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

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1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart Mechanical Fuel vapor hoses EVAP canister Vapor management valve (VMV) 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the NGS tester does not power up, refer to the New Generation STAR tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS tester responds with: CKT914, CKT915 or CKT70-ALL ECUS NO RESP/NOT EQUIP, REFER to Section 418-00. NO RESP/NOT EQUIP for Powertrain Control Module (PCM), REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual. System passed, retrieve and record the continuous diagnostic trouble codes (DTCs). 6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index. 7. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to continue diagnostics. Electrical Loose or corroded connector(s) Symptom Chart Symptom Chart Hissing sound when removing the fuel cap Excessive fuel odor Condition Possible Sources Circuit(s). Vapor Management Valve (VMV). EVAP canister purge Valve. Blocked fuel vapor hose. Circuit(s). Vapor Management Valve (VMV). EVAP canister purge Valve. EVAP canister. Fuel vapor hose. Action Go To Pinpoint Test A. Go To Pinpoint Test B.

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ISSUE Some 2005-2009 Escape Hybrid and 2006-2009 Mariner Hybrid vehicles may exhibit an intermittent Red Triangle On and Stop Safely Now message displayed on the message center accompanied by a sudden RPM loss/no start symptom with a diagnostic trouble code (DTC) P1A0C. Vehicles may exhibit this symptom on the first start of the morning or after an extended idle. The symptom will clear on the next key cycle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE For vehicles outside the new vehicle limited warranty, if diagnostics lead to replacing the throttle body you may use this procedure to clean the throttle body as an alternative to replacing it. This procedure is not covered by the new vehicle limited warranty. NOTE THIS CLEANING PROCEDURE CAN ONLY BE USED ON NON-COATED THROTTLE BODIES. Refer to Workshop Manual, Section 303-04C Removal and Installation – Throttle Body. 1. Remove the throttle body. 2. With the throttle body positioned to the side, open the throttle plate. 3. Using Motorcraft® Choke and Linkage Cleaner or equivalent, spray the throttle body plate and bore. 4. Using a suitable (nylon) brush, clean the edges of the throttle plate and the mating surface of the throttle bore to remove all carbon build up. 5. Reapply Motorcraft® Choke and Linkage Cleaner or equivalent and wipe clean with a lint-free cloth. 6. Remove old throttle body gasket and discard. Install a new throttle body gasket. 7. Install the throttle body.

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ISSUE Some 2003-2007 F-Super Duty, 2003-2005 Excursion and 2004-2010 E-Series vehicles equipped with a 6.0L engine may exhibit a runs rough, lacks power, hard start, no start concern with or without diagnostic trouble code (DTC) P0611 code or various injector circuit codes. This concern may be caused by a DC-DC converter located in one half of the Fuel Injector Control Module (FICM) or by the main circuit board in the other half of the FICM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE FICM Information: The FICM contains two major internal components, the main circuit board and a DC-DC converter. The DC-DC converter is the device that amplifies battery voltage to 48 volts to operate the injectors. Low FICM supply voltage results in increased FICM operating loads, potentially damaging or shortening the life of the FICM. For contribution codes without circuit codes, go to Powertrain Controls/Emissions Diagnosis (PC/ED) pinpoint test P. Do not continue with this procedure. 1. Connect Integrated Diagnostic System (IDS) scan tool and confirm battery voltage is greater then 11.5 volts key on engine off (KOEO). a. If battery voltage is less then 11.5 volts KOEO, do not continue with this article. Refer to Workshop Manual (WSM), Section 414-00. b. If battery voltage is 11.5 volts KOEO or higher, continue to Step 2. 2. Remove the FICM relay.

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ISSUE Some 2004 Explorer 4dr/Mountaineer vehicles with a 4.0L engine may exhibit one, or both, of the following conditions: • No crank with diagnostic trouble code (DTC) B1601 (PATS received incorrect key code from ignition key transponder) and/or B1213 (anti-theft number of programmed keys is below minimum). • When PATS security access is attempted for this, or any other PATS issue, WDS will ask for a coded access “INCODE”. ACTION To service, reprogram the powertrain control module (PCM) to the latest calibration using WDS release B31.10 or higher. Calibration files may also be obtained at www.motorcraft.com. Clear all DTCs. If the condition is not corrected by PCM reprogramming, continue with normal diagnostics to pinpoint root cause.

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Customer Concern: Tests/Procedures: Potential Causes: Diagnostic Codes: The service engine soon light is on with trouble code P1416 present. 1. Use a scanner and command the air pump on with the engine running at idle. Check if the O2 sensors go lean. 2. If the O2 sensor does not go lean on one bank, see if the check valve at the exhaust manifold is stuck closed, not allowing air into the manifold. Defective Check Valve P1416 Confirmed Fix Summary Confirmed Fix 18 – Air Injection Reaction (AIR) Check Valve 1 – Air Injection Reaction (AIR) Check Valve, Air Injection Reaction (AIR) Pump