Repair manual
Wiring diagrams
Lincoln Aviator I Repair Manual
Step-by-step repair and maintenance instructions for the Lincoln Aviator I (2002–2005): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
82sections
718articles
ENManual language
- Range Selection
- Park
- Reverse
- Neutral
- Overdrive
- Drive - Overdrive Canceled
- 3rd Position - 3rd Gear
- 2nd Position - 2nd Gear
- Manual Low Position
- Upshifts
- Downshifts
- Coastdown
- Kickdown
- Geartrain
- Planetary Gearset - Overdrive
- Planetary Gearset - Forward
- Planetary Gearset - Low/Reverse
- Input Shaft
- Output Shaft
- Band - Overdrive
- Band - Low/Reverse
- Band - Intermediate
- Clutches - Direct
- Clutches - Forward
- Clutches - Coast
- One-Way Clutch - Direct
- One-Way Clutch - Low/Reverse
- Filter
- Main Control
- Powertrain Control Module (PCM)
- Air Conditioning (A/C) Clutch
- Brake Pedal Position (BPP) Switch
- Engine Coolant Temperature (ECT) Sensor
- Electronic Ignition (EI) System
- Intake Air Temperature (IAT) Sensor
- Mass Air Flow (MAF) Sensor
- Transmission Control Switch (TCS)
- Transmission Control Indicator Lamp (TCIL)
- Throttle Position (TP) Sensor
- Digital Transmission Range (TR) Sensor
- Turbine Shaft Speed (TSS) Sensor
- Output Shaft Speed (OSS) Sensor
- Intermediate Shaft Speed Sensor
- Pressure Control Solenoids (PCA, PCB, PCC)
- Shift Solenoids - (SSA, SSB, SSC, SSD)
- Transmission Cooling
- External Controls
- Shift Interlock System
- Know and Understand the Concern
- Verification of Condition
- Determine Customer Concern
- Shift Linkage Check
- Check TSBs
- Output State Control (OSC) Mode
- Output State Control (OSC) Procedures
- OSC - Transmission Bench Modes
- SSA, SSB, SSC, SSD and TCC in BENCH MODE
- PCA, PCB, PCC in BENCH MODE
- BENCH MODE Procedure for PCx
- OSC - Transmission DRIVE MODES
- GEAR in DRIVE MODE
- DRIVE MODE Procedure for GEAR
- TCC in DRIVE MODE
- Drive Mode Procedures for TCC
- FIRM___SFT in DRIVE MODE
- Using Output State Control (OSC) and Accessing PIDs
- Before Pinpoint Tests
- Rotunda Transmission Tester
- Shift Solenoid Failure Mode Chart
- Pinpoint Tests
- Possible Causes
- Engine Idle Speed Check
- External Sealing — Part 1
- External Sealing — Part 2
- Preliminary Inspection
- Road Testing Vehicle
- Shift Point Road Test
- Visual Inspection
- Carry Out On-Board Diagnostics (KOEO, KOER)
- On-Board Diagnostics with NGS
- Transmission Drive Cycle Test
- After On-Board Diagnostics
- Diagnostic Trouble Code Charts
- Wiggle Test Information for Open/Shorts
- Shift Solenoid Pre-Diagnosis
- Line Pressure Test
- Stall Speed Test
- Leakage Inspection
- Leak Check Test
- Transmission Fluid Cooler Flow Test
- Diagnosis by Symptom Index - Directions — Part 1
- Diagnosis by Symptom Index - Directions — Part 2
- Inspection and Verification
- General Specifications
- Torque Specifications
- Torque Demand
- Torque Converter
- Torque Converter Clutch (TCC) Solenoid
- Torque Converter Diagnosis
- Torque Converter Operation Test
- Fluid Leakage in Torque Converter Area
- Torque Converter Cleaning And Inspection — Part 1
- Torque Converter Cleaning And Inspection — Part 2
- Insulation
- Liquid Butyl Sealer
- Caulking Cord
- Weatherstrip Adhesive
- Silicone Lubricant
- Heated Exterior Mirror
- Memory Exterior Mirror
- Rear Window Defrost
- High Speed Windshield Wipers
