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 information 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 information cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this service information 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 information, 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 information provides a step-by-step approach for diagnosing driveability, emission, and powertrain control system symptoms. Before beginning diagnosis, it may be helpful to refer to any EXTXREF Technical Service Bulletins (TSBs) or On-line Automotive Service Information System (OASIS) information when this is available. TSB/OASIS information is available on either the Professional Technician Society (PTS) or Motorcraft® website.
Note. For the diesel engines, refer to the appropriate Diesel Powertrain Control/Emissions Diagnosis (PC/ED) information to continue diagnosis. For the Escape Hybrid or the Mariner Hybrid, refer to the Escape Hybrid, Mariner Hybrid PC/ED article to continue diagnosis. For the Fusion Hybrid or the Milan Hybrid, refer to the Fusion Hybrid, Milan Hybrid PC/ED article to continue diagnosis.
This information is used in conjunction with the appropriate article(s) and appropriate SYSTEM WIRING DIAGRAMS article(s). The appropriate articles provide additional diagnostic or component removal and installation information. The appropriate SYSTEM WIRING DIAGRAMS article(s) provide vehicle specific wiring information, component, connector, and splice locations.
The following is a description of the information contained in each information of this service information.
Section 5: Pinpoint Tests
All pinpoint tests are included in this service information. 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 information contains the Typical Diagnostic Reference Values charts. The technician is directed to these charts from PINPOINT TEST Z .
What's New in this Information
The following is a list of changes to this service information for 2010
- Fusion and Milan with 2.5L 4V engine
- Fusion with 3.5L 4V engine option
- Fusion and Milan with 2.5 and 3.0L engines equipped 190-pin PCM
- Fusion and Milan with 3.0L engines are equipped with universal heated oxygen sensor (HO2S)
- Fusion and Milan with 3.0L engines are equipped with 3-pin Hall-effect type camshaft position (CMP) sensor
- New On Board Diagnostic (OBD) Drive Cycle
- Secondary AIR system discontinued
- Flex, MKS and Taurus with option of new 3.5L GTDI engine
- MKT equipped with 3.5L GTDI or 3.7L engine
- Transit Connect with 2.0L engine
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 appropriate information within this PC/ED information or appropriate article(s) for additional information regarding the specific vehicle being repaired.
2V: Two valves per engine cylinder
3V: Three valves per engine cylinder
4V: Four valves per engine cylinder
4WD: Four Wheel Drive
ABS: Anti-Lock Brake System
A/D: Analog-to-Digital
APP: Accelerator Pedal Position
BARO: Barometric Pressure
BJB: Battery Junction Box
BPP: Brake Pedal Position
BTDC: Before Top Dead Center
CAC: Charge Air Cooler
CAN: Controller Area Network
CCM: Comprehensive Component Monitor
CF: Cooling Fan
CHT: Cylinder Head Temperature
CKP: Crankshaft Position
CL: Closed Loop
CMP: Camshaft Position
CO: Carbon Monoxide
CO 2 : Carbon Dioxide
COP: Coil On Plug
CPP: Clutch Pedal Position
CPU: Central Processing Unit
CTO: Clean Tach Output
CV: Canister Vent
DBA: Driver Brake Application
DC: 1. Direct Current 2. Duty Cycle
DEPS: Dual Equal Phase Shifting
DFI: Direct Fuel Injection
DFSO: Deceleration Fuel Shut-Off
DIPS: Dual Independent Phase Shifting
DLC: Data Link Connector
DMM: Digital Multimeter
DRI: Deposit Resistant Injector
DTC: Diagnostic Trouble Code
E10: Fuel containing 10% ethanol
E85: Fuel containing 85% ethanol
EATC: Electronic Automatic Temperature Control
ECM: Electronic Control Module
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: Electronic Ignition
EMD: Engine Manufacturers Diagnostics
EMI: Electromagnetic Interference
EONV: Engine Off Natural Vacuum
EOT: Engine Oil Temperature
EPC: Electronic Pressure Control
EPS: Exhaust Phase Shifting
E-Quizzer: Enhanced Quizzer
ERFS: Electronic Returnless Fuel System
ESM: EGR System Module
ESOF: Electronic Shift-on-the-Fly
ETB: Electronic Throttle Body
ETBTACM: Electronic Throttle Body Throttle Actuator Control Motor
ETBTPS: Electronic Throttle Body Throttle Position Sensor
ETC: Electronic Throttle Control
EVAP: Evaporative Emission
EVAPCP: Evaporative Canister Purge Valve
FAOS: Fore-Aft Oxygen Sensor
FC: Fan Control
FCIL: Fuel Cap Indicator Lamp
FCV: Fan Control Variable
FEPS: Flash EEPROM Programming Signal
FFV: Flexible Fuel Vehicle
FLI: Fuel Level Input
FMEM: Failure Mode Effects Management
FP: Fuel Pump
