock cylinder release button and remove the ignition lock
cylinder.
3.
If a new lock cylinder with keys is replaced, the new PATS keys must be programmed. For additional
information, refer to Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic
Equipment in Section 419-01B or Section 419-01C .
4.
Ignition Lock Cylinder 809
Ignition Lock Cylinder 810
Entry Systems
Workshop Manual
Door Lock Cylinder
1 5421991 Door lock cylinder
2 5426685 Exterior door handle reinforcement
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.
501-11 .
1.
section.
2.
3.
5.
Release the tab and remove the door lock cylinder. 7.
Door Lock Cylinder 811
NOTE: Upon installation, make sure that the d-slot in the lock cylinder lines up with the d-slot in the
lock cylinder lever.
8.
Door Lock Cylinder 812
Entry Systems
Workshop Manual
Luggage Compartment Lid Lock Cylinder
Special Tool(s)
Heavy Duty Riveter
501-D011 (D80L-23200-A) or equivalent
1 - Luggage compartment lid lock cylinder actuating
cable (part of 5443200)
2 - Luggage compartment lid lock cylinder electrical
connector (part of 13A412) (if equipped)
3 W525174-S300 Luggage compartment lid lock cylinder rivets (2
required)
4 5443262 Luggage compartment lid lock cylinder
Remove the 10 pin-type retainers and the luggage compartment lid trim panel. 1.
Disconnect the luggage compartment lid lock cylinder actuating cable from the luggage compartment
lid lock cylinder.
2.
If equipped, disconnect the electrical connector from the luggage compartment anti-theft inhibit
switch.
3.
Remove the 2 rivets and the luggage compartment lid lock cylinder. 4.
Use the special tool to install new rivets.
5.
Luggage Compartment Lid Lock Cylinder 813
Luggage Compartment Lid Lock Cylinder 814
Entry Systems
Workshop Manual
Door Lock Control Switch
1 - Interior front door handle finish panel screw
2 5422620/
5422621
Interior front door handle finish panel (RH/LH)
3 - Door lock control switch electrical connector (part of
14630/14631)
4 14028 Door lock control switch
Open the cover, remove the screw and position the interior front door handle finish panel aside. 1.
Disconnect the door lock control switch electrical connector. 2.
Release the locking clips and remove the door lock control switch. 3.
Door Lock Control Switch 815
Door Lock Control Switch 816
Entry Systems
Workshop Manual
Luggage Compartment Lid Release Switch
Fusion
1 5404481 Instrument panel side finish panel
2 5404338 Switch bezel
3 54432A38 Luggage compartment lid release switch
MKZ
1 5404481 Instrument panel side finish panel
2 5404338 Switch bezel
3 54432A38 Luggage compartment lid release switch
Remove the instrument panel side finish panel. 1.
NOTE: The switch bezel is removed by pushing from behind.
Remove the switch bezel.
Disconnect the electrical connectors.
2.
Release the tabs and remove the luggage compartment lid release switch. 3.
Luggage Compartment Lid Release Switch 817
MKZ 818
Entry Systems
Workshop Manual
Item
Part
Number Description
1 - Grommet
2 - Keyless entry keypad retaining clip (2 required) (part of
14A626)
3 - Keyless entry keypad electrical connector (part of
14631)
4 14A626 Keyless entry keypad
Remove the grommet. 1.
Using a suitable tool, release the rear keyless entry keypad retaining clip and position the keyless
entry keypad aside.
2.
Remove the keyless entry keypad.
3.
Keyless Entry Keypad 819
Keyless Entry Keypad 820
Entry Systems
Workshop Manual
Special Tool(s)
1 - Driver Door Module (DDM) nuts (2 required)
2 - DDM electrical connectors (part of 14631)
3 13C791 DDM
NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges,
damage may result.
NOTE: Prior to the removal of the module, it is necessary to upload the module configuration information to
the appropriate scan tool. This information needs to be downloaded into the new module once installed. For
NOTE: This step is necessary only if the Driver Door Module (DDM) is being replaced.
Upload the module configuration information from the DDM into the scan tool. For additional
information, refer to Section 418-.
1.
Remove the driver door trim panel. For additional information, refer to Section 501-05 . 2.
Remove the 2 nuts.
3.
Disconnect the 2 electrical connectors and remove the DDM . 4.
Driver Door Module (DDM) 821
NOTE: If the DDM was not replaced, this substep is not necessary.
Download the DDM configuration from the scan tool into the new DDM . For additional

5.
SECTION 501-16: Wipers and
Washers
Manual
Material
Capacity
Motorcraft Premium Quality
Windshield Washer Fluid
(Canada)
CXC-37-(A, B, D, and F)
(Canada)
- -
Motorcraft Premium Windshield
Washer Concentrate (US)
ZC-32-A or B (US)
WSB-M8B16-A2 -
Windshield washer reservoir bolts 7 62
Windshield washer reservoir nut 7 62
Windshield wiper mounting arm and pivot shaft assembly bolts 5 44
Wiper motor-to-wiper mounting arm bolts 8 71
Wiper pivot arm nuts 20 177
SECTION 501-16: Wipers and Washers
Workshop Manual
Wipers and Washers
The windshield wiper and washer system consists of the following:
Windshield wiper pivot arm
Windshield wiper mounting arm and pivot shaft
Windshield wiper motor
Windshield washer reservoir
Windshield washer pump
Multifunction switch
Wiper/washer module
SJB
Rain sensor (if equipped)
Rain sensor bracket (if equipped)
Wipers
The wiper system is activated by the multifunction switch. The multifunction switch provides input to the
wiper/washer module to activate wash, low, high and intermittent modes.
Washer
The washer system consists of the washer reservoir and washer pump. When the multifunction switch is
placed into the wash mode, the wiper/washer module integral electronics activate the washer pump to direct
washer fluid to the windshield.
Wiper Activated Headlamps (If Equipped with Autolamp System)
When the headlamp control switch is in the AUTOLAMP position and the wipers are on for greater than 3
seconds, the SJB will activate the headlamps. When the SJB detects that the wipers have been turned off, the
SJB will turn off the headlamps after 30 seconds.
Speed Sensitive Wipers
When the wiper control is set on any intermittent setting except INT 1, the speed dependant wipers will
automatically adjust with the vehicle speed. This feature decreases the time between wipes when the vehicle
speed increases.
Rain Sensitive Wipers (if equipped)
When equipped, the rain sensitive wipers feature replaces the standard intermittent wiper feature. The
multifunction switch must be positioned to any of the 5 auto/intermittent settings to activate the rain sensitive
wipers. The lowest setting (closest to OFF) is the least sensitive to moisture. The highest setting is the most
sensitive to moisture. The windshield wipers cycle when the multifunction switch is placed into or changing
between the auto/intermittent settings. When the rain sensitive wiper feature is active, the system adjusts the
wiper speed automatically when moisture is detected on the windshield.
A lens/bracket service kit is available to repair/replace a detached bracket or a damaged/contaminated gel-type
lens. The rain sensor gel-type lens cannot be reused on a rain sensor of this type. When reinstalling a rain
Wipers and Washers 824
sensor, a new lens from the lens/bracket service kit must be installed to the rain sensor. Refer to Rain Sensor .
Rain Sensitive Wipers (if equipped) 825
Workshop Manual
Wipers and Washers
Special Tool(s)
Flex Probe Kit
300-NUD105-R025DE or equivalent
Windshield Wiper Operation
The multifunction switch supplies ground inputs to the wiper/washer module (located behind the Smart
Junction Box (SJB) to determine the wiper speed, including low, high and intermittent. The wiper/washer
module also receives feedback from the wiper motor to determine the park position. The wiper/washer module
sends power to the wiper motor through the high and low circuits.
Wiper Activated Headlamps (If Equipped with Autolamp System)
The SJB sends a voltage signal to the wiper/washer module in order to monitor the status of the wipers. When
the wipers are turned on, the wiper/washer module will pull the voltage down. Once the SJB detects a drop in
voltage it will turn on the headlamps after 3 seconds. When the SJB detects the voltage raising, it will
determine that the wipers have been turned off and the SJB will turn off the headlamps after 30 seconds.
Rain Sensitive Wipers (if equipped)
The rain sensitive feature replaces the intermittent wiper feature. When the rain sensitive wiper system is
active, the rain sensor sends data to the wiper/washer module. The wipers activate based on the amount of
moisture detected on the windshield and the setting on the multifunction switch.
The rain sensor optically senses water on the windshield. An infrared beam lights a section of the windshield.
The intensity of the reflected beam is measured and compared to the intensity of the transmitted beam. If there
is water on the surface of the windshield, the beam distorts, reducing the intensity of the beam. If the beam is
not reflected completely, it is interpreted as rain on the windshield and the windshield wipers are activated.
If a fault is detected with the rain sensor input by the wiper/washer module, the wiper/washer module to a
default intermittent mode. The timing of the wipers correspond to a standard intermittent setting based on the
selection on the multifunction switch.
A gel-type lens is used as the interface between the rain sensor and the windshield. If the lens is missing or
damaged, the rain sensing wipers may be inoperative. If the rain sensitive wipers are inoperative and do not
default to the intermittent mode, inspect the rain sensor and confirm that the gel-type lens over the rain sensor
is undamaged.
Speed Sensitive Wipers
When the wiper control is set on any intermittent setting except INT 1, the speed dependant wipers will
automatically adjust with the vehicle speed. Vehicle speed is supplied to the wiper/washer module from the
PCM. The wiper/washer module is hardwired to the PCM. This feature decreases the time between wipes
when the vehicle speed increases.
Visually inspect for obvious signs of mechanical and electrical damage. 2.
Wiper linkage
Washer nozzles
Washer pump hoses
Washer reservoir
Wiper pivot shaft
mounting

Wiper blades
Battery Junction Box (BJB) fuse 9
(20A)

(5A)

Wiper motor
Washer pump
Rain sensor
Wiper/washer module
Wiring harness
3.
NOTE: The wiper/washer module does not communicate on the network.
4.
5.
refer to Section 418-00 to diagnose no response from the SJB .
6.
418-00 .

(CMDTCs).

7.
Clear the CMDTCs and carry out the self-test diagnostics for the SJB . 8.
If the DTCs retrieved are related to the concern, go to Smart Junction Box (SJB) DTC Chart. For all
other DTCs, refer to Section 419-10 .
9.
DTC Chart
B2008 Wipers On Signal Circuit Short to
Ground
GO to Pinpoint Test G .
All other
DTCs
- REFER to the Master DTC Chart in Section
419-10 .
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test A: The Wipers are Inoperative
Refer to Wiring Diagrams Cell 81 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Wipers and Washers for
Normal Operation
The wiper/washer module is hot at all times through circuit SBB09 (RD). When the ignition switch is in the
RUN or ACCESSORY position, voltage is supplied to the wiper/washer module through circuit CBP45 (YE).
The wiper/washer module and wiper motor are grounded through circuit GD121 (BK/YE). The multifunction
switch is grounded through circuit GD116 (BK/VT). The multifunction switch sends open and ground input
signals to the wiper/washer module through circuits CRW17 (GN/VT), CRW18 (VT/WH), CRW19 (BU/OG)
and CRW08 (VT/OG) in order to activate the wiper motor to the requested modes. The wiper/washer module
supplies voltage to the wiper motor through circuits CRW16 [(GY/BN) low] and CRW15 [(BN/WH) high].
Fuse(s)
Wiper motor
Wiper/washer module
PINPOINT TEST A: THE WIPERS ARE INOPERATIVE
A1 CHECK WIPER MOTOR GROUND
Ignition OFF.
Disconnect: Wiper Motor C125.
Measure the resistance between front wiper motor C125-4,

Yes
GO to A2 .
No
A2 CHECK WIPER MOTOR FOR VOLTAGE
Ignition ON.
With the multifunction switch in the low position, measure
the voltage between wiper motor C125-5, circuit CRW16
(GY/BN), harness side and ground.

Yes
INSTALL a new wiper motor.
REFER to Wiper Motor in this
section. TEST the system for
normal operation.
No
GO to A3 .
A3 CHECK WIPER MOTOR HIGH/LOW CIRCUITS FOR
AN OPEN
PINPOINT TEST A: THE WIPERS ARE INOPERATIVE 829
Ignition OFF.
Disconnect: Wiper/Washer Module C2157.
Measure the resistance between wiper/washer module
C2157-4, circuit CRW16 (GY/BN), harness side and wiper
motor C125-5, circuit CRW16 (GY/BN), harness side; and
between wiper/washer module C2157-11, circuit CRW15
(BN/WH), harness side and wiper motor C125-3, circuit
CRW15 (BN/WH), harness side.

Yes
GO to A4 .
No
system for normal operation
A4 CHECK WIPER/WASHER MODULE FOR VOLTAGE
Ignition ON.
Measure the voltage between wiper/washer module
C2157-9, circuit SBB09 (RD), harness side and ground; and
between wiper/washer module C2157-10, circuit CBP45

Yes
GO to A5 .
No
VERIFY Battery Junction Box
(BJB) fuse 9 (20A) and Smart
Junction Box (SJB) fuse 45 (5A)
are OK. If OK, REPAIR the
circuit. TEST the system for
normal operation.
Diagrams manual to identify
A5 CHECK WIPER/WASHER MODULE FOR GROUND
Ignition OFF.
C2157-12, circuit GD121 (BK/YE), harness side and
ground.

Yes
GO to A6 .
No
A6 CHECK THE MULTIFUNCTION SWITCH
Disconnect: Multifunction Switch C202.
Carry out the Multifunction Switch Component Test.

Did the multifunction switch pass the component test?
Yes
GO to A7 .
No
INSTALL a new multifunction
switch. REFER to Section 211-05 .
A7 CHECK MULTIFUNCTION SWITCH FOR GROUND
Measure the resistance between multifunction switch
C202-15, circuit GD116 (BK/VT), harness side and ground.

Yes
GO to A8 .
No
A8 CHECK THE WIPER/WASHER MODULE FOR
PROPER OPERATION
Check for:
corrosion.
pushed-out pins.
Connect the wiper/washer module connector and make sure
it is seated correctly, and reconnect the related wiper
components.

Yes
INSTALL a new wiper/washer
module. REFER to Wiper/Washer
No
normal operation.
Pinpoint Test B: The Wipers Stay On Continuously
Normal Operation
Under normal operation, the wiper motor receives open and ground inputs from the multifunction switch
through circuits CRW08 (VT/OG), CRW17 (GN/VT), CRW18 (VT/WH) and CRW19 (BU/OG) to activate
the wipers to the appropriate speeds. The wiper/washer module supplies voltage to the wiper motor through
circuits CRW16 ([GY/BN] low) and CRW15 ([BN/WH] high).
Wiper/washer module
PINPOINT TEST B: THE WIPERS STAY ON CONTINUOUSLY
B1 CHECK WIPER MOTOR FOR SHORT TO
VOLTAGE
Ignition OFF.
Ignition ON.
With the wipers in the OFF position, measure the
voltage between wiper motor C125-3, circuit CRW15
(BN/WH), harness side and ground; and between wiper
motor C125-5, circuit CRW16 (GY/BN), harness side
and ground.

Yes
REPAIR the circuit(s) for a short to
voltage. TEST the system for normal
operation.
No
GO to B2 .
B2 CHECK THE MULTIFUNCTION SWITCH
Carry out the Multifunction Switch component test.

Did the multifunction switch pass the component
test?

Yes
GO to B3 .
No
INSTALL a new multifunction switch.
B3 CHECK FOR A SHORT TO GROUND IN THE
MULTIFUNCTION SWITCH HARNESS
wiper/washer module:

C2157-8, circuit CRW08 (VT/OG), harness
side.

C2157-13, circuit CRW17 (GN/VT), harness
side.

C2157-14, circuit CRW19 (BU/OG), harness
side.

C2157-6, circuit CRW18 (VT/WH), harness
side.

Yes
GO to B4 .
No
REPAIR the circuit(s) in question.
B4 CHECK FOR CORRECT WIPER/WASHER
MODULE OPERATION
Disconnect all wiper/washer module connectors.
Check for:
corrosion.
pushed-out pins.
Connect all wiper/washer module connectors and make

present.

Yes
No
normal operation.
Pinpoint Test C: The High/Low Wiper Speeds Do Not Operate Correctly
Normal Operation
Under normal operation, the wiper/washer module receives open and ground inputs from the multifunction
switch through circuits CRW08 (VT/OG), CRW17 (GN/VT), CRW18 (VT/WH) and CRW19 (BU/OG) to
activate the wiper motor in the high and low speeds. The wiper/washer module supplies voltage to the wiper
motor through circuits CRW16 ([GY/BN] low) and CRW15 ([BN/WH] high).
Wiper motor
Wiper/washer module
PINPOINT TEST B: THE WIPERS STAY ON CONTINUOUSLY 833
PINPOINT TEST C: THE HIGH/LOW WIPER SPEEDS DO NOT OPERATE CORRECTLY
C1 CHECK THE MULTIFUNCTION SWITCH
Ignition OFF.

Did the multifunction switch pass the component test?
Yes
GO to C2 .
No
switch. REFER to Section
normal operation.
C2 CHECK FOR A SHORT TO GROUND IN THE
Measure the resistance between ground and wiper/washer
module:

C2157-8, circuit CRW08 (VT/OG), harness side.
C2157-13, circuit CRW17 (GN/VT), harness side.
C2157-14, circuit CRW19 (BU/OG), harness side.
C2157-6, circuit CRW18 (VT/WH), harness side.
Yes
GO to C3 .
No
REPAIR the circuit(s) in
question. TEST the system for
normal operation.
C3 CHECK FOR AN OPEN IN THE MULTIFUNCTION
SWITCH HARNESS
Measure the resistance between multifunction switch C202,
harness side and wiper/washer module C2157, harness side

Multifunction
Switch Circuit
Wiper/Washer
Module
C202-16 CRW19
(BU/OG)
C2157-14
C202-9 CRW08
(VT/OG)
C2157-8
C202-12 CRW17 C2157-13
Yes
GO to C4 .
No
REPAIR the circuit(s) in
question. TEST the system for
normal operation.
PINPOINT TEST C: THE HIGH/LOW WIPER SPEEDS DO NOT OPERATE CORRECTLY 834
(GN/VT)
C202-11 CRW18
(VT/WH)
C2157-6
C4 CHECK FOR A SHORT IN THE WIPER/WASHER
MODULE HARNESS
Measure the resistance between multifunction switch C202,
harness side, using the following chart:

Multifunction
Switch Circuitry
Multifunction
Switch
C202-16 CRW19
(BU/OG)/
CRW18
(VT/WH)
C202-11
C202-16 CRW19
(BU/OG)/
CRW08 (VT/OG)
C202-9
C202-16 CRW19
(BU/OG)/
CRW17 (GN/VT)
C202-12
C202-11 CRW18
(VT/WH)/
CRW08 (VT/OG)
C202-9
C202-11 CRW18
(VT/WH)/
CRW17 (GN/VT)
C202-12
C202-9 CRW08
(VT/OG)/
CRW17 (GN/VT)
C202-12
Yes
GO to C5 .
No
REPAIR the circuit(s). TEST
operation.
Is the resistance greater than 10,000 ohms for all
measurements?

C5 CHECK WIPER MOTOR LOW SPEED FOR VOLTAGE
Connect: Wiper/Washer Module C2157.
Connect: Multifunction Switch C202.
Ignition ON.
With the multifunction switch in the low position, measure the
(GY/BN), harness side and ground.

Yes
GO to C7 .
No
GO to C6 .
C6 CHECK WIPER MOTOR LOW SPEED FOR AN OPEN
Ignition OFF.
Measure the resistance between wiper motor C125-5, circuit
CRW16 (GY/BN), harness side and wiper/washer module
C2157-4, circuit CRW16 (GY/BN), harness side.

Yes
GO to C9 .
No
C7 CHECK WIPER MOTOR HIGH SPEED FOR VOLTAGE
With the multifunction switch in the high position, measure the
(BN/WH), harness side and ground.

Yes
INSTALL a new wiper motor.
REFER to Wiper Motor in this
section. TEST the system for
normal operation.
No
GO to C8 .
C8 CHECK WIPER MOTOR HIGH SPEED FOR AN OPEN
Ignition OFF.
Measure the resistance between wiper motor C125-3, circuit
CRW15 (BN/WH), harness side and wiper/washer module
C2157-11, circuit CRW15 (BN/WH), harness side.

Yes
GO to C9 .
No
C9 CHECK FOR CORRECT WIPER/WASHER MODULE
OPERATION
Check for:
corrosion.
pushed-out pins.
Connect all wiper/washer module connectors and make sure

Yes
module. REFER to
Wiper/Washer Module in this
section.
No
correctly at this time. Concern
may have been caused by a
loose or corroded connector.
operation.
Pinpoint Test D: The Intermittent Wiper Speed Does Not Operate Correctly (High/Low Speeds OK)
Normal Operation
Under normal operation, the wiper/washer module receives open and ground inputs from the multifunction
switch through circuits CRW08 (VT/OG), CRW17 (GN/VT), CRW18 (VT/WH) and CRW19 (BU/OG) to
activate the wiper motor in the high, low and intermittent speeds.
Wiper/washer module
PINPOINT TEST D: THE INTERMITTENT WIPER SPEED DOES NOT OPERATE CORRECTLY (HIGH/LOW SPEEDS
OK)
D1 VERIFY IF THE VEHICLE IS EQUIPPED WITH
RAIN SENSITIVE WIPERS
NOTE: If sent here from Pinpoint Test E, GO to D2.
Inspect the vehicle for rain sensitive wipers.
Is the vehicle equipped with rain sensitive wipers?
Yes
GO to Pinpoint Test E .
No
GO to D2 .
D2 CHECK THE MULTIFUNCTION SWITCH
Ignition OFF.

Did the multifunction switch pass the component
test?

Yes
GO to D3 .
No
INSTALL a new multifunction switch.
REFER to Section 211-05 . TEST the
D3 CHECK FOR A SHORT TO GROUND IN THE
wiper/washer module:

C2157-8, circuit CRW08 (VT/OG), harness
side.

C2157-13, circuit CRW17 (GN/VT), harness
side.

C2157-14, circuit CRW19 (BU/OG), harness
side.

C2157-6, circuit CRW18 (VT/WH), harness
side.

Yes
GO to D4 .
No
REPAIR the circuit(s) in question. TEST
PINPOINT TEST D: THE INTERMITTENT WIPER SPEED DOES NOT OPERATE CORRECTLY (HIGH/LOW SPEEDS OK) 838
D4 CHECK FOR AN OPEN IN THE
C202, harness side and wiper/washer module C2157,
harness side using the following chart:

Multifunction
Switch Circuit
Wiper/Washer
Module
C202-16 CRW19
(BU/OG)
C2157-14
C202-9 CRW08
(VT/OG)
C2157-8
C202-12 CRW17
(GN/VT)
C2157-13
C202-11 CRW18
(VT/WH)
C2157-6
Yes
GO to D5 .
No
REPAIR the circuit(s) in question. TEST
D5 CHECK FOR A SHORT IN THE WIPER/WASHER
MODULE HARNESS
C202, harness side, using the following chart:

Multifunction
Switch Circuitry
Multifunction
Switch
C202-16 CRW19
(BU/OG)/
CRW18
(VT/WH)
C202-11
C202-16 CRW19
(BU/OG)/
CRW08
(VT/OG)
C202-9
Yes
GO to D6 .
No
REPAIR the circuit(s). TEST the system
C202-16 CRW19
(BU/OG)/
CRW17
(GN/VT)
C202-12
C202-11 CRW18
(VT/WH)/
CRW08
(VT/OG)
C202-9
C202-11 CRW18
(VT/WH)/
CRW17
(GN/VT)
C202-12
C202-9 CRW08
(VT/OG)/
CRW17
(GN/VT)
C202-12
Is the resistance greater than 10,000 ohms for all
measurements?

D6 CHECK FOR CORRECT WIPER/WASHER
MODULE OPERATION
Check for:
corrosion.
pushed-out pins.
Connect all wiper/washer module connectors and

present.

Yes
INSTALL a new wiper/washer module.
REFER to Wiper/Washer Module in this
section.
No
time. Concern may have been caused by
a loose or corroded connector. TEST the
Pinpoint Test E: The Rain Sensitive Wipers Are Inoperative
Normal Operation
Voltage is supplied to the rain sensor when the ignition is ON. The rain sensor sends data to the wiper/washer
module on a dedicated circuit. When the multifunction switch is in one of the 5 auto/intermittent settings, the
rain sensitive wipers activate.
The rain sensor optically senses water on the windshield. An infrared beam lights a section of the windshield.
The intensity of the reflected beam is measured and compared to the intensity of the transmitted beam. When
there is water on the surface of the windshield, the beam distorts, reducing the intensity of the beam. When the
beam is not reflected completely, it is interpreted as rain on the windshield and the windshield wipers activate
based on the sensitivity setting.
If a fault is detected with the rain sensor input by the wiper/washer module, the wiper/washer module switches
to a default intermittent mode. The timing of the wipers correspond to a standard intermittent setting based on
the selection on the multifunction switch.
A gel-type lens is used as the interface between the rain sensor and the windshield. If the lens is missing or
damaged, the rain sensing wipers may be inoperative. If the rain sensitive wipers are inoperative and do not
default to the intermittent mode, inspect the rain sensor and confirm that the gel-type lens over the rain sensor
is undamaged.
Fuse
Wiper blades
Rain sensor mounting bracket not secured to the windshield
Rain sensor gel-type lens
Rain sensor
Foreign material on windshield, such as dirt, dust or bugs
Damaged windshield
Wiper motor
Wiper/washer module
SJB
PINPOINT TEST E: THE RAIN SENSITIVE WIPERS ARE INOPERATIVE
E1 CHECK THE INPUT FROM THE
MULTIFUNCTION SWITCH
Ignition ON.
Cycle the multifunction switch from off through each
of the auto/intermittent settings, waiting 10 seconds
between cycling the switch to the next setting.

Set the multifunction switch to the wipers off setting.
Do the wipers cycle when the switch is changed to
each setting?

Yes
GO to E2 .
No
E2 CHECK THE RAIN SENSITIVE WIPERS FOR
DEFAULT INTERMITTENT MODE
NOTE: Make sure the windshield is dry when carrying
out this step.

NOTE: The windshield wipers activate when the
multifunction switch is cycled through the
auto/intermittent settings. The initial wiper activation
after changing the setting should not be considered part
of an intermittent wiper operation.

Cycle the multifunction switch to auto/intermittent
setting 5, the most sensitive to moisture.

Do the wipers default to a standard intermittent
setting?

Yes
GO to E9 .
No
GO to E3 .
E3 CHECK THE WINDSHIELD FOR DAMAGE
Ignition OFF.
Inspect the windshield glass for any cracks, pits or
other visible damage around the area of the rain sensor.

Is any windshield damage present near the area of
the rain sensor?

Yes
INSTALL a new windshield. REFER to
normal operation.
No
GO to E4 .
E4 CHECK THE WINDSHIELD GLASS FOR
STREAKING
Ignition ON.
Turn the multifunction switch to the low speed wiper
setting and while applying water to the windshield
surface. Observe the wipe quality, especially around the
area or the rain sensor.

Is any streaking present on the windshield around
the area of the rain sensor?

Yes
GO to E5 .
No
GO to E7 .
E5 CHECK THE WINDSHIELD WIPER BLADES FOR
STREAKING
Ignition OFF.
Clean the windshield glass with glass cleaner.
Clean the wiper blades with isopropyl alcohol swabs.
Wipe the entire length of the wiper blades.

Ignition ON.
Turn the multifunction switch to the low speed wiper
setting and while applying water to the windshield
surface. Observe the wipe quality, especially around the
area or the rain sensor.

Was there noticeable improvement in the wipe
quality after cleaning the glass and the wiper
blades?

Yes
GO to E6 .
No
INSTALL new wiper blades. GO to E6
.
E6 RECHECK THE RAIN SENSITIVE WIPERS
OPERATION
Turn the multifunction switch to the auto/intermittent 5
setting (most sensitive to moisture) while applying
water on the windshield above the rain sensor.

Do the wipers operate when water is applied to the
windshield surface?

Yes
time. The concern may have been
caused by poor wipe quality on the
windshield around the rain sensor.
PINPOINT TEST E: THE RAIN SENSITIVE WIPERS ARE INOPERATIVE 842
No
GO to E7 .
E7 CHECK FOR THE PRESENCE OF THE LENS GEL
Ignition OFF.
Lightly press the rain sensor against the windshield and
release the rain sensor clips.

Does the rain sensor remain adhered to the
windshield?

Yes
ATTACH the retaining clips. GO to E8
.
No
The sensor lens is missing or damaged.
INSTALL a new gel-type lens using the
rain sensor bracket service kit. TEST
E8 INSPECT THE RAIN SENSOR MOUNTING AREA
NOTE: The rain sensor gel-type lens can be damaged
or contaminated during rain sensor removal, rain sensor
bracket separation or incorrect installation.
From the outside of the vehicle, inspect the area of the
windshield glass where the rain sensor is mounted. The
rain sensor contact area should appear black, with no
bubbles, air pockets or contaminants between the
windshield glass and the rain sensor.

Does the rain sensor contact area appear black, with
no bubbles, air pockets or contaminants between the
windshield glass and the rain sensor?

Yes
GO to E9 .
No
REMOVE the gel-type lens. INSTALL
a new gel-type lens using the rain
sensor bracket service kit. TEST the
system for normal operation. If the
concern is still present, GO to E9 .
E9 CHECK FOR VOLTAGE TO THE RAIN SENSOR
Ignition OFF.
Disconnect: Rain Sensor C914.
Ignition ON.
Measure the voltage between the rain sensor C914-4,
circuit CBP43 (GY), harness side and ground.

Yes
GO to E11 .
No
VERIFY SJB fuse 43 (10A) is OK. If
OK, GO to E10 . If not OK, REFER to
the Wiring Diagrams manual to identify
the possible causes of the circuit short.
E10 CHECK THE RAIN SENSOR VOLTAGE SUPPLY
CIRCUIT FOR AN OPEN
Ignition OFF.
Measure the resistance between the rain sensor C914-4,
circuit CBP43 (GY), harness side and the SJB
C2280D-22, circuit CBP43 (GY), harness side.

Yes
GO to E16 .
No
E11 CHECK THE RAIN SENSOR GROUND CIRCUIT
FOR AN OPEN
Ignition OFF.

Yes
GO to E12 .
No
E12 CHECK THE RAIN SENSOR SIGNAL CIRCUIT
Ignition ON.
Measure the voltage between the rain sensor C914-2,
circuit VMC05 (VT/OG), harness side and ground.

Yes
No
GO to E13 .
Ignition OFF.

Yes
GO to E14 .
No
FOR AN OPEN
circuit VMC05 (VT/OG), harness side and the
wiper/washer module C2157-1, circuit VMC05
(VT/OG), harness side.

Yes
GO to E15 .
No
E15 CHECK FOR CORRECT RAIN SENSOR
OPERATION
Check for:
corrosion.
pushed-out pins.
Connect the rain sensor connector and make it seats
correctly.

Operate the system and determine if the concern is still
present.

Yes
INSTALL a new rain sensor. REFER to
Rain Sensor . TEST the system for
normal operation. If the concern is still
present, GO to E17 .
No
connector.
E16 CHECK FOR CORRECT SJB OPERATION
Check for:
corrosion.
pushed-out pins.
correctly.

present.

Yes
normal operation.
No
connector.
E17 CHECK FOR CORRECT WIPER/WASHER
MODULE OPERATION
Check for:
corrosion.
pushed-out pins.
Connect the wiper/washer module connector and make
it seats correctly.

present.

Yes
REFER to Wiper/Washer Module in
normal operation.
No
connector.
Pinpoint Test F: The Washer Pump is Inoperative
Normal Operation
The multifunction switch provides a ground signal to the wiper/washer module through circuit CRW07
(GY/BN) when the wash function is selected on the multifunction switch. When the wiper/washer module
detects this input, the wiper/washer module activates an internal washer relay that provides voltage to the
washer pump through circuit CRW14 (BU/WH). The washer pump is grounded through circuit GD123
(BK/GY).
Blocked washer hose/washer jet
Washer pump motor
Wiper/washer module
PINPOINT TEST F: THE WASHER PUMP IS INOPERATIVE
F1 CHECK WASHER PUMP MOTOR FOR GROUND
Disconnect: Washer Pump Motor C137.
Ignition OFF.
Measure the resistance between washer pump motor
C137-2, circuit GD123 (BK/GY) harness side and ground.

Yes
GO to F2 .
No
F2 CHECK WASHER PUMP MOTOR FOR VOLTAGE
Ignition ON.
Measure the voltage between washer pump motor C137-1,
circuit CRW14 (BU/WH), harness side and ground while
depressing the multifunction switch to the WASH position.

Yes
INSTALL a new washer pump.
REFER to Washer Pump in this
section.
No
GO to F3 .
F3 CHECK WASHER PUMP MOTOR VOLTAGE CIRCUIT
FOR AN OPEN
Ignition OFF.
C2157-3, circuit CRW14 (BU/WH), harness side and
washer pump motor C137-1, circuit CRW14 (BU/WH),
harness side.

Yes
GO to F4 .
No
F4 CHECK MULTIFUNCTION SWITCH WASHER
OUTPUT CIRCUIT
C2157-5, circuit CRW07 (GY/BN) harness side and ground
while depressing the multifunction switch to the WASH
position.

Yes
GO to F6 .
No
GO to F5 .
PINPOINT TEST F: THE WASHER PUMP IS INOPERATIVE 847
F5 CHECK MULTIFUNCTION SWITCH OUTPUT
CIRCUIT FOR AN OPEN
C2157-5, circuit CRW07 (GY/BN), harness side and
multifunction switch C202-10, circuit CRW07 (GY/BN),
harness side.

Yes
switch. REFER to Section 211-05 .
operation.
No
F6 CHECK FOR CORRECT WIPER/WASHER MODULE
OPERATION
Check for:
corrosion.
pushed-out pins.
Connect all wiper/washer module connectors and make sure

Yes
No
normal operation.
Pinpoint Test G: The Headlamps Do Not Illuminate When the Wipers are On
Refer to Wiring Diagrams Cell 81 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Front Wipers and Washers
Normal Operation
The Smart Junction Box (SJB) sends a 12 volt reference signal on circuit CRW01 (WH) to the wiper motor
module in order to monitor the status of the wipers. When the headlamp control switch is in the AUTOLAMP
position and the wipers are on, the wiper motor module will pull the voltage reference signal low. After 3
seconds, the SJB will activate the headlamps.
DTC B2008 (Wipers On Signal Circuit Short to Ground) - Sets when a short to ground is detected on
the wiper motor status input circuit.

Wiper/washerodule
SJB
PINPOINT TEST G: THE HEADLAMPS DO NOT ILLUMINATE WHEN THE WIPERS ARE ON
G1 CHECK WIPER ON SIGNAL FOR VOLTAGE
Ignition ON.
Measure the voltage between wiper/washer module
C2157-2, circuit CRW01 (WH), harness side and
ground.

Yes
REFER to Wiper/Washer Module in
this section. CLEAR the DTCs.
No
GO to G2 .
G2 CHECK WIPER ON SIGNAL FOR AN OPEN OR
SHORT TO GROUND
Ignition OFF.
Disconnect: SJB C2280F.
Measure the resistance between SJB C2280F-8, circuit
CRW01 (WH), harness side and wiper/washer module
C2157-2, circuit CRW01 (WH); and between SJB
C2280F-8, circuit CRW01 (WH), harness side and
ground.

Yes
GO to G3 .
No
PINPOINT TEST G: THE HEADLAMPS DO NOT ILLUMINATE WHEN THE WIPERS ARE ON 849
Is the resistance less than 5 ohms between the SJB
and wiper/washer module and greater than 10,000
ohms between the SJB and ground?

G3 CHECK FOR CORRECT MODULE OPERATION
Check for:
corrosion.
pushed-out pins.
Connect all the SJB connectors and make sure they are
seated correctly.

present.

Yes
Section 419-10 . CLEAR the DTCs.
No
time. Concern may have been caused
self-test.
Pinpoint Test H: The Speed Dependent Interval Mode Does Not Operate Correctly
Normal Operation
Under normal operation, the windshield wiper/washer module receives vehicle speed information from the
PCM through circuit VMC05 (VT/OG). The windshield wiper/washer module then determines the speed of
the windshield wiper motor. The speed dependant wipers function in all INT modes except INT 1.
Wiper/washer module
PINPOINT TEST H: THE SPEED DEPENDENT INTERVAL MODE DOES NOT OPERATE CORRECTLY
H1 CHECK PCM FOR DTCs
Review the DTCs from the PCM self-test.
Are any Vehicle Speed Sensor (VSS) related DTCs present?
Yes
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual to diagnose
the VSS .
No
GO to H2 .
H2 CHECK THE VEHICLE SPEED CIRCUIT FOR AN OPEN OR
SHORT TO GROUND
Ignition OFF.
Disconnect: PCM C175B.
Measure the resistance between wiper/washer module C2157-1,
circuit VMC05 (VT/OG), harness side and PCM C175B-5, circuit
VMC05 (VT/OG), harness side; and between wiper/washer
module C2157-1, circuit VMC05 (VT/OG), harness side and
ground.

Is the resistance less than 5 ohms between wiper/washer
module and PCM; and greater than 10,000 ohms between
wiper/washer module and ground?

Yes
GO to H3 .
No
operation.
H3 CHECK THE VEHICLE SPEED CIRCUIT FOR A SHORT TO
VOLTAGE
Ignition ON.
Measure the voltage between wiper/washer module C2157-1,

Yes
operation.
No
GO to H4 .
PINPOINT TEST H: THE SPEED DEPENDENT INTERVAL MODE DOES NOT OPERATE CORRECTLY 851
H4 CHECK FOR CORRECT WIPER/WASHER MODULE
OPERATION
Check for:
corrosion.
pushed-out pins.
Connect all wiper/washer module connectors and make sure they
seat correctly.

Yes
INSTALL a new
wiper/washer module.
REFER to Wiper/Washer
No
Pinpoint Test I: The Wipers Will Not Park at the Correct Position
Normal Operation
Under normal operation, the wiper motor sends a ground signal through circuit CRW09 (BN/BU) to the
wiper/washer module when the wipers are in the park position. If there is a open or short in circuit CRW09
(BN/BU) the wipers will not park and will stop in the position the wipers are currently in when the wipers are
turned off.
Damaged wiper mounting arm and pivot shaft
Pivot arm adjustment
Wiper motor
Wiper/washer module
PINPOINT TEST I: THE WIPERS WILL NOT PARK AT THE CORRECT POSITION
I1 CHECK FOR WIPER MOUNTING ARM
AND PIVOT SHAFT DAMAGE
Check the wiper mounting arm and pivot shaft
for damage.

Is there damage to wiper mounting arm or
pivot shaft?

Yes
If there is damage to mounting arm or pivot
shaft, INSTALL a new wiper mounting arm or
INSTALL a new pivot shaft. REFER to Wiper
Mounting Arm and Pivot Shaft or Wiper Pivot
Arm in this section.
No
GO to I2 .
I2 CHECK WIPER PIVOT ARM ALIGNMENT
Check the wiper pivot arm adjustment.
Is the wiper pivot arm correctly adjusted?
Yes
GO to I3 .
No
ADJUST the wiper blade and pivot arm. REFER
to Wiper Blade and Pivot Arm Adjustment in
operation.
I3 CHECK WIPER MOTOR FOR A INTERNAL
SHORT TO GROUND
Ignition ON.
Operate the wipers until the wipers are no
longer in the PARK position and turn off the
wipers.

Ignition OFF.
Measure the resistance between wiper/washer
module C2157-7, circuit CRW09 (BN/BU),

Yes
GO to I5 .
No
GO to I4 .
I4 CHECK WIPER PARK SIGNAL FOR A
SHORT TO GROUND
Measure the resistance between wiper motor
C125-1, circuit CRW09 (BN/BU), harness
side and ground.

Yes
INSTALL a new wiper motor. REFER to Wiper
Motor in this section. TEST the system for
normal operation.
No
operation.
PINPOINT TEST I: THE WIPERS WILL NOT PARK AT THE CORRECT POSITION 853
I5 CHECK WIPER PARK SIGNAL FOR AN
OPEN
Measure the resistance between wiper/washer
module C2157-7, circuit CRW09 (BN/BU),
harness side and wiper motor C125-1, circuit
CRW09 (BN/BU), harness side.

Yes
GO to I6 .
No
operation.
I6 CHECK FOR CORRECT WIPER/WASHER
MODULE OPERATION
Disconnect all wiper/washer module
connectors.

Check for:
corrosion.
pushed-out pins.
Connect all wiper/washer module connectors
and make sure they seat correctly.

still present.

Yes
INSTALL a new wiper/washer module. REFER
to Wiper/Washer Module in this section.
No
corroded connector. TEST the system for normal
operation.
SECTION 501-16: Wipers and
Washers
Manual
Wiper Blade and Pivot Arm Adjustment
Cycle and park the windshield wipers. 1.
Verify that the RH and LH wiper blades are located at the alignment marks on the glass. 2.
If necessary, remove the nuts and the windshield wiper pivot arms and reposition them to the correct
locations.
3.
Wiper Blade and Pivot Arm Adjustment 856
Workshop Manual
Wiper and Washer System - Exploded View
Windshield Wipers
Item
Part
Number Description
1 17C526 Wiper pivot arm caps (2 required)
2 W520403 Wiper pivot arm nuts (2 required)
3 17526 Wiper pivot arm assembly
4 W701121 Windshield wiper mounting arm and pivot shaft
assembly bolts (2 required)
5 17566 Windshield wiper mounting arm and pivot shaft
assembly
6 - Wiper motor-to-wiper mounting arm bolts (part of
17508) (2 required)
7 17508 Wiper motor assembly
Washer Pump and Reservoir - Hybrid
Wiper and Washer System - Exploded View 857
1 W707399 Windshield washer reservoir bolts (2 required)
2 W702751 Windshield washer reservoir nut
3 14A005 Windshield washer pump electrical connector
4 17664 Windshield washer pump
5 17618 Windshield washer reservoir
6 17618 Windshield washer reservoir filler neck
7 W500214 Windshield washer reservoir filler neck retaining bolt
8 W702751 Coolant reservoir nut
9 W505252 Coolant reservoir bolt
10 8A080 Coolant reservoir
Washer Pump and Reservoir - Non-Hybrid
Washer Pump and Reservoir - Hybrid 858
1 W707399 Windshield washer reservoir bolts (2 required)
2 W702751 Windshield washer reservoir nut
3 14A005 Windshield washer pump electrical connector
4 17664 Windshield washer pump
5 17618 Windshield washer reservoir
6 17618 Windshield washer reservoir filler neck
7 W500214 Windshie washer reservoir filler neck retaining bolt
Washer Pump and Reservoir - Non-Hybrid 859
Washer Pump and Reservoir - Non-Hybrid 860
Workshop Manual
Wiper Pivot Arm
Remove the wiper pivot arm cap. 1.
Remove the wiper pivot arm retaining nut and the wiper pivot arm.
2.
Wiper Pivot Arm 861
Workshop Manual
Wiper Mounting Arm and Pivot Shaft
Remove the upper cowl panel grille. For additional information, refer to Section 501-02 . 1.
Disconnect the windshield wiper motor electrical connector. 2.
Remove the 2 windshield wiper mounting arm and pivot shaft assembly bolts and the windshield
wiper mounting arm and pivot shaft assembly.
3.
Wiper Mounting Arm and Pivot Shaft 862
Workshop Manual
Wiper Motor
Remove the wiper pivot arms. For additional information, refer to Wiper Pivot Arm in this section. 1.
Remove the windshield wiper mounting arm and pivot shaft. For additional information, refer to
Wiper Mounting Arm and Pivot Shaft in this section.
2.
Separate the wiper motor linkage arm from the wiper mounting arm and pivot shaft assembly. 3.
Remove the 2 wiper motor-to-wiper mounting arm bolts and the wiper motor.
4.
Wiper Motor 863
Workshop Manual
Washer Pump
Material
Item Specification
Windshield Washer Fluid (Canada)
CXC-37-(A, B, D, and F) (Canada)
-
ZC-32-A or B (US)
WSB-M8B16-A2
100-02 .
1.
Remove the RH front fender splash shield. For additional information, refer to Section 501-02 . 2.
WARNING: Carefully read cautionary information on product label. For EMERGENCY
MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft
products call: 1-800-959-3673. For additional information, consult the product Material Safety
Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious
personal injury.
NOTICE: When installing the windshield washer pump, be careful not to damage the rubber
grommet.
NOTE: To prevent spilling windshield washer fluid, dn the windshield washer reservoir before
washer pump removal.
Remove the windshield washer pump.
Disconnect the hoses. 2.
Remove the windshield washer pump. 3.
3.
NOTICE: 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.
4.
Washer Pump 864
Fill the windshield washer reservoir with windshield washer fluid.
Washer Pump 865
Workshop Manual
Washer Reservoir
Material
Item Specification
Windshield Washer Fluid (Canada)
CXC-37-(A, B, D, and F) (Canada)
-
ZC-32-A or B (US)
WSB-M8B16-A2
All vehicles
100-02 .
1.
Remove the RH front fender splash shield. For additional information, refer to Section 501-02 . 2.
Disconnect the windshield washer pump electrical connector. 3.
MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft
products call: 1-800-959-3673. For additional information, consult the product Material Safety
Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious
personal injury.
NOTE: To prevent spilling windshield washer fluid,ain the windshield washer reservoir before
removal.
Disconnect the washer pump hose.
4.
Hybrid vehicles
Remove the coolant reservoir bolt and nut and position the reservoir aside in order to gain access to
the washer reservoir filler neck.
5.
All vehicles
Washer Reservoir 866
Remove the bolt and the windshield washer reservoir filler neck.
6.
Remove the windshield washer reservoir fasteners and the windshield washer reservoir.
7.
NOTICE: 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.
Fill the windshield washer reservoir with windshield washer fluid.
8.
Washer Reservoir 867
Workshop Manual
Rain Sensor
NOTE: Vehicle without Headlamp Control Module 2 (HCM-2) shown, vehicle with HCM-2 similar.
1 - Electrical connector (part of 17C712)
2 17D547 Rain sensor
3 17D550 Rain sensor cover
Removal
NOTE: If reinstalling the original rain sensor, a new lens/bracket service kit (19G382) must be acquired prior
to performing this procedure.
On vehicles equipped with a Headlamp Control Module 2 (HCM-2), remove the HCM-2 . For
1.
On vehicles equipped with only a rain sensor, remove the rain sensor cover. 2.
Disconnect the rain sensor electrical connector. 3.
NOTE: Lightly press the rain sensor against the windshield to relieve the clip tension.
Release the 2 rain sensor retaining clips and remove the rain sensor.
4.
Rain Sensor 868
Installation
Reinstalling the original rain sensor
NOTICE: Do not touch the rain sensor lens-to-windshield contact area or allow it to become
contaminated with dust or debris. Touching or contaminating the rain sensor lens will result in the rain
sensitive wiper feature being inoperative or working incorrectly.
Disengage the 3 rain sensor plastic clips and separate the electronics backing plate from the rain
sensor lens.
Discard the rain sensor lens.
1.
Disengage the 3 rain sensor plastic clips on the rain sensor lens protective backing and separate the
rain sensor protective backing from the new rain sensor lens.
2.
NOTE: Do not remove the white rain sensor lens protective cover at this time.
Install the rain sensor lens onto the electronics backing plate.
3.
Rain Sensor 869
All rain sensors
Remove the white rain sensor lens protective cover from the rain sensor lens. 4.
Clean any residual rain sensor lens material from the rain sensor viewing window. 5.
Install the rain sensor onto the rain sensor mounting bracket, making sure that the alignment tab on
the rain sensor is aligned with the notch on the mounting bracket.
Press the metal rain sensor mounting bracket clips to engage the clips onto the mounting
bracket.

6.
Connect the rain sensor electrical connector. 7.
On vehicles equipped with only a rain sensor, install the rain sensor cover. 8.
Rain Sensor 870
On vehicles equipped with a Headlamp Control Module 2 (HCM-2), install the HCM-2 . For
9.
Rain Sensor 871
Workshop Manual
Rain Sensor Bracket
NOTE: The rain sensor bracket primer and adhesive are not included in service kit (part number 19G382) and
will have to be ordered separately. The rain sensor bracket primer and adhesive part numbers and ordering
instructions are available in the parts ordering system.
NOTE: The rain sensor bracket adhesive will take at least 6 hours to dry.
Disconnect the rain sensor electrical connector. 1.
NOTICE: Make sure not to scratch the windshield glass.
Using a razor blade, carefully remove any residual glue from the windshield glass.
2.
Using a clean cloth, wipe the windshield glass to remove any loose glue particles and any residual
rain sensor lens material.
3.
Apply specified primer onto a clean cloth. 4.
Insert a cotton swab, or equivalent, onto the wet area of the cloth. 5.
NOTICE: Do not apply primer to the rain sensor view window area.
Using the cotton swab, or equivalent, apply the primer onto the contact area of the rain sensor
mounting bracket area of the windshield glass.
6.
NOTE: Apply the adhesive to the side of the rain sensor bracket that is opposite of the notch and that
does not contain numbers and letters.
7.
Rain Sensor Bracket 872
Using a 3M EPX Plus II applicator or equivalent, apply a 2 to 3 mm (0.078 in to 0.118 in) bead of
specified adhesive to the rain sensor mounting bracket.
NOTE: If the rain sensor mounting bracket is not mounted in the correct location on the windshield
glass, the rain sensor trim cover will not install correctly.
Apply the rain sensor mounting bracket onto the windshield making sure that the notch on the bracket
is in the 1 o'clock position and that the bracket is centered around the rain sensor view window area.
8.
NOTE: Do not apply masking tape onto the rain sensor view window area.
Apply masking tape onto the rain sensor mounting bracket and the windshield glass in order to hold
the bracket onto the windshield.
9.
Allow the adhesive to dry for at least 6 hours. 10.
Disengage the metal rain sensor mounting clips from the old rain sensor bracket and separate the old
rain sensor bracket from the rain sensor.
Discard the old rain sensor bracket, it is not to be reused.
11.
Install the rain sensor. For additional information, refer to Rain Sensor in this section. 12.
Workshop Manual
Wiper/Washer Module
NOTE: Instrument panel removed for clarity.
1 15605 Smart Junction Box (SJB)
2 14B205 Wiper/washer module
3 14401 Wiper/washer module electrical connector
Position the Smart Junction Box (SJB) aside by pushing upward then pulling outward to release it
from the SJB bracket.
1.
Disconnect the wiper/washer module connector. 2.
Pull down on the wiper/washer module to release it from the SJB bracket. 3.
Wiper/Washer Module 875
SECTION 501-17: Roof Opening Panel
Workshop Manual
Item Specification
Front edge of roof panel-to-roof opening panel -1.5 to 0 mm
(-0.059 to 0 in)
Rear edge of roof panel-to-roof opening panel 0 to 1.5 mm
(0 to 0.059 in)
Roof opening panel air deflector screws 1 9
Roof opening panel frame bolts 12 106
Roof opening panel glass screws 6 53
Roof opening panel motor screws 4 35
SECTION 501-17: Roof Opening
Panel
Manual
Roof Opening Panel
The roof opening panel consists of the following:
Concertina blinds
Air deflector
Trough assembly
Roof opening panel glass
Roof opening panel motor/module
Roof opening panel shield
Roof opening panel switch
Roof opening panel drain hoses
The roof opening panel is an electronically operated panel that can be opened or closed by pressing a switch
located on the overhead console. It also has one-touch open, one-touch close, one-touch vent open and
one-touch vent close features.
When the roof opening panel is in the fully CLOSED position, pressing the roof opening panel control switch
rearward to the second detent and then releasing it will activate the one-touch open feature. Pressing the roof
opening panel control switch in either direction with the roof opening panel moving will cancel the one-touch
open operation.
With the roof opening panel glass in any OPEN position except VENT, rocking the roof opening panel control
switch forward and then releasing it will activate the one-touch close feature. Pressing the roof opening panel
control switch in either direction with the roof opening panel moving will cancel the one-touch close
operation and the motion will immediately stop. Near the end of the forward travel, the rear portion of the roof
opening panel glass moves upward on 2 lifter arms. This allows a weather-tight seal when the roof opening
panel glass is closed.
If an obstacle contacts the leading edge of the roof opening panel glass during one-touch close operation, the
roof opening panel glass will reverse direction and open to approximately the mid position and stop. The
operator cannot stop this open motion once it has begun.
If an obstacle contacts the rear edge of the roof opening panel glass during one-touch vent close operation, the
roof opening panel glass will reverse direction to the vent OPEN position.
When the roof opening panel glass is in the fully CLOSED position, pressing the roof opening panel control
switch forward and then releasing it will activate the one-touch vent feature. Pressing the roof opening panel
control switch in either direction with the roof opening panel moving will cancel the one-touch vent operation.
There is a one-touch vent close feature.
Global Open
Roof Opening Panel 878
When the unlock button of the Remote Keyless Entry (RKE) is held for 2 seconds, the SJB sends a signal on
the global open circuit, to both front door window motors and the roof opening panel motor, to open the
windows. If the accessory delay relay is active, the global open feature will not operate.
Roof Opening Panel Drain Hose Routing
Roof Opening Panel Drain Hose Routing 879
Panel
Manual
Roof Opening Panel
Special Tool(s)
Flex Probe Kit
Roof Opening Panel
The roof opening panel assembly uses an integrated motor and module to operate the roof opening panel. The
roof opening panel motor and module are installed new as an assembly. The roof opening panel is an
electronically operated glass panel that can be opened, closed or tilted by the roof opening panel switch.
Actuating the switch in either a forward or rearward motion supplies a ground to the roof opening panel
motor/module. The roof opening panel has one-touch open and one-touch close features that are activated
when the switch is momentarily pressed to the double detent OPEN or CLOSE position. These functions are
controlled by the roof opening panel motor/module.
The roof opening panel motor must be initialized whenever the roof opening panel motor has been removed
from the roof opening panel system, the roof opening panel assembly has been removed from the vehicle, a
new roof opening panel motor has been installed or a new roof opening panel assembly has been installed.
Global Open
When the unlock button of the Remote Keyless Entry (RKE) transmitter is held for 2 seconds, the global open
activates. The SJB sends a signal to activate the one-touch vent operation of the roof opening panel. The
global open feature does not operate if the delay accessory is active.
Verify the customer concern by operating the system. 1.
Roof opening panel
Roof opening panel frame
Roof opening panel drain hoses
Roof opening panel lifter
assemblies

Roof opening panel trough
Roof opening panel air deflector
assembly

Roof opening panel seal
Roof opening panel shield
(20A)

Smart Junction Box (SJB) fuse 41 (15A)
Circuitry
Roof opening panel motor and module
assembly

3.
If the concern is not visually evident, determine the symptom. GO to Symptom Chart - Roof Opening
Panel or GO to Symptom Chart - NVH .
4.
Symptom Chart - Roof Opening Panel
Symptom Chart - Roof Opening Panel
Symptom Chart - NVH
Symptom Chart - NVH
The roof opening panel has excessive wind noise
Incorrect adjustment
Roof opening panel weatherstrip/seals
Mechanism mistimed
GO to Pinpoint Test A .
The roof opening panel rattles
Roof opening panel
Roof opening panel tracks
Roof opening panel air deflector assembly
Roof opening panel lifter assemblies
Roof opening panel water trough guide
Headliner
Motor pad
Rear side brackets
GO to Pinpoint Test C .
The roof opening panel is noisy during operation
Roof opening panel
Roof opening panel tracks
Roof opening panel adjustment
Roof opening panel motor/module assembly
Pinpoint Tests
Pinpoint Test A: The Roof Opening Panel Has Excessive Wind Noise
Normal Operation
When the roof opening panel glass is completely closed, it is flush with the roof panel.
Incorrect roof opening panel alignment
Poorly fitting roof opening panel seal/weatherstrip
Incorrect installation of the roof opening panel and motor/module
Incorrect curvature of the air deflector
PINPOINT TEST A: THE ROOF OPENING PANEL HAS EXCESSIVE WIND NOISE
A1 VERIFY ROOF OPENING
PANEL NOISE
Road test the vehicle with the roof
opening panel in the CLOSED
and OPEN positions.

Is the wind noise present only in
the OPEN position?

Yes
GO to A4 .
No
GO to A2 .
A2 CHECK THE ROOF OPENING
PANEL WEATHERSTRIP
NOTE: Make sure the
weatherstrip is secured to the
glass, not cut, cracked, pinched,
loose or obstructed in CLOSED,
VENT and OPEN positions.
Check the roof opening panel
weatherstrip.

Is the roof opening panel
weatherstrip OK?

Yes
GO to A3 .
No
INSTALL a new roof opening panel weatherstrip. REFER to
Roof Opening Panel - Exploded View in this section. TEST
A3 CHECK ROOF OPENING
PANEL ALIGNMENT
alignment.

Is the alignment OK?
Yes
CHECK for correct installation of the roof opening panel and
motor/module. REFER to Roof Opening Panel - Exploded
View , Roof Opening Panel Frame and Roof Opening Panel
Motor in this section. TEST the system for normal operation.
No
ALIGN the roof opening panel. REFER to Roof Opening
Panel Alignment in this section. TEST the system for normal
operation.
A4 CHECK THE AIR DEFLECTOR
Make sure the air deflector is
securely attached.

Is the air deflector OK?
Yes
PARTIALLY CLOSE the roof opening panel until the noise
is eliminated. If the noise is eliminated, INFORM the
customer that changing glass location will eliminate the wind
noise. If the wind noise is not eliminated, INSTALL a new
air deflector. TEST the system for normal operation.
No
INSTALL new air deflector assembly. REFER to Roof
Opening Panel - Exploded View and Air Deflector in this
Pinpoint Test B: The Roof Opening Panel Leaks
Normal Operation
When the roof opening panel glass is completely closed, it is flush with the roof panel.
NOTE: Water may accumulate on both outside front corners of the glass panel after rain or after a car wash.
If the glass panel is opened with water in the front corners, this water will fall into the channel for the glass
panel track (which is not sealed) and down into the headliner. If the source of a suspected leak cannot be
determined, this situation may be the source. This is a normal condition, do not replace any part of the roof
opening panel system due to this condition.
Incorrect roof opening panel adjustments
Damaged roof opening panel drain hoses
Damaged roof opening panel seal/weatherstrip
Damaged roof opening panel frame
PINPOINT TEST A: THE ROOF OPENING PANEL HAS EXCESSIVE WIND NOISE 883
Incorrect position of the roof opening panel glass
PINPOINT TEST B: THE ROOF OPENING PANEL LEAKS
B1 CHECK THE ALIGNMENT OF
THE ROOF OPENING PANEL
NOTE: Make sure the roof
opening panel weatherstrip is not
cracked or loose.

weatherstrip.

Does the roof opening panel seal
correctly?

Yes
GO to B2 .
No
ALIGN the roof opening panel. REFER to Roof Opening
Panel Alignment in this section. TEST the system for normal
operation.
B2 CHECK THE ROOF OPENING
PANEL DRAIN HOSES
opening panel drain hoses are not
cracked, slit, pinched or
obstructed.

Check the 4 roof opening panel
drain hoses for correct operation.

Are the roof opening panel
drain hoses OK?

Yes
GO to B3 .
No
REPAIR or INSTALL a new roof opening panel drain
hose(s). TEST the system for normal operation.
PANEL DRAIN HOSE
ATTACHMENT POINTS
opening panel drain hose
attachment points are not
damaged or obstructed.

drain hose attachment points for
correct attachment.

drain hose attachment points
OK?

Yes
GO to B4 .
No
REPAIR or INSTALL a new roof opening panel frame.
REFER to Roof Opening Panel - Exploded View and Roof
Opening Panel Frame in this section. TEST the system for
normal operation.
PANEL REAR TROUGH
CONDITION
Check the roof opening panel rear
trough for damage.

Is the roof opening panel trough
OK?

Yes
GO to B5 .
No
REPAIR or INSTALL a new roof opening panel rear trough.
REFER to Roof Opening Panel - Exploded View , Roof
Opening Panel Frame and Trough Assembly in this section.
B5 CHECK THE CONDITION OF
THE ROOF OPENING PANEL
FRAME
frame for damage that may cause
the roof opening panel glass seal
to seat incorrectly.

Is the roof opening panel frame
OK?

Yes
INSTALL a new roof opening panel glass. REFER to Roof
Opening Panel - Exploded View and Roof Opening Panel
Glass in this section. TEST the system for normal operation.
No
REPAIR or INSTALL a new roof opening panel frame.
normal operation.
Pinpoint Test C: The Roof Opening Panel Rattles
Normal Operation
When the roof opening panel glass is completely closed, it is flush with the roof panel. All components should
be secured correctly.
Roof opening panel
Roof opening panel air deflector assembly
Headliner
Roof opening panel motor/module pad
Roof opening panel frame
PINPOINT TEST C: THE ROOF OPENING PANEL RATTLES
C1 CHECK THE ROOF OPENING PANEL
WEATHERSTRIP
NOTE: Make sure the weatherstrip is
secured to the glass, not cut, cracked,
pinched, loose or obstruct in CLOSED,
VENT and OPEN positions.

Check the roof opening panel weatherstrip.
Is the roof opening panel weatherstrip
OK?

Yes
GO to C2 .
No
INSTALL a new roof opening panel weatherstrip.
REFER to Roof Opening Panel - Exploded View
operation.
TIGHTNESS
Manually push up and fore/aft.
Is the roof opening panel loose?
Yes
ALIGN the roof opening panel. REFER to Roof
Opening Panel Alignment in this section. TEST
PINPOINT TEST B: THE ROOF OPENING PANEL LEAKS 885
No
GO to C3 .
TRACKS
Open the roof opening panel.
Check the roof opening panel tracks for
obstructions and damage.

Are the roof opening panel tracks OK?
Yes
GO to C4 .
No
REMOVE all the roof opening panel track
obstructions and REPAIR the roof opening panel
tracks. If the roof opening panel tracks cannot be
repaired, INSTALL a new roof opening panel
frame. REFER to Roof Opening Panel - Exploded
View and Roof Opening Panel Frame in this
TROUGH AND TROUGH GUIDES
Check the water roof opening panel trough
and trough guides for any loose obstructions.

Are the roof opening panel tugh and
trough guides installed securely and free
from obstructions?

Yes
GO to C5 .
No
REMOVE all obstructions from the roof opening
panel trough guides and INSTALL securely.
INSTALL a new roof opening panel frame if the
trough guides are damaged. REFER to Roof
Opening Panel - Exploded View and Roof
Opening Panel Frame in this section. TEST the
SHIELD (SUNSHADE)
Check the roof opening panel shield for
correct installation.

Is the roof opening panel shield installed
correctly?

Yes
GO to C6 .
No
INSTALL the roof opening panel shield correctly.
REFER to Roof Opening Panel Shield in this
AIR DEFLECTOR ASSEMBLY
Check the roof opening panel air deflector
assembly for obstructions and damage.

Is the roof opening panel air deflector
assembly OK?

Yes
GO to C7 .
No
REMOVE all obstructions and REPAIR or
INSTALL a new roof opening panel air deflector
assembly. REFER to Roof Opening Panel -
Exploded View and Roof Opening Panel Frame in
this secti. TEST the system for normal operation.
GLASS
PINPOINT TEST C: THE ROOF OPENING PANEL RATTLES 886
Verify the roof opening panel glass is free
from obstructions and damage, and is
securely fastened.

Is the roof opening panel glass OK?
Yes
GO to C8 .
No
REPAIR or INSTALL a new roof opening panel
glass. REFER to Roof Opening Panel - Exploded
View and Roof Opening Panel Glass in this
LIFTER ASSEMBLIES
Verify the roof opening panel lifter
assemblies are free from obstructions and
damage.

Are the roof opening panel lifter
assemblies OK?

Yes
GO to C9 .
No
REMOVE all obstructions from the roof opening
panel lifter assemblies and REPAIR any damage.
If the roof opening panel lifter assemblies cannot
be repaired, INSTALL a new roof opening panel
frame. REFER to Roof Opening Panel - Exploded
View and Roof Opening Panel Frame in this
C9 CHECK ROOF OPENING PANEL FRAME
INSTALLATION
Check all roof opening fasteners for correct
torque and verify correct installation of the
roof opening panel frame. Refer to Roof
Opening Panel Frame in this section.

Is the roof opening panel correctly
installed and tightened to specification?

Yes
GO to C10 .
No
TIGHTEN the loose fasteners or REINSTALL the
roof opening panel frame. REFER to Roof
Opening Panel Frame in this section. TEST the
FRAME FOR RATTLES
Check the roof opening panel frame
assembly for any loose parts or for any
condition that will cause rattles.

Is there a condition that will cause rattles?
Yes
INSTALL a suitable sound damper material to
correct the condition. If the rattle still persists,
INSTALL a new roof opening panel frame.
and Roof Opening Panel Frame in this section.
No
INSTALL a new roof opening panel frame.
and Roof Opening Panel Frame in this section.
Pinpoint Test D: The Roof Opening Panel is Noisy During Operation
PINPOINT TEST C: THE ROOF OPENING PANEL RATTLES 887
Normal Operation
The roof opening panel operates smoothly while opening and closing.
Obstructed or damaged roof opening panel
Obstructed or damaged roof opening panel lifter assemblies
Incorrect roof opening panel adjustment
Noisy roof openinnel motor/module assembly
PINPOINT TEST D: THE ROOF OPENING PANEL IS NOISY DURING OPERATION
D1 CHECK THE ROOF
OPENING PANEL FOR
OBSTRUCTIONS OR DAMAGE
for any obstructions and
damage.

Are there any obstructions
and/or damage?

Yes
REMOVE all obstructions. REPAIR any damage. If the damage
cannot be repaired, INSTALL a new roof opening panel frame.
normal operation.
No
GO to D2 .
D2 CHECK THE ROOF
OPENING PANEL OPERATION
durinoperation.

loose or incorrectly aligned?

Yes
ALIGN the roof opening panel. REFER to Roof Opening Panel
Alignment in this section. TEST the system for normal
operation.
No
GO to D3 .
D3 CHECK THE ROOF
OPENING PANEL TRACKS
Open the roof.
tracks for obstructions and
damage.

tracks OK?

Yes
GO to D4 .
No
REMOVE all obstructions and REPAIR any damage. If the roof
opening panel tracks cannot be repaired, INSTALL a new roof
opening panel frame. REFER to Roof Opening Panel - Exploded
View and Roof Opening Panel Frame in this section. TEST the
D4 CHECK THE ROOF
OPENING PANEL SHIELD
shield for correct movement.

Yes
GO to D5 .
No
shield moving correctly?
REMOVE and REINSTALL the roof opening panel shield.
REFER to Roof Opening Panel Shield in this section. TEST the
D5 CHECK THE ROOF
OPENING PANEL LIFTER
ASSEMBLIES
lifter assemblies for
obstructions and damage.

lifter assemblies OK?

Yes
GO to D6 .
No
REMOVE all obstructions and REPAIR any damage. If the roof
opening panel lifter assemblies cannot be repaired, INSTALL a
new roof opening panel frame. REFER to Roof Opening Panel -
Exploded View and Roof Opening Panel Frame in this section.
D6 CHECK THE ROOF
OPENING PANEL
MOTOR/MODULE
Remove the roof opening
panel motor/module and leave
the electrical connector
connected.

Operate the roof opening panel
to the full OPEN and CLOSED
position.

Does the motor/module make
excessive noise?

Yes
INSTALL a new roof opening panel motor/module. REFER to
Roof Openg Panel - Exploded View and Roof Opening Panel
Motor in this section. TEST the system for normal operation.
No
REINSTALL the roof opening panel motor/module. TEST the
system for normal operation. If the roof opening panel is still
noisy, INSTALL a new roof opening panel frame. REFER to
Roof Opening Panel - Exploded View and Roof Opening Panel
Frame in this section. If the roof opening panel is no longer
noisy, the system is operating correctly. The concern may have
been caused by an incorrectly installed roof opening panel
motor.
Pinpoint Test E: The Roof Opening Panel Does Not Open or Close
Refer to Wiring Diagrams Cell 101 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Roof Opening Panel for
The roof opening panel motor must be initialized whenever the roof opening panel motor has been removed
from the roof opening panel system, the roof opening panel assembly has been removed from the vehicle, a
new roof opening panel motor has been installed or a new roof opening panel assembly has been installed.
Refer to Roof Opening Panel Motor Initialization in this section.
Normal Operation
The roof opening panel motor/module receives voltage from the accessory delay relay when the ignition is in
the ACC or RUN position. The overhead console switch supplies ground signals to the roof opening panel
motor/module to operate the roof opening panel.
Fuse(s)
PINPOINT TEST D: THE ROOF OPENING PANEL IS NOISY DURING OPERATION 889
Roof opening panel motor/module assembly
Roof opening panel motor not initialized
PINPOINT TEST E: THE ROOF OPENING PANEL DOES NOT OPEN OR CLOSE
E1 CHECK THE ROOF OPENING PANEL
OPERATION
Ignition ON.
Attempt to operate the roof opening panel to
the VENT position.

Does the roof opening panel operate to the
VENT position?

Yes
GO to E2 .
No
GO to E3 .
E2 CHECK THE MOTOR/MODULE FOR
INITIALIZATION
Carry out the roof opening panel motor
initialization procedure. Refer to Roof
Opening Panel Motor Initialization in this
section.

Yes
GO to E3 .
No
The system is operating normally at this time. The
roof opening panel motor was not initialized.
E3 CHECK THE POWER WINDOWS
Ignition ON.
Verify the power windows operate.
Do the power windows operate?
Yes
GO to E4 .
No
accessory delay relay circuit.
SWITCH
Ignition OFF.
Disconnect: Roof Opening Panel Switch
C912.

Carry out the Roof Opening Panel Switch
component test.

Is the roof opening panel switch OK?
Yes
GO to E5 .
No
INSTALL a new roof opening panel switch.
REFER to Roof Opening Panel Control Switch in
operation.
E5 CHECK VOLTAGE TO THE ROOF
OPENING PANEL MOTOR/MODULE
Ignition OFF.
Disconnect: Roof Opening Panel
Motor/Module C921.

Ignition ON.
Measure the voltage between roof opening
panel motor/module C921-2, circuit CBP41
(BU) and C921-1, circuit SBB33 (RD),

Yes
GO to E6 .
No
VERIFY Smart Junction Box (SJB) fuse 41 (15A)
and Battery Junction Box (BJB) fuse 33 (20A) are
OK. If OK, REPAIR the circuit. TEST the system
operation.
GROUND
Ignition OFF.
Measure the resistance between roof opening
panel motor/module C921-4, circuit GD139
(BK/YE), harness side and ground.

Yes
GO to E7 .
No
operation.
E7 CHECK SWITCH COMMON CIRCUIT
FOR AN OPEN
Measure the resistance between overhead
console C912-4, circuit CPR39 (VT/WH)
and roof opening panel motor/module
C921-11, circuit CPR39 (VT/WH), harness
side.

Yes
CHECK the overhead console jumper harness for
loose pins, an open or a short in circuit CPR39
(VT/WH) between the roof opening panel switch
socket and overhead console C912-4. If the
overhead console jumper harness is not OK,
INSTALL a new overhead console jumper harness
and TEST the system for normal operation. If the
overhead console jumper harness is OK, GO to E8
.
No
operation.
PINPOINT TEST E: THE ROOF OPENING PANEL DOES NOT OPEN OR CLOSE 891
E8 CHECK SWITCH CLOSE CIRCUIT FOR
AN OPEN
console C912-7, circuit CPR40 (YE/OG) and
roof opening panel motor/module C921-6,
circuit CPR40 (YE/OG), harness side.

Yes
(YE/OG) between the roof opening panel switch
overhead console jumper harness is OK, GO to E9
.
No
operation.
E9 CHECK SWITCH OPEN CIRCUIT FOR
AN OPEN
console C912-3, circuit CPR31 (VT/BN) and
roof opening panel motor/module C921-5,
circuit CPR31 (VT/BN), harness side.

Yes
(VT/BN) between the roof opening panel switch
INSTALL a new overhead console jumper
harness, and TEST the system for normal
operation. If the overhead console jumper harness
is OK, GO to E10 .
No
operation.
E10 CHECK SWITCH AUTO CIRCUIT FOR
AN OPEN
console C912-2, circuit CPR38 (WH/BU)
and roof opening panel motor/module
C921-7, circuit CPR38 (WH/BU), harness
side.

Yes
(WH/BU) between the roof opening panel switch
overhead console jumper harness is OK, GO to
E11 .
No
operation.
PINPOINT TEST E: THE ROOF OPENING PANEL DOES NOT OPEN OR CLOSE 892
MOTOR/MODULE FOR CORRECT
OPERATION
Disconnect the roof opening panel
motor/module connector.

Check for:
corrosion.
bent or pushed-out pins.
Connect the roof opening panel
motor/module connector and make sure it
seats correctly.

still present.

Yes
INSTALL a new roof opening panel
motor/module. REFER to Roof Opening Panel
Motor in this section. TEST the system for normal
operation.
No
corroded connector. TEST the system for normal
operation.
Pinpoint Test F: The Global Open Function is Inoperative/Does Not Operate Correctly
Refer to Wiring Diagrams Cell 101 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Roof Opening Panel for
Normal Operation
When the global open feature is activated, the Smart Junction Box (SJB) sends a signal to the roof opening
panel motor to place the roof opening panel in the VENT position. The global open feature does not function
when the delayed accessory is active. Any interference in the circuit or the window motor may cause the
global open feature to not operate correctly.
Roof opening panel motor
SJB
Remote Keyless Entry (RKE) transmitters
Roof opening panel not initialized
Door window motor
PINPOINT TEST F: THE GLOBAL OPEN FUNCTION IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
NOTE: One-touch open must be operational for the global open function to operate correctly. Make sure the
one-touch open is operational before proceeding with this diagnostic.
F1 VERIFY THE POWER WINDOWS ARE
OPERATIONAL
Operate the power windows using the
global open procedure.

Do the power windows operate
correctly?

Yes
GO to F2 .
No
inoperative windows.
F2 CHECK LF DRIVER WINDOW MOTOR
Remove LF driver door window motor SJB
fuse 1 (30A).


Does the roof opening panel operate
correctly?

Yes
INSTALL a new LF driver window motor. REFER
to Section 501-11 . TEST the system for normal
operation.
No
REINSTALL SJB fuse 1 (30A). GO to F3 .
F3 CHECK RF PASSENGER WINDOW
MOTOR
Remove RF passenger door window motor
SJB fuse 4 (30A).


Does the roof opening panel operate
correctly?

Yes
INSTALL a new RF passenger window motor.
REFER to Section 501-11 . TEST the system for
normal operation.
No
REINSTALL SJB fuse 4 (30A). GO to F4 .
F4 CHECK GLOBAL OPEN CIRCUIT FOR
AN OPEN
Disconnect: Roof Opening Panel Motor
C921.

Measure the resistance between roof
opening panel motor C921-10, circuit
CPW01 (BN/BU), harness side and the
C2280C-10, circuit CPW01 (BN/BU),
harness side.

Yes
INSTALL a new roof opening panel motor. REFER
to Roof Opening Panel Motor in this section.
INITIALIZE the roof opening panel motor. REFER
to Roof Opening Panel Motor Initialization in this
No
REPAIR the circuit. INITIALIZE the roof opening
panel motor. REFER to Roof Opening Panel Motor
normal operation.
PINPOINT TEST F: THE GLOBAL OPEN FUNCTION IS INOPERATIVE/DOES NOT OPERATE CORRECTLY 894
PINPOINT TEST F: THE GLOBAL OPEN FUNCTION IS INOPERATIVE/DOES NOT OPERATE CORRECTLY 895
Panel
Manual
Roof Opening Panel Alignment
Open the roof opening panel to the VENT position. 1.
Loosen the 4 roof opening panel glass screws.
To access the glass screws, unclip the top portion of the concertina blind and position aside as
shown.

2.
Close the roof opening panel glass. 3.
NOTE: The correct position of the roof opening panel glass to the roof panel should be -1.50 mm to
0 mm (-0.059 to 0 in) at the front edge and 0 mm to 1.5 mm (0 to 0.059 in) at the rear edge of the roof
panel.
Make sure the roof opening panel is centered in the roof opening.
Adjust the roof opening panel glass.
4.
Tighten the 4 roof opening panel glass screws to 6 Nm (53 lb-in). 5.
Roof Opening Panel Alignment 896
Open roof opening panel to the VENT position. 6.
Reattach the concertina blind making sure that it is fully seated on the 3 clips in the roof panel glass. 7.
Roof Opening Panel Alignment 897
Panel
Manual
Roof Opening Panel Motor Initialization
WARNING: Keep objects and body parts clear of the glass panel when carrying out the
initialization procedure. During the initialization procedure, the glass panel closes with high force and
cannot detect objects in its path. Failure to follow this instruction may result in serious personal injury.
NOTE: A new roof opening panel motor must be initialized after installation. It will only move toward the
VENT position until initialized.
NOTE: The roof opening panel motor initialization procedure must be done when repairs are carried out on
any part of the roof opening panel system, including: any time the roof opening panel motor has been
removed from the roof opening panel assembly, a new roof opening panel motor has been installed or when a
new roof opening panel assembly has been installed.
Turn the ignition to the RUN position. 1.
For a new roof opening panel motor, press and hold the roof opening panel control switch forward
until the roof opening panel glass moves to the full VENT position.
2.
NOTE: Make sure the front door is open during this step.
Cycle the ignition from ON to OFF and then back to ON.
3.
Within 5 seconds:
press and release the roof opening panel control switch forward.
press and hold the roof opening panel control switch forward.
4.
Continue holding the roof opening panel control switch forward for 5 seconds after the roof opening
panel motor stops moving to confirm this position to the roof opening panel motor.
5.
NOTE: Only complete open and close motions count towards the cycle count. If the roof opening
panel reverses during closing operations, perform the cycles with the roof opening panel control
switch continuously held during the closing motions.
Release the roof opening panel switch and test the system for normal operation by checking the
one-touch open, one-touch close, one-touch vent and close operations. Five complete cycles must be
carried out for the roof opening panel motor to be correctly initialized.
If the roof opening panel does not operate correctly, repeat Steps 2 through 6.
6.
Roof Opening Panel Motor Initialization 898
Roof Opening Panel Motor Initialization 899
Panel
Manual
Timing Adjustment
NOTE: Anytime a roof opening panel motor is removed, the cables/mechanisms can experience free-play
movement. It is important that the cables do not move. They are timed to be parallel with each other. If one or
both are moved in either direction, they must be re-timed.
Remove the roof opening panel glass. For additional information, refer to Roof Opening Panel Glass
in this section.
1.
Remove the roof opening panel motor. For additional information, refer to Roof Opening Panel Motor
in this section.
2.
Using a flat-blade screwdriver, push on the back of the drive slide until it contacts the timing screw.
Repeat on other side.
3.
Reinstall the roof opening panel motor, but do not carry out the roof opening panel motor
initialization. For additional information, refer to Roof Opening Panel Motor in this section.
4.
Reinstall the roof opening panel glass. For additional information, refer to Roof Opening Panel Glass
in this section.
5.
Operate the roof opening panel to the full VENT position and hold for 6 seconds. 6.
Initialize the roof opening panel motor. For additional information, refer to Roof Opening Panel
Motor Initialization in this section.
7.
Timing Adjustment 900
Timing Adjustment 901
Panel
Manual
Roof Opening Panel - Exploded View
Item
Part
Number Description
1 500A66 Concertina blinds (2 required)
2 - Roof opening panel glass screw (4 required) (part of
roof opening panel glass)
3 54500A18 Roof opening panel glass
4 5451884 Roof opening panel glass seal
5 54500A26 Roof opening panel air deflector
6 7854022 Roof opening panel trough
7 54519A02 Roof opening panel shield
8 - Roof opening panel motor screw (3 required) (part of
roof opening panel motor)
9 15B689 Roof opening panel motor
10 502C52A Front drain hoses
11 502C52B Rear drain hoses
12 W302325 Roof opening panel frame bolt (8 required)
13 54502C22 Roof opening panel frame
14 - Air deflector screws (part of roof opening panel air
deflector)
For additional informatioo the individual procedures in this section. 1.
Roof Opening Panel - Exploded View 902
Roof Opening Panel - Exploded View 903
Panel
Manual
Roof Opening Panel Glass
Open the roof opening panel to the VENT position. 1.
Remove the 4 roof opening panel glass screws.
To access the glass screws, unclip the top portion of the concertina blind and position aside as
shown.

2.
Verify that the roof opening panel glass is centered and aligned before tightening the roof
opening panel glass screws. For additional information, refer to Roof Opening Panel
Alignment in this section.

Initialize the roof opening panel motor. For additional information, refer to Roof Opening
Panel Motor Initialization in this section.

3.
Roof Opening Panel Glass 904
Panel
Manual
Roof Opening Panel Shield
in this section.
1.
Remove the trough assembly. For additional information, refer to Trough Assembly in this section. 2.
Slide the roof opening panel shield forward halfway. 3.
Disengage the roof opening panel shield guide feet.
Lift the front portion of the roof opening panel shield upward at center until able to disengage
one of the front guide feet.

4.
With one of the guide feet released, carefully rotate the roof opening panel in a clockwise manner to
disengage the remaining guide feet.
5.


6.
Roof Opening Panel Shield 905
Roof Opening Panel Shield 906
Panel
Manual
Roof Opening Panel Motor
NOTE: Anytime a roof opening panel motor is removed, the cables/mechanisms can experience free-play
movement. It is important that the cables do not move. They are timed to be parallel with each other. If one or
both are moved in either direction, they must be re-timed.
Close the roof opening panel glass. 1.
Remove the 4 passenger assist handles. 2.
Remove the A-pillar trim panels. For additional information, refer to Section 501-05 . 3.
Remove the B-pillar trim panels. For additional information, refer to Section 501-05 . 4.
Remove the C-pillar trim panels. For additional information, refer to Section 501-05 . 5.
6.
If equipped, disconnect the automatic-dimming rear view mirror electrical connector. 7.
If equipped, disconnect the windshield rain sensor electrical connector. 8.
Remove the sun visors and the sun visor clips.
If equipped, disconnect the electrical connectors.
9.
Remove the 2 headliner pushpins at the rear. 10.
Remove the interior lamp.
11.
Position the headliner forward to gain access to the roof opening panel motor. 12.
Remove the 3 roof opening panel motor screws and the roof opening panel motor.
13.

14.
Roof Opening Panel Motor 907
Roof Opening Panel Motor 908
Panel
Manual
Air Deflector
Position the roof opening panel glass to the full OPEN position. 1.
Disengage the front portion of the roof opening panel air deflector. Remove the 2 screws.
2.
Lift upward and pull to unlock the spring on each side to remove the air deflector assembly. 3.

4.
Air Deflector 909
Panel
Manual
Roof Opening Panel Frame
NOTE: If installing a new roof opening panel frame, the following components will need to be transferred
from the original assembly: concertina blinds, roof opening panel glass, roof opening panel air deflector, roof
opening panel trough, roof opening panel shield, roof opening panel motor, front and rear drain hoses.
Remove the roof opening panel glass. Refer to Roof Opening Panel Glass . 1.
If installing a new roof opening panel frame, transfer all components from the original assembly to be
installed on the new opening panel frame. Refer to Roof Opening Panel - Exploded View .
2.
Remove the headliner. For additional information, refer to Section 501-05 . 3.
Disconnect the 4 roof opening panel drain hoses. 4.
Remove the 8 roof opening panel frame bolts and remove the roof opening panel frame.
To install tighten to 12 Nm (106 lb-in).
6.

7.
Roof Opening Panel Frame 910
Panel
Manual
Trough Assembly
in this section.
1.
Remove the trough assembly.
Pull the trough assembly arms outward to release the trough assembly guide arm pins from
the roof opening panel frame to remove.

2.


3.
Trough Assembly 911
Panel
Manual
Roof Opening Panel Control Switch
1 54519A70 Overhead console
2 - Overhead console electrical connectors
3 15B69 Roof opening panel control switch
Open the storage compartment cover and remove the 2 screws. 1.
Disconnect the overhead console electrical connectors. 2.
Disengage the clips and remove the switch from the overhead console. 3.
Roof Opening Panel Control Switch 912
SECTION 501-19: Bumpers 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop Manual
Front bumper bolts 25 18 -
Rear bumper bolts 25 18 -
Rear bumper nuts 25 18 -
Rear bumper stud 15 - 133
SECTION 501-19: Bumpers
Manual
REMOVAL AND
INSTALLATION
Bumper - Exploded View, Front
Fusion
1 W711676 Upper radiator grille bolt (4 required)
2 N807389 Upper radiator grille pin-type retainer (2
required)
3 W709976 Lower air deflector screw (4 required)
4 N807389 Fender splash shield pin-type retainer (6
required)
7 W704277 Lower air deflector clip (part of 8327) (4
required)
9 N807389 Lower air deflector pin-type retainer (4
required)
10 W709976 Fender splash shield screw (6 required)
11 W711676 Bumper cover mounting bracket front bolt
12 17D958 LH/ 17D959
RH
Bumper cover mounting bracket
13 N808650 Bumper cover mounting bracket rear bolt
Bumper - Exploded View, Front 915
MKZ
1 W711676 Upper radiator grille bolt (2 required)
2 N807389 Upper radiator grille pin-type retainer (2
required)
required)
6 N807389 Lower air deflector pin-type retainer (4
required)
8 W709976 Fender splash shield screw (6 required)
9 N808650 Bumper cover mounting bracket rear bolt
10 17D958 LH/ 17D959
RH
Bumper cover mounting bracket
11 W711676 Bumper cover mounting bracket front bolt
Fusion 916
MKZ 917
Manual
REMOVAL AND
INSTALLATION
Bumper Cover - Front
All vehicles
100-02 .
1.
Remove the 6 pin-type retainers (3 each side). 2.
Remove the 6 fender splash shield screws (3 each side). 3.
Remove the 4 lower air deflector screws. 4.
If equipped, disconnect the fog lamp electrical connectors. 5.
Remove the 2 bolts and the 2 pin-type retainers from the top of the radiator grille. 6.
Fusion only
Remove the 4 bolts and 2 pin-type retainers from the top of the radiator grille. 7.
All vehicles
NOTE: The rearward upper portion of the bumper cover must be pulled outward to unclip it from the
bumper cover mounting bracket.
Remove the front bumper cover.
8.
Bumper Cover - Front 918
Bumper Cover - Front 919
Manual
REMOVAL AND
INSTALLATION
Bumper - Front
1 17C882 Front bumper isolator
2 N811479 Front bumper mounting bolts (8 required)
3 17757 Front bumper
Remove the front bumper cover. For additional information, refer to Bumper Cover - Front in this
section.
1.
Remove the front bumper isolator from the front bumper.
Pull the isolator rearward while releasing the retainers.
2.
Remove the 8 front bumper bolts (4 each side).
3.
Remove the front bumper. 4.
Bumper - Front 920
Bumper - Front 921
Manual
REMOVAL AND
INSTALLATION
Bumper - Exploded View, Rear
Fusion
1 N807389 Rear bumper cover pin-type retainer (2
required)
2 N806034 Rear bumper cover screw (2 required)
3 17K835 Rear bumper cover
4 N807389 Rear bumper cover valence pin-type retainer (2
required)
5 17808 Rear bumper cover valence
required)
7 N806034 Rear bumper cover bracket screw (4 required)
8 17D948 LH/ 17D949
RH
Rear bumper cover bracket
9 - Rear parking assist electrical connectors (part
of 14N139)
MKZ
Bumper - Exploded View, Rear 922
1 N807389 Rear bumper cover pin-type retainers (4
required)
2 N806034 Rear bumper cover screws (2 required)
3 17K835 Rear bumper cover
required)
5 - Rear parking assist electrical connectors (part
of 14N139)
6 N806034 Rear bumper cover bracket screw (4 required)
7 17D948 LH/ 17D949
RH
Rear bumper cover bracket
MKZ 923
MKZ 924
Manual
REMOVAL AND
INSTALLATION
Bumper Cover - Rear
Remove the rear lamp assemblies. For additional information, refer to Section 417-01 . 1.
Remove the 6 pin-type retainers (3 each side) from the rear splash shield. 2.
Remove the 2 pin-type retainers from the lower rear bumper cover. 3.
Remove the 2 bolts and 2 pin-type retainers from the top of the rear bumper cover.
Remove the 2 bolts (1 shown). 1.
Remove the 2 pin-type retainers (1 shown). 2.
4.
Remove the 2 upper bumper cover screws (1 each side). 5.
If equipped, disconnect the license plate lamp electrical connector. 6.
NOTE: The forward upper portion of the bumper cover must be pulled outward to unclip it from
theper cover mounting bracket.
Reposition the bumper cover.
Pull outward on both sides of the bumper cover.
7.
If equipped, disconnect the parking aid system electrical connector. 8.
Route the wiring harness out of the body. 9.
Remove the rear bumper cover. 10.
Bumper Cover - Rear 925
Bumper Cover - Rear 926
Manual
REMOVAL AND
INSTALLATION
Bumper - Rear
1 N811479 Rear bumper bolt (4 required)
2 W709361 Rear bumper nut (2 required)
3 17906 Rear bumper
4 17787 Rear bumper isolator
5 N808889 Rear bumper stud (2 required)
Remove the rear bumper cover. For additional information, refer to Bumper Cover - Rear in this
section.
1.
Remove the rear bumper isolator from the rear bumper.
Pull the isolator rearward to remove it from the retaining pins.
2.
Remove the 2 rear bumper nuts.
3.
Remove the 4 rear bumper bolts.
4.
Remove the rear bumper. 5.
tall, reverse the removal procedure. 6.
Bumper - Rear 927
Bumper - Rear 928
SECTION 501-20A: Safety Belt System
Workshop Manual
Front Safety Belts
D-ring bolt 40 30 -
Front safety belt buckle bolt 40 30 -
Safety belt retractor anchor bolt 40 30 -
Safety belt retractor and pretensioner bolt (lower) 40 30 -
Safety belt retractor and pretensioner bolt (upper) 10 - 89
Safety belt shoulder height adjuster bolt 40 30 -
Second Row Safety Belts
Center safety belt anchor bolt 48 35 -
Center safety belt retractor bolt 40 30 -
Child safety seat tether anchor bolts 28 21 -
Rear outboard safety belt anchor bolt 48 35 -
Rear outboard safety belt retractor boltop" align="center">40 30 -
Rear safety belt buckle bolt 48 35 -
Bumper - Rear 929
SECTION 501-20A: Safety Belt
System
Manual
Safety Belt System
WARNING: After a crash, the following safety belt components and attaching hardware must be
inspected and tested to verify correct function:
Retractors
Buckles
Child safety seat tether bracket assemblies
Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only)
Belt tension sensor (BTS) (if equipped)
Front safety belt buckle support assemblies (slide bar) (if equipped)
Safety belt shoulder belt height adjusters (if equipped)
Components that do not operate correctly or pass all Functional Tests in the Component Tests of this section
must be replaced with new components.
Safety belt assembly attaching areas must be inspected. Damaged or distorted attaching areas must be restored
to their original structural integrity and a new safety belt assembly with new attaching hardware must be
installed.
After deployment of the front safety belt pretensioners, a new safety belt system (including retractors, buckles
and height adjusters) must be installed.
Failure to follow this instruction may result in incorrect operation of the safety belt system and increases the
risk of serious personal injury or death in a crash.
When installing any new active occupant restraint components, use only Ford specified service parts.
The active restraint system consists of the following serviceable items:
Front safety belt shoulder height adjusters
Front row safety belt buckles attached to the inboard side of the seats
Front row safety belt retractors and pretensioners located behind the lower B-pillar trim panels
Rear center safety belt retractor, attached to the parcel shelf sheet metal and LH safety belt buckle
assembly, attached to the floor pan under the rear seat cushion

Rear dual safety belt buckle assembly, attached to the floor pan under the seat cushion
Child safety seat tether anchors attached to the parcel shelf sheet metal at all 3 rear seating positions
Lower anchors and tethers for children serviced with the rear seat backrest pivot assemblies
The lower anchors and tethers for children at the inboard side of the LH rear seat position is welded to the
floor pan below the rear seat cushion and is not serviceable.
Safety Belt Retractors
The safety belt retractors consist of the following features:
Safety belt pretensioner (front only)
Dual locking mode
Emergency Locking Retractor (ELR)

Safety Belt System 930
Automatic Locking Retractor (ALR) (all except driver seat)
Safety Belt Retractor and Pretensioner
The pretensioner is a pyrotechnic device that deploys when activated by the Restraints Control Module
(RCM) to remove excess safety belt webbing from the shoulder and lap safety belt in the event of an impact.
If a deployment of the safety belt retractor and pretensioners occurs, a new assembly must be installed. Refer
to Safety Belt Retractor and Pretensioner in this section.
For safety belt retractor and pretensioner diagnostic and disposal information, refer to Section 501-20B .
Emergency Locking Retractor (ELR)
The ELR is a vehicle sensitive feature designed to activate and lock the safety belt webbing when braking
hard, cornering hard or in an impact of approximately 8 km/h (15 mph). The ELR feature helps to reduce the
forward movement of the driver and passengers. For testing, refer to the appropriate Functional Test
procedure in Safety Belt System in this section.
Automatic Locking Retractor (ALR)
The ALR mode is used when locking a child seat in an outboard seating position. The ALR mode is
automatically activated when the safety belt webbing is fully extracted from the retractor and then allowed to
retract. As the safety belt webbing is retracted back onto the spool, an audible clicking sound is made
indicating the safety belt retractor is in ALR mode and the safety belt webbing will not pull back out of the
safety belt retractor. To disengage the ALR mode, allow the safety belt webbing to fully retract back onto the
spool. The ALR mode is disengaged when the webbing is free to extract and retract back into the retractor.
For testing, refer to the appropriate Functional Test procedure in Safety Belt System in this section.
Safety Belt Buckles
The front seat safety belt buckles are attached to the front seat tracks.
The rear dual seat safety belt buckles are attached to the floor pan behind the rear seat cushion.
Child Safety Seat Restraints
The child safety seat restraints include the following items:
Child safety seat tether anchors located at each second row seating position attached to the parcel
shelf.

Non-serviceable lower anchors and tethers for children system located at the outboard seating
positions and is a structural member of the seat frame and floor pan beneath the rear seat cushion.

If a child safety seat was in use during a collision, inspect the child safety seat component mounting areas and
repair any damage and restore the vehicle to the original production configuration.
System
Manual
Safety Belt System
Retractors
Buckles
installed.
Safety Belt Warning System
The safety belt warning indicator illuminates and a chime sounds to remind the occupants to fasten their
safety belts.
The conditions of operation for the safety belt warning indicator and chime are as follows:
If the driver and/or front passenger safety belt is not buckled before the ignition switch is turned to
ON, the safety belt warning indicator illuminates for 1 to 2 minutes and the warning chime sounds for
4 to 8 seconds.

If the driver and/or front passenger safety belt is buckled while the warning indicator is illuminated
and the warning chime is sounding, the safety belt warning indicator and warning chime turn off.

If the driver and/or front passenger safety belt is buckled before the ignition switch is turned to ON,
the safety belt warning indicator and warning chime remain off.

Belt-Minder
The Belt-Minder feature is a supplemental warning to the safety belt warning function. This feature provides
additional reminders to the driver that the driver and/or front passenger safety belt is unbuckled by
intermittently sounding a chime and illuminating the safety belt warning indicator in the Instrument Panel
Cluster (IPC).
Either the driver or front passenger safety belt systems may activate the Belt-Minder. If the Belt-Minder
warnings have expired (warnings for approximately 5 minutes) for one occupant (driver or front passenger),
the other occupant can still activate the Belt-Minder feature.
When a MyKey
TM
is in the ignition, deactivation of the Belt-Minder will be ignored. The Belt-Minder
feature can be activated or deactivated by the administrator key. Using a MyKey
TM
(non-administrator key)
will override the 5-minute Belt-Minder timer and the deactivation of the Belt-Minder feature. Refer to
Section 419-01B or the Owner's Literature for further information on MyKey
TM
functionality.
The passenger Belt-Minder feature is activated only when the Occupant Classification Sensor (OCS) system
detects a passenger front seat and the passenger weight exceeds a programmed limit. For information on the
OCS system, refer to Section 501-20B .
To activate or deactivate the Belt-Minder feature, refer to Section 413-01 .
If... Then...
the driver and/or front passenger safety belt is buckled
before the ignition switch is turned to the ON position
or less than 1-2 minutes have elapsed since the ignition
switch has been turned ON...
the Belt-Minder feature will not activate.
the driver and/or front passenger safety belt is not
buckled before the vehicle has reached at least 5 km/h
(3 mph) and 1-2 minutes have elapsed since the
ignition switch has been turned to ON...
the Belt-Minder feature is activated - the safety belt
warning indicator illuminates and the warning chime
sounds for 6 seconds every 30 seconds, repeating for
approximately 5 minutes or until the safety belt(s) is
buckled.
the driver or front passenger safety belt becomes
unbuckled for approximately 1 minute while the
vehicle is traveling at least 5 km/h (3 mph) and more
than 1-2 minutes have elapsed since the ignition switch
has been turned to ON...
the Belt-Minder feature is activated - the safety belt
warning indicator illuminates and the warning chime
sounds for 6 seconds every 30 seconds, repeating for
approximately 5 minutes or until the safety belt(s) is
buckled.
Verify the customer concern by operating the active restraint system to duplicate the condition. 1.
Inspect to determine if any of the following mechanical or electrical concerns apply: 2.
Cut, frayed or incorrectly routed safety belt
webbing
Safety belt buckle and tongue assembly
Safety belt retractor
Safety belt warning indicator burned out or
broken

High Speed Controller Area Network
(HS-CAN) network concern

If the inspection reveals an obvious concern(s) that can be readily identified, service as required. With
the exception of removing a twist from the safety belt webbing, do not attempt to repair a component
of the safety belt system; new componenst be installed.
3.
If the concern remains after the inspection, determine the symptom. GO to Symptom Chart . 4.
To check the active restraint system for correct operation, carry out the appropriate Functional Test(s). 5.
Symptom Chart
Symptom Chart
Component Test
Retractors
Buckles
installed.
Carry out the appropriate Functional Test(s) as determined in Inspection and Verification.
Functional Test - Buckle and Tongue
The safety belt buckle and tonguessembly must operate freely during the latching and unlatching function.
Fasten the safety belt by inserting the tongue (male portion) into the buckle (female portion).
Verify the following during the latching sequence:
Tongue insertion is not hindered by excessive effort.
A click is heard when the safety belt buckle latches the tongue.
1.
Verify the system integrity by forcefully pulling on the safety belt webbing. 2.
Unlatch the safety belt by fully depressing the safety belt buckle release button and allowing the
safety belt to release and retract.
3.
Verify the following during the unlatching process:
Push-button depression does not require excessive effort.
The tongue can be removed easily from the buckle.
4.
Repeat the above steps 3 times. 5.
If the functional test reveals a concern(s), install a new safety belt buckle or safety belt retractor as
required.
6.
Functional Test - Safety Belt Retractor
The safety belt retractor must be freely operational for extraction and retraction of the safety belt webbing
between full extension and in-vehicle stowed positions.
Extract and retract the safety belt between the full extension and stowed positions. 1.
Verify the safety belt retractor operates without excessive effort or binding. 2.
Install a new safety belt retractor if any concern is found or the complaint has been verified. 3.
Functional Test - Safety Belt Retractor, Automatic Locking Retractor (ALR) Mode
Position the seat backrest fully upright (if adjustable). 1.
Fasten the safety belt. 3.
Pull out the safety belt webbing until the ALR feature is activated. 4.
Allow the safety belt webbing to retract until it stops. 5.
Pull on the safety belt webbing to check that the safety belt retractor has remained in the ALR mode.
If the safety belt retractor is not locked, install a new safety belt retractor.
6.
Unfasten the safety belt and allow the safety belt webbing to retract to its stowed position. 7.
Pull out and retract the safety belt webbing to verify the safety belt retractor has converted
automatically out of ALR mode. If the safety belt retractor remains locked in the ALR mode, install a
new safety belt retractor.
8.
Functional Test - Safety Belt Retractor, Road Test Inspection
WARNING: The driver and passenger must be prepared brace themselves in the event the safety
belt retractor does not lock. Failure to follow this instruction may result in serious personal injury.
NOTE: Make sure there is no excessive slack in the safety belt webbing across the torso during testing.
NOTE: Do not jerk on the safety belt webbing when carrying out this test.
Test the safety belts in the following sequence:
Fasten the safety belts and proceed to a safe area. 1.
Attain a speed of 24 km/h (15 mph). 2.
WARNING: Apply maximum brake force only on dry concrete or equivalent hard
surface, NEVER on wet pavement or gravel. Failure to follow this instruction may
Grasp the shoulder harness, lean forward and apply the brakes, making a maximum braking
application without a skid.
3.
The safety belts should lock up with minimum webbing extension. 4.
If there is a lockup of all safety belt retractors being tested, the safety belt retractors are
functioning correctly. If any safety belt retractor fails to lock up, install a new safety belt
retractor(s).
5.
1.
System
Manual
Safety Belt Cleaning
WARNING: Do not bleach or re-dye the safety belt webbing, as the webbing may weaken.
Failure to follow this instruction may increase the risk of serious personal injury or death in a
crash.
Clean the safety belt webbing only with a mild soap solution recommended for cleaning upholstery or
carpets. Follow the instructions provided with the soap.
1.
Safety Belt Cleaning 938
System
Manual
Safety Belt Maintenance
Retractors
Buckles
installed.
The safety belt assemblies should be periodically inspected to make sure that they have not become
damaged and that they remain in correct operating condition, particularly if they have been subjected
to severe stress.
1.
Before installing the new safety belt assembly, the safety belt retaining areas must be inspected for
damage and distortion. If the retaining points are damaged and distorted, the sheet metal must be
reworked back to its original shape and structural integrity.
2.
Install the new safety belt(s) using the appropriate instructions. Carry out the appropriate Functional
Test Procedure. For additional information, refer to the appropriate Functional Test procedure in
Safety Belt System , Component Test, in this section.
3.
Safety Belt Maintenance 939
Safety Belt Maintenance 940
System
Manual
Safety Belt Procedure After a Collision
Retractors
Buckles
installed.
Before installing a new safety belt assembly, the safety belt attaching areas must be inspected for
damage and distortion. If the attaching points are damaged and distorted, the sheet metal must be
worked back to its original shape and structural integrity.
1.
Install the new safety belt(s). For additional information, refer to the appropriate procedure in this
section. Carry out all applicable Functional Tests for the component(s). For additional information,
refer to the appropriate Functional Test procedure in Safety Belt System in this section.
2.
Safety Belt Procedure After a Collision 941
Safety Belt Procedure After a Collision 942
System
Manual
Safety Belt Tongue Rotated on Belt
Fold the safety belt as indicated. 1.
Pull the safety belt tongue over the fold in the safety belt. 2.
Safety Belt Tongue Rotated on Belt 943
System
Manual
Safety Belt Twisted at the Safety Belt Guide
NOTE: Typical D-ring shown, others similar.
Grasp the belt webbing at the shoulder belt guide (D-ring). 1.
Rotate and fold the belt webbing over itself to remove the twist. 2.
Feed the folded portion of the belt through the safety belt guide (D-ring). 3.
Safety Belt Twisted at the Safety Belt Guide 944
Workshop Manual
Safety Belt Retractor and Pretensioner
1 - Bolt, D-ring (part of 611B09 LH/ 611B08 RH)
2 60262 Cover, D-ring
3 W505253 Bolt, safety belt retractor (upper)
5 W700883 Bolt, safety belt retractor and pretensioner
(lower)
6 - Bolt, safety belt retractor anchor (part of 611B08
RH/ 611B09 LH)
7 611B08 RH/
611B09 LH
Safety belt retractor and pretensioner
Retractors
Buckles
Safety Belt Retractor and Pretensioner 945
installed.
After deployment of the front safet pretensioners, a new safety belt system (including retractors, buckles and
height adjusters) must be installed.
WARNING: Never disassemble or tamper with safety belt buckle/retractor pretensioners, adaptive
load limiting retractors, safety belt inflators, or probe the electrical connectors. Failure to follow this
instruction may result in the accidental deployment of the safety belt pretensioners, adaptive load
limiting retractors, or safety belt inflators, which increases the risk of serious personal injury or death.
Depower the SRS . For additional information, refer to Supplemental Restraint System (SRS)
1.
NOTE: Inspect the D-ring cover for damage. If the cover is damaged or does not remain attached,
install a new D-ring cover.
Remove the D-ring cover.
2.
Remove the bolt and D-ring.
3.
Remove the lower B-pillar trim panel. For additional information, refer to Section 501-05 . 4.
Remove the safety belt retractor anchor.
For passenger seat, remove the seat side shield cover.
Remove the bolt and safety belt retractor anchor.

5.
Remove the upper bolt.
7.
Remove the lower bolt and safety belt retractor and pretensioner.
8.
NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and
buckles are accessible to the occupants.
9.
Repower the SRS . For additional information, refer to Supplemental Restraint System (SRS)
10.
Check the active restraint system for correct operation. For additional information, refer to the
appropriate Functional Test procedure in Safety Belt System in this section.
11.
Workshop Manual
Safety Belt Retractor - Rear, Center
1 611B66 Rear center safety belt retractor
2 - Bolt, safety belt retractor (part of 611B66)
3 - Bolt, safety belt anchor (part of 611B66)
Retractors
Buckles
Safety belt assembly attaching areas mustected. Damaged or distorted attaching areas must be restored to their
original structural integrity and a new safety belt assembly with new attaching hardware must be installed.
Safety Belt Retractor - Rear, Center 948
2.
Remove the bolt and center safety belt retractor.
3.
4.
5.
Safety Belt Retractor - Rear, Center 949
Workshop Manual
Safety Belt Retractor - Rear, Outboard
1 - Bolt, safety belt retractor (part of 611B68)
2 611B68 Safety belt retractor assembly
3 - Bolt, safety belt anchor (part of 611B68)
Retractors
Buckles
must be replaced with new components. r>Safety belt assembly attaching areas must be inspected. Damaged
or distorted attaching areas must be restored to their original structural integrity and a new safety belt
assembly with new attaching hardware must be installed.
Safety Belt Retractor - Rear, Outboard 950
2.
Remove the bolt and safety belt retractor.
3.
4.
5.
Safety Belt Retractor - Rear, Outboard 951
Workshop Manual
Safety Belt Shoulder Height Adjuster
1 602B82 Safety belt shoulder height adjuster
2 - Bolt (part of 602B82)
Retractors
Buckles
installed.
Remove the upper B-pillar trim panel. For additional information, refer to Section 501-05 . 1.
Position the safety belt shoulder height adjuster down and remove the bolt.
2.
Safety Belt Shoulder Height Adjuster 952
NOTE: When installing the safety belt shoulder height adjuster, the lower T-tab must be engaged into
the body prior to installing the bolt.
Remove the safety belt shoulder height adjuster.
Rotate the safety belt shoulder height adjuster downward to release the lower tab. 1.
Remove the safety belt shoulder height adjuster. 2.
3.
4.
5.
Safety Belt Shoulder Height Adjuster 953
Workshop Manual
Safety Belt Buckle - Front
1 61203 LH/ 61202 RH Safety belt buckle
3 - Bolt (part of 61203 LH/ 61202 RH)
Retractors
Buckles
Safety belt assembly attaching areas must cted. Damaged or distorted attaching areas must be restored to their
original structural integrity and a new safety belt assembly with new attaching hardware must be installed.
Safety Belt Buckle - Front 954
All seats
Remove the seat. For additional information, refer to Section 501-10 . 1.
Release the retainer on the side of the seat cushion cover to remove the wire for the safety belt
buckle switch.

2.
Remove the bolt.
3.
Remove the safety belt buckle through the opening in the seat cushion cover. 4.
For correct installation, make sure the safety belt buckle is routed through the seat cushion
cover.

5.
Install the seat. If the passenger seat has been serviced, do not prove out the SRS at this time. For
6.
Passenger seat
Carry out the Occupant Classification Sensor (OCS) System Reset. For additional information, refer
to General Procedures in Section 501-20B .
7.
All seats
8.
Safety Belt Buckle - Front 955
Workshop Manual
Safety Belt Buckle - Rear
1 - Bolt (part of 60044)
2 60044 RH and center safety belt buckle assembly
Retractors
Buckles
to their original structural integrity and a new safety belt assembl new attaching hardware must be installed.
NOTE: The LH safety belt buckle is a part of the center safety belt retractor assembly and is not serviced
separately. To remove the LH safety belt buckle, refer to Safety Belt Retractor - Rear, Center in this section.
Remove the rear seat cushion. For additional information, refer to Section 501-10 . 1.
Safety Belt Buckle - Rear 956
Remove the bolt and dual safety belt buckle assembly.
2.
NOTE: The anti-rotation tab of the safety belt anchor buckle assembly must be correctly aligned
before tightening fastener for correct installation.
3.
Check the active restraint system for correct operation. For addition information, refer to the
4.
Safety Belt Buckle - Rear 957
Workshop Manual
Child Safety Seat Tether Anchor
1 - Bolts (part of 613D26)
2 613D26 Safety seat tether anchors
Retractors
Buckles
installed.
Open the cover and remove the bolt and child safety seat tether anchor.
1.
Child Safety Seat Tether Anchor 958
WARNING: Always tighten the child safety seat tether anchor/bolt to specification. Failure to
follow this instruction may result in the child's safety seat being incorrectly secured, which
increases the risk of serious personal injury or death to the child in a sudden stop or crash.
2.
3.
SECTION 501-20B: Supplemental Restraint
System
Workshop Manual
Front impact severity sensor bolts 12 - 106
Knee air bag module bolts - driver (Hybrid) 9 - 80
Occupant Classification System (OCS) weight sensor assembly bolts 25 18 -
Passenger air bag module-to-deployment chute bolts 9 - 80
Passenger air bag module bolts (to cross-car beam bracket) 9 - 80
Passenger air bag module deployment chute nuts 10 - 89
Restraints Control Module (RCM) bolts 12 - 106
Seat position sensor bolt 6 - 53
Seat risers-to- OCS weight sensor assembly bolts 25 18 -
Seat track-to-floor bolts 47 35 -
Side air bag module nuts 8 - 71
Side air curtain module bolts 8 - 71
Side impact sensor (front door) bolt 2 - 18
Side impact sensor (C-pillar) bolt 12 - 106
Steering column opening cover reinforcement 3 - 27
System
Workshop Manual
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
The Supplemental Restraint System (SRS) is designed to provide increased crash protection for front seat and
second row outboard occupants, in addition to that provided by the 3-point safety belt system. Safety belt use
is necessary to obtain the best occupant protection and to receive the full advantage of the SRS .
The serviceable air bag and safety belt pretensioner SRS components are shown in the following illustrations.
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) Components (1 of 2)
1 611D10 RH/ 611D11
LH
Seat side air bag module
2 042D94 RH/ 042D95
LH
Side air curtain modules
3 043B13 Driver air bag module
4 14A664 Clockspring
5 045J77 Driver knee air bag module (hybrid vehicles
only)
6 044A74 Passenger air bag module assembly
7 611B08 RH/ 611B09
LH
Safety belt retractor pretensioner
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) 961
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) Components (2 of 2)
1 61708 RH/
61709 LH
Occupant Classification System (OCS) weight
sensor assembly (2 required)
2 10A936 Passenger Air Bag Deactivation (PAD) indicator
(Fusion)
3 14B345 Side impact sensor (C-pillar)
4 14B345 Side impact sensor (front door) (pressure sensor)
5 14B416 Driver seat track position sensor
6 14B321 Restraints Control Module (RCM)
7 14B345 Front impact severity sensor (2 required)
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) Components (2 of 2) 962
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) Components (2 of 2) 963
System
Workshop Manual
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
Refer to Wiring Diagrams Cell 46 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ) for schematic and connector
information.
Special Tool(s)
Flex Probe Kit
The Restraints Control Module (RCM) continuously receives/monitors all inputs from the following
Supplemental Restraint System (SRS) components.
LH and RH front impact severity sensor
Driver and Passenger front door side impact sensor
Driver and Passenger C-pillar side impact sensor
Safety belt buckle switches (driver and passenger)
Driver seat track position sensor
Occupant Classification System Module (OCSM)
If the RCM detects sudden vehicle deceleration and/or lateral deceleration based on all the information
received from all sensors and switches and determines that deployment is required, the RCM sends voltage
and current to deploy the appropriate SRS components.
During a frontal or side crash, the RCM may deploy the following SRS components, based on crash severity
and sensor input.
Safety belt retractor pretensioner(s)
Seat side air bag(s)
Side air curtain(s)
Driver/passenger dual-stage air bag (one or both stages)
The fact that the safety belt retractor pretensioners, side air curtains and side air bags did not activate for both
front seat occupants in a crash does not mean that something is wrong with the system.
The RCM performs a self-test of the SRS during each startup. If a SRS fault exists, the air bag warning
indicator will illuminate and remain illuminated for the rest of the ignition cycle. In addition to the self-test at
start up, the RCM continuously monitors all of its SRS components and circuitry for correct operation.
Air Bag Warning Indicator
The air bag warning indicator:
located in the Instrument Panel Cluster (IPC) will prove out by lighting for 6 seconds then turn off.
will flash and/or illuminate based on the message the IPC receives from the RCM .
will illuminate if the IPC does not receive a message from the RCM .
Air Bag Module Second Stage Deployment Check
Because the driver and passenger front air bags each have 2 deployment stages, it is possible that stage 1 has
deployed and stage 2 has not.
If a front air bag module has deployed, it is mandatory that the front air bag module be remotely deployed
using the appropriate air bag disposal procedure.
For information on driver air bag module and/or passenger air bag module remote deployment, refer
to Pyrotechnic Device Disposal in this section.

Clockspring
The clockspring allows for continuous electrical connections between the driver air bag module and the RCM
when the steering wheel is turned.
Driver Air Bag Module
The driver air bag module is a dual-stage air bag, deploying at 1 of 2 different rates depending upon impact
severity and sensor input.
High Speed Controller Area Network (HS-CAN)
This vehicle utilizes a communication system called a High Speed Controller Area Network (HS-CAN). The
RCM communicates with various modules for required information about the vehicle. Refer to Section 418-00
for additional information about the HS-CAN .
Impact Sensors
For these vehicles, the SRS employs 7 impact sensors. One of the sensors is integral to the RCM and is not
separately serviceable. The RCM is mounted on the center tunnel between the front seats. There are 2 front
impact severity sensors located in the front-center of the vehicle, behind the grille. In addition, there are 4 side
impact sensors. The first row side impact sensors are pressure sensors mounted to each front door behind the
trim panel. The second row side sensors are located on or near the base of the C-pillar. Mounting orientation
is critical for correct operation of all impact sensors.
The side impact sensors are not interchangeable.
Occupant Classification System (OCS) System
The Occupant Classification System (OCS) system is found only on the front passenger seat. The OCS system
classified the size of the front passenger seat occupant and provides this information to the Restraints Control
Module (RCM). The RCM uses this information (and other inputs) in determining the deployment strategy of
the passenger air bag module and pretensioner. The front passenger OCS system is comprised of the
following: 4 OCS weight sensor bolts that are mounted to each corner of the seat track and an OCSM which is
mounted to the electrical bracket underneath the seat cushion pan. The weight of any occupant or object on
the front passenger seat is electronically communicated to the OCSM . The OCS weight sensor bolts are
serviced as an assembly (2 weight sensor bolts and mounting bracket per side), the OCSM is serviced
separately.
The OCS system is also used for operation of the passenger Belt-Minder. For information on the passenger
Belt-Minder feature, refer to Section 501-20A . To deactivate or reactivate the passenger Belt-Minder
feature, refer to Section 413-01 or the Owner's Literature.
Passenger Air Bag Deactivation (PAD) Indicator
The RCM controls the state of the Passenger Air Bag Deactivation (PAD) indicator, based on information
provided by the OCS system. The PAD indicator is lit to indicate the front passenger air bag module is
disabled. An exception 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 cases, the PAD indicator is off
when the passenger air bag module is enabled.
The RCM briefly activates the PAD indicator to prove-out the indicator function and verify to the front
occupants correct functional operation of the PAD indicator.
The following table indicates the passenger air bag status and the PAD indicator status based on the size of the
front passenger occupant.
Passenger Air Bag and PAD Indicator Status
Occupant Size Passenger Safety Belt Buckle Status Pass. Air Bag Status PAD Ind. Status
Empty Unbuckled Disabled Unlit
Empty Buckled Disabled Lit
Infant or Small Child Buckled/ Unbuckled Disabled Lit
Adult Sized Buckled/ Unbuckled Enabled Unlit
Passenger Air Bag Module
The passenger air bag module is a dual-stage air bag, deploying at 1 of 2 different rates depending upon
impact severity, sensor input, safety belt usage and passenger seat occupant classification.
Restraints Control Module (RCM)
in a crash.
NOTE: This vehicle is equipped with the SYNC feature which contains the 911 assist option. Refer to the
Owner's Literature.
The RCM carries out the following functions:
Deploys the air bag(s)/side air curtain(s) in the event of a deployable collision
Activates the safety belt retractor pretensioner to control tension on the safety belt in the event of a
deployable collision

Monitors the SRS for faults
Sends a message to the IPC to flash/illuminate the air bag warning indicator if a fault is detected
Communicates through the DLC the current or historical DTCs
The RCM monitors the SRS for possible faults. If a SRS fault exists, the RCM sends a message to the span
title="Instrument Panel Cluster" class="popup" onmouseover="this.className='popupnounderline';"
onmouseout="this.className='popup';">IPC to illuminate the air bag warning indicator.
When the ignition is cycled (OFF and then ON), the IPC will prove out the air bag warning indicator by
lighting for 6 seconds and then turn off. If a fault is detected, the RCM requests illumination of the air bag
warning indicator and will remain illuminated for the rest of the ignition cycle. If the RCM requests
illumination of the air bag warning indicator and the air bag warning indicator does not function, the IPC will
automatically activate an audible chime.
The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air
bags in the event that the ignition circuit is lost or damaged during impact. The backup power supply will
deplete its stored energy approximately one minute after power and/or ground has been removed from the
RCM .
Event Notification Signal
The purpose of the deployment event notification feature is to provide other vehicle subsystems with
information pertaining to restraint system deployment or fuel cutoff status. Signal communication between the
RCM and fuel pump control module allows the PCM to initiate fuel cut-off to disable the fuel system in the
event of a crash.
The RCM does not monitor for any circuit faults and will not set a DTC if a fault occurs.
Safety Belt Retractor Pretensioners
The safety belt retractor pretensioners remove excess slack from the safety belt webbing. The pretensioners
are activated by the RCM when the module detects a crash event force exceeding a programmed limit.
Safety Belt Buckle Switches
Safety belt buckle switches indicate to the RCM whether the safety belts are buckled or unbuckled. The RCM
uses this information in determining the deployment of the dual-stage driver and passenger air bag modules.
Seat Track Position Sensor
The seat track position sensor indicates to the RCM the position of the driver seat, forward or rearward. The
RCM uses this information in determining the deployment of the dual-stage driver air bag module.
Secondary Air Bag Warning (Chime)
The secondary air bag warning chime, is an audible chime controlled by the IPC . If the IPC has detected a
fault with the air bag warning indicator, a DTC will be stored in the memory of the IPC . Upon receiving the
message from the RCM that a SRS fault has been detected, the IPC will sound the secondary air bag warning
chime in a pattern of 5 sets of 5 beeps.
Seat Side Air Bag Module
The seat side air bag module:
will deploy upon receiving a flow of current from the RCM , initiated by the side impact sensor and
internal RCM circuitry.

is mounted in the seat backrest.
is used in conjunction with a side air curtain module.
Side Air Curtain Module
deploying incorrectly and increases the risk of serious personal injury or death in a crash.
The side air curtain module:
is mounted above the headliner.
attaches from the A-pillar frame to the C-pillar frame.
Driver Knee Bolster Air Bag Module (Hybrid Vehicles Only)
The driver knee bolster air bag module is mounted behind the steering column opening trim panel and deploys
upon receiving a flow of current from the RCM .
Verify the customer concern by checking the air bag warning indicator in the IPC . Refer to Prove Out
the System in this section.
1.
Visually inspect for obvious signs of mechanical or electrical damage. Do not disconnect electrical
connectors until directed to do so within the pinpoint test.
2.
Damaged Restraints Control Module
(RCM) or loose mounting

Damaged front impact severity sensor(s) or
loose mounting

Damaged side impact sensor(s) or loose
mounting

Damaged or disconnected Passenger Air
Bag Deactivation (PAD) indicator

Damaged or disconnected Occupant
Classification System Module (OCSM) or
loose mounting

Open Smart Junction Box (SJB) fuse 32 (10A) (
RCM ) or fuse 46 (7.5A) ( OCSM and PAD
indicator)

Damaged wiring harness
Loose, damaged or corroded connectors
Circuitry open/shorted
Damaged shorting bars
Loose, damaged or pinched passenger seat wire
harness

3.
If the cause is not visually evident, connect the scan tool to the DLC .
4.
5.
verify the ignition is ON.
6.
418-00 .

If the network test passes, retrieve and record on-demand and CMDTCs from the RCM and
OCSM .

7.
If the DTCs retrieved are related to the concern, go to the DTC Charts. For all other DTCs, refer to
Section 419-10 .
8.
DTC Charts
The DTCs can be retrieved from the RCM and the OCSM with a scan tool via the DLC .
Restraints Control Module (RCM) DTC Chart
NOTE: Always make sure the correct SRS component is being installed. Parts released for other vehicles
may not be compatible even if they appear physically similar. Check the part number listed in the Master Parts
Catalog to make sure the correct component is being installed. If an incorrect SRS component is installed,
DTCs may set.
DTC
a
Description Action To Take
Continuous
lamp
The Air Bag Indicator is
Illuminated Continuously
B0001:11 Driver Frontal Stage 1
Deployment Control: Circuit
Short to Ground
Short to Battery
Open
B0001:1A Driver Frontal Stage 1
Resistance Below Threshold
B0001:2B Driver Frontal Stage 1
Deployment Control: Signal
Cross Coupled
Deployment Control:
Incorrect Component
Installed
Short to Ground
Short to Battery
Open
B0002:2B Driver Frontal Stage 2
Cross Coupled
Deployment Control:
Incorrect Component
Installed
B0004:11 Driver Knee Bolster
Short to Ground
Short to Battery
Open
B0004:1A Driver Knee Bolster
B0004:2B Driver Knee Bolster
Cross Coupled
B0004:4A Driver Knee Bolster
Deployment Control:
Incorrect Component
Installed
B0010:11 Passenger Frontal Stage 1
Short to Ground
Short to Battery
Open
B0010:1A Passenger Frontal Stage 1
B0010:2B Passenger Frontal Stage 1
Cross Coupled
Deployment Control:
Incorrect Component
Installed
Short to Ground
GO to Pinpoint Test F .
Short to Battery
B0011:13 GO to Pinpoint Test F .
Passenger Frontal Stage 2
Open
B0011:2B Passenger Frontal Stage 2
Cross Coupled
Deployment Control:
Incorrect Component
Installed
B0020:11 Left Side Airbag Deployment
Control: Circuit Short to
Ground
Battery
Control: Circuit Open
B0020:1A Left Side Airbag Deployment
Control: Circuit Resistance
Below Threshold
B0020:2B Left Side Airbag Deployment
Control: Signal Cross
Coupled
B0020:4A Left Side Airbag Deployment
Control: Incorrect Component
Installed
B0021:11 Left Curtain Deployment
Control 1: Circuit Short to
Ground
Battery
Control 1: Circuit Open
B0021:1A Left Curtain Deployment
Control 1: Circuit Resistance
Below Threshold
B0021:2B Left Curtain Deployment
Control 1: Signal Cross
Coupled
B0021:4A Left Curtain Deployment
Installed
B0028:11 Right Side Airbag
Short to Ground
Short to Battery
Open
B0028:1A Right Side Airbag
Deployment Control 1:
Circuit Resistance Below
Threshold
B0028:2B Right Side Airbag
Cross Coupled
B0028:4A Right Side Airbag
Deployment Control:
Incorrect Component
Installed
B0029:11 Right Curtain Deployment
Ground
Battery
Control 1: Circuit Open
B0029:1A Right Curtain Deployment
Control 1: Circuit Resistance
Below Threshold
B0029:2B Right Curtain Deployment
Control 1: Signal Cross
Coupled
B0029:4A Right Curtain Deployment
Control 1: Incorrect
Component Installed
B0050:11 Driver Seatbelt Sensor:
Circuit Open
B0050:1D Driver Seatbelt Sensor:
Circuit Current Out of Range
B0050:2B Driver Seatbelt Sensor:
Signal Cross Coupled
B0050:4A Driver Seatbelt Sensor:
Incorrect Component
Installed
B0052:11 Passenger Seatbelt Sensor:
B0052:12 GO to Pinpoint Test L .
Passenger Seatbelt Sensor:
B0052:13 Passenger Seatbelt Sensor:
Circuit Open
B0052:1D Passenger Seatbelt Sensor:
B0052:2B Passenger Seatbelt Sensor:
Signal Cross Coupled
B0052:4A Passenger Seatbelt Sensor:
Incorrect Component
Installed
B0090:11 Left Frontal Restraints
Sensor: Circuit Short to
Ground
B0090:4A Left Frontal Restraints
Sensor: Incorrect Component
Installed
Sensor: Invalid Serial Data
Received
INSTALL a new LH front impact severity sensor. REFER to
Front Impact Severity Sensor in this section.
Sensor: No Operation
Sensor: Component Internal
Failure
INSTALL a new LH front impact severity sensor. REFER to
B0091:11 Left Side Restraints Sensor 1:
GO to Pinpoint Test N .
B0091:4A Left Side Restraints Sensor 1:
Incorrect Component
Installed
Invalid Serial Data Received
INSTALL a new driver front door side impact sensor. REFER to
Side Impact Sensor - Front Door in this section.
No Operation
Component Internal Failure
INSTALL a new driver front door side impact sensor. REFER to
Side Impact Sensor - Front Door in this section.
GO to Pinpoint Test O .
B0092:4A Left Side Restraints Sensor 2:
Incorrect Component
Installed
Invalid Serial Data Received
INSTALL a new driver C-pillar side impact sensor. REFER to
Side Impact Sensor - C-Pillar in this section.
No Operation
Component Internal Failure
INSTALL a new driver C-pillar side impact sensor. REFER to
Side Impact Sensor - C-Pillar in this section.
B0095:11 Right Frontal Restraints
Sensor: Circuit Short to
Ground
B0095:4A Right Frontal Restraints
Sensor: Incorrect Component
Installed
Sensor: Invalid Serial Data
Received
INSTALL a new RH front impact severity sensor. REFER to
Sensor: No Operation
Sensor: Component Internal
Failure
INSTALL a new RH front impact severity sensor. REFER to
B0096:11 Right Side Restraints Sensor
1: Circuit Short to Ground
B0096:4A Right Side Restraints Sensor
1: Incorrect Component
Installed
1: Invalid Serial Data
Received
INSTALL a new passenger front door side impact sensor.
REFER to Side Impact Sensor - Front Door in this section.
1: No Operation
1: Component Internal
Failure
INSTALL a new passenger front door side impact sensor.
REFER to Side Impact Sensor - Front Door in this section.
2: Circuit Short to Ground
B0097:4A Right Side Restraints Sensor
2: Incorrect Component
Installed
2: Invalid Serial Data
Received
INSTALL a new passenger C-pillar side impact sensor. REFER
to Side Impact Sensor - C-Pillar in this section.
2: No Operation
2: Component Internal
Failure
INSTALL a new passenger C-pillar side impact sensor. REFER
to Side Impact Sensor - C-Pillar in this section.
B00A0:09 Occupant Classification
System: Component Failure
B00A0:4A Occupant Classification
System: Incorrect Component
Installed
System: Circuit / Component
Protection Time-Out
System: Signal Plausibility
Failure
B00A0:68 GO to Pinpoint Test S .
Occupant Classification
System: Event Information
B00B5:11 Driver Seat Track Position
Restraints Sensor: Circuit
Short to Ground
GO to Pinpoint Test Y .
Short to Battery
Open
B00B5:1D Driver Seat Track Position
Current Out of Range
B00B5:2B Driver Seat Track Position
Restraints Sensor: Signal
Cross Coupled
B00B5:4A Driver Seat Track Position
Restraints Sensor: Incorrect
Component Installed
B00D5:11 Restraint System Passenger
Disable Indicator: Circuit
Short to Ground
Short to Battery
Open
B00D5:4A Restraint System Passenger
Disable Indicator: Incorrect
Component Installed
B1193:00 Crash Event Storage Full and
Locked: No Sub Type
Information
This DTC indicates the vehicle has been involved in a collision.
INSTALL a new RCM and impact sensors. REFER to Inspection
and Repair After a Supplemental Restraint System (SRS)
Deployment in this section.
B1211:11 Driver Seatbelt Retractor
Pretensioner Deployment
Ground
Battery
B1211:1A Driver Seatbelt Retractor
Below Threshold
B1211:2B Driver Seatbelt Retractor
Coupled
B1211:4A Driver Seatbelt Retractor
Installed
B1214:11 Passenger Seatbelt Retractor
Ground
Battery
B1214:1A Passenger Seatbelt Retractor
Below Threshold
B1214:2B Passenger Seatbelt Retractor
Coupled
B1214:4A Passenger Seatbelt Retractor
Installed
U0028:08 Vehicle Communication Bus
A: Bus Signal / Message
Failure
GO to Pinpoint Test AG .
U0028:88 Vehicle Communication Bus
A: Bus Off
GO to Pinpoint Test AG .
U0154:00 Lost Communication With
Restraints Occupant
Classification System
Module: No Sub Type
Information
NOTE: The DTC will set in a module that is reporting a
communication fault from another module on the data bus. The
module that reports the fault is not the problem module. Do not
install a new RCM as part of repair.
REFER to Section 418-00 to diagnose the no communication
with the Occupant Classification System Module (OCSM).
Instrument Panel Cluster
(IPC) Control Module: No
Sub Type Information
NOTE: The DTC will set in a module that is reporting a
communication fault from another module on the data bus. The
module that reports the fault is not the problem module. Do not
install a new RCM as part of repair.
REFER to Section 418-00 to diagnose the no communication
with the Instrument Panel Cluster (IPC).
U0253:00
Lost Communication With
Accessory Protocol Interface
Module: No Sub Type
Information
NOTE: This DTC will set in the RCM if a message is not
received from the Accessory Protocol Interface Module (APIM).
Check for additional RCM and APIM DTCs.
REFER to the appropriate section to diagnose DTCs concern. If
no other DTCs are present, REFER to APIM Software Level
Check in the General Procedures portion of Section 415-00 .
U0300:00 Internal Control Module
Software Incompatibility: No
CARRY OUT Programmable Module Installation (PMI).
RETRIEVE RCM DTCs.
If RCM DTC U0300:00 is retrieved on-demand during self-test,
INSTALL a new RCM . REFER to Restraints Control Module
(RCM) in this section.
U0554:00 Invalid Data Received From
Accessory Protocol Interface
Module: No Sub Type
Information
CHECK for additional RCM and APIM DTCs.
REFER to the appropriate section to diagnose the DTCs. If no
other DTCs are present, REFER to Accessory Protocol Interface
Module (APIM) Software Level Check in the General
Procedures portion of Section 415-00 .
U2100:00 Initial Configuration Not
Complete: No Sub Type
Information
CARRY OUT PMI . RETRIEVE RCM DTCs. If RCM DTC
U2100:00 is retrieved on-demand, INSTALL a new RCM .
REFER to Restraints Control Module (RCM) in this section.
U2200:00 Control Module
Configuration Memory
Corrupt: No Sub Type
Information
INSTALL a new RCM and CARRY OUT Programmable
Module Installation (PMI). Use as-built data when CARRYING
out PMI for this DTC. REFER to Restraints Control Module
U3000:46 Control Module: Calibration /
Parameter Memory Failure
INSTALL a new RCM . REFER to Restraints Control Module
U3000:49 Control Module: Internal
Electronic Failure
INSTALL a new RCM and CARRY OUT Programmable
Module Installation (PMI). If DTC U2200:00 is also present, use
as-built data when CARRYING out PMI . REFER to Restraints
Control Module (RCM) in this section.
U3000:4A Control Module: Incorrect
Component Installed
U3003:16 Battery Voltage: Circuit
Voltage Below Threshold
Voltage Above Threshold
a
DTC: Retrieved using scan tool.
Occupant Classification System Module (OCSM) DTC Chart
DTC
a
Description Action To Take
System: Missing Calibration
System: Signal Incorrect After
Event
CARRY OUT the OCS System Reset. REFER to Occupant
Classification Sensor (OCS) System Reset in this section.
System: Wrong Mounting
Position
System: Component or System
Operation Obstructed or
Blocked
GO to Pinpoint Test T .
B00C0:12 Passenger Seat Occupant
Classification Sensor "A":
Circuit Open
B00C0:1A Passenger Seat Occupant
Circuit Resistance Below
Threshold
Internal Electronic Failure
Invalid Serial Data
CARRY out the Occupant Classification System (OCS) System
Reset. REFER to Occupant Classification Sensor (OCS) System
Reset in this section.
Classification Sensor "B":
GO to Pinpoint Test V .
Circuit Open
Circuit Resistance Blow
Threshold
Invalid Serial Data
Classification Sensor "C":
Circuit Open
Threshold
Invalid Serial Data
Classification Sensor "D":
Circuit Open
Threshold
Invalid Serial Data
B1193:00 Crash Event Storage Full and
Locked: No Sub Type
Information
INSTALL new OCS left and right weight sensor assemblies.
REFER to Inspection and Repair After a Supplemental Restraint
System (SRS) Deployment in this section.
B1A59:01 Sensor 5 Volt Supply: General
Electrical Failure
B1A59:11 Sensor 5 Volt Supply: Circuit
Short to Ground
ECM/PCM "A": No Sub Type
Information
U0100:00 will set in a module that is reporting a communication
fault from another module on the data bus. The module that
reports the fault is not the problem module. Do not install a new
OCSM as part of repair for DTC U0100:00.
REFER to Section 418-00 to diagnose lost communication with
the PCM.
Restraints Control Module: No
REFER to Section 418-00 to diagnose lost communication with
the Restraints Control Module (RCM).
ECM/PCM "A": No Sub Type
Information
CARRY OUT PCM Self Test. REPAIR any speed-related
DTCs.
REFER to DTC chart in Powertrain Control/Emissions
Diagnosis (PC/ED) manual.
U200D:12 Control Module Output Power
A: Circuit Short To Battery
GO to Pinpoint Test AH .
Electronic Failure
INSTALL a new OCSM . REFER to Occupant Classification
System Module (OCSM) in this section.
U3000:53 Control Module: Deactivated INSTALL a new OCSM . REFER to Occupant Classification
System Module (OCSM) in this section.
U3000:54 Control Module: Missing
Calibration
a
DTC: Retrieved using scan tool.
Symptom Chart
Symptom Chart
Pinpoint Test - Supplemental Restraint System (SRS)
Pinpoint Test A: The Air Bag Warning Indicator is Illuminated Continuously
Refer to Wiring Diagrams Cell 46 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Supplemental Restraint
System for schematic and connector information.
Normal Operation
During normal operation, the Instrument Panel Cluster (IPC) will illuminate the air bag warning indicator
continuously for 6 seconds. If the Supplemental Restraint System (SRS) is fault free, the air bag warning
indicator will turn off and remain off. If a fault is detected in the SRS , the air bag warning inditor will
illuminate and remain illuminated for the rest of the ignition cycle until the fault is no longer detected. The
Restraints Control Module (RCM) communicates to the IPC via the High Speed Controller Area Network
(HS-CAN). The IPC will illuminate the air bag warning indicator based on messaging from the RCM or if
there is no communication between the RCM and IPC .
IPC
RCM
PINPOINT TEST A: THE AIR BAG WARNING INDICATOR IS ILLUMINATED CONTINUOUSLY
WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor
(if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation,
which increases the risk of personal injury or death in a crash.
NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection and
may not be compatible even if they appear physically similar. Check the part number listed in the Ford
Catalog AdvantageTM to make sure the correct component is being installed. If an incorrect SRS component
is installed, DTCs may set.
A1 RETRIEVE RCM DTCs
Ignition ON.
mode on the scan tool: Self Test -
RCM .

Were any DTCs retrieved
on-demand dug self-test?

Yes
GO to the DTC Charts in this section for diagnostic
direction.
Do not clear any DTCs until all DTCs have been resolved.
No
If the RCM does communicate with the scan tool, REFER
to Section 413-01 to diagnose the IPC concern.
Do not clear any DTCs until all DTCs have been resolved.
Pinpoint Test B: DTCs B0001:11, B0001:12, B0001:13 and B0001:1A
Normal Operation
The Restraints Control Module (RCM) continuously monitors the driver air bag module stage 1 and circuits
for the following faults:
Resistance out of range
Unexpected voltage
Short to ground
Faulted driver air bag module
If a fault is detected, the RCM will store DTC B0001:11, B0001:12, B0001:13 or B0001:1A in memory and
send a message to the Instrument Panel Cluster (IPC) to illuminate the air bag warning indicator.
The RCM analyzes the deployment loop resistance and uses this measurement in combination with an age
correction factor to determine if a fault exists. The value displayed in the PID is the deployment loop
resistance as measured by the RCM . If the value displayed is lower or higher than the desired range (refer to
diagram below), the RCM can set a DTC. As the deployment loop resistance drifts farther outside the desired
range, the chance for a DTC increases. The RCM fault trigger threshold may vary as the vehicle ages. Small
PINPOINT TEST A: THE AIR BAG WARNING INDICATOR IS ILLUMINATED CONTINUOUSLY982
variations in resistance can occur due to the effect of road vibrations on terminal fit and/or temperature
changes. These variables can result in an intermittent fault. For this reason, the test will require the PID value
to be within the desired range before the fault is considered repaired, regardless if the module is reporting an
on-demand DTC at time of diagnosis. Following this direction will help make sure that minor changes in
resistance do not create a repeat concern. This test will use a process of elimination to diagnose each part of
the deployment loop circuit including:
Wiring
Connections
Clockspring
Driver air bag module
RCM
DTC Description Fault Trigger Condition
B0001:11 - Driver Frontal Stage 1
Deployment Control: Circuit Short to
Ground

When the RCM senses a short to ground on either driver air
bag stage 1 circuit, a fault will be indicated.
Battery

When the RCM senses a short to voltage on either driver air
Deployment Control: Circuit Open

When the RCM measures greater than the desired range
between driver air bag stage 1 circuits, a fault will be
indicated.
B0001:1A - Driver Frontal Stage 1
Deployment Control: Circuit Resistance
Below Threshold

When the RCM measures less than the desired range
indicated.
Clockspring
RCM
PINPOINT TEST B: DTCs B0001:11, B0001:12, B0001:13 AND B0001:1A
modules. Failureollow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection and
NOTE: Supplemental Restraint System (SRS) components should only be disconnected or reconnected
when instructed to do so within a pinpoint test step. Failure to follow this instruction may result in
incorrect diagnosis of the SRS .
B1 RETRIEVE RCM DTCs
Ignition ON.
Self Test - RCM .

Was DTC B0001:11, B0001:12, B0001:13 or
B0001:1A retrieved on-demand during self-test?

Yes
This fault cannot be cleared until it is
corrected and the DTC is no longer
retrieved on-demand during self-test.
For DTC B0001:13 or B0001:1A, GO to
B2 .
For DTC B0001:11, GO to B11 .
No
This is an intermittent fault when present
as a Continuous Memory Diagnostic
Trouble Code (CMDTC) only.
B19 .
B2 CHECK THE DRIVER FRONTAL STAGE 1
DEPLOYMENT CONTROL RESISTANCE
(DEPLOY_00_R) PID
DataLogger - RCM .

DEPLOY_00_R PID
Does the PID value read between 2 and 3.68 ohms?
Yes
GO to B18 .
No
GO to B3 .
(DEPLOY_00_R) PID WHILE CARRYING OUT THE
PINPOINT TEST B: DTCs B0001:11, B0001:12, B0001:13 AND B0001:1A 984
HARNESS TEST
Remove the lower steering column shroud to access
the clockspring connectors.

While monitoring the DEPLOY_00_R PID, carry out
the harness test of the driver air bag circuits and
accessible connectors (including any in-line
connectors) by wiggling and flexing the wire harness,
connectors, tilting and rotating the steering wheel
frequently.

Does the PID value read between 2 and 3.68 ohms
while carrying out the harness test?

Yes
DEPOWER the SRS and REPAIR the
connector, terminals or wire harness or
INSTALL a new clockspring as needed.
REFER to Clockspring in this section.
Hybrid ), Connector Repair Procedures
GO to B23 .
No
For PID value less than 2 ohms, GO to
B4 .
For PID value greater than 3.68 ohms,
GO to B7 .
DEPLOYMENT CONTROL DTC FOR A FAULT
STATUS CHANGE (LOW RESISTANCE INDICATED)
NOTE: This pinpoint test step will attempt to change
the fault reported by the RCM by inducing a different
fault condition. If the fault reported changes, this
indicates the RCM is functioning correctly and is not
the source of the fault.
Ignition OFF.
System (SRS) Depowering and Repowering in this
section.

Remove the driver air bag module. Refer to Driver
Air Bag Module in this section.

Repower the SRS . Do not prove out the SRS at this
time. Refer to Supplemental Restraint System (SRS)
Depowering and Repowering in this section.

Ignition ON.
Self Test - RCM .

DIAGNOSTIC TIP: When viewing DTCs with the
driver air bag module disconnected, open circuit
faults would normally be retrieved on stage 1 and 2.

Did the on-demand DTC change from B0001:1A to
B0001:13?

Yes
GO to B16 .
No
GO to B5 .
STATUS CHANGE (LOW RESISTANCE INDICATED)
(CLOCKSPRING DISCONNECTED)
Yes
GO to B17 .
Ignition OFF.
Disconnect: Clockspring C218A.
Ignition ON.
Self Test - RCM .

driver air bag module / clockspring disconnected,
open circuit faults would normally be retrieved on
stage 1 and 2.

B0001:13?

No
GO to B6 .
B6 CHECK THE RCM FOR LOW RESISTANCE
Ignition OFF.
section.

Disconnect: RCM C310A and C310B.
Measure the resistance between RCM C310A pins 3
and 4, component side.

Yes
REPAIR circuits CR101 (VT/BN) and
RR101 (YE/GN).
GO to B23 .
No
GO to B18 .
B7 CHECK THE DRIVER AIR BAG STAGE 1
Ignition OFF.
section.


Measure the resistance between RCM C310A,
harness side and driver air bag module stage 1
electrical connector, harness side, using the following
chart.

Yes
GO to B9 .
No
GO to B8 .
RCM Circuit
Stage 1 Electrical
Connector
C310A-4 CR101
(VT/BN)
Stage 1 electrical connector
C310A-3 RR101
(YE/GN)
Stage 1 electrical connector
Are the resistances less than 1 ohm?
CIRCUITS FOR AN OPEN (CLOCKSPRING
DISCONNECTED)
Measure the resistance between RCM C310A,
harness side and clockspring C218A, harness side
using the following chart.

RCM Circuit Clockspring
C310A-4 CR101 (VT/BN) C218A-1
C310A-3 RR101 (YE/GN) C218A-9
Are the resistances less than 0.5 ohm?
Yes
GO to B17 .
No
REPAIR circuit CR101 (VT/BN) or
RR101 (YE/GN).
GO to B23 .
STATUS CHANGE (OPEN INDICATED)
Yes
GO to B16 .
No
GO to B10 .
Connect: RCM C310A and C310B.
Connect a fused jumper wire between driver air bag
module stage 1 electrical connector pins 1 and 2,
harness side.


Ignition ON.
Self Test - RCM .

driver air bag stage 1 circuits shorted together, a low
resistance fault would normally be retrieved on stage
1. Stage 2 will show an open circuit fault due to the
driver air bag being disconnected.

Was DTC B0001:1A retrieved on-demand during
self-test?

CIRCUITS FOR AN OPEN (CLOCKSPRING
DISCONNECTED)
Ignition OFF.
section.

Connect a fused jumper wire between clockspring
electrical connector C218A pins 1 and 9, harness side.


Ignition ON.
Self Test - RCM .

clockspring stage 1 circuits shorted together, a low
resistance fault would normally be retrieved on stage
1. Stage 2 will show an open circuit fault due to the
driver air bag being disconnected.

self-test?

Yes
GO to B17 .
No
GO to B18 .
STATUS CHANGE (SHORT TO GROUND
INDICATED)
Ignition OFF.
Yes
GO to B16 .
No
GO to B12 .
section.



Ignition ON.
Self Test - RCM .

driver air bag module disconnected, open circuit
faults would normally be retrieved on stage 1 and 2.

Did the on-demand DTC change from B0001:11 to
B0001:13?

STATUS CHANGE (SHORT TO GROUND
INDICATED) (CLOCKSPRING DISCONNECTED)
Ignition OFF.
Ignition ON.
Self Test - RCM .

clockspring disconnected, open circuit faults would
normally be retrieved on driver air bag stage 1 and 2.

B0001:13?

Yes
GO to B17 .
No
GO to B13 .
CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
section.

Measure the resistance between clockspring:
C218A-1, circuit CR101 (VT/BN), harness
side and ground.

C218A-9, circuit RR101 (YE/GN), harness
side and ground.

Yes
GO to B18 .
No
Due to the shorting bar feature in the
RCM electrical connector, the fault can
exist in either circuit. Do not remove or
defeat the shorting bar.
RR101 (YE/GN).
GO to B23 .
STATUS CHANGE (SHORT TO BATTERY
INDICATED) (CLOCKSPRING DISCONNECTED)
Ignition OFF.
section.



Ignition ON.
Self Test - RCM .

driver air bag module/clockspring disconnected, open
circuit faults would normally be retrieved on driver
air bag stage 1 and 2.

B0001:13?

Yes
GO to B17 .
No
GO to B15 .
CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF.
section.


Ignition ON.
Measure the voltage between clockspring:
C218A-1, circuit CR101 (VT/BN), harness
side and ground.

Yes
Due to the shorting bar feature in the
RCM electrical connector, the fault can
exist in either circuit. Do not remove or
defeat the shorting bar.
RR101 (YE/GN).
C218A-9, circuit RR101 (YE/GN), harness
side and ground.

GO to B23 .
No
GO to B18 .
B16 CONFIRM THE DRIVER AIR BAG MODULE
FAULT
NOTE: Make sure all restraint system components
and the RCM electrical connectors are connected
before carrying out the self-test. If not, DTCs will be
recorded.
Ignition OFF.
section.

If installed previously, remove the fused jumper wire
from the air bag electrical connector.

Install the driver air bag module. Refer to Driver Air
Bag Module in this section.


Ignition ON.
Self Test - RCM .

Was the original DTC retrieved on-demand
during self-test?

Yes
INSTALL a new driver air bag module.
REFER to Driver Air Bag Module in this
section. GO to B23 .
No
In the process of diagnosing the fault, the
fault condition has become intermittent.
Do not install any new SRS
components at this time. SRS
components should only be installed
when directed to do so in the pinpoint
test.
B19 .
B17 CONFIRM THE CLOCKSPRING FAULT
recorded.
Ignition OFF.
section.

Connect: Clockspring C218A.
Install the driver air bag module. Refer to Driver Air
Bag Module in this section.


Ignition ON.
Yes
INSTALL a new clockspring. REFER to
Clockspring in this section. GO to B23 .
No
test.
B19 .
Self Test - RCM .

during self-test?

B18 CONFIRM THE RCM FAULT
recorded.
Ignition OFF.
section.

If installed previously, remove the fused jumper wire
from the air bag electrical connector.

Prior to reconnecting any previously disconnected
SRS component:

inspect connector(s) (including any in-line
connectors) for pushed-out, loose or spread
terminals and loose or frayed wire
connections at terminals.

inspect wire harness for any damaged,
pinched, cut or pierced wires.

inspect RCM C310A and C310B Connector
Position Assurance (CPA) lever/lock for
correct operation. Refer to Restraints Control
Module (RCM) in this section.

repair any concerns found.
Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ),
Connector Repair Procedures for schematic

If previously removed, install the driver air bag
module. Refer to Driver Air Bag Module in this
section.

Connect: Clockspring C218A (if previously
disconnected).

Connect: RCM C310A and C310B (if previously
disconnected).


Ignition ON.
Self Test - RCM .

during self-test?

Yes
INSTALL a new RCM . REFER to
Restraints Control Module (RCM) in this
section. GO to B23 .
No
test.
B19 .
(DEPLOY_00_R) PID FOR AN INTERMITTENT LOW
RESISTANCE OR OPEN CIRCUIT FAULT
DataLogger - RCM .

DEPLOY_00_R PID
Attempt to recreate the fault by wiggling connectors
(including any in-line connectors) and flexing the
wire harness, tilting and rotating the steering wheel
frequently.

Yes
The fault is not present and cannot be
recreated at this time. Do not install any
new SRS components at this time. SRS
test. GO to B22 .
No
DEPOWER the SRS and REPAIR as
necessary.
GO to B23 .
DEPLOYMENT CONTROL FOR AN INTERMITTENT
SHORT TO GROUND FAULT
frequently.

Self Test - RCM .

Was DTC B0001:11 retrieved on-demand during
self-test?

Yes
necessary.
GO to B23 .
No
test. GO to B22 .
SHORT TO BATTERY FAULT
Ignition OFF.
section.



Ignition ON.
Yes
necessary.
GO to B23 .
frequently.

Self Test - RCM .

self-test?

No
test. GO to B22 .
B22 CHECK THE HARNESS AND CONNECTORS
Ignition OFF.
section.

Remove the driver air bag module:
connectors) for corrosion, loose or spread

inspect wire harness for any damage,

Inspect RCM C310A and C310B CPA lever/lock for
correct operation. Refer to Restraints Control Module

Were any concerns found?
Yes
REPAIR as necessary.
GO to B23 .
No
test. GO to B23 .
B23 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF.
WARNING: Turn the ignition OFF and wait
one minute to deplete the backup power supply.
Failure to follow this instruction may result in
serious personal injury or death in the event of an

Reconnect all SRS components (if previously
disconnected).

If previously directed to depower the SRS , repower
the SRS . Do not prove out the SRS at this time.
Refer to Supplemental Restraint System (SRS)

Ignition ON.
Self Test - Restraints.

NOTE: When selecting Restraints from the Self Test
menu, DTCs will be retrieved from the RCM and
OCSM .

Are any RCM and/or OCSM DTCs retrieved
on-demand during self-test?

Yes
Do not clear any DTCs until all DTCs
have been resolved. GO to the DTC
Charts in this section for pinpoint test
direction.
No
CLEAR all RCM and OCSM CMDTCs .
PROVE OUT the SRS . Repair is
complete. RETURN the vehicle to the
customer.
Pinpoint Test C: DTCs B0002:11, B0002:12, B0002:13 and B0002:1A
Normal Operation
The Restraints Control Module (RCM) continuously monitors the driver air bag module stage 2 and circuits
for the following faults:
Unexpected voltage
Short to ground
Faulted driver air bag module
Wiring
Connections
Clockspring
RCM
Ground

When the RCM senses a short to ground on either driver air
Battery
When the RCM senses a short to voltage on either driver air

When the RCM measures greater than the desired range
indicated.
B0002:1A - Driver Frontal Stage 2
Deployment Control: Circuit Resistance
Below Threshold
When the RCM measures less than the desired range
indicated.
Clockspring
RCM
PINPOINT TEST C: DTCs B0002:11, B0002:12, B0002:13 AND B0002:1A
WARNING: Never probe the electrical connectors on aig, Safety Canopy or side air curtain
Ignition ON.
Test - RCM .

Was DTC B0002:11, B0002:12, B0002:13 or B0002:1A
retrieved on-demand during self-test?

Yes
This fault cannot be cleared until it
is corrected and the DTC is no
longer retrieved on-demand during
self-test.
For DTC B0002:13 or B0002:1A,
GO to C2 .
For DTC B0002:11, GO to C11 .
No
This is an intermittent fault when
present as a Continuous Memory
Diagnostic Trouble Code
PINPOINT TEST C: DTCs B0002:11, B0002:12, B0002:13 AND B0002:1A 996
(CMDTC) only.
For DTC B0002:13 or B0001A,
GO to C19 .
C2 CHECK THE DRIVER FRONTAL STAGE 2
DEPLOYMENT CONTROL RESISTANCE (DEPLOY_01_R)
PID
DataLogger - RCM .

DEPLOY_01_R PID
Yes
GO to C18 .
No
GO to C3 .
PID WHILE CARRYING OUT THE HARNESS TEST
Remove the lower steering column shroud to access the
clockspring connector.

While monitoring the DEPLOY_01_R PID, carry out the
harness test of the driver air bag circuits and accessible
connectors (including any in-line connectors), by wiggling
and flexing the wire harness, connectors, tilting and rotating
the steering wheel frequently.

Does the PID value read between 2 and 3.68 ohms while
carrying out the harness test?

Yes
DEPOWER the SRS and REPAIR
the connector, terminals or wire
harness or INSTALL a new
clockspring as needed. REFER to
Clockspring in this section.
Hybrid ), Connector Repair
Procedures for schematic and
connector information.
GO to C23 .
No
For PID value less than 2 ohms,
GO to C4 .
For PID value greater than 3.68
ohms, GO to C7 .
DEPLOYMENT CONTROL DTC FOR A FAULT STATUS
CHANGE (LOW RESISTANCE INDICATED)
NOTE: This pinpoint test step will attempt to change the
fault reported by the RCM by inducing a different fault
condition. If the fault reported changes, this indicates the
RCM is functioning correctly and is not the source of the
fault.
Ignition OFF.
(SRS) Depowering and Repowering in this section.

Yes
GO to C16 .
No
GO to C5 .
Remove the driver air bag module. Refer to Driver Air Bag

Repower the SRS . Do not prove out the SRS at this time.
Refer to Supplemental Restraint System (SRS) Depowering
and Repowering in this section.

Ignition ON.
Test - RCM .

DIAGNOSTIC TIP: When viewing DTCs with the driver
air bag module disconnected, open circuit faults would
normally be retrieved on stage 1 and 2.

B0002:13?

CHANGE (LOW RESISTANCE INDICATED)
condition. the fault reported changes, this indicates the
fault.
Ignition OFF.
Ignition ON.
Test - RCM .

air bag module/clockspring disconnected, open circuit faults
would normally be retrieved on stage 1 and 2.

B0002:13?

Yes
GO to C17 .
No
GO to C6 .
C6 CHECK FOR A SHORT BETWEEN DRIVER AIR BAG
STAGE 2 CIRCUITS
Ignition OFF.

Measure the resistance between C218A-2, circuit CR102
(BU), harness side and C218A-10, circuit RR102 (WH),
harness side.

Yes
GO to C18 .
No
REPAIR circuits CR102 (BU) and
RR102 (WH).
GO to C23 .
C7 CHECK THE DRIVER AIR BAG STAGE 2 CIRCUITS
FOR AN OPEN
Ignition OFF.


Measure the resistance between RCM C310A, harness side
and driver air bag module stage 2 electrical connector,
harness side using the following chart.

RCM Circuit
Driver Air Bag Module Stage 2
Electrical Connector
C310A-7 CR102
(BU)
electrical connector
C310A-8 RR102
(WH)
Are the resistances less than 1 ohm?
Yes
GO to C9 .
No
GO to C8 .
FOR AN OPEN (CLOCKSPRING DISCONNECTED)
Measure the resistance between RCM C310A, harness side
and clockspring C218A, harness side using the following
chart.

RCM Circuit Clockspring
C310A-7 CR102 (BU) C218A-2
C310A-8 RR102 (WH) C218A-10
Yes
GO to C17 .
No
REPAIR circuit CR102 (BU) or
RR102 (WH).
GO to C23 .
Are the resistances less than 0.5 ohm?
CHANGE (OPEN INDICATED)
fault.
Connect: RCM C310A and C310B.
Connect a fused jumper wire between driver air bag module
stage 2 electrical connector pins 1 and 2, harness side.


Ignition ON.
Test - RCM .

DIAGNOSTIC TIP: When viewing DTCs with driver air
bag module stage 2 circuits shorted together, a low
resistance fault would normally be rrieved on stage 2. Stage
1 will show an open circuit fault due to the driver air bag
being disconnected.

self-test?

Yes
GO to C16 .
No
GO to C10 .
FOR AN OPEN (CLOCKSPRING DISCONNECTED)
Ignition OFF.

Remove the fused jumper wire from the driver air bag
module stage 2 electrical connector.

Connect a fused jumper wire between clockspring electrical
connector C218A pins 2 and 10, harness side.


Ignition ON.
Test - RCM .

clockspring stage 2 circuits shorted together, a low
resistance fault would normally be retrieved on stage 2.

Yes
GO to C17 .
No
GO to C18 .
Stage 1 will show an open circuit fault due to the driver air
bag being disconnected.
self-test?

CHANGE (SHORT TO GROUND INDICATED)
fault.
Ignition OFF.



Ignition ON.
Test - RCM .

air bag module disconnected, open circuit faults would
normally be retrieved on stage 1 and 2.

B0002:13?

Yes
GO to C16 .
No
GO to C12 .
CHANGE (SHORT TO GROUND INDICATED)
NE: This pinpoint test step will attempt to change the fault
reported by the RCM by inducing a different fault condition.
If the fault reported changes, this indicates the RCM is
functioning correctly and is not the source of the fault.
Ignition OFF.
Ignition ON.
Test - RCM .


B0002:13?

Yes
GO to C17 .
No
GO to C13 .
Ignition OFF.

Measure the resistance between clockspring:
C218A-2, circuit CR102 (BU), harness side and ground.
C218A-10, circuit RR102 (WH), harness side and ground.
Yes
GO to C18 .
No
RR102 (WH).
GO to C23 .
CHANGE (SHORT TO BATTERY INDICATED)
fault.
Ignition OFF.



Ignition ON.
Test - RCM .


B0002:13?

Yes
GO to C17 .
No
GO to C15 .
Ignition OFF.


Ignition ON.
Measure the voltage between clockspring:
C218A-2, circuit CR102 (BU), harness side and
ground.

C218A-10, circuit RR102 (WH), harness side and
ground.

Yes
RR102 (WH).
GO to C23 .
No
GO to C18 .
C16 CONFIRM THE DRIVER AIR BAG MODULE FAULT
NOTE: Make sure all restraint system components and the
RCM electrical connectors are connected before carrying
out the self-test. If not, DTCs will be recorded.
Ignition OFF.

If installed previously, remove the fused jumper wire from
the driver air bag electrical connector.

Install the driver air bag module. Refer to Driver Air Bag


Ignition ON.
Test - RCM .

Was the original DTC retrieved on-demand during
self-test?

Yes
INSTALL a new driver air bag
module. REFER to Driver Air Bag
Module in this section. GO to C23 .
No
In the process of diagnosing the
fault, the fault condition has
become intermittent. Do not install
any new SRS components at this
time. SRS components should
only be installed when directed to
do so in the pinpoint test.
For DTC B0002:13 or B0002:1A,
GO to C19 .
C17 CONFIRM THE CLOCKSPRING FAULT
Ignition OFF.

Yes
INSTALL a new clockspring.
REFER to Clockspring in this
section. GO to C23 .
No
the clockspring electrical connector C218A.

Connect: Clockspring C218A.
Install the driver air bag module. Refer to Driver Air Bag


Ignition ON.
Test - RCM .

self-test?

time. SRS components should
only be installed when directed to
do so in the pinpoint test.
For DTC B0002:13 or B0002:1A,
GO to C19 .
C18 CONFIRM THE RCM FAULT
Ignition OFF.

the clockspring electrical connector C218A.

Prior to reconnecting any previously disconnected SRS
component:

connectors) for pushed-out, loose or spread
terminals and loose or frayed wire connections at
terminals.

inspect wire harness for any damage, pinched, cut
or pierced wires.

inspect RCM C310A and C310B Connector
Position Assurance (CPA) lever/lock for correct
operation. Refer to Restraints Control Module

Fusion Hybrid/MKZ Hybrid ), Connector Repair
Procedures for schematic and connector
information.

If previously removed, install the driver air bag module.
Refer to Driver Air Bag Module in this section.

Connect: Clockspring C218A (if previously disconnected).
Connect: RCM C310A and C310B (if previously
disconnected).


Ignition ON.
Test - RCM .

Yes
INSTALL a new RCM . REFER to
in this section. GO to C23 .
No
time. SRS components shod only
be installed when directed to do
so in the pinpoint test.
For DTC B0002:13 or B0002:1A,
GO to C19 .
self-test?

PID FOR AN INTERMITTENT LOW RESISTANCE OR
OPEN CIRCUIT FAULT
DataLogger - RCM .

DEPLOY_01_R PID
(including any in-line connectors) and flexing the wire
harness, tilting and rotating the steering wheel frequently.

Yes
The fault is not present and cannot
be recreated this time. Do not
install any new SRS components
at this time. SRS components
should only be installed when
directed to do so in the pinpoint
test. GO to C22 .
No
as necessary.
GO to C23 .
SHORT TO GROUND FAULT

Test - RCM .

self-test?

Yes
as necessary.
GO to C23 .
No
be recreated at this time. Do not
test. GO to C22 .
SHORT TO BATTERY FAULT
Ignition OFF.



Ignition ON.

Test - RCM .

self-test?

Yes
as necessary.
GO to C23 .
No
test. GO to C22 .
C22 CHECK HARNESS AND CONNECTORS
Ignition OFF.

Remove the driver air bag module.
connectors) for corrosion, loose or spread terminals
and loose or frayed wire connections at terminals.

inspect wire harness for any damage, pinched, cut
or pierced wires.

Inspect RCM C310A and C310B CPA lever/lock for correct
operation. Refer to Restraints Control Module (RCM) in this
section.

Yes
REPAIR as necessary.
GO to C23 .
No
test. GO to C23 .
C23 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF.
WARNING: Turn the ignition OFF and wait one
minute to deplete the backup power supply. Failure to
follow this instruction may result in serious personal
injury or death in the event of an accidental deployment.

Reconnect all SRS components (if previously disconnected).
If previously directed to depower the SRS , repower the
SRS . Do not prove out the SRS at this time. Refer to
Supplemental Restraint System (SRS) Depowering and
Repowering in this section.

Ignition ON.
Yes
Do not clear any DTCs until all
DTCs have been resolved. GO to
the DTC Charts in this section for
pinpoint test direction.
No
CLEAR all RCM and OCSM
CMDTCs . PROVE OUT the SRS .
Repair is complete. RETURN the
vehicle to the customer.
Test - Restraints.

NOTE: When selecting Restraints from the Self Test menu,
DTCs will be retrieved from the RCM and OCSM .

Are any RCM and/or OCSM DTCs retrieved
on-demand during self-test?

Pinpoint Test D: DTCs B0004:11, B0004:12, B0004:13 and B0004:1A
Normal Operation
The Restraints Control Module (RCM) continuously monitors the driver knee bolster air bag module and
circuits for the following faults:
Unexpected voltage
Short to ground
Faulted driver knee bolster air bag module
Wiring
Connections
Driver knee bolster air bag module
RCM
When the RCM senses a short to ground on either driver knee
bolster air bag module circuit, a fault will be indicated.
B0004:11 - Driver Knee Bolster
Deployment Control: Circuit Short
to Ground

Deployment Control: Circuit Short
to Battery

When the RCM senses a short to voltage on either driver knee
bolster air bag module circuit, a fault will be indicated.

When the RCM measures greater than the desired resistance
range between driver knee bolster air bag module circuits, a
fault will be indicated.
B0004:1A - Driver Knee Bolster

When the RCM measures less than the desired resistance range
between driver knee bolster air bag module circuits, a fault will
be indicated.
Driver knee bolster air bag module
RCM
PINPOINT TEST D: DTCs B0004:11, B0004:12, B0004:13 AND B0004:1A
verification before proceeding with the pinpoint test. <
D1 RETRIEVE RCM DTCs
Ignition ON.
Self Test - RCM .

Yes
This fault cannot be cleared until it is
corrected and the DTC is no longer
retrieved on-demand during self-test.
PINPOINT TEST D: DTCs B0004:11, B0004:12, B0004:13 AND B0004:1A 1008
Was DB0004:11, B0004:12, B0004:13 or B0004:1A
For DTC B0004:13 or B0004:1A, GO
to D2 .
For DTC B0004:11, GO to D8 .
No
This is an intermittent fault when
present as a CMDTC only.
For DTC B0004:13 or B0004:1A, GO
to D13 .
D2 CHECK THE DRIVER KNEE BOLSTER
(DEPLOY_02_R) PID
DataLogger - RCM .

DEPLOY_02_R PID
Does the PID value read between 1.7 and 2.78
ohms?

Yes
GO to D12 .
No
GO to D3 .
D3 CHECK THE DRIVER KNEE BOLSTER
(DEPLOY_02_R) PID WHILE CARRYING OUT THE
HARNESS TEST
PINPOINT TEST D: DTCs B0004:11, B0004:12, B0004:13 AND B0004:1A 1009
System
Workshop Manual
Supplemental Restraint System (SRS) Depowering and Repowering
Special Tool(s)
Depowering Procedure
WARNING: To rduce the risk of accidental deployment, do not use any memory saver devices.
Failure to follow this instruction may result in serious personal injury or death.
Turn all vehicle accessories OFF. 1.
Turn the ignition to OFF. 2.
At the Smart Junction Box (SJB), located below the LH side of the instrument panel, remove the
cover and the RCM fuse 32 (10A) from the SJB . For additional information, refer to the Wiring
Diagrams manual.
3.
Turn the ignition ON and monitor the air bag indicator for at least 30 seconds. The air bag warning
indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the
air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before
proceeding.
4.
Turn the ignition OFF. 5.
WARNING: Always deplete the backup power supply before repairing or installing any new
front or side air bag supplemental restraint system (SRS) component and before servicing,
removing, installing, adjusting or striking components near the front or side impact sensors or
the restraints control module (RCM). Nearby components include doors, instrument panel,
console, door latches, strikers, seats and hood latches. Refer to the Description and Operation
portion of Section 501-20B for location of the RCM and impact sensor(s). To deplete the backup
6.
Supplemental Restraint System (SRS) Depowering and Repowering 1010
power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to
disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these
instructions may result in serious personal injury or death in the event of an accidental
deployment.
Disconnect the battery ground cable and wait at least one minute. For additional information, refer to
Section 414-01 .
Repowering Procedure
Turn the ignition from OFF to ON. 1.
Install RCM fuse 32 (10A) in the SJB and close the cover. 2.
WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in
front of any air bag module when the battery is connected. Failure to follow these instructions
may result in serious personal injury in the event of an accidental deployment.
Connect the battery ground cable.
3.
Prove out the SRS as follows:
Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition ON and monitor the air
bag warning indicator with the air bag modules installed. The air bag warning indicator will light
continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is detected, the air
bag warning indicator will:
- fail to light.
- remain lit continuously.
- flash.
The flashing might not occur until approximately 30 seconds after the ignition has been turned from
the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS
. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern
of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be
diagnosed and repaired.
Clear all RCM and OCSM CMDTCs .
4.
System
Workshop Manual
Supplemental Restraint System (SRS) Deactivation and Reactivation
Special Tool(s)
Deactivation
WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices.
Failure to follow this instruction may result in serious personal injury or death.
modules. Failure to follow this instruction may result in the accidental eployment of these modules,
death.
All vehicles
Turn all vehicle accessories OFF. 1.
At the Smart Junction Box (SJB), located below the LH side of the instrument panel, remove the
cover and the RCM fuse 32 (10A) from the SJB . For additional information, refer to the Wiring
Diagrams manual.
3.
Turn the ignition ON and monitor the air bag warning indicator for at least 30 seconds. The air bag
warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been
removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM
fuse before proceeding.
4.
Supplemental Restraint System (SRS) Deactivation and Reactivation 1013
WARNING: Always deplete the backup power supply before repairing or installing any new
front or side air bag supplemental restraint system (SRS) component and before servicing,
removing, installing, adjusting or striking components near the front or side impact sensors or
the restraints control module (RCM). Nearby components include doors, instrument panel,
console, door latches, strikers, seats and hood latches. Refer to the Description and Operation
portion of Section 501-20B for location of the RCM and impact sensor(s). To deplete the backup
power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to
disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these
instructions may result in serious personal injury or death in the event of an accidental
deployment.
Disconnect the battery ground cable and wait at least one minute. For additional information, refer to
Section 414-01 .
6.
Remove the driver air bag module. For additional information, refer to Driver Air Bag Module in this
section.
7.
Hybrid vehicles
Remove the steering column opening trim panel.
Remove the 2 screws.
Pull downward to release the retainers and remove the steering column opening panel.
8.
Disconnect the knee air bag module electrical connector. 9.
All vehicles
Disconnect the glove compartment damper and lower the glove compartment. 10.
NOTE: RH HVAC register omitted for clarity.
Remove the RH instrument panel side finish panel to access the RH passenger air bag module
11.
Through the glove compartment opening, access the LH passenger air bag electrical connector. 12.
NOTICE: Do not pull the electrical connectors out by the Connector Position Assurance (CPA)
clip. Damage to the clip can occur.
Using an appropriate tool, lift up and release the Connector Position Assurance (CPA) clips and
disconnect the 2 electrical connectors.
13.
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.
14.
Remove the RH C-pillar trim cover retainer cap. 15.
Remove the retainer and RH C-pillar trim cover. 16.
Disconnect the RH side air curtain module electrical connector. 17.
Remove the LH C-pillar trim cover retainer cap. 18.
Remove the retainer and LH C-pillar trim cover. 19.
Disconnect the LH side air curtain module electrical connector. 20.
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.
21.
Install RCM fuse 32 (10A) in the SJB . 22.
Connect the battery ground cable. For additional information, refer to Section 414-01 . 23.
Reactivation
All vehicles
Remove RCM fuse 32 (10A) from the SJB . 1.
Disconnect the battery ground cable and wait at least one minute. 2.
Connect the driver seat side air bag module electrical connector and then slide and engage the seat
side air bag electrical connector locking clip.
3.
Connect the LH side air curtain module electrical connector. 4.
Install the LH C-pillar trim cover and retainer. 5.
Install the LH C-pillar trim cover retainer cap. 6.
Connect the RH side air curtain module electrical connector. 7.
Install the RH C-pillar trim cover and retainer. 8.
Install the RH C-pillar trim cover retainer cap. 9.
Connect the passenger seat side air bag module electrical connector and slide and engage the seat side
air bag electrical connector locking clip.
10.
NOTICE: The Connector Position Assurance (CPA) clip must be in the released position before
installing the electrical connector. Failure to have the CPA clip in the released position may
break the tabs on the clip causing DTCs to set in the Restraints Control Module (RCM).
Through the RH instrument panel side finish panel opening, connect the RH passenger air bag module
electrical connector and push in to seat the CPA clip.
Verify that the clip is fully seated.
11.
Install the RH instrument panel side finish panel. 12.
installing the electrical connector. Failure to have the CPA clip in the released position may
break the tabs on the clip causing DTCs to set in the Restraints Control Module (RCM).
Through the glove compartment opening, connect the LH passenger air bag electrical connector and
push in to seat the CPA clip.
Verify that the clip is fully seated.
13.
Attach the glove compartment damper cable. 14.
Hybrid vehicles
Connect the knee air bag module electrical connector. 15.
Install the steering column opening trim panel and 2 screws. 16.
All vehicles
Install the driver air bag module. For additional information, refer to Driver Air Bag Module in this
section.
17.
Turn the ignition from OFF to ON. 18.
Install RCM fuse 32 (10A) in the SJB and close the cover. 19.
WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in
front of any air bag module when the battery is connected. Failure to follow these instructions
may result in serious personal injury in the event of an accidental deployment.
Connect the battery ground cable.
20.
- fail to light.
- flash.
the OFF to the ON position. This is the time required to complete testing of the SRS . If the air bag
warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5
beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed
and repaired.
Clear all RCM and OCSM CMDTCs .
21.
System
Workshop Manual
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 SRS , the restraint system diagnostic tools (if required) must be
removed before operating the vehicle over the road.
NOTE: Deployable devices (such as air bag modules, pretensioners) may deploy alone or in various
combinations depending on the impact event.
NOTE: Always refer to the appropriate workshop manual procedures prior to carrying out vehicle repairs
affecting the SRS and safety belt system.
All vehicles
NOTE: Refer to the correct removal and installation procedure for all SRS components being
installed.
When any deployable device or combination of devices have deployed and/or the RCM has DTC
B1231/B1193:00 (Event Threshold Exceeded) in memory, the repair of the vehicle SRS is to include
the removal of all deployed devices and the installation of new deployable devices, the removal and
installation of new impact sensors and the removal and installation of a new RCM . DTCs must be
cleared from all required modules after repairs are carried out.
1.
Vehicles with an OCS
NOTE: After installation of new OCS components, carry out the OCS Reset procedure as instructed
in the workshop manual. Refer to the appropriate workshop manual for OCS removal and installation
procedure.
When a vehicle has been involved in a collision and the OCSM has DTC B1231/B1193:00 stored in
memory, the repair of the OCS is to include the following procedures for the specified system:
For rail-type OCS , inspect the passenger side floorpan for damage and repair as necessary.
Install new OCS rails. Do not install a new OCSM unless DTC B1231 cannot be cleared.

For weight sensor bolt-type OCS , inspect the passenger side floorpan for damage and repair
as necessary. Install a new seat track with OCS weight sensor bolts. DTC must be cleared
from the OCSM before carrying out OCS Reset. Do not install a new OCSM unless DTC
B1231/B1193:00 cannot be cleared.

For bladder-type OCS , inspect for damage and repair as necessary. If installation of an OCS
component is required, an OCS service kit must be installed.

2.
All vehicles
Inspection and Repair After a Supplemental Restraint System (SRS) Deployment 1021
When any damage to the impact sensor mounting points or mounting hardware has occurred, repair or
install new mounting points and mounting hardware as needed.
3.
When the driver air bag module has deployed, a new clockspring must be installed. 4.
New driver and/or front passenger safety belt systems (including retractors, buckles, anchors and
height adjusters) must be installed if the vehicle is involved in a collision that results in deployment of
the driver and/or front passenger safety belt pretensioners. For additional information, refer to Section
501-20A .
5.
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, safety belt retractors and safety belt anchors. For additional
information, refer to Section 501-20A .

SRS wiring, wiring harnesses and connectors
6.
After carrying out the review and inspection of the entire vehicle for damage, repair or install new
components as needed.
7.
Inspection and Repair After a Supplemental Restraint System (SRS) Deployment 1022
System
Workshop Manual
Occupant Classification Sensor (OCS) System Reset
Special Tool(s)
WARNING: The following precautions must be taken before carrying out the following procedure
on the front passenger seat:
Park the vehicle on level ground.
Make sure the occupant classification system (OCS) is stabilized at a temperature in the range of
5C to 48C (41F to 118F) and is not exposed to temperatures outside that range.

Make sure the front passenger seat is empty and dry.
Make sure the front passenger seat repair is complete and all attached components (head restraint, seat
side shield) are correctly installed.

Make sure nothing is placed in the map pockets (if equipped) of the front passenger seat.
Make sure nothing is underneath the front passenger seat.
Make sure no non-factory installed items (seat covers, DVD screens) are on or contacting the front
passenger seat. If any non-factory items were installed to the seat, remove the item(s) and
communicate to the customer that any alteration/modification to the front passenger seat may affect
performance of the OCS. Refer to the Owner's Literature.

Make sure the seat is correctly installed in the vehicle.
Failure to follow these instructions may result in incorrect operation of the OCS and increases the risk of
NOTE: After installation of new OCS system component(s) and the completion of Inspection and Repair
After a Supplemental Restraint System (SRS) Deployment , the OCSM will have DTC B1193:00 stored in
memory. In the event of a crash, DTC B1193:00 must be cleared before carrying out the Occupant
Classification System (OCS) System Reset.
If a SRS deployment has occurred, carry out the following steps:
Verify that all steps have been carried out as outlined in the Inspection and Repair After a
Supplemental Restraint System (SRS) Deployment procedure in this section.

NOTE: A new RCM must be installed before clearing OCSM DTC B1193:00, if a new RCM
is not installed first, the OCSM DTC B1193:00 will not clear.
Clear OCSM DTC B1193:00.

Proceed to Step 4 to carry out the System Reset .
1.
If SRS deployment has NOT occurred, if the front passenger seat has been removed and/or serviced
or new OCS components have been installed, proceed to Step 3 to carry out the System Reset .
2.
NOTE: After installation of new OCS system component(s), (seat track assembly or OCSM ), the OCSM will
have DTC B00A0:54 stored in memory. This DTC will clear after a successful System Reset.
Occupant Classification Sensor (OCS) System Reset 1023
Carry out the RCM self-test. If DTC B00A0:09 is retrieved on-demand, retrieve OCSM DTCs.
If OCSM DTCs are retrieved on-demand and NO new components have been installed, refer
to the OCSM DTC Chart for diagnostic direction.

If no OCSM DTCs are retrieved on-demand, CLEAR the DTC from the RCM and proceed to
step 4 to carry out the System Reset

3.
Turn the ignition to the OFF position. 4.
Prepare the passenger seat for a System Reset and make sure:
the OCS weight sensor bolt harness connections are correct for each sensor at the correct
locations. Refer to Wiring Diagrams cell 46 for schematic and connector information. Refer
to the illustration for correct sensor location on the seat.

the seat wiring harnesses are routed and secured correctly and are not twisted, pinched,
pulling down or pushing up on any seat component.

all seat fasteners have been tightened to specification as identified in the Workshop Manual.

make sure the seat track and backrest frame are not bent, twisted or damaged.
move the seat and backrest to all seating positions. Make sure the seat track does not bind or
have any resistance when moved to all seating positions. Make sure that there are no
obstructions contacting any seat component when the seat is moved to all seating positions.

the seat is correctly installed in the vehicle.
the passenger safety belt buckle is unbuckled .
the front passenger seat is empty and there is nothing underneath the seat. Remove any items
that were not factory components installed and make sure that the seat is correctly installed in
the vehicle

the seat backrest is in a normal seating (vertical) position.
the seat is at the mid-point of seat track travel.
the hysteresis has been removed from the front passenger seat by firmly hitting the seat
backrest 3 times.

the vehicle electrical system voltage is below 18 volts and above 11.5 volts before
continuing with the OCS System Reset.

5.
NOTE: Typical seat track shown, others similar.
Turn the ignition ON, wait 8 seconds. 6.
Carry out the OCSM System Reset.
If the System Reset was successful, carry out the OCS Zero Seat Weight Test. For additional
information, refer to Occupant Classification Sensor (OCS) System Zero Seat Weight Test in
this section.

If the System Reset was unsuccessful, proceed to step 8 .
7.
NOTE: Do not install any new OCS system components at this time. OCS system components should
only be installed when directed to do so.
Retrieve OCSM DTCs.
8.
If DTC B00A0:54 is retrieved on-demand, refer to the DTC Charts for diagnostic direction of
this DTC.

If any other DTCs are retrieved on-demand from the OCSM , proceed to Step 9 .
Inspect all the items listed in Step 5 for causes of a unsuccessful System Reset, repair as necessary.
Retest the system.
9.
If the System Reset was successful, carry out the Occupant Classification Sensor (OCS) System Zero
Seat Weight Test in this section.
If the System Reset was unsuccessful, install OCS weight sensor assemblies, refer to Occupant
Classification Sensor .
10.
System
Workshop Manual
Occupant Classification Sensor (OCS) System Zero Seat Weight Test
Special Tool(s)
WARNING: The following precautions must be taken before carrying out the following procedure
on the front passenger seat:
Make sure the occupant classification system (OCS) is stabilized at a temperature in the range of
5C to 48C (41F to 118F) and is not exposed to temperatures outside that range.

Make sure the front passenger seat repair is complete and all attached components (head restraint, seat
side shield) are correctly installed.

Make sure no non-factory installed items (seat covers, DVD screens) are on or contacting the front
passenger seat. If any non-factory items were installed to the seat, remove the item(s) and
communicate to the customer that any alteration/modification to the front passenger seat may affect
performance of the OCS. Refer to the Owner's Literature.

Failure to follow these instructions may result in incorrect operation of the OCS and increases the risk of
NOTICE: Make sure the Occupant Classification System (OCS) weight sensor bolt protection brackets
are correctly installed to the seat track and that it does not contact the cushion side shield, wire harness
or any other surrounding parts. Failure to follow this instruction may result in the incorrect operation
of the OCS system.
NOTE: The Zero Seat Weight Test is done with the passenger seat positioned in 2 different positions to make
sure that there is nothing to affect the performance and operation of the Occupant Classification System
(OCS) system.
NOTE: The Zero Seat Weight Test verifies the OCS system measures zero weight for an empty seat. It is
necessary to carry out the Zero Seat Weight Test procedure after a successful System Reset or as directed to
do so in the workshop manual procedures.
NOTE: If the Occupant Classification System Module (OCSM) has any on-demand DTCs present, the fault
condition(s) must be repaired and the DTCs cleared before carrying out the Zero Seat Weight Test on the front
passenger seat. Failure to follow this instruction will result in an unsuccessful Zero Seat Weight Test and the
incorrect operation of the OCS system.
Occupant Classification Sensor (OCS) System Zero Seat Weight Test 1026
WARNING: The following precautions must be taken before carrying out the following
procedure on the front passenger seat:
Make sure the occupant classification system (OCS) is stabilized at a temperature in the range
of 5C to 48C (41F to 118F) and is not exposed to temperatures outside that
range.

Make sure the front passenger seat repair is complete and all attached components (head
restraint, seat side shield) are correctly installed.

Make sure no non-factory installed items (seat covers, DVD screens) are on or contacting the
front passenger seat. If any non-factory items were installed to the seat, remove the item(s)
and communicate to the customer that any alteration/modification to the front passenger seat
may affect performance of the OCS. Refer to the Owner's Literature.

Failure to follow these instructions may result in incorrect operation of the OCS and increases the risk
of serious personal injury or death in a crash.Make sure the front passenger seat is empty and there is
nothing underneath the seat. Remove any items from the seat that were not factory installed and make
sure that the seat is correctly installed in the vehicle. For additional information, refer to Occupant
Classification System (OCS) System in Air Bag and Safety Belt Pretensioner Supplemental Restraint
System (SRS) in this section.
Make sure the passenger safety belt buckle is unbuckled.
Make sure the vehicles electrical system voltage is below 18 volts and above 11.5 volts before
continuing.
1.
Position the front passenger seat in the first position.
Position the seat backrest in the upright position.
Position the seat in the full forward position of seat track travel.
Position the seat height to its highest position (power seat only).
2.
WARNING: Remove binding or resistance between all components of the front passenger
seat as directed in the following procedure. Failure to follow this instruction may result in
incorrect operation of the occupant classification system (OCS) and increases the risk of serious
Remove hysteresis from the front passenger seat by firmly hitting the seat backrest 3 times.
3.
WARNING: Make sure nothing is placed on the front passenger seat during the following
procedure. Do not press, touch or lay anything on the front passenger seat until the following
procedure has been completed. Failure to follow these instructions may result in incorrect
operation of the occupant classification system (OCS) and increase the risk of serious personal
injury or death in a crash.
Turn the ignition ON.
5.
NOTE: Make sure a minimum 8-second time period has passed after cycling the ignition ON before
carrying out the Zero Seat Weight Test active command.
Carry out the Zero Seat Weight Test using the scan tool.
6.
If the system passed, proceed to Step 7.
If the system did not pass (DTC B00A0:67 Occupant Classification System: Signal Incorrect
After Event retrieved on-demand), proceed to Step 9.

Position the front passenger seat to the second position.
Position the seat in the full rearward position of seat track travel.
Position the seat height to its lowest position (power seat only).
7.
Carry out the Zero Seat Weight Test using the scan tool.
If the system passed, repair is complete, Proceed to Step 10.
If the system did not pass (DTC B00A0:67 Occupant Classification System: Signal Incorrect
After Event retrieved on-demand), proceed to Step 9.

8.
NOTE: Check the repair history of the vehicle for any previous repair that required the removal or
service of the passenger seat. The repair history may lead to an area of concern.
Inspect the following for causes of an unsuccessful Zero Seat Weight Test.
Make sure the front passenger seat is empty and there is nothing underneath the seat. Remove
any items from the seat that were not factory installed and make sure that the seat is correctly
installed in the vehicle.

Make sure the passenger safety belt buckle is unbuckled.
Make sure the seat wiring harnesses are routed and secured correctly and are not twisted,
pinched, pulling down or pushing up on any seat component.

Make sure the OCS weight sensor bolt protection brackets are correctly installed to the seat
track and are not contacting the cushion side shield, wire harness or any other surrounding
parts.

Make sure the seat track and backrest frame are not bent, twisted or damaged.
Move the seat and backrest to all seating positions. Make sure the seat track does not bind or
have any resistance when moved to all seating positions. Make sure that there are no
obstructions contacting any seat component when the seat is moved to all seating positions.

Make sure the vehicles electrical system voltage is below 18 volts and above 11.5 volts .
Make sure the seat is assembled correctly and all fasteners are tightened to specifications.
If a concern was found, repair as necessary, proceed to Step 1.
If no concern was found, install new OCS weight sensor assemblies. Refer to
Occupant Classification Sensor in this section.

9.
Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back to ON and visually
monitor the air bag warning indicator with the air bag modules installed. The air bag warning
indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault
is present, the air bag warning indicator will:
fail to light.
remain lit continuously.
flash at a 5 Hz rate ( RCM not configured).
The air bag warning indicator might not light until approximately 30 seconds after the ignition has
been turned from the OFF to the ON position. This is the time required for the RCM to complete the
testing of the SRS . If the air bag warning indicator is inoperative and a SRS fault exists, a chime will
sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault
discovered must be diagnosed and repaired.
Repair any unresolved DTCs.
Clear all continuous DTCs from the RCM and OCSM using a scan tool.
10.
System
Workshop Manual
Pyrotechnic Device Disposal
Disposal of Deployable Devices and Pyrotechnic Devices That are Undeployed/Inoperative
NOTE: All inoperative air bag modules and safety belt pretensioners have been placed on the Mandatory
Return List. All discolored or damaged air bag modules must be treated the same as any inoperative live air
bag being returned.
Depower the SRS . Refer to Supplemental Restraint System (SRS) Depowering and Repowering in
the General Procedures portion of this section.
1.
Remove the undeployed/inoperative device. Refer to the appropriate procedure in this section or
Section 501-20A .
2.
NOTE: When installing a new air bag module or inflatable safety belt inflator, a prepaid return
postcard is provided with the replacement air bag module. The serial number for the new part and the
VIN must be recorded and sent to Ford Motor Company.
If installing a new air bag module or inflatable safety belt inflator, record the necessary information
and return the inoperative air bag module to Ford Motor Company.
3.
Disposal of Deployable Devices and Pyrotechnic Devices That Are Deployed
1.
Remove the deployed device. Refer to the appropriate procedure in this section or Section 501-20A . 2.
NOTE: If a dual stage driver or passenger air bag module has deployed due to a crash event, the air
bag module requires manual deployment to make sure both stages and the active canister vent have
deployed before scrapping the vehicle or disposing of the air bag module. To determine if a vehicle is
equipped with dual stage driver or passenger air bag modules, refer to the Description and Operation
Dispose of the deployed device in the same manner as any other part to be scrapped.
3.
Disposal of Deployable Devices and Pyrotechnic Devices That Require Manual Deployment
Safety and environmental concerns require consideration and treatment of restraints system
deployable and pyrotechnic devices when disposing of vehicles, deployable devices or pyrotechnic
devices. Deploying deployable and pyrotechnic devices before scrapping a vehicle or the device
eliminates the potential for hazardous exposures or reactions during processing. If special handling
procedures are followed, deployable and pyrotechnic devices can be deployed safely and recycled
with the vehicle, shipped separately to a recycling facility or disposed of safely.
NOTE: To determine the deployable devices a vehicle is equipped with, refer to the Description and
Operation portion of this section.
1.
Pyrotechnic Device Disposal 1030
A vehicle equipped with any of the following deployable devices requires manual deployment of the
devices before scrapping the vehicle or component. Refer to the appropriate portion of this procedure.
Inflatable safety belt inflators
Knee air bag module
Passenger air bag module
Seat side air bag modules
Safety Canopy modules
Side air curtain modules
NOTE: To determine the pyrotechnic devices a vehicle is equipped with, refer to the Description and
Operation portion of this section.
A vehicle equipped with any of the following pyrotechnic devices requires manual deployment of the
devices before scrapping the vehicle or component. Refer to the appropriate portion of this procedure.
Safety belt buckle pretensioners
Safety belt retractor pretensioners
Safety belt anchor pretensioners
Adaptive load-limiting retractors
Deployable steering column
2.
NOTE: To determine if a vehicle is equipped with dual stage driver or passenger air bag modules,
refer to the Description and Operation portion of this section.
If a dual stage driver or passenger air bag module has deployed due to a crash event, the air bag
module requires manual deployment to make sure both stages and the active canister vent have
deployed before scrapping the vehicle or disposing of the air bag module. Refer to Driver Air Bag
Module, Passenger Air Bag Module, Knee Air Bag Module and Seat Side Air Bag Module - Remote
Deployment in this procedure.
3.
Driver Air Bag Module, Passenger Air Bag Module, Knee Air Bag Module and Seat Side Air Bag
Module - Remote Deployment
serious personal injury or in the event of an accidental deployment.
limiters, etc.) outdoors with all personnel at least 9 meters (30 feet) away to make sure of personal
safety. Due to the loud report which occurs when an SRS device is deployed, hearing protection is
required. Failure to follow these instructions may result in serious personal injury.
NOTE: For air bag modules with multiple loops, deploy all of the loops on the air bag module.
NOTE: Some driver and passenger front air bags have 2 deployment stages and an active canister vent. After
a collision it is possible that Stage 1 has deployed and Stage 2 and the active canister vent have not.
If a front air bag module has deployed, it is mandatory that the front air bag module be remotely deployed
using the appropriate air bag disposal procedure.
NOTE: A typical air bag disposal is shown that is similar for all vehicles.
All driver, passenger, knee and seat side air bag modules
Make a container to house the air bag module for deployment.
NOTE: The tires must be of sufficient size to accommodate the air bag module.
Obtain a tire and wheel assembly and an additional 4 tires (without wheels) of the same size.

With the tire and wheel assembly on the bottom, stack the tires.
Securely tie all of the tires together.
1.
2.
Remove the air bag module. Refer to the appropriate procedure in this section. 3.
NOTE: If the air bag module does not have a hard-wired pigtail, cut the wires and connector(s) from
the vehicle wire harness and reconnect to the air bag module.
Cut each of the air bag module wires near the electrical connector that connects to the vehicle wire
harness.
4.
Remove any sheathing (if present) and strip the insulation from the ends of the cut wires. 5.
NOTE: Typical driver air bag module with 2 loops shown, other air bag modules with multiple loops
or multiple features (canister vent, active tether) similar.
For air bag modules with multiple loops, twist together a wire from each loop then repeat for the
remaining wires from each loop.
6.
Make a jumper harness to deploy the air bag module.
Obtain 2 wires (20 gauge minimum) at least 9.14 m (30 ft) long and strip both ends of each
wire.

At one end of the jumper harness, connect the wires together.
7.
Using the end of the jumper harness where the wires are not connected together, attach each wire of
the jumper harness to each wire of the air bag module or to the twisted-together wires if multiple
loops. Use tape or other insulating material to make sure that the leads do not make contact with each
other.
8.
Driver air bag modules
NOTE: Make sure the air bag connections are maintained.
For driver air bag modules, with the stack of tires upright and the wheel on the bottom, carefully place
the driver air bag module, with the trim cover facing up, on the wheel.
9.
Passenger, knee and seat side air bag modules
NOTE: Make sure the air bag connections are maintained.
Tip the stack of tires on its side and place the air bag module inside the center tire, making sure that
there are 2 tires beneath the tire containing the air bag module and 2 tires (including the tire and wheel
assembly) above the tire containing the air bag module.
10.
Place the tire stack upright, with the wheel on top. 11.
All driver, passenger, knee and seat side air bag modules
Remain at least 9.14 m (30 ft) away from the air bag module. 12.
From the end of the jumper harness that is not connected to the air bag module, disconnect the 2 wires
of the jumper harness from each other.
13.
Deploy the air bag module by touching the ends of the 2 wires of the jumper harness to the terminals
of a 12-volt battery.
14.
To allow for cooling, wait at least 10 minutes before approaching the deployed air bag module. 15.
Dispose of the deployed air bag module in the same manner as any other part to be scrapped. 16.
Safety Belt Anchor Pretensioners, Safety Belt Buckle Pretensioners, Safety Belt Retractor
Pretensioners, Adaptive Load Limiting Safety Belt Retractors and Safety Belt Inflators - Remote
Deployment
pretensioners, load limiters and inflators. Ner back probe deployable device electrical connectors.
death.
NOTE: A typical safety belt buckle, retractor and inflator disposal is shown that is similar for all vehicles.
Make a container to house the safety belt buckle or retractor for deployment.
NOTE: The tires must be of sufficient size to accommodate the safety belt buckle, retractor
or inflator.
Obtain a tire and wheel assembly and 4 additional tires (without wheels) of the same size.

With the tire and wheel assembly on the bottom, stack the tires.
Securely tie all of the tires together.
1.
2.
Remove the safety belt buckle, retractor or inflator. Refer to the appropriate procedure in Section
501-20A .
When deploying a safety belt buckle pretensioner, install a nut and bolt of sufficient length
and of the same diameter as was used to retain it to the seat.

3.
NOTE: If the safety belt anchor, buckle, retractor or inflator does not have a hard-wired pigtail, it will
be necessary to cut the wires and connector(s) from the vehicle wire harness and reconnect to the
safety belt buckle, retractor or inflator.
Cut each of the safety belt anchor, buckle, retractor or inflator wires near the electrical connector that
connects to the vehicle wire harness.
4.
Make a jumper harness to deploy the safety belt buckle, retractor or inflator.
wire.

6.
NOTE: Typical safety belt retractor pretensioner shown, other safety belt anchor pretensioners,
buckle pretensioners, load-limiting retractors and safety belt inflators similar.
Using the end of the jumper harness that the wires are not connected together, attach each wire of the
jumper harness to each wire of the safety belt anchor, buckle, retractor or inflator. Use tape or other
insulating material to make sure that the leads do not make contact with each other.
7.
NOTE: Make sure the safety belt anchor, buckle, retractor or inflator connections are maintained. 8.
Tip the stack of tires on its side and place the safety belt anchor, buckle, retractor or inflator inside the
center tire, making sure that there are 2 tires beneath the tire containing the safety belt anchor, buckle,
retractor or inflator and 2 tires (including the tire and wheel assembly) above the tire containing the
safety belt anchor, buckle, retractor or inflator.
Place the tire stack upright, with the wheel on top. 9.
Remain at least 9.14 m (30 ft) away from the safety belt anchor, buckle, retractor or inflator. 10.
From the end of the jumper harness that is not connected to the safety belt anchor, buckle, retractor or
inflator, disconnect the 2 wires of the jumper harness from each other.
11.
Deploy the safety belt anchor pretensioner, buckle pretensioner, retractor pretensioner or inflator by
touching the ends of the 2 wires of the jumper harness to the terminals of a 12-volt battery.
12.
To allow for cooling, wait at least 10 minutes before approaching the deployed safety belt anchor
pretensioner, buckle pretensioner, retractor pretensioner or inflator.
13.
Dispose of the deployed safety belt anchor, buckle, retractor or inflator in the same manner as any
other part to be scrapped.
14.
Safety Belt Anchor Pretensioners, Safety Belt Buckle Pretensioners, Safety Belt Retractor Pretensioners
and Load Limiting Safety Belt Retractors - In-Vehicle Deployment
death.
limiters, etc.) outdoors with all personnel at least 9 meters (30 feet) ay to make sure of personal safety.
Due to the loud report which occurs when an SRS device is deployed, hearing protection is required.
NOTE: A typical safety belt buckle and retractor disposal is shown that is similar for all vehicles.
1.
Access the safety belt anchor, buckle or retractor electrical connectors. For additional information,
refer to Section 501-20A .
2.
Cut each of the safety belt anchor, buckle or retractor wires, leaving at least 101.6 mm (4 in) to work
with.
3.
Make a jumper harness to deploy the safety belt anchor, buckle or retractor.
wire.

5.
NOTE: Typical safety belt retractor pretensioner shown, other safety belt anchor pretensioners,
buckle pretensioners and load-limiting retractors are similar.
Using the end of the jumper harness that the wires are not connected together, attach each wire of the
jumper harness to each wire of the safety belt anchor, buckle or retractor. Use tape or other insulating
material to make sure that the leads do not make contact with each other.
6.
Remain at least 9.14 m (30 ft) away from the safety belt anchor, buckle or retractor. 7.
From the end of the jumper harness that is not connected to the safety belt anchor, buckle or retractor,
disconnect the 2 wires of the jumper harness from each other.
8.
Deploy the safety belt anchor pretensioner, buckle pretensioner or retractor pretensioner by touching
the ends of the 2 wires of the jumper harness to the terminals of a 12-volt battery.
9.
To allow for cooling, wait at least 10 minutes before approaching the deployed safety belt anchor
pretensioner, buckle pretensioner or retractor pretensioner.
10.
Dispose of the deployed safety belt anchor, buckle or retractor in the same manner as any other part to
be scrapped.
11.
Safety Canopy Modules and Side Air Curtain Modules - In-Vehicle Deployment
NOTE: The Safety Canopy module deployment for a scrapped vehicle will occur in its installed position in
the vehicle.
NOTE: A typical Safety Canopy module disposal is shown that is similar for all vehicles.
1.
Access the Safety Canopy/side air curtain module electrical connectors. For additional information,
refer to the appropriate procedure in this section.
2.
Cut each of the Safety Canopy/side air curtain module wires leaving at least 101.6 mm (4 in) to
work with.
3.
NOTE: Typical Safety Canopy/side air curtain module with 2 loops shown, other Safety
Canopy/side air curtain modules wioops are similar.
For Safety Canopy/side air curtain modules with multiple loops, twist together a wire from each
loop then repeat for the remaining wires from each loop.
5.
Make a jumper harness to deploy the Safety Canopy/side air curtain module.
wire.

6.
the jumper harness to each wire of the Safety Canopy/side air curtain module or to the
twisted-together wires if multiple loops. Use tape or other insulating material to make sure that the
leads do not make contact with each other.
7.
From the end of the jumper harness that is not connected to the Safety Canopy/side air curtain
module, disconnect the 2 wires of the jumper harness from each other.
8.
Deploy the Safety Canopy/side air curtain module by touching the ends of the 2 wires of the jumper
harness to the terminals of a 12-volt battery.
9.
To allow for cooling, wait at least 10 minutes before apping the deployed Safety Canopy/side air
curtain module.
10.
Dispose of the deployed Safety Canopy/side air curtain module in the same manner as any other
part to be scrapped.
11.
Deployable Steering Column - In-Vehicle Deployment
1.
NOTE: It may be necessary to lower or remove the deployable steering column from the instrument
panel to access the deployable steering column electrical connector.
Access the deployable steering column electrical connector.
2.
NOTE: If the deployable steering column does not ha hard-wired pigtail, it will be necessary to cut
the wires and connector(s) from the vehicle wire harness and reconnect to the deployable steering
column.
Cut each of the deployable steering column wires, leaving at least 101.6 mm (4 in) to work with.
3.
Make a jumper harness to deploy the deployable steering column.
wire.

5.
the jumper harness to each wire of the deployable steering column. Use tape or other insulating
material to make sure that the leads do not make contact with each other.
6.
Remain at least 9.14 m (30 ft) away from the deployable steering column. 7.
From the end of the jumper harness that is not connected to the deployable steering column,
disconnect the 2 wires of the jumper harness from each other.
8.
Deploy the deployable steering column by touching the ends of the 2 wires of the jumper harness to
the terminals of a 12-volt battery.
9.
To allow for cooling, wait at least 10 minutes before approaching the deployed steering column. 10.
Dispose of the deployed steering column in the same manner as any other part to be scrapped. 11.
System
Workshop Manual
Rivet Nut Replacement
NOTICE: If the Safety Canopy/side air curtain module has deployed, the tether cord rivet nut must
be inspected and replaced if damagd before installing a new Safety Canopy.
NOTE: A typical rivet nut replacement is shown that is similar for all vehicles.
Depower the Supplemental Restraint System (SRS). For additional information, refer to Supplemental
Restraint System (SRS) Depowering and Repowering in this section.
1.
Remove the necessary trim panel(s). For additional information, refer to Section 501-05 . 2.
Remove the bolt and bracket for the tether cord (if present). 3.
If needed, position and secure the Safety Canopy/side air curtain tether cord and bracket assembly
aside.
4.
Using the appropriate service tool, sand the rivet nut shoulder until the shoulder surface is removed. 5.
Punch the remaining portion of the rivet nut through the rivet nut hole. 6.
NOTE: Use only Ford Motor Company factory-authorized replacement parts for rivet nut repair
procedure.
Obtain the correct square shank rivet nut for the vehicle application from the Ford Catalog
AdvantageTM or equivalent and insert it into the rivet nut hole.
7.
Using a suitable rivet nut installing tool, install the rivet nut. For additional information, refer to the
tool manufacturer's operating instructions.
8.
Rivet Nut Replacement 1041
If present, position the tether cord. Install the bolt. See the appropriate component removal and
installation procedure or Specifications for the correct torque specification.
9.
NOTE: The tether cord must be positioned correctly in place before installing the A-pillar trim panel.
Install the necessary trim panel(s). For additional information, refer to Section 501-05 .
10.
Rivet Nut Replacement 1042
System
Workshop Manual
Clockspring
Item
Part
Number Description
1 3530 Upper steering column shroud
2 - Steering wheel rotation sensor electrical connector (part
of 14401)
3 3F818 Steering wheel rotation sensor
4 W506942 Steering wheel rotation sensor screws (2 required)
5 3K512 Lower steering column shroud
6 - Lower steering column shroud screws (3 required) (part
of 3K512)
7 W506942 Clockspring screws (2 required)
8 - Clockspring electrical connector (part of 14401)
9 14A664 Clockspring
Removal
Remove the driver air bag module. For additional information, refer to Driver Air Bag Module in this
section.
1.
NOTICE: Make sure the road wheels are in the straight-ahead position. Damage to the
clockspring may occur.
Remove the steering wheel. For additional information, refer to steering wheel Removal and
Installation in Section 211-04 .
Release the upper steering column shroud by pressing inward on the sides, lift
upwards and remove.
3.
Remove the 3 screws and lower steering column shroud. 4.
Remove the steering wheel rotation sensor.
5.
2.
Clockspring 1043
Remove the 2 screws and sensor.
Remove the clockspring.
Remove the 2 screws.
Remove the clockspring.
6.
Installation
WARNING: If the clockspring is not correctly centralized, it may fail prematurely.
If in doubt, repeat the centralizing procedure. Failure to follow these instructions may
increase the risk of serious personal injury or death in a crash.
NOTICE: Do not over-rotate the clockspring inner rotor. The internal ribbon wire is
connected to the clockspring rotor. The internal ribbon wire acts as a stop and can be
broken from its internal connection. Failure to follow this instruction may result in
component damage and/or system failure.
NOTICE: If installing a new clockspring, do not remove the clockspring anti-rotation
key until the steering wheel is installed. If the anti-rotation key has been removed before
installing the steering wheel, the clockspring must be centered. Failure to follow this
instruction may result in component damage and/or system failure.
Install the clockspring and 2 screws. 1.
Connect the clockspring electrical connector. 2.
Install the steering wheel rotation sensor and 2 screws. 3.
If a new clockspring was installed and the anti-rotation key has not been removed,
proceed to Step 8 , otherwise proceed to Step 6 .
4.
If a new clockspring was installed and the anti-rotation key has been removed before
the steering wheel is installed or the same clockspring is being installed, rotate the
clockspring inner rotor counterclockwise and carefully feel for the ribbon wire to run
out of length with slight resistance. Stop rotating the clockspring inner rotor at this
point.
5.
Starting with the clockspring inner rotor in the 12 o'clock position, rotate the inner
rotor clockwise through approximately 2.25 turns to center the clockspring.
The clockspring inner rotor must be in the 12 o'clock position to be correctly
centered.

6.
NOTICE: To prevent damage to the clockspring, make sure the road wheels are
in the straight-ahead position.
Install the steering wheel. For additional information, refer to Section 211-04 .
7.
If a new clockspring was installed, remove the anti-rotation key. 8.
Install the driver air bag module. For additional information, refer to Driver Air Bag
9.
Install the upper and lower steering column shrouds.
Clip the lower steering column shroud to the upper steering column shroud.
Install the 3 screws.
10.
Repower the SRS . For additional information, refer to Supplemental Restraint
System (SRS) Depowering and Repowering in this section.
11.
Clockspring 1044
Clockspring 1045
System
Workshop Manual
Item
Part
Number Description
1 - Driver air bag module electrical connectors (part of
14A664)
2 3600 Steering wheel
3 - Driver air bag module locking pins (part of 43B13)
4 43B13 Driver air bag module
Removal
Depowering and Repowering in the General Procedures portion of this section.
1.
NOTE: Repeat this step for both locking pins.
Using a 3-mm Allen wrench or a suitable tool through the access hole on the backside of the steering
wheel, position the tool against the spring clip and push in, disengaging the clip from the locking pin.
With the spring clip disengaged from the locking pin, gently pull back on that side of the driver air
bag module to release it from the steering wheel.
2.
Driver Air Bag Module 1046
NOTICE: Do not pull the driver air bag module electrical connectors out by the locking buttons.
Damage to the locking buttons can occur.
Using a small screwdriver as shown, lift up and release the locking buttons on the driver air bag
module electrical connectors. With the locking buttons released, remove the electrical connectors and
the driver air bag module.
3.
Installation
NOTICE: The driver air bag module electrical connector locking buttons must be in the
released position when connected. Do not install the driver air bag module electrical connectors
by the locking buttons. Failure to follow these instructions may cause connector damage.
With the locking buttons released, install the driver air bag module electrical connectors fully into the
driver air bag module and seat the locking buttons.
1.
Align the driver air bag module locking pins to the steering wheel and, while pushing inward, seat the
2 driver air bag module locking pins to the steering wheel wire clips.
2.
3.
System
Workshop Manual
Front Impact Severity Sensor
Item
Part
Number Description
1 - Front impact severity sensor electrical connectors (part
of 14290)
2 14B006 RH front impact severity sensor
3 W505256 Front impact severity sensor bolts
4 14B006 LH front impact severity sensor
in a crash.
Depower the SRS . For additional information, refer to Supplemental Restraint Sysm (SRS)
1.
Remove the front bumper cover. For additional information, refer to Section 501-19 . 2.
Front Impact Severity Sensor 1049
Disconnect the front impact severity sensor electrical connector. 3.
Remove the bolt and front impact severity sensor.
4.
WARNING: Always tighten the fasteners of the restraints control module (RCM) and
impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect
restraint system operation, which increases the risk of personal injury or death in a crash.
NOTE: Make sure the radiator support and front impact severity sensor and bracket assembly mating
surfaces are clean and free of foreign material.
5.
6.
Front Impact Severity Sensor 1050
System
Workshop Manual
Knee Air Bag Module
1 3K512 Lower steering column shroud
2 W707658 Lower steering column shroud screw (3
required)
3 017A28 Steering column opening cover reinforcement
4 W505422 Steering column opening cover reinforcement
bolt (4 required)
5 04459 Steering column opening trim panel
6 - Steering column opening trim panel screw (2
required)
7 045J77 Knee air bag module
8 - Electrical connector (part of 14401)
9 W503924 Bolt (4 required)
Removal
Knee Air Bag Module 1051
NOTE: Always make sure the correct Supplemental Restraint System (SRS) component is being installed.
Parts released for other vehicles may not be compatible even if they appear physically similar. Check the part
number listed in the Master Parts Catalog to make sure the correct component is being installed. If an
incorrect SRS component is installed, DTCs may set.
1.
Remove the 2 screws and steering column opening trim panel. 2.
Remove the three screws and lower steering column shroud. 3.
Remove the 4 bolts and steering column opening cover reinforcement. 4.
Disconnect the knee air bag module electrical connector. 5.
Remove the wiring harness from the knee air bag module bracket. 6.
From the back side of the instrument panel bracket, remove the 4 knee air bag module bolts. 7.
Remove the knee air bag module. 8.
Remove and discard the 4 J-nuts. 9.
Installation
Install 4 new J-nuts. 1.
Install the knee air bag module and 4 bolts.
2.
Connect the knee air bag module electrical connector. 3.
Attach the wiring harness to the knee air bag module bracket. 4.
Install the lower steering column shroud. 5.
Install the steering column opening cover reinforcement and 4 bolts.
6.
Install the steering column opening trim panel and 2 screws. 7.
8.
System
Workshop Manual
Occupant Classification System Module (OCSM)
NOTE: Power seat shown, manual seat similar.
Item
Part
Number Description
1 - Occupant Classification System Module (OCSM)
electrical connector (part of 14A698)
2 14B422 OCSM
3 - OCSM rivets (2 required)
Remove the passenger seat. For additional information, refer to Section 501-10 . 1.
NOTICE: Make sure to remove all metal chips from the Occupant Classification System
Module (OCSM) and the surrounding areas after drilling out the rivets. Failure to follow this
instruction may result in component damage and/or system failure.
Drill out the 2 rivets and remove the Occupant Classification System Module (OCSM).
3.
If installing a new OCSM , carry out the system reset procedure. For additional information, refer to
Occupant Classification Sensor (OCS) System Reset in the General Procedures portion of this section.
5.
Occupant Classification System Module (OCSM) 1054
Occupant Classification System Module (OCSM) 1055
System
Workshop Manual
Occupant Classification Sensor
NOTE: Outboard shown, inboard similar.
Item
Part
Number Description
1 - Cushion side shield scrivet (if equipped)
2 - Manual recliner handle spring clip (part of 61198) (if
equipped)
3 61198 Manual recliner handle (if equipped)
6 - Occupant Classification System (OCS) weight sensor
assembly locating pin (part of 61708)
7 61708 OCS weight sensor assembly
8 - OCS weight sensor assembly front mounting position
front bolt (part of 61708)
9 - OCS weight sensor assembly front mounting position
rear bolt (part of 61708)
10 - OCS weight sensor assembly rear bolt (part of 61708) (2
required)
11 61913 Forward seat riser
12 - Forward seat riser bolt
13 - OCS weight sensor assembly electrical connector (part of
14A698)
Occupant Classification Sensor 1056
14 61913 Rearward seat riser
15 - Rearward seat riser bolt (2 required)
Removal
WARNING: Use care when handling the front passenger seat and track assembly. Dropping the
assembly, placing excessive weight on or sitting on a front passenger seat that is not secured in the
vehicle may result in damaged seat components. Failure to follow these instructions may result in
incorrect operation of the occupant classification system (OCS) and increases the risk of serious
All Occupant Classification System (OCS) weight sensor assemblies
Remove the passenger seat. For additional information, refer to Section 501-10 . 1.
Outboard OCS weight sensor assembly
If equipped, remove the manual lumbar control knob. 2.
If equipped, remove the spring clip and the manual recliner handle. 3.
NOTICE: Do not reinstall the cushion side shield or side shield retainers after removal. These
are one-time-use items that become damaged during removal and may not remain attached if
reinstalled. Install a new side shield (includes new retainers attached).
Remove and discard the cushion side shield.
If equipped, remove the scrivet.
Pull out on the side and rear of the cushion side shield and release the retainers.
Separate the wire harness from the cushion side shield.

Remove the side shield and any remaining side shield retainers from the seat and discard.
4.
Seat receiving a new OCS weight sensor assembly
Remove the bolt and the forward seat riser from the affected side OCS weight sensor assembly. 5.
Remove the 2 bolts and the rearward seat riser from the affected side OCS weight sensor assembly. 6.
All OCS weight sensor assemblies
NOTE: Note the position and the routing of the OCS system electrical wiring and connector for
installation.
On the affected side, disconnect the OCS weight sensor assembly electrical connector.
7.
If equipped, disconnect the power seat track motor electrical connector. 8.
Move the seat to the forward most position.
If equipped with a power seat track, apply power and ground to the pins shown.
9.
Remove the 2 rear bolts from the affected OCS weight sensor assembly. 10.
Move the seat to the rearward most position.
11.
Remove the 2 front bolts and the OCS weight sensor assembly. 12.
Installation
All Occupant Classification System (OCS) weight sensor assemblies
NOTE: If installing a new seat track, position it so the seat will be in the rearward most position before
installing the OCS weight sensor assembly.
NOTE: To make sure of correct installation, the OCS weight sensor assembly bolts must be installed
in the sequence shown.
While holding the OCS weight sensor assembly firmly in position, install the OCS weight sensor
assembly front mounting position rear bolt.
1.
While still holding the OCS weight sensor assembly firmly in position, install the OCS weight sensor
assembly front mounting position front bolt.
2.
Move the seat to the forward most position.
3.
Install the 2 rear OCS weight sensor assembly bolts.
4.
Connect the OCS weight sensor assembly electrical connector. 5.
Center the seat track to the seat cushion pan.
6.
If equipped, connect the power seat track motor electrical connector. 7.
Seat receiving a new OCS weight sensor assembly
Install the rearward seat riser and the 2 bolts.
8.
Install the forward seat riser and bolt.
9.
Outboard OCS weight sensor assembly
NOTICE: Do not reinstall the cushion side shield or side shield retainers after removal. These
are one-time-use items that become damaged during removal and may not remain attached if
reinstalled. Install a new side shield (includes new retainers attached).
Install a new cushion side shield.
10.
If equipped, install the spring clip and the manual recliner handle. 11.
If equipped, install the manual lumbar control knob. 12.
All OCS weight sensor assemblies
Install the passenger seat. Do not prove out the SRS at this time. For additional information, refer to
Section 501-10 .
13.
Carry out the Occupant Classification System (OCS) System Reset procedure and prove out the SRS .
For additional information, refer to Occupant Classification Sensor (OCS) System Reset in this
section.
14.
System
Workshop Manual
Passenger Air Bag Deactivation (PAD) Indicator
Fusion
1 10A936 Passenger Air Bag Deactivation (PAD) indicator
2 13594 Upper storage compartment
NOTE: The MKZ Passenger Air Bag Deactivation (PAD) indicator is part of the Front Controls Interface
Module (FCIM) and is not serviceable separately. For additional information, refer to Section 412-01 .
NOTE: A DTC will set in the Restraints Control Module (RCM) if the PAD electrical connector is
disconnected with the ignition ON. The RCM memory must be cleared before releasing the vehicle.
WARNING: Turn the ignition OFF and wait one minute to deplete the backup power
supply. Failure to follow this instruction may result in serious personal injury or death in the
Turn the ignition OFF and wait one minute.
1.
Remove the upper storage compartment. For additional information, refer to Section 501-12 . 2.
Release the tab and remove the PAD indicator. 3.
Prove out the Supplemental Restraint System (SRS) as follows:
- fail to light.
- flash.
the OFF to the ON position. This is the time required to complete testing of the SRS . If the air bag
5.
Passenger Air Bag Deactivation (PAD) Indicator 1061
warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5
beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed
and repaired.
Clear all RCM and Occupant Classification System Module (OCSM) Continuous Memory Diagnostic
Trouble Codes (CMDTCs).
Fusion 1062
System
Workshop Manual
Passenger Air Bag Module
1 19893 RH instrument panel register
2 - Screw
3 - Screw
4 19B680 Ventilation duct
5 19B680 Defroster duct
6 - Screw
7 - Passenger air bag module electrical
connector (part of 14401) (2 required)
8 - Passenger air bag module deployment
chute (part of instrument panel)
9 W505253 Passenger air bag module-to-deployment
chute bolts (4 required)
10 044A74 Passenger air bag module
11 W505253 Passenger air bag module bracket bolts
(2 required)
12 -
Passenger Air Bag Module 1063
Passenger air bag module bracket (part
of 044A74)
Removal
Remove the instrument panel. For additional information, refer to Section 501-12 . 1.
Remove the RH instrument panel register. 2.
Remove the screw and RH ventilation duct. 3.
Remove the screw and RH defroster duct. 4.
NOTICE: Do not pull the electrical connectors out by the Connector Position Assurance (CPA)
clip. DTCs can be set in the Restraints Control Module (RCM).
Using an appropriate tool, lift up and release the Connector Position Assurance (CPA) clips and
disconnect the passenger air bag module electrical connectors.
5.
Remove the 4 passenger air bag module-to-deployent chute bolts. 6.
Remove the passenger air bag module from the deployment chute. 7.
Remove the 2 bolts and passenger air bag module bracket. 8.
Installation
Install the passenger air bag module in the instrument panel. 1.
Install the 4 passenger air bag module-to-deployment chute bolts.
2.
Install the passenger air bag module bracket and 2 bolts. 3.
installing the connector. Failure to have the CPA clip in the released position may break the
tabs causing Diagnostic Trouble Codes (DTCs) to set in the Restraints Control Module (RCM).
Connect the passenger air bag module electrical connectors.
Lift up the CPA clip and install the electrical connector fully and lock the clip.
4.
Install the RH instrument panel register. 5.
Install the RH defroster duct and screw. 6.
Install the RH ventilation duct and screw. 7.
Install the instrument panel. For additional information, refer to Section 501-12 . 8.
System
Workshop Manual
Special Tool(s)
1 W707722 Restraints Control Module (RCM) bolts (3 required)
2 - RCM small connector (part of 14A005)
3 - RCM large connector (part of 14A005)
4 14B321 RCM
Removal
WARNING: Do not handle, move or change the original horizontal mounting position of the
restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to
follow this instruction may result in the accidental deployment of the Safety Canopy and cause serious
personal injury or death.
bags have deployed. Failure to follow these instructions may resulserious personal injury or death in a
crash.
Restraints Control Module (RCM) 1066
NOTICE: When installing a new Restraints Control Module (RCM), it is necessary to carry out
Programmable Module Installation (PMI). System failure may occur if PMI is not performed. For
NOTE: When installing a new RCM always make sure the correct RCM is being installed. If an incorrect
RCM is installed, DTCs will be set.
NOTE: Carrying out Programmable Module Installation (PMI) will not enable the 911 assist option that is
disabled. The RCM and Accessory Protocol Interface Module (APIM) must be configured correctly to fully
support 911 assist functionality.
NOTE: This vehicle is equipped with the SYNC V2 feature which contains the 911 assist option. Refer to
the Owners' Literature.
may not be compatible even if they appear physically similar. Check the part number listed in the Master Parts
Catalog to make sure the correct component is being installed. If an incorrect SRS component is installed,
DTCs may set.
If installing a new RCM , carry out the steps necessary to prepare for Programmable Module
Installation (PMI). For additional information, refer to Section 418-01 .
1.
2.
Remove the 2 RH RCM bolts.
Position the carpet back at the RH side of the center tunnel area under the instrument panel
and remove the 2 bolts.

3.
Disconnect the large RCM connector.
Pinch the thumb tab and pivot the Connector Position Assurance (CPA) lever back. 1.
Disconnect the RCM connector. 2.
4.
Remove the RCM .
Disconnect the small RCM connector. 1.
Remove the LH bolt. 2.
Remove the RCM . 3.
5.
Installation
Position the RCM .
Install the 2 RH RCM bolts.

Position the carpet back at the RH side of the center tunnel area under the instrument panel.
1.
Install the RCM .
Install the LH RCM bolt.

2.
Connect the small RCM connector. 3.
Verify that the CPA lever is positioned back completely (as shown) before connecting the large RCM
connector.
4.
NOTICE: Placing the large Restraints Control Module (RCM) electrical wiring connector into
the RCM on an angle can cause bad electrical connections and damaged components.
Position the large RCM electrical connector into the RCM .
NOTICE: Do not push the connector such that the Connector Position Assurance (CPA)
lever pivots and seats. Use light force to insert the connector into the Restraints Control
Module (RCM) before using the CPA lever to lock the connector. Damage to the
connector or component may occur.
With the large RCM electrical connector uniformly aligned to the RCM , push in until a slight
resistance is felt.

5.
Connect the large RCM connector.
Insert the connector into the RCM .
Push to lock the CPA lever thumb tab to the RCM .

6.
7.
If a new RCM was installed, carry out the appropriate steps necessary to complete PMI . For
8.
System
Workshop Manual
Side Air Curtain Module
1 042D94 RH/
042D95 LH
Side air curtain module
2 W713437 Side air curtain module front tether bracket bolt
3 W709453 Pin-type retainer (to garnish moulding bracket)
(part of 042D94 RH/ 042D95 LH)
4 026A52 RH/
026A53 LH
Garnish moulding bracket
5 W713437 Side air curtain module bolt (rear of A-pillar)
6 W713437 Side air curtain module center guide bolts
7 - Side air curtain center guide hook sheet metal slot
8 - Pin-type retainers (part of 042D94 RH/ 042D95
LH)
9 W713437 Side air curtain module middle rear bolt
10 W713437 Side air curtain module rear bracket bolts
11 - Side air curtain module electrical connector (part
of 042D94 RH/ 042D95 LH)
Side Air Curtain Module 1070
12 - Rear body wire harness (part of 14A005)
serious personal injury or death in the event of an accidental deployment.
deploying incorrectly and increases the risk of serious pury or death in a crash.
WARNING: Do not obstruct or place objects in the deployment path of the Safety Canopy or side
air curtain module. Failure to follow this instruction may result in the Safety Canopy or side air
curtain module deploying incorrectly and increases the risk of serious personal injury or death in a
crash.
2.
Disconnect the side air curtain module electrical connector and detach the pin-type retainer from the
C-pillar sheet metal.
3.
Remove the bolt and side air curtain module front tether.
4.
Detach the pin-type retainer from the garnish moulding bracket. 5.
Remove the side air curtain module bolt, located to the rear of the A-pillar.
6.
Remove the 2 side air curtain module middle rear bolts.
7.
NOTE: Note the position of the side air curtain module rear bracket hook for installation.
Remove the side air curtain module 2 rear bracket bolts.
8.
NOTE: Note the position of the side air curtain module center guide hook retainer for installation. 9.
Remove the side air curtain module 2 center guide bolts. Detach the side air curtain module center
guide hook retainer from the vehicle sheet metal.
Remove the side air curtain module.
Move the side air curtain module toward the front of the vehicle to release the rear bracket
hook from the C-pillar sheet metal.

10.
WARNING: When installing a new headliner on a vehicle equipped with Safety Canopy or
side air curtain modules, make sure the headliner has the word AIRBAG on the headliner
where it meets each B-pillar trim panel. Otherwise, you have the wrong headliner. Failure to
follow this instruction may result in the Safety Canopy or side air curtain module not
deploying or deploying incorrectly, increasing the risk of personal injury or death in a crash.
WARNING: Before installing a Safety Canopy or side air curtain module, inspect the
roofline for any damage. If necessary, the sheet metal must be reworked to its original condition
and structural integrity. Install new fasteners if damaged and remove foreign material. Failure
to follow these instructions may result in the Safety Canopy or siir curtain deploying
incorrectly, which increases the risk of serious personal injury or death in a crash.
WARNING: Inspect a Safety Canopy or side air curtain module before installation. If the
module is damaged, the cover has separated or the Safety Canopy or side air curtain material
has been exposed, install a new module. Do not attempt to repair the module. Failure to follow
these instructions may result in the Safety Canopy or side air curtain deploying incorrectly,
which increases the risk of serious personal injury or death in a crash.
WARNING: Never put any type of fastener or tie strap around any part of a Safety
Canopy module, side air curtain module or interior trim panel. This will prevent the Safety
Canopy or side air curtain module from deploying correctly. Failure to follow this instruction
may increase the risk of serious personal injury or death in a crash.
NOTE: Make sure all side air curtain module bolt holes line up with each sheet metal hole.
11.
12.
System
Workshop Manual
Seat Position Sensor
1 - Seat position sensor electrical connector (part of
14A699)
2 14B416 Seat position sensor
3 W505256 Seat position sensor bolt
Remove the driver seat. For additional information, refer to Section 501-10 . 1.
Disconnect the seat position sensor electrical connector. 2.
Remove the bolt and seat position sensor.
3.
WARNING: Always tighten the seat position sensor retaining bolt to specified torque.
Failure to do so may result in incorrect restraint system operation, which increases the risk of
4.
Install the driver seat. For additional information, refer to Section 501-10 . 5.
Seat Position Sensor 1074
Seat Position Sensor 1075
System
Workshop Manual
Side Air Bag Module
NOTE: Drivers seat shown, passenger seat similar.
1 611D10 Side air bag module
2 - Side air bag module locator hook (part of 611D10)
3 - Side air bag module electrical connector (part of
14K155)
4 N620480 Side air bag module nuts (2 required)
Removal
cannot be repaired. A new trier must be installed. Cleaning is permissible. Failure to follow these
NOTE: If a side air bag deployment took place, a new seat backrest foam pad, backrest cover, side air bag
module and nuts must be installed. The seat backrest frame should be replaced if necessary. For additional
information, refer to the front seat backrest disassembly and assembly procedure in Section 501-10 .
Side Air Bag Module 1076
Remove the seat backrest. For additional information, refer to Section 501-10 . 1.
Separate the seat backrest cover from the inboard and outboard recliners on the seat backrest frame.
2.
Release the seat backrest cover J-clip. 3.
WARNING: Front seat backrest trim covers installed on seats equipped with seat side air
bags cannot be repaired. A new trim cover must be installed. Cleaning is permissible. Failure to
follow these instructions may result in the seat side air bag module deploying incorrectly and
increase the risk of serious personal injury or death in a crash.
NOTICE: Use care when separating the seat backrest cover from the hook-and-loop strips, or
the hook-and-loop strip can be torn from the seat backrest foam pad.
Place a hand between the seat backrest cover and foam pad and carefully separate the hook-and-loop
strips, then carefully roll up the seat backrest cover in an inside out fashion to the row of hog rings in
the front.
4.
Remove and discard the 3 hog rings. 5.
Detach the hook-and-loop strips and invert the seat backrest cover up enough to expose the side air
bag.
6.
Remove and discard the 2 side air bag module nuts.
Pull outward on the side air bag module until the studs clear the backrest frame and then lift
upwards to detach the locator hook from the frame.

7.
NOTICE: Do not pull the side air bag electrical connector out by the locking button. Damage to
the locking button can occur.
8.
Using a small screwdriver, lift up and release the locking button and disconnect the electrical
connector.
Remove the side air bag module.
Installation
With the locking button released, install the electrical connector fully into the side air bag module and
seat the locking button.
1.
WARNING: If the seat side air bag cover has been damaged or separated from its mounting,
or if the air bag material has been exposed, install a new seat side air bag module. Never try to
repair the seat side air bag module. Failure to follow these instructions may result in the seat
side air bag deploying incorrectly, which increases the risk of serious personal injury or death
in a crash.
WARNING: Inspect the seat side air bag module and mounting surfaces for any damage or
foreign material before installing the seat side air bag module. If any damage is found, install
new components. If any foreign material is found, remove it. Failure to follow these instructions
may result in the seat side air bag module deploying incorrectly and increase the risk of serious
NOTICE: Make sure that the side air bag module locator hook is correctly positioned into the
backrest frame before tightening the nuts or damage to the side air bag module can occur.
Position the side air bag module to the seat backrest frame and install 2 new nuts.
2.
Roll the seat backrest cover down, attaching the hook-and-loop strips and install the 3 hog rings. 3.
Roll the seat backrest cover down attaching the remaining hook-and-loop strips and attach the seat
backrest cover J-clip.
4.
Attach the backrest cover to the inboard and outboard recliners on the seat backrest frame.
5.
Install the seat backrest. For additional information, refer to Section 501-10 . 6.
System
Workshop Manual
Side Impact Sensor - Front Door
1 W705314 Side impact sensor bolts (2 required)
2 - Side impact sensor electrical connector (part
of 14630)
3 14B345 Side impact sensor
4 W713617 Side impact sensor pushnuts (2 required)
in a crash.
NOTE: The Supplemental Res System (SRS) must be fully operational and free of faults before releasing the
vehicle to the customer.
2.
Slide the locking wedge back and disconnect the side impact sensor electrical connector. 3.
Remove the 2 bolts and the side impact sensor.
4.
Side Impact Sensor - Front Door 1080
NOTE: Make sure the door sheet metal and side impact sensor mating surfaces are clean.
5.
6.
Side Impact Sensor - Front Door 1081
System
Workshop Manual
Side Impact Sensor - C-Pillar
1 14B006 Side impact sensor
2 W505256 Side impact sensor bolt
3 - Side impact sensor electrical connector (part of
14A005)
1.
Remove the rear seat bolster. For additional information, refer to Section 501-10 . 2.
Disconnect the side impact sensor electrical connector. 3.
Remove the bolt and side impact sensor.
4.
NOTE: Make sure the C-pillar and side impact sensor mating surfaces are clean.
5.
6.
Side Impact Sensor - C-Pillar 1082
SECTION 501-35: Body Repairs
Manual
Material
Capacity
TA-32
ESB-M4G92-A -
Flexible Foam Repair
Fusor 121, or equivalent; obtain
locally
- -
Metal Bonding Adhesive
TA-1
- -
Motorcraft Acid Neutralizer
ZC-1-A
- -
Motorcraft Alkaline Neutralizer
ZC-2-A
- -
3MTM Perfect-ItTM Show Car
Liquid Wax
39026
- -
Motorcraft Detail Wash
ZC-3-A
- -
Motorcraft Metal Surface Prep
ZC-31-A
- -
Premium Undercoating
ValuGardTM VG101, VG101A
(aerosol)
- -
Rust Inhibitor
(aerosol)
- -
Plastic Bonding Adhesive
TA-9
- -
Roof Ditch Sealer
Fusor 122EZ, 3MTM 08307
- -
Seam Sealer
TA-2
- -
Trim and Weatherstrip Adhesive
Permatex 81850 or equivalent
- -
General
Equipment
3 Phase
Inverter Spot
Welder
254-00002
Compuspot
700F Welder
190-50080
I4 Inverter
Spot Welder
254-00014
General Specifications -Welding Specifications
Item Specification
Plug Weld Hole 8 mm (0.31 in)
Weld Wire ER70S-3 or equivalent 0.9-1.1 mm
(0.035-0.045 in)
Weld Nugget Chart
Test Thickness of Metal (mm) Nugget Size
0.7 + 0.7 4.3 mm (0.16 in)
0.7 + 0.7 + 0.7 4.3 mm (0.16 in)
0.9 + 0.9 4.7 mm (0.18 in)
0.9 + 0.9 + 0.9 4.7 mm (0.18 in)
1.0 + 1.0 5.2 mm (0.2 in)
1.0 + 1.0 + 1.0 5.2 mm (0.2 in)
2.0 + 2.0 7.1 mm (0.27 in)
2.0 + 2.0 + 2.0 7.1 mm (0.27 in)
3.0 + 3.0 8.7 mm (0.34 in)
3.0 + 3.0 + 3.0 8.7 mm (0.34 in)
3.0 + 0.7 4.3 mm (0.16 in)
0.7 + 3.0 + 1.0 5.2 mm (0.2 in)
2.0 + 2.0 + 0.7 4.3 mm (0.16 in)
0.9 + 0.9 + 2.0 4.7 mm (0.18 in)
2.0 + 0.9 + 1.0 5.2 mm (0.2 in)
1.0 + 3.0 + 1.0 5.2 mm (0.2 in)
3.0 + 1.0 + 2.0 7.1 mm (0.27 in)
0.9 + 0.7 + 0.9 4.3 mm (0.16 in)
Descriptions of Ford Steel Families
Grade Alloy Content Heat Treatment
Typical
Applications Comments
Mild Steel, Bake
Hardened, Solid
Solution
Strengthened
Low Fully annealed/dead
soft
Body panels
(closures, floor pan,
dash panel)
-
High-Strength Low
Alloy (HSLA)
Low Fully annealed/dead
soft
Rails, structural
members
Strengthened with
fine particles and
small grain size
Dual Phase MediumManganese
Silicon, Molybdenum
Chromium)
Fully
annealed/partially
hardened
Rails, structural
members
15-50% of structure
is hard martensite
Ultra High Strength
Steel (UHSS)
(Martensitic, Boron)
Low Fully hardened Rocker
reinforcements, door
beams, bumper
beams
100% of structure is
hard martensite
Transformation
Induced Plasticity
Steel
High (Manganese,
Phosophorus, Silicon,
Aluminum)
Fully annealed/
partially hardened
To be determined Complex
microstructure for
high strength and
ductility
Ford Recommended Steel Repairability Matrix
Grade
Trade
Descrip-
tions
Welding Method
Cold
Repairs
Use of
Heat for
Repair
Temp-
erature
Range
Max-
imum
Heat
Metal
Inert
Gas
(MIG)
Squeeze-
Type Resist-
ance Spot
Welding
(STRW)
MIG
Braze
Mild Steel Mild Yes Yes NA Yes
a
Yes Up to
650C
(1,200F)
90 sec.
x 2
Laminate Steel Quiet Steel No Yes No Yes
a
NA NA NA
Bake Hardened BH 180,
BH210, BH
250, BH
280
Yes Yes Yes
b
Yes
a
Yes Up to
650C
(1,200F)
90 sec.
x 2
Solid Solution
Strength- ened
- Yes Yes Yes
b
Yes
a
Yes Up to 650
C (1,200F)
90 sec.
x 2
High- Strength
Low Alloy
(HSLA)
HSLA 250,
HSLA 350,
HSLA 550
Yes Yes Yes
b
Yes
a
Yes Up to
650C
(1,200F)
90 sec.
x 2
Dual Phase = 600
MPa Ultimate
Tensile Strength
DP 500, DP
600
Yes Yes Yes
b
Yes
a
No NA NA
Dual Phase = 600
MPa Ultimate
Tensile Strength
DP 700, DP
780, DP 900
Yes
d
Yes Yes
b
No No NA NA
particular to 780
and 980 grades)
c
Ultra High
Strength Steel
(UHSS) (Martens-
itic, Boron)
e
Boron Yes
a
Yes Yes
b
No No NA NA
Trans- formation
Induced Plasticity
Steel (TRIP) Steel
TRIP 590,
TRIP 780,
TRIP 980
NA NA NA NA NA NA NA
a
Cold repairs can be performed if damage excludes kinks. May section only if approved procedure in
workshop manual.
b
MIG braze allowed for non-structural applications only.
c
Dual phase steels DP 700, DP 780 and DP 980 must be replaced at factory joints, no sectioning unless
approved procedure in workshop manual.
d
For DP 980, use MIG plug welding only, no stitch welding.
e
Boron components must be replaced at factory joints, no sectioning allowed.
Manual
Body
NOTICE: The High Voltage Traction Battery (HVTB) in a Hybrid Electric Vehicle (HEV) can be
affected and damaged by excessively high temperatures. The temperature in some body shop paint
booths can exceed 60C (140F). Therefore, during refinishing operations, the paint booth temperature
must set at or belo60C (140F) with a bake time of 45 minutes or less. Temperatures in excess of 60C
(140F) or bake durations longer than 45 minutes will require the HVTB be removed from the vehicle
prior to placing in the paint booth. For information, refer to Section 414-03 .
NOTE: For information regarding vehicles equipped with High Voltage Traction Battery (HVTB) systems,
The body consists of the following:
Unibody construction
Radiator support bolster constructed of glass fiber polypropylene material and is non-repairable
High-Strength Low Alloy (HSLA) and mild steels
Dual Phase Steel (DP) steel in select body structure components
Bolted, removable steel front fenders, hinged doors and hood
Underhood and body side door opening dimensions common between Ford Fusion and Lincoln MKZ
Steel doors incorporating serviceable outer panels
Steel luggage compartment lid
Rear body openings unique for each model
Bolt-on front and rear bumper beams constructed of Ultra High Strength Steel (UHSS), martensitic
grade steel

Front and rear subframe assembliessing suspension and steering components
Underbody common between Ford Fusion and Lincoln MKZ
Tailor-welded blanks used in underbody (front floor rails and rear frame rails)
For dimensional information, refer to the following illustrations:
NOTE: The following dimensional illustrations apply to the Ford Fusion and Lincoln MKZ unless otherwise
indicated.
Body Margins
NOTE: Dimensions apply to right and left side.
Item Description Specification Flushness Specification
Body 1088
1 Fender to side marker
lamp
1.0 mm (0.039 in) 1.0 mm (0.039 in) -
2 Headlamp assembly
to fascia
2.0 mm (0.078 in) 1.7 mm (0.039 in) -
3 Hood to fascia 5.0 mm (0.196 in) 3.0 mm (0.118 in) -
4 Hood to headlamp 5.0 mm (0.196 in) 3.0 mm (0.118 in) (overslam
clearance of 9.0 mm [0.35 in])
-
5 Hood to fender 3.0 mm (0.118 in) 1.5 mm (0.059 in) 0.0 mm ( in) 1.5 mm
(0.059 in)
6 Fender to door 4.0 mm (0.157 in) 1.5 mm (0.059 in) 0.5 mm (0.019 in) 1.5 mm
(0.059 in)
Body Margins
NOTE: Dimensions apply to the right and left side.
Item Description Specification Flushness Specification
7 Front dr 4.0 mm (0.157 in) 1.5 mm (0.059 in) 0.0 mm ( in) 1.5 mm (0.059
in)
8 Rear door to quarter panel 4.0 mm (0.157 in) 1.5 mm (0.059 in) 0.0 mm ( in) 1.5 mm (0.059
in)
9 Fuel door to quarter panel 3.0 mm (0.118 in) 1.0 mm (0.039 in) 1.0 mm (0.039 in) 1.25 mm
(0.049 in)
10 Quarter panel to luggage
compartment lid
3.0 mm (0.118 in) 1.5 mm (0.059 in) 0.0 mm ( in) 1.5 mm (0.059
in)
11 Lamp assembly to quarter
panel
1.2 mm (0.047 in) + 1.2 mm (0.047 in)
/ - 0.0 mm ( in)
1.0 mm (0.039 in) 1.0 mm
(0.039 in)
12 Lamp assembly to fascia 2.0 mm (0.078 in) 1.7 mm (0.066 in) -
13 Luggage compartment lid to
fascia
6.0 mm (0.236 in) 2.5 mm (0.098 in) -
Underhood Dimensions
NOTICE: The radiator bolster is glass fiber polypropylene material. If damage occurs to the radiator
support component, it should not be repaired. A new component should be installed. Refer to Section
303-03A .
NOTE: Measurements are obtained on center, unless otherwise indicated.
Body Margins 1089
Body Side Closure Dimensions
Rear Opening Dimensions
Ford Fusion
Body Margins 1090
Lincoln MKZ
Underbody Dimensions
Front Subframe
Ford Fusion 1091
Rear Subframe
NOTE: Front Wheel Drive (FWD) shown, All-Wheel Drive (AWD) common dimensionally. Measurements
are obtained on center, unless otherwise indicated.
NOTICE: A structural frame rail or unibody service sectioning kit is available for this vehicle. For
information regarding frame rail sectioning, refer to Frame Members - Front or Frame Members -
Rear in this section.
Frame Datum Height
NOTE: Datum height determined measuring from holes and slots on center, unless otherwise indicated.
Front Subframe 1092
Underbody Dimensions
Underbody Dimensions 1093
Manual
Welding Precautions - Steel
General
Equipment
3 Phase
Inverter Spot
Welder
254-00002
Compuspot
700F Welder
190-50080
I4 Inverter
Spot Welder
254-00014
Inverter
Welder with
MIG Welder
254-00015
Weld Nugget Chart
Test Thickness of Metal (mm) Nugget Size
0.7 + 0.7 4.3 mm (0.16 in)
0.7 + 0.7 + 0.7 4.3 mm (0.16 in)
0.9 + 0.9 4.7 mm (0.18 in)
0.9 + 0.9 + 0.9 4.7 mm (0.18 in)
1.0 + 1.0 5.2 mm (0.2 in)
1.0 + 1.0 + 1.0 5.2 mm (0.2 in)
2.0 + 2.0 7.1 mm (0.27 in)
2.0 + 2.0 + 2.0 7.1 mm (0.27 in)
3.0 + 3.0 8.7 mm (0.34 in)
3.0 + 3.0 + 3.0 8.7 mm (0.34 in)
3.0 + 0.7
0.7 + 3.0 + 1.0 5.2 mm (0.2 in)
2.0 + 2.0 + 0.7 4.3 mm (0.16 in)
0.9 + 0.9 + 2.0 4.7 mm (0.18 in)
2.0 + 0.9 + 1.0 5.2 mm (0.2 in)
1.0 + 3.0 + 1.0 5.2 mm (0.2 in)
3.0 + 1.0 + 2.0 7.1 mm (0.27 in)
0.9 + 0.7 + 0.9 4.3 mm (0.16 in)
Welding Precautions - Steel 1094
Item Specification
Plug weld hole 8 mm (0.31 in)
Weld wire ER70S-3 or equivalent 0.9-1.1 mm
(0.035-0.045 in)
NOTICE: Hybrid vehicles contain a High Voltage Traction Battery (HVTB). Before welding near the
HVTB , the HVTB must be removed to avoid heat damage. For information, refer to Section 414-03 .
The correct equipment and settings must be used when welding mild or high-strength steel. Metal Inert Gas
(MIG) and Squeeze-Type Resistance Spot Welding (STRW) are the preferred methods. Surfaces must be
clean and free of foreign materials.
Correct eye protection must be worn.
The correct protective clothing should always be worn.
Adequate ventilation must be provided to avoid accumulation of poisonous gases.
Refer to the Ford Recommended Steel Repairability Matrix in the Specifications portion of this
section for specific information regarding steel descriptions.

A test weld should always be carried out on a test sample.
Use cleaning brushes and abrasive grinding wheels dedicated to the type of materials being welded.
Follow equipment manufacturer's prescribed procedures and equipment settings for the type of welder
being used. ER70S-3 or ER70S-6 wire are typically used for MIG welding steel.

On non-hybrid vehicles, disconnect the battery ground cable. Refer to Section 414-01 .
Disconnect on-vehicle modules and protect them from possible heat damage and electrical currents
when welding.

Corrosion protection must be restored whenever bare metal repairs are made. Refer to Restoring
Corrosion Protection Following Repair in this section.

Weld through primer is recommended when welding overlapping surfaces or substrates.
Components made of high-strength steel should not be heated should not be heated to straighten or
repair. If components are severely bent or kinked, new components should be installed.

Adequate power supply needs to be used to make sure of correct equipment performance.
Factory spot welds may be substituted with either STRW or MIG plug welds. Spot/plug welds should
equal factory welds in both location and quantity. Do not place a new spot weld directly over an
original weld location. Plug weld hole should equal 8 mm (0.31 in) diameter.

Vehicles equipped with optional safety canopy require removal of these components prior to any
welding procedures being carried out in the roof-line or body side areas of the vehicle. Refer to
Section 501-20B .

Manual
Sound Deadeners and Insulators
NOTICE: Mastic is made of a combustible material and should be removed prior to carrying out
welding procedures to the area. Heat zones from welding near the mastic may cause the mastic material
to burn.
NOTICE: Corrosion protection must be restored to the area AFTER the mastic material is applied.
Corrosion protection products contain wax and loss of adhesion may occur.
NOTE: To restore the vehicle to design intent, missing or damaged sound deadeners and insulators should be
installed with the correct service replacement component.
NOTE: The following illustrations serve as a reference to indicate mastic sound deadener locations. Sound
deadener material is applied from the factory in a pumpable form. Additional insulators and sound deadeners
are used beyond those indicated in the illustration.
Interior Floor Pan
NOTE: Arrow indicates rear of vehicle.
Exterior Floor Pan
NOTE: Arrow indicates rear of vehicle.
Sound Deadeners and Insulators 1097
Whenever replacement of an existing mastic insulator is carried out, the surface must be thoroughly
cleaned to make sure correct adhesion will occur. The surface should be 10C (50F) or greater before
applying the mastic. The use of a heat gun to warm the metal surface will aid in adhesion.
1.
Exterior Floor Pan 1098
Manual
Plastic Components
Exterior Plastic Components - Painted
NOTE: Ford Fusion shown, Lincoln MKZ similar.
NOTE: The following illustration(s) are not all-inclusive of trim levels available. The actual trim level of the
vehicle will determine the viability of carrying out a plastic repair.
1 17C831 Bumper cover (front) - Thermoplastic Olefin
(TPO)
2 25557 LH/ 25556
RH
Door moulding (front) - TPO
3 20879 LH/ 20878
RH
Door moulding (rear) - TPO
4 10155 LH/ 10154
RH
Rocker moulding - TPO
5 40602 Spoiler - Acrylonitrile Butadiene Styrene (ABS)
6 17K835 Bumper cover (rear) - TPO
Several considerations will detty of plastic repair procedure(s):
Is the damage cosmetic or structural?
Can the repair be carried out on the vehicle?
Is the part readily available?
Is component repair the most cost effective method?
Can the component be economically restored to original strength and appearance?
Will the repair provide for the fastest, highest quality repair?
Several types of plastic are in use for automotive application. However, all plastics will fall into 2 primary
categories of thermoplastic or thermosetting plastic.
Thermosetting Plastic
Generally, thermosetting plastics are made with 2-part thermosetting resins. When mixed together, heat is
generated, producing a cure that is irreversible. Because of this, thermosetting plastics will require the use of a
2-part adhesive for repair.
Plastic Components 1099
Sheet-Molded Composite
Sheet-Molded Composite (SMC) is a type of thermosetting plastic that uses glass fibers or nylon fibers in
combination with thermosetting polyester resins. When fully cured, SMC is strong and rigid.
SMC is similar to, but not identical to fiberglass. Ford Motor Company uses SMC in components such as
fenders, hoods and liftgates.
Thermoplastic Compounds
Thermoplastic compounds are manufactured by a process that is reversible. Thermoplastics can be remolded
repeatedly by reheating. This characteristic of thermoplastics makes plastic welding a possible repair
alternative. A repair of thermoplastic compounds is still possible through the use of 2-part adhesive and filler
repair materials and reinforcements as needed. Thermoplastics are widely used in interior trim components,
wheel flares, body side cladding and bumper covers.
Polyolefin
Polyolefins fall into the family of thermoplastics with one unique characteristic: An oily or waxy feel to the
material when sanded or ground. Polyolefin lends itself very well to remolding through the use of heat.
Because of this, components made of this material lend themselves well to the possibility of plastic welding.
Most adhesive repair materials and paint will not bond to surface of a polyolefin unless an adhesion promoter
specially formulated for plastic is first applied to the exposed raw surface. Otherwise, polyolefins are repaired
like most other thermoplastics. Some typical uses of polyolefins are:
bumper covers.
fan shrouds.
wheel housings.
Proper identification of the various types of plastic is necessary to select the appropriate repair method(s) to
carry out high quality plastic repairs. For information, refer to Plastics Identification in this section.
Sheet-Molded Composite 1100
Manual
Sealers
The correct sealing of joints is essential to repairing the vehicle correctly. Sealers are used to prevent wind
noise, water leaks, exhaust fumes and dust from entering the vehicle. They also provide anti-corrosion
barriers. Sealers are applied to areas such as door and rear compartment hem flanges, wheelhouse, quarter
outer, floor, cowl, roof and other panel-to-panel attaching points. The following joint sealers are
recommended for use depending upon the application:
Brushable Seam Sealer - A sealer intended to restore the original brushed seam appearance. It is used
to seal lap joints in sheet metal that are spot welded (for example, floorpans and cowls). Use a product
obtained locally.

Roof Ditch Sealer - A self-leveling sealer used for drip rails, roof seams, quarter panels to rear deck
and for water leaks.

Seam Sealer - Heavy-bodied, non-sag adhesive/sealer for use on standing cosmetic seams, truck bed
seams, tooled door skin seams and floor pans. Also used for water leaks and noise concerns.

Sealers should remain flexible after curing and must be paintable. Follow the manufacturer's directions for
correct application of these materials.
Any damage to originally sealed joints should be repaired by resealing. Along with attaching points of new
panels, open joints that require bridging of sealer to close a gap should be sealed using a heavy-bodied sealer.
Polyolefin 1101
Manual
Adhesives
Material
Item Specification
Clear Silicone Rubber TA-32 ESB-M4G92-A
Metal Bonding Adhesive TA-1 -
Plastic Bonding Adhesive TA-9 -
Seam Sealer TA-2 -
Trim and Weatherstrip Adhesive TA-14-A -
must set at or below 60C (140F) with a bake time of 45 minutes or less. Temperatures in excess of
60C (140F) or bake durations longer than 45 minutes will require the HVTB be removed from the
vehicle prior to placing in the paint booth. For information, refer to Section 414-03 .
Depower the High Voltage Traction Battery (HVTB) before carrying out any removal or installation
procedures affecting the high-voltage battery system. Refer to Section 414-03 for the correct
procedure to depower the HVTB system on hybrid-equipped vehicles.
1.
NOTE: When it is necessary to carry out weld-bonding procedures, refer to Weld-Bonding in this section.
Adhesives are used in a variety of applications. Typical uses for adhesives include roof panels, door skins and
quarter panels. Trim applications include body side mouldings, emblems, stationary glass and
weatherstripping. Combination sealer/adhesives are also used. Surface preparation is critical to a high quality
repair. Following the label instructions for the product is essential.
Work in a well-ventilated area and protect adjacent surfaces when working with adhesives. The use of eye
protection and protective clothing is also recommended when working with adhesives. Carry out a trial fit,
mark and align the surfaces before bonding the materials together.
Seam sealers and corrosion protection may be necessary once the adhesive(s) has cured, depending on the
application. The following is a list of adhesives recommended for certain types of applications:
Metal Bonding Adhesive - For bonding cold-rolled steel, galvanized steel, aluminum and correctly
prepared E-coat. It is used for door skin and roof panel replacement and OEM structural adhesive
replacement.

Plastic Bonding Adhesive - For bonding a variety of plastics to plastics and plastics to primed, painted
or E-coated metals. Also for general purpose bonding of trim components.

Seam Sealer - Heavy-bodied, non-sag adhesive/sealer for use on: standing cosmetic seams, truck bed
seams, tooled doo seams and floor pans.

Trim and Weatherstrip Adhesive - For use on body side moulding, emblems, trim, bumper impact
strips and carpeting.

Clear Silicone Rubber - Used for sealing water leaks, noise concerns, remounting trim and repairing
torn weatherstripping.

Sealers 1102
NOTE: The following illustration identifies structural adhesive location(s).
Rear Bodyside Outer to Inner
Door Panel
1 20201 LH/ 20200 RH Door panel outer
2 TA-1 Metal bonding adhesive
3 20125 LH/ 20124 RH Door shell assembly
Adhesives 1103
Door Panel 1104
SECTION 501-35: Body Repairs 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop Manual
Sectioning Guidelines
Special Tool(s)
Heat Treatment Induction Resistance Spot
Welder
254-00001
Pro 230 MIG Welder
208-00030
Material
Item Specification
TA-1
-
ZC-31-A
-
Rust Inhibitor
(aerosol)
-
Seam Sealer
TA-2
-
shade providing adequate visibility are recommended. It is strongly recommendesons working in the
weld area wear flash safety goggles. Also wear protective clothing. Failure to follow these instructions
Sectioning Guidelines 1105
NOTE: Factory spot welds may be substituted with either Squeeze-Type Resistance Spot Welding (STRW)
or Metal Inert Gas (MIG) plug welds. Spot/plug welds should equal factory welds in both location and
quantity. Do not place a new spot weld directly over an original location. Plug weld hole should equal 8 mm
(0.31 in) diameter.
NOTE: The design of the front and rear doors incorporates a new precision weatherstrip seal retainer flange
above the belt line. Dimensions of this flange are critical to maintain correct sealing from water leaks or wind
noise. If these upper channels are damaged in a collision, the entire door shell should be replaced. The door
assembly also incorporates:
an open bottom hem flange for improved corrosion protection.
flat modified front and rear door hem flanges, below the belt lines. After hemming the production
doors, a secondary operation adds a taper to the inside surface of the hem that reduces the variability
of the door dimensions. This allows for smaller factory margins between the doors, fenders and
quarter panels.

NOTE: Illustration applicable to Ford Fusion and Lincoln MKZ. Cut lines shown in illustration are
approximate.
NOTE: When it is necessary to carry out weld-bonding procedures, refer to Weld-Bonding in this section.
Corrosion protection needs to be restored whenever it is necessary to sand or grind through painted
surfaces or E-coat, or when bare metal repairs are carried out. For additional information, refer to
Restoring Corrosion Protection Following Repair in this section.
1.
NOTICE: Electronic modules and related wiring may be damaged when exposed to heat from
welding procedures. Carefully disconnect and remove, or position away from heat affected
areas. For additional information, refer to Welding Precautions - Steel in this section.
2.
Where possible, create a backer piece using a portion of the old panel. This will create a stronger
joint.
NOTICE: Hybrid vehicles contain a High Voltage Traction Battery (HVTB). Before welding
near the HVTB , the HVTB must be removed to avoid heat damage. For additional information,
When welding overlapping surfaces or substrates, apply a weld through primer or similar
anti-corrosion material between the surfaces prior to welding. When the repair area has been welded
and refinished, apply rust inhibitor to the exterior surfaces or substrates.
Make sure horizontal joints and flanges are correctly sealed with seam sealer to prevent
moisture intrusion. Water and moisture migrate to horizontal joints and corrosion tends to
occur more rapidly in these areas. Surfaces must be clean and dry before applying seam
sealer.

3.
NOTICE: The High Voltage Traction Battery (HVTB) in a Hybrid Electric Vehicle (HEV) can
be affected and damaged by excessively high temperatures. The temperature in some body shop
paint booths can exceed 60C (140F). Therefore, during refinishing operations, the paint booth
temperature must set at or below 60C (140F) with a bake time of 45 minutes or less.
Temperatures in excess of 60C (140F) or bake durations longer than 45 minutes will require
the HVTB be removed from the vehicle prior to placing in the paint booth. For additional
Proceed with refinish procedures following Ford-approved paint guidelines.
4.
Restoring Corrosion Protection Following Repair
Special Tool(s)
Rust Inhibitor Installation Kit
286-00002
Undercoating Spray Gun
286-00001
Material
Item Specification
ZC-31-A
-
(aerosol)
-
Rust Inhibitor
(aerosol)
-
injury.
NOTICE: Drilling access holes in body panels is not recommended. Drilling holes will break the original
paint finish and promote corrosion.
NOTE: Corrosion protection needs to be restored whenever it is necessary to sand or grind through painted
surfaces or E-coat, or when bare metal repairs are made.
NOTE: Refer to product label for preparation and handling instructions.
The surfaces must be free of oil, dirt and other foreign material. Carry out the process in the following
sequence.
Thoroughly clean and deetal surfaces using metal surface prep to remove wax and grease. 1.
For best results, the vehicle should be at room temperature. Attach the rust inhibitor canister
to the Rust Inhibitor Installation Kit 286-00002.
2.
Rust inhibitor should be applied after the welding and refinishing process. Product cannot be
welded through.
3.
Air pressure setting for applicator gun is 448-517 kPa (65-75 psi).
Use the long wand when spraying enclosed areas. The spray nozzle provides a
360-degree spray pattern. Insert the wand as far as possible into the access hole, pull

4.
1.
Restoring Corrosion Protection Following Repair 1108
the trigger and wait 2-3 seconds and slowly pull the wand out of the access hole.
The short, hook-shaped wand sprays in one direction and must be rotated to provide
complete coverage.

Apply the material in light mist coats.
Material displaces moisture.
Clean up any overspray with a mild solvent such as mineral spirits or bug and tar remover. 5.
NOTE: The following illustrations provide typical applications of body seams and spot welded flanges and
are not vehicle specific.
NOTE: Door assembly lower view.
Apply rust inhibitor as shown to the inside of the door shell on all the interior metal surfaces using the
most suitable applicator wand. Apply material to the exposed edges after carrying out the welding
process. Make sure horizontal surfaces are well protected as they are more susceptible to corrosion.
Keep door drain holes clear to prevent moisture buildup.
2.
NOTE: Quarter panel inner view.
Apply rust inhibitor to the closed channel portion of the spot weld flange areas using the short,
hook-shaped wand. Apply material to the exposed edges after carrying out the welding process. Make
sure horizontal surfaces are well protected as they are more susceptible to corrosion.
3.
NOTE: Door frame opening view.
Apply rust inhibitor to the closed channel portion of the spot weld flange areas using the short,
hook-shaped wand. Make sure horizontal surfaces are well protected as they are more susceptible to
corrosion.
4.
Body and Frame Undercoating
WARNING: Always refer to Material Safety Data Sheet (MSDS) when handling chemicals
and wear protective equipment as directed. Examples may include but are not limited to
respirators and chemically resistant gloves. Failure to follow these instructions may result in
WARNING: Always wear protective equipment including eye protection with side shields,
and a dust mask when sanding or grinding. Failure to follow these instructions may result in
NOTICE: Do not allow undercoating on powertrain components. Failure to follow these
instructions may result in incorrect operation of these components.
NOTE: Refer to product label for preparation and handling instructions.
NOTE: Avoid high-pressure water spray cleaning to treated underbody area for 24 hours.
Wire brush the area and make sure the surfaces are free of oil, dirt and other foreign material. Carry
out the undercoating process in the following sequence.
Thoroughly clean and degrease metal surfaces using metal surface prep to remove wax and
grease.
1.
For best results, the vehicle should be at room temperature.
Canister attaches directly to the dispensing gun. Attach the undercoating canister to
the Undercoating Spray Gun 286-00001.

2.
Undercoat should be applied after the welding and refinishing process. Product cannot be
welded through.
3.
Air pressure setting for applicator gun is 552-621 kPa (80-90 psi).
Apply light mist coats, applicator sprays in fogging pattern.
Material displaces moisture.
4.
Clean up any overspray with a mild solvent such as mineral spirits or bug and tar remover. 5.
1.
NOTE: The following illustrations provide typical applications to frame rails and are not vehicle specific.
NOTE: Frame rail exterior spot-weld flange view.
Apply undercoat material to the exterior exposed edges after carrying out the welding and refinishing
process.
2.
NOTE: Cross section view of typical unibody frame rail shown.
Apply rust inhibitor to the inner surfaces of the rail after carrying out welding process. Use the long
wand and insert as far as possible, depress trigger and wait 2-3 seconds and slowly pull the wand to
make sure the area is completely fogged.
3.
NOTE: Full frame vehicle, front rail-to-mid rail section repair shown.
Apply undercoat material to the exposed surfaces after carrying out the welding process. Make sure to
completely cover any bare metal areas.
4.
Refinishing - Environmental Damage
Material
Item Specification
Motorcraft Acid Neutralizer
ZC-1-A
-
Motorcraft Alkaline Neutralizer
ZC-2-A
-
3MTM Perfect-ItTM Show Car Liquid
Wax
39026
-
ZC-3-A
-
Iron Oxide (Rail Dust) or Acid Rain Decontamination
NOTICE: In extreme cases of contamination, the vehicle may require refinishing. To avoid paint
failure, follow the appropriate decontamination procedure prior to carrying out any panel refinishing
procedure.
NOTE: Iron oxide contamination appears as tiny rust spots on horizontal surfaces and in severe cases can be
felt. This damage is typically caused from rail shipment, storage near railroad tracks or fallout from industrial
manufacturing facilities.
NOTE: Acid rain contamination can be identified as water spotting and in severe cases staining within the
water spots.
NOTICE: Never paint over iron particles as rust spots will reoccur. Use only the recommended
decontamination procedure detailed below.
Rinse any dust, dirt and foreign material from the vehicle body with cold water. Flush liberally.
1.
Prepare the acid neutralizer by mixing 8 parts of water to 1 part neutralizer in a bucket. 2.
NOTICE: To avoid paint failure, do not allow the product to dry on the vehicle.
NOTE: Use a separate wash mitt for eac to the vehicle.
Working quickly and beginning at the top of the vehicle and working to the sides, apply the acid
neutralizer mix to the entire vehicle. Keep the vehicle wet with the solution and lightly agitate for 5 to
7 minutes. Continue around the vehicle 4 to 5 times. For severe conditions, work the product for up to
8 minutes.
3.
Rinse the vehicle completely with cold water to remove the product. 4.
Dry only the horizontal surfaces of the vehicle, do not dry the glass at this time. 5.
Refinishing - Environmental Damage 1113
NOTICE: Do not apply the alkaline neutralizer directly to the vehicle plastic trim as the plastic
can be damaged.
NOTE: Use a separate wash mitt for each product applied to the vehicle.
NOTE: Alkaline neutralizer is a ready-to-use product. Do not mix with water.
Pour the alkaline neutralizer into a squirt bottle and apply the solution to a clean wash mitt.
6.
NOTICE: To avoid paint failure, do not allow the alkaline neutralizer to dry on the vehicle.
Apply the product to the vehicle keeping the solution wet and lightly agitate for 5 to 7 minutes. For
severe conditions, work the product for up to 8 minutes.
7.
Rinse the vehicle completely with cold water to remove the product. 8.
Prepare the detail wash by mixing 29.5 ml (1 oz) with 3.78L (1 gal) of water. 9.
Using a clean wash mitt, shampoo the entire vehicle and rinse with cold water. Dry the vehicle
completely.
10.
Visually inspect the paint surface for any remaining evidence of ferrous metal particles. Repeat
procedure as necessary.
11.
If required, proceed with the refinish process following paint manufacturer's guidelines.
12.
Surface Finishing Following Decontamination
NOTICE: When attempting to affect a repair by buffing, polishing or color sanding, do not
remove an excess of 0.3 MIL of paint film or refinishing will be required.
NOTE: Acid rain discoloring or etching may require color sanding in addition to buffing and
polishing. In extreme cases, refinishing may be required if the following procedure does not restore
the vehicle finish.
NOTE: Do not intermix buffing products. Use only one manufacturer's product.
NOTE: Always follow the manufacturer's product usage sequence. Use the appropriate buffing or
polishing pad at the recommended buffing speed as specified by the product manufacturer.
Apply rubbing compound to the vehicle surface as recommended by the product manufacturer.
1.
Apply machine glaze to the vehicle surface ammended by the product manufacturer. 2.
Use an alcohol and water mixture (1 to 1) to clean the buffed and polished areas. Verify removal of 3.
scratches and swirls before the application of the final polish.
Apply a final clear coat polish material by hand, with a dual-action sander and foam pad, or with an
orbital polisher and appropriate polishing bonnet.
4.
Wash and dry the vehicle. 5.
Refinishing - Manufacturing Damage
Material
Item Specification
ZC-3-A
-
Rust Inhibitor
(aerosol)
-
injury.
NOTICE: Protect adjacent areas/substrates when preparing for and during refinishing to avoid
overspray damage.
NOTE: Peeling/delamination concerns can be described as lack of adhesion, either between the substrate and
topcoats or between individual coats of paint.
Wash the repair area with pH-neutral soap and water. 1.
Remove any trim, emblems and hardware from the area to be repaired. 2.
NOTE: All delamination must be removed.
Sand or media blast the damaged surface, keeping the repair area as minimal as possible.
3.
Treat any bare metal surface to prevent flash corrosion, and prime and block sand as necessary prior
to refinishing.
4.
Mask the adjacent panels to protect from overspray. 5.
NOTICE: The High Voltage Traction Battery (HVTB) in a Hybrid Elecle (HEV) can be affected
and damaged by excessively high temperatures. The temperature in some body shop paint
booths can exceed 60C (140F). Therefore, during refinishing operations, the paint booth
Spot repair the base coat as necessary, following the paint manufacturer's prescribed procedures.
6.
Following paint manufacturer's guidelines, apply clear coat to the entire panel. 7.
Refinishing - Manufacturing Damage 1116
Refinishing - Manufacturing Damage 1117
Weld-Bonding
General Equipment
Heat Treatment Induction Resistance Spot Welder
254-00001
Pro 230 MIG Welder 208-00030
Material
Item Specification
TA-1
-
ZC-31-A
-
(aerosol)
-
Rust Inhibitor
(aerosol)
-
Seam Sealer
TA-2
-
Weld-Bonding - Squeeze-Type Resistance Spot Welding (STRW) Method
and skin. Always use protectioner's helmet with dark-colored filter lenses of the correct density.
Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade
providing adequate visibility are recommended. It is strongly recommended that persons working in
the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow these
Weld-Bonding 1118
injury.
NOTE: Corrosion protection needs to be restored whenever it is necessary to grind through painted surfaces
or E-coat, or when bare metal repairs are made. For additional information, refer to Restoring Corrosion
Protection Following Repair in this section.
NOTE: Weld-bonding is a method used to join metals using Squeeze-Type Resistance Spot Welding (STRW)
or Metal Inert Gas (MIG) and structural adhesive. The steps listed in this procedure apply to both types of
welding. STRW is the preferred method. MIG welding should only be used when areas to be welded cannot
be accessed using STRW -type machinery.
NOTE: Factory spot welds should be substituted with either resistance spot welds or MIG plug welds.
Spot/plug welds should equal factory welds in both location and quantity. Do not place a new spot weld
directly over an original weld location. Plug weld hole should equal 8 mm (0.31 in) diameter.
Verify the vehicle is dimensionally correct on a frame machine. Straighten if necessary. 1.
2.
Remove damaged panels with an air saw or air chisel. Remove only large portions of the damaged
panel. Avoid cutting into mating flanges or adjacent parts.
3.
Drill out the spot welds using an appropriate spot-weld cutter and remove the remaining portions of
the panel to be replaced.
4.
Prepare any damaged flanges on the vehicle using hammer and dolly. 5.
Grind the mating surface of the original flanges not greater than 25 mm (0.98 in) where the metal
bonding adhesive will be applied.
Be sure to remove galvanizing on metal. Metal should have a shiny appearance.
Be careful not to damage the corners or thin the metal. The E-coat should also be removed on
the opposite side of the flange only where the spot welds are to be placed.

6.
Dry-fit and clamp the replacement service parts to verify a correct fit.
Remove the service part after verifying correct fit and alignment.
7.
NOTE: The ends of welding clamps should be insulated on the ends using tape or similar material
when welding is carried out.
Follow manufacturer's prescribed welding procedures and settings. For additional information, refer
to Welding Precautions - Steel in this section.
8.
NOTE: Welding can be carried out anytime during the adhesive curing process, or after the adhesive
is fully cured. Welder settings will vary when welding through wet adhesive versus welding through
fully cured adhesive. Refer to welder manufacturer's recommended settings for welding through fully
cured adhesive. It is recommended to place a shunt weld in an area with no adhesive to make sure of
-34.
Weld-Bonding 1119
conductivity, particularly when welding through fully cured adhesive.
Create a test sample.
Prepare the metal and adhesive as described. Apply a 6-9 mm (0.23-0.35 in) bead of adhesive
and weld the sample.
1.
Place the welded sample in a vise and perform destructive weld tests by peeling the scrap
metal apart using large lock-type pliers. Measure the weld nugget to determine that the nugget
meets Ford weld nugget requirements. If the weld nugget does not meet required size, adjust
welder settings until the correct weld nugget size is achieved.
2.
When the correct weld nugget size is achieved, the service part can be weld-bonded.
Weld Nugget Chart
Test Thickness of Metal (in millimeters) Nugget Size
0.7 + 0.7 4.3 mm (0.16 in)
0.7 + 0.7 + 0.7 4.3 mm (0.16 in)
0.9 + 0.9 4.7 mm (0.18 in)
0.9 + 0.9 + 0.9 4.7 mm (0.18 in)
1.0 + 1.0 5.2 mm (0.2 in)
1.0 + 1.0 + 1.0 5.2 mm (0.2 in)
2.0 + 2.0 7.1 mm (0.27 in)
2.0 + 2.0 + 2.0 7.1 mm (0.27 in)
3.0 + 3.0 8.7 mm (0.34 in)
3.0 + 3.0 + 3.0 8.7 mm (0.34 in)
3.0 + 0.7 4.3 mm (0.16 in)
0.7 + 3.0 + 1.0 5.2 mm (0.2 in)
2.0 + 2.0 + 0.7 4.3 mm (0.16 in)
0.9 + 0.9 + 2.0 4.7 mm (0.18 in)
2.0 + 0.9 + 1.0 5.2 mm (0.2 in)
1.0 + 3.0 + 1.0 5.2 mm (0.2 in)
3.0 + 1.0 + 2.0 7.1 mm (0.27 in)
0.9 + 0.7 + 0.9 4.3 mm (0.16 in)
3.
NOTE: Refer to the product label for preparation and handling instructions.
Apply a 6-9 mm (0.23-0.35 in) bead of metal bonding adhesive to the vehicle prepared flange surface.
11.
Place the service part(s) in the correct position on the vehicle.
When positioned, do not pull the component away from the vehicle. If repositioning is
necessary, slide the service part(s). This will make sure of correct contact between the
components and adhesive.

12.
Clamp evenly and tightly. The adhesive contains glass beads which will prevent over-clamping the
component.
13.
NOTE: If welding will not be carried out immediately, allow a minimum of 1.5 to 2 hours of
adhesive cure time at 21C (70F) before removing clamps. Cure time at lower temperatures should
14.
Weld-Bonding 1120
be increased. Clamps may be removed immediately after the component is welded.
Wipe excess adhesive from the panel before it cures.
Finish any cosmetic section seams with fiber-filled body filler. Rough sand the filler, after the
adhesive cures, apply conventional body filler and block-sand the area.
15.
Use seam sealer wherever a cosmetic seam sealer is required. 16.
Mix and apply primer surfacer per Ford-approved paint recommdations. 17.
Mix and apply basecoat per paint manufacturer's recommendations.
18.
Mix and apply clearcoat per paint manufacturer's recommendations. Refinishing materials may be
force-dried following paint manufacturer's recommendations.
19.
Apply rust inhibitor or undercoating as required to provide corrosion protection to the repair area. 20.
Weld-Bonding - Metal Inert Gas (MIG) Welding Method
WARNING: Invisible ultraviolet and infrared rays emitted ng can injure unprotected eyes and skin.
Always use protection such as a welder's helmet with dark-colored filter lenses of the correct density.
Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade
providing adequate visibility are recommended. It is strongly recommended that persons working in
the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow these
injury.
NOTE: Metal Inert Gas (MIG) weld-bonding can be substituted as an alternative to Squeeze-Type Resistance
Spot Welding (STRW). It may only be used to weld areas that are inaccessible to STRW machinery.
However, when accessible, STRW is the preferred method.
NOTE: Corrosion protection needs to be restored whenever it is necessary to grind through painted surfaces
or E-coat, or when bare metal repairs are made. For additional information, refer to Restoring Corrosion
Protection Following Repair in this section.
NOTE: Factory spot welds should be substituted with either resistance spot welds or MIG plug welds.
Spot/plug welds should equal factory welds in both location and quantity. Do not place a new spot weld
Weld-Bonding 1121
directly over an original weld location. Plug weld hole should equal 8 mm (0.31 in) diameter.
Verify the vehicle is dimensionally correct on a frame machine. Straighten if necessary. 1.
2.
Remove damaged panels with an air saw or air chisel. Remove only large portions of the damaged
panel. Avoid cutting into mating flanges or adjacent parts.
Drill out the spot welds using an appropriate spot-weld cutter and remove the remaining
portions of the panel to be replaced.

3.
After removing the damaged sheet metal panel(s), repair any damaged flanges on the vehicle using a
hammer and dolly.
4.
Using an appropriate grinder, carefully grind around the entire receiving flange area following the
original welds. Be sure to remove all E-coat, paint or galvanized coating from the mating surfaces of
the joint.
Be sure to remove galvanizing on metal. Metal should have a shiny appearance.
Be careful not to damage the corners or thin the metal. The E-coat should also be removed on
the opposite side of the flange only where the spot welds are to be placed.

5.
Repeat the procedure from Step 3 on the mating surface of the replacement service part(s). 6.
Prepare the new service panel for plug welds.
Using the original panel as a reference, drill or punch 8 mm (0.31 in) diameter holes in the
exact number as the original spot welds. The holes should be positioned as close as possible
to the original spot weld locations, without lining up exactly on top of an original spot weld
site.

To make sure of correct weld performance, grind the immediate perimeter of plug weld hole.
Grind only in the area of the plug weld, this will keep corrosion to a minimum.

7.
Dry-fit and clamp the replacement service parts to verify a correct fit and alignment.
Remove the service part after verifying correct fit and alignment.
8.
The vehicle prepared flange areas where plug welds will be located must be kept free of adhesive.
Apply 25 mm (0.98 in) tape to the plug weld areas to prevent contamination from the adhesive.
9.
Prepare the adhesive. Dispense a small amount of metal bonding adhesive from the cartridge to make
sure of an even flow of both components. Attach the mixing tip and dispense a mixing tip length of
adhesive to make sure of correct mix ratio.
10.
NOTE: Refer to the product label for preparation and handling instructions.
Apply a 6-9 mm (0.23-0.35 in) bead of adhesive to the vehicle prepared flange surface. Remove the
tape from the plug weld areas.
11.
Place the service part(s) in the correct position on the vehicle.
When positioned, do not pull the component away from the vehicle. If repositioning is
necessary, slide the service part(s). This will make sure of correct contact between the
components and adhesive.

12.
Clamp evenly and tightly. The adhesive contains glass beads which will prevent over-clamping the 13.
Weld-Bonding 1122
component.
NOTE: Welding can be carried out anytime during the adhesive curing process, or after the adhesive
is fully cured.
NOTE: If welding will not be carried out immediately, allow a minimum of 1.5 to 2 hours of
adhesive cure time at 21C (70F) before removing clamps. Cure time at lower temperatures should
be increased. Clamps may be removed immediately after the component is welded.
Wipe excess adhesive from the panel before it cures.
14.
Finish any cosmetic section seams with fiber-filled body filler. Rough sand the filler, apply
conventional body filler after the adhesive cures and block-sand the area.
15.
Usseam sealer wherever a cosmetic seam sealer is required. 16.
Mix and apply primer surfacer per Ford-approved paint recommendations. 17.
Mix and apply basecoat per Ford-approved paint recommendations.
18.
Mix and apply clearcoat per Ford-approved paint recommendations. Refinishing materials may be
force-dried following paint manufacturer's recommendations.
19.
Apply rust inhibitor or undercoating as required to provide corrosion protection to the repair area. 20.
Weld-Bonding 1123
Plastics Identification
injury.
NOTE: Identification of the various plastic types is necessary to select the appropriate repair methods to
make high quality plastic repairs. Plastics can generally be broken down into 2 categories, thermoplastics and
thermosetting plastics. Thermoplastics can be remolded by heating. This makes plastic welding a possible
repair alternative.
NOTE: In some instances, a code or material designation is stamped indicating the plastic type.
Thermoplastics are solvent reactive. Types of thermoplastics include Thermoplastic Olefin (TPO),
Polyvinyl Chloride (PVC) and Acrylonitrile Butadiene Styrene (ABS). Polyolefins have an oily or
waxy appearance. Examples include some bumper covers, stone shields, fender aprons and fan
shrouds. Polyolefins require an adhesion promoter prior to carrying out any refinish procedure.
To determine if the part is a polyolefin, grind the damaged area in an out-of-sight area.
Grinding a polyolefin will melt and smear the plastic and leave a ragged edge. If the part is
non-polyolefin, the area will grind or sand smoothly, producing a powdery dust.
Rigid Plastic Parts
Code Family Name Common Trade Name Typical Application
ABS Acrylonitrile Butadiene
Styrene
ABS, Cycolac, Lustran,
Kralistic
A-Pillars, Consoles,
Grilles
SMC Sheet Molded Composite SMC Body Panels
Flexible Plastic Parts
Code Family Name Common Trade Name Typical Application
RRIM Reinforced Reaction
Injection-Mold Material
PUR
RRIM Fascias, Body Panels, Body
Trims
TPO Thermoplastic Polyolefin Polytrope, Renflex,
Santropren Telcar,
Vistaflex, ETA, Apex,
TPO
Bumpers, End Caps, Rubber
Strips, Sight Shields,
Claddings, Interior B-Post

1.
Plastics Identification 1124
Polyolefin plastic can also be identified by placing a small sliver in a container of water, if the sample
floats, it is a polyolefin plastic. A non-polyolefin will sink when placed in a container of water.
2.
Generally, thermosetting plastics are rigid or semi-rigid. Sheet-Molded Composite (SMC) is
reinforced with glass and other fibers and are strong and rigid. SMC is used for large panels such as
hoods, liftgates, fenders and quarter panels.
A burn test can be a reliable method to determine if a plastic is a thermosetting plastic.
Extreme care must be exercised when using this method.
NOTICE: The component must be isolated away from the vehicle and all
combustible materials to perform this test.
Apply an open flame to the corner of the damaged component. If the material
crystallizes and becomes hard, it is a thermosetting plastic.

3.
Plastics Identification 1125
Plastics Refinishing
All Components
WARNING: Do not paint any air bag module trim covers or deployment doors. Paint may cause the
air bag to deploy incorrectly. Failure to follow this instruction may increase the risk of serious personal
injury or death in a crash.
NOTE: When using any Ford-approved refinishing product, it is recommended to stay within the same paint
system throughout the process. For example, do not use one manufacturer's primers and another
manufacturer's topcoats.
NOTE: Care must be used if applying heat to parts. Thermoplastics soften and tend to lose their
shape when heated.
The first step for any repair or refinish procedure is to identify the type of plastic. Is it thermosetting
or thermoplastic, grained or smooth? This will determine how it should be cleaned and prepared for
refinishing. For additional information, refer to Plastics Identification in this section.
It is essential that the correct cleaner is used, depending on which painting system is
employed, solvent-based or water-based.

Clean part with warm water/mild detergent, then with plastic cleaner to remove wax, silicone
and other contaminants. Do not allow parts to remain wet for extended periods.

As a general rule, if water beads on the part, it requires additional cleaning as all the
manufacturing release agents have not been removed.

1.
New parts may require baking in a spray booth or heating with heat lamps to release trapped solvents
or mold release agents used in the manufacturing processes.
2.
Non-grained components
After cleaning, lightly sand with 600-grit or finer sandpaper. Remove sanding residue with plastic
cleaner and wipe dry.
3.
Grained components
After cleaning, light use of a gray scuff pad is permissible providing the graining not be flattened.
Remove sanding residue with plastic cleaner and wipe dry.
4.
All components
Apply a plastics adhesion promoter to any bare plastic part following manufacturer's
recommendation. Throughout the refinish procedure, any time bare plastic is exposed for any reason,
it is essential that adhesion promoter be reapplied to that area.
5.
A sealer may be required to prevent wrinkling and lifting of the topcoat prior to carrying out the
refinish procedure.
6.
Plastics Refinishing 1126
Flexible and non-flexible components should be refinished separately as a flex additive may be
required when refinishing flexible parts (refer to the paint manufacturer's recommendation).
7.
It is recommended to carry out refinishing of exterior components on-vehicle (after cut-in) to control
color match and blending to adjacent panels.
8.
Proceed with the refinish process and follow the Ford-approved paint system procedures. Steps may
vary between paint manufacturers.
9.
Plastics Refinishing 1127
Plastics Repair
Material
Item Specification
Plastic Bonding Adhesive
TA-9
-
injury.
In deciding whether to repair or install a new component, follow these guidelines.
Is a part readily available?
Can the damaged part be economically returned to its original strength and appearance, or
will the labor cost exceed the cost of a new component?

Will repair provide for the fastest, highest quality repair?
1.
NOTICE: Never apply solvents such as lacquer thinner or reducer at any stage of plastic repair.
Solvents, cleaners and water are absorbed by many types of plastics and by the glass fibers used
for reinforcements. If this occurs, the plastic may swell in the area of repair and cause the
repair to fail. Remove cleaners and water quickly and use air and heat to speed up dryg.
NOTICE: During the repair of many plastics and particularly polyolefin plastics, an adhesion
promoter must be applied to the substrate to allow repair materials and paint to bond correctly.
Reapplication is required when grinding or sanding through the sealer or primered layers.
NOTE: When possible, it is recommended to carry out as much of the plastic repair as possible on the
vehicle. Parts mounted on the vehicle are held in correct alignment throughout the repair. Attempting
to repair the part off the vehicle may cause misalignment. This could lead to failure of the repair.
Select the correct repair method by identifying the type of plastic being repaired. For additional
information, refer to Plastics Identification in this section to determine the type of plastic being
repaired.
2.
NOTE: Always refer to the manufacturer's label directions for the type of repair materials, fillers and
bonding agents being used as they are material specific.
Determine whether a reinforcement piece is needed as a backer on large repairs.
Construct a reinforcement piece from a scrap piece of the type of plastic being repaired and
follow manufacturer's label directions for the type of system being used.

When repairing Sheet-Molded Composite (SMC), a reinforcement piece can be constructed
using several layers of glass cloth saturated with resin or structural adhesive. The weave of
the cloth or screening should be loose enough to allow the resin to thoroughly penetrate.
Reinforcement should cover the entire area of damage and extend outward beyond the

3.
Plastics Repair 1128
damage or joint area.
Sheet-Molded Composite (SMC) Panel Repair
NOTE: The following procedure applies to repair of structural cracks and large gouges. If damage is
cosmetic, use of reinforcing cloth may not be necessary.
Panels to be repaired should be dry and at room temperature 18C (65F) to 24C (75F) prior to
carrying out any repairs. Both sides of the panel must be thoroughly cleaned before sanding or
grinding.
1.
Cover the break in the SMC (front and back) with masking tape. This protects the damaged area from
absorbing the prep cleaner and eliminates wicking of the cleaner through the fibers into the SMC .
2.
Remove all waxes, silicones, dirt and road oils from the area surrounding both sides of the damaged
area with a plastics wax and grease remover.
Remove the tape and sand the back of the repair area with an angle grinder, Dual Action
(D/A) sander or by hand using 80-grit sandpaper. Remove all dust with a vacuum and tack
cloth.

3.
Create a reinforcing patch using a piece of scrap SMC that conforms well to the back of the damaged
area or form a patch from fiberglass cloth.
Cut a section of cloth large enough to cover the repair, plus 25.4 mm (1 in) around the repair
area.

Cut a section of plastic film backing approximately 25.4 mm (1 in) larger than the cloth. Lay
the plastic smooth, flat surface where it will be used to create a pyramid patch.

4.
Follow manufacturer's directions and apply plastic repair adhesive to the plastic film backing and
smooth with plastic spreader to recommended thickness. Place the pre-cut fiberglass cloth on the
adhesive-coated plastic film. Cover the cloth with a coat of repair adhesive and spread to the
recommended thickness.
5.
Apply the prepared patch to the backside of the panel and compress. Follow manufacturer's
instructions for adhesive cure. Remove plastic film after adhesive cures and sand as necessary to
remove roughness.
6.
Remove masking tape from the front side of damaged area and grind down to the backing patch. Use
an angle grinder with a 30- to 40-grit wheel. Make a gradual taper in the area, this will prevent
bull's-eyes or read-through in the finished repair. Sand prepared area with a D/A sander or hand-sand
with 80-grit sandpaper.
7.
Build a pyramid patch using fiberglass cloth or equivalent and plastic repair adhesive. Following
manufacturer's directions, apply patch to damaged area.
8.
Rough-grind area to remove excess adhesive. Sand repair area with 80-grit sandpaper, making sure to
cut slightly below the SMC finished surface. This will allow for a finish coat of plastic body repair
material.
9.
Apply a finish coat of plastic repair filler material per manufacturer's directions. 10.
Finish-sand, prime and topcoat using Ford-approved paint systems. 11.
Thermoplastic Compounds
In deciding whether to repair or install a new component, follow these guidelines.
Is a part readily available?
Can the damaged part be economically returned to its original strength and appearance, or
will the labor cost exceed the cost of a new component?

Will repair provide for the fastest, highest quality repair?
1.
NOTE: The following steps are to be used as a guideline. Depending on what brand of adhesives or
patch materials are used, procedures may vary slightly.
Thoroughly clean the damaged area with wax and grease remover formulated for use with plastics.
2.
Hand sand the repair area with 80-grit sandpaper and remove any foreign material with compressed
air.
3.
Apply a plastics adhesion promoter per label directions to the repair area. 4.
For small repairs, a plastic adhesive filler can be applied to the damaged area. Follow manufacturer's
directions and build layers to form a thickness above the damaged area. This will allow the area to be
sanded smooth.
5.
To repair large holes or cracks, measure and cut a piece of fiberglass cloth or equivalent 25.4 mm (1
in) larger than the crack or hole.
Apply plastic repair adhesive to the damaged area and immediately apply fiberglass cloth into
plastic adhesive for reinforcement. Apply additional plastic repair adhesive for strength and
shape as required.

6.
Contour and shape the repair as necessary with a D/A sander. Avoid sanding through the repair. 7.
Finish-sand the area and carry out any required paint operations using Ford-approved paint systems. 8.
Tab Repair - Bumper
NOTE: Inspect the bumper cover to determine if part of it can be repaired to an acceptable level of
quality of appearance, fit and durability. Will labor and material cost of the repair meet or exceed the
cost of a new replacement bumper cover? If the bumper cover is determined to be repairable, proceed
to the following steps.
NOTE: The following steps are to be used as a guideline. Depending on what brand of adhesives or
patch materials are used, procedures may vary slightly.
Remove the affected bumper. For additional information, refer to Section 501-19 .
1.
NOTE: Illustration is not vehicle specific.
Clean the broken tab(s) with a plastics wax and grease remover. 2.
Hand sand the repair area with 80-grit sandpaper and remove any foreign material with compressed
air.
3.
Apply a plastics adhesion promoter per label directions to the repair area. 4.
Measure and cut a patch of fiberglass cloth or equivalent large enough to form the front of the tab,
then slope back in a wedge shape approximately 51 mm (2 in) from original tab.
5.
Manual
REMOVAL AND
INSTALLATION
Inner Body Reinforcing Panels
Special Tool(s)
Heat Treatment Induction Resistance Spot
Welder
254-00001
Pro 230 MIG Welder
208-00030
Material
Item Specification
TA-1
-
(aerosol)
-
Rust Inhibitor
(aerosol)
-
ZC-31-A
-
Seam Sealer
TA-2
-
Exploded View
NOTE: Left side shown, right side similar.
Inner Body Reinforcing Panels 1132
1 02527 LH/
02526 RH
Front body pillar reinforcement - High-Strength Low
Alloy (HSLA) 250 steel (part of 025A01 LH/ 025A00
RH service assembly)
2 513A13 LH/
513A12 RH
A-pillar reinforcement - HSLA 300 steel (part of
025A01 LH/ 025A00 RH service assembly)
3 - Reinforcement - HSLA 300 steel (part of 02509 LH/
02508 RH service assembly)
4 24321 LH/
24320 RH
B-pillar inner - HSLA 300 steel (part of 24301 LH/
5 - Roof rail reinforcement HSLA 250 steel (part of
24301 LH/ 24300 RH service assembly)
6 27791 LH/
27790 RH
Body side inner panel - mild steel
7 45115 LH/
45114 RH
Luggage compartment drain trough - mild steel
8 46571 LH/
46570 RH
Package tray support panel - mild steel
9 46561 LH/
46560 RH
Package tray support on lower body - mild steel
10 46775 LH/
46774 RH
Package tray to wheelhouse strainer - mild steel
11 27887 LH/
27886 RH
Quarter panel inner wheelhouse - mild steel
12 10143 LH/
10142 RH
Rocker panel reinforcement - Dual Phase Steel (DP)
600 (part of 24301 LH/ 24300 RH service assembly)
13 244A29 LH/
24428 RH
Center body pillar reinforcement - HSLA 350 steel
(part of 24301 LH/ 24300 RH service assembly)
14 - Cowl side panel - HSLA 300 steel (part of 02509 LH/
Underbody - Front
Item
Part
Number Description
Exploded View 1133
1 10136 Floor side member (RH) - High-Strength Low Alloy
(HSLA) 250 steel
2 617C50 Seat track reinforcement (RH) - mild steel
3 10684 Crossmember No. 3 - mild steel
4 11135 Floor pan - mild steel
5 111K36 Floor tunnel reinforcement - mild steel
6 612K55 Seat track reinforcement (LH) - mild steel
7 10137 Floor side member (LH) - HSLA 250 steel
8 54611 Floor tunnel reinforcement - mild steel
9 10063 Floor side member extension (LH) - HSLA 250 steel
10 53656 Crossmember reinforcement - mild steel
11 10062 Floor side member extension (RH) - HSLA 250 steel
Underbody - Rear
Item
Part
Number Description
12 101A14 Floor side member assembly (RH) - High-Strength Low
Alloy (HSLA) 300
13 17A750 Bumper mount bracket - HSLA 350 steel
14 10692A Crossmember - mild steel
15 11160 Center floor pan - mild steel
16 11215 Rear floor pan - mild steel
17 11250B Rear floor pan extension assembly (RH) - mild steel
18 11251B Rear floor pan extension assembly (LH) - mild steel
19 17A750 Bumper mount bracket - HSLA 350 steel
20 101A15 Floor side member assembly (LH) - HSLA 300
21 10692B Crossmember - mild steel
22 10716 Crossmember - mild steel
23 11B42 Floor panel - mild steel
Front Structure - Exploded View
NOTE: Left side shown, right side similar
Underbody - Front 1134
1 17B750 Bumper bracket - mild steel
2 5410063 LH/ 5410062
RH
Front rail inner - Dual Phase Steel (DP)
600
3 5416055 LH/ 5416054
RH
Apron assembly - mild steel
4 5410414 Lower dash crossmember - mild steel
5 16A50 Dash panel - mild steel
6 5402030 Upper dash panel - mild steel
7 024A15 LH/ 024A14 RH Cowl reinforcement - mild steel
8 54381 LH/ 54380 RH Torque box - mild steel
9 5410633 LH/ 5410632
RH
Front rail outer - DP 600 steel
10 16155 LH/ 16154 RH Fender reinforcement upper - mild steel
injury.
Front Structure - Exploded View 1135
NOTE: Factory spot welds may be substituted with either Squeeze-Type Resistance Spot Welding (STRW)
or Metal Inert Gas (MIG) plug welds. Spot/plug welds should equal factory welds in both location and
quantity. Do not place a new spot weld directly over an original weld location. Plug weld hole should equal 8
mm (0.31 in) diameter.
NOTICE: Electronic modules and related wiring may be damaged when exposed to heat from
welding procedures. Carefully disconnect and remove, or position away from heat-affected
areas. For additional information, refer to Welding Precautions - Steel in this section.
Detrim the vehicle and remove the outer body sheet metal from the affected area, prior to performing
any reinforcing panel replacement. For additional information, refer to Sectioning Guidelines in this
section.
1.
Where possible, create a backer piece using a portion of the old panel. This will create a stronger
joint.
2.
When welding overlapping surfaces or substrates, apply a weld-through primer between the surfaces
prior to welding.
Make sure horizontal joints and flanges are correctly sealed with seam sealer to prevent
moisture intrusion. Water and moisture migrate to horizontal joints and corrosion tends to
occur more rapidly in these areas. Metal surfaces must be clean and dry before applying seam
sealer.

3.
Refinish the repair area as required, per Ford-apppaint guidelines. apply corrosion protection to the
4.
repair area as required.
Manual
REMOVAL AND
INSTALLATION
Roof Panel
Special Tool(s)
Heat Gun
107-R0300
General Equipment
3 Phase Inverter Spot Welder 254-00002
Compuspot 700F Welder 190-50080
I4 Inverter Spot Welder 254-00014
Inverter Welder with MIG Welder 254-00015
Material
Item Specification
TA-1
-
Roof Ditch Sealer
Fusor 122EZ, 3MTM 08307
-
Seam Sealer
TA-2
-
Roof Assembly
NOTE: Windshield header damper assembly, part No. 034A08, is used on Ford models only and is provided
as a separate service component.
Item
Part
Number Description
1 50202 Roof panel - mild steel
Roof Panel 1138
2 42220 Rear window frame - High-Strength Low Alloy
(HSLA) 350 steel
3 51269 Roof bow - HSLA 350 steel
4 034A08 Damper - mild steel
5 03410 Windshield header - HSLA 350 steel
Removal
W damage repair must conform to the instructions contained in this workshop manual.
Replacement components must be new, genuine Ford Motor Company parts. Recycled, salvaged,
aftermarket or reconditioned parts (including body parts, wheels or safety restraint components) are
not authorized by Ford.
injury.
NOTICE: Be sure to adequately protect all glass, exterior finish and interior trim to avoid damage
during the repair procedure.
NOTE: The roof panel is affixed using a process not previously employed on a Ford Motor Company vehicle.
The driver and passenger sides of the roof panel are laser skip-welded. Installation of a new roof panel will
employ a weld-bonding technique. The use of mechanical welding and chemical bonding are both part of the
installation technique.
1.
Remove the windshield and rear window glass. For additional information, refer to Section 501-05 . 2.
Remove the roof ditch mouldings. 4.
Roof Assembly 1139
NOTE: For installation purpose, particular attention must be paid to the depth (thickness) of the
sealer removed.
Using a Heat Gun and a narrow scraper, remove the sealant along the entire length of the roof sides.
Remove sealer as completely as possible.
5.
From inside the vehicle, leaving as much of the foam as possible intact, separate the NVH foam along
the roof bows from the roof panel using a flexible and sharp broad scraper or knife.
6.
Remove (drill out) all the roof panel spot welds from the windshield and rear window glass openings. 7.
Using a cut-off wheel, plasma cutter or an air hammer equipped with a panel cutter bit, carefully
separate the panel from the vehicle by cutting the entire length along the inner portion of the roof
ditch seam on each side of the roof panel.
8.
Roof Assembly 1140
NOTE: If the windshield header is damaged and requires service, Ford and Mercury models use a
damper which is welded to the header and is serviced as a separate component. The damper can be
transferred to the replacement header if it is not damaged.
With the help of an assistant, remove the roof panel from the vehicle.
9.
Using an air hammer equipped with a flat chisel, remove the remaining portion of the roof panel from
the roof ditch area.
10.
Installation
must set at or below 60C (140F) with a bake time of 45 minutes or less. Temperatures in excess of
60C (140F) or bake durations longer than 45 minutes will require the HVTB be removed from the
vehicle prior to placing in the paint booth. For additional information, refer to Section 414-03 .
NOTICE: Be sure to adequately protect all glass, exterior finish and interior trim to avoid damage
during the repair procedure.
Using a hammer any, straighten any damage caused to flange areas during removal. 1.
Using a grinder, carefully prepare the roof ditch area for the new roof panel. 2.
With the help of an assistant, position the new roof panel on the vehicle. 3.
Properly align and index-mark the positioning of the panel-to-vehicle and remove the panel. 4.
Apply a 13 mm (0.51 in) tall bead of seam sealer TA-2 directly to the NVH foam remaining on the
roof bows and immediately reinstall the roof panel aligning it to the index marks made during the test
fitting.
If necessary, application of flexible foam repair (locally obtained), may be used with the seam
sealer.

5.
Roof Assembly 1141
Make sure good contact is made with the sealer and carefully clamp the roof panel on all sides. 6.
Using the resistance spot welder, weld the roof panel to the vehicle in the windshield and rear window
glass areas. Spot welds should match factory welds in both location and quantity.
7.
Using the Metal Inert Gas (MIG) welder, seam-weld the roof panel sides with 10 mm (0.39 in) long
weld beads spaced 40 mm (1.57 in) apart. Each corner must have a 10 mm (0.39 in) weld bead
applied.
8.
Prepare the repair area for refinish material application following the paint manufacturer's
recommendations.
9.
Apply a quality primer-sealer following the paint manufacturer's recommendation for both
compatibility and application.
10.
NOTE: Always use refinishing materials from a single paint manufacturer. Combining products from
more than one manufacturer may result in refinishing material incompatibility issues and potential
void of warranty for each product applied.
If required, follow up with a quality primer-surfacer following the paint manufacturer's
recommendations. Block sand to level using the recommended grit sandpaper.
11.
NOTICE: Failure to purge air bubbles from the roof ditch sealer may result in air trapped in
the roof ditch which may cause refinishing materials to pop.
Stand the roof ditch sealer vertically (nose up) for a minimum of 30 minutes prior to application to
permit trapped air to rise to the top so it may be purged.
12.
Position the vehicle so it is level front-to-rear. 13.
Using masking tape, form a dam at each end of the roof ditch (both sides) to prevent roof ditch sealer
run-off.
14.
Roof Assembly 1142
Apply the roof ditch sealer following product directions to a depth equal to the sealer noted during
removal.
15.
Allow the material to cure 40-60 minutes at room temperature before refinishing. If roof ditch sealer
has been allowed to cure in excess of 2 hours, scuff the surface using a red scuff pad.
16.
Refinish the roof and repair area following Ford-approved paint system recommendations. 17.
Allow refinishing materials sufficient cure time to permit safe handling (refer to paint manufacturer's
specification) and install the roof ditch moulding.
18.
Install the headliner. For additional information, refer to Section 501-05 . 19.
Install the windshield and rear window glass. For additional information, refer to Section 501-11 . 20.
Roof Assembly 1143
Manual
REMOVAL AND
INSTALLATION
Door Outer Panel
Special Tool(s)
Heat Gun
107-R0300
Pro 230 MIG Welder
208-00030
Material
Item Specification
TA-1
-
Rust Inhibitor
(aerosol)
-
Door Assembly
1 20205 LH/ 20204
RH
Door outer panel - mild steel
2 - Upper belt reinforcement (part of door assembly)
- mild steel
3 20125 LH/ 20124
RH
Door assembly - mild and High-Strength Steel
(HSS)
Door Outer Panel 1144
adversely affect structural integrity and crash safety performance, which could result rsonal injury to
vehicle occupants in a crash.
injury.
Remove the door trim panel from the affected door and window glass. For additional information,
1.
Remove the outside door handle and mirror assembly. For additional information, refer to Section
501-09 .
2.
Remove door trim including mouldings and weatherstrips. 3.
Remove the door assembly and secure on a workstand. 4.
NOTICE: Use extreme care to avoid cutting the door shell or inner panel.
Using a high-speed cut off wheel, make cuts to the beltline portion of the outer panel in the areas
indicated by the arrows.
Using a grinder, grind along the perimeter of the outer door panel hem to separate the hem
edges as indicated in the illustration.

5.
NOTE: The use of a heat gun may be required to soften door panel adhesive.
Prior to removing the outer panel, use a sharp knife to cut the adhesive between the door outer panel,
flutter beam, beltline reinforcement and intrusion beam.
Using a flat-blade chisel or equivalent, remove the original panel.
Using a sharp knife or broad edge scraper, remove the remaining portion of the hem flange
from the door shell.

6.
Door Assembly 1145
Remove any remaining adhesive from the door shell flange.
Trial fit the service replacement panel to the door shell assembly and carefully mark the cut lines on
the panel to match the cut lines on the original panel.
7.
Cut the service replacement panel and recheck the fit to make sure of proper alignment. 8.
Temporarily secure the outer panel to the door assembly and install on the vehicle to verify correct
alignment and fit.
9.
Prepare the service replacement panel joint areas by grinding clean all mating surfaces. 10.
Prepare the door shell assembly by grinding all the mating surfaces including:
the inner hem and outer belt reinforcement. 1.
the flutter beam. 2.
the intrusion beam. 3.
11.
Apply metal bonding adhesive to the following areas: service replacement hem flange, intrusion
beam-to-outer panel, flutter beam-to-outer panel, and outer belt reinforcement-to-outer panel.
12.
Position and align the new door skin to the door shell assembly, carefully turn the assembly over and
begin the hemming process.
Using a door panel installation tool or the hammer and dolly method, close the perimeter door
hem and smooth any residual adhesive in the joints.

