95 Ford Lincoln Mercury SM

1995 Town Car ,
Crown Victoria ,
Grand Marquis
0 0 - 0 1 - 1
GROUP
\mm
:
m
m i l
SECTION TITLE PAGE SECTI ON TI TLE PAGE
IDENTIFICATION CODES . 00-01-1 MAINTENANCE AND LUBRICATION.. ..00-03-1
LIFTING, JACKING AND SPARE TIRE NOISE, VIBRATION AND HARSHNESS 00-04-1
STOWAGE 00-02-1
SECTION 00-01 Identification Codes
SUBJECT PAGE
VEHICLE APPLICATION 00-01-1
DESCRIPTION AND OPERATION
Build Date Stamp Locati on 00-01-2
Certi fi cati on Label . . . . 00-01-2
Vehicle Identi fi cati on Number (VIN) 00-01-1
VEHICLE IDENTIFICATION NUMBER
Assembl y Plant 00-01-7
Check Digit.. 00-01-7
Engine Type .... 00-01-6
Li ne, Series, Body Type 00-01-6
Manufacturer Speci fi cati on ..00-01-5
Producti on Sequence Number 00-01-7
Restraint System Type.. 00-01-5
Vehicle Model Year .00-01-7
World Manufacturer Identi fi er ..00-01-4
SUBJECT PAGE
VEHICLE CERTIFICATION LABEL (VC LABEL)
CODES
Axle Ratio Codes ..00-01-13
Body Type Codes 00-01-9
Di stri ct Codes ....00-01-15
Exteri or Paint Color Codes 00-01-8
Interi or Trim (Color) Codes 00-01-12
Interi or Trim (Fabric) Codes 00-01-11
Moul di ng Codes.. 00-01-10
Radio Type Codes 00-01-12
Speci al Order Codes 00-01-16
Sun Roof / Moon Roof Codes 00-01-12
Suspensi on Spri ng Codes , 00-01-14
Transmission Codes 00-01-13
VEHICLE APPLICATION
Town Car, Crown Vi ct ori a, Grand Marqui s
Vehi cle I dent i f i cat i on Number (VIN)
The official Vehicle Identification Number (VIN) for title
and regi strati on purposes is st amped on a metal t ab
t hat is f ast ened to t he instrument panel cl ose t o t he
wi ndshi el d gl ass ( 03100) on t he LH si de of t he vehi cl e
and is visible f rom outsi de.
1995 To wn Ca r , Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s Jul y 1994
00- 01- 2 I d e n t i f i c a t i o n Codes
00- 01- 2

DESCRIPTION AND OPERATION (Cont i nued)
C e r t i f i c a t i o n L a b e l
The Vehicle Certification Label (V.C. Label ) is affi xed
on the LH front door lock panl or door pillar. The
upper half of the label contai ns:
The name of manufacturer.
Month and year of manufacture.
Gross Vehicle Wei ght Rating (GVWR).
Gross Axl e Wei ght Rating (GAWR).
The certi fi cati on statement.
The V.C. Label al so contai ns a 17 charact er Vehicle
Identification Number. This number is used for
warrant y identification of t he vehi cl e and i ndi cates:
Manufacturer.
Type of restrai nt syst em.
Line, seri es, body t ype.
Engine.
Model year.
Consecuti ve unit number.
The last si x digits of the Vehicle Identification
Number indicate the Consecuti ve Unit Number of
each unit built at each assembl y plant. The
Consecuti ve Unit Numbers begin as f ol l ows:
000, 001 through 599, 999: Ford Division
Vehicles
600, 001 through 999, 999: Li ncol n/ Mercury
Division Vehicles
The remaining information on the V.C. Label contai ns
t he following vehicle identification codes:
Color.
Body t ype.
Vinyl roof.
Moul di ng.
Interior t ri m.
Additional codes indicate vehi cl es equi pped wi t h:
Air condi ti oni ng.
Radio t ype.
Sun roof t ype (if any).
There are al so t he following codes:
Axl e rati o.
Transmi ssi on.
Spri ng.
Di stri ct sal es offi ce.
Speci al order codes.
Build Date St amp Locat i on
The vehi cl e build dat e is al so included on t he vehi cl e
Certi fi cati on Label (VC Label ).
The build dat e includes the month, day and year that
the vehi cl e was produced.
The VC label is affi xed t o the LH door j amb bel ow
t he l atch stri ker.
The fol l owi ng chart s provi de vari ous codes and their
respect i ve identification.
1995 To wn Car, Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s Jul y 1994
i dent i f i cat i on Codes 00- 01- 3
DESCRI PT I ON AMD PEF1AT10W ( Co n t i n u e d )
Cert i f i cat i on Label (Typi cal)
1LMIJ/S83W9SY60QQ01
VEHICLE IDENTIFICATION
UNITED STATES
rear ma-* ;
xxxxxxxxxxxxxxxxx
l l l i l i
m m
MADE IN CANADA V?(e-SKMM.0-H|
D
CANADA
DECAL APPLIED
TO CANADA BUILT UNITS
ffffl. I I
: xxxxxxxxxxxxxxxxx
Tt i
UNITED STATES EXPORT LABEL SHOWN
(CANADIAN EXPORT LABEL SIMILAR)
NOTE: X'S OH LABELS ARE
SHOWM M PLACE OF ACTUAL
\ LABELS OMLY
WORLD MANUFACTURER IDENTIFIER
RESTRAINT SYSTEM TYPE

MANUFACTURER
SPECIFICATION
LINE, SERI ES, BODY TYPE
ENGINE TYPE
CHECK DIGIT
VEHICLE MODEL YEAR
ASSEMBLY PLANT
PRODUCTION SEQUENCE NUMBER
1
EXTERIOR PAINT COLOR CODES
BODY TYPE CODES
VINYL ROOF CODES
I I MOULDING CODES
INTERIOR TRIM CODES (FIRST CODE
SEAT TYPE, LETTER = FABRIC AND
SECOND CODE = COLOR)
TAPE STRIPE CODES
fl;^ RADIO TYPE CODES
! ) SUN ROOF/MOON ROOF CODES
I 'J ) AXLE RATIO CODES
i > TRANSMISSION/TRANSAXLE CODES
* ) SUSPENSION SPRING CODES
DISTRICT CODES
i SPECIAL ORDER CODES
ktJ ACCESSORY RESERVE LOAD CODES
Y5111-A
1995 Town Car, Crown Victoria, Grand Marquis July 1994
00- 01- 4 I d e n t i f i c a t i o n Codes
00- 01- 4
VEHICLE IDENTIFICATION NUMBER
World Manufacturer Identi fi er
VIN POSITIONS 1,2 AND 3
LM83W9SY600001
Code Manufacturer Make Type
1FA Ford Motor Company, USA Ford Passenger Car
1FM Ford Motor Company, USA Ford MPV
1FT Ford Motor Company, USA Ford Truck (Complete Vehicle)
1FD Ford Motor Company, USA Ford Incomplete Vehicle
1FC Ford Motor Company, USA Ford Basic (Stripped) Chassis
1FB Ford Motor Company, USA Ford Bus
