PROGRAMMING
Note. New Generation Star (NGS) Tool or Worldwide Diagnostic System (WDS) is required when removing and installing PCM.
PCM SECURITY ACCESS PROCEDURE
Connect scan tool to Data Link Connector (DLC). DLC is located under center of dash panel. Turn ignition on. Using scan tool, select ICM. Select ENTER SECURITY ACCESS. Wait 10 minutes for security access to be granted. Select PARAMETER RESET. Disconnect scan tool. Turn ignition off, then on, then off again. Remove key from ignition.
COMPUTERIZED ENGINE CONTROLS
| CAUTION | When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. Before disconnecting battery, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION. |
POWERTRAIN CONTROL MODULE
Note. New Generation Star (NGS) Tool or Worldwide Diagnostic System (WDS) is required when removing and installing PCM.
- Disconnect negative battery cable. Powertrain Control Module (PCM) is located on right side of cowl, behind right shock tower. Remove 2 pivot arm nut covers and 2 nuts. Remove 2 wiper pivot arms. Remove left and right side cowl vent screen extension panels. Disconnect windshield washer nozzle hoses from engine main wiring harness at lower right side of engine compartment.
- Remove 9 pin-type retainers and remove cowl vent screen. Push on right corner of filter and release left side clip, and remove cabin air filter. (Scheme 24) Remove 7 bolts and remove strut support brace. (Scheme 25)
- Remove bolts retaining cabin air filter housing. (Scheme 26) Lift outboard side of cabin air filter housing and remove housing. Remove 3 bolts retaining plenum panel and remove plenum panel. (Scheme 27) Loosen bolts and disconnect PCM harness connectors.
- Remove instrument panel finish panel above glove compartment. (Scheme 28) Release assist cable from glove compartment. Release tabs and lower glove compartment. If equipped with a compact disc changer, remove 5 screws retaining glove compartment inner panel and remove panel. (Scheme 29)
- Remove 4 screws retaining glove compartment instrument panel finish panel and remove panel. (Scheme 30) Remove 2 PCM bracket bolts and bracket, and remove PCM.
Scheme 24
Scheme 25
Scheme 26
Scheme 27
Scheme 28
Scheme 29
Scheme 30
- Install PCM into vehicle through glove box and install bolts into bracket. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-142371-S40552191752002073100000). Install glove compartment instrument panel finish panel and install screws. If equipped with a compact disc changer, install glove compartment inner panel and install screws.
- Position the stop tabs and raise glove compartment. Connect assist cable to glove compartment. Install instrument panel finish panel. Connect PCM harness connectors and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-142371-S40552191752002073100000).
- Install plenum panel and install 3 retaining bolts. Tighten bolts to specification. Install cabin air filter housing and air filter housing bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-142371-S40552191752002073100000). Install strut support brace and 7 retaining bolts and tighten bolts to specification. Install cabin air filter.
- Install cowl vent screen and 9 pin-type retainers. Connect windshield washer nozzle hoses. Install left and right side cowl vent screen extension panels. Install windshield wiper and pivot arms onto pivot shaft. Align wiper blade to heated wiper park/windshield locator dots on windshield glass within specification. (Scheme 31) Tighten windshield wiper pivot arm nuts and install 2 pivot arm nut covers.
- Connect negative battery cable. At this point PCM requires security access from ICM. Perform «PCM SECURITY ACCESS PROCEDURE»(ref-142371-S29705038872002102200000) under PROGRAMMING.
Scheme 31
CAMSHAFT POSITION SENSOR
See CAMSHAFT POSITION SENSOR under IGNITION SYSTEMS.
CRANKSHAFT POSITION SENSOR
See CRANKSHAFT POSITION SENSOR under IGNITION SYSTEMS.
CYLINDER HEAD TEMPERATURE SENSOR
See CYLINDER HEAD TEMPERATURE SENSOR under FUEL SYSTEMS.
FUEL RAIL PRESSURE SENSOR
See FUEL RAIL PRESSURE SENSOR under FUEL SYSTEMS.
FUEL TANK PRESSURE SENSOR
In-line fuel tank pressure sensor is repaired along with fuel vapor vent valve and fuel vapor control valve as a fuel vapor control valve tube assembly. For removal and installation of in-line fuel tank pressure sensor, see FUEL VAPOR CONTROL TUBE ASSEMBLY VALVE under EVAPORATIVE EMISSION SYSTEMS.
HEATED OXYGEN SENSOR
See HEATED OXYGEN SENSOR under FUEL SYSTEMS.
INTAKE AIR TEMPERATURE SENSOR
See INTAKE AIR TEMPERATURE SENSOR under FUEL SYSTEMS.