- Low Speed Windshield Wipers
- Intermittent Speed Windshield Wipers
- Speed Dependent Windshield Wipers
- Intermittent Rear Window Wiper System
- Washer System
- Default Mode
- Dust and Water Leaks
- Rear View Mirrors
- Possible Causes
- Glass, Frames and Mechanisms
- Wipers and Washers
- Low Speed
- High Speed
- Washer Pump Relay (Integral)
- On Mode
- Front and rear door
- Door Window Motor Initialization
- Fender
- Windshield Washer Pump and Reservoir
- Exterior Mirror
- Rear Bumper
- Mouldings
- Adjustable Pedals
- Driver Seat Module
- Programming Adjustable Pedal Positions
- Recalling a Stored Adjustable Pedal Position
- Brake Master Cylinder - Normal Conditions
- Brake Master Cylinder - Abnormal Conditions
- Possible Causes
- Brake Booster
- Check Valve
- Compensator Port Check
- Master Cylinder Bleeding
- Brake Caliper Bleeding
- Heat Transfer
- Latent Heat of Vaporization
- Relative Humidity
- Effects of Pressure on Boiling or Condensation
- Compressor Anti-Slugging Strategy
- The Refrigerant Cycle
- Dual Automatic Temperature Control System
- AUTO
- OFF
- PANEL
- PANEL/FLOOR
- FLOOR
- FLOOR/DEFROST
- DEFROST
- Air Distribution
- Heating and Ventilation
- Heater Core
- Blower Motor
- Heater Control Valve
- Heater Core and Evaporator Core Housing
- Air Conditioning
- Thermostatic Expansion Valve
- Condenser Core
- Refrigerant Lines
- Evaporator Core
- A/C Compressor Pressure Relief Valve
- A/C Thermostatic Switch
- Low Charge Protection Switch
- Refrigerant Containment Switch
- Peanut Fitting
- Refrigerant System Dye
- Auxiliary Climate Control
- Auxiliary System Air Distribution
- Dual Automatic Temperature Control
- Control System Inputs
- DATC Module
- Steering Wheel Audio/Climate Control Switch
- Ambient Air Temperature Sensor
- In-Vehicle Temperature Sensor
- Solar Radiation Sensor
- PCM
- Control System Outputs
- Automatic Temperature Control (ATC) Solenoid and Manifold
- Blower Motor Speed Control
- Temperature Blend Door Actuators
- Vacuum Control Motors
- Dual Automatic Temperature Control Module - Retrieve Continuous DTCs
- Possible Causes
- Heater Core - Plugged
- Air Conditioning (A/C) System Check - Retail Procedure
- Florescent Dye Detection
- Fluorescent Dye Injection - Using an A/C Refrigerant Center and Dye Injector
- Fluorescent Dye Injection - Using a Dye Injector Loop Kit
- Refrigerant System Recovery
- Refrigerant System Evacuation
- Refrigerant System Charging
- Contaminated Refrigerant Handling
- Heater Core - Front
- Heater Core - Auxiliary
- Heater Control Valve and Heater Hoses
- Auxiliary Heater Outlet and Inlet Line - Front
- Dual Automatic Temperature Control Module - Diagnostic Methods
- Dual Automatic Temperature Control Module Self-Test
- DUAL/ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (DATC) MODULE DIAGNOSTIC TROUBLE CODE (DTC) INDEX
- Test Procedure
- Heater Core - Pressure Test
- A/C Evaporator/Condenser Core - On Vehicle Leak Test
- A/C Compressor - External Leak Test
- Visual inspection
- Item 6: Rear Axle Assembly Isolator Bushing Removal Note
- Item 6: Rear Axle Assembly Isolator Bushing Installation Note
- Removal and Installation
- Item 6: U-Joint Snap Ring Installation Note
- Item 4: U-Joint Strap Installation Note
- Item 3: U-Joint Bolt Installation Note
- Item 2: CV Joint Installation Note
- Item 1: CV Joint Bolts Installation Note