1FF Ford Motor Company, USA Ford Motor Vehicle Equipment w/o Engine/Powertrain (Glider)
1ME Ford Motor Company, USA Mercury Passenger Car
1MH Ford Motor Company, USA Mercury Incomplete Vehicle
1LN Ford Motor Company, USA Lincoln Passenger Car
1U Ford Motor Company, USA Lincoln Incomplete Vehicle
1ZV Auto Alliance International, Inc. Ford Passenger Car
2FA Ford Motor Company of Canada, Ltd. Ford Passenger Car
2FM Ford Motor Company of Canada, Ltd. Ford MPV
2FT Ford Motor Company of Canada, Ltd. Ford Truck (Complete Vehicle)
2FD Ford Motor Company of Canada, Ltd. Ford Incomplete Vehicle
2FC Ford Motor Company of Canada, Ltd. Ford Basic (Stripped) Chassis
2FB Ford Motor Company of Canada, Ltd. Ford Bus
2FF Ford Motor Company of Canada, Ltd. Ford Motor Vehicle Equipment w/o Engine/Powertrain (Glider)
2ME Ford Motor Company of Canada, Ltd. Mercury Passenger Car
2MH Ford Motor Company of Canada, Ltd. Mercury Incomplete Vehicle
3FA Ford Motor Company Ford Passenger Car
S. A. de C. V. (Mexico)
Passenger Car
3FC Ford Motor Company
S. A. de C. V. (Mexico)
Ford Basic (Stripped) Chassis
3MA Ford Motor Company Mercury Passenger Car
S. A. deC. V. (Mexico)
Passenger Car
4F2 Ford Motor Company, USA Mazda MPV
4F3 Ford Motor Company, USA Mazda Incomplete Vehicle
4F4 Ford Motor Company, USA Mazda Truck (Complete Vehicle)
4M2 Ford Motor Company, USA Mercury MPV
4M3 Ford Motor Company, USA Mercury Incomplete Vehicle
4M4 Ford Motor Company, USA Mercury Truck (Complete Vehicle)
4N2 Ford Motor Company, USA Nissan MPV
4N3 Ford Motor Company, USA Nissan Incomplete Vehicle
4N4 Ford Motor Company, USA Nissan Truck (Complete Vehicle)
KNJ Kia Motors Inc., Korea Ford Passenger Car (Imported Aspire)
CY5112-A
00- 01- 5 I d e n t i f i c a t i o n Co d e s 00- 01- 5
VEHICLE IDENTIFICATION NUMBER (Cont i nued)
Re s t r a i n t S y s t e m T y p e
VIN POSITION 4
1LN[ I 1m83W9SY600001
VIN Code Description
A Active Belt (Driver), Passive Belts
(Passenger) and Driver Air Bag
B Active Belts (All Positions)
C Active Belts (All Positions) and Driver
Air Bag
L Active Belts (All Positions) and Air Bags
(Passenger and Driver)
P Passive Belts (Front) and Active Belts (Rear)
R Passive Belts (Driver, Passenger)
and Driver Air Bag
S Passive Belts (Driver, Passenger) and Air
Bags (Driver, Passenger)
CY4292-A
Manufacturer Speci f i cat i on
VIN POSITION 5
1LNL[Ml83W9SY600001
Code Vehicle
M Passenger Car - Lincoln and Mercury North
American Vehicles
P Passenger Car Ford North American
Vehicles
T Passenger Car- All passenger cars imported
from outside North America
or Non-Ford built passenger
cars marketed by Ford in
North America
CY5114-A
00- 01- 6 Identification Codes 0 0 - 0 1 - i
VEHICLE IDENTIFICATION NUMBER ( Co n t i n u e d )
Li ne, Se r i e s , B o d y T y p e
VIN POSITIONS 6 AND 7
1LNLM|W|W9SY600001
I
Additional Optional
VIM Code Line Series Exterior Nameplates Body Type Body Code
l at e Ford
71 Crown Victoria Police Interceptor 4-Dr. Sedan PC
72 Crown Victoria S (Fleet-LPO: 4-Dr. Sedan BA4
Commercial App.)
73 Crown Victoria Standard 4-Dr. Sedan BA4
74 Crown Victoria IX 4-Dr. Sedan LX4
Make Mercury
74 Grand Marquis GS 4-Dr. Sedan GS4
75 Grand Marquis LS 4-Dr. Sedan LS4
Make Lincoln
81 Town Car Executive 4-Dr. Sedan BA4
82 Town Car Signature 4-Dr. Sedan SI4
83 Town Car Cartier 4-Dr. Sedan CA4
CY5115-A
Engine Type
VIN POSITION 8
1LNLM83lwJ9SY600001
VIN Code Cylinders Fuel Manufacturer - VIN Code Liter CID Cylinders Fuel Manufacturer -
W 4.6LSFI (2V) 281 V-8 Gasoline Ford
CY5116-A
00- 01- 7 i d e n t i f i c a t i o n Co d e s
<TKrr
r
m
7
TTr
00- 01- 7
VEHICLE IDENTIFICATION NUMBER (Cont i nued)
C h e c k Di gi t
WIN POSITION
1LNLM83W 9 SY600001
CY5117-A
Ve h i c l e Mo d e l Year
VIN POSITION 10
1LNLM83W9|S|Y600001
1 ' . _ _ .
VIN Code
Year
s . . . . . 1995
T 1996
V 1997
W 1998
CY5118-A
Assembly Pi ant
VIN POSITION 11
1LNLM83W9S FTI 600001
VIN Code Plant Location
A Atlanta: Hapeville, Georgia
B Oakville: Oakville, Ontario
D Ohio: Avon Lake, Ohio
F Dearborn: Dearborn, Michigan
G Chicago: Chicago, Illinois
H Lorain; Lorain, Ohio
J IMMSA: Monterrey, Mexico
K Kansas City: Claycomo, Missouri
N Norfolk: Norfolk, Virginia
P Twin Cities: St. Paul, Minnesota
R Hermosillo: Hermosillo, Mexico
T Edison: Edison, New Jersey
U Louisville: Louisville, Kentucky
W Wayne: Wayne, Michigan
X St. Thomas: Talbotville, Ontario
Y Wixom: Wixom, Michigan
Z St. Louis: Hazelwood, Missouri
5 AAI: Flat Rock, Michigan
6 Mazda-Kia: Kyung Ki-Do, Korea
CY5119-A
Production Sequence Number
VIN POSITIONS 12 THROUGH 17
1LNLM83W9SY 600001
Sequence Number
100,001 through 599,999 Ford Division Vehicles
600,001 through 999,999 ~ Lincoln and Mercury Division
Vehicles
CY5120-A
00- 01- 8
Identification Codes 00- 01- 8
CODES
Ext eri or Paint Color Codes
rH
EXTERIOR PAINT COLORS
F0276
R0141
DSO
BODY VR MLDG. INT. TRIM TAPE TR
CA4 YB i B6 A 5 B 8 TBBBB
CODE COLOR SPEC REF CODE COLOR SPEC . REF
Town Car Crown Victoria/Grand Marquis
UA Ebony C/C UAWAW M6373 UA Ebony C/C UAWAWHA M6373
DK Pumice Metallic C/C DCQEWH M6612 EG Electric Currant Red C/C EAZEWHA M6425
GJ Lt. Amethyst C/C GCNCWH M6613 DK Pumice Metallic C/C DCQEWHA M6612
XB Dk. Portofino Blue C/C KXZEWH M6618 XB Dark Portofino Blue C/C KXZEWHA M6618