KNOCK SENSOR
See KNOCK SENSOR under IGNITION SYSTEMS.
MASS AIRFLOW SENSOR
See MASS AIRFLOW SENSOR under AIR INDUCTION SYSTEMS.
POWER STEERING PRESSURE SWITCH
See POWER STEERING PRESSURE SWITCH under IDLE CONTROL SYSTEMS.
THROTTLE POSITION SENSOR
See THROTTLE POSITION SENSOR under IDLE CONTROL SYSTEMS.
CANISTER PURGE VALVE
See CANISTER PURGE VALVE under EVAPORATIVE EMISSION SYSTEMS.
CANISTER VENT SOLENOID
See CANISTER VENT SOLENOID under EVAPORATIVE EMISSION SYSTEMS.
IDLE AIR CONTROL VALVE
See IDLE AIR CONTROL VALVE under IDLE CONTROL SYSTEMS.
COOLING SYSTEM PRECAUTIONS
| CAUTION | Coolant must be recovered in a suitable, clean container for reuse. If coolant is contaminated, it must be recycled or disposed of correctly. |
| WARNING | Never remove pressure relief cap while engine is operating or when cooling system is hot. Failure to follow these instructions can result in damage to cooling system or engine, or personal injury. To avoid scalding hot coolant or steam blown out of degas bottle when removing pressure relief cap, wait until engine cools, then wrap a thick cloth around pressure relief cap and turn it slowly. Step back while pressure is released from cooling system. When all pressure has been released, still using cloth, turn and remove pressure relief cap. |
Some vehicle cooling systems are filled with Motorcraft Premium Engine Coolant VC-4-A (in Oregon VC-5, in Canada CXC-10) or equivalent meeting Ford specification ESE-M97B44-A (Green color). Other vehicles are filled with Motorcraft Premium Gold Engine Coolant VC-7-A or equivalent meeting Ford specification WSS-M97B51-A1 (Yellow color). Always fill cooling system with same coolant that is present in system. Do not mix coolant types. Addition of Motorcraft Cooling System Stop Leak Pellets, VC-6, darkens Motorcraft Premium Gold Engine Coolant from Yellow to Golden Tan. When adding engine coolant, use a 50/50 mixture of engine coolant and clean, drinkable water. Do not add/mix Orange-colored Motorcraft Speciality Orange Engine Coolant VC-2 or equivalent meeting Ford specification WSS-M97B44-D. Mixing coolants may degrade coolant's corrosion protection. Do not add alcohol, methanol, brine, or any engine coolants mixed with alcohol or methanol antifreeze. These can cause engine damage from overheating or freezing. Do not mix with recycled coolant unless it meets requirements of Ford specification ESE-M97B44-A or WSS-M97B51-A1. Not all coolant recycling processes meet these Ford specifications. Use of such coolants can harm engine and cooling system components.
COOLING SYSTEM FILLING & BLEEDING
- Remove engine coolant fill cap. (Scheme 32) Open heater air bleed. (Scheme 33) Add coolant to degas bottle, allowing system to equalize until no more coolant can be added. Replace degas bottle cap. Care must be taken to ensure accessory drive belt does not become contaminated with engine coolant. Leave heater air bleed open and add as much coolant as possible to engine fill. Replace engine coolant fill cap and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-142371-S40552191752002073100000).
- Start engine and allow it to idle. Place heater control to MAX position. Close heater air bleed when a steady stream of coolant comes from it. Once heater air bleed is closed, allow engine to idle for 5 minutes. Add coolant to degas bottle as needed to maintain cold fill MAX mark. Reopen heater air bleed to release any trapped air and close it again.
- Maintain engine speed of 2000 RPM for 3-5 minutes or until hot air comes from heater. Allow engine speed to return to idle and verify hot air is still coming from heater. Set heater temperature setting to 75°F (24°C) and allow vehicle to idle for 2 minutes. Turn ignition off and allow engine to cool. After engine has cooled, add coolant to degas bottle to bring level to cold fill MAX mark.
Scheme 32
Scheme 33
Note. When battery is disconnected and reconnected, some abnormal drive symptoms may occur while vehicle relearns its adaptive strategy. Vehicle may need to be driven 10 miles or more to relearn strategy.
Safe Fuel Handling Practices
| CAUTION | Fuel in fuel system remains under high pressure even when engine is not running. To avoid injury or fire, release fuel pressure from fuel system before disconnecting any fuel line. To release pressure from system, perform FUEL SYSTEM PRESSURE RELEASE procedure. To avoid unnecessary fuel spillage and fire hazard, any time fuel lines are disconnected, ignition switch must be in OFF position unless fuel pump operation is required for test purposes. |
| WARNING | Use care to prevent combustion from fuel spillage. No smoking, open flames or any kind of arcing. |
Fire
- Report all fires to proper authorities.
