Filed Under (Ford) by admin on 30-03-2011
All vehicles 1. Remove the passenger air bag module. For additional information, refer to Section 501-20B. 2. Remove the defroster opening grille. 3. Detach and position aside the RH demister hose. Vehicles with anti-theft/keyless entry 4. Remove the screws and position aside the anti-theft/keyless entry module. All vehicles 5. Working through the opening near the RH defroster nozzle, remove the screw. 6. Remove the temperature blend door actuator. 1. Disconnect the electrical connector. 2. Remove the screws and the temperature blend door actuator. 7. To install, reverse the removal procedure.
Filed Under (Ford) by admin on 30-03-2011
CAUTION: Syncro Positioning Tool T95T-12200-A (3.0L, 4.0L) or T96T-12200-A (5.0L) must be obtained prior to installation of the replacement synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine (6007), possibly causing engine damage. CAUTION: Prior to the removal of the camshaft position sensor (CMP sensor) (12A112), set No. 1 cylinder to 0 degrees top dead center (TDC) of compression stroke. Then note the position of the camshaft position sensor electrical connector. The installation procedure requires that the electrical connector be located in the same position. Removal 1. Disconnect battery ground cable (14301). 2. Disconnect fuel charging wiring electrical connector from camshaft position sensor. 3. Remove the CMP sensor screws and camshaft position sensor from camshaft synchronizer. CAUTION: Do not move crankshaft (6303) until entire installation procedure is complete. Doing so will result in the fuel system being out of time with the engine resulting in possible emissions fault. NOTE: If camshaft synchronizer is to be removed from the cylinder block (6010), proceed with Step 4. If the camshaft synchronizer is not being removed, proceed to installation Step 8. 4. Remove hold-down clamp (12270). 5. Remove camshaft synchronizer from cylinder block. Installation 1. Attach Syncro Positioning Tool T95T-12200-A (3.0L, 4.0L) or T96T-12200-A (5.0L). Camshaft Synchronizer — 3.0L, 4.0L Camshaft Synchronizer — 5.0L 2. Align the synchronizer vane with the radial slot of the Syncro Positioning Tool T95T-12200-A (3.0L) or T96T-12200A (5.0L). 3. Rotate the tool on the synchronizer base until the tool’s boss engages the base notch. 4. Dip gear end into ESE-M2C123-A oil or equivalent to coat gear, thrust washer and lower bearing. Syncro Positioning Tool — 3.0L, 4.0L 5. CAUTION: Do not rotate crankshaft when syncro positioning tool is on the camshaft synchronizer. Armature tab will be damaged and synchronizer timing may be shifted. On 3.0L engines, install camshaft synchronizer so that drive gear engagement occurs when arrow on Syncro Positioning Tool T95T-12200-A is pointed approximately 75 degrees (3.0L), 60 degrees (4.0L) counterclockwise off the centerline of the engine. This step will locate camshaft position sensor electrical connector to the original position. Syncro Positioning Tool — 5.0L On 5.0L engines, install camshaft synchronizer into cylinder block making sure that arrow on Syncro Positioning Tool T96T-12200-A is pointing forward parallel to center line of crankshaft. This step will locate camshaft position sensor electrical connector to the pre-removal position. 6. CAUTION: If camshaft position sensor electrical connector is not positioned properly, DO NOT reposition the connector by rotating the synchronizer assembly. This will result in the fuel system being out of time with the engine, possibly causing engine damage. Remove the synchronizer assembly and repeat Step 5. Install hold-down clamp and tighten to 19-30 Nm (14-22 lb-ft) on 3.0L, 4.0L and 23-34 Nm (17-25 lb-ft) on 5.0L. 7. Remove Syncro Positioning Tool. 8. Install CMP sensor and CMP sensor screws. Tighten to 2.5-3.5 Nm (23-30 lb-in). 9. Connect fuel charging wiring electrical connector to camshaft position sensor (CMP sensor). 10. NOTE: When battery voltage is removed from the powertrain control module (PCM) (12A650), all learned values will be cleared and reset to predetermined values. When battery voltage is restored to the PCM, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. Connect battery ground cable. Camshaft Position (CMP) Sensor — 3.0L Shown, 4.0L, 5.0L Similar
Filed Under (Ford) by admin on 30-03-2011
NOTE: Removal and installation steps are the same for both camshaft and auxiliary shaft sprockets. Removal 1. Remove outer timing belt cover as outlined in this section. 2. Remove timing belt as outlined in this section. 3. Install Cam and Auxiliary Shaft Sprocket Tool T74P-6256-B on sprocket. Use tool to hold sprocket and remove bolt and washer. 4. Install threaded puller insert in Cam and Auxiliary Sprocket Tool T74P-6256-B and remove sprocket. 5. Remove tool from sprocket. Installation 1. Position key and sprocket on shaft. 2. Install Cam and Auxiliary Shaft Sprocket Tool T74P-6256-B, without threaded puller insert, on sprocket. 3. Install sprocket bolt and washer and tighten to 70-95 Nm (52-70 ft-lb). 4. Remove tool. 5. Install timing belt as outlined in this section. 6. Install outer timing belt cover as outlined in this section.