XD Lt. Santa Fe C/C CXNEWH M6620 WT Performance White C/C ZGFAWHA M6640
XC Portofino C/C KXQCWH M6623 XC Portofino C/C KXQCWHA M6623
FD Desert Coral C/C ECQCWH M6626 FG Medium Berry Metallic C/C FE8EWHA M6707
GF Elec Currant Red Tint C/C EWYEWT M6628 SL Lt. Willow Metallic C/C SGNCWHA M6708
WT Performance White C/C ZGFAWH M6640 SH Medium Willow Metallic C/C SGWEWH M6715
FE Evergreen Frost C/C PFQEWH M6641 TS Silver Frost C/C ZJKEWHA M6720
GK Red Nightmist C/C HCTEWH M6653
TA Venetian Blue Met C/C MPWEW M6703
FJ Berry Metallic C/C FEWEWH M6705
TR Medium Graphite Met C/C ZUTCWH M6712
SH Medium Willow Met C/C SGWEW M6715
HA Ivory 3C AUGGWH M6718
TS Silver Frost C/C ZJKEWH M6720
XB Dark Portofino Blue KXZCXXG M6693
DK Pumice DCQCXXG M6740
TR Medium Graphite ZUTCXXG M6770
Note: C/C is Clear Coat
CY5121-A
0- 01- 9 I dent i f i cat i on Codes 00- 01- 9
CODES (Cont i nued)
Body T y p e C o d e s
F0276
I R0141
2A 482450
EXTERIOR PAINT COLORS DSO
BODY VR | MLDG. | INT. TRIM | TAPE
t ~ r
j
YB 6 B6 A 5 B 8 TBBBB

VIN Code Line Series Body Type Body Code
l at eFo r d
71 Crown Victoria Police Interceptor 4-Dr. Sedan FC
72 Crown Victoria S (Fleet-LPO: Commercial App.) 4-Dr. Sedan BA4
73 Crown Victoria Standard 4-Dr. Sedan BA4
74 Crown Victoria LX 4-Dr. Sedan LX4
Make Mercury
74 Grand Marquis GS 4-Dr. Sedan GS4
75 Grand Marquis LS 4-Dr. Sedan LS4
l at e Lincoln
81 Town Car Executive 4-Dr. Sedan BA4
82 Town Car Signature 4-Dr. Sedan SI4
83 Town Car Cartier 4-Dr Sedan CA4
CY5123-A
00- 01- 10 i dent i f i cat i on Codes 00- 01- 10
CODES (Conti nued)
Moulding Codes
2A
F0276
R0141
482450
DSO
BODY
CA4
VR
YB
MLDG. INT. TRI i
- B6
TAPE
A
AX
8
TR
TBBBB
LINE (SERIES) CODE COLOR (COMPONENTS) SPEC
Town Car A Pumice
Town Car B Evergreen Frost PNPFB
Town Car C Berry PNFED
Town Car D Electric Currant Red Tint PNEW :
Town Car E Red Nightmisi
Town Car F Ivory Tricoat PNAUA
Town Car G Med. Willow Mel PNSGC
Town Car H Venetian Blue PNMPA
Town Car I Med. Graphite PNZUB
Town Car J Silver Frost
Town Car K Ebony
Town Car L Performance White
Town Car M Dk. Portofino PNKXB
Town Car (Cartier) N Portofino PNKX. ;
Town Car (Cartier) P Cordovan
Crown Victoria, Grand Marquis A Ebony
Crown Victoria, Grand Marquis B Dk. Portofino PNKXB
Crown Victoria, Grand Marquis D Lt./Med. Aubergine
Crown Victoria, Grand Marquis G Med. Berry
Crown Victoria, Grand Marquis H Med. Willow PNSGC
Crown Victoria, Grand Marquis K Pumice PM
r
;CA
Crown Victoria, Grand Marquis L Lt. Willow
Crown Victoria, Grand Marquis S Silver Frost PNZJF
Crown Victoria, Grand Marquis 1 Electric Currant Red
Crown Victoria, Grand Marquis 2 Performance White PNZG
Crown Victoria, Grand Marquis 3 Portofino PNKXv: I
CY5124-A
00- 01- 11 I dent i f i cat i on Codes 00- 01- 11
C OD E S (Cont i nued)
I nt er i or T r i m ( Fabr i c ) C o d e s
F0276
R0141
2A 482450
BODY VR MLDG. INT. TAPE
R J S
AX TR
TRIM
I
CA4 YB 6 [BJ 6 A 5 B 8 TBBBB
4
Code Trim Scheme Fabric Seat Type
Crown Victoria
C
E
H
I
M
Leather
Vinyl
Cloth
Cloth/Vinyl
Cloth
K-Split Bench
K-Split Bench
Bucket
Bucket
K-Split Bench
Grand Marquis
S
T
H
9
C
Cloth
Cloth
Leather
Cloth
Leather
K-Split Bench
K-Split Bench
K-Split Bench
K-Split Bench
K-Split Bench
Town Car
B
D
F
J
K
M
Leather 1
Leather 2
Leather
Cloth
Cloth
Leather 3
K-Split Bench
K-Split Bench
K-Split Bench
K-Split Bench
K-Split Bench
K-Split Bench
CY5125-A
CODES (Cont i nued)
Interi or Trim (Color) Codes
2A
F027S
R0141
482450
DSO
BODY | VR | MLDG. INT. TRIM | TAPE
( R 1 S I AX 1 TR
CA4
1
YB 6 A
5 B 8 TBBBB
Code Trim Color Code Trim Color
Town Car
Crown Victoria, Grand Marquis
C Currant C Currant
E Evergreen G Willow
J Ebony P Portofino
P Portofino S Saddle
S Saddle X OWhite/Lt. Graphite
2 Lt. Graphite 2 Lt. Graphite
5 Ivory/Med. Saddle
7 Ivory/Evergreen
9 Ivory/Portofino
CY5126-A
Radio Type Codes
2A
F0276
R0141
482450
DSO
BODY VR MLDG. INT.
TRIM
TAPE | R S AX
CA4 YB 6 B6 A m B 8
TR
Codes
5 Premium AM/FM Stereo
6 AM/FM/MPX, Electronic Premium Cassette
7 AM/FM/MPX, Cassette
8 Premium AM/FM, Clock Cassette
9 AM/FM, Clock Cassette Electronic Tune
F AM/FM Stereo-Electronic
H AM/FM Stereo/Cassette, Electronic
L Lux Radio AM/FM Stereo/Cassette
M Low Line AM/FM Stereo/Cassette
P AM/FM Stereo/Cassette
Y Delete
CY5127-A
Sun Roof / Moon Roof Codes
2A
F0276
R0141
482450
DSO
BODY VR MLDG. INT.
TRIM
TAPE R S AX TR
CA4 YB 6 B6 A 5
9
8 TBBBB
Code Sun Roof/Moon Roof
B
C
Sliding
Removable
CY5128-A
00- 01- 13 I dent i f i cat i on Codes 0 0 - 0 1 - 1 3
CODES (Cont i nued)
Axle Ratio Codes
2A
F0276
R0141
482450
DSO
CA4 YB
MLDG. INT. TAPE R S
TRIM
6 B6 A 5 B
S AX TR
Town Car
Code
Conventional Lock Rear Axle Ratio
Y

3.08
5 E 3.27
Crown Victoria, Grand Marquis
8

2.73
Z 3.08
5 E 3.27
CY5129-A
Transmi ssi on Codes
2A
F0276
R0141
482450
DSO
BODY VR MLDG. INT. I A/C
TRIM J
R S AX TR
CA4 YB 6 B6 A 5 B
.IT
pBBBB
Code Automatic
U Automatic Overdrive 4R70W
CY5130-A
1995 To wn Car , Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s Jul y 1994
00- 01- 14
Identification Codes 00- 01- 14
CODES (Cont i nued)
Suspensi on Spri ng Codes
CROWN VICTORIA, GRAND MARQUIS
FRONTL& R, REAR L i R
NOTE: SPRING CODES WILL APPEAR DIRECTLY AFTER
THE TRANSMISSION COPE
2A
F0276
R0141
482450
DSO
BODY
CA4
VR
YB
] MLDG.