- Flames from methanol or methanol-gasoline blends can be invisible.
- Know locations of portable fire extinguishers, fire blankets, fire alarms and eye/wash shower facilities and learn how to use them.
- Use a "B" or "AFFF" (light water) type fire extinguisher to fight flammable liquid fires.
First Aid
- If gasoline has been swallowed, do not induce vomiting. Seek medical attention immediately!
- If methanol or a methanol/gasoline blend has been swallowed, induce vomiting under the direction of a physician or Poison Control Center. Seek medical attention immediately!
- When overcome by vapors, if safe, move victim to fresh air. If not breathing, give artificial respiration or CPR (Cardiopulmonary Resuscitation) as appropriate. Seek medical attention immediately!
- If splashed in eyes, flush with large amounts of water for 15 minutes. Remove contact lenses, if worn. Seek medical attention.
- If splashed on skin, remove contaminated clothing. Wash skin thoroughly with soap and water.
Health
- All fuels can be harmful or fatal if swallowed.
- Be aware, if fuel is swallowed, onset of serious health effects can be delayed 12 to 24 hours.
- Fuels and products containing methanol (e.g. windshield washer fluid) can cause blindness if swallowed.
- All fuel vapors can be harmful if inhaled.
- All fuels can be harmful if absorbed through skin.
- All fuels are irritating to eyes and respiratory system.
- Some fuels made with gasoline contain benzene which is a cancer causing agent.
Handling
- Use flammable liquid handling precautions.
- Wear chemical goggles and nitrile gloves (additional protective clothing and equipment may be necessary in some instances).
- Keep flammable liquids in approved, labeled, closed containers.
- Use in well ventilated areas and control vapors. Be aware that vapors are not visible, are heavier than air, can travel along floor, and will settle in lower areas.
- When transferring flammable liquids, bond receiving container to source and ground source to earth.
- DO NOT smoke or use heat or spark producing equipment near vapors.
- DO NOT eat, smoke or drink where these products are handled, processed or stored.
- Never siphon by mouth.
- Wash hands thoroughly after handling any fuel.
Spills
- Notify proper authorities in the event of any spill you have not been trained to clean up.
- Stop, contain, and clean up small spills with an absorbent material.
FUEL SYSTEM PRESSURE RELEASE
| WARNING | Always relieve fuel pressure before disconnecting any fuel injection related component. DO NOT allow fuel to contact engine or electrical components. |
Remove fuel filler cap to release fuel tank pressure. Remove engine appearance cover. Remove relief valve (Schrader valve) cap. Relief valve is located on fuel supply manifold. Using Fuel Pressure Gauge (T80L-9974-B), release fuel pressure from relief valve. This will drain some fuel out of fuel system.
FUEL LINE CONNECTORS
Note. Three types of fuel couplings are used. Use illustrations to identify proper servicing procedures. see scheme 23, see scheme 24 or (Scheme 34).
FUEL PUMP MODULE
| CAUTION | Fuel pump modules must be handled carefully to avoid damage to float arm and filter during removal. Fuel pump modules will contain residual fuel. Lift straight up and out of tank to drain remaining fuel out of reservoir. Drain excess fuel into suitable container. |
| WARNING | On vehicles with electronic air suspension, power to air suspension system must be shut off prior to hoisting, jacking or towing vehicle. |
Note. Fuel pump module may also be referred to as Fuel Pump Delivery Module (FPDM). Fuel transfer pump may also be referred to as Jet Pump Module (JPM).
Note. Downstream HO2S may also be referred to as a catalyst monitor sensor.
INTAKE MANIFOLD
See INTAKE MANIFOLD under AIR INDUCTION SYSTEMS.
Note. Throttle Position (TP) sensor is not adjustable.
EVAPORATIVE EMISSION SYSTEM SAFETY PRECAUTIONS
| WARNING | DO NOT smoke or carry lighted tobacco or open flame of any type when working on or around any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury. |
VAPOR LINE CONNECTORS
Disconnect negative battery cable. Disconnect vapor tube from fitting by squeezing fitting and pulling apart. (Scheme 34) To reconnect fitting, clean and inspect fitting and tube for damage. Push tube into fitting until it snaps in place. Pull on connection to ensure fitting is secure.
Scheme 34
FUEL VAPOR VENT VALVE
Note. Fuel vapor vent valve and fuel vapor control valve are permanently mounted to fuel tank and must be replaced as an assembly.
AFTER REPAIR PROCEDURE
Ensure EVAP system does not leak. Perform EVAPORATIVE EMISSIONS SYSTEM LEAK TEST and EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE in SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV article.