Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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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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Note: There are two different fuel filter systems. In system 1, the fuel filter is located on the engine, under the engine cover. In system 2, the fuel filter is located to the left in the engine compartment, on the strut tower. Special tools, testers and auxiliary items required Suction pump VAS 5226 Remove engine cover Removing: Upper engine cover, removing and installing . Remove plug – arrow – from fuel filter housing water drain connector. Extract diesel fuel via water drain connection located on the side of the fuel filter housing – arrow – using V.A.G 1390 and V.A.G 1390/1 . Seal off oil plug again and tighten to 3 Nm. Remove line connectors for fuel lines Remove screws – arrows – along with connection lines to fuel filter housing Removing fuel filter cover: Remove screws – arrow – for fuel filter housing and remove cover Remove fuel filters – 3 – from cover – 1 – Note: Observe waste disposal regulations! Installing: Install new fuel filters – 3 – and replace seal – 2 – Install fuel filter cover – 1 – . Tighten screws – arrows – for fuel filter cover (8 Nm) Install line connectors for fuel lines. Note: Replace sealing ring between fuel filter covers and line unions for fuel hoses. Tighten bolts – arrows – to 8 Nm. Fuel system, bleeding In order to ensure engine starts immediately after changing fuel filter, fuel system must be bled with diagnostic tester. Connect diagnostic tester Switch ignition on. Select “Guided Functions” . Perform vehicle identification. Diagnostic testing unit, connecting .

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Connect the Saab Intelligent Tester (ISAT-86 10 651) scanner to Green diagnostic connector located under right front seat. Follow manufacturer’s test procedure to retrieve and erase DTCs. See ABS DTCS table. When fault-tracing ABS system, DO NOT directly probe ABS ECU connector pins. Use breakout box and breakout box lead connected between ABS ECU and connector. See Fig. 6 . Breakout box pin numbers are identical to ABS ECU terminal numbers. Problem ABS ECU Fault ABS ECU Fault (RAM) Defective System Relay No Signal From Left Front Wheel Sensor No Signal From Right Front Wheel Sensor No Signal From Left Rear Wheel Sensor Diagnose all other DTCs before diagnosing DTCs 42251 or 1. Breakout box pin numbers and ABS ECU terminal numbers are identical. 1. Turn ignition switch to RUN position. Check for battery voltage between breakout box pins No. 1 and 3, and pins No. 1 and 33. If no voltage is present at either pin No. 3 or 33, check ABS 30-amp fuse in main bulkhead fuse box. Also check Red wire from fuse to main relay and distribution block on battery tray. 2. If wiring is okay but voltage is still not present, ensure continuity is present between breakout box pin No. 3 and relay terminal No. 30 (White wire), and between breakout box pin No. 33 and relay terminal No. 87a (Black wire). Ensure 10-amp ABS fuse is okay.

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Some 2006-2007 Freestar and Monterey vehicles may experience a melted or damaged spark plug electrode, malfunction indicator lamp (MIL) with diagnostic trouble codes (DTC’s) P030X, rough idle, engine knock/ping on acceleration. Pre-ignition (which yields these symptoms) may be caused by water entering the powertrain control module (PCM). ACTION: Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove PCM from vehicle. Refer to Workshop Manual (WSM), Section 303-14. 2. Remove the PCM cover by carefully bending back the four (4) retaining clips holding the galvanized metal cover to the top plate. (Figure 1) Figure 1 – Article 07-14-1 3. Look for evidence of water within the PCM (liquid water, rust, water stains or deposits). (Figure 2) If found – obtain a replacement PCM before continuing on to Step 4. If no water is found, continue on to step 4 with the vehicle’s original PCM. Figure 2 – Article 07-14-1 4. Set the PCM top plate in a clean, dry location where the circuitry will be protected from damage. 5. With the PCM cover removed, drill a 1/4″ hole on each of the four (4) corners of the PCM cover. Get as close to the corner as possible. (Figure 3) Figure 3 – Article 07-14-1 6. De-burr the edges on both inside and outside surfaces. (Figure 3) Be sure to vacuum off all chips and wipe off all metal dust and any machining oil. 7. Clean the surfaces of the PCM cover with Motorcraft ZC-21 (Metal Surface Cleaner) or equivalent. Also clean the edges of the PCM top plate. The metal surfaces must be completely clean before proceeding to Step 8. 8. Apply Motorcraft TA-29 Ultra Silicone Sealant to all edges depicted. (Figure 4, 5, 6, 7) Proceed directly to Step 9 – do not let the sealant skin over. NOTE: Motorcraft TA-32 can NOT be used since its constituents may damage the PCM circuitry.

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FORD: 1980-86 LTD 1980-92 CROWN VICTORIA 1980-93 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1980-86 MARQUIS 1980-87 CONTINENTAL 1980-92 GRAND MARQUIS, TOWN CAR 1980-93 COUGAR 1984-92 MARK VII LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150 This TSB article is being republished because of the occasional need for the information it contains. Originally published as TSB 83-13-10 in June of 1983, this article is not easily locatable in many dealerships today; the model application has been updated. Also, The Service Manual contains this information. ISSUE: A no 3-4 upshift condition or a slipping 4th gear may result from ^ Direct clutch checkball leaking ^ Missing plug in end of output shaft ^ Case bore wear ^ Leakage at O/D band servo piston and/or case bore ^ Seal leakage at 3-4 accumulator piston ^ Blocked hydraulic circuit condition ^ Improper valve body attaching bolt torque ^ Leaking governor circuit ^ Torque converter damper/hub malfunction ACTION: Road test, diagnose and repair the transmission as required. Refer to the following diagnostic and repair procedure for service details.