6
INT. TRIM
B6
TAPE
A
AX
8
TR
TBBBB
BB B B
Front L R
Rear L R
Coding Part No. Catch-Word Coding Part No. Catch-Word
Front Springs "5310" - Left (267), Right (268) Rear Springs "5560" - Left (269), Right (270)
2 F4AC-AA AFD E D9AC-AEA TOW
3 F4AC-BA BOS J F4AC-AA ARP
4 F4AC-CA CKV K F4AC-BA BKM
5 F4AC-DA DHL L F4AC-CA CWT
6 F4AC-EA ETR X DZAB-DA HDS
7 F4AC-FA FPK Z DZAB-CA AIR
N D9AC-ANA NUL
CY5131-A
CODES (Conti nued)
Di st ri ct Codes
F0276
R0141
2A P t p
EXTERIOR PAINT COLORS | P S 0 l
_ _ | |
M L D G
| INT. TRIM f TAPE | R | S f | TR
CA4 YD 6 B6 A 5 B 8 TBBBB
The D.S.O. Space will Show a Two Digit Code Number of the District Sales Office Which Ordered the Unit. This Code will Appear on all Units,
Domestic Special Order ExportEtc.

Ford Division I'M Division
Code District Code District Code District
11 Boston Region 52 Dallas Region 36 Philadelphia
13 New York Region 53 Kansas City Region
16 Philadelphia Region 56 Denver Region 38 Atlanta
21 Atlanta Region 58 Twin Cities Region
23 Memphis Region 71 Los Angeles Region 64 Detroit
24 Orlando Region 72 San Francisco Region
27 Washington Region 74 Seattle Region 73 Denver
41 Chicago Region 75 Los Angeles
44 Pittsburgh Region 83 Government 78 Dallas
47 Cincinnati Region 84 Home Office Reserve 83 Government
48 Detroit Region 85 American Red Cross 84 Home Office Reserve
86 Recreational Vehicle Pool 85 American Red Cross
9A Export
87 Body Company
89 Transportation Services
9A Export
Ford of Canada
Code
Mercury
Regions Code
Mercury
Regions Code
Ford
Regions Code
Ford
Regions
A1 Central A6 Western B1 Central B6 Western
A2 Eastern A7 Pacific B2 Eastern B7 Pacific
A3 Atlantic A8 Great Lakes B3 Atlantic B8 Great Lakes
A4 Midwestern 11 Export B4 Midwestern 11 Export
CY5132-A
CODES (Cont i nued)
Special Order Codes
I
F0276
I
R0141
2A
48[2450H
BODY VR I MLDG. I INT. | TAPEj R s AX I TR
I I TRIM I
CA4 YB 6 B6 A 5 B 8 TBBBB
I
IF UNIT IS BUILT ON A D.S.O., F.S.O., P.T.O. (SPECIAL
ORDERS), THE COMPLETE ORDER NUMBER IS TO APPEAR
AFTER THE DISTRICT CODE.
CY5133-A
00- 02 - 1 Li f t i ng, Jacki ng, a n d Sp a r e Ti r e S t o w a g e 00- 02 - 1
SECTION 00-08 Lifting, Jacking, and Spare Tire
Stowage
SUBJECT PAGE SUBJECT PAGE
VEHICLE APPLICATION 00-02-1 HOISTING AND JACKING (Cont ' d. )
HOISTING AND JACKING Lifting I nst r uct i ons . 00-02-1
Hoi st, Drive-On 00-02-1 TIRE STOWAGE
Hoi st , Frame Cont act . . 00-02-2 Ti re, Spa r e Conve nt i ona l 00-02-3
Hoi st , Twi n Post ...00-02-2 Ti re, Spar eRemoval 00-02-3
Ja c k, Floor 00-02-3 Ti re, Spar eTempor ar y . .00-02-3
VEHICLE APPLICATION
HOISTING AND JACKING
L i f t i n g I n s t r u c t i o n s If a t wo-post hoi st is used t o lift a vehi cl e, pl ace t he
WARNI NG: ON VEHI CLES EQUI PPED WI TH AI R adapt ers under the front suspension l ower arms.
SUSPENSI ON, THE ELECTRI CAL POWER SUPPLY
TO THE AI R SUSPENSI ON SYSTEM MUST BE
SHUT OFF PRIOR TO HOI STI NG THE VEHI CLE.
THI S CAN BE ACCOMPLI SHED BY
DI SCONNECTI NG THE BATTERY OR TURNI NG
OFF THE POWER SWI TCH LOCATED IN THE
LUGGAGE COMPARTMENT ON THE RH SI DE.
FAI LURE TO DO SO MAY RESULT IN UNEXPECTED
I NFLATI ON OR DEFLATI ON OF THE REAR
SPRI NGS ( 5560) WHI CH MAY RESULT IN
SHI FTI NG OF THE VEHI CLE DURI NG THESE
OPERATI ONS.
CAUTI ON: Do n o t al l ow t h e h o i s t a d a p t e r s t o
c o n t a c t t h e s t e e r i n g l i n ka ge , s u s p e n s i o n a r ms ,
st a bi l i ze r ba r , or t o c o mp r e s s t h e l o we r
s u s p e n s i o n a r m st abi l i zer bar i n s u l a t o r s ( 5493) .
Da ma ge t o s u s p e n s i o n , e x h a u s t a n d / o r s t e e r i n g
l i n ka ge c o mp o n e n t s may o c c u r If car e i s n o t
e x e r c i s e d w h e n p o s i t i o n i n g t he h o i s t a d a p t e r s o f
t w o - p o s t h o i s t s pr i o r t o l i f t i ng t h e v e h i c l e .
For hoisting and lifting l ocati ons, refer t o t he illustration
under Hoi st, Frame Cont act .
Hoi st, Drive-On
To prevent possi bl e damage t o the underbody, do not
drive t he vehi cl e onto t he drive-on hoist wi thout first
checki ng f or possi bl e i nterference bet ween t he upright
fl anges of t he hoist rails and the underbody. If
i nterference exi st s, t he hoist flanges shoul d be
modified as necessary and/ or the appr oach ramps
built up t o provi de the necessary cl earance.
00- 02- 2 Li f t i ng, J ac k i ng, and Spar e Tare S t o w a g e 00-02-2
HOISTING AND JACKING (Cont i nued)
Hoi st , Frame Cont act
WARNI NG: WHEN HOI STI NG AT LI FT POI NTS,
ESPECI ALLY FRONT LI FT POI NTS, BE CAREFUL
OF CONTACTI NG BRAKE LI NES AND FUEL LI NES.
CAUTI ON: Ai l f o u r c o n t a c t p o i n t s mu s t c o n t a c t
t h e a d a p t e r s .
CAUTI ON: Ne v e r u s e t h e d i f f e r e n t i a l h o u s i n g as a
l i f t p o i n t ( a ppl i e s t o al l r e a r wh e e l d r i v e v e h i c l e s ) .
On f rame cont act hoi sts, adapt ers are necessary t o
lift t he vehi cl e. The adapt ers must be pl aced at four
cont act poi nts. Position the adapt ers so they are
cent ered on the adapt er cont act ar ea.
FRON T S US P E NS I ON L I FT P OI NTS RE A R S US P E NS I ON
L I FT P OI NT S
Y2627-D
NOTE: Before hoisting the vehi cl e, verify that there is
sufficient cl earance between the hoist and t he exhaust
syst em components.
Exerci se care when hoisting vehi cl es equi pped wi t h
catal yti c convert er(s). On vehi cl es so equi pped,
ensure necessary cl earance between hoist and
exhaust syst em components before energizing hoi st.