FPC: Fuel Pump Control
FPDM: Fuel Pump Driver Module
FPM: Fuel Pump Monitor
FRP: Fuel Rail Pressure
FRPT: Fuel Rail Pressure Temperature
FSS: Fan Speed Sensor
FTP: Fuel Tank Pressure
FWD: Front Wheel Drive
GPM: 1. Grams per Mile 2. Gallons per Minute
GTDI: Gasoline Turbocharged Direct Injection
H: Hydrogen
HC: 1. Hydrocarbon 2. High Compression
HDR: High Data Rate
HFC: High Fan Control
HLOS: Hardware Limited Operating Strategy
HO2S: Heated Oxygen Sensor
Hz: Hertz
IAC: Idle Air Control
IAT: Intake Air Temperature
IAT2: Intake Air Temperature 2
IDM: Ignition Diagnostic Monitor
IDS: Integrated Diagnostic System
IFS: Inertia Fuel Shut-Off
I/M: Inspection/Maintenance
IMRC: Intake Manifold Runner Control
IMRCM: Intake Manifold Runner Control Monitor
IMTV: Intake Manifold Tuning Valve
INJ: Injector
IPC: Independent Plausibility Checker
IPS: Intake Phase Shifting
ISO: International Standards Organization
KAM: Keep Alive Memory
KAPWR: Keep Alive Power
KOEO: Key On Engine Off
KOER: Key On Engine Running
Km/h: Kilometers per Hour
kPa: Kilopascal
KS: Knock Sensor
L: Liters
LCM: Lighting Control Module
LDR: Low Data Rate
LFC: Low Fan Control
LONGFT: Long-Term Fuel Trim
LOS: Limited Operating Strategy
MAF: Mass Air Flow
MAP: Manifold Absolute Pressure
MAP/IAT2: Manifold Absolute Pressure/Intake Air Temperature 2
MFF: Misfire Freeze Frame
MIL: Malfunction Indicator Lamp
MRFS: Mechanical Returnless Fuel System
MSOF: Manual Shift-on-the-Fly
N: Nitrogen
NMOG: Non-Methane Organic Gases
NO X : Oxides of Nitrogen
NVM: Non-Volatile Memory
NVRAM: Non-Volatile Random Access Memory
OASIS: On-line Automotive Service Information System
OBD: On Board Diagnostic
OHC: Overhead Cam
OL: Open Loop
ORVR: On-board Refueling Vapor Recovery
OSC: Output State Control
OSR: On-Board System Readiness
OTM: Output Test Mode
PATS: Passive Anti-Theft System
PCM: Powertrain Control Module
PCM-VSO: Powertrain Control Module - Vehicle Speed Output
PCV: Positive Crankcase Ventilation
PCVHC: Positive Crankcase Ventilation Heater Control
PCVHF: Positive Crankcase Ventilation Heater Fitting
Pd: Palladium
PDJB: Power Distribution Junction Box
PID: Parameter Identification
PIP: Profile Ignition Pickup
PPM: Parts per Million
PS: Pressure Switch
PSP: Power Steering Pressure
PSPT: Power Steering Pressure Transducer
Pt: Platinum
PTO: Power Take-Off
PTS: Professional Technician Society
PWM: Pulse Width Modulation
PZEV: Partial Zero Emission Vehicle
RAM: Random Access Memory
RFI: Radio Frequency Interference
Rh: Rhodium
ROM: Read-Only Memory
RPM: Revolutions Per Minute
RWD: Rear Wheel Drive
SAE: Society of Automotive Engineers
SCB: Supercharger Bypass
SFI: Sequential Multiport Fuel Injection
SHRTFT: Short-Term Fuel Trim
SJB: Smart Junction Box
SMR: Starter Motor Request
TAC: Throttle Actuator Control
TACM: Throttle Actuator Control Motor
TC: Turbocharger
TCBP/CACT: Turbocharger Boost Pressure/Charge Air Cooler Temperature
TCBY: Turbocharger Bypass
TCBY2: Turbocharger Bypass 2
TCIL: Transmission Control Indicator Lamp
TCM: Transmission Control Module
TCSS: Transfer Case Speed Sensor
TDC: Top Dead Center
TP: Throttle Position
TPPC: Throttle Plate Position Controller
TSB: Technical Service Bulletin
TWC: Three-Way Catalytic Converter
VCM: Vehicle Communication Module
VCT: Variable Camshaft Timing
VECI: Vehicle Emission Control Information
VID: Vehicle Identification
VIN: Vehicle Identification Number
VMV: Vapor Management Valve
VR: Variable Reluctance
VSS: Vehicle Speed Sensor
WOT: Wide Open Throttle
Transmissions
Note. The automatic transmission naming convention is as follows: The first character, a number, is the number of forward gears. The second character, either the letter F or R, represents front (transaxle) or rear (transmission) wheel drive. The next set of characters, a grouping of numbers, represents the design torque capacity of the transmission/transaxle. The last character, if used, is one of the following: E for electronic shift N for non-synchronous shift S for synchronous shift W for wide ratio
As an example, for the 4F27E transaxle, the number of forward gears is 4, the character F indicates front transaxle, 27 represents 270 ft-lbs of torque capacity and the character E represents an electronic shift.
A/T: Automatic Transmission
CCS: Coast Clutch Solenoid
EPC: Electronic Pressure Control
ESS: Electronic Shift Scheduling
ISS: Intermediate/Input Shaft Speed Sensor
M/T: Manual Transmission/Transaxle
OCS: Overdrive Cancel Switch
OSS: Output Shaft Speed
PNP: Park/Neutral Position Switch
SSA/SSB/SSC/SSD/SSE: Shift Solenoids
SS1/SS2/SS3: Shift Solenoids
TCC: Torque Converter Clutch
TCIL: Transmission Control Indicator Lamp
TCS: Transmission Control Switch
TFT: Transmission Fluid Temperature
TR: Transmission Range
TSS: Turbine Shaft Speed
VSS: Vehicle Speed Sensor