- Item 2: Driveshaft Flange Yoke Removal Note
- Item 7: U-Joint Spider Installation Note
- Item 1: U-Joint Flange Bolt Installation Note
- Item 2 and 4: Driveshaft Flange Yoke Removal Note
- Item 6 and 8: U-Joint Snap Ring Installation Note
- Item 1 and 3: Driveshaft Flange Bolts Installation Note
- Item 1: Rear Disc Brake Caliper Removal Note
- Item 2: Rear Axle Wheel Hub Retainer and Washer Installation Note
- Item 1: Front Disc Brake Caliper Removal Note
- Item 2: Front Axle Wheel Hub Retainer Removal Note
- Item 5: Upper Ball Joint Nut Removal Note
- Item 2: Front Axle Wheel Hub Retainer Installation Note
- Item 3: Pinion Oil Seal Installation Note
- Item 2: Pinion Flange Installation Note
- Item 3: Rear Pinion Oil Seal Installation Note
- Item 2: Differential Pinion Shaft Lock Bolt Installation Note
- Engine Performance Diagnostic Routine Outline - General Information
- Engine Performance Safety Precautions
- Parasitic Load Explanation & Test Procedures - General Information 2
- Waveforms - Injector Pattern Tutorial - General Information 2
- Electrostatic Discharge Warning - General Information
- State Emission Standards - Diesel
- Material
- Engine Oil Leaks
- Engine Oil Leaks-Fluorescent Oil Additive Method
- Leakage Points-Underhood
- Leakage Points-Under Engine-With Vehicle on Hoist
- Leakage Points-With Transmission and Flywheel Removed
- Compression Pressure Limit Chart
- Cylinder Leakage Detection
- Excessive Engine Oil Consumption
- Valve Train Analysis-Engine Off-Valve Cover Removed
- Valve Train Analysis-Engine Off, Rocker Arm
- Valve Train Analysis-Engine Off, Camshaft Roller Followers and Hydraulic Lash Adjusters, Overhead Camshaft
- Valve Train Analysis-Engine Off, Camshaft-Engines
- Valve Train Analysis-Valve Springs
- Valve Train Analysis-Engine Off, Valve Spring Retainer and Valve Spring Retainer Keys
- Valve Train Analysis-Engine Off, Valves and Cylinder Head
- Valve Train Analysis-Engine Running
- Valve Train Analysis-Engine Running, Valves and Cylinder Head
- Valve Train Analysis-Engine Running, Camshaft Lobe Lift-Push Rod Engine
- Valve Train Analysis-Engine Running, Valve Tappet
- Camshaft Journal Clearance - OHC Engines
- Camshaft End Play - Push Rod Engines
- Camshaft End Play - OHC Engines
- Camshaft Lobe Lift
- Camshaft Runout
- Crankshaft Main Bearing Journal Clearance
- Crankshaft End Play
- Crankshaft Runout
- Piston To Cylinder Bore Clearance
- Piston - Selection
- Piston Ring End Gap
- Connecting Rod Cleaning
- Connecting Rod Bearing Journal Clearance
- Valve Stem to Valve Guide Clearance
- Valve Spring Strength
- Valve and Seat Refacing Measurements
- Cylinder Head Distortion
- Cylinder Block Distortion
- Cylinder Bore Cleaning
- Spark Plug Hole Thread Repair
- Fuel Tank and Lines
- Acceleration Control
- Evaporative Emissions
- Evaporative Emission (EVAP) Canister Purge Valve
- Evaporative Emission (EVAP) Canister
- Canister Vent Solenoid
- Fuel Tank Pressure (FTP) Sensor
- Fuel Filler Pipe Check Valve
- Fuel Filler Cap
- Evaporative Emission System Monitor
- Pinpoint Tests
- Drive Cycle Recommendations
- Power Locks
- Power Unlock Inhibit
- Deactivating/Activating The Door Lock Control Switch UNLOCK Button Inhibit
- Auto-lock
- Auto-lock Enable/Disable - Using the Keyless Entry Keypad
- Auto-lock Enable/Disable- Using the Ignition Switch
- Smart Unlock