Vehicles wi t h unitized body-frame constructi on requi re
speci al precauti ons and procedures when the vehicle
is j acked up or hoi sted. In some cases, speci al hoist
adapt ers must be used as recommended by speci fi c
hoist manufacturers.
Hoi st, Twi n Post
To ensure safe hoi sti ng, t he front post adapt ers must
be posi ti oned carefully t o cont act t he center of t he
l ower suspension arms.
00- 02- 3 Li f t i ng, Jacki ng, a
HOISTING AND JACKING (Conti nued)
J a c k , Fl o o r
WARNI NG: NEVER RUN THE ENGINE WI TH ONE
WHEEL OFF THE GROUND, SUCH AS WHEN
CHANGI NG A TI RE. THE WHEEL STI LL ON THE
GROUND COULD CAUSE THE VEHI CLE TO MOVE.
CAUTI ON: The ser vi ce j ack ( 17 080) pr ovi ded
wi t h t he vehi cl e i s onl y i nt ended t o be used en a n
emer genc y f or changi ng a def l at ed t i r e. Ne v e r
use t he ser vi ce j ack t o hoi st t he vehi cl e f or any
ot her ser vi ce. Ref er t o t he Owner Gui de when
usi ng t he j ack suppl i ed wi t h t he vehi cl e.
CAUTI ON: Do not at t empt t o use j ack pr essur e o n
ei t her t he f r ont bumper ( 17 7 57 ) o r t he r ear
bumper ( 17 906) of any uni t i zed vehi cl e.
When using a floor j ack the vehicle may be rai sed at
several l ocati ons. The front of the vehicle may be lifted
by positioning the floor j ack under the center of the No.
2 crossmember. The front, as well as either si de of the
rear end, may be lifted by positioning the fl oor j ack
under the rocker fl ange at the cont act poi nts used for
the servi ce j ack supplied wi t h the vehicle.
CAUTI ON: Car e must be exer ci sed not t o c ont ac t
t he st eer i ng l i nkage o r t o c o mp r e s s t he l ower
suspensi on ar m st abi l i zer bar i nsul at or s ( 5493) .
CAUTI ON: Never use t he di f f er ent i al housi ng a s a
l i f t poi nt .
Position j acks under t he rear axl e housing t ubes
between t he suspension arm bracket s and t he
differential housing. Do not pl ace j acks under the
suspensi on arm bracket s.
TIRE STOWAGE
Tire, S p a r e R e mo v a l
1. NOTE: Locati on of t he spare ti re is wi thi n the
l uggage compart ment .
Remove spare ti re cover ( 45026) .
2. Unscrew wing-nut holding down spare ti re.
3. Lift out spare ti re. Al so remove j ack handl e and
wheel nut wrench ( 17032) and j ack ( 17080) .
Tire, SpareConventi onal
NOTE: If t he vehi cl e is equi pped wi th a conventi onal
spare ti re, spare may differ f rom the road wheel s.
The conventi onal spare ti re supplied wi th t he vehi cl e
can be used as a spare or regul ar ti re. Thi s ti re is
identical t o the t i res suppl i ed wi t h the vehi cl e.
Tire, SpareTemporary
WARNI NG: THE TEMPORARY SPARE TI RE IS
DESI GNED FOR EMERGENCY USE ONLY. FAI LURE
TO FOLLOW THE SUBSEQUENT PRECAUTI ONS
COULD CAUSE TIRE FAI LURE, LOSS OF VEHI CLE
CONTROL AND POSSI BLE I NJURY TO YOURSELF
OR OTHERS.
NOTE: Ext ended use of other than matchi ng si ze ti res
on a Tracti on-Lok rear axl e coul d result in a permanent
reducti on in effecti veness. Thi s l oss of effecti veness is
not noti ceabl e t o the driver under normal driving
condi ti ons.
The t emporary spare ti re is smaller than conventional
ti res and desi gned for emergency use onl y. The spare
ti re is l abel ed wi t h TEMPORARY USE ONLY. Repl ace
t emporary spare on t he vehi cl e as soon as possi bl e
wi th a conventi onal road ti re.
When using a t emporary spare ti re, observe t he
following precauti ons:
Al ways check pressure in spare tire monthly. If
spare ti re is in use, check pressure only after t he
vehicle has been st opped for more than t hree
hours. Do not reduce pressure when ti re is hot. Use
tire gauge t o maintain inflation pressure at 415 kPa
( 60 psi ).
Al ways remove t emporary spare ti re f rom servi ce
as soon as possi bl e.
Never exceed the maxi mum vehicle l oad rati ng
listed on ti re decal or ti re si dewal l .
Never dri ve faster than 80 k m/ h ( 50 mph) under
any ci rcumst ances.
Never dri ve on smooth t emporary spare ti re. The
compl ete t emporary spare ti re and wheel shoul d be
repl aced as an assembl y when t he t read dept h
reaches 1.52 mm (0. 06 inch) as shown by t read
wear i ndi cators in t read grooves.
Never use ti re chains wi th a t emporary spare ti re.
Never attempt t o repair a t emporary spare ti re or
remove if f rom the wheel .
Never use the wheel for any other t ype of ti re.
Never use a t emporary spare tire for ti re rotati on.
Never dri ve through an automati c car wash wi th a
t emporary spare ti re. The t emporary spare ti re
reduces ground cl earance, allowing the vehi cl e t o
get caught in t he car wash rails.
Avoi d driving over road hazards and through
pothol es. Si nce ground cl earance is reduced,
obst acl es may come in cont act wi th t he underside
of t he vehicle.
00- 03- 1 Ma i n t e n a n c e a n d L u b r i c a t i o n 00- 03- 1
SECTION 00-03 Maintenance and Lubrication
SUBJECT PAGE
VEHI CLE APPLICATION 00-03-1
DESCRIPTION
Engi ne Oil Vi scosi t y 00-03-2
Gasoli ne Oct ane Rati ng 00-03-2
Scheduled Mai nt enanceEmi ssi ons 00-03-1
Vehicle Emi ssi on Cont rol Information (VECI)
Decal .... 00-03-1
MAINTENANCE
Mai nt enance I nf ormat i on ..00-03-2
Normal Schedul e 00-03-6
SUBJECT PAGE
MAINTENANCE (Cont 'd. )
Owner Mai nt enance Checks ...00-03-2
Severe Duty Schedul e. . . 00-03-3
What Mai nt enance Schedul e Do You
Fol l ow? 00-03-2
LUBRICATION
Lubri cat i on Poi nt s 00-03-8
Servi ce Poi nt sChassi s 00-03-11
Servi ce Poi nt sEngi ne Compar t ment ....00-03-9
SPECIFICATIONS 00-03-12
VEHICLE APPLICATION
Town Car, Crown Vi ctori a, Grand Marqui s
DESCRIPTION
Vehicle Emission Cont rol Inf ormat i on (VECI)
Decal
Vacuum hoses on the engine use a col or stri pe t o aid in
hose routing checks. The stri pe will usually be the
same col or as on the Vehicle Emission Control
Information (VECI) decal , but the correct vacuum hose
routing must be verified by using the correct
component connecti ons shown on the VECI decal .
Ty pi c a l VECI Decal
ITHICl I f MISSION
.COIITRO!' itjf om.iAimrj *
COfilHOlr DrS H-.1ISSK
DU VFHICUIF
BCH6mMMt>MB&QN
TMt vehicle is equipped with electronic engine control
systems. Engine kite speed, Ms mtoure, and Ignition timing
are not adjustable. Sm Powsrtraki ConirolÊmissJons
Diagnosis Manual for ackfttonat Information.
