REPAIR TECHNIQUES
Appropriate service methods and procedures are essential for the safe, reliable operation of all motor vehicles as well as the personal safety of the individual doing the work. This article provides general directions for performing service with tested, effective techniques. Following them will help assure reliability.
There are numerous variations in procedure, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual doing the work. This article cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this article must first establish that they compromise neither their personal safety nor the vehicle integrity by their choice of methods, tools or parts.
NOTE, NOTICE, CAUTION AND WARNING
As you read through this article, you may come across a NOTE, NOTICE, CAUTION or WARNING. Each one is there for a specific purpose. A NOTE calls attention to unique, additional or essential information related to the subject procedure. A NOTICE identifies a hazard that could damage the vehicle or property. A CAUTION identifies a hazard that could result in minor personal injury to yourself or others. A WARNING identifies a hazard that could result in severe personal injury or death to yourself or others. Some general WARNINGS that you should follow when you work on a vehicle are listed below.
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- KEEP SOLVENTS AWAY FROM IGNITION SOURCES. SOLVENTS MAY BE FLAMMABLE AND COULD IGNITE OR EXPLODE IF NOT HANDLED CORRECTLY.
- USE SAFETY STANDS WHENEVER A PROCEDURE REQUIRES YOU TO BE UNDER THE VEHICLE.
- MAKE SURE THAT THE IGNITION SWITCH IS ALWAYS IN THE OFF POSITION, UNLESS OTHERWISE REQUIRED BY THE PROCEDURE.
- SET THE PARKING BRAKE WHEN WORKING ON THE VEHICLE. IF YOU HAVE AN AUTOMATIC TRANSMISSION, SET IN PARK UNLESS INSTRUCTED OTHERWISE FOR A SPECIFIC OPERATION. IF YOU HAVE A MANUAL TRANSMISSION, IT SHOULD BE IN REVERSE (ENGINE OFF) OR NEUTRAL (ENGINE ON) UNLESS INSTRUCTED OTHERWISE FOR A SPECIFIC OPERATION. PLACE WOOD BLOCKS (4" X 4" OR LARGER) OR WHEEL CHOCKS AGAINST THE FRONT AND REAR SURFACES OF THE TIRES TO HELP PREVENT THE VEHICLE FROM MOVING.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA TO AVOID THE DANGER OF CARBON MONOXIDE POISONING.
- KEEP YOURSELF AND YOUR CLOTHING AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE DRIVE BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT METAL PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD, TAIL PIPE, THREE-WAY CATALYTIC CONVERTER AND MUFFLER.
- DO NOT SMOKE WHILE WORKING ON A VEHICLE.
- TO AVOID INJURY, ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND LOOSE CLOTHING BEFORE BEGINNING TO WORK ON A VEHICLE.
- WHEN IT IS NECESSARY TO WORK UNDER THE HOOD, KEEP HANDS AND OTHER OBJECTS CLEAR OF THE COOLING FAN BLADES!
Preface
This article provides a step-by-step approach for diagnosing driveability, emission, powertrain and hybridelectric control system symptoms. Before beginning diagnosis, it may be helpful to reference any Technical Service Bulletins (TSBs) or On-line Automotive Service Information System (OASIS) information when this is available. The TSB/OASIS information is available on the Professional Technician Society (PTS) or Motorcraft® website.
This article is used in conjunction with the Workshop and Wiring Diagrams articles. The Workshop article is used to provide additional diagnostics when directed by this article. The Workshop article is also used for component removal and installation information. Refer to the Wiring Diagrams for vehicle specific wiring information and component, connector and splice location.
The following is a description of the information contained in each part of this article.
Section 5: Pinpoint Tests
This part contains all pinpoint tests. Never enter a pinpoint test unless directed there. When directed to a pinpoint test, always read the information included at the beginning of the pinpoint test.
Section 6: Reference Values
This part contains the Typical Diagnostic Reference Values charts. The technician is directed to these charts from Pinpoint Test Z in PINPOINT TESTS .
What's New in this article
The following is a list of changes to this article for 2009
- Modified computer controlled shutdown feature.
- New 2.5L engine.
- New 190 pin powertrain control module (PCM).
- New deceleration fuel shut-off (DFSO) strategy.
- New dual speed mechanical return less fuel system.
- New electronic throttle body (ETB) with non contacting throttle position (TP) sensor.
- New enhanced thermostat monitor.
- New Hall effect camshaft position (CMP) sensor changed from variable reluctance type.
- New misfire monitor for applicable vehicles.
- New permanent P-code DTCs and clearing conditions.
- New universal heated oxygen sensor (HO2S).
- New variable camshaft timing (VCT) system.
- Power sustain relay (PSR) deleted.
Acronyms and Definitions
Note. This acronyms and definitions listing contains technical terms applicable to Ford Motor Company products. It is not intended to be an all-inclusive dictionary of components and their functions. If a detailed description of a particular system or component is desired, refer to the applicable part within this PC/ED article or consult the Workshop article for the specific vehicle being repaired.