13.
Turn the door over and Metal Inert Gas (MIG) weld the upper beltline joint. Finish grind and trial fit
the upper beltline moulding and mirror.
14.
Door Assembly 1146
Prime and paint the door using Ford approved paint system. 15.
Apply rust inhibitor inside the door to all hem areas and upper beltline area. For additional
information, refer to Restoring Corrosion Protection Following Repair in this section.
16.
Reassemble and install door and align. For additional information regarding door fitment
specifications, refer to Body in this section.
17.
Door Assembly 1147
Manual
REMOVAL AND
INSTALLATION
Frame Members - Front
Special Tool(s)
286-00002
286-00001
General Equipment
Material
Item Specification
ZC-31-A
-
(aerosol)
-
Rust Inhibitor
(aerosol)
-
Front Frame Rail
Frame Members - Front 1148
1 - Front structure assembly - mild steel
2 3057-A Subframe bolt
3 10219 LH/ 10218
RH
Member assembly - front side outer - Dual Phase
Steel (DP) 600
4 10063 LH/ 10062
RH
Member assembly - front side inner - DP 600
steel
5 17B750 LH/
17B749 RH
Bumper bracket - mild steel
6 - Subframe nut
adversely affect structural integrity and crash safety performancesult in serious personal injury to
vehicle occupants in a crash.
WARNING: Frame rail crush zones absorb crash energy during a collision and must be replaced if
damaged. Prior to replacement of frame rail crush zones, straighten damaged frame rails to correct
frame dimensions. Failure to follow these instructions may adversely affect frame rail crush zone
performance and may result in serious personal injury to vehicle occupants in a crash.
injury.
surfaces or E-coat, or when bare metal repairs are made. For additional information, refer to Restoring
Front Frame Rail 1149
NOTE: Observe prescribed welding procedures when carrying out repairs to the frame assembly. For
additional information, refer to Welding Precautions - Steel in this section.
NOTE: The following repair procedure illustrates the sectioning of the lower front apron rail inner and outer
assemblies. Damage extending beyond this area requires the entire frame rail be replaced at the original
factory seams.
All vehicles
Position the vehicle on a frame repair rack following the manufacturer's recommendations. Measure
the vehicle to determine if the body requires straightening and alignment. If necessary, rough pull the
vehicle to restore the vehicle to manufactured dimensions. For dimensional information, refer to Body
in this section.
Remove the front bumper. For additional information, refer to Section 501-19 .
1.
On non-hybrid vehicles remove the battery. For additional information, refer to Section 414-01 . 2.
Remove the fender(s) from the affected side(s). For additional information, refer to Section 501-02 . 3.
Hybrid vehicles
procedure to depower the HVTB system.
4.
Left hand side
Remove the Air Cleaner (ACL), intake air resonator and bracket. For additional information, refer to
the appropriate 303-12 section.
5.
Right hand side
Remove the windshield washer reservoir. For additional information, refer to Section 501-16 . 6.
All vehicles
NOTE: MKZ shown, Fusion similar.
Remove the bolts and the underbody shield, if equipped.
7.
Remove the subframe nut from the affected side.
8.
NOTE: The original subframe bolt is welded to the frame rail.
Remove the subframe bolt.
Grind off the head of the bolt.
Drive the bolt out and discard.
9.
NOTICE: The frame rail must not be cut or welded at the factory locator line.
Mark and measure the outer rail.
Identify the locator line on the frame outer rail.
Measure 30 mm (1.181 in) forward of locator line and scribe.
10.
NOTICE: The frame rail must not be cut or welded at the factory locator line.
Mark and measure the inner frame rail.
Identify the locator line on the frame inner rail.
Measure 50 mm (1.968 in) rearward of the locator line and scribe.
11.
NOTE: Factory spot welds may be substituted with either resistance spot welds or Metal Inert Gas
(MIG) plug welds. Spot/plug welds should equal factory welds in both location and quantity. Do not
place a new spot weld directly over an original weld location. Plug weld hole should equal 8 mm
12.
(0.31 in) diameter.
Drill out all the spot welds forward of the scribe line made on the inner frame rail.
Using a die-grinder, plasma cutter or reciprocating saw, carefully cut the OUTER RAIL ONLY along
the scribe line and remove the outer frame rail.
13.
Using a die-grinder, plasma cutter or reciprocating saw, carefully cut the INNER RAIL ONLY along
the scribe line and remove the inner frame rail. Clean surfaces with metal surface prep or equivalent.
14.
Installation
All vehicles
Measure mark and cut 50 mm (1.968 in) rearward of the locator line on the replacement INNER
frame rail.
1.
Prepare all the mating surfaces for MIG welding.
Chamfer the mating surfaces of the inner frame rail on the vehicle and the replacement rail
from the inside to improve butt weld condition. Clean metal surfaces with metal surface prep
or equivalent.
1.
Remove E-coat from the immediate weld area on the vehicle frame rail and the replacement
rail section.
2.
Apply a commercially available weld-through primer to the immediate weld area on both
mating surfaces.
3.
2.
Install and clamp the replacement inner frame rail in position. Verify correct dimensions. For
additional information, refer to Body in this section.
3.
Seam weld along the inside of the section joint using a MIG welder and ER70S-3 wire 0.9 mm (0.035
in) to 1.1 mm (0.043 in) diameter.
4.
Use a dye penetrant to determine if any cracks or voids exist in the weld joint. If cracks or other
defects exist, grind out the defect and repair until the weld is free of defects.
5.
Measure mark and cut 30 mm (1.181 in) forward of the locator line on the replacement outer frame
rail.
6.
Prepare all the mating surfaces for MIG welding.
Chamfer the mating surfaces of the outer frame rail on the vehicle and the replacement rail
from the inside, to improve butt weld condition.
1.
Remove E-coat from the immediate weld area on the vehicle frame rail and the replacement
rail section.
2.
Apply a commercially available weld-through primer to the immediate weld area on both
mating surfaces.
3.
7.
If Squeeze-Type Resistance Spot Welding (STRW) is to be replaced with MIG plug welds, drill 8 mm
(0.314 in) plug weld holes in the replacement outer frame rail mating flange. These must equal factory
spot welds in both location and quantity.
Remove E-coat from the immediate weld area of both inner and outer frame rail mating
surfaces.
1.
Apply a commercially available weld-through primer to the immediate weld area only on the
mating surfaces.
If resistance spot welds are to be used on the frame rail flange surfaces, E-coat
2.
8.
preparation is not necessary.
Position and clamp the replacement outer frame rail to the inner frame rail. All mating surfaces must
make full contact.
Verify correct dimensions. For additional information, refer to Body in this section.
9.
Seam weld the butt joint using a MIG welder and ER70S-3 wire 0.9 mm (0.035 in) to 1.1 mm (0.043
in) diameter.
10.
Using a MIG welder or STRW welder, plug or spot weld the inner and outer frame rail flange mating
surfaces.
Restore corrosion protection to the inner and outer surface of the repair area. For additional

11.
Install new subframe bolt and position the subframe in place.
Install the subframe washer and nut. Tighten to 150 Nm (111 lb-ft).
12.
Remove E-coat from the immediate weld area of the frame rail and bumper mounting bracket.
Apply a commercially available weld-through primer to the immediate weld area only on
both mating surfaces.

13.
Clamp the replacement bumper bracket to the vehicle, install the steel bumper and verify correct
dimensions and alignment. Remove the bumper.
14.
Seam weld the butt joint using a MIG welder and ER70S-3 wire 0.9 mm (0.035 in) to 1.1 mm (0.043
in) diameter.
15.
Restore corrosion protection to the inner and outer surface of the repair area. For additional
16.
Refinish the outer portion of the repair following Ford-approved paint recommendations. 17.
temperature must set at or below 60C (140F) with a bake time o minutes or less.
Refinish the outer portion of the repair following Ford-approved paint recommendations.
18.
Right hand side
Install the windshield washer reservoir. For additional information, refer to Section 501-16 . 19.
Left hand side
Install the ACL bracket, ACL and intake resonator. For additional information, refer to the
appropriate 303-12 section.
20.
All vehicles
Install the underbody shield and bolts, if equipped. 21.
Install the fender(s) on the affected side(s). For additional information, refer to Section 501-02 . 22.
Install the bumper. For additional information, refer to Section 501-19 .
On hybrid vehicles, repower the HVTB . For additional information, refer to Section 414-03 .
23.
On non-hybrid vehicles, install the battery. For additional information, refer to Section 414-01 . 24.
Manual
REMOVAL AND
INSTALLATION
Frame Members - Rear
Special Tool(s)
286-00002
286-00001
General Equipment
Material
Item Specification
ZC-31-A
-
(aerosol)
-
Rust Inhibitor
(aerosol)
-
Rear Frame Rail
Frame Members - Rear 1155
1 17906 Rear bumper - Ultra High Strength Steel
(UHSS) martensitic steel
2 10457 LH/ 10456 RH Frame member assembly - High-Strength
Low Alloy (HSLA) 300 steel
3 - Rear floor pan assembly - mild steel
4 17787 Rear bumper brackets - HSLA 300 steel
WARNING: Frame rail crush zones absorb crash energy during a collision and must be replaced if
damaged. Prior to replacement of frame rail crush zones, straighten damaged frame rails to correct
frame dimensions. Failure to follow these instructions may adversely affect frame rail crush zone
performance and may result in serious personal injury to vehicle occupants in a crash.
injury.
surfaces or E-coat, or when bare metal repairs are made. For additional information, refer to Restoring
NOTE: Observe prescribed welding procedures when carrying out repairs to the frame assembly. For
additional information, refer to Welding Precautions - Steel in this section.
NOTE: The following repair procedure illustrates the sectioning of the rear frame rail assembly. Damage
extending beyond this area requires the entire frame rail be replaced at the original factory seams.
Position the vehicle on a frame repair rack following the manufacturer's recommendations. Measure
the vehicle to determine if the body requires straightening and alignment. For additional dimensional
information, refer to Body in this section.
Remove the rear bumper. For additional information, refer to Section 501-19 .
1.
2.
Position aside the exhaust system (if required). 3.
Drill out the spot welds and remove the bumper bracket. 4.
Rear Frame Rail 1156
Measure and mark 375 mm (14.763 in) forward of the bumper bracket attachment flange on the frame
rail of the affected side.
5.
NOTICE: If equipped, the frame rail must not be cut or welded at the factory locator line.
Using a die-grinder, plasma cutter or reciprocating saw, carefully cut the rear frame rail at the mark.
6.
NOTICE: Do not drill pilot holes in an attempt to aid in spot weld removal.
Drill out the spot welds using a spot weld cutter or equivalent rearward of the rail mark and remove
the rail section.
7.
Installation
Measure and mark 375 mm (14.763 in) forward of the bumper bracket attachment flange on the
replacement frame rail.
1.
NOTE: Factory spot welds may be substituted with either resistance spot welds or Metal Inert Gas
(MIG) plug welds. Spot/plug welds should equal factory welds in both location and quantity. Do not
place a new spot weld directly over an original weld location. Plug weld hole should equal 8 mm
(0.31 in) diameter.
Prepare all mating surfaces for MIG welding.
Grind smooth all spot weld nuggets on the vehicle floor pan. 1.
Drill or punch plug weld holes in the replacement frame rail. 2.
Chamfer the mating surfaces of the inner frame rail and the replacement rail section. 3.
Remove the E-coat from the immediate weld area on the vehicle frame rail and the
replacement rail section. Clean the surfaces with metal surface prep or equivalent.
4.
2.
Apply a commercially available weld-through primer to the immediate weld area only, on all
mating surfaces.
5.
Install and clamp the replacement frame rail to the vehicle. Verify correct dimensions and alignment.
For additional information, refer to Body in this section.
3.
Seam weld the section joint using a MIG welder and ER70S-3 wire 0.9 mm (0.035 in) to 1.1 mm
(0.043 in) diameter.
4.
Plug weld the replacement rail to the floor pan using a MIG welder and ER70S-3 wire 0.9 mm (0.035
in) to 1.1 mm (0.043 in) diameter.
5.
Use a dye penetrant to determine if any cracks or large voids exist in the weld joint. If cracks or other
defects exist, grind out the defect and repair until the weld is defect free.
6.
Position and install the bumper bracket. 7.
Apply rust inhibitor to the inner surface of the repair area. Refinish the exterior following
Ford-approved paint procedures.
8.
Apply undercoating to the exterior surface of the frame rail. 9.
Reinstall the exhaust components as required. 10.
Reinstall the bumper assembly. For additional information, refer to Section 501-19 . 11.
SECTION 502-00: Uni-Body, Subframe and
Mounting System
Workshop Manual
Brake caliper anchor plate bolts 26 19 -
Crossmember-to-front subframe nuts 65 48 -
Driveshaft bolts 83 61 -
Electronic Power Assist Steering (EPAS) ground wire bolt 10 - 89
Front bushing brace-to-body bolts 25 18 -
Front subframe nuts 150 111 -
Front subframe support bracket bolts 103 76 -
Lower control arm ball joint lower nuts 200 148 -
Lower control arm-to-strut through bolts 103 76 -
Motor Electronics Cooling System (MECS) bolt 10 - 89
Parking brake cable-to-trailing link bracket bolts 22 16 -
Power steering pressure line bracket bolt 9 - 80
Power steering return line bolts 9 - 80
Rear hub spindle-to-brake caliper bolts 59 44 -
Rear shock-to-trailing link lower bolts 115 85 -
Rear subframe front mounting nuts 115 85 -
Rear subframe rear mounting nuts 115 85 -
Roll restrictor bolt 90 66 -
Stabilizer bar link nuts 42 31 -
Steering column shaft bolt 20 15 -
Steering gear mounting bolts 107 79 -
a
Tie-rod end nuts 48 35 -
Trailing arm-to-frame bolts 125 92 -
Trailing links-to-vehicle body 103 76 -
Underbody shield bolts 7 - 62
Upper arm bolts 110 81 -
a
Refer to the procedure in this section.
SECTION 502-00: Uni-Body, Subframe and
Mounting System
Workshop Manual
Subframe and Mounting Systems
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.
Rear Subframe
The rear subframe is bolted to the body and is used to:
aid in structural support.
provide the mounting surface for the rear suspension upper control arms, rear suspension lower
control arms and (if equipped) a mounting location for the rear differential.

Underbody misalignment can affect front and rear wheel alignment, the operation of the suspension parts and
drivetrain operation. Door and window opening concerns and air or water leaks at the doors are often caused
by incorrectly tightened bolts and body misalignment. For information on underbody dimensions, refer to
Section 501-35 .
Subframe and Mounting Systems 1161
SECTION 502-00: Uni-Body, Subframe and Mounting
System
Subframe - Front
Special Tool(s)
Remover, Front Hub
205-D070 (D93P-1175-B) or equivalent
Installer, Halfshaft
204-161 (T97P-1175-A)
Ball Joint Separator
204-592
Powertrain Lift
300-OTC1585AE or equivalent
2.5L Hybrid
1 W520416 Front subframe nuts (4 required)
2 3C496 Front subframe support bracket bolts (4
required)
3 5884 Subframe support bracket
Rear Subframe 1162
4 W500545 Roll restrictor bolt
5 W506410 Electronic Power Assist Steering (EPAS)
ground wire bolt
6 5C145 Front subframe
7 - EPAS jumper harness connector (part of
3F720)
8 6E5C Tie-rod end nut (2 required)
9 5A552 Front subframe washers
2.5L
2 3C496 ont subframe support bracket bolts (4 required)
ground wire bolt
3F720)
2.5L Hybrid 1163
3.0L
2 3C496 Front subframe support bracket bolts (4
required)
ground wire bolt
3F720)
3.5L
3.0L 1164
2 3C496 Front subframe support bracket bolts (4 required)
Removal
All vehicles
100-02 .
1.
Vehicles equipped with Electronic Power Assist Steering (EPAS)
NOTE: Use a steering wheel holding device (such as Hunter 28-75-1 or equivalent).
Using a suitable holding device, hold the steering wheel in the straight-ahead position.
2.
Remove the 2 lower steering column shaft joint cover nuts and the cover. 3.
NOTICE: Do not allow the steering column to rotate while the steering column shaft is
disconnected from the steering gear or damage to the clockspring may occur. If there is
4.
3.5L 1165
evidence that the steering column has rotated, the clockspring must be removed and recentered.
For additional information, refer to Section 501-20B .
Remove the bolt and disconnect the steering column shaft from the steering gear.
Discard the bolt.
NOTICE: Remove the steering gear/dash seal or damage to the seal may occur.
Remove the steering gear/dash seal.
5.
All vehicles
Remove the wheels and tires. For additional information, refer to Section 204-04 . 6.
Remove the bolts and the underbody shield, if equipped. 7.
NOTE: RH side shown, LH side similar.
Remove the 4 screws from each side and position the RH and LH fender splash
shields aside.
8.
Remove the 6 pin-type retainers (4 shown) from the LH and RH splash shields. 9.
2.5L Hybrid
Remove the Motor Electronics Cooling System (MECS) bolt and position the MECS
aside.
10.
3.5L 1166
Vehicles equipped with Hydraulic Power Assist Steering (HPAS)
Remove the 3 power steering return line bolts. 11.
Remove the 3 steering gear mounting bolts. 12.
NOTE: The steering gear is not removed with the front subframe and must be
positioned aside.
Position the steering gear aside using mechanic's wire.
13.
Vehicles equipped with EPAS
Remove the exhaust flexible pipe. For additional information, refer to Section 309-00
.
14.
Disconnect the 2 front EPAS in-line electrical connectors and the 4 wiring retainers. 15.
Remove the EPAS ground wire bolt.
16.
All vehicles
Remove the bolt from the roll restrictor. 17.
3.5L 1167
Remove the 2 upper stabilizer bar link nuts (one each side) and separate from the
stabilizer bar.
18.
Remove the lower control arm-to-strut through bolts and flagnuts. 19.
Remove the 2 outer tie-rod end cotter pins and nuts.
Discard the cotter pins.
20.
NOTICE: Do not use a hammer to separate the outer tie-rod end from the wheel
knuckle or damage to the wheel knuckle may result.
Using the Ball Joint Separator, separate the outer tie-rod ends from the knuckle.
21.
NOTE: Left side shown.
Remove the front lower arm-to-subframe bolts.
Discard the bolts.
22.
Remove the brake flexible hose bracket-to wheel knuckle bolts and position the hose
and brackets aside.
23.
3.5L 1168
NOTE: Apply the brake to keep the halfshaft from rotating.
Remove and discard the wheel hub nuts.
24.
Using a wax pencil (or equivalent) apply witness marks to the vehicle and subframe
to aid in installation.
25.
Position the Powertrain Lift under the subframe. 26.
Remove the 4 front subframe support bracket bolts. 27.
Remove and discard the 4 front subframe nuts. 28.
Partially lower the subframe. 29.
Remove the rear lower arm-to subframe bolts.
Discard the bolt and washer.
30.
Using the Front Hub Remover, separate the halfshaft from the wheel hub.
Using mechanics wire or equivalent, support the halfshaft.
Repeat on the opposite side.
31.
Position aside the lower control arms. 32.
Lower the subframe from the vehicle. 33.
Installation
3.5L 1169
All vehicles
Partially raise the subframe. 1.
Position the halfshafts to the wheel hubs. 2.
Position the lower control arms to the subframe.
Loosely install new rear lower arm-to-subframe bolts.
3.
Raise the subframe and align to the witness marks made during removal. 4.
Install the 4 new front subframe nuts.
5.
Install the 4 front subframe bracket bolts.
Tighten to 103 Nm 76 lb-ft).
6.
Remove the Powertrain Lift. 7.
Using the Halfshaft Installer, in the halfshafts Into the wheel hubs. 8.
NOTICE: Do not tighten the halfshaft nuts with the vehicle on the ground. The
nuts must be tightened to specification before the vehicle Is lowered onto the
wheels. Wheel bearing damage will occur If the wheel bearing Is loaded with the
weight of the vehicle applied.
Install the wheel hub nuts.
9.
Position the brake flexible hose and brackets and install the bolts.
10.
Before tightening any suspension busing fasteners, the suspension must be at 402 mm
(15.826 in) between the center of the hub and the lip of the fender. This will prevent
incorrect clamp load and bushing damage.
Use a suitable jack to raise the suspension to specification.
11.
3.5L 1170
Tighten the front lower arm-to-subframe bolts.
Tighten an additional 90 with the suspension at the bushing fastener
tightening position.
2.
12.
Tighten the rear lower arm-to-subframe bolts to 110 Nm (81 lb-ft). 13.
Install the outer tie-rod ends to the control arms.
Position to the wheel hubs. 1.
Install the nuts. 2.
Install new cotter pins. 4.
14.
Install the lower control arm-to-strut through bolts and flagnuts.
15.
Position the stabilizer bar links and install the nuts. 16.
Install the roll restrictor bolt.
17.
Install the EPAS ground wire and bolt.
18.
3.5L 1171
Connect the 2 front EPAS in-line electrical connectors and the 4 wiring retainers. 19.
Install the exhaust flexible pipe. For additional Information, refer to Section 309-00 . 20.
Vehicles equipped with HPAS
Position the steering gear.
Install the 3 steering gear mounting bolts. 1.
21.
Install the 3 power steering return line bolts.
22.
2.5L Hybrid
Install the MECS and bolt.
23.
All vehicles
NOTE: RH side shown, LH side similar.
Position the LH and RH fender splash shields and Install the screws.
24.
3.5L 1172
Install the LH and RH splash shields and pin-type retainers 6 each side, 4 shown). 25.
Install the underbody shield and bolts (if equipped).
26.
Install the wheels and tires. For additional information, refer to Section 204-04 . 27.
NOTICE: The steering gear/dash seal must be fully seated In the steering valve tower
groove before the retaining clips are fully engaged Into the body. If the steering
gear/dash seal Is not seated to the steering gear valve tower groove and the clips are not
fully engaged to the body, water and foreign material may enter the passenger
compartment and damage the vehicle Interior.
Install the steering gear/dash seal.
To install, apply hand force to the center of the seal, install the steering gear/dash seal
onto the steering gear valve tower until fully seated In the valve tower groove. Install
the steering gear/dash seal until the clips are fully engaged Into the body.

28.
Position the steering column shaft to the steering gear.
Install a new steering column shaft bolt.
29.
Install the steering column shaft joint cover and nuts. 30.
Remove the steering wheel holding device. 31.
3.5L 1173
3.5L 1174
SECTION 502-00: Uni-Body, Subframe and Mounting
System
Subframe - Rear
Special Tool(s)
Powertrain Lift
1 W712755 Front bushing brace-to-body bolt (4 required)
2 W520515 Rear subframe nut (4 required)
3 5K067 Rear subframe
4 5E028 Rear subframe washers
5 W704586 Shock absorber lower bolt
6 W711493 Trailer arm-to-frame bolts (4 required)
7 - Brake caliper anchor plate bolts (4 required)
NOTICE: Suspension fasteners are critical parts because they affect performance of vital parts and
systems and their failure can result in major service expense. A new part with the same part number
must be installed if installation bec necessary. Do not use a replacement part of lesser quality or
substitute design. Torque values must be used as specified during reassembly to make sure of correct
retention of these parts.
All vehicles
Remove the rear wheels. For additional information, refer to Section 204-04 . 1.
Subframe - Rear 1175
With a wax pencil, mark the relationship alignment of the rear subframe to the underbody at the
mounting locations.
2.
Remove the LH and RH rear lower arms. For additional information, refer to Section 204-02 . 3.
Remove the catalytic converter, muffler and tailpipe as an assembly. 4.
All-Wheel Drive (AWD) only
NOTE: Index-mark the rear axle pinion flange and the driveshaft yoke.
Remove the 4 driveshaft bolts.
5.
All vehicles
Remove the bolt from the LH and RH wheel speed sensors. 6.
Remove the RH and LH wheel speed sensor nuts from the stud and position aside. 7.
AWD only
Disconnect the differential electrical connector on the LH side of the subframe. 8.
All vehicles
Remove the 4 bolts (2 each side) from the rear hub spindle-to-brake caliper.
9.
Position the brake calipers aside using mechanic's wire. It is not necessary to disconnect the hydraulic
brake lines.
10.
Remove the bolts from the parking brake cable-to-trailing link bracket.
11.
Remove and discard the rear shock-to-trailing link lower bolts and flagnuts.
To install, tighten to 115 Nm (85 lb-ft) with the suspension at the bushing fastener tightening
position.

12.
Remove the 4 bolts and cone washers (2 each side) from the trailing links-to-vehicle body.
13.
NOTICE: The rear subframe must be secured to the lifting table. The rear subframe can become
unstable and fall from the lifting table.
NOTE: For All-Wheel Drive (AWD) vehicles, the rear differential is removed with the rear subframe.
Position the Powertrain Lift under the rear subframe. 14.
Remove the 4 front (2 each side) bushing brace-to-body bolts.
15.
Remove the 2 front (1 each side) mounting nuts and washers.
16.
Remove the 2 rear mounting nuts. 17.
Remove the rear subframe. 18.
Transfer the components as necessary. 19.
NOTE: Make sure the vehicle is at the correct vehicle ride height. For additional information, refer to
Section 204-00 .
20.
SECTION 303-00: Engine System - General
Information
Workshop Manual
Material
Capacity
Dye-Lite Gasoline Engine Oil
Leak Detection Dye
164-R3700 (Rotunda)
- 29.6 ml (1
oz)
Motorcraft SAE 5W-20
Premium Synthetic Blend Motor
Oil (US); Motorcraft SAE
5W-20 Super Premium Motor
Oil (Canada)
XO-5W20-QSP (US);
CXO-5W20-LSP12 (Canada)
WSS-M2C945-A -
Threadlock 262
TA-26
WSK-M2G351-A6 -
Information
Workshop Manual
Engine
NOTICE: When repairing engines, all parts must be contamination free. If contamination/foreign
material is present when repairing an engine, premature engine failure may occur.
NOTE: Specifications show the expected minimum or maximum condition. Refer to the appropriate section
in Group 303 for the procedure.
NOTE: If a component fails to meet the specifications, it is necessary to refinish it or install a new
component. Wear limits are provided as an aid to determine if the component can be refinished. A new
component must be installed when any component fails to meet specifications and cannot be refinied.
NOTE: This section contains information, steps and procedures that may not be specific to this engine.
This section covers general procedures and diagnosis and testing of the engine system, except for exhaust
emission control devices, which are covered in the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
The engine incorporates the following features: Refer to the appropriate section in Group 303 for the
procedure.
Crankcase ventilation or breather system
Exhaust emission control system
Evaporative Emission (EVAP) control system
Some engines incorporate a fail-safe cooling system. Refer to the appropriate section in Group 303 for the
procedure.
The engine, fuel system, ignition system, emissions system and exhaust system all affect exhaust emission
levels and must be maintained according to the maintenance schedule. Refer to the scheduled Maintenance
Guide.
Correct engine identification is required to order parts. Refer to the appropriate section in Group 303 for the
procedure.
For complete vehicle and engine identification codes, refer to Section 100-01 .
Engine 1181
Engine 1182
Information
Workshop Manual
Engine
Special Tool(s)
12 Volt Master UV Diagnostic Inspection
Kit
164-R0756 or equivalent (Leak Detector)
Dial Indicator Gauge with Holding Fixture
100-002 (TOOL-4201-C) or equivalent
Engine Cylinder Leak Detection/Air
Pressurization Kit
EngineEAR
EngineEAR/ChassisEAR
Oil Pressure Gauge
303-088 (T73L-6600-A)
Quick Disconnect Compression Tester
Vacuum/Pressure Tester
Material
Item Specification
Dye-Lite Gasoline Engine Oil
Leak Detection Dye
164-R3700 (Rotunda)
-
Motorcraft SAE 5W-20 Premium
Synthetic Blend Motor Oil (US);
Motorcraft SAE 5W-20 Super
Premium Motor Oil (Canada)
XO-5W20-QSP (US);
WSS-M2C945-A
Engine 1183
There are 2 diagnostic paths that can be followed depending on the type of engine concern. Carry out
Inspection and Verification - Engine Performance or Inspection and Verification - NVH.
Inspection and Verification - Engine Performance
Verify the customer concern by operating the engine to duplicate the condition. 1.
Visually inspect for obvious signs of mechanical damage. Refer to the following chart.
Visual Insrt
Mechanical
Engine coolant leaks
Engine oil leaks
Fuel leaks
Damaged or severely worn
parts

Loose mounting bolts, studs
and nuts

2.
If the inspection reveals obvious concerns that can be readily identified, repair as necessary. 3.
4.
5.
6.
418-00 .

7.
Clear the continuous DTCs and carry out the self-test diagnostics for the Battery Control Module -
High Voltage Traction Battery (BCM-HVTB) and PCM.
8.
If the DTCs retrieved are related to the concern, go to the Battery Control Module - High Voltage
Traction Battery (BCM-HVTB) DTC Chart, refer to Section 414-03 . For all other DTCs, refer to
Section 419-10 .
9.
Engine 1184
If no DTCs related to the concern are retrieved, GO to Symptom Chart - Engine Performance . 10.
Inspection and Verification - NVH
NVH symptoms should be identified using the diagnostic tools and techniques that are available. For
a list of these techniques, tools, an explanation of their uses and a glossary of common terms, refer to
Section 100-04 .
1.
Verify the customer concern by operating the engine to duplicate the condition. 2.
Check the engine oil level and check the oil for contamination. Low engine oil level or contaminated
oil are a common cause of engine noise. If the oil is contaminated, the source of the contamination
must be identified and repaired as necessary.
3.
Visually inspect for obvious signs of mechanical damage. Refer to the following chart.
Mechanical
Loose mounting bolts, studs and nuts
Damaged or leaking powertrain mounts
Damaged or disconnected vacuum hoses
Obstruction of cooling fan
Obstruction of Front End Accessory Drive (FEAD)
Obstruction of Rear End Accessory Drive (READ), if
equipped

Damaged or disconnected air intake components
4.
If the inspection reveals obvious concerns that can be readily identified, repair as necessary. 5.
If the cause is not visually evident, connect the scan tool to the DLC .
6.
NOTE: The VCM LED prove out confirms power and ground from the DLC are provided to the
VCM .
7.
8.
418-00 .

9.
Engine 1185
Clear the continuous DTCs and carry out the self-test diagnostics for the BCM-HVTB and PCM. 10.
If the DTCs retrieved are related to the concern, go to the Battery Control Module - High Voltage
Traction Battery (BCM-HVTB) DTC Chart, refer to Section 414-03 . For all other DTCs, refer to
Section 419-10 .
11.
If no DTCs related to the concern are retrieved, continue the inspection and verification if a noise
concern is related to the engine. For vibration concerns and noise concerns, such as powertrain
mounts, air intake system and starter, GO to Symptom Chart - NVH .
12.
In some cases, a noise may be a normal characteristic of that engine type. In other cases the noise may require
further investigation. Comparing the noise to a similar year/model vehicle equipped with the same engine will
aid in determining if the noise is normal or abnormal.
Once a customer concern has been identified as an abnormal engine noise, it is critical to determine the
location of the specific noise. Use the EngineEAR/ChassisEAR or stethoscope to isolate the location of the
noise to one of the following areas.
Fuel injector(s)
Upper end of engine
Lower end of engine
Front of engine
Rear of engine
Fuel injector noise
A common source of an engine ticking noise can be related to the fuel injector(s). This is normal engine noise
that can be verified by listening to another vehicle. If the injector noise is excessive or irregular, use the
EngineEAR/ChassisEAR or stethoscope to isolate the noise to a specific fuel injector.
Upper end engine noise
A common source of upper end engine noise (ticking, knocking or rattle) includes the camshaft(s) and valve
train. Upper end engine noise can be determined using the EngineEAR/ChassisEAR or stethoscope on the
valve cover bolts. If the noise is loudest from the valve cover bolts, then the noise is upper end. The
EngineEAR/ChassisEAR or stethoscope can be used to further isolate the noise to the specific cylinder bank
and cylinder. Removal of the valve covers will be required to pinpoint the source of the noise.
Lower end engine noise
A common source of lower end engine noise (ticking or knocking) includes the crankshaft, connecting rod(s)
and bearings. Lower end noises can be determined by using the oil pan or lower cylinder block. If the noise is
loudest from these areas, then the noise is lower end. If an engine noise is isolated to the lower end, some
disassembly of the engine may be required to inspect for damage or wear.
Front of engine noise
A common source of noise from the front of the engine (squeal, chirp, whine or hoot) is the Front End
Accessory Drive (FEAD) components. To isolate FEAD noise, carry out the Engine Accessory Test, refer to
Section 100-04 .
Some other noises from the front of the engine (ticking, tapping or rattle) may be internal to the engine. Use
the EngineEAR/ChassisEAR or stethoscope on the engine front cover to determine if the noise is internal to
Fuel injector noise 1186
the engine. Removal of the engine front cover may be necessary to inspect internal engine components.
Rear of engine noise
A common source of noise from the rear of the engine (knocking) is the flywheel/flexplate. Inspection of the
flywheel/flexplate will be necessary.
Some engines have timing drive components at the rear of the engine and may be the source of noise (ticking,
knocking or rattle). Use the EngineEAR/ChassisEAR or stethoscope on the rear of the engine if it is suspected
that the noise is internal to the engine. Some disassembly of the engine may be required to inspect for damage
or wear.
If equipped, the Rear End Accessory Drive (READ) can also be a source of noise from the rear of the engine
(squeal or chirp). The READ consists of the coolant pump and belt.
After localizing the noise, note the characteristics of the noise, including type of noise, frequency and
conditions when the noise occurs and GO to Symptom Chart - NVH .
13.
Symptom Chart - Engine Performance
Symptom Chart - Engine Performance
Symptom Chart - NVH
Symptom Chart - NVH
possible that any one of multiple systems may be the cause of the symptom, it may be necessary to use a
process of elimination type of diagnostic approach to pinpoint the responsible system. If this is not the causal
system for the symptom, refer back to Section 100-04 for the next likelstem and continue diagnosis.
Drone type noise
Powertrain mount(s)
CARRY OUT the Powertrain/Drivetrain Mount Neutralizing procedure in this section. TEST the
system for normal operation after the repair.

Drumming noise - occurs inside the vehicle during idle or high idle, hot or cold. Very low-frequency
drumming is very rpm dependent

Engine vibration excites the body resonances inducing interior noise

Engine drumming noise - accompanied by vibration
Front of engine noise 1187
Powertrain mount(s)

Rattle - occurs at idle or at light acceleration from a stop
Powertrain mount(s)
CHECK the powertrain mounts for damage. INSTALL new mounts as necessary. For engine, Refer to
the appropriate section in Group 303 for the procedure. For automatic transmission, Refer to the
appropriate section in Group 307 for the procedure. For manual transmission, REFER to Section
308-03 . TEST the system for normal operation after the repair.

Whine/moan type noise - pitch increases or changes with vehicle speed
Powertrain mount(s)
CHECK the porain mounts for damage. INSTALL new mounts as necessary. For engine, Refer to the
appropriate section in Group 303 for the procedure. For automatic transmission, Refer to the

Clunk - occurs when shifting from PARK or between REVERSE and DRIVE
Powertrain mounts
CHECK the powertrain/drivetrain mounts for damage. INSTALL new mounts as necessary. For
engine, Refer to the appropriate section in Group 303 fothe procedure. For automatic transmission,
Refer to the appropriate section in Group 307 for the procedure. For manual transmission, REFER to
Section 308-03 . TEST the system for normal operation after the repair.

Idle speed is too high
CHECK for the correct idle speed. TEST the system for normal operation after the repair.
Accessory drive bearing hoot - occurs at idle or high idle in cold temperatures of approximately 4C
(40F) or colder at the first start of the day

Accessory drive idler or tensioner pulley bearing is experiencing stick/slip between ball bearings and
the bearing race

CARRY OUT the engine cold soak procedure. REFER to Section 100-04 .
PLACE the EngineEAR probe directly on the idler/tensioner center post or bolt to verify h bearing is
making the noise. INSTALL new parts as necessary. Refer to the appropriate section in Group 303 for
the procedure. TEST the system for normal operation after the repair.

Accessory drive belt noise, squeal or chirping
Defective/worn or incorrect accessory drive belt
Misaligned pulley(s)
Pulley runout
Damaged or worn accessory drive component or idler
Fluid contamination of the accessory drive belt or pulleys
Rear of engine noise 1188
Damaged or worn accessory drive belt tensioner
Damaged pulley grooves
CARRY OUT the Engine Accessory Test. REFER to Section 100-04 . INSPECT components and
INSTALL new parts as necessary. Refer to the appropriate section in Group 303 for the procedure.
TEST the system for normal operation after the repair.

Clunking noise
Coolant pump has excessive end play or imbalance
CHECK the coolant pump for excessive end play. INSPECT the coolant pump for imbalance with the
drive belt off. INSTALL a new coolant pump as necessary. REFER to Section 303-03A or Section
303-03B for Hybrid. TEST the system for normal operation after the repair.

Whine or moaning noise
Air intake system
CHECK the air cleaner and ducts for correct fit. INSPECT the air intake system for leaks or damage.
REPAIR as necessary. TEST the system for normal operation after the repair.

Whistling noise - normally accompanied with poor idle condition
Air intake system
CHECK the air intake ducts, air cleaner, Throttle Body (TB) and vacuum hoses for leaks and correct
fit. REPAIR or ADJUST as necessary. TEST the system for normal operation after the repair.

Hissing noise - occurs during idle or high idle that is apparent with the hood open
type="disc">
Vacuum leak
USE the EngineEAR/ChassisEAR to locate the source. SCAN the air intake system from the inlet to
each cylinder intake port. DISCARD the leaking parts, and INSTALL a new component. TEST the

Vehicles with a plastic intake manifold
Acceptable condition. Some plastic intake manifolds exhibit this noise, which is the effect of the
plastic manifold.

Grinding noise - occurs during engine cranking
Incorrect starter motor mounting
INSPECT the starter motor for correct mounting. REPAIR as necessary. REFER to Section 303-06 .

Starter motor
CHECK the starter motor. INSTALL a new starter motor as necessary. REFER to Section 303-06 .

Incorrect starter mor drive engagement
INSPECT the starter motor drive for wear or damage. INSTALL a new starter motor as necessary.
REFER to Section 303-06 . TEST the system for normal operation after the repair.

INSPECT the flywheel/flexplate for wear or damage. INSTALL a new flywheel/flexplate as
necessary. Refer to the appropriate section in Group 303 for the procedure. TEST the system for
normal operation after the repair.

Engine noise, front of engine - knocking noise from lower front of engine
Damaged or separated crankshaft pulley/damper
CHECK for obvious signs of damage or wobble during operation. INSTALL new as necessary. Refer
to the appropriate section in Group 303 for the procedure. TEST the system for normal operation after
the repair.

Engine noise, front ofngine - ticking, tapping or rattling noise from the front of the engine
Timing drive components
REMOVE the accessory drive belt. Refer to the appropriate section in Group 303 for the procedure.
USE the EngineEAR to isolate the noise to the engine front cover.
REMOVE the engine front cover and INSPECT the timing drive components. INSTALL new parts as

Engine noise, upper end - ticking noise near the fuel rail and intake manifold
Fuel rail clip
CHECK for loose or damaged fuel rail clip(s). REPAIR as necessary.
Fuel injector
USE the EngineEAR to isolate the noisy injector(s). INSTALL a new injector(s) as necessary. Refer
to the appropriate section in Group 303 for the procedure. TEST the system for normal operation after
the repair.

Engine noise, upper end - ticking, knocking or rattle noise that occurs during idle or high idle during
the first cold start of the day and may disappear as the engine warms

Valve train noise (bled down lash adjuster)
CARRY OUT the Valve Train Analysis Component Test in this section. INSTALL new parts as

Engine noise, upper end - occurs mostly with a warm engine at light/medium acceleration
Worn or damaged spark plugs
REMOVE the spark plugs. INSPECT and INSTALL new as necessary. Refer to the appropriate
section in Group 303 for the procedure. TEST the system for normal operation after the repair.

Carbon accumulation in combon chamber
Bore scope the cylinder. ELIMINATE carbon buildup. TEST the system for normal operation after
the repair.

Engine noise, upper end - rattling noise from the valve train. Worse when the engine is cold
Low oil level
CHECK the oil level. FILL as necessary.
Thin or diluted oil
INSPECT the oil for contamination. If the oil is contaminated, CHECK for the source. REPAIR as
necessary. CHANGE the oil and filter.

Low oil pressure
CARRY OUT an oil pressure test. If not within specifications, REMOVE the engine oil pan. Refer to
the appropriate section in Group 303 for the procedure. INSPECT for a blocked oil pick up tube.

Worn valve train components
CARRY OUT the Valve Train Analysis Component Test in this section. INSTALL new parts as
necessary. TEST the system for normal operation after the repair.

Worn valve guides
CARRY OUT the Valve Guide Inner Diameter procedure in this section.
Excessive runout of the valve seats on the valve face
CARRY OUT the Valve Seat Inspection procedure in this section.
Engine noise, upper end - pinging noise
Gasoline octane too low
VERIFY with customer the type of gasoline used. CORRECT as necessary. TEST the system for

Knock Sensor (KS) operation
CHECK the KS . INSTALL a new KS as necessary. Refer to the appropriate section in Group 303 for
the procedure. TEST the system for normal operation after the repr.

Incorrect spark timing
CHECK the spark timing. REPAIR as necessary. TEST the system for normal operation after the
repair.

High operating temperature
INSPECT the cooling system for leaks. CHECK the coolant level. REFILL as necessary. CHECK the
coolant for the correct mix ratio. DRAIN and REFILL as needed. VERIFY the engine operating
temperature is within specifications. REPAIR as necessary. TEST the system for normal operation
after the repair.
Spark plug
CHECK the spark plugs. REPAIR or INSTALL new spark plugs as necessary. TEST the system for

Catalytic converter
COMPARE with a similar vehicle for what is acceptable noise.
Engine noise, lower end - ticking or knocking noise near the oil filter adapter
Oil pump
USE the EngineEAR to verify the oil pump as the source of the noise at low rpm. REPAIR as

Engine noise, lower end - light knocking noise, also described as piston slap. Noise is most noticeable
when the engine is cold with light to medium acceleration. The noise disappears as the engine warms

Excessive clearance between the piston and the cylinder wall
CARRY OUT the Piston To Cylinder Bore Clearance procedure in this section. Refer to the
appropriate section in Group 303 for the procedure. TEST the system for normal operation after the
repair.

Engine noise, lower end - light double knock or sharp rap sound. Occurs mostly with a warm engine
at idle or low speeds in drive. Increases in relation to engine load. Associated with a poor lubrication
history

Excessive clearance between the piston and the piston pin
CARRY OUT the Piston Pin Bore Diameter and Piston Pin Diameter procedures in this section.
Engine noise, lower end - light knocking noise. The noise is most noticeable when the engine is
warm. The noise tends to decrease when the vehicle is coasting or in NEUTRAL

Excessive clearance between the connecting rod bearings and the crankshaft
CARRY OUT the Connecting Rod Bearing Journal-to-Bearing Clearance procedure in this section.
Engine noise, lower end - Deep knocking noise. The noise is most noticeable when the engine is
warm, at lower rpm and under a light load and then at float

Worn or damaged crankshaft main bearings
CARRY OUT the Crankshaft Main Bearing Journal-to-Bearing Clearance procedure in this section.
Engine noise, rear of engine - knocking noise at rear of engine
maged flywheel/flexplate
CARRY OUT the Flywheel Inspection or the Flexplate Inspection procedure in this section.
Engine vibration - vibration felt at all times
Excessive engine pulley runout
CARRY OUT the Engine Accessory Test. REFER to Section 100-04 . INSTALL a new engine pulley
as necessary. TEST the system for normal operation after the repair.

Damaged or worn accessory component
CARRY OUT the Engine Accessory Test. REFER to Section 100-04 /a>. REPAIR or INSTALL a
new component as necessary. TEST the system for normal operation after the repair.

Engine vibration - at idle, a low-frequency vibration (5-20 Hz) or mild shake that is felt through the
seat/floorpan

Cylinder misfire
Using the scan tool, CARRY OUT the cylinder power balance and the relative compression test.
REPAIR as necessary. Refer to the appropriate section in Group 303 for the procedure. TEST the

Engine or torque converter out of balance
VERIFY the torque converter to crankshaft pilot clearance is correct. REPAIR as necessary.
RE-INDEX the torque converter on the flexplate by 180 degrees for a 4-bolt converter. Refer to the
appropriate section in Group 307 for the procedure. TEST the system for normal operation after the
repair.

Engine vibration - is felt with increases and decreases in engine rpm
Powertrain mount(s)
CHECK the powertrain ts for damage. INSTALL new mounts as necessary. For engine, Refer to the
appropriate section in Group 303 for the procedure. For automatic transmission, Refer to the

Engine or transmission grounded to chassis
INSPECT the powertrain/drivetrain for correct clearances. REPAIR as necessary. TEST the system
for normal operation after the repair.

Engine vibration - increases intensity as the engine rpm is increased
Engine out-of-balance
CARRY OUT the Neutral Engine Run-Up (NERU) Test. REFER to Section 100-04 . ROTATE the
torque converter 180 degrees for 4-bolt. INSPECT the torque converter pilot outer
diameter-to-crankshaft pilot inner diameter. REPAIR as necessary. Refer to the appropriate section in
Group 307 for the procedure. TEST the system for normal operation after the repair.

Engine vibration - mostly at coast/neutral coast. Condition improves with vehicle acceleration
Combustion instability
CHECK the ignition system. INSTALL new components as necessary. Refer to the appropriate
section in Group 303 for the procedure. TEST the system for normal operation after the repair.

Engine vibration or shudder - occurs with light to medium acceleration above 56 km/h (35 mph)
Worn or damaged spark plugs
INSPECT the spark plugs for cracks, high resistance or broken insulators. INSTALL a new spark
plug(s) as necessary. Referthe appropriate section in Group 303 for the procedure. TEST the system

Plugged fuel injector
REPAIR or INSTALL a new injector as necessary. Refer to the appropriate section in Group 303 for
the procedure. TEST the system for normal operation after the repair.

Contaminated fuel
INSPECT the fuel for contamination. DRAIN the fuel system and refill. TEST the system for normal
operation after the repair.

Component Tests
The following component tests are used to diagnose engine concerns.
Engine Oil Leaks
NOTE: If an overnight drive is done, the fan air or road air blast can cause erroneous readings.
NOTE: When diagnosing engine oil leaks, the source and location of the leak must be positively identified
prior to repair.
Prior to carrying out this procedure, clean the cylinder block, cylinder heads, valve covers, oil pan and
flywheel with a suitable solvent to remove all traces of oil.
Engine Oil Leaks - Fluorescent Oil Additive Method
Use the 12 Volt Master UV Diagnostic Inspection Kit to carry out the following procedure for oil leak
diagnosis.
Add 29.6 ml (1 oz) of gasoline engine oil leak detection dye to a minimum of 0.47L (1/2 qt) and a
maximum of 0.95L (1 qt) engine oil and fill through the engine oil fill. Thoroughly premix the
gasoline engine oil dye or it will not have enough time to reach the crankcase, oil galleries and seal
surfaces during this particular 15 minute test. The additive must be mixed well with oil and added
through the oil fill. Check the level on the oil level indicator to determine what amount of oil to
premix. If it is in the middle of the crosshatch area or below the full mark, use 0.95L (1 qt). If it is at
the full mark, use 0.47L (1/2 qt).
1.
Run the engine for 15 minutes. Stop the engine and inspect all seal and gasket areas for leaks using
the UV Leak Detector Kit. A clear bright yellow or orange area will identify the leak. For extremely
small leaks, several hours may be required for the leak to appear.
2.
At the end of the test, make sure the oil level is within the upper and lower oil indicator marks.
Remove oil as necessary if it registers above the full mark.
3.
Leakage Points - Underhood
Examine the following areas for oil leakage:
Valve cover gaskets
Cylinder head gaskets
Oil cooler, if equipped
Oil filter adapter
Engine front cover
Oil filter adapter and filter body
Oil level indicator tube connection
Oil pressure sensor
Leakage Points - Under Engine, With Vehicle on Hoist
Oil pan gaskets
Oil pan sealer
Engine front cover gasket
Crankshaft front seal
Crankshaft rear oil seal
Oil filter adapter and filter body
Oil cooler, if equipped
Leakage Points - With Transmission and Flywheel Removed
Crankshaft rear oil seal
Rear main bearing cap parting line
Flexplate mounting bolt holes (with flexplate installed)
Pipe plugs at the end of oil passages
Oil leaks at crimped seams in sheet metal parts and cracks in cast or stamped parts can be detected when using
the dye method.
Compression Test - Hybrid
The compression test requires cranking the engine a minimum of 5 compression strokes with the throttle plate
in the wide-open position for each cylinder. The engine cranking diagnostic mode must be used to crank the
engine and the brake/accelerator pedals must be used to position the throttle plate during the compression test.
The engine cranking diagnostic mode is a PCM strategy which is separate from the normal operating strategy.
It allows the engine to crank in a similar fashion as a conventional vehicle with the fuel disabled. When in this
mode, the PCM commands the Transmission Control Module (TCM) to spin the generator, which cranks the
engine with the speed between 900 and 1,200 rpm. The engine will crank as long as the traction battery state
of charge stays greater than 35%.
Make sure the oil in the crankcase is of the correct viscosity and at the correct level. Operate the
vehicle until the engine is at normal operating temperature.
1.
Using the Vehicle Communication Module (VCM), access the Battery Control Module - High
Voltage Traction Battery (BCM-HVTB) and monitor the traction battery state of charge PID. If the
monitored PID displays the state of charge below 45%, start and idle the engine with full A/C ON.
When the traction battery state of charge exceeds 45%, the engine cranking diagnostic mode c be
activated.
2.
Turn the ignition switch to the OFF position, then remove all the spark plugs. 3.
Install a compression gauge such as the Quick Disconnect Compression Tester in the No. 1 cylinder. 4.
Activate the cranking diagnostic mode as follows:
Apply the parking brake.
Place the gear selector in the PARK position.
Verify the key is in the OFF position.
NOTE: Do not crank the engine.
Turn the key to the ON position with the engine OFF.

Within 5 seconds of the key in the ON position, fully apply the accelerator pedal and hold for
10 seconds.

Within 5 seconds release the accelerator pedal, shift the gear selector to the NEUTRAL
position and fully apply the accelerator pedal.

Hold the accelerator pedal fully applied for 10 seconds.
Release the accelerator pedal and shift the gear selector to the PARK position.
If the sequence is correctly executed, the Instrument Cluster (IC) hazard indicator
(red triangle) flashes once per second when the gear selector is shifted to the PARK
position. The PCM exits the engine cranking diagnostic mode when the traction
battery state of charge drops below 35%, the gear selector is shifted to any gear other
than PARK or when the ignition key is turned to the OFF or ACC position.

5.
NOTE: If the ignition key stays in the START position for 15 seconds or longer, the PCM may set
DTC P2535.
NOTE: If the brake pedal is not depressed and held prior to depressing the accelerator pedal, the
throttle plate will fail to open.
Crank the engine as follows:
Depress and hold the brake pedal.
Fully depress and hold the accelerator pedal.
Turn the key to the START position and crank the engine a minimum of 5 compression
strokes and record the highest reading. Return the key to the ON position.

Release the accelerator pedal.
Release the brake pedal.
6.
Repeat the test on each cylinder, cranking the engine approximately the same number of compression
strokes.
7.
Position the key to the OFF position to deactivate the cranking diagnostic mode. 8.
Clear all DTCs. 9.
Compression Test - All Vehicles Except Hybrid
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.
1.
Set the throttle plates in the wide-open position. 2.
Install a compression gauge such as the Quick Disconnect Compression Tester in the No. 1 cylinder. 3.
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.
4.
Repeat the test on each cylinder, cranking the engine approximately the same number of compression
strokes.
5.
Compression Test - Test Results
The indicated compression pressures are considered within specification if the lowest reading cylinder is at
least 75% of the highest reading. Refer to the Compression Pressure Limit Chart.
Compressioessure 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
Compressioessure Limit Chart 1197
If compression improves considerably, piston rings are worn or damaged. 1.
If compression does not improve, valves are sticking or not seating correctly. 2.
If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not
increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in
cylinders could result from this condition.
Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest
reading is within 75% of the highest reading.
3.
Cylinder Leakage Detection
When a cylinder produces a low reading, use of the Engine Cylinder Leak Detection/Air Pressurization Kit
will be helpful in pinpointing the exact cause.
The leakage detector is inserted in the spark plug hole, the piston is brought up to Top Dead Center (TDC) on
the compression stroke, and compressed air is admitted.
Once the combustion chamber is pressurized, a special gauge included in the kit will read the percentage of
leakage. Leakage exceeding 20% is excessive.
While the air pressure is retained in the cylinder, listen for the hiss of escaping air. A leak at the intake valve
will be heard in the Throttle Body (TB). A leak at t exhaust valve can be heard at the tailpipe. Leakage past
the piston rings will be audible at the PCV connection. If air is passing through a blown head gasket to an
adjacent cylinder, the noise will be evident at the spark plug hole of the cylinder into which the air is leaking.
Cracks in the cylinder block or gasket leakage into the cooling system may be detected by a stream of bubbles
in the radiator.
Excessive Engine Oil Consumption
Nearly all engines consume oil, which is essential for normal lubrication of the cylinder bore walls and pistons
and rings. Determining the level of oil consumption may require testing by recording how much oil is being
added over a given set of miles.
Customer driving habits greatly influence oil consumption. Mileage accumulated during towing or heavy
loading generates extra heat. Frequent short trips, stop-and-go type traffic or extensive idling, prevent the
engine from reaching normal operating temperature. This prevents component clearances from reaching
specified operating ranges.
The following diagnostic procedure may be utilized to determine internal oil consumption. Make sure that the
concern is related to internal oil consumption, and not external leakage, which also consumes oil. Verify there
are no leaks before carrying out the test. Once verified, the rate of internal oil consumption can be tested.
A new engine may require extra oil in the early stages of operation. Internal piston-to-bore clearances and
sealing characteristics improve as the engine breaks in. Engines are designed for close tolerances and do not
require break-in oils or additives. Use the oil specified in the Owner's Literature. Ambient temperatures may
determine the oil viscosity specification. Verify that the correct oil is being used for the vehicle in the
geographic region in which it is driven.
Basic Pre-checks
For persistent complaints of oil consumption, interview the customer to determine the oil 1.
consumption characteristics. If possible, determine the brand and grade of oil currently in the oil pan.
Look at the oil filter or oil-change station tags to determine if Ford-recommended maintenance
schedules have been followed. Make sure that the oil has been changed at the specified mileage
intervals. If vehicle mileage is past the first recommended drain interval, the OEM production filter
should have been changed.
Ask how the most current mileage was accumulated. That is, determine whether the vehicle was
driven under the following conditions:
Extended idling or curbside engine operation
Stop-and-go traffic or taxi operation
Towing a trailer or vehicle loaded heavily
Frequent short trips (engine not up to normal operating temperature)
Excessive throttling or high engine-rpm driving
2.
Verify that there are no external leaks. If necessary, review the diagnostic procedure under Engine Oil
Leaks in the Diagnosis and Testing portion of this section.
3.
Inspect the crankcase ventilation system for:
disconnected hoses at the valve cover or TB .
loose or missing valve cover fill cap.
missing or incorrectly seated engine oil level indicator.
incorrect or dirty PCV valve.
a PCV valve grommet unseated in the valve cover (if so equipped).
4.
Inspect for signs of sludge. Sludge affects PCV performance and can plug or restrict cylinder head
drainback wells. It can also increase oil pressure by restricting passages and reducing the drainback
capability of piston oil control rings. Sludge can result from either excessive water ingestion in the
crankcase or operation at extremely high crankcase temperatures.
5.
Inspect the air filter for dirt, sludge or damage. A hole in the filter element will allow unfiltered air to
bypass into the air induction system. This can cause premature internal wear (engine dusting),
allowing oil to escape past rings, pistons, valves and guides.
6.
If the engine is hot or was recently shut down, wait at least 5 minutes to allow the oil to drain back.
Ask the customer if this requirement has been followed. Adding oil without this wait period can cause
an overfill condition, leading to excessive oil consumption and foaming which may cause engine
damage.
7.
Make sure the oil level indicator (dipstick) is correctly and fully seated in the indicator tube. Remove
the oil level indicator and record the oil level.
8.
Detailed Pre-checks
Check the thermostat opening temperature to make sure that the cooling system is operating at the
specified temperature. If it is low, internal engine parts are not running at specified internal operating
clearances.
1.
Verify the spark plugs are not oil saturated. Oil leaking into one or more cylinders will appear as an
oil soaked condition on the plug. If a plug is saturated, a compression check may be necessary at the
conclusion of the oil consumption test.
2.
Oil Consumption Test
Once all of the previous conditions are met, carry out an oil consumption test.
Drain the engine oil and remove the oil filter. Install a new manufacturer-specified oil filter. Make
sure the vehicle is positioned on a level surface. Refill the oil pan to a level one liter (quart) less than
the specified fill level, using manufacturer-specified oil.
1.
Run the engine for 3 minutes (if hot) or 10 minutes (if cold). Allow for a minimum 5-minute
drainback period and then record the oil level shown on the oil level indicator. Place a mark on the
backside of the oil level indicator noting the oil level location.
2.
Add the final one liter (quart) to complete the normal oil fill. Restart the engine and allow it to idle for
2 minutes. Shut the engine down.
3.
After a 5-minute drainback period, record the location of the oil level again. Mark the oil level
indicator with the new oil level location. (Note: Both marks should be very close to the MIN-MAX
upper and lower limits or the upper and lower holes on the oil level indicator. These marks will
exactly measure the engine's use of oil, with a one liter (quart) differential between the new marks.)
Demonstrate to the customer that the factory-calibrated marks on the oil level indicator are where the
oil should fall after an oil change with the specified fill amount. Explain however, that this may vary
slightly between MIN-MAX or the upper and lower holes on the oil level indicator.
4.
Record the vehicle mileage. 5.
Advise the customer that oil level indicator readings must be taken every 320 km (200 mi) or weekly,
using the revised marks as drawn. Remind the customer that the engine needs a minimum 5-minute
drainback for an accurate reading and that the oil level indicator must be firmly seated in the tube
prior to taking the reading.
6.
When the subsequent indicator readings demonstrate a full liter (quart) has been used, record the
vehicle mileage. The mileage driven between the 2 readings should not be less than 4,800 km (3,000
miles). The drive cycle the vehicle has been operated under must be considered when making this
calculation. It may be necessary to have the customer bring the vehicle in for a periodic oil level
indicator reading to closely monitor oil usage.
7.
Post Checks, Evaluation and Corrective Action
If test results indicate excessive oil consumption, carry out a cylinder compression test. The cylinder
compression test should be carried out with a fully charged battery and all spark plugs removed. See
the Compression Test Chart in this section for pressure range limits.
1.
Compression should be consistent across all cylinders. Refer to the Compression Testing portion of
this section. If compression tested within the specifications found in this section, the excessive oil
consumption may be due to wear on the valve guides, valves or valve seals.
2.
A cylinder leak detection test can be carried out using an Engine Cylinder Leak Detection/Air
Pressurization Kit. This can help identify valves, piston rings, or worn valve guides/valve stems,
inoperative valve stem seals or other related areas as the source of oil consumption.
3.
NOTE: An oil-soaked appearance on the porcelain tips of the spark plugs also indicates excessive oil use. A
typical engine with normal oil consumption will exhibit a light tan to brown appearance. See Spark Plug
Analysis in this section for details. A single or adjoining, multiple cylinder leak can be traced by viewing the
tips.
If an internal engine part is isolated as the root cause, determine if the repair will exceed cost limits
and proceed with a repair strategy as required.
4.
Once corrective action to engine is complete and verifying that all pre-check items were eliminated in
the original diagnosis, repeat the Oil Consumption Test as described above and verify consumption
results.
5.
Intake Manifold Vacuum Test
Bring the engine to normal operating temperature. Connect the Vacuum/Pressure Tester to the intake
manifold. Run the engine at the specified idle speed.
The vacuum gauge should read between 51-74 kPa (15-22 in-Hg) depending upon the engine condition and
the altitude at which the test is conducted. Subtract 4.0193 kPa (1 in-Hg) from the specified reading for every
304.8 m (1,000 ft) of elevation above sea level.
The reading should be steady. If necessary, adjust the gauge damper control (where used) if the needle is
fluttering rapidly. Adjust the damper until the needle moves easily without excessive flutter.
Intake Manifold Vacuum Test - Interpreting Vacuum Gauge Readings
A careful study of the vacuum gauge reading while the engine is idling will help pinpoint trouble areas.
Always conduct other appropriate tests before arriving at a final diagnostic decision. Vacuum gauge readings,
although helpful, must be interpreted carefully.
Most vacuum gauges have a normal band indicated on the gauge face.
The following are potential gauge readings. Some are normal; others should be investigated further.
NORMAL READING: Needle between 51-74 kPa (15-22 in-Hg) and holding steady. 1.
NORMAL READING DURING RAPID ACCELERATION AND DECELERATION: When the
engine is rapidly accelerated (dotted needle), the needle will drop to a low reading (not to zero). When
the throttle is suddenly released, the needle will snap back up to a higher than normal figure.
2.
NORMAL FOR HIGH-LIFT CAMSHAFT WITH LARGE OVERLAP: The needle will register as
low as 51 kPa (15 in-Hg) but will be relatively steady. Some oscillation is normal.
3.
WORN RINGS OR DILUTED OIL: When the engine is accelerated (dotted needle), the needle drops
to 0 kPa (0 in-Hg). Upon decelerationthe needle runs slightly above 74 kPa (22 in-Hg).
4.
STICKING VALVES: When the needle (dotted) remains steady at a normal vacuum but occasionally
flicks (sharp, fast movement) down and back about 13 kPa (4 in-Hg), one or more valves may be
sticking.
5.
BURNED OR WARPED VALVES: A regular, evenly-spaced, downscale flicking of the needle
indicates one or more burned or warped valves. Insufficient valve clearance will also cause this
reaction.
6.
POOR VALVE SEATING: A small but regular downscale flicking can mean one or more valves are
not seating.
7.
WORN VALVE GUIDES: When the needle oscillates over about a 13 kPa (4 in-Hg) range at idle
speed, the valve guides could be worn. As engine speed increases, the needle will become steady if
guides are responsible.
8.
WEAK VALVE SPRINGS: When the needle oscillation becomes more violent as engine rpm is
increased, weak valve springs are indicated. The reading at idle could be relatively steady.
9.
LATE VALVE TIMING: A steady but low reading could be caused by late valve timing. 10.
IGNITION TIMING RETARDING: Retarded ignition timing will produce a steady but somewhat
low reading.
11.
INSUFFICIENT SPARK PLUG GAP: When spark plugs are gapped too close, a regular, small
pulsation of the needle can occur.
12.
INTAKE LEAK: A low, steady reading can be caused by an intake manifold or Throttle Body (TB)
gasket leak.
13.
BLOWN HEAD GASKET: A regular drop of fair magnitude can be caused by a blown head gasket
or warped cylinder head-to-cylinder block surface.
14.
RESTRICTED EXHAUST SYSTEM: When the engine is first started and is idled, the reading may
be normal, but as the engine rpm is increased, the back pressure caused by a clogged muffler, kinked
tailpipe or other concerns will cause the needle to slowly drop to 0 kPa (0 in-Hg). The needle then
may slowly rise. Excessive exhaust clogging will cause the needle to drop to a low point even if the
engine is only idling.
15.
When vacuum leaks are indicated, search out and correct the cause. Excess air leaking into the system
will upset the fuel mixture and cause concerns such as rough idle, missing on acceleration or burned
valves. If the leak exists in an accessory unit such as the power brake booster, the unit will not
function correctly. Always fix vacuum leaks.
16.
Oil Pressure Test
Disconnect and remove the Engine Oil Pressure (EOP) switch from the engine. 1.
Connect the engine Oil Pressure Gauge to the oil pressure sender oil galley port. 2.
Run the engine until normal operating temperature is reached. 3.
Run the engine at the specified rpm and record the gauge reading. 4.
The oil pressure should be within specifications; for additional information, refer to the specification
chart in the appropriate engine section.
5.
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
6.
Valve Train Analysis
The following component tests are used to diagnose valve train concerns.
Valve Train Analysis - Engine Off, Valve Cover Removed
Check for damaged or severely worn parts and correct assembly. Maksure correct parts are used with the
static engine analysis as follows.
Valve Train Analysis - Camshafts
Check for broken or damaged parts.
Check for loose mounting bolts on camshaft caps.
Valve Train Analysis - Camshaft Roller Followers and Hydraulic Lash Adjusters - 3.0L Engine
Check for incorrectly installed roller followers.
Check for collapsed hydraulic lash adjusters.
Valve Train Analysis - Valve Tappet - 2.5L and 3.5L Engines
Check for valve tappet face wear.
Check for excessive valve tappet clearance. Refer to Valve Clearance Check. For the 2.5L engine,
refer to Section 303-01A . For the 3.5L engine, refer to Section 303-01C . For 2.5L Hybrid engine,
refer to Section 303-01D .

Valve Train Analysis - Valve Springs, Valve Spring Retainers and Valve Spring Retainer Keys
NOTE: Valve tap removed on 2.5L and 3.5L engines.
Check for correct seating of the valve spring retainer key on the valve stem and in valve spring
retainer.

Check for correct seating on the valve stem.
Valve Train Analysis - Valves and Cylinder Head
NOTE: Valve tappets must be removed on 2.5L and 3.5L engines.
Check for plugged oil drain back holes.
Check for worn or damaged valve tips.
Check for missing or damaged guide-mounted valve stem seal.
Check for missing or worn valve spring seats.
Check for plugged oil metering orifice in cylinder head oil reservoir (if equipped).
Valve Train Analysis - Camshaft Lobe Lift
Check the lift of each camshaft lobe in consecutive order and make a note of the readings.
Remove the spark plugs. Refer to the appropriate 303-07 section. 1.
Install the Dial Indicator Gauge with Holding Fixture so the rounded tip of the Dial Indicator Gauge is
on top of the camshaft lobe and on the same plane as the valve tappet (2.5L and 3.5L) or hydraulic
lash adjuster (3.0L).
2.
Rotate the crankshaft using a breaker bar and socket attached to the crankshaft pulley retainer bolt.
Rotate the crankshaft until the base circle of the camshaft lobe is reached.
3.
Zero the Dial Indicator Gauge. Continue to rotate the crankshaft until the high-lift point of the
camshaft lobe is in the fully-raised position (highest indicator reading).
4.
To check the accu of the original indicator reading, continue to rotate crankshaft until the base circle
is reached. The Dial Indicator Gauge reading should be zero. If zero reading is not obtained, repeat
Steps 1 through 6.
5.
If the lift on any lobe is below specified service limits, install a new camshaft and camshaft roller
followers or valve tappets.
6.
Install the spark plugs. Refer to the appropriate 303-07 section. 7.
Information
Workshop Manual
Sprockets
Inspect the sprockets for cracks and worn or chipped teeth. 1.
Sprockets 1206
Information
Workshop Manual
Camshaft Bearing Journal Diameter
NOTE: Refer to the appropriate Section 303-01 for the specification.
Measure each camshaft journal diameter in 2 directions. 1.
r>
Camshaft Bearing Journal Diameter 1207
Information
Workshop Manual
Camshaft Journal to Bearing Clearance - OHC Engines
NOTE: The camshaft journals must meet specifications before checking camshaft journal clearance.
Measure each camshaft bearing in 2 directions.
Subtract the camshaft journal diameter from the camshaft bearing diameter.

1.
Camshaft Journal to Bearing Clearance - OHC Engines 1208
Information
Workshop Manual
Camshaft End Play - OHC Engines
Special Tool(s)
Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft end play. 1.
tart="2">
Position the camshaft to the rear of the cylinder head.
Zero the Dial Indicator Gauge. 3.
Move the camshaft to the front of the cylinder head. Note and record the camshaft end play.
If camshaft end play exceeds specifications, install a new camshaft and recheck end play.
If camshaft end play exceeds specification after camshaft installation, install a new cylinder
head.

4.
Camshaft End Play - OHC Engines 1209
Information
Workshop Manual
Camshaft Surface Inspection
Inspect camshaft lobes for pitting or damage in the contact area. Minor pitting is acceptable outside
the contact area.
1.
Camshaft Surface Inspection 1210
Information
Workshop Manual
Camshaft Lobe Lift
Special Tool(s)
td>
Dial Indicator Gauge with Holding
Fixture
Use the Dial Indicator Gauge with Holding Fixture to measure camshaft intake/exhaust lobe lift.
Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest
Dial Indicator Gauge reading to figure the camshaft lobe lift.

1.
Camshaft Lobe Lift 1211
Information
Workshop Manual
Camshaft Runout
Special Tool(s)
NOTE: Camshaft journals must be within specifications before checking runout.
Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft runout.
Camshaft must be supported on the first and last camshaft bearing journal.
Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest
Dial Indicator Gauge reading.

1.
Camshaft Runout 1212
Information
Workshop Manual
Crankshaft Main Bearing Journal Diameter
Measure each of the crankshaft main bearing journal diameters in at least 2 directions. 1.
Crankshaft Main Bearing Journal Diameter 1213
Information
Workshop Manual
Crankshaft Main Bearing Journal Taper and Out-of-Round
Measure each of the crankshaft main bearing journal diameters in at least 2 directions at each end of
the main bearing journal.
1.
Crankshaft Main Bearing Journal Taper and Out-of-Round 1214
Information
Workshop Manual
Crankshaft Main Bearing Journal-to-Bearing Clearance
NOTE: Crankshaft main bearing journals must be within specifications before checking journal clearance.
Remove the crankshaft main bearing caps and crankshaft main bearing. 1.
Lay a piece of Plastigage across the face of each crankshaft main bearing surface. 2.
NOTE: Do not turn the crankshaft while carrying out this procedure.
Install and remove the crankshaft main bearing cap.

Verify the crankshaft journal clearance. 4.
Crankshaft Main Bearing Journal-to-Bearing Clearance 1215
Information
Workshop Manual
Crankshaft End Play
Special Tool(s)
>NOTE: Refer to the appropriate Section 303-01 for the specification.
Install the Dial Indicator Gauge with Holding Fixture. 1.
Position the crankshaft to the rear of the cylinder block. 2.
Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. 4.
Crankshaft End Play 1216
Information
Workshop Manual
Connecting Rod Bearing Journal Taper and Out-of-Round
Measure the crankshaft connecting rod journal diameters in 2 directions perpendicular to one another
at each end of the connecting rod journal. The difference in the measurements from one end to the
other is the taper. Verify measurement is within the wear limit.
1.
Connecting Rod Bearing Journal Taper and Out-of-Round 1217
Information
Workshop Manual
Cylinder Bore Taper
Measure the cylinder bore at the top, middle and bottom of piston ring travel in 2 directions as
indicated. Verify the cylinder bore is within the wear limit. The difference indicates the cylinder bore
taper. If the cylinder bore taper does not meet specification, bore the cylinder to the next oversize
limit.
1.
Cylinder Bore Taper 1218
Information
Workshop Manual
Cylinder Bore Out-of-Round
Measure the cylinder bore in 2 directions. The difference is the out-of-round. 1.
&np;
Cylinder Bore Out-of-Round 1219
Information
Workshop Manual
GENERAL PROCEDURES Procedure resion date: 06/03/2011
Piston Inspection
Special Tool(s)
Scraper, Piston Ring Groove
303-D033 (D81L-6002-D) or equivalent
NOTICE: Do not use a caustic cleaning solution or a wire brush to clean the pistons or damage can
occur.
Clean and inspect the (1) ring lands, (2) skirts, (3) pin bosses and the (4) tops of the pistons. If wear
marks, scores or glazing is found on the piston skirt, check for a bent or twisted connecting rod.
1.
Use the Piston Ring Groove Scraper to clean the piston ring grooves.
Make sure the oil ring holes are clean.
2.
Piston Inspection 1220
Piston Inspection 1221
Information
Workshop Manual
Piston Pin Bore Diameter
NOTE: Piston and piston pins are a matched set and should not be interchanged.
Measure the piston pin bore diameter in 2 directions on each side. Verify the diameter is within
specification.
1.
bsp;
Piston Pin Bore Diameter 1222
Information
Workshop Manual
Piston Diameter
Measure the piston diameter 90 degrees from the piston pin and 42 mm (1.65 in) down from the top of
the piston at the point indicated.
1.
Piston Diameter 1223
Information
Workshop Manual
Piston To Cylinder Bore Clearance
Subtract the piston diameter from the cylinder bore diameter to find the piston-to-cylinder bore
clearance.
1.
Piston To Cylinder Bore Clearance 1224
Information
Workshop Manual
Piston Selection
NOTE: The cylinder bore must be within the specifications for taper and out-of-round before fitting a piston.
Select a piston size based on the cylinder bore. 1.
NOTE: For precision fit, new pistons are divided into 3 categories within each size rangbased on
their relative position within the range. A paint spot or specific size grade on a new piston indicates
the position within the size range.
Choose the piston with the correct paint color or specific size grade.
Refer to the appropriate section in Group 303 for the procedure.
2.
Piston Selection 1225
Information
Workshop Manual
Piston Ring End Gap
Special Tool(s)
Feeler Gauge Set
NOTICE: Use care when fitting piston rings to avoid posble damage to the piston ring or the cylinder
bore.
NOTE: Piston rings should not be transferred from one piston to another.
NOTE: The cylinder bore must be within specification for taper and out-of-round.
Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel. 1.
Use the Feeler Gauge Set to measure the top piston ring end gap and the second piston ring end gap. 2.
Piston Ring End Gap 1226
Piston Ring End Gap 1227
Information
Workshop Manual
Piston Ring-to-Groove Clearance
Special Tool(s)
Feeler Gauge Set
NOTE: Refer to the appropriate Secon 303-01 for the specification.
Inspect the piston for ring land damage or accelerated wear. 1.
Using the Feeler Gauge Set, measure the piston ring-to-groove clearance. 2.
Piston Ring-to-Groove Clearance 1228
Information
Workshop Manual
Piston Pin Diameter
Measure the piston pin diameter in 2 directions at the points shown. Verify the diameter is within
specification.
1.
&np;
Piston Pin Diameter 1229
Information
Workshop Manual
Connecting Rod Cleaning
NOTICE: Do not use a caustic cleaning solution or damage to connecting rods can occur.
NOTE: The connecting rod large end is a matched set. The connecting rod cap must be installed on
the original connecting rod in the original position. Do not reverse the cap. Parts are not
interchangeable.
Mark and separate the parts and clean with solvent. Clean the oil passages.
1.
Connecting Rod Cleaning 1230
Information
Workshop Manual
Connecting Rod Large End Bore
Tighten the bolts to specification, then measure the bore in 2 directions. The difference is the
connecting rod bore out-of-round. Verify the out-of-round is within specification.
1.
Connecting Rod Large End Bore 1231
Information
Workshop Manual
Connecting Rod Bushing Diameter
Use a telescoping gauge to determine the ID of the connecting rod buing, if equipped. 1.
Measure the telescoping gauge with a micrometer. Verify the diameter is within specification. 2.
Connecting Rod Bushing Diameter 1232
Information
Workshop Manual
Connecting Rod Bend
Special Tool(s)
Feeler Gauge Set
NOTE: Refer to the appropriate Section 303-01 for the specication.
Using the Feeler Gauge Set, measure the connecting rod bend on a suitable alignment fixture. Follow
the instructions of the fixture manufacturer. Verify the bend measurement is within specification.
1.
Connecting Rod Bend 1233
Information
Workshop Manual
Connecting Rod Twist
Special Tool(s)
Feeler Gauge Set
NOTE: Refer to the appropriate Section 303-01 for the spification.
Using the Feeler Gauge Set, measure the connecting rod twist on a suitable alignment fixture. Follow
the instructions of the fixture manufacturer. Verify the measurement is within specification.
1.
Connecting Rod Twist 1234
Information
Workshop Manual
Connecting Rod Bearing Journal-to-Bearing Clearance
NOTE: The crankshaft connecting rod journals must be within specifications to check the connecting rod
bearing journal clearance.
Remove the connecting rod bearing cap. 1.
Position a piece of Plastigage across the bearing surface. 2.
NOTE: Do not turn the crankshaft during this step.
Install and tighten to specifications, then remove the connecting rod bearing cap.
3.
Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage should be
smooth and flat. A changing width indicates a tapered or damaged connecting rod or connecting rod
bearing.
4.
Connecting Rod Bearing Journal-to-Bearing Clearance 1235
Connecting Rod Bearing Journal-to-Bearing Clearance 1236
Information
Workshop Manual
Connecting Rod to Crankshaft Side Clearance
Special Tool(s)
Feeler Gauge Set
Using the Feeler Gauge Set, measure the clearance between the connecting rod and the crankshaft.
Verify the measurement is within specification.
1.
Connecting Rod to Crankshaft Side Clearance 1237
Information
Workshop Manual
Valve Stem Diameter
Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter
is within specification.
1.
Valve Stem Diameter 1238
Information
Workshop Manual
Valve Inspection
Inspect the following valve areas:
The end of the stem for grooves or scoring. 1.
The valve face and the edge for pits, grooves or scores. 2.
The valve head for signs of burning, erosion, warpage and cracking. 3.
The valve margin for wear. 4.
1.
Valve Inspection 1239
Information
Workshop Manual
Valve Guide Inner Diameter
NOTE: Valve guides tend to wear in an hourglass pattern. The ball gauge can be inserted into the
combustion chamber side of the valve guide, if necessary.
Use a ball gauge to determine the inside diameter of the valve guides in 2 directions at the top, middle
and bottom of the valve guide.
1.
Measure the ball gauge with a micrometer. 2.
If the valve guide is not within specifications, install a new cylinder head assembly. 3.
Valve Guide Inner Diameter 1240
Information
Workshop Manual
Valve Stem to Valve Guide Clearance
Special Tool(s)
Clearance Gauge, Valve Guide
303-004 (TOOL-6505-E) or equivalent
NOTE: The valve stem diameter must be within specifications before checking valve stem-to-valve guide
clearance.
NOTE: If necessary, use a magnetic base.
Install a Valve Guide Clearance Gauge on the valve stem and install a Dial Indicator Gauge with
Holding Fixture. Lower the valve until the clearance gauge contacts the upper surface of the valve
guide.
1.
Move the Valve Guide Clearance Gauge toward the Dial Indicator Gauge with Holding Fixture and
zero the Dial Indicator Gauge. Move the Valve Guide Clearance Gauge away from the Dial Indicator
Gauge with Holding Fixture and note the reading. The reading will be DOUBLE the valve
stem-to-valve guide clearance.
2.
Valve Stem to Valve Guide Clearance 1241
Valve Stem to Valve Guide Clearance 1242
Information
Workshop Manual
Valve Spring Installed Length
Measure the installed length of each valve spring. 1.
&nbsp
Valve Spring Installed Length 1243
Information
Workshop Manual
Valve Spring Free Length
Measure the free length of each valve spring. 1.
Valve Spring Free Length 1244
Information
Workshop Manual
Valve Spring Squareness
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.

Valve Spring Squareness 1245
Information
Workshop Manual
Valve Spring Strength
Special Tool(s)
Pressure Gauge, Valve/Clutch Spring
303-006 (TOOL-6513-DD) or equivalent
Use the Valve/Clutch Spring Pressure Gauge to check the valve spring for correct strength at the
specified valve spring length.
1.
Valve Spring Strength 1246
Information
Workshop Manual
Valve Seat Inspection
Valve and Seat Refacing Measurements
NOTE: After grinding valves or valve seats, check valve clearance.
Check the valve head and seat.
Check valve angles.
Check margin width.
Be sure margin width is within specification.
1.
Inspect for abnormalities on the valve face and seat. Install a new cylinder head assembly if
abnormalities are found.
2.
Valve Seat Inspection 1247
Information
Workshop Manual
Valve Seat Width
Measure the valve seat width. If necessary, grind the valve seat to specification.
Measure the intake valve seat width.
Measure the exhaust valve seat width.
Recheck the valve spring installed length after the seats have been ground, and shim the valve
springs as necessary to achieve the correct installed spring length.

Dependi on the engine, check the valve lash. Refer to General Procedures in Section 303-01.
1.
Valve Seat Width 1248
Information
Workshop Manual
Valve Seat Runout
Use a valve seat runout gauge to check valve seat runout. 1.
bsp;
Valve Seat Runout 1249
Information
Workshop Manual
Flexplate Inspection
Inspect the flexplate for:
any cracks. 1.
worn ring gear teeth. 2.
chipped or cracked ring gear teeth. 3.
1.
Flexplate Inspection 1250
Information
Workshop Manual
Flywheel Inspection
NOTE: The flywheel cannot be resurfaced, it must be replaced.
Inspect the flywheel for:
any cracks. 1.
worn ring gear teeth. 2.
chipped or cracked ring gear teeth. 3.
scratches, nicks and discoloration. 4.
1.
Flywheel Inspection 1251
Information
Workshop Manual
Cylinder Head Distortion
Special Tool(s)
Feeler Gauge Set
NOTE: Make sure all cylinder head surfaces are clear of any gasket material, silicone sealant, oil and
coolant. The cylinder head surface must be clean and dry before running a flatness check.
NOTE: Use a Straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002
in) per running foot of length, such as Snap-On GA438A or equivalent. For example, if the
Straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from
end to end.
Using a Straightedge and a Feeler Gauge Set, inspect the cylinder head for flatness in the sequence
shown.
1.
Cylinder Head Distortion 1252
Cylinder Head Distortion 1253
Information
Workshop Manual
Cylinder Block Distortion
Special Tool(s)
Feeler Gauge Set
end to end.
Use a Straightedge and a Feeler Gauge Set to inspect the cylinder block for flatness.
1.
Cylinder Block Distortion 1254
Information
Workshop Manual
Cylinder Bore Cleaning
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
NOTICE: If these procedures are not followed, rusting of the cylinder bores may occur.
Clean the cylinder bores with soap or detergent and water.
1.
Thoroughly rinse with clean water and wipe dry with a clean, lint-free cloth. 2.
Use aan, lint-free cloth and lubricate the cylinder bores.
Use clean engine oil meeting Ford specification.
3.
Cylinder Bore Cleaning 1255
Information
Workshop Manual
Bearing Inspection
Inspect bearings for the following defects:
Cratering - fatigue failure 1.
Spot polishing - incorrect seating 2.
Imbedded dirty engine oil 3.
Scratching - dirty engine oil 4.
Base exposed - poor lubrication 5.
Both edges worn - journal damaged 6.
One edge worn - journal tapered or bearing not seated 7.
1.
Bearing Inspection 1256
Information
Workshop Manual
Exhaust Manifold Cleaning and Inspection
Special Tool(s)
Feeler Gauge Set
Clean the exhaust manifold using a suitable solvent. Use a plastic scraping tool to clean the gasket
sealing surfaces.
1.
NOTE: New exhaust manifold gaskets, studs, nuts and/or bolts must be installed when an exhaust
manifold is serviced.
end to end.
Using the Straightedge and a Feeler Gauge Set, check the exhaust manifold sealing surface for
warpage. If the warpage is greater than 0.76 mm (0.0299 in), install a new exhaust manifold.
2.
Exhaust Manifold Cleaning and Inspection 1257
Exhaust Manifold Cleaning and Inspection 1258
Information
Workshop Manual
Spark Plug Inspection
Inspect the spark plug for a bridged gap.
Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil
or carbon fouling.

Install a new spark plug.
1.
Check for oil fouling.
Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil
entering the combustion chamber through worn rings and pistons, excessive valve-to-guide
clearance or worn or loose bearings.

Correct the oil leak concern.
2.
Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed
shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner,
too rich a fuel mixture or excessive idling.
Install new spark plugs.
3.
Inspect for normal burning.
Check for light tan or gray deposits on the firing tip.
4.
Spark Plug Inspection 1259
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.
5.
Inspect for overheating, identified by white or light gray spots and a bluish-burnt appearance of
electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs
with an incorrect heat range, low fuel pump pressure or incorrect ignition timing.
6.
Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters.
These are caused by sudden acceleration.
Install new spark plugs.
7.
Information
Workshop Manual
Core Plug Replacement
Special Tool(s)
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
Threadlock 262
TA-26
WSK-M2G351-A6
All core plugs
NOTE: Cylinder block core plug shown, cylinder head core plug similar.
Use the Slide Hammer and a freeze plug remover to remove the core plug.
1.
NOTE: Oversize plugs are identified by the OS stamped in the flat located on the cup side of the
plug.
Inspect the core plug bore for any damage that would interfere with the correct sealing of the plug. If
the core plug bore is damaged, bore for the next oversize plug.
2.
Cup-type
NOTICE: Use care during this procedure so as not to disturb or distort the cup sealing surface.
NOTE: When installed, the flanged edge must be below the chamfered edge of the bore to effectively
seal the bore.
Coat the cup-type core plug and bore lightly with sealant and install the core plug using a freeze plug
installer.
3.
Core Plug Replacement 1262
Expansion-type
NOTICE: Do not contact the crown when installing an expansion-type core plug. This could
expand the plug before seating and result in leakage.
Coat the expansion-type core plug and bore lightly with sealant and install the core plug using a
freeze plug installer.
4.
Core Plug Replacement 1263
Information
Workshop Manual
Valve Tappet Inspection
Inspect the valve tappet for damage, especially in the indicated areas. If any damage is evident,
inspect the camshaft lobes and valves for damage. Install new components as necessary.
1.
Valve Tappet Inspection 1264
Information
Workshop Manual
Roller Follower Inspection
Inspect the roller follower for flat spots or scoring. If any damage is found, inspect the camshaft lobes
and hydraulic lash adjuster for damage.
1.
Roller Follower Inspection 1265
Information
Workshop Manual
Hydraulic Lash Adjuster Inspection
Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found, inspect the
camshaft lobes and valves for damage.
1.
Hydraulic Lash Adjuster Inspection 1266
Information
Workshop Manual
Powertrain/Drivetrain Mount Neutralizing
NOTE: Refer to the appropriate section and procedure for special instructions on loosening and tightening
mount fasteners.
100-02 .
1.
Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 2.
Lower the vehicle. 3.
NOTICE: Do not twist or stra the powertrain/drivetrain mounts or damage to the mounts may
occur.
Start the vehicle and move it in forward 0.6-1.2 m (2-4 ft). Then move the vehicle in reverse the same
distance.
4.
Raise and support the vehicle. 5.
Tighten the powertrain/drivetrain mount fasteners. 6.
Lower the vehicle. 7.
Test the system for normal operation. 8.
Powertrain/Drivetrain Mount Neutralizing 1267
SECTION 303-01A: Engine - 2.5L
Manual
Material
Capacity
High Temperature 4x4 Front
Axle and Wheel Bearing
Grease
XG-11
WSS-M1C267-A1 -
Motorcraft Metal Surface
Prep
ZC-31-A
- -
Premium Synthetic Blend
Motor Oil (US); Motorcraft
SAE 5W-20 Super Premium
Motor Oil (Canada)
XO-5W20-QSP (US);
WSS-M2C945-A 5.0L (5.3 qt)
includes
filter change
Motorcraft Specialty Green
Engine Coolant
VC-10-A2 (US); CVC-10-A
(Canada)
WSS-M97B55-A
a
Motorcraft Orange
Antifreeze/Coolant
Concentrated
VC-3-B (US); CVC-3-B2
(Canada)
WSS-M97B44-D
a
Motorcraft XL-5 (aerosol)
and/or CRC SL3151
ESB-M1C93-B -
Silicone Brake Caliper Grease
and Dielectric Compoun>
ESE-M1C171-A -
TA-30
WSE-M4G323-A4 -
Motorcraft Silicone Gasket
Remover
ZC-30
- -
Thread Sealant with PTFE
TA-24
WSK-M2G350-A2 -
a
Early build vehicle cooling systems are filled with Motorcraft Specialty Green Engine Coolant and late
build vehicle cooling systems are filled with Motorcraft Specialty Orange Engine Coolant. Use the same
type of coolant that was originally used to fill the cooling system. Do not mix coolant types. Mixing coolant
types degrades the coolant corrosion protection and may damage the engine or cooling system.
Item Specification
Displacement 2.5L
No. of cylinders 4
Bore/stroke 89.0/100.0
Firing order 1-3-4-2
Oil pressure (normal operating
temperature @ 2,000 rpm)
200-450 kPa
(29-65 psi)
Compression ratio 9.7:1
Engine weight (without accessory drive
components and flexplate or flywheel)
115.8 kg (255.3 lb)
Engine and transaweight (without
accessory drive components)
203.8 kg (449.3 lb)
Cylinder Block
Cylinder bore diameter 89.0-89.03 mm
(3.503-3.505 in)
Cylinder bore maximum out-of-round 0.008 mm
(0.0003 in)
Main bearing bore diameter 57.018-57.040 mm
(2.244-2.245 in)
Head gasket surface flatness 0.1 mm/general
0.05 mm/200 x 200
(0.004 in/general)
(0.0019 in/7.87 x 7.87)
Piston
Diameter (1) 88.965-88.975 mm
(3.5025-3.5029 in)
Diameter (2) 88.975-88.985 mm
(3.5029-3.5033 in)
Diameter (3) 88.985-88.995 mm
(3.5033-3.5037 in)
Piston-to-bore clearance 0.025-0.045 mm
(0.0009-0.0017 in)
Ring groove width - top 1.203-1.205 mm
(0.0473-0.0474 in)
Ring groove width - 2nd 1.202-1.204 mm
(0.0473-0.0474 in)
Ring groove width - oil 2.501-2.503 mm
(0.0984-0.0985 in)
Piston skirt coatingness 0.008-0.016 mm
(0.0003-0.0007 in)
Piston Pin
Diameter 19.995-20.0 mm
(0.8265-0.8267 in)
Length 54.7-55.0 mm
(2.1535-2.1653 in)
Cylinder Head
Cylinder head flatness 0.08 (0.0031 in) maximum overall, a maximum
of 0.05 mm (0.0019 in) within 150 mm (5.9 in)
Valve lift @ zero lash (exhaust) 7.7 mm (0.30 in)
Valve lift @ zero lash (intake) 8.8 mm (0.35 in)
Valve guide inner diameter 5.509-5.539 mm
(0.216-0.218 in)
Valve seat width - intake/exhaust 0.99-1.84 mm
(0.038-0.072 in)
Valve seat angle 45 degrees
Valve seat runout 0.075 mm (0.0029 in)
Valve lash adjuster bore diameter 31.00-31.03 mm
(1.220-1.221 in)
Cam bore diameter 25.015-25.040 mm
(0.984-0.985 in)
Valve
Valve head diameter - intake 34.85-35.15 mm
(1.37283 in)
Valve head diameter - exhaust 29.85-30.15 mm
(1.175-1.187 in)
Valve stem diameter - intake 5.470-5.485 mm
(0.2153-0.2159 in)
Valve stem diameter - exhaust 5.465-5.480 mm
(0.2151-0.2157 in)
Valve stem-to-guide clearance - intake 0.0027 mm (0.00010 in)
Valve stem-to-guide clearance - exhaust 0.0029 mm (0.00011 in)
Valve face runout 0.05 mm (0.0019 in)
Valve face angle 45 degrees
Valve Spring - Compression Pressure
Intake and exhaust (installed) 17.5 kg (38.667 lb)
Intake (valve open) 8.9 mm (0.35 in) of lift 44 kg (97.032 lb)
Exhaust (valve open) 7.4 mm (0.29 in) of
lift
42 kg (93.338 lb)
Free length 44.92 mm (1.768 in)
Assembled height 37.9 mm (1.492 in)
Crankshaft
Main bearing journal diameter 51.978-52.002 mm
(2.046-2.047 in)
51.730-51.750 mm
(2.036-2.037 in)
Main bearing clearance 0.016-0.047 mm
(0.0006-0.0015 in)
Connecting rod journal diameter 51.978-52.002 mm
((2.046-2.047 in)
Production repair 51.730-51.750 mm
(2.036-2.037 in)
End play 0.22-0.450 mm
(0.008-0.018 in)
Rings
Width - top 1.17-1.19 mm
(0.0460-0.0468 in)
Width - 2nd 1.17-1.19 mm
(0.0460-0.0468 in)
Width - oil 2.38-2.45 mm
(0.093-0.096 in)
Piston ring end gap - compression (top,
gauge diameter)
0.16-0.26 mm
(0.006-0.0102 in)
Piston ring end gap - compression (bottom,
gauge diameter)
0.31-0.46 mm
(0.012-0.018 in)
Piston ring end gap - oil ring (steel rail,
gauge diameter)
0.15-0.40 mm
(0.01575-0.0591 in)
Valve Tappet
Diameter
30.97-30.98 mm
(1.2192-1.2196 in)
Tappet-to-valve clearance - intake
Tappet-to-valve clearance - exhaust 0.27-0.33 mm (0.010-0.013 in)
Tappet-to-bore clearance 0.02-0.06 mm
(0.0007-0.0023 in)
Camshaft
Lobe lift - intake 8.24999 mm (0.324 in)
Lobe lift - exhaust 7.80007 mm (0.307 in)
Runout (1)
a
0.03 mm (0.001 in)
Thrust clearance 0.09-0.24 mm
(0.003-0.009 in)
Journal diameter 24.96-24.98 mm
(0.982-0.983 in)
Journal-to-bore clearance 0.035-0.080 mm
(0.001-0.003 in)
Connecting Rod
Bearing clearance 0.027-0.052 mm
(0.001-0.002 in)
Bearing thickness 1.496-1.520 mm
(0.058-0.059 in)
Crank bore diameter 55.025-55.045 mm
(2.166-2.167 in)
Pin bore diameter 20.010-20.021 mm
(0.7878-0.7882 in)
Length (center-to-center) 151.8 mm (5.976 in) 0.14-0.36 mm
(0.005-0.014
in)
a
No. 3 Journal - Supported by No. 1 and No. 5 journals.
A/C compressor mounting bolts 25 18 -
A/C manifold tube bolt 25 18 -
A/C tube nut 8 - 71
A/C tube-to-condenser nut 8 - 71
Accessory drive belt idler pulley and
bracket bolts
25 18 -
Accessory drive belt idler pulley bolt 25 18 -
Accessory drive belt tensioner bolts 25 18 -
Balance shaft bolts
a
Bellhousing-to-engine bolts 48 35 -
Bellhousing-to-oil pan bolt 48 35 -
Block heater 40 30 -
Camshaft bearing cap bolts
a
- - -
Camshaft sprocket bolt 72 53 -
Clutch pressure plate
a
- - -
Clutch slave cylinder bolts 22 16 -
Clutch tube bracket bolts 22 16 -
Coil-on-plug bolts 8 - 71
Connecting rod cap bolts
a
- -
Coolant outlet bolts 10 - 89
Coolant pump bolts 10 - 89
Coolant pump pulley bolts 20 - 177
Crankcase rear main oil seal retainer plate
bolts
a
- - -
Crankcase vent oil separator bolts 10 - 89
Crankshaft Position (CKP) sensor bolts
a
- - -
Crankshaft pulley bolt
a
- - -
Crankshaft rear seal retainer bolts
a
- - -
Cylinder head bolts
a
- - -
Cylinder head studs 17 - Cylinder Head
Temperature
(CHT) sensor
12 - 106
Degas bottle nut and bolt 9 - 80
EGR tube 55 41 -
EGR valve bolts 20 - 177
Electronic Power Assist Steering (EPAS)
ground wire bolt
12 - 106
Engine front cover bolts
a
- - -
Engine front cover timing hole plug
(lower)
12 - 106
Engine front cover timing hole plug
(upper)
10 - 89
Engine front cover-to-oil pan bolts 10 - 89
Engine mount bolts 55 41 -
Engine moun valign="top"
align="center">115
85 -
Engine mount bracket nuts 103 76 -
Engine mount damper bolt 23 17 -
Engine mount ground wire bolt 10 - 89
Engine mount nut 55 41 -
Engine oil filter
b
- - -
Engine Oil Pressure (EOP) switch 15 - 133
Engine plug bolt 20 - 177
Engine roll-restrictor bolt 90 66 -
Exhaust flexible pipe bracket bolts 35 26 -
Exhaust manifold heat shield bolts 10 -ign="center">89
Exhaust manifold nuts
a
- - -
Flexplate bolts
a
- - -
Flywheel bolts
a
- - -
Fuel rail bolts 23 17 -
Generator B+ wiring harness nut 12 - 106
Generator mounting nuts and bolt 47 35 -
Generator stud bolts 24 18 -
Ground wire-to-body bolt 12 - 106
Ground wire-to-engine mount bracket bolt 10 - 89
Intake manifold bolts 18 - 159
Kno"top" align="center">20 - 177
Main bearing beam bolts
a
- - -
Oil filter adapter bolts 25 18 -
Oil pan bolts
a
- - -
Oil pan-to-bellhousing bolts 48 35 -
Oil pan drain plug 28 21 -
Oil pump bolts
a
- - -
Oil pump drive chain tensioner shoulder
bolt
10 - 89
Oil pump drive chain tensioner spring
shoulder bolt
10 - 89
Oil pump screen and pickup tube bolts 10 - 89
Oil pump sprocket bolt 25 ter">18 -
Oil squirters 4 - 35
Positive battery cable nuts 9 - 80
Radio capacitor and nut 10 - 89
Spark plugs 12 - 106
Starter motor solenoid wire nut 5 - 44
Starter motor B+ wire nut 12 - 106
Starter motor bolt and stud bolt 25 18 -
Starter motor stud bolt ground wire nut 18 - 159
Steering column shaft bolt 20 - 177
Subframe nuts 150 111 -
Subframe b 103 76 -
Sway bar link nuts 40 30 -
Thermostat housing bolts 10 - 89
Timing chain guide bolts 10 - 89
Timing chain tensioner bolts 10 - 89
Torque converter nuts 35 26 -
Transaxle mount bolts 90 66 -
Transaxle mount through bolt 90 66 -
Valve cover bolts
a
- - -
Variable Camshaft Timing (VCT) solenoid
bolt
a
10 89
VCT system oil filter plug 17 - 150
Windshield washer reservoir/A/C tube
bracket bolt
7 - 62
a
Refer to the procedure for the specification.
b
Lubricate the engine oil filter gasket with clean engine oil. Tighten the oil filter three-fourths turn after the
oil filter gasket makes contact with the oil filter adapter.
Manual
Engine
The 2.5L (153 CID) 4-cylinder engine has the following features:
DOHC
Four valves per cylinder
Sequential Multi-Port Fuel Injection (SFI)
Aluminum cylinder head
Aluminum cylinder block
Electronic ignition system with 4 coil-on-plug ignition coils
The 2.5L engine is a 4 valve-per-cylinder, dual overhead camshaft engine. The engine uses a coil-on-plug
ignition system. The cylinder block is made of aluminum and the bearing caps are integrated into the ladder
assembly. An aluminum oil pan bolts to the bottom of the lower cylinder block and to the transmission to
provide greater strength. The camshafts are mounted in the cylinder heads and act against valve tappets to
open and close the valves. The camshafts are driven off the front of the cylinder head by one timing chain.
The chain is driven by a sprocket that is located on the crankshaft. The piston assembly is an aluminum piston
with a cast iron connecting rod. The oil pump is driven by the crankshaft via a dedicated chain that is driven
by the same sprocket that drives the timing chain.
Engine Identification
Always refer to these labels when installation of new parts is necessary or when checking engine calibrations.
The engine parts often differ within a CID family. Verification of the identification codes will make sure that
the correct parts are obtained. These codes contain all the pertinent information relating to the dates, optional
equipment and revisions. The Ford Master Parts Catalog contains a complete listing of the codes and their
applications.
Engine Code Information Label
The engine code information label, located on the front side of the valve cover, contains the following:
Item Description
1 Engine part number
2 Chihuahua engine plant
3 Engine displacement
4 Bar code
5 Running number
Engine 1276
6 Engine build date (DDMMYY)
7 Plant shift line
8 Bar code
Engine Cylinder Identification
Exhaust Emission Control System
Operation and necessary maintenance of the exhaust emission control devices used on this engine are covered
in the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Induction System
The SFI provides the fuel/air mixture needed for combustion in the cylinders. The 4 solenoid-operated fuel
injectors:
are mounted in the intake manifold.
meter fuel into the air intake stream in accordance with engine demand.
are positioned so that their tips direct fuel just ahead of the engine intake valves.
are connected in series with the fuel pressure sensor.
supply fuel from the fuel tank with a fuel pump mounted in the fuel tank.
A constant fuel pressure is maintained across the fuel injectors by the fuel pressure sensor. The fuel pressure
sensor is positioned upstream from the fuel injectors on the fuel injection supply manifold.
PCV System
All engines are equipped with a closed-type PCV system recycling the crankcase vapors to the intake
manifold.
Lubrication System
The engine lubrication system operates as follows:
Engine 1277
Oil is drawn into the oil pump through the oil pump screen cover and tube in the sump of the oil pan.
Oil is pumped through the oil filter on the left front side of the cylinder block.
Oil enters the main gallery where it is distributed to the crankshaft main journals and to the cylinder
head.

From the main journals, the oil is routed through cross-drilled passages in the crankshaft to lubricate
the connecting rod bearings. Controlled leakage through the crankshaft main bearings and connecting
rod bearings is slung radially outward to cool and lubricate the cylinder walls as well as the entire
connecting rod, piston and piston ring assembly.

Engine 1278
SECTION 303-01A: Engine - 2.5L 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop Manual
Engine
For basic engine mechanical concerns, refer to Section 303-00 . For driveability concerns, refer to the
Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Engine 1279
Manual
Valve Clearance Check
Remove the valve cover. For additional information, refer to Valve Cover in this section. 1.
NOTE: 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 clearanf each valve and record its location.
2.
NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example,
a tappet with the number 0.650 has the thickness of 3.650 mm.
NOTE: The nominal clearance is:
intake: 0.25 mm (0.0095 in).
exhaust: 0.30 mm (0.0115 in).
NOTE: The acceptable clearances after being fully installed are:
intake: 0.22-0.28 mm (0.008-0.011 in).
exhaust: 0.27-0.33 mm (0.010-0.013 in).
Select tappets using this formula: ideal tappet thickness = measured clearance + the existing tappet
thickness - nominal clearance.
Select the closest tappet size to the ideal tappet thickness available and mark the installation location.
3.
If any tappets do not measure within specifications, install new tappets in these locations. For
additional information, refer to Valve Train Components - Exploded View and Valve Tappets in this
sectn.
4.
Valve Clearance Check 1280
Balance Shaft Backlash
Special Tool(s)
100-002 (TOOL-4201-C)
Timing Peg, Crankshaft TDC
303-507
Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the
crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at Top
Dead Center (TDC).
1.
Mark the balancer unit and shafts on the top for reference that the balancer unit is at TDC . 2.
NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.
Remove the 4 bolts and the balancer unit.
3.
Balance Shaft Backlash 1282
Remove the adjustment shims from the seat faces of the balancer unit. 4.
NOTICE: Visually inspect the balancer unit gear for damage and verify that the shaft turns
smoothly. If there is any damage or malfunction, replace the balancer unit.
Install the master adjustment shims (No. 50) on the seat faces of the balancer unit.
5.
With the balancer unit shaft marks at the TDC position, slowly install the balancer unit to the cylinder
block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
6.
Install the balancer unit bolts.
Tighten in the sequence shown in 2 stages.
Stage 1: Tighten to 25 Nm (18 lb-ft).

7.
Remove the Crankshaft TDC Timing Peg.
Rotate the crankshaft to confirm that there are no meshing problems between the balancer
unit gear and the crankshaft gear.

8.
crankshaft balance weight is up against the Crankshaft TDC Timing Peg.
9.
NOTE: Measure the backlash and verify that it is within specified range at all of the following 6
positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be
necessary to reset the measuring equipment between measurements.
NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm
Allen wrench and worm clamp set up as shown. Mark the Allen wrench with a file 80 mm (3.149 in)
above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the
balance shaft housing.
NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as
shown into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction
with the screwdriver, using a prying action as shown.
Position the Dial Indicator Gauge with Holding Fixture as shown. Measure the gear backlash.
Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm
(3.149 in) above the driven gear shaft center (2) on the balancer unit.

Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions:
10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees.

10.
NOTE: If maximum backlash exceeds 0.101 mm (0.003 in), install a new balancer unit.
Using the backlash measurement, select the proper shims from the Adjustment Shim Selection Table.
Remove the balancer unit from the cylinder block.
Install the selected adjustment shims on the seat faces of the balancer unit.
11.
crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC .
12.
With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder
13.

14.
NOTE: Remeasure the backlash and verify that it is within specified range at all of the following 6

15.

If the backlash exceeds the specified range of 0.005 to 0.101 mm (0.00019 to 0.0039 in),
install a new balancer unit and repeat the procedure.

IN-VEHICLE REPAIR Procedure revision date: 06/03/2011
Intake Manifold
Intake Manifold (View 1 of 2)
Item
Part
Number Description
1 19D848 Vacuum supply hose
2 9D289 Fuel vapor return hose
3 14A464 Manifold Absolute Pressure (MAP) sensor electrical
connector (part of 12C508)
4 14A464 Knock Sensor (KS) electrical connector (part of 12C508)
5 14A624 KS wire har pin-type retainer (part of 12C508)
6 14A464 Evaporative Emission (EVAP) canister purge valve
electrical connector (part of 12C508)
7 14A464 Electronic throttle control electrical connector (part of
12C508)
8 18K580 Heater hose pin-type retainer
9 13A506 A/C compressor wiring harness retainer (part of 14B060)
10 13A506 Wire harness pin-type retainer
11 14197 Wire harness pin-type retainer
Intake Manifold 1288
1 W500311 Intake manifold bolt (7 required)
2 6A785 Crankcase vent oil separator tube (part of 6A785)
3 9E470 EGR tube
4 9424 Intake manifold
5 9461 Intake manifold gasket
With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02
.
1.
Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Section 303-12A . 2.
Disconnect the vacuum supply hose.
Depress the quick connect locking ring.
Pull the vacuum hose out of the quick connect fitting.
3.
Disconnect the fuel vapor return hose from the intake manifold. 4.
Disconnect the Manifold Absolute Pressure (MAP) electrical connector. 5.
Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector. 6.
Disconnect the electronic throttle control electrical connector. 7.
Disconnect the Knock Sensor (KS) electrical connector.
Detach the wire harness pin-type retainer.
8.
Detach the heater hose pin-type retainer. 9.
Detach the A/C compressor wiring harness retainer. 10.
Intake Manifold (View 2 of 2) 1289
Detach the 2 wiring harness pin-type retainers from the intake manifold and position the wiring
harness aside.
11.
If equipped, remove the 7 screws and the underbody cover. 12.
Remove the intake manifold lower bolt.
13.
Remove the 6 bolts and position the intake manifold aside to access the crankcase vent oil separator
tube and the EGR tube.
14.
Remove the EGR tube.
15.
Squeeze the 2 crankcase vent oil separator tube tabs and disconnect the tube from the intake manifold.
Remove the intake manifold.
16.
NOTICE: If the engine is repaired or replaced because of upper engine failure, typically
including valve or piston damage, check the intake manifold for metal debris. If metal debris is
found, install a new intake manifold. Failure to follow these instructions can result in engine
damage.
Inspect and install new intake manifold gaskets if necessary.
17.
Valve Cover
Material
Item Specification
ZC-31-A
-
TA-30
WSE-M4G323-A4
Valve Cover (View 1 of 2)
Item
Part
Number Description
1 6750 Oil level indicator
2 6853 Crankcase vent hose
3 14A464 Cylinder Head Temperature (CHTr electrical connector
(part of 12B637)
4 14A464 Camshaft Position (CMP) sensor electrical connector
(part of 12B637)
5 14A464 Wire harness retainer (part of 12C508)
7 14A464 Radio capacitor electrical connector (part of 12C508)
8 14A163 Variable Camshaft Timing (VCT) oil control solenoid
9 14A163 Wire harness retainer (part of 14290)
Valve Cover 1292
1 6C291 Valve cover retainer (10 required)
3 6M293 Valve cover
4 6K260 Valve cover gasket
Removal
NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material,
including any material created while cleaning gasket surfaces, that enters the oil passages, coolant
passages or the oil pan can cause engine failure.
Remove the oil level indicator. 1.
Remove the ignition coil-on-plugs. For additional information, refer to Section 303-07A . 2.
Disconnect the crankcase vent hose. 3.
Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 4.
Disconnect the Camshaft Position (CMP) sensor electrical connector. 5.
Disconnect the radio capacitor electrical connector. 6.
Disconnect the Variable Camshaft Timing (VCT) solenoid electrical connector. 7.
Detach all of the wiring harness retainers from the valve cover studs and position the harness aside. 8.
Remove the 14 valve cover retainers and the valve cover.
Discard the gasket.
9.
Installation
NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These tools cause scratches and gouges which make leak
paths.
Clean and inspect the sealing surfaces.
1.
Valve Cover (View 2 of 2) 1293
NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve
cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with
metal surface prep.
Apply silicone gasket and sealant to the locations shown.
2.
Install the valve cover, new gasket and retainers.
Tighten in the sequence shown to 10 Nm (89 lb-in).
3.
Position the wiring harness and attach all of the wiring harness retainers to the valve cover studs. 4.
Connect the VCT solenoid electrical connector. 5.
Connect the radio capacitor electrical connector. 6.
Connect the CMP sensor electrical connector. 7.
Connect the CHT sensor electrical connector. 8.
Connect the crankcase vent hose. 9.
Install the ignition coil-on-plugs. For additional information, refer to Section 303-07A . 10.
NOTE: Make sure the notch on the oil level indicator is aligned with the V-shaped boss on the valve
cover and fully engaged into the valve cover.
Install the oil level indicator.
11.
Crankshaft Pulley and Crankshaft Front Seal - Exploded View
1 6K340 Crankshaft pulley bolt
2 - Crankshaft pulley washer (part of 6K340)
3 6316 Crankshaft pulley
4 6700 Crankshaft front seal
5 6378 Diamond washer
NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special
tools as instructed in this procedure. The crankshaft pulley and the timing sprocket are not
keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted
together by friction, using diamond washers between the flange faces on each part. For that
reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any
repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and
camshafts must be locked in place by the special service tools, otherwise severe engine damage
can occur.
For additional information, refer to the procedures in this section.
1.
Crankshaft Pulley and Crankshaft Front Seal - Exploded View 1296
Crankshaft Pulley
Special Tool(s)
Alignment Plate, Camshaft
303-465 (T94P-6256-CH)
Holding Tool, Crankshaft Damper
303-1416
303-507
General Equipment
6 mm x 18 mm bolt
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
Removal
NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as
instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to
the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction,
using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket
is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the
crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service
tools, otherwise severe engine damage can occur.
NOTICE: During engine repair procedures, cleliness is extremely important. Any foreign material,
100-02 .
1.
Crankshaft Pulley 1298
Remove the front RH wheel and tire. For additional information, refer to Section 204-04 . 2.
Remove the accessory drive belt. For additional information, refer to Section 303-05A in this section. 4.
NOTICE: Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage
to the engine. Turn the engine in the normal direction of rotation only.
Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top
Dead Center (TDC).
The hole in the crankshaft pulley should be in the 6 o'clock position.
6.
NOTICE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to
prevent engine rotation can result in engine damage.
NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Plate cannot be installed,
rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
7.
Remove the engine plug bolt. 8.
NOTE: The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it from turning past
TDC . However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft
must remain at the TDC position during the crankshaft pulley removal and installation.
Install the Crankshaft TDC Timing Peg.
9.
NOTICE: The crankshaft must remain in the Top Dead Center (TDC) position during removal
of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be
held in place with the Crankshaft Damper Holding Tool and the bolt should be removed using
an air impact wrench (1/2-in drive minimum).
NOTICE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley.
The diamond washer must be replaced, remove and discard the diamond washer. If the
diamond washer is not installed, engine damage may occur.
Using the Crankshaft Damper Holding Tool and an air impact wrench, remove the crankshaft pulley.
Remove and discard the crankshaft pulley bolt and washer.
Remove the crankshaft pulley.
Remove the diamond washer and discard.
10.
Installation
Install a new diamond washer. 1.
NOTE: Do not install the crankshaft pulley bolt at this time.
NOTE: Apply clean engine oil on the seal area before installing.
Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
2.
NOTICE: Only hand-tighten the 6 mm bolt or damage to the front cover can occur.
NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
3.
NOTICE: The crankshaft must remain in the Top Dead Center (TDC) position during
installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft
pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be
installed using hand tools only.
NOTE: Do not reuse the crankshaft pulley bolt.
Install a new crankshaft pulley bolt. Using the Crankshaft Damper Holding Tool to hold the
crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:

Stage 2: Tighten an additional 90 degrees (one-fourth turn).
4.
Remove the 6 mm x 18 mm bolt. 5.
Remove the Crankshaft TDC Timing Peg. 6.
Remove the Camshaft Alignment Plate. 7.
NOTE: Only turn the engine in the normal direction of rotation.
Turn the crankshaft clockwise one and three-fourths turns.
8.
Install the Crankshaft TDC Timing Peg. 9.
Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.
10.
NOTICE: Only hand-tighten the bolt or damage to the front cover can occur.
Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley.
If it is not possible to install the bolt, the engine valve timing must be corrected by repeating
this procedure.

11.
Install the Camshaft Alignment Plate to check the position of the camshafts.
If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be
corrected by repeating this procedure.

12.
Install the engine plug bolt.
16.
If equipped, install the underbody cover and the 7 screws. 17.
Install the accessory drive belt. For additional information, refer to Section 303-05A . 18.
Install the valve cover. For additional information, refer to Valve Cover in this section. 19.
Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the
on-screen instructions.
20.
Crankshaft Front Seal
Special Tool(s)
Installer, Camshaft Front Oil Seal
303-096 (T74P-6150-A)
Remover, Oil Seal
303-409 (T92C-6700-CH)
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
Removal
Remove the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section. 1.
NOTICE: Use care not to damage the engine front cover or the crankshaft when removi the
seal.
Using the Oil Seal Remover, remove the crankshaft front oil seal.
2.
Crankshaft Front Seal 1306
Installation
NOTE: Remove the through bolt from the Camshaft Front Oil Seal Installer.
NOTE: Lubricate the oil seal with clean engine oil.
Using the Camshaft Front Oil Seal Installer, install the crankshaft front oil seal.
1.
Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section. 2.
Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View
1 6379 Flexplate or flywheel bolt (6 required)
2 6K375/6K390 Flexplate or flywheel
3 6730 Oil pan drain plug
4 W500215 Engine front cover bolt (4 required)
5 940604 Engine front cover stud bolt
6 W706284 Oil pan bolt (2 required)
7 W500224 Oil pan bolt (11 required) 8 6675 Oil
pan
9 W500212 Crankshaft rear oil seal with retainer
plate bolt (6 required)
10 6K318 Crankshaft rear oil seal with retainer
plate
Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View 1308
Flexplate
Special Tool(s)
Removal
100-02 .
1.
Remove the automatic transaxle. For additional information, refer to the appropriate automatic
transion section.
2.
Remove the 6 bolts and the flexplate. 3.
Installation
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.
1.
Install the automatic transaxle. For additional information, refer to the appropriate automatic
transmission section.
2.
After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile
Correction procedure following the on-screen instructions.
3.
Flexplate 1310
Flexplate 1311
Flywheel
Special Tool(s)
Removal
100-02 .
1.
Remove the clutch. For additional information, refer to Section 308-01 . 2.
Remove the 6 bolts and the flywheel. 3.
Installation
Install the flywheel and tighten the bolts in the sequence shown in 3 stages.
1.
Install the clutch and manual transaxle. For additional information, refer to Section 308-01 . 2.
3.
Flywheel 1312
Flywheel 1313
Crankshaft Rear Seal
Special Tool(s)
Installer, Crankshaft Rear Main Oil Seal
303-328 (T88P-6701-B1)
Material
Item Specification
ZC-31-A
-
Premium Synthetic Blr Oil (US);
XO-5W20-QSP (US);
WSS-M2C945-A
TA-30
WSE-M4G323-A4
Removal
100-02 .
1.
Remove the flexplate or flywheel. For additional information, refer to Flexplate or Flywheel in this
section.
2.
Drain the engine oil.
Install the drain plug.
3.
NOTICE: If the oil pan is not removed, damage to the rear oil seal retainer joint can occur.
Remove the 16 bolts, stud bolt and the oil pan.
4.
Remove the 6 bolts and the crankshaft rear oil seal with retainer plate. 5.
Installation
Using the Crankshaft Rear Main Oil Seal Installer, position the crankshaft rear oil seal with retainer
plate onto the crankshaft.
1.
Crankshaft Rear Seal 1314
Install the crankshaft rear oil seal with retainer plate and bolts.
To install, tighten in the sequence shown to 10 Nm (89 lb-in).
2.
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, engine front cover and cylinder block mating surfaces.
3.
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 prep. Allow to dry until there is no sign of
wetness, or 4 minutes, whichever is longer. Failure to follow these instructions 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 in) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Install
the 2 oil pan bolts finger-tight.
4.
Install the 3 bolts and the stud bolt.
5.
Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown to 20 Nm (177
lb-in).
6.
Install the flexplate or flywheel. For additional information, refer to Flexplate or Flywheel in this
section.
7.
Fill the engine with clean engine oil. 8.
Engine Front Cover
Special Tool(s)
Alignment Tool, Crank
303-1417
303-096 (T74P-6150-A)
Remover, Oil Seal
303-409 (T92C-6700-CH)
General Equipment
6 mm x 18 mm bolt
Material
Item Specification
ZC-31-A
-
5W-20 Super Premium Motor Oil
(Canada)
XO-5W20-QSP (US);
WSS-M2C945-A
TA-30
WSE-M4G323-A4
Engine Front Cover 1317
Item
Part
Number Description
1 W500224 Accessory drive belt idler pulley bolt (2 required)
2 19A216 Accessory drive belt idler pulley and bracket
4 W500221 Coolant pump pulley bolt (3 required)
5 8509 Coolant pump pulley
6 14A464 Crankshaft Position (CKP) sensectrical connector (part
of 12C508)
7 W701219 CKP sensor bolt (2 required)
8 6C315 CKP sensor
10 W500320 Engine front cover bolt
11 W500300 Engine front cover bolt
13 - Engine front cover stud bolt
14 6019 Engine front cover
Removal
l start="1">
With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 .
Loosen the 3 coolant pump pulley bolts. 2.
Remove the accessory drive belt and the accessory drive idler pulley. For additional information, refer
to Section 303-05A .
3.
Remove the engine mount. For additional information, refer to Engine Mount in this section. 6.
NOTICE: Use care not to damage the engine front cover or the crankshaft when removing the
seal.
Using the Oil Seal Remover, remove and discard the crankshaft front oil seal.
7.
Remove the 3 bolts and the coolant pump pulley. 8.
Remove the 2 bolts and the accessory drive belt idler pulley and bracket. 9.
Disconnect the Crankshaft Position (CKP) sensor electrical connector. 10.
Remove the 2 bolts and the CKP sensor. 11.
Remove the 22 bolts and the engine front cover. 12.
Installation
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.
1.
NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying
the silicone gasket and sealant.
leakage.
Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint
areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover.
2.
Install the engine front cover. Tighten the bolts in the sequence shown, to the following
specifications:
Tighten the 8-mm bolts to 10 Nm (89 lb-in).
Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
3.
Install the accessory drive belt idler pulley and bracket and the 2 bolts.
4.
NOTE: The coolant pump pulley bolts should be tightened after the accessory drive belt is installed.
Install the coolant pump pulley and bolts.
5.
6.
Install the engine mount. For additional information, refer to Engine Mount in this section. 7.
9.
Install the CKP sensor and the 2 bolts.
Do not tighten the bolts at this time.
10.
Using the Crank Alignment Tool, adjust the CKP sensor.
Tighten the bolts to 7 Nm (62 lb-in).
11.
Connect the CKP sensor electrical connector. 12.
Install the accessory drive belt and the accessory drive idler pulley. For additional information, refer
15.
Tighten the 3 coolant pump pulley bolts to 20 Nm (177 lb-in). 16.
Timing Drive Components
Removal
including any material created whileaning gasket surfaces, that enters the oil passages, coolant passages
or the oil pan can cause engine failure.
100-02 .
1.
Remove the engine front cover. For additional information, refer to Engine Front Cover in this
section.
2.
Compress the timing chain tensioner in the following sequence.
Using a small pick, release and hold the ratchet mechanism. 1.
While holding the ratchet mechanism in the released position, compress the tensioner by
pushing the timing chain arm toward the tensioner.
2.
Insert a paper clip into the hole to retain the tensioner. 3.
3.
Remove the 2 bolts and timing chain tensioner. 4.
Remove the timing chain tensioner arm. 5.
Timing Drive Components 1324
Remove the timing chain. 6.
Remove the 2 bolts and the timing chain guide. 7.
Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust
camshaft sprocket.
8.
Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the camshaft phaser
and sprocket.
9.
Installation
Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time. 1.
Install the timing chain guide and the 2 bolts.
2.
Install the timing chain. 3.
Install the timing chain tensioner arm. 4.
NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position,
follow the next 4 steps.
NOTICE: Do not compress the ratchet assembly. This will damage the ratchet assembly.
Using the edge of a vise, compress the timing chain tensioner plunger.
5.
Using a small pick, push back and hold the ratchet mechanism. 6.
While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing. 7.
Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger
in during installation.
8.
Install the timing chain tensioner and the 2 bolts. Remove the paper clip to release the piston.
9.
Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.
10.
Install the engine front cover. For additional information, refer to Engine Front Cover in this section. 11.
Variable Camshaft Timing (VCT) System Oil Filter
1 W710451 Plug
2 6C683 Variable Camshaft Timing (VCT) system oil filter
Remove the Variable Camshaft Timing (VCT) solenoid. For additional information, refer to Section
303-14A .
1.
Remove the plug and the VCT system oil filter from the intake camshaft thrust cap.
2.
Variable Camshaft Timing (VCT) System Oil Filter 1329
Camshafts
Special Tool(s)
303-465 (T94P-6256-CH)
303-507
General Equipment
6 mm x 18 mm bolt
M6 x 30 mm bolt
Material
Item Specification
(Canada)
XO-5W20-QSP (US);
WSS-M2C945-A
TA-30
WSE-M4G323-A4
Removal
NOTICE: Do not rotate the camshafts or crankshaft unless instructed to do so in this procedure.
Rotating the camshafts or crankshaft with timing components loosened or removed can cause serious
damage to the valves or pistons.
100-02 .
1.
Remove the accessory drive belt. For additional information, refer to Section 303-05A . 2.
Remove the front RH wheel and tire. For additional information, refer to Section 204-04 . 3.
Camshafts 1331
303-14A .
5.
Check the valve clearance. For additional information, refer to Valve Clearance Check in this section. 6.
Dead Center (TDC).
7.
8.
Camshafts 1332
must remain at the TDC position during the camshaft removal and installation.
10.
11.
Remove the lower timing hole plug from the engine front cover. 12.
Remove the upper timing hole plug from the engine front cover. 13.
Reposition the Camshaft Alignment Plate to the slot on the rear of the intake camshaft only. 14.
Camshafts 1333
NOTE: Releasing the ratcheting mechanism in the timing chain tensioner allows the plunger to
collapse and create slack in the timing chain. Installing the M6 x 30 mm bolt into the upper front
cover timing hole will lock the tensioner arm in a retracted position and allow enough slack in the
timing chain for removal of the exhaust camshaft gear.
Using a small pick tool, release the timing chain tensioner ratchet through the lower front cover
timing hole.
Have an assistant rotate the exhaust camshaft clockwise (using the flats of the camshaft) to
collapse the timing chain tensioner plunger.

Insert the M6 x 30 mm bolt into the upper front cover timing hole to hold the tensioner arm in
the retracted position.

15.
camshaft drive gear.
16.
Camshafts 1334
Remove the timing chain from the intake camshaft drive gear. 18.
Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference. 19.
NOTICE: Failure to follow the camshaft loosening procedure can result in damage to the
camshafts.
NOTE: Mark the location and orientation of each camshaft bearing cap.
Remove the camshafts from the engine.
Loosen the camshaft bearing cap bolts, in the sequence shown, one turn at a time until all
tension is released from the camshaft bearing caps.

Remove the bolts and the camshaft bearing caps.
Remove the camshafts.
20.
If removal of the camshaft phaser and sprocket is necessary, mark the sprocket and camshaft for
reference during installation.
If necessary, place the camshaft in a soft-jawed vise. Remove the bolt and the camshaft
phaser and sprocket.

21.
Camshafts 1335
Installation
NOTE: If new parts are installed, transfer the reference marks made during disassembly to the new
parts.
If necessary, position the camshaft in a soft-jawed vise and install the camshaft phaser and sprocket
and the bolt.
Align the reference marks on the camshaft phaser and sprocket and the camshaft. Tighten the
bolt to 72 Nm (53 lb-ft).

1.
NOTICE: Install the camshafts with the alignment slots in the camshafts lined up so the
Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes
on the No. 1 cylinder are in the same position as noted in the removal procedure. Rotating the
camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of
position can cause severe damage to the valves and pistons.
NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
Install the camshafts and bearing caps in their original locations and orientation. Tighten the bearing
caps in the sequence shown in 3 stages:
Stage 1: Tighten the camshaft bearing cap bolts until finger-tight.
Stage 2: Tighten to 7 Nm (62 lb-in).
2.
Install the Camshaft Alignment Plate. 3.
Camshafts 1336
Install the timing chain on the intake camshaft drive gear. 4.
NOTE: The timing chain must be correctly engaged on the teeth of the crankshaft timing sprocket
and the intake camshaft drive gear in order to install the exhaust camshaft drive gear onto the exhaust
camshaft.
Position the exhaust camshaft drive gear in the timing chain and install the gear and bolt on the
exhaust camshaft.
Hand-tighten the bolt.
5.
NOTE: Releasing the tensioner arm will remove the slack from the timing chain.
Remove the M6 x 30 mm bolt from the upper front cover timing hole to release the tensioner arm.
6.
Using the flats on the camshaft to prevent camshaft rotation, tighten the exhaust camshaft drive gear
7.
Camshafts 1337
Install the upper timing hole plug in the engine front cover.
11.
Apply silicone gasket and sealant to the threads of the lower timing hole plug. 12.
Camshafts 1338
Install the lower timing hole plug in the engine front cover.

13.
Install the front RH wheel and tire. For additional information, refer to Section 204-04 . 15.
Install the VCT solenoid. For additional information, refer to Section 303-14A . 17.
Camshafts 1339
Camshafts 1340
Camshaft Phaser and Sprocket
Special Tool(s)
303-465 (T94P-6256-CH)
303-507
General Equipment
6 mm x 18 mm bolt
M6 x 30 mm bolt
Material
Item Specification
(Canada)
XO-5W20-QSP (US);
WSS-M2C945-A
TA-30
WSE-M4G323-A4
Removal
100-02 .
1.
If equipped, remove the 7 screws and the undbody cover. 3.
Camshaft Phaser and Sprocket 1341
303-14A .
4.
Dead Center (TDC).
6.
7.
9.
10.
collapse and create slack in the timing chain. Installing the M6 x 30 mm bolt into the upper front
cover timing hole will lock the tensioner arm in a retracted position and allow enough slack in the
timing chain for removal of the exhaust camshaft gear.
timing hole.
Have an assistant rotate the exhaust camshaft clockwise (using the flats of the camshaft) to

Insert the M6 x 30 mm bolt into the upper front cover timing hole to hold the tensioner arm in
the retracted position.

14.
15.
Remove the timing chain from the intake camshaft drive gear. 17.
NOTICE: Failure to follow the camshaft loosening procedure can result in damage to the intake
camshaft.
Remove the intake camshaft from the engine.
Loosen the intake camshaft bearing cap bolts, in the sequence shown, one turn at a time until
all tension is released from the camshaft bearing caps.

Remove the intake camshaft.
19.
Mark the camshaft phaser and sprocket and the camshaft for reference during installation. 20.
Place the camshaft in a soft-jawed vise. Remove the bolt and the camshaft phaser and sprocket. 21.
Installation
parts.
Position the camshaft in a soft-jawed vise. Install the camshaft phaser and sprocket and the bolt.

1.
NOTICE: Install the intake camshaft with the alignment slots in the camshafts lined up so the
NOTE: Lubricate the intake camshaft journals and bearing caps with clean engine oil.
Install the intake camshafts and bearing caps. Tighten the intake camshaft bearing caps in the
sequence shown in 3 stages:
Stage 1: Tighten the intake camshaft bearing cap bolts until finger-tight.
2.
Install the timing chain on the intake camshaft drive gear. 4.
camshaft.
exhaust camshaft.
5.
6.
7.
11.
Apply silicone gasket and sealant to the threads of the lower timing hole plug.

12.
13.
Install the VCT solenoid. For additional information, refer to Section 303-14A . 16.
Valve Train Components - Exploded View
1 6500 Valve tappet (16 required)
2 6518 Valve collet (16 required)
3 6514 Valve spring retainer (16 required)
4 6513 Valve spring (16 required)
5 6517 Valve seal (16 required)
p;
Valve Train Components - Exploded View 1350
Valve Springs
Special Tool(s)
Compressor, Valve Spring
303-300 (T87C-6565-A)
303-350 (T89P-6565-A)
303-472 (T94P-6565-AH)
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
Motorcraft XL-5 (aerosol) and/or
CRC SL3151
ESB-M1C93-B
Removal
100-02 .
1.
Remove the camshafts. For additional information, refer to Camshafts in this section. 2.
NOTE: If the camshafts and valve tappets are to be reusmark 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,
Remove and inspect the valve tappets. For additional information, refer to Section 303-00 .
3.
Remove the spark plugs. For additional information, refer to Section 303-07A . 4.
Valve Springs 1351
NOTICE: Use compressed air at 7-10 bars (100-150 psi). Do not disconnect the compressed air
from the cylinder until the valve spring, valve spring retainer and valve collet are installed. Any
loss of air pressure will allow the valve to fall into the cylinder.
Connect compressed air supply to the No. 1 cylinder.
5.
NOTE: Place all parts in order to one side.
Apply compressed air to the cylinder and remove the valve spring.
Using the Valve Spring Compressors, compress the valve spring and remove the valve collet,
using some grease and a small screwdriver.

Remove the valve spring retainer and the valve spring.
6.
Installation
NOTE: Check the seating of the valve collet.
Using the Valve Spring Compressors, install the valve spring.
Insert the valve spring and the valve spring retainer.
Compress the valve spring and install the valve collet using some grease and a small
screwdriver.

1.
Disconnect the compressed air supply. 2.
Repeat the appropriate removal and installation steps for all of the other cylinders. 3.
Install the spark plugs. For additional information, refer to Section 303-07A . 4.
Coat the valve tappets with clean engine oil and insert them. 5.
Install the camshafts. For additional information, refer to Camshafts in this section. 6.
Valve Springs 1352
Valve Springs 1353
Valve Seals
Special Tool(s)
303-300 (T87C-6565-A)
303-350 (T89P-6565-A)
303-472 (T94P-6565-AH)
Installer, Valve Stem Oil Seal
303-470 (T94P-6510-CH)
Remover, Valve Stem Oil Seal
303-468 (T94P-6510-AH)
Slide Hammer
307-005 (T59L-100-B)
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
Motorcraft XL-5 (aerosol) and/or
CRC SL3151
ESB-M1C93-B
Removal
100-02 .
1.
Valve Seals 1354
NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to
3.
NOTICE: Use compressed air at 7-10 bars (100-150 psi). Do not disconnect the compressed air
from the cylinder until the valve spring, valve spring retainer and valve collet are installed. Any
loss of air pressure will allow the valve to fall into the cylinder.
Connect compressed air supply to the No. 1 cylinder.
5.

6.
Using the Valve Stem Oil Seal Remover and Slide Hammer, remove and discard the valve seal. 7.
Installation
Install the valve stem seal installation sleeve. 1.
Using the Valve Stem Oil Seal Installer, install the valve seal. 2.
Valve Seals 1355
screwdriver.

3.
Valve Seals 1356
Valve Tappets
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
100-02 .
1.
3.
Coat the valve tappets with clean engine oil prior to installation.
4.
Valve Tappets 1357
Valve Tappets 1358
Cylinder Head
Special Tool(s)
303-465 (T94P-6256-CH)
Engine Support Bar
303-F072
Lifting Bracket, Engine
303-050 (T70P-6000)
Material
Item Specification
ZC-31-A
-
(Canada)
XO-5W20-QSP (US);
WSS-M2C945-A
TA-30
WSE-M4G323-A4
Remover
ZC-30
-
Degas Bottle
Cylinder Head 1359
1 8276 Degas bottle-to-radiator hose
2 8C351 Lower degas bottle hose
3 W707398 Degas bottle-to-fender bolt
4 W709603 Degas bottle-to-fender nut
5 8A080 Degas bottle
6 8100 Pressure relief cap
Engine Mount
1 W711879 Damper bolt
2 7458 Damper
3 W705936 Ground wire bolt
4 19A095 Ground wire
5 W711684 Engine mount bracket bolt
6 W520214 Engine mount bracket nut (2 required)
7 6A094 Engine mount bracket
8 W711578 Engine mount nut
9 W706496 Engine mount bolt (2 required)
Degas Bottle 1360
10 6F012 Engine mount
Camshafts
1 W500211 Variable Camshaft Timing (VCT) oil control solenoid
bolt
2 6M280 VCT oil control solenoid
3 W500301 Intake camshaft bearing cap bolt
4 6A258 Intake camshaft bearing cap
5 W703383 Camshaft bearing cap bolt (20 required)
6 6A284 Camshaft bearing cap (9 required)
7 6A272 Exhaust camshaft
8 6A267 Intake camshaft
Cylinder Head
1 W527372 Upper radiator hose clamp
Engine Mount 1361
2 8B274 Upper radiator hose
3 15161 EGR coolant tube clamp
4 - EGR coolant hose (part of 18C266)
5 W525958 Bypass hose clamp
6 8548 Bypass hose
7 - Heater hose clamp (part of 18C266)
8 18C266 Heater hose
9 14A464 EGR valve electrical connector (part of 12B637)
10 6065 Cylinder head bolt (10 required)
11 6050 Cylinder head
12 6051 Cylinder head gasket
Removal
100-02 .
1.
Release the fuel system pressure. For additional information, refer to Section 310-00 . 2.
Drain the engine cooling system. For additional information, refer to Section 303-03A . 4.
Disconnect the degas bottle-to-radiator hose from the degas bottle. 5.
Remove the nut and bolt and position the degas bottle to access the lower degas bottle hose. 6.
Disconnect the lower degas bottle hose and remove the degas bottle. 7.
Remove the generator. For additional information, refer to Section 414-00 . 8.
Remove the fuel supply rail. For additional information, refer to Section 303-04A . 9.
Remove the intake manifold. For additional information, refer to Intake Manifold in this section. 10.
Remove the exhaust manifold. For additional information, refer to Exhaust Manifold in this section. 11.
Remove the bolt and the engine mount damper from the engine mount bracket. 12.
Remove the bolt and the ground wire from the engine mount bracket. 13.
Cylinder Head 1362
Remove the engine mount bracket bolt. 14.
Install the Engine Lifting Brackets and a suitable length of chain to the threaded hole in the LH side
of the engine block.
15.
Using the Engine Support Bar and Engine Lifting Brackets, lift the engine 25 mm (0.98 in). 16.
Remove the nut, 2 bolts and the engine mount. 17.
Lower the engine 25 mm (0.98 in). 18.
Remove the 2 nuts and the engine mount bracket. 19.
Remove the timing drive components. For additional information, refer to Timing Drive Components
in this section.
20.
Remove the bolt and the Variable Camshaft Timing (VCT) solenoid. 23.
NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts. 24.
Cylinder Head 1363

25.
Disconnect the upper radiator hose, coolant bypass hose and heater hose from the engine coolant
outlet.
26.
Disconnect the EGR valve electrical connector. 27.
Disconnect the coolant hose from the EGR valve. 28.
Remove the 10 bolts and the cylinder head.
Discard the bolts.
Discard the cylinder head gasket.
29.
Installation
means to clean the sealing surfaces. These tools cause scratches and gouges that make leak
paths. Use a plastic scraping tool to remove all traces of the head gasket.
NOTICE: Observe all warnings or cautions and follow all application directions contained on
the packaging of the silicone gasket remover and the metal surface prep.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and
prepare the surfaces.
Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder
block in the following sequence.
Remove any large deposits of silicone or gasket material with a plastic scraper. 1.
Apply silicone gasket remover, following package directions, and allow to set for several
minutes.
2.
1.
Cylinder Head 1364
Remove the silicone gasket remover with a plastic scraper. A second application of silicone
gasket remover may be required if residual traces of silicone or gasket material remain.
3.
Apply metal surface prep, following package directions, to remove any traces of oil or
coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the
metal shiny. Some staining of the metal surfaces is normal.
4.
Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign
material is removed.
2.
Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion
and the cylinder block distortion. For additional information, refer to Section 303-00 .
3.
Apply silicone gasket and sealant to the locations shown. 4.
Install a new cylinder head gasket. 5.
NOTE: The cylinder head bolts are a torque-to-yield design and must not be reused. New cylinder
head bolts must be installed.
NOTE: Lubricate the bolts with clean engine oil prior to installation.
Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in 5 stages:
Stage 4: Turn 90 degrees.
Stage 5: Turn an additional 90 degrees.
6.
Connect the coolant hose to the EGR valve. 7.
Connect the EGR valve electrical connector. 8.
Connect the upper radiator hose, coolant bypass hose and heater hose to the engine coolant outlet. 9.
NOTE: Coat the valve tappets with clean engine oil prior to installation.
Install the valve tappets.
10.
Cylinder Head 1365
Stages 1: Tighten the camshaft bearing cap bolts until finger-tight.
Stages 2: Tighten to 7 Nm (62 lb-in).
Stages 3: Tighten to 16 Nm (142 lb-in).
11.
Install the VCT solenoid and bolt.
13.
Install the timing drive components. For additional information, refer to Timing Drive Components in
this section.
14.
Install the engine mount bracket and the 2 nuts.
15.
Using the Engine Support Bar and Engine Lifting Brackets, lift the engine 25 mm (0.98 in). 16.
Install the engine mount, nut and 2 bolts.
17.
Lower the engine 25 mm (0.98 in). 18.
Cylinder Head 1366
Install the engine mount bracket bolt.
19.
Install the ground wire-to-engine mount bracket and bolt.
20.
Install the engine mount damper and the bolt.
21.
Install the exhaust manifold. For additional information, refer to Exhaust Manifold in this section. 22.
Install the intake manifold. For additional information, refer to Intake Manifold in this section. 23.
Install the fuel supply rail. For additional information, refer to Section 303-04A . 24.
Install the generator. For additional information, refer to Section 414-00 . 25.
Connect the lower degas bottle hose to the degas bottle. 26.
Install the degas bottle and the nut and bolt.
27.
Connect the degas bottle-to-radiator hose. 28.
Fill and bleed the engine cooling system. For additional information, refer to Section 303-03A . 29.
Cylinder Head 1367
Engine Lubrication Components - Exploded View
Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch
Item
Part
Number Description
1 6714 Oil filter
2 14A464 Engine Oil Pressure (EOP) switch electrical connector
(part of 12C508)
3 9278 EOP switch
4 W500225 Oil filter adapter bolt (4 required)
5 6884 Oil filter adapter
6 6A636 Oil filter adapter gasket
Transmission Bolts for Oil Pan Removal
NOTE: Automatic transmission shown, manual transmission similar.
Item Description
Engine Lubrication Components - Exploded View 1368
Part
Number
1 W500121 Upper bellhousing-to-engine bolts
2 W500121 LH bellhousing-to-engine bolt (1 required for automatic
transmission, 2 required for manual transmission)
Oil Pan, Oil Pump Screen and Pickup Tube
1 W500121 RH engine-to-bellhousing bolts
2 W500235 Bellhousing-to-oil pan bolt (2 required)
3 W500121 Oil pan-to-bellhousing bolt (2 required)
5 940604 Engine front cover-to-oil pan stud bolt
6 W500215 Engine front cover-to-oil pan bolt (3 required)
9 6675 Oil pan
10 W706282 Oil pump screen and pickup tube bolt (2 required)
11 6622 Oil pump screen and pickup tube
12 6625 Oil pump screen and pickup tube gasket
Transmission Bolts for Oil Pan Removal 1369
Oil Pump
1 W703651 Oil pump drive chain tensioner shoulder bolt
2 6C271 Oil pump drive chain tensioner
3 6A895 Oil pump drive chain
4 W704397 Oil pump sprocket bolt
5 6652 Oil pump sprocket
6 W703647 Oil pump bolt (4 required)
7 6600 Oil pump
Oil Pump 1370
Oil Filter Adapter
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
100-02 .
1.
Remove the oil filter.
To install, lubricate the oil filter gasket with clean engine oil and tighten the oil filter
three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.

3.
Disconnect the Engine Oil Pressure (EOP) switch electrical connector. 4.
NOTE: Discard the gasket.
Remove the 4 bolts and the oil filter adapter.
5.
Oil Filter Adapter 1371
Engine Oil Pressure (EOP) Switch
Material
Item Specification
TA-24
WSK-M2G350-A2
All vehicles
100-02 .
1.
If equipped,ove the 7 screws and the underbody cover. 2.
Vehicles equipped with manual transaxle
Remove the 2 bolts and position the clutch slave cylinder aside.
3.
All vehicles
Remove the EOP switch.
5.
Apply thread sealant to the EOP switch threads.
6.
Engine Oil Pressure (EOP) Switch 1373
Oil Pan
Material
Item Specification
ZC-31-A
-
(Canada)
XO-5W20-QSP (US);
WSS-M2C945-A
TA-30
WSE-M4G323-A4
Removal
All vehicles
100-02 .
1.
Remove the Ai (ACL). For additional information, refer to Section 303-12A . 2.
Automatic transmission
Remove the battery tray. For additional information, refer to Section 414-01 . 3.
All vehicles
NOTICE: To prevent damage to the transmission, do not loosen the transmission-to-engine bolts
more than 5 mm (0.19 in).
Loosen the 3 upper transaxle-to-engine bolts 5 mm (0.19 in).
4.
Loosen the 1 (automatic transmission) or 2 (manual transmission) LH bellhousing-to-engine bolt(s) 5
mm (0.19 in).
6.
Oil Pan 1375
Loosen the RH engine-to-bellhousing bolt and stud bolt 5 mm (0.19 in). 7.
Remove the 2 oil pan-to-bellhousing bolts. 8.
Remove the bellhousing-to-oil pan bolt. 9.
Slide the transmission rearward 5 mm (0.19 in). 10.
11.
Remove the 3 engine front cover-to-oil pan bolts and the stud bolt. 12.
Remove the 13 bolts and the oil pan. 13.
Installation
All vehicles
Clean and inspect all mating surfaces.
1.
leakage.
Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan-to-engine block and to the
oil pan-to-engine front cover mating surface.
2.
Position the oil pan onto the engine and install the oil pan bolts finger-tight. 3.
Install the 3 engine front cover-to-oil pan bolts and the stud bolt.
4.
Tighten the oil pan bolts in the sequence shown. 5.
Oil Pan 1376
Alternate tightening the 1 LH and 1 RH lower bolts to slide the transmission and engine together.
6.
Tighten the remaining LH bolt (manual transmission) and RH stud bolt.
7.
Install the bellhousing-to-oil pan bolt.
8.
Install the 2 oil pan-to-bellhousing bolts.
9.
Tighten the 3 top bellhousing-to-engine bolts.
11.
Automatic transmission
Install the battery tray. For additional information, refer to Section 414-01 . 12.
All vehicles
Install the ACL assembly. For additional information, refer to Section 303-12A . 13.
Oil Pan 1377
Oil Pan 1378
Oil Pump Screen and Pickup Tube
100-02 .
1.
Remove the oil pan. For additional information, refer to Engine Lubrication Components - Exploded
View and Oil Pan in this section.
2.
NOTE: Discard the gasket and clean and inspect the gasket mating surfaces.
Remove the 2 bolts and the oil pump screen and pickup tube.
3.
Oil Pump Screen and Pickup Tube 1379
Oil Pump
Material
Item Specification
ZC-31-A
-
(Canada)
XO-5W20-QSP (US);
WSS-M2C945-A
TA-30
WSE-M4G323-A4
Removal
With the engine in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .
1.
section.
2.
Drain the engine oil, then install the drain plug.
3.
6.
Remove the oil pump drive chain tensioner.
Release the tension on the tensioner spring. 1.
Remove the tensioner and the 2 shoulder bolts. 2.
7.
Oil Pump 1380
Remove the chain from the oil pump sprocket. 8.
Remove the bolt and oil pump sprocket. 9.
Remove the 4 bolts and the oil pump. 10.
Installation
NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface prep.
Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in 2 stages:
1.
Install the oil pump sprocket and bolt.
2.
Install the chain onto the oil pump sprocket. 3.
Install the oil pump drive chain tensioner shoulder bolt.
4.
Install the oil pump chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt.
5.
Install the oil pump screen and pickup tube and the 2 bolts.
6.
paths. Use a plastic scraping tool to remove traces to sealant.
7.
Oil Pump 1381
Clean all mating surfaces with metal surface prep.
leakage.
Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan.
Position the oil pan onto the engine and install the 2 rear oil pan bolts finger-tight.
8.
Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the
engine block.
9.
Install the remaining oil pan bolts.
Tighten in the sequence shown to 25 Nm (18 lb-ft).
10.
11.
Oil Pump 1382
Oil Pump 1383
Exhaust Manifold
Item
Part
Number Description
1 14A464 Heated Oxygen Sensor (HO2S) electrical connector
(part of 12C508)
2 W713299 Exhaust manifold heat shield bolt (4 required)
3 9N454 Exhaust manifold heat shield
4 - Block heater wire harness retainer (if equipped)
5 W713652 Exhaust manifold nut (7 required)
6 9430 Exhaust manifold
7 9448 Exhausfold gasket
8 W704474 Cylinder head stud (7 required)
Removal
100-02 .
1.
Remove the exhaust flexible pipe. For additional information, refer to Section 309-00 . 2.
Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 3.
Remove the 4 exhaust manifold heat shield bolts and the heat shield. 4.
If equipped, detach the block heater wire harness retainer from the exhaust manifold stud. 5.
Remove and discard the 7 exhaust manifold nuts. 6.
Remove the exhaust manifold and discard the exhaust manifold gasket. 7.
Remove and discard the 7 cylinder head studs. 8.
Clean and inspect the exhaust manifold. For additional information, refer to Section 303-00 . 9.
Installation
Exhaust Manifold 1384
Install the 7 new cylinder head studs.
1.
NOTICE: Failure to tighten the catalytic converter nuts to specification before installing the
converter bracket bolts will cause the converter to develop an exhaust leak.
NOTICE: Failure to tighten the catalytic converter nuts to specification a second time will cause
the converter to develop an exhaust leak.
Install a new exhaust manifold gasket, the exhaust manifold and 7 new nuts in the sequence shown in
2 stages:
2.
If equipped, attach the block heater wire harness retainer to the exhaust manifold stud. 3.
Install the exhaust manifold heat shield and the 4 bolts.
4.
Connect the HO2S electrical connector. 5.
Install the exhaust flexible pipe. For additional information, refer to Section 309-00 . 6.
Exhaust Manifold 1385
Engine Mount
Special Tool(s)
Engine Support Bar
303-F072
1 W711879 Engine mount damper bolt
2 7458 Engmount damper
6 W520214 Engine mount bracket nut (2 required)
7 6061 Engine mount bracket
8 W711578 Engine mount nut
10 6038 Engine mount
100-02 .
1.
Remove the engine coolant degas bottle. For additional information, refer to Section 303-03A . 2.
Install the Engine Support Bar to the front and rear engine lifting eyes. 3.
Engine Mount 1386
Remove the bolt and the engine mount damper.
4.
Remove the bolt and the ground wire.
5.
Remove the engine mount bracket bolt.
6.
Use the Engine Support Bar to raise the engine 25 mm (0.98 in). 7.
Remove the 2 engine mount bracket nuts.
8.
Remove the nut, 2 bolts and the engine mount.
9.
NOTE: If the engine mount bracket is to be removed, the engine must be lowered to avoid contact
between the A/C tubes and the engine mount bracket.
Use the Engine Support Bar to lower the engine 25 mm (0.98 in).
Remove the engine mount bracket.
10.
Engine Mount 1387
Engine Mount 1388
REMOVAL Procedure revision date: 06/03/2011
Engine - Automatic Transaxle
Special Tool(s)
Disconnect Tool, Transmission Cooler Line
307-569
2,200# Floor Crane, Fold Away
300-OTC1819E or equivalent
Powertrain Lift
Remover, Tie-Rod End
211-105
Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
Adjustable Grip Arm, 1735A
100-02 .
1.
Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to
Section 303-12A .
3.
Recover the A/C system. For additional information, refer to Section 412-00A . 4.
Remove the 2 nuts and the battery cables from the positive battery cable. 6.
Engine - Automatic Transaxle 1389
Disconnect the engine wiring harness electrical connector. 7.
Remove the bolt and the ground wire from the body. 8.
Detach the 2 negative battery cable pin-type retainers from the transaxle mount and battery tray
bracket.
9.
Disconnect the 2 engine harness electrical connectors. 10.
11.
Remove the 2 nuts and the steering joint cover. 12.
NOTICE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or
damage to the clockspring can occur. If there is evidence that the intermediate shaft has
rotated, the clockspring must be removed and recentered. For additional information, refer to
Section 501-20B .
Discard the bolt.
13.
Drain the transaxle. For additional information, refer to Section 307-01A . 15.
Drain the cooling system. For additional information, refer to Section 303-03A . 16.
NOTICE: The steering gear-to-dash seal must be removed or it will be damaged when lowering
the subframe.
Release the 4 clips (2 shown) and slide the steering gear-to-dash seal off of the steering gear and into
the passenger compartment.
17.
Remove the engine roll restrictor bolt. 18.
Remove the 4 screws and position the RH fender splash shield aside. 19.
Remove the 6 pin-type retainers (4 shown) and the RH splash shield. 20.
Remove the 4 screws and position the LH fender splash shield aside. 21.
Remove the 6 pin-type retainers (4 shown) and the LH splash shield. 22.
Remove the LH halfshaft and the intermediate shaft. For additional information, refer to Section
205-04 .
23.
Disconnect the 2 Electronic Power Assist Steering (EPAS) system electrical connectors. 24.
Detach the 2 EPAS system wiring harness pin-type retainers from the subframe. 25.
Detach the EPAS system wiring harness pin-type retainer from the subframe under the LH fender
splash shield.
26.
Remove the bolt and the EPAS system wiring harness ground. 27.
Remove the cotter pins and nuts from the tie-rod ends.
28.
Using the Tie-Rod End Remover, separate the tie-rod ends from the steering knuckles.
29.
Remove the nuts and separate the sway bar links from the struts.
30.
Position the Powertrain Lift under the subframe assembly. 31.
Remove the subframe bracket-to-body bolts.
32.
Remove the subframe nuts and the subframe brackets.
33.
Remove the front subframe nuts.
34.
Lower the subframe assembly from the vehicle. 35.
Remove the engine oil pan drain plug and drain the engine oil.
Install the drain plug and tighten to 28 Nm (21 lb-ft).
36.
Remove the engine oil filter. 37.
Disconnect the crankcase vent tube from the valve cover. 39.
Depress the locking ring and disconnect the brake booster vacuum supply tube from the intake
manifold.
40.
Disconnect the fuel vapor return tube. 41.
Disconnect the fuel supply tube quick connect coupling. For additional information, refer to Section
310-00 .
42.
Detach the coolant hose retainer. 43.
Disconnect the upper radiator and heater hoses from the coolant outlet and disconnect the heater hose
in-line connector.
44.
Disconnect the shift cable from the transaxle manual lever and remove the transaxle shift cable from
the bracket.
45.
Remove the 2 secondary latches from the transaxle fluid cooler tubes. 46.
Using the Transmission Cooler Line Disconnect Tool, disconnect the 2 transaxle fluid cooler tubes (1
shown).
47.
Remove the bolt and the ground wire from the engine mount. 48.
Remove the A/C tube/windshield washer reservoir bracket bolt. 49.
Remove the nut and disconnect the A/C tube.
Discard the O-ring seal.
50.
Detach the coolant vent hose retaining clip from the A/C tube. 51.
Remove the nut and disconnect the upper A/C tube from the condenser.
52.
Detach the Knock Sensor (KS) electrical connector from the intake manifold. 53.
Remove the lower radiator hose from the thermostat housing. 54.
If equipped, position the block heater shield aside and disconnect the block heater electrical
connector.
Detach the 8 block heater wiring harness retainers (1 shown) and remove the block heater
wiring harness.

55.
Detach the lower radiator hose pin-type retainer from the cooling fan shroud. 56.
Remove the 2 bellhousing-to-oil pan bolts. 57.
NOTE: Position a block of wood under the transaxle.
Install the Powertrain Lift and Adjustable Grip Arm onto the engine.
Raise the engine and transaxle 25.4 mm (1 in) to neutralize the engine and transaxle mounts.
59.
Remove the nut and the transaxle mount through bolt. 60.
Remove the bolt, 2 nuts and the engine mount bracket. 61.
Lower the engine and transaxle from the vehicle. 62.
Disconnect the A/C compressor electrical connector. 63.
Detach the A/C compressor wiring harness pin-type retainer from the intake manifold. 64.
Remove the 2 nuts and disconnect the starter motor wires. 65.
Remove the nut and the ground wire from the starter motor stud bolt. 66.
Remove the bolt, stud bolt and the starter motor. 67.
Remove the starter motor isolator. 68.
Press the locking tab to release the generator air duct and remove. 69.
Disconnect the generator electrical connection. 70.
Remove the nut and the generator B+ wiring harness. 71.
Detach the 4 wiring harness retainers (3 shown) from the valve cover stud bolts. 72.
Remove the 4 torque converter nuts. 73.
Install the Floor Crane and Spreader Bar and remove the engine and transaxle from the Powertrain
Lift table.
74.
Remove the remaining bellhousing-to-engine retainers.
Separate the engine and transaxle.
75.
Engine - Manual Transaxle
Special Tool(s)
Powertrain Lift
211-105
Spreader Bar
100-02 .
1.
Section 303-12A .
3.
Engine - Manual Transaxle 1403
Remove the bolt and the ground wire from the body. 8.
Detach the 2 negative battery cable pin-type retainers from the transaxle mount and battery tray
bracket.
9.
Disconnect the 2 engine harness electrical connector. 10.
Use a steering wheel holding device (such as Hunter 28-75-1 or equivalent).
11.
Section 501-20B .
Discard the bolt.
13.
the subframe.
16.
205-04 .
22.
Disconnect the 2 Electronic Power Assist Steering (EPAS) system electrical connectors. 23.
splash shield.
25.
Remove the bolt and the EPAS system wiring harness ground. 26.
27.
28.
29.
31.
Remove the rear subframe nuts and the subframe brackets.
32.
33.
Remove the engine oil pan drain plug and drain the engine oil.
35.
Disconnect the crankcase vent tube from the valve cover. 38.
Depress the locking ring and disconnect the brake booster vacuum supply tube from the intake
manifold.
39.
Disconnect the fuel vapor return tube. 40.
Disconnect the fuel supply tube quick connect coupling. For additional information, refer to Section
310-00 .
41.
Detach the coolant hose retainer. 42.
Disconnect the upper radiator and heater hoses from the coolant outlet and disconnect the heater hose
in-line connector.
43.
Disconnect the transaxle control cables from the control levers.
Detach the control cables from the bracket.
44.
Remove the 2 clutch tube bracket bolts. 45.
Remove the 2 bolts and position the clutch slave cylinder aside. 46.
Remove the bolt and the ground wire from the engine mount. 47.
Remove the A/C tube/windshield washer reservoir bracket bolt. 48.
49.
Detach the coolant vent hose retaining clip from the A/C tube. 50.
Remove the nut and disconnect the upper A/C tube from the condenser.
51.
Detach the Knock Sensor (KS) electrical connector from the intake manifold. 52.
Remove the lower radiator hose from the thermostat housing. 53.
If equipped, position the block heater shield aside and disconnect the block heater electrical
connector.
Detach the 8 block heater wiring harness retainers (1 shown) and remove the block heater
wiring harness.

54.
Detach the lower radiator hose pin-type retainer from the cooling fan shroud. 55.
Remove the bellhousing-to-oil pan bolt. 56.
58.
Remove the 2 transaxle mount bolts. 59.
Remove the bolt, 2 nuts and the motor mount bracket. 60.
Detach the A/C compressor wiring harness pin-type retainer from the intake manifold. 63.
Remove the 2 nuts and disconnect the starter wires. 64.
Remove the nut from the starter motor stud bolt. 65.
Remove the bolt, stud bolt and the starter. 66.
Remove the starter motor isolator. 67.
Press the locking tab to release the generator air duct and remove. 68.
Disconnect the generator electrical connection. 69.
Remove the nut and the generator wiring harness. 70.
Detach the 4 wiring harness retainers (3 shown) from the valve cover stud bolts. 71.
Install the Floor Crane and Spreader Bar and remove the engine and transaxle from the Powertrain
Lift table.
72.
Remove the bellhousing-to-engine retainers.
Separate the engine and transaxle.
73.
Manual
DISASSEMBLY Procedure revision date: 06/03/2011
Engine
Special Tool(s)
303-465 (T94P-6256-CH)
Engine Stand
303-1416
Installer, Connecting Rod
303-462 (T94P-6136-AH)
Remover, Oil Seal
303-409 (T92C-6700-CH)
303-507
including any material created while cleaning gasket surfaces that enters the oil passages, coolant
passages or the oil pan, can cause engine failure.
NOTE: For additional information, refer to the exploded views under the Engine Assembly procedure in this
section.
Vehicles with manual transaxle
WARNING: The clutch disc and clutch pressure plate are heavy and may fall if not held
when the bolts are removed. Failure to follow this instruction may result in serious personal
injury.
NOTICE: Loosen the 6 bolts evenly to prevent pressure plate damage.
Remove the 6 bolts, clutch pressure plate and clutch disc.
1.
Engine 1417
Vehicles with automatic transaxle
All vehicles
Mount the engine on a suitable Engine Stand. 4.
Using the hex feature, rotate the accessory drive belt tensioner clockwise and remove the accessory
drive belt from the engine.
5.
Remove the 2 bolts and the tensioner. 6.
Remove the bolt and the accessory drive belt idler pulley. 7.
Engine 1418
Remove the 3 bolts and the coolant pump.
Remove and discard the O-ring seal.
9.
Disconnect the Knock Sensor (KS) electrical connector. 10.
Remove the 2 bolts and the accessory drive belt idler pulley and bracket. 11.
Disconnect the coolant hose from the EGR valve. 12.
Engine 1419
Remove the coolant tube retainer from the intake manifold. 13.
Remove the 3 bolts and the thermostat housing assembly. 14.
Disconnect the Crankshaft Position (CKP) sensor electrical connector and detach the wiring harness
pin-type retainer.
15.
Disconnect the Heated Oxygen Sensor (HO2S) electrical connector and detach the 2 wiring harness
retainers from the generator stud bolts.
16.
Engine 1420
Disconnect the Variable Camshaft Timing (VCT) electrical connector and detach the wiring harness
retainer from the valve cover stud bolt.
17.
Remove the 2 nuts, 1 bolt and the generator. 18.
Remove the 2 generator studs. 19.
Remove the 2 bolts and the exhaust flexible pipe bracket. 20.
Remove the 4 exhaust manifold heat shield bolts and the heat shield. 21.
Remove and discard the 7 exhaust manifold nuts. 22.
Engine 1421
Remove the exhaust manifold and discard the exhaust manifold gasket. 23.
Clean and inspect the exhaust manifold. For additional information, refer to Section 303-00 . 24.
Remove the bolt and the A/C manifold tube.
Discard the 2 O-ring seals.
26.
Remove the 3 bolts and the A/C compressor. 27.
Discard the gasket.
29.
Engine 1422
Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector. 30.
Disconnect the electronic throttle control and Evaporative Emission (EVAP) canister purge valve
electrical connectors.
31.
Detach the 2 wiring harness retainers from the intake manifold. 32.
Disconnect the radio capacitor electrical connector. 34.
Engine 1423
Disconnect the 4 fuel injector electrical connectors.
Detach the 2 wiring harness retainers and remove the wiring harness assembly.
35.
Disconnect the 4 ignition coil-on-plugs and Camshaft Position (CMP) sensor electrical connectors. 36.
Position the rubber boot aside and disconnect the Cylinder Head Temperature (CHT) sensor electrical
connector and remove the wiring harness.
37.
Remove the fuel rail insulator. 38.
Remove the nut and the radio capacitor. 39.
Engine 1424
Remove the 2 stud bolts, fuel rail and fuel injectors as an assembly. 40.
Remove the 7 bolts (3 shown) and position the intake manifold aside. 41.
damage.
Squeeze the 2 crankcase vent oil separator tube tabs and disconnect the tube from the intake manifold.
42.
Remove the EGR tube. 43.
Disconnect the bypass hose. 44.
Engine 1425
Remove the bypass hose from the coolant outlet. 45.
Remove the bolt and the KS . 46.
Remove the 8 bolts and the crankcase vent oil separator. 47.
If equipped, remove the block heater. 48.
Engine 1426
NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and
ease removal.
Remove the 4 bolts and the 4 coil-on-plugs.
50.
Remove the 14 retainers and the valve cover. 51.
NOTICE: Failure to position the No. 1 position at Top Dead Center (TDC) can result in damage
Dead Center (TDC).
53.
NOTICE: The Camshaft Alignment Plate is for camshaft alignment only. Using this to prevent
engine rotation can result in engine damage.
54.
Engine 1427
must remain at the TDC position during disassembly.
56.
The diamond washer must be replaced, remove and discard the diamond washer. If the
Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft
pulley.
Use an air impact wrench to remove the crankshaft pulley bolt.
57.
Engine 1428
seal.
58.
Remove the 22 bolts and the engine front cover. 59.
2.
60.
Engine 1429
Remove the RH timing chain guide. 62.
Remove the 2 bolts and the LH timing chain guide. 64.
camshaft sprocket.
65.
Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the intake camshaft
sprocket.
66.
Engine 1430
Remove the tensioner and the 2 shoulder bolts. 2.
67.
NOTE: Remove and discard the crankshaft sprocket diamond washer located behind the crankshaft
sprocket.
NOTE: The oil pump chain sprocket must be held in place.
Remove the oil pump chain and sprockets.
Remove the bolt. 1.
Remove the chain and sprockets. 2.
68.
Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference. 69.
Remove the bolt and the VCT solenoid. 70.
Engine 1431
Remove the plug and the VCT system oil filter from the intake camshaft thrust cap. 71.
camshafts.

72.
73.
Remove the cylinder head.
Remove and discard the 10 cylinder head bolts.
Remove and discard the cylinder head gasket.
74.
75.
Remove the 2 cylinder head alignment dowels. 76.
Engine 1432
Remove the 6 bolts and the rear crankshaft seal. 78.
Remove the 2 bolts, oil pump pickup tube and gasket. 79.
Make sure the Crankshaft TDC Timing Peg is still installed and the engine is still at Top Dead Center
(TDC).
Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the
Crankshaft TDC Timing Peg.

81.
Engine 1433
NOTICE: Due to the precision interior construction of the balancer unit, it should not be
disassembled.
83.
Engine 1434
Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or
carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's
instructions.
85.
NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in
numerical order for correct orientation for reassembly.
Remove the connecting rod cap bolts and cap.
86.
NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.
Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine
block.

87.
Remove the bolts in the sequence shown.
Remove the main bearing beam.
Discard the bolts.
88.
Remove the crankshaft from the engine block. 89.
NOTE: If the main bearings are being reused, mark them in order for correct orientation and
reassembly.
90.
Engine 1435
Remove the main bearings from the main bearing beam.
reassembly.
NOTE: The center bulkhead has the thrust bearing.
Remove the main bearings from the cylinder block.
91.
NOTE: If the oil squirters are being reused, mark them in order for correct location during
reassembly.
NOTE: The front bulkhead does not have an oil squirter.
Remove the 4 oil squirters.
92.
Inspect the cylinder block, main bearing beam, pistons and connecting rods. For additional
93.
Engine 1436
Engine 1437
DISASSEMBLY AND ASSEMBLY OF
SUBASSEMBLIES
Cylinder Head
Special Tool(s)
303-300 (T87C-6565-A)
303-350 (T89P-6565-A)
303-472 (T94P-6565-AH)
303-470 (T94P-6510-CH)
303-468 (T94P-6510-AH)
Slide Hammer
307-005 (T59L-100-B)
Material
Item Specification
Motorcraft SAE
5W-20 Premium
Synthetic Blend
Motor Oil (US);
Motorcraft SAE
5W-20 Super
Premium Motor Oil
(Canada)
XO-5W20-QSP
(US);
CXO-5W20-LSP12
(Canada)
WSS-M2C945-A
Cylinder Head 1438
Multi-Purpose
Grease
Motorcraft XL-5
(aerosol) and/or
CRC SL3151
Item
Part
Number Description
1 W500015 Coolant
outlet bolt (4
required)
2 8K556 Coolant
outlet
3 - Coolant
outlet gasket
(part of
8K556)
4 W500225 EGR valve
bolt (2
required)
5 9D475 EGR valve
6 9D476 EGR valve
gasket
7 6G004 Cylinder
Head
Temperature
(CHT)
sensor
8 12405 Spark plug (4
required)
9 6518 Valve collet
(16 required)
10 6514 Valve spring
retainer (16
required)
11 6513 Valve spring
(16 required)
12 6517 Valve seal
(16 required)
13 6505 Intake valve
(8 required)
14 6507 Exhaust
valve (8
required)
15 6049 Cylinder
head
Disassembly
NOTE: If the components are to be
reinstalled, they must be installed in the
same positions. Mark the components
removed for locations.
Remo the 4 bolts and the coolant
outlet.
1.
Cylinder Head 1439
Discard the gasket.
Remove the 2 bolts and the EGR
valve.
Discard the gasket.
2.
Remove the Cylinder Head
Temperature (CHT) sensor.
3.
NOTICE: Only use hand tools
when removing or installing the
spark plugs, damage can occur
to the cylinder head or spark
plug.
Remove the spark plugs.
4.
NOTE: Use a small screwdriver
and grease to remove the valve
collets.
Using the Valve Spring
Compressors, compress the valve
springs and remove the valve
collets, valve spring retainers and
the valve springs.
5.
Inspect the components, if
necessary. For additional
information, refer to Section
303-00 .
6.
Cylinder Head 1440
Remove the valves. 7.
Using the Valve Stem Oil Seal
Remover and Slide Hammer,
remove and discard the valve
seals.
8.
Inspect the valves. For additional
information, refer to Section
303-00 . Install new parts, as
necessary.
9.
Assembly
NOTE: Coat the valve stems with
clean engine oil.
Install the valves.
1.
NOTE: Use the protector
provided with the replacement kit
to prevent damage to the valve
seals. Lubricate the valve stems
and guides with clean engine oil.
Using the Valve Stem Oil Seal
Installer, install the valve seals.
2.
NOTE: Check the seating of the
valve collets.
Using the Valve Spring
Compressors, install the valve
springs.
Insert the valve springs
and the valve spring
retainers.

3.
Cylinder Head 1441
Compress the valve
springs and install the
valve collets, using grease
and a small screwdriver.

NOTICE: Only use hand tools
when removing or installing the
spark plugs, damage can occur
to the cylinder head or spark
plug.
Install the spark plugs.
Tighten to 12 Nm (106
lb-in).

4.
Install the CHT sensor.
lb-in).

5.
Install the EGR valve, using a new
gasket.
lb-in).

6.
Using a new gasket, install the
coolant outlet and bolts.
lb-in).

7.
Cylinder Head 1442
Cylinder Head 1443
SUBASSEMBLIES
Piston
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
1 6150 Piston compression upper ring
2 6152 Piston compression lower ring
3 6159 Piston oil control upper segment ring
4 6161 Piston oil control spacer
5 6159 Piston oil control lower segment ring
6 6140 Piston pin retainer
8 6135 Piston pin
9 6200 Connecting rod
10 6110 Piston
Disassembly
Remove the piston rings from the piston.
Discard the piston rings.
1.
Remove the 2 piston pin retainers and the piston pin. 2.
Piston 1444
NOTE: If the piston and connecting rod are to be reinstalled, they must be assembled in the same
orientation. Mark the piston orientation to the connecting rod for reassembly.
Separate the piston from the connecting rod.
3.
Clean and inspect the piston and connecting rod. For additional information, refer to Section 303-00 . 4.
Assembly
NOTE: The arrow on the top of the piston points towards the front of the engine.
Align the piston-to-connecting rod orientation marks, and position the connecting rod in the piston.
1.
Lubricate the piston pin and pin bore with clean engine oil. 2.
Install the piston pin in the piston and connecting rod assembly. 3.
Install the piston pin retaining clips in the piston. 4.
Lubricate the piston and the new piston rings with clean engine oil. 5.
NOTE: The piston compression upper and lower ring should be installed with the paint mark on the
outside diameter circumference of the ring to be positioned on the right side of the ring gap. The
lower compression ring needs to be installed with the undercut side downward.
NOTE: The upper and lower compression ring gaps are not controlled for installation.
Install the piston rings onto the piston as shown.
Piston pin 1.
Upper oil control ring gap location 2.
Lower oil control ring gap location 3.
Center line of the piston pin bore and the expander gap 4.
6.
Piston 1445
Piston 1446
ASSEMBLY Procedure revision date: 06/03/2011
Engine
Special Tool(s)
Aligner, Clutch Disc
308-006 (T71P-7137-H)
303-465 (T94P-6256-CH)
Aligner, Crankshaft Sens
303-1417
Compressor, Piston Ring
303-D032 (D81L-6002-C)
100-002 (TOOL-4201-C)
303-1416
303-096 (T74P-6150-A)
303-462 (T94P-6136-AH)
303-328 (T88P-6701-B1)
Spreader Bar
303-507
General Equipment
6 mm x 18 mm bolt
Engine 1447
Material
Item Specification
High Temperature 4x4 Front Axle
and Wheel Bearing Grease
XG-11
WSS-M1C267-A1
ZC-31-A
-
(Canada)
XO-5W20-QSP (US);
WSS-M2C945-A
Engine Coolant
VC-10-A2 (US); CVC-10-A
(Canada)
WSS-M97B55-A
Motorcraft Orange
Antifreeze/Coolant Concentrated
(Canada)
WSS-M97B44-D
Silicone Brake Caliper Grease and
Dielectric Compound
XG-3-A
ESE-M1C171-A
TA-30
WSE-M4G323-A4
Remover
ZC-30
-
Lower Engine Block (View 1)
Lower Engine Block (View 1) 1448
1 6010 Cylinder block
2 6K318 Crankshaft rear oil seal and retainer
4 6675 Oil pan
5 6714 Engine oil filter
7 9278 Engine Oil Pressure (EOP) switch
9 6A785 Crankcase vent oil separator
10 8575 Thermostat assembly
1 6161 Piston oil control spacer (4 required)
2 6150 Piston compression upper ring (4 required)
3 6152 Piston compression lower ring (4 required)
4 6159 Piston oil control upper segment ring (4 required)
5 6159 Piston oil control lower segment ring (4 required)
6 6140 Piston pin retainer (8 required)
7 6135 Piston pin (4 required)
8 6200 Connecting rod (4 required)
9 6211 Connecting rod upper bearing (4 required)
10 6110 Piston (4 required)
11 6211 Connecting rod lower bearing (4 required)
12 6210 Connecting rod cap (4 required)
14 6333 Cylinder block crankshaft main bearing (5 required)
15 6303 Crankshaft
16 6333 Crankshaft main bearing beam bearing (5 required)
17 6F098 Main bearing beam
18 6K360 Balance shaft assembly
Front Engine Block
Front Engine Block 1450
1 6B209 Accessory drive belt tensioner
2 10300 Generator
3 8501 Coolant pump and pulley
4 6C315 Crankshaft Position (CKP) sensor
5 6A340 Crankshaft pulley bolt
7 6C348 Smooth idler pulley
8 19A216 Idler pulley and bracket
11 6K254 Timing chain tensioner
12 6K255 Timing chain tensioner arm
13 6268 Timing chain
14 6K297 Timing chain guide
15 6C271 Oil pump chain tensioner
16 6A895 Oil pump chain
17 6652 Oil pump drive gear
19 6306 Crankshaft sprocket
21 6600 Oil pump
Cylinder Head
1 12A366 Coil-on-plug assembly (4 required)
2 6766 Oil filler cap
3 12K073 Camshaft Position (CMP) sensor
4 6M293 Valve cover
5 6K260 Valve cover gasket
6 6M280 Variable Camshaft Timing (VCT) solenoid
7 6A284 Camshaft bearing cap (9 required)
8 6A258 Camshaft bearing cap
9 6A272 Camshaft (exhaust)
10 6A271 Camshaft (intake)
11 6C251 Camshaft sprocket
12 6C525 VCT actuator
17 6A517 Valve stem seal (16 required)
18 6G004 Cylinder Head Temperature (CHT) sensor
19 12405 Spark plug (4 required)
Cylinder Head 1452
22 6505 Exhaust valve (8 required)
23 6507 Intake valve (8 required)
24 6051 Head gasket
26 9448 Exhaust manifold gasket
28 9N454 Exhaust manifold heat shield
Intake Manifold
1 9288 Fuel supply tube
2 8K556 Coolant outlet
3 9D475 EGR valve
4 9F991 Throttle Body (TB)
7 12A699 Knock Sensor (KS)
9 9439 Intake manifold gasket
10 8A582 Coolant bypass hose
12 9F593 Fuel injector (4 required)
13 9H487 Fuel rail
14 - Fuel rail insulator
NOTICE: During engine repair procedures, cleanliness is extremely important. All parts must be
thoroughly cleaned and any foreign material, including any material created while cleaning gasket
surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.
NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine
block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in
determining if the engine components will require replacement. For additional information, refer to Section
303-00 .
All vehicles
NOTE: If the oil squirters are being reused, they must be installed in the same location as marked
during disassembly.
NOTE: The front bulkhead does not have oil squirter.
Install the 4 oil squirters.
1.
Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the
smallest diameter for each journal.
2.
Position the main bearing beam in the engine block with the main bearing beam mounted flush with
the rear face of the engine block.
3.
Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts.
Tighten the bolts in the sequence shown in 3 stages.
Stage 3: Tighten an additional 90 degrees.
4.
Measure each crankshaft block main bearing bore diameter.
Remove the bolts and the main bearing beam.
Discard the main bearing beam bolts.
5.
Using the chart, select the crankshaft main bearings. 6.
NOTICE: The rod cap installation must keep the same orientation as marked during
disassembly or engine damage may occur.
Using the original connecting rod cap bolts, install the connecting caps and bolts.
Tighten the bolts in 2 stages.
7.
Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each
connecting rod.
Remove the bolts and the connecting rod cap.
Discard the connecting rod cap bolts.
8.
Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.
Record the smallest measurement for each connecting rod journal.
9.
Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal. 10.
NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint
and foreign material. Also, make sure the coolant and oil passages are clear.
NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation
as noted during disassembly.
NOTE: The center bulkhead is the thrust bearing.
Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main
bearings in the cylinder block.
11.
Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main
bearings in the main bearing beam.
12.
Lubricate journals on the crankshaft with clean engine oil. 13.
Position the crankshaft in the cylinder block. 14.
Lubricate the 10 main bearing beam side fit surfaces (front 2 shown) with clean engine oil. 15.
Lubricate the crankshaft bearing journals on the main bearing beam with clean engine oil. Then
position the main bearing beam in the engine block with the main bearing beam mounted flush with
16.
NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads with clean engine oil. 17.
NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the
front of the cylinder block before tightening the main bearing beam bolts.
Install and tighten the 10 new main bearing beam bolts.
Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.
Position the crankshaft to the rear of the cylinder block.
Zero the Dial Indicator Gauge with Holding Fixture.
Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end
play.

Acceptable crankshaft end play is 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play
exceeds the specified range, install new parts as necessary.

18.
NOTICE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting
rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.
NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with
clean engine oil.
NOTE: Make sure the piston arrow on top is facing toward the front of the engine.
Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting
rod assemblies.
When installing the pistons and connecting rod assemblies, the oil ring gaps must be
positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander
gap.

The position of the upper and lower compression ring gaps are not controlled for installation.
19.
NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and
tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting
rods for cylinders 2 and 3 and tighten.
NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth
operation.
Install the connecting rod caps and the new bolts.
20.
Dead Center (TDC).
21.
disassembled.
NOTE: The original adjustment shims must be installed in their original position.
NOTE: Confirm by visual inspection that there is no damage to the balancer unit gear and verify that
the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit.
Install the adjustment shims in their original position on the seat faces of the balancer unit.
22.
23.

24.
Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear
and the crankshaft gear.
26.
27.

28.

Backlash specifications are 0.005 to 0.101 mm (0.00019 to 0.0039 in).
If the backlash exceeds the specified range, carry out the balance shaft backlash procedure.
For additional information, refer to the Balance Shaft Backlash procedure in this section.

Turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).
29.
must remain at the TDC position until the timing drive components and crankshaft pulley are
installed.
30.
31.
Install a new gasket, oil pump pickup tube and the 2 bolts.
32.
Using the Crankshaft Rear Main Oil Seal Installer, install the crankshaft rear main oil seal. 33.
Tighten the 6 crankshaft rear main oil seal retainer plate bolts in the sequence shown.
34.
35.
leakage.
Position the oil pan onto the engine and install the 2 rear oil pan bolts finger-tight.
36.
engine block.
37.
38.
Install the 2 cylinder head alignment dowels. Dowels must be fully seated in the cylinder block. 39.
NOTE: Observe all warnings and cautions and follow all application directions contained on the
packaging of the silicone gasket remover and the metal surface prep.
40.
minutes.
2.
3.
4.
Install a new head gasket. 42.
NOTE: The cylinder head bolts are a torque-to-yield design and must not be reused. New cylinder
head bolts must be installed.
NOTE: Lubricate the bolts with clean engine oil prior to installation.
Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in 5 stages:
43.
44.
Stage 1: Tighten the camshaft bearing cap bolts until finger-tight.
45.
Install the Variable Camshaft Timing (VCT) system oil filter and the plug in the intake camshaft
thrust cap.
46.
Install the Variable Camshaft Timing (VCT) solenoid and the bolt.
47.
NOTE: Install a new crankshaft sprocket diamond washer on both sides of the crankshaft sprocket.
Install the crankshaft sprocket and new crankshaft sprocket diamond washers.
The crankshaft sprocket flange must be facing away from the engine block.
48.
Install the oil pump drive chain, sprocket and bolt.
49.
50.
Install the oil pump drive chain tensioner and bolt. Hook the tensioner spring around the shoulder
bolt.
51.
52.
54.
57.
60.
61.
Using the flats on the camshafts to prevent camshaft rotation, tighten the camshaft sprocket bolts.
62.
63.
64.
Install the engine front cover. Tighten the 22 bolts in the sequence shown, to the following
specifications:
65.
Using the Camshaft Front Oil Seal Installer, install a new crankshaft front oil seal.
66.
67.
NOTICE: Only hand-tighten the 6 mm bolt or damage to the front cover can occur.
68.
69.
73.
75.
If it is not possible to install the bolt, the engine valve timing must be corrected.
76.
corrected.

77.
Install the Crankshaft Position (CKP) sensor and the 2 bolts.
79.
Using the Crankshaft Sensor Aligner, adjust the CKP sensor.
Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
80.
83.
paths.
Clean the valve cover gasket surface with metal surface prep.
84.
metal surface prep.
85.
Install the valve cover.
Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
86.
NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.
Install the 4 coil-on-plugs and the 4 bolts.
87.
88.
If equipped, install the block heater.
89.
Install the crankcase vent oil separator and the 8 bolts.
90.
NOTE: The Knock Sensor (KS) must not touch the crankcase vent oil separator.
Install the KS and the bolt.
91.
Install the coolant bypass hose on the coolant outlet. 92.
Connect the coolant bypass hose. 93.
Install the EGR tube.
94.
damage.
Position the intake manifold and connect the crankcase vent oil separator tube.
95.
NOTE: Inspect and install new intake manifold gaskets, if necessary.
Install the intake manifold gaskets, intake manifold and the 7 bolts (3 shown).
96.
NOTICE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary
O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.
Install new fuel injector O-rings.
Separate the fuel injectors from the fuel rail.
Remove and discard the fuel injector O-rings.
Install new O-rings and lubricate with clean engine oil.
Install the fuel injectors onto the fuel rail.
97.
Install the fuel rail and injector assembly and the 2 stud bolts. 98.
Install the radio capacitor and nut.
99.
Install the fuel rail insulator. 100.
Position the engine control wiring harness on the engine and connect the CHT sensor and install the
rubber boot.
101.
Connect the 4 ignition coil-on-plugs and Camshaft Position (CMP) sensor electrical connectors. 102.
Connect the 4 fuel injector electrical connectors.
Attach the 2 wiring harness retainers.
103.
Connect the radio capacitor electrical connector. 104.
Attach the 2 wiring harness retainers to the intake manifold. 106.
Connect the electronic throttle control and Evaporative Emission (EVAP) canister purge valve
107.
Connect the Manifold Absolute Pressure (MAP) sensor electrical connector. 108.
Using a new gasket install the oil filter adapter and the 4 bolts.
109.
Connect the Engine Oil Pressure (EOP) switch electrical connector. 110.
Install the A/C compressor and the 3 bolts.
111.
Using new O-ring seals, install the A/C manifold tube and the bolt.
112.
Install 7 new cylinder head studs.
113.
Install the new exhaust manifold gasket on the engine. 114.
NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause
the exhaust manifold to develop an exhaust leak.
NOTE: Make sure to tighten the nuts in the sequence in 2 stages.
Position the exhaust manifold and tighten the 7 new exhaust manifold nuts in the sequence shown in 2
stages:
115.
Install the exhaust manifold heat shield and the 4 bolts.
116.
Install the exhaust flexible pipe bracket and the 2 bolts.
117.
Install the 2 generator studs.
118.
Install the generator, 2 nuts and 1 bolt.
119.
Connect the Variable Camshaft Timing (VCT) electrical connector and attach the wiring harness
retainer to the valve cover stud bolt.
120.
Connect the Heated Oxygen Sensor (HO2S) electrical connector and attach the 2 wiring harness
retainers to the generator stud bolts.
121.
Connect the CKP sensor electrical connector and attach the wiring harness pin-type retainer. 122.
Install the thermostat housing and the 3 bolts.
123.
Install the coolant tube retainer to the intake manifold. 124.
Connect the coolant hose to the EGR. 125.
Install the accessory drive belt idler pulley and bracket and the 2 bolts.
126.
Connect the KS electrical connector and attach the wiring harness pin-type retainer. 127.
NOTICE: Make sure the coolant pump is correctly seated to the engine block before installing
and tightening the fasteners, or damage to the coolant pump may occur.
NOTE: Clean the coolant pump mating surface with metal surface prep.
128.
NOTE: Lubricate the new coolant pump O-ring with clean engine coolant.
Install the new O-ring, coolant pump and the 3 bolts.
Install the coolant pump pulley and the 3 bolts.
129.
Install the accessory drive belt idler pulley.
130.
Install the accessory drive belt tensioner and the 2 bolts.
131.
Position the accessory drive belt onto the tensioner and all of the accessory drive pulleys except the
coolant pump pulley.
132.
Using the hex feature, rotate the accessory drive belt tensioner clockwise and install the accessory
drive belt onto the coolant pump pulley.
133.
Using the Floor Crane and Spreader Bar, remove the engine from the engine stand. 134.
Vehicles with automatic transaxle
Install the flexplate and the 6 bolts. Tighten the 6 bolts in the sequence shown in 3 stages:
135.
Vehicles with manual transaxle
Install the flywheel and the 6 bolts. Tighten the 6 bolts in the sequence shown in 3 stages:
136.
Lubricate the transaxle input shaft pilot bearing with front axle grease. 137.
Using the Clutch Disc Aligner, position the clutch disc on the flywheel. 138.
NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.
Position the clutch pressure plate and install the 6 bolts.
Tighten to 29 Nm (21 lb-ft) in a star pattern sequence.
139.
Manual
INSTALLATION Procedure revision date: 06/03/2011
Engine - Automatic Transaxle
Special Tool(s)
Powertrain Lift
Spreader Bar
Adjustable Grip Arm
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
ignited. Failure to flow these instructions may result in serious personal injury.
Using the Floor Crane and Spreader Bar, position the engine and transaxle together. Install the
bellhousing-to-engine bolts.
1.
Using the Floor Crane and Spreader Bar, position the engine and transaxle onto the Powertrain Lift
table.
2.
NOTE: Position a suitable block of wood under the transaxle.
3.
NOTICE: Only rotate the engine in a clockwise direction or engine damage may occur.
Install the 4 new torque converter nuts.
4.
Position the generator wiring harness and attach the 4 wiring harness retainers (3 shown) to the valve
cover stud bolts.
5.
Connect the generator B+ wiring harness and install the nut.
6.
Connect the generator electrical connection. 7.
Install the generator air duct. 8.
Install the starter motor isolator. 9.
Install the starter, bolt and the stud bolt.
10.
Position the wiring harness and install the ground wire to the starter motor stud bolt and install the
nut.
11.
Connect the starter wires and install the 2 nuts.
Tighten the large starter motor B+ wire nut to 12 Nm (106 lb-in).
Tighten the small starter motor solenoid wire nut to 5 Nm (44 lb-in).
12.
Attach the A/C compressor wiring harness pin-type retainer to the intake manifold. 13.
Connect the A/C compressor electrical connector. 14.
Raise the engine and transaxle into the vehicle. 15.
Install the transaxle mount through bolt and nut.
16.
Install the engine mount bracket, 2 nuts and the bolt.
Tighten the nuts to 103 Nm (76 lb-ft).
Tighten the bolt to 115 Nm (85 lb-ft).
17.
18.
Install the 2 bellhousing-to-oil pan bolts.
19.
Attach the lower radiator hose pin-type retainer to the cooling fan shroud. 20.
If equipped, connect the block heater electrical connector and position back the block heater shield.
Attach the 8 block heater wiring harness retainers (1 shown).
21.
Install the lower radiator hose to the thermostat housing. 22.
Attach the Knock Sensor (KS) electrical connector to the intake manifold. 23.
Install a new O-ring seal and connect the upper A/C tube to the condenser and install the nut.
24.
Attach the coolant vent hose retaining clip to the A/C tube. 25.
Install a new O-ring seal and connect the A/C tube and install the nut.
26.
Install the windshield washer reservoir/A/C tube bracket bolt.
27.
Install the ground wire on the engine mount and the bolt.
28.
Connect the 2 transaxle fluid cooler tubes. 29.
Install the 2 secondary latches to the transaxle fluid cooler tubes. 30.
Connect the transaxle shift cable to the bracket and attach the shift cable to the transaxle manual lever. 31.
Connect the heater hose in-line connector and connect the upper radiator and heater hoses to the
coolant outlet.
32.
Attach the coolant hoses retainer. 33.
Connect the fuel supply tube quick connect coupling. For additional information, refer to Section
310-00 .
34.
Connect the fuel vapor return tube. 35.
Insert the brake booster vacuum supply tube into the locking ring on the intake manifold. 36.
Connect the crankcase vent tube to the valve cover. 37.
Install the engine oil filter.
Lubricate the engine oil filter gasket with clean engine oil and tighten the oil filter

39.
Place the subframe assembly on the Powertrain Lift and raise the subframe into the installed position. 40.
Install the front subframe nuts.
41.
Position the subframe brackets and install the bolts finger-tight.
42.
Install the subframe nuts.
43.
Tighten the subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
44.
Install the sway bar links and nuts to the struts.
45.
Install tie-rod ends and nuts.
Install the cotter pin.
46.
Install the Electronic Power Assist Steering (EPAS) system wiring harness ground and the bolt.
12 Nm (106 lb-in).
47.
Attach the EPAS system wiring harness pin-type retainer to the subframe under the LH fender splash
shield.
48.
Attach the 2 EPAS system wiring harness pin-type retainers to the subframe. 49.
Connect the 2 EPAS system electrical connectors. 50.
Install the LH halfshaft and the intermediate shaft. For additional information, refer to Section 205-04
.
51.
Install the LH splash shield and the 6 pin-type retainers (4 shown). 52.
Position the LH fender splash shield and install the 4 screws. 53.
Install the RH splash shield and the 6 pin-type retainers (4 shown). 54.
Position the RH fender splash shield and install the 4 screws. 55.
Install the engine roll restrictor bolt.
56.
Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips (2 shown)
into the body.
From under the vehicle, verify that the seal is correctly installed on the steering gear and the
retaining clips are fully engaged into the dash.

57.
If equipped, install the 7 screws and the underbody cover. 58.
Install the steering column shaft onto the steering gear and install the bolt.
59.
Install the steering joint cover and the 2 nuts. 60.
Connect the 2 engine harness electrical connectors. 61.
Attach the 2 negative battery cable pin-type retainers to the transaxle mount and battery tray bracket. 62.
Install the ground wire-to-body and the bolt.
63.
Connect the engine wiring harness electrical connector. 64.
Install the 2 battery cables to the positive battery cable and the 2 nuts.
65.
Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to Section
303-12A .
67.
Fill and bleed the cooling system. For additional information, refer to Section 303-03A . 69.
Fill the transaxle. For additional information, refer to Section 307-01A . 70.
Recharge the A/C system. For additional information, refer to Section 412-00A . 71.
72.
Manual
Engine - Manual Transaxle
Special Tool(s)
Powertrain Lift
Spreader Bar
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
ignited. Failure to llow these instructions may result in serious personal injury.
Using the Floor Crane and Spreader Bar, position the engine and transaxle together. Install the
bellhousing-to-engine bolts.
1.
Using the Floor Crane and Spreader Bar, position the engine and transaxle onto the Powertrain Lift
table.
2.
Install the Powertrain Lift and Adjustable Grip Arm onto the engine. 3.
Position the generator wiring harness and attach the 4 wiring harness retainers (3 shown) to the valve
cover stud bolts.
4.
Connect the generator B+ wiring harness and install the nut.
5.
Connect the generator electrical connection. 6.
Install the generator air duct. 7.
Install the starter motor isolator. 8.
Install the starter, bolt and stud bolt.
9.
Position the wiring harness and install the ground wire to the starter motor stud bolt and install the
nut.
10.
Connect the starter wires and install the 2 nuts.
Tighten the large starter motor B+ wire nut to 12 Nm (106 lb-in).
11.
Attach the A/C compressor wiring harness pin-type retainer to the intake manifold. 12.
Install the 2 transaxle mount bolts.
15.
Install the engine mount bracket, 2 nuts and the bolt.
16.
17.
Install the bellhousing-to-oil pan bolt.
18.
Attach the lower radiator hose pin-type retainer to the cooling fan shroud. 19.
If equipped, connect the block heater electrical connector and position back the block heater shield.
Attach the 8 block heater wiring harness retainers (1 shown).
20.
Install the lower radiator hose to the thermostat housing. 21.
Attach the Knock Sensor (KS) electrical connector to the intake manifold. 22.
Install a new O-ring seal and connect the upper A/C tube to the condenser and install the nut.
23.
Attach the coolant vent hose retaining clip to the A/C tube. 24.
Install a new O-ring seal and connect the upper A/C tube and install the nut.
25.
Install the A/C tube/windshield washer reservoir bracket bolt.
26.
Install the ground wire on the engine mount and the bolt.
27.
Attach the transaxle control cables to the bracket.
Connect the control cables to the control levers.
28.
Install the clutch slave cylinder and the 2 bolts.
29.
Install the 2 clutch tube bracket bolts.
30.
Connect the heater hose in-line connector and connect the upper radiator and heater hoses to the
coolant outlet.
31.
Attach the coolant hoses retainer. 32.
Connect the fuel supply tube quick connect coupling. For additional information, refer to Section
310-00 .
33.
Connect the fuel vapor return tube. 34.
Insert the brake booster vacuum supply tube into the locking ring on the intake manifold. 35.
Connect the crankcase vent tube to the valve cover. 36.
Install the engine oil filter.
Lubricate the engine oil filter gasket with clean engine oil and tighten the oil filter

38.
40.
41.
42.
43.
44.
45.
Install the Electronic Power Assist Steering (EPAS) system wiring harness ground and the bolt.
46.
shield.
47.
Connect the 2 EPAS system electrical connectors. 49.
.
50.
55.
into the body.

56.
Install the steering column shaft onto the steering gear and install the bolt.
58.
Connect the 2 engine harness electrical connectors. 60.
Attach the 2 negative battery cable pin-type retainers to the transaxle mount and battery tray bracket. 61.
Install the ground wire-to-body and the bolt.
62.
64.
303-12A .
66.
70.
SECTION 303-01B: Engine - 3.0L (4V)
Workshop Manual
Material
Capacity
Prep
ZC-31-A
- -
Motor Oil (Canada)
XO-5W20-QSP (US);
WSS-M2C945-A 5.7L (6.0 qt)
includes
filter change
and Dielectric Compound
XG-3-A
ESE-M1C171-A -
TA-30
WSE-M4G323-A4 -
TA-24
WSK-M2G350-A2 -
Item Specification
Engine
Bore/stroke 89.0 x 79.5 mm (3.12 in)
Displacement 3.0L (4V) (182 Cubic Inch Displacement (CID))
Engine and transaxle assembly weight
(without accessory drive components)
234 kg (516 lb)
Engine weight (without accessory
drive components and flexplate)
146 kg (322 lb)
Fire order 1-4-2-5-3-6
No. cylinders 6
Oil pressure (Minimum at 1,500 rpm
with engine warmed up after 10
minutes of idling)
172 kPa (25 psi)
Spark plug CGSF-22F Gap = 1.15-1.25 mm
(0.045-0.049 in)
Cylinder Head and Valve Train
Combustion chamber volume 51.2 cc +/- 1.5 cc
Cylinder head gasket surface flatness 0.025 mm (0.001 in) in any 25 mm (1 in) X 25
mm (1 in) area, 0.05 mm (0.002 in) in any 150
mm (6 in) area, 0.15 mm (0.005 in) overall
Roller follower ratio @ max. lift 2.0:1
Valve arrangement (front to rear) LH intake I-I-I-I-I-I
LH exhaust E-E-E-E-E-E
RH intake I-I-I-I-I-I
RH exhaust E-E-E-E-E-E
Valve face angle 45.5 degrees
Valve face runout 0.04 mm (0.001 in)
Valve guide bore diameter 6.015-6.044 mm (0.236-0.237 in)
Valve head diameter - exhaust 30 mm (1.18 in)
Valve head diameter - intake 35 mm (1.38 in)
Valve head diameter (exhaust) - gauge
diameter
28.0 mm (1.10236 in)
Valve head diameter (intake) - gauge
diameter
33.5 mm (1.3189 in)
Valve seat angle 44.75 degrees
Valve seat width - exhaust 1.4-1.7 mm
(0.055-0.066 in)
Valve seat width - intake 1.1-1.4 mm
(0.043-0.055 in)
Valve spring compression pressure
(Nm @ spec. length)
780 Nm @ 32.29 mm
(575 lb @ 1.27 in)
Valve spring free length (approx.) 50.52 mm (1.988 in)
Valve spring installed height (Nm @
spec. length)
42.61 mm (1.677 in)
Valve spring installed pressure 280 Nm @ 42.61 mm (206 lb @ 1.677 in)
Valve spring installed pressure -
service limit
5% force loss @ specified height
Valve spring squareness 1.2 mm (0.047 in) from ID
Valve stem diameter - exhaust 5.950-5.970 mm (0.2343-0.2350 in)
Valve stem diameter - intake 5.975-5.995 mm (0.2350-0.2358 in)
Valve stem-to-guide clearance -
exhaust
0.045-0.094 mm (0.0017-0.037 in)
Valve stem-to-guide clearance - intake 0.019-0.069 mm (0.0007-0.0027 in)
Hydraulic Lash Adjuster
Clearance to bore 0.018-0.069 mm (0.0007-0.0027 in)
Collapsed lash adjuster gap 0.50-1.11 mm (0.019-0.043 in)
Diameter (standard) 15.988-16.000 mm (0.6294-0.6299 in)
Hydraulic leakdown rate 5-25 seconds
Camshaft
Camshaft journal bore inside diameter 26.987-27.012 mm (1.062-1.063 in)
Camshaft journal-to-bearing clearance
- service limit 0.121 mm (0.0047 in)
Camshaft journal-to-bearing clearance
- standard
0.025-0.076 mm (0.001-0.0029 in)
End play - service limit 0.241 mm (0.009 in)
Journal diameter (all) 26.936-26.962 mm (1.060-1.061 in)
Lobe lift (intake) 5.084 mm (0.2 in)
Lobe lift (exhaust) 5.084 mm (0.2 in)
Runout -
Theoretical valve lift @ 0 lash 10.38 mm (0.408 in)
Cylinder Block
Cylinder bore diameter - grade 1 89.000-89.010 mm (3.50393-3.504323 in)
Cylinder bore maximum out-of-round 0.015 mm (0.0005 in)
Cylinder bore maximum out-of-round -
service limit
0.020 mm (0.0007 in)
Cylinder bore maximum taper 0.020 mm (0.0008 in)
Head gasket surface flatness 0.025 mm any 25 mm (1 in) X 25 mm (1 in)
area, 0.05 mm (0.002 in) in any 150 mm (6 in)
area, 0.15 mm (0.005 in) overall
Main bearing bore inside diameter 67.998-68.022 mm (2.677-2.6780 in)
Crankshaft
Connecting rod journal diameter 49.969-49.991 mm (1.967-1.968 in)
Connecting rod journal maximum
out-of-round
0.006 mm (0.0002 in)
Connecting rod journal maximum
taper
0.008 mm (0.0003 in)
Crankshaft end play 0.100-0.255 mm (0.003-0.010 in)
Main bearing journal diameter 62.968-62.992 mm (2.467-2.479 in)
Main bearing journal maximum
out-of-round
0.006 mm (0.0002 in)
Main bearing journal maximum taper 0.008 mm (0.0003 in)
Main bearing journal-to-cylinder block
clearance
0.024-0.046 mm (0.0009-0.0018 in) (select fit
bearings)
Piston and Connecting Rod
Connecting rod bearing bore diameter 53.015-53.035 mm (2.0872-2.0879 in)
Connecting rod bearing-to-crankshaft
clearance
0.028-0.066 mm (0.001-0.0025 in)
Connecting rod length
(center-to-center)
138.06-138.14 mm (5.435-5.38 in)
Connecting rod maximum allowed
bend
0.038 mm per 25
(0.0014 per 0.984 in)
Connecting rod maximum allowed
twist
0.050 mm per 25
(0.0019 per 0.984 in)
Connecting rod pin bore diameter 21.017-21.031 mm (0.827-0.828 in)
Connecting rod side clearance 0.100-0.30 mm (0.0039-0.0118 in)
Connecting rod-to-pin clearance -
service limit
0.035 mm (0.0013 in)
Connecting rod-to-pin clearance -
standard
0.004-0.02 mm (0.0001-0.0007 in)
Piston diameter - coated, grade 1 88.980-88.995 mm (3.5031-3.5037 in)
Piston diameter - uncoated, grade 1 88.970-88.980 mm (3.50275-3.50314 in)
Piston pin bore diameter 21..8273-0.8275 in)
Piston pin diameter 21.011-21.013 mm (0.8271-0.8273 in)
Piston pin length 60.08-60.51 mm (2.365-2.382 in)
Piston ring end gap - compression
(bottom, gauge diameter)
0.27-0.42 mm (0.0106-0.0165 in)
Piston ring end gap - compression
(bottom, service limit)
0.65 mm (0.0255 in) max
gauge diameter)
a
0.100-0.250 mm (0.0039-0.0098 in)
service limit)
0.50 mm (0.0196 in) max
gauge diameter)
0.15-0.65 mm (0.0059-0.0255 in)
service limit)
0.90 mm (0.0354 in) max
Piston ring groove width - compression
(bottom)
1.530-1.555 mm (0.0602-0.0612 in)
Piston ring groove width - compression
(top)
1.230-1.255 mm (0.0484-0.0494 in)
Piston ring groove width - oil ring 2.53-2.555 mm (0.0996-0.1005 in)
Piston ring-to-groove clearance -
Piston ring width - 0.002 to 0.009 mm
(0.00007-0.0003
in)
Piston-to-connecting rod clearance -
Piston-to-cylinder bore clearance
(coated)
0.003 to 0.032 mm (0.0001-0.0012 in)
Piston-to-cylinder bore clearance
(uncoated)
0.012 to 0.022 mm (0.0005-0.0009 in)
a
Specification 82.4 mm (3.2441 in) diameter gauge.
A/C compressor bolts 25 18 -
A/C compressor bracket bolts 25 18 -
A/C manifold bolt 15 - 133
A/C tube nut 8 - 71
A/C tube/windshield washer bottle bracket bolt 10 - 89
Battery terminal power feed wire nuts 6 - 53
Camshaft bearing cap bolts
a
- - -
Camshaft phaser and sprocket bolts 18 - 159
Camshaft oil seal retainer bolts 10 - 89
Catalytic converter nuts - LH - - -
Catalytic converter nuts - RH All-Wheel Drive
(AWD)
40 30 -
Catalytic converter studs 12 - 106
a
- - -
Coolant pump housing bolts - 89
Coolant pump housing hose clamps 7 - 62
a
- - -
Cylinder head bolts
a
- - -
EGR tube fittings 40 30 -
Electronic Power Assist Steering (EPAS) ground
wire bolt
10 - 89
a
- - -
Engine support insulator bracket bolt 115 85 -
Engine support insulator bracket nuts 63 46 -
Engine mount damper bolt 23 17 -
Engine mount bolts and nuts 55 -
Engine oil filter
a
- - -
Engine roll-restrictor bolts 90 66 -
Exhaust heat shield - LH and RH 10 - 89
Exhaust heat shield bracket bolts (inboard half) 40 30 -
Exhaust heat shield bracket nuts (outboard half) 20 - 177
a
- - -
Exhaust manifold studs 12 - 106
Flexplate bolts 80 59 -
Fuel rail and injectors assembly bolts 10 - p" align="left">Generator B+ terminal 8 - 71
nut
Generator nuts and bolt 47 35 -
Generator studs 8 - 71
Ground wire-to-engine mount bracket 10 - 89
Ground wire-to-strut tower bolt 10 - 89
Heated Oxygen Sensor (HO2S)
a
- - -
Ignition coil-on-plug bolts 6 - 53
Intermediate steering shaft bolt 20 - 177
Lower cylinder block bolts
a
- - -
Lower intake manifold bolts
a
- - -
Oil level indicaton="top" align="center">9 - 80
Oil pan baffle nuts
a
- - -
Oil pan bolts
a
- - -
Oil pan-to-front cover bolts 25 18 -
Oil pan-to-transaxle bolts 40 30 -
Oil pump bolts
a
- - -
Oil separator cover bolts 10 - 89
PCM ground wire bolt 10 - 89
Power Transfer Unit (PTU) bracket bolts 55 -
PTU -to-transaxle bolts 90 66 -
Radio frequency interference capacitor nut 6 - 53
Rear driveshaft-to- PTU flange bolts 70 52 -
Spark plugs 15 - 133
Starter motor bolts 27 20 -
Starter (large) terminal nut 12 - 106
Starter (small) terminal nut 5 - 44
Starter ground wire nut 18 -
Subframe bracket-to-body bolts 103 76 -
Timing chain guide bolts 25 18 -
Timing chain tensioner bolts 25 18 -
Torque converter-to-flexplate nuts 40 30 -
Transaxle control cable bracket bolts 23 17 -
Transaxle support through bolt 103 76 -
Transaxle-to-engine bolts 48 35 -
Upper intake manifold bolts
a
- - -
Upper intake manifold 10 - 89
Valve cover bolts and stud bolts
a
- - -
Variable Camshaft Timing (VCT) assembly bolts 10 - 89
a
SECTION 303-01B: Engine - 3.0L
(4V)
Manual
Engine
The 3.0L (4V) is a V-6 engine with the following features:
Dual overhead camshafts
A composite lower intake manifold and a composite upper intake manifold
Aluminum cylinder heads
Two-piece design aluminum cylinder block
Variable Camshaft Timing (VCT) system
Electronic ignition system with 6 ignition coils
For quick identification, refer to the safety certification decal.
The decal is located on the LH front door lock face panel.
Item Description
2 Cleveland engine plant 2
4 Bar code
5 Running number
7 Plant shift line
8 Bar code
Engine 1523
Operation and required maintenance of the exhaust emission control devices used on this engine are covered
Induction System
injectors:
are mounted between the fuel rail and the intake manifold.
Valve Train
The camshafts are mounted in the cylinder heads and act against a roller follower to open and close the valves.
A hydraulic lash adjuster is located on one side of the roller follower and the valve tip on the opposite end.
The camshafts are driven off the front of each cylinder head by 2 chains (one each side). Both of the chains
are driven by sprockets that are located on the crankshaft, just in front of the oil pump.
Variable Camshaft Timing (VCT) System
The VCT system changes intake camshaft timing dependent on engine speed, load and oil temperature. Oil
pressure advances and retards camshaft timing to improve low-speed and high-speed engine performance,
engine idle quality and exhaust emissions.
PCV System
All engines are equipped with a closed-type positive crankcase ventilation system recycling the crankcase
vapors to the upper intake manifold.
Lubrication System
Engine 1524
The engine lubrication system is of the force-feed type in which oil is supplied under full pressure to the
crankshaft, connecting rod bearings and timing chain tensioners. The flow of oil to the valve tappets and valve
train is controlled by a restricting orifice located in the head gaskets.
Oil Pump
The lubrication system is designed to provide optimum oil flow to critical components of the engine through
its entire operating range.
The heart of the system is a positive displacement internal gear oil pump.
Generically this design is known as a gerotor pump, which operates as follows:
The oil pump is mounted on the front face of the cylinder block.
The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft.
System pressure is limited by an integral, internally-vented relief valve which directs the bypassed oil
back to the inlet side of the oil pump.

Oil pump displacement has been selected to provide adequate volume to make sure of correct oil
pressure both at hot idle and maximum speed.

The relief valve calibration protects the system from excessive pressure during high viscosity
conditions.

The relief valve is designed to provide adequate connecting rod bearing lubrication under
high-temperature and high-speed conditions.

Cooling System
The engine cooling system includes the following components:
Radiator
Electric cooling fan motor
Degas bottle (aids in maintaining the correct volume of engine coolant)
Coolant thermostat
Coolant hoses
Coolant pump housing
Engine 1525
Engine 1526
(4V)
Manual
Engine
Engine 1527
(4V)
Manual
Upper Intake Manifold
Upper Intake Manifold (View 1 of 2)
Item
Part
Number Description
2 9D289 EVAP tube-to- EVAP canister purge valve quick
connect coupling
3/td> 14A464 Electronic throttle control electrical connector (part of
12C508)
4 14A464 EGR valve electrical connector (part of 12C508)
5 - EGR tube fitting (part of 9D477)
6 W700497 Engine control wiring harness retainer (part of 12C508)
7 - Brake booster vacuum tube
8 6K817 PCV tube
10 - Fuel tube and EVAP tube-to- EVAP canister purge
valve tube retainer
Upper Intake Manifold 1528
1 W713391 Upper intake manifold bolt
2 9Y450 Upper intake manifold bolt (6 required)
3 9424 Upper intake manifold
4 - Upper intaold gasket
5 W701775 Upper intake manifold support bracket bolts (2
required)
6 9J444 Upper intake manifold support bracket
Removal
Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Section 303-12B . 1.
Remove the battery. For additional information, refer to Section 414-01 . 2.
Remove the EGR tube fitting from the EGR valve. 3.
Disconnect the EGR valve electrical connector and detach the wiring retainer. 6.
Disconnect the EVAP tube-to- EVAP canister purge valve quick connect coupling and the brake
booster vacuum tube from the upper intake manifold.
Detach the fuel tube and EVAP tube-to- EVAP canister purge valve tube retainer from the
upper intake manifold.

7.
Detach the engine control wiring harness retainer from the upper intake manifold. 8.
Disconnect the PCV tube from the upper intake manifold. 9.
Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector and detach the wiring
retainer.
10.
Remove the 2 upper intake manifold support bracket bolts from the upper intake manifold. 11.
Remove the 7 bolts and the upper intake manifold.
Remove and discard the gaskets.
12.
Upper Intake Manifold (View 2 of 2) 1529
Installation
damage.
Clean and inspect all of the sealing surfaces of the upper intake manifold.
1.
NOTE: Install new upper intake manifold gaskets.
Position the upper intake manifold and install the 7 bolts.
Tighten the bolts in 2 stages in the sequence shown.

2.
Install the 2 upper intake manifold support bracket bolts.
3.
Connect the MAP sensor electrical connector and attach the wiring retainer. 4.
Connect the PCV tube to the upper intake manifold. 5.
Attach the engine control wiring harness retainer to the upper intake manifold. 6.
Connect the EVAP tube-to- EVAP canister purge valve quick connect coupling and the brake booster
vacuum tube to the upper intake manifold.
Attach the fuel tube and EVAP tube-to- EVAP canister purge valve tube retainer to the upper
intake manifold.

7.
Connect the EGR valve electrical connector and attach the wiring retainer. 8.
Connect the EVAP canister purge valve electrical connector. 9.
Connect the electronic throttle control electrical connector. 10.
Install the EGR tube fitting to the EGR valve.
11.
Install the battery. For additional information, refer to Section 414-01 . 12.
Install the ACL outlet pipe. For additional information, refer to Section 303-12B . 13.
(4V)
Manual
Lower Intake Manifold
1 W503279 Lower intake manifold bolt (8 required)
2 9K461 Lower intake manifold
3 9439 Lower intake manifold gasket (6 required)
Removal
Disconnect the battery ground cable. For additional information, refer to Section 414-01 . 2.
Remove the fuel rail. For additional information, refer to Section 303-04B . 3.
Remove the 8 lower intake manifold bolts and the lower intake manifold.
4.
Installation
Lower Intake Manifold 1532
damage.
NOTE: Clean and inspect all sealing surfaces. Install new gaskets.
Position the lower intake manifold and install the 8 bolts.
1.
Install the fuel rail. For additional information, refer to Section 303-04B . 2.
(4V)
Manual
Valve Cover - LH
Material
Item Specification
ZC-31-A
-
TA-30
WSE-M4G323-A4
LH Valve Cover (View 1 of 2)
Item
Part
Number Description
1 - Valve cover wiring retainers (part of 12A581)
2 - B+ cable valve cover stud bolt wiring retainers (part of
14tr>
3 14A464 Variable Camshaft Timing (VCT) electrical connector
(part of 12A581)
4 14A464 LH Heated Oxygen Sensor (HO2S) electrical connector
(part of 12A581)
Valve Cover - LH 1534
LH Valve Cover (View 2 of 2)
1 6C519 Valve cover stud bolt (6 required)
2 6C519 Valve cover bolt (8 required)
3 6A505 Valve cover
4 6A559 Valve cover gasket
5 6C527 Valve cover spark plug gasket (3 required)
6 6C535 Variable Camshaft Timing (VCT) valve cover seal
Removal
NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material
(including any material created while cleaning gasket surfaces) that enters the oil passages, coolant
passages or the oil pan may cause engine failure.
Remove the LH ignition coil-on-plugs. For additional information, refer to Section 303-07B . 1.
Detach the 3 wiring retainers from the valve cover. 2.
Detach the wiring retainer from the valve cover stud bolt and 1 retainer from the valve cover. 3.
Disconnect the Variable Camshaft Timing (VCT) electrical connector. 4.
NOTE: Inspect the crankcase ventilation tube and valve cover sealing area. If either a new valve
cover or crankcase ventilation tube is required, both components must be installed new.
Remove the 9 bolts, 5 stud bolts and the valve cover.
Remove and discard the gasket.
6.
LH Valve Cover (View 2 of 2) 1535
Installation
Install the new gasket in the valve cover in the following sequence.
Install the gasket at waffle pads and then the corners. 1.
Install the gasket around bolt holes. 2.
Install the remaining part of the gasket. 3.
1.
NOTE: The valve cover must be installed and the bolts and studs tightened within 4 minutes of
sealant application.
NOTE: Clean cylinder head and front cover surface and the cam seal retainer-to-cylinder head
surface using metal surface prep before applying silicone gasket and sealant.
Apply an 8 mm (0.31 in) dot of silicone gasket and sealant at the cylinder block to front cover mating
surface and the cam seal retainer-to-cylinder head joints.
2.
Position the valve cover and install the bolts and stud bolts.
3.
Position the wire harness and connect the HO2S electrical connector. 4.
Connect the VCT electrical connector. 5.
Attach the wiring retainer to the valve cover stud bolt and attach the pin-type wiring retainer to the
valve cover.
6.
Attach the 3 wiring retainers to the valve cover. 7.
Install the LH ignition coil-on-plugs. For additional information, refer to Section 303-07B . 8.
(4V)
Manual
Valve Cover - RH
Material
Item Specification
ZC-31-A
-
TA-30
WSE-M4G323-A4
RH Valve Cover (View 1 of 2)
Item
Part
Number Description
1 - Main engine control wiring harness valve cover stud bolt
retainer (part of 12A581) (4 required)
2 - Main enging harness valve cover retainer (part of
3 14A464 Variable Camshaft Timing (VCT) electrical connector
(part of 12A581)
4 - Crankshaft Position (CKP) electrical connector and
wiring harness retainer (part of 12A581)
5 - Catalyst Monitor Sensor (CMS) electrical connector (part
of 12A581)
Valve Cover - RH 1538
6 - Heated Oxygen Sensor (HO2S) electrical connector (part
of 12A581)
7 - Heated PCV electrical connector (part of 12A581)
8 - Cylinder head Knock Sensor (KS) electrical connector
(part of 12A581)
9 - Cylinder block KS electrical connector (part of 12A581)
10 - Cylinder Head Temperature (CHT) electrical connector
(part of 12A581)
RH Valve Cover (View 2 of 2)
Item
Part
Number Description
1 6C519 Valve cover stud bolt (11
required)
2 6C519 Valve cover bolt (3 required)
3 6582 Valve covertr valign="top"> 4 6584 Valve cover
gasket
5 6C527 Valve cover spark plug gasket (3
required)
6 6C535 Variable Camshaft Timing (VCT)
valve cover seal
Removal
Remove the RH ignition coil-on-plugs. For additional information, refer to Section 303-07B . 1.
RH Valve Cover (View 1 of 2) 1539
Detach the 3 main engine control wiring harness retainers from the valve cover and 4 retainers from
the valve cover stud bolts.
2.
Disconnect the Variable Camshaft Timing (VCT) electrical connector. 3.
Disconnect the Crankshaft Position (CKP) electrical connector and detach the 2 wiring harness
retainers.
5.
Disconnect the Catalyst Monitor Sensor (CMS) electrical connector. 6.
Disconnect the heated PCV electrical connector. 7.
Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector and the cylinder head
and cylinder block Knock Sensor (KS) electrical connectors.
8.
Remove the 11 bolts, 3 stud bolts and the valve cover.
9.
Installation
Install the new gasket in the valve cover in the following sequence.
Install the gasket at waffle pads and then corners. 1.
1.
NOTE: The valve cover must be installed and the bolts and stud bolts tightened within 4 minutes of
NOTE: Clean cylinder head and front cover surface using metal surface prep before applying silicone
gasket and sealant.
Apply an 8 mm (0.31 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints.
2.
Position the valve cover and install the bolts and stud bolts.
3.
Connect the CHT sensor electrical connector and the cylinder head and cylinder block KS electrical
connectors.
4.
Connect the heated PCV electrical connector. 5.
Connect the CMS electrical connector. 6.
Connect the CKP electrical connector and attach the wiring harness retainer. 7.
Connect the HO2S electrical connector. 8.
Connect the VCT electrical connector. 9.
Attach the 3 main engine control wiring harness retainers to the valve cover and the 4 retainers to the
valve cover stud bolts.
10.
Install the RH ignition coil-on-plugs. For additional information, refer to Section 303-07B . 11.
(4V)
Manual
1 W701512 Crankshaft pulley bolt
2 N806165 Washer
(4V)
Manual
Crankshaft Pulley
Special Tool(s)
3 Jaw Puller
303-D121 (or equivalent)
Installer, Crankshaft Vibration Damper
303-102 (T74P-6316-B)
Material
Item Specification
ZC-31-A
-
(Canada)
XO-5W20-QSP (US);
WSS-M2C945-A
TA-30
WSE-M4G323-A4
Removal
100-02 .
1.
Remove the accessory drive belt. For additional information, refer to Section 303-05B . 2.
Remove the crankshaft pulley bolt and washer.
Discard the crankshaft pulley bolt.
3.
Using the 3 Jaw Puller, remove the crankshaft pulley. 4.
Installation
Lubricate the crankshaft front seal inner lip with clean engine oil. 1.
NOTE: Clean the keyway and slot using metal surface prep before applying silicone gasket and
sealant.
NOTE: The crankshaft pulley must be installed and the bolt tightened within 4 minutes of applying
Apply silicone gasket and sealant to the end of the keyway slot.
2.
NOTE: Lubricate the outside diameter sealing surface with clean engine oil.
Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
3.
Install the bolt and washer. Tighten the bolt in 4 stages:
Stage 2: Loosen one full turn.
4.
Install the accessory drive belt. For additional information, refer to Section 303-05B . 5.
6.
(4V)
Manual
Special Tool(s)
303-102 (T74P-6316-B)
Remover, Oil Seal
303-409 (T92C-6700CH)
Material
Item Specification
ZC-31-A
-
XO-5W20-QSP (US);
WSS-M2C945-A
Removal
100-02 .
1.
Using the Oil Seal Remover, remove and discard the crankshaft front seal. 3.
Installation
NOTE: Clean all sealing surfaces with metal surface prep.
Apply clean engine oil to the seal lip and seal bore before installing the seal.
1.
Using the Front Cover Oil Seal Installer and the Crankshaft Vibration Damper Installer,
install a new crankshaft front seal.
2.
Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this
section.
3.
(4V)
Manual
1 W701559 Flexplate bolt (8 required)
2 6375 Flexplate
3 6701 Crankshaft rear oil seal
(4V)
Manual
Flexplate
Special Tool(s)
100-02 .
1.
Remove the transaxle. For additional information, refer to Section 307-01B . 2.
Remove the bolts and the flexplate.
3.
5.
Flexplate 1550
(4V)
Manual
Special Tool(s)
Inser Bolts, Crankshaft Rear Main Oil Seal
303-384 (T91P-6701-A)
303-178 (T82L-6701-A)
Remover, Crankshaft Rear Oil Seal
303-519 (T95P-6701-EH)
Slide Hammer
307-005 (T59L-100-B)
Material
Item Specification
ZC-31-A
-
XO-5W20-QSP (US);
WSS-M2C945-A
Removal
100-02 .
1.
Remove the flexplate. For additional information, refer to Flexplate in this section. 2.
Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the
crankshaft rear oil seal.
3.
Installation
NOTE: Apply clean engine oil to the seal lip and seal bore before installing the seal.
Using the Crankshaft Rear Main Oil Seal Installer Bolts and the Crankshaft Rear Main Oil Seal
Installer, install the crankshaft rear oil seal.
1.
Install the flexplate. For additional information, refer to Flexplate in this section. 2.
(4V)
Manual
Engine Front Cover
Special Tool(s)
Material
Item Specification
ZC-31-A
-
XO-5W20-QSP (US);
WSS-M2C945-A
TA-30
WSE-M4G3td>
Engine Front Cover (View 1 of 3)
1 W709986 Generator bolt
2 10300 Generator
3 W710416 Generator stud
4 W520414 Generator stud nut (2 required)
6 W503297 Accessory drive belt tensioner bolt (3 required)
Item
Part
Number Description
(part of 12A581) (2 required)
2 - CMP sensor wiring harness retainer (part of 1281)
3 14A464 Crankshaft Position (CKP) electrical connector (part of
12A581)
4 - CKP wiring harness retainer (part of 12A581)
2 W710030 Engine front cover stud bolt (2 required)
Engine Front Cover (View 1 of 3) 1554
6 6D081 Engine front cover gaskets
7 W709678 Oil pan-to-front cover bolts
Removal
With the vehicle in NEUTRAL, position it on a hoist. For additional information, refeto Section
100-02 .
1.
Remove the crankshaft front seal. For additional information, refer to Crankshaft Pulley and
Crankshaft Front Seal - Exploded View and Crankshaft Front Se in this section.
4.
Remove the generator bolt and the 2 nuts. 5.
Remove the 2 studs and position the generator away from the engine. 6.
Remove the 3 bolts and the accessory drive belt tensioner. 7.
Detach the wiring harness retainer from the engine front cover stud bolt. 8.
Disconnect the Crankshaft Position (CKP) electrical connector and detach the wiring harness retainer. 9.
Disconnect the 2 Camshaft Position (CMP) sensor electrical connectors and detach the wiring harness
retainer from the engine front cover stud bolt.
10.
Remove the LH and RH Variable Camshaft Timing (VCT) oil control solenoids. For additional
information, refer to Section 303-14B .
11.
Remove the 2 oil pan-to-front cover bolts. 13.
Remove the 14 bolts, 2 stud bolts and the engine front cover.
14.
Installation
paths.
NOTICE: Do not damage the oil pan gasket while cleaning the sealant from the lower cylinder
block-to-oil pan joint.
Use a plastic scraping tool to remove all traces of sealant.
Clean all sealing surfaces with metal surface prep and install new gaskets.
1.
sealant.
Apply a 6 mm (0.23 in) diameter dot of silicone gasket and sealant to the cylinder block, lower
cylinder block, cylinder head and oil pan mating surfaces.
2.
Position the engine front cover and install the bolts. Tighten in the sequence shown to 25 Nm (18
lb-ft).
1 W701525 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 47.5
3 W708222 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 64
4 W710030 Stud, Hex Flange Head Pilot, M6 x 1 x 20 / M8 x 1.25 x 47.5
3.
13 W710030 Stud, Hex Flange Head Pilot, M6 x 1 x 20 / M8 x 1.25 x 47.5
Install the 2 oil pan-to-front cover bolts.
4.
Remove the oil pan drain plug and drain the engine oil.
Install the plug and tighten to 26 Nm (19 lb-ft).
5.
Install the LH and RH VCT oil control solenoids. For additional information, refer to Section
303-14B .
7.
Connect the 2 CMP sensor electrical connectors and attach the wiring harness retainer to the engine
front cover stud bolt.
8.
Connect the Crankshaft Position (CKP) electrical connector and attach the wiring harness retainer. 9.
Attach the wiring harness retainer to the engine front cover stud bolt. 10.
11.
Position the generator and install the 2 studs.
12.
Install the generator bolt and 2 nuts.
13.
Install the crankshaft front seal. For additional information, refer to Crankshaft Pulley and Crankshaft
Front Seal - Exploded View and Crankshaft Front Seal in this section.
14.
Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure following the
17.
(4V)
Manual
Removal
NOTICE: Failure to verify correct timing drive component alignment will result in severe engine
damage.
section.
1.
Section 303-07B .
NOTE: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway
in the slot stamped "30RFF" (orange in color).
Remove the ignition pulse wheel.
3.
Install the crankshaft pulley bolt and washer. 4.
Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and
position the camshafts in the correct position. This will position the No. 1 cylinder at Top Dead
Center (TDC).
Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn
and recheck.

5.
Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in
the neutral position.
6.
Verify that the RH camshafts are in the neutral position. 7.
Remove the RH timing chain tensioner arm.
Remove the 2 bolts. 1.
Remove the tensioner. 2.
Remove the tensioner arm. 3.
8.
Remove the 2 bolts and the RH timing chain guide.
Remove the RH timing chain from the engine.
9.
Rotate the crankcase clockwise 600 degrees (one and two-third turns) to position the crankcase
keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
10.
Verify the LH camshafts are in the neutral position. 11.
Remove the LH timing chain and tensioner arm.
12.
Remove the 2 bolts and the LH timing chain guide.
Remove the LH timing chain from the engine.
13.
Remove the crankshaft pulley bolt and the crankshaft sprocket. 14.
Installation
NOTICE: Failure to verify correct timing drive component alignment will result in severe
engine damage.
Install the crankshaft sprocket with the timing mark facing out. The timing mark on the LH and RH
timing chains will be aligned to this mark during assembly.
1.
Position the chain tensioner in a soft-jawed vise.
2.
Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
3.
NOTICE: During tensioner compression, do not release the ratchet stem until the tensioner
piston is fully bottomed in its bore or damage to the ratchet stem will result.
Slowly compress the timing chain tensioner.
4.
Retain the tensioner piston with a 1.5 mm (0.06 in) diameter wire or paper clip. 5.
If timing marks in the timing chains are not evident, use a permanent-type marker to mark the
crankshaft and camshaft timing marks on the LH and RH timing chains.
Mark any link to use as the crankshaft timing mark. 1.
Starting with the crankshaft timing mark, count 29 links and mark the link. 2.
Continue counting to link 42 and mark the link. 3.
6.
Position the LH timing chain and guide and install the bolts.
Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
7.
Install the LH timing chain tensioner arm and the LH timing chain tensioner.
Install the tensioner arm. 1.
Position the tensioner. 2.
Install the bolts.
3.
8.
Install the crankshaft pulley bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft
keyway is in the 3 o'clock position.
9.
Verify that the RH camshafts are correctly positioned. 10.
Install the RH timing chain and chain guide and install the bolts.
11.
Install the RH timing chain tensioner and tensioner arm.
Install the bolts. 3.
12.
Remove the LH and RH timing chain tensioner piston retaining wires. 13.
Rotate the crankshaft counterclockwise 120 degrees to TDC . 14.
engine damage.
Verify the timing with the following steps.
There should be 12 chain links between the camshaft timing marks. 1.
There should be 27 chain links between the camshaft and the crankshaft timing marks. 2.
15.
Remove the crankshaft pulley bolt and washer. 16.
in the slot stamped "30RFF" only (orange in color).
Install the ignition pulse wheel.
17.
Install the LH and RH spark plugs. For additional information, refer to Section 303-07B . 18.
(4V)
Manual
LH Side Roller Follower, Hydraulic Lash Adjuster and Valve Spring
1 6529 Roller follower (12 required)
2 6C501 Hydraulic lash adjuster (12
required)
3 Valve spring retainer key (24
required)
4 6514 Valve spring retainer (12
required)
LH Side Intake and Exhaust Camshafts
7 W713106 Camshaft phaser and sprocket bolt (3 required)
8 6C524 Camshaft phaser and sprocket
9 6C683 Variable Camshaft Timing (VCT) system oil filter
10 6250 LH intake camshaft
11 6B280 Intake camshaft thrust bearing cap
12 W710702 Intake camshaft bearing cap bolt (8 required)
13 6B280 Intake camshaft bearing cap (3 required)
14 6250 LH exhaust camshaft
15 6B280 Exhaust camshaft thrust bearing cap
16 W710702 Exhaust camshaft bearing cap bolt (10 required)
17 6B280 Exhaust camshaft bearing cap (4 required)
Coolant Pump Belt and Pulley
18 8K543 Coolant pump drive belt
19 6A359 Coolant pump drive pulley
20 - Camshaft oil seal
21 W701242 Camshaft oil seal retainer bolt (2 required)
22 6B293 Camshaft oil seal retainer
23 6B295 Camshaft oil seal retainer gasket
RH Side Roller Follower, Hydraulic Lash Adjuster and Valve Spring
LH Side Intake and Exhaust Camshafts 1568
24 6529 Roller follower (12 required)
25 6518 Valve spring retainer key (24 required)
29 6C501 Hydraulic lash adjuster (12 required)
RH Side Intake and Exhaust Camshaft
30 W713106 Camshaft phaser and sprocket bolt (3 required)
31 6C524 Camshaft phaser and sprocket
32 6C683 VCT system oil filter
34 6B280 Intake camshaft thrust bearing cap
35 W710702 Intake camshaft bearing cap bolt (8 required)
36 6B280 Intake camshaft bearing cap (3 required)
38 6B280 Exhaust camshaft thrust bearing cap
39 W710702 Exhaust camshaft bearing cap bolt (10 required)
RH Side Roller Follower, Hydraulic Lash Adjuster and Valve Spring 1569
40 6B280 Exhaust camshaft bearing cap (3 required)
RH Side Intake and Exhaust Camshaft 1570
(4V)
Manual
Special Tool(s)
Locking Tool, Timing Chain
303-1175
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
Removal
LH camshaft phaser and sprocket
100-02 . Click here to view a video version of this procedure.
1.
Remove the LH Variable Camshaft Timing (VCT) oil control solenoid. For additional information,
refer to Section 303-14B .
2.
Remove the LH Camshaft Position (CMP) sensor. For additional information, refer to Section
303-14B .
3.
Remove the 6 pin-type retainers and the RH splash shield. 5.
NOTICE: The camshafts must be in the neutral position before removing the bearing caps or
damage to the engine may occur.
NOTE: The engine front cover is removed for clarity.
Rotate the crankshaft until the LH camshafts are in the neutral position as shown.
6.
NOTICE: The Timing Chain Locking Tool must be installed square to the timing chain and the
engine block or damage may result.
NOTE: The Timing Chain Locking Tool will lock the timing chain in place.
Install the Timing Chain Locking Tool in the LH timing chain as shown.
7.
NOTICE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the
Timing Chain Locking Tool is removed or out of placement, the engine front cover must be
removed and the engine must be retimed. For additional information, refer to Timing Drive
Components in this section.
NOTICE: The timing chain must be installed in its original position onto the camshaft phaser
and sprocket and exhaust camshaft using the marks, or damage to valves and pistons will result.
Mark the timing chain links and LH camshaft phaser and sprocket and exhaust camshaft gear as
shown for installation.
8.
Loosen the intake camshaft bolts evenly in the sequence shown. 9.
Remove the 2 bolts and the intake camshaft bearing thrust cap. 10.
NOTICE: Do not allow the camshaft to rotate from the neutral position while removing the
camshaft phaser and sprocket or damage to the engine may occur.
NOTICE: Only use hand tools to remove the camshaft phaser and sprocket bolts or damage
may occur to the camshaft or camshaft phaser and sprocket.
NOTE: Install a 3/8-in ratchet and extension into the D-slot on the rear of the LH intake camshaft to
hold the camshaft in place for removal of the camshaft phaser and sprocket bolts.
Loosen the 3 bolts for the LH camshaft phaser and sprocket.
11.
NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
NOTE: The camshaft will move and needs to be positioned towards the rear of the engine.
Using your hands, press the LH camshaft phaser and sprocket bolts towards the rear of the engine
while using a rocking motion to release the LH camshaft phaser and sprocket from the camshaft.
Once the LH camshaft phaser and sprocket has separated from the camshaft, remove the
timing chain from the LH camshaft phaser and sprocket and remove.

12.
RH camshaft phaser and sprocket
Remove the RH VCT oil control solenoid. For additional information, refer to Section 303-14B . 13.
Remove the RH CMP sensor. For additional information, refer to Section 303-14B . 14.
17.
Rotate the crankshaft until the RH camshafts are in the neutral position as shown.
NOTICE: The Timing Chain Locking Tool must be installed square to the timing chain and the
engine block or damage may result.
NOTE: The Timing Chain Locking Tool will lock the timing chain in place.
Install the Timing Chain Locking Tool in the RH timing chain as shown.
18.
NOTICE: Do not remove the Timing Chain Locking Tool at any time. If the Timing Chain
Locking Tool is removed or out of placement, the engine front cover must be removed and the
engine must be retimed. For additional information, refer to Timing Drive Components in this
section.
and sprocket and exhaust camshaft gear using the marks, or damage to valves and pistons will
result.
Mark the timing chain links and RH camshaft phaser and sprocket and exhaust camshaft gear as
shown for installation.
19.
Loosen the intake camshaft bolts evenly in the sequence shown. 20.
Remove the 2 bolts and the intake camshaft bearing thrust cap. 21.
NOTICE: Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may
occur to the camshaft or camshaft phaser and sprocket.
NOTE: Install a 3/8-in ratchet and extension into the D-slot on the rear of the RH intake camshaft to
hold the camshaft in place for removal of the camshaft phaser and sprocket bolts.
Loosen the 3 bolts for the RH camshaft phaser and sprocket.
22.
NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
NOTE: The camshaft will move and needs to be positioned towards the rear of the engine.
Using your hands, press the RH camshaft phaser and sprocket bolts towards the rear of the engine
while using a rocking motion to release the RH camshaft phaser and sprocket from the camshaft.
Once the RH camshaft phaser and sprocket has separated from the camshaft, remove the
timing chain from the RH camshaft phaser and sprocket and remove.

23.
Installation
RH camshaft phaser and sprocket
NOTICE: Do not remove the Timing Chain Locking Tool at any time during installation. If the
and sprocket using the marks, or damage to valves and pistons will result.
NOTE: If replacement of the camshaft phaser and sprocket is necessary, transfer the mark to the new
camshaft phaser and sprocket.
Position the RH camshaft phaser and sprocket into the timing chain with the alignment marks.
Make sure the timing chain mark is in alignment with the exhaust camshaft gear mark.
1.
NOTICE: Do not allow the camshaft to rotate from the neutral position while installing the
NOTICE: Only use hand tools to install the camshaft phaser and sprocket bolts or damage may
Using the 3/8-in ratchet and extension into the D-slot on the rear of the RH intake camshaft, align the
RH camshaft phaser and sprocket with the camshaft and install the 3 bolts.
2.
Tighten the 3 bolts in a clockwise pattern until the RH camshaft phaser and sprocket is seated
on the camshaft.

Torque the 3 bolts to 18 Nm (159 lb-in), using the 3/8-in ratchet and extension to hold
camshaft from turning.

Lubricate the bearing surface of the RH intake camshaft bearing thrust cap with clean engine oil and
install the camshaft bearing thrust cap and the 2 bolts.
Do not torque at this time.
3.
Tighten the RH intake camshaft bearing cap bolts in the sequence shown in 2 stages.
Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 Nm (89 lb-in).
4.
Verify the timing chain links and RH camshaft phaser and sprocket and exhaust camshaft gear are in
alignment.
5.
Remove the Timing Chain Locking Tool from the RH timing chain.
6.
Install the RH splash shield and the 6 pin-type retainers. 7.
Install the RH CMP sensor. For additional information, refer to Section 303-14B . 9.
Install the RH VCT oil control solenoid. For additional information, refer to Section 303-14B . 10.
LH camshaft phaser and sprocket
NOTICE: Do not remove the Timing Chain Locking Tool at any time during installation. If the
and sprocket using the marks, or damage to valves and pistons will result.
NOTE: If replacement of the camshaft phaser and sprocket is necessary, transfer the mark to the new
camshaft phaser and sprocket.
11.
Position the LH camshaft phaser and sprocket into the timing chain with the alignment marks.
Make sure the timing chain mark is in alignment with the exhaust camshaft gear mark.
NOTICE: Do not allow the camshaft to rotate from the neutral position while installing the
NOTICE: Only use hand tools to install the camshaft phaser and sprocket bolts or damage may
Using the 3/8-in ratchet and extension into the D-slot on the rear of the LH intake camshaft, align the
LH camshaft phaser and sprocket with the camshaft and install the 3 bolts.
Tighten the 3 bolts in a clockwise pattern until the LH camshaft phaser and sprocket is seated
on the camshaft.

Torque the 3 bolts to 18 Nm (159 lb-in), using the 3/8-in ratchet and extension to hold
camshaft from turning.

12.
Lubricate the bearing surface of the LH intake camshaft bearing thrust cap with clean engine oil and
install the camshaft bearing thrust cap and the 2 bolts.
13.
Tighten the LH intake camshaft bearing cap bolts in the sequence shown in 2 stages.
14.
Verify the timing chain links and LH camshaft phaser and sprocket and exhaust camshaft gear are in
alignment.
15.
Remove the Timing Chain Locking Tool from the LH timing chain.
16.
Install the LH CMP sensor. For additional information, refer to Section 303-14B . 19.
Install the LH VCT oil control solenoid. For additional information, refer to Section 303-14B . 20.
(4V)
Manual
Removal
Remove the camshaft phaser and sprocket. For additional information, refer to Camshaft Phaser and
Sprocket in this section.
1.
NOTE: RH Variable Camshaft Timing (VCT) system oil filter shown, LH similar.
Remove and discard the VCT system oil filter from the camshaft.
2.
Installation
NOTE: RH VCT system oil filter shown, LH similar.
Install the new VCT system oil filter in the camshaft.
1.
Install the camshaft phaser and sprocket. For additional information, refer to Camshaft Phaser and
2.
(4V)
Manual
Camshafts - LH
Special Tool(s)
Installer, Camshaft Oil Seal
303-464 (T94P-6256-BH)
Installer, Camshaft Pulley
303-458 (T94P-6312-AH3), part of
303-S455
Installer, Power Steering Pump Pulley
211-185 (T91P-3A733-A)
Plate, Water Pump Pulley
303-456 (T94P-6312-AH1), part of
303-S455
Protector, Camshaft Oil Seal
303-463 (T94P-6256-AH)
Protector, Water Pump Shaft
303-457 (T94P-6312-AH2), part of
303-S455
Remover, Crankshaft Vibration Damper
303-009 (T58P-6316-D)
Remover, Oil Seal
303-409 (T92C-6700-CH)
Spacer, Water Pump Pulley
303-459 (T94P-6312-AH4), part of
303-S455
Material
Item Specification
ZC-31-A
-
XO-5W20-QSP (US);
WSS-M2C945-A
Removal
Camshafts - LH 1584
Remove the coolant pump belt. For additional information, refer to Section 303-05B . 1.
NOTICE: Failure to use the correct special tools, assembled as shown in the illustration, will
result in damage to the coolant pump pulley and/or special tools.
Using the Water Pumpey Plate, Water Pump Shaft Protector and the Crankshaft Vibration Damper
Remover, remove the coolant pump pulley.
2.
Remove the LH camshaft phaser and socket. For additional information, refer to Camshaft Phaser and
3.
NOTICE: Do not scratch the camshaft sealing surface while removing the camshaft oil seal. If
scratched, camshaft oil seal leakage may occur.
Using the Oil Seal Remover, remove and discard the camshaft oil seal.
4.
Remove the 2 bolts and the camshaft oil seal retainer.
Discard the press-in-place gasket.
5.
NOTICE: Cylinder head camshaft bearing caps must be assembled in their original positions.
Some engines have factory markings on the camshaft bearing caps (as shown in illustration).
Engines that do not have the factory markings must be marked for correct position and
orientation prior to removal. Failure to install the camshaft bearing caps in their original
positions may result in severe engine damage.
6.
Camshafts - LH 1585
If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.
Loosen the bolts evenly in the sequence shown. 7.
NOTICE: After loosening the camshaft bearing cap bolts, remove the camshaft bearing thrust
cap (1L) first, or damage to the thrust cap may occur.
NOTE: Make sure the camshaft bearing caps are marked as instructed in the previous step.
Remove the camshaft cap bolts.
Remove the camshaft bearing thrust cap (1L). 1.
Remove the remaining camshaft bearing caps. 2.
Remove the camshafts from the cylinder head. 3.
8.
Camshafts - LH 1586
Installation
Lubricate the LH camshafts with clean engine oil and carefully position the camshafts onto the
cylinder head.
Align the LH camshafts as shown.
1.
NOTICE: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that
they are assembled in their original positions. If not reassembled in their original positions,
severe engine damage may occur.
NOTICE: Do not install the camshaft journal thrust cap until all of the camshaft bearing caps
have been installed or damage to the thrust cap can occur.
Lubricate the bearing surfaces of the LH camshaft bearing caps with clean engine oil and install the
bearing caps.
Loosely install the bolts.
2.
Camshafts - LH 1587
Lubricate the bearing surface of the LH exhaust camshaft bearing thrust cap with clean engine oil and
install the bearing thrust cap.
3.
NOTE: Make sure to tighten the camshaft bearing cap bolts in sequence in 2 stages.
Tighten the LH exhaust camshaft bearing cap bolts in the sequence shown in 2 stages.
4.
NOTE: Clean the sealing surfaces with metal surface prep before installing a new press-in-place
gasket.
Install the camshaft oil seal retainer and the 2 bolts.
5.
Camshafts - LH 1588
NOTE: Lubricate the camshaft oil seal with clean engine oil.
Using the Camshaft Oil Seal Installer, Camshaft Oil Seal Protector and the Power Steering Pump
Pulley Installer, install the camshaft oil seal.
6.
Install the LH camshaft phaser and socket. For additional information, refer to Camshaft Phaser and
7.
Install the Camshaft Pulley Installer in the camshaft as shown in the illustration.
Adjust the collar on the Camshaft Pulley Installer screw to get the best thread engagement in
the rear of the camshaft.

8.
NOTE: Only the roller collared nut from the Power Steering Pump Pulley Installer (211-185) is used
on Camshaft Pulley Installer (303-458).
Position the coolant pump pulley over the previously installed Camshaft Pulley Installer and on the
end of the camshaft. Install the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and
the Water Pump Pulley Spacer as shown in the illustration.
Using the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water
Pump Pulley Spacer, install a new service coolant pump pulley flush with the end of the
camshaft.

9.
Install the coolant pump belt. For additional information, refer to Section 303-05B . 10.
Camshafts - LH 1589
Camshafts - LH 1590
(4V)
Manual
Camshafts - RH
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
Removal
100-02 .
1.
Remove the RH camshaft phaser and socket. For additional information, refer to Camshaft Phaser and
2.
3.
Loosen the bolts evenly in the sequence shown. 4.
Camshafts - RH 1591
NOTICE: After loosening the camshaft bearing cap bolts, remove the camshaft bearing thrust
cap (1R) first, or damage to the thrust cap may occur.
Remove the camshaft cap bolts.
Remove the camshaft bearing thrust cap (1R). 1.
5.
Installation
Lubricate the RH camshafts with clean engine oil and carefully position the camshafts onto the
cylinder head.
Align the RH camshafts as shown.
1.
Camshafts - RH 1592
NOTICE: Do not install the camshaft journal thrust cap until all of the camshaft bearing caps
have been installed or damage to the thrust cap can occur.
Lubricate the bearing surfaces of the RH camshaft bearing caps with clean engine oil and install the
bearing caps.
2.
Lubricate the bearing surface of the RH exhaust camshaft bearing thrust cap with clean engine oil and
install the bearing thrust cap.
3.
Tighten the RH camshaft bearing cap bolts in the sequence shown in 2 stages.
4.
Camshafts - RH 1593
Install the RH camshaft phaser and socket. For additional information, refer to Camshaft Phaser and
5.
Camshafts - RH 1594
(4V)
Manual
Camshaft Roller Follower
Special Tool(s)
303-473 (T94P-6565-BH)
Material
Item Specification
XO-5W20-QSP (US); CXOLSP12
(Canada)
WSS-M2C945-A
100-02 .
1.
Remove the LH and RH valve covers. For additional information, refer to Valve Cover - LH and
Valve Cover - RH in this section.
2.
NOTICE: Only use hand tools when removing or installing the spark plugs or damage can occur
to the cylinder head or spark plug.
Remove the 6 spark plugs.
3.
Camshaft Roller Follower 1595
Rotate the crankshaft until the camshaft lobe is pointing directly away from the roller follower. 6.
NOTE: Mark the positions of the roller followers to make sure they are assembled in their original
positions.
Using the Valve Spring Compressor, remove the roller followers.
7.
NOTE: Lubricate the roller followers with clean engine oil.
8.
Camshaft Roller Follower 1596
(4V)
Manual
Hydraulic Lash Adjuster
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
Remove the camshaft roller followers. For additional information, refer to Camshaft Roller Follower
in this section.
1.
NOTE: Mark the positions of the hydraulic lash adjusters to make sure they are assembled in their
original positions.
Remove the hydraulic lash adjusters.
2.
NOTE: Inspect the hydraulic lash adjusters for scoring marks and uneven wear in the bore. Install
new lash adjusters if necessary.
Lubricate the hydraulic lash adjusters with clean engine oil.
3.
Hydraulic Lash Adjuster 1597
Hydraulic Lash Adjuster 1598
(4V)
Manual
Valve Spring, Retainer, and Seal
Special Tool(s)
303-473 (T94P-6565-BH)
303-470 (T94P-6510-CH)
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
Removal
Remove the camshaft roller followers. For additional information, refer to Camshaft Roller Follower
in this section.
1.
NOTICE: If the components are to be reinstalled, they must be installed in their original
positions or damage to the engine may occur. Mark the components for installation into their
original locations.
NOTE: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will
allow the valve(s) to fall into the cylinder. A rubber band, tape or string wrapped around the end of
the valve stem will prevent this from happening.
NOTE: If a valve drops into the cylinder, remove the cylinder head. For additional information, refer
Cylinder Head - RH or Cylinder Head - LH in this section.
Pressurize the cylinder using compressed air.
2.
Using the Valve Spring Compressor, remove the key, retainer and the valve spring. 3.
Valve Spring, Retainer, and Seal 1599
NOTE: Camshaft removed for clarity.
Remove and discard the valve seal.
4.
Installation
NOTE: Lubricate the valve guide with clean engine oil.
Using the Valve Stem Oil Seal Installer, install the new valve seal.
1.
NOTICE: If the components are to be reinstalled, they must be installed in their original
positions or damage to the engine may occur.
Using the Valve Spring Compressor, install the valve spring, retainer and key.
2.
Install the camshaft roller followers. For additional information, refer to Camshaft Roller Follower in
this section.
3.
(4V)
Manual
Cylinder Head - RH
Material
Item Specification
ZC-31-A
-
XO-5W20-QSP (US);
WSS-M2C945-A
Part Number Description
2 6529 Camshaft roller follower (12 required)
Removal
Cylinder Head - RH 1602
100-02 .
1.
Remove the lower intake manifold. For additional information, refer to Lower Intake Manifold in this
section.
2.
Remove the RH exhaust manifold. For additional information, refer to Exhaust Manifold - RH in this
section.
3.
Remove the coolant pump housing. For additional information, refer to Section 303-03A . 4.
in this section.
5.
Verify the RH camshafts are in the neutral position.
6.
NOTE: Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold
the camshaft in place for removal of the camshaft phasernd sprocket bolts.
Remove the 3 bolts and the RH camshaft phaser and sprocket.
7.
8.
NOTICE: After loosening all of the camshaft bearing cap bolts, remove the camshaft bearing
thrust caps (5R and 1R) first, or damage to the thrust caps may occur.
Loosen the bolts evenly in the sequence shown.
Remove the camshaft bearing thrust caps (5R and 1R). 1.
9.
NOTICE: The camshaft roller followers must be installed in their original positions. If not
reassembled in their original positions, severe engine damage may occur.
Remove the camshaft roller followers.
10.
NOTICE: The hydraulic lash adjusters must be installed in their original positions. If not
11.
NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be
reused.
12.
Discard the bolts and gasket.
13.
Installation
paths.
Use a plastic scraping tool to remove all traces of the head gasket.
Clean all surfaces with metal surface prep.
1.
Position a new gasket and the cylinder head. 2.
reused.
Install the bolts and tighten in 6 stages in the sequence shown.
Stage 2: Tighten 90 degrees.
3.
Install the hydraulic lash adjusters.
4.
5.
Install the camshaft roller followers.
Lubricate the camshaft roller followers with clean engine oil.
Position the RH camshaft phaser and sprocket onto the intake camshaft.
Install the 3 bolts finger-tight.
6.
cylinder head.
7.
NOTICE: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps
have been installed or damage to the thrust caps can occur.
NOTE: Lubricate the bearing surfaces of the RH camshaft bearing caps with clean engine oil.
Install the camshaft bearing caps.
8.
NOTE: Lubricate the bearing surfaces of the RH camshaft bearing thrust caps with clean engine oil.
Install the camshaft bearing thrust caps.
9.
10.
NOTICE: Do not allow the camshaft to rotate from the neutral position while tightening the
camshaft phaser and sprocket bolts or damage to the engine may occur.
the camshaft in place for tightening of the camshaft phaser and sprocket bolts.
Tighten the 3 RH camshaft phaser and sprocket bolts to 18 Nm (159 lb-in).
11.
this section.
12.
Install the coolant pump housing. For additional information, refer to Section 303-03A . 13.
Install the RH exhaust manifold. For additional information, refer to Exhaust Manifold - RH in this
section.
14.
Install the lower intake manifold. For additional information, refer to Lower Intake Manifold in this
section.
15.
(4V)
Manual
Cylinder Head - LH
Special Tool(s)
303-464 (T94P-6256-BH)
303-458 (T94P-6312-AH3), part of
303-S455
211-185 (T91P-3A733-A)
303-456 (T94P-6312-AH1), part of
303-S455
303-463 (T94P-6256-AH)
303-457 (T94P-6312-AH2), part of
303-S455
303-009 (T58P-6316-D)
Remover, Oil Seal
303-409 (T92C-6700-CH)
303-459 (T94P-6312-AH4), part of
303-S455
Material
Item Specification
ZC-31-A
-
XO-5W20-QSP (US);
WSS-M2C945-A
Cylinder Head - LH 1609
LH Cylinder Head
2 6529 Camshaft rollerower (12 required)
6 6754 Oil level indicator tube
7 W701822 Oil level indicator tube stud bolt
8 110282 Oil level indicator tube O-ring
Removal
100-02 .
1.
Remove the lower intake manifold. For additional information, refer to Lower Intake Manifold in this
section.
2.
Remove the LH catalytic converter. For additional information, refer to Section 309-00 . 3.
Remove the coolant pump housing. For additional information, refer to Section 303-03A . 4.
in this section.
5.
LH Cylinder Head 1610
Using the Water Pump Pulley Plate, Water Pump Shaft Protector and the Crankshaft Vibration
Damper Remover, remove the coolant pump pulley.
6.
Using the Oil Seal Remover, remove and discard the camshaft oil seal.
7.
8.
Verify the LH camshafts are in the neutral position.
9.
the camshaft in place for removal of the camshaft phaser and sprocket bolts.
Remove the 3 bolts and the LH camshaft phaser and sprocket.
10.
11.
thrust caps (1L and 5L) first, or damage to the thrust caps may occur.
Remove the camshaft bearing thrust caps (1L and 5L). 1.
12.
Remove the camshaft roller followers.
13.
14.
Remove the stud bolt and then remove the oil level indicator tube.
16.
reused.
17.
18.
Installation
paths.
Use a plastic scraping tool to remove all traces of the head gasket.
Clean all surfaces with metal surface prep.
1.
Position a new gasket and the cylinder head. 2.
reused.
Install the bolts and tighten in 6 stages in the sequence shown.
3.
NOTE: Installation of the oil level indicator may require the assistance of a second technician to align
the tube with the orifice.
NOTE: Install a new O-ring seal and lubricate with clean engine oil.
Install the oil level indicator tube and install the stud bolt.
4.
Install the oil level indicator. 5.
6.
Install the camshaft roller followers.
Lubricate the camshaft roller followers with clean engine oil.
7.
Position the camshaft phaser and sprocket onto the intake camshaft.
8.
cylinder head.
9.
bearing caps.
10.
Lubricate the bearing surfaces of the LH camshaft bearing thrust caps with clean engine oil and install
the bearing thrust caps.
11.
Tighten the LH camshaft bearing cap bolts in the sequence shown in 2 stages.
12.
Tighten the 3 LH camshaft phaser and sprocket bolts to 18 Nm (159 lb-in).
13.
NOTE: Clean the sealing surfaces with metal surface prep before installing a new press-in-place
gasket.
14.
NOTE: Lubricate the camshaft oil seal with clean engine oil.
Using the Camshaft Oil Seal Installer, Camshaft Oil Seal Protector and the Power Steering Pump
Pulley Installer, install the camshaft oil seal.
15.

16.
camshaft.

17.
this section.
18.
Install the coolant pump housing. For additional information, refer to Section 303-03A . 19.
Install the LH catalytic converter. For additional information, refer to Section 309-00 . 20.
Install the lower intake manifold. For additional information, refer to Lower Intake Manifold in this
section.
21.
(4V)
Manual
Oil Pan, Oil Pan Baffle and Oil Pump Screen and Pickup Tube
1 W709678 Oil pan-to-engine bolt (15 required)
2 W500120 Oil pan-to-transaxle bolt (2 required)
3 6675 Oil pan
4 6710 Oil pan gasket
5 W701582 Oil pan baffle nut (4 required)
6 W700005 Oil pump screen and pickup tube bolts (2 required)
8 6625 Oil pump screen and pickup tube O-ring seal
9 W701542 Oil pan baffle nut (4 required)
10 6687 Oil pan baffle
Oil Pump
2 6621 Oil pump
Oil Pump 1620
(4V)
Manual
Oil Pan
Material
Item Specification
ZC-31-A
-
(Canada)
XO-5W20-QSP (US);
WSS-M2C945-A
TA-30
WSE-M4G323-A4
Removal
100-02 .
1.
Remove the LH catalytic converter manifold. For additional information, refer to Section 309-00 . 2.
Drain the engine oil and install the drain plug.
3.
Remove and discard the oil filter. 4.
Remove the access cover. 5.
Remove the 2 oil pan-to-transaxle bolts. 6.
Remove the 15 bolts and the oil pan.
Remove and discard the oil pan gasket.
7.
Installation
Oil Pan 1621
paths.
Use a plastic scraping tool to remove all traces of the oil pan gasket.
Clean all sealing surfaces with metal surface prep and install a new oil pan gasket.
1.
NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of sealant application.
Apply a 10 mm (0.40 in) diameter dot of silicone sealant to the areas indicated.
2.
Position the oil pan and loosely install the bolts. 3.
Install the 2 oil pan-to-transaxle bolts.
4.
Tighten the oil pan-to-engine bolts in the sequence shown to 25 Nm (18 lb-ft). 5.
Install the access cover. 6.
NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing.
Install a new oil filter.
Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
7.
Install the LH catalytic converter manifold. For additional information, refer to Section 309-00 . 8.
Oil Pan 1622
Oil Pan 1623
(4V)
Manual
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
Removal
passages or the oil pan, may cause engine failure.
100-02 .
1.
2.
Remove the bolts the oil pump screen and pickup tube.
3.
Installation
Install a new O-ring seal on the oil pump screen and pickup tube.
Lubricate the O-ring seal with clean engine oil.
1.
Install the oil pump screen and pickup tube.
Position the oil pump screen and pickup tube. 1.
Install the bolts and tighten to 10 Nm (89 lb-in). 2.
2.
Install the oil pan. For additional information, refer to Oil Pan in this section. 3.
(4V)
Manual
Oil Pan Baffle
100-02 .
1.
Remove the oil pump screen and pickup tube. For additional information, refer to Engine Lubrication
Components - Exploded View and Oil Pump Screen and Pickup Tube in this section.
2.
Remove the 8 nuts and the oil pan baffle in the following sequence.
To install, tighten the 4 M6 oil pan baffle nuts in 2 stages.
1.
Then install and tighten the 4 M8 oil pan baffle nuts in 2 stages.
2.
3.
Oil Pan Baffle 1626
Oil Pan Baffle 1627
(4V)
Manual
Oil Pump
Removal
100-02 .
1.
in this section.
2.
Remove the oil pump screen and pickup tube. For additional information, refer to Engine Lubrication
3.
Remove the bolts in the sequence shown. 4.
Installation
Position the oil pump aninstall the bolts.
1.
Install the oil pump screen and pickup tube. For additional information, refer to Engine Lubrication
2.
this section.
3.
Oil Pump 1628
Oil Pump 1629
(4V)
Manual
Material
Item Specification
TA-24
WSK-M2G350-A2
2 14A464
3 9278 EOP
100-02 .
1.
NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing.
Remove the engine oil filter.
To install, tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
2.
4.
Apply thread sealant with PTFE to the EOP switch threads.
5.
(4V)
Manual
Oil Level Indicator and Tube
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
1 - Block heater wiring harness (if equipped)
2 110282 Oil level indicator O-ring seal
6754 Oil level indicator tube
4 W701822 Oil level indicator tube stud bolt
100-02 .
1.
If equipped, disconnect the block heater electrical connector and wiring harness retainers. 3.
Remove the stud bolt and the oil level indicator tube.
4.
NOTE: Install a new O-ring seal and lubricate with clean engine oil.
5.
Oil Level Indicator and Tube 1632
Oil Level Indicator and Tube 1633
(4V)
Manual
Exhaust Manifold - RH
Material
Item Specification
ZC-31-A
-
1 5E258 RH catalytic converter heat shield
2 W701706 RH exhaust manifold nut (6 required)
3 9430 RH exhaust manifold
4 W701732 RH exhaust manifold sired)
5 9448 RH exhaust manifold gasket
6 W500724 Power Transfer Unit (PTU) bracket bolt (5 required)
7 7A444 PTU bracket
Removal
100-02 .
1.
Remove the EGR tube. For additional information, refer to Section 303-08B . 2.
Remove the RH catalytic converter. For additional information, refer to Section 309-00 . 3.
Exhaust Manifold - RH 1634
NOTE: The heat shield that was unbolted from the exhaust manifold during removal of the RH
catalytic converter cannot be removed from the vehicle until the Power Transfer Unit (PTU) bracket
is removed.
Remove the 5 bolts and the PTU bracket.
Remove the catalytic converter heat shield from the vehicle.
4.
Remove the 6 nuts and the RH exhaust manifold.
Discard the gasket and nuts.
5.
Clean and inspect the RH exhaust manifold. For additional information, refer to Section 303-00 . 6.
Remove and discard the 6 RH exhaust manifold studs. 7.
means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak
paths. Use a plastic scraper to clean the sealing surfaces.
Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the
directions on the packaging.
8.
Installation
Install 6 new RH exhaust manifold studs.
1.
NOTE: The catalytic converter heat shield must be positioned up into the engine compartment prior
to installing the PTU bracket.
Position the catalytic converter heat shield into the engine compartment.
2.
Install the PTU bracket and the 5 bolts.
3.
Install a new gasket, the RH exhaust manifold and 6 new nuts.
Tighten to 20 Nm (177 lb-in) in the sequence shown.
4.
Install the RH catalytic converter. For additional information, refer to Section 309-00 . 5.
Install the EGR tube. For additional information, refer to Section 303-08B . 6.
(4V)
Manual
Engine Mount
1 W711879 Damper bolt
2 7458 Damper
6 W712334 Engine support insulator bracket nut (3 required)
8 W711578 Engine mount nut td>
Remove the engine coolant degas bottle. For additional information, refer to Section 303-03A . 1.
Remove the bolt and position aside the ground wire.
2.
Remove the bolt and damper.
3.
Remove the engine support insulator bracket bolt.
4.
NOTE: Failure to position the wood block and floor jack as illustrated can result in damage to the oil
pan.
Position a floor jack with a block of wood under the front of the oil pan.
Using the floor jack, lift the engine 12 mm (0.47 in).
5.
Engine Mount 1638
Remove the 3 nuts and the engine support insulator bracket.
6.
Remove the nut, 2 bolts and the engine mount.
7.
NOTE: If the engine mount bracket is to be removed, the engine must be lowered to avoid contact
between the A/C tubes and the engine mount bracket.
Use the floor jack to lower the engine 25 mm (0.98 in).
Remove the engine mount bracket.
8.
Engine Mount 1639
Workshop Manual
Engine
Special Tool(s)
307-569
Engine Lifting Bracket Set
303-1140
303-050 (T70P-6000)
Lifting Brackets, Engine
Powertrain Lift
Socket, Exhaust Gas Oxygen Sensor
303-476 (T94P-9472-A)
Spreader Bar
Tie-Rod End Remover
211-105 (T85M-3395-A)
All vehicles
100-02 .
1.
Engine 1640
Place the steering wheel in the straight-ahead position and the ignition key in the OFF position. 5.
6.
Section 501-20B .
8.
Engine 1641
Remove the bolt and the Electronic Power Assist Steering (EPAS) wiring ground wire from in the RH
front wheel well.
12.
All-Wheel Drive (AWD) vehicles
NOTE: Index-mark the driveshaft for installation.
Remove the 4 bolts (3 shown) and support the driveshaft with a length of mechanic's wire.
16.
All vehicles
Engine 1642
the subframe.
17.
If equipped, remove the 2 bolts and the heat shield. 18.
Remove the 2 bolts and the engine roll restrictor. 19.
20.
21.
Engine 1643
Remove the nuts and separate the stabilizer bar links from the struts.
22.
205-04 .
23.
Disconnect the 2 EPAS electrical connectors near the front of the subframe. 24.
Detach the 3 wiring harness retainers from the LH front of the subframe. 25.
27.
Engine 1644
28.
29.
Remove the 2 transaxle fluid cooler tube secondary latches. 31.
Using the Transmission Cooler Line Disconnect Tool, disconnect the 2 transaxle fluid cooler tubes. 32.
Remove the drain plug and drain the engine oil.
33.
Engine 1645
Remove and discard the engine oil filter. 34.
Section 303-12B .
35.
Remove the 2 nuts and disconnect the power feed wires from the battery terminal. 37.
Disconnect the 2 engine wiring harness electrical connectors. 39.
Remove the bolt and position aside the ground wire. 40.
Detach the 2 wiring harness retainers from the battery tray bracket and transaxle mount. 41.
Engine 1646
Remove the PCM ground bolt and position aside the ground wire. 42.
Disconnect the 3 PCM electrical connectors. 43.
Disconnect the fuel supply tube from the fuel rail. For additional information, refer to Section 310-00
.
44.
Disconnect the EVAP tube-to- EVAP canister purge valve quick connect coupling and the brake
booster vacuum tube from the upper intake manifold.
Detach the fuel tube and EVAP tube-to- EVAP canister purge valve tube retainer from the
upper intake manifold.

45.
Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector. 46.
Disconnect the upper and lower radiator hoses. 47.
Engine 1647
Disconnect the 2 heater hoses. 48.
Disconnect the gearshift cable from the transaxle. 49.
Remove the 2 shift cable bracket bolts, and position the cable and bracket aside. 50.
Remove the A/C tube/windshield washer bottle bracket bolt. 51.
Discard the gasket.
52.
Engine 1648
Disconnect the LH Catalyst Monitor Sensor (CMS) electrical connector. 53.
Remove the 4 bolts (3 shown) and the LH catalytic converter heat shield. 54.
Remove the 6 nuts and the LH catalytic converter manifold.
Discard the 6 LH catalytic converter manifold nuts and gasket.
55.
Clean and inspect the LH catalytic converter manifold. For additional information, refer to Section
303-00 .
56.
Remove and discard the 6 LH catalytic converter manifold studs. 57.
Remove the bolt and separate the A/C manifold from the A/C compressor.
Discard the gasket.
58.
Engine 1649
AWD vehicles
Disconnect the RH CMS electrical connector. 59.
Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector. 60.
Using the Exhaust Gas Oxygen Sensor Socket, remove the RH HO2S . 61.
Remove the 5 bolts and the RH exhaust heat shield. 62.
Remove the 3 nuts and the RH exhaust heat shield bracket (outboard half). 63.
Engine 1650
Remove the 2 bolts and the RH exhaust heat shield bracket (inboard half). 64.
Remove the 3 nuts (2 shown) and the RH catalytic converter.
Discard the nuts and gasket.
65.
Remove the 5 bolts and the PTU support bracket. 66.
Remove the 5 bolts and the PTU . 67.
Engine 1651
All vehicles
Remove the torque converter nut access plug. 68.
Remove the 4 torque converter nuts. 69.
Remove the 2 nuts and the transaxle-to-engine stud. 71.
Engine 1652
Install the Powertrain Lift and the Adjustable Grip Arm onto the engine.
72.
Remove the rear transaxle support through bolt. 73.
Remove the bolt and ground strap from the engine mount bracket. 74.
Remove the bolt and damper. 75.
Remove the bolt, 3 nuts and the engine mount bracket. 76.
Remove the transaxle-to-engine bolt. 78.
Engine 1653
Install the Adjustable Grip Arm and the Engine Lifting Bracket. 79.
Install the Engine Lifting Bracket. 80.
NOTE: When installing the lower half of the lifting bracket it will be easier to loosely install the
upper bolt first then install the lower bolt.
Install the lower half of the Engine Lifting Bracket Set.
81.
Install the upper half of the Engine Lifting Bracket Set. 82.
Using the Spreader Bar, Engine Lifting Brackets, Engine Lifting Bracket Set and a suitable engine
crane, remove the engine and transaxle from the lift table.
83.
Engine 1654
Remove the nut and the starter wiring ground. 84.
Remove the 2 nuts and the starter wiring. 85.
Remove the 2 stud bolts and the starter. 86.
Detach the wiring harness retainer from the transmission indicator tube. 87.
Disconnect the 2 transmission electrical connectors and detach the wiring retainer from the stud bolt. 88.
Engine 1655
Remove the 4 remaining transaxle-to-engine bolts. 89.
Using the Spreader Bar, Engine Lifting Brackets, Engine Lifting Bracket Set and the Heavy Duty
Floor Crane, separate the engine and transaxle.
90.
Engine 1656
(4V)
Manual
Engine
Special Tool(s)
3 Jaw Puller
303-D121
303-462 (T94P-6136-AH)
303-456 (T94P-6312-AH1), part of
303-S455
303-457 (T94P-6312-AH2), part of
303-S455
303-519 (T95P-6701-EH)
303-009 (T58P-6316-D)
Remover, Oil Seal
303-409 (T92C-6700CH)
Remover, Stretchy Belt
303-1419
Slide Hammer
307-005 (T59L-100-B)
NOTE: For additional information, refer to the exploded view under the Assembly procedure in this section.
All engines
Engine 1657
Remove the engine-to-transaxle separator plate. 2.
Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the
crankshaft rear oil seal.
3.
Mount the engine on a suitable stand. 4.
Detach the 2 B+ wiring harness retainers from the valve cover stud bolts. 5.
Disconnect the A/C compressor clutch electrical connector. 6.
Disconnect the generator electrical connector. 7.
Engine 1658
Remove the nut and the B+ wire from the generator.
Remove the B+ harness from the engine.
8.
Disconnect the 3 engine wiring connectors.
Disconnect the engine block Knock Sensor (KS) electrical connector.
Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
Disconnect the cylinder head KS electrical connector.
9.
Disconnect the EGR regulator electrical connector and detach the wiring retainer. 12.
Engine 1659
Disconnect the PCV valve electrical connector. 13.
Detach the wiring harness retainer from the upper intake manifold. 14.
Disconnect the Manifold Absolute Pressure (MAP) electrical connector and detach the wiring
retainer.
15.
Disconnect the RH coil-on-plug electrical connectors.
Detach the 2 wiring harness retainers.
16.
Disconnect the RH Variable Camshaft Timing (VCT) electrical connector and detach the wiring
harness retainer from the valve cover stud bolt.
17.
Engine 1660
Disconnect the Crankshaft Position (CKP) sensor electrical connector and detach the 2 wiring harness
retainers.
18.
Disconnect the 2 Camshaft Position (CMP) sensor electrical connectors and detach the wiring harness
19.
Disconnect the fuel injector wiring harness electrical connector and detach the wiring harness retainer. 20.
Disconnect the LH VCT electrical connector. 21.
Engine 1661
Remove the nut and the radio frequency interference capacitor. 22.
Disconnect the Engine Oil Pressure (EOP) switch electrical connector and detach the wiring retainer
from the oil indicator tube.
23.
Disconnect the 3 LH coil-on-plug electrical connectors.
Detach the 2 wiring harness retainers.
24.
Remove the 2 upper intake manifold bracket bolts (1 shown). 25.
26.
Remove the 4 bolts and the fuel rail and injectors as an assembly. 27.
Engine 1662
Remove the 8 lower intake manifold bolts and the lower intake manifold.
28.
FWD vehicles
Remove the 3 bolts and the RH heat shield. 29.
Remove the 3 nuts and the RH catalytic converter.
30.
All engines
Remove the 6 RH exhaust manifold nuts and the manifold.
31.
Clean and inspect the RH catalytic converter manifold. For additional information, refer to Section
303-00 .
32.
Engine 1663
Remove and discard the 6 RH catalytic converter manifold studs. 33.
Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt. 34.
Remove the bolt, 2 nuts and the generator. 36.
Remove the 3 bolts and the A/C compressor bracket. 37.
Position the Stretchy Belt Remover under the coolant pump belt as shown. 38.
Engine 1664
NOTE: Feed the Stretchy Belt Remover on to the camshaft coolant pump pulley 90 degrees.
Turn the crankshaft clockwise and feed the Stretchy Belt Remover evenly on the camshaft coolant
pump pulley as shown.
39.
Remove the coolant pump belt.
Fold the Stretchy Belt Remover over the top of the coolant pump belt.
In one quick motion, pull the Stretchy Belt Remover up and toward the front of the engine
removing the coolant pump belt.

40.
Using the Water Pump Pulley Plate, Water Pump Shaft Protector and the Crankshaft Vibration
Damper Remover, remove the coolant pump pulley.
41.
Remove the 5 coolant pump housing bolts. 42.
Engine 1665
Loosen the clamp and detach the coolant hose.
Remove the coolant pump housing.
43.
Remove the stud bolt and the oil level indicator and tube.
44.
Remove the EOP switch and, if equipped, the block heater. 45.
Remove the bolts and the 6 coil-on-plugs.
46.
Remove the bolts and the RH valve cover.
Discard the gasket.
47.
Engine 1666
Remove the bolts and the LH valve cover.
Discard the gasket.
48.
Discard the gasket.
49.
Remove the 2 bolts and the oil pump screen and pickup tube. 50.
Remove and discard the O-ring seal. 51.
Remove the oil pan baffle.
Remove the 4 M6 oil pan baffle nuts. 1.
Remove the 4 M8 oil pan baffle nuts. 2.
52.
Engine 1667
Remove the crankshaft pulley bolt and washer.
Discard the crankshaft pulley bolt.
54.
NOTE: Note the position of the alignment dowel on the engine front cover.
Remove the 2 bolts and the LH VCT .
57.
Engine 1668
Remove the 2 bolts and the RH VCT .
58.
means to clean the sealing surface. These tools cause scratches and gouges, which make leak
paths. Use a plastic scraping tool to remove all traces of sealant.
NOTE: Note the location of all bolts and stud bolts for installation.
Remove the 14 bolts, 2 stud bolts and the engine front cover.
Discard the gaskets.
59.
Remove the LH and RH spark plugs.
60.
Engine 1669
in the slot stamped "30RFF" (orange in color).
Remove the ignition pulse wheel.
61.
Install the crankshaft pulley bolt and washer. 62.
Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and
position the camshafts in the correct position. This will position the No. 1 cylinder at Top Dead
Center (TDC).
Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn
and recheck.

63.
Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in
the neutral position.
64.
Engine 1670
Verify that the RH camshafts are in the neutral position. 65.
Remove the RH timing chain tensioner arm.
66.
Remove the 2 bolts and the RH timing chain guide.
Remove the RH timing chain from the engine.
67.
Rotate the crankcase clockwise 600 degrees (one and two-thirds turns) to position the crankcase
keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
68.
Verify the LH camshafts are in the neutral position. 69.
Engine 1671
Remove the LH timing chain and tensioner arm.
70.
Remove the 2 bolts and the LH timing chain guide.
Remove the LH timing chain from the engine.
71.
Remove the crankshaft pulley bolt and the crankshaft sprocket. 72.
Remove the 4 bolts in the sequence shown.
Remove the oil pump.
73.
Using the Oil Seal Remover, remove the camshaft oil seal and discard.
74.
Engine 1672
75.
76.
Remove the 3 bolts and the LH camshaft phaser and sprocket.
77.
Remove and discard the VCT system oil filter screen from the LH camshaft. 78.
Engine 1673
79.
thrust caps (1L and 5L) first, or damage to the thrust caps may occur.
Remove the camshaft bearing thrust caps (1L and 5L). 1.
80.
Verify the RH camshafts are in the neutral position.
81.
Engine 1674
Remove the 3 bolts and the RH camshaft phaser and sprocket.
82.
Remove and discard the VCT system oil filter screen from the RH camshaft. 83.
84.
Engine 1675
thrust caps (5R and 1R) first, or damage to the thrust caps may occur.
Remove the camshaft bearing thrust caps (5R and 1R). 1.
85.
Remove the LH and RH camshaft roller followers.
Mark the location of the roller followers, using a permanent-type marker.
86.
87.
Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads.
Discard the bolts and the gaskets.
88.
Engine 1676
Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head
distortion and the cylinder block distortion. For additional information, refer to Section 303-00 .
89.
Remove the bolts and the oil separator cover.
Discard the gasket.
90.
Remove the crankshaft key. 91.
instructions.
92.
NOTE: Clearly mark the position and orientation of the pistons, connecting rods, connecting rod caps
and connecting rod bearings for reassembly.
93.
Repeat these 2 steps until all the piston/rod assemblies are removed from the engine block.
94.
Engine 1677
Remove the engine block from the stand and place on a workbench. 95.
Remove the bolts and studs in the indicated sequence.
Discard the lower cylinder block bolts.
Remove the lower cylinder block.
96.
Remove the crankshaft rear main seal.
Remove the crankshaft.
97.
Remove the crankshaft thrust bearing from the cylinder block. 98.
NOTE: If the main bearings are being reused, mark them for correct position and orientation for
reassembly.
Remove the bearings from the lower cylinder block.
99.
Engine 1678
reassembly.
Remove the crankshaft main bearings from the cylinder block.
100.
Inspect the cylinder block, lower cylinder block, pistons and connecting rods. For additional
101.
Engine 1679
SUBASSEMBLIES
Cylinder Head
Special Tool(s)
303-300 (T87C-6565-A)
303-350 (T89P-6565-A)
303-1418
303-470 (T94P-6510-CH)
Cylinder Head
Disassembly
Cylinder Head 1680
NOTICE: If the components are to be reinstalled, they must be installed in the same positions. Mark the
components removed for locations. If not reassembled in their original positions, severe engine damage
may occur.
Using the Valve Spring Compressors, remove the keys, retainer and spring. 1.
Remove the valve from the cylinder head. 2.
Remove the valve stem seal. 3.
Assembly
Using the Valve Stem Oil Seal Installer, install the valve stem seal. 1.
Install the valve. 2.
Using the Valve Spring Compressors, install the valve spring, retainer and keys. 3.
Cylinder Head 1681
Cylinder Head 1682
SUBASSEMBLIES
Piston
Material
Item Specification
Premium Motor Oil
(Canadr>XO-5W20-QSP (US);
WSS-M2C945-A
8 6135 Piston pin
10 6110 Piston
Disassembly
1.
Piston 1683
3.
Assembly
Align the piston-to-connecting rod orientation marks and position the connecting rod in the piston. 1.
NOTE: The piston compression lower ring should be installed with the "O" mark on the ring face
pointing up toward the top of the piston.
NOTE: When installing the piston oil control spacer, orient the gap such that the cut ends are pointed
toward the top of the piston.
Center line of the piston parallel to the wrist pin bore 1.
Upper compression ring gap location 2.
Upper oil control segment ring gap location 3.
Lower oil control segment ring gap location 4.
Expander ring and lower compression ring gap location 5.
6.
Piston 1684
Piston 1685
Workshop Manual
Engine
Special Tool(s)
303-D032 (D81L-6002-C)
100-002 (TOOL-4201-C)
303-1140
303-464 (T94P-6256-BH)
303-458 (T94P-6312-AH3), part of
303-S455
303-462 (T94P-6136-AH)
303-178 (T82L-6701-A)
303-102 (T74P-6316-B)
Installer, Front Cover Oil Seal
303-335 (T88T-6701-A)
211-185 (T91P-3A733-A)
Installer Bolts, Crankshaft Rear Main Oil
Seal
303-384 (T91P-6701-A)
303-050 (T70P-6000)
Engine 1686
303-463 (T91P-6256-AH)
303-459 (T94P-6312-AH4), part of
303-S455
Spreader Bar
Universal Adapter Brackets
014-0001
Material
Item Specification
ZC-31-A
-
(Canada)
XO-5W20-QSP (US);
WSS-M2C945-A
XG-3-A
ESE-M1C171-A
TA-30
WSE-M4G323-A4
TA-24
WSK-M2G350-A2
1 12A227 Ignition pulse wheel
2 6L266 RH timing chain tensioner
3 6K255 RH timing chain tensioner arm
4 6268 RH timing chain
5 6M256 RH timing chain guide
6 6306 Crant sprocket
7 6L266 LH timing chain tensioner
8 6K255 LH timing chain tensioner arm
9 6268 LH timing chain
10 6B297 LH timing chain guide
11 6621 Oil pump
12 W701923 Cup plug
13 6B752 Oil separator gasket
14 6869 Oil separator cover
15 8A505 Water inlet tube
16 6701 Crankshaft rear oil seal
17 6A373 Spacer plate
18 6375 Flexplate
20 W701528 Woodruff key
21 6622 Oil pickup tube and screen
22 6687 Oil pan baffle
23 6714 Oil filter
24 6675 Oil pan
25 10300 Generator
28 6316 Crankshaft vibration damper
29 N806165 Crankshaft vibration damper washer
30 W701512 Crankshaft vibration damper bolt
32 12K073 Camshaft Position (CMP) sensor (2 required)
33 6M280 Variable Camshaft Timing (VCT) solenoid (2
required)
34 6019 Front cover
Item
Part
Number Description
15 6A341 Crankshaft upper thrust bearing
16 6303 Crankshaft
17 6333 Lower cylinder block crankshaft main bearings (3
required)
18 6337 Lower cylinder block crankshaft main thrust bearing
19 6F095 Lower cylinder block
Cylinder Heads and Intake Manifolds
1 6582 RH valve cover
2 9F479 Mass Air Flow (MAF) sensor
5 12029 Coil-on-plug (6 required)
6 6A505 LH valve cover
7 9F792 Fuel rail
9 9424 Lower intake manifold
10 6B280 Camshaft thrust bearing cap
Cylinder Heads and Intake Manifolds 1690
11 6B280 Camshaft bearing cap
12 6C683 LH Variable Camshaft Timing (VCT) system oil filter
13 6A267 LH intake camshaft
14 6C524 LH camshaft phaser and sprocket
15 6A269 LH exhaust camshaft
16 6B295 Camshaft oil seal retainer gasket
17 6B293 Camshaft oil seal retainer
18 - Camshaft oil seal
19 6A359 Coolant pump drive pulley
20 6050 LH cylinder head
24 6529 Camshaft roller follower (24 required)
25 8501 Coolant pump housing
26 8K453 Coolant pump belt
30 - Oil level indicator
31 6754 Oil leindicator tube
32 6083 LH cylinder head gasket
35 6051 RH cylinder head gasket
36 6050 RH cylinder head
37 6C524 RH camshaft phaser and sprocket
38 6C683 RH VCT system oil filter
39 6A266 RH intake camshaft
40 6A268 RH exhaust camshaft
41 6A268 Camshaft thrust bearing cap
NOTICE: If the oil pan was removed during engine disassembly, it must be installed after the engine
and transaxle are assembled and the transaxle-to-engine bolts are installed. Failure to follow this
assembly sequence can result in engine oil leaks.
303-00 .
All engines
NOTE: This procedure is for selecting bearings using a new crankshaft.
Select the crankshaft main bearings for each crankshaft journal.
Read the code on the crankshaft flange. 1.
Read the code on the cylinder block rear face.
The first 2 numbers after the asterisk make up the code for main No. 1 and the next 2
numbers for main No. 2.

The first 2 numbers after the second asterisk make up the code for main No. 3 and the
last 2 numbers for main No. 4.

2.
1.
Using the chart, choose a bearing for each main. Match the block and crankshaft code with its
corresponding column or row, by reading across the "crankshaft" row and down the "block" column.
For example: If the block code is *0609*0711* and the crankshaft code is *8580*8082*,
main No. 1 should use grade 1 bearings, as determined by the intersection of the 06 block
column and the 85 crankshaft row. Mains 2, 3 and 4 should all be grade 2.

2.
3.
Lubricate the lower crankshaft main bearings with clean engine oil and install the 4 crankshaft main
bearings in the lower cylinder block.
4.
Lubricate the crankshaft thrust bearing with clean engine oil and install in the cylinder block. 5.
Install the crankshaft key. 6.
Apply clean engine oil to the crankshaft main and rod bearing journals. 7.
NOTICE: The lower cylinder block must be installed and the bolts tightened within 4 minutes of
applying the sealant.
NOTE: Clean and degrease both surfaces using metal surface prep before applying sealant.
Apply gasket and sealant to the cylinder block as shown.
9.
NOTICE: Fasteners No. 5 through 8 are studs. Fasteners No. 18 through 22 are M8 x 1.25 mm x
79.3 mm (0.05 in x 3.12 in) bolts. Fasteners No. 1 through 4, 17 are M8 x 1.25 mm x 96 mm (0.05
in x 3.75 in) bolts. Fasteners 9 through 12 are M10 x 1.5 mm x 106.8 mm (0.06 in x 4.20 in) /M8
x 1.25 mm x 21.5 mm (0.05 in x 0.84 in) studs. Fasteners 13 through 16 are M10 x 1.5 mm x
106.5 mm (0.06 in x 4.17 in) bolts. The bolts and studs must be installed in the correct position
or engine damage can result.
Position the lower cylinder block and install the new bolts and new studs.
Tighten the bolts and studs in the sequence shown in 4 stages.
Stage 1: Tighten fasteners 1 through 8 to 25 Nm (18 lb-ft).
Stage 3: Tighten fasteners 1 through 16 an additional 90 degrees.
10.
play.

Acceptable crankshaft end play is 0.100-0.255 mm (0.003-0.010 in). If the crankshaft end
play exceeds the specified range, install new parts as necessary.

11.
Using the Crankshaft Rear Main Oil Seal Installer and the Crankshaft Rear Main Oil Seal Installer
Bolts, install the crankshaft rear oil seal.
12.
Install the engine-to-transaxle separator plate. 13.
Position the flexplate and install the bolts.
14.
Mount the engine on an engine stand. 15.
Using the chart, select the correct piston grade size for the cylinder bores.
Measure the cylinder block bore diameter.
Mark the outside of the block with the appropriate number(s) to identify bore grade size.
Choose the correct piston grade size for the cylinder bore.
16.
clean engine oil.
NOTE: Make sure the piston rings are positioned to specifications for installation. For additional
information, refer to Disassembly and Assembly of Subassemblies - Piston in this section.
17.
NOTE: After installation of each piston and connecting rod, rotate the crankshaft to verify smooth
operation.
rod assemblies.
18.
Install the oil separator cover, a new gasket and the bolts.
19.
Position the new LH and RH cylinder heads and gaskets. Install new bolts and tighten in the sequence
shown in 6 stages.
20.
Install the crankshaft pulley bolt and rotate the crankshaft keyway to the 11 o'clock position to locate
Top Dead Center (TDC).
21.
22.
Apply clean engine oil to the LH and RH camshaft roller followers. 23.
Install the LH and RH camshaft roller followers.
24.
Install the new LH and RH oil filter screens in the intake camshafts.
25.
Position the camshaft phaser and sprockets onto the intake camshafts.
26.
cylinder head.
27.
have been installed, or damage to the thrust caps can occur.
bearing caps.
28.
Lubricate the bearing surfaces of the LH camshaft bearing thrust caps with clean engine oil and install
the bearing thrust caps.
29.
Tighten the LH camshaft bearing cap bolts in the sequence shown in 2 stages.
30.
Tighten the 3 LH camshaft phaser and sprocket bolts to 18 Nm (159 lb-in).
31.
NOTE: Clean the sealing surface with metal surface prep before installing a new press-in-place
gasket.
32.
NOTE: Apply clean engine oil to the seal lip and seal bore before installing the seal.
Using the Power Steering Pump Pulley Installer, Camshaft Oil Seal Installer and the Camshaft Oil
Seal Protector, install a new camshaft oil seal.
33.
cylinder head.
34.
NOTE: Lubricate the bearing surfaces of the RH camshaft bearing caps with clean engine oil.
Install the camshaft bearing caps.
35.
NOTE: Lubricate the bearing surfaces of the RH camshaft bearing thrust caps with clean engine oil.
Install the camshaft bearing thrust caps.
36.
37.
Tighten the 3 RH camshaft phaser and sprocket bolts to 18 Nm (159 lb-in).
38.
Position the oil pump and install the bolts.
39.
Remove the crankshaft pulley bolt. 40.
engine damage.
41.
Install the crankshaft sprockets with the timing marks facing out. The timing mark on the LH and RH
timing chains will be aligned to this mark during assembly.
Position the chain tensioner in a soft-jawed vise.
42.
Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
43.
NOTICE: During tensioner compression, do not release the ratchet stem until the tensioner
piston is fully bottomed in its bore or damage to the ratchet stem will result.
Slowly compress the timing chain tensioner.
44.
Retain the tensioner piston with a 1.5 mm (0.06 in) diameter wire or paper clip. 45.
If timing marks in the timing chains are not evident, use a permanent-type marker to mark the
crankshaft and camshaft timing marks on the LH and RH timing chains.
Mark any link to use as the crankshaft timing mark. 1.
Starting with the crankshaft timing mark, count 29 links and mark the link. 2.
Continue counting to link 42 and mark the link. 3.
46.
Position the LH timing chain and guide and install the bolts.
47.
Install the LH timing chain tensioner arm and the LH timing chain tensioner.
48.
Install the crankshaft pulley bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft
keyway is in the 3 o'clock position.
49.
Verify that the RH camshafts are correctly positioned. 50.
Install the RH timing chain and chain guide and install the bolts.
51.
Install the RH timing chain tensioner and tensioner arm.
52.
Remove the LH and RH timing chain tensioner piston retaining wires. 53.
Rotate the crankshaft counterclockwise 120 degrees to TDC . 54.
engine damage.
Verify the timing with the following steps.
There should be 12 chain links between the camshaft timing marks. 1.
55.
Remove the crankshaft pulley bolt and washer. 56.
in the slot stamped "30RFF" only (orange in color).
Install the ignition pulse wheel.
57.
NOTICE: Only use hand tools when removing or installing the spark plugs, damage can occur
Install the LH and RH spark plugs.
58.
paths.
NOTICE: Do not damage the oil pan gasket while cleaning the sealant from the lower cylinder
block-to-oil pan joint.
Use a plastic scraping tool to remove all traces of sealant.
Clean all sealing surfaces with metal surface prep and install new gaskets.
59.
NOTE: Clean and degrease the sealing surfaces with metal surface prep before applying gasket and
sealant.
NOTE: The front cover must be installed and the bolts tightened within 4 minutes of sealant
application.
Apply a 6 mm (0.24 in) dot of silicone gasket and sealant to the cylinder block to lower cylinder block
and cylinder head mating surfaces.
60.
NOTE: Fasteners 4 and 13 are stud bolts.
Position the front cover and install the bolts and stud bolts.
61.
Install the 2 bolts and the LH Variable Camshaft Timing (VCT) solenoid.
62.
Install the 2 bolts and the RH VCT solenoid.
63.
Apply clean engine oil to the seal lip and seal bore before installing the seal.
64.
Using the Front Cover Oil Seal Installer and the Crankshaft Vibration Damper Installer, install a new
crankshaft front seal.
65.
NOTE: Clean the keyway and slot using metal surface prep before applying silicone gasket and
sealant.
NOTE: Sealing surfaces must be free of dirt and oil.
NOTE: The crankshaft pulley must be installed and the bolt tightened within 4 minutes of sealant
application.
Apply silicone gasket and sealant to the end of the crankshaft pulley keyway slot.
66.
NOTE: Lubricate the outside diameter sealing surface with clean engine oil.
Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
67.
Install the bolt and washer. Tighten the bolt in 4 stages:
68.
Install the belt tensioner and the 3 bolts.
69.
Install the 8 nuts and the oil pan baffle.
Tighten the 4 M6 oil pan baffle nuts in 2 stages.
1.
Then install and tighten the 4 M8 oil pan baffle nuts in 2 stages.
2.
70.
Install a new O-ring seal on the oil pump screen and pickup tube.
Lubricate the O-ring seal with clean engine oil.
71.
Install the oil pump screen and pickup tube.
Position the oil pump screen and pickup tube. 1.
Install the 2 bolts and tighten to 10 Nm (89 lb-in). 2.
72.
Install the new gasket in the LH valve cover in the following sequence.
73.
NOTE: The valve cover must be installed and the bolts and studs tightened within 4 minutes of
NOTE: Clean cylinder head and front cover surface and the cam seal retainer-to-cylinder head
surface using metal surface prep before applying silicone gasket and sealant.
Apply an 8 mm (0.31 in) dot of silicone gasket and sealant at the cylinder block to front cover mating
surface and the cam seal retainer-to-cylinder head joints.
74.
NOTE: Install a new valve cover gasket.
Position the LH valve cover and install the bolts and stud bolts.
75.
Install the new gasket in the RH valve cover in the following sequence.
76.
NOTE: The valve cover must be installed and the bolts and stud bolts tightened within 4 minutes of
NOTE: Clean cylinder head and front cover surface using metal surface prep before applying silicone
gasket and sealant.
Apply an 8 mm (0.31 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints.
77.
NOTE: Install a new valve cover gasket.
Position the RH valve cover and install the bolts and stud bolts.
78.
79.
NOTE: Apply thread sealant with PTFE to the Engine Oil Pressure (EOP) switch threads.
Install the EOP switch.
80.
Position the coolant pump housing and attach the coolant hose.
Tighten the clamp to 7 Nm (62 lb-in).
81.
Install the 5 coolant pump housing bolts.
82.

83.
84.
camshaft.

Install the coolant pump belt on the coolant pump pulley and position it on the camshaft pulley. 85.
NOTICE: Do not use any screwdrivers, pliers or other metal objects that could cause damage to
the belt or camshaft pulley while installing the belt.
Rotate the crankshaft clockwise to seat the water pump belt on the camshaft pulley.
86.
Install a new O-ring on the oil level indicator tube. Apply clean engine oil to the O-ring. 87.
Position the oil level indicator and tube and install the stud bolt.
88.
Install the 3 bolts and the A/C compressor bracket. 89.
Position the generator and install the bolt and 2 nuts.
90.
91.
Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt. 92.
93.
Install a new gasket and the RH exhaust manifold and new nuts.
Tighten the nuts in 2 stages in the sequence shown.

94.
Front Wheel Drive (FWD)
Install a new gasket and the RH catalytic converter and the 3 new nuts.
95.
Install the 3 bolts and the RH heat shield.
96.
All engines
Apply a light film of silicone brake caliper grease and dielectric compound to the interior of the spark
plug boot prior to installation.
Install the 6 coil-on-plugs and the bolts.
97.
damage.
98.
Position the lower intake manifold and install the 8 bolts.
99.
Install the 4 bolts and the fuel rail and injectors assembly.
100.
damage.
Position the upper intake manifold and install the 7 bolts.
Tighten the bolts in 2 stages in the sequence shown.

101.
Loosen the upper intake manifold bracket lower bolt. Install the upper bolts (1 shown), then tighten all
the bolts.
102.
Connect the 3 LH coil-on-plug electrical connectors.
103.
Connect the Engine Oil Pressure (EOP) switch electrical connector and attach the wiring retainer to
the oil indicator tube.
104.
Install the radio interference capacitor and the nut.
105.
Connect the LH VCT electrical connector. 106.
Connect the fuel injector wiring harness electrical connector and attach the wiring harness retainer. 107.
Connect the 2 Camshaft Position (CMP) sensor electrical connectors and attach the wiring harness
108.
Connect the Crankshaft Position (CKP) sensor electrical connector and attach the 2 wiring harness
retainers.
109.
Connect the RH VCT electrical connector and attach the wiring harness retainer to the valve cover
stud bolt.
110.
Connect the RH coil-on-plug electrical connectors.
111.
Connect the Manifold Absolute Pressure (MAP) electrical connector and attach the wiring retainer. 112.
Attach the wiring harness retainer to the upper intake manifold. 113.
Connect the PCV valve electrical connector. 114.
Connect the EGR regulator electrical connector and attach the wiring retainer. 115.
Connect the Evaporative Emission (EVAP) canister purge valve electrical connector. 116.
Connect the 3 engine wiring connectors.
Connect the engine block Knock Sensor (KS) electrical connector.
Connect the Cylinder Head Temperature (CHT) sensor electrical connector.
Connect the cylinder head KS electrical connector.
118.
Position the B+ wiring harness and attach the 2 harness retainers to the valve cover stud bolts. 119.
Install the B+ wire and nut on the generator.
120.
Connect the generator electrical connector. 121.
Connect the A/C compressor clutch electrical connector. 122.
NOTE: When installing the lower half of the lifting bracket it will be easier to loosely install the
upper bolt first then install the lower bolt.
123.
Install the Engine Lifting Bracket. 125.
Install the Engine Lifting Bracket and the Universal Adapter Bracket. 126.
crane, remove the engine from the engine stand.
127.
(4V)
Manual
Engine
Special Tool(s)
303-1140
303-050 (T70P-6000)
Powertrain Lift
303-476
Spreader Bar
Material
Item Specification
ZC-31-A
-
(Canada)
XO-5W20-QSP (US);
WSS-M2C945-A
Engine 1723
TA-30
WSE-M4G323-A4
Installation
NOTICE: If the oil pan was removed during engine disassembly, it must be installed after engine and
transaxle are assembled and the transaxle-to-engine bolts are installed. Failure to follow this assembly
sequence can result in engine oil leaks.
All vehicles
crane, align the transaxle to the engine.
1.
Install the 4 transaxle-to-engine bolts.
2.
Install the transaxle-to-engine bolt.
3.
Connect the 2 transmission electrical connectors and attach the wiring harness retainer to the stud
bolt.
4.
Attach the wiring harness retainer to the transmission indicator tube. 5.
Engine 1724
Install the starter and the 2 stud bolts.
6.
Install the starter wiring and the 2 nuts.
Tighten the large starter motor solenoid battery cable nut to 12 Nm (106 lb-in).
7.
paths.
Use a plastic scraping tool to remove all traces of the oil pan gasket.
Clean all sealing surfaces with metal surface prep and install a new oil pan gasket.
8.
Install the starter wiring ground wire and nut.
9.
crane, position the engine and transaxle onto the lift table.
10.
Engine 1725
Install the Adjustable Grip Arm and the Powertrain Lift to the engine.
11.
Raise the engine and transaxle up into the vehicle. 12.
Install the engine support insulator bracket, 3 nuts and the bolt.
13.
Install the damper and bolt.
14.
Install the ground strap and bolt on the engine mount bracket.
15.
Install the rear transaxle support through bolt. 16.
Engine 1726
Install the transaxle-to-engine stud and 2 nuts.
17.
NOTE: Clean and degrease all sealing surfaces with metal surface prep.
NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of the sealant
application.
Apply a 10 mm (0.39 in) dot of silicone gasket and sealant to the front cover-to-cylinder block sealing
surface.
18.
NOTE: Install a new oil pan gasket.
Position the oil pan and gasket and loosely install the bolts and stud bolts.
19.
20.
Engine 1727
Tighten the oil pan bolts in the sequence shown to 25 Nm (18 lb-ft). 21.
Install the 4 torque converter nuts.
22.
Install the access cover. 23.
Install the Power Transfer Unit (PTU) and the 5 bolts.
24.
Engine 1728
Install the PTU support bracket and the 5 bolts.
25.
NOTE: A new PTU seal must be installed whenever the intermediate shaft is removed.
Install a new PTU seal. For additional information, refer to Section 308-07B .
26.
Using a new gasket, install the RH catalytic converter and 3 new nuts.
27.
Install the RH exhaust heat shield bracket (inboard half) and the 2 bolts.
28.
Install the RH exhaust heat shield bracket (outboard half) and the 3 nuts.
29.
Engine 1729
Install the RH exhaust heat shield and the 6 bolts.
30.
Using the Exhaust Gas Oxygen Sensor Socket, install the RH Heated Oxygen Sensor (HO2S).
Calculate the correct torque wrench setting for the following torque. Refer to the Torque
Wrench Adapter Formulas in the Appendix.

31.
Connect the RH HO2S electrical connector. 32.
Connect the RH Catalyst Monitor Sensor (CMS) electrical connector. 33.
Engine 1730
All vehicles
Position the A/C manifold onto the A/C compressor and install the bolt.
Install a new gasket.
34.
Install 6 new LH catalytic converter studs.
35.
Install a new gasket, the LH catalytic converter and 6 new nuts.
Tighten to 20 Nm (177 lb-in) in the sequence shown.
36.
Install the heat shield and the 4 bolts (3 shown).
37.
Connect the LH CMS electrical connector. 38.
Engine 1731
Connect the A/C tube and install the nut.
39.
Install the A/C tube/windshield washer bottle bracket bolt.
40.
Position the transaxle control cable bracket in place, install the 2 bolts.
41.
Connect the gearshift cable to the transaxle. 42.
Connect the 2 heater hoses. 43.
Engine 1732
Connect the upper and lower radiator hoses. 44.
Connect the LH HO2S electrical connector. 45.
Connect the Evaporative Emission (EVAP) tube-to- EVAP canister purge valve quick connect
coupling and the brake booster vacuum tube to the upper intake manifold.
Attach the fuel tube and EVAP tube-to- EVAP canister purge valve tube retainer to the upper
intake manifold.

46.
Connect the fuel supply tube to the fuel rail. For additional information, refer to Section 310-00 . 47.
Connect the 3 PCM electrical connectors. 48.
Position the PCM ground wire and install the bolt.
49.
Engine 1733
Attach the 2 wiring harness retainers to the battery tray bracket and transaxle mount. 50.
Install the ground wire-to-inner fender and bolt.
51.
Connect the 2 engine wiring harness electrical connectors. 52.
Connect the power feed wires to the battery terminal and install the 2 nuts.
54.
Engine 1734
303-12B .
56.
Install a new engine oil filter.
57.
Position the transmission fluid cooler tubes in place. Install the transmission fluid cooler tubes in the
transaxle by inserting the tube into the fitting until a click is heard/felt. Pull back to confirm
connection is secure and install the secondary latches.
58.
60.
Engine 1735
61.
62.
63.
Attach the 3 wiring harness retainers to the LH front of the subframe. 64.
Engine 1736
Connect the 2 Electronic Power Assist Steering (EPAS) electrical connector on the front of the
subframe.
65.
Install the intermediate shaft and the LH halfshaft. For additional information, refer to Section 205-04
.
66.
Install the stabilizer bar links and nuts to the struts.
67.
Install the tie-rod ends and nuts.
68.
Install the engine roll restrictor and the 2 bolts.
69.
If equipped, install the heat shield and the 2 bolts. 70.
Engine 1737
into the body.
From under the vehicle, verify that the seal is properly installed on the steering gear and the
retaining clips are fully engaged into the body.