- Remote Transmitter Lock/Unlock Control- Unlock
- Remote Transmitter Lock/Unlock Control- Lock
- Panic Alarm
- Keyless Entry Keypad
- Programming/Erasing Personal Codes
- Anti-Scan Feature
- Unlocking the Doors with the Keyless Entry Keypad System
- Locking the Doors with the Keyless Entry Keypad System
- Possible Causes
- Remote Transmitter Programming
- Door Lock Control Switch
- Instrument Cluster and Panel Illumination
- Instrument Cluster
- Integrated Circuit Display
- Speedometer
- Odometer/Trip Odometer
- Fuel Gauge
- Engine Coolant Temperature Gauge
- Tachometer
- Charging System Warning Indicator (Red)
- BRAKE Warning Indicator (Red)
- ABS Warning Indicator (Amber)
- Malfunction Indicator Lamp (MIL) (Amber)
- Air Bag Warning Indicator (Amber)
- Safety Belt Warning Indicator (Red)
- Engine Coolant Temperature Warning Indicator (Red)
- Low Oil Pressure Warning Indicator (Red)
- Traction Control Indicator (Amber)
- RH and LH Turn Indicators (Green)
- High Beam Indicator (Blue)
- Speed Control Indicator (Green)
- Overdrive Off Indicator (Amber)
- All-Wheel Drive (AWD) LOCKED Indicator (Amber)
- Horn
- Information And Message Center
- Tire Pressure Monitoring System
- Information Displays
- Setup Displays
- Warning Messages
- Parking Aid
- Possible Causes
- Normal Conditions
- Vehicle Demagnetizing
- Preparation
- Deactivating/Activating
- Elevation System Check
- Message Center
- Powertrain Control Module (PCM)
- Anti-Lock Brake/Traction Control (ABS/TC) Module or Stability Assist Module
- Restraint Control Module (RCM)
- Dual Electronic Automatic Temperature Control (DEATC) Module
- Instrument Cluster
- Tire Pressure Monitor Module
- Variable Assist Power Steering (VAPS) Module
- Driver Seat Module (DSM)
- Vehicle Security Module
- Driver Climate Controlled Seat Module
- Passenger Climate Controlled Seat Module
- Parking Aid Module
- Four-Wheel Drive (4WD) Control Module
- Navigation Module
- Module Configuration
- Programmable Parameters
- As-Built Data Center
- Configurable Modules
- Module Controlled Functions
- Possible Causes
- Driver Seat Module
- Easy Entry/Easy Exit
- Programming Seat Positions
- Recalling a Stored Seat Position
- Front Seats
- Rear Seats - Second Row
- 40/20/40
- 40/Center Console/40
- Seats - Third Row
- Climate Controlled Seat System
- Heating Characteristics
- Cooling Characteristics
- Seats
- Pinpoint Tests
- Possible Causes
- Deactivation
- Reactivation
- Rear Seat - 40 Percent Second Row
- Rear Seat Cushion - 40 Percent, Second Row
- Variable Assist Power Steering (VAPS)
- Possible Causes
- Drift/Pull
- Excessive Steering Wheel Play
- Feedback
- Hard Steering or Lack of Assist
- Nibble
- Poor Returnability/Sticky Steering
- Shimmy
- Wander
- Steering Gear Insulator
- Steering Gear Valve
- Tie-Rod Articulation Torque
- Steering Column Switches
- Ignition Switch Mechanical Check
- Ignition Switch Continuity Check
- Multifunction Switch
- Deactivation
- Reactivation
- Variable Assist Power Steering (VAPS) Module
- Engine Controls - Self-Diagnostics - Cng, Flex-Fuel & Gasoline
- Engine Controls - Trouble Shooting - No Codes - Cng, Flex-Fuel & Gasoline 4
- Engine Controls - System & Component Tests - Gasoline 2
- Engine Controls - Theory & Operation - Cng, Flex-Fuel & Gasoline 5
- Engine Controls - Basic Diagnostic Procedures - Except Diesel 3