Filed Under (Ford) by admin on 28-03-2011
Inspection and Verification 1. Verify the customer’s concern by operating the climate control system to duplicate the condition. 2. Inspect to determine if one of the following mechanical or electrical concerns apply: Visual Inspection Chart Loose, missing or damaged A/C compressor drive belt. Loose or disconnected A/C clutch. Loose, misrouted or damaged vacuum lines. Broken or leaking vacuum control motora Discharged A/C system. Broken or leaking refrigerant lines. a a A leak in the vacuum control circuit may occur during acceleration (slow leak), may exist at all times (large leak), and may exist only when specific functions are selected (indicating a leak in that portion of the circuit). The vacuum hoses used in the passenger compartment control circuit are constructed from PVC plastic material. The vacuum hoses used in the engine compartment are constructed of Hytrel®. Because of the materials used, never pinch the vacuum hoses off during diagnosis to locate a leak. A wood golf tee can be used as a plug when it is necessary to plug one end of the vacuum hose for leak test purposes. 3. If the inspection reveals obvious concern(s) that can be readily identified, service as required. 4. If equipped with the electronic automatic temperature control system, go to Step 6. 5. If equipped with a manual A/C system, determine the symptom and go to the Symptom Chart. 6. If the concern remains after the inspection, connect the Rotunda New Generation Star (NGS) Tester to the data link connector (DLC) located beneath the instrument panel to carry out the DATA LINK DIAGNOSTICS test. If the NGS responds with NO RESPONSE/NOT EQUIPPED for the electronic automatic temperature control module, GO to Pinpoint Test A. If the DATA LINK DIAGNOSTICS test is passed for the electronic automatic temperature control module, retrieve the continuous DTCs and execute the Self-Test Diagnostics for the electronic automatic temperature control module to retrieve the current DTCs. Mechanical Electrical Open fuses. Blower motor inoperative. A/C compressor inoperative. Circuitry open/shorted. Disconnected electrical connectors. 7. If the self-test is passed and no DTCs are retrieved, go to the Symptom Chart to continue diagnostics. 8. If DTCs are retrieved, go to the Electronic Automatic Temperature Control (EATC) Module Diagnostic Trouble Code (DTC) Index to continue diagnostics. 9. If the electronic automatic temperature control module cannot be accessed by the NGS, GO to Pinpoint Test A. Electronic Automatic Temperature Control Module Self-Test The EATC module self-test will not detect concerns associated with data link messages like engine coolant temperature or vehicle speed signals. A NGS tester must be used to retrieve these concerns. The EATC module self-test will detect concerns in the system control functions and will display hard diagnostic trouble codes (DTCs) in addition to intermittent diagnostic trouble codes for concerns that occur during system operation. The vehicle interior temperature should be between 4-32° (40-90°F) when performing the self-test. If the temperatures are C not within the specified ranges, false in-car temperature sensor DTCs will be displayed. The self-test can be initiated at any time. Normal operation of the system stops when the self-test is activated. To enter the self-test, press the OFF and FLOOR buttons simultaneously and then press the AUTOMATIC button within two seconds. The display will show a pulse tracer going around the center of the display window. The test may run as long as 30 seconds. Record all DTCs displayed. If any DTCs appear during the self-test, follow the diagnostics procedure given under ACTION for each DTC given. If a condition exists but no DTCs appear during the self-test, refer to the Symptom Chart Condition: The EATC System Is Inoperative, Intermittent or Improper Operation. To exit self-test and retain all intermittent DTCs, push the blue (cooler temperature) button. The control will exit self-test, retain all intermittent DTCs and then turn OFF (display blank). To exit self-test and clear all DTCs, press the DEFROST button. The vacuum fluorescent display window will show 888 and all function symbols for one second. Then, the EATC control assembly will turn OFF (display blank) and all DTCs will be cleared. Always exit the self-test before powering the system down (system turned OFF). Intermittent DTCs will be deleted after 80 ignition switch ON cycles after the intermittent condition occurs.
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Filed Under (Ford) by admin on 28-03-2011
Removal WARNING: All vehicles are equipped with gas pressurized shock absorbers which will extend unassisted. Do not apply heat or flame to the shock absorbers during removal or component servicing. Failure to follow these instructions can result in personal injury. CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and their failure can result in major service expense. They must be replaced with the same part number or an 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 ensure proper retention of these parts. Vehicles equipped with air suspension 1. WARNING: The electrical power to the air suspension system must be turned off prior to hoisting, jacking or towing an air suspension vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Turn the air suspension service switch off. All vehicles 2. Raise and support the vehicle. For additional information, refer to Section 100-02. 3. Use the special tool 014-00942 or equivalent to support the rear axle. Vehicles equipped with air suspension 4. WARNING: Do not remove an air spring under any circumstances when there is air pressure in the air spring. Do not remove any components supporting an air spring without exhausting the air. Release the air pressure from the air springs. For additional information, refer to Section 204-05. All vehicles 5. NOTE: Replace shock absorbers individually as required. It is not necessary to replace in pairs. NOTE: To assist in removing the upper attachment on shock absorbers, use a plastic dust tube and place an open end wrench on the hex stamped into the dust tube’s metal cap. For shock absorbers with a steel dust tube, simply grasp the tube to prevent stud rotation when loosening the retaining nut. Remove the shock absorber upper retaining nut, washer and insulator from the stud on the upper side of the frame. 6. Remove and discard the nut. Disconnect the shock absorber lower stud from the mounting bracket on the rear axle assembly. Installation All vehicles 1. To install, reverse the removal procedure. Vehicles equipped with air suspension 2. Inflate the air springs. For additional information, refer to Section 204-05.