71.
AWD vehicles
Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during
removal and install the 4 bolts (3 shown).
72.
All vehicles
Engine 1738
Install the EPAS ground wire and bolt in the RH front wheel well.
76.
Install the steering intermediate shaft onto the steering gear and install the bolt.
79.
Engine 1739
Check the transaxle fluid and add fluid if necessary. For additional information, refer to the
transmission fluid drain and refill procedure in Section 307-01A .
84.
86.
Engine 1740
SECTION 303-01C: Engine - 3.5L
Manual
Material
Capacity
Motorcraft High
Performance Engine
RTV Silicone
TA-357
WSE-M4G323-A6 -
Motorcraft Metal
Surface Prep
ZC-31-A
- -
Motorcraft SAE
5W-20 Premium
Synthetic Blend
Motor Oil (US);
Motorcraft SAE
5W-20 Super
Premium Motor Oil
(Canada)
XO-5W20-QSP
(US);
CXO-5W20-LSP12
(Canada)
WSS-M2C945-A 5.2L (5.5
qt)
includes
filter
change
Motorcraft
Silicone Gasket
Remover
ZC-30
- -
Motorcraft
Specialty Green
Engine Coolant
VC-10-A2 (US);
CVC-10-A
(Canada)
WSS-M97B55-A
a
Motorcraft
Orange
Antifreeze/Coolant
Concentrated
VC-3-B (US);
CVC-3-B2
(Canada)
WSS-M97B44-D
a
Thread Sealant with
PTFE
TA-24
WSK-M2G350-A2 - Threadlock
and Sealer
TA-25
WSK-M2G351-A5 -
a
Engine 1741
Item Specification
Engine
Displacement 3.5L (4V) (214 CID)
No. cylinders 6
Bore/stroke 92.5/86.7 mm (3.641/3.413 in)
Fire order 1-4-2-5-3-6
Oil pressure Minimum 30 psi @ 1,500 rpm with engine at normal
operating temperature
Spark plug AYSF-22FM Gap = 1.29-1.45 mm (0.051-0.057 in)
components)
161 kg (355 lb)
Engine and transaxle weight (without accessory
drive components)
260.8 kg (575 lb)
Cylinder head gasket surface flatness
a
Flat within 0.08 mm (0.003 in) length end to end, area
150 mm (5.9 in) X 150 mm (5.9 in) (or full width)
should be less than 0.05 mm (0.002 in)
Combustion chamber volume 55.84 cc (3.41 CI)
Valve tappet clearance intake 0.15-0.25 mm
(0.006-0.01 in)
Valve tappet clearance - exhaust 0.360-0.460 mm
(0.0142-0.0181 in)
Engine must be at room temperature before measuring
Valve guide bore inner diameter 5.519-5.549 mm
(0.217-0.218 in)
(0.2157-0.2164 in)
(0.2151-0.2159 in)
Valve stem-to-guide clearance - intake 0.022-0.070 mm
(0.0008-0.0027 in)
Valve stem-to-guide clearance - exhaust 0.035-0.083 mm
(0.0013-0.032 in)
(1.44-1.46 in)
Engine 1742
(1.21-1.22 in)
Valve 0.05 mm (0.0001 in)
Valve face angle 44.5-45.5 degrees
Valve seat width - intake 1.3-1.5 mm
(0.051-0.059 in)
Valve seat width - exhaust 1.7-2.0 mm
(0.067-0.079 in)
Valve seat runout 0.04 mm
(0.0001 in) MAX
Valve seat angle 44.5-45.5 degrees
Valve spring free length (approx.) 48.0 mm (1.889 in)
Valve spring compression pressure (N @ spec.
length)
525 N @ 27.0 mm
(114.7 lb @ 1.06 in)
Valve spring installed height 37.0 mm (1.45 in)
Valve spring installed height pressure (N @ spec.
length)
235 N @ 37.0 mm
(53 lb @ 1.45 in)
Valve spring installed pressure - service limit 10% force loss @ specified height
Camshaft
Theoretical valve lift @ 0 lash 9.6798 mm (0.38 in)
Allowaift loss 0.062 mm (0.0024 in)
Camshaft journal bore inside diameter - 1st journal 31.0375-31.0625 mm
(1.221-1.222 in)
Camshaft journal bore inside diameter -
intermediate journals
25.9875-26.0125 mm
(1.023-1.024 in)
Camshaft bearing outside diameter - 1st journal 30.993-31.013 mm
(1.2202-1.2209 in)
Camshaft bearing outside diameter - intermediate
journals
25.937-25.963 mm
(1.021-1.022 in)
Camshaft journal-to-bearing clearance, 1st journal
- service limit
0.0725 mm
(0.0029 in) MAX
Camshaft journal-to-bearing clearance,
intermediate journals - service limit
0.0755 mm (0.0029 in) MAX
Runout 0.040 mm (0.0015 in) MAX
End play - standard 0.032-0.170 mm
Engine 1743
(0.0012-0.0066 in)
End play - service limit 0.190 mm (0.00748 in) MAX
Cylinder Block
Cylinder bore roundness 0.013 mm (0.0005 in)
Cylinder bore taper
Block main bore roundness 0.008 mm (0.0003 in)
Main bearing bore inside diameter 72.400-72.424 mm (2.8503-2.8513 in)
Head gasket surface flatness Flat within 0.150 mm (0.005 in) overall
0.050 mm (0.001 in) per 150 mm (5.905 in) x 150 mm
(5.905 in)
0.025 mm (0.0009 in) per 25 mm (0.98 in) x 25 mm
(0.98 in)
Crankshaft
Main bearing journal diameter 67.5 mm (2.657 in)
Main bearing journal maximum taper 0.004 mm (0.00015 in)
Main bearing journal maximum out-of-round 0.006 mm (0.00023 in)
Main bearing journal-to-cylinder block clearance 0.026-0.041 mm (0.0010-0.0016 in)
Connecting rod journal diameter 55.983-56.003 mm (2.204-2.205 in)
Connecting rod journal maximum taper 0.004 mm (0.00015 in)
Connecting rod journal maximum out-of-round 0.006 mm (0.00023 in)
Crankshaft maximum end play 0.101-0.291 mm (0.0039-0.0114 in)
Piston and Connecting Rod
Piston diameter - single grade 92.476-92.490 mm
(3.6407-3.6413 in)
Piston-to-cylinder bore clearance 0.010 to 0.044 mm
(0.0003-0.0017 in)
Piston ring end gap - compression (top, gauge
diameter)
0.15-0.25 mm
(0.0059-0.0098 in)
Piston ring end gap - compression (bottom, gauge
diameter)
0.30-0.55 mm (0.0118-0.0216 in)
Piston ring end gap - oil ring (steel rail, gauge
diameter)
0.15-0.45 mm
(0.0059-0.0177 in)
Piston ring groove width - compression (top) 1.230-1.25 mm
(0.0484-0.0492 in)
Piston ring groove width - compression (bottom) 1.530-1.55 mm
(0.0602-0.0610 in)
Piston ring groove width - oil ring 2.53-2.55 mm
Engine 1744
(0.0996-0.1003 in)
Piston ring width - upper comp ring 1.17-1.19 mm
(0.0460-0.0468 in)
Piston ring width - lower comp ring 1.47-1.49 mm
(0.0578-0.0586 in)
Piston ring-to-groove clearance (upper and lower
compression rings)
0.040-0.080 mm
(0.0015-0.0031 in)
Piston pin bore diameter 23.004-23.008 mm
(0.9056-0.9058 in)
Piston pin diameter 22.997-23.000 mm
(0.9053-0.9055 in)
Piston pin length 55.975 mm (2.203 in)
Piston pin-to-piston fit 0.004 to 0.011 mm
(0.00015-0.00043 in)
Piston-to-connecting rod clearance 2.7 mm (0.1 in)
Connecting rod-to-pin clearance - standard 0.007-0.022 mm
(0.0002-0.0009 in)
Connecting rod pin bore diameter 23.007-23.019 mm
(0.905-0.906 in)
Connecting rod length (center-to-center) 152.68 mm (6.01 in)
Connecting rod maximum allowed bend 0.038 mm (0.0014 in)
Connecting rod maximum allowed twist 0.050 mm (0.0019 in)
Connecting rod bearing bore diameter - grade 1 59.866-59.872 mm
(2.3569-2.3571 in)
(2.3572-2.3574 in)
(2.3574-2.3577 in)
Connecting rod bearing-to-crankshaft clearance 0.020-0.054 mm (0.0007-0.0021 in)
Connecting rod side clearance (assembled to
crank) - s/TD>
0.175-0.425 mm
(0.0068-0.0167 in)
Connecting rod side clearance (assembled to
crank) - service limit
0.175-0.425 mm (0.0068-0.0167 in)
a
Engine 1745
A/C compressor bolts and nut 25 18 -
A/C compressor stud 9 - 80
A/C manifold bolt 25 18 -
A/C tube bracket bolts 10 - 89
A/C tube fitting bolts and nuts 8 - 71
A/C tube retaining clamp bolt 8 - 71
A/C tube retaining clamp bolts and nut 10 - 89 Accessory drive belt tensioner
bolts
11 - 97
Block coolant drain plug - RH
a
- - -
Block coolant drain plug - LH
b
- - -
Block oil galley plug - LH 48 35 -
Block oil galley plug - rear 85 63 -
Block oil galley plug - RH 32 24 -
Camshaft cap bolts
c
- - -
Camshaft Position (CMP) sensor bolts 10 - 89
Camshaft sprocket bolts
c
- - -
40 30 -
Catalytic converter bracket-to-engine bolts and
nuts
40 30 -
Catalytic converter bracket-to-converter bolts 20 - 177
c
- - -
Coolant pump bolts
c
- - -
Crankshaft Position (CKP) sensor bolt 10 - 89
c
- - -
Crankcase rear seal retainer plate bolts
c
- - -
Cylinder head bolts
c
- - -
Cylinder Head Temperature (CHT) sensor 10 - 89
9 - 80
c
- - -
Engine lifting eye bolts 24 18 -
Engine mount brace bolts 25 18 -
Engine mount bracket bolts
c
- - -
Engine mount studs
c
- - -
Engine mount-to-engine nuts
c
- - -
Engine mount-to-frame bolts 55 41 -
Engine mount-to-frame nut 63 46 -
Engine oil filter
d
- - -
Engine Oil Pressure (EOP) switch <="center">- - -
Engine roll-restrictor bolt 90 66 -
Engine-to-transaxle bolts 48 35 -
Exhaust manifold heat shield bolts 10 - 89
c
- - -
Engine 1746
Exhaust Y-pipe nuts 40 30 -
Flexplate bolts 80 59 -
Fuel rail bolts 10 - 89
Generator bolt and nut 48 35 -
Generator B+ terminal nut 12 - 106 12 - 106
Ground wire-to-engine mount bolt 10 - 89
Ground wire-to-transaxle bolt 12 - 106
Heat shield nut and bolt 10 - 89
Ignition coil-on-plug bolts 7 - 62
Intermediate steering shaft bolt 25 18 -
Knock Sensor (KS) bolts 20 - 177
Lower intake manifold bolts
c
- - -
Main bearing bolts
c
- - -
Main bearing cap support brace bolts
c
- - -
Oil filter adapteralign="top" align="center">- - -
Oil pan bolts
c
- - -
Oil pan-to-transaxle bolts 48 35 -
Oil pump bolts 10 - 89
Positive battery cable nuts 9 - 80
Power Steering Pressure (PSP) hose bracket and
nut
9 - 80
PSP tube banjo bolt 37 27 -
PSP tube bracketTD> 10 - 89
Power steering pump bolts 25 18 -
Power Transfer Unit (PTU) 90 66 -
PTU bracket bolts 70 52 -
Rear drive shaft-to- PTU flange bolts 70 52 -
Starter bolts 26 19 -
Starter B+ terminal nut 12 - 106
Starter S-terminal nut 5 - 44
Subframe bracket bolts 76 -
Timing chain guide pin
c
- - -
Timing chain tensioner arm pin
c
- - -
Torque converter-to-flexplate nuts 36 27 -
Transaxle control cable bracket bolts and nut 12 - 106
Engine 1747
Transaxle support insulator bracket bolt and nut 80 -
Transaxle support insulator through bolt and nut 90 66 -
Upper intake manifold bolts
c
- - -
Upper intake manifold support bracket bolt 10 - 89
Variable Camshaft Timing (VCT) assembly bolts
c
- - -
VCT housing bolts
c
- - -
Valve cover bolts and stud bolts
c
- - -
Wiring harness retainer bolt and stud bolt 10 - 89
Wiring harness retainer bracket nuts 4 -
a
Tighten to 10 Nm (89 lb-in) plus an additional 720 degrees.
b
c
d
Engine 1748
Manual
Engine
The 3.5L (4V) is a V-6 engine with the following features:
Dual overhead camshafts
An aluminum lower intake manifold and a composite upper intake manifold
Aluminum cylinder heads
An aluminum, 60-degree V-cylinder block
Timing chain driven coolant pump
Variable Camshaft Timing (VCT) system
The electronic ignition system with 6 ignition coils
For quick identification, refer to the safety certification decal.
The decal is located on the LH front door lock face panel.
Item Description
2 Engine plant (Lima)
4 Engine configuration
5 Duratech 3.5L
6 Bar code
7 Bar code
8 Running number
10 Plant shift line
11 Derivative code
Engine 1749
Operation and required maintenance of the exhaust emission control devices used on this engine is covered in
the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Induction System
injectors:
are mounted between the fuel rail and the intake manifold.
Valve Train
The valve train uses Direct Acting Mechanical Buckets (DAMB). The camshaft lobes are positioned directly
above mechanical buckets which are positioned on top of the valves.
Variable Camshaft Timing (VCT) System
The VCT system changes intake camshaft timing dependent on engine speed, load and oil temperature. Oil
pressure advances and retards camshaft timing to improve low-speed and high-speed engine performance,
engine idle quality and exhaust emissions.
PCV System
All engines are equipped with a closed-type PCV system recycling the crankcase vapors to the upper intake
manifold.
Lubrication System
Engine 1750
The engine lubrication system is of the force-feed type in which oil is supplied under full pressure to the
crankshaft, connecting rod bearings, timing chain tensioners and VCT solenoids. The flow of oil to the valve
tappets and valve train is controlled by a restricting orifice located in the cylinder head, front camshaft cap.
Oil Pump
The lubrication system is designed to provide optimum oil flow to critical components of the engine through
its entire operating range.
The heart of the system is a positive displacement internal gear oil pump.
Generically, this design is known as a gerotor pump, which operates as follows:
The oil pump is mounted on the front face of the cylinder block.
The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft.
System pressure is limited by an integral, internally-vented relief valve which directs the bypassed oil
back to the inlet side of the oil pump.

Oil pump displacement has been selected to provide adequate volume to make sure of correct oil
pressure both at hot idle and maximum speed.

The relief valve calibration protects the system from excessive pressure during high-viscosity
conditions.

The relief valve is designed to provide adequate connecting rod bearing lubrication under
high-temperature and high-speed conditions.

Cooling System
NOTICE: Early build vehicle cooling systems are filled with Motorcraft Specialty Green Engine
Coolant and late build vehicle cooling systems are filled with Motorcraft Specialty Orange Engine
Coolant. Use the same type of coolant that was originally used to fill the cooling system. Do not mix
coolant types. Mixing coolant types degrades the coolant corrosion protection and may damage the
engine or cooling system.
NOTICE: Motorcraft Specialty Green Engine Coolant is very sensitive to light. Do NOT allow this
product to be exposed to ANY LIGHT for more than a day or two. Extended light exposure causes this
product to degrade.
NOTE: ring normal vehicle operation, Motorcraft Specialty Orange Engine Coolant may change color from
orange to pink or light red. As long as the engine coolant is clear and uncontaminated, this color change does
not indicate the engine coolant has degraded nor does it require the engine coolant to be drained, the system to
be flushed, or the engine coolant to be replaced.
The engine cooling system includes the following:
Radiator
Timing chain driven coolant pump
Electric fan assembly(s)
Degas bottle (aids in maintaining the correct volume of engine coolant)
Coolant thermostat
Coolant hoses
Engine 1751
Engine 1752
Manual
Engine
Engine 1753
SECTION 303-01C: Engine - 3.5L 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop Manual
Remove the valve covers. For additional information, refer to Valve Cover - LH and Valve Cover -
RH in this section.
1.
NOTE: Engine must be at room temperature before measuring. The valve clearance must be
measured with the camshaft at base circle. The engine will have to be rotated with the crankshaft
pulley bolt to bring each valve to base circle.
Use a feeler gauge to measure the clearance of each valve and record its location. A midrange
clearance is thesirable:
Intake: 0.15-0.25 mm (0.006-0.01 in)
Exhaust: 0.360-0.460 mm (0.0142-0.0181 in)
2.
NOTE: The number on the valve tappet reflects the thickness of the valve tappet. For example, a
tappet with the number 3.310 has the thickness of 3.31 mm (0.13 in).
If any of the valve clearances are out of specification, select new tappets using this formula: tappet
thickness = measured clearance + the base tappet thickness - most desirable thickness.
Select the tappets and mark the installation location.
3.
If required, install the new selected valve tappets in the marked locations. For additional information,
refer to Valve Tappets in this section.
4.
Upper Intake Manifold
1 6K817 PCV hose
2 13A506 Block heater wiring harness retainer (part of 6B018)
3 14A464 Throttle Body (TB) electrical connector (part of
12C508)
4 CS16140 Brake booster-to-intake manifold vacuum hose clamp
5 6K817 Brake booster-to-intake manifold vacuum hose
6 9D661 Evaporative Emission (EVAP)-to-intake manifold tube
7 W503274 Upper intake manifold support bracket bolt
8 - Engine control wiring harness retainer (part of
12C508)
Upper Intake Manifold 1756
1 13A506 Wire harness pin-type retainers (part of 14B060)
2 W503282 Upper intake manifold bolt (5 required)
3 W707083 Upper intake manifold bolt
4 9S455 Upper intake manifold
5 9H486 Upper intake manifold gasket (3 required)
Removal
Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Section 303-12C . 1.
Disconnect the Throttle Body (TB) electrical connector. 2.
Disconnect the Evaporative Emission (EVAP)ube from the intake manifold. For additional
3.
Disconnect the brake booster vacuum hose from the intake manifold. 4.
Disconnect the PCV tube from the PCV valve. 5.
Detach all the wiring harness retainers from the upper intake manifold. 6.
If equipped, detach the cylinder block heater wiring harness retainer from the upper intake manifold. 7.
Remove the upper intake manifold support bracket bolt. 8.
Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.
9.
Installation
damage.
Using new gaskets, install the upper intake manifold and the 6 bolts.
1.
Install the upper intake manifold support bracket bolt.
2.
If equipped, attach the cylinder block heater wiring harness retainer to the upper intake manifold. 3.
Attach all the wiring harness retainers to the upper intake manifold. 4.
Connect the PCV tube to the PCV valve. 5.
Connect the brake booster vacuum hose to the intake manifold. 6.
Connect the EVAP tube to the intake manifold. For additional information, refer to Section 310-00 . 7.
Connect the TB electrical connector. 8.
Install the ACL outlet pipe. For additional information, refer to Section 303-12C . 9.
Lower Intake Manifold
1 W708607 Thermostat housing-to-lower intake manifold bolt
2 W503279 Thermostat housing-to-lower intake manifold bolt
3 9439 Lower intake manifold gasket (8 required)
4 8A571 Thermostat housing gasket
5 W503279 Lower intake manifold bolt (10 required)
6 9K461 Lower ke manifold
Removal
100-02 .
1.
Remove the fuel rail. For additional information, refer to Section 303-04C . 2.
Remove the 2 thermostat housing-to-lower intake manifold bolts. 4.
Remove the 10 bolts and the lower intake manifold.
Remove and discard the intake manifold and thermostat housing gaskets.
Clean and inspect all sealing surfaces.
5.
Installation
damage.
1.
Using new intake manifold and thermostat housing gaskets, install the lower intake manifold and the
10 bolts.
Install the 2 thermostat housing-to-lower intake manifold bolts.
2.
Install the fuel rail. For additional information, refer to Section 303-04C . 3.
Valve Cover - LH
Special Tool(s)
Handle
205-153 (T80T-4000-W)
Installer, VCT Spark Plug Tube Seal
303-1247/2
Remover, VCT Spark Plug Tube Seal
303-1247/1
Material
Item Specification
Motorcraft High Performance
Engine RTV Silicone
TA-357
WSE-M4G323-A6
ZC-31-A
-
Remover
ZC-30
-
Valve Cover - LH (View 1 of 2)
Valve Cover - LH 1761
Item
Part
Number Description
1 - Engine control wiring
harness electrical
harness electrical
3 W520100 Wiring harness retaining
bracket nut (2 required)
harness electrical
5 - Wiring harness retaining
bracket (part of 12C508)
6 - LH fuel injector electrical
connector (3 required)
(part of 12C508)
7 - LH Variable Camshaft
Timing (VCT) electrical
connector (part of 12
valign="top">
8 W700497 Engine control
wiring harness
retainer (part of
12C508)
Valve Cover - LH (View 2 of 2)
Valve Cover - LH (View 1 of 2) 1762
3 6C535 Spark plug tube seal (3 required)
4 6C535 Variable Camshaft Timing (VCT) solenoid seal
5 6A505 LH valve cover
6 6A559 LH valve cover gasket
Removal
Remove the LH ignition coils.or additional information, refer to Section 303-07C . 2.
Disconnect the LH Variable Camshaft Timing (VCT) solenoid electrical connector. 4.
Detach the 2 wiring harness retainers. 5.
Disconnect the 2 engine control wiring harness electrical connectors. 6.
Remove the 2 nuts and the wiring harness retaining bracket. 7.
Detach all of the wiring harness retainers from the valve cover and the stud bolts. 8.
Disconnect the 3 LH fuel injector electrical connectors. 9.
Loosen the 9 stud bolts and remove the LH valve cover.
Discard the gasket.
10.
NOTE: VCT solenoid seal removal shown, spark plug tube seal removal similar.
Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals.
Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
11.
Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep. 12.
Installation
NOTE: Installation of new seals is only required if damaged seals were removed during disassembly
of the engine.
NOTE: Spark plug tube seal installation shown, VCT solenoid seal installation similar.
1.
Using the VCT Spark Plug Tube Seal Installer and Handle, install new VCT solenoid and/or spark
plug tube seals.
NOTICE: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the
engine oil to foam excessively and result in serious engine damage.
NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant
must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover
and metal surface prep. Failure to follow this procedure can cause future oil leakage.
Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine
front cover-to-LH cylinder head joints.
2.
Using a new gasket, install the LH valve cover and tighten the 9 stud bolts.
3.
Connect the 3 LH fuel injector electrical connectors. 4.
Attach all of the wiring harness retainers to the valve cover and the stud bolts. 5.
Install the wiring harness retaining bracket and the 2 nuts.
6.
Connect the 2 engine control wiring harness electrical connectors. 7.
Attach the 2 wiring harness retainers. 8.
Connect the LH VCT solenoid electrical connector. 9.
Install the LH ignition coils. For additional information, refer to Section 303-07C . 11.
Install the ACL outlet pipe. For additional information, refer to Section 303-12C . 12.
Valve Cover - RH
Special Tool(s)
Handle
205-153 (T80T-4000-W)
303-1247/2
303-1247/1
Material
Item Specification
Engine RTV Silicone
TA-357
WSE-M4G323-A6
ZC-31-A
-
Remover
ZC-30
-
Valve Cover - RH (View 1 of 3)
1 W503924 A/C tube retaining clamp bolt (2 required)
2 W505422 A/C tube retaining clamp bolt
Valve Cover - RH 1767
Item
Part
Number Description
1 - Power Steering Pressure (PSP) switcconnector (part of
12C508)
2 - RH Catalyst Monitor Sensor (CMS) electrical connector
(part of 12C508)
3 - RH Variable Camshaft Timing (VCT) electrical
4 - RH fuel injector electrical connector (3 required) (part
of 12C508)
5 W700497 Engine control wiring harness retainer (part of 12C508)
6 - RH Heated Oxygen Sensor (HO2S) electrical connector
(part of 12C508)
7 W520100 PSP hose bracket nut
8 3A719 PSP hose bracket
Valve Cover - RH (View 2 of 3) 1768
2 6C520 Valve cover bolt
3 6C535 Variable Camshaft Timing (VCT) solenoid seal
4 6C535 Spark plug t3 required)
6 6584 RH valve cover gasket
Removal
Remove the RH ignition coils. For additional information, refer to Section 303-07C . 1.
Remove the power steering fluid reservoir. For additional information, refer to Section 211-02 . 2.
Disconnect the Power Steering Pressure (PSP) switch electrical connector. 3.
Disconnect the RH Catalyst Monitor Sensor (CMS) electrical connector and retainer. 4.
Remove the PSP hose bracket nut from the valve cover stud bolt and position the bracket aside. 5.
Disconnect the RH Variable Camshaft Timing (VCT) electrical connector. 7.
Disconnect the 3 RH fuel injector electrical connectors. 8.
Detach all of the wiring harness retainers from the valve cover and the stud bolts. 9.
Remove the A/C tube retaining clamp bolt. 10.
Remove the 2 A/C tube retaining clamp bolts. 11.
NOTE: It is necessary to reposition the A/C tubes to remove the valve cover.
Loosen the bolt and the 8 stud bolts and remove the RH valve cover.
Discard the gasket.
12.
13.
Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep. 14.
Installation
of the engine.
plug tube seals.
1.
front cover-to-RH cylinder head joints.
2.
Using a new gasket, install the RH valve cover, bolt and the 8 stud bolts.
3.
Position the A/C tubes and install the 2 retaining clamp bolts.
4.
Install the A/C tube retaining clamp bolt.
5.
Attach all of the wiring harness retainers to the valve cover and the stud bolts. 6.
Connect the 3 LH fuel injector electrical connectors. 7.
Connect the LH VCT electrical connector. 8.
Install the PSP hose bracket and nut.
10.
Connect the RH CMS electrical connector and retainer. 11.
Connect the PSP switch electrical connector. 12.
Install the power steering fluid reservoir. For additional information, refer to Section 211-02 . 13.
Install the RH ignition coils. For additional information, refer to Section 303-07C . 14.
2 N806165 Washer
Crankshaft Pulley
Special Tool(s)
3 Jaw Puller
303-D121 or equivalent
303-102 (T74P-6316-B)
303-335
Strap Wrench
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
Removal
100-02 .
1.
Remove the accessory drive belt and the powesteering belt. For additional information, refer to
Section 303-05C .
2.
Using the Strap Wrench, remove the crankshaft pulley bolt and washer.
Discard the bolt.
3.
Installation
Lubricate the crankshaft front seal inner lip with clean engine oil. 1.
NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
Using the Front Cover Oil Seal Installer and Crankshaft Vibration Damper Installer, install the
crankshaft pulley.
2.
Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages.
3.
Install the accessory drive belt and the power steering belt. For additional information, refer to
Section 303-05C .
4.
5.
Special Tool(s)
303-102 (T74P-6316-B)
Installer, Front Crankshaft Seal
303-1251
Remover, Oil Seal
303-409 (T92C-6700CH)
Material
Item Specification
ZC-31-A
XO-5W20-QSP (US);
WSS-M2C945-A
Removal
100-02 .
1.
Using the Oil Seal Remover, remove and discard the crankshaft front seal.
Clean all sealing surfaces with metal surface prep.
3.
Installation
NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover. 1.
Using the Front Crankshaft Seal Installer and Crankshaft Vibration Damper Installer, install a new
src="SCS~us~en~file=N0056874.jpg~gen~ref.jpg" height="211" width="325" border="1">
1 W701559 Flexplate bolt (8 required)
2 6375 Flexplate
3 12A227 Crankshaft sensor ring
4 6701 Crankshaft rear seal
Flexplate
Special Tool(s)
Removal
100-02 .
1.
Remove the transaxle. For additional information, refer to Section 307-01A . 2.
Installation
NOTE: One of the 8 flexplate holes are offset so the flexplate can only be installed in one position.
Install the flexplate and the 8 bolts.
1.
Install the transaxle. For additional information, refer to Section 307-01A . 2.
3.
Flexplate 1780
Flexplate 1781
Special Tool(s)
Handle
205-153 (T80T-4000-W)
Installer, Rear Main Seal
303-1250
303-519 (T95P-6701-EH)
Slide Hammer
307-005 (T59L-100-B)
Material
Item Specification
ZC-31-A
-
XO-5W20-QSP (US);
WSS-M2C945-A
Removal
100-02 .
1.
start="3">
Remove the crankshaft sensor ring.
Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the crankshaft
rear seal.
Clean all sealing surfaces with metal surface prep.
4.
Installation
NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.
Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear
seal onto the tool.
1.
Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal. 2.
Install the crankshaft sensor ring. 3.
5.
Oil Filter Adapter
2 W503283 Oil filter adapter bolt (3 required)
4 6840 Oil filter adapter gasket
Removal
100-02 .
1.
If equipped, remove the 6 screws and the underbody shield. 2.
Discard the gasket.
Clean and inspect all sealing surfaces.
4.
Installation
Using a new gasket, install the oil filter adapter and the 3 bolts.
1.
2.
If equipped, install the 6 screws and the underbody shield. 3.
Material
Item Specification
TA-24
WSK-M2G350-A2
Item
Part
Number Description
(part of 12C508)
2 9278 EOP switch
100-02 .
1.
To install, tighten to 14 Nm (124 lb-in) plus an additional 180 degrees.
4.
Apply thread sealant with PTFE to the EOP switch threads prior to installation.
5.
Exhaust Manifold - LH
Material
Item Specification
ZC-31-A
-
1 W713299 LH exhaust manifold heat shield bolt (3
required)
2 9Y427 exhaust manifold heat
shield
3 W701706 LH exhaust manifold nut (6 required)
4 9431 LH exhaust manifold
5 9448 LH exhaust manifold gasket
6 W701732 LH exhaust manifold stud (6 required)
Removal
Remove the LH Heated Oxygen Sensor (HO2S). For additional information, refer to Section 303-14C
.
2.
Remove the 3 bolts and the LH exhaust manifold heat shield. 3.
Remove the 6 nuts and the LH exhaust manifold.
4.
Clean and inspect the LH exhaust manifold. For additional information, refer to Section 303-00 . 5.
Remove and discard the 6 LH exhaust manifold studs. 6.
Exhaust Manifold - LH 1789
7.
Installation
Install 6 new LH exhaust manifold studs.
1.
Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the
sequence shown:
2.
Install the LH exhaust manifold heat shield and the 3 bolts.
3.
Install the LH HO2S . For additional information, refer to Section 303-14C . 4.
Install the LH catalytic converter. For additional information, refer to Section 309-00 . 5.
Exhaust Manifold - RH
Material
Item Specification
ZC-31-A
-
1 14A464 RH Heated Oxygen Sensor (HO2S) electrical
connector
2 W701706 RH exhaust manifold nut (6 required)
5 W701732 RH exhaust manifold stud (6 required)
Removal
3.
6.
Installation
1.
Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the
sequence shown:
2.
Engine Mount
Engine Mount (View 1 of 3)
1 W503924 A/C tube retaining clamp bolt (2 required)
2 W505422 A/C tube retaining clamp bolt
1 14197 Wiring harness retainer
2 W707398 Engine coolant degas bottle-to-fender bolt
3 W709603 Engine coolant degas bottle-to-fender nut
4 8A080 Engine coolant degas bottle
Engine Mount 1794
1 3493 Power steering hose retainer
4 W708764 Engine mount brace bolt (3 required)
5 6K075 Engine mount brace
6 W705891 Engine mount-to-engine nut (4 required)
7 6B095 Engine mount spacer (2 required)
8 W705891 Engine mount-to-frame nut
9 W500720 Engine mount-to-frame bolt (2 required)
NOTICE: Failure to position the wood block and floor jack as illustrated can result in damage
to the oil pan.
Position a floor jack with a block of wood under the front of the oil pan.
1.
Remove the A/C tube retaining clamp bolt.
2.
Engine Mount (View 3 of 3) 1795
Remove the 2 A/C tube retaining clamp bolts.
3.
Detach the wiring harness retainer from the degas bottle. 4.
Remove the nut, bolt and position the engine coolant degas bottle aside.
5.
Detach the power steering hose retainer from the engine mount brace. 6.
Remove the bolt and the ground wire from the engine mount brace.
7.
Remove the 3 bolts and the engine mount brace.
8.
Remove the 4 engine mount-to-engine nuts.
To install, tighten in the sequence shown to 70 Nm (52 lb-ft).
9.
Remove the 2 engine mount spacers. 10.
Using the floor jack, lower the engine 25 mm (1 in). 11.
NOTE: It is necessary to reposition the A/C tubes to remove the engine mount.
Remove the nut, the 2 bolts and the engine mount.
To install, tighten the bolts to 55 Nm (41 lb-ft) and the nut to 63 Nm (46 lb-ft).
12.
Oil Pan
Material
Item Specification
Engine RTV Silicone
TA-357
WSE-M4G323-A6
ZC-31-A
-
(Canada)
XO-5W20-QSP (US);
WSS-M2C945-A
Remover
ZC-30
-
Removal
1 6730ain plug - 27 Nm (20 lb-ft)
3 W714288 Oil pan-to-bellhousing
bolt (4 required)
4 W503297 Engine front cover bolt (4
required)
5 W708221 Oil pan bolt
Oil Pan 1798
8 6675 Oil pan
All Vehicles
100-02 .
1.
Remove the Air Cleaner (ACL) and outlet pipe assembly. For additional information, refer to Section
303-12C .
2.
Detach the wiring harness retainer from the upper bell housing-to-engine stud bolt. 5.
Loosen the 2 upper bellhousing-to-engine bolts and stud bolt 5 mm (0.19 in). 6.
Remove the exhaust Y-pipe. For additional information, refer to Section 309-00 . 7.
Remove the 2 bolts and the engine roll restrictor. 8.
Oil Pan 1799
9.
Remove the 5 bolts and the Power Transfer Unit (PTU) support bracket. 12.
All vehicles
Remove the A/C compressor nut.
Remove the stud from the oil pan boss (stud will remain in compressor housing).
13.
Oil Pan 1800
Loosen the 3 LH bellhousing-to-engine bolts 5 mm (0.19 in). 14.
NOTE: All-Wheel Drive (AWD) vehicle shown, Front Wheel Drive (FWD) similar. Parts removed
from graphic for clarity.
Loosen the RH engine-to-bellhousing bolt 5 mm (0.19 in).
15.
Remove the 2 fasteners and the inspection cover. 16.
Oil Pan 1801
Remove the 2 LH catalytic converter bracket bolts. 17.
Remove the 4 oil pan-to-bellhousing bolts and the LH catalytic converter bracket. 18.
Separate the engine and transaxle 5 mm (0.19 in). 19.
Oil Pan 1802
Remove the 4 lower engine front cover bolts. 20.
Remove the 16 oil pan bolts. 21.
Install 2 of the oil pan bolts (finger-tight) into the 2 threaded holes in the oil pan.
Alternately tighten the 2 bolts one turn at a time until the oil pan-to-cylinder block seal is
released.
Remove the oil pan.

22.
NOTICE: Only use a 3MTM Roloc Bristle Disk (2-in white, part number 07528) to clean the
oil pan. Do not use metal scrapers, wire brushes or any other powerbrasive disk to clean. These
tools cause scratches and gouges that make leak paths.
23.
Oil Pan 1803
Clean the engine oil pan using a 3MTM Roloc Bristle Disk (2-in white, part number 07528) in a
suitable tool turning at the recommended speed of 15,000 rpm.
Thoroughly wash the oil pan to remove any foreign material, including any abrasive particles
created during the cleaning process.

NOTICE: Do not use wire brushes, power abrasive discs or 3MTM Roloc Bristle Disk (2-in
white, part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges
that make leak paths. They also cause contamination that causes premature engine failure.
Remove all traces of the gasket.
Clean the sealing surfaces of the cylinder block and engine front cover in the following sequence.
Remove any large deposits of silicone or gasket material. 1.
Apply silicone gasket remover and allow to set for several minutes. 2.
Remove the silicone gasket remover. A second application of silicone gasket remover may be
required if residual traces of silicone or gasket material remain.
3.
Apply metal surface prep to remove any remaining traces of oil and to prepare the surfaces to
bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
4.
24.
Installation
All vehicles
Apply a 5.5 mm (0.21 in) bead of Motorcraft High Performance Engine RTV Silicone to the 2
engine front cover-to-cylinder block joint areas on the sealing surface of the oil pan.
1.
NOTE: The oil pan and the 4 specified bolts must be installed and the oil pan aligned to the cylinder
block within 4 minutes of sealant application. Final tightening of the oil pan bolts must be carried out
within 60 minutes of sealant application.
Apply a 3 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the sealing
surface of the oil pan-to-engine block and to the oil pan-to-engine front cover mating surface.
2.
Oil Pan 1804
crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.
3.
NOTE: The oil pan and the 4 specified bolts must be installed within 4 minutes of the start of sealant
application.
NOTE: Keep the oil pan as close as possible to the transmission while installing, then slide forward
towards the engine front cover to prevent wiping off of the sealant.
Install the oil pan and bolts 10, 11, 13 and 1inger tight.
4.
Oil Pan 1805
Draw the bellhousing up to the engine by tightening the LH bellhousing-to-engine bolt.
5.
Draw the bellhousing up to the engine by tightening the RH engine-to-bellhousing bolt.
6.
Install the LH catalytic converter bracket and the 4 oil pan-to-bellhousing bolts.
7.
Oil Pan 1806
Install the 2 LH catalytic converter bracket bolts.
8.
Install the A/C compressor stud and nut.
Tighten the stud to 9 Nm (80 lb-in).
Hand tighten the nut.
9.
Tighten bolts 10, 11, 13 and 14 in the sequence shown to 3 Nm (27 lb-in). 10.
Install the 4 lower engine front cover bolts.
11.
Oil Pan 1807
Install the remaining oil pan bolts and tighten in the sequence shown.
Tighten bolts 1 through 9 and 11 through 14 to 20 Nm (177 lb-in), then rotate an additional
45 degrees.

Tighten bolts 15 and 16 to 10 Nm (89 lb-in), then rotate an additional 45 degrees.
Tighten bolt 10 to 20 Nm (177 lb-in), then rotate an additional 90 degrees.
12.
Tighten the 4 lower engine front cover bolts to 24 Nm (18 lb-ft). 13.
Tighten the A/C compressor nut to 25 Nm (18 lb-ft). 14.
Oil Pan 1808
Tighten the 4 oil pan-to-bellhousing bolts to 48 Nm (35 lb-ft). 15.
Tighten the RH engine-to-bellhousing bolt to 48 Nm (35 lb-ft).
16.
Tighten the 3 LH bellhousing-to-engine bolts to 48 Nm (35 lb-ft). 17.
Oil Pan 1809
Install the inspection cover and the 2 fasteners. 18.
Install the Power Transfer Unit (PTU) support bracket and the 5 bolts.
19.
All vehicles
NOTE: Do not lubricate the engine oil filter gasket. 21.
Oil Pan 1810
Install the engine roll restrictor and the 2 bolts.
22.
Install the exhaust Y-pipe. For additional information, refer to Section 309-00 . 23.
Tighten the 3 upper bellhousing-to-engine bolts to 48 Nm (35 lb-ft). 24.
Attach the wiring harness retainer to the upper bell housing-to-engine stud bolt. 25.
Oil Pan 1811
Install the Air Cleaner (ACL) and outlet pipe assembly. For additional information, refer to Section
303-12C .
28.
NOTICE: Do not expose the Motorcraft High Performance Engine RTV Silicone to engine oil
for at least 90 minutes after installing the oil pan. Failure to follow these nstructions may cause
engine oil leakage.
Fill the engine with clean engine oil.
29.
Oil Pan 1812
Removal
Item
Part
Number Description
1 W503278 Oil pump screen and pickup tube bolt (2 required) - 10
Nm (89 lb-in)
2 6625 O-ring seal
Remove the oil pan. For additional information, refer to Oil Pan in this section. 1.
2.
Installation
Using a new O-ring seal, install the oil pump screen and pickup tube and the 2 bolts.
1.
Install the oil pan. For additional information, refer to Oil Pan in this section. 2.
Crankshaft Rear Seal with Retainer Plate
Special Tool(s)
Handle
205-153 (T80T-4000-W)
303-1250
303-519 (T95P-6701-EH)
Slide Hammer
307-005 (T59L-100-B)
Material
Item Specification
Engine RTV Silicone
TA-357
WSE-M4G323-A6
ZC-31-A
-
(Canada)
XO-5W20-QSP (US);
WSS-M2C945-A
Remover
ZC-30
-
Removal
100-02 .
1.
Remove the crankshaft sensor ring. 3.
Crankshaft Rear Seal with Retainer Plate 1815
Remove the bolt and the CKP sensor. 5.
Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the rear
crankshaft seal.
6.
Remove the 2 oil pan to crankshaft rear seal retainer bolts. 7.
Remove the 8 crankshaft rear seal retainer bolts. 8.
Install the 2 M6 oil pan bolts (finger-tight) into the 2 threaded holes in the crankshaft rear seal
retainer.
Alternately tighten the 2 bolts one turn at a time until the crankshaft rear seal
retainer-to-cylinder block seal is released.
Remove the crankshaft rear seal retainer.

9.
NOTICE: Only use a 3MTM Roloc Bristle Disk (2-in white, part number 07528) to clean the
crankshaft rear seal retainer plate. Do not use metal scrapers, wire brushes or any other power
10.
abrasive disk to clean the crankshaft rear seal retainer plate. These tools cause scratches and
gouges that make leak paths.
Clean the crankshaft rear seal retainer plate using a 3MTM Roloc Bristle Disk (2-in white, part
number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm.
Thoroughly wash the crankshaft rear seal retainer plate to remove any foreign material,
including any abrasive particles created during the cleaning process.

NOTICE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the
towels so foreign material is not dropped into the engine. Any foreign material (including any
material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may
cause engine failure.
NOTICE: Do not use wireshes, power abrasive discs or 3MTM Roloc Bristle Disk (2-in white,
part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that
make leak paths. They also cause contamination that will cause premature engine failure.
Clean the sealing surfaces of the cylinder block and oil pan flange in the following sequence.
3.
Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the
surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces
is normal.
4.
11.
Installation
NOTE: The crankshaft rear seal retainer must be installed and the bolts tightened within 10 minutes
of sealant application.
Apply 5 mm (0.196 in) beads of Motorcraft High Performance Engine RTV Silicone to the 2
cylinder block/oil pan joints.
1.
engine oil to foam excessively and result in serious e damage.
NOTE: The crankshaft rear seal retainer must be installed and the bolts tightened within 10 minutes
of sealant application.
surface of the crankshaft rear seal retainer.
2.
NOTE: Use the 2 oil pan bolts as handles during installation to avoid touching the sealant.
Install the crankshaft rear seal retainer at an angle above the oil pan flange to avoid scraping off the
sealer. Tilt the seal retainer up and onto the rear of the cylinder block.
3.
Install the 8 bolts and tighten in the sequence shown to 10 Nm (89 lb-in). 4.
Install the 2 oil pan to crankshaft rear seal retainer bolts.
5.
NOTE: Lubricate the seal lips and bore ith clean engine oil prior to installation.
seal onto the tool.
6.
Install the Crankshaft Position (CKP) sensor and install the bolt.
8.
Engine
Special Tool(s)
300-OTC1819E
Engine Lift Eye
303-1245
Powertrain Lift
300-OTC1585AE
211-105
Spreader Bar
All vehicles
100-02 .
1.
Remove the accessory drive belt and the power steering belt. For additional information, refer to
Section 303-05C .
4.
205-04 .
5.
Engine 1821
Disconnect the power steering cooler tube and drain the power steering fluid into a suitable drain pan. 7.
Remove the degas bottle. For additional information, refer to Section 303-03A . 9.
Section 303-12C .
10.
Detach the 2 wiring harness retainers from the transmission mount and the battery tray bracket. 13.
Engine 1822
Disconnect the vacuum hose and the Evaporative Emission (EVAP) tube from the upper intake
manifold.
16.
Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat
housing.
17.
Disconnect the transaxle control cable from the control lever. 18.
Remove the 3 nuts and position the transaxle control cable bracket aside. 19.
Remove the bolt and position the ground wire aside. 20.
Engine 1823
If equipped, detach the engine block heater harness from the radiator support, power steering hose,
A/C tube and the engine wiring harness.
21.
Detach the coolant tube retainer clips from the A/C tube. 22.
Remove the nut and disconnect the A/C tube from the condenser.
23.
Remove the 2 A/C tube bracket bolts. 24.
Remove the A/C tube bracket bolt. 25.
Remove the 2 nuts and disconnect the A/C tubes.
26.
Engine 1824
Remove the 2 wiring harness retainers from the LH valve cover stud bolts and position the wiring
harness aside.
29.
Disconnect the hose from the power steering reservoir.
Detach the pin-type retainer from the engine mount brace.
31.
Engine 1825
Using a small screwdriver, release the retaining clip and detach the power steering reservoir from the
cowl.
32.
.
33.
Remove the bolt and the ground wire from the engine mount brace. 34.
Remove the 3 bolts and the engine mount brace. 35.
Disconnect the PCM electrical connectors and pin-type retainers. 36.
Engine 1826
Remove the Power Steering Pressure (PSP) hose bracket bolt. 37.
Remove and discard the PSP hose banjo bolt and the 2 seals from the steering gear. 38.
39.
Engine 1827
Section 501-20B .
installation.
Discard the bolt.
41.
the subframe.
Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the
passenger compartment.
44.
Disconnect the transaxle cooler hoses. 45.
Engine 1828
46.
Remove the 6 nuts and the Y-pipe assembly.
Discard the gaskets and nuts.
48.
Remove and discard the 4 torque converter nuts. 51.
Engine 1829
Remove and discard the 4 bolts (3 shown) and support the driveshaft with a length of mechanic's
wire.
52.
All vehicles
Remove the engine roll restrictor-to-subframe through bolt. 53.
54.
55.
Engine 1830
56.
Using a wax pencil, mark the relationship of the front subframe to the underbody at the mounting
locations.
57.
Remove the 4 subframe bracket-to-body bolts.
59.
Remove the 2 rear subframe nuts and the 2 subframe brackets.
60.
Engine 1831
Remove the 2 front subframe nuts.
61.
Remove the 2 RH catalytic converter bracket bolts. 63.
Front Wheel Drive (FWD) vehicles
Remove the 2 nuts and remove the RH catalytic converter bracket. 64.
Disconnect the RH Catalyst Monitor Sensor (CMS) electrical connector. 65.
Discard the gasket.
66.
Engine 1832
Remove the 5 bolts and the Power Transfer Unit (PTU) support bracket. 67.
Remove the 5 bolts and the PTU . 68.
All vehicles
Install the Powertrain Lift and Adjustable Grip Arms.
69.
Remove the transaxle support insulator through bolt and nut. 70.
Engine 1833
Remove the transaxle support insulator bracket bolt and the 2 nuts. 71.
Remove the 4 engine mount nuts.
Remove the 2 engine mount spacers.
72.
Lower the engine and transaxle assembly from the vehicle. 74.
Disconnect the wiring harness fasteners from the transaxle-to-engine stud bolt and the starter. 75.
Remove the bolt and ground wire. 76.
Engine 1834
Disconnect the Transmission Control Module (TCM) electrical connector. 77.
Remove the 2 nuts and the starter motor wiring. 78.
Remove the 2 bolts and the starter. 79.
Install the Engine Lift Eye on the LH cylinder head. 80.
Using the Floor Crane and Spreader Bar, remove the engine and transaxle from the lift table. 81.
Engine 1835
Remove the 2 engine-to-transaxle bolts. 82.
Remove the transaxle-to-engine stud bolt and the 4 transaxle-to-engine bolts.
Separate the transaxle from the engine.
83.
Engine 1836
Engine Front Cover
Special Tool(s)
3 Jaw Puller
Handle
Powertrain Lift
300-OTC1585AE
Remover, Oil Seal
303-409 (T92C-6700CH)
211-105
303-1247/1
Strap Wrench
Material
Item Specification
ZC-31-A
-
Motorcraft Silicone Gasket Remover
ZC-30
-
All vehicles
100-02 .
1.
Remove the accessory drive belt and the power steering belt. For additional information, refer to
Section 303-05C .
4.
205-04 .
5.
Disconnect the power steering cooler tube and drain the power steering fluid into a suitable drain pan. 7.
Section 303-12C .
10.
Detach the 2 wiring harness retainers from transmission mount and the battery tray bracket. 13.
Disconnect the vacuum hose and the Evaporative Emission (EVAP) tube from the upper intake
manifold.
16.
Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat
housing.
17.
Disconnect the transaxle control cable from the control lever. 18.
Remove the 3 nuts and position the transaxle control cable bracket aside. 19.
Remove the bolt and position the ground wire aside. 20.
If equipped, detach the engine block heater harness from the radiator support, power steering hose,
A/C tube and the engine wiring harness.
21.
Detach the coolant tube retainer clips from the A/C tube. 22.
Remove the nut and disconnect the A/C tube from the condenser.
Discard the O-ring seals.
23.
Remove the 2 A/C tube retaining clamp bolts. 24.
Remove the 2 nuts and disconnect the A/C tubes.
26.
Remove the 2 wiring harness retainers from the LH valve cover stud bolts and position the wiring
harness aside.
29.
Disconnect the hose from the power steering reservoir.
Detach the pin-type retainer from the engine mount brace.
31.
Using a small screwdriver, release the retaining clip and detach the power steering reservoir from the
cowl.
32.
.
33.
Remove the bolt and the ground wire from the engine mount brace. 34.
Remove the 3 bolts and the engine mount brace. 35.
Disconnect the PCM electrical connectors and pin-type retainers. 36.
Remove the Power Steering Pressure (PSP) hose bracket bolt. 37.
Remove and discard the PSP banjo bolt and the 2 seals from the steering gear. 38.
NOTE: Use a steering wheel holding device (such as Hunter 28-75-1 or equivalent). 39.
damage to the clockspring may occur. If there is evidence that the intermediate shaft has
Section 501-20B .
installation.
Discard the bolt.
41.
the subframe.
Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the
passenger compartment.
44.
Disconnect the transaxle cooler hoses. 45.
46.
Remove the 6 nuts and the Y-pipe assembly.
Discard the gaskets and nuts.
48.
Remove and discard the 4 bolts (3 shown) and support the driveshaft with a length of mechanic's
wire.
49.
All vehicles
Remove the engine roll restrictor-to-subframe through bolt. 50.
51.
52.
53.
Using a wax pencil, mark the relationship of the front subframe to the underbody at the mounting
locations.
54.
56.
Remove the 2 subframe nuts and the 2 subframe brackets.
57.
58.
Using the Powertrain Lift, lower the subframe assembly from the vehicle. 59.
Remove the 2 nuts and remove the RH catalytic converter bracket. 61.
All vehicles
62.
Remove the transaxle support insulator through bolt. 63.
Remove the transaxle support insulator bracket bolt and the 2 nuts. 64.
Remove the 4 engine mount nuts.
Remove the 2 engine mount spacers.
65.
Lower the engine and transaxle assembly from the vehicle. 67.
If equipped, detach the block heater wiring harness retainer from the upper intake manifold. 68.
If equipped, detach the block heater wiring harness retainers from the PSP hose and the power
steering reservoir hose.
69.
Disconnect the PCV hose from the PCV valve. 70.
Detach the wiring harness retainers from the upper intake manifold. 72.
damage.
74.
Disconnect the RH Catalyst Monitor Sensor (CMS) electrical connector. 75.
Disconnect the PSP switch electrical connector. 76.
Disconnect the RH VCT solenoid electrical connector. 77.
Disconnect the 3 RH coil-on-plug electrical connectors. 78.
Detach all of the wiring harness retainers from the RH valve cover and stud bolts. 79.
Disconnect the LH VCT solenoid electrical connector. 80.
Disconnect the 3 LH coil-on-plug electrical connectors. 81.
Detach all of the wiring harness retainers from the LH valve cover and stud bolts. 82.
83.
Detach the PSP hose retainer from the engine lifting eye. 84.
Remove the PSP hose bracket nut and position the PSP hose aside. 85.
Discard the gasket.
87.
Loosen the bolt, the 8 stud bolts and remove the RH valve cover.
Discard the gasket.
88.
Inspect the VCT solenoid seals and the spark plug tube seals. Install new seals if damaged.
89.
Remove the 3 bolts and position the power steering pump aside. 90.
Discard the bolt.
92.
Remove the 2 bolts and the engine mount bracket. 95.
NOTE: Only use hand tools to remove the studs.
Remove the 2 engine mount studs.
96.
Remove the 22 engine front cover bolts. 98.
Install 6 of the engine front cover bolts (finger-tight) into the 6 threaded holes in the engine front
cover in the following sequence.
Tighten the bolts one turn at a time in a crisscross pattern until the engine front
cover-to-cylinder block seal is released.
1.
Remove the engine front cover. 2.
99.
NOTICE: Only use a 3M Roloc Bristle Disk (2-in white, part number 07528) to clean the
engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to
clean the engine front cover.
Clean the engine front cver using a 3M Roloc Bristle Disk (2-in white, part number 07528) in a
suitable tool turning at the recommended speed of 15,000 rpm.
Thoroughly wash the engine front cover to remove any foreign material, including any
abrasive particles created during the cleaning process.

100.
NOTICE: Do not use wire brushes, power abrasive discs or 3MTM Roloc Bristle Disk (2-in
white, part number 07528) to clean the sealing surfaces of the engine block, cylinder heads, and
oil pan. These tools cause contamination that can cause premature engine failure. Remove all
traces of sealant, including any sealant from the inner surface of the cylinder block and cylinder
head.
Clean all engine sealing surfaces, including the cylinder heads, the oil pan and cylinder block in the
following sequence.
3.
is normal.
4.
Make sure the 2 locating dowel pins are seated correctly in the cylinder block. 5.
101.
sp;
Special Tool(s)
Tool, Camshaft Holding
303-1248
section.
1.
Rotate the crankshaft clockwise and align timing marks on the Variable Camshaft Timing (VCT)
assemblies as shown.
2.
NOTE: The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.
Install the Camshaft Holding Tool onto the flats of the LH camshafts.
3.
NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Install the Camshaft Holding Tool onto the flats of the RH camshafts.
4.
Remove the 3 bolts and the RH VCT housing. 5.
Remove the 3 bolts and the LH VCT housing. 6.
NOTE: The following 3 steps are for primary timing chains when the colored links are not visible.
Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as
shown.
7.
Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as
shown.
8.
NOTE: The crankshaft sprocket timing mark should be between the 2 colored links.
Mark the 2 timing chain links that align with the timing mark on the crankshaft sprocket as shown.
9.
Remove the 2 bolts and the primary timing chain tensioner. 10.
Remove the primary timing chain tensioner arm. 11.
Remove the 2 bolts and the lower LH primary timing chain guide. 12.
Remove the primary timing chain. 13.
Remove the crankshaft timing chain sprocket. 14.
Remove the bolt and the upper LH primary timing chain guide. 15.
Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the
tensioner in the collapsed position.
16.
NOTE: The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed.
However, the exhaust camshaft washer is reusable.
Remove and discard the LH VCT assembly bolt and the LH exhaust camshaft sprocket bolt.
Remove the LH VCT assembly, secondary timing chain and the LH exhaust camshaft
sprocket as an assembly.

17.
NOTE: It is necessary to tilt the Camshaft Holding Tool toward the rear of the engine to access the
rearmost secondary timing chain tensioner bolt.
Remove the 2 bolts and the LH secondary timing chain tensioner.
18.
Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the
19.
Remove and discard the RH VCT assembly bolt and the RH exhaust camshaft sprocket bolt.
Remove the RH VCT assembly, secondary timing chain and the RH exhaust camshaft

20.
Remove the 2 bolts and the RH secondary timing chain tensioner.
21.
Remove the bolt and the RH timing chain guide. 22.
Camshaft
Special Tool(s)
303-1248
All camshafts
section.
1.
Rotate the crankshaft clockwise and align thming marks on the Variable Camshaft Timing (VCT)
2.
3.
4.
Camshaft 1865
shown.
7.
shown.
8.
Camshaft 1866
9.
Camshaft 1867
LH camshafts
14.

15.
Camshaft 1868
NOTE: When the Camshaft Holding Tool is removed, valve spring pressure will rotate the LH
camshafts approximately 3 degrees to a neutral position.
Remove the Camshaft Holding Tool from the LH camshafts.
16.
NOTICE: The camshafts must remain in the neutral position during removal or engine damage
may occur.
17.
NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their
original positions.
Remove the bolts and the LH camshaft bearing caps.
Remove the LH camshafts.
18.
Camshaft 1869
RH camshafts
19.

20.
Remove the Camshaft Holding Tool from the RH camshafts. 21.
may occur.
Rotate the RH camshafts counterclockwise to the neutral position.
22.
original positions.
Remove the bolts and the RH camshaft bearing caps.
23.
Camshaft 1870
Remove the RH camshafts.
Camshaft 1871
Valve Tappets
Depending on the valve tappets being serviced, remove the LH and/or the RH camshafts. For
additional information, refer to Camshaft in this section.
1.
NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the
components for installation into their original locations.
Remove the valve tappets from the cylinder head.
2.
Valve Tappets 1872
Valve Spring, Retainer and Seal
Special Tool(s)
303-300 (T87C-6565-A)
303-350 (T89P-6565-A)
303-1249
Remove the valve tappets from the cylinder being serviced. For additional information, refer to Valve
Tappets in this section.
1.
Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke. 2.
NOTICE: If air pressure has forced the piston to the bottom of the cylinder, any loss of air
pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support
the valve prior to removal or engine damage may occur.
NOTE: If a valve drops into the cylinder, remove the cylinder head. For additional information, refer
to Cylinder Head - RH or Cylinder Head - LH in this section.
Pressurize the cylinder using compressed air.
3.
Remove and discard the valve stem seal. 5.
Valve Spring, Retainer and Seal 1873
Cylinder Head - RH
Material
Item Specification
ZC-31-A
-
ZC-30
-
All vehicles
Remove the RH camshafts. For additional information, refer to Camshaft in this section. 1.
If equipped, remove the heat shield and disconnect the block heater electrical connector.
Remove the block heater wiring harness from the engine.li>
2.
Disconnect the RH Camshaft Position (CMP) sensor electrical connector. 4.
Remove the bolt and the Power Steering Pressure (PSP) tube and bracket assembly. 5.
Disconnect the 6 fuel injector electrical connectors (3 shown). 6.
Disconnect the LH Catalyst Monitor Sensor (CMS) sensor electrical connector. 8.
Remove the 4 nuts (3 shown) and the LH catalytic converter.
Discard the nuts and the gasket.
10.
Remove the LH cylinder block drain plug.
Allow coolant to drain from the cylinder block.
11.
All vehicles
13.
Remove the RH cylinder block drain plug or, if equipped, the block heater.
14.
Remove the 3 bolts and the RH exhaust manifold heat shield. 15.
Discard the nuts and exhaust manifold gaskets.
16.
Remove the 2 bolts and the RH secondary timing chain tensioner. 20.
Remove the 2 bolts and the engine lifting eye. 21.
NOTE: Index-mark the location of the bracket on the cylinder head for installation.
Remove the bolt and the upper intake manifold support bracket.
22.
Remove the bolt and the RH CMP sensor. 23.
Disconnect the coolant bypass hose from the thermostat housing. 25.
Remove the 2 thermostat housing-to-lower intake manifold bolts.
Remove the thermostat housing and discard the gasket and O-ring seal.
26.
damage.
27.
Disconnect and remove the CHT sensor jumper harness. 28.
29.
Remove and discard the M6 bolt. 30.
NOTICE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so
foreign material is not dropped into the engine. Any foreign material (including any material
created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause
engine failure.
NOTICE: Aluminum surfaces are soft and may be scratched easily. Never place the cylinder
head gasket surface, unprotected, on a bench surface.
NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are a
tighten-to-yield design and cannot be reused.
Remove and discard the 8 bolts from the cylinder head.
31.
NOTE: Observe all warnings or cautions and follow all application directions contained on the
Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder
minutes.
2.
3.
Apply metal surface prep, following package directions, to remove any remaining traces of
oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to
make the metal shiny. Some staining of the metal surfaces is normal.
4.
32.
33.
Cylinder Head - LH
Material
Item Specification
ZC-31-A
-
ZC-30
-
All vehicles
Remove the LH camshafts. For additional information, refer to Camshaft in this section. 1.
If equipped, remove the heat shield and disconnect the block heater electrical connector.
Remove the block heater wiring harness from the engine.li>
2.
Remove the nut and disconnect the generator B+ cable. 4.
Detach the wiring harness retainer from the generator. 6.
Remove the nut, bolt and the generator. 7.
Detach the wiring harness pin-type retainer. 8.
Disconnect the LH Camshaft Position (CMP) sensor electrical connector. 11.
Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector. 12.
Disconnect the LH Catalyst Monitor Sensor (CMS) electrical connector. 13.
Remove the wiring harness retainer bolt from the rear of the LH cylinder head. 14.
Remove the 4 nuts (3 shown) and the LH catalytic converter.
16.
Discard the nuts and the exhaust manifold gasket.
18.
21.
All vehicles
23.
24.
Remove the thermostat housing and discard the gasket and O-ring seal.
27.
damage.
28.
Remove the bolt and the LH CMP sensor. 29.
Remove the 2 bolts and the LH secondary timing chain tensioner. 31.
32.
Remove and discard the M6 bolt. 33.
engine failure.
34.
Remove and discard the 8 bolts from the cylinder head.
minutes.
2.
3.
4.
35.
36.
Oil Pump
Special Tool(s)
303-1248
section.
1.
Rotate the crankshaft clockwise and align the timing marks on the Variableshaft Timing (VCT)
2.
3.
4.
Oil Pump 1892
shown.
7.
shown.
8.
Oil Pump 1893
9.
Oil Pump 1894
Remove the 2 oil pump screen and pickup tube bolts. 15.
Remove the 3 oil pump bolts.
Rotate the oil pump clockwise and separate the oil pump from the oil pump screen and pickup
tube.

Remove the oil pump.
Discard the oil pump screen and pickup tube O-ring seal.
16.
Oil Pump 1895
Oil Pump 1896
Engine
Special Tool(s)
3 Jaw Puller
Handle
205-153 (T80T-4000-W)
303-519 (-6701-EH)
Remover, Oil Seal
303-409 (T92C-6700CH)
303-1247/1
Slide Hammer
307-005 (T59L-100-B)
Strap Wrench
303-1248
Material
Item Specification
ZC-31-A
-
ZC-30
-
NOTE: For additional information, refer to the exploded view under the Assembly procedure in this section.
All engines
Engine 1897
Remove the crankshaft sensor ring. 2.
Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the rear
crankshaft seal.
3.
NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil
pan.
Mount the engine on a suitable engine stand.
4.
If equipped, detach the block heater wiring harness retainer from the upper intake manifold. 5.
If equipped, remove the heat shield and disconnect the block heater electrical connector. 6.
If equipped, detach the block heater wiring harness retainer from the power steering reservoir hose
and the Power Steering Pressure (PSP) hose.
Remove the block heater wiring harness from the engine.
7.
Engine 1898
Disconnect the PCV hose from the PCV valve. 8.
Detach the wiring harness retainers from the upper intake manifold. 10.
damage.
12.
Engine 1899
Disconnect the PSP switch electrical connector. 13.
Disconnect the RH Catalyst Monitor Sensor (CMS) sensor electrical connector. 14.
All engines
Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector. 16.
Engine 1900
Disconnect the 3 RH coil-on-plug electrical connectors. 17.
Detach all of the wiring harness retainers from the RH valve cover and stud bolts. 18.
Disconnect the RH Camshaft Position (CMP) sensor electrical connector. 20.
Engine 1901
Disconnect the LH CMP sensor electrical connector. 24.
Disconnect the LH CMS sensor electrical connector. 25.
Disconnect the LH HO2S electrical connector. 26.
Disconnect the 3 LH coil-on-plug electrical connectors. 27.
Engine 1902
Disconnect the LH VCT solenoid electrical connector. 28.
Detach all of the wiring harness retainers from the LH valve cover and stud bolts. 29.
Remove the wiring harness retainer bolt from the rear of the LH cylinder head. 30.
Remove the nut, the bolt and the heat shield. 31.
Remove the wiring harness retainer stud bolt. 32.
Remove the wiring harness grommet. 33.
Engine 1903
Remove the nut and disconnect the generator B+ cable. 36.
Detach the wiring harness retainer from the generator. 38.
Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the wiring harness pin-type
retainer.
Remove the wiring harness from the engine.
39.
Engine 1904
Remove the bolt and the A/C manifold.
40.
Remove the nut, 2 bolts and the A/C compressor. 41.
Remove the A/C compressor mounting stud from the oil pan. 42.
Remove the bolt, nut and the generator. 43.
Detach the PSP hose retainer from the engine lifting eye. 44.
Engine 1905
Remove the PSP hose bracket nut. 45.
Remove the PSP tube bracket bolt from the RH cylinder head. 46.
Remove the 3 bolts and the power steering pump. 47.
Remove the 4 nuts (3 shown) and the LH catalytic converter. 49.
Engine 1906
51.
FWD vehicles
54.
All engines
Engine 1907
Remove the 3 bolts and the RH exhaust manifold heat shield. 55.
56.
59.
60.
Engine 1908
Remove the pin-type retainer and the cover. 61.
Remove the 2 bolts and the engine lifting eye. 62.
Remove the bolt and the upper intake manifold support bracket. 63.
Remove the bolt and the RH CMP sensor. 64.
Engine 1909
Remove the 2 bolts and the catalytic converter bracket. 65.
All engines
Remove the thermostat housing and discard the gasket.
67.
damage.
68.
Engine 1910
Disconnect and remove the CHT sensor jumper harness. 69.
Remove the bolt and the LH CMP sensor. 70.
Remove the bolt and the CKP sensor. 71.
Remove the EOP switch. 72.
Discard the gasket.
73.
Engine 1911
74.
Discard the gasket.
76.
Loosen the bolt, 8 stud bolts and remove the RH valve cover.
Discard the gasket.
77.
78.
Engine 1912
Discard the bolt.
79.
NOTE: Only use hand tools to remove the studs. 83.
Engine 1913
Remove the 2 engine mount studs.
Remove the 22 engine front cover bolts. 85.
Install 6 of the engine front cover bolts (finger-tight) into the 6 threaded holes in the engine front
cover in the following sequence.
Tighten the bolts one turn at a time in a crisscross pattern until the engine front
cover-to-cylinder block seal is released.
1.
Remove the engine front cover. 2.
86.
Engine 1914
Rotate the crankshaft clockwise and align the timing marks on the Variable Camshaft Timing (VCT)
87.
88.
89.
Engine 1915
shown.
92.
shown.
93.
Engine 1916
94.
Engine 1917
101.

102.
Engine 1918
NOTE: When the Camshaft Holding Tool is removed, valve spring pressure will rotate the LH
camshafts approximately 3 degrees to a neutral position.
Remove the Camshaft Holding Tool from the LH camshafts.
103.
may occur.
104.
Remove the 2 bolts and the LH secondary timing chain tensioner. 105.
original positions.
Remove the bolts and the LH camshaft bearing caps.
Remove the LH camshafts.
106.
Engine 1919
107.

108.
Remove the Camshaft Holding Tool from the RH camshafts. 109.
may occur.
Rotate the RH camshafts counterclockwise to the neutral position.
110.
Engine 1920
Remove the 2 bolts and the RH secondary timing chain tensioner. 111.
original positions.
Remove the bolts and the RH camshaft bearing caps.
Remove the RH camshafts.
113.
Engine 1921
Remove the valve tappets from the cylinder heads.
114.
Remove and discard the M6 bolt from each cylinder head.
115.
engine failure.
Remove and discard the 8 bolts from each cylinder head.
Remove the cylinder heads.
Discard the cylinder head gaskets.
116.
paths. Use a plastic scraping tool to remove all traces of the gasket.
117.
Engine 1922
minutes.
2.
3.
4.
118.
Remove the coolant inlet tube.
Remove and discard the O-ring seals.
119.
Remove the 2 bolts and the Knock Sensor (KS). 120.
Remove the 8 bolts and the coolant pump. 121.
Remove the 16 oil pan bolts. 122.
Engine 1923
Install 2 of the oil pan bolts (finger-tight) into the 2 threaded holes in the oil pan in the following
sequence.
Alternately tighten the 2 bolts one turn at a time until the oil pan-to-cylinder block seal is
released.
1.
Remove the oil pan. 2.
123.
124.
Engine 1924
Remove the 8 crankshaft rear seal retainer bolts. 126.
Install the 2 M6 oil pan bolts (finger-tight) into the 2 threaded holes in the crankshaft rear seal retainer
in the following sequence.
Alternately tighten the 2 bolts one turn at a time until the crankshaft rear seal
retainer-to-cylinder block seal is released.
1.
Remove the crankshaft rear seal retainer. 2.
127.
NOTICE: Only use a 3M Roloc Bristle Disk (2-in white, part number 0752) to clean the engine
front cover, oil pan and crankshaft rear seal retainer plate. Do not use metal scrapers, wire
brushes or any other power abrasive disk to clean the engine front cover, oil pan and crankshaft
rear seal retainer plate. These tools cause scratches and gouges that make leak paths.
Clean the engine front cover, oil pan and crankshaft rear seal retainer plate using a 3M Roloc Bristle
Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000
rpm.
Thoroughly wash the engine front cover, oil pan and crankshaft rear seal retainer plate to
remove any foreign material, including any abrasive particles created during the cleaning
process.

128.
instructions.
129.
NOTE: The main bearing cap support brace bolts must be discarded and new bolts must be installed.
They are a tighten-to-yield design and cannot be reused.
Remove the main bearing cap support brace.
Discard the bolts.
130.
Engine 1925
NOTE: The connecting rod cap bolts are torque to yield. The original connecting rod cap bolts will
be used when measuring the connecting rod large end bore during assembly. The connecting rod cap
bolts will be discarded after measurement.
NOTE: Clearly mark the positin and orientation of the connecting rods, connecting rod caps and
connecting rod bearings for reassembly.
131.
Remove the piston/rod assembly from the engine block.
132.
Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block. 133.
NOTE: The 8 main bearing cap side bolts and the 8 main bearing cap bolts must be discarded and
new bolts must be installed. They are a tighten-to-yield design and cannot be reused.
NOTE: Clearly mark the position and orientation of the main bearing caps for reassembly.
Remove the 8 main bearing cap side bolts and the 8 main bearing cap bolts in the sequence shown.
Discard the bolts.
134.
reassembly.
NOTE: Note the position of the thrust washer on the outside of the No. 4 rear main bearing cap.
Remove the 4 main bearing caps.
135.
Engine 1926
NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing
bulkhead.
Remove the crankshaft.
136.
NOTE: Inside shown, outside similar.
Remove the 2 crankshaft thrust bearings from the rear main bearing bulkhead.
137.
reassembly.
Remove the 4 crankshaft main bearings from the cylinder block.
138.
reassembly.
Remove the 4 crankshaft main bearings from the main bearing caps.
139.
Engine 1927
Inspect the cylinder block, bearing cap support brace, pistons and connecting rods. For additional
140.
NOTICE: Do not use wire brushes, power abrasive discs or 3M Roloc Bristle Disk (2-in white,
part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that
make leak paths. They also cause contamination that will cause premature engine failure.
Clean all engine sealing surfaces of the cylinder block in the folowing sequence.
3.
is normal.
4.
Make sure the 2 engine front cover locating dowel pins are seated correctly in the cylinder
block.
5.
141.
Engine 1928
SUBASSEMBLIES
Cylinder Head
Special Tool(s)
303-300 (T87C-6565-A)
303-350 (T89P-6565-A)
303-1249
303-470 (T94P-6510-CH)
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
Cylinder Head - RH
Cylinder Head 1929
2 W714090 Timing chain tensioner arm pin
3 W714090 Timing chain guide pin
4 6518 Intake valve spring retainer key (12 required)
5 6514 Intake valve spring retainer (6 required)
6 6513 Intake valve spring (quired)
7 6A517 Intake valve stem seal (6 required)
9 6518 Exhaust valve spring retainer key (12 required)
10 6514 Exhaust valve spring retainer (6 required)
11 6513 Exhaust valve spring (6 required)
12 6A517 Exhaust valve stem seal (6 required)
Cylinder Head - LH
1 6518 Intake valve spring retainer key (12 required)
2 6514 Intake valve spring retainer (6 required)
3 6513 Intake valve spring (6 required)
4 6A517 Intake valve stem seal (6 required)
7 6A517 Exhaust valve stem seal (6 required)
8 13 Exhaust valve spring (6 required)
9 6514 Exhaust valve spring retainer (6 required)
10 6518 Exhaust valve spring retainer key (12 required)
11 W714090 Timing chain tensioner arm pin
Disassembly
All cylinder heads
Remove the valve from the cylinder head. 2.
Remove and discard the valve stem seal. 3.
Repeat the above steps for each valve. 4.
Remove the timing chain guide pin. 5.
RH cylinder head
Remove the timing chain tensioner arm pin. 6.
Remove and discard the Cylinder Head Temperature (CHT) sensor. 7.
Assembly
All cylinder heads
NOTE: Lubricate the valve stem seal with clean engine oil prior to installation.
Using the Valve Stem Oil Seal Installer, install a new valve stem seal.
1.
Install the valve. 2.
Using the Valve Spring Compressors, install the valve spring, retainer and key. 3.
Repeat the above steps for each valve. 4.
Install the timing chain guide pin and tighten in 2 stages.
5.
RH cylinder head
Install the timing chain tensioner arm pin and tighten in 2 stages.
6.
Install a new CHT sensor.
7.
SUBASSEMBLIES
Piston
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
Item > Part Number Description
1 - Piston compression upper ring (part of 6148)
2 - Piston compression lower ring (part of 6148)
3 - Piston oil control upper segment ring (part of 6148)
4 - Piston oil control spacer (part of 6148)
5 - Piston oil control lower segment ring (part of 6148)
6 6140 Piston pin retainer clip
7 6140 Piston pin retainer clip
8 6135 Piston pin
10 6110 Piston
Disassembly
1.
Remove the 2 piston pin retainers and the piston pin.
Discard the 2 piston pin retainer clips.
2.
Piston 1933
NOTE: If the piston and/or connecting rod are being installed new, the piston rod orientation marks
and the arrow on the top of the dome of the piston should be facing toward the front of the engine
block.
3.
Assembly
Align the piston-to-connecting rod orientation marks and position the connecting rod in the piston. 1.
Install the new piston pin retaining clips in the piston.
The piston pin retaining clip gap orientation must be toward the top or dome of piston.
4.
NOTE: The piston compression upper and lower ring should be installed with the "O" mark on the
ring face pointing up toward the top of the piston.
6.
Piston 1934
Piston 1935
Engine
Special Tool(s)
300-OTC1819E
Alignment Pins
307-399
303-D032 (D81L-6002-C) d>
100-002 (TOOL-4201-C)
Eye, Engine Lift
303-1245
Handle
205-153 (T80T-4000-W)
303-102 (T74P-6316-B)
303-335
303-1251
303-1250
303-1247/2
Spreader Bar
Strap Wrench
Engine 1936
303-1248
Material
Item Specification
Engine RTV Silicone
TA-357
WSE-M4G323-A6
ZC-31-A
-
(Canada)
XO-5W20-QSP (US);
WSS-M2C945-A
Remover
ZC-30
-
Engine Coolant
VC-10-A2 (US); CVC-10-A
(Canada)
WSS-M97B55-A
Motorcraft Orange
Antifreeze/Coolant Concentrated
(Canada)
WSS-M97B44-D
TA-24
WSK-M2G350-A2
Threadlock and Sealer
TA-25
WSK-M2G351-A5
Engine Upper
Engine Upper 1937
1 12A581 Engine control harness
3 9F792 Fuel rail
4 9J444 Upper intake manifold support bracket
5 9424 Lower intake manifold
6 8A586 Thermostat housing
7 9N271 Coolant tube
Engine Upper - LH Cylinder Head
1 6051 LH cylinder head gasket
Engine Upper - LH Cylinder Head 1938
2 6C261 LH Variable Camshaft Timing (VCT) housing
3 W712244 LH exhaust manifold stud (6 required)
4 6500 Valve tappet (24 quired)
6 6279 LH camshaft bolt (2 required)
7 W710738 LH exhaust camshaft sprocket washer
8 6A257 LH VCT assembly
9 6256 LH exhaust camshaft sprocket
10 6268 LH secondary timing chain
11 6A258 LH camshaft cap (8 required)
12 6582 LH valve cover
15 6K254 LH secondary timing chain tensioner
Engine Upper - RH Cylinder Head
1 W712244 RH exhaust manifold stud (6 required)
2 6051 RH cylinder head gasket
3 6G004 Cylinder Head Temperature (CHT)
sensor
14A411 CHT sensor jumper
harness
5 6B288 Camshaft Position (CMP) sensor (2
required)
6 6049 RH cylinder head
7 17A084 Engine lift eye
8 6C260 RH Variable Camshaft Timing (VCT)
housing
9 6279 RH camshaft bolt (2 required)
10 W710738 RH exhaust camshaft sprocket washer
Engine Upper - RH Cylinder Head 1939
11 6256 RH exhaust camshaft sprocket
12 6A257 RH VCT assembly
13 6268 RH secondary timing chain
14 6250 RH intake camshaft
15 6250 RH exhaust camshaft
17 6A258 RH camshaft cap (8 required)
19 12A375 Coil-on-plug (6 required)
20 6C270 RH secondary timing chain tensioner
Engine Front
1 6A0003 Engine mount bracket
3 N806165 Crankshaft pulley washer
6 6C086 Engine front cover
7 6675 Oil pan
1 6268 Timing chain
Engine Front 1940
2 6306 Crankshaft timing sprocket
3 6K254 Primary timing chain tensioner
4 6K255 Primary timing chain tensioner arm
5 6B274 LH lower primary timing chain guide
6 6M256 RH primary timing chain guide
7 6K297 LH upper primary timing chain guide
8 8501 Coolant pump
Engine Lower (View 1)
1 6675 Oil pan
3 6625 Oil pump screen and pickup tube O-ring seal
4 6600 Oil pump
6 6K301 Crankshaft rear seal retainer
7 12A227 Crankshaft sensor ring
8 6375 Flexplate
Item
Part
Number Description
1 - Piston compression upper ring (6 required) (part of
6148)
2 - Piston compression lower ring (6 required) (part of
6148)
3 - Piston oil control upper segment ring (6 required) (part
of 6148)
4 - Piston oil control spacer (6 required) (part of 6148)
5 - Piston oil control lower segment ring (6 required) (part
of 6148)
12 - Connecting rod cap (part of 6200) (6 required)
14 6D309 Crankshaft upper thrust washer (2 required)
15 6D309 Cylinder block crankshaft main bearing (4 required)
16 6303 Crankshaft
17 6K302 Crankshaft lower thrust washer
18 6D309 Lower crankshaft main bearings (4 required)
20 6C364 Main bearing cap support brace
303-00 .
All engines
NOTE: This procedure is for selecting bearings using a new crankshaft.
Select the crankshaft main bearings for each crankshaft journal.
Read the code on the crankshaft flange.
Read the code on the cylinder block face.
The first letter after the first asterisk makes up the code for main No. 1 and the next
letter for main No. 2. The first letter after the second asterisk makes up the code for
main No. 3 and the last letter for main No. 4.

1.
NOTE: This chart is for selecting main bearings 1 and 4 only, the remaining bearings will be selected
using a different chart in the next step.
Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the
required bearing grade for main bearings 1 and 4.
Read the first letter of the engine block main bearing code and the first letter of the crankshaft
main bearing code.

Read down the column below the engine block main bearing code letter and across the row
next to the crankshaft main bearing code letter, until the 2 intersect. This is the required
bearing grade(s) for the No. 1 crankshaft main bearing.

As an example, if the engine block code letter is "F" and the crankshaft code letter is "P", the
correct bearing grade for this main bearing is a "1" for the upper bearing and a "2" for the
lower bearing.

Repeat the above steps using the fourth letter of the block and crankshaft codes to select the
No. 4 bearing.

2.
NOTE: This chart is for selecting main bearings 2 and 3 only.
Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the
required bearing grade for main bearings 2 and 3.
Read the second letter of the engine block main bearing code and the second letter of the
crankshaft main bearing code.

Read down the column below the engine block main bearing code letter and across the row
next to the crankshaft main bearing code letter, until the 2 intersect. This is the required
bearing grade for the No. 2 crankshaft main bearing.

As an example, if the engine block code letter is "F" and the crankshaft code letter is "P", the
correct bearing grade for this main bearing is "1".

Repeat the above steps using the third letter of the block and crankshaft codes to select the
No. 3.

3.
Using the original connecting rod cap bolts, install the connecting rod caps and bolts.
4.
Measure the connecting rod large end bore in 2 directions. 5.
Remove the bolts and the rod cap.

Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. 6.
8.
NOTE: Do not install the upper thrust bearings until the crankshaft is installed.
NOTE: Lubricate the thrust surfaces of the crankshaft with clean engine oil.
Install the crankshaft onto the upper main bearings.
9.
NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust
surface.
Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No.
4 rear bulkhead.
10.
surface.
Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No.
4 rear bulkhead.
11.
Lubricate the crankshaft lower main bearings with clean engine oil and install them into the main
bearing caps. Visually check seating and squareness of the bearings to make sure of proper seating in
caps.
12.
Position the No. 1, No. 2 and No. 3 main bearing caps on the cylinder block and, keeping the caps as
square as possible, alternately draw the caps down evenly using the new bolts until the main bearing
caps are seated.
13.
surface.
NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.
Install the lower crankshaft thrust washer to the back side of the No. 4 rear main bearing cap, with the
tab aligned with the cutout in the main bearing cap.
14.
Position main bearing cap No. 4 on the cylinder block and keeping the cap as square as possible,
alternately draw the cap down evenly using the new bolts until the main bearing cap is seated.
15.
Loosen the No. 4 main bearing cap bolts. 16.
NOTE: While tightening the main bearing vertical bolts, push the crankshaft forward and the No. 4
main bearing cap rearward to seat the crankshaft thrust washers.
Tighten the main bearing bolts in the sequence shown in 2 stages.
17.
Install the new 8 main bearing cap side bolts. Tighten in the sequence shown in 2 stages.
18.
Zero the Dial Indicator Gauge.
play.

19.
Prepare the connecting rod and cap.
Insert the new bolts in the rod cap.
Insert the upper and lower rod bearings into the rod and cap.
20.
Before installing the pistons into the cylinder block, verify proper ring gap location.
21.
22.
NOTE: The next 3 steps are for all 6 connecting rods, rod caps and pistons. Only 1 connecting rod,
rod cap and piston is shown.
clean engine oil.
NOTE: Make sure the piston rings are positioned to specifications for installation. For additional
information, refer to Disassembly and Assembly of Subassemblies - Piston in this section.
NOTE: If the piston and or connecting rod are being installed new, the piston rod orientation marks
and the arrow on the top of the dome of the piston should be facing toward the front of the engine
block.
NOTE: If the piston and connecting rod are to be reinstalled, they must be installed in the same
orientation as disassembled.
Using the Piston Ring Compressor, install the piston and connecting rod assemblies.
Seat the connecting rod on the crankshaft journal. 23.
NOTE: After installation of each piston, connecting rod, rod cap and bolts, rotate the crankshaft to
verify smooth operation.
Install the connecting rod cap and bolts.
24.
Repeat the previous 3 steps until all 6 piston, connecting rod and connecting rod cap assemblies are
installed.
25.
Install the main bearing cap support brace and the new bolts. Tighten in the sequence shown in 2
steps.
Stage 1: Tighten fasteners to 24 Nm (18 lb-ft).
Stage 2: Tighten fasteners an additional 180 degrees.
26.
NOTE: The crankshaft rear seal retainer must be installed and the bolts tightened within 4 minutes of
surface of the crankshaft rear seal retainer.
27.
Install the rear seal retainer and the 8 bolts.
28.
Install the oil pump and the 3 bolts.
29.
Using a new O-ring seal, install the oil pump screen and pickup tube and the 2 bolts. 30.
NOTE: The A/C compressor must be installed on the cylinder block and the 2 bolts tightened prior to
installing the oil pan.
31.
NOTE: The oil pan and the 4 specified bolts must be installed and the oil pan aligned to the cylinder
block and A/C compressor within 4 minutes of sealant application. Final tightening of the oil pan
bolts must be carried out within 60 minutes of sealant application.
surface of the oil pan.
crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil
pan.

32.
NOTE: The oil pan and the 4 specified bolts must be installed within 4 minutes of the start of sealant
application.
33.
Install the oil pan and bolts 10, 11, 13 and 14.
Loosen the bolts 180 degrees.
Align the oil pan to the cylinder block and A/C compressor.
Position the oil pan so the mounting boss is against the A/C compressor and using a
straightedge, align the oil pan flush with the rear of the cylinder block at the 2 areas shown.

34.
Tighten bolts 10, 11, 13 and 14 in the sequence shown, to 3 Nm (27 lb-in). 35.
Install the remaining oil pan bolts. Tighten all the oil pan bolts in the sequence shown.
Tighten the large bolts (1-14) to 24 Nm (18 lb-ft).
Tighten the small bolts (15 and 16) to 10 Nm (89 lb-in).
36.
Install the A/C compressor mounting stud and nut.
Tighten the stud to 9 Nm (80 lb-in) and the nut to 25 Nm (18 lb-ft).
37.
Install the coolant pump and the 8 bolts. Tighten in the sequence shown in 2 stages:
38.
Install the Knock Sensor (KS) and the 2 bolts.
39.
NOTE: Apply clean engine coolant to the O-ring seals prior to installation.
Using new O-ring seals, install the coolant inlet tube.
40.
Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in 5
stages:
41.
Install the new M6 bolt.
42.
Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in 5
stages:
43.
44.
NOTICE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9
o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do
not turn the crankshaft until instructed to do so. Failure to follow this process will result in
severe engine damage.
Position the crankshaft dowel pin in the 9 o'clock position.
45.
NOTE: The valve tappets must be installed in their original positions.
46.
NOTICE: The camshafts must remain in the neutral position during installation or engine
damage may occur.
NOTE: Coat the camshafts with clean engine oil prior to installation.
Position the camshafts onto the RH cylinder head in the neutral position as shown.
47.
original positions.
Install the 8 camshaft caps and the 16 bolts. Tighten the bolts in the sequence shown in the following
stages:
Stage 1: Tighten bolts 1, 2, 3 and 4 to 8 Nm (71 lb-in) then an additional 45 degrees.
Stage 2: Tighten bolts 5 and 6 to 8 Nm (71 lb-in).
Stage 3: Tighten bolts 7 and 8 to 8 Nm (71 lb-in) then an additional 45 degrees.
Stage 4: Loosen bolts 5 and 6.
Tighten bolts 5 and 6 to 8 Nm (71 lb-in) then an additional 45 degrees.


48.
damage may occur.
Position the camshafts onto the LH cylinder head in the neutral position as shown.
49.
original positions.
stages:


50.
NOTICE: If any components are installed new, the engine valve clearance must be
checked/adjusted or engine damage may occur.
NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet
clearances are not within specification, the clearance must be adjusted by installing new valve
tappet(s) of the correct size. For additional information, refer to Valve Clearance Check in this
section.
51.
Install the RH timing chain guide and bolt.
52.
Install the RH secondary timing chain tensioner and the 2 bolts.
53.
Rotate the RH camshafts to the Top Dead Center (TDC) position and install the Camshaft Holding
Tool on the flats of the camshafts.
54.
Assemble the RH Variable Camshaft Timing (VCT) assembly, the RH exhaust camshaft sprocket and
the RH secondary timing chain.
Align the colored links with the timing marks.
55.
Position the RH secondary timing assembly onto the camshafts. 56.
Install 2 new bolts and the original washer. Tighten in 4 stages.
57.
Remove the lockpin from the RH secondary timing chain tensioner. 58.
Install the LH secondary timing chain tensioner and the 2 bolts.
59.
Rotate the LH camshafts to the Top Dead Center (TDC) position and install the Camshaft Holding
60.
Assemble the LH VCT assembly, the LH exhaust camshaft sprocket and the LH secondary timing
chain.
61.
Position the LH secondary timing assembly onto the camshafts. 62.
63.
Remove the lockpin from the LH secondary timing chain tensioner. 64.
Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock). 65.
Install the crankshaft timing chain sprocket. 66.
Install the upper LH primary timing chain guide and the bolt.
67.
Install the primary timing chain with the colored links aligned with the timing marks on the VCT
assemblies and the crankshaft sprocket.
68.
Install the lower LH primary timing chain guide and the 2 bolts.
69.
Install the primary timing chain tensioner arm. 70.
Reset the primary timing chain tensioner.
Release the ratchet detent. 1.
Using a soft-jawed vise, compress the ratchet plunger. 2.
Align the hole in the ratchet plunger with the hole in the tensioner housing and install a
suitable lockpin.
3.
71.
NOTE: It may be necessary to rotate the crankshaft slightly to remove slack from the timing chain
and install the tensioner.
72.
Install the primary tensioner and the 2 bolts.
Remove the lockpin.
As a post-check, verify correct alignment of all timing marks.
There are 48 links between the RH intake VCT assembly colored link (1) and the LH intake
VCT assembly colored link (2).

There are 35 links between the LH intake VCT assembly colored link (2) and the 2 crankshaft
sprocket colored links (3).

73.
Inspect the VCT housing seals for damage and replace as necessary. 74.
NOTE: During removal, the O-ring seal may remain on the cylinder head. If so, remove the O-ring
seal from the cylinder head, inspect the seal (replace as necessary) and install the O-ring seal on the
VCT housing.
Inspect the VCT housing-to-cylinder head O-ring seals for damage and replace as necessary.
75.
NOTICE: Make sure the dowels on the Variable Camshaft Timing (VCT) housing are fully
engaged in the cylinder head prior to tightening the bolts. Failure to follow this process will
result in severe engine damage.
Install the LH VCT housing and the 3 bolts.
76.
Install the RH VCT housing and the 3 bolts.
77.
Install the Alignment Pins. 78.
NOTE: The engine front cover and bolts 17, 18, 19 and 20 must be installed within 4 minutes of the
initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket
bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time
limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To
clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this
procedure can cause future oil leakage.
Apply a 3.0 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine
front cover sealing surfaces including the 3 engine mount bracket bosses.
Apply a 5.5 mm (0.21 in) bead of Motorcraft High Performance Engine RTV Silicone to the
oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the
engine front cover in 5 places as indicated.

79.
NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
Install the engine front cover and bolts 17, 18, 19 and 20.
Tighten in sequence to 3 Nm (27 lb-in).
80.
Remove the Alignment Pins. 81.
NOTE: Do not tighten the bolts at this time.
Install the engine mount bracket and the 3 bolts.
82.
for at least 90 minutes after installing the engine front cover. Failure to follow this instruction
may cause oil leakage.
Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine
mount bracket bolts in the sequence shown in 2 stages:
Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (133
lb-in).

Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55
lb-ft).

83.
NOTICE: The thread sealer on the engine mount studs (including new engine mount studs if
applicable) must be cleaned off with a wire brush and new Threadlock and Sealer applied prior
to installing the engine mount studs. Failure to follow this procedure may result in damage to
the engine mount studs or engine.
Install the engine mount studs in the following sequence.
Clean the front cover engine mount stud holes with pressurized air to remove any foreign
material.
1.
Clean all the thread sealer from the engine mount studs (old and new studs). 2.
Apply new Threadlock and Sealer to the engine mount stud threads. 3.
Install the 2 engine mount studs.
4.
84.
85.
NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
86.
crankshaft pulley.
87.
Stage 1: Tighten to 120 Nm (89 (lb-ft).
88.
of the engine.
plug tube seals.
89.
90.
Using a new gasket, install the RH valve cover and tighten the bolt and 8 stud bolts.
91.
92.
Using a new gasket, install the LH valve cover and tighten the 9 stud bolts.
93.
94.
Install the 6 coil-on-plug assemblies and the 6 bolts.
95.
Using a new gasket, install the oil filter adapter and 3 bolts.
96.
NOTE: Apply thread sealant with PTFE to the Engine Oil Pressure (EOP) switch threads.
Install the EOP switch.
97.
Install the Crankshaft Position (CKP) sensor and install the bolt.
98.
Install LH Camshaft Position (CMP) sensor and the bolt.
99.
Install and connect the Cylinder Head Temperature (CHT) sensor jumper harness. 100.
damage.
Using new gaskets, install the lower intake manifold and the 10 bolts.
101.
Using a new gasket, install the thermostat housing and the 2 bolts.
102.
NOTICE: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary
O-rings may cause the fuel system to leak. Do not reuse the O-ring seals.
NOTE: The upper and lower O-ring seals are not interchangeable.
Install new fuel injector O-ring seals.
Remove the retaining clips and separate the fuel injectors from the fuel rail.
Install new O-ring seals and lubricate with clean engine oil.
Install the fuel injectors and the retaining clips onto the fuel rail.
103.
Install the fuel rail and injectors as an assembly and install the 4 bolts.
104.
Install the catalytic converter bracket and the 2 bolts.
105.
All engines
Install the RH CMP sensor and the bolt.
106.
Install the engine lifting eye and the 2 bolts.
107.
Install the cover and the pin-type retainer. 108.
Install the LH cylinder block drain plug.
109.
Install the RH cylinder block drain plug or, if equipped, the block heater.
Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees.
Tighten the block heater to 40 Nm (30 lb-ft).
110.
111.
sequence shown:
112.
Using a new gasket, install the RH catalytic converter and the 4 new nuts.
113.
All engines
114.
sequence shown:
115.
116.
Using a new gasket, install the LH catalytic converter and the 4 new nuts (3 shown).
117.
118.
Install the power steering pump and the 3 bolts.
119.
Install the Power Steering Pressure (PSP) tube bracket and bolt to the RH cylinder head.
120.
Install the PSP hose bracket nut.
121.
Attach the PSP hose retainer to the engine lifting eye. 122.
Install the generator, the nut and the bolt.
123.
Using new O-ring seals, install the A/C manifold and the bolt.
124.
Position the wiring harness onto the engine. 125.
Connect the EOP switch electrical connector and the wiring harness pin-type retainer. 126.
Attach the wiring harness retainer to the generator. 127.
Connect the generator B+ cable and install the nut.
129.
Install the wiring harness grommet. 132.
Install the wiring harness retainer stud bolt.
133.
Install the heat shield, the nut and the bolt.
134.
Install the wiring harness retainer bolt on the rear of the LH cylinder head.
135.
Attach all of the wiring harness retainers to the LH valve cover and stud bolts. 136.
Connect the LH camshaft VCT solenoid electrical connector. 137.
Connect the 3 LH coil-on-plug electrical connectors. 138.
Connect the LH HO2S electrical connector. 139.
Connect the LH Catalyst Monitor Sensor (CMS) electrical connector. 140.
Connect the LH CMP sensor electrical connector. 141.
Connect the 6 fuel injector electrical connectors (3 shown). 143.
Connect the KS electrical connector. 144.
Connect the RH CMP sensor electrical connector. 145.
Connect the coolant bypass hose to the thermostat housing. 146.
Attach all of the wiring harness retainers to the RH valve cover and stud bolts. 147.
Connect the 3 RH coil-on-plug electrical connectors. 148.
Connect the RH VCT solenoid electrical connector. 149.
FWD vehicles
Connect the RH CMS electrical connector. 150.
All engines
damage.
152.
Install the upper intake manifold support bracket and the 2 bolts (one shown).
153.
Install the RH exhaust manifold heat shield and the 3 bolts.
154.
Attach the wiring harness retainers to the upper intake manifold. 156.
Connect the Throttle Body (TB) electrical connector. 157.
Connect the PCV hose to the PCV valve. 158.
If equipped, position the block heater wiring harness onto the engine.
Attach the block heater wiring harness retainer to the power steering reservoir hose and the
PSP hose.

159.
If equipped, connect the block heater electrical connector and install the heat shield. 160.
If equipped, attach the block heater wiring harness retainer to the upper intake manifold. 161.
Using the Floor Crane and Spreader Bar, remove the engine from the stand. 163.
NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.
seal onto the tool.
164.
NOTE: One of the 8 flexplate holes are offset so the flexplate can only be installed in one position.
Install the flexplate and the 8 bolts.
167.
Engine
Special Tool(s)
300-OTC1819E
Powertrain Lift
300-OTC1585AE
Spreader Bar
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
All vehicles
Align the transaxle to the engine. 1.
Install the 4 transaxle-to-engine bolts and the transaxle-to-engine stud bolt.
2.
Install the 2 engine-to-transaxle bolts.
3.
Engine 1987
Using the Floor Crane and the Spreader Bar, position the engine and transaxle onto the lift table. 4.
5.
Install the starter and the 2 bolts.
6.
Attach the starter wire terminals and install the 2 nuts.
Tighten to 12 Nm (106 lb-in). 1.
Position the starter terminal boot over the starter terminal.
2.
7.
Engine 1988
Connect the Transmission Control Module (TCM) electrical connector. 8.
Install the ground wire and bolt.
9.
Connect the wiring harness fasteners to the transaxle-to-engine stud bolt and the starter. 10.
Raise the engine and transaxle assembly into the vehicle. 11.
Install the engine mount, the nut and the 2 bolts.
Tighten the bolts to 55 Nm (41 lb-ft).
Tighten the nut to 63 Nm (46 lb-ft).
12.
Install the 2 engine mount spacers and the 4 engine mount nuts.
13.
Engine 1989
Install the 2 transaxle support insulator bracket nuts and the bolt.
14.
Install the transaxle support insulator through bolt and nut.
15.
NOTE: A new compression seal must be installed whenever the Power Transfer Unit (PTU) is moved
from the vehicle.
Using a small screwdriver, remove the compression seal and discard.
16.
Using a soft face hammer, install the new compression seal. 17.
Engine 1990
Position the PTU in place and install the 5 bolts.
18.
Position the PTU support bracket in place and install the 5 bolts.
19.
NOTE: Do not tighten the 4 catalytic converter nuts at this time.
20.
Install the 2 catalytic converter-to-bracket bolts.
Tighten the 4 catalytic converter nuts to 40 Nm (30 lb-ft).
Tighten the 2 catalytic converter-to-bracket bolts to 20 Nm (177 lb-in).
21.
Engine 1991
Connect the RH Catalyst Monitor Sensor (CMS) electrical connector. 22.
NOTE: Do not tighten the 2 catalytic converter support bracket bolts at this time.
Install the RH catalytic converter support bracket and the 2 bolts.
23.
Install the 2 catalytic converter support bracket nuts.
Tighten the 2 catalytic converter support bracket bolts to 20 Nm (177 lb-in).
24.
All vehicles
NOTE: Align the index marks on the subframe to the index marks on the underbody that were made
during removal.
Using the Powertrain Lift, raise the subframe into the installed position.
25.
Engine 1992
Install the 2 front subframe nuts.
26.
Position the subframe brackets and install the 4 bolts finger-tight.
27.
Install the 2 rear subframe nuts.
28.
Tighten the 4 subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
29.
Engine 1993
30.
Install new cotter pins.
31.
Install the engine roll restrictor-to-subframe through bolt.
32.
AWD vehicles
removal and install the 4 new bolts.
33.
Engine 1994
All vehicles
Install 4 new torque converter nuts.
34.
Install the inspection cover and the 2 fasteners. 35.
36.
Using new gaskets, install the Y-pipe assembly and 6 new nuts.
37.
38.
Connect the 2 transmission fluid cooler hoses. 39.
Engine 1995
Connect the power steering cooler tube. 40.
Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips into the
body.
From under the vehicle, verify that the seal is properly installed on the steering gear and the

41.
If equipped, install the underbody shield and the 6 screws. 42.
Engine 1996
NOTE: Align the index marks made during removal.
Install the steering intermediate shaft onto the steering gear and install a new bolt.
45.
Using a new banjo bolt and 2 new seals, install the Power Steering Pressure (PSP) tube onto the
steering gear.
47.
Install the PSP tube bracket and bolt.
48.
Connect the PCM electrical connectors and pin-type retainers. 49.
Engine 1997
Install the engine mount brace and the 3 bolts.
50.
Install the ground wire and the bolt.
51.
Connect the fuel supply tube from the fuel rail. For additional information, refer to Section 310-00 . 52.
Attach the power steering reservoir onto the cowl. 53.
Engine 1998
Connect the hose to the power steering reservoir.
Attach the pin-type retainer to the engine mount brace.
54.
Attach the 2 wiring harness retainers to the LH valve cover stud bolts. 56.
Using new O-ring seals, connect the A/C tubes and install the 2 nuts.
59.
Engine 1999
Install the A/C tube bracket bolt.
60.
Install the 2 A/C tube bracket bolts.
61.
Using a new O-ring seal, connect the A/C tube to the condenser and install the nut.
62.
Attach the coolant tube retainer clips to the A/C tube. 63.
If equipped, attach the engine block heater harness to the radiator support, power steering hose, A/C
tube and the engine wiring harness.
64.
65.
Engine 2000
Position the transaxle control cable bracket in place and install the 3 nuts.
66.
Connect the transaxle control cable to the control lever. 67.
Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing. 68.
Connect the vacuum hose and the Evaporative Emission (EVAP) tube to the upper intake manifold. 69.
70.
Engine 2001
71.
Attach the 2 wiring harness retainers to the transmission mount and the battery tray bracket. 72.
Install the engine Air Cleaner (ACL) and the ACL outlet pipe. For additional information, refer to
Section 303-12C .
75.
Install the degas bottle. For additional information, refer to Section 303-03A . 76.
.
77.
Section 303-05C .
78.
Engine 2002
Fill the power steering system. For additional information, refer to Section 211-00B . 81.
Transmission Fluid Drain and Refill procedure in Section 307-01A .
82.
84.
Engine 2003
Engine Front Cover
Special Tool(s)
Alignment Pins
307-399
Handle
205-153 (T80T-4000-W)
Installer, Crankshaft Vibration Da
303-102 (T74P-6316-B)
303-335
303-1251
303-1247/2
Powertrain Lift
300-OTC1585AE
Strap Wrench
Material
Item Specification
Engine RTV Silicone
TA-357
WSE-M4G323-A6
ZC-31-A
-
(Canada)
WSS-M2C945-A
XO-5W20-QSP (US);
Remover
ZC-30
-
TA-25
WSK-M2G351-A5
ignited. Failure to follow these instructions may result in serious persona
All vehicles
Install the Alignment Pins. 1.
NOTE: The engine front cover and bolts 17, 18, 19 and 20 must be installed within 4 minutes of the
initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket
bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time
limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To
clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this
procedure can cause future oil leakage.
Apply a 3.0 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine
front cover sealing surfaces including the 3 engine mount bracket bosses.
Apply a 5.5 mm (0.21 in) bead of Motorcraft High Performance Engine RTV Silicone to the
oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the
engine front cover in 5 places as indicated.

2.
NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
Install the engine front cover and bolts 17, 18, 19 and 20.
Tighten in sequence to 3 Nm (27 lb-in).
3.
Remove the Alignment Pins. 4.
NOTE: Do not tighten the bolts at this time.
5.
Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine
mount bracket bolts in the sequence shown in 2 stages:
Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (133
lb-in).

Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55
lb-ft).

6.
NOTICE: The thread sealer on the engine mount studs (including new engine mount studs if
applicable) must be cleaned off with a wire brush and new Threadlock and Sealer applied prior
to installing the engine mount studs. Failure to follow this procedure may result in damage to
the engine mount studs or engine.
Install the engine mount studs in the following sequence.
Clean the front cover engine mount stud holes with pressurized air to remove any foreign
material.
1.
Clean all the thread sealer from the engine mount studs (old and new studs). 2.
Apply new Threadlock and Sealer to the engine mount stud threads. 3.
Install the 2 engine mount studs.
4.
7.
8.
NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
9.
crankshaft pulley.
10.
11.
12.
Install the power steering pump and the 3 bolts.
13.
of the engine.
NOTE: Spark plug tube seal installation shown, Variable Camshaft Timing (VCT) solenoid seal
installation similar.
plug tube seals.
14.
15.
Using a new gasket, install the RH valve cover and tighten the bolt and 8 stud bolts.
16.
17.
Using a new gasket, install the RH valve cover and tighten the 9 stud bolts.
18.
19.
Install the Power Steering Pressure (PSP) hose bracket and nut.
20.
Attach the PSP hose retainer to the engine lifting eye. 21.
Install the 6 coil-on-plug assemblies and the 6 bolts.
22.
Attach all of the wiring harness retainers to the LH valve cover and stud bolts. 23.
Connect the 3 LH coil-on-plug electrical connectors. 24.
Connect the LH camshaft VCT solenoid electrical connector. 25.
Attach all of the wiring harness retainers to the RH valve cover and stud bolts. 26.
Connect the 3 RH coil-on-plug electrical connectors. 27.
Connect the RH VCT solenoid electrical connector. 28.
Connect the RH Catalyst Monitor Sensor (CMS) sensor electrical connector. 30.
damage.
31.
Install the upper intake manifold support bracket bolt.
32.
Attach the wiring harness retainers to the upper intake manifold. 33.
Connect the Throttle Body (TB) electrical connector. 34.
Connect the PCV hose to the PCV valve. 35.
If equipped, attach the block heater wiring harness retainer to the PSP tube and the power steering
reservoir hose.
36.
If equipped, attach the block heater wiring harness retainer to the upper intake manifold. 37.
Raise the engine and transaxle assembly into the vehicle. 38.
Install the engine mount, the nut and the 2 bolts.
Tighten the bolts to 55 Nm (41 lb-ft).
Tighten the nut to 63 Nm (46 lb-ft).
39.
Install the 2 engine mount spacers and the 4 engine mount nuts.
40.
Install the transaxle support insulator bracket, bolt and the 2 nuts.
41.
Install the transaxle support insulator through bolt and nut.
42.
NOTE: Do not tighten the 2 catalytic converter support bracket bolts at this time.
Install the RH catalytic converter support bracket and the 2 bolts.
43.
Install the 2 catalytic converter support bracket nuts.
Tighten the 2 catalytic converter support bracket bolts to 20 Nm (177 lb-in).
44.
NOTE: A new Power Transfer Unit (PTU) seal must be installed whenever the intermediate shaft is
removed.
Install a new PTU seal. For additional information, refer to Section 303-07B .
45.
All vehicles
NOTE: Align the index marks on the subframe to the index marks on the underbody that were made
during removal.
Using the Powertrain Lift, raise the subframe into the installed position.
46.
47.
48.
49.
50.
51.
52.
Install the engine roll restrictor-to-subframe through bolt.
53.
AWD vehicles
removal and install the 4 new bolts (3 shown).
54.
All vehicles
Using new gaskets, install the Y-pipe assembly and the 6 new nuts.
55.
56.
Connect the 2 transmission fluid cooler hoses. 57.
Connect the power steering cooler tube. 58.
Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips into the
body.

59.
NOTE: Align the index marks made during removal.
63.
Using a new banjo bolt and 2 new seals, install the PSP tube onto the steering gear.
65.
Install the PSP tube bracket and bolt.
66.
Connect the PCM connectors and pin-type retainers. 67.
Install the engine mount brace and the 3 bolts.
68.
69.
Connect the fuel supply tube to the fuel rail. For additional information, refer to Section 310-00 . 70.
Attach the power steering reservoir onto the cowl. 71.
Connect the hose to the power steering reservoir.
Attach the pin-type retainer to the engine mount brace.
72.
Attach the 2 wiring harness retainers to the LH valve cover stud bolts. 74.
Using new O-ring seals, connect the A/C tubes and install the 2 nuts.
77.
78.
Install the 2 A/C tube retaining clamp bolts.
79.
Using a new O-ring seal, connect the A/C tube to the condenser and install the nut.
80.
Attach the coolant tube retainer clips to the A/C tube. 81.
If equipped, attach the engine block heater harness to the radiator support, power steering hose, A/C
tube and the engine wiring harness.
82.
83.
Position the transaxle control cable bracket in place and install the 3 nuts.
84.
Connect the transaxle control cable to the control lever. 85.
Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing. 86.
Connect the vacuum hose and the Evaporative Emission (EVAP) tube to the upper intake manifold. 87.
88.
89.
Attach the 2 wiring harness retainers to the transmission mount and the battery tray bracket. 90.
Install the engine Air Cleaner (ACL) and the ACL outlet pipe. For additional information, refer to
Section 303-12C .
93.
Install the degas bottle. For additional information, refer to Section 303-03A . 94.
.
95.
Section 303-05C .
96.
for at least 90 minutes after installing the engine front cover. Failure to follow this instruction
may cause oil leakage.
Fill the engine with clean engine oil.
97.
Fill the power steering system. For additional information, refer to Section 211-00B . 99.
Transmission Fluid Drain and Refill procedure in Section 307-01A .
100.
102.
Special Tool(s)
303-1248
1.
1.
Assemble the RH Variable Camshaft Timing (VCT) assembly, the RH exhaust camshaft sprocket and
the RH secondary timing chain.
3.
5.
7.
Assemble the LH VCT assembly, the LH exhaust camshaft sprocket and the LH secondary timing
chain.
8.
10.
Install the upper LH primary timing chain guide and the bolt. 13.
14.
15.
suitable lockpin.
3.
17.
Remove the lockpin.
18.

19.

VCT housing.
21.
22.
23.
Camshaft
Special Tool(s)
303-1248
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
All camshafts
WARNING: Do not smoke, carry lighted tobacco oran open flame of any type when working on or
near any fuel-related component. Highly flammable mixtures are always present and may be ignited.
NOTICE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9
o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do
not turn the crankshaft until instructed to do so. Failure to follow this process will result in
severe engine damage.
Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position.
1.
LH camshafts
damage may occur.
2.
Camshaft 2035
Position the camshafts onto the LH cylinder head in the neutral position as shown.
original positions.
stages:


3.
RH camshafts
damage may occur.
Position the camshafts onto the RH cylinder head in the neutral position as shown.
4.
Camshaft 2036
original positions.
stages:


5.
All camshafts
NOTICE: If any components are installed new, the engine valve clearance must be
checked/adjusted or engine damage can occur.
Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet
clearances are not within specification, the clearance must be adjusted by installing new valve
tappet(s) of the correct size. For additional information, refer to Valve Clearance Check in this
section.
6.
Camshaft 2037
LH camshafts
Rotate the LH camshafts to the Top Dead Center (TDC) position and install the Camshaft Holding
7.
Assemble the LH Variable Camshaft Timing (VCT) assembly, the LH exhaust camshaft sprocket and
the LH secondary timing chain.
8.
10.
Camshaft 2038
RH camshafts
Rotate the RH camshafts to the TDC position and install the Camshaft Holding Tool on the flats of
the camshafts.
12.
Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing
chain.
13.
15.
Camshaft 2039
All camshafts
Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock). 17.
18.
19.
Camshaft 2040
suitable lockpin.
3.
21.
22.
Camshaft 2041
Remove the lockpin.


23.
VCT housing.
25.
Camshaft 2042
26.
27.
Camshaft 2043
Camshaft 2044
Valve Tappets
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
1.
Depending on the valve tappets being serviced, install the LH and/or the RH camshafts. For addial
information, refer to Camshaft in this section.
2.
Valve Tappets 2045
Valve Tappets 2046
Valve Spring, Retainer and Seal
Special Tool(s)
303-300 (T87C-6565-A)
303-350 (T89P-6565-A)
303-470 (T94P-6510-CH)
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
NOTE: Lubricate the valve stem seal with clean engine oil prior to installation.
Using the Valve Stem Oil Seal Installer, install a new valve stem seal.
1.
Using the Valve Spring Compressors, install the valve spring, retainer and key. 2.
Install the valve tappets. For additional information, refer to Valve Tappets in this section. 3.
Cylinder Head - RH
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
All engines
Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in 5
stages:
1.
2.
3.
Install and connect the Cylinder Head Temperature (CHT) sensor jumper harness. 4.
damage.
5.
Using a new gasket and O-ring seal, install the thermostat housing and the 2 bolts.
6.
8.
9.
Install the RH Camshaft Position (CMP) sensor and the bolt.
10.
NOTE: Align the bracket with the index mark made during removal.
Install the upper intake manifold support bracket and the bolt.
11.
Install the engine lifting eye and the 2 bolts.
12.
13.
14.
15.
sequence shown:
16.
Install the RH exhaust manifold heat shield and the 3 bolts.
17.
18.
19.
Install the 2 RH catalytic converter bracket bolts.
Tighten the 2 catalytic converter brackets to 20 Nm (177 lb-in).
20.
21.
All engines
22.
Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown).
23.
24.
Connect the LH Catalyst Monitor Sensor (CMS) sensor electrical connector. 25.
Install the Power Steering Pressure (PSP) tube bracket and bolt.
28.
Connect the RH CMP sensor electrical connector. 29.
If equipped, install the block heater wiring harness onto the engine.
Connect the block heater electrical connector and install the heat shield.
31.
Install the RH camshafts. For additional information, refer to Camshaft in this section. 32.
Cylinder Head - LH
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
All vehicles
Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in 5
stages:
1.
2.
3.
4.
Install the upper LH primary timing chain guide and the bolt.
5.
Install LH Camshaft Position (CMP) sensor and the bolt.
6.
damage.
7.
Using a new gasket and O-ring seal, install the thermostat housing and the 2 bolts.
8.
10.
11.
12.
13.
Install the 2 RH catalytic converter bracket bolts.
Tighten the 2 catalytic converter brackets to 20 Nm (177 lb-in).
14.
15.
All vehicles
16.
17.
sequence shown:
18.
19.
Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown).
20.
21.
Install the wiring harness retainer bolt on the rear of the LH cylinder head.
22.
Connect the LH Catalyst Monitor Sensor (CMS) sensor electrical connector. 23.
Connect the LH Heated Oxygen Sensor (HO2S) electrical connector. 24.
Connect the LH CMP sensor electrical connector. 25.
Connect the Cylinder Head Temperature (CHT) sensor electrical connector. 26.
Attach the wiring harness pin-type retainer. 28.
Install the generator, the bolt and the nut.
29.
Attach the wiring harness retainer to the generator. 30.
Connect the generator B+ cable and install the nut.
32.
If equipped, install the block heater wiring harness onto the engine.
Connect the block heater electrical connector and install the heat shield.
34.
Install the LH camshafts. For additional information, refer to Camshaft in this section. 35.
Oil Pump
NOTE: Install a new oil pump screen and pickup tube O-ring seal prior to installing the oil pump.
Position the oil pump onto the crankshaft and rotate counterclockwise to position the pump onto the
oil pump screen and pickup tube.
Install the 3 bolts and tighten to 10 Nm (89 lb-in).
1.
Install the 2 oil pump screen and pickup tube bolts.
2.
4.
Oil Pump 2067
5.
suitable lockpin.
3.
7.
Oil Pump 2068
Remove the lockpin.
8.


9.
Install new VCT housing seals. 10.
Oil Pump 2069
VCT housing.
11.
12.
13.
Oil Pump 2070
Oil Pump 2071
SECTION 303-01D: Engine - 2.5L Hybrid
Workshop Manual
Material
Capacity
Prep
ZC-31-A
- -
Motor Oil (Canada)
XO-5W20-QSP (US);
WSS-M2C945-A 5.0L (5.3 qt)
includes
filter change
Engine Coolant
VC-10-A2 (US); CVC-10-A
(Canada)
WSS-M97B55-A
a
Motorcraft Specialty Orange
Engine Coolant
VC-3-B (US); CVC-3-B
(Canada)
WSS-M97B44-D
a
XG-4 and/or XL-5
ESB-M1C93-B -
XG-3-A
ESE-M1C171-A -
TA-30
WSd> -
Remover
ZC-30
- -
TA-24
WSK-M2G350-A2 -
a
Item Specification
Displacement 2.5L
No. of cylinders 4
Oil Pump 2072
Bore/stroke 89/100
Oil pressure (hot @ 2,000 rpm) 29-39 psi
200-268 kPa
components)
121.3 kg (267.5 lb)
Engine and transaxle weight (without accessory
drive components)
257.1 kg (567 lb)
Cylinder Block
Cylinder bore diameter
89-89.3 mm
(3.503-3.517 in)
Cylinder bore maximum out-of-round 0.008 mm
(0.0003 in)
Main bearing bore diameter 57.018-57.040 mm
(2.244-2.245 in)
Head gasket surface flatness 0.1 mm/general
0.05 mm/200 x 200
(0.003 in/general)
(0.0019 in/7.87 x 7.87)
Piston
Diameter (1) 88.965-88.975 mm
(3.5025-3.5026 in)
Diameter (2) 88.975-88.985 mm
(3.5026-3.5033 in)
Diameter (3) 88.985-88.995 mm
(3.5033-3.5037 in)
Piston-to-bore clearance 0.025-0.045 mm
(0.0009-0.0017 in)
Ring groove width - top 1.203-1.205 mm
(0.0473-0.0474 in)
Ring groove width - 2nd 1.202-1.204 mm
(0.0473-0.0474 in)
Ring groove width - oil 2.501-2.503 mm
(0.0984-0.0985 in)
Piston skirt coating thickness
Oil Pump 2073
0.008-0.016 mm
(0.0003-0.0006 in)
Piston Pin
Diam 19.995-20 mm
(0.7872-0.7874 in)
Length 54.7-55 mm
(2.153-2.165 in)
Piston-to-pin clearance Floating Pin
Pin-to-rod clearance Clips
Cylinder Head
Cylinder head flatness 0.08 mm (0.0031 in) maximum overall, a maximum of
0.05 mm (0.0019 in) within 150 mm (5.9 in)
Valve lift @ zero lash (exhaust) 7.7 mm (0.30 in)
Valve lift @ zero lash (intake) 8.8 mm (0.35 in)
Valve guide diameter 5.509-5.539 mm
(0.216-0.218 in)
Valve seat width - intake/exhaust 0.99-1.84 mm
(0.038-0.072 in)
Valve seat angle 45 degrees
Valve lash adjuster bore diameter 31.00-31.03 mm
(1.220-1.221 in)
Cam bore diameter 25.015-25.040 mm
(0.984-0.985 in)
Valve
(1.3.383 in)
(1.175-1.187 in)
(0.2153-0.2159 in)
(0.2151-0.2157 in)
Valve stem-to-guide clearance - intake 0.0027 mm (0.00010 in)
Valve stem-to-guide clearance - exhaust 0.0029 mm (0.00011 in)
Valve face runout (maximum) 0.075 mm (0.0029 in)
Valve face angle 45 degrees
Oil Pump 2074
Valve Spring - Compression Pressure
Intake and exhaust (installed) 38.667 lb
Intake (valve open) 8.9 mm (0.35 in) of lift 97.032 lb
Exhaust (valve open) 7.4 mm of lift 93.338 lb
Free length 44.92 mm (1.768 in)
Assembled height 37.9 mm (1.492 in)
Crankshaft
Main bearing journal diameter 51.978-52.002 mm
(2.046-2.047 in)
Production repa valign="top"
align="center">51.730-51.750 mm
(2.036-2.037 in)
Main bearing clearance 0.016-0.047 mm
(0.0006-0.0015 in)
Connecting rod journal diameter 51.978-52.002 mm
(2.0463-2.0473 in)
Production repair 51.730-51.750 mm
(2.0366-2.0374 in)
End play 0.22-0.43 mm
(0.008-0.016 in)
Rings
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 0.16-0.26 mm
(0.006-0.010 in)
Ring gap (in bore) - 2nd 0.31-0.46 mm
(0.012-0.018 in)
Ring gap (in bore) - oil 0.2-0.7 mm
(0.007-0.027 in)
Valve Tappet
Diameter 30.97-30.98 mm
(1.2192-1.2196 in)
Oil Pump 2075
Tappet-to-valve clearance - intake 0.22- 0.28 mm (0.008-0.011 in)
Tappet-to-valve exhaust 0.27-0.33 mm (0.010-0.013 in)
Tappet-to-bore clearance 0.02-0.06 mm
(0.0007-0.0023 in)
Camshaft
Runout (1)
a
0.03 mm (0.001 in)
Thrust clearance 0.09-0.24 mm
(0.003-0.009 in)
Journal diameter 24.96-24.98 mm
(0.982-0.983 in)
Journal-to-bore clearance 0.035-0.080 mm
(0.001-0.003 in)
Connecting Rod
Bearing clearance 0.027-0.052 mm
(0.001-0.002 in)
Bearing thickness 1.496-1.520 mm
(0.058-0.059 in)
Crank bore diameter 55.023-55.047 mm
(2.166-2.167 in)
Pin bore diameter 20.965-20.985 mm
(0.825-0.826 in)
Length (center to center) 151.8 mm (5.976 in)
Side clearance 1.95-3.05 mm
(0.076-0.12)
Axial clearance 0.14-0.36 mm
(0.005-0.014 in)
a
No. 3 Journal - Supported by No. 1 and No. 5 journals.
A/C compressor mounting bolts 25 18 -
A/C manifold tube-to-A/C compressor nut 15 - 133
A/C tube bracket bolt 6 - 53
Oil Pump 2076
A/C tube bracket-to-strut tower bolt 6 - 53
A/C tube-to-A/C compressor nut 15 - 133
A/C tube nut 15 - 133
Accessory drive belt tensioner 25 18 -
Air Cleaner (ACL) outlet tube clamps 3 - 27
Auxiliary coolant pump bolts 10 - 89
Balance shaft bolts
a
- - -
Block heater (if equipped) 40 30 -
Block-off plate bolts 25 18 -
Camshaft bearing caps
a
- - -
Camshaft sprocket bolt 72 53 -
Catalytic converter-to-cylinder head nuts
a
- - -
Catalytic converter manifold bracket-to-engine block bolts 35 26 -
Catalytic converter manifold heat shield bolts - 89
Coil-on-plug retaining stud bolts 8 - 71
a
- - -
Coolant outlet bolts 10 - 89
Coolant pump bolts 10 - 89
Coolant pump pulley bolts 20 - 177
Crankcase vent oil separator bolts 10 - 89
Crankshaft Position (CKP) sensor 7 - 62
a
- - -
Crankshaft rear oil seal with retainer bolts 10 - 89
Cylinder head bolts
a
- gn="center">-
EGR tube 55 41 -
EGR valve assembly bolts 20 - 177
a
- - -
Engine mount bolts and nut 55 41 -
Engine mount bracket ground strap bolt 10 - 89
Engine mount bracket-to-engine nuts 103 76 -
Engine mount bracket-to-mount bolt 115 85 -
Engine plug bolt 20 - 177
90 66 -
Engine timing plug bolt 20 - 177
Engine-to-transaxle bolts 48 35 -
Engine wiring harness connector bracket 15 - 133
Electronic Power Assist Steering (EPAS) ground wire bolt 10 - 89
Flywheel bolt
a
- - -
Fuel rail bolts 23 17 -
Intake manifold bolts 18 - 159
Knock Sensor (KS) 20 - 177
Oil Pump 2077
Lower front cover timing hole plug 12
Main bearing beam bolts
a
- - -
Master cylinder reservoir bolts 10 - 89
Motor Electronics Cooling System (MECS) coolant expansion tank nut and bolt 10 - 89
Oil drain plug 28 21 -
Oil filter adapter bolts 25 18 -
Oil filter
b
- - -
Oil pan bolts
a
- - -
Oil pan-to-bellhousing bolts 48 35 -
Oil pump drive chain tensioner shoulder bolts 10 - 89
Oil pump screen and pickup tube bolts 10 89
Oil pump sprocket bolt 25 18 -
Oil pump-to-engine block bolts
a
- - -
Oil squirters 4 - 35
Radio capacitor nut 10 - 89
Spark plug 12 - 106
Steering column shaft-to-steering gear bolt 23 17 -
Tie-rod end nuts 35 -
Transaxle selector lever cable bracket nuts 12 - 106
Transaxle damper bolts 29 21 -
Transaxle ground wire nut 10 - 89
Transaxle harness wiring retainer bolt 10 - 89
Upper transaxle insulator nuts 90 66 -
Upper front cover timing hole plug 10 - 89
Vacuum pump assembly bolts 25 18 -
Vacuum pump assembly nut 25 18 -
Valve cover bolts
a
- - -
Variable Camshaft Timing (VCT) plug 17 - 150
VCT solenoid bolt 10 - 89
a
b
Tighten the pin-on oil filter three-fourths of a turn after the oil filter gasket makes contact with the oil filter
adapter.
Oil Pump 2078
Oil Pump 2079
SECTION 303-01D: Engine - 2.5L
Hybrid
Manual
Engine
The 2.5L (153 CID) 4-cylinder engine has the following features:
Dual overhead camshaft
Aluminum cylinder head
Aluminum cylinder block
Electronic ignition system with 4 coil-on-plug ignition coils
The 2.5L engine is a 4 valve-per-cylinder, dual overhead camshaft engine. The engine uses a coil-on-plug
ignition system. The cylinder block is made of aluminum and the bearing caps are integrated into the ladder
assembly. An aluminum oil pan bolts to the bottom of the lower cylinder block and to the transmission to
provide greater strength. The camshafts are mounted in the cylinder heads and act against valve tappets to
open and close the valves. The camshafts are driven off the front of the cylinder head by one timing chain.
The chain isven by a sprocket that is located on the crankshaft. The piston assembly is an aluminum piston
with a cast iron connecting rod. The oil pump is driven by the crankshaft via a dedicated chain that is driven
by the same sprocket that drives the timing chain.
Always refer to these labels when installation of new parts is necessary or when checking engine calibrations.
The engine parts often differ within a CID family. Verification of the identification codes will make sure the
correct parts are obtained. These codes contain all the pertinent information relating to the dates, optional
equipment and revisions. The Ford Catalog AdvantageTM or equivalent contains a complete listing of the
codes and their applications.
Item Description
2 Chihuahua engine plant
4 Bar code
5 Running number
Engine 2080
7 Plant shift line
8 Bar code
Operation and necessary maintenance of the exhaust emission control devices used on this engine are covered
Induction System
injectors:
are mounted in the intake manifold.
are connected in series with the fuel pressure sensor.
supply fuel from the fuel tank with a fuel pump mounted in the fuel tank.
A constant fuel pressure is maintained across the fuel injectors by the fuel pressure sensor. The fuel pressure
sensor:
is positioned upstream from the fuel injectors on the fuel injection supply manifold.
Lubrication System
The engine lubrication system operates as follows:
Oil is drawn into the oil pump through the oil pump screen cover and tube in the sump of the oil pan.
Oil is pumped through the oil filter on the left front side of the cylinder block.
Oil enters the main galley where it is distributed to the crankshaft main journals and to the cylinder
head.

Engine 2081
From the main journals, the oil is routed through cross-drilled passages in the crankshaft to lubricate
the connecting rod bearings. Controlled leakage through the crankshaft main bearings and connecting
rod bearings is slung radially outward to cool and lubricate the cylinder walls, as well as the entire
connecting rod, piston and piston ring assembly.

Engine 2082
Workshop Manual
Engine
Refer to Section 303-00 for basic mechanical concerns or refer to the Powertrain Control/Emissions Diagnosis
(PC/ED) manual for driveability concerns.
Engine 2083
Hybrid
Manual
NOTE: 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.
4.
NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example,
NOTE: The nominal clearance is:
intake: 0.25 mm (0.0095 in).
exhaust: 0.30 mm (0.0115 in).
The acceptable clearances after being fully installed are:
intake: 0.22-0.28 mm (0.008-0.011 in).
exhaust: 0.27-0.33 mm (0.010-0.013 in).
5.
Select tappets using this formula: tappet thickness = measured clearance + the existing tappet
thickness - nominal clearance.
Select the closest tappet size to the ideal tappet thickness available and mark the installation location.
If any tappets do not measure within specifications, install new tappets in these locations. For
additional information, refer to Valve Train Components - Exploded View and Valve Tappets in this
section.
6.
Hybrid
Manual
Balance Shaft Backlash
Special Tool(s)
100-002 (TOOL-4201-C)
303-507
Dead Center (TDC).
1.
NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.
3.
Remove the adjustment shims from the seat faces of the balancer unit. 4.
NOTICE: Visually inspect the balancer unit gear for damage and verify that the shaft turns
smoothly. If there is any damage or malfunction, replace the balancer unit.
Install the master adjustment shims (No. 50) on the seat faces of the balancer unit.
5.
With the balancer unit shaft marks at the TDC position, slowly install the balancer unit to the cylinder
6.

7.
Rotate the crankshaft to confirm that there are no meshing problems between the balancer
unit gear and the crankshaft gear.

8.
9.


10.
NOTE: If maximum backlash exceeds 0.101 mm (0.003 in), install a new balancer unit.
Using the backlash measurement, select the proper shims from the Adjustment Shim Selection Table.
Remove the balancer unit from the cylinder block.
Install the selected adjustment shims on the seat faces of the balancer unit.
11.
crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC .
12.
13.

14.
NOTE: Remeasure the backlash and verify that it is within specified range at all of the following 6

15.

If the backlash exceeds the specified range of 0.005 to 0.101 mm (0.00019 to 0.0039 in),
install a new balancer unit and repeat the procedure.

Hybrid
Manual
Intake Manifold
Item
Part
Number Description
1 14A464 Engine Oil Pressure (EOP)
switch electrical connector
(part of 12A581)
2 14A464 Manifold Absolute
Pressure (MAP) sensor
electrical connector (part of
12A581)
3 - Wiring harness retainer (3
required) (part of 12A581)
4 - Vacuum tube
5 - Evaporative Emission
(EVAP) canister purge
valve electrical connector
(part of 12A581)
6 6C324 EVAP tube-to-
EVAP canister
purge valve quick
connect coupling
7 - Auxiliary coolant pump
8 - Auxiliary coolant pump
wiring retainers (2
required)
9 - Lower radiator hose
retainer
10 - Engine wiring harness
retainer (part of 12A581)
11 - Vehicle high voltage
electrical system wire
retainer
electrical connector (male
side, part of 12A581)
13 14A464 KS electrical connector
(female side, part of
12A581)
1 W500311 Intake manifold bolt (7 required)
2 9424 Intake manifol/tr>
3 9441 Intake manifold gasket (4 required)
4 9E470 EGR tube
5 W500326 A/C compressor bolt (3 required)
6 19703 A/C compressor
7 6758 PCV hose connector
.
1.
NOTICE: Before removing the high voltage cables, the vehicle electrical system must be
completely shut down for at least 5 minutes to allow for the high voltage capacitors to discharge.
Depower the vehicle high voltage electrical system. For additional information, refer to Section
414-03 .
2.
Remove the fuel rail. For additional information, refer to Section 303-04D . 3.
Remove the Throttle Body (TB). For additional information, refer to Section 303-04D . 4.
Remove the accessory drive belt tensioner. For additional information, refer to Section 303-05D . 5.
Disconnect the EVAP tube-to- EVAP canister purge valve quick connect coupling and the vacuum
tube from the intake manifold.
9.
Detach the 3 wiring retainers from the intake manifold near the throttle body mounting area. 10.
Disconnect the auxiliary coolant pump electrical connector and detach the 2 wiring retainers. 11.
Detach the lower radiator hose retainer from the intake manifold. 12.
Detach the engine wiring harness retainer and the vehicle high voltage electrical system wire retainer
from the intake manifold.
13.
Disconnect the Knock Sensor (KS) electrical connector and detach the retainer from the intake
manifold.
14.
Remove the cooling fan motor and shroud. For additional information, refer to Section 303-03B . 15.
Remove the 3 A/C compressor bolts and position the compressor aside.
16.
NOTE: The cylinder head side of the intake manifold is showing the location of the 7 bolts.
Remove the 7 bolts and position the intake manifold aside to access the PCV hose connector.
17.
Squeeze the 2 PCV hose connector tabs and disconnect the PCV hose from the intake manifold. 18.
Remove the intake manifold and gaskets. 19.
damage.
Inspect and install new intake manifold gaskets if necessary.
20.
Hybrid
Manual
Valve Cover
Material
Item Specification
ZC-31-A
-
TA-30
WSE-M4G323-A4
Item
Part
Number Description
1 6853 Crankcase vent hose
2 6A957 Engine cover stud (4 required)
3 14A163
(part of 12A581)
5 14A464 Cylinder Head Temperature (CHT) sensor electrical
connector (part of 12A581)
6 14A464 Variable Camshaft Timing (VCT) solenoid electrical
connector (part of 12A581)
Valve Cover 2096
8 18472 Heater hose tube assembly
9 - Block heater wiring retainers (if equipped) (2 required)
10 - High voltage wiring harness retainer (part of 14300)
3 6582 Valve cover
4 6584 Valve cover gasket
Removal
passages or the oil can cause engine failure.
100-02 .
1.
Remove the ignition coil-on-plugs. For additional information, refer to Section 303-07A . 2.
Disconnect the crankcase vent hose from the valve cover. 3.
Detach the 2 block heater wiring harness retainers (if equipped) and the 2 high voltage wiring harness
retainers from the valve cover studs.
4.
Remove the 4 engine cover studs. 5.
Position the heater tube assembly off the valve cover stud bolts. 6.
Detach the 3 wire harness retainers from the valve cover and stud bolts. 7.
Disconnect the Variable Camshaft Timing (VCT) solenoid electrical connector. 10.
Remove the 14 valve cover retainers, the valve cover and gasket. 12.
Installation
paths.
Clean and inspect the sealing surfaces.
1.
metal surface prep.
2.
NOTE: Clean and inspect the gasket. Install a new gasket, if necessary.
Install the valve cover, gasket and retainers.
3.
Connect the VCT solenoid electrical connector. 5.
Connect the CMP sensor electrical connector. 7.
Attach the 3 wire harness retainers to the valve cover stud bolts. 8.
Position the heater tube assembly on the valve cover stud bolts. 9.
Install the 4 engine cover studs. 10.
Attach the 2 block heater wiring harness retainers (if equipped) and the 2 high voltage wiring harness
retainers to the valve cover studs.
11.
Connect the crankcase vent hose to the valve cover. 12.
Install the ignition coil-on-plugs. For additional information, refer to Section 303-07A . 13.
Hybrid
Manual
2 - Crankshaft pulley washer (part of 6K340)
>
Hybrid
Manual
Crankshaft Pulley
Special Tool(s)
303-465 (T94P-6256-CH)
303-1416
303-507
General Equipment
6 mm x 18 mm bolt
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
Removal
crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools
or severe engine damage can occur.
100-02 .
1.
Remove the RF wheel and tire. For additional information, refer to Section 204-04 . 2.
Remove the accessory drive belt. For additional information, refer to Section 303-05D . 3.
Dead Center (TDC).
5.
6.
8.
held in place with the Crankshaft Damper Holding Tool, and the bolt should be removed using
The diamond washer must be replaced. Remove and discard the diamond washer. If the
Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft
pulley. Use an air impact wrench to remove the crankshaft pulley bolt.
9.
Installation
Install a new diamond washer. 1.
2.
NOTICE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover can occur.
Install a 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
3.
NOTE: The crankshaft must remain in the TDC position during installation of the pulley bolt or
damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the
Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only.
Install a new crankshaft pulley bolt. Use the Crankshaft Damper Holding Tool and a suitable 1/2-in
drive hand tool to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages:
4.
8.
10.
If it is not possible to install the bolt, the engine valve timing must be corrected by repeating
this procedure.

11.
corrected by repeating this procedure.

12.
16.
Install the accessory drive belt. For additional information, refer to Section 303-05D . 17.
Install the RF wheel and tire. For additional information, refer to Section 204-04 . 18.
Hybrid
Manual
Special Tool(s)
303-096 (T74P-6150-A)
Remover, Oil Seal
303-409 (T92C-6700-CH)
Material
Item Specification
craft SAE 5W-20 Super Premium
Motor Oil (Canada)
XO-5W20-QSP (US);
WSS-M2C945-A
Removal
Remove the crankshaft pulley. For additional information, refer to Crankshaft Pulley and Crankshaft
Front Seal - Exploded View and Crankshaft Pulley in this section.
1.
NOTICE: Use care not to damage the engine nt cover or the crankshaft when removing the seal.
Using the Oil Seal Remover, remove the crankshaft front seal.
2.
Installation
1.
Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley and Crankshaft
Front Seal - Exploded View and Crankshaft Pulley in this section.
2.
&nbs
Hybrid
Manual
Item
Part
Number Description
1 6379 Flywheel bolt (6 required)
2 6477 Flywheel
7 6675 Oil pan
> W500212 Crankshaft rear oil seal with retainer plate bolt (6
required)
9 6K318 Crankshaft rear oil seal with retainer plate
Hybrid
Manual
Flywheel
Removal
100-02 .
1.
Remove the engine. For additional information, refer to Engine in this section. 2.
Installation
Install the flywheel and tighten the bolts in the sequence shown in the following 3 stages:
1.
Install the engine. For additional information, refer to Engine in this section. 2.
Flywheel 2112
Flywheel 2113
Hybrid
Manual
Special Tool(s)
303-328 (T88P-6701-B1)
Material
Item Specification
ZC-31-A
-
(Canada)
XO-5W20-QSP (US);
WSS-M2C945-A
TA-30
WSE-M4G323-A4
Removal
100-02 .
1.
Remove the flywheel. For additional information, refer to Flywheel in this section. 2.
3.
NOTICE: If the oil pan is not removed, damage to the rear oil seal retainer joint can occur.
4.
Remove the 6 bolts and the crankshaft rear oil seal with retainer plate. 5.
Installation
Using the Crankshaft Rear Main Oil Seal Installer, position the crankshaft rear oil seal with retainer
plate onto the crankshaft.
1.
src="SCS~us~en~file=A0087575.jpg~gen~ref.jpg" height="211" width="325" border="1">
Install the crankshaft rear oil seal with retainer plate and bolts. 2.
paths. Use a plastic scraping tool and metal surface cleaner to remove traces of sealant.
Clean and inspect all the oil pan and cylinder block mating surfaces.
3.
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.
4.
Install the oil pan. Install the 2 oil pan bolts finger-tight. 5.
Install the 4 bolts.
6.
Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown to 25 Nm (18
lb-ft).
7.
Install the flywheel. For additional information, refer to Flywheel in this section. 8.
Hybrid
Manual
Engine Front Cover
Special Tool(s)
Aligner, Crankshaft Sensor
303-1417
303-096 (T74P-6150-A)
Remover, Oil Seal
303-409 (T92C-6700-CH)
General Equipment
6 mm x 18 mm bolt
Material
Item Specification
(Canada)
XO-5W20-QSP (US);
WSS-M2C945-A
TA-30
WSE-M4G323-A4
1 W707399 A/C tube bracket bolt
2 - Vehicle high voltage electrical connector (part
of 14300)
3 14B227 DC/DC converter
4 - Vehicle high voltage electrical wiring retainer
(part of 14300)
Item
Part
Number Description
4 14A464 Crankshaft Position (CKP) sensor electrical connector
(part of 12B637)
5 W701219 CKP sensor bolt (2 required)
6 6C315 CKP sensor
8 W705310 Engine front cover stud bolt (2 required)
9 W500300 Engine from cover bolt
Removal
100-02 .
1.
414-03 .
2.
Remove the accessory drive belt and tensioner. For additional information, refer to Section 303-05D . 3.
seal.
Using the Oil Seal Remover, remove the crankshaft front seal.
6.
Remove the A/C tube bracket bolt from the strut tower. 10.
Disconnect the vehicle high voltage electrical connector from the DC/DC converter and detach the
wiring retainer.
11.
Remove the bolts and the engine front cover. 12.
Installation
NOTICE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive
1.
2.
specifications:
3.
Connect the vehicle high voltage electrical connector to the DC/DC converter and attach the wiring
retainer.
4.
Install the A/C tube bracket bolt to the strut tower.
5.
Using the Camshaft Front Oil Seal Installer, install the crankshaft front seal.
6.
Install the coolant pump pulley and the 3 bolts.
7.
Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into
the front cover.
10.
Install the CKP sensor and the 2 bolts. 11.
12.
Install the accessory drive belt and tensioner. For additional information, refer to Section 303-05D . 15.
Repower the vehicle high voltage electrical system. For additional information, refer to Section
414-03 .
16.
Hybrid
Manual
Removal
including any material created while cleaning gasket surf, that enters the oil passages, coolant passages
100-02 .
1.
section.
2.
2.
3.
Remove the timing chain tensioner arm. 5.
Remove the 2 bolts and the timing chain guide. 7.
camshaft sprocket.
8.
Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the camshaft phaser
and sprocket.
9.
Installation
2.
5.
8.
9.
10.
Hybrid
Manual
1 W710451 Plug
2 6731 Variable Camshaft Timing (VCT) system oil filter
303-14D .
1.
Remove the plug and the VCT system oil filter from the intake camshaft thrust cap.
2.
Hybrid
Manual
Camshafts
Special Tool(s)
303-465 (T94P-6256-CH)
303-507
General Equipment
6 mm x 18 mm bolt
M6 x 30 mm bolt
Material
Item Specification
(Canada)
XO-5W20-QSP (US);
WSS-M2C945-A
TA-30
WSE-M4G323-A4
Removal
NOTICE: Do not rotate the camshafts unless instructed to in this procedure. Rotating the camshafts or
crankshaft with timing components loosened or removed can cause serious damage to the valves and
pistons.
100-02 .
1.
Remove the degas bottle. For additional information, refer to Section 303-03B . 2.
Remove the Variable Camshaft Timing (VCT) oil control solenoid. For additional informationrefer to
Section 303-14D .
3.
Camshafts 2131
Dead Center (TDC).
6.
NOTICE: The Camshaft Alignment Plate 303-465 is for camshaft alignment only. Using this tool
to prevent engine rotation can result in engine damage.
7.
Camshafts 2132
10.
Remove the lower front cover timing hole plug from the engine front cover. 11.
Remove the upper front cover timing hole plug from the engine front cover. 12.
Camshafts 2133
collapse and create slack in the timing chain. Installing an M6 x 30 mm (1.18 in) bolt into the upper
front cover timing hole will hold the tensioner arm in a retracted position and allow enough slack in
the timing chain for removal of the exhaust camshaft gear.
Using a small pick tool, unlock the chain tensioner ratchet through the lower front cover timing hole.
Using the flats of the camshaft, have an assistant rotate the exhaust camshaft clockwise to

Insert an M6 x 30 mm (1.18 in) bolt into the upper front cover timing hole to hold the
tensioner arm in the retracted position.

14.
Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and exhaust camshaft
drive gear.
16.
Remove the timing chain from the camshaft phaser and sprocket. 17.
Camshafts 2134
camshafts.
Loosen the camshaft bearing cap bolts, in sequence, one turn at a time until all tension is
released from the camshaft bearing caps.

19.
If removal of the camshaft phaser and sprocket is necessary, mark the sprocket and camshaft for
reference during installation.
If necessary, place the camshaft in a soft-jawed vise. Remove the bolt and the camshaft

20.
Installation
parts.
1.
Camshafts 2135
If necessary, position the camshaft in a soft-jawed vise and install the camshaft phaser and sprocket
and the bolt.

Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing
Stage 1: Tighten the camshaft bearing cap bolts one turn at a time, until finger-tight.
2.
Install the timing chain on the camshaft phaser and sprocket. 4.
Camshafts 2136
camshaft.
exhaust camshaft.
5.
6.
Using the flats on the camshaft to prevent camshaft rotation, tighten the bolt.
7.
Camshafts 2137
Install the upper front cover timing hole plug.
11.
Apply silicone gasket and sealant to the threads of the lower front cover timing hole plug.
Install the plug and tighten to 12 Nm (106 lb-in).
12.
13.
Install the VCT oil control solenoid. For additional information, refer to Section 303-14D . 15.
Camshafts 2138
Install the degas bottle. For additional information, refer to Section 303-03B . 17.
Camshafts 2139
Hybrid
Manual
Special Tool(s)
303-465 (T94P-6256-CH)
303-507
General Equipment
6 mm (0.23 in) x 18 mm (0.7 in)
M6 x 30(1.18 in)
Material
Item Specification
(Canada)
XO-5W20-QSP (US);
WSS-M2C945-A
TA-30
WSE-M4G323-A4
Removal
100-02 .
1.
Reme the Variable Camshaft Timing (VCT) solenoid. For additional information, refer to Section
303-14D .
3.
Dead Center (TDC).
5.
6.
8.
9.
collapse and create slack in the timing chain. Installing the M6 x 30 mm (1.18 in) bolt into the upper
front cover timing hole will lock the tensioner arm in a retracted position and allow enough slack in
the timing chain for removal of the exhaust camshaft gear.
timing hole.
Have an assistant rotate (using the flats of the camshaft) the exhaust camshaft clockwise to

Insert the M6 x 30 mm (1.18 in) bolt into the upper front cover timing hole to hold the
tensioner arm in the retracted position.

13.
14.
Remove the timing chain from the camshaft phaser and sprocket. 16.
NOTICE: Failure to follow the camshaft loosening procedure can result in damage to the intake
camshaft.
Remove the intake camshaft from the engine.
Loosen the intake camshaft bearing cap bolts, in the sequence shown, one turn at a time until
all tension is released from the camshaft bearing caps.

Remove the intake camshaft.
18.
Mark the camshaft phaser and sprocket and the camshaft for reference during installation. 19.
Place the camshaft in a soft-jawed vise. Remove the bolt and the camshaft phaser and sprocket. 20.
Installation
parts.
Position the camshaft in a soft-jawed vise. Install the camshaft phaser and sprocket and the bolt.
1.

NOTICE: Install the intake camshaft with the alignment slots in the camshafts lined up so the
NOTE: Lubricate the intake camshaft journals and bearing caps with clean engine oil.
Install the intake camshafts and bearing caps. Tighten the intake camshaft bearing caps in the
sequence shown in 3 stages:
Stage 1: Tighten the intake camshaft bearing cap bolts until finger-tight.
2.
Install the timing chain on the camshaft phaser and sprocket. 4.
5.
camshaft.
exhaust camshaft.
Remove the M6 x 30 mm (1.18 in) bolt from the upper front cover timing hole to release the tensioner
arm.
6.
7.
11.
Apply silicone gasket and sealant to the threads of the lower timing hole plug.

12.
13.
Install the VCT solenoid. For additional information, refer to Section 303-14D . 15.
Hybrid
Manual
6513 Valve spring (16 required)
5 6517 Valve seal (16 required)
Hybrid
Manual
Valve Springs
Special Tool(s)
303-300 (T87C-6565-A)
Compressor, Valve Sp
303-350 (T89P-6565-A)
303-472 (T94P-6565-AH)
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
XG-4 and/or XL-5
ESB-M1C93-B
Removal
100-02 .
1.
3.
Valve Springs 2150
NOTICE: Use compressed air at 7 to 10 bars (100-150 psi). Do not disconnect the compressed
air from the cylinder until the valve spring, valve spring retainer and valve collet is installed.
Any loss of air pressure will allow the valve to fall into the cylinder.
Connect the compressed air supply to the No. 1 cylinder.
5.

6.
Installation
screwdriver.

1.
Valve Springs 2151
Valve Springs 2152
Hybrid
Manual
Valve Seals
Special Tool(s)
303-300 (T87C-6565-A)
Compressor, Valve Springbr>303-350
(T89P-6565-A)
303-472 (T94P-6565-AH)
303-470 (T94P-6510-CH)
303-468 (T94P-6510-AH)
Slide Hammer
307-005 (T59L-100-B)
Material
Item Specification
XOW20-QSP (US);
WSS-M2C945-A
XG-4 and/or XL-5
ESB-M1C93-B
Removal
100-02 .
1.
Valve Seals 2153
3.
NOTICE: Use compressed air at 7 to 10 bars (100-150 psi). Do not disconnect the compressed
air from the cylinder until the valve spring, valve spring retainer and valve collet is installed.
Any loss of air pressure will allow the valve to fall into the cylinder.
Connect the compressed air supply to the No. 1 cylinder.
5.

6.
Using the Slide Hammer and the Valve Stem Oil Seal Remover, remove and discard the valve seal. 7.
Installation
Install the valve stem seal installation sleeve. 1.
Using the Valve Stem Oil Seal Installer, install the valve seal. 2.
Valve Seals 2154
screwdriver.

3.
Valve Seals 2155
Hybrid
Manual
Valve Tappets
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
(including any material created while cleaning gasket surfaces) that enters the oil passages, coolant es
100-02 .
1.
3.
Coat the valve tappets with clean engine oil prior to installation.
4.
Valve Tappets 2156
Valve Tappets 2157
Hybrid
Manual
Cylinder Head
Special Tool(s)
303-465 (T94P-6256-CH)
Material
Item Specification
ZC-31-A
-
(Canada)
XO-5W20-QSP (US);
WSS-M2C945-A
Silicone Gasket and Sealant WSE-M4G323-A4
Remover
ZC-30
-
Cylinder Head 2158
1 14A464 EGR valve electrical connector (part of 12A581)
3 8260 Upper radiator hose
4 W527212 Coolant bypass hose clamp
5 8075 Coolant bypass hose
6 W527362 Heater hose clamp
7 18472 Heater hose
8 W527302 EGR coolant hose clamp
9 18472 EGR coolant hose
10 W527362 Coolant vent hose clamp
11 18472 Coolant vent hose
Removal
instructin this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to
100-02 .
1.
Drain the engine cooling system. For additional information, refer to Section 303-03B . 3.
Remove the intake manifold. For additional information, refer to Intake Manifold in this section. 4.
Remove the Variable Camshaft Timing (VCT) oil control solenoid. For additional information, refer
to Section 303-14D .
5.
in this section.
6.
Cylinder Head 2159
camshafts.
Loosen the camshaft bearing cap bolts, in sequence, one turn at a time until all tension is
released from the camshaft bearing caps.

9.
Remove the valve tappets.
10.
Inspect the valve tappets. For additional information, refer to Section 303-00 . 11.
Remove the catalytic converter. For additional information, refer to Section 309-00 . 12.
Disconnect the upper radiator hose, coolant bypass hose, EGR coolant hose, heater hose and coolant
vent hose from the engine coolant outlet and the EGR valve.
14.
Remove the bolts and the cylinder head.
Discard the bolts and the cylinder head gasket.
15.
Installation
1.
Cylinder Head 2160
minutes.
2.
3.
4.
2.
Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign
material is removed.
3.
Install a new cylinder head gasket. 5.
NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts
must be installed.
Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in the following 5
stages:
6.
Connect the upper radiator hose, coolant bypass hose, EGR coolant hose, heater hose and coolant vent
hose to the engine coolant outlet and the EGR valve.
7.
Cylinder Head 2161
Install the catalytic converter. For additional information, refer to Section 309-00 . 9.
NOTE: Lubricate the valve tappets with clean engine oil.
Install the valve tappets in their original positions.
10.
NOTICE: Install the camshafts with the alignment notches in the camshafts lined up so the
camshaft alignment plate can be installed. Make sure the lobes on the No. 1 cylinder are in the
same position as noted in the removal procedure. Failure to follow this procedure can cause
severe damage to the valves and pistons.
Stage 1: Tighten the camshaft bearing cap bolts, one turn at a time, until finger-tight.
Stage 2: Tighten the bolts to 7 Nm (62 lb-in).
Stage 3: Tighten the bolts to 16 Nm (142 lb-in).
11.
this section.
13.
Install the VCT oil control solenoid. For additional information, refer to Section 303-14D . 14.
Install the intake manifold. For additional information, refer to Intake Manifold in this section. 15.
Fill and bleed the engine cooling system. For additional information, refer to Section 303-03B . 16.
Cylinder Head 2162
Cylinder Head 2163
Hybrid
Manual
Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch
Item
Part
Number Description
(part of 12C508)
2 9278 EOP switch
3 6731 Oil filter
Oil Pan, Oil Pump Screen and Pickup Tube
1 6730 Drain plug
3 W500122 Oil pan-to-bellhousing bolt (2 required)
4 W500122 Bellhousing-to-oil pan bolt (2 required)
6 6675 Oil pan
7 W706282 Oil pump screen and pickup tube bolt (2 required)
9 6625 Oil pump screen and pickup tube gasket
Oil Pump
1 W703651
Oil Pan, Oil Pump Screen and Pickup Tube 2165
Oil pump drive chain tensioner shoulder bolt
(2 required)
2 6C271 Oil pump drive chain tensioner
3 6A895 Oil pump drive chain
4 W704397 Oil pump sprocket bolt
5 6652 Oil pump sprocket
7 6600 Oil pump
Oil Pump 2166
Hybrid
Manual
Oil Filter Adapter
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
100-02 .
1.
Remove oil filter.
To install, lubricate the oil filter O-ring with clean eoil and then tighten the oil filter

3.
NOTE: Discard the gasket.
4.
Hybrid
Manual
Material
Item Specification
TA-24
WSK-M2G350-A2
100-02 .
1.
To inl, tighten to 15 Nm (133 lb-in).
3.
Apply thread sealant with PTFE to the EOP switch threads.
4.
Hybrid
Manual
Oil Pan
Material
Item Specification
ZC-31-A
-
(Canada)
XO-5W20-QSP (US);
WSS-M2C945-A
TA-30
WSE-M4G323-A4
Removal
Witicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 . 1.
2.
section.
3.
Installation
1.
leakage.
2.
Oil Pan 2170
Position the oil pan and install the 2 rear oil pan bolts finger-tight. 3.
Using a suitable straightedge, align the front surface of the oil pan flush with the front surface of the
engine block.
4.
5.
6.
Oil Pan 2171
Oil Pan 2172
Hybrid
Manual
100-02 .
1.
2.
3.
Hybrid
Manual
Oil Pump
Material
Item Specification
ZC-31-A
-
(Canada)
XO-5W20-QSP (US);
WSS-M2C945-A
TA-30
WSE-M4G323-A4
Removal
With the engine in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .
1.
section.
2.
3.
6.
Remove the 2 shoulder bolts and the tensioner. 2.
7.
Remove the chain from the oil pump sprocket. 8.
Oil Pump 2174
Remove the bolt and oil pump sprocket. 9.
Installation
1.
Install the oil pump sprocket and bolt.
2.
Install the chain onto the oil pump sprocket. 3.
4.
Install the oil pump drive chain tensioner and bolt. Hook the tensioner spring around the shoulder
bolt.
5.
Install the oil pump screen and pickup tube and the 2 bolts.
6.
paths. Use a plastic scraping tool to remove traces to sealant.
7.
Oil Pump 2175
Clean all mating surfaces with metal surface prep.
leakage.
Apply a 2.5 mm (0.09 in) bead of sealant gasket and sealant to the oil pan.
8.
Position the oil pan onto the engine and install the 2 rear oil pan bolts finger-tight. 9.
engine block.
10.
11.
Oil Pump 2176
12.
Oil Pump 2177
Hybrid
Manual
Engine Mount
Special Tool(s)
Support Bar, Engine
303-F072
1 - Block heater wiring retainer (if equipped) (2 required)
2 - High voltage wiring harness retainer (part of 14300)
3 - Ground strap bolt
4 - Ground strap
5 N807144 Engine mount bracket nut (3 required)
9 - Engine mount nut
100-02 .
1.
Remove the engine coolant degas bottle. For additional information, refer to Section 303-03B . 2.
Install the Engine Support Bar to the front and rear engine lifting eyes. 3.
Engine Mount 2178
Remove the engine mount bracket bolt.
4.
Use the Engine Support Bar to raise the engine 25 mm (0.98 in). 5.
Remove the bolt and the ground strap from the engine mount bracket.
6.
Remove the 3 nuts and the engine mount bracket.
7.
Remove the 2 bolts and nut and the engine mount.
8.
Engine Mount 2179
Hybrid
Manual
Engine
Special Tool(s)
Powertrain Lift
211-105 (T85M-3395-A)
Spreader Bar
303-D089 (D93P-6001-A3) (part of
303-DS086) or equivalent
100-02 .
1.
414-03 .
4.
Recover the A/C system. For additional information, refer to Section 412-00B . 5.
Place the seering wheel in the straight-ahead position and the ignition key in the OFF position.
6.
Engine 2180
Section 501-20B .
8.
Remove the 7 screws and the underbody cover. 9.
Drain the cooling system. For additional information, refer to Section 303-03B . 10.
Drain the Motor Electronics Cooling System (MECS). For additional information, refer to Section
307-02B .
11.
Remove the engine Air Cleaner (ACL) pipe. For additional information, refer to Section 303-12D . 12.
Remove the front wheels and tires. For additional information, refer to Section 204-04 . 13.
Engine 2181
Remove the bolt and the Electronic Power Assist Steering (EPAS) wiring ground wire from in the RH
front wheel well.
17.
205-04 .
20.
the subframe.
21.
Engine 2182
23.
24.
25.
Disconnect the 2 EPAS electrical connectors near the front of the subframe.
Detach the connector retainer from the subframe.
26.
Engine 2183
Detach the auxiliary coolant hose retainer from the subframe. 27.
Detach the 3 wiring harness retainers (2 shown) from the LH front of the subframe. 28.
Disconnect the MECS electrical connector and detach the pump from the bracket. 29.
31.
Remove the subframe nuts and the subframe brackets. 32.
Engine 2184
33.
Disconnect the vacuum pump assembly electrical connector and detach the wiring retainer. 35.
Disconnect the transaxle coolant temperature sensor and the Transmission Range (TR) sensor
Detach the wiring harness retainer.
36.
Remove the transaxle ground wire and nut. 37.
Disconnect the transaxle shift cable from the transaxle. 38.
Engine 2185
Remove the 2 nuts and the transaxle shift cable bracket. 39.
Detach the transaxle shift cable routing retainer from the transaxle. 40.
41.
NOTE: Lower radiator hose shown, upper similar.
Remove the retaining clips and disconnect the upper and the lower radiator hose.
43.
Engine 2186
If equipped, detach the 3 block heater wiring retainers. 44.
Discard the gasket.
45.
Remove the A/C tube bracket bolt from the strut tower. 46.
Remove the nut and disconnect the A/C tube from the A/C compressor. 48.
Engine 2187
Remove the nut and disconnect the A/C tube from the A/C condenser.
Discard the gasket.
49.
Disconnect the 2 vehicle high voltage electrical system electrical connectors.
Detach the wiring harness retainer.
50.
Detach the 2 block heaters (if equipped) and the high voltage electrical system wiring retainers from
the valve cover stud bolts.
51.
Disconnect the 2 heater hoses. 52.
Detach the engine wiring harness retainer from the bracket. 53.
Engine 2188
Disconnect the engine wiring harness connector and detach it from the bracket. 54.
Disconnect the fuel supply tube. For additional information, refer to Section 310-00 . 55.
Disconnect the upper Evaporative Emission (EVAP) tube quick connect coupling from the purge
valve. For additional information, refer to Section 310-00 .
56.
Remove the MECS coolant expansion tank nut and bolt. 57.
Disconnect the hose from the transaxle and remove the MECS coolant expansion tank. 58.
Engine 2189
Remove the bolt and detach the wiring retainer.
Disconnect the transaxle harness electrical connector.
59.
Remove the 2 bolts and position the master cylinder reservoir aside. 60.
Disconnect the 2 transaxle electrical connectors. 61.
Disconnect the 2 engine wiring harness connectors and detach the wiring retainer. 62.
Disconnect the brake booster vacuum hose. 63.
Engine 2190
NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
Remove the 2 transaxle-to-engine bolts.
64.
NOTE: The transaxle-to-engine bolts differ in length, mark the bolts for correct installation.
Remove the 2 transaxle-to-engine bolts.
65.
NOTE: Due to the weight of the transaxle, special care should be taken to mount the powertrain
securely to the Powertrain Lift.
Using the Powertrain Lift and Adjustable Grip Arm, secure the engine to the Powertrain Lift.
66.
Remove the engine mount bracket bolt. 67.
Remove the nuts and the engine mount bracket. 68.
Engine 2191
Remove the 3 nuts from the upper transaxle insulator. 69.
Remove the 3 bolts and position aside the auxiliary coolant pump and bracket. 71.
Remove the 2 engine cover studs from the valve cover stud bolts.. 72.
Disconnect the 2 heater hoses from the coolant outlet. 73.
Using the Floor Crane and the Spreader Bar, remove the engine and transaxle from the Powertrain
Lift.
74.
NOTE: The transaxle-to-engine bolts differ in length, mark the bolts for correct installation.
Remove the 2 transaxle bolts.
75.
Engine 2192
Remove the transaxle bolt. 76.
Remove the 3 transaxle bolts and separate the engine and transaxle. 77.
NOTE: Due to packaging requirements the correct bolt must be used at the damper locations.
NOTE: The damper contains a clutch which is designed to slip briefly during vehicle operation. It is
essential that no grease, oil or cleaning solvents be allowed to contaminate the slip clutch. Do not use
grease on transmission input shaft. Should the damper become contaminated, it must be replaced.
Remove the bolts and the transaxle damper.
78.
Engine 2193
Engine 2194
Workshop Manual
Engine
Special Tool(s)
303-465 (T94P-6256-CH)
Engine Stand
303-1416
303-462 (T94P-6136-AH)
Remover, Oil Seal
303-409 (T92C-6700-CH)
Spreader Bar
303-507
or severe engine damage may occur.
NOTE: Due to the precision fit and timing of the balancer shaft assembly, it cannot be removed from the
engine block.
NOTE: For additional information, refer to the exploded views under engine Assembly in this section.
Engine 2195
Mount the engine on a suitable engine stand. 2.
If equipped, disconnect the engine block heater. 3.
Disconnect the Heated Oxygen Sensor (HO2S) electrical connector.
Detach the connector from the engine wiring harness connector bracket.
4.
Remove the bolt and the engine wiring harness connector bracket. 7.
Engine 2196
Detach the 2 engine wiring harness pin-type retainers. 8.
Remove the 6 bolts and the catalytic converter manifold heat shield. 9.
Remove the 2 catalytic converter manifold bracket-to-engine block bolts. 10.
Remove the 7 nuts and the catalytic converter manifold.
Discard the nuts and the catalytic converter manifold gasket.
11.
Engine 2197
Detach the vehicle high voltage electrical system electrical connector retainer from the accessory
drive belt tensioner.
14.
Engine 2198
Disconnect the Knock Sensor (KS) electrical connector and detach the electrical connector pin-type
retainer from the intake manifold.
20.
Engine 2199
Disconnect the Variable Camshaft Timing (VCT) oil control solenoid electrical connector and detach
the wiring harness retainer from the valve cover stud bolt.
23.
Detach the 3 wire harness pin-type retainers. 24.
Detach the 2 auxiliary coolant pump wiring retainers and the lower radiator hose retainer. 25.
Disconnect the auxiliary coolant pump hose and the upper radiator hose. 26.
Disconnect the EGR coolant hose and the auxiliary coolant pump hose.
Remove the upper radiator hose and the auxiliary coolant pump as an assembly.
27.
Engine 2200
Remove the 2 bolts and the A/C compressor bracket. 28.
Disconnect the vacuum hose from the intake manifold. 29.
Remove the 2 bolts, the nut and the vacuum pump assembly. 30.
Detach the 3 wire harness pin-type retainers from the intake manifold. 31.
NOTE: The cylinder head side of the intake manifold is showing the location of the 7 bolts.
Remove the 7 bolts and position the intake manifold aside to access the PCV hose connector.
32.
Engine 2201
Squeeze the 2 PCV hose connector tabs and disconnect the PCV hose from the intake manifold.
Remove the intake manifold.
33.
Remove the EGR tube. 34.
Disconnect the 4 fuel injector electrical connectors, radio capacitor electrical connector and the
Camshaft Position (CMP) sensor electrical connector.
35.
Disconnect the 4 coil-on-plug electrical connectors. 36.
Position the rubber boot aside and disconnect the Cylinder Head Temperature (CHT) sensor electrical
connector.
37.
Engine 2202
Disconnect the EGR valve electrical connector and detach the 2 wiring harness retainers from the
valve cover and stud bolt.
Remove the engine control wiring harness from the engine.
38.
Remove the fuel rail insulator. 39.
Remove the nut and the radio capacitor. 40.
Remove the 2 stud bolts and the fuel rail with the fuel injectors. 41.
Engine 2203
Remove the 3 bolts and the thermostat housing. 44.
Disconnect the bypass hose. 45.
Remove the 8 bolts and the crankcase vent oil separator. 47.
Engine 2204
Discard the gasket.
48.
If equipped, remove the block heater. 49.
Remove the crankshaft vent tube. 50.
Remove the 2 engine cover studs (one shown). 51.
Remove the 4 stud bolts and the coil-on-plugs from the valve cover. 52.
Engine 2205
Remove the CHT sensor. 54.
Remove the bolts and the valve cover. 55.
Dead Center (TDC).
56.
NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Plate 303-465 cannot be
installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
57.
Engine 2206
59.
The diamond washer must be replaced; remove and discard the diamond washer. If the
Using the Crankshaft Damper Holding Tool and an air impact wrench, remove the crankshaft pulley.
60.
Engine 2207
seal.
61.
Remove the bolts and the engine front cover. 63.
2.
64.
Engine 2208
Remove the RH timing chain guide. 66.
Remove the bolts and the LH timing chain guide. 68.
NOTICE: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage
to the tool or the camshaft can occur.
camshaft sprocket.
69.
Engine 2209
Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the intake camshaft
70.
Remove the oil pump chain tensioner.
Remove the tensioner and the shoulder bolts. 2.
71.
NOTE: Remove and discard the crankshaft sprocket diamond washer located behind the crankshaft
sprocket.
NOTE: The oil pump chain sprocket must be held in place.
Remove the oil pump chain and sprockets.
Remove the bolt. 1.
Remove the chain and sprockets. 2.
72.
Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference. 73.
Engine 2210
Remove the bolt and the Variable Camshaft Timing (VCT) solenoid. 74.
Remove the plug and the VCT system oil filter from the intake camshaft thrust cap. 75.
camshafts.
Loosen the camshaft bearing bolts in the sequence shown, one turn at a time. Repeat until all
the tension is released.

Remove the camshaft bearing caps.
76.
77.
Engine 2211
Remove and discard the cylinder head bolts.
Remove and discard the cylinder head gasket.
78.
Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head
distortion and the cylinder block distortion. For additional information, refer to Section 303-00 .
79.
Remove the cylinder head alignment dowels. 80.
Remove the bolts and the oil pan. 81.
Remove the bolts and the crankshaft rear oil seal with retainer. 82.
Remove the bolts, oil pump pickup tube and gasket. 83.
Remove the bolts and the oil pump. 84.
Engine 2212
Remove the bolts and the block-off plate. 85.
Make sure the Crankshaft TDC Timing Peg is still installed and the engine is still at Top Dead Center
(TDC).
Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the
Crankshaft TDC Timing Peg.

86.
Mark the balancer unit front shafts on the top for reference that the balancer unit is at TDC . 87.
disassembled.
88.
Engine 2213
instructions.
90.
NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in
numerical order for correct orientation for reassembly.
91.
Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine
block.

92.
Engine 2214
Remove the main bearing beam.
Discard the bolts.
93.
Remove the crankshaft from the engine block. 94.
reassembly.
Remove the main bearings from the main bearing beam.
95.
reassembly.
NOTE: The center bulkhead has the thrust bearing.
Remove the main bearings from the cylinder block.
96.
NOTE: If the oil squirters are being reused, mark them in order for correct location during
reassembly.
Remove the 4 oil squirters.
97.
Engine 2215
Inspect the cylinder block, main bearing beam, pistons and connecting rods. For additional
98.
Engine 2216
SUBASSEMBLIES
Cylinder Head
Special Tool(s)
303-300 (T87C-6565-A)
303-350 (T89P-6565-A)
303-472 (T94P-6565-AH)
303-470 (T94P-6510-CH)
303-468 (T94P-6510-AH)
Slide Hammer
307-005 (T59L-100-B)
Material
Item Specification
Motorcraft SE 5W-20 Premium
XO-5W20-QSP (US);
WSS-M2C945-A
XG-4 and/or XL-5
ESB-M1C93-B
Cylinder Head 2217
1 W500225 EGR valve bolt (2 required)
2 9D475 EGR valve
3 9D476 EGR valve gasket
4 W500015 Coolant outlet bolt (4 required)
6 8255 Coolant outlet gasket
11 6A517 Valve seal (16 required)
Disassembly
NOTE: If the components are to be reinstalled, mark the location of the components removed, they must be
installed in the same location.
Remove the 2 bolts and the EGR valve.
Discard the gasket.
1.
Remove the 4 bolts and the coolant outlet.
Discard the gasket.
2.
Remove the Cylinder Head Temperature (CHT) sensor. 3.
to the cylinder head or spark plugs.
Remove the spark plugs.
4.
Remove the valve tappets. 5.
NOTE: Use a small screwdriver and grease to remove the valve collets. 6.
Cylinder Head 2218
Using the Valve Spring Compressors, compress the valve springs and remove the valve collets, valve
spring retainers and the valve springs.
Inspect the components, if necessary. For additional information, refer to Section 303-00 . 7.
Remove the valves. 8.
Using the Slide Hammer and the Valve Stem Oil Seal Remover, remove and discard the valve seals. 9.
Inspect the valves. For additional information, refer to Section 303-00 . Install new parts, as
necessary.
10.
Assembly
NOTE: Coat the valve stems with clean engine oil.
Install the valves.
1.
NOTE: Use the protector provided with the replacement kit to prevent damage to the valve seals.
Lubricate the valve stems and guides with clean engine oil.
Using the Valve Stem Oil Seal Installer, install the valve seals.
2.
NOTE: Check the seating of the valve collets.
Using the Valve Spring Compressors, install the valve springs.
Insert the valve springs and the valve spring retainers.
Compress the valve springs and install the valve collets, using grease and a small screwdriver.
3.
Cylinder Head 2219
NOTE: Coat the valve tappets with clean engine oil.
4.
to the cylinder head or spark plugs.
Install the spark plugs.
5.
Install the CHT sensor.
6.
Using a new gasket, install the coolant outlet and bolts.
7.
Install the EGR valve, using a new gasket.
8.
Cylinder Head 2220
SUBASSEMBLIES
Piston
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
8 6135 Piston pin
10 6110 Piston
Disassembly
1.
3.
Piston 2221
Assembly
NOTE: The arrow on the top of the piston points towards the front of the engine.
Align the piston-to-connecting rod orientation marks, and position the connecting rod in the piston.
1.
NOTE: The piston compression upper and lower ring should be installed with the paint mark on the
outside diameter circumference of the ring to be positioned on the right side of the ring gap. The
lower compression ring needs to be installed with the undercut side downward.
NOTE: The upper and lower compression ring gaps are not controlled for installation.
Piston pin 1.
Upper oil control ring gap location 2.
Lower oil control ring gap location 3.
Center line of the piston pin bore and the expander gap 4.
6.
Piston 2222
Piston 2223
Workshop Manual
Engine
Special Tool(s)
303-1417
303-465 (T94P-6256-CH)
Compressor, Pistong
303-D032 (D81L-6002-C)
100-002 (TOOL-4201-C)
303-1416
303-096 (T74P-6150-A)
303-462 (T94P-6136-AH)
303-328 (T88P-6701-B1)
Spreader Bar
303-507
General Equipment
6 mm x 18 mm bolt
Material
Engine 2224
Item Specification
ZC-31-A
-
(Canada)
XO-5W20-QSP (US);
Engine Coolant
a
VC-10-A2 (US); CVC-10-A
(Canada)
WSS-M97B55-A
Engine Coolant
a
VC-3-B (US); CVC-3-B (Canada)
WSS-M97B44-D
Dielectric Compound
XG-3-A
ESE-M1C171-A
TA-30
WSE-M4G323-A4
Remover
ZC-30
-
a
2 6K318 Crankshaft rear oil seal and retainer
3 6K390 Flywheel
5 6675 Oil pan
7 8575 Thermostat assembly
11 2A451 Vacuum pump and bracket
15 6303 Crankshaft
16 6333 Crankshaft main bearing beam bearing (5 required)
17 6F098 Main bearing beam
18 6K360 Balance shaft assembly
Front Engine Block
1 6C301 Accessory drive belt
2 6A228 Accessory drive belt tensioner
3 19D629 Electric A/C compressor
4 8501 Coolant pump
10 6K254 Timing chain tensioner
11 6K255 Timing chain tensioner arm
12 6268 Timing chain
13 6K297 Timing chain guide
14 6C271 Oil pump chain tensioner
15 6A895 Oil pump chain
16 6652 Oil pump drive gear
18 6306 Crankshaft sprocket
20 6600 Oil pump
Cylinder Head
1 12A366 Coil-on-plug assembly
2 6M293 Valve cover
3 12K073 Camshaft Position (CMP) sensor
4 6766 Oil filler cap
5 6M293 Valve cover gasket
7 6M280 Variable Camshaft Timing (VCT) solenoid
Cylinder Head 2228
9 6A272 Camshaft (exhaust)
10 6A271 Camshaft (intake)
11 6C251 Camshaft sprocket
12 6C525 VCT actuator
24 6051 Head gasket
26 9448 Catalytic converter gasket
27 5E211 Catalytic converter
Intake Manifold
3 9D475 EGR valve
4 9F991 Electronic Throttle Body (TB)
9 9439 Intake manifold gasket (4 required)
10 8A582 Coolant hose
13 9H487 Fuel rail
14 - Fuel rail insulator
instrucd in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to
303-00 .
NOTE: If the oil squirters are being reused, they must be installed in the same location as marked
during disassembly.
Install the 4 oil squirters.
1.
Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the
smallest diameter for each journal.
2.
Position the main bearing beam in the engine block with the main bearing beam mounted flush with
3.
Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts.
4.
Measure each crankshaft block main bearing bore diameter.
Remove the bolts and the main bearing beam.
Discard the main bearing beam bolts.
5.
Using the chart, select the crankshaft main bearings. 6.
Using the original connecting rod cap bolts, install the connecting caps and bolts.
7.
Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each
connecting rod.
Remove the bolts and the connecting rod cap.
8.
Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.
Record the smallest measurement for each connecting rod journal.
9.
NOTE: The center bulkhead is the thrust bearing.
11.
Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main
bearings in the main bearing beam.
12.
Lubricate journals on the crankshaft with clean engine oil. 13.
Lubricate the 10 main bearing beam side fit surfaces (front 2 shown) with clean engine oil. 15.
Lubricate the crankshaft bearing journals on the main bearing beam with clean engine oil. Then
position the main bearing beam in the engine block with the main bearing beam mounted flush with
16.
NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads with clean engine oil.
NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the
front of the cylinder block before tightening the main bearing beam bolts.
Install and tighten the 10 new main bearing beam bolts.
17.
play.

18.
Acceptable crankshaft end play is 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play
exceeds the specified range, install new parts as necessary.

clean engine oil.
rod assemblies.
When installing the pistons and connecting rod assemblies, the oil ring gaps must be
positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander
gap.

The position of the upper and lower compression ring gaps are not controlled for installation.
19.
NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and
tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting
rods for cylinders 2 and 3 and tighten.
NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth
operation.
20.
Dead Center (TDC).
21.
disassembled.
NOTE: The original adjustment shims must be installed in their original position.
NOTE: Confirm by visual inspection that there is no damage to the balancer unit gear and verify that
the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit.
Install the adjustment shims in their original position on the seat faces of the balancer unit.
22.
23.

24.
Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear
and the crankshaft gear.
26.
27.
28.


Backlash specifications are 0.005 to 0.101 mm (0.00019 to 0.0039 in).
If the backlash exceeds the specified range, carry out the balance shaft backlash procedure.
For additional information, refer to the Balance Shaft Backlash procedure in this section.

Turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).
29.
must remain at the TDC position until the timing drive components and crankshaft pulley are
installed.
30.
Install the block-off plate and bolts.
31.
Install the oil pump assembly. Tighten the bolts in the sequence shown in the following 2 stages:
32.
Install a new oil pump pickup tube gasket and the pickup tube.
33.
Using the Crankshaft Rear Main Oil Seal Installer, install the crankshaft rear oil seal with retainer. 34.
Tighten the crankshaft rear oil seal with retainer bolts in the sequence shown.
35.
paths. Use a plastic scraping tool and metal surface cleaner to remove traces of sealant.
36.
leakage.
37.
Install the oil pan and install the 2 oil pan bolts finger-tight. 38.
Using a suitable straightedge, align the front surface of the oil pan flush with the front surface of the
engine block.
39.
Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown.
40.
Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block. 41.
NOTE: Observe all warnings and cautions and follow all application directions contained on the
minutes.
2.
3.
4.
42.
Install a new head gasket. 44.
NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts
must be installed.
Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in the following 5
stages:
45.
46.
on the No. 1 cylinder are in the same position as noted in the disassembly 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.
Stage 1: Tighten 1 turn at a time until tight.
47.
Install the Variable Camshaft Timing (VCT) system oil filter and plug in the intake camshaft thrust
cap.
48.
Install the VCT solenoid and the bolt.
49.
NOTE: Install a new crankshaft sprocket diamond washer on both sides of the crankshaft sprocket.
Install the crankshaft sprocket, new crankshaft sprocket diamond washers, oil pump chain and oil
pump sprocket.
The crankshaft sprocket flange must be facing away from the engine block.
50.
Install the oil pump chain, sprocket and bolt.
51.
Install the shoulder bolt.
52.
Install the oil pump chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt.
53.
54.
Install the LH timing chain guide and the bolts.
56.
Install the RH timing chain guide. 58.
59.
62.
63.
64.
NOTICE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive
65.
66.
specifications:
67.
Using the Camshaft Front Oil Seal Installer, install the crankshaft front seal.
68.
69.
NOTICE: Only hand-tighten the 6-mm bolt or damage to the front cover can occur.
Install a standard 6-mm x 18-mm bolt through the crankshaft pulley and thread it into the front cover.
70.
71.
Remove the 6-mm x 18-mm bolt. 72.
Turn the crankshaft clockwise one and three-fourth turns.
75.
77.
Using the 6-mm x 18-mm bolt, check the position of the crankshaft pulley.
If it is not possible to install the bolt, the engine valve timing must be corrected.
78.
corrected.

79.
Install the Crankshaft Position (CKP) sensor and the 2 bolts.
81.
82.
Remove the 6-mm x 18-mm bolt. 83.
85.
paths.
Clean the valve cover gasket surface with metal surface prep.
86.
metal surface cleaner.
Install the valve cover.
88.
89.
Install the Cylinder Head Temperature (CHT) sensor.
90.
NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.
Install the 4 coil-on-plugs and the 4 bolts. Install the crankshaft vent tube.
91.
Install the engine cover studs (one shown). 92.
Install the crankshaft vent tube. 93.
94.
NOTE: Clean the gasket mating surfaces with metal surface prep.
Install the oil filter adapter with a new gasket.
95.
Install the crankcase vent oil separator and the 8 bolts.
96.
NOTE: The Knock Sensor (KS) must not touch the crankcase vent oil separator.
97.
Install the coolant hose. 98.
NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket if necessary.
Install the thermostat housing.
99.
NOTE: Clean the coolant pump mating surface with metal surface cleaner.
NOTE: Lubricate the coolant pump O-ring with clean engine coolant.
Install the new O-ring, coolant pump and the 3 bolts.
100.
Install the coolant pump pulley and bolts.
101.
102.
Install the fuel rail with the fuel injectors and stud bolts.
103.
Install the radio capacitor and the nut.
104.
Install the fuel rail insulator. 105.
Attach the 2 wiring harness retainers to the valve cover and stud bolt.
Connect the EGR valve electrical connector.
106.
Connect the CHT sensor and install the rubber boot. 107.
Connect the 4 coil-on-plug electrical connectors. 108.
Connect the 4 fuel injector electrical connectors, radio capacitor electrical connector and the Camshaft
Position (CMP) sensor electrical connector.
109.
Install the EGR tube.
110.
Position the intake manifold and connect the PCV hose. 111.
damage.
112.
NOTE: Inspect and install new intake manifold gaskets, if necessary.
NOTE: The cylinder head side of the intake manifold is showing bolt location.
Install the intake manifold gasket, intake manifold and 7 bolts.
Attach the 3 wire harness pin-type retainers to the intake manifold. 113.
Install the vacuum pump assembly, the nut and the 2 bolts.
114.
Connect the vacuum hose to the intake manifold. 115.
Install the A/C compressor bracket and 2 bolts.
116.
Connect the EGR coolant hose and the auxiliary coolant pump hose. 117.
Connect the auxiliary coolant pump hose and the upper radiator hose. 118.
Attach the 2 auxiliary coolant pump wiring retainers and the lower radiator hose retainer. 119.
Attach the 3 wire harness pin-type retainers. 120.
Connect the VCT electrical connector and attach the wiring harness retainer to the valve cover stud
bolt.
121.
122.
Attach the pin-type retainer to the intake manifold and connect the KS electrical connector. 124.
Connect the Manifold Absolute Pressure (MAP) sensor electrical connector. 125.
Connect the Engine Oil Pressure (EOP) switch electrical connector. 126.
Connect the Evaporative Emission (EVAP) canister purge valve electrical connector. 127.
Install the accessory drive belt tensioner.
129.
Attach the vehicle high voltage electrical system electrical connector retainer to the accessory drive
belt tensioner.
130.
Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt. 131.
Install 7 new cylinder head studs in the cylinder head.
132.
Install the new catalytic converter manifold gasket on the engine. 133.
NOTICE: Failure to tighten the catalytic converter nuts to specification before installing the
converter bracket bolts will cause the converter to develop an exhaust leak.
134.
NOTICE: Failure to tighten the catalytic converter nuts to specification a second time will cause
the converter to develop an exhaust leak.
Position the catalytic converter manifold and tighten the 7 new nuts in the sequence shown in 2
stages:
Install the 2 catalytic converter manifold bracket-to-engine block bolts.
135.
Install the catalytic converter manifold heat shield and the 6 bolts.
136.
Attach the 2 engine wiring harness pin-type retainers. 137.
Install the engine wiring harness connector bracket.
138.
Connect the Crankshaft Position (CKP) sensor electrical connector. 139.
Connect the Catalyst Monitor Sensor (CMS) electrical connector. 140.
Connect the Heated Oxygen Sensor (HO2S) connector. Attach the connector to the engine wiring
harness connector bracket.
141.
If equipped, connect the engine block heater. 142.
Using the Floor Crane and the Spreader Bar, remove the engine from the engine stand. 143.
Install the flywheel and the bolts. Tighten the bolts in the sequence shown in the following 3 stages:
144.
Hybrid
Manual
Engine
Special Tool(s)
Powertrain Lift
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
NOTE: Due to packaging requirements, the correct bolt must be used at the damper locations.
NOTE: The damper contains a clutch which is designed to slip briefly during vehicle operation. It is
essential that no grease, oil or cleaning solvents be allowed to contaminate the slip clutch. Do not use
grease on transmission input sha. Should the damper become contaminated, it must be replaced.
Install the transaxle damper.
1.
Engine 2264
NOTE: When positioning the engine to the transaxle, care must be taken to maintain alignment of the
damper spline with the transaxle input shaft.
NOTE: Transaxle removed from view for clarity.
Using the Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 6
transaxle-to-engine bolts.
2.
Connect the 2 heater hoses to the coolant outlet. 3.
Install the 2 engine cover studs onto the valve cover studs. 4.
Position the auxiliary coolant pump and bracket and install the 3 bolts.
5.
Using the Floor Crane and Engine Lifting Bracket, position the engine and transaxle onto the
Powertrain Lift.
6.
NOTE: Due to the weight of the transaxle, special care should be taken to mount the powertrain
securely to the Powertrain Lift.
Using the Adjustable Grip Arm, secure the engine to the Powertrain Lift.
7.
Engine 2265
Install the 3 nuts on the upper transaxle insulator.
9.
Install the engine mount bracket and 3 nuts.
10.
Install the engine mount bracket bolt.
11.
12.
13.
Engine 2266
Connect the brake booster vacuum hose. 14.
Connect the 2 engine wiring harness connectors and attach the wiring retainer. 15.
Connect the 2 transaxle electrical connectors. 16.
Position the master cylinder reservoir and install the 2 bolts.
17.
Connect the transaxle harness electrical connector, attach the wiring retainer and install the bolt.
18.
Engine 2267
Connect the Motor Electronics Cooling System (MECS) coolant expansion tank hose. 19.
Install the MECS coolant expansion tank nut and bolt.
20.
Connect the upper Evaporative Emission (EVAP) tube quick connect coupling to the purge valve. For
21.
Connect the fuel supply tube. For additional information, refer to Section 310-00 . 22.
Connect the engine wiring harness connector and attach it to the bracket. 23.
Engine 2268
Attach the engine wiring harness retainer to the bracket. 24.
Connect the 2 heater hoses. 25.
Attach the 2 block heater (if equipped) and the high voltage electrical system wiring retainers to the
valve cover stud bolts.
26.
Connect the 2 vehicle high voltage electrical system electrical connectors.
Attach the wiring harness retainer.
27.
Install a new gasket and connect the A/C tube to the A/C condenser.
Install the nut.
28.
Engine 2269
Install a new gasket and connect the A/C tube to the A/C compressor.
Install the nut.
29.
30.
Install the A/C tube bracket bolt to the strut tower.
31.
Install a new gasket and connect the A/C tube.
Install the nut.
32.
If equipped, attach the 3 block heater wiring retainers. 33.
Engine 2270
NOTE: Lower radiator hose shown, upper similar.
Connect the upper and lower radiator hoses and install the retaining clips.
34.
NOTE: Lubricate the oil filter O-ring with clean engine oil before installation.
Tighten the oil filter three-fourths of a turn after the oil filter gasket makes contact with the oil filter
adapter.
35.
Attach the transaxle shift cable routing retainer to the transaxle. 36.
Position the selector lever cable bracket in place and install the 2 nuts.
37.
Connect the selector lever cable end to the manual control lever. Check selector lever cable
adjustment. For additional information, refer to Section 307-05B .
38.
Engine 2271
Install the transaxle ground wire and nut.
39.
Connect the transaxle coolant temperature sensor and the Transmission Range (TR) sensor electrical
connectors.
Attach the wiring harness retainer.
40.
Connect the vacuum pump assembly electrical connector and attach the wiring retainer. 41.
43.
Engine 2272
44.
45.
46.
Connect the MECS electrical connector and attach the pump to the bracket. 47.
Attach the 3 wiring harness retainers (2 shown) to the LH front of the subframe. 48.
Engine 2273
Attach the auxiliary coolant hose retainer to the subframe. 49.
Connect the 2 Electronic Power Assist Steering (EPAS) electrical connectors near the front of the
subframe.
Attach the connector retainer from the subframe.
50.
51.
52.
53.
Engine 2274
into the body.
From under the vehicle, verify that the seal is correctly installed on the steering gear and the 4

54.
Install the EPAS wiring ground wire and bolt in the RH front wheel well.
57.
Engine 2275
Install the front wheels and tires. For additional information, refer to Section 204-04 . 61.
If equipped, install the underbody cover and 7 screws. 63.
Connect the steering column shaft to the steering gear and install the bolt.
64.
Repower the vehicle high-voltage electrical system. For additional information, refer to Section
414-03 .
66.
Engine 2276
Install the engine Air Cleaner (ACL) outlet pipe. For additional information, refer to Section 303-12D
.
68.
Reset the Passive Anti-Theft System (PATS). For additional information, refer to Section 419-01B . 69.
Fill and bleed the MECS . For additional information, refer to Section 307-02B . 70.
Fill and bleed the cooling system. For additional information, refer to Section 303-03B . 71.
Recharge the A/C system. For additional information, refer to Section 412-00B . 72.
Engine 2277
SECTION 303-03A: Engine Cooling
Manual
Material
Capacity
Motorcraft Premium Cooling
System Flush
VC-1
ESR-M14P7-A -
(Canada)
XO-5W20-QSP (US);
WSS-M2C945-A -
Engine Coolant
a b c
VC-10-A2 (US); CVC-10-A
(Canada)
WSS-M97B55-A 2.5L engine
8.1L (8.6
qt);
3.0L engine
9.2L (9.7
qt);
3.5L engine
9.5L (10.0
qt)
Engine Coolant
a b d
(Canada)
WSS-M97B44-D 2.5L engine
8.1L (8.6
qt);
3.0L engine
9.2L (9.7
qt);
3.5L engine
9.5L (10.0
qt)
a
The cooling system is filled with Motorcraft Specialty Green Engine Coolant or Motorcraft Specialty
Orange Engine Coolant. Always fill the cooling system with the manufacturer's specified coolant. Chemically
flush the cooling system if a non-specified coolant has been used.
b
Use Motorcraft Specialty Green Engine Coolant or Motorcraft Specialty Orange Engine Coolant. Use
the same type of coolant that was originally used to fill the cooling system. Do not mix coolant types. Mixing
coolant types degrades the coolant corrosion protection and may damage the engine or cooling system.
c
Motorcraft Specialty Green Engine Coolant is very sensitive to light. Do NOT allow this product to be
exposed to ANY LIGHT for more than a day or two. Extended light exposure causes this product to degrade.
d
During normal vehicle operation, Motorcraft Specialty Orange Engine Coolant may change color from
not indicate the engine coolant has degraded nor does it requicoolant to be drained, the system to be flushed,
or the engine coolant to be replaced.
Engine 2278
Item Specification
Pressure Tests
Complete cooling system maximum pressure 124 kPa (18 psi)
Pressure relief cap 89-124 kPa (13-18 psi)
Radiator (out of vehicle) 138 kPa (20 psi)
Thermostat Opening Temperatures
Thermostat starts to open (2.5L) 80-84C (176-183F)
Thermostat starts to open (3.0L) 84-88C (183-190F)
Thermostat starts to open (3.5L) 79.5-83.3C (171.1-181.9F)
Thermostat fully open (2.5L) 97C (207F)
Thermostat fully open (3.0L) 99C (210F)
Thermostat fully open (3.5L) 94.5C (202.1F)
Description Nm lb-ft
lb-in
R>
Block
heater
40 30 -
Cooling fan module bolt 7 - 62
Coolant inlet pipe bolts 10 - 89
Coolant inlet pipe hose clamp 5 - 44
Coolant pump bolts (2.5L) 10 - 89
Coolant pump bolts (3.0L) 10 - 89
Coolant pump bolts (3.5L)
a
- - -
Coolant pump housing nuts and bolts (3.0L) 10 - 89
Coolant pump housing studs (3.0L) 4 - 35
Coolant pump pulley bolts (2.5L) 20 - 177
Degas bottle-to-fender bolt and p" align="center">9 - 80
Engine oil filter
a
- - -
Oil pan drain plug (3.5L) 27 20 -
Primary timing chain guide bolts (3.5L) 10 - 89
Primary timing chain tensioner bolts (3.5L) 10 - 89
Transmission cooler tubes 30 22 -
Upper radiator support bracket bolts 10 - 89
Variable Camshaft Timing (VCT) oil control solenoid housing bolts
(3.5L)
a
- - -
a
Engine 2279
Engine 2280
SECTION 303-03A: Engine Cooling
Manual
Engine Cooling
NOTICE: The engine cooling system is filled with Motorcraft Specialty Green Engine Coolant or
Motorcraft Specialty Orange Engine Coolant. Always fill the cooling system with the manufacturer's
specified coolant. Chemically flush the cooling system if a non-specified coolant has be used. Refer to
Cooling System Flushing in this section. Failure to follow these instructions may damage the engine or
cooling system.
NOTICE: Use Motorcraft Specialty Green Engine Coolant or Motorcraft Specialty Orange Engine
product to degrade.
NOTICE: Stop-leak style pellets/products must not be used as an additive in this engine cooling system.
The addition of stop-leak style pellets/products can clog or damage the cooling system, resulting in
degraded cooling system performance and/or failure.
NOTE: During normal vehicle operation, Motorcraft Specialty Orange Engine Coolant may change color
from orange to pink or light red. As long as the engine coolant is clear and uncontaminated, this color change
does not indicate the engine coolant has degraded nor does it require the engine coolant to be drained, the
system to be flushed, or the engine coolant to be replaced.
The cooling system components are the:
block heater (if equipped).
radiator.
bypass tube.
pressure relief cap.
degas bottle.
radiator draincock.
coolant pump.
thermostat (cold side).
Engine Coolant Temperature (ECT) sr.
variable speed fan motor assembly.
fan control module.
engine block coolant weep hole (3.5L only).
On 3.5L engines the coolant pump is located under the engine front cover mounted to the block. A weep hole
is provided on the front left side of the engine behind the generator. It is adjacent to a 13.5 mm (0.531 in) cup
plug. The plug and the weep hole create a reservoir for normal coolant seepage and evaporation. Every
coolant pump will have some leakage past the dynamic mechanical seal. Dampness and crusting around the
weep hole is acceptable and an expected result of normal engine operation. Coolant spray or leakage amounts
great enough to puddle should be addressed.
Engine Cooling 2281
Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion protection to the
engine and cooling components. In order to obtain these protections, maintain the engine coolant at the correct
concentration and fluid level in the degas bottle.
When adding engine coolant, use a 50/50 mixture of engine coolant and distilled water. A coolant
concentration of 50% provides freeze point protection down to -37C (-34F).
To maintain the integrity of the coolant and the cooling system:
add Motorcraft Specialty Green Engine Coolant or Motorcraft Specialty Orange Engine Coolant.
Use the same type of coolant that was originally used to fill the cooling system. Mixing different
coolant types degrades the corrosion protection of the original coolant. Do not mix any type of
coolants.

do not add alcohol, methanol or brine, or any engine coolants mixed with alcohol or methanol
antifreeze. T can cause engine damage from overheating or freezing.

Ford Motor Company does NOT recommend the use of recycled engine coolant in vehicles.
Used engine coolant should be disposed of in an appropriate manner. Follow the community's
regulations and standards for recycling and disposing of automotive fluids.

Fail Safe Cooling
NOTE: If the driver is using a high percentage of throttle travel (for example, an overtaking maneuver) when
the PCM starts, engine deactivation will be delayed for 10 seconds.
NOTE: After the cylinder deactivation operation has begun, the engine will not revert to operating on all
cylinders, even if the temperature should fall, until the ignition is switched OFF and then ON again.
NOTE: The Malfunction Indicator Lamp (MIL) can only be extinguished by using a scan tool after the fault
has been rectified and the DTC cleared.
The vehicle has a strategy built into the PCM that will control the engine if it starts to overheat.
Stage 1 of the strategy will commence if the engine starts to overheat. The Cylinder Head Temperature (CHT)
sensor transmits a signal to the PCM, which then moves the temperature gauge pointer into the red zone.
If the engine is not switched OFF and the temperature continues to rise, the powertrain check lamp is
illuminated. This indicates to the driver that the engine is approaching critical limits and should be stopped. At
this point, DTC P1285 is set in the PCM and can be retrieved using a scan tool.
Stage 2 of the strategy will commence if the lamp and temperature gauge are ignored by the driver. The PCM
will start to control the engine by cutting out cylinders and restricting the rpm to below 3,000 rpm.
Simultaneously, the MIL will be illuminated. This indicates that long-term engine damage can occur and
vehicle emissions will be affected. At this point, DTC 1299 is set in the PCM and can be retrieved using a
scan tool.
Engine Cooling 2282
Air is then drawn into the deactivated cylinders. This helps to control the temperature of the engine internal
components. The deactivated cylinders are alternated to allow even cooling of all the cylinders.
Stage 3 of the strategy will commence if the engine temperature still continues to rise. This will result in the
engine being totally disabled before major engine damage or seizure occurs. The powertrain check lamp will
begin to flash, indicating to the driver that the engine will be switched OFF after 30 seconds. This allows the
driver time to choose a suitable parking place.
Coolant Flow Diagram
2.5L
NOTE: Black arrows indicate hot, white arrows indicate cold.
2 8B273 Lower radiator hose
3 18C266 Heater core outlet-to-thermostat housing hose
4 8575 Thermostat housing
5 8501 Coolant pump
6 6010 Engine block
7 6051 Head gasket
10 19B555 Heater core
11 18C266 Heater core inlet hose
12 18C266 Heater core outlet hose
13 8K556 Coolant outlet adapter
14 8A582 Coolant outlet adapter-to-engine block hose
15 9D475 EGR valve assembly
17 8005 Radiator
18 8C362 Bleed valve hose
2.5L 2283
3.0L
6 8005 Radiator
9 8B585 Thermostat and coolant pump housing
10 9N271 Coolant inlet pipe
13 8A505 Coolant inlet tube
15 6010 Engine block
3.5L
3.0L 2284
2 8005 Radiator
8 9N271 Water inlet tube
9 9K461 Lower intake manifold
10 8501 Coolant pump
11 6010 Engine block
17 8B541 Degas bottle-to-thermostat housing hose
3.5L 2285
3.5L 2286
SECTION 303-03A: Engine
Cooling
Manual
Engine Cooling
Special Tool(s)
3-Way HD Antifreeze Coolant Test Kit
328-00001
Coolant/Battery Refractometer
ROB75240 or equivalent
D-Gas Adapter
300-OTC014-R1068 or equivalent
Radiator Tester
STN12270 or equivalent
UView Combustion Leak Tester
UVU560000-R
software with appropriate hardware or
Material
Item Specification
Engine Coolant
VC-10-A2 (US); CVC-10-A
(Canada)
WSS-M97B55-A
Engine Coolant
WSS-M97B44-D
Engine coolant flows primarily from the engine to the radiator circuit and back to the coolant pump. Coolant
is sent from the coolant pump through the engine block and cylinder heads. A separate circuit from the engine
also feeds the heater core with coolant. The 2.5L engine coolant pump is operated by engine rotation through
a pulley driven by the accessory drive belt. The 3.0L coolant pump is operated by a V-ribbed belt driven by a
pulley attached to the camshaft. The 3.5L coolant pump is operated through a sprocket driven by the timing
chain. The coolant thermostat is a control valve actuated by coolant temperature. When the thermostat is
closed, coolant flow bypasses the radiator circuit and returns to the coolant pump. When the thermostat is
opened, coolant flows through the radiator circuit to transfer engine-generated heat to the outside air.
Engine Cooling 2287
The degas bottle holds surplus coolant and removes air from the cooling system, which reduces hot spots. It
also allows for coolant expansion and system pressurization, replenishes coolant to the cooling system and
serves as the locati for service fill.
The cooling fan draws air through the radiator to help cool the system coolant as it passes through the radiator.
The thermostat monitor is a function of the PCM and is designed to verify correct thermostat operation. The
monitor executes once per drive cycle and has a monitor run duration of 300-800 seconds. If a malfunction
occurs, DTC P0125 or P0128 is set, and the Malfunction Indicator Lamp (MIL) will be illuminated.
For engine specific information, refer to Engine Cooling in the Description and Operation portion of this
section.
specified coolant. Chemically flush the cooling system if a non-specified coolant has been used. Refer to
cooling system.
product to degrade.
NOTE: Vehicles have the pressure relief cap on the degas bottle and no radiator cap.
Visually check the engine coolant level at the degas bottle when the system is cold. 2.
Make sure the pressure relief cap is installed correctly. 3.
Record any cooling system DTCs retrieved. Refer to the PCM DTC Chart in this section for DTC
descriptions.
4.
NOTE: Take note of any coolant odor or steam coming from cooling system components.
If the system coolant is filled correctly and no DTCs associated with fail-safe cooling are retrieved,
verify the customer's concern by operating the engine to duplicate the condition.
5.
NOTE: For the coolant flow diagrams, refer to Engine Cooling in the Description and Operation
6.
Engine Cooling 2288
Visually inspect for obvious signs of any mechanical or electrical concerns damage.
Leaks or weeps at:
Hoses
Tubes
Clamp joints
Gaskets
O-rings
Thermostat housing
Radiator
Pressure relief cap
Coolant pump weep hole (LH side of block, 3.5L
only)

Heater core (wet floor or coolant odor in vehicle)
Degas bottle
Cylinder block core plugs
Cylinder head core plugs
Block heater (if equipped)
Inoperative or damaged:
Electric cooling fan
Wiring, connectors,
relays or modules

Cylinder Head
Temperature (CHT)
sensor

Vehicle Speed Sensor
(VSS)

Cracked or damaged:
Hoses
Tubes
Hose clamps
Thermostat housing
Radiator
Pressure relief cap
Cooling fan
Coolant pump
Degas bottle

Restricted airflow through the A/C condenser/radiator
Excessive white or light gray exhaust smoke (may have burnt
coolant odor)

Coolant in engine oil
Engine oil in coolant
Coolant in automatic transmission fluid (if equipped)
Automatic transmission fluid (if equipped) in coolant
Engine vent hose check valve installed correctly (3.5L only)
If the inspection reveals an obvious concern that can be readily identified, repair it as necessary. Test
7.
Engine Cooling 2289
NOTICE: The engine cooling system is filled with Motorcraft Specialty Green Engine Coolant
or Motorcraft Specialty Orange Engine Coolant. Always fill the cooling system with the
manufacturer's specified coolant. Chemically flush the cooling system if a non-specified coolant
has been used. Refer to Cooling System Flushing in this section. Failure to follow these
instructions may damage the engine or cooling system.
NOTICE: Use Motorcraft Specialty Green Engine Coolant or Motorcraft Specialty Orange
Engine Coolant. Use the same type of coolant that was originally used to fill the cooling system.
Do not mix coolant types. Mixing coolant types degrades the coolant corrosion protection and
may damage the engine or cooling system.
NOTICE: Motorcraft Specialty Green Engine Coolant is very sensitive to light. Do NOT allow
this product to be exposed to ANY LIGHT for more than a day or two. Extended light exposure
causes this product to degrade.
NOTICE: Stop-leak style pellets/products must not be used as an additive in this engine cooling
system. The addition of stop-leak style pellets/products can clog mage the cooling system,
resulting in degraded cooling system performance and/or failure.
NOTE: NOTE: During normal vehicle operation, Motorcraft Specialty Orange Engine Coolant may
change color from orange to pink or light red. As long as the engine coolant is clear and
uncontaminated, this color change does not indicate the engine coolant has degraded nor does it
require the engine coolant to be drained, the system to be flushed, or the engine coolant to be
replaced.
Inspect the coolant condition in the following sequence:
Inspect the coolant color.
If the coolant has a clear or pale green color, this indicates higher water content than
required. Test the engine coolant freezing point range with the Coolant/Battery
Refractometer. The freezing point should be in the range -50C to -26C (-58F to
-15F). If the vehicle is driven in cold climates less than -37C (-34F), it may be
necessary to increase the coolant concentration to get adequate freeze protection.
Recommended coolant concentration is 50/50 engine coolant to distilled water.

Discoloration of Motorcraft Specialty Orange Engine Coolant may indicate that
incorrect coolant may have been added to the system. Use of incorrect (green or
yellow) coolant degrades the corrosion protection of Motorcraft Specialty Orange
Engine Coolant. Addition of Motorcraft Specialty Green Engine Coolant may cause
the color to appear to be a murky green-brown color. The addition of Motorcraft
Premium Gold Engine Coolant, however, may not change the color or appearance of
the orange colored coolant. Detection of contamination with Motorcraft Premium
Gold Engine Coolant is determined by the presence of nitrite. If contamination with
Motorcraft Premium Gold Engine Coolant is suspected, test the coolant with the
3-Way HD Antifreeze Coolant Test Kit. Follow the directions in the kit with regard
to nitrite testing. If nitrite is prese system and refill with the correct mixture of
Motorcraft Specialty Orange Engine Coolant and distilled water. Refer to Cooling
System Flushing in this section.

A darker color with the presence of debris could indicate a commercially available
stop-leak may have been used and could result in loss of coolant flow the critical
parts of the engine. If sediment is present in the coolant sample, flush the system and
refill with the correct mixture of distilled water and the correct engine coolant. Refer
to Cooling System Flushing in this section.

A light or reddish brown color or reddish brown particles indicate that rust may be
present in the cooling system. Flush the system and refill with the correct mixture of

1.
Engine Cooling 2290
distilled water and the correct engine coolant. Refer to Cooling System Flushing in
this section.
An iridescent sheen on top of the coolant could indicate a trace of oil is entering the
system. For information on engine diagnosis, refer to Section 303-00 .

A milky brown color may indicate that engine oil is entering the cooling system.
Pressure test the cooling system. Refer to Component Tests in this section. If engine
oil is suspected, the cause of the leak may be internal to the engine. Refer to Section
303-00 . Flush the cooling system. Refer to Cooling System Flushing in this section.

If the engine coolant appearance is acceptable, test the engine coolant freezing point range
with the Coolant/Battery Refractometer. The freezing point should be in the range -50C to
-26C (-50F to -15F). If the vehicle is driven in cold climates less than -37C (-34F), it
may be necessary to increase the coolant concentration to get adequate freeze protection.
Maximum coolant concentration is 60/40 for cold weather areas.
Minimum coolant concentration is 40/60 for warm weather areas.
2.
Adjust coolant ranglevel if necessary:
If coolant is low, add specified coolant mixture only.
If the engine coolant tests too weak, remove some of the engine coolant and add
undiluted engine coolant until the readings are within acceptable levels.

If the engine coolant tests strong, remove some of the engine coolant and add distilled
water until the readings are within acceptable levels.

3.
8.
If an obvious cause for an observed or reported concern is found, correct the cause and test the system
for normal operation before proceeding to the next step.
9.
10.
11.
12.
418-00 .

13.
Clear the continuous DTCs and carry out the self-test diagnostics PCM. 14.
If the DTCs recovered are related to the concern, go to the PCM DTC Chart. For all other PCM
DTCs, refer to Section 303-14A for 2.5L engines, Section 303-14B for 3.0L (4V) engines, or Section
303-14C for 3.5L engines.
15.
Engine Cooling 2291
DTC Chart
PCM DTC Chart
P0125 Insufficient Coolant Temp For Closed
Loop Fuel Control
P0128 Coolant Thermostat (Coolant Temp
Below Thermostat Regulating
Temperature)
P0217 Engine Coolant Overtemperature
Condition
P0480
P0481
P0482
Fan 1, 2 or 3 Control Circuit,
Respectively
REFER to the Powertrain Control/Emissions Diagnosis
(PC/ED) manual.
P1285 Cylinder Head Overtemperature
Condition
P1299 Cylinder Head Overtemperature
Protection Active
All Other
PCM DTCs
- REFER to Section 303-14A for 2.5L engines, Section
303-14B for 3.0L (4V) engines or Section 303-14C for
3.5L engines.
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test A: Loss of Coolant
Normal Operation
The engine cooling system is a closed system providing for coolant expansion and contraction and also
changes in pressure as coolant warms and cools with engine operation. Various gaskets, seals, hoses and
clamps contain coolant within the cooling system and keep other fluids and contaminants from entering the
cooling system.
Coolant loss can be attributed to either external or internal leaks anywhere within the cooling system.
section.
Coolant hoses or tubes
Hose clamps
Thermostat O-ring seal
Thermostat housing O-ring seal
Thermostat housing
Coolant pump O-ring seal or gasket
Coolant pump
Radiator
Transmission fluid cooler in radiator (if equipped)
Pressure relief cap
Coolant pump leaking from weep hole
Heater core
Engine gaskets
Degas bottle
PINPOINT TEST A: LOSS OF COOLANT
A1 CARRY OUT INSPECTION AND
VERIFICATION
Carry out the Inspection and
Verification procedure in this section.

Yes
REPAIR as needed. TEST the system for normal
operation.
No
GO to A2 .
A2 CHECK THE ENGINE COOLANT
LEVEL
NOTE: Allow the engine to cool
before checking the engine coolant
level.
Ignition OFF.
Visually inspect the engine coolant
level at the degas bottle.

Is the engine coolant level within
specifications?

Yes
GO to A3 .
No
ADJUST the engine coolant level as necessary. GO to A3
.
A3 PRESSURE TEST THE ENGINE
COOLING SYSTEM
PINPOINT TEST A: LOSS OF COOLANT 2293
Pressure test the engine cooling
system. Refer to Component Tests,
Cooling System Pressure Test in this
section.

Does the engine cooling system leak
externally?

Yes
REPAIR or INSTALL new components. TEST the
No
GO to A4 .
A4 CHECK THE ENGINE COOLANT
FOR AN INTERNAL LEAK
Inspect the engine coolant in the
degas bottle for signs of engine oil.

Is engine oil evident in the coolant?
Yes
If engine oil is evident, GO to Section 303-00 for engine
diagnosis.
No
GO to A5 .
A5 CHECK THE ENGINE OIL AND
TRANSMISSION FLUID FOR
COOLANT
Remove the oil level indicators from
the engine and the transmission.

Is coolant evident in the oil or
transmission fluid?

Yes
If coolant is in the engine oil, GO to Section 303-00 . If
coolant is in the transmission fluid, INSTALL a new
radiator. REPAIR the transmission as necessary. Refer to
the appropriate section in Group 307 for the procedure.
No
GO to A6 .
A6 CHECK THE COOLING SYSTEM
FOR COMBUSTION GASES
NOTE: Use UView Combustion
Leak Tester, part No. UVU560000-R
or equivalent.

Using a cooling system combustion
gas leak tester, following the
instructions supplied with the tester,
check the coolant for combustion
gases.

Are combustion gases present?
Yes
GO to Section 303-00 for engine diagnosis.
No
The cooling system is operational.
Pinpoint Test B: The Engine Overheats
Normal Operation
The engine cooling system maintains engine temperatures during operation. Correct coolant flow through the
engine, radiator and remainder of cooling system passages and components is essential to maintaining a
correct engine temperatue.
Engine coolant flows primarily from the engine to the radiator circuit and back to the coolant pump. From the
coolant pump, coolant is sent through the engine block and cylinder heads. Coolant is sent from the coolant
pump through the engine block and cylinder heads. A separate circuit from the engine also feeds the heater
core with coolant. The 2.5L engine coolant pump is operated by engine rotation through a pulley driven by the
accessory drive belt. The 3.0L coolant pump is operated by a V-ribbed belt driven by a pulley attached to the
camshaft. The 3.5L coolant pump is operated through a sprocket driven by the timing chain. The coolant
thermostat is a control valve actuated by coolant temperature. When the thermostat is closed, coolant flow
bypasses the radiator circuit and returns to the coolant pump. When the thermostat is opened, coolant flows
through the radiator circuit in order to transfer engine-generated heat to the outside air.
Engine overheating generally occurs when there is a disruption in the ability to control either coolant flow at
the correct rate, the inability to transfer heat from the engine through the coolant (including low coolant) or an
inability to transfer engine-generated heat to the outside air through the radiator.
section.
DTC P0217 (Engine Coolant Overtemperature Condition) - Indicates an engine overheat condition
was sensed by the Cylinder Head Temperature (CHT) sensor.

DTC P1285 (Cylinder Head Overtemperature Condition) - Indicates an engine overheat condition was
sensed by the CHT sensor.

DTC P1299 (Cylinder Head Overtemperature Protection Active) - Indicates an engine overheat
condition was detected by the CHT sensor. A failure mode effects management strategy called
fail-safe cooling was activated to cool the engine.

Low coolant level
External engine coolant leak
Airlock in system
Pressure relief cap installation
Internal engine coolant leak
Coolant condition/concentration
Accessory drive components
Non-OEM engine enhancement components
Engine Coolant Temperature (ECT) gauge
Cylinder Head Temperature (CHT) sensor
Heater core
Coolant pump
Coolant flow restriction
Missing engine vent hose check valve or incorrect orientation of check valve (3.5L only)
PINPOINT TEST B: THE ENGINE OVERHEATS
Failure to follow these instructis may result in serious personal injury.
B1 CARRY OUT INSPECTION AND
VERIFICATION
Verification procedure in this
section.

Yes
REPAIR as needed. TEST the system for normal operation.
No
GO to B2 .
PINPOINT TEST B: THE ENGINE OVERHEATS 2295
B2 CHECK FOR DTCs
Check for DTC P0217, P1285 or
P1299.

Is DTC P0217, P1285 or P1299
present?

Yes
GO to B3 .
No
Actual engine overheating has not been verified. CHECK the
ECT gauge operation. REFER to Section 413-01 . If any
other PCM DTCs are retrieved, REFER to Section 303-14A
for 2.5L engines, Section 303-14B for 3.0L (4V) engines or
Section 303-14C for 3.5L engines.
B3 CHECK FOR AN AIRFLOW
OBSTRUCTION
Check the radiator or A/C
condenser for an external
obstruction such as leaves or
cardboard.

Is an obstruction present?
Yes
REMOVE the obstruction. TEST the system for normal
operation.
No
GO to B4 .
B4 CHECK THE ENGINE
COOLANT LEVEL
before checking the coolant level.
Ignition OFF.
Visually check the engine coolant
level in the degas bottle.

Is the engine coolant level
within specification?

Yes
GO to B5 .
No
ADJUST the engine coolant level as necessary. GO to B5 .
B5 PRESSURE TEST THE ENGINE
COOLING SYSTEM
system. Refer to Component
Tests, Cooling System Pressure
Test in this section.

Does the engine cooling system
leak externally?

Yes
REPAIR or INSTALL new components. TEST the system
No
GO to B6 .
B6 CHECK THE ENGINE
COOLANT FOR AN INTERNAL
LEAK
degas bottle for signs of engine
oil.

Is engine oil evident in the
coolant?

Yes
diagnosis.
No
GO to B7 .
B7 CHECK THE ENGINE OIL AND
TRANSMISSION FLUID FOR
COOLANT
Yes
If coolant is in the engine oil, GO to Section 303-00 . If
Remove the oil level indicators
from the engine and the
transmission.

Is coolant evident in the oil or
transmission fluid?

coolant is in the transmission fluid, INSTALL a new radiator.
REPAIR the transmission as necessary. Refer to the
appropriate section in Group 307 for the procedure.
No
GO to B8 .
B8 CHECK THE COOLING
SYSTEM FOR COMBUSTION
GASES
NOTE: Use UView
Combustion Leak Tester, part No.
UVU560000-R or equivalent.

Using a cooling system
combustion gas leak tester,
following the instructions
supplied with the tester, check the
coolant for combustion gases.

Yes
No
GO to B9 .
B9 CHECK COOLANT CONDITION
Check the coolant for dirt, rust or
contamination and check the
coolant concentration.

Is the coolant condition OK?
Yes
GO to B10 .
No
FLUSH the engine cooling system. REFER to Cooling
System Flushing in this section. TEST the system for normal
operation.
B10 CHECK THE ELECTRIC
COOLING FAN OPERATION
Start the engine.
Place the climate control function
selector in the MAX A/C position
and the blower motor switch in
the HI position.

Did the electric cooling fan
operate?

Yes
GO to B11 .
No
DIAGNOSE the electric cooling fan operation. REFER to
B11 CHECK THE COOLANT PUMP
OPERATION
Start the engine.
Allow the engine to run for 30
minutes. Place the climate control
function selector in the MAX
HEAT position. Feel the heater
outlet hose.

Is the heater outlet hose hot?
Yes
GO to B12 .
No
INSTALL a new coolant pump. TEST the system for normal
operation.
B12 CHECK THE THERMOSTAT
OPERATION
Start the engine.
Yes
CHECK the ECT gauge operation. REFER to Section 413-01
.
minutes. Feel the lower radiator
hose.

Is the lower radiator hose hot?
No
For 3.5L engines, GO to B13 . For 2.5L and 3.0L engines,
GO to B14 .
B13 CHECK THE ENGINE VENT
HOSE CHECK VALVE
Disconnect the engine vent hose
from the engine and degas bottle.

Using a light, look inside the end
of the vent hose that connects to
the engine. A check valve should
be installed 50 mm (1.96 in) from
the end of the hose.

Using regulated compressed air,
confirm air flows freely from the
engine end to the degas bottle
end.

Using regulated compressed air,
confirm air does not flow from
the degas bottle end to the engine
end.

Is the check valve installed in
the vent hose and does air flow
through in one direction and
not the other?

Yes
GO to B14 .
No
INSTALL a new engine vent hose. TEST the system for
normal operation.
B14 VISUALLY INSPECT THE
THERMOSTAT
Carry out the Thermostat Visual
Inspection in the Component
Tests portion of this section.

Is the thermostat damaged?
Yes
INSTALL a new thermostat. TEST the system for normal
operation.
No
operation. If the engine still overheats, INSTALL a new
radiator. TEST the system for normal operation.
Pinpoint Test C: The Engine Does Not Reach Normal Operating Temperature
Normal Operation
correct engine temperature.
coolant pump, coolant is sent through the engine block and cylinder heads. A separate circuit from the engine
also feeds the heater core with coolant. The 2.5L engine coolant pump is operated by engine rotation through
a pulley driven by the accessory drive belt. The 3.0L coolant pump is operated by a V-ribbed belt driven by a
pulley attached to the camshaft. The 3.5L coolant pump is operated through a sprocket driven by the timing
chain. The coolant thermostat is a control valve actuated by coolant temperature. When the thermostat is
closed, coolant flow bypasses the radiator circuit and returns to the coolant pump. When the thermostat is
opened, coolant flows through the radiator circuit in order to transfer engine generated heat to the outside air.
Concerns of engine inability to reach normal operating temperature typically occur when the rate of coolant
flow through some coolant circuits (radiator, heater core) is more than expected given the conditions, or when
the electric cooling fans operate all the time. Heat is not allowed to build in the engine because a heat
exchanger is removing too much heat, including the radiator, heater core and oil cooler. In addition, perceived
concerns that the engine does not reach normal operating temperature can be related to a low coolant level or
trapped air which does not allow for hot coolant to be available at the heater core, an inoperative climate
control system, or for concerns perceived or related to an incorrect engine temperature gauge indication.
section.
DTC P0125 (Insufficient Coolant Temp for Closed Loop Fuel Control) - Indicates the Cylinder Head
Temperature (CHT) sensor has not achieved the required temperature level to enter closed loop
operating conditions within a specified amount of time after starting the engine.

DTC P0128 (Coolant Thermostat [Coolant Temp Below Thermostat Regulating Temperature]) -
Indicates that the thermostat monitor has not achieved the required engine operating temperature
within a specified amount of time after starting the engine.

Low coolant level
Thermostat
Engine cooling fan
PINPOINT TEST C: THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE
is under pressure; steam and hot liquid can come out forcly when the cap is loosened slightly. Failure to
follow these instructions may result in serious personal injury.
C1 CARRY OUT
INSPECTION AND
VERIFICATION
Carry out the
Inspection and
Verification
procedure in this
section.

Were any
concerns found?

Yes
No
GO to C2 .
C2 CHECK FOR DTC
P0125 or P0128
Check for DTC
P0125 or P0128.

Is DTC P0125
Yes
GO to C3 .
No
PINPOINT TEST C: THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE 2299
or P0128
present?
The cooling system is operational. If an inoperative engine coolant
temperature gauge is suspected, CHECK the engine coolant temperature
gauge operation. REFER to Section 413-01 . If an inoperative climate control
system is suspected, CHECK the climate control system operation. REFER to
Section 412-00A . If any other PCM DTCs are retrieved, REFER to Section
303-14A for 2.5L engines, Section 303-14B for 3.0L (4V) engines or Section
303-14C for 3.5L engines.
C3 CHECK THE
ELECTRIC COOLING
FAN OPERATION
Allow the engine
to cool.

Make sure the
A/C switch is
OFF (if
equipped).

Start the engine.
Check the
electric cooling
fan.

Is the electric
cooling fan on
all the time?

Yes
DIAGNOSE the electric cooling fan operation. REFER to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual.
No
GO to C4 .
C4 CHECK THE
COOLANT LEVEL
NOTE: Allow
the engine to
cool before
checking the
coolant level.

Visually check
the engine
coolant level in
the degas bottle.

Is the engine
coolant level
within
specification?

Yes
INSTALL a new thermostat. TEST the system for normal operation.
No
GO to Pinpoint Test A to diagnose a coolant leak.
Component Tests
Cooling System Pressure Test
Turn the engine OFF. 1.
Check the engine coolant level. Adjust the coolant level as necessary. 2.
Attach the D-Gas Adapter to the degas bottle nipple and overflow hose. Install the Radiator Tester to
the quick connect fitting of the D-Gas Adapter.
3.
NOTICE: Do not pressurize the cooling system beyond the maximum pressure listed in the
specifications table in this section or cooling system components may be damaged.
NOTE: If the plunger of the pressure tester is pressed too fast, an erroneous pressure reading will
result.
Slowly press the plunger of the pressure test pump until the pressure gauge reading stops increasing
and note the highest pressure reading obtained. If the pressure reading exceeds the maximum cap
pressure listed in the specifications table, install a new pressure relief cap.
4.
If the system does not hold pressure, remove the pressure relief cap and wash in clean water to
dislodge all the foreign material from the gasket. Check the sealing surface in the filler neck of the
degas bottle for nicks or cuts. Install the pressure relief cap.
5.
Pressurize the engine cooling system as described in Step 4. Observe the gauge reading for
approximately 2 minutes. Pressure should not drop during this time. If the pressure drops within this
time, inspect for leaks and repair as necessary.
6.
If no leaks are found and the pressure drops. the pressure relief cap may be leaking. Install a new
pressure relief cap and retest the system.
7.
If no leaks are found after a new pressure relief cap is installed, and the pressure drops, the leak may
be internal to the radiator transmission cooler (if equipped). Inspect the coolant for transmission fluid
and the transmission fluid for coolant. Repair as necessary.
8.
If there is no contamination of the coolant or transmission fluid, the leak may be internal to the
engine. Inspect the coolant for engine oil and the engine oil for coolant. Refer to Section 303-00 to
diagnose the engine.
9.
Release the system pressure by loosening the pressure relief cap. Check the coolant level and adjust as
necessary.
10.
Thermostat
A new thermostat should be installed only after the following tests and checks have been carried out:
Pinpoint Test A, B or C
Thermostat Visual Inspection
Remove the thermostat. 1.
Examine the thermostat for signs of damage including:
Valve not fully seated (light visible through the valve)
Foreign material lodged in the main valve
Bent or broken frame or flange
Bent or broken spring
Bent or broken valve or valve stem
Wax leaking from wax reservoir or a bulge in the reservoir
Any other damage or distortion
2.
NOTE: If no damage is found during the inspection, do not attempt to open the thermostat using hot
water or other heat sources. This method is not an accurate means to test the function of the
thermostat and may damage the thermostat.
If damage is found during the inspection, remove any foreign material or broken pieces and install a
new thermostat.
3.
If no damage is found during the inspection, continue troubleshooting the system concern. Go to the
Symptom Chart for further instructions.
4.
Radiator Leak Test, Removed From Vehicle
NOTICE: Never leak test an aluminum radiator in the same water that copper/brass radiators are
tested in. Flux and caustic cleaners may be present in the cleaning tank and they will damage aluminum
radiators.
NOTE: 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 tank.
Leak test the radiator in clean water with air pressurized to the maximum pressure listed in the Specifications.
Cooling
Manual
Cooling System Draining, Filling and Bleeding
Special Tool(s)
Airlift Cooling System Tester
UVU550000 or equivalent
Material
Item Specification
Engine Coolant
VC-10-A2 (US); CVC-10-A
(Canada)
WSS-M97B55-A
Engine Coolant
WSS-M97B44-D
Draining
100-02 .
1.
WARNING: Always allow the engine to cool before opening the cooling system. Do not
unscrew the coolant pressure relief cap when the engine is operating or the cooling system is
hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when
the cap is loosened slightly. Failure to follow these instructions may result in serious personal
injury.
NOTE: The coolant must be recovered in a suitable, clean container for reuse. If the coolant is
contaminated it must be recycled or disposed of correctly. Using contaminated coolant may
result in damage to the engine or cooling system components.
2.
Cooling System Draining, Filling and Bleeding 2304
system. The addition of stop-leak style pellets/products may clog or damage the cooling system,
NOTE: During normal vehicle operation, Motorcraft Specialty Orange Engine Coolant may change
color from orange to pink or light red. As long as thene coolant is clear and uncontaminated, this color
change does not indicate the engine coolant has degraded nor does it require the engine coolant to be
drained, the system to be flushed, or the engine coolant to be replaced.
NOTE: Less than 80% of coolant capacity can be recovered with the engine in the vehicle. Dirty,
rusty or contaminated coolant requires replacement.
Release the pressure in the cooling system by slowly turning the pressure relief cap one-half turn
counterclockwise. When the pressure is released, remove the pressure relief cap.
Place a suitable container below the radiator draincock.
Open the draincock and allow to drain.
Close the draincock after draining.
3.
Filling and Bleeding with a Vacuum Cooling System Filler - 2.5L and 3.0L Engines
NOTICE: The cooling system is filled with Motorcraft Specialty Green Engine Coolant or
Motorcraft Specialty Orange Engine Coolant. Always fill the cooling system with the
NOTICE: Engine coolant provides boil protection, corrosion protection, freeze protection, and
cooling efficiency to the engine and cooling components. In order to obtain these protections,
maintain the engine coolant at the correct concentration and fluid level in the degas bottle.
Add Motorcraft Specialty Green Engine Coolant or Motorcraft Specialty Orange Engine
Coolant. Use the same type of coolant that was originally used to fill the cooling system. Do
not mix coolant types.

Do not add or mix with any other type of engine coolant. Mixing coolants may degrade the
coolant's corrosion protection.

Do not add alcohol, methanol, or brine, or any engine coolants mixed with alcohol or
methanol antifreeze. These can cause engine damage from overheating or freezing.

Ford Motor Company does NOT recommend the use of recycled engine coolant in v
originally equipped with Motorcraft Specialty Green Engine Coolant or Motorcraft
Specialty Orange Engine Coolant since a Ford-approved recycling process is not yet
available.

system. The addition of stop-leak style pellets/products can clog or damage the cooling system
1.
Install the vacuum cooling system filler and follow the manufacturer's instructions to fill and bleed the
cooling system.
For extremely cold climates (less than -37C [-34F]):
It may be necessary to increase the coolant concentration above 50%.
NEVER increase the coolant concentration above 60%.
A coolant concentration of 60% provides freeze point protection down to -50C
(-58F).

Engine coolant concentration above 60% decreases the overheat protection
characteristics of the engine coolant and may damage the engine.

For extremely hot climates:
It is still necessary to maintain the coolant concentration above 40%.
NEVER decrease the coolant concentration below 40%.
(-15F).

Engine coolant concentration below 40% decreases the corrosion and freeze
protection characteristics of the engine coolant and may damage the engine. l>

Vehicles driven year-round in non-extreme climates should use a 50/50 mixture of
engine coolant and distilled water for optimum cooling system and engine protection.

Filling and Bleeding without a Vacuum Cooling System Filler - 2.5L and 3.0L Engines
cooling system.
product to degrade.
NOTICE: Engine coolant provides boil protection, corrosion protection, freeze protection, and cooling
efficiency to the engine and cooling components. In order to obtain these protections, maintain the
engine coolant at the correct concentration and fluid level in the degas bottle.
To maintain the integrity ofcoolant and the cooling system:
Add Motorcraft Specialty Green Engine Coolant or Motorcraft Specialty Orange Engine Coolant.
Use the same type of coolant that was originally used to fill the cooling system. Do not mix coolant
types.

Do not add or mix with any other type of engine coolant. Mixing coolants may degrade the coolant's
corrosion protection.

Do not add alcohol, methanol, or brine, or any engine coolants mixed with alcohol or methanol
antifreeze. These can cause engine damage from overheating or freezing.

Ford Motor Company does NOT recommend the use of recycled engine coolant in vehicles originally
equipped with Motorcraft Specialty Green Engine Coolant or Motorcraft Specialty Orange Engine
Coolant since a Ford-approved recycling process is not yet available.

The addition of stop-leak style pellets/products can clog or damage the cooling system resulting in
2.5L engine
Remove the degas bottle cap and the bleed valve on the back of the engine coolant outlet. 1.
3.0L engine
Remove the degas bottle cap and the bleed valve on the top of the coolant pump housing. 2.
2.5L and 3.0L engines
NOTE: Make sure the coolant flows from the radiator through the upper radiator hose and fills the
engine. When full, coolant should flow from the bleed hole.
Fill the degas bottle to the MAX fill line.
(-58F).



3.
(-15F).
protection characteristics of the engine coolant and may damage the engine.

Vehicles driven year-round in non-extreme climates should use a 50/50 mixture of engine
coolant and distilled water for optimum cooling system and engine protection.

Install the degas bottle cap and the bleed valve leaving both loose.
Start the engine and let it idle A mixture of air and coolant should escape from the open bleed valve. 5.
After all of the air has escaped from the bleed valve turn off the engine and close the bleed valve and
the degas bottle cap.
6.
NOTICE: If the engine overheats or the fluid level drops below the minimum fill line, shut off the
engine and add fluid to the degas bottle maximum fill line once the engine cools. Failure to follow these
instructions may result in damage to the engine.
Start the engine and let it idle for 10 minutes (3.0L), 30 minutes (2.5L) or until the engine reaches
normal operating temperature.
7.
Carry out the following:
Increase the engine speed to 3,000 rpm for 10 seconds. 1.
Idle engine for 50 seconds. 2.
Repeat Steps 1 and 2 a total of 15 times. 3.
8.
injury.
Check the engine coolant level in degas bottle and fill as necessary.
9.
Filling and Bleeding - 3.5L Engine
Cooling System Flushing in this section. Failure to follow these instructions may damage the engine
or cooling system.


Do notalcohol, methanol, or brine, or any engine coolants mixed with alcohol or methanol

Ford Motor Company does NOT recommend the use of recycled engine coolant in vehicles
available.

cooling system.
(-58F).


A coolant concentration of ovides freeze point protection down to -26C (-15F).


Fill the degas bottle to 25 mm (0.984 in) above the COLD FILL line. 2.
Install the degas bottle cap until at least 1 audible click is heard. 3.
Turn the climate control system off. 4.
Start the engine and increase the engine speed to 3,500 rpm and hold for 30 seconds. 5.
Turn the engine off for and wait for 1 minute to purge any large air pockets from the cooling system. 6.
the cap is loosened slightly. Failure to follow these instructions may result in seris personal
injury.
7.
Check the engine coolant level in degas bottle and if necessary fill to 25 mm (0.984 in) above the top
of the COLD FILL LEVEL on the degas bottle if the engine is warm or to the top of the COLD FILL
LEVEL if the engine is cold.
Start the engine and let it idle until the engine reaches normal operating temperature and the
thermostat is fully open. A fully open thermostat is verified by the cooling fan cycling on at least
once.
8.
Increase the engine speed to 3,500 rpm and hold for 30 seconds. 9.
Allow the engine to idle for 30 seconds. 10.
Turn the engine off for 1 minute. 11.
Repeat steps 9 through 11 a total of 5 times to remove any remaining air trapped in the system. 12.
injury.
Check the engine coolant level in degas bottle and if necessary fill to 25 mm (0.984 in) above the top
of the COLD FILL LEVEL on the degas bottle if the engine is warm or to the top of the COLD FILL
LEVEL if the engine is cold.
13.
Install the degas bottle cap until at least 1 audible click is heard. 14.
Cooling
Manual
Cooling System Flushing
Material
Item Specification
System Flush
VC-1
ESR-M14P7-A
NOTE: To remove rust, sludge and other foreign material from the cooling system, use cooling system flush
that is safe for use with aluminum radiators. For additional information, refer to Specifications in this section.
This cleaning restores cooling system efficiency and helps prevent overheating. A pulsating or reversed
direction of flushing water will loosen sediment more quickly than a steady flow in the normal coolant flow
direction. In severe cases where cleaning solvents will not clean the cooling system efficiently, it will be
necessary to use the pressure flushing method using cooling system flusher. Dispose of old coolant and
flushing water contaminated with antifreeze and cleaning chemicals in accordance with local, state or federal
laws.
Add Premium Cooling System Flush to the cooling system and follow the directions on the package. 1.
Remove the radiator. For additional information, refer to Radiator - 2.5L, 3.0L (4V) or Radiator -
3.5L in this section.
2.
NOTICE: Radiator internal pressure must not exceed 138 kPa (20 psi). Damage to the radiator
can result.
Backflush the radiator with the radiator in an upside-down position with a high-pressure hose in the
lower hose location and backflush.
3.
NOTE: On 2.5L engines, the thermostat and housing are serviced as an assembly.
Remove the thermostat. For additional information, refer to Thermostat Housing - 2.5L , Thermostat -
3.0L (4V) or Thermostat - 3.5L in this section.
4.
Backflush the engine. Position the high-pressure water hose into the engine through the upper radiator
hose and backflush the engine.
5.
Cooling System Flushing 2311
Cooling
Manual
REMOVAL AND
INSTALLATION
Block Heater
2.5L
Item
Part
Number Description
1 - Block heater electrical connector heat shield (part of
6B018)
2 6B018 Block heater electrical connector
3 6A051 Block heater
3.0L
Block Heater 2313
3.5L
1 030104 Block heater heat shield
All engines
100-02 .
1.
Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and
Bleeding in this section.
2.
2.5L engine
Position the block heater heat shield aside. 4.
3.5L engine
Remove the block heater heat shield. 6.
All engines
3.5L 2314
NOTICE: 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.
7.
Remove the block heater.
8.
Fill and bleed the cooling system. For additional information, refer to Cooling System Draining,
Filling and Bleeding in this section.
10.
3.5L 2315
Cooling
Manual
REMOVAL AND
INSTALLATION
Thermostat Housing - 2.5L
1 14A464 Knock Sensor (KS) electrical connector (part of
12C508)
2 14A624 KS electrical connector pin-type retainer (part of
12C508)
5 W500015 Thermostat housing bolt (3 required)
7 W527372 Lower radiator hose clamp
9 8K530 Gasket
NOTE: The thermostat and thermostat housing are serviced as an assembly.
100-02 .
1.
2.
Disconnect the Knock Sensor (KS) electrical connector and detach the wiring harness pin-type
retainer.
3.
NOTE: Disconnecting the heater hose first will aid in the removal of the bottom thermostat housing
bolt.
Disconnect the heater hose at the thermostat housing.
4.
Thermostat Housing - 2.5L 2316
NOTE: The view of the thermostat housing bolts is obstructed by A/C and engine components.
However, the bolts can be removed using 1/4-in drive hand tools.
Remove the 3 bolts and reposition the thermostat housing to gain access to the lower radiator hose
clamp.
5.
Disconnect the lower radiator hose at the thermostat housing. 6.
7.
8.
Cooling
Manual
REMOVAL AND
INSTALLATION
Thermostat - 3.0L (4V)
Material
Item Specification
Engine Coolant
VC-10-A2 (US); CVC-10-A
(Canada)
WSS-M97B55-A
Engine Coolant
WSS-M97B44-D
1 W527375 Radiator hose clamp
3 W500015 Thermostat housing cover bolts (2 required)
4 8K528 Thermostat housing cover
5 N806807 O-ring seal
6 8575 Thermostat
100-02 .
1.
2.
Disconnect the positive battery cable. For additional information, refer to Section 414-01 . 3.
Disconnect the lower radiator hose from the thermostat housing. 4.
Thermostat - 3.0L (4V) 2318
Remove the 2 bolts, thermostat housing cover, O-ring seal and thermostat.
5.
Clean and inspect the O-ring seal. Install a new seal if necessary.
Lubricate the thermostatring seal with clean engine coolant.
6.
7.
Thermostat - 3.0L (4V) 2319
Cooling
Manual
REMOVAL AND
INSTALLATION
Thermostat - 3.5L
Material
Item Specification
Engine Coolant
VC-10-A2 (US); CVC-10-A
(Canada)
WSS-M97B55-A
Engine Coolant
WSS-M97B44-D
1 8B273 Lower radiator-to-thermostat housing cover hose
2 W500014 Thermostat housing cover bolt (2 required)
3 8594 Thermostat housing cover
4 - O-ring seal
5 8575 Thermostat
1.
Removr cleaner and outlet pipe. For additional information, refer to Section 303-12C . 2.
Disconnect the lower radiator hose from the thermostat housing cover and position it aside. 3.
Remove the 2 bolts, thermostat housing cover, O-ring seal and thermostat.
Clean and inspect the O-ring seal. Install a new seal if necessary.
4.
Thermostat - 3.5L 2320
Lubricate the thermostat O-ring seal with clean engine coolant.
5.
Filling and Bleeding in thisction.
6.
Thermostat - 3.5L 2321
Cooling
Manual
REMOVAL AND
INSTALLATION
Thermostat Housing - 3.5L
Material
Item Specification
Engine Coolant
VC-10-A2 (US); CVC-10-A
(Canada)
WSS-M97B55-A
Engine Coolant
WSS-M97B44-D
1 8B274 Upper radiator-to-thermostat housing hose
2 18C266 Heater outlet hose
3 18C266 Heater inlet hose
6 8565 O-ring seal
7 8A571 O-ring seal
8 8B541 Thermostat housing-to-degas bottle hose
Remove the thermostat. For additional information, refer to Thermostat - 3.5L in this section. 1.
Disconnect the 4 coolant hoses from the thermostat housing and position them aside. 2.
Remove the 2 thermostat housing bolts.
3.
NOTE: Do not pull the other end of the coolant tube out of the engine block when separating the
thermostat housing.
Separate the thermostat housing from the coolant tube and remove the thermostat housing.
4.
Lubricate the new O-ring seals with clean engine coolant.
5.
Cooling
Manual
REMOVAL AND
INSTALLATION
Bypass Tube - 2.5L
1 W525958 Hose clamp (2 required)
2 8548 Bypass tube
100-02 .
1.
2.
Remove the intake manifold. For additional information, refer to Section 303-01A . 3.
Disconnect and remove the coolant bypass tube from the engine. 4.
6.
Bypass Tube - 2.5L 2324
Bypass Tube - 2.5L 2325
Cooling
Manual
REMOVAL AND
INSTALLATION
Coolant Inlet Pipe - 3.0L (4V)
Material
Item Specification
Engine Coolant
VC-10-A2 (US); CVC-10-A
(Canada)
WSS-M97B55-A
Engine Coolant
WSS-M97B44-D
1 W503281 Coolant inlet pipe bolts
2 8594 Coolant inlet pipe
3 8255 O-ring seal
4 W527485 Coolant inlet pipe clamp (2 required)
5 8B573 Coolant inlet pipe hose
1.
Remo Throttle Body (TB). For additional information, refer to Section 303-04B . 2.
Remove the 2 coolant inlet pipe housing bolts.
3.
Loosen the clamp and disconnect the coolant inlet pipe from the coolant inlet pipe hose.
4.
Coolant Inlet Pipe - 3.0L (4V) 2326
Remove and inspect the O-ring seal, install a new seal if necessary. 5.
Lubricate the O-ring seal with clean engine coolant.
6.
Fill and bleed the cooling system. For additional information, refer to Cooling System Draining, Filg
and Bleeding in this section.
7.
Coolant Inlet Pipe - 3.0L (4V) 2327
Cooling
Manual
REMOVAL AND
INSTALLATION
Coolant Pump - 2.5L
Material
Item Specification
Engine Coolant
VC-10-A2 (US); CVC-10-A
(Canada)
WSS-M97B55-A
Engine Coolant
WSS-M97B44-D
3 W500015 Coolant pump bolt (3 required)
4 8501 Coolant pump
5 8507 Coolant pump O-ring seal
1.
Loosen the 3nt pump pulley bolts.
2.
Coolant Pump - 2.5L 2328
5.
Lubricate the new O-ring seal with clean engine coolant.
6.
7.
Cooling
Manual
REMOVAL AND
INSTALLATION
Coolant Pump Housing - 3.0L (4V)
Coolant Hoses
2 18K580 Heater outlet hose
4 18K579 Heater inlet hose
Coolant Pump Housing
Coolant Pump Housing - 3.0L (4V) 2330
1 W705764 Coolant pump housing nut (2 required)
2 W707643 Coolant pump housing bolt
3 W713511 Coolant pump housing stud (2 required)
4 8C387 Gasket
5 8565 O-ring seal
6 W503281 Coolant pump housing bolt (2 required)
7 8B858 Coolant pump housing
8 W503281 Coolant inlet pipe bolt (2 required)
9 8255 O-ring seal
1.
Remove the Throttle Body (TB). For additional information, refer to Section 303-04B . 2.
Disconnect the upper radiator hose from the coolant pump housing. 4.
Disconnect the lower radiator hose from the thermostat housing. 5.
Disconnect both heater hoses from the coolant pump housing. 6.
Remove the 2 coolant inlet pipe bolts.
7.
Remove the 3 bolts, 2 nuts and the coolant pump housing.
Remove and discard the O-ring seals and gasket.
8.
Coolant Pump Housing 2331
Install new O-ring seals and gasket.
9.
10.
Coolant Pump Housing 2332
Cooling
Manual
REMOVAL AND
INSTALLATION
Coolant Pump - 3.0L (4V)
3 W503276 Coolant pump assembly bolt (3 required)
4 8501 Coolant pump assembly
5 8507 Gasket
1.
Disconnect the lower radiator hfrom the thermostat housing. 3.
5.
6.
Coolant Pump - 3.0L (4V) 2333
7.
Coolant Pump - 3.0L (4V) 2334
Cooling
Manual
REMOVAL AND
INSTALLATION
Coolant Pump - 3.5L
Special Tool(s)
Camshaft Holding Tool
303-1248
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
Removal
NOTE: On early build engines, the timing chain rides on the inner side of the RH timing chain guide. Late
build engines are equipped with a different design RH timing chain guide that requires the timing chain to ride
on the outer side of the RH timing chain guide. For service, all replacement RH timing chain guides will be
the late build design.
All vehicles
Remove the engine front cover. For additional information, refer to Section 303-01C . 1.
Engines equipped with early build RH timing chain guides
Rotate the crankshaft clockwise and align the timing marks on the Variable Camshaft Timing (VCT)
3.
Engines equipped with late build/replacement RH timing chain guides
Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown. 4.
All vehicles
5.
NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC .
6.
shown.
9.
shown.
10.
Mark the timing chain link that aligns with the timing mark on the crankshaft sprocket as shown. 11.
Remove the 2 bolts and the upper LH primary timing chain guide. 16.
Remove the RH primary timing chain guide lower bolt. 17.
NOTE: The RH primary timing chain guide must be repositioned to allow the coolant pump to be
removed.
Loosen the RH primary timing chain guide upper bolt.
Rotate the guide and tighten the bolt.
18.
Remove the RH primary timing chain guide lower bolt. 19.
NOTE: The RH primary timing chain guide must be repositioned to allow the coolant pump to be
removed.
Rotate the guide and tighten the bolt.
20.
All vehicles
Place clean, lint-free shop towels in the oil pan opening to prevent coolant from entering the oil pan
during coolant pump removal.
21.
Installation
All vehicles
NOTE: Clean and inspect all sealing surfaces. 1.
Install the coolant pump and the 8 bolts. Tighten in the sequence shown in 2 stages:
Remove all of the shop towels from the oil pan opening. 2.
NOTICE: Any coolant that has accumulated in the oil pan must be drained from the pan and
any residual coolant cleaned from the front of the engine and oil pan. Failure to remove all
traces of the coolant can result in oil contamination and severe engine damage.
Remove the oil pan drain plug and allow any accumulated coolant to drain.
Remove any residual coolant from the front of the engine and the oil pan using regulated,
compressed air and clean, lint-free shop towels.

Install the oil pan drain plug and tighten to 27 Nm (20 lb-ft).
3.
Position the RH primary timing chain guide and install the lower bolt.
Tighten the 2 bolts to 10 Nm (89 lb-in).
4.
Position the RH primary timing chain guide and install the lower bolt.
Tighten the 2 bolts to 10 Nm (89 lb-in).
5.
All vehicles
6.
Install the upper LH primary timing chain guide and the 2 bolts.
7.
8.
Rotate the lever counterclockwise.
Using a soft-jawed vise, compress the plunger.
Align the hole in the lever with the hole in the tensioner housing.
Install a suitable lock pin.
10.
11.
Remove the lock pin.
There are 38 links in between the RH intake VCT assembly colored link (1) and the LH
intake VCT assembly colored link (2).

There are 27 links in between LH intake VCT assembly colored link (2) and the crankshaft
sprocket link (3).

12.
VCT housing.
14.
15.
16.
NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.
17.
Install the engine front cover. For additional information, refer to Section 303-01C . 18.
Cooling
Manual
REMOVAL AND
INSTALLATION
Cooling Fan Motor and Shroud - 2.5L, 3.0L (4V)
2.5L and 3.0L Engines
1 13A506 Wiring harness retainers
2 14A163 Block heater retainers (part of 6B018)
3 - RH lower radiator hose pin-type retainer (part
of 8B273)
4 256844 Transmission fluid cooler tube retaining clips
(automatic transmission only) (part of 7R081)
5 - LH lower radiator hose pin-type retainer (3.0L
only)
6 14A464 Cooling fan motor electrical connector
7 8C607 Cooling fan motor and shroud
Detach all the wiring harness retainers from the cooling fan and shroud. 1.
If equipped, detach the 2 block heater wiring retainers from the cooling fan motor and shroud. 2.
Remove the splash shield. 3.
Cooling Fan Motor and Shroud - 2.5L, 3.0L (4V) 2347
Detach the RH lower radiator hose pin-type retainer from the cooling fan motor and shroud. 4.
If equipped, detach the 2 transmission cooler tube retainers from the cooling fan motor and shroud. 5.
If equipped, detach the LH lower radiator hose pin-type retainer from the cooling fan motor and
shroud.
6.
Disconnect the cooling fan electrical connector.
Detach the pin-type retainer.
7.
Release the 2 tabs and remove the cooling fan motor and shroud.
8.
2.5L and 3.0L Engines 2348
Cooling
Manual
REMOVAL AND
INSTALLATION
Cooling Fan Motor and Shroud - 3.5L
Cooling Fan Motor and Shroud (View 1 of 2)
Item
Part
Number Description
1 - RH lower radiator hose pin-type retainer (part of
8B273)
3 256844 Transmission fluid cooler tube retaining clips (part of
7R081)
5 14A099 Wire harness retainers (part of 14290)
6 14A099 Wire harness retainer (part of 14290)
7 14A099 Wire harness shield retainers (part of 14290)
8 14A099 Wire harness shield retainer (part of 14290)
9 14A464 Cooling fan module electrical connector (part of 14290)
10 - Cooling fan module electrical connectors (part of
8C607)
11 - Cooling fan module bolt
12 - Cooling fan module
Cooling Fan Motor and Shroud - 3.5L 2349
Cooling Fan Motor and Shroud (View 2 of 2)
.
1.
3.
Detach the lower radiator hose pin-type retainer from the RH side of the cooling fan motor and
shroud.
4.
Detach the lower radiator hose from the LH side of the cooling fan motor and shroud. 5.
Detach the transmission cooler tube retaining clips from the cooling fan motor and shroud. 6.
Remove the Air Cleaner (ACL) and inlet air resonator. For additional information, refer to Section
303-12C .
7.
Disconnect the 3 cooling fan module electrical connectors. 9.
Remove the bolt and the cooling fan module.
10.
Cooling Fan Motor and Shroud (View 2 of 2) 2350
Detach the 5 pin-type retainers from the cooling fan and shroud. 11.
Detach the wiring harness pin-type retainer from the frame rail. 12.
Disconnect the upper radiator hose from the radiator. 13.
14.
16.
Cooling Fan Motor and Shroud (View 2 of 2) 2351
Cooling
Manual
REMOVAL AND
INSTALLATION
Radiator - 3.5L
Radiator (View 1 of 2)
1 8276 Radiator-to-degas bottle hose
2 7H420 Transmission cooler tubes (2 required)
3 19710 A/C condenser-to-radiator pin-type retainer
Radiator - 3.5L 2352
1 W500214 LH upper radiator support bracket bolt
2 8A194 LH upper radiator support bracket
3 W500214 RH upper radiator support bracket bolt
4 8A194 RH upper radiator support bracket
5 - Power steering hose retainer
6 3493 Coolant hose retainer
7 19710 A/C condenser
8 8005 Radiator
1.
Remove the cooling fan motor and shroud. For additional information, refer to Cooling Fan Motor
and Shroud - 3.5L in this section.
2.
Detach the power steering hose retainer from the radiator. 3.
Detach the coolant hose retainer from the radiator. 4.
Disconnect the 2 transmission cooling tubes from the radiator.
-34.
Disconnect the lower radiator hose from the radiator. 7.
Remove the 2 bolts from the upper radiator support brackets and position the radiator towards the
engine and remove the 2 upper radiator support brackets from the radiator.
8.
Remove the A/C condensor-to-radiator pin-type retainer. 9.
Radiator (View 2 of 2) 2353
Squeeze the tabs and separate the A/C condenser from the radiator.
Remove the radiator.
10.
12.
Cooling
Manual
REMOVAL AND
INSTALLATION
Radiator - 2.5L, 3.0L (4V)
Item
Part
Number Description
2 7H420 Transmission cooler tubes (automatic transmissions) (2
required)
3 19710 A/C condenser-to-radiator pin-type retainer
4 8286 Lower radiator hose
5 8260 Upper radiator hose
Radiator - 2.5L, 3.0L (4V) 2355
4 8A194 RH upper radiatorport bracket
6 8005 Radiator
1.
and Shroud - 2.5L, 3.0L (4V) in this section.
2.
Disconnect the radiator-to-degas bottle hose from the radiator. 4.
If equipped, disconnect the 2 transmission cooling tubes from the radiator.
5.
Remove the 2 bolts from the upper radiator support brackets, position the radiator towards the engine
and remove the 2 upper radiator support brackets from the radiator.
7.
9.
11.
Cooling
Manual
REMOVAL AND
INSTALLATION
Degas Bottle
2.5L and 3.0L Engines
3.5L Engines
1 8B541 Degas bottle-to-thermostat housing hose
Degas Bottle 2358
6 14197 Wiring harness retainer (if equipped)
All vehicles
injury.
1.
Using hose clamp pliers, clamp the lower degas bottle hose. 2.
Using a suitable suction device, siphon the coolant from the degas bottle. 3.
Disconnect the degas bottle-to-radiator hose. 4.
3.5L engines
If equipped, detach the wiring harness retainer from the degas bottle. 5.
Disconnect the degas bottle-to-thermostat housing hose. 6.
All vehicles
Disconnect the lower degas bottle hose. 7.
Remove the nut, bolt and the degas bottle.
8.
Fill the degas bottle. Refer to Cooling System Draining, Filling and Bleeding in this section for the
recommended coolant mixture and fill level.
10.
3.5L Engines 2359
3.5L Engines 2360
SECTION 303-03B: Engine Cooling - Hybrid
Workshop Manual
Material
Capacity
System Flush
VC-1
ESR-M14P7-A -
Engine Coolant
a b c
VC-10-A2 (US); CVC-10-A
(Canada)
WSS-M97B55-A 9.0L (9.5
qt)
Engine Coolant
a b d
(Canada)
WSS-M97B44-D 9.0L (9.5
qt)
a
The cooling system is filled with Motorcraft Specialty Green Engine Coolant or Motorcraft Specialty
Orange Engine Coolant. Always fill the cooling system with the manufacturer's specified coolant. Chemically
flush the cooling system if a non-specified coolant has been used.
b
Use Motorcraft Specialty Green Engine Coolant or Motorcraft Specialty Orange Engine Coolant. Use
the same type of coolant that was originally used to fill the cooling system. Do not mix coolant types. Mixing
coolant typee coolant corrosion protection and may damage the engine or cooling system.
c
Motorcraft Specialty Green Engine Coolant is very sensitive to light. Do NOT allow this product to be
exposed to ANY LIGHT for more than a day or two. Extended light exposure causes this product to degrade.
d
During normal vehicle operation, Motorcraft Specialty Orange Engine Coolant may change color from
not indicate the engine coolant has degraded nor does it require the engine coolant to be drained, the system to
be flushed, or the engine coolant to be replaced.
Item Specification
Pressure Tests
Complete cooling system maximum pressure 124 kPa (18 psi)
Pressure relief cap 89-124 kPa (13-18 psi)
Radiator (out of vehicle) 138 kPa (20 psi)
Thermostat Opening Temperatures
Thermostat starts to open 80-84C (176-183F)
Thermostat fully open 97C (207F)
3.5L Engines 2361
A/C tubes retainer bolt 7 62
Auxiliary relay box bolts 8 71
Block heater 20 177
Coolant pump bolts 10 89
Coolant pump pulley bolts 20 177
Degas bottle-to-fender bolt 9 80
Degas bottle-to-fender nut 9 80
Thermostat housing bolts 10 89
Upper radiator support bracket bolts 10 89
3.5L Engines 2362
SECTION 303-03B: Engine Cooling - Hybrid
Workshop Manual
Engine Cooling
cooling system.
NOTICE: Use Motorcraft Specialty Green Engine Coolant or Motorcraft Specialty Orange Engine
product to be exposed to ANY LIGHT for more than a day or tded light exposure causes this product to
degrade.
The addition of stop-leak style pellets/products can clog or damage the cooling system, resulting in
The cooling system components are the:
block heater (if equipped).
radiator.
bypass tube.
pressure relief cap.
degas bottle.
radiator draincock.
coolant pump.
thermostat housing.
auxiliary coolant flow pump, refer to Section 412-01 for removal and installation and Section
412-00B for diagnostics.

Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion protection to the
engine and cooling components. In order to obtain these protections, maintain the engine coolant at the
correctconcentration and fluid level in the degas bottle.
When adding engine coolant, use a 50/50 mixture of engine coolant and distilled water. A coolant
concentration of 50% provides freeze point protection down to -37C (-34F).
add the correct coolant type to the engine cooling system. The engine cooling system is filled with
Motorcraft Specialty Green Engine Coolant or Motorcraft Specialty Orange Engine Coolant. Use

Engine Cooling 2363
the same type of coolant that was originally used to fill the cooling system. Mixing different coolant
types degrades the corrosion protection of the original coolant. Do not mix any type of coolants.
do not add alcohol, methanol or brine, or any engine coolants mixed with alcohol or methanol

Ford Motor Company does NOT recommend the use of recycled engine coolant in vehicles.
Coolant Flow Diagram
4 18C266 Thermostat housing-to-auxiliary coolant pump hose
5 18D473 Auxiliary coolant flow pump
6 8501 Coolant pump
7 6010 Engine block
14 8A582 Coolant outlet adapter-to-engine bypass tube hose
15 9D475 EGR valve assembly
17 8005 Radiator
18 18C266 EGR valve assembly-to-heater core outlet hose
19 8C362 Bleed valve hose
Engine Cooling 2364
Engine Cooling 2365
SECTION 303-03B: Engine Cooling -
Hybrid
Manual
Engine Cooling
Special Tool(s)
3-Way HD Antifreeze Coolant Test Kit
328-00001
Coolant/Battery Refractometer
ROB75240 or equivalent
D-Gas Adapter
300-OTC014-R1068 or equivalent
Radiator Tester
STN12270 or equivalent
UView Combustion Leak Tester
UVU560000-R
software with appropriate hardware or
Material
Item Specification
Engine Coolant
VC-10-A2 (US); CVC-10-A
(Canada)
WSS-M97B55-A
Engine Coolant
WSS-M97B44-D
Engine coolant flows primarily from thngine to the radiator circuit and back to the coolant pump. Coolant is
sent from the coolant pump through the engine block and cylinder heads. A separate circuit from the engine
also feeds the heater core and turbochargers with coolant. The coolant pump, operated by engine rotation
through a sprocket which is driven by the timing chain, circulates the coolant. The coolant thermostat is a
control valve actuated by coolant temperature. When the thermostat is closed, coolant flow bypasses the
radiator circuit and returns to the coolant pump. When the thermostat is opened, coolant flows through the
radiator circuit to transfer engine-generated heat to the outside air.
The degas bottle holds surplus coolant and removes air from the cooling system, which reduces hot spots. It
also allows for coolant expansion and system pressurization, replenishes coolant to the cooling system and
Engine Cooling 2366
serves as the location for service fill.
The cooling fan draws air through the radiator to help cool the system coolant as it passes through the radiator.
The thermostat monitor is a function of the PCM and is designed to verify correct thermostat operation. The
monitor executes once per drive cycle and has a monitor run duration of 300-800 seconds. If a malfunction
occurs, DTC P0125 or P0128 is set, and the Malfunction Indicator Lamp (MIL) is illuminated.
section.
cooling system.
product to degrade.
NOTE: Vehicles have the pressure relief cap on the degas bottle and no raor cap.
Visually check the engine coolant level at the degas bottle when the system is cold. 2.
Make sure the pressure relief cap is installed correctly. 3.
Record any cooling system DTCs retrieved. Refer to the PCM DTC Chart in this section for DTC
descriptions.
4.
NOTE: Take note of any coolant odor or steam coming from cooling system components.
If the system coolant is filled correctly and no DTCs associated with fail-safe cooling are retrieved,
verify the customer's concern by operating the engine to duplicate the condition.
5.
NOTE: For the coolant flow diagram, refer to Engine Cooling in the Description and Operation
Visually inspect for obvious signs of any mechanical or electrical damage.
6.
Engine Cooling 2367
Leaks or weeps at:
Hoses
Tubes
Clamp joints
Gaskets
O-rings
Thermostat housing
Radiator
Pressure relief cap
Heater core (wet floor or coolant odor in vehicle)
Degas bottle
Coolant crossover
Auxiliary coolant flow pump
Inoperative or damaged:
Wiring, connectors,
relays or modules

Cylinder Head
Temperature (CHT)
sensor

Cracked or damaged:
Hoses
Tubes
Hose clamps
Thermostat housing
Radiator
Pressure relief cap
Cooling fan
Coolant pump
Degas bottle
Auxiliary coolant flow pump

Excessive white or light gray exhaust smoke (may have burnt
coolant odor)

Coolant in engine oil
Engine oil in coolant
If the inspection reveals an obvious concern that can be readily identified, repair it as necessary. Test
7.
8.
Engine Cooling 2368
Engine Coolanse the same type of coolant that was originally used to fill the cooling system. Do
not mix coolant types. Mixing coolant types degrades the coolant corrosion protection and may
damage the engine or cooling system.
system. The addition of stop-leak style pellets/products can clog or damage the cooling system,
NOTE: NOTE: During normal vehicle operation, Motorcraft Specialty Orange Engine Coolant may
change color from orange to pink or light red. As long as the engine coolant is clear and
uncontaminated, this color change does not indicate the engine coolant has degraded nor does it
require the engine coolant to be drained, the system to be flushed, or the engine coolant to be
replaced.
Inspect the coolant condition in the following sequence:
Inspect the coolant color.
If the coolant has a clear or pale green color, this indicates higher water content than
required. Test the engine coolant freezing point range with the Coolant/Battery
Refractometer. The freezing point should be in the range -50C to -26C (-58F to
-15F). If the vehicle is driven in cold climates less than -37C (-34F), it may be
necessary to increase the coolant concentration to get adequate freeze protection.

Discoloration of Motorcraft Specialty Orange Engine Coolant may indicate that
incorrect coolant may have been added to the system. Use of incorrect (green or
yellow) coolant degrades the corrosion protectioncraft Specialty Orange Engine
Coolant. Addition of Motorcraft Specialty Green Engine Coolant may cause the
color to appear to be a murky green-brown color. The addition of Motorcraft
Premium Gold Engine Coolant, however, may not change the color or appearance of
the orange colored coolant. Detection of contamination with Motorcraft Premium
Gold Engine Coolant is determined by the presence of nitrite. If contamination with
Motorcraft Premium Gold Engine Coolant is suspected, test the coolant with the
3-Way HD Antifreeze Coolant Test Kit. Follow the directions in the kit with regard
to nitrite testing. If nitrite is present, flush the system and refill with the correct
mixture of Motorcraft Specialty Orange Engine Coolant and distilled water. Refer

A darker color with the presence of debris could indicate a commercially available
stop-leak may have been used and could result in loss of coolant flow the critical
parts of the engine. If sediment is present in the coolant sample, flush the system and
refill with the correct mixture of distilled water and the correct engine coolant. Refer

A light or reddish brown color or reddish brown particles indicate that rust may be
present in the cooling system. Flush the system and refill with the corrxture of
distilled water and the correct engine coolant. Refer to Cooling System Flushing in
this section.

An iridescent sheen on top of the coolant could indicate a trace of oil is entering the
system. For information on engine diagnosis, refer to Section 303-00 .

A milky brown color may indicate that engine oil is entering the cooling system.
Pressure test the cooling system. Refer to Component Tests in this section. If engine

1.
Engine Cooling 2369
oil is suspected, the cause of the leak may be internal to the engine. Refer to Section
303-00 . Flush the cooling system. Refer to Cooling System Flushing in this section.
If the engine coolant appearance is acceptable, test the engine coolant freezing point range
with the Coolant/Battery Refractometer. The freezing point should be in the range -50C to
-26C (-58F to -15F). If the vehicle is driven in cold climates less than -37C (-34F), it
may be necessary to increase the coolant concentration to get adequate freeze protection.
2.
Adjust coolant range and level if necessary:
If coolant is low, add specified coolant mixture only.
If the engine coolant tests too weak, remove some of the engine coolant and add
undiluted engine coolant until the readings are within acceptable levels.

If the engine coolant tests strong, remove some of the engine coolant and add distilled
water until the readings are within acceptable levels.

3.
If an obvious cause for an observed or reported concern is found, correct the cause and test the system
for normal operation before proceeding to the next step.
9.
10.
If the scan tool does not communiith the VCM :
11.
12.
418-00 .

13.
Clear the continuous DTCs and carry out the self-test diagnostics PCM. 14.
If the DTCs recovered are related to the concern, go to the PCM DTC Chart. For all other PCM
DTCs, refer to Section 303-14D .
15.
If no PCM DTCs related to the concern are retrieved, GO to Symptom Chart . 16.
DTC Chart
PCM DTC Chart
Engine Cooling 2370
P0125 Insufficient Coolant Temp For Closed Loop
Fuel Control
P0128 Coolant Thermostat (Coolant Temp Below
Thermostat Regulating Temperature)
P0217 Engine Coolant Overtemperature Condition GO to Pinpoint Test B .
P0480
P0481
P0482
Fan 1, 2 or 3 Control Circuit, Respectively REFER to the Powertrain Control/Emissions
P1285 Cylinder Head Overtemperature Condition GO to Pinpoint Test B .
P1299 Cylinder Head Overtemperature Protection
Active
All Other
PCM DTCs
- REFER to Section 303-14D .
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test A: Loss of Coolant
Normal Operation
The engine cooling system is a closed system providing for coolant expansion and contraction and also
changes in pressure as coolant warms and cools with engine operation. Various gaskets, seals, hoses and
clamps contain coolant within the cooling system and keep other fluids and contaminants from entering the
cooling system.
Coolant loss can be attributed to either external or internal leaks anywhere within the cooling system.
section.
Coolant hoses or tubes
Hose clamps
Thermostat housing gasket
Coolant pump O-ring seal
Thermostat housing
Radiator
Pressure relief cap
Coolant pump leaking from weep hole
Heater core
Engine gaskets
Degas bottle
PINPOINT TEST A: LOSS OF COOLANT
A1 CARRY OUT INSPECTION AND VERIFICATION
Carry out the Inspection and Verification procedure in
this section.

Yes
REPAIR as needed. TEST the system
No
GO to A2 .
A2 CHECK THE ENGINE COOLANT LEVEL
NOTE: Allow the engine to cool before checking the
engine coolant level.
Ignition OFF.
Visually inspect the engine coolant level at the degas
bottle.

Is the engine coolant level within specifications?
Yes
GO to A3 .
No
ADJUST the engine coolant level as
necessary. GO to A3 .
A3 PRESSURE TEST THE ENGINE COOLING SYSTEM
Pressure test the engine cooling system. Refer to
Component Tests, Cooling System Pressure Test in this
section.

Does the engine cooling system leak externally?
Yes
REPAIR or INSTALL new
components. TEST the system for
normal operation.
No
GO to A4 .
A4 CHECK THE ENGINE COOLANT FOR AN
INTERNAL LEAK
Inspect the engine coolant in the degas bottle for signs of
engine oil.

Is engine oil evident in the coolant?
Yes
If engine oil is evident, GO to Section
303-00 for engine diagnosis.
No
GO to A5 .
A5 CHECK THE ENGINE OIL FOR COOLANT
Remove the oil level indicator from the engine.
Is coolant evident in the oil?
Yes
If coolant is in the engine oil, GO to
Section 303-00 .
PINPOINT TEST A: LOSS OF COOLANT 2372
No
GO to A6 .
A6 CHECK THE COOLING SYSTEM FOR
COMBUSTION GASES
NOTE: Use UView Combustion Leak Tester, part No.

Using a cooling system combustion gas leak tester,
following the instructions supplied with the tester, check
the coolant for combustion gases.

Yes
GO to Section 303-00 for engine
diagnosis.
No
The cooling system is operational.
Pinpoint Test B: The Engine Overheats
Normal Operation
Engine coolant flows primarily from the engine to the radiator circuit and back to the coolant pump. Coolant
is sent from the coolant pump through the engine block and cylinder heads. A separate circuit from the engine
also feeds the heater core with coolant. The coolant pump, operated by engine rotation through a sprocket
driven by the timing chain, circulates the coolant. The coolant thermostat is a control valve actuated by
coolant temperature. When the thermostat is closed, coolant flow bypasses the radiator circuit and returns to
the coolant pump. When the thermostat is opened, coolant is allowed to flow through the radiator circuit in
order to transfer engine-generated heat to the outside air.
Engine overheating generally occurs when there is a disruption in the ability to control either coolant flow at
the correct rate, the inability to transfer heat from the engine through the coolant (including low coolant) or an
inability to transfer engine-generated heat to the outside air through the radiator.
section.
DTC P0217 (Engine Coolant Overtemperature Condition) - Indicates an engine overheat condition
was sensed by the Cylinder Head Temperature (CHT) sensor.

DTC P1285 (Cylinder Head Overtemperature Condition) - Indicates an engine overheat condition was
sensed by the CHT sensor.

DTC P1299 (Cylinder Head Overtemperature Protection Active) - Indicates an engine overheat
condition was detected by the CHT sensor. A failure mode effects management strategy called
fail-safe cooling was activated to cool the engine.

Low coolant level
External engine coolant leak
Airlock in system
Pressure relief cap installation
Internal engine coolant leak
Coolant condition/concentration
Accessory drive components
Non-OEM engine enhancement components
Heater core
Coolant pump
Coolant flow restriction
PINPOINT TEST B: THE ENGINE OVERHEATS
is under pr; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to
B1 CARRY OUT INSPECTION AND
VERIFICATION
Verification procedure in this
section.

Yes
REPAIR as needed. TEST the system for normal
operation.
No
GO to B2 .
B2 CHECK FOR DTCs
Check for DTC P0217, P1285 or
P1299.

Is DTC P0217, P1285 or P1299
present?

Yes
GO to B3 .
No
Actual engine overheating has not been verified. CHECK
the Engine Coolant Temperature (ECT) gauge operation.
REFER to Section 413-01 . If any other PCM DTCs are
retrieved, REFER to Section 303-14D .
B3 CHECK FOR AN AIRFLOW
OBSTRUCTION
Check the radiator or A/C condenser
for an external obstruction such as
leaves or cardboard.

Is an obstruction present?
Yes
REMOVE the obstruction. TEST the system for normal
operation.
No
GO to B4 .
B4 CHECK THE ENGINE COOLANT
LEVEL
before checking the coolant level.
Ignition OFF.
Visually check the engine coolant
level in the degas bottle.

Is the engine coolant level within
specification?

Yes
GO to B5 .
No
ADJUST the engine coolant level as necessary. GO to B5 .
B5 PRESSURE TEST THE ENGINE
COOLING SYSTEM
system. Refer to Component Tests,
Cooling System Pressure Test in this
section.

Does the engine cooling system
leak externally?

Yes
REPAIR or INSTALL new components. TEST the system
No
GO to B6 .
B6 CHECK THE ENGINE COOLANT
FOR AN INTERNAL LEAK
degas bottle for signs of engine oil.

Is engine oil evident in the
coolant?

Yes
diagnosis.
No
GO to B7 .
B7 CHECK THE ENGINE OIL FOR
COOLANT
Remove the oil level indicator from
the engine.

Is coolant evident in the oil?
Yes
If coolant is in the engine oil, GO to Section 303-00 .
No
GO to B8 .
B8 CHECK THE COOLING SYSTEM
FOR COMBUSTION GASES
NOTE: Use UView Combustion
Leak Tester, part No.

Using a cooling system combustion
gas leak tester, following the
instructions supplied with the tester,
check the coolant for combustion
gases.

Yes
No
GO to B9 .
B9 CHECK COOLANT CONDITION
Check the coolant for dirt, rust or
contamination and check the coolant
concentration.

Is the coolant condition OK?
Yes
GO to B10 .
No
FLUSH the engine cooling system. REFER to Cooling
System Flushing in this section. TEST the system for
normal operation.
B10 CHECK THE ELECTRIC
COOLING FAN OPERATION
Start the engine.
Place the climate control function
selector in the MAX A/C position
and the blower motor switch in the
HI position.

Yes
GO to B11 .
No
DIAGNOSE the electric cooling fan operation. REFER to
Did the electric cooling fan
operate?

B11 CHECK THE COOLANT PUMP
OPERATION
Start the engine.
minutes. Place the climate control
function selector in the MAX HEAT
position. Feel the heater outlet hose.

Is the heater outlet hose hot?
Yes
GO to B12 .
No
INSTALL a new coolant pump. TEST the system for
normal operation.
B12 CHECK THE THERMOSTAT
OPERATION
Start the engine.
minutes. Feel the lower radiator
hose.

Is the lower radiator hose hot?
Yes
CHECK the engine coolant temperature gauge operation.
No
GO to B13 .
B13 VISUALLY INSPECT THE
THERMOSTAT
Carry out the Thermostat Visual
Inspection in the Component Tests

Is the thermostat damaged?
Yes
operation.
No
operation. If the engine still overheats, INSTALL a new
radiator. TEST the system for normal operation.
Pinpoint Test C: The Engine Does Not Reach Normal Operating Temperature
Normal Operation
coolant pump, coolant is sent through the engine block and cylinder heads. A separate circuit from the engine
also feeds the heater core with coolant. The coolant pump, operated by engine rotation through a sprocket
which is driven by the timing chain, circulates the coolant. The coolant thermostat is a control valve actuated
by coolant temperature. When the thermostat is closed, coolant flow bypasses the radiator circuit and returns
to the coolant pump. When the thermostat is opened, coolant flows through the radiator circuit to transfer
engine generated heat to the outside air.
Concerns of engine inability to reach normal operating temperature typically occur when the rate of coolant
flow through some coolant circuits (radiator, heater core) is more than expected given the conditions, or when
the electric cooling fans operate all the time. Heat is not allowed to build in the engine because a heat
exchanger is removing too much heat, including the radiator, heater core and oil cooler. In addition, perceived
concerns that the engine does not reach normal operating temperature can be related to a low coolant level or
trapped air which does not allow for hot coolant to be available at the heater core, an inoperative climate
control system, or for concerns perceived or related to an incorrect engine temperature gauge indication.
section.
DTC P0125 (Insufficient Coolant Temp for Closed Loop Fuel Control) - Indicates the Cylinder Head
Temperature (CHT) sensor has not achieved the required temperature level to enter closed loop
operating conditions within a specified amount of time after starting the engine.

DTC P0128 (Coolant Thermostat [Coolant Temp Below Thermostat Regulating Temperature]) -
Indicates that the thermostat monitor has not achieved the required engine operating temperature
within a specified amount of time after starting the engine.

This pinpoint test is intended to diagnthe following:
Low coolant level
Thermostat
Engine cooling fan
PINPOINT TEST C: THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE
C1 CARRY OUT
INSPECTION AND
VERIFICATION
Carry out the
Inspection and
Verification
procedure in this
section.

Were any
concerns found?

Yes
No
GO to C2 .
C2 CHECK FOR DTC
P0125 or P0128
Check for DTC
P0125 or P0128.

Is DTC P0125 or
P0128 present?

Yes
GO to C3 .
No
The cooling system is operational. If an inoperative engine coolant
temperature gauge is suspected, CHECK the engine coolant temperature
gauge operation. REFER to Section 413-01 . If an inoperative climate
control system is suspected, CHECK the climate control system operation.
REFER to Section 412-00B . If any other PCM DTCs are retrieved, REFER
to Section 303-14D .
C3 CHECK THE
ELECTRIC COOLING
FAN OPERATION
Allow the engine
to cool.

Make sure the A/C
switch is OFF.

Start the engine.
Check the electric
cooling fan.

Is the electric
cooling fan on all
the time?

Yes
DIAGNOSE the electric cooling fan operation. REFER to the Powertrain
No
GO to C4 .
C4 CHECK THE
COOLANT LEVEL
NOTE: Allow the
engine to cool
before checking
the coolant level.

Visually check the
engine coolant
level in the degas
bottle.

Is the engine
coolant level
within
specification?

Yes
INSTALL a new thermostat. TEST the system for normal operation.
No
GO to Pinpoint Test A to diagnose a coolant leak.
Component Tests
Cooling System Pressure Test
NOTICE: The engine cooling system is filled with Motorcraft Specialty Green Engine Coolant. Do not
mix coolant types. Mixing coolant types degrades the corrosion protection of the coolant. Failure to
follow these instructions may result in engine or cooling system damage.
NOTICE: Genuine Motorcraft Specialty Green Engine Coolant is very sensitive to light. Do NOT
allow this product to be exposed to ANY LIGHT for more than a day or two. Extended light exposure
Turn the engine OFF. 1.
Check the engine coolant level. Adjust the coolant level as necessary. 2.
Attach the D-Gas Adapter to the degas bottle nipple and overflow hose. Install the Radiator Tester to
the quick connect fitting of the D-Gas Adapter.
3.
NOTICE: Do not pressurize the cooling system beyond the maximum pressure listed in the
specifications table in this section or cooling system components may be damaged.
NOTE: If the plunger of the pressure tester is pressed too fast, an erroneous pressure reading will
sult.
Slowly press the plunger of the pressure test pump until the pressure gauge reading stops increasing
and note the highest pressure reading obtained. If the pressure reading exceeds the maximum cap
pressure listed in the specifications table, install a new pressure relief cap.
4.
If the system does not hold pressure, remove the pressure relief cap and wash in clean water to
dislodge all the foreign material from the gasket. Check the sealing surface in the filler neck of the
degas bottle for nicks or cuts. Install the pressure relief cap.
5.
Pressurize the engine cooling system as described in Step 4. Observe the gauge reading for
approximately 2 minutes. Pressure should not drop during this time. If the pressure drops within this
time, inspect for leaks and repair as necessary.
6.
If no leaks are found and the pressure drops, the pressure relief cap may be leaking. Install a new
pressure relief cap and retest the system.
7.
If no leaks are found after a new pressure relief cap is installed and the pressure drops, the leak may
be internal to the radiator transmission cooler (if equipped). Inspect the coolant for transmission fluid
and the transmission fluid for coolant. Repair as necessary.
8.
If there is no contamination of the coolant or transmission fluid, the leak may be internal to the
engine. Inspect the coolant for engine oil and the engine oil for coolant. Refer to Section 303-00 to
diagnose the engine.
9.
Release the system pressure by loosening the pressure relief cap. Check the coolant level and adjust as
necessary.
10.
Thermostat
A new thermostat should be installed only after the following tests and checks have been carried out:
Pinpoint Test A, B or C
Remove the thermostat. 1.
Examine the thermostat for signs of damage including:
Valve not fully seated (light visible through the valve)
Foreign material lodged in the main valve
Bent or broken frame or flange
Bent or broken spring
Bent or broken valve or valve stem
Wax leaking from wax reservoir or a bulge in the reservoir
Any other damage or distortion
2.
NOTE: If no damage is found during the inspection, do not attempt to open the thermostat using hot
water or other heat sources. This method is not an accurate means to test the function of the
thermostat and may damage the thermostat.
If damage is found during the inspection, remove any foreign material or broken pieces and install a
new thermostat.
3.
If no damage is found during the inspection, continue troubleshooting the system concern. Go to the
Symptom Chart for further instructions.
4.
Radiator Leak Test, Removed From Vehicle
NOTICE: Never leak test an aluminum radiator in the same water that copper/brass radiators are
tested in. Flux and caustic cleaners may be present in the cleaning tank and they will damage aluminum
radiators.
NOTE: 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 tank.
Leak test the radiator in clean water with air pressurized to the maximum pressure listed in the Specifications.
Hybrid
Manual
Cooling System Draining, Filling and Bleeding
Special Tool(s)
Airlift Cooling System Tester
UVU550000 or equivalent
Material
Item Specification
Engine Coolant
VC-10-A2 (US); CVC-10-A
(Canada)
WSS-M97B55-A
Engine Coolant
WSS-M97B44-D
Draining
100-02 .
1.
injury.
NOTICE: The coolant must be recovered in a suitable, clean container for reuse. If the coolant
is contaminated it must be recycled or disposed of correctly. Using contaminated coolant may
result in damage to the engine or cooling system components.
instructions may damage t engine or cooling system.
2.
system. The addition of stop-leak style pellets/products may clog or damage the cooling system,
NOTE: Less than 80% of coolant capacity can be recovered with the engine in the vehicle. Dirty,
rusty or contaminated coolant requires replacement.
Place a suitable container below the radiator draincock.
Open the draincock and allow to drain.
Close the draincock after draining.
3.
Filling and Bleeding with a Vacuum Cooling System Filler
Motorcraft Specialty Orange Engine Coolant. Always fill the cooling system with the


Do not add alcohol, methanol, or brine, or any engine coolants mixed with alcohol or
methanol antifreeze. These can cause engine damage from overheating or freezing.

Ford Motor Company does NOT recommend the use of recycled engine coolant in vehicles
available.

resulting in degraded cooling system performance and/failure.
cooling system.
1.
(-58F).


(-15F).



Filling and Bleeding without a Vacuum Cooling System Filler
cooling system.
product to degrade.
NOTICE: Engine coolant provides boil protection, corrosion protection, freeze protection, and cooling
efficiency to the engine and cooling components. In order to obtain these protections, maintain the
engine coolant at the correct concentration and fluid level in the degas bottle.
Add Motorcraft Specialty Green Engine Coolant or Motorcraft Specialty Orange Engine Coolant.
Use the same type of coolant that was originally used to fill the cooling system. Do not mix coolant
types.

Do not add or mix with any other type of engine coolant. Mixing coolants may degrade the coolant's
corrosion protection.

Do not add alcohol, methanol, or brine, or any engine coolants mixed with alcohol ohanol antifreeze.
These can cause engine damage from overheating or freezing.

Ford Motor Company does NOT recommend the use of recycled engine coolant in vehicles originally
equipped with Motorcraft Specialty Green Engine Coolant or Motorcraft Specialty Orange Engine

Coolant since a Ford-approved recycling process is not yet available.
The addition of stop-leak style pellets/products can clog or damage the cooling system resulting in
Remove the degas bottle cap and the bleed valve on the top of the engine coolant outlet. 1.
NOTE: Make sure the coolant flows from the radiator through the upper radiator hose and fills the
engine. When full, coolant should flow from the bleed hole.
Fill the degas bottle to the COLD FILL RANGE line.
(-58F).

Engine coolant concentration above 60eases the overheat protection characteristics of
the engine coolant and may damage the engine.

(-15F).



2.
Install the degas bottle cap and the bleed valve leaving both loose. 3.
Start the engine and let it idle A mixture of air and coolant should escape from the open bleed valve. 4.
After all of the air has escaped from the bleed valve turn off the engine and close the bleed valve and
the degas bottle cap.
5.
NOTICE: If the engine overheats or the fluid level drops below the minimum fill line, shut off the
engine and add fluid to the degas bottle to the cold fill range line once the engine cools. Failure to follow
these instructions may result in damage to the engine.
Start the engine and let it idle for 30 minutes or until the engine reaches normal operating
temperature.
6.
Turn the heater to the MAX position 7.
Carry out the following:
Increase the engine speed to 3,000 rpm for 10 seconds. 1.
Idle engine for 50 seconds.
8.
Repeat Steps 1 and 2 a total of 15 times. 3.
injury.
Check the engine coolant level in degas bottle and fill as necessary.
9.
Hybrid
Manual
Cooling System Flushing
Material
Item Specification
System Flush
VC-1
ESR-M14P7-A
NOTE: To remove rust, sludge and other foreign material from the cooling system, use cooling system flush
that is safe for use with aluminum radiators. For additional information, refer to Specifications in this section.
This cleaning restores cooling system efficiency and helps prevent overheating. A pulsating or reversed
direction of flushing water will loosen sediment more quickly than a steady flow in the normal coolant flow
direction. In severe cases where cleaning solvents will not clean the cooling system efficiently, it will be
necessary to use the pressure flushing method using cooling system flusher. Dispose of old coolant and
flushing water contaminated with antifreeze and cleaning chemicals in accordance with local, state or federal
laws.
Add Premium Cooling System Flu the cooling system and follow the directions on the package. 1.
Remove the radiator. For additional information, refer to Radiator in this section. 2.
NOTICE: Radiator internal pressure must not exceed 138 kPa (20 psi). Damage to the radiator
can result.
Backflush the radiator with the radiator in an upside-down position and a high-pressure hose in the
lower hose location.
3.
NOTE: Thermostat and housing are serviced as an assembly.
Remove the thermostat housing. For additional information, refer to Thermostat Housing in this
section.
4.
Position a high-pressure water hose into the engine through the upper radiator hose and backflush the
engine.
5.
Hybrid
Manual
Block Heater
Item
Part
Number Description
1 - Block heater electrical connector heat shield (part of
6B018)
100-02 .
1.
2.
Position the block heater heat shield aside. 4.
Remove the block heater heat shield. 5.
NOTICE: 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.
6.
Block Heater 2389
Remove the block heater.
7.
9.
Block Heater 2390
Hybrid
Manual
Thermostat Housing
1 14A464 Knock Sensor (KS) electrical connector (part of
12C508)
2 14A624 KS electrical connector pin-type retainer (part of
12C508)
9 8K530 Gasket
NOTE: The thermostat and thermostat housing are serviced as an assembly.
100-02 .
1.
2.
Remove the accessory drive belt tensioner. For additional information, refer to Section 303-05D . 3.
Disconnect the Knock Sensor (KS) electrical connector and detach the wiring harness pin-type
retainer.
4.
NOTE: Disconnecting the heater hose first will aid in the removal of the bottom thermostat housing
bolt.
Disconnect the heater hose at the thermostat housing.
5.
Thermostat Housing 2391
NOTE: The view of the thermostat housing bolts is obstructed by A/C and engine components.
However, the bolts can be removed using 1/4-in drive hand tools.
Remove the 3 bolts and reposition the thermostat housing to gain access to the lower radiator hose
clamp.
6.
Disconnect the lower radiator hose at the thermostat housing. 7.
8.
9.
Thermostat Housing 2392
Hybrid
Manual
Bypass Tube
1 W525958 Hose clamp (2 required)
2 8548 Bypass tube
With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to . 1.
2.
Remove the intake manifold. For additional information, refer to Section 303-01D . 3.
Disconnect the 2 hose clamps and remove the coolant bypass tube. 4.
6.
Bypass Tube 2393
Bypass Tube 2394
Hybrid
Manual
Coolant Pump
Material
Item Specification
Engine Coolant
VC-10-A2 (US); CVC-10-A
(Canada)
WSS-M97B55-A
Engine Coolant
WSS-M97B44-D
Degas Bottle
Coolant Pump
Coolant Pump 2395
3 W500015 Coolant pump bolt (3 required)
4 8501 Coolant pump
5 8507 Coolant pump O-ring seal
100-02 .
1.
2.
Remove the nut, bolt and position the degas bottle for access to the lower degas bottle hose.
4.
Disconnect the lower degas bottle hose and remove the degas bottle. 5.
Loosen the 3 coolant pump pulley bolts. 6.
Remove the 3 bolts and the coolant pump pulley.
8.
9.
10.
Coolant Pump 2396
t product to be exposed to ANY LIGHT for more than a day or two. Extended light exposure
Lubricate the O-ring seal with clean engine coolant.
11.
Coolant Pump 2397
Hybrid
Manual
Cooling Fan Motor and Shroud
Cooling Fan and Shroud (View 1 of 2)
Item
Part
Number Description
Cooling Fan and Shroud (View 2 of 2)
1 13A506 Wiring harness retainers
Cooling Fan Motor and Shroud 2398
3 - Lower radiator hose pin-type retainer
4 W500214 Auxiliary relay box bolts
5 14A464 Auxiliary relay box
6 14A464 Cooling fan motor electrical connector
100-02 .
1.
Detach the lower radiator hose pin-type retainer from the cooling fan motor and shroud. 4.
Remove the 2 bolts and position the auxiliary relay box aside.
6.
Detach all the wiring harness retainers from the cooling fan and shroud. 7.
Disconnect the cooling fan electrical connector. 9.
10.
Cooling Fan and Shroud (View 2 of 2) 2399
Cooling Fan and Shroud (View 2 of 2) 2400
Hybrid
Manual
Radiator
3 W527351 Radiator-to-degas bottle hose clamp
7 19710 A/C condenser-to-radiator pin-type reta
Radiator 2401
4 8A194 RH upper radiator support bracket
5 W505422 A/C tubes retainer bolt
7 8005 Radiator
1.
and Shroud in this section.
2.
Disconnect the radiator-to-degas bottle hose from the radiator. 4.
Remove the A/C tubes retainer bolt.
6.
Remove the 2 bolts from the upper radiator support brackets and position the radiator towards the
engine and remove the 2 upper radiator support bracket from the radiator.
7.
9.
11.
Hybrid
Manual
Degas Bottle
injury.
1.
Using hose clamp pliers, clamp the lower degas bottle hose. 2.
Using a suction device, siphon the coolant from the degas bottle. 3.
Remove the nut, bolt and position the degas bottle for access to the lower degas bottle hose.
5.
Disconnect the lower radiator hose and remove the degas bottle. 6.
Degas Bottle 2404
Fill the degas bottle. For additional information, refer to Cooling System Draining, Filling and
8.
Degas Bottle 2405
SECTION 303-04A: Fuel Charging and Controls -
2.5L
Workshop Manual
Material
Capacity
Synthetic Blend Motor Oil
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada);
or equivalent
WSS-M2C930-A -
Fuel rail stud bolts 23 17 -
Throttle Body (TB) bolts 10 - 89
Degas Bottle 2406
2.5L
Workshop Manual
Fuel Charging and Controls
The fuel charging and controls system consists of the:
Throttle Body (TB).
fuel injectors.
Fuel Pump (FP) control module.
fuel rail.
The fuel charging and controls system is:
a Sequential Multi-Port Fuel Injection (SFI) system.
Pulse Width Modulated (PWM).
Mass Air Flow (MAF) controlled.
Fuel is metered into each intake port in a sequential firing order. Fuel injectors pulse to follow engine firing
order in accordance with engine demand on a tuned intake manifold.
The basic fuel requirement of the engine is determined from the data supplied to the PCM by the MAF sensor,
which measures the amount of air being drawn into the engine.
Other sensors are used to measure:
air temperature.
engine coolant temperature.
engine speed.
exhaust oxygen content.
The various sensors detect any changes in the operating conditions and send signals to the PCM. This permits
the PCM to control the opening duration (pulse width) of the fuel injectors and maintain optimum exhaust
emission control and engine performance for all operating conditions.
Throttle Body (TB)
The TB :
controls air supply to the upper intake manifold by electronically positioning the throttle plate.
is not adjustable.
cannot be cleaned.
is serviced as a complete assembly only.
Fuel Injectors
The fuel injectors:
Fuel Charging and Controls 2407
are electronically operated by the PCM.
atomize the fuel as the fuel is delivered.
each have an internal solenoid that opens a needle valve, which injects fuel into the intake port in the
cylinder head.

are deposit resistant.
Fuel Rail
The fuel rail:
receives fuel from the fuel supply tube.
delivers fuel to the fuel injectors.
Fuel Pump (FP) Control Module
The FP control module:
is electronically operated by the PCM.
controls voltage (10 or 12 volts) to the FP module depending on load.
2.5L
Workshop Manual
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
SECTION 303-04A: Fuel Charging and
Controls - 2.5L
Workshop Manual
Throttle Body
2 9E836 Throttle Body (TB) gasket
3 9E926 TB
4 W500305 TB bolt (4 required)
5 14A464 Elonic throttle control electrical connector
Remove the 4 bolts and the Throttle Body (TB).
Discard the TB gasket.
3.
NOTE: Install a new TB gasket.
4.
Throttle Body 2410
Throttle Body 2411
Controls - 2.5L
Workshop Manual
Fuel Rail and Fuel Injector - Exploded View
Fuel Rail
Item
Part
Number Description
1 W705790 Radio capacitor nut
2 18801 Radio capacitor
3 W711061 Fuel rail stud bolt (2 required)
4
d>9H487
Fuel rail
5 - Wire harness pin-type retainer (part of 12B637) (2
required)
6 - Fuel supply tube-to-fuel rail quick connect
coupling (part of 9288)
Fuel Injectors
Fuel Rail and Fuel Injector - Exploded View 2412
1 9H487 Fuel rail
2 9U509 Fuel injector O-ring seals (2 required per injector)
3 9C995 Fuel injector clip (4 required)
4 14A464 Fuel injector electrical connector (4 required)
Fuel Injectors 2413
Controls - 2.5L
Workshop Manual
Fuel Rail
Material
Item Specification
or equivalent
WSS-M2C930-A
Removal
on or near any fuel-related component. Highly flammable mixtures are always present and may gnited.
personal injury.
Disconnect the fuel tube-to-fuel rail quick connect coupling. For additional information, refer to
Section 310-00 .
3.
Detach the 2 wire harness pin-type retainers from the fuel rail. 4.
Disconnect the 4 fuel injector electrical connectors. 5.
Remove the nut and position the radio capacitor aside. 6.
Remove the 2 fuel rail stud bolts. 7.
Remove the fuel rail and fuel injectors as an assembly. 8.
Remove the 4 fuel injector retainer clips and the fuel injectors. 9.
Fuel Rail 2414
Remove and discard the 8 fuel injector O-ring seals.
Installation
O-ring seals 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.
NOTE: Make sure the fuel rail retainer clips snap back into place.
Install the 4 fuel injectors and the retainer clips into the fuel rail.
1.
Install the fuel rail and fuel injectors as an assembly. 2.
Install the 2 fuel rail stud bolts.
3.
Position the radio capacitor and install the nut.
4.
Connect the 4 fuel injector electrical connectors. 5.
Connect the fuel tube-to-fuel rail quick connect coupling. For additional information, refer to Section
310-00 .
7.
Fuel Rail 2415
Controls - 2.5L
Workshop Manual
Fuel Injectors
The fuel injectors are serviced with the fuel rail. For additional information, refer to Fuel Rail and
Fuel Injector - Exploded View and Fuel Rail in this section.
1.
Fuel Injectors 2416
Controls - 2.5L
Workshop Manual
Fuel Pump Control Module
1 14A464 Fuel Pump (FP) control module electrical connector
2 W707373 FP control module pin-type retainer (2 required)
3 9345 FP control module
Position aside the LR quarter panel luggage compartment trim. 1.
Disconnect the Fuel Pump (FP) control module electrical connector. 2.
Remove the 2 pin-type retainers and the FP control module. 3.
Fuel Pump Control Module 2417
SECTION 303-04B: Fuel Charging and Controls - 3.0L
(4V)
Material
Capacity
XO-5W20-QSP (US);
Premium Motor Oil
CXO-5W20-LSP12 (Canada); or
equivalent
WSS-M2C930-A -
Fuel rail bolts 10 89
10 89
SECTION 303-04B: Fuel Charging and Controls
- 3.0L (4V)
Workshop Manual
Throttle Body (TB).
fuel injectors.
fuel rail.
aimperature.
engine speed.
Throttle Body (TB)
The TB :
is not adjustable.
cannot be cleaned.
Fuel Injectors
The fuel injectors:
cylinder head.

Fuel Rail
The fuel rail:
has a Schrader valve on early build vehicles.
SECTION 303-04B: Fuel Charging and Controls -
3.0L (4V)
- 3.0L (4V)
Workshop Manual
Throttle Body
2 14A464 Electronic throttle control electrical connector
4 9E926 TB
3.
4.
Throttle Body 2423
Throttle Body 2424
- 3.0L (4V)
Workshop Manual
Fuel Rail
Item
Part
Number Description
1 - Fuel charging wiring harness
pin-type retainer (part of
9D930) (5 required)
2 - Engine wiring harness
pin-type retainer (part of
12A581)
3 9F792 Fuel rail
4 - Fuel rail Schrader valve (part
of 9F792)
5 - Fuel injector electrical
connector (part of 9D930) (6
required)
6 W503275 Fuel rail bolt
(4 required)
7 9J285 Fuel jumper tube
8 - Fuel jumper tube-to-fuel rail
quick connect coupling (part
of 9J285)
Fuel Injector
Item
Part
Number Description
1 9229 Upper fuel injector O-ring seal (6 required)
3 - Fuel injector electrical connector (part of 14B485) (6
required)
5 9229 Lower fuel injector seal (6 required)
6 9F792 Fuel rail
Fuel Injector 2426
- 3.0L (4V)
Workshop Manual
Fuel Rail
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
Removal
personal injury.
Remove the upper intake manifold. For additional information, refer to Section 303-01B . 3.
Section 310-00 .
4.
Release the 5 fuel charging wire harness pin-type retainers from the fuel rail. 5.
Release the engine wire harness pin-type retainer from the fuel rail. 6.
Remove the 4 fuel rail bolts. 8.
Remove the fuel rail and injectors as an assembly. 9.
Fuel Rail 2427
Remove the 6 fuel injector clips and the 6 fuel injectors.
10.
Installation
Install the 6 fuel injectors and the 6 fuel injector clips into the fuel rail.
1.
Install the 4 fuel rail bolts.
3.
Attach the engine wire harness pin-retainer to the fuel rail. 5.
Attach the 5 fuel charging wire harness pin-retainers to the fuel rail. 6.
310-00 .
7.
Install the upper intake manifold. For additional information, refer to Section 303-01B . 8.
Fuel Rail 2428
SECTION 303-04B: Fuel Charging and Controls - 3.0L
(4V)
REMOVAL AND INALLATION Procedure revision date: 06/03/2011
Fuel Injectors
1.
Fuel Injectors 2429
- 3.0L (4V)
Workshop Manual
SECTION 303-04C: Fuel Charging and Controls -
3.5L
Workshop Manual
Material
Capacity
or equivalent
WSS-M2C930-A -
Nm lb-in
Fuel rail bolts 10 89
Throttle Body (TB) bolts 10 89
SECTION 303-04C: Fuel Charging and Controls -
3.5L
Workshop Manual
Throttle Body (TB).
fuel injectors.
fuel rail.
Fuel is metered into each intake port isequential firing order. Fuel injectors pulse to follow engine firing order,
in accordance with engine demand, on a tuned intake manifold.
Throttle Body (TB)
The TB :
controls air supply to the intake manifold by electronically positioning the throttle plate.
is not adjustable.
Fuel Injectors
The fuel injectors:
cylinder head.

Fuel Rail
The fuel rail:
SECTION 303-04C: Fuel Charging and
Controls - 3.5L
Workshop Manual
Controls - 3.5L
Workshop Manual
Throttle Body
Item
Part
Number Description
1 14A464 Electronic throttle control electrical connector (part of
12B637)
2 W503285 Throttle Body (TB) bolt (4 required)
3 9E926 TB
4 9E936 TB gasket
3.
4.
Throttle Body 2436
Throttle Body 2437
Controls - 3.5L
Workshop Manual
Item
Part
Number Description
1 9J285 Fuel tube-to-fuel rail spring lock coupling
2 14A464 Fuel injector electrical connector (6 required) (part of
12B637)
3 W503279 Fuel rail bolt (4 required)
4 9F792 Fuel rail
5 9N976
7 9229 Upper fuel injector O-ring seal (6 required)
8 9229 Lower fuel injector O-ring seal (6 required)
Controls - 3.5L
Workshop Manual
Fuel Rail
Material
Item Specification
or equivalent
WSS-M2C930-A
Removal
on or near any fuel-related component. Highly flammable mixtures are always present and may bnited.
personal injury.
Remove the upper intake manifold. For additional information, refer to Section 303-01C . 3.
Disconnect the fuel tube-to-fuel rail spring lock coupling. For additional information, refer to Section
310-00 .
4.
Remove the 4 fuel rail bolts. 6.
Remove the fuel rail and injectors as an assembly. 7.
Remove the 6 fuel injector clips and the 6 fuel injectors.
8.
Fuel Rail 2440
Installation
NOTE: The upper and lower fuel injector O-ring seals are similar in appearance, but are not
interchangeable.
Install the 6 fuel injectors and the 6 fuel injector clips into the fuel rail.
1.
Install the 4 fuel rail bolts.
3.
Connect the fuel tube-to-fuel rail spring lock coupling. For additional information, refer to Section
310-00 .
5.
Install the upper intake manifold. For additional information, refer to Section 303-01C . 6.
Fuel Rail 2441
Controls - 3.5L
Workshop Manual
Fuel Injectors
1.
Fuel Injectors 2442
SECTION 303-04D: Fuel Charging and Controls -
Hybrid
Material
Capacity
or equivalent
WSS-M2C930-A -
Fuel rail stud bolts 23 17 -
Throttle Body (TB) bolts 10 - 89
Fuel Injectors 2443
SECTION 303-04D: Fuel Charging and
Controls - Hybrid
Workshop Manual
Throttle Body (TB).
fuel injectors.
fuel rail.
air temperature.
engine speed.
Throttle Body (TB)
The TB :
is not adjustable.
cannot be cleaned.
Fuel Injectors
The fuel injectors:
cylinder head.

Fuel Rail
The fuel rail:
Controls - Hybrid
Workshop Manual
Controls - Hybrid
Workshop Manual
Throttle Body
3 9E926 TB
5 14A464
Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Section 303-12D . 1.
3.
4.
Throttle Body 2447
Throttle Body 2448
Controls - Hybrid
Workshop Manual
Fuel Rail
Item
Part
Number Description
1 W705790 Radio capacitor nut
2 18801 Radio capacitor
3 W711061 Fuel rail stud bolt (2 required)
9H487 Fuel rail
5 - Wire harness pin-type retainer (part of 12B637) (2
required)
6 - Fuel supply tube-to-fuel rail quick connect coupling
(part of 9288)
Fuel Injectors
1 9H487 Fuel rail
2 9U509 Fuel injector O-ring seals (2 required per injector)
4 14A464 Fuel injector electrical connector (4 required)
Fuel Injectors 2450
Controls - Hybrid
Workshop Manual
Fuel Rail
Material
Item Specification
or equivalent
WSS-M2C930-A
Removal
on or near any fuel-related component. Highly flammable mixtures are always present and be ignited.
personal injury.
Section 310-00 .
3.
Detach the 2 wire harness pin-type retainers from the fuel rail. 4.
Remove the nut and position the radio capacitor aside. 6.
Remove the 2 fuel rail stud bolts. 7.
Remove the fuel rail and fuel injectors as an assembly. 8.
Remove the 4 fuel injector retainer clips and the fuel injectors. 9.
Fuel Rail 2451
Installation
NOTE: Make sure the fuel rail retainer clips snap back into place.
Install the 4 fuel injectors and the retainer clips into the fuel rail.
1.
Install the 2 fuel rail stud bolts.
3.
Position the radio capacitor and install the nut.
4.
310-00 .
7.
Fuel Rail 2452
Controls - Hybrid
Workshop Manual
REMOVAL AND INSTALLAON Procedure revision date: 06/03/2011
Fuel Injectors
1.
Fuel Injectors 2453
Controls - Hybrid
Workshop Manual
SECTION 303-05A: Accessory Drive - 2.5L
Workshop Manual
Item Specification
Accessory drive belt 6 ribs
Accessory drive belt idler pulley and bracket bolts 25 18
Accessory drive belt tensioner bolts 25 18
Accessory drive belt idler pulley bolt 25 18
p;
Workshop Manual
Accessory Drive
The accessory drive:
has a single serpentine drive belt with 6 ribs.
has automatic tensioning.
is not adjustable.
The accessory drive system provides power to operate components which power other systems. These could
include components such as the generator, power steering pump and A/C compressor. Each of these
components is equipped with a pulley which is driven by the accessory drive belt. The accessory drive belt is
driven by the engine crankshaft pulley. One or more idler pulleys may be provided to facilitate belt routing
and alignment. The automatic belt tensioner maintains correct belt tension and compensates for component
wear and changes in system load. System load changes can be caused by the A/C compressor clutch engaging
or disengaging, or demand changes on other systems powered by the accessory drive belt. To maintain correct
operation of this system, it is critical that the correct length drive belt be installed. The pulleys must also be
correctly aligned and kept clean.
Accessoryve Belt Routing
1 19D784 A/C compressor pulley
3 6A228 Belt tensioner
4 10300 Generator pulley
5 8678 Idler pulley
6 8678 Idler pulley
8 8620 Accessory drive belt
Belt Tensioner
NOTE: The accessory drive belt tensioner must be replaced as a complete unit.
Accessory Drive 2457
Automatic tensioners are calibrated to provide the correct amount of tension to the belt for a given accessory
drive system. Unless a spring or damping band within the tensioner assembly breaks, or some other
mechanical part of the tensioner fails, there is no need to check the tensioner for correct tension.
Workshop Manual
Accessory Drive
NOTICE: Under no circumstances should the accessory drive belt, tensioner or pulls have any fluids or
belt dressing applied to them as damage to the belt material and tensioner damping mechanism may
occur.
Visually inspect for obvious signs of mechanical damage. 2.
Mechanical
Drive belt cracking/chunking/wear
Belt/pulley contamination
Incorrect accessory drive belt
Incorrectly routed accessory drive belt
Pulley misalignment or excessive pulley
runout

Loose or mislocated hardware
Incorrectly routed power steering tubes
(rubbing)

Loose accessory drive belt
Damaged pulleys
Tensioner arm misalignment
Belt Tensioner With Belt Length Indicator
NOTE: Belt tensioner is shown in the free-state position against the arm travel stops.
NOTE: 6.2L engine accessory drive belt tensioner shown, other accessory drive belt tensioners similar.
Item Description
1 Belt length indicator
2 Acceptable belt installation and wear range
3 Belt replacement range
4 Belt tension relief point
Check that the belt length indicator, if equipped, on the belt tensioner is in the acceptable belt
installation and wear range. If the indicator is in the belt replacement range, either an incorrect belt is
installed or the belt is worn beyond the service limit. Install a new belt as necessary.
3.
Eliminate all other non-belt related noises that could cause belt misdiagnosis, such as A/C compressor
engagement chirp, A/C slugging noise, power steering cavitations at low temperatures, Variable
Camshaft Timing (VCT) tick or generator whine.
4.
If a concern is found, correct the condition before proceeding to the next step. 5.
V-Ribbed Serpentine Drive Belt With Cracks Across Ribs
Check the belt for cracks. Up to 15 cracks in a rib over a distance of 100 mm (4.0 in) can be
considered acceptable. If cracks exceed this standard, install a new belt.
6.
V-Ribbed Serpentine Belt With Piling
NOTE: Piling is an excessive buildup in the V-grooves of the belt.
Belt Tensioner With Belt Length Indicator 2460
The condition of the V-ribbed drive belt should be compared against the illustration and appropriate
action taken.
Small scattered deposits of rubber material. This is not a concern, therefore, installation of a
new belt is not required.
1.
Longer deposit areas building up to 50% of the rib height. This is not considered a durability
concern, but it can result in excessive noise. If noise is apparent, install a new belt.
2.
Heavy deposits building up along the grooves resulting in a possible noise and belt stability
concern. If heavy deposits are apparent, install a new belt.
3.
7.
V-Ribbed Serpentine Belt With Chunks of Rib Missing
There should be no chunks missing from the belt ribs. If the belt shows any evidence of this, install a
new accessory drive belt.
8.
If the concern is not visually evident, verify the symptom and GO to Symptom Chart . 9.
Symptom Chart
Symptom Chart
Component Tests
Drive Belt - Noise/Flutter
NOTICE: Under no circumstances should the accessory drive belt, tensioner or pulleys have any fluids
or belt dressing applied to them as damage to the belt material and tensioner damping mechanism may
occur.
V-Ribbed Serpentine Belt With Piling 2461
Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a
damaged or incorrectly aligned grooved pulley.
To correct, determine the area where the noise comes from. Chec of the pulleys in that area with a
straightedge to the crankshaft pulley. Look for accessory pulleys out of position in the fore/aft direction or at
an angle to the straightedge.
Drive belt squeal may be an intermittent or constant noise that occurs when the drive belt slips on an
accessory pulley under certain conditions.
A short intermittent squeal may occur during engine start up and shut down or during very rapid engine
acceleration and decelerations, such as:
Wide Open Throttle (WOT) 1-2 and 2-3 shifts or 2-3 and 3-4 back-out shifts on automatic
transmissions.