To chock engine tinting set parking brake and block
wheels. Engine must be at norma) operating temperature,
transmission In neutral, and accessories off.
(1) Turn off engine.
(2) Disconnect the in-line Spout Connector ( =od ).
(3) Re-start previously warmed-up engine.
(4) Verify that the ignWon timing is 10BTDC. If not tea
shop manual.
(5) Turn engine off and restore electrical connection.
Use SAE SW-30 AMERICAN PETROLEUM INSTITUTE
CERTIFIED OILS tor GASOLINE ENGINES.
*ME<#OW
K U U
9pMk Ptug/Doufju:
AGSF-34PP
Ce vehtaul est i qui pi <ff tfspoWfs de command
etoctronique dy mottur. L regime d raterrtl, ts melange de
ralentj et le caJaga de Manage m sent pas regiables. Pour
de plus amptes, rerwignemtfrts, consulter Is Manuel de
diagnostic de la commande dtectrcnique du groupe
fnotoproputseur et dee digposltife antipoilution.
Pour verifier t'allumage, serrer le freln da stattonnement
et bfoquer les roues. Le moteur doit etre normalerrtent
chaud, la BV au pomt mort et tot accessoinas hors circuit.
(1) Arreter le moteur.
(2) Oebrancher le connecteur (=Qd ) irtfercaJe dans le
circuit de dectertehemerrt de fetlncelle.
(3) Redemarrer le moieur preaJabtement rechauffe.
(4) Conflrmer un cateft de 10avant PfafH. Si non
ccflforma, voir te manual de reparation.
(5) Amlter ie moteur et rebrancher le conneeteur.
Pour lee MOTEURS A ESSENCE, employer des
HUILES SAE SW30 HOMOLOGUEES PAR
L'AMERICAN PETROLEUM INSTITUTE.
A23307-A
Scheduled Mai nt enanceEmi ssi ons
The Emission Syst ems Required Mai ntenance
Schedul e lists the items required t o maintain vehicle
emission syst ems at levels determi ned by the Federal
Government (Environmental Protecti on Agency):
Mai ntenance servi ce adj ustments must conform t o:
Speci fi cati ons contai ned here and listed in the
Speci fi cati ons Manual.
Shown on the Vehicle Emission Control Information
Decal or the emissions syst em may become
inoperative.
As a safety precauti on, before starti ng the engine t o
perform maintenance, ensure:
DESCRI PT I ON ( Co n t i n u e d )
The transmission is in PARK.
The parki ng brake is set and the wheel s are
bl ocked.
Ga s o l i n e Oc t a n e Ra t i n g
All vehicles are designed t o use regular unleaded fuel
wi th an octane rating of 87. At servi ce stati ons, the I
octane rating is di spl ayed in a label on the pumps.
in some regions, " r egul ar " grade fuels are sol d wi th
oct ane ratings of 86 or lower. This is commonpl ace
in areas of high altitude.
It is not recommended to use such fuels.
Al ways use a fuel wi th an octane rating of 87, even
if it is sol d as a " mi dgr ade" or " pr emi um" .
Using a fuel wi th a lower oct ane rating can cause
persi stent and heavy knocki ng, whi ch can damage
the engine.
Do not be concerned if the engine someti mes
knocks lightly when you dri ve up a hill or when
accel erati ng. See a dealer or a qualified servi ce
techni ci an if, when using a fuel wi th the speci fi ed
oct ane rati ng:
Engine knocks heavily under all driving .
conditions.
Engine knock lightly while you drive at cruising
speed on level roads.
In most cases it should not be necessary t o use a
" pr emi um" grade of fuel wi th an oct ane rating of
higher than 87.
If the engine has difficulty starti ng, rough engine idle,
or hesitation when the engine is col d, it may be caused
by fuel wi th low volatility.
Trying a different grade and / or brand of fuel may
sol ve the condi ti on. If t he condition persi sts, see
your dealer or a qualified servi ce techni ci an.
E n g i n e Oi l V i s c o s i t y
Refer t o Lubri cant and Mai ntenance Materi al s
Speci fi cati ons tabl e.
MAINTENANCE
Ma i n t e n a n c e I n f o r ma t i o n
The required schedul ed mai ntenance servi ces listed in
thi s chapt er are essenti al t o t he proper operati on,
saf et y and performance of your Ford Mot or Company
vehi cl e. Al so perform t he Owner Mai ntenance Checks
l i sted. These servi ces are mat t ers of day-to-day care
that are also i mportant t o the proper operati on of your
vehi cl e. The recommended l ubri cants, fluids and
servi ce parts conformi ng to Ford Speci fi cati ons are
avai l abl e f rom your dealer.
Mai ntenance is an investment whi ch will pay di vi dends
in the f orm of i mproved reliability, durability, and resal e
value.
To assure the durability of your vehicle and its
emission control syst ems it is necessary that
schedul ed maintenance be perf ormed at the
desi gnated i nterval s.
Ford recommends the use of genuine Ford
repl acement part s. You may, however, elect t o have
mai ntenance, repl acement, or repair of the emissions
control devi ces and syst ems (the cost of whi ch is not
covered by warrant y) perf ormed by any automoti ve
repair establ i shment or individual and may el ect t o use
other than Ford servi ce part s for such maintenance or
repair. If other than Ford or Mot orcraf t parts or Ford
authori zed, remanufactured part s are used for
maintenance repl acements or for t he servi ce of
components affecti ng emissions control , the owner
should assure himself that such part s are warrant ed
by their manufacturer t o be equivalent t o genuine Ford
Mot or Company parts in performance and durability.
Please consult your warrant y bookl et for compl ete
warrant y information.
What Mai ntenance Schedule Do You Fol l ow?
Schedul es are based on how you dri ve your vehi cl e.
Fol l ow Severe Duty Schedule if your driving habi ts
MAINLY include one or more of the following
conditions:
Short tri ps of less than 10 miles (16 km) when
outside temperatures remain bel ow freezi ng.
Operati ng during hot weat her in stop-and-go " r ush
hour " traffi c.
Towing a trailer or using a car-t op carrier.
Operati ng in severe dust condi ti ons.
Extensi ve idling, such as pol i ce, t axi or door-to-door
delivery servi ce.
Fol l ow Normal Schedul e if, generally, you dri ve your
vehicle on a daily basi s for more than 10 miles ( 16 km)
and none of the conditions for Severe Duty Schedul e
appl y to your driving habi ts.
Refer t o the maintenance schedul e for maintenance
items and intervals for the appl i cabl e vehicle.
Owner Mai ntenance Checks
Li sted bel ow are vehicle checks and inspections that
should be performed by the owner or qualified servi ce
techni ci an at the intervals i ndi cated t o help ensure
safe, dependabl e operati on of your vehicle.
Any adverse conditions or concerns should be brought
to the attention of your deal er or qualified servi ce
techni ci an as soon as possi bl e.
These Owner Mai ntenance Checks are generally not
covered by warranti es and you may be charged for
labor, part s and lubricants used.
MAINTENANCE (Cont i nued)
Wh e n e v e r You Stop for Fuel
Check the engine oil level,
Check the windshield washer fluid level.
Look for low or under-inflated ti res.
At Leas t Mont hl y
Check the ti re pr essur echeck ti res when col d,
not after a long dri ve (including the spare).
Check cool ant in the radi ator cool ant recovery
reservoi r ( 8A080) .
Check the operati on of all exteri or l amps including
the stopl amps, turn signals and hazard warni ng
fl ashers.
At Leas t Twi c e A Year
Check windshield washer spray and wi per
operati on.
Check and repl ace worn windshield wi per bl ade
( 17528) .
Check for worn ti res and loose lug nuts.