4V: Four valves per engine cylinder
ABS: Anti-Lock Brake System
A/C: Air Conditioning
A/CC: Air Conditioning Clutch
A/CCR: A/C Clutch Control Relay
A/CLPCS: A/C Low Pressure Cycling Switch
ACCS: Air Conditioning Cycling Switch
ACET: Air Conditioning Evaporator Temperature
ACPSW: Air Conditioning Pressure Switch
ACRDV: Air Conditioning (A/C) Refrigerant Distribution Valve
A/D: Analog-to-Digital
APP: Accelerator Pedal Position
ARB: Air Resource Board
ATDC: After Top Dead Center
BARO: Barometric Pressure
BPO: Battery Power Off
BPP: Brake Pedal Position
BPS: Brake Pedal Switch
BTDC: Before Top Dead Center
CAFE: Corporate Average Fuel Economy
CAN: Controller Area Network
CCM: Comprehensive Component Monitor
CHT: Cylinder Head Temperature
CKP: Crankshaft Position
CL: Closed Loop
CMP: Camshaft Position
CO: Carbon Monoxide
CO 2 : Carbon Dioxide
COP: Coil On Plug
CT: Closed Throttle
CTO: Clean Tach Output
DC: 1. Direct Current 2. Duty Cycle
DFSO: Deceleration Fuel Shut-Off
DLC: Data Link Connector
DMM: Digital Multimeter
DOHC: Dual Overhead Cam
DTC: Diagnostic Trouble Code
ECT: Engine Coolant Temperature
EEC: Electronic Engine Control
EEGR: Electric Exhaust Gas Recirculation
EEPROM: Electrically Erasable Programmable Read-Only Memory
EGR: Exhaust Gas Recirculation
EI: Integrated Electronic Ignition
EI-LDR: Electronic Ignition-Low Data Rate
EMI: Electromagnetic Interference
EOT: Engine Oil Temperature
EPA: Environmental Protection Agency
ETB: Electronic Throttle Body
EVAP: Evaporative Emissions
EVO: Electronic Variable Orifice
FC: Fan Control
FCS: Fuel Control Solenoid
FCIL: Fuel Cap Indicator Lamp
FEAD: Front End Accessory Drive
FEPS: Flash EEPROM Programming Signal
FLI: Fuel Level Input
FMEM: Failure Mode Effects Management
FP: Fuel Pump
FTP: Fuel Tank Pressure
FWD: Front-Wheel Drive
GCU: Generator Control Unit
GPM: 1. Grams per Mile 2. Gallons per Minute
GVW: Gross Vehicle Weight
HC: Hydrocarbon
HO2S: Heated Oxygen Sensor
Hz: Hertz
IAT: Intake Air Temperature
IDS: Integrated Diagnostic System
IFS: Inertia Fuel Shut-Off
IPC: 1. Instrument Panel Cluster 2. Independent Plausibility Checker
IPS: Intake Phase Shifting
ISO: International Standards Organization
KAM: Keep Alive Memory
KOEO: Key On Engine Off
KOER: Key On Engine Running
Km/h: Kilometers per Hour
kPa: Kilopascal
LDR: Low Data Rate
MAF: Mass Air Flow
MAP: Manifold Absolute Pressure
MCU: Motor Control Unit
MECP: Motor Electronics Coolant Pump
MECT: Motor Electronics Coolant Temperature
MIL: Malfunction Indicator Lamp
NO X : Oxides of Nitrogen
NVRAM: Non-Volatile Random Access Memory
OASIS: On-line Automotive Service Information System
OBD: On Board Diagnostics
OC: Oxidation Catalytic converter
OHC: Overhead Camshaft
OSC: Output State Control
OTM: Output Test Mode
PCM: Powertrain Control Module
PCV: Positive Crankcase Ventilation
PID: Parameter Identification
PIP: Profile Ignition Pickup
PPM: Parts Per Million
PSCM: Power Steering Control Module
PWM: Pulse Width Modulation
PZEV: Partial Zero Emission Vehicle
RAM: Random Access Memory
RFI: Radio Frequency Interference
ROM: Read-Only Memory
RPM: Revolutions per Minute
RWD: Rear-Wheel Drive
SAE: Society of Automotive Engineers
SFI: Sequential Multiport Fuel Injection
TB: Throttle Body
TBCM: Traction Battery Control Module
TCM: Transaxle Control Module
TDC: Top Dead Center
TGAC: Torque of Generator AC signal
TMAC: Torque of Motor AC signal
TP: Throttle Position
TR: Transmission Range
VECI: Vehicle Emission Control Information
VCM: Vehicle Communication Module
VCT: Variable Camshaft Timing
VIN: Vehicle Identification Number
VSC: Vehicle System Controller
VSS: Vehicle Speed Sensor
WAC: Wide Open Throttle A/C Cut-Off
WOT: Wide Open Throttle