WOT 1-2 and 2-3 shifts and any combination of rapid downshifting on manual transmissions.
These special short-term transient events are expected, and are due to the higher system inertias required to
meet the electrical and cooling demands on today's vehicle systems. Constant or reoccurring drive belt squeal
can occur:
if the A/C discharge pressure goes above specifications:
the A/C system is overcharged.
the A/C condenser core airflow is blocked.
the A/C anti-slugging strategy executes after a long hot heat soak.

if the A/C off equalized pressure (the common discharged and suction pressure that occurs after
several minutes) exceeds specifications.

if any of the accessories or idler pulley(s) are damaged or have a worn or damaged bearing. All
accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory.

if there is evidence of fluid contamination on the accessory drive belt. When the drive belt has been
exposed to fluid contamination during vehicle operation, such as leaks from the power steering
system, A/C system or cooling system, clean all pulleys with soap and water, rinse with clean water
and install a new accessory drive belt. If the drive belt has been exposed to fluids in a localized area
during routine vehicle service, such as replacement of hoses or fluids, the drive belt and pulleys
should be washed with soap and water immediately (prior to starting the engine), and rinsed with
clean water.

if the accessory drive belt is too long. A drive belt that is too long will allow the accessory drive belt
tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release
tension to the drive belt. If the accessory drive belt tensioner indicator is outside the normal
installation wear range window, install a new accessory drive belt.

NOTE: The accessory drive belt tensioner arm should rotate freely without binding.
Install a new accessory drive belt tensioner if the drive belt tensioner is worn or damaged.

Drive Belt - Incorrect Installation
NOTICE: Incorrect accessory drive belt installation will cause excessive drive belt wear and may cause
the drive belt to come off the pulleys.
Non-standard accessory drive belts can track differently or incorrectly. If an accessory drive belt tracks
incorrectly, install a new accessory drive belt to avoid performance failure or loss of the drive belt.
V-Ribbed Serpentine Belt With Chunks of Rib Missing 2462
Incorrect Installation
Correct Installation
With the engine running, check accessory drive belt tracking on all pulleys. If the edge of the accessory drive
belt rides beyond the edge of the pulleys, noise and premature wear will occur. Make sure the accessory drive
belt rides correctly on the pulley. If an accessory drive belt tracking condition exists, proceed with the
following:
Visually check the accessory drive belt tensioner for damage and wear, especially the mounting pad
surface and arm alignment. If the accessory drive belt tensioner is not installed correctly, the
mounting surface pad will be out of position. If the tensioner arm is worn, the arm will be out of
alignment. Either of these conditions will result in chirp and squeal noises.

With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the
pulley forward faces) for excessive wobble. Install new components as necessary.

Check all accessories, mounting brackets and the accessory drive belt tensioner for any interference
that would prevent the component from mounting correctly. Correct any interference condition and
recheck the accessory drive belt tracking.

Tighten all accessories, mounting brackets and accessory drive belt tensioner retaining hardware to
specification. Recheck the accessory drive belt tracking.

Belt Tensioner - Mechanical
The only mechanical check that needs to be made is a check for tensioner stick, grab or bind.
With the engine off, check routing of the accessory drive belt. Refer to the illustrations under
Accessory Drive in the Description and Operation portion of this section.
1.
NOTE: The accessory drive belt tensioner spring is very strong and requires substantial force to
release.
Release the tension on the belt and detach the accessory drive belt from the tensioner. Carry out the
following tests:
Move the tensioner from its relaxed position, through its full stroke and back to the relaxed
position to make sure there is no stick, grab or bind, and to make sure that there is tension on
the tensioner spring.

2.
Incorrect Installation 2463
Rotate the tensioner pulley by hand and check for a binding, contaminated or seized
condition.

Inspect the area surrounding the accessory drive belt tensioner for oil leaks or contamination
and repair any leaks.

If the accessory drive belt tensioner does not meet the criteria in the previous step, install a new
tensioner. If the accessory drive belt tensioner meets the criteria in the previous step, proceed to
testing the tensioner dynamically.
3.
If the tensioner is saturated with oil and grease internally, install a new tensioner. 4.
Belt Tensioner - Dynamics
The accessory drive belt tensioner can be checked dynamically as follows:
With the engine running, observe the accessory drive belt tensioner movement. The accessory drive
tensioner should move (respond) when the A/C clutch cycles (if equipped), or when the engine is
accelerated rapidly. If the accessory drive belt tensioner movement is excessive without A/C clutch
cycling or engine acceleration, check belt rideout. Excessive belt rideout (uneven depth of grooves in
the belt) can cause excessive accessory drive belt tensioner movement. Check rideout condition by
installing a new belt. If excessive accessory drive belt tensioner mement still exists, install a new
accessory drive belt tensioner.
1.
Correct Installation 2464
SECTION 303-05A: Accessory Drive -
2.5L
Manual
Front End Accessory Drive (FEAD) - Exploded View
Item
Part
Number Description
1 N807389 Pin-type retainer (6 required)
2 010204 RH splash shield
6 19A216 Accessory drive belt idler pulley (smooth)
7 W500225
Accessory drive belt idler pulley and bracket bolt (2
required)
8 19A216 Accessory drive belt idler pulley (grooved) and bracket
Front End Accessory Drive (FEAD) - Exploded View 2465
2.5L
Manual
Accessory Drive Belt
100-02 .
1.
drive belt from the coolant pump pulley.
Remove the accessory drive belt from the engine.
4.
Accessory Drive Belt 2467
2.5L
Manual
Accessory Drive Belt Tensioner
100-02 .
1.
drive belt from the coolant pump pulley.
4.
Remove the 2 bolts and the accessory drive belt tensioner.
5.
Accessory Drive Belt Tensioner 2468
2.5L
Manual
Accessory Drive Belt Idler Pulley
All idler pulleys
100-02 .
1.
Using the hex feature, rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt
from the idler pulley.
Smooth idler pulley
Loosen the bolt and remove the accessory drive belt idler pulley.
5.
Grooved idler pulley
NOTE: The grooved accessory drive belt idler pulley and bracket must be replaced as a complete
unit.
Remove the 2 bolts and the grooved accessory drive belt idler pulley and bracket.
6.
Accessory Drive Belt Idler Pulley 2470
SECTION 303-05B: Accessory Drive - 3.0L (4V)
Workshop Manual
Item Specification
Coolant pump belt 3 ribs
SECTION 303-05B: Accessory Drive - 3.0L
(4V)
Workshop Manual
Accessory Drive
has an automatic drive belt tensioner.
has a V-ribbed coolant pump belt.
driven by the engine crankshaft pulley. One or more idler pulleys may be provided to facilitate belt routing
and alignment. The automatic belt tensioner maintains correct belt tension and compensates for component
wear and changes in system load. System load changes can be caused by the A/C compressor clutch engaging
or disengaging, or demand changes on other systpowered by the accessory drive belt. To maintain correct
operation of this system, it is critical that the correct length drive belt be installed. The pulleys must also be
correctly aligned and kept clean.
Accessory Drive Belt Routing
3 19D784 A/C clutch pulley
Coolant Pump Drive Belt
1 6A359 Camshaft drive pulley
2 8620 Coolant pump drive belt
3 8A528 Coolant pump pulley
Belt Tensioner
Coolant Pump Drive Belt 2474
SECTION 303-05B: Accessory Drive -
3.0L (4V)
Workshop Manual
Accessory Drive
NOTICE: Under no circumstances should the accessory drive belt, tension or pulleys have any fluids or
occur.
Mechanical
runout

(rubbing)

Damaged pulleys
Item Description
3.
4.
6.
action taken.
1.
2.
3.
7.
8.
Symptom Chart
Symptom Chart
Component Tests
occur.
To correct, determine the area where the noise comes Check each of the pulleys in that area with a
transmissions.

can occur:



clean water.



following:




1.
release.
following tests:

2.
condition.


3.
installing a new belt. If excessive accessory drive belt tsioner movement still exists, install a new
1.
(4V)
Workshop Manual
(4V)
Workshop Manual
100-02 .
1.
(4V)
Workshop Manual
100-02 .
1.
Rotate the accessory drive belt tensioner counterclockwise and position the accessory drive belt off of
the accessory drive belt tensioner.
4.
5.
(4V)
Workshop Manual
Coolant Pump Belt
Special Tool(s)
303-1419
1 8620 Coolant pump belt
Ral
100-02 .
1.
Coolant Pump Belt 2485
Position the Stretchy Belt Remover under the coolant pump belt as shown. 4.
NOTE: Feed the Stretchy Belt Remover on to the camshaft coolant pump pulley approximately 90
degrees.
With the help of an assistant, turn the crankshaft clockwise and feed the Stretchy Belt Remover
evenly on the camshaft coolant pump pulley as shown.
5.
Remove the coolant pump belt.
Fold the Stretchy Belt Remover over the top of the coolant pump belt.
In one quick motion, pull the Stretchy Belt Remover up and toward the RH front of the
vehicle removing the coolant pump belt.

6.
Installation
Install the coolant pump belt on the coolant pump pulley and position it on the camshaft pulley. 1.
NOTICE: Do not use any screwdrivers, pliers or other metal objects that could cause damage to
the belt or camshaft pulley while installing the belt.
Rotate the crankshaft clockwise to seat the coolant pump belt on the camshaft pulley.
2.
SECTION 303-05C: Accessory Drive - 3.5L
Workshop Manual
Item Specification
Power steering pump drive belt (if equipped) 4 ribs
SECTION 303-05C: Accessory Drive -
3.5L
Manual
Accessory Drive
This vehicle is equipped with the following components:
V-ribbed serpentine accessory drive belt
Automatic drive belt tensioner
V-ribbed power steering pump drive belt
driven by the engine crankshaft pulley. The automatic belt tensioner maintains correct belt tension and
compensates for component wear and changes in system load. System load changes can be caused by the A/C
compressor clutch engaging or disengaging or demand changes on other systems powered by the accessory
drive belt. To maintain correct operation of this system, it is critical that the correct length drive belt be
installed. The pulleys must also be correctly aligned and kept clean.
Front End Accessory Drive (FEAD) Belt
1 6B209 Accessory drive belt tensioner pulley
3 19D784 A/C clutch pulley
Power Steering Pump Belt
1 6C301 Power steering pump drive belt
3 3D639 Power steering pump pulley
Belt Tensioner
drive system. Unless a spring or damping band within the tensioner assembly breaks or some other
Power Steering Pump Belt 2490
3.5L
Manual
Accessory Drive
occur.
Mechanical
runout

(rubbing)

Damaged pulleys
NOTE: Modular engine (without A/C) btensioner shown, others similar.
1 - Belt length indicator
2 - Acceptable belt installation and wear range
3 - Belt replacement range
4 - Belt tension relief point
3.
engagement chirp, A/C slugging noise, power steering cavitations at low temperatures or generator
whine.
4.
6.
action taken.
1.
2.
3.
7.
8.
Symptom Chart
Symptom Chart
Component Tests
occur.
To correct, determine the area where the noise comes from. Check each of the pulleys in that area with a
transmissions.

can occur:
the A/C condenser core airfw is blocked.



clean water.



Non-standard accessory drive belts can track differently or incorrectly. If an accessory dri belt tracks
following:




1.
release.
Using a suitable, commercially available serpentine belt tensioner release tool, release the tension on
the belt and detach the accessory drive belt from the tensioner. Carry out the following tests:
Using the release tool, move the tensioner from its relaxed position, through its full stroke and
back to the relaxed position to make sure there is no stick, grab or bind, and to make sure that
there is tension on the tensioner spring.

2.
condition.


3.
If the tensioner is saturated with oil and grease internally, install a new tensioner.
installing a new belt. If excessive accessory drive belt tensioner movement still exists, install a new
1.
3.5L
Manual
1 N807389 Pin-type retainer (6 required)
2 010204 RH splash shield
6 6C301 Power steering pump drive belt
sp;
3.5L
Manual
Removal
NOTICE: Under no circumstances should the accessory drive belt, tensioner or pulleys be lubricated as
potential damage to the belt material and tensioner damping mechanism will occur. Do not apply any
fluids or belt dressing to the accessory drive belt or pulleys.
100-02 .
1.
Working from the top of the vehicle, rotate the accessory drive belt tensioner clockwise and remove
the accessory drive belt from the generator pulley.
2.
Working from under the vehicle, remove the accessory drive belt. 5.
Installation
Working from under the vehicle, position the accessory drive belt on all pulleys, with the exception of
the generator pulley.
1.
NOTE: After installation, make sure the accessory drive belt is correctly seated on all pulleys.
Working from the top of the vehicle, rotate the accessory drive belt tensioner clockwise and install the
accessory drive belt on the generator pulley.
2.
3.5L
Manual
Removal
100-02 .
1.
2.
Remove 3 bolts and the accessory drive belt tensioner. 5.
Installation
1.
2.
3.5L
Manual
Power Steering Pump Belt
Special Tool(s)
303-1419
Tool, Stretchy Belt Installer
303-1252/2
Removal
NOTICE: Under no circumstances should the accessory drive belt, tensioner or pulleys be lubricated as
potential damage to the belt material and tensioner damping mechanism will occur. Do not apply any
fluids or belt dressing to the accessory drive belt or pulleys.
100-02 .
1.
2.
Position the accessory drive belt off the crankshaft pulley. 5.
Position the Stretchy Belt Remover on the power steering pump pulley belt as shown. 6.
NOTE: Feed the Stretchy Belt Remover onto the power steering pump pulley approximately 90
degrees.
7.
Turn the crankshaft clockwise and feed the Stretchy Belt Remover evenly on the power steering pump
pulley as shown.
Remove the power steering pump belt.
Fold the Stretchy Belt Remover under the inside of the power steering pump belt as shown.
In one quick motion, firmly pull the Stretchy Belt Remover out of the RH fender well,
removing the power steering pump belt.

8.
Installation
Install the power steering belt on the crankshaft pulley. 1.
NOTE: After installation, make sure the belt is correctly seated on the crankshaft and power steering
pulleys.
Position the power steering belt around the Stretchy Belt Installer Tool and the power steering pulley.
Make sure the belt is engaged with the power steering pulley and rotate the crankshaft clockwise to
install the power steering belt.
2.
Position the accessory drive belt on the crankshaft pulley. 3.
4.
SECTION 303-05D: Accessory Drive - Hybrid
Workshop Manual
A/C hose retainer bracket bolt 6 - 53
Workshop Manual
Accessory Drive
has automatic tensioning.
is not adjustable.
The accessory drive system provides power to operate components which power other systems. The accessory
drive system provides power to operate the coolant pump. The coolant pump is equipped with a pulley which
is driven by the accessory drive belt. The accessory drive belt is driven by the engine crankshaft pulley. The
automatic belt tensioner maintains correct belt tension and compensates for component wear and changes in
system load. System load changes can be caused by the demand changes on other systems powered by the
accessory drive belt. To maintain correct operation of this system, it is critical that the correct length drive belt
be installed. The pulleys must also be properly aligned and kept clean.
3 6A228 Belt tensioner
Belt Tensioner
Workshop Manual
Accessory Drive
NOTICE: Under no circumstances should the accessory drive belt, tensioner or lleys have any fluids or
occur.
Mechanical
runout

(rubbing)

Damaged pulleys
Item Description
3.
4.
6.
action taken.
1.
2.
3.
7.
8.
Symptom Chart
Symptom Chart
Component Tests
occur.
To correct, determine the area where the noise comes from. each of the pulleys in that area with a straightedge
to the crankshaft pulley. Look for accessory pulleys out of position in the fore/aft direction or at an angle to
the straightedge.
transmissions.

can occur:



clean water.



following:




1.
release.
following tests:

2.
condition.


3.
installing a new belt. If excessive accessory drive belt tension movement still exists, install a new
1.
SECTION 303-05D: Accessory Drive -
Hybrid
Manual
1 W503924 A/C hose retainer bracket bolt
2 - Vehicle high voltage electrical system
5 6C301 Accessory drive belt
For additional information,the procedures in this section. 1.
Hybrid
Manual
100-02 .
1.
Remove the A/C hose retainer bracket bolt.
4.
Hybrid
Manual
414-03 .
1.
NOTE: RH front wheel and tire are removed for clarity.
Remove the 6 pin-type retainers and the RH splash shi
3.
Remove the A/C hose retainer bracket bolt.
4.
Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt from
the tensioner pulley.
5.
Disconnect the 2 vehicle high voltage electrical system electrical connectors. 6.
Detach the vehicle high voltage electrical system electrical connector retainer from the accessory
drive belt tensioner.
7.
8.
SECTION 303-06: Starting System
Manual
Item Specification
Normal engine cranking speed 200-250 rpm
Starting circuit maximum voltage drop (engine at normal operating temperature) 0.5 volt
Starter motor maximum load current draw 800 amps
Starter motor no-load current draw 60-80 amps
Starter motor normal load current draw 130-190 amps
Ground wire nut - 2.5L 18 - 159
Ground wire nut - 3.0L 18 - 159
Starter motor bolt and stud bolt (2.5L) 25 18 -
Starter motor bolts (3.5L) 27 20 -
Starter motor solenoid battery cable nut 12 - 106
Starter motor solenoid wire nut 5 - 44
Starter motor stud bolts (3.0L) 27 20 -
Manual
Starting System
The starting system consists of the following components:
Starter motor
Starter motor relay
Transmission Range (TR) sensor - automatic transmission
Clutch cutoff switch - manual transmission
Battery
Ignition switch
PCM
Start diode
When the key is placed in the START position, the starter relay is energized and this sends current to the
starter motor, and the drive pinion gear cranks the flexplate/flywheel to start the engine. When current flows
to the starter motor, the starter solenoid pull-in coil is bypassed and the hold-in coil keeps the drive pinion
gear engaged with the flywheel until the ignition switch is released from the START position.
An overrunning clutch in the starter drive protects the starter motor from excessive speeds during the brief
period before the driver releases the ignition switch from the START position as the engine starts.
Vehicles equipped with an automatic transmission have a TR sensor mounted in the transaxle. The TR sensor
prevents operation of the starter motor unless NEUTRAL or PARK is selected.
Vehicles equipped with a manual transaxle have a clutch cutoff switch mounted on the clutch pedal bracket.
The clutch cutoff switch prevents operation of the starter motor unless the clutch is fully depressed.
One-Touch Integrated Start (OTIS)
The vehicle has One-Touch Integrated Start (OTIS), a computer-assisted cranking system. This feature assists
in starting the engine. If the ignition key is turned to the START position and released when the engine begins
cranking, the engine may continue cranking for up to 10 seconds or until the vehicle starts.
Once the ignition is turned to the START position and the vehicle is in NEUTRAL or PARK or the clutch p is
depressed, the PCM reads starter motor request from the ignition switch and gains control of the starter
engagement. The customer is no longer in the loop after the initial crank request, the customer may release the
key to the RUN/START position. The PCM will disengage the starter motor based on the following events:
The engine is started (rpm threshold)
A set time has been exceeded (calibrated)
The ignition key has been turned to the OFF position
Starting System 2520
Manual
Starting System
Special Tool(s)
Flex Probe Kit
105-R025D or equivalent
Hybrid
For hybrid starting system diagnostics, refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Starting System - Anti-Theft Intervention
The starting system is electronically controlled by the Passive Anti-Theft System (PATS). The PATS
recognizes the correct electronically coded ignition key and signals the PCM to provide a ground for the
starter relay. The energized relay provides voltage to the starter solenoid with the key in the START position,
thereby allowing the starter motor to activate.
personal injury.
NOTE: The anti-theft system must be functioning correctly before a logical starting system diagnosis can be
carried out. Address anti-theft system concerns before continuing. Refer to Section 419-01B .
Verify the customer concern by operating the starting system to duplicate the conditions. 1.
Remove the accessory drive belt. Refer to Section 303-05A for 2.3L engines, Section 303-05B for
3.0L (4V) or Section 303-05C for 3.5L engines. Verify the crankshaft and each of the components
driven by the accessory drive belt rotate and are not seized or damaged.
2.
Inspect to determine if any of the following mechanical or electrical concerns apply. 3.
Starter
motor

Starter
motor
bolts

Flexplate
Flywheel
Battery
(30A)

(20A)

Wiring harness
Starter motor relay
Anti-theft system
4.
5.
6.
7.
418-00 .

(CMDTCs).

8.
Clear the continuous DTCs and carry out the self-test diagnostics for the PCM. 9.
If the DTCs retrieved are related to the concern, refer to the PCM DTC Chart. For all other DTCs,
10.
DTC Chart
PCM DTC Chart
P0512 Starter Request Circuit -
Circuit has Power With the
Ignition in the OFF Position
CARRY OUT the Ignition Switch Component Test. Refer to Wiring
Diagrams Cell 149 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ) for
component testing. If necessary, INSTALL a new ignition switch. If
the ignition switch passed the component test, REPAIR circuit
CDC35 (BU/WH) for a short to power.
P0706 TR Sensor A Circuit
Range/Performance
P0707 TR Sensor A Circuit Low Refer to the appropriate section in Group 307 for the procedure.
P0708 TR Sensor A Circuit High Refer to the appropriate section in Group 307 for the procedure.
P0830 Clutch Pedal Switch A Circuit REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual.
P0833 Clutch Pedal Switch B Circuit REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual.
P1260 Theft Detected, Vehicle
Immobilized
REFER to DTC Chart in Section 419-01B .
Symptom Chart
NOTE: For hybrid starting system diagnostics, refer to the Powertrain Control/Emissions Diagnosis (PC/ED)
manual.
Symptom Chart
Pinpoint Tests
Pinpoint Test A: The Engine Does Not Crank
Refer to Wiring Diagrams Cell 20 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Starting System for
Normal Operation
Under normal operation, constant power is supplied to the starter relay on circuit SBB05 (GY/RD), the starter
on circuit SBB02 (RD) and to the ignition switch on circuit SBP27 (BU/RD). When the key is placed in the
START position, with the vehicle in PARK or NEUTRAL or with the clutch pedal depressed, power flows to
the starter motor relay through CE336 (GN/WH). Inputs from the Transmission Range (TR) sensor and clutch
cutoff switch to the PCM provide a ground to the starter relay on circuit CDC12 (YE). When the coil of the
relay is energized, it sends power to the starter motor on circuit CDC25 (BN/GN).
Battery
Fuse(s)
Ignition switch
Starter motor relay
PCM
TR sensor
Clutch cutoff switch
Circuitry
Start diode
Anti-theft system
PINPOINT TEST A: THE ENGINE DOES NOT CRANK
A1 CHECK THE BATTERY
Check the battery condition and charge. Refer
to Section 414-01 .

Is the battery OK?
Yes
GO to A2 .
No
CHARGE or INSTALL a new battery as
necessary. REFER to Section 414-01 . TEST the
A2 CHECK THE PCM FOR DTCs
Check for PCM DTCs.
Were any PCM DTCs retrieved?
Yes
If PCM DTC P1260 is retrieved, REFER to
Section 419-01B . All other PCM DTCs,
REFER to Powertrain Control/Emissions
No
For automatic transmission, GO to A3 . For
manual transmission, GO to A4 .
A3 CHECK THE AUTOMATIC TR SENSOR
scan tool: TCM DataLogger PID.

While observing the Transmission Control
Module (TCM) TR sensor PID, place the
vehicle in PARK and NEUTRAL.

Does the PID match the gear selection?
Yes
GO to A5 .
No
GO to the appropriate automatic transmission
section to diagnose the TR sensor.
A4 CHECK THE CLUTCH CUTOFF SWITCH
(CPP_ BOT) PID
scan tool: DataLogger - PCM.

While observing the CPP_ BOT PID, fully
disengage the clutch.

Does the PID change from NO to YES?
Yes
GO to A5 .
No
GO to A28 .
A5 CHECK THE STARTER MOTOR
CONTROL OUTPUT DETECTED (SMC_MON)
PID

NOTE: For manual transaxle, fully disengage
the clutch.

Yes
GO to A6 .
No
GO to A13 .
PINPOINT TEST A: THE ENGINE DOES NOT CRANK 2525
Monitor the PCM PID SMC_MON with the
ignition switch in the START position.

Does the PID change from OFF to ON?
A6 CHECK THE STARTER MOTOR RELAY
ENABLE (STRT_RLY) PID

the clutch.

Monitor the PCM PID STRT_RLY with the

Does the PID change from DISABLED to
ENABLED?

Yes
GO to A7 .
No
GO to A24 .
A7 CHECK STARTER MOTOR RELAY
POWER
NOTICE: Use the correct probe adapter(s)
when making measurements. Failure to use
the correct probe adapter(s) may damage
the connector.
Disconnect: Starter Motor Relay.
Measure the voltage between Battery Junction
Box (BJB) starter motor relay pin 30, circuit
SBB05 (GY/RD), harness side and ground.

Yes
GO to A8 .
No
VERIFY BJB fuse 5 (30A) is OK. If OK,
REPAIR circuit SBB05 (GY/RD). TEST the
system for normal operation. If not OK, REFER
to the Wiring Diagrams manual to identify the
A8 CHECK THE BATTERY GROUND CABLE
Measure the voltage between the positive
battery post and the battery ground cable
connection at the engine.

Yes
GO to A9 .
No
INSTALL a new battery ground cable. REFER
operation.
A9 CHECK THE STARTER MOTOR GROUND
Measure the voltage between the positive
battery post and the starter motor case.

Yes
GO to A10 .
No
CLEAN the starter motor mounting flange and
make sure the starter motor is correctly
mounted. TEST the system for normal
operation.
A10 CHECK THE POWER SUPPLY TO THE
STARTER MOTOR
Measure the voltage between starter motor
C197A, circuit SDC02 (RD) and ground.

Yes
GO to A11 .
No
INSTALL a new positive battery cable. REFER
operation.
A11 CHECK THE STARTER MOTOR B-PIN
Connect one end of a fused (30A) jumper wire
to starter motor solenoid 197A, circuit SDC02
(RD). Momentarily connect the other end of
the jumper to starter motor C197B, circuit
CDC25 (BN/GN).

Yes
GO to A12 .
No
INSTALL a new starter motor. REFER to
Starter Motor - 2.5L , Starter Motor - 3.0L or
Starter Motor - 3.5L in this section. TEST the
Did the starter motor engage and the engine
crank?

A12 CHECK THE CIRCUIT TO THE STARTER
MOTOR
the connector.
Ignition OFF.
Disconnect: Starter Motor Solenoid C197B.
Measure the resistance between starter motor
solenoid S-terminal C197B, circuit CDC25
(BN/GN), harness side and the BJB starter
motor relay pin 87, circuit CDC25 (BN/GN),
harness side.

Yes
INSTALL a new starter motor relay. TEST the
No
REPAIR circuit CDC25 (BN/GN). TEST the
POWER
Yes
GO to A14 .
No
VERIFY BJB fuse 5 (30A) is OK. If OK, REPAIR
circuit SBB05 (GY/RD). TEST the system for normal
operation. If not OK, REFER to the Wiring Diagrams
manual to identify the possible causes of the circuit
short.
Carry out the Starter Motor Relay Component
Test.

Did the starter motor relay pass the
component test?

Yes
GO to A15 .
No
A15 CHECK THE START DIODE
Disconnect: Start Diode.
Check the start diode for an open or shorted
condition.

Is the start diode OK?
Yes
GO to A16 .
No
INSTALL a new start diode. TEST the system
A16 CHECK THE START SIGNAL TO THE
STARTER MOTOR RELAY
Connect: Start Diode.
the clutch.

Measure the voltage between the BJB starter
motor relay pin 86, circuit CE336 (GN/WH),
harness side and ground with the ignition
switch in the START position.

Yes
For 2.5L and 3.0L vehicles, GO to A20 . For
3.5L vehicles, GO to A22 .
No
GO to A17 .
A17 CHECK CIRCUIT CE336 (GN/WH) FOR AN
OPEN BETWEEN START DIODE AND
STARTER RELAY
Measure the resistance between the start diode,
circuit CE336 (GN/WH), harness side and BJB
starter motor relay pin 86, circuit CE336
(GN/WH), harness side.

Yes
GO to A18 .
No
REPAIR circuit CE336 (GN/WH) for an open.
A18 CHECK CIRCUIT SBP27 (BU/RD) FOR
VOLTAGE
Connect: Starter Motor Relay.
Disconnect: Ignition Switch C250.
Measure the voltage between ignition switch
C250-4, circuit SBP27 (BU/RD), harness side
and ground.

Yes
GO to A19 .
No
VERIFY SJB fuse 27 (20 A) is OK. If OK,
REPAIR circuit SBP27 (BU/RD) for an open.
TEST the system for normal operation. If not
OK, REFER to the Wiring Diagrams manual to
identify the possible causes of the circuit short.
A19 CHECK THE IGNITION SWITCH
Carry out the Ignition Switch Component Test.

Did the ignition switch pass the component
test?

Yes
REPAIR circuit CDC35 (BU/WH) for an open.
No
INSTALL a new ignition switch. REFER to
operation.
A20 CHECK CIRCUIT CDC35 (BU/WH) FOR
AN OPEN
Measure the resistance between the start diode
cell, circuit CDC35 (BU/WH), harness side and
PCM C175B-16, circuit CDC35 (BU/WH),
harness side.

Yes
GO to A21 .
No
A21 CHECK THE CIRCUIT CE336 (GN/WH)
BETWEEN THE BJB AND THE PCM
Ignition OFF.
Measure the resistance between the BJB starter
harness side and PCM C175B-37, circuit
CE336 (GN/WH), harness side.

Yes
INSTALL a new PCM. REFER to Section
303-14A , Section 303-14B or Section 303-14C
No
REPAIR circuit CE336 (GN/WH). TEST the
A22 CHECK CIRCUIT CDC35 (BU/WH) FOR
AN OPEN
Measure the resistance between the start diode
cell, circuit CDC35 (BU/WH), harness side and
harness side.

Yes
GO to A23 .
No
A23 CHECK CIRCUIT CE336 (GN/WH)
Ignition OFF.

Yes
No
POWER
the connector.
Measure the voltage between BJB starter motor
relay pin 30, circuit SBB05 (GY/RD), harness
side and ground.

Yes
GO to A25 .
No
REPAIR circuit SBB05 (GY/RD). TEST the
system for normal operation. If not OK, REFER
to the Wiring Diagrams manual to identify the
Carry out the Starter Motor Relay Component
Test.

Did the starter motor relay pass the
component test?

Yes
For 2.5L and 3.0L vehicles, GO to A26 . For
3.5L vehicles, GO to A27 .
No
A26 CHECK CIRCUIT CDC12 (YE) FOR AN
OPEN
relay pin 85, circuit CDC12 (YE), harness side
and PCM C175B-7, circuit CDC12 (YE),
harness side.

Yes
No
REPAIR circuit CDC12 (YE). TEST the system
A27 CHECK CIRCUIT CDC12 (YE) FOR AN
OPEN
relay pin 85, circuit CDC12 (YE), harness side
and PCM C175B-34, circuit CDC12 (YE),
harness side.

Yes
No
A28 CHECK CIRCUIT GD120 (BK/GN) FOR AN
OPEN
Ignition OFF.
Disconnect: Clutch Cutoff Switch C2072.
Measure the resistance between clutch cutoff
switch C2072-2, circuit GD120 (BK/GN),

Yes
GO to A29 .
No
REPAIR circuit GD120 (BK/GN). TEST the
A29 CHECK CIRCUIT CE903 (BU/OG) FOR AN
OPEN
Ignition OFF.
Disconnect: PCM C175T.
switch C2072-1, circuit CE903 (BU/OG),
harness side and PCM C175T-26, circuit
CE903 (BU/OG), harness side.

Yes
GO to A30 .
No
REPAIR circuit CE903 (BU/OG). TEST the
A30 CHECK CPP SWITCH FOR AN OPEN
switch C2072-2 and C2072-1, component side,
fully disengage the clutch.

Yes
No
REPLACE the clutch cutoff switch. TEST the
Pinpoint Test B: One-Touch Integrated Start (OTIS) Does Not Operate Correctly
Refer to Wiring Diagrams Cell 20 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Starting System for
Normal Operation
When the ignition switch is turned to the START position and released, the PCM receives a starter motor
request signal through circuit CDC35 (BU/WH). With the vehicle in PARK or NEUTRAL or with the clutch
pedal depressed, power flows from the PCM to the starter motor relay through circuit CE336 (GN/WH). A
ground is supplied through circuit CDC12 (YE) from the PCM causing the starter motor relay coil to energize
and the relay contacts close. This allows power from starter motor relay through circuit CDC25 (BN/GN) to
the starter solenoid. The solenoid is grounded at the starter motor. Energizing the starter solenoid will engage
the starter drive into the ring gear and closes the solenoid contacts, allowing power directly from the battery
through circuit SDC02 (RD) to the starter motor to start the engine. The customer is no longer in the loop after
the initial crank request, the customer may release the key to the RUN/START position. The PCM will
disengage the starter motor based on engine running (rpm threshold), a set crank time has been exceeded or
the ignition switch has been turned to the OFF position.
Circuitry
PCM
PINPOINT TEST B: ONE-TOUCH INTEGRATED START (OTIS) DOES NOT OPERATE CORRECTLY
B1 CHECK THE STATUS OF OTIS
(OTS_STAT) PID

Monitor the PCM PID OTS_STAT with the
ignition switch in the RUN position.

Is the OTIS PID enabled?
Yes
GO to B2 .
No
ENABLE One-Touch Integrated Start (OTIS).
TEST the system for normal operation. If OTIS
will not enable, INSTALL a new PCM. REFER
to Section 303-14A , Section 303-14B or Section
303-14C . TEST the system for normal
operation.
B2 CHECK THE KEY POSITION FOR START
INDICATED (START_KEY) PID

the clutch.

Monitor the PCM PID START_KEY with the

Yes
GO to B5 .
No
For 2.5L and 3.0L vehicles, GO to B3 . For 3.5L
vehicles, GO to B4 .
B3 CHECK CIRCUIT CDC35 (BU/WH)
Measure the restance between start diode cell,
circuit CDC35 (BU/WH), harness side and
harness side.

Yes
303-14A , Section 303-14B or Section 303-14C .
No
REPAIR circuit CDC35 (BU/WH). TEST the
B4 CHECK CIRCUIT CDC35 (BU/WH)
Measure the resistance between start diode
cell, circuit CDC35 (BU/WH), harness side
and PCM C175B-10, circuit CDC35
(BU/WH), harness side.

Yes
No
REPAIR circuit CDC35 (BU/WH). TEST the
PINPOINT TEST B: ONE-TOUCH INTEGRATED START (OTIS) DOES NOT OPERATE CORRECTLY 2537
B5 CHECK THE STARTER MOTOR
CONTROL OUTPUT DETECTED (SMC_MON)
PID
scan tool: DataLogger -CM.

the clutch.

Monitor the PCM PID SMC_MON with the

Yes
GO to B8 .
No
For 2.5L and 3.0L vehicles, GO to B6 . For 3.5L
vehicles, GO to B7 .
B6 CHECK THE CIRCUIT CE336 (GN/WH)
Ignition OFF.
Measure the resistance between the Battery
Junction Box (BJB) starter motor relay pin 86,
circuit CE336 (GN/WH), harness side and
PCM C175B-37, circuit CE336 (GN/WH),
harness side.

Yes
No
B7 CHECK THE CIRCUIT CE336 (GN/WH)
Ignition OFF.

Yes
No
B8 CHECK THE STARTER MOTOR RELAY
ENABLE (STRT_RLY) PID

the clutch.

Monitor the PCM PID STRT_RLY with the

Does the PID change from DISABLED TO
ENABLED?

Yes
No
Pinpoint Test C: Unusual Starter Noise
Starter motor mounting
Starter motor mounting bolts
Starter motor drive
Flywheel or flexplate ring gear
Starter motor
PINPOINT TEST C: UNUSUAL STARTER NOISE
Test ep Result / Action to Take
C1 CHECK THE STARTER MOUNTING
Inspect the starter motor mounting bolts for
looseness.

Is the starter motor mounted correctly?
Yes
GO to C2 .
No
INSTALL the starter motor correctly. REFER to
Starter Motor - 2.5L , Starter Motor - 3.0L or
Starter Motor - 3.5L in this section. TEST the
C2 CHECK FOR ENGINE NOISE
Turn the ignition switch to the OFF position.
Connect a fused jumre from the B-terminal
to the S-terminal of the starter motor. Engage
the starter motor and verify that the noise is
due to the starter operation.

Is the noise due to the starter motor
engagement?

Yes
GO to C3 .
No
REFER to Section 303-00 to continue the
diagnosis.
C3 CHECK FOR UNUSUAL WEAR
Remove the starter motor. Refer to Starter
Motor - 2.5L , Starter Motor - 3.0L or Starter
Motor - 3.5L in this section.

Inspect the ring gear for damaged or worn
teeth.

Is the noise due to flexplate/flywheel ring
gear tooth damage?

Yes
INSTALL a new flexplate/flywheel ring gear.
EXAMINE the starter pinion teeth. If damaged,
INSTALL a new starter motor. REFER to Starter
Motor - 3.5L in this section. TEST the system for
normal operation.
No
INSTALL a new starter motor. REFER to Starter
Motor - 3.5L in this section. TEST the system for
normal operation.
Component Tests
personal injury.
Connect the Fluke 77-IV Digital Multimeter at the component terminal rather than at the wiring end
connector. Making a connection at the wiring end connector could result in false readings because the meter
will not pick up a high resistance between the wiring connector and the component.
Starter Motor - Motor Feed Circuit
Make sure the battery is fully charged. Carry out a battery load test. Refer to Section 414-01 . 1.
PINPOINT TEST C: UNUSUAL STARTER NOISE 2540
Connect a remote starter switch between the starter solenoid S-terminal and the battery positive (+)
terminal.
2.
Connect the Fluke 77-IV Digital Multimeter positive lead to the battery positive (+) post. Connect the
negative lead to the M-terminal.
3.
Engage the remote starter switch. Read and record the voltage. The voltage reading should be 0.8 volt
or less.
4.
If the voltage reading is 0.8 volt or less, go to the Starter Motor - Ground Circuit Component Test. 5.
If the voltage reading is greater than 0.8 volt, this is an indication of excessive resistance in the
connections, the positive battery cable or in the starter solenoid. Move the Fluke 77-IV Digital
Multimeter negative lead to the starter solenoid B-terminal and repeat the test. If the voltage reading
at the B-terminal is lower than 0.8 volt, the concern is either in the connections at the starter solenoid
or in the solenoid contacts.
6.
Remove the cables from solenoid B-, S- and M-terminals. Clean the cables and connections and
reinstall the cables to the correct terminals. Repeat Steps 3 through 6. If the voltage drop reading is
still greater than 0.8 volt when checked at the M-terminal and less than 0.8 volt when checked at the
B-terminal, the concern is in the solenoid contacts. Install a new starter motor. Refer to Starter Motor
- 2.5L , Starter Motor - 3.0L or Starter Motor - 3.5L in this section.
7.
If the voltage reading taken at the solenoid B-terminal is still greater than 0.8 volt after cleaning the
cables and the connections at the solenoid, the concern is either in the positive (+) battery cable
connection or in the positive battery cable itself. Clean the positive (+) battery cable connection. If
this does not solve the problem, install a new positive battery cable. Refer to Section 414-01 .
8.
Starter Motor - Ground Circuit
A slow cranking condition can be caused by resistance in the ground or return portion of the cranking circuit.
Check the voltage drop in the ground circuit as follows:
Connect the Fluke 77-IV Digital Multimeter positive lead to the starter motor housing (the connection
clean and free of rust or grease). Connect the negative lead to the negative (-) battery terminal.
1.
Engage the remote starter switch and crank the engine. Read and record the voltage reading. The
reading should be 0.5 volt or less.
2.
If the voltage is more than 0.5 volt, clean the negative cable connections at the battery, the body
ground connections and the starter ground connections. Retest.
3.
If the voltage is more than 0.5 volt, install a new cable. If the voltage reading is less than 0.5 volt and
the engine still cranks slowly, install a new starter motor. Refer to Starter Motor - 2.5L , Starter Motor
- 3.0L or Starter Motor - 3.5L in this section.
4.
&nbP>
Manual
REMOVAL AND
INSTALLATION
Starter Motor - 2.5L
1 N805320 Starter motor solenoid wire nut
2 14463 Starter motor solenoid wire (part of 14B060)
3 14603 Starter motor solenoid battery cable terminal cover
4 W706414 Starter motor solenoid battery cable nut
5 14463 Starter motor solenoid battery cable (part of 14B060)
6 W705790 Ground wire nut
7 14463 Ground wire (part of 14B060)
8 W706194 Starter motor stud bolt
9 W705877 Starter motor bolt
10 11000 Starter motor
starter motor battery terminal lead. If a tool is shorted at ttarter motor battery terminal, the tool can
quickly heat enough to cause a skin burn. Failure to follow this instruction may result in serious
personal injury.
100-02 .
1.
Starter Motor - 2.5L 2543
Remove the starter motor solenoid wire nut and position the wire aside.
4.
Position the starter motor solenoid battery cable terminal cover aside. 5.
Remove the starter motor solenoid battery cable nut and position the cable aside.
6.
Remove the ground wire nut from the starter motor stud bolt and position the ground wire aside.
7.
Remove the starter motor bolt, stud bolt and the starter motor.
8.
Manual
REMOVAL AND
INSTALLATION
6 - Ground wire nut
7 14463 Ground wire (part of 14A280)
8 W503297 Starter motor stud bolt (2 required)
can quickly heat enough to cause a skin burn. Failure to follow this ction may result in serious personal
injury.
2.
Position the starter motor solenoid terminal battery cable cover aside. 3.
Remove the starter motor solenoid battery cable nut and position aside the cable.
4.
Remove the ground wire nut from the starter motor stud bolt and position the ground wire aside.
5.
Remove the 2 starter motor stud bolts and the starter motor.
6.
Manual
REMOVAL AND
INSTALLATION
6 W503297 Starter motor bolt (2 required)
personal injury.
2.
Position the starter motor solenoid terminal battery cable cover aside. 3.
Remove the starter motor solenoid battery cable nut and position aside the cable.
4.
Remove the 2 starter motor bolts and the starter motor.
5.
SECTION 303-07A: Engine Ignition - 2.5L
Workshop Manual
Material
Capacity
Dielectric Compound
XG-3-A
ESE-M1C171-A -
Item Specification
Spark plug 6M8G-12405-BB
Spark plug gap 1.25-1.35 mm (0.049-0.053 in)
Description Nm l
Ignition coil-on-plug bolts 10 89
Spark plugs 12 106
SECTION 303-07A: Engine Ignition - 2.5L
Workshop Manual
Engine Ignition
The Electronic Ignition (EI) system is a coil-on-plug ignition system. The coil-on-plug ignition system
consists of the:
ignition coil-on-plugs.
spark plugs.
Crankshaft Position (CKP) sensor.
Camshaft Position (CMP) sensor.
The ignition coil-on-plugs:
change low voltage signals from the PCM to high voltage pulses.
supply the high voltage pulses to the spark plugs.
are connected directly to each spark plug.
have replaceable coil boots.
The spark plugs:
change high voltage pulses into a spark which ignites the fuel and air mixture.
The CKP sensor:
is a variable reluctance sensor.
is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft.
provides base timing and crankshaft speed (rpm) to the PCM.
is essential for calculating spark ng.
The CMP sensor:
is a Hall-effect sensor.
provides camshaft rotational location information to the PCM.
sends the PCM a signal indicating camshaft position used for fuel synchronization.
Engine Ignition 2550
SECTION 303-07A: Engine Ignition -
2.5L
Manual
Engine Ignition
2.5L
Manual
Engine Ignition Components - Exploded View
Item
Part
Number Description
1 14A464 Ignition coil-on-plug electrical connector (part of
12B637) (4 required)
2 W500215 Ignition coil-on-plug bolt (4 required)
3 12A366 Ignition coil-on-plug (4 required)
4 12A402 Ignition coil-on-plug boot (4 required)
For additional inforrefer to the procedures in this section. 1.
Engine Ignition Components - Exploded View 2553
2.5L
Manual
Ignition Coil-On-Plug
Material
Item Specification
Dielectric Compound
XG-3-A
ESE-M1C171-A
Disconnect the 4 ignition coil-on-plug electrical connectors. 1.
ease removal.
Remove the 4 bolts and the ignition coil-on-plugs.
2.
Inspect the ignition coil-on-plug boots for rips, nicks or tears. Remove and discard any damaged
ignition coil-on-plug boots.
To install, slide the new coil-on-boot onto the coil until fully seated at the top of the coil.
3.
Apply a small amouf dielectric grease to the inside of the ignition coil-on-plug boots before
attaching to the spark plugs.

4.
Ignition Coil-On-Plug 2555
2.5L
Manual
Spark Plugs
Remove the 4 ignition coil-on-plugs. For additional information, refer to Ignition Coil-On-Plug in this
section.
1.
NOTICE: Only use hand tools when removing or installing the spark plugs, or damage can
occur to the cylinder head or spark plug.
NOTE: Use compressed air to remove any foreign material in the spark plug well before removing
the spark plugs.
2.
Inspect the 4 spark plugs. For additional information, refer to Section 303-00 . 3.
Adjust the spark plug gap as necessary.
4.
Spark Plugs 2557
SECTION 303-07B: Engine Ignition - 3.0L (4V)
Workshop Manual
Material
Capacity
Dielectric Compound
XG-3-A
ESE-M1C171-A -
Item Specification
Firing order 1-4-2-5-3-6
Spark plug CGSF-22N
Spark plugs 15 133
Spark Plugs 2558
SECTION 303-07B: Engine Ignition - 3.0L
(4V)
Workshop Manual
Engine Ignition
consists of the:
spark plugs.
The CMP sensor:
is a Hall-effect sensor.
is mounted in the front cover.
is triggered by the high point mark on the LH exhaust camshaft.
The CKP sensor:
is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft.
is essential falculating spark timing.
produce the high voltage pulses to the spark plugs.
The spark plugs:
originally equipped on the vehicle have a fine wire design platinum-enhanced active electrode for
long life.

(4V)
Workshop Manual
Engine Ignition
(4V)
Workshop Manual
LH Side
Item
Part
Number Description
1 14A464 LH ignition coil-on-plug electrical connector (part of
2 W708833 LH ignition coil-on-plug bolt (3 required)
3 12A375 LH ignition coil-on-plug (3 required)
RH Side
Item
Part
Number Description
1 14A464 RH ignition coil-on-plug electrical connector (part of
2 W708833 RH ignition coil-on-plug bolt (3 required)
3 12A375 RH ignition coil-on-plug (3 required)
LH Side 2563
(4V)
Workshop Manual
Material
Item Specification
Dielectric Compound
XG-3-A
ESE-M1C171-A
RH side
NOTE: The upper intake manifold must be removed to access the RH ignition coil-on-plugs only.
Remove the upper intake manifold. For additional information, refer to Section 303-01B .
1.
Both sides
ease removal.
Remove the 6 bolts and the 6 ignition coil-on-plugs.
3.
Apply a small amount of dielectric grease to the inside of the ignition coil-on-plug boots
before attaching to the spark plugs.

4.
(4V)
Workshop Manual
Spark Plugs
section.
1.
the spark plugs.
2.
Inspect the 6 spark plugs. For additional information, refer to Section 303-00 . 3.
4.
Spark Plugs 2566
SECTION 303-07C: Engine Ignition - 3.5L
Workshop Manual
Material
Capacity
Dielectric Compound
XG-3-A
ESE-M1C171-A -
Item Specification
Engine Ignition
Spark plug AYFS-22FM
Spark plugs 15 133
Spark Plugs 2567
SECTION 303-07C: Engine Ignition -
3.5L
Manual
Engine Ignition
consists of:
Camshaft Position (CMP) sensors.
a Crankshaft Position (CKP) sensor.
spark plugs.
The CMP ors:
are variable reluctance sensors.
are mounted in the rear of the cylinder head.
are triggered by a 3-plus-1 timing wheel on each intake camshaft.
provides camshaft rotational location information to the PCM.
The CKP sensor:
is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft, at the rear of the engine.
produce the high voltage pulses to the spark plugs.
have replaceable coil seals.
The spark plugs:
originally equipped on the vehicle have a platinum-enhanced fine wire electrode for long life.
3.5L
Manual
Engine Ignition
3.5L
Manual
LH Side
Item
Part
Number Description
1 6758 Crankcase ventilation tube-to-valve cover fitting quick
connect coupling
2 - Ignition coil-on-plug electrical connector (part of
4 12A375 Ignition coil- required)
6 12A384 Coil seal (3 required)
RH Side
Item
Part
Number Description
1 - Ignition coil-on-plug electrical connector (part of
3 12A375 Ignition coil-on-plug (3 required)
5 12A384 Coil seal (3 required)
RH Side 2572
3.5L
Manual
Material
Item Specification
Dielectric Compound
XG-3-A
ESE-M1C171-A
LH side
Disconnect the crankcase ventilation tube-to-valve cover quick connect coupling and position aside.
1.
RH side
NOTE: The upper intake manifold must be removed to access the RH ignition coil-on-plugs.
Remove the upper intake manifold. For additional information, refer to Section 303-01C .
1.
Both sides
ease removal.
Remove the 6 bolts and the 6 ignition coil-on-plugs.
4.
Inspect the coil seals for rips, nicks or tears. Remove and discard any damaged coil seals.
To install, slide the new coil seal onto the coil until it is fully seated at the top of the coil.
5.
Apply a small amount of dielectric grease to the inside of the ignition coil-on-plug boots
before attaching to the spark plugs.

6.
3.5L
Manual
Spark Plugs
section.
1.
the spark plugs.
2.
Inspect 6 spark plugs. For additional information, refer to Section 303-00 . 3.
4.
Spark Plugs 2575
SECTION 303-08A: Engine Emission Control -
2.5L
Workshop Manual
Material
Item Specification Fill Capacity
ZC-31-A
- -
Crankcase vent oil separator bolts 10 89
EGR valve bolts 20 177
Spark Plugs 2576
SECTION 303-08A: Engine Emission
Control - 2.5L
Workshop Manual
Engine Emission Control
NOTE: Do not permanently remove or render inoperative any part of the vehicle emission control system
including related hardware. Failure to comply may violate applicable state and federal laws.
NOTE: The vehicle emission vacuum routing diagrams are contained in the Description and Operation
subsection of the Engine Emissions Control section. For additional information, refer to Section 303-13A .
The engine emission control system consists of the:
EGR system.
PCV system.
EGR system
The EGR system returns a small amount of exhaust gas into the intake manifold. This reduces the overall
combustion temperature. Cooler combustion temperatures provide a significant reduction of the Nitrogen Ox
(NOx) in the exhaust emissions.
The engine incorporates a stepper motor-controlled EGR valve which receives its signal from the PCM.
Engine coolant is used to cool the EGR valve. The EGR valve and stepper motor are serviced as an assembly.
The amount of recirculated exhaust gas depends on:
engine rpm.
intake manifold vacuum.
exhaust backpressure.
Engine Coolant Temperature (ECT).
Throttle Position (TP).
PCV system
The PCV system uses intake manifold vacuum to ventilate blow-by vapors from the crankcase and return the
vapors to the intake manifold for combustion. The PCV valve varies the amount of blow-by vapors returned to
the intake manifold based on available engine vacuum. The PCV valve also prevents entry of combustion
backfiring into the crankcase. The PCV valve is serviced as part of the crankcase vent oil separator.
Engine Emission Control 2577
SECTION 303-08A: Engine Emission
Control - 2.5L
Workshop Manual
SECTION 303-08A: Engine Emission Control
- 2.5L
Workshop Manual
Exhaust Gas Recirculation (EGR) Valve
Material
Item Specification
ZC-31-A
-
1 - EGR valve coolant hose (part of 18C266)
3 9D475 EGR valve
4 W525952 EGR valve cose clamp
5 W500225 EGR valve bolt
6 14A464 EGR valve electrical connector
Release the clamp and remove the EGR coolant outlet hose from the EGR valve. 4.
Discard the gasket.
5.
paths. Use a plastic scraping tool to remove all traces of the Exhaust Gas Recirculation (EGR)
valve gasket.
6.
Exhaust Gas Recirculation (EGR) Valve 2580
prepare the mating surfaces.
Clean the mating surfaces of any residual gasket material.
SECTION 303-08A: Engine Emission Control
- 2.5L
Workshop Manual
Crankcase Vent Oil Separator
1 W500214 Crankcase vent oil separator bolt (8 required)
3 - Coolant bypass hose clip (part of 9A785)
4 6A785 Crankcase vent oil separator gasket
Remove the intake manifold. For additional information, to Section 303-01A . 1.
Release the coolant bypass hose from the clip. 2.
Remove the 8 bolts and the crankcase vent oil separator and gasket.
3.
Clean the engine block mating surface.
4.
Crankcase Vent Oil Separator 2582
SECTION 303-08B: Engine Emission Control -
3.0L (4V)
Workshop Manual
Material
ZC-31-A
- -
Exhaust manifold-to-EGR valve tube fittings 40 30 <
3.0L (4V)
Workshop Manual
including related hardware. Failure to comply may violate applicable state and federal laws.
EGR system.
PCV system.
EGR system
combustion temperature. Cooler combustion temperatures provide a significant reduction of the Ngen Oxides
The EGR valve:
is electronically controlled by the PCM.
is connected to the exhaust manifold by the EGR valve-to-exhaust manifold tube.
controls recirculated exhaust gas flow to the intake manifold.
monitors the flow of recirculated exhaust gases through the EGR valve-to-exhaust manifold tube.
returns a signal to the PCM.
The amount of recirculated exhaust gas depends upon:
engine rpm.
exhaust back pressure.
PCV system
The PCV system:
uses intake manifold vacuum to ventilate blow-by vapors from the crankcase.
returns the vapors to the intake manifold for combustion.
The PCV system consists of the:
crankcase ventilation tube.
PCV valve.
3.0L (4V)
Workshop Manual
3.0L (4V)
Workshop Manual
Exhaust Gas Recirculation (EGR) System Components - Exploded View
Item
Part
Number Description
2 9D475 EGR valve
3 W500313 EGR valve bolts (2 required)
5 - Exhaust manifold-to-EGR valve tube fitting (part of
9D477)
6 9D477 Exhaust manGR valve tube
7 - Exhaust manifold-to-EGR valve tube fitting (part of
9D477)
Exhaust Gas Recirculation (EGR) System Components - Exploded View 2588
Exhaust Gas Recirculation (EGR) System Components - Exploded View 2589
3.0L (4V)
Workshop Manual
Material
Item Specification
ZC-31-A
-
Disconnect the exhaust manifold-to-EGR valve tube fitting from the EGR valve.
2.
Discard the gasket.
3.
i>NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to
clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic
scraping tool to remove all traces of the Exhaust Gas Recirculation (EGR) system module gasket.
Clean the mating surfaces of any residual gasket material.
4.
Install a new EGR valve gasket.
5.
3.0L (4V)
Workshop Manual
Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube
Removal
100-02 .
1.
All vehicles
Disconnect the exhaust manifold-to-EGR valve tube fitting from the EGR valve. 2.
Disconnect the exhaust manifold-to-EGR valve tube fitting from the exhaust manifold. 3.
Remove the exhaust manifold-to-EGR valve tube. 4.
Installation
Install the exhaust manifold-to-EGR valve tube. 1.
Hand start txhaust manifold-to-EGR valve tube fitting to the exhaust manifold. 2.
Hand start the exhaust manifold-to-EGR valve tube fitting to the EGR valve. 3.
Tighten the exhaust manifold-to-EGR valve tube fittings to 40 Nm (30 lb-ft). 4.
Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube 2592
3.0L (4V)
Workshop Manual
Positive Crankcase Ventilation (PCV) Valve
2 W527382 Crankcase ventilation tube clamp
3 6K817 Crankcase ventilation tube
5 W527382 Crankcase ventilation tube clamp
6 6A666 PCV valve
7 - PCV valve O-ring seal of 6A666)
Release the clamp and disconnect the crankcase ventilation tube from the PCV valve. 1.
NOTICE: A new Positive Crankcase Ventilation (PCV) valve must be installed if removed from
the valve cover. Damage will occur to the locking mechanism on the PCV valve.
NOTE: To install, apply clean engine oil to the O-ring seal.
Rotate counterclockwise and remove the PCV valve from the valve cover.
Discard the PCV valve.
2.
Install a new PCV valve.
3.
Positive Crankcase Ventilation (PCV) Valve 2593
SECTION 303-08C: Engine Emission Control -
3.5L
Workshop Manual
Material
Capacity
or equivalent
WSS-M2C930-A -
SECTION 303-08C: Engine Emission
Control - 3.5L
Workshop Manual
including related hardware. Failure to comply may violate applicable state and federal law.
The engine emission control system consists of the PCV system:
PCV System
The PCV system:
uses intake manifold vacuum to ventilate blow-by vapors from the crankcase.
returns the vapors to the intake manifold for combustion.
The PCV system consists of the:
crankcase ilation tube.
PCV valve.
The PCV valve:
varies the amount of blow-by vapors returned to the intake manifold based on available engine
vacuum.

prevents combustion gases backfiring into the crankcase.
SECTION 303-08C: Engine Emission
Control - 3.5L
Workshop Manual
SECTION 303-08C: Engine Emission Control -
3.5L
Workshop Manual
Positive Crankcase Ventilation (PCV) Valve
Material
Item Specification
or equivalent
WSS-M2C930-A
1 - Crankcase ventilation tube spring clamp (part of
6A664)
2 6K817 Craentilation tube
3 6A666 PCV valve
4 - PCV valve O-ring seal (part of 6A666)
Disconnect the crankcase ventilation tube from the PCV valve. 1.
NOTICE: A new Positive Crankcase Ventilation (PCV) valve must be installed if removed from
the valve cover. Damage will occur to the locking mechanism on the PCV valve.
NOTE: To install, apply clean engine oil to the O-ring seal.
Rotate the PCV valve counterclockwise and remove from the valve cover.
Discard the PCV valve.
2.
Install a new PCV valve.
3.
SECTION 303-08D: Engine Emission Control -
Hybrid
Workshop Manual
Material
ZC-31-A
- -
Coolant outlet adapter bolts 10 89
Crankcase vent oil separator bolts 10 89
High-voltage wire harness bolt 9 80
Motor Electronics Cooling System (MECS) coolant expansion tank bolt 9 80
MECS coolant expansion tank nut 9 80
SECTION 303-08D: Engine Emission Control
- Hybrid
Workshop Manual
including related hardware. Failure to comply may violate applicable state and federal law.
subsection of the Engine Emissions Control section. For additional information, refer to Section 303-13B .
EGR system.
PCV system.
EGR System
combustion temperature. Cooler combustion temperatures provide a significant reduction of the Nitrogendes
The engine incorporates a stepper motor-controlled EGR valve which receives its signal from the PCM.
Engine coolant is used to cool the EGR valve. The EGR valve and stepper motor are serviced as an assembly.
The amount of recirculated exhaust gas depends on:
engine rpm.
exhaust backpressure.
Engine Coolant Temperature (ECT).
PCV system
The PCV system uses intake manifold vacuum to ventilate blow-by vapors from the crankcase and return the
vapors to the intake manifold for combustion. The PCV valve varies the amount of blow-by vapors returned to
the intake manifold based on available engine vacuum. The PCV valve also prevents entry of combustion
backfiring into the crankcase. The PCV valve is serviced as part of the crankcase vent oil separator.
- Hybrid
Workshop Manual
- Hybrid
Workshop Manual
Material
Item Specification
ZC-31-A
-
Coolant Hoses
3 - Heater hose clf 18C266)
4 9D475 EGR valve
5 - Heater hose (part of 18C266)
6 - Heater hose tee (part of 18C266)
7 8548 Coolant bypass hose
8 W525958 Coolant bypass hose clamp
11 - Heater hose (part of 18C266)
13 - Upper radiator hose clamp (part of 8B274)
Motor Electronics Cooling System (MECS) Expansion Tank
Item
Part
Number Description
1 W701152 Motor Electronics Cooling System (MECS) coolant
expansion tank nut
2 W505424 MECS coolant expansion tank bolt
3 8C045 MECS coolant expansion tank
Transaxle High-Voltage Electrical Wire Harness
1 14B322 High-voltage wire harness
2 W704683 High-voltage wire harness bolt
3 - High-voltage wire harness electrical connector
(part of 14B322)
4 7000 Transaxle
Motor Electronics Cooling System (MECS) Expansion Tank 2605
Engine Wire Harness
1 - Engine wire harness retainer (part of 12C508)
2 6C295 Valve cover stud
3 12C508 Engine wire harness
Coolant Outlet Adapter <
1 8255 Coolant outlet adapter gasket
3 W500015 Coolant outlet adapter bolt (4 required)
EGR Valve
Engine Wire Harness 2606
3 W500225 EGR valve bolt (2 required)
Depower the High Voltage Traction Battery (HVTB) system. For additional information, refer to
Section 414-03 .
1.
Drain the cooling system. For additional information, refer to Section 303-03B . 2.
Remove the Throttle Body (TB). For additional information, refer to Section 303-04D . 3.
Release the clamp and separate the upper heater hose. 4.
Release the clamp and remove the bypass hose from the coolant outlet adapter. 5.
Release the clamp and remove the upper radiator hose from the coolant outlet adapter. 6.
Release the clamp and remove the heater hose from the EGR valve. 7.
Remove the bolt and the nut and position the Motor Electronics Cooling System (MECS) coolant
expansion tank aside.
8.
Release the engine wire harness retainer from the valve cover stud. 10.
Remove the high-voltage wire harness bolt.
11.
Disconnect the transaxle high-voltage electrical connector. 12.
Carefully position the upper heater hose aside. 13.
Release the clamp and remove the lower heater hose from the coolant outlet adapter. 14.
Remove the 4 bolts and position the coolant outlet adapter aside. 15.
EGR Valve 2607
16.
paths. Use a plastic scraping tool to remove all traces of the coolant outlet adapter gasket.
Remove the coolant outlet adapter and discard the gasket.
Clean and inspect the coolant outlet adapter mating surfaces.
17.
paths. Use a plastic scraping tool to remove all traces of the Exhaust Gas Recirculation (EGR)
valve gasket.
prepare the surfaces
NOTE: Do not reuse the EGR valve gasket.
Remove and discard the EGR valve gasket.
Clean and inspect the EGR gasket mating surfaces.
18.
Fill and bleed the cooling system. For additional information, refer to Section 303-03B . 20.
EGR Valve 2608
- Hybrid
Workshop Manual
Crankcase Vent Oil Separator
1 W500214 Crankcase vent oil separator bolt (8 required)
3 - Coolant bypass hose clip (part of 9A785)
4 6A785 Crankcase vent oil separator gasket
Remove the intake manifold. For additional informatifer to Section 303-01D . 1.
Release the coolant bypass hose from the clip. 2.
Remove the 8 bolts and the crankcase vent oil separator and gasket.
3.
Clean the engine block mating surface.
4.
SECTION 303-12A: Intake Air Distribution and Filtering
- 2.5L
Air Cleaner (ACL) insulator support bracket bolt 25 18 -
ACL outlet pipe-to- ACL housing cover clamp 4 - 35
ACL outlet pipe-to-Throttle Body (TB) clamp 4 - 35
Intake air resonator nut 15 - 133
Mass Air Flow (MAF) sensor screw 2 - 18
SECTION 303-12A: Intake Air Distribution and
Filtering - 2.5L
Intake Air Distribution and Filtering
The air intake system consists of the:
Air Cleaner (ACL) outlet pipe.
ACL element.
Mass Air Flow (MAF) sensor.
ACL housing assembly.
intake air resonator.
The air intake system:
cleans intake air with a replaceable, dry-type ACL element.
measures airflow and air temperatwith the MAF sensor.
The engine ACL contains an ACL element made of treated, pleated paper, which must be replaced
periodically as scheduled. Engine performance and fuel economy are adversely affected when maximum
restriction of the ACL element is reached.
Intake Air Distribution and Filtering 2612
Filtering - 2.5L
Workshop Manual
Filtering - 2.5L
Workshop Manual
Intake Air System Components - Exploded View
Item
Part
Number Description
1 9C490 Vacuum hose
2 6853 Crankcase ventilation tube
3 - Crankcase ventilation tube-to-Air Cleaner (ACL) outlet
pipe quick connect coupling (part of 6853)
4 - ACL outlet pipe-to-Throttle Body (TB) clamp (part otd>
5 9F991 TB
6 9F805 ACL outlet pipe
7 14A464 Mass Air Flow (MAF) sensor electrical connector
8 - ACL outlet pipe-to- ACL housing cover clamp (part of
9F805)
9 W711655 MAF sensor screw (2 required)
10 12B579 MAF sensor
11 - Snow shield pin-type retainer (part of 16A554) (2
required)
12 - ACL housing cover (part of 9C662)
13 16A554 Snow shield
14 9601 ACL element
15 9C662 ACL housing
16 - ACL inlet pipe (part of 9C662)
17 W707375 ACL insulator support bracket bolt (2 required)
Intake Air System Components - Exploded View 2614
18 W520413 Intake air resonator nut (3 required)
19 9647 ACL insulator support bracket
20 9F763 Intake air resonator
Filtering - 2.5L
Workshop Manual
Air Cleaner
Disconnect the Mass Air Flow (MAF) sensor electrical connector. 1.
Loosen the clamp and disconnect the Air Cleaner (ACL) outlet pipe from the ACL housing cover.
2.
NOTE: No tools are needed to remove the ACL assembly. Removal should be carried out using
hands only.
Separate the 3 ACL feet from the rubber grommets and the ACL inlet pipe and remove the ACL
assembly.
3.
NOTE: Make sure that the 3 ACL feet are seated into the rubber grommets under the ACL assembly.
NOTE: The ACL outlet pipe should be securely sealed to prevent unmetered air from entering the
engine.
4.
Air Cleaner 2616
Filtering - 2.5L
Workshop Manual
Air Cleaner Outlet Pipe
Disconnect the crankcase ventilation tube-to-Air Cleaner (ACL) outlet pipe quick connect coupling.
1.
Remove the vacuum tube to ACL outlet pipe. 2.
Loosen the clamp and remove the ACL outlet pipe from the Throttle Body (TB).
3.
Loosen the ACL outlet pipe-to- ACL housing cover clamp.
Remove the ACL outlet pipe.
1.
engine.
5.
Air Cleaner Outlet Pipe 2617
Filtering - 2.5L
Workshop Manual
Intake Air Resonator
100-02 .
1.
Remove the 3 nuts and the intake air resonator.
3.
NOTE: Make sure that the ACL inlet pipe is securely seated to the intake air resonator.
4.
Intake Air Resonator 2618
SECTION 303-12B: Intake Air Distribution and Filtering -
3.0L (4V)
Air Cleaner (ACL) insulator support bracket bolt 25 18 -
ACL outlet pipe-to- ACL housing cover clamp 4 - 35
ACL outlet pipe-to-Throttle Body (TB) clamp 4 - 35
Intake air resonator nuts 15 - 133
Mass Air Flow (MAF) sensor screw 2 - 18
SECTION 303-12B: Intake Air Distribution and
Filtering - 3.0L (4V)
Workshop Manual
ACL element.
measures airflow and air temperature with the MAF sensor.
SECTION 303-12B: Intake Air Distribution and Filtering
- 3.0L (4V)
3.0L (4V)
Item
Part
Number Description
2 - Air Cleaner (ACL) outlet pipe-to- TB clamp (part of
9F805)
3 - Crankcase ventilation tube-to- outlet pipe quick connect
5 9C805 ACL outlet pipe
6 9C490 Vacuum hose (All-Wheel Drive (AWD) only)
9C805)
11 9C662 ACL housing cover
12 - Snow shield pin-type retainer (part of 16A554) (2
required)
13 16A554 Snow shield
14 9601 ACL element
15 - ACL inlet pipe (part of 9C662)
3.0L (4V)
Air Cleaner
Loosen the clamp and disconnect the Air Cleaner (ACL) outlet pipe-to- ACL housing cover.
2.
hands only.
Separate the 3 ACL feet from the rubber grommets and the ACL inlet pipe and remove the n
title="Air Cleaner" class="popup" onmouseover="this.className='popupnounderline';"
onmouseout="this.className='popup';">ACL assembly.
3.
engine.
4.
Air Cleaner 2624
3.0L (4V)
Disconnect the vacuum hose from the Air Cleaner (ACL) outlet pipe. 1.
All vehicles
Disconnect the crankcase ventilation tube-to- ACL outlet pipe quick connect coupling. For additional
2.
Loosen the ACL outlet pipe-to-Throttle Body (TB) clamp.
3.
4.
engine.
5.
3.0L (4V)
100-02 .
1.
Remove the 3 nuts and the air intake resonator.
To install, tighten to 15 Nm (133 lb-in)/li>
3.
NOTE: Make sure that the Air Cleaner (ACL) inlet pipe is securely seated to the intake air resonator.
4.
SECTION 303-12C: Intake Air Distribution and
Filtering - 3.5L
Workshop Manual
Air Cleaner (ACL) housing bolt 4 35
ACL inlet pipe bolts 4 35
ACL insulator support bracket bolt 20 177
ACL outlet pipe-to- ACL housing cover clamp 4 35
ACL outlet pipe-to-Throttle Body (TB) clamp 4 35
Intake air resonator nuts 15 133
Mass Air Flow (MAF) sensor screws 2 18
Filtering - 3.5L
Workshop Manual
ACL element.
Filtering - 3.5L
Filtering - 3.5L
Workshop Manual
Item
Part
Number Description
9F805)
4 -
Crankcase ventilation tube-to- ACL outlet pipe quick
connect coupling (part of 6758)
6 - Vacuum hose clamp (part of 9C482)
7 9C482 Vacuum hose
9F805)
9 12B579 Mass Air Flow (MAF) sensor
11 14A464 MAF electrical connector
12 - Wire harness pin-type retainer (part of 14A464)
13 - ACL housing cover (part of 9C662)
14 9601 ACL element
15 W710317 ACL housing bolt
21 W710317 ACL inlet pipe bolt (2 required
22 9C675 ACL inlet pipe
23 9E931 ACL inlet pipe seal
Filtering - 3.5L
Workshop Manual
Air Cleaner
Disconnect the Mass Air Flow (MAF) sensor electrical connector and release the wiring harness
pin-type retainer from the Air Cleaner (ACL) housing.
1.
Loosen the clamp and disconnect the ACL outlet pipe from the ACL housing cover.
2.
Remove the ACL housing bolt.
3.
Remove the 2 AC/span> inlet pipe bolts.
4.
hands only.
Separate the 2 ACL feet from the rubber grommets and remove the ACL and the ACL inlet pipe as an
assembly.
5.
engine.
6.
Air Cleaner 2632
Filtering - 3.5L
Workshop Manual
Disconnect the crankcase ventilation tube-to-Air Cleaner (ACL) outlet pipe quick connect coupling.
1.
Release the clamp and disconnect the vacuum hose from the ACL outlet pipe. 2.
3.
4.
engine.
5.
Filtering - 3.5L
Workshop Manual
100-02 .
1.
Remove the 2 nuts and the air intake resonator.
3.
NOTE: Make sure that the Air Cleaner (ACL) inlet pipe is securely seated to the intake air resonator.
4.
SECTION 303-12D: Intake Air Distribution and
Filtering - Hybrid
Workshop Manual
Air Cleaner (ACL) assembly nut 15 133
ACL outlet pipe-to- ACL assembly clamp 4 35
ACL outlet pipe-to-intake air resonator clamp 4 ACL outlet pipe-to-Throttle Body (TB) clamp 4 35
Intake air resonator bolt 4 35
Mass Air Flow (MAF) sensor screw 2 18
SECTION 303-12D: Intake Air Distribution and Filtering
- Hybrid
ACL assembly.
intake air resonator assembly.
cleans intake air with a long life ACL assembly.
The vehicle utilizes a long life ACL assembly designed to last the life of the vehicle. The ACL is serviced as a
complete ACL assembly.
SECTION 303-12D: Intake Air Distribution and
Filtering - Hybrid
Workshop Manual
- Hybrid
Item
Part
Number Description
9F805)
4 - Crankcase ventilation tube-to- ACL outlet pipe quick
connect coupling (part of 6853)
6 - ACL outlet pipe-to-intake air resonator clamp (part of
9F805)
7 W710317 Intake air resonator bolt
12 - ACL outlet pipe-to- ACL assembly clamp (part of
9F805)
13 9600 ACL assembly
14 W520413 ACL assembly nut (3 required)
15 - ACL intake pipe (part of 9600)
- Hybrid
Air Cleaner
100-02 .
1.
Loosen the clamp and disconnect the Aieaner (ACL) outlet pipe from the ACL assembly.
4.
Remove the 3 nuts, release the ACL intake pipe and remove the ACL assembly.
5.
Air Cleaner 2640
- Hybrid
Disconnect the crankcase ventilation tube -to-Air Cleaner (ACL) outlet pipe quick connect coupling.
1.
2.
Loosen the ACL outlet pipe-to- ACL assembly clamp.
3.
engine.
4.
- Hybrid
Loosen the Air Cleaner (ACL) outlet pipe-to-intake air resonator clamp.
1.
Remove the bolt and the air intake resonator.
2.
NOTE: Make sure that the intake air resonator is securely seated to the ACL outlet pipe.
3.
SECTION 303-13A: Evaporative
Emissions
Manual
Evaporative Emission (EVAP) canister bolts 6 - 53
EVAP canister nuts 6 - 53
EVAP canister purge valve bolts 10 - 89
Fuel tank filler pipe heat shield nuts 10 - 89
Fuel tank filler pipe hose clamp 4 - 35
Fuel tank strap bolts 40 30 -
SECTION 303-13A: Evaporative Emissions
Workshop Manual
Evaporative Emissions
The Evaporative Emission (EVAP) system consists of the:
EVAP canister purge valve.
EVAP canister (includes the dust separator and the vent solenoid).
fuel vapor tube assembly (includes the Fuel Tank Pressure (FTP) sensor).
Easy FuelTM (capless) fuel tank filler pipe.
The EVAP system:
prevents hydrocarbon emissions from reaching the atmosphere.
stores fuel vapors in the EVAP canister, that are generated during vehicle operation or hot soak, until
they can be consumed by the engine during normal engine operation.

routes the stored fuel vapors to the engine during engine operation.
is controlled by the PCM which, using various sensor inputs, calculates the desired amount of purge
flow. The PCM regulates the purge flow, induced by the application of intake manifold vacuum, by
varying the duty cycle applied to the EVAP canister purge valve.

The fuel vapors are routed:
from the fuel tank through the fuel vapor vent valve.
to the EVAP canisters through a vapor tube.
from the EVAP canister to the engine when the EVAP canister purge valve is opened by the PCM.
The FTP sensor (part of fuel vapor tube assembl):
monitors the pressure levels in the fuel tank.
communicates the pressure reading to the PCM during the OBD II leak test.
The fuel vapor tube assembly:
is located under the rear of the vehicle.
is used to control the flow of fuel vapors entering the EVAP system.
includes the FTP sensor.
The EVAP canister:
includes the dust separator and vent solenoid.
contains activated carbon.
stores fuel vapors.
The Easy Fuel
TM
capless fuel tank filler pipe:
relieves system vacuum below -3.5 kPa (-16.00 in H
2
O).
The EVAP canister vent solenoid:
is normally open.
Evaporative Emissions 2644
seals the EVAP system for the inspection and maintenance (I/M 240) test and OBD II leak and
pressure tests.

is serviced as part of the EVAP canister.
The EVAP canister purge valve:
is normally closed.
regulates the purging of the EVAP canister.
is controlled by the PCM.
is repaired as a separate item.
is mounted to the intake manifold on the 2.5L and 3.0L.
is mounted below the lower cowl panel on the 3.5L.
The dust separator:
is attached to the EVAP canister vent solenoid.
prevents suspended dust and dirt particles from entering the EVAP system.
The EVAP system monitor:
is a self-test strategy within the PCM which tests the integrity of the EVAP system.
monitors the EVAP system for leaks.
monitors electronic EVAP components for irrationally high or low voltages.
monitors for correct EVAP system operation.
uses negative and positive leak test methods to test and activate the EVAP system.
The engine ON EVAP leak-check monitor:
is executed by the individual components of the enhanced EVAP system. Intake manifold vacuum is
utilized to reach a target vacuum on the EVAP system. The FTP sensor is used by the engine ON
EVAP leak-check monitor to determine if the target vacuum necessary to carry out the leak-check on
the EVAP system has been reached. Once target vacuum on the EVAP system is achieved, the change
in EVAP system vacuum over a calibrated period of time determines if a leak exists.

The Engine Off Natural Vacuum (EONV) EVAP leak-check monitor is executed:
once the engine ON EVAP leak-check monitor is completed and the key is turned OFF. The EONV
EVAP leak-check monitor determines if a leak is present when the naturally occurring change in the
fuel tank pressure or vacuum does not exceed a calibrated limit during a calibrated amount of time. A
separate, low-power consuming microprocessor in the PCM manages the EONV leak-check. The
engine OFF EVAP leak-check monitor is executed by the individual components of the enhanced
EVAP system.

Vehicle Emission Vacuum Routing
2.5L
1 - PCV valve (part of 6A785)
3 6582 Valve cover
4 9C915 Evaporative Emission (EVAP) canister purge valve
5 9B659 Air Cleaner (ACL) outlet pipe
6 9002 Fuel tank
7 - Fuel vapor solenoid separator assembly (part of
9E857)
8 - Fuel Tank Pressure (FTP) sensor (part of 9A228)
9 9034 Fuel tank filler pipe
10 9E857 EVAP canister
3.0L (4V)
All-Wheel Drive (AWD) Vehicles
6 6A666 PCV valve
7 9002 Fuel tank
9 - Fuel tank pressure sensor (part of 9A228)
10 -
All-Wheel Drive (AWD) Vehicles 2646
Fuel vapor solenoid separator assembly (part of
9E857)
Front Wheel Drive (FWD) Vehicles
Item Part Number ription
6 6A666 PCV valve
7 9002 Fuel tank
9 - Fuel tank pressure sensor (part of 9A228)
9E857)
3.5L
Front Wheel Drive (FWD) Vehicles 2647
3 9S455 Intake manifold
6 6A666 PCV valve
7 9002 Fuel tank
9E857)
3 9S455 Intake manifold
6 6A666 PCV valve
7 9002 Fuel tank
9E857)
Emissions
Manual
Emissions
Manual
Evaporative Emission System Leak Test
Special Tool(s)
VACUTEC Smoke Machine Fuel
Evaporative Emission System Tester
Phase 1 - Leak Verification
All vehicles
Run the EVAP Test with the scan tool. 1.
NOTE: Some small leaks may not be detected using the EVAP Test. If the system has passed the test
but a leak is still suspected, then proceed to Phase 2.
If the Evaporative Emission (EVAP) system failed the EVAP Test, then proceed to Phase 2.
2.
Phase 2 - System Leak Check
2.5L and 3.0L vehicles
Disconnect the fuel vapor tube-to- EVAP canister purge valve quick connect coupling. For additional
1.
Connect the VACUTEC Smoke Machine Fuel Evaporative Emission System Tester to the fuel vapor
tube quick connect coupling. For additional information, refer to the manufacturer's instructions.
2.
3.5L vehicle
Disconnect the upper vapor tube-to- EVAP canister purge valve quick connect coupling. For
1.
Connect the VACUTEC Smoke Machine Fuel Evaporative Emission System Tester to the upper
EVAP canister purge valve fitting. For additional information, refer to the manufacturer's instructions.
2.
All vehicles
100-02 .
1.
Evaporative Emission System Leak Test 2651
NOTE: The battery ground cable was previously disconnected in the vapor tube quick connect
coupling disconnect procedure.
Connect the battery ground cable. For additional information, refer to Section 414-01 .
2.
3.5L vehicle
NOTE: In the scan tool, the EVAP canister purge valve is referred to as the EVAP vapor
management valve.
Open the EVAP canister purge valve with the scan tool.
1.
All vehicles
Close the canister vent solenoid with the scan tool. 1.
NOTE: The supplemental refueling adapter is located in the luggage compartment.
Install the supplemental refueling adapter into the Easy Fuel
TM
(capless) fuel tank filler pipe
assembly.
2.
NOTE: If smoke does not exit the fuel tank filler pipe neck area after the system is pressurized, open
the canister vent solenoid with the scan tool to allow the air to purge. Once smoke is seen at the
canister vent solenoid, close the canister vent solenoid with the scan tool.
Introduce smoke from the VACUTEC Smoke Machine Fuel Evaporative Emission System Tester into
the EVAP system and verify that smoke is exiting the fuel tank filler pipe neck area. For additional
information, refer to the manufacturer's instructions.
3.
Remove the supplemental refueling adapter once smoke is observed exiting the fuel tank filler pipe
neck area.
4.
Continue to enter smoke into the system for 60 seconds to obtain pressure. 5.
Press and release the remote start button in intervals of 15 seconds ON and 15 seconds OFF while
checking for exiting smoke.
6.
Use the halogen light provided with the VACUTEC Smoke Machine Fuel Evaporative Emission
System Tester to follow the EVAP system path and look for smoke exiting at the source of the
leak(s).
7.
Repair any leaks as necessary. 8.
Repeat the leak test until the system passes. 9.
Emissions
Manual
Evaporative Emission Canister Purge Valve
2.5L Vehicles
Item
Part
Number Description
1 9G271 Vapor tube
2 - Vapor tube-to-Evaporative Emission (EVAP) canister
purge valve quick connect coupling (part of 9G271)
3 14A464 EVAP canister purge valve electrical connector
5 9G866 EVAP canister purge valve
6 W503278 EVAP canister purge valve bolt (2 required)
3.0L Vehicles
Evaporative Emission Canister Purge Valve 2654
Item
Part
Number Description
1 9G271 Vapor tube
3.5L Vehicles
Item
Part
Number Description
1 9F931
3.0L Vehicles 2655
Evaporative Emission (EVAP) canister purge valve
bracket
4 - Vapor tube-to- EVAP canister purge valve quick
connect coupling (part of 9G271)
5 9G271 Vapor tube
6 - Vapor tube-to- EVAP canister purge valve quick
connect coupling (part of 9G279)
7 9G279 Vapor tube
All vehicles
Disconnect the vapor tube-to- EVAP canister purge valve quick connect coupling. For additional
3.
Remove the 2 bolts and the EVAP canister purge valve.
4.
3.5L vehicles
NOTE: The lower cowl panel grille must be removed to access the EVAP canister purge valve.
Remove the lower cowl panel grille. For additional information, refer to the Cowl Panel Grille
procedure in Section 501-02 .
5.
Disconnect the EVAP canister purge valve electrical connector. 6.
Disconnect the 2 vapor tube-to- EVAP canister purge valve quick connect couplings. For additional
7.
Depress the tab and remove the EVAP canister purge valve from the bracket. 8.
3.5L Vehicles 2656
All vehicles
Carry out the Evaporative Emission System Leak Test. For additional information, refer to
Evaporative Emission System Leak Test in this section.

9.
3.5L Vehicles 2657
Emissions
Manual
Evaporative Emission Canister
Item
Part
Number Description
1 W708029 Evaporative Emission (EVAP) canister bolt (2 required)
2 W707142 EVAP canister nut (2 required)
3 14A464 EVAP canister vent solenoid electrical connector (part
of 14A005)
4 - Fresh air hose (part of 9034)
5 - Vapor tube-to- EVAP canister quick connect coupling
(part of 9J279)
6 - Fuel vapor tube assembly-to- EVAP canister quick
connect coupling (part of 9A228)
7 9E857 EVAP canister assembly
mixtures are always present and may be ignited. Failurollow these instructions may result in serious
personal injury.
Evaporative Emission Canister 2658
100-02 .
1.
NOTE: Clean the Evaporative Emission (EVAP) canister vent solenoid electrical connector and the
immediate surrounding area of any dirt or foreign material.
Disconnect the EVAP canister vent solenoid electrical connector.
3.
Disconnect the fresh air hose from the dust separator. 4.
Disconnect the fuel vapor tube assembly-to- EVAP canister quick connect couplings. For additional
5.
Disconnect the vapor tube-to- EVAP canister quick connect couplings. For additional information,
6.
Remove the 2 nuts, 2 bolts and the EVAP canister assembly.
7.

8.
Emissions
Manual
Fuel Vapor Tube Assembly - All Wheel Drive (AWD)
Special Tool(s)
Fuel Storage Tanker
Powertrain Lift
Item
Part
Number Description
1 9002 Fuel tank
2 9092 Fuel tank strap (2 required)
3 9C052 Fuel Tank Pressure (FTP) sensor (part of 9A228)
4 - Retainer clip (part of 9A228) (3 required)
5 - Fuel vapor tube assembly-to-fuel tankonnect coupling
(part of 9A228)
6 W505444 Fuel tank strap bolt (4 required)
7 9A228 Fuel vapor tube assembly
8 14A464 FTP sensor electrical connector
9 - Fuel tank filler pipe hose (part of 9034)
10 W525937 Fuel tank filler pipe hose clamp
11 -
Fuel Vapor Tube Assembly - All Wheel Drive (AWD) 2660
Fuel vapor tube assembly-to-Evaporative Emission
(EVAP) canister quick connect coupling (part of 9A228)
12 9G676 Fuel vapor separator and solenoid assembly (part of
9E857)
14 - Fuel vapor tube assembly-to-recirculation tube quick
15 - Fuel tank filler pipe recirculation tube (part of 9034)
17 5411268 Fuel tank filler pipe heat shield
18 W707142 Fuel tank filler pipe heat shield nut (3 required)
100-02 .
1.
Using the supplemental refueling adapter and the Fuel Storage Tanker, drain any residual fuel from
the fuel tank filler pipe.
3.
Remove the 3 nuts and the fuel tank filler pipe heat shield.
4.
Disconnect the fuel vapor tube assembly-to-Evaporative Emission (EVAP) canister quick connect
coupling. For additional information, refer to Section 310-00 .
5.
Disconnect the fuel vapor tube assembly from the fuel vapor separator and solenoid assembly. 6.
Disconnect the fuel vapor tube assembly-to-recirculation tube quick connect coupling. For additional
7.
Release the 3 retainer clips. 8.
Install the Powertrain Lift under the fuel tank. 9.
Remove the 4 bolts and the fuel tank straps.
10.
Partially lower the fuel tank enough to access the fuel tank filler pipe hose clamp. 11.
NOTE: Some residual fuel may remain in the fuel tank filler pipe. When removing the filler pipe,
carefully drain the fuel into a suitable container.
Release the clamp and disconnect the fuel tank filler pipe hose from the fuel tank.
12.
Disconnect the Fuel Tank Pressure (FTP) sensor electrical connector. 13.
Disconnect the fuel vapor tube assembly-to-fuel tank quick connect coupling. For additional
14.
Remove the fuel vapor tube assembly. 15.

16.
Emissions
Manual
Fuel Vapor Tube Assembly Front Wheel Drive (FWD)
Item
Part
Number Description
1 9002 Fuel tank
2 Fuel vapor tube assembly-to-fuel tank quick connect
coupling (part of 9A228)
3 14A464 Fuel Tank Pressure (FTP) sensor electrical connector
4 9C052 FTP sensor (part of 9A228)
6 Fuel vapor tube assembly-to-Evaporative Emission
7 9G676 Fuel vapor solenoid and separator assembly (part of
9E857)
9 Fuel vapor tube assembly pin-type retainer (part of
9A228)
10 Fuel vapor tube-to-recirculation tube quick connect
11 Fuel tank filler pipe recirculation tube (part of 9034)
Fuel Vapor Tube Assembly Front Wheel Drive (FWD) 2664
100-02 .
1.
3.
5.
6.
Disconnect the fuel vapor tube assembly from the fuel vapor separator and solenoid assembly. 7.
Release the pin-type retainer. 8.
9.

11.
SECTION 303-13B: Evaporative Emissions -
Hybrid
Workshop Manual
Evaporative Emission
(EVAP) canister bolts
6 53
EVAP canister nuts 6 53
EVAP canister purge
valve bolts
10 89
Fuel tank filler pipe
heat shield nuts
10 89
Hybrid
Workshop Manual
The Evaporative Emission (EVAP) system consists of the:
EVAP canister purge valve.
EVAP canister (includes the dust separator and the vent solenoid).
fuel vapor tube assembly (includes the Fuel Tank Pressure (FTP) sensor and the vapor blocking
valve).

Easy FuelTM (capless) fuel tank filler pipe.
The EVAP system:
prevents hydrocarbon emissions from reaching the atmosphere.
stores fuel vapors in the EVAP canister, that are generated during vehicle operation or hot soak, until
they can be consuy the engine during normal engine operation.

routes the stored fuel vapors to the engine during engine operation.
is controlled by the PCM which, using various sensor inputs, calculates the desired amount of purge
flow. The PCM regulates the purge flow, induced by the application of intake manifold vacuum, by
varying the duty cycle applied to the EVAP canister purge valve.

The fuel vapors are routed:
from the fuel tank through the fuel vapor vent valve.
to the EVAP canisters through a vapor tube.
from the EVAP canister to the engine when the EVAP canister purge valve is opened by the PCM.
The FTP sensor (part of fuel vapor tube assembly):
monitors the pressure levels in the fuel tank.
communicates the pressure reading to the PCM during the OBD II leak test.
The fuel vapor tube assembly:
is used to monitor fuel pressure and relay information to the PCM.
includes the FTP sensor and the vapor blocking valve.
The EVAP canister:
includes the dust separator and vent solenoid.
contains activated carbon.
stores fuel vapors.
The Easy FuelTM (capless) fuel tank filler pipe:
relieves system vacuum below -3.5 kPa (-16.00 in H
2
O).
The EVAP canister vent solenoid:
is normally open.
seals the EVAP system for the inspection and maintenance (I/M 240) test and OBD II leak and
pressure tests.

The EVAP canister purge valve:
is normally closed.
regulates the purging of the EVAP canisters.
is controlled by the PCM.
is repaired as a separate item.
is mounted to the intake manifld.
The dust separator:
is attached to the EVAP canister vent solenoid.
prevents suspended dust and dirt particles from entering the EVAP system.
The EVAP system monitor:
is a self-test strategy within the PCM which tests the integrity of the EVAP system.
monitors the EVAP system for leaks.
monitors electronic EVAP components for irrationally high or low voltages.
monitors for correct EVAP system operation.
uses negative and positive leak test methods to test and activate the EVAP system.
The engine ON EVAP leak-check monitor:
is executed by the individual components of the enhanced EVAP system. Intake manifold vacuum is
utilized to reach a target vacuum on the EVAP system. The FTP sensor is used by the engine ON
EVAP leak-check monitor to determine if the target vacuum necessary to carry out the leak-check on
the EVAP system has been reached. Once target vacuum on the EVAP system is achieved, the change
in EVAP system vacuum over a calibrated period of time determines if a leak exists.

The Engine Off Natural Vacuum (EONV) EVAP leak-check monitor is executed:
once the engine ON EVAP leak-check monitor is completed and the key is turned OFF. The EONV
EVAP leak-check monitor determines if a leak is present when the naturally occurring change in the
fuel tank pressure or vacuum does not exceed a calibrated limit during a calibrated amount of time. A
separate, low-power consuming microprocessor in the PCM manages the EONV leak-check. The
engine OFF EVAP leak-check monitor is executed by the individual components of the enhanced
EVAP system.

Vehicle Emission Vacuum Routing
1 - PCV valve (part of 6A785)
6582 Valve cover
6 9002 Fuel tank
9E857)
9 9G712 Fuel vapor vent valve
SECTION 303-13B: Evaporative Emissions
Hybrid
Workshop Manual
SECTION 303-13B: Evaporative Emissions
Hybrid
Workshop Manual
Evaporative Emission System Leak Test
Special Tool(s)
VACUTEC Smoke Machine Fuel
Evaporative Emission System Tester
Phase 1 Leak Verification
Run the EVAP Test with the scan tool. 1.
NOTE: Some small leaks may not be detected using the EVAP Test. If the system has passed the test
but a leak is still suspected, then proceed to Phase 2.
If the Evaporative Emission (EVAP) system failed the EVAP Test, then proceed to Phase 2.
2.
Phase 2 System Leak Check
100-02 .
1.
Disconnect the fuel vapor tube-to- EVAP canister purge valve quick connect coupling. For additional
2.
Connect the VACUTEC Smoke Machine Fuel Evaporative Emissions System Tester to the fuel vapor
tube quick connect coupling. For additional information, refer to the manufacturer's instructions.
3.
NOTE: The battery ground cable was previously disconnected in the vapor tube quick connect
coupling disconnect procedure.
Connect the battery ground cable. For additional information, refer to Section 414-01 .
4.
Close the canister vent solenoid with the scan tool. 5.
NOTE: The supplemental refueling adapter is located in the luggage compartment
Install the supplemental refueling adapter into the Easy Fuel
TM
(capless) fuel tank filler pipe
assembly.
6.
NOTE: If smoke does not exit the fuel tank filler pipe neck area after the system is pressurized, open
the canister vent solenoid with the scan tool to allow the air to purge. Once smoke is seen at the
canister vent solenoid, close the canister vent solenoid with the scan tool.
7.
Introduce smoke from the VACUTEC Smoke Machine Fuel Evaporative Emission System Tester into
the EVAP system and verify that smoke is exiting the fuel tank filler pipe neck area. For additional
information, refer to the manufacturer's instructions.
Remove the supplemental refueling adapter once smoke is observed exiting the fuel tank filler pipe
neck area.
8.
Continue to enter smoke into the system for 60 seconds to obtain pressure. 9.
Press and release the remote start button in intervals of 15 seconds ON and 15 seconds OFF while
checking for exiting smoke.
10.
Use the halogen light provided with the VACUTEC Smoke Machine Fuel Evaporative Emission
System Tester to follow the EVAP system path and look for smoke exiting at the source of the
leak(s).
11.
Repair any leaks as necessary. 12.
Repeat the leak test until the system passes. 13.
Hybrid
Workshop Manual
Evaporative Emission Canister Purge Valve
Item
Part
Number Description
1 9G271 Vapor tube
Disconnect the vapor tube-to- EVAP canister purge valve quick connect coupling. For additional
3.
Remove the 2 bolts and the EVAP canister purge valve.
4.

5.
Hybrid
Workshop Manual
Evaporative Emission Canister
Item
Part
Number Description
1 W708029 Evaporative Emission (EVAP) canister bolt (2 required)
2 W713475 EVAP canister nut (2 required)
3 14A464 EVAP canister vent solenoid electrical connector >
4 - Fresh air tube (part of 9034)
(part of 9J279)
(part of 9A228)
mixtures are always present and may beed. Failure to follow these instructions may result in serious
personal injury.
100-02 .
1.
NOTE: Clean the Evaporative Emission (EVAP) canister vent solenoid electrical connector and the
immediate surrounding area of any dirt or foreign material.
Disconnect the EVAP canister vent solenoid electrical connector.
3.
Disconnect the fresh air tube from the EVAP canister. 4.
Disconnect the vapor tube assembly-to- EVAP canister quick connect couplings. For additional
5.
Remove the 2 nuts, 2 bolts and the EVAP canister assembly.
6.

7.
Hybrid
Workshop Manual
Fuel Vapor Tube Assembly
Item
Part
Number Description
1 9002 Fuel tank
2 - Fuel vapor tube assembly-to-fuel tank quick connect
3 14A464 Fuel Tank Pressure (FTP) sensor electrical connector
4 9C052 FTP sensor (part of 9A228)
5 9G712 Vapor blockive (part of 9A228)
6 14A464 Vapor blocking valve electrical connector
8 - Fuel vapor tube assembly-to-Evaporative Emission
9 - Two-stage recirculation orifice (part of 9A228)
10 - Fuel vapor tube assembly pin-type retainer (part of
9A228)
11 - Fuel vapor tube-to-recirculation tube quick connect
12 9G676 Fuel vapor solenoid and separator assembly (part of
9E857)
Fuel Vapor Tube Assembly 2678
on or near any fuel-related component. Highly flammable mixtures are always present aignited. Failure
100-02 .
1.
3.
Disconnect the vapor blocking valve electrical connector. 5.
6.
7.
Disconnect the fresh air tube (part of the fuel vapor tube assembly) from the fuel vapor separator and
solenoid assembly.
8.
Release the pin-type retainer. 9.
10.

12.
SECTION 303-14A: Electronic Engine Controls -
2.5L
Workshop Manual
Material
Capacity
High Temperature Nickel
Anti-Seize Lubricant
XL-2
ESE-M12A4-A -
XO-5W20-QSP (US);
Premium Motor Oil
equivalent
WSS-M2C930-A -
- -
Camshaft Position (CMP) sensor bolt 7 Catalyst Monitor Sensor (CMS)
a
- -
a
- -
Cylinder block plug 20 177
Cylinder Head Temperature (CHT) sensor 12 106
a
- -
Knock Sensor (KS) bolt 20 177
Manifold Absolute Pressure (MAP) sensor screw 3 27
PCM bolts 11 97
Variable Camshaft Timing (VCT) oil control solenoid bolt 10 89
a
2.5L
Workshop Manual
Electronic Engine Controls
The electronic engine controls consist of the following:
PCM
Camshaft Position (CMP) sensor
Crankshaft Position (CKP) sensor
Mass Air Flow (MAF) sensor
Catalyst Monitor Sensor (CMS)
Knock Sensor (KS)
Variable Camshaft Timing (VCT) oil control solenoid
Manifold Absolute Pressure (MAP) sensor
The PCM:
accepts input from various engine sensors to compute the fuel flow rate necessary to maintain a
prescribed air/fuel ratio throughout the entire engine operational range.

outputs a command to the fuel injectors to meter the appropriate quantity of fuel.
The CMP sensor:
The CKP sensor:
sends the PCM a signal indicating crankshaft position.
is essential for calculating spark timing.
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.

The HO2S :
creates a voltage signal dependent on exhaust oxygen content.
provides feedback information to the PCM used to calculate fuel delivery.
The CMS :
monitors oxygen content after it flows through the catalytic converter.
The CHT sensor:
sends the PCM a signal indicating cylinder head temperature.
resistance decreases as coolant temperature increases.
Electronic Engine Controls 2683
The KS :
is used to detect engine detonation.
sends a voltage signal to the PCM.
is able to provide a signal which retards the ignition timing, as necessary.
The VCT oil control solenoid:
is an electrically controlled hydraulic valve that directs engine oil to the variable camshaft. Once the
PCM transmits a signal, the solenoid moves a valve spool, directing oil into the camshaft phaser
cavity. This action changes valve timing by either inducing an advance or retard condition. The
camshaft is, thereby repositioned in relation to crankshaft timing and allows for optimum engine
performance and lower emissions.

The MAP sensor:
measures manifold vacuum and converts it to an electrical signal. This provides the PCM information
on engine load.

2.5L
Workshop Manual
DTC Charts
PCM DTC Chart
P0125 Insufficient Coolant Temp For Closed Loop Fuel
Control
REFER to Section 03A .
P0217 Engine Coolant Overtemperature Condition REFER to Section 303-03A .
P0512 Starter Request Circuit REFER to Section 303-06 .
P0532 A/C Refrigerant Pressure Sensor A Circuit Low REFER to Section 412-00A .
P0533 A/C Refrigerant Pressure Sensor A Circuit High REFER to Section 412-00A .
P0563 System Voltage High REFER to Section 414-00 .
P0572 Brake Switch "A" Circuit Low REFER to Section 419-03 .
P0573 Brake Switch "A" Circuit High REFER to Section 419-03 .
P0579 Cruise Control Multi-Function Input A Circuit
Range/Performance
High
P0602 Powertrain Control Module Programming Error REFER to Section 418-01 .
P0605 Internal Control Module Read Only Memory
(ROM) Error
P0620 Generator Control Circuit REFER to Section 414-00 .
P0625 Generator Field Terminal Circuit Low REFER to Section 414-00 .
P0626 Generator Field Terminal Circuit High REFER to Section 414-00 .
P0645 A/C Clutch Relay Control Circuit REFER to Section 412-00A .
P0657 Actuator Supply Voltage A Circuit/Open REFER to Section 307-01B .
P065B Generator Control Circuit Range/Performance REFER to Section 414-00 .
P0701 Transmission Control System Range/Performance REFER to Section 307-01B .
P0706 Transmission Range Sensor "A" Circuit
Range/Performance
P0707 Transmission Range Sensor "A" Circuit Low REFER to Section 307-01B .
P0708 Transmission Range Sensor "A" Circuit High REFER to Section 307-01B .
P0710 Transmission Fluid Temperature Sensor "A"
Circuit
Circuit Range/Performance
P0712 Transmission Fluid Temperature Sensor "A" REFER to Section 307-01B .
Circuit Low
Circuit High
P0715 Turbine/Input Shaft Speed Sensor "A" Circuit REFER to Section 307-01B .
P0717 Turbine/Input Shaft Speed Sensor "A" Circuit No
Signal
P0718 Turbine/Input Shaft Speed Sensor "A" Circuit
Intermittent
P0720 Output Shaft Speed Sensor Circuit REFER to Section 307-01B .
P0721 Output Shaft Speed Sensor Circuit
Range/Performance
P0722 Output Shaft Speed Sensor Circuit No Signal REFER to Section 307-01B .
P0729 Gear 6 Incorrect Ratio REFER to Section 307-01B .
P0740 Torque Converter Clutch Solenoid Circuit/Open REFER to Section 307-01B .
P0741 Torque Converter Clutch Solenoid Circuit
Performance/Stuck Off
P0742 Torque Converter Clutch Solenoid Circuit Stuck
On
Electrical
Intermittent
P0748 Pressure Control Solenoid "A" Electrical REFER to Section 307-01B .
P0750 Shift Solenoid "A" REFER to Section 307-01B .
P0751 Shift Solenoid "A" Performance/Stuck Off REFER to Section 307-01B .
P0752 Shift Solenoid "A" Stuck On REFER to Section 307-01B .
P0753 Shift Solenoid "A" Electrical REFER to Section 307-01B .
P0754 Shift Solenoid "A" Intermittent REFER to Section 307-01B .
P0755 Shift Solenoid "B" REFER to Section 307-01B .
P0756 Shift Solenoid "B" Performance/Stuck Off REFER to Section 307-01B .
P0757 Shift Solenoid "B" Stuck On REFER to Section 307-01B .
P0758 Shift Solenoid "B" Electrical REFER to Section 307-01B .
P0759 Shift Solenoid "B" Intermittent REFER to Section 307-01B .
P0760 Shift Solenoid "C" REFER to Section 307-01B .
P0761 Shift Solenoid "C" Performance/Stuck Off REFER to Section 307-01B .
P0762 Shift Solenoid "C" Stuck On REFER to Section 307-01B .
P0763 Shift Solenoid "C" Electrical REFER to Section 307-01B .
P0764 Shift Solenoid "C" Intermittent REFER to Section 307-01B .
P0765 Shift Solenoid "D" REFER to Section 307-01B .
P0766 Shift Solenoid "D" Performance/Stuck Off REFER to Section 307-01B .
P0767 Shift Solenoid "D" Stuck On REFER to Section 307-01B .
P0768 Shift Solenoid "D" Electrical REFER to Section 307-01B .
P0769 Shift Solenoid "D" Intermittent REFER to Section 307-01B .
P0770 Shift Solenoid "E" REFER to Section 307-01B .
P0771 Shift Solenoid "E" Performance/Stuck Off REFER to Section 307-01B .
P0772 Shift Solenoid "E" Stuck On REFER to Section 307-01B .
P0773 Shift Solenoid "E" Electrical REFER to Section 307-01B .
P0774 Shift Solenoid "E" Intermittent REFER to Section 307-01B .
P07A5 Transmission Friction Element "B" Stuck On REFER to Section 307-01B .
P07A8 Transmission Friction Element "D"
P07A9 Transmission Friction Element "D" Stuck On REFER to Section 307-01B .
P07AA Transmission Friction Element "E"
P0867 Transmission Fluid Pressure REFER to Section 307-01B .
P0960 Pressure Control Solenoid A Control Circuit/Open REFER to Section 307-01B .
P0961 Pressure Control Solenoid "A" Control Circuit
Range/Performance
Low
High
P0973 Shift Solenoid "A" Control Circuit Low REFER to Section 307-01B .
P0974 Shift Solenoid "A" Control Circuit High REFER to Section 307-01B .
P0976 Shift Solenoid "B" Control Circuit Low REFER to Section 307-01B .
P0977 Shift Solenoid "B" Control Circuit High REFER to Section 307-01B .
P0979 Shift Solenoid "C" Control Circuit Low REFER to Section 307-01B .
P0980 Shift Solenoid "C" Control Circuit High REFER to Section 307-01B .
P0982 Shift Solenoid "D" Control Circuit Low REFER to Section 307-01B .
P0983 Shift Solenoid "D" Control Circuit High REFER to Section 307-01B .
P0984 Shift Solenoid "E" Control Circuit
Range/Performance
P1260 Theft Detected, Vehicle Immobilized REFER to Section 419-01B .
P1285 Cylinder Head Overtemperature Condition REFER to Section 303-03A .
P1299 Cylinder Head Overtemperature Protection Active REFER to Section 303-03A .
P1464 A/C Demand Out Of Self Test Range REFER to Section 412-00A .
P1602 Immobilizer/ECM Communication Error REFER to Section 419-01B .
P1622 Immobilizer ID Does Not Match REFER to Section 419-01B .
P1636 Inductive Signature Chip Communication Error REFER to Section 307-01B .
P1639 Vehicle ID Block Corrupted, Not Programmed REFER to Section 418-01 .
P163E Transmission Control Module Programming Error REFER to Section 307-01B .
P163F Transmission ID Block Corrupted, Not
Programmed
P1702 Transmission Range Sensor Circuit Intermittent REFER to Section 307-01B .
P1703 Brake Switch Out Of Self Test Range REFER to Section 419-03 .
P1705 Transmission Range Circuit Not Indicating
Park/Neutral During Self Test
P1711 Transmission Fluid Temperature Sensor Out Of
Self Test Range
P1714 Shift Solenoid "A" Inductive Signature REFER to Section 307-01B .
Performance
P1780 Transmission Control Switch (O/D Cancel) Circuit
Out Of Self Test Range
P1783 Transmission Overtemperature Condition REFER to Section 307-01B .
P1910 Reverse Lamp Control Circuit/Open REFER to Section 417-01 .
P2700 Transmission Friction Element "A" Apply Time
Range/Performance
P2701 Transmission Friction Element "B" Apply Time
Range/Performance
P2702 Transmission Friction Element "C" Apply Time
Range/Performance
P2703 Transmission Friction Element "D" Apply Time
Range/Performance
P2704 Transmission Friction Element "E" Apply Time
Range/Performance
P2705 Transmission Friction Element "F" Apply Time
Range/Performance
P2760 Torque Converter Clutch Pressure Control
Solenoid Intermittent
P2783 Torque Converter Temperature Too High REFER to Section 307-01B .
U0300 Internal Control Module Software Incompatibility REFER to Section 418-01 .
All Other
DTCs
- REFER to Powertrain Control/Emissions
SECTION 303-14A: Electronic Engine
Controls - 2.5L
Workshop Manual
Camshaft Position (CMP) Sensor
Material
Item Specification
or equivalent
WSS-M2C930-A
Item
Part
Number
1 14A464
12B637)
2 W701219 CMP
sensor bolt
3 12K073 CMP
4 - CMP
O-ring seal
Remove the bolt and the CMP .
2.
NOTE: Lubricate the CMP O-ring seal with clean engine oil.
3.
Camshaft Position (CMP) Sensor 2690
Controls - 2.5L
Workshop Manual
Crankshaft Position (CKP) Sensor
Special Tool(s)
303-1417
303-507
General Equipment
6 mm x 18 mm bolt
Item
Part
Number Description
(part of 12B637)
2 W701219-S CKP sensor bolt (2 required)
3 6C315 CKP sensor
Removal
100-02 .
1.
Crankshaft Position (CKP) Sensor 2692
Turn the crankshaft clockwise until the hole in the crankshaft pulley is in the 3 o'clock position. 4.
Remove the cylinder block plug. 5.
NOTE: When the crankshaft contacts the Crankshaft TDC Timing Peg, the No. 1 cylinder will be at
Install the Crankshaft TDC Timing Peg and turn the crankshaft clockwise until the crankshaft contacts
the Crankshaft TDC Timing Peg.
6.
Remove the bolts and discard the CKP sensor. 8.
Installation
Install a 6 mm (0.23 in) x 18 mm (0.7 in) standard bolt in the crankshaft pulley.
1.
2.
Adjust the CKP sensor with the Crankshaft Sensor Aligner.
3.
Remove the 6 mm (0.23 in) bolt from the crankshaft pulley. 5.
Install the cylinder block plug.
6.
Install the 6 pin-type retainers and the RH splash shield. 7.
Install the 4 screws and position the RH fender splash shield aside. 8.
9.
Controls - 2.5L
Workshop Manual
Powertrain Control Module (PCM)
1 14A464 PCM electrical connector (3 required)
2 W505428 PCM bolt (2 required)
3 12A650 PCM
4 12A659 PCM bracket
Removal
NOTE: PCM replacement DOES NOT require new keys or programming of keys.
Retrieve the module configuration. Carry out the module configuration retrieval steps of the
Programmable Module Installation (PMI) procedure. For additional information, refer to Section
418-01 .
1.
Remove the 2 bolts and the PCM. 4.
Installation
Install the PCM and the 2 bolts.
1.
NOTE: If the Programmable Module Installation (PMI) procedure was not successful in downloading
the data from the vehicles original PCM, then the oil life data of the vehicle is lost. If this occurs, and
the oil life cannot be determined through service history or customer interview, it is recommended the
vehicle engine oil and filter be changed and the oil change minder reset.
4.
Powertrain Control Module (PCM) 2696
Restore the module configuration. Carry out the module configuration restore steps of the
418-01 .
Reprogram the Passive Anti-Theft System (PATS). Carry out the Parameter Reset procedure. For
additional information, refer to Section 419-01B .
5.
6.
Controls - 2.5L
Workshop Manual
Mass Air Flow (MAF) Sensor
Item
Part
Number Description
1 14A464 Mass Air Flow (MAF) sensor electrical connector (part
of 12B637)
2 W709287-S MAF sensor sc(2 required)
3 12B579 MAF sensor
Remove the 2 screws and the MAF sensor.
2.
Mass Air Flow (MAF) Sensor 2698
Controls - 2.5L
Workshop Manual
Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View
Non-Partial Zero Emissions Vehicle (PZEV)
Item
Part
Number Description
1 14A64 Heated Oxygen Sensor (HO2S) electical connector (part
of 12B637)
2 9F472 HO2S sensor
3 14A464 Cataitor Sensor (CMS) electrical connector
4 9G444 CMS sensor
Partial Zero Emissions Vehicle (PZEV)
Item
Part
Number Description
1 14A64 Heated Oxygen Sensor (HO2S) electical connector (part
Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View 2700
of 12B637)
2 9F472 HO2S sensor
3 14A464 Catalyst Monitor Sensor (CMS) electrical connector
4 9G444 CMS sensor
Partial Zero Emissions Vehicle (PZEV) 2701
Controls - 2.5L
Workshop Manual
Special Tool(s)
303-476 (T94P-9472-A)
Material
Item Specification
High Temperature Nickel Anti-Seize
Lubricant
XL-2
ESE-M12A4-A
-
Disconnect the Heated Oxygen Sensor (HO2S) electconnector. 1.
NOTE: If necessary, lubricate the sensor threads with penetrating and lock lubricant to assist in
removal.
Using the Exhaust Gas Oxygen Sensor Socket, remove the HO2S .
Wrench Adapter Formulas in the Appendix .

2.
NOTE: Apply a light coat of anti-seize lubricant to the threads of the HO2S .
3.
Heated Oxygen Sensor (HO2S) 2702
Controls - 2.5L
Workshop Manual
Catalyst Monitor Sensor
Special Tool(s)
303-476 (T94P-9472-A)
Material
Item Specification
Lubricant
XL-2
ESE-M12A4-A
-
With the vehicle in NEUTRAL, position it on a hoist. Fotional information, refer to Section 100-02 . 1.
removal.
Using the Exhaust Gas Oxygen Sensor Socket, remove the CMS .
Wrench Adapter Formulas in the Appendix .

3.
NOTE: Apply a light coat of anti-seize lubricant to the threads of the CMS .
4.
Catalyst Monitor Sensor 2704
Controls - 2.5L
Workshop Manual
Cylinder Head Temperature (CHT) Sensor
Item
Part
Number Description
1 14603 Cylinder Head Temperature (CHT) sensor cover (part
of 12C508)
2 14A464 CHT sensor electrical connector (part of 12C508)
3 6G004 CHT sensor
Detach the Cylinder Head Temperature (CHT) sensor cover and position aside. 1.
Disconnect the CHT sensor electrical connector. 2.
Remove the CHT sensor.
3.
Cylinder Head Temperature (CHT) Sensor 2706
Controls - 2.5L
Workshop Manual
Clutch Pedal Position (CPP) Switch
Item
Part
Number Description
1 - Clutch Pedal Position (CPP) switch electrical connector
(part of 14290)
2 7C534
Disconnect the Clutch Pedal Position (CPP) switch electrical connector. 1.
Rotate the CPP switch clockwise and remove the CPP switch. 2.
Clutch Pedal Position (CPP) Switch 2708
Clutch Pedal Position (CPP) Switch 2709
Controls - 2.5L
Workshop Manual
Knock Sensor (KS)
1 W5000025 Knock Sensor (KS) bolt
2 12A699 KS
100-02 .
1.
Remove the intake manifold. For additional information, refer to Section 303-01A . 2.
Remove the bolt and the Knock Sensor (KS).
3.
NOTE: The KS must not touch the crankcase vent oil separator.
4.
Knock Sensor (KS) 2710
Controls - 2.5L
Workshop Manual
Variable Camshaft Timing (VCT) Oil Control Solenoid
bolt
Remove the valve cover. For additional information, refer to 1.
Remove the bolt and the Variable Camshaft Timing (VCT) oil control solenoid.
2.
Variable Camshaft Timing (VCT) Oil Control Solenoid 2711
Controls - 2.5L
Workshop Manual
Manifold Absolute Pressure (MAP) Sensor
Material
Item Specification
or equivalent
WSS-M2C930-A
Item
Part Number
Description
1 14A464 Manifold Absolute Pressure (MAP) sensor
2 W701459 MAP sensor screw
3 9F479 MAP sensor
Remove the screw and the MAP sensor.
2.
NOTE: Lubricate the MAP sensor O-ring seal with clean engine oil.
3.
Manifold Absolute Pressure (MAP) Sensor 2713
SECTION 303-14B: Electronic Engine Controls - 3.0L
(4V)
Material
Capacity
XL-2
ESE-M12A4-A -
XO-5W20-QSP (US);
Premium Motor Oil
equivalent
WSS-M2C930-A -
- -
Camshaft Position (CMP) sensor bolt 10 - 89
a
- - -
Crankshaft Position (CKP) sensor bolt 10 - 89
a
- - -
Knock Sensor (KS) bolt (cylinder-block mounted) 25 18 -
Knock Sensor (KS) bolt (cylinder-head mounted) 25 18 -
Manifold Absolute Pressure (MAP) sensor bolt 6 - 53
Mass Air Flow (MAF) sensor screws 2 - 18
PCM bolts 8 - 71
Radio frequency interference capacitor 6 - 53
Variable Camshaft Timing (VCT) oil control solenoid bolt 10 - 89
a
SECTION 303-14B: Electronic Engine Controls - 3.0L
(4V)
The electronic engine controls consist of the:
PCM.
Cylinder Head Temperature (CHT) sensor.
Heated Oxygen Sensor (HO2S).
Catalyst Monitor Sensor (CMS).
Variable Camshaft Timing (VCT) oil control solenoid.
Knock Sensor (KS) (cylinder-block mounted).
KS (cylinder-head mounted).
Manifold Absolute Pressure (MAP) sensor.
The PCM carries out the following functions:
accepts input from various engine sensors to compute the fuel flow rate necessary to mainta

The CMP sensor:
The CKP sensor:
The MAF sensor:

The CHT sensor:
NOTE: If the cylinder head is being replaced, the CHT must be replaced.
sends the PCM a signal indicating engine temperature.
resistance decreases as coolant temperature increases.
The HO2S :
The CMS :
provides a voltage to the PCM used to calculate catalytic converter integrity.

The KS :
NOTE: There are 2 KS , one is located on the RH cylinder head and one is mounted on the engine block in
the intake manifold valley.
The MAP sensor:
on engine load.

SECTION 303-14B: Electronic Engine Controls
- 3.0L (4V)
Workshop Manual
DTC Charts
PCM DTC Chart
Control
REFER to .
Range/Performance
High
(ROM) Error
Range/Performance
Circuit
Circuit Low
Circuit High
Signal
Intermittent
Range/Performance
On
Electrical
Intermittent
Range/Performance
Low
High
Range/Performance
Programmed
Self Test Range
Performance
Range/Performance
Range/Performance
Range/Performance
Range/Performance
Range/Performance
Range/Performance
All Other
DTCs
SECTION 303-14B: Electronic Engine Controls -
3.0L (4V)
Workshop Manual
Material
Item Specification
or equivalent
WSS-M2C930-A
1 14A464 LH Camshaft Position (CMP) sensor electrical
2 W500214 LH CMP
sensor bolt
3 12K073 LH CMP sensor
4 - LH CMP sensor O-ring seal
5 14A464 RH CMP sensor electrical connector (part of
12C508)
6 W500214 RH CMP sensor bolt
7 12K073 RH CMP sensor
8 - RH CMP sensor O-ring seal
Disconnect the Camshaft Position (CMP) electrical connector. 1.
Remove the bolt and the CMP sensor.
2.
NOTE: Lubricate the CMP O-ring seal with clean engine oil. 3.
3.0L (4V)
Workshop Manual
Special Tool(s)
Material
Item Specification
or equivalent
WSS-M2C930-A
2 W500214 CKP sensor bolt
3 6C315 CKP sensor
4 - CKP sensor O-ring seal
100-02 .
1.
Remove the bolt and the CKP .
3.
Inspect the O-ring seal and install new as necessary.
NOTE: Lubricate the CKP O-ring seal with clean engine oil.
4.
5.
3.0L (4V)
Workshop Manual
3 12A650 PCM
Removal
Programmable Module Installation (PMI) procedure. For additional information, refer Section 418-01
.
1.
Installation
Install the PCM and the 2 bolts.
1.
NOTE: If the Programmable Module Installation (PMI) procedure was not successful in downloading
the data from the vehicles original PCM, then the oil life data of the vehicle is lost. If this occurs, and
the oil life cannot be determined through service history or customer interview, it is recommended the
vehicle engine oil and filter be changed and the oil change minder reset.
4.
418-01 .
5.
6.
3.0L (4V)
Workshop Manual
2 W709287 MAF sensor screw (2 reed)
3 12B579 MAF sensor
2.
3.0L (4V)
Workshop Manual
1 14A464 Cylinder Head Temperature (CHT) sensor
2 6G004 CHT sensor
NOTE: If the cylinder head is being replaced, the Cylinder Head Temperature (CHT) sensor must be
replaced.
Remove the battery tray. For additional informationfer to Section 414-01 . 1.
3.
3.0L (4V)
Workshop Manual
NOTE: Front Wheel Drive (FWD) shown, All-Wheel Drive (AWD) similar.
1 14A464 Heated Oxygen Sensor (HO2S) electrical connectors
2 9F472 HO2S
3 14A464 Catalyst Monitor Sensor (CMS) eleconnectors
4 9G444 CMS
3.0L (4V)
Workshop Manual
Special Tool(s)
303-476 (T94P-9472-A)
Material
Item Specification
Lubricant
XL-2
ESE-M12A4-A
-
Rear sensor
With the e in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 . 1.
Both sensors
removal.

3.
4.
3.0L (4V)
Workshop Manual
Special Tool(s)
303-476 (T94P-9472-A)
Material
Item Specification
Lubricant
XL-2
ESE-M12A4-A
-
With the vehicle in NEUTRAL, position it on a. For additional information, refer to Section 100-02 . 1.
removal.
Using the Exhaust Gas Oxygen Sensor Socket, remove the CMS sensor.

3.
NOTE: Apply a light coat of anti-seize lubricant to the threads of the CMS sensor.
4.
3.0L (4V)
Workshop Manual
Item
Part
Number Description
bolt (2 required) (part of 6B297)
2 6B297 VCT oil control solenoid
3 W713305 VCT oil control solenoid bolt (2 required) (part of
6B297)
Remove the LH or RH valve cover. For additional information, refer to Section 303-01B . 1.
Remove the 2 bolts and the Variable Camshaft Timing (VCT) oil control solenoid.
2.
3.0L (4V)
Workshop Manual
Knock Sensor (KS)
Cylinder-Head Mounted Knock Sensor (KS)
1 14A464 Knock Sensor (KS) electrical connector
2 W500310 KS bolt
3 12A699 KS
Cylinder-Block Mounted Knock Sensor (KS)
2 W500310 KS bolt
3 12A699 KS
Removal
Cylinder head-mounted
Engine block-mounted
Remove the lower intake manifold. For additional information, refer to Section 303-01B . 3.
Disconnect the KS electrical connector. 4.
Installation
Engine block-mounted
1.
Install the lower intake manifold. For additional information, refer to Section 303-01B . 3.
Cylinder head-mounted
4.
Cylinder-Block Mounted Knock Sensor (KS) 2742
3.0L (4V)
Workshop Manual
Item
Part
Number Description
2 W710652 MAP sensor bolt
3 9F479 MAP
Remove the bolt and the MAP sensor.
When installing the sensor, if the bolt fails to hold specified torque, relocate the sensor and
retain, using the auxiliary bolt hole in the intake manifold.

2.
NOTE: Clean and inspect the sealing surface.
3.
SECTION 303-14C: Electronic Engine Controls -
3.5L
Workshop Manual
Material
Capacity
XL-2
- -
XO-5W20-QSP (US);
Premium Motor Oil
equivalent
WSS-M2C930-A -
Engine Coolant
VC-10-A2 (US); CVC-10-A
(Canada)
a
WSS-M97B55-A -
- -
a
Genuine Mazda Extended Life Coolant and Motorcraft Specialty Green Engine Coolant are very
sensitive to light. Do NOT allow these products to be exposed to ANY LIGHT for more than a day or two.
Extended light exposure causes these products to degrade.
Camshaft Position (CMP) sensor bolts 10 89
a
- -
Crankshaft Position (CKP) sensor bolt 10 89
Heat shield bolt and nut 10 89
a
- -
PCM bolts 8 71
Variable Camshaft Timing (VCT) oil control solenoid bolts 10 89
a
Refer to the procedure for specification.
p;
3.5L
Workshop Manual
The electronic engine controls consist of the:
PCM.
Cylinder Head Temperature (CHT) sensor.
Heated Oxygen Sensor (HO2S).
Catalyst Monitor Sensor (CMS).
Variable Camshaft Timing (VCT) oil control solenoid.
Knock Sr (KS).
The PCM:

The CHT sensor:
resistance decreases as cylinder head temperature increases.
The CMP sensor:
The CKP sensor:
The MAF sensor:

The HO2S :
The CMS :
provides a voltage to the PCM used to calculate catalytic converter integrity.

The KS :
3.5L
Workshop Manual
DTC Charts
PCM DTC Chart
Control
REFER to Section 03A .
Range/Performance
High
(ROM) Error
Range/Performance
Circuit
Circuit Low
Circuit High
Signal
Intermittent
Range/Performance
On
Electrical
Intermittent
Range/Performance
Low
High
Range/Performance
Programmed
Self Test Range
Performance
Range/Performance
Range/Performance
Range/Performance
Range/Performance
Range/Performance
Range/Performance
All Other
DTCs
SECTION 303-14C: Electronic Engine
Controls - 3.5L
Workshop Manual
Material
Item Specification
or equivalent
WSS-M2C930-A
Item Part Number Destion
1 14A464 RH Camshaft Position (CMP) sensor electrical
connector
2 W503279 RH CMP sensor bolt
3 6B288 RH CMP sensor
4 14A464 LH CMP sensor electrical connector
5 W503279 LH CMP sensor bolt
6 6B288 LH CMP sensor
Remove the bolt and the CMP sensor.
3.
NOTE: Lubricate the CMP sensor O-ring seal with clean engine oil.
4.
Controls - 3.5L
Workshop Manual
Special Tool(s)
Item Part Number
1 W701542 Heat shield nut
2 W701669 Heat shield bolt
3 6K342 Heat shield
4 6C070 Rubber grommet cover
6 6D327 CKP sensor bolt
7 6C315 CKP sensor
100-02 .
1.
Remove the bolt, nut and the heat shield.
3.
Remove the rubber grommet cover. 4.
Remove the bolt and the CKP sensor.
6.
8.
Controls - 3.5L
Workshop Manual
Special Tool(s)
1 14A464 PCM electrical connector (part of 12B637) (2
required)
3 12A650 PCM
Removal
418-01 .
1.
Installation
Install the PCM and the bolts.
1.
418-01 .
4.
5.
6.
Controls - 3.5L
Workshop Manual
3 12B579 MAF sensor
Remove the 2 screws and the MAF span> sensor.
2.
Controls - 3.5L
Workshop Manual
Item
Part
Number Description
1 14A464 Cylinder Head Temperature (CHT) sensor electrical
connector
2 6G004 CHT sensor
Section 303-01C .
Remove and discard the CHT sensor.
3.
Do not reuse the CHT sensor, install a new sensor.
4.
Controls - 3.5L
Workshop Manual
RH Sensors
2 9F472
4 9G444 CMS
5 6A664 PCV hose
LH Sensors
2 9F472 HO2S
4 9G444 CMS
LH Sensors 2765
Controls - 3.5L
Workshop Manual
Special Tool(s)
303-476 (T94P-9472-A)
Material
Item Specification
Lubricant
XL-2
ESE-M12A4-A
RH sensor
Remove the PCV hose. 1.
Both sensors
removal.

3.
4.
&nbs
Controls - 3.5L
Workshop Manual
Special Tool(s)
303-476 (T94P-9472-A)
Material
Item Specification
Lubricant
XL-2
ESE-M12A4-A
-
100-02 .
1.
removal.

3.
4.
Controls - 3.5L
Workshop Manual
bolt
Remove the LH or RH valve cover. For additional information, refer to Section 303-01C . 1.
2.
Controls - 3.5L
Workshop Manual
Knock Sensor (KS)
Material
Item Specification
Engine Coolant
VC-10-A2 (US); CVC-10-A
(Canada)
WSS-M97B55-A
1 9N271 Coolant tube
2 8565 O-ring seal
4 W704749 KS bolts (2 required)
5 12A699 KS
Remove the thermostat housing. For additional information, refer to Section 303-03A . 1.
Remove the lower intake manifold. For additional information, refer to Section 303-01C . 2.
Remove the coolant tube.
3.
NOTICE: Only use hand tools when removing or installing the Knock Sensor (KS) or damage to
the KS can occur.
Remove the 2 bolts and the KS .
5.
NOTE: Genuine Mazda Extended Life Coolant and Motorcraft Specialty Green Engine
Coolant are very sensitive to light. Do NOT allow these products to be exposed to ANY
LIGHT for more than a day or two. Extended light exposure causes these products to degrade.
Lubricate the new O-ring seal with clean engine coolant.

6.
SECTION 303-14D: Electronic Engine Controls -
Hybrid
Material
Capacity
XL-2
ESE-M12A4-A -
XO-5W20-QSP (US);
Premium Motor Oil
equivalent
WSS-M2C930-A -
- -
Description gn="bottom" align="center">Nm lb-in
Camshaft Position (CMP) sensor bolt 7 62
a
- -
a
- -
Engine plug bolt 20 177
a
- -
Manifold Absolute Pressure (MAP) sensor screw 3 27
PCM bolts 8 71
Variable Camshaft Timing (VCT) oil control solenoid bolt 10 89
a
Refer to the procedure for specification.
P>
SECTION 303-14D: Electronic Engine
Controls - Hybrid
Workshop Manual
The electronic engine controls consist of the following:
PCM
Crankshaft Position (CKP) sensor
Mass Air Flow (MAF) sensor
Knock Sensor (KS)
Variable Camshaft Timing (VCT) oil control solenoid
Manifold Absolute Pressure (MAP) sensor
The PCM:
prescribed air/fuel ratio throughout the entire engine operating range.

The CMP sensor:
provides camshaft position information which is used by the PCM for fuel synchronization. Refer to
Section 303-14A .

The CKP sensor:
The MAF sensor:
uses a hot wire sensing element to measure the amount of air entering the engine.
sends the PCM a signal to determine the intake air mass. The PCM will then calculate the required
fuel injector pulse width in order to provide the desired air/fuel ratio.

The HO2S :
has the ability to create a voltage signal dependent on exhaust oxygen content.
The CMS :
The CHT sensor:
resistance decreases as coolant temperature increases. Refer to Section 303-14A .
The KS :

The MAP sensor:
on engine load.

SECTION 303-14D: Electronic Engine
Controls - Hybrid
Workshop Manual
DTC Charts
PCM DTC Chart
Control
P0217 Engine Coolant Overtemperature Condition REFER to Section 303-03B .
P0562 System Voltage Low REFER to Section 414-05 .
Range/Performance
High
(ROM) Error
P1285 Cylinder Head Overtemperature Condition REFER to Section 303-03B .
P1299 Cylinder Head Overtemperature Protection Active REFER to Section 303-03B .
P2600 Coolant Pump "A" Control Circuit/Open REFER to Section 412-00B .
All Other
DTCs
SECTION 303-14D: Electronic Engine Controls
- Hybrid
Workshop Manual
Material
Item Specification
or equivalent
WSS-M2C930-A
Item
Part
Number
1 14A464
12B637)
2 W701219 CMP
sensor bolt
3 12K073 CMP
4 - CMP
O-ring seal
Remove the bolt and the CMP .
2.
NOTE: Lubricate the CMP O-ring seal with clean engine oil.
3.
- Hybrid
Workshop Manual
Special Tool(s)
303-1417
303-507
General Equipment
6 mm x 18 mm bolt
Item
Part
Number Description
(part of 12B637)
2 W701219-S CKP sensor bolt (2 required)
3 6C315 CKP sensor
Removal
100-02 .
1.
Turn the crankshaft clockwise until the hole in the crankshaft pulley is in the 3 o'clock position. 4.
Remove the cylinder block plug. 5.
NOTE: When the crankshaft contacts the Crankshaft TDC Timing Peg, the No. 1 cylinder will be at
Install the Crankshaft TDC Timing Peg and turn the crankshaft clockwise until the crankshaft contacts
the Crankshaft TDC Timing Peg.
6.
Remove the bolts and discard the CKP sensor. 8.
Installation
Install a 6 mm (0.23 in) x 18 mm (0.7 in) standard bolt in the crankshaft pulley.
1.
2.
Adjust the CKP sensor with the Crankshaft Sensor Aligner.
3.
Remove the 6 mm (0.23 in) bolt from the crankshaft pulley. 5.
Install the cylinder block plug.
6.
Install the 6 pin-type retainers and the RH splash shield. 7.
Install the 4 screws and position the RH fender splash shield aside. 8.
- Hybrid
Workshop Manual
3 12A650 PCM
5 - Upper PCM bracket (part of 12A692)
6 - Upper PCM bracket bolt (part of 12A692)
Removal
With the in NEUTRAL, position on a hoist. For additional information, refer to Section 100-02 . 1.
418-01 .
2.
Disconnect the vacuum hose from the vacuum brake booster. 4.
Remove the ground strap bolt and disconnect the ground strap retainer. 6.
Remove the two LH splash shield pin-type retainers and position the LH splash shield aside. 7.
Remove the lower PCM bolt and the upper PCM bracket bolt.
Remove the PCM.
8.
Remove the upper PCM bolt and the PCM bracket from the PCM. 9.
Installation
Install the PCM bracket and the upper PCM bolt to the PCM.
1.
Install the PCM and the lower PCM bolt.
2.
Install the upper PCM bracket bolt.
3.
Position the LH splash shield and install the two LH splash shield pin-type retainers. 4.
Connect the ground strap retainer and install the ground strap bolt .
Tighten to 10 Nm (89 lb-in)
5.
Connect the vacuum hose to the vacuum brake booster. 7.
418-01 .
9.
- Hybrid
Workshop Manual
3 12B579 MAF sensor
ol start="1">
Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Section 303-12D .
3.
- Hybrid
Workshop Manual
Item
Part
Number Description
(part of 12C508)
2 9F472 HO2S
3 9G444 Catalyst Monitor Sensor (CMS)
4 14A464 CMS electrical connector (part of 12C508)
- Hybrid
Workshop Manual
Special Tool(s)
303-476 (T94P-9472-A)
Material
Item Specification
Lubricant
XL-2
ESE-M12A4-A
-
Disconnect the Heated Oxygen Sensor (HO2S) ecal connector. 1.
removal.

2.
3.
- Hybrid
Workshop Manual
Special Tool(s)
303-476 (T94P-9472-A)
Material
Item Specification
Lubricant
XL-2
ESE-M12A4-A
-
With the vehicle in NEUTRAL, position it on a hoistadditional information, refer to Section 100-02 . 1.
removal.

3.
4.
- Hybrid
Workshop Manual
Item
Part
Number Description
1 14603 Cylinder Head Temperature (CHT) sensor cover (part
of 12C508)
2 14A464 CHT sensor electrical connector (part of 12C508)td>
3 6G004 CHT sensor
Detach the Cylinder Head Temperature (CHT) sensor cover and position aside. 1.
3.
- Hybrid
Workshop Manual
Knock Sensor (KS)
1 W5000025 Knock Sensor (KS) bolt
2 12A699 KS
100-02 .
1.
Remove the intake manifold. For additional information, refer to Section 303-01D . 2.
Remove the bolt and the Knock Sensor (KS).
3.
- Hybrid
Workshop Manual
bolt
Remove the valve cover. For additional information, refer to Section 303-01D . 1.
2.
- Hybrid
Workshop Manual
Material
Item Specification
or equivalent
WSS-M2C930-A
Item
Part Number th
valign="bottom">Description
1 14A464 Manifold Absolute Pressure
(MAP) sensor electrical
connector
2 W701459 MAP sensor screw
3 9F479 MAP sensor
Remove the screw and the MAP sensor.
2.
NOTE: Lubricate the MAP sensor O-ring seal with clean engine oil.
3.
SECTION 204-00: Suspension System - General
Information
Alignment Specifications
Item LH RH Total/Split
Front
Camber -0.03 -0.75 -0.03 -0.75 0 1.0
Caster 3.88 1.0 4.13 1.0 -0.25 1.0
Toe - - 0.20 0.20
Rear
Camber -1.25 0.75 0
Thrust angle - - 0 0.10
Toe 0.12 0.12 0.12 0.12 0.24 0.20
Clear Vision @ Straight Drive Specification
Location Nominal Tolerance
Front 0.50 +/-2.00
Rear Not applicable Not applicable
Item Specification
Ball Joint Deflection
Lower 0-0.4 mm (0-0.016 in)
Upper 0-0.2 mm (0-0.008 in)
Bushing Fastener Tightening Height
Front
a
402 mm (15.82 in)
Rear
a
395 mm (15.55 in)
Front - All-Wheel Drive (AWD) 68 mm (2.677 in)
19 mm (0.748 in)
Front - Front Wheel Drive (FWD) 68 mm (2.677 in)
19 mm (0.748 in)
Rear - AWD 42 mm (1.653 in)
23 mm (0.905 in)
Rear - FWD 60 mm (2.362 in)
23 mm (0.905 in)
a
Curb conditioning, full fluids (including fuel).
Front tie-rod jam nuts 80 59
Rear camber adjustment nuts 101 74
Rear toe link jam nuts 102 75
Information
Wheel Alignment Angles
Front toe is adjusted through the use of adjustable tie-rod ends. Front caster is adjusted by installing new
upper control arms with offset bushings. The upper arms can adjust caster angles 0.4 degrees and have
separate part numbers. Front camber is not adjustable on the vehicle. Rear toe is adjusted through the use of
adjustable toe links. Rear caster is not adjustable on the vehicle. Rear camber is adjusted through the use of a
cam bolt that attaches the rear lower control arm to the rear subframe.
Camber
Negative and Positive Camber
Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and
has a direct affect on tire wear.
Caster
Item Description
1 True vertical
2 Positive caster angle
3 Shock-to-ball joint centerline
4 Pivot centerline
Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the
side. The caster specifications in this section will give the vehicle the best directional stability characteristics
when loaded and driven. The caster setting is not related to tire wear.
Toe
Wheel Alignment Angles 2805
Positive Toe (Toe In)
Negative Toe (Toe Out)
The vehicle toe setting affects tire wear and directional stability.
Incorrect Thrust Angle (Dogtracking)
Item Description
1 Vehicle centerline
2 Axle centerline
3 Thrust angle
Incorrect thrust angle (also known as dogtracking) is the condition in which the rear axle is not square to the
chassis. Heavily crowned roads can give the illusion of dogtracking.
Wander
Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to
maintain a straight path down a level road.
Shimmy
Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting
from large, side-to-side (lateral) tire/wheel movements.
Positive Toe (Toe In) 2806
Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts
pot holes or irregularities in the road surface.
Nibble
Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road
surfaces and observed by the driver as small rotational oscillations of the steering wheel. For wheel and tire
diagnosis, refer to Section 204-04 .
Poor Returnability/Sticky Steering
Poor returnability and sticky steering is used to describe poor return of the steering wheel to center after a turn
or steering correction.
Drift/Pull
Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle
going straight.
Drift describes what a vehicle with this condition does with hands off the steering wheel.
A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead
path and require constant steering input in the opposite direction to counteract the effect.

Drift/pull may be induced by conditions external to the vehicle (for example, wind, road crown).
A drift or pull condition may exist even if the front alignment is within specifications. To aid in
correcting this condition, there are 4 additional upper control arms available with off-set bushings (2
for LH, 2 for RH). These upper control arms will allow the caster to be adjusted 0.4 degrees. Refer
to Caster Adjustment - Front in this section.

Poor Groove Feel
Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as the wheel
is rocked slowly left and right within very small turns around center or straight-ahead (under 20 degrees of
steering wheel turn). Efforts may be said to be "flat on center".
Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of gear teeth
in the steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from
the self-aligning forces at the road wheel or tire patch.

In the diagnosis of a roadability problem, it is important to understand the difference between wander
and poor groove feel.

Incorrect Thrust Angle (Dogtracking) 2807
Poor Groove Feel 2808
Information
Workshop Manual
Suspension System
Road test the vehicle.
If any suspension alignment or ride height concerns are present, GO to Symptom Chart -
Suspension System .

Verify the customer concern by carrying out a road test on a smooth road. If any vibrations
are present, GO to Symptom Chart - NVH .

1.
Inspect the tires. 2.
Check the tire pressures with all normal loads in the vehicle and the tires cold. Refer to the Vehicle
Certification (VC) label.
3.
Verify that all tires are sized to specification. Refer to the VC label.
Inspect the tires for incorrect wear and damage. Install new tires as necessary.
Inspect the chassis and underbody.
Remove any excessive accumulation of mud, dirt or road deposits from the chassis and
underbody.

3.
Inspect for aftermarket equipment.
Check for aftermarket changes to the steering, suspension, and wheel and tire components
(such as competition or heavy duty). The specifications shown in this manual do not apply to
vehicles equipped with aftermarket equipment.

4.
Mechanical
Front or rear suspension
components

Suspension fastener(s)
Incorrect spring usage
Spring(s)
Shock absorber(s)
Strut(s)
Suspension bushing(s)
Steering system components
Wheel bearing(s)
Non-OEM parts or
modifications

If an obvious cause for an observed or reported condition is found, correct the cause (if possible)
before proceeding to the next step.
5.
Suspension System 2809
If the fault is not visually evident, GO to Symptom Chart - Suspension System or GO to Symptom
Chart - NVH .
6.
Symptom Chart - Suspension System
Symptom Chart - Suspension System
Symptom Chart - NVH
Symptom Chart - NVH
Squeak or grunt - noise from the front suspension, occurs more in cold ambient temperatures. More
noticeable over rough roads or when turning

Front stabilizer bar insulators
Under these conditions, the noise is accepta
Clunk - noise from the front suspension, occurs in and out of turns
Loose front suspension
INSPECT for loose nuts or bolts. TIGHTEN to specifications. REFER to Section 204-01 for front
suspension and Section 204-02 for rear suspension.

Clunk - noise from the rear suspension, occurs when shifting from REVERSE to drive
Loose rear suspension components
INSPECT for loose or damaged rear suspension components. REPAIR or INSTALL new components
as necessary. REFER to Section 204-02 .

Click or pop - noise from the front suspension. More noticeable over rough roads or over bumps
Worn or damaged ball joint(s) /ul>
CARRY OUT a ball joint inspection. INSTALL new ball joint(s) or control arm(s) as necessary.
REFER to Ball Joint Inspection in this section.

Front suspension noise - a squeak, creak or rattle noise. Occurs mostly over bumps or rough roads
Shock absorber jounce bumper(s)
LUBRICATE shock absorber jounce bumper(s). REFER to Disassembly and Assembly - Shock
Absorber and Spring Assembly in Section 204-01 .

Loose or damaged front struts, shock absorber(s) or shock absorber bushing(s)
Damaged spring or spring mount(s)
Damaged or worn control/radius arm bushing(s)
Worn or damaged stabilizer bar bushings or link(s)
INSPECT the front suspension. INSTALL new components as necessary. REFER to Section 204-01 .
Rear suspension noise - a squeak, creak or rattle noise. Occurs mostly over bumps or rough roads
Loose or damaged rear shock absorber(s) or shock absorber bushing(s)
Damaged spring or sprint(s)
Damaged or worn control arm bushing(s)
Worn or damaged stabilizer bar bushing(s) or link(s)
INSPECT the rear suspension. INSTALL new components as necessary. REFER to Section 204-02 .
Shudder - occurs during acceleration from a slow speed or stop
Incorrect ride height causing incorrect driveline angle
REFER to Section 205-00 for driveline angle diagnosis.
Shimmy
Loose wheel nut(s)
TIGHTEN the nut(s) to specification. REFER to Section 204-04 .
Loose front suspension fastener(s)
TIGHTEN the fastener(s) to specification. REFER to Section 204-01 .
Loose front wheel bearing(s)
INSPECT the front wheel bearing(s). INSTALL new bearing(s) as necessary. REFER to Section
204-01 .

Strut(s) or shock absorber(s)
INSTALL new struts or shock absorbers as necessary. REFER to Section 204-01 for front suspension
or Section 204-02 for rear suspension.

Shimmy - most noticeable on coast/deceleration. Also hard steering condition
Excessive positive caster
CHECK the wheel alignment. REFER to Caster Adjustment - Front in this section. ADJUST as
necessary.

Rough/harsh ride
Incorrect tire pressure
ADJUST the tire pressure. REFER to the Vehicle Certification (VC) label.
Strut(s) or shock absorber(s)
INSTALL new struts or shock absorbers as necessary. REFER to Section 204-01 for front suspension

Spring(s)
MEASURE the ride height. REFER to Ride Height Measurement in this section. INSTALL new
springs as necessary. REFER to Section 204-01 for front suspension or Section 204-02 for rear
suspension.

Loose, worn or damaged suspension component(s)
INSTALL new suspension component(s) as necessary. REFER to Section 204-01 for front suspension

Pinpoint Tests
Pinpoint Test A: Vehicle Drifts/Pulls
Unevenly loaded vehicle
Tire pressure
Tire forces
Brake drag
Incorrect vehicle alignment
Steering system
PINPOINT TEST A: VEHICLE DRIFTS/PULLS
A1 CHECK FOR UNEVENLY LOADED
VEHICLE
Visually check the vehicle for an uneven
loading condition.

Is the vehicle unevenly loaded?
Yes
ADVISE the customer of uneven loading condition.
No
GO to A2 .
A2 CHECK THE TIRE PRESSURES AND
TIRE CONDITIONS
Check the tire pressures. Refer to the
Vehicle Certification (VC) label located on
the driver door jamb. Check the tires for

Yes
GO to A3 .
No
PINPOINT TEST A: VEHICLE DRIFTS/PULLS 2812
uneven/abnormal wear. Refer to Diagnosis
and Testing - Wheels and Tires in Section
204-04 .
Are the tire pressures and tire
conditions OK?

ADJUST the tire pressures to the specified pressure
or INSTALL new tires as necessary.
A3 ISOLATE TIRE DRIFT/PULL
CONDITION
Cross the front wheel and tire assemblies
from left-to-right. Refer to Section 204-04
.

Does the vehicle drift/pull?
Yes
If the vehicle drifts/pulls in the opposite direction,
tire forces are causing the drift/pull. REFER to
Section 204-04 to diagnose the tire drift/pull. If the
vehicle drifts/pulls in the same direction, GO to A4 .
No
Tire forces were causing the drift/pull and the
concern has been corrected.
A4 CHECK FOR BRAKE DRAG
Spin all 4 wheel and tire assemblies by
hand and check for brake drag.

Do the wheels spin freely?
Yes
GO to A5 .
No
REFER to Section 206-00 to diagnose brake drag
condition.
A5 CHECK THE WHEEL ALIGNMENT
Using alignment equipment and the
manufacturer's instructions, check the
wheel alignment.

Is the wheel alignment out of
specification?

Yes
ADJUST the alignment as necessary. REFER to
General Procedures in this section.
No
REFER to Section 211-00A or Section 211-00B to
diagnose steering system drift/pull/wander
condition. For Electronic Power Assist Steering
(EPAS) vehicles, refer to Section 211-00B to
condition. For Hydraulic Power Assist Steering
(HPAS) vehicles, refer to Section 211-00A to
condition.
Component Tests
Ball Joint Inspection
Prior to inspecting the ball joints for wear, inspect the wheel bearings. Install a new wheel bearing as
necessary. Refer to Section 204-01 .
1.
NOTE: In order to obtain accurate measurements, the suspension must be in full rebound with the
weight of the vehicle supported by the frame.
Raise and support the vehicle by the frame to allow the wheels to hang in the rebound position.
2.
Inspect the ball joint and ball joint boot for damage. 3.
If the ball joint or ball joint boot is damaged, install a new ball joint as necessary. Refer to
Section 204-01 .

NOTICE: Do not use any tools or equipment to move the wheel and tire assembly or suspension
components while checking for relative movement. Suspension damage may occur. The use of
tools or equipment will also create relative movement that may not exist when using hand force.
Relative movement must be measured using hand force only.
NOTE: To avoid lateral movement of the steering linkage and steering components, make sure to
apply hand force only at the 12 o'clock and 6 o'clock positions of the wheel and tire assembly.
Inspect the ball joint for relative movement by alternately pulling outward and pushing inward on the
wheel and tire assembly, at the 12 o'clock and 6 o'clock positions, by hand. Note any relative
movement between the wheel knuckle and both lower arms at the lower ball joints.
If relative movement is not felt or seen, the ball joints are OK. Do not install new ball joints.
If relative movement is found, continue with Step 5.
4.
NOTE: In order to obtain an accurate measurement, the dial indicator should be aligned as close as
possible with the center line of the forward front lower ball joint.
To measure ball joint deflection, attach a suitable dial indicator with a flexible arm between the
forward front lower arm and the wheel knuckle at the forward front lower ball joint.
5.
Measure the ball joint deflection while an assistant alternately pulls outward and pushes inward on the
wheel and tire assembly, at the 12 o'clock and 6 o'clock positions, by hand.
If the deflection exceeds the specification, install a new forward and rearward lower ball joint.

If the deflection meets the specification, continue with the procedure.
6.
NOTICE: Do not use any tools or equipment to move the wheel and tire assembly or suspension
components while checking for relative movement. Suspension damage can occur. The use of
tools or equipment will also create relative movement that may not exist when using hand force.
Relative movement must be measured using hand force only.
Inspect the ball joint for relative movement by alternately pulling downward and pushing upward on
the upper arm by hand. Note any relative vertical movement between the wheel knuckle and upper
arm at the upper ball joint.
If relative movement is not felt or seen, the ball joint is OK. Do not install a new ball joint.
7.
If relative movement is found, continue with Step 8.
NOTE: In order to obtain an accurate measurement, the dial indicator should be aligned as close as
possible with the vertical axis of the ball joint.
To measure ball joint deflection, attach a suitable dial indicator with a flexible arm between the upper
arm and the wheel knuckle or ball joint stud.
8.
Measure the ball joint deflection while an assistant pushes up and then pulls down on the upper arm,
by hand.
If the deflection exceeds the specification, a new ball joint must be installed. Refer to Section
204-01 .

If the deflection meets the specification, no further action is required.
9.
Information
Workshop Manual
Ride Height Measurement
Front Ride Height Measurement
Item Description
1 Ride height = 2 - 3
2 Measurement 2
3 Measurement 3
NOTE: Make sure that the vehicle is posied on a flat, level surface and the tires are inflated to the correct
pressure. Vehicle should have a full tank of fuel.
Position a suitable surface gauge (such as Starrett 57D Surface Gauge), on a flat, level surface and
adjust the arm of the gauge until the scriber point is located in the center of the front lower
arm-to-subframe bolt.
Lock the surface gauge in this position.
1.
With the surface gauge positioned on a flat, level surface, record the measurement of the surface
gauge position (measurement 2).
2.
Position the surface gauge on the same flat, level surface as used in Step 1, adjust the gauge's arm
until the scriber point is located at the lowest part of the wheel knuckle, next to the front lower arm
ball joint nut.
3.
Ride Height Measurement 2816
Lock the surface gauge in this position.
With the surface gauge positioned on a flat, level surface, record the measurement of the surface
gauge position (measurement 3).
4.
Subtract measurement 3 from measurement 2 to obtain the front ride height.
Refer to Specifications in this section.
5.
Rear Ride Height Measurement
Item Description
1 Ride height = 2 - 3
2 Measurement 2
3 Measurement 3
NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the correct
pressure. Vehicle should have a full tank of fuel.
Measure the distance between the flat level surface and center of the lower arm inboard cam bolt
(measurement 2).
1.
Measure the distance between the flat level surface and the center of the lower arm outboard bolt
(measurement 3).
2.
Subtract measurement 3 from measurement 2 to obtain the rear ride height. 3.
Information
Workshop Manual
Caster Adjustment - Front
NOTE: If caster adjustment is necessary to resolve a vehicle alignment issue, then installing a revised upper
control arm(s) is an acceptable method. This procedure should not be routinely performed with all alignments
and only after all other possible sources have been inspected and corrected as necessary.
Using alignment equipment and the manufacturer's instructions, measure the caster. 1.
NOTE: The revised upper control arms have the same base part number, but they are identified by the
amount of caster they change (for example: + 0.4 degrees or - 0.4 degrees).
Use the following table and the measurements taken in Step 1 to determine which front upper control
arm should be installed.
Part Number Degree of Change
3084 RH + 0.4 degree
3084 RH - 0.4 degree
3091 LH + 0.4 degree
3091 LH - 0.4 degree
2.
Install a revised front upper control arm(s) as necessary. For additional information, refer to Section
204-01 .
3.
Recheck the front caster settings and adjust as necessary. 4.
Check and, if necessary, adjust the front toe. For additional information, refer to Toe Adjustment -
5.
Caster Adjustment - Front 2819
Caster Adjustment - Front 2820
Information
Workshop Manual
Camber Adjustment - Rear
NOTE: Before carrying out a camber adjustment, check the tires for the correct pressure. Inspect the tires for
incorrect wear or damage. Inspect the front suspension components for wear or damage.
Using alignment equipment and the manufacturer's instructions, measure the rear camber. 1.
Loosen the rear camber adjustment nut. 2.
Rotate the camber adjustment bolt until the camber setting is within specifications. 3.
NOTE: Do not allow the camber adjustment bolt to rotate while tightening the nut.
Tighten the camber adjustment nut to 101 Nm (74 lb-ft).
Recheck the rear camber and adjust as necessary. 5.
Camber Adjustment - Rear 2821
Information
Workshop Manual
Toe Adjustment - Front
Start the engine and center the steering wheel. 1.
Turn the engine OFF and, using a suitable steering wheel holding device, lock the steering wheel in
the straight ahead position.
2.
Using alignment equipment and the manufacturer's instructions, measure the front toe. 3.
Remove the steering gear bellows clamps. 4.
Loosen the tie-ruts. 5.
NOTE: Do not allow the steering gear bellows to twist when the tie rod is rotated.
Rotate the tie rods until the toe setting is within specifications.
6.
Tighten the jam nuts to 80 Nm (59 lb-ft). 7.
Install the steering gear bellows clamps. 8.
Recheck the front toe settings and adjust as necessary. 9.
Toe Adjustment - Front 2822
Toe Adjustment - Front 2823
Information
Workshop Manual
Toe Adjustment - Rear
Using alignment equipment and the manufacturer's instructions, measure the rear toe. 1.
Loosen the toe link jam nuts. 2.
Rotate the toe link adjusting rod until the toe setting is within specifications. 3.
NOTE: llow the adjusting rod to rotate while tightening the jam nuts.
Tighten the toe link jam nuts to 102 Nm (75 lb-ft).
4.
Recheck the rear toe and adjust as necessary. 5.
Toe Adjustment - Rear 2824
SECTION 204-01: Front Suspension
Manual
Material
Capacity
Dielectric Compound
XG-3-A
ESE-M1C171-A -
Brake caliper anchor plate bolt 90 66 -
Brake disc bolt 20 - 177
Brake flexible hose bracket-to-wheel knuckle bolt 20 - 177
Catalytic converter nuts 40 30 -
Damper fork-to-front lower arm bolt 103 76 -
Front lower arm-to-subframe bolt
a
- - -
Lower ball joint nut 200 148 -
Rear driveshaft-to-Power Transfer Unit (PTU) bolts 70 52 -
Rear lower arm-to-subframe bD> - - -
Shock absorber rod nut 40 30 -
Shock absorber-to-damper fork bolt 48 35 -
Shock absorber upper mount nut 30 22 -
Stabilizer bar bracket nut 48 35 -
Steering column shaft bolt (vehicles with Hydraulic Power Assist Steering (HPAS)) 25 18 -
Steering column shaft bolt (vehicles with Electronic Power Assist Steering (EPAS)) 20 - 177
Steering gear-to-subframe bolt 107 79 -
Subframe bracket-to-body bolt 103 76 -
150 111 -
Tie-rod end nut 48 35 -
Underbody cover shield bolts 7 - 62
Upper arm-to-body bolt 55 41 -
Upper ball joint nut 48 35 -
Wheel hub nut 255 189 -
Wheel speed sensor bolt 23 17 -
Wheel speed sensor harness bolt 23 17 -
a
Manual
Front Suspension
The front suspension consists of the following components:
Wheel bearings
Wheel hubs
Wheel studs
Front and rear lower arms
Upper arms
Stabilizer bar
Stabilizer bar bushings
Stabilizer bar links
Shock and spring assemblies
Wheel knuckles
The front suspension is an independent suspension design. This front suspension uses 3 parallel arms (one
upper arm and 2 lower arms). Each arm has a mounting position to the chassis and a ball joint attachment at
the wheel knuckle. The shock absorber mounts to the lower arm and along with the spring, controls vertical
movement. A stabilizer bar and links are included to control suspension lean/sway during turns. The multiple
arm design allows for carefully controlled motion of the wheel throughout suspension travel, controlling such
parameters as camber angle, caster angle and toe.
Front Suspension 2827
SECTION 204-01: Front
Suspension
Manual
Front Suspension
Front Suspension 2828
Suspension
Manual
REMOVAL AND
INSTALLATION
Wheel Bearing and Wheel Hub
Special Tool(s)
Remover, Front Hub
204-161 (T97P-1175-A)
Ball Joint Separator
204-592
Installer, Wheel Hub Bearing Cup
205-147
Remover, Drive Pinion Bearing Cone
Remover/Installer, Wheel Hub Cup
204-020
Step Plate
205-117
Installer, Axle Bearing Cup.
205-225
Remover/Installer, Drive Pinion Oil Seal
205-440
Wheel Bearing and Wheel Hub 2829
1 1104 Wheel hub
2 3B625 Snap ring
3 1215 Wheel bearing
4 2K005 LH/ 2K004 RH Disc brake shield
5 3K171 LH/ 3K170 RH Wheel knuckle
Removal
NOTICE: Suspension fasteners are critical parts because they affect performance of vital components
and systems and their failure may result in major service expense. New parts must be installed with the
same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to make
sure of correct retention of these parts.
NOTE: This procedure is shown for the LH side, the RH side is similar.
NOTE: If removing the wheel hub, a new wheel bearing must be installed.
100-02 .
1.
Remove the wheel and tire. For additional information, refer to Section 204-04 . 2.
Remove the bolts and the underbody shield, if equipped. 3.
Remove the 4 screws position the fender splash shield aside. 4.
Remove the 6 pin-type retainers (4 shown) from the splash shield. 5.
Remove the upper stabilizer bar link nut and separate from the stabilizer bar. 6.
Remove the lower control arm-to-strut through bolt and flagnut. 7.
Remove the outer tie-rod end cotter pin and nut.
Discard the cotter pin.
8.
NOTICE: Do not use a hammer to separate the outer tie-rod end from the wheel knuckle or
damage to the wheel knuckle may result.
Using the Ball Joint Separator, separate the outer tie-rod end from the knuckle.
9.
Remove the front lower arm-to-subframe bolt.
Discard the bolt.
10.
If equipped, remove the wheel speed sensor bolt. 11.
If equipped, remove the wheel speed sensor harness bolt and position the wheel speed sensor aside. 12.
Remove the brake flexible hose bracket-to wheel knuckle bolt and position the hose and bracket aside. 13.
Remove and discard the wheel hub nut.
14.
NOTICE: Do not allow the caliper and anchor plate assembly to hang from the brake hose or
damage to the hose can occur.
Remove the bolts and position the caliper and anchor plate assembly aside.
Support the caliper and anchor plate assembly using mechanic's wire.
15.
Remove the 2 brake disc bolts and the brake disc. 16.
Using a wax pencil (or equivalent) apply witness marks to the vehicle and subframe to aid in
installation.
17.
Position a suitable jackstand under the subframe. 18.
Remove the 4 front subframe support bracket bolts. 19.
Remove the 2 front subframe rear nuts and remove the front subframe support bracket. 20.
NOTE: Do not remove the front subframe forward bolts, loosen to allow the front subframe to be
lowered.
Loosen the 2 front subframe forward nuts
21.
Partially lower the subframe, to allow removal of the rear lower arm-to subframe bolt. 22.
Remove the rear lower arm-to subframe bolt.
23.
Using the Front Hub Remover, separate the halfshaft from the wheel hub.
Using mechanics wire or equivalent, support the halfshaft.
24.
Remove and discard the upper ball joint nut. 25.
Using the Steering Arm Remover, separate the upper ball joint from the wheel knuckle and remove
the wheel knuckle assembly.
26.
Using the Step Plate, press the wheel hub from the wheel bearing. 27.
NOTE: This step may not be necessary if the inner wheel bearing race remains on the wheel bearing
after removing the wheel hub.
If necessary, using the Drive Pinion Bearing Cone Remover, press the inner wheel bearing race from
the wheel hub.
28.
Remove the snap ring. 29.
Using the Wheel Hub Cup Remover/Installer, press the wheel bearing from the wheel knuckle. 30.
Installation
Using the Wheel Hub Bearing Cup Installer, press the wheel bearing into the wheel knuckle. 1.
Install the snap ring. 2.
Using the Step Plate and Wheel Hub Bearing Cup Installer, press the wheel hub into the wheel
bearing.
3.
Position the wheel knuckle and install the new upper ball joint nut.
4.
Partially raise the subframe. 5.
Position the halfshaft to the wheel hub. 6.
Position the lower control arms to the subframe.
Loosely install a new rear lower arm-to-subframe bolt.
Loosely install a new front lower arm-to-subframe bolt.
7.
Raise the subframe and align to the witness marks made during removal. 8.
Position the front subframe support bracket and tighten the 2 new front subframe rear nuts.
9.
Tighten the 4 front subframe bracket bolts.
Tighten to 103 Nm 76 lb-ft).
10.
Tighten the 2 new front subframe forward nuts.
11.
Remove the jackstand. 12.
If equipped, position the wheel speed sensor and install the bolt.
13.
If equipped, install the wheel speed sensor harness bolt.
14.
Install the brake disc and the 2 brake disc bolts.
15.
Position the brake caliper and anchor plate assembly and install the 2 bolts.
16.
Using the Halfshaft Installer, in the halfshaft Into the wheel hub. 17.
NOTICE: Do not tighten the halfshaft nut with the vehicle on the ground. The nuts must be
tightened to specification before the vehicle Is lowered onto the wheels. Wheel bearing damage
will occur If the wheel bearing Is loaded with the weight of the vehicle applied.
Install the wheel hub nut.
18.
Stake the new nut in line with the keyway to a recommended minimum depth of 1 mm (0.039 in)
below the keyway diameter to engage the locking feature.
19.
Position the brake flexible hose and bracket and install the bolt.
20.
Before tightening any suspension busing fasteners, the suspension must be at 402 mm (15.826 in)
between the center of the hub and the lip of the fender. This will prevent incorrect clamp load and
bushing damage.
Use a suitable jack to raise the suspension to specification.
21.
Tighten the front lower arm-to-subframe bolt.
Tighten an additional 90 with the suspension at the bushing fastener tightening position. 2.
22.
Tighten the rear lower arm-to-subframe bolts to 110 Nm (81 lb-ft). 23.
Install the outer tie-rod end to the control arm.
Position to the wheel hub. 1.
Install the nut. 2.
li>Install new cotter pin.
24.
Install the lower control arm-to-strut through bolt and flagnut. 25.
Position the stabilizer bar link and install the nut.
26.
Install the splash shield and 6 pin-type retainers, (4 shown). 27.
Position the fender splash shield and Install the screws. 28.
Install the underbody shield and bolts (if equipped).
29.
Install the wheel and tire. For additional information, refer to Section 204-04 . 30.
Suspension
Manual
REMOVAL AND
INSTALLATION
Wheel Studs
1 1104 Wheel hub
2 1107 Wheel stud
Removal
Remove the wheel hub. For additional information, refer to Wheel Bearing and Wheel Hub in this
section.
1.
Using a press, remove the wheel stud from the wheel bearing and hub assembly. 2.
Installation
Position the new wheel stud in the wheel hub, aligning the serrations in the wheel hub flange made by
the original wheel stud.
1.
Using a press, install a new wheel stud. 2.
Install the wheel hub. For additional information, refer to Wheel Bearing and Wheel Hub in this
section.
3.
Wheel Studs 2839
Wheel Studs 2840
Suspension
Manual
REMOVAL AND
INSTALLATION
Lower Arm - Front
Special Tool(s)
Adapter for 204-592
204-592/1
Separator, Ball Joint
204-592
1 3A423 Lower arm (front)
2 W500550 Damper fork-to-lower arm bolt
3 3C499 Lower ball joint nut (front)
4 3C156 Damper
5 W712840 Front lower arm-to-subframe bolt
6 3C347 Damper fork-to-lower arm flagnut
Removal Installation
100-02 .
1.
Using a suitable jack, support the front wheel knuckle at the rear lower ball joint. 2.
Remove the front lower arm-to-subframe bolt. 3.
Lower Arm - Front 2841
Discard the bolt.
To install, tighten the new bolt to 110 Nm (81 lb-ft), then tighten an additional 90 degrees
with the suspension at the bushing fastener tightening position.

Remove the damper fork-to-lower arm bolt flagnut and damper.
Discard the bolt and flagnut.
To install, tighten the new bolt and flagnut to 103 Nm (76 lb-ft) with the suspension at the
bushing fastener tightening position.

4.
Remove and discard the front lower ball joint nut.
To install, tighten the new nut to 200 Nm (148 lb-ft).
5.
NOTICE: When the lower ball joint is separated from the wheel knuckle, the lower arm may
strike the outer Constant Velocity (CV) joint boot with enough force to damage the boot clamp.
This will result in a loss of grease from the outer CV joint. Place a block of wood, or similar
item, between the lower arm and the outer CV joint to prevent the lower arm from striking the
outer CV joint.
NOTE: Once pressure is applied to the ball joint with the Ball Joint Separator and Adapter, it may be
necessary to tap the wheel knuckle at the ball joint area to separate the ball joint from the wheel
knuckle.
Using the Ball Joint Separator and Adapter, separate the front lower ball joint from the wheel knuckle
and remove the front lower arm.
6.
NOTICE: Before tightening any suspension bushing fasteners, the suspension must be at the
bushing fastener tightening position. Use a suitable jack to raise the suspension until the
distance between the center of the hub and the lip of the fender is equal to 402 mm (15.83 in).
This will prevent incorrect clamp load and bushing damage.
7.
Suspension
Manual
REMOVAL AND
INSTALLATION
Lower Arm - Rear
Special Tool(s)
Adapter for 204-592
204-592/1
204-592
1 3079 LH/ 3078
RH
Lower arm (rear)
2 3C499 Lower ball joint nut (rear)
3 W500752 Rear lower arm-to-subframe bolt
4 999581222 Washer
5 W520416 Subframe bracket-to-subframe nut (2 required)
6 5A552 Subframe bracket-to-subframe washer (2 ired)
7 3B155 LH/ 3B154
RH
Subframe bracket (2 required)
8 3C496 Subframe bracket-to-body bolts (4 required)
10 W705443
Lower Arm - Rear 2844
Catalytic converter manifold-to-exhaust flexible
pipe nuts (2 required)
11 3R827 Steering column shaft bolt
12 3C611B Steering column shaft-to-dash seal
13 5801691 Lower steering column shaft joint cover nut (2
required)
14 3C611A Lower steering column shaft joint cover
disconnected or damage to the clockspring may result. If there is evidence that the lower shaft
has rotated, the clockspring must be removed and recentered. For additional information, refer
1.
Remove the 2 lower steering column shaft joint cover nuts and cover. 2.
NOTICE: Do not allow the steering column shaft to rotate while it is disconnected from the gear
or damage to the clockspring can occur. If there is evidence that the steering column shaft has
Section 501-20B .
NOTE: If equipped with Hydraulic Power Assist Steering (HPAS), index-mark the steering column
shaft position to the steering gear for reference during installation.
Remoe the bolt and disconnect the steering column shaft from the steering gear.
3.
To install on HPAS vehicles, align the index marks and tighten to 25 Nm (18 lb-ft).
To install on Electronic Power Assist Steering (EPAS) vehicles, tighten to 20 Nm (177 lb-in).
NOTICE: Remove the steering column shaft-to-dash seal or damage to the seal can occur.
NOTICE: When installing, make sure that the dash seal is correctly positioned on the steering
gear and the retaining clips are fully engaged into the body or damage to the steering gear can
result.
Remove the steering column shaft-to-dash seal.
4.
Remove the 8 screws and position the LH and RH splash shields aside. 6.
If equipped, remove the 7 screws and the underbody cover shield.
To install, tighten 7 Nm (62 lb-in).
9.
Remove and discard the 2 catalytic converter manifold-to-exhaust flexible pipe nuts and separate the
exhaust flexible pipe.
To install, tighten the new nuts to 40 Nm (30 lb-ft).
10.
Using 2 suitable jack stands, support the rear of the subframe assembly. 11.
Remove and discard the 4 subframe bracket-to-body bolts, the 2 subframe bracket-to-subframe nuts
and washers. Lower the rear of the subframe.
To install, tighten the new bolts to 103 Nm (76 lb-ft).
12.
Remove and discard the rear lower ball joint nut.
13.
outer CV joint.
knuckle.
Using the Ball Joint Separator and Adapter, separate the rear lower ball joint from the wheel knuckle.
14.
Remove the rear lower arm-to-subframe bolt and washer and remove the rear lower arm.
To install, tighten the new bolt to 65 Nm (48 lb-ft), then tighten an additional 90 degrees.
15.
16.
Suspension
Manual
REMOVAL AND
INSTALLATION
Upper Arm
Special Tool(s)
Remover, Steering Arm
211-003 (T64P-3590-F)
1 3091 LH/ 3084 RH Upper arm
2 3C498 Upper ball joint nut
3 W500525 Upper arm-to-body bolt (2 required)
4 5B800 Shock absorber upper mount nut (3 required)
5 W500020 Wheel speed sensor harness bolt
6 W500222 Wheel speed sensor bolt
7 2C204 RH/ 2C205 LH Wheel speed sensor
Removal
Remove and discard the 3 shock absorber upper mount nuts. 1.
Upper Arm 2849
Remove the wheel speed sensor bolt. 3.
Remove the wheel speed sensor harness bolt and position the wheel speed sensor aside. 4.
Using the Steering Arm Remover, separate the upper ball joint from the wheel knuckle. 6.
Position the shock absorber and spring assembly toward the wheel knuckle to access the upper
arm-to-body bolts.
7.
Remove the 2 upper arm-to-body bolts and the upper arm.
Discard the bolts.
8.
Installation
NOTE: Do not tighten the upper arm-to-body bolts at this time.
Position the upper arm and install the 2 new upper arm-to-body bolts.
1.
Set the upper arm bushing fastener tightening position by aligning the hole in the upper arm with the
hole in the body bracket and inserting a 6.35 mm (0.25 in) drill bit through both holes.
2.
Tighten the upper arm-to-body bolts to 55 Nm (41 lb-ft) and remove the drill bit. 3.
Position the shock and spring assembly and install the 3 new shock upper mount nuts.
4.
Position the upper ball joint and install a new nut.
5.
Upper Arm 2850
Position the wheel speed sensor harness and install the bolt.
6.
Position the wheel speed sensor and install the bolt.
7.
Check and, if necessary, align the front end. For additional information, refer to Section 204-00 . 9.
Upper Arm 2851
Suspension
Manual
REMOVAL AND
INSTALLATION
Stabilizer Bar Link
1 3053 LH/ 3052 RH Stabilizer bar link
2 3C494 Stabilizer bar link lower nut
3 3C494 Stabilizer bar link upper nut
NOTE: Use the hex-holding feature to prevent the ball stud from turning while removing or installing
the stabilizer bar link nut.
Remove and discard the stabilizer bar link upper nut.
2.
Remove and discard the stabilizer bar link lower nut and remove the stabilizer bar link.
3.
Stabilizer Bar Link 2852
Stabilizer Bar Link 2853
Suspension
Manual
REMOVAL AND
INSTALLATION
Stabilizer Bar Bushing
Special Tool(s)
211-105 (T85M-3395-A)
Item
Part
Number Description
1 W705443 Catalytic converter-to-exhaust flexible pipe nuts (2
required)
2 W711918 Rear driveshaft-to-Power Transfer Unit (PTU) bolt (4
required)
3 5006930 Rear driveshaft assembly
required)
Stabilizer Bar Bushing 2854
9 W520414 Stabilizer bar bracket nut (4 required)
10 5486 Stabilizer bar bushing bracket (2 required)
11 5484 Stabilizer bar bushing (2 required)
12 3C497 Steering gear-to-subframe bolt (3 required)
All vehicles
1.
Section 501-20B .
3.
To install on HPAS vehicles, align the index marks and tighten to 25 Nm (18 lb-ft).
result.
4.
100-02 .
5.
9.
Remove and discard the 2 tie-rod end cotter pins and nuts.
10.
NOTICE: Do not use a hammer to separate the tie-rod end from the wheel knuckle or damage
to the wheel knuckle can result.
Using the Tie-Rod End Remover, separate the 2 tie-rod ends from the wheel knuckles.
11.
Remove and discard the 2 catalytic converter-to-exhaust flexible pipe nuts and separate the exhaust
flexible pipe.
12.
Index the rear driveshaft-to-Power Transfer Unit (PTU).
Remove and discard the 4 bolts and position the driveshaft aside.
13.
All vehicles
Remove RH steering gear-to-subframe bolt.
14.
Remove the 2 LH steering gear-to-subframe bolts and position the steering gear to access the
stabilizer bar LH bracket front nut.
15.
Remove and discard the 4 stabilizer bar bracket nuts and remove the 2 stabilizer bar brackets.
To install, tighten the new bracket nuts to 48 Nm (35 lb-ft).
16.
Remove the 2 stabilizer bar bushings. 17.
NOTICE: Before tightening the stabilizer bar bracket nuts, the suspension must be at the
18.
Suspension
Manual
REMOVAL AND
INSTALLATION
Stabilizer Bar
Special Tool(s)
211-105 (T85M-3395-A)
Item
Part
Number Description
1 W705443 Catalytic converter-to-exhaust flexible pipe nuts (2
required)
2 W711918 Rear driveshaft-to-Power Transfer Unit (PTU) bolt (4
required)
3 5006930 Rear driveshaft assembly
required)
Stabilizer Bar 2859
10 5486 Stabilizer bar bracket (2 required)
11 3C494 Stabilizer bar link lower nut (2 required)
12 5494 Stabilizer bar
13 3C497 Steering gear-to-subframe bolt (3 required)
14 W520416 Subframe bracket-to-subframe nut (4 required)
15 5A552 Front subframe washer (4 required)
16 3C496 Subframe-to-body bolt (4 required)
17 3B154 RH front subframe support bracket
18 3B155 LH front subframe support bracket
Stabilizer Bar 2860
All vehicles
1.
Section 501-20B .
To install on HPAS vehicles, align the index marks, tighten to 25 Nm (18 lb-ft).
3.
result.
4.
Stabilizer Bar 2861
9.
Remove and discard the 2 tie-rod end cotter pins and nuts.
To install, tighten the new nuts to 48 Nm (35 lb-ft) and install new cotter pins.
10.
Using the Tie-Rod End Remover, separate the tie-rod ends from the wheel knuckles.
11.
Stabilizer Bar 2862
the stabilizer bar link nuts.
Remove and discard the 2 stabilizer bar link lower nuts and disconnect both stabilizer bar links from
the stabilizer bar.
12.
flexible pipe.
13.
Index-mark the rear driveshaft-to-Power Transfer Unit (PTU).
Remove and discard the 4 bolts and position the driveshaft aside.
14.
All vehicles
Using 2 suitable jackstands, support the rear of the subframe assembly. 15.
Remove and discard the 4 subframe bracket-to-body bolts, the 2 subframe bracket-to-subframe nuts
and lower the rear of the subframe.
16.
Remove the RH steering gear-to-subframe bolt.
17.
Remove the 2 LH steering gear-to-subframe bolts and position the steering gear to access the
stabilizer bar LH bracket front nut.
18.
Remove and discard the 4 stabilizer bar bracket nuts and remove the 2 stabilizer bar brackets.
To install, tighten the new bracket nuts to 48 Nm (35 lb-ft).
19.
Remove the 2 stabilizer bar bushings. 20.
Remove the stabilizer bar through the LH wheel opening. 21.
Stabilizer Bar 2863
NOTICE: Before tightening the stabilizer bar bracket nuts, the suspension must be at the
22.
Stabilizer Bar 2864
Suspension
Manual
REMOVAL AND
INSTALLATION
Wheel Knuckle
Special Tool(s)
Adapter for 204-592
204-592/1
204-161 (T97P-1175-A)
Remover, Front Hub
211-003 (T64P-3590-F)
211-105 (T85M-3395-A)
204-592
1 3N405 Wheel hub nut
Wheel Knuckle 2865
2 - Brake caliper and anchor plate assembly
3 W505741 Brake disc bolt (2 required)
4 1032 Brake disc
5 3K171 LH/ 3K170
RH
Wheel knuckle
6 3C499 Lower ball joint nut (2 required)
7 W711241 Brake caliper anchor plate bolt (2 required)
8 3C498 Upper ball joint nut
9 3D000 Tie-rod end nut
12 W505263 Brake flexible hose bracket-to-wheel knuckle
bolt
Removal
If equipped, remove the wheel speed sensor bolt. 2.
If equipped, remove e wheel speed sensor harness bolt and position the wheel speed sensor aside. 3.
Remove the brake flexible hose bracket-to-wheel knuckle bolt and position the hose and bracket
aside.
4.
5.
NOTICE: Do not allow the caliper and anchor plate assembly to hang from the brake hose or
damage to the hose can occur.
Remove the bolts and position the caliper and anchor plate assembly aside.
Support the caliper and anchor plate assembly using mechanic's wire.
6.
Using the Front Hub Remover, separate the halfshaft from the wheel hub. 8.
Wheel Knuckle 2866
Remove and discard the tie-rod end cotter pin and nut. 11.
Using the Tie-Rod End Remover, separate the tie-rod end from the wheel knuckle.
12.
Remove and discard the 2 lower ball joint nuts. 13.
outer CV joint.
knuckle.
Using the Ball Joint Separator and Adapter, separate the 2 lower ball joints from the wheel knuckle
and remove the wheel knuckle.
14.
Installation
Position the wheel knuckle and install the 2 new lower ball joint nuts.
1.
Position the tie-rod end and install the new nut and cotter pin. 2.
Wheel Knuckle 2867
Position the upper ball joint and install the new nut.
3.
If equipped, position the wheel speed sensor and install the bolt.
4.
If equipped, install the wheel speed sensor harness bolt.
5.
Position the brake flexible hose bracket and install the bolt.
6.
7.
8.
Using the Halfshaft Installer, install the halfshaft into the wheel hub. 9.
NOTICE: Do not tighten the halfshaft nut with the vehicle on the ground. The nut must be
tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage
will occur if the wheel bearing is loaded with the weight of the vehicle applied.
Install the wheel hub nut.
10.
Stack the new nut in line with the keyway to a recommended depth of 1 mm (0.039 in) below the
keyway diameter to engage the locking feature.
11.
Wheel Knuckle 2868
Wheel Knuckle 2869
Suspension
Manual
REMOVAL AND
INSTALLATION
Shock Absorber and Spring Assembly
1 W500550 Damper fork-to-lower arm bolt
2 3C156 Damper
4 - Shock absorber and spring assembly
5 W302117 Damper fork-to-lower arm flagnut
6 W302128 Shock absorber upper mount nut (3 required)
7 3462 Damper fork
8 W302119 Shock absorber-to-damper fork bolt
11 2C204 RH/ 2C205 LH Wheel speed sensor
Remove and discard the 3 shock absorber upper mount nuts.
1.
Shock Absorber and Spring Assembly 2870
Remove the wheel speed sensor bolt.
3.
Remove the wheel speed ssor harness bolt and position the wheel speed sensor aside.
4.
Using a suitable jack, support the wheel knuckle at the lower ball joints. 5.
Remove and discard the stabilizer bar link upper nut.
6.
Remove the damper fork-to-front lower arm bolt, flagnut and damper.
Discard the bolt and flagnut.

7.
Remove and discard the shock absorber-to-damper fork bolt and separate the damper fork from the
shock absorber and spring assembly.
To install, tighten the new bolt to 48 Nm (35 lb-ft).
8.
Lower the wheel knuckle and remove the shock absorber and spring assembly. 9.
10.
For additional information on the disassembly and assembly of the shock absorber and spring
assembly, refer to Shock Absorber and Spring Assembly in this section.
11.
Manual
Shock Absorber and Spring Assembly
Material
Item Specification
Dielectric Compound
XG-3-A
ESE-M1C171-A
1 18A179 Shock absorber rod protective cap
2 18A161 Shock absorber rod nut
3 18183 Shock absorber upper mount
4 - Strut bearing (part of 18183)
5 - Spring seat (part of 18183)
6 5793 Spring seat - rubber
7 3C239 Dust boot
8 5310 Spring
9 18184 Shock absorber and lower mount assembly
10 18198 Jounce bumper
11 W302119 Shock absorber-to-damper fork bolt
12 3463 LH/ 3462 RH Damper fork
WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber
and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may
WARNING: Keep all body parts clear of shock absorbers or strut rods. Shock absorbers or struts
can extend unassisted. Failure to follow this instruction may result in serious personal injury.
WARNING: The coil spring is under extreme load. Care must be taken at all times when removing
or installing a loaded spring. Failure to follow this instruction may result in serious personal injury.
NOTICE: The coil spring is coated with long-term corrosion protective paint. Do not damage the paint
during component servicing or damage to the coil spring may occur.
Remove the shock absorber and spring assembly. For additional information, refer to Shock Absorber
and Spring Assembly in this section.
1.
Position the shock and spring assembly in a suitable spring compressor.
2.
Compress the spring enough to relieve the tension on the shock and spring assembly. 3.
Remove the shock rod protective cap. 4.
NOTICE: Do not use an impact wrench on the shock absorber rod nut or damage to the shock
absorber may occur.
NOTE: Use the hex-holding feature to prevent the shock absorber rod from turning while removing
or installing the nut.
While holding the shock absorber rod, remove and discard the nut.
5.
Remove the shock absorber and lower mount assembly. 6.
Remove the shock absorber upper mount, spring upper seat and dust boot. 7.
Carefully release the tension on the spring compressor and remove the spring. 8.
Remove and discard the shock absorber-to-damper fork bolt, then separate the shock and damper fork.
To install, tighten the new bolt to 48 Nm (35 lb-ft).
9.
NOTE: Before installing the jounce bumper, apply silicone brake caliper grease and dielectric
compound 360 degrees around the upper and lower contact surfaces.
Remove the jounce bumper.
10.
NOTE: Before tightening the shock absorber rod nut, position the end of the spring within 0-10 mm
(0-0.39 in) of the step on the spring mount.
To assemble, reverse the disassembly procedure.
11.
SECTION 204-02: Rear Suspension
Manual
Material
Capacity
Premium Long-Life Grease
XG-1-C or XG-1-K (US);
CXG-1-C (Canada)
ESA-M1C75-B -
Brake caliper anchor plate bolt 70 52 -
Brake disc bolt 20 - 177
Brake disc shield bolt 23 17 -
Jounce stop 55 41 -
Lower arm cam adjuster nut 101 74 -
Lower arm outboard nut 103 76 -
Parking brake cable bracket bolt 10 - 89
Shock absorber bracket bolt 40 30 -
Shock absorber lower bolt - All-Wheel Drive (AWD) 90
Manual
Rear Suspension
The rear suspension consists of the following components:
Wheel bearing and wheel hub assemblies
Wheel studs
Upper arms
Lower arms
Toe links
Stabilizer bar
Stabilizer bar bushings
Stabilizer bar links
Trailing arms
Wheel knuckles
Wheel spindles
Shock absorbers
Coil springs
The rear suspension utilizes an independent short/long arm design. This suspension system incorporates a
separate wheel knuckle for each wheel and allows the wheels to react to road imperfections independent of
each other. This independent action offers improved isolation from the effects of jounce and rebound.
Rear Suspension 2877
Manual
Rear Suspension
Rear Suspension 2878
Manual
REMOVAL AND
INSTALLATION
Wheel Bearing and Wheel Hub
Special Tool(s)
Installer, Wheel Bearing Cup
205-147
Remover, Drive Pinion Bearing Cone
Remover/Installer, Wheel Bearing Cup
204-020
Step Plate
205-117
3 2C026 Brake disc
4 1N135 Grease cap
5 W712435 Wheel hub nut
6 1104 Wheel hub and bearing assembly
8 2C187 Wheel speed sensor
10 2860 Parking brake cable clip
11 2A815 Rear parking brake cable assembly
1 1104 Wheel hub
2 W303280 Snap ring
3 1215 Wheel bearing
Removal
same part numbers or equivalent part, if replacement is necessary. Do not use a replacement partf
Remove the wheel speed sensor bolt and position the sensor aside. 2.
Disconnect the parking brake cable from the brake caliper in the following sequence.
Remove the clip. 1.
Disconnect the parking brake cable from the brake caliper. 2.
3.
NOTICE: Do not allow the brake caliper and anchor plate assembly to hang from the brake
hose or damage to the hose can occur.
4.
Remove the anchor plate bolts and position the brake caliper and anchor plate assembly aside.
Support the brake caliper and anchor plate assembly using mechanic's wire.
Remove and discard the grease cap. 6.
Remove and discard the wheel hub nut and remove the wheel hub and bearing assembly. 7.
Remove the wheel knuckle. For additional information, refer to Wheel Knuckle in this section. 8.
Using the Step Plate, press the wheel hub from the wheel bearing. 9.
NOTE: This step may be necessary if the inner wheel bearing race remains in the wheel knuckle after
removing the wheel hub.
Install the Drive Pinion Bearing Cone Remover, position in a suitable press and press the inner wheel
bearing race from the wheel hub.
10.
Using the Wheel Bearing Cup Remover/Installer, press the outer wheel bearing race from the wheel
knuckle.
12.
Installation
AWD vehicles
Using the Wheel Bearing Cup Installer, press the wheel bearing into the wheel knuckle. 1.
Using the Wheel Bearing Cup Installer and Step Plate, press the wheel hub into the wheel bearing. 2.
Install the wheel knuckle. For additional information, refer to Wheel Knuckle in this section. 3.
FWD vehicles
4.
5.
Position the brake caliper and install the brake caliper anchor plate bolts.
6.
NOTICE: Do not tighten the rear wheel hub nut with the vehicle on the ground. The nut must
be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing
damage will occur if the bearing is loaded with the weight of the vehicle applied.
Install the new wheel hub and bearing and a new wheel hub nut.
While applying the brakes to keep the halfshaft from rotating, tighten to 255 Nm (189 lb-ft).
7.
Connect the parking brake cable to the brake caliper in the following sequence.
Install the clip. 1.
Connect the parking brake cable to the brake caliper. 2.
8.
Manual
REMOVAL AND
INSTALLATION
Wheel Studs
NOTE: Front Wheel Drive (FWD) vehicle shown, All-Wheel Drive (AWD) similar.
1 1104 Wheel bearing and wheel hub assembly
2 1107 Wheel stud
Removal
100-02 .
1.
Remove the wheel bearing and wheel hub. For additional information, refer to Wheel Bearing and
Wheel Hub in this section.
2.
Using a press, remove the wheel stud from the wheel hub. 3.
Installation
Position the new wheel stud in the wheel hub, aligning the serrations in the wheel hub flange made by
the original wheel stud.
1.
Using a press, install the new wheel stud. 2.
Install the wheel bearing and wheel hub. For additional information, refer to Wheel Bearing and
Wheel Hub in this section.
3.
Wheel Studs 2884
Wheel Studs 2885
Manual
REMOVAL AND
INSTALLATION
Wheel Knuckle
Special Tool(s)
204-161 (T97P-1175-4)
Remover, Front Wheel Hub
NOTE: All-Wheel Drive (AWD) MKZ vehicle shown, other vehicles similar.
3 2C026 Brake disc
4 W712435 Wheel hub nut
Wheel Knuckle 2886
6 W520515 Trailing arm-to-wheel knuckle nuts (4
required)
7 5B860 Trailing arm-to-wheel knuckle bolts (4
required)
8 W520515 Upper arm outboard nut
9 W500547 Upper arm outboard bolt
10 5A968 Wheel knuckle
11 W520215 Lower arm outboard nut
12 W513798 Lower arm outboard bolt
13 W302116 Shock absorber lower flagnut
15 2C187 LH/ 2C187
RH
Wheel speed sensor
17 2A815 Parking brake cable assembly
18 2860 Parking brake cable clip
Removal
surof correct retention of these parts.
100-02 .
1.
Detach the 2 wheel speed sensor harness retainers. 2.
Remove the wheel speed sensor bolt and position the sensor aside. 3.
Disconnect the parking brake cable from the brake caliper in the following sequence.
Remove the clip. 1.
Disconnect the parking brake cable from the brake caliper. 2.
4.
5.
NOTICE: Do not allow the brake caliper and anchor plate assembly to hang from the brake
hose or damage to the hose can occur.
Remove the anchor plate bolts and position the brake caliper and anchor plate assembly aside.
6.
Wheel Knuckle 2887
Support the brake caliper and anchor plate assembly using mechanic's wire.
Using the Front Wheel Hub Remover, separate the halfshaft from the wheel hub. 8.
Remove and discard the shock absorber lower bolt and flagnut.
If equipped, remove the shock absorber damper.
9.
Using a suitable jack, raise the lower arm. 10.
Remove and discard the upper arm outboard bolt. 11.
Remove and discard the lower arm outboard bolt. 12.
Remove the 4 trailing arm-to-knuckle nuts and the wheel knuckle.
Discard the nuts.
13.
Installation
NOTICE: Before tightening any suspension bushing fasteners, the suspension must be at the bushing
fastener tightening position. Use a suitable jack to raise the suspension until the distance between the
center of the hub and the lip of the fender is equal to 395 mm (15.55 in). This will prevent incorrect
clamp load and bushing damage.
Position the wheel knuckle and loosely install the 4 new trailing arm-to-knuckle nuts. 1.
Loosely install the new lower arm outboard bolt. 2.
Loosely install the new upper arm outboard bolt. 3.
Loosely install the new shock absorber lower bolt and flagnut. 4.
5.
6.
Wheel Knuckle 2888
Using the Halfshaft Installer, install the halfshaft into the wheel hub. 7.
NOTICE: Do not tighten the wheel hub nut with the vehicle on the ground. The nut must be
tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage
Install a new wheel hub nut.
While applying the brakes to prevent the wheel hub nut from turning, tighten to 255 Nm (189
lb-ft).

8.
Stake the new nut in line with the keyway to a recommended depth of 1 mm (0.039 in) below the
keyway diameter to engage the locking feature.
9.
Connect the parking brake cable to the brake caliper in the following sequence.
Connect the parking brake cable to the brake caliper. 2.
10.
Install the wheel speed sensor and the bolt.
11.
Attach the 2 wheel speed sensor harness retainers. 12.
This will prevent unequal clamp load and bushing damage.
Using the positioned suitable jack, raise the lower arm to bushing fastener tightening position.
13.
Wheel Knuckle 2889
Tighten the 4 trailing arm-to-knuckle nuts to 100 Nm (74 lb-ft). 14.
Tighten the lower arm outboard bolt to 103 Nm (76 lb-ft). 15.
Tighten the upper arm outboard bolt to 110 Nm (81 lb-ft). 16.
Tighten the shock absorber lower bolt.
Tighten to 90 Nm (66 lb-ft), All-Wheel Drive (AWD) vehicles.
Tighten to 115 Nm (85 lb-ft), Front Wheel Drive (FWD) vehicles.
17.
Lower and remove the jack. 18.
Wheel Knuckle 2890
Manual
REMOVAL AND
INSTALLATION
Wheel Spindle
1 W500020 Brake disc shield bolt (3 required)
2 2K046 LH/ 2K045 RH Brake disc shield
3 4A013 Wheel spindle
4 W715590 Wheel spindle bolt (4 required)
Remove the wheel bearing and wheel hub assembly. For additional information, refer to Wheel
Bearing and Wheel Hub in this section.
1.
Remove the 3 brake disc shield bolts and remove the brake disc shield.
2.
Remove and discard the 4 wheel spindle bolts and remove the wheel spindle.
3.
Wheel Spindle 2891
Wheel Spindle 2892
Manual
REMOVAL AND
INSTALLATION
Lower Arm
1 5A649 Lower arm
2 5K751 Cam bolt
3 W520515 Cam adjuster nut
4 6269 Cam adjuster
Remove the spring. For additional information, refer to Spring in this section. 1.
Remove the cam adjuster nut, cam adjuster, cam bolt and the lower arm.
Discard the nut.
To install, tighten the new nut to 101 Nm (74 lb-ft) with the suspension at the bushing
fastener tightening position.

2.
3.
Lower Arm 2893
NOTE: Do not fully tighten the cam adjuster nut until the rear alignment has been checked and, if
necessary, adjusted.
NOTE: Install the cam bolt and the cam adjuster with the cam facing upward.
Lower Arm 2894
Manual
REMOVAL AND
INSTALLATION
Upper Arm
1 5500 Upper arm
2 W712769 Upper arm inboard bolt
1 W520215 Upper arm inboard nut
2 W712769 Upper arm inboard bolt
3 5500 Upper arm
Upper Arm 2895
5 W520215 Upper arm outboard nut
7 18080 Shock absorber
8 - Shock absorber lower mount bushing
All vehicles
Using a suitable jack, support the trailing arm. 2.
NOTICE: Do not fully tighten the shock absorber lower nut until the suspension is at the
bushing fastener tightening position. This will prevent incorrect clamp load and bushing
damage.
To install, tighten the new bolt and flagnut to 90 Nm (66 lb-ft), All-Wheel Drive (AWD)
vehicles.

To install, tighten the new bolt and flagnut to 115 Nm (85 lb-ft), Front Wheel Drive (FWD)
vehicles.

3.
Remove and discard the upper arm outboard bolt.
To install, tighten the new bolt to 110 Nm (81 lb-ft) with the suspension at the bushing
fastener thtening position.

4.
Remove and discard the upper arm outboard bolt and nut.
To install, tighten the new nut and bolt to 110 Nm (81 lb-ft) with the suspension at the

5.
All vehicles
Carefully lower the trailing arm and remove the jack. 6.
NOTE: Position the shock absorber as necessary to remove the upper arm.
NOTE: When tightening the upper arm inboard bolt, the suspension must be at the bushing fastener
Remove and discard the upper arm inboard bolt and remove the upper arm.
7.
To install, tighten the new bolt to 100 Nm (74 lb-ft) and then rotate an additional 90 degrees.
8.
Check and, if necessary, adjust the rear camber. For additional information, refer to Section 204-00 . 9.
Manual
REMOVAL AND
INSTALLATION
Toe Link
1 5G095 Toe link shield
2 W709453 Pushpin
3 5B674 Toe link
4 W500214 Toe link shield bolt
5 W520515 Toe link inboard nut
6 W500547 Toe link outboard bolt
7 W500547 Toe link inboard bolt
1 W500547 Toe link inboard bolt
Toe Link 2898
2 W520515 Toe link inboard nut
4 W520515 Toe link outboard nut
5 5B674 Toe link
All vehicles
Remove the toe link shield bolt.
2.
Remove the pushpin and the shield. 3.
All vehicles
Remove and discard the toe link inboard nut and bolt.
To install, tighten the new nut to 110 Nm (81 lb-ft) with the suspension at the bushing

4.
Remove and discard the toe link outboard nut and bolt and remove the toe link.
To install, tighten the new nut to 90 Nm (66 lb-ft) with the suspension at the bushing fastener

5.
FWD vehicles
Remove the toe link outboard bolt and remove the toe link.

6.
All vehicles
7.
Check and, if necessary, adjust the rear toe. For additional information, refer to Section 204-00 . 8.
Manual
REMOVAL AND
INSTALLATION
Trailing Arm
1 W711493 Trailing arm-to-frame bolt (2 required)
5 5A995 LH/ 5A994 RH Trailing arm
8 6C028 Cone washer (2 required)
Trailing Arm 2901
1 W711493 Trailing arm-to-frame bolts (2 required)
2 6C028 Cone washers (2 required)
3 5A995 LH/ 5A994
RH
Trailing arm
4 - Wheel speed sensor bracket (part of 2C186
RH/2C187 LH)
5 W520102 Wheel speed sensor bracket nut
6 5A757 Trailing arm toe link bracket
7 5B860 Trailing arm-to-knuckle nut (4 required)
All vehicles
Remove the parking brake cable bracket bolt and position the parking brake cable aside.
2.
Remove the wheel spine. For additional information, refer to Wheel Spindle in this section. 3.
If equipped, detach the wheel speed sensor harness from the trailing arm. 4.
Using a suitable jack, support the trailing arm. 5.
WARNING: The coil spring is under extreme load. Care must be taken at all times when
removing or installing a loaded spring. Failure to follow this instruction may result in serious
personal injury.
6.
Remove and discard the lower arm outboard bolt.

Remove and discard the upper arm outboard bolt.

7.
Carefully lower the trailing arm and remove the jack. 8.

9.
Remove and discard the toe link outboard bolt.

10.
AWD vehicles
Remove the wheel speed sensor harness bracket nut and position aside the bracket.
11.
Remove the toe link. For additional information, refer to Toe Link in this section. 12.
Remove the 4 trailing arm-to-wheel knuckle nuts and the trailing arm toe link bracket.
Discard the nuts.
13.
All vehicles
Remove the 2 trailing arm-to-frame bolts, cone washers and the trailing arm.
Discard the bolts.
14.
15.
Check and, if necessary, align the rear end. For additional information, refer to Section 204-00 . 16.
Manual
REMOVAL AND
INSTALLATION
Stabilizer Bar and Link
1 5A486 Stabilizer bar link
2 W302134 Stabilizer bar link lower bolt
1 5B498 Stabilizer bar bracket (2 required)
2 5493 Stabilizer bar bushing (2 required)
3 5A772 Stabilizer bar
Stabilizer Bar and Link 2905
5 W302131 Stabilizer bar bracket bolt (2 required)
6 3C494 Stabilizer bar link upper nut (2 required)
Remove the rear halfshafts. For additional information, refer to Section 205-05 . 1.
Remove the RH side spring. 2.
100-02 .
3.
All vehicles
Remove and discard the 2 stabilizer bar link upper nuts.
4.
Remove the 2 stabilizer bar link lower bolts and the stabilizer bar links.
Discard the bolts.
To install, tighten the new bolts to 45 Nm (33 lb-ft) with the suspension at the bushing

5.
Remove and discard the stabilizer bar bracket nuts.
To install, tighten the new nuts to 40 Nm (30 lb-ft) with the suspension at the bushing fastener

6.
Remove the stabilizer bar bracket bolts and the brackets.
Discard the bolts.
To install, tighten the new bolts to 40 Nm (30 lb-ft) with the suspension at the bushing

7.
FWD vehicles
Remove the stabilizer bar. 8.
AWD vehicles
NOTICE: Be careful not to contact the fuel lines or wiring harness when removing and
installing the stabilizer bar or damage to the wiring harness or fuel lines may occur.
Remove the stabilizer bar from the RH side of the vehicle.
9.
All vehicles
Inspect the stabilizer bar bushings and install a new bushing(s), if necessary. 10.
damage.
11.
Manual
REMOVAL AND
INSTALLATION
Spring
Material
Item Specification
XG-1-C or XG-1-K (US); CXG-1-C
(Canada)
ESA-M1C75-B
NOTE: Front Wheel Drive (FWD) shown, AWD similar.
1 5536A Spring lower seat
2 5560 Spring
3 5536B Spring upper seat
4 W302134 Stabilizer bar link lower bolt
6 5K570 Jounce bumper
Removal
NOTICE: The coil spring is coated with long-term corrosion protective paint. Do not damage the paint
during component servicing or spring damage may occur.
Spring 2908
NOTE: Do not fully tighten the cam adjuster nut until the rear alignment has been checked and, if
necessary, adjusted.
Index-mark the cam bolt and cam adjuster and then loosen the cam adjuster nut.
2.
Remove and discard the stabilizer bar link lower bolt. 3.
Using a suitable jack, support the lower arm. 4.
WARNING: The coil spring is under extreme load. Care must be taken at all times when
removing or installing a loaded spring. Failure to follow this instruction may result in serious
personal injury.
Remove and discard the lower arm outboard bolt.
5.
Lower the lower arm and remove the spring.
Inspect the spring upper and lower seats and install new seats as necessary.
6.
Installation
Inspect and if necessary, install a new jounce bumper.
Lubricate the top of the new jounce bumper with grease.
1.
Position the spring upper seat onto the spring with the end of the spring 0-10 mm (0-0.39 in) from the
step on the seat.
2.
If removed, position the spring lower seat into the lower arm aligning the recess in the seat with the
projection on the lower arm.
3.
Position the spring onto the lower arm with the end of the spring 0-10 mm (0-0.39 in) from the step
on the spring seat.
4.
Spring 2909
NOTE: Do not tighten the bolt at this time.
Using the jack, raise the lower arm and install a new lower arm outboard bolt.
5.
damage.
Using the jack, raise the suspension until the distance between the center of the hub and the lip of the
fender is equal to 395 mm (15.55 in).
6.
Tighten the lower arm outboard bolt to 110 Nm (81 lb-ft). 7.
Install a new stabilizer bar link lower bolt.
8.
Align the index mark on the cam bolt and cam adjuster with the index mark on the lower arm and
tighten the cam adjuster nut to 101 Nm (74 lb-ft).
9.
Check and, if necessary, align the rear end. For additional information, refer to Section 204-00 . 10.
Spring 2910
Spring 2911
Manual
REMOVAL AND
INSTALLATION
Shock Absorber
2 W302277 Shock absorber bracket bolt (3 required)
3 18165 LH/ 18164 RH Shock absorber bracket
4 W520515 Shock absorber upper nut
5 W500748 Shock absorber upper bolt
All-Wheel Drive (AWD) MKZ Vehicles
Shock Absorber 2912
6 18199 Shock absorber lower mount bushing
8 18165 LH/ 18164 RH Shock absorber bracket
All-Wheel Drive (AWD) Fusion/Milan Vehicles
All-Wheel Drive (AWD) MKZ Vehicles 2913
4 18165 LH/ 18164 RH Shock absorber upper bracket
7 5B695 Shock absorber damper LH side
8 5B695 Shock absorber damper RH side
9 W712848 Shock absorber lower flagnut (with 17-in
wheel)
9 W302117 Shock absorber lower flagnut (with 16-in
wheel)
Removal
NOTE: The new shock absorber is shipped with a strap securing it in the compressed position. Do not remove
this strap until the shock absorber and bracket assembly are in position and the 3 bracket bolts have been
installed.
Remove the upper arm. For additional information, refer to Upper Arm in this section. 1.
Compress the shock absorber and secure it in the compressed position using tie straps or a similar
item.
2.
Remove the 3 shock absorber bracket bolts and remove the shock absorber and upper bracket. 3.
All-Wheel Drive (AWD) Fusion/Milan Vehicles 2914
Discard the bolts.
Index-mark the shock absorber to the bracket. 4.
Remove the shock absorber upper bolt, nut and the bracket. 5.
Installation
Copy the index mark from the shock absorber that was removed to the shock absorber that is being
installed.
1.
NOTE: Do not fully tighten the shock absorber upper bolt and nut at this time.
Position the shock absorber into the bracket and loosely install a new shock absorber upper bolt and
nut.
2.
NOTICE: Do not allow the angle between the shock absorber and bracket to change while
tightening the shock absorber upper nut or damage to the shock absorber may occur.
Align the index marks so the center line of the shock absorber is approximately 118 degrees from the
alignment tab on the bracket and tighten the shock absorber upper bolt.
For All-Wheel Drive (AWD) vehicles, tighten to 90 Nm (66 lb-ft).
For Front Wheel Drive (FWD) vehicles, tighten to 103 Nm (76 lb-ft).
3.
Position the shock absorber and bracket assembly and install the 3 new bracket bolts.
4.
Install the upper arm. For additional information, refer to Upper Arm in this section. 5.
SECTION 204-04: Wheels and Tires
Manual
Material
Capacity
Lubricant
XL-2
- -
Motorcraft Wheel and Tire
Cleaner
ZC-37-A
- -
Item Specification
Tire Inflation
Tires See Safety Certification Label on driver door jamb
Wheel Weights
Wheel weight
type
Use a wheel weight manufacturer's rim gauge to determine the correct wheel weight
application
Valve stem-to-Tire Pressure Monitoring System (TPMS) sensor screw 1.5 13
Wheel nuts
a
- -
a
Manual
Wheels And Tires
Safety Precautions
WARNING: Always match the tire size to the wheel size during assembly. Incorrect matching can
result in tire bead damage or tire separation from the wheel. Failure to follow this instruction may
result in serious personal injury to technician or vehicle occupant(s).
WARNING: Before servicing any tire, ask the customer if anyone injected a tire sealant into the tire.
Tire sealants may be flammable and can burn or explode if exposed to an ignition source. Failure to
WARNING: Replacement wheels must be equivalent to the original equipment wheels in:
load carrying capacity.
diameter, width and offset.
pilot hole and bolt circle.
Combined load carrying capacity of replacement wheels for a given axle, must be equal to or greater than that
axle's gross axle weight rating (GAWR) identified on the vehicle's Safety Compliance Certification label. All
other specifications should be evaluated by measurement of both the original wheel and the replacement
wheel. If specifications are not equivalent, the safety and handling of the vehicle may be degraded, which may
result in serious injury to the vehicle occupant(s).
WARNING: Keep eyes away from valve stem when deflating tires. Reduce air pressure in tire as
much as possible by pushing in valve core plunger prior to removing the core. Escaping air can carry
particles that can injure the eyes. Failure to follow these instructions may result in serious personal
injury.
WARNING: Only use replacement tires that are the same size, load index, speed rating and type
(such as P-metric versus LT-metric or all-season versus all-terrain) as those originally provided by
Ford. The recommended tire and wheel size may be found on either the Safety Compliance
Certification Label or the Tire Label, which is located on the B-pillar or edge of the driver's door. If the
information is not found on these labels, consult a Ford dealer. Use of any tire or wheel not
recommended by Ford can affect the safety and performance of the vehicle, which could result in an
increased risk of loss of vehicle control, vehicle rollover, personal injury and death. Additionally, the
use of non-recommended tires and wheels could cause steering, suspension, axle or transfer case/power
transfer unit failure.
NOTICE: Do not clean aluminum wheels with steel wool, abrasive-type cleaners or strong detergents or
damage to the wheel finish may occur. Use Wheel and Tire Cleaner ZC-37-A or -B or equivalent.
Wheels And Tires 2919
Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including
full-rated load capacity when inflated to recommended inflation pressures.
Correct tire pressure and driving techniques have an important influence on tire life. Heavy cornering,
excessively rapid acceleration and unnecessary sharp braking increase tire wear.
To equalize tire wear, the tires should be rotated at recommended intervals.
Tire Pressure Monitoring System (TPMS)
NOTE: The Smart Junction Box (SJB) is also identified as the Generic Electronic Module (GEM).
The Tire Pressure Monitoring System (TPMS) includes:
the SJB , TPMS functionality is integrated within the SJB .
four valve stem mounted tire pressure sensors.
an Instrument Cluster (IC) indicator.
a message center (if equipped).
Tire Pressure Monitoring System (TPMS) Module
The SJB contains the TPMS functionality. Refer to Tire Pressure Monitoring System (TPMS) in Diagnosis
and Testing for TPMS fault diagnosis and repair.
The SJB compares the information of each tire pressure sensor transmission against a pressure limit. If the
SJB determines that the tire pressure has fallen below the low limit, the SJB communicates this to the IC on
the vehicle communication bus.
Tire Pressure Monitoring System (TPMS) Pressure Sensor
The SJB monitors the air pressure in the 4 road tires with tire pressure sensors. The sensors transmit radio
frequency signals to the SJB approximately every 60 seconds when the vehicle speed exceeds 32 km/h (20
mph).
The tire pressure sensors are battery operated and are mounted to the valve stem.
Instrument Cluster (IC) and Message Center
The IC illuminates the TPMS indicator when it receives a message from the TPMS to do so and displays the
appropriate message(s) in the message center (if equipped).
The IC and message center are diagnosed and serviced in their own respective workshop manual sections.
Manual
Wheels And Tires
Special Tool(s)
Digital Tire Gauge
204-354
Hunter Road Force Wheel Balancer
GSP9700 Series
Verify the customer concern by carrying out a road test on a smooth road. If any vibrations are apparent, GO
to Symptom Chart - NVH .
To maximize tire performance, inspect for signs of incorrect inflation and uneven wear, which may indicate a
need for balancing, rotation or front suspension alignment.
Correct tire pressure and driving techniques have an important influence on tire life. Heavy cornering,
excessively rapid acceleration and unnecessary sharp braking increase tire wear.
Replacement tires must follow the recommended:
tire sizes.
speed rating.
load range.
tire construction type.
The use of any other tire/wheel size, load range or type can seriously affect:
ride.
handling.
speedometer/odometer calibration.
vehicle ground clearance.
tire clearance between the body and chassis.
wheel bearing life.
braking performance.
New wheels need to be installed when the vehicle wheels:
are bent.
are cracked.
are dented.
are heavily corroded.
are leaking.
have elongated wheel hub bolt holes.
have excessive lateral or radial runout.
It is mandatory to use only the tire sizes recommended on the tire label located on the driver door or door
pillar attached to the vehicle. Larger or smaller tires can damage the vehicle, affect durability and require
changing the speedometer calibration. Make sure wheel size and offsets match those recommended for the tire
in use.
Inspect the tires for signs of uneven wear. Refer to the following descriptions to identify the type of
wear and GO to Symptom Chart - Tire Wear for the appropriate repair action to be carried out.
1.
Check the tires for:
cuts.
stone bruises.
abrasions.
blisters.
embedded objects.
2.
Check the valve stems for:
cracks.
cuts.
3.
Install a new valve stem when damage is found or anytime a new tire is installed.
Tread wear indicators are molded into the bottom of the tread grooves. Install a new tire when the
indicator bands become less than 2/32 inch.
4.
Tire Wear
Tire wear is commonly defined as a loss of tread depth. Tire tread wear occurs due to friction with the contact
surface (road/pavement). The tread should wear down uniformly all the way around the circumference of the
tire and all the way across the tread face. When this does not occur, the tire may have abnormal/incorrect
wear.
Normal Tire Wear
Normal tire wear is identified as even wear around and across the tread. Because there are many factors
(driving style, road surfaces, type of vehicle, type of tire) that can affect tire wear, there is no absolute mileage
expectation for a normal wear condition. A tire is considered worn-out when the tread has worn to the level of
the tread-wear indicators.
Abnormal/Incorrect Tire Wear
Abnormal/incorrect tire wear is identified as tire wear that is not even around or across the tread and that
creates performance-related issues.
Abnormal/incorrect wear can be caused by numerous factors, some of which include driving style (aggressive,
passive), climate (hot, cold), road conditions, vehicle loading and maintenance (correct tire pressure, rotation
intervals and balance). It is important to determine the root cause of wear on a vehicle before carrying out
repair. Tires exhibiting abnormal/incorrect tire wear may still be serviceable provided that the minimum tread
depth is greater than 2/32 inch and the tire is not causing a vehicle performance (noise/vibration) concern.
Normal Tire Wear 2923
Some abnormal/incorrect wear patterns look the same all the way around the tread of the tire, other wear
patterns are not consistent and can occur in various spots on the tread area. The underlying causes of the 6
wear categories are different. Refer to the following descriptions to identify the type of wear and GO to
Symptom Chart - Tire Wear for the appropriate repair action to be carried out.
Inner Edge/Shoulder Wear
Inner edge (or shoulder) wear occurs on the inside edge of the tire and is usually caused by excessive toe out
and/or excessive negative camber. If the tread depth of the outer shoulder is at least 50% greater than the tread
depth of the inner shoulder, the tire is experiencing inner edge/shoulder wear. To determine whether tires have
this type of wear, visually inspect the tires. In some instances, it may be necessary to measure the tread depth
of each rib and compare it to that of the shoulder.
NOTE: RF tire shown, others similar.
Outer Edge/Shoulder Wear
Outer edge (or shoulder) wear occurs on the outside edge of the tire and is usually caused by excessive toe in
and/or excessive positive camber. If the tread depth of the inner shoulder is at least 50% greater than the tread
depth of the outer shoulder, the tire is experiencing outer edge/shoulder wear. To determine whether tires have
this type of wear, visually inspect the tires. In some instances, it may be necessary to measure the tread depth
of each rib and compare it to that of the shoulder.
NOTE: RF tire shown, others similar.
Heel/Toe Wear
Heel/toe wear (also known as feathering) occurs along the outside or inside edge/shoulder of the tire. To
determine whether tires have this type of wear, visually inspect the tires in both the inside and outside
shoulder ribs. In some instances, it may be necessary to measure the difference in tread depth of leading
versus trailing edge of each lug in the inside and outside shoulder rib.
Abnormal/Incorrect Tire Wear 2924
Diagonal Wear
Diagonal wear occurs diagonally across the tread area and around the circumference of the tire. To determine
whether tires have this type of wear, visually inspect the tires to determine if the wear pattern runs diagonally
across the tread and around the circumference of the tire. In some instances, the difference in tread depth
along the diagonal wear pattern may need to be measured.
Symptom Chart - Tire Wear
Symptom Chart - Tire Wear
NOTE: For suspension system and additional alignment diagnosis, refer to Section 204-00 .
Inner edge/shoulder wear
Excessive toe out and/or negative camber
Incorrect wheel and tire assembly rotation intervals
High-speed cornering
Outer edge/shoulder wear
Excessive toe in and/or positive camber
High-speed cornering
Heel/toe wear
Diagonal Wear 2925
Excessive toe in/out
ROTATE the wheel and tire assemblies. CHECK the alignment, ADJUST as necessary.
Diagonal wear
Incorrect tire rotation intervals
Loose, worn or damaged suspension components
Symptom Chart - NVH
Symptom Chart - NVH
tools, an explanation of their uses and a glry of common terms, refer to Section 100-04 . Since it is possible
any one of multiple systems may be the cause of a symptom, it may be necessary to use a process of
Wobble or shimmy
Bent wheel
INSTALL a new wheel as necessary.
Damaged tire
INSTALL a new tire as necessary.
Loose wheel nuts
TIGHTEN to specification.
High-speed shake
Tires/wheels
REFER to Wheel and Tire Runout Component Tests in this section.
Vehicle vibration
Diagonal Wear 2926
Tires/wheels
REFER to Wheel and Tire Runout Component Tests in this section.
Pinpoint Tests
For a description of the various tire wear patterns, refer to Inspection and Verification.
Pinpoint Test A: Inner Edge/Shoulder Wear
Excessive toe out
Incorrect wheel and tire rotation
PINPOINT TEST A: INNER EDGE/SHOULDER WEAR
A1 MEASURE THE TREAD
DEPTH
Using a tread depth gauge or
similar tool, measure the inside
edge/shoulder tread depth.

Is the tread depth greater than
2/32 inch?

Yes
ROTATE the wheel and tire assemblies.
CHECK and ADJUST the toe to nominal +0.15 degrees (toe
in). CHECK and ADJUST caster and camber to nominal.
No
INSTALL a new tire(s). CHECK and ADJUST the toe to
nominal. CHECK and ADJUST caster and camber to nominal.
Pinpoint Test B: Outer Edge/Shoulder Wear
Excessive toe in
PINPOINT TEST B: OUTER EDGE/SHOULDER WEAR
B1 MEASURE THE TREAD DEPTH
Using a tread depth gauge or
similar tool, measure the outside
edge/shoulder tread depth.

Yes
ROTATE the wheel and tire assemblies.
CHECK and ADJUST the toe to nominal -0.15 degrees (toe
PINPOINT TEST A: INNER EDGE/SHOULDER WEAR 2927
Is the tread depth greater than
2/32 inch?
out). CHECK and ADJUST caster and camber to nominal.
No
INSTALL a new tire(s). CHECK and ADJUST the toe to
nominal. CHECK and ADJUST caster and camber to
nominal. REFER to Section 204-00 .
Pinpoint Test C: Diagonal Wear
Incorrect tire inflation
Loose, worn or damaged suspension components
PINPOINT TEST C: DIAGONAL WEAR
C1 MEASURE THE
TREAD DEPTH
Using a tread
depth gauge or
similar tool,
measure the tread
depth of the wear
pattern.

Is the tread
depth greater
than 2/32 inch?

Yes
If no performance concerns (noise/vibration) are present, the tire can remain
in service. CHECK the air pressure in the tires, ADJUST as necessary.
ROTATE the wheel and tire assemblies. INSPECT for loose, worn or
damaged suspension components. INSTALL new components as necessary.
CHECK the alignment and ADJUST as necessary. REFER to Section 204-00 .
No
INSTALL a new tire(s). CHECK the air pressure in the tires, ADJUST as
necessary. ROTATE the wheel and tire assemblies. INSPECT for loose, worn
or damaged suspension components. INSTALL new components as
necessary. CHECK the alignment and ADJUST as necessary. REFER to
Section 204-00 .
Component Tests
Radial Runout
Radial runout is the egg-shaped deviation from a perfect circle and is measured perpendicular to the
circumference. On a wheel and tire assembly, this means measuring the center tire tread rib. The center rib is
indicative of the condition of the tire as a whole. Total runout is the difference between the
maximum-to-minimum gauge reading. The high spot is the location of maximum runout.
PINPOINT TEST B: OUTER EDGE/SHOULDER WEAR 2928
Item Description
1 High spot
2 Low spot
Loaded Runout Measurement (Hunter Road Force 9700 Series Wheel Balancer)
NOTE: Diagnosis of tire/wheel vibration should not be performed on tires with less than 320 km (200 mi).
Some initial tire/wheel vibration issues (such as flat spotting) may correct themselves after the tires have been
in service for 320 km (200 mi).
This procedure is intended to assist with the diagnosis of wheel and tire assembly runout and/or force
variation issues.
The Hunter Road Force 9700 Series Wheel Balancer measures the wheel and tire assembly's loaded runo
and the tire's radial spring rate. The balancer then converts the runout into pounds of force (termed as Road
Force). Measuring loaded runout (Road Force) is more effective than measuring unloaded runout using a
dial indicator.
Using a tire crayon, record the vehicle position on the inward sidewall of all 4 tires. 1.
Remove the wheel and tire assemblies. Refer to Wheel and Tire in this section. 2.
NOTE: Use only the Digital Tire Gauge any time tire pressures are measured to be sure that accurate
values are obtained.
Make sure that the tire pressures are set to the correct pressure as indicated on the Vehicle
3.
NOTICE: Make sure that the correct wheel balancer adapters are used when mounting the
assembly to the wheel balancer or damage to the wheel may occur.
NOTE: Make sure that the wheel and tire assembly is clean and free of foreign material prior to
installation on the balancer.
NOTE: The wheel balancer inflation station must be turned OFF for tires with inflation pressures of
414 kPa (60 psi) or above.
Mount the wheel and tire assembly on a suitable wheel balancer using the correct wheel balancer
adapters as shown. Refer to the list of recommended wheel bancer adapters on the PTS website.
4.
PINPOINT TEST C: DIAGONAL WEAR 2929
Item Description
1 Wheel balancer
2 Cone
3 Wheel and tire assembly
4 Finger plate
5 Balancer wing nut
Measure the Road Force.
Temporarily mark the high spot and the Road Force value on the sidewall of the tire. If the
wheel and tire assembly Road Force value is greater than 9 kg (20 lb), carry out the Match
Mounting procedure to optimize the wheel and tire assembly.

If the wheel and tire assembly Road Force value is 9 kg (20 lb) or less, permanently mark
the high spot and the Road Force value on the inward sidewall of the tire for reference
during future wheel and tire service. Balance the assembly and install the wheel and tire on
the vehicle using the Wheel-to-Hub Optimization procedure.

5.
Runout Measurement (Dial Indicator)
NOTE: Diagnosis of tire/wheel vibration should not be performed on tires with less than 320 km (200 mi).
Some initial tire/wheel vibration issues (such as flat sng) will correct themselves after the tires have been in
service for 320 km (200 mi).
NOTE: Loaded run-out measurements are the preferred method for verifying tire serviceability. While a dial
indicator can be used to optimize the position of the tire on the wheel, the unloaded run-out measurement
cannot accurately determine if the tire should be removed from service.
The following procedures should be used if normal diagnostics leads to a potential runout issue.
Some vehicles may exhibit a wheel and tire vibration caused by excessive runout. Radial runout
measurements can be taken using a dial indicator and should be measured with the wheel and tire assembly
mounted on a suitable wheel balancer. The dial indicator should be mounted securely to eliminate gauge
movement when measuring runout.
NOTE: Use only the Digital Tire Gauge any time tire pressures are measured to be sure that accurate
Make sure that the tire pressures are set to the correct pressure as indicated on the VC label.
1.
Using a tire crayon, record the vehicle position on the inward sidewall of all 4 tires. 2.
Remove the wheel and tire assemblies. Refer to Wheel and Tire in this section. 3.
NOTICE: Make sure that the correct wheel balancer adapters are used when mounting the
assembly to the wheel balancer or damage to the wheel may occur.
NOTE: Make sure that the wheel and tire assembly is clean and free of foreign material prior to
installation on the balancer.
Mount the wheel and tire assembly on a suitable wheel balancer using the correct wheel balancer
adapters as shown. Refer to the list of recommended wheel balancer adapters on the PTS website.
4.
Item Description
1 Wheel balancer
2 Cone
3 Wheel and tire assembly
4 Finger plate
5 Balancer wing nut
NOTE: Masking tape can be applied on the center tread rib to allow for a smoother measuring
surface. Some fluctuation of the gauge reading is expected. Observe the overall sweep of the gauge
from the highest to the lowest spot on the tire.
Position a suitable dial indicator and stand with the dial indicator on the center tread rib.
Rotate the wheel and tire assembly (or wheel) to locate the low spot.
Adjust the runout gauge to read 0.
Rotate the wheel and tire assembly one complete revolution to make sure that the low spot
has been found and that the dial indicator returns to a 0 reading.

5.
While slowly and constantly rotating the wheel and tire assembly (or wheel), measure the radial
runout.
6.
Note the variance (runout) from 0 on the dial of the gauge.
If the runout reading of a wheel and tire assembly is greater than 1.14 mm (0.045 in), locate
and temporarily mark the high spot and runout reading on the sidewall of the tire and carry
out the Match Mounting procedure to optimize the wheel and tire assembly.

If the runout reading of a wheel and tire assembly is 1.14 mm (0.045 in) or less, permanently
mark the high spot and the runout reading on the inward sidewall of the tire for reference
during future wheel and tire service. Balance the assembly and install the wheel and tire on
the vehicle using the Wheel-to-Hub Optimization procedure.

Match Mounting
NOTE: Road Force values in illustrations are shon in pounds.
Match mounting is a technique used to reduce radial runout or road force on wheel and tire assemblies.
Excessive runout is a source of ride quality complaints and match mounting can be used to minimize the
runout. Match mounting can be accomplished by changing the position of the tire on the wheel.
Position the wheel and tire assembly on a tire machine and put a reference mark on the tire sidewall at
the valve stem position.
1.
Item Description
1 Valve stem
2 Reference mark
NOTICE: For vehicles equipped with a Tire Pressure Monitoring System (TPMS), the sensor
may be damaged by incorrect tire mounting or dismounting. Dismount the tire from the wheel
as instructed in the Disassembly and Assembly procedure. Failure to follow these instructions
may result in TPMS component damage.
NOTE: Always make sure that the final high spot and measurement values are permanently marked
on the inward sidewall of the tire for reference during future wheel and tire service.
Using a suitable tire machine, separate the tire beads from the wheel.
Lubricate the tire beads using a suitable fast drying, corrosion inhibiting tire bead lubricant.
2.
Position the tire 180 degrees (half-way around) on the rim so the valve stem reference mark is
now opposite the valve stem.

Re-inflate the wheel and tire assembly to the specified air pressure and measure the assembly again
using a suitable dial indicator or Hunter Road Force 9700 Series Wheel Balancer. Mark the second
high spot on the tire.
If the runout or Road Force is reduced to within specifications, the concern has been
resolved. Balance the assembly and install on the vehicle using the Wheel-to-Hub
Optimization procedure.

3.
If the second runout or Road Force measurement is still not within specification and both high spots
are close to each other (within 101.6 mm [4 in]), the root cause is probably the tire (the high spot
followed the tire).
To be SURE that the tire is causing the high runout, it is necessary to have 2 runout or Road
Force measurements that are not within specification and the high spots must be in
approximately the same location on the tire's sidewall. If the tire is the cause, install a new
tire, balance the assembly and install on the vehicle using the Wheel-to-Hub Optimization
procedure.

If the second high spot is not within 101.6 mm (4 in) of the first high spot, proceed to the next
step.

4.
Item Description
First high spot on the tire
2 Second high spot on the tire
If the second high spot is still above specification and is within 101.6 mm (4 in) of being opposite the
first high spot on the wheel, the root cause is probably the wheel (the high spot followed the wheel).
Dismount the tire from the wheel, mount the wheel on a balancer and check the wheel runout. If the
wheel runout exceeds 1.14 mm (0.045 in), install a new wheel, balance the assembly and install on the
vehicle using the Wheel-to-Hub Optimization procedure.
5.
Item Description
1 First high spot on the tire
NOTE: If the second high spot did not follow the wheel or the tire and the runout is still not within
specification, improvements may be made by rotating the tire 90 degrees (one-fourth turn).
Draw an arrow on the tire sidewall from the second high spot towards the first high spot (in the
shortest direction).
Separate the tire beads from the wheel and rotate the tire 90 degrees (one-fourth turn) in the
direction of the arrow.

6.
Item Description
1 First high spot on the tire
Wheel-to-Hub Optimization
Wheel-to-hub optimization is important. Clearance between the wheel and hub can be used to offset or
neutralize the Road Force or run-out of the wheel and tire assembly. For every 0.001 inch of wheel-to-hub
clearance, the Road Force can be affected between 1 and 3 pounds depending on the tire stiffness.
NOTE: The example below illustrates how the clearance between the wheel and the hub can be used to offset
the high spot of radial run-out or Road Force. Following the procedure will make sure of the best
optimization.
Position the wheel and tire assembly on the vehicle so that the high spot location of radial run-out or
Road Force is at the 6 o'clock position and install the wheel nuts by hand until snug.
1.
NOTE: Do not allow the full weight of the vehicle to rest on the tires while tightening the wheel nuts.
Lower the vehicle until the tires make contact with the ground, sliy loading the suspension. Tighten
2.
the wheel nuts as described in Wheel and Tire in this section.
Manual
Tire Pressure Monitoring System (TPMS)
Special Tool(s)
Activation Tool, Tire Pressure Monitor
204-363
Digital Tire Pressure Gauge
204-354
NOTE: The Smart Junction Box (SJB) is also referred to as the Generic Electronic Module (GEM).
The Tire Pressure Monitoring System (TPMS) monitors the air pressure of all 4 road tires. The
wheel-mounted tire pressure sensors transmit via radio frequency signals, to the SJB . TPMS functionality is
integral to the SJB . These transmissions are sent approximately every 60 seconds when the vehicle speed
exceeds 32 km/h (20 mph). The TPMS function compares each tire pressure sensor transmission against a
low-pressure limit. If it has been determined that the tire pressure has fallen below this limit, the SJB
communicates this on the vehicle communication bus to the Instrument Cluster (IC). The IC then illuminates
the TPMS indicator and displays the appropriate message(s) in the message center (if equipped).
For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire
pressures must be adjusted and the tire pressure sensors must be trained following a tire rotation. Failure to
train the sensors will cause the TPMS indicator to illuminate.
For vehicles with the same tire pressures for front and rear tires, tire rotation will not affect the system.
Ambient Temperature Change and Tire Pressure
NOTICE: Do not inflate tire higher than maximum pressure stamped on tire sidewall. Premature tire
wear or damage to the tire may result.
Tire Pressure Monitoring System (TPMS) 2936
Tire pressures fluctuate with temperature changes. For this reason, tire pressure must be set to specification
when tires are at outdoor ambient temperatures. If the vehicle is allowed to warm up to shop temperatures, and
the outside temperature is less than shop temperature, the tire inflation pressure must be adjusted accordingly.
If the tires are inflated to specification at shop temperatures, and the vehicle is moved outdoors when the
outdoor ambient temperature is significantly lower, the tire pressure may drop enough to be detected by the
TPMS and activate the TPMS warning lamp.
As the ambient temperature decreases by 6C (10F), tire pressure decreases 7 kPa (1 psi). Adjust the tire
pressure by 7 kPa (1 psi) for each 6C (10F) ambient temperature drop as necessary to keep the tire at the
specified Vehicle Certification (VC) label pressure. Refer to the following tables to adjust the tire pressure
indoors for colder outside temperatures.
Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages
The TPMS indicator and vehicle message center (if equipped) sometimes displays faults that cannot be
resolved by the customer. Treat these messages as TPMS faults that must be serviced.
>
Tire Pressure Monitoring System (TPMS) Indicator Illuminates Continuously
NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the vehicle to
restore complete TPMS functionality before carrying out any diagnosis.
NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain F-Series), the
tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will result in a false
low tire pressure event, which will cause the TPMS indicator to illuminate.
The TPMS indicator remains on continuously for the following condition:
Low Tire Pressure - The TPMS indicator is illuminated solid and the message center displays
LOW TIRE PRESSURE (if equipped). This is displayed when any of the tire pressures are

1.
low. When this condition exists, the tire pressure must be adjusted to the recommended cold
pressure as indicated on the VC label.
NOTE: The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been
stationary for more than 30 minutes, it will be necessary to wake up the sensors so they will transmit
the latest tire pressure information to the SJB .
If the vehicle has been stationary for more than 30 minutes, carry out the Tire Pressure Monitoring
System (TPMS) Sensor Activation procedure in this section.
2.
Tire Pressure Monitoring System (TPMS) Indicator Flashes
The TPMS indicator flashes for 70 seconds, then remains ON solid when the ignition swch is turned to the
ON position, for the following conditions:
Tire Pressure Sensor Fault - If equipped, the message center will display TIRE PRESSURE SENSOR
FAULT when a tire pressure sensor is malfunctioning. GO to Symptom Chart .
1.
No communication with the SJB ( TPMS is integral to the SJB ) - The TPMS indicator is illuminated
when the IC has not received any signals from the SJB for more than 5 seconds. If equipped, the
message center displays TIRE PRESSURE MONITOR FAULT. GO to Som Chart .
2.
Tire Pressure Monitor Fault - If equipped, the message center will display TIRE PRESSURE
MONITOR FAULT when the TPMS is malfunctioning or communication with the IC has been lost.
GO to Symptom Chart .
3.
Tire Pressure Monitoring System (TPMS) PID Definitions and Intermittent Troubleshooting
TPMS Status PID
The SJB monitors the TPMS status. The current status can be viewed by accessing the TPMS status PID:
TP_STAT using the scan tool. This helps identify the current system status and may aid in diagnosing the
system. The PID has 4 valid states:
TP_STAT = SENSOR FAULT.
If the module has not received the tire pressure status from 1 3 TPMS sensors for 20 minutes
when the vehicle speed is above 32 km/h (20 mph), the PID displays SENSOR FAULT.

1.
TP_STAT = SYSTEM FAULT.
If the module has not received the tire pressure status from all 4 TPMS sensors for 20 minutes
and the vehicle speed is above 32 km/h (20 mph), the PID displays SYSTEM FAULT.

2.
TP_STAT = LOW.
If the module has detected that at least 1 TPMS sensor is reporting low tire pressure, the PID
displays LOW.

3.
TP_STAT = SYSTEM ACTIVE.
If the TPMS is functioning normally, the PID displays SYSTEM ACTIVE.
4.
TPMS Last Warning Event PID Definitions
The TPMS uses the TPMS last warning event PIDs to store detailed information about the last 5 times the
TPMS warning indicator was activated. These PIDs can be used to acquire more information about a
particular TPMS event.
EVT1_IGN through EVT5_IGN
The number of key cycles since the TPMS warning indicator was activated. This PID cycles from zero to 255
and then starts over from zero again. This can be used to determine how long ago a TPMS event occurred and
the time (in key cycles) between events.
EVT1_TLOC through EVT5_TLOC
This is the last programmed location for the sensor identifier causing each TPMS event. Due to tire rotation,
the sensor may no longer be at the original location. It is suggested that all the PIDs be recorded, the system
retrained, and then the sensor identifier PIDs be used to pinpoint the actual location of each sensor.
EVT1_PSI through EVT5_PSI
This is the tire pressure associated with each TPMS warning indicator event. This can be used along with the
function code to clearly identify the TPMS events that were strictly due to low pressure. It can also be used to
determine when a sensor is transmitting inaccurate tire pressure.
EVT1_STAT through EVT5_STAT
Describes the warning status of each TPMS event by using the information received from the TPMS status
(TP_STAT) PID. If there is a communication issue, the status could be Normal.
Unknown
Normal (normal operation)
Low (low pressure event)
Fault (sensor fault or system fault)
EVT1_TxID through EVT5_TxID
This is the identifier of the sensor involved in each TPMS event. EVT1 is the most recent event that triggered
the TPMS warning indicator.
Wheel Rotation and Sensor Training Techniques
Moving a Problem Sensor/Wheel to a Different Position
If a sensor in a certain location has caused several events, yet the sensor trains and seems to operate normally,
moving that particular wheel to a different location on the vehicle is a good way to isolate the issue to a
certain sensor/wheel location. Rotate the wheels and road test the vehicle. This can be done in an attempt to
replicate the issue. This determines if the issue followed the sensor or remained in the original sensor location.
Training Sensors in a Different Order
This is a technique to get past a left front sensor that may not be responding to determine if the remaining
sensors train to the module. This can help save time determining if other sensors are having issues or if the
module is experiencing training difficulties with a certain location.
Training Known Good Sensors From Another Vehicle
Training known good sensors from another vehicle cannot differentiate between a faulted module and Radio
Frequency Interference (RFI), as some noise source could be preventing the module from receiving the tire
pressure status from the original sensors as well as the known good sensors. This technique that can be used to
EVT1_IGN through EVT5_IGN 2939
differentiate between a sensor and module issue. If the module in the vehicle cannot train any of its own
sensors, and likewise cannot train known good sensors from another vehicle, then the issue is with the module
or the RFI , and not with the original sensors. The original sensors should not be replaced.
Items That Cause RFI
Non-OEM Equipment
The following equipment has been found to sometimes cause RFI :
Video equipment has been found to cause RFI especially when the video and power supply lines are
near the TPMS .

Car alarms (even those installed by dealerships) have been found to create enough RFI to cause the
TPMS to malfunction or lose considerable range. These car alarms can sometimes be difficult to
locate, as they are usually hidden somewhere out of the way for reduced accessibility.

Many different in-vehicle cell phone chargers have been found to cause considerable RFI . The
vehicles with the power point closest to the TPM are the most affected. It must be noted that most cell
phone chargers do not produce high levels of RFI all the time. This depends on the state of charge of
the cell phone battery. The phone must be almost completely discharged in some cases.

Power supplies and DC/AC inverters typically create a lot of RFI . Most consumer grade equipment
has very little filtering or shielding.

OEM Modules
In some cases, the RFI may actually be caused by a module or ground on the vehicle. Depending on the
severity of the issue, a dirty ground, improperly built ground shield or module can disable the system.
Modules that have microcontrollers using clock circuits to create the timing pulses for the microprocessor
may radiate RFI .
Using Customer's Electronics to Pinpoint the Radio Frequency Interference (RFI) Source
This can be a way to determine the cause of an issue well before the sensors and module are replaced with
little or no affect on the system performance. Since this takes more up-front work, it relies on working with
the customer to determine what equipment was being used at the time of the event.
Options for Eliminating Intermittent TPMS Conditions Caused by RFI
If an OEM component or customer device is causing an RFI issue, replace the device.
If a phone charger is causing an RFI issue, the customer should consult their cell phone provider to
acquire a different phone charger.

If a device such as a dealer-installed alarm is causing an RFI issue, move the device to another
location on the vehicle. In the case of a portable device, move the power cord to another power point
location.

In summary, if the RFI source is present and cannot be moved or replaced, the intermittent issue remains. The
vehicle owner must accept RFI and the unwanted system operation it can cause.
NOTE: The tire pressure sensors are not designed to be used with aftermarket wheels.
NOTE: The use of run-flat tires (tires with steel body cord plies in the tire sidewall) where not
originally equipped, may cause the TPMS to malfunction and is therefore not recommended.
1.
Training Known Good Sensors From Another Vehicle 2940
Verify the customer concern by inspecting the vehicle and observing the message center (if equipped)
and the TPMS indicator.
NOTE: The valve-mounted TPMS sensors and the strap-mounted TPMS sensors are not compatible.
Swapping wheels from one vehicle to another with the different systems will adversely affect TPMS
operation.
NOTE: Swapping wheels between vehicles with the same TPMS will cause a TPMS fault to be set if
the sensors are not trained. Refer to Tire Pressure Monitoring System (TPMS) Sensor Training in this
section.
NOTE: Non-OEM modifications made to the vehicle may result in false TPMS warnings.
Inspect to determine if one of the following mechanical or electrical concerns apply:
2.
Low tire pressure
Tire Pressure Monitoring System (TPMS) sensor damaged or missing
Spare tire installed as a road wheel
Incorrect TPMS sensor installed
TPMS sensor installed incorrectly
Sensors not trained after a tire rotation on vehicles with different front
and rear tire pressures

Non-OEM wheels installed (aftermarket rims)
Non-OEM equipped run-flat tires installed
Other non-OEM modifications (roll cages, service barriers, part racks,
ladder racks)

connectors

Smart Junction Box
(SJB)

Aftermarket
electronic accessories

3.
4.
5.
6.
Using Customer's Electronics to Pinpoint the Radio Frequency Interference (RFI) Source 2941
418-00 .

(CMDTCs).

7.
Clear the CMDTCs and carry out the self-test diagnostics for the SJB (the TPMS is part of the SJB ). 8.
If the DTCs retrieved are related to the concern, go to the Tire Pressure Monitoring System (TPMS)
DTC Chart. For all other DTCs, refer to the Master DTC Chart in Section 419-10 .
9.
DTC Charts
Tire Pressure Monitoring System (TPMS) DTC Chart
DTC Description Source Action
B106B Tire Pressure Sensor
Low Battery
Smart
Junction
Box (SJB)
DTC B106B can be set during SJB configuration. GO to
Pinpoint Test G .
B106D Tire Pressure
Monitoring System
(TPMS) Initiators Not
Configured
SJB DTC B106D is only present when a new SJB is installed, the
SJB is incorrectly flashed or the SJB is incorrectly
configured. Successfully configuring the SJB is the only way
to clear this DTC. VERIFY the SJB is correctly configured. If
DTC B106D is still present, REFER to Section 418-01 .
B2477 Module Configuration
Failure/Mismatch
SJB DTC B2477 is only present when a new SJB is installed, the
SJB is incorrectly flashed or the SJB is incorrectly
configured. Successfully configuring the SJB is the only way
to clear this DTC. MAKE SURE the SJB is configured
correctly. If DTC B2477 is still present, REFER to Section
418-01 .
B2868 LF Tire Pressure Sensor
Fault
SJB is flashed or the SJB is reconfigured. TRAIN the tire
pressure sensors. REFER to Tire Pressure Monitoring System
(TPMS) Sensor Training in this section.
B2869 RF Tire Pressure Sensor
Fault
B2870 RR Tire Pressure Sensor
Fault
B2871 LR Tire Pressure Sensor
Fault
B2872 SJB
Tire Pressure Sensor
Fault
NOTE: If the vehicle has been stationary for more than 30
minutes, the sensors will go into a "sleep mode" to conserve
battery power. It will be necessary to wake them up so they
will transmit the latest tire pressure information to the SJB .
ACTIVATE the TPMS sensors. REFER to Tire Pressure
Monitoring System (TPMS) Sensor Activation in this section.
B287A Tire Pressure System
Fault
SJB GO to Pinpoint Test F .
C2780 ECU in Manufacturing
Mode
SJB DTC C2780 is only present when a new SJB is installed, the
U0155 Lost Communication
with Instrument Cluster
(IC)
SJB REFER to Section 418-00 to diagnose the no communication
problem.
All other
SJB
DTCs
- SJB REFER to the Master DTC Chart in Section 419-10 .
Symptom Chart
Symptom Chart
NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain F-Series), the
tire pressures must be adjusted and the tire pressure sensors must be trained following a tire rotation. Failure
to train the sensors will result in a false low tire pressure event, which will cause the Tire Pressure Monitoring
System (TPMS) indicator to illuminate.
For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system.
Failure of a TPMS component may not cause the message center to display a fault message or a DTC to be
stored. The Symptom Chart is a starting point to begin diagnosis of these concerns.
Tire Pressure Monitoring System (TPMS) indicator ON solid and message center (if equipped)
displays LOW TIRE PRESSURE

Spare tire currently in use
INSTALL the repaired road wheel/tire in place of the spare tire.
Air pressure not set to specifications listed on the Vehicle Certification (VC) label
Sensors not trained following tire rotation
ADVISE customer that on vehicles with different front and rear tire pressure, the sensors must be
trained as directed in the Owner's Literature.

Smart Junction Box (SJB) will not enter sensor training mode when using the TPMS sensor training
procedure

Brake ON/OFF switch
Ignition switch
Vehicle communication bus
SJB
TPMS indicator FLASHES for 70 seconds and then remains ON solid when the ignition key is turned
to the ON position, the message center (if equipped) displays TIRE PRESSURE SENSOR FAULT
and DTC B2872 is present

Intermittent TPMS operation due to Radio Frequency Interference (RFI)
TPMS sensors not trained
Not all TPMS sensors are installed
TPMS sensor(s)
SJB
NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep
mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest
tire pressure information to the SJB .

ACTIVATE the TPMS sensors. REFER to Tire Pressure Monitoring System (TPMS) Sensor
Activation in this section. GO to Pinpoint Test F .
to the ON position, the message center (if equipped) displays TIRE PRESSURE MONITOR FAULT
and DTC B287A is present

TPMS sensors not trained
NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep
mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest
tire pressure information to the SJB .

ACTIVATE the TPMS sensors. REFER to Tire Pressure Monitoring System (TPMS) Sensor
Activation in this section. GO to Pinpoint Test F .
to the ON position, the message center (if equipped) displays TIRE PRESSURE MONITOR FAULT
and there are no DTCs present

Vehicle communication issue between the SJB and the Instrument Cluster (IC)
REFER to Section 418-00 to diagnose the no communication concern.
SJB
REFER to Section 419-10 to diagnose the SJB .
One or more sensors will not train
TPMS sensor(s)
Vehicle communication issue
SJB
RETRIEVE and RECORD DTCs. REFER to Tire Pressure Monitoring System (TPMS) DTC Chart in
this section.

One or more sensors will not train and no DTCs are present
TPMS sensor(s)
Attempting to install a banded TPMS sensor that is not compatible with a valve mounted sensor
TRAIN all 4 tire pressure sensors. REFER to Tire Pressure Monitoring System (TPMS) Sensor
Training in this section.

If a sensor does not respond to the Tire Pressure Monitor Activation Tool, MOVE the vehicle to rotate
the wheels at least one-fourth of a turn and ATTEMPT to activate the same sensor again. If the sensor
still does not respond, ATTEMPT to activate the same sensor again using the customer activation tool
(if available). If the sensor still fails to train, ATTEMPT to train the sensor with the vehicle doors
open.

If the sensor(s) fails to train a second time, INSTALL a new sensor(s). REFER to Tire Pressure
Monitoring System (TPMS) Sensor in this section.

Pinpoint Tests
Pinpoint Test D: Tire Pressure Monitoring System (TPMS) Indicator ON Solid and Message Center (if
equipped) Displays LOW TIRE PRESSURE
Normal Operation
The Tire Pressure Monitoring System (TPMS) monitors the air pressure of all 4 road tires. The
wheel-mounted tire pressure sensors transmit via radio frequency signals, to the Smart Junction Box (SJB).
TPMS functionality is integral to the SJB . These transmissions are sent approximately every 60 seconds
when the vehicle speed exceeds 32 km/h (20 mph). The TPMS function (integral to the SJB ) compares each
tire pressure sensor transmission against a low-pressure limit. If it has been determined that the tire pressure
has fallen below this limit, the SJB communicates this on the vehicle communication bus to the Instrument
Cluster (IC). The IC then illuminates the TPMS indicator and displays the appropriate message(s) in the
message center (if equipped).
This symptom can also be caused by a spare tire currently being used in place of a road tire. Make sure that
the spare tire is not currently in use. On vehicles with different front and rear tire pressures, if the sensors are
not trained following a tire rotation, this symptom will also be present. Advise the customer that on vehicles
with different front and rear tire pressures, the sensors must be trained as directed in the Owner's Literature.
Low air pressure in tire(s)
Tire pressure sensor(s)
PINPOINT TEST D: TIRE PRESSURE MONITORING SYSTEM (TPMS) INDICATOR ON SOLID AND MESSAGE
CENTER (IF EQUIPPED) DISPLAYS LOW TIRE PRESSURE
NOTE: Use only the Digital Tire Gauge any time tire pressures are measured to be sure that accurate values
are obtained.
NOTE: If a warranty case is opened for an actual TPMS fault, document and include the actual tire pressure
data in all warranty communications.
D1 CHECK THE TIRE PRESSURE
Using the Digital Tire Gauge,
measure and record the air
pressure in all 4 road tires.

Adjust the air pressure for those
found to be below the specification
listed on the Vehicle Certification
(VC) label.

NOTE: If the vehicle has been
stationary for more than 30
minutes, activate each TPMS
sensor. Refer to Tire Pressure
Monitoring System (TPMS)
Sensor Activation in this section.
The TPMS sensor does not
transmit when the vehicle is
stationary.

Verify system operation.
Have the TPMS indicator and
the message center (if equipped)
warnings gone out?

Yes
The system is functioning normally, diagnosis is complete.
INFORM the customer of correct tire pressure maintenance
as instructed in the scheduled maintenance guide and the
Owner's Literature.
No
GO to D2 .
D2 CHECK THE SYSTEM
COMPONENTS
Train all 4 tire pressure sensors.
Refer to Tire Pressure Monitoring
System (TPMS) Sensor Training in
this section.

Connect the scan tool.
Ignition ON.
mode on the scan tool: DataLogger
- SJB .

Read and record the following
PIDs:

Left Front Tire Pressure
(LF_PRES)

Right Front Tire Pressure
(RF_PRES)

Left Rear Outer Tire
Pressure (LRO_PRES)

Right Rear Outer Tire
Pressure (RRO_PRES)

Yes
The system is functioning normally, diagnosis complete.
No
Before installing a new sensor(s): If a sensor does not
respond to the Tire Pressure Monitor Activation Tool,
MOVE the vehicle to rotate the wheels at least one-fourth of
a turn and ATTEMPT to activate the same sensor again. If
the sensor still does not respond, ATTEMPT to activate the
same sensor again using the customer activation tool (if
available). If the sensor still fails to train, ATTEMPT to train
the sensor with the vehicle doors open.
INSTALL new tire pressure sensors for those with
discrepancies or those that fail to activate. REFER to Tire
Pressure Monitoring System (TPMS) Sensor in this section.
PINPOINT TEST D: TIRE PRESSURE MONITORING SYSTEM (TPMS) INDICATOR ON SOLID AND MESSAGE CENTER (IF EQUIPPED) DISPLAYS LOW TIRE PRESSURE 2946
Compare the air pressure readings
recorded from the function test to
those recorded in D1.

Do the compared tire pressure
values match within 5 psi, and
have the TPMS indicator and
the message center (if equipped)
warnings gone out?

Pinpoint Test E: Smart Junction Box (SJB) Will Not Enter Sensor Training Mode When Using the Tire
Pressure Monitoring System (TPMS) Sensor Training Procedure
Normal Operation
For the Smart Junction Box (SJB) to enter Tire Pressure Monitoring System (TPMS) sensor training mode,
the SJB must receive valid inputs from the brake ON/OFF switch (OFF-ON-OFF) and ignition switch (both
OFF and RUN), and it must receive valid vehicle speed sensor input (0 km/h [0 mph]) from the Instrument
Cluster (IC). Refer to Tire Pressure Monitoring System (TPMS) Sensor Training in this section for the
complete sensor training procedure.
Brake ON/OFF switch
Ignition switch
SJB
PINPOINT TEST E: SMART JUNCTION BOX (SJB) WILL NOT ENTER SENSOR TRAINING MODE WHEN USING
THE TIRE PRESSURE MONITORING SYSTEM (TPMS) SENSOR TRAINING PROCEDURE
E1 CHECK THE SJB BRAKE ON/OFF
(GEM_BOO) PID
Ignition ON.
the scan tool: DataLogger - SJB .

Monitor the GEM_BOO PID ( SJB
reads the brake switch directly).

Press and release the brake pedal while
monitoring the PID.

Do the brake pedal PID values match
the brake pedal positions?

Yes
GO to E2 .
No
stoplamp switch.
E2 CHECK THE SJB IGNITION SWITCH
PIDs
Monitor the following ignition switch
PIDs:

Ignition Switch Off
(IGN_O_ECU)

Yes
GO to E3 .
No
ignition switch.
Ignition Switch RUN
(IGN_R_ECU)

Cycle the ignition switch to the RUN
and OFF position while monitoring the
PIDs ( SJB reads the ignition switch
directly).

Do the ignition switch status PID
values match the ignition switch
positions?

E3 CHECK THE SJB VEHICLE SPEED
SENSOR (VSS_GEM) PID
Monitor the VSS_GEM PID ( SJB
receives vehicle speed from the IC ).

Is the vehicle speed less than 5 km/h
(3 mph)?

Yes
GO to E4 .
No
IC /vehicle speed concern.
E4 CHECK FOR CORRECT SJB
OPERATION
Check the connectors for:
corrosion.
pushed-out pins.
spread terminals.
make sure that they are seated correctly.


Yes
No
connector. CLEAR the DTCs. REPEAT the self-test.
Pinpoint Test F: TPMS Indicator FLASHES for 70 Seconds and Then Remains ON Solid When the
Ignition Key is Turned to the ON Position, the Message Center (if equipped) Displays TIRE
PRESSURE SENSOR or MONITOR FAULT and DTC B2872 or B287A is Present
Normal Operation
If there is a fault with 1, 2 or 3 of the Tire Pressure Monitoring System (TPMS) sensors, DTC B2872 sets.
The TPMS warning indicator flashes for 70 seconds and then remains ON continuously when the ignition
switch is turned to the ON position and the message center (if equipped) displays TIRE PRESSURE SENSOR
FAULT.
If the Smart Junction Box (SJB) does not get a response from all 4 of the TPMS sensors, DTC B287A sets
and the message center (if equipped) displays TIRE PRESSURE MONITOR FAULT.
It should be noted that TPMS communication can be interrupted by Radio Frequency Interference (RFI),
which can cause intermittent issues. RFI is generated by electrical motors and appliance operation, cellular
telephones, remote transmitters, power inverters and portable entertainment equipment. Anytime the TPMS
sensor training procedure is performed successfully, the warning indicator is extinguished and the vehicle
must be driven for 18-20 minutes before the SJB initiates a self test to verify system operation.
DTC B2872 (Tire Pressure Sensor Fault) - set by the SJB when 1, 2 or 3 of the tire pressure sensors
PINPOINT TEST E: SMART JUNCTION BOX (SJB) WILL NOT ENTER SENSOR TRAINING MODE WHEN USINGTHE TIRE PRESSURE MONITORING SYSTEM (TPMS) SENSOR TRAINING PROCEDURE 2948
are faulted, not responding or when data is not received by the SJB .
DTC B287A (Tire Pressure Monitor Fault) - When all 4 of the tire pressure sensors are faulted, not
responding or when data is not received by the SJB .

TP_STAT PID = SYSTEM FAULT is displayed if the SJB does not receive a signal transmission
from all 4 TPMS sensors for 20 minutes and the vehicle speed is above 32 km/h (20 mph).

TP_STAT PID = SENSOR FAULT is displayed if the SJB does not receive a signal transmission
from 1, 2, or 3 TPMS sensors for 20 minutes and the vehicle speed is above 32 km/h (20 mph).

Intermittent TPMS operation due to RFI
TPMS sensor(s) not trained
TPMS sensor(s)
SJB
PINPOINT TEST F: TPMS INDICATOR FLASHES FOR 70 SECONDS AND THEN REMAINS ON SOLID WHEN THE
IGNITION KEY IS TURNED TO THE ON POSITION, THE MESSAGE CENTER (IF EQUIPPED) DISPLAYS TIRE
PRESSURE SENSOR OR MONITOR FAULT AND DTC B2872 OR B287A IS PRESENT
F1 CHECK THE HORN OPERATION
Press the steering wheel horn pad for
2 seconds.

Does the horn sound?
Yes
GO to F2 .
No
For horn diagnosis, REFER to Section 413-06 .
F2 CHECK THE TPMS STATUS
(TP_STAT) PID
NOTE: Make sure that all
aftermarket electronic equipment has
been disconnected (if possible) and
that the customer has been
questioned about the kinds of
electronic equipment they may have
been using in the vehicle when this
issue was identified.
NOTE: A spare tire cannot be
programmed to the vehicle, even if
equipped with a TPMS sensor. If a
damaged road wheel is located in the
trunk and the SJB cannot
communicate with it, or if the
damaged wheel has been dropped off
at a dealership or repair shop, the
SJB sets a TPMS sensor fault.

Ignition ON.
on the scan tool: DataLogger - SJB .

Monitor the TP_STAT PID.
Yes
GO to F3 .
No
If the TP_STAT PID displays SYSTEM FAULT, GO to
F5 .
Does the PID display SENSOR
FAULT?

F3 CARRY OUT THE SENSOR
TRAINING PROCEDURE
this section.

Did all of the tire pressure sensors
transmit correctly and did the
horn sound when each TPMS
sensor transmitted to the SJB ?

Yes
may have been caused by RFI . CLEAR the DTCs.
REPEAT the self-test. TEST for normal operation.
REFER to PID Definitions and Intermittent
Troubleshooting in this section for information on locating
sources of RFI .
No
GO to F4 .
F4 CHECK FOR CORRECT TPMS
OPERATION
Move the vehicle to rotate the
wheels at least one-fourth of a turn.
Leave the vehicle doors open. Start
the sensor training procedure at a
different wheel.

this section.

Did any of the tire pressure
sensors transmit correctly and did
the horn sound when each TPMS
sensor transmitted to the SJB ?

Yes
If some of the TPMS sensors trained, INSTALL a new
TPMS sensor for the TPMS sensor(s) that failed to train.
REFER to Wheel and Tire in this section. If all of the
TPMS sensors trained, the concern may have been cause
by RFI . CLEAR the DTCs. REPEAT the self-test. TEST
for normal operation. REFER to PID Definitions and
Intermittent Troubleshooting in this section for
information on locating sources of RFI .
No
GO to F5 .
F5 CHECK FOR CORRECT SJB
OPERATION
Disconnect all the SJB electrical
connectors.

Check the connectors for:
corrosion
pushed-out pins
bent pins
spread terminals
make sure that they are seated
correctly.


Yes
NOTE: The sensors may not be present. DISMOUNT the
tire. REFER to Wheel and Tire in this section. VERIFY
the sensors are present and mounted to the wheels. If
missing, INSTALL new sensors.
If the sensors are present, INSTALL a new SJB . REFER
to Section 419-10 . CLEAR the DTCs. REPEAT the
self-test.
No
Pinpoint Test G: DTC B106B
PINPOINT TEST F: TPMS INDICATOR FLASHES FOR 70 SECONDS AND THEN REMAINS ON SOLID WHEN THEIGNITION KEY IS TURNED TO THE ON POSITION, THE MESSAGE CENTER (IF EQUIPPED) DISPLAYS TIREPRESSURE SENSOR OR MONITOR FAULT AND DTC B2872 OR B287A IS PRESENT 2950
Normal Operation
If there is a fault in the Tire Pressure Monitoring System (TPMS), such as a damaged or missing sensor(s),
damaged module or a communication issue within the vehicle, DTCs are set in the Smart Junction Box (SJB),
the TPMS warning indicator will flash for 70 seconds and then remain ON solid when the ignition switch is
turned to the ON position and the message center (if equipped) will display TIRE PRESSURE SENSOR
FAULT.
The tire pressure sensor is battery powered.
This DTC may be set when attempting to train a tire pressure sensor(s) with a low battery.
Tire pressure sensor battery
Tire pressure sensor(s)
PINPOINT TEST G: DTC B106B
G1 DETERMINE WHICH
SENSOR HAS A LOW
BATTERY
Train all 4 tire pressure
sensors. Refer to Tire
Pressure Monitoring
System (TPMS) Sensor
Training in this section.

Did all of the tire
pressure sensors
transmit correctly and
did the horn sound
when each tire
pressure sensor
transmitted to the SJB
?

Yes
CLEAR the DTCs. REPEAT the self-test. VERIFY system operation.
No
Before installing a new sensor(s) : If a sensor does not respond to the
Tire Pressure Monitor Activation Tool, MOVE the vehicle to rotate the
wheels at least one-fourth of a turn and ATTEMPT to activate the
same sensor again. If the sensor still does not respond, ATTEMPT to
activate the same sensor again using the customer activation tool (if
available). If the sensor still fails to train, ATTEMPT to train the
sensor with the vehicle doors open.
If the sensor(s) fails to train a second time, INSTALL a new tire
pressure sensor(s). REFER to Tire Pressure Monitoring System
(TPMS) Sensor in this section.
PINPOINT TEST G: DTC B106B 2952
SECTION 204-04: Wheels and
Tires
Manual
Tire Pressure Monitoring System (TPMS) Sensor Training
Special Tool(s)
204-363
NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to
conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure
information to the BCM . For additional information, refer to Tire Pressure Monitoring System (TPMS)
Sensor Activation in this section.
NOTE: The Tire Pressure Monitoring System (TPMS) Training procedure must be done on a single vehicle,
in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire
Pressure Monitoring System (TPMS).
Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote
transmitters, power inverters and portable entertainment equipment.
NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, move the vehicle to rotate
the wheels at least one-fourth of a turn and attempt to activate the same sensor again. If the sensor still does
not respond, attempt to activate the same sensor again using the customer activation tool (if available). If the
sensor still fails to train, attempt to train the sensor with the vehicle doors open.
NOTE: The BCM has a 2-minute time limit between sensor responses. If the BCM does not recognize any 1
of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if
equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated.
NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the
tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS
indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will not
affect the system.
NOTE: An animated version of this procedure is available on-line.
Turn the ignition switch to the OFF position, then press and release the brake pedal.
1.
Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
2.
Press and release the brake pedal. 3.
Turn the ignition switch to the OFF position. 4.
Tire Pressure Monitoring System (TPMS) Sensor Training 2953
Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
The horn will sound once and the TPMS indicator will flash if the training mode has been
entered successfully. If equipped, the message center will display TRAIN LF TIRE.

5.
NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire
Pressure Monitor Activation Tool must remain in place at the valve stem.
Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall at the valve stem. Press and
release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to
indicate that the tire pressure sensor has been recognized by the BCM .
6.
Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF
tire sidewall at the valve stem and press and release the test button to train the RF tire pressure sensor.
7.
NOTE: Do not wait more than 2 minutes between training each sensor or the BCM will time out and
the entire procedure must be repeated.
Repeat Step 7 for the RR and LR tires.
The procedure is completed after the last tire has been trained. When the training procedure is
complete, the message center (if equipped) will display TIRE TRAINING COMPLETE.
For vehicles not equipped with a message center, successful completion of the training procedure will
be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn
sounds twice when the switch is turned to the OFF position, the training procedure was not successful.
8.
Using the scan tool, locate the updated TPMS sensor identifiers trained to the BCM and document
them on the applicable warranty claim.
9.
NOTE: This step is required to clear DTC C2780, cause the BCM to exit the manufacturing mode
and to make sure there are no other concerns with a newly programmed BCM .
If the sensors are being trained due to the installation of a new BCM , clear any DTCs and carry out
the BCM On-Demand Self Test.
10.
Tires
Manual
Tire Pressure Monitoring System (TPMS) Sensor Activation
Special Tool(s)
204-363, or Customer Activation Tool, Tire
Pressure Monitor
NOTE: The tire pressure sensors will go into a "sleep mode" when a vehicle is stationary to conserve battery
power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so
they will transmit the latest tire pressure information.
Turn the ignition switch to the ON position. 1.
Position the Tire Pressure Monitor Activation Tool against the LF tire sidewall at the tire valve stem. 2.
NOTE: The Tire Pressure Monitor Activation Tool will provide feedback in the form of a flashing
green light and a beep sound for each successful response from a tire pressure sensor. This feedback
may not always be present, do not rely on it as a confirmation that the module heard a particular
sensor.
NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, move the vehicle
to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. If the
sensor still does not respond, attempt to activate the same sensor again using the customer activation
tool (if available). If the sensor still fails to train, attempt to train the sensor with the vehicle doors
open.
Press the test button on the Tire Pressure Monitor Activation Tool to activate the sensor. Activate the
sensor at least 2 times.
3.
Repeat Steps 2 and 3 for the remaining tires. 4.
If the Tire Pressure Monitoring System (TPMS) indicator remains illuminated after adjusting and
activating each sensor, refer to the Symptom Chart in Diagnosis and Testing in this section.
5.
Tire Pressure Monitoring System (TPMS) Sensor Activation 2956
Tire Pressure Monitoring System (TPMS) Sensor Activation 2957
Manual
Wheel and Tire
Material
Item Specification
Lubricant
XL-2
-
NOTE: Typical 5 lug wheel shown.
1 1012 Wheel nut (5 required)
2 - Wheel and tire assembly
Removal
100-02 .
1.
NOTICE: Do not use heat to loosen a seized wheel nut or damage to the wheel and wheel
bearing can occur.
NOTICE: If equipped with full wheel cover with exposed wheel nuts, the wheel nuts must be
removed prior to removing the wheel cover or damage to the wheel cover will occur.
Remove the 5 wheel nuts.
2.
Remove the wheel and tire assembly. 3.
Installation
Wheel and Tire 2958
WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign
material present on the mounting surface of the wheel and the mounting surface of the wheel
hub, brake drum or brake disc. Make sure that any fasteners that attach the rotor to the hub
are secured so they do not interfere with the mounting surfaces of the wheel. Failure to follow
these instructions when installing wheels may result in the wheel nuts loosening and the wheel
coming off while the vehicle is in motion, which could result in loss of control, leading to serious
injury or death to vehicle occupant(s).
NOTICE: Make sure to apply a thin coat of anti-seize lubrication only to the interface between
the wheel pilot bore and the hub pilot. Do not allow the anti-seize to make contact with the
wheel-to-brake disc/drum mounting surface, wheel studs, wheel nuts, brake pads or brake disc
friction surfaces or damage to components may occur.
Clean the wheel mounting surfaces and apply a thin coat of anti-seize to the wheel hub pilot surface
(wheel only).
1.
Install the wheel and tire assembly. 2.
WARNING: Retighten wheel nuts within 160 km (100 mi) after a wheel is reinstalled.
Wheels can loosen after initial tightening. Failure to follow this instruction may result in serious
injury to vehicle occupant(s).
NOTICE: Failure to tighten the wheel nuts in a star/cross pattern can result in high brake disc
runout, which will speed up the development of brake roughness, shudder and vibration.
NOTE: The wheel nut torque specification is for clean, dry wheel stud and wheel nut threads.
Install the 5 wheel nuts by hand.
Tighten the wheel nuts in a star/cross pattern to 135 Nm (100 lb-ft).
3.
Wheel and Tire 2959
Tires
Manual
DISASSEMBLY AND
ASSEMBLY
Wheel and Tire
Special Tool(s)
Digital Tire Pressure Gauge
204-354
Item
Part
Number Description
1 1508 Tire
2 1007 Wheel
3 1700 Valve stem and screw (also part of 1A189)
4 1A189 Tire Pressure Monitoring System (TPMS) sensor (a new
sensor assembly includes W714266 screw and 1700 valve
stem and cap)
5 - Valve stem-to- TPMS sensor screw (part of 1700)
6 1A163 Valve stem cap (also part of 1A189)
Disassembly
NOTICE: Failure to follow the instructions below may result in damage to the Tire Pressure
Monitoring System (TPMS) sensor.
NOTICE: The Tire Pressure Monitoring System (TPMS) sensor is mounted to the valve stem. Removal
of the valve stem requires dismounting the tire from the wheel and removal of the TPMS sensor.
Wheel and Tire 2960
NOTE: Use only the Digital Tire Pressure Gauge any time tire pressures are measured to be sure that accurate
Remove the wheel and tire. For additional information, refer to Wheel and Tire in this section. 1.
NOTICE: The valve stem is connected to the Tire Pressure Monitoring System (TPMS) sensor.
Do not pull the valve stem from the wheel, or damage to the sensor will occur.
Remove the valve stem core and fully deflate all air from the tire.
If a new Tire Pressure Monitoring System (TPMS) sensor is being installed, remove and
discard the valve stem-to-sensor screw and the sensor.

2.
NOTICE: Do not allow the tire beads to move beyond the wheel mid-plane (middle of the wheel) when
separating the beads from the wheels, damage to the Tire Pressure Monitoring System (TPMS) sensor
may occur.
NOTICE: Tire and valve stem position is critical to prevent damage to the Tire Pressure
Monitoring System (TPMS) sensor when using a paddle-type bead separator.
NOTE: Some machines may have a nylon roller bead separator at the 12 o'clock position instead of
the paddle-type bead separator at the 3 o'clock position.
Position the wheel and tire assembly on a suitable tire machine and separate both beads of the tire
from the wheel.
For a paddle-type tire machine, position the valve stem at the 12 o'clock or 6 o'clock position
and the paddle at the 3 o'clock position.

For a roller-type tire machine, align the valve stem with the roller at any position.
3.
NOTE: Index-mark the valve stem and wheel weight positions on the tire.
Place the wheel and tire assembly on the turntable of the tire machine with the valve stem at the 11:30
position and the machine arm at the 12 o'clock position and dismount the outer bead from the wheel.
4.
Wheel and Tire 2961
Reset the wheel and tire assembly on the turntable of the tire machine with the valve stem at the 11:30
position and the machine arm at the 12 o'clock position and dismount the inner bead from the wheel.
5.
NOTE: A new valve stem must be installed whenever a new tire or wheel is installed.
Remove the TPMS sensor in the following sequence.
Using a T10 Torx, remove the valve stem-to- TPMS sensor screw. 1.
Carefully and firmly, pull the sensor straight down and separate it from the valve stem. 2.
6.
NOTICE: Use care not to damage the wheel surface when removing the valve stem.
Using a suitable valve stem puller and a wood block, remove the valve stem from the wheel.
7.
NOTE: When installing a new wheel, always install a new valve stem and sensor screw. Reuse the
TPMS sensor from the previous wheel if possible. The TPMS will not have to be trained if the sensor
is reused.
If the TPMS sensor is being reused, inspect the TPMS sensor for damage and install a new sensor as
necessary.
8.
Assembly
NOTICE: Damage to the Tire Pressure Monitoring System (TPMS) sensor may result if the tire
mounting is not carried out as instructed.
Wheel and Tire 2962
NOTICE: To prevent Tire Pressure Monitoring System (TPMS) sensor and valve stem damage,
the valve stem must be installed onto the TPMS sensor and then installed into the wheel as an
assembly.
Install a new valve stem onto the TPMS sensor.
Tighten the new valve stem-to- TPMS sensor screw to 1.5 Nm (13 lb-in).
1.
NOTICE: It is important to pull the valve stem and Tire Pressure Monitoring System (TPMS)
sensor assembly through the wheel rim hole in a direction parallel to the valve stem hole axis. If
the assembly is pulled through at an angle, damage to the valve stem and sensor assembly may
occur.
NOTICE: Use care not to damage the wheel surface when installing the valve stem and Tire
Pressure Monitoring System (TPMS) sensor assembly.
Lubricate the valve stem with soapy water and install the valve stem and TPMS sensor assembly into
the wheel using a block of wood and a suitable valve stem installer.
2.
Make sure the valve stem rubber is fully seated against the wheel. 3.
NOTE: Lubricate the tire beads using a suitable fast-drying, corrosion-inhibiting tire bead lubricant.
NOTE: Do not mount the tire at this time.
Position the wheel on the turntable of the tire machine, then lubricate and position the bottom bead of
the tire on the wheel.
4.
Position the wheel to align the valve stem with the machine arm, at the 6 o'clock position, and mount
the bottom bead of the tire.
5.
Wheel and Tire 2963
Reposition the wheel to align the valve stem with the machine arm at the 6 o'clock position, and
mount the top bead of the tire.
6.
NOTE: Use only the Digital Tire Pressure Gauge any time tire pressures are measured to make sure
that accurate values are obtained.
Inflate the tire to the pressure specified on the Vehicle Certification (VC) label located on the driver
door or door pillar.
Proceed to Step 8 if the tire beads do not seat at the specified inflation pressure.
7.
WARNING: If there is a need to exceed the maximum pressure indicated on the sidewall of
the tire in order to seat the beads, follow all steps listed below. Failure to follow these steps may
The following steps should only be carried out if the tire beads cannot be seated by inflating the
tire up to the maximum inflation pressure listed on the tire sidewall.
Relubricate the tire bead and wheel bead seat area. 1.
Install a remote valve and pressure gauge. 2.
Wear eye and ear protection and stand at a minimum of 3.65 m (12 ft) away from the wheel
and tire assembly.
3.
Inflate the tire using the remote valve and tire gauge until the beads have seated or until the
pressure gauge is 138 kPa (20 psi) more than maximum inflation pressure on tire sidewall. If
beads have not seated, deflate the tire and proceed to the next step.
4.
Place the wheel and tire assembly in an OSHA-approved tire safety cage. 5.
Inflate the tire using the remote valve and pressure gauge until the beads have seated or until
the pressure gauge is 276 kPa (40 psi) more than maximum inflation pressure on the tire
sidewall. Do not exceed 276 kPa (40 psi) above the maximum pressure on tire sidewall.
Install a new tire if the beads do not seat at this pressure.
6.
8.
Install the wheel and tire. For additional information, refer to Wheel and Tire in this section. 9.
Wheel and Tire 2964
Wheel and Tire 2965
SUBASSEMBLIES
Tire Pressure Monitoring System (TPMS) Sensor
Disassembly
NOTE: The Tire Pressure Monitoring System (TPMS) sensor cannot be removed without
disassembly of the wheel and tire.
Disassemble the wheel and tire. For additional information, refer to Wheel and Tire in this section.
1.
Tire Pressure Monitoring System (TPMS) Sensor 2966
SECTION 205-00: Driveline System - General
Information
Material
Capacity
Premium Rear Axle Lubricant
XY-80W90-QL (US);
CXY-80W90-1L (Canada)
WSP-M2C197-A 1.15L
(2.43 pt)
Item Specification
End play
Wheel bearing end play 0.00 mm (0.000 in) maximum
Runout
Driveshaft runout 0.89 mm (0.035 in)
Pilot runout 0.15 mm (0.006 in) maximum
Wheel hub face runout 0.254 mm (0.010 in) maximum
Wheel hub flange bolt circle runout 0.38 mm (0.015 in) maximum
Tire Pressure Monitoring System (TPMS) Sensor 2967
Information
Workshop Manual
Driveline System
The driveline system consists of the following components:
Center support bearing
Driveshaft assembly
Front halfshafts
Rear halfshafts
Active torque coupling/rear axle
On Front Wheel Drive (FWD) vehicles, the transaxle transmits power from the engine to the halfshafts.
On All-Wheel Drive (AWD) vehicles, power is transmitted from the engine through the transaxle to the
Power Transfer Unit (PTU). The PTU transfers engine power from the transaxle to the front halfshafts, and
through the driveshaft to the active torque coupling/rear axle and halfshafts. For information on the PTU ,
refer to Section 308-07A or Section 308-07B .
The engine angle is built into the engine mounts. If the engine angle is out of specification, the engine mounts
must be inspected for damage. Refer to Section 303-01A , Section 303-01B or Section 303-01C .
Vehicle Certification (VC) Label Example
The Vehicle Certification (VC) label is located in the driver door jamb. The axle code is on the VC label.
The axle ratio is 2.93 and the ring gear has a diameter of 174 mm (6.85 in).
The wheel speed sensor rings for FWD vehicles are located on the front halfshafts and are mounted to the rear
inner spindles.
The wheel speed sensor rings are located on the front and rear halfshafts for AWD vehicles.
Driveshaft
The driveshaft is a 3-piece shaft with rubber-isolated center bearings.
Driveline System 2968
The driveshaft has traditional balance weights attached (spot-welded) by the manufacturer.
U-joints
The CV and U-joints are installed new with the driveshaft.
The front CV joint is:
lubricated with a special lubricant and requires no additional lubrication.
The center U-joints are:
a lubed-for-life design that requires no periodic lubrication.
equipped with nylon thrust washers located at the base of each bearing cup which control end play,
position the needle bearings and improve grease movement.

Rear Drive Unit
The active torque coupling/Rear Drive Unit (RDU) is serviced as an assembly.
The RDU housing cover uses a silicone sealant rather than a gasket.
Each halfshaft is held in the RDU case by a halfshaft circlip that is located on the inner CV joint stub shaft
pilot bearing housing. When each halfshaft is installed, the halfshaft circlip engages a slot in the differential
side gear.
The RDU operates as follows:
The RDU pinion receives power from the engine through the transaxle, PTU , driveshaft and active
torque coupling, and is always engaged.

The pinion gear rotates the differential case, which is bolted to the differential case outer flange.
Inside the differential case, 2 differential pinion gears are mounted on a differential pinion shaft that is
pinned to the differential case.

These differential pinion gears are engaged with the differential side gears, to which the halfshafts are
splined.

As the differential case turns, it rotates the halfshafts and rear wheels.
When it is necessary for one wheel and halfshaft to rotate faster than the other, the faster turning
differential side gear causes the differential pinion gears to roll on the slower turning differential side
gear. This allows differential action between the 2 halfshafts.

Halfshafts
The drive halfshafts consist of the following components:
Inner CV joints
Outer CV joints
CV joint boot clamps
CV joint boots
Tripod joint housings
Retainer circlips
Front intermediate shaft bearing
Vehicle Certification (VC) Label Example 2969
The front intermediate shaft bearing is pressed on and is only serviced as an assembly with the intermediate
shaft.
NOTICE: An inspection of the outer and inner Constant Velocity (CV) joint 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.
The inner and outer CV joints connect to a splined shaft. A circlip holds the cross groove inner race
assembly (inner CV joint) together.

A circlip retains the splined inner CV joint. Install a new axle circlip each time the halfshaft is
removed from the vehicle.

A wheel hub nut secures the side shaft assembly (interconnecting shaft and outer CV joint) to the
wheel hub. Install a new wheel hub nut each time the halfshaft is removed from the vehicle.

Halfshaft Handling
NOTICE: Handle the halfshaft only by the interconnecting shaft to avoid pull-apart and potential
damage to the Constant Velocity (CV) joints. Damage will occur to an assembled inner CV joint if it is
over-plunged outward from the joint housing or over angled.
Handle all halfshaft components carefully during removal and installation procedures. Never use a hammer to
remove or install the halfshafts. Never use the halfshaft assembly as a lever to position other components.
Always support the free end of the halfshaft. Do not allow the boots to contact sharp edges or hot exhaust
components. Do not drop assembled halfshafts. The impact may cut the boots from the inside without
evidence of external damage.
Vehicle Certification (VC) Label Example 2970
Information
Driveline System
Material
Item Specification
Additive Friction Modifier
XL-3 (US); CXL-3 (Canada)
EST-M2C118-A
XY-80W90-QL (US);
WSP-M2C197-A
Principals of Operation
Driveline System - General Information
The driveline system enables the power generated by the engine and transferred through the transmission in
Front Wheel Drive (FWD), or the transmission and the Power Transfer Unit (PTU) in All-Wheel Drive
(AWD) to place the vehicle in motion. Rotational torque received from the transmission or PTU is delivered
to the front wheels by halfshafts or the rear axle by way of the driveshaft(s). The U-joints or CV joints at the
ends of the shafts allow the shafts to rotate smoothly in an allowable angle plane. The rotational torque is
introduced into the axle drive pinion which drives the differential ring gear. The ring gear is bolted to the axle
differential which divides the torque between the left and right axle shafts, while permitting the shafts to turn
at different speeds when required, such as when cornering.
Visually inspect for obvious signs of mechanical damage.
Mechanical
U-joints
CV joints
Center bearings
Driveshaft tubes
Mounting brackets
Flanges
Housing and cover
damage

Differential
bearings

2.
Differential
gearsets

Pinion bearings
3.
If the cause is not visually evident, verify the symptom and GO to Symptom Chart - NVH . 4.
Driveshaft Center U-Joint and CV Joint Inspection
With the vehicle in NEUTRAL, position it on a hoist. Refer to Section 100-02 . Rotate the driveshaft by hand.
Check for rough operation or seizure of the U-joints or CV joints. Install a new driveshaft if it shows signs of
seizure, excessive wear or incorrect seating. Refer to Section 205-01 .
Driveshaft Center Bearing
With the vehicle in NEUTRAL, position it on a hoist. Refer to Section 100-02 . Rotate the driveshaft by hand.
If the bearing shows signs of roughness or is noisy, install a new driveshaft assembly. Refer to Section 205-01
.
Symptom Charts - NVH
Symptom Charts - NVH
Axle howling or whine - front or rear axle
Axle lubricant low
CHECK the lubricant level. FILL the axle to specification.
Axle housing damage
INSPECT the axle housing for damage. INSTALL a new axle as necessary. REFER to Section
205-02 .

Damaged or worn wheel hub bearings
CHECK for abnormal wheel hub bearing play or roughness. REFER to Section 204-01 or Section
204-02 .

Damaged or worn differential ring and pinion
INSPECT and INSTALL a new axle assembly as necessary. REFER to Section 205-02 .
Damaged or worn differential side or pinion bearings
Driveline clunk - loud clunk when shifting from reverse to drive
Incorrect axle lubricant level
CHECK the lubricant level. FILL the axle to specification.
Excessive backlash in the axle
CHECK the axle backlash. INSPECT and INSTALL a new axle assembly as necessary. REFER to
Section 205-02 .

Damaged or worn pinion bearings
Damaged or worn U-joints
INSPECT the U-joints for wear or damage. INSTALL a new driveshaft as necessary. REFER to
Section 205-01 .

Driveline clunk - occurs as the vehicle starts to move forward following a stop
Worn driveshaft CV joint or U-joints with excessive play
INSPECT the CV joint and U-joints for a worn condition. INSTALL a new driveshaft as necessary.

Loose rear axle mount
CHECK the axle for loose bolts. TIGHTEN to specification. REFER to Section 205-02 .
Driveline clunk (Front Wheel Drive (FWD) vehicles) - occurs during acceleration or from cruise to
coast/deceleration

Damaged or worn inner CV joint
INSPECT the inner CV joint and boot. INSTALL a new CV joint as necessary. REFER to Section
205-04 .

Clicking, popping or grinding - occurs while the vehicle is turning
Inadequate or contaminated lubrication in the CV joints
CHECK the CV boots and joints for wear or damage. INSTALL new components as necessary.

Loose wheel end nut
CHECK wheel hub nut torque. REPAIR as necessary. REFER to Section 205-04 .
Another component contacting the halfshaft
CHECK the halfshafts and the area around the halfshafts. REPAIR as necessary.
High pitched chattering - noise from the rear axle when the vehicle is turning
Incorrect or contaminated lubricant
CHECK the vehicle by driving in tight circles (5 clockwise, 5 counterclockwise). DRAIN and
REFILL with the specified rear axle lubricant and friction modifier as necessary.

Damaged or worn differential (differential side gears and pinion gears)
Buzz - buzzing noise is the same at cruise or coast/deceleration
Incorrect driveline angles
CHECK for correct driveline angles. REPAIR as necessary. REFER to Driveline Angle Measurement
in this section.

Rumble or boom - noise occurs at coast/deceleration, usually driveshaft speed-related and noticeable
over a wide range of speeds

Driveshaft is out-of-balance
CHECK the driveshaft for damage, missing balance weights or undercoating. REFER to Driveshaft
Runout and Balancing in this section.

U-joints are binding or seized
ROTATE the driveshaft and CHECK for rough operation or seized U-joints. INSTALL a new
driveshaft as necessary. REFER to Section 205-01 .

Grunting - normally associated with a shudder experienced during acceleration from a complete stop
Driveshaft CV joint binding
INSTALL a new driveshaft as necessary. REFER to Section 205-01 .
Loose rear axle mount bolts or suspension fasteners
INSPECT the rear suspension and axle. TIGHTEN the fasteners to specification. REFER to Section
205-02 .

Howl - can occur at various speeds and driving conditions. Affected by acceleration and deceleration
Incorrect ring and pinion contact, incorrect bearing preload or gear damage
Chuckle - heard at coast/deceleration. Also described as a knock
Incorrect ring and pinion contact or damaged teeth on the coast side of the ring and pinion
Knock - noise occurs at various speeds. Not affected by acceleration or deceleration
Gear tooth damage to the drive side of the ring and pinion
INSPECT and INSTALL a new axle assembly as necessary. REFER to
Scraping noise - a continuous low pitched noise starting at low speeds
Worn or damaged pinion bearings
INSTALL a new axle assembly as necessary. REFER to Section 205-02 .
Driveline shudder - occurs during acceleration from a slow speed or stop
Rear drive axle assembly mispositioned
CHECK the axle mounts and the rear suspension for damage or wear. REPAIR as necessary. REFER
to Section 205-02 .

Loose rear axle bolts
CHECK the rear axle for loose bolts. TIGHTEN the bolts to specification. REFER to Section 205-02 .
Driveline angles out of specification
CHECK for correct driveline angles. REFER to Driveline Angle Measurement in this section.
U-joints binding or seized
ROTATE the driveshaft and CHECK for rough operation or seized U-joints. INSTALL a new
driveshaft as necessary. REFER to Section 205-01 .

Binding or damaged driveshaft CV joint
INSPECT the driveshaft CV joint and coupling shaft for wear or damage. INSTALL a new driveshaft

Driveline vibration - occurs at cruising speeds
Worn U-joints
CHECK for wear or incorrect seating. INSTALL a new driveshaft as necessary. REFER to Section
205-01 .

Worn or damaged driveshaft center bearing support
CHECK the insulator for damage or wear. ROTATE the driveshaft and CHECK for rough operation.
INSTALL a new driveshaft as necessary. REFER to Section 205-01 .

Loose axle pinion flange bolts
INSPECT the axle pinion flange. TIGHTEN the pinion flange bolts to specification. REFER to
Section 205-01 .

Excessive axle pinion flange runout
CARRY OUT a runout check. REPAIR as necessary. REFER to Section 205-02 .
Driveshaft is out-of-balance
CHECK the driveshaft for damage, missing balance weights or undercoating. CHECK the driveshaft
balance. CARRY OUT a driveline vibration test. REFER to Driveshaft Runout and Balancing in this
section.

Binding or damaged driveshaft CV joint
INSPECT the driveshaft CV joint for wear or damage. INSTALL a new driveshaft as necessary.

Excessive driveshaft runout
CARRY OUT a runout check. REFER to Driveshaft Runout and Balancing in this section.
Driveline angles out of specification
CHECK for correct driveline angles. REPAIR as necessary. REFER to Driveline Angle Measurement
in this section.

Incorrectly seated CV joint in the wheel hub
CHECK the outer CV joint for correct seating into the hub. REPAIR as necessary. REFER to Section
205-04 for the front CV joints or Section 205-05 for the rear CV joints.

Analysis of Leakage
Clean up the leaking area enough to identify the exact source.
A plugged Rear Drive Unit (RDU) housing vent can cause excessive pinion seal lip wear due to internal
pressure buildup.
Verify the RDU lubricant level is at least 3-5 mm (1/8-3/16 in) below the bottom of the fill hole.
Axle Vent
A plugged vent will cause excessive seal lip wear due to internal pressure buildup. If a leak occurs, check the
vent. If the vent cannot be cleared, install a new vent.
Drive Pinion Seal
Leaks at the drive pinion seal originate from the following causes:
Damaged seal
Worn seal journal surface
Any damage to the seal bore (dings, dents, gouges or other imperfections) distorts the seal casing and allows
leakage past the outer edge of the drive pinion seal.
The drive pinion seal can be torn, cut or gouged if it is not installed correctly. The spring that holds the drive
pinion seal against the pinion flange may be knocked out and allow fluid to pass the lip.
Metal chips trapped at the sealing lip can cause oil leaks. These can cause a wear groove on the drive pinion
flange and result in pinion seal wear.
When a seal leak occurs, install a new drive pinion seal and check the vent to make sure it is clean and free of
foreign material.
A new drive pinion flange must be installed if any of these conditions exist.
Drive Pinion Nut
NOTICE: Install the drive pinion nut to the correct torque specifications or damage to the differential
components may occur.
On some high-mileage vehicles, oil may leak through the threads of the drive pinion nut. This condition can
be corrected by installing a new nut.
Differential Seals
NOTICE: When installing shafts, do not allow splines to contact seals during installation or damage to
the seals may occur.
Halfshaft pilot bearing housing seals are susceptible to the same types of damage as drive pinion seals if
incorrectly installed. The seal bore must be clean and the lip handled carefully to avoid cutting or tearing it.
The seal journal surface must be free of nicks, gouges and rough surface texture.
For information on differential seals, refer to Section 205-02 .
Inrmation
Workshop Manual
Driveline Angle Measurement
Special Tool(s)
Anglemaster II Driveline
Inclinometer/Protractor
NOTE: This procedure does not apply to CV joints, flex couplers or double cardan joints that are used in
some driveshafts. This check is for single-cross and roller-style joints found in the driveshafts.
NOTE: Prior to checking driveline angularity, inspect the U-joints for correct operation.
NOTE: An incorrect driveline angle can cause a vibration or shudder. For additional information, refer to
Section 100-04 .
NOTE: Driveline angularity is the angular relationship between the engine crankshaft, the driveshaft and the
rear axle pinion. Factors determining driveline angularity include ride height, rear spring and engine mounts.
All vehicles
Carry out the following preliminary setup steps:
Inspect the U-joints for correct operation.
Park the vehicle on a level surface such as a drive-on hoist, or back onto a front end
alignment rack.

Verify the curb position ride height is within specifications with the vehicle unloaded and all
of the tires are inflated to their normal operating pressures.

Calibrate the Anglemaster II Driveline Inclinometer/Protractor by placing it on a clean, flat
level section of the frame rail and press the ALT-ZERO button.

1.
Vehicles with flat-flanged, split-pin or slip-flanged U-joints
NOTE: If equipped, remove the snap ring to allow access to the base of the U-joint cup. Make sure
the Anglemaster II Driveline Inclinometer/Protractor is seated against the U-joint cup.
NOTE: Rotate the driveshaft until the flange U-joint cup is parallel with the floor. This will simplify
taking measurements.
To check the U-joint operating angle, install the Anglemaster II Driveline Inclinometer/Protractor.
Check and record the flange angle as angle A.
2.
Driveline Angle Measurement 2979
Using the Anglemaster II Driveline Inclinometer/Protractor, measure the slope of the connecting
component. Record the measurement of the component angle as angle B.
3.
Multiple piece driveshafts
NOTE: Repeat this step for each center support bearing on the driveshaft.
NOTE: It is not necessary to remove the U-joint snap ring, if equipped, for these measurements.
Using the Anglemaster II Driveline Inclinometer/Protractor, measure the slope of the components in
front and behind the center support bearing U-joint in the area indicated. Record the front component
as angle A and the rear component as angle B.
4.
All vehicles
NOTE: When 2 connected components slope in the same direction, subtract the smallest number
from the larger number to find the U-joint operating angle. When 2 connected components slope in
the opposite direction, add the measurements to find the U-joint operating angle.
Calculate the difference in the slope of the components to determine the U-joint operating angle.
The U-joint operating angle is the angle formed by 2 yokes connected by a cross and bearing
kit. Ideally, the operating angles on each connection of the driveshaft must:
be equal or within one degree of each other.
have a 3 degree maximum operating angle.
have at least one-half of one degree continuous operating angle.

5.
If the angle is not within specifications, repair or adjust to obtain the correct angle. Inspect the engine
mounts, transmission mounts, center support bearing mounting, rear suspension, rear axle, rear axle
mounting or the frame for wear or damage.
6.
Information
Workshop Manual
Driveshaft Runout and Balancing
Special Tool(s)
Mastertech Series MTS 4000 Driveline
Balance and NVH Analyzer (Vetronix)
Driveshaft Inspection
NOTE: Driveline vibration exhibits a higher frequency and lower amplitude than high-speed shake. Drivee
vibration is directly related to the speed of the vehicle and is noticed at various speeds. Driveline vibration can
be perceived as a tremor in the floorpan or heard as a rumble, hum or boom.
NOTE: Refer to Specifications in this section for all runout specifications.
NOTE: Do not make any adjustments before carrying out a road test. Do not change the tire pressure
or the vehicle load.
Carry out a visual inspection of the vehicle. Operate the vehicle and verify the condition by
reproducing it during the road test.
The concern should be directly related to vehicle road speed, not affected by acceleration or
deceleration or could not be reduced by coasting in NEUTRAL.

1.
100-02 .
The driveshaft should be kept at an angle equal to or close to the curb-weighted position. Use
a twin-post hoist or a frame hoist with jackstands.

2.
Inspect the driveshaft for damage, undercoating or incorrectly seated U-joints. Rotate the driveshaft
slowly by hand and feel for binding or end play in the U-joint trunnions. Remove the driveshaft. For
additional information, refer to Section 205-01 . Inspect the slip yoke splines for any galling, dirt, rust
or incorrect lubrication. Clean the driveshaft or install new U-joints as necessary. Install a new
driveshaft if damaged. After any corrections or new components are installed, recheck for the
vibration at the road test speed.
If the vibration is gone, test drive the vehicle.
If the vibration persists or the driveshaft passes visual inspection, measure the driveshaft
runout.

3.
Driveshaft Runout
Install the Dial Indicator Gauge with Holding Fixture. Rotate the driveshaft by turning the axle and
measure the runout at the front, the center and the rear of the driveshaft.
1.
Driveshaft Runout and Balancing 2982
If the runout exceeds 1 mm (0.040 in) at the front or center, install a new driveshaft.
If the front and center is within 1 mm (0.040 in), but the rear runout is not, index-mark the
rear runout high point and proceed to Step 2.

If the runout is within 1 mm (0.040 in) at all points, recheck for vibration at road test speed. If
the vibration persists, balance the driveshaft. For additional information, refer to Driveshaft
Balancing in this procedure.

NOTE: Circular pinion flanges can be turned in 90 degree or one-fourth increments. Half-round
pinion flanges are limited to 2 positions.
Index-mark the driveshaft to the pinion flange. Disconnect the driveshaft and rotate it 180 degrees.
Reconnect the driveshaft. Recheck the runout at the rear of the driveshaft.
If the runout is still over specification, mark the high point and proceed to Step 3.
If the runout is within specification, check for the vibration at the road test speed. If the
vibration is still present, balance the driveshaft. For additional information, refer to Driveshaft
Balancing in this procedure.

2.
Excessive driveshaft runout can originate in the driveshaft itself or from the pinion flange. To find the
source, compare the 2 high points previously determined.
If the index marks are close together, within 25 mm (1 in), the driveshaft is eccentric. Install a
new driveshaft.

If the marks are on opposite sides of the driveshaft, 180 degrees apart, the slip yoke or pinion
flange is responsible. Check the pinion flange runout. If the pinion flange runout exceeds
specifications, a bent pinion is indicated.

If the pinion flange and pinion runouts are within specifications, road test and check for the
vibration at the road test speed. If the vibration persists, balance the driveshaft. For additional
information, refer to Driveshaft Balancing in this procedure.

3.
Driveshaft Balancing - Using the Mastertech Series MTS 4000 Driveline Balance and NVH Analyzer
(Vetronix)
All vehicles
Install the Mastertech Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix) to the
vehicle.
1.
Working under the vehicle, install ccelerometer. The accelerometer can be attached and mounted near 2.
either the transmission or differential end of the driveshaft.
Clean an area of the driveshaft and install the reflective tape, then install the photo-tachometer sensor.
The sensor should be placed at approximately a 20-degree angle from perpendicular to the surface of
the reflective tape. Make sure the sensor does not get moved during the balance procedure.
Reflective tape. 1.
Photo-tachometer sensor. 2.
3.
Using the Mastertech Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix), run a
driveshaft balance test with the driveshaft unmodified.
4.
Vehicles with tapped pinion flanges
Label the tapped holes in the pinion flange numerically, starting at the top hole as 1. Mark the
remaining holes 2, 3 and 4. Label in the direction of rotation.
5.
second test with the 12 mm (0.47 in) test weight set screw in the No. 1 hole, previously marked on the
pinion flange.
6.
Remove the test weight, then install the weight combination directed by the Maertech Series MTS
4000 Driveline Balance and NVH Analyzer (Vetronix).
7.
Vehicles without tapped pinion flanges
second test with a test weight. Using a metal band, secure the test weight to the end of the driveshaft.
The weight should be placed at the end of the driveshaft tube, as close to the tube-to-yoke weld seam
as possible. Mark the location of the test weight on the driveshaft, as shown in the figure below.
Test weight. 1.
Tube-to-yoke weld seam. 2.
Driveshaft pinion flange. 3.
8.
Select the test weight based on driveshaft size. Larger driveshafts use 10 g (0.353 oz). Smaller
driveshafts use 5 g (0.176 oz).