Check pressure in spare ti re.
o Check headl amp alignment.
Check muffler ( 5230) , exhaust pi pes and cl amps.
Check the lap-shoulder safety belts for wear and
function.
Check radiator, heater and air conditioning hoses
for l eaks or damage.
At Leas t On c e A Year
Lubri cate all hinges, l atches and all outsi de door
l ock cyl i nders.
Lubri cate the door rubber weat herst ri ps.
Clean the body wat er drain holes.
Check the air conditioning syst em before the war m
weat her season.
Check the power steering fluid level.
Check the brake fluid level.
Clean the battery connecti ons.
Lubri cate the transmission control s and linkage.
Check the transmission fluid.
Refer t o the Lubri cant and Maintenance Materi al s
Speci fi cati ons tabl e for recommended lubricants.
NOTE: Rear axl e lube quantities must be repl aced
every 100, 000 miles ( 160, 000 km) or if the axl e has
been submerged in water. Otherwi se, the lube should
not be checked or changed unless a leak is suspected
or servi ce requi red.
While operati ng your vehicle:
Note any changes in the sound of the exhaust or
any smell of exhaust fumes in the vehi cl e.
Check for vi brati ons in the steeri ng wheel ( 3600) .
Noti ce any i ncreased steeri ng effort or l ooseness in
t he steeri ng wheel .
Noti ce if your vehi cl e consi stentl y turns slightly or
" pul l s" t o one si de of the road.
When stoppi ng, listen and check for strange
sounds, pulling t o one si de, i ncreased brake pedal
travel or hard t o push brake pedal .
If any slipping or changes in the operati on of your
transmi ssi on occurs, check t he transmi ssi on fluid
level.
Check for fluid l eaks under your vehi cl e (wat er
dri ppi ng f rom the air conditioning syst em after use is
normal ).
Check automati c transmi ssi on PARK functi on.
Check parki ng brake.
If any of these condi ti ons are noted, bring t hem t o t he
attenti on of your dealer or qualified servi ce techni ci an
as soon as possi bl e.
Severe Duty Schedule
Servi ce intervals Perform at t he di stances or
months shown, whi chever occurs fi rst.
FOR ITEMS MARKED WITH A NUMBER IN
PARENTHESES SUCH AS (1), SEE FOOTNOTE AT
THE END OF THE APPROPRIATE MAINTENANCE
SCHEDULE.
been submerged in water. Otherwi se, the lube shoul d
not be checked or changed unless a leak is suspect ed
NOTE: The Town Car is equi pped wi t h a vehicle
maintenance monitor (VMM). Change oil and filter
when indicated by VMM, but do not go beyond 7, 500
miles ( 12, 000 km) or 6 months, whi chever occurs
fi rst.
NOTE: Severe Duty Schedule provi des mai ntenance
intervals for replacing your air cl eaner element if you
dri ve in severe dust conditions. However, the
condi ti ons you dri ve in may require even more frequent
air cl eaner repl acement intervals than those shown.
Check wi t h your dealer.
Check engine cool ant protecti on, hoses and cl amps
once a year
1
.
1 I t e m f o r E mi s s i o n Co n t r o l Se r v i c e .
00- 03- 4
^ ^ ^ ^ ^ ^
mmttmrnm
00- 03- 4
MAINTENANCE (Cont i nued)
Every 6 months l ubri cate hood l atch pivot points,
internal cont act areas and external hood l atch
areas that make cont act wi th the hood st ri ker
2
.
Repl ace engine cool ant every 36 mont hs
2
.
NOTE: Ki l ometer intervals are rounded off.
3 , 0 0 0 MI L ES ( 5 , 0 0 0 Ki l omet er s )
Change engine oil and oil filter ( 6731) every 3, 000
miles ( 5, 000 km) or 3 mont hs
2
.
6 , 0 0 0 MI LES ( 1 0 , 0 0 0 Ki l o me t e r s )
Change engine oil and oil filter every 3, 000 miles
( 5, 000 km) or 3 mont hs
2
.
Rotate ti res and adjust air pressure.
9 , 0 0 0 MI LES ( 1 5 , 0 0 0 Ki l o me t e r s )
2
.
1 2 , 0 0 0 MI LES ( 2 0 , 0 0 0 Ki l o me t e r s )
2
.
1 5 , 0 0 0 MI LES ( 2 5 , 0 0 0 K i l o me t e r s )
2
.
Inspect engine cool i ng syst em, hoses and cl amps;
and check cool ant strength every 15, 000 miles
( 25, 000 km) or 12 months.
Lubri cate suspension (Town Car).
Lubri cate steeri ng linkage (Town Car).
9 Rotate ti res and adjust air pressure.
9 Change engine oil and oil filter every 3, 000 miles
2
.
Change automati c transmi ssi on fluid.
2
.
2
.
Rotate ti res and adj ust air pressure.
2
.
2
.
and check cool ant st rengt h every 15, 000 miles
( 25, 000 km) or 12 mont hs.
Repl ace spark plugs ( 12405) .
Repl ace air cleaner element (ACL el ement ) ( 9601)
2
.
Inspect exhaust heat shi el ds.
Inspect front and rear brake shoes and linings
( 2001) and front di sc brake rotor (1125)(s) and rear
di sc brake rot ors ( 2C026) (if equi pped). (2)
Lubri cate steeri ng linkage.
3 3 , 0 0 0 MI L ES ( 5 5 , 0 0 0 Ki l o me t e r s )
2
.
3 6 , 0 0 0 MI L ES ( 6 0 , 0 0 0 Ki l o me t e r s )
2
.
3 9 , 0 0 0 MI L E S ( 6 5 , 0 0 0 Ki l o me t e r s )
2
.
Chance automati c transmi ssi on fluid.
2
.
2
.
Inspect engine cool i ng syst em, hoses and cl amps:
( 25, 000 km) or 12 mont hs
2
.
2
Change engine cool ant initially at 48, 000 miles
( 80, 000 km) or 48 months. Thereafter, change
engine cool ant every 30, 000 miles ( 50, 000 km) or
36 mont hs
2
.
5 1 , 0 0 0 MI L E S ( 8 5 , 0 0 0 K i l o me t e r s )
2
.
5 4 , 0 0 0 MI L E S ( 9 0 , 0 0 0 K i l o me t e r s )
2
.
5 7 , 0 0 0 MI L E S ( 9 5 , 0 0 0 Ki l omet er s )
2
.
2 I t e m f or E mi s s i o n Co n t r o l Se r v i c e .
Mai nt enance and L u b r i c a t i o n 00- 03- 5
MAINTENANCE (Conti nued)
6 0 , 0 0 0 MI LES ( 1 0 0 , 0 0 0 Ki l omet er s )
3
.
Inspect engine cooling syst em, hoses and cl amps:
( 25, 000 km) or 12 mont hs
3
.
Repl ace engine coolant every 30, 000 miles ( 50, 000
km) or 36 mont hs
3
.
Repl ace positive crankcase ventilation valve (PCV
val ve) ( 6A666)
3
.
Repl ace spark pl ugs.(2)
Inspect accessory drive belts ( 8620)
3
.
i nspect exhaust heat shields.
Inspect front and rear brake shoes and linings and
front disc brake rotor(s) and rear disc brake rotors
(if equi pped). (2)
Lubri cate steering l i nkage
3
.
Repl ace air cleaner el ement
3
. (1)
3
.
3
.
3
.
3
.
3
.
Inspect engine cooling syst em, hoses and cl amps;
and check cool ant strength every 15, 000 ( 25, 000
km) or 12 mont hs
3
.
3
.