Remove the test weight, then install the recommended weight at the position directed by the
Mastertech Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix). Using a metal band
and epoxy, secure the test weight to the driveshaft, as shown in the figure below.
Test weight. 1.
Measure in this direction. 2.
Driveshaft diameter. 3.
Directional rotation. 1.
Balance weight relative to test weight centerline. 5.
The results are displayed with respect to the location to where the test weight was placed.
9.
All vehicles
third test to verify the repair.
10.
Driveshaft Balancing - Hose Clamp Method
Install 1 or 2 hose clamps on the driveshaft, near the rear. Position of the hose clamp head(s) can be
determined through trial and error.
1.
Mark the rear of the driveshaft into 4 approximately equal sectors and number the marks 1 through 4.
Install a hose clamp on the driveshaft with its head at position No. 1, as shown in the figure below.
Check for vibration at road speed. Recheck with the clamp at each of the other positions to find the
position that shows minimum vibration. If 2 adjacent positions show equal improvement, position the
clamp head between them.
2.
If the vibration persists, add a second clamp at the same position and recheck for vibration. 3.
If no improvement is noted, rotate the clamps in opposite directions, equal distances from the best
position determined in Step 2. Separate the clamp heads about 13 mm (1/2 in) and recheck for
vibration at the road speed.
4.
Repeat the process with increasing separation until the best combination is found or the vibration is
reduced to an acceptable level.
5.
SECTION 205-01: Driveshaft 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop Manual
Center bearing support nuts 55 41
Exhaust flex pipe nuts 40 30
Front driveshaft-to-Power Transfer Unit (PTU) flange bolts 70 52
Rear driveshaft-to-pinion flange bolts 70 52
SECTION 205-01: Driveshaft
Manual
Driveshaft
NOTE: All driveshaft assemblies are balanced. If undercoating the vehicle, protect the driveshaft to prevent
overspray of any undercoating material.
The driveshaft assembly consists of the following:
Rubber isolated center support bearings
CV joint at the Power Transfer Unit (PTU)
U-joints at the center support and pinion flange
Assembly balanced with traditional balance weights
Lubed-for-life joints requiring no periodic lubrication
The driveshaft transfers torque from the PTU to the rear axle. It is attached to the PTU flange with a CV joint.
The driveshaft is connected by a staked U-joint at the center bearing and attached to the rear pinion flange.
The driveshaft joints allow the smooth continuous rotation of the driveshaft through the allowable angle
planes and length variations required in normal vehicle operation. The driveshaft is always turning at front
wheel speed. The driveshaft is not serviceable. A new driveshaft must be installed if worn or damaged.
Driveshaft 2988
Manual
Universal Joints
The U-joints consist of the following:
A single spider (cross)
Lubed-for-life design and require no periodic lubrication
Nylon thrust washers, located at each base of the bearing cup, which control end play, position the
needle bearing and improve grease movement

Grease seals located at the opening of each bearing cup to retain the grease for the bearing lubrication
Bearing cups that retain the needle bearings and locate the spider on the centerline of the shaft bore to
control shaft runout and balance

The U-joints are staked in place and are not serviced individually. If worn or damaged, install a new
driveshaft assembly.
The U-joints in this driveshaft assembly allow the driveshaft tubes to rotate smoothly through the varying
angles of the Power Transfer Unit (PTU), the center support bearings and the Rear Drive Unit (RDU). The
angles that cause the U-joints to accelerate and decelerate may cause vibration in the driveshaft assembly if
the angles are either too great or too small. Refer to Section 205-00 .
Universal Joints 2989
SECTION 205-01: Driveshaft 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop Manual
Driveshaft
Driveshaft 2990
Manual
REMOVAL AND
INSTALLATION
Driveshaft
Driveshaft
Item
Part
Number Description
1 W711960 Front driveshaft-to-Power Transfer Unit (PTU)
Driveshaft flange bolt (4 required)
2 - Front driveshaft flange
3 W520113 Center bearing support nuts (4 required)
4 - Rear driveshaft flange
5 W705443 Exhaust flex pipe flange nuts (2 required)
6 W711960 Rear driveshaft-to-pinion flange bolt (4 required)
NOTE: Index-mark both the driveshaft flanges.
100-02 .
1.
NOTICE: Make sure to adequately support the exhaust flex pipe or damage may occur.
Remove and discard the 2 nuts and separate the exhaust system at the flex pipe.
Install new nuts and tighten to 40 Nm (30 lb-ft).
2.
Support the exhaust system and disconnect the 2 front exhaust hangers from the exhaust system. 3.
Driveshaft 2991
Carefully lower the exhaust system to allow clearance for removal of the driveshaft. 4.
NOTE: Do not reuse the CV joint bolts.
Remove and discard the 4 front driveshaft-to-Power Transfer Unit (PTU) flange bolts.
Install new bolts and tighten to 70 Nm (52 lb-ft).
5.
Using a suitable pry bar as shown, separate the driveshaft flange from the PTU flange. 6.
NOTICE: Do not reuse the bolts for the rear U-joint flange. Install new bolts or damage to the
component may occur.
Remove and discard the 4 rear driveshaft-to-pinion flange bolts.
Install new bolts and tighten to 70 Nm (52 lb-ft).
7.
Driveshaft 2992
With the help of an assistant, remove the 4 center bearing support nuts and the driveshaft.
8.
NOTE: If a driveshaft is installed and driveshaft vibration is encountered after installation, index the
driveshaft. For additional information, refer to Section 205-00 .
9.
Driveshaft 2993
SECTION 205-02: Rear Drive Axle/Differential
Workshop Manual
Material
Capacity
TA-32
ESB-M4G92-A -
XY-80W90-QL (US);
WSP-M2C197-A 1.15L
(2.43 pt)
CXG-1-C (Canada)
ESA-M1C75-B -
Differential housing cover bolts 23 17
Differential housing-to-front insulator bracket bolts 90 66
Filler plug 29 21
Pinion nut 244 180
Side insulator bracket-to-rear axle differential bolts 90 66
Driveshaft 2994
SECTION 205-02: Rear Drive
Axle/Differential
Workshop Manual
Rear Drive Axle and Differential
The rear drive axle consists of the following components:
Dished circular flange
Full-time fluid drive coupling
Aluminum housing with steel housing cover
Matched ring and pinion
Conventional open differential
Rubber bushing isolated mounting points
Cover mounted axle vent
Silicone sealant rather than a gasket
The rear drive axle is serviced as follows:
The active torque coupling is installed new as an assembly with the rear axle
The pinion seal and the differential halfshaft seals are the only serviced components of the rear drive
axle. If other components of the rear drive axle are worn or damaged, the assembly must be installed
new

The rear axle drive pinion receives power from the engine through the transaxle, Power Transfer Unit (PTU),
driveshaft and active torque coupling, and is engaged ON DEMAND. The pinion gear rotates the differential
ring gear, which is bolted to the differential case outer flange. Inside the differential case, 2 differential pinion
gears are mounted on a differential pinion shaft, which is pinned to the case. These differential pinion gears
are engaged with the splined differential side gears. The halfshafts are held in the differential side gears by a
retainer circlip that is located on the inboard CV joint stub shaft. When each halfshaft is installed, the retainer
circlip engages a step in the differential side gear. There are no stub shaft bearings in the differential housing.
As the differential case turns, it rotates the halfshafts and rear wheels. When it is necessary for one wheel and
halfshaft to rotate faster than the other, the faster turning differential side gear causes the differential pinion
gears to roll on the slower turning differential side gear. This allows differential action between the 2
halfshafts.
Rear Drive Axle and Differential 2995
Axle/Differential
Workshop Manual
Rear Drive Axle and Differential
Axle/Differential
Workshop Manual
Stub Shaft Seal
Special Tool(s)
Adapter for 303-224 (Handle)
205-153 (T80T-4000-W)
Installer, Front Axle Oil Seal
205-350 (T95T-3010-A)
Remover, Torque Converter Fluid Seal
307-309 (T94P-77001-BH)
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
(Canada)
ESA-M1C75-B
1 4B416 Stub shaft seal
2 4010 Differential housing
Removal
NOTE: The Rear Drive Unit (RDU) does not have stub shaft pilot bearings. It has stub shaft seals only.
Remove the halfshaft. For additional information, refer to Section 205-05 . 1.
Stub Shaft Seal 2998
Using the Torque Converter Fluid Seal Remover and Slide Hammer, remove the stub shaft seal. 2.
Installation
NOTE: Lubricate the new stub shaft seal with grease.
Using the Front Axle Oil Seal Installer and Adapter Handle, install the stub shaft pilot bearing
housing seal.
1.
Install the halfshaft assembly. For additional information, refer to Section 205-05 . 2.
Stub Shaft Seal 2999
Axle/Differential
Workshop Manual
Drive Pinion Seal
Special Tool(s)
2 Jaw Puller
Converter Seal Remover
307-309 (T94P-77001-BH)
Holding Fixture, Drive Pinion Flange
205-126 (T78P-4851-A)
Pinion Seal Replacer
205-133 (T79P-4676-A)
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
(Canada)
ESA-M1C75-B
1 4320 Drive pinion nut
2 4858 Drive pinion flange
3 4N299 Drive pinion seal
Removal
100-02 .
1.
Drive Pinion Seal 3000
Remove the driveshaft. For additional information, refer to Section 205-01 . 2.
Using the Drive Pinion Flange Holding Fixture, hold the pinion flange and remove the pinion flange
nut.
Discard the nut.
3.
Index-mark the location of the pinion flange to the yoke. 4.
Using the 2 Jaw Puller, remove the pinion flange. 5.
Using the Converter Seal Remover and Slide Hammer, remove and discard the drive pinion seal. 6.
Installation
NOTE: Make sure that the mating surface is clean before installing the new seal.
Using the Pinion Seal Replacer, install the drive pinion seal.
1.
NOTE: Lubricate the pinion flange splines with grease.
Line up the index marks and position the pinion flange.
2.
Using the Drive Pinion Flange Holding Fixture, install the new pinion flange nut.
3.
Install the driveshaft. For additional information, refer to Section 205-01 . 4.
Axle/Differential
Workshop Manual
Differential Housing Cover
Material
Item Specification
TA-32
ESB-M4G92-A
XY-80W90-QL (US);
WSP-M2C197-A
1 W505262 Differential housing cover bolt (10 required)
2 4N282 Filler plug
Removal
100-02 .
1.
Remove the 10 bolts and the differential housing cover.
Drain the differential fluid from the housing.
2.
Differential Housing Cover 3004
Installation
NOTICE: 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 rubber. The inside of
the rear axle must be covered when cleaning the machined surface to prevent damage to the
component.
NOTE: Make sure the differential vent located on the rear cover is free of obstruction.
Clean the gasket mating surfaces of the differential housing and the differential housing cover.
1.
NOTE: The differential housing cover must be installed within 15 minutes of application of the
silicone rubber, or new silicone rubber must be applied. If possible, allow one hour before filling with
lubricant to make sure the silicone rubber has correctly cured.
Apply a continuous bead of clear silicone rubber as shown in the illustration.
2.
Install the differential housing cover and the 10 bolts.
3.
Remove the filler plug, fill the rear axle with 1.15L (2.43 pt) of rear axle lubricant, 3-5 mm
(0.118-0.196 in) below the bottom of the filler hole and install the filler plug.
4.
SECTION 205-02: Rear Drive Axle/Differential
Workshop Manual
Axle Assembly
Axle Assembly
Item
Part
Number Description
1 W500442 Differential housing-to-front insulator bracket bolts (4
required)
2 W500444 Side insulator bracket-to-rear axle differential bolts (6
required)
3 4000 Rear axle assembly
Remove the rear halfshafts. For additional information, refer to Section 205-05 . 2.
Position a suitable transmission hydraulic jack to the axle housing. Securely strap the jack to the
housing.
3.
Remove the 4 differential housing-to-front insulator bracket bolts. 4.
Axle Assembly 3007
Remove the 3 RH side insulator bracket-to-rear axle differential bolts.
5.
Remove the 3 LH side insulator or bracket-to-rear axle differential bolts.
6.
Lower the axle to gain clearance and disconnect the active torque coupling electrical connector. 7.
Remove the rear axle assembly. 8.
Axle Assembly 3008
Axle Assembly 3009
SECTION 205-04: Front Drive
Halfshafts
Manual
Brake flexible hose bracket -to-wheel knuckle bolt 23 17 -
Catalytic converter support bracket bolts 20 - 177
Catalytic converter support bracket nuts 23 17 -
Damper fork-to-front lower arm bolt 103 76 -
Halfshaft support bracket bolts 40 30 -
Intermediate shaft bearing support bolts 40 30 -
Upper ball joint nut 48 35 -
Wheel hub nut 255 185 -
Wheel speed sensor bolt 23 17 -
Wheel speed sensor harness bracket-to-wheel knuckle bolt 23 17 -
Axle Assembly 3010
Halfshafts
Manual
Front Drive Halfshafts
The halfshaft and intermediate shaft consist of the following components:
Inner CV joints
Outer CV joints
Interconnecting shafts
The halfshafts are splined on the outboard stub shaft to drive the wheel hubs. They are retained in the wheel
hubs by special wheel hub nuts which also control the wheel bearing preload. The LH halfshaft is splined on
the inboard stub shaft and is retained in the differential side gear in the transaxle by a circlip. The RH
halfshaft has internal splines which are driven by the intermediate shaft. The intermediate shaft has a circlip
on the outboard end and is retained inside the inboard stub shaft. The circlips must be installed new whenever
they are removed. The intermediate shaft is retained in the transaxle differential side gear by bolts that go
through the intermediate shaft support bearing. The intermediate shaft also goes through the Power Transfer
Unit (PTU) on All-Wheel Drive (AWD) vehicles. The outer seal of the PTU must be installed new whenever
the intermediate shaft is removed.
The front drive halfshaft CV joints consist of the following components:
Convoluted CV joint boots
Ball and cage housings
Special CV high-temperature grease
Halfshaft handling consists of the following:
On the LH side, the inboard CV joint is retained in the differential side gear with a unique retainer
circlip. Install a new circlip every time the halfshaft is disconnected

On the RH side, a unique driveshaft bearing retainer circlip retains the splined inboard CV joint to the
intermediate shaft. Install a new circlip every time the halfshaft is disconnected from the intermediate
shaft

A staked front axle wheel hub retainer secures the splined outboard CV joint to the wheel hub
Do not overangle the CV joints
Damage will occur to an assembled inboard CV joint if it is overplunged outward from the joint
housing

Never use a hammer to remove or install the halfshafts from the front hub
Never use the halfshaft assembly as a lever to position other components. Always support the free end
of the halfshaft

Do not allow the boots to contact sharp edges or hot exhaust components
Handle the halfshaft only by the interconnecting shaft to avoid pull-apart and potential damage to the
CV joints

Do not drop assembled halfshafts. The impact will cut the boots from the inside without evidence of
external damage

Do not remove the outer CV joint by pulling on the interconnecting shaft
Inspect all machined surfaces and splines for damage
The CV joint mates the interconnecting shaft with the stub shaft. The joint allows for smooth rotation of the
interconnecting shaft and the stub shafts. They also adjust for length variances and angle requirements as the
Front Drive Halfshafts 3011
vehicle goes through jounce and rebound.
The halfshaft joints are not repairable and are serviced as assemblies only.
Halfshafts
Manual
Front Drive Halfshafts
Halfshafts
Manual
Halfshaft
Special Tool(s)
Halfshaft Remover
205-832
204-161 (T97P-1175-A)
Protector, Differential Oil Seal (pair)
205-461
Remover, Front Wheel Hub
211-003 (T64P-3596-F)
Slide Hammer
100-001 (T50T-100-A)
Halfshaft (View 1 of 2)
NOTE: LH halfshaft shown, RH similar.
Halfshaft 3014
1 W302122 Upper ball joint nut
2 W500550 Damper fork-to-front lower arm bolt
3 W302117 Damper fork-to-front lower arm flagnut
4 3B477 Wheel hub nut
5 W711241 Brake caliper anchor plate bolt
7 W500020 Brake flexible hose-to-wheel knuckle bolt
Halfshaft (View 2 of 2)
NOTE: LH halfshaft shown, RH similar.
8 3A427/3A428 LH/RH halfshaft
Halfshaft (View 1 of 2) 3015
Removal
RH and LH halfshafts
2.
Remove wheel speed ssor harness bracket-to-wheel knuckle bolt. 3.
Remove the wheel speed sensor bolt and position the wheel speed sensor aside. 4.
Remove the brake flexible hose bracket-to-wheel knuckle bolt. 5.
WARNING: Do not breathe dust or use compressed air to blow dust from storage containers
or friction components. Remove dust using government-approved techniques. Friction
component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous
components may occur if dusts are created during repair of friction components, such as brake
pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract,
and may cause allergic reactions and/or may lead to other chronic health effects. If irritation
persists, seek medical attention or advice. Failure to follow these instructions may result in
NOTICE: Do not allow the brake caliper to hang from the brake hose or damage to the hose can
occur.
Remove the 2 brake caliper anchor plate bolts and position the caliper and anchor plate assembly
aside.
Support the caliper using mechanic's wire.
6.
Remove and discard the damper fork-to-front lower arm bolt and flagnut. 9.
Using the Front Wheel Hub Remover, separate the halfshaft from the wheel hub. 10.
Remove the pin-type retainers and position the splash shield aside. 11.
RH halfshaft
Use a brass drift to strike the RH halfshaft in the indicated area and separate the RH halfshaft from the
intermediate shaft.
12.
LH halfshaft
Using the Halfshaft Remover and Slide Hammer, separate the halfshaft from the transmission. 13.
Position the damper fork and halfshaft forward of the front lower arm and remove the halfshaft. 14.
Remove and discard the stub shaft circlip (LH) or the intermediate shaft circlip (RH). 15.
Installation
NOTICE: Make sure to install the correct circlip for each application. Failure to use the correct
diameter circlip may result in shaft removal concerns or shaft damage during vehicle operation.
Install a new circlip.
1.
LH halfshaft
Install the Differential Oil Seal Protector. 2.
NOTICE: The sharp edges on the stub shaft splines can slice or puncture the oil seal. Use care
when inserting the stub shaft into the transmission or damage to the seal may occur.
Push the stub shaft into the transmission so the circlip locks into the differential side gear.
After insertion, pull the halfshaft inner end to make sure the circlip is locked.
3.
RH halfshaft
Align the splines on the RH halfshaft with the intermediate shaft and push the stub shaft in until the
circlip locks the shafts together.
After insertion, pull the halfshaft inner end to make sure the circlip is locked.
4.
Position the damper fork and install a new damper fork-to-front lower arm bolt and flagnut.
5.
Position the splash shield and install the pin-type retainers. 6.
Insert the halfshaft into the wheel hub. 7.
Insert the upper ball joint into the wheel knuckle and install a new nut.
8.
9.
Position the brake flexible hose bracket and install the bolt.
10.
11.
Position the wheel speed sensor harness bracket and install the bolt.
12.
Using the Halfshaft Installer, seat the halfshaft into the wheel hub. 13.
NOTICE: Do not tighten the front wheel hub nut with the vehicle on the ground. The nut must
be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing
damage will occur if the wheel bearing is loaded with the weight of the vehicle applied.
Install a new front wheel hub nut.
14.
15.
Halfshafts
Manual
Intermediate Shaft - Front Wheel Drive (FWD)
1 W500235 Halfshaft support bracket bolts (2 required)
2 3A329 Intermediate shaft assembly
Removal
All vehicles
Remove the RH halfshaft. For additional information, refer to Halfshaft in this section. 1.
3.0L vehicles
Remove the 2 halfshaft support bracket bolts. 2.
3.5L vehicles
Remove the 2 catalytic converter bracket bolts. 3.
Remove the 2 nuts and the catalytic converter support bracket. 4.
Intermediate Shaft - Front Wheel Drive (FWD) 3021
Remove the 3 halfshaft support bracket bolts. 5.
All vehicles
NOTICE: Use care when removing the intermediate shaft or damage to the transaxle seals may
occur.
Carefully remove the intermediate shaft while supporting both ends of the intermediate shaft.
6.
Remove and discard the circlip from the outboard end of the intermediate shaft. 7.
Installation
All vehicles
Install a new circlip on the outboard end of the intermediate shaft.
1.
Position the intermediate shaft in the transaxle and engage the intermediate shaft splines with the
transaxle side gears. Make sure the circlip is locked in the gear.
2.
3.0L vehicles
Install the 2 halfshaft support bracket bolts.
3.
3.5L vehicles
Install the 3 halfshaft support bracket bolts.
4.
Install the catalytic converter support bracket and the 2 nuts.
5.
Install the 2 catalytic converter bracket bolts.
6.
All vehicles
Install the RH halfshaft. For additional information, refer to Halfshaft in this section. 7.
Halfshafts
Manual
Intermediate Shaft - All Wheel Drive (AWD)
1 W500235 Intermediate shaft bearing support bolts (2 required)
2 3A329 Intermediate shaft assembly
Removal
NOTICE: A new intermediate shaft seal in the Power Transfer Unit (PTU) must be installed whenever
the intermediate shaft is removed or damage to the seal may occur. For additional information, refer to
Section 308-07B .
Remove the RH halfshaft. For additional information, refer to Halfshaft in this section. 1.
Remove the 2 intermediate shaft bearing support bolts. 2.
NOTE: Do not damage the transaxle seals when removing the intermediate shaft.
Carefully remove the intermediate shaft while supporting both ends of the intermediate shaft.
3.
Remove and discard the circlip from the outboard end of the intermediate shaft. 4.
Intermediate Shaft - All Wheel Drive (AWD) 3025
Installation
Install a new circlip on the outboard end of the intermediate shaft.
1.
Install a new intermediate shaft seal. For additional information, refer to Section 308-07B . 2.
Position the intermediate shaft in the transaxle and engage the intermediate shaft splines with the
transaxle side gears. Make sure the circlip is locked in the gear.
3.
Install the 2 intermediate shaft bearing support bolts.
4.
Install the RH halfshaft. For additional information, refer to Halfshaft in this section. 5.
Halfshafts
Manual
Material
Capacity
Rear Axle Lubricant
XY-80W90-QL (US);
WSP-M2C197-A 1.15L
(2.43 pt)
ABS wheel speed sensor bolt 23 17
Shock absorber lower bolt 115 85
Tie-rod bracket nuts 90 66
Toe link bracket nut 90 66
Upper arm bolt 110 81
Wheel hub nut 255 188
SECTION 205-05: Rear Drive Halfshafts
Workshop Manual
Rear Drive Halfshafts
The halfshafts consist of the following components:
Inner CV joints
Outer CV joints
Interconnecting shafts
The halfshafts are splined on the outboard stub shaft to drive the wheel hubs. They are retained in the wheel
hubs by special wheel hub nuts which also control the wheel bearing preload. The halfshafts are splined on the
inboard stub shaft and are retained by circlips. New circlips must be installed whenever the old circlips are
removed.
Halfshaft Joint
CV joints consist of the following components:
Convoluted CV joint boots
Ball and cage housings
Retainer circlips
Special CV high-temperature grease
The CV joints mate the interconnecting shaft with the stub shaft. The joints allow for smooth rotation of the
interconnecting shaft and the stub shafts. They also adjust for length variances and angle requirements as the
vehicle goes through jounce and rebound.
The halfshaft joints are not repairable and are serviced as assemblies only.
Halfshaft Handling
Handle all halfshaft components carefully during removal and installation and during various component
disassembly and assembly procedures.
Never pick up or hold the halfshaft only by the inboard or outboard CV joint.
Do not overangle the CV joints.
Damage will occur to an assembled inboard CV joint if it is overplunged outward from the joint
housing.

Never use a hammer to remove or install the halfshafts from the rear hub.
Never use the halfshaft assembly as a lever to position other components. Always support the free end
of the halfshaft.

Do not allow the boots to contact sharp edges or hot exhaust components.
Handle the halfshaft only by the interconnecting shaft to avoid pull-apart and potential damage to the
CV joints.

Excessive pulling force on the interconnecting shaft between joints of the halfshaft will result in
internal joint damage. Axial loads used in assisting removal must be applied through the inboard joint
housing only.

Rear Drive Halfshafts 3028
Do not drop assembled halfshafts. The impact will cut the boots from the inside without evidence of
external damage.

Do not remove the outer CV joint by pulling on the interconnecting shaft.
Inspect all machined surfaces and splines for damage.
SECTION 205-05: Rear Drive Halfshafts
Workshop Manual
Rear Drive Halfshafts
Halfshafts
Manual
Halfshaft
Special Tool(s)
Axle Seal Protector
205-816
Front Hub Remover
Halfshaft Installer
204-161 (T97P-1175-A)
Material
Item Specification
Rear Axle Lubricant
XY-80W90-QL (US);
WSP-M2C197-A
1 3N405 Wheel hub nut
2 W500547 ABS wheel speed sensor bolt
3 2C187 ABS wheel speed sensor
Halfshaft 3031
4 W500547 Upper arm bolt
5 W520515 Upper arm nut
6 W520515 Tie-rod bracket nuts (4 required)
7 W712880 Lower shock absorber bolt
8 W712848 Shock absorber lower flagnut (with 17-in wheel)
8 W302117 Shock absorber lower flagnut (with 16-in wheel)
9 4B402 Halfshaft assembly
Removal
Remove and discard the wheel hub nut. 2.
Remove the bolt and position the ABS wheel speed sensor aside. 3.
Remove the shock absorber lower bolt and flagnut. 4.
Support the lower arm. 5.
Remove the upper arm nut and bolt. 6.
Remove the 4 toe link bracket nuts. 7.
Using the Front Hub Remover, separate the halfshaft from the wheel hub. 8.
NOTICE: Do not damage the oil seal protector when removing the axle halfshaft from the
differential.
Using a suitable pry bar, remove the halfshaft.
9.
Halfshaft 3032
Remove and discard the circlip from the stub shaft. 10.
Installation
diameter circlip may result in shaft removal concerns or shaft separation during vehicle
operation.
Install a new circlip on the stub shaft.
1.
Using the Axle Seal Protector, install the halfshaft into the differential.
Make sure the circlip locks in the side gear.
2.
Using the Halfshaft Installer, install the halfshaft into the hub assembly. 3.
Install the upper arm bolt and nut.
4.
NOTICE: Do not tighten the rear wheel hub nut with the vehicle on the ground. The nut must
be tightened to specification before the vehicle is lowered to the ground. Wheel bearing damage
Install the new wheel hub nut.
5.
Halfshaft 3033
6.
Install the 4 rear toe link bracket nuts.
7.
Install the shock absorber lower bolt and flagnut.
8.
Position the ABS wheel speed sensor and install the bolt.
9.
Fill the axle with the specified quantity of the specified lubricant. 10.
Halfshaft 3034
SECTION 206-00: Brake System - General
Information
Workshop Manual
Material
High Performance DOT
3 Motor Vehicle Brake
Fluid
PM-1-C (US); CPM-1-C
(Canada)
WSS-M6C62-A or
WSS-M6C65-A1
590-790 ml
(1.24-1.66 pt)
a
Metal Brake Parts
Cleaner
PM-4-A or PM-4-B
(US); CPM-4 (Canada)
- -
Silicone Brake Caliper
Grease and Dielectric
Compound
XG-3-A
ESE-M1C171-A -
a
Actual brake fluid capacity will vary depending on vehicle options.
Item Specification
Front Disc Brake
Brake disthickness 23.0 mm (0.905 in)
Brake pad maximum taper wear (in any direction) 3.0 mm (0.118 in)
Brake pad minimum thickness 3.0 mm (0.118 in)
Rear Disc Brake
Brake disc minimum thickness 8.0 mm (0.314 in)
Bleeder screw 8 - 71
Brake caliper guide pin bolts 26 19 -
Master cylinder brake tubes 28 21 -
Halfshaft 3035
Halfshaft 3036
Information
Workshop Manual
Brake System
The brake system has the following components:
Brake master cylinder and fluid reservoir
Cable/caliper actuated parking brake system
Clevis pin
Electric vacuum pump (hybrid vehicles)
Fixed position brake pedal (non-hybrid vehicles)
Fixed position brake pedal with integrated brake-by-wire system (hybrid vehicles)
Four-wheel ABS
Front and rear disc brake systems
Vacuum-assisted power brake booster (non-hybrid vehicles)
Vacuum-assisted active booster (hybrid vehicles)
Red brake light indicator
Conventional Brake System (Non-Hybrid Vehicles)
The brake pedal is connected to the vacuum power brake booster, which is connected to the brake master
cylinder. When the brake pedal is applied, brake fluid is pushed through the double-walled steel tubes and
flexible hoses to the disc brake calipers. The brake fluid enters the disc brake calipers, forcing the caliper
pistons and brake pads outward against theke disc friction surfaces, slowing or stopping wheel rotation. When
the brake pedal is released, brake fluid pressure is relieved, returning the disc brake systems to the unapplied
position.
Regenerative Braking System (Hybrid Vehicles)
During braking, the regenerative brake system utilizes the electric motor portion of the hybrid electric power
train as a generator to create electrical current. This recharges the High Voltage Traction Battery (HVTB) in
combination with the vehicle's conventional friction brakes while slowing the vehicle. The amount of brake
torque provided by the electric motor is dependent upon the state of charge of the HVTB . When the HVTB is
almost fully charged, the amount of regenerative braking is limited to avoid overcharging, and the requested
deceleration is produced by conventional friction braking alone.
For information on the following components:
Front disc brakes, refer to Section 206-03
Rear disc brakes, refer to Section 206-04
Parking brake actuation, refer to Section 206-05
Hydraulic brake actuation, refer to Section 206-06
Vacuum-assisted power brake booster, refer to Section 206-07
ABS, refer to Section 206-09
Vacuum-assisted active brake booster, refer to Section 206-09
Electric vacuum pump, refer to Section 206-09
Brake System 3037
Brake System 3038
Information
Workshop Manual
Conventional Brake System
Applying the brake pedal produces hydraulic pressure in the master cylinder. Using engine vacuum, the brake
booster increases the pressure applied to the master cylinder. The pressure builds in the master cylinder and
brake tubes as the brake pedal is applied further. The pressure between the primary and secondary piston
forces the secondary piston to compress, building pressure in its circuit. The hydraulic pressure is transmitted
by brake fluid through the brake tubes to the ABS Hydraulic Control Unit (HCU), which then distributes that
pressure to the individual brake calipers. The brake calipers use hydraulic pressure to apply the pads. The
application of the brake pads will cause the rotation of the wheels to slow or stop, depending on how murake
pressure is applied. The parking brakes carry out the same function except that they are mechanically actuated
by a cable that only connects to the rear brakes.
Brake Master Cylinder Compensator Ports
The purpose of the compensator ports in the brake master cylinder is to supply additional brake fluid from the
master cylinder reservoir when needed by the brake system due to brake lining wear and allow brake fluid to
return to the master cylinder reservoir when the brakes are released. The returning brake fluid creates a slight
turbulence in the master cylinder reservoir. This is a normal condition and indicates that the compensator
ports are not clogged. Clogged compensator ports may cause the brakes to hang up or not fully release.
Red Brake Warning Indicator
The red brake warning indicator alerts the driver to certain conditions that exist in the brake system. The
Instrument Cluster (IC) performs a bulb check when the ignition key is turned to the RUN position. The
conditions that cause the indicator to illuminate are low brake fluid level, the parking brake is applied or there
is a fault in the brake system. To diagnose red brake warning indicator concerns, refer to Section 413-01 .
For information on the following hybrid systems, refer to Section 206-09 .
Regenerative brake system
Brake-by-wire
Electric vacuum pump
Principles of Operation 3039
Principles of Operation 3040
Information
Workshop Manual
Inspection And Verification
Material
Item Specification
High Performance DOT 3
Motor Vehicle Brake Fluid
(Canada)
WSS-M6C62-A or
WSS-M6C65-A1
MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products
call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet
(MSDS) if available. Failure to follow these instructions may result in serious personal injury.
NOTICE: Blistering or swelling of rubber brake components can indicate contamination of the brake
fluid by a petroleum-based substance. The entire hydraulic brake system must be flushed with clean,
specified brake fluid and contaminated rubber components must be replaced to prevent
recontamination.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If
brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.
On a conventional brake system, the first indication that something may be wrong in the brake system is a
change in the feel through the brake pedal. The brake warning indicator in the Instrument Cluster (IC) and the
brake fluid level in the brake master cylinder reservoir are also indicators of system concerns.
If a wheel is locked and the vehicle must be moved, open a bleeder screw at the locked wheel to let out
enough fluid to relieve the pressure. Close the bleeder screw. If multiple wheels are locked, check the brake
pedal free play to verify brake pedal is not partially applied. These operations may release the brakes, but will
not correct the concern. If this does not relieve the locked wheel condition, repair the locked components
before proceeding.
For parking brake concerns, refer to Section 206-05 .
For vacuum pump (hybrid vehicles) concerns, refer to Section 206-09 .
For ABS concerns, refer to Section 206-09 .
For brake-by-wire (hybrid vehicles) concerns, refer to Section 206-09 .
For active brake booster (hybrid vehicles) concerns, refer to Section 206-09 .
For vacuum sensor (3.0L AWD and 3.5L) concerns, refer to Section 206-09 .
Inspection And Verification 3041
Brake fluid level and condition
Brake master cylinder
Brake master cylinder reservoir
Brake booster
Brake booster check valve
Brake booster vacuum hose
Brake hoses and tubes
Brake caliper, guide pins and
anchor plate

Brake discs
Brake pads
Brake pedal, bracket and booster
linkage

Electric vacuum pump (hybrid
vehicles)

Aftermarket modifications
Active brake booster sensors (hybrid vehicles)
Brake booster travel sensor
Vacuum pressure sensor

3 (40A)
7 (40A)
8 (50A)
10 (30A)
37 (5A)
47 (10A)

Electric vacuum pump mechanical relay (hybrid
vehicles)

Electric vacuum pump solid state relay (hybrid
vehicles)

PCM relay
Active brake booster solenoid (hybrid vehicles)
Brake pedal cut off valve (hybrid vehicles)
Brake-by-wire pedal sensors (hybrid vehicles)
Brake pedal angle sensor
Brake pedal simulator pressure sensor

Brake fluid level switch
Parking brake switch
Vacuum sensor (3.0L All-Wheel Drive (AWD)
and 3.5L)

If brake system concern is not evident, visually inspect the suspension system and tires for obvious
signs of wear or damage.
3.
For suspension system concerns, refer to Section 204-00 .
For tire concerns, refer to Section 204-04 .
4.
If the cause is not visually evident, refer to Symptom Chart in this section. 5.
Information
Workshop Manual
Symptom Chart
Symptom Chart - Brake System (Non-Hybrid Vehicles)
Symptom Chart - Brake System (Non-Hybrid Vehicles)
Symptom Chart - Brake System (Hybrid Vehicles)
Symptom Chart - Brake System (Hybrid Vehicles)
Symptom Chart - NVH
Symptom Chart - NVH
Vibration when the brakes are applied
Brake disc(s)
Suspension components
Brake vibration/shudder - occurs when the brake pedal is released
Brake drag
GO to Symptom Chart - Brake System .
Rattling noise
Caliper guide pins or guide pin bolts
CHECK the caliper guide pins and guide pin bolts. REFER to Brake System Inspection in this
section.

Missing or damaged anti-rattle clips or springs
Symptom Chart 3044
CHECK the brake pads for missing clips or broken springs. INSTALL new components as necessary.
REFER to Section 206-03 for front disc brakes or Section 206-04 for rear disc brakes.

Loose brake disc shield
TIGHTEN the brake disc shield bolts to specification. REFER to Section 206-03 for front disc brakes
or Section 206-04 for rear disc brakes.

Squealing noise - occurs on first (morning) brake application
Brake pads
Acceptable condition. Caused by humidity and low brake pad temperature.
Squealing noise - a continuous squeal
Brake pads
INSPECT the brake pads/shoes. REFER to Brake System Inspection in this section.
Squealing noise - an intermittent squeal
Brake pads
Acceptable condition. Caused by cold, heat, water, mud or snow.
Groaning noise - occurs at low speeds with brake lightly applied (creeping)
Brake pads
Grinding/moaning noise - continuous
Brake pads
Brake disc
INSPECT the brake pads/discs and attaching hardware for damage. VERIFY brake components are
within specifications. REFER to Brake System Inspection in this section.

Excessive vacuum pump noise (above 60-70 dB)
Vacuum pump
INSTALL new vacuum pump as necessary.
Symptom Chart 3045
Symptom Chart 3046
Information
Workshop Manual
Pinpoint Tests
Pinpoint Test A: Vibration When the Brakes are Applied
Normal Operation
During moderate to heavy braking, noise from the Hydraulic Control Unit (HCU) and pulsation in the brake
pedal can be observed. Pedal pulsation coupled with noise during heavy braking or on loose gravel, bumps,
wet or snowy surfaces is acceptable and indicates correct functioning of the ABS. Pedal pulsation or steering
wheel nibble when the brakes are applied (frequency is proportioned to the vehicle speed) indicates a concern
with a brake or suspension component.
PINPOINT TEST A: VIBRATION WHEN THE BRAKES ARE APPLIED
A1 ROAD TEST THE VEHICLE - LIGHT BRAKING
Road test the vehicle. Warm the brakes by slowing the vehicle from 80
to 32 km/h (50 to 20 mph) using light brake force. At highway speeds
of 89-97 km/h (55-60 mph), apply the brake using light pedal force.

Is there a vibration/shudder felt in the steering wheel, seat or brake
pedal?

Yes
GO to A4 .
No
GO to A2 .
A2 ROAD TEST THE VEHICLE - MODERATE TO HEAVY
BRAKING
Road test the vehicle. At highway speeds of 89-97 km/h (55-60 mph),
apply the brake using a moderate to heavy pedal force.

Is there a vibration/shudder?
Yes
GO to A3 .
No
The concern is not
present at this time.
A3 CHECK ABS OPERATION
NOTE: During moderate to heavy braking, noise from the HCU and
pulsation in the brake pedal can be observed. Pedal pulsation coupled
with noise during heavy braking or on loose gravel, bumps, wet or
snowy surfaces is acceptable and indicates correct operation of the
ABS. Pedal pulsation or steering wheel nibble with the frequency
proportional to vehicle speed indicates a concern with a brake or
suspension component.

Road test the vehiclend apply the brakes on a dry, firm surface, then
apply the brakes on a wet, snowy or loose surface (such as gravel).

Is the vibration/shudder only present on a wet, snowy or loose
surface?

Yes
This is a normal
operating condition of
the ABS.
No
GO to A5 .
A4 ISOLATE BRAKE VIBRATION
Pinpoint Tests 3047
NOTE: This test is not applicable to vehicles with drum-in-hat type
parking brakes. For vehicles with drum-in-hat parking brakes, proceed
to the next test step. For all other vehicles, apply the parking brake to
identify if the problem is in the front or rear brake.

Apply the parking brake to identify if the problem is in the front or rear
brake. At highway speeds of 89-97 km/h (55-60 mph), lightly apply the
parking brake until the vehicle slows down. Release the parking brake
immediately after the test.

Is there a vibration/shudder?
Yes
GO to A7 .
No
GO to A5 .
A5 CHECK THE FRONT SUSPENSION
Check the front suspension. Refer to Section 204-00 .
Are all the suspension components in satisfactory condition?
Yes
GO to A6 .
No
REPAIR or INSTALL
new components as
necessary. TEST the
system for normal
operation.
A6 CHECK THE FRONT BRAKE DISCS
Inspect the front brake discs. Refer to Brake System Inspection in this
section.

Is the vibration/shudder present?
Yes
GO to A7 .
No
The concern has been
repaired.
A7 CHECK THE REAR SUSPENSION
Check the rear suspension. Refer to Section 204-00 .
Are all the suspension components in satisfactory condition?
Yes
INSPECT the rear brake
discs. REFER to Brake
System Inspection in
this section.
No
REPAIR or INSTALL
new components as
necessary. TEST the
system for normal
operation.
PINPOINT TEST A: VIBRATION WHEN THE BRAKES ARE APPLIED 3048
PINPOINT TEST A: VIBRATION WHEN THE BRAKES ARE APPLIED 3049
Information
Workshop Manual
Component Tests
Brake Booster (Non-Hybrid Vehicles)
Inspect the brake booster. For additional information, refer to Brake System Inspection in this section. 1.
Disconnect the check valve/vacuum hose from the brake booster and connect a suitable
vacuum/pressure tester to the booster side of the check valve/vacuum hose.
2.
Apply the parking brake, start the engine and place the transmission in NEUTRAL.
Allow the engine to reach normal operating temperature.
3.
NOTE: Subtract approximately 3.38 kPa (1 in-Hg) from the specified reading for every 304.8 m
(1,000 ft) of elevation above sea level.
Verify that vacuum iailable at the check valve/vacuum hose with engine running at normal idle speed.
The vacuum gauge should read between 51-74 kPa (15-22 in-Hg).
If specified vacuum is available, stop the engine, connect the check valve/vacuum hose and
continue with Step 5.

On vehicles equipped with a check valve, if specified vacuum is not available, continue with
Step 4.

On vehicles not equipped with a check valve, if specified vacuum is not available, stop the
engine, connect the vacuum hose to the check valve and refer to Section 303-00 to diagnose
the no/low vacuum condition.

4.
Disconnect the check valve from the vacuum hose and verify that the specified vacuum is available at
the hose with the engine at idle speed and the transmission in NEUTRAL.
If specified vacuum is available, stop the engine, install a new check valve and continue with
Step 5.

If specified vacuum is not available, stop the engine, connect the vacuum hose to the check
valve and refer to Section 303-00 to diagnose the no/low vacuum condition.

5.
Apply the brake pedal several times to exhaust all vacuum from the system. 6.
Apply the brake pedal and hold it in the applied position. Start the engine and verify that the brake
pedal moves downward after the engine starts.
If the brake pedal moves, the brake booster is operating correctly.
If the brake pedal does not move, install a new brake booster. Refer to Section 206-07 .
7.
Operate the engine a minimum of 20 seconds at idle. Stop the engine and let the vehicle stand for 10
minutes, then apply the brake pedal. The brake pedal feel should be the same as that noted with the
engine operating.
If the brake pedal feels hard (no power assist), install a new brake booster check valve and
retest.

If condition still exists, install a new brake booster. Refer to Section 206-07 .
If the brake pedal feels the same as noted with the engine operating, the check valve is
functioning properly.

8.
Component Tests 3050
Brake Master Cylinder - Bypass Condition
Disconnect the brake tubes from the master cylinder. 1.
Plug the outlet ports of the master cylinder. 2.
NOTE: Make sure the outlet port plugs do not show signs of leakage.
Lightly apply the brakes d hold for 10 seconds. Release the brakes and then reapply with heavy force.
If brake pedal height cannot be maintained, the brake master cylinder has an internal leak and a new
brake master cylinder must be installed.
3.
Brake Master Cylinder - Compensator Port
With the vehicle in NEUTRAL, position it on a hoist. Refer to Section 100-02 . 1.
Apply and release the brakes. 2.
With the brakes released, attempt to rotate each wheel and check for any brake drag.
If an excessive amount of brake drag exists at multiple wheels, continue to Step 4.
If an excessive amount of brake drag exists at only one wheel, it indicates a possible seized
brake caliper, brake wheel cylinder or parking brake component. Repair or install new
components as necessary.

3.
Check the brake stoplamp switch and the brake pedal free play to verify that the brake pedal is not
partially applied.
4.
Loosen the brake master cylinder nuts and position the brake master cylinder away from the brake
booster.
5.
With the brakes released, attempt to rotate each wheel and check for any brake drag.
If the brake drag is no longer present, install a new brake booster. Refer to Section 206-07 .
If the brake drag is still present, install a new master cylinder. Refer to Section 206-06 .
6.
Information
Workshop Manual
Brake System Inspection
Material
Item Specification
Metal Brake Parts Cleaner
PM-4-A or PM-4-B (US); CPM-4
(Canada)
-
Dielectric Compound
XG-3-A
ESE-M1C171-A
Brake Pads
NOTE: It is not required to install new brake pads when the brake discs are machined.
Inspect the brake pad friction material for contamination.
If the friction material shows evidence of contamination, install new brake pads. For
additional information, refer to Section 206-03 for front brake pads or Section 206-04 for rear
brake pads.

1.
Inspect and measure the thickness of the brake pad friction material. For additional information, refer
to Specifications in this section.
Minor surface cracks do not require pad replacement, however, if there are missing chunks or
cracks in the lining through to the backing plate, install new brake pads. For additional
information, refer to Section 206-03 for front brake pads or Section 206-04 for rear brake
pads.

If the thickness of the friction material is less than the specified thickness, install new brake
pads. For additional information, refer to Section 206-03 for front brake pads or Section
206-04 for rear brake pads.

If the friction material shows taper wear that is not within specifications, install new brake
pads and verify the caliper guide pins are functioning correctly. For additional information,
refer to Brake Caliper Guide Pins inspection in this section.

2.
Brake Discs
NOTICE: Using an impact tool without a torque socket will lead to unevenly tightened wheel nuts. This
causes brake disc on-vehicle lateral runout and brake roughness.
Inspect the brake discs and measure the brake disc thickness. Record the measurements. Refer to
Specifications in this section.
If the brake disc is cracked or otherwise damaged, install a new brake disc. For additional
information, refer to Section 206-03 for front brakes or Section 206-04 for rear brakes.

If the measurement is below the minimum thickness specification, install a new brake disc.
For additional information, refer to Section 206-03 for front brakes or Section 206-04 for rear
brakes.

1.
Brake System Inspection 3053
If the diagnosis has revealed vibration in the steering wheel, seat or pedal while braking that
varies with vehicle speed, machine the brake disc. Heavily scored brake discs, similar to that
caused by pads worn down to the backing plate, should also be machined. In order to
machine, discs must be above the minimum thickness specification. For additional
information, refer to Specifications and Brake Disc Machining in this section.

Brake Calipers
Inspect the brake calipers for leaks, damage to seals and piston corrosion or binding.
If the brake caliper is leaking or otherwise damaged, install a new brake caliper. For
additional information, refer to Section 206-03 for front brake calipers or Section 206-04 for
rear brake calipers.

1.
Brake Caliper Guide Pins
The guide pins should slide with a reasonable amount of hand force. If the brake pads show taper
wear or the guide pins are difficult to move, carry out the following steps.
Disassemble the brake caliper guide pins and inspect the guide pins and guide pin bores for
wear, damage and corrosion. If bore is worn or damaged, replace the damaged component.

Use a wire brush, rolled-up sandpaper or emery cloth to remove all corrosion and foreign
material from the caliper guide pin bores. Clean any remaining foreign material from the
bores with brake parts cleaner and compressed air.

Assemble the caliper seals, boots and guide pins. Use an ample amount of the specified
grease to lubricate the bores and guide pins.

Inspect the brake pads. For additional information, refer to Brake Pads inspection in this
section.

1.
Brake Flexible Hoses and Tubes
NOTICE: Never use copper tubing. It is subject to fatigue, cracking and corrosion, which may result in
brake tube failure.
NOTE: Double-wall steel tubing is used throughout the brake hydraulic system. All brake tube fittings must
be correctly double flared to provide strong, leakproof connections. When bending tubing to fit the underbody
or rear axle contours, be careful not to kink or crack the tube.
Inspect brake tubes for corrosion, cracks, leaks or any other signs of damage.
If a section of the brake tube is damaged, the entire section must be installed with a new tube
of the same type, size, shape and length.

When installing the hydraulic brake tubing, hoses or connectors, tighten all connections to
specifications. After installation, bleed the brake system. For additional information, refer to
Brake System Bleeding in this section.

1.
Inspect the brake flexible hoses for cracks, leaks and swelling during brake application or any other
signs of damage.
Install a new brake flexible hose if the hose shows signs of softening, cracking or other
damage. For additional information, refer to Section 206-03 for the front brake flexible hose
or Section 206-04 for the rear brake flexible hose.

2.
Brake Master Cylinder
NOTE: During normal operation of the brake master cylinder, the fluid level in the brake master cylinder
reservoir will fall during brake application and rise during release. The returning brake fluid creates a slight
turbulence in the master cylinder reservoir. This is a normal condition and indicates that the compensator
ports are not clogged. Clogged compensator ports may cause the brakes to hang up or not fully release. The
net fluid level (such as after brake application and release) will remain unchanged. Fluid level will decrease
with pad wear.
NOTE: A trace of brake fluid will exist on the booster shell below the master cylinder mounting flange. This
results from the normal lubricating action of the master cylinder bore and seal.
Inspect the brake master cylinder for fluid leaks.
Install a new master cylinder or brake fluid reservoir if signs of excessive leaking are present.

To check for correct brake master cylinder operation, refer to Component Tests in this
section.

1.
Brake Booster (Non-Hybrid Vehicles)
Inspect the brake booster for excessive corrosion or damage. Inspect the vacuum hoses for leaks and
kinks.
Install a new brake booster if signs of excessive corrosion or damage is found. For additional

Repair or replace vacuum hoses as necessary.
To check for correct brake booster operation, refer to Component Tests in this section.
1.
Brake Booster (Hybrid Vehicles)
Inspect the brake booster for excessive corrosion or damage. Inspect the vacuum hoses for leaks and
kinks.
Install a new brake booster if signs of excessive corrosion or damage are found. For

Repair or replace vacuum hoses as necessary.
1.
Check all electrical connections by wiggling connectors and flexing the wire harnesses.
Repair the connectors, terminals or wire harnesses as necessary.
2.
Retrieve any ABS module DTCs. For additional information, refer to Section 206-09 . 3.
Information
Workshop Manual
Brake Disc Machining
NOTE: Do not use a bench lathe to machine the brake discs. Use an on-vehicle brake lathe only. Read the
entire operating manual and/or view the video shipped with the lathe before installing, operating or repairing
the lathe.
NOTE: An on-vehicle brake lathe with an automatic runout adjustment feature is preferred. However, if the
lathe is not self adjusting, the lathe oscillation must be adjusted using a dial indicator. The total indicated
runout target is 0.000 mm (0.000 i. The maximum indicated runout should be no more than 0.050 mm (0.002
in). If the runout adjustment (automatic or manual) is carried out correctly prior to machining, then the final
brake disc runout will be within specification and a runout measurement is not necessary after machining.
NOTE: Lateral runout and disc thickness variation measurements are not required because correct adjustment
of the on-vehicle brake lathe will make sure that these dimensions are within specification.
NOTICE: Do not allow the caliper to hang from the brake hose or damage to the hose may
occur.
Remove the bolts and position the brake caliper or brake caliper and anchor plate assembly aside, as
required.
Support the brake caliper using mechanic's wire.
2.
Install the hub adapter using:
four wheel nuts on a 4-stud wheel hub.
five wheel nuts on a 5-stud wheel hub.
six wheel nuts on a 6-stud wheel hub.
four wheel nuts on a 7- or 8-stud wheel hub.
five wheel nuts on a 10-stud wheel hub.
3.
Install the cutting lathe. 4.
If the lathe is not self adjusting, adjust the lathe oscillation using a dial indicator. The total indicated
runout target is 0.000 mm (0.000 in). The maximum indicated runout should be no more than 0.050
mm (0.002 in).
5.
Center the cutting head, adjust the cutting bits and install the chip deflector/silencer. 6.
NOTE: The depth of the cut should be between 0.10 and 0.40 mm (0.004 and 0.015 in). Lighter cuts
will cause the bit to heat up and wear faster. Heavier cuts will cause poor brake disc surface finish.
Machine the brake disc.
7.
Remove the lathe and the silencer. 8.
Remove the wheel nuts and hub adapter. 9.
Remove the metal shavings. 10.
Brake Disc Machining 3057
Measure the brake disc thickness.
If the measurement is below the minimum specification, install a new brake disc. For
additional information, refer to Section 206-03 for front disc brakes or Section 206-04 for rear
disc brakes.

11.
NOTE: It is not required to install new brake pads if friction material is within specifications. For
additional information, refer to Specifications in this section.
Position the brake caliper or brake caliper and anchor plate assembly.
Install the bolts.
For fastener torque specifications, refer to Section 206-03 for front disc brakes or Section
206-04 for rear disc brakes.

12.
Brake Disc Machining 3058
Information
Workshop Manual
Brake System Bleeding
Special Tool(s)
Material
Item Specification
(Canada)
WSS-M6C62-A or
WSS-M6C65-A1
Pressure Bleeding
WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation.
Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance.
NOTE: Due to the complexity of the fluid path within the hydraulic system, it is necessary to pressure bleed
the system.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new
components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected.
NOTE: Due to the complexity of the fluid path within the rear integral parking brake calipers, it is necessary
to press and release the parking brake during the bleed procedure.
NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any
components upstream of the HCU are installed new.
Brake System Bleeding 3059
All vehicles
Clean all the dirt from around the brake fluid reservoir cap and remove the cap. Fill the brake master
cylinder reservoir with clean, specified brake fluid.
1.
NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of
pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter.
Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose to
the fitting on the adapter.
2.
NOTE: Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding
operation.
Open the valve on the bleeder tank.
Apply 207-345 kPa (30-50 psi) to the brake system.
3.
Remove the RH rear bleeder cap and place a box-end wrench on the bleeder screw. Attach a rubber
drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially
filled with clean, specified brake fluid.
4.
Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten
the RH rear bleeder screw.
Press and release the parking brake 5 times.
Repeat until clear, bubble-free fluid comes out.
5.
Tighten the RH rear bleeder screw to specifications, refer to Specifications in this section. Remove
the rubber hose and install the bleeder screw cap.
6.
Repeat Steps 4 through 6 for the LH rear brake caliper. 7.
Remove the RH front bleeder cap and place a box-end wrench on the bleeder screw. Attach a rubber
drain tube to the RH front bleeder screw and submerge the free end of the tube in a container partially
8.
Loosen the RH front bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten
the RH front bleeder screw.
9.
Tighten the LH rear bleeder screw to specifications, refer to Specifications in this section. Remove the
rubber hose and install the bleeder screw cap.
10.
Repeat Steps 8 through 10 for the LH front brake caliper. 11.
Close the bleeder tank valve and release the pressure. Remove the tank hose from the adapter and
remove the adapter. Fill the reservoir with clean, specified brake fluid and install the reservoir cap.
12.
Hybrid vehicles
NOTE: On hybrid vehicles, the brake booster push rod has an elongated slot that attaches to the brake
pedal with a clevis pin. The elongated slot allows for a small amount of pedal travel (free play) to
occur without the brake pedal applying pressure on the booster push rod. When performing a bleed
procedure, it is important to push the pedal through the air gap, so that the clevis pin is contacting the
brake booster push rod. Except when required by the scan tool, the ignition key must remain off
during the bleed procedure to allow minimal force required to push through the gap.
With the ignition off, press the brake pedal through the gap to seat the clevis pin against the brake
booster push rod and then confirm the pedal is firm.
If the brake pedal is spongy (soft), repeat the Pressure Bleeding procedure to remove any
remaining air from the system.

13.
Non-hybrid vehicles
Apply the brakes several times to verify correct brake operation.
If the brake pedal is spongy (soft), repeat the Pressure Bleeding procedure to remove any
remaining air from the system.

14.
Hydraulic Control Unit (HCU) Bleeding
NOTE: When any part of the hydraulic system is disconnected for repair or installation of new components,
air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic
system after it is correctly connected.
All vehicles
Use the Pressure Bleeding procedure to bleed the system. For additional information, refer to Brake
System Bleeding in this section.
1.
Connect the scan tool and follow the ABS HCUHydraulic Control Unit (HCU) bleeding instructions. 2.
Repeat the Pressure Bleeding procedure to bleed the system. 3.
Hybrid vehicles
Following the scan tool instructions, carry out the Multi-Calibration Routine. 4.
Information
Workshop Manual
Component Bleeding
Special Tool(s)
Adjuster, Rear Caliper Piston
206-026 (T87P-2588-A)
Material
Item Specification
(Canada)
WSS-M6C62-A or
WSS-M6C65-A1
Master Cylinder
air can enter the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system
after it is correctly connected.
NOTE: When a new brake master cylinder has been installed, or the system is emptied or partially emptied, it
should be primed to prevent air from entering the system.
Disconnect the brake tubes from the master cylinder. 1.
Component Bleeding 3063
Install short brake tubes onto the primary and secondary ports with the ends submerged in the brake
master cylinder reservoir.
2.
Fill the brake master cylinder reservoir with clean, specified brake fluid. 3.
Have an assistant slowly pump the brake pedal until clear fluid flows from the brake tubes, without air
bubbles.
4.
Remove the short brake tubes and install the master cylinder brake tubes.
Tighten to specifications, refer to Specifications in this section.
5.
Bleed the brake system, refer to Brake System Bleeding in this section. 6.
Front Brake Caliper
NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was disconnected or
installed new.
Remove the brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach
a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially
1.
Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake
pedal.
2.
Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains
pressure on the brake pedal, tighten the bleeder screw.
Repeat until clear, bubble-free fluid comes out.
Refill the brake master cylinder reservoir as necessary.
3.
Tighten the bleeder screw to specifications, refer to Specifications in this section. Remove the rubber
hose and install the bleeder screw cap.
4.
Rear Brake Caliper
air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic
system after it is correctly connected. The hydraulic system can be bled manually or with pressure bleeding
equipment.
NOTE: Due to the complexity of the fluid path within the rear integral parking brake calipers, it may be
necessary to follow this procedure when new calipers are installed.
NOTE: This procedure is necessary only when installing a new rear brake caliper. To bleed the brake
system, refer to Brake System Bleeding in this section.
Remove the wheel and tire. For additional information, refer to Section 204-04 .
1.
Remove the 2 brake caliper guide pin bolts and position the brake caliper aside. 2.
Remove the outer brake pad. 3.
NOTE: Place a shop towel between the caliper and the brake disc.
Install the brake caliper using the 2 guide pin bolts.
4.
Slowly apply the brake pedal to extend the brake caliper piston outward. 5.
Remove the 2 guide pin bolts and position the brake caliper aside. 6.
Remove the brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach
a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially
7.
Loosen the brake caliper bleeder screw. 8.
Using the Rear Caliper Piston Adjuster, fully retract the brake caliper piston and tighten the bleeder
screw to specifications, refer to Specifications in this section.
9.
Repeat Steps 4 through 9 until clear, bubble free fluid comes out.
Refill the brake master cylinder reservoir as necessary.
Remove the rubber hose and install the bleeder screw cap.
10.
Remove the 2 guide pin bolts and the shop towel. 11.
Install the outer brake pad. 12.
Position the brake caliper and install the 2 guide pin bolts.
13.
SECTION 206-03: Front Disc Brake
Manual
Material
Fluid
PM-1-C (US);
CPM-1-C (Canada)
WSS-M6C62-A or
WSS-M6C65-A1
590-790 ml
(1.24-1.66 pt)
a
High Temperature
Nickel Anti-Seize
Lubricant
XL-2
- -
Metal Brake Parts
Cleaner
PM-4-A or PM-4-B
- -
a
Item Specification
Brake caliper flow bolt 25 18 -
Brake disc screws 20 - 177
Brake flexible hose bracket-to-body bolt 18 - 159
Brake flexible hose bracket-to-wheel knuckle bolt 23 17 -
Brake tube fitting 17 - 150
Manual
Front Disc Brake
The front brake disc system consists of the following components:
Brake pads
Brake caliper anchor plate
Brake caliper
Brake disc
Brake disc shield
Brake flexible hose
When mechanical force is applied by the driver to the brake pedal, the force is converted into hydraulic
pressure by the master cylinder. The hydraulic force is directed to the disc brake calipers and transferred to the
brake pads. The brake pads are then forced against the brake friction surfaces by the brake caliper pistons. The
friction of the brake pads on the brake disc causes the slowing of wheel rotation and the vehicle.
Front Disc Brake 3071
Manual
Front Disc Brake
Front Disc Brake 3072
Manual
REMOVAL AND
INSTALLATION
Brake Pads
Material
Item Specification
(Canada)
WSS-M6C62-A or
WSS-M6C65-A1
1 2L527 Brake caliper guide pin bolts (2 required) (part of kit)
2 - Brake pad retraction spring (2 required) (part of 2001)
3 - Brake pad slide (2 required) (part of 2001)
4 - Stainless steel shims (2 required) (part of 2001)
5 - Brake pad shims (2 required) (part of 2001)
6 2001 Brake pads (2 required)
7 - Brake pad slide clips (4 required) (part of 2001)
Removal
Brake Pads 3073
Check the brake fluid level in the brake master cylinder reservoir.
If required, remove the fluid until the brake master cylinder reservoir is half full.
1.
NOTICE: Do not pry in the caliper sight hole to retract the pistons as this can damage the
pistons and boots.
occur.
Remove the 2 brake caliper guide pin bolts and position the caliper aside.
3.
Remove the 2 brake pad retraction springs. 4.
Remove the brake pads, brake pad shims and stainless steel shims.
Inspect the brake pads and shims for wear or contamination.
5.
Remove the brake pad slides. 6.
Remove the 4 brake pad slide clips. 7.
Installation
Install the 4 brake pad slide clips. 1.
NOTICE: Protect the piston and boots when pushing the caliper piston into the caliper piston
bores or damage to components may occur.
NOTICE: Make sure that the caliper guide pin boots are fully seated or damage to the caliper
guide pin boots can occur.
If installing new brake pads, using a C-clamp and a worn brake, compress the disc brake caliper
pistons into the caliper.
2.
Install the brake pad slides. 3.
Apply the black grease (6E1-2L064-AA) that is supplied to the pad backing plate and shims in the
areas indicated.
Apply grease to the back of the brake pad. 1.
Apply grease to the inner piston side stainless steel shim. 2.
Apply grease to the outer stainless steel shim. 3.
4.
Brake Pads 3074
Apply the white grease (6E1-2L064-BA) that is supplied to the brake pad retainer clips as indicated. 5.
NOTE: LH inboard shim shown.
NOTE: The cut shim is directional and used on the inboard pad only. The cut is positioned toward the
leading side. Correct installation can be verified if the shim hole is positioned on the bottom side.
Install the brake pad shims and the stainless steel shims to the brake pads.
6.
Install the 2 brake pad retraction springs. 7.
NOTICE: The caliper guide pin boots must be seated correctly on the anchor plate or the guide
pins may become contaminated.
Inspect the guide pin boots and make sure they are seated on the anchor plate correctly. The boot has
a lip that fits under the edge of the anchor plate extension.
8.
Brake Pads 3075
NOTE: Make sure that the brake caliper hose does not become twisted.
Position the brake caliper and install the 2 guide pin bolts.
9.
Install the wheel and tire. For additional information, refer to Section 204-04 .
Apply brakes several times to verify correct brake operation.
11.
Brake Pads 3076
Manual
REMOVAL AND
INSTALLATION
Brake Caliper
Material
Item Specification
(Canada)
WSS-M6C62-A or
WSS-M6C65-A1
1 2L527 Brake caliper guide pin bolt (2 required) (part of
kit)
2 2M085 Brake caliper flow bolt
3 99562 Copper washers (2 required)
4 2078 Front brake hose
5 2B120 RH/ 2B121
LH
Brake caliper
6 2L126 Bleeder screw cap
Brake Caliper 3077
NOTE: The brake caliper and anchor plate are serviced together as a kit.
Remove the brake pads. For additional information, refer to Brake Pads in this section. 1.
Remove the brake caliper flow bolt and position the hose aside.
Discard the 2 copper washers.
2.
Remove the 2 brake caliper anchor plate bolts.
3.
NOTICE: The caliper guide pin boots must be seated correctly on the anchor plate or the guide
pins may become contaminated.
Inspect the guide pin boots and make sure they are seated on the anchor plate correctly. The boot has
a lip that fits under the edge of the anchor plate extension.
4.
NOTE: During installation, make sure that the brake caliper hose does not become twisted.
Install new copper washers.
Bleed the brake caliper. For additional information, refer to Component Bleeding in Section
206-00 .

5.
Brake Caliper 3078
Manual
REMOVAL AND
INSTALLATION
Brake Caliper Anchor Plate
NOTE: The brake caliper and anchor plate are serviced together as a kit.
For additional information, refer to Brake Caliper in this section.
Brake Caliper Anchor Plate 3079
Manual
REMOVAL AND
INSTALLATION
Brake Disc
Material
Item Specification
Lubricant
XL-2
-
(Canada)
-
1 W711241 Brake caliper anchor plate bolts (2 required)
2 2B292 Brake caliper and anchor plate assembly
3 W505741 Brake disc screws (2 required)
4 1032 Brake disc
occur.
Remove the brake caliper anchor plate bolts and position the brake caliper, pads and anchor plate
aside as an assembly.
To install, tighten the bolts to 90 Nm (66 lb-ft).
2.
Remove the 2 brake disc screws.
Tstall, tighten to 20 Nm (177 lb-in).
3.
Brake Disc 3080
Remove the brake disc. 4.
NOTE: During installation, make sure that the brake caliper hose does not become twisted.
NOTE: Make sure the brake disc-to-hub mounting surface is free of rust and foreign material before
applying anti-seize lubricant.
NOTE: Do not allow anti-seize to make contact with the wheel studs.
Using the specified brake cleaner, clean the mating surfaces.
Apply specified lubricant as shown.
5.
Brake Disc 3081
Manual
REMOVAL AND
INSTALLATION
Brake Flexible Hose
Material
Item Specification
(Canada)
WSS-M6C62-A or
WSS-M6C65-A1
1 - Brake tube fitting (part of 2263 RH/ 2264 LH)
2 W505263 Brake flexible hose bracket-to-body bolt
3 W500020 Brake flexible hose bracket-to-wheel knuckle bolt
4 2L122 Brake caliper flow bolt
5 2149 Copper washers (2 required)
6 2078 Brake flexible hose
Brake Flexible Hose 3082
brake fluid ispilled onto a painted or plastic surface, immediately wash the surface with water.
Remove the brake caliper flow bolt and discard the 2 copper washers.
1.
Disconnect the brake tube fitting from the brake flexible hose.
2.
Remove the brake flexible hose bracket-to-wheel knuckle bolt.
3.
Remove the brake flexible hose bracket-to-body bolt and the brake flexible hose.
To install, tighten bolt to 18 Nm (159 lb-in).
4.
Install new copper washers.
Bleed the brake caliper. For additional information, refer to Component Bleeding in Section
206-00 .

5.
SECTION 206-04: Rear Disc Brake
Manual
Material
Fluid
PM-1-C (US);
CPM-1-C (Canada)
WSS-M6C62-A or
WSS-M6C65-A1
590-790 ml
(1.24-1.66 pt)
a
High Temperature
Nickel Anti-Seize
Lubricant
XL-2
ESE-M12A4-A -
Metal Brake Parts
Cleaner
PM-4-A or PM-4-B
- -
a
Item Specification
Brake Disc
Brake Pad
Bleeder screw 8 - 71
Brake caliper flow bolt 25 18 -
Brake disc screws 20 - 177
Brake disc shield bolts 23 17 -
Brake tube fitting 17 - 150
Manual
Rear Disc Brake
The rear disc brake system consists of the following components:
Brake caliper anchor plate
Brake caliper
Brake disc
Brake flexible hose
Brake pads
When mechanical force is applied by the driver to the brake pedal, the force is converted into hydraulic
pressure by the master cylinder. The hydraulic force is directed to the disc brake calipers and transferred to the
brake pads. The brake pads are then forced against the brake friction surfaces by the brake caliper pistons. The
friction of the brake pads on the brake disc causes the slowing or stopping of wheel rotation and the vehicle.
Rear Disc Brake 3086
Manual
Rear Disc Brake
Rear Disc Brake 3087
Manual
REMOVAL AND
INSTALLATION
Brake Pads
Special Tool(s)
Adapter, Rear Brake Caliper Piston Adjuster
206-026 (T87P-2588-A) or equivalent
Material
Item Specification
(Canada)
WSS-M6C62-A or
WSS-M6C65-A1
1 2860 Parking brake cable conduit retaining clip
2 2A815 Parking brake cable
3 - Brake caliper guide pin bolts (part of 2386)
4 2552 LH/ 2553 RH Brake caliper
Brake Pads 3088
5 - Brake pad slide clip (2 required) (part of 2200)
6 - Brake pad shim (2 required) (part of 2200)
7 2200 Brake pad (2 required)
Removal
Check the brake fluid level in the brake master cylinder reservoir.
If required, remove the fluid until the brake master cylinder reservoir is 1/2 full.
1.
Disconnect the parking brake cable from the brake caliper.
Pull back the parking brake lever.
Disconnect the cable from the parking brake lever.
Remove the cable conduit retaining clip.
Disconnect the cable from the brake caliper.
3.
NOTICE: Do not pry in the caliper sight hole to retract the pistons, as this can damage the
pistons and boots.
occur.
Remove the 2 brake caliper guide pin bolts and position the caliper aside.
4.
Remove the 2 brake pads, shims and retraction clips. Inspect the brake pads and shims for wear,
damage or contamination.
Discard the slide clips.
Inspect the brake pads for wear and contamination.
5.
Installation
NOTE: Make sure the caliper piston boot is clean and free of foreign material.
Using the Rear Brake Caliper Piston Adjuster Adapter, compress the brake caliper piston into the
brake caliper bore.
1.
Brake Pads 3089
Position the notch in the caliper piston so that it will correctly align with the pin on the backside of the
inboard brake pad.
2.
NOTE: If installing new brake pads, install all new hardware as supplied with the brake pad kit.
Install the shims and slide clips to the brake caliper anchor plate.
3.
Apply equal amounts of lubricant (supplied with brake pad kit) to all brake pad-to-caliper anchor
plate contact points and install brake pads.
4.
NOTE: Make sure that the brake caliper hose is not twisted.
Position the brake caliper on the anchor plate and install the 2 bolts.
5.
Install the parking brake cable to the brake caliper.
Connect the cable to the parking brake lever.
Install the cable conduit retaining clip.
6.
Brake Pads 3090
Cycle the park brake several times to verify normal operation. For additional information on parking
brake adjustment, refer to Section 206-05 .
9.
Brake Pads 3091
Manual
REMOVAL AND
INSTALLATION
Brake Caliper
Material
Item Specification
(Canada)
WSS-M6C62-A or
WSS-M6C65-A1
3 2M085 Brake caliper flow bolt
4 99562 Copper washers
5 2282 Brake hose
6 - Brake caliper guide pin bolt (2 required) (part of
2386)
7 2552 LH/ 2553
RH
Brake caliper
Brake Caliper 3092
8 2426 Brake caliper bleeder screw cap
Removal
2.
Remove the brake caliper flow bolt and position the brake hose aside.
Discard the 2 copper washers.
3.
Remove the 2 brake caliper guide pin bolts and the brake caliper.
If a leaking or damaged caliper piston boot is found, install a new disc brake caliper.
4.
Installation
Position the notch in the caliper piston so that it will correctly align with the pin on the backside of the
inboard brake pad.
1.
Position the brake caliper onto the anchor plate.
2.
Install the 2 brake caliper guide pin bolts. 3.
Brake Caliper 3093
Using 2 new copper washers, position the brake hose and install the brake caliper flow bolt.
4.
5.
Bleed the brake caliper. For additional information, refer to Section 206-00 Component Bleeding. 6.
Cycle the park brake several times to verify normal operation. 7.
Brake Caliper 3094
Manual
REMOVAL AND
INSTALLATION
Brake Disc
Material
Item Specification
Lubricant
XL-2
ESE-M12A4-A
(Canada)
-
Item
Part
Number Description
4 - Brake caliper, brake pads and brake caliper anchor plate
assembly
5 W505741 Brake disc screw (2 required)
6 2C026 Brake disc
Brake Disc 3095
Removal
2.
occur.
Remove the 2 brake caliper anchor plate bolts and position the brake caliper, brake pads and brake
caliper anchor plate aside as an assembly.
Support the brake caliper, brake pads and brake caliper anchor plate assembly using
mechanic's wire.

3.
Remove the 2 brake disc screws and the brake disc. 4.
Installation
NOTE: Make sure the brake disc-to-hub mounting surface is free of rust and foreign material before
applying anti-seize lubricant.
Install the brake disc and the 2 brake disc screws.
Using the specified brake cleaner, clean the mating surfaces.
Apply specified lubricant as shown.
Tighten the screws to 20 Nm (177 lb-in).
1.
Position the brake caliper, brake pads and brake caliper anchor plate assembly and install the 2 brake
caliper anchor plate bolts.
2.
3.
Cycle the park brake several times to verify normal operation. 5.
Brake Disc 3096
Brake Disc 3097
Manual
REMOVAL AND
INSTALLATION
Brake Disc Shield - Front Wheel Drive (FWD)
1 N500020 Brake disc shield bolts (3 required)
2 2K045 RH/ 2K046 LH Brake disc shield
Remove the wheel bearing and wheel hub. For additional information, refer to Section 204-02 . 1.
Remove the 3 brake disc shield bolts and the brake disc shield.
2.
Brake Disc Shield - Front Wheel Drive (FWD) 3098
Brake Disc Shield - Front Wheel Drive (FWD) 3099
Manual
REMOVAL AND
INSTALLATION
Brake Disc Shield - All Wheel Drive (AWD)
Special Tool(s)
Remover/Installer, Front Subframe Bushing
204-362/2
1 2K005 LH/ 2K004 RH Brake disc shield
2 3K186 LH/ 3K185 RH Wheel knuckle
Removal
Remove the wheel bearing and wheel hub. For additional information, refer to Section 204-02 . 1.
Index-mark the brake disc shield to the wheel knuckle. 2.
Cut the brake disc shield and remove it from the wheel knuckle. 3.
Installation
Transfer the index mark from the removed brake disc shield to the new brake disc shield. 1.
Position the brake disc shield onto the wheel knuckle. 2.
Brake Disc Shield - All Wheel Drive (AWD) 3100
Align the index marks and install the brake disc shield onto the wheel knuckle using the Front
Subframe Bushing Remover/Installer.
3.
Brake Disc Shield - All Wheel Drive (AWD) 3101
Manual
REMOVAL AND
INSTALLATION
Brake Flexible Hose
Material
Item Specification
(Canada)
WSS-M6C62-A or
WSS-M6C65-A1
1 - Brake tube fitting (part of 2268 RH/ 9J279 LH)
2 2L198 Brake flexible hose retaining clip (part of 2282)
3 2L122 Brake caliper flow bolt
4 2149 Copper washers
5 2282 Brake flexible hose
move the wheel and tire. For additional information, refer to Section 204-04 . 1.
Remove the brake caliper flow bolt and discard the 2 copper washers.
2.
Disconnect the brake tube fitting from the brake flexible hose.
3.
Remove the brake flexible hose retaining clip and the brake hose. 4.
Bleed the brake caliper. For additional information, refer to Section 206-00 Component
Bleeding.

5.
SECTION 206-05: Parking Brake and Actuation
Workshop Manual
Catalytic converter-to-exhaust flexible pipe nut 40 30 -
Parking brake cable routing bracket bolts 23 17 -
Parking brake cable routing bracket nuts 9 - 80
Parking brake control bolt 20 - 177
Parking brake control nuts 20 - 177
SECTION 206-05: Parking Brake and Actuation
Workshop Manual
Parking Brake
The parking brake system consists of the following components:
Parking brake control
Parking brake warning indicator switch
Rear parking brake cable assembly
The parking brake system is a mechanical system that activates a self-adjusting brake system within the rear
brake caliper.
The parking brake system is cable-actuated and controlled by an independent, hand-operated parking brake
control. The parking brake control applies tension to rear brake pads through the front parking brake cable and
conduit and the LH and RH rear parking brake cables. The parking brake warning indicator is located in the
instrument cluster. It illuminates to signal the driver that the parking brake is applied or to signal a low brake
fluid condition. The warning indicator system is diagnosed in Section 413-01 .
Parking Brake 3105
SECTION 206-05: Parking Brake and
Actuation
Manual
Parking Brake
Parking Brake System
control that is not self adjusting. The parking brake system is actuated when the parking brake control is
pulled up. When the parking brake control is pulled, tension is applied to the front parking brake cable. This
tension pulls on both rear parking brake cables, which are attached to the brake caliper parking brake actuators
and apply the brake pads. When the parking brake release button is pressed and the brake control is released,
the return springs on the brake calipers and the parking brake control return the system to the released
position.
NOTE: Prior to carrying out any diagnosis, make sure the red brake warning indicator is functional. Refer to
Section 413-01 .
The first indication that something may be wrong in the brake system is a change in the feeling through the
parking brake control. The parking brake not holding on an incline or dragging after being released are also
indicators of system concerns.
Check the operation of the parking brake system with the vehicle on a hoist and the parking brake control
fully released. Check for any damaged cables and install new components as necessary. Carry out the brake
system diagnosis.
Mechanical
Front parking brake cable and
conduit

Parking brake equalizer
Rear brake calipers
Rear parking brake cables and
conduits

Parking Brake 3106
3.
If the cause is not visually evident, verify the symptom and GO to Symptom Chart . 4.
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test A: The Parking Brake Will Not Apply
Normal Operation
control that is not self adjusting. The parking brake system is actuated when the parking brake control is
pulled up. When the parking brake control is pulled, tension is applied to the front parking brake cable. This
tension pulls on both rear parking brake cables, which are attached to the brake caliper parking brake actuators
and apply the brake pads.
Parking brake cables
Rear brake calipers
PINPOINT TEST A: THE PARKING BRAKE WILL NOT APPLY
A1 CHECK THE PARKING BRAKE CONTROL
Apply the parking brake control.
Does the parking brake control move?
Yes
GO to A2 .
No
GO to A3 .
A2 CHECK FOR BROKEN CABLES
NOTE: Have an assistant apply and release the
parking brake control to help isolate disconnected
cables or cables that do not move.

Inspect the following items for damage and correct
connections:

Front cable
Equalizer
LH rear cable
RH rear cable
Yes
CONNECT the component(s) or INSTALL a
new parking brake component(s) as
necessary. TEST the system for normal
operation.
No
VERIFY that the rear pads are within
thickness specifications. REFER to
Specifications in Section 206-00 . If the rear
pads are OK, INSTALL new rear brake
Parking Brake System 3107
Rear brake caliper actuators
Is any damage found or are any components
disconnected?

calipers. REFER to Section 206-04 .
A3 ISOLATE THE PARKING BRAKE CONTROL
AND FRONT PARKING BRAKE CABLE
Remove the floor console rear access panel.
Loosen the parking brake adjustment nut and
disconnect the rear cables from the equalizer.

Apply the parking brake control.
Yes
GO to A4 .
No
INSTALL a new parking brake control.
REFER to Parking Brake Control in this
operation.
A4 ISOLATE THE REAR PARKING BRAKE
CABLES
Disconnect the LH and RH parking brake cables
from the brake calipers.

While holding the cable conduit, attempt to slide
the cable inside the conduit.

Does the cable slide freely inside the conduit?
Yes
INSTALL new rear brake calipers. REFER
to Section 206-04 . ADJUST the parking
brake cable. REFER to Parking Brake Cable
Adjustment in this section.
No
INSTALL a new rear brake cable(s). REFER
to Parking Brake Cable - Rear in this section.
Pinpoint Test B: The Parking Brake Will Not Release
Normal Operation
When the parking brake release button is pressed and the brake control is released, the return springs on the
brake calipers and the parking brake control return the system to the released position.
Parking brake cables
Parking brake rear wheel components
PINPOINT TEST A: THE PARKING BRAKE WILL NOT APPLY 3108
PINPOINT TEST B: THE PARKING BRAKE WILL NOT RELEASE
B1 CHECK THE PARKING BRAKE
CONTROL
Press the release button on the parking brake
control and release the handle.

Yes
GO to B2 .
No
INSTALL a new parking brake control. REFER
to Parking Brake Control in this section. TEST
B2 CHECK THE REAR PARKING BRAKE
CABLES
Loosen the parking brake adjustment nut and
disconnect the rear cables from the equalizer.

Disconnect the LH and RH parking brake
cables from the brake calipers.

While holding the rear cable conduit, attempt
to slide the rear cable inside the conduit.

Does the cable slide freely inside the
conduit?

Yes
INSTALL new rear brake calipers. REFER to
Section 206-04 . ADJUST the parking brake
cable. REFER to Parking Brake Cable
No
INSTALL new rear brake cable(s). REFER to
Parking Brake Cable - Rear in this section. TEST
PINPOINT TEST B: THE PARKING BRAKE WILL NOT RELEASE 3109
PINPOINT TEST B: THE PARKING BRAKE WILL NOT RELEASE 3110
Actuation
Workshop Manual
Parking Brake Cable Adjustment
NOTE: Do not pry at the floor console rear access panel with a screwdriver or damage to the panel
may occur.
1.
100-02 .
2.
NOTE: The dimension will vary depending on the amount of cable stretch. New cables require
cycling the parking brake control 5-10 times to remove the cable slack.
Adjust the parking brake adjustment nut as shown.
3.
Verify correct operation of the parking brake system.
At 2 clicks of the parking brake control, slight drag at the rear wheels should be present.
At 5 clicks of the parking brake control, no movement at the rear wheels should be present.
4.
Install the floor console rear access panel. 5.
Parking Brake Cable Adjustment 3111
Parking Brake Cable Adjustment 3112
Actuation
Workshop Manual
Parking Brake Warning Indicator Switch
NOTE: Parking brake control cover removed for clarity.
Item
Part
Number Description
1 - Parking brake warning indicator switch electrical
connector
2 - Parking brake warning indicator switch screw
3 - Parking brake warning indicator switch
Remove the floor console. For additional information, refer to Section 501-12 . 1.
Disconnect the parking brake warning indicator switch electrical connector. 2.
Remove the parking brake warning indicator switch screw. 3.
Remove the parking brake warning indicator switch. 4.
Parking Brake Warning Indicator Switch 3113
Parking Brake Warning Indicator Switch 3114
Actuation
Workshop Manual
Parking Brake Control
1 2A815 Rear parking brake cables
2 W520413 Parking brake control nut (2 required)
3 W706246 Parking brake control bolt
4 2780 Parking brake control
Make sure the parking brake control is in the released position. 2.
Disconnect the warning indicator switch electrical connector. 3.
Loosen the parking brake control adjusting nut. 4.
Remove the 2 parking brake control nuts.
5.
Remove the parking brake control bolt and the parking brake control.
6.
Adjust the parking brake cable. For additional information, refer to Parking Brake Cable

7.
Parking Brake Control 3115
Parking Brake Control 3116
Actuation
Workshop Manual
Parking Brake Cable - Rear
1 W505263 Parking brake cable routing bracket bolts (6
required)
2 2860 Parking brake cable routing clip (2 required)
3 2552 LH/ 2553
RH
Brake caliper
4 W705443 Catalytic converter-to-exhaust flexible pipe nut (2
required)
5 2A815 Rear parking brake cable assembly
6 5G203 Exhaust flexible pipe
7 9451 Gasket
8 W709729 Heat shield nut (6 required)
9 114B04 Heat shield
10 W707142 Parking brake cable routing bracket nuts (2
required)
NOTE: Do not use oil or grease-based lubricants on the isolators.
Parking Brake Cable - Rear 3117
Loosen the parking brake control adjusting nut. 2.
Disconnect the rear parking brake cables from the equalizer. 3.
100-02 .
4.
Support the muffler and tailpipe with a suitable jackstand. 5.
Separate the 2 muffler and tailpipe isolators from the vehicle. 6.
flexible pipe and the catalytic converter.
Discard the gasket.
To install, position a new gasket and tighten the new nuts to 40 Nm (30 lb-ft).
7.
Remove the heat shield.
Remove the 6 nuts, the 2 pin-type retainers and the heat shield.
8.
Remove the 2 parking brake cable routing bracket nuts.
9.
Remove the 6 parking brake cable routing bracket bolts.
10.
Remove the 2 parking brake cable routing clips. 11.
Disconnect the rear parking brake cables from the calipers and remove the cables. 12.
Adjust the parking brake cable. For additional information, refer to Parking Brake Cable

13.
SECTION 206-06: Hydraulic Brake Actuation
Workshop Manual
Material
Fluid
PM-1-C (US);
CPM-1-C (Canada)
WSS-M6C62-A or
WSS-M6C65-A1
590-790 ml
(1.24-1.66 pt)
a
a
Brake booster nuts
a
- - -
Brake fluid remote reservoir nuts 7 - 62
Brake fluid reservoir pin bolt 6 - 53
Brake master cylinder brake tube fittings (non-hybrid) 28 21 -
Brake master cylinder brake tube fittings (hybrid) 20 - 177
Brake master cylinder nuts 20 - 177
Brake pedal and bracket upper bolts 23 17 -
Brake pedal angle sensor screws 2 - 18
Brake pedal bracket bolts
a
- - -
Brake pressure control valve bolts 11 - 97
Brake pressure control valve brake tube fittings 20 - 177
Steering column opening trim panel reinforcement bolts 3 - 27
a
SECTION 206-06: Hydraulic Brake
Actuation
Manual
Hydraulic Brake Actuation
The hydraulic brake actuation system consists of the following components:
Brake pedal and bracket assembly
Brake tubes and hoses
Hydraulic Control Unit (HCU)
Pressure control valve (non-hybrid vehicles only)
The hydraulic brake system is diagonally split with the LH front and RH rear brakes on one circuit and the RH
front and LH rear brakes on the other circuit.
The brake pedal is connected to the power brake booster, which is connected to the brake master cylinder.
When the brake pedal is pressed, brake fluid is pushed from the master cylinder through the steel tubes, HCU ,
pressure control valve (non-hybrid vehicles only) and flexible hoses to the front brake calipers and rear wheel
cylinders. When the brake pedal is released, brake fluid pressure is relieved, returning the front and rear brake
components to the unapplied position.
Brake Pedal Assembly - Hybrid
Hybrid vehicles are equipped with a brake pedal assembly that utilizes driver input and electronic components
to apply the brakes. The brake booster push rod has an elongated slot that attaches to the brake pedal with a
clevis pin. The elongated slot allows for a small amount of pedal travel (freeplay) to occur without the brake
pedal applying pressure on the booster push rod. This freeplay allows regenerative braking to occur. To
compensate for the freeplay, the pedal assembly is equipped with a hydraulic brake pedal feel simulator that
provides the same feel and resistance as a conventional brake pedal. On light or normal brake applications,
sensors attached to the brake pedal assembly measure brake pedal angle and the amount of pressure applied to
the brake pedal. The sensors send signals to ABS module which activates a solenoid inside the brake booster.
The solenoid draws the booster push rod into the booster, applying pressure to the master cylinder piston
which then applies hydraulic pressure to the brake system. On hard brake applications, the brake pedal will
travel to the end of the elongated slot, eliminating the freeplay and physically engaging the booster push rod,
operating the brakes similar to a conventional brake actuation system.
Hydraulic Brake Actuation 3122
SECTION 206-06: Hydraulic Brake Actuation
Workshop Manual
Actuation
Manual
Brake Pedal and Bracket - Non-Hybrid
1 7B096 Brake booster push rod pin clip
2 2N513 Brake booster push rod pin
3 W505263 Brake pedal bracket bolt (2 required)
4 W520212 Brake pedal bracket nut (4 required)
5 2455 Brake pedal and bracket
NOTICE: Do not service the brake pedal or brake booster without first removing the stoplamp
switch. This switch must be removed with the brake pedal in the at-rest position. The switch
plunger must be compressed for the switch to rotate in the bracket. Attempting to remove the
switch when the plunger is extended (during pedal apply) will result in damage to the switch.
Remove the stoplamp switch. For additional information, refer to Section 417-01 .
1.
Remove the brake booster push rod pin clip. 2.
Remove the brake booster push rod pin. 3.
Remove the 2 brake pedal bracket bolts.
4.
NOTICE: Use only hand tools to remove the fasteners or damage to the booster may occur.
Remove the 4 brake pedal bracket nuts and the brake pedal and bracket assembly.
5.
Brake Pedal and Bracket - Non-Hybrid 3125
NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp
switch. This switch must be installed with the booster push rod attached to the brake pedal and
with the brake pedal in the at-rest position. Installing this switch with the brake pedal in any
other position will result in incorrect adjustment and may damage the switch.
6.
NOTICE: Use only hand tools to install the fasteners or damage to the booster may occur.
Tighten the brake pedal bracket nuts to 23 Nm (17 lb-ft) in the sequence shown.
7.
Brake Pedal and Bracket - Non-Hybrid 3126
Actuation
Manual
Brake Pedal and Bracket - Hybrid
Special Tool(s)
Item
Part
Number Description
1 2L523 Brake booster push rod clevis locking pin
2 - Brake pedal angle sensor electrical connector (part of
14290)
3 - Simulator cut off valve solenoid electrical connector
(part of 14290)
4 - Simulator fluid pressure sensor electrical connector
(part of 14290)
5 W520112 Brake booster nut (4 required)
6 W505263 Brake pedal and bracket upper bolts (2 required)
7 W505263 Brake pedal bracket bolt (2 required)
8 2455
9 2468 Brake pedal bracket
Remove the knee air bag module. For additional information, refer to Section 501-20B . 1.
Remove the 4 steering column opening trim panel reinforcement bolts and the steering column
opening trim panel reinforcement.
2.
Brake Pedal and Bracket - Hybrid 3127
NOTICE: Do not service the brake pedal without first removing the stoplamp switch. This
switch must be removed with the brake pedal in the at-rest position. The switch plunger must
be compressed for the switch to rotate in the bracket. Attempting to remove the switch when the
plunger is extended (during pedal apply) will result in damage to the switch.
3.
Remove the 3 lower steering column shroud screws and separate the lower steering column shroud
from the upper shroud.
4.
Disconnect the 3 electrical connectors from the brake pedal and bracket assembly. 5.
NOTE: The booster push rod clevis-locking pin is a one-time use only part. Any time the booster
push rod clevis-locking pin is removed, a new booster push rod clevis-locking pin should be used.
NOTE: Remove the clevis-locking pin by squeezing the locking tabs and pulling outward on the
opposite end.
Remove and discard the booster push rod clevis-locking pin.
6.
Remove the 2 brake pedal and bracket upper bolts.
7.
NOTICE: Use only hand tools to remove and install the fasteners or damage to the booster may
occur.
Remove and discard the 4 brake booster nuts.
To install, tighten new nuts to 23 Nm (17 lb-ft) following a clockwise pattern starting with the
lower left nut.

8.
From the engine compartment, pull the brake booster toward the front of the vehicle until the brake
booster studs are clear of the brake pedal bracket holes.
9.
10.
Carry out the Multi-Calibration Routine. Follow the scan tool directions. 11.
Actuation
Manual
Brake Master Cylinder
Material
Item Specification
(Canada)
WSS-M6C62-A or
WSS-M6C65-A1
NOTE: Non-hybrid vehicle shown, hybrid vehicle similar.
Item
Part
Number Description
1 2L364 Brake master cylinder nut (2 required)
2 2140 Brake master cylinder assembly
3 - Brake master cylinder brake tube fitting (2 required)
(part of 2C360)
4 2152 Brake master cylinder-to-brake booster seal
Brake Master Cylinder 3130
Remove the brake fluid reservoir. For additional information, refer to Brake Fluid Reservoir in this
section.
1.
If equipped with a manual transmission, disconnect the clutch master cylinder feed hose.
Plug the clutch master cylinder feed hose.
2.
Disconnect the brake master cylinder brake tube fittings, plug the brake tubes and the brake master
cylinder ports.
Non-hybrid vehicles: To install, tighten to 28 Nm (21 lb-ft).
Hybrid vehicles: To install, tighten to 20 Nm (177 lb-in).
3.
NOTICE: Use only hand tools to remove and install the fasteners or damage to the booster may
occur.
Remove the 2 brake master cylinder nuts.
4.
Remove the brake master cylinder. 5.
NOTICE: Do not allow the flexible portion of the brake tubes to twist during installation, or
damage to the brake tubes may occur.
Bleed the master cylinder. For additional information, refer to Section 206-00 .
If equipped with a manual transmission, bleed the clutch master cylinder. For additional

6.
Brake Master Cylinder 3131
Actuation
Manual
Brake Fluid Reservoir
Material
Item Specification
(Canada)
WSS-M6C62-A or
WSS-M6C65-A1
2.5L Non-Hybrid
Item
Part
Number Description
1 - Brake fluid level warning switch electrical connector
(part of 14290)
2 2B176 Brake fluid reservoir pin bolt
3 2L074 Brake fluid reservoir seal (2 required)
4 2C246 Brake fluid reservoir
2.5L Hybrid, 3.0L and 3.5L
Brake Fluid Reservoir 3132
Item
Part
Number Description
1 W520111 Brake fluid remote reservoir nuts (2 required)
2 2K478 Brake fluid remote reservoir
3 - Spring clamp (part of 2K478)
4 - Brake fluid reservoir hose (part of 2K478)
5 - Brake fluid level warning switch electrical connector
(part of 14290)
6 - Spring clamp (part of 2K478)
7 2B176 Brake fluid reservoir pin bolt
8 2K478 Brake fluid reservoir
9 2L074 Brake fluid reservoir seals (2 required)
All vehicles
Using a suitable suction device, remove the brake fluid from the remote reservoir. 1.
Disconnect the brake fluid level switch electrical connector. 2.
2.5 Hybrid, 3.0L and 3.5L vehicles
Remove the lower cowl panel grille. For additional information, refer to Section 501-02 . 3.
Disconnect the hose from the remote reservoir. 4.
2.5L Hybrid, 3.0L and 3.5L 3133
Disconnect the brake fluid level switch harness from the brake fluid reservoir. 5.
All vehicles
Remove the brake fluid reservoir pin bolt and the brake fluid reservoir.
6.
Remove and discard the 2 brake fluid reservoir seals. 7.
NOTE: Install new brake fluid reservoir seals. Lubricate the seals with clean, specified brake fluid.
Bleed the brake system. For additional information, refer to Section 206-00 .
If equipped with a manual transmission, bleed the clutch master cylinder. For additional

8.
2.5L Hybrid, 3.0L and 3.5L 3134
Actuation
Manual
Brake Pedal Angle Sensor
Special Tool(s)
Item
Part
Number Description
1 - Brake pedal angle sensor electrical connector (part of
14290)
2 - Brake pedal angle sensor screws (2 required) (part of
14F385A)
3 14F385A Brake pedal angle sensor
Remove the brake pedal bracket. For additional information, refer to Brake Pedal and Bracket -
Hybrid in this section.
1.
Remove and discard the 2 brake pedal angle sensor screws. 2.
Remove the brake pedal angle sensor. 3.
Install new brake pedal angle sensor screws.
4.
Carry out the Multi-Calibration Routine. Follow the scan tool directions. 5.
Brake Pedal Angle Sensor 3135
Brake Pedal Angle Sensor 3136
Actuation
Manual
Brake Pressure Control Valve
Material
Item Specification
(Canada)
WSS-M6C62-A or
WSS-M6C65-A1
Item
Part
Number Description
1 - Brake pressure control valve brake tube fittings (part of
9J279)
2 W711239 Brake pressure control valve bolts (2 required)
3 43900 Brake pressure control valve
All vehicles
With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 1.
Brake Pressure Control Valve 3137
100-02 .
Remove the RH fender splash shield. For additional information, refer to Section 501-02 . 2.
All vehicles
Remove the nut and the brake tube heat shield. 3.
Disconnect the brake pressure control valve brake tube fittings, plug the tubes and the ports on the
brake pressure control valve.
4.
Remove the 2 brake pressure control valve bolts and the brake pressure control valve.
5.
6.
SECTION 206-07: Power Brake Actuation
Workshop Manual
A/C compressor bolts 25 18 -
Auxiliary coolant pump bracket bolts 25 18 -
Brake booster nuts
a
- - -
Ground cable bolt 12 - 106
Motor Electronics Cooling System (MECS) coolant pump bolts 20 - 177
MECS expansion tank nut and bolt 12 - 106
PCM bracket nuts 11 - 97
Push rod jam nut 17 - 150
Remote brake fluid reservoir nuts 7 - 62
Transmission fluid level indicator tube op" align="center">8 - 71
Transmission selector lever cable bracket nuts 23 17 -
Vacuum pump bracket bolt 25 18 -
Vacuum pump bracket nut 25 18 -
a
SECTION 206-07: Power Brake
Actuation
Manual
Brake Booster
The power brake actuation system consists of the following components:
Brake booster
Brake booster check valve
Brake booster vacuum supply hose
Brake booster vacuum sensor
Brake booster travel sensor (hybrid vehicles)
Engine-mounted vacuum pump (hybrid vehicles)
Conventional brake booster
The brake booster uses engine vacuum from the intake manifold to create a partial vacuum inside the vacuum
booster on both sides of the diaphragm. When the brake pedal is pressed, the booster rod opens a valve,
allowing air to enter the booster on one side of the diaphragm while sealing off the opposite side. This
increases pressure on that side of the diaphragm so that it helps push the rod, which in turn pushes the piston
in the master cylinder. As the brake pedal is released, the valve seals off the outside air supply while opening
the vacuum valve. This restores vacuum to both sides of the diaphragm, allowing everything to return to its
original position. Vehicles with 3.0L All-Wheel Drive (AWD) and 3.5L engines are equipped with a vacuum
sensor. The ABS module uses the signals produced by the vacuum pressure sensor to verify that vacuum
maintained in the brake booster.
Active brake booster (hybrid vehicles)
The active brake booster uses vacuum supplied by an electric vacuum pump mounted on the engine when
engine vacuum is unavailable. The active brake booster is similar to a conventional brake booster but with the
addition of a brake booster (vacuum) solenoid, a brake booster travel sensor and a vacuum sensor. If it is
necessary to apply the friction brakes, the ABS module will send a Pulse Width Modulated (PWM) signal to
the brake booster solenoid that is proportional to the amount of brake torque requested. The booster solenoid
will open to allow vacuum to draw the booster diaphragm and push rod toward the master cylinder piston,
building hydraulic pressure. The vacuum sensor is used by the ABS module to monitor vacuum maintained
inside the brake booster. The brake booster travel sensor is used to monitor the performance of the brake
booster.
Brake Booster 3140
Active brake booster (hybrid vehicles) 3141
Actuation
Manual
Power Brake System
Power Brake System 3142
Actuation
Manual
Brake Booster - Exploded View
Brake Booster - Hybrid Vehicles
2 2L523 Booster rod clevis-locking pin
3 - Vacuum sensor electrical connector (part of 14290)
4 - Booster solenoid electrical connector (part of 14290)
5 - Booster travel sensor electrical connector (part of
14290)
6 2005 Brake booster
7 9C482 Vacuum supply tube
8 2M113 Brake booster travel sensor
9 2365 Brake booster vacuum sensor
10 N804795 PCM bracket nut (3 required)
Brake Booster - Non-Hybrid Vehicles
NOTE: 3.0L Front Wheel Drive (FWD) shown, 3.0L All-Wheel Drive (AWD) and 3.5L similar.
Brake Booster - Exploded View 3143
1 9C840 Vacuum hose/aspirator assembly
2 - Harness fastener (part of 14290)
3 N804795 PCM bracket nuts
5 2N513 Brake booster push rod pin
6 7B096 Brake booster push rod clip
8 2B022 Brake booster-to-cowl gasket
9 2B195 Brake booster with check valve
Vacuum Pump - Hybrid Vehicles
Brake Booster - Non-Hybrid Vehicles 3144
1 - Vacuum pump electrical connector
(part of 14A411)
2 W701626 A/C compressor bolt (2 required)
3
W500320
A/C compressor
bracket bolts
4 19D624 A/C compressor bracket
5 W500233 Vacuum pump bracket bolt
6 W520212 Vacuum pump bracket nut
7 2A451 Vacuum pump assembly
8 9C482 Vacuum hose
Vacuum Sensor - 3.0L All-Wheel Drive (AWD) and 3.5L Vehicles
Vacuum Pump - Hybrid Vehicles 3145
1 W520111 Remote brake fluid reservoir nut (2 required)
2 2K478 Remote brake fluid reservoir
3 - Vacuum sensor electrical connector (part of 14290)
4 2C444 Vacuum sensor
Vacuum Sensor - 3.0L All-Wheel Drive (AWD) and 3.5L Vehicles 3146
Actuation
Manual
Brake Booster - Hybrid
Special Tool(s)
Disconnect the 2 low-voltage electrical connectors. 1.
Remove the master cylinder. For additional information, refer to Section 206-06 . 2.
Remove the bolt and position the ground cable aside.
To install, tighten the bolt to 12 Nm (106 lb-in).
3.
Remove the PCM. For additional information, refer to Section 303-14D . 4.
Detach the wiring harness and brake tube routing retainers from the PCM bracket. 5.
Remove the 3 nuts and the PCM mounting bracket.
To install, tighten the nuts to 11 Nm (97 lb-in).
6.
Disconnect the vacuum hose/check valve assembly from the brake booster. 7.
Brake Booster - Hybrid 3147
Disconnect the vacuum sensor, booster solenoid and the booster travel sensor electrical connectors. 8.
NOTICE: Do not service the brake pedal or brake booster without first removing the stoplamp
switch. This switch must be removed with the brake pedal in the at-rest position. The switch
plunger must be compressed for the switch to rotate in the bracket. Attempting to remove the
switch when the plunger is extended (during pedal apply) will result in damage to the switch.
9.
NOTE: The booster push rod clevis-locking pin is a one-time-use only part. Any time the booster
push rod clevis-locking pin is removed, a new booster push rod clevis-locking pin must be used.
NOTE: Remove the clevis-locking pin by squeezing the locking tabs and pulling outward on the
opposite end.
Remove and discard the booster push rod clevis-locking pin.
10.
Remove and discard the 4 brake booster nuts and remove the brake booster.
To install, tighten the new nuts to 23 Nm (17 lb-ft) in a clockwise pattern, starting with the
lower left nut.

11.
12.
Following the scan tool instructions, carry out the Multi-Calibration Routine. 13.
Brake Booster - Hybrid 3148
Actuation
Manual
Brake Booster - Non-Hybrid
All vehicles
Remove the brake master cylinder. For additional information, refer to Section 206-06 . 1.
Remove the PCM. For additional information, refer to Section 303-14A or Section 303-14B . 2.
If equipped, remove the brake booster vacuum sensor. For additional information, refer to Brake
Booster Vacuum Sensor - Non-Hybrid in this section.
4.
Remove the bolt and position the ground cable aside.
To install, tighten the bolt to 12 Nm (106 lb-in).
5.
Disconnect the harness fastener and remove the 3 nuts and the PCM bracket.
6.
NOTICE: Make sure that the aspirator tube is routed correctly and that the clamps are
positioned so they do not make contact with surrounding components or damage to the tube
may occur.
Disconnect the vacuum hose/check valve assembly from the brake booster.
7.
Automatic transmission vehicles
NOTE: It is not necessary to remove the fluid level indicator tube from the transmission. The tube
can be positioned aside with only the bolt removed.
Remove the transmission fluid level indicator tube bolt and position the tube aside.
8.
All vehicles
Remove the brake booster push rod pin and clip and disconnect the push rod from the brake pedal. 9.
NOTICE: Use only hand tools to remove the fasteners or damage to the booster may occur.
Remove the 4 nuts and the brake booster
10.
Brake Booster - Non-Hybrid 3149
NOTICE: Prior to installation, make sure that the distance between the booster mating surface
and the push rod center point is as shown or reduced brake assist may occur.
Check for correct booster push rod distance and adjust as necessary.
Tighten the booster push rod jam nut to 17 Nm (150 lb-in).

11.
NOTICE: Use only hand tools to install the fasteners or damage to the booster may occur.
Tighten the brake booster nuts to 23 Nm (17 lb-ft) in the sequence shown.
12.
Brake Booster - Non-Hybrid 3150
Actuation
Manual
Brake Booster Travel Sensor - Hybrid
Special Tool(s)
Remove the Motor Electronics Cooling System (MECS) expansion tank nut and bolt, position the
tank aside.
To install, tighten the nut and bolt to 12 Nm (106 lb-in).
1.
Disconnect the brake booster travel sensor electrical connector. 2.
Release the brake booster travel sensor retainer ring and remove the travel sensor. 3.
Following the scan tool instructions, carry oue Multi-Calibration Routine. 5.
Brake Booster Travel Sensor - Hybrid 3151
Brake Booster Travel Sensor - Hybrid 3152
Actuation
Manual
Brake Booster Vacuum Sensor - Hybrid
Special Tool(s)
Remove the Motor Electronics Cooling System (MECS) expansion tank nut and bolt, position the
tank aside.
To install, tighten the nut and bolt to 12 Nm (106 lb-in).
1.
Disconnect the brake booster vacuum sensor electrical connector. 2.
Release the brake booster vacuum sensor retainer ring and remove the vacuum sensor. 3.
Following the scan tool instructions, carry oue Multi-Calibration Routine. 5.
Brake Booster Vacuum Sensor - Hybrid 3153
Brake Booster Vacuum Sensor - Hybrid 3154
Actuation
Manual
Brake Booster Vacuum Sensor - Non-Hybrid
Remove the battery. For additional information, refer to Section 414-01 . 1.
Remove the 2 brake fluid remote reservoir nuts and position the reservoir aside.
2.
Disconnect the vacuum sensor electrical connector and remove the vacuum sensor. 3.
Brake Booster Vacuum Sensor - Non-Hybrid 3155
Actuation
Manual
Brake Vacuum Pump
100-02 .
1.
Detach the 3 wiring harness retainers from the subframe. 2.
Disconnect the electrical connector and the selector lever cable.
Detach the harness retainer and position harness aside.
3.
Remove the 2 transmission selector lever cable bracket nuts and position cable and bracket aside.
To install, tighten the nuts to 23 Nm (17 lb-ft).
4.
Remove the Motor Electronics Cooling System (MECS) coolant pump bolts and position the pump
aside.
To install, tighten the bolts to 20 Nm (177 lb-in).
5.
Remove the 2 lower A/C compressor bolts.
6.
Brake Vacuum Pump 3156
Remove the 2 A/C compressor bracket bolts and the bracket.
7.
Remove the 3 auxiliary coolant pump bracket bolts and position the auxiliary coolant pump aside.
8.
Disconnect the vacuum pump electrical connector. 9.
Remove the vacuum pump bracket nut.
10.
Remove the vacuum pump bracket bolt.
Position the vacuum pump to release the clamp, detach the vacuum hose and remove the
vacuum pump.

11.
SECTION 206-09: Anti-Lock Brake System (ABS) and
Stability Control
Material
Fluid
PM-1-C (US);
CPM-1-C (Canada)
WSS-M6C62-A or
WSS-M6C65-A1
590-790 ml
(1.24-1.67 pt)
a
a
ABS module screws - Hybrid
a
- - -
ABS module screws - Non-hybrid 2 - 18
Degas bottle hose nut 20 177 -
Front brake tube fittings - Hybrid 20 - 177
Front brake tube fittings - Non-hybrid 20 - 177
Front wheel speed sensor bolt 23 17 -
Front wheel speed sensor harness bracket-to-body bolt 7 - 62
Hydraulic Control Unit (HCU) bracket bolts 23 17 -
HCU bracket-to-frame bolt 23 17 -
HCU bracket-to-frame nut 23 17 -
HCU bracket-to-frame stud bolt 23 17 -
HCU bracket-to- HCU bolt 9 - 80
Master cylinder brake tube fittings - Hybrid 20 - 177
Master cylinder brake tube fittings - Non-hybrid 27 20 -
Rear brake tube fittings - Hybrid 20 - 177
Rear brake tube fittings - Non-hybrid 20 - 177
Rear wheel speed sensor bolt 23 17
Rear wheel speed sensor harness bolt - All-Wheel Drive (AWD) 23 17 -
Rear wheel speed sensor harness nut - AWD 23 17 -
Windshield washer reservoir filler neck bolt 7 62 -
a
SECTION 206-09: Anti-Lock Brake System (ABS)
and Stability Control
Workshop Manual
Anti-Lock Control
ABS with AdvanceTrac Stability Enhancement System
The ABS with AdvanceTrac system coists of the following components:
ABS module - attached to the Hydraulic Control Unit (HCU), but can be serviced separately from the
HCU .

Front wheel speed sensors - one sensor is located in each front wheel knuckle. The sensors are
serviced separately from the knuckle.

Front wheel speed sensor tone rings - one tone ring is located on the outer CV joint of each halfshaft
and is serviced with the halfshaft.

HCU - which contains several valves (inlet, outlet, isolation and dump) and the hydraulic pump
motor. On hybrid vehicles, the HCU is mounted in the rear, RH side of the engine compartment near
the RH shock tower. On all other vehicles, the HCU is mounted in the front, RH side of the engine
compartment near the degas bottle.

Rear wheel speed sensors - one sensor is located in each rear wheel knuckle, the sensors are serviced
separately from the knuckle).

Rear wheel speed sensor tone rings - on All-Wheel Drive (AWD) vehicles, one tone ring is located on
the outer CV joint of each halfshaft and is serviced with the halfshaft. On Front Wheel Drive (FWD)
vehicles, one tone ring is located on each rear wheel hub and is serviced with the wheel hub.

Stability control sensors - located inside the Restraints Control Module (RCM) and consist of the
following sensors: yaw rate, lateral accelerometer and longitudinal accelerometer. The sensors are
integral to the RCM and cannot be serviced separately.

Steering wheel rotation sensor - only on vehicles equipped with a 3.5L engine, the rotation sensor is
located on the RH side of the clockspring and is serviced separately from the clockspring assembly.
On all other vehicles, steering wheel rotation position information is sent from the Power Steering
Control Module (PSCM) over the High Speed Controller Area Network (HS-CAN).

Steering wheel rotation sensor ring - only on vehicles equipped with a 3.5L engine, the rotation sensor
ring is located on the clockspring and is serviced with the clockspring assembly.

Traction control switch - on Fusion and Milan vehicles, the switch is part of a 2 or 3 switch package
(depending on vehicle options) located in the instrument panel center finish panel and is serviced
separately from the finish panel. On MKZ vehicles, the switch is part of the Front Controls Interface
Module (FCIM) and is serviced with the module.

Vacuum sensor (3.0L AWD , 3.5L and hybrid) - located on the front of the brake booster in the 12
o'clock position on non-hybrid vehicles, and in the 10 o'clock position on hybrid vehicles. The sensor
can be serviced separately from the booster, refer to Section 206-07 .

Anti-Lock Braking
The anti-lock braking system aids in the prevention of wheel lock-up during braking events which allows the
driver to maintain control and stop in the shortest distance possible under most conditions. This is
accomplished by the ABS module and HCU modulating brake fluid pressure to the affected brake caliper(s).
When the ABS activates, both of the following can occur:
A rumble or grinding sound may be heard
If the driver's foot is on the brake pedal, a vibration may be felt in the brake pedal
Anti-Lock Control 3160
Electronic Brake Distribution (EBD)
The ABS module and HCU incorporate a strategy called Electronic Brake Distribution (EBD). The EBD
strategy uses the HCU as an electronic proportioning valve to create a balanced braking condition between the
front and rear wheels and minimize the chance of rear wheel lockup during hard braking.
AdvanceTrac Stability Enhancement System
The AdvanceTrac system is made up of 2 distinct vehicle systems: traction control and ESC .
Traction Control System
The traction control system aids in the prevention of excessive wheel spin which allows the vehicle to
maintain traction during acceleration. This is accomplished by the ABS module and the HCU modulating
brake fluid pressure to the affected brake caliper(s) and by the PCM modulating engine torque.
ESC System
The ESC system constantly monitors the vehicle's direction of travel relative to the driver's intended course,
except when the vehicle is traveling in reverse, and aids in keeping the vehicle traveling along that course.
This is accomplished by the ABS module and the HCU modulating brake fluid pressure to the affected brake
caliper(s) and by the PCM modulating engine torque.
When the ABS, traction control or ESC system activates, any of the following can occur:
A rumble or grinding sound may be heard, much like ABS
If the driver's foot is on the brake pedal, a vibration may be felt in the brake pedal, much like ABS
A small deceleration or a reduction in the acceleration of the vehicle
The stability/traction control indicator (also known as the sliding car icon) flashes
Traction Control Switch
The traction control switch can be used by the driver to disable and enable the traction control portion of the
AdvanceTrac system. When the switch is pressed, the sliding car OFF icon in the Instrument Panel Cluster
(IPC) illuminates The conventional ABS and the ESC system cannot be disabled through the use of the
traction control switch. If a MyKeyTM restricted key is in use with AdvanceTrac always-on feature
configured to "on", the traction control system cannot be disabled. An admin key must be used in order to
enable and disable the traction control system.
Stability/Traction Control Indicators
There are 2 separate sliding car icons; the sliding car OFF icon and the sliding car icon. The sliding car OFF
icon is used to alert the driver that the traction control portion of the AdvanceTrac system has been disabled
by the driver. This icon only illuminates continuously and does not flash. The sliding car icon is used to alert
the driver that a stability/traction event is taking place (flashes twice per second) and to alert the driver of
potential concerns in the AdvanceTrac system (illuminates solidly).
Optimized Hydraulic Braking (3.0L All-Wheel Drive (AWD) and 3.5L only)
Traction Control System 3161
Optimized hydraulic braking is a system built into the ABS module to aid in bringing the vehicle to a safe,
controlled stop in the event of severe vacuum loss at the brake booster. The ABS module continually monitors
the vacuum in the brake booster through the use of a sensor. If a loss of vacuum is detected, the ABS module
activates the pump motor in the HCU to assist with vehicle braking.
Hybrid Braking System
The hybrid vehicle is equipped with a few additional components, including:
Active brake booster - which includes the booster vacuum sensor, the active brake booster solenoid
and the active brake booster travel sensor. The sensors are serviced separately from the active brake
booster. The booster solenoid is not serviced separately from the active brake booster.

Brake pedal angle sensor - located on the brake pedal bracket and can be serviced separately from the
pedal bracket.

Brake pedal feel cut-off solenoid - located on the brake pedal bracket and is serviced with the pedal
bracket.

Brake pedal feel simulator - located on the brake pedal bracket and is serviced with the pedal bracket.
Electric vacuum pump - located in the front of the engine compartment below the intake manifold.
Vacuum pump relays - vacuum pump operation is controlled by 1 solid state relay and 1 mechanical
relay. Both relays are located in the auxiliary relay box.

Regenerative Braking
During a braking event (not an ABS or other stability control event), the regenerative braking system utilizes
the electric motor portion of the Electronically Controlled Continuously Variable Transmission (eCVT) as a
generator to create electrical current. This current is used to recharge the High Voltage Traction Battery
(HVTB) and creates brake torque that is used in place of, or in combination with, the conventional friction
brakes to slow the vehicle. The amount of brake torque provided by the electric motor is dependent upon the
state-of-charge of the HVTB . When the HVTB is almost fully charged, the amount of brake torque provided
is limited to avoid overcharging the HVTB and vehicle deceleration is produced by conventional friction
braking alone.
Brake-By-Wire
Because much of the necessary brake torque required to stop the vehicle can be accomplished through
regenerative braking, it is not always necessary to apply the conventional friction brakes. Under most normal
brake applications, the ABS module applies the friction brakes as needed.
During a normal brake application, the brake pedal feel simulator allows the pressure applied to the brake
pedal by the driver's foot to act against a spring instead of the brake booster push rod. The brake pedal angle
sensor is mounted to the brake pedal assembly and provides the ABS module with an analog signal indicating
the amount of deceleration the driver is demanding. If it is necessary for the conventional friction brakes to be
applied, the ABS module applies a Pulse Width Modulated (PWM) voltage to a solenoid inside the active
brake booster. The solenoid allows vacuum from either the combustion engine (if the engine is running) or the
electric vacuum pump to move the booster push rod. This in turn pushes the piston in the master cylinder
creating hydraulic brake pressure. If the brake pedal is applied quickly and forcefully enough, the driver can
overcome the brake pedal feel simulator spring pressure, allowing a direct connection between the brake
pedal, booster push rod and master cylinder.
ESC System 3162
ESC System 3163
Workshop Manual
Anti-Lock Control - Non-Hybrid
Special Tool(s)
Flex Probe Kit
Rotunda Active Wheel Speed Sensor Tester
Principles of Operations
Anti-Lock Braking
The ABS module continuously monitors and compares the rotational speed of each wheel. This is
accomplished through the use of 4 active wheel speed sensors, 1 for each wheel. The wheel speed sensors are
connected to the ABS module by 2 circuits. One circuit provides voltage for sensor operation and the other
circuit provides sensor input to the ABS module. As the wheels spin, the wheel speed sensor tone rings pass
through the magnetic field generated by the active wheel speed sensor. This creates a square-wave signal that
is sent to the ABS module to indicate individual wheel speed.
The ABS module uses a Hydraulic Control Unit (HCU) to prevent the wheels from locking up during a
braking event. The HCU contains several solenoid-controlled valves, a pump motor, an accumulator and
several sensors. The fluid flows through 4 normally open inlet valves inside the HCU , and through the outlet
ports of the HCU to the brake calipers. If the ABS module senses that a wheel is about to lock up, based on
wheel speed sensor data, the module closes the normally open inlet valve for that wheel. This prevents more
fluid from getting to the brake caliper. The ABS module then reads the wheel speed sensor signal from the
affected wheel again. If the wheel is still decelerating (locking up), the module opens the normally closed
outlet valve. This allows a controlled amount of hydraulic pressure in the brake caliper to be relieved into the
HCU accumulator. The ABS pump motor runs during an ABS braking event so that sufficient brake fluid
pressure is consistently available to the HCU valves. This procedure of closing and opening valves is repeated
several times per second until the speed of the affected wheel matches the speeds of the other wheels. Once
this has been accomplished, the ABS module returns the solenoid valves to their normal position.
The ABS module is self-monitoring. When the ignition switch is turned to the RUN position, the ABS module
carries out a preliminary electrical check of the wheel speed sensor circuitry by sending voltage through the
sensor and checking for the voltage to return. At speeds above 15 km/h (9 mph), without the brake pedal
being pressed, the pump motor is commanded ON for approximately one-half second to check pump motor
Anti-Lock Control - Non-Hybrid 3164
operation. Also, during all phases of operation while the vehicle is in motion, the ABS module checks for
correct operation of the wheel speed sensors. In the event that the ABS module detects a concern, the module
sets a DTC and sends a message to the Instrument Panel Cluster (IPC) over the High Speed Controller Area
Network (HS-CAN) bus to illuminate the yellow ABS warning indicator, the stability/traction control
indicator (also known as the sliding-car icon) and/or the red brake warning indicator. If the concern is severe
enough, ABS may be disabled. Normal power-assisted braking, however, remains.
The ABS module incorporates a strategy called Electronic Brake Distribution (EBD). The EBD strategy uses
the HCU as an electronic proportioning valve. On initial application of the brake pedal, full pressure is applied
to the rear brakes. The ABS module uses wheel speed input to calculate an estimated rate of deceleration.
Once vehicle deceleration exceeds a certain threshold, the ABS module closes the appropriate solenoid valves
in the HCU to hold the rear brake pressure constant while allowing the front brake pressure to build. This
creates a balanced braking condition between the front and rear wheels and minimizes the chance of rear
wheel lockup during hard braking. As the vehicle decelerates, the valves are opened to increase the rear brake
pressure in proportion to the front brake pressure.
If there is a DTC in the ABS module specifically for the HCU or there are 2 or more wheel speed sensor
DTCs, EBD is disabled. When EBD is disabled, the ABS warning indicator, the red brake warning indicator
and the sliding-car icon illuminates.
Optimized Hydraulic Braking (3.0L All-Wheel Drive (AWD) and 3.5L only)
When the vacuum sensor in the booster indicates vacuum is below a predetermined level, a DTC is set in the
ABS module. A low vacuum DTC is set after a pre-determined time, depending on driving conditions. It
could take as long as 10 minutes to set the DTC with vehicle speed above 2 km/h and greater than 30%
throttle. If the brake pedal is applied with low vacuum in the booster, the ABS module activates the pump
motor in the HCU to assist with braking.
Refer to Section 206-07 for sensor removal and installation information.
The AdvanceTrac system provides the following stability enhancement features for certain driving
situations:
Traction Control System - helps to avoid excessive drive-wheel spin and loss of traction.
Electronic Stability Control (ESC) System - helps to avoid skids and lateral slides.
The traction control system uses the ABS and the PCM to limit wheel spin. When the ABS module detects a
wheel spinning excessively, brake pressure to the appropriate brake caliper is modulated. This is
accomplished by opening and closing the appropriate solenoid valves inside the HCU while the hydraulic
pump motor is activated. At the same time, the ABS module sends a message over the bus that a traction
control event is taking place. When the IPC receives this message, it flashes the sliding-car icon (twice per
second). If the event is severe enough, the ABS module also sends a message to the PCM over the HS-CAN
bus to assist with traction control. When the PCM receives this message, it adjusts engine timing and decrease
fuel injector pulses. Once the affected wheel returns to normal speed, the ABS module returns the solenoid
valves in the HCU to their normal position, deactivates the hydraulic pump motor and sends another message
over the HS-CAN bus indicating that the traction event has ended. The PCM returns engine timing and fuel
Traction Control System 3165
injectors to normal operation and the IPC extinguishes the sliding-car icon.
Once vehicle speed reaches or exceeds 100 km/h (62 mph), traction control is accomplished only through
PCM intervention.
Certain DTCs in the ABS module disables the traction control system. Depending on the DTCs present, the
yellow ABS warning indicator and/or the sliding-car icon is illuminated.
Electronic Stability Control (ESC) System
The ESC system is controlled by the ABS module and uses the same wheel speed sensors and tone rings that
are used for anti-lock braking. The ESC system also uses input from the steering wheel rotation sensor (3.5L)
or Power Steering Control Module (PSCM) (2.5L, 3.0L and Hybrid), and the stability control sensors (yaw
rate, longitudinal acceleration and lateral acceleration), which are internal to the Restraints Control Module
(RCM). Additional information from other modules is sent over the HS-CAN bus to help maintain vehicle
stability.
The ABS module uses the various sensors to continuously monitor vehicle direction of travel relative to the
driver's intended course. If the ABS module determines from all these inputs that the vehicle is unable to
travel in the intended direction, it modulates brake pressure to the appropriate brake caliper(s) by opening and
closing the appropriate solenoid valves inside the HCU while the hydraulic pump motor is activated. At the
same time, the ABS module sends a message over the HS-CAN bus that a stability event is taking place.
When the IPC receives this message, it flashes the sliding-car icon. Under certain conditions during a stability
event, the PCM may be requested to reduce engine torque as it does for traction control. Once the stability
condition has been corrected, the ABS module sends another message over the HS-CAN bus indicating that
the event has ended. The PCM returns engine timing and fuel injectors to normal operation and the IPC
extinguishes the sliding-car icon.
Certain DTCs being present in the ABS module may disable the ESC system. Depending on the DTCs
present, the yellow ABS warning indicator and/or the sliding-car icon is illuminated.
Unlike conventional ABS, the traction control portion of the AdvanceTrac can be deactivated by the driver
through the use of the traction control switch. The switch is hardwired to the IPC . When pressed, the switch
sends a ground signal to the IPC . The IPC then sends a message over the HS-CAN bus indicating that the
driver has requested that the system be deactivated and illuminates the sliding-car OFF icon. One disabled, the
system remains in that state until the driver presses the switch again or the ignition key is cycled.
Stability Control Sensors
The stability control sensors for the AdvanceTrac system consist of the yaw rate sensor, lateral
accelerometer and longitudinal accelerometer. The sensors are housed in the RCM which sends sensor
information to the ABS module over the dedicated Controller Area Network (CAN) bus. If any of the sensors
are defective, a new RCM must be installed. Refer to Section 501-20B for additional information on the RCM
.
The yaw rate sensor measures the relative vehicle motion about the vertical axis through the vehicle
center of gravity.

The longitudinal accelerometer measures the acceleration corresponding to the force involved when
the vehicle moves forward and rearward in the horizontal plane, along the centerline of the vehicle's
front and rear wheels.

Electronic Stability Control (ESC) System 3166
The lateral accelerometer measures the acceleration that corresponds to the force involved when the
vehicle moves sideways.

Lateral acceleration has 2 forms. The first is the centrifugal acceleration that is generated when the
vehicletravels around in a circle. The second is the acceleration due to gravity. On level ground there is no
contribution from this acceleration. However, if the vehicle is parked sideways on a bank or incline, the sensor
measures some lateral acceleration due to gravity, even though the vehicle is not moving.
Steering Wheel Position Information
On vehicles equipped with Electronic Power Assist Steering (EPAS) (2.5L, 3.0L and Hybrid vehicles), the
steering wheel position information is sent to the ABS module from the PSCM along the HS-CAN bus. The
PSCM calculates steering position based on motor position within the EPAS steer gear. For information on
EPAS , refer to Section 211-00A .
On vehicles equipped with Hydraulic Power Assist Steering (HPAS) (3.5L vehicles only), the steering wheel
rotation information is sent from the steering wheel rotation sensor. The steering wheel rotation sensor
measures the rate of rotation of the steering wheel by monitoring the steering wheel rotation ring as it passes
through the sensor gap. The rotation sensor uses 2 signal lines to transmit information to the ABS module
about whether the steering wheel is being turned left or right and how far it is being turned. The rotation
sensor does not indicate the position of the steering wheel relative to straight-ahead. The ESC system learns
this position by comparing the steering wheel position with other signals and storing the position it has
learned. The ESC system confirms this position and modifies it as necessary during every new driving cycle.
ABS Module Configuration
Module configuration is a scan tool process which configures specific vehicle settings in a new module. If
installing a new ABS module and/or a new HCU , the ABS module must be configured. To configure the
ABS module, refer to Programmable Module Installation (PMI) in Section 418-01 .
ABS Module Calibration
Non-hybrid vehicles do not require a module calibration. For module calibration information for hybrid
vehicles, refer to ABS Module Calibration in Anti-Lock Control - Hybrid in this section.
Verify the stoplamps operate correctly by pressing and releasing the brake pedal with the ignition
switch in the ON position. If the stoplamps do not operate correctly, refer to Section 417-01 . If the
stoplamps operate correctly, proceed to the next step.
2.
Base brake system
Incorrectly inflated tires
Mismatched wheels or tires on
vehicle

Steering wheel rotation sensor
ring

Wheel speed sensor tone ring
ABS module
8 (40A)
10 (30A)

Electronic Power Assist Steering (EPAS) gear (2.5L and
3.0L only)

Restraints Control Modu (RCM)
Stoplamp switch
Traction control switch
Steering wheel rotation sensor (3.5L only)
Vacuum sensor (2.5L and 3.0L only)
Wheel speed sensors
4.
5.
6.
7.
418-00 .

(CMDTCs).

8.
Clear the CMDTCs and carry out the self-test diagnostics for the ABS module. 9.
If the DTCs retrieved are related to the concern, go to the ABS Module DTC Chart. For all other
DTCs, refer to Section 419-10 .
10.
DTC Charts
NOTE: This DTC chart applies to non-hybrid vehicles only . For hybrid vehicle DTCs, refer to the ABS
Module DTC Chart in Anti-Lock Control - Hybrid in this section.
ABS Module DTC Chart
DTCs Description Action
B1342 ECU is Faulted CLEAR the DTCs. CYCLE the ignition switch. REPEAT the self-test.
RETRIEVE the DTCs.
If other DTCs are retrieved, ADDRESS those DTCs before addressing DTC
B1342.
If only DTC B1342 is returns, INSTALL a new ABS module. REFER to
Anti-Lock Brake System (ABS) Module in this section.
B83 Brake Pedal Input
Open Circuit
B1676 Battery Pack Voltage
Out of Range
B2477 Module Configuration
Failure
CLEAR the DTCs. REPEAT the self-test. If DTC B2477 is retrieved again,
INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS)
Module in this section. REPEAT the self-test.
B2900 VIN Mismatch NOTE: This DTC is usually set when a new ABS module is installed.
C1095 ABS Hydraulic Pump
Motor Circuit Failure
C109D Low Vacuum
Condition
C109E Vacuum Sensor
Circuit Fault
C109F Vacuum Sensor
Signal Fault
C1145 Wheel Speed Sensor
RF Input Circuit
Failure
LF Input Circuit
Failure
RR Input Circuit
Failure
LR Input Circuit
Failure
C1233 Wheel Speed LF
Signal Fault
C1234 Wheel Speed RF
Signal Fault
C1235 Wheel Speed RR
Signal Fault
C1236 Wheel Speed LR
Signal Fault
C1277 Steering Wheel Angle
1 and 2 Circuit Failure
C1278 Steering Wheel Angle
1 and 2 Signal Faulted
C1280 Yaw Rate Sensor
Signal Fault
NOTE: The yaw rate sensor is integral to the Restraints Control Module
(RCM) and cannot be serviced separately. If a new yaw rate sensor is needed,
a new RCM must be installed.
REFER to Restraints Control Module (RCM) Removal and Installation in
Section 501-20B . ADHERE to all safety warnings in the procedure.
INSPECT the RCM for damage. VERIFY that all RCM fasteners are
tightened to their correct specification. CLEAR the DTCs. TEST DRIVE the
vehicle at speeds above 20 km/h (12 mph). REPEAT the self-test. If DTC
C1280 returns, INSTALL a new RCM . REFER to Section 501-20B .
C1282 Lateral Accelerometer
Signal Fault
NOTE: The lateral acceleration sensor is integral to the RCM and cannot be
serviced separately. If a new lateral acceleration sensor is needed, a new
RCM must be installed.
C1288 Pressure Sensor
Main/Primary Input
Circuit Failure
C1440 Pressure Sensor
Main/Primary Signal
Faulted
C1470 TCS Function
Temporarily Disabled
(Thermal Brake
Protection)
a
ALLOW the brake fluid time to cool. CLEAR the DTC. TEST DRIVE the
vehicle and VERIFY traction control system operation.
C1805 Mismatched PCM
and/or ABS-TC
Module
b
C1963 Stability Assist Inhibit
Warning
NOTE: This DTC cannot clear until the vehicle has been driven above 48
km/h (30 mph) with input from the steering wheel rotation sensor.
NOTE: REPAIR all other non-communication DTCs before repairing DTC
C1963.
C1991 Module Calibration
Failure
CLEAR the DTCs.
CYCLE the ignition switch.
RETRIEVE the DTCs.
If DTC C1991 is present, INSTALL a new ABS module. REFER to
Anti-Lock Brake System (ABS) Module in this section.
C1996 Active Yaw and/or
Roll Control Disabled
C2770 Longitudinal
Acceleration Sensor
Signal Fault
NOTE: The longitudinal acceleration sensor is integral to the RCM and
cannot be serviced separately. If a new longitudinal acceleration sensor is
needed, a new RCM must be installed.
C2777 Sensor Cluster Bus
Failure
U0001 HS-CAN
Communication Bus
REFER to Section 418-00 to diagnose the HS-CAN bus.
With ECM /PCM
REPAIR all other DTCs first. If DTC U0100 is still present, REFER to
Section 418-00 to diagnose the HS-CAN bus.
With TCM
With Four-Wheel
Drive (4WD) Clutch
Control Module
with Body Control
Module
With Restraints
Control Module
(RCM)
With Instrument Panel
Cluster (IPC) Control
Module
U0401 Invalid Data Received
From ECM /PCM
VERIFY the correct ABS module configuration. VERIFY that the correct
Vehicle Identification Number (VIN) is programmed to the PCM. CARRY
OUT the PCM self-test, RETRIEVE and RECORD any DTCs. REFER to the
Diagnostic Trouble Code (DTC) Chart in Section 419-10 .
From TCM
VIN is programmed to the PCM. CARRY OUT the PCM self-test,
RETRIEVE and RECORD any DTCs. REFER to the Diagnostic Trouble
Code (DTC) Chart in Section 419-10 .
From Four-Wheel
Drive (4WD) Clutch
Control Module
VIN is programmed to the PCM. CARRY OUT the on-demand self test for
the 4x4 Control Module, RETRIEVE and RECORD any DTCs. REFER to
the Diagnostic Trouble Code (DTC) Chart in Section 419-10 .
From Restraints
Control Module
(RCM)
U1901 CAN Network #2
Communication Bus
Fault
U2050 No Application
Present
VERIFY that the ABS module installed is the correct module for the vehicle
configuration. If the ABS module is OK, CLEAR the DTCs. CARRY OUT
the self-test, RETRIEVE and RECORD any DTCs. If DTC U2050 is
retrieved again, INSTALL a new ABS module. REFER to Anti-Lock Brake
System (ABS) Module in this section. CLEAR the DTCs. REPEAT the
self-test.
a
b
Traction Control
C0089:11 TCS Disable Switch: Circuit Short
to Ground
a
Instrument Panel
Cluster (IPC)
- All Other IPC DTCs IPC REFER to the Master DTC Chart in
Section 419-10 .
a
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test A: DTC B1483
Refer to Wiring Diagrams Cell 42 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Vehicle Dynamic Systems
Normal Operation
When the brake pedal is pressed, the Brake Pedal Position (BPP) switch opens, this interrupts a voltage signal
that is sent to the PCM. When the PCM detects this interruption, it sends a message over the High Speed
Controller Area Network (HS-CAN) bus indicating that the brake pedal has been pressed. The PCM uses the
BPP switch information for the speed control system. The ABS module receives the BPP switch information
from the PCM over the HS-CAN bus.
The BPP is also known as the stoplamp switch.
DTC B1483 (Brake Pedal Input Open Circuit) - The ABS module compares the BPP message against
other inputs (brake pressure and wheel speed) and if the message does not match the other inputs and
there are no DTCs present for those inputs, DTC B1483 is set.

BPP switch
PCM
ABS module
PINPOINT TEST A: DTC B1483
A1 CHECK THE ABS MODULE DTCs
Review the DTCs recorded during Inspection
and Verification.

Were any wheel speed sensor DTCs
retrieved?

Yes
For DTC C1145, C1155, C1165 or C1175, GO to
Pinpoint Test C .
For DTC C1233, C1234, C1235 or C1236, GO to
Pinpoint Test D .
No
GO to A2 .
A2 CHECK FOR PCM DTCs
Ignition ON.
scan tool: KOEO Self Test - PCM.

Retrieve and record any PCM DTCs.
Are any DTCs present in the PCM?
Yes
REFER to the Diagnostic Trouble Code (DTC)
No
GO to A3 .
A3 CHECK THE ABS MODULE DTCs
Review the DTCs recorded during Inspection
and Verification.

Are DTCs U0100 and/or U0401 also
present?

Yes
DIAGNOSE DTCs U0100 and/or U0401 before
diagnosing B1483. REFER to the ABS Module
DTC Chart.
No
If DTCs C1288 and/or C1440 are present, GO to
Pinint Test I .
If no other DTCs are present, GO to A4 .
A4 CHECK THE ABS MODULE BRAKE
ON/OFF (BOO_ABS) PID
PINPOINT TEST A: DTC B1483 3173
scan tool: DataLogger - ABS Module.

Monitor the BOO_ABS PID while pressing
and releasing the brake pedal.

Does the PID agree with the pedal
position?

Yes
CLEAR the DTC. REPEAT the self-test.
No
GO to A5 .
A5 CHECK THE PCM BOO1 PID

Monitor the BOO1 PID while pressing and
releasing the brake pedal.

Does the PID agree with the pedal
position?

Yes
REFER to to diagnose the communication
concern.
No
REFER to Section 419-03 and diagnose the speed
control deactivation switch.
Pinpoint Test B: DTC B1676
Normal Operation
The operating voltage required to supply the ABS module, hydraulic pump and isolation valves is in a range
between 10 and 16 volts.
Fused battery voltage is supplied to the ABS module from the Battery Junction Box (BJB). Fused ignition
voltage is supplied to the ABS module from the Smart Junction Box (SJB).
DTC B1676 (Battery Pack Voltage Out of Range) - If during normal operation, the vehicle battery
voltage becomes less than 9.7 volts for more than 210 ms with vehicle speed greater than 20 km/h (12
mph), or the vehicle battery voltage becomes greater than 18 volts at any time, DTC B1676 is set.
Also, if during the ABS module self-test the vehicle battery voltage becomes higher than 18 volts,
DTC B1676 sets.

Fuse(s)
Charging system
ABS module
PINPOINT TEST B: DTC B1676
NOTE: DTC B1676 can be set if the vehicle has been recently jump started, the battery has been recently
charged or the battery has been discharged. The battery may become discharged due to excessive load(s) on
the charging system from aftermarket accessories or if the battery has been left unattended with the
accessories on.
NOTE: Carry out a thorough inspection and verification before proceeding with the pinpoint test. Refer to
Inspection and Verification in this section.
B1 RETRIEVE ALL CMDTCs IN ALL MODULES
Ignition ON.
Test - All CMDTCs .

Is DTC B1317, B1318 or B1676 present in one or more
modules AND DTC P0563, P0620, P0625, P0626 or
P065B present in the PCM?

Yes
REFER to Section 414-00 for
diagnosis of the battery and
charging system.
No
GO to B2 .
B2 CHECK BATTERY CONDITION
Ignition OFF.
Refer to Section 414-01 and carry out the Battery - Condition
Test.

Does the battery pass the condition test?
Yes
If the battery passed the condition
test, but required a recharge,
REFER to Section 414-00 to
diagnose the charging system.
self-test.
If the battery passed the condition
test and did not require a recharge,
GO to B3 .
No
INSTALL a new battery. REFER
to Section 413-01 . CLEAR the
B3 CHECK CHARGING SYSTEM VOLTAGE
NOTE: Do not allow the engine speed to increase above
2,000 rpm while performing this step or the generator may
self excite and result in default charging system output
voltage. If engine speed goes above 2,000 rpm, shut the
vehicle OFF and restart the engine before performing this
step.
Start the engine.
Measure the voltage of the battery with and without a load on
the charging system as follows:

Turn off all accessories and run the engine at 1,500
rpm for a minimum of 2 minutes while measuring
battery voltage.

Turn on headlights and HVAC fan on high and run
engine at 1,500 rpm for a minimum of 2 minutes
while measuring battery voltage.

Yes
GO to B4 .
No
REFER to Section 414-00 to
diagnose the charging system.
self-test.
PINPOINT TEST B: DTC B1676 3175
B4 CHECK THE VOLTAGE TO THE ABS MODULE
NOTE: The degas bottle may need to be positioned aside to
access the ABS module connector.
Ignition OFF.
Disconnect: ABS Module C135.
Ignition ON.
ABS module C135-1, SBB08 (VT/RD), harness side.
ABS module C135-8, CBP42 (GN), harness side.
ABS module C135-32, SBB10 (YE/RD), harness
side.

Yes
GO to B5 .
No
VERIFY BJB fuse 8 (40A) is OK.
If OK, REPAIR circuit SBB08
(VT/RD).
VERIFY SJB fuse 42 (10A) is
OK. If OK, REPAIR circuit
CBP42 (GN).
VERIFY BJB fuse 10 (30A) is
OK. If OK, REPAIR circuit
SBB10 (YE/RD).
If any fuse is not OK, REFER to
the Wiring Diagrams manual to
identify the possible causes of the
circuit short.
self-test.
B5 CHECK CIRCUIT GD123 (BK/GY) FOR AN OPEN
Ignition OFF.
Measure the resistance between ABS module C135-16,
circuit GD123 (BK/GY), harness side and ground.

Yes
self-test. If DTC B1676 is
retrieved again, GO to B6 .
No
REPAIR circuit GD123 (BK/GY).
self-test.
B6 CHECK FOR CORRECT ABS MODULE OPERATION
Check ABS module C135 for:
corrosion.
pushed-out pins.
spread terminals.
Yes
INSTALL a new ABS module.
REFER to Anti-Lock Brake
System (ABS) Module in this
section. CLEAR the DTCs.
PINPOINT TEST B: DTC B1676 3176
Connect: ABS Module C135.
Make sure the connector seats correctly, then operate the
system and verify the concern is still present.

No
corroded connector. CLEAR the
Pinpoint Test C: DTCs C1145, C1155, C1165 and C1175
Normal Operation
Active wheel speed sensors generate a square wave signal that is sent to the ABS module. The wheel speed
sensor circuitry connects to the ABS module through 2 wires and a connector at each wheel speed sensor.
When the ignition switch is turned to the RUN position, the ABS module carries out a self-test by sending a
reference voltage through the wheel speed sensors and their circuitry.
C1145 - RF
Wheel Speed
Sensor Input
Circuit Failure

C1155 - LF
Wheel Speed
Sensor Input
Circuit Failure

C1165 - RR
Wheel Speed
Sensor Input
Circuit Failure

C1175 - LR
Wheel Speed
Sensor Input
Circuit Failure

If, during the ABS module on-demand self test or during normal operation, the
ABS module detects an open, short to ground or voltage or a defecti speed sensor
input circuit, the appropriate DTC is set. These DTCs are usually set by a damaged
sensor or a circuit fault.
Wheel speed sensor ring (part of the wheel bearing and hub assembly)
Wheel speed sensors
ABS module
PINPOINT TEST C: DTCs C1145, C1155, C1165 AND C1175
C1 CHECK FOR FAULT
REPEATABILITY
Ignition ON.
the scan tool: Clear the ABS module
DTCs.

Drive the vehicle at least 16 km/h (10
mph).

Retrieve and record the ABS module
DTCs.

Is DTC C1145, C1155, C1165 or
C1175 retrieved?

Yes
For DTC C1145 or C1155, if the Rotunda Active
Wheel Speed Sensor Tester is available, GO to C2 .
For DTC C1165 or C1175, or if the Rotunda Active
Wheel Speed Sensor Tester is not available, GO to C4
.
No
INSPECT the wheel speed sensors, wheel speed
sensor wiring and wheel speed sensor tone rings.
REPAIR or INSTALL new as necessary. If any other
DTCs are retrieved, GO to the ABS Module DTC
Chart.
C2 CHECK THE ABS MODULE OUTPUT
USING THE ROTUNDA ACTIVE WHEEL
SPEED SENSOR TESTER
NOTE: The front wheel speed sensor
electrical connectors are located behind
the wheel well splash shields. The rear
wheel speed sensor electrical connectors
are located under the rear seat cushion.
Ignition OFF.
Disconnect: Suspect Wheel Speed
Sensor.

Connect the Rotunda Active Wheel
Speed Sensor Tester to the wheel speed
sensor connectors.

Ignition ON.
Select the correct system polarity on the
Rotunda Active Wheel Speed Sensor
Tester and turn the power switch to the
ON position.

Is the module output LED
illuminated?

Yes
GO to C3 .
No
GO to C6 .
C3 CHECK THE WHEEL SPEED SENSOR
OUTPUT WITH THE ROTUNDA ACTIVE
WHEEL SPEED SENSOR TESTER
Raise the suspect wheel until it can spin
freely. Refer to Section 100-02 .

While monitoring the Rotunda Active
Wheel Speed Sensor Tester, slowly spin

Yes
PINPOINT TEST C: DTCs C1145, C1155, C1165 AND C1175 3178
the suspect wheel.
Do the sensor output LEDs illuminate
and flash and is the current overload
LED not illuminated?

No
If the current level LED is not illuminated and the
sensor output LEDs do not illuminate or if the current
level LED is illuminated red, INSTALL a new wheel
speed sensor. REFER to Wheel Speed Sensor - Front
or Wheel Speed Sensor - Rear, Front Wheel Drive
(FWD) in this section. CLEAR the DTCs. REPEAT
the self-test.
sensor output LEDs illuminate green, but do not flash,
INSPECT the wheel speed sensor tone ring and
INSTALL new if necessary. If tone ring is OK,
INSTALL a new wheel speed sensor. REFER to
Wheel Speed Sensor - Front or Wheel Speed Sensor -
Rear, Front Wheel Drive (FWD) in this section.
NOTICE: No measurements should be
taken with the wheel speed sensor
connected. Damage to the wheel speed
sensor results.
NOTE: Both circuits must be checked
for each DTC.
NOTE: The degas bottle may need to be
positioned aside to access the ABS
module connector.
wheel speed sensor electrical connectors
are located under the rear seat cushion.
Ignition OFF.
Sensor.

Ignition ON.
For DTC C1145 , measure the voltage
between ground and:

ABS module C135-34, circuit
VCA05 (GY/VT), harness side.

RCA19 (VT), harness side.

Yes
REPAIR the affected circuit(s). CLEAR the DTCs.
No
GO to C5 .
between ground and:

VCA03 (VT/WH), harness side.

RCA17 (YE), harness side.

between ground and:

VCA06 (WH/OG), harness side.

RCA20 (BN), harness side.

between ground and:

VCA04 (BU/OG), harness side.

RCA18 (BN/GN), harness side.

for each DTC.
Ignition OFF.
For DTC C1145 , measure the
resistance between ground and:

VCA05 (GY/VT), harness side.



VCA03 (VT/WH), harness side.



VCA06 (WH/OG), harness side.



VCA04 (BU/OG), harness side.


Yes
GO to C6 .
No
Are the resistances greater than
10,000 ohms?

for each DTC.
Ignition OFF.
Sensor.

Measure the resistance between ABS
module C135, harness side and the
suspect wheel speed sensor connector,
harness side as indicated in the following
chart:

ABS
Module Circuit
Wheel Speed
Sensor
DTC C1145
C135-34 VCA05
(GY/VT)
C160-1
C135-33 RCA19 (VT) C160-2
DTC C1155
C135-45 VCA03
(VT/WH)
C150-1
C135-46 RCA17 (YE) C150-2
DTC C1165
C135-43 VCA06
(WH/OG)
C426-3
C135-42 RCA20 (BN) C426-1
DTC C1175
C135-36 VCA04
(BU/OG)
C440-3
C135-37 RCA18
(BN/GN)
C440-1
Yes
GO to C7 .
No
REPEAT the ABS self-test.
C7 CHECK FOR SHORTED WHEEL
SPEED SENSOR CIRCUITS
resistance between:

RF wheel speed sensor C160-1,
circuit VCA05 (GY/VT),
harness side and RF wheel speed
sensor C160-2, circuit RCA19
(VT), harness side.

resistance between:

LF wheel speed sensor C150-1,
circuit VCA03 (VT/WH),
harness side and LF wheel speed
(YE), harness side.

resistance between:

RR wheel speed sensor C426-3,
circuit VCA06 (WH/OG),
harness side and RR wheel
speed sensor C426-1, circuit

Yes
GO to C8 .
No
resistance between:

LR wheel speed sensor C440-3,
circuit VCA04 (BU/OG),
harness side and LR wheel speed

Are the resistances greater than
10,000 ohms?

C8 CHECK THE ABS MODULE OUTPUT
Ignition ON.
between:

circuit VCA05 (GY/VT),
harness side and RF wheel speed
(VT), harness side.

between:

circuit VCA03 (VT/WH),
harness side and LF wheel speed
(YE), harness side.

Yes
Wheel Speed Sensor - Front , Wheel Speed Sensor -
Rear, All Wheel Drive (AWD) or Wheel Speed Sensor
- Rear, Front Wheel Drive (FWD) in this section.
No
GO to C9 .
between:

circuit VCA06 (WH/OG),
harness side and RR wheel
speed sensor C426-1, circuit

between:

circuit VCA04 (BU/OG),
harness side and LR wheel speed

C9 CHECK FOR CORRECT ABS
MODULE OPERATION
Ignition OFF.
Disconnect: ABS Module C135. Check
the connector for:

corrosion.
pushed-out pins.
spread terminals.
Make sure the connector seats correctly,
then operate the system and verify the

Yes
INSTALL a new ABS module. REFER to Anti-Lock
Brake System (ABS) Module in this section. CLEAR
No
Pinpoint Test D: DTCs C1233, C1234, C1235 and C1236
Normal Operation
The wheel speed sensor and sensor ring generate a square wave signal to the ABS module that is proportional
to the wheel speed. The ABS module compares the wheel speed inputs from all the wheel speed sensors to
determine an impending wheel lockup.
C1233 - LF
Wheel Speed
Sensor Signal
Fault

C1234 - RF
Wheel Speed
Sensor Signal
Fault

C1235 - RR
Wheel Speed
Sensor Signal
Fault

C1236 - LR
Wheel Speed
Sensor Signal
Fault

If the ABS module does not receive a signal from a wheel speed sensor when the
vehicle speed is greater than 15 km/h (9 mph), the appropriate DTC is set. If the
difference of 2 wheel speed values is greater than 25 km/h (16 mph), the appropriate
DTC sets.
These DTCs are usually set by a damaged wheel speed sensor or damaged sensor
tone ring, they can also be set by wheels and/or tires of different sizes being installed
on the vehicle or a difference in tire pressures.
Mismatched tire sizes
Wheel speed sensor ring (part of the wheel bearing and hub assembly)
Wheel speed sensor
ABS module
PINPOINT TEST D: DTCs C1233, C1234, C1235 AND C1236
D1 CHECK THE DTCs FROM THE
SELF-TEST
Review the DTCs recorded during
Inspection and Verification.

Yes
No
Are DTCs C1145, C1155, C1165 or C1175
present?
GO to D2 .
D2 CHECK THE TIRES SIZE AND
PRESSURE
Verify that the tires are the correct size for
the vehicle as indicated on the Vehicle

Verify that the air pressure in all the tires is
correct as indicated on the VC label.

Are the wheels and tires OK?
Yes
GO to D3 .
No
INSTALL the correct tires or ADJUST tire
pressure as necessary. CLEAR the DTCs. TEST
D3 INSPECT THE WHEEL SPEED SENSOR
MOUNTING
Ignition ON.
With the vehicle in NEUTRAL, position it
on a hoist. Refer to Section 100-02 .

Inspect the suspect wheel speed sensor for
looseness.

Is the wheel speed sensor loose?
Yes
TIGHTEN the wheel speed sensor to specification.
REFER to Specifications in this section. CLEAR
the DTCs. GO to D4 .
No
GO to D5 .
D4 RECHECK THE WHEEL SPEED PIDs
Ignition ON.

Monitor the following PIDs while iving the
vehicle at a constant speed:

Left Front Wheel Speed Sensor
(LF_WSPD)

Right Front Wheel Speed Sensor
(RF_WSPD)

Left Rear Wheel Speed Sensor
(LR_WSPD)

Right Rear Wheel Speed Sensor
(RR_WSPD)

Are all the wheel speed sensor PID values
similar?

Yes
The vehicle is OK. The concern may have been
caused by a loose wheel speed sensor.
No
GO to D5 .
FOR DAMAGE
NOTE: Examine the wheel speed sensor
wire carefully with a good light source.
Failure to verify damage in the wheel speed
sensor wire can lead to unnecessary
installation of a new component.

Inspect the suspect wheel speed sensor for
general damage.

Is the wheel speed sensor OK?
Yes
GO to D6 .
No
Wheel Speed Sensor - Front , Wheel Speed Sensor
- Rear, Front Wheel Drive (FWD) or Wheel Speed
Sensor - Rear, All Wheel Drive (AWD) in this
RING AND WHEEL BEARING FOR DAMAGE
PINPOINT TEST D: DTCs C1233, C1234, C1235 AND C1236 3187
Inspect the wheel bearing for damage.
Inspect the suspect wheel speed sensor ring
for damaged or missing teeth. Rotate the
wheel to verify that no teeth are missing.

Is the wheel speed sensor ring and wheel
bearing OK?

Yes
If the Active Wheel Speed Sensor Tester is
available, GO to D7 . If the Active Wheel Speed
Sensor Tester is not available, GO to D9 .
No
INSTALL a new front or rear wheel hub and
bearing. REFER to Section 204-01 for front wheel
hubs or Section 204-02 for rear wheel hubs.
D7 CHECK THE ABS MODULE OUTPUT
USING THE ACTIVE WHEEL SPEED
SENSOR TESTER
Ignition OFF.
Disconnect: Suspect Wheel Speed Sensor.
Connect the Active Wheel Speed Sensor
Tester to the wheel speed sensor connectors.

tester and turn the tester power switch to the
ON position.

Ignition ON.
Is the module output LED illuminated?
Yes
GO to D8 .
No
GO to D10 .
D8 CHECK THE WHEEL SPEED SENSOR
OUTPUT WITH THE ACTIVE WHEEL SPEED
SENSOR TESTER
Raise the suspect wheel until it can spin
freely. Refer to Section 100-02 .

While monitoring the Active Wheel Speed
Sensor Tester, slowly spin the suspect
wheel.

Do the sensor output LEDs illuminate and
flash and is the current overload LED not
illuminated?

Yes
INSPECT the wheel speed sensor tone ring for
damage and looseness. INSTALL new components
as necessary. If the tone ring is OK, the concern
may have been caused by a loose or corroded
connector. CLEAR the DTCs. REPEAT the
self-test.
No
sensor output LEDs do not illuminate or if the
current level LED is illuminated red, INSTALL a
new wheel speed sensor. REFER to Wheel Speed
Sensor - Front , Wheel Speed Sensor - Rear, Front
Wheel Drive (FWD) or Wheel Speed Sensor -
Rear, All Wheel Drive (AWD) in this section.
sensor output LEDs illuminate green, but do not
flash, INSPECT the wheel hub and bearing (tone
ring is part of the wheel bearing). INSTALL new
as necessary. If the wheel hub and bearing are OK,
D9 ABS MODULE OUTPUT
Ignition OFF.
Disconnect: Suspect Wheel Speed Sensor.
Ignition ON.
between:

circuit VCA03 (VT/WH), harness
side and LF wheel speed sensor
C150-2, circuit RCA17 (YE),
harness side.

between:

circuit VCA05 (GY/VT), harness
side and RF wheel speed sensor
C160-2, circuit RCA19 (VT),
harness side.

between:

circuit VCA06 (WH/OG), harness
side and RR wheel speed sensor
C426-1, circuit RCA20 (BN),
harness side.

Yes
No
GO to D10 <
between:

circuit VCA04 (BU/OG), harness
side and LR wheel speed sensor
C440-1, circuit RCA18 (BN/GN),
harness side.

D10 CHECK THE WHEEL SPEED SENSOR
NOTE: Both circuits must be checked for
each DTC.
Ignition OFF.
Disconnect: Suspect Wheel Speed Sensor (if
not previously disconnected).

Measure the resistance between the ABS
module connector, harness side and the
suspect wheel speed sensor connector,
harness side as indicated in the following
chart:

Wheel Speed
Sensor Circuit
ABS
Module
DTC C1233 - LF Wheel Speed Sensor
Signal Fault
C150-1 VCA03
(VT/WH)
C135-45
C150-2 RCA17 (YE) C135-46
DTC C1234 - RF Wheel Speed Sensor
Signal Fault
C160-1 VCA05
(GY/VT)
C135-34
C160-2 RCA19 (VT) C135-33
DTC C1235 - RR Wheel Speed Sensor
Signal Fault
C426-1 RCA20 (BN) C135-42
C426-3
Yes
GO to D11 .
No
VCA06
(WH/OG)
DTC C1236
- LR Wheel
Speed
Sensor
Signal Fault
C440-1 RCA18
(BN/GN)
C135-37
C440-3 VCA04
(BU/OG)
C135-36
D11 CHECK FOR CORRECT ABS MODULE
OPERATION
Check for:
corrosion.
pushed-out pins.
spread terminals.
Connect the ABS module connector and
make sure it seats correctly.

still present.

Yes
INSTALL a new ABS module. REFER to
Anti-Lock Brake System (ABS) Module in this
No
corroded connector. CLEAR the DTCs. REPEAT
the self-test.
Pinpoint Test E: DTC C1095
Normal Operation
The operating voltage required to supply the hydraulic pump motor is in a range between 10 and 16 volts.
Fused battery voltage for the hydraulic pump is supplied to the ABS module from Battery Junction Box
(BJB). Ground for the hydraulic pump is provided through the ABS module.
DTC C1095 (ABS Hydraulic Pump Motor Circuit Failure) - If the ABS module detects an open
circuit, a short to voltage or ground or a defective internal power transistor during normal operation or
the ABS module self-test, DTC C1095 sets. The ABS module commands the pump motor ON for 100
ms (6 ms), then command the motor OFF and measure the voltage produced by the motor after 6 ms.
If the voltage indicates that the motor is spinning at less than 500 rpm, there may be a locked motor. If
this condition is detected 4 times, then DTC C1095 is set. The pump motor is also checked for an
open circuit 2 seconds after the most recent successful pump motor off command. If the pump motor
feedback remains greater than 0.75 volt for more than 50 ms (6 ms) after these conditions have been

met, then DTC C1095 sets.
Fuse
ABS module
PINPOINT TEST E: DTC C1095
E1 CHECK THE ABS PUMP MOTOR
Ignition OFF.
Ignition ON.
Is the ABS pump motor running all the
time?

Yes
GO to E2 .
No
GO to E3 .
E2 CHECK THE ABS MODULE CONNECTOR
Ignition OFF.
Check the connector for:
corrosion.
pushed-out pins.
spread terminals.
Is the connector undamaged and free of any
corrosion?

Yes
INSTALL a new ABS module and HCU .
REFER to Anti-Lock Brake System (ABS)
Module and Hydraulic Control Unit (HCU) in
this section. CLEAR the DTCs. REPEAT the
self-test.
No
REPAIR as necessary. CLEAR the DTCs.
E3 CHECK THE PUMP MOTOR OUTPUT
COMMAND (PMP_MOTOR)
scan tool: DataLogger - ABS.

Toggle the PMP_MOTOR output command
ON.

Does the ABS pump motor run for
approximately 2 seconds?

Yes
TOGGLE the PMP_MOTOR output command
OFF. GO to E4 .
No
TOGGLE the PMP_MOTOR output command
OFF.
CLEAR the DTCs. CYCLE the ignition switch.
RETRIEVE and RECORD the ABS module
DTCs.
If DTC C1095 is retrieved, GO to E5 .
For all other ABS module DTCs, GO to the ABS
Module DTC Chart.
E4 CHECK FOR RETURNING ABS MODULE
DTCs
PINPOINT TEST E: DTC C1095 3192
scan tool: Self Test - ABS Module.

Retrieve and record the ABS module DTCs.
Are any ABS module DTCs present?
Yes
If DTC C1095 is retrieved, INSTALL a new
HCU . REFER to Hydraulic Control Unit (HCU)
in this section. CLEAR the DTCs. REPEAT the
self-test.
For all other ABS module DTCs, GO to the ABS
Module DTC Chart.
No
corroded connector. CLEAR the DTCs. CARRY
OUT the self-test with the brake pedal not
applied.
E5 CHECK THE VOLTAGE TO THE ABS
MODULE
positioned aside to access the ABS module
connector.
Ignition OFF.
Ignition ON.
Measure the voltage between ABS module
C135-1, circuit SBB08 (VT/RD), harness side
and ground.

Yes
GO to E6 .
No
REPAIR circuit SBB08 (VT/RD). CLEAR the
circuit short.
E6 CHECK CIRCUIT GD123 (BK/GY) FOR AN
OPEN
Measure the resistance between ABS module
C135-16, circuit GD123 (BK/GY), harness
side and ground.

Yes
GO to E7 .
No
REPAIR circuit GD123 (BK/GY). CLEAR the
PINPOINT TEST E: DTC C1095 3193
E7 CHECK FOR CORRECT ABS MODULE
OPERATION
Ignition OFF.
corrosion.
pushed-out pins.
spread terminals.
Make sure the connector seats correctly, then
operate the system and verify the concern is
still present.

Yes
INSTALL a new ABS module and HCU .
REFER to Anti-Lock Brake System (ABS)
Module and Hydraulic Control Unit (HCU) in
self-test.
No
Pinpoint Test F: DTCs C1277, C1278 and C1963
Normal Operation
On vehicles equipped with Hydraulic Power Assist Steering (HPAS) (3.5L vehicles only), a slotted wheel is
attached to the steering column inside the clockspring and the steering wheel rotation sensor is attached to the
RH side of the multifunction switch just above the ignition lock cylinder. The steering wheel rotation senor
has a LED and an opposing optical sensor. As the steering wheel is turned, the slotted wheel passes between
the LED and the sensor, interrupting the signal and indicating how far and how fast the steering wheel is being
turned. This information is sent to the ABS module and is used to help determine if the AdvanceTrac system
needs to be activated.
On vehicles equipped with Electronic Power Assist Steering (EPAS), the steering wheel rotation sensor is
located inside the EPAS gear assembly. Rotation speed and angle are sent to the ABS module from the Power
Steering Control Module (PSCM) along the High Speed Controller Area Network (HS-CAN) bus.
C1277 - Steering
Wheel Angle 1
and 2 Circuit
Failure (vehicles
with HPAS )

If the ABS module detects an open circuit, short to voltage or short to ground
during normal operation or an on-demand self test, DTC C1277 sets. An internal
failure of the steering wheel rotation sensor may also cause DTC C1277 to set.
C1277 - Steering
Wheel Angle 1
and 2 Circuit
Failure (vehicles
with EPAS )
If the ABS module does not receive the steering wheel rotation/angle message
from the PSCM for more than 5 seconds with vehicle speed above 3 km/h (2
mph), DTC C1277 sets. This could be due to a failure of the HS-CAN bus or a
failure of the EPAS system, which causes other ABS module DTCs to set.
C1278 - Steering
Wheel Angle 1
and 2 Signal
Faulted

If during normal operation or the ABS module on-demand self test, the ABS
module does not receive the steering wheel rotation sensor input or if the input
received does not agree with the input from other sensors, DTC C1278 sets.
C1963 - Stability
Assist Inhibit
Warning

If conditions exist during normal operation that prevent the AdvanceTrac
system from operating, DTC C1963 sets. This DTC is usually set due to the
steering wheel rotation sensor being damaged/installed incorrectly or due to
invalid/missing data from the Restraints Control Module (RCM).
Wiriminals or connectors
Steering wheel rotation sensor incorrectly installed
Steering wheel rotation sensor
ABS module
PINPOINT TEST F: DTCs C1277, C1278 AND C1963
F1 VERIFY THE VEHICLE STEERING
SYSTEM TYPE
NOTE: Steering system type can be
identified by checking for the presence of a
power steering pump. Vehicles equipped
with EPAS do not have a power steering
pump.

Verify the type of steering system the
vehicle is equipped with, HPAS or EPAS .

Is the vehicle equipped with HPAS ?
Yes
GO to F4 .
No
GO to F2 .
F2 CHECK THE ABS MODULE DTCs
Review the DTCs retrieved during

Are there any communication "U-code"
DTCs present in the ABS module?

Yes
REFER to the ABS Module DTC Chart and
DIAGNOSE the U-code DTCs before diagnosing
DTC C1963.
No
GO to F3 .
F3 CHECK FOR PSCM DTCs
Yes
REFER to Section 211-00A to diagnose the EPAS
PINPOINT TEST F: DTCs C1277, C1278 AND C1963 3195
Ignition ON.
scan tool: Self Test - PSCM .

Are there any DTCs present in the
PSCM ?

system concern.
No
F4 MONITOR THE STEERING ROTATION
SENSOR POSITION (SWA POS) PID
Ignition ON.

Monitor the SWA POS PID while rotating
the steering wheel clockwise and
counterclockwise very slowly, from lock to
lock.

Does the PID move in intervals of 1.5
degrees?

Yes
CLEAR the DTCs. DRIVE the vehicle above 48
km/h (30 mph) with input from the steering wheel
rotation sensor. RETRIEVE the DTCs. If DTC
C1277 or C1278 is still present, GO to F13 .
If DTC C1963 is present, INSPECT the steering
wheel rotation sensor for damage and
correctnstallation. INSPECT for possible sources of
light intrusion (cracked, missing or poor fitting
steering shroud). REINSTALL or INSTALL new as
necessary. If the sensor is OK, GO to F5 .
No
GO to F5 .
STEERING WHEEL ROTATION SENSOR
NOTE: The steering wheel rotation sensor
is located on the RH side of the
multifunction switch.
Ignition OFF.
Disconnect: Steering Wheel Rotation
Sensor C226.

Ignition ON.
Measure the voltage between steering
wheel rotation sensor C226-4, circuit
CCA40 (GY/BU), harness side and
ground.

Yes
GO to F6 .
No
REPAIR circuit CCA40 (GY/BU). CLEAR the
F6 CHECK THE GROUND CIRCUIT FOR
AN OPEN
steering wheel rotation sensor C226-1,
circuit RCA40 (BN/VT), harness side.

Yes
GO to F7 .
No
REPAIR circuit RCA40 (BN/VT). CLEAR the
F7 CHECK THE CHANNEL "A" CIRCUIT
FOR AN OPEN OR A SHORT TO GROUND
VCA41 (VT/GN), harness side and

Is the voltage between 4.75 volts and
5.25 volts?

Yes
GO to F8 .
No
REPAIR circuit VCA41 (VT/GN). CLEAR the
F8 CHECK THE CHANNEL "B" CIRCUIT
FOR AN OPEN OR A SHORT TO GROUND
VCA42 (VT/OG), harness side and

Yes
GO to F9 .
No
REPAIR circuit VCA42 (VT/OG). CLEAR the
Is the voltage between 4.75 volts and
5.25 volts?

F9 CHECK THE STEERING POSITION
SENSOR CIRCUITS FOR AN OPEN
positioned aside to access the ABS module
connector.
Ignition OFF.
Disconnect: Steering Wheel Rotation
Sensor C226.

Measure the resistance between ABS
module C135, harness side and steering
wheel rotation sensor C226, harness side
using the following table:

Steering Wheel
Rotation Sensor Circuit
ABS
Module
C226-1 RCA40
(BN/VT)
C135-40
C226-2 VCA41
(VT/GN)
C135-41
C226-3 VCA42
(VT/OG)
C135-9
C226-4 CCA40
(GY/BU)
C135-5
Yes
GO to F10 .
No
SENSOR CIRCUITS FOR A SHORT TO
VOLTAGE
Ignition ON.
ground.


Yes
No
GO to F11 .
ground.
RCA40 (BN/VT), harness side and
ground.

ground.

SENSOR CIRCUITS FOR A SHORT TO
GROUND
Ignition OFF.
ground.

ground.

RCA40 (BN/VT), harness side and
ground.

ground.

ohms?

Yes
GO to F12 .
No
F12 CHECK THE CHANNEL "A" AND "B"
Measure the resistance between steering
circuit VCA42 (VT/OG), harness side.

Yes
If DTC C1963 is present, GO to Pinpoint Test G .
INSTALL a new steering wheel rotation sensor.
REFER to Steering Wheel Rotation Sensor in this
ohms?

No
F13 CHECK FOR CORRECT ABS MODULE
OPERATION
Ignition OFF.
corrosion.
pushed-out pins.
spread terminals.
Make sure the connector seats correctly,
then operate the system and verify the

Yes
No
the self-test.
Pinpoint Test G: DTCs C1963, C2777, U0151, U0452 and U1901
Normal Operation
The yaw rate sensor, lateral accelerometer and longitudinal accelerometer are contained in Restraints Control
Module (RCM). The RCM measures vehicle yaw rate, lateral acceleration and longitudinal acceleration and
then sends the information to the ABS module along the dedicated Controller Area Network (CAN) bus. This
dedicated CAN bus is used only for communication between the RCM and the ABS module. The information
sent to the ABS module is used to help determine if the AdvanceTrac system needs to be activated.
C2777 - Sensor
Cluster Bus Failure

U0151 - Lost
Communication With
Restraints Control
Module (RCM)

U1901 - CAN
Network #2
Communication Bus

If, during normal operation or the ABS module on-demand self test the ABS
module detects an open circuit, a short to voltage or a short to ground on one
or both of the dedicated CAN bus circuits, or a failure of the RCM causes the
appropriate DTC to set.
Fault
C1963 - Stability
Control Inhibit
Warning

If conditions exist during normal operation that prevent the AdvanceTrac
system from operating, DTC C1963 sets. This DTC is usually set due to the
steering wheel rotation sensor or the RCM being damaged or installed
incorrectly.
U0452 - Invalid Data
Received From RCM

This DTC indicates that one or more of the stability/traction control system
sensors internal to the RCM have failed and the RCM is transmitting on
"invalid data" message.
RCM incorrectly mounted
RCM
ABS module
PINPOINT TEST G: DTCs C1963, C2777, U0151, U0452 AND U1901
death.
G1 CHECK FOR AN HS-CAN CONCERN
WITH THE RCM
Ignition ON.
NOTE: The Network Test does not test the
dedicated CAN communications between the
ABS module and RCM .

Using the scan tool, carry out the Network
Test.

Does the RCM pass the Network Test?
Yes
GO to G2 .
No
REFER to Section 418-00 to diagnose the High
Speed Controller Area Network (HS-CAN)
concern.
G2 CHECK FOR CORRECT RCM
Ignition OFF.
Yes
GO to G3 .
PINPOINT TEST G: DTCs C1963, C2777, U0151, U0452 AND U1901 3201
WARNING: Turn the ignition OFF
and wait one minute to deplete the backup
power supply. Failure to follow this
instruction may result in serious personal
injury or death in the event of an

Gain access to the RCM and check the part
number on the RCM against the part number
listed in the master parts catalog. Refer to
Section 501-20B .

Does the part number on the RCM match
the part number listed in the master parts
catalog?

No
INSTALL the correct RCM . REFER to Section
501-20B . GO to G13 .
G3 CHECK FOR CORRECT ABS MODULE
scan tool: Log Viewer.

Retrieve and record the ABS module part
number from Log Viewer and check the part
number on the ABS module against the part
number listed in the master parts catalog.

Does the part number retrieved from the
ABS module match the part number listed
in the master parts catalog?

Yes
GO to G4 .
No
INSTALL the correct ABS module. REFER to
section. GO to G13 .
G4 CHECK THE RCM CONDITION AND
INSTALLATION
Depower the Supplemental Restraint System
(SRS). Refer to Supplemental Restraint
System (SRS) Depowering and Repowering
in Section 501-20B .

Inspect the RCM for cracks in the case,
broken anchor tabs, broken electrical
connector and correct installation. Refer to
Removal and Installation, Restraints Control
Module (RCM) in Section 501-20B .

Is the RCM installed correctly and
undamaged?

Yes
GO to G5 .
No
REINSTALL or INSTALL new as necessary. GO
to G13 .
G5 CHECK THE DEDICATED CAN
Disconnect: RCM C310B.
module C135, harness side and the RCM
C310B, harness side as indicated in the
following chart:

ABS Module Circuit RCM
Yes
GO to G6 .
No
REPAIR the affected circuit(s). CLEAR the
DTCs. CYCLE the ignition key. REPEAT the
self-test. GO to G13 .
C135-18 VCA23 (BU/WH) C310B-20
C135-19 VCA24 (GN/OG) C310B-19
Measure the resistance between ground and:
VCA24 (GN/OG), harness side.

VCA23 (BU/WH), harness side.

ohms?

Yes
GO to G7 .
No
REPAIR the affected circuit(s). GO to G13 .
C135-19, circuit VCA24 (GN/OG), harness
side and ABS module C135-18, circuit

ohms?

Yes
GO to G8 .
No
Ignition ON.


Yes
No
GO to G9 .
G9 CHECK RCM TERMINATING RESISTOR
Ignition OFF.
Connect: RCM C310B.
C135-18, circuit VCA23 (BU/WH), harness
side and C135-19, circuit VCA24 (GN/OG),
harness side.

Is the resistance between 108 and 132
ohms?

Yes
GO to G10 .
No
GO to G11 .
G10 CHECK THE ABS MODULE FOR
CORRECT OPERATION
Prior to reconnecting any previously
disconnected SRS component:

inspect connector(s) (including any
in-line connectors) for pushed-out,
loose or spread terminals and loose
or frayed wire connections at
terminals.


inspect RCM C310A and C310B
Connector Position Assurance
(CPA) lever/lock for correct
operation. Refer to RCM in Section
501-20B .

Yes
section. GO to G13 .
No
corroded connector. GO to G13 .
inspect ABS module C135 for dirt,
corrosion, water intrusion, pushed
out, loose or spread terminals and
loose or frayed wire connections at
terminals.


Connect: All Previously Disconnected
Component(s)/Connector(s).

Repower the SRS . Do not prove out the
SRS at this time. Refer to Supplemental
Repowering in Section 501-20B .


Do any of the DTCs listed in Normal
Operation return?

G11 CONFIRM THE RCM FAULT
NOTE: Make sure all restraint system
components, sensor electrical connectors and
the RCM electrical connectors are connected
before carrying out the self-test. If not, DTCs
can be recorded.
If previously directed to repower the SRS ,
depower the SRS . Refer to Supplemental


terminals.


CPA lever/lock for correct
operation. Refer to RCM Removal
and Installation in Section 501-20B .

corrosion, water intrusion, pushed
out, loose or spread terminals and
loose or frayed wire connections at
terminals.

Yes
INSTALL a new RCM . REFER to Section
501-20B . GO to G13 .
No
In the process of diagnosing the fault, the fault
condition has become intermittent.
CHECK for causes of the intermittent fault.
ATTEMPT to recreate the hard fault by flexing the
wire harness and cycling the ignition frequently.
ACTIVATE other systems in the same wire
harness. Do not install any new SRS components
at this time. SRS components should only be
installed when directed to do so in the pinpoint
test. b> GO to G12 .


scan tool: Self Test - RCM .

Were DTCs U0028:08 and/or U0028:88

G12 CHECK FOR AN INTERMITTENT
FAULT
Ignition OFF.

Disconnect RCM C310B and ABS module
C135:

in-line connectors) for corrosion,
terminals.





Ignition ON.

Are any RCM DTCs retrieved on-demand
during thself-test?

Yes
REFER to Diagnosis and Testing in Section
501-20B .
No
The fault is not present and cannot be recreated at
this time. Do not install any new SRS
components at this time. SRS components
should only be installed when directed to do so
in the pinpoint test. GO to G13 .
G13 CHECK FOR ADDITIONAL RCM AND
ABS MODULE DTCs
Ignition OFF. Do not clear any DTCs until all DTCs have been

Reconnect all SRS components (if
previously disconnected).

If previously directed to depower the SRS ,
repower the SRS . Do not prove out the SRS
at this time. Refer to Supplemental Restraint

Ignition ON.


Were any DTCs retrieved on-demand
from the RCM or ABS module during
self-test?

resolved. GO to the appropriate DTC Chart in this
section and/or Section 501-20B for pinpoint test
direction.
No
CLEAR all Continuous Memory Diagnostic
Trouble Codes (CMDTCs). PROVE OUT the SRS
. REFER to Supplemental Restraint System (SRS)
Depowering and Repowering in Section 501-20B .
Repair is complete. RETURN the vehicle to the
customer.
Pinpoint Test H: DTCs B2900 and C1805
Normal Operation
When the ignition is turned to the RUN position, the ABS module and the PCM share Vehicle Identification
Number (VIN) information over the High Speed Controller Area Network (HS-CAN) bus.
DTC B2900 ( VIN Mismatched) - If the VIN information stored in the ABS module does not match
the information transmitted by the PCM, DTC B2900 set.

DTC C1805 (Mismatched PCM and/or ABS Module) - If the VIN information stored in the ABS
module does not match the information transmitted by the PCM, DTC C1805 sets.

Module configuration (ABS and PCM)
ABS module
PINPOINT TEST H: DTCs B2900 AND C1805
H1 VERIFY PCM VIN &nbs
Ignition ON.
Using the scan tool, carry
out the Network Test.

Yes
GO to H2 .
No
RECONFIGURE the PCM. FOLLOW the instructions on the scan
tool. CLEAR the DTCs. CYCLE the ignition key. REPEAT the
Enter the following
tool: Log Viewer.

Compare the VIN in Log
Viewer to the vehicle VIN
plate.

Does VIN in Log Viewer
match the vehicle VIN
plate?

self-test.
H2 VERIFY ABS MODULE
PART NUMBER
Retrieve and record the
ABS module part number
from Log Viewer and verify
that the vehicle has the
correct ABS module
installed.

Is the correct ABS module
installed in the vehicle?

Yes
CONFIGURE the ABS module. REFER to Programmable Module
Installation (PMI) Using the Integrated Diagnostic System (IDS)
When the Original Module is NOT Available in Section 418-01 .
CLEAR the DTC. CYCLE the ignition key. REPEAT the self-test.
No
INSTALL a new ABS module. REFER to Anti-Lock Brake System
(ABS) Module in this section. CLEAR the DTC. CYCLE the
ignition key. REPEAT the self-test.
Pinpoint Test I: DTCs C1288 and C1440
Normal Operation
The ABS module monitors the pressure of the hydraulic brake system through the use of a brake pressure
transducer. The brake pressure transducer is internal to the Hydraulic Control Unit (HCU). The brake pressure
transducer cannot be serviced separately. If a new brake pressure transducer is needed, a new HCU must be
installed.
DTC C1288 (Pressure Transducer Main/Primary Input Circuit Failure) - If there is an improper
connection between the ABS module and HCU , if the brake pressure transducer is faulted or if the
ABS module is faulted internally, this DTC sets.

DTC C1440 (Pressure Transducer Main/Primary Signal Faulted) - If there is an improper connection
between the ABS module and the HCU , if there is air in the hydraulic brake system, if the brake
pressure transducer is faulted or if the ABS module is faulted internally, this DTC sets.

HCU
ABS module
PINPOINT TEST I: DTCs C1288 AND C1440
Test Step h> Result / Action to Take
PINPOINT TEST H: DTCs B2900 AND C1805 3208
I1 MONITOR THE PCM BRAKE
ON/OFF (BOO) PID
Ignition ON.
DataLogger - PCM.

Press and release the brake
pedal while monitoring the
BOO PID.

Does the PID switch to ON
with the brake pedal pressed
and then to OFF with the
brake pedal released?

Yes
GO to I2 .
No
RETRIEVE any PCM DTCs. REFER to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual for
non-communication DTCs and REFER to Section 418-00 for
any communication DTCs.
I2 REVIEW THE ABS MODULE
DTCs
Ignition ON.
mode on the scan tool: Clear All
ABS Module DTCs.

Ignition OFF.
Ignition ON.
- ABS Module .

Retrieve and record any ABS
module DTCs.

Is DTC C1288 or C1440
present?

Yes
G I4 .
No
GO to I3 .
I3 CHECK FOR RETURNING
DTCs
ABS Module DTCs.

Drive the vehicle in a straight
line at a speed greater than 40
km/h (25 mph) for at least 60
seconds.

- ABS Module .

Retrieve and record any ABS
module DTCs.

present?

Yes
For DTC C1288, GO to I5 . For DTC C1440, GO to I4 .
No
The concern is not present at this time. For all other DTCs,
REFER to the ABS Mule DTC Chart.
I4 CARRY OUT THE ABS
SERVICE BLEED
Yes
GO to I6 .
PINPOINT TEST I: DTCs C1288 AND C1440 3209
Carry out the Brake System
Service Bleed, refer to Section
206-00 . Clear the DTCs.
Repeat the self-test.

Ignition ON.
ABS Module DTCs.

Drive the vehicle in a straight
line at a speed greater than 40
km/h (25 mph) for at least 60
seconds.

- ABS Module .

present?

No
The system is operating correctly at this time. The concern may
have been caused by air trapped in the hydraulic brake system.
I5 CHECK THE ABS TO HCU
CONNECTION
Ignition OFF.
Remove the ABS module. Refer
to Anti-Lock Brake System
(ABS) Module in this section.

Inspect the ABS module-to-
HCU mating surfaces for
damage or contamination.

Inspect the 4-pin
pressure sensor
connector in the ABS
module and on the HCU
side for damage,
corrosion or
contamination.

Are the ABS-to- HCU mating
surfaces undamaged and free
of contamination or
corrosion?

Yes
GO to I6 .
No
INSTALL a new HCU . REFER to Hydraulic Control Unit
(HCU) in this section. If there is visible damage to the ABS
module, INSTALL a new ABS module. REFER to Anti-Lock
Brake System (ABS) Module in this section.
I6 CHECK THE ABS MAIN
BRAKE PRESSURE (MPRETDR)
PID
If not already done, separate the
ABS module from the HCU .
Refer to Anti-Lock Brake
System (ABS) Module in this
section.

With the ABS module separated
from the HCU , connect ABS
module C135.

Ignition ON.
Yes
INSTALL a new HCU . REFER Hydraulic Control Unit
(HCU) in this section. CLEAR the DTCs. TEST the system for
normal operation.
No
INSTALL a new ABS module. REFER to Anti-Lock Brake
System (ABS) Module in this section. CLEAR the DTCs.
PINPOINT TEST I: DTCs C1288 AND C1440 3210
DataLogger - ABS Module .

Monitor the MPRETDR PID.
Is the PID value between
21.13K and 22.59K?

Pinpoint Test J: DTC C1996
Normal Operation
The ABS module uses information (wheel speed, steering wheel position, vehicles stability) received from
various sensors and modules to determine if a vehicle instability event is about to occur. If an event is going to
occur, the ABS module adjusts the brake torque at specific wheels and the PCM reduces engine torque to
make the vehicle more stable. Once the ABS module has determined that the stability event has been
corrected, it returns brake and engine torque to normal and continues to monitor the vehicle.
DTC C1996 (Active Yaw and/or Roll Control Disabled) - The ABS module monitors the stability
event and is programmed to set DTC C1996 and disable the stability control system if the stability
event lasts longer than 15 seconds.

Steering wheel rotation sensor (3.5L only)
Wheel speed sensors
ABS module
High Speed Controller Area Network (HS-CAN)
Power Steering Control Module (PSCM)
PINPOINT TEST J: DTC C1996
J1 CHECK FOR ABS
MODULE DTCs
Review the DTCs
recorded during
Inspection and
Verification.

Are any DTCs other
than C1996 present?

Yes
REPAIR all other DTCs before repairing C1996. GO to the ABS
Module DTC Chart in this section.
No
GO to J2 .
J2 CHECK RETURNING
DTCs
Ignition ON.
Using the scan tool,
clear all ABS module
DTCs.

Cycle the ignition
switch from RUN to

Yes
If only DTC C1996 is present, GO to J3 .
If DTC C1996 is present along with other DTCs, REPAIR the other
DTCs before repairing DTC C1996. GO to the ABS Module DTC
Chart in this section.
No
OFF and back to RUN.
Test drive the vehicle
above 49 km/h (30
mph).

Enter the following
ABS Module.

Are any ABS module
DTCs present?

The condition is not present at this time.
a>J3 CHECK THE WHEEL
SPEED SENSOR PIDs
Ignition ON.
Enter the following
ABS Module .

While driving the
vehicle, have an
assistant monitor the
following wheel speed
sensor PIDs:

Left Front
Wheel Speed
Sensor
(LF_WSPD)

Right Front
Wheel Speed
Sensor
(RF_WSPD)

Left Rear
Wheel Speed
Sensor
(LR_WSPD)

Right Rear
Wheel Speed
Sensor
(RR_WSPD)

Do all the PIDs match
the vehicle speed and
match each other?

Yes
GO to J8 .
No
GO to J4 .
J4 INSPECT THE WHEEL
SPEED SENSOR
MOUNTING
Ignition OFF.
With the vehicle in
NEUTRAL, position it
on a hoist. Refer to
Section 100-02 .

Yes
GO to J5 .
No
TIGHTEN the wheel speed sensor bolt to specification. REFER to
Specifications in this section. CLEAR the DTCs.
PINPOINT TEST J: DTC C1996 3212
Verify the bolt of the
suspect wheel speed
sensor is tightened to
specifications.

Is the bolt tightened to
specifications?

SPEED SENSOR AND
HARNESS FOR DAMAGE
NOTE: Examine the
wheel speed sensor
harness carefully with a
good light source.
Failure to verify
damage in the sensor
harness can lead to
unnecessary installation
of a new component.

Inspect the suspect
wheel speed sensor and
harness for cuts, broken
tabs, broken casing
and/or corrosion.

Are the wheel speed
sensor and harness
OK?

Yes
GO to J6 .
No
INSTALL a new wheel speed sensor. REFER to Wheel Speed Sensor -
Front , href="SCS~us~en~file=SCS69011.HTM~gen~ref.HTM"
>Wheel Speed Sensor - Rear, All Wheel Drive (AWD) or Wheel Speed
Sensor - Rear, Front Wheel Drive (FWD) in this section. CLEAR the
SPEED SENSOR RING FOR
DAMAGE
NOTE: Examine the
wheel speed sensor ring
carefully with a good
light source. Failure to
verify damage in the
sensor ring can lead to
unnecessary installation
of a new component.

Inspect the suspect
wheel speed sensor ring
for cracks, chips or
missing teeth. Rotate
the wheel to verify that
no teeth are missing.

Is the wheel speed
sensor ring OK?

Yes
GO to J7 .
No
INSTALL a new wheel hub and bearing assembly (wheel speed sensor
rings are part of the wheel hub and bearing assembly). Refer to the
appropriate section in Group 204 for the procedure. CLEAR the DTCs.
BEARING FOR DAMAGE
AND LOOSENESS
Verify that the wheel
bearing has no end-play

Yes
INSTALL a new wheel speed sensor. REFER to Wheel Speed Sensor -
Front , Wheel Speed Sensor - Rear, All Wheel Drive (AWD) or Wheel
and is undamaged.
Is the wheel bearing
OK?

Speed Sensor - Rear, Front Wheel Drive (FWD) in this section.
No
INSTALL a new wheel hub and bearing assembly. Refer to the
appropriate section in Group 204 for the procedure. CLEAR the DTCs.
J8 CHECK THE ABS
MODULE YAW RATE
(YAWRATE) PID
NOTE: The vehicle
must be on level ground
and at a complete
standstill. Any vehicle
movement results in
false values for this test.

Monitor the
YAWRATE PID.

Is the YAWRATE PID
value between -0.05
and 0.05?

Yes
GO to J9 .
No
GO to J11 .
J9 CHECK THE ABS
MODULE LATERAL
ACCELERATION
(LAT_ACCL) PID
NOTE: The vehicle
and at a complete
movement results in

Monitor the
LAT_ACCL PID.

Is the LAT_ACCL
PID value between
-0.4 and 0.4?

Yes
If the vehicle is equipped with All-Wheel Drive (AWD), GO to J10 .
For all other vehicles, GO to J12 .
No
GO to J11 .
J10 CHECK THE ABS
MODULE LONGITUDINAL
ACCELERATION
(LONG_ACCL) PID
NOTE: The vehicle
and at a complete
movement results in

Monitor the
LONG_ACCL PID.

Is the LONG_ACCL
PID value between

Yes
GO to J12 .
No
GO to J11 .
-0.4 and 0.4?
J11 CHECK THE RCM
INSTALLATION AND
MOUNTING SURFACE
Ignition OFF.
WARNING: Turn
the ignition OFF and
wait one minute to
deplete the backup
power supply. Failure
to follow this
instruction may result
in serious personal
injury or death in the
deployment.

Gain access to the RCM
and inspect the RCM
installation. Make sure
that the nuts are fully
seated and tightened
correctly. Refer to
Section 501-20B .

Inspect the mounting
surface for damage,
corrosion or dirt.

Is the RCM installed
correctly and is the
mounting surface
clean and free from
damage?

Yes
INSTALL a new RCM . REFER to Section 501-20B . TEST the system
No
REPAIR, REINSTALL or INSTALL new as necessary. CLEAR the
DTC. REPEAT the self-test.
J12 CHECK THE
STEERING WHEEL ANGLE
SENSOR POSITION (SWA
POS) PID
NOTE: For all vehicles
except those with a
3.5L engine, the
steering wheel angle
information is sent to
the ABS module from
the PSCM over the
HS-CAN bus.
Monitor the SWA POS
PID while rotating the
steering wheel
clockwise and
counterclockwise very
slowly, from lock to
lock.

Yes
GO to J13 .
No
For vehicles equipped with a 3.5L engine, INSTALL a new steering
wheel rotation sensor. REFER to Steering Wheel Rotation Sensor in
this section. CLEAR the DTCs. REPEAT the self-test.
For all other vehicles, CARRY OUT a self-test of the PSCM . REFER
Does the PID change
in intervals of 1.5
degrees on vehicles
with a 3.5L engine
(intervals of 0.05-0.25
degrees on all other
vehicles) and show a
360-degree increase
for each complete
revolution of the
steering wheel?

J13 CHECK FOR
CORRECT ABS MODULE
OPERATION
Disconnect: ABS
Module C155.

Check the connector
for:

corrosion.
pushed-out
pins.

spread
terminals.

Connect: ABS Module
C155.

Make sure the ABS
module electrical
connector is fully
seated, then operate the
system and verify the

Is the concern still
present?

Yes
(ABS) Module in this section. CLEAR the DTCs. REPEAT the
self-test.
No
The system is operating correctly at this time. The concern may have
been caused by a loose or corroded connector. CLEAR the DTCs.
Pinpoint Test K: DTCs C109D, C109E and C109F
Normal Operation
The vacuum sensor is used by the ABS module to determine if hydraulic pump intervention is necessary due
to loss of vacuum. The ABS module sends a 5-volt reference voltage to the sensor, the sensor compares the
pressure in the booster to the ambient air pressure in the engine compartment and sends a varying voltage
back to the ABS module based on the difference between the pressures. Normally, the pressure in the booster
is much lower than ambient air pressure, as the pressure in the booster gets higher (closer to matching ambient
air pressure), the lower the voltage sent back to the ABS module becomes.
When the vacuum in the brake booster falls below a predetermined level, the ABS module commands the
hydraulic pump motor to activate on the next (and any subsequent) brake pedal application to assist with
vehicle braking. The ABS module continues to use the pump motor for braking assist as long as the low
vacuum condition exists.
DTC C109D (Low Vacuum Condition Detected) - This DTC is set when the optimized hydraulic
brake system is activated and does not necessarily indicate a concern with the vacuum sensor, the
related wiring or the ABS module. This DTC most likely indicates a vacuum concern in the brake
booster, engine and any related vacuum hoses/tubes. High altitude locations with low ambient air
temperatures can cause a low vacuum condition to exist in the booster until the engine compartment
warms up.

DTC C109E (Vacuum Sensor Circuit Fault) - If, during normal operation or the ABS module
on-demand self test, the ABS module detects an open circuit, a short to voltage or a short to ground
on the vacuum sensor circuits, DTC C109E sets. Also, a failure of the vacuum sensor causes DTC
C109E to set.

DTC C109F (Vacuum Sensor Signal Fault) - The vacuum sensor has 4 ambient air pressure inlet ports
(2 on each side). If these ports become restricted or clogged, DTC C109F sets.

Vacuum sensor
ABS module
PINPOINT TEST K: DTCs C109D, C109E AND C109F
probe adapter(s) may damage the connector.Test StepResult / Action to Take K1 CHECK THE ABS
MODULE DTCs
Review the DTCs recorded during Inspection and Verification.
Was DTC C109D the only recorded DTC?
Yes
GO to K2 .
No
If DTC C109E and/or C109F was retrieved, GO to K6 .
For all other DTCs, REFER to the ABS Module DTC Chart in this section. K2 CHECK DTC
RETURNABILITY
Using the scan tool, clear the ABS module DTCs.
Ignition OFF.
Disconnect the scan tool.
Start the engine.
NOTE: It may take up to 3 minutes for DTC C109D to set.
Allow the vehicle to idle for a minimum of 4 minutes.
Ignition OFF.
Ignition ON.
Enter the following diagnostic mode on the scan tool: Self Test - ABS Module.
Is DTC C109D the only vacuum sensor DTC present?
Yes
GO to K3 .
No
If DTC C109E and/or C109F was retrieved, GO to K6 .
PINPOINT TEST K: DTCs C109D, C109E AND C109F 3217
For all other DTCs, REFER to the ABS Module DTC Chart in this section. K3 CHECK THE ENGINE
VACUUM
Carry out the Intake Manifold Vacuum Test, refer to Diagnosis and Testing in Section 303-00 .
Record the vacuum reading.
Does the vacuum gauge indicate normal vacuum?
Yes
GO to K4 .
No
FOLLOW the diagnostic direction as laid out in Section 303-00 . K4 CHECK THE BRAKE BOOSTER
Carry out the Brake Booster Component Test, refer to Diagnosis and Testing in Section 206-00 .
Do the brake booster and check valve pass the component test?
Yes
GO to K5 .
No
REPAIR or INSTALL new as necessary. CLEAR the DTC. REPEAT the self-test. K5 CHECK THE
BRAKE BOOSTER VACUUM LEVEL PID
Start the engine.
Enter the following diagnostic mode on the scan tool: DataLogger - ABS Module.
Compare the recorded vacuum reading to the brake booster vacuum level PID.
Does the PID match the recorded vacuum reading?
Yes
INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. TEST The
No
INSTALL a new brake booster vacuum sensor. REFER to Section 206-07 . CLEAR the DTCs. TEST the
system for normal operation. K6 CHECK THE BRAKE BOOSTER VACUUM SENSOR
Inspect the vacuum sensor ambient air pressure inlet ports.
Are all 4 ports free of contamination and/or foreign material?
Yes
GO to K7 .
No
REPAIR or INSTALL a new vacuum sensor as necessary. REFER to Section 206-07 . CLEAR the DTCs.
REPEAT the self-test. K7 CHECK THE BRAKE BOOSTER VACUUM SENSOR CIRCUITS FOR A
SHORT TO GROUND
Ignition OFF.
Disconnect: Brake Booster Vacuum Sensor C1603.
brake booster vacuum sensor C1603-1, circuit VCA38 (BN/VT), harness side.
brake booster vacuum sensor C1603-2, circuit RCA37 (WH/BU), harness side.
brake booster vacuum sensor C1603-3, circuit LCA37 (YE/OG), harness side.
Yes
GO to K8 .
No
REPAIR the affected circuit(s). CLEAR the DTCs. REPEAT the self-test. K8 CHECK THE BRAKE
BOOSTER VACUUM SENSOR CIRCUITS FOR AN OPEN
Measure the resistance between the ABS module C135, harness side and the brake booster vacuum
sensor C1603, harness side as indicated in the following chart:

ABS Module Circuit Vacuum Sensor
C135-30 VCA38 (BN/VT) C1603-1
C135-27 RCA37 (WH/BU) C1603-2
C135-26 LCA37 (YE/OG) C1603-3
Yes
GO to K9 .
No
REPAIR the affected circuit(s). CLEAR the DTCs. REPEAT the self-test. K9 CHECK THE BRAKE
BOOSTER VACUUM SENSOR CIRCUITS FOR A SHORT TOGETHER
brake booster vacuum sensor C1603-1, circuit VCA38 (BN/VT), harness side and brake
booster vacuum sensor C1603-2, circuit RCA37 (WH/BU), harness side.

brake booster vacuum sensor C1603-1, circuit VCA38 (BN/VT), harness side and brake
booster vacuum sensor C1603-3, circuit LCA37 (YE/OG), harness side.

brake booster vacuum sensor C1603-2, circuit RCA37 (WH/BU), harness side, and brake
booster vacuum sensor C1603-3, circuit LCA37 (YE/OG), harness side.

Yes
GO to K10 .
No
REPAIR the affected circuit(s). CLEAR the DTCs. REPEAT the self-test. K10 CHECK THE ACTIVE
BRAKE BOOSTER CIRCUITS FOR A SHORT TO VOLTAGE
Ignition ON.
brake booster vacuum sensor C1603-1, circuit VCA38 (BN/VT), harness side.
brake booster vacuum sensor C1603-2, circuit RCA37 (WH/BU), harness side.
brake booster vacuum sensor C1603-3, circuit LCA37 (YE/OG), harness side.
Yes
REPAIR the affected circuit(s). CLEAR the DTCs. REPEAT the self-test.
No
GO to K11 . K11 CHECK THE ABS MODULE CONNECTORS
Check ABS module C135 for:
corrosion.
pushed-out pins.
spread terminals.
Make sure the connector seats correctly, then operate the system and verify the concern is still
present.

Yes
INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. TEST the
No
The system is operating correctly at this time. The concern may have been caused by a loose or corroded
Pinpoint Test L: Poor Vehicle Tracking During Anti-Lock Function
Normal Operation
The operating voltage required to supply the ABS module, hydraulic pump and isolation valves is in a range
between 10 and 16 volts. The ABS module uses input from several different sensors (wheel speed sensors,
Brake Pedal Position (BPP) switch, sensor cluster, etc.) to determine if an ABS event is necessary. If an ABS
event is necessary, the ABS module commands the hydraulic pump motor on and command the Hydraulic
Control Unit (HCU) to actuate the appropriate solenoids. During an ABS event, the front and rear end of the
vehicle should track true to the direction of travel along the vehicle centerline unless driver input dictates
otherwise, there is an internal issue with the HCU or an issue with the base brake system (caliper, tubes, etc.)
that allows one or more wheels to lock up.
Fused battery voltage is supplied to the ABS module from Battery Junction Box (BJB) fuse 10 (30A) along
circuit SBB10 (YE/RD) and fuse 8 (40A) along circuit SBB08 (VT/RD). Fused ignition voltage is supplied to
the ABS module from Smart Junction Box (SJB) fuse 42 (10A) along CBP42 (GN) and ground is provided to
the module along circuit GD123 (BK/GY).
Base brake system
HCU
PINPOINT TEST L: POOR VEHICLE TRACKING DURING ANTI-LOCK FUNCTION
L1 BLEED THE BRAKE SYSTEM
Bleed the brake system using the scan tool.

Test drive the vehicle.
Does the vehicle track correctly?
Yes
The brake system is operating correctly. The
concern may have been caused by air in the
hydraulic system or a sticking valve in the HCU .
No
GO to L2 .
L2 VERIFY VEHICLE TRACKING DURING
NON-ABS BRAKING
Test drive the vehicle and verify vehicle
tracking during normal braking.

Does the vehicle track correctly during
normal braking?

Yes
GO to L3 .
No
The condition could be caused by a base brake
component or vehicle alignment. REFER to
Section 206-00 to verify base brake components
and REFER to Section 204-00 to verify suspension
components.
L3 CHECK THE ABS INLET VALVE
(CLOSED POSITION)
Yes
TOGGLE the LF_INLET output command OFF.
With the vehicle in NEUTRAL, position it
on a hoist. Refer to Section 100-02 .

Rotate all the wheels to make sure they
rotate freely (the transaxle must be in
NEUTRAL).

Ignition ON.
scan tool: ABS DataLogger.

Apply moderate brake pedal effort.
Toggle the left front inlet valve
(LF_INLET) active command ON and at
the same time, have an assistant attempt to
rotate the LF wheel.

Does the LF wheel rotate?
GO to L4 .
No
TOGGLE the LF_INLET output command OFF.
INSTALL a new HCU . REFER to Hydraulic
Control Unit (HCU) in this section. TEST the
L4 CHECK THE ABS INLET VALVE (OPEN
POSITION)
Have an assistant attempt to rotate the LF
wheel.

Yes
No
GO to L5 .
L5 CHECK THE ABS OUTPUT VALVE
(OPEN POSITION)
NOTE: Each activation of the output
command runs the pump for 2 seconds.

Toggle the following active commands ON:
LF_INLET
Left front outlet valve
(LF_OUTLET)

Hydraulic pump motor
(PMP_MOTOR)

At the same time, have an
assistant attempt to rotate
the LF wheel.

Yes
TOGGLE all output commands OFF. GO to L6 .
No
TOGGLE all output commands OFF. INSTALL a
new HCU . REFER to Hydraulic Control Unit
(HCU) in this section. TEST the system for normal
operation.
L6 CHECK THE ABS INLET AND OUTLET
VALVE (CLOSED POSITION)
Have an assistant attempt to rotate the LF
wheel.

Yes
No
Beginning with Step L3, REPEAT this procedure
for the RF, LR and RR wheels using the
appropriate output commands. If no failure occurs,
the system is operating normally.
PINPOINT TEST L: POOR VEHICLE TRACKING DURING ANTI-LOCK FUNCTION 3222
Pinpoint Test M: The Stability/Traction Control System Cannot Be Disabled
Normal Operation
The traction control portion of the AdvanceTrac can be disabled by pressing the traction control switch
located on the instrument panel center finish panel. When the system is disabled, the sliding car OFF icon in
the Instrument Panel Cluster (IPC) illuminates continuously. On MKZ vehicles, the traction control switch is
part of the Front Controls Interface Module (FCIM). On Fusion and Milan vehicles, the traction control
switch is part of the ambient lighting switch.
The IPC sends 5 volts to the traction control switch along circuit CCA15 (YE/GY). When the traction control
switch is pressed, this voltage is sent through the switch and to ground along circuit GD116 (BK/VT). When
the IPC detects this ground, it sends a message to the PCM and the ABS module along the High Speed
Controller Area Network (HS-CAN) bus that the driver has disabled the system. An open circuit or a defective
traction control switch prevents the system from being disabled, but does not set a DTC.
If a MyKeyTM restricted key is in use with Advance Trac always-on feature configured to "on", the traction
control system cannot be disabled. An admin key must be used irder to enable and disable the traction control
system.
DTC C0089:11 (TCS Disable Switch: Circuit Short to Ground) - If the IPC detects the ground signal during
the on-demand self test or if it is shorted to ground, DTC C0089:11 sets. Also, if the traction control switch is
held or stuck closed for more than 2 minutes during normal operation, DTC C0089:11 sets.
IPC
PINPOINT TEST M: THE STABILITY/TRACTION CONTROL SYSTEM CANNOT BE DISABLED
M1 CHECK FOR ANY COMMUNICATION DTCs
Ignition ON.
Check the IPC , the PCM and the ABS module for any
communication DTCs.

Are any communication DTCs present?
Yes
For ABS communication
DTCs, GO to the ABS
Module DTC Chart.
For IPC and PCM
mmunication DTCs,
REFER to the Diagnostic
Trouble Code (DTC)
No
GO to M2 .
M2 ISOLATE THE TRACTION CONTROL SWITCH
Yes
GO to M3 .
NOTE: If a MyKeyTM restricted key is in use with Advance Trac
always-on feature configured to "on", the traction control system
cannot be disabled. An admin key must be used in order to enable
and disable the traction control system.
Ignition OFF.
Disconnect: FCIM C2402 (MKZ).
Disconnect: Traction Control/Ambient Lighting Switch C2304
(Fusion/Milan).

For Fusion or Milan , measure the resistance between traction
control/ambient lighting switch C2304 pin-7 and pin-1, component
side, while pressing and releasing the traction control switch.

For MKZ , measure the resistance between FCIM C2402 pin-7 and
pin-8, component side, while pressing and releasing the switch.

Is the resisnce less than 5 ohms with the switch pressed and
greater than 10,000 ohms with the switch released?

No
For Fusion or Milan ,
INSTALL a new traction
control switch. REFER to
Traction Control Switch in
this section.
For MKZ , INSTALL a
new FCIM . REFER to
Section 415-00 .
TEST the system for
normal operation.
M3 CHECK THE TRACTION CONTROL SWITCH GROUND
CIRCUIT FOR AN OPEN
control/ambient lighting switch C2304-1, circuit GD116 (BK/VT),

For MKZ , measure the resistance between FCIM C2402-8, circuit
GD116 (BK/VT), harness side and ground.

Yes
GO to M4 .
No
(BK/VT). TEST the
system for normal
operation.
M4 CHECK THE TRACTION CONTROL SWITCH CONTROL
CIRCUIT FOR AN OPEN
Disconnect: IPC C220.
control/ambient lighting switch C2304-7, circuit CCA15 (YE/GY),
harness side and IPC C220-18, circuit CCA15 (YE/GY), harness
side.

Yes
GO to M5 .
No
REPAIR circuit CCA15
(YE/GY). TEST the
system for normal
PINPOINT TEST M: THE STABILITY/TRACTION CONTROL SYSTEM CANNOT BE DISABLED 3224
CCA15 (YE/GY), harness side and IPC C220-18, circuit CCA15
(YE/GY), harness side.

operation.
M5 CHECK THE TRACTION CONTROL SWITCH CONTROL
control/ambient lighting switch C2304-7, circuit CCA15 (YE/GY),

CCA15 (YE/GY), harness side and ground.

Yes
GO to M6 .
No
(YE/GY). TEST the
system for normal
operation.
M6 CHECK FOR CORRECT IPC OPERATION
Ignition OFF.
Yes
INSTALL a new IPC .
Check IPC C220 for:
corrosion.
pushed-out pins.
spread terminals.
Connect: IPC C220.
Make sure the connector is seated correctly, then operate the system
and verify the concern is still present.

. TEST the system for
normal operation.
No
corroded connector.
Workshop Manual
Anti-Lock Control Hybrid
Special Tool(s)
Flex Probe Kit
Regenerative Braking
The regenerative brake system utilizes the electric motor portion of the hybrid electric powertrain as a
generator to create electrical current. This recharges the High Voltage Traction Battery (HVTB) and delivers
brake torque to be used in place of or in combination with the conventional friction brakes to slow the vehicle.
The amount of brake torque provided by the electric motor is dependent upon the state of charge of the HVTB
. When the HVTB is almost fully charged, the amount of regenerative braking is limited to avoid
overcharging, and the requested deceleration is produced by conventional friction braking alone.
Conventional Friction Braking
If the HVTB is almost fully charged, or the requested amount of braking cannot be achieved by regenerative
braking alone, the ABS module applies the conventional friction brakes. The friction brakes utilize
components similar to those found in a conventional vacuum assisted brake system with ABS. For a list of
components, refer to Section 206-00 .
Brake-By-Wire
During a normal brake application, the brake pedal feel simulator allows the pressure applied to the brake
pedal by the driver's foot to act against a spring instead of the brake booster push rod. The brake pedal angle
sensor is mounted to the brake pedal assembly and provides the ABS module with an analog signal indicating
the amount of deceleration the driver is demanding. If it is necessary for the conventional friction brakes to be
applied, the ABS module applies a Pulse Width Modulated (PWM) voltage to a vacuum solenoid inside the
active brake booster. The solenoid allows vacuum from either the combustion engine (if the engine is running)
Anti-Lock Control Hybrid 3227
or the electric vacuum pump to move the booster push rod which in turn pushes the piston in the master
cylinder and create hydraulic brake pressure. If the brake pedal is applied quickly and forcefully enough, the
driver can overcome the brake pedal feel simulator spring pressure, allowing a direct connection between the
brake pedal, booster push rod and master cylinder.
Brake Pedal Feel Simulator and Cut-Off Device
When the ignition is turned on, the ABS module runs a series of checks to make sure the system is running
properly. Once these checks are complete, the ABS module closes the valve in the simulator cut-off device
which puts the brake system into brake-by-wire mode. Brake-by-wire mode is when the pedal feedback to the
driver is provided by the pedal feel simulator and not the pressure in the base brake system. The simulator
uses spring pressure to provide a familiar brake pedal sensation. When the driver presses the brake pedal, the
ABS module interprets the pedal movement through the brake pedal angle sensor. Based on the pedal angle
and the amount of brake torque that can be provided through regenerative braking, the ABS module
determines how much brake torque is provided by the power train and how much is provided by the hydraulic
brakes. The brake pedal is uncoupled from the brake booster push rod allowing the system to hold off
hydraulic pressure when regenerative braking is providing the necessary brake torque. When hydraulic
braking is required, the ABS module activates the booster solenoid, this allows the vacuum booster to push on
the master cylinder creating pressure in the hydraulic system. In the event a fault occurs which inhibits the
brake-by-wire mode, the ABS module opens the cut-off device valve. This puts the system into conventional
mode with vacuum boosted hydraulic brakes and no regenerative braking. In this mode, the pedal feedback to
the driver is provided by the booster. When the driver pushes the pedal, the uncoupling between the pedal and
the booster push rod is overcome, and the pedal arm pushes on the booster push rod as in a conventional brake
system.
Active Brake Booster
The active brake booster is similar to a conventional vacuum assisted brake booster with the addition of a
brake booster solenoid, a brake booster travel sensor and a vacuum pressure sensor. If it is necessary to apply
the friction brakes due to inadequate deceleration from regenerative braking, the ABS module sends a PWM
voltage to the brake booster solenoid that is proportional to the amount of brake torque requested. The booster
solenoid opens, which allows the vacuum booster push rod to push on the master cylinder creating pressure in
the hydraulic system.
The ABS module uses the signals produced by the vacuum pressure sensor to verify that vacuum is being
maintained in the brake booster. The ABS module uses the signals produced by the brake booster travel sensor
to monitor brake booster performance.
Electric Vacuum Pump
When the combustion engine is not running, an electric vacuum pump is used to maintain vacuum inside the
brake booster. The ABS module turns the electric vacuum pump on and off through the use of a mechanical
relay and a solid state relay. If the ABS module detects a vacuum pump motor circuit concern, a vacuum
system leak or a vacuum pump performance concern, a DTC sets in the ABS module and the combustion
engine runs to provide vacuum for the brake booster.
Anti-Lock Braking
The ABS module continuously monitors and compares the rotational speed of each wheel. This is
accomplished through the use of 4 active wheel speed sensors, one for each wheel. The wheel speed sensors
are connected to the ABS module by 2 circuits. One circuit provides voltage for sensor operation and the other
circuit provides sensor input to the ABS module. As the wheels spin, the wheel speed sensor tone rings pass
through the magnetic field generated by the active wheel speed sensor. This creates a square-wave signal that
is sent to the ABS module to indicate individual wheel speed.
The ABS module uses a Hydraulic Control Unit (HCU) to prevent the wheels from locking up during a
braking event. The HCU contains several solenoid-controlled valves, a pump motor, an accumulator and
several sensors. The fluid flows through 4 normally open inlet valves inside the HCU and through the outlet
ports of the HCU to the brake calipers. If the ABS module senses that a wheel is about to lock up, based on
wheel speed sensor data, the module closes the normally open inlet valve for that wheel. This prevents more
fluid from getting to the brake caliper. The ABS module then reads the wheel speed sensor signal from the
affected wheel again. If the wheel is still decelerating (locking up), the module opens the normally closed
outlet valve. This allows a controlled amount of hydraulic pressure in the brake caliper to be relieved into the
HCU accumulator. The ABS pump motor runs during an ABS braking event so that sufficient brake fluid
pressure is consistently available to the HCU valves. This procedure of closing and opening valves is repeated
several times per second until the speed of the affected wheel matches the speeds of the other wheels. Once
this has been accomplished, the ABS module returns the solenoid valves to their normal positions.
The ABS module is self-monitoring. When the ignition switch is turned to the RUN position, the ABS module
carries out a preliminary electrical check of the wheel speed sensor circuitry by sending voltage through the
sensor and checking for the voltage to return. At speeds above 20 km/h (12 mph), without the brake pedal
being pressed, the pump motor is commanded ON for less than 2 seconds to check pump motor operation.
Also, during all phases of operation while the vehicle is in motion, the ABS module checks for correct
operation of the wheel speed sensors. In the event that the ABS module detects a concern, the module sets a
DTC and send a message to the Instrument Panel Cluster (IPC) over the High Speed Controller Area Network
(HS-CAN) bus to illuminate the yellow ABS warning indicator, the stability/traction control indicator (also
known as the sliding-car icon) and/or the red brake warning indicator. If the concern is severe enough, ABS
may be disabled. Normal power-assisted braking, however, remains.
The ABS module incorporates a strategy called Electronic Brake Distribution (EBD). The EBD strategy uses
the HCU as an electronic proportioning valve. On initial application of the brake pedal, full pressure is applied
to the rear brakes. The ABS module uses wheel speed input to calculate an estimated rate of deceleration.
Once vehicle deceleration exceeds a certain threshold, the ABS module closes the appropriate solenoid valves
in the HCU to hold the rear brake pressure constant while allowing the front brake pressure to build. This
creates a balanced braking condition between the front and rear wheels and minimizes the chance of rear
wheel lockup during hard braking. As the vehicle decelerates, the valves are opened to increase the rear brake
pressure in proportion to the front brake pressure.
Some drivers may feel a slight bump sensation in the brake pedal when EBD is active.
If there is a DTC in the ABS module specifically for the HCU or there are 2 or more wheel speed sensor
DTCs, EBD is disabled. When EBD is disabled, the ABS warning indicator, the red brake warning indicator
and the sliding-car icon is illuminated.
The AdvanceTrac system provides the following stability enhancement features for certain driving
situations:
Traction Control System helps to avoid excessive drive-wheel spin and loss of traction.
Electronic Stability Control (ESC) System helps to avoid skids and lateral slides.
The traction control system uses the ABS and the PCM to limit wheel spin. When the ABS module detects a
wheel spinning excessively, brake pressure to the appropriate brake caliper is modulated. This is
accomplished by opening and closing the appropriate solenoid valves inside the HCU while the hydraulic
pump motor is activated. At the same time, the ABS module sends a message over the HS-CAN bus that a
traction control event is taking place. When the IPC receives this message, it flashes the sliding-car icon
(twice per second). If the event is severe enough, the ABS module also sends a message to the PCM over the
HS-CAN bus to assist with traction control. When the PCM receives this message, it adjusts engine timing
and decreases fuel injector pulses. Once the affected wheel returns to normal speed, the ABS module returns
the solenoid valves in the HCU to their normal position, deactivates the hydraulic pump motor and sends
another message over the HS-CAN bus indicating that the traction event has ended. The PCM returns engine
timing and fuel injectors to normal operation and the IPC extinguishes the sliding-car icon.
Once vehicle speed reaches or exceeds 100 km/h (62 mph), traction control is accomplished only through
PCM intervention.
Certain DTCs in the ABS module disables the traction control system. Depending on the DTCs present, the
yellow ABS warning indicator and/or the sliding-car icon are illuminated.
Electronic Stability Control (ESC) System
The ESC system is controlled by the ABS module and uses the same wheel speed sensors and tone rings that
are used for anti-lock braking. The ESC system also uses input from the steering wheel rotation sensor and the
stability control sensors (yaw rate, roll rate, longitudinal acceleration and lateral acceleration), which are
internal to the Restraints Control Module (RCM). Additional information from other modules is sent over the
HS-CAN bus to help maintain vehicle stability.
The ABS module uses the various sensors to continuously monitor vehicle direction of travel relative to the
driver's intended course. If the ABS module determines from all these inputs that the vehicle is unable to
travel in the intended direction, it modulates brake pressure to the appropriate brake caliper(s) by opening and
closing the appropriate solenoid valves inside the HCU while the hydraulic pump motor is activated. At the
same time, the ABS module sends a message over the HS-CAN bus that a stability event is taking place.
When the IPC receives this message, it flashes the sliding-car icon. Under certain conditions during a stability
event, the PCM may be requested to reduce engine torque as it does for traction control. Once the stability
condition has been corrected, the ABS module sends another message over the HS-CAN bus indicating that
the event has ended. The PCM returns engine timing and fuel injectors to normal operation and the IPC
extinguishes the sliding-car icon.
Certain DTCs being present in the ABS module may disable the ESC system. Depending on the DTCs
present, the yellow ABS warning indicator and/or the sliding-car icon is illuminated.
Unlike conventional ABS, the traction control portion of the AdvanceTrac can be deactivated by the driver
through the use of the traction control switch. The switch is hardwired to the IPC . When pressed, the switch
sends a ground signal to the IPC . The IPC then sends a message over the HS-CAN bus indicating that the
driver has requested that the system be deactivated and illuminates the sliding-car OFF icon. Once disabled,
the system remains in that state until the driver presses the switch again or the ignition is cycled.
Stability Control Sensors
The stability control sensors for the AdvanceTrac system consist of the yaw rate sensor, lateral
accelerometer and longitudinal accelerometer. The sensors are housed in the RCM which sends sensor
information to the ABS module over the dedicated Controller Area Network (CAN) bus. If any of the sensors
are defective, a new RCM must be installed. Refer to Section 501-20B for additional information on the RCM
.
The yaw rate sensor measures the relative vehicle motion about the vertical axis through the vehicle
center of gravity.

The longitudinal accelerometer measures the acceleration corresponding to the force involved when
the vehicle moves forward and rearward in the horizontal plane, along the centerline of the vehicle's
front and rear wheels.

The lateral accelerometer measures the acceleration that corresponds to the force involved when the
vehicle moves sideways.

Lateral acceleration has 2 forms. The first is the centrifugal acceleration that is generated when the vehicle
travels around in a circle. The second is the acceleration due to gravity. On level ground there is no
contribution from this acceleration. However, if the vehicle is parked sideways on a bank or incline, the sensor
measures some lateral acceleration due to gravity, even though the vehicle is not moving.
Steering Wheel Position Information
The steering wheel position information is sent to the ABS module from the Power Steering Control Module
(PSCM) along the HS-CAN bus. The PSCM calculates steering position based on motor position within the
Electronic Power Assist Steering (EPAS) steering gear. For information on the PSCM and EPAS system, refer
ABS Module Calibration (Multi-Calibration Routine)
When an ABS fault has been corrected or an ABS component has been replaced, it is necessary to calibrate
the ABS module. The calibration procedure is required for the brake-by-wire sensors to learn the
"zero-position" of the vehicle which means the vehicle must not be moving and that the brake pedal must not
be applied.
To carry out the calibration procedure, connect the scan tool, proceed to the Multi-Calibration routine and
follow the scan tool instructions.
ABS Module Configuration
When a new ABS module is installed, it must be configured. To configure the ABS module, refer to
Programmable Module Installation (PMI) in Section 418-01 .
NOTE: If a new ABS module is installed, it must be configured and the multi-calibration completed. Follow
the scan tool directions.
Verify the stoplamps operate correctly by applying and releasing the brake pedal with the ignition
switch in the OFF position. If the stoplamps do not operate correctly, refer to Section 417-01 . If the
stoplamps operate correctly, proceed to the next step.
2.
Verify the PRNDL operates correctly on the instrument cluster. If the PRNDL does not operate
correctly, refer to Section 413-01 . If the PRNDL operates correctly, proceed to the next step.
3.
Active brake booster
Base brake system
Brake pedal assembly
Incorrectly inflated tires
Mismatched wheels or tires on vehicle
installation

Steering components and suspension
components

Wheel speed sensor ring
ABS module
Battery Junction Box (BJB)
fuse(s):
3 (40A)
7 (40A)
8 (50A)
10 (30A)
37 (5A)
47 (10A)

Brake fluid level switch
mechanical relay

Electric vacuum pump solid
state relay

PCM relay
RCM
Stoplamp switch
Wheel speed sensor
5.
6.
7.
8.
418-00 .

(CMDTCs).

9.
NOTE: The vehicle must be at a complete standstill and on a level surface while carrying out the
self-test. Any movement of the vehicle during the self-test may result in false DTCs being set.
Carry out the self-test diagnostics for the ABS module.
10.
If the DTCs retrieved are related to the concern, go to ABS Module DTC Chart in this section. For all
11.
DTC Charts
NOTE: This DTC chart applies to hybrid vehicles only . For non-hybrid vehicle DTCs, refer to the ABS
Module DTC Chart in Anti-Lock Control Non-Hybrid in this section.
ABS Module DTC Chart
C0001:49 TCS Control Channel A
Valve 1: Internal Electric
Failure
a
This DTC indicates that part of the ABS module has failed
internally. CLEAR the DTCs. REPEAT the self-test. If DTC
C0001:49 returns, INSTALL a new ABS module. REFER to
Anti-Lock Brake System (ABS) Module Hybrid in this
section.
C0002:49 TCS
a
Control Channel A
Valve 2: Internal Electronic
Failure
section.
C0003:49 TCS
a
Control Channel "B"
Failure
section.
C0004:49 TCS
a
Control Channel "B"
Failure
section.
C0010:49 Left Front Inlet Control:
section.
C0011:49 Left Front Outlet Control:
section.
C0014:49 Right Front Inlet Control:
section.
C0015:49 Right Front Outlet Control:
section.
C0018:49 Left Rear Inlet Control:
section.
C0019:49 Left Rear Outlet Control:
section.
C001C:49 Right Rear Inlet Control:
C001C:49 returns, INSTALL a new ABS module. REFER to
section.
C001D:49 Right Rear Outlet Control:
C001D:49 returns, INSTALL a new ABS module. REFER to
section.
C0020:11 ABS Pump Motor Control:
Circuit Short To Ground
C0020:11 returns, INSTALL a new HCU and ABS module.
REFER to Hydraulic Control Unit (HCU) Hybrid in this
section.
C0020:12 returns, INSTALL a new HCU and ABS module.
REFER to Hydraulic Control Unit (HCU) Hybrid in this
section.
Circuit Open
Actuator Stuck
C0021:21 Brake Booster Performance:
Signal Amplitude
GO to Pinpoint Test Q .
Signal Has Too Many
Transitions/Events
Commanded Position Not
Reachable
C0022:11 Brake Booster Solenoid:
Circuit Open
Circuit Short To Ground or
Open
C0022:1D Brake Booster Solenoid:
C0030:07 Left Front Tone Wheel:
Mechanical Failure
C0031:01 Left Front Wheel Speed
Sensor: General Electrical
Failure
Sensor: Signal Invalid
C0031:2F Left Front Wheel Speed
Sensor: Signal Erratic
Sensor: Signal Plausibility
Failure
C0033:07 Right Front Tone Wheel:
Mechanical Failure
C0034:01 Right Front Wheel Speed
Failure
C0034:2F Right Front Wheel Speed
Failure
C0036:07 Left Rear Tone Wheel:
Mechanical Failure
C0037:01 Left Rear Wheel Speed
Failure
C0037:2F Left Rear Wheel Speed
Failure
C0039:07 Right Rear Tone Wheel:
Mechanical Failure
C003A:01 Right Rear Wheel Speed
Failure
C003A:2F Right Rear Wheel Speed
Failure
C0044:28 Brake Pressure Sensor "A":
Signal Bias Level Out of
Range/Zero Adjustment
Failure
This DTC is set if the brake pressure sensor signals do not match.
This fault could set by either an internal ABS module failure or a
pressure sensor failure. The pressure sensors are internal to the
HCU and cannot be serviced separately.
CLEAR the DTCs. REPEAT the self-test. If DTC C0044:28
returns, make sure all ABS module-to- HCU fasteners are
tightened to their correct torque specifications.
If all fasteners are tightened to their correct torque specifications,
System (ABS) Module Hybrid in this section. CLEAR the
DTCs. TEST DRIVE the vehicle. REPEAT the self-test.
If C0044:28 returns again, INSTALL a new HCU . REFER to
Hydraulic Control Unit (HCU) Hybrid in this section.
Signal Plausibility Failure
C0048:11 Brake Booster Travel Sensor:
NOTE: This DTC can set as a result of a booster travel sensor
circuit fault or a circuit fault with other brake system components.
C0061:28 Lateral Acceleration Sensor:
Failure
C0061:64 Lateral Acceleration Sensor:
C0063:28 Yaw Rate Sensor: Signal Bias
Level Out of Range/Zero
Adjustment Failure
C0063:64 Yaw Rate Sensor: Signal
Plausibility Failure
C100A:28 Brake Pedal Angle Sensor:
Failure
This DTC indicates the brake pedal cannot return to the fully
released position. INSTALL a new brake pedal and bracket.
REFER to Brake Pedal and Bracket Hybrid in Section 206-06
.
General Checksum Failure
C100A:41 returns, INSTALL a new ABS module. REFER to
section.
Signal Compare Failure
This DTC can set due to a brake pedal angle sensor, brake pedal
feel simulator cut-off pressure sensor or brake pedal feel simulator
cut-off valve solenoid fault or a mechanical fault with the brake
pedal assembly. CORRECT all other DTCs for the brake pedal
angle sensor and brake pedal feel simulator first.
If only DTC C100A:64 is present, INSTALL a new brake pedal
assembly. REFER to Brake Pedal and Bracket Hybrid in
Section 206-06 .
C100D:21 Brake Pedal Angle Sensor
Circuit 1: Signal Amplitude
Minimum
C100D:22 Brake Pedal Angle Sensor
Circuit 1: Signal Amplitude >
Maximum
C100E:21 Brake Pedal Angle Sensor
Circuit 2: Signal Amplitude
Minimum
C100E:22 Brake Pedal Angle Sensor
Circuit 2: Signal Amplitude >
Maximum
C100F:11 Brake Pedal Angle Sensor
Supply: Circuit Short To
Ground
C100F:12 Brake Pedal Angle Sensor
Supply: Circuit Short To
Battery
C1011:1C Brake Pedal Feel Simulator
Cut-Off Pressure Sensor:
Circuit Voltage Out of Range
C1011:1F Brake Pedal Feel Simulator
Circuit Intermittent
C1011:67 Brake Pedal Feel Simulator
Signal Incorrect After Event
C1012:01 Brake Pedal Feel Simulator
Cut-Off Valve Solenoid:
General Electrical Failure
C1014:07 Brake System Total Volume
Balance: Mechanical Failure
This DTC can set as a result of a brake booster travel sensor fault,
a brake fluid pressure sensor fault or air trapped in the hydraulic
brake system. CORRECT all DTCs that indicate a brake booster
travel sensor fault or a hydraulic brake pressure sensor fault. If
only DTC C1014:07 is present, CARRY OUT the Brake System
Service Bleed, REFER to Brake System Bleeding in Section
206-00 . CLEAR the DTCs, REPEAT the self-test.
If DTC C1014:07 returns, INSTALL a new brake booster. REFER
to Brake Booster in Section 206-07 . CLEAR the DTCs. REPEAT
the self-test.
If DTC C1014:07 returns, INSTALL a new ABS module. REFER
to Anti-Lock Brake System (ABS) Module Hybrid in this
If DTC C1014:07 returns, INSTALL a new HCU . REFER to
C1015:64 Vacuum Supply: Signal
This DTC sets if the ABS module detects a vacuum leak. If other
DTCs are present for the vacuum pump, vacuum pressure sensor
or booster travel sensor, DIAGNOSE them first.
If only DTC C1015:64 is present, INSPECT the vacuum hoses,
lines and fittings for vacuum leaks. REPAIR as necessary.
If DTC C1015:64 returns, INSTALL a new vacuum pump.
REFER to Brake Vacuum Pump in Section 206-07 .
C1015:7A Vacuum Supply: Fluid Leak
or Seal Failure
This DTC sets if the ABS module detects a vacuum leak.
CARRY OUT the brake booster component test. REFER to
Section 206-00 . INSTALL new as necessary. CLEAR the DTCs.
C1015:7B Vacuum Supply: Low Fluid
Level
This DTC sets if the ABS module detects a vacuum leak.
If other DTCs are present for the vacuum pump, vacuum pressure
sensor or booster travel sensor, DIAGNOSE them first. If only
DTC C1015:7B is present, INSPECT the vacuum hoses, lines and
fittings for vacuum leaks. REPAIR as necessary. CLEAR the
If DTC C1015:7B returns, INSTALL a new vacuum pump.
REFER to Brake Vacuum Pump in Section 206-07 .
C1018:00 Regenerative Braking: No
This DTC can set as a result of missing network messages or
invalid data from the PCM over the High Speed Controller Area
Network (HS-CAN) bus. RETRIEVE the DTCs from the PCM.
REFER to the Diagnostic Trouble Code (DTC) Chart in Section
419-10 .
C1018:46 Regenerative Braking:
Calibration/Parameter
Memory Failure
Using the scan tool, CARRY OUT the Multi-Calibration routine.
Follow the scan tool instructions. CLEAR the DTCs. REPEAT the
self-test.
C1018:62 Regenerative Braking: Signal
Compare Failure
This DTC indicates that the PCM cannot provide the amount of
brake torque that the ABS module is requesting.
RETRIEVE the DTCs from the PCM. REFER to the Diagnostic
Trouble Code (DTC) Chart in Section 419-10 .
C101A:1C Vacuum Pressure Sensor:
Circuit Voltage Out of Range
C101A:62 Vacuum Pressure Sensor:
Signal Compare Failure
C101A:64 Vacuum Pressure Sensor:
C101B:1C Vacuum Pressure Sensor
Circuit B: Circuit Voltage
Out of Range
C101C:01 Brake Vacuum Pump:
General Electrical Failure
C101C:71 Brake Vacuum Pump:
Actuator Stuck
C1021:21 ABS Booster Control
Pressure: Signal Amplitude
Minimum
This DTC indicates that other DTCs are present for the brake
pedal angle sensor, the vacuum pressure sensor or a brake (fluid)
pressure sensor. If DTCs for one or more of these components is
present, DIAGNOSE them first. CLEAR the DTCs. REPEAT the
self-test.
If only DTC C1021:21 is present, INSTALL a new ABS module.
REFER to Anti-Lock Brake System (ABS) Module Hybrid in
this section.
CLEAR all DTCs. REPEAT the self-test. If DTC C1021:21
returns, INSTALL a new HCU . REFER to Hydraulic Control
Unit (HCU) Hybrid in this section.
C1021:22 ABS Booster Control
Pressure: Signal Amplitude >
Maximum
This DTC indicates that other DTCs are present for the brake
pedal angle sensor, the vacuum pressure sensor or a brake (fluid)
pressure sensor. If other DTCs are present for the brake pedal
angle sensor, the vacuum pressure sensor or a brake (fluid)
pressure sensor, DIAGNOSE them first. CLEAR the DTCs.
If only DTC C1021:22 is present, INSTALL a new ABS module.
REFER to Anti-Lock Brake System (ABS) Module Hybrid in
this section.
C1025:21 Brake Primary Circuit
Overboost Pressure: Signal
Amplitude Minimum
INSPECT the brake system for brake fluid leaks. REPAIR as
necessary. If no leaks are found, CARRY OUT the Brake System
section. CLEAR the DTCs. TEST DRIVE the vehicle. REPEAT
the self-test.
If C1025:21 returns, INSTALL a new HCU . REFER to Hydraulic
Control Unit (HCU) Hybrid in this section.
C1025:22 Brake Primary Circuit
Amplitude > Maximum
the self-test.
C1026:21 ABS Secondary Circuit
Amplitude Minimum
the self-test.
C1026:22 ABS Secondary Circuit
Amplitude > Maximum
the self-test.
C1027:62 Master Cylinder (MC) to
Primary Circuit Pressure:
Signal Amplitude >
Maximum
the self-test.
C1028:62 ABS Primary Circuit Wheel
Pressure: Signal Compare
Failure
the self-test.
C1029:00 ABS Primary Circuit Pressure
Lower Than Secondary: No
GO to Pinpoint Test AC
C102A:62 Brake Secondary Circuit
Pressure Mismatch Between
Wheels: Signal Compare
Failure
If DTC C102A:62 returns, INSTALL a new ABS module. REFER
the self-test.
If C102A:62 returns, INSTALL a new HCU . REFER to
C102B:00 ABS Secondary Circuit
Pressure Lower Than
Primary: No Sub Type
Information
GO to Pinpoint Test AC
C1108:11 Pedal Sensor(s) Supply
Voltage: Circuit Short To
Ground
C1108:12 Pedal Sensor(s) Supply
Voltage: Circuit Short To
Battery
C1108:1C Pedal Sensor(s) Supply
Voltage: Circuit Voltage Out
of Range
C1133:28 Left Front Brake Pressure
Sensor: Signal Bias Level Out
of Range/Zero Adjustment
Failure
CLEAR the DTCs. REPEAT the self-test. If DTC C1133:28 is
present, make sure all ABS module-to- HCU fasteners are
INSTALL a new HCU and ABS module. REFER to Hydraulic
Sensor: Internal Electronic
Failure
Failure
C1134:28 Right Front Brake Pressure
Failure
Failure
Failure
tightened to their correct torque specifications
C1135:28 Left Rear Brake Pressure
Failure
Failure
Failure
C1136:28 Right Rear Brake Pressure
Failure
Failure
Failure
C1A99:28
Pressure Sensor: Signal Bias
Level Out of Range/Zero
Adjustment Failure
Hydraulic Control Unit (HCU) and cannot be serviced separately.
If C1A99:28 returns, INSTALL a new HCU . REFER to
C1B00:28 Steering Angle Sensor: Signal
Bias Level Out of Range/Zero
Adjustment Failure
NOTE: The Electronic Power Assist Steering (EPAS) gear
assembly contains the steering wheel angle sensor. The sensor is
not serviceable separately from the assembly.
The ABS module receives the steering wheel angle sensor
information from the Power Steering Control Module (PSCM)
over the HS-CAN bus.
The cause of this DTC is indicated by a DTC in the PSCM .
CARRY OUT a self-test of the PSCM . REFER to Diagnosis and
Testing in Section 211-00A to diagnose the DTCs retrieved.
Invalid
NOTE: The EPAS gear assembly contains the steering wheel
angle sensor. The sensor is not serviceable separately from the
assembly.
information from the PSCM over the HS-CAN bus.
assembly.
Invalid
assembly.
P0561:1C
System Voltage Unstable:
Circuit Voltage Out Of Range
The ABS module receives low voltage system information from
the DC to DC Converter Control Module (DC/DC) over the
HS-CAN bus.
If the message the ABS module receives indicates that system
voltage has dropped below 9 volts or has risen above 16 volts,
DTC P0561:1C sets.
CARRY OUT a self-test of the DC/DC converter. REFER to
Diagnosis and Testing in Section 414-05 to diagnose the DTCs
retrieved.
U0001:88 High Speed Controller Area
Network (HS-CAN)
Communication Bus: Bus Off
REFER to Section 418-00 to diagnose the network communication
concern.
ECM /PCM "A": No Sub
Type Information
REFER to Section 418-00 to diagnose the network communication
concern.
Power Steering Control
Module: Missing Message
This DTC can set due to a fault in the EPAS system or because the
PSCM is unable to communicate over the HS-CAN bus.
CARRY OUT a self-test of the PSCM . If the scan tool indicates
that the PSCM is not responding, REFER to Section 418-00 to
diagnose the network communication concern.
If PSCM DTCs are present, REFER to Section 211-00A to
diagnose the EPAS system fault.
Restraints Control Module
(RCM): Missing Message
RCM : Bus off
Instrument Panel Cluster
(IPC) Control Module:
Missing Message
This DTC can set due to an IPC fault or because the IPC is unable
to communicate over the HS-CAN bus.
CARRY OUT a self-test of the IPC . If the scan tool indicates that
the IPC is not responding, REFER to Section 418-00 to diagnose
the network communication concern.
If IPC DTCs are present, REFER to Section 413-01 to diagnose
the IPC fault.
DC to DC Converter Control
Module (DC/DC) "A":
Missing Message
This DTC can set due to a DC/DC fault or because the DC/DC is
unable to communicate over the HS-CAN bus.
CARRY OUT a self-test of the DC/DC . If the scan tool indicates
that the module is not responding, REFER to Section 418-00 to
If DTCs are present in the DC/DC , REFER to Section 414-05 to
diagnose the module fault.
U0300:51 Internal Control Module
Software Incompatibility: Not
Programmed
Installation (PMI) in Section 418-01 . REPEAT the self-test.
If U0300:51 returns, INSTALL a new ABS module. REFER to
section.
ECM /PCM "A": No Sub
Type Information
The PCM sends an "invalid data" message to the ABS module if
there are DTCs in the PCM that prevent known good data from
being sent.
RETRIEVE the DTCs from the PCM. REFER to the Diagnostic
Trouble Code (DTC) Chart in Section 419-10 to diagnose the
powertrain fault.
Power Steering Control
Module: Missing Message
This DTC can set due to a fault in the EPAS system or because the
PSCM is unable to communicate over the HS-CAN bus.
CARRY OUT a self-test of the PSCM . If the scan tool indicates
that the PSCM is not responding, REFER to Section 418-00 to
If PSCM DTCs are present, REFER to Section 211-00A to
diagnose the EPAS system fault.
Instrument Panel Control
Module: Signal Plausibility
Failure
This DTC indicates that the ABS module has not received network
messages from the IPC . This DTC can set due to an IPC fault or
because the IPC is unable to communicate over the HS-CAN bus.
CARRY OUT a self-test of the IPC . If the scan tool indicates that
the IPC is not responding, REFER to Section 418-00 to diagnose
the network communication concern.
If IPC DTCs are present, REFER to Section 413-01 to diagnose
the IPC fault.
Restraints Control Module
(RCM): Signal Invalid
Complete: No Sub Type
Information
section.
Complete: General Checksum
Failure
section.
Complete:
Invalid/Incompatible
Configuration
section.
U3000:41 Control Module: General
Checksum Failure
CORRECT all other DTCs prior to addressing DTC U3000:41. If
only DTC U3000:41 was retrieved from the ABS module,
System (ABS) Module Hybrid in this section.
U3000:43 Control Module: Special
Memory Failure
CLEAR the DTCs. REPEAT the self-test. If U3000:43 is returns,
System (ABS) Module Hybrid in this section.
U3000:47 Control Module:
Watchdog/Safety WC Failure
This DTC can set if the ABS module electrical connector is not
fully seated and locked. DISCONNECT the ABS module C135.
INSPECT the connector for bent or loose pins. REPAIR as
necessary.
If OK, RECONNECT C135. CLEAR the DTCs. REPEAT the
self-test.
If DTC U3000:47 is retrieved again, INSTALL a new ABS
module. REFER to Anti-Lock Brake System (ABS) Module
Electronic Failure
CLEAR the DTCs. REPEAT the self-test. If DTC U3000:49 is
present, INSTALL a new ABS module. REFER to Anti-Lock
Brake System (ABS) Module Hybrid in this section.
U3000:4B Control Module: Over
Temperature
This DTC is set if the signal from the temperature sensor internal
to the ABS module is out of range or is implausible when
compared to the temperature sensors inside the HCU .
CLEAR the DTCs. REPEAT the self-test. If DTC U3000:4B is
present, INSTALL a new ABS module. REFER to Anti-Lock
U3002:62 Vehicle Identification
Number: Signal Compare
Failure
NOTE: This DTC can set as if the ABS module cannot
communicate with the PCM. Correct any network
communications DTCs prior to diagnosing DTC U3002:62.
a
C0089:11 TCS Disable Switch: Circuit Short
to Ground
a
Instrument Panel
Cluster (IPC)
All Other IPC DTCs IPC REFER to the Master DTC Chart in
Section 419-10 .
a
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test N: DTCs C0020:13 and 71
Normal Operation
The ABS module uses an internal solid state switch to operate the ABS pump motor. When the engine speed
is above 700 rpm or the vehicle speed is at approximately 7 km/h (4 mph), the ABS module tests the ABS
pump motor by activating it for 30 milliseconds. While the pump motor is being activated, the ABS module
monitors the voltage drop across the ABS pump motor solid state switch and the amount of current the ABS
pump motor draws through the solid state switch. If the voltage drop is too high or if the ABS pump motor is
drawing too much current, the ABS module sets a DTC. After 30 milliseconds have passed, the ABS module
stops applying voltage to the pump motor and observe the voltage that the spinning ABS pump motor is
generating. The voltage generated by the motor indicates how fast the motor is spinning. A voltage that is too
low indicates that the motor is not spinning freely and a DTC sets.
DTC C0020:13 (ABS Pump Motor Control: Circuit Open) If the voltage supplied to the ABS
module is less than 10 volts, if there is an open or high resistance on the ABS pump motor circuit
between the ABS module and the Hydraulic Control Unit (HCU), or if the ABS module is faulted
internally, this DTC sets.

DTC C0020:71 (ABS Pump Motor Control: Circuit Actuator Stuck) If the ABS module detects
that the ABS pump motor is not rotating, when it is commanded to run, this DTC sets.

Fuse(s)
HCU
ABS module
PINPOINT TEST N: DTCs C0020:13 AND 71
N1 VERIFY ALL WIRING CONNECTIONS
Disconnect: ABS Module C135 .
Using a good light source, inspect each
connector terminal for any corrosion.

Inspect both connectors for any pushed-out pins.
, Fusion Hybrid/MKZ Hybrid ) for schematic

Using a suitable mating terminal, check each
female terminal for deformed or enlarged
contacts by comparing the mating terminal's fit
between each of the following pins:

C135-1
C135-47
, Fusion Hybrid/MKZ Hybrid ) for schematic

Is each terminal free of corrosion, pushed-out
pins or spread terminals?

Yes
GO to N2 .
No
REPAIR the affected terminal(s). CLEAR the
N2 CHECK THE PUMP MOTOR (PMP_MTR)
ACTIVE COMMAND
Connect: ABS Module C135 .
Ignition ON.
tool: DataLogger ABS Module .

Toggle the PMP_MTR active command ON.
Does the ABS pump motor run for
approximately 4 seconds?

Yes
TOGGLE the PMP_MTR active command
OFF. CLEAR the DTCs. DRIVE the vehicle at
speeds greater than 20 km/h (12 mph).
RETRIEVE the DTCs. If DTCs C0020:13 or
71 are retrieved, GO to N5 . For all other ABS
module DTCs, GO to the ABS Module DTC
No
TOGGLE the ABS module PMP_MTR active
command OFF. GO to N3 .
N3 CHECK THE PUMP MOTOR VOLTAGE
SUPPLY TO THE ABS MODULE
Ignition OFF.
Ignition ON.
Measure the voltage between ABS module
C135-1, circuit SBB08 (VT/RD), harness side
and ground.

Yes
GO to N4 .
No
VERIFY that BJB fuse 8 (50A) is OK. If OK,
REPAIR circuit SBB08 (VT/RD).
If the fuse is not OK, REFER to the Wiring
Diagrams manual to identify the cause of the
circuit short.
PINPOINT TEST N: DTCs C0020:13 AND 71 3249
CLEAR the DTCs and REPEAT the self-test.
N4 CHECK THE ABS MODULE GROUND
CIRCUIT FOR AN OPEN
Ignition OFF.
C135-47, circuit GD121 (BK/YE), harness side
and ground.

Yes
GO to N5 .
No
REPAIR circuit GD121 (BK/YE). CLEAR the
N5 CHECK FOR CORRECT ABS MODULE
OPERATION
Check for:
corrosion
pushed-out pins
spread terminals
Make sure the connector is seated correctly, then
operate the system and verify the concern is still
present.

Yes
INSTALL a new HCU and ABS module.
REFER to Hydraulic Control Unit (HCU)
No
or corroded connector. CLEAR the DTCs.
Pinpoint Test O: DTCs U3003:16 and 17
Normal Operation
The voltage required for correct ABS operation is between 10 and 17.8 volts. Fused battery voltage is
supplied to the ABS module from the Battery Junction Box (BJB), BJB ). Fused ignition voltage is supplied to
the ABS module from the BJB .
DTC U3003:16 (Battery Voltage: Circuit Voltage Below Threshold) If the voltage is below 10
volts, this DTC sets.

DTC U3003:17 (Battery Voltage: Circuit Voltage Above Threshold) If the voltage is above 17
volts, this DTC sets.

Fuses
ABS module
PINPOINT TEST O: DTCs U3003:16 AND 17
NOTE: DTCs U3003:16 and 17 can set if the vehicle has been recently jump started, the 12-volt battery has
been recently charged or the 12-volt battery has been discharged. The 12-volt battery may become discharged
due to excessive load(s) on the charging system from aftermarket accessories or if the battery has been left
unattended with the accessories on.
O1 VERIFY ALL WIRING CONNECTIONS
Using a good light source, inspect each connector
terminal for any corrosion.

Fusion Hybrid/MKZ Hybrid ) for schematic and

Using a suitable mating terminal, check each female
terminal for deformed or enlarged contacts by
comparing the mating terminal's fit between each of
the following pins:

C135-1
C135-8
C135-16
C135-32
C135-47


Yes
GO to O2 .
No
REPAIR the affected terminal(s). CLEAR
PINPOINT TEST O: DTCs U3003:16 AND 17 3251
O2 RETRIEVE ALL CMDTCs IN ALL MODULES
Ignition ON.
tool: Self Test All CMDTCs .

Is DTC U3003:16 or 17, DTCs B1317, B1318
and/or B1676 present in one or more modules
AND DTC P0563, P0620, P0625, P0626 or P065B
present in the PCM?

Yes
REFER to Section 414-05 for diagnosis of
the battery and charging system.
No
GO to O3 .
O3 CHECK BATTERY CONDITION
Ignition OFF.
Refer to Section 414-01 and carry out the Battery
Condition Test.

Yes
If the battery passed the condition test but
required a recharge, REFER to Section
414-00 to diagnose the charging system.
CLEAR all Continuous Memory
If the battery passed the condition test and
did not require a recharge, GO to O4 .
No
operation.
O4 CHECK CHARGING SYSTEM VOLTAGE
Start the vehicle, verify that the ready indicator is
illuminated.

Measure the voltage of the battery with and without
a load on the charging system as follows:

Turn off all accessories and measure battery
voltage.

Turn on headlights and HVAC fan on high
and measure battery voltage.

Yes
GO to O5 .
No
charging system. CLEAR all CMDTCs .
O5 CHECK THE ABS MODULE GROUND CIRCUIT
FOR AN OPEN
Ignition OFF.
ABS module C135-16, circuit GD121

ABS module C135-47, circuit GD121

Repeat this measurement while wiggling
the harness.

Yes
GO to O6 .
No
REPAIR circuit GD121 (BK/YE). CLEAR
all CMDTCs . REPEAT the self-test.
O6 CHECK FOR VOLTAGE AT THE ABS MODULE
Ignition ON.
ABS module C135-1, SBB08 (VT/RD),
harness side.

ABS module C135-8, CBK03 (GY),
harness side.

ABS module C135-32, SBB10 (YE/RD),
harness side.

Yes
GO to O7 .
No
VERIFY that BJB fuses 8 (50A), 10 (30A)
and 47 (10A) are OK. If OK, REPAIR the
affected circuit(s).
If the fuses are not OK, REFER to the
Wiring Diagrams manual to identify the
CLEAR the DTCs and REPEAT the
self-test.
O7 CHECK FOR CORRECT ABS MODULE
OPERATION
Ignition OFF.
Check for:
corrosion
pushed-out pins
spread terminals
Make sure the connector seats correctly, then
present.

Yes
Anti-Lock Brake System (ABS) Module
Hybrid in this section. TEST the
No
by a loose or corroded connector. CLEAR
Pinpoint Test P: DTCs C0022:11, 12, 13, 14, 1D and 49
Normal Operation
The brake booster solenoid is internal to the brake booster. During normal braking, the ABS module applies a
Pulse Width Modulated (PWM) voltage to the brake booster solenoid. The ABS module provides ground to
the solenoid along circuit VCA22 (GN/BN). The ABS module constantly checks the integrity of the booster
solenoid and circuits. If a booster solenoid fault is detected, the brake system transitions from brake-by-wire
mode to conventional friction braking. Other DTCs for brake booster performance may set as a result of a
brake booster solenoid circuit fault. The brake booster solenoid cannot be serviced separately from the brake
booster. If a new brake booster solenoid is needed, a new brake booster must be installed.
C0022:11 Brake
Booster Solenoid: Circuit
Short to Ground

If the ABS module detects a short to ground on either circuit, this DTC
sets.
C0022:12 Brake
Short to Battery

If the ABS module detects a short to voltage on either circuit, this DTC
sets.
C0022:13 Brake
Open

If the ABS module detects an open or high resistance on either circuit,
this DTC sets.
C0022:14 Brake
Short to Ground or Open

If the ABS module detects a short to ground, open or high resistance
on either circuit or the solenoid, this DTC sets.
C0022:1D Brake
Current Out of Range

If the ABS module detects a short to ground, open or high resistance
on either circuit , the solenoid or if the ABS module is faulted
internally, this DTC sets.
C0022:49 Brake
Booster Solenoid: Internal
Electronic Failure

If the ABS module detects a short to ground on either circuit, the
solenoid or if the ABS module is faulted internally, this DTC sets.
Brake booster
ABS module
PINPOINT TEST P: DTCs C0022:11, 12, 13, 14, 1D and 49
P1 VERIFY ALL WIRING CONNECTIONS
Disconnect: Brake Booster C1602 .
Using a good light source, inspect each connector terminal for
any corrosion.

Hybrid/MKZ Hybrid ) for schematic and connector
information.

Using a suitable mating terminal, check each female terminal
for deformed or enlarged contacts by comparing the mating
terminal's fit between each of the following pins:

C135-17
C135-31
C1602-3
C1602-4
Hybrid/MKZ Hybrid ) for schematic and connector
information.

Is each terminal free of corrosion, pushed-out pins or
spread terminals?

Yes
GO to P2 .
No
REPAIR the affected
terminal(s). CLEAR the DTCs.
P2 REVIEW THE DTCs FROM THE ABS MODULE
SELF-TEST
Review the DTCs retrieved and recorded during Inspection
and Verification.

Is DTC C0022:13, C0022:14 or C0022:1D present?
Yes
GO to P3 .
No
If DTC C0022:11 or C0022:49
were retrieved from the self-test,
GO to P4 . If DTC C0022:12
was retrieved from the self-test,
GO to P5 .
P3 CHECK THE BRAKE BOOSTER SOLENOID CIRCUITS
FOR AN OPEN
PINPOINT TEST P: DTCs C0022:11, 12, 13, 14, 1D and 49 3255
Ignition OFF.
Measure the resistance between ABS module C135 harness
side, and brake booster solenoid C1602 harness side as
indicated in the following chart:

ABS Module Circuit Brake Booster Solenoid
C135-17 CCA22 (GY/YE) C1602-3
C135-31 VCA22 (GN/BN) C1602-4
Yes
If DTC C0022:14 or C0022:1D
GO to P4 . If DTC C0022:13
GO to P6 .
No
REPAIR the affected circuit(s).
self-test.
brake booster solenoid C1602-3, circuit CCA22

brake booster solenoid C1602-4, circuit VCA22
(GN/BN), harness side.

Yes
GO to P6 .
No
self-test.
Ignition ON.
brake booster solenoid C1602-3, circuit CCA22

brake booster solenoid C1602-4, circuit VCA22
(GN/BN), harness side.

Yes
self-test.
No
GO to P6 .
P6 CHECK THE BRAKE BOOSTER SOLENOID FOR
CORRECT OPERATION
Ignition OFF.
Connect: Brake Booster C1602 .
Ignition ON.
Start then engine.
Apply and release the brake pedal.
Allow the engine to run for 10 to 15 seconds in order to build
vacuum in the brake booster.

Ignition OFF.
Connect a fused jumper wire between ABS module C135-31,
circuit VCA22 (GN/BN), harness side and ground.

While observing the clevis on the brake booster push rod for
movement, momentarily connect a fused jumper wire
between ABS module C135-17, circuit CCA22 (GY/YE),
harness side and the battery positive post.

Does the brake pedal move?
Yes
GO to P8 .
No
GO to P7 .
P7 CHECK THE BRAKE BOOSTER SOLENOID
Disconnect: All fused jumper wires .
Measure the resistance between ABS module C135-17, circuit
CCA22 (GY/YE), harness side and ABS module C135-31,
circuit VCA22 (GN/BN), harness side.

Is the resistance between 1 and 3 ohms?
Yes
GO to P8 .
No
INSTALL a new brake booster.
REFER to Brake Booster in
Section 206-07 . CLEAR the
P8 CHECK FOR CORRECT ABS MODULE OPERATION
Disconnect: All Fused Jumper Wires (if not previously
disconnected) .

Check for:
corrosion
pushed-out pins
spread terminals
Make sure the connector seats correctly, then operate the

Yes
INSTALL a new ABS module.
REFER to Anti-Lock Brake
System (ABS) Module
No
corroded connector. CLEAR the
Pinpoint Test Q: DTCs C0021:21, 66 and 77
Normal Operation
The ABS module measures the amount of hydraulic brake pressure generated every time the brakes are
applied. The ABS module tests the brake booster every key cycle by operating the brake booster
independently of brake pedal input and measuring the hydraulic brake pressure generated. The ABS module
utilizes input from the brake pedal angle sensor, brake booster travel sensor, the brake pressure sensors
internal to the Hydraulic Control Unit (HCU) and the vacuum pressure sensor to determine if the required
amount of hydraulic brake pressure is being generated. If the ABS module detects that the brake booster is not
able to build adequate hydraulic brake pressure in the master cylinder, the brake system transitions from
brake-by-wire mode into low temperature conventional mode. While in low temperature conventional mode,
the ABS module continues to test the brake booster. If the brake booster begins to generate the expected
amount of pressure in hydraulic system, the brake system recovers into brake-by-wire mode. If the brake
system has to transition from brake-by-wire mode to low temperature conventional mode 3 times in the same
ignition cycle because of a brake booster performance fault, the brake system downgrades to conventional
brake pedal operation for the rest of the ignition cycle.
DTC C0021:21 (Brake Booster Performance: Signal Amplitude Minimum) This DTC is for
information only and does not cause any indicators to illuminate. However, other DTCs that cause
DTC C0021:21 to set may cause indicators to illuminate. If the red brake warning indicator is
illuminated, diagnose all other DTCs before diagnosing DTC C0021:21. Otherwise, disregard DTC
C0021:21.

If the brake booster is not able to build adequate hydraulic brake pressure when the brakes are
applied either through input from the driver or when the ABS module checks the brake
booster, DTC C0021:21 sets. In most cases DTC C0021:21 sets if the vehicle was started in
low ambient temperatures or as a result of low ambient temperatures causing slow booster
reaction time. This DTC set as a result of other brake booster, brake pedal angle sensor,
hydraulic brake pressure sensors or vacuum pressure sensor DTCs being set.

DTC C0021:66 (Brake Booster Performance: Signal Has Too Many Transitions) This DTC
indicates that the regenerative brake system has switched from brake-by-wire mode to low
temperature conventional mode 3 times due to the cause of DTC C0021:21. When this DTC is
present, the regenerative brake system downgrades to conventional mode until the cause of DTC
C0021:21 has been corrected. The red brake warning indicator illuminates when this DTC is set. If
only DTCs C0021:21 and 66 are present, there is likely to be mechanical damage to the brake booster,
brake pedal and bracket, master cylinder, a hydraulic brake fluid leak, air trapped in the hydraulic
system or a vacuum leak may be present.

DTC C0021:77 (Brake Booster Performance: Commanded Position is Not Reachable) This DTC
is for information only and does not indicate a fault with the brake system. If the hydraulic brake
pressure does not change when the ABS module checks the brake booster, this DTC sets. This DTC
does not cause any indicators to illuminate and may set as a result of low ambient temperatures
causing slow booster reaction time. If the red brake warning indicator is not illuminated, this DTC
should be disregarded. Diagnose all other DTCs retrieved along with this DTC.

Wheel speed sensor
ABS module
PINPOINT TEST Q: DTCs C0021:21, 66 AND 77
Q1 CHECK THE DTCs FROM THE SELF-TEST
Review the DTCs retrieved and recorded in

Are other DTCs present along with DTC
C0021:21, 66 or 77?

Yes
The other ABS module DTCs indicates
the cause of DTCs C0021:21, 66 and/or
77.
DIAGNOSE all other ABS module DTCs
before diagnosing DTC C0021:21, 66 or
77. REFER to the ABS Module DTC
No
GO to Q2 .
Q2 CHECK THE BRAKE PEDAL AND BRACKET
Inspect the brake pedal and bracket and the clevis
end of the booster push rod for misalignment or
damage. Verify that all brake pedal and bracket
fasteners are tightened to the specified torque. Apply

Yes
GO to Q3 .
No
REPAIR or INSTALL new components
PINPOINT TEST Q: DTCs C0021:21, 66 AND 77 3259
and release the brake pedal. Verify that the brake
pedal moves freely and returns to the full released
position.
Is the brake pedal and bracket OK?
Q3 CHECK THE BRAKE BOOSTER AND BRAKE
MASTER CYLINDER
Inspect the brake booster and brake master cylinder
for misalignment or damage. Verify that all brake
booster and master cylinder fasteners are tightened to
the specified torque.

Is the brake booster and the brake master
cylinder OK?

Yes
GO to Q4 .
No
as necessary. REFER to Section 206-07
for the brake booster. REFER to Section
206-06 for the brake master cylinder.
Q4 CHECK FOR VACUUM LEAKS
Inspect the vacuum pump and brake booster vacuum
hoses, lines and fittings for vacuum leaks.

Are the vacuum pump and brake booster vacuum
hoses, lines and fittings OK?

Yes
GO to Q5 .
No
Q5 CHECK THE BRAKE SYSTEM FOR BRAKE
FLUID LEAKS
Inspect the brake system for brake fluid leaks.
Are any brake fluid leaks found?
Yes
REPAIR as necessary. FILL the brake
master cylinder reservoir using the
specified brake fluid. BLEED the brake
system, REFER to Brake System
Bleeding in Section 206-00 .
No
GO to Q6 .
Q6 CHECK FOR AIR IN THE BRAKE SYSTEM
Bleed the brake system, refer to Brake System
Bleeding in Section 206-00 .

Ignition ON.
Using the scan tool, clear all Continuous Memory

Disconnect the scan tool.
Test drive the vehicle at speeds greater than 32 km/h
(20 mph).

Ignition ON.
Self Test ABS Module .

Carry out the ABS module self-test.
Are DTCs C0021:21, 66 and 77 present?
Yes
GO to Q7 .
No
by air trapped in the hydraulic brake
system. CLEAR the DTCs. REPEAT the
self-test.
Q7 CHECK FOR CORRECT ABS MODULE
OPERATION
Yes
INSTALL a ABS module. REFER to
PINPOINT TEST Q: DTCs C0021:21, 66 AND 77 3260
Using a good light source, carefully inspect ABS
module connector C135 for corroded terminals.

Inspect for any pushed-out pins.

comparing the mating terminal's fit between each pin
location.

Make sure the connector seats correctly, then operate
the system and verify the concern is still present.

system for normal operation. CLEAR the
DTCs. DRIVE the vehicle.
REPEAT the self-test. If the DTCs
identified in the normal operation of this
pinpoint test are retrieved, INSTALL a
new HCU . REFER to Hydraulic Control
Unit (HCU) Hybrid in this section.
No
Pinpoint Test R: DTC C0031:01; C0034:01; C0037:01 or C003A:01
Normal Operation
Active wheel speed sensors generate a square wave signal that is sent to the ABS module. The wheel speed
sensor circuitry connects to the ABS module through 2 wires and a connector at each wheel speed sensor.
When the ignition switch is turned to the RUN position, the ABS module carries out a self-test by sending a
reference voltage through the wheel speed sensors and their circuitry.
Both voltage and ground are supplied to the active wheel speed sensors from the ABS module.
C0031:01 Left Front Wheel
Speed Sensor: General Electrical
Failure

If the left front wheel speed sensor signal current is below 45 mA
or above 20 mA for longer than 140 milliseconds, this DTC sets.
C0034:01 Right Front
Wheel Speed Sensor: General
Electrical Failure

If the right front wheel speed sensor signal current is below 45 mA
C0037:01 Left Rear Wheel
Speed Sensor: General Electrical
Failure

If the left rear wheel speed sensor signal current is below 45 mA or
above 20 mA for longer than 140 milliseconds, this DTC sets.
C003A:01 Right Rear
Wheel Speed Sensor: General
Electrical Failure

If the right rear wheel speed sensor signal current is below 45 mA
Wheel speed sensor
ABS module
PINPOINT TEST R: DTC C0031:01; C0034:01; C0037:01 OR C003A:01
R1 VERIFY ALL WIRING CONNECTIONS
Disconnect: Suspect Wheel Speed Sensor .

Inspect both connectors for any pushed-out
pins.

female terminal for deformed or enlarged
contacts by comparing the mating terminal's fit

C135-33
C135-34
C135-36
C135-37
C135-42
C135-43
C135-45
C135-46
Suspect wheel speed sensor, pin-1
Suspect wheel speed sensor, pin-2
(front sensor) or pin-3 (rear sensor)


Is each terminal free of corrosion,
pushed-out pins or spread terminals?

Yes
GO to R2 .
No
REPAIR the affected terminal(s). CLEAR the
PINPOINT TEST R: DTC C0031:01; C0034:01; C0037:01 OR C003A:01 3262
R2 CHECK FOR FAULT REPEATABILITY
Connect: Suspect Wheel Speed Sensor .
Ignition ON.
Using the scan tool, clear the ABS module
DTCs.

Drive the vehicle at least 20 km/h (12 mph).
scan tool: Self Test ABS Module .

Retrieve and record the ABS module DTCs.
Are DTCs C0031:01, C0034:01, C0037:01
and/or C003A:01 retrieved?

Yes
For DTCs C0031:01 and C0034:01, if the
Rotunda Active Wheel Speed Sensor Tester is
available, GO to R3 . If the Rotunda Active
Wheel Speed Sensor Tester is not available, GO
to R5 .
For DTCs C0037:01 and C003A:01, GO to R5 .
No
INSPECT the wheel speed sensors, wheel speed
sensor wiring and wheel speed sensor tone rings.
REPAIR or INSTALL new as necessary. If any
other DTCs are retrieved, GO to the ABS
R3 CHECK THE ABS MODULE OUTPUT
USING THE ROTUNDA ACTIVE WHEEL
SPEED SENSOR TESTER
electrical connectors are located behind the
wheel well splash shields. The rear wheel
speed sensor electrical connectors are located
under the rear seat cushion.
Ignition OFF.
Connect the Rotunda Active Wheel Speed
Sensor Tester to the wheel speed sensor
connectors.

Ignition ON.
and turn the power switch to the ON position.

Is the module output LED illuminated?
Yes
GO to R4 .
No
GO to R7 .
R4 CHECK THE WHEEL SPEED SENSOR
OUTPUT WITH THE ROTUNDA ACTIVE
WHEEL SPEED SENSOR TESTER
Raise the suspect wheel until it can spin freely.

While monitoring the Rotunda Active Wheel
Speed Sensor Tester, slowly spin the suspect
wheel.

Do the sensor output LEDs illuminate and
flash and is the current overload LED not
illuminated?

Yes
No
If the current level LED is not illuminated and
the sensor output LEDs do not illuminate or if
the current level LED is illuminated red,
Wheel Speed Sensor Front or Wheel Speed
Sensor Rear, Front Wheel Drive (FWD) in
self-test.
If the current level LED is not illuminated and
the sensor output LEDs illuminate green, but do
not flash, INSPECT the wheel speed sensor tone
ring and INSTALL new if necessary. If the tone
ring is OK, INSTALL a new wheel speed sensor.
REFER to Wheel Speed Sensor Front or
Wheel Speed Sensor Rear, Front Wheel
Drive (FWD) in this section. CLEAR the DTCs.
CIRCUITS FOR A SHORT TO POWER
NOTICE: No measurements should be
taken with the wheel speed sensor
connected. Damage to the wheel speed
sensor results.
Ignition OFF.
Ignition ON.
For DTC C0031:01 (LF) , measure the
voltage between ground and:

ABS module C135-45, circuit VCA03
(VT/WH), harness side.

ABS module C135-46, circuit RCA17
(YE), harness side.

For DTC C0034:01 (RF) , measure the

(VT), harness side.


Yes
No
GO to R6 .
For DTC C0037:01 (LR) , measure the



For DTC C003A:01 (RR) , measure the

(BN), harness side.


NOTE: Both circuits must be checked for
each DTC.
Ignition OFF.

(VT/WH), harness side.

(YE), harness side.

Yes
GO to R7 .
No


(VT), harness side.






(BN), harness side.

ohms?

R7 CHECK THE WHEEL SPEED CIRCUITS
FOR AN OPEN
Ignition OFF.
connector C135, harness side and the suspect
wheel speed sensor connector, harness side as

ABS Module Circuit
Wheel
Speed
Sensor
DTC C0031:01 (LF)
C135-45 VCA03 (VT/WH) C150-1
C135-46 RCA17 (YE) C150-2
DTC C0034:01 (RF)
C135-34 VCA05 (GY/VT) C160-1
C135-33 RCA19 (VT) C160-2
DTC C0037:01 (LR)
C135-36 VCA04 (BU/OG) C440-3
C135-37 RCA18 (BN/GN) C440-1
DTC C003A:01 (RR)
C135-43 VCA06 (WH/OG) C426-3
C135-42 RCA20 (BN) C426-1
Yes
GO to R8 .
No
R8 CHECK FOR SHORTED WHEEL SPEED
SENSOR CIRCUITS
resistance between:

LF wheel speed sensor C150-1, circuit
VCA03 (VT/WH), harness side and

Yes
GO to R9 .
No
resistance between:

RF wheel speed sensor C160-1, circuit
VCA05 (GY/VT), harness side and

resistance between:

LR wheel speed sensor C440-3, circuit
VCA04 (BU/OG), harness side and

resistance between:

circuit VCA06 (WH/OG), harness side
and RR wheel speed sensor C426-1,
circuit RCA20 (BN), harness side.

Is the resistance greater 10,000 ohms?
R9 CHECK FOR CORRECT ABS MODULE
OUTPUT
Ignition ON.
voltage between:

VCA03 (VT/WH), harness side and

voltage between:

VCA05 (GY/VT), harness side and

voltage between:

VCA04 (BU/OG), harness side and

voltage between:

circuit VCA06 (WH/OG), harness side
and RR wheel speed sensor C426-1,
circuit RCA20 (BN), harness side.

Yes
Wheel Speed Sensor Front , Wheel Speed
Sensor Rear, Front Wheel Drive (FWD) or
Wheel Speed Sensor Rear, All Wheel Drive
(AWD) in this section. CLEAR the DTCs.
No
GO to R10 .
R10 CHECK FOR CORRECT ABS MODULE
OPERATION
Check for:
corrosion
pushed-out pins
spread terminals
Make sure the connector is seated correctly,
then operate the system and verify the concern
is still present.

Yes
Hybrid in this section. TEST the system for
normal operation.
No
Pinpoint Test S: DTC C0030:07; C0031:29, 2F, 64; C0033:07; C0034:29, 2F, 64; C0036:07: C0037:29,
2F, 64; C0039:07; C003A:29, 2F or 64
Normal Operation
The wheel speed sensor and sensor ring generate a square wave signal to the ABS module that is proportional
to wheel speed. The ABS module compares wheel speed inputs from all wheel speed sensors to determine an
impending wheel lockup.
Speed Sensor: Mechanical
Failure

Damage to the wheel speed sensor ring or damage to the wheel
bearing causes this DTC to set.
Speed Sensor: Signal Invalid

This DTC can set by a damaged wheel speed sensor ring, a
damaged or defective wheel speed sensor, a wheel speed sensor
that is not mounted properly or mismatched tire sizes.
C0031:2F Left Front Wheel
Speed Sensor: Signal Erratic

damaged or defective wheel speed sensor or a wheel speed sensor
that is not mounted properly.
Speed Sensor: Signal Plausibility
Failure
C0033:07 Right Front Wheel
Failure


C0034:2F Right Front Wheel

Failure

Failure


C0037:2F Left Rear Wheel

Failure

C0039:07 Right Rear Wheel
Failure

C003A:29 Right Rear Wheel

C003A:2F Right Rear Wheel

C003A:64 Right Rear Wheel
Failure

Tire size
Tire pressure
Wheel speed sensor
Wheel speed sensor ring
Wheel bearing
ABS module
PINPOINT TEST S: DTC C0030:07; C0031:29, 2F, 64; C0033:07; C0034:29, 2F, 64; C0036:07: C0037:29, 2F, 64;
C0039:07; C003A:29, 2F or 64
S1 VERIFY ALL WIRING
CONNECTIONS
Sensor .


Inspect both connectors for any
pushed-out pins.
Hybrid ) for schematic and connector
information.

Using a suitable mating terminal, check
each female terminal for deformed or
enlarged contacts by comparing the
mating terminal's fit between each of
the following pins:

C135-33
C135-34
C135-36
C135-37
C135-42
C135-43
C135-45
C135-46
Suspect wheel speed sensor,
pin-1

Suspect wheel speed sensor,
pin-2 (front sensor) or pin-3
(rear sensor)

Yes
GO to S2 .
No
REPAIR the affected terminal(s). CLEAR the DTCs.
PINPOINT TEST S: DTC C0030:07; C0031:29, 2F, 64; C0033:07; C0034:29, 2F, 64; C0036:07: C0037:29, 2F, 64; C0039:07; C003A:29, 2F or 64 3272
information.

pushed-out pins or spread
terminals?

S2 CHECK THE DTCs FROM THE
SELF-TEST
Review the DTCs retrieved and
recorded during Inspection and
Verification.

Are DTCs C0031:01; C0034:01;
C0037:01 and/or C003A:01 present?

Yes
No
If DTC C0030:07; C0033:07; C0036:07; or C0039:07 is
present, GO to S5 . If DTCs C0031:2F; C0034:2F;
C0037:2F; and/or C003A:2F are present, GO to S4 . If
DTCs C0031:29, 64; C0034:29, 64; C0037:29, 64;
C003A:29 and/or 64 are present, GO to S3 . For all
other DTCs, REFER to the ABS Module DTC Chart in
this section.
S3 CHECK THE TIRES SIZE AND
PRESSURE
Verify that all tires and wheels are the
same size and that the inflation
pressures are correct as indicated on
the Vehicle Certification (VC) label.

Are the wheels and tires OK?
Yes
GO to S4 .
No
INSTALL the correct size tire or ADJUST tire pressure
as necessary.
S4 MONITOR THE WHEEL SPEED
SENSOR PIDs
Ignition ON.
the scan tool: DataLogger ABS
Module .

Drive the vehicle at a speed greater
than 20 km/h (12 mph) while
monitoring the following PIDs:

Left front wheel speed sensor
(LF_WSPD)

Right front wheel speed sensor
(RF_WSPD)

Left rear wheel speed sensor
(LR_WSPD)

Yes
CLEAR the DTCs. DRIVE the vehicle. RETRIEVE the
DTCs. If DTCs C0031:29, 2F, 64; C0034:29, 2F, 64;
C0037:29, 2F, 64; C003A:29, 2F; and/or C003A:64 are
present, GO to S14 .
No
GO to S5 .
Right rear wheel speed sensor
(RR_WSPD)

Are the wheel speed PIDs consistent
with each other, within 5 km/h (3
mph) and the vehicle speed as
indicated on the speedometer?

S5 INSPECT THE WHEEL SPEED
SENSOR MOUNTING
Ignition OFF.
With the vehicle in NEUTRAL,
position it on a hoist. Refer to Section
100-02 .

Inspect the wheel speed sensor and
fastener for looseness.

Are the wheel speed sensor and
fastener tight?

Yes
GO to S7 .
No
TIGHTEN the wheel speed sensor to specification.
REFER to Specifications in this section. CLEAR the
DTCs. GO to S6 .
S6 RECHECK THE WHEEL SPEED PIDs
Ignition ON.
the scan tool: DataLogger ABS
Module .

Drive the vehicle at a speed greater
than 20 km/h (12 mph) while
monitoring the following PIDs:

LF_WSPD
RF_WSPD
LR_WSPD
RR_WSPD
Are the wheel speed PIDs consistent
with each other, within 5 km/h (3
mph) and the vehicle speed as
indicated on the speedometer?

Yes
concern may have been caused by a loose wheel speed
sensor.
No
GO to S7 .
S7 CHECK THE WHEEL SPEED
SENSOR FOR DAMAGE
Ignition OFF.
With the vehicle in NEUTRAL,
position it on a hoist. Refer to Section
100-02 .

NOTE: Examine the wheel speed
sensor wire carefully with a good light
source. Failure to verify damage in the
wheel speed sensor wire can lead to
unnecessary installation of a new
component.

Inspect the wheel speed sensor and
harness for abrasion, broken connector
tabs or water intrusion.

Is the wheel speed sensor and
harness OK?

Yes
GO to S8 .
No
INSTALL a new wheel speed sensor. REFER to Wheel
Speed Sensor Front , Wheel Speed Sensor
Rear, Front Wheel Drive (FWD) or Wheel Speed Sensor
S8 CHECK FOR WHEEL SPEED
SENSOR RING DAMAGE
Inspect the wheel speed sensor ring for
damaged or missing teeth. Rotate the
wheel to verify that no teeth are
missing.

Is the wheel speed sensor ring OK?
Yes
GO to S9 .
No
INSTALL a new halfshaft. For front halfshafts, REFER
to Section 205-04 . For rear halfshafts, REFER to
Section 205-05 . CLEAR the DTCs. REPEAT the
self-test.
S9 CHECK FOR WHEEL BEARING
DAMAGE
Inspect the wheel bearings for damage.
Are the wheel bearings OK?
Yes
For front wheel speed sensor concerns, if the Rotunda
Active Wheel Speed Sensor Tester is available, GO to
S10 .
If the Rotunda Active Wheel Speed Sensor Tester is not
available, GO to S12 .
For rear wheel speed sensor concerns, GO to S12 .
No
INSTALL new wheel bearings as necessary. REFER to
Section 204-01 for front wheel bearings or Section
204-02 for rear wheel bearings. CLEAR the DTCs.
S10 CHECK THE ABS MODULE
OUTPUT USING THE ROTUNDA
ACTIVE WHEEL SPEED SENSOR
TESTER
wheel speed sensor electrical
connectors are located under the rear
seat cushion.
Ignition OFF.
Sensor .

Connect the Rotunda Active Wheel
Speed Sensor Tester to the wheel speed
sensor connectors.

Ignition ON.
Select the correct system polarity on
the Rotunda Active Wheel Speed
Sensor Tester and turn the power
switch to the ON position.

Is the module output LED
illuminated?

Yes
GO to S11 .
No
GO to S14 .
SENSOR OUTPUT WITH THE ROTUNDA
ACTIVE WHEEL SPEED SENSOR
TESTER
Raise the suspect wheel until it can
spin freely. Refer to Section 100-02 .

While monitoring the Rotunda Active
Wheel Speed Sensor Tester, slowly
spin the suspect wheel.

Do the sensor output LEDs
illuminate and flash and is the
current overload LED not
illuminated?

Yes
No
sensor output LEDs do not illuminate or if the current
level LED is illuminated red, INSTALL a new wheel
speed sensor. REFER to Wheel Speed Sensor Front
or Wheel Speed Sensor Rear, Front Wheel Drive
(FWD) in this section. CLEAR the DTCs. REPEAT the
self-test.
sensor output LEDs illuminate green, but do not flash,
INSPECT the wheel speed sensor tone ring and
INSTALL new if necessary. If the tone ring is OK,
Speed Sensor Front or Wheel Speed Sensor
Rear, Front Wheel Drive (FWD) in this section. CLEAR
S12 CHECK FOR CORRECT ABS
MODULE OUTPUT
seat cushion.
Ignition OFF.
Sensor .

Ignition ON.
For LF wheel speed sensor DTCs ,
measure the voltage between:

LF wheel speed sensor
C150-1, circuit VCA03
(VT/WH), harness side and LF
wheel speed sensor C150-2,
circuit RCA17 (YE), harness
side.

Yes
GO to S13 .
No
GO to S14 .
For RF wheel speed sensor DTCs ,

RF wheel speed sensor
(GY/VT), harness side and RF
circuit RCA19 (VT), harness
side.

For LR wheel speed sensor DTCs ,

LR wheel speed sensor
(BU/OG), harness side and LR
circuit RCA18 (BN/GN),
harness side.

For RR wheel speed sensor DTCs ,

RR wheel speed sensor
(WH/OG), harness side and
RR wheel speed sensor
C426-1, circuit RCA20 (BN),
harness side.

SENSOR OUTPUT
seat cushion.
Sensor .

For LF wheel speed sensor DTCs :
connect the meter between LF
circuit RCA17 (YE), harness
side and LF wheel speed
sensor pin-1, component side.

connect a fused jumper wire
between LF wheel speed
sensor C150-2, circuit VCA03
(VT/WH), harness side and LF
wheel speed sensor pin-2,
component side.

For RF wheel speed sensor DTCs :
connect the meter between RF
circuit RCA19 (VT), harness
side and RF wheel speed

between RF wheel speed
(GY/VT), harness side and RF
component side.

For LR wheel speed sensor DTCs :
connect the meter between LR
circuit RCA18 (BN/GN),
harness side and LR wheel
speed sensor pin-1, component
side.

between LR wheel speed

Yes
GO to S14 .
No
Speed Sensor Front , Wheel Speed Sensor
Rear, Front Wheel Drive (FWD) or Wheel Speed Sensor
(BU/OG), harness side and LR
component side.
For RR wheel speed sensor DTCs :
connect the meter between RR
circuit RCA20 (BN), harness
side and RR wheel speed

between RR wheel speed
sensor C426-3, circuit VAC06
(WH/OG), harness side and
RR wheel speed sensor pin-3,
component side.

Ignition ON.
Measure the current while slightly
rotating the wheel, using incremental
turns.

Does the automotive meter switch
between the low state (5 to 8 mA)
and the high state (12 to 16 mA)?

S14 CHECK FOR CORRECT ABS
MODULE OPERATION
Check for:
corrosion
pushed-out pins
spread terminals
Make sure the connector is seated
correctly, then operate the system and
verify the concern is still present.

Yes
Brake System (ABS) Module Hybrid in this
No
Pinpoint Test T: DTCs C0048:11, 12, 64; C1108:11, 12 and 1C
Normal Operation
The booster travel sensor provides the ABS module with an analog signal indicating the position of the
diaphragm inside the brake booster. The ABS module supplies a 5-volt reference voltage to the sensor and
ground. The ABS module receives a varying voltage proportional to the position of the diaphragm inside the
brake booster. The ABS module monitors the brake booster travel sensor circuits for circuit faults. The ABS
module compares the brake booster travel sensor signal with other brake system inputs to verify that the brake
booster travel sensor signal is accurate. If a brake booster travel sensor circuit or signal fault is detected, the
red brake warning indicator illuminates.
C0048:11 Brake
Booster Travel Sensor:
Circuit Short To
Ground

If circuit VCB34 (WH/BU) is open or shorted to ground or if the ABS
module is faulted internally, this DTC sets.
C0048:12 Brake
Circuit Short to
Battery

If the circuit is open, or if the ABS module is faulted internally, this DTC
sets.
C0048:64 Brake
Signal Plausibility
Failure

This DTC can set if the booster travel sensor is improperly mounted, if the
booster travel sensor is faulted internally or if the ABS module is faulted
internally. This DTC can also set as a result of other brake booster travel
sensor faults. All other brake booster travel sensor DTCs should be diagnosed
prior to diagnosing DTC C0048:64.
C1108:11 Pedal
Sensor(s) (Booster
Travel Sensor) Supply
Voltage: Circuit Short
to Ground

This DTC is set if the brake booster travel sensor supply circuit is shorted
ground, if the booster travel sensor is shorted internally or if the ABS module
is faulted internally.
C1108:12 Pedal
Sensor(s) (Booster
Voltage: Circuit Short
to Battery

This DTC is set if the brake booster travel sensor supply circuit is shorted
voltage, if the booster travel sensor is shorted internally or if the ABS module
is faulted internally.
C1108:1C Pedal
Sensor(s) (Booster
Voltage: Circuit

This DTC can set as a result of other brake booster travel sensor circuit faults
or if the ABS module is faulted internally. All other booster travel sensor
DTCs should be diagnosed prior to diagnosing DTC C1108:1C.
Booster travel sensor
ABS module
PINPOINT TEST T: DTCs C0048:11, 12, 64; C1108:11, 12 and 1C
T1 VERIFY ALL WIRING CONNECTIONS
PINPOINT TEST T: DTCs C0048:11, 12, 64; C1108:11, 12 and 1C 3280
Disconnect: Brake Booster Travel Sensor C149 .


female terminal for deformed or enlarged contacts
by comparing the mating terminal's fit between
each of the following pins:

C135-26
C135-27
C135-38
C149-1
C149-2
C149-3


Yes
GO to T2 .
No
T2 CHECK THE DTCs FROM THE SELF-TEST
Review the DTCs retrieved and recorded during

Is DTC C0048:11, 12 or 64 present?
Yes
If DTC C0048:11 is present, GO to T3 . If
DTC C0048:12 is present, GO to T4 . If only
DTC C0048:64 is present, GO to T5 .
No
If DTC C1108:11 is present, GO to T8 . If
DTC C1108:12 is present, GO to T7 . If only
DTC C1108:1C is present, GO to T10 . For
all other DTCs, REFER to the ABS Module
DTC Chart in this section.
T3 CHECK THE SENSOR SIGNAL RETURN
Ignition OFF.
Disconnect: Booster Travel Sensor C149 .
Measure the resistance between brake booster
travel sensor C149-3, circuit VCB34 (WH/BU),

Yes
GO to T5 .
No
REPAIR circuit VCB34 (WH/BU). CLEAR
T4 CHECK THE SENSOR SIGNAL RETURN
Ignition OFF.
Ignition ON.
Measure the voltage between brake booster travel
sensor C149-3, circuit VCB34 (WH/BU), harness
side and ground.

Yes
REPAIR circuit VCB34 (WH/BU). CLEAR
No
GO to T5 .
T5 CHECK ALL SENSOR CIRCUITS FOR A
SHORT TOGETHER
Ignition OFF.
Measure the resistance between brake booster
travel sensor C149 pins, harness side, as indicated
in the following chart:

Brake Booster
Travel Sensor Circuit
Brake Booster
Travel Sensor
C149-1 CCB33
(GY/OG)/
RCB33
(VT/GY)
C149-2
C149-1 CCB33
(GY/OG)/
C149-3
Yes
GO to T6 .
No
VCB34
(WH/BU)
C149-2 VCB34
(WH/BU)/
RCB33
(VT/GY)
C149-3
T6 CHECK ALL SENSOR CIRCUITS FOR AN
OPEN
C135, harness side and brake booster travel sensor
C149, harness side as indicated in the following
chart:

ABS
Module Circuit
Brake Booster
Travel Sensor
C135-26 CCB33
(GY/OG)
C149-1
C135-27 RCB33
(VT/GY)
C149-2
C135-38 VCB34
(WH/BU)
C149-3
Yes
If only DTC C0048:64 was retrieved from
the self-test, INSPECT the installation of the
sensor. CORRECT the installation as
necessary.
If the sensor is correctly installed, INSTALL
a new brake booster travel sensor. REFER to
Booster Travel Sensor in Section 206-07 .
For DTCs C0048:11 and C0048:12, GO to
T9 .
No
T7 CHECK THE SENSOR VOLTAGE SUPPLY
Ignition OFF.
Ignition ON.
Measure the voltage between the brake booster
travel sensor C149-1, circuit CCB33 (GY/OG),

Yes
REPAIR circuit CCB33 (GY/OG). CLEAR
No
GO to T9 .
T8 CHECK THE SENSOR VOLTAGE SUPPLY
Ignition OFF.
Measure the resistance between the brake booster
travel sensor C149-1, circuit CCB33 (GY/OG),

Yes
GO to T9 .
No
REPAIR circuit CCB33 (GY/OG). CLEAR
T9 CHECK THE BOOSTER TRAVEL SENSOR
INSTALLATION
Inspect the installation of the booster travel sensor
to the brake booster. Verify the booster travel is
securely attached to the booster and that the
booster and booster travel sensor are free of
damage.

Is the booster travel sensor installed correctly
and are the sensor and booster free of any
damage?

Yes
GO to T10 .
No
INSTALL a new brake booster travel sensor
and/or brake booster as necessary. REFER to
Booster Travel Sensor and/or Brake Booster
in Section 206-07 .
T10 CHECK THE BOOSTER TRAVEL SENSOR
(BRKBST_MEMB) PID
Connect: Booster Travel Sensor C149 .
Yes
CLEAR the DTCs. DRIVE the vehicle.
REPEAT the self-test. If any of the DTCs
Ignition ON.

Monitor the BRKBST_MEMB PID while
applying and releasing the brake pedal.

Does the PID value increase when the brake
pedal is pressed and decrease when the brake
pedal is released?

identified in the normal operation of this
pinpoint test return, GO to T11 .
No
INSTALL a new brake booster travel sensor.
REFER to Booster Travel Sensor in Section
206-07 .
T11 CHECK FOR CORRECT ABS MODULE
OPERATION
Check for:
corrosion
pushed-out pins
spread terminals
present.

Yes
Hybrid in this section. TEST the system for
normal operation.
No
time. The concern may have been caused by
a loose or corroded connector. CLEAR the
Pinpoint Test U: DTCs C100A:62; C100D:21, 22; C100E:21, 22 and C100F:11, 12
Normal Operation
The ABS module uses input from the brake pedal angle sensor to determine the amount of deceleration the
driver is requesting. The brake pedal angle sensor utilizes 2 Hall-effect sensors that provide redundant signals
indicating the position of the brake pedal. The ABS module provides a 5-volt reverence voltage used by both
of the sensors. The ABS module provides a signal return common to both sensors.
C100A:62
Brake Pedal Angle
Sensor: Signal
Compare Failure

This DTC sets if 1 of the 2 sensors inside the brake pedal angle sensor is
inconsistent with the other or if the ABS module is faulted internally. This DTC
can set as a result of other DTCs indicating a brake pedal angle sensor circuit
fault. If DTCs C100D:21, 22 or C100E:21, 22 are present along with this DTC,
diagnose them first.
C100D:21
Brake Pedal Angle
Sensor Circuit 1:
Signal Amplitude
Minimum

If the voltage is less than 300 millivolts or if the ABS module is faulted
internally, this DTC can set. This DTC can set as a result of a brake pedal
sensor supply or signal return circuit fault (such as an open circuit). Diagnose
DTC C100F:11 or 12 first if it is retrieved along with this DTC.
C100D:22
Brake Pedal Angle

If the voltage is greater than 4.72 volts, this DTC can set. This DTC can set as a
result of a brake pedal angle sensor supply or signal return circuit fault (such as
an open circuit), an internal brake pedal angle sensor fault or an internal ABS
Sensor Circuit 1:
Signal Amplitude >
Maximum
module fault. Diagnose DTC C100F:11 or 12 first if it is retrieved along with
this DTC.
C100E:21
Brake Pedal Angle
Sensor Circuit 2:
Signal Amplitude
Minimum

If the voltage is less than 300 millivolts, this DTC can set. This DTC can set as
a result of a brake pedal angle sensor supply or signal return circuit fault (such
as an open circuit), an internal brake pedal angle sensor fault or an internal ABS
this DTC.
C100E:22
Brake Pedal Angle
Sensor Circuit 2:
Signal Amplitude >
Maximum

If the voltage is greater than 4.72 volts, this DTC can set. This DTC can set as a
result of a brake pedal angle sensor supply or signal return circuit fault (such as
an open circuit), an internal brake pedal angle sensor fault or an internal ABS
this DTC.
C100F:11
Brake Pedal Angle
Sensor Supply:
Circuit Short To
Ground

If the circuit is shorted to ground, this DTC sets. The ABS module supplies
power to both of the sensors inside the brake pedal angle sensor. Correct this
DTC before diagnosing DTCs C100D:21, 22 or C100E:21, 22.
C100F:12
Brake Pedal Angle
Sensor Supply:
Circuit Short To
Battery

If the circuit is shorted to voltage, this DTC sets. Correct this DTC before
diagnosing DTCs C100D:21, 22 or C100E:21, 22.
Brake pedal angle sensor
ABS module
PINPOINT TEST U: DTCs C100A:62; C100D:21, 22; C100E:21, 22 AND C100F:11, 12
U1 VERIFY ALL WIRING
CONNECTIONS
Disconnect: Brake Pedal Angle Sensor
C2299 .

Using a good light source, inspect
each connector terminal for any
corrosion.

Inspect both connectors for any
pushed-out pins.

Yes
GO to U2 .
No
REPAIR the affected terminal(s). CLEAR the DTCs.
PINPOINT TEST U: DTCs C100A:62; C100D:21, 22; C100E:21, 22 AND C100F:11, 12 3286
information.
Using a suitable mating terminal,
check each female terminal for
deformed or enlarged contacts by
comparing the mating terminal's fit

C135-2
C135-11
C135-14
C135-44
C2299-1
C2299-2
C2299-3
C2299-4
C2299-5
C2299-6
information.

pushed-out pins or spread
terminals?

U2 CHECK THE DTCs FROM THE ABS
MODULE
Review the DTCs retrieved and
recorded during Inspection and
Verification.

Is DTC C100F:11 or 12 present?
Yes
If DTC C100F:11 or 12 is present, GO to U3 .
No
If DTC C100D:21 is present, GO to U10 . If DTC
C100D:22 is present, GO to U11 . If DTC C100E:21 is
present, GO to U7 . If DTC C100E:22 is present, GO to
U8 . If only DTC C100A:62 is present, GO to U6 . If
DTCs C100D:22 and C100E:22 are present, GO to U13
. For all other ABS module DTCs, REFER to the ABS
U3 CHECK THE VOLTAGE SUPPLY
TO THE PEDAL ANGLE SENSOR
Ignition ON.
Measure the voltage between ground
and:

brake pedal angle sensor
C2299-1, circuit LCA27


Are the voltages approximately 5
volts?

Yes
INSTALL a new brake pedal angle sensor. REFER to
Brake Pedal Angle Sensor in Section 206-06 .
No
If the voltage is less than 5 volts, GO to U4 . If the
voltage is greater than 5 volts, GO to U5 .
U4 CHECK THE SENSOR VOLTAGE
SUPPLY CIRCUIT FOR A SHORT TO
GROUND
Ignition OFF.
ground and:



ohms?

Yes
No
REPAIR circuit LCA27 (BN/WH). CLEAR the DTCs.
SUPPLY CIRCUIT FOR A SHORT TO
VOLTAGE
Ignition OFF.
Ignition ON.
Measure the voltage between ground
and:



Yes
No
U6 CHECK THE BRAKE PEDAL
ANGLE SENSOR PIDs
Connect: Brake Pedal Angle Sensor
C2299 .

Ignition ON.
on the scan tool: DataLogger
ABS Module .

Monitor the following PIDs while
applying and releasing the brake
pedal:

Circuit 1 (BRK_PDL)

Circuit 2 (BRK_PDL_B)

Do the PID values reflect the
movement of the brake pedal?

Yes
CLEAR the DTCs. REPEAT the self-test. If DTC
C100A:62 returns, INSTALL a new ABS module.
REFER to Anti-Lock Brake System (ABS) Module
Hybrid in this section. TEST the system for normal
operation.
No
If the BRK_PDL PID does not reflect the movement of
the brake pedal, GO to U10 . If the BRK_PDL_B PID
does not reflect the movement of the brake pedal, GO to
U7 .
U7 CHECK THE SENSOR SIGNAL 1
RETURN CIRCUIT FOR A SHORT TO
GROUND
Ignition OFF.
C2299 (if not previously disconnected)
.

Disconnect: ABS Module C135 (if not
previously disconnected) .

Measure the resistance between brake
pedal angle sensor C2229-3, circuit
VCA30 (YE/VT), harness side and
ground.

Yes
GO to U9 .
No
REPAIR circuit VCA30 (YE/VT). CLEAR the DTCs.
ohms?

VOLTAGE
Ignition OFF.
C2299 .

Ignition ON.
Measure the voltage between brake
ground.

Yes
No
GO to U13 .

Yes
GO to U14 .
No
GROUND
Ignition OFF.
C2299 (if not previously disconnected)
.

Disconnect: ABS Module C135 (if not
previously disconnected) .

VCA43 (WH/GN), harness side and
ground.

ohms?

Yes
GO to U12 .
No
REPAIR circuit VCA43 (WH/GN). CLEAR the DTCs.
VOLTAGE
Ignition ON.
Measure the voltage between brake
ground.

Yes
No
GO to U13 .
(WH/GN), harness side.

Yes
GO to U14 .
No
U13 CHECK THE SENSOR GROUND
CIRCUIT FOR AN OPEN
Ignition OFF.
RCA27 (WH), harness side and ABS
module C135-14, circuit RCA27
(WH), harness side.

Yes
No
REPAIR circuit RCA27 (WH). CLEAR the DTCs.
SUPPLY CIRCUIT FOR AN OPEN
LCA27 (BN/WH), harness side and
ABS module C135-2, circuit LCA27

Yes
No
Pinpoint Test V: DTCs C1011:1C, 1F, 67 and C1012:01
Normal Operation
The brake pedal feel simulator cut-off solenoid valve and brake pedal feel simulator cut-off pressure sensor
are located within the brake pedal feel simulator, which is attached to the brake pedal assembly. The ABS
module applies a Pulse Width Modulated (PWM) ground signal to the brake pedal feel simulator cut-off
solenoid valve to increase the resistance felt when the driver applies the brake pedal. The ABS module uses
input from the brake pedal feel simulator cut-off valve pressure sensor to verify that the brake pedal feel
simulator cut-off solenoid valve is functioning properly. If the ABS module detects a fault with a brake
system component that would adversely affect brake-by-wire operation, the module removes power from the
brake pedal feel simulator cut-off valve solenoid, relieving simulator fluid pressure.
The ABS module provides power to the brake pedal feel simulator cut-off valve solenoid.
The ABS module provides the brake pedal feel simulator cut-off pressure sensor a 5-volt reference voltage.
The brake pedal feel simulator provides a signal voltage proportional to the fluid pressure in the brake pedal
feel simulator cut-off device to the ABS module. The ABS module provides a signal return for brake pedal
feel simulator cut-off pressure sensor.
Both the brake pedal feel simulator cut-off solenoid valve and brake pedal feel simulator cut-off pressure
sensor are internal to the brake pedal feel simulator and cannot be serviced separately. If a new brake pedal
feel simulator is needed, a new brake pedal assembly must be installed.
C1011:1C Brake Pedal
Feel Simulator Cut-Off
Pressure Sensor: Circuit

If the brake pedal feel simulator cut-off pressure sensor circuits are
intermittently shorted to ground, shorted to voltage or have high
resistance, this DTC sets.
C1011:1F Brake Pedal
Pressure Sensor: Circuit
Intermittent

If the brake pedal feel simulator cut-off pressure sensor circuits are
shorted to ground, shorted to voltage or have high resistance, this DTC
sets.
C1011:67 Brake Pedal
Pressure Sensor: Signal
Incorrect After Event

If the test signal produced by the brake pedal feel simulator cut-off
pressure sensor is incorrect, this DTC sets.
C1012:01 Brake Pedal
Valve Solenoid: General
Electrical Failure

If the brake pedal feel simulator cut-off valve solenoid circuits are
shorted to ground, shorted to power or have high resistance or if the
brake pedal feel simulator cut-off valve solenoid is shorted internally,
this DTC sets.
Brake pedal feel simulator cut-off pressure sensor
Brake pedal feel simulator valve solenoid
ABS module
PINPOINT TEST V: DTCs C1011:1C, 1F, 67 AND C1012:01
V1 VERIFY ALL WIRING CONNECTIONS
Disconnect: Brake Pedal Feel Simulator Cut-Off
Pressure Sensor C2405 .

Valve Solenoid C2406 .



the following pins:

C135-5
C135-40
C135-41
C2405-1
C2405-2
C2405-3
C2406-1
C2406-2


Yes
GO to V2 .
No
V2 CHECK THE DTCs FROM THE ABS MODULE
SELF-TEST

Is DTC C1011:1C, 1F, 67 or C1012:01 present?
Yes
If DTC C1011:1C, 1F, or 67 is present,
GO to V3 . If DTC C1012:01 is present,
GO to V8 .
PINPOINT TEST V: DTCs C1011:1C, 1F, 67 AND C1012:01 3294
No
For all other ABS module DTCs, REFER
to the ABS Module DTC Chart in this
section.
V3 CHECK THE BRAKE PEDAL FEEL SIMULATOR
CUT-OFF PRESSURE SENSOR CIRCUITS FOR A
SHORT TO GROUND
Ignition OFF.
brake pedal feel simulator cut-off pressure
sensor C2405-1, circuit RCA16 (BU/BN),
harness side.

sensor C2405-2, circuit VCA13 (YE/BU),
harness side.

sensor C2405-3, circuit LCA16 (GN),
harness side.

Yes
GO to V4 .
No
REPAIR the affected circuit(s). CLEAR
V4 CHECK THE BRAKE FLUID PRESSURE
SENSOR CIRCUITS FOR AN OPEN
Measure the resistance between ABS module C135,
harness side and brake pedal feel simulator cut-off
pressure sensor C2405, harness side as indicated in

ABS
Module Circuit
Brake Pedal Feel
Simulator Cut-Off
Pressure Sensor
C135-5 LCA16
(GN)
C2405-3
C135-41 VCA13
(YE/BU)
C2405-2
C135-40 RCA16
(BU/BN)
C2405-1
Yes
GO to V5 .
No
SHORT TO VOLTAGE
Ignition ON.
sensor C2405-1, circuit RCA16 (BU/BN),
harness side.

sensor C2405-2, circuit VCA13 (YE/BU),
harness side.

sensor C2405-3, circuit LCA16 (GN),
harness side.

Yes
No
GO to V6 .
SHORT TOGETHER
Measure the resistance between brake pedal feel
simulator cut-off pressure sensor C2405 pins,
harness side, as indicated in the following chart:

Brake Pedal Feel
Simulator Cut-off
Pressure Sensor Circuit
Brake Pedal Feel
Simulator Cut-off
Pressure Sensor
C2405-1 RCA16
(BU/BN)/
VCA13
(YE/BU)
C2405-2
C2405-1 RCA16
(BU/BN)/
C2405-3
Yes
GO to V7 .
No
LCA16
(GN)
C2405-2 VCA13
(YE/BU)/
LCA16
(GN)
C2405-3
V7 CHECK THE ABS MODULE OUTPUT
Ignition OFF.
Ignition ON.
Measure the voltage between brake pedal feel
simulator cut-off pressure sensor C2405-3, circuit
LCA16 (GN), harness side and ground.

Is the voltage approximately 5 volts?
Yes
INSTALL a new brake pedal and bracket
assembly. REFER to Brake Pedal and
Bracket Hybrid in Section 206-06 .
No
GO to V12 .
CUT-OFF VALVE SOLENOID CIRCUITS FOR A
SHORT TO GROUND
Ignition OFF.
Valve Solenoid C2406 .

brake pedal feel simulator cut-off valve
solenoid C2406-1, circuit CCB31 (BU/OG),
harness side.

solenoid C2406-2, circuit CCB32 (GN/VT),
harness side.

Yes
GO to V9 .
No
CUT-OFF VALVE SOLENOID CIRCUITS FOR AN
OPEN
harness side and brake pedal feel simulator cut-off
valve solenoid C2406, harness side as indicated in

ABS
Module Circuit
Brake Pedal Feel
Simulator Cut-Off Valve
Solenoid
C135-4 CCB31
(BU/OG)
C2406-1
C135-3 CCB32
(GN/VT)
C2406-2
Yes
GO to V10 .
No
V10 CHECK THE BRAKE PEDAL FEEL
SIMULATOR CUT-OFF VALVE SOLENOID
Ignition ON.
solenoid C2406-1, circuit CCB31 (BU/OG),
harness side.

solenoid C2406-2, circuit CCB32 (GN/VT),
harness side.

Yes
No
GO to V11 .
V11 ISOLATE THE BRAKE PEDAL FEEL
SIMULATOR CUT-OFF VALVE SOLENOID
Measure the resistance between brake pedal feel
simulator cut-off valve solenoid C2406 pin-1 and
pin-2, component side.

Is the resistance between 18 and 20 ohms?
Yes
GO to V12 .
No
INSTALL a new brake pedal assembly.
REFER to Brake Pedal and Bracket in
Section 206-06 .
V12 CHECK FOR CORRECT ABS MODULE
OPERATION
corrosion.
pushed-out pins.
spread terminals.
present.

Yes
No
Pinpoint Test W: DTC C101A:1C, 62, 64 or C101B:1C
Normal Operation
The vacuum pressure sensor produces 2 signals used by the ABS module to check the integrity of the vacuum
lines, hoses and fittings, and to measure the performance of the brake vacuum pump and brake booster. The
ABS module provides a 5-volt reference voltage to the vacuum pressure sensor. The ABS module provides a
signal return to the vacuum pressure sensor along circuit.
C101A:1C
Vacuum Pressure
Sensor: Circuit

If vacuum pressure sensor circuit is shorted to ground, shorted to voltage or
has high resistance, this DTC sets. A short to ground or a short to voltage, or
an open on or short to voltage on circuit could cause both DTCs C101A:1C
and C101B:1C to set.
C101A:62
Vacuum Pressure
Sensor: Signal
Compare Failure
If the 2 vacuum pressure signals produced by the vacuum pressure sensor do
not match, this DTC sets. If vacuum sensor circuit has high resistance (open
circuit), this DTC sets. This DTC can set as a result of DTCs C101A:1C, 64
and C101B:1C.
C101A:64
Vacuum Pressure
Sensor: Signal

If the vacuum pressure sensor signal A, circuit is shorted to vacuum pressure
sensor signal B, circuit, this DTC sets.
C101B:1C
Vacuum Pressure
Sensor Circuit B:
Circuit Voltage Out of
Range

If vacuum pressure sensor circuit is shorted to ground, shorted to voltage or
has high resistance, this DTC sets. A short to ground or a short to voltage on
circuit, or an open on or short to voltage on circuit could cause both DTCs
C101A:1C and C101B:1C to set.
Vacuum pressure sensor
ABS module
PINPOINT TEST W: C101A:1C, 62, 64 or C101B:1C
W1 VERIFY ALL WIRING CONNECTIONS
Ignition OFF.
Disconnect: Vacuum Sensor C1603 .


the following pins:

C135-6
C135-25
C135-28
C135-30
C1603-1
C1603-2
C1603-3
Yes
GO to W2 .
No
REPAIR the affected terminal(s).
self-test.
PINPOINT TEST W: C101A:1C, 62, 64 or C101B:1C 3300
C1603-4

Is each terminal free of corrosion, pushed-out pins
or spread terminals?

W2 CHECK THE DTCs FROM THE ABS MODULE
SELF-TEST
Review the DTCs recorded during Inspection and
Verification.

Are both DTCs C101A:1C and C101B:1C present?
Yes
GO to W9 .
No
If DTC C101A:1C is present without
DTC C101B:1C, GO to W3 .
If DTC C101B:1C is present without
DTC C101A:1C, GO to W6 .
If DTC C101A:64 is present, GO to
W13 .
If only DTC C101A:62 is present, GO
to W11 .
For all other DTCs, GO to the ABS
W3 CHECK THE SENSOR SIGNAL 1 RETURN
Measure the resistance between vacuum sensor
C1603-4, circuit VCA38 (BN/VT), harness side and
ground.

Yes
GO to W4 .
No
REPAIR circuit VCA38 (BN/VT).
self-test.
Ignition ON.
Measure the voltage between vacuum sensor C1603-4,
circuit VCA38 (BN/VT), harness side and ground.

Yes
self-test.
No
GO to W5 .
CIRCUIT FOR AN OPEN
Ignition OFF.
C1603-4, circuit VCA38 (BN/VT), harness side and
ABS module C135-30, circuit VCA38 (BN/VT),
harness side.

Yes
GO to W9 .
No
self-test.
C1603-1, circuit VCA39 (BU/GN), harness side and
ground.

Yes
GO to W7 .
No
REPAIR circuit VCA39 (BU/GN).
self-test.
Ignition ON.
circuit VCA39 (BU/GN), harness side and ground.

Yes
self-test.
No
GO to W8 .
CIRCUIT FOR AN OPEN
Ignition OFF.
ABS module C135-25, circuit VCA39 (BU/GN),
harness side.

Yes
GO to W9 .
No
self-test.
W9 CHECK THE SENSOR VOLTAGE SUPPLY
C1603-3, circuit LCA37 (YE/OG), harness side and
ground.

Yes
GO to W10 .
No
REPAIR circuit LCA37 (YE/OG).
self-test.
W10 CHECK THE SENSOR VOLTAGE SUPPLY AND
GROUND CIRCUITS FOR A SHORT TO VOLTAGE
Ignition ON.
C1603-3, circuit LCA37 (YE/OG), harness
side.

C1603-2, circuit RCA37 (WH/BU), harness
side.

Yes
No
GO to W11 .
W11 CHECK THE SENSOR VOLTAGE SUPPLY AND
GROUND CIRCUITS FOR AN OPEN
Ignition OFF.
harness side and vacuum sensor C1603, harness side as

C135-6 LCA37 (YE/OG) C1603-3
C135-28 RCA37 (WH/BU) C1603-2
Yes
If only DTC C101A:62 is present, GO
to W12 .
For all other DTCs, GO to W13 .
No
W12 CHECK BOTH SENSOR SIGNAL RETURN
harness side and vacuum sensor C1603, harness side as

Yes
GO to W13 .
No
C135-30 VCA38 (BN/VT) C1603-4
C135-25 VCA39 (BU/GN) C1603-1
W13 CHECK BOTH SENSOR SIGNAL RETURN
ABS module C1603-4, circuit VCA38 (BN/VT),
harness side.

Yes
GO to W14 .
No
W14 CHECK ABS MODULE OUTPUT
Ignition ON.
circuit LCA37 (YE/OG) and ground.

Is the voltage between 4.7 and 5.1 volts?
Yes
INSTALL a new vacuum sensor.
REFER to Section 206-07 . CLEAR the
No
INSTALL a new ABS module. REFER
to Anti-Lock Brake System (ABS)
Module Hybrid in this section.
Pinpoint Test X: DTCs C101C:01 and 71
Normal Operation
When the combustion engine is not running, the electric vacuum pump is utilized to maintain a vacuum inside
the brake booster. The ABS module controls the electric vacuum pump through the use of a mechanical relay
located in the Battery Junction Box (BJB) and a solid state relay located in the auxiliary relay box. The
mechanical relay provides power to the solid state relay. The solid state relay provides power to the electric
vacuum pump motor. When the ignition is in the RUN position, the ABS module closes the mechanical relay.
After the vehicle is started (the ready indicator is illuminated), the ABS module activates the solid state relay
as necessary to maintain a vacuum inside the brake booster.
Fused battery voltage is provided to the mechanical relay from the BJB . When the ignition switch is turned to
the RUN position, the ABS module grounds the output side of the mechanical relay solenoid. This closes the
mechanical relay and send voltage to the solid state relay. When it is necessary to build vacuum in the brake
booster, the ABS module grounds the solid state relay along circuit. The solid state relay then sends voltage to
the vacuum pump and BJB fuse 37. The voltage passes through BJB fuse 37 (5A) and is delivered to the ABS
module along circuit. The ABS module uses this voltage input to monitor the vacuum pump.
The logic internal to the solid state relay provides circuit protection for the vacuum pump circuit. If a short to
ground on circuit is detected, the relay stops applying power until the short has been repaired.
If a vacuum pump DTC is set, the red brake warning indicator illuminates and the combustion engine runs to
supply vacuum to the brake booster.
DTC C101C:01 (Brake Vacuum Pump: General Electrical Failure) If the ABS module detects a
short to ground, an open or high resistance on circuits CBB37 (WH), CCB29 (WH/VT) and CCB30
(GY/VT), or an open or high resistance , this DTC sets.

DTC C101C:71 (Brake Vacuum Pump: Actuator Stuck) If the ABS module detects that vacuum
in the brake booster is increasing when the vacuum pump is commanded off and the combustion
engine is not running, this DTC sets.

Fuses
Electric vacuum pump solid state relay
Electric vacuum pump solid mechanical relay
ABS module
PINPOINT TEST X: DTCs C101C:01 AND 71
X1 VERIFY ALL WIRING CONNECTIONS
Disconnect: Vacuum Pump Motor C1119 .
Disconnect: Vacuum Pump Solid State Relay .
Disconnect: Vacuum Pump Mechanical Relay .

Yes
GO to X2 .
No

the following pins:

C135-15
C135-20
C135-35
C1119-1
C1119-2
Vacuum pump solid state relay cavities
Vacuum pump mechanical relay cavities


X2 CHECK THE DTCs FROM THE ABS MODULE
SELF-TEST
Connect: Vacuum Pump Motor C1119 .
Connect: Vacuum Pump Solid State Relay .
Connect: Vacuum Pump Mechanical Relay .

Is DTC C101C:01 or C101C:71 present?
Yes
If DTC C101C:01 is present, GO to X5 .
If DTC C101C:71 is present, GO to X3 .
No
For all other ABS module DTCs, GO to the
ABS Module DTC Chart in this section.
X3 CHECK THE SOLID STATE RELAY CONTROL
Ignition OFF.
Measure the resistance between the vacuum pump
solid state relay socket 86, circuit CCB30 (GY/VT)
and ground.

Yes
INSTALL a new vacuum pump solid state
relay.
No
GO to X4 .
PINPOINT TEST X: DTCs C101C:01 AND 71 3307
X4 ISOLATE THE SOLID STATE RELAY
CONTROL CIRCUIT
Ignition OFF.
solid state relay socket 86, circuit CCB30 (GY/VT)
and ground.

Yes
GO to X24 .
No
REPAIR circuit CCB30 (GY/VT). CLEAR
X5 CHECK THE VACUUM PUMP MOTOR
Ignition ON.
Is the vacuum pump running all the time?
Yes
GO to X6 .
No
GO to X11 .
X6 ISOLATE THE SOLID STATE RELAY
Is the vacuum pump running all the time?
Yes
GO to X9 .
No
GO to X7 .
X7 CHECK THE SOLID STATE RELAY CONTROL
Ignition OFF.
solid state relay cavity 86, circuit CCB30 (GY/VT)
and ground.

Yes
INSTALL a new solid state relay. CLEAR
No
GO to X8 .
X8 ISOLATE THE ABS MODULE
solid state relay cavity 86, circuit CCB30 (GY/VT)
and ground.

Yes
GO to X24 .
No
X9 ISOLATE THE VACUUM PUMP MOTOR
CONTROL CIRCUIT
Disconnect: BJB Fuse 37 (5A) .
Is the pump running all the time?
Yes
REPAIR circuit CCB29 (WH/VT). CLEAR
No
GO to X10 .
X10 CHECK THE ABS MODULE PUMP MOTOR
MONITOR CIRCUIT
Connect: BJB Fuse 37 (5A) .
Ignition OFF.
Ignition ON.
Is the pump running all the time?
Yes
REPAIR circuit CBB37 (WH). CLEAR the
No
GO to X24 .
X11 CHECK THE VACUUM PUMP GROUND
CIRCUIT FOR AN OPEN
Ignition OFF.
Measure the resistance between vacuum pump
motor C1119-2, circuit GD121 (BK/YE), harness
side and ground.

Yes
GO to X12 .
No
REPAIR circuit GD121 (BK/YE). CLEAR
X12 CHECK THE VACUUM PUMP MECHANICAL
RELAY INPUT CIRCUIT FOR VOLTAGE
vacuum pump mechanical relay cavity 3,
circuit SBB07 (WH/RD).

vacuum pump mechanical relay cavity 2,
circuit SBB07 (WH/RD).

Yes
GO to X13 .
No
REPAIR circuit SBB07 (WH/RD).
manual to identify the cause of the circuit
short.
X13 ISOLATE THE VACUUM PUMP
MECHANICAL RELAY
Ignition ON.

Install a fused jumper wire between vacuum pump
mechanical relay cavity 3, circuit SBB07 (WH/RD)
and cavity 5, circuit CBB07 (GN/BU).

Using the scan tool, toggle the vacuum pump
(VAC_PMP) active command on.

Does the pump motor run?
Yes
REMOVE the fused jumper wire. GO to
X14 .
No
GO to X16 .
X14 CHECK THE MECHANICAL RELAY
Ignition OFF.
C135-35, circuit CBB30 (GY/BK), harness side and
vacuum pump mechanical relay socket 1, circuit
CBB30 (GY/BK).

Yes
GO to X15 .
No
REPAIR circuit CBB30 (GY/BK). CLEAR
X15 CHECK THE MECHANICAL RELAY
C135-35, circuit CBB30 (GY/BK), harness side and
ground.

Yes
INSTALL a new vacuum pump mechanical
relay. CLEAR the DTCs. REPEAT the
self-test.
No
REPAIR circuit CBB30 (GY/BK). CLEAR
the DTCs and REPEAT the self-test.
X16 CHECK THE SOLID STATE RELAY INPUT
CIRCUIT FOR VOLTAGE
Measure the voltage between vacuum pump solid
state relay cavity 30, circuit CBB07 (GN/BU) and
ground.

Yes
REMOVE the fused jumper wire. GO to
X17 .
No
REPAIR circuit CBB07 (GN/BU). CLEAR
X17 CHECK THE SOLID STATE RELAY
CONTROL CIRCUIT FOR AN OPEN CIRCUIT
solid state relay cavity 86, circuit CCB30 (GY/VT),
and ABS module C135-15, circuit CCB30

Yes
GO to X18 .
No
X18 CHECK THE SOLID STATE RELAY
C135-15, circuit CCB30 (GY/VT), harness side and
ground.

Yes
GO to X19 .
No
X19 CHECK THE VACUUM PUMP SOLID STATE
RELAY OUTPUT CIRCUIT FOR A SHORT TO
GROUND
Disconnect: BJB Fuse 37 (5A) .
solid state relay cavity 87, circuit CBB29
(WH/VT), harness side and ground.

Yes
GO to X20 .
No
REPAIR circuit CBB29 (WH/VT). CLEAR
X20 CHECK THE VACUUM PUMP SOLID STATE
RELAY OUTPUT CIRCUIT FOR AN OPEN CIRCUIT
solid state relay cavity 87, circuit CBB29 (WH/VT)
and:

vacuum pump motor C1119-1, circuit
CBB29 (WH/VT), harness side.

BJB fuse 37 (5A), circuit CBB29
(WH/VT), input side.

Yes
GO to X21 .
No
REPAIR circuit CBB29 (WH/VT). CLEAR
X21 CHECK THE VACUUM PUMP MONITOR
CIRCUIT FOR AN OPEN CIRCUIT
Measure the resistance between BJB fuse 37 (5A),
circuit CBB37 (WH), input side and ABS module
C135-20, circuit CBB37 (WH), harness side.

Yes
GO to X22 .
No
DTCs and REPEAT the self-test.
X22 CHECK THE VACUUM PUMP MONITOR
C135-20, circuit CBB37 (WH), harness side and
ground.

Yes
GO to X23 .
No
DTCs and REPEAT the self-test.
X23 CHECK THE VACUUM PUMP OPERATION
Connect: Vacuum Pump Motor Solid State Relay .
Install a fused jumper wire between vacuum pump
mechanical relay cavity 3, circuit SBB07 (WH/RD)
and cavity 5, circuit CBB07 (GN/BU).

Momentarily connect a fused jumper wire between
ABS module C135-15, circuit CBB30 (GY/BK),

Does the pump run when the jumper wire is
connected to ground?

Yes
REMOVE both fused jumper wires. GO to
X24 .
No
REMOVE the fused jumper wire from the
ABS module connector. GO to X25 .
X24 CHECK FOR CORRECT ABS MODULE
OPERATION
corrosion.
pushed-out pins.
spread terminals.
Yes
No
present.

X25 ISOLATE THE VACUUM PUMP MOTOR
Disconnect: Vacuum Pump Motor Solid State Relay
.

NOTE: The fused jumper wire on the mechanical
relay should still be installed from the previous
step.

Momentarily connect a fused jumper wire between
vacuum pump solid state relay cavity 30, circuit
CCB29 (WH/VT) and cavity 87, circuit CBB07
(GN/BU).

Does the pump run when the jumper wire is
connected?

Yes
INSTALL a new solid state relay. CLEAR
No
INSTALL a new vacuum pump. REFER to
Brake Vacuum Pump in Section 206-07 .
Pinpoint Test Y: DTCs C0061:28, 64; C0063:28, 64; U0151:87, 88 and U0452:29
Normal Operation
The yaw rate sensor, lateral accelerometer and longitudinal accelerometer are contained in the Restraints
Control Module (RCM). The RCM measures vehicle yaw rate and lateral acceleration and then sends the
information to the ABS module along the dedicated Controller Area Network (CAN) bus. This CAN bus is
used only for communication between the RCM and the ABS module. The information sent to the ABS
module is used to help determine if the AdvanceTrac system needs to be activated.
C0061:28 Lateral
Acceleration Sensor: Signal
Bias Level Out of
Failure

This DTC is set if the lateral acceleration sensor measures acceleration
when the vehicle is not moving.
This DTC indicates that the lateral acceleration sensor is inconsistent
with other acceleration sensor, steering wheel angle sensor and wheel
C0061:64 Lateral
Acceleration Sensor: Signal
speed sensor signals.
C0063:28 Yaw Rate
Sensor: Signal Bias Level
Out of Range/Zero
Adjustment Failure

This DTC indicates that the yaw rate sensor is measuring rotation
when the vehicle is not moving.
C0063:64 Yaw Rate
Failure

This DTC indicates that the yaw rate sensor is inconsistent with other
acceleration sensor, steering wheel angle sensor and wheel speed
sensor signals.
U0151:87 Lost
Communication With
Restraints Control Module:
Missing Message

This DTC sets as a result of a loss of communication with the RCM
over either the High Speed Controller Area Network (HS-CAN) bus or
the dedicated CAN bus.
U0151:88 Lost
Communication With
Restraints Control Module:
Bus Off

This DTC can set if either the dedicated CAN circuits are open,
shorted to ground or shorted to each other. Other DTCs indicating
missing messages or invalid signal from the RCM sensors can set as a
result of a dedicated CAN bus fault.
U0452:29 Invalid Data
Received From Restraints
Control Module: Signal
Invalid

This DTC indicates that one or more of the stability/traction control
system sensors internal to the RCM have failed and the RCM is
transmitting an "invalid data" message.
RCM incorrectly mounted
RCM
ABS module
PINPOINT TEST Y: DTCs C0061:28, 64; C0063:28, 64; U0151:87, 88 AND U0452:29
death.
PINPOINT TEST Y: DTCs C0061:28, 64; C0063:28, 64; U0151:87, 88 AND U0452:29 3316
Y1 CHECK FOR AN HS-CAN CONCERN
WITH THE RCM
Ignition ON.
NOTE: The Network Test does not test the
dedicated CAN communications between the
ABS module and RCM .

Using the scan tool, carry out the Network
Test.

Does the RCM pass the Network Test?
Yes
GO to Y2 .
No
HS-CAN concern.
Y2 CHECK FOR CORRECT RCM
Ignition OFF.

Gain access to the RCM and check the part
number on the RCM against the part number
listed in the master parts catalog. Refer to
Section 501-20B .

Does the part number on the RCM match
the part number listed in the master parts
catalog?

Yes
GO to Y3 .
No
INSTALL the correct RCM . REFER to Section
501-20B . GO to Y13 .
Y3 CHECK FOR CORRECT ABS MODULE
scan tool: Log Viewer .

Retrieve and record the ABS module part
number from Log Viewer and check the part
number on the ABS module against the part
number listed in the master parts catalog.

Does the part number retrieved from the
ABS module match the part number listed
in the master parts catalog?

Yes
GO to Y4 .
No
INSTALL the correct ABS module. REFER to
section. GO to Y13 .
Y4 CHECK THE RCM CONDITION AND
INSTALLATION

Inspect the RCM for cracks in the case,
broken anchor tabs, broken electrical
connector and correct installation. Refer to

Yes
GO to Y5 .
No
REINSTALL or INSTALL new as necessary. GO
to Y13 .
Removal and Installation, Restraints Control
Module (RCM) in Section 501-20B .
Is the RCM installed correctly and
undamaged?

Y5 CHECK THE DEDICATED CAN
Ignition OFF.
Disconnect: RCM C310B .
module C135, harness side and the RCM
C310B, harness side as indicated in the
following chart:

ABS Module Circuit RCM
C135-18 VCA23 (BU/WH) C310B-20
C135-19 VCA24 (GN/OG) C310B-19
Yes
GO to Y6 .
No
DTCs. CYCLE the ignition key. REPEAT the
self-test. GO to Y13 .


ohms?

Yes
GO to Y7 .
No
REPAIR the affected circuit(s). GO to Y13 .
C135-19, circuit VCA24 (GN/OG), harness
side and ABS module C135-18, circuit

ohms?

Yes
GO to Y8 .
No
Ignition ON.


Yes
No
GO to Y9 .
Y9 CHECK RCM TERMINATING RESISTOR
Ignition OFF.
Connect: RCM C310B .
C135-18, circuit VCA23 (BU/WH), harness
side and C135-19, circuit VCA24 (GN/OG),
harness side.

Is the resistance between 108 and 132
ohms?

Yes
GO to Y10 .
No
GO to Y11 .
Y10 CHECK THE ABS MODULE FOR
CORRECT OPERATION

terminals.


Connector Position Assurance
(CPA) lever/lock for correct
operation. Refer to Restraints
Control Module (RCM) in Section
501-20B .

corrosion, water intrusion,
pushed-out, loose or spread


Component(s)/Connector(s) .



Do any of the DTCs listed in Normal
Operation return?

Yes
section. GO to Y13 .
No
corroded connector. GO to Y13 .
Y11 CONFIRM THE RCM FAULT
NOTE: Make sure all restraint system
components, sensor electrical connectors and
the RCM electrical connectors are connected
before carrying out the self-test. If not, DTCs
can be set.
If previously directed to repower the SRS ,
depower the SRS . Refer to Supplemental


Yes
INSTALL a new RCM . REFER to Section
501-20B . GO to Y13 .
No
In the process of diagnosing the fault, the fault
condition has become intermittent.
CHECK for causes of the intermittent fault.
ATTEMPT to recreate the hard fault by flexing
the wire harness and cycling the ignition
frequently. ACTIVATE other systems in the same
wire harness. Do not install any new SRS
terminals.


CPA lever/lock for correct operation.
Refer to Restraints Control Module
(RCM) Removal and Installation in
Section 501-20B .

corrosion, water intrusion,
pushed-out, loose or spread




scan tool: Self Test RCM .

Were DTCs U0028:08 and/or U0028:88

in the pinpoint test. GO to Y12 .
Y12 CHECK FOR AN INTERMITTENT
FAULT
Ignition OFF.

Disconnect RCM C310B and ABS module
C135:

in-line connectors) for corrosion,
terminals.



Yes
REFER to Diagnosis and Testing in Section
501-20B .
No
The fault is not present and cannot be recreated at
this time. Do not install any new SRS
in the pinpoint test. GO to Y13 .


Ignition ON.

Are any RCM DTCs retrieved on-demand
during the self-test?

Y13 CHECK FOR ADDITIONAL RCM AND
ABS MODULE DTCs
Ignition OFF.

Reconnect all SRS components (if
previously disconnected).

If previously directed to depower the SRS ,
repower the SRS . Do not prove out the SRS
at this time. Refer to Supplemental Restraint

Ignition ON.


Were any DTCs retrieved on-demand
from the RCM or ABS module during
self-test?

Yes
Do not clear any DTCs until all DTCs have been
resolved. GO to the appropriate DTC Chart in this
section and/or Section 501-20B for pinpoint test
direction.
No
Trouble Codes (CMDTCs). PROVE OUT the SRS
. REFER to Supplemental Restraint System (SRS)
Depowering and Repowering in Section 501-20B .
Repair is complete. RETURN the vehicle to the
customer.
Pinpoint Test Z: DTC U3002:62
Normal Operation
When the ignition is turned to the RUN position, the ABS module and the PCM share Vehicle Identification
Number (VIN) information over the High Speed Controller Area Network (HS-CAN) bus.
DTC U3002:62 (Vehicle Identification Number: Signal Compare Failure) This DTC indicates
that the VIN message sent by the PCM over the HS-CAN bus does not match the VIN stored in the
ABS module.

Module configuration (ABS and PCM)
ABS module
PINPOINT TEST Z: DTC U3002:62
Z1 VERIFY PCM VIN
Ignition ON.
Enter the following
tool: Log Viewer .

Compare the VIN in Log
Viewer to the vehicle VIN
plate.

Does VIN in Log Viewer
match the vehicle VIN
plate?

Yes
GO to Z2 .
No
RECONFIGURE the PCM. FOLLOW the instructions on the scan
tool. CLEAR the DTCs. CYCLE the ignition key. REPEAT the
self-test.
Z2 VERIFY ABS MODULE
PART NUMBER
Retrieve and record the
ABS module part number
from Log Viewer and verify
that the vehicle has the
correct ABS module
installed.

Is the correct ABS module
installed in the vehicle?

Yes
Installation (PMI) Using the Integrated Diagnostic System (IDS)
When the Original Module is NOT Available in Section 418-01 .
CLEAR the DTC. CYCLE the ignition key. REPEAT the self-test.
No
(ABS) Module Hybrid in this section. CLEAR the DTC.
CYCLE the ignition key. REPEAT the self-test.
Pinpoint Test AA: The Stability/Traction Control System Cannot Be Disabled
Normal Operation
The traction control portion of the AdvanceTrac can be disabled by pressing the traction control switch
located on the instrument panel. When the system is disabled, the sliding car OFF icon in the Instrument Panel
Cluster (IPC) illuminates continuously. The traction control switch is part of the ambient lighting switch.
The IPC sends 5 volts to the traction control switch. When the traction control switch is pressed, this voltage
is sent through the switch and to ground. When the IPC detects this ground, it sends a message to the PCM
and the ABS module along the High Speed Controller Area Network (HS-CAN) bus that the driver has
disabled the system. An open circuit or a defective traction control switch prevents the system from being
disabled, and does not set a DTC.
If a MyKey restricted key is in use with Advance Trac always-on feature configured to "on", the
traction control system cannot be disabled. An admin key must be used in order to enable and disable the
traction control system.
PINPOINT TEST Z: DTC U3002:62 3323
DTC C0089:11 (TCS Disable Switch: Circuit Short to Ground) If the IPC detects the ground signal
during the on-demand self test or if circuit CCA15 (YE/GY) is shorted to ground, DTC C0089:11 is set. Also,
if the traction control switch is held or stuck closed for more than 2 minutes during normal operation, DTC
C0089:11 is set. If a MyKey restricted key is in use with Advance Trac always-on feature configured
to "on", an admin key must be used in order to enable and disable the traction control system.
IPC
PINPOINT TEST AA: THE STABILITY/TRACTION CONTROL SYSTEM CANNOT BE DISABLED
AA1 VERIFY ALL WIRING CONNECTIONS
Disconnect: Instrument Panel Cluster (IPC) C220 .
Disconnect: Traction Control/Ambient Lighting Switch C2304 .
Using a good light source, inspect each connector terminal for any
corrosion.

Hybrid/MKZ Hybrid ) for schematic and connector information.

Using a suitable mating terminal, check each female terminal for
deformed or enlarged contacts by comparing the mating terminal's
fit between each of the following pins:

C220-22
C2304-1
C2304-7
Hybrid/MKZ Hybrid ) for schematic and connector information.

Is each terminal free of corrosion, pushed-out pins or spread
terminals?

Yes
GO to AA2 .
No
REPAIR the affected
terminal(s). CLEAR the
DTCs. REPEAT the
self-test.
AA2 CHECK FOR ANY COMMUNICATION DTCs
Connect: Traction Control/Ambient Lighting Switch C2304 .
Connect: IPC C220 .
Ignition ON.
Yes
For ABS communication
DTCs, GO to the ABS
Module DTC Chart.
Check the IPC , the PCM and the ABS module for any
communication DTCs.

Are any communication DTCs present?
For IPC and PCM
communication DTCs,
REFER to the Diagnostic
Trouble Code (DTC) Chart
in Section 419-10 .
No
GO to AA3 .
AA3 ISOLATE THE TRACTION CONTROL SWITCH
NOTE: If a MyKey restricted key is in use with Advance
Trac always-on feature configured to "on", the traction control
system cannot be disabled. An admin key must be used in order to
enable and disable the traction control system.
Ignition OFF.
Disconnect: Traction Control/Ambient Lighting Switch C2304 .
Measure the resistance between traction control/ambient lighting
switch C2304 pin-7 and pin-1, component side, while pressing and
releasing the traction control switch.

Is the resistance less than 5 ohms with the switch pressed and
greater than 10,000 ohms with the switch released?

Yes
GO to AA4 .
No
INSTALL a new traction
control switch. REFER to
Traction Control Switch in
system for normal
operation.
AA4 CHECK THE TRACTION CONTROL SWITCH GROUND
CIRCUIT FOR AN OPEN
switch C2304-1, circuit GD116 (BK/VT), harness side and ground.

Yes
GO to AA5 .
No
(BK/VT). TEST the system
AA5 CHECK THE TRACTION CONTROL SWITCH CONTROL
CIRCUIT FOR AN OPEN
Disconnect: IPC C220 .
switch C2304-7, circuit CCA15 (YE/GY), harness side and IPC
C220-22, circuit CCA15 (YE/GY), harness side.

Yes
GO to AA6 .
No
(YE/GY). TEST the system
PINPOINT TEST AA: THE STABILITY/TRACTION CONTROL SYSTEM CANNOT BE DISABLED 3325
AA6 CHECK THE TRACTION CONTROL SWITCH CONTROL
switch C2304-7, circuit CCA15 (YE/GY), harness side and ground.

Yes
GO to AA7 .
No
(YE/GY). TEST the system
AA7 CHECK FOR CORRECT IPC OPERATION
Ignition OFF.
Disconnect: IPC C220 .
Check for:
corrosion
pushed-out pins
spread terminals
Connect: IPC C220 .
Make sure the connector is seated correctly, then operate the

Yes
INSTALL a new IPC .
operation.
No
corroded connector.
Pinpoint Test AB: Soft or Excessive Brake Pedal Travel
Normal Operation
The brake pedal should be firm at all times when applied.
Leak in the hydraulic system
Air in brake system
PINPOINT TEST AB: SOFT OR EXCESSIVE BRAKE PEDAL TRAVEL
AB1 RETRIEVE THE RECORDED DTCs
FROM THE ABS SELF-TEST
Check for recorded ABS DTCs from the
self-test.

Yes
REFER to DTC charts in this section.
No
GO to AB2 .
AB2 CHECK THE BRAKE SYSTEM
COMPONENTS FOR CORRECT
INSTALLATION OR DAMAGE
Inspect the brake system for the following
concerns:

Check the brake pedal and bracket,
brake master cylinder, brake calipers
and fluid lines/hoses for correct
installation.

Check the brake pedal and bracket,
brake master cylinder, brake calipers
and fluid lines/hoses for damage or
leaks.

Check the flexible brake hoses for
bulging with the brake pedal is
pressed.

For brake pedal and master cylinder,

For brake booster, refer to Section
206-07 .

Are the brake system components
correctly installed and free from leaks or
damage?

Yes
GO to AB3 .
No
REPAIR the identified concern. TEST the system
AB3 BLEED THE BRAKE SYSTEM
Bleed the brake system including the
Hydraulic Control Unit (HCU) bleeding
procedure. Refer to Section 206-00 .

Yes
GO to AB4 .
No
concern may have been caused by air in the brake
system.
AB4 CHECK BRAKE MASTER CYLINDER
Carry out the Brake Master Cylinder
Bypass Condition Test in Section 206-00 ,
Component Tests.

Did the master cylinder pass the
component test?

Yes
No
INSTALL a new master cylinder. REFER to
operation.
PINPOINT TEST AB: SOFT OR EXCESSIVE BRAKE PEDAL TRAVEL 3327
Pinpoint Test AC: DTCs C1029:00, C102B:00
Normal Operation
The primary channel consists of the RF and LR hydraulic circuits, and the secondary brake channel consists of
the LF and RR hydraulic circuits. Pressure imbalances between the primary or secondary hydraulic pressure
could be caused by air in the lines or fluid leaks in the brake fluid system.
C1029:00 (ABS Primary Circuit Pressure Lower Than Secondary: No Sub type Information) this
DTC sets if the ABS module detects that the pressure in the primary circuit is less than in the
secondary circuit.

C102B:00 (ABS Secondary Circuit Pressure Lower Than Primary: No Sub Type Information)
this DTC sets if the ABS module detects that the pressure in the secondary circuit is less than in the
primary circuit .

Air in brake fluid system
Master Cylinder
Hydraulic Control Unit.
PINPOINT TEST AC: DTC C1029:00, C102B:00
AC1 BLEED THE BRAKES
Bleed the brakes. Refer to Section 206-00 .
Clear the DTCs.
Yes
GO to AC2
No
concern may have been caused by air in the brake
system.
AC2 MONITOR THE ABS PRIMARY AND
SECONDARY CHANNEL PRESSURES
Ignition ON.
scan tool: ABS Module DataLogger.

Select the following PIDs to monitor the
primary and secondary channels.

Left front brake pressure
(LF_BRK_PRS)

Right rear brake pressure
(RR_BRK_PRS)

Right front brake pressure
(RF_BRK_PRS)

Left rear brake pressure
(LR_BRK_PRS)

Depress the brake pedal firmly and note the
brake pressures displayed by each PID.

Yes
CLEAR the DTCs, REPEAT the self-test. If
C1029:00 or C102B:00 returns, INSTALL a new
HCU . REFER to Hydraulic Control Unit (HCU) in
this section.
No
CLEAR the DTCs, REPEAT the self-test. If
C1029:00 or C102B:00 returns, INSTALL a new
brake master cylinder. REFER to Section 206-06 .
Add the pressures for the left front brake
pressure and the right rear brake pressure
together (secondary channel).

Add the pressures for the right front brake
pressure and the left rear brake pressure
together (primary channel).

Are the primary and secondary channel
pressures within 10% of each other?

PINPOINT TEST AC: DTC C1029:00, C102B:00 3329
Workshop Manual
Material
Item Specification
(Canada)
WSS-M6C62-A or
WSS-M6C65-A1
1 - ABS module electrical connector (part of
14290)
2 - Master cylinder secondary brake tube
fitting (part of 2C360)
3 - RH front brake tube fitting (part of 2263)
4 - Rear back pressure valve brake tube fitting
(part of 2C360)
5 - Master cylinder primary brake tube fitting
(part of 2C360)
6 - Rear back pressure valve brake tube fitting
(part of 2C360)
7 - LH front brake tube fitting (part of 2C360)
8 W520102 Hydraulic Control Unit (HCU)
bracket-to-frame nut
Hydraulic Control Unit (HCU) 3330
9 W712710 HCU bracket-to-frame bolt (Torx head)
(3.5L only)
9 W505433 HCU bracket-to-frame bolt (hex head) all
other engines
10 2C398 HCU bracket-to- HCU bolt
11 W704925 HCU bracket-to-frame stud bolt
12 4 HCU bracket
13 2C346 HCU
NOTICE: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted
or plastic surface, immediately wash it with water.
Position the engine coolant degas bottle aside.
If equipped, detach the wiring harness retainer from the degas bottle. 1.
Remove the bolt.
2.
Remove the nut.
3.
1.
Recover the refrigerant. For additional information, refer to Section 412-00A . 2.
Remove the condenser-to-evaporator line and compressor manifold and tube bracket bolts.
3.
Remove the condenser-to-evaporator line and compressor manifold and tube fitting nuts. Disconnect
the fittings.
Discard the gasket seals.
4.
Disconnect the ABS module electrical connector. 5.
Disconnect the brake tube fittings.
To install:
tighten the front and rear brake tube fittings to 20 Nm (177 lb-in).
tighten the master cylinder brake tube fittings to 27 Nm (20 lb-ft).

6.
Remove the HCU bracket-to- HCU bolt.
7.
Remove the HCU . 8.
NOTE: Make sure the HCU and ABS module are clean and free of any brake fluid or foreign
material before separating the components.
Install new O-ring seals and new gasket seals.
Add the correct amount of clean PAG oil. For additional information, refer to the Refrigerant
Oil Adding procedure in Section 412-00A

9.
Evacuate, leak test and charge the refrigerant system. For additional information, refer to Section
412-00A
10.
Workshop Manual
Hydraulic Control Unit (HCU) - Hybrid
Special Tool(s)
Material
Item Specification
(Canada)
WSS-M6C62-A or
WSS-M6C65-A1
1 - Master cylinder primary brake tube fitting
(part of 2C360)
2 - RH front brake tube fitting (part of 2263)
3 - LH front brake tube fitting (part of 2C360)
4 - Master cylinder secondary brake tube
fitting (part of 2C360)
5 -
6 - LH rear brake tube fitting (part of 9J279)
Hydraulic Control Unit (HCU) - Hybrid 3333
7 - ABS module electrical connector (part of
14290)
8 W505433 Hydraulic Control Unit (HCU)
bracket-to-frame bolts
9 2C065 HCU
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the sue may occur. If
NOTE: This step is necessary only if a new ABS module is being installed.
Connect the scan tool and upload the module configuration information from the ABS module. For
1.
Remove the Thermostatic Expansion Valve (TXV) manifold and tube assembly. For additional
2.
Remove the 2 engine cover studs from the valve cover stud bolts. 3.
Detach the wire harness push-type fastener from the Hydraulic Control Unit (HCU) bracket and
position the harness aside.
5.
Disconnect the brake tube fittings.
6.
With the vehicle in NEUTRAL, position it on a hoist. For additional information refer to Section
100-02 .
7.
Remove the HCU bracket-to-frame bolts.
8.
Remove the HCU and bracket assembly. 9.
10.
If a new ABS module was installed, download the module configuration information from the scan
tool. For additional information, refer to Section 418-01 .
11.
If a new ABS module and/or a new HCU was installed, carry out the Multi-Calibration routine, follow
the scan tool directions.
12.
Workshop Manual
1 - ABS module electrical connector (part of 14290)
2 2M101 ABS module screw (4 required)
3 2C219 ABS module
NOTICE: Electronic modules are sensitive to electrical charges. The ABS module can be damaged if
exposed to these charges.
NOTICE: Do not allow any brake fluid or foreign material to enter the mating side of the ABS module
or damage to the solenoids can occur.
All vehicles
If a new ABS module is being installed, connect the scan tool and upload the module configuration
from the ABS module. For additional information, refer to Section 418-01 .
1.
Vehicles equipped with a 3.5L engine
Detach the body harness from the 2 valve cover studs and position the harness aside. 3.
Detach the wire harness from the 2 valve cover studs and position the harness aside. 4.
Anti-Lock Brake System (ABS) Module 3336
Remove the bolt and position the windshield washer reservoir filler neck aside.
5.
Remove the nut and position the degas bottle hose aside.
6.
All vehicles
Remove the 4 ABS module screws and the ABS module.
8.
NOTE: Visually inspect the ABS module terminals for damage before installation.
9.
If a new ABS module was installed, download the module configuration information from the scan
tool. For additional information, refer to Section 418-01 .
10.
Workshop Manual
Anti-Lock Brake System (ABS) Module - Hybrid
1 2M101 ABS module screws (4 required)
2 2C219 ABS module
NOTICE: Electronic modules are sensitive to electrical charges. The Anti-lock Brake System (ABS)
module can be damaged if exposed to these charges.
NOTICE: Do not allow any brake fluid or foreign material to enter the mating side of the Anti-lock
Brake System (ABS) module or damage to the solenoids can occur.
Remove the Hydraulic Control Unit (HCU). For additional information, refer to Hydraulic Control
Unit (HCU) - Hybrid in this section.
1.
Remove the 4 ABS module screws and the ABS module.
2.
NOTE: Visually inspect the ABS module terminals for damage before installation.
3.
Anti-Lock Brake System (ABS) Module - Hybrid 3339
Anti-Lock Brake System (ABS) Module - Hybrid 3340
Workshop Manual
Wheel Speed Sensor - Front
1 - Wheel speed sensor electrical connector (part of
14290)
2 W500020 Wheel speed sensor harness bracket-to-body bolt
4 2C204 RH/ 2C205
LH
Wheel speed sensor
100-02 .
1.
Remove the fender splash shield. For additional information, refer to Section 501-02 . 2.
Disconnect the wheel speed sensor electrical connector. 3.
<
Remove the wheel speed sensor harness bracket-to-body bolt.
4.
Detach the wheel speed sensor harness from the wheel knuckle bracket. 5.
Remove the wheel speed sensor bolt and the wheel speed sensor.
6.
Wheel Speed Sensor - Front 3341
Wheel Speed Sensor - Front 3342
Workshop Manual
Wheel Speed Sensor - Rear, Front Wheel Drive (FWD)
14A227)
3 2C186 RH/ 2C187
LH
Wheel speed sensor
100-02 .
3.
Using a suitable tool, disconnect theet from the body. 4.
NOTE: It is not necessary to remove the harness routing brackets.
Disconnect the wheel speed sensor harness from the brackets.
5.
Remove the wheel speed sensor wire bolt and the wheel speed sensor.
6.
Wheel Speed Sensor - Rear, Front Wheel Drive (FWD) 3343
Wheel Speed Sensor - Rear, Front Wheel Drive (FWD) 3344
Workshop Manual
Wheel Speed Sensor - Rear, All Wheel Drive (AWD)
14A227)
3 2C186 RH/ 2C187
LH
Wheel speed sensor
4 W520102 Wheel speed sensor harness nut
100-02 .
3.
Using a suitable tool, disconnect the grommet from the body. 4.
Remove the wheel speed sensor harness nut and bolt.
5.
Remove the wheel speed sensor bolt and the wheel speed sensor.
6.
Wheel Speed Sensor - Rear, All Wheel Drive (AWD) 3345
Wheel Speed Sensor - Rear, All Wheel Drive (AWD) 3346
Workshop Manual
1 432A38 Traction control switch
2 04302 Instrument panel center finish panel
NOTE: For MKZ when equipped with a navigation system, the traction control switch is serviced with the
Front Controls Interface Module (FCIM). For additional information, refer to Section 415-00 .
Remove the instrument panel center finish panel. For additional information, refer to Section 501-12 . 1.
Press the retaining tabs and remove the traction control switch. 2.
Traction Control Switch 3347
Traction Control Switch 3348
Workshop Manual
Steering Wheel Rotation Sensor
Special Tool(s)
Item
Part
Number Description
1 - Steering wheel rotation sensor electrical connector (3.5L
Fusion part of 2C011, MKZ part of 14401)
2 W506942 Steering wheel rotation sensor bolt (2 required)
3 3F818 Steering wheel rotation sensor
Remove the steering column shroud. For additional information, refer to Section 211-04 . 1.
Disconnect the steering wheel rotation sensor electrical connector. 2.
Remove the 2 bolts and the steering wheel rotation sensor. 3.
Using the scan tool, calibrate the new steering wheel rotation sensor to the ABS module.
Follow the scan tool instructions for Interactive Vehicle Dynamics (IVD) Initialization.

4.
Steering Wheel Rotation Sensor 3349
SECTION 307-01A: Automatic
Transaxle/Transmission - Aisin AW21
Material
Capacity
Dye-Lite ATF/Power Steering
Fluid Leak Detection Dye
164-R3701 (Rotunda)
- -
Motorcraft Premium
Automatic Transmission Fluid
XT-8-QAW (US);
CXT-8-LAW12 (Canada)
WSS-M2C924-A 7.0L (7.4
qt)
XG-4 and/or XL-5
ESB-M1C93-B -
TA-25
WSK-M2G351-A5 -
Ultra Silicone Sealant
TA-29
- -
Item Specification
Fluid
NOTICE: The use
of any
transmission fluid
other than what is
recommended for
this transaxle will
cause transaxle
damage. Refer to
the Owner's
Literature to
determine the
correct service
interval for the
specific vehicle.
NOTICE: Do not
use water-based
cleaners to clean or
flush the
transmission fluid
cooler tubes or
transaxle damage
will occur. Use
only clean
transmission fluid
designated for this
transaxle.
Item Specification
Torque Converter End Play
New or rebuilt 0.355-1.04 mm (0.013-0.04 in)
Used 0.355-1.87 mm (0.013-0.073 in)
Transmission Fluid Filter
Internal to the transmission -
Gear and Solenoid Operation Chart
Gear SSC SSD SSE SSF SSA SSB
1st OFF ON ON ON OFF ON
1st Engine Braking OFF ON ON ON ON ON
2nd OFF ON ON OFF OFF OFF
3rd OFF ON OFF ON OFF OFF
4th OFF OFF ON ON OFF OFF
5th ON OFF OFF ON OFF OFF
6th ON OFF ON OFF OFF OFF
Gear Ratio
Gear Ratio
1st 4.148 to 1
2nd 2.370 to 1
3rd 1.556 to 1
4th 1.155 to 1
5th 0.859 to 1
6th 0.686 to 1
Reverse 3.394 to 1
Final Drive 3.329 to 1
Shift Speed
Manual D km/h mph
1-2 upshift 14-21 9-13
2-3 upshift 21-29 13-18
3-4 upshift 33-40 20-25
4-5 upshift 49-55 30-35
5-6 upshift 65-70 40-44
3-1 downshift 7-17 4-11
4-3 downshift 26-36 16-24
5-4 downshift 38-46 24-29
6-5 downshift 56-63 35-39
Stall Speed
Engine rpm
3.5L 1,878-2,678
Solenoid Resistance Reading
Component
Readings (ohm) @
20C (68F)
Shift Solenoid A (SSA) and Shift Solenoid B (SSB) 11-15 ohms
Shift Solenoid C (SSC), Shift Solenoid D (SSD), Shift Solenoid E (SSE), Shift
Solenoid F (SSF), Line Pressure Control (LPC) and Torque Converter Clutch (TCC)
5.0-5.6 ohms
Clutch and Brake Pressure Chart
Clutch/Band Range Pressure
C1
(Drive Clutch)
Drive (1st-4th) 196-1,372 kPa (28-199 psi)
C2
(Drive Clutch)
196-1,372 kPa (28-199 psi)
C3
(Drive Clutch)
Drive (3rd-5th) 196-1,372 kPa (28-199 psi)
C3
(Drive Clutch)
Reverse 392-1,863 kPa (57-270 psi)
B1 Drive 196-1,372 kPa (28-199 psi)
(Brake Clutch) (2nd and 6th)
B2
(Brake Band)
Low, manual 1st 588-1,372 kPa (85-199 psi)
B2
(Brake Band)
Reverse 392-1,863 kPa (57-270 psi)
Ground strap bolts 12 - 106
Main control valve body bolts
a
- - -
Power steering return line bolts 9 - 80
trol lever nut 12 - 106
Roll restrictor bracket bolts 90 66 -
Selector lever cable bracket bolts 12 - 106
Selector lever cable bracket nut 12 - 106
Steering gear mounting bolts 107 79 -
Tie rod end nuts 48 35 -
Transaxle insulator-to-frame bolts
b
62 46 -
Transaxle support insulator bracket bolt 80 59 -
Transaxle support insulator bracket nuts 90 66 -
Transaxle support insulator bracket through bolt 150 111 -
Transmission Control Module (TCM) 24 18 -
Transmission fluid cooler tubes 10 - 89
Transmission fluid drain plug 47 35 -
Transmission fluid fill plug 39 29 -
Transmission fluid pan bolts 13 - 115
Transmission Fluid Temperature (TFT) sensor 10 89
Turbine Shaft Speed (TSS) sensor 12 - 106
a
b
When reinstalling fasteners originally coated with threadlock, clean the fasteners with a wire brush prior to
applying new threadlock. Apply threadlock and sealer to threads of the bolt.
Transaxle Description
This transaxle is a compact, lightweight, next generation electronically controlled, 6-speed automatic
transaxle that employs Ravigeneaux-type and one single planetary gear set.
This transaxle contains a high-precision clutch hydraulic control system for a smooth, highly responsive gear
shift feel.
All hydraulic functions are directed by electronic solenoids to control:
engagement feel.
shift feel.
shift scheduling.
modulated Torque Converter Clutch (TCC) applications.
engine braking, utilizing the coast clutch.
Automatic Transmission
Transaxle Description 3356
Identification Tags
When servicing the automatic transaxle, use the bar code identification label located on side of the transaxle
case.
Automatic Transmission 3357
Range Selection
Range Selection
This transaxle has 5 fixed range positions: P, R, N, D, M and 2 spring-loaded manual positions (-) and (+).
Park
In the P position:
the transmission is locked and prevents the wheels from turning.
there is no powerflow through the transaxle.
the parking pawl locks the final drive.
the engine may be started.
the ignition key may be removed.
Reverse
In the R position:
the vehicle may be operated in a backward direction, at a reduced gear ratio. i>
engine braking will occur.
Neutral
In the N position:
the vehicle is able to roll.
the output shaft is not held and is free to turn.
Drive
D is the normal position for most forward driving.
D provides:
Identification Tags 3358
automatic shifts - 1st through 6th gears, which includes Overdrive (O/D).
apply and release of the Torque Converter Clutch (TCC).
maximum fuel economy during normal operation.
Manual
The transaxle is in MANUAL when the selector lever is moved to the right (M) position without commanding
a gear by pushing the selector lever backward (+) or forward (-).
In the M position:
O/D is cancelled.
the transmission operates in gears 1st through 4th.
grade assist is activated.
some engine braking may occur.
Grade Assist
Improves vehicle handling in hilly terrain or mountainous areas by providing additional engine
braking and extends lower gear operation on uphill climbs.

Additional engine braking is provided through the automatic transaxle shift strategy which reacts to
vehicle inputs including vehicle acceleration, accelerator pedal, brake pal and vehicle speed.

The transaxle will select gears that will provide the engine braking desired, based on the vehicle
inputs, this will increase engine rpm during engine braking.

It is recommended to return to DRIVE mode on flat terrain to provide the best fuel economy and transaxle
function. The transaxle returns to O/D when the selector lever is moved back into the D position.
Select Shift Transmission Selector Lever
The select shift transmission selector lever gives the driver the ability to change gears up or down manually as
desired.
The transaxle is in the select shift whenever the selector lever is moved backward to the (+) position or
forward to the (-) position from the (M) position.
In the - M + position:
Range Selection 3359
Gears 1 through 6 available.
Moving the selector lever to the forward (-) or backward (+) position will allow the transmission to
utilize the Manual Mode for select shifting.

Moving the spring-loaded selector lever forward into (-) in the gate and releasing the selector lever,
the selector lever will return to the M position and the transmission will downshift.

Moving the spring-loaded selector lever backward into (+) in the gate and releasing the selector lever,
the selector lever will return to the M position and the transmission will upshift.

When selecting the appropriate gear in select shift transmission mode, the instrument cluster will display the
current selected gear.
The select shift transmission will make some shifts automatically, primarily to protect the engine from
stalling.
The transmission will not upshift if the redline is approached and must be shifted manually by moving the
selector lever back into (+) and releasing.
Gear Availability
Range Selection 3360
Shift Patterns
Based on signals from the sensors, the system controls gear shift lockup.
Downshifts
Under certain conditions the transaxle will downshift automatically to a lower gear range (without moving the
selector lever). There are 3 categories of automatic downshifts:
Coastdown
Torque demand
Forced or kickdown shifts
Coastdown
The coastdown downshift occurs when the vehicle is coasting down to a stop.
Torque Demand
The torque demand downshift occurs (automatically) during part throttle acceleration when the demand for
torque is greater than the engine can provide hat gear ratio. If applied, the transaxle will disengage the Torque
Converter Clutch (TCC) to provide added acceleration.
Kickdown
For maximum acceleration, the driver can force a downshift by pressing the accelerator pedal to the floor. A
forced downshift into a lower gear is possible below calibrated speeds. Specifications for downshift speeds are
subject to variations due to tire size, engine and transmission calibration requirements.
Shift Patterns 3361
Shift Patterns 3362
Transaxle Operational Strategies
Automatic Gearshift Control
In automatic gearshift control, based on each gearshift pattern, Shift Solenoid A (SSA) and Shift Solenoid B
(SSB) turn ON or OFF and Shift Solenoid C (SSC), Shift Solenoid D (SSD), Shift Solenoid E (SSE) and Shift
Solenoid F (SSF) are operated linearly according to information that includes vehicle speed, the degree to
which the accelerator is open and brake signal.
Driver Adaptive Shift Control
This automatic transaxle does not have a driving mode selection switch that allows drivers to select a mode
themselves. The vehicle is ordinarily in adaptive mode. However, when specific conditions are met, the
Transmissiontrol Module (TCM) selects a shifting pattern appropriate to driving conditions from all of the
shifting patterns and switches automatically.
GREEN - Mode 1 - Switched from mode 2 to warm up the transmission fluid. This mode acts to
protect the transaxle before the adaptive mode.

GREEN - Mode 2 - After engine start-up, warm-up speed is increased for a certain period when
transmission fluid temperature is low and the vehicle speed is 0.

HIGH TEMP - When transmission fluid temperature becomes too high, this mode activates lock-up at
an earlier timing to stop the temperature rise and lower the temperature.

DOWN SLOPE - When driving down a slope, the TCM detects a down slope based on the engine
control unit signal and output rpm. TCM switches to down slope mode to alleviate the load to the
brake by downshifting.

Gear Shift Control
When the selector lever is moved from N to D or from N to R, after the engine is started, shift control solenoid
assembly SSC , SSD or SSE is used for the fluid pressure required by C1 clutch or C3 clutch and
appropriately regulated fluid pressure is supplied to the clutch, engaging smoothly without shov>
Reverse Converter Control
If the selector lever is moved from N to R while the vehicle is moving forward and the transaxle shifts into
REVERSE, the wheels will be locked, which is extremely dangerous. In order to avoid this, the TCM inhibits
the transaxle from shifting into REVERSE while moving forward.
Torque Converter Clutch (TCC)
Based on output rpm signals, signals from the engine control unit (engine rpm and throttle opening) and
vehicle speed, a smooth engagement is carried out through linear control of the Torque Converter Clutch
(TCC) solenoid. Also, the slip rate is detected by adding input rpm signals and slip control is carried out.
Transaxle Operational Strategies 3363
Engagement Control - control is carried out using a TCC solenoid. The TCC solenoid is linearly
turned ON and OFF. The clutch inside the torque converter is operated and the pump impeller and
turbine runner are connected. Through this, the engine and the transaxle are coupled and engine
output is connected directly to the transaxle, eliminating transaxle loss and enhancing fuel economy

Slip Control - control is carried out using a TCC solenoid. The TCC soleno is linearly turned ON and
OFF and the clutch within the torque converter is operated outside of the engagement range. The
clutch slides without being in a completely coupled condition, increasing transaxle efficiency and
enhancing fuel economy.

Transaxle Operational Strategies 3364
Torque Converter
The torque converter transmits and multiplies torque by means of transmission fluid inside the torque
converter. The torque converter is composed of the following:
Converter case
Pump impeller assembly
Turbine assembly
Stator assembly/One-Way Clutch (OWC)
Lock-up clutch
In addition, the use of the lock-up clutch is intended to improve fuel economy as a direct coupling between the
engine and the transaxle.
The standard torque converter components operate as follows:
Rotation of the converter housing and impeller sets the transmission fluid in motion.
The turbine reacts to the transmission fluid motion from the impeller, transferring rotation to the
geartrain through the input shaft.

The tor redirects transmission fluid going back into the impeller, providing for torque multiplication.
The clutch and damper assembly dampens powertrain torsional vibration and provides a direct
mechanical connection for improved efficiency.

Power is transmitted from the torque converter to the planetary gearsets and other components
through the input shaft.

Item Description
1 Converter clutch and damper (part of 7902)
2 Reactor (part of 7902)
3 Turbine (part of 7902)
4 Impeller (part of 7902)
5 Transmission fluid motion
6 Transmission input rotation
Torque Converter 3365
7 Input shaft
8 Engine rotation
Geartrain
The geartrain consists of the planetary gearsets, apply components, final drive gearset and differential.
Gear Ratio
Gear Ratio
1st 4.148 to 1
2nd 2.370 to 1
3rd 1.556 to 1
4th 1.155 to 1
5th 0.859 to 1
6th 0.686 to 1
Reverse 3.394 to 1
Final drive 3.to 1
Differential
The differential allows the halfshafts and wheels to rotate at different speeds during cornering.
The differential assembly consists of the following components:
Differential case (part of the final drive carrier)
Two pinion gears supported by a pinion shaft
Two side gears supported by the differential case and halfshafts
When driving in a straight line, both front wheels rotate at relatively the same speed. This means both side
gears are rotating at the same speed, as well, while both pinion gears revolve (but do not rotate) with the side
gears. During cornering, the wheel on the outside of the turn is forced to rotate faster than the wheel on the
inside of the turn. Since the side gears must now rotate at different speeds, the pinion gears rotate on the
pinion shaft allowing the drive axles to rotate at different speeds while still transferring output torque.
Geartrain 3367
Geartrain 3368
Apply Components
C1 Drive Clutch
The C1 clutch connects the front planetary carrier to the rear sun gear of the rear planetary set. The C1 clutch
is applied in 1st (typical operation during engine braking), 2nd, 3rd and 4th gears.
C2 Drive Clutch
The C2 clutch connects the intermediate shaft to the rear planetary carrier. The C2 clutch is applied in 4th, 5th
and 6th gears.
C3 Drive Clutch
The C3 clutch connects the front planetary carrier to the middle sun gear of the rear planetary set. The C3
clutch is applied in 3rd and 5th gears, and also in REVERSE when the vehicle speed is 7 km/h (4 mph) or
less.
B1 Brake Clutch
The B1 brake locks the middle sun gear of the rear planetary gear set. The B1 brake is applied in 2nd and 6th
gears.
B2 Brake Band
The B2 brake locks the rear planetary carrier in REVERSE gear when the vehicle speed is 7 km/h (4 mph) or
less.
F1 One-Way Clutch
The F1 one-way clutch locks the counterclockwise rotation of the rear planetary carrier during 1st gear
operation (during both normal operation and engine braking).
Hydraulic Systems
Valve Body
The valve body supplies transmission fluid by switching the transmission fluid circuit for the hydraulic
pressure that is generated by the transmission fluid pump. Based on the hydraulic pressure generated by the
transmission fluid pump the Transmission Control Module (TCM) sends control signals to the solenoid valves
in accordance with vehicle conditions. When the solenoid valve is activated, the control hydraulic pressure to
the clutch and brakes is determined (according to the equilibrium with the obtained hydraulic pressure) and
gear shift and lockup are accomplished. In addition, an appropriate amount of transmission fluid is supplied to
Apply Components 3369
the torque converter, planetary gears and lubricating parts.
Apply Components 3370
Transaxle Electronic Control System
Transmission Control Module (TCM) Control Function
The Transmission Control Module (TCM) and its input/output network controls the following operations:
Shift timing
Line pressure (shift feel)
The transaxle control is separate from the engine control strategy in the PCM, although some of the input
signals are shared between the TCM and PCM. When determining the best operating strategy for transaxle
operation, the TCM uses input information from certain engine-related and driver-demand related sensors and
switches supplied by the PCM.
In addition, the TCM receives input signals from certain transaxle-related sensors and switches. The TCM
also uses these signals when determining transaxle operating strategy.
Using all of these input signals, the TCM can determine when the time and conditions are right for a shift, or
when to apply or release the torque converter clutch. It will also determine the best line pressure needed to
optimize shift feel. To accomplish this the TCM uses output solenoids to control transaxle operation.
The following provides a brief description of each of the sensors and actuators used to control transaxle
operation.
Transmission Range (TR) Sensor
The Transmission Range (TR) sensor is built in the TCM , it detects the automatic transmission range
information via the Hall-effect sensor and outputs the information to the TCM . The TCM reads the voltage
and adjusts the automatic transmission range.
Brake Pedal Position (BPP)
The Brake Pedal Position (BPP) switch tells the PCM when the brakes are applied. The TCC disengages when
the brakes are applied and the BPP switch closes when the brakes are applied and opens when they are
released.
Transmission Fluid Temperature (TFT) Sensor
Transaxle Electronic Control System 3371
The Transmission Fluid Temperature (TFT) sensor, which is integrated within the transmission wiring, is
installed on the front of the valve body. It directs the transmission fluid temperature within the hydraulic
pressure control circuit and transmits a signal based on that temperature to the TCM . Through this it controls
gear shift, lockup and slip in response to changes in transmission fluid temperature for smooth shifting across
wide fluid temperature zones.
Transaxle Shift Solenoids SSA , SSB
Item Description
1 Shift Solenoid A (SSA)
2 Shift Solenoid B (SSB)
The transaxle Shift Solenoid A (SSA) is installed on the middle valve body. The transaxle solenoid assembly
Shift Solenoid B (SSB) is installed on the front valve body. The solenoids turn ON and OFF in response to
signals output from the TCM . According to the ON or OFF status of SSA or SSB , the 1st gear engine brake
operates or the gear shifts into REVERSE. As a fail-safe function, if any transaxle solenoid assembly
abnormality occurs, the TCM will disable the current to the solenoids.
Shift Control Solenoids ( SSC , SSD , SSE , SSF )
Item Description
1 Shift Solenoid C (SSC)
2 Shift Solenoid D (SSD)
3 Shift Solenoid E (SSE)
4 Shift Solenoid F (SSF)
The shift control solenoid assembly (Shift Solenoid C (SSC), Shift Solenoid D (SSD), Shift Solenoid E (SSE),
Shift Solenoid F (SSF)) is installed on the front valve body. The solenoids linearly control hydraulic pressure
in response to signals, output from the TCM . Through this, it controls hydraulic pressure to the clutch (C1,
C2, C3) and brakes (B1) for smooth shifting. According to the combination of ON or OFF status of the shift
control solenoid assembly, the transaxle shifts from 1st gear into 6th gear and vice versa. As a fail-safe
function, if any shift control solenoid assembly abnormality occurs, the TCM will disable the current to the
shift control solenoids.
Line Pressure Control (LPC)
The Line Pressure Control (LPC) is installed on the front valve body. Based on a signal indicating the degree
to which the throttle is opened, engine torque, and according to a duty ratio predetermined in the TCM , the
solenoids control line hydraulic pressure by linearly changing the comparable throttle hydraulic pressure.
Through this, it controls operating hydraulic pressure to the clutch and brakes for smooth shifting. As a
fail-safe function, if any shift control solenoid assembly abnormality occurs, the TCM will disable the current
to the shift control solenoids. The line pressure is maximized, if the shift control solenoid assembly current is
disabled when any abnormality other than locking occurs.
Speed Sensor
The 2 speed sensors are installed in the transaxle case. One speed sensor detects revolutions of the
intermediate shaft's C2 drum as input shaft revolutions. The other speed sensor detects the counterdrive gear
as output shaft revolutions. These signals are transmitted to the TCM . Based on these signals, the TCM
controls engine torque, shift timing and lockup.
Adaptive Shift Control
The TCM has an adaptive learning strategy to electronically control the transaxle which will automatically
adjust the shift feel. The first few hundred miles of operation of the transaxle may have abrupt shifting. This is
a normal operation. If the battery has been disconnected for any reason it will need to be kept disconnected for
approximately 20 minutes to reset the adaptive shift pressure strategy or use the scan tool to carry out the keep
alive memory reset.
Torque Converter Clutch (TCC) Solenoid
The TCC solenoid is used in the transaxle control system to control the application, modulation and release of
the torque converter clutch.
The TCC control solenoid is installed on the front valve body. Based on engine rpm, throttle opening degree
signals and speed sensor signals, it linearly controls clutch hydraulic pressure. Through this, engagement and
slip are controlled. As a fail-safe function, if any control solenoid assembly abnormality occurs, the TCM will
disable the current to the TCC solenoid.
Diagnostic Strategy
Troubleshooting an electronically controlled automatic transaxle is simplified by using the proven method of
diagnosis. One of the most important things to remember is there's a definite procedure to follow.
NOTE: Do not take short cuts or assume that critical checks or adjustments have already been made.
Follow the procedures as written to avoid missing critical components or steps.
To correctly diagnose a concern, have the following publications available:
Powertrain Control/Emissions Diagnosis (PC/ED) manual
TSBs
Wiring Diagrams manual
These publications provide the information required when diagnosing transaxle concerns.
Use the Diagnostic Flow Chart as a guide and follow the steps as indicated.
Preliminary Inspection
Know and understand the customer's concern.
Verify the concern by operating the vehicle.
Check the transmission fluid level and condition.
Check for nontory-installed items and verify correct installation.
Check selector lever linkage for correct adjustment.
Check TSBs regarding the concern.
Retrieve and record all DTCs.
Diagnostics
Retrieve and record all DTCs.
Repair all non-transaxle codes first.
Repair all transaxle codes second.
Erase all continuous codes and attempt to repeat them with the drive cycle test. Refer to Transaxle
Drive Cycle Test in this section.

Repair all continuous memory codes.
If only pass codes are obtained, proceed to the Diagnosis By Symptom in this section for further
information and diagnosis.

Follow the diagnostic sequence to diagnose and repair the concern the first time.
Diagnostic Strategy 3375
Diagnostic Flow Chart
Special Tool(s)
Prior to carrying out the flow test, the following items should be checked:
Know and understand the customer concerns
Verify the concern by operating the vehicle
Check the transmission fluid level and condition
Check for non-factory-installed items and verify correct installation
Check the selector lever linkage for correct adjustment
Check TSBs regarding the concern
Retrieve and recorl DTCs
Test Result Action
1) Are any DTCs recorded? Yes
REPAIR all hard DTCs. FOLLOW the pinpoint tests. REFER
to the Powertrain Control/Emissions Diagnosis (PC/ED)
manual first, then this workshop manual, GO to Step 2.

No
REFER to Diagnosis By Symptom in this section, GO to Step
5.

2) Are any continuous test
memory codes present?
Yes
CLEAR codes and CARRY OUT the drive cycle test. If code
returns, GO to Step 3.

No
GO to Step 4.
3) Did the continuous test
memory codes reappear?
Yes
REPAIR all continuous test memory codes. FOLLOW the
pinpoint tests. REFER to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual, then the Transmission Reference
manual, then this workshop manual, GO to Step 2.

No
GO to Step 4.
4) Is the concern repaired? Yes
VERIFY no DTCs are present. CLEAR memory codes.
No
Diagnostic Flow Chart 3377
REFER to Diagnosis By Symptom in this section.
5) Was the transmission
concern corrected when the
scan tool was installed?
Yes
(PC/ED) manual, intermittent fault diagnosis section and use
the scan tool to diagnose cause of concern in the processor,
vehicle harness or external inputs (sensors or switches).

No
REFER to the hydraulic and mechanical routine to diagnose the
concern, GO to Step 6.

6) Is the concern repaired? Yes
CARRY OUT the drive cycle test and VERIFY no DTCs are
present. CLEAR memory codes.

No
Concern should have been repaired. GO back through the
Diagnostic Flow Chart and REVIEW other components that
may have contributed to the concern. CHECK and DIAGNOSE
those components. GET assistance from other sources.

Special Tool(s)
Material
Item Specification
Motorcraft Premium Automatic
Transmission Fluid
XT-8-QAW (US); CXT-8-LAW12
(Canada)
WSS-M2C924-A
The following items must be checked prior to beginning the diagnostic procedures.
Know and Understand the Concern
In order to correctly diagnose a concern, first understand the customer complaint or condition. Customer
contact may be required in order to begin to verify the concern. Understand the conditions as to when the
concern occurs. For example:
Hot or cold vehicle temperature
Hot or cold ambient temperatures
Vehicle driving conditions
Vehicle loaded/unloaded
After understanding when and how the concern occurs, proceed to verifying the concern.
Verification of Condition
This section provides information which must be used in both determining the actual cause of customer
concerns and carrying out the appropriate procedures.
The following procedures must be used when verifying customer concerns for the transmission.
Determine Customer Concern
NOTE: Some transaxle conditions may cause engine concerns. An Electronic Pressure Control (EPC) short
circuit can cause engine misfiring. The Torque Converter Clutch (TCC) not disengaging will stall the engine.
Determine customer concerns relative to vehicle use and dependent driving conditions, paying attention to the
following items:
Preliminary Inspection 3379
Hot or cold vehicle operating temperature
Type of terrain
City/highway driving
Upshift
Downshift
Coasting
Engagement (harsh or soft)
Noise/vibration - check for engine rpm, vehicle speed, shift, gear, range or temperature dependencies
Check Transmission Fluid Level and Condition p>
NOTICE: The vehicle should not be driven if the transmission fluid level indicator shows the
transmission fluid below the DO NOT DRIVE mark or internal failure could result.
If the vehicle is operated for an extended period of time at highway speeds, city traffic, hot weather or while
pulling a trailer, the transmission fluid needs to cool down to obtain an accurate reading.
The transmission fluid level reading on the transmission fluid level indicator will differ depending on
operating and ambient temperatures. The correct reading should be within the normal operating temperature
range.
Transmission Fluid Level Check
NOTE: Transmission fluid should be checked at normal operating temperature 60C-70C (140F-158F) on
a level surface. Normal operating temperature is reached after approximately 32 km (20 mi) of driving and
can be checked using the scan tool.
Check the transmission fluid level during normal maintenance. If the transaxle starts to slip, shifts slowly or
shows signs of transmission fluid leaking, the transmission fluid level should be checked.
With the selector lever in PARK, engine at idle, brake pedal applied, move the selector lever through
each gear range and allow engagement of each gear. Place the selector lever in the PARK position.
1.
Wipe the transmission fluid level indicator cap and remove the transmission fluid level indicator. 2.
Wipe the transmission fluid level indicator with a clean cloth. 3.
Install the transmission fluid level indicator back in the transmission fluid filler tube until it is fully
seated, then remove the indicator. The transmission fluid level should be within the normal operating
range.
4.
Item Description
1 Transmission fluid level at operating temperature 60C-70C (140F-158F)
2 Transmission fluid level cold 15C-25C (59F-77F)
3 Do not drive mark
High Transmission Fluid Level
Transmission fluid level that is too high may cause the transmission fluid to become aerated due to the
churning action of the rotating internal parts. This will cause erratic control pressure, foaming, loss of
transmission fluid from the vent tube and possible transaxle malfunction and/or damage. If an overfill reading
is indicated, refer to Transmission Fluid Exchange in this section.
Low Transmission Fluid Level
Low transmission fluid level could result in poor transaxle engagement, slipping, malfunction and/or damage.
This could also indicate a leak in one of the transaxle seals or gaskets.
Adding Transmission Fluid
NOTICE: The use of any type of transmission fluid other than specified could result in transaxle
malfunction and/or damage.
If transmission fluid needs to be added, add transmission fluid in 0.25L (1/2 pt) increments through the
transmission fluid filler tube. Do not the transmission fluid. For transmission fluid type, refer to the
specification chart in this section.
Transmission Fluid Condition Check
Check the transmission fluid level. 1.
Hold the transmission fluid level indicator over a white facial tissue and allow the transmission fluid
to drip onto the facial tissue and examine the stain.
2.
Observe the color and the odor. The color under normal circumstances should be dark red, not brown
or black or have a burnt odor.
3.
If evidence of solid material is found, the transmission fluid pan should be removed for further
inspection.
4.
If the stain is a foamy pink color this may indicate coolant in the transaxle. The engine cooling system
should also be inspected at this time.
5.
If transmission fluid contamination or transaxle failure is confirmed by the sediment in the bottom of
the transmission fluid pan, install a new transaxle. If installing a new transaxle the transmission fluid
cooler bypass valve, transmission fluid coolers and transmission cooler tubes should be cleaned.
6.
Carry out diagnostic checks and adjustments. Refer to Diagnosis By Symptom in this section. 7.
Water in Transmission Fluid
To correctly repair an automatic transaxle that had water or coolant introduced into the system, only install a
new transaxle for the units that cannot be disassembled and cleaned. Prior to installing the transaxle, the
transmission fluid cooler(s), transmission fluid cooler tubes and transmission fluid cooler hoses need to be
flushed and cleaned.
Road Testing Vehicle
NOTE: Always drive the vehicle in a safe manner according to driving conditions and obey all traffic laws.
The Shift Point Road Test and Torque Converter Operation Tests provide diagnostic information on shift
controls and torque converter operation.
Road Testing Vehicle 3383
Shift Point Road Test
Special Tool(s)
NOTE: Shift speed ranges are approximate for all applications.
This test verifies that the shift control system is operating correctly.
Bring engine and transaxle up to normal operating temperature. 1.
Operate vehicle with selector lever in D range. 2.
Using the shift speed charts, apply minimum throttle and observe the speeds at which the transaxle
upshifts. The transaxle willhift 1st through 6th gears.
3.
Press the accelerator pedal to the floor, Wide Open Throttle (WOT). The transaxle should downshift
to the next lower gear depending on the vehicle speed. The Torque Converter Clutch (TCC) should
release.
4.
Shift Speed
Manual D km/h mph
1-2 upshift 14-21 9-13
2-3 upshift 21-29 13-18
3-4 upshift 33-40 20-25
4-5 upshift 49-55 30-35
5-6 upshift 65-70 40-44
3-1 downshift 7-17 4-11
4-3 downshift 26-36 16-24
5-4 downshift 38-46 24-29
6-5 downshift 56-63 35-39
If the transaxle fails to upshift/downshift or the TCC does not apply and release, refer to Diagnosis By
Symptom in this section for possible causes.
5.
Shift Point Road Test 3384
Torque Converter Diagnosis
Special Tool(s)
Prior to torque converter installation, 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 installew or remanufactured torque converter.
Begin with the normal diagnostic procedures as follows:
Preliminary Inspection 1.
Know and Understand the Customer Concern 2.
Verify the Concern - carry out the torque converter operation test 3.
Carry out Diagnostic Procedures:
Retrieve and record all DTCs. Refer to Diagnostics in this section.
Repair all non-transaxle related DTCs first.
Repair all transaxle DTCs.
Carry out Pressure Test. Refer to Special Testing Procedures in this section.
Carry out Stall Speed Test. Refer to Special Testing Procedures in this section.
Carry out diagnostic routines. Refer to Diagnosis By Symptom in this section.
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.

4.
Torque Converter Operation Test
NOTE: The Torque Converter Clutch (TCC) will not engage if the Transmission Fluid Temperature (TFT) is
below 0C (32F).
Using the scan tool, make sure the TFT is within specification 43C-47C (109F-117F). 1.
Accelerate the vehicle to 35-60 km/h (22-37 mph) and maintain a consistent speed. 2.
Release the accelerator pedal to close the throttle then press the accelerator to partially open the
throttle while monitoring the scan tool engine speed and TCCAMP_MES. The PID will read 0 when
the TCC is released, and 1 when the TCC is applied. The engine speed will increase when the TCC is
released and decrease when the TCC is appl
3.
Torque Converter Diagnosis 3386
If these actions do not occur, see Torque Converter Operations Concerns, refer to Diagnosis By
Symptom in this section.
4.
Visual Inspection
This inspection will identify modifications or additions to the vehicle operating system that may affect
diagnosis. Inspect the vehicle for non-Ford factory add-on devices such as:
Electronic add-on items:
A/C
Generator (alternator)
Engine turbo
Cellular telephone
Cruise control
CB radio
Linear amplifiers
Backup alarm signal
Computer

Vehicle modification:
These items, if not installed correctly, will affect the PCM or transmission function. Pay
particular attention to add-on wiring splices in the PCM harness or transmission wiring
harness, abnormal tire size or axle ratio changes.

Leaks. Refer to Leakage Inspectiona> in this section.
Correct selector lever linkage adjustments. Refer to Section 307-05A .

Selector Lever Linkage Check
Hydraulic leakage at the manual control valve can cause delay in engagements and/or slipping while operating
if the selector lever linkage is not correctly adjusted. Refer to Section 307-05A for selector lever linkage
adjustment.
Check TSBs
Refer to all TSBs which pertain to the concern and follow the procedure.
Visual Inspection 3388
Diagnostics
Special Tool(s)
Self DiagnoFunction
The Transmission Control Module (TCM) monitors the communication status of each sensor, electronic
component and the PCM. If any malfunctions occur, the TCM function warns the driver and stores the
malfunction as a diagnosis code.
Fail-Safe
With the fail-safe function, if any malfunction should occur in the transaxle system, the TCM will output a
control signal, and control will be carried out to make traveling a minimum distance possible. If all shift
solenoids malfunction, the TCM will cancel the output of control signals to the solenoids. If this happens, the
automatic transmission gear shifting will be controlled by transmission fluid pressure circuits only and the
gears will shift as shown in the following table.
Selector Lever Position Gear Position
R Reverse
D 3rd or 5th gear
On-Board Diagnostic (OBD) With Scan Tool
NOTE: For detailed instruction and other diagnostic methods using the scan tool or equivalent, refer to the
Scan Tool Tester manual and the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
These Self Tests should be used to diagnose the PCM and should be carried out in order.
Self Test - Key ON Engine OFF (KOEO)
Self Test - Continuous Memory Codes
Self Test - Key ON Engine Running (KOER)
Special Test Modes
Wiggle Test Mode
Output Test Mode

Diagnostics 3390
PCM Reset Mode
Clearing DTCs P1000
On-Board Diagnostic (OBD) II Drive Cycle
Other scan tool features
Diagnostics 3391
Diagnostic Parameters Identification (PID) Chart
Special Tool(s)
PID Name Description Units
DTCTCM Continuous codes Number of DTCs
Gear Gear commanded by module Gear (1-6)
GEAR_OSC Gear commanded by output state control
0 = commanded gear is
not controlled by OSC

2 = 1st gear is commanded
by OSC

4 = 2nd gear is
commanded by OSC

12 = 6th gear is
commanded by OSC

LPC Line Pressure Control (LPC) Pressure (psi)
LPC_AMP LPC Current (amps)
LPC_F LPC INT
OSS Output Shaft Speed (OSS) rpm
OSS_SRC OSS rpm
LPCAMP_MES Measured current for LPC Current (amps)
RPMTCM Engine revolutions per minute rpm
SHFTCTRL Shift control
00 Economy mode
01 Sport mode
02 Up slope 1 mode
03 Up slope 2 mode
04 Down slope mode
05 Hot 1 (over
temperature 1) mode

06 Hot 2 (over
temperature 2) mode

07 Cruise mode
08 Traction mode
09 l Position mode
0A Tiptronic mode
0B Coast shift
Diagnostic Parameters Identification (PID) Chart 3392
Flexible Fuel (FF) Invalid
data

SSA_F Shift solenoid 1 status
00 is not fault detected
01 is short to ground
02 is open circuit load
04 is short circuit to
battery power

80 is general
(non-specific) fault

SSB_F Shift solenoid 2 status
battery power

40 is stack failure
80 is general

SSC_AMP Shift Solenoid Pressure Control C (SSPCC)
current
Current (amps)
SSCAMP_MES Measured current Shift Solenoid C (SSC) Current (amps)
SSDAMP_MES Measured current Shift Solenoid D (SSD) Current (amps)
SSD_AMP SSD Current (amps)
SSEAMP_MES Measured current Shift Solenoid E (SSE) Current (amps)
SSE_AMP Shift Solenoid Pressure Control E (SSPCE) Current (amps)
SSFAMP_CMD Commanded current Shift Solenoid F (SSF) Current (amps)
SSFAMP_MES Measured current SSF Current (amps)
SSPCC SSPCC Pressure (psi)
SSPCC_F SSPCC status
battery power

80 is general

SSPCD Shift Solenoid Pressure Control D (SSPCD) Pressure (psi)
SSPCD_F SSPCD status
ground

04 is short to battery
power

80 is general (non
specific) fault

SSPCE SSPCE Pressure (psi)
SSPCE_F SSPCE status
ground

battery power

80 is general

SSPCF_CMD Commanded pressure Shift Solenoid Pressure
Control F (SSPCF)
Pressure (psi)
SSPCF_F SSPCF status
battery power

80 is general

TC_SLIPACT Torque converter slip actual TCCMACT rpm
TCC_AMP Torque Converter Clutch (TCC) pressure
control
Current (amps)
TCCAMP_MES Measured current for the TCC pressure
control
Current (amps)
TCCPC Converter pressure control Pressure (psi)
TCCSLPDSD TCC slip desired rpm
TCC_F TCC fault
battery power

80 is general

TCC_OSC Output state control of torque converter
00 TCC not controlled by
OSC

01 TCC is disengaged by
OSC

02 TCC is engaged by
OSC

TCC_RAT Transmission slip ratio Ratio
TFT Transmission Fluid Temperature (TFT) Temperature (C, F)
TFT TFT Voltage
TORQUE Net engine torque Torque (lb-ft)
TP_REL Relative Throttle Position (TP) Percentage
TR Transmission Range (TR)
P = 7
R = 6
N = 5
D = 4
L = 1
TRAN_RAT Transmission gear ratio Ratio
TSS_SRC Turbine Shaft Speed (TSS) TSS TSS rpm
TR_V TR Voltage
VPWRTCM Module supply voltage VBAT Voltage
VSS Vehicle Speed Sensor (VSS) Speed (mph)
Transaxle Drive Cycle Test
NOTICE: Prior to carrying out the Transaxle Drive Cycle Test, make sure that the transaxle is full of
transmission fluid or damage to the transaxle may occur.
Use the Transaxle Drive Cycle Test for checking continuous codes.
NOTE: The Transaxle Drive Cycle Test must be followed exactly. Malfunctions must occur multiple times
consecutively for shift error or Torque Converter Clutch (TCC) codes to set.
NOTE: When carrying out the Transaxle Drive Cycle Test, see the Solenoid Operation Chart for correct
solenoid operation. Refer to Specifications in this section.
Record and then erase all DTCs. 1.
Warm engine to normal operating temperature.
Make sure transmission fluid level is correct. 3.
With the selector lever in DRIVE, moderately accelerate from stop to 80 km/h (50 mph). This allows
the transaxle to shift into 6th gear. Hold speed and throttle steady for minimum of 15 seconds. Brake
to a stop and remain stopped for minimum of 20 seconds.
4.
Repeat Step 4 at least 5 times. 5.
Retrieve and record any DTCs. 6.
If DTCs are present, refer to Diagnostic Trouble Code (DTC) Charts in this section. Service all
non-transaxle DTCs first as they can directly affect the operation of the transaxle. Repeat the Road
Test to verify the correction. Erase DTCs, carry out the Transaxle Drive Cycle Test, and road test
after completing service on the DTCs.

If the continuous test passes (system pass) and a concern is still present, refer to Diagnosis By
Symptom in this section and check TSBs for diagnostic concern.

After On-Board Diagnostic (OBD)
NOTE: The vehicle wiring harness, PCM and non-transaxle sensors may affect transaxle operations. Service
these concerns first.
After the On-Board Diagnostic (OBD) procedures are completed, service all DTCs.
Begin with non-transaxle related DTCs, then service any transaxle related DTCs. Refer to the Diagnostic
Trouble Code (DTC) Charts in this section for information on Condition and Symptoms. This chart will be
helpful in referring to the correct manual(s) and to aid in diagnosing internal transaxle concerns and external
non-transaxle inputs. The pinpoint tests are used in diagnosing electrical concerns of the transaxle. Make sure
that the vehicle wiring harness and the PCM are diagnosed as well. Refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for diagnosing non-transaxle electronic components. The diagnostic routine
Transaxle Drive Cycle Test 3396
hydraulic/mechanical charts will help in diagnosing internal transaxle concerns and external non-transaxle
inputs.
Before Pinpoint Tests
NOTE: Prior to entering pinpoint tests, check the PCM wiring harness for correct connections, bent or broken
pins, corrosion, loose wires, correct routing, correct seals and their condition. Check the PCM, sensors and
actuators for damage. Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
NOTE: If a concern still exists after electrical diagnosis has been carried out, refer to Diagnosis By Symptom
in this section.
If DTCs appear while carrying out the on-board diagnostics, refer to the Diagnostic Trouble Code (DTC)
Charts in this section for the appropriate repair procedure. Prior to entering pinpoint tests, refer to TSBs for
transaxle concerns.
Diagnostic Trouble Code (DTC) Charts
DTC Chart
NOTICE: This module utilizes a 5-character DTC followed by a 2-character failure type code. The
failure type code provides information about specific fault conditions such as open or shorted to ground
circuits. Continuous Memory Diagnostic Trouble Code (CMDTC) has an additional 2-character DTC
status code suffix to assist in determining DTC history.
DTC Component Description Condition Symptom Action
P0562:00 Battery System vol low. PCM detected a
voltage level below
9 volts.
No
engagements,
no adaptive or
self-learning
strategy.
CHECK charging system,
.
P0563:00 Battery System voltage
high.
PCM detected a
voltage level above
18 volts.
No adaptive or
self-learning
strategy.
CHECK charging system,
.
P0601:00 Transmission
Control
Module
(TCM)
TCM Read-Only
Memory (ROM)
error.
TCM detected an
internal software
concern with ROM
.
No
engagements,
no adaptive or
self-learning
strategy.
INSTALL a new TCM .
P0603:00 TCM TCM Keep Alive
Memory (KAM)
error.
TCM detected an
internal software
concern with KAM
.
No
engagements,
no adaptive or
self-learning
strategy.
INSTALL a new TCM .
P0604:00 TCM TCM Random
Access Memory
(RAM) error.
TCM detected an
internal software
concern with RAM
.
No
engagements,
no adaptive or
self-learning
strategy.
INSTALL a new TCM .
Range (TR)
TR sensor range
or performance
error.
TR sensor signal is
out of normal range.
TR sensor
indicates a
stuck position
(D-3rd gear),
no adaptive or
self-learning
strategy.
INSTALL a new TCM .
P0707:00 TR Sensor TR sensor circuit
low input.
TR sensor signal is
below threshold of
0.127 volt,
sensor/circuit
electrical
malfunction.
TR sensor
indicates a
stuck position
(D-3rd gear),
no adaptive or
self-learning
strategy.
INSTALL a new TCM .
P0708:00 TR Sensor INSTALL a new TCM .
Diagnostic Trouble Code (DTC) Charts 3398
TR sensor circuit
high input.
TR sensor signal is
above threshold of
4.87 volts,
sensor/circuit
electrical
malfunction.
TR sensor
indicates a
stuck position
(D-3rd gear),
no adaptive or
self-learning
strategy.
Fluid
Temperature
(TFT) Sensor
No change in
TFT during
operation.
PCM has detected
no TFT change
during operation.
TFT value stuck at
some normal
reading.
TFT indicates
80C (176F) at
all times, no
self-learning
strategy, no
Torque
Converter
Clutch (TCC)
engagement.
P0712:00 TFT Sensor 200C (329F)
indicated, TFT
sensor circuit
grounded.
Voltage drop across
TFT sensor exceeds
scale set for
temperature -43C
(-45F).
TFT indicates
80C (176F) at
all times, no
self-learning
strategy, no
TCC
engagement.
P0713:00 TFT Sensor -43C (-45F)
indicated, TFT
sensor circuit
grounded.
Voltage drop across
TFT sensor exceeds
scale set for
temperature -43C
(-45F).
TFT indicates
80C (176F) at
all times, no
self-learning
strategy, no
TCC
engagement.
P0716:00 Turbine Shaft
Speed (TSS)
Sensor
TSS range out of
performance,
insufficient input
from TSS .
PCM has detected a
loss or noisy TSS
signal during
operation.
No TCC
engagements,
no adaptive or
self-learning
strategy.
P0717:00 TSS Sensor No TSS signal. PCM has not
detected a TSS
signal. No TSS
signal when Output
Shaft Speed (OSS)
signal present.
No TCC
engagements,
no adaptive or
self-learning
strategy.
P0721:00 OSS Sensor OSS range out of
performance,
insufficient input
from OSS .
PCM has detected a
loss or noisy OSS
signal during
operation.
No adaptive or
self-learning
strategy.
P0722:00 OSS Sensor No OSS signal. PCM has detected
no OSS signal.
No
engagements,
no adaptive or
self-learning
strategy.
P0729:00 Transaxle 6th gear ratio. No 6th gear ratio
detected by TCM .
No 6th gear, no
TCC
engagements,
no adaptive or
self-learning
strategy.
P0730:00 Clutch Control
Solenoids or
Internal Parts
Gear ratio error. PCM has detected a
gear ratio error.
No
self-learning
strategy.
P0731:00 Solenoid or
Internal Parts
1st gear ratio. No 1st gear ratio
detected by TCM .
No 1st gear, no
TCC
engagements,
no adaptive or
self-learning
strategy.
Internal Parts
2nd gear ratio. No 2nd gear ratio
detected by TCM .
No 2nd gear, no
TCC
engagements,
no adaptive or
self-learning
strategy.
Internal Parts
3rd gear ratio. No 3rd gear ratio
detected by TCM .
No 3rd gear, no
TCC
engagements,
no adaptive or
self-learning
strategy.
Internal Parts
4th gear ratio. No 4th gear ratio
detected by TCM .
No 4th gear, no
TCC
engagements,
no adaptive or
self-learning
strategy.
Internal Parts
5th gear ratio. No 5th gear ratio
detected by TCM .
No 5th gear, no
TCC
engagements,
no adaptive or
self-learning
strategy.
P0736:00 Transaxle Reverse gear
ratio.
No reverse gear
ratio detected by
TCM .
No reverse
gear, no
self-learning
strategy.
Valve Internal
to Transaxle
Universal
shifting (stuck
valve).
Valve stuck. Increase rpm
during shifts.
Slipping or
erratic shifting.
GO to Main Control
Valve Body in this
section.
P0813:00 Reverse
Output Circuit
Reverse lamp
circuit.
Reverse lamp
circuit short to
ground, power or
open.
Reverse lamps
inoperative.
GO to Section 417-01 .
P0817:00 TCM /PCM
Starter Circuit
Starter disable
circuit open or
shorted to
TCM detected a
failure in the starter
lock circuit, failed
DTC is set.
Warning lamp
is illuminated.
power/ground. ON or OFF.
Ignition switch is
ON, TCM and PCM
communication is
normal. No voltage
is detected on the
start lock circuit for
more than 0.1
second or a
continuous 12-volt
output is detected
for more than 0.1
second. Conditions
present 2 times to
set DTC.
P0819:00 SelectShiftTM
Transmission
Control Circuit
Up And Down
Shift Swich To
Transmission
Range (TR)
Correlation
The associated
circuitry connected
to the
SelectShiftTM
switch or fuse, or
the SelectShiftTM
switch itself may
have an issue
causing a
SelectShiftTM
malfunction.
No manual up
or down shift
available.
GO to Section 307-05A .
P0961:00 Line Pressure
Control (LPC)
LPC circuit or
solenoid failure.
LPC circuit or
solenoid failed
during operation.
Incorrect
commanded current
detected by TCM .
No
engagements,
no adaptive or
self-learning
strategy.
P0962:00 LPC LPC solenoid
signal or
grounded circuits
either short or
open, solenoid
circuit failure.
Voltage through
LPC is checked. An
error will be noted
if tolerance is
exceeded.
No
engagements,
no adaptive or
self-learning
strategy.
P0963:00 LPC LPC solenoid
short to power
circuit failure.
Voltage through
LPC is checked. An
error will be noted
if tolerance is
exceeded.
No
engagements,
no adaptive or
self-learning
strategy.
P0973:00 Shift Solenoid
A (SSA)
SSA solenoid or
circuit shorted to
ground.
Voltage through
SSA (S1) circuit is
checked. An error
will be noted if
tolerance is
exceeded. Short to
ground failure
detected.
No
engagements,
no adaptive or
self-learning
strategy.
P0974:00 SSA GO to Pinpoint Test A .
SSA or circuit
shorted to power
or open.
Voltage through
SSA (S1) circuit is
checked. An error
will be noted if
tolerance is
exceeded. Short to
power failure or
open circuit
detected.
No
engagements,
no adaptive or
self-learning
strategy.
B (SSB)
SSB solenoid or
circuit shorted to
ground.
Voltage through
SSB (S2) circuit is
checked. An error
will be noted if
tolerance is
exceeded. Short to
ground failure
detected.
No
engagements,
no adaptive or
self-learning
strategy.
P0977:00 SSB SSB solenoid or
circuit shorted to
power or open.
Voltage through
SSB solenoid (S2)
circuit is checked.
An error will be
noted if tolerance is
exceeded. Short to
power failure or
open circuit
detected.
No
engagements,
no adaptive or
self-learning
strategy.
C (SSC)
SSC circuit or
solenoid failure.
SSC circuit or
solenoid failed
during operation.
Incorrect
commanded current
detected by TCM .
No
engagements,
no adaptive or
self-learning
strategy.
P0979:00 SSC SSC solenoid
signal or
grounded circuits
either shorted or
open, solenoid
circuit failure.
Voltage through
SSC circuit is
checked. An error
will be noted if
tolerance is
exceeded. Short to
power failure or
open circuit
detected.
No
engagements,
no adaptive or
self-learning
strategy.
P0980:00 SSC SSC solenoid or
circuit shorted to
power.
Voltage through
SSC circuit is
checked. An error
will be noted if
tolerance is
exceeded. Short to
power failure or
open circuit
detected.
No
engagements,
no adaptive or
self-learning
strategy.
D (SSD)
SSD circuit or
solenoid failure.
SSD circuit or
solenoid failed
during operation.
No
engagements,
no adaptive or
Incorrect
commanded current
detected by TCM .
self-learning
strategy.
P0982:00 SSD SSD signal or
grounded circuits
either shorted or
open, solenoid
circuit failure.
Voltage through
SSD circuit is
checked. An error
will be noted if
tolerance is
exceeded. Short to
power failure or
open circuit
detected.
No
engagements,
no adaptive or
self-learning
strategy.
P0983:00 SSD SSD or circuit
shorted to power.
Voltage through
SSD circuit is
checked. An error
will be noted if
tolerance is
exceeded. Short to
power failure or
open circuit
detected.
No
engagements,
no adaptive or
self-learning
strategy.
E (SSE)
SSE circuit or
solenoid failure.
SSE circuit or
solenoid failed
during operation.
Incorrect
commanded current
detected by TCM .
No
engagements,
no adaptive or
self-learning
strategy.
P0985:00 SSE SSE signal or
grounded circuits
either shorted or
open, solenoid
circuit failure.
Voltage through
SSE circuit is
checked. An error
will be noted if
tolerance is
exceeded. Short to
power failure or
open circuit
detected.
No
engagements,
no adaptive or
self-learning
strategy.
P0986:00 SSE SSE or circuit
shorted to power.
Voltage through
SSE circuit is
checked. An error
will be noted if
tolerance is
exceeded. Short to
power failure or
open circuit
detected.
No
engagements,
no adaptive or
self-learning
strategy.
F (SSF)
SSF circuit or
solenoid failure.
SSF circuit or
solenoid failed
during operation.
Incorrect
commanded current
detected by TCM .
No
engagements,
no adaptive or
self-learning
strategy.
P0998:00 SSF SSF signal or
grounded circuits
Voltage through
SSF circuit is
No
engagements,
either shorted or
open, solenoid
circuit failure.
checked. An error
will be noted if
tolerance is
exceeded. Short to
power failure or
open circuit
detected.
no adaptive or
self-learning
strategy.
P0999:00 SSF SSF or circuit
shorted to power.
Voltage through
SSF circuit is
checked. An error
will be noted if
tolerance is
exceeded. Short to
power failure or
open circuit
detected.
No
engagements,
no adaptive or
self-learning
strategy.
P1573:00 Accelerator
Pedal Position
(APP) Sensor
APP sensor input
error.
PCM has detected
an input error from
the APP sensor.
No adaptive or
self-learning
strategy.
NOTE: If this DTC is
displayed, a malfunction
occurred in the vehicle
not the TCM . Do not
install a new TCM .
Control/Emissions
Diagnosis (PC/ED)
manual.
P1576:00 Throttle
Position (TP)
Sensor
TP sensor input
error.
TP not available. Limited
function.
install a new TCM .
Control/Emissions
Diagnosis (PC/ED)
manual.
P1657:00 TCM TCM
communication
link error.
Controller Area
Network (CAN)
link error detected
by PCM.
No
engagements,
no adaptive or
self-learning
strategy.
Limited fuel
and spark.
INSTALL a new TCM .
P1700:00 Transaxle Drive
engagement
error.
TCM detected
neutral in the
DRIVE position.
No
engagements,
no adaptive or
self-learning
strategy.
REFER to Diagnosis By
P1701:00 Transaxle Reverse
engagement
error.
TCM detected
neutral in the
REVERSE position.
No
self-learning
strategy.
REFER to Diagnosis By
P1719:00 PCM Engine torque
signal.
Torque engine
accuracy from PCM
Firm shifts and
no adaptive
PERFORM self-test of
PCM. REFER to the
inaccurate. learning. Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual to diagnose any
DTCs present. If no
DTCs, IDENTIFY the
driveability symptom
present and REFER to the
Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual for further
diagnosis.
P1919:00 Engine
Coolant
Temperature
(ECT)
Sensor signal
error.
PCM/ TCM have
detected an error in
the CAN ECT
information.
No TCC
engagements,
ECT set to
80C (176F).
not, the TCM . Do
notnstall a new TCM .
Control/Emissions
Diagnosis (PC/ED)
manual.
P2757:00 TCC Solenoid TCC solenoid
circuit failure,
stuck OFF.
TCC solenoid
circuit fails to
provide voltage
drop across
solenoid. Circuit
open, shorted or
PCM driver failure
during On-Board
Diagnostic (OBD).
No TCC
engagements,
no adaptive or
self-learning
strategy.
P2758:00 TCC Solenoid TCC solenoid
circuit failure,
stuck ON.
TCC solenoid
circuit fails to
provide voltage
drop across
solenoid. Circuit
open, shorted or
PCM driver failure
during OBD .
No TCC
engagements,
no adaptive or
self-learning
strategy.
P2762:00 TCC Solenoid TCC circuit or
solenoid failure.
TCC circuit or
solenoid failed
during operation.
Incorrect
commanded current
detected by TCM .
No
engagements,
no adaptive or
self-learning
strategy.
P2763:00 TCC Solenoid TCC circuit
shorted to power.
TCC solenoid
circuit fails to
provide voltage
drop across
solenoid. Circuit
shorted to power.
No TCC
engagements,
no adaptive or
self-learning
strategy.
P2764:00 TCC Solenoid GO to Pinpoint Test A .
TCC solenoid
signal or
grounded circuits
either short or
open solenoid
circuit failure.
TCC solenoid
circuit fails to
provide voltage
drop across
solenoid.
No TCC
engagements,
no adaptive or
self-learning
strategy.
U0073:00 TCM CAN TCM
communication
link error.
CAN link error
detected by PCM.
No
engagements,
no adaptive or
self-learning
strategy.
.
U0100:00 TCM CAN TCM
communication
link error.
CAN link error
detected by PCM.
No
engagements,
no adaptive or
self-learning
strategy.
install a new TCM .
A module cannot
communicate with other
modules on the
communication network
while being
reprogrammed. CLEAR
any network
communication DTCs
which may have been set
in other modules during
reprogramming.
CHECK CAN harness
between TCM and other
modules. For diagnostic
information, REFER to
the Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual and REFER to
Section 418-00 .
Transaxle Connector Layouts
Transaxle Bulkhead Electrical Connector
Pin Number Circuit Function
1 Line Pressure Control (LPC) ground
2 Shift Solenoid B (SSB)
3 LPC signal
4 Torque Converter Clutch (TCC) ground
5 Shift Solenoid A (SSA)
6 NOT USED
7 Transmission Fluid Temperature (TFT) ground
8 TFT
9 TCC signal
10 Shift Solenoid C (SSC) ground
11 SSC signal
12 Turbine Shaft Speed (TSS) sensor signal
13 TSS sensor signal ground
14 Shift Solenoid E (SSE) signal
15 NOT USED
16 Shift Solenoid F (SSF) ground
17 Shift Solenoid D (SSD) signal
18 SSD ground
19 Output Shaft Speed (OSS) sensor signal
20 OSS sensor signal ground
21 SSF signal
22 SSE ground
Transmission Range (TR) Transmission Control Module (TCM) C1533 (A) Vehicle Harness
Transaxle Connector Layouts 3408
1 Battery feed
2 NOT USED
3 Manual upshift command
4 Manual downshift command
5 Start lock signal out
6 Controller Area Network (CAN) -
7 NOT USED
8 NOT USED
9 Transmission Control Module (TCM) ground
10 NOT USED
11 Ignition switch signal input
12 NOT USED
13 Reverse lamp signal out
14 CAN +
15 NOT USED
16 NOT USED
Transaxle Control Module Terminal Testing
NOTE: For testing, place the positive lead on the terminal with the + sign and place the negative lead on the
terminal with the - sign.
Pin
Number
Pin
Acronym Description
Input /
Output to
Trans-
mission
Control
Module
(TCM) Measure pins
Condition For
Testing
Reference
Value
Transmission Range (TR) Transmission Control Module (TCM) C1533 (A) Vehicle Harness 3409
A1 B+ Battery voltage - +A1 to ground Hot at all times 10-14
volts
A3 SST(+) Select shift
upshift signal
Input +A3 to -A9 Voltage high
when upshift
commanded by
select shift
10-14
volts
A4 SST(-) Select shift
downshift
signal
Input +A4 to -A9 Voltage high
when downshift
commanded by
select shift
10-14
volts
A5 STLK Start lock
signal output
Output +A5 to -A9 Ignition ON in
PARK
Ignition ON in
other than PARK
0-0.8 volt
9-14 volts
A6
CAN L
Controller Area
Network
(CAN)
communi-
cation low
Input/output +A6 to -A9 Engine idling -
A8 K Diagnostic
signal
Input/output +A8 to -A9 - -
A9 GRND Transmission
Control Module
(TCM) ground
- +ground to chassis
ground
- -
A11 IG Ignition switch
signal input
Input +A11 to -A9 Ignition ON 10-14
volts
A12 Reverse
Lamp
Reverse lamp is
indicated in
reverse
Output +A12 to -A9 Voltage high
when not in
REVERSE
Voltage low
when in
REVERSE
0-14 volts
A14 CAN H communi-
cation high
Input/output +A14 to -A9 Engine idling -
B1 LPC
ground
Line Pressure
Control (LPC)
ground (SLTG)
- - - -
B2 SSB Shift Solenoid
B (SSB) (S2)
Output +B2 to ground Vehicle in
PARK, engine
idling
0-1.5 volts
B3 LPC LPC Output +B3 to -B1 Vehicle in
PARK, engine
idling
-
B4 TCC
solenoid
ground
Torque
Converter
Clutch (TCC)
solenoid ground
(SLUG)
- - - -
B5 SSA Output +B5 to ground 0-1.5 volts
Transaxle Control Module Terminal Testing 3410
Shift Solenoid
A (SSA) (S1)
Vehicle in
PARK, engine
idling
B7 TFT
ground
Transmission
Fluid
Temperature
(TFT) sensor
ground (OTG)
- - - -
B8 TFT TFT sensor
(OT)
Input +B8 to -B7 TFT at 10C to
110C (50F to
230F)
4.0 to 0.0
volts
B9 TCC TCC solenoid
(SLU)
Output +B9 to -B4 Vehicle in
PARK, engine
idling
-
B10 SSC
ground
Shift Solenoid
C (SSC) ground
(SLC1G)
- - - -
B11 SSC
(SLC1)
Output +B11 to -B10 Vehicle in PARK,
engine idling
-
B12 ISS Input shaft
speed sensor
signal (NIN)
Input +B12 to -B13 Vehicle in
PARK, engine
idling
-
B13 ISS ground Input shaft
speed sensor
signal (NIN)
- - - -
B14 SSE Shift Solenoid
E (SSE)
Output +B14 to -B22 Vehicle in
PARK, engine
idling
-
B16 SSF
ground
Shift Solenoid
F (SSF) ground
(SLB1G)
- - - -
B17 SSD Shift Solenoid
D (SSD)
(SLC2)
Output +B17 to="top"
align="left">Vehicle in
PARK, engine idling
-
B18 SSD
ground
SSD ground
(SLC2G)
- - - -
B19 OSS Output Shaft
Speed (OSS)
sensor signal
(SP+)
Input +B19 to -B20 Vehicle speed
approximately 20
km/h (12 mph)
-
B20 OSS
ground
OSS sensor
ground (SP-)
- - - -
B21 SSF SSF (SLB1G) Output +B21 to -B16 Vehicle in
PARK, engine
idling
-
B22 SSE
ground
SSE ground
(SLC3G)
- - - -
Pinpoint Tests - OSC Equipped Vehicle
Special Tool(s)
Anyelectrical connector or solenoid body is disconnected, inspect the connector for pin condition, corrosion
and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector as
required.
Prior to carrying out the pinpoint tests, check the following:
Transmission fluid level
Transmission fluid condition (burned, metal particles or discolored)
Engine cooling system
Other non-related transmission DTCs
Pinpoint Tests
information.
PINPOINT TEST A: SHIFT SOLENOIDS
NOTE: Refer to the Transaxle Vehicle Harness Connector illustrations within the Transaxle Connector
Layouts procedure in this section.
A1 ELECTRONIC DIAGNOSTICS
Check to make sure the transaxle
harness connector is fully seated, pins
are fully engaged in the connector and
in good condition before proceeding.

Ignition OFF.
Ignition ON.
on the scan tool: Retrieve DTCs.

Yes
For Shift Solenoid A (SSA) and Shift Solenoid B (SSB),
GO to A2 . For the Line Pressure Control (LPC), Shift
Solenoid C (SSC), Shift Solenoid D (SSD), Shift
Solenoid E (SSE), Shift Solenoid F (SSF) and Torque
Converter Clutch (TCC), GO to A4 .
No
CLEAR all DTCs. ROAD TEST to verify if concern is
still present. Concern could be intermittent. If concern is
Pinpoint Tests - OSC Equipped Vehicle 3413
Are there any transmission DTC
faults present?
still present or reappears, GO to the appropriate pinpoint
test steps: For shift solenoids SSA and SSB , GO to A2 .
For shift solenoids LPC , SSC , SSD , SSE , SSF and
TCC , GO to A4 .
A2 CHECK RESISTANCE OF THE
ON/OFF SOLENOID CIRCUIT
Ignition OFF.
Remove the Transmission Control
Module (TCM).

Measure the resistance at the transaxle
bulkhead electrical connector between
pin 2 and ground for SSB .

bulkhead electrical connector between
pin 5 and ground for SSA .

Is the resistance between 11-15
ohms?

Yes
INSTALL a new Transmission Control Module (TCM)
and REFLASH to the latest level calibration. CLEAR all
DTCs. ROAD TEST to verify concern is not present.
Concern could be intermittent. If concern is still present
or reappears, GO to A3 .
No
GO to A3 .
ON/OFF SOLENOIDS
Remove the transaxle side cover.
Remove the wiring connector from the
affected solenoid ( SSA or SSB ).

solenoid pin 1 and ground of the
affected solenoid.

Yes
INSTALL a new internal wire harness or REPAIR
affected circuit.
No
INSTALL a new main control.
PINPOINT TEST A: SHIFT SOLENOIDS 3414
Is the solenoid resistance between
11-15 ohms?

A4 CHECK LINEAR SOLENOID SHORT
TO GROUND
Ignition OFF.
Remove the TCM .
Measure the resistance between the
transaxle bulkhead electrical connector
pin and ground using the following
chart:

Transaxle Bulkhead Electrical
Connector
Pin
Number Circuit Function
1 Line Pressure Control
(LPC) ground
3 LPC signal
4 Torque Converter Clutch
(TCC) ground
9 TCC signal
10 Shift Solenoid C (SSC)
ground
11 SSC signal
14 Shift Solenoid E (SSE)
signal
16 Shift Solenoid F (SSF)
ground
17 Shift Solenoid D (SSD)
signal
18 SSD ground
21 SSF signal
22 SSE ground
Is each resistance greater than
10,000 ohms?

Yes
GO to A5 .
No
GO to A6 .
LINEAR SOLENOID(S)
Inspect both sides of the TCM for
damaged or pushed-out pins, corrosion
or damaged seals.

For the TCC solenoid, measure the
resistance between pin 4 and pin 9 at
the transaxle.

For the LPC solenoid, measure the
the transaxle.

For the SSF solenoid, measure the
the transaxle.

For the SSC solenoid, measure the
the transaxle.

Yes
INSTALL a new TCM and REFLASH to the latest level
calibration. CLEAR all DTCs. ROAD TEST to verify
concern is not present. Concern could be intermittent. If
concern is still present or reappears, GO to A6 .
No
GO to A6 .
For the SSD solenoid, measure the
the transaxle.

For the SSE solenoid, measure the
the transaxle.

Is the resistance between 5.0 - 5.6
ohms?

A6 CHECK CONTINUITY OF THE
INTERNAL HARNESS
Remove the wiring connector from the
affected solenoid(s) ( LPC , SSC , SSD
, SSE , SSF and TCC ).

bulkhead connector and the affected
solenoid electrical connector.

Yes
INSTALL a new main control.
No
INSTALL a new internal wire harness or repair affected
circuit.
PINPOINT TEST B: TFT SENSOR
B1 ELECTRONIC DIAGNOSTICS
Check to make sure the transaxle harness connector
is fully seated, pins are fully engaged in connector
and in good condition before proceeding.

Ignition ON.
Yes
GO to B2 .
No
REPEAT procedure to enter DataLogger.
If vehicle did not enter DataLogger,
PINPOINT TEST B: TFT SENSOR 3417
Select DataLogger.
Select PID/TFT.
Does the vehicle enter DataLogger?
Control/Emissions Diagnosis (PC/ED)
manual.
B2 TEMPERATURE SIGNAL CHECK
Ignition ON.
Select DataLogger.
Select TFT PID.
Monitor the TFT PID. The temperature value should
be within -55C to 175C (-67F to 347F).

Is the Transmission Fluid Temperature (TFT)
within specified range?

Yes
GO to B3 .
No
GO to B4 .
B3 WARM-UP/COOL-DOWN CYCLE
While monitoring the TFT PIDs, carry out the
following test: If transmission is cold, run
transmission to warm it up. If transmission is warm,
allow transmission to cool down.

Do the TFT PIDs increase as the transmission is
warmed up, decrease as the transmission is cooled
and does the TFT stay within the specified range?

Yes
INSTALL a new Transmission Control
Module (TCM) and REFLASH to the
latest level calibration. CLEAR all DTCs.
ROAD TEST to verify concern is not
present. Concern could be intermittent. If
concern is still present or reappears, GO to
B4 .
No
GO to B4 .
B4 SIGNAL RESISTANCE
Remove the TCM .
Inspect both sides of the TCM for damaged or
pushed-out pins, corrosion or damaged seals.

Measure the resistance between pins 7 and 8 at the
transaxle bulkhead electrical connector. Refer to the
following table.

TRANSMISSION FLUID TEMPERATURE
(TFT) Sensor Resistance
C F Resistance (Ohms)
10 50 6.445
25 77 3.5
110 230 0.247
Yes
GO to B5 .
No
INSTALL a new internal harness and TFT
assembly.
Record the resistance.
Is the resistance within range?
B5 SHORT TO GROUND
Measure the resistance between pin 7 and ground at
the transaxle bulkhead electrical connector.

Measure the resistance between pin 8 and ground at
the transaxle bulkhead electrical connector.

Record the resistances.
Yes
INSTALL a new TCM and REFLASH to
the latest level calibration.
No
INSTALL a new internal harness and TFT
assembly.
PINPOINT TEST C: OSS SENSORS
C1 ELECTRONIC DIAGNOSTICS
Check to make sure the Transmission Control
Module (TCM) connector is fully seated, pins
are fully engaged in the connector and in good
condition before proceeding.

Ignition ON.
Monitor the PID for the Output Shaft Speed
(OSS) sensor.

Yes
CLEAR all DTCs. ROAD TEST to verify
concern is not present. Concern could be
intermittent. If concern is still present or
reappears, GO to C2 .
No
GO to C2 .
PINPOINT TEST C: OSS SENSORS 3419
Monitor and record speed.
Does the OSS match the vehicle speed?
C2 CHECK OSS SENSOR RESISTANCE
Remove the TCM .
bulkhead electrical connector between pin 19
and 20.

Yes
No
GO to C4 .
C3 CHECK OSS SENSOR FOR SHORT TO
GROUND
Remove the TCM .
and ground.

and ground.

Yes
INSTALL a new TCM and REFLASH to the
latest level calibration. CLEAR all DTCs. ROAD
TEST to verify concern is not present. Concern
could be intermittent. If concern is still present or
No
GO to C4 .
C4 CHECK OSS SENSOR RESISTANCE
PINPOINT TEST C: OSS SENSORS 3420
Measure the resistance at the speed sensor
electrical connector between pin 1 and 2.

Yes
INSTALL a new internal harness.
No
INSTALL a new transaxle assembly.
PINPOINT TEST D: TSS SENSOR
D1 ELECTRONIC DIAGNOSTICS
Check to make sure the Transmission Control
Module (TCM) connector is fully seated, pins
are fully engaged in connector and in good

Ignition ON.
Monitor the PID for the Turbine Shaft Speed
(TSS) sensor.

Monitor and record speed.
Does the TSS match the engine rpm?
Yes
reappears, GO to D2 .
No
GO to D2 .
D2 CHECK TSS SENSOR RESISTANCE
Remove the TCM .
and 13.

Yes
No
GO to D4 .
D3 CHECK TSS SENSOR CIRCUIT FOR
SHORT TO GROUND
PINPOINT TEST D: TSS SENSOR 3421
Remove the TCM .
and ground.

and ground.

Yes
INSTALL a new TCM and REFLASH to the
latest level calibration. CLEAR all DTCs. ROAD
TEST to verify concern is not present. Concern
could be intermittent. If concern is still present or
No
GO to D4 .
D4 ELECTRONIC DIAGNOSTICS
Measure the resistance at the TSS sensor
electrical connector between pin 1 and 2.

Yes
reappears, INSTALL a new internal harness.
No
The sensor is defective, INSTALL a new TSS
sensor.
PINPOINT TEST E: PARK NEUTRAL SIGNAL
E1 CHECK RESISTANCE ON CIRCUIT
CET40 (GN/OG)
Selector lever in PARK or NEUTRAL.
C175B-16, circuit CET40 (GN/OG) and
chassis ground.

Yes
GO to E2 .
No
GO to E3 .
PINPOINT TEST E: PARK NEUTRAL SIGNAL 3422
Is the resistance between 13 to 40
ohms?

E2 CHECK RESISTANCE ON CIRCUIT
CET40 (GN/OG)
Selector lever in REVERSE, DRIVE or
M.

C175B-16, circuit CET40 (GN/OG) and
chassis ground.

Is the resistance greater than 1000
ohms?

Yes
INSTALL a new TCM . After installing the new TCM
, VERIFY that the starting system is operating
correctly. If not, REFER to Section 303-03A to check
starting system.
No
GO to E3 .
E3 CHECK VEHICLE HARNESS
CIRCUIT CET40 (GN/OG) FOR AN OPEN
Disconnect: Transmission Control
Module (TCM) C1533.

C1533-5, circuit CET40 (GN/OG) and
C175B-16.

Yes
GO to E4 .
No
REPAIR circuit CET40 (GN/OG) for an open.
E4 CHECK VEHICLE HARNESS
CIRCUIT CET40 (GN/OG) FOR A SHORT
TO GROUND
C1533-5, circuit CET40 (GN/OG) and
chassis ground.

ohms?

Yes
INSTALL a new PCM. After installing the new PCM,
VERIFY that the starting system is operating
correctly. If not, REFER to Section 303-03A to check
starting system.
No
REPAIR circuit CET40 (GN/OG) for a short to
ground.
Special Testing Procedures
Special Tool(s)
Transmission Fluid Pressure Gauge
307-004 (T57L-77820-A)
Vehicle Communication Module and
Integrated Diagnostic System software with
appropriate hardware, or equivalent scan
tool
The special tests are designed to aid the technician in diagnosing the hydraulic and mechanical portions of the
transaxle.
Engine Idle Speed Check
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for diagnosis and testing of the engine
idle speed.
Pressure Test
Pressure Tap Location
Item Description
1 Clutch C1 drive
2 Clutch C2 drive
Special Testing Procedures 3425
3 Clutch C3 drive
4 Lube circuit
5 Clutch B2
NOTICE: If the pressure is low at stall, do not continue with the test or further transaxle damage will
occur. Do not maintain Wide Open Throttle (WOT) in any transaxle range for more than 5 seconds.
This test verifies that the pressure is within specification.
Connect the Transmission Fluid Pressure Gauge to the appropriate pressure tap. 1.
Start the engine and check the pressures, see the pressure charts to determine if the pressures are
within specification.
2.
Clutch and Brake Pressure Chart
Clutch/Band Range Pressure
C1
(Drive Clutch)
Drive (1st-4th) 196-1,372 kPa (28-199 psi)
C2
(Drive Clutch)
Drive (4th-6th) 196-1,372 kPa (28-199 psi)
C3
(Drive Clutch)
Drive (3rd-5th) 196-1,372 kPa (28-199 psi)
C3
(Drive Clutch)
Reverse 392-1,863 kPa (57-270 psi)
B1
(Brake Clutch)
Drive
(2nd and 6th)
196-1,372 kPa (28-199 psi)
B2
(Brake Band)
Low manual (1st) 588-1,372 kPa (85-199 psi)
B2
(Brake Band)
Reverse 392-1,863 kPa (57-270 psi)
Pressure Diagnostic Chart
Test Results Possible Source
Values of both DRIVE and REVERSE ranges are lower
than the standards Line Pressure Control (LPC)
Pressure Tap Location 3426
Primary regulator valve failure
Transmission oil pump failure
Leak from hydraulic circuit of DRIVE
or REVERSE range

Only the value of DRIVE range is lower than the standards
DRIVE range hydraulic circuit failure
C1 clutch failure
Only the value of REVERSE range is lower than the
standards REVERSE range hydraulic circuit
failure

C3 clutch failure
B2 brake failure
If the pressure is not within specification, install a new main control valve body. 3.
If the pressures are OK, clear all DTCs. Test drive vehicle, code could be intermittent. If DTC returns,
install a new valve body.
4.
Stall Speed Test
The Stall Speed Test checks:
Torque Converter Clutch (TCC) operation and installation.
holding ability of the forward clutch.
reverse clutch (the low-reverse bands).
planetary One-Way Clutch (OWC).
engine driveability concerns.
Conduct this test with the engine coolant and transmission fluid at correct levels and at normal operating
temperature.
Apply the park brake firmly for each Stall Speed Test.
Find the specified stall rpm for the vehicle, see the Stall Speed Chart. Use a grease pencil to mark the
rpm on the dial of a tachometer.
1.
Stall Speed
Engine rpm
3.5L 1,878-2,678
Connect a scan tool. 2.
NOTE: If the rpm recorded by the scan tool exceeds the maximum limits, release the accelerator
pedal immediately because clutch or band slippage is indicated.
In each of the following range REVERSE, DRIVE and LOW, press the accelerator pedal to the floor
and hold it just long enough to let the engine get to Wide Open Throttle (WOT). Do not hold the
throttle open for more than 5 seconds at a time.
3.
Note the results in each range. 4.
After each range, move the selector lever to NEUTRAL and run the engine at 1,000 rpm for about 15
seconds to cool the torque converter before the next test.
5.
Use the stall speed diagnosis chart for corrective actions. 6.
NOTE: The stall speed in REVERSE will be lower.
If stall speeds were too high, see the Stall Speed Chart. If stall speeds were too low, first check engine
idle speed and tune up. If engine is OK, remove torque converter and check TCC for slippage.
7.
Pressure Diagnostic Chart
Values of both DRIVE and REVERSE ranges are lower
than the standards Insufficient engine power
Torque converter stator One-Way Clutch
(OWC) slipping

Only the value of DRIVE range is higher than the
standards Low line pressure. Shift control solenoid
assembly failure, primary regulator valve
failure

Valve body failure (hydraulic pressure
system)

C1 clutch slipping
OWC F1 failure
Only the value of REVERSE range is higher than the
standards Low line pressure. Shift control solenoid
failure

Valve body failure (hydraulic pressure
system)

C3 clutch failure
B2 brake failure
Values of both DRIVE and REVERSE ranges are
higher than the standards Low line pressure. Shift control solenoid
failure

Primary regulator valve failure
Oil pump failure
Oil strainer clogging
Leakage Inspection
Material
Item Specification
164-R3701 (Rotunda)
-
Transmission Fluid
(Canada)
WSS-M2C924-A
NOTICE: Do not try to stop the fluid leak by increasing the torque beyond specifications. This may
cause damage to the case threads.
Use the following chart to inspect and correct any external transmission fluid leaks.
External Transmission Fluid Leaks
Description Action
Leaks at the transmission
fluid pan to case
Tighten to specification or i new transmission fluid gasket.
Transmission fluid filler plug
leaks
Install a new transmission fluid filler plug.
Transmission fluid cooler or
fittings leaking
Tighten to specification or install new transmission fluid cooler tubes. Refer to
Section 307-02A .
Transmission fluid cooler nut
to case fitting leaking
Inspect for damage or missing O-ring seals. Tighten to specification, install
new transmission fluid cooler tubes or install new O-rings. Refer to Section
307-02A .
Leaks at the transmission
fluid cooler
Inspect the transmission fluid cooler for damage, if damaged, install a new
transmission fluid cooler. Refer to Section 307-02A .
Leaks at the manual control
lever seal
Install a new manual control lever seal.
Leaks at the solenoid body
harness connector
Install a new solenoid body harness connector O-ring seal, either on the
harness end or the solenoid body.
External Sealing
The transaxle has the following parts to prevent external transmission fluid leakage:
Gaskets
Leakage Inspection 3430
Lip type seals
O-ring seals
Seal rings
Seal grommets
Thread sealant
External Sealing
Item
Part
Number Description
1 7902 Torque converter
2 - Torque converter hub seal
3 1177 Axle shaft seals
4 - Transmission Control Module (TCM)
5 - TCM bolt
6 7045 Manual control lever shaft nut
7 7C208 Manual control lever shaft nut washer
8 7A256 Manual control lever
td> 7A010 Transmission fluid fill plug
10 7E050 Transmission fluid fill plug O-ring
11 - Breather hose
12 - Main control valve body assembly
13 - Main control valve body bolt
14 - Lock plate
External Sealing 3431
15 - Lock plate bolt
16 - Suction cover gasket
17 - Suction cover
18 - Suction cover bolt
19 - Main control valve body side cover
20 - Main control valve body side cover bolt
21 7J227 Transmission fluid cooler O-rings
22 7R081 Transmission fluid cooler tube
23 7E050 Transmission fluid level indicator tube O-rings
24 7A228 Transmission fluid level indicator tube
25 7A443 Transmission fluid level indicator tube bolts
26 7A228 Transmission fluid level indicator tube
27 7L101 Transmission fluid drain plug gasket
28 7A010 Transmission fluid drain plug
29 7M101 Turbine Shaft Speed (TSS) sensor
30 7G276 Internal wire harness and Transmission Fluid
Temperature (TFT) sensor
Transmission Fluid Leakage in Torque Converter Area
Leakage at the front of transmission, as evidenced by transmission fluid around the torque converter housing
part of the case, may have several sources. By careful observation it is possible, in many instances, to pinpoint
the source of a leak before removing the transmission from the vehicle. The paths which the transmission fluid
takes to reach the bottom of the torque converter housing are shown in the illustration. The 5 numbers in the
illustration correspond with the 5 flow path steps.
Leak Path Symptom Possible Source
1, 2 and 4 Leak at front of transmission Torque converter hub seal
1, 2 and 4 Leak at front of transmission Vent
1, 2 and 4 Leak at front of transmission Converter hub weld
1, 2 and 4 Leak at front of transmission External pump seal (large)
1, 2 and 4 Leak at front of transmission Pump to case screws
1, 2 and 4 Leak at front of transmission Pump gasket
3 Leak at front of transmission Torque converter seal weld
3 Leak at front of transmission Torque converter stud
5 Leak at front of transmission Engine oil leak; rear main seal
5 Leak at front of transmission Engine valve cover
5 Leak at front of transmission Oil galley
5 Leak at front of transmission Pump lip seal
5 Leak at front of transmission Engine Oil Pressure (EOP) sensor
Leak Check Test With Ultraviolet Lamp
Use Dye-Lite ATF /Power Steering Fluid Leak Detection Dye to detect a transmission fluid leak.
Add dye to the transmission fluid. Use 30.0 ml (1 oz) of dye solution for every 3.8L (4 qt) of
transmission fluid.
1.
Start and run the engine until the transaxle reaches its normal operating temperature. Using an
ultraviolt light, observe the back of the cylinder block and top of the torque converter housing for
evidence of fluid leakage. Raise the vehicle on a hoist and run the engine at fast idle, then at engine
idle, occasionally shifting to the DRIVE and REVERSE ranges to increase pressure within the
transaxle. Observe the front of the flexplate, back of the cylinder block (in as far as possible), and
inside the torque converter housing and front of the case. Continue running the engine until fluid
leakage is evident and the probable source of leakage can be determined.
2.
Diagnosis By Symptom
Special Tool(s)
The Diagnosis by Symptom charts give the techni diagnostic information, direction and suggest possible
components, using a symptom as a starting point.
The Diagnosis by Symptom charts are divided into 2 categories: Electrical Routines, indicated by 200 series
numbers, and Hydraulic/Mechanical Routines, indicated by 300 series numbers. The Electrical Routines list
the possible electrical components that could cause or contribute to the symptom described. The
Hydraulic/Mechanical Routines list the possible hydraulic or mechanical components that could cause or
contribute to the symptom described.
Diagnosis by Symptom Chart Directions
Using the Diagnosis by Symptom Index, select the concern/symptom that best describes the
condition.
1.
See the routine indicated in the Diagnosis by Symptom Index. 2.
Always begin diagnosis of a symptom with:
Preliminary inspections. 1.
Verifications of condition. 2.
Checking the fluid levels. 3.
Carry out other test procedures as directed. 4.
3.
NOTE: Not all concerns and conditions with electrical components will set a DTC. Be aware that the
components listed may still be the cause. Verify correct function of these components prior to
proceeding to the routine listed.
Begin with the routine indicated. Follow the reference or action required statements. Always carry out
the On-Board Diagnostic (OBD) tests as required. Never skip steps. Repair as required. These
components are listed in the removal sequence and by the most probable cause. All components listed
must be inspected to make sure of correct repair.
4.
Diagnosis by Symptom Index
Diagnosis By Symptom 3434
Title Routines
Engagement Concerns
No forward and/or No reverse 207
Harsh 208
Soft 209
Torque Converter Clutch Operation Concerns
Does not apply 240
Cycling/shudder/chatters 242
NVH
Noise/vibration - forward or reverse 254
Other Concerns
Transmission fluid level 286
Transmission fluid condition 287
Transmission control module software 288
Diagnostic Routines
Engagement Concerns: No Forward and/or No Reverse
Possible Component Reference/Action
207 - ROUTINE
No Forward, No
Reverse, No Forward
or Reverse
Selector
lever linkage
damaged or
out of
position
Using a scan tool, CHECK selector lever position. REFER to Section
307-05A .

Incorrect
neutral
switch
position
CARRY OUT neutral position learning. REFER to Neutral Position
Learning in this section.

DISCONNECT the Transmission Control Module (TCM) electrical
connector. If concern still exists, this indicates an internal mechanical
problem. CONNECT the TCM and CARRY OUT pressure checks.

If concern is resolved by disconnecting the TCM , this indicates an electrical
concern. INSTALL a new TCM . REFER to Transmission Control Module
(TCM) in this section. CHECK wiring harness (external and internal) valve
body connections.

Halfshafts
broken
INSPECT for damaged or broken halfshafts. REFER to Section 205-04 .
Engagement Concerns: Harsh
208 - ROUTINE
Harsh Engagements
Initial learn values wrong CARRY OUT Transmission Control Module (TCM) initial
learning procedure. REFER to Transmission Control Module
(TCM) Initial Learning in this section.

Damaged internal transaxle
components causing high or
low pressures
CARRY OUT pressure test. Refer to Special Testing
Procedures in this section.

Damaged or malfunctioning
solenoids
CARRY OUT pinpoint test. REFER to Pinpoint Tests - OSC
Equipped Vehicle in this section.

Engagement Concerns: Soft
209 - ROUTINE
Soft Engagements
Initial learn
values
wrong
CARRY OUT
Transmission Control
Module (TCM) initial
learning procedure.
REFER to
Damaged
internal
transaxle
components
causing high or
low pressures
CARRY OUT
pressure test.
REFER to
Special Testing
Procedures in this
section.

Damaged or
malfunctioning
solenoids
CARRY OUT pinpoint
test. REFER to Pinpoint
Tests - OSC Equipped
Vehicle in this section.

Torque Converter Clutch Operations Concerns: Does Not Apply
240 - ROUTINE
Torque Converter Does
Not Apply
Damaged or
malfunctioning
solenoid
CARRY OUT pinpoint test. REFER to Pinpoint Tests - OSC Equipped
Vehicle in this section. INSTALL a new main control valve body.
REFER to Main Control Valve Body in this section.

Damaged or
disconnected wire
harness
INSPECT wire harness. CHECK connections to the Torque Converter
Clutch (TCC) solenoid.

Damaged or
malfunctioning
torque converter
INSTALnew torque converter. REFER to Torque Converter in this
section.

Torque Converter Clutch Operations Concerns: Cycling/Shutter/Chatters
242 - ROUTINE
Torque Converter
Cycling/Shudder/Chatters
Damaged or malfunctioning Torque
Converter Clutch (TCC) solenoid
INSTALL a new main control valve body. REFER
to Main Control Valve Body in this section.

Damaged or disconnected wire
harness
INSPECT wire harness. CHECK connections to the
TCC solenoid.

Damaged or malfunctioning torque
converter
INSTALL a new torque converter. REFER to Torque
Converter in this section.

Other Concerns: Noise/Vibration - Forward or Reverse
254 - ROUTINE
Powertrain Control System
Transmission Control Module
(TCM), vehicle wiring harnesses,
Shift Solenoid A (SSA) and Shift
Solenoid B (SSB)
CARRY OUT On-Board Diagnostic (OBD) tests.
REFER to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for diagnosis and
testing of the TCM . GO to Pinpoint Test A .
REPAIR as required. CLEAR the DTCs, road

test and retrieve any DTCs.
Incorrect Transmission Fluid Level
Transmission flu level
low/overfilled
CHECK the transmission fluid level. ADJUST
the transmission fluid level as necessary. REFER
to Preliminary Inspection in this section.

Torque Converter
Worn or damaged torque
converter
REFER to Torque Converter Diagnosis in this
section.

Transaxle Support Insulator
Worn or damaged transaxle
support insulator
INSPECT the transaxle support insulator for
damage. INSTALL new as necessary. REFER to
Transaxle Support Insulator in this section.

Other Concerns: Transmission Fluid Level
286 - ROUTINE
Low Transmission
Fluid Level
Axle shaft seal
leaking
INSTALL new axle shaft seals. REFER to Differential Seals - LH ,
Differential Seals - RH, Front Wheel Drive (FWD) and Differential Seals -
RH, All Wheel Drive (AWD) in this section.

Transmission
fluid pan
leaking
RESEAL the transmission fluid pan.
Torque
converter hub
seal leaking
INSTALL a new torque converter hub seal. REFER to Torque Converter
Hub Seal in this section.

Transmission
fluid cooler
tubes leaking
INSTALL new transmission fluid cooler tube O-rings.
Manual
control lever
seal leaking
INSTALL a new manual control lever seal. REFER to Manual Control
Lever Shaft and Seal in this section.

Transmission
fluid drain
plug leaking
INSTALL a new transmission fluid drain plug seal.
Other Concerns: Transmission Fluid Condition
287 - ROUTINE
Transmission Fluid Burnt or Contaminated
Internal components damaged (clutch
plate material)
INSTALL a new transaxle. REFER to Transaxle
in this section.

Other Concerns: Transmission Control Module (TCM) Software
288 - ROUTINE
Shifting and Driveability Concerns
Transmission Control Module (TCM) not at
current software level
REPROGRAM the
TCM to current
software level.

Transmission Fluid Cooler - Backflushing and Cleaning
Special Tool(s)
Transmission Heated Cooler Line Flusher
222-00007, 222-00004 or equivalent
Material
Item Specification
Motorcraft Premium
Autansmission Fluid
(Canada)
WSS-M2C924-A
NOTE: Transmission fluid cooler backflushing and cleaning will be performed using the Transmission
Heated Cooler Line Flusher or equivalent. Follow the manufacturer's instructions included with the machine.
Test the equipment to make sure that a vigorous fluid flow is present before proceeding.
NOTE: If the vehicle is equipped with an in-line transmission fluid thermal by-pass valve, the in-line
transmission fluid thermal by-pass valve must be removed prior to flushing out the transmission fluid cooler
and transmission fluid cooler lines.
Check and top off fluid level of the cooler line flusher tank with transmission fluid. 1.
Allow the fluid in the cooler line flusher 15-30 minutes to heat up to 60C (140F) before using. 2.
Install the line adapters into the transmission cooler lines. 3.
Attach the cooler line flusher red line to the transmission fluid cooler pressure line quick disconnect
fitting.
4.
Attach the cooler line flusher blue line to the transmission fluid cooler return line quick disconnect
fitting.
5.
Follow the equipment instructions to purge the cooler lines and cooler prior to starting the flushing
procedure.
6.
Allow the cooling system to backflush for 10-15 minutes, then flush the cooler in a normal flow
direction for an additional 10-15 minutes.
7.
Clean the transaxle mounted cooler tubes by hand. 8.
Transmission Fluid Cooler - Backflushing and Cleaning 3440
Transmission Fluid Cooler - Backflushing and Cleaning 3441
Transmission Fluid Drain and Refill
Special Tool(s)
Material
Item Specification
Moraft Premium Automatic
Transmission Fluid
(Canada)
WSS-M2C924-A
NOTICE: The use of any fluid other than what is recommended for this transmission will cause
transmission damage.
Draining
100-02 .
1.
Remove the transmission fluid drain plug and allow the transmission fluid to drain. 2.
Refill
Install the transmission fluid drain plug.
3.
Remove the transmission fluid fill plug. 4.
Transmission Fluid Drain and Refill 3442
Fill the transaxle with approximately 3.7L (4 qt) of clean transmission fluid. 5.
Install the transmission fluid fill plug.
6.
With the transaxle in (P) PARK, the vehicle should be on a level surface, the engine at idle (680-780
rpm), foot pressed on the brake, move the selector lever through each gear and allow engagement of
each gear. Place the selector lever back in the PARK position.
7.
Wipe the transmission fluid level indicator cap and remove the fluid level indicator. 8.
NOTE: In order to get an accurate transmission fluid level reading, the vehicle should be on a level
surface, the engine at idle (680-780 rpm) for 5 minutes and the transmission fluid temperature should
be at least 60C-70C (140F-158F) using the scan tool.
If transmission fluid needs to be added, add transmission fluid in 0.25L (1/2 pint) increments through
the transmission fluid fill plug located on top of the transaxle near the transmission fluid level
indicator. Do not overfill the transmission fluid. Install the transmission fluid level indicator back in
the transmission fluid filler tube until it is fully seated, then remove the indicator. The transmission
fluid level should be at the upper-most mark on the transmission fluid level indicator. Only fill to the
upper-most mark on the transmission fluid indicator. Do not overfill. Damage to the transaxle will
occur.
10.
NOTE: The correct transmission fluid level at normal operating temperature of 60C-70C
(140F-158F) is between the top 2 marks on the transmission fluid level indicator.
Fill the transaxle to the correct transmission fluid level.
11.
NOTE: The correct transmission fluid level at cool operating temperature of 15C-25C (59F-77F),
is at the bottom mark on the transmission fluid level indicator.
If the Transmission Fluid Temperature (TFT) is low, fill the transaxle with transmission fluid to the
cold range on the transmission fluid level indicator. Recheck the transmission fluid level when the
transaxle has reached the normal operating temperature.
12.
Torque Converter Contamination Inspection
Material
Item Specification
Transmission Fluid
(Canada)
WSS-M2C924-A
A new or remanufactured torque converter must be installed if one or more of the following
statements is true:
A torque converter malfunction has been determined based on complete diagnostic
procedures.

The torque converter stud or studs, impeller hub or bushing are damaged.
The torque converter exhibits external discoloration (due to overheating).
There is evidence of transmission assembly or fluid contamination due to the
following transmission or converter failure modes.
Major metallic failure
Multiple clutch plates or band failures
Sufficient component wear which results in metallic contamination
Water or antifreeze contamination

1.
If none of the above conditions are present, continue with the following fluid inspection. 2.
Pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or
through a paper filter.
3.
Examine the fluid for contaminants, color and smell. The fluid must be free of contaminants, red in
color and not have a burnt smell.
4.
NOTICE: Do not use water-based cleaners or mineral spirits to clean or flush the torque
converter or transmission damage will occur.
If the fluid passed inspection:
drain the remaining fluid from the torque converter.
using only the recommended transmission fluid, add 1.9L (2 qt) of clean fluid into the
converter and agitate by hand.

thoroughly drain the fluid.
5.
Torque Converter Contamination Inspection 3445
Transmission Fluid Exchange
Special Tool(s)
ATF Fluid Exchanger W/Power Steering
Fluid Exchanger
Material
Item Specification
Transmission Fluid
(Canada)
WSS-M2C924-A
NOTICE: Use transmission fluid specific for this transmission. Do not use any supplemental
transmission fluid additives or cleaning agents. The use of these products can cause internal
transmission components to fail, which will affect the operation of the transmission.
100-02 .
1.
Use the ATF Fluid Exchanger W/Power Steering Fluid Exchanger to change the fluid. 2.
Connect the ATF Fluid Exchanger W/Power Steering Fluid Exchanger to the transmission fluid coler
tube after the transmission fluid cooler on the return tube. This will help remove any foreign material
trapped in the transmission fluid coolers.
3.
Perform the transmission fluid exchange using the ATF Fluid Exchanger W/Power Steering Fluid
Exchanger. Follow the manufacturer's instructions included with the machine.
4.
Once the transmission fluid exchange is completed, disconnect the ATF Fluid Exchanger W/Power
Steering Fluid Exchanger. Reconnect any disconnected transmission fluid cooler tubes.
5.
Using the scan tool with the engine running, check and make sure that the transmission is at normal
operating temperature 66-77C (150-170F). Check and adjust the transmission fluid level and check
for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt)
until the correct level is achieved.
6.
Transmission Fluid Exchange 3447
Neutral Position Learning
Special Tool(s)
NOTE: When installing a new Transmission Control Module (TCM), the initialized learned values will need
to be carried out.
100-02 .
1.
Install the scan tool. 2.
Turn the ignition ON. 3.
The scan tool should indicate NEUTRAL.
If the scan tool does not indicate NEUTRAL, carry out TCM adjustment. For additional
information, refer to Transmission Control Module (TCM) in this section.

4.
If NEUTRAL is indicated on the scan tool, move the selector lever to PARK and turn the ignition
OFF.
5.
Turn the ignition ON and move the selector lever from PARK to DRIVE.
The scan tool should indicate each PRNDL position.
6.
If the diagnostic display indicates each PRNDL position, check for any DTCs. 7.
If the diagnostic display does not indicate each PRNDL position, carry out Transmission Control
Module (TCM) Initial Learning in this section.
8.
Neutral Position Learning 3449
Neutral Position Learning 3450
Transmission Control Module (TCM) Initial Learning
Special Tool(s)
NOTICE: Do not raise the Transmission Fluid Temperature (TFT) by stalling the engine, internal
transaxle damage will occur.
NOTE: Clear all DTCs first.
NOTE: When insing a new transmission, Transmission Control Module (TCM) or reflashing the TCM , the
initialized learned values will need to be carried out.
NOTE: This procedure cannot be carried out if the transmission fluid is not within the correct temperature
specification.
100-02 .
1.
Install the scan tool. 2.
Monitor and note the engagement and shift harshness. 3.
With the engine idling, monitor the Transmission Fluid Temperature (TFT). The TFT should be
between 66C-110C (151F-230F).
4.
With a foot on the brake, move the selector lever to NEUTRAL and hold for 3 seconds. Then move
the selector lever to DRIVE and hold for 3 seconds. Carry this out 5 times. Then move the selector
lever to PARK.
5.
With a foot on the brake, move the selector lever to NEUTRAL and hold for 3 seconds. Then move
the selector lever to REVERSE and hold for 3 seconds. Carry this out 5 times. Then move the selector
lever to PARK.
6.
Drive the vehicle and monitor the scan tool. 7.
Drive the vehicle with the throttle opening between 20-25%. Drive until the vehiceaches 6th gear, not
to exceed 80 km/h (50 mph). Then release the accelerator and coast to a stop within 60 seconds. Carry
this out 10 times.
8.
If engagements and/or shifts are harsh, repeat Steps 4 through 8 one more time. 9.
Transmission Control Module (TCM) Initial Learning 3451
Transmission Control Module (TCM) Initial Learning 3452
Main Control Valve Body
Special Tool(s)
Material
Item Specification
Transmission Fluid
(Canada)
WSS-M2C924-A
TA-29
-
Removal
NOTICE: The use of any transmission fluid other than what is recommended for this transaxle will
cause transaxle damage.
100-02 .
1.
Remove the screws and the underbody cover. 2.
Disconnect the transmission fluid cooler tubes at the transaxle and position the tubes aside. 4.
Main Control Valve Body 3453
Remove and discard the transmission fluid pan bolts and remove the pan. 5.
NOTICE: When removing the sealer, use care not to damage the sealing surfaces.
Remove the sealer off the fluid pan.
6.
Disconnect the wire harness from the solenoids.
Remove the wire harness from the clamps. 1.
Disconnect the 8 solenoid connectors and the 2 speed sensor connectors.
7.
Remove the 2 speed sensor wire connectors from the solenoid clamp.
Remove the Output Shaft Speed (OSS) sensor wire connector from the solenoid clamp. 1.
Remove the Turbine Shaft Speed (TSS) sensor wire connector from the solenoid clamp. 2.
8.
Remove the bolt and the lock plate and pull out the Transmission Fluid Temperature (TFT) sensor. 9.
Remove the 2 bolts, suction cover and gasket. 10.
Remove the 6 main control valve body bolts in the sequence shown. 11.
NOTE: Be careful when removing the main control valve body, the manual control lever will fall out
of its bore. Also, once all the bolts are removed, the main control valve body will fall out of the
transaxle.
Remove the main control valve body.
12.
Installation
NOTICE: When installing the main control valve body, place the wire harness in the open space
of the separate plate, being careful not to pinch the harness. Damage to the harness will occur.
Connect the manual valve link and position the main control valve body in place.
1.
Loosely install the 6 main control valve body bolts in the sequence shown. 2.
Install the suction cover gasket, cover and loosely install the 2 bolts. 3.
Tighten the 8 bolts to 10 Nm (89 lb-in) in the sequence shown. 4.
Lubricate the O-ring with clean automatic transmission fluid and install the TFT sensor.
5.
Install the 2 speed sensor wire connectors on the solenoid clamp.
Install the Output Shaft Speed (OSS) sensor wire connector on the solenoid clamp. 1.
Install the Turbine Shaft Speed (TSS) sensor wire connector on the solenoid clamp. 2.
6.
Connect the wire harness to the solenoids.
Install the wire harness into the clamps. 1.
Connect the 8 solenoid connectors and the 2 speed sensor connectors.
7.
Install a bead of sealer to the fluid pan. 8.
Using new pan bolts, install the fluid pan.
9.
NOTE: Lubricate the new O-rings with clean automatic transmission fluid and install them onto the
transmission fluid cooler tubes.
Connect the transmission fluid cooler tubes to the transaxle.
10.
11.
Install the underbody cover and the screws. 12.
Fill the transaxle with approximately 4.7L (5 qt) of clean transmission fluid. 14.
15.
With the transaxle in PARK, the vehicle on a level surface, the engine at idle (680-780 rpm) and foot
pressed on the brake, move the selector lever through each gear and allow engagement of each gear.
Place the selector lever back in the PARK position.
16.
surface. Idle the engine to reach the normal operating temperature. Using the scan tool, verify that the
transaxle is at normal operating temperature 60C-70C (140F-158F), prior to adjusting the
transmission fluid level.
If transmission fluid needs to be added, add transmission fluid in 0.25L (1/2 pt) increments through
the transmission fluid fill plug located on the top of the transaxle near the transmission fluid level
the transmission fluid filler tube until it is fully seated, then remove the transmission fluid level
indicator. The transmission fluid level should be at the upper most mark on the transmission fluid
level indicator. Only fill to the upper most mark on the transmission fluid level indicator. Do not
overfill. Damage to the transaxle will occur.
19.
20.
If the TFT is low, fill the transaxle with transmission fluid to the cold range on the transmission fluid
level indicator. Recheck the transmission fluid level when the transaxle has reached the normal
operating temperature.
21.
Turbine Shaft Speed (TSS) Sensor
Removal
Remove the main control valve body. For additional information, refer to Main Control Valve Body
in this section.
1.
Remove the bolt and the Turbine Shaft Speed (TSS) sensor. 2.
Installation
Lubricate the O-ring with clean automatic transmission fluid and install the TSS sensor.
1.
Install the main control valve body. For additional information, refer to Main Control Valve Body in
this section.
2.
Turbine Shaft Speed (TSS) Sensor 3461
Differential Seals - LH
Special Tool(s)
Installer, Output Shaft Seal
307-567
Vehicle Communicaule (VCM) and
Integrated Diagnostic System (IDS)
Material
Item Specification
Transmission Fluid
(Canada)
WSS-M2C924-A
Removal
Remove the LH halfshaft. For additional information, refer to Section 205-04 . 1.
NOTICE: Be careful not to damage the case while removing the seal.
Using a suitable awl, poke a small hole in the seal.
2.
Using a suitable dent puller, remove the LH differential fluid seal. 3.
Differential Seals - LH 3463
Installation
Position the new differential fluid seal in place. 1.
Using the Output Shaft Seal Installer, install the outer differential fluid seal. 2.
Install the LH halfshaft. For additional information, refer to Section 205-04 . 3.
4.
indicator. The transmission fluid level should be at the uppermost mark on the transmission fluid level
indicator. Only fill to the uppermost mark on the transmission fluid level indicator. Do not overfill.
Damage to the transaxle will occur.
7.
8.
NOTE: The correct transmission fluid level at cold operating temperature of 15C-25C (59F-77F)
is at the bottom mark on the transmission fluid level
9.
Fill the transaxle with clean transmission fluid. 11.
12.
Differential Seals - RH, Front Wheel Drive (FWD)
Special Tool(s)
Installer, Output Shaft Seal
307-568
Material
Item Specification
Transmission Fluid
(Canada)
WSS-M2C924-A
Removal
Remove the RH halfshaft. For additional information, refer to Section 205-04 . 1.
NOTICE: Be careful not to damage the case while removing the seal.
Using a suitable dent puller, remove the differential fluid seal.
2.
Installation
Position the new differential fluid seal on the Output Shaft Seal Installer. 1.
Differential Seals - RH, Front Wheel Drive (FWD) 3467
Using the Output Shaft Seal Installer, install the outer differential fluid seal. 2.
Install the RH halfshaft. For additional information, refer to Section 205-04 . 3.
4.
the transmission fluid fill plug located on the topthe transaxle near the transmission fluid level
the transmission fluid filler tube until it is fully seated, then remove the transmission fluid lever
7.
8.
9.
12.
Differential Seals - RH, All Wheel Drive (AWD)
Special Tool(s)
Axle Seal Installer
307-593
Handle
205-153 (T80T-4000-W)
Remover, Input Shaft Oil Seal
308-375
Slide Hammer
307-005 (T59L-100-B)
Material
Item Specification
Transmission Fluid
(Canada)
WSS-M2C924-A
Removal
Remove the Power Transfer Unit (PTU). For additional information, refer to Section 308-07B . 1.
NOTE: Transaxle removed for clarity.
Using the Input Shaft Oil Seal Remover and Slide Hammer, remove the differential fluid seals.
2.
Differential Seals - RH, All Wheel Drive (AWD) 3471
Installation
Position the new inner differential fluid seal in place. 1.
Using the Axle Seal Installer and Handle, install the inner differential fluid seal. 2.
Position the new outer differential fluid seal in place. 3.
Using the Axle Seal Installer and Handle, install the outer differential fluid seal. 4.
Install the PTU . For additional information, refer to Section 308-07B . 5.
6.
transaxle is at normal operating temperature 60C-70C (140F-158F), prior tousting the
9.
10.
cold range on the transmission fluid level i. Recheck the transmission fluid level when the transaxle
has reached the normal operating temperature.
11.
14.
Intermediate Servo
Special Tool(s)
Material
Item Specification
Transmission Fluid
(Canada)
WSS-M2C924-A
Servo Kit - 3.5L Engine
NOTE: Kit assembly part number is 7D027.
1 - Servo spring
2 - Servo piston
3 7D024 Servo piston O-ring
Intermediate Servo 3475
4 7D027 Servo cover
5 7D024 Servo cover O-rings (2 required)
6 7H074 Servo retainer
Removal
100-02 .
1.
NOTICE: The servo cover is under pressure from the servo spring. Failure to use a jackstand
can result in damage to the snap ring, servo piston, servo cover or the transaxle case.b>
Using an adjustable jackstand and a suitable tool, support the load of the servo spring and remove the
servo snap ring.
3.
NOTE: Transmission fluid will drain from the transaxle when removing the servo cover.
NOTE: If the servo cover is stuck in the bore, lightly tap on the servo cover to dislodge it from the
bore.
Position a drain pan under the transaxle and slowly lower the jackstand to allow the servo spring to
push the servo cover out of the bore. Remove the servo cover, servo piston and the servo spring from
the transaxle case.
4.
Using a pick, gently scrape the snap ring groove to clean the groove of any loose corrosion or debris. 5.
Servo Kit - 3.5L Engine 3476
Remove the servo spring and the servo piston from the servo cover. 6.
Discard the servo cover. 7.
Remove the O-ring from the piston. 8.
Installation
Install 2 new O-rings on the new servo cover and lubricate them with clean transmission fluid. 1.
Install a new O-ring on the servo piston and lubricate it with clean automatic transmission fluid. 2.
NOTE: The piston will rest on top of the servo.
Position the servo spring on the piston and install the servo piston in the servo cover.
3.
Position the servo in place in the servo bore. 4.
NOTICE: Shake the servo cover when installing the servo to help align it in the bore or damage
to the O-ring can result causing a leak.
NOTICE: Install the snap ring with the bevel facing down or the snap ring can come loose
causing damage to the transaxle.
NOTE: Position the snap ring under the servo cover before positioning the tool used to push the servo
in the transaxle case.
Using a suitable tool and an adjustable jackstand, compress the servo spring. Install the servo and the
snap ring into the transaxle case with the snap ring gap facing the right (engine side) of the transaxle.
5.
Inspect the snap ring to be sure it is fully seated in the snap ring groove. Be sure that the snap ring gap
is facing right.
6.
Slowly fill the transaxle through the transmission fluid level indicator tube with approximately 1.9L
(2 qt) of clean transmission fluid.
8.
9.
the transmission fluid level indicator tube. Do not overfill the transmission fluid. Install the
transmission fluid level indicator back in the transmission fluid filler tube unit is fully seated, then
remove the transmission fluid level indicator. The transmission fluid level should be at the upper most
mark on the transmission fluid level indicator. Only fill to the upper most mark on the transmission
fluid level indicator. Do not overfill. Damage to the transaxle will occur.
11.
12.
13.
Transmission Control Module (TCM)
Removal
100-02 .
1.
Remove the Air Cleaner (ACL) assembly. For additional information, refer to Section 303-12C . 3.
Disconnect the selector lever cable end. 4.
Remove the manual control lever nut. 6.
Remove the manual control lever. 7.
Remove the bolts and remove the TCM . 8.
Transmission Control Module (TCM) 3481
Installation
Verify that the manual lever position markings are aligned. Markings should indicate that the manual
lever is in the OVERDRIVE position.
1.
Install the TCM .
2.
Install the manual control lever. 3.
Install the manual control lever nut.
4.
Connect the TCM electrical connector. 5.
NOTICE: Support the underside of the manual control lever when installing the selector lever
cable or damage to the manual control lever or shaft may occur.
Connect the selector lever cable end.
6.
Install the ACL assembly. For additional information, refer to Section 303-12C . 7.
Carry out the TCM initial learning procedure. For additional information, refer to Transmission
Control Module (TCM) Initial Learning in this section.
9.
Check for correct vehicle operation. 10.
Special Tool(s)
Oil Pan Holding Fixture
303-1295
Material
Item Specification
TA-25
WSK-M2G351-A5
1 W711873 Transaxle insulator through bolt
2 W711872 Transaxle insulator through bolt flagnut
3 W709234 Transaxle insulator-to-frame bolts
4 6F020 Transaxle insulator
Removal
Transaxle Support Insulator 3484
100-02 .
1.
Remove the battery and battery tray. For additional information, refer to Section 414-01 . 2.
Remove the 6 pin-type retainers and the LH front structure-to-subframe splash shield. 4.
Remove the lower 2 transaxle insulator-to-frame bolts. 5.
Remove the exhaust Y-pipe. For additional information, refer to Section 309-00 . 6.
NOTICE: The Oil Pan Holding Fixture must be carefully aligned to the mounting bosses on the
oil pan. Failure to follow these instructions may result in damage to the oil pan.
Position a floor jack and the Oil Pan Holding Fixture under the oil pan.
7.
Remove the Air Cleaner (ACL). For additional information, refer to Section 303-01C . 8.
Remove the upper 2 transaxle insulator-to-frame bolts and remove the transaxle insulator. 10.
Installation
Clean the rear transaxle support insulator bolts using a wire brush and apply new threadlock to the
threads.
1.
Position the transaxle support insulator in place and install the upper 2 transaxle insulator-to-frame
bolts.
2.
Install the transaxle insulator through bolt and flagnut.
3.
Remove the floor jack and the Oil Pan Holding Fixture. 4.
Install the ACL . For additional information, refer to Section 303-01C . 5.
Install the exhaust Y-pipe. For additional information, refer to Section 309-00 . 6.
Position the transaxle support insulator in place and install the lower 2 transaxle insulator-to-frame
bolts.
7.
Position the LH front structure-to-subframe splash shield in place and install the 6 pin-type retainers. 8.
Position the LH splash shield in place and install the 4 screws. 9.
Install the battery and battery tray. For additional information, refer to Section 414-01 . 10.
Manual Control Lever Shaft and Seal
Special Tool(s)
Installer, Shift Shaft Fluid Seal
307-549
Removal
100-02 .
1.
Disconnect the battery ground cabler additional information, refer to Section 414-01 . 2.
Remove the manual control lever nut. 6.
Remove the manual control lever. 7.
Manual Control Lever Shaft and Seal 3489
Remove the bolts and remove the TCM . 8.
Using a suitable pick, remove the manual control lever seal. 9.
Installation
Using the Shift Shaft Fluid Seal Installer, install the manual control lever seal. 1.
Verify that the manual lever position markings are aligned. Markings should indicate that the manual
lever is in the OVERDRIVE position.
2.
Install the TCM .
3.
Install the manual control lever. 4.
Install the manual control lever nut.
5.
Connect the TCM electrical connector. 6.
NOTICE: Support the underside of the manual control lever when installing the selector lever
cable or damage to the manual control lever or shaft may occur.
Connect the selector lever cable end.
7.
Check for correct vehicle operation. 10.
Transaxle
Special Tool(s)
Eye, Engine Lift
303-1245
Bar, Engine Spreader
303-1246
Powertrain Lift With Tilting Plate
300-OTC-1585AE
211-105
Support Bar, Engine
303-F072
NOTE: Refer to the Transmission Cooler Flushing Job Aid on the FMCDealer website.
All vehicles
100-02 .
1.
Remove the Air Cleaner (ACL) and the outlet pipe. For additional information, refer to Section
303-12C .
2.
Remove the starter motor. For additional information, refer to Section 303-06 . 3.
Remove the upper intake manifold. For additional information, refer to Section 303-01C . 4.
Remove the 2 bolts and the nut for the selector lever cable bracket and position the cable and bracket
aside.
6.
Transaxle 3493
Disconnect the wire harness from the Transmission Control Module (TCM). 7.
Disconnect the wiring harness fasteners from the torque converter housing stud bolt and the starter
motor.
8.
Remove the 2 ground strap bolts and position aside the ground straps. 9.
Remove the 4 upper torque converter housing bolts. 10.
Transaxle 3494
Install the Engine Support Bar and Engine Spreader Bar to support the engine. 12.
Using the Engine Support Bar, lower the transaxle and remove the 2 transaxle support insulator
bracket nuts, the bolt and the bracket.
14.
If a transaxle exchange or overhaul is required, the transmission fluid must be drained.
Remove the transmission drain plug and allow the transmission fluid to drain.
15.
If removed, install the transmission fluid drain plug.
16.
Transaxle 3495
Remove the RH intermediate shaft. For additional information, refer to Section 205-04 . 23.
Transaxle 3496
Remove the PTU . For additional information, refer to Section 308-07B . 24.
All vehicles
Remove the 2 roll restrictor bracket bolts.
25.
26.
27.
28.
Remove the 3 power steering return line bolts. 29.
Transaxle 3497
Remove the 3 steering gear mounting bolts. 30.
NOTICE: Use care when handling the steering gear to avoid unseating the steering gear/dash
seal. If the steering gear/dash seal becomes unseated, water and foreign material may enter the
passenger compartment and damage to the vehicle interior can occur.
NOTE: The steering gear is not removed with the front subframe and must be positioned aside.
Position the steering gear aside using mechanic's wire.
31.
Position the Powertrain Lift With Tilting Plate under the subframe assembly. 32.
33.
Remove the 2 rear subframe nuts and the 2 subframe brackets.
34.
Transaxle 3498
35.
Remove and discard the 4 torque converter nuts. 38.
Disconnect the transmission fluid cooler hoses from the transmission fluid cooler tubes. 39.
Support the transaxle with a suitable transmission jack. Secure the transaxle to the transmission jack
with a safety strap.
40.
Remove the 7 torque converter housing bolts and remove the transaxle. 41.
Transaxle 3499
If installing a new transaxle, the transmission fluid cooler will need to be backflushed and cleaned.
Carry out transmission fluid cooler tube backflushing and cleaning. For additional information, refer
to Transmission Fluid Cooler - Backflushing and Cleaning in this section.
42.
Transaxle 3500
SUBASSEMBLIES
Torque Converter Hub Seal
Special Tool(s)
Installer, Fluid Pump Seal
307-548
308-375
Slide Hammer
307-005 (T59L100-B)
Disassembly
Remove the transaxle. For additional information, refer to Transaxle in this section. 1.
Remove the torque converter. 2.
Using the Input Shaft Oil Seal Remover and Slide Hammer, remove the torque converter hub seal. 3.
Assembly
Position the torque converter hub seal in place. 1.
Torque Converter Hub Seal 3501
Using the Fluid Pump Seal Installer, install the torque converter hub seal. 2.
Install the torque converter. 3.
Install the transaxle. For additional information, refer to Transaxle in this section. 4.
Torque Converter Hub Seal 3502
SUBASSEMBLIES
Torque Converter
Disassembly
Remove the transaxle. For additional information, refer to Transaxle in this section. 1.
Remove the torque converter. 2.
Assembly
Install the torque converter. 1.
Install the transaxle. For additional information, refer to Transaxle in this section. 2.
Transaxle
Special Tool(s)
Eye, Engine Lift
303-1245
Bar, Engine Spreader
303-1246
300-OTC-1585AE
Support Bar, Engine
303-F072
Material
Item Specification
Transmission Fluid
XT-8-QAW (US);
WSS-M2C924-A
XG-4 and/or XL-5
ESB-M1C93-B
TA-25
WSK-M2G351-A5
NOTE: If the transaxle was overhauled, or if installing a new transaxle and the transmission fluid cooler has
not been flushed, flush the transmission fluid cooler at this time. For additional information, refer to
Transmission Fluid Cooler - Backflushing and Cleaning in this section.
All vehicles
Secure the transaxle to a suitable transmission jack with a safety strap. 1.
Prior to installing the transaxle, apply multi-purpose grease to the torque converter pilot hub. 2.
Transaxle 3505
Position the transaxle to the back of the engine. 3.
4.
Connect the transmission fluid cooler hoses to the transmission cooler tubes. 5.
Install 4ew torque converter nuts.
6.
Position the inspection cover in place and install the 2 fasteners. 7.
Transaxle 3506
Using the Powertrain Lift With Tilting Plate, raise the subframe into the installed position. 8.
9.
10.
11.
Transaxle 3507
12.
NOTICE: Use care when handling the steering gear to avoid unseating the steering gear/dash
seal. If the steering gear/dash seal becomes unseated, water and foreign material may enter the
passenger compartment and damage to the vehicle interior can occur.
Position the steering gear.
Install the 3 steering gear mounting bolts. 1.
13.
Install the 3 power steering return line bolts.
14.
15.
NOTE: LH shown, RH similar. 16.
Transaxle 3508
Install the 2 roll restrictor bracket bolts.
17.
Install the Power Transfer Unit (PTU). For additional information, refer to Section 308-07B . 18.
Install the RH intermediate shaft. For additional information, refer to Section 205-04 . 20.
All vehicles
Transaxle 3509
Apply threadlock and sealer to the threads and install the transaxle support insulator bracket, the 2
nuts and the bolt.
Tighten the bolt to 80 Nm (59 lb-ft). 1.
Tighten the nuts to 90 Nm (66 lb-ft). 2.
26.
Using the Engine Support Bar, raise the transaxle. Apply threadlock and sealant to the threads and
install the transaxle support insulator through bolt.
27.
Remove the Engine Support Bar and Engine Spreader Bar. 28.
Transaxle 3510
Remove the Engine Lift Eye from the LH cylinder head. 29.
Install the 4 upper transaxle-to-engine bolts.
30.
Position the 2 ground straps in place and install the 2 ground strap bolts.
31.
Connect the wiring harness fasteners on the torque converter housing stud bolt and the starter motor. 32.
Connect the Transmission Control Module (TCM) electrical connector. 33.
Transaxle 3511
Position the selector lever cable bracket in place and install the 2 bolts and the nut.
34.
Connect the selector lever cable end. 35.
38.
Install the upper intake manifold. For additional information, refer to Section 303-01C . 39.
Install the starter. For additional information, refer to Section 303-06 . 40.
Install the Air Cleaner (ACL) and outlet tube. For additional information, refer to Section 303-12C . 41.
Transaxle 3512
Remove the transmission fluid level indicator and make sure that the transaxle has transmission fluid
in it.
42.
43.
NOTE: In order to get an accurate transmission fluid level reading the vehicle should be on a level
the transmission fluid filler tube until it is fully seated, then remove the indicator. The transmission
fluid level should be at the upper most mark on the transmission fluid level indicator. Only fill to the
upper most mark on the transmission fluid level indicator. Do not overfill. Damage to the transaxle
will occur.
46.
47.
If the Transmission Fluid Temperature (TFT) is low, fill the transaxle with transmission flold range
on the transmission fluid level indicator. Recheck the transmission fluid level when the transaxle has
reached the normal operating temperature.
48.
Transaxle 3513
Correction procedure, following the on-screen instructions.
49.
Transaxle 3514
SECTION 307-01B: Automatic
Transaxle/Transmission - 6F35
Workshop Manual
Material
Capacity
164-R3701 (Rotunda)
- -
Motorcraft MERCON LV
XT-10-QLVC
MERCON LV 8.5L (9 qt)
XG-4 and/or XL-5
ESB-M1C93-B -
TA-25
WSK-M2G351-A5 -
TA-29
- -
Item Specification
Transaxle Weight 86 kg (189 lb)
Solenoid Operation Chart
Base Selector
Lever
Position
PCM
Commanded
Gear
Shift Solenoid
TCC
(VFS)
NL
SSA (VFS)
NL (CB
1,2,3,4)
SSB (VFS)
NH (3,5,R)
SSC (VFS)
NL (CB
2,6)
SSD (VFS)
NH (CB
L,R/C 4,5,6)
SSE
(On/Off)
NC
P P Off On Off Off On Off
R R Off Off Off Off On Off
N N Off On Off Off On Off
D 1 On On Off Off
a
On
b
Off
2 On On On On Off Off
3 On Off Off On Off Off
4 On On Off Off Off On/Off
5 Off Off Off Off Off On/Off
6 Off On On Off Off On/Off
L 1 On On Off Off On Off
a
Turns on above 8 km/h (5 mph).
b
Turns off above 8 km/h (5 mph).
CB = Clutch brake
Transaxle 3515
NC = Normally closed
NH = Normally high
NL = Normally low
Clutch Application Chart
Gear
Direct (C
3,5,R)
Overdrive (C
4,5,6)
Forward (CB
1,2,3,4)
Low/ Reverse
(CB L,R)
Inter- mediate
(CB 2,6) One-Way
1st X X
a
X
2nd X X O/R
3rd X X O/R
4th X X O/R
5th X X O/R
6th X X O/R
Reverse X X
a
CB = Clutch brake
O/R = Overrunning
Line Pressure Chart
Gear Line
Pressures at Idle
a
P 338-379 kPa (49-55 psi)
R 621-689 kPa (90-100 psi)
N 338-379 kPa (49-55 psi)
D 338-379 kPa (75-85 psi)
L 338-379 kPa (75-85 psi)
Pressure at Wide Open
Throttle (WOT) Stall
a
P 338-379 kPa (49-55 psi)
R 1,868-2,068 kPa
(271-300 psi)
N 338-379 kPa (49-55 psi)
D 1,868-2,068 kPa
(271-300 psi)
Transaxle 3516
L 1,868-2,068 kPa
(271-300 psi)
a
All pressures are approximate.
Stall Speed Chart
Selector Lever Engine rpm
Drive 2.5 2,200-2,300
Drive 3.0 2,400-2,500
Gear Ratio Chart
Gear Ratio
1st/low 4.584:1
2nd 2.964:1
3rd 1.912:1
4th 1.446:1
5th 1:1
6th 0.746:1
Reverse 2.94:1
Shift Speeds 2.5L
Throttle Position Range Shift KM/H MPH
Light D 1-2 11-16 7-10
Throttle
a
D 2-3 21-27 13-17
D 3-4 29-37 18-23
D 4-5 45-56 28-35
D 5-6 72-90 45-56
Medium D 1-2 27-43 17-23
Throttle
a
D 2-3 42-55 26-34
D 3-4 58-77 36-48
D 4-5 77-106 48-66
D 5-6 135-177 84-110
Heavy D 1-2 51-66 32-41
Throttle
a
D 2-3 79-100 49-62
D 3-4 113-143 70-89
D 4-5 150-190 93-118
D 5-6 201-245 125-152
Transaxle 3517
a
Do not exceed the speed limit.
Shift Speeds 3.0L
Light D 1-2 13-18 8-11
Throttle
a
D 2-3 19-26 12-16
D 3-4 29-37 18-23
D 4-5 45-56 28-35
D 5-6 72-90 45-56
Medium D 1-2 32-42 20-26
Throttle
a
D 2-3 48-61 30-38
D 3-4 63-82 39-51
D 4-5 80-108 50-67
D 5-6 117-159 73-99
Heavy D 1-2 58-72 36-45
Throttle
a
D 2-3 85-106 53-66
D 3-4 126-156 78-97
D 4-5 151-192 94-119
D 5-6 217-261 135-162
a
Battery Junction Box (BJB) support bracket 10 - 89
Clutch support tower bolts 12 - 106
EGR valve bracket bolts 10 - 89
Electronic Power Assist Steering (EPAS) ground bolt 12 - 106
Line pressure tap plug 12 - 106
Lube funnel hold-down bracket bolts 12 - 106
Main control cover bolts/stud bolts 12 - 106
Manual control lever nut 24 18 -
Main control stud nut
a
- - -
Main control-to-case stud 10 - 89
Main control valve body bolts
a
- -
Output Shaft Speed (OSS) sensor bolt 10 - 89
Pump assembly-to-torque converter housing bolts 35 26 -
RH exhaust manifold heat shield bolts 11 - 97
Roll restrictor bolts 90 66 -
Selector lever cable bracket nuts 12 - 106
Transaxle 3518
Separator plate bolts 10 - 89
Solenoid body bolts 10 - 89
Solenoid body-to-valve body bolts 10 - 89
20 - 177
Torque converter housing bolts 48 35 -
Transaxle case-to-torque converter housing bolts 24 18 -
Transaxle support insulator bolts 62 46 -
Transaxle support insulator bracket bolt 63 46 -
Transaxle support insulator bracket nuts 63 46 -
Transaxle support insulator through bolt 150 111 -
Transmissio 12 - 106
Transmission fluid cooler tube bracket nuts 9 - 80
Transmission fluid drain plug 12 - 106
Transmission fluid filler tube nut 11 - 97
Transmission Range (TR) sensor detent spring bolt 13 - 115
Turbine Shaft Speed (TSS) sensor bolt 10 - 89
a
Transaxle 3519
Workshop Manual
This automatic transaxle is a 6-speed transaxle with electronic shift control. It is designed for operation in a
transverse powertrain for Front Wheel Drive (FWD) and All-Wheel Drive (AWD) vehicles.
This transaxle has a 4-element torque converter design, which includes a Torque Converter Clutch (TCC) and
a geartrain with 3 planetary gearsets.
The hydraulic control system of this transaxle uses 7 electronically controlled solenoids for:
Shift feel (through line pressure control and shift pressure control)
Shift scheduling and timing
TCC operation
p;
Workshop Manual
Identification Tags
Identification Tag Location
1 7G342 Solenoid body identification tag
2 7B148 Transaxle identification tag
Transaxle Identification Tag
Description
1 Transaxle part number
2 Bar code 1
3 Assembly plant line shift
4 Transaxle build date (DDMMYY)
5 Transaxle serial number
6 Bar code 2
When servicing the transaxle, use the transaxle identification tag located on top of the transaxle case.
Identification Tags 3521
Original Solenoid Body Tag
Item Description
1 Thirteen-digit solenoid body strategy
2 Seven-digit solenoid body identification
The solenoid body strategy is a file that is programmed into the PCM to control the shift, Line Pressure
Control (LPC) and Torque Converter Clutch (TCC) solenoids to prevent harsh shifts. The solenoid body tag
on the transaxle case contains the 13-digit solenoid body strategy and the 7-digit solenoid body identification.
Replacement Solenoid Body Tag
Item Description
Any time a new solenoid body is installed, a new solenoid body strategy file is downloaded into the PCM
using the scan tool. A replacement solenoid body tag is supplied with the new solenoid body which contains
the 13-digit solenoid body strategy and the 7-digit solenoid body identification. The new tag is placed over the
original solenoid body tag.
Solenoid Body Identification and Strategy
Original Solenoid Body Tag 3522
Item Description
If the solenoid body strategy printed on the solenoid body connector does not match the solenoid body tag, a
new solenoid body must be installed and the solenoid body strategy must be downloaded into the PCM or
harsh shifts will result.
Solenoid Band Number
The solenoids are calibrated from the factory and are not all the same. The solenoids can be replaced
separately, but only with a replacement solenoid with a band that matches the solenoid being replaced. When
solenoid(s) are replaced, the new solenoid band number must match the old solenoid band number. The band
number is the last digit of the number stamped on the side of the solenoid and will be a 1, 2, 3, 4 or 5.
Solenoid Body Identification and Strategy 3523
Solenoid Band Number 3524
Workshop Manual
Major Components
This transaxle has the following major components:
Case with torque converter housing
Two drive clutches:
Direct clutch
Overdrive (O/D) clutch

Four brake clutches:
Forward clutch
Low one-way clutch
Low/reverse clutch
Intermediate clutch

Three planetary gearsets:
Front
Center
Rear

Drive chain and sprockets
Final drive planetary gearset and differential assembly
Pump and filter assembly
Main control:
Valve body assembly
Solenoid body assembly

Major Component Cutaway View
Major Components 3525
Major Component Exploded View
1 7G391 Solenoid body
2 7A100 Valve body
3 7B164 Forward clutch (clutch brake 1, 2, 3, 4)
4 7B164 Low/reverse clutch (clutch brake low/reverse)
5 7B164 Intermediate clutch (clutch brake 2, 6)
6 7A089 Low One-Way Clutch (OWC)
7 7B164 Direct clutch (drive clutch 3, 5, R)
8 7B164 Overdrive (O/D) clutch (drive clutch 4, 5, 6)
9 7D491 Rear planetary assembly
10 7D491 Center planetary assembly
11 7D491 Front planetary assembly
12 7F465 Final drive carrier and differential assembly
13 7G132 Drive chain driven sprocket
14 7G384 Input shaft assembly and direct/overdrive clutch hub
15 7A103 Pump assembly
17 7G132 Drive chain drive sprocket
18 7G249 Drive chain
19 7060 Park gear
20 7A441 Park pawl
Major Component Exploded View 3526
Major Component Exploded View 3527
Workshop Manual
Gear Ratios
This transaxle has 6 forward speeds and reverse.
Gear Ratio Chart
Gear Ratio
1st/low 4.584:1
2nd 2.964:1
3rd 1.912:1
4th 1.446:1
5th 1:1
6th 0.746:1
Reverse 2.94:1
Gear Ratios 3528
Workshop Manual
Torque Converter
The torque converter transmits and multiplies torque. The torque converter is a 4-element device:
Impeller and cover assembly
Turbine
Reactor
Clutch and damper assembly
Rotation of the torque converter housing and impeller set the transmission fluid in motion by driving the
impeller blades and pump.
The turbine is driven by the transmission fluid from the impeller and transmits power to the input shaft.
The reactor redirects transmission fluid flow returned from the turbine to the impeller so that it rotates in the
same direction as the impeller. This action assists in torque multiplication.
The reactor has a One-Way Clutch (OWC) to hold it stationary during torque multiplication and allows it to
rotate at higher vehicle speeds.
Torque Converter Operation
Item Description
1 Torque Converter Clutch (TCC)
2 Reactor
3 Turbine
4 Impeller and cover assembly
5 One-Way Clutch (OWC)
6 Fluid motion
7 Input shaft rotation
8 Input shaft
9 Engine rotation
The Torque Converter Clutch (TCC) connects the torque converter housing to the damper when the TCC is
applied.
During TCC release, the direction that the transmission fluid flows through the torque converter allows the
TCC to release. During TCC apply, the transmission fluid flows in the opposite direction to apply the TCC .
The PCM controls TCC operation using the TCC solenoid in the solenoid body. TCC solenoid operation
provides the modulation of hydraulic pressure to change the position of the TCC control valve and TCC
regulator apply valve which changes the pressure and transmission fluid direction in the torque converter.
The TCC can be applied in 3rd, 4th, 5th and 6th gears.
Torque Converter Internal Component Exploded View
Item Description
1 Impeller and cover assembly
2 Torque Converter Clutch (TCC) and damper assembly
3 Turbine
4 Reactor
5 One-Way Clutch (OWC)
6 Thrust bearings
Torque Converter Operation 3530
Torque Converter Internal Component Exploded View 3531
Workshop Manual
Shift Patterns
Upshifts
Upshifting is controlled by the PCM. The PCM receives inputs from various engine or vehicle sensors and
driver demands to control shift scheduling, shift feel and Torque Converter Clutch (TCC) operation.
The PCM has an adaptive learn strategy to electronically control the transaxle which will automatically adjust
the shift feel through the life of the vehicle. The first few hundred miles of operation of the transaxle may
have abrupt shifting. This is a normal operation. To reset the adaptive shift pressure strategy, use the scan tool
to clear the transmission keep alive memory tables.
Downshifts
Under certain conditions, the transaxle will downshift automatically to a lower gear range (without moving
the selector lever). There are 3 categories of automatic downshifts: coastdown, torque demand and forced or
kickdown shifts.
Coastdown
The coastdown downshift occurs when the vehicle is ting down to a stop.
Torque Demand
The torque demand downshift occurs (automatically) during part throttle acceleration when the demand for
torque is greater than the engine can provide at that gear ratio. If applied, the transmission will disengage the
TCC to provide added acceleration.
Kickdown
For maximum acceleration, the driver can force a downshift by pressing the accelerator pedal to the floor. A
forced downshift into a lower gear is possible below calibrated speeds. Specifications for downshift speeds are
subject to variations due to tire size, engine and transaxle calibration requirements.
Shift Patterns 3532
Shift Patterns 3533
Workshop Manual
Mechanical Components and Functions
Planetary Gearset
This transaxle has 3 planetary gearsets to provide operation in reverse and 6 forward speeds.
The gearsets are comprised of the following components:
Front planetary sun gear (part of the front sun gear and shell assembly)
Front planetary carrier
Front planetary ring gear
Center planetary sun gear
Center planetary carrier
Center planetary ring gear
Rear planetary ring gear
Rear planetary carrier
Rear planetary sun gear and shell assembly
The front planetary sun gear is splined to the forward (1, 2, 3, 4) clutch and is held stationary in 1st, 2nd, 3rd
and 4th gears.
The front planetary carrier is splined to the rear planetary ring gear and transfers power from the rear
planetary gearset to the front planetary gearset in 2nd, 3rd, 5th and 6th gears and reverse. The front planetary
carrier is splined to the drive chain drive sprocket. The front planetarrrier is the output component for the
planetary gearset.
The front planetary ring gear is splined to the center planetary carrier and transfers power from the center
planetary gearset to the front planetary gearset in 1st, 2nd, 3rd and 4th gears.
The center planetary sun gear is splined to the input shaft and is used as input to the planetary gearsets in 1st,
2nd, 3rd and 4th gear.
The center planetary ring gear is splined to the rear planetary carrier and transfers power from the center
planetary gearset to the rear planetary gearset in 3rd gear, from the rear planetary gearset to the center
planetary gearset in 4th gear and is held stationary by the low One-Way Clutch (OWC) and low/reverse clutch
in 1st gear and reverse.
The rear planetary carrier is splined to the Overdrive (O/D) (4, 5, 6) clutch hub and transfers power from the
input shaft to the rear planetary carrier in 4th, 5th and 6th gears.
The rear planetary sun gear and shell assembly is splined to both the intermediate (2, 6) clutch and the direct
(3, 5, R) clutch. The rear planetary sun gear and shell assembly is held stationary by the intermediate (2, 6)
clutch in 2nd and 6th gear and is driven by the direct (3, 5, R) clutch in 3rd and 5th gears and reverse.
Planetary Gearset Cutaway View
Mechanical Components and Functions 3534
Planetary Gearset Exploded View
1 7A019 Front planetary sun gear and shell assembly
2 7D491 Front planetary carrier/rear planetary ring gear
assembly
3 7D063 Gear - center planetary sun
4 7D491 Center planetary carrier/front ring gear assembly
5 7D491 Rear planetary carrier/center ring gear assembly
6 7A019 Rear planetary sun gear and shell assembly
Input Shaft
The input shaft is part of the direct/ O/D clutch assembly and is splined to the torque converter turbine and the
center planetary sun gear. The input shaft transfers power from the torque converter to the rear planetary
gearset through the center planetary sun gear and the direct (3, 5, R) and O/D (4, 5, 6) clutches.
Input Shaft Cutaway View
Planetary Gearset Cutaway View 3535
Input Shaft Exploded View
1 7G384 Direct (3, 5, R)/ Overdrive (O/D) (4, 5, 6) clutch hub
2 7F213 Input shaft
3 7B164 Direct (3, 5, R) clutch
4 7B164 O/D (4, 5, 6) clutch
5 7D491 Center planetary sun gear
Front Planetary Carrier Hub (Output Hub)
The front planetary carrier hub/park gear is splined to the front planetary carrier and the drive chain drive
sprocket. This allows torque to be transferred from the planetary gearset to the final drive gearset.
Front Planetary Carrier Hub Cutaway View
Input Shaft Cutaway View 3536
Front Planetary Carrier Hub Exploded View
1 7D491 Front planetary carrier
2 7060 Front planetary carrier hub/park gear
Final Drive Chain, Sprockets and Planetary Gearset
The final drive consists of a drive chain and sprockets and a planetary gearset and differential assembly. The
drive chain and sprockets transfer torque from the front planetary carrier hub to the differential assembly that
has a planetary gearset integrated into it for final drive torque multiplication.
The final drive consists of the following components:
Drive sprocket
Drive chain
Driven sprocket
Final drive sun gear
Final drive ring gear
Final drive planetary carrier and differential assembly
Front Planetary Carrier Hub Cutaway View 3537
Final Drive Component Cutaway View
Final Drive Component Exploded View
2 7G249 Drive chain
4 7F342 Final drive planetary sun gear
5 7F465 Differential assembly
6 7F343 Final drive planetary ring gear
7 7975 Torque converter housing
Differential
The differential allows the halfshafts and wheels to rotate at different speeds during cornering and transfers
power to the Power Transfer Unit (PTU) for All-Wheel Drive (AWD) vehicles.
The differential assembly consists of the following components:
Differential case (part of the final drive carrier)
Final Drive Component Cutaway View 3538
Two pinion gears supported by a pinion shaft
Two side gears supported by the differential case and halfshafts
When driving in a straight line, both front wheels rotate at relatively the same speed. This means both side
gears are rotating at the same speed, as well, while both pinion gears revolve (but do not rotate) with the side
gears. During cornering, the wheel on the outside of the turn is forced to rotate faster than the wheel on the
inside of the turn. Since the side gears must now rotate at different speeds, the pinion gears rotate on the
pinion shaft allowing the drive axles to rotate at different speeds while still transferring output torque.
Differential Cutaway View
Differential Exploded View
1 7F465 Differential housing
2 - Pinion shaft
3 - Pinion gears
4 - Side gears
Direct (3, 5, R) Clutch
The direct clutch is a drive clutch that transfers power from the direct/ O/D clutch hub assembly to the rear
planetary sun gear and shell assembly. The direct clutch is applied in 3rd and 5th gears and reverse.
Hydraulic pressure from the regulator valve in the valve body pushes the direct clutch piston against the direct
clutch pack to apply the clutch. The input shaft and direct/ O/D clutch hub assembly transfers torque to the
rear planetary sun gear and shell assembly as a result of the clutch being applied.
Final Drive Component Exploded View 3539
Direct (3, 5, R) Clutch Cutaway View
Direct (3, 5, R) Clutch Exploded View
1 7C122 Direct clutch cylinder snap ring
2 7F283 Direct clutch cylinder
3 7A262 Direct clutch piston
4 7F235 Direct clutch piston return spring
5 7C099 Direct clutch piston seals
6 7G384 Direct/Overdrive (O/D) clutch hub
7 7F213 Input shaft
8 7B070 Direct clutch wave spring
9 7B164 Direct (3, 5, R) clutch assembly
10 7B066 Direct clutch pressure plate
11 7D483 Direct clutch snap ring
Overdrive (O/D) (4, 5, 6) Clutch
Direct (3, 5, R) Clutch Cutaway View 3540
The O/D clutch is a drive clutch that transfers power from the direct/ O/D clutch hub assembly to the rear
planetary carrier. The O/D clutch is applied in 4th, 5th and 6th gears.
Hydraulic pressure from the regulator valve in the valve body pushes the O/D clutch piston against the O/D
clutch pack to apply the clutch. The input shaft and direct/ O/D clutch hub assembly transfers torque to the
rear planetary carrier as a result of the clutch being applied.
Overdrive (O/D) (4, 5, 6) Clutch Cutaway View
Overdrive (O/D) (4, 5, 6) Clutch Exploded View
1 7G384 Direct/Overdrive (O/D) clutch hub assembly
2 7A548 O/D clutch piston inner seal
3 7F213 Input shaft
4 7A548 O/D clutch piston outer seals
5 7A262 O/D clutch piston
6 7F222 O/D clutch piston return spring
7 7H360 O/D clutch balance piston
8 7C122 O/D clutch balance piston snap ring
Direct (3, 5, R) Clutch Exploded View 3541
9 7B164 O/D (4, 5, 6) clutch assembly
10 7B066 O/D clutch pressure plate
11 7D483 O/D clutch snap ring
12 7H351 O/D clutch hub
13 7D491 Rear planetary carrier
Forward (1, 2, 3, 4) Clutch
The forward clutch is a brake clutch that holds the front sun gear and shell assembly. The forward clutch is
applied in 1st, 2nd, 3rd and 4th gears.
Hydraulic pressure from the regulator valve in the valve body pushes the forward clutch piston against the
forward clutch pack to apply the clutch. The front sun gear and shell assembly is held stationary to the
transaxle case as a result of the clutch being applied.
Forward (1, 2, 3, 4) Clutch Cutaway View
Forward (1, 2, 3, 4) Clutch Exploded View
1 7005 Transaxle case
Overdrive (O/D) (4, 5, 6) Clutch Exploded View 3542
2 7L328 Center support
3 7A262 Forward clutch piston
4 7B070 Forward clutch piston return spring
5 7H365 Forward clutch piston return spring snap ring
6 7B070 Forward clutch wave spring
7 7B164 Forward (1, 2, 3, 4) clutch
8 7B066 Forward clutch pressure plate
9 7D483 Forward clutch snap ring
10 7A019 Front sun gear and shell assembly
Low/Reverse Clutch
The low/reverse clutch is a brake clutch that holds the low OWC which is splined to the rear planetary carrier.
The low/reverse clutch is applied in manual LOW, REVERSE and 1st gear up to 8 km/h (5 mph).
Hydraulic pressure from the regulator valve in the valve body pushes the low/reverse clutch piston against the
low/reverse clutch pack to apply the clutch. The rear planetary carrier is held stationary to the transaxle case
as a result of the clutch being applied.
Low/Reverse Clutch Cutaway View
Low/Reverse Clutch Exploded View
Forward (1, 2, 3, 4) Clutch Exploded View 3543
4 7B066 Low/reverse clutch pressure plate
5 7B164 Low/reverse clutch
6 7E085 Low/reverse clutch wave spring
7 7C122 Low/reverse clutch piston return spring snap ring
8 7B070 Low/reverse clutch piston return spring
9 7D402 Low/reverse clutch piston
Intermediate (2, 6) Clutch
The intermediate clutch is a brake clutch that holds the rear planetary sun gear and shell assembly. The
intermediate clutch is applied in 2nd and 6th gears.
Hydraulic pressure from the regulator valve in the valve body pushes the intermediate clutch piston against
the intermediate clutch pack to apply the clutch. The low OWC works as a pressure plate for the intermediate
(2, 6) clutch. The rear planetary sun gear and shell assembly is held stationary to the transaxle case as a result
of the clutch being applied.
Intermediate (2, 6) Clutch Cutaway View
Low/Reverse Clutch Exploded View 3544
Intermediate (2, 6) Clutch Exploded View
2 7E005 Intermediate clutch piston
3 7B070 Intermediate clutch piston return spring
4 7D483 Intermediate clutch piston return spring snap ring
5 7E005 Intermediate clutch apply ring
7 7E085 Intermediate clutch wave spring
8 7B164 Intermediate clutch assembly
9 7A089 Low/One-Way Clutch (OWC)
Low One-Way Clutch (OWC)
The low OWC is a brake clutch that holds the rear planetary carrier in one direction and allows it to freewheel
in the opposite direction which eliminates engine braking in 1st gear when the transaxle is in DRIVE. The low
OWC is also the pressure plate for the intermediate (2, 6) clutch.
Intermediate (2, 6) Clutch Cutaway View 3545
Low One-Way Clutch (OWC) Cutaway View
Low One-Way Clutch (OWC) Exploded View
External Sealing
The torque converter housing has a lip-type seal that seals the torque converter hub. The pump assembly seals
to the torque converter housing with a rubber seal. The manual shaft and halfshafts also use lip-type seals.
All-Wheel Drive (AWD) vehicles do not use a RH halfshaft seal, the transaxle is sealed by the Power Transfer
Unit (PTU) on the RH side.
The torque converter housing is sealed to the transaxle case with silicone sealant.
The main control cover is sealed to the transaxle case with silicone sealant and seals to the solenoid body with
a reusable rubber gasket. The Turbine Shaft Speed (TSS) sensor is sealed to the transaxle case with an O-ring
seal.
The line pressure tap plug and transmission fluid drain plug have pipe threads and seal when tightened to
specification.
Low One-Way Clutch (OWC) Cutaway View 3546
The transmission fluid filler tube is sealed to the torque converter housing with an O-ring seal.
External Sealing Exploded View
2 7A248 Torque converter hub seal
5 7A248 Pump assembly-to-torque converter housing O-ring
seal
6 7F337 Manual control shaft seal
7 1177 RH halfshaft seal
8 1177 LH halfshaft seal
11 - TSS sensor O-ring seal
12 7G004 Main control cover
13 7B329 Main control-to-cover seal
14 7H398 Line pressure tap plug
15 7010 Drain plug
16 7A228 Transmission fluid filler tube
17 391308 Transmission fluid filler tube O-ring seal
Bearing and Thrust Washer Locations
Low One-Way Clutch (OWC) Exploded View 3547
1 7F242 No. 1 thrust bearing
2 7D234 No. 2 thrust bearing
4 7G177 No. 5 thrust bearing
5 7C096 No. 6 thrust bearing
7 7C096 . 8 thrust bearing
11 7G099 No. 13 thrust washer
The No. 4 thrust bearing is part of the rear planetary carrier assembly. The No. 9 thrust bearing is part of the
front planetary carrier assembly. The No. 14 thrust bearing is part of the differential assembly.
Lubrication
Transmission fluid enters the lubrication circuits after flowing through the transmission fluid cooler. The
transmission fluid cooler is mounted at the front of the vehicle. When the transmission fluid is not up to
operating temperature, an internal thermal bypass valve allows the transmission fluid to bypass the
transmission fluid cooler. When the transmission fluid circulates through the transmission fluid cooler, the
transmission fluid returns to the transaxle from the transmission fluid cooler tubes through the back
transmission fluid cooler tube.
The transmission fluid enters main lubrication circuit through the transaxle case and flows through passages in
the input shaft to lubricate the transaxle.
External Sealing Exploded View 3548
The transmission fluid in the input shaft circuit flows from the back of the input shaft toward the front of the
input shaft and passes through ports in the input shaft to lubricate the planetary gearset, clutches, final drive
assembly and other components of the transaxle.
1 7D273 Transmission fluid cooler return tube fitting
2 7H322 Thermal bypass valve assembly
Lubrication Passages
Park
The park gear is splined to the front planetary carrier and the drive chain drive sprocket. There are lugs around
the outer diameter of the park gear to allow the park pawl to hold the park gear stationary to the transaxle case
which holds the final drive assembly in place and keeps the vehicle from moving.
Lubrication Passages 3549
When the manual control lever is rotated to the PARK position, the park lock works as follows:
The Transmission Range (TR) sensor rotates the range detent plate which pushes the park pawl
actuator rod towards the park pawl.

The actuator rod pivots the park pawl into the lugs on the park gear, locking the gear stationary to the
transaxle case.

Park Component Exploded View
1 W714437 Transmission Range (TR) sensor detent spring bolt
2 7E332 TR sensor detent spring
3 7G100 Manual shaft-to- TR sensor pin
4 7A232 Park pawl actuator rod
5 7H557 TR sensor
6 7C493 Manual shaft
7 7A256 Manual lever
8 7F337 Manual shaft seal
9 W302864 Manual lever nut
10 7A441 Park pawl
11 7D071 Park pawl pin
12 7D070 Park pawl spring
14 7090 Park gear
16 7C122 Drive sprocket snap ring
Park Component Exploded View 3550
20 7F342 Final drive planetary gearset sun gear
21 7F465 Final drive planetary carrier/differential assembly
22 7C122 Final drive planetary ring gear snap ring
23 7F343 Final drive planetary ring gear
Park Component Exploded View 3551
Workshop Manual
Hydraulic System
The transmission fluid in the sump area at the bottom of the transaxle case flows through a transmission fluid
filter to the pump assembly. The pump is bolted to the torque converter housing and is driven by the torque
converter hub.
Fluid Pump and Transmission Fluid Filter Components
3 7A098 Transmission fluid filter
4
5 W302860 Pump-to-torque converter housing bolt
Transmission Fluid Level
The transmission fluid level is checked with the transaxle at normal operating temperature between 85C and
93C (185F and 200F).
The transmission fluid level indicator is part of the transmission fluid filler tube located at the back of the
torque converter housing.
The correct transmission fluid level is between the minimum and maximum marks on the transmission fluid
level indicator.
Transmission Fluid Level Indicator
Hydraulic System 3552
Item
Part
Number Description
1 7A020 Transmission fluid level indicator
2 7A228 Transaxle filler tube
3 - Correct transmission fluid level at normal operating
temperature 85C-93C (185F-200F)
4 - Minimum transmission fluid level mark
5 - Maximum transmission fluid level mark
6 - Flat tow transmission fluid level
Main Control
The hydraulic system has a main contromain control assembly consists of a valve body and a solenoid body.
Both the valve body and the solenoid body contain hydraulic shift valves. The solenoid body contains the shift
solenoids that control the hydraulic valves. The solenoid body can be serviced as an assembly with the
solenoids or the solenoids can be serviced individually. The solenoid body is controlled by the PCM. The
PCM has software stored in it specific to the solenoid body currently in the transaxle, called the solenoid body
strategy. A new solenoid body strategy must be downloaded into the PCM anytime a new solenoid body is
installed.
The pump assembly contains the main pressure regulator valve assembly and the Torque Converter Clutch
(TCC) control valve assembly.
Main Control Components
Transmission Fluid Level Indicator 3553
4 7Z490 Main control-to-transaxle case separator plate
5 7A100 Valve body
6 7E195 Check balls
7 7J191 Solenoid damper (Shift Solenoid A (SSA))
8 7G391 Solenoid body assembly
1 7C389 Manual valve
2 7G473 Solenoid pressure regulator valve assembly
3 7G179 Clutch bypass valve
4 7G307 Torque Converter Clutch (TCC) regulator valve
5 7B200 Control pressure regulator
6 7D102 Direct (3, 5, R) clutch regulator valve
Main Control Components 3554
7 7D102 Intermediate (2, 6) clutch regulator valve
8 7D102 Forward (1, 2, 3, 4) clutch regulator valve
9 7J187 Forward (1, 2, 3, 4) clutch latch valve
10 7D102 Low reverse/overdrive (4, 5, 6) clutch regulator valve
11 7A100 Valve body
Solenoid Body
1 7Z490 Main control valve body-to-solenoid body separator
plate
3 7G276 Solenoid body leadframe
4 7J187 Direct (3, 5, R) clutch latch valve
5 7J187 Intermediate (2, 6) clutch latch valve
6 7J187 Low reverse/overdrive (4, 5, 6) clutch latch valve
7 7G383 Line Pressure Control (LPC) solenoid
8 7G136 Shift Solenoid C (SSC)
9 7G136 Torque Converter Clutch (TCC)
10 7G484 ON/OFF solenoid
11 7G136 Shift Solenoid A (SSA)
12 7G383 Shift Solenoid B (SSB)
13 7G383 Shift Solenoid D (SSD)
Pump Assembly
2 - Main pressure regulator valve assembly
3 - Torque Converter Clutch (TCC) control valve
assembly
Pump Assembly 3556
Workshop Manual
Hydraulic Circuits
Hydraulic Circuit Identification and Function
Hydraulic Circuit Identification Chart
Circuit Name Description
BYPASS Pressure from the main pressure regulator valve to the pump assembly suction circuit for line
pressure control.
C1234 Regulated line pressure from the 1234 regulator valve supplied to the forward (1, 2, 3, 4)
clutch to apply the clutch.
C1234 FDBK C1234 pressure from the 1234 latch valve supplied to the 1234 regulator valve to oppose
movement of the valve from VBS C1234 pressure during forward (1, 2, 3, 4) clutch
application.
C35R Regulated line pressure from the 35R regulator valve supplied to the direct (3, 5, R) clutch to
apply the clutch.
C35R FD Line pressure from the REVERSE circuit supplied to the DRIVE 2/C35R FD shuttle valve by
the clutch control bypass valve to supply the 35R regulator valve with line pressure in
reverse.
C35R FDBK C35R pressure from the 35R latch valve supplied to the 35R regulator valve to oppose
movement of the valve from VBS C35R pressure during direct (3, 5, R) clutch application.
C456 Regulated line pressure from the low reverse/456 regulator valve directed to the Overdrive
(O/D) (4, 5, 6) clutch by the clutch control bypass valve. C456 also provides latch pressure
for the clutch control bypass valve.
CB26 Regulated line pressure from the 26 regulator valve to the intermediate (2, 6) clutch to apply
the clutch in 2nd and 6th gears.
CB26 FDBK CB26 pressure from the 26 latch valve supplied to the 26 regulator valve to oppose
movement of the valve from VBS C26 pressure during intermediate (2, 6) clutch application.
CBR1 Regulated line pressure from the low reverse/456 regulator valve directed to the low/reverse
clutch by the clutch control bypass valve.
CBR1/C456
Hydraulic Circuits 3557
Regulated line pressure from the low reverse/456 regulator valve to the clutch control bypass
valve.
CBR1/C456
FDBK
CBR1/C456 pressure from the low reverse/456 latch valve supplied to the low reverse/456
regulator valve to oppose movement of the valve from VBS CBR1/456 pressure during
low/reverse or O/D (4, 5, 6) clutch application.
COMP FD Pressure supplied to the opposite side of the O/D (4, 5, 6) and direct (3, 5, R) clutch apply
pistons to oppose centrifugal application of the clutches.
CONV FD Line pressure from the main pressure regulator valve supplied to the Torque Converter
Clutch (TCC) control valve for TCC release.
COOLER FD Return pressure from the torque converter during TCC release that is directed to the
transmission fluid cooler by the TCC control valve.
DRIVE Line pressure directed to the clutch control bypass valve, 1234 regulator valve and the 26
regulator valve by the manual valve in the DRIVE position.
DRIVE 2 DRIVE pressure directed to the TCC regulator valve and the DRIVE 2/C35R FD shuttle
valve by the clutch control bypass valve to supply the 35R regulator valve with line pressure
in 3rd and 5th gears.
DRIVE
2/C35R FD
DRIVE 2 or C35R FD pressure supplied to the 35R regulator valve from the DRIVE 2/C35R
FD shuttle valve during direct (3, 5, R) clutch application.
EXH Fluid exhausted from the valves that drains to the sump area.
EXH BF Unpressurized fluid from the manual valve that fills the unused hydraulic circuits.
LINE Pressure from the pump to the control pressure regulator, solenoid regulator valve, manual
valve and low reverse/456 regulator valve. Line pressure is regulated by the main pressure
regulator valve.
LUBE Transaxle lubrication circuit (through the input shaft)
ON/OFF SIG Full solenoid output pressure from Shift Solenoid E (SSE) to the clutch control bypass valve
and the TCC regulator valve. ON/OFF SIG pressure positions the clutch control bypass valve
to apply either the low/reverse clutch or the O/D (4, 5, 6) clutch.
REG APPLY Regulated DRIVE 2 pressure supplied to the TCC control valve by the control pressure
regulator for TCC application.
REVERSE Line pressure directed to the clutch control bypass valve by the manual valve in the
REVERSE position.
SOL FD Regulated line pressure supplied to the shift, TCC and Line Pressure Control (LPC)
solenoids.
TCC APPLY Pressure supplied to the torque converter by the TCC control valve to apply the clutch. TCC
APPLY is also the return circuit for the TCC RELEASE circuit.
TCC
RELEASE
Pressure supplied to the torque converter by the TCC control valve to release the clutch. TCC
RELEASE is also the return circuit for the TCC APPLY circuit.
VBS C1234 Variable SOL FD pressure supplied to the 1234 regulator valve and 1234 latch valve by Shift
Solenoid A (SSA) to position the valves to apply the forward (1, 2, 3, 4) clutch.
VBS C35R Variable SOL FD pressure supplied to the 35R regulator valve and 35R latch valve by Shift
Solenoid B (SSB) to position the valves to apply the direct (3, 5, R) clutch.
VBS CB26 Variable SOL FD pressure supplied to the 26 regulator valve and 26 latch valve by Shift
Solenoid C (SSC) to position the valves to apply the intermediate (2, 6) clutch.
VBS
CBR1/456
Variable SOL FD pressure supplied to the low reverse/456 regulator valve and low
reverse/456 latch valve by Shift Solenoid D (SSD) to position the valves to apply the
low/reverse clutch or O/D (4, 5, 6) clutch.
VBS LINE Variable SOL FD pressure supplied to the main pressure regulator valve by the LPC solenoid
to control line pressure.
VBS TCC
Variable SOL FD pressure supplied to the TCC regulator valve and TCC control valve to
position the valves by the TCC solenoid to apply the TCC .
Line Pressure Hydraulic Circuits
Line pressure is controlled by the Line Pressure Control (LPC) solenoid, which is controlled by the PCM.
This effects shift feel and apply component operation.
When the engine is running, the pump supplies pressure to the main pressure regulator valve, which is
controlled by the LPC solenoid. The main pressure regulator valve controls the line pressure to the LINE
circuit which supplies the manual valve solenoid regulator valve and the control pressure regulator valve.
When the manual valve is in the reverse position, it supplies the clutch control bypass valve with line pressure
to position it to supply line pressure to the direct (3, 5, R) regulator valve and regulated line pressure to the
low/reverse clutch to apply the clutch.
When the manual valve is in the DRIVE or LOW positions, it directs line pressure from the LINE circuit to
the DRIVE circuit to supply line pressure to the:
Clutch control bypass valve
Forward (1, 2, 3, 4) regulator valve
Intermediate (2, 6) regulator valve
Torque Converter Clutch (TCC) regulator valve
Direct (3, 5, R) clutch regulator valve
Torque Converter Clutch (TCC) And Lubrication Hydraulic Circuits
Pressure for TCC release is supplied by the main pressure regulator valve to the TCC control valve through
the CONV FD circuit. The CONV FD circuit also supplies lubrication for the differential. When the TCC is
released, the TCC control valve is positioned by the TCC solenoid to direct CONV FD pressure to the TCC
RELEASE circuit to release the TCC . TCC RELEASE pressure returns to the TCC control valve through the
TCC APPLY circuit. The position of the TCC control valve opens the TCC APPLY circuit to the COOLER
FD circuit which allows the transmission fluid returned from the torque converter to cycle through the thermal
bypass valve circuit when the Transmission Fluid Temperature (TFT) is below 80C-93C (176F-200F) or
the transmission fluid cooler when the temperature is above 80C-93C (176F-200F).
Return transmission fluid from tal bypass valve or the transmission fluid cooler supplies transaxle lubrication
through the LUBE circuit which runs through the input shaft.
For lubrication passage location and description, refer to Mechanical Components and Functions in this
section.
The position of the TCC control valve is controlled by pressure from the TCC solenoid through the VBS TCC
circuit. The TCC solenoid is controlled by the PCM.
When the TCC clutch is applied, the TCC solenoid applies pressure to the TCC control and regulator valves to
position the valves to apply the TCC clutch. Regulated line pressure is supplied to the TCC control valve
through the REG APPLY circuit by the TCC regulator valve. The TCC control valve directs the regulated line
pressure from the REG APPLY circuit to the TCC APPLY circuit to apply the TCC . The TCC control valve
blocks the TCC RELEASE circuit to maintain pressure in the TCC APPLY circuit. The TCC control valve
directs the CONV FD circuit to the COOLER FD circuit to allow the transmission fluid to flow through the
thermal bypass valve or the transmission fluid cooler to the LUBE circuit to lubricate the transaxle.
Solenoid Hydraulic Circuits
Line pressure from the main pressure regulator valve is directed to the individual shift, TCC and LPC
solenoids by the solenoid regulator valve through the SOL FD circuit. The solenoids, controlled by the PCM,
direct the fluid to the valves that they control.
The LPC solenoid applies varying pressure to the main pressure regulator valve to control line pressure.
In the PARK and NEUTRAL positions, Shift Solenoid D (SSD) applies varying pressure to the low
reverse/456 regulator and latch valves through the VBS CBR1/456 hydraulic circuit to position the valves to
apply the low/reverse clutch. ON/OFF Shift Solenoid E (SSE) directs pressure to the clutch control bypass
valve to position the valve to direct regulated line pressure from the low reverse/456 regulator valve to the
low/reverse clutch.
In the REVERSE position, SSD applies varying pressure to the low reverse/456 regulator and latch valves
through the VBS CBR1/456 hydraulic circuit to position the valves to apply the low/reverse clutch. ON/OFF
SSE directs pressure to the clutch control bypass valve to position the valve to direct regulated line pressure
from the low reverse/456 regulator valve to the low/reverse clutch. The clutch control bypass valve also
directs line pressure from the REVERSE circuit to the 35R regulator valve through the C35R FD and DRIVE
2/C35R FD circuits. Shift Solenoid B (SSB) directs varying pressure to the 35R regulator and latch valves
through the VBS C35R hydraulic circuit to apply the direct (3, 5, R) clutch.
In 1st gear, Shift Solenoid A (SSA) applies varying pressure to the 1234 clutch regulator and latch valves
through the VBS C1234 hydraulic circuit to apply the forward (1, 2, 3, 4) clutch.
When vehicle speed is below 8 km/h (5 mph), or the selector lever is in the manual low position, SSD applies
varying pressure to the low reverse/456 regulator and latch valves through the VBS CBR1/456 hydraulic
circuit to position the valves to apply the low/reverse clutch. ON/OFF SSE directs pressure to the clutch
control bypass valve to position the valve to direct regulated line pressure from the low reverse/456 regulator
valve to the low/reverse clutch. As vehicle speed increases above 8 km/h (5 mph) in 1st gear, SSD removes
pressure from the low reverse/456 regulator and latch valves and SSE removes pressure from the clutch
control bypass valve to release the low/reverse clutch.
In 2nd gear, the forward (1, 2, 3, 4) clutch remains applied. SSC applies varying pressure to the 26 regulator
and latch valves through the VBS CB26 hydraulic circuit to apply the intermediate (2, 6) clutch.
In 3rd gear, the forward (1, 2, 3, 4) clutch remains applied. SSC releases pressure to the 26 regulator and latch
valves to release the intermediate (2, 6) clutch. SSB directs pressure to the 35R regulator and latch valves
through the VBS CB26 hydraulic circuit to apply the direct (3, 5, R) clutch.
In 4th gear, the forward (1, 2, 3, 4) clutch remains applied. SSB releases pressure to the 35R regulator and
latch valves. SSD directs pressure to the low reverse/456 regulator and latch valves through the VBS
CBR1/456 hydraulic circuit. With SSE released, the clutch control bypass valve directs the regulated line
pressure from the low reverse/456 regulator valve to the Overdrive (O/D) (4, 5, 6) clutch to apply the clutch.
In 5th gear, the O/D (4, 5, 6) clutch remains applied. SSA releases pressure to the 1234 regulator and latch
valves to release the forward (1, 2, 3, 4) clutch. SSB directs pressure to the 35R regulator and latch valves
through the VBS C35R hydraulic circuit to apply the direct (3, 5, R) clutch.
In 6th gear, the O/D (4, 5, 6) clutch remains applied. SSB releases pressure to the 35R regulator and latch
valves. SSC applies varying pressure to the 26 clutch regulator and latch valves through the VBS CB26
hydraulic circuit to apply the intermediate (2, 6) clutch.
The TCC can be applied in 4th, 5th or 6th gear. To apply the TCC , the TCC solenoid applies pressure to the
TCC regulator valve and the TCC control valve to position the valves to apply the clutch.
During a mechanical, hydraulic or electrical failure with the manual lever in the DRIVE position, the transaxle
defaults to 5th gear. When the transaxle is in 5th gear failsafe, the PCM does not control the shift solenoids
and they default to their normal state (maximum pressure, minimum pressure, on or off). The LPC solenoid
defaults to maximum pressure, SSA defaults to minimum pressure, SSB defaults to maximum pressure, SSC
defaults to minimum pressure, SSD defaults to maximum pressure and the TCC solenoid defaults to minimum
pressure.
With SSB applying maximum pressure to the direct (3, 5, R) regulator and latch valves, the direct (3, 5, R)
clutch is applied. With SSD applying maximum pressure to the low reverse/456 regulator and latch valves
with SSE in the OFF position, the O/D (4, 5, 6) clutch is applied, providing 5th gear.
Forward (1, 2, 3, 4) Clutch Hydraulic Circuits
Line pressure is supplied to the 1234 regulator valve by the manual valve in the DRIVE and LOW position.
To apply the forward (1, 2, 3, 4) clutch, SSA supplies varying solenoid pressure to the 1234 regulator and
latch valves. As the regulator valve moves, it supplies the forward (1, 2, 3, 4) clutch and 1234 latch valve with
regulated line pressure through the C1234 circuit. The 1234 latch valve directs the regulated line pressure to
the opposite side of the 1234 regulator valve through the C1234 FDBK circuit for gradual forward (1, 2, 3, 4)
clutch engagement. The forward (1, 2, 3, 4) clutch is applied in 1st, 2nd, 3rd and 4th gears and manual LOW
position.
When the forward (1, 2, 3, 4) clutch is released in 5th and 6th gears, solenoid pressure from SSA is removed
from the 1234 regulator and latch valves which positions the valves to block line pressure and release the
forward (1, 2, 3, 4) clutch. When the forward (1, 2, 3, 4) clutch is released in the PARK, REVERSE or
NEUTRAL position, line pressure is not supplied to the forward (1, 2, 3, 4) regulator valve.
In the released position, exhaust backfill supplied to the 1234 regulator and latch valves by the manual valve
through the EXH BF circuit is directed to the forward (1, 2, 3, 4) clutch to fill the unused circuits with
unpressurized transmission fluid.
Direct (3, 5, R) Clutch Hydraulic Circuits
When the direct (3, 5, R) clutch is applied in the REVERSE position, line pressure from the manual valve is
directed to the clutch control bypass valve through the REVERSE circuit. Line pressure in the REVERSE
circuit positions the clutch control bypass valve and supplies line pressure to apply the direct (3, 5, R) clutch.
Line pressure from the clutch control bypass valve is supplied to the 35R regulator valve through the C35R
FD circuit, DRIVE 2/C35R FD shuttle ball and DRIVE 2/C35R FD circuit.
To apply the direct (3, 5, R) clutch, SSB applies varying solenoid pressure to the 35R regulator and latch
valves. As the regulator valve moves, it supplies the direct (3, 5, R) clutch and 35R latch valve with regulated
line pressure through the C35R circuit. The 35R latch valve directs the regulated line pressure to the opposite
side of the 35R regulator valve through the C35R FDBK circuit for gradual direct (3, 5, R) clutch
engagement.
When the direct (3, 5, R) clutch is applied in 3rd and 5th gear, line pressure from the pump is directed to the
clutch control bypass valve by the manual valve through the DRIVE hydraulic circuit. The clutch control
bypass valve directs the pressure to the 35R regulator valve through the TCC regulator valve, DRIVE 2
circuit, DRIVE 2/C35R FD shuttle ball and DRIVE 2/C35R FD circuit.
To apply the direct (3, 5, R) clutch, SSB applies varying solenoid pressure to the 35R regulator and latch
valves. As the 35R regulator valve moves, it supplies the direct (3, 5, R) clutch and 35R latch valve with
regulated line pressure through the C35R circuit. The 35R latch valve directs the regulated line pressure to the
opposite side of the regulator valve through the C35R FDBK circuit for gradual direct (3, 5, R) clutch
engagement.
When the direct (3, 5, R) clutch is released, solenoid pressure from SSB is removed from the 35R regulator
and latch valves which positions the valves to block line pressure and release the direct (3, 5, R) clutch. When
the direct (3, 5, R) clutch is released in the PARK or NEUTRAL position, line pressure is not supplied to the
35R regulator valve.
Compensator feed pressure is supplied to the 35R regulator valve from the control pressure regulator through
the COMP FD circuit and is supplied to the opposite side of the direct (3, 5, R) and O/D (4, 5, 6) clutch
pistons to keep the clutches from centrifugally applying. COMP FD pressure is only about 83 kPa (12 psi) and
is applied through all gears. When the direct (3, 5, R) clutch is released, COMP FD is applied by the 35R
regulator valve to the direct (3, 5, R) clutch to fill the unused circuits.
Intermediate (2, 6) Clutch Hydraulic Circuits
Line pressure is supplied to the 26 regulator valve by the manual valve in the DRIVE and LOW positions. To
apply the intermediate (2, 6) clutch, SSC supplies varying solenoid pressure to the 26 regulator and latch
valves. As the 26 regulator valve moves, it supplies the intermediate (2, 6) clutch and 26 latch valve with
regulated line pressure through the CB26 circuit. The 26 latch valve directs the regulated line pressure to the
opposite side of the 26 regulator valve through the CB26 FDBK circuit for gradual intermediate (2, 6) clutch
engagement. The intermediate (2, 6) clutch is applied in 2nd and 6th gears.
When the intermediate (2, 6) clutch is released in 1st, 3rd, 4th and 5th gears and manual LOW position,
solenoid pressure from SSC is removed from the 26 regulator and latch valves which positions the valves to
block line pressure and release the intermediate (2, 6) clutch. When the intermediate (2, 6) clutch is released
in the PARK, REVERSE or NEUTRAL position, line pressure is not supplied to the 26 regulator valve.
In the released position, exhaust backfill supplied to the 26 clutch regulator valve by the manual valve through
the EXH BF circuit is directed to the intermediate (2, 6) clutch and 26 latch valve to fill the unused circuits
with unpressurized transmission fluid.
Low/Reverse Clutch Hydraulic Circuits
Line pressure is supplied to the low reverse/456 regulator valve by the pump in every gear and manual lever
position. To apply the low/reverse clutch, SSD supplies varying solenoid pressure to the low reverse/456
regulator and latch valves. As the low reverse/456 regulator valve moves, it supplies the clutch control bypass
valve and low reverse/456 latch valve with regulated line pressure through the CBR1/C456 circuit. The low
reverse/456 latch valve directs the regulated line pressure to the opposite side of the 456 regulator valve
through the CBR1/C456 FDBK circuit for gradual low reverse/456 clutch engagement. The low/reverse clutch
is applied in PARK, REVERSE, NEUTRAL, 1st gear below 8 km/h (5 mph) and manual LOW position.
In REVERSE, both solenoid pressure from ON/OFF SSE and line pressure from the manual valve in the
REVERSE circuit apply pressure to the clutch control bypass valve to position it for low/reverse clutch
application. Regulated line pressure from the CBR1/C456 circuit is directed to the low/reverse clutch by the
clutch control bypass valve through the CBR1 circuit to apply the low/reverse clutch.
When the low/reverse clutch is applied in PARK, NEUTRAL, LOW or 1st gear below 8 km/h (5 mph), only
pressure from ON/OFF SSE , positions the clutch control bypass valve. Line pressure from the REVERSE
circuit is not supplied by the manual valve.
When the low/reverse clutch is released in 1st gear above 8 km/h (5 mph), 2nd and 3rd gears, solenoid
pressure from SSD is removed from the low reverse/456 regulator and latch valves which positions the valves
to block line pressure and release the low/reverse clutch. Solenoid pressure from SSE is removed from the
clutch control bypass valve to position it to apply the O/D (4, 5, 6) clutch.
When the low/reverse clutch is released in 1st gear above 8 km/h (5 mph), 2nd and 3rd gears, exhaust backfill
supplied to the low reverse/456 clutch regulator valve and the clutch control bypass valve by the manual valve
through the EXH BF circuit is directed to the low reverse/456 latch valve, low/reverse clutch and O/D (4, 5, 6)
clutch to fill the unused circuits with unpressurized transmission fluid.
When the low/reverse clutch is released in 4th, 5th and 6th gears, the low reverse/456 regulator valve supplies
regulated pressure to the clutch control bypass valve through the CBR1/C456 circuit. With ON/OFF SSE in
the OFF position, the regulated pressure is directed to the O/D (4, 5, 6) clutch.
Overdrive (4, 5, 6) Clutch Hydraulic Circuits
Line pressure is supplied to the low reverse/456 regulator valve by the pump in every gear and manual lever
position. To apply the low/reverse clutch, SSD supplies varying solenoid pressure to the low reverse/456
regulator and latch valves. As the regulator valve moves, it supplies the clutch control bypass valve and low
reverse/456 latch valve with regulated line pressure through the CBR1/C456 circuit. The low reverse/456
latch valve directs the regulated line pressure to the opposite side of the low reverse/456 regulator valve
through the CBR1/C456 FDBK circuit for gradual O/D (4, 5, 6) clutch engagement.
To apply the O/D (4, 5, 6) clutch, the position of the clutch control bypass valve allows the regulated line
pressure in the CBR1/C456 circuit to supply the C456 circuit, applying the O/D (4, 5, 6) clutch. Clutch
control bypass valve latch pressure is supplied by the C456 circuit. The O/D (4, 5, 6) clutch is applied in 4th,
5th and 6th gears.
When the O/D (4, 5, 6) clutch is released in 1st gear above 8 km/h (5 mph), 2nd and 3rd gears, solenoid
pressure from SSD is removed from the low reverse/456 regulator and latch valves which positions the valves
to block line pressure and release the O/D (4, 5, 6) clutch.
When the O/D (4, 5, 6) clutch is released in 1st gear above 8 km/h (5 mph), 2nd and 3rd gears, exhaust
backfill supplied to the low reverse/456 clutch regulator valve and the clutch control bypass valve by the
manual valve through the EXH BF circuit is directed to the low reverses latch valve, low/reverse clutch and
O/D (4, 5, 6) clutch to fill the unused circuits with unpressurized transmission fluid.
When the O/D (4, 5, 6) clutch is released in PARK, REVERSE, NEUTRAL and 1st gear below 8 km/h (5
mph), the low reverse/456 regulator valve supplies regulated pressure to the clutch control bypass valve
through the CBR1/C456 circuit. With ON/OFF SSE in the ON position, the regulated pressure is directed to
the low/reverse clutch.
Workshop Manual
Transaxle Electronic Control System
Electronic System Description
The PCM and its input/output network control the following operations:
Shift timing
Line pressure (shift feel)
The transaxle control is separate from the engine control strategy in the PCM, although some of the input
signals are shared. When determining the best operating strategy for transaxle operation, the PCM uses input
information from certain engine-related and driver-demand related sensors and switches.
In addition, the PCM receives input signals from certain transaxle-related sensors and switches. The PCM also
uses these signals when determining transaxle operating strategy.
Using all of these input signals, the PCM can determine when the time and conditions are right for a shift, or
when to apply or release the TCC . It will also determine the best line pressure needed to optimihift
engagement feel. To accomplish this, the PCM uses output solenoids to control transaxle operation.
The following provides a brief description of each of the sensors and actuators used to control transaxle
operation.
Electronic Ignition (EI)
The Electronic Ignition (EI) system consists of the PCM, a Crankshaft Position (CKP) sensor and ignition
coils. The CKP sensor sends a crankshaft position signal to the PCM. The PCM then sends the appropriate
ignition signal to the ignition coils. The PCM also uses this signal as well as Wide Open Throttle (WOT) shift
control, TCC control and electronic pressure control.
Accelerator Pedal Position (APP)
The Accelerator Pedal Position (APP) sensor is mounted on the accelerator pedal. The APP detects the
position of the accelerator pedal and inputs this information as a voltage to the PCM. The PCM uses APP
sensor information to aid in determining line pressure, shift scheduling and TCC operation. Failure of this
sensor will cause the transmission to operate at higher line pressure to avoid damage to the transmission. This
higher line pressure causes harsh upshifts and harsh engagements.
Throttle Position (TP) Sensor
The Throttle Position (TP) sensor is a potentiometer mounted on the Throttle Body (TB). The TP sensor
detects the position of the throttle plate and sends this information to the processor assembly as varying
voltage signal.
The PCM uses the monitored voltage level of the TP sensor for control of Line Pressure Control (LPC), TCC
operation and shift scheduling.
If a malfunction occurs in the TP sensor circuit, the processor will recognize that the TP sensor signal is out of
specification. The processor will then operate the transaxle in a high capacity mode to prevent transaxle
damage.
PCM
The PCM controls operation of the transaxle. Many input sensors provide information to the PCM. The PCM
then controls the actuators which affect transaxle operation.
Transmission Range (TR) Sensor Assembly
The Transmission Range (TR) sensor assembly is an internally mounted sensor that includes the detent
bracket and is located above the main control assembly. The components of the TR sensor are factory adjusted
and is installed as a calibrated assembly. The TR sensor contains electronic circuitry that provides the PCM a
fixed frequency duty cycle for each of the various positions of the manual lever (PARK, REVERSE,
NEUTRAL, DRIVE and LOW to the PCM). The PCM uses the TR sensor signal for engine start, reverse
lamps, LPC , shift scheduling and TCC operation.
Brake Pedal Position (BPP) Switch
The Brake Pedal Position (BPP) switch tells the PCM when the brakes are applied. The BPP switch closes
when the brakes are applied and opens when they are released. The BPP signal is used for the brake shift
interlock actuation.
This Turbine Shaft Speed (TSS) sensor is a Hall-effect pickup that sends a signal to the PCM that indicates
transaxle turbine shaft input speed. The TSS sensor provides converter turbine speed information for TCC
strategy. Also used in determining static LPC pressure settings.
Output Shaft Speed (OSS) Sensor
The Output Shaft Speed (OSS) sensor is a Hall-effect pickup, located on the transfer shaft drive gear, that
sends a signal to the PCM to indicate transmission output speed. The OSS is used for TCC control and shift
scheduling.
Solenoid Body
NOTICE: If the solenoid body identification and strategy does not match the solenoid body information
in the Powertrain Control Module (PCM), transaxle damage or driveability concerns can occur.
The solenoid body contains 7 solenoids, 5 shift solenoids (Shift Solenoid A (SSA), Shift Solenoid B (SSB),
Shift Solenoid C (SSC), Shift Solenoid D (SSD) and Shift Solenoid E (SSE)), TCC solenoid and LPC
solenoid. The Transmission Fluid Temperature (TFT) is also located in the solenoid body. The solenoid body
is serviced as an assembly.
The solenoid body has a unique strategy data file that must be downloaded to the PCM. There is a 7-digit
solenoid body identification and a 13-digit solenoid body strategy for each solenoid body. Any time a new
solenoid body is installed or a new transaxle is installed, the scan tool must be used to get the solenoid body
strategy data file and download it into the PCM.
If the PCM is replaced, the solenoid body identification and solenoid body strategy must be downloaded into
the PCM.
Line Pressure Control (LPC) Solenoid
The LPC solenoid is a Variable Force Solenoid (VFS) that varies hydraulic pressure by actuating a hydraulic
valve.
The PCM applies variable current to the LPC solenoid which varies pressure in the VBS LINE hydraulic
circuit to the main pressure regulator valve. Refer to Hydraulic Circuits for additional information.
The LPC solenoid uses inversely proportional operation. As the current from the PCM decreases, the pressure
from the solenoid increases. As the current from the PCM increases, the pressure from the solenoid decreases.
The LPC solenoid is supplied hydraulic pressure from the SOL FD circuit.
With zero current, the LPC solenoid fully opens the hydraulic valve which applies the maximum amount of
hydraulic pressure to the Main Pressure Regulator Valve through the VBS LINE hydraulic circuit and applies
maximum line pressure in the LINE hydraulic circuit. With maximum current to the solenoid, the hydraulic
valve fully closes the outlet port for minimum pressure to the VBS LINE hydraulic circuit to lower the line
pressure in the LINE hydraulic circuit.
Line Pressure Control (LPC) Inversely Proportional Variable Force Solenoid (VFS)
Torque Converter Clutch (TCC) Solenoid
The TCC solenoid is a VFS that varies hydraulic pressure by actuating a hydraulic valve.
Line Pressure Control (LPC) Inversely Proportional Variable Force Solenoid (VFS) 3577
The PCM applies variable current to the TCC solenoid which varies pressure in the VBS TCC hydraulic
circuit to the TCC regulator valve and the TCC control valve. Refer to Hydraulic Circuits for additional
information.
The TCC solenoid uses proportional operation. As the current from the PCM decreases, the pressure from the
solenoid decreases. As the current from the PCM increases, the pressure from the solenoid increases. The
TCC solenoid is supplied hydraulic pressure from the SOL FD circuit.
With zero current, the TCC solenoid fully closes the hydraulic valve which applies the minimum amount of
hydraulic pressure to the TCC regulator valve through the VBS TCC hydraulic circuit and releases the TCC .
With maximum current to the solenoid, the hydraulic valve fully opens the outlet port for maximum pressure
to the VBS TCC hydraulic circuit to apply the TCC .
Torque Converter Clutch (TCC) Proportional Variable Force Solenoid (VFS)
Shift Solenoid A (SSA), Shift Solenoid B (SSB), Shift Solenoid C (SSC) and Shift Solenoid D (SSD)
Shift solenoids A-D are variable force type solenoids that vary hydraulic pressure by actuating a hydraulic
valve.
The PCM applies variable current to the shift solenoids which varies pressure in the hydraulic circuit to the
regulator and latch valves of the clutch that it controls. Refer to Hydraulic Circuits for additional information.
SSA and SSC use proportional operation. As the current from the PCM decreases, the pressure from the
solenoid decreases. As the current from the PCM increases, the pressure from the solenoid increases. SSA and
SSC are supplied hydraulic pressure from the SOL FD circuit.
With zero current, SSA and SSC fully close the hydraulic valves which applies zero amount of hydraulic
pressure to the clutch regulator and latch valves of the clutch that it controls and releases the clutch. With
maximum current to the solenoids, the hydraulic valves are fully open for maximum pressure to the clutch
regulator and latch valves to apply the clutch.
Torque Converter Clutch (TCC) Proportional Variable Force Solenoid (VFS) 3578
Shift Solenoid A (SSA) and Shift Solenoid C (SSC) Proportional Variable Force Type Solenoids
1 7G136 Shift Solenoid A (SSA) Variable Force Solenoid
(VFS)
2 7G136 Shift Solenoid C (SSC) VFS
SSB and SSD use inversely proportional operation. As the current from the PCM decreases, the pressure from
the solenoid increases. As the current from the PCM increases, the pressure from the solenoid decreases. SSB
and SSD are supplied hydraulic pressure from the SOL FD circuit.
With zero current, SSB and SSD fully open the hydraulic valves which applies maximum hydraulic pressure
to the clutch regulator and latch valves to apply the clutch that it controls. With maximum current to the
solenoids, the hydraulic valve is fully closed to apply zero amount of hydraulic pressure to the clutch regulator
and latch valves of the clutch that it controls and releases the clutch.
Shift Solenoid B (SSB) and Shift Solenoid D (SSD) Inverse Proportional Variable Force Type Solenoids
Shift Solenoid A (SSA) and Shift Solenoid C (SSC) Proportional Variable Force Type Solenoids3579
1 7G383 Shift Solenoid B (SSB) Variable Force Solenoid (VFS)
2 7G383 Shift Solenoid D (SSD) VFS
Shift Solenoid E (SSE)
SSE is an ON/OFF solenoid. When SSE is in the ON position, SSD controls the clutch regulator and latch
valves to apply the low/reverse clutch. When SSE is in the OFF position, SSD controls the clutch regulator
and latch valves to apply the overdrive (4, 5, 6) clutch. Refer to Hydraulic Circuits for additional information.
SSE is supplied hydraulic pressure from the SOL FD circuit. When SSE is OFF, the solenoid supply is
blocked and the outlet port (ON/OFF SIG circuit) is connected to the exhaust port. When SSE is ON, the
exhaust port is blocked and the solenoid supply is connected to the outlet port (ON/OFF SIG circuit),
supplying pressure to the clutch control bypass valve.
Shift Solenoid E (SSE) ON/OFF Solenoid
Shift Solenoid B (SSB) and Shift Solenoid D (SSD) Inverse Proportional Variable Force Type Solenoids 3580
Shift Solenoid E (SSE) ON/OFF Solenoid 3581
Workshop Manual
Transaxle Operation
Transaxle Operation Overview
Torque Converter
This transaxle uses a torque converter with the following elements:
Impeller
Turbine
Reactor
For component information, refer to Torque Converter in this section.
Planetary Gearsets
Operation of this transaxle involves the use of the following planetary gearsets:
Front
Center
Rear
Apply Clutches
This transaxle uses the following clutches to operate the 3 planetary gearsets:
Forward (1, 2, 3, 4) clutch
Low/reverse clutch
Low One-Way ClutOWC)
Direct (3, 5, R) clutch
Intermediate (2, 6) clutch
Overdrive (O/D) (4, 5, 6) clutch
For additional information about planetary gearsets or the apply clutches, refer to Mechanical Components
and Functions in this section.
Hydraulic System
The hydraulic system of this transaxle consists of the following components:
Transmission fluid pump with filter
Transmission fluid filler tube with transmission fluid level indicator
Main control assembly (valve body and solenoid body)
For component information, refer to Hydraulic System in this section.
Electronic Operation
Transaxle Operation 3582
The PCM controls the operation of the transaxle with the following solenoids:
Line Pressure Control (LPC) solenoid
Shift Solenoid A (SSA)
Shift Solenoid B (SSB)
Shift Solenoid C (SSC)
Shift Solenoid D (SSD)
TCC solenoid
For solenoid information, refer to Transaxle Electronic Control System in this section.
Park Position
Mechanical Operation
Apply components:
Park pawl engaged, holding the final drive assembly stationary
Low/reverse clutch applied
Planetary Gearset Operation
Front planetary gearset driven components:
None
Center planetary gearset driven components:
Mechanical Operation 3583
Sun gear
Rear planetary gearset driven components:
None
Front planetary gearset held components:
Planetary carrier assembly (splined to final drive assembly, held stationary by park pawl)
Center planetary gearset held components:
Center ring gear (splined to rear planetary carrier)
Rear planetary gearset held components:
Planetary carrier
Rear ring gear (splined to front carrier)
Park Position Clutch Application Chart
Gear/Manual Lever
Position
Direct (3,
5, R)
Overdrive (4,
5, 6)
Forward (1,
2, 3, 4)
Low/ Reverse
(L, R)
Intermediate
(2, 6) One-Way
PARK X
For component information, refer to Mechanical Components and Functions in this section.
Park Position Power Flow
Planetary Gearset Operation 3584
Hydraulic Operation
Line pressure hydraulic circuits:
Line pressure from the pump is supplied to the main pressure regulator valve, low reverse/456
regulator valve, manual valve, solenoid regulator valve and control pressure regulator.

Line pressure is controlled by the position of the main pressure regulator valve.
The position of the main pressure regulator valve is controlled by varying pressure from the LPC
solenoid through the VBS LINE circuit.

Torque converter circuits:
Regulated line pressure from the main pressure regulator valve is directed to the TCC control valve
through the CONV FD hydraulic circuit.

When the TCC is released, CONV FD pressure is directed to the TCC RELEASE circuit by the TCC
control valve. Pressure from the TCC RELEASE circuit releases the TCC .

Fluid from the TCC RELEASE returns to the TCC control valve through the TCC APPLY circuit.
Cooler and lubrication hydraulic circuits:
The TCC control valve directs fluid from the TCC APPLY circuit (return circuit from the torque
converter when the TCC is released) to the COOLER FD circuit.

In the COOLER FD circuit, transmission fluid flows through the transmission fluid cooler or the
thermal bypass valve to the LUBE circuit in the input shaft to supply lubrication to the transaxle.

Solenoid hydraulic circuits:
The LPC solenoid applies varying pressure to the main pressure regulator valve through the VBS
LINE hydraulic circuit. The LPC solenoid regulates line pressure by controlling the position of the
main pressure regulator valve.

SSD applies pressure to the low reverse/456 regulator and latch valves to apply the low/reverse
clutch.

SSE applies pressure to the clutch control bypass valve to position the valve to direct regulated line
pressure in the CBR1/C456 circuit to the low/reverse clutch.

Clutch hydraulic circuits:
Line pressure from the pump is supplied to the low reverse/456 regulator valve. To apply the
low/reverse clutch, SSD supplies varying solenoid pressure to the low reverse/456 regulator and latch
valves. As the low reverse/456 regulator valve moves, it supplies the clutch control bypass valve and
low reverse/456 latch valve with regulated line pressure through the CBR1/C456 circuit. The latch
valve directs the regulated line pressure to the opposite side of the regulator valve through the
CBR1/C456 FDBK circuit for gradual low/reverse clutch engagement.

Regulated line pressure at the clutch control bypass valve in the CBR1/C456 circuit is directed to the
low/reverse clutch through the CBR1 circuit to apply the clutch.

For additional hydraulic circuit information, refer to Hydraulic Circuits in this section.
Electrical Operation
Solenoid operation:
Hydraulic Operation 3585
Park Position Solenoid Operation Chart
Base Selector
Lever
Position
PCM
Commanded
Gear
Shift Solenoid
TCC
(VFS)
NL
SSA (VFS)
NL (1, 2, 3,
4)
SSB (VFS)
NH (3, 5,
R)
SSC
(VFS) NL
(2, 6)
SSD (VFS)
NH (L, R/4,
5, 6)
SSE
(On/Off)
NC
NH = Normally high
NL = Normally low
Printable / zoomable view of this graphic
Reverse Position
Electrical Operation 3586
Apply components:
Direct (3, 5, R) clutch applied
Planetary carrier
Sun gear (does not contribute to power flow)
Sun gear
None
Center ring (does not contribute to power flow)
Planetary carrier
Reverse Position Clutch Application Chart
Gear/Manual Lever
Position
Direct (3,
5, R)
Overdrive (4,
5, 6)
Forward (1,
2, 3, 4)
Low/ Reverse
(L, R)
Intermediate
(2, 6) One-Way
REVERSE X X
Reverse Position Power Flow
Hydraulic Operation







SSB applies pressure to the 35R regulator and latch valves to apply the direct (3, 5, R) clutch.
SSD applies pressure to the low reverse/456 regulator valve to apply the low/reverse clutch.
pressure in the CBR1/C456 circuit to the CBR1 circuit to apply the low/reverse clutch.

Line pressure supplied to the manual valve is directed to the clutch control bypass valve through the
REVERSE circuit.

The clutch control bypass valve directs the REVERSE circuit to the 35R regulator valve through the
C35R FD circuit, DRIVE 2/C35R FD shuttle ball and DRIVE 2/C35R FD circuit. To apply the direct
(3, 5, R) clutch, SSB applies varying solenoid pressure to the 35R regulator and latch valves. As the
35R regulator valve moves, it supplies the direct (3, 5, R) clutch and 35R latch valve with regulated
line pressure through the C35R circuit. The 35R latch valve directs the regulated line pressure to the
opposite side of the 35R regulator valve through the C35R FDBK circuit for gradual direct (3, 5, R)
clutch engagement.

valves. As the regulator valve moves, it supplies the clutch control bypass valve and low reverse/456
latch valve with regulated line pressure through the CBR1/C456 circuit. The low reverse/456 latch


Solenoid operation:
Reverse Position Solenoid Operation Chart
Base Selector
Lever
Position
PCM
Commanded
Gear
Shift Solenoid
TCC
(VFS)
NL
SSA (VFS)
NL (1, 2, 3,
4)
SSB (VFS)
NH (3, 5,
R)
SSC
(VFS) NL
(2, 6)
SSD (VFS)
NH (L, R/4,
5, 6)
SSE
(On/Off)
NC
NH = Normally high
NL = Normally low
Neutral Position
Apply components:
None
Sun gear
None
None
Ring gear
Planetary carrier
Neutral Position Clutch Application Chart
Gear/Manual Lever
Position
Direct (3,
5, R)
Overdrive (4,
5, 6)
Forward (1,
2, 3, 4)
Low/ Reverse
(L, R)
Intermediate
(2, 6) One-Way
NEUTRAL X
Power Flow
Hydraulic Operation







clutch.




Solenoid operation:
Neutral Position Solenoid Operation Chart
Base Selector
Lever
Position
PCM
Commanded
Gear
Shift Solenoid
TCC
(VFS)
NL
SSA (VFS)
NL (1, 2, 3,
4)
SSB (VFS)
NH (3, 5,
R)
SSC
(VFS) NL
(2, 6)
SSD (VFS)
NH (L, R/4,
5, 6)
SSE
(On/Off)
NC
NH = Normally high
NL = Normally low
1st Gear Above 8 km/h (5 mph)
NOTE: The transaxle operates differently in 1st gear above and below 8 km/h (5 mph). For transaxle
operation below 8 km/h (5 mph), refer to Manual LOW Position and 1st Gear Below 8 km/h (5 mph) in this
section.
Apply components:
OWC
Ring gear
Planetary carrier
Sun gear
Planetary carrier
Ring gear
Sun gear
Ring gear
Rear planetary carrier (does not contribute to power flow)
1st Gear Above 8 km/h (5 mph) Clutch Application Chart
Gear
Direct (3, 5,
R)
Overdrive (4, 5,
6)
Forward (1, 2, 3,
4)
Low/ Reverse (L,
R)
Intermediate (2,
6) One-Way
1st
gear
X X
Power Flow
Hydraulic Operation







SSA applies pressure to the 1234 regulator and latch valves to apply the forward (1, 2, 3, 4) clutch.
SSD releases pressure to the low reverse/456 regulator and latch valves to release the low/reverse
clutch.

SSE releases pressure to the clutch control bypass valve to position it so that regulated line pressure
supplied in the CBR1/C456 circuit for 4th, 5th and 6th gear will apply the O/D (4, 5, 6) clutch.

Power Flow 3595
SSD removes pressure from the low reverse/456 regulator and latch valves which positions the valves
to block line pressure and release the low/reverse clutch. Solenoid pressure from SSE is removed
from the clutch control bypass valve to position it to apply the O/D (4, 5, 6) clutch.

Line pressure is supplied to the 1234 regulator valve by the manual valve in the DRIVE and LOW
position. To apply the forward (1, 2, 3, 4) clutch, SSA supplies varying solenoid pressure to the 1234
regulator and latch valves. As the 1234 regulator valve moves, it supplies the forward (1, 2, 3, 4)
clutch and 1234 latch valve with regulated line pressure through the C1234 circuit. The 1234 latch
valve directs the regulated line pressure to the opposite side of the regulator valve through the C1234
FDBK circuit for gradual forward (1, 2, 3, 4) clutch engagement.

Solenoid operation:
1st Gear Above 8 km/h (5 mph) Solenoid Operation Chart
Base Selector
Lever
Position
PCM
Commanded
Gear
Shift Solenoid
TCC
(VFS)
NL
SSA (VFS)
NL (1, 2, 3,
4)
SSB (VFS)
NH (3, 5,
R)
SSC
(VFS) NL
(2, 6)
SSD (VFS)
NH (L, R/4,
5, 6)
SSE
(On/Off)
NC
D 1 On On Off On Off Off
NH = Normally high
NL = Normally low
2nd Gear
Apply components:
Planetary carrier
Ring gear
Sun gear
Planetary carrier
Ring gear
Planetary carrier
Ring gear
Sun gear
None
Sun gear
2nd Gear Clutch Application Chart
Gear
Direct (3, 5,
R)
Overdrive (4, 5,
6)
Forward (1, 2, 3,
4)
Low/ Reverse (L,
R)
Intermediate (2,
6) One-Way
2nd
gear
X X
Power Flow
Hydraulic Operation







SSC applies pressure to the 26 regulator and latch valves to apply the intermediate (2, 6) clutch.
regulator and latch valves. As the regulator valve moves, it supplies the forward (1, 2, 3, 4) clutch and
1234 latch valve with regulated line pressure through the C1234 circuit. The 1234 latch valve directs
the regulated line pressure to the opposite side of the regulator valve through the C1234 FDBK circuit
for gradual forward (1, 2, 3, 4) clutch engagement.

positions. To apply the intermediate (2, 6) clutch, SSC supplies varying solenoid pressure to the 26
regulator and latch valves. As the 26 regulator valve moves, it supplies the intermediate (2, 6) clutch
and 26 latch valve with regulated line pressure through the CB26 circuit. The 26 latch valve directs
the regulated line pressure to the opposite side of the 26 regulator valve through the CB26 FDBK
circuit for gradual intermediate (2, 6) clutch engagement.

For additional hydraulic circuit and information, refer to Hydraulic Circuits in this section.
Solenoid operation:
2nd Gear Solenoid Operation Chart
Base Selector
Lever
Position
PCM
Commanded
Gear
Shift Solenoid
TCC
(VFS)
NL
SSA (VFS)
NL (1, 2, 3,
4)
SSB (VFS)
NH (3, 5,
R)
SSC
(VFS) NL
(2, 6)
SSD (VFS)
NH (L, R/4,
5, 6)
SSE
(On/Off)
NC
D 2 On On On On Off Off
NH = Normally high
NL = Normally low
3rd Gear
Apply components:
Planetary carrier
Ring gear
Sun gear
Planetary carrier
Ring gear
Sun gear
Planetary carrier
Ring gear
Sun gear
None
None
3rd Gear Clutch Application Chart
Gear
Direct (3, 5,
R)
Overdrive (4, 5,
6)
Forward (1, 2, 3,
4)
Low/ Reverse (L,
R)
Intermediate (2,
6) One-Way
3rd
gear
X X
Power Flow
Hydraulic Operation







SSC releases pressure to the 26 regulator and latch valves to release the intermediate (2, 6) clutch.
latch valve with regulated line pressure through the C1234 circuit. The 1234 latch valve directs the
regulated line pressure to the opposite side of the 1234 regulator valve through the C1234 FDBK

Power Flow 3602
circuit for gradual forward (1, 2, 3, 4) clutch engagement.
Solenoid pressure from SSC is removed from the 26 regulator and latch valves which positions the
valves to block line pressure and release the intermediate (2, 6) clutch.

Line pressure from the pump is directed to the clutch control bypass valve by the manual valve
through the DRIVE hydraulic circuit. The clutch control bypass valve directs the pressure to the 35R
regulator valve through the TCC regulator valve, DRIVE 2 circuit, DRIVE 2/C35R FD shuttle ball
and DRIVE 2/C35R FD circuit. SSB applies varying solenoid pressure to the 35R regulator and latch
valves. As the regulator valve moves, it supplies the direct (3, 5, R) clutch and 35R latch valve with
regulated line pressure through the C35R circuit. The 35R latch valve directs the regulated line
pressure to the opposite side of the 35R regulator valve through the C35R FDBK circuit for gradual
direct (3, 5, R) clutch engagement.

Solenoid operation:
3rd Gear Solenoid Operation Chart
Base Selector
Lever
Position
PCM
Commanded
Gear
Shift Solenoid
TCC
(VFS)
NL
SSA (VFS)
NL (1, 2, 3,
4)
SSB (VFS)
NH (3, 5,
R)
SSC
(VFS) NL
(2, 6)
SSD (VFS)
NH (L, R/4,
5, 6)
SSE
(On/Off)
NC
D 3 On Off Off On Off Off
NH = Normally high
NL = Normally low
4th Gear
Apply components:
O/D (4, 5, 6) clutch
Planetary carrier
Ring gear
Sun gear
Planetary carrier
Ring gear
Planetary carrier
Sun gear
None
None
4th Gear Clutch Application Chart
Gear
Direct (3, 5,
R)
Overdrive (4, 5,
6)
Forward (1, 2, 3,
4)
Low/ Reverse (L,
R)
Intermediate (2,
6) One-Way
4th
gear
X X
Power Flow
Hydraulic Operation




Fluid from the TCC RELEASE circuit returns to the TCC control valve through the TCC APPLY
circuit.




SSB releases pressure to the 35R clutch regulator and latch valves to release the direct (3, 5, R)
clutch.

SSD applies pressure to the low reverse/456 regulator and latch valves to apply the O/D (4, 5, 6)
clutch.


Power Flow 3606
1234 latch valve with regulated line pressure through the C1234 circuit. The 1234 latch valve directs
the regulated line pressure to the opposite side of the 1234 regulator valve through the C1234 FDBK
Solenoid pressure from SSB is removed from the 35R regulator and latch valves which positions the
valves to block line pressure and release the direct (3, 5, R) clutch.

Line pressure from the pump is supplied to the low reverse/456 regulator valve. SSD supplies varying
solenoid pressure to the low reverse/456 regulator and latch valves. As the regulator valve moves, it
supplies the clutch control bypass valve and low reverse/456 latch valve with regulated line pressure
through the CBR1/C456 circuit. The low reverse/456 latch valve directs the regulated line pressure to
the opposite side of the low reverse/456 regulator valve through the CBR1/C456 FDBK circuit for
gradual clutch engagement.

O/D (4, 5, 6) clutch through the C456 circuit to apply the clutch.

Regulated line pressure in the C456 also supplies the latch pressure for the clutch control bypass
valve.

Solenoid operation:
4th Gear Solenoid Operation Chart
Base Selector
Lever
Position
PCM
Commanded
Gear
Shift Solenoid
TCC
(VFS)
NL
SSA (VFS)
NL (1, 2, 3,
4)
SSB (VFS)
NH (3, 5,
R)
SSC
(VFS) NL
(2, 6)
SSD (VFS)
NH (L, R/4,
5, 6)
SSE
(On/Off)
NC
D 4 On On Off Off Off Off
NH = Normally high
NL = Normally low
5th Gear
Apply components:
Planetary carrier
Sun gear
Planetary carrier
None
None
None
5th Gear Clutch Application Chart
Gear
Direct (3, 5,
R)
Overdrive (4, 5,
6)
Forward (1, 2, 3,
4)
Low/ Reverse (L,
R)
Intermediate (2,
6) One-Way
5th
gear
X X
Power Flow
Hydraulic Operation







clutch.

SSA releases pressure to the 1234 regulator and latch valves to release the forward (1, 2, 3, 4) clutch.

Power Flow 3610
the opposite side of the regulator valve through the CBR1/C456 FDBK circuit for gradual clutch
engagement.

Regulated line pressure in the C456 also supplies the latch pressure for the clutch control bypass
valve.

Solenoid pressure from SSA is removed from the 1234 regulator and latch valves which positions the
valves to block line pressure and release the forward (1, 2, 3, 4) clutch.

and DRIVE 2/C35R FD circuit. SSB applies varying solenoid pressure to the 35R regulator and latch
valves. As the regulator valve moves, it supplies the direct (3, 5, R) clutch and 35R latch valve with
regulated line pressure through the C35R circuit. The 35R latch valve directs the regulated line
pressure to the opposite side of the 35R regulator valve through the C35R FDBK circuit for gradual
direct (3, 5, R) clutch engagement.

Solenoid operation:
5th Gear Solenoid Operation Chart
Base Selector
Lever Position
PCM
Commanded
Gear
Shift Solenoid
SSA (VFS)
NL (1, 2, 3,
4)
SSB (VFS)
NH (3, 5, R)
SSC (VFS)
NL (2, 6)
SSD (VFS)
NH (L, R/4, 5,
6)
SSE
(On/Off)
NC
D 5 Off Off Off Off Off
NH = Normally high
NL = Normally low
6th Gear Torque Converter Clutch (TCC) Applied
Apply components:
TCC
Planetary carrier
Planetary carrier
Ring gear
None
None
Sun gear
6th Gear TCC Applied Clutch Application Chart
Gear
Direct (3, 5,
R)
Overdrive (4, 5,
6)
Forward (1, 2, 3,
4)
Low/ Reverse (L,
R)
Intermediate (2,
6) TCC
6th
gear
X X X
Power Flow
Hydraulic Operation


When the torque converter is applied, line pressure from the manual valve is directed to the TCC
regulator valve by the clutch control bypass valve through the DRIVE 2 circuit. The TCC solenoid
supplies varying solenoid pressure to the TCC regulator valve and the TCC control valve to position
the valves to apply the TCC .

As the TCC regulator valve moves, it supplies the TCC control valve with regulated line pressure
through the REG APPLY circuit. The TCC control valve directs the REG APPLY circuit to the TCC
APPLY circuit to apply the TCC .

Pressure from the torque converter returns to the TCC control valve through the TCC RELEASE
circuit.

through the CONV FD hydraulic circuit. When the TCC is applied, CONV FD pressure supplies the
COOLER FD circuit which circulates through the transmission fluid cooler or the thermal bypass
valve.



clutch.

SSB releases pressure to the 35R regulator and latch valves to release the direct (3, 5, R) clutch.
SSC applies pressure to the 26 regulator and latch valves to apply the direct (2, 6) clutch.
Power Flow 3614
The TCC solenoid applies pressure to the TCC control valve and the TCC regulator valve to apply the
TCC .

the opposite side of the low reverse/456 regulator valve through the CBR1/C456 FDBK circuit for
gradual clutch engagement.


Regulated line pressure in the C456 circuit also supplies the latch pressure for the clutch control
bypass valve.

Solenoid pressure from SSB is removed from the 35R regulator and latch valves which positions the
valves to block line pressure and release the direct (3, 5, R) clutch.

positions. To apply the intermediate (2, 6) clutch, SSC supplies varying solenoid pressure to the 26
regulator and latch valves. As the regulator valve moves, it supplies the intermediate (2, 6) clutch and
26 latch valve with regulated line pressure through the CB26 circuit. The 26 latch valve directs the
regulated line pressure to the opposite side of the regulator valve through the CB26 FDBK circuit for
gradual intermediate (2, 6) clutch engagement.

Solenoid operation:
6th Gear TCC Applied Solenoid Operation Chart
Base Selector
Lever
Position
PCM
Commanded
Gear
Shift Solenoid
TCC
(VFS)
NL
SSA (VFS)
NL (1, 2, 3,
4)
SSB (VFS)
NH (3, 5,
R)
SSC
(VFS) NL
(2, 6)
SSD (VFS)
NH (L, R/4,
5, 6)
SSE
(On/Off)
NC
D 6 Off On On Off Off On
NH = Normally high
NL = Normally low
Manual LOW Position and 1st Gear Below 8 km/h (5 mph) Solenoid Operation Chart
NOTE: The transaxle operates differently in first gear above and below 8 km/h (5 mph). For transaxle
operation above 8 km/h (5 mph), refer to 1st Gear Above 8 km/h (5 mph) in this section.
Apply components:
Low/reverse clutch
Low OWC
Ring gear
Planetary carrier
Sun gear
Planetary carrier
None
Sun gear
Ring gear
Rear planetary carrier (does not contribute to power flow)
Manual LOW Position and 1st Gear Below 8 km/h (5 mph) Clutch Application Chart
Gear
Direct (3, 5,
R)
Overdrive (4, 5,
6)
Forward (1, 2, 3,
4)
Low/ Reverse (L,
R)
Intermediate (2,
6) One-Way
1st
gear
X X X
Power Flow
Hydraulic Operation







clutch.


regulator and latch valves. As the 1234 regulator valve moves, it supplies the forward (1, 2, 3, 4)

Power Flow 3618
clutch and 1234 latch valve with regulated line pressure through the C1234 circuit. The latch valve
directs the regulated line pressure to the opposite side of the regulator valve through the C1234 FDBK
valve directs the regulated line pressure to the opposite side of the low reverse/456 regulator valve
through the CBR1/C456 FDBK circuit for gradual low/reverse clutch engagement.


Solenoid operation:
Manual LOW Position and 1st Gear Below 8 km/h (5 mph) Solenoid Operation Chart
Base Selector
Lever
Position
PCM
Commanded
Gear
Shift Solenoid
TCC
(VFS)
NL
SSA (VFS)
NL (1, 2, 3,
4)
SSB (VFS)
NH (3, 5,
R)
SSC
(VFS) NL
(2, 6)
SSD (VFS)
NH (L, R/4,
5, 6)
SSE
(On/Off)
NC
NH = Normally high
NL = Normally low
5th Gear Failsafe
5th Gear Failsafe Description
When the transaxle has an electrical, hydraulic or mechanical failure, the PCM removes ground (control) from
the shift, TCC and LPC solenoids. The uncontrolled solenoids default to their normal states. SSB , SSD and
the LPC solenoid are normally high solenoids which means in their normal state, they provide high pressure
to the valves they control. This provides only 5th gear with maximum line pressure.
Apply components:
Planetary carrier
Sun gear
Planetary carrier
None
None
None
5th Gear Failsafe Clutch Application Chart
Gear
Direct (3, 5,
R)
Overdrive (4, 5,
6)
Forward (1, 2, 3,
4)
Low/ Reverse (L,
R)
Intermediate (2,
6) One-Way
5th
gear
X X
Power Flow
Hydraulic Operation

solenoid through the VBS LINE circuit. In 5th gear failsafe, full solenoid pressure is supplied by the
LPC solenoid to the main pressure regulator valve for maximum line pressure.

Pressure from the main pressure regulator valve is directed to the TCC control valve through the
CONV FD hydraulic circuit.


Fluid from the TCC RELEASE circuit returns to the TCC control valve through the TCC APPLY
circuit.



The LPC solenoid applies maximum solenoid output pressure to the main pressure regulator valve
through the VBS LINE hydraulic circuit. The LPC solenoid defaults to maximum output to provide
maximum line pressure.

SSD applies maximum solenoid pressure to the low reverse/456 clutch regulator and latch valves to
apply the O/D (4, 5, 6) clutch.

SSB applies maximum solenoid pressure to the 35R clutch regulator and latch valves to apply the
direct (3, 5, R) clutch.

Line pressure from the pump is supplied to the low reverse/456 regulator valve. SSD supplies
maximum solenoid pressure to the low reverse/456 regulator and latch valves to provide full line

Power Flow 3622
pressure in the CBR1/C456 circuit.
Maximum line pressure at the clutch control bypass valve in the CBR1/C456 circuit is directed to the

Pressure in the C456 also supplies the latch pressure for the clutch control bypass valve.
and DRIVE 2/C35R FD circuit. SSB applies maximum solenoid pressure to the 35R regulator and
latch valves to provide full line pressure to the direct (3, 5, R) clutch.

Solenoid operation:
5th Gear Failsafe Solenoid Operation Chart
Base Selector
Lever Position
PCM
Commanded
Gear
Shift Solenoid
SSA (VFS)
NL (1, 2, 3,
4)
SSB (VFS)
NH (3, 5, R)
SSC (VFS)
NL (2, 6)
SSD (VFS)
NH (L, R/4, 5,
6)
SSE
(On/Off)
NC
D 5 Off Off Off Off Off
NH = Normally high
NL = Normally low
Workshop Manual
Diagnostic Strategy
Troubleshooting an electronically controlled automatic transmission is simplified by using the proven method
of diagnosis. One of the most important things to remember is that there is a definite procedure to follow.
NOTE: Do not take shortcuts or assume that critical checks or adjustments have already been made.
Follow the procedures as written to avoid missing critical components or steps.
To correctly diagnose a concern, have the following publications available:
Transmission reference manual
TSBs
Wiring diagrams manual
These publications provide the information required when diagnosing transmission concerns.
Use the Diagnostic Flow C as a guide and follow the steps as indicated.
Know and understand the customer concern.
Check the fluid levels and condition.
Check for non-factory add-on items.
Check selector lever linkage for correct adjustment.
Check TSB messages regarding the concern.
Diagnostics
Carry out OBD test procedures, KOEO and KOER self-tests.
Record all DTCs.
Repair all non-transmission codes first.
Repair all transmission codes second.
Clear all continuous codes and attempt to repeat them.
Repair all continuous codes.
If only pass codes are obtained, refer to Diagnosis By Symptom for further information and diagnosis.
Follow the diagnostic sequence to diagnose and repair the concern the first time.
Transaxle/Transmission 6F35
Workshop Manual
Special Tool(s)
Prior to carrying out the flow test, the following items should be checked:
Know and understand the customer concern.
Check the transmission fluid level and condition.
Check for non-factory installed items and verify correct installation.
Check the selector lever linkage adjustments.
Check TSB messages for vehicle concerns.
Carry out both KOEO and KOER self-test.
Record all DTCs.
Test Result Action
1) Were any DTCs
recorded?
Yes
REPAIR all hard DTCs. FOLLOW the pinpoint tests. REFER
to the Powertrain Control/Emissions Diagnosis (PC/ED)
manual first, then this workshop manual, GO to Step 2.

No
REFER to Diagnosis By Symptom , GO to Step 5.
2) Are any continuous
test memory codes present?
Yes
CLEAR codes and CARRY OUT drive cycle test, GO to Step
3.

No
GO to Step 4.
3) Did the continuous test
memory codes reappear?
Yes
REPAIR all continuous test memory codes. FOLLOW the
pinpoint tests. REFER to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual, then the transmission reference
manual, then this workshop manual, GO to Step 4.

No
GO to Step 4.
4) Is the concern
repaired?
Yes
CARRY OUT the final self-test and verify no DTCs are

No REFER to Diagnosis By Symptom , GO to Step 5.
5) Are there any electrical
concerns?
Yes
INSTALL the scan tool. CARRY OUT static and drive test
with the scan tool, GO to Step 6.

No
REFER to the hydraulic and mechanical routine to diagnose
and repair the concern, GO to Step 7.

6) Was the transmission
concern corrected when the
scan tool was installed?
Yes
(PC/ED) manual, intermittent fault diagnosis section and use
the scan tool to diagnose cause of concern in the processor,
vehicle harness or external inputs (sensors or switches).

No
REFER to the hydraulic and mechanical routine to diagnose
the concern, GO to Step 7.

7) Is the concern
repaired?
Yes
CARRY OUT the final self-test and verify no DTCs are

No
Concern should have been repaired. GO back through the
Diagnostic Flow Chart and review other components that may
have contributed to the concern. CHECK and DIAGNOSE
those components. Get assistance from other sources.

Workshop Manual
Material
Item Specification
XT-10-QLVC
MERCON
LV
The following items must be checked prior to beginning the diagnostic procedures.
Know and Understand the Concern
In order to correctly diagnose a concern, first understand the customer complaint or condition. Customer
contact may be required in order to begin to verify the concern. Understand the conditions as to when the
concern occurs. For example:
Hot or cold vehicle temperature
Hot or cold ambient temperature
Vehicle driving conditili>
After understanding when and how the concern occurs, proceed to verifying the concern.
Verification of Condition
This section provides information which is used in determining the actual cause of customer concern and
carrying out the appropriate procedures.
The following procedures must be used when verifying customer concerns for the transmission.
Determine Customer Concern
NOTE: Some transaxle conditions may cause engine concerns. The torque converter not disengaging may
stall the engine.
Determine customer concerns relative to vehicle use and dependent driving conditions, paying attention to the
following items:
Hot or cold vehicle operating temperature
Type of terrain
Upshift
Downshift
Coasting
Engagement
Noise/vibration - check for engine rpm , vehicle speed, shift, gear, range or temperature dependencies.
Check Transmission Fluid Level and Condition
NOTICE: Do not drive the vehicle if the transmission fluid level indicator shows the transmission fluid
is below the minimum transmission fluid level mark or internal failure could result.
If the vehicle has been operated for an extended period of time at highway speeds, in city traffic, in hot
weather or while pulling a trailer, the transmission fluid may need to cool down to obtain an accurate reading.
operating and ambient temperatures. The correct reading should be within the crosshatch area.
Transmission Fluid Level Check NOTE: Transmission fluid should be checked at normal operating
temperature 85C-93C (185F-200F) on a level surface. Normal operating temperature can be reached after
approximately 32 km (20 mi) of driving and can be checked using the scan tool.
Check the transmission fluid level during normal maintenance. If the transaxle starts to slip, shifts slowly or
shows signs of leaking, the transmission fluid level should be checked.
With the selector lever in PARK, engine at idle, brake pedal applied, move the selector lever through
each gear range and allow engagement of each gear. Place the selector lever in the PARK position.
1.
seated.
4.
Remove the transmission fluid level indicator. The transmission fluid level should be within the
crosshatch area.
5.
Item Description
1 Correct transmission fluid level at operating temperature 85C-93C (185F-200F)
2 Minimum transmission fluid level mark
3 Maximum transmission fluid level mark
4 Flat tow transmission fluid level
High transmission fluid level may cause the transmission fluid to become aerated due to the churning action
of the rotating internal parts. This will cause erratic control pressure, foaming, loss of transmission fluid from
the vent tube and possible transaxle malfunction and/or damage. If an overfill reading is indicated, refer to
Transmission Fluid Drain and Refill in this section.
Low transmission fluid level could result in poor transaxle engagement, slipping, malfunction and/or damage.
This could also indicate a leak in one of the transaxle seals or gaskets.
NOTICE: The use of any type of transmission fluid other than specified could result in transaxle
malfunction and/or damage.
transmission fluid filler tube with the selector lever in PARK and the engine idling. Do not overfill the
transmission. For transmission fluid type, refer to Material chart in this section.
Flat Tow Fluid Level
Recreati flat towing of the vehicle may require the transmission fluid to be set to a lower fluid level. This will
prevent damage to the transmission. The transmission fluid level is within the normal operating range and will
not require the transmission fluid level to be readjusted after recreational towing.
2.
Observe the color and the odor. Under normal circumstances, the color should be dark red, not brown
or black or have a burnt odor.
3.
If evidence of solid material is found, remove the transmission fluid pan for further inspection. 4.
If the stain is a foamy pink color, this may indicate coolant or water in the transaxle. Inspect the
engine cooling system at this time.
5.
If transmission fluid contamination or transaxle failure is confirmed by the sediment in the
transmission fluid, disassemble and thoroughly clean the transaxle, including the torque converter,
cooler bypass valve, coolers and cooler tubes.
6.
Carry out diagnostic checks and adjustments, refer to Diagnosis By Symptom in this section. 7.
Water in Transmission Fluid
To correctly repair a transaxle that had water or coolant introduced into the system, completely disassemble,
clean and replace the following parts:
All internal and external seals
All friction material; clutches
Torque converter
All parts with bonded seals
All solenoids
All transmission fluid filters
Prior to installing the transaxle, flush and clean the transmission fluid cooler(s), transmission fluid cooler
tubes and transmission fluid cooler hoses.
Workshop Manual
Solenoid Body Strategy
Special Tool(s)
Solenoid Body Identification Procedure
Using the scan tool, select Powertrain, Transmission and Transion Solenoid Body Identification from
the toolbox icon and follow the instructions displayed on the scan tool.
The solenoid body identification screen displays solenoid body identification information:
Solenoid body identification 7-digits
Solenoid body strategy 13-digits
The next screen displays the current solenoid body identification and strategy data file stored
in the TCM . If the solenoid body strategy field is blank, the module contains a partial
transmission solenoid body strategy. This is due to a corrupt or missing file at the time the
programmable parameters were completed.

1.
NOTE: The 13-digit solenoid body strategy number consists of only numbers. Letters are not used.
Compare the solenoid body identification and strategy (if available) to the solenoid body service tag
or the replacement solenoid body tag located on top of the transmission case.
2.
Original Solenoid Body Service Tag
Item Description
1 13-digit solenoid body strategy
2 7-digit solenoid body identification
Replacement Solenoid Body Service Tag
Solenoid Body Strategy 3633
Item Description
If the solenoid body identification and strategy on the scan tool match the solenoid body service tag or
replacement tag, then the solenoid body identification and strategy are correct for this transmission
and a solenoid body strategy download is not required. If the solenoid body service tag or replacement
tag is missing or damaged so that it is not readable or does not match the identification or strategy on
the scan tool, remove the solenoid body connector and view the solenoid body identification and
strategy printed on the solenoid body connector. If it is not readable, remove the main control cover,
refer to Main Control Cover .
The 7-digit identification number and the 13-digit strategy number are stamped on the solenoid body.
3.
NOTICE: If the solenoid body information does not match the module information,
transmission damage or driveability concerns can occur.
Inspect the solenoid body identification and strategy printed on the solenoid body connector and
compare this to the solenoid body service tag on the transmission case. If the solenoid body
identification and strategy printed on the solenoid body connector does not match the solenoid body
service tag or if the solenoid body identification and strategy printed on the solenoid body connector
match the solenoid body service tag on the transmission case but do not match the solenoid body
identification and strategy numbers displayed on the scan tool, a solenoid body strategy data
download is required.
4.
Solenoid Body Identification Tag
Item Description
Replacement Solenoid Body Service Tag 3634
Solenoid Body Strategy Data Download
Using the scan tool, select Module Programming and Programmable Parameters under the toolbox
icon and select transmission. Follow the instructions displayed on the scan tool.
There are fields to enter the solenoid body 7-digit identification and 13-digit strategy recorded from
the solenoid body.
1.
NOTICE: If the solenoid body information is not correct, transmission damage or driveability
concerns can occur.
Enter the solenoid body identification and strategy.
The scan tool will verify the numbers entered are valid and display a message if the information is not
valid.
The scan tool checks to see if the file is present on the scan tool. If the file is present, the technician
may proceed with downloading the file to the TCM . If the file is not present, the scan tool will need
to be connected to the PTS server to download the file onto the scan tool.
2.
Verify the file is present on the scan tool. If the file is present, go to Step 8. If the file is not present,
continue with this procedure.
3.
Connect the scan tool to the PTS server.
The screen will display a progress bar when connecting to the network.
4.
Follow the instructions on the network to download the strategy file to the scan tool.
The screen will display a progress bar when downloading the strategy file to the scan tool and display
a message if it is downloaded successfully.
5.
If the scan tool cannot connect to the PTS server, download the file from www.motorcraft.com.
If the scan tool cannot download a strategy from the web site, a partial strategy will automatically be
downloaded.
6.
Reconnect the scan tool to the vehicle. 7.
Follow the instructions displayed on the scan tool. 8.
If a new solenoid body was installed, compare the 7-digit identification and the 13-digit strategy fields
from the solenoid body to the replacement solenoid body tag provided with the solenoid body service
kit and place it over the existing identification tag.
The scan tool will automatically download the strategy file or partial strategy file to the TCM and will
display a progress bar while downloading. The scan tool will display a message when it is finished
downloading the data that states that the file was downloaded successfully.
9.
Item Description
Solenoid Body Identification Tag 3635
NOTICE: If a drive cycle is not completed, the customer may feel erratic shifts and driveability
concerns.
Test drive the vehicle. Refer to Solenoid Body Strategy Drive Cycle in this procedure.
10.
Solenoid Body Strategy Drive Cycle
Carry out the drive cycle after downloading the solenoid body strategy data file to the TCM .
NOTE: The engine and transmission must be at normal operating temperature.
Bring the transmission to normal operating temperature.
1.
With the engine running and the brake applied, move the selector lever through the gears in the
following order, pausing in each gear for 4 seconds: N, R, N, D, R, D, N. Repeat this pattern 2 times.
If any engagements feel soft or harsh, repeat this procedure.
2.
Drive the vehicle and accelerate at a moderate throttle so the upshifts occur at 2,000 rpm up to 80
km/h (50 mph) and brake lightly to a stop. Repeat this pattern 2 times.
3.
Drive the vehicle and accelerate at a moderate throttle so the upshifts occur at 3,000 rpm up to 80
km/h (50 mph) and brake lightly to a stop. Repeat this pattern 2 times.
4.
With the engine running and the brake applied, move the selector lever through the gears in the
following order, pausing in each gear for 4 seconds: N, R, N, D, R, D, N. Repeat this pattern 2 times.
5.
From a stop, accelerate to 25 mph, then release the throttle. Keeping the throttle closed, pull the
selector lever into the "L" position and coast down to 10 mph. Repeat this pattern 2 times.
6.
Workshop Manual
Road Testing Vehicle
NOTE: If a new or remanufactured transmission assembly is being installed or a new solenoid body is
installed, the TCM will have to be re-programed with a new solenoid body strategy and identification data
file. The solenoid body strategy drive cycle should also be carried out. Refer to Solenoid Body Strategy .
The Shift Point Road Test and Torque Converter Operation Test provide diagnostic information on shift
controls and torque converter operation.
Road Testing Vehicle 3638
Workshop Manual
Shift Point Road Test
This test verifies the shift control system is operating correctly.
Bring engine and transaxle up to normal operating temperature. 1.
Operate vehicle with the selector lever in D range. 2.
NOTE: Shift speed ranges are approximate for all applications.
Apply minimum throttle and observe the vehicle speed when an upshift occurs and the torque
converter engages using the Shift Speeds chart.
Shift Speeds 2.5L
Light D 1-2 11-16 7-10
Throttle
a
D 2-3 21-27 13-17
D 3-4 29-37 18-23
D 4-5 45-56 28-35
D 5-6 72-90 45-56
Medium D 1-2 27-43 17-23
Throttle
a
D 2-3 42-55 26-34
D 3-4 58-77 36-48
D 4-5 77-106 48-66
D 5-6 135-177 84-110
Heavy D 1-2 51-66 32-41
Throttle
a
D 2-3 79-100 49-62
D 3-4 113-143 70-89
D 4-5 150-190 93-118
D 5-6 201-245 125-152
a
Shift Speeds 3.0L
Light D 1-2 13-18 8-11
Throttle
a
D 2-3 19-26 12-16
D 3-4 29-37 18-23
D 4-5 45-56 28-35
D 5-6 72-90 45-56
3.
Medium D 1-2 32-42 20-26
Throttle
a
D 2-3 48-61 30-38
D 3-4 63-82 39-51
D 4-5 80-108 50-67
D 5-6 117-159 73-99
Heavy D 1-2 58-72 36-45
Throttle
a
D 2-3 85-106 53-66
D 3-4 126-156 78-97
D 4-5 151-192 94-119
D 5-6 217-261 135-162
a
With vehicle speed above 43 km/h (27 mph), press the accelerator pedal to Wide Open Throttle
(WOT). The transaxle should shift from 4th to 3rd, or 4th to 2nd, depending on vehicle speed. The
torque converter should disengage.
4.
With vehicle speed above 56 km/h (35 mph), move the selector lever from the D range to the L range
and remove foot from accelerator pedal. The transaxle should immediately downshift to 2nd gear.
When vehicle speed drops below 32 km/h (20 mph), the transaxle should downshift into 1st gear.
5.
If the transaxle fails to upshift/downshift or the torque converter does not apply and release, refer to
Diagnosis By Symptom in this section for possible causes.
6.
Workshop Manual
Torque Converter Diagnosis
Special Tool(s)
Prior to torque converter installation, all diagnostic procedures must be followed. This is to prevent the
unnecessary installation of new or remanufactured torque convertAfter a complete diagnostic evaluation can a
decision be made to install a new or remanufactured torque converter.
Begin with the normal diagnostic procedures as follows:
Preliminary inspection 1.
Know and understand the customer concern 2.
Verify the concern - carry out the Torque Converter Operation Test 3.
Carry out diagnostic procedures:
Run OBD . Refer to Diagnostics .
Repair all non-transmission related DTCs first.
Repair all transmission DTCs.
Rerun OBD test to verify repair.
Carry out Line Pressure Test. Refer to Special Testing Procedures .
Carry out Stall Speed Test. Refer to Special Testing Procedures .
Carry out diagnostic routines. Refer to Diagnosis By Symptom .
Use the index to locate the appropriate routine that best describes the symptom(s).
The routine will list possible components that may cause or contribute to the
symptom. Check each component listed, diagnose and repair as required before
installing a new torque converter.

4.
Torque Converter Operation Test
This test verifies the TCC control system and the torque converter are operating correctly.
Carry out self-test and check for DTCs. 1.
Connect the scan tool and monitor engine rpm. 2.
Bring the engine to normal operating temperature by driving the vehicle at highway speeds with the
selector lever in the (D) position.
3.
If the vehicle stalls in (D) at idle with the vehicle at a stop, move the selector lever to manual L
position. If the vehicle stalls, see Torque Converter Operation Concerns, refer to Diagnosis By
Symptom . Repair as required. If the vehicle does not stall in (D), refer to Diagnosis By Symptom .
4.
Workshop Manual
Visual Inspection
This inspection will identify modifications or additions to the vehicle operating system that may affect
diagnosis. Inspect the vehicle for non-Ford factory add-on devices such as:
Electronic add-on items:
A/C
generator (alternators)
engine turbo
cellular telephone
cruise control
CB radio
linear amplifiers
backup alarm signal
computer

Vehicle modification.
These items, if not installed correctly, will affect PCM or transmission function. Pay particular
attention to add-on wiring splices in the PCM harness or transmission wiring harness, abnormal tire
size or axle ratio changes.

Leaks, refer to Leakage Inspection in this section.
Section 307-05A .
Selector Lever Linkage Check
Hydraulic leakage at the manual control valve can cause delay in engagements and/or slipping while operating
if the linkage is not correctly adjusted. Refer to Section 307-05A for selector lever linkage adjustment.
Check TSBs
Refer to all TSBs which pertain to the concern and follow the procedure.
Carry Out On-Board Diagnostics, Key ON Engine OFF (KOEO), Key ON Engine Running (KOER)
After a road test, with the engine and transmission at normal operating temperature and before disconnecting
any connectors, use the scan tool to perform the self-test procedure. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual for diagnosis and testing of the powertrain control system.
Workshop Manual
Diagnostics
OBD with Scan Tool
These self-tests should be used to diagnose the TCM and should be carried out in order.
If the cause is not visually evident, connect the scan tool to the DLC . 1.
NOTE: The VCM LED prove-out confirms power and ground from the DLC to the VCM .
refer to Section 418-00 to diagnose no power to the scan tool.
2.
verify the ignition is in the RUN position.
verify scan tool operation with a known good vehicle.
refer to Section 418-00 to diagnose no response from the TCM .
3.
If the scan tool responds with no communication from one or more modules, refer to Section
418-00 .

If the network test passes, retrieve and record the continuous memory DTCs.
4.
Clear the continuous DTCs and carry out the TCM self-test. 5.
If DTCs retrieved are related to the concern, GO to the DTC Chart. 6.
If no DTCs related to the concern are retrieved, GO to Diagnosis By Symptom . 7.
Diagnostics 3645
Diagnostics 3646
Workshop Manual
Output State Control (OSC) Mode
Special Tool(s)
Description
Output state control allows a diagnostic scan tool direct control of specific transmissiomponents or functions.
Output state control allows the technician to control the main functions or components of the transmission to
help the technician diagnose the transmission quickly and easily. For example, output state control may be
used to change gears or remain in a specific gear. Output state control may be used to control the operation of
the TCC to engage or disengage, or to keep the converter clutch from engaging at all. Output state control
may be used to help carry out solenoid electrical pinpoint tests by turning a solenoid off or on by controlling
the actual current to the VFS solenoid.
Procedure
NOTE: Retrieve Continuous Codes and carry out a KOEO and KOER On-Demand Self Test before using any
output state control. Any DTCs related to the TR sensor, the OSS sensor or the TSS sensor must be fixed or
the TCM will not allow the output state control to operate.
Output state control is used to test various transmission components and functions when the vehicle is in the
service bay or being driven on the road. Specific vehicle conditions are required for output state control to
control each specific function or component. The following describes which transmission functions and
components output state control may control and the specific vehicle conditions necessary for its operation.
Service Bay - Vehicle State No. 1
Vehicle state No. 1 is functional ONLY when the ignition is in the ON position and the selector lever is in
PARK or NEUTRAL with the engine OFF. Vehicle state No. 1 is required when using output state control to
carry out electrical pinpoint tests. The following transmission components may be controlled using output
state control in vehicle state No. 1.
SSA_AMP - Controls the current to SSA , VFS
SSB_AMP - Controls the current to SSB , VFS
SSC_AMP - Controls the current to SSC , VFS SSD_AMP - Controls the current to SSD , VFS
SSE - Directs TCM to command SSE OFF or ON
LPC_AMP - Controls the current to the LPC VFS
TCC_AMP - Controls the current to the TCC VFS
The vehicle requirements must be met when sending an output state control value to control each component
such as the solenoids stated above. If the vehicle requirements are not met when sending the output state
Output State Control (OSC) Mode 3647
control value, an error message may appear. When an error message appears, output state control is cancelled
and should be restarted.
After sending the output state control value, if the vehicle requirements are no longer met, the error message
will not appear but the output state control value will be cancelled by the TCM . Use the scan tool to monitor
the PID that corresponds to each output state control function or component to determine if the TCM is using
the output state control value or normal control.
Output state control may be cancelled at any time, to return the TCM to normal control for a specific output
state control function or component. See instructions for specific scan tool.
Service Bay - Vehicle State No. 2
Vehicle state No. 2 is functional ONLY when the engine is running and the selector lever is in PARK or
NEUTRAL with engine speed greater than 1,100 rpm. Vehicle state No. 2 is required when using output state
control to carry out a line pressure check. Most, but not all, of the solenoids may be controlled during this
vehicle state. It is recommended to use vehicle state No. 1 when using output state control to control the
solenoids. The following transmission function and components may be controlled using output state control
in vehicle state No. 2.
LINEDSD - Output state control function to command line pressure to a desired pressure
SSD_AMP - Controls the current to SSD , VFS
SSC_AMP - Controls the current to SSC VFS
SSB_AMP - Controls the current to SSB , VFS
SSA_AMP - Controls the current to SSA , VFS
The vehicle requirements must be met when sending an output state control value to control each component
such as the solenoids stated above. If the vehicle requirements are not met when sending the output state
control value, an error message may appear. When an error message appears, output state control is cancelled
and should be restarted.
will not appear but the output state control value will be cancelled by the TCM . Use the scan tool to monitor
the PID that corresponds to each output state control function or component to determine if the TCM is using
the output state control value or normal control.
Output state control values for SSA_AMP, SSB_AMP, SSC_AMP, SSD_AMP, LPC_AMP and TCC_AMP
to control the current on the VFS solenoids are between zero (0) and one (1) amp. The following are
examples.
0 - Commands TCM to control current to zero amps
0.25 - Commands TCM to control current to 1/4 amp or 250 milliamps
1 - Commands TCM to control current to 1 amp or 1,000 milliamps
Output state control aids in testing the electronic functions of the TCM , VFS solenoid and associated
circuitry. Output state control allows the technician to control the TCM commanded current of the VFS
solenoids and the commanded state of the on/off solenoid. This allows the technician to accurately test the
electronic circuitry by comparing the commanded current with the actual current or the on/off state with the
actual voltage. Shifting the transmission through the various gears tests the mechanical operation of the VFS
solenoids. When using output state control to control the VFS current, the technician may measure the circuit
current using an inductive pickup or measure the circuit voltage drop to help verify the proper electrical
operation of each VFS solenoid.
The output state control values for LINEDSD to command a desired line pressure are between 414 kPa (60
psi) and 1,931 kPa (280 psi). The following are examples.
60 psi - Commands TCM to control line pressure to 414 kPa (60 psi)
200 psi - Commands TCM to control line pressure to 1,517 kPa (200 psi)
NOTICE: Do NOT command line pressure LOWER then 414 kPa (60 psi) or HIGHER then 1,931 kPa
(280 psi) or damage to the transmission can occur.
Output state control allows the technician to control the TCM commanded line pressure. This allows the
technician to accurately test the electronic pressure control system by comparing the output state control
commanded line pressure to the actual line pressure indicated on the pressure gauge. The pressure gauge
should be connected to the line pressure tap on the transmission. The PID corresponding to the commanded
line pressure must be monitored to make sure the TCM is using the output state control value for the
commanded line pressure. This test will help verify the correct operation of the transmission pump assembly,
pump regulator valve and the operation of the LPC solenoid.
Drive Test
Output state control allows control of 3 transmission functions while driving on the road.h transmission
function has a unique set of vehicle operating requirements that the technician is required to meet before the
TCM will allow output state control.
TCC_OSC - Commands the TCM to engage or disengage the TCC
GEAR_OSC - Commands the TCM to change gears (upshift or down-shift) or remain in a gear
HRSH_SFT - Commands a slightly higher hydraulic pressure during engagements and upshifts
The vehicle requirements must be met when sending an output state control value to control the specific
functions stated above. If the vehicle requirements are not met when sending the output state control value, an
error message may appear. When an error message appears, output state control is cancelled and should be
restarted.
will not appear but the output state control value is cancelled by the TCM . Use the scan tool to monitor the
PID that corresponds to each output state control function or component to determine if the TCM is using the
outpte control value or normal control.
Drive Test - Torque Converter Clutch Control
The output state control values for TCC_OSC to engage or disengage the TCC are as follows:
0 - TCM in normal control of TCC and output state control is cancelled
1 or OFF - Commands TCM to keep the torque converter clutch from engaging
2 or ON - Commands TCM to engage the TCC using a normal ramp rate
3 or ON - Commands TCM to engage the TCC using a fast ramp rate
Controlling the TCC will assist the technician in testing the operation of the torque converter for engagements
and disengagements. Also, the technician may find it easier to evaluate upshifts and downshifts by first using
output state control to keep the TCC from engaging.
Vehicle requirements when using TCC_OSC - Controlling the TCC .
When SENDING the TCC_OSC value [1 or OFF], the engine must be running with the transmission in the
DRIVE position and the vehicle speed must be greater than 5 km/h (3 mph).
When SENDING the TCC_OSC value [2 or 3 or ON], the engine must be running with the selector lever in
the DRIVE position, transmission in 3rd, 4th, 5th or 6th gear, transmission temperature between 4C (40F)
and 121C (250F), the vehicle speed must be below 24 km/h (15 mph) and engine speed greater than 1,100
rpm with minimal engine load.
Drive Test - Upshift and Downshift Control
NOTE: Once output state control has successfully commanded the transmission to shift to the desired output
state control gear, the transmission will remain in that gear until output state control commands a different
gear or the vehicle conditions are no longer correct.
The output state control values for GEAR_OSC to control the transmission gear changes are as follows:
0 - TCM in normal shift control and output state control is cancelled
1 - Commands TCM to shift to 1st gear - no engine braking
2 - Commands TCM to shift to 2nd gear - with engine braking
3 - Commands TCM to shift to 3rd gear - with engine braking
4 - Commands TCM to shift to 4th gear - with engine braking
Controlling the gear changes will assist the technician in testing the various clutches and whether the
transmission is slipping in any particular gear. Output state control will command the TCM to upshift or
downshift depending on the output state control gear value the technician selects. The transmission will
remain in the output state control gear selected until another output state conor until output state control is
cancelled and/or the vehicle conditions for using output state control are no longer met.
Vehicle requirements when using GEAR_OSC - Controlling Gear Changes
When SENDING a GEAR_OSC value, the engine must be running with the selector lever in the DRIVE
position, and the vehicle speed must be greater than 5 km/h (3 mph).
Additional vehicle conditions required for upshifts:
Vehicle speed must be greater then 32 km/h (20 mph) when commanding an upshift to 5th or 6th gear
Additional vehicle conditions required for downshifts:
Vehicle speed must be less then 32 km/h (20 mph) when commanding a downshift to 1st gear
Vehicle speed must be less then 64 km/h (40 mph) when commanding a downshift to 2nd gear
Vehicle speed must be less then 97 km/h (60 mph) when commanding a downshift to 3rd gear
Vehicle speed must be less then 129 km/h (80 mph) when commanding a downshift to 4th gear
Vehicle speed must be less then 161 km/h (100 mph) when commanding a downshift to 5th gear
Drive Test - Pressure Added for Engagements and Upshifts
The output state control values for HRSH_SHFT to command a slight or moderate increase in hydraulic
pressure to test for harsh engagements and upshifts are as follows:
0 or OFF - TCM in normal pressure control for shifts and engagements and output state control is
cancelled

1 or ON - Commands TCM to moderately increase hydraulic pressure during engagements and
upshifts

Setting HRSH_SFT to 1 or ON allows the tn to moderately increase the pressure when performing
engagements such as P-R, P-D, N-R, N-D, R-D and when performing automatic upshifts. This can provide
additional diagnostic information to help the technician determine whether the electronic pressure control
system is providing at least limited control (a normal shift would become harsh). Using output state control to
control HRSH_SHFT [1 or ON] should make a softer engagement or shift more normal and an already normal
shift or engagement harsher by slightly increasing the pressure. This test should only be used to provide
additional diagnostic information and should not be the only scan tool or test to determine a faulty electronic
or hydraulic component.
Using Output State Control and Monitoring PIDs
To confirm that the output state control value was sent by the scan tool and the TCM has accepted the output
state control command, a corresponding PID for each output state control parameter must be monitored. After
SENDING the output state control value, the corresponding PID value should be the same as the output state
control value that was sent. Additional PIDs are listed that may be monitored to help the technician accurately
diagnose the transmission.
The following is a list of output state control parameters and their corresponding PIDs:
Output State Control Parameter Corresponding PID Additional PIDs
GEAR_OSC GEAR GEAR_RAT
HRSH_SHFT - GEAR, GEAR_RAT
LINEDSD LPC LPC_F
LPC_AMP LPC TCCRAT, TCCMCMD, TSLIP
SSA_AMP SSPCA SSPCA_F
SSB_AMP SSPCB SSPCB_F
SSC_AMP SSPCC SSPCC_F
SSD_AMP SSPCD SSPCD_F
TCC AMP TCC TCC_F, TCC_RAT
TCC_OSC TCC TCC_F, TCC_RAT
Workshop Manual
Diagnostic Parameters Identification (PID) Chart
Special Tool(s)
PID Name PID Description Units
GEAR PCM commanded transaxle gear P, R, N, 1, 2, 3, 4, 5
and 6
GEAR_OSC Output state control commanded gear P, R, N, 1, 2, 3, 4, 5
and 6
GEAR_RAT Transaxle gear ratio Ratio
HRSH_SHFT Output state control commanded firm shift On/Off
IN_GEAR PCM commanded transaxle gear P, R, N, 1, 2, 3, 4, 5
and 6
LINEDSD Output state control commanded line pressure Pressure
LPC PCM commanded pressure for the Line Pressure Control (LPC)
Variable Force Solenoid (VFS)
Pressure
LPC AMP Output state control commanded current for the LPC VFS Amperes
LPC_F Fault status for the LPC VFS Fault/No Fault
OSS_F Fault status for Output Shaft Speed (OSS) sensor Fault/No Fault
OSS_SRC Actual speed of the OSS sensor (rpm) rpm
SSA_AMP Output state control commanded current for the Shift Solenoid A
(SSA)/CB1234 VFS
Amperes
SSB_AMP Output state control commanded current for the Shift Solenoid B
(SSB)/C35R VFS
Amperes
SSC_AMP Output state control commanded current for the Shift Solenoid C
(SSC)/CB26 VFS
Amperes
SSD_AMP Output state control commanded current for the Shift Solenoid D
(SSD)/CBLR, C456 VFS
Amperes
SSPCA PCM commanded pressure for the SSA /CB1234 VFS Pressure
SSPCA_F Fault status for the SSA /CB1234 VFS Fault/No Fault
SSPCB Commanded pressure for the SSB /C35R VFS Pressure
SSPCB_F Fault status for the SSB /C35R VFS Fault/No Fault
SSPCC PCM commanded pressure for the SSC /CB26 VFS Pressure
SSPCC_F Fault status for the SSC /CB26 VFS Fault/No Fault
SSPCD PCM commanded pressure for the SSD /CBLR, C456 VFS Pressure
SSPCD_F Fault status for the SSD /CBLR, C456 VFS Fault/No Fault
SSPCE_F Fault status for On/Off Shift Solenoid E (SSE)/CBLR, C456 VFS Fault/No Fault
TCC PCM commanded pressure for the Torque Converter Clutch (TCC)
VFS
Pressure
TCC AMP Output state control commanded current for the TCC VFS Amperes
TCC_F Fault status for TCC VFS Fault/No Fault
TCC_OSC Output state control commanded pressure to the TCC VFS Pressure
TCC_RAT Actual speed ratio of torque converter (1.0 = fully engaged) Ratio
TCIL Transmission Control Indicator Lamp (TCIL) status On/Off
TCS_DEPRES Transmission Control Switch (TCS) status Depressed/Not
Depressed
TCS_STATE TCS status On/Off
TCC_SLIPACT Actual difference between engine speed and turbine speed,
measured in rpm
rpm
TCC_SLIPDSD PCM commanded difference between engine speed and turbine
speed, measured in rpm
rpm
TFT Transmission Fluid Temperature (TFT) Degrees
TFTV TFT voltage Voltage
TFT_F Fault status for TFT sensor Fault/No Fault
TR Transmission Range (TR) Range (P, R, N, D, L)
TRAN_RAT Actual transaxle gear ratio Ratio
TR_CRANK TR Range (P, R, N, D, L)
TR_DC TR Duty Cycle Frequency
TR_F Fault status for TR sensor Fault/No Fault
TR_FREQ TR Frequency Frequency
TSS_F Fault status for Turbine Shaft Speed (TSS) sensor Fault/No Fault
TSS_SRC Actual speed of the TSS sensor (rpm) rpm
Workshop Manual
Transaxle Drive Cycle Test
Special Tool(s)
After carrying out the self-test, use the followinansmission Drive Cycle Test for checking continuous codes:
NOTE: The Transmission Drive Cycle Test must be followed exactly. Malfunctions must occur 4 times
consecutively for the shift error DTC to be set. Torque converter failures must occur 5 times consecutively for
a continuous DTC to be set.
NOTE: When carrying out the Transmission Drive Cycle Test, see the Solenoid Operation Chart for correct
solenoid operation. Refer to Pinpoint Tests - OSC Equipped Vehicle .
Record then clear self-test DTCs. 1.
Warm engine to normal operating temperature. 2.
Make sure transmission fluid level is correct. 3.
With transmission in DRIVE, moderately accelerate from stop to 80 km/h (50 mph). This allows the
transmission to shift into 6th gear. Hold speed and throttle opening steady for a minimum of 15
seconds.
4.
With transmission in 6th gear and maintaining steady speed and throttle opening, lightly apply and
release the brake to operate the stoplamps. Hold speed and throttle steady for additional 5 seconds
minimum.
5.
Brake to a stop and remain stopped for minimum of 20 seconds. 6.
Repeat Steps 4 through 6 at least 5 times. 7.
Carry out the self-test and record continuous codes. 8.
If DTCs are present, refer to Diagnostic Trouble Code (DTC) Charts . Service all non-transmission
DTCs first as they can directly affect the operation of the transmission. Repeat the self-test and road
test the vehicle to verify the correction. Clear the DTCs, carry out drive cycle and repeat the self-test
after completing service on the DTCs.

If the self-test passes and a concern is still present, refer to Diagnosis By Symptom . Check TSBs for
diagnostic concern.

After OBD
NOTE: The vehicle wiring harness, TCM and non-transmission sensors may affect transmission operations.
Service these concerns first.
After the OBD procedures are complete, service all DTCs.
Begin with non-transmission related DTCs, then service any transmission related DTCs. Refer to the
Diagnostic Trouble Code (DTC) Charts for information on condition and symptoms. This chart is helpful
referring to the correct manual(s) and to aid in diagnosing internal transmission concerns and external
non-transmission inputs. The pinpoint tests are used in diagnosing electrical concerns of the transmission.
Make sure the vehicle wiring harness and TCM are diagnosed as well. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual for diagnosing non-transmission electronic components. The
diagnostic routine hydraulic/mechanical charts will help in diagnosing internal transmission concerns and
external non-transmission inputs.
Before Pinpoint Tests
NOTE: Prior to entering pinpoint tests, check the TCM wiring harness for correct connections, bent or broken
terminals, corrosion, loose wires, correct routing, correct seals and their condition. Check the TCM , sensors
and actuators for damage. Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
NOTE: If a concern exists after the electrical diagnosis has been carried out, refer to Diagnosis By Symptom .
If DTCs appear while carrying out the OBD test, refer to the Diagnostic Trouble Code (DTC) Charts for the
appropriate repair procedure. Prior to entering pinpoint tests, refer to TSBs for transmission concerns.
Workshop Manual
Diagnostic Trouble Code (DTC) Charts
Special Tool(s)
DTC Chart
NOTE: Using a scan tool, retrieve DTCs. Begin with and repair all non-transmission related DTCs. Start with
the U-DTCs (communication link codes) and repair any transmission-related DTCs.
DTC Grouping Component H> Description Condition Symptom Action
P0657 - Transaxle
solenoid power
control
Actuator supply
voltage A
circuit/open
Transaxle solenoid
power control
provides power to all
the solenoids. This
DTC sets if the
transaxle solenoid
power control relay
circuit is open.
Harsh
engagements.

No
voltage
to
solenoids.

Maximum
line
pressure.

Only
PARK,
REVERSE,
NEUTRAL
and 5th
gear
available.

No
Torque
Converter
Clutch
(TCC).

Poor
launch
due to
5th
gear
drive
away.

Will
GO to
Pinpoint Test
E .
turn on
Malfunction
Indicator
Lamp
(MIL).
P0701 P2700
(Forward
Clutch),
P2701 (Direct
Clutch),
P2702
(Intermediate
Clutch),
P2703
(Low/Reverse
Clutch) and
P2704
(Overdrive
Clutch)
Transmission
hydraulic and
clutch systems
(including
non-electrical
shift solenoid
faults, main
control valve
body and
clutch(s)).
Transmission
control system
range/performance
The PCM has detected
an intermittent clutch
on fault and the
control system keeps
getting stuck on ratio
changes but when it
turns off the suspected
clutch it releases. No
stuck on DTCs s.
Vehicle
decelerates
during
upshifts
or
hangs
in gear

Will
turn on
wrench
lamp.

Non-electrical
failure.
REPAIR the
more specific
DTC first.
CLEAR the
DTCs. TEST
the system for
normal
operation. If
the DTC
returns,
REFER to
Diagnosis By
Symptom in
this section.
P0706 P1702, P1921 TR sensor TR sensor A circuit
range/performance.
TR sensor frequency
out of range. PCM
receives a duty cycle
at 125 Hz. If the
frequency is out of
range (75 to 175 Hz is
the acceptable range)
this DTC will set.
Possible wiring,
connector or TR
sensor issue.
Possible
no
crank.

Only
PARK,
REVERSE,
NEUTRAL
and 5th
gear
available.

Harsh
engagements.

Extremely
delayed
engagements
(until a
DTC is
set).

After a
DTC is
set and
the
high
side
opened.
Harsh
engagements.

Poor
performance
(due
to
a

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test D .
5th
gear
drive
away).
No
shifts.

Will
turn on
MIL .

low.
TR sensor circuit duty
cycle out of range,
low. TR sensor duty
cycle below the
minimum value for
park (possible open
circuit, short to
ground, wiring,
connector or TR
sensor issue).
Possible
no
crank.

Only
PARK,
REVERSE,
NEUTRAL
and 5th
gear
available.

Harsh
engagements.

Extremely
delayed
engagements
(until a
DTC is
set).

After a
DTC is
set and
the
high
side
opened.
Harsh
engagements.

Poor
performance
(due
to
a
5th
gear
drive
away).

No
shifts.

Will
turn on
MIL .

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test D .
high.
TR sensor duty cycle
duty cycle out of
range, high. Duty
Possible
no

REPAIR the
more specific
DTC first. GO
cycle above the
maximum value for
LOW (possible short
to power, wiring,
connector or TR
sensor issue).
crank.
Only
PARK,
REVERSE,
NEUTRAL
and 5th
gear
available.

Harsh
engagements.

Extremely
delayed
engagements
(until a
DTC is
set).

After a
DTC is
set and
the
high
side
opened.
Harsh
engagements.

Poor
performance
(due
to
a
5th
gear
drive
away).

No
shifts.

Will
turn on
MIL .

to Pinpoint
Test D .
P0710 P0711, P0712,
P0713
Transmission
Fluid
Temperature
(TFT) sensor
TFT sensor A
circuit TFT sensor
voltage input
too low or too
high. TFT
input
indicates a
short to
ground or an
open circuit
(could be a
wiring,
connector or
sensor issue).
TCC
and
stabilized
shift
schedule
may be
enabled
sooner
after
cold
start.

Harsh
or soft
shifts.

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test B .
Also see
P0711, P0712
and P0713.
Will
turn on
wrench
lamp.

P0711 - TFT sensor TFT sensor A
circuit
range/performance.
PCM has detected no
TFT sensor change
during operation.
TCC
and
stabilized
shift
schedule
may be
enabled
sooner
after a
cold
start.

Harsh
or soft
shifts.

Will
turn on
wrench
lamp.

GO to
Pinpoint Test
B .
P0712 P0710, P0712 TFT sensor TFT sensor A
circuit low.
a voltage drop across
the TFT sensor
exceeds a temperature
greater than 171C
(340F) for more then
2.5 seconds (grounded
circuit).
TCC
and
stabilized
shift
schedule
may be
enabled
sooner
after
cold
start.

Harsh
or soft
shifts.

Will
turn on
MIL .

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test B .
P0713 P0710, P0713 TFT sensor TFT sensor A
circuit high.
a voltage drop across
the TFT sensor
exceeds a temperature
less than -45C
(-50F) for more then
2.5 seconds (open
circuit).
TCC
and
stabilized
shift
schedule
may be
enabled
sooner
after
cold
start.

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test B .
Harsh
or soft
shifts.

Will
turn on
MIL .

P0715 P0717 Turbine Shaft
Speed (TSS)
sensor
TSS sensor A
circuit. PCM has
detected TSS
sensor signal
failed to 0
speed when
vehicle
conditions
(mainly
output speed)
indicate TSS
sensor output
should be
present.

Electrical
failures (open,
short) of the
TSS sensor
wiring,
connector or a
failure of the
sensor itself
will cause this
failure.

Failure
Mode
Effect
Management
action
opens
transaxle
solenoid
power
control
(removes
power
from
all
solenoids).
Provides
PARK,
REVERSE,
NEUTRAL
and
5th
gear
with
maximum
line
pressure
and
open
TCC
available
(controlled
by
the
manual
lever).

Harsh
engagements
(due to
maximum
line
pressure).

Poor
launch
performance
(due to
5th
gear

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test F .
drive
away).
Will
turn on
MIL .

P0717 P0715 TSS sensor TSS sensor A
circuit no signal. Non- MIL
sister code to
P0715. Used
to illuminate
the wrench
light.
Failure
Mode
Effect
Management
action
opens
transaxle
solenoid
power
control
(removes
power
from
all
solenoids).
Provides
PARK,
REVERSE,
NEUTRAL
and
5th
gear
with
maximum
line
pressure
and
open
TCC
available
(controlled
by
the
manual
lever).

Harsh
engagements
(due to
maximum
line
pressure).

Poor
launch
performance
(due to
5th
gear
drive

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test F .
away).
P0718 - TSS sensor TSS sensor A
circuit intermittent.
PCM has detected an
erratic or noisy TSS
sensor signal.
Will turn on
wrench lamp.
GO to
Pinpoint Test
F .
P0720 P0722 Output Shaft
Speed (OSS)
sensor
OSS sensor circuit.
PCM has
detected OSS
sensor signal
failed to 0
speed when
vehicle
conditions
(mainly
turbine speed)
indicate OSS
sensor output
should be
present.

Electrical
failures (open,
short) of the
OSS sensor
wiring,
connector or a
failure of the
OSS sensor
itself will
cause this
failure.

Failure
Mode
Effect
Management
action
opens
transaxle
solenoid
power
control
(removes
power
from
all
solenoids).
provides
PARK,
REVERSE,
NEUTRAL
and
5th
gear
with
maximum
line
pressure
and
open
TCC
available
(controlled
by
the
manual
lever).

Harsh
engagements
(due to
maximum
line
pressure).

Poor
launch
performance
(due to
5th
drive
away).

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test C .
Will
turn on
MIL .

P0721 - OSS sensor OSS sensor circuit
range/performance.
PCM has detected an
erratic or noisy OSS
sensor signal.
Will turn on
wrench lamp.
GO to
Pinpoint Test
C .
P0722 P0720 OSS sensor OSS sensor circuit
no signal. Non- MIL
sister code to
P0720. Used
to illuminate
the wrench
light.
Failure
Mode
Effect
Management
action
opens
transaxle
solenoid
power
control
(removes
power
from
all
solenoids).
Provides
PARK,
REVERSE,
NEUTRAL
and
5th
gear
with
maximum
line
pressure
and
open
TCC
available
(controlled
by
the
manual
lever).

Harsh
engagements
(due to
maximum
line
pressure).

Poor
launch
performance
(due to
5th
gear

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test C .
drive
away).
P0729 - Transaxle Gear 6 incorrect
ratio
The PCM did not
detect a 6th gear ratio.
Shift Solenoid
C (SSC)
and/or Shift
Solenoid D
(SSD) stuck
off
non-electrical
fault (no
pressure).

Low/reverse
clutch and/or
overdrive
clutch
regulator
valve stuck in
default
position.

Low/reverse
clutch and/or
overdrive
clutch boost
valve stuck in
default
position.

Customer
may
notice
flares
or
neutral
conditions
on
shifts.

Erratic
shifting,
flares,
neutral
conditions
while
the
code is
being
set.

6th
gear
disabled.

Will
turn on
MIL .

TCIL
flashing

Will
turn on
wrench
lamp.

Intermediate
(2,6) clutch or
overdrive
(4,5,6) clutch
slip or failed
to apply.
REFER to the
Clutch
Application
chart located
in
Specifications
in this section.
CLEAR the
DTCs. TEST
the system for
normal
operation. If
the DTC
returns,
REFER to
Diagnosis By
Symptom in
this section.
ratio Forward
clutch,
low/reverse
clutch or
One-Way
Clutch
(OWC) failed
to apply.

Shift Solenoid
A (A) and/or
SSD stuck off
non-electrical
fault (no
pressure).

Forward
clutch and/or
low/reverse
clutch
regulator

Customer
might
notice
flares
or
neutral
conditions,
hangs
in gear.

Disable
1st
gear.

No
engine
braking.

Will
turn on
wrench
lamp.

Forward
(1,2,3,4)
clutch,
low/reverse
(L,R) clutch or
OWC slip or
failed to
apply. REFER
to the Clutch
Application
chart located
in
Specifications
in this section.
CLEAR the
DTCs. TEST
the system for
normal
operation. If
the DTC
valve stuck in
default
position.
Forward
clutch and/or
low/reverse
clutch boost
valve stuck in
default
position.

returns,
REFER to
Diagnosis By
Symptom in
this section.
ratio Forward
clutch or
intermediate
clutch failed
to apply.

SSA and/or
SSC stuck off
non-electrical
fault (no
presse).

Forward
clutch and/or
intermediate
clutch
regulator
valve stuck in
default
position.

Forward
clutch and/or
intermediate
clutch boost
valve stuck in
default
position.

Customer
might
notice
flares
or
neutral
conditions,
hangs
in gear.

Disable
2nd
gear.

Will
turn on
wrench
lamp.

Forward
(1,2,3,4)
clutch, or
intermediate
(2,6) clutch
failed to
apply. REFER
to the Clutch
Application
chart located
in
Specifications
in this section.
CLEAR the
DTCs. TEST
the system for
normal
operation. If
the DTC
returns,
REFER to
Diagnosis By
Symptom in
this section.
ratio Forward
clutch or
direct clutch
failed to
apply.

SSA and/or
Shift Solenoid
B (SSB) stuck
off
non-electrical
fault (no
pressure).

Forward
clutch and/or
direct clutch
regulator
valve stuck in

Customer
might
notice
flares
or
neutral
conditions,
hangs
in gear.

Disable
3rd
gear.

Will
turn on
wrench
lamp.

Forward
(1,2,3,4)
clutch, or
direct (3,5,R)
clutch failed to
apply. REFER
to the Ctch
Application
chart located
in
Specifications
in this section.
CLEAR the
DTCs. TEST
the system for
normal
operation. If
the DTC
default
position.
Forward
clutch and/or
direct clutch
boost valve
stuck in
default
position.

returns,
REFER to
Diagnosis By
Symptom in
this section.
ratio Forward
clutch or
overdrive
clutch failed
to apply.

SSA and/or
SSD stuck off
non-electrical
fault (no
pressure).

Forward
clutch and/or
overdrive
clutch
regulator
valve stuck in
default
position.

Forward
clutch and/or
overdrive
clutch boost
valve stuck in
default
position.

Customer
might
notice
flares
or
neutral
conditions,
hangs
in gear.

Disable
4th
gear.

Will
turn on
wrench
lamp.

Forward
(1,2,3,4)
clutch, or
overdrive
(4,5,6) clutch
failed to
apply. REFER
to the Clutch
Application
chart located
in
Specifications
in this section.
CLEAR the
DTCs. TEST
the system for
normal
operation. If
the DTC
returns,
REFER to
Diagnosis By
Symptom in
this section.
ratio Direct clutch
or overdrive
clutch failed
to apply.

SSB and/or
SSD stuck off
non-electrical
fault (no
pressure).

Direct clutch,
low/reverse
clutch and/or
overdrive
regulator
valve stuck in
default
position.

Customer
might
notice
flares
or
neutral
conditions,
hangs
in gear.

Disable
5th
gear.

Will
turn on
wrench
lamp.

Direct (3,5,R)
clutch, or
overdrive
(4,5,6) clutch
failed to
apply. REFER
to the Clutch
Application
chart located
in
Specifications
in this section.
CLEAR the
DTCs. TEST
the system for
normal
operation. If
the DTC
returns,
Low/reverse
clutch and/or
overdrive
clutch boost
valve stuck in
default
position.
REFER to
Diagnosis By
Symptom in
this section.
P0740 P0743 TCC TCC solenoid
circuit open
Open circuit.
TCC
failed
off.

Will
turn on
MIL .

TCIL
flashing

GO to
Pinpoint Test
A .
circuit
performance/stuck
off.
TCC mechanically
stuck off. Non-electrical
TCC
solenoid
stuck
off.

TCC
mechanical
failure.

TCC
regulator
apply
valve
stuck in
release
position.

TCC
control
valve
stuck in
release
position.

TCC
failed
to
apply
(less
than 80
rpm
slip
error
lasting
at least
3
seconds
when
TCC is

DTC P0741 is
a
non-electrical
DTC. CLEAR
the DTCs.
TEST the
system for
normal
operation. If
the DTC
returns,
REFER to
Torque
Converter
Operation
Concerns, No
Apply in
Diagnosis By
Symptom in
this section.
commanded
on) 3
consecutive
times.
Will
turn on
MIL .

TCIL
flashing

circuit stuck on.
Circuit shorted to
ground, TCC failed
on.
Failure
Mode
Effect
Management
action
opens
the
transaxle
solenoid
power
control,
removing
power
from
all
solenoids
(get
PARK,
REVERSE,
NEUTRAL
and 5th
gear as
the
only
forward
gear
with
TCC
open).

Harsh
engagements.

Poor
launch
performance
(due to
5th
gear
drive
away).

No
TCC
apply.

No
shifts.

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
Will
turn on
MIL .

TCIL
flashing

P0743 P0740, P0742
or P0744
TCC TCC solenoid
circuit electrical.
Sister code to P0740,
P0742 or P0744 used
to illuminate the
wrench light.
Will
turn on
wrench
lamp.

TCIL
flashing

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
circuit intermittent.
Circuit short to power.
TCC
failed
off.

Will
turn on
MIL .

TCIL
flashing

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
P0748 P0960, P0962
and P0963
Line Pressure
Control (LPC)
LPC electrical. LPC circuit failure
non- MIL . Sister code
to P0960, P0962 and
P0963 used to
illuminate the wrench
light. Additional
common fault DTCs,
P0750, P0751, P0752.
Failure
Mode
Effect
Management
action,
see
DTCs
P0960,
P0962
and
P0963.

Will
turn on
wrench
lamp.

TCIL
flashing

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
P0750 P0751 Shift Solenoid A
(SSA)
SSA Open circuit.
Customer
might
notice a
neutral
condition,
or a
single
erratic
or
unexpected
shift.