8 0 , 0 0 0 MILES ( 1 2 8 , 7 2 0 Kilometers)
Repl ace cool ant every 80, 000 miles ( 128, 720 km)
or 84 months.
3
.
3
.
3
.
3
.
( 25, 000 km) or 12 mont hs
3
.
Repl ace spark pl ugs
3
.
Inspect accessory dri ve bel t s
3
.
3
. (1)
Inspect exhaust heat shi el ds.
front di sc brake rot ors and rear di sc brake rot ors (if
equi pped). (2)
3
.
3
.
3
.
1 0 0 , 0 0 0 MI LES ( 1 6 0 , 0 0 0 Ki l omet er s )
Repl ace rear axl e lubricant.
3
.
00- 03- 6 Mai nt enance and Lubr i cat i on
00- 03- 8
MAINTEIv/
:
-i."-!-' r > nt i nued)
1 0 5 , 0 0 0 MILES f 1 7 6 , 0 0 0 Ki l o me t e r s )
4
.
and check coolant strength every 15, 000 miles
( 25, 000 km) or 12 mont hs
4
.
1 0 8 , 0 0 0 MI LES ( 1 8 0 , 0 0 0 Ki l o me t e r s )
4
.
Change engine cool ant every 30, 000 miles ( 50, 000
km) or 36 months.
4
.
4
.
4
.
4
.
Inspect engine cooling syst em, hose and cl amps;
( 25, 000 km) or 12 months.
Repl ace posi ti ve crankcase ventilation val ves
4
.
4
.
Inspect accessory drive bel t s
4
.
@ inspect exhaust heat shields.
front di sc brake rot ors and rear disc brake rot ors (if
equi pped). (2)
Lubri cate suspensi on (Town Car).
4
. (1)
been submerged in water. Otherwi se, the lube should
(1) If operati ng in severe dust, more frequent intervals
may be requi red. Consult your dealer.
(2) If your driving includes continuous stop-and-go
driving or driving in mountainous areas, more
frequent intervals may be requi red.
(3) At 60, 000 miles (96, 000 km) your deal er will
repl ace the positive crankcase ventilation val ve at
no cost expect California and Canada vehi cl es.
No r ma l Sc h e d u l e
Service intervals Perform at the months or
di stances shown, whi chever occurs fi rst.
FOR ITEMS MARKED WITH NUMBER IN
PARENTHESES SUCH AS (1), SEE FOOTNOTE AT
THE END OF THE APPROPRIATE MAINTENANCE
SCHEDULE.
NOTE: Ki l ometer intervals are rounded off.
Check engine cool ant protecti on, hoses and cl amps
once a year
4
.
Every 6 months l ubri cate hood l atch pivot poi nts,
internal cont act areas and external hood l atch
areas that make cont act wi th the hood stri ker.
Repl ace engine cool ant every 36 mont hs
4
.
5 , 0 0 0 MI LES ( 8 , 0 0 0 Ki l omet er s )
Change engine oil and oil filter ( 6731) every 5, 000
miles ( 8, 000 km) or 6 mont hs
4
.
1 0 , 0 0 0 MI LES ( 1 6 , 0 0 0 Ki l omet er s )
4
.
4
.
( 24, 000 km) or 12 mont hs
4
.
Lubri cate steeri ng linkage (Crown Vi ct ori a, Grand
Marqui s).
Rotate tires and adjust air pressure.
4
.
4
.
4
.
4 I t e m f o r E mi s s i o n Co n t r o l Se r v i c e
00- 03- 7 Maintenance and Lubrication 00- 03- 7
j Inspect engine cool i ng syst em, hoses and cl amps;
! ( 24, 000 km) or 12 mont hs
5
.
j Repl ace spark plugs ( 12405)
5
.
Repl ace air cleaner element (ACL el ement ) ( 9601)
5
.
(1)
Inspect exhaust heat shields.
! Every 6 months lubricate hood l atch pivot poi nts,
| internal cont act areas and external hood l atch
areas that make cont act wi th the hood striker.
| Lubri cate suspension (Town Car).
! Lubri cate steering linkage.
j ( 8, 000 km) or 6 mont hs
5
.
6
.
5
.
( 24, 000 km) or 12 mont hs
5
.
5
.
Change engine cool ant initially at 50, 000 miles
( 80, 000 km) or 48 months. Thereafter, change
engine cool ant every 30, 000 miles ( 48, 000 km) or
36 months.
5
.
5
.
( 24, 000 km) or 12 mont hs
5
.
5
.
5
. (1)
Repl ace positive crankcase ventilation valve (PCV
val ve) ( 6A666)
5
. (3)
Inspect accessor y dri ve bel ts ( 8620)
5
.
Inspect front and rear brake shoes and linings
( 2001) and front di sc brake rot ors ( 1125) and rear
di sc brake rot ors ( 2C026) (if equi pped). (2)
Inspect exhaust heat shields.
Lubri cate steeri ng l i nkage (Town Car).
Lubri cate suspensi on (Town Car).
5
.
5
.
5
.
( 24, 000 km) or 12 mont hs
5
.
5
.
Repl ace engine cool ant every 30, 000 miles ( 48, 000
km) or 36 months.
( 8, 000 km) ( 1)
5
.
( 8, 000 km)
5
. ( 1)
( 24, 000 km) or 12 mont hs
5
.
5
.
5
.
5
. (1)
Inspect exhaust heat shi el d(s).
front di sc brake rot ors and rear di sc brake rot ors (if
equi pped). (2)
Lubri cate steeri ng l i nkage (Town Car).
00- 03- 8 Mai nt enance and Lubr i cat i on 00- 03- 8
9 5 , 0 0 0 MI LES ( 1 5 2 , 0 0 0 Kilometers)
( 8, 000 km) .(1)
( 8, 000 k mf . ( D
Repl ace rear axl e lubricant.
( 8, 000 k mf . ( 1)
( 24, 000 km) or 12 mont hs
6
.
( 8, 000 km) \ ( 1)
Repl ace engine cool ant every 30, 000 miles ( 48, 000
km) or 36 mont hs
6
.
( 8, 000 k mf . ( 1)
( 8, 000 km) .(1)
6
.
6
.
Repl ace air cl eaner el ement
6
. (1)
Repl ace posi ti ve crankcase ventilation val ve
6
.
( 24, 000 km) or 12 mont hs
6
.
Change automati c transmi ssi on f l ui d
6
.
Inspect exhaust heat shi el d(s)
6
.
front di sc brake rotors and rear di sc brake rot ors (if
equi pped). (2)
been submerged in water. Ot herwi se, the lube should
(1) If operati ng in severe dust, more frequent intervals
may be requi red. Consult your dealer.
(2) If your driving includes continuous stop-and-go
driving or driving in mountainous areas, more
frequent intervals may be requi red.
(3) At 60, 000 miles ( 96, 000 km) your dealer will
repl ace posi ti ve crankcase ventilation val ve at no
cost except California and Canada vehicles.
LUBRICATION
L u b r i c a t i o n P o i n t s
The illustrations show typi cal chassi s and engine
servi ce and lubrication poi nts. Vehicles wi th optional or
speci al equipment may have slightly different or
additional lubrication poi nts. i
LUBRICATION (Cont i nued)
Servi ce Poi nt sEngi ne Compartment
4. 6L Engi ne
2
z > *
Cjfeo 1 or-
P Mot a oa RH
Y3072-F
00- 03- 10 Mai nt enance and L u b r i c a t i o n
LUBRICATION (Conti nued)
0 0 - 0 3 - 1 0
Par t
I t em Number Descr i pt i on
1 7A020 Transmission Fluid Level
Indicator
2 6750 Engine Oil