5th and
6th

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
gears
only.
Poor
launch
due to
5th
gear
drive
away.

Will
turn on
MIL .

P0751 P2700 Forward clutch SSA
performance/stuck
off.
Forward (1,2,3,4)
clutch failed to apply
when commanded.
SSA
non-electrical
failed stuck
off (no
pressure).

Forward
clutch stuck
off due to
mechanical
failure.

Forward
clutch
regulator
valve stuck in
the default
position.

Forward
clutch boost
valve stuck in
the default
position.

Customer
may
notice
neutral
conditions
or
flares
on
downshifts
from
5th or
6th
gear.

Once
the
DTC is
stored,
gears 1
through
4 are
disabled
-
leaving
5th and
6th
gears
as the
only
forward
gears.

Erratic
shifting,
harsh
engagements,
neutral
conditions,
flares,
poor
launch
performance,
harsh

REFER to
Diagnosis By
Symptom in
this section.
reverse
engagements.
Will
turn on
MIL .

P0752 - SSA SSA stuck o Forward (1,2,3,4)
clutch failed to release
when commanded.
SSA
non-electrical
failed stuck
on (pressure).

Forward
clutch stuck
on due to
mechanical
failure.

Forward
clutch
regulator
valve stuck in
the spring
compressed
position.

Customer
may
notice a
vehicle
deceleration
on a
shift
into 5th
or 6th
gear
(forward
clutch
failing
to
release
will
cause a
tie-up
in 5th
or 6th
gear).

Customer
might
notice
erratic
shifting
or
being
stuck in
4th
gear.

Once
the
DTC is
stored,
5th and
6th
gears
are
disabled.

Will
turn on
MIL .

REFER to
Diagnosis By
Symptom in
this section.
P0753 P0750, P0973
and P0974
SSA SSA electrical. Sister code to P0750,
P0973 and P0974
used to illuminate the
wrench light.
Additional common
Failure
Mode
Effect
Management

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
fault DTCs, P0752,
P0754, P0755.
action,
see
DTCs
P0750,
P0973
and
P0974.
Will
turn on
wrench
lamp.

P0754 - SSA SSA intermittent. Intermittent SSA
circuit faults but not
lasting long enough to
trip DTC, P0750,
P0973 or P0974.
Customer
might
notice
unexpected
upshifts,
downshifts,
flairs or
neutral
conditions.

Will
turn on
wrench
lamp.

GO to
Pinpoint Test
A .
P0755 P0756 SSB SSB . Open circuit or short
to power. Customer
might
notice
unexpected
upshift.

3rd and
5th
gears
available.

Harsh
engagements.

Poor
launch
performance.

Will
turn on
MIL .

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
P0756 P2701 Direct clutch SSB
performance/stuck
off.
Direct (3,5,R) clutch
failed off
Non-electrical
failures where
SSB direct
clutch is stuck
off (no
pressure).

Direct clutch
regulator

Customer
may
notice
flares
or
neutral
conditions
on
shifts
into 3rd

REFER to
Diagnosis By
Symptom in
this section.
valve stuck in
default
position.
Direct clutch
mechanical
failure.

or 5th
gear.
PCM
will
command
3 shifts
into 3rd
or 5th
gear,
and if
direct
clutch
is
failed
off the
customer
will
notice
flares
or
neutral
conditions
that last
one
second
or so.

3rd and
5th
gears
are
disabled,
customer
might
notice
transmission
hangs
in 2nd
on
acceleration
until
customer
tips out
to
closed
pedal
(done
to
protect
overdrive
clutch).

Will
turn on
MIL .

P0757 P2701 SSB SSB stuck on.
SSB (direct clutch)
failed on, causing
direct clutch failed on.
Since the hydraulic
controls prevent direct
clutch and low/reverse
clutch on together in
the forward ranges we
can isolate the
solenoid from the
clutch.
This code sets if:
Non-electrical
failures where
SSB (direct
clutch) is
stuck on
(pressure).

Direct clutch
regulator
valve stuck in
spring
compress
position.

Customer
may
notice a
vehicle
deceleration
on a
shift
into
2nd,
4th or
6th
gear.

Harsh
1-3
shift.

Poor
launch
performance
lack of
shifts.

Will
turn on
MIL .

REFER to
Diagnosis By
Symptom in
this section.
P0758 P0755, P0976
and P0977
SSB SSB electrical. Sister code to P0755,
P0976 and P0977
wrench light.
Additional common
fault DTCs, P0755,
P0976, P0977.
Failure
Mode
Effect
Management
action
see
P0755,
P0976
and
P0977.

Will
turn on
wrench
lamp.

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
P0759 - SSB SSB intermittent. Intermittent SSB
trip DTC, P0755,
P0758, P0976 or
P0977.
Customer
might
notice
unexpected
upshifts,
downshifts,
flairs or
neutral
conditions.

Will
turn on

GO to
Pinpoint Test
A .
wrench
lamp.
P0760 P0761 SSC SSC . Open circuit.
Customer
might
notice
erratic,
delayed
or
harsh
shifts.

Disable
2nd
and 6th
gears.

Will rn
on MIL
.

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
P0761 P2702 Intermediate
clutch
SSC
performance/stuck
off.
Intermediate clutch
failed off
Non-electrical
failures where
SSC
intermediate
clutch is stuck
off (no
pressure).

Intermediate
clutch stuck
off due to
mechanical
failure.

Intermediate
clutch
regulator
valve stuck in
the default
position.

Customer
may
notice
neutral
conditions
or
flares
on
shifts
to 2nd
or 6th
gear.

Disabled
2nd
and 6th
gears.

Erratic
shifting,
neutral
conditions,
flares,
higher
engine
speeds
on
highway
due to
6th
gear
being
disabled.

Will
turn on
MIL .

REPAIR the
more specific
DTC first.
REFER to
Diagnosis By
Symptom in
this section.
P0762 P0763 SSC SSC stuck on.
Intermediate clutch
failed on, could be
due to:
Intermediate
clutch SSC
non-electrical
failed stuck
on (pressure).

Intermediate
clutch stuck
on due to
mechanical
failure.

Intermediate
clutch
regulator
valve stuck in
the spring
compressed
position.

Customer
may
notice a
vehicle
deceleration
on a
shift
into 3rd
or 5th
gear
(intermediate
clutch
failing
to
release
will
cause a
tie-up
in 3rd
or 5th
gear).

Erratic
shifting
or
being
stuck in
6th
gear.

3rd, 4th
and 5th
gears
are
disabled.

Hangs
in 2nd
gear on
acceleration
since
2nd-6th
upshifts
only
occur
at
closed
pedal
(due to
energy
limitations
of
overdrive
clutch),
harsh
reverse
engagements

REPAIR the
more specific
DTC first.
REFER to
Diagnosis By
Symptom in
this section.
(since
low/reverse
clutch
is not
on in
2nd
gear).
Will
turn on
MIL .

P0763 P0760, P0979
and P0980
SSC SSC electrical. Sister code to P0760,
P0979 and P0980
wrench light.
Additional common
fault DTCs, P0755,
P0976, P0977.
Failure
Mode
Effect
Management
action
see
P0760,
P0979
and
P0980.

Will
turn on
wrench
lamp.

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
P0764 - SSC SSC intermittent. Intermittent SSC
trip DTC, P0760,
P0979 and P0980.
Customer
might
notice
unexpected
upshifts,
downshifts,
flairs or
neutral
conditions.

Will
turn on
wrench
lamp.

GO to
Pinpoint Test
A .
P0765 P0766 SSD SSD . Open circuit.
Overdrive
clutch
failed
on,
only
4th, 5th
and 6th
gears
available.

Harsh
engagements.

Poor
launch
due to

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
4th
gear
drive
away.
Will
turn on
MIL .

P0766 P2704 Overdrive clutch
system fault
includes
non-electrical
SSD fault, main
control valve
body and clutch
SSD performance
stuck off.
Overdrive clutch
failed off.
Non-electrical
failure where
SSD ,
low/reverse
and overdrive
clutch is stuck
off (no
pressure).

Low/reverse
clutch/overdrive
clutch
regulator
valve stuck in
default
position.

Low/reverse
clutch/overdrive
clutch boost
valve stuck in
default
position.

Customer
may
notice
flares
or
neutral
conditions
on
shifts
into
4th, 5th
or 6th
gear.

Erratic
shifting,
flares,
neutral
conditions
while
the
code is
being
set.

1st,
4th, 5th
and 6th
gears
are
disabled
- may
notice
high
engine
rpm
since
3rd is
highest
available
gear.

May
get
delayed
or no
reverse
engagement
(need

REPAIR the
more specific
DTC first.
REFER to
Diagnosis By
Symptom in
this section.
low/reverse
clutch
on to
achieve
reverse).
Will
turn on
MIL .

P0767 P07A9, P2704 Overdrive or
low/reverse
clutch
SSD stuck on. Overdrive clutch
failed on, could be
due to:
Low/reverse
or overdrive
clutch SSD
non-electrical
failed stuck
on (pressure).

Overdrive
clutch stuck
on due to
mechanical
failure.

Low/reverse,
overdrive
clutch
regulator
valve stuck in
the
spring-compressed
position.

Customer
may
notice
vehicle
deceleration
on
shifts
into
2nd or
3rd
gear
(overdrive
clutch
failing
to
release
will
cause a
tie-up
in 2nd
or 3rd
gear).

1st, 2nd
and 3rd
gears
are
disabled.

Poor
launch
due to
4th
gear
drive
away.

Harsh
engagements.

Will
turn on
MIL .

REPAIR the
more specific
DTC first.
REFER to
Diagnosis By
Symptom in
this section.
P0768 P0765, P0982
and P0983
SSD SSD electrical Sister code to P0765,
P0982 and P0983
wrench light.
Additional common
fault DTCs, P0767,
Failure
Mode
Effect
Management
action

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
P0769, P0770. see
P0765,
P0982
and
P0983.
Will
turn on
wrench
lamp.

P0769 - SSD SSD intermittent. Intermittent SSD
trip DTC, P0765,
P0768, P0982 and
P0983.
Customer
might
notice
unexpected
upshifts,
downshifts,
flairs or
neutral
conditions.

Will
turn on
wrench
lamp.

GO to
Pinpoint Test
A .
P0770 P0773 Shift Solenoid E
(SSE)
SSE . Open, short to ground
or short to power.
SSE failed off
(no pressure):
Customer
might
notice
4th
gear
drive
away
when
1st gear
is
commanded.

Failed
off (no
pressure)
then 1st
gear
with
engine
braking
is
disabled.

May or
may
not
notice
2nd
gear
provided

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
when
1st gear
selected
in low
manual
range.
Harsh
reverse
engagements
since
low/reverse
clutch
does
not
apply
in
neutral
or drive
in this
failure
mode.

SSE failed on
(pressure):
High
side is
turned
off.

Poor
launch
performance
due to
5th
gear
drive
away.

Harsh
engagements.

No
TCC
apply.

Will
turn on
MIL .

P0771 P0984 SSE failed off SSE
performance/stuck
off.
SSE controls
the
multiplexing
of SSD
low/reverse
and overdrive
clutch. If
solenoid fails
If SSE
is
failed
off or
valve 2
is stuck
in
default

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
off (no
pressure) then
1st gear is
failed to 4th
gear.
If clutch
select valve 2
sticks in the
default
position then
1st gear with
engine
braking is
failed to 4th
gear and
reverse is
failed to
neutral.

The
diagnostic
does not
distinguish
SSE stuck off
from valve 2
stuck in
default. This
code means
either:
SSE
short
to
power,
failed
off
(no
pressure).

Valve
2
stuck
in
default
position.

position
then
the
customer
will get
4th
gear
when
1st gear
is
selected.
Will
turn on
wrench
lamp.

P0772 P0984 SSE failed on SSE stuck on.
SSE controls
the
multiplexing
of SSD
low/reverse
and overdrive
clutch. If the
solenoid fails
on (pressure)
then, 1st and
2nd gear are
If SSE
is
failed
on or
valve 2
is stuck
in
spring
compressed
position,
then 1st

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
the only
available
gears. 3rd
gear is failed
to 1st gear,
4th gear is
failed to 1st
gear, 5th gear
is failed to
neutral, and
6th gear is a
tie-up.
If clutch
select valve 2
sticks in the
spring-compressed
position, the
same ratio
pattern will
occur. This
code means
either:
SSE
short
to
ground,
failed
on
(pressure).

Valve
2
stuck
in
spring
compressed
position.

and
2nd
gears
are the
only
available
gears.
Customer
might
notice
flares
on
shifts
into 3rd
gear.
Deceleration
on
shifts
into 4th
gear
since
you get
1st gear
or a
neutral
condition
on
shifts
into 5th
gear.
High
engine
rpm
since
2nd
gear is
top
available
gear.

Will
turn on
wrench
lamp.

P0773 P0770 SSE SSE electrical. Open, short to ground
or short to power in
solenoid or wiring.
Sister code to
P0770 used to
illuminate the
wrench light.
Failure
Mode
Effect
Management
action
see

GO to
Pinpoint Test
A .
P0770.
Will
turn on
wrench
lamp.

P0774 - SSE SSE intermittent. Intermittent SSD
trip DTC, P0770.
Failure
Mode
Effect
Management
action
see
P0770.

Will
turn on
wrench
lamp.

GO to
Pinpoint Test
A .
P07A5 - Direct clutch Transmission direct
clutch stuck on.
Ratio based test. The
clutch control bypass
valve (multiplex
valve) exhausts the
direct clutch when the
valve is in the
compressed position,
where SSD points in
the low/reverse
position, the
diagnostic can isolate
the direct clutch stuck
on from SSB stuck on
because getting 3rd
gear in 1st when the
valve is in the spring
compressed position
indicates that SSB
cannot be the cause.
Customer
may
notice
slow
acceleration
from
stop.
May be
in 3rd
gear
when
1st gear
is
commanded.

Once
the
DTC is
stored,
3rd and
5th
gears
are
only
available.

Erratic
shifting,
harsh
engagements,
poor
launch
performance.

Will
turn on
wrench
lamp.

REFER to
Diagnosis By
Symptom in
this section.
P07A8 -
Low/reverse
clutch
Transmission
low/reverse clutch
performance/stuck
off.
SSD is multiplexed
through the clutch
control bypass valve
(multiplex valve) to
the low/reverse and
overdrive clutch, the
the low/reverse clutch
failed off from SSD
stuck off when the
overdrive clutch
applies normally and
the low/reverse clutch
did not.
Customer
may
notice
no
reverse.

Disable
1st
gear.

Delayed
engagement
into
drive.

Poor
launch
performance
due to
2nd
gear
launch.

Will
turn on
wrench
lamp.

REFER to
Diagnosis By
Symptom in
this section.
P07A9 P0767 Low/reverse
clutch
Transmission
low/reverse clutch
stuck on.
SSD is multiplexed
through the clutch
(multiplex valve) to
the low/reverse and
the low/reverse stuck
on by turning off SSE
. If the transaxle shifts
into 4th when the
valve moves SSD is
stuck on, but if the
transaxle stays in 1st
then the low/revers is
stuck on.
Low/reverse
clutch
failed
on.

One-Way
Clutch
(OWC)
transmits
torque
in both
directions.

Stuck
in 1st
gear.

Will
turn on
wrench
lamp.

REFER to
Diagnosis By
Symptom in
this section.
P07AA - Overdrive clutch Transmission
overdrive clutch
performance/stuck
off.
SSD is multiplexed
through the clutch
(multiplex valve)
between the
low/reverse and
the overdrive clutch
failed off from SSD
stuck off when the
low/reverse clutch
Overdrive
clutch
failed
off.

Disable
4th, 5th
and 6th
gears.

Reverse
may be
delayed

REFER to
Diagnosis By
Symptom in
this section.
applies normally but
the overdrive clutch is
stuck off.
or
disabled.
High
engine
rpm.

Will
turn on
wrench
lamp.

P0815 - Upshift switch
circuit
SelectSwtchTM
upshift switch
output circuit
failure
The associated
circuitry to and from
the SelectSwtchTM
switch, fuse or the
SelectSwtchTM
switch itself may have
an open or is shorted
to ground.
SelectSwtchTM
upshift
inoperative.

Will
turn on
wrench
lamp.

REFER to
Section
307-05A .
P0816 - Downshift
switch circuit
SelectSwtchTM
downshift switch
output circuit
failure
The associated
circuitry to and from
the SelectSwtchTM
switch, fuse or the
SelectSwtchTM
switch itself may have
an open or is shorted
to ground.
SelectSwtchTM
downshift
inoperative.

Will
turn on
wrench
lamp.

REFER to
Section
307-05A .
P0867 - Transmission
hydraulic and
clutch systems
Transmission fluid
pressure.
The control valve test
raissure to insure that
the clutch control
bypass valve
(multiplex valve) is
latched, then turns on
SSE to test for a stuck
TCC control valve
under steady state
operation in 4th, 5th
and 6th gear. If the
ratio breaks away the
test is aborted. If
enough ratio break
away occur, the DTC
is set.
Multiplex
latch
pressure
inadequate
(valve
moves
when
SSE
turns
on).

Overdrive
clutch
pressure
issue.

Line
pressure
issues.

Solenoid
regulator
valve
issues.

Customer
may
notice
flairs
during
test.

REFER to
Diagnosis By
Symptom in
this section.
Will
turn on
wrench
lamp.

P0960 P0748 LPC LPC control
circuit/open.
LPC circuit has failed
to 0 current. Failed
to
maximum
line
pressure.

Harsh
engagements.

Will
turn on
MIL .

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
P0961 P0748 LPC LPC control circuit
range/performance.
Intermittent LPC short
to ground. Fault
present long enough
to notice a neutral
condition (minimum
pressure) but not
present long enough
to store a DTC.
Harsh
engagement
and
harsh
shifts.

Will
turn on
wrench
lamp.

GO to
Pinpoint Test
A .
low.
LPC short to ground
circuit failure.
Failed to 0
current,
minimum line
pressure:
Failure
Mode
Effect
Management
action
opens
the
transaxle
solenoid
power
control
relay,
removing
power
from
all
solenoids
which
provides
maximum
line
pressure.

Harsh
engagements.

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
Poor
launch
performance
(due to
5th
gear
drive
away).

No
TCC
apply.

No
shifts.

Will
turn on
MIL .

high.
LPC short to power
circuit fault.
Failed to 0
current,
maximum line
pressure:
Harsh
engagements.

Will
turn on
MIL .

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
P0973 P0753 SSA SSA control circuit
low.
Short to ground.
Failure
Mode
Effect
Management
action
opens
the
transaxle
solenoid
power
control
relay,
removing
power
from
all
solenoids
(get
PARK,
REVERSE,
NEUTRAL
and 5th
gear as
the
only
forward
gear

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
with
TCC
open).
Harsh
engagements.

Poor
launch
performance
(due to
5th
gear
drive
away).

No
TCC
apply.

No
shifts.

Will
turn on
MIL .

P0974 P0753 SSA SSA control circuit
high.
Short to power.
Forward
clutch
is
failed
off -
5th and
6th
gears
only
available
forward
gears.

Neutral
condition
or flare
when
fault
occurs.

Poor
launch
due to
5th
gear
drive
away

Will
turn on
MIL

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
P0976 P0758 SSB SSB control circuit
low.
Short to ground.
Failure
Mode
Effect

REPAIR the
more specific
DTC first. GO
to Pinpoint
Management
action
opens
the
transaxle
solenoid
power
control
relay,
removing
power
from
all
solenoids
(get
PARK,
REVERSE,
NEUTRAL
and 5th
gear as
the
only
forward
gear
with
TCC
open).
Harsh
engagements.

Poor
launch
performance
(due to
5th
gear
drive
away).

No
TCC
apply.

No
shifts.

Will
turn on
MIL .

Test A .
P0977 P0758 SSB SSB control circuit
high.
Short to power.
Direct
clutch
failed
on -
only
3rd and
5th
gears

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
available.
Harsh
1-3
shift if
failure
occurs
while
in 1st.

Poor
launch
due to
3rd
gear
drive
away.

Will
turn on
MIL .

P0979 P0763 SSC SSC control circuit
low.
ort to ground.
Failure
Mode
Effect
Management
action
opens
the
transaxle
solenoid
power
control
relay,
removing
power
from
all
solenoids
(get
PARK,
REVERSE,
NEUTRAL
and 5th
gear as
the
only
forward
gear
with
TCC
open).

Harsh
engagements.

Poor
launch
performance

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
(due to
5th
gear
drive
away).
No
TCC
apply.

No
shifts.

Will
turn on
MIL .

P0980 P0763 SSC SSC control circuit
high.
Open circuit.
If fault
occurs
while
in 2nd
or 6th
gear,
customer
might
notice a
neutral
condition
before
diagnostics
disables
2nd
and 6th
gears.

Erratic,
delayed
or
harsh
shifts.

Will
turn on
MIL .

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
P0982 P0768 SSD SSD control circuit
low.
Short to ground.
Failure
Mode
Effect
Management
action
opens
the
transaxle
solenoid
power
control
relay,
removing
power

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
from
all
solenoids
(get
PARK,
REVERSE,
NEUTRAL
and 5th
as the
only
forward
gear
with
TCC
open),
harsh
engagements.
Poor
launch
performance
(due to
5th
gear
drive
away).

No
TCC
apply.

No
shifts.

Will
turn on
MIL .

P0983 P0768 SSD SSD control circuit
high.
Open circuit.
Only
4th, 5th
and 6th
gears
available.

Harsh
engagements.

Poor
launch
due to
4th
gear
drive
away.

Will
turn on
MIL .

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
P0984 P0771, P0772 SSE SSE control circuit
range/performance.
This DTC sets with
either P0771 or
P0772.
Will
turn on

REPAIR the
more specific
DTC first. GO
wrench
lamp.
to Pinpoint
Test A .
P1500 P0722 VSS sensor OSS sensor circuit.
PCM has
detected VSS
sensor signal
failed to 0
speed when
vehicle
conditions
(mainly
turbine speed)
indicate OSS
sensor output
should be
present.

Electrical
failures (open,
short) of the
OSS sensor
wiring,
connector or a
failure of the
OSS sensor
itself will
cause this
failure.

Failure
Mode
Effect
Management
action
opens
transaxle
solenoid
power
control
(removes
power
from
all
solenoids).
provides
PARK,
REVERSE,
NEUTRAL
AND
5th
gear
with
maximum
line
pressure
and
open
TCC
available
(controlled
by
the
manual
lever).

Harsh
engagements
(due to
maximum
line
pressure).

Poor
launch
performance
(due to
5th
drive
away).

Will
turn on
MIL .

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test C .
P1636 - PCM Inductive signature
chip
communication
error.
Lost communication
with solenoid driver.
The solenoid
driver is an
internal PCM
chip that
controls the
solenoids. The
main
microchip
communicates
with the
solenoid
driver over a
serial
interface,
sending out
the desired
solenoid state
and receiving
back a circuit
fault status.

If
communication
is lost with
the solenoid
driver, the
solenoid
states become
unknown, so
the control
system forces
the transaxle
solenoid
power control
relay off.

Traaxle
solenoid
power
control
relay
turned
off,
providing
PARK,
REVERSE,
NEUTRAL
and 5th
gear
with
TCC
open
and
maximum
line
pressure.

Harsh
engagements.

Poor
performance
launch
(due to
5th
drive
away).

No
TCC
apply.

No
shifts.

Will
turn on
MIL .

INSTALL a
new PCM.
REFER to
Section
303-14A or
Section
303-14B .
P163E - TRID block Transmission
control module
programming error.
TRID version
incorrect
(TRID
version does
not match
version in
PCM
Calibration).

7-digit service
banding code
checksum or
total TRID
block
checksum
invalid.

Costumer
may
notice,
high
engine
rpm.

1st and
3rd
gear
only.

No
TCC
apply.

Will
turn on
MIL .

REFER to
Solenoid Body
Strategy in
this section.
Solenoid and
Clutch
characterization
data
unavailable.

Failure Me
Effect
Management
will increase
pressure and
allow only
PARK,
REVERSE,
NEUTRAL,
1st and 3rd
gear only.

P163F - TRID block TRID ID block
corrupted, not
programmed.
TRID data not
programmed.

Solenoid and
Clutch
strategy data
unavailable.

Failure Mode
Effect
Management
will increase
pressure and
allow only
PARK,
REVERSE,
NEUTRAL,
1st and 3rd
only.

Failure
Mode
Effect
Management
action
of
limits
function
to 1st
and 3rd
gear.

High
engine
rpm,
lack of
shifts
complaints.

No
TCC
apply.

Will
turn on
MIL .

REFER to
Solenoid Body
Strategy in
this section.
P1702 P0706, P0707
and P0708
TR sensor TR sensor circuit
intermittent.
Sister code to P0706
P0707 and P0708
wrench light.
Possible
no
crank,
only
PARK,
REVERSE,
NEUTRAL
and 5th
gear
available,
harsh
engagements.

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test D .
Extremely
delayed
engagements
(until a
DTC is
set).

After a
DTC is
set and
the
high
side
opened
- harsh
engagements,
poor
performance
(due to
a 5th
gear
drive
away),
no
shifts.

Will
turn on
wrench
lamp.

P1705 - TR sensor TR circuit not
indicating
park/neutral during
self-test.
TR sensor not
indicating Park or
Neutral during Key
ON Engine OFF
(KOEO) or Key ON
Engine Running
(KOER) self-test.
- Rerun KOEO
or KOER
only.
P1711 - TFT TFT sensor out of
self-test range.
TFT sensor out of
self-test range equals
less than -1C (30F)
or greater than 105C
(220F) during KOEO
or KOER> self-test.
- RERUN
KOEO or
KOER only.
circuit.
Sister code to P0741
wrench light.
Additional common
DTC, P163F.
Will turn on
wrench lamp.
REFER to
Diagnosis By
Symptom in
this section.
Control Switch
(TCS)
TCS (Overdrive
(O/D) Cancel)
circuit out of
self-test range.
TCS did not change
states during KOER
self-test.
Customer
cannot enter or
exit the
overdrive
feature.
REFER to
Section
307-05A .
overtemperature
Transmission over
temperature
Transmission over
temperature condition
REFER to
Diagnosis By
condition. (greater than 135C
[275F] for at least 5
seconds).
Torque
converter
lockup
happens
earlier
than
expected.

Will
turn on
wrench
lamp.

Symptom in
this section.
P1910 - Reverse lamp
control
Reverse lamp
control circuit/open.
Reverse lamp control
circuit fault. 6F35
TRan> sensor does
not have a high
current reverse lamp
control switch. This
has moved to the
PCM.
Reverse
lamps
do not
function
correctly.

Will
turn on
wrench
lamp.

REFER to
Section
417-01 .
P1921 P0706, P0707
and P0708
TR switch Transmission range
signal
The PCM sets this
DTC when the
ignition switch is
turned to the crank
position and before
the PCM receives an
engine run signal.
Engine
may
not
crank.

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test D .
P2700 P0751 and
P0752
Forward clutch
system fault
Transmission
forward clutch
apply time
range/performance.
This code sets with
either DTC P0751 or
P0752.
Will
turn on
wrench
lamp.

REPAIR the
more specific
DTC first.
REFER to
Diagnosis By
Symptom in
this section.
P2701 P0756 and
P0757
Direct clutch
system fault
Transmission direct
clutch apply time
range/performance.
This code sets with
either DTC P0756 or
P0757.
Will
turn on
wrench
lamp.

REPAIR the
more specific
DTC first.
REFER to
Diagnosis By
Symptom in
this section.
P2702 P0761 and
P0762
Intermediate
clutch system
faults
Transmission
intermediate clutch
apply time
range/performance.
This code sets with
either DTC P0761 or
P0762.
Will
turn on
wrench
lamp.

REPAIR the
more specific
DTC first.
REFER to
Diagnosis By
Symptom in
this section.
P2703 P0766 and
P2704
Low/Reverse
clutch and OWC
faults (covers
just the clutches)
Transmission
low/reverse clutch
apply time
range/performance.
Low/reverse clutch
stuck off with
overdrive clutch stuck
off. Most likely cause
Low/reverse
clutch
off is a

REPAIR the
more specific
DTC first.
REFER to
is SSD non-electrical
failure or
low/reverse/overdrive
regulator valve stuck
in default position.
ratio
based
test.
Low/reverse
clutch
is only
tested
for
failed
off in
the low
manual
lever
position.

The
customer
might
notice
no
engine
braking
in 1st
gear,
and
erratic
shifting
as the
diagnostics
isolates
the
fault to
low/reverse
clutch
failed
off.

Delayed
or no
reverse
engagement.

Will
turn on
wrench
lamp.

Diagnosis By
Symptom in
this section.
P2704 P0766, P0767
and P2703
Overdrive clutch
system faults
Transmission
overdrive clutch
apply time
range/performance.
Overdrive clutch stuck
off with low/reverse
clutch stuck off. Most
likely cause is SSD
non-electrical failure
or
in default position.
Overdrive clutch stuck
Overdrive
clutch
failed
off.

Will
turn on
wrench
lamp.

REPAIR the
more specific
DTC first.
REFER to
Diagnosis By
Symptom in
this section.
on. Possibly overdrive
clutch, SSD ,
in spring compressed
position.
P2705 - OWC failed Transmission OWC
apply time
range/performance.
The OWC
holds in 1st
gear. If the
OWC fails
off, 1st gear is
failed to
neutral.

1st gear is
disabled for
this failure
since
low/reverse
clutch is not
intended to
hold power on
torque in 1st
gear.

Customer
might
notice
neutral
conditions
when
1st gear
is
commanded.

Erratic
shifting
as the
diagnostic
isolates
the
cause
of the
neutral
condition
to the
OWC
being
failed.

Poor
launch
performance
(due to
2nd
gear
drive
away).

Harsh
engagements.

Will
turn on
wrench
lamp.

REFER to
Diagnosis By
Symptom in
this section.
P2760 P0743 and
P0744
TCC solenoid TCC pressure
control solenoid
intermittent.
Intermittent TCC
solenoid short to
ground. A short to
ground will cause the
TCC to apply, which
can stall the engine at
low vehicle speeds.
The PCM will disable
the high side driver
until vehicle speed is
Poor
launch
performance
(due to
5th
gear
drive
away).

REPAIR the
more specific
DTC first. GO
to Pinpoint
Test A .
high enough that the
engine won't stall.
With the high side
driver off the fault can
not be detected. If the
fault goes away while
the high side is off the
vehicle will have a 5th
gear launch with no
DTC.
If this occurs 3 times
with no DTC P0742
being set, then DTC
P2760 will set.
No
TCC
apply.

No
shifts.

Will
turn on
wrench
lamp.

P2783 - Torque
converter
Torque converter
temperature too
high.
TCC control
valve stuck in
the apply
position.
When the
TCC is
commanded
open there
will be no
flow through
the TCC (both
apply and
release
circuits will
be exhausted).

Test will run
in 3rd gear or
higher when
valve 2 is in
the latched
position,
pointing SSD
at overdrive
clutch when
the TCC is
commanded
open. SSE is
turned on, if
the control
valve is stuck,
this will cause
the TCC to
apply even
though the
TCC solenoid
is off.

Torque
converter
temperature
too
high.

Erratic
shifts,
vehicle
disengages
at a
stop
while
in drive
or low,
early
TCC
apply.

Will
turn on
MIL .

REFER to
Diagnosis By
Symptom in
this section.
Workshop Manual
Transaxle Connector Layouts
PCM Transaxle Harness - C175T
1 Transmission Range (TR), Output Shaft Speed (OSS) and Turbine Shaft Speed (TSS) voltage
supply
10 Shift Solenoid D (SSD) control
11 Shift Solenoid E (SSE) control
16 TSS sensor signal
19 Transmission Fluid Temperature (TFT) sensor signal
25 OSS sensor signal
31 Transmission Control Switch (TCS)
34 Line Pressure Control (LPC) control
36 TR , OSS and TSS sensor ground
39 TR signal
41 TFT ground
43 Shift Solenoid B (SSB) control
44 Shift Solenoid C (SSC) control
45 Shift Solenoid A (SSA) control
46 Torque Converter Clutch (TCC) solenoid control
50 Transaxle solenoid power control voltage
Transaxle Vehicle Harness - C1520A
Transaxle Connector Layouts 3705
1 Transmission Fluid Temperature (TFT) ground
2 TFT sensor signal
5 Transaxle solenoid power control voltage
7 ON/OFF Shift Solenoid E (SSE) control
17 Transmission Range (TR) signal
18 TR and Output Shaft Speed (OSS) sensor power
19 OSS sensor signal
20 TR / OSS sensor ground
Solenoid Body Leadframe-to-Transmission Range (TR) Sensor Internal Circuit Diagram
Transaxle Vehicle Harness - C1520A 3706
Solenoid Body Leadframe Main Connector Pin
Number TR Sensor Pin Number Circuit Function
18 1 Transmission Range
(TR) power
17 2 TR signal
20 3 TR ground
1 Transmission Range (TR) power
2 TR signal
3 TR ground
Solenoid Body Leadframe Transmission Fluid Temperature (TFT) Sensor Pins
1 Transmission Fluid Temperature (TFT) signal return
2 TFT signal
Solenoid Body Leadframe-to-Output Shaft Speed (OSS) Sensor Internal Circuit Diagram
Solenoid Body Leadframe-to-Transmission Range (TR) Sensor Internal Circuit Diagram 3707
Solenoid Body Leadframe Main
Connector Pin Number
Output Shaft Speed (OSS)
Sensor Pin Number Circuit Function
20 1 Transmission Range (TR)/ Output Shaft
Speed (OSS) sensor ground circuit
19 3 OSS sensor signal
18 4 TR / OSS sensor power supply
1 Output Shaft Speed (OSS) sensor ground
3 OSS signal
4 OSS sensor power
Turbine Shaft Speed (TSS) Sensor - C1520B
Solenoid Body Leadframe-to-Output Shaft Speed (OSS) Sensor Internal Circuit Diagram 3708
Pin Number Ciuit Function
1 Turbine Shaft Speed (TSS) sensor ground
2 TSS sensor signal
3 TSS sensor power
1 Turbine Shaft Speed (TSS) sensor ground
2 TSS sensor signal
3 TSS sensor power
Solenoid Body Leadframe-to-Solenoid Internal Circuit Diagram
Solenoid Body Leadframe Main Connector Pin Number Circuit Function
Turbine Shaft Speed (TSS) Sensor - C1520B 3709
5 Solenoid power supply circuit
7 Shift Solenoid E (SSE) control
Solenoid Body Leadframe-to-Solenoid Internal Circuit Diagram 3710
Workshop Manual
Pinpoint Tests - OSC Equipped Vehicle
Special Tool(s)
When an electrical conr solenoid body is disconnected, inspect the connector for terminal condition, corrosion
and contamination. Also inspect the connector seal for damage. Clean, repair or install new components as
required.
Shift Solenoid Pre-Diagnosis
Use the following shift solenoid operation information when carrying out Pinpoint Test A.
Solenoid Operation Chart
Base Selector
Lever
Position
PCM
Commanded
Gear
Shift Solenoid
TCC
(VFS)
NL
SSA (VFS)
NL (CB
1,2,3,4)
SSB (VFS)
NH (3,5,R)
SSC (VFS)
NL (CB
2,6)
SSD (VFS)
NH (CB
L,R/C 4,5,6)
SSE
(On/Off)
NC
D 1 On On Off Off
a
On
b
Off
2 On On On On Off Off
3 On Off Off On Off Off
4 On On Off Off Off On/Off
5 Off Off Off Off Off On/Off
6 Off On On Off Off On/Off
a
Turns on above 8 km/h (5 mph).
b
CB = Clutch brake
NH = Normally high
NL = Normally low
Shift Solenoid Failure Mode Chart "Failed ON" or "Failed OFF"
Failed ON/OFF due to PCM and/or vehicle wiring concerns and/or solenoid electrically, mechanically or
hydraulically stuck on/off.
Shift Solenoid A (SSA)
Gear Commanded
Actual Gears Obtained
Failed ON (High Pressure) Failed OFF (Low Pressure)
R R R
D 1, 2, 3, 4 5, 6
Shift Solenoid B (SSB)
Gear Commanded
Failed ON (Low Pressure) Failed OFF (High Pressure)
R N
a
R
D 1, 2, 4, 6 3, 5
a
Reverse is available if the solenoid circuit failed causing transaxle solenoid power control solenoid to
remove voltage to all solenoids.
Shift Solenoid C (SSC)
Gear Commanded
R R R
D 2, 6 1, 3, 4, 5
Shift Solenoid D (SSD)
Gear Commanded
Failed ON (Low Pressure) Failed OFF (High Pressure)
R N
a
R
D 1, 2, 3
b
4, 5, 6
a
Reverse is available if the solenoid circuit failed causing transaxle solenoid power control solenoid to
remove voltage to all solenoids.
b
No engine braking.
Gear Commanded
R R R
D 1, 2 1, 2, 3, 4, 5, 6
a
a
No engine braking.
Pinpoint Tests
information.
PINPOINT TEST A: TRANSAXLE CONTROL SOLENOIDS
NOTE: Refer to the transaxle connector illustrations and solenoid body leadframe internal wiring diagram
Transaxle Connector Layouts in this section.
A1 ELECTRONIC DIAGNOSTICS
Check to make sure the transaxle harness
connector is fully seated, terminals are
engaged in connector and in good

Carry out the Key ON Engine OFF
(KOEO) until continuous DTCs have been
displayed.

Enter the Output Test Mode.
Select the mode ALL ON. Push START to
turn outputs ON. Push STOP to turn
outputs OFF.

Does vehicle enter Output Test Mode?
Yes
GO to A2 .
No
PRESS START. If vehicle does not enter Output
Test Mode, REFER to the Powertrain
A2 CHECK THE SOLENOID CIRCUIT FOR
AN OPEN
PINPOINT TEST A: TRANSAXLE CONTROL SOLENOIDS 3713
Ignition OFF.
Disconnect: Transaxle Vehicle Harness
C1520A.

Use a mirror to inspect both ends of the
connector for damage or pushed-out pins,
corrosion, loose wires and missing or
damaged seals.

Disconnect: PCM Transaxle Harness
C175T .

connector for damage or pushed out pins,
corrosion, loose wires and missing or
damaged seals.

Measure the resistance of the suspect
solenoid circuit between the PCM
transaxle harness C175T and transaxle
vehicle harness C1520A using the
following chart.

Shift Solenoid
Transaxle
Vehicle
Harness PCM
Shift Solenoid
A (SSA)
CET05
(BU/GN)
C1520A-8 C175T-45
Shift Solenoid
B (SSB)
CET06
(GN/BN)
C1520A-9 C175T-43
Shift Solenoid
C (SSC)
CET07
(GY/OG)
C1520A-4 C175T-44
Shift Solenoid
D (SSD)
CET08
(BN/WH)
C1520A-10 C175T-10
Shift Solenoid
E (SSE) CET18
(GY/YE)
C1520A-7 C175T-11
Line Pressure
Control (LPC)
CET09
(YE/VT)
C1520A-3 C175T-34
Torque
Converter
Clutch (TCC)
CET10
C1520A-6 C175T-46
Yes
GO to A3 .
No
REPAIR the circuit(s) for an open. RECONNECT
all components. TEST the system for normal
operation.
(BU/GY)
A SHORT TO GROUND
transaxle vehicle harness C1520A, harness
side and ground using the following chart.

Shift Solenoid
Transaxle
Vehicle
Harness Ground
Shift Solenoid A
(SSA) CET05
(BU/GN)
C1520A-8 Ground
Shift Solenoid B
(SSB) CET06
(GN/BN)
C1520A-9 Ground
Shift Solenoid C
(SSC) CET07
(GY/OG)
C1520A-4 Ground
Shift Solenoid D
(SSD) CET08
(BN/WH)
C1520A-10 Ground
Shift Solenoid E
(SSE) CET18
(GY/YE)
C1520A-7 Ground
Line Pressure
Control (LPC)
CET09 (YE/VT)
C1520A-3 Ground
Torque
Converter Clutch
(TCC) CET10
(BU/GY)
C1520A-6 Ground
ohms?

Yes
GO to A4 .
No
REPAIR the circuit(s) for a short to ground.
RECONNECT all components. TEST the system for
normal operation.
A SHORT TO POWER
Measure the voltage between the transaxle
vehicle harness electrical C1520A, harness
side and ground using the following chart.

Yes
REPAIR the circuit(s) for a short to power.
normal operation.
No
GO to A5 .
Shift Solenoid
Transaxle
Vehicle
Harness Ground
Shift Solenoid A
(SSA) CET05
(BU/GN)
C1520A-8 Ground
Shift Solenoid B
(SSB) CET06
(GN/BN)
C1520A-9 Ground
Shift Solenoid C
(SSC) CET07
(GY/OG)
C1520A-4 Ground
Shift Solenoid D
(SSD) CET08
(BN/WH)
C1520A-10 Ground
Shift Solenoid E
(SSE) CET18
(GY/YE)
C1520A-7 Ground
Line Pressure
Control (LPC)
CET09 (YE/VT)
C1520A-3 Ground
Torque
Converter Clutch
(TCC) CET10
(BU/GY)
C1520A-6 Ground
A5 CHECK THE RESISTANCE OF THE
SOLENOID FIELD CIRCUIT
transaxle solenoid body leadframe main
electrical connector C1520A-5, component
side and the suspect solenoid pin,
component side and compare the value to
the specifications in the table below.

Shift
Solenoid
Solenoid
Body Lead -
Frame Pin
C1520A-5
(Component
Side)
Shift
Solenoid A
(SSA)
C1520A-8 C1520A-5
Shift
Solenoid B
(SSB)
C1520A-9 C1520A-5
Shift
Solenoid C
C1520A-4 C1520A-5
Yes
INSTALL a new PCM. REFER to Section 303-14A
or Section 303-14B . RECONNECT all components.
No
REMOVE the main control cover. REFER to Main
Control Cover in this section. INSPECT the solenoid
body for foreign material such as metal shavings on
the exposed metal contacts or other components.
CLEAR the solenoid body and RECHECK the
resistance values. If the resistance values are still out
of specification, GO to A6 . INSTALL a new
solenoid(s). REFER to Solenoids in this section.
normal operation.
(SSC)
Shift
Solenoid D
(SSD)
C1520A-10 C1520A-5
Shift
Solenoid E
(SSE)
C1520A-7 C1520A-5
Line
Pressure
Control
(LPC)
C1520A-3 C1520A-5
Torque
Converter
Clutch
(TCC)
C1520A-6 C1520A-5
Solenoid Resistance Values: SHIFT
SOLENOID A (SSA), SHIFT
SOLENOID B (SSB), SHIFT
SOLENOID C (SSC), SHIFT
SOLENOID D (SSD), TORQUE
CONVERTER CLUTCH (TCC) and
LINE PRESSURE CONTROL (LPC)
Temperature
Resistance (ohms)
C F
-20 to -10 -4 to 14 3.24-5.13
-10 to 0 14-32 3.43-5.32
0-10 32-50 3.62-5.51
10-20 50-68 3.81-5.70
20-30 68-86 4.00-5.89
30-40 86-104 4.19-6.08
40-50 104-122 4.38-6.27
50-60 122-140 4.57-6.46
60-70 140-158 4.76-6.65
70-80 158-176 4.95-6.83
80-90 176-194 5.13-7.02
90-100 194-212 5.32-7.21
Solenoid Resistance Values: SHIFT
SOLENOID E (SSE) (ON/OFF)
Temperature
Resistance (ohms)
C F
-20 to -10 -4 to 14 15.45-24.35
-10 to 0 14-32 16.35-25.25
0-10 32-50 17.25-26.15
10-20 50-68 18.15-27.05
20-30 68-86 19.05-27.95
30-40 86-104 19.95-28.85
40-50 104-122 20.85-29.75
50-60 122-140 21.75-30.65
60-70 140-158 22.65-31.54
70-80 158-176 23.54-32.44
80-90 176-194 24.44-33.34
90-100 194-212 25.34-34.24
Is the resistance within specifications?
A6 CHECK THE SOLENOID BODY
LEADFRAME FOR AN OPEN
Remove the solenoid body leadframe.
Refer to Solenoid Body Leadframe in this
section.

solenoid body leadframe main electrical
connector C1520A, component side and
the corresponding solenoid pins using the
following chart.

Solenoid Body
Leadframe Main
Connector Pin
Number Circuit Function
3 Line Pressure
Control (LPC)
solenoid control
4 Shift Solenoid C
(SSC) control
5 Solenoid power
supply
6 Torque Converter
Clutch (TCC)
solenoid control
7 Shift Solenoid E
(SSE) control
8 Shift Solenoid A
(SSA) control
9
Yes
INSTALL a new solenoid(s). REFER to Solenoids in
this section. RECONNECT all components. TEST
No
INSTALL a new solenoid body leadframe. REFER
to Solenoid Body Leadframe in this section.
Shift Solenoid B
(SSB) control
10 Shift Solenoid D
(SSD) control
PINPOINT TEST B: TFT SENSOR
Test Step
Result / Action to
Take
B1 ELECTRONIC DIAGNOSTICS
Check to make sure the transaxle vehicle harness C1520A is fully seated,
terminals are fully engaged in connector and in good condition before
proceeding.

Have the above items been checked?
Yes
GO to B2 .
No
CARRY OUT
checks. CLEAR the
DTCs. REPEAT the
self-test.
B2 CHECK THE TFT SENSOR CIRCUITS FOR AN OPEN
Ignition OFF.
Disconnect: Transaxle Vehicle Harness C1520A.
Disconnect: PCM Transaxle Harness C175T.
Use a mirror to inspect both ends of the connector for damage or
pushed-out terminals, corrosion, loose wires and missing or damaged
seals.

Measure the resistance between PCM transaxle harness C175T-19, circuit
VET27 (BN/YE) and transaxle vehicle harness C1520A-2, circuit VET27
(BN/YE).

Yes
GO to B3 .
No
REPAIR the
circuit(s) for an open.
CONNECT all
components. TEST
the system for
normal operation.
Measure the resistance between PCM transaxle harness C175T-41, circuit
RE406 (GY/VT) and transaxle vehicle harness C1520A-1, circuit RE406
(GY/VT).

B3 CHECK THE TFT SENSOR CIRCUITS FOR A SHORT TO GROUND
Disconnect: Catalyst Monitor Sensor (CMS) C141.
Disconnect: CMS C142.
Measure the resistance between transaxle vehicle harness C1520A-2,
circuit VET27 (BN/YE) and ground.

Measure the resistance between transaxle vehicle harness C1520A-1,
circuit RE406 (GY/VT) and ground.

Yes
GO to B4 .
No
REPAIR the
circuit(s) for a short
to ground.
CONNECT all
components. TEST
the system for
normal operation.
B4 CHECK THE TFT CIRCUITS FOR A SHORT TO VPWR
Measure the voltage between transaxle vehicle harness C1520A-2, circuit
VET27 (BN/YE) and ground.

Measure the voltage between transaxle vehicle harness C1520A-1, circuit
RE406 (GY/VT) and ground.

Yes
REPAIR the
circuit(s) for a short
to voltage.
CONNECT all
components. TEST
the system for
normal operation.
No
GO to B5 .
B5 CHECK THE RESISTANCE OF THE TFT SENSORS/HARNESS
Vehicle must be at normal operating temperature.
Connect: Transaxle Vehicle Harness C1520A.
TEST 1.
Measure and record the resistance between PCM transaxle harness
C175T-19, circuit VET27 (BN/YE) and C175T-41, circuit RE406
(GY/VT).

Compare the resistance value to the following table ranges:
TRANSMISSION FLUID TEMPERATURE (TFT)
C F Resistance (Ohms)
-40 to -20 -40 to -4 1076K-269K
-19 to -1 -3 to 31 309K-91K
0-20 32-68 104K-35K 21-40 69-104 40K-15K
Yes
INSTALL a new
PCM. CONNECT all
components. TEST
the system for
normal operation.
No
INSTALL a new
solenoid body
leadframe. REFER to
Solenoid Body
Leadframe in this
section.
RECONNECT all
components. TEST
the system for
normal operation.
41-70 105-158 17K-4.9K
71-90 159-194 5.6K-2.5K
91-110 195-230 3.0K-1.4K
111-130 231-266 1.7K-0.8K
131-150 267-302 0.97K-0.56K
TEST 2.
Check for intermittent short or open.
If the resistance was between 0.8K and 100K ohms carry out the
following test. If the transaxle is warm, allow it to cool. Check the TFT
sensor resistance again. Compare the resistance with the initial resistance.
The resistance should decrease if the transaxle was heated and should
increase if the transaxle was allowed to cool. If correct, then change in the
resistance occurs, repeat On-Board Diagnostic (OBD).

Is the resistance in range?
PINPOINT TEST C: OSS SENSOR
NOTE: Output Shaft Speed (OSS) codes may be a result of a bad common power or ground shared between
the Transmission Range (TR) sensor, OSS sensor and Turbine Shaft Speed (TSS) sensor.
Check to make sure the transaxle vehicle harness
C1520A is fully seated, terminals are engaged in
connector and in good condition before
proceeding.

Have the items above been checked?
Yes
GO to C2 .
No
CARRY OUT the checks. CLEAR the
codes. RERUN the On-Board Diagnostic
(OBD) tests.
Monitor the OSS sensor PIDs while test driving
the vehicle.

Is the OSS sensor signal present and consistent?
Yes
The condition that set the DTC is
intermittent and is not currently present.
CLEAR the DTCs. RERUN the OBD tests.
No
GO to C3 .
C3 CHECK THE VEHICLE HARNESS FOR AN
OPEN CIRCUIT
Use a mirror to inspect both ends of the connectors
for damage or pushed-out terminals, corrosion,
loose wires and missing or damaged seals.

Measure the resistance for the OSS sensor circuit,
Yes
GO to C4 .
No
REPAIR the circuit(s) for an open.
CONNECT all components. TEST the
PINPOINT TEST C: OSS SENSOR 3722
between the transaxle vehicle harness C1520A and
the PCM transaxle harness C175T, harness using
the following chart.
Output Shaft Speed
Sensor Circuit
Transaxle
Vehicle
Harness PCM
Output Shaft Speed
(OSS) sensor power
supply LE111
(VT/GN)
C1520A-18 C175T-1
OSS sensor ground
RET24 (BN/BU)
C1520A-20 C175T-36
OSS sensor signal
VET26 (BN/GN)
C1520A-19 C175T-25
C4 CHECK THE VEHICLE HARNESS FOR A
SHORT TO GROUND
Disconnect: Transaxle Vehicle Harness C1520B.
Measure the resistance for the OSS sensor circuit
between the transaxle vehicle harness C1520A and

Output Shaft Speed
Sensor Circuit
Transaxle
Vehicle
Harness Ground
Transmission Range
(TR)/ OSS sensor power
supply LE111 (VT/GN)
C1520A-18 Ground
TR / OSS sensor ground
RET24 (BN/BU)
C1520A-20 Ground
OSS sensor signal
VET26 (BN/GN)
C1520A-19 Ground
Yes
GO to C5 .
No
REPAIR the circuit(s) for a short to ground.
C5 CHECK THE VEHICLE HARNESS FOR A
SHORT TO VPWR
Check for voltage between the OSS sensor circuits
and the transaxle vehicle harness C1520A using
the following chart.

Yes
REPAIR the circuit(s) for a short to voltage.
No
Output Shaft Speed
Sensor Circuit
Transaxle
Vehicle
Harness Ground
Transmission Range
(TR)/ OSS sensor power
supply LE111 (VT/GN)
C1520A-18 Ground
TR / OSS sensor ground
RET24 (BN/BU)
C1520A-20 Ground
OSS sensor signal
VET26 (BN/GN)
C1520A-19 Ground
GO to C6 .
C6 CHECK THE SOLENOID BODY FOR AN
INTERNAL OPEN CIRCUIT
Remove the main control cover. Refer to Main
Control Cover in this section.

Disconnect: TR Sensor.
Disconnect: OSS Sensor.

Measure the resistance of the solenoid body
internal sensor power circuit between the main
solenoid body leadframe connector pin 18,
leadframe side and the OSS sensor connector pin
4, leadframe side.

internal sensor signal circuit between the main
3, leadframe side.

Yes
GO to C7 .
No
INSTALL a new solenoid body leadframe.
REFER to Solenoid Body Leadframe in this
section. CONNECT all components. TEST
internal sensor ground circuit between the main
1, leadframe side.

C7 CHECK FOR VOLTAGE AND GROUND AT
THE OSS SENSOR CONNECTOR
Connect: PCM C175T.
Ignition ON.
Measure the voltage on the solenoid body
leadframe between OSS sensor connector pins 1
and 4.

Yes
INSTALL a new speed sensor. REFER to
Output Shaft Speed (OSS) Sensor in this
operation. If the condition is still present,
303-14A or Section 303-14B .
No
303-14A or Section 303-14B . CONNECT
all components. TEST the system for normal
operation.
PINPOINT TEST D: TR SENSOR
NOTE: Transmission Range (TR) codes may be a result of a bad common power and ground shared between
the TR sensor, Output Shaft Speed (OSS) sensor and Turbine Shaft Speed (TSS) sensor.
D1 VERIFY DTCs
Ignition OFF.
Select PARK.
Start the engine.
Carry out the On-Board Diagnostic (OBD)
Test. DTCs P0706, P0707 and P0708 cannot
be set by an incorrectly adjusted selector lever
cable.

Are only TR DTC codes present?
Yes
GO to D3 .
No
GO to D2 .
D2 VERIFY SELECTOR LEVER
CABLE/LINKAGE ADJUSTMENT
Verify that the selector lever cable/linkage is
correctly adjusted. Refer to Section 307-05A .

Is the selector lever cable/linkage correctly
adjusted?

Yes
GO to D3 .
No
ADJUST the selector lever cable/linkage.
REFER to Section 307-05A . GO to D4 .
D3 CHECK THE ELECTRICAL SIGNAL
OPERATION
Select PARK.
Disconnect: PCM Transaxle C175T.
C1520A.

connectors for damaged or pushed-out
terminals, corrosion, loose wires and missing
or damaged seals.

Is there damage to the connectors, terminals
or harness?

Yes
REPAIR as required. CLEAR the DTCs and
RERUN OBD tests.
No
GO to D4 .
D4 CHECK ELECTRICAL SYSTEM
OPERATION ( TR AND PCM)
PINPOINT TEST D: TR SENSOR 3726
Ignition OFF.
Connect: PCM Transaxle Harness C175T.
Ignition ON.
scan tool: TR PIDs TR_DC and TR_FREQ.

Move the selector lever into each gear and
stop.

Observe the following PIDs; TR_DC and
TR_FREQ while wiggling harness or driving
the vehicle.

Monitor PID: TR_FREQ.
Compare the PID: TR_DC to the TR position
Duty Cycle Chart.

Selector Lever
Position
Range (% Duty
Cycle)
P 8.0 - 25.8
R 37.50 - 49.31
N 54.54 - 62.49
D 67.35 - 81.15
L 81.15 - 92
Is PID TR_FREQ between 100 to 150 Hz?
Is PID TR_DC in range?
Do the PIDs TR_DC and TR_FREQ remain
steady when the harness is wiggled or the
vehicle driven?

Yes
The problem is not in the TR sensor system.
REFER to Diagnosis By Symptom in this
section for further diagnosis.
No
If the PIDs change when wiggling the harness or
driving the vehicle, the problem may be
intermittent. GO to D5 .
D5 CHECK THE TRANSAXLE VEHICLE
HARNESS FOR AN OPEN
Disconnect: Transae Harness C1520A.
Measure the resistance for the TR sensor
circuits between the transaxle vehicle harness
C1520A and the PCM transaxle harness
C175T using the following chart.

Transmission
Range Sensor
Circuit
Transaxle
Vehicle
Harness PCM
TR Ground RET24
(BN/BU)
C1520A-20 C175T-36
Yes
GO to D6 .
No
REPAIR the circuit. CONNECT all
components. TEST the system for normal
operation.
TR Signal VET32
(VT)
C1520A-17 C175T-39
TR Power LE111
(VT/GN)
C1520A-18 C175T-1
HARNESS FOR A SHORT TO GROUND
C1520B.

Measure the resistance for the TR sensor
circuits between the transaxle vehicle harness
C1520A and ground using the following chart.

Transmission
Range Sensor
Circuit
Transaxle
Vehicle
Harness Ground
TR Ground RET24
(BN/BU)
C1520A-20 Ground
TR Signal VET32
(VT)
C1520A-17 Ground
TR Power LE111
(VT/GN)
C1520A-18 Ground
Are all resistances greater than 10,000
ohms?

Yes
GO to D7 .
No
REPAIR shorted circuit(s). RECONNECT all
operation.
HARNESS FOR A SHORT TO POWER
Measure the voltage for the TR sensor circuits
between the transaxle vehicle harness C1520A
and ground using the following chart.

Transmission
Range Sensor
Circuit
Transaxle
Vehicle
Harness Ground
TR Ground RET24
(BN/BU)
C1520A-20 Ground
TR Signal VET32
(VT)
C1520A-17 Ground
TR Power LE111
(VT/GN)
C1520A-18 Ground
Yes
REPAIR shorted circuit(s). RECONNECT all
operation.
No
GO to D8 .
D8 CHECK FOR A SHORT BETWEEN TR
/PCM INPUT SIGNAL CIRCUITS
Measure the resistance between TR sensor
circuits at the transaxle vehicle harness
C1520A using the following chart.

Transaxle
Vehicle
Harness
TR Sensor
Circuit
Transaxle
Vehicle
Harness
C1520A-20 TR Ground
RET24
(BN/BU)
C1520A-17
and
C1520A-18
C1520A-17 TR Signal
VET32 (VT)
C1520A-18
and
C1520A-20
C1520A-18 TR Power
LE111
(VT/GN)
C1520A-17
and
C1520A-20
Are all resistances greater than 10,000
ohms?

Yes
GO to D9 .
No
REPAIR shorts on circuits having less than
10,000 ohms between other TR /PCM input
signal circuits. RECONNECT all components.
D9 CHECK FOR AN INTERNAL SOLENOID
BODY OPEN FOR THE TR SENSOR CIRCUITS
Remove the main control cover. Refer to Main

Disconnect: TR Sensor Connector.
connector for damage or pushed-out terminals,
corrosion, loose wires and missing or damaged
seals.

Measure the resistance of the TR sensor
circuits between the solenoid body leadframe
main connector, component side and the TR
sensor connector, leadframe side.

Solenoid Body
Leadframe
Main Connector
Pin Number
TR Sensor
Pin
Number
Circuit
Function
(Wire Color)
18 1 Transmission
Range (TR)
power (RD)
17 2 TR signal
(WH)
Yes
GO to D10 .
No
INSTALL a new solenoid body leadframe.
REFER to Solenoid Body Leadframe in this
section. RECONNECT all components. TEST
20 3 TR ground
(BK)
D10 CHECK FOR VOLTAGE AND GROUND
AT THE TR SENSOR CONNECTOR
Connect: PCM C175T.
Ignition ON.
Measure the voltage on the solenoid body
leadframe between TR sensor connector pins 1
(RD) and 3 (BK) solenoid body leadframe
side.

Yes
INSTALL a new TR sensor. REFER to Digital
Transmission Range (TR) Sensor in this section.
TEST the system for normal operation. If the
condition is still present, INSTALL a new PCM.
REFER to Section 303-14A or Section 303-14B
.
No
303-14A or Section 303-14B . CONNECT all
operation.
PINPOINT TEST E: TRANSAXLE SOLENOID PRESSURE CONTROL CIRCUIT
NOTE: Refer to the Transaxle Vehicle Harness Connector illustration Transaxle Connector Layouts in this
section.
E1 CHECK FOR VOLTAGE AT THE TRANSAXLE VEHICLE
HARNESS CONNECTOR
PINPOINT TEST E: TRANSAXLE SOLENOID PRESSURE CONTROL CIRCUIT 3730
NOTICE: Do not use a solenoid control circuit that may be at
fault. Failure to jump pin 5 to a known good solenoid control
circuit can cause incorrect diagnostic results. For additional
information, REFER to Diagnostic Trouble Code (DTC)
Charts in this section for a fault listing.
Ignition OFF.
Inspect the connector for damaged or pushed out terminals,
corrosion, loose wires and missing or damaged seals.

Using the chart, connect a fused jumper between one of the 7
solenoid control circuit pins on the transmission vehicle harness
C1520A and C1520A-5.

Transmission Vehicle
Harness C1520A
Solenoid Control Circuit
C1520A-8 Shift Solenoid A (SSA) CET05
(BU/GN)
C1520A-9 Shift Solenoid B (SSB) CET06
(GN/BN)
C1520A-4 Shift Solenoid C (SSC) CET07
(GY/OG)
C1520A-10 Shift Solenoid D (SSD) CET08
(BN/WH)
C1520A-7 Shift Solenoid E (SSE) CET18
(GY/YE)
C1520A-3 Line Pressure Control (LPC) solenoid
CET09 (YE/VT)
C1520A-6 Torque Converter Clutch (TCC)
solenoid CET10 (BU/GY)
Ignition ON.
Measure the voltage between the transaxle vehicle harness
C1520A-5 circuit CET25 (BU/GN) harness side to ground.

Yes
INSTALL a new Line
Pressure Control (LPC)
solenoid. REFER to
Solenoids in this section.
RECONNECT all
components. TEST the
system for normal
operation.
No
GO to E2 .
E2 CHECK THE TRANSAXLE SOLENOID PRESSURE
PINPOINT TEST E: TRANSAXLE SOLENOID PRESSURE CONTROL CIRCUIT 3731
Ignition OFF.
Measure the resistance between the PCM transaxle C175T-50,
circuit CET25 (BU/GN) and transaxle vehicle harness C1520A-5,
circuit CET25 (BU/GN).

Yes
GO to E3 .
No
REPAIR circuit CET25
(BU/GN) for an open.
RECONNECT all
system for normal
operation.
E3 CHECK THE TRANSAXLE SOLENOID POWER CONTROL
Measure the resistance between the transaxle vehicle harness
C1520A-5, circuit CET25 (BU/GN) and ground.

Yes
INSTALL a new PCM.
REFER to Section 303-14A
RECONNECT all
system for normal
operation.
No
REPAIR circuit CET25
(BU/GN) for a short to
ground. RECONNECT all
system for normal
operation.
PINPOINT TEST F: TSS SENSOR
NOTE: Turbine Shaft Speed (TSS) sensor codes may be a result of bad power and ground circuits shared
between the Transmission Range (TR) sensor, Output Shaft Speed (OSS) sensor and TSS sensor.
F1 ELECTRONIC DIAGNOSTICS
Check to make sure the transaxle vehicle harness
C1520A is fully seated, terminals are engaged in
connector and in good condition before proceeding.

Have the items above been checked?
Yes
GO to F2 .
No
CARRY OUT the checks. CLEAR the
DTCs. RERUN the On-Board Diagnostic
(OBD) tests.
PINPOINT TEST F: TSS SENSOR 3732
F2 ELECTRONIC DIAGNOSTICS
Monitor the TSS sensor PIDs while test driving the
vehicle.

Is the TSS sensor signal present and consistent?
Yes
The condition that set the DTC is
intermittent and is not currently present.
CLEAR the DTCs. RERUN the OBD tests.
No
GO to F3 .
F3 CHECK THE TRANSAXLE VEHICLE HARNESS
FOR AN OPEN CIRCUIT
Disconnect: TSS Sensor C1520B.

Measure the resistance between the TSS C1520B
and the PCM transaxle C175T.

Turbine Shaft
Speed (TSS) Sensor
Circuit
Turbine Shaft
Speed (TSS)
Sensor PCM
TSS sensor power
supply LE111
(VT/GN)
C1520B-3 C175T-1
TSS sensor ground
RET24 (BN/BU)
C1520B-1 C175T-36
TSS sensor signal
VET33 (WH/OG)
C1520B-2 C175T-16
Yes
GO to F4 .
No
REPAIR the circuit(s) for an open.
Disconnect: Transaxle Vehicle Harness Connector
C1520A.

Measure the resistance between TSS sensor C1520B
and ground.

Turbine Shaft Speed
(TSS) Sensor Circuit
Turbine Shaft
Speed (TSS)
Sensor Ground
TSS sensor ground
RET24 (BN/BU)
C1520B-1 Ground
C1520B-2 Ground
Yes
GO to F5 .
No
ground. CONNECT all components. TEST
TSS sensor signal
VET33 (WH/OG)
TSS sensor power
supply LE111
(VT/GN)
C1520B-3 Ground
FOR A SHORT TO POWER
Check for voltage between the TSS sensor C1520B
and ground.

Turbine Shaft Speed
(TSS) Sensor Circuit
Turbine Shaft
Speed (TSS)
Sensor Ground
TSS sensor ground
RET24 (BN/BU)
C1520B-1 Ground
TSS sensor signal
VET33 (WH/OG)
C1520B-2 Ground
TSS sensor power
supply LE111
(VT/GN)
C1520B-3 Ground
Yes
voltage. CONNECT all components. TEST
No
GO to F6 .
F6 CHECK FOR VOLTAGE AND GROUND AT THE
TSS SENSOR CONNECTOR
Connect: PCM C175T.
Ignition ON.
Measure the voltage between TSS sensor C1520B-1
and C1520B-3.

Yes
INSTALL a new speed sensor. REFER to
Turbine Shaft Speed (TSS) in this section.
the condition is still present, INSTALL a
new PCM. REFER to Section 303-14A or
Section 303-14B .
No
303-14A or Section 303-14B . CONNECT
all components. TEST the system for
normal operation.
Workshop Manual
Special Testing Procedures
Special Tool(s)
Transmission Fluid Pressure Gauge
307-004 (T57L-77820-A)
The special tests are designed to aid the technician in diagnosing the hydraulic and mechanical portions of the
transaxle.
Engine Idle Speed Check
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for diagnosis and testing of the engine
idle speed.
Line Pressure Test
NOTICE: Carry out the Line Pressure Test prior to carrying out the Stall Speed Test. If the line
pressure is low at stall, do not carry out the Stall Speed Test or further transaxle damage will occur. Do
not maintain Wide Open Throttle (WOT) in any range for more than 5 seconds.
This test verifies that the line pressure is within specification.
Connect the Transmission Fluid Pressure Gauge to the line pressure tap. 1.
Start the engine and check the line pressures. Refer to the Line Pressure Chart to determine if the line
pressure is within specification.
2.
Line Pressure Chart
Gear Line
Pressures at Idle
a
P 338-379 kPa (49-55 psi)
R 621-689 kPa (90-100 psi)
N 338-379 kPa (49-55 psi)
D 338-379 kPa (49-55 psi)
L 338-379 kPa (49-55 psi)
Pressure at Wide Open
Throttle (WOT) Stall
a
P N/A
R 1,868-2,068 kPa
(271-300 psi)
N N/A
D 1,868-2,068 kPa
(271-300 psi)
L 1,868-2,068 kPa
(271-300 psi)
a
All pressures are approximate.
If the line pressure is not within specification, see the Line Pressure Diagnosis Chart for line pressure
concern causes.
3.
When the pressure tests are complete, install the line pressure tap plug.
4.
Line Pressure Diagnosis Chart
HIGH at IDLE - ALL RANGES Wiring Harnesses
Line Pressure Control (LPC) Solenoid
Main Regulator Valve
LOW at IDLE - ALL RANGES Low Transmission Fluid
Fluid Inlet Filter/Seal
Main Control Body
Cross Leaks
Gaskets
Pump
Separator Plate
LOW in Park ONLY Valve Body
LOW in Reverse ONLY Separator Plate
Reverse Clutch
Valve Body
Forward Clutch
LOW in Neutral ONLY Valve Body
LOW in Drive O/D ONLY Forward Clutch
Valve Body
LOW in Manual Low ONLY Forward Clutch
Valve Body
Stall Speed Test
NOTICE: Carry out the Line Pressure Test prior to carrying out the Stall Speed Test. If the line
pressure is low at stall, do not carry out the Stall Speed Test or further transaxle damage will occur.
The Stall Speed Test checks:
torque convertor operation and installation.
holding ability of the forward clutch.
reverse clutch.
planetary One-Way Clutch (OWC).
engine driveability concerns.
Conduct this test with the engine coolant and transmission fluid at correct levels and at normal operating
temperature.
Apply the park brake firmly for each Stall Speed Test.
Stall Speed Chart
Selector Lever Engine rpm
Drive 2.5 2,200-2,500
Drive 3.0 2,400-2,500
Connect the scan tool. 1.
NOTE: If the recorded rpm exceeds the maximum limits, release the accelerator pedal immediately,
clutch slippage is indicated.
In each of the following ranges D, L and R, press the accelerator pedal to Wide Open Throttle
(WOT). Do not hold the throttle open for more than 5 seconds at a time.
2.
Note the results in each range. 3.
After each range, move the selector lever to NEUTRAL and run the engine at 1,000 rpm for about 15
seconds to cool the torque converter before going to the next test.
4.
Use the stall speed diagnosis chart for corrective actions. 5.
If stall speeds were too high, see the Stall Speed Diagnosis Chart. If stall speeds were too low, first
check engine idle speed and tune up. If engine is OK, remove torque converter and check TCC for
slippage.
6.
Stall Speed Diagnosis Chart
Range Possible Source
D, L Forward Clutch
Low/Reverse Clutch
Low/One-Way Clutch
R Low/Reverse Clutch
Direct Clutch
Workshop Manual
Leakage Inspection
Special Tool(s)
Material
Item Specification
Dye-Lite ATF/Power Steering Fluid
Leak Detection Dye
164-R3701 (Rotunda)
-
XT-10-QLVC
MERCON
LV
NOTICE: Do not try to stop the fly increasing the torque beyond specifications. This may cause damage
to the case threads.
Leaks at the transaxle main control cover-to-transaxle often can be stopped by tightening the attaching bolts to
12 Nm (106 lb-in). If necessary, remove the main control cover and inspect for damage. Refer to Main
Check the transmission fluid filler tube connection at the transmission case. If leakage is found here, install a
new grommet.
Check transmission fluid tubes and fittings between the transmission and the cooler in the radiator tank for
wear or damage. When transmission fluid is found leaking between the case and the transmission fluid cooler
tube fitting, check for a missing or damaged O-ring, then tighten the fitting to specification.
If the leak continues, install a new transmission fluid cooler tube fitting and tighten to specification. The same
procedure should be followed for transmission fluid leaks between the radiator cooler and the transmission
fluid cooler tube fittings. Refer to Section 307-02A .
Check the engine coolant in the radiator. If transmission fluid is present in the coolant, the cooler in the
radiator is probably leaking. The cooler can be further checked for leaks by disconnecting the transmission
fluid cooler tubes from the cooler fittings and applying no more than 345 kPa (50 psi) air pressure to the
fittings. Remove the coolant recovery cap to relieve the pressure at the exterior of the transmission fluid
cooler tank. If the cooler is leaking and/or will not hold pressure, install a new cooler.
If transmission fluid leakage is found at the transaxle range selector lever, install a new seal.
If transmission fluid leakage is found at the transaxle internal harness connector, install a new O-ring.
Fluid Leakage in Torque Converter Area
Diagnosing and correcting fluid leaks in the torque converter area, use the following procedures to locate the
exact cause of the leakage. Leaks at the front of the transaxle, as evidenced by fluid around the torque
converter housing, may have several sources. By careful observation it is possible to pinpoint the source of the
leak before removing the transaxle from the vehicle. The paths which the fluid takes to reach the bottom of the
torque converter housing are shown in the illustration. The 5 steps following correspond with the numbers in
the illustration.
Transmission fluid leaking by the converter hub seal lip will tend to move along the drive hub and
onto the back of the torque converter. Except in the case of a total seal failure, transmission fluid
leakage by the lip of the seal will be deposited on the inside of the torque converter housing only, near
the outside diameter of the housing.
1.
Transmission fluid leakage by the outside diameter of the converter impeller hub seal and the case
will follow the same path that leaks by the ID of the converter hub seal follow.
2.
Transmission fluid leakage from the converter cover weld or the converter-to-flexplate stud weld will
appear at outside diameter of torque converter on the back face of the flexplate and in the converter
housing only near the flexplate. If a converter-to-flexplate lug, lug weld or converter cover weld leak
is suspected, remove the converter and pressure check.
3.
Transmission fluid leakage from the bolts inside the converter housing will flow down the back of the
torque converter housing. Leakage may be from loose or missing bolts.
4.
Engine oil leaks are sometimes incorrectly diagnosed as transaxle converter hub seal leaks. The
following areas of possible leakage should also be checked to determine if engine oil leakage is
causing the concern.
Leakage at the valve cover gasket may allow engine oil to flow over the torque converter
housing or seep down between the torque converter housing and cylinder block causing oil to
be present in or at the bottom of the torque converter housing.
1.
Oil galley plug leaks will allow engine oil to flow down the rear face of the cylinder block to
the bottom of the torque converter housing.
2.
Leakage at the crankshaft rear oil seal will work back to the flexplate, and then into the torque
converter housing.
3.
Leakage at oil pressure sensor will allow engine oil to flow down the rear face of the cylinder
block to the bottom of the torque converter housing.
4.
5.
Leak Check Test
Remove the transmission fluid level indicator and note the color of the transmission fluid. 1.
Remove the torque converter housing cover. Clean off any transmission fluid from the top and bottom
of the torque converter housing, the front of the case and rear face of the engine and oil pan. Clean the
torque converter area by washing with a suitable nonflammable solvent and blow-dry with
compressed air.
2.
Wash the torque converter housing, the front of the flexplate and the converter drain plugs. The torque
converter housing may be washed out using cleaning solvent and a squirt-type oil can. Blow-dry all
washed areas with compressed air.
3.
Using the scan tool, start and run the engine until the transaxle reaches its normal operating
temperature. Observe the back of the cylinder block and top of the torque converter housing for
evidence of transmission fluid leakage. Raise the vehicle on a hoist and run the engine at fast idle,
then at low idle, occasionally shifting to the OVERDRIVE and REVERSE ranges to increase pressure
within the transaxle. Observe the front of the flexplate, back of the cylinder block (in as far as
possible) and inside the torque converter housing and front of the case. Run the engine until
transmission fluid leakage is evident and the probable source of leakage can be determined.
4.
Leak Check Test With Black Light
NOTE: Use Dye-Lite ATF/Power Steering Fluid Leak Detection Dye to detect a transmission fluid leak.
Add dye to the transmission fluid. Use one 30 ml (1 oz) bottle of dye solution for every 3.8L (4 qt) of
transmission fluid.
1.
Using the scan tool, start and run the engine until the transaxle reaches its normal operating
temperature. Using a suitable tool, observe the back of the cylinder block and top of the torque
converter housing for evidence of fluid leakage. Raise the vehicle on a hoist and run the engine at fast
idle, then at low idle, occasionally shifting to the DRIVE and REVERSE ranges to increase pressure
within the transaxle. Observe the front of the flexplate, back of the cylinder block (in as far as
possible), inside the torque converter housing and the entire case until fluid leakage is evident and
theprobable source of leakage can be determined.
2.
Workshop Manual
Transmission Fluid Cooler
Special Tool(s)
Transaxle Cooling - 6F35
Item
Part
Number Description
1 8005 Radiator
2 7R081 Transmission fluid cooler supply tube assembly (supplies
transmission fluid to the transmission fluid cooler from
the transaxle)
3 7R081 Transmission fluid cooler return tube assembly
(transmission fluid return tube from the transmission fluid
cooler to the transaxle)
4 7J081 Secondary latches
5 7H420 Transaxle mounted transmission fluid cooler tubes
When internal wear or damage has occurred in the transaxle, metal particles or clutch plate material may have
been carried into the torque converter and transaxle fluid cooler. These contaminants are a major cause of
recurring transaxle issues and must be removed from the system before the transaxle is put back into use.
Transmission Fluid Cooler 3744
Refer to Transmission Fluid Cooler Backflushing and Cleaning in this section.
Transmission Fluid Cooler Flow Test
NOTE: The selector lever linkage, selector lever cable adjustment, transmission fluid level and line pressure
must be within specification before carrying out this test. Refer to Section 307-05A for selector lever linkage
and selector lever cable adjustment and refer to Special Testing Procedures in this section for line pressure
test. The transmission fluid must be above 85C (185F) for the cooler by-pass to open to carry out this test.
Using a scan tool, run the engine to establish the correct transmission fluid temperature of 85C
(185F).
1.
Remove the transmission fluid level indicator from the transmission fluid filler tube. 2.
Place funnel in the transmission fluid filler tube. 3.
Remove the transmission fluid cooler return tube (rear fitting) from the fitting on the transaxle case. 5.
Connect one end of a hose to the cooler return tube and route other end of the hose up to a point
where it can be inserted into the funnel at the transmission fluid filler tube.
6.
Start the engine and run it at idle with the transmission in NEUTRAL. 7.
When transmission fluid flowing from hose is in a steady stream, a liberal amount of transmission
fluid should be observed. "Liberal" is described as about 1L (1 qt) delivered in 30 seconds. If a liberal
flow is observed, the test is cote.
8.
If the flow is not liberal, stop the engine. Disconnect the hose from the cooler return tube and connect
it to the converter outlet tube fitting (front fitting) on the transaxle case.
9.
Repeat Steps 7 and 8. If flow is now approximately 1L (1 qt) in 30 seconds, refer to Transmission
Fluid Cooler Backflushing and Cleaning . If the flow is still not approximately 1L (1 qt) in 30
seconds, repair the pump and/or the torque converter.
If new transmission fluid cooler tubes need to be installed, refer to Section 307-02A .
10.
Transaxle Cooling - 6F35 3745
Transaxle/Transmission 6F35
Workshop Manual
Diagnosis By Symptom
The Diagnostic Routines give the technician diagnostic information, direction and suggest possible
components, using a symptom as a starting point.
The Diagnostic Routines are divided into 2 categories: Electrical Routines, indicated by 200 series numbers,
and Hydraulic/Mechanical Routines, indicated by 300 series numbers. The Electrical Routines list the possible
electrical components that may cause or contribute to the symptom described. The Hydraulic/Mechanical
Routines list the possible hydraulic or mechanical components that may cause or contribute to the symptom
described.
Diagnosis by Symptom Index Directions
Using the Symptom Index, select the Concern/Symptom that best describes the condition. 1.
See the routine indicated in the Diagnosis By Symptom Index. 2.
Always begin diagnosis of a symptom with:
Preliminary inspections. 1.
Verifications of condition. 2.
Checking the fluid levels. 3.
Carry out other test procedures as directed. 4.
3.
NOTE: Not all concerns and conditions with electrical components sets a DTC. Be aware that the
components listed may be the cause. Verify correct function of these components prior to proceeding
to the Hydraulic/Mechanical Routine.
Begin with the Electrical Routine, if indicated. Follow the Reference/Action statements. Always carry
out the OBD tests as required. Never skip steps. Repair as required. If the concern is still present after
electrical diagnosis, then proceed to the Hydraulic/Mechanical Routine.
4.
The Hydraulic/Mechanical Routines list possible hydraulic or mechanical components that could
cause the concern. These components are listed in the removal sequence and by most probable cause.
All components listed must be inspected to verify a correct repair.
5.
Diagnosis by Symptom Index
Title
Routines
Electrical
(1)
Hydraulic/ Mechanical
Engagement Concerns
No Forward 201 301
No Reverse 202 302
Harsh Reverse 203 303
Harsh Forward 204 304
Delayed/Soft Reverse 205 305
Delayed/Soft Forward 206 306
No Forward and No Reverse 207 307
Delayed/Soft Forward and Reverse 209 309
Shift Concerns
Some or All Shifts Missing 210 310
Timing Early/Late 211 311
Timing Erratic/Hunting 212 312
Soft/Slipping 213 313
Harsh 214 314
No 1st Gear, Engages in Higher Gear 215 315
No Manual Low 1st Gear 216 316
No 1-2 Shift (Automatic) 220 320
Soft/Slipping 1-2 Shift (Automatic) 230 330
Harsh 1-2 Shift (Automatic) 240 340
Torque Converter Operation Concerns
Torque Converter: No Apply 250 350
Torque Converter: Always Applied/Stalls Vehicle 251 351
Torque Converter: Cycling/Shudder/Chatter 252 352
Other Concerns
No Engine Braking in 1st Gear, Manual 1st Position 260 360
Selector Lever Efforts High 261 361
External Leaks 262 362
Vehicle Driveability Concerns 263 363
Noise/Vibration Forward or Reverse 264 364
Engine Will Not Crank 265 365
No Park Range 266 366
Overheating 267 367
(1)
Carry out electrical routine first.
Diagnostic Routines
Engagement Concern: No Forward
201 ELECTRICAL ROUTINE
Powertrain Control
System
No electrical
concerns

301 HYDRAULIC/MECHANICAL ROUTINE
Transmission Fluid
Level
Low
transmission
fluid level
CHECK transmission fluid level and adjust as necessary. REFER to
Preliminary Inspection .

Condition CARRY OUT transmission fluid condition check. REFER to Preliminary
Inspection .

Selector Lever Linkage
(Internal/External)
Damaged or out
of adjustment
INSPECT for damage. REPAIR as required. VERIFY selector lever
cable adjustment. REFER to Section 307-05A .

Incorrect Pressures
LPC solenoid
stuck low
CHECK pressure at line pressure tap. CARRY OUT Line Pressure Tests
and Stall Speed Tests. REFER to Special Testing Procedures . SEE the
Line Pressure Chart for specification. If pressures are low, CHECK the
following possible components:

Main control valve body
Pump assembly
LPC solenoid
Main Control Valve
Body
Bolts out of
torque
specification
TIGHTEN bolts to specification.
Gaskets and
separator plate
damaged,
off location
INSTALL new as required.
Manual control
valve
damaged
Pump Assembly
Bolts out of
torque
specification
Porosity/cross
leaks/ball
missing or
leaking
INSTALL a new pump as required.
Components
damaged
Engagement Concern: No Reverse
Powertrain Control
System
No electrical
concerns

Low transmission
fluid level

Transmission
fluid condition
CARRY OUT transmission fluid condition check. REFER to

(Internal/External)
Damaged or out
of adjustment
REPAIR as required. VERIFY selector lever cable adjustment. REFER

Incorrect Pressures
Line pressure
low
CARRY OUT Line Pressure and Stall Speed Tests. REFER to Special
Testing Procedures . CHECK pressure at line pressure tap. SEE the Line
Pressure Chart for specifications. If pressures are low, CHECK the
following possible components:

Main control valve body
Pump assembly
Low/reverse clutch assembly
Direct clutch assembly
SSB , SSD and SSE
Bolts out of
torque
specification
Gasket and
separator plate
damaged, off
location
Manual control
valve, springs
stuck,
damaged
Multiplex valve,
springs
stuck, damaged
Low/reverse
clutch valve,
springs
stuck, damaged
Direct clutch
valve, springs
stuck,
damaged
Pump Assembly
Bolts out of
torque
specification
Porosity/cross
leaks, pump
assembly leaking,
plugged hole
Components
damaged
Low/Reverse Clutch
Assembly
SSD stuck
low
INSTALL a new SSD as required. REFER to Solenoids .
Low/reverse
regulator valve
stuck
REPAIR as required.
Seals, piston,
springs
damaged
REPAIR as required.
Clearance check
out of
specification
CARRY OUT clearance checks.
Friction elements
damaged or
worn
REPAIR as required.
Direct Clutch Assembly
Seals, piston,
spring
damaged
REPAIR or install new as required.
SSB INSTALL a new SSB as required. REFER to Solenoids .
Direct clutch
regulator valve
Clearance check
out of
specification
Friction elements
damaged,
clearance check
incorrect
REPAIR as required.
Engagement Concern: Harsh Reverse
Electrical inputs/outputs, vehicle wiring
harnesses, TCM , MAF sensor, IAT sensor,
TP sensor, ISC , PSP sensor, engine rpm, LPC
solenoid, TFT sensor, TSS sensor, OSS
sensor, TR sensor, SSB , SSD or transmission
solenoid power control circuit open/shorted
RUN OBD . REFER to the Powertrain
manual for diagnosis. GO to Pinpoint Test
A , GO to Pinpoint Test B , GO to Pinpoint
Test C , GO to Pinpoint Test D and GO to
Pinpoint Test E .

Solenoid Body
Incorrect solenoid body strategy data stored in
the TCM
VERIFY solenoid body strategy data stored
in the TCM , download new identification
and strategy as necessary. REFER to
Solenoid Body Strategy .

Incorrect Pressures
Line pressure high CARRY OUT Line Pressure and Stall
Speed Tests. REFER to Special Testing
Procedures . CHECK pressure at line
pressure tap. SEE the Line Pressure Chart
for specifications. If high, CHECK the main
control valve body.

Pump Assembly
Bolts out of torque specification TIGHTEN bolts to specification.
Porosity/cross leaks, pump assembly leaking,
plugged hole
Components damaged INSTALL a new pump as required.
Main regulator valve stuck, damaged INSTALL new as required.
Main Controls
Gasket and separator plate damaged, off
location
Low/reverse regulator valve stuck,
damaged
Low/Reverse latch valve stuck, damaged INSTALL new as required.
Direct regulator valve stuck, damaged INSTALL new as required.
Direct latch valve stuck, damaged INSTALL new as required.
SSB mechanically stuck high INSTALL a new SSB as required. REFER
to Solenoids .

SSD mechanically stuck high INSTALL a new SSD as required. REFER
to Solenoids .

Low/Reverse Clutch Assembly
SSD stuck low INSTALL a new SSD as required. REFER
to Solenoids .

Low/reverse regulator valve stuck INSTALL a new solenoid body as required.
Seals, piston, springs damaged REPAIR as required.
Clearance check out of specification CARRY OUT clearance checks.
Friction elements damaged or worn REPAIR as required.
Seals, piston, spring damaged REPAIR or INSTALL new as required.
SSB stuck INSTALL a new SSB as required. REFER
to Solenoids .

Direct clutch regulator valve REPAIR or INSTALL new as required.
Clearance check out of specification CARRY OUT clearance checks.
Friction elements damaged, clearance
check incorrect
REPAIR or INSTALL new as required.
Engagement Concern: Harsh Forward
harnesses, TCM , MAF sensor, IAT sensor,
TP sensor, ISC , PSP sensor, engine rpm,
LPC solenoid, TFT sensor, TSS sensor,
OSS sensor, TR sensor, SSA and or
transmission solenoid power control circuit
open/shorted
Control/Emissions Diagnosis (PC/ED) manual
for diagnosis. GO to Pinpoint Test A , GO to
Pinpoint Test B , GO to Pinpoint Test C , GO
to Pinpoint Test D and GO to Pinpoint Test E
.

Solenoid Body
Incorrect solenoid body strategy data stored
in the TCM
VERIFY solenoid body strategy data stored in
the TCM , download new identification and
strategy as necessary. REFER to Solenoid
Body Strategy .

Incorrect Pressures
Line pressure high CARRY OUT Line Pressure and Stall Speed
Tests. REFER to Special Testing Procedures .
Check pressure at line pressure tap. SEE the
Line Pressure Chart for specifications. If
pressures are high, CHECK the main control
valve body, pump assembly.

Pump Assembly
Porosity/cross leaks, pump assembly
leaking, plugged hole
Components damaged INSTALL a new pump as required.
Main regulator valve stuck, damaged INSTALL new as required.
Main Controls
Gasket and separator plate damaged,
off location
Forward clutch seal leaking between
valve body and case
Forward clutch regulator valve stuck,
damaged
Forward clutch latch valve stuck,
damaged
Forward Clutch Assembly
Seals, piston worn, damaged INSTALL new as required.
Friction elements damaged INSTALL new as required.
Wave spring damaged INSTALL new as required.
Engagement Concern: Delayed/Soft Reverse
Electrical
inputs/outputs,
vehicle wiring
harnesses, TCM ,
LPC solenoid, TFT
sensor
RUN OBD . REFER to the Powertrain Control/Emissions Diagnosis
(PC/ED) manual for diagnosis. GO to Pinpoint Test A and GO to
Pinpoint Test B .

Solenoid Body
Incorrect solenoid
body strategy data
stored in the TCM
VERIFY solenoid body strategy data stored in the TCM , download
new identification and strategy as necessary. REFER to Solenoid
Body Strategy .

Low transmission
fluid level

Transmission fluid
condition

(Internal/External)
Damaged, out of
adjustment
REPAIR as required. VERIFY selector lever cable adjustment.

Incorrect Pressures
Line pressure
low
CHECK pressure at line pressure tap. CARRY OUT Line Pressure
and Stall Speed Tests. REFER to Special Testing Procedures . SEE
the Line Pressure Chart for specifications. If pressures are low,
CHECK the following possible components: main control valve body,
pump assembly, low/reverse clutch assembly, direct clutch assembly.

Main Controls
Bolts out of torque
specification
Gaskets and
separator plate
damaged, off
location
Low/reverse
regulator valve
stuck, damaged
Low/reverse latch
valve stuck,
damaged

Direct regulator
valve stuck,
damaged
Direct latch valve
stuck, damaged
Manual control
valve, springs
missing, damaged,
misassembled
SSB stuck low INSPECT for damage. GO to Pinpoint Test A . INSTALL a new SSB
as required. REFER to Solenoids .

SSD stuck low INSTALL a new SSD as required. REFER to Solenoids .
Pump Assembly
Pump Assembly
worn/cross
leaks, leaking
Main regulator
valve stuck,
damaged
Low/Reverse Clutch
Assembly
SSD stuck low INSTALL a new SSD as required. REFER to Solenoids .
Low/reverse
regulator valve
stuck
Seals, piston,
springs
damaged
REPAIR as required.
Clearance check out
of specification
Friction elements
damaged or
worn
REPAIR as required.
Seals, piston, spring
damaged
SSB stuck INSTALL a new SSB as required. REFER to Solenoids .
Direct clutch
regulator valve
Clearance check out
of specification
Friction elements
damaged,
clearance check
incorrect
REPAIR as required.
Engagement Concern: Delayed/Soft Forward
Electrical
inputs/outputs, vehicle
wiring harnesses, TCM
, LPC solenoid, TFT
sensor and TSS sensor
RUN OBD . REFER to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for diagnosis. GO to Pinpoint Test A ,
GO to Pinpoint Test B and GO to Pinpoint Test C .

Solenoid Body
Incorrect solenoid body
strategy data stored in
the TCM
VERIFY solenoid body strategy data stored in the TCM ,
download new identification and strategy as necessary. REFER to

Low transmission fluid
level
CHECK transmission fluid level and adjust as necessary. REFER
to Preliminary Inspection .

Transmission fluid
condition

Damaged, out of
adjustment

Incorrect Pressures
Line pressure low
CHECK pressure at line pressure tap. CARRY OUT Line Pressure
and Stall Speed Tests. REFER to Special Testing Procedures .
SEE the Line Pressure Chart for specifications. If pressures are
low, CHECK the following possible components: main control
valve body, pump assembly, and forward clutch.

Main Controls
Bolts out of torque
specification
Gaskets and separator
plate damaged, off
location
Forward clutch
regulator valve stuck or
damaged
Forward clutch latch
valve stuck or damaged
LPC solenoid stuck
low
INSTALL a new LPC as required. REFER to Solenoids .
SSA stuck low INSTALL a new SSA as required. REFER to Solenoids .
Pump Assembly
Bolts out of torque
specification
Worn/cross leaks INSTALL new as required.
Main regulator valve
stuck, damaged,
missing
REPAIR as required.
Clutch plates, seals,
piston worn,
damaged
Wave spring
damaged
Engagement Concern: No Forward and No Reverse
No electrical
concerns

Low transmission
fluid level

Transmission
fluid condition

Halfshaft
Splines worn,
damaged
REPAIR as required.
Shaft
misassembled,
incorrect
REPAIR as required.
(Internal/External)
Damaged, out of
adjustment
REPAIR as required. VERIFY selector lever cable adjustment. REFER

Incorrect Pressures
Line pressure
low
CHECK pressure at the line pressure tap. CARRY OUT Line Pressure
and Stall Tests. REFER to Special Testing Procedures . SEE the Line
Pressure Chart for specifications. If pressures are low, CHECK the
following possible components: transmission fluid filter and seal
assembly, main control, pump assembly, low/reverse clutch assembly,
forward clutch assembly.

and Seal Assembly
Plugged,
damaged, not
correctly seated
INSTALL a new filter and seal assembly.
Filter, seal
damaged
Main Controls
Manual valve INSTALL new as required.
Shift valves INSTALL new as required.
Bolts out of
torque
specification
Gaskets and
separator plate
damaged, off
location
Components
damaged, check
balls stuck
REPAIR as required.
Pump Assembly
Bolts out of
torque
specification
Porosity/cross
leaks leaking,
plugged hole
INSTALL a new pump assembly.
Main regulator
valve (only if line
pressure is out of
specification)
damaged
REPAIR as required.
Output Shaft
Splines
damaged
REPAIR as required.
Other Possible
Components
Turbine shaft REPAIR as required.
Flexplate REPAIR as required.
Sun gear and shell
assemblies
REPAIR as required.
Planetaries REPAIR as required.
Final drive
assembly
REPAIR as required.
Engagement Concern: Delayed/Soft Forward and Reverse
Electrical inputs/outputs,
vehicle wiring harnesses,
TCM TFT sensor, TSS
sensor, LPC solenoid
RUN OBD . REFER to Powertrain Control/Emissions Diagnosis
(PC/ED) manual for diagnosis. GO to Pinpoint Test A , GO to
Pinpoint Test B and GO to Pinpoint Test C .

Solenoid Body
strategy data stored in the
TCM
download new identification and strategy as necessary. REFER
to Solenoid Body Strategy .

Low transmission fluid
level
CHECK transmission fluid level and adjust as necessary.
REFER to Preliminary Inspection .

Transmission fluid
condition

(Internal/External)
Damaged, out of
adjustment

Incorrect Pressures
Line pressure low CARRY OUT Line Pressure and Stall Speed Tests. REFER to
Special Testing Procedures . SEE the Line Pressure Chart for
specifications. If pressures are low, CHECK the following
possible components: main control, pump assembly and LPC
solenoid.

Transmission Fluid Filter and
Seal Assembly
Plugged, damaged, not
correctly seated
Filter, seal damaged INSTALL a new filter and seal assembly.
Main Controls
Bolts out of torque
specification
plate damaged, off
location
Seals, manual valve REPAIR or INSTALL new as required.
Pump Assembly
Bolts out of torque
specification
Worn/cross leaks
leaking
INSTALL a new pump assembly.
Components damaged INSTALL new as required.
Main regulator valve
missing, damaged or
misassembled
REPAIR as required.
Shift Concerns: Some or All Shifts Missing
harnesses, TCM , SSA , SSB , SSC , SSD ,
SSE , TP sensor, MAF sensor, OSS
sensor, TSS sensor, TR sensor and LPC
solenoid
Pinpoint Test C and GO to Pinpoint Test D .

Incorrect transmission fluid level CHECK transmission fluid level and adjust as
necessary. REFER to Preliminary Inspection .

Transmission fluid condition CARRY OUT transmission fluid condition
check. REFER to Preliminary Inspection .

Selector Lever Linkage (Internal/External)
Damaged, out of adjustment REPAIR as required. VERIFY selector lever

Vehicle Speed Input
Insufficient, erratic or no input received by
the TCM from the OSS sensor
REPAIR as required. GO to Pinpoint Test C .
Transmission Fluid Filter and Seal Assembly
Plugged, damaged, not correctly seated INSTALL a new filter and seal assembly.
Main Controls
Regulator and/or latch valves stuck,
damaged, misassembled
Plugged solenoid body filter INSTALL new as required.
Planetary Gear Sets
Damaged REPAIR as required.
Other Components
Clutches REPAIR as required.
Output shafts (differential) REPAIR as required.
Powerflow components REPAIR as required.
Go to shift concerns: See the appropriate shift concern and routine:
Shift Concern: No 1-2, Routine 220/320
Shift Concerns: Timing Early/Late
harnesses, TCM , SSA , SSB , SSC , SSD ,
SSE , TP sensor, MAF sensor, OSS sensor,
TSS sensor, IAT sensor, ECT sensor and
LPC solenoid
RUN OBD . REFER to Powertrain
manual for diagnosis. GO to Pinpoint Test A
, GO to Pinpoint Test B and GO to Pinpoint
Test C .

CARRY OUT Shift Point Road Test. REFER
to Shift Point Road Test . CARRY OUT
Torque Converter Operation Test. REFER to
Torque Converter Diagnosis .

Solenoid Body
Incorrect solenoid body strategy data stored
in the TCM
VERIFY solenoid body strategy data stored
in the TCM , download new identification
and strategy as necessary. REFER to

Other
Tire size SEE the specification decal and verify
vehicle has original equipment. Changes in
tire size will affect shift timing.

Low transmission fluid level CHECK transmission fluid level and adjust
as necessary. REFER to Preliminary
Inspection .


cable adjustment. REFER to Section
307-05A .

Main Controls
Gaskets and separator plate damaged,
off location
Valves, accumulators, seals, springs, clips,
check balls damaged, missing,
misassembled
REPAIR as required.
One-Way Clutch Assembly
Damaged REPAIR or INSTALL new as required.
Other Components
Clutches REPAIR or INSTALL new as required.
Vehicle Speed Input
Insufficient, erratic or no input received by
the TCM from the OSS or TSS sensors
Shift Concerns: Timing Erratic/Hunting
harnesses, TCM , TCC solenoid, SSA ,
SSB , SSC , SSD , SSE , TP sensor, OSS
sensor, ECT sensor, IAT sensor, MAF
sensor, TR sensor, TFT sensor and TSS
sensors
Pinpoint Test B , GO to Pinpoint Test C , GO to
Pinpoint Test D and GO to Pinpoint Test E .

CARRY OUT Shift Point Road Test. REFER to
Shift Point Road Test . CARRY OUT Torque
Converter Operation Test. REFER to Torque
Converter Diagnosis .

Solenoid Body
Incorrect solenoid body strategy data
stored in the TCM
VERIFY solenoid body strategy data stored in
the TCM , download new identification and
strategy as necessary. REFER to Solenoid Body
Strategy .

Low transmission fluid level CHECK transmission fluid level and adjust as



Gaskets and separator plate damaged,
off location
Valves, seals, clips, check ball stuck,
damaged, contaminated
Vehicle Speed Input
Insufficient, erratic or no input received
by the TCM from the OSS sensor or TSS
sensor
TCC
SEE Torque Converter Cycling (Routine
254/354).

Planetary Gear Sets
Damaged REPAIR as required.
Clutch Assemblies
Damaged clutch plates, pistons, seals,
return springs
For Diagnosis Related to a Specific Shift
SEE the appropriate shift concern and routine
for further diagnosis:

Shift Concern: Soft/Slip 1-2, Routine 230/330
Shift Concern: Harsh 1-2, Routine 240/340
Shift Concerns: Feel Soft/Slipping
Electrical inputs/outputs, vehicle
wiring harnesses, TCM , LPC
solenoid, MAF sensor, TP sensor,
ECT sensor, IAT sensor, TFT sensor,
OSS sensor and TSS sensor
diagnosis. GO to Pinpoint Test A , GO to Pinpoint
Test B and GO to Pinpoint Test C .

Solenoid Body
Incorrect solenoid body strategy data
stored in the TCM
VERIFY solenoid body strategy data stored in the
TCM , download new identification and strategy as
necessary. REFER to Solenoid Body Strategy .

Transmission Fluid
Low transmission fluid level CHECK transmission fluid level and adjust as

Transmission fluid condition CARRY OUT transmission fluid condition check.

Damaged, out of adjustment REPAIR as required. VERIFY selector lever cable
adjustment. REFER to Section 307-05A .

Incorrect Pressures
Line pressure low CARRY OUT Line Pressure and Stall Speed Tests.
REFER to Special Testing Procedures . SEE the Line
Pressure Chart for specifications. If pressures are low
or all shifts are soft/slipping. REFER to Main
Control Valve Body .

If pressures are OK and a specific shift is
soft/slipping, SEE the following chart:

Soft/Slipping Shift 1-2, Routine 230/330
Transmission Fluid Filter and Seal
Assembly
Plugged, damaged, not correctly
seated
Main Controls
Gaskets and separator plate
damaged, off location
Sticking or binding valves, check
balls, clips, springs damaged,
missing
Pump Assembly
Pump assembly worn/cross
leaks, leaking
Shift Concerns: Feel Harsh
wiring harnesses, TCM , LPC
solenoid, MAF sensor, TP
sensor, OSS sensor, TSS sensor,
ECT sensor, IAT sensor, PSP
switch, TFT sensor, TR sensor
SSA , SSB , SSC , SSD and SSE
RUN OBD . REFER to Powertrain Control/Emissions
Diagnosis (PC/ED) manual for diagnosis. GO to Pinpoint
Test A , GO to Pinpoint Test B , GO to Pinpoint Test C
and GO to Pinpoint Test D .

Solenoid Body
Incorrect solenoid body strategy
data stored in the TCM
download new identification and strategy as necessary.
REFER to Solenoid Body Strategy .

Low transmission fluid level CHECK transmission fluid level and adjust as necessary.

Condition CARRY OUT transmission fluid condition check.

Incorrect Pressures
Line pressure high CARRY OUT Line Pressure and Stall Speed Tests.
REFER to Special Testing Procedures . CHECK pressure
at line pressure tap. SEE the Line Pressure Chart for
specifications. If pressures are high or all shifts are harsh,
CHECK the main control. REFER to Main Control Valve
Body . If pressures are OK and a specific shift is harsh.
SEE the appropriate shift routine in the following chart:

Shift 1-2, Routine 240/340
Valves, springs, clips, check
balls stuck, damaged
Pump Assembly
Pump assembly worn/cross
leaks, leaking
Shift Concerns: No 1st Gear, Engages in Higher Gear
harnesses, TCM , SSA , SSB , SSC ,
SSD , SSE , OSS sensor, TSS sensor
diagnosis. GO to Pinpoint Test A , GO to Pinpoint

and transmission solenoid power
control circuit no voltage at
transmission connector
Test C and GO to Pinpoint Test E . REPAIR as
required. CLEAR the DTCs. ROAD TEST and
RERUN OBD .
Forward clutch regulator valve, springs,
clips stuck, damaged, missing,
misassembled
REPAIR as required.
Shift solenoid stuck, damaged REPAIR as required. GO to Pinpoint Test A .
ACTIVATE solenoid using output state control.
REPAIR as required.

For diagnosis related to a specific gear,
use the scan tool to select the gear
SEE the following routines:
Mechanical
Clutches or seals damaged or worn REPAIR or INSTALL new as required.
Low One-Way Clutch Assembly
Not overrunning, damaged INSTALL new as required.
Shift Concerns: No Manual Low 1st Gear
TCM , SSA , SSD , SSE
and TR sensor
Diagnosis (PC/ED) manual for diagnosis. GO to Pinpoint Test
A and GO to Pinpoint Test D . REPAIR as required. CLEAR
the DTCs. ROAD TEST and RERUN OBD .

(Internal/External)
Damaged or out of
adjustment

Incorrect Pressures
Line pressure low CHECK pressure at line pressure tap. CARRY OUT Line
Pressure and Stall Speed Tests. REFER to Special Testing
Procedures . SEE the Line Pressure Chart for specifications. If
pressures are low, CHECK the following possible components:
main control. REFER to Main Control Valve Body .

Bolts out of torque
specification
plate damaged, off
location
Forward latch, forward
regulator, low/reverse
latch, low/reverse
regulator valves, clips
stuck, damaged,
missing
REPAIR as required.
Multiplex shift valve clips
stuck, damaged,
missing
CHECK 4th gear ratio. REPAIR as required.
Check ball damaged,
missing
REPAIR as required.
damaged
Clutches damaged,
burnt, worn
Worn, damaged,
misassembled
REPAIR as required.
damaged
Clutches damaged,
burnt, worn
REPAIR as required.
Worn, damaged,
misassembled

Case damaged REPAIR as required.
Shift Concerns: No 1-2 Shift (Automatic)
TCM , SSC and TR
sensor
A and GO to Pinpoint Test D .

Incorrect Pressures
Line pressure CHECK pressure at line pressure tap. CARRY OUT Line
Pressure Test. REFER to Special Testing Procedures . SEE the
Line Pressure Chart for specifications. If not OK, CHECK main
control. REFER to Main Control Valve Body .

Bolts out of torque
specification
plate damaged, off
location
Intermediate regulator
valve, springs, clips
loose, stuck, missing,
misassembled stuck off
SSC not functioning
correctly
ACTIVATE solenoid using scan tool. REFER to Output State
Control (OSC) Mode . GO to Pinpoint Test A . INSTALL a
new solenoid as required. REFER to Solenoids .

Intermediate Clutch Assembly
Failed Off
Seals damaged INSTALL new as required.
Piston damaged INSTALL new as required.
Friction damaged,
worn

Cylinder hub
damaged
Return spring assembly
damaged
Failed On
Friction overheated INSTALL new as required.
Cylinder hub
damaged
damaged
Pump Assembly
Component damaged INSTALL a new pump assembly as required.
Not overrunning,
damaged
TCM , SSB failed, SSC
stuck on and TR sensor

Incorrect Pressures
Line pressure CARRY OUT Line Pressure Test. REFER to Special Testing
Procedures . CHECK pressure at line pressure tap. SEE the
Line Pressure Chart for specifications. If not OK, CHECK

Bolts out of torque
specification
gaskets and separator plate
Direct regulator and latch
valves, springs, clips
misassembled, stuck off
Intermediate regulator and
latch valves, springs, clips
misassembled, stuck on
SSB or SSC not functioning
correctly

Direct Clutch Assembly Failed
Off
Friction damaged,
worn
Cylinder hub damaged INSTALL new as required.
damaged
Failed On
Friction damaged,
worn
damaged
harnesses, TCM , SSD failed, SSB stuck
on and TR sensor
manual for diagnosis. GO to Pinpoint Test

Overdrive regulator and latch valves,
springs, clips loose, stuck, missing,
misassembled, clutch failed off
Direct regulator and latch valves,
springs, clips loose, stuck, missing,
misassembled, clutch failed on
SSD not functioning correctly, SSB
stuck on
ACTIVATE solenoid using scan tool.
REFER to Output State Control (OSC)
Mode . GO to Pinpoint Test A . INSTALL
a new solenoid as required. REFER to
Solenoids .

Overdrive Clutch Assembly Failed Off
Friction damaged, worn INSTALL new as required.
Return spring assembly damaged INSTALL new as required.
Direct Clutch Assembly Failed On
Return spring assembly damaged INSTALL new as required.
wiring harnesses, TCM , SSB
failed, SSA stuck on and TR
sensor
Diagnosis (PC/ED) manual for diagnosis. GO to
Pinpoint Test A and GO to Pinpoint Test D .

springs, clips loose, stuck,
missing, misassembled, clutch
failed off
Forward regulator and latch
valves, springs, clips loose,
stuck, missing, misassembled,
clutch failed on
SSB not functioning correctly,
SSA stuck on
ACTIVATE solenoid using scan tool. REFER to Output
State Control (OSC) Mode . GO to Pinpoint Test A .
INSTALL a new solenoid as required. REFER to
Solenoids .

Direct Clutch Assembly Failed Off
damaged
Forward Clutch Assembly Failed On
damaged
wiring harnesses, TCM , SSC
failed, SSB stuck on and TR
sensor

TCS / O/D Cancel Switch
Switch control circuit
open/shorted, switch damaged
Intermediate regulator and latch
clutch failed off
failed on
SSC not functioning correctly,
SSB stuck on
ACTIVATE solenoid using scan tool. REFER to
Output State Control (OSC) Mode . GO to Pinpoint
Test A . INSTALL a new solenoid as required. REFER
to Solenoids .

Intermediate Clutch Assembly Failed
Off
damaged
damaged
failed, SSC stuck on and TR
sensor

clutch failed on
failed off
SSC not functioning correctly,
SSB stuck on
to Solenoids .

Intermediate Clutch Assembly Failed
On
damaged
damaged
wiring harnesses, TCM , SSA
failed, SSB stuck on and TR
sensor

failed on
clutch failed off
SSA not functioning correctly,
SSB stuck on
Solenoids .

damaged
Forward Clutch Assembly Failed
Off
damaged
failed, SSD stuck on and TR
sensor

Overdrive regulator and latch
clutch failed on
failed off
SSB not functioning correctly,
SSD stuck on
to Solenoids .

Overdrive Clutch Assembly Failed
On
damaged

damaged
wiring harnesses, TCM , SSC
failed, SSB stuck on, TR sensor
for diagnosis. GO to Pinpoint Test A and GO to
Pinpoint Test D .

Incorrect Pressures
Line pressure CHECK pressure at line pressure tap. CARRY
OUT Line Pressure Test. REFER to Special
Testing Procedures . SEE the Line Pressure
Chart for specifications. If not OK, CHECK
main control. REFER to Main Control Valve
Body .

missing, misassembled, stuck on
stuck off
correctly
Output State Control (OSC) Mode . GO to
Pinpoint Test A . INSTALL a new solenoid as
required. REFER to Solenoids .

damaged
Intermediate Clutch Assembly Failed Off
damaged
TCM , SSC stuck on and TR
sensor
Diagnosis (PC/ED) manual for diagnosis. GO to Pinpoint
Test A and GO to Pinpoint Test D .

Incorrect Pressures
Pressure Test. REFER to Special Testing Procedures . SEE
the Line Pressure Chart for specifications. If not OK, CHECK
main control valve body.
Bolts out of torque
specification
misassembled, stuck on
SSC not functioning
correctly, stuck on

Failed On
damaged
Damaged not holding INSTALL new as required.
Planetary Carrier
Damaged INSTALL new as required.
Shift Concerns: Soft/Slipping 1-2 Shift (Automatic)
Solenoid Body
VERIFY solenoid body strategy data stored in the TCM .
DOWNLOAD new identification and strategy as necessary.

TCM REFER to Solenoid Body Strategy .
Incorrect Pressures

Bolts out of torque
specification
binding, misassembled
SSC not functioning
correctly
new solenoid as required. Refer to Solenoids .

Friction damaged,
worn
damaged
Pump Assembly
Component damaged INSTALL a new pump assembly if required.
Solenoid Body
TCM

Incorrect Pressures

Bolts out of torque
specification
loose, stuck, binding,
missing, misassembled
Multiplex valve, springs,
clips loose, stuck,
missing, binding
misassembled
correctly

Friction damaged,
worn
damaged

Friction damaged,
worn
damaged
Solenoid Body
DOWNLOAD new identification and strategy as

stuck, binding, missing,
misassembled
misassembled
SSD or SSB not functioning
correctly
Solenoids .

Overdrive Clutch Assembly
damaged
damaged
Solenoid Body

misassembled
misassembled
SSB or SSA not functioning
correctly
Solenoids .

damaged
damaged
Solenoid Body

misassembled
binding, missing, misassembled
SSC or SSB not functioning
correctly
Solenoids .

damaged
damaged
Solenoid Body

misassembled
correctly
Solenoids .

damaged
Return spring assembly INSTALL new as required.
damaged
Solenoid Body
VERIFY solenoid body strategy data stored in the TCM
. DOWNLOAD new identification and strategy as

failed on
clutch failed off
SSB stuck on
Solenoids .

damaged
damaged
Solenoid Body
TCM . DOWNLOAD new identification and strategy
as necessary. REFER to Solenoid Body Strategy .

misassembled
binding, missing, misassembled,
clutch failed off
SSB or SSD not functioning
correctly
Test A . INSTALL a new solenoid as required.
REFER to Solenoids .

damaged
damaged
Solenoid Body
TCM

Incorrect Pressures
the Line Pressure Chart for specifications. If not OK,
CHECK main control valve body.

Bolts out of torque
specification
loose, stuck, binding, missing,
misassembled
correctly
INSTALL a new solenoid as required. REFER to Solenoids
.

damaged
damaged
Solenoid Body
TCM

Incorrect Pressures

Bolts out of torque
specification
SSC not functioning
correctly

Friction damaged,
worn
damaged
Planetary Carrier
Damaged INSTALL new as required.
Shift Concerns: Harsh 1-2 Shift (Automatic)
Solenoid Body
TCM

Incorrect Pressures

Bolts out of torque
specification
binding, misassembled
SSC not functioning
correctly

Friction damaged,
worn
damaged
Pump Assembly
Component damaged INSTALL a new pump assembly if required.
Solenoid Body
TCM

Incorrect Pressures

Bolts out of torque
specification
misassembled
Multiplex valve, springs, clips
binding misassembled
correctly
.

damaged
damaged
Solenoid Body

misassembled
misassembled
SSD or SSB not functioning
correctly
Solenoids .

damaged
damaged
Solenoid Body

misassembled
Forward regulator and latch REPAIR or INSTALL new as required.
misassembled
SSB or SSA not functioning
correctly
Solenoids .

damaged
damaged
Solenoid Body

misassembled
correctly
Solenoids .

damaged
damaged
Solenoid Body

misassembled
correctly
Solenoids .

damaged
damaged
Solenoid Body
VERIFY solenoid body strategy data stored in the TCM
. DOWNLOAD new identification and strategy as

failed on
clutch failed off
SSB stuck on
Solenoids .

damaged
damaged
Solenoid Body
TCM . DOWNLOAD new identification and strategy
as necessary. REFER to Solenoid Body Strategy .

misassembled
binding, missing, misassembled,
clutch failed off
SSB or SSD not functioning
correctly
Test A . INSTALL a new solenoid as required.
REFER to Solenoids .

damaged
damaged
Solenoid Body
TCM

Incorrect Pressures

Bolts out of torque
specification
misassembled
correctly
.

damaged
damaged
Solenoid Body
TCM

Incorrect Pressures

Bolts out of torque
specification
SSC not functioning
correctly

Friction damaged,
worn
damaged
Torque Converter Operation Concerns: No Apply
wiring harnesses, TCM , TCC
solenoid, TP sensor, TFT
sensor, TSS sensor, OSS sensor
and shorted shift solenoid
CARRY OUT Torque Converter Operation Test. REFER
to Torque Converter Diagnosis . RUN OBD . REFER to
for diagnosis. GO to Pinpoint Test A , GO to Pinpoint
Test B and GO to Pinpoint Test C .

Incorrect Pressures
Pressure Test. REFER to Special Testing Procedures .
SEE the Line Pressure Chart for specifications. If not OK,

TCC control valve, springs,
clips loose, stuck, missing,
misassembled
TCC solenoid not
functioning correctly
Solenoids .

Turbine Shaft
Seals damaged, missing INSTALL new as required.
Holes missing, plugged REPAIR as required.
Pump Assembly
Seals damaged, missing INSTALL new as required.
Holes missing, plugged REPAIR as required.
Torque converter hub bushing
worn
INSTALL a new torque converter as required.
Torque converter worn INSTALL a new torque converter as required.
Torque Converter Operation Concern: Always Applied/Stalls Vehicle
Electrical
inputs/outputs,
vehicle wiring
harnesses, TCM ,
TCC Solenoid
CARRY OUT Torque Converter Operation Test. REFER to Torque
Converter Diagnosis . RUN OBD . REFER to Powertrain
Control/Emissions Diagnosis (PC/ED) manual for diagnosis. GO to
Pinpoint Test A . REPAIR as required. CLEAR the DTCs. ROAD
TEST and RERUN OBD .

Main Controls
Bolts out of torque
specification
plate damaged,
off location
REPAIR as required.
TCC regulator valve,
springs, clips
missing,
misassembled
TCC solenoid
not functioning
correctly
Control (OSC) Mode . GO to Pinpoint Test A . INSTALL a new
solenoid as required. REFER to Solenoids .

Torque Converter Operation Concern: Cycling/Shudder/Chatter
Powertrain Control
System
Electrical
inputs/outputs,
vehicle wiring
harnesses, TCM
and TCC solenoid
CARRY OUT Torque Converter Operation Test. REFER to Torque
Converter Diagnosis . RUN OBD . REFER to Powertrain
Control/Emissions Diagnosis (PC/ED) manual for diagnosis. GO to
Pinpoint Test A . REPAIR as required. CLEAR the DTCs. ROAD
TEST and RERUN OBD .

Solenoid Body
Incorrect solenoid
body strategy data
stored in the TCM
VERIFY solenoid body strategy data stored in the TCM . DOWNLOAD
new identification and strategy as necessary. REFER to Solenoid Body
Strategy .

Transmission
fluid condition
Prior to carrying out this action, make sure all electrical diagnostics
have been carried out. INSPECT transmission fluid condition. If burnt,
drain transmission fluid and converter. INSTALL new transmission
fluid and transmission fluid filter assembly. Bring vehicle to normal
operating temperature. CARRY OUT Transmission Drive Cycle Test.
RERUN OBD . If condition still exists, continue diagnostics.

Incorrect Pressures
Line pressure CHECK pressure at line pressure tap. CARRY OUT Line Pressure Test.
REFER to Special Testing Procedures . SEE the Line Pressure Chart for

specifications. If not OK, CHECK Main Control. REFER to Main
Control Valve Body .
Main Controls
Bolts out of
torque
specification
Gaskets and
separator plate
damaged, off
location
REPAIR as required.
TCC regulator
valve, springs,
clips loose,
stuck, binding,
missing,
misassembled
TCC solenoid
not
functioning
correctly
ACTIVATE solenoid using scan tool. REFER to Output State Control
(OSC) Mode . GO to Pinpoint Test A . INSTALL a new solenoid as
required. REFER to Solenoids .

Turbine Shaft
Seals
damaged, missing
Torque Converter
Torque converter
damaged
REFER to Torque Converter Contamination Inspection .
Pump Assembly
Stator support
assembly
worn, damaged
Stator support
seals worn,
damaged, leaking
Other Concerns: No Engine Braking In Manual Low Position
No electrical concerns
Bolts out of torque
specification
Low/reverse regulator valve,
binding, missing,
misassembled
Low/reverse latch valve,
binding, missing,
misassembled
SSD not functioning correctly ACTIVATE solenoid using scan tool. REFER to Output
Solenoids .

damaged
Other Concerns: Selector Lever Efforts High
Selector Lever Linkage (Internal, External)
Damaged or out of adjustment INSPECT for damage.
VERIFY selector lever

adjustment. REFER to
Section 307-05A .
Manual Control Lever
External retaining pin damaged, nut loose, detent
spring bent, damaged; or park mechanism damaged,
incorrect lever used
REPAIR or INSTALL
new as required.

Manual valve stuck REPAIR or INSTALL
new as required.

Bolts out of torque specification TIGHTEN bolts to
specification.

Brake Shift Interlock
Mechanically damaged REFER to Section
307-05A .

TR sensor indicating park GO to Pinpoint Test D .
Other Concerns: External Leaks
High transmission fluid level CHECK transmission fluid level and
adjust as necessary. REFER to

Condition CARRY OUT transmission fluid
condition check. REFER to

Seals, Gaskets
Leaks: converter, TSS sensor, halfshaft axles,
gasket/seal manual lever, fluid level indicator,
main control cover, incorrect hub seal
LOCATE source of leak. REPAIR as
required.

Other
Leaks: cooler fitting, pressure taps, transmission
connector, transmission pan, cooler tubes, case
porosity, case cracked
LOCATE source of leak. REPAIR as
required.

Vent blocked damaged REPAIR as required.
Other Concerns: Poor Vehicle Performance
wiring harnesses, TCM , TCC
Solenoid, TP sensor, OSS sensor,
MAF sensor, IAT sensors, internal
wiring harness
diagnosis. GO to Pinpoint Test C . REPAIR as
required. CLEAR the DTCs. ROAD TEST and
RERUN OBD .

CARRY OUT Shift Point Road Test. REFER to
Shift Point Road Test and CARRY OUT Torque
Converter Operation Test. REFER to Torque
Converter Diagnosis .

Transmission Fluid
Low level CHECK transmission fluid level and adjust as

Verify Correct Shift Scheduling,
Engagements, Line Pressures and Stall
Speed
GO to appropriate Diagnostic Routines per index.
Converter Clutch Always Applied
GO to Routine 351.
Other Concerns: Noise/Vibration Forward Or Reverse
For Noises/Vibrations That Change With Engine Speed
Converter components LOCATE source of disturbance.
REPAIR as required.

Transmission fluid level (low)
pump cavitation.

Pump assembly.
Engine drive accessories
Transmission fluid cooler tubes grounding out
Flexplate
For Noises/Vibrations That Change With Vehicle Speed
Engine mounts loose or damaged LOCATE source of disturbance.
REPAIR as required.

Driveline concerns:
Halfshaft shudder
CV joints
Suspension
Modifications
Output/halfshaft splines worn or
damaged

TSS sensor incorrectly installed REPAIR as required.
Other Noises/Vibrations
Main controls valve resonance LOCATE source of disturbance.
REPAIR as required.

Selector lever cable vibration, grounding LOCATE source of disturbance.
REPAIR as required.

Transmission fluid cooler tubes
grounding
LOCATE source of disturbance.
REPAIR as required.

ABS REFER to Section 206-09 .
Power steering pump REFER to Section 211-02 .
Other Concerns: Engine Will Not Crank
Electrical
inputs/outputs, vehicle
wiring harnesses, TCM ,
TR sensor
CARRY OUT Torque Converter Operation Test. REFER to
Torque Converter Diagnosis . RUN OBD . REFER to the
Powertrain Control/Emissions Diagnosis (PC/ED) manual for
diagnosis.

(Internal, External)
Damaged or out of
adjustment
INSPECT for damage. VERIFY selector lever cable adjustment.

Other Concerns: No Park Range
Damaged or out of adjustment INSPECT for damage.
VERIFY selector lever
cable adjustment.
REFER to Section
307-05A .

Park Mechanism
Park brake pawl, park pawl return spring, park rod abutment,
park pawl shaft, park pawl actuating rod, manual control
lever, manual lever detent spring damaged
REPAIR as required.
Other Concerns: Transmission Overheating
No electrical
concerns

Transmission Fluid
Incorrect
transmission
fluid level
CHECK transmission fluid level. ADJUST as necessary. REFER to

Condition CARRY OUT transmission fluid condition check. REFER to Preliminary
Inspection .

Transmission Fluid
Cooler Tubes
Damaged,
blocked,
reversed, leaking
REPAIR as required.
Auxiliary Cooler
Damaged,
blocked,
restricted or
incorrectly
installed
REPAIR as required.
Vehicle Concerns
Causing Engine
Overheating
Main Control Valve
Body
Torque converter
regulator
valve/spring
stuck, damaged
REPAIR as required.
Torque converter
control
valve/spring
stuck, damaged
REPAIR as required.
Torque Converter Not
Applying
Seized converter
one-way clutch
SEE Routine 250/350. INSPECT for damage. REPAIR as required.
Excessive Towing Loads
CHECK GVW .
Idle or Driveability
Concern
REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Incorrect Clutch
Application or Oil
Pressure Control System
CARRY OUT line pressure tests. REFER to Special Testing Procedures
and carry out shift point road test. REFER to Shift Point Road Test .
REPAIR as required. SEE the Line Pressure Chart, and Clutch
Application Chart for specifications. REPAIR as required.

Workshop Manual
Transmission Fluid Cooler Backflushing and Cleaning
Special Tool(s)
Turbo-Tank Heated Cooler Line Flusher
Material
Item Specification
XT-10-QLVC
MERCON
LV
1 - Transmission fluid pressure tube (outlet)
2 - Transmission fluid return tube (inlet)
NOTE: Transmission fluid cooler backflushing will be carried out using the Turbo-Tank Heated Cooler Line
Flusher or equivalent. Follow the manufacturer's instructions included with the machine. Test the equipment
to make sure that a vigorous fluid flow is present before proceeding.
Check and top off fluid level of the Turbo-Tank Heated Cooler Line Flusher or equivalent tank with
transmission fluid.
1.
Allow the fluid in the Turbo-Tank Heated Cooler Line Flusher or equivalent 15-30 minutes to heat up
to 60C (140F) before using.
2.
Transmission Fluid Cooler Backflushing and Cleaning 3820
Install the line adapters into the transmission cooler lines. 3.
NOTE: The TOP transaxle cooler tube on the transaxle is the pressure line.
Attach the Turbo-Tank Heated Cooler Line Flusher or equivalent red line to the transmission fluid
cooler pressure line quick disconnect fitting.
4.
Attach the Turbo-Tank Heated Cooler Line Flusher or equivalent blue line to the transmission fluid
cooler return line quick disconnect fitting.
5.
Follow the equipment instructions to purge the cooler lines and cooler prior to starting the flushing
procedure.
6.
Allow the cooling system to backflush for 10-15 minutes, then flush the cooler in a normal flow
direction for an additional 10-15 minutes.
7.
Clean the transaxle mounted fluid cooler tubes by hand. 8.
Transmission Fluid Cooler Backflushing and Cleaning 3821
Workshop Manual
Material
Item Specification
XT-10-QLVC
MERCON
LV
NOTE: In order to completely clean the torque converter, this procedure needs to be carried out 3 times.
100-02 .
1.
NOTE: If an internal problem is suspected, drain the transmission 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 ent, the transaxle will need to be overhauled.
Remove the transmission fluid drain plug and allow the transmission fluid to drain.
2.
3.
Start the engine and let it run for 3 minutes. Move the range selector lever into each gear position.
Repeat Steps 2, 3, 4 and 5 two more times.
5.
After the transmission fluid has been changed a total of 3 times, using the scan tool with the engine
running, check and make sure that the transmission is at normal operating temperature 85-93C
(185-200F). Check and adjust the transmission fluid level and check for any leaks. If transmission
fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is
achieved.
6.
P>
Workshop Manual
Transmission Fluid Exchange
Special Tool(s)
ATF Fluid Exchanger W/Power Steering
Fluid Exchanger
Material
Item Specification
XT-10-QLVC
MERCON
LV
NOTICE: Use transmission fluid specific for this transmission. Do not use any supplemental
transmission fluid additives or cleaning agents. The use of these products can cause internal
transmission components to fail, which will affect the operation of the transmission.
100-02 .
1.
Use the ATF Fluid Exchanger W/Power Steering Fluid Exchanger to change the fluid. 2.
Connect the ATF Fluid Exchanger W/Power Steering Fluid Exchanger to the transmission fluid
cooler tube after the transmission fluid cooler on the return tube. This will help remove any foreign
material trapped in the transmission fluid coolers.
3.
Perform the transmission fluid exchange using the ATF Fluid Exchanger W/Power Steering Fluid
Exchanger. Follow the manufacturer's instructions included with the machine.
4.
Once the transmission fluid exchange is completed, disconnect the ATF Fluid Exchanger W/Power
Steering Fluid Exchanger. Reconnect any disconnected transmission fluid cooler tubes.
5.
for any leaks. If transmission fluid ised, add transmission fluid in increments of 0.24L (0.5 pt) until
the correct level is achieved.
6.
Workshop Manual
Torque Converter Contamination Inspection
Material
Item Specification
XT-10-QLVC
MERCON
LV
A new or remanufactured torque converter must be installed if one or more of the following
statements is true:
A torque converter malfunction has been determined based on complete diagnostic
procedures.

The torque converter stud or studs, impeller hub or bushing are damaged.
The torque converter exhibits external discoloration (due to overheating).
There is evidence of transmission assembly or fluid contamination due to the following
transmission or converter failure modes.
Major metallic failure
Multiple clutch plates or band failures
ficient component wear which results in metallic contamination

Water or antifreeze contamination
1.
If none of the above conditions are present, continue with the following fluid inspection. 2.
Pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or
through a paper filter.
3.
Examine the fluid for contaminants. The fluid must be free of metallic contaminants. 4.
NOTICE: Do not use water-based cleaners or mineral spirits to clean or flush the torque
converter or transmission damage will occur.
If the fluid passed inspection:
drain the remaining fluid from the torque converter.
using only the recommended transmission fluid, add 1.9L (2 qt) of clean fluid into the
converter and agitate by hand.

thoroughly drain the fluid.
5.
Workshop Manual
Transaxle Filler Tube
2 - Transaxle vent tube (part of 7A228)
3 13A506 Wiring harness retainer
4 N805320 Transaxle filler tube nut
6 - Transaxle filler tube O-ring
Removal
All vehicles
Remove the transaxle vent hose from the transaxle filler tui> 1.
Disconnect the wiring harness retainer from the transmission fluid filler tube. 2.
Transaxle Filler Tube 3828
All vehicles
Remove the transaxle filler tube nut.
3.
Pull and rotate the transaxle filler tube clockwise and remove the transaxle filler tube. 4.
Installation
Inspect the O-ring seal on the transaxle filler tube for damage and install a new O-ring if needed.
Lubricate the O-ring seal with clean automatic transmission fluid.
1.
Workshop Manual
Main Control Cover
Material
Item Specification
XT-10-QLVC
MERCON
LV
TA-29
-
1 14A464 Transaxle main harness electrical connector
2 9S318 Wiring harness retainer
4 N805320 Transmission fluid cooler tube nut
5 7H420 Transmission fluid cooler tube bracket
6 W500213 Main control cover bolt
7 W705619 Main control cover studbolt
100-02 .
1.
Main Control Cover 3831
Remove the Air Cleaner (ACL) assembly. For additional information, refer to Section 303-12A or
Section 303-12B .
3.
5.
Disconnect the transaxle electrical connector. 6.
Remove the transaxle electrical wiring harness retainers from the main control cover stud bolts. 7.
Remove the 2 nuts, pull the transmission fluid cooler tube bracket and tubes away from the transaxle
and position it aside.
8.
NOTE: Note the location of the stud bolts for assembly.
Remove the 8 bolts, 5 stud bolts and the main control cover.
9.
Installation
Clean the main control cover sealing surface and inspect for damage. 1.
Apply silicone to the main control sealing surface of the transaxle case. 2.
Position the main control cover in place. 3.
NOTICE: Inspect the main control-to-main control cover grommet to make sure that the seals is
on the inside of the main control cover. Transmission fluid leak will occur.
NOTE: Install the stud bolts in the locations noted during disassembly.
Tighten the 8 main control cover bolts and 5 stud bolts.
4.
Position the transmission fluid cooler tube bracket and transmission fluid cooler tube assembly in
place and install the 2 nuts.
5.
Connect the transaxle electrical wiring harness retainers to the main control cover stud bolts. 6.
Connect the transaxle electrical connector. 7.
Install the ACL assembly. For additional information, refer to Section 303-12A or Section 303-12B . 9.
Start the engine and move the range selector lever into each gear position. 11.
12.
Workshop Manual
Manual Control Lever Shaft Seal
Special Tool(s)
Manual Lever Seal Installer
307-581
Material
Item Specification
XT-10-QLVC
MERCON
LV
TA-29
-
1 7E395 Selector lever cable
2 W708455 Manual control lever nut
7 N805320 Transmission fluid cooler tube nuts
Manual Control Lever Shaft Seal 3837
9 W500213 Main control cover bolts
10 W705619 Main control cover studbolts
12 7G276 Transmission Range (TR) electrical connector
13 W711235 Manual valve detent spring bolt
14 7E332 Manual valve detent spring
15 7G100 Manual control shaft pin
16 7C493 Manual control shaft
Removal
100-02 .
1.
Section 303-12B .
2.
5.
Disconnect the selector lever cable end from the manual control lever. 6.
Remove the nut and the manual control lever. 7.
10.
NOTE: Note the location of the stud bolts for assembly. 11.
Disconnect the Transmission Range (TR) sensor electrical connector. 12.
Remove the bolt and the TR sensor detent spring. 13.
Using a small pair of Vise Grips or an equivalent suitable tool, remove and discard the TR sensor
locking pin.
14.
Slide the manual shaft out of the transaxle case. 15.
Using a suitable tool, remove the manual control lever shaft seal. 16.
Installation
Using the Manual Lever Seal Installer, install a new manual control lever shaft seal. 1.
Install the manual control lever shaft in the transaxle case and through the TR sensor. 2.
Inspect the manual pin to make sure it is correctly installed in the manual valve. If it is not, pull the
manual control lever shaft out and correctly install the manual pin in the manual valve and position
the manual control lever shaft in place.
3.
Using a suitable tool, install a new TR sensor roll pin. 4.
Install the TR sensor detent spring and the bolt.
5.
Connect the TR sensor electrical connector. 6.
Clean the main control cover sealing surface. 7.
NOTICE: Inspect the main control-to-main control cover grommet to make sure that the seal is
10.
11.
NOTICE: Make sure that when installing the manual control lever it is fully seated onto the
manual control lever shaft or damage to the manual control lever shaft will occur and the lever
will come loose.
NOTICE: Make sure to hold the manual control lever while tightening the manual control lever
nut or damage to the manual control lever and park components will occur.
Install the manual control lever and the nut.
15.
Connect the selector lever cable end to the manual control lever with the manual control lever and
selector lever in DRIVE. Check selector lever cable adjustment. For additional information, refer to
Section 307-05A
16.
20.
Workshop Manual
Digital Transmission Range (TR) Sensor
Material
Item Specification
XT-10-QLVC
MERCON
LV
TA-29
-
Item
Part
Number Description
2 W708455 Manual control lever
nut
3 7A256 Manual control lever 4 14A464 Transaxle main
harness electrical
connector
7 N805320 Transmission fluid
cooler tube nuts
8 7H420 Transmission fluid
cooler tube bracket
Digital Transmission Range (TR) Sensor 3846
9 W500213 Main control cover
bolts
10 W705619 Main control cover
studbolts
12 7G276 Transmission Range
(TR) electrical
connector
13 W711235 Manual valve detent
spring bolt
14 7E332 Manual valve detent
spring
15 7G100 Manual control shaft
pin
17 7H155 TR sensor
Removal
100-02 .
1.
Section 303-12B .
2.
5.
Remove the nut and the manual control lever. 7.
Remove the transmission fluid cooler tube bracket nuts from the main control cover studs and
position the transmission fluid cooler tubes and bracket aside.
10.
11.
Using a small pair of Vise Grips or an equivalent suitable tool, remove and discard the TR sensor
locking pin.
14.
Remove the TR sensor in the following sequence.
Hold the TR sensor in place and slide the manual shaft outward until the manual shaft is out
of the transaxle case.
1.
Remove the TR sensor from the transaxle, leaving the park pawl actuating rod attached to the
TR sensor.
2.
15.
Installation
Install the TR sensor.
Install the TR sensor and park pawl actuating rod in the transaxle case. 1.
Install the manual shaft in the transaxle case through the TR sensor. 2.
1.
Inspect the manual pin to make sure it is correctly installed in the manual valve. If it is not, pull the
manual control lever shaft out and correctly install the manual pin in the manual valve and position
the manual control lever shaft in place.
2.
Using a suitable tool, install a new TR sensor locking pin. 3.
Install the TR sensor detent spring and the bolt.
4.
NOTICE: Inspect the main control cover grommet to make sure that the seal is on the inside of
the main control cover. Transmission fluid leak will occur.
Install the main control cover 8 bolts and 5 stud bolts.
9.
Position the transmission fluid cooler tube bracket and transmission fluid cooler tubes in place and
install the 2 nuts.
10.
NOTICE: Make sure that when installing the manual control lever it is fully seated onto the
manual control lever shaft or damage to the manual control lever shaft will occur and the lever
will come loose.
14.
Section 307-05A .
15.
19.
Workshop Manual
Solenoid Body Leadframe
Special Tool(s)
Pins, Leadframe Guide
307-636
Material
Item Specification
XT-10-QLVC
MERCON
LV
TA-29
-
Solenoid Body Leadframe 3855
10 W505513 Main control leadframe screw (5 required)
11 7G276 Main control leadframe
Removal
100-02 .
1.
Section 303-12B .
2.
5.
8.
9.
Disconnect the Output Shaft Speed (OSS) sensor electrical connector. 11.
Remove the main control cover grommet. 12.
NOTICE: Be careful not to bend or twist the leadframe or the solenoid terminals when
removing the leadframe or damage can occur to the leadframe or the solenoids.
Remove the 5 screws and the leadframe from the solenoids by lifting it straight up evenly.
13.
Installation
Install the Leadframe Guide Pins in the solenoid body to align the lead frame for installation. 1.
Position the leadframe on the Leadframe Guide Pins and carefully install the leadframe by pushing
straight down into the solenoids.
2.
Remove the Leadframe Guide Pins. 3.
Install the 5 leadframe screws. 4.
Connect the OSS sensor electrical connector. 5.
Install the main control cover grommet. 7.
the main control cover. Transmission fluid leak will occur.
11.
12.
19.
Workshop Manual
Solenoids
Special Tool(s)
307-636
Material
Item Specification
XT-10-QLVC
MERCON
LV
TA-29
-
Solenoids 3863
11 7G276 Main control leadframe
12 7H111 Solenoid retaining pin (14 required)
13 7G136 Shift Solenoid A (SSA) (normally low)
14 7G383 Shift Solenoid B (SSB) (normally high)
15 7G136 Shift Solenoid C (SSC) (normally low)
16 7G383 Shift Solenoid D (SSD) (normally high)
17 7G484 Shift Solenoid E (SSE) (normally closed [OFF])
18 7G136 Torque Converter Clutch (TCC) solenoid (normally
low)
19 7G383 Line Pressure Control (LPC) solenoid (normally high)
Removal
100-02 .
1.
Section 303-12B .
3.
5.
Solenoids 3864
8.
9.
Solenoids 3865
NOTICE: Be careful not to bend or twist the leadframe or the solenoid terminals when
removing the leadframe or damage can occur to the leadframe or the solenoids.
Remove the 5 screws and the leadframe from the solenoids by lifting it straight up evenly.
13.
Using a paint pen, number the solenoids and solenoid body to clearly mark which solenoid was
removed from which bore in the solenoid body.
14.
Solenoids 3866
Remove the solenoid retaining pin(s). 15.
Remove the solenoid(s) from the solenoid body. 16.
Installation
Inspect the solenoid(s) for damage. 1.
If a new solenoid is not being installed, install the solenoid(s) into the bore from which it was
removed.
2.
If installing a new Variable Force Solenoid (VFS), determine the base part number of the solenoid(s).
The Torque Converter Clutch (TCC) solenoid, Shift Solenoid A (SSA) and Shift Solenoid C (SSC)
are all normally low pressure solenoids. The Line Pressure Control (LPC) solenoid, Shift Solenoid B
(SSB) and Shift Solenoid D (SSD) are all normally high pressure solenoids. Shift Solenoid E (SSE) is
not a VFS , it is an ON/OFF solenoid.
3.
Solenoids 3867
1 7G136 SSA (normally low)
2 7G383 SSB (normally high)
3 7G136 SSC (normally low)
4 7G383 SSD (normally high)
5 7G484 SSE (normally closed [OFF])
6 7G136 TCC solenoid (normally low)
7 7G383 LPC solenoid (normally high)
If installing a new LPC solenoid, SSB or SSD , note the color of the electrical terminal area of the
solenoid. The color will be blue or green and the solenoid can only be replaced with the same color
solenoid. If a new solenoid with that color is not available, install a new solenoid body, refer to
Solenoid Body Assembly in this section.
4.
Determine the part number suffix by checking the solenoid service band number etched on the side of
the solenoid. The band number is the third digit on the side of the solenoid and will be a 1, 2, 3, 4 or
5. Use the following table to determine the part number suffix and match the new solenoid base part
number and suffix with the old solenoid. Install the solenoid in the solenoid body.
Solenoid Band Number Part Number Suffix
1 B
2 C
3 D
4 E
5 F
5.
Install the solenoid retaining pin(s). 6.
Install the Leadframe Guide Pins in the solenoid body to align the lead frame for installation. 7.
Solenoids 3868
Position the leadframe on the Leadframe Guide Pins and carefully install the leadframe by pushing
straight down into the solenoids.
8.
Remove the Leadframe Guide Pins. 9.
Solenoids 3869
the main control cover, or a transmission fluid leak will occur.
17.
Solenoids 3870
18.
Solenoids 3871
25.
Solenoids 3872
Workshop Manual
Material
Item Specification
XT-10-QLVC
MERCON
LV
TA-29
-
10 W302863 Main control-to-transaxle case bolt (long) (10 required)
11 W302862 Main control-to-transaxle case bolt (short) (12
required)
12 W520412 Main control nut
13 W500303 Solenoid body-to-valve body bolt (2 required)
15 7A100 Valve body assembly
Removal
100-02 .
1.
Section 303-12B .
2.
5.
8.
9.
Remove the main control-to-main control cover grommet. 12.
NOTICE: The main control should be handled with care or damage to the main control may
occur.
NOTE: Note the location of the different length bolts for assembly.
Remove the nut, 22 bolts and the main control.
13.
Remove and discard the main control-to-transaxle case separator plate. 14.
Remove the 2 bolts and separate the solenoid body assembly from the main control valve body. 15.
Remove the 2 bolts and remove and discard the separator plate. 16.
Installation
Install the new separator plate and the 2 separator bolts.
1.
NOTE: If cleaning the main control assembly or inspecting the valves, refer to Main Control Valve
Body in this section. If installing a new main control assembly, continue with this procedure.
Install the solenoid body assembly onto the main control valve body. Install the 2 bolts.
2.
Position the OSS and TR sensor wiring harnesses aside and install the new main control-to-transaxle
case separator plate.
3.
NOTE: Make sure that the manual lever pin (part of the TR sensor) is correctly installed in the
manual valve.
Install the main control.
4.
NOTICE: Make sure not to pinch the Output Shaft Speed (OSS) or Transmission Range (TR)
sensor wiring harnesses when installing the main control.
NOTE: Install the different length bolts in the locations noted during disassembly.
Install the main control stud nut and 22 main control valve body bolts. Tighten in a crisscross pattern.
5.
Install the main control-to-main control cover grommet. 8.
12.
13.
Connect the transaxle electrical wiring harness retainers to the main control cover studbolts. 14.
20.
If a new solenoid body is installed, the solenoid body strategy and solenoid body
identification will need to be updated. For additional information, refer to Solenoid Body
Strategy in this section
21.
If a replacement transaxle assembly is being installed or a new solenoid body is installed, the
PCM will have to be reflashed with a new solenoid body strategy and identification data file.
For additional information, refer to Solenoid Body Strategy in this section.
22.
Workshop Manual
Material
Item Specification
XT-10-QLVC
MERCON
LV
TA-29
-
3 14A163 Wiring harness retatd>
required)
Output Shaft Speed (OSS) Sensor 3883
13 7A100 Main control assembly
15 W713644 Output Shaft Speed (OSS) sensor bolt
16 7H103 OSS sensor
Removal
100-02 .
1.
Section 303-12B .
2.
5.
8.
9.
Remove the main control-to-main control cover grommet. 12.
occur.
13.
Remove the main control-to-transaxle separator plate. 14.
Remove the bolt and the OSS sensor. 15.
Installation
Install the OSS sensor and the bolt.
1.
Position the OSS and TR sensor wiring harnesses aside and install the main control-to-transaxle
separator plate.
2.
manual valve.
3.
4.
Route the OSS sensor wiring harness and connect the electrical connector. 5.
Install the main control-to-main control cover grommet. 7.
on the inside of the main control cover or a transmission fluid leak will occur.
Install the 8 main control cover bolts and 5 stud bolts.
11.
12.
Connect the transaxle electrical wiring harness retainers to the main control cover studbolts. 13.
19.
Workshop Manual
Solenoid Body Assembly
Special Tool(s)
Material
Item Specification
XT-10-QLVC
MERCON
LV
TA-29
-
Solenoid Body Assembly 3892
required)
15 7A100 Valve body assembly
100-02 .
1.
Section 303-12B .
2.
5.
Disconnect the transaxle electrical wiring harness retainers from the main control cover stud bolts. 7.
8.
9.
occur.
13.
Remove the 2 bolts and separate the solenoid body from the main control valve body. 15.
Installation
1.
NOTE: If cleaning the solenoid body assembly or inspecting the valves, refer to Solenoid Body
Assembly in this section. If installing a new solenoid body assembly, continue with this procedure.
Install the solenoid body onto the main control valve body. Install the 2 bolts.
2.
Position the OSS and TR sensor wiring harnesses aside and install the new main control-to-transaxle
case separator plate.
3.
manual valve.
4.
5.
Route the OSS sensor wiring harness and connect the electrical connector. 6.
on the inside of the main control cover or a transmission fluid leak will occur.
12.
13.
20.
Download a new solenoid body strategy to the PCM. For additional information, refer to Solenoid
Body Strategy in this section.
21.
Using the scan tool, select Module Programming and Programmable Parameters under the tool box
icon and select Transmission. Follow the instructions displayed on the scan tool.
There are fields to enter the solenoid body 7-digit identification and 13-digit strategy recorded from
the solenoid body.
22.
NOTICE: If the solenoid body information is not correct, transaxle damage or driveability
concerns can occur.
Enter the solenoid body identification and strategy.
The scan tool will verify that the numbers entered are valid and display a message if the information
is not valid.
The scan tool checks to see if the file is present on the scan tool. If the file is present, the technician
may proceed with downloading the file to the PCM. If the file is not present, the scan tool will need to
be connected to the Professional Technician Society (PTS) server to download the file ontohe scan
tool.
23.
Verify that the file is present on the scan tool. If the file is present, go to Step 25. If the file is not
present, continue with this procedure.
24.
Connect the scan tool to the PTS server.
The screen will display a progress bar when connecting to the network.
25.
Follow the instructions on the network to download the strategy file to the scan tool.
The screen will display a progress bar when downloading the strategy file to the scan tool and display
a message if it is downloaded successfully.
26.
If the scan tool cannot connect to the PTS server, download the file from www.motorcraft.com.
If the scan tool cannot download a strategy from the web site, a partial strategy will automatically be
downloaded.
27.
Reconnect the scan tool to the vehicle. 28.
Follow the instructions displayed on the scan tool. 29.
If a new solenoid body was installed, compare the 7-digit identification and the 13-digit strategy fields
from the solenoid body to the replacement solenoid body tag provided with the solenoid body service
kit and place it over the existing identification tag.
The scan tool will automatically download the strategy file or partial strategy file to the PCM and will
display a progress bar while downloading. The scan tool will display a message when it is finished
downloading the data that states that the file was downloaded successfully.
30.
Workshop Manual
Material
Item Specification
XT-10-QLVC
MERCON
LV
1 14A464 Turbine Shaft Speed (TSS) sensor electrical
connector
2 W500214 TSS sensor bolt
7M101 TSS sensor
Removal
100-02 .
1.
Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector. 3.
Remove the bolt and the TSS sensor. 4.
Installation
Install the TSS sensor and the bolt.
1.
Connect the TSS sensor electrical connector. 2.
Install the LH front structure-to-subframe splash shield and the 6 pin-type retainers. 3.
6.
Workshop Manual
Halfshaft Seal - RH, All Wheel Drive (AWD)
Special Tool(s)
Installer, Halfshaft Oil Seal
308-431
307-428
Material
Item
XT-10-QLVC
MERCON
LV
1 1177 Seal assembly - halfshaft
2 7000 Transaxle
Removal
100-02 .
1.
Using a suitable awl, poke a small hole in the RH transaxle differential seal. 3.
Halfshaft Seal - RH, All Wheel Drive (AWD) 3906
Using a suitable dent puller, remove the halfshaft seal. 4.
Installation
Install a new halfshaft seal on the Halfshaft Oil Seal Installer. 1.
Using the RH Halfshaft Oil Seal Installers, install the RH halfshaft seal onto the transaxle case. 2.
Install the PTU . For additional information, refer to Section 308-07B . 3.
6.
Workshop Manual
Halfshaft Seal - RH, Front Wheel Drive (FWD)
Special Tool(s)
Handle
205-153 (T80T-4000-W)
Installer, Seal
307-626
Material
Item Specification
Automatic Transmid
XT-10-QLVC
MERCON
LV
1 1177 Seal assembly - halfshaft
2 3K183 Intermediate shaft
Removal
100-02 .
1.
Remove the front RH halfshaft. For additional information, refer to Section 205-04 . 2.
Using a suitable awl, poke a small hole in the halfshaft seal. 3.
Halfshaft Seal - RH, Front Wheel Drive (FWD) 3909
Installation
Install a new halfshaft seal on the Seal Installer and Handle. 1.
Using the Seal Installer and Handle, install the RH halfshaft seal. 2.
Install the front RH halfshaft. For additional information, refer to Section 205-04 . 3.
6.
Workshop Manual
Halfshaft Seal - LH
Special Tool(s)
Handle
205-153 (T80T-4000-W)
Installer, Differential Seal
307-626
Material
Item Specification
XT-10-QLVC
MERCON
LV
1 3A428 LH halfshaft
Removal
100-02 .
1.
Remove the front LH halfshaft. For additional information, refer to Section 205-04 . 2.
Using a suitable awl, poke a small hole in the halfshaft seal. 3.
Halfshaft Seal - LH 3912
Installation
Inspect the bushing surface on the LH halfshaft and the LH halfshaft bushing in the transaxle case for
damage or excessive wear. If the LH halfshaft or the LH halfshaft bushing shows signs of excessive
wear or damage, inspect the transaxle case for damage. Install a new LH halfshaft. Install a new LH
halfshaft bushing. For additional information, refer to Transaxle case bushing in this section.
If the LH halfshaft or the LH halfshaft bushing shows signs of excessive wear or damage but
the transaxle case does not, install a new LH halfshaft. Install a new LH halfshaft bushing.
For additional information, refer to Transaxle case bushing in this section.

If the transaxle case is damaged, install a new LH halfshaft. Install a new transaxle case. For
additional information, refer to Transaxle - 2.5L or Transaxle - 3.0L and Transaxle in this
section.

If the bushing is not damaged or worn excessively, clean the area behind the seal and install a
new seal following this procedure.

1.
Install a new halfshaft seal on the Differential Seal Installer and Handle. 2.
Using the Differential Seal Installer and Handle, install the LH halfshaft seal. 3.
Install the front LH halfshaft. For additional information, refer to Section 205-04 . 4.
6.
Workshop Manual
Transaxle Support Insulator - 3.0L
Special Tool(s)
303-050 (T70P-6000)
Support Bar, Engine
303-F072
Universal Adapter Brackets
014-0001
Material
Item Specification
TA-25
WSK-M2G351-A5
1 W709234 Transaxle support insulator-to-frame rail bolts
2 W711873 Transaxle support insulator through bolt
4 W702434 Power Distribution Box (PDB) bolts
Transaxle Support Insulator - 3.0L 3915
5 N806543 PDB nut
6 180101 PDB
7 6F020 Transaxle support insulator
Removal
100-02 .
1.
303-12B .
2.
Remove the cooling fan motor and shroud. For additional information, refer to Section 303-03A . 7.
Install the Engine Lifting Bracket and Universal Adapter Bracket "L" hook on the LH side of the
engine.
8.
Install the Engine Support Bar to support the engine. 9.
Remove the wiring harness retainer from the transaxle support insulator and position the wiring
harness aside.
11.
Disconnect the wiring harness retainer from the LH shock tower. 12.
Remove the electrical connector bracket from the Battery Junction Box (BJB). 13.
Remove the 2 bolts and the nut and position the BJB aside far enough to gain access to the top 2
transaxle support insulator bolts.
14.
Remove the top 2 transaxle support insulator bolts and remove the transaxle support insulator. 15.
Installation
Clean the rear transaxle support insulator bolts using a wire brush and apply new threadlock to the
threads.
1.
Position the transaxle support insulator in place and install the upper 2 transaxle support insulator
bolts.
2.
Install the lower 2 transaxle insulator-to-frame bolts.
3.
Position the BJB and bracket in place and install the 2 bolts and the nut.
6.
Install the electrical connector bracket on the BJB . 7.
Connect the wiring harness retainer on the LH shock tower. 8.
Position the wiring harness in place and install the retainer on the transaxle support insulator. 9.
Install the through bolt.
10.
Remove the Engine Support Bar. 11.
Remove the Engine Lifting Bracket and the Universal Adapter Bracket "L" hook from the from the
LH side of the engine.
12.
Install the cooling fan motor and shroud. For additional information, refer to Section 303-03A . 13.
Install the ACL and the outlet pipe. For additional information, refer to Section 303-12B . 15.
Workshop Manual
Transaxle Support Insulator - 2.5L
Special Tool(s)
Support Bar, Engine
303-F072
Material
Item Specification
TA-25
WSK-M2G351-A5
1 W709234 Transaxle support insulator-to-frame rail bolts
2 W711873 Transaxle support insulator through bolt
4 W702434 Power Distribution Box (PDB) bolts
5 N806543 PDB nut
6 180101 PDB
7 6F020 Transaxle support insulator
Removal
100-02 .
1.
303-12A .
2.
Using the Engine Support Bar, support the engine. 7.
Remove the wiring harness retainer from the transaxle support insulator and position the wiring
harness aside.
9.
Disconnect the wiring harness retainer from the LH shock tower. 10.
Remove the electrical connector bracket from the Battery Junction Box (BJB). 11.
Remove the 2 bolts and the nut and position the BJB aside far enough to gain access to the top 2
transaxle support insulator bolts.
12.
Remove the top 2 transaxle support insulator bolts and remove the transaxle support insulator. 13.
Installation
Clean the transaxle support insulator frame bolts using a wire brush and apply new threadlock to the
threads.
1.
Position the transaxle support insulator in place and install the upper 2 transaxle support insulator
bolts.
2.
Install the lower 2 transaxle support insulator bolts.
3.
Position the BJB and bracket in place and install the 2 bolts and the nut.
6.
Install the electrical connector bracket on the BJB . 7.
Connect the wiring harness retainer on the LH shock tower. 8.
Position the wiring harness in place and install the retainer on the transaxle support insulator. 9.
Install the through bolt.
10.
Install the ACL and the outlet pipe. For additional information, refer to Section 303-12A . 13.
Workshop Manual
Transaxle Support Insulator - Anti-Roll
1 W711575 Roll restrictor bolts
2 6P082 Roll restrictor
Removal
All vehicles
100-02 .
1.
Remove the Y-pipe. For additional information, refer to Section 309-00 . 3.
All vehicles
Remove the 2 bolts and remove the roll restrictor. 4.
Transaxle Support Insulator - Anti-Roll 3927
Installation
All vehicles
Position the roll restrictor in place and install the bolts.
1.
Install the Y-pipe. For additional information, refer to Section 309-00 . 2.
All vehicles
Workshop Manual
Transaxle Case Bushing
Special Tool(s)
Handle
205-153 (T80T-4000-W)
Installer, Seal
307-626
Step Plate
205-D015 (D80L-630-4) or equivalent
Remover, Transmission Extension Housing
Bushing
308-070 (T77L-7697-E)
Installer, Bushing
307-664
Material
Item Specification
XT-10-QLVC
MERCON
LV
2 7025 LH halfshaft bushing
Removal
Remove the fronH halfshaft seal. For additional information, refer to Halfshaft Seal - LH in this
section.
1.
NOTE: Leave the drain plug out after the transmission fluid drains. The drain plug will need to
remain out to clean any debris from the damaged or worn bushing.
Remove the drain plug and drain the transmission fluid.
2.
Transaxle Case Bushing 3930
Install the Step Plate in the differential carrier. 3.
Using the Transmission Extension Housing Bushing Remover remove the LH halfshaft bushing. 4.
Remove the Step Plate from the differential carrier. 5.
Installation
Clean the halfshaft bushing area of the transaxle case. 1.
Assemble the Handle and the Bushing Installer and install a new bushing on the Bushing Installer. 2.
Using the Handle and the Bushing Installer, install a new bushing in the transaxle case. 3.
Install a new halfshaft seal on the Seal Installer and Handle. 4.
Using the Seal Installer and Handle, install the LH halfshaft seal. 5.
Install a new LH halfshaft. For additional information, refer to Section 205-04 . 6.
7.
Fill the transaxle with clean transmission fluid. For additional information, refer to Transmission
Fluid Drain and Refill in this section.
8.
Start the engine and let it run for 5 minutes. 9.
Remove the transmission fluid drain plug and drain the transmission fluid a second time. 10.
Install the transmission fluid drain plug. 11.
13.
Workshop Manual
Transaxle - 2.5L
Special Tool(s)
307-569
300-OTC-1585AE
Retainer, Torque Converter
307-566
Support Bar, Engine
303-F072
Removal
NOTE: Refer to the Transmission Cooler Flushing Job Aid on the FMCDealer website.
100-02 .
1.
303-12A .
2.
Remove the 2 nuts and position the selector lever cable and bracket aside. 5.
Transaxle - 2.5L 3934
Disconnect the wiring harness retainers from the main control cover studbolts. 6.
Remove the 3 top bellhousing bolts. 7.
NOTE: Use a steering wheel holding device such as Hunter 28-75-1 or equivalent, to hold the
steering wheel.
8.
Section 501-20B .
Remove and discard the bolt and disconnect the steering column shaft from the steering gear.
10.
NOTE: If transaxle disassembly or installation of a new transaxle is necessary, drain the transmission
fluid.
Remove the drain plug and allow the transmission fluid to drain.
12.
13.
Release the 4 clips and slide the steering gear/dash seal off of the steering gear.
14.
Remove the 2 roll restrictor bracket bolts. 15.
205-04 .
20.
Disconnect the 2 in-line Electronic Power Assist Steering (EPAS) system electrical connectors at the
front of the subframe.
21.
splash shield.
23.
Remove the bolt and the EPAS system wiring harness ground from behind the RH splash shield. 24.
25.
Position the Powertrain Lift With Tilting Plate under the subframe assembly. 26.
27.
28.
29.
Install the Engine Support Bar and support the engine and transaxle. 31.
Remove the transaxle support insulator through bolt and lower the transaxle 19 mm (0.748 in). 32.
Remove the 3 nuts, the bolt and remove the transaxle support insulator bracket. 33.
Remove the rubber insulator from the bellhousing. 35.
NOTICE: Only rotate the engine in a clockwise direction or engine damage will occur.
NOTE: Mark one stud and the flexplate for assembly reference.
Remove and discard the 4 torque converter nuts.
36.
Disconnect the transaxle main electrical connector. 37.
Disconnect the Turbine Shaft Speed (TSS) electrical connector. 38.
Remove the transmission fluid cooler tube secondary latches. 39.
Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes. 40.
41.
Remove the 3 rear torque converter housing bolts. 42.
Remove the 4 front torque converter housing bolts. 43.
Separate the transaxle from the engine and install the Torque Converter Retainer. 44.
Remove the transaxle from the vehicle. 45.
Remove the transmission fluid level indicator. 46.
Remove the transmission fluid filler tube nut. 47.
Remove the transaxle vent tube from the transaxle case and remove the transmission fluid filler tube. 48.
Open the transmission fluid cooler tube retainers. 49.
Remove the 2 secondary latches. 50.
Using the Transmission Cooler Line Disconnect Tool, disconnect and remove the transmission fluid
cooler tubes from the transaxle.
51.
Remove the 2 nuts and remove the transmission fluid cooler tube bracket. 52.
If installing a new transaxle or overhauling the transaxle, the transmission fluid cooler will need to be
backflushed and cleaned. Carry out transmission fluid cooler backflushing and cleaning. For
additional information, refer to Transmission Fluid Cooler Backflushing and Cleaning in this section.
Clean the transaxle-mounted transmission fluid cooler tubes by hand.
53.
Workshop Manual
Transaxle - 3.0L
Special Tool(s)
307-569
303-1140
303-050 (T70P-6000)
Powertrain Lift
307-566
Support Bar, Engine
303-F072
All vehicles
100-02 .
1.
303-12B .
2.
Remove the 2 nuts and position the selector lever cable and bracket aside. 5.
Disconnect the wiring harness retainers from the main control cover stud bolts. 6.
Disconnect the wiring harness retainer from the transmission fluid filler tube. 7.
Remove the 3 upper torque converter housing bolts. 8.
Remove the EGR valve and tube. For additional information, refer to Section 303-08B . 9.
Remove the 2 bolts and the EGR valve bracket. 10.
steering wheel. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
11.
Section 501-20B .
13.
NOTE: If transaxle disassembly or installation of a new transaxle is necessary, drain the transmission
fluid.
Remove the drain plug and allow the transmission fluid to drain.
15.
16.
17.
Remove the intermediate shaft. For additional information, refer to Section 205-04 . 24.
Disconnect the RH O2 sensor electrical connector. 25.
Remove the 5 bolts and position the RH exhaust manifold heat shield aside. 26.
All vehicles
If equipped, remove the 2 bolts and the heat shield. 28.
Remove the 2 roll restrictor bracket bolts.
29.
Disconnect the 2 in-line EPAS system electrical connectors at the front of the subframe. 30.
Detach the 3 wiring harness retainers from the LH front of the subframe. 31.
Remove the bolt and the Electronic Power Assist Steering (EPAS) system wiring harness ground from
behind the RH splash shield.
32.
33.
35.
36.
37.
NOTE: When installing the Engine Lifting Bracket Set, it will be easier to loosely install the upper
bolt first, then install the lower bolt.
39.
NOTE: The washers are used to space the Engine Lifting Bracket far enough from the RH cylinder
head so that the Engine Support Bar can clear the RH valve cover. The washers used must fit on a 12
mm X 1.75 bolt.
Stack washers together to reach a 25.4 mm (1 in) to 28.575 mm (1.125 in) height.
41.
NOTE: The bolt hole in the LH cylinder head that is used to install the Engine Lifting Bracket is a 12
mm X 1.75 thread.
NOTE: The bolt used to install the Engine Lifting Bracket must be between 65 mm (2.5 in) and 70
mm (2.75 in) long.
Assemble a 12 mm X 1.75 bolt with the Engine Lifting Bracket and the washers and install the bolt in
the threaded hole on the LH cylinder head with the lifting hook facing up.
42.
Install the Engine Support Bar to support the engine. 43.
Remove the transaxle support insulator through bolt and lower the transaxle 19 mm (0.748 in). 44.
Remove the 3 nuts, the bolt and remove the transaxle support insulator bracket. 45.
Remove the inspection cover. 46.
NOTE: Mark one stud and the flexplate for assembly reference.
Remove and discard the 4 torque converter nuts.
47.
Disconnect the transaxle main electrical connector. 48.
Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector. 49.
52.
Remove the 2 bolts, 2 nuts and the stud from the front of the torque converter housing. 53.
Remove the 2 back torque converter housing bolts and remove the transaxle from the dowel pins. 54.
Separate the transaxle from the engine and install the Torque Converter Retainer. 55.
Remove the transaxle from the vehicle. 56.
Remove the transmission fluid level indicator. 57.
Remove the transmission fluid filler tube nut. 58.
Remove the transaxle vent tube from the transaxle case and remove the transmission fluid filler tube. 59.
Remove the 2 secondary latches. 61.
62.
Remove the 2 nuts and remove the transmission fluid cooler tube bracket. 63.
If installing a new transaxle, the transmission fluid cooler will need to be backflushed and cleaned.
Carry out transmission fluid cooler backflushing and cleaning. For additional information, refer to
Transmission Fluid Cooler Backflushing and Cleaning in this section.
64.
Workshop Manual
Transaxle
Special Tool(s)
Handle, Torque Converter
307-091 (T81P-7902-C)
Holding Fixture
307-625
Installer, Wheel Speed Sensor Ring
206-084/2
Remover, Roll Pin
211-061 (T78P-3504-N1)
307-566
Install the Holding Fixture 307-625. 1.
Using the Holding Fixture 307-625, install the transaxle on a bench-mounted holding fixture. 2.
Remove the Torque Converter Retainer 307-566. 3.
Transaxle 3958
Install the Torque Converter Handle 307-091. 4.
NOTICE: The torque converter is heavy. Be careful not to drop it or damage will result.
Using Torque Converter Handle 307-091, remove the torque converter from the transaxle.
5.
Remove the 13 bolts and the main control cover.
6.
Transaxle 3959
Remove the solenoid body-to-main control cover grommet. 9.
NOTE: Note the location of the short and long main control bolts for reassembly.
Remove the nut and the 22 Torx bolts and remove the main control assembly.
10.
Remove and discard the forward (1, 2, 3, 4) clutch and low/reverse clutch transaxle case-to-center
support seals.
Forward (1, 2, 3, 4) clutch transaxle case-to-center support seal. 1.
Low/reverse clutch transaxle case-to-center support seal. 2.
12.
Remove the internal cooler bypass spring, sleeve and valve. 13.
Transaxle 3960
Remove the bolt and the Turbine Shaft Speed (TSS) sensor. 14.
Remove the bolt and the OSS sensor. 16.
Remove the 17 torque converter housing bolts.
17.
Transaxle 3961
Using a suitable tool, pry the torque converter housing loose from the transaxle case. 18.
Remove the torque converter housing from the transaxle case. 19.
Remove the No. 15 differential thrust bearing. 20.
Remove the differential. 21.
Remove the differential planetary sun gear. 22.
Transaxle 3962
Remove the No. 13 thrust washer. 23.
Remove the No. 11 drive sprocket thrust bearing. 24.
Simultaneously remove the drive and driven sprockets and the chain. 25.
Transaxle 3963
Remove the No. 12 driven sprocket thrust bearing. 26.
Remove the No. 10 front sun gear and shell assembly thrust bearing. 27.
Remove the 2 bolts and the transmission fluid reservoir. 28.
Transaxle 3964
Remove the 2 bolts and the transmission fluid baffle. 29.
Remove the park pawl pin and spring. 30.
Remove the park pawl. 31.
NOTE: The forward (1, 2, 3, 4) clutch snap ring is beveled. The beveled side of the snap ring goes up
(flat side down).
NOTE: The forward (1, 2, 3, 4) clutch snap ring gap faces the front of the transmission.
32.
Transaxle 3965
Remove the forward (1, 2, 3, 4) clutch snap ring.
Remove the forward (1, 2, 3, 4) clutch pressure plate, clutch assembly and wave spring. 33.
Remove the front sun gear and shell assembly. 34.
Remove the front planetary carrier/rear ring gear assembly. 35.
Remove the No. 7 and No. 8 thrust bearings.
No. 7 thrust bearing 1.
36.
Transaxle 3966
Remove the center planetary carrier/front ring gear assembly. 37.
Remove the center planetary sun gear. 38.
Remove the No. 5 and No. 6 thrust bearings.
39.
Remove the center support assembly. 40.
Remove the rear planetary carrier/center ring gear assembly. 41.
Transaxle 3967
Remove the low/reverse wave spring, clutch pack and pressure plate. 42.
Remove the low One-Way Clutch (OWC). 43.
NOTE: The intermediate (2, 6) clutch is removed with the rear planetary sun gear and shell assembly.
Remove the rear planetary sun gear and shell assembly and remove the intermediate (2, 6) clutch from
the assembly.
44.
Remove the pressure plate and the wave spring. 45.
Transaxle 3968
Remove the No. 3 thrust bearing. 46.
Remove the overdrive/direct clutch assembly. 47.
NOTE: If the No. 1 thrust bearing is stuck to the overdrive/direct clutch assembly, remove the No. 1
thrust bearing from the overdrive/direct clutch assembly.
Remove the No. 1 thrust bearing.
48.
Remove the intermediate (2, 6) clutch apply ring. 49.
Remove the 3 bolts and the clutch support tower. 50.
Transaxle 3969
NOTE: Note the location of the snap ring gap for assembly.
Remove the intermediate (2, 6) clutch return spring snap ring.
51.
NOTE: Note the position of the return spring for assembly.
Remove the intermediate (2, 6) clutch return spring.
52.
NOTE: Note the position of the intermediate clutch piston for assembly.
Remove the intermediate (2, 6) clutch piston.
53.
Transaxle 3970
Remove and discard the 5 clutch feed seals. 54.
Remove the nut and the manual control lever from the manual shaft. 55.
NOTICE: Do not drive the roll pin through the manual shaft. The roll pin will contact the
transaxle case causing damage to the transaxle case.
Using Roll Pin Remover 211-061, pull the roll pin out of the manual shaft.
56.
Remove the manual shaft. 57.
Transaxle 3971
Remove the TR sensor and the park pawl actuator rod and remove the park pawl actuator rod from the
TR sensor.
58.
Using a suitable tool, remove and discard the manual shaft seal. 59.
Using a suitable tool, remove and discard the LH halfshaft seal. 60.
NOTE: Press the bushing out of the transaxle case from the outside to the inside so that the transaxle
case rests on a flat surface.
Using the Wheel Speed Sensor Ring Installer 206-084/2 and a suitable press, remove and discard the
LH transaxle case bushing from the transaxle case.
61.
Remove the 2 bolts and the oil baffle from the torque converter housing. 62.
Transaxle 3972
Remove the 8 bolts and the pump and filter assembly. 63.
Remove the differential ring gear snap ring. 64.
Remove the differential ring gear. 65.
Using a suitable tool, remove and discard the RH halfshaft seal. 66.
Transaxle 3973
Transaxle 3974
Workshop Manual
SUBASSEMBLIES
Final Drive Carrier and Differential Assembly
Disassembly
Using a suitable tool, drive the roll pin out of the differential. Discard the roll pin. 1.
Remove the differential pin. 2.
NOTICE: Do not mix up the washers from the side or spider gears that they were originally
assembled with. Assembly of the differential with the wrong washcan cause excessive wear to
the differential carrier, spider or side gears.
Rotate the side gears along with the spider gears and remove the side gears and the spider gears.
Side gear 1.
Spider gear 2.
3.
Remove the washers from the side and spider gears, but keep the washers with the gear that it was
originally assembled with.
4.
Final Drive Carrier and Differential Assembly 3975
Assembly
Clean and inspect the side gears and spider gears and washers for damage or excessive wear and
install new components as necessary.
1.
Clean and inspect the differential pin for damage or excessive wear and install new if necessary. 2.
Clean and inspect the differential for damage and install new if necessary.
Inspect the thrust bearing surfaces. 1.
Inspect the differential planetary gear teeth. 2.
Inspect the differential planetary gear teeth to be sure they spin freely and do not move back
and forth or side to side excessively.
3.
3.
Clean and inspect the differential sun gear for damage or excessive wear and install new if necessary. 4.
NOTICE: Do not mix up the washers from the side or spider gears that they were originally
assembled with. Assembly of the differential with the wrong washers can cause excessive wear
to the differential carrier, spider or side gears.
Install the washers on the side or spider gears that they were removed from.
5.
Position the side gears in the differential carrier. 6.
Place the spider gears in the differential carrier and rotate the side gears with the spider gears until the
differential pin hole lines up to the holes in the spider gears.
7.
Install the differential pin with the roll pin holes aligned. 8.
Using a suitable tool, install a new roll pin. 9.
Workshop Manual
SUBASSEMBLIES
Pump and Filter Assembly
Special Tool(s)
Collet, 3/4 Inch to 7/8 Inch
303-D019 (D80L-100-Q)
Installer, Converter Seal
307-627
Seal Installer, Turbine Shaft
307-634
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
XT-10-QLVC
MERCON
LV
Pump Assembly
1 7A103 Pump housing
2 - Main pressure regulator valve assembly
3 -
Pump and Filter Assembly 3979
Torque Converter Clutch (TCC) control valve
assembly
Disassembly
NOTE: Note the orientation of the fluid filter to the fluid pump.
Remove the filter from the pump.
Rotate the filter 90 degrees clockwise. 1.
Pull the filter out pump. 2.
1.
Remove the magnet from the filter. 2.
Assemble the Slide Hammer 100-001 and 3/4 Inch to 7/8 Inch Collet 303-D019 and remove and
discard the input shaft seal.
3.
Remove the pump-to-torque converter housing seal. 4.
Pump Assembly 3980
If equipped, remove the torque converter hub seal snap ring. 5.
Using a suitable dent puller, remove the torque converter hub seal. 6.
Position the pump assembly in the torque converter housing and install 2 pump-to-torque converter
housing bolts hand-tight.
7.
Loosen the 23 pump bolts. 8.
Remove the 2 bolts and the pump from the torque converter housing. 9.
Pump Assembly 3981
Remove the 23 pump bolts and separate the pump halves. 10.
NOTE: The dot on the inner pump gear faces up.
Remove the pump gears.
11.
Compress the main pressure regulator valve spring with a screwdriver and remove the retainer with a
magnet.
12.
Install an M4 bolt in the valve and remove the main pressure regulator valve assembly. 13.
Compress the Torque Converter Clutch (TCC) control valve spring with a screwdriver and remove the
retainer with a magnet.
14.
Pump Assembly 3982
Remove the TCC control valve assembly. 15.
Assembly
Clean and inspect the components of the pump assembly for wear or damage. Inspect the fluid
drained from the pump for excessive metal or foreign material. If excessive wear, damage or
excessive metal is found, replace the fluid pump as an assembly.
1.
NOTE: TCC control valve retainer shown assembled in the pump body, main pressure regulator
valve retainer similar.
Assemble the TCC control valve and main pressure regulator valve and install the valves in the pump.
Compress the valve springs with a screwdriver and install the retainers.
2.
NOTE: The dot on the inner pump gear faces up.
Install the pump gears.
3.
Pump Assembly 3983
Position the stator support on the pump housing and install the 23 bolts hand-tight. 4.
Install the pump assembly in the torque converter housing and install 2 bolts hand-tight. 5.
Tighten the 23 pump housing bolts.
6.
Remove the 2 bolts and the pump assembly from the torque converter housing. 7.
Install a new torque converter hub seal on Converter Seal Installer 307-627. 8.
Using the Converter Seal Installer 307-627, install a new torque converter hub seal. 9.
Pump Assembly 3984
If equipped, install the torque converter hub seal snap ring. 10.
Install a new pump-to-torque converter housing seal. 11.
Install a new turbine shaft seal on Turbine Shaft Seal Installer 307-634. 12.
Using Turbine Shaft Seal Installer 307-634, install the turbine shaft seal. 13.
Install a new O-ring on a new filter and lubricate it with clean automatic transmission fluid. 14.
Pump Assembly 3985
Install the magnet on the filter. 15.
Install the filter.
Position the filter in the pump. 1.
Rotate the filter counterclockwise 90 degrees. 2.
16.
Pump Assembly 3986
Pump Assembly 3987
Workshop Manual
SUBASSEMBLIES
Clutch Support Tower
Special Tool(s)
Input Shaft Support Seal Installer (Back
Plate, Multiple Rings)
307-578 (includes 307-578/1, 307-578/2
and 307-578/3)
Disassembly
Using a suitable tool, remove and discard the 4 Teflon seals. 1.
Clean and inspect the clutch support towerdamage. Install a new clutch support tower if damaged. 2.
Assembly
Install the Input Shaft Support Seal Installer 307-578/3 on the clutch support tower and adjust the
Input Shaft Support Seal Installer to align the bottom edge of the tool with the top edge of the bottom
Teflon seal groove.
1.
Install a new Teflon seal on the Input Shaft Support Seal Installer 307-578/3. 2.
Clutch Support Tower 3988
Install the Input Shaft Support Seal Installer 307-578/2 over 307-578/3. Using the Input Shaft Support
Seal Installer 307-578/2, slide the Teflon seal over the clutch support tower and into the groove.
3.
Remove the Input Shaft Support Seal Installer 307-578/2 and 307-578/3.
Repeat Steps 1 through 4 for the other 3 Teflon seals.
4.
Install the Input Shaft Support Seal Installer 307-578/1 on the clutch support tower to size the 4
Teflon seals.
5.
Workshop Manual
SUBASSEMBLIES
1 W500303 Solenoid body-to-valve body bolt
3 7A100 Main control valve body
4 7E195 Check balls
5 7J191 Solenoid damper (Shift Solenoid A (SSA))
6 7C389 Manual valve
7 7G473 Solenoid pressure regulator valve assembly
8 7G179 Clutch bypass valve
9 7G307 Torque Converter Clutch (TCC) regulator valve
10 7B200 Control pressure regulator
11 7D102 Direct (3, 5, R) clutch regulator valve
12 7D102 Intermediate (2, 6) clutch regulator valve
13 7D102 Forward (1, 2, 3, 4) clutch regulator valve
14 7J187 Forward (1, 2, 3, 4) clutch latch valve
15 7D102 Low reverse/overdrive (4, 5, 6) clutch regulator valve
Disassembly
Remove the 2 bolts and separate the solenoid body from the valve body. 1.
Remove the 3 check balls and the damper.
Check balls 1.
Solenoid damper 2.
3.
Remove the manual valve. 4.
NOTICE: Remove the valves by tapping the valve body on the palm of the hand to slide the
valves out of the bores or by threading a 4-mm bolt into the valves and pulling them out. It may
be necessary to remove the valves and springs using a pick. If it is necessary to use a pick, use
extreme caution to prevent damaging the valves or valve bores. If necessary, disassemble parts
of the main control valve body in small groups. Take special care when handling the main
control components, since they are the most precise and delicate parts of the transaxle. Neatly
arrange the parts as they are removed to avoid mixing similar pieces.
NOTICE: Do not stone or polish any valves or damage to the valves can occur. If the valves do
not move freely, install a new assembly.
NOTE: The bypass valve is held in with a spring-loaded retainer. Be careful not to lose the retainer
when removing it.
Compress the valve springs with a screwdriver and remove the retainers with a magnet. Use a pick to
remove the bypass valve retainer. Remove the individual valves and springs from the main control
valve body by tapping the valve body on the palm of the hand to slide the valves out of the bores. If
needed, use a 4-mm bolt to thread into the valves to remove the valves. See the Valve Body
illustration for valve and spring locations. Clean valves, springs and main control valve body.
5.
Assembly
not move freely during assembly, install a new valve body.
Install the valve body valves, springs and retaining clips in the main control valve body. See the
Valve Body illustration at the beginning of this procedure for valve and spring locations.
1.
Install the manual valve in the valve body. 2.
Install the 3 check balls and the damper.
Check balls 1.
Solenoid damper 2.
3.
4.
For disassembly and assembly of the solenoid body, refer to Solenoid Body Assembly in this section. 5.
Position the solenoid body assembly on the valve body and install the 2 bolts.
6.
Workshop Manual
SUBASSEMBLIES
Solenoid Body Assembly
Special Tool(s)
307-636
Solenoid Body
Item
Part
Number Description
1 W500303 Solenoid body-to-valve body bolt
3 N605770 Solenoid body-to-valve body separator plate bolt (2
required)
4 7Z490 Solenoid body-to-valve body separator plate
5 7K221 Circuit filter
7 W505513 Leadframe screw (5 required)
8 7G276 Leadframe
9 7H111 Solenoid retaining pin (14 required)
10 7J187 Direct (3, 5, R) clutch latch valve
11 7J187 Intermediate (2, 6) clutch latch valve
12 7J187 Low reverse/overdrive (4, 5, 6) clutch latch valve
13 7G383 Line Pressure Control (LPC) solenoid
14 7G136 Shift Solenoid C (SSC)
15 7G136 Torque Converter Clutch (TCC) solenoid
16 7G484 Shift Solenoid E (SSE) ON/OFF solenoid
17 7G136 Shift Solenoid A (SSA)
18 7G383 Shift Solenoid B (SSB)
19 7G383 Shift Solenoid D (SSD)
Disassembly
If not previously done, remove the 2 bolts and separate the solenoid body from the valve body. 1.
Remove and discard the circuit filter. 3.
Solenoid Body 3997
Compress the valve springs with a screwdriver and remove the retainers with a magnet. Remove the
individual valves and springs from the solenoid body by tapping it on the palm of the hand to slide the
valves out of the bores. See the Solenoid Body illustration at the beginning of this procedure for valve
and spring locations.
4.
NOTICE: Be careful not to bend or twist the solenoid body leadframe or the solenoid terminals
when removing the leadframe or damage can occur to the leadframe or the solenoids.
Remove the 5 screws and carefully remove the leadframe from the solenoids by lifting it straight up
evenly.
5.
NOTICE: The solenoids are calibrated from the factory and are not all the same. Failure to
mark the solenoids to the ports they were originally in can result in mixing the solenoids and
can cause damage to the transaxle or a harsh shift.
Using a paint marker, number the solenoids and the solenoid body to correspond with the ports from
which the solenoids are located in the solenoid body.
6.
Solenoid Body 3998
Remove the solenoid retaining pins. 7.
Remove the solenoids from the solenoid body. 8.
Assembly
NOTICE: Be careful not to wash the numbers from the solenoids or the solenoid body. Failure
to install the solenoids in the ports they were originally in can result in damage to the transaxle
or a harsh shift.
not move freely during assembly, install a new solenoid body.
Clean and inspect the solenoid body, solenoids and valve assemblies for damage. Inspect the solenoid
screens for debris that may restrict fluid flow through the screen.
1.
NOTICE: The solenoids are calibrated from the factory and are not all the same. Failure to
install the solenoids in the ports they were originally in can result in damage to the transaxle or
a harsh shift.
If new solenoid(s) are not being installed, position the solenoids in the solenoid body ports from
which their numbers correspond.
2.
Solenoid Body 3999
If installing a new Variable Force Solenoid (VFS), determine the base part number of the solenoid(s).
The Torque Converter Clutch (TCC) solenoid, Shift Solenoid A (SSA) and Shift Solenoid C (SSC)
are all normally low pressure solenoids. The Line Pressure Control (LPC) solenoid, Shift Solenoid B
(SSB) and Shift Solenoid D (SSD) are all normally high pressure solenoids. Shift Solenoid E (SSE) is
not a VFS ; it is an ON/OFF solenoid.
1 7G136 SSA (normally low)
2 7G383 SSB (normally high)
3 7G136 SSC (normally low)
4 7G383 SSD (normally high)
5 7G484 SSE (normally closed [OFF])
6 7G136 TCC solenoid (normally low)
7 7G383 LPC solenoid (normally high)
3.
If installing a new LPC solenoid, SSB or SSD , note the color of the electrical terminal area of the
solenoid. The color will be blue or green and the solenoid can only be replaced with the same color
solenoid. If a new solenoid with that color is not available, install a new solenoid body, refer to
Solenoid Body Assembly in this section.
4.
Determine the part number suffix by checking the solenoid service band number etched on the side of
the solenoid. The band number is the third digit on the side of the solenoid and will be a 1, 2, 3, 4 or
5. Use the following table to determine the part number suffix and match the new solenoid base part
number and suffix with the old solenoid. Install the solenoid in the solenoid body.
Solenoid Band Number Part Number Suffix
1 B
2 C
3 D
4 E
5.
Solenoid Body 4000
5 F
Install the solenoid retaining pins. 6.
Install Leadframe Guide Pins 307-636 in the solenoid body to align the leadframe for installation. 7.
Position the leadframe on the guide pins and carefully install the leadframe by pushing it straight
down into the solenoids.
8.
Remove Leadframe Guide Pins 307-636. 9.
Solenoid Body 4001
NOTICE: If the valves do not move freely during assembly, install a new solenoid body. Failure
to install a new solenoid body can result in a harsh shift or damage to the transaxle.
Install the solenoid body valves, springs and retaining clips in the solenoid body. See the Solenoid
Body illustration at the beginning of this procedure for valve and spring locations.
11.
Install the circuit filter. 12.
Install the new separator plate and the 2 bolts.
13.
If not previously done, refer to Main Control Valve Body in this section for disassembly and
assembly of the valve body.
14.
Position the solenoid body assembly on the valve body and install the 2 bolts.
15.
Solenoid Body 4002
Solenoid Body 4003
Workshop Manual
SUBASSEMBLIES
Planetary Gearsets And Chain Drive Parts
Clean and inspect the front planetary sun gear and shell assembly for damage or wear and install new,
as necessary.
Gear teeth
Shell-to-clutch pack surfaces
Thrust bearing surfaces
1.
Clean and inspect the front planetary gear carrier/rear ring gear assembly for damage or excessive
wear and install new, as necessary.
Pinion gear teeth
Pinion gear surfaces
Pinion gear bearings
Spline teeth
Thrust bearing
Thrust bearing surfaces <
Ring gear teeth
2.
Clean and inspect the center planetary gear carrier/front ring gear assembly for damage or excessive
3.
Planetary Gearsets And Chain Drive Parts 4004
Pinion gear teeth
Spline teeth
Ring gear teeth
Clean and inspect the center planetary sun gear for damage or excessive wear and install new, as
necessary.
Sun gear teeth
Spline teeth
4.
Clean and inspect the rear planetary gear carrier/center ring gear assembly for damage or excessive
Pinion gear teeth
Spline teeth
Thrust bearing
Ring gear teeth
5.
Clean and inspect the rear planetary sun gear and shell assembly for damage or wear and install new,
if necessary.
Sun gear teeth
Shell-to-clutch pack surfaces
Bearing surfaces
6.
Remove the drive chain from the drive and driven sprockets. 7.
Clean and inspect the drive chain for damage or excessive wear and install new, if necessary.
Check the drive chain for wear, stretching or tightness of the chain links.
Check that the chain moves freely.
8.
Inspect the driven sprocket for damage or excessive wear and install new, if necessary.
Chain teeth
Spline teeth
Bearing
9.
Remove the snap ring and remove the drive sprocket from the front planetary hub/park gear assembly. 10.
Inspect the drive sprocket for damage or excessive wear and install new, if necessary.
Chain teeth
Spline teeth
Thrust washer surface
11.
Inspect the front planetary hub/park gear assembly for damage or excessive wear and install new, if
necessary.
Park gear teeth
Spline teeth
12.
Thrust washer surface
Thrust bearing surface
Bearing surfaces
Needle bearing
Install the drive sprocket on the front planetary hub/park gear assembly and install the snap ring. 13.
Install the drive chain on the drive and driven sprockets. 14.
Workshop Manual
SUBASSEMBLIES
Low One-Way Clutch
NOTICE: Do not clean in water or with water-based solvents. Damage to the component may
occur.
NOTE: The low One-Way Clutch (OWC) should not be disassembled.
Clean and inspect the low OWC for cracks and damaged splines. The internal splined section should
rotate clockwise and lock when rotated counterclockwise. If any damage is found or the clutch does
not rotate or lock, install a new low OWC .
1.
Inspect the intermediate () clutch surface for damage. If the surface is burned or worn excessively,
install a new OWC .
2.
Low One-Way Clutch 4010
Workshop Manual
SUBASSEMBLIES
Overdrive/Direct Clutch Assembly
Special Tool(s)
Compressor, Forward/Intermediate Spring
307-584 (includes 307-584/1 and
307-584/2)
Compressor, Overdrive Clutch, Balance
Piston and Direct Clutch
307-589 (includes 307-589/1 and
307-589/2)
Dial Indicator Gauge With Holding Fixture
100-002 (TOOL-4201-C)
307-578 (includes 307-578/1, 307-578/2
and 307-578/3)
Material
Item Specification
XT-10-QLVC
MERCON
LV
Disassembly
Remove the input shaft snap ring. 1.
Remove the input shaft. 2.
Overdrive/Direct Clutch Assembly 4011
Remove thverdrive (O/D) (4, 5, 6) clutch hub. 3.
Remove the O/D (4, 5, 6) clutch hub, No. 2 thrust bearing. 4.
Remove the O/D (4, 5, 6) clutch snap ring. 5.
Remove the O/D (4, 5, 6) clutch pressure plate and clutch assembly. 6.
Install the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1 and
Forward/Intermediate Spring Compressor 307-584/2 on the balance piston.
7.
Using a press, compress the O/D (4, 5, 6) clutch return spring and remove the snap ring. 8.
Remove the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1 and
Forward/Intermediate Spring Compressor 307-584/2.
9.
Remove and discard the balance piston. 10.
Remove the O/D (4, 5, 6) piston return spring. 11.
Install the clutch support tower in the transmission case and install the 3 bolts. 12.
Remove the Input Shaft Support Seal Installer 307-578/1 (sizer). 13.
Install the No. 1 O/D /direct clutch assembly thrust bearing. 14.
Position the O/D /direct clutch assembly in the transaxle case. 15.
Apply compressed air to the O/D (4, 5, 6) clutch piston port and remove the O/D (4, 5, 6) clutch
piston.
16.
Remove the O/D /direct clutch assembly from the transaxle case. 17.
Remove the O/D (4, 5, 6) clutch piston seal from the O/D /direct clutch assembly. 18.
Remove the 2 seals from the O/D (4, 5, 6) clutch piston. 19.
NOTICE: Only compress the direct clutch piston return spring far enough to take the tension
from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston
alignment tab may be broken off.
Forward/Intermediate Spring Compressor 307-584/2 on the direct (3, 5, R) clutch cylinder. Using a
press, compress the direct (3, 5, R) clutch piston return spring, and remove the snap ring.
Do not contact the O/D /direct clutch hub and shaft assembly with the direct (3, 5, R) clutch
cylinder.
1.
20.
21.
Remove the direct (3, 5, R) clutch cylinder. 22.
Remove and discard the direct (3, 5, R) clutch piston. 23.
NOTE: Note the position of the return spring for assembly. The flat side faces down.
Remove the direct (3, 5, R) clutch piston return spring.
24.
Remove the direct (3, 5, R) clutch snap ring.
Slightly lift up on the direct (3, 5, R) clutch so that the snap ring floats freely. 1.
Using a suitable tool, compress the snap ring. 2.
Allow the direct (3, 5, R) clutch and pressure plate to drop so that the snap ring is out of the
pressure plate groove.
3.
25.
Remove the direct (3, 5, R) clutch pressure plate, clutch pack and wave spring. 26.
Remove and discard the 3 direct (3, 5, R) clutch piston seals. 27.
Assembly
Clean and inspect the O/D /direct clutch assembly for damage or excessive wear and install new
1.
Install new direct (3, 5, R) clutch piston seals and lubricate the seals with petroleum jelly. 2.
Install the direct (3, 5, R) clutch wave spring. 3.
Soak the direct (3, 5, R) clutch pack in clean automatic transmission fluid. 4.
Install the direct (3, 5, R) clutch assembly and pressure plate. 5.
Install the direct (3, 5, R) clutch snap ring.
Using a suitable tool, compress the snap ring. 1.
Lift the direct (3, 5, R) clutch so that the snap ring is in the groove of the pressure plate. 2.
Release the tension on the snap ring. 3.
6.
NOTE: Install the direct (3, 5, R) clutch piston return spring with the flat side facing down.
Install the direct (3, 5, R) clutch piston return spring.
7.
Lubricate a new direct (3, 5, R) clutch piston with petroleum jelly and install the piston. 8.
Install the direct (3, 5, R) clutch cylinder. 9.
NOTICE: Only compress the direct clutch piston return spring far enough to take the tension
from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston
alignment tab may be broken off.
Forward/Intermediate Spring Compressor 307-584/2 on the direct (3, 5, R) clutch cylinder. Using a
press, compress the direct (3, 5, R) clutch piston return spring, and install the snap ring.
Do not contact the O/D /direct clutch hub and shaft assembly with the direct (3, 5, R) clutch
cylinder.
1.
Install the snap ring. 2.
10.
11.
Install 2 new seals on the O/D (4, 5, 6) clutch piston and lubricate the seals with petroleum jelly. 12.
Install a new O/D (4, 5, 6) clutch piston inner seal and lubricate the seal with petroleum jelly. 13.
Position the O/D (4, 5, 6) clutch piston in place. 14.
Using the Overdrive Clutch, Balance Piston, and Direct Clutch Compressor 307-589/1, install the O/D
(4, 5, 6) clutch piston into the O/D /direct clutch assembly by hand.
15.
NOTE: Holes face up on the O/D (4, 5, 6) clutch piston return spring.
Install the O/D (4, 5, 6) clutch piston return spring.
16.
Lubricate the seals on a new balance piston and position the piston in place. 17.
Forward/Intermediate Spring Compressor 307-584/2 on the balance piston.
18.
Using a press, compress the O/D (4, 5, 6) clutch return spring and install the snap ring. 19.
20.
Install the No. 2 thrust bearing. 21.
Install the O/D (4, 5, 6) clutch hub. 22.
Soak the O/D (4, 5, 6) clutch pack in clean automatic transmission fluid. 23.
Install the O/D (4, 5, 6) clutch pack. 24.
Install the O/D (4, 5, 6) clutch pressure plate. 25.
Install the O/D (4, 5, 6) clutch snap ring. 26.
Install the input shaft. 27.
While holding the input shaft in place, install the snap ring. 28.
Position the O/D /direct clutch assembly in the transaxle case, install Dial Indicator Gauge With
Holding Fixture 100-002 or a suitable dial indicator and position the plunger on the O/D (4, 5, 6)
29.
clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the O/D (4, 5, 6) clutch piston port
while recording the clutch pack clearance on the Dial Indicator. The clearance should be between
0.950 mm (0.037 in) and 1.778 mm (0.07 in). If the clearance is out of range, check the O/D (4, 5, 6)
clutch pack for correct installation. If the O/D (4, 5, 6) clutch pack is correctly installed, install a new
O/D (4, 5, 6) clutch pack.
Position the plunger on one of the top direct (3, 5, R) clutch plate tabs. Apply 483 kPa (70 psi) of air
pressure to the direct (3, 5, R) clutch piston port while recording the clutch pack clearance on Dial
Indicator Gauge With Holding Fixture 100-002. The clearance should be between 0.412 mm (0.016
in) and 1.728 mm (0.068 in). If the clearance is out of range, check the direct (3, 5, R) clutch pack for
correct installation. If the direct (3, 5, R) clutch pack is correctly installed, install a new direct (3, 5,
R) clutch pack.
30.
Remove Dial Indicator Gauge With Holding Fixture 100-002, O/D /direct clutch assembly and the
No. 1 O/D /direct clutch assembly thrust bearing.
31.
Workshop Manual
SUBASSEMBLIES
Center Support
Special Tool(s)
Compressor, Center Support Piston Spring
307-630
Seal Protector, Low Reverse Piston
307-628 (includes 307-628/1 and
307-628/2)
Seal Protector, Low Reverse / 1-2-3-4
Piston
307-629
Disassembly
NOTICE: The piston return spring, snap ring or snap ring retainer from the low/reverse clutch side of
the center support are not interchangeable with the forward clutch side of the center support. When
disassembling the center support, be careful not to mix the components from the low/reverse clutch side
with the forward clutch side of the center support. Failure to assemble the center support with the
components in the correct side will result in damage to the center support, low/reverse or forward
clutch.
NOTE: The low/reverse clutch piston in the center support is the side of the center support with the
long legs.
Using the Center Support Piston Spring Compressor 307-630 and a press, compress the low/reverse
clutch return spring and remove the snap ring and the snap ring retainer.
1.
Remove the low/reverse clutch return spring. 2.
Center Support 4026
Apply 483 kPa (70 psi) of air pressure to the low/reverse clutch piston port and remove the
low/reverse clutch piston.
3.
NOTE: The forward clutch piston in the center support is the side of the center support with the short
legs.
Using the Center Support Piston Spring Compressor 307-630 and a press, compress the forward (1, 2,
3, 4) clutch return spring and remove the snap ring and the snap ring retainer.
4.
Remove the return spring from the forward (1, 2, 3, 4) clutch piston. 5.
Center Support 4027
Apply 483 kPa (70 psi) of air pressure to the forward (1, 2, 3, 4) clutch piston port and remove the
forward (1, 2, 3, 4) clutch piston.
6.
Assembly
NOTICE: The piston return spring, snap ring or snap ring retainer from the low/reverse clutch side of
the center support are not interchangeable with the forward clutch side of the center support. When
assembling the center support, be careful not to mix the components from the low/reverse clutch side
with the forward clutch side of the center support. Failure to assemble the center support with the
components in the correct side will result in damage to the center support, low/reverse or forward
clutch.
Clean and inspect the center support for damage. Install a new center support if necessary. 1.
NOTE: The forward clutch piston in the center support is the side of the center support with the short
legs.
Install the Low Reverse Piston Seal Protector 307-628/2 and the Low Reverse / 1-2-3-4 Piston Seal
Protector 307-629 on the forward clutch piston side of the center support.
2.
Lubricate the sealing surfaces of the forward (1, 2, 3, 4) clutch piston with petroleum jelly. 3.
Center Support 4028
Position the forward (1, 2, 3, 4) clutch piston on Low Reverse Piston Seal Protector 307-628/2 and the
Low Reverse / 1-2-3-4 Piston Seal Protector 307-629 and push it down into the center support.
4.
Install the forward (1, 2, 3, 4) clutch piston return spring. 5.
Using the Center Support Piston Spring Compressor 307-630 and a press, compress the forward (1, 2,
3, 4) clutch return spring and install the snap ring retainer and the snap ring.
6.
Inspect the snap ring to be sure it is seated in the groove on the center support. 7.
Center Support 4029
Turn the center support over and install the Low Reverse Piston Seal Protector 307-628/1 and
307-628/2 on the low/reverse piston side of the center support.
8.
Lubricate the sealing surfaces of the low/reverse piston with petroleum jelly. 9.
Position the low/reverse clutch piston on the Low Reverse Piston Seal Protector 307-628/1 and
307-628/2 and push it down into the center support.
10.
Install the low/reverse piston return spring. 11.
Center Support 4030
Using the Center Support Piston Spring Compressor 307-630 and a press, compress the low/reverse
clutch return spring and install the snap ring retainer and the snap ring.
12.
Inspect the snap ring to be sure it is seated in the groove on the center support. 13.
Center Support 4031
Workshop Manual
Transaxle
Special Tool(s)
Compressor, Forward Clutch Spring
307-574 (includes 307-574/1 and
307-574/2)
Compressor, Forward/Intermediate Spring
307-584 (includes 307-584/1 and
307-584/2)
100-002 (TOOL-4201-C)
Handle
205-153 (T80T-4000-W)
Handle, Torque Converter
307-091 (T81P-7902-C)
Holding Fixture
307-625
307-578 (includes 307-578/1, 307-578/2
and 307-578/3)
Installer, Bushing
307-664
Installer, Differential Seal
307-626
Installer, RH Halfshaft Fluid Seal
307-428
Manual Lever Seal Installer
307-581
307-566
Seal Protector, 2-6 Piston
307-632
Transaxle 4032
Seal Protector, Turbine Shaft
307-635
Shim Selection Gauge
307-300 (T94P-77000-Q) (17-055)
Spring Compressor, 2-6 Piston Return
307-633 (Includes 307-633/1 and
307-633/2)
Material
Item Specification
XT-10-QLVC
MERCON
LV
TA-29
-
Disassembled Views
Disassembled Views 4033
2 7A130 Clutch support tower
3 7D019 Clutch support tower seals (4 required)
4 W302855 Clutch support tower bolt (3 required)
5 7F242 No. 1 thrust bearing
6 7E005 Intermediate (2, 6) clutch piston
7 7B070 Intermediate (2, 6) clutch piston return spring
8 7D483 Intermediate (2, 6) clutch return spring snap ring
9 7E005 Intermediate (2, 6) clutch apply ring
10 7C122 Direct (3, 5, R) clutch cylinder snap ring
11 7F283 Direct (3, 5, R) clutch cylinder
12 7A262 Direct (3, 5, R) clutch piston
13 7F235 Direct (3, 5, R) clutch piston return spring
14 7C099 Direct (3, 5, R) clutch piston inner (rear) seal
15 7C099 Direct (3, 5, R) clutch piston inner (front) seal
16 7A548 Direct (3, 5, R) clutch piston outer seal
17 7C122 Input shaft snap ring
18 7G384 Direct (3, 5, R)/Overdrive (O/D) (4, 5, 6) clutch
cylinder and hub assembly
19 7A548 O/D (4, 5, 6) clutch piston inner seal
20 7F213 Input shaft
22 7B070 Direct (3, 5, R) clutch wave spring
23 7B164 Direct (3, 5, R) clutch friction plates (3 required)
24 7B442 Direct (3, 5, R) clutch steel plates (3 required)
25 7B066 Direct (3, 5, R) clutch pressure plate
26 7D483 Direct (3, 5, R) clutch snap ring
27 7A548 O/D (4, 5, 6) clutch piston outer (rear) seal
28 7A548 O/D (4, 5, 6) clutch piston outer (front) seal
29 7A262 O/D (4, 5, 6) clutch piston
30 7F222 O/D (4, 5, 6) clutch piston return spring
31 7H360 O/D (4, 5, 6) clutch balance piston
32 7C122 O/D (4, 5, 6) clutch piston snap ring
33 7B164 O/D (4, 5, 6) clutch friction plates (5 required)
34 7B442 O/D (4, 5, 6) clutch steel plates (5 required)
35 7B066 O/D (4, 5, 6) clutch pressure plate
36 7D483 O/D (4, 5, 6) clutch snap ring
37 7H351 O/D (4, 5, 6) clutch hub
40 7E085 Intermediate (2, 6) clutch wave spring
41 7B164 Intermediate (2, 6) clutch friction plates (2
required)
42 7B442 Intermediate (2, 6) clutch steel plates (2
required)
43 7A089 One-Way Clutch (OWC)
44 7D491 Rear planet carrier/center ring gear
47 7B066 Low/reverse clutch pressure plate
48 7B164 Low/reverse clutch friction plates (3 required)
49 7B442 Low/reverse clutch steel plates (3 required)
50 7E085 Low/reverse clutch wave spring
51 7C122 Low/reverse clutch piston snap ring
52 7H318 Low/reverse clutch piston snap ring retainer
53 7B070 Low/reverse clutch piston return spring
54 7D402 Low/reverse clutch piston
56 7A262 Forward (1, 2, 3, 4) clutch piston
57 7B070 Forward (1, 2, 3, 4) clutch piston return spring
58 7D041 Forward (1, 2, 3, 4) clutch piston snap ring
retainer
59 7H365 Forward (1, 2, 3, 4) clutch piston snap ring
60 7D491 Center planetary carrier/front ring gear
61 7D063 Center planetary sun gear
64 7D491 Front planetary carrier/rear ring gear
65 7A019 Front planetary sun gear and shell assembly
67 7B070 Forward (1, 2, 3, 4) clutch wave spring
68 7B164 Forward (1, 2, 3, 4) clutch friction plates (2
required)
69 7B442 Forward (1, 2, 3, 4) clutch steel plates (2
required)
70 7B066 Forward (1, 2, 3, 4) clutch pressure plate
71 7D483 Forward (1, 2, 3, 4) clutch snap ring
72 7978 Transmission fluid baffle
73 W500214 Transmission fluid baffle bolt (2 required)
74 7060 Park gear
76 7C122 Drive sprocket snap ring
79 7D234 No. 11 thrust washer
80 7048 Input shaft seal
81 7A098 Transmission fluid filter
82 7L027 Magnet
83 W302860 Pump-to-torque converter housing bolt (8
required)
85 7A248 Pump assembly-to-torque converter housing
O-ring seal
86 7A248 Torque converter hub seal
87 7P113 Torque converter hub seal retainer
88 7F343 Different ring gear
89 7C122 Differential ring gear snap ring
90 7H245 Differential transmission fluid baffle
91 W500214 Differential transmission fluid baffle bolt (2
required)
93 W701606 Torque converter housing stud bolt
94 7A443 Torque converter housing bolt (16 required)
96 1177 RH halfshaft seal
97 391308-S Transaxle filler tube O-ring
99 W520101 Transaxle filler tube nut
103 7F342 Differential sun gear
104 7F465 Differential assembly
106 7B362 Torque converter housing-to-transaxle case
guide pins
107 7D070 Park pawl spring
108 7A441 Park pawl
109 7D071 Park pawl pin
112 7H557 Transmission Range (TR) sensor
114 7G100 Manual control shaft pin
116 W708455 Manual control lever nut
117 7E332 Manual valve detent spring
118 W711235 Manual valve detent spring bolt
119 7J387 Lubrication funnel
120 7A248 Torque converter housing-to-transaxle case seal
(large)
121 7A248 Torque converter housing-to-transaxle case seal
(small) (4 required)
122 7B431 Main control alignment pin
123 7C207 Main control stud
124 7G199 Main control-to-center support seal (2 required)
125 7H322 Thermal bypass valve and sleeve
126 - Thermal bypass valve spring (part of 7H322)
127 W713644 Output Shaft Speed (OSS) sensor bolt
128 7H103 OSS sensor
131 N605770 Separator plate-to-soledoid body bolt (2
required)
132 7Z490 Main control valve body-to-solenoid body
separator plate
135 W302863 Main control-to-transaxle case bolt (long) (10
required)
required)
138 7G276 Main ctrol leadframe
142 W714629 Main control cover stud bolt (5 required)
143 W500214 Main control cover bolt (8 required)
144 7010 Drain plug
145 7H398 Line pressure tap
146 7D273 Transmission fluid cooler tube fittings (2
required)
148 7025 LH halfshaft bushing
150 W500214 TSS bolt
151 7A246 Vent tube
152 W500214 Lubrication funnel bolts
153 7G342 Solenoid body strategy tag
154 7B148 Transaxle service identification tag
155 - Direct clutch (3, 5, R)
156 - Intermediate clutch (2, 6)
157 - O/D clutch (4, 5, 6)
158
td>-
Forward clutch (1,
2, 3, 4)
159 - Low/reverse clutch
All vehicles
Clean and inspect the transaxle case for damage. Clean the silicone from the transaxle case-to-torque
converter housing sealing surface and the main control cover sealing surface.
1.
Assemble the Handle 205-153 and the Bushing Installer 307-664 and install a new bushing on the
Bushing Installer.
2.
Using the Handle 205-153 and the Bushing Installer 307-664, install the new bushing in the transaxle
case.
3.
Assemble the Handle 205-153 and Seal Installer 307-626. Install a new LH halfshaft seal on the
Differential Seal Installer 307-626.
4.
Using the Differential Seal Installer 307-626 and Handle 205-153, install the new LH halfshaft seal in
the transaxle case.
5.
Install a new manual control shaft seal on Manual Lever Seal Installer 307-581. 6.
Using the Manual Lever Seal Installer 307-581, install the new manual control shaft seal in the
transaxle case.
7.
If not previously installed, install the clutch support tower and the 3 bolts.
8.
Remove Input Shaft Support Seal Installer 307-578/1. 9.
Install 2-6 Piston Seal Protector 307-632. 10.
Lubricate the seals on the intermediate (2, 6) clutch piston with clean transmission fluid. 11.
NOTICE: Be sure the bleed hole is aligned in the correct position as noted during disassembly
or damage to the transaxle can occur.
Install the intermediate (2, 6) clutch piston on the seal protector with the bleed hole aligned at the top
of the transaxle case.
12.
Position the intermediate (2, 6) clutch piston return spring on the piston to align the piston before
pushing it in its bore. The tabs of the return spring should fit into the indentions of the piston and the 2
outer tabs should be at the clockwise most position of the open area at the bottom of the transaxle
case. The bleed hole on the piston should be aligned between the inner double tabs of the return
spring.
Outer tabs 1.
Open area at the bottom of the transaxle case 2.
Bleed hole 3.
Inner double tabs 4.
13.
Remove the intermediate (2, 6) clutch piston return spring. 14.
Install Forward/Intermediate Spring Compressor 307-584/1 on the intermediate (2, 6) clutch piston. 15.
Using Forward/Intermediate Spring Compressor 307-584/1, push the intermediate (2, 6) clutch piston
into the clutch cylinder by hand.
16.
Remove Forward/Intermediate Spring Compressor 307-584/1 and Clutch Piston Seal Protector
307-632.
17.
NOTICE: Be sure the return spring is positioned correctly with the forward clutch bleed hole
aligned between the inner double tabs and the outer tab in the clockwise most position of the
slot at the bottom of the case or damage to the transaxle can occur.
Install the intermediate (2, 6) clutch piston return spring. The tabs of the return spring should fit into
the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the slot at
the bottom of the case. The bleed hole on the piston should be aligned between the inner double tabs
of the return spring.
Outer tabs 1.
Bleed hole 2.
Inner double tabs 3.
18.
NOTICE: Be sure the snap ring is aligned with the gap facing the front of the transaxle or
damage to the transaxle can occur. The front of the transaxle is where the low/reverse and
forward (1, 2, 3, 4) clutch hydraulic ports are located.
Position the snap ring in place. Align the gap of the snap ring to face the front of the transaxle.
Snap ring 1.
Snap ring gap 2.
Low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports (located at the front of the
transaxle case)
3.
19.
Install the 2-6 Piston Return Spring Compressor 307-633/2 on the transaxle case to center the
intermediate (2, 6) clutch return spring.
20.
Install the 2-6 Piston Return Spring Compressor 307-633/1 on the snap ring. 21.
Install Forward Clutch Spring Compressor 307-574/1 on the transaxle case. 22.
NOTICE: Be sure the return spring is centered or it can bind on the snap ring groove and cause
damage to the transaxle case.
Using the Forward Clutch Spring Compressor 307-574/1 and the 2-6 Piston Return Spring
Compressor 307-633, install the intermediate (2, 6) clutch snap ring in the groove.
23.
Remove the Forward Clutch Spring Compressor 307-574/1 and the 2-6 Piston Return Spring
Compressor 307-633.
24.
Install the intermediate (2, 6) clutch apply ring. Tap the ring in place using a suitable tool. 25.
NOTICE: Be sure to install the No. 1 thrust bearing with the flat side facing up or damage to the
transaxle can occur.
Install the No. 1 thrust bearing with the flat side facing up.
26.
Install the overdrive/direct clutch assembly. 27.
NOTICE: Be sure to install the No. 3 thrust bearing with the flat side facing down or damage to
the transaxle can occur.
Install the No. 3 thrust bearing with the flat side facing down.
28.
Install the direct/intermediate clutch hub and rear sun gear assembly. 29.
Install the intermediate (2, 6) wave spring assembly. 30.
Soak the intermediate (2, 6) clutch assembly in clean transmission fluid. 31.
Install the intermediate (2, 6) clutch assembly, temporarily reversing the top friction and steel plates
for the clutch stack-up measurement.
32.
Install the Shim Selection Gauge 307-300 on the transaxle case. 33.
Using a suitable depth gauge, measure and record as measurement A, the distance from the Shim
Selection Gauge 307-300 to the top of the intermediate (2, 6) clutch pack at 3 different points and
average the 3 distances.
34.
Using a suitable depth gauge, measure and record as measurement B, the distance from the top of
Shim Selection Gauge 307-300 to the transaxle case step above the intermediate (2, 6) clutch.
35.
Subtract measurement B from measurement A The clearance should be between 0.240 mm (0.009 in)
and 2.60 mm (0.102 in). If the clearance is out of range, check the intermediate (2, 6) clutch pack for
correct installation. If the intermediate (2, 6) clutch pack is correctly installed, install a new clutch
pack.
Description Reading
Measurement A
Measurement B
Subtract measurement B from measurement A and check to see if it is within range of
0.240 mm (0.009 in) and 2.60 mm (0.102 in)
36.
NOTE: When the intermediate (2, 6) clutch is correctly installed, a friction plate is on top.
Remove the top intermediate (2, 6) clutch friction and steel plate and correctly install the plates back
in the transaxle case.
37.
Install the One-Way Clutch (OWC) assembly. 38.
Install the rear planetary carrier/center ring gear assembly. 39.
NOTE: Note the position of the low/reverse pressure plate. When installing the center support, the
long support legs must fit through the low/reverse pressure plate and rest on the OWC .
Position the low/reverse pressure plate so that the center support legs fit through the pressure plate
and rest on the OWC and install the low/reverse pressure plate.
40.
Soak the low/reverse clutch in clean automatic transmission fluid. 41.
Align the low/reverse clutch pack with the pressure plate and install it in the transaxle case
temporarily reversing the wave spring and top steel plate.
42.
Install the Shim Selection Gauge 307-300 on the side of the center support with the long support legs. 43.
Using a suitable depth gauge, measure and record as measurement A, the distance from the top of
Shim Selection Gauge 307-300 to the contact surface of the low/reverse clutch piston.
44.
Using a suitable depth gauge, measure and record as measurement B, the distance from the top of
Shim Selection Gauge 307-300 to the leg surface of the center support.
45.
Subtract measurement B from measurement A and record as measurement C.
Description Reading
Measurement A
Measurement B
Subtract measurement B from measurement A and record as measurement C.
46.
Install the Shim Selection Gauge 307-300 on the transaxle case. 47.
Using a suitable depth micrometer, measure and record as measurement D, the distance from the
Shim Selection Gauge 307-300 to the top of the OWC .
48.
Using a suitable depth gauge, measure and record as measurement E, the distance from the top of
Shim Selection Gauge 307-300 to the top of the low/reverse clutch at 3 different points and average
the 3 distances.
49.
Subtract measurement E from measurement D and record as measurement F.
Description Reading
Measurement D
Measurement E
Subtract measurement E from measurement D and record as measurement F
50.
Subtract measurement F from measurement C to get the low/reverse clutch clearance. The clearance
should be between 0.406 mm (0.015 in) and 2.000 mm (0.078 in). If the clearance is out of range,
check the low/reverse clutch pack for correct installation. If the low/reverse clutch pack is correctly
installed, install a new clutch pack.
Description Reading
Measurement C
Measurement F
Subtract measurement F from measurement C and check to see if it is within range of 0.406
mm (0.015 in) and 2.000 mm (0.078 in)
51.
NOTE: When the low/reverse clutch is correctly installed, the wave spring is on top.
Remove the top low/reverse clutch steel plate and wave spring and correctly install the plates back in
the transaxle case.
52.
NOTE: Be sure the center support is installed with the long support legs facing down and the feed
holes facing the front of the transaxle.
Install the center support with the long legs facing down and the feed holes aligned with the feed
holes in the transaxle case.
Long center support legs face down 1.
Feed holes face the front of the transaxle case 2.
53.
Install the No. 5 and No. 6 thrust bearings.
54.
Install the center sun gear. 55.
Install the center carrier/front ring gear assembly. 56.
Install the No. 7 and No. 8 thrust bearings.
57.
Install the front planetary/rear ring gear assembly. 58.
Install the forward (1, 2, 3, 4) clutch wave spring. 59.
Soak the forward (1, 2, 3, 4) clutch pack in clean automatic transmission fluid. 60.
Install the forward (1, 2, 3, 4) clutch pack. 61.
Install the forward (1, 2, 3, 4) clutch pressure plate. 62.
NOTICE: Be sure to install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side
facing down or the snap ring can come loose, causing damage to the transaxle.
Install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side down with the gap facing the
front of the transaxle.
Forward (1, 2, 3, 4) clutch snap ring 1.
Forward (1, 2, 3, 4) clutch snap ring gap 2.
63.
Using a suitable tool, seat the snap ring in the snap ring groove. 64.
Install Dial Indicator Gauge With Holding Fixture 100-002 or a suitable dial indicator on the transaxle
case and position the plunger on the top forward (1, 2, 3, 4) clutch friction plate.
65.
Install the new low/reverse and forward (1, 2, 3, 4) clutch feed seals in the transaxle case. 66.
Apply 483 kPa (70 psi) of air pressure to the forward (1, 2, 3, 4) clutch piston port while recording the
clutch pack clearance on the dial indicator. The clearance should be between 0.076 mm (0.002 in) and
1.840 mm (0.072 in). If the clearance is out of range, check the forward (1, 2, 3, 4) clutch pack for
correct installation and the transaxle for correct assembly. If the forward (1, 2, 3, 4) clutch pack is
correctly installed, install a new forward (1, 2, 3, 4) clutch pack.
67.
Install the front planetary sun gear and shell assembly. 68.
Install the park pawl. 70.
Install the park pawl pin and spring. 71.
Install the park pawl actuator rod in the Transmission Range (TR) sensor. 72.
Position the park pawl aside and position the park pawl actuator rod and the TR sensor in the
transaxle case.
73.
Install the manual control shaft and align the roll pin holes. 74.
Install the manual control shaft roll pin. 75.
76.
Install the 5 new clutch feed seals. 77.
Position the transmission fluid baffle in place and install the 2 bolts.
78.
Position the lube funnel in place and install the 2 bolts.
79.
Simultaneously install the drive/driven sprocket and chain assembly. Lightly tap on the driven
sprocket to be sure it is fully seated in the case.
81.
Install the No. 13 thrust washer. 83.
Install the final drive sun gear. 84.
Install the differential assembly. 85.
Install the Turbine Shaft Seal Protector 307-635 on the input shaft. 87.
Clean the torque converter housing sealing surface. 88.
Assemble the Handle 205-153 and Differential Seal Installer 307-626. Install a new RH seal on the
Seal Installer 307-626.
89.
Using the Handle 205-153 and Differential Seal Installer 307-626, install the new RH halfshaft seal. 90.
Install a new RH seal on the RH Halfshaft Fluid Seal Installer 307-428. 91.
Using the RH Halfshaft Fluid Seal Installer 307-428, install the new RH halfshaft seal. 92.
All vehicles
Install the differential ring gear in the torque converter housing. 93.
NOTICE: Be sure the flat side of the beveled snap ring is facing down or the ring can come
loose, causing damage to the transaxle.
Install the beveled differential ring gear snap ring with the flat side facing down.
94.
Seat the snap ring using a suitable tool. 95.
Install the pump and filter assembly in the torque converter housing and install the 8 pump bolts.
96.
Install the transmission fluid baffle and the 2 bolts.
97.
NOTE: Be sure the sealing surfaces of the torque converter housing and the transaxle housing are
free of oil before applying silicone.
Apply silicone to the sealing surface of the transaxle case.
98.
NOTE: Be sure the stud bolt is in the correct location as noted during disassembly.
Install the torque converter housing on the transaxle case and install the 17 transaxle case-to-torque
converter housing bolts.
Stud bolt location. 2.
99.
Remove the Turbine Shaft Seal Protector 307-635. 100.
Install the Turbine Shaft Speed (TSS) sensor and the bolt.
101.
Install the Output Shaft Speed (OSS) sensor and the bolt.
102.
Assemble the bypass valve in the sleeve and install the assembly in the case.
Bypass valve 1.
Bypass valve sleeve 2.
103.
Install the bypass valve spring. 104.
Install the new main control-to-transaxle case separator plate and align it on the stud and the guide
pin.
105.
NOTE: Be sure that the manual pin (part of the TR sensor) is correctly installed in the manual valve.
Position the main control assembly in place and align the manual valve on the TR sensor.
106.
Install the nut hand-tight. 107.
Install the short bolts hand-tight. 108.
Install the long bolts hand-tight. 109.
Tighten the main control bolts and the nut in a crisscross pattern.
110.
Position the TR sensor detent spring in place with the alignment tab in the alignment hole and install
the bolt.
111.
NOTE: Be sure the solenoid body-to-main control cover seal is installed with the holes facing up.
Install the solenoid body-to-main control cover seal.
112.
NOTE: Install the main control cover stud bolts in the correct location as noted during disassembly.
Install the main control cover bolts.
Bolt location 1.
Stud bolt location 2.
118.
NOTICE: The torque converter is heavy. Be careful not to drop it or damage will result.
Using the Torque Converter Handle 307-091, install the torque converter.
119.
Remove the Torque Converter Handle 307-091. 120.
Install the Torque Converter Retainer 307-566. 121.
Remove the transaxle from the bench-mounted holding fixture. 122.
Remove the Holding Fixture 307-625. 123.
Workshop Manual
Transaxle - 2.5L
Special Tool(s)
300-OTC-1585AE
307-566
Support Bar, Engine
303-F072
Material
Item Specification
XT-10-QLVC
MERCON LV
XG-4 and/or XL-5
ESB-M1C93-B
TA-25
WSK-M2G351-A5
Installation
Transmission Fluid Cooler Backflushing and Cleaning in this section. Clean the transaxle-mounted
transmission fluid cooler tubes by hand.
Install the transmission fluid cooler tube bracket and the 2 nuts. 1.
Tighten to 9 Nm (80 lb-in). 2.
Install the transmission fluid cooler tubes in the transaxle by inserting the tube into the fitting until a
click is heard/felt. Pull back to confirm connection is secure and position them in the retainer mounted
on the main control cover studbolts.
2.
Install the 2 secondary latches. 3.
Position the transmission fluid cooler tubes in the retainers and close the 2 transmission fluid cooler
tube retainers.
4.
5.
Position the transmission fluid cooler tube in place and install the vent tube. 6.
Install the transmission fluid filler tube nut.
7.
Install the transmission fluid level indicator. 8.
Position the transaxle into the engine compartment. 11.
Remove the Torque Converter Retainer. 12.
NOTE: Make sure that the dowel pins are installed in the engine block prior to installing the
transaxle.
Position the transaxle on the dowel pins.
13.
NOTE: Note the location of the different length bolts. 14.
Install the 4 front torque converter housing bolts.
Install the 3 rear torque converter housing bolts.
15.
Remove the transmission jack. 16.
Connect the transmission fluid cooler tubes by inserting the tube into the fitting until a click is
heard/felt. Pull back to confirm that the connection is secure.
17.
Install the transmission fluid cooler tube secondary latches. 18.
Connect the Turbine Shaft Speed (TSS) electrical connector. 19.
Connect the transaxle main electrical connector. 20.
NOTICE: Rotate the engine in a clockwise direction only or engine damage will occur.
21.
Install the rubber insulator in the bellhousing. 22.
Install the starter motor. For additional information, refer to Section 303-06 . 23.
nuts and the bolt.
24.
Lift the transaxle until the transaxle support insulator bracket is aligned with the transaxle support
insulator, apply threadlock and sealant to the threads and install the through bolt.
25.
Place the subframe assembly on the Powertrain Lift With Tilting Plate and raise the subframe into the
installed position.
27.
28.
29.
30.
31.
32.
Install the Electronic Power Assist Steering (EPAS) system wiring harness ground and the bolt behind
the RH splash shield.
33.
shield.
34.
Connect the 2 in-line EPAS system electrical connectors at the front of the subframe. 36.
.
37.
42.
NOTICE: The steering gear/dash seal must be fully seated in the steering valve tower groove
before the retaining clips are fully engaged into the body. If the steering gear/dash seal is not
seated to the steering gear valve tower groove and the clips are not fully engaged to the body,
water and foreign material may enter the passenger compartment and damage the vehicle
interior can occur.
Apply hand force to the center of the seal, install the steering gear/dash seal onto the steering
gear valve tower until the seal is fully seated in the valve tower groove. Install the steering
gear/dash seal until the retaining clips are fully engaged into the body.

44.
Install the steering column shaft onto the steering gear and install a new bolt.
45.
Install the 3 top torque converter housing bolts.
47.
Connect the wiring harness retainers to the main control cover studbolts. 48.
49.
Section 307-05A .
50.
Install the Air Cleaner (ACL) and the outlet pipe. For additional information, refer to Section
303-12A .
52.
55.
If a replacement transaxle assembly is being installed or a new solenoid body is installed, the PCM
will have to be reflashed with a new solenoid body strategy and identification data file. For additional
information, refer to Solenoid Body Strategy in this section.
56.
57.
Workshop Manual
Transaxle - 3.0L
Special Tool(s)
303-1140
303-050 (T70P-6000)
Powertrain Lift
014-00765
307-566
Support Bar, Engine
303-F072
Material
Item Specification
XT-10-QLVC
MERCON LV
XG-4 and/or XL-5
ESB-M1C93-B
TA-25
WSK-M2G351-A5
Transmission Fluid Cooler Backflushing and Cleaning in this section.
All vehicles
Install the transmission fluid cooler tube bracket and the 2 nuts.
1.
2.
Install the 2 secondary latches. 3.
tube retainers.
4.
5.
Position the transmission fluid filler tube in place and install the vent tube. 6.
Install the transmission fluid filler tube nut.
7.
Install the transmission fluid level indicator. 8.
Position the transaxle into the engine compartment. 11.
Remove the Torque Converter Retainer. 12.
NOTE: Make sure that the dowel pins are installed in the engine block prior to installing the
transaxle.
Position the transaxle on the dowel pins of the engine.
13.
Install the 2 back torque converter housing bolts.
14.
Install the 2 bolts, 2 nuts and the stud in the front of the torque converter housing.
15.
Remove the transmission jack. 16.
heard/felt. Pull back to confirm connection is secure.
17.
Connect the Turbine Shaft Speed (TSS) electrical connector. 19.
Connect the transaxle main electrical connector. 20.
21.
Install the inspection cover. 22.
nuts and the bolt.
23.
Lift the transaxle until the transaxle support insulator bracket is aligned with the transaxle support
insulator, apply threadlock and sealant to the threads and install the through bolt.
24.
Remove the bolt and the Engine Lifting Bracket from the LH cylinder head. 26.
Remove the upper half of the Engine Lifting Bracket Set. 27.
Remove the lower half of the Engine Lifting Bracket Set. 28.
30.
31.
32.
33.
34.
35.
Attach the 3 wiring harness retainers to the LH front of the subframe. 36.
38.
If equipped, install the heat shield and the 2 bolts. 39.
Install the Power Transfer Unit (PTU). For additional information, refer to Section 308-07B . 40.
Install the RH exhaust manifold heat shield on the manifold and install the 5 bolts.
41.
Connect the RH Heated Oxygen Sensor (HO2S) electrical connector. 42.
Install the intermediate shaft. For additional information, refer to Section 205-04 . 43.
All vehicles
interior can occur.
51.

52.
Install the EGR valve bracket and install the 2 bolts.
54.
Install the EGR valve and tube. For additional information, refer to Section 303-08B . 55.
Install the 3 upper torque converter housing bolts.
56.
Connect the wiring harness retainer on the transmission fluid filler tube. 57.
Connect the wiring harness retainers to the main control cover studbolts. 58.
59.
Section 307-05A .
60.
Install the Air Cleaner (ACL) and the outlet pipe. For additional information, refer to Section
303-12B .
62.
65.
If a replacement transaxle assembly is being installed or a new solenoid body is installed, the PCM
will have to be reflashed with a new solenoid body strategy and identification data file. For additional
information, refer to Solenoid Body Strategy in this section.
66.
SECTION 307-01C: Automatic Transaxle/Transmission -
Electronically Controlled Continuously Variable Transmission
(eCVT)
2012 Fusion, MKZ, Fusion Hybrid,
MKZ Hybrid Workshop Manual
SPECIFICATIONS
Procedure revision date:
06/03/2011
Material
Capacity
XT-10-QLVC
MERCON
LV
4.05L
(4.28 qt)
a b
a
Transmission filled for life.
b
The correct transaxle fill level is to the bottom of the fill plug, which is the upper plug.
Item Specification
Weight
Engine and transaxle assembly weight 257 kg (567 lb)
Transaxle weight 136 kg (300 lb)
Battery Junction Box (BJB) bolt 10 - 89
Battery Junction Box (BJB) nut 10 - 89
Drain plug 40 30 -
Fill plug 40 30 -
Manual control lever nut 12 - 106
Roll restrictor bolts 90 66 -
Transaxle support insulator nuts 90 66 -
Transmission Range (TR) sensor bolts 5 - 44
nbsp;
(eCVT)
DESCRIPTION AND OPERATION
06/03/2011
Transaxle Components
The Electronically Controlled Continuously Variable Transmission (eCVT) has the following internal
components:
Traction motor
Generator
Planetary gearset
Range Selection
Park
With the range selector in PARK:
the parking pawl locks the output shaft to the case.
the ignition key can be removed.
the ignition switch can be cycled from OFF to START or RUN. The ready indicator l will illuminate
on the Instrument Cluster (IC) when the ignition switch is cycled to the START postion.

The ready indicator light is located on the lower right hand corner of the IC .
Ready Indicator Light
Reverse
With the range selector in REVERSE:
the vehicle may be operated in a rearward direction.
reversing lamps are illuminated.
if the ready indicator light is not illuminated, which lights when the ignition switch is cycled to the
START position, there is no reverse gear engagement.

Neutral
With the range selector in NEUTRAL:
no power flows through the transmission.
the output shaft is disengaged from the drive wheels.
Drive
The range selector DRIVE position provides:
low speed driving.
acceleration.
cruise conditions.
deceleration.
If the ready indicator light is not illuminated, which lights when the ignition switch is cycled to the START
position, there is no forward gear engagement.
Low
The range selector LOW position provides:
engine braking.
improved traction on slippery roads.
Brake Shift Interlock System
The brake shift interlock system prevents a shift out of PARK unless the brake pedal is depressed. The brake
shift interlock system has a Brake Shift Interlock Actuator (BSIA) mounted on the floor selector lever
assembly. If the ignition switch is in the RUN position, the BSIA is continually on unless the brake pedal is
depressed.
External Controls
The external control of the eCVT is mechanically controlled by a selector lever cable connected to the floor
selector lever. The floor selector lever position determines PARK, REVERSE, NEUTRAL, DRIVE and low
modes.
Motor Electronics Cooling System (MECS)
The vehicle uses a pump driven cooling system, referred to as the Motor Electronics Cooling System (MECS)
pump, to transfer heat generated by the eCVT and the Hybrid Electric Vehicle (HEV) DC/DC converter to the
atmosphere. The system uses a coolant-to-air radiator design.
Ready Indicator Light 4095
The MECS pump is an electric pump that runs any time the ignition is in the ON position. Unlike traditional
cooling systems, there is no thermostat in the MECS , so coolant flow should be continuous and considerably
less than traditional powertrain cooling systems.
The flow direction is from the DC/DC converter to the MECS pump through the eCVT , then through the
MECS cooler from the LH to RH side of the vehicle back to the DC/DC converter.
The MECS cooling pump will make an audible noise if it is running and a slight vibration may be felt by
touch.
The MECS cooling system has a coolant expansion tank mounted on top of the transaxle.
Item
Part
Number Description
1 8C045 Motor Electronics Cooling System (MECS) coolant
expansion tank
2 8C351 MECS coolant expansion tank outlet hose
3 8B273 Electronically Controlled Continuously Variable
Transmission (eCVT)-to- MECS cooler hose
4 8005 MECS cooler
5 8B274 MECS cooler-to-DC/DC converter tube/hose assembly
7 15179 DC/DC converter-to- MECS pump hose
8 8C419 MECS pump
9 8A567 MECS pump-to- eCVT hose
(eCVT)
DIAGNOSIS AND TESTING
06/03/2011
Diagnostics
Symptom Chart
Symptom Chart
elimination type of diagnostic approach to pinpoihe responsible system. If this is not the causal system for the
symptom, refer to Section 100-04 for the next likely system and continue diagnosis.
Clunk - occurs when shifting from PARK to a DRIVE or REVERSE position
Damaged transmission insulators
INSPECT the transmission insulators for damage. INSTALL new insulators as necessary. REFER to
Transaxle Support Insulator or Transaxle Support Insulator - Anti-Roll in this section.

Diagnostics 4098
(eCVT)
GENERAL PROCEDURES
06/03/2011
Material
Item Specification
XT-10-QLVC
MERCON
LV
100-02 .
1.
NOTE: If an integral problem is suspected, drain the transmission fluid through a paper filter. A
small amount of metal particles may be found from normal wear. However, if excessive metal
particles are present, internal service will be required.
Remove the drain plug and drain the transmission fluid.
4.
Remove the fill plug on the side of the transaxle. 5.
NOTE: After the transmission fluid has been drained, clean the drain plug threads.
NOTE: Inspect the plug and washer for damage and install a new plug if necessary.
6.
NOTICE: Use only clean transmission fluid specific for this transmission. Do not use any
supplemental transmission fluid additives or cleaning agents. The use of these products can
cause internal transmission components to fail, which will affect the operation of the
transmission.
Fill the transaxle with clean transmission fluid as specified until the level reaches the bottom of the
fill plug hole.
7.
NOTE: Clean the area around the fill plug removing transmission fluid that may have spilled on the
transaxle case.
Install the fill plug.
8.
Install the underbody cover and 7 screws. 9.
(eCVT)
IN-VEHICLE REPAIR
06/03/2011
Differential Seals - LH
Special Tool(s)
Handle
205-153 (T80T-4000-W)
Installer, Differential Seals RH and LH
307-665
308-375
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
XT-10-QLVC
MERCON
LV
Removal
100-02 .
1.
Remove the drain plug and drain the transmission fluid. 4.
Remove the LH halfshaft. For additional Information, refer to Section 205-04 . 5.
Using the Slide Hammer and Input Shaft Oil Seal Remover, remove and discard the LH differential
seal.
6.
Installation
Using the Differential Seal RH and LH Installer (two sided tool eCVT) and Handle, install the LH
differential seal.
1.
Clean the drain plug threads and install the drain plug.
3.
fill plug hole.
5.
transaxle case.
6.
NOTE: The check and fill plug is located on the left side of the transaxle near the front.
NOTE: The transmission fluid is checked and filled by removing the fill plug and adding
transmission fluid to the bottom of the fill plug hole.
Start the engine and check for correct forward and reverse operation.
7.
(eCVT)
IN-VEHICLE REPAIR
06/03/2011
Differential Seals - RH
Special Tool(s)
Handle, Driver 32 in
205-907
Installer, Differential Seals RH and LH
307-665
Remover, RH Halfshaft Fluid Seal
307-429
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
XT-10-QLVC
MERCON
LV
Removal
100-02 .
1.
Remove the drain plug and drain the transmission fluid. 4.
Differential Seals - RH 4105
Using the Slide Hammer and RH Halfshaft Fluid Seal Remover, remove and discard the RH
differential seal.
6.
Installation
Using the Differential Seal RH and LH Installer (two sided tool eCVT) and Driver 32 Inch Handle,
install the RH differential seal.
1.
Clean the drain plug threads and install the drain plug.
3.
fill plug hole.
5.
transaxle case.
6.
NOTE: The check and fill plug is located on the left side of the transaxle near the front.
NOTE: The transmission fluid is checked and filled by removing the fill plug and adding
transmission fluid to the bottom of the fill plug hole.
Start the engine and check for correct forward and reverse operation.
7.
(eCVT)
IN-VEHICLE REPAIR
06/03/2011
Removal
Disconnect the Transmission Range (TR) sensor electrical cotor. 3.
Remove the nut and the manual lever. 4.
Remove the 2 bolts, slide the TR sensor off of the manual shaft and remove the TR sensor. 5.
Transmission Range (TR) Sensor 4109
Installation
Position TR sensor on the manual shaft, align the 2 TR sensor bolt holes and install the 2 bolts.
1.
2.
Adjust the selector lever cable. For additional information, refer to Section 307-05B . Connect the
selector lever cable end.
4.
(eCVT)
IN-VEHICLE REPAIR
06/03/2011
Special Tool(s)
Support Bar, Engine
303-F072
Item Part Number < Description
1 W520214 Transaxle support insulator nuts
2 14A464 Transaxle support insulator
Remove the Air Cleaner (ACL) assembly. For additional information, refer to Section 303-12D . 1.
Install the Engine Support Bar and support the engine and transaxle. 2.
Disconnect the hood ajar electrical connector. 3.
Remove the bolt and the nut and position aside the Battery Junction Box (BJB).
4.
Remove the 5 nuts and remove the transaxle support insulator and the bracket.
5.
(eCVT)
IN-VEHICLE REPAIR
06/03/2011
Transaxle Support Insulator - Anti-Roll
1 W706674 Rear roll restrictor bolt
2 W500545 Front roll restrictor bolt
3 6P082 Roll restrictor assembly
Removal
100-02 .
1.
Remove the 2 bolts and remove the roll restrictor. 3.
Installation
Position the roll restrictor in place and install the 2 bolts. 1.
(eCVT)
REMOVAL
06/03/2011
Transaxle
NOTICE: Do not drain the oil when removing the engine to service the transaxle.
To remove the transaxle, follow the engine removal procedure. For additional information, refer to
Section 303-01D . Before removing the engine and transaxle from the vehicle, remove the drain plug
and drain the transmission fluid.
1.
Transaxle 4116
(eCVT)
INSTALLATION
06/03/2011
Transaxle
To install the transaxle, follow the engine installation procedure. For additional information, refer to
Section 303-01D .
1.
Transaxle 4117
SECTION 307-02A: Transaxle/Transmission Cooling -
Aisin AW21/6F35
Material
Capacity
XT-10-QLV
MERCON LV 8.5L (9 qt)
a
Transmission Fluid
XT-8-QAW (US);
WSS-M2C924-A 7.0L (7.4
qt)
b
a
6F35 Transaxle
b
Aisin AW21 Transaxle
Item Specification
Fluid
The use of any
transmission fluid
other than what is
recommended for
this transaxle will
cause transaxle
damage. Refer to
the material
specificatthe
correct fluid. The
transmission fluid
should be changed
every 96,560 km
(60,000 mi)
regardless of
normal or special
operating
conditions.
NOTICE: The
transmission
fluids used in the
6F35 and AW21
transaxles are
unique and are
not
interchangeable.
Transaxle 4118
NOTICE: Do not
use water-based
cleaners to clean
or flush the
transmission fluid
cooler tubes or
transmission
damage will
occur. Mineral
spirits can be used
to clean the
transmission fluid
cooler tubes,
providing the
transmission fluid
cooler tubes are
flushed with clean
automatic
transmission fluid
and blown dry
with shop air. Use
only clean
automatic
transmission fluid
designated for this
transaxle and
torque converter
being serviced.
Transmission fluid cooler tubes 10 - 89
Transmission fluid cooler tubes (at the radiator) 20 - 177
Transmission fluid fill plug (Aisin AW21) 39 29 -
Transaxle 4119
Transaxle 4120
Aisin AW21/6F35
Transaxle Cooling - Aisin AW21
These vehicles are equipped with an internal transmission fluid cooler. The transmission fluid cooler is
mounted in the engine radiator tank. During operation, transmission fluid travels from the transaxle to the
transmission fluid cooler, then back to the transaxle. The transmission fluid cooler transfers heat from the
transmission fluid to the engine coolant.
1 8005 Radiator
2 7H420 Transmission fluid e assembly
3 19710-A Transmission mounted fluid cooler tube
Transaxle Cooling - Aisin AW21 4121
Aisin AW21/6F35
These vehicles are equipped with an internal transmission fluid cooler. The transmission fluid cooler is
mounted in the engine radiator tank. During operation, transmission fluid travels from the transaxle to the
transmission fluid cooler, then back to the transaxle. The transmission fluid cooler transfers heat from the
transmission fluid to the engine coolant.
Transaxle Cooling
Item
Part
Number Description
1 8005 Radiator
2 7R081 Transmission fluid cooler supply tube assemblyes
transmission fluid to the transmission fluid cooler from
the transaxle)
3 7R081 Transmission fluid cooler return tube assembly
(transmission fluid return tube from the transmission fluid
cooler to the transaxle)
4 7J081 Transmission fluid cooler tube secondary latches
5 7H420 Transaxle mounted transmission fluid cooler tubes
Transaxle Cooling 4124
Aisin AW21/6F35
Special Tool(s)
Material
Item Specification
Transmission Fluid
(Canada)
WSS-M2C924-A
Verify mer concern by operating the vehicle to duplicate the condition. 1.
If the inspection reveals an obvious concern(s) that can be readily identified, repair as necessary. 2.
Install new components if a transmission fluid leak is found in any of the transaxle cooling
components.
3.
If the concern(s) remains after the inspection, determine the symptom(s). GO to Symptom Chart -
Transaxle Cooling or GO to Symptom Chart - NVH .
4.
Symptom Chart - Transaxle Cooling
Symptom Chart - NVH
Symptom Chart - NVH
Vibration - a high frequency (20-80 Hz) that is felt through the seat or selector lever. Changes with
engine speed

Transmission fluid cooler tubes grounded
CHECK the transmission fluid cooler tubes. REPAIR as necessary.
Check Transmission Fluid Level and Condition
transmission fluid below the minimum fluid level mark or internal failure may result.
If the vehicle has been operated for an extended period of time at highway speeds, in city traffic, in hot
range.
NOTE: The transmission fluid should be checked at normal operating temperature 60C-70C (140F-158F)
on a level surface. Normal operating temperature can be reached after approximately 32 km (20 mi) of driving
and can be checked using the scan tool.
Under normal circumstances the transmission fluid level should be checked during normal maintenance. If the
transaxle starts to slip, shifts slowly or shows signs of transmission fluid leaking, the transmission fluid level
should be checked.
With the transaxle in PARK, the engine at idle, foot pressed on the brake, move the selector lever
through each gear and allow engagement of each gear. Place the selector lever in the PARK position.
1.
Install the transmission fluid level indicator back in the fluid indicator tube until it is fully seated, then
remove the indicator. The transmission fluid level should be within the normal operating range.
4.
Item
Part
Number Description
1 - Transmission fluid level at operating temperature
60C-70C (140F-158F)
2 - Transmission fluid level cool 15C-25C (59F-77F)
3 - Do not drive mark
A transmission fluid level that is too high may cause the transmission fluid to become aerated due to the
is indicated, refer to Section 307-01A .
A low transmission fluid level could result in poor transaxle engagement, slipping, malfunction and/or
damage. This could also indicate a leak in one of the transaxle seals or gaskets.
NOTICE: The use of any fluid other than what is recommended for this transaxle will cause transaxle
damage.
indicator tube. Do not overfill the transaxle. For transmission fluid type, refer to the specification chart in this
section.
Observe the color and the odor. The color under normal circumstances should be a dark red color, not
brown or black or have a burnt odor.
2.
3.
inspection.
4.
If the stain is a foamy pink color, this may indicate coolant in the transaxle. The engine cooling
system should also be inspected at this time.
5.
the fluid pan, install a new transaxle. If installing a new transaxle, the transmission fluid cooler and
transmission fluid cooler tubes should be cleaned.
6.
If the transaxle is to be overhauled or if installing a new transaxle, the fluid cooler must be
backflushed. Refer to Section 307-01A .
7.
Aisin AW21/6F35
Special Tool(s)
Material
Item Specification
XT-10-QLV
MERCON
LV
Verify the customer concern by operating tto duplicate the condition. 1.
If the inspection reveals obvious concern(s) that can be readily identified, repair as necessary. 2.
Install new components if a transmission fluid leak is found in any of the transaxle cooling
components.
3.
If the concern(s) remains after the inspection, determine the symptom(s). GO to Symptom Chart -
Transaxle Cooling or GO to Symptom Chart - NVH .
4.
Symptom Chart - NVH
Symptom Chart - NVH
Vibration - a high frequency (20-80 Hz) that is felt through the seat or selector lever. Changes with
engine speed

Transmission fluid cooler tubes grounded
CHECK the transmission fluid cooler tubes. REPAIR as necessary.
Check Transmission Fluid Level and Condition (All Vehicles)
transmission fluid below the minimum transmission fluid level mark or internal failure could result.
If the vehicle has been operated for an extended period of time, at highway speeds, in city traffic, in hot
range.
NOTE: The transmission fluid should be checked at normal operating temperature 85C-93C (185F-200F)
on a level surface. Normal operating temperature can be reached after approximately 32 km (20 mi) of driving
and can be checked using the scan tool.
Under normal circumstances the transmission fluid level should be checked during normal maintenance. If the
transaxle starts to slip, shifts slowly or shows signs of transmission fluid leaking, the transmission fluid level
should be checked.
With the transaxle in PARK, gine at idle, foot pressed on the brake, move the selector lever through
each gear and allow engagement of each gear. Place the selector lever in the PARK position.
1.
seated, then remove the indicator. The transmission fluid level should be within the crosshatch.
4.
Item Description
1 Correct transmission fluid level at operating temperature 85C-93C (185F-200F)
2 Minimum transmission fluid level mark
3 Maximum transmission fluid level mark
4 Flat tow transmission fluid level
High Transmission Fluid Levelb>
A transmission fluid level that is too high may cause the transmission fluid to become aerated due to the
is indicated, refer to Section 307-01B .
A low transmission fluid level could result in poor transaxle engagement, slipping, malfunction and/or
damage. This could also indicate a leak in one of the transaxle seals or gaskets.
NOTICE: Automatic transmission fluids are not interchangeable. The use of any fluid other than what
is recommended for this transaxle will cause transaxle damage.
transmission fluid level indicator tube with the selector lever in PARK and the engine idling. Do not overfill
the transmission fluid. For transmission fluid type, refer to the material chart in this section.
Flat Tow Fluid Level
Recreational flat towing of the vehicle may require the transmission fluid to be set to a lower fluid level. This
will prevent damage to the transmission. The transmission fluid level is within the normal operating range and
will not require the transmission fluid level to be readjusted after recreational towing.
Observe the color and the odor. The color under normal circumstances should be a dark red color, not
brown or black or have a burnt odor.
2.
3.
inspection.
4.
the transmission fluid pan, repair the transaxle and clean the transmission fluid cooler tubes and the
transmission fluid cooler.
5.
If the transaxle is to be overhauled or if installing a new transaxle, the transmission fluid cooler must
be backflushed. Refer to Section 307-01B .
6.
Aisin AW21/6F35
Transmission Fluid Cooler
NOTE: The transmission fluid cooler is mounted in the radiator tank and cannot be serviced
separately.
Install a new radiator. For additional information, refer to Section 303-03A .
1.
Transmission Fluid Cooler 4133
Aisin AW21/6F35
Transmission Fluid Cooler Tubes - Aisin AW21
Material
Item Specification
Transmission Fluid
(Canada)
WSS-M2C924-A
Transmission Fluid Cooler Tubes - Aisin AW21
1 M52923 Transmission fluid cooler tube radiator fittings
2
3 7H420 Transmission fluid cooler tube assembly
4 19710-A Transmission fluid cooler tube fittings at the transaxle
6 256679 Transmission fluid cooler tube retaining clip
Removal
Transmission Fluid Cooler Tubes - Aisin AW21 4134
100-02 .
1.
Disconnect the upper transmission fluid cooler tube from the radiator. 2.
Remove the bolts and the splash shield. 3.
Remove the front splash shield.
Remove the 2 screws. 1.
Remove the 4 retainers. 2.
Remove the 4 bolts and the splash shield. 3.
4.
Disconnect the lower transmission fluid cooler tube from the radiator. 5.
NOTICE: Use care not to overstretch or extend the hose clamps as damage may occur to the
hose clamp and cause a leak.
6.
NOTICE: The hose clamps are held on the hose with a special epoxy. Damage may occur to the
hose if the clamp is removed from the hose. If the clamp or hose is damaged, install a new fluid
cooler tube.
Disconnect the transmission fluid cooler hoses from the transmission fluid cooler tubes.
Remove the 2 bolts and remove the transmission fluid cooler tubes. 7.
NOTE: When removing the transmission fluid cooler tubes from the retainers, do not remove the
retainers from the shroud.
Remove the transmission fluid cooler tubes from the retainers.
8.
Remove the transmission fluid cooler tube retainer and remove the transmission fluid cooler tubes. 9.
Installation
Install new O-rings on the transmission fluid cooler tubes. 1.
Install the transmission fluid cooler tubes.
2.
Position the transmission fluid cooler tubes in place and install the retainer. 3.
Install the transmission fluid cooler tubes in the retainers. 4.
NOTE: The power steering hose is routed between the 2 transmission fluid cooler hoses.
Position the transmission fluid cooler hoses in place.
5.
NOTICE: Use care not to overstretch or extend the hose clamps as damage may occur to the
hose clamp and cause a leak.
NOTICE: The hose clamps are held on the hose with a special epoxy. Damage may occur to the
hose if the clamp is removed from the hose. If the clamp or hose is damaged, install a new fluid
cooler tube.
6.
Connect the transmission fluid cooler hoses to the transmission fluid cooler tubes.
Install the lower transmission fluid cooler tube in the radiator.
7.
Install the front splash shield.
Position the splash shield in place and install the 2 screws. 1.
Install the 4 retainers. 2.
Install the 4 bolts. 3.
8.
Install the bolts and the splash shield. 9.
Install the upper transmission fluid cooler tube in the radiator.
10.
NOTE: Transmission fluid level at normal operating temperature is between the top 2 marks on the
fluid level indicator.
Check the transmission fluid level and add transmission fluid as necessary.
12.
13.
Aisin AW21/6F35
Transmission Fluid Cooler Tubes - 6F35
Special Tool(s)
307-569
Material
Item Specification
XT-10-QLV
MERCON
LV
Transmission Fluid Cooler Tubes
1 - Transmission fluid cooler tube nut (part of 7H420)
2 7B407 Radiator splash shield
3 - Transmission fluid cooler tube nut (part of 7H420)
4 7J081 Transmission fluid cooler tube secondary latches
5 7R081 Transmission fluid cooler supply tube
6 7R081 Transmission fluid cooler return tube
Transmission Fluid Cooler Tubes - 6F35 4141
8 256679 Transmission fluid cooler tube retaining clip
9 - Transmission fluid cooler tube retainer (part of 7H420)
10 - Transmission fluid cooler tube retainer (part of 7H420)
11 7H420 Transaxle mounted transmission fluid cooler return
tube
12 7H420 Transaxle mounted transmission fluid cooler supply
tube
Removal
NOTICE: Automatic transmission fluids are not interchangeable. The use of any fluid other than what
is recommended for this transaxle will cause transaxle damage.
With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to 1.
Disconnect the upper transmission fluid cooler tube from the radiator. 2.
Remove the radiator splash shield.
4.
Disconnect the lower transmission fluid cooler tube from the radiator. 5.
Transmission Fluid Cooler Tubes 4142
NOTE: When removing the transmission fluid cooler tubes from the retainers, do not remove the
retainers from the shroud.
Release the transmission fluid cooler tube retainers and remove the transmission fluid cooler tubes
from the retainers.
8.
Remove the transmission fluid cooler tube retainer and remove the transmission fluid cooler tubes
from the vehicle.
9.
303-12A or Section 303-12B .
10.
Remove the 2 transmission fluid cooler tube secondary latches. 13.
14.
Installation
1.
Install the 2 transmission fluid cooler tube secondary latches. 2.
tube retainers.
3.
Install the ACL and the outlet pipe. For additional information, refer to Section 303-12A or Section
303-12B .
5.
Position the transmission fluid cooler tubes in place in the vehicle and install the retainer. 6.
Position the transmission fluid cooler tubes in the retainers and close the retainers. 7.
heard/felt. Pull back to confirm that the connection is secure.
8.
Install the lower transmission fluid cooler tube in the radiator.
10.
Install the radiator splash shield
Install the 6 screws. 1.
Install the 4 retainers. 2.
11.
If equipped, install the bolts and the splash shield. 12.
Install the upper transmission fluid cooler tube in the radiator.
13.
15.
bsp;
SECTION 307-02B: Transaxle/Transmission Cooling -
Hybrid
Material
Motorcraft Specialty
Green Engine Coolant
VC-10-A2 (US);
CVC-10-A (Canada)
WSS-M97B55-A 2.75L (2.9 qt)
approximate dry fill
capacity
a b
Motorcraft Specialty
Orange Engine
Coolant
VC-3-B (US);
CVC-3-B (Canada)
WSS-M97B44-D 2.75L (2.9 qt)
approximate dry fill
capacity
a
a
Vehicles (built on or after July 6, 2009 through June 5, 2011) cooling systems are filled with Motorcraft
Specialty Green Engine Coolant. Vehicles (built on or after June 6, 2011) are filled with Motorcraft
Specialty Orange Engine Coolant. Mixing coolant types degrades the corrosion protection of the coolant. Do
not mix coolant types. Failure to follow these instructions may result in engine or cooling system damage.
b
Genuine Mazda Extended Life Coolant and Motorcraft Specialty Green Engine Coolant are very
sensitive to light. Do NOT allow these products to be exposed to ANY LIGHT for a day or two. Extended
light exposure causes these products to degrade.
Motor Electronics Cooling System (MECS) bleed screw 3 27
MECS cooler hose bolt 15 133
MECS coolant expansion tank bolt 8 71
MECS coolant expansion tank nut 8 71
MECS radiator bolts 8 71
Hybrid
Transaxle Cooling
Motor Electronics Cooling System (MECS)
The vehicle uses a pump driven cooling system, referred to as the Motor Electronics Cooling System (MECS)
pump, to transfer heat generated by the Electronically Controlled Continuously Variable Transmission
(eCVT) and the Hybrid Electric Vehicle (HEV) DC/DC converter to the atmosphere. The system uses a
coolant-to-air radiator design.
The MECS pump is an electric pump that runs any time the ignition is in the ON position. Unlike traditional
cooling systems, there is no thermostat in the MECS , so coolant flow should be continuous and considerably
less than traditional powertrain cooling systems.
The flow direction is from the DC/DC converter to the MECS pump through the eCVT , then through the
MECS cooler from the LH to RH side of the vehicle back to the DC/DC converter.
The MECS cooling pump will make an audible noise if it is running and a slight vibration may be felt by
touch.
The MECS cooling system has a coolant expansion tank mounted on top of the transaxle.
Item
Part
Number Description
1 8C045 Motor Electronics Cooling System (MECS) coolant
expansion tank
3 8B273 Electronically Controlled Continuously Variable
Transmission (eCVT)-to- MECS cooler hose
4 8005 MECS radiator
5 8B274 MECS cooler-to-DC/DC converter tube/hose assembly
7 15179 DC/DC converter-to- MECS pump hose
8 8C419 MECS pump
9 8A567 MECS pump-to- eCVT hose
10 W710743 MECS bleed screw
Hybrid
Transaxle Cooling
Special Tool(s)
Flex Probe Kit
105-R025D
Motor Electronics Cooling System (MECS) component
damage:
Motor electronics radiator
MECS coolant hoses
MECS coolant pump

Coolant leaks
(15A)

BJB fuse 47 (10A)
MECS cooling pump relay ( BJB
relay 44)

Wiring harness
Connector
Circuitry
Symptom Chart - NVH
Symptom Chart - NVH
Vibration - a high frequency (20-80 Hz) that is felt through the seat or selector lever
Motor Electronics Cooling System (MECS) pump
CHECK the MECS pump. INSTALL a new pump as necessary.
Pinpoint Tests
Pint Test A: MECS Cooling Pump Fault
Refer to Wiring Diagrams Cell 54 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Climate Control for
Normal Operation
The Motor Electronics Cooling System (MECS) pump is electrically driven and controlled by the PCM
through the MECS pump relay. The PCM energizes the MECS pump relay by pulling the MECS pump output
to ground when the ignition is in the ON position.
BJB fuse 47 (10A)
MECS coolant pump
Wiring
MECS coolant pump relay
PINPOINT TEST A: MECS COOLING PUMP FAULT
NOTICE: Use the Flex Probe Kit for all test connections to prevent damage to the wiring terminals. Do
not use standard multi-meter probes.
A1 CHECK FOR DTCs
tool: RETRIEVE.

Carry out the PCM on-demand self test.
Are DTCs retrieved?
Yes
REFER to Section 307-01C .
No
GO to A2 .
A2 CHECK BJB FUSE 13 (15A)
Check fuse: BJB 13 (15A).
Yes
GO to A5 .
No
GO to A3 .
A3 CHECK THE MECS COOLANT PUMP
RELAY POWER SUPPLY CIRCUIT FOR A
SHORT TO GROUND
Disconnect: BJB Fuse 13 (15A).
Disconnect: BJB Relay 44.
Disconnect: BJB Relay 42.
Measure the resistance between the output side of
BJB fuse 13 (15A) and ground.

Yes
GO to A4 .
No
REPAIR circuit SBB13 (GY/RD) for a short
to ground. CONNECT all components. TEST
A4 CHECK THE MECS COOLANT PUMP AND
HEATER PUMP POWER SUPPLY CIRCUITS FOR
A SHORT TO GROUND
Disconnect: MECS Coolant Pump C1466.
Disconnect: Heater Pump Motor C1450.
Measure the resistance between BJB relay 44 pin
5 circuit CE621 (YE/GY), BJB side and ground.

5 circuit CHC01 (BN/YE), BJB side and ground.

Yes
The condition that caused BJB fuse 13 (15A)
to blow is not present. Inspect the wiring
harness for an intermittent condition. Repeat
test Steps A3 and A4 while wiggling the
vehicle wiring harness and visually checking
for damage.
No
REPAIR circuit CE621 (YE/GY) or CHC01
(BN/YE) for a short to ground. CONNECT all
operation.
RELAY ( BJB RELAY 44)
PINPOINT TEST A: MECS COOLING PUMP FAULT 4154
Carry out the relay component test.
component testing.

Is MECS pump relay ( BJB relay 44) OK?
Yes
GO to A6 .
No
INSTALL a new MECS pump relay ( BJB
relay 44). TEST the system for normal
operation.
RELAY POWER SUPPLY CIRCUIT FOR AN
OPEN
Measure the resistance between BJB fuse 13
(15A) circuit CE621 (YE/GY), BJB side and BJB
relay 44 pin 5 circuit CE621 (YE/GY), BJB side.

Yes
GO to A7 .
No
REPAIR circuit CE621 (YE/GY) for an open.
CONNECT all components. TEST the system
POWER SUPPLY CIRCUIT FOR AN OPEN
5 circuit CE621 (YE/GY), BJB side and MECS
coolant pump C1466-2, circuit CE621 (YE/GY).

Yes
GO to A8 .
No
REPAIR circuit CE621 (YE/GY) for an open.
Measure the resistance between MECS coolant
pump 1466-1 circuit GD121 (BK/YE) and
ground.

Yes
GO to A9 .
No
REPAIR circuit GD121 (BK/YE).
A9 CHECK BJB FUSE 47 (10A)
Check fuse: BJB 47 (10A).
Yes
GO to A10 .
No
REPAIR circuit CBK03 (GY) for a short to
ground. CONNECT all components. TEST
A10 CHECK FOR VOLTAGE SUPPLIED TO BJB
FUSE 47 (10A)
Ignition ON.
Measure the voltage at the supply side of BJB
fuse 47 (10A).

Yes
GO to A11 .
No
REPAIR circuit CE612 (GY/VT) for an open.
RELAY CONTROL POWER SUPPLY CIRCUIT
FOR AN OPEN
Ignition OFF.
Measure the resistance between the output side of
BJB fuse 47 (10A), circuit CBK03 (GY) and BJB
relay 44 pin 1 circuit CBK03 (GY).

Yes
GO to A12 .
No
REPAIR circuit CBK03 (GY) for an open.
A12 CHECK FOR GROUND AT THE MECS
COOLANT PUMP RELAY
Connect: BJB fuse 47 (10A).
Ignition ON.
Measure the voltage between BJB relay 44 pins 1
and 2, BJB side.

Yes
INSTALL a new MECS pump. REFER to
Motor Electronics Pump in this section.
No
GO to A13 .
RELAY CONTROL GROUND CIRCUIT FOR AN
OPEN
Ignition OFF.
2, BJB side circuit CE318 (VT) and PCM
C175T-49 circuit CE318 (VT).

Yes
303-14D . CONNECT all components. TEST
No
REPAIR circuit CE318 (VT) for an open.
Hybrid
Motor Electronics Cooling System Draining and Filling
Material
Item Specification
Engine Coolant
VC-10-A2 (US); CVC-10-A
(Canada)
WSS-M97B55-A
Engine Coolant
WSS-M97B44-D
Draining
NOTICE: The coolant must be recovered in a suitable, clean container for reuse or damage can occur to
the transaxle cooling system. If the coolant is contaminated, it must be recycled or disposed of correctly.
NOTICE: Always refill the Motor Electronics Cooling System (MECS) with the same type of coolant
that was drained from the system. Do not mix coolant types. Mixing coolant types may cause MECS
damage.
he vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 . 1.
Compress the constant tension clamps and remove the hoses from the transaxle to allow the coolant to
drain.
4.
Connect the hoses to the transaxle and install the hose clamps. 5.
Motor Electronics Cooling System Draining and Filling 4159
Filling and Bleeding
NOTICE: Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion
protection to the engine and cooling components. In order to obtain these protections, the engine
coolant must be maintained at the correct concentration and fluid level in the degas bottle. When
adding engine coolant, use a 50/50 mixture of engine coolant and distilled water.
Vehicle cooling systems are filled with Motorcraft Specialty Green Engine Coolant or Motorcraft
Specialty Orange Engine Coolant. Always fill the cooling system with the same coolant that is present
in the system. Do not mix coolant types.

Do not add alcohol, methanol or brine, or any engine coolants mixed with alcohol or methanol

Ford Motor Company does NOT recommend the use of recycled engine coolant since a
Ford-approved recycling process is not yet available.

Used engine coolant should be disposed of in an appropriate manner. Follow community regulations
and standards for recycling and disposing of automotive fluids.

NOTICE: Adhesives, stop-leak pellets or small foreign material in the Motor Electronics
Cooling System (MECS) can cause poor performance or temporary blockage of the motor
electronics pump. Only use clean, approved coolant when filling the system.
Loosen the Motor Electronics Cooling System (MECS) bleed screw on the DC/DC converter and
slowly fill the coolant expansion tank with coolant until it begins to flow out of the bleed hole. Then,
close the bleed screw.
1.
Turn the ignition to the ON position to actuate the MECS coolant pump and continue to fill the
coolant expansion tank to the FULL COLD level labeled on the side of the tank.
2.
To bleed air from the MECS , turn the ignition switch to the OFF position. Loosen the MECS bleed
screw on the DC/DC converter and allow air to escape the MECS .
3.
Hybrid
Motor Electronics Coolant Expansion Tank
Item
Part
Number Description
1 W505424 Motor Electronics Cooling System (MECS) coolant
expansion tank bolt
2 W701152 MECS coolant expansion tank nut
3 W701152 MECS coolant expansion tank
Drain the Motor Electronics Cooling System (MECS). For additional information, refer to Motor
Electronics Cooling System Draining and Filling in this section.
1.
Remove the nut and the bolt and position the MECS coolant expansion tank aside.
2.
Compress the constant tension clamp and remove the MECS hose from the coolant expansion tank. 3.
Motor Electronics Coolant Expansion Tank 4162
Motor Electronics Coolant Expansion Tank 4163
Hybrid
Motor Electronics Cooler
1 8B273 Motor Electronics Cooling System (MECS)
radiator inlet hose
2 N808349 MECS radiator outlet tube bolt
3 8B274 MECS radiator outlet ho
4 W711685-S MECS radiator bolts
5 8005 MECS radiator
1.
Remove the 4 bolts and the 2 retainers and position the front grille aside far enough to gain access to
the MECS radiator. For additional information, refer to Section 501-19 .
2.
Remove the bolt and remove the upper MECS radiator tube from the MECS cooler.
3.
Motor Electronics Cooler 4164
Remove the radiator splash shield.
4.
Compress the constant tension clamp and disconnect the MECS radiator hose from the MECS
radiator.
5.
Remove the MECS radiator bolts and remove the radiator.
6.
Hybrid
Motor Electronics Pump
Item
Part
Number Description
1 14A464 Motor Electronics Cooling System (MECS) coolant
pump electrical connector
2 8A567 MECS coolant pump outlet hose
3 15179 MECS coolant punlet hose
4 8C419 MECS pump
1.
Disconnect the MECS cooling pump electrical connector. 2.
Compress the 2 retainers, remove the MECS pump from the bracket and pull the MECS pump down
to gain access to the constant tension clamps that hold the hoses on.
3.
Compress the constant tension clamps and disconnect the inlet and outlet hoses from the MECS
pump.
4.
Motor Electronics Pump 4167
SECTION 307-05A: Automatic Transaxle/Transmission External
Controls - Aisin AW21/6F35
SPECIFICATIONS
06/03/2011
Selector lever cable grommet nuts 9 80
Selector lever nuts 20 177
DESCRIPTION AND OPERATION
06/03/2011
External Controls
Item
Part
Number Description
1 7L010 Selector lever knob (vehicles equipped with a 3.5L
engine)
2 7L010 Selector lever knob (vehicles equipped with a 2.5L
engine)
3 - Transmission Control Switch (TCS) (2.5L engine) (part
of 7L010)
4 7L010 Selector lever knob (vehicles equipped with a 2.5L or
3.0L (4V) engine)
5 - SelectShiftTM switch (2.5L or 3.0L (4V) engine) (part
of 7L010)
6 - Lower selector lever knob bezel (part o
7 7E034 Selector lever bezel (Fusion)
8 7K004 Selector lever assembly (Fusion)
9 7E034 Selector lever bezel (MKZ)
10 7K004 Selector lever assembly (MKZ)
External Controls 4170
12 57809 Selector lever cable grommet
13 - Selector lever cable end (Aisin AW21) (part of 7E395)
14 - Selector lever cable adjustment lock tab (Aisin AW21)
(part of 7E395)
15 7A257 Manual control lever (Aisin AW21)
16 - Selector lever cable end (6F35) (part of 7E395)
17 - Selector lever cable adjustment lock tab (6F35) (part of
7E395)
18 7A257 Manual control lever (6F35)
The transaxle selector lever control linkage consists of:
a selector lever cable that connects the transaxle range selector lever to the selector lever assembly.
a Brake Shift Interlock Actuator (BSIA) that is integral to the selector lever assembly.
The selector lever assembly:
locks the transaxle range selector lever in the PARK position when the ignition switch is in the lock
position.

requires the transaxle range selector lever to be in the PARK position to turn the ignition switch to the
lock position.

Transmission Control Switch (TCS)-2.5L
Vehicles equipped with a Transmission Control Switch (TCS) have a momentary contact switch located on
the selector lever knob that allows the driver to cancel the operation of Overdrive (O/D) and provides grade
assist.
Grade Assist
Improves vehicle handling in hilly terrain or mountainous areas by providing additional engine
braking and extends lower gear operation on uphill climbs.

Additional engine braking is provided through the automatic transaxle shift strategy which reacts to
vehicle inputs including vehicle acceleration, accelerator pedal, brake pedal and vehicle speed.

The transaxle will select gears that will provide the engine braking desired, based on the vehicle
inputs, this will increase engine rpm during engine braking.

It is recommended to return to DRIVE mode on flat terrain to provide the best fuel economy and transaxle
function. The transaxle returns to O/D and grade assist is cancelled when the TCS is pressed again.
Range Selection-SelectShiftTM
The H-gate selector lever has 5 fixed range positions: P, R, N, D, M and 2 spring-loaded manual positions (-)
and (+).
Transmission Control Switch (TCS)-2.5L 4171
H-Gate Selector-3.5L
The SelectShiftTM switch selector lever has 5 fixed range positions: P, R, N, D, M and a (-) and (+)
SelectShiftTM switch.
SelectShiftTM Switch Selector-2.5L, 3.0L (4V)
Park
In the P position:
the transaxle is locked and prevents the wheels from turning.
the parking pawl locks the final drive.
the ignition key may be removed.
Reverse
In the R position:
the vehicle may be operated in a backward direction, at a reduced gear ratio.
engine braking will occur.
Neutral
In the N position:
the vehicle is able to roll.
the output shaft is not held and is free to turn.
Drive
D is the normal position for most forward driving.
H-Gate Selector-3.5L 4172
D provides:
automatic shifts - 1st through 6th gears, which includes O/D .
apply and release of the Torque Converter Clutch (TCC).
Ma/b>
H-Gate
SelectShiftTM Switch
In the M position:
O/D is cancelled.
the 6F35 transaxle operates in gears 1st through 5th and the Aisin AW21 operates in gears 1st through
4th.

grade assist is activated.
some engine braking may occur.
SelectShiftTM Shift Transmission Selector Lever-H-Gate
The SelectShiftTM shift transmission selector lever gives the driver the ability to change gears up or down
manually as desired.
- M +
O/D can be selected.
SelectShiftTM Switch Selector-2.5L, 3.0L (4V) 4173
Moving the selector lever to the forward (-) or backward (+) position will allow the transmission to
utilize the Manual for SelectShiftTM shifting.

Moving the spring-loaded selector lever forward into (-) in the gate and releasing the selector lever,
the selector lever will return to the M position and the transmission will down shift.

Moving the spring loaded selector lever backward into (+) in the gate and releasing the selector lever,
the selector lever will return to the M position and the transmission will up shift.

When selecting the appropriate gear in SelectShiftTM transmission mode, the instrument cluster will display
the current selected gear.
The SelectShiftTM shift transmission will make some shifts automatically, primarily to protect the engine
from stalling.
The transmission will not up shift if the redline is approached and must be shifted manually by moving the
selector lever back into (+) and releasing.
SelectShiftTM Transmission Selector Lever-SelectShiftTM Switch
The SelectShiftTM transmission selector lever gives the driver the ability to change gears up or down
manually as desired.
- M +
O/D can be selected.
Moving the selector lever to M position will allow the transmission to utilize the Manual Mode for
SelectShiftTM shifting.

Pressing the SelectShiftTM switch (-) on the selector lever, the transmission will down shift.
Pressing the SelectShiftTM switch (+) on the selector lever, the transmission will up shift.
When selecting the appropriate ectShiftTM transmission mode, the message center will display the current
selected gear.
The SelectShiftTM shift transmission will make some shifts automatically, primarily to protect the engine
from stalling.
The transmission will not up shift if the redline is approached and must be shifted manually by pressing the
SelectShiftTM switch (+) on the selector lever and releasing.
Gear Availability
SelectShiftTM Switch 4174
SelectShiftTM Switch 4175
DIAGNOSIS AND TESTING
06/03/2011
External Controls
Special Tool(s)
<
If an obvious cause for an observed or reported concern is found, correct the cause before
3.
If the concern is not visually evident, verify the symptom. GO to Symptom Chart - External
Controls or GO to Symptom Chart - NVH .
4.
Transmission selector
lever cable

Manual control lever
Selector lever or selector
lever knob

Connections
Wiring harness
Brake Pedal Position (BPP) switch
Brake Shift Interlock Actuator (BSIA)
SelectShiftTM switch
Transmission Control Switch (TCS) (vehicles equipped
with a 2.5L engine)

Diagnostic Trouble Code Chart
B2572
Brake Shift
Interlock
Brake Shift
Interlock Output
Circuit Failure
The associated circuitry
connected to the Smart
Junction Box (SJB) or
fuse, or the SJB itself may
have an issue causing a
brake shift interlock
concern.
Brake shift
interlock is
inoperative or does
not operate
correctly.
GO to
Pinpoint
Test A .
P0815 SelectShiftTM
Switch
SelectShiftTM
Switch Output
Circuit Failure
connected to the
SelectShiftTM switch or
fuse, or the SelectShiftTM
switch itself may have an
issue causing a fault.
SelectShiftTM
operation is
inoperative or does
not operate
correctly.
GO to
Pinpoint
Test C .
P0816 SelectShiftTM
Switch
SelectShiftTM
Switch Output
Circuit Failure
connected to the
SelectShiftTM
operation is
inoperative or does
not operate
correctly.
GO to
Pinpoint
Test C .
P0819 SelectShiftTM
Switch
Up And Down
Shift Switch To
Transmission
Range (TR)
Correlation
connected to the
SelectShiftTM
operation is
inoperative or does
not operate
correctly.
GO to
Pinpoint
Test D .
Symptom Chart - External Controls
Symptom Chart - NVH
Symptom Chart - NVH
NOTE: NVH symptoms should be identified using the diagnostic tools that are available. For a list of
these tools, an explanation of their uses and a glossary of common terms, refer to Section 100-04 .
Since it is possible any one of multiple systems may be the cause of a symptom, it may be necessary
to use a process of elimination type of diagnostic approach to pinpoint the responsible system. If this
is not the causal system for the symptom, refer back to Section 100-04 for the next likely system and
continue diagnosis.
Vibration - a high frequency (20-80 Hz) that is felt through the seat or selector lever. Changes
with engine speed

Selector lever cable incorrectly routed, grounded out or loose
CHECK the selector lever cable. REPAIR as necessary.
Electrical Connectors
Selector Lever Harness C3233
Pin
Number
Circuit
Circuit Function
1 CET53
(BU/OG)
Brake Shift Interlock Actuator (BSIA) solenoid power circuit
2 CET22
(GY/BN)
Park position signal to ignition switch
3 CET52 (GN) Park position signal to Instrument Cluster (IC)
4 VLN04
(VT/GY)
Power to PRNDL LED illumination (Fusion/Milan)
4 VLN37
(BU/WH)
Power to PRNDL white lighting illumination (MKZ)
5 GD116
(BK/VT)
Ground
6 CET34
(BN/GN)
Transmission Control Switch (TCS)/Grade Assist button signal return
(vehicles equipped with a 2.5L engine)
7 CBK03 (GY) TCS /Grade Assist power supply from Battery Junction Box (BJB) fuse
47 (10A) (vehicles equipped with a 2.5L engine)
8 CBK03 (GY) SelectShiftTM sensor power supply from BJB fuse 47 (10A)
9 CET43 (GY) SelectShiftTM sensor upshift circuit
10 CET42
(GN/VT)
SelectShiftTM sensor downshift circuit
11 RE407
(YE/VT)
SelectShiftTM sensor ground circuit (Fusion/ Milan)
11 GD116
(BK/VT)
SelectShiftTM sensor ground circuit (MKZ)
12 - Empty
Pinpoint Tests
Refer to Wiring Diagrams Cell 29 ( Fusion/MKZ , Fusion Hybridybrid ), Transmission Controls
-Aisin AW21 for schematic and connector information.
Refer to Wiring Diagrams Cell 30 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Transmission
Controls-6F35 for schematic and connector information.
Selector Lever Harness C3233 4178
PINPOINT TEST A: THE BRAKE SHIFT INTERLOCK SYSTEM DOES NOT RELEASE/LOCK CORRECTLY
A1 CHECK DTCs
Ignition ON.
Is DTC B2575 set?
Yes
GO to A2 .
No
The issue may not be in the Brake
Shift Interlock Actuator (BSIA)
electrical system. GO to Symptom
Chart - External Controls in this
section.
A2 CHECK FUSE 5 (10A)
Ignition OFF.
Remove Smart Junction Box (SJB) fuse 5 (10A).
Check fuse: SJB 5 (10A).
Yes
GO to A3 .
No
GO to A4 .
A3 CHECK THE POWER CIRCUIT FOR
VOLTAGE
Disconnect: Selector Lever C3233.
Ignition ON.
Measure the voltage between selector lever harness
C3233-1, circuit CET53 (BU/OG), vehicle harness
side and ground, while applying the brake pedal.

Yes
GO to A6 .
No
GO to A5 .
A4 CHECK THE POWER CIRCUIT FOR A SHORT
TO GROUND
Ignition OFF.
Measure the resistance between selector lever
harness C3233-1, circuit CET53 (BU/OG), vehicle

Yes
GO to A5 .
No
REPAIR circuit CET53 (BU/OG)
for a short to ground. CLEAR the
DTCs. TEST the system for normal
operation.
PINPOINT TEST A: THE BRAKE SHIFT INTERLOCK SYSTEM DOES NOT RELEASE/LOCK CORRECTLY 4179
A5 CHECK THE POWER CIRCUIT FOR AN OPEN
Ignition OFF.
Measure the resistance between the selector lever
harness C3233-1, circuit CET53 (BU/OG), vehicle
harness side and SJB C2280C-23, circuit CET53
(BU/OG), vehicle harness side.

Yes
INSTALL a new SJB . CLEAR the
DTCs. TEST the system for normal
operation.
No
REPAIR circuit CET53 (BU/OG)
for an open. CLEAR the DTCs.
operation.
A6 CHECK THE GROUND CIRCUIT FOR AN
OPEN
Ignition OFF.
harness C3233-5, circuit GD116 (BK/VT), vehicle

Yes
INSTALL a new selector lever.
REFER to Selector Lever - Fusion or
Selector Lever - MKZ in this
section.
No
REPAIR circuit GD116 (BK/VT) for
an open. CLEAR the DTCs. TEST
PINPOINT TEST B: TCS DOES NOT OPERATE CORRECTLY (VEHICLES EQUIPPED WITH A 2.5L ENGINE
ONLY)
B1 CHECK THE IC
Using the scan tool, monitor the TCS
PID while cycling the Transmission
Control Switch (TCS).

Does the TCS PID cycle from
Yes
REFER to Section 413-01 for diagnosis of the
Instrument Cluster (IC) illumination.
No
PINPOINT TEST B: TCS DOES NOT OPERATE CORRECTLY (VEHICLES EQUIPPED WITH A 2.5L ENGINE ONLY) 4180
depressed to not depressed? GO to B2 .
B2 CHECK FUSE 47 (10A)
Check fuse: Battery Junction Box
(BJB) fuse 47 (10A).

Yes
GO to B3 .
No
GO to B6 .
B3 CHECK THE POWER CIRCUIT
FOR VOLTAGE
Ignition ON.
Measure the voltage between selector
lever harness C3233-7, circuit CBK03
(GY), vehicle harness side and
ground.

Yes
GO to B5 .
No
GO to B4 .
B4 CHECK THE POWER CIRCUIT
FOR AN OPEN
Ignition OFF.
Disconnect: BJB fuse 47 (10A).
output side of BJB fuse 47 (10A) and
selector lever harness C3233-7 circuit
CBK03 (GY), vehicle harness side.

Yes
Install a new BJB .
No
REPAIR circuit CBK03 (GY) for an open. TEST
B5 CHECK THE TCS
selector lever harness C3533 pins 6
and 7, component side, while cycling
the TCS .

when pressed and greater than
10,000 ohms when released?

Yes
GO to B7 .
No
INSPECT the selector lever wiring harness for
damage. REPAIR the wiring harness as required.
If the selector lever wiring harness is not
damaged, INSTALL a new selector lever knob.
REFER to Selector Lever Knob in this section.
B6 CHECK THE SIGNAL CIRCUIT
Ignition OFF.
selector lever harness C3233-6,
circuit CET34 (BN/GN) and ground.

10,000?

Yes
REPAIR circuit CBK03 (GY) for a short to
ground. INSTALL a new fuse. TEST the system
No
REPAIR circuit CET34 (BN/GN) for a short to
ground. INSTALL a new fuse. TEST the system
B7 CHECK THE SIGNAL CIRCUIT
FOR AN OPEN
selector lever harness C3233-6,
circuit CET34 (BN/GN) and PCM
C175T-31, circuit CET34 (BN/GN).

Is the resistance less then 5 ohms?
Yes
303-14A .
No
REPAIR circuit CET34 (BN/GN) for an open.
PINPOINT TEST C: SELECTSHIFTTM DOES NOT OPERATE CORRECTLY
C1 CHECK FUSE 47 (10A)
Check fuse: Battery Junction Box (BJB) 47
(10A).

Yes
GO to C2 .
No
REPAIR circuit CBK03 (GY) for a short
to ground. INSTALL a new fuse.
CLEAR the DTCs. TEST the system for
normal operation.
C2 CHECK THE POWER CIRCUIT FOR
VOLTAGE
Ignition ON.
Measure the voltage between selector lever
harness C3233-8, circuit CBK03 (GY), vehicle

Yes
GO to C4 .
No
GO to C3 .
C3 CHECK THE POWER CIRCUIT FOR AN
OPEN
Ignition OFF.
Measure the resistance between the output side
of BJB fuse 47 (10A) and selector lever
harness C3233-8 circuit CBK03 (GY), vehicle
harness side.

Yes
INSTALL a new BJB .
No
REPAIR circuit CBK03 (GY) for an
open. CLEAR the DTCs. TEST the
PINPOINT TEST C: SELECTSHIFTTM DOES NOT OPERATE CORRECTLY 4183
C4 CHECK THE GROUND CIRCUIT
C3233-8, CBK03 (GY), vehicle harness side
and C3233-11, circuit RE407 (YE/VT),
vehicle harness side.

Yes
GO to C6 .
No
GO to C5 .
C5 CHECK THE GROUND CIRCUIT FOR AN
OPEN
C3233-11, circuit RE407 (YE/VT) and PCM
C175B-56, circuit RE407 (YE/VT).

Yes
INSTALL a new PCM. REFER to
Section 303-14B .
No
REPAIR circuit RE407 (YE/VT) for an
open. CLEAR the DTCs. TEST system
C6 CHECK CIRCUITS FOR A SHORT TO
GROUND
Measure the resistance between PCM
C175B-23, circuit CET43 (GY) and ground.

C175B-24, circuit CET42 (GN/VT) and
ground.

Yes
GO to C7 .
No
REPAIR circuit CET43 (GY) or circuit
CET42 (GN/VT) for a short to ground.
CLEAR the DTCs. TEST system for
normal operation.
C7 CHECK CIRCUITS FOR AN OPEN
C175B-23, circuit CET43 (GY) and selector
lever C3233-9.

C175B-24, circuit CET43 (GY) and selector
lever C3233-10.

Yes
INSTALL a new selector lever. REFER
to Selector Lever - Fusion in this
section. CLEAR the DTCs. TEST the
system for normal operation. If the
condition still exists, INSTALL a new
PCM. REFER to Section 303-14B .
No
CET42 (GN/VT) for an open. CLEAR
the DTCs. TEST system for normal
operation.
PINPOINT TEST D: SELECTSHIFTTM DOES NOT OPERATE CORRECTLY
D1 CHECK FUSE 47 (10A)
Check fuse: Battery Junction Box (BJB) 47
(10A).

Yes
GO to D2 .
No
REPAIR circuit CBK03 (GY) for a short
to ground. INSTALL a new fuse. CLEAR
operation.
D2 CHECK THE POWER CIRCUIT FOR
VOLTAGE
Ignition ON.
harness C3233-8, circuit CBK03 (GY),
vehicle harness side and ground.

Is the voltage greater than 10 volts? /b>
Yes
GO to D4 .
No
GO to D3 .
D3 CHECK THE POWER CIRCUIT FOR AN
OPEN
Ignition OFF.
Measure the resistance between the output
side of BJB fuse 47 (10A) and selector lever
harness C3233-8 circuit CBK03 (GY),
vehicle harness side.

Yes
INSTALL a new BJB .
No
REPAIR circuit CBK03 (GY) for an open.
CLEAR the DTCs. TEST the system for
normal operation.
PINPOINT TEST D: SELECTSHIFTTM DOES NOT OPERATE CORRECTLY 4186
D4 CHECK THE GROUND CIRCUIT
C3233-11, circuit RE407 (YE/VT) (Fusion)
or circuit GD116 (BK/VT) (MKZ) and
ground.

Yes
GO to D5 .
No
REPAIR circuit RE407 (YE/VT) (Fusion)
or circuit GD116 (BK/VT) (MKZ) for an
open. CLEAR the DTCs. TEST system
D5 CHECK CIRCUITS FOR A SHORT TO
GROUND
Disconnect: Transmission Control Module
(TCM) C1533.

Measure the resistance between TCM
C1533-3, circuit CET43 (GY) and ground.

C1533-4, circuit CET42 (GN/VT) and
ground.

Yes
GO to D6 .
No
CET42 (GN/VT) for a short to ground.
CLEAR the DTCs. TEST system for
normal operation.
ohms?

D6 CHECK CIRCUITS FOR AN OPEN
C1533-3, circuit CET43 (GY) and selector
lever C3233-9.

C1533-4, circuit CET43 (GY) and selector
lever C3233-10.

Yes
INSTALL a new selector lever. REFER to
Selector Lever - Fusion or Selector Lever
- MKZ in this section. CLEAR the DTCs.
the condition still exists, INSTALL a new
TCM. REFER to Section 307-01A .
No
CET42 (GN/VT) for an open. CLEAR the
DTCs. TEST system for normal operation.
p;
GENERAL PROCEDURES
06/03/2011
Brake Shift Interlock Override
NOTE: If it is necessary to use the override procedure to move the selector lever out of the PARK position, it
is possible that a fuse has blown and the brake lights are not operational. Before driving the vehicle, verify
that the brake lights are working.
This vehicle is equipped with a brake shift interlock feature that prevents the selector lever from being moved
out of PARK when the ignition is in the ON position unless the brake pedal is depressed.
If the selector lever cannot be moved out of the PARK position when the ignition is in the ON position and
the brake pedal is depressed, carry out the following procedure.
Fusion
Remove the selector lever trim ring. 2.
Remove tenter console trim panel 3.
NOTE: Vehicles equipped with a 3.0L/3.5L shown, vehicles equipped with a 2.5L similar.
Using a suitable tool, push the brake shift interlock override forward, apply the brake, press the
selector lever knob button and move the selector lever into NEUTRAL.
4.
Start the vehicle. 5.
Brake Shift Interlock Override 4190
Install the center console trim panel. 6.
Install the selector lever trim ring. 7.
MKZ
Remove the access panel. 8.
Insert a suitable tool into the access hole, depress the brake shift interlock override mechanism on the
selector lever, apply the brake, depress the button on the selector lever knob and move the selector
lever into NEUTRAL.
9.
Install the access panel. 11.
GENERAL PROCEDURES
06/03/2011
Selector Lever Cable Adjustment - Aisin AW21
Place the selector lever in DRIVE. 3.
Place the manual control lever in DRIVE.
Place the manual control lever in PARK. 1.
Move the manual control lever counterclockwise 3 detents to the DRIVE position. 2.
4.
Release the selector lever cable adjuster lock.
Pull out on the adjuster lock tabs. 1.
Slide the lock up to unlock the selector lever cable. 2.
5.
Align the selector lever cable end to the manual control lever ball stud and install it with the adjuster
unlocked.
6.
Selector Lever Cable Adjustment - Aisin AW21 4193
Slide the adjuster tab in place to lock the selector lever cable. 7.
Verify that the vehicle starts in PARK and NEUTRAL only and that the reverse lamps illuminate in
REVERSE.
9.
Selector Lever Cable Adjustment - Aisin AW21 4194
GENERAL PROCEDURES
06/03/2011
Selector Lever Cable Adjustment - 6F35
NOTE: SelectShiftTM shown, Transmission Control Switch (TCS) similar.
Place the selector lever in the D position.
2.
Place the manual control lever in the D position.
Rotate the manual control lever counterclockwisPARK position. 1.
Rotate the manual control lever clockwise 3 detents to the D position. 2.
3.
Release the selector lever cable adjuster lock.
Pull out on the adjuster lock tabs. 1.
Slide the lock up to unlock the selector lever cable. 2.
4.
Selector Lever Cable Adjustment - 6F35 4195
unlocked.
5.
Slide the adjuster tab in place to lock the selector lever cable. 6.
REVERSE.
7.
REMOVAL AND INSTALLATION
06/03/2011
Selector Lever Cable
Selector Lever Cable - Aisin AW21
Selector Lever Cable - 6F35 Transaxle
Selector Lever Cable 4198
2 54017A40
3 W707142 Selector lever cable grommet retaining nuts
Removal
Remove the heater core and evaporator core housing. For additional information, refer to Section
412-01 .
1.
Remove the Restraints Control Module (RCM). For additional information, refer to Section 501-20B . 2.
NOTE: Aisin AW21 shown, 6F35 similar.
Disconnect the selector lever cable end from the manual control lever.
4.
Release the 2 tabs and remove the selector lever cable from the selector lever cable bracket.
5.
Disconnect the 2 wiring harness fasteners and position the RCM wiring harness aside. 6.
Position the insulation blanket away from the bulkhead to gain access to the 2 selector lever cable
bracket nuts.
7.
Selector Lever Cable - 6F35 Transaxle 4199
Remove the 2 selector lever cable grommet nuts and remove the selector lever cable through the
interior of the vehicle.
8.
Installation
Position the selector lever cable in place and install the 2 nuts.
1.
Position the insulation blanket in place over the selector lever cable grommet. 2.
Position back the RCM wiring harness and install the fasteners on the studs. 3.
NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs
are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector
lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the
4.
selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure
that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever
cable end to make sure that the selector lever cable end is correctly installed.
Install the selector lever cable in the bracket. Be sure the tabs are locked in place.
Connect the selector lever cable end on the manual control lever.
5.
Install the RCM . For additional information, refer to Section 501-20B . 7.
Install the heater core and evaporator core housing. For additional information, refer to Section
412-01 .
8.
Adjust the selector lever cable. For additional information, refer to Selector Lever Cable Adjustment -
Aisin AW21 or Selector Lever Cable Adjustment - 6F35 in this section.
9.
06/03/2011
Selector Lever - Fusion
NOTE: Transmission Control Switch (TCS) selector lever shown, SelectShiftTM selector lever similar.
2 14489 Selector lever electrical connector
3 W714098 Selector lever nuts (4 required)
4 7K004 Selector lever assembly
Removal
Remove the center console. For additional information, refer to Section 501-12 . 1.
Disconnect the selector lever cable end from the selector lever. 2.
Release the tab on the selector lever cable and remove it from the selector lever housing. 3.
Selector Lever - Fusion 4203
Remove the 4 nuts and remove the selector lever. 5.
Installation
Install the selector lever and the 4 nuts.
1.
Install the selector lever cable in the selector lever housing.
3.
Connect the selector lever cable end to the selector lever. 4.
Install the center console. For additional information, refer to Section 501-12 . 5.
Adjust the selector lever cable. For additional information, refer to Selector Lever Cable Adjustment -
Aisin AW21 or Selector Lever Cable Adjustment - 6F35 in this section.
6.
06/03/2011
Selector Lever - MKZ
1 14A459 Selector lever bezel electrical connector
2 1181081 Floor console lower trim panel
3 W709955 Floor console screw
6 W714098 Selector lever nuts
7 d>7210 Selector lever
Removal
Remove the selector lever bezel. For additional information, refer to Selector Lever Bezel - MKZ in
this section.
1.
Remove the PRNDL electrical connector from the RH side of the center console. 2.
Remove the LH and RH center console trim covers.
3.
Selector Lever - MKZ 4206
Remove the LH and RH center console-to-selector lever screws.
4.
Disconnect the selector lever cable end from the selector lever ball stu 5.
Disconnect the selector lever electrical connector. 6.
Remove the 4 selector lever nuts. 7.
Position the selector lever off of the studs, release the tab on the selector lever cable and remove it
from the selector lever.
8.
Installation
Install the selector lever cable in the selector lever and position the selector lever on the studs. 1.
Install the 4 selector lever nuts.
2.
Connect the selector lever electrical connector. 3.
Connect the selector lever cable end on the selector lever ball stud. 4.
Install the LH and RH center console-to-selector lever screws.
5.
Install the LH and RH center console trim covers.
6.
Install the PRNDL electrical connector on the RH side of the center console. 7.
Install the selector lever bezel. For additional information, refer to Selector Lever Bezel - MKZ in this
section.
8.
Check the selector lever cable adjustment. Make sure that the vehicle starts in PARK and NEUTRAL
and the reverse lamps illuminate in REVERSE. If an adjustment is necessary, refer to Selector Lever
Cable Adjustment - Aisin AW21 in this section.
9.
p;
06/03/2011
Selector Lever Bezel - Fusion
NOTE: Transmission Control Switch (TCS) shown, SelectShiftTM switch similar.
2 54045A76 Center console trim panel
3 54045A07 Utility tray
4 14A459 Transmission Control Switch (TCS) electrical
connector (2.5L engine only)
5 - Selector lever knob bezel
6 W701894 Selector lever knob screws
7L010
Selector lever
knob
8 14A459 Selector lever bezel electrical connector
9 7E034 Selector lever bezel
Removal
All vehicles
Selector Lever Bezel - Fusion 4211
Remove the center console trim panel. 2.
Remove the utility tray from the center console. 3.
Disconnect the electrical connector and remove the utility tray. 4.
Vehicles equipped with a 2.5L or 3.0L (4V) engine
Disconnect the Transmission Control Switch (TCS) or SelectShiftTM switch electrical connector. 5.
All vehicles
NOTE: TCS shown, SelectShiftTM switch similar.
Slide the selector lever knob bezel downward to gain access to the 2 selector lever knob screws.
6.
NOTICE: It is necessary to route the Transmission Control Switch (TCS) harness or
SelectShiftTM switch harness out of the selector lever bezel when removing the selector lever
knob.
Remove the 2 screws from the selector lever knob. Remove the selector lever knob and selector lever
knob bezel.
7.
Disconnect the selector lever bezel electrical connector. 8.
NOTE: Selector lever removed for clarity.
Release the 3 tabs and remove the selector lever knob bezel.
9.
Installation
NOTICE: Be sure that the override lever is inserted in the override lever guide or the shift
interlock override button will not work correctly.
Install the selector lever bezel on the selector lever.
Position the override lever in the override lever guide.
Make sure that the 3 locking tabs are locked in place.
1.
Install the selector lever bezel on the selector lever and be sure the 3 tabs are locked in place.
2.
All vehicles
Connect the selector lever bezel electrical connector. 3.
NOTICE: It is necessary to route the Transmission Control Switch (TCS) harness or
SelectShiftTM switch harness out of the selector lever bezel when removing the selector lever
knob.
NOTE: TCS shown, SelectShiftTM switch similar.
4.
Install the selector lever knob on the selector lever and install the screws.
Slide the selector lever knob bezel up and install it on the selector lever knob. 5.
Vehicles equipped with 2.5L or 3.0L (4V) engine
Connect the TCS or SelectShiftTM switch electrical connector. 6.
All vehicles
Position the utility tray in place and connect the electrical connector. 7.
Install the utility tray on the center console. 8.
06/03/2011
Selector Lever Bezel - MKZ
1 061A16 Floor console finish moulding
3 7L010 Selector lever knob
5 7B118 Selector lever boot
6 - Selector lever trim ring (part of 7B118)
Re>
Remove the LH and RH console finish moldings. 1.
Slide the selector lever knob trim ring down to expose the 2 selector lever knob screws. 2.
Remove the 2 selector lever knob screws and remove the selector lever knob. 3.
Selector Lever Bezel - MKZ 4218
Lift the arm rest, apply the emergency brake, pull directly up on the selector lever bezel and remove it
from the center console.
4.
Disconnect the selector lever bezel electrical connector and remove the selector lever bezel. 5.
Compress the retention tabs on the selector lever boot and remove the boot from the bottom of the
selector lever bezel.
6.
Compress the retention tabs on the selector lever trim ring and remove the trim ring through from the
top of the selector lever bezel.
7.
Installation
Install the selector lever trim ring in the selector lever bezel. 1.
NOTICE: When installing the selector lever boot, be sure it is in the correct position or the
selector lever boot can not be installed on the selector lever knob. If needed, align the selector
lever knob to the selector lever boot when installing the boot.
Install the selector lever boot in the selector lever bezel.
2.
Position the selector lever bezel in place and connect the electrical connector. 3.
Position the selector lever bezel in place and install it onto the center console. 4.
Position the selector lever knob onto the selector lever and install the screws. 5.
Slide the selector lever knob trim ring up and install it on the selector lever knob. 6.
Install the LH and RH console finish moldings. 7.
06/03/2011
Selector Lever Knob
NOTE: Transmission Control Switch (TCS) shown, select switch similar.
2 54045A76 Upper console panel
3 14A459 Transmission Control Switch (TCS) electrical
connector (2.5L engine only)
4 - Selector lever knob shroud (part of 7L010)
6 7L010 td>Selector
lever knob
Removal
Selector Lever Knob 4222
Disconnect the Transmission Control Switch (TCS) or select switch electrical connector. 3.
All vehicles
NOTE: TCS shown, select switch similar.
Slide the selector lever knob shroud downward to gain access to the 2 selector lever knob screws.
4.
NOTICE: It is necessary to route the Transmission Control Switch (TCS) harness or select
switch harness out of the selector lever shroud when removing the selector lever knob.
Remove the 2 screws from the selector lever knob. Remove the selector lever knob and selector lever
knob shroud.
5.
Installation
All vehicles
NOTICE: It is necessary to route the Transmission Control Switch (TCS) harness or select
switch harness through the selector lever shroud when installing the selector lever knob.
NOTE: TCS shown, select switch similar.
Install the selector lever knob on the selector lever and install the screws.
1.
Slide the selector lever knob shroud up and install it on the selector lever knob. 2.
Vehicles equipped with 2.5L or 3.0L (4V) engine
Connect the TCS or select switch electrical connector. 3.
SECTION 307-05B: Automatic Transaxle/Transmission
External Controls - Hybrid
Selector lever cable grommet nuts 9 80
Selector lever nuts 20 177
External Controls
2 - Lower selector lever knob bezel (part of 7L010)
7 - Selector lever cable enof 7E395)
8 - Selector lever cable adjustment lock tab (part of
7E395)
Range Selection
Park
With the range selector in PARK:
the parking pawl locks the output shaft to the case.
the ignition key can be removed.
the ignition switch can be cycled from OFF to START or RUN. The ready indicator light will
illuminate on the Instrument Cluster (IC) when the ignition switch is cycled to the START position.

The ready indicator light is located on the lower right hand corner of the IC .
Ready Indicator Light
Reverse
With the range selector in REVERSE:
the vehicle may be operated in a rearward direction.
reversing lamps are illuminated.
if the ready indicator light is not illuminated, which lights when the ignition switch is cycled to the
START position, there is no reverse gear engagement.

Neutral
With the range selector in NERAL:
no power flows through the transmission.
the output shaft is disengaged from the drive wheels.
Drive
The range selector DRIVE position provides:
low speed driving.
acceleration.
cruise conditions.
deceleration.
Low
The range selector LOW position provides:
engine braking.
improved traction on slippery roads.
Brake Shift Interlock System
The brake shift interlock system prevents a shift out of PARK unless the brake pedal is depressed. The brake
shift interlock system has a Brake Shift Interlock Actuator (BSIA) mounted on the selector lever assembly. If
the ignition switch is in the RUN position, the BSIA will allow the selector lever to be moved out of PARK
only when the brake pedal is pressed.
External Controls
The external control of the Electronically Controlled Continuously Variable Transmission (eCVT) is
mechanically controlled by a cable connected to the selector lever and electronically controlled by the TR
sensor (located on the transaxle). The selector lever position determines PARK, REVERSE, NEUTRAL,
DRIVE and LOW modes. For diagnosis, removal and installation of the TR sensor, refer to Section 307-01C .
External Controls
Special Tool(s)
If an obvious cause for an observed or reported concern is found, correct the cause before proceeding
to the next step.
3.
If the concern is not visually evident, verify the symptom. GO to Symptom Chart . 4.
Transmission selector lever
cable

Manual control lever
Selector lever or selector
lever knob

(10A)

Connections
Wiring harness
Brake Pedal Position (BPP)
switch

Brake Shift Interlock Actuator
(BSIA)

DTC Chart
B2572 Brake Shift
Interlock
Brake Shift
Interlock Output
connected to the Smart Junction
Brake shift interlock
is inoperative or
GO to
Pinpoint
Circuit Failure Box (SJB) or fuse, or the SJB
itself may have an issue causing a
brake shift interlock concern.
does not operate
correctly.
Test A .
Symptom Chart - NVH
Symptom Chart - NVH
Vibration - a high frequency (20-80 Hz) vibration that is felt through the seat or the selector lever.
Changes with engine speed

Selector lever cable incorrectly routed, grounded out or loose
REFER to Selector Lever Cable in this section.
Loose selector lever cable bracket
CHECK the selector lever cable and bracket for damage and correct assembly. REFER to Selector
Lever Cable in this section. REPAIR as necessary.

Rattle, noise, buzz or other noise
Selector lever loose
Noisy selector lever
TIGHTEN the selector lever nuts.
INSTALL a new selector lever. REFER to the Selector Lever in this section.
Electrical Connectors
Selector Lever Harness C3233
Selector Lever Harness C3233 4232
Pin Number Circuit Circuit Function
1 CET53 (BU/OG) Brake Shift Interlock Actuator (BSIA) solenoid power circuit
2 CET22 (GY/BN) Park position signal to ignition switch
3 CET52 (GN) Park position signal to Instrument Cluster (IC)
4 VLN04 (VT/GY) Power to PRNDL LED illumination
5 GD116 (BK/VT) Ground
6 - Empty
7 - Empty
8 D> - Empty
9 - Empty
10 - Empty
11 - Empty
12 - Empty
Pinpoint Test
PINPOINT TEST A: THE BRAKE SHIFT INTERLOCK SYSTEM DOES NOT RELEASE/LOCK CORRECTLY
A1 TEST THE BRAKE LIGHTS
Apply the brake pedal and view the brake lights.
Do the brake lights illuminate?
Yes
GO to A2 .
No
A2 TEST SJB FUSE 5 (10A)
Check fuse: Smart Junction Box (SJB) 5 (10A).
Yes
GO to A3 .
No
INSTALL a new fuse. GO to
A3 .
A3 TEST BSIA POWER CIRCUIT
Disconnect: Selector Lever Electrical C3233.
Ignition ON.
Measure the voltage between selector lever harness C3233-1,
circuit CET53 (BU/OG), vehicle harness side and ground, while
applying the brake pedal.

Yes
GO to A6 .
No
GO to A4 .
A4 TEST THE BSIA POWER CIRCUIT FOR A SHORT TO
GROUND
Ignition OFF.
Measure the resistance between selector lever harness C3233-1,
circuit CET53 (BU/OG), vehicle harness side and ground.

Yes
GO to A5 .
No
operation.
A5 TEST THE BSIA POWER CIRCUIT FOR AN OPEN
Ignition OFF.
Measure the resistance between the selector lever harness
C3233-1, circuit CET53 (BU/OG), vehicle harness side and SJB
C2280C-23, circuit CET53 (BU/OG), vehicle harness side.

Yes
INSTALL a new SJB . TEST
operation.
No
operation.
A6 TEST THE BSIA GROUND CIRCUIT
Ignition OFF.
Measure the resistance between selector lever harness C3233-5,
circuit GD116 (BK/VT), vehicle harness side and ground.

Yes
INSTALL a new selector
lever. REFER to Selector
Lever in this section.
No
operation.
Brake Shift Interlock Override
NOTE: If it is necessary to use the override procedure to move the selector lever out of the PARK position, it
is possible that a fuse has blown and the brake lights are not operational. Before driving the vehicle, verify
that the brake lights are working.
This vehicle is equipped with a brake shift interlock feature that prevents the selector lever from being moved
out of PARK when the ignition is in the ON position unless the brake pedal is depressed.
If the selector lever cannot be moved out of the PARK position when the ignition is in the ON position and
the brake pedal is depressed, carry out the following procedure:
Using a suitable tool, push the brake shift interlock override forward, apply the brake, press the
selector lever knob button and move the selector lever into NEUTRAL.
4.
Selector Lever Cable Adjustment
NOTICE: The ignition must be in the OFF position to make sure that the Electronically
Controlled Continuously Variable Transmission (eCVT) and the engine are OFF.
.
1.
Place the selector lever in the D position. 2.
l start="3">
Remove the bolts and the splash shield.
Place the manual control lever in the D position.
Rotate the manual control lever counterclockwise to the PARK position. 1.
Rotate the manual control lever clockwise 3 detents to the D position. 2.
5.
Unlock the adjuster by sliding the locking tab over. 6.
Selector Lever Cable Adjustment 4238
unlocked.
7.
Slide the selector lever cable adjuster tab in place to lock the selector lever cable. 8.
REVERSE.
9.
Install the splash shield and the bolts. 10.
Selector Lever Cable
2 54017A40 Insulation blanket
3 W707142 Selector lever cable grommet retaining nuts
Removal
100-02 .
1.
412-01 .
2.
Release the 2 tabs and remove the selector lever cable from the selector lever cable bracket. 6.
Remove the selector lever cable from the retainer. 7.
Disconnect the 2 wiring harness fasteners and position the RCM wiring harness aside. 8.
Position the insulation blanket away from the bulkhead to gain access to the 2 selector lever cable
bracket nuts.
9.
Remove the 2 selector lever cable grommet nuts and remove the selector lever cable through the
interior of the vehicle.
10.
Installation
Position the selector lever cable in place and install the 2 nuts.
1.
Position the insulation blanket in place over the selector lever cable grommet. 2.
Position back the RCM wiring harness and install the fasteners on the studs. 3.
Install the selector lever cable in the retainer. 4.
5.
Install the selector lever cable in the bracket. Be sure the tabs are locked in place.
Connect the selector lever cable end on the manual control lever. 6.
412-01 .
8.
Adjust the selector lever cable. 9.
Selector Lever
3 W714098 Selector lever nuts (4 required)
Removal
Remove the center console. For additional information, refer to Section 501-12 . 1.
Disconnect the selector lever cable end from the selector lever. 2.
Release the tab on the selector lever cable and remove it from the selector lever housing. 3.
Selector Lever 4245
Remove the 4 nuts and remove the selector lever. 5.
Installation
Install the selector lever and the 4 nuts.
1.
Install the selector lever cable in the selector lever housing.
3.
Selector Lever 4246
Connect the selector lever cable end to the selector lever. 4.
Install the center console. For additional information, refer to Section 501-12 . 5.
Adjust the selector lever cable. For additional information, refer to Selector Lever Cable Adjustment
in this section.
6.
Selector Lever 4247
Selector Lever Knob
1 - Lower selector lever knob bezel (part of 7L010)
Removal
Slide the selector lever knob bezel downward to gain access to the 2 selector lever knob screws. 1.
Remove the 2 screws from the selector lever knob. Remove the selector lever knob and the selector
lever knob bezel.
2.
Installation
Install the selector lever knob on the selector lever and install the screws. 1.
Selector Lever Bezel
2 54045A76 Center console trim panel
3 54045A07 Utility tray
4 - Selector lever knob bezel
7 14A459 Selector lever bezel electricalctor
Removal
Selector Lever Bezel 4251
Remove the utility tray from the center console. 3.
Disconnect the electrical connector and remove the utility tray. 4.
Slide the selector lever knob bezel downward to gain access to the 2 selector lever knob screws. 5.
Remove the 2 screws from the selector lever knob. Remove the selector lever knob and the selector
lever knob bezel.
6.
Disconnect the selector lever bezel electrical connector. 7.
Release the 3 tabs and remove the selector lever knob bezel.
8.
Installation
NOTICE: Be sure that the override lever is inserted in the override lever guide or the shift
interlock override button will not work correctly.
Install the selector lever bezel on the selector lever.
Position the override lever in the override lever guide.
Make sure that the 3 locking tabs are locked in place.
1.
Connect selector lever bezel electrical connector. 2.
Install the selector lever knob on the selector lever and install the screws. 3.
Position the utility tray in place and connect the electrical connector. 5.
Install the utility tray on the center console. 6.
SECTION 308-00: Manual Transaxle/Transmission and Clutch -
General Information
Material
Capacity
Motor Vehicle Brake
Fluid
(Canada)
WSS-M6C62-A or
WSS-M6C65-A1
-
SAE 75W-90 API GL-4
Gear Oil
XT-4-QGL
WSS-M2C203-A1 2.84L (3.0
qts.)
Item Specification
Clutch Disc
Maximum runout 0.7 mm (0.027 in)
Minimum allowable depth to rivet head 0.3 mm (0.011 in)
Clutch pedal free play 1.0-3.0 mm
(0.39-0.118 in)
Clutch Pressure Plate
Flywheel Runout
Pressure Plate Diaphragm Spring Fingers
Maximum clearance 0.3 mm (0.011 in)
Maximum depth 0.6 mm (0.023 in)
Bleeder screw 7 62
Clutch pedal locknut 15 133
General Information
Manual Transaxle and Clutch
The transaxle and clutch system consist of the following:
Six-speed manual transaxle
Clutch disc
Clutch release hub and bearing
Clutch hydraulic system
Clutch pedal
Flywheel
Pilot bearing
Shift controls
The function of the transaxle is to move the vehicle from a rest position to motion. The transaxle uses gears to
adapt the torque to the demands of load and road conditions. It matches engine power to vehicle needs. This
power is delivered from the engine's flywheel to the transaxle. The power is transmitted through a
driver-operated clutch, which allows for engagement and disengagement of the engine to the transaxle.
The transaxle input shaft receives the power when the clutch is engaged. The transaxle then uses a system of
gears to change the speed and torque relationship between the engine crankshaft and the transaxle differential.
The purpose of the clutch is to connect and dnnect a manually operated transaxle, and the halfshafts, from the
engine. This allows starting and stopping the vehicle, shifting and changing vehicle speeds that correspond to
the engine speed through gear changes.
The manual transmission has a tag to identify assemblies for repair purposes. Refer to Section 308-03 for the
transmission tag information.
Manual Transaxle and Clutch 4259
General Information
Manual Transaxle and Clutch
Material
Item Specification
SAE 75W-90 API GL-4 Gear Oil
XT-4-QGL
WSS-M2C203-A1
The function of the transaxle is to move the vehicle from a rest position to motion. The transaxle uses gears to
adapt the torque to the demands of load and road conditions. It matches engine power to vehicle needs. This
power is delivered from the engine's flywheel to the transaxle. The power is transmitted through a
driver-operated clutch, which allows for engagement and disengagement of the engine to the transaxle.
The transaxle input shaft receives the power when the clutch is engaged. The transaxle then uses a system of
gears to change the speed and torque relationship between the engine crankshaft and the transaxle differential.
The clutch master cylinder trans hydraulic fluid pressure to the clutch slave cylinder, when the clutch pedal is
depressed, which in turn moves the clutch release hub and bearing. The clutch hydraulic system uses brake
fluid supplied from the brake master cylinder. The clutch is a single-plate, dry-friction disc with a
diaphragm-style spring pressure plate. The clutch disc has frictional material where it contacts the flywheel
and the clutch pressure plate. The clutch pressure plate applies pressure to the clutch disc, holding it tightly
against the surface of the flywheel.
In the engaged position, the clutch pressure plate diaphragm spring holds the clutch pressure plate against the
clutch disc, so that the engine torque is transmitted to the input shaft. When the clutch is depressed, movement
is transmitted through the clutch hydraulic system.
NOTICE: If transaxle noise is reported, first check the manual transmission fluid level. The vehicle
should not be driven if the manual transmission fluid level is low or damage can occur.
NOTE: Before attempting to rectify any concerns, road test the vehicle to ascertain in which system the
concern falls.
NOTE: If any evaluation or inspection reveals an obvious concern, repair the vehicle.
The technician should have a thorough knowledge of transaxle/clutch operation and accepted general
transaxle/clutch guidelines to detect any problems.
A gear-driven unit will produce a certain amount of noise. Some noise is acceptable and audible at certain
speeds or under various driving conditions. Certain conditions, such as road and weather, will amplify normal
vehicle noise.
The following overview is a guide to diagnose a transaxle/clutch concern:
Verify and document the customer concern.
During the customer interview, if a leak was noticed or if a leak is the concern, check the
manual transmission fluid. The vehicle should not be driven if the manual transmission fluid
level is low.

Check the manual transmission fluid level and condition.
Evaluation of the clutch hydraulic system.
Evaluation of the clutch.
Inspect gearshift mechanism.
Road test.
Find the cause of the problem and correct it.
Verify Customer Concern
Verify and document the customer concern.
When was it first noticed? 1.
Did it appear suddenly or gradually? 2.
Did anything unusual occur that would coincide with it or precede it? 3.
Identify when the condition occurs:
Hot or cold vehicle operating conditions
Type of terrain
Driving at a particular speed
coasting
hard acceleration

Shifting
upshifts
downshifts
in a particular gear
in all gears

4.
Has the transaxle/clutch been repaired before or components installed?
Check the vehicle service record. Note any repairs.
5.
1.
Check Manual Transmission Fluid Level and Condition
NOTE: The vehicle should not be driven if the manual transmission fluid level is low.
An incorrect manual transmission fluid level may affect the transaxle operation and can result in transaxle
damage. To correctly check and add manual transmission fluid to the transaxle, refer to transaxle draining and
filling in Section 308-03 .
A low manual transmission fluid level can result in poor transaxle shifting, engagement or damage. It can also
indicate a leak in one of the transaxle seals or gaskets.
Check the manual transmission fluid condition.
Observe the color and the odor of the manual transmission fluid. Allow the manual
transmission fluid to drip onto a white cloth and examine the stain. Check the manual
transmission fluid for contamination or metal particles.
Manual transmission fluid should appear nearly clear, similar to clean engine oil.

1.
Evaluation of Clutch Hydraulic System
Verify that the brake/clutch hydraulic fluid reservoir is filled to the correct level.
If the clutch hydraulic fluid level is correct, proceed to clutch check.
1.
If the rear chamber hydraulic fluid level is low, add fluid as necessary. Check the clutch
hydraulic system for leaks and repair as necessary.

Evaluation of the Clutch
Depress and release the clutch pedal slowly to check if the pedal is binding. Make sure the clutch
pedal can be fully depressed and is not restricted by the floor mat. Verify that the pedal return spring
is present and functions correctly.
1.
Measure the clutch reserve. With the engine idling, the parking brake on and the clutch pedal up,
gently move the gearshift lever toward reverse gear until gear clash can be heard. Depress the clutch
pedal slowly.
If the gears cease to clash (full disengage at 25.4 to 38.1 mm (1 to 1.5 in) from the floor), then
hold the pedal at the point of disengagement and increase engine to 4,000 rpm. The clutch
should remain disengaged, clutch OK.

Any concerns indicate a worn or damaged clutch. Repair as necessary.
2.
With the engine idling, move the gearshift lever into 4th gear. Increase the rpm to 2,000 and slowly
release the clutch pedal.
If the engine stalls, the clutch is OK.
If the engine does not stall, the clutch is slipping. Repair as necessary.
3.
Compare the clutch evaluation results with the following table. The following list of conditions are
typical faults into which clutch concerns will fall.
4.
Inspect the Gearshift Mechanism
Inspect the cables for:
signs of damage.
broken locks.
binding.
cables not fully seated or in hold-down brackets.
hold-down bracket nuts are loose.
correct routing.
correct adjustment.
If the concern is a gear(s) cannot be selected, adjust the cables. Refer to Gearshift
Cable Adjustment in this section.

1.
Inspect the gearshift for:
free play in the gearshift lever (must be no more than 5 mm [0.196 in]). This specification is
for an absolute or "no load" free play.
If the gearshift lever free play is too great, check the gearshift cables and repair as
necessary.

If the gearshift lever free play is OK, adjust the gearshift linkage.

2.
Evaluation of the Transmission
During the road test, use the following driving methods to diagnose the problem.
Start the engine.
Evaluate the noise in NEUTRAL while the vehicle is parked.
Check whether the noise is present with the clutch fully disengaged (pedal fully
depressed). Check to see if the pedal pulsates abnormally (for clutch diaphragm
finger run out).

Check whether the noise is present with the gearshift in the NEUTRAL position and

1.
the clutch fully engaged (foot off pedal). With the parking brake engaged, move the
gearshift towards the 1st gear position. Apply very slight pressure and note if the gear
noise level is reduced. (for gear rollover noise).
With the clutch fully engaged (foot off pedal), check whether the noise is present as
the engine speed is raised. If the noise reduces, note the engine speed at which this
occurs.

Listen for any change in noise while depressing and releasing the clutch pedal.
Listen for any change in noise while changing the engine rpm.
Drive the vehicle and shift through all of the gear ranges, including reverse. Listen for any
change in noise in a particular gear.

Drive the vehicle in the gear in which the noise is most noticeable. Depress the clutch pedal
and leave the gear engaged. Listen for any change in noise.

Drive the vehicle in the gear in which the noise is most noticeable. Depress the clutch pedal
and shift the transmission into NEUTRAL. Release the clutch pedal and allow the vehicle to
coast.

Compare the road test results with the following symptom charts. It is a list of conditions that are
typical faults into which the transaxle will fall:
2.
GO to Symptom Chart - Clutch Operation , GO to Symptom Chart - Transaxle or GO to Symptom Chart -
NVH in this section.
Symptom Chart - Clutch Operation
Symptom Chart - Clutch Operation
Symptom Chart - Transaxle
Symptom Chart - Transaxle
Symptom Chart - NVH
Symptom Chart - NVH
NOT NVH symptoms should be identified using the diagnostic tools that are available. For a list of these
Clutch related vibrations
Engine component grounding against frame
Accessory drive belt
Clutch release bearing
Flywheel bolts
Flywheel
Imbalanced clutch pressure plate
Excessive noise
Clutch disc damper damaged
Transaxle input shaft pilot bearing worn or damaged
Excessive crankshaft end play
Clutch release bearing worn or damaged
Clutch pedal
Clutch slave cylinder
GO to Pinpoint Test C . REFER to Section 308-01 . INSPECT the clutch disc for damage. INSPECT
the transaxle input shaft and the transaxle input shaft pilot bearing for wear and damage. CHECK the
crankshaft endplay. Refer to the appropriate section in Group 303 for the procedure. CHECK the
clutch release hub and bearing, and guide tube for wear and damage. REPAIR all components as
necessary. TEST the system for normal operation.

Clutch rattling noise - occurs with clutch engaged, noise changes/disappears with clutch pedal
depressed

Flywheel bolts, clutch housing bolts or clutch pressure plate bolts loe
CHECK the bolts for damage. TIGHTEN the bolts to specifications. REFER to Section 308-01 .
Clutch squeaking noise - noise is heard when the clutch is operated. Vehicle moves slowly or creeps
when the clutch is disengaged. Can also be difficult to shift into 1st and REVERSE gears

Pilot bearing seized or damaged
INSPECT the transaxle pilot bearing for wear or damage. REPAIR as necessary. REFER to Section
308-01 .

Clutch squeaking noise - occurs with clutch pedal depressed/released
Worn clutch pedal shaft or bushings
INSPECT the clutch pedal for wear or damage. REPAIR as necessary. REFER to Section 308-02 .
Worn, damaged or misaligned clutch release bearing
INSPECT the clutch release bearing for wear or damage. REPAIR as necessary. REFER to Section
308-01 .

Clutch grating/grinding noise - occurs when clutch pedal is depressed
Clutch pressure plate fingers bent or worn
INSPECT the clutch pressure plate release fingers. INSTALL a new pressure plate as necessary.

Contact surface of clutch release bearing worn or damaged
INSPECT the clutch release bearing. REPAIR as necessary. REFER to Section 308-01 .
Clutchtter - a small amount of noise when clutch pedal is released at initial take off
Clutch engagement
Acceptable operating condition.
Clutch chatter/grabs - in some cases a shudder is felt. Occurs with clutch pedal depressed/released
Damaged or worn powertrain/driveline mounts
INSPECT the powertrain/drivetrain mounts. INSTALL new mounts as necessary. Refer to the

Binding or dragging plunger of the clutch master cylinder or slave cylinder
CHECK the master and slave cylinder operation. INSPECT the components for damage or wear.
INSTALL a new master or slave cylinder as necessary. REFER to Section 308-02 .

Grease or oil on the clutch disc facing
CHECK the input shaft seal and rear main oil seal. REPAIR as necessary. INSTALL a new clutch
disc. REFER to Section 308-01 .

Clutch disc surface glazed or damaged
INSPECT the clutch disc surface for a glazed, hardened or damage condition. CARRY OUT a clutch
disc check. INSTALL a new clutch disc as necessary. REFER to Section 308-01 .

Damaged or worn clutch pressure plate
INSPECT the clutch pressure plate for wear or damage. INSTALL a new clutch pressure plate as
necessary. REFER to Section 308-01 .

Flywheel surface damaged or glazed
INSPECT the flywheel for damage or wear. CARRY OUT a flywheel runout check. INSTALL a new
flywheel as necessary. Refer to the appropriate section in Group 303 for the procedure.

Clutch chatter noise - noise when clutch pedal is released at initial take off. Clutch is hard to engage
and disengage

Pilot bearing worn, damaged or not correctly aligned in bore
INSPECT the clutch pressure plate release fingers for uneven wear, clutch components burnt or a
seized pilot bearing. INSTALL a new pilot bearing as necessary. REFER to Section 308-01 .

Transaxle rattling/clattering noise - occurs in NEUTRAL or in gear, at idle
Incorrect manual transmission fluid level or fluid quality
CHECK that the transaxle is filled to the correct level and with the specified manual transmission
fluid. REFER to Section 308-03 for the manual transmission fluid type.

Transaxle rattling/clattering noise - noise at idle in NEUTRAL
Wornugh reverse idler gear
CHECK the reverse idler gear. REPAIR as necessary. REFER to Section 308-03 .
Excessive backlash in gears
CHECK the gear backlash. ADJUST as necessary. REFER to Section 308-03 .
Worn countershaft gears
REPAIR as necessary. REFER to Section 308-03 .
Transaxle whine - a mild whine at extreme speeds or high rpm
Rotating gears/geartrain
Acceptable noise.
Transaxle whine - a high pitched whine, also described as a squeal
Transaxle gears are worn (hmileage vehicle)
Result of normal gear wear. REPAIR as necessary. REFER to Section 308-03 .
Mismatched gear sets
INSPECT the gear sets for an uneven wear pattern on the face of the gear teeth. REPAIR as

Damaged or worn transaxle bearing
INSPECT the transaxle bearings. INSTALL new bearings as necessary. REFER to Section 308-03 .
Transaxle growling/humming - noise occurs in the forward gears. The noise is more prominent when
the gear is loaded. The problem gear can be located as the noise occurs in a specific gear position

Gear is cracked, chipped or rough
INSPECT the transaxle gears for damage or wear. INSTALL new gears as necessary. REFER to Section
308-03 .
Transaxle hissing - noise in NEUTRAL or in forward gears. As bearings wear or break up, the noise
changes to a thumping noise

Damaged or worn bearings
Transaxle knocking/thudding - noise at low speeds in forward gears
Bearings with damaged balls or rollers or with pitted and spalled races
Transaxle rumble/growl - noise at all speeds in forward gears, monounced in a heavy acceleration
condition

Damaged or worn transaxle bearing or gears (high mileage vehicles)
CHECK manual transmission fluid for excessive metal particles. REPAIR as necessary.
Pinpoint Tests
Pinpoint Test A: Clutch Pedal Pulsation
Normal Operation
Clutch pedal feel should be smooth when disengaging and engaging the clutch. Clutch pedal movement is
transmitted by hydraulic fluid pressure, which actuates the clutch release fork and bearing. The clutch release
fork and bearing pushes on the spring center towards the flywheel. The diaphragm spring pivots at the
fulcrum, relieving the load on the clutch pressure plate. Steel spring straps riveted in the clutch pressure plate
cover pull the clutch pressure plate from the clutch disc, disengaging the engine torque from the transmission.
Clutch disc
Flywheel
PINPOINT TEST A: CLUTCH PEDAL PULSATION
A1 CHECK THE CLUTCH
PEDAL PULSATION
Start the engine.
With the transmission in
NEUTRAL, slowly press the
clutch pedal.

Does the clutch pedal
pulsate while being pressed?

Yes
GO to A2 .
No
VERIFY customer concern.
A2 INSPECT THE PRESSURE
PLATE BOLTS
Inspect the pressure
plate-to-flywheel bolts.

Are any of the pressure
plate-to-flywheel bolts
loose?

Yes
TIGHTEN or INSTALL new bolts. REFER to Section 308-01 .
No
GO to A3 .
A3 INSPECT THE CLUTCH
PRESSURE PLATE
Remove the clutch pressure
plate. Refer to Section 308-01
.

Inspect the clutch pressure
plate for wear or damage.

Are there any signs of
damage present on the
clutch pressure plate?

Yes
INSTALL a new clutch pressure plate. REFER to Section 308-01
No
GO to A4 .
A4 INSPECT THE CLUTCH
DISC
Check the clutch disc for
wear or damage.

Is the clutch disc OK?
Yes
GO to A5 .
No
INSTALL a new clutch disc. REFER to Section 308-01 . TEST
A5 INSPECT THE FLYWHEEL
Inspect the flywheel for wear
or damage.

Is flywheel OK?
Yes
VERIFY customer concern.
No
TIGHTEN or INSTALL a new flywheel as necessary. Refer to
the appropriate section in Group 303 for the procedure. TEST the
Pinpoint Test B: Clutch Related Vibrations
Normal Operation
The clutch is designed to transfer the power from the engine to the transmission, which may be either
stationary (starting) or rotating at a different speed (upshifting or downshifting). The clutch is functioning
correctly when both the engine and transmission are rotating at the same speed with the clutch engaged and no
vibrations are felt.
Engine components
Accessory drive component
Flywheel
PINPOINT TEST B: CLUTCH RELATED VIBRATIONS
B1 CHECK FOR ENGINE COMPONENT
GROUNDING
With the vehicle in NEUTRAL, position
it on a hoist. Refer to Section 100-02 .

Check the engine mount interlocks for
grounding.

Yes
REPAIR any components as necessary.
No
GO to B2 .
PINPOINT TEST A: CLUTCH PEDAL PULSATION 4268
Check for the exhaust manifold or other
engine components grounding on the
body or frame.

Is there evidence of grounding on the
body or frame?

B2 CHECK FOR ACCESSORY DRIVE
VIBRATIONS
Ignition OFF.
Remove the accessory drive belt and
check for vibration.

Start the engine.
Does the vibration stop when the
accessory drive belts are removed from
the engine?

Yes
REFER to Section 303-05A to diagnose the accessory
drive belt components.
No
INSTALL the accessory drive belt. GO to B3 .
B3 CHECK FOR RELEASE BEARING
NOISE
Start the engine.
Press and hold the clutch pedal but do not
disengage the clutch.

Is a whirring, grating or grinding noise
present only when the pedal is pushed?

Yes
INSTALL a new clutch release bearing. REFER to
Section 308-01 .
No
GO to B4 .
B4 INSPECT THE FLYWHEEL
Remove the clutch disc and pressure
plate. Refer to Section 308-01 .

Inspect for loose flywheel bolts.
Check for an excessively burnt or
severely cracked contact surface.

Inspect the flywheel runout. Refer to
Flywheel Runout Check in this section.

Is the flywheel OK?
Yes
GO to B5 .
No
TIGHTEN or INSTALL a new flywheel. Refer to the
B5 CHECK FOR PRESSURE PLATE
IMBALANCE
NOTICE: Failure to support the engine
correctly could result in damage to the
vehicle.

Support the engine securely.
Operate the engine with the transaxle
removed.

Is the vibration still present?
Yes
REFER to Section 100-04 to diagnose the engine
vibration concern.
No
INSTALL a new clutch pressure plate. REFER to
Section 308-01 .
Pinpoint Test C: Excessive Noise
Normal Operation
The manual transaxle is controlled by a floor-mounted gearshift lever located in the floor console. Connection
between the floor-mounted gearshift lever and the manual transaxle shift control lever assembly is made
through 2 gearshift cables.
When the operator moves the floor-mounted gearshift lever, that movement is transmitted through 2 gearshift
PINPOINT TEST B: CLUTCH RELATED VIBRATIONS 4269
cables routed through the body to the transaxle. The 2 gearshift cables are attached to the transaxle at the
transaxle shift control lever assembly. The transaxle shift control lever assembly transfers the movement of
the gearshift cables to the shift rods and shift forks located inside the transaxle.
The clutch is designed to transfer the power from the engine to the transmission, which may be either
stationary (starting) or rotating at a different speed (upshifting or downshifting). The clutch is functioning
correctly when both the engine and transmission are rotating at the same speed with the clutch engaged.
Clutch pedal movement is transmitted by hydraulic fluid pressure, which actuates the clutch release hub and
bearing. The clutch release hub and bearing pushes on the spring center towards the flywheel. The diaphragm
spring pivots at the fulcrum, relieving the load on the clutch pressure plate. Steel spring straps riveted in the
clutch pressure plate cover pull the clutch pressure plate from the clutch disc, disengaging the engine torque
from the transmission.
Internal transaxle components
Clutch pedal
Clutch disc
PINPOINT TEST C: EXCESSIVE NOISE
C1 TRANSAXLE NEUTRAL GEAR ROLLOVER
TEST
Start the engine and let it idle.
NOTE: With the clutch pedal fully pressed, the
input shaft should stop rotating.

Press the clutch pedal.
Does the noise stop when the clutch pedal is
pressed?

Yes
REFER to Section 308-03 for transaxle
concerns.
No
GO to C2 .
C2 CHECK THE CLUTCH PEDAL FREE PLAY
Press the clutch pedal lightly by hand.
Measure the distance the clutch pedal travels.
Is the clutch pedal travel within 1-3 mm
(0.039-0.118 in)?

Yes
GO to C3 .
No
ADJUST clutch pedal freeplay. REFER to
Clutch Pedal Freeplay Adjustment in this
section.
C3 CHECK THE CLUTCH SLAVE CYLINDER
Inspect the clutch slave cylinder for wear or loss of
lubrication.

Are there signs of wear or loss of lubrication?
Yes
INSTALL a new clutch slave cylinder.
No
GO to C4 .
C4 CHECK THE CLUTCH PRESSURE PLATE
Inspect the clutch pressure plate for damage or
Yes
INSTALL a new clutch pressure plate.
material between the pressure plate and flywheel.
Are there signs of damage?
No
GO to C5 .
C5 CHECK CLUTCH PEDAL SWITCHES
Inspect clutch pedal switches for damage or
incorrect installation.

Are there any signs of damage or incorrect
installation?

Yes
REPLACE or REINSTALL clutch pedal
switches as necessary.
No
REFER to Section 308-03 for transaxle
concerns.
Pinpoint Test D: Clutch System Leakage
Normal Operation
Clutch pedal movement is transmitted to the clutch by hydraulic fluid pressure from the master cylinder
reservoir through the hydraulic clutch tubes to the slave cylinder. This actuates the clutch release fork and
bearing. The clutch release fork and bearing pushes on the spring center towards the flywheel. The diaphragm
spring pivots at the fulcrum, relieving the load on the clutch pressure plate. Steel spring straps riveted in the
clutch pressure plate cover pull the clutch pressure plate from the clutch disc, disengaging the engine torque
from the transmission.
Clutch master cylinder
Hydraulic tubes
PINPOINT TEST D: CLUTCH SYSTEM LEAKAGE
D1 INSPECT THE CLUTCH MASTER
CYLINDER
Inspect clutch master cylinder for
leakage.

Is the clutch master cylinder OK?
Yes
GO to D2 .
No
REPAIR or INSTALL a new clutch master cylinder as
D2 INSPECT THE CLUTCH SLAVE
CYLINDER
Inspect clutch slave cylinder for leaks.
Is the clutch slave cylinder OK?
Yes
GO to D3 .
No
REPAIR or INSTALL a new clutch slave cylinder as
D3 INSPECT THE SYSTEM
HYDRAULIC TUBES
Yes
PINPOINT TEST C: EXCESSIVE NOISE 4271
Inspect clutch hydraulic tubes for
loose or damaged fittings causing
leakage.

Are the clutch hydraulic tubes OK?
CARRY OUT a road test to VERIFY customer
complaint.
No
REPAIR or INSTALL new components as necessary.
TEST the clutch system for normal operation.
Component Tests
Clutch Slippage
Chock the wheels. 1.
Depress and release the clutch pedal slowly to check if the pedal is binding.
If the clutch pedal is not binding, proceed to the next step of this procedure.
If the clutch pedal is binding, inspect and repair as necessary. Test the system for normal
operation. Proceed to the next step in this procedure, if necessary.

3.
Depress the clutch pedal. 4.
Start the engine. 5.
Shift the transmission to 4th gear. 6.
Increase engine rpm to 2,000 and slowly release the clutch pedal. If the engine stalls within 5 seconds,
the clutch is not slipping.
If the clutch is slipping, remove the clutch disc and pressure plate. Refer to Section 308-01 .
Inspect the clutch disc and pressure plate for wear or damage. Inspect the flywheel for glazing
and damage. Check the clutch release hub and bearing for binding and inspect the guide tube.
Inspect the input shaft for wear and damage. Repair all components as necessary.

7.
Clutch Chatter or Shudder
Inspect the engine and transmission mounts for looseness and damage.
If the mounts are OK, proceed to the next step in this procedure.
If the mounts are loose or damaged, tighten or install new mounts as necessary. Test the

2.
Check for loose bolts that retain the clutch pressure plate to the flywheel.
If the bolts are tightened to specification proceed to the next step in this procedure.
If the bolts are loose, tighten the bolts to specification. Refer to Section 308-01 . Test the

3.
Remove the clutch disc and pressure plate. Refer to Section 308-01 . Inspect the clutch disc and
pressure plate for wear and damage, and check the clutch disc runout. Refer to Clutch Disc Check in
this section. Inspect the flywheel for glazing and damage. Refer to Flywheel Runout Check in this
section. Inspect the input shaft for wear, damage and eccentricity. Repair all components as necessary.
4.
Clutch Drag
PINPOINT TEST D: CLUTCH SYSTEM LEAKAGE 4272
Verify that the clutch hydraulic fluid reservoir is filled to the correct level.
If the fluid level is correct, proceed to the next step in this procedure.
If the fluid level is low, add fluid as necessary. Inspect the clutch hydraulic system for leaks
and repair as necessary. Refer to Section 308-02 . Test the system for normal operation.

1.
Depress and release the clutch pedal to check for a spongy pedal.
If the pedal feels OK, proceed to the next step in this procedure.
If the pedal feels spongy, bleed the clutch hydraulic system. Refer to Clutch System Bleeding
in this section. Test the system for normal operation.

2.
pressure plate for wear and damage, and check the clutch disc runout. Refer to Clutch Disc Check in
this section. Repair all components as necessary.
3.
Hard Shifting
Verify that the clutch hydraulic fluid reservoir is filled to the correct level.
If the fluid level is correct, proceed to the next step in this procedure.
If the fluid level is low, add fluid as necessary. Check the clutch baldric system for leaks, and
repair as necessary. Refer to Section 308-02 . Test the system for normal operation.

1.
Depress and release the clutch pedal to check for a spongy pedal.
If the pedal feels OK, proceed to the next step in this procedure.
If the pedal feel spongy, bleed the clutch hydraulic system. Refer to Clutch System Bleeding
in this section. Test the system for normal operation.

2.
pressure plate for wear or damage. Refer to Clutch Disc Check in this section. Check the clutch
release hub and bearing for binding and inspect the guide tube. Inspect the input shaft for wear and
damage. If all of the components are OK, proceed to the next step in this procedure. Otherwise, repair
all components as necessary. Test the system for normal operation.
3.
Inspect the transmission housing, shafts, forks and synchronizer assemblies. Refer to Section 308-03 .
Repair all components as necessary.
4.
General Information
Clutch Disc Check
Special Tool(s)
Check the clutch disc lining surface for hardening, the presence of oil or grease. 1.
Check for a worn clutch disc lining. Measure the minimum allowable depth to the rivet heads with a
slide caliper.
If the measurement is less than the minimum, install a new clutch disc.
2.
Check for loose clutch disc lining rivets.
Install a new clutch disc as necessary.
3.
Check the clutch disc for cracking, scoring, discoloration or other surface marks.
Install a new clutch disc if necessary.
4.
Using the Dial Indicator Gauge with Holding Fixture, check the maximum allowable runout of the
clutch disc.
If the runout exceeds the maximum, install a new clutch disc.
5.
Use an emery cloth to remove minor imperfections in the clutch disc lining surface. 6.
Clutch Disc Check 4275
Check for wear or rust on the splines. If necessary, clean them with an emery cloth. 7.
Clutch Disc Check 4276
General Information
Clutch Pedal Freeplay Adjustment
Measure the clutch pedal travel.
If the measurement is not within specification, turn the clutch pedal adjustment bolt as
necessary.
1.
Tighten the clutch pedal locknut to 15 Nm (133 lb-in).
Recheck the measurement.
2.
1.
Measure clutch pedal free play.
Depress the clutch pedal by hand until the push rod contacts the clutch master cylinder piston. 1.
If the measurement is not within specification, loosen the locknut and turn the push rod as
necessary. Tighten the clutch pedal locknut to 15 Nm (133 lb-in).
Recheck the measurement.
2.
2.
Clutch Pedal Freeplay Adjustment 4277
Clutch Pedal Freeplay Adjustment 4278
General Information
Clutch Pressure Plate Check
Check the clutch pressure plate surface for scoring, cracks or discoloration.
Minor scratches or discoloration should be removed with a fine emery cloth.
1.
Measure the flatness of the clutch pressure plate surface with a straightedge and a feeler gauge.
Install a new pressure plate as necessary.
2.
Check the diaphragm spring fingers for discoloration, scoring and bent or broken segments. 3.
Measure the wear of the diaphragm spring fingers.
Install a new pressure plate as necessary.
4.
Clutch Pressure Plate Check 4279
General Information
Flywheel Runout Check
Special Tool(s)
Mount the Dial Indicator Gauge with Holding Fixture so that the Dial Indicator Gauge contact point
rides on the clutch disc contact surface.
1.
Rotate the flywheel and check the runout.
If the runout exceeds the maximum runout 0.076 mm (0.0034 in), install a new flywheel.
2.
Flywheel Runout Check 4280
General Information
Clutch System Bleeding
Material
Item Specification
(Canada)
WSS-M6C62-A or
WSS-M6C65-A1
NOTICE: Brake fluid is harmful to ted and plastic surfaces. If brake fluid is spilled onto a painted or
plastic surface, immediately wash it with cold water.
NOTE: When any part of the hydraulic system has been disconnected for repair or new installation, air may
get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after
it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding
equipment.
NOTE: Make sure the brake fluid reservoir is to the MAX mark before bleeding the clutch system.
Do not allow the fluid level to drop below 6 mm (0.236 in) of the MAX mark.
Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container
partially filled with clean brake fluid.
1.
Press the clutch pedal slowly to the floor. 2.
With the clutch pedal held to the floor, loosen the bleeder screw until fluid and air are expelled from
the system.
3.
With the clutch pedal held to the floor, tighten the bleeder screw. 4.
NOTICE: The clutch hydraulic system fluid is separated from the brake system fluid by a
separate reservoir within the brake reservoir. Do not allow the clutch hydraulic system fluid
level in the reservoir to fall more than 6 mm (0.236 in) below the MAX mark during the
bleeding operation or fluid supply to the clutch release system will be starved, allowing air to
enter the clutch master cylinder. Keep the brake master cylinder reservoir filled with clean,
5.
Clutch System Bleeding 4281
specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic
system.
Repeat Steps 2 through 4 until no air bubbles appear in the fluid.
1 - Brake fluid reservoir
2 - Minimum fluid level for clutch reservoir to fill
3 - Inner clutch fluid reservoir
Tighten the bleeder screw.
6.
Fill the brake reservoir. 7.
Check system for normal operation. 8.
Clutch System Bleeding 4282
General Information
Gearshift Cable Adjustment
Set the parking brake. 1.
Place the gearshift in neutral. 2.
Remove the gearshift knob and the floor console finish panel. 3.
NOTE: Console removed for clarity.
Disengage the safety lock by sliding it away from the shifter ball stud.
4.
NOTE: If the cable lock is difficult to slide out, disconnect the shift cable from the stud, push the
lock from the rear and reattach the shift cable to the ball stud.
Disengage the cable lock by sliding it out from the shift cable end fitting.
5.
Allow the gearshift lever to center itself. With the shifter and the transmission in NEUTRAL, push the
cable lock onto the cable.
6.
Engage the safety lock by sliding it over the primary shift cable lock. 7.
Gearshift Cable Adjustment 4283
Check for normal operation. 8.
SECTION 308-01: Clutch 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop Manual
Material
Capacity
CXG-1-C (Canada)
ESA-M1C75-B -
Item Specification
Diaphragm spring finger misalignment 0.6 mm (0.023 in) maximum
Clutch pressure plate bolts
a
- -
a
SECTION 308-01: Clutch
Manual
Clutch
The clutch system includes the following components:
Flywheel
Clutch disc
Clutch release fork
The clutch is a single-plate, dry-friction disc with a diaphragm-style spring clutch pressure plate. The clutch
disc has a hub which is splined to the transmission input shaft. The clutch disc has friction material where it
contacts the flywheel and the clutch pressure plate. The clutch pressure plate applies pressure to the clutch
disc, holding it tightly against the surface of the flywheel. In the engaged position, the diaphragm spring holds
the clutch pressure plate against the clutch disc, so that engine torque is transmitted to the input shaft.
When the clutch pedal is applied, the release bearing pushes the diaphragm spring center of the clutch
pressure plate toward the flywheel. The diaphragm spring pivots at the fulcrum, relieving the load on the
clutch pressure plate. The clutch slave cylinder assists in the effort it takes to relieve the load on the clutch
pressure plate. Steel spring straps riveted to the clutch pressure plate cover pull the clutch pressure plate from
the clutch disc, disengaging the engine torque from the transaxle.
Clutch 4286
SECTION 308-01: Clutch 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop Manual
Clutch
Clutch 4287
Manual
REMOVAL AND
INSTALLATION
Clutch Disc and Pressure Plate
Special Tool(s)
100-002
Flywheel Holding Tool
303-103 (T74P-6375-A)
Material
Item Specification
(Canada)
ESA-M1C75-B
1 7550 Clutch disc
2 7563 Clutch pressure plate
3 - Clutch pressure plate bolt (6 required)
4 7548 Clutch release bearing
5 7515 Clutch release fork
Removal
Clutch Disc and Pressure Plate 4288
Clutch disc and clutch pressure plate
Remove the transaxle. For additional information, refer to Section 308-03 . 1.
Inspect the clutch pressure plate.
Check the diaphragm spring fingers for discoloration, scoring, bent or broken segments.
Using the Dial Indicator Gauge with Holding Fixture, rotate the flywheel and check for sprg
ends that are higher or lower than the rest.
The specification is 0.6 mm (0.023 in) maximum.

2.
Using the Flywheel Holding Tool, lock the flywheel to the engine. 3.
NOTE: Loosen each bolt, one turn at a time in a star pattern, until spring tension is released.
Using a suitable clutch disc aligner, remove the bolts, the clutch pressure plate and the clutch disc.
4.
NOTE: Do not immerse the clutch pressure plate in solvent.
Using a suitable cleaning solution, clean the clutch pressure plate.
5.
Inspect the clutch pressure plate surface for burn marks, scores, flatness, ridges or cracks. For
Maximum clearance for flatness check is 0.3 mm (0.011 in).
6.
NOTICE: If the clutch disc is saturated with oil, inspect the rear engine crankshaft seal or
transmission input shaft seal for leakage. If leakage is found, install a new seal prior to clutch
disc installation. For additional information, refer to Section 303-01A or Section 308-03 .
NOTE: Use an emery cloth to remove minor imperfections in the clutch disc lining surface.
Inspect the clutch disc for the following:
7.
Oil or grease saturation
Worn or loose facings
Warpage or loose rivets at the hub
Wear or rust on the splines
Install a new clutch disc if any of these conditions are present.
Check the clutch disc runout. For additional information, refer to Clutch Disc Check in Section
308-00 .
8.
If necessary, conduct a Flywheel Runout Check. For additional information, refer to Section 308-00 . 9.
Clutch release bearing and clutch release fork
Remove the clutch release bearing. 10.
Inspect the clutch release bearing for wear or damage.
Rotate the bearing while applying pressure in the axial direction. If the bearing feels rough,
sticks or has excessive resistance, install a new bearing.

11.
Inspect the release bearing guide tube for wear or damage.
Slide the release bearing on the guide tube. Check for roughness or sticking.
12.
Remove the clutch release fork. Inspect the fork for wear or damage. 13.
Installation
Clutch release bearing and clutch release fork
Install the clutch release fork. 1.
Check for roughness or sticking. If the bearing feels rough, sticks or has excessive resistance, install a
new bearing. Slide the release bearing on the guide tube.
2.
Install the clutch release bearing. 3.
Clutch disc and clutch pressure plate
Apply a very small amount of grease in the clutch disc hub. Wipe off excess grease to avoid
contaminating the clutch disc and affecting clutch function.
4.
Using a suitable clutch disc aligner, position the clutch disc on the flywheel.
1 - Transaxle side
2 - Engine side
5.
Position the clutch pressure plate on the flywheel and to the dowels. Install the 6 clutch pressure plate
bolts.
Tighten the bolts one turn at a time in a star pattern. Tighten to 29 Nm (21 lb-ft).
6.
Apply a small amount of grease to:
the clutch release fork fingers.
the clutch release fork spring.
the guide tube.
the clutch slave cylinder end that contacts the release fork.
7.
NOTE: Apply a very small amount of grease to the transmission input shaft end and on the splines.
Install the transaxle. For additional information, refer to Section 308-03 .
8.
If the clutch was replaced, use the scan tool to perfohe Misfire Monitor Neutral Profile Correction
procedure, following the on-screen instructions.
9.
Manual
REMOVAL AND
INSTALLATION
Pilot Bearing
Special Tool(s)
Installer, Pilot Bearing
308-105 (T85T-7137-A)
Remover, Pilot Bearing
308-001 (T58L-101-B)
Removal
Remove the clutch disc and pressure plate. For additional information, refer to Clutch Disc and
Pressure Plate in this section.
1.
Using the Pilot Bearing Remover, remove the pilot bearing. 2.
Inspect the pilot bearing for:
misalignment and looseness in the flywheel.
needle rollers for scoring, worn or broken needle rollers, inadequate grease or discoloration.
seal leakage.
3.
Installation
NOTE: The pilot bearing can only be installed with the seal facing the transmission. The pilot
bearing is pregreased and does not require additional lubrication. A new pilot bearing must be
installed whenever it is removed.
Using a soft-face hammer and the Pilot Bearing Installer, install the pilot bearing.
1.
Install the clutch disc and pressure plate. For additional information, refer to Clutch Disc and Pressure 2.
Pilot Bearing 4293
Plate in this section.
Pilot Bearing 4294
SECTION 308-02: Clutch Controls
Manual
Material
Capacity
(Canada)
WSS-M6C62-A or
WSS-M6C65-A1
-
CXG-1-C (Canada)
ESA-M1C75-B -
Clutch hydraulic tube nut 17 - 150
Clutch master cylinder nuts 21 15 -
Clutch pedal bracket nut 21 15 -
Clutch pedal locknut 10 - 89
Clutch slave cylinder bolts 19 - 168
PCM bolts 10 - 89
PCM bracket nuts 10 - 89
Pilot Bearing 4295
Manual
Clutch Controls
The clutch controls system consists of the following components:
Clutch pedal
Clutch master cylinder
Clutch hydraulic fluid tube
Clutch release fork
When the clutch pedal is applied, the clutch master cylinder transmits hydraulic fluid pressure to the clutch
slave cylinder. The clutch slave cylinder and the clutch release fork transfer the clutch pedal motion to the
clutch release bearing. The release bearing presses against the pressure plate diaphragm spring, releasing the
clutch disc.
The clutch master cylinder uses brake fluid and shares a common reservoir with the brake master cylinder.
Clutch Controls 4296
Manual
Clutch Controls
For diagnosis and testing of the clutch controls, refer to Section 308-00 .
Clutch Controls 4297
Manual
REMOVAL AND
INSTALLATION
Clutch Pedal
Material
Item Specification
(Canada)
ESA-M1C75-B
1 - Clutch master cylinder nut (2 required)
2 7A543 Clutch master cylinder
3 - Clutch switch (cruise control cancel)
4 11A152 Clutch Pedal Position (CPP) switch
5 - Clutch pedal bracket nuts
6 - Retaining clip
7 - Clutch pedal and bracket assembly
8 - Master cylinder push rod clevis
9 - Clevis bushing
10 - Clevis pin
11 - Clutch pedal locknut
12 - Master cylinder push rod
13 - Retaining clip
Removal
Remove the battery and the battery tray. For additional information, refer to Section 414-01 . 1.
Remove the PCM.
2.
Clutch Pedal 4298
Remove the 2 PCM bolts. 2.
Remove the 3 PCM bracket nuts and the bracket. 3.
Remove the clutch master cylinder nut. 4.
Working under the instrument panel, disconnect the clutch switch (cruise control cancel)
5.
Disconnect the Clutch Pedal Position (CPP) electrical connector. 6.
Remove the clutch master cylinder nut and the clutch pedal bracket nut. 7.
Remove the clutch pedal and bracket assembly. 8.
Installation
NOTE: Make sure to align the push rod into the clutch master cylinder piston as the pedal
assembly is installed.
Install the clutch pedal and bracket assembly
Apply a small amount of grease to the:
clevis bushing.
end of the clutch switch.
end of the master cylinder push rod.

1.
Working under the instrument panel, connect the clutch switch (cruise control cancel)
2.
Install the clutch master cylinder nut and the clutch pedal bracket nut.
3.
Clutch Pedal 4299
Connect the CPP electrical connector. 4.
Install the clutch master cylinder nut.
5.
Install the PCM bracket and the 3 PCM bracket nuts.
6.
Install the PCM.
Install the 2 PCM bolts.
1.
Connect the electrical connectors. 2.
7.
Install the battery tray and the battery. For additional information, refer to Section 414-01 . 8.
Clutch Pedal 4300
Clutch Pedal 4301
Manual
REMOVAL AND
INSTALLATION
Clutch Master Cylinder
Material
Item Specification
(Canada)
WSS-M6C62-A or
WSS-M6C65-A1
1 - Clutch hydraulic tube nut
2 - Clutch hydraulic tube
3 7A543 Clutch master cylinder
4 - Clutch master cylinder nut
5 2K478 Clutch system reservoir
6 - Clutch master cylinder reservoir hose
7 7519 Clutch pedal and bracket
8 - Clutch master cylinder nut
Removal
Clutch Master Cylinder 4302
WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master
cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure
to follow this instruction may result in serious personal injury.
get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after
it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding
equipment.
Working under the instrument panel, remove the clutch master cylinder nut. 1.
Using a suitable suction tool, remove the brake fluid to just below the clutch reservoir hose. 2.
Remove the PCM.
Remove the 2 PCM bolts. 2.
4.
Remove 3 PCM bracket nuts and the PCM bracket. 5.
Disconnect the clutch master cylinder-to-clutch hydraulic tube. 6.
Disconnect the clutch master cylinder reservoir hose. 7.
Remove the clutch master cylinder nut. 8.
Remove the clutch master cylinder assembly. 9.
Installation
Install the clutch master cylinder assembly. 1.
Install the clutch master cylinder nut.
2.
Working under the instrument panel, install the clutch master cylinder nut.
3.
Connect the clutch master cylinder reservoir hose. 4.
Connect the clutch master cylinder-to-clutch hydraulic tube.
Tighten the clutch hydraulic tube nut to 17 Nm (150 lb-in).
5.
Install the PCM bracket and 3 PCM bracket nuts.
6.
Install the PCM.
Install the 2 PCM bolts.
1.
Connect the electrical connectors. 2.
7.
Bleed the clutch hydraulic system. For additional information, refer to Section 308-00 . 9.
Manual
REMOVAL AND
INSTALLATION
Clutch Slave Cylinder
Material
Item Specification
(Canada)
WSS-M6C62-A or
WSS-M6C65-A1
CXG-1-C (Canada)
ESA-M1C75-B
1 7A508 Clutch slave cylinder
2 - Clutch slave cylinder bolts (2 required)
3 7T504 Clutch hydraulic tube
4 - Clutch hydraulic tube nut
Removal
Clutch Slave Cylinder 4307
get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system afte
has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding
equipment.
Using a suitable suction tool, remove the brake fluid to just below the clutch reservoir hose. 1.
Disconnect the clutch hydraulic tube. 2.
Remove the 2 clutch slave cylinder bolts and the clutch slave cylinder. 3.
Installation
NOTE: Apply a small amount of grease on the end of the slave cylinder push rod.
Install the clutch slave cylinder and the 2 clutch slave cylinder bolts.
1.
Connect the clutch hydraulic tube.
2.
WARNING: Do not allow the brake master cylinder to run dry during the bleeding
operation. Master cylinder may be damaged if operated without fluid, resulting in degraded
braking performance. Failure to follow this instruction may result in serious personal injury.
Bleed the air from the system. For additional information, refer to Section 308-00 .
3.
SECTION 308-03: Manual
Transaxle/Transmission
Workshop Manual
Material
Capacity
CXG-1-C (Canada)
ESA-M1C75-B -
SAE 75W-90 API GL-4 Gear
Oil
XT-4-QGL
WSS-M2C203-A1 2.84L (3.0
qts.)
TA-30
WSE-M4G323-A4 -
TA-25
WSK-M2G351-A5 -
Item Specification
Differential
Preload 1.4-1.9 Nm
(13-17 lb-in)
Secondary shaft gear runout (maximum) 0.015 mm (0.0006 in)
Side gear and pinion gear backlash 0.050-0.150 mm
(0.0020-0.059 in)
End Play
Input shaft 0.00-0.06 mm
(0.00-0.0024 in)
Mainshaft 0.00-0.06 mm
(0.00-0.0024 in)
Gear Clearance
1st Gear End Play
Clearance 0.05-0.28 mm
(0.002-0.011 in)
Maximum 0.33 mm (0.012 in)
(0.007-0.018 in)
3rd Gear Thrust Clearance
(0.002-0.007 in)
4th Gear End Play
(0.007-0.014 in)
5th Gear Thrust Clearance
(0.0040-0.0086 in)
6th Gear Thrust Clearance
(0.0040-0.0086 in)
Runout
Input shaft gear runout (maximum) 0.05 mm (0.001 in)
Reverse idler gear runout (maximum) 0.04-0.14 mm
(0.0016-0.0060 in)
Reverse idler gear component dimension 57.0-57.5 mm
(2.244-2.263 in)
Shift Fork and Hub Sleeve Clearance
Reverse Shift Fork and Hub Sleeve
Standard 0.10-0.40 mm
(0.004-0.015 in)
Clearance Between 1st/2nd Shift Fork and Hub Sleeve
(0.004-0.017 in)
Clearance Between 3rd/4th Shift Fork and Hub Sleeve
(0.004-0.015 in)
Clearance Between 5th/6th Shift Fork and Hub Sleeve
(0.003-0.014 in)
Synchronizer Ring Clearance
Clearance Between Synchronizer Ring and Flank Surface of
Gear
Standard 0.80 mm (0.031 in)
Secondary Shaft to Gear Clearance
Gear Shaft Outer Diameter Gear Inner Diameter Clearance
1st 39.445-39.470 mm
(1.553-1.554 in)
39.500-39.525 mm
(1.555-1.556 in)
0.030-0.080 mm
(0.002-0.003 in)
2nd 34.945-34.965 mm
(1.376-1.377 in)
35.000-35.025 mm
(1.378-1.379 in)
0.05-0.09 mm
(0.002-0.003 in)
3rd 35.945-35.970 mm
(1.415-1.416 in)
36.000-36.025 mm
(1.417-1.418 in)
0.030-0.080 mm
(0.002-0.003 in)
4th 30.945-30.970 mm
(1.218-1.219 in)
31.000-31.025 mm
(1.220-1.221 in)
0.030-0.080 mm
(0.001-0.003 in)
5th 33.945-33.970 mm
(1.3365-1.3373 in)
34.000-34.025 mm
(1.3386-1.3395 in)
0.030-0.080 mm
(0.0012-0.0031 in)
Differential Shim Thickness (7067)
mm Inch
0.1 0.003
0.20 0.007
0.25 0.009
0.30 0.011
0.35 0.013
0.40 0.015
0.45 0.017
0.50 0.019
0.55 0.021
0.60 0.023
0.65 0.025
0.70 0.027
0.75 0.029
0.80 0.031
0.85 0.033
0.90 0.035
0.95 0.037
1.0 0.039
1.05 0.041
1.10 0.043
1.15 0.045
1.20 0.047
Primary Shaft Gear Shim Thickness (7L172)
mm Inch
0.30 0.011
0.35 0.013
0.40 0.015
0.45 0.017
0.50 0.019
0.55 0.021
0.60 0.023
0.65 0.025
0.70 0.027
0.75 0.029
0.80 0.031
0.85 0.033
0.90 0.035
0.95 0.037
1.0 0.039
Secondary Shaft Gear Shim Thickness (7L172)
mm Inch
0.20 0.007
0.25 0.009
0.30 0.011
0.35 0.013
0.40 0.015
0.45 0.017
0.50 0.019
0.55 0.021
0.60 0.023
0.65 0.025
0.70 0.027
Reverse Thrust Washer Thickness
mm Inch
2.04 0.080
2.09 0.082
2.14 0.084
2.19 0.086
2.24 0.088
2.29 0.090
2.34 0.092
2.39 0.094
Anchor bolt 10 - 89
Breather cover bolts 10 - 89
Case cover bolts 45 33 -
Clutch housing-to-oil pan bolts 48 35 -
Clutch slave cylinder bolts 20 - 177
Clutch tube hydraulic line bracket bolts 22 16 -
12 - 106
Drain plug 49 36 -
Electronic Power Assist Steering (EPAS) ground bolt 12 - 106
Fill plug 49 36 -
Oil pan-to-clutch housing bolts 48 35 -
Primary and secondary shaft locknuts 160 118 -
Reverse idler shaft lock bolt 22 16 -
Roll restrictor bracket through bolt 90 66 -
Roll restrictor-to-subframe through bolt 90 66 -
Shim selection set bolts 33 -
Shift control selector plate bolts
a
- - -
Shift detent bolt 18 - 159
Shift gate bolt 13 - 115
Shift lever assembly bolts 22 16 -
Shift rail guide bolt 12 - 106
Splash shield bolts 9 - 80
Steering shaft pinch bolt 20 - 177
45 33 -
Transaxle rear support insulator bolt and nuts 80 59 -
Transaxle rear support insulator-to-frame bolts (upper and lower) (4 required) 63 46 -
Upper transaxle-to-engine bolts 48 35 -
Vehicle Speed Sensor (VSS) bolt 9 - 80
a
Workshop Manual
Manual Transaxle
Manual Transaxle
The G6M 6-speed manual transaxle features the following:
Fully synchronized 6-speed transaxle
Synchronized reverse gear
Six forward speeds and one reverse speed
An aluminum main case, clutch housing and structural cover
The function of the transmission is to move the vehicle from a rest position to motion. This is done by
transferring the engine torque, through the transaxle, to the front wheels. The transmission input shaft receives
power when the clutch is engaged. Torque flows through the input shaft to the drive gear. The forward gears
are selected by a synchronizer mechanism. The helical-cut forward gears are in constant mesh with the
corresponding gears on the opposing shaft. Reverse gears have helical-cut teeth and are engaged through the
reverse idler gear.
External Shift Linkage
between the floor-mounted gear shift lever and the manual transaxle gear shift control mechanism is made
through 2 shift cables. The clutch pedal disengages the clutch allowing the transaxle to be shifted from one
gear to another.
Internal Shift Linkage
The G6M manual transaxle is shifted internally by 4 shift forks. The reverse gear shift fork shifts in and out of
the reverse gear. The 1st/2nd, 3rd/4th and 5th/6th shift forks control all forward gear shifts.
Reverse Gear
The reverse idler gear is mounted on a reverse idler gear shaft supported at one end in the clutch housing and
at the other in the transaxle case by a reverse idler shaft lock bolt.
When the reverse idler gear slides on the reverse idler gear shaft, it engages the reverse drive gear on the input
shaft and the reverse gear on the output shaft. The driving gear is part of the input shaft and the reverse gear is
machined on the outside diameter of the 1st/2nd synchronizer sleeve.
When the reverse idler gear rotates on the reverse idler gear shaft, it reverses the power flow to the output
shaft.
To engage the reverse idler gear, the motion of the shift fork is transferred to the reverse gearshift lever
through the shift gate. The reverse gearshift lever is mounted on a meshlock plunger that allows it to act as a
fulcrum. When the reverse gearshift selector arm moves its end of the shift fork, the opposite end slides the
reverse idler gear into engagement with the input shaft and output shaft reverse gears.
Differential
Manual Transaxle 4316
The ends of the differential are supported on tapered roller differential bearings. The cups for these
differential bearings are seated in the transaxle case and the flywheel housing. Differential bearing preload is
set using a selective differential bearing shim that is installed under the differential bearing cup in the
transaxle case.
The differential includes the differential side gears and the shaft mounted differential pinion gears. Direct
contact between the gears and the differential case is prevented by the differential side gear thrust washers
installed under the gears. The differential pinion shaft is held in position by a differential pinion shaft lock pin
that extends through the end of the differential pinion shaft and the differential case.
The speedometer drive gear is also mounted on the differential case. It is located between the tapered roller
differential bearing and the differential case. A tab on the speedometer drive gear and a matching slot in the
differential case prevent the speedometer drive gear from spinning on the differential case.
Workshop Manual
Manual Transaxle
Workshop Manual
Transaxle Draining and Filling
Material
Item Specification
XT-4-QGL
WSS-M2C203-A1
1 - Transaxle drain plug
2 - Transaxle fill plug
100-02 .
1.
Remove the drain plug and drain the fluid. 2.
Install a new washer and the drain plug.
3.
NOTE: Prior to removal, clean the area of the fill plug.
Remove the fill plug.
4.
NOTE: Do not overfill the transaxle. This may result in increased operating temperature or cause
transaxle fluid to be forced out of the case.
Fill the transaxle with the recommended fluid.
5.
Transaxle Draining and Filling 4319
1 - Correct level
2 - Low level
Install a new washer and fill plug.
6.
p;
Transaxle Draining and Filling 4320
Workshop Manual
Halfshaft Seal
Special Tool(s)
308-119 (T87C-77000-H)
Remover, Stator Case Bearing
307-163 (T86P-70043-A)
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
XT-4-QGL
WSS-M2C203-A1
1 4B436 LH halfshaft assembly
2 7052 Halfshaft oil seal
3 - RH intermediate shaft
4 7052 Halfshaft oil seal
NOTICE: New halfshaft oil seals should be installed any time the halfshafts are removed. Failure to
install new halfshafts seals may result in transaxle oil leak(s) and damage to the transmission may
occur.
Remove the transaxle drain plug and drain the fluid. 1.
Remove the RH intermediate shaft or LH halfshaft. For additional information, refer to Section
205-04 .
2.
Halfshaft Seal 4321
Using the Slide Hammer with the Stator Case Bearing Remover, remove the RH intermediate shaft oil
seal or the LH halfshaft oil seal.
3.
Installation
Using the Halfshaft Oil Seal Installer, install the RH intermediate shaft or the LH halfshaft oil seal. 1.
NOTE: Do not allow t splines on the halfshaft to touch the oil seal.
Install the RH intermediate shaft or LH halfshaft. For additional information, refer to Section 205-04 .
2.
Fill the transaxle to specification. For additional information, refer to Transaxle Draining and Filling
in this section.
3.
Halfshaft Seal 4322
Workshop Manual
Transaxle Rear Support Insulator
Special Tool(s)
Support Bar, Engine
303-F072
1 10723 Battery tray
2 - Battery tray bolts (2 required)
3 - Power Distribution Box (PDB) bolt (2 required)
4 - PDB nut
5 - PDB electrical connectors
6 14A067 PDB assembly
7 - Clutch hydraulic tube
8 5410494 Splash shield
9 W707398-S Splash shield bolt (7 required)
10 6F020 Transaxle rear support insulator
11 W710645-S Transaxle rear support insulator nut (2 required)
12 W711487-S Transaxle rear support insulator bolt
13 W709234-S Transaxle rear support insulator-to-frame bolt (4
required)
Removal
Transaxle Rear Support Insulator 4323
100-02 .
1.
Remove the 7 splash shield bolts and the splash shield. 1.
Remove the 2 lower transaxle rear support insulator bolts. 3.
Remove the 2 Power Distribution Box (PDB) bolts and the lower nut. Pull the PDB upward to unclip
the pushpin.
5.
Disconnect the 2 electrical connectors. 6.
Install the Engine Support Bar. 7.
Remove the clutch hydraulic tube spring clip. Push downward on the clutch tube to release it from the
bracket.
8.
Remove the clutch hydraulic tube from the plastic retainer. 9.
NOTE: If one or both of the mount studs are removed or come out, do not reinstall the old stud(s).
Install a new stud(s). Make sure the studs are properly seated in the case, even if they were not
replaced.
Remove the remaining 2 transaxle rear support insulator-to-frame bolts, the 2 transaxle rear support
insulator nuts and the transaxle rear support insulator-to-transaxle bolt.
10.
Remove the transaxle rear support insulator. 11.
Installation
Install the transaxle rear support insulator. 1.
replaced.
Install the 2 upper transaxle rear support insulator-to-frame bolts.
2.
Install the 2 transaxle rear support insulator nuts and the transaxle rear support insulator bolt.
3.
Install the clutch hydraulic tube into the plastic retainer. 4.
Install the clutch hydraulic tube spring clip. Push upward on the clutch tube to attach it to the bracket. 5.
Position the PDB in place. Connect the 2 electrical connectors. 7.
Push the PDB downward to clip the pushpin. Install the 2 PDB bolts and the lower nut. 8.
Install the battery tray and battery. For additional information, refer to Section 414-01 . 9.
Install the 2 lower transaxle rear support insulator-to-frame bolts.
10.
Install the splash shield and the 7 splash shield bolts.
11.
Workshop Manual
Vehicle Speed Sensor (VSS)
Material
Item Specification
XT-4-QGL
WSS-M2C203-A1
1 14487 Vehicle Speed Sensor (VSS) electrical connector
2 - VSS bolt
3 17271 VSS
100-02 .
1.
Disconnect the Vehicle Speed Sensor (VSS) electrical connector. 2.
Remove the VSS bolt.
3.
Remove the VSS .
Discard the O-ring.
4.
Vehicle Speed Sensor (VSS) 4328
Apply clean manual transaxle fluid to a new O-ring and install it on the VSS .
5.
Vehicle Speed Sensor (VSS) 4329
Workshop Manual
Transaxle
Special Tool(s)
Powertrain Lift
Support Bar, Engine
303-F072
100-02 .
1.
Remove the Air Cleaner (ACL) assembly. For additional information, refer to Section 303-12A . 3.
Disconnect the shift cables from the transaxle shift control lever, using a suitable tool to lightly pry
them off the transaxle shift control lever.
4.
NOTICE: Carefully pry the retainer on the shift cables. Do not damage the shift cable retainers.
Using a small screwdriver push from the back.
Disconnect the shift cables from the transaxle bracket.
5.
Transaxle 4330
Install the Engine Support Bar. 6.
Detach the wire harness from the transaxle. 7.
Remove the 3 upper transaxle-to-engine bolts. 8.
replaced.
Remove the transaxle rear support insulator nuts and the transaxle rear support insulator bolt.
9.
steering wheel.
10.
Section 501-20B .
12.
Transaxle 4331
NOTE: If disassembly of the transaxle is required, remove the drain plug and drain the transaxle.
Remove the drain plug and drain the transaxle.
14.
Once fluid has drained, install the drain plug.
15.
Remove the 2 clutch tube hydraulic line bracket bolts. 16.
Remove the 2 bolts and position the clutch slave cylinder aside. 17.
Disconnect the reverse lamp switch electrical connector. 18.
Transaxle 4332
Disconnect the Output Shaft Speed (OSS) electrical connector. 20.
21.
Remove the 2 roll restrictor bracket bolts. 23.
Transaxle 4333
205-04 .
28.
Disconnect the 2 in-lineElectronic Power Assist Steering (EPAS) system electrical connectors at the
front of the subframe.
29.
splash shield.
31.
Remove the bolt and the EPAS system wiring harness ground from behind the RH splash shield. 32.
Transaxle 4334
33.
35.
Remove the rear subframe nuts and the subframe brackets.
36.
37.
Transaxle 4335
39.
Remove the clutch housing-to-oil pan bolt. 40.
Remove the 2 oil pan-to-clutch housing bolts. 41.
Remove the remaining 4 transaxle-to-engine bolts. 42.
Move the transaxle away from the engine and lower it from the vehicle. 43.
Transaxle 4336
Transaxle 4337
Workshop Manual
Transaxle
Special Tool(s)
Holding Fixture
307-003 (T57L-500-B)
Turning Torque Socket, Transmission
308-160 (T88C-7025-GH)
NOTE: Clean the transaxle exterior before disassembly.
NOTE: Clean all removed parts and all sealing surfaces with solvent, and dry with compressed air.
NOTE: Clean out all holes and passages with compressed air and verify that there are no obstructions.
Mount the transaxle to the Holding Fixture. 1.
Remove the clutch release fork and bearing.
NOTE: May need to use a screwdriver to pry the clutch release fork off the anchor bolt, if needed.
Remove the clutch release bearing. 1.
Remove the clutch release fork and diaphragm. 2.
2.
If necessary, remove the anchor bolt. 3.
Transaxle 4338
Remove the bolt and the Vehicle Speed Sensor (VSS). 4.
Remove the reversing lamp switch wiring harness retainer bolt and reversing lamp switch. 5.
Shift the transaxle into the NEUTRAL position. 6.
Remove the 9 case cover bolts and the case cover. 7.
Remove and discard the 5th/6th gear shift fork roll pin. 8.
Shift the 5th/6th gear shift fork to 5th. 9.
Transaxle 4339
NOTE: Do not reuse locknuts.
Remove the primary and secondary shaft locknuts.
Using the Transmission Turning Torque Socket, keep the input shaft from turning. 1.
Using a punch, release the locking tabs from the shafts. Remove and discard the primary and
secondary shaft locknuts.
2.
10.
NOTICE: Make sure the tabs of the suitable tool are securely positioned on the gear or damage
to the gear may occur.
Using a suitable tool, remove the bearing and 6th gear from the secondary shaft.
11.
NOTICE: Make sure the tabs of the suitable tool are securely positioned on the gear or damage
to the gear may occur.
Using a suitable tool, remove the bearing and 6th gear from the primary shaft.
12.
Transaxle 4340
Remove the gear sleeve. 13.
Remove the 5th/6th shift fork and synchronizer assembly. 14.
Remove the spacer and the gear sleeve. 15.
Remove the 5th speed primary and secondary gears. 16.
NOTE: Make sure the transaxle is in neutral.
Transaxle 4341
Remove the reverse idler shaft lock bolt and shift rail guide bolt. 17.
Remove the shift detent bolt, spring and ball. 18.
Remove the 15 transaxle case bolts and separate the transaxle case.
After separating the transaxle cases, position the removed case on its side. Use care not to
damage the funnel.

19.
Remove the funnel bolt and the funnel. 20.
Remove the magnet. 21.
Remove the shift lever shaft pin, then remove the shift lever shaft and shift fork selector lever. 22.
Transaxle 4342
Remove the shift gate bolt. 23.
Remove the shift control shaft and remove the shift gate. 24.
Move the shift forks upward into 2nd and 4th gears. 25.
Remove the reverse idler gear assembly and shift fork. 26.
Rotate the main shift control shaft clockwise to free the interlock from the 1-2 and 3-4 shift forks. 27.
Raise the main shift control shaft until it clears the bore in the transaxle case and remove the main
shift control shaft assembly, shift forks.
28.
Transaxle 4343
Remove the primary and secondary shafts at the same time. 29.
Remove the differential. 30.
For further disassembly of the transaxle case, refer to Transaxle Case in this section. 31.
Transaxle 4344
Workshop Manual
SUBASSEMBLIES
5th/6th Gear
Inspect the 5th and 6th gear synchronizer cones, gear teeth and rings for wear or damage. Replace as
necessary.
1.
NOTE: Set the synchronizer ring squarely on the gear and measure around the circumference.
Using a feeler gauge, while applying pressure and rotating the synchronizer ring, measure the
clearance between the 5th gear synchronizer ring and the flank surface of the gear. The measurement
should be the same around the entire circumference. Replace the synchronizer ring if less than the
minimum specification.
5th Gear Synchronizer Ring Clearance
Standard Minimum
1.50 mm (0.059 in) 0.80 mm (0.031 in)
2.
NOTE: Set the synchronizer ring squarely on the gear and measure around the circumference.
Using a feeler gauge, while applying pressure and rotating the synchronizer ring, measure the
clearance between the 6th gear synchronizer ring and the flank surface of the gear. The measurement
should be the same around the entire circumference. Replace the synchronizer ring if less than the
minimum specification.
6th Gear Synchronizer Ring Clearance
Standard Minimum
1.50 mm (0.059 in) 0.80 mm (0.031 in)
3.
5th/6th Gear 4345
Measure the clearance between the clutch hub sleeve and the shift fork. Replace if it exceeds the
maximum specification.
Inspect the clutch hub sleeve and clutch hub operation. Replace if there is a malfunction.
5th/6th Gear Clutch Hub Sleeve and Shift Fork Clearance
Standard Maximum
0.10-0.36 mm (0.004-0.014 in) 0.86 mm (0.033 in)

4.
Using a telescoping gauge, measure the ID of the 5th gear. Using a micrometer, measure the OD of
the gear sleeve.
5.
Measure the telescoping gauge to determine if the gear to the gear sleeve clearances are within
specifications. If not within specifications, replace as needed.
6.
Using a telescoping gauge, measure the ID of the 6th gear. Using a micrometer, measure the OD of
the gear sleeve.
7.
5th/6th Gear 4346
Measure the telescoping gauge to determine if the gear to the gear sleeve clearances are within
specifications. If not within specifications, replace as needed.
5th and 6th Gear Oil Clearance
Gear Gear ID Gear Sleeve OD Clearance
5th 34.00-
34.025 mm (1.3386-
1.3395 in)
33.945-
33.970 mm (1.3365-
1.3373 in)
0.030-
0.80 mm
(0.001-
0.003 in)
6th 34.00-
34.025 mm (1.3386-
1.3395 in)
33.945-
33.970 mm (1.3365-
1.3373 in)
0.030-
0.80 mm (0.001-
0.003 in)
8.
5th/6th Gear 4347
5th/6th Gear 4348
Workshop Manual
SUBASSEMBLIES
Input Shaft
Special Tool(s)
100-002 (TOOL-4201-A)
Installer, Differential Bearing Cup
308-155 (T88C-7025-DH)
Installer, Transaxle Bearing Cone
307-181 (T87C-77000-D)
Plate, Bearing/Oil Seal
205-090 (T75L-1165-B)
Puller, Bearing
Shaft Protector Set
205-DS004 (D80L-625-A) or equivalent
Material
Item Specification
XT-4-QGL
WSS-M2C203-A1
1 7025 Bearing
Input Shaft 4349
2 7017 Input shaft
3 7101 3rd gear
4 - Double cone (part of 7Z018)
5 - Inner cone (part of 7Z018)
6 7Z018 Synchronizer blocking ring (part of blocking ring set)
7 7109 Synchronizer blocking springs (part of 7124)
8 7A044 Synchronizer hub insert (part of 7124)
9 7105 Synchronizer hub (part of 7124)
10 7106 Synchronizer sleeve (part of 7124)
11 7124 Synchronizer hub assembly
12 7064 Snap ring
13 - Double cone (part of 7Z018)
14 - Inner cone (part of 7Z018)
15 7110 4th gear
16 7025 Bearing
Disassembly
Measure the input shaft clearances.
Measure the clearance between the 3rd and 2nd gears. Third gear thrust clearance is 0.05-0.20
mm (0.001-0.007 in).
1.
Measure the clearance between 4th gear and the bearing cone. Fourth gear endplay is
0.17-0.37 mm (0.006-0.014 in).
2.
1.
NOTE: When pressing off components, hold the shaft so it does not fall.
NOTE: Use the Shaft Protector Set to pamage to the shaft.
Using the Bearing Puller and a suitable press, press off the bearing.
Discard the bearing.
Always install new bearings and cups as a set.
2.
Input Shaft 4350
NOTE: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order
that they were removed.
Remove 4th gear and the synchronizer blocking ring.
3.
Remove and discard the snap ring. 4.
NOTICE: The synchronizer blocking rings are not interchangeable. Make sure to keep them in
the order that they were removed.
NOTE: Use the Shaft Protector Set to prevent damage to the shaft.
Using the Bearing Puller and a suitable press, press off the synchronizer hub assembly, the
synchronizer blocking ring and 3rd gear as an assembly.
5.
Input Shaft 4351
NOTE: Using a paint pen, mark the hub to sleeve position for reassembly.
Disassemble the synchronizer assembly.
Remove the synchronizer blocking spring. 1.
Remove the opposite synchronize spring. 2.
Remove the synchronizer hub inserts. 3.
Separate the synchronizer hub from the sleeve.
Inspect all synchronizer components for wear and damage. Install a new synchronizer
as necessary.

4.
6.
Using the Bearing Puller and a suitable press, press off the bearing.
7.
Input Shaft 4352
Using the Dial Indicator Gauge with Holding Fixture, measure the input shaft gear runout.
Inspect the input shaft for worn or damaged gears. Install a new input shaft as necessary.
Input shaft gear maximum runout is 0.05 mm (0.001 in).
8.
Set the synchronizer ring set squarely on the gear, then measure around the circumference.
Measure the clearance from the side of the gear.
Synchronizer ring clearance is 0.80-1.50 mm (0.031-0.059 in).

Inspect for smooth engagement with the gear.
Inspect for worn or damaged teeth. Install new components as necessary.
9.
Inspect the synchronizer hub.
Inspect for worn or damaged splines, synchronizer insert groove or end surface.
Inspect for smooth hub sleeve movement when it is installed.
10.
Measure the clearance between the 3rd/4th synchronizer hub and its shift fork.
Shift fork and hub sleeve clearance is 0.10-0.90 mm (0.003-0.035 in).
11.
Assembly
NOTE: Do not reassemble the input shaft dry.
Lubricate all input shaft components with the recommended transmission lubricant during
reassembly.
1.
Using the Bearing/Oil Seal Plate, Transaxle Bearing Cone Installer and a suitable press, press on the
new bearing.
2.
Input Shaft 4353
Install 3rd gear. 3.
Assemble the synchronizer.
Position the synchronizer hub and sleeve together. 1.
Install the synchronizer hub inserts. 2.
Install the synchronizer blocking spring. 3.
Rotate the synchronizer and install the opposite synchronizer blocking spring. 4.
4.
Assemble 3rd gear blocking ring set and synchronizer assembly 5.
NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring groove
and synchronizer hub inserts.
NOTE: Make sure to have the ridge facing the 3rd gear when installing the synchronizer hub
assembly.
NOTE: Make sure that the 4 grooves in the synchronizer hub are facing the 3rd gear.
NOTE: Make sure 3rd gear rotates freely on the shaft.
Using the Bearing/Oil Seal Plate, Differential Bearing Cup Installer and a suitable press, press the
input shaft onto the 3rd gear synchronizer blocking ring and synchronizer assembly.
6.
Input Shaft 4354
NOTE: Invert the input shaft.
Install a new snap ring.
7.
Assemble the 4th gear blocking ring set. 8.
Assemble the 4th gear synchronizer assembly. 9.
Install the 4th gear blocking ring set and synchronizer assembly into the input shaft. 10.
NOTICE: Press the bearing onto the input shaft by the inner race only. Pressing on the outer
race will damage the bearing.
NOTE: Make sure 4th gear rotates freely on the shaft.
NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring tab and
synchronizer hub inserts.
Using the Bearing Puller and a suitable press, press on a new bearing.
11.
NOTE: If not within specifications, disassemble and reassemble the input shaft assembly.
Measure the input shaft clearances.
Measure the clearance between the 3rd and 2nd gears. 1.
12.
Input Shaft 4355
2nd gear end play is 0.018-0.46 mm (0.007-0.018 in), maximum end play is 0.51 mm
(0.02 in).

Measure the clearance between the 4th gear and the bearing cone.
4th gear end play is 0.17-0.37 mm (0.006-0.014 in), maximum end play is 0.42 mm
(0.016 in).

2.
Input Shaft 4356
Workshop Manual
SUBASSEMBLIES
Output Shaft
Special Tool(s)
Bearing Puller
100-002 (TOOL-4201-A)
308-155 (T88C-7025-DH)
Installer, Transaxle Bearing Cone
307-181 (T87C-77000-D)
Plate, Bearing/Oil Seal
205-090 (T75L-1165-B)
Material
Item Specification
XT-4-QGL
WSS-M2C203-A1
1 7F431 Output shaft bearing
2 7061 Output shaft
3 - Spacer
4 - Friction dampener
5 7100 1st gear
6 - Synchronizer inner cones
7 - Synchronizer outer cones
Output Shaft 4357
8 7107 Synchronizer blocking rings
9 - 1st/2nd gear synchronizer assembly
10 - Synchronizer key springs
11 - Synchronizer key
12 - 1st/2nd clutch hub
13 - Clutch hub sleeve (reverse gear)
14 7064 Snap ring
15 7102 2nd gear
16 - Friction damper cone
17 - Secondary 3rd gear
18 7064 Snap ring
19 - Secondary 4th gear
20 7025 Bearing
Disassembly
NOTE: When pressing off components, hold the shaft so it does not fall.
Measure the output shaft clearances.
Measure the clearance between 1st gear and the differential drive gear. First gear endplay is
0.05-0.33 mm (0.001-0.012 in).
1.
Measure the clearance between 2nd gear and secondary 3rd gear. Second gear endplay is
0.18-0.51 mm (0.007-0.02 in).
2.
1.
Using the Bearing Puller and a suitable press, press off the bearing and 4th gear.
2.
Output Shaft 4358
Using the Bearing Puller and a suitable press, press off the 3rd gear and 2nd gear. 4.
NOTE: The synchronizer blocking rings are not interchangeable. Be sure to keep them in the order
Remove the synchronizer blocking ring, the synchronizer inner cone and the synchronizer outer cone.
5.
NOTE: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order
Using the Bearing/Oil Seal Plate and a suitable press, press off the synchronizer hub, synchronizer
blocking ring and 1st gear.
7.
NOTE: Using a paint pen, mark the hub to sleeve position for reassembly. 8.
Output Shaft 4359
Disassemble the synchronizer assembly.
Remove the synchronizer blocking spring. 1.
Rotate the synchronizer and remove the opposite spring. 2.
Remove the hub inserts. 3.
Separate the synchronizer hub from the sleeve.
Inspect all synchronizer components for wear or damage. Install a new synchronizer
as necessary.

4.
NOTE: Always install new bearings and cups as a set.
Using the Bearing Puller and a suitable press, press off the bearing and discard.
9.
Using a Dial Indicator Gauge with Holding Fixture, measure the output shaft gear runout.
Inspect the output shaft for wear or damage.
Inspect the output shaft for a plugged oil passage.
Maximum output shaft gear runout is 0.015 mm (0.0006 in).
Install a new output shaft as necessary.
10.
Set the synchronizer ring squarely in the gear, then measure around the circumference.
Measure the clearance from the side of the gear.
Synchronizer ring clearance is 0.80-1.50 mm (0.031-0.059 in).

Inspect for smooth engagement with the gear.
Inspect for worn or damaged teeth or tapered surface. Install new components as necessary.
11.
Output Shaft 4360
Inspect the synchronizer hub.
Inspect for worn or damaged splines, synchronizer insert groove or end surface.
Inspect for smooth hub sleeve movement when it is installed.
12.
Measure the clearance between the 1st/2nd synchronizer hub and its shift fork.
Shift fork and hub sleeve clearance is 0.10-0.95 mm (0.003-0.037 in).
13.
Assembly
NOTE: Do not reassemble the output shaft dry. Apply lubricant throughout the assembly procedure.
Lubricate all output shaft components with the recommended transmission lubricant during
reassemble.
1.
Using the Bearing/Oil Seal Plate, Transaxle Bearing Cup Installer and a suitable press, press on a new
bearing.
2.
If installing a new output shaft, using a suitable press, install the new spacer. 3.
Install the friction dampener. 4.
Assemble the synchronizer.
Position the synchronizer hub to the sleeve. 1.
Install the hub inserts. 2.
Install the blocking spring. 3.
Rotate the synchronizer and install the opposite blocking spring. 4.
5.
Assemble the 1st gear blocking ring set and synchronizer. 6.
NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring groove
and synchronizer hub inserts to prevent damage.
Using the Bearing/Oil Seal Plate, Differential Bearing Cup Installer and a suitable press, press on the
1st gear, the synchronizer blocking ring and synchronizer assembly.
7.
Output Shaft 4361
Invert the shaft. 8.
Install a new snap ring. 9.
NOTE: Make sure 1st gear rotates freely.
Install the synchronizer blocking ring, the synchronizer outer cone and the synchronizer inner cone.
10.
Install the friction damper cone onto 2nd gear. 11.
Install 2nd gear. 12.
Using a suitable tool, press on 3rd gear.
Make sure the slots on 3rd gear are aligned with the fingers on the friction damper cone.
13.
NOTE: Make sure 2nd gear rotates freely. 14.
Output Shaft 4362
Install a new snap ring.
Using a suitable tool, press on 4th gear. 15.
NOTICE: Only press on the inner race of the bearing or damage may occur to the bearing.
Invert the output shaft in the press. Using a suitable tool, install a new bearing.
16.
NOTE: If not within specifications, disassemble and reassemble the output shaft assembly.
Measure the output shaft clearances.
Measure the clearance between 1st gear and the differential drive gear. First gear endplay is
0.05-0.33 mm (0.001-0.012 in).
1.
Measure the clearance between 2nd gear and 3rd gear. Second gear endplay is 0.18-0.51 mm
(0.007-0.02 in).
2.
17.
Output Shaft 4363
Output Shaft 4364
Workshop Manual
SUBASSEMBLIES
Differential
Special Tool(s)
Adapter Set, Step Plate
Bearing Puller
100-002 (TOOL-4201-A)
308-162 (T88C-77000-EH)
Push/Puller Set
1 4221 Differential bearings
2 17285 Speedometer drive gear
3 4241 Differential pinion shaft lock pin
4 4026 Differential
5 4228 Differential side gear thrust washers
6 4236 Differential side gears
7 4230 Differential pinion gear thrust washers
8 4215 Differential pinion gears
Differential 4365
9 4211 Differential pinion shaft
Disassembly
Inspect the differential for wear or damage.
Inspect for damaged or worn gears.
Inspect for worn or damaged differential bearings.
Install new components as necessary.
1.
Remove the differential side gears and thrust washers.
Rotate the differential side gears to remove.
2.
Remove and discard the differential pinion shaft lock pin. 3.
Remove the differential pinion shaft, the differential pinon gears and the thrust washers. 4.
Using the Step Plate Adapter Set, Bearing Puller and the Push/Puller Set, remove the differential
bearing.
5.
Remove the speedometer drive gear. 6.
Differential 4366
Rotate the differential assembly. Using the Step Plate Adapter Set, Bearing Puller and the Push/Puller
Set, remove the other differential bearing.
7.
Assembly
Align the locking tabs and install the speedometer drive gear. 1.
NOTICE: Press the differential bearings onto the differential case by the inner race only.
Pressing on the outer race will damage the bearing.
Using the Differential Bearing Cup Installer and a suitable press, press the differential bearing onto
the differential case.
2.
Differential 4367
Rotate the differential case. Using the Differential Bearing Cup Installer and a suitable press, press on
the differential bearing.
3.
Install the differential pinion gears and thrust washers. 4.
Install the differential pinion shaft. 5.
Install the new differential pinion shaft lock pin. 6.
Install the differential side gears and thrust washers. 7.
Measure the differential backlash using the following steps in the following sequence:
Install the LH and RH halfshafts in the differential. 1.
Support the halfshafts on V-blocks as shown. 2.
Using the Dial Indicator Gauge with Holding Fixture, measure the backlash of both pinion
gears.
If not within specification, replace worn and damaged parts.
3.
8.
Differential 4368
Differential 4369
Workshop Manual
SUBASSEMBLIES
Transaxle Case
Special Tool(s)
Handle
205-153 (T80T-4000-W)
Installer, Clutch Housing Oil Seal
308-057 (T77J-7025-G)
308-162 (T88C-77000-EH)
308-119 (T87C-77000-H)
Remover, Stator Case Bearing
307-163 (T86P-70043-A)
Slide Hammer
100-001 (T50T-100-A
Transaxle Case Exploded View
Transaxle Case 4370
1 7025 Bearing race
2 7052 Oil seal
3 7F431 Bearing race
4 7L276 Funnel
5 7479 Shift control selector plate
6 7K470 Vent cover
7 7034 Vent
8 17271 Vehicle Speed Sensor (VSS)
9 7052 Oil seal
10 - Bearing race
11 7B096 Drain plug
12 99562 Drain plug washer
13 7025 Bearing race
14 - Selective shim (part of 7L172)
15 7025 Bearing race
16 - Selective shim (part of 4067)
17 7052 Oil seal
18 7277B Dust boot (part of 7439)
19 7Z262 Spring pin
20 99576 Snap ring (part of 7439)
21 - Selector lever (part of 7439)
22 - Bracket (part of 7439)
23 7202 Shift lever
24 7277A Dust boot
25 7B220 Key
26 7B125 Control rod end
27 7G046 Spring and washer
28 7358 Shift lever shaft
29 7288 Oil seal
30 7A174 Oil funnel
31 7141 Bushing
Place the transaxle clutch housing on a bench. 1.
Remove the 2 vent cover bolts and the vent cover. 2.
Using the Slide Hammer and Stator Case Bearing Remover, remove the differential bearing cup. 3.
Transaxle Case Exploded View 4371
Inspect the cup for wear or damage. Install a new cup as necessary.
Using a screwdriver, remove and discard the differential seal. 4.
Remove the input shaft bearing cup.
5.
Using a screwdriver, remove and discard the input shaft oil seal. 6.
Remove the output shaft bearing cup and the funnel.
7.
Remove the shift control selector plate bolts and the shift control selector plate. 8.
Working on the transaxle case:
Remove the 2 shift lever assembly bolts and separate the boot from the case. 1.
Separate the shift arm, boot and bushing from the shift lever assembly. 2.
9.
Remove the control arm bolt. 10.
Pull the shift lever outward, then remove the washer, spring and the control arm. 11.
Remove the control arm key. 12.
Remove the shift lever from the case.
Inspect all components for wear or damage. Install new components as necessary.
13.
Inspect the shift lever bushing and replace if necessary. 14.
Remove the shift lever boot. 15.
Remove the shift lever seal. 16.
Remove the input shaft bearing cup and shims.
17.
Remove the output shaft bearing cup and shims.
18.
Using the Slide Hammer and Stator Case Bearing Remover, remove the differential bearing cup and
shims.
19.
Remove and discard the differential oil seal. 20.
Assembly
Do not install the following components into the transaxle case at this time. These components will be
installed during final assembly.
Input shaft bearing cup and shim
Output shaft bearing cup and shim
Differential bearing cup and shim
Funnel
1.
Working on the transaxle clutch housing side, install the vent cover and the 2 vent cover bolts.
2.
Using the Clutch Housing Oil Seal Installer, install a new input shaft seal. 3.
Install the input shaft bearing cup into the clutch housing. 4.
Align and install the funnel and the output shaft bearing cup into the clutch housing. 5.
Using the Differential Bearing Cup Installer and Handle, install the differential bearing cup into the
clutch housing.
6.
Using the Halfshaft Oil Seal Installer, install new halfshaft seals. 7.
Install the shift control selector plate.
Tighten the bolt on the left to 10 Nm (89 lb-in).
Tighten the bolt on the right to 28 Nm (21 lb-ft).
8.
Install the shift lever boot. 9.
Install shift lever seal into the case. 10.
Install the shift lever rod into the case. Install the control arm key. 11.
NOTE: Use care not to let the washer fall off the rod.
Install the control arm, the spring and the washer. Push the assembly inward. Align the control arm
bolt with the notch on the shift lever rod. Install the bolt.
12.
Install the shift lever assembly.
Install the 2 shift lever assembly bolts and attach the boot and bushing to the case.
1.
Attach the shift arm, boot and bushing to the shift assembly. 2.
13.
Workshop Manual
SUBASSEMBLIES
Reverse Idler Gear
1 - Roll pin
2 - Reverse idler gear support
3 - Washer
4 - Reverse idler gear
5 - Thrust washer
6 - Reverse clutch hub sleeve
7 - Reverse synchronizer ring
8 - Synchronizer key spring
10 - Friction damper
11 - Reverse idler gear shaft
12 - Needle bearing
13 - Thrust washer
14 - Clip
Disassembly
Remove the clip. 1.
Remove the thrust washer. 2.
Reverse Idler Gear 4378
Remove the needle bearing. 3.
Remove the reverse idler gear. 4.
Remove the friction damper. 5.
Remove the reverse synchronizer assembly. 6.
Remove the reverse idler gear washer. 7.
Remove the reverse idler gear. 8.
Remove the reverse idler gear washer. 9.
Assembly
Install the reverse idler gear washer. 1.
Install the reverse idler gear. 2.
Install the reverse idler gear washer. 3.
Install the reverse synchronizer assembly.
Reverse clutch hub inspection.
Inspect the clutch hub sleeve and hub operation. Install new components as
necessary.

4.
Inspect the gear teeth for damage, wear, and cracks. Install new components as
necessary.

Measure the clearance between the hub sleeve and shift forks. If it exceeds the
maximum specification replace the hub sleeve and shift fork as a set.
Reverse Clutch Hub Sleeve and Shift Fork Clearance
Standard Maximum
0.10 mm-0.40 mm (0.003-0.015 in) 0.90 mm (0.035 in)

Reverse synchronizer ring inspection.
Inspect the synchronizer teeth for damage, wear and cracks. Install new components
as necessary.

Inspect the tapered surface for wear or cracks. Install new components as necessary.
NOTE: Set the synchronizer ring squarely on the gear and measure around the
circumference.
Measure the clearance between the synchronizer ring and the flank surface on the
gear. If it is less than minimum specification, replace the synchronizer ring.
Reverse Synchronizer Ring Clearance
Standard Minimum
1.50 mm (0.059 in) 0.80 mm (0.031 in)

Install the friction damper onto the reverse idler gear. 5.
NOTE: The reverse idler gear is not serviced separately. A kit consisting of the output shaft reverse
gear, the countershaft reverse gear and the reverse idler gear is available for service. All 3 gears in the
kit must be installed. The replacement gears are not compatible with the existing gears.
Install the reverse idler gear.
Reverse idler gear inspection.
Inspect the synchronizer cones for wear. Install new components as necessary.

6.
Inspect the gear teeth for damage, wear and cracks. Install new components as
necessary.

Inspect the synchronizer ring matching teeth for damage or wear. Install new

Install the needle bearing. 7.
Install the thrust washer. 8.
Measure the reverse idler gear component dimension.
Reverse Thrust Washer Thickness
mm Inch
2.04 0.080
2.09 0.082
2.14 0.084
2.19 0.086
2.24 0.088
2.29 0.090
10.
2.34 0.092
2.39 0.094
If the reverse idler gear component dimension is not within specification, install a thrust
washer of the correct thickness.

Workshop Manual
Transaxle
Special Tool(s)
100-002 (TOOL-4201-A)
Handle
205-153 (T80T-4000-W)
Holding Fixture
307-003 (T57L-500-B)
Installer, Differential Bearing Cup Replacer
308-162 (T88C-77000-EH)
Rotator, Differential
308-165 (T88C-77000-L)
Shim Selection Set
308-161 (T88C-77000-C)
Shim Selection Set
308-164 (T88C-77000-JF)
Turning Torque Socket, Transmission
308-160 (T88C-7025-GH)
Material
Item Specification
TA-30
WSE-M4G323-A4
Transaxle 4384
1 7505 Clutch housing
2 - Control rod
3 - Control end
4 - 1st/2nd shift fork
5 - Control lever
6 - Interlock lever
7 - 3rd/4th shift fork
8 - Inner shift lever
9 - Spring pin
10 - Push pin component and spring
11 4026 Differential
12 - Secondary shaft gear assembly
13 - Primary shaft gear assembly
14 - Shift fork and shift rod assembly
16 - Reverse shift fork
17 - 5th/reverse shift rod end
18 - 5th/reverse shift rod
19 7L027 Magnet
20 7F116 Crank lever component
21 - O-ring
22 7C355 Crank lever shaft
Transaxle 4385
23 - Pin
24 7005 Transaxle case component
25 7G072 Neutral switch
26 - Push pin component
27 - Detent spring
g bolt and washer
29 15520 Reversing lamp switch
30 - Lock bolt
31 - Shift rail guide bolt
32 - Reverse idler shaft lock bolt
33 - Clutch hub
34 - Clutch hub sleeve
36 - Spacer
37 - Gear sleeve
38 - 5th gear
39 - 5th gear synchronizer
41 - 5th/6th clutch hub
42 - 5th/6th shift fork
45 - 6th gear synchronizer
46 - 6th gear
47 - Gear sleeve
48 - Bearing (secondary shaft)
49 - Bearing (primary shaft)
50 7N170 Locknut (secondary shaft)
51 7N170 Locknut (primary shaft)
52 7222 Rear cover
NOTE: Whenever the transaxle has been disassembled, the bearing preload must be and differential bearing
preload can be adjusted by selecting shims to insert between the bearing races and the case.
Install the input shaft. 1.
Install the bearing cup onto the bearing. 2.
Transaxle 4386
Install the Shim Selection Set. 3.
Install the transaxle case.
Position the transaxle case in place. 1.
Install the Shim Selection Set bolts.
2.
4.
Mount the Dial Indicator Gauge with Holding Fixture to the transaxle case. 5.
Rotate the input shaft to seat the bearings. 6.
Zero the Dial Indicator Gauge with Holding Fixture. 7.
NOTE: The shaft must be lifted equally on both sides or it may bind on one side, resulting in an
incorrect reading.
Rotate the input shaft until the Dial Indicator Gauge returns to zero, then raise the input shaft and read
the end play.
Take and record 3 readings within 0.10 mm (0.003 in) of each other. Use the formula below
to select the correct shim size.
Average the 3 readings Example
Reading A 0.019

8.
Transaxle 4387
Reading B 0.014
Reading C +0.021
0.054 3 = 0.018
Final Shim Size 0.018
NOTE: Do not use more than 2 shims.
From the Shim Selection Set, select the shim(s) that is closest to (or slightly thinner than) the final
shim size calculated in the previous step.
9.
Remove the transaxle case, Shim Selection Set, bearing cup and input shaft. 10.
Install the input shaft shim(s). 11.
Install the input shaft bearing cup. 12.
Install the funnel and the output shaft bearing cup. 13.
Install the output shaft. 14.
Transaxle 4388
NOTE: The gauge halves must be turned to eliminate any gap between them.
Install the Shim Selection Set.
16.
2.
17.
Mount the Dial Indicator Gauge with Holding Fixture on the transaxle case. 18.
Rotate the output shaft to seat the bearings. 19.
Transaxle 4389
NOTE: The shaft must be lifted equally on both sides or it may bind on one side, resulting in an
incorrect reading.
Rotate the output shaft until the Dial Indicator Gauge returns to zero, then raise the output shaft and
read the end play.
Take and record 3 readings within 0.10 mm (0.003 in) of each other. Use the formula below
to select the correct shim size.
Average the 3 readings Example
Reading A 0.019
Reading B 0.014
Reading C +0.021
0.054 3 = 0.018
Final Shim Size 0.018

21.
NOTE: Do not use more than 2 shims.
From the Shim Selection Set, select the shim(s) that is closest to (or slightly thinner than) the final
shim size determined in the previous step.
2.
Remove the transaxle case, Shim Selection Set, bearing cup and output shaft. 23.
Install the shim. 24.
Install the funnel and the output shaft bearing cup. 25.
Install the differential. 26.
Transaxle 4390
NOTE: The gauge halves must be turned to eliminate any gap between them.
Install the Shim Selection Set.
28.
2.
29.
Using the Shim Selection Set, adjust gauge until the free play is removed. Turn gauge back together. 30.
Insert the Differential Rotator through the transaxle case and engage the differential pinion shaft. 31.
Transaxle 4391
Using the Differential Rotator and Shim Selector Set, adjust gauge until the differential rotation is
within specification.
32.
Measure the gap in the Shim Selector Set. 33.
NOTICE: Do not use more than 2 differential shims.
Add 0.15 mm (0.005 in) to the measurement to achieve the final clearance.
Using the following chart, select the differential bearing shims that are closest to (or slightly
larger than) the final shim size.
Shim Thickness
0.10 mm (0.003 in)
0.15 mm (0.005 in)
0.20 mm (0.007 in)
0.25 mm (0.009 in)
0.30 mm (0.011 in)
0.35 mm (0.013 in)
0.40 mm (0.015 in)
0.45 mm (0.017 in)
0.50 mm (0.019 in)
0.55 mm (0.021 in)
0.60 mm (0.023 in)
0.65 mm (0.025 in)
0.70 mm (0.027 in)
0.75 mm (0.029 in)
0.80 mm (0.031 in)

34.
Transaxle 4392
0.85 mm (0.033 in)
0.90 mm (0.035 in)
0.95 mm (0.037 in)
1.00 mm (0.039 in)
1.05 mm (0.041 in)
1.10 mm (0.043 in)
1.15 mm (0.045 in)
1.20 mm (0.047 in)
Remove the transaxle case, Shim Selection Set, differential and bearing cup. 35.
Install the differential bearing cup shim(s) into the transaxle case. 36.
Using the Differential Bearing Cup Installer and Handle, install the differential bearing cup into the
transaxle case.
37.
Install the output shaft, the input shaft and the differential together. 38.
Install the spring and the shift detent. 39.
Shift the synchronizers into the 2nd and 4th gear positions. 40.
Transaxle 4393
Install the main shift control shaft assembly, shift forks. 41.
NOTE: Align the reverse idler shaft anchor bolt hole for installation of the bolt through the case.
Install the reverse idler gear and shift fork.
42.
Install the shift control shaft and the shift gate. 43.
NOTE: Make sure to align the shift gate at the bottom and the shift gate with the main shift control.
Install the shift gate bolt.
44.
NOTE: Shift lever shaft uses a solid pin.
Install the shift lever shaft, shift fork selector lever and shift shaft pin.
45.
Transaxle 4394
Install the magnet. 46.
Position the 2nd and 4th gear synchronizers into neutral, then shift the 1st/2nd gear synchronizer into
neutral.
47.
Install the oil funnel. 48.
NOTE: The transaxle case must be installed within 4 minutes after applying silicone gasket and
sealant.
Apply a small bead of silicone gasket and sealant to the transaxle mating surface.
Install the transaxle case and the 2 transaxle case bolts.
Make sure to align the shift lever to the shift lever shaft. Do not move the shaft outward to the
stop. The washer can slide off of the shaft into the case.

49.
Install the shift detent ball, spring and bolt.
50.
NOTE: Make sure that the shift rail guide bolt is in the groove of the shift rail.
NOTE: Do not shift the transaxle until the reverse idler shaft lock bolt and the shift rail guide bolt are
installed.
51.
Transaxle 4395
Install the reverse idler shaft lock bolt and the shift rail guide bolt.
Install the reverse idler shaft lock bolt.
Tighten the reverse idler shaft lock bolt to 22 Nm (16 lb-ft).
1.
Install the shift rail guide bolt.
Tighten the shift rail guide bolt to 12 Nm (106 lb-in).
2.
Check the shift function. 52.
Install the remaining 13 transaxle case bolts.
53.
Install the primary and secondary 5th gears. 54.
Install the spacer and the gear sleeve. 55.
Install the 5th/6th shift fork and synchronizer assembly. 56.
Install the gear spacer. 57.
Transaxle 4396
Install the primary and secondary 6th gears. 58.
NOTE: When the locknuts are tightened to specifications they will seat the bearings.
Install the 6th gear bearings onto the primary and secondary shafts.
59.
Shift the 5th/6th gear shift fork to 5th. 60.
NOTE: Do not reuse locknuts.
Install the new primary and secondary shaft locknuts.
Shifting into 5th/6th gears and using the Transmission Turning Torque Socket will keep the
primary shaft from turning.
1.
Install the new primary and secondary shaft locknuts. Using a punch, stake the locknuts to the
shafts.
2.
61.
Transaxle 4397
NOTE: Shift 5th/6th into neutral.
Install a new 5th/6th shift fork roll pin.
62.
NOTE: The case cover must be installed within 4 minutes after applying silicone gasket and sealant.
Apply a small bead of silicone gasket and sealant to the case and case cover mating surface.
63.
Install the case cover and the 9 case cover bolts.
64.
If removed, install the anchor bolt.
65.
Install the clutch release fork and bearing.
Install the clutch release fork and diaphragm. 1.
Install the clutch release bearing. 2.
66.
Transaxle 4398
Remove the transaxle from the Holding Fixture. 67.
Transaxle 4399
Workshop Manual
Transaxle
Special Tool(s)
Powertrain Lift
Support Bar, Engine
303-F072 or equivalent
Material
Item Specification
CXG-1-C (Canada)
ESA-M1C75-B
XT-4-QGL
WSS-M2C203-A1
TA-25
WSK-M2G351-A5
NOTE: Wipe off excess grease. The splines should have a thin film of grease only. Excess grease can
contaminate the clutch facing and affect clutch function.
Apply a very small amount of grease on the input shaft splines.
1.
Secure the transaxle to a suitable transmission jack with a safety strap. Raise and position the
transaxle behind the engine.
2.
Install the clutch housing-to-oil pan bolt.
3.
Transaxle 4400
Install the 2 oil pan-to-clutch housing bolts.
4.
Install the 4 lower transaxle-to-engine bolts.
5.
Apply threadlock and sealer to the threads and install the 2 transmission lower mount nuts and bolt to
the transaxle. Do not tighten the fasteners at this time.
6.
Position the clutch slave cylinder to the clutch release arm and install the bolts.
7.
Install the clutch tube hydraulic line bracket bolts.
8.
Transaxle 4401
11.
12.
13.
14.
Transaxle 4402
Install the stabilizer bar links and nuts on the struts.
15.
16.
17.
shield.
18.
Transaxle 4403
.
21.
Transaxle 4404
Connect the reverse lamp switch electrical connector. 27.
Connect the Output Shaft Speed (OSS) sensor electrical connector. 28.
Fill the transaxle with clean gear oil. For additional information, refer to Transaxle Draining and
Filling in this section.
29.
Install the splash shield and the 7 bolts.
30.
interior can occur.

31.
Transaxle 4405
Install the steering column shaft onto the steering gear and install a new bolt.
32.
NOTE: If one or both of the mount studs were removed or came out, do not reinstall the old stud(s).
Install a new stud(s). Make sure they are properly seated in the case.
Tighten the transaxle rear support insulator nuts and bolt to specification.
34.
Install the 3 upper transaxle-to-engine bolts.
35.
Attach the wire harness to the transaxle. 36.
Install the gearshift and shift cables onto the transaxle bracket and gearshift control assembly. Make
sure the cables are engaged in the shift bracket and fully installed on the gearshift control assembly.
38.
Install the battery tray and battery. For additional information, refer to Section 414-01 . 39.
Transaxle 4406
Install the Air Cleaner (ACL) assembly. For additional information, refer to Section 303-12A . 40.
If the input shaft was replaced, use the scan tool to perform the Misfire Monitor Neutral Profile
41.
Check the vehicle for normal operation. 42.
Transaxle 4407
SECTION 308-06: Manual Transaxle/Transmission
External Controls
Gearshift cable grommet nuts 8 - 71
Gearshift lever nuts 23 17 -
Transaxle 4408
External Controls
External Controls
The manual transaxle external controls consist of the following:
Gearshift lever
Gearshift lever knob and boot
Gearshift cables
between the floor mounted gearshift lever and the manual transaxle gearshift control assembly is made
through 2 gearshift cables.
When the operator moves the floor mounted gearshift lever, that movement is transmitted through 2 gearshift
cables routed through the body to the transaxle. The 2 gearshift cables are attached to the transaxle at the
gearshift control assembly. The gearshift control assembly transfers the movement of the gearshift cables to
the shift rods and shift forks located inside the transaxle. Removal and installation of the gearshift cables
requires specific adjustments for correct shifting of the transaxle. For information regarding gearshift cable
adjustments, refer to Section 308-00 .
External Controls
Gearshift Lever
1 7210 Gearshift lever assembly
2 - Gearshift lever nut (4 required)
3 7E395 Shift cable
4 7E395 Select cable
Removal
Remove the gearshift knob. 1.
Open the storage compartment door. 2.
Remove the floor console finish panel. Disconnect the electrical connectors. 3.
Remove the LH floor console trim panel. For additional information, refer to Section 501-12 . 4.
Disconnect the shift cable and the select cable from the gearshift lever. 5.
Gearshift Lever 4410
NOTICE: Carefully disconnect the gearshift cables from the gearshift lever base. Do not
damage the gearshift cable retainers.
Disconnect the gearshift cables from the gearshift lever base.
6.
Remove the 4 gearshift lever nuts. 7.
Remove the gearshift lever assembly. 8.
Installation
Position the gearshift lever assembly in the vehicle. 1.
Install the 4 gearshift lever nuts.
2.
NOTICE: Make sure the gearshift cables are fully seated into the gearshift lever base or damage
may occur.
Connect the gearshift cables to the gearshift lever base.
3.
Connect the select cable and the shift cable to the gearshift lever. 4.
Adjust the gearshift cables. For additional information, refer to Section 308-00 . 5.
Install the LH floor console trim panel. For additional information, refer to Section 501-12 . 6.
Install the floor console finish panel and connect the electrical connectors. 7.
Close the storage compartment door. 8.
Install the gearshift knob. 9.
External Controls
Gearshift Cables
1 7K391 Gearshift cable ends
2 7E395 Shift cable
4 - Gearshift cable grommet (part of 7E395)
5 W707142-S439 Gearshift cable grommet nuts
6 7E395 Shift cable
8 - Gearshift lever nut (4 required)
9 7210 Gearshift lever assembly
Removal
412-01 .
1.
Disconnect the gearshift cables from the transaxle shift control lever. 3.
Gearshift Cables 4414
NOTE: Carefully pry the retainer on the gearshift cables. Do not damage the gearshift cable retainers.
Disconnect the gearshift cs from the transaxle bracket.
4.
Position the insulation blanket aside. 6.
Remove the wiring harness from the studs. 7.
Remove the 2 gearshift cable grommet nuts and detach the gearshift cables from the floor. 8.
Disconnect the shift cable and select cable from the gearshift lever. 9.
NOTICE: Carefully disconnect the gearshift cables from the gearshift lever base. Do not
damage the gearshift cable retainers.
Disconnect the gearshift cables from the gearshift lever base.
10.
Pull the gearshift cables through the bulkhead into the interior. 11.
Installation
NOTICE: When inserting the gearshift cables through the bulkhead, use care and do not
damage the heat shielding.
NOTE: When inserting the gearshift cables through the bulkhead, make sure the arrow on the
grommet is pointing upward.
Pull the gearshift cables through the bulkhead into the exterior.
1.
Install the 2 gearshift cable grommet nuts and attach the gearshift cables to the floor.
2.
Install the wiring harness onto the studs. 3.
NOTICE: Make sure the gearshift cables are fully seated into the gearshift lever base or damage
may occur.
Connect the gearshift cables to the gearshift lever base.
4.
Connect the select cable and the shift cable to the gearshift lever. 5.
Position the insulation blanket into place. 6.
NOTICE: Make sure the gearshift cables are fully seated into the transaxle bracket or damage
may occur.
NOTE: The gearshift cable ends and transaxle bracket slots are unique. They can only be fully seated
in the correct slot.
NOTE: The top cable will have id tape.
Connect the gearshift cables to the transaxle bracket.
8.
Connect the gearshift cables to the transaxle shift control lever. 9.
Adjust the gearshift cables. For additional information, refer to Section 308-00 . 10.
412-01 .
12.
SECTION 308-07A: Four Wheel Drive (4WD)
Systems
Workshop Manual
Material
Capacity
Synthetic Rear Axle Lubricant
XY-75W140-QL (US);
WSL-M2C192-A 530 ml
(18 oz)
a
XY-80W90-QL (US);
WSP-M2C197-A 1.15L
(2.43 pt)
b
a
Power transfer unit (PTU)
b
Rear differential unit (RDU)
4X4 control module nuts 9 80
Systems
Workshop Manual
Four Wheel Drive (4WD) Systems
The All-Wheel Drive (AWD) system consists of the following:
Power Transfer Unit (PTU)
Rear driveshaft
AWD relay module
Rear axle with coupling device
Torque from the engine is transferred through the transaxle to the PTU . This torque is transferred from the
driveshaft to the rear axle, which drives the rear halfshafts. The AWD system, also referred to as an Active
Torque Coupling (ATC) system, is always active and requires no driver input.
The AWD system continuously monitors vehicle conditions and automatically adjusts the torque distribution
between the front and rear wheels. During normal operation, most of the torque is delivered to the front
wheels. If wheel slip between the front and rear wheels is detected, or if the vehicle is under heavy
acceleration, the AWD system increases torque to the rear wheels to prevent or control wheel slip. When the
AWD system is functioning properly, there should be no perceived speed difference between the front and
rear axles when launching or driving the vehicle on any uniform surface. Traction should be similar to a part
time Four-Wheel Drive (4WD) system in 4H (4X4 HIGH), but have no binding in turns.
Serviceable components of the PTU are limited to the output shaft seal and flange, intermediate shaft seal and
deflector, and the PTU transaxle compression seal. No internal components are serviced. There should be no
need to remove the PTU cover. If any of the internal geared components, bearings, case cover or shafts are
worn or damaged, a new PTU must be installed.
Four Wheel Drive (4WD) Systems 4420
Systems
Workshop Manual
Four Wheel Drive (4WD) Systems
Special Tool(s)
Flex Probe Kit
105-R025D or equivalent
The vehicle is equipped with an All-Wheel Drive (AWD) system, also referred to as Active Torque Coupling
(ATC), that is always active and requires no driver input. The system has no Mode Select Switch (MSS).
Two transmissions are used with AWD . Vehicles with a 3.0L engine have the 6F35 transmission, controlled
by the PCM. Vehicles with the 3.5L engine use the Aisin AW21, which is controlled by a stand-alone
Transmission Control Module (TCM).
The system continuously monitors vehicle conditions and automatically adjusts the torque distribution
between the front and rear wheels. During normal operation, most of the torque is sent to the front wheels. If
wheel slip between the front and rear wheels is detected or if the vehicle is under heavy acceleration
(high-throttle position), the AWD system increases torque to the rear wheels to prevent or control wheel slip.
AWD faults may be indicated in the message center by the wrench lamp as well as the CHECK AWD
message.
The system consists of a Power Transfer Unit (PTU), 4X4 control module, rear axle and a solenoid actuated
ATC device. Based on the amount of current sent to the clutch, the module varies the torque sent to the rear
wheels by sending a duty cycle to the ATC device, located inside the rear axle. For concerns with the PTU ,
refer to Section 308-07B .
The 4X4 control module also provides the brake system with its current clutch duty cycle and determines
whether or not the brake system may take command of the clutch duty cycle.
NOTE: The ATC solenoid is not repairable. If a new component is required, the ATC solenoid and rear axle
are installed as an assembly. Refer to Section 205-02 .
The active, on-demand AWD system uses data from other systems as inputs to the 4X4 control module. The
4X4 control module uses the inputs to determine the appropriate amount of current to send to the ATC
solenoid that delivers the desired torque to the rear wheels. Specific inputs to the 4X4 control module are:
Four Wheel Drive (4WD) Systems 4421
Accelerator pedal position via the High Speed Controller Area Network (HS-CAN)
Transaxle range from the TCM or PCM via the HS-CAN
Brake system status from the ABS module via the HS-CAN
Wheel speed from all 4 wheels from the ABS module via the HS-CAN
4X4 control module outputs are:
Solid-state clutch (Pulse-Width Modulation (PWM) signal) to the ATC solenoid
Percent of torque transfer commanded signal to the ABS module via the HS-CAN
Torque request available signal to the ABS module via the HS-CAN
Heat Protection Mode
During very extreme off-road operation, the AWD system utilizes a heat protection mode to protect the ATC
solenoid (part of rear axle) from damage. If the system detects an overheat condition, it enters a locked mode.
If the heat in the system continues to rise once in the locked mode, the 4X4 control module disables the ATC
solenoid. Allow the system to cool down at least 10 minutes with the ignition switch in the ON position.
Inspect for obvious signs of mechanical or electrical damage. 2.
Active Torque Coupling (ATC) solenoid (part of
rear axle)

Rear Drive Unit (RDU)
Halfshafts and CV joints
Driveshaft and U-joints
Fluid leaks
Wheel/tire size and brand
Matching tire size and brand
Tire pressure
Smart Junction Box (SJB)
fuse(s):
11 (10A)
35 (10A)

4X4 control module
Wiring harness
Connector(s)
Circuitry
3.
4.
5.
Heat Protection Mode 4422
6.
418-00 .

(CMDTCs).

7.
Clear the DTCs and carry out the self-test diagnostics for the 4X4 control module. 8.
If the DTCs retrieved are related to the concern, go to the 4X4 Control Module DTC Chart. For all
9.
DTC Chart
4X4 Control Module DTC Chart
B1317 Battery Voltage High GO to Pinpoint Test B .
B1318 Battery Voltage Low GO to Pinpoint Test B .
B1342 Electronic Control Unit (ECU) is
Faulted
CLEAR the DTCs. REPEAT the self-test. If DTC B1342 is
retrieved again, INSTALL a new 4X4 control module. REFER
to 4X4 Control Module in this section.
B2900 Vehicle Identification Number (VIN)
Mismatch
CHECK the PCM configuration. REFER to Section 418-01 .
P1635 Tire/Axle Out of Acceptable Range GO to Pinpoint Test F .
P1824 Four-Wheel Drive (4WD) Clutch
Relay Circuit Failure
P1825 4WD Clutch Relay Open Circuit Check for a possible open fuse (B+) . GO to Pinpoint Test D .
U0100 Lost Communication with PCM or
Transmission Control Module (TCM)
(3.5L only)
REFER to Section 418-00 to diagnose the lost communication
with the PCM or TCM (3.5L only).
U0121 Lost Communication with Anti-lock
Brake System (ABS) Control Module
with the ABS control module.
U0155 Lost Communication with IC Control
Module
with the IC .
U0401 Invalid Data Received From PCM or
TCM (3.5L only)
REFER to Powertrain Control/Emissions Diagnosis (PC/ED)
manual to diagnose the accelerator position, engine coolant or
keep alive memory fault.
U0415 GO to Pinpoint Test C .
Invalid Data Received From
Anti-lock Brake System (ABS)
Control Module
U2050 No Application Present REPLACE the 4X4 control module. REFER to 4X4 Control
U2051 One or More Calibration Files
Missing/Corrupt
REPLACE the 4X4 control module. REFER to 4X4 Control
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test A: All-Wheel Drive (AWD) System Functional Test
Refer to Wiring Diagrams Cell 34 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), All Wheel Drive (AWD)
Normal Operation
The All-Wheel Drive (AWD) system continuously monitors vehicle conditions and automatically adjusts the
torque distribution between the front and rear wheels. During normal operation, most of the torque is
delivered to the front wheels. If wheel slip between the front and rear wheels is detected, or if the vehicle is
under heavy acceleration, the AWD system increases torque to the rear wheels to prevent or control wheel
slip.
AWD system concern without on-demand or continuous DTCs
PINPOINT TEST A: ALL-WHEEL DRIVE (AWD) SYSTEM FUNCTIONAL TEST
WARNING: When directed to drive the vehicle as part of this test, drive the vehicle on a hard
surface in an area without traffic to prevent a crash. Failure to follow these instructions may result in
personal injury.
NOTE: Carry out a thorough inspection and verification as outlined before carrying out this pinpoint test.
A1 CHECK FOR WRENCH LIGHT
PROVE-OUT
Turn the ignition to the ON position and
observe the wrench light.

Does the wrench light illuminate for 3
seconds and then turn OFF?

Yes
GO to A2 .
No
REFER to Section 413-01 for further diagnosis of
the Instrument Cluster (IC).
A2 CHECK FOR ATC SOLENOID (PART OF
REAR AXLE) LOCK
Drive the vehicle on a dry, hard surface in
turns while applying the accelerator pedal.

Is driveline wind-up present in turns?
Yes
With the ignition switch in ON position, allow the
Active Torque Coupling (ATC) solenoid to cool
down for at least 10 minutes and repeat the test.
CHECK for wind-up again. If no wind-up is
found, GO to A3 . If still present, GO to Pinpoint
Test E .
No
GO to A3 .
A3 CHECK FOR VALID ACCELERATOR
PEDAL POSITION MONITORING THE
ACCELERATOR PEDAL POSITION (AP) PID
scan tool: DataLogger - 4X4 Control Module
.

Monitor the AP PID while pressing the
accelerator pedal.

Does the accelerator pedal position match
the AP PID percent value?

Yes
GO to A4 .
No
Diagnosis (PC/ED) manual to diagnose the
accelerator pedal position sensor concern.
A4 CHECK 4X4 CONTROL MODULE
WHEEL SPEED SENSOR PIDs
.

While driving the vehicle at 48 km/h (30
mph), monitor the following wheel speed
sensor PIDs:

(LF_WSPD)

(LR_WSPD)

(RF_WSPD)

(RR_WSPD)

Are all 4 wheel speeds within 2 km/h (1.2
mph) of each other?

Yes
GO to A5 .
No
A5 CHECK VEHICLE ACCELERATION IN A
STRAIGHT LINE
Carry out 3 accelerations from 0-48 km/h
(0-30 mph) in a straight line (one each with
low, medium and full accelerator pedal
application).

Does the vehicle pulsate or shudder while
accelerating?

Yes
No
GO to A6 .
PINPOINT TEST A: ALL-WHEEL DRIVE (AWD) SYSTEM FUNCTIONAL TEST 4425
A6 CHECK VEHICLE TURNING ABILITY
Drive the vehicle in a fully locked turn, on
dry pavement, at 8 km/h (5 mph).

Does the vehicle bind in the turn or resist
turning?

Yes
No
GO to A7 .
A7 CHECK FOR TORQUE AT REAR
WHEELS USING PWM OUTPUT CONTROL
COMMAND #1 (CLCH_SOL) ACTIVE
COMMAND
.

Using the scan tool, command CLCH_ SOL
to energize the ATC solenoid to a constant
100% applied.

Drive the vehicle in a fully locked turn, on
dry pavement, at 8 km/h (5 mph).

Does the vehicle bind in the turn or resist
turning?

Yes
END the active command. The concern cannot be
duplicated at this time. RETURN the vehicle to
the customer.
No
END the active command. CHECK that the
driveshaft rotates when the transaxle is in gear. If
yes, GO to Pinpoint Test D . If no, CHECK the
Power Transfer Unit (PTU). REFER to Section
308-07B .
npoint Test B: DTCs B1317 and B1318
Normal Operation
If the 4X4 control module observes an overpower or underpower voltage condition, DTCs are set and the 4X4
control module may not allow Four-Wheel Drive (4WD) operation.
DTC B1317 Battery Voltage High - When the 4X4 control module detects battery voltage greater
than 16 volts for at least 10 seconds, this DTC is set.

DTC B1318 Battery Voltage Low - When the 4X4 control module detects battery voltage less than 9
volts for at least 10 seconds, with the engine running at 1,500 rpm or greater, this DTC is set.

Fuses
Vehicle battery
Charging system
4X4 control module
PINPOINT TEST B: DTCs B1317 AND B1318
NOTE: DTC B1or B1318 can be set if the vehicle has been recently jump started, the battery has been
recently charged or the battery has been discharged. The battery may become discharged due to excessive
load(s) on the charging system from aftermarket accessories or if the battery has been left unattended with the
accessories on.
B1 RETRIEVE ALL CMDTCs IN ALL MODULES
tool: Self Test - All CMDTCs .

Is DTC B1317 or B1318 present in more than
one module AND P0563, P0620, P0625, P0626
or P065B present in the PCM?

Yes
REFER to Section 414-00 for diagnosis of the
battery and charging system.
No
GO to B2 .
B2 CHECK BATTERY CONDITION
Refer to Section 414-01 and carry out the Battery
- Condition Test.

Yes
If the battery passed the condition test but
required a recharge, REFER to Section
414-00 to diagnose the charging system.
Trouble Codes (CMDTCs). TEST the system
for normal operation. If the battery passed the
condition test and did not require a recharge,
GO to B3 .
No
operation.
&sp; B3 CHECK THE CHARGING SYSTEM
VOLTAGE
NOTE: Do not allow the engine rpm to increase
above 2,000 rpm while performing this step or the
generator may self excite and result in default
charging system output voltage. If engine rpm has
gone above 2,000 rpm, shut the vehicle off and
restart the engine before performing this step.
Start the engine.
Measure the voltage of the battery.
For DTC B1317, turn off all accessories
and run the engine at 1,500 rpm for a
minimum of 2 minutes.

For DTC B1318, turn on headlights and
HVAC fan on high and run engine at
1,500 rpm for a minimum of 2 minutes.

Yes
GO to B4 .
No
charging system. CLEAR all CMDTCs .
PINPOINT TEST B: DTCs B1317 AND B1318 4427
Is the battery voltage between 13-15.2 volts?
B4 CHECK FOR VOLTAGE BY MONITORING
THE MODULE SUPPLY VOLTAGE (VBAT_4X4)
PID
tool: DataLogger - 4X4 Control Module .

With the engine running, monitor the battery
voltage VBAT_4X4 PID.

Is the battery voltage less than 9 or greater
than 15.5 volts?

Yes
If voltage is less than 9 volts, GO to B5 .
If voltage is greater than 15.5 volts,
INSTALL a new 4X4 control module.
REFER to 4X4 Control Module in this
section. CLEAR all CMDTCs . REPEAT the
self-test.
No
GO to B7
B5 CHECK CIRCUIT GD126 (BK/WH) FOR AN
OPEN
Ignition OFF.
Disconnect: 4X4 Control Module C3253 .
Measure the resistance between 4X4 control
module C3253-15, circuit GD126 (BK/WH),

Repeat this measurement while wiggling the
harness.

Yes
GO to B6 .
No
REPAIR the circuit. CLEAR all CMDTCs .
B6 CHECK POWER TO 4X4 CONTROL MODULE
Ignition ON.
Measure the voltage between 4X4 control module
C3253-4, circuit CBP35 (YE/GY), harness side
and ground; and between 4X4 control module
C3253-5, circuit SBP11 (BU/RD), harness side
and ground.

Yes
GO to B7 .
No
VERIFY the Smart Junction Box (SJB)
fuse(s) 11 (10A) and 35 (10A) are OK. If
fuse(s) are OK, REPAIR the circuit in
question. If SJB fuse(s) are not OK, REFER
to the Wiring Diagrams manual to identify
possible causes of the circuit short. CLEAR
all CMDTCs . REPEAT the self-test.
PINPOINT TEST B: DTCs B1317 AND B1318 4428
B7 CHECK FOR CORRECT 4X4 CONTROL
MODULE OPERATION
Disconnect the 4X4 control module.
Check the harness and component side connectors
for:

corrosion.
pushed-out/bent pins.
Connect the 4X4 control module and make sure it
seats correctly.

Operate the system and determine if the concern
is still present.

Yes
INSTALL a new 4X4 control module.
REFER to 4X4 Control Module in this
section. CLEAR the CMDTCs . REPEAT the
self-test.
No
or corroded connector. CLEAR all CMDTCs
. REPEAT the self-test.
Pinpoint Test C: DTC U0415
Normal Operation
The All-Wheel Drive (AWD) system uses data from other systems as inputs to the 4X4 control module. The
4X4 control module uses the inputs to determine the appropriate duty cycle to send to the Active Torque
Coupling (ATC) solenoid (part of rear axle) that delivers the desired torque to the rear wheels. Specific inputs
to the 4X4 control module are: accelerator pedal position output from the PCM, transmission range from the
PCM or Transmission Control Module (TCM) (3.5L only), brake system status and all 4 wheel speeds from
the ABS module. Communication between the 4X4 control module and other modules is obtained through the
High Speed Controller Area Network (HS-CAN). If the 4X4 control module loses communication with, or
receives invalid data from any of the necessary modules, DTCs are set and the 4X4 control module may not
allow Four-Wheel Drive (4WD) operation.
DTC U0415 Invalid Data Received from Anti-lock Brake System (ABS) Control Module - When the
4X4 control module receives invalid HS-CAN bus data or invalid wheel speed(s) from the ABS
module for more than 5 seconds, this DTC is set.

ABS module
PINPOINT TEST C: DTC U0415
personal injury.
NOTE: Carry out a thorough inspection and verification as outlined before carrying out this pinpoint st.
C1 CHECK FOR ABS MODULE DTCs
Yes
Ignition ON.
Carry out the ABS module self-test.
Review the results of the ABS module
self-test.

REFER to Section 206-09 for further diagnosis of the
ABS.
No
GO to C2 .
C2 CHECK WHEEL SPEED SENSORS
PIDs
on the scan tool: DataLogger - 4X4
Control Module .

While driving the vehicle at 48 km/h
(30 mph), monitor the following wheel
speed sensor PIDs:

Left Front Wheel Speed
Sensor (LF_WSPD)

(LR_WSPD)

Right Front Wheel Speed
Sensor (RF_WSPD)

Right Rear Wheel Speed
Sensor (RR_WSPD)

Do the 4 wheel speed sensors match
the speedometer and are they within
2 km/h (1.2 mph) of each other?

Yes
The system is operating correctly athis time. CLEAR the
No
INSPECT for proper tire size and tire inflation. If no
concerns with the tires are found, REFER to Section
206-09 for further diagnosis of the ABS.
Pinpoint Test D: DTCs P1824 and P1825
Normal Operation
The All-Wheel Drive (AWD) system uses data from other systems as inputs to the 4X4 control module. The
4X4 control module uses the inputs to determine the appropriate duty cycle to send to the Active Torque
Coupling (ATC) solenoid (part of rear axle) that delivers the desired torque to the rear wheels. If the 4X4
control module loses communication with, or receives invalid data from any of the necessary modules, DTCs
are set and the 4X4 control module may not allow Four-Wheel Drive (4WD) operation.
DTC P1824 4-Wheel Drive Clutch Relay Circuit Failure - When the 4X4 control module detects a
short to ground on the ATC solenoid feedback circuit, this DTC is set.

DTC P1825 4-Wheel Drive Clutch Relay Open Circuit - When the 4X4 control module detects an
open or short to ground on the ATC solenoid command or feedback circuit for more than 2 seconds,
this DTC is set.

Tire/axle out of range
ATC solenoid (part of rear axle)
4X4 control module
PINPOINT TEST C: DTC U0415 4430
PINPOINT TEST D: DTCs P1824 AND P1825
D1 CHECK FOR 4X4
CONTROL MODULE DTCs
Ignition ON.
Carry out the 4X4 control
module self-test.

Are any DTCs received?
Yes
For DTC P1824 or P1825, GO toa
href="SCS~us~en~file=SCS87A03.HTM~gen~ref.HTM#D2" >D2 .
For all other DTCs, REFER to the 4X4 Control Module DTC Chart in
this section.
No
GO to D2 .
D2 CHECK CIRCUITS
CCF21 (VT/WH) AND RCF21
(WH/VT) FOR A SHORT TO
GROUND WITH ATC
SOLENOID (PART OF REAR
AXLE) CONNECTED
Ignition OFF.
Disconnect: 4X4 Control
Module C3253 .

between 4X4 control
module C3253-8, circuit
CCF21 (VT/WH),
harness side and ground;
and between 4X4 control
RCF21 (WH/VT),

Are the resistances
greater than 10,000
ohms?

Yes
GO to D5 .
No
GO to D3 .
D3 CHECK CIRCUITS
(WH/VT) FOR A SHORT TO
GROUND WITH C3051
DISCONNECTED
PINPOINT TEST D: DTCs P1824 AND P1825 4431
Disconnect: ATC
Solenoid Jumper Harness
C3051 .

between 4X4 control
CCF21 (VT/WH),
harness side and ground;
and between 4X4 control
RCF21 (WH/VT),

Are the resistances
greater than 10,000
ohms?

Yes
GO to D4 .
No
REPAIR the circuit(s) in question. CLEAR the DTCs. REPEAT the
self-test.
D4 CHECKING THE ATC
SOLENOID JUMPER
HARNESS
NOTICE: The Active
Torque Coupling (ATC)
solenoid jumper harness
must be secured to
prevent damage to the
wiring.
Disconnect: ATC
Solenoid C3254 .

Inspect the ATC solenoid
jumper harness for
damage.

Is the ATC solenoid
jumper harness
damaged?

Yes
REPAIR or INSTALL a new ATC solenoid jumper harness. CLEAR
No
INSTALL a new rear axle assembly. REFER to Section 205-02 .
D5 CHECK CIRCUITS
(WH/VT) FOR AN OPEN
WITH ATC SOLENOID
CONNECTED
Connect: ATC Solenoid
C3254 and ATC Solenoid
Jumper Harness C3051 .

between 4X4 control
CCF21 (VT/WH),
harness side and 4X4
control module
C3253-16, circuit RCF21

Is the resistance less
than 10 ohms?

Yes
GO to D8 .
No
GO to D6 .
D6 CHECK CIRCUITS
(WH/VT) FOR AN OPEN AT
C3051
Disconnect: ATC
Solenoid Jumper Harness
C3051 .

between 4X4 control
CCF21 (VT/WH),
harness side and ATC
C3051-1, circuit CCF21
(VT/WH).

Repeat this measurement
while wiggling the
harness.

between 4X4 control

Yes
GO to D7 .
No
REPAIR the circuit in question. CLEAR the DTCs. REPEAT the
self-test.
RCF21 (WH/VT),
harness side and ATC
while wiggling the
harness.

Are the resistances less
than 5 ohms?

D7 CHECK THE ATC
SOLENOID CIRCUIT FOR
AN INTERNAL OPEN
NOTICE: The Active
Torque Coupling (ATC)
must be secured to
prevent damage to the
wiring.
Disconnect: ATC
Solenoid C3254 .

between ATC solenoid
C3254-1, circuit CCF21
(VT/WH), component
side, and ATC solenoid
(WH/VT), component
side.

while wiggling the
harness.

Yes
REPAIR or INSTALL a new ATC solenoid jumper harness. CLEAR
No
INSTALL a new rear axle assembly. REFER to Section 205-02 .
than 10 ohms?

D8 CHECK CIRCUIT GD126
(BK/WH) FOR AN OPEN
between 4X4 control
GD126 (BK/WH),

while wiggling the
harness.

than 5 ohms?

Yes
GO to D9 .
No
REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
D9 CHECK THE 4X4
CONTROL MODULE
POWER CIRCUITS
Ignition ON.
Measure the voltage
between 4X4 control
CBP35 (YE/GY), harness
side and ground; and
between 4X4 control
SBP11 (BU/RD), harness
side and ground.

Are the voltages greater
than 10 volts?

Yes
GO to D10 .
No
VERIFY the Smart Junction Box (SJB) fuse(s) 11 (10A) and 35
(10A) are OK. If fuse(s) are OK, REPAIR the circuit in question. If
SJB fuse(s) are not OK, REFER to the Wiring Diagrams manual to
identify possible causes of the circuit short. CLEAR all Continuous
Memory Diagnostic Trouble Codes (CMDTCs). REPEAT the
self-test.
D10 CHECK FOR CORRECT
4X4 CONTROL MODULE
OPERATION
Disconnect: 4X4 Control
Module C3253 .

Check the harness and
component side
connectors for:

corrosion.
pushed-out/bent
pins.

Check the ATC solenoid
jumper harness between
the 4X4 control module
and the ATC solenoid,
located on the rear
subframe.

Connect the 4X4 control
module and make sure it
seats correctly.

Operate the system and
determine if the concern
is still present.

Is the concern still
present?

Yes
INSTALL a new 4X4 control module. REFER to 4X4 Control
Module in this section. CLEAR the DTCs. REPEAT the self-test.
No
The system is operating correctly at this time. The concern may have
been caused by a loose or corroded connector. CLEAR the DTCs.
Pinpoint Test E: Vehicle Binds in a Turn or Resists Turning/Pulsates or Shudders in a Straight Line
Normal Operation
torque distribution between the front and rear wheels. During normal operation, most of the torque is sent to
the front wheels. If wheel slip between the front and rear wheels is detected or the vehicle is under heavy
acceleration, the AWD system increases torque to the rear wheels.
Rear axle
Wheels/tires
PCM
ABS module
4X4 control module
PINPOINT TEST E: VEHICLE BINDS IN A TURN OR RESISTS TURNING/PULSATES OR SHUDDERS IN A
STRAIGHT LINE
E1 CHECK FOR TORQUE AT THE REAR
WHEELS
Ignition OFF.
Disconnect: Active Torque Coupling (ATC)
Solenoid (part of rear axle) C3254 .

Drive the vehicle in a straight line on dry
pavement.

Is a pulsation or shudder still present?
Yes
REFER to Section 205-00 for additional axle
diagnosis.
No
GO to E2 .
E2 CHECK TO SEE IF THE ATC SOLENOID
IS BEING COMMANDED ON MONITORING
4WD CLUTCH PWM STATUS
(4WDCPWMST) PID
Ignition OFF.
Connect: ATC Solenoid C3254 .
Ignition ON.
scan tool: DataLogger - 4X4 Control
Module .

Monitor the 4WDCPWMST PID.
Drive the vehicle no faster than 8 km/h (5
mph) in tight turns on dry pavement while
monitoring the ATC solenoid duty cycle.

Is the duty cycle greater than 20%?
Yes
GO to E3 . No
E3 CHECK FOR THE CORRECT WHEEL
SPEEDS USING THE WHEEL SPEED
SENSORS PIDs
Module .

sensor PIDs:

(LF_WSPD)

(LR_WSPD)

(RF_WSPD)

(RR_WSPD)

Are all 4 wheel speeds within 2 km/h (1.2
mph) of each other?

Yes
GO to E4 .
No
E4 CHECK FOR VALID ACCELERATOR
PEDAL POSITION MONITORING
ACCELERATOR PEDAL POSITION (AP) PID
Key ON Engine OF(KOEO).
Module .

Monitor AP PID while pressing/releasing
the accelerator pedal.

Yes
GO to E5 .
No
Diagnosis (PC/ED) manual to diagnose the engine
control system.
PINPOINT TEST E: VEHICLE BINDS IN A TURN OR RESISTS TURNING/PULSATES OR SHUDDERS IN ASTRAIGHT LINE 4437
Does the accelerator position match the
PID percent value?

E5 CHECK FOR CORRECT 4X4 CONTROL
MODULE OPERATION
Disconnect the 4X4 control module.
Check the harness and component side
connectors for:

corrosion.
pushed-out/bent pins.
Check the ATC solenoid jumper harness
between the 4X4 control module and the
ATC solenoid, located on the rear subframe.

Connect the 4X4 control module and make
sure it seats correctly.

Operate the system and determine if the

Yes
INSTALL a new 4X4 control module. REFER to
4X4 Control Module in this section. CLEAR the
No
the self-test.
Pinpoint Test F: DTC P1635
Normal Operation
torque distribution between the front and rear wheels. During normal operation, most of the torque is sent to
the front wheels. If wheel slip between the front and rear wheels is detected or the vehicle is under heavy
acceleration, the AWD system increases torque to the rear wheels.
DTC P1635 Tire/Axle Out of Acceptable Range - When the 4X4 control module detects inappropriate
mini spare or road wheels/tires (greater than 7% across the front and rear axle or 14% at one wheel)
installed, this DTC is set.

Wheels/tires
Wheel speed sensors
ABS module
4X4 control module
PINPOINT TEST F: DTC P1635
personal injury.
F1 CHECK THE RECENT TIRE USAGE
Check with customer about recent tire
usage or installation.

Has a tire been installed on the vehicle
recently that was not originally
supplied with the vehicle?

Yes
INFORM the customer to only use tires of the type
supplied with the vehicle. CLEAR the DTCs.
No
GO to F2 .
F2 CHECK TIRE SIZE AND BRAND
Check the tire size and the brand of tire.
Are all 4 tires the same size and brand?
Yes
GO to F3 .
No
INSTALL tires that are the same size and brand.
INFORM the customer to only use the same size tires
and brand. CLEAR the DTCs. REPEAT the self-test.
F3 CHECK TIRE AIR PRESSURES
Check the air pressure in all 4 tires.
Are all 4 tires at the recommended air
pressure?

Yes
GO to F4 .
No
ADJUST the tire air pressures. CLEAR the DTCs.
REPEAT the self-test. INFORM the customer to
maintain the correct tire air pressure.
F4 CHECK FOR CORRECT WHEEL
SPEEDS
the scan tool: DataLogger - 4X4 Control
Module .

sensor PIDs:

(LF_WSPD)

(LR_WSPD)

(RF_WSPD)

(RR_WSPD)

Are all 4 wheel speeds within 2 km/h
(1.2 mph) of each other?

Yes
GO to F5 .
No
The ABS module is sending invalid wheel speed data
to the 4X4 control module. REFER to Section 206-09
for additional ABS diagnosis.
F5 CHECK FOR CORRECT 4X4
CONTROL MODULE OPERATION
Disconnect: 4X4 Control Module C3253 .
Check for:
corrosion.
pushed-out pins.
Connect the 4X4 control module and
make sure it seats correctly.

Yes
INSTALL a new 4X4 control module. REFER to 4X4
Control Module in this section. CLEAR the DTCs.
No
PINPOINT TEST F: DTC P1635 4439
Operate the system and determine if the

PINPOINT TEST F: DTC P1635 4440
Systems
Workshop Manual
4X4 Control Module
1 - Electrical connector (part of 14A005)
2 W706840 4X4 control module nuts and washers (2 required)
3 7E453 4X4 control module and bracket assembly
From below the LH side instrument panel, disconnect the 4X4 control module harness connector. 1.
Remove the two 4X4 control module nuts.
2.
Remove the 4X4 control module and bracket. 3.
4X4 Control Module 4441
SECTION 308-07B: Transfer Case - Power Transfer Unit
(PTU)
Material
Capacity
PM-4-A or PM-4-B (US);
CPM-4 (Canada)
- -
XT-10-QLVC
MERCON LV -
Motorcraft Premium
XT-8-QAW (US);
WSS-M2C924-A -
XY-75W140-QL (US);
WSL-M2C192-A
and GL-5
0.53L (18
oz)
XG-3-A
ESE-M1C171-A -
Nm lb-ft lb-in
Driveshaft-to-output flange bolts 70 52 -
Filler plug 20 - 177
Pinion flange nut
a
- - -
Power Transfer Unit (PTU) support bracket bolts 48 35 -
PTU -to-transaxle bolts 90 66 -
a
SECTION 308-07B: Transfer Case - Power Transfer
Unit (PTU)
The AWD system consists of the following:
PTU
Rear driveshaft
4X4 control module
Rear axle with coupling device
The PTU is a mechanical device attached to the transaxle. It supplies torque to the rear axle through the rear
driveshaft. The 4X4 control module is an electronic device which controls the rear axle coupling to apply the
torque generated from the PTU to the rear wheels when required.
Power Transfer Unit (PTU) 4445
SECTION 308-07B: Transfer Case - Power
Transfer Unit (PTU)
Workshop Manual
The Power Transfer Unit (PTU) is a gearbox that attaches to the transaxle. Vehicles equipped with the 3.0L
engine have the 6F35 transaxle and those with the 3.5L engine have the Aisin AW21 transaxle. The PTU
design is similar between the two. The RH intermediate shaft passes through the PTU and engages the
differential side gear as in normal Front Wheel Drive (FWD) applications. The PTU directs power to the rear
driveshaft through a helical gear spline coupled to the transaxle differential case, a helical gear drop (idler
gear) and hypoid/helical riear assembly and pinion set. The PTU is sealed from the transaxle and has its own
oil sump.
Serviceable components of the PTU are limited to the output shaft seal and flange, intermediate shaft seal and
deflector, cover seal and the PTU -transaxle compression seal. The internal components are not serviced. Do
not remove the cover of the PTU . If any of the geared components, bearings, case cover or internal shafts are
worn or damaged, a new PTU must be installed.
Heat Protection Mode
During very extreme off-road operation, the All-Wheel Drive (AWD) system utilizes a heat protection mode
to protect the Active Torque Coupling (ATC) solenoid (part of rear axle) from damage. If the system detects
an overheat condition, it enters a locked mode. If the heat in the system continues to rise once in the locked
mode, the 4X4 control module disables the ATC solenoid. Allow the system to cool down at least 10 minutes
with the ignition switch in the ON position.
For concerns with the 4X4 control module or ATC , refer to Section 308-07A .
Inspect for obvious signs of mechanical damage. 2.
Mechanical
Power Transfer Unit
(PTU)

Halfshafts and CV
joints

Driveshaft and
U-joints

Wheel/tire size and
brand

Matching tire size
and brand

Tire pressure
3.
If the cause is not visually evident, verify the symptom and GO to Symptom Chart - Power Transfer
Unit (PTU) .
4.
Symptom Chart - Power Transfer Unit (PTU)
Symptom Chart - Power Transfer Unit (PTU)
Analysis of Leakage
NOTE: There are 2 different PTU configurations used depending on the transaxle. The repairs made for
leakage on these 2 different PTU s may vary depending upon the type and location of the leakage. The
specified tools called out in this section will allow seal replacement without causing damage to the PTU case
and drive gear.
NOTE: Inspection of the seal's mating journal should be performed every time a seal is replaced. The mating
part/journal should be replaced if it has any of the following conditions: Radial wear groove that can be felt by
running a finger nail across it where seal lip runs. Scratches, pitting, galling, nicks or other shaft damage
under or near where the seal lip runs. Discoloration or coked oil on the shaft where the seal lip runs. Shaft
corrosion under or near where the seal lip runs. Sharp edges or burrs on the shaft lead in chamfer. NEVER use
emery cloth on journal finishes, replace the part.
The PTU may leak different color fluids, red ATF or tan/brown/black gear lube. The PTU and transaxle seals
prevent these types of fluids from leaking. It is important to note which color of fluid is leaking to determine
the most appropriate service procedure. The residue of red ATF should be cleaned from the PTU to prevent a
inaccurate diagnosis of a red ATF leak following the repair.
PTU Leaks From the RH Side
Vehicles Equipped with Aisin AW21 Transaxle
NOTE: The intermediate shaft seal functions as a dust seal and is not a source of a red ATF leak.
If the leak is red ATF , this indicates the transaxle seal is leaking and needs to be replaced. For additional
If the leak is tan/brown/black gear lube, the PTU cover seal is leaking and needs to be replaced. This cover
seal is located on the PTU cover, behind the deflector. For additional information, refer to Cover Seal
procedure in this section.
Vehicles Equipped with 6F35 Transaxle
If the leak is red ATF , this indicates the intermediate shaft seal is leaking and needs to be replaced. For
additional information, refer to Intermediate Shaft Seal - 6F35 procedure in this section.
If the leak is tan/brown/black gear lube, the PTU cover seal is leaking and needs to be replaced. The cover
seal is located on the PTU cover, behind the deflector. For additional information, refer to Cover Seal
procedure in this section.
PTU Leaks From the LH Side
Vehicles Equipped with Aisin AW21 Transaxle
NOTE: The compression seal functions as a dust seal and is not the main source of the red ATF leak.
If the leak is tan/brown/black gear lube and not at the vent, check the non-serviceable PTU inboard seal for
leakage. If the PTU inboard seal is leaking, the PTU must be replaced. If the leak is from the vent, the PTU
may be overfilled. Determine if the red ATF has entered the PTU . If red ATF has entered the PTU , the
transaxle seal and PTU must be replaced. For additional information, refer to Section 307-01A and Power
Transfer Unit (PTU) in this section.
Vehicles Equipped with 6F35 Transaxle
information, refer to Section 307-01B .
If the leak is tan/brown/black gear lube, the PTU may be overfilled and leaking from the vent. If the PTU is
overfilled, adjust the level as necessary. If the leak is not at the vent, the non-serviceable PTU inboard seal is
leaking and the PTU must be replaced. For additional information, refer to Power Transfer Unit (PTU) in this
section.
Transfer Unit (PTU)
Workshop Manual
Power Transfer Unit (PTU) Draining and Filling
Material
Item Specification
XY-75W140-QL (US);
WSL-M2C192-A
and GL-5
NOTICE: A new Power Transfer Unit (PTU) must be installed any time the PTU has been submerged
in water.
NOTE: The Power Transfer Unit (PTU) is not to be drained unless contamination is suspected. To drain the
PTU fluid, the PTU must be removed from the vehicle. The fluid that is drained may appear black and have a
pungent odor. Do not mistake this for contaminated fluid. For additional information, refer to Power Transfer
Unit (PTU) in the Removal portion of this section.
NOTE: Fill level checks are done in-vehicle only. Let the vehicle sit 10 minutes after the road test before
checking the fluid level.
100-02 .
1.
Clean the area around the filler plug before removing. 2.
Remove and discard the filler plug. 3.
With the vehicle on a flat, level surface, fill the PTU with lubricant. The fluid must be even with the
bottom of the fill opening.
Fluid capacity is 0.53L (18 oz).
4.
Install a new filler plug.
5.
Power Transfer Unit (PTU) Draining and Filling 4449
Power Transfer Unit (PTU) Draining and Filling 4450
Unit (PTU)
Cover Seal
Special Tool(s)
Handle, Driver (32 in)
205-907
308-431td>
Installer, Shaft Bearing Cup
308-221 (T94P-7025-BH)
Remover, Halfshaft
205-241
Slide Hammer
100-01 (T50T-100-A)
Removal
NOTE: The Power Transfer Unit (PTU) may leak different color fluids, red Automatic Transmission Fluid
(ATF) and tan/brown/black gear lube for PTU fluid. The PTU seals prevent these types of fluids from leaking.
It is important to note which color fluid is leaking to determine the most appropriate service procedure. This
procedure will correct a tan/brown/black (gear lube) leak from the RH side of the PTU . For additional
information, refer to Analysis of Leakage in this section.
NOTE: This procedure is to be performed through the RH wheel opening. It is not necessary to remove the
exhaust components to complete this repair.
Remove the intermediate shaft seal deflector. For additional information, refer to Intermediate Shaft
Seal Deflector in this section.
1.
NOTE: There is a bearing inside the PTU directly behind the cover seal. The bearing is not serviced.
Remove the cover seal using the Slide Hammer, the extension from the Halfshaft Remover and a
suitable seal puller inserted into the groove of the seal.
2.
Installation
Cover Seal 4451
Assemble the Driver Handle, the Halfshaft Oil Seal Installer and the Shaft Bearing Cup Installer as
shown.
1.
Using the Driver Handle, the Halfshaft Oil Seal Installer and the Shaft Bearing Cup Installer, install
the cover seal in the PTU .
2.
Install the intermediate shaft seal deflector. For additional information, refer to Intermediate Shaft
Seal Deflector in this section.
3.
Fill the PTU as necessary. For additional information, refer to Power Transfer Unit (PTU) Draining
and Filling in this section.
4.
Cover Seal 4452
Transfer Unit (PTU)
>
Workshop Manual
Output Shaft Seal
Special Tool(s)
Holding Fixture, Drive Pinion Flange
205-126 (T78P-4851-A)
Installer, PTU Drive Gear Outer Oil Seal
308-430
Remover, Output Flange
307-523
Output Shaft Seal and Flange
Item Description
1 Collapsible spacer (part of 7275 kit)
2 Output shaft seal (part of 7275 kit)
3 Output pinion flange (part of 7275 kit)
4 Pinion flange nut (part of 7275 kit)
Removal
All vehicles
All vehicles except GTDI
Remove the 2 exhaust Y-pipe-to-muffler and tail pipe flange nuts.
2.
NOTICE: The resonator must be supported to prevent damage to the flexible pipe. 3.
Output Shaft Seal 4453
Using a length of mechanic's wire, support the resonator.
GTDI vehicles
Remove the 4 LH and RH exhaust flexible pipes-to-underbody catalytic converter nuts.
4.
All vehicles
NOTE: Index-mark both the driveshaft flanges for installation.
Remove the 4 driveshaft-to- PTU output flange bolts. Disconnect the driveshaft from the PTU and
position it aside.
Using mechanic's wire, support the driveshaft.
5.
NOTE: Rotational torque of the PTU rear output shaft flange must be measured and recorded using a
Nm (lb-in) torque wrench for correct pinion bearing preload when reassembled. This will be the
torque-to-turn measurement.
Using a suitable torque wrench, measure and record the rotational torque of the PTU output shaft.
6.
Using the Drive Pinion Flange Holding Fixture, hold the output pinion flange. Remove and discard
the pinion nut.
7.
NOTE: Index-mark the output pinion flange to the pinion shaft.
Using the Output Flange Remover, remove the output pinion flange.
8.
Remove and discard the output shaft seal. 9.
Remove the bearing from the output shaft. 10.
Output Shaft Seal and Flange 4454
Remove and discard the collapsible spacer. 11.
Installation
All vehicles
Install the new collapsible spacer. 1.
Install the bearing onto the output shaft. 2.
Using the PTU Drive Gear Outer Oil Seal Installer, install the output shaft seal. 3.
NOTE: Install the output pinion flange to engage the spline as previously marked.
Install the output pinion flange.
4.
NOTICE: Refer to the rotational torque previously recorded with the Nm (lb-in) torque wrench.
Tighten the pinion nut in small increments until it is within 0.3 Nm (3 lb-in) of the reference
measurement. If 0.3 Nm (3 lb-in) is exceeded, then the collapsible spacer will be damaged and a
new collapsible spacer will be required.
Using the Drive Pinion Flange Holding Fixture to hold the output pinion flange, install and tighten the
new pinion flange nut.
5.
Using the index mark, position the driveshaft and install the 4 driveshaft-to- PTU output flange bolts.
6.
GTDI vehicles
Install the new LH and RH exhaust flexible pipe-to-underbody catalytic converter gaskets and nuts.
7.
All vehicles except GTDI
Install the new exhaust Y-pipe-to-muffler and tail pipe flange gasket and nuts.
8.
All vehicles
Fill the PTU as necessary. Refer to Power Transfer Unit (PTU) Draining and Filling . 9.
Unit (PTU)
Intermediate Shaft Seal Deflector
Special Tool(s)
Handle, Driver 32 in
205-907
Remover, Halfshaft
205-241
Remover, Transfer Case Bearing Cup
308-125 (T87P-7120-D)
Slide Hammer Master Set
General Equipment
16 mm (5/8 in) washer (used with 308-125)
Material
Item Specification
(Canada)
-
XT-10-QLVC
MERCON LV
Transmission Fluid
(Canada) WSS-M2C924-A
Dielectric Compound
XG-3-A
ESE-M1C171-A
Removal
NOTE: This procedure is to be performed through the RH wheel opening. It is not necessary to remove the
exhaust components to complete this repair.
Intermediate Shaft Seal Deflector 4457
NOTE: The following instruction will prevent the Transfer Case Bearing Cup Remover from opening
too far which would make removing the intermediate shaft seal deflector difficult.
Place a 16 mm (5/8 in) washer between the components of the Transfer Case Bearing Cup Remover
as shown.
2.
NOTICE: Failure to utilize the recommended tools may result in serious damage to the Power Transfer
Unit (PTU).
Assemble the special tools as indicated in the following table and illustration:
Item Description
1 308-125
2 Extension from 205-241
3 100-D112 Slide Hammer Master Set
3.
NOTE: Using a Slide Hammer Master Set eases the removal of the seal deflector.
Using the Bearing Cup Remover, the extension from the Halfshaft Remover and a suitable slide
hammer, remove the seal deflector.
The seal deflector will have been damaged during removal. Remove all foreign material from
the PTU before continuing with the repair.

4.
Installation
NOTICE: Do not overheat (melt) the seal deflector. Monitor the temperature of the deflector
with a suitable temperature measuring device, such as a digital temperature laser or infrared
1.
thermometer, while heating. Do not allow the temperature to exceed 100C (212F).
Overheating will damage the deflector. If the deflector is damaged, a new deflector must be
used.
NOTE: Apply a small amount of silicone brake caliper grease and dielectric compound to the inner
lip of the deflecr where it installs on the tube inside the PTU before heating. This will ease the
installation of the deflector.
Position the deflector on the PTU Linkshaft Seal Dust Shield Installer using silicone brake caliper
grease and dielectric compound to retain it to the installer. Using a suitable heat gun, heat the
deflector to a minimum of 71C (160F) and a maximum of 93C (200F) by concentrating the heat
across the back of the installer while rotating the tool. Once the optimum temperature is achieved on
the tool, move the heat gun to the front of the tool and heat the inside of the deflector where it snaps
onto the PTU shaft until the temperature of the deflector is a minimum of 100C (212F).
As an alternative method to heating the seal deflector, place the deflector in boiling water for
3 to 5 minutes. Dry off the deflector and install.

Using a 5-pound or larger dead blow hammer, install the seal deflector immediately after heating
using the PTU Linkshaft Seal Dust Shield Installer and Driver Handle.
2.
Make sure the deflector is completely seated all the way around and there are no cracks on the face.
The deflector is correctly installed when the face of the deflector is recessed 3-5 mm (0.12-0.20 in)
into the pocket all the way around.
3.
Fully install the intermediate and halfshaft assembly and the 2 bolts.
4.
NOTE: A significant amount of residual fluid will collect between the seal and deflector during this
repair. This is a normal condition and should not be misinterpreted as a leak after the repair is
complete.
Using metal brake parts cleaner, thoroughly clean the deflector and intermediate shaft area of any
residual fluid that may have accumulated during the repair.
5.
Fill the transaxle to the correct fluid level. 6.
Transfer Unit (PTU)
Workshop Manual
NOTE: 3.5L with Aisin AW21 transaxle shown, 3.0L with 6F35 transaxle similar.
Item
Part
Number Description
1 W500324 Power Transfer Unit (PTU)-to-support bracket bolts (2
required)
2 W500324 PTU support bracket-to-engine block bolts (3 required)
3 7A444 PTU support bracket
4 W500741 PTU -to-transaxle bolts (5 required)
5 7251 PTU
6 7087 Compression seal (vehicles equipped with Aisin AW21
transaxle)
All vehicles
100-02 .
1.
Remove and discard the 4 front driveshaft-to-Power Transfer Unit (PTU) flange bolts. 2.
Using a suitable pry bar as shown, separate the driveshaft flange from the PTU flange. 3.
3.0L vehicles
All vehicles
Remove the 2 PTU -to-support bracket bolts, then remove the 3 PTU support bracket bolts and the
PTU support bracket.
6.
Remove the 5 PTU -to-transaxle bolts. 7.
Separate the PTU from the transaxle. Remove the PTU from the vehicle. 8.
Vehicles equipped with Aisin AW21 transaxle
NOTICE: A new compression seal must be installed whenever the PTU is removed from the
vehicle. Failure to replace the compression seal may allow debris to enter the area around the
transaxle seal and cause the transaxle seal to fail.
Using a suitable tool, remove the compression seal and discard.
9.
Transfer Unit (PTU)
Workshop Manual
Intermediate Shaft Seal - 6F35
Special Tool(s)
Remover, PTO Driven Gear Oil Seal
308-428
Slide Hammer
100-001 (T50T-100-A)
NOTE: Red Automatic Transmission Fluid (ATF) leaking from the RH side of the Power Transfer
Unit (PTU) indicates a ntermediate shaft seal. For additional information, refer to Analysis of
Leakage in this section.
Remove the PTU . For additional information, refer to Power Transfer Unit (PTU) in the section.
1.
Using the PTO Driven Gear Oil Seal Remover and Slide Hammer, remove the intermediate shaft seal. 2.
Intermediate Shaft Seal - 6F35 4464
Transfer Unit (PTU)
Workshop Manual
Material
Item Specification
XT-10-QLVC
MERCON LV
Motorcraft Premium
XT-8-QAW (US);
WSS-M2C924-A
XY-75W140-QL (US);
WSL-M2C192-A
and GL-5
NOTE: 3.5L with Aisin AW21 transaxle shown, 3.0L with 6F35 transaxle similar.
Item
Part
Number Description
1 7087 Compression seal
(vehicles with
Aisin AW21
transaxle)
2 W500324 Power Transfer
Unit
(PTU)-to-support
bracket bolts (2
required)
3 W500324 PTU support
bracket-to-engine
block bolts (3
required)
4 7A444 PTU support
bracket
5 W500741 PTU -to-transaxle
bolts (5 required)
6 7251 PTU
Vehicles equipped with Aisin AW21 transaxle
NOTICE: A new compression seal must be installed whenever the Power Transfer Unit (PTU) is
removed from the vehicle. Failure to replace the compression seal may allow debris to enter the
area around the transaxle seal and cause the transaxle seal to fail.
Using a suitable tool, install the new compression seal.
1.
All vehicles
Position the Power Transfer Unit (PTU) to the transaxle. Install the 5 PTU -to-transaxle bolts.
2.
Position the PTU support bracket into place and install the 5 PTU support bracket bolts.
Tighten the bolts to the PTU to 48 Nm (35 lb-ft). 1.
Tighten the bolts to the engine to 48 Nm (35 lb-ft). 2.
3.
Position the driveshaft and install 4 new driveshaft-to- PTU flange bolts.
4.
3.0L vehicles
All vehicles
Fill the transaxle and/or PTU as necessary. 7.
Transfer Unit (PTU)
Workshop Manual
Intermediate Shaft Seal - 6F35
Special Tool(s)
Handle
205-153 (T80T-4000-W)
Installer, PTO Driven Gear Oil Seal
308-429
Using the Handle and PTO Driven Gear Oil Seal Installer, install the intermediate shaft seal. 1.
Install the Power Transfer Unit (PTU). For additional information, refer to Power Transfer Unit
(PTU) in this section.
2.
SECTION 309-00: Exhaust System
Manual
Bracket-to-LH catalytic converter bolts (3.5L) 20 - 177
Bracket-to-RH catalytic converter bolts (3.5L) 20 - 177
Catalytic converter manifold bracket nuts and bolts (2.5L, 3.0L) 20 - 177
Catalytic converter manifold nuts (2.5L)
a
- - -
Catalytic converter manifold shield bolts (2.5L, 3.0L) 10 - 89
Catalytic converter manifold shield bracket bolts (2.5L) 20 - 177
Catalytic converter manifold studs (2.5L) 17 - 150
Catalytic converter support bracket-to-engine block nuts (3.5L) 40 30 -
Catalytic converter support bracket-to-transmission bolts (3.5L) 48 35 -
Catalytic converter-to-exhaust flexible pipe nuts (2.5L) 40 30 -
Exhaust flexible pipe-to-catalytic converter nuts (2.5L, 3.0L) 40 30 -
Exhaust manifold nuts (2.5L) 40 30 -
Exhaust manifold studs (2.5L) 25 18 -
Exhaust Y-pipe-to-LH catalytic converter nut (3.5L) 40 30 -
Exhaust Y-pipe-to-RH catalytic converter nut (3.5L) 40 30 -
Exhaust Y-pipe-to-resonator nuts (3.5L) 40 30 -
LH catalytic converter heat shield bolt (3.5L) 10 - 89
LH catalytic converter manifold bracket bolts (3.0L) 20 - 177
LH catalytic converter manifold nuts (3.0L)
a
- - -
LH catalytic converter manifold shield bolts "top" align="center">10 - 89
LH catalytic converter manifold shield bracket bolts (3.0L) 20 - 177
LH catalytic converter manifold studs (3.0L) 11 - 97
LH catalytic converter-to-exhaust flexible pipe nuts (3.0L) 40 30 -
LH catalytic converter-to-exhaust manifold nuts (3.5L) 40 30 -
LH catalytic converter-to-exhaust manifold studs (3.5L) 25 18 -
Power steering gear shield bolts 15 - 133
RH catalytic converter heat shield bolt (3.5L) 10 - 89
RH catalytic converter manifold shield bracket bolt (3.0L) 20 - 177
RH catalytic converter manifold shield bracket nuts (3.0L) 20 177
RH catalytic converter-to-exhaust flexible pipe bolts (3.0L) 40 30 -
RH catalytic converter-to-exhaust manifold nuts (3.5L) 40 30 -
RH catalytic converter-to-exhaust manifold studs (3.5L) 25 18 -
RH catalytic converter-to-manifold nuts (3.0L) 40 30 -
RH catalytic converter-to-manifold studs (3.0L) 25 18 -
Roll restrictor bolt (3.0L, 3.5L) 90 66 -
Torca clamp 47 35 -
U-bolt nuts (2.5L) 30 22 -
Worm gear clamp 7 - 62
a
&nb
Manual
Exhaust System
The 2.5L exhaust system consists of:
a one-piece catalytic converter manifold (hybrid only).
an exhaust manifold (except hybrid).
an exhaust flexible pipe.
an underbody catalytic converter.
a Catalyst Monitor Sensor (CMS) mounted to the underbody catalytic converter.
a production muffler and tail pipe assembly.
isolators installed on the body and muffler hangers.
a one-piece catalytic converter manifold.
a RH exhaust manifold-mounted catalytic converter.
an exhaust flexible pipe.
an underbody catalytic converter.
two exhaust manifold-mounted catalytic converters.
an exhaust Y-pipe.
a resonator and flex assembly.
The exhaust system provides an exit for exhaust gases and reduces engine noise by passing exhaust gases
through the catalytic converters, a muffler assembly and resonator. Rubber exhaust hanger isolators attach the
exhaust system to the hangers welded on the body.
Catalytic Converter
The catalytic converter plays a major role in the emission control system. The catalytic converter operates as a
gas reactor. Its catalytic function is to speed the heat-producing chemical reaction of components in the
exhaust gases in order to reduce air pollutants.
The catalyst material inside the catalytic converter consists of a ceramic substrate.
The catalytic converter is designed to provide a long life. No maintenance is necessary for the catalytic
converter.
Precautions
NOTICE: Do not use leaded fuel in a vehicle equipped with a catalytic converter. In a vehicle that is
continually misfueled, the lead in the fuel will be deposited in the catalytic converter and completely
blanket the catalyst. Lead reacts with platinum to "poison" the catalyst. Continuous use of leaded fuel
Exhaust System 4471
can destroy the catalyst and render the catalytic converter useless. The addition of lead to the catalytic
converter can also solidify the catalyst, causing excessive back pressure in the exhaust system and
possibly causing engine damage.
NOTICE: Extremely high temperatures of 1,100C (2,012F) or above due to misfiring or an over-rich
fuel/air mixture will cause the ceramic substrate to sinter or burn, destroying the catalytic converter.
Do not continue to operate the vehicle if the engine is misfiring, there is a power loss or other unusual
operating conditions, such as engine overheating and backfiring.
Some exhaust fasteners must be discarded and new ones installed as indicated in the procedures. Also, any
damaged or heavily corroded fasteners should be discarded and new ones installed. Some exhaust fasteners
are of a prevailing torque design. Use only new fasteners with the same part number as the original. Torque
values must be used as specified during reassembly to make sure of correct retention of exhaust components.
Sound Insulators and Shields
Sound insulators and shields, attached to the underbody, protect the vehicle from exhaust system heat and
should be inspected at regular intervals to make sure they are not dented or out of position. If a sound
insulator and shield is damaged or shows evidence of deterioration, install a new insulator and shield. The
sound insulators and shields for the muffler, muffler pipe, resonator and catalytic converter pipe are installed
separately.
Exhaust System 4472
Manual
Exhaust System
Visually inspect the components of the exhaust system and related controls that may affect exhaust
gas quality or loss of power.
2.
Visually inspect for obvious signs of mechanical damage. Refer to the following chart. 3.
Mechanical
Exhaust pipe pinched or crushed
Damaged muffler
Broken or damaged exhaust hanger brackets or
isolators

Damaged catalytic converter
Cracked exhaust manifold
Loose or damaged heat shields
Verify that the exhaust system is installed correctly, with clamps correctly located and tightened to
specification.
4.
If the fault is not visually evident, determine the symptom. GO to Symptom Chart - Exhaust System
or GO to Symptom Chart - NVH .
5.
Symptom Chart - Exhaust System
Symptom Chart - Exhaust System
Symptom Chart - NVH
Symptom Chart - NVH
Exhaust System 4473
Rattle, squeaks or buzz type noise - from the bottom of the vehicle
Loose or damaged heat shield
INSPECT the exhaust system for loose or missing heat shields or foreign material trapped between
the heat shields and the exhaust system components. If any heat shields are loose, INSTALL worm
gear clamp 7L5Z-5A231-AA and tighten to 7 Nm (62 lb-in). If the heat shields are missing,
INSTALL new heat shields or exhaust system components as necessary. If a rattle, noise or buzz
condition persists, INSTALL a new heat shield or component as necessary. TEST the system for

Loose or damaged exhaust isolators
VERIFY that the exhaust isolators are correctly installed. INSPECT the exhaust isolators for wear or
damage. INSTALL new isolators as necessary. TEST the system for normal operation after the repair.

Damaged exhaust isolator hanger bracket
INSPECT the exhaust system components for damage or broken hangers. INSTALL new components
as necessary. CHECK for loose or damaged exhaust hanger brackets. INSTALL new components as

Loose or damaged catalytic converter or muffler
Exhaust grounded to chassis
INSPECT for signs of exhaust components-to-body contact. If necessary, CARRY OUT the Exhaust
System Alignment in this section.

Drone or clunk type noise - from the bottom of the vehicle
Loose or damaged exhaust isolators
INSPECT the exhaust isolators for wear or damage. INSTALL new isolators as necessary. TEST the

Exhaust grounded to chassis
INSPECT for signs of exhaust components-to-body contact. If necessary, CARRY OUT the Exhaust
System Alignment in this section.

Whistles, boom, hum or ticking type noise - noise tends to change as the engine warms. The noises
are often accompanied by exhaust fumes

Exhaust system leak
INSPECT the entire exhaust system for leaks. CHECK for punctures, loose or damaged
clamps/fasteners, gaskets, sensors or broken welds. EXAMINE the chassis for grayish-white or black
exhaust soot, which indicates exhaust leakage at that point. To magnify a small leak, have an assistant
hold a rag over the tail pipe outlet while listening for a leak. REPAIR or INSTALL new components

Exhaust System 4474
as necessary. TEST the system for normal operation after the repair.
Catalytic converter
MOVE the exhaust system to simulate the bouncing action of the vehicle, checking for
exhaust-to-body contact while moving the exhaust system. Using a rubber mallet, TAP on the exhaust
components to duplicate the noise concern. Lightly TAP on the muffler and the catalytic converter.
DETERMINE if there are loose or broken baffles in the muffler, or a loose or broken element in the
catalytic converter. REPAIR or INSTALL new components as necessary. TEST the system for

Exhaust muffler/resonator drain hole enlarged due to corrosion
CONFIRM the drain holes are the noise source. INSTALL new components as necessary. TEST the

Hissing or rushing noise - high frequency sound. Vehicle performance is unaffected
Exhaust system. Exhaust flow through pipes
CHECK the exhaust system for leaks. Using a rubber mallet, TAP on the exhaust components to
duplicate the noise concern. Lightly TAP on the muffler and the catalytic converter. DETERMINE if
there are loose or broken baffles in the muffler, or a loose or broken element in the catalytic converter.
REPAIR or INSTALL new components as necessary. TEST the system for normal operation after the
repair.

Pinging noise - occurs when exhaust system is hot, engine turned off
Catalytic converter/exhaust system
Cool down pinging is a result of the exhaust system expanding and contracting during heating and
cooling. This is a normal condition.

Vibration - occurs at idle and at low speeds. Also accompanied by a clunk or buzz type noise
Loose or damaged exhaust isolator
INSPECT the exhaust isolators for wear or damage. INSTALL new isolators as necessary. TEST the

Loose or damaged exhaust isolator hanger brackets
INSPECT the exhaust isolator hanger brackets for wear or damage. INSTALL or REPAIR as

Exhaust system grounded to chassis
CARRY OUT the Exhaust System Alignment in this section.
Engine drumming noise - normally accompanied by vibration
Damaged or misaligned exhaust system
INSPECT the exhaust system for loose or damaged fasteners, Torca clamps or isolators. CARRY
Exhaust System 4475
OUT the Exhaust System Alignment in this section.
Sputter type noise - noise worse when cold, lessens or disappears when the vehicle is at operating
temperature

Damaged or worn exhaust system
INSPECT the exhaust system for leaks or damage. REPAIR as necessary. TEST the system for

Thumping noise - from the bottom of the vehicle, worse at acceleration
Misaligned exhaust system
CHECK the exhaust system to chassis clearance. CHECK the exhaust system isolators for damage.
REPAIR as necessary. TEST the system for normal operation after the repair.

Loose or damaged body shield
CHECK the body shield for damaged, loose or missing fasteners. REPAIR or REPLACE as

Engine vibration - is felt with increases and decreases in engine rpm
Strain on exhaust system isolators
CARRY OUT the Exhaust System Alignment in this section. REPAIR as necessary. TEST the system

Drumming noise - occurs inside the vehicle during idle or high idle, hot or cold. Very low-frequency
drumming is very rpm dependent

Exhaust system vibration excites the body resonances inducing interior noise
Pinpoint Test
PINPOINT TEST A: DRUMMING NOISE
A1 CHECK THE EXHAUST SYSTEM
Start the engine.
Increase the engine rpm until the noise is the loudest. Note the
engine rpm.

Ignition OFF.
Add approximately 9 kg (20 lb) of weight to the exhaust
system.st place the weight at the tail pipe and test, then at the

Yes
REFER to Exhaust System
Alignment in this section. TEST
No
CONDUCT a diagnosis on other
PINPOINT TEST A: DRUMMING NOISE 4476
front pipe.
Start the engine.
Increase the engine rpm and listen for the drumming noise.
Note the engine rpm if the noise occurs.

Ignition OFF.
Remove the weight from the exhaust system.
Is the noise/vibration reduced or eliminated, or does the
noise/vibration occur at a different rpm?

suspect systems. REFER to
Section 100-04 .
PINPOINT TEST A: DRUMMING NOISE 4477
Manual
Exhaust System Alignment
100-02 .
1.
Loosen all fasteners joining the exhaust system components. 2.
Beginning at the front of the vehicle, align the exhaust system to establish the maximum clearance.
Make sure all fit pipes are pushed all the way into the preceding pipe and the notches are correctly
lined up with the tabs.
3.
Beginning at the front of the vehicle, tighten all fasteners and clamps to specification. For additional
information, refer to Specifications in this section.
4.
Start the engine and check the exhaust system for leaks. 5.
Exhaust System Alignment 4478
Manual
Torca Clamp
Remove the nut from the Torca clamp. 1.
Grind the spot weld from the Torca clamp and remove the clamp. 2.
Clean the uneven surface area and position a Torca clamp. 3.
NOTE: Make sure the clamp position is no more than 27.5 mm (1.08 in) or less than 25.5 mm (1 in)
from the inlet of the resonator pipe.
Make sure the back of the slot is covered by the clamp and the button is fully seated inside the notch.
4.
NOTE: Do not tighten the clamp until the exhaust system has been aligned.
Tighten the Torca clamp.
5.
Torca Clamp 4479
Torca Clamp 4480
Manual
REMOVAL AND
INSTALLATION
Exhaust System - Exploded View
2.5L Hybrid
Item
Part
Number Description
1 W704474 Catalytic converter manifold stud (7 required)
2 5K282 Catalytic converter manifold shield
3 W503921 Catalytic converter manifold shield bolt (6 required)
6 5K291 Catalytic converter manifold shield bracket
7 W500021 Catalytic converter manifold shield bracket bolt (2
required)
8 W708176 Catalytic converter manifold nut (7 required)
9 9448 Catalytic converter manifold gasket
10 - Catalytic converter manifold bracket
11 5G236 Catalytic converter manifold
12 9451 Gasket
Exhaust System - Exploded View 4481
14 W520414 Catalytierter-to-exhaust flexible pipe nut (2 required)
15 W520414 Exhaust flexible pipe-to-catalytic converter nut (2
required)
16 9451 Gasket
18 5221 Torca clamp
19 5F262 Muffler and tail pipe isolator (4 required)
20 5C257 Muffler and tail pipe
2.5L
Item
Part
Number Description
1 9N454 Catalytic converter manifold shield
2 W503921 Catalytic converter manifold shield bolt (4 required)
4 W711133 Exhaust manifold stud (2 required)
5 9451 Gasket
6 W520414 Exhaust manifold nut (2 required)
7 N802137 U-bolt
2.5L Hybrid 4482
9 W520414 U-bolt nut (2 required)
10 5K222 Catalytic converter manifold braket
12 5221 Torca clamp
14 9451 Gasket
required)
16 5C257 Muffler and tail pipe
3.0L Front Wheel Drive (FWD) (View 1 of 3)
1 W503921 LH catalytic converter manifold shield
bolt (4 required)
2 5K282 LH catalytic converter manifold shield
3 14A464 Heated Oxygen Sensor (HO2S)
4 9448 LH catalytic converter manifold gasket
5 W701732 LH catalytic converter manifold stud (6
required)
6 W711132 LH catalytic converter manifold bracket
bolt (2 required)
2.5L 4483
7 5K223 LH catalytic converter manifold bracket
8 5G232 LH catalytic converter manifold
9 14A464 Catalyst Monitor Sensor (CMS)
10 5K292 LH catalytic converter manifold shield
bracket
11 W500021 LH catalytic converter manifold shield
bracket bolt (2 required)
12 W701706 LH catalytic converter manifold nut (6
required)
13 W503921 RH catalytic converter manifold shield
bolt (5 required)
14 5K282 RH catalytic converter manifold shield
bracket nut (2 required)
bracket bolt
17 5K281 RH catalytic converter manifold shield
bracket
18 W520414 RH catalytic converter-to-manifold nut
(3 required)
19 5G236 RH catalytic converter manifold
20 5K291 RH catalytic converter manifold bracket
21 5F263 RH catalytic converter manifold gasket
22 W711133 RH catalytic converter-to-manifold stud
(3 required)
24 5F262 Muffler and tail pipe isolator (5
required)
25 5G213 Muffler and tail pipe
3.0L, 3.5L (View 2 of 3)
3.0L Front Wheel Drive (FWD) (View 1 of 3) 4484
3.0L All-Wheel Drive (AWD) (View 3 of 3)
Item
Part
Number Description
1 W713002 RH catalytic converter-to-exhaust flexible pipe bolt (2
required)
2 9451 Gasket
3 W520414 LH catalytic converter-to-exhaust flexible pipe nut (2
required)
4 5E241 Gasket
required)
7 9451 Gasket
9 5221 Torca clamp
11 5G213 Muffler and til pipe
3.0L All-Wheel Drive (AWD) (View 3 of 3) 4485
3.5L (View 1 of 3)
1 14A464 Catalyst Monitor Sensor (CMS)
2 - Catalytic converter support
bracket-to-transmission bolts (2
required)
3 W520414 LH catalytic converter-to-exhaust
manifold nut (4 required)
4 5F263 Gasket
5 W500222 Bracket-to-LH catalytic converter bolt
(2 required)
6 5E213 LH catalytic converter
7 9451 Gasket
8 W520414 Exhaust Y-pipe-to-LH catalytic
converter nut (2 required)
9 W520414 Exhaust Y-pipe-to-resonator nut (2
required)
10 5G274 Exhaust Y-pipe
11 5H292 Resonator
12 5G213 Muffler and tail pipe
13 9451 Gasket
14 W712458 LH catalytic converter-to-exhaust
manifold stud (4 required)
15 W500211
LH catalytic converter heat shield bolt
(3 required)
3.5L (View 1 of 3) 4486
3.5L (View 2 of 3)
16 14A464 RH CMS electrical connector
17 W710512/
W520414
Catalytic converter support bracket-to-engine block
nut (2 required)
18 W500222 Bracket-to-RH catalytic converter bolt (2 required)
19 W520414 RH catalytic converter-to-exhaust manifold nut (4
required)
20 5F263 Gasket
21 5E211 RH catalytic converter
22 W520414 Exhaust Y-pipe-to-RH catalytic converter nut (2
required)
23 5221 Torca clamp
25 W712458 RH catalytic converter-to-exhaust manifold stud (4
required)
26 W500211 H catalytic converter heat shield bolt (3 required)
27 - Gasket
3.5L (View 2 of 3) 4487
3.5L (View 3 of 3)
28 W500210 Power steering gear shield bolt (2 required)
29 - Power steering gear shield
3.5L (View 3 of 3) 4488
Manual
REMOVAL AND
INSTALLATION
Catalytic Converter - Manifold, Hybrid
Removal
NOTE: Always install new fasteners and gaskets as indicated. Clean flange faces prior to new gasket
installation to make sure of proper sealing.
100-02 .
1.
Disconnect the Heated Oxygen Sensor (HO2S) and the Catalyst Monitor Sensor (CMS) electrical
connectors.
2.
Remove the 2 catalytic converter manifold-to-exhaust flexible pipe nuts.
Discard the gasket and the 2 nuts.
3.
Remove the 6 catalytic converter manifold shield bolts and the heat shield. 4.
Remove the 2 catalytic converter manifold shield bracket bolts and the bracket. 5.
Loosen the 2 catalytic converter manifold bracket bolts. 6.
Remove the 7 catalytic converter manifold nuts and remove the converter from the vehicle.
Discard the 7 nuts and the gasket.
7.
Remove and discard the 7 catalytic converter manifold studs. 8.
Clean and inspect the catalytic converter manifold. For additional information, refer to Section 303-00
.
9.
Installation
Install the 7 new catalytic converter manifold studs.
1.
Position a new catalytic converter manifold gasket on the studs. 2.
NOTICE: Failure to tighten the catalytic converter manifold nuts to specification before
installing the converter bracket bolts will cause the converter to develop an exhaust leak.
NOTICE: Failure to tighten the catalytic converter manifold nuts to specification a second time
will cause the converter to develop an exhaust leak.
NOTE: Make sure to tighten the nuts in the following sequence in 2 stages.
Position the catalytic converter manifold and tighten the 7 new nuts in the sequence shown, in 2
stages.
3.
Catalytic Converter - Manifold, Hybrid 4489
Tighten the 2 catalytic converter manifold bracket bolts.
4.
Install the 2 catalytic converter manifold shield bracket bolts and the bracket.
5.
Position the catalytic converter manifold shield and install the 6 heat shield bolts.
6.
Install the exhaust flexible pipe to the catalytic converter.
Install a new gasket and nuts.
7.
Connect the HO2S and the CMS electrical connectors. 8.
Catalytic Converter - Manifold, Hybrid 4490
Manual
REMOVAL AND
INSTALLATION
Catalytic Converter - 3.0L RH
Removal
100-02 .
1.
Remove the RH front wheel and tire. For additional information, refer to Section 204-04 . 2.
Remove the pin-type retainers and position the splash shield aside. 3.
Remove the exhaust flexible pipe. For additional information, refer to Exhausexible Pipe - 2.5L, 3.0L
in this section.
4.
Remove the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS). For additional
information, refer to Section 303-14B.
5.
Remove the roll restrictor bolt and rotate the engine forward. 6.
Remove the 5 bolts and position aside the catalytic converter manifold shield. 7.
Remove the bolt, 2 nuts and the RH catalytic converter manifold brackets. 8.
Rotate the RH catalytic converter so the flex-pipe flange opening is facing toward the front of
the vehicle to remove.

Discard the 3 RH catalytic converter nuts and gasket. Click here to view a video version of
this procedure.

9.
Installation
NOTE: Do not tighten the 3 new RH catalytic converter nuts at this time.
Install the RH catalytic converter and a new gasket.
Loosely install the 3 new nuts.
1.
NOTE: Do not tighten the catalytic converter manifold brackets bolt and 2 nuts at this time. 2.
Catalytic Converter - 3.0L RH 4491
Install the RH catalytic converter manifold brackets.
Tighten the 3 RH catalytic converter nuts.

NOTE: Do not tighten the 5 catalytic converter manifold shield bolts at this time.
Install the catalytic converter manifold shield.
Loosely install the 5 bolts.
4.
Tighten the RH catalytic converter manifold brackets bolt and 2 nuts.
5.
Tighten the catalytic converter manifold shield 5 bolts.
6.
Install the roll restrictor bolt.
7.
NOTICE: Prior to installation, inspect the Heated Oxygen Sensor (HO2S) and the Catalyst
Monitor Sensor (CMS) wiring harness for damage.
Install the HO2S and CMS . For additional information, refer to Section 303-14B.
8.
Install the exhaust flexible pipe. For additional information, refer to Exhaust Flexible Pipe - 2.5L,
3.0L in this section.
9.
Install the splash shield and the pin-type retainers. 10.
Install the RH front wheel and tire. For additional information, refer to Section 204-04 . 11.
Manual
REMOVAL AND
INSTALLATION
Catalytic Converter - 3.0L LH Manifold
Removal
100-02 .
1.
Remove the oil level indicator and tube. For additional information, refer to Section 303-01B . 2.
Disconnect the Heated Oxygen Sensor (HO2S) and the Catalyst Monitor Sensor (CMS) electrical
connectors.
3.
Remove the 2 LH catalytic converter-to-exhaust flexible pipe nuts.
Discard the gasket and the 2 nuts.
4.
Remove the 4 bolts and the LH catalytic converter manifold shield. 5.
Remove the 2 LH catalytic converter manifold shield bracket bolts and the shield bracket. 6.
Remove the 2 LH catalytic converter manifold bracket bolts and bracket. 7.
Remove the 6 nuts and the LH catalytic converter manifold.
Discard the 6 LH catalytic converter manifold nuts and the gasket.
8.
Remove and discard the 6 LH catalytic converter manifold studs. 9.
Clean and inspect the catalytic crter manifold. For additional information, refer to Section 303-00 . 10.
Installation
Install the 6 new LH catalytic converter manifold studs.
1.
Position a new LH catalytic converter manifold gasket on the studs. 2.
Position the LH catalytic converter manifold and finger-tighten the 6 new nuts. 3.
Install a new gasket and finger-tighten 2 new nuts at the LH catalytic converter-to-exhaust flexible
pipe.
4.
NOTICE: Failure to tighten the catalytic converter manifold nuts to specification before
installing the converter bracket bolts will cause the converter to develop an exhaust leak.
NOTICE: Failure to tighten the catalytic converter manifold 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 shown in 2 stages.
5.
Catalytic Converter - 3.0L LH Manifold 4494
Position the LH catalytic converter manifold and tighten the 6 new nuts in the sequence shown, in 2
stages.
Install the shield bracket and the 2 LH catalytic converter manifold shield bracket bolts.
6.
Install the LH catalytic converter manifold bracket and 2 bolts.
7.
Position the LH catalytic converter manifold shield and install the 4 bolts.
8.
Tighten the 2 new LH catalytic converter-to-exhaust flexible pipe nuts.
9.
Connect the HO2S and the CMS electrical connectors. 10.
Install the oil level indicator and tube. For additional information, refer to Section 303-01B . 11.
Catalytic Converter - 3.0L LH Manifold 4495
Manual
REMOVAL AND
INSTALLATION
Catalytic Converter - 3.5L RH
All vehicles
100-02 .
1.
Remove the exhaust Y-pipe. For additional information, refer to Exhaust Y-Pipe - 3.5L in this section. 2.
All vehicles
Remove the 2 bolts and the power steering gear shield.
4.
Remove the roll restrictor bolt and rotate the engine forward.
5.
Remove the 2 bracket-to-RH catalytic converter bolts.
7.
Discard the 4 RH catalytic converter-to-exhaust manifold nuts and gasket.
8.
NOTICE: Prior to Installation, Inspect the CMS wiring harness for damage.
Install a new gasket, nuts and studs as indicated.
9.
Manual
REMOVAL AND
INSTALLATION
Catalytic Converter 3.5L LH
100-02 .
1.
Remove the exhaust Y-pipe. For additional information, refer to Exhaust Y-Pipe 3.5L in this
section.
3.
Remove the 2 catalytic converter support bracket-to-transmission bolts.
4.
Remove the 4 nuts and the LH catalytic converter.
Discard the 4 LH catalytic converter-to-exhaust manifold nuts and gasket.
5.
Install a new gasket, nuts and studs as indicated.
6.
Catalytic Converter 3.5L LH 4498
Manual
REMOVAL AND
INSTALLATION
Exhaust Flexible Pipe - 2.5L, 3.0L
Removal
NOTICE: Do not excessively bend, twist or allow the exhaust to hang from the flexible pipe or damage
to the exhaust system may occur.
All vehicles
100-02 .
1.
Remove and discard the 2 exhaust flexible pipe-to-catalytic converter nuts.
Discard the gasket.
3.
3.0L vehicles
Remove and discard the 2 RH catalytic converter-to-exhaust flexible pipe nuts.
Discard the gasket.
4.
Remove and discard the 2 LH catalytic converter-to-exhaust flexible pipe nuts and remove the
Discard the gasket.
5.
2.5L vehicles
Remove and discard the 2 catalytic converter manifto-exhaust flexible pipe nuts and remove the
Discard the gasket.
6.
Installation
2.5L vehicles
Using a new gasket, install the exhaust flexible pipe and 2 new catalytic converter
manifold-to-exhaust flexible pipe nuts.
1.
Exhaust Flexible Pipe - 2.5L, 3.0L 4499
3.0L vehicles
Using a new gasket, install the exhaust flexible pipe and 2 new LH catalytic converter-to-exhaust
flexible pipe nuts.
2.
Using a new gasket, install the 2 new exhaust flexible pipe-to-catalytic converter nuts.
3.
All vehicles
Using a new gasket, install 2 new exhaust flexible pipe-to-catalytic converter nuts.
4.
Start the engine and check for exhaust leaks. 6.
Exhaust Flexible Pipe - 2.5L, 3.0L 4500
Manual
REMOVAL AND
INSTALLATION
Exhaust Y-Pipe - 3.5L
NOTE: Always install new fasteners and gaskets. Clean flange faces prior to new gasket installation
to make sure of proper sealing.
100-02 .
1.
Remove and discard the 2 exhaust Y-pipe-to-resonator nuts.
Discard the gasket.
3.
Remove and discard the 2 RH catalytic converter-to-exhaust Y-pipe nuts.
4.
Remove and discard the 2 exhaust Y-pipe-to-LH catalytic converter nuts and remove the exhaust
Y-pipe.
Discard the gasket.
5.
Install new gaskets and nuts.
6.
Start the engine and check for exhaust leaks/li> 7.
Exhaust Y-Pipe - 3.5L 4501
Exhaust Y-Pipe - 3.5L 4502
Manual
REMOVAL AND
INSTALLATION
Catalytic Converter - Underbody
100-02 .
1.
Remove and discard the 2 exhaust flexible pipe-to-catalytic converter nuts.
Discard the gasket.
2.
Remove the Torca clamp. For additional information, refer to Torca Clamp in this section. 3.
Separate the catalytic converter from the muffler and tail pipe.
Remove the catalytic converter.
4.
5.
Catalytic Converter - Underbody 4503
Manual
REMOVAL AND
INSTALLATION
Resonator - 3.5L
100-02 .
1.
Remove and discard the 2 exhaust Y-pipe-to-resonator nuts.
Discard the gasket.
2.
Loosen Torca clamp nut.
3.
Separate the resonator from the muffler and tail pipe and remove the resonator. 4.
5.
Resonator - 3.5L 4504
Manual
REMOVAL AND
INSTALLATION
Muffler and Tailpipe
NOTICE: Do not use oil or grease-based lubricants on the isolators. They may cause deterioration of
the rubber.
NOTICE: Oil or grease-based lubricants on the isolators may cause the exhaust hanger isolator to
separate from the exhaust hanger bracket during vehicle operation.
100-02 .
1.
Support the muffler and tail pipe with a suitable jackstand. 2.
NOTICE: Do not excessively bend, twist or allow the exhaust to hang from the flexible pipe or
damage to the exhaust system may occur.
Support the catalytic converter with a suitable jackstand.
3.
Disconnect the ground clip from the exhaust hanger. 4.
Loosen Torca clamp nut.
5.
NOTE: Do not damage or tear the isolators during removal.
Using soapy water, separate the 4 or 5 muffler and tail pipe isolators from the vehicle.
6.
Separate the muffler and tail pipe from the catalytic converter and remove the muffler and tail pipe. 7.
Inspect and replace any isolators damaged or torn during the removal process.
8.
Muffler and Tailpipe 4505
SECTION 310-00: Fuel System - General
Information
Workshop Manual
Material
Capacity
XO-5W20-QSP (US);
Premium Motor Oil
equivalent
WSS-M2C930-A -
Item Specification
Fuel tank capacity (All-Wheel Drive (AWD) vehicles) 62.46L (16.5 gal)
Fuel tank capacity (Front Wheel Drive (FWD) vehicles) 66.24L (17.5 gal)
Fuel Pressure
2.5L and 3.0L engine running fuel pressure 379-399 kPa (55-58 psi)
3.5L engine running fuel pressure 441-461 kPa (64-67 psi)
Fuel tank filler pipe hose clamp 4 35
Information
Workshop Manual
Fuel System
Fuel System
The fuel system consists of the:
All-Wheel Drive (AWD) saddle-type or Front Wheel Drive (FWD) L-shaped fuel tank.
Fuel Pump (FP) module.
fuel level sensor assembly (saddle-type fuel tank).
fuel level sender (mounted on the FP module and, if equipped, on the fuel level sensor assembly).
Easy Fuel
TM
(capless) fuel tank filler pipe assembly.
FP control module on 2.5L and 3.0L vehicles.
Inertia Fuel Shutoff (IFS) switch on 3.5L vehicles.
fuel tubes.
fuel injectors.
fuel rail.
Fuel Tank Pressure (FTP) sensor (part of the fuel vapor tube assembly).
The vehicle
has a single speed Mechanical Retess Fuel System (MRFS) on 3.5L vehicles.
has a 2-speed MRFS on 2.5L and 3.0L vehicles.
has either a single container (L-shaped) ( FWD ) or a dual container (saddle-type) ( AWD ) fuel tank.
has a FP module containing:
an electric FP , which provides pressurized fuel to the fuel rail.
a serviceable fuel level sender.
a check valve, which maintains system pressure after the FP is shut off.
a pressure relief valve for overpressure protection in the event of restricted fuel flow.
a lifetime fuel filter providing filtration to protect the fuel injectors from foreign material.

has an individual fuel level sensor, AWD vehicles only.
has a fuel rail-mounted Schrader valve on early build 3.0L vehicles.
has fuel, vapor and brake tubes in an integrated bundle assembly attached to the underside of the
vehicle by retaining clips.

has an Easy Fuel
TM
(capless) fuel tank filler pipe assembly, which cannot be modified in any way.
has a supplemental refueling adapter located in the luggage compartment.
has a FTP sensor (part of the fuel vapor tube assembly).
is equipped with a sequential Multi-Port Fuel Injection (MFI) system.
uses separately controlled fuel injectors for each cylinder. The fuel injectors are mounted to the intake
manifold.

fuel injectors are supplied with pressurized fuel from the FP module to the fuel rail.
Fuel System Shutoff Feature
In event of a moderate to severe collision, the vehicle is equipped with a FP shutoff feature that is initiated by
the event notification signal. The event notification signal is provided by the Restraints Control Module
(RCM) to the FP control module. Signal communication between the RCM and the FP control module allows
Fuel System 4509
the PCM to shutoff the FP module. Should the vehicle shut off after a collision due to this feature, restart the
vehicle by first turning the ignition to the OFF position and then turn the ignition to the ON position. In some
instances, the vehicle may not restart the first time and may take an additional attempt.
3.5L vehicles
The FP module is controlled by the PCM. Electrical power to the FP module is provided through the IFS
switch that will de-energize the fuel delivery secondary circuit in the event of a moderate to severe collision.
The IFS switch is a safety device, located under the RH front door scuff plate. Should the vehicle shutoff after
a collision due to this feature, restart the vehicle by first turning the ignition OFF, push the reset button on the
IFS switch, then turn the ignition to the ON position.
2.5L and 3.0L vehicles 4510
Information
Workshop Manual
Fuel System
Special Tool(s)
NOTE: The following procedure diagnoses a slow to fill concern only. For all other concerns refer to the
The fuel tank filler pipe assembly is used to refuel the vehicle. The fuel tank inlet check valve prevents
spitback of fuel during and after refueling. The fuel tank stores the fuel. The fuel tank contains a Fuel Pump
(FP) module. The FP module consists of a fuel level sensor and a FP . The fuel level sender sends a signal to
the fuel gauge informing the driver of how much fuel is in the fuel tank. The FP provides fuel to the fuel tubes
which supply the fuel rail.
During refueling, the fuel tank vents to the atmosphere through the vent and filler pipes, on vehicles without
On-Board Refueling Vapor Recovery (ORVR) systems. In vehicles equipped with ORVR , the fuel tank and
filler pipe are designed so that when the vehicle is being refueled, fuel vapors in the fuel tank travel to the
Evaporative Emission (EVAP) canister, which absorbs the fuel vapors and vents the pressure from the fuel
tank during refueling.
Verify the customer's concern by refueling the vehicle and observe the fuel fill rate. 1.
Inspect to determine if any of the following mechanical concerns apply. 2.
Mechanical
3.5L vehicles 4511
Bent, kinked or damaged fuel tank filler pipe
Bent, kinked or damaged fuel tank filler pipe vent tube (if equipped)
Incorrect routing of the fuel tank filler pipe
Incorrect routing of the fuel tank filler pipe vent tube (if equipped)
Incorrect position of fuel tank filler pipe clamps
Incorrect position of fuel tank filler pipe vent tube clamps (if equipped)
Fuel tank mounted vapor tubes bent or damaged
Evaporative Emission (EVAP) system tubes or hoses bent or damaged
Accident damage to the fuel tank
Accident damage to the vehicle effecting the fuel tank filler pipe-to-body
connection

Unauthorized modifications and/or alterations to the vehicle
EVAP system fresh air tube plugged (dirt, spider webbing)
3.
4.
5.
6.
418-00 .

(CMDTCs).

7.
Clear the continuous DTCs and carry out the self-test diagnostics for the EVAP system. 8.
If the DTCs retrieved are related to the concern, go to Evaporative Emission (EVAP) System DTC
Chart. For PCM-related DTCs, refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
For all other DTCs, refer to Section 419-10 .
9.
DTC Chart
Evaporative Emission (EVAP) System DTC Chart
Fuel System 4512
P0446 Evaporative Emission System Vent Control Circuit GO to Pinpoint Test A .
P0451 Evaporative Emission System Pressure Sensor/Switch Range/Performance GO to Pinpoint Test A .
P0452 Evaporative Emission System Pressure Sensor/Switch Low GO to Pinpoint Test A .
P0453 Evaporative Emission System Pressure Sensor/Switch High GO to Pinpoint Test A .
P0454 Evaporative Emission System Pressure Sensor/Switch Intermittent GO to Pinpoint Test A .
P1450 Unable to Bleed up Fuel Tank Vacuum GO to Pinpoint Test A .
P1451 Evaporative Emission System Vent Control Circuit GO to Pinpoint Test A .
P260F Emission System Monitoring Processor Performance GO to Pinpoint Test A .
Symptom Chart
Symptom Chart
Pinpoint Test
Pinpoint Test A: Slow to Fill
Normal Operation
Under normal operation, fuel should flow at a steady rate through the fuel tank filler pipe into the fuel tank.
As fuel enters the fuel tank, air is vented through the filler pipe or the On-Board Refueling Vapor Recovery
(ORVR) system.
Fuel tank filler pipe vent tube, if equipped
Fuel tank filler pipe
Evaporative Emission (EVAP) system
Fuel tank inlet check valve (part of the fuel tank)
Fuel level vent valve (part of the fuel tank)
PINPOINT TEST A: SLOW TO FILL
A1 CARRY OUT INSPECTION AND
VERIFICATION
Carry out inspection and verification.
Was the cause of the concern found?
Yes
REPAIR or INSTALL new components to correct the
concern.
No
GO to A2 .
A2 CHECK THE SYSTEM FOR ANY
EVAP DTCs
Check the system for any of the
following EVAP DTCs: P0446, P0451,
P0452, P0453, P0454, P1450, P1451
and P260F.

Are any of these DTCs present?
Yes
REFER to Powertrain Control/Emissions Diagnosis
(PC/ED) manual to diagnose the EVAP system.
No
GO to A3 .
A3 MONITOR THE FTP WHILE
FILLING THE FUEL TANK
Monitor the Fuel Tank Pressure (FTP)
reference value while filling the fuel
tank. Refer to Powertrain
manual.

Is FTP within specification?
Yes
GO to A5 .
No
GO to A4 .
A4 MONITOR THE FTP WHILE
FILLING THE FUEL TANK WITH THE
EVAP SYSTEM DISCONNECTED
Disconnect the fuel tank-to- EVAP
canister quick connect coupling at the
EVAP canister. Refer to Quick Connect
Coupling in this section.

Monitor the FTP reference value while
filling the fuel tank. Refer to Powertrain
manual.

Is FTP within specification?
Yes
INSPECT the EVAP system for blockage or
restrictions. REPAIR the blockage or restriction. If the
restriction or blockage cannot be repaired, INSTALL
new EVAP system components.
No
GO to A5 .
A5 CHECK THE FUEL TANK FILLER
PIPE ASSEMBLY FOR BLOCKAGE OR
RESTRICTION
Remove the fuel tank filler pipe
assembly. Refer to Section 310-01A .

Inspect the fuel tank filler pipe and fuel
tank filler pipe vent tube (if equipped)
for a blockage or restriction.

Is the fuel tank filler pipe or fuel tank
filler pipe vent tube (if equipped)
blocked or restricted?

Yes
If possible, REPAIR the blockage or restriction. If the
blockage or restriction cannot be repaired, INSTALL a
new fuel tank filler pipe or fuel tank filler pipe vent
tube.
No
GO to A6 .
A6 CHECK THE FUEL TANK INLET
CHECK VALVE
Inspect the fuel tank inlet check valve
for restriction or sticking.

Is the fuel tank filler pipe inlet check
valve restricted or sticking?

Yes
If possible, REPAIR the restriction. If the restriction
cannot be repaired, INSTALL a new fuel tank. REFER
No
INSTALL a new fuel tank. REFER to Section 310-01A
.
PINPOINT TEST A: SLOW TO FILL 4514
PINPOINT TEST A: SLOW TO FILL 4515
Information
Workshop Manual
Fuel System Pressure Release
equipment of any type when working on or near any fuel-related component. Highly flammamixtures
are always present and may be ignited. Failure to follow these instructions may result in serious
personal injury.
3.5L vehicles
Remove the RF door scuff plate. 3.
Disconnect the Inertia Fuel Shutoff (IFS) switch. 4.
Fuel System Pressure Release 4516
All vehicles
Start the engine and allow it to idle until it stalls. 5.
After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel system
pressure has been released.
6.
Turn the ignition switch to the OFF position. 7.
When fuel system service is complete, reconnect the FP control module electrical connector. 8.
Position the LR quarter panel luggage compartment trim. 9.
3.5L vehicles
When fuel system service is complete, reconnect the IFS switch electrical connector. 10.
Install the RF door scuff plate. 11.
All vehicles
NOTE: It may take more than one key cycle to pressurize the fuel system.
Cycle the ignition key and wait 3 seconds to pressurize the fuel system.
12.
NOTE: Carry out a Key ON Engine OFF (KOEO) visual inspection for fuel leaks prior to starting the
engine.
Start the vehicle and check the fuel system for leaks.
13.
Fuel System Pressure Release 4517
Information
Workshop Manual
Fuel System Pressure Test
Special Tool(s)
Adapter, Fuel Pressure Test
310-180
Fuel Pressure Test Kit
310-D009 (D95L-7211A)
NOTE: Early build 3.0L engines are equipped with a Schrader valve on the fuel rail. Late build 3.0L engines
do not have a Schrader valve.
2.5L engine
Release the fuel system pressure. For additional information, refer to Fuel System Pressure Release in
this section.
1.
Disconnect the fuel jumper tube-to-fuel rail quick connect coupling. For additional information, refer
to Quick Connect Coupling in this section.
3.
Install the Fuel Pressure Test Kit between the fuel jumper tube and the fuel rail. 4.
Fuel System Pressure Test 4518
NOTE: The Fuel Pump (FP) control module was disconnected in the fuel system pressure release.
Connect the FP control module electrical connector.
5.
Early build 3.0L engine
Remove the fuel rail Schrader valve cap. 7.
Install the Fuel Pressure Test Kit to the fuel rail Schrader valve. 8.
Late build 3.0L engine
Disconnect the fuel jumper tube-to-fuel tube quick connect coupling. For additional information, refer
to Quick Connect Coupling in this section.
9.
Install the Fuel Pressure Test Kit between the fuel jumper tube and the fuel tube. 10.
3.5L engine
this section.
11.
Disconnect the fuel tube-to-fuel rail spring lock coupling. For additional information, refer to Spring
Lock Couplings in this section.
14.
Install the Fuel Pressure Test Adapter and Fuel Pressure Test Kit between the fuel tube and the fuel
rail.
15.
NOTE: The ACL outlet pipe must be installed prior to completing the fuel system pressure test.
Install the ACL outlet pipe. For additional information, refer to Section 303-12C .
16.
NOTE: The Inertia Fuel Shutoff (IFS) switch was disconnected in the fuel system pressure release.
Connect the IFS switch electrical connector.
17.
All engines
NOTE: Carry out a Key ON Engine OFF (KOEO) visual inspection for fuel leaks prior to completing
the fuel system pressure test.
NOTE: After completion of the fuel system pressure test, open the drain valve on the Fuel Pressure
Test Kit and release any residual fuel into a suitable container prior to removing the tool.
Test the fuel system pressure to make sure it is within the specified range. For additional information,
refer to Specifications in this section.
19.
Information
Workshop Manual
Fuel Tank Draining - 2.5L
Special Tool(s)
Fuel Storage Tanker
Fuel Tank Sender Unit Wrench
310-123
NOTE: For vehicles with an inaccurate or inoperable fuel gauge, follow the instructions for draining a fuel
tank with more than three-fourths of a tank of fuel.
All vehicles
this section.
1.
Vehicles with more than three-fourths of a tank of fuel
Install the supplemental refueling adapter and a length of semi-rigid fuel drain tube into the Easy Fuel
TM
(capless) fuel tank filler pipe until the tube enters the fuel tank.
3.
Fuel Tank Draining - 2.5L 4522
NOTE: This step will remove approximately one-fourth tank of the fuel from a completely full fuel
tank and the majority of any residual fuel in the fuel tank filler pipe, lowering the fuel level below the
Fuel Pump (FP) module mounting flange.
Attach the Fuel Storage Tanker to the fuel drain tube and remove one-fourth (approximately 4
gallons) of fuel from the tank.
4.
All vehicles
Remove the rear seat lower cushion. For additional information, refer to Section 501-10 . 5.
Remove the 4 screws and the FP module access cover. 6.
NOTE: Clean the FP module connections, couplings, flange surfaces and the immediate surrounding
area of any dirt or foreign material.
Disconnect the FP module electrical connector.
7.
NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage.
Disconnect the fuel tube-to- FP module quick connect coupling. For additional information, refer to
Section 310-00 .
8.
NOTE: Make sure to install a new FP module O-ring seal. 9.
Install the Fuel Tank Sender Unit Wrench, remove the FP module lock ring.
Discard the FP module O-ring seal.
NOTICE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float
arm.
Position the FP module aside and insert the tube from the Fuel Storage Tanker into the FP module
aperture and drain as much fuel from the fuel tank as possible.
10.
Information
Workshop Manual
Fuel Tank Draining - 3.0L Front Wheel Drive (FWD)
Special Tool(s)
Fuel Storage Tanker
310-123
tank with more than three-fourths of a tank of fuel.
All vehicles
this section.
1.
Vehicles with more than three-fourths of a tank of fuel
NOTE: The Easy Fuel
TM
(capless) fuel tank filler pipe on 3.0L vehicles have an anti-siphon grate that will
not allow a fuel drain tube to penetrate the fuel tank and requires the following steps to drain the fuel.
100-02 .
3.
NOTE: Index-mark the fuel tank filler pipe hose and the clamp prior to removal for correct
installation.
4.
Fuel Tank Draining - 3.0L Front Wheel Drive (FWD) 4525
Release the clamp and disconnect the hose from the fuel tank filler pipe.
Insert a semi-rigid fuel drain tube into the fuel tank filler pipe hose until it enters the fuel tank. 5.
NOTE: This step is to remove approximately one-fourth tank of the fuel from a completely full fuel
tank, lowering the fuel level below the Fuel Pump (FP) module mounting flange.
6.
All vehicles
9.
NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage. 10.
Section 310-00 .
NOTE: Make sure to install a new FP module O-ring seal.
Install the Fuel Tank Sender Unit Wrench and remove the FP module lock ring.
11.
arm.
12.
Information
Workshop Manual
Fuel Tank Draining - 3.0L All Wheel Drive (AWD)
Special Tool(s)
Fuel Storage Tanker
310-123
tank with more than one-half of a tank of fuel.
All vehicles
this section.
1.
Vehicles with more than one-half of a tank of fuel
NOTE: The Easy Fuel
TM
100-02 .
3.
installation.
4.
Fuel Tank Draining - 3.0L All Wheel Drive (AWD) 4529
NOTE: This step is to remove approximately one-half tank of the fuel from a completely full fuel
tank, lowering the fuel level below the Fuel Pump (FP) module mounting flange.
Attach the Fuel Storage Tanker to the fuel drain tube and remove one-half (approximately 9 gallons)
of fuel from the tank.
6.
All vehicles
9.
NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage. 10.
Section 310-00 .
11.
arm.
12.
Remove the 3 screws and the fuel level sensor access cover. 13.
NOTE: Clean the fuel level sensor electrical connector, flange surface and the immediate surrounding
Disconnect the fuel level sensor electrical connector.
14.
Release the lock tab and rotate the fuel level sensor counterclockwise approximately one-fourth turn,
lift and position aside.
15.
Insert the tube from the Fuel Storage Tanker into the fuel level sensor aperture and drain the
remainder of the fuel from the fuel tank.
16.
Information
Workshop Manual
Fuel Tank Draining - 3.5L
Special Tool(s)
Fuel Storage Tanker
310-123
NOTE: For (Front Wheel Drive (FWD)) vehicles with an inaccurate or inoperable fuel gauge, follow the
instructions for draining a fuel tank with more than three-fourths of a tank of fuel.
NOTE: For (All-Wheel Drive (AWD)) vehicles with an inaccurate or inoperable fuel gauge, follow the
instructions for draining a fuel tank with more than one-half of a tank of fuel.
All vehicles
this section.
1.
Front Wheel Drive (FWD) vehicles with more than three-fourths tank of fuel
TM
4.
NOTE: This step will remove approximately one-fourth tank of the fuel from a completely full fuel
5.
All-Wheel Drive (AWD) vehicles with more than one-half tank of fuel
TM
6.
tank, lowering the fuel level below the FP module mounting flange.
7.
FWD vehicles
AWD vehicles
All vehicles
10.
Section 310-00 .
11.
Install the Fuel Tank Sender Unit Wrench, remove the FP module lock ring.
12.
arm.
Position the FP module aside and insert the tube from the fuel storage tanker into the FP module
13.
AWD vehicles
Remove the 3 screws and the fuel level sensor access cover. 14.
NOTE: Clean the fuel level sensor electrical connector, flange surface and the immediate surrounding
15.
Release the lock tab and rotate the fuel level sensor counterclockwise approximately one-fourth turn,
lift and position aside.
16.
Insert the tube from the Fuel Storage Tanker into the fuel level sensor aperture and drain the
remainder of the fuel from the fuel tank.
17.
Information
Workshop Manual
Quick Connect Coupling
Special Tool(s)
Disconnect Tool, Fuel Pipe (5/16")
310-040
Material
Item Specification
or equivalent
WSS-M2C930-A
Disconnect - Type I
NOTICE: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove
any foreign material from the connector retaining clip area before separating from the tube or damage
to the tube or connector retaining clip can occur. Apply clean engine oil to the end of the tube before
inserting the tube into the connector.
NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
essential that absolute cleanliness is observed when working with these components or component
damage can occur. Always install plugs to any open orifices or tubes.
Quick Connect Coupling 4538
NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components which
may cause fuel leaks.
If servicing a liquid fuel tube quick connect coupling, release the fuel system pressure. For additional
information, refer to Fuel System Pressure Release in this section.
1.
Depress the locking tab and release the quick connect coupling from the tube. 3.
Connect - Type I
NOTE: Make sure the retainer clip is fully seated and locked onto the tube by pulling on the quick
connect coupling.
Install the quick connect coupling onto the tube until it is fully seated.
1.
Disconnect - Type II
on or near auel-related component. Highly flammable mixtures are always present and may be ignited.
Release the lock tab on the quick connect coupling. 2.
Separate the quick connect coupling from the fitting. 3.
Connect - Type II
NOTE: Apply clean engine oil to the O-ring seals.
connect coupling.
Release the lock tab and install the quick connect coupling onto the fitting.
1.
Apply the lock tab into the latched position. 2.
Disconnect - Type III
1.
Release the quick connect coupling lock tab. 3.
Rotate the primary locking tab to the fully opened position and squeeze the secondary locking tabs to
release the locking mechanism.
4.
Push the locking mechanism outward and release the tube. 5.
Remove the quick connect coupling from the tube. 6.
Connect - Type III
1.
Depress the retainer clip until it is flush with the quick connect coupler housing and is fully seated on
the tube.
2.
connect coupling.
Rotate the primary locking tab on the retainer clip to the closed position.
3.
Disconnect - Type IV
1.
Squeeze the quick connect coupling retainer clip tabs to release the locking mechanism. 3.
Push the locking mechanism outward to release the tube. 4.
Connect - Type IV
Install the quick connect coupling onto the tube.
1.
Depress the quick connect coupling locking mechanism into the locked position. 2.
connect coupling.
Visually inspect and verify that the locking mechanism is flush with the quick connect coupling
housing and that the tabs are locked in place.
3.
Disconnect - Type V
1.
Install the Fuel Pipe Disconnect Tool on the tube and push into the quick connect coupling locking
clip to release.
3.
Connect - Type V
NOTE: Apply ean engine oil to the O-ring seals.
connect coupling.
1.
Disconnect - Type VI
WARNING: Do not carry persal electronic devices such as cell phones, pagers or audio equipment
of any type when working on or near any fuel-related component. Highly flammable mixtures are
always present and may be ignited. Failure to follow these instructions may result in serious personal
injury.
1.
Depress the legs of the retainer clip and position the clip in an outward position. 3.
Disconnect the quick connect coupling from the tube. 4.
Connect - Type VI
NOTE: Apply clean engine oil to the end of the tube and quick connect coupling O-ring seals.
Install the quick connect coupling onto the tube until fully seated.
1.
connect coupling.
Press the retainer clip into the quick connect coupling body until flush and the legs are locked in
place.
2.
Disconnect - Type VII
1.
Push the tube into the quick connect coupling and depress the release mechanism. 3.
Disconnect the quick connect coupling from the tube. 4.
Connect - Type VII
NOTE: Apply clean engine oil to the end of the tube and quick connect coupling O-ring seals.
Install the quick connect coupling onto the tube until fully seated.
1.
Pull the tube and the coupling in separate directions to ensure the quick connect coupling is secured
on the tube.
2.
Connect the battery ground cable. For additiol information, refer to Section 414-01 . 3.
Information
Workshop Manual
Spring Lock Couplings
Special Tool(s)
Disconnect Tool, Spring Lock Coupling
310-S039 (T90T-9550-S) or equivalent
Material
Item Specification
SAE 5W-20 Super Premium Motor Oil
equivalent WSS-M2C930-A
Disconnect
Spring Lock Couplings 4550
this section.
1.
Install the Spring Lock Coupling Disconnect Tool on the tube and push into the spring lock coupling
to release.
3.
Separate the spring lock coupling from the tube. 4.
Connect
NOTE: Lubricate the fuel tube with clean engine oil.
Align and push the spring lock coupling onto the tube until a click is heard.
1.
Pull on the coupling to make sure it is fully engaged. 2.
SECTION 310-01A: Fuel Tank and Lines
Workshop Manual
Material
Capacity
XO-5W20-QSP (US);
WSS-M2C945-A -
Item Specification
Fuel tank capacity (All-Wheel Drive (AWD) vehicles) 62.46L (16.5 gal)
Fuel tank capacity (Front Wheel Drive (FWD) vehicles) 66.24L (17.5 gal)
Fuel level sensor access cover screws 2 - 18
Fuel Pump (FP) module access cover screws 2 - 18
Fuel tank filler pipe bracket bolt 7 - 62
Fuel tank filler pipe bracket nut 7 - 62
Fuel tank filler pipe heat shield nuts 9 - 80
Fuel tank strap bolts 40 30 -
Inertia Fuel Shutoff (IFS) switch bolt 2 - 18
LR parking brake cable assembly bracket bolts 23 17 -
Lower crossover support brace nuts 76 56 -
Workshop Manual
Fuel Tank and Lines
Fuel System
The fuel system consists of:
a single-speed Mechanical Returnless Fuel System (MRFS) (3.5L vehicles).
a 2-speed MRFS (2.5L and 3.0L vehicles).
an All-Wheel Drive (AWD) saddle-type or Front Wheel Drive (FWD) L-shaped fuel tank.
an Easy Fuel
TM
a Fuel Pump (FP) module containing:

fuel, vapor and brake tubes in an integrated bundle assembly attached to the underside of the vehicle
by retaining clips.

an Inertia Fuel Shutoff (IFS) switch (3.5L vehicles).
a FP control module (2.5L and 3.0L vehicles).
an individual fuel level sensor, AWD vehicles only.
In event of a moderate to severe collision, the vehicle is equipped with a FP shutoff feature that is initiated by
the event notification signal. The event notification signal is provided by the Restraints Control Module
(RCM) to the FP control module. Signal communication between the RCM and the FP control module allows
the PCM to shutoff the FP module. Should the vehicle shut off after a collision due to this feature, restart the
vehicle by first turning the ignition to the OFF position and then turn the ignition to the ON position. In some
instances, the vehicle may not restart the first time and may take an additional attempt.
3.5L vehicles
The FP module is controlled by the PCM. Electrical power to the FP module is provided through the IFS
switch that will de-energize the fuel delivery secondary circuit in the event of a moderate to severe collision.
The IFS switch is a safety device, located under the RH front door scuff plate. Should the vehicle shutoff after
a collision due to this feature, restart the vehicle by first turning the ignition OFF, push the reset button on the
IFS switch, then turn the ignition to the ON position.
Fuel Tank and Lines 4555
3.5L vehicles 4556
Workshop Manual
Fuel Tank and Lines
SECTION 310-01A: Fuel Tank and
Lines
Manual
Fuel Tank and Filler Pipe - Exploded View
Fuel Tank Supports and Shields (Front Wheel Drive (FWD) Vehicles)
1 9092 RH fuel tank strap
3 9092 LH fuel tank strap
4 9A031 Fuel tank heat shield
5 W700430 Fuel tank heat shield nut (2 required)
6 9B328 Fuel tank heat shield clip (2 required)
10 529330 Fuel tank filler pipe heat shield bracket
11 W701259 Splash shield pin-type retainer (6 required)
12 5428371 LR splash shield
13 N807379 Splash shield rivet (3 required)
&nb
Fuel Tank and Filler Pipe ( FWD Vehicles)
Fuel Tank and Filler Pipe - Exploded View 4558
Item
Part
Number Description
1 W807011 Fuel Pump (FP) module access cover screw (4 required)
2 54111 FP module access cover
3 9C385 FP module lock ring
4 14A464 FP module electrical connector
5 - Fuel tube-to- FP module quick connect coupling (part of
9J279)
6 9J279 Fuel tube
7 9H307 FP module
9 9002 Fuel tank
13 9047 Fuel tank filler pipe hose
14 - Fuel vapor tube assembly-to-fuel tank filler pipe
recirculation tube quick connect coupling (part of 9A228)
15 N806543 Fuel tank filler pipe bracket nut
17 27936 Fuel tank filler pipe housing
18 9K072 Information bezel
19 9B178 Fuel tank filler pipe
20 W707398 Fuel tank filler pipe bracket bolt
21 - Fuel tank filler pipe housing retainer (3 required) (part of
27936)
Fuel Tank and Filler Pipe ( FWD Vehicles) 4559
Fuel Tank Supports and Shields (All-Wheel Drive (AWD) Vehicles)
8 5428371 LR splash shield
Fuel Tank and Filler Pipe ( AWD Vehicles)
Fuel Tank Supports and Shields (All-Wheel Drive (AWD) Vehicles) 4560
Item
Part
Number Description
1 W807011 Fuel level sensor access cover screw (3 required)
2 54111 Fuel level sensor access cover
3 14A464 Fuel Pump (FP) module electrical connector
5 14A464 Fuel level sensor electrical connector
6 9275 Fuel level sensor
7 9002 Fuel tank
8 - Fuel tube-to- FP module quick connect coupling (part of
9J279)
9 9J279 Fuel tube
10 - Internal crossover fuel tube-to- FP module quick connect
11 - Internal crossover fuel tube (part of 9002)
12 9H307 FP module
13 9276 FP module O-ring seal
14 W807011 FP module access cover screw (3 required)
15 54111 span> module access cover
recirculation tube quick connect coupling (part of 9A228)
27 9K072 Information bezel
28 - Fuel tank filler pipe housing retainer (3 required) (part of
27936)
Fuel Tank and Filler Pipe ( AWD Vehicles) 4561
Fuel Tank and Filler Pipe ( AWD Vehicles) 4562
Lines
Manual
Fuel Tank - Front Wheel Drive (FWD)
Special Tool(s)
Powertrain Lift
100-02 .
1.
Drain the fuel tank. For additional information, refer to Section 310-00 . 2.
Remove the muffler and tailpipe. For additional information, refer to Section 309-00 . 3.
NOTE: Some residual fuel may remain in the fuel tank filler pipe after draining the fuel tank.
Carefully drain any remaining fuel into a suitable container.
4.
5.
Fuel Tank - Front Wheel Drive (FWD) 4563
Remove the 4 nuts, 2 clips and release the heat shield from the fuel tank. 6.
Remove the 4 bolts and the 2 fuel tank straps.
8.
Carefully lower and remove the fuel tank from the vehicle. 9.
Fuel Tank - Front Wheel Drive (FWD) 4564
Lines
Manual
Fuel Tank - All Wheel Drive (AWD)
Special Tool(s)
Powertrain Lift
100-02 .
1.
6.
Fuel Tank - All Wheel Drive (AWD) 4565
8.
9.
Fuel Tank - All Wheel Drive (AWD) 4566
Lines
Manual
Fuel Tank Filler Pipe - Front Wheel Drive (FWD)
Special Tool(s)
Fuel Storage Tanker
100-02 .
1.
If the vehicle is equipped with a dual exhaust system, remove the muffler and tailpipe. For additional
3.
TM
(capless) fuel tank filler pipe.
4.
Fuel Tank Filler Pipe - Front Wheel Drive (FWD) 4567
Attach the Fuel Storage Tanker to the fuel drain tube and remove any residual fuel in the fuel tank
filler pipe.
5.
Remove the LR wheel and tire. For additional information, refer to Section 204-04 . 6.
Remove the 3 rivets, 6 pin-type retainers and the LR splash shield. 7.
8.
Remove the fuel tank filler pipe bolt and nut.
9.
Disconnect the fuel vapor tube assembly-to-fuel tank filler pipe recirculation tube quick connect
10.
Remove the information bezel. 11.
Release the 3 retainers and remove the fuel tank filler pipe housing. 12.
NOTE: Some fuel may remain in the fuel tank filler pipe after the initial drain. Carefully drain any
residual fuel into a suitable container.
13.
NOTE: The fuel tank filler pipe assembly has to be directed upward and partially out of the fuel door
opening, then it can be lowered and removed from the vehicle.
Remove the fuel tank filler pipe assembly from the vehicle.
14.
Lines
Manual
Fuel Tank Filler Pipe - All Wheel Drive (AWD)
Special Tool(s)
Fuel Storage Tanker
Powertrain Lift
WARN Do not carry personal electronic devices such as cell phones, pagers or audio equipment of
any type when working on or near any fuel-related component. Highly flammable mixtures are always
100-02 .
1.
TM
4.
Fuel Tank Filler Pipe - All Wheel Drive (AWD) 4570
filler pipe.
5.
Remove the 3 rivets, 6 pin-type retainers and the LR splash shield. 7.
8.
Remove the fuel tank filler pipe bolt and nut.
9.
10.
14.
16.
NOTE: The fuel tank filler pipe assembly has to be directed upward and partially out of the fuel door
opening, then it can be lowered and removed from the vehicle.
Remove the fuel tank filler pipe assembly from the vehicle.
17.
Lines
Manual
Fuel Pump Module - Front Wheel Drive (FWD)
Special Tool(s)
Fuel Storage Tanker
310-123
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
ignited. Failure to follow tnstructions may result in serious personal injury.
NOTE: Vehicles with an inaccurate or inoperable fuel gauge, follow the instructions for draining a fuel tank
with more than three-fourths of a tank of fuel.
All vehicles
Fuel Pump Module - Front Wheel Drive (FWD) 4573
2.5L and 3.5L vehicles with more than three-fourths of a tank of fuel
TM
4.
5.
3.0L vehicles with more than three-fourths of a tank of fuel
NOTE: The Easy Fuel
TM
100-02 .
6.
TM
7.
filler pipe.
8.
installation.
9.
11.
All vehicles
Remove the 4 screws and the FP module access cover.
12.
13.
Section 310-00 .
14.
NOTE: Place absorbent pads on the floor pan in the immediate area in case of fuel spills. Carefully
remove the FP module from the vehicle to avoid fuel spillage inside the vehicle.
15.
arm.
16.
NOTE: The FP module will have residual fuel remaining internally, drain into a suitable container.
Carefully remove the FP module from the fuel tank.
NOTICE: Inspect the mating surfaces of the Fuel Pump (FP) module flange and the fuel tank
O-ring seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank
flange or the fuel tank. Install a new FP module or fuel tank if the O-ring seal contact area is
bent, scratched or corroded.
NOTE: To install, apply clean engine oil to the new O-ring seal.
Remove and discard the FP module O-ring seal.
17.
Make sure the alignment tab on the FP module and the fuel tank meet before tightening the
FP module lock ring.

18.
Lines
Manual
Fuel Pump Module - All Wheel Drive (AWD)
Special Tool(s)
Fuel Storage Tanker
310-123
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
ignited. Failure to follow theseuctions may result in serious personal injury.
NOTE: Vehicles with an inaccurate or inoperable fuel gauge, follow the instructions for draining a fuel tank
with more than one-half of a tank of fuel.
All vehicles
Fuel Pump Module - All Wheel Drive (AWD) 4577
2.5L and 3.5L vehicles with more than one-half of a tank of fuel
TM
4.
5.
3.0L vehicles with more than one-half of a tank of fuel
NOTE: The Easy Fuel
TM
100-02 .
6.
TM
7.
filler pipe.
8.
installation.
9.
11.
All vehicles
12.
13.
Section 310-00 .
14.
15.
Carefully lift the FP module out of the fuel tank enough to access and release the internal fuel tube-to-
FP module quick connect coupling. For additional information, refer to Section 310-00 .
16.
arm.
Carefully remove the FP module from the fuel tank.
17.
18.

19.
Lines
Manual
Fuel Level Sensor
Special Tool(s)
Fuel Storage Tanker
Material
Item Specification
XO-5W20-QSP (US);
WSS-M2C945-A
serious personal inry.
NOTE: Only All-Wheel Drive (AWD) vehicles are equipped with a fuel level sensor (sub-side module) in the
RH side of the saddle-type tank.
All vehicles
Fuel Level Sensor 4581
NOTE: The Easy Fuel
TM
100-02 .
3.
TM
4.
filler pipe.
5.
installation.
6.
tank, lowering the fuel level below the fuel level sensor mounting flange.
8.
NOTE: The supplemental refueling adapter is located in the luggage compartment. 9.
TM
tank, lowering the fuel level below the fuel level sensor mounting flange.
10.
All vehicles
Remove the 3 screws and the fuel level sensor access cover.
11.
NOTE: Clean the fuel level sensor connections, flange surfaces and the immediate surrounding area
of any dirt or foreign material.
12.
NOTE: Place absorbent pads in the general work area in case of fuel spillage.
Release the lock tab, rotate the fuel level sensor counterclockwise approximately one-fourth turn and
lift upward.
13.
NOTICE: Inspect the mating surfaces of the fuel level sensor flange and the fuel tank O-ring
seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange
or the fuel tank. Install a new fuel level sensor or fuel tank if the O-ring seal contact area is
NOTICE: The fuel level sensor must be handled carefully to avoid damage to the float arm.
NOTE: Carefully remove the fuel level sensor from the fuel tank to avoid fuel spillage inside the
vehicle.
Carefully lift and remove the fuel level sensor from the fuel tank.
14.
Make sure the fuel level sensor locking tab is correctly positioned.
15.
Lines
Manual
Fuel Level Sender
1 9H307 Fuel Pump (FP) module
2 9A299 Fuel level sender
3 - Fuel level sender electrical connector (part of 9A299)
NOTE: The fuel level sender is serviced as part of a kit (9A299).
Remove the Fuel Pump (FP) module. For additional information, refer to Fuel Pump Module - Front
Wheel Drive (FWD) or Fuel Pump Module - All Wheel Drive (AWD) in this section.
1.
Disconnect the fuel level sender electrical connector. 2.
Depress the lock tab and slide the fuel level sender upwards and remove. 3.
Fuel Level Sender 4585
To install, reverse the removal edure. 4.
Lines
Manual
Fuel Lines - Front Wheel Drive (FWD)
2.5L Vehicles
Item
Part
Number Description
2 54017 Heat shield
4 020602 Heat shield
5 9G271 Vapor jumper tube
6 - Vapor jumper tube-to-vapor tube quick connect coupling
(part of 9G271)
8 - Fuel jumper tube-to-fuel tube quick connect coupling
(part of 9J280)
9 5884 Lower crossover support brace
10 W580415 Lower crossover support brace nut (4 required)
11 - Fuel tube bundle retaining clip (part of 9J279) (9
required)
12 9J279 Fuel tube
13 - Fuel tube-to-Fuel Pump (FP) module quick connect
coupling (part of 9J279)
14 9J279 Vapor tube
15 - Vapor jumper tube-to-ck connect coupling (part of
9J279)
16 9J279 Vapor jumper tube
17 - Vapor jumper tube-to-Evaporative Emission (EVAP)
canister quick connect coupling (part of 9J279)
18 - Stone shield (part of 2A815)
19 2A815 LR parking brake cable assembly
Fuel Lines - Front Wheel Drive (FWD) 4587
20 W505263 Rear parking brake cable assembly bolt
3.0L Vehicles
Item
Part
Number Description
2 54017 Heat shield
6 - Vapor jumper tube-to-vapor tube
quick connect coupling (part of
9G271)
8 - Fuel jumper tube-to-fuel tube
9J280)
10 W580415 Lower crossover support brace
nut (4 required)
11 - Fuel tube bundle
retaining clip
(part of 9J279) (9
required)
12 9J279 Fuel tube
13 - Fuel tube-to-Fuel Pump (FP)
module quick connect coupling
(part of 9J279)
14 9J279 Vapor tube
15 - Vapor jumper tube-to-vapor tube
9J279)
17 - Vapor jumper tube-to-Evaporative
Emission (EVAP) canister quick
2.5L Vehicles 4588
connect coupling (part of 9J279)
20 W505263 Rear parking brake cable
assembly bolt
3.5L Vehicles
Item
Part
Number Description
2 54017 Heat shield
6 - Vapor jumperor tube quick connect coupling (part of
9G271)
(part of 9J280)
required)
12 9J279 Fuel tube
14 9J279 Vapor tube
(part of 9J279)
3.0L Vehicles 4589
on or near any fuel-related component. Highly flammable mixtures are always may be ignited. Failure
All vehicles
100-02 .
1.
3.5L vehicles
NOTE: The lower cowl panel must be removed to access the fuel and vapor tube quick connect
couplings.
Remove the lower cowl panel. For additional information, refer to the Cowl Panel Grille procedure in
Section 501-02 .
5.
All vehicles
Remove the 4 nuts and the 2 heat shields. 6.
NOTE: Some residual fuel may remain in the fuel tubes after releasing the fuel system pressure.
When disconnecting or removing any fuel tubes, carefully drain any residual fuel into a suitable
container.
7.
3.5L Vehicles 4590
to Section 310-00 .
Disconnect the vapor jumper tube-to-vapor tube quick connect coupling. For additional information,
8.
Remove the 4 nuts and the lower crossover support brace.
9.
Remove the fuel tank. For additional information, refer to Fuel Tank - Front Wheel Drive (FWD) in
this section.
10.
NOTE: The LR parking brake cable bolt also retains a stone shield. Position the cable and shield
aside.
Remove the bolt and position the LR parking brake cable assembly aside.
11.
12.
Release the 9 fuel tube bundle retaining clips and remove the fuel and vapor tubes. 13.
Disconnect the vapor jumper tube-to-Evaporative Emission (EVAP) canister quick connect coupling
and remove the vapor jumper tube. For additional information, refer to Section 310-00 .
14.
3.5L Vehicles 4591
Lines
Manual
Fuel Lines - All Wheel Drive (AWD)
3.0L Vehicles
Item
Part
Number Description
2 54017 Heat shield
(part of 9G271)
(part of 9J280)
required)
12 9J279 Fuel tube
14 9J279 Vapor tube
15 - Vapor jumper tube-to-vapoonnect coupling (part of
9J279)
Fuel Lines - All Wheel Drive (AWD) 4592
3.5L Vehicles
Item
Part
Number Description
2 54017 Heat shield
(part of 9G271)
(part of 9J280)
11 -
Fuel tube bundle retaining clip (part of 9J279) (9
required)
12 9J279 Fuel tube
14 9J279 Vapor tube
(part of 9J279)
3.0L Vehicles 4593
WARNING: Do not carry personal electres such as cell phones, pagers or audio equipment of any
type when working on or near any fuel-related component. Highly flammable mixtures are always
All vehicles
100-02 .
1.
3.5L vehicles
NOTE: The lower cowl panel must be removed to access the fuel and vapor tube quick connect
couplings.
Remove the lower cowl panel. For additional information, refer to the Cowl Panel Grille procedure in
Section 501-02 .
5.
All vehicles
Remove the 4 nuts and the 2 heat shields. 6.
container.
to Section 310-00 .
7.
8.
3.5L Vehicles 4594
9.
Remove the fuel tank. For additional information, refer to Fuel Tank - All Wheel Drive (AWD) in this
section.
10.
aside.
Remove the bolt and position the LR parking brake cable assembly aside.
11.
12.
14.
&nbs
3.5L Vehicles 4595
Lines
Manual
Inertia Fuel Shutoff (IFS) Switch - 3.5L
1 9341 Inertia Fuel Shutoff (IFS) switch
2 W504148 IFS bolt (2 required)
3 14489A IFS switch electrical connector
4 5413200 RH front door scuff plate
Remove the RH front door scuff plate. 1.
Disconnect the Inertia Fuel Shutoff (IFS) switch electrical connector. 2.
NOTICE: Do not overtighten the fasteners or damage to the switch will occur.
Remove the 2 bolts and the IFS switch.
3.
Inertia Fuel Shutoff (IFS) Switch - 3.5L 4596
p;
SECTION 310-01B: Fuel Tank and Lines - Hybrid
Workshop Manual
Material
Capacity
XO-5W20-QSP (US);
Premium Motor Oil
equivalent
WSS-M2C930-A -
Item Specification
Fuel tank capacity 66.24L (17.5 gal)
Fuel Pump (FP) ccess cover screws 2 - 18
Fuel tank filler pipe bracket bolt 7 - 62
Fuel tank filler pipe bracket nut 7 - 62
Fuel tank filler pipe heat shield nut 9 - 80
Fuel tank strap bolt 40 30 -
LH rear parking brake cable assembly bracket bolt 23 17 -
Lower crossover support brace nut 76 56 -
SECTION 310-01B: Fuel Tank and Lines -
Hybrid
Workshop Manual
Fuel Tank and Lines
Fuel System
The fuel system consists of:
a 2-speed Mechanical Returnless Fuel System (MRFS).
a standard L-shaped fuel tank.
an Easy Fuel
TM
a Fuel Pump (FP) module containing:

fuel, vapor anake tubes in an integrated bundle assembly attached to the underside of the vehicle by
retaining clips.

a FP control module.
The vehicle is equipped with a FP shutoff feature that is initiated by theRestraints Control Module (RCM).
The FP control module receives an event notification signal from the RCM to disable the FP . The event
notification signal is sent on a dedicated circuit between the FP control module and the RCM . Should the
vehicle shut-off after a collision due to this feature, restart the vehicle by first turning the ignition to the OFF
position and then turn the ignition to the ON position. In some instances, the vehicle may not restart the first
time and may take an additional attempt.
Hybrid
Workshop Manual
Fuel Tank and Lines
Hybrid
Workshop Manual
Fuel Tank and Filler Pipe - Exploded View
Fuel Tank and Filler Pipe
1 W807011 Fuel Pump (FP) module access cover screw (4
required)
2 54111 FP module access cover
4 14A464 FP module electrical connector
5 - Fuel tube-to- FP module quick connect coupling
(part of 9J279)
6 9H307 FP module
7 9J279 Fuel tube
8 9276 FP module O-ring seal
9 9002 Fuel tank
10 - Fuel vapor tube assembly-to-fuel tank quick
recirculation tube quick connect coupling (part of
9A228)
Fuel Tank and Filler Pipe - Exploded View 4603
16 - Fuel tank filler pipe recirculation tube (part of
9034)
18 9K072
>Information
bezel
21 - Fuel tank filler pipe housing retainer (3 required)
(part of 27936)
Fuel Tank Supports and Shields
4 9A031 Fuel tank heat shield
6 9B328 Fuel tank heat shield clip (2 required)
12 5428371 LH splash shield
Fuel Tank and Filler Pipe 4604
Fuel Tank Supports and Shields 4605
Hybrid
Workshop Manual
Fuel Tank
Special Tool(s)
Powertrain Lift
ignited. Failure to follow these instructions may result erious personal injury.
100-02 .
1.
4.
5.
Fuel Tank 4606
Remove the 4 nuts, 2 clips and release the heat shield from the fuel tank. 6.
8.
Fuel Tank 4607
Hybrid
Workshop Manual
Fuel Tank Filler Pipe
Special Tool(s)
Fuel Storage Tanker
ignited. Failure to follow these ructions may result in serious personal injury.
100-02 .
1.
TM
3.
fuel tank inlet.
4.
Fuel Tank Filler Pipe 4608
Remove the 3 rivets, 6 pin-type retainers and the LR wheel splash shield. 6.
7.
Remove the fuel tank filler pipe bracket nut.
8.
Remove the fuel tank filler pipe bracket bolt.
9.
10.
NOTE: Some fuel may remain in the fuel tank filler pipe after the initial drain. Carefully drain any
residual fuel into a suitable container.
13.
Remove the fuel tank filler pipe assembly from the vehicle. 14.
Hybrid
Workshop Manual
Fuel Pump Module
Special Tool(s)
Fuel Storage Tanker
310-123
Material
Item Specification
Motorc SAE 5W-20 Premium
or equivalent
WSS-M2C930-A
under high pressure, even when thengine is not running. Failure to follow this instruction may result in
NOTE: The supplemental refueling adapter is located in the luggage compartment. 3.
Fuel Pump Module 4611
TM
Fuel Pump (FP) module flange.
4.
6.
Disconnect the FP module electrical connector. 7.
Section 310-00 .
8.
9.
arm.
Completely remove the FP module from the fuel tank.
10.
11.

12.
Hybrid
Workshop Manual
Fuel Level Sender
1 9H307 Fuel Pump (FP) module
2 9A299 Fuel level sender
3 - Fuel level sender electrical connector (part of 9A299)
NOTE: The fuel level sender is serviced as part of a kit (9A299).
Remove the Fuel Pump (FP) module. For additional information, refer to Fuel Pump Module in this
section.
1.
Disconnect the fuel level sender electrical connector. 2.
Depress the lock tab and slide the fuel level sender upwards and remove. 3.
Hybrid
Workshop Manual
Fuel Lines
2 54017 Heat shield
6 - Vapor jumper tube-to-vapor
tube quick connect coupling
(part of 9G271)
8 Fuel jumper tube-to-fuel tube
9J280)
9 - Hybrid fuel tube bundle
shield (part of 9J279)
10 - Hybrid fuel tube bundle
shield pin-type retainer
(part of 9J279)
11 5884 Lower crossover support
brace
12 W580415 Lower crossover support
brace nut (4 required)
13 - Fuel tube bundle retaining
clip (part of 9J279) (9
required)
14 9J279 Fuel tube
15 - Fuel tube-to-Fuel Pump
(FP) module quick connect
16 9J279 Vapor tube
Fuel Lines 4616
17 - Vapor jumper tube-to-vapor
tube quick connect coupling
(part of 9J279)
19 - Vapor jumper
tube-to-Evaporative
Emission (EVAP) canister
quick connect coupling
(part of 9J279)
20 - Stone shield (part of
2A815)
21 2A815 LR parking brake cable
assembly
22 W505263 Rear parking brake cable
assembly bolt
on or near anymponent. Highly flammable mixtures are always present and may be ignited. Failure to
100-02 .
1.
Remove the 4 nuts and 2 heat shields. 4.
Release the pin-type retainer and remove the hybrid fuel tube bundle shield. 5.
container.
6.
Fuel Lines 4617
to Section 310-00 .
7.
If equipped, remove the 6 bolts and the underbody shield. 8.
9.
Remove the fuel tank. For additional information, refer to Fuel Tank in this section. 10.
aside.
Remove the bolt, stone shield and position the LR parking brake cable assembly aside.
11.
12.
14.
Fuel Lines 4618
Fuel Lines 4619
SECTION 310-02: Acceleration
Control
Manual
Accelerator pedal and
sensor assembly nuts
10 89
Fuel Lines 4620
Control
Manual
Acceleration Control
The acceleration controls consist of an accelerator pedal and sensor assembly.
The engine management system electronically operates the accelerator of the engine in response to accelerator
pedal movements initiated by the driver. In the event of a system failure, the engine management system
provides a "limp home" mode which allows the vehicle to be driven with limited performance.
Acceleration Control 4621
Control
Manual
Acceleration Control
Acceleration Control 4622
Control
Manual
Accelerator Pedal and Bracket
2.5L, 2.5L Hybrid and 3.0L Vehicles
1 14A464 Accelerator pedal sensor electrical connector
2 9F836 Accelerator pedal and sensor assembly
3 W706131 Accelerator pedal and sensor assembly nut (2
required)
3.5L Vehicles
1 14A464 Accelerator pedal sensor electrical connector
2 9F836 Accelerator pedal and sensor assembly
3 W706131 Accelerator pedal and sensor assembly nut (2
required)
Accelerator Pedal and Bracket 4623
NOTE: The sport metallic accelerator pedal pad is not to be re-used. If the sport metallic accelerator pedal
pad is removed it should be discarded and replaced with a new sport metallic accelerator pedal pad.
Disconnect the accelerator pedal sensor electrical connector. 1.
Remove the 2 nuts and the accelerator pedal and sensor assembly.
2.
3.5L Vehicles 4624
Acronyms
2WD - 2-Wheel Drive
4WD - Four-Wheel Drive
A/C - Air Conditioning
ABS - Acrylonitrile Butadiene Styrene
ABS - Anti-Lock Brake System
ACCM - Air Conditioning Compressor Module
ACL - Air Cleaner
ACM - Audio Control Module
ACM - Audio Front Control Module
ALR - Automatic Locking Retractor
APIM - Accessory Protocol Interface Module
APP - Accelerator Pedal Position
ATC - Active Torque Coupling
ATF - Automatic Transmission Fluid
AWD - All-Wheel Drive
BCM - Body Control Module
BCM-HVTB - Battery Control Module - High Voltage Traction Battery
BEC - Bussed Electrical Center
BECM - Battery Energy Control Module
BJB - Battery Junction Box
BLIS - Blind Spot Information System
BLISTM - Blind Spot Information System
BPP - Brake Pedal Position
BPSM - Battery Pack Sensor Module
BSIA - Brake Shift Interlock Actuator
BTS - Belt Tension Sensor
Acronyms 4625
CAN - Controller Area Network
CAN2 - Controller Area Network 2
CASS - Compressor Anti-Slugging Strategy
CCA - Cold Cranking Amps
CHT - Cylinder Head Temperature
CID - Cubic Inch Displacement
CIP - Consumer Interface Processor
CKP - Crankshaft Position
CMDTC - Continuous Memory Diagnostic Trouble Code
CMDTCs - Continuous Memory Diagnostic Trouble Codes
CMP - Camshaft Position
CMS - Catalyst Monitor Sensor
CPA - Connector Position Assurance
CPP - Clutch Pedal Position
CTA - Cross Traffic Alert
CVT - Continuously Variable Transaxle
D/A - Dual Action
DAMB - Direct Acting Mechanical Buckets
DATC - Dual Automatic Temperature Control
DC/DC - DC to DC Converter Control Module
DCSM - Dual Climate Controlled Seat Module
DDM - Driver Door Module
DERU - Drive Engine Run-Up
DLC - Data Link Connector
DMM - Digital Multimeter
DOHC - Dual Overhead Camshaft
DP - Dual Phase Steel
Acronyms 4626
DRL - Daytime Running Lamps
DRM - Digital Rights Management
DSM - Driver Seat Module
DSO - District Special Order
DSP - Digital Signal Processing
DTC - Diagnostic Trouble Code
DTE - Distance To Empty
EATC - Electronic Automatic Temperature Control
EBD - Electronic Brake Distribution
ECM - Engine Control Module
ECT - Engine Coolant Temperature
ECU - Electronic Control Unit
eCVT - Electronically Controlled Continuously Variable Transmission
EEPROM - Electrically Erasable Programmable Read-Only Memory
EGR - Exhaust Gas Recirculation
EI - Electronic Ignition
ELR - Emergency Locking Retractor
EMTC - Electronic Manual emperature Control
EONV - Engine Off Natural Vacuum
EOP - Engine Oil Pressure
EPAS - Electronic Power Assist Steering
EPC - Electronic Pressure Control
ESC - Electronic Stability Control
ESN - Electronic Serial Number
ETC - Electronic Throttle Control
EVA - Electronic Vibration Analyzer
EVAP - Evaporative Emission
Acronyms 4627
FC - Fan Control
FCIM - Front Controls Interface Module
FDIM - Front Display Interface Module
FEAD - Front End Accessory Drive
FET - Field-Effect Transistor
FF - Flexible Fuel
FP - Fuel Pump
FTP - Fuel Tank Pressure
FWD - Front Wheel Drive
GEM - Generic Electronic Module
GPS - Global Positioning System
GPSM - Global Positioning System Module
GTDI - Gasoline Turbocharged Direct Injection
GVW - Gross Vehicle Weight
GVWR - Gross Vehicle Weight Rating
HCM - Headlamp Control Module
HCM-2 - Headlamp Control Module 2
HCU - Hydraulic Control Unit
HEV - Hybrid Electric Vehicle
HID - High Intensity Discharge
HO2S - Heated Oxygen Sensor
HPAS - Hydraulic Power Assist Steering
HS-CAN - High Speed Controller Area Network
HSLA - High-Strength Low Alloy
HSS - High-Strength Steel
HVAC - Heating Ventilation Air Conditioning
HVTB - High Voltage Traction Battery
Acronyms 4628
IAT - Intake Air Temperature
IC - Instrument Cluster
IDS - Integrated Diagnostic System
IFS - Inertia Fuel Shutoff
IKT - Integrated Keyhead Transmitter
IKTs - Integrated Keyhead Transmitters
ILCM - Interior Lighting Control Module
IPC - Instrument Panel Cluster
IPM-A - Image Processing Module - A
ISC - Idle Speed Control
KAM - Keep Alive Memory
KOEO - Key ON Engine OFF
KOER - Key ON Engine Running
KS - Knock Sensor
LCD - Liquid Crystal Display
LPC - Line Pressure Control
MACS - Mobile Air Conditioning Society
MAF - Mass Air Flow
MAP - Manifold Absolute Pressure
MECS - Motor Electronics Cooling System
MFI - Multi-Port Fuel Injection
MIG - Metal Inert Gas
MIL - Malfunction Indicator Lamp
MRFS - Mechanical Returnless Fuel System
MS-CAN - Medium Speed Controller Area Network
MSS - Mode Select Switch
NERU - Neutral Engine Run-Up
Acronyms 4629
NOx - Nitrogen Oxides
NVM - Non-Volatile Memory
O/D - Overdrive
OASIS - On-Line Automotive Service Information System
OBD - On-Board Diagnostic
OCS - Occupant Classification Sensor
OCS - Occupant Classification System
OCSM - Occupant Classification System Module
OHC - Overhead Camshaft
ORVR - On-Board Refueling Vapor Recovery
OSS - Output Shaft Speed
OTIS - One-Touch Integrated Start
OWC - One-Way Clutch
PAD - Passenger Air Bag Deactivation
PAM - Parking Aid Module
PATS - Passive Anti-Theft System
PC/ED - Powertrain Control/Emissions Diagnosis
PCM - Powertrain Control Module
PDB - Power Distribution Box
PIN - Personal Identification Number
PMI - Programmable Module Installation
PSCM - Power Steering Control Module
PSP - Power Steering Pressure
PTS - Professional Technician Society
PTU - Power Transfer Unit
PVC - Polyvinyl Chloride
PWM - Pulse Width Modulated
Acronyms 4630
PWM - Pulse-Width Modulation
PZEV - Partial Zero Emissions Vehicle
RAM - Random Access Memory
RCM - Restraints Control Module
RCU - Rear Control Unit
RDU - Rear Drive Unit
READ - Rear End Accessory Drive
RFI - Radio Frequency Interference
RKE - Remote Keyless Entry
ROM - Read-Only Memory
ROW - Rest Of World
RSC - Roll Stability Control
SDARS - Satellite Digital Audio Receiver System
SFI - Sequential Multi-Port Fuel Injection
SJB - Smart Junction Box
SMC - Sheet-Molded Composite
SOD-L - Side Obstacle Detection Control Module - Left
SOD-R - Side Obstacle Detection Control Module - Right
SRS - Supplemental Restraint System
SSA - Shift Solenoid A
SSB - Shift Solenoid B
SSC - Shift Solenoid C
SSD - Shift Solenoid D
SSE - Shift Solenoid E
SSF - Shift Solenoid F
SSPCC - Shift Solenoid Pressure Control C
SSPCD - Shift Solenoid Pressure Control D
Acronyms 4631
SSPCE - Shift Solenoid Pressure Control E
SSPCF - Shift Solenoid Pressure Control F
STRW - Squeeze-Type Resistance Spot Welding
TB - Throttle Body
TCC - Torque Converter Clutch
TCIL - Transmission Control Indicator Lamp
TCM - Transmission Control Module
TCS - Transmission Control Switch
TDC - Top Dead Center
TED - Thermo-Electric Device
TEDs - Thermo-Electric Devices
TFT - Transmission Fluid Temperature
TIC - Transmitter Identification Code
TICs - Transmitter Identification Codes
TP - Throttle Position
TPM - Tire Pressure Monitor
TPMS - Tire Pressure Monitoring System
TPO - Thermoplastic Olefin
TR - Transmission Range
TRIP - Transformation Induced Plasticity Steel
TSB - Technical Service Bulletin
TSBs - Technical Service Bulletins
TSS - Turbine Shaft Speed
TTS - Text-To-Speech
TXV - Thermostatic Expansion Valve
UHSS - Ultra High Strength Steel
USB - Universal Serial Bus
Acronyms 4632
VC - Vehicle Certification
VCM - Vehicle Communication Module
VCT - Variable Camshaft Timing
VFS - Variable Force Solenoid
VID - Vehicle Identification
VIN - Vehicle Identification Number
VIP - Vehicle Interface Processor
VSS - Vehicle Speed Sensor
WMI - World Manufacturer Identifier
WOT - Wide Open Throttle
Acronyms 4633
Alphabetical Index
4 | 5 | A | B | C | D | E | F | G | H | I | J | K | L | M | N | O | P | Q | R | S | T | U | V | W
4
4X4 Control Module (REMOVAL AND INSTALLATION, Four Wheel Drive (4WD) Systems)
5
5th/6th Gear (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Manual Transaxle/Transmission)
A
A-Pillar Trim Panel (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Acceleration Control (DESCRIPTION AND OPERATION)
Acceleration Control (DIAGNOSIS AND TESTING)
Acceleration Control (Section Table of Contents)
Acceleration Control (SPECIFICATIONS)
Accelerator Pedal and Bracket (REMOVAL AND INSTALLATION, Acceleration Control)
Accessory Drive (DESCRIPTION AND OPERATION, Accessory Drive - 2.5L)
Accessory Drive (DESCRIPTION AND OPERATION, Accessory Drive - 3.0L (4V))
Accessory Drive (DESCRIPTION AND OPERATION, Accessory Drive - 3.5L)
Accessory Drive (DESCRIPTION AND OPERATION, Accessory Drive - Hybrid)
Accessory Drive (DIAGNOSIS AND TESTING, Accessory Drive - 2.5L)
Accessory Drive (DIAGNOSIS AND TESTsory Drive - 3.0L (4V))
Accessory Drive (DIAGNOSIS AND TESTING, Accessory Drive - 3.5L)
Accessory Drive (DIAGNOSIS AND TESTING, Accessory Drive - Hybrid)
Accessory Drive Belt (REMOVAL AND INSTALLATION, Accessory Drive - 2.5L)
Accessory Drive Belt (REMOVAL AND INSTALLATION, Accessory Drive - 3.0L (4V))
Accessory DriveOVAL AND INSTALLATION, Accessory Drive - 3.5L)
Alphabetical Index 4634
Accessory Drive Belt (REMOVAL AND INSTALLATION, Accessory Drive - Hybrid)
Accessory Drive Belt Idler Pulley (REMOVAL AND INSTALLATION, Accessory Drive - 2.5L)
Accessory Drive Belt Tensioner (REMOVAL AND INSTALLATION, Accessory Drive - 2.5L)
Accessory Drive Belt Tensioner (REMOVAL AND INSTALLATION, Accessory Drive - 3.0L (4V))
Accessory Drive Belt Tensioner (REMOVAL AND INSTALLATION, Accessory Drive - 3.5L)
Accessory Drive Belt Tensioner (REMOVAL AND INSTALLATION, Accessory Drive - Hybrid)
Accessory Drive - 2.5L (Section Table of Contents)
Accessory Drive - 2.5L (SPECIFICATIONS)
Accessory Drive - 3.0L (4V) (Section Table of Contents)
Accessory Drive - 3.0L (4V) (SPECIFICATIONS)
Accessory Drive - 3.5L (Section Table of Contents)
Accessory Drive - 3.5L (SPECIFICATIONS)
Accessory Drive - Hybrid (Section Table of Contents)
Accessory Drive - Hybrid (SPECIFICATIONS)
Accessory Protocol Interface Mo) (REMOVAL AND INSTALLATION, Information and Entertainment
Systems)
Accessory Protocol Interface Module (APIM) Programming (GENERAL PROCEDURES, Module
Configuration)
Accessory Protocol Interface Module (APIM) Software Level Check (GENERAL PROCEDURES,
Information and Entertainment Systems)
Adaptive Headlighting (DIAGNOSIS AND TESTING, Exterior Lighting)
Adhesives (DESCRIPTION AND OPERATION, Body Repairs)
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) (DESCRIPTION AND
OPERATION, Supplemental Restraint System)
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) (DIAGNOSIS AND TESTING,
Supplemental Restraint System)
Air Cleaner (REMOVAL AND INSTALLATION, Intake Air Distribution and Filtering - 2.5L)
Air Cleaner (REMOVAL AND INSTALLATION, Intake Air Distribution and Filtering - 3.0L (4V))
Air Cleaner (REMOVAL AND INSTALLATION, Intake Air Distribution and Filtering - 3.5L)
Air Cleaner (REMOVAL AND INSTALLATION, Intake Air Distribution and Filtering - Hybrid)
A 4635
Air Cleaner Outlet Pipe (REMOVAL AND INSTALLATION, Intake Air Distribution and Filtering - 2.5L)
Air Cleaner Outlet Pipe (REMOVAL AND INSTALLATION, Intake Air Distribution and Filtering - 3.0L
(4V))
Air Cleaner Outlet Pipe (REMOVAL AND INSTALLATION, Intake Air Distribution and Filtering - 3.5L)
Air Cleane Pipe (REMOVAL AND INSTALLATION, Intake Air Distribution and Filtering - Hybrid)
Air Conditioning (DESCRIPTION AND OPERATION, Climate Control)
Air Conditioning (A/C) Clutch Air Gap Adjustment (GENERAL PROCEDURES, Climate Control System -
General Information and Diagnostics)
Air Conditioning (A/C) Compressor - 2.5L (REMOVAL AND INSTALLATION, Climate Control)
Air Conditioning (A/C) Compressor - 3.0L, 3.5L (REMOVAL AND INSTALLATION, Climate Control)
Air Conditioning (A/C) Compressor - Hybrid (REMOVAL AND INSTALLATION, Climate Control)
Air Conditioning (A/C) Evaporator Discharge Air Temperature Sensor (REMOVAL AND INSTALLATION,
Climate Control)
Air Conditioning (A/C) Odor Treatment (GENERAL PROCEDURES, Climate Control System - General
Information and Diagnostics)
Air Conditioning (A/C) Pressure Relief Valve (REMOVAL AND INSTALLATION, Climate Control)
Air Conditioning (A/C) Pressure Transducer (REMOVAL AND INSTALLATION, Climate Control)
Air Conditioning (A/C) System Flushing (GENERAL PROCEDURES, Climate Control System - General
Air Conditioning (A/C) System Recovery, Evacuation and Charging (GENERAL PROCEDURES, Climate
Control System - General Information and Diagnostics)
Air Deflector (REMOVAL AND INSTALLATION, Roof Opening Panel)
Air Distribution and Filtering (DESCRIPTION AND OPERATION, Climate Control)
Alternating Current (AC) Powerpoint (REMOVAL AND INSTALLATION, High Voltage
Converter/Inverter)
Ambient Air Temperature Sensor (REMOVAL AND INSTALLATION, Climate Control)
Ambient Lighting Module (REMOVAL AND INSTALLATION, Interior Lighting)
Ambient Lighting Switch (REMOVAL AND INSTALLATION, Interior Lighting)
Antenna Cable - AM/FM (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Antenna Cable - Satellite Radio (REMOVAL AND INSTALLATION, Information and Entertainment
Systems)
A 4636
Antenna Module (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Antenna - AM/FM (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Antenna - AM/FM/Satellite Radio/Navigation (REMOVAL AND INSTALLATION, Information and
Entertainment Systems)
Antenna - Satellite Radio (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Anti-Lock Brake System (ABS) and Stability Control (Section Table of Contents)
Anti-Lock Brake System (ABS) and Stability Control (SPECIFICATIONS)
Anti-Lock Brake System (ABS) Module (REMOVAL AND INSTALLATION, Anti-Lock Brake System
(ABS) and Stability Control)
Anti-Lock Brake System (ABS) Module - Hybrid (REMOVAL AND INSTALLATION, Anti-Lock Brake
System (ABS) and Stability Control)
Anti-Lock Control (DESCRIPTION AND OPERATION, An-Lock Brake System (ABS) and Stability
Control)
Anti-Lock Control - Hybrid (DIAGNOSIS AND TESTING, Anti-Lock Brake System (ABS) and Stability
Control)
Anti-Lock Control - Non-Hybrid (DIAGNOSIS AND TESTING, Anti-Lock Brake System (ABS) and
Stability Control)
Anti-Theft (DESCRIPTION AND OPERATION, Anti-Theft - Passive Anti-Theft System (PATS))
Anti-Theft (DESCRIPTION AND OPERATION, Anti-Theft - Passive Anti-Theft System (PATS) - Hybrid)
Anti-Theft (DESCRIPTION AND OPERATION, Anti-Theft - Perimeter)
Anti-Theft (DIAGNOSIS AND TESTING, Anti-Theft - Passive Anti-Theft System (PATS))
Anti-Theft (DIAGNOSIS AND TESTING, Anti-Theft - Passive Anti-Theft System (PATS) - Hybrid)
Anti-Theft (DIAGNOSIS AND TESTING, Anti-Theft - Perimeter)
Anti-Theft Inhibit Switch - Luggage Compartment (REMOVAL AND INSTALLATION, Anti-Theft -
Perimeter)
Anti-Theft Security Access (GENERAL PROCEDURES, Anti-Theft - Passive Anti-Theft System (PATS))
Anti-Theft Security Access (GENERAL PROCEDURES, Anti-Theft - Passive Anti-Theft System (PATS) -
Hybrid)
Anti-Theft - Passive Anti-Theft System (PATS) (Section Table of Contents)
Anti-Theft - Passive Anti-Theft System (PATS) - Hybrid (Section Table of Contents)
Anti-Theft - Perimeter (Section Table of Contents)
A 4637
Applique - Luggage Compartment Lid (REMOVAL AND INSTALLATION, Exterior Trim and
Ornamentation)
Apply Components (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - Aisin AW21)
Audio Amplifier (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Audio Control Module (ACM) Self-Diagnostic Mode (GENERAL PROCEDURES, Information and
Audio Control Mod(ACM) - Fusion (REMOVAL AND INSTALLATION, Information and Entertainment
Systems)
Audio Control Module (ACM) - MKZ (REMOVAL AND INSTALLATION, Information and Entertainment
Systems)
Audio Digital Signal Processing (DSP) Module (REMOVAL AND INSTALLATION, Information and
Audio Input Jack (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Autolamps (DIAGNOSIS AND TESTING, Exterior Lighting)
Autolamps Time Delay Adjustment (GENERAL PROCEDURES, Exterior Lighting)
Autolock and Auto-Unlock Programming (GENERAL PROCEDURES, Handles, Locks, Latches and Entry
Systems)
Automatic Transaxle/Transmission External Controls - Aisin AW21/6F35 (Section Table of Contents)
Automatic Transaxle/Transmission External Controls - Aisin AW21/6F35 (SPECIFICATIONS)
Automatic Transaxle/Transmission External Controls - Hybrid (Section Table of Contents)
Automatic Transaxle/Transmission External Controls - Hybrid (SPECIFICATIONS)
Automatic Transaxle/Transmission - 6F35 (Section Table of Contents)
Automatic Transaxle/Transmission - 6F35 (SPECIFICATIONS)
Automatic Transaxle/Transmission - Aisin AW21 (Section Table of Contents)
Automatic Transaxle/Transmission - Aisin AW21 (SPECIFICATIONS)
Automatic Transaxle/Transmission - Electronically Controlled Continuously Variable Transmission (eCVT)
(SPECIFICATIONS)
Auxiliary Coolant Flow Pump (REMOVAL AND INSTALLATION, Climate Control)
Axle Assembly (REMOVAL AND INSTALLATION, Rear Drive Axle/Differential)
Azimuth System CheGENERAL PROCEDURES, Parking Aid)
A 4638
B
B-Pillar Trim Panel (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Balance Shaft Backlash (GENERAL PROCEDURES, Engine - 2.5L)
Balance Shaft Backlash (GENERAL PROCEDURES, Engine - 2.5L Hybrid)
Ballast (REMOVAL AND INSTALLATION, Exterior Lighting)
Battery (REMOVAL AND INSTALLATION, Battery, Mounting and Cables)
Battery and Battery Tray - Exploded View (REMOVAL AND INSTALLATION, Battery, Mounting and
Cables)
Battery and Cables (DESCRIPTION AND OPERATION, Battery, Mounting and Cables)
Battery Cables - 2.5L (REMOVAL AND INSTALLATION, Battery, Mounting and Cables)
Battery Disconnect (GENERAL PROCEDURES, Battery, Mounting and Cables)
Battery Energy Control Module (BECM) (REMOVAL AND INSTALLATION, High Voltage Traction
Battery)
Battery Pack Sensor Module (BPSM) (REMOVAL AND INSTALLATION, High Voltage Traction Battery)
Battery Tray (REMOVAL AND INSTALLATION, Battery, Mounting and Cables)
Battery, Mounting and Cables (Section Table of Contents)
Battery, Mounting and Cables (SPECIFICATIONS)
Bearing Inspection (GENERAL PROCEDURES, Engine System - General Information)
Belt-Minder Deactivating/Activating (GENERAL PROCEDURES, Instrumentation, Message Center, and
Warning Chimes)
Beltline Moulding - Front Door (REMOVAL AND INSTALLATION, Exterior Trim and Ornamentation)
Beltline Moulding - Rear Door (REMOVAL AND INSTALLATION, Exterior Trim and Ornamentation)
Blind Spot Monitoring (DESCRIPTION AND OPERATION, Side And Rear Vision)
Blind Spot Monitoring (DIAGNOSIS AND TESTING, Side And Rear Vision)
Block Heater (REMOVAL AND INSTALLATION, Engine Cooling)
Block Heater (REMOVAL AND INSTALLATION, Engine Cooling - Hybrid)
Blower Motor (REMOVAL AND INSTALLATION, Climate Control)
B 4639
Blower Motor Resistor (REMOVAL AND INSTALLATION, Climate Control)
Blower Motor Speed Control (REMOVAL AND INSTALLATION, Climate Control)
Body (DESCRIPTION AND OPERATION, Body Repairs)
Body Closures (Section Table of Contents)
Body Closures (SPECIFICATIONS)
Body Repairs (Section Table of Contents)
Body Repairs (SPECIFICATIONS)
Body Sealer Types And Applications (DESCRIPTION AND OPERATION, Body System - General
Information)
Body System (DIAGNOSIS AND TESTING, Body System - General Information)
Body System - General Information (Section Table of Contents)
Body System - General Information (SPECIFICATIONS)
Brake Booster (DESCRIPTION AND OPERATION, Power Brake Actuation)
Brake Booster Travel Sensor - Hybrid (REMOVAL AND INSTALLATION, Power Brake Actuation)
Brake Booster Vacuum Sensor - Hybrid (REMOVAL AND INSTALLATION, Power Brake Actuation)
Brake Booster Vacuum Sensor - Non-Hybrid (REMOVAL AND INSTALLATION, Power Brake Actuation)
Brake Booster - Exploded View (REMOVAL AND INSTALLATION, Power Brake Actuation)
Brake Booster - Hybrid (REMOVAL AND INSTALLATION, Power Brake Actuation)
Brake Booster - Non-Hybrid (REMOVAL AND INSTALLATION, Power Brake Actuation)
Brake Caliper (REMOVAL AND INSTALLATION, Front Disc Brake)
Brake Caliper (REMOVAL AND INSTALLATION, Rear Disc Brake)
Brake Caliper Anchor Plate (REMOVAL AND INSTALLATION, Front Disc Brake)
Brake Disc (REMOVAL AND INSTALLATION, Front Disc Brake)
Brake Disc (REMOVAL AND INSTALLATION, Rear Disc Brake)
Brake Disc Machining (GENERAL PROCEDURES, Brake System - General Information)
Brake Disc Shield - All Wheel Drive (AWD) (REMOVAL AND INSTALLATION, Rear Disc Brake)
Brake Disc Shield - Front Wheel Drive (FWD) (REMOVAL AND INSTALLATION, Rear Disc Brake)
Brake Flexible Hose (REMOVAL AND INSTALLATION, Front Disc Brake)
B 4640
Brake Flexible Hose (REMOVAL AND INSTALLATION, Rear Disc Brake)
Brake Fluid Reservoir (REMOVAL AND INSTALLATION, Hydraulic Brake Actuation)
Brake Master Cylinder (REMOVAL AND INSTALLATION, Hydraulic Brake Actuation)
Brake Pads (REMOVAL AND INSTALLATION, Front Disc Brake)
Brake Pads (REMOVAL AND INSTALLATION, Rear Disc Brake)
Brake Pedal and Bracket - Hybrid (REMOVAL AND INSTALLATION, Hydraulic Brake Actuation)
Brake Pedal and Bracket - Non-Hybrid (REMOVAL AND INSTALLATION, Hydraulic Brake Actuation)
Brake Pedal Angle Sensor (REMOVAL AND INSTALLATION, Hydraulic Brake Actuation)
Brake Pressure Control Valve (REMOVAL AND INSTALLATION, Hydraulic Brake Actuation)
Brake Shift Interlock Override (GENERAL PROCEDURES, Automatic Transaxle/Transmission External
Controls - Aisin AW21/6F35)
Brake Shift Interlock Override (GENERAL PROCEDURES, Automatic Transaxle/Transmission External
Controls - Hybrid)
Brake System (DESCRIPTION AND OPERATION, Brake System - General Information)
Brake System Bleeding (GENERAL PROCEDURES, Brake System - General Information)
Brake System Inspection (GENERAL PROCEDURES, Brake System - General Information)
Brake System - General Information (Section Table of Contents)
Brake System - General Information (SPECIFICATIONS)
Brake Vacuum Pump (REMOVAL AND INSTALLATION, Power Brake Actuation)
Bumper Cover - Front (REMOVAL AND INSTALLATION, Bumpers)
Bumper Cover - Rear (REMOVAL AND INSTALLATION, Bumpers)
Bumper - Exploded View, Front (REMOVAL AND INSTALLATION, Bumpers)
Bumper - Exploded View, Rear (REMOVAL AND INSTALLATION, Bumpers)
Bumper - Front (REMOVAL AND INSTALLATION, Bumpers)
Bumper - Rear (REMOVAL AND INSTALLATION, Bumpers)
Bumpers (Section Table of Contents)
Bumpers (SPECIFICATIONS)
Bypass Tube (REMOVAL AND INSTALLATION, Engine Cooling - Hybrid)
B 4641
Bypass Tube - 2.5L (REMOVASTALLATION, Engine Cooling)
C
C-Pillar Trim Panel (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Cabin Air Filter (REMOVAL AND INSTALLATION, Climate Control)
Camber Adjustment - Rear (GENERAL PROCEDURES, Suspension System - General Information)
Camshaft (INSTALLATION, Engine - 3.5L)
Camshaft (REMOVAL, Engine - 3.5L)
Camshaft Bearing Journal Diameter (GENERAL PROCEDURES, Engine System - General Information)
Camshaft End Play - OHC Engines (GENERAL PROCEDURES, Engine System - General Information)
Camshaft Journal to Bearing Clearance - OHC Engines (GENERAL PROCEDURES, Engine System -
General Information)
Camshaft Lobe Lift (GENERAL PROCEDURES, Engine System - General Information)
Camshaft Phaser and Sprocket (IN-VEHICLE REPAIR, Engine - 2.5L)
Camshaft Phaser and Sprocket (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Camshaft Phaser and Sprocket (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Camshaft Position (CMP) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - 2.5L)
Camshaft Position (CMP) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - 3.0L
(4V))
Camshaft Position (CMP) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - 3.5L)
Camshaft Position (CMP) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - Hybrid)
Camshaft Roller Follower (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Camshaft Runout (GENERAL PROCEDURES, Engine System - General Information)
Camshaft Surface Inspection (GENERAL PROCEDURES, Engine System - General Information)
Camshafts (IN-VEHICLE REPAIR, Engine - 2.5L)
Camshafts (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Camshafts - LH (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Camshafts - RH (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
C 4642
Caster Adjustment - Front (GENERAL PROCEDURES, Suspension System - General Information)
Catalyst Monitor Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - 2.5L)
Catalyst Monitor Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - 3.0L (4V))
Catalyst Monitor Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - 3.5L)
Catalyst Monitor Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - Hybrid)
Catalytic Converter - 3.0L LH Manifold (REMOVAL AND INSTALLATION, Exhaust System)
Catalytic Converter - 3.0L RH (REMOVAL AND INSTALLATION, Exhaust System)
Catalytic Converter - 3.5L LH (REMOVAL AND INSTALLATION, Exhaust System)
Catalytic Converter - 3.5L RH (REMOVAL AND INSTALLATION, Exhaust System)
Catalytic Converter - Manifold, Hybrid (REMOVAL AND INSTALLATION, Exhaust System)
Catalytic Converter - Underbody (REMOVTALLATION, Exhaust System)
Center Support (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Automatic
Transaxle/Transmission - 6F35)
Charging System (DESCRIPTION AND OPERATION)
Charging System (Section Table of Contents)
Charging System (SPECIFICATIONS)
Child Safety Seat Tether Anchor (REMOVAL AND INSTALLATION, Safety Belt Stem)
Climate Control (Section Table of Contents)
Climate Control (SPECIFICATIONS)
Climate Control System (DESCRIPTION AND OPERATION, Climate Control System - General
Climate Control System (DESCRIPTION AND OPERATION, Climate Control System - General
Information and Diagnostics - Hybrid)
Climate Control System (DIAGNOSIS AND TESTING, Climate Control System - General Information and
Diagnostics - Hybrid)
Climate Control System - General Information and Diagnostics (Section Table of Contents)
Climate Control System - General Information and Diagnostics (SPECIFICATIONS)
Climate Control System - General Information and Diagnostics - Hybrid (Section Table of Contents)
Climate Control System - General Information and Diagnostics - Hybrid (SPECIFICATIONS)
C 4643
Clockspring (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Clutch (DESCRIPTION AND OPERATION)
Clutch (DIAGNOSIS AND TESTING)
Clutch (Section Table of Contents)
Clutch (SPECIFICATIONS)
Clutch and Clutch Field Coil (REMOVAL AND INSTALLATION, Climate Control)
Clutch Controls (DESCRIPTION AND OPERATION)
Clutch Controls (DIAGNOSIS AND TESTING)
Clutch Controls (Section Table of Contents)
Clutch Controls (SPECIFICATIONS)
Clutch Disc and Pressure Plate (REMOVAL AND INSTALLATION, Clutch)
Clutch Disc Check (GENERAL PROCEDURES, Manual Transaxle/Transmission and Clutch - General
Information)
Clutch Master Cylinder (REMOVAL AND INSTALLATION, Clutch Controls)
Clutch Pedal (REMOVAL AND INSTALLATION, Clutch Controls)
Clutch Pedal Freeplay Adjustment (GENERAL PROCEDURES, Manual Transaxle/Transmission and Clutch
- General Information)
Clutch Pedal Position (CPP) Switch (REMOVAL AND INSTALLATION, Electronic Engine Controls -
2.5L)
Clutch Pressure Plate Check (GENERAL PROCEDURES, Manual Transaxle/Transmission and Clutch -
Clutch Slave Cylinder (REMOVAL AND INSTALLATION, Clutch Controls)
Clutch Support Tower (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Automatic
Clutch System Bleeding (GENERAL PROCEDURES, Manual Transaxle/Transmission and Clutch - General
Information)
Communications Network (DESCRIPTION AND OPERATION, Module Communications Network)
Communications Network (DIAGNOSIS AND TESTING, Module Communications Network)
Communications Network - Hybrid (DESCRIPTION AND OPERATION, Module Communications
Network)
Compass Calibration (GENERAL PROCEDURES, Instrumentation, Message Center, and Warning Chimes)
C 4644
Compass Zone Adjustment (GENERAL PROCEDURES, Instrumentation, Message Center, and Warning
Chimes)
Component Bleeding (GENERAL PROCEDURES, Brake System - General Information)
Component Test (DIAGNOSIS AND TESTING, Battery, Mounting and Cables)
Component Tests (DIAGNOSIS AND TESTING, Brake System - General Information)
Compressor Manifold and Tube Assembly - 2.MOVAL AND INSTALLATION, Climate Control)
Compressor Manifold and Tube Assembly - 3.0L, 3.5L (REMOVAL AND INSTALLATION, Climate
Control)
Compressor to Condenser Discharge Line - Hybrid (REMOVAL AND INSTALLATION, Climate Control)
Condenser Core - 2.5L, 3.0L, Hybrid (REMOVAL AND INSTALLATION, Climate Control)
Condenser Core - 3.5L (REMOVAL AND INSTALLATION, Climate Control)
Connecting Rod Bearing Journal Taper and Out-of-Round (GENERAL PROCEDURES, Engine System -
Connecting Rod Bearing Journal-to-Bearing Clearance (GENERAL PROCEDURES, Engine System -
Connecting Rod Bend (GENERAL PROCEDURES, Engine System - General Information)
Connecting Rod Bushing Diameter (GENERAL PROCEDURES, Engine System - General Information)
Connecting Rod Cleaning (GENERAL PROCEDURES, Engine System - General Information)
Connecting Rod Large End Bore (GENERAL PROCEDURES, Engine System - General Information)
Connecting Rod to Crankshaft Side Clearance (GENERAL PROCEDURES, Engine System - General
Information)
Connecting Rod Twist (GENERAL PROCEDURES, Engine System - General Information)
Console - Floor, Fusion (REMOVAL AND INSTALLATION, Instrument Panel and Console)
Console - Floor, MKZ (REMOVAL AND INSTALLATION, Instrument Panel and Console)
Console - Overhead (REMOVAL AND INSTALLATION, Instrument Panel and Console)
Control Components (DESCRIPTION AND OPERATION, Climate Control)
Coolant Inlet Pipe - 3.0L (4V) (REMOVAL AND INSTALLATION, Engine Cooling)
Coolant Pump (REMOVAL AND INSTALLATION, Engine Cooling - Hybrid)
Coolant Pump Belt (REMOVAL AND INSTALLATION, Accessory Drive - 3.0L (4V))
Coolant Pump Housing - 3.0L (4V) (REMOVAL AND INSTALLATION, Engine Cooling)
C 4645
Coolant Pump - 2.5L (REMOVAL AND INSTALLATION, Engine Cooling)
Coolant Pump - 3.0L (4V) (REMOVAL AND INSTALLATION, Engine Cooling)
Coolant Pump - 3.5L (REMOVAL AND INSTALLATION, Engine Cooling)
Cooling Fan Motor and Shroud (REMOVAL AND INSTALLATION, Engine Cooling - Hyb
Cooling Fan Motor and Shroud - 2.5L, 3.0L (4V) (REMOVAL AND INSTALLATION, Engine Cooling)
Cooling Fan Motor and Shroud - 3.5L (REMOVAL AND INSTALLATION, Engine Cooling)
Cooling System Draining, Filling and Bleeding (GENERAL PROCEDURES, Engine Cooling)
Cooling System Draining, Filling and Bleeding (GENERAL PROCEDURES, Engine Cooling - Hybrid)
Cooling System Flushing (GENERAL PROCEDURES, Engine Cooling)
Cooling System Flushing (GENERAL PROCEDURES, Engine Cooling - Hybrid)
Core Plug Replacement (GENERAL PROCEDURES, Engine System - General Information)
Cover Seal (IN-VEHICLE REPAIR, Transfer Case - Power Transfer Unit (PTU))
Cowl Panel Grille (REMOVAL AND INSTALLATION, Front End Body Panels)
Crankcase Vent Oil Separator (REMOVAL AND INSTALLATION, Engine Emission Control - 2.5L)
Crankcase Vent Oil Separator (REMOVAL AND INSTALLATION, Engine Emission Control - Hybrid)
Crankshaft End Play (GENERAL PROCEDURES, Engine System - General Information)
Crankshaft Front Seal (IN-VEHICLE REPAIR, Engine - 2.5L)
Crankshaft Front Seal (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Crankshaft Front Seal (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Crankshaft Front Seal (IN-VEHICLE REPAIR, Engine - 3.5L)
Crankshaft Main Bearing Journal Diameter (GENERAL PROCEDURES, Engine System - General
Information)
Crankshaft Main Bearing Journal Taper and Out-of-Round (GENERAL PROCEDURES, Engine System -
Crankshaft Main Bearing Journal-to-Bearing Clearance (GENERAL PROCEDURES, Engine System -
Crankshaft Position (CKP) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - 2.5L)
Crankshaft Position (CKP) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - 3.0L
(4V))
C 4646
Crankshaft Position (CKP) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - 3.5L)
Crankshaft Position (CKP) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls -
Hybrid)
Crankshaft Pulley (IN-VEHICLE REPAIR, Engine - 2.5L)
Crankshaft Pulley (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Crankshaft Pulley (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Crankshaft Pulley (IN-VEHICLE REPAIR, Engine - 3.5L)
Crankshaft Pulley and Crankshaft Front Seal - Exploded View (IN-VEHICLE REPAIR, Engine - 2.5L)
Crankshaft Pulley and Crankshaft Front Seal - Exploded View (IN-VEHICLE REPAIR, Eng Hybrid)
Crankshaft Pulley and Crankshaft Front Seal - Exploded View (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Crankshaft Pulley and Crankshaft Front Seal - Exploded View (IN-VEHICLE REPAIR, Engine - 3.5L)
Crankshaft Rear Seal (IN-VEHICLE REPAIR, Engine - 2.5L)
Crankshaft Rear Seal (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Crankshaft Rear Seal (IN-VEHICLE REPAIR, Engine - 3.5L)
Crankshaft Rear Seal with Retainer Plate (IN-VEHICLE REPAIR, Engine - 3.5L)
Cruise Control (DESCRIPTION AND OPERATION)
Cruise Control (DIAGNOSIS AND TESTING)
Cruise Control (Section Table of Contents)
Cruise Control Deactivator Switch (REMOVAL AND INSTALLATION, Cruise Control)
Cruise Control Switch (REMOVAL AND INSTALLATION, Cruise Control)
Cylinder Block Distortion (GENERAL PROCEDURES, Engine System - General Information)
Cylinder Bore Cleaning (GENERAL PROCEDURES, Engine System - General Information)
Cylinder Bore Out-of-RoundNERAL PROCEDURES, Engine System - General Information)
Cylinder Bore Taper (GENERAL PROCEDURES, Engine System - General Information)
Cylinder Head (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Engine - 2.5L)
Cylinder Head (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Engine - 2.5L Hybrid)
Cylinder Head (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Engine - 3.0L (4V))
Cylinder Head (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Engine - 3.5L)
C 4647
Cylinder Head (IN-VEHICLE REPAIR, Engine - 2.5L)
Cylinder Head (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Cylinder Head Distortion (GENERAL PROCEDURES, Engine System - General Information)
Cylinder Head Temperature (CHT) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls
- 2.5L)
- 3.0L (4V))
- 3.5L)
- Hybrid)
Cylinder Head - LH (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Cylinder Head - LH (INSTALLATION, Engine - 3.5L)
Cylinder Head - LH (REMOVAL, Engine - 3.5L)
Cylinder Head - RH (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Cylinder Head - RH (INSTALLATION, Engine - 3.5L)
Cylinder Head - RH (REMOVAL, Engine - 3.5L)
D
Daytime Running Lamps (DRL) (DIAGNOSIS AND TESTING, Exterior Lighting)
Degas Bottle (REMOVAL AND INSTALLATION, Engine Cooling)
Degas Bottle (REMOVAL AND INSTALLATION, Engine Cooling - Hybrid)
Diagnosis By Symptom (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6F35)
Diagnosis By Symptom (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - Aisin AW21)
Diagnostic Flow Chart (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6F35)
Diagnostic Flow Chart (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - Aisin AW21)
Diagnostic Methods (DESCRIPTION AND OPERATION, Service Information)
Diagnostic Parameters Identification (PID) Chart (DIAGNOSIS AND TESTING, Automatic
D 4648
Diagnostic Parameters Identification (PID) Chart (DIAGNOSIS AND TESTING, Automatic
Transaxle/Transmission - Aisin AW21)
Diagnostic Strategy (DIAGNOSIS AND TESTING, Automatic Tra/Transmission - 6F35)
Diagnostic Strategy (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - Aisin AW21)
Diagnostic Trouble Code (DTC) Chart (DIAGNOSIS AND TESTING, Charging System)
Diagnostic Trouble Code (DTC) Chart (DIAGNOSIS AND TESTING, Exterior Lighting)
Diagnostic Trouble Code (DTC) Chart (DIAGNOSIS AND TESTING, Multifunction Electronic Modules)
Diagnostic Trouble Code (DTC) Charts (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission -
6F35)
Diagnostic Trouble Code (DTC) Charts (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission -
Aisin AW21)
Diagnostics (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6F35)
Diagnostics (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - Aisin AW21)
Diagnostics (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - Electronically Controlled
Continuously Variable Transmission (eCVT))
Differential (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Manual Transaxle/Transmission)
Differential Housing Cover (IN-VEHICLE REPAIR, Rear Drive Axle/Differential)
Differential Seals - LH (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - Aisin AW21)
Differential Seals - LH (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - Electronically
Controlled Continuously Variable Transmission (eCVT))
Differential Seals - RH (IN-VEHICLE REPAIic Transaxle/Transmission - Electronically Controlled
Continuously Variable Transmission (eCVT))
Differential Seals - RH, All Wheel Drive (AWD) (IN-VEHICLE REPAIR, Automatic
Differential Seals - RH, Front Wheel Drive (FWD) (IN-VEHICLE REPAIR, Automatic
Digital Transmission Range (TR) Sensor (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - 6F35)
Direct Current/Alternating Current (DC/AC) Inverter (REMOVAL AND INSTALLATION, High Voltage
Converter/Inverter)
Direct Current/Direct Current (DC/DC) Converter (REMOVAL AND INSTALLATION, High Voltage
Converter/Inverter)
Door (REMOVAL AND INSTALLATION, Body Closures)
D 4649
Door Alignment - Front (GENERAL PROCEDURES, Body Closures)
Door Alignment - Rear (GENERAL PROCEDURES, Body Closures)
Door Check Arm (REMOVAL AND INSTALLATION, Body Closures)
Door Glass Run and Bracket - Rear (REMOVAL AND INSTALLATION, Glass, Frames and Mechanisms)
Door Glass Top Run - Front (REMOVAL AND INSTALLATION, Glass, Frames and Mechanisms)
Door Handle Reinforcement - Exterior, Front (REMOVAL AND INSTALLATION, Handles, Locks, Latches
and Entry Systems)
Door Handle Reinforcement - Exterior, Rear (REMOVAL AND INSTALLATION, Handles, Locks, Latches
and Entry Systems)
Door Latch Release Cable (REMOVAL AND INSTALLATIONs, Locks, Latches and Entry Systems)
Door Lock Control Switch (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry
Systems)
Door Lock Cylinder (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry Systems)
Door Outer Panel (REMOVAL AND INSTALLATION, Body Repairs)
Door Trim Panel - Front (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Door Trim Panel - Rear (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Drive Pinion Seal (IN-VEHICLE REPAIR, Rear Drive Axle/Differential)
Driveline Angle Measurement (GENERAL PROCEDURES, Driveline System - General Information)
Driveline System (DESCRIPTION AND OPERATION, Driveline System - General Information)
Driveline System (DIAGNOSIS AND TESTING, Driveline System - General Information)
Driveline System - General Information (Section Table of Contents)
Driveline System - General Information (SPECIFICATIONS)
Driver Air Bag Module (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Driver Door Module (DDM) (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry
Systems)
Driver Seat Module (DSM) (REMOVAL AND INSTALLATION, Seating)
Driveshaft (DESCRIPTION AND OPERATION)
Driveshaft (DIAGNOSIS AND TESTING)
Driveshaft (REMOVAL AND INSTALLATION)
D 4650
Driveshaft (Section Table of Contents)
Driveshaft (SPECIFICATIONS)
Driveshaft Runout and Balancing (GENERAL PROCEDURES, Driveline System - General Information)
Dual Climate Controlled Seat Module (DCSM) (REMOVAL AND INSTALLATION, Seating)
E
Electronic Engine Controls (DESCRIPTION AND OPERATION, Electronic Engine Controls - 2.5L)
Electronic Engine Controls (DESCRIPTION AND OPERATION, Electronic Engine Controls - 3.0L (4V))
Electronic Engine Controls (DESCRIPTION AND OPERATION, Electronic Engine Controls - 3.5L)
Electronic Engine Controls (DESCRIPTION AND OPERATION, Electronic Engine Controls - Hybrid)
Electronic Engine Controls (DIAGNOSIS AND TESTING, Electronic Engine Controls - 2.5L)
Electronic Engine Controls (DIAGNOSIS AND TESTING, Electronic Engine Controls - 3.0L (4V))
Electronic Engine Controls (DIAGNOSIS AND TESTING, Electronic Engine Controls - 3.5L)
Electronic Engine Controls (DIAGNOSIS AND TESTING, Electronic Engine Controls - Hybrid)
Electronic Engine Controls - 2.5L (Section Table of Contents)
Electronic Engine Controls - 2.5L (SPECIFICATIONS)
Electronic Engine Controls - 3.0L (4V) (Section Table of Contents)
Electronic Engine Controls - 3.0L (4V) (SPECIFICATIONS)
Electronic Engine Controls - 3.5L (Section Table of Contents)
Electronic Engine Controls - 3.5L (SPECIFICATIONS)
Electronic Engine Controls - Hybrid (Section Table of Contents)
Electronic Engine Controls - Hybrid (SPECIFICATIONS)
Electronic Leak Detection (GENERAL PROCEDURES, Climate Control System - General Information and
Diagnostics)
Elevation System Check (GENERAL PROCEDURES, Parking Aid)
Engine (ASSEMBLY, Engine - 2.5L)
Engine (ASSEMBLY, Engine - 2.5L Hybrid)
Engine (ASSEMBLY, Engine - 3.0L (4V))
E 4651
Engine (ASSEMBLY, Engine - 3.5L)
Engine (DESCRIPTION AND OPERATION, Engine System - General Information)
Engine (DESCRIPTION AND OPERATION, Engine - 2.5L)
Engine (DESCRIPTION AND OPERATION, Engine - 2.5L Hybrid)
Engine (DESCRIPTION AND OPERATION, Engine - 3.0L (4V))
Engine (DESCRIPTION AND OPERATION, Engine - 3.5L)
Engine (DIAGNOSIS AND TESTING, Engine System - General Information)
Engine (DIAGNOSIS AND TESTING, Engine - 2.5L)
Engine (DIAGNOSIS AND TESTING, Engine - 2.5L Hybrid)
Engine (DIAGNOSIS AND TESTING, Engine - 3.0L (4V))
Engine (DIAGNOSIS AND TESTING, Engine - 3.5L)
Engine (DISASSEMBLY, Engine - 2.5L)
Engine (DISASSEMBLY, Engine - 2.5L Hybrid)
Engine (DISASSEMBLY, Engine - 3.0L (4V))
Engine (DISASSEMBLY, Engine - 3.5L)
Engine (INSTALLATION, Engine - 2.5L Hybrid)
Engine (INSTALLATION, Engine - 3.0L (4V))
Engine (INSTALLATION, Engine - 3.5L)
Engine (REMOVAL, Engine - 2.5L Hybrid)
Engine (REMOVAL, Engine - 3.0L (4V))
Engine (REMOVAL, Engine - 3.5L)
Engine Cooling (DESCRIPTION AND OPERATION)
Engine Cooling (DESCRIPTION AND OPERATION, Engine Cooling - Hybrid)
Engine Cooling (DIAGNOSIS AND TESTING)
Engine Cooling (DIAGNOSIS AND TESTING, Engine Cooling - Hybrid)
Engine Cooling (Section Table of Contents)
Engine Cooling (SPECIFICATIONS)
E 4652
Engine Cooling - Hybrid (Section Table of Contents)
Engine Cooling - Hybrid (SPECIFICATIONS)
Engine Emission Control (DESCRIPTION AND OPERATION, Engine Emission Control - 2.5L)
Engine Emission Control (DESCRIPTION AND OPERATION, Engine Emission Control - 3.0L (4V))
Engine Emission Control (DESCRIPTION AND OPERATION, Engine Emission Control - 3.5L)
Engine Emission Control (DESCRIPTION AND OPERATION, Engine Emission Control - Hybrid)
Engine Emission Control (DIAGNOSIS AND TESTING, Engine Emission Control - 2.5L)
Engine Emission Control (DIAGNOSIS AND TESTING, Engine Emission Control - 3.0L (4V))
Engine Emission Control (DIAGNOSIS AND TESTING, Engine Emission Control - 3.5L)
Engine Emission Control (DIAGNOSIS AND TESTING, Engine Emission Control - Hybrid)
Engine Emission Control - 2.5L (Section Table of Contents)
Engine Emission Control - 2.5L (SPECIFICATIONS)
Engine Emission Control - 3.0L (4V) (Section Table of Contents)
Engine Emission Control - 3.0L (4V) (SPECIFICATIONS)
Engine Emission Control - 3.5L (Section Table of Contents)
Engine Emission Control - 3.5L (SPECIFICATIONS)
Engine Emission Control - Hybrid (Section Table of Contents)
Engine Emission Control - Hybrid (SPECIFICATIONS)
Engine Front Cover (IN-VEHICLE REPAIR, Engine - 2.5L)
Engine Front Cover (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Engine Front Cover (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Engine Front Cover (INSTALLATION, Engine - 3.5L)
Engine Front Cover (REMOVAL, Engine - 3.5L)
Engine Ignition (DESCRIPTION AND OPERATION, Engine Ignition - 2.5L)
Engine Ignition (DESCRIPTION AND OPERATION, Engine Ignition - 3.0L (4V))
Engine Ignition (DESCRIPTION AND OPERATION, Engine Ignition - 3.5L)
Engine Ignition (DIAGNOSIS AND TESTING, Engine Ignition - 2.5L)
E 4653
Engine Ignition (DIAGNOSIS AND TESTING, Engine Ignition - 3.0L (4V))
Engine Ignition (DIAGNOSIS AND TESTING, Engine Ignition - 3.5L)
Engine Ignition Components - Exploded View (REMOVAL AND INSTALLATION, Engine Ignition - 2.5L)
Engine Ignition Components - Exploded View (REMOVAL AND INSTALLATION, Engine Ignition - 3.0L
(4V))
Engine Ignition Components - Exploded View (REMOVAL AND INSTALLATION, Engine Ignition - 3.5L)
Engine Ignition - 2.5L (Section Table of Contents)
Engine Ignition - 2.5L (SPECIFICATIONS)
Engine Ignition - 3.0L (4V) (Section Table of Contents)
Engine Ignition - 3.0L (4V) (SPECIFICATIONS)
Engine Ignition - 3.5L (Section Table of Contents)
Engine Ignition - 3.5L (SPECIFICATIONS)
Engine Lubrication Components - Exploded View (IN-VEHICLE REPAIR, Engine - 2.5L)
Engine Lubrication Components - Exploded View (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Engine Lubrication Components - Exploded View (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Engine Mount (IN-VEHICLE REPAIR, Engine - 2.5L)
Engine Mount (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Engine Mount (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Engine Mount (IN-VEHICLE REPAIR, Engine - 3.5L)
Engine Oil Pressure (EOP) Switch (IN-VEHICLE REPAIR, Engine - 2.5L)
Engine Oil Pressure (EOP) Switch (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Engine Oil Pressure (EOP) Switch (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Engine Oil Pressure (EOP) Switch (IN-VEHICLE REPAIR, Engine - 3.5L)
Engine System - General Information (Section Table of Contents)
Engine System - General Information (SPECIFICATIONS)
Engine - 2.5L (Section Table of Contents)
Engine - 2.5L (SPECIFICATIONS)
Engine - 2.5L Hybrid (Section Table of Contents)
E 4654
Engine - 2.5L Hybrid (SPECIFICATIONS)
Engine - 3.0L (4V) (Section Table of Contents)
Engine - 3.0L (4V) (SPECIFICATIONS)
Engine - 3.5L (Section Table of Contents)
Engine - 3.5L (SPECIFICATIONS)
Engine - Automatic Transaxle (INSTALLATION, Engine - 2.5L)
Engine - Automatic Transaxle (REMOVAL, Engine - 2.5L)
Engine - Manual Transaxle (INSTALLATION, Engine - 2.5L)="nospace">Engine - Manual Transaxle
(REMOVAL, Engine - 2.5L)
Evaporative Emission Canister (REMOVAL AND INSTALLATION, Evaporative Emissions)
Evaporative Emission Canister (REMOVAL AND INSTALLATION, Evaporative Emissions - Hybrid)
Evaporative Emission Canister Purge Valve (REMOVAL AND INSTALLATION, Evaporative Emissions)
Evaporative Emission Canistge Valve (REMOVAL AND INSTALLATION, Evaporative Emissions -
Hybrid)
Evaporative Emission System Leak Test (GENERAL PROCEDURES, Evaporative Emissions)
Evaporative Emission System Leak Test (GENERAL PROCEDURES, Evaporative Emissions - Hybrid)
Evaporative Emissions (DESCRIPTION AND OPERATION)
Evaporative Emissions (DESCRIPTION AND OPERATION, Evaporative Emissions - Hybrid)
Evaporative Emissions (DIAGNOSIS AND TESTING)
Evaporative Emissions (DIAGNOSIS AND TESTING, Evaporative Emissions - Hybrid)
Evaporative Emissions (Section Table of Contents)
Evaporative Emissions (SPECIFICATIONS)
Evaporative Emissions - Hybrid (Section Table of Contents)
Evaporator Core (REMOVAL AND INSTALLATION, Climate Control)
Evaporator to Compressor Suction Line - Hybrid (REMOVAL AND INSTALLATION, Climate Control)
Exhaust Flexible Pipe - 2.5L, 3.0L (REMOVAL AND INSTALLATION, Exhaust System)
Exhaust Gas Recirculation (EGR) System Components - Exploded View (REMOVAL AND
INSTALLATION, Engine Emission Control - 3.0L (4V))
Exhaust Gas Recirculation (EGR) Valve (REMOVAL AND INSTALLATION, Engine Emission Control -
E 4655
2.5L)
3.0L (4V))
Hybrid)
Exhaust Manifold (IN-VEHICLE REPAIR, Engine - 2.5L)
Exhaust Manifold Cleaning and Inspection (GENERAL PROCEDURES, Engine System - General
Information)
Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube (REMOVAL AND INSTALLATION,
Engine Emission Control - 3.0L (4V))
Exhaust Manifold - LH (IN-VEHICLE REPAIR, Engine - 3.5L)
Exhaust Manifold - RH (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Exhaust Manifold - RH (IN-VEHICLE REPAIR, Engine - 3.5L)
Exhaust System (DESCRIPTION AND OPERATION)
Exhaust System (DIAGNOSIS AND TESTING)
Exhaust System (Section Table of Contents)
Exhaust System (SPECIFICATIONS)
Exhaust System Alignment (GENERAL PROCEDURES, Exhaust System)
Exhaust System - Exploded View (REMOVAL AND INSTALLATION, Exhaust System)
Exhaust Y-Pipe - 3.5L (REMOVAL AND INSTALLATION, Exhaust System)
Exterior Door Handle (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry Systems)
Exterior Lighting (DESCRIPTION AND OPERATION)
Exterior Lighting (Section Table of Contents)
Exterior Lighting (SPECIFICATIONS)
Exterior Mirror (REMOVAL AND INSTALLATION, Rear View Mirrors)
Exterior Mirror Control Switch (REMOVAL AND INSTALLATION, Rear View Mirrors)
Exterior Mirror Cover (REMOVAL AND INSTALLATION, Rear View Mirrors)
Exterior Mirror Glass (REMOVAL AND INSTALLATION, Rear View Mirrors)
Exterior Mirror Motor (REMOVAL AND INSTALLATION, Rear View Mirrors)
E 4656
Exterior Mirrors - Exploded View (REMOVAL AND INSTALLATION, Rear View Mirrors)
Exterior Trim and Ornamentation (Section Table of Contents)
Exterior Trim and Ornamentation (SPECIFICATIONS)
External Controls (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission External
Controls - Aisin AW21/6F35)
External Controls (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission External
Controls - Hybrid)
External Controls (DESCRIPTION AND OPERATION, Manual Transaxle/Transmission External Controls)
External Controls (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission External Controls -
Aisin AW21/6F35)
External Controls (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission External Controls -
Hybrid)
F
Fender (REMOVAL AND INSTALLATION, Front End Body Panels)
Fender Splash Shield (REMOVAL ANSTALLATION, Front End Body Panels)
Final Drive Carrier and Differential Assembly (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES,
Automatic Transaxle/Transmission - 6F35)
Flexplate (IN-VEHICLE REPAIR, Engine - 2.5L)
Flexplate (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Flexplate (IN-VEHICLE REPAIR, Engine - 3.5L)
Flexplate InspGENERAL PROCEDURES, Engine System - General Information)
Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View (IN-VEHICLE REPAIR, Engine - 2.5L)
Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View (IN-VEHICLE REPAIR, Engine - 2.5L
Hybrid)
Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View (IN-VEHICLE REPAIR, Engine - 3.0L
(4V))
Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View (IN-VEHICLE REPAIR, Engine - 3.5L)
Fluorescent Dye Leak Detection (GENERAL PROCEDURES, Climate Control System - General Information
and Diagnostics)
Flywheel (IN-VEHICLE REPAIR, Engine - 2.5L)
F 4657
Flywheel (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Flywheel Inspection (GENERAL PROCEDURES, Engine System - General Information)
Flywheel Runout Check (GENERAL PROCEDURES, Manual Transaxle/Transmission and Clutch - General
Information)
Fog Lamp (REMOVAL AND INSTALLATION, Exterior Lighting)
Fog Lamp Bulb (REMOVAL AND INSTALLATION, Exterior Lighting)
Fog Lamps (DIAGNOSIS AND TESTING, Exterior Lighting)
Four Wheel Drive (4WD) Systems (DESCRIPTION AND OPERATION)
Four Wheel Drive (4WD) Systems (DIAGNOSIS AND TESTING)
Four Wheel Drive (4WD) Systems (Section Table of Contents)
Four Wheel Drive (4WD) Systems (SPECIFICATIONS)
Frame Members - Front (REMOVAL AND INSTALLATION, Body Repairs)
Frame Members - Rear (REMOVAL AND INSTALLATION, Body Repairs)
Front Controls Interface Module (FCIM) - Fusion (REMOVAL AND INSTALLATION, Information and
Front Controls Interface Module (FCIM) - MKZ (REMOVAL AND INSTALLATION, Information and
Front Disc Brake (DESCRIPTION AND OPERATION)
Front Disc Brake (DIAGNOSIS AND TESTING)
Front Disc Brake (Section Table of Contents)
Front Disc Brake (SPECIFICATIONS)
Front Display Interface Module (FDIM) - Fusion (REMOVAL AND INSTALLATION, Information and
Front Display Interface Module (FDIM) - MKZ (REMOVAL AND INSTALLATION, Information and
Front Door Handles, Locks and Latches - Exploded View (REMOVAL AND INSTALLATION, Handles,
Locks, Latches and Entry Systems)
Front Door Latch (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry Systems)
Front Drive Halfshafts (DESCRIPTION AND OPERATION)
Front Drive Halfshafts (DIAGNOSIS AND TESTING)
F 4

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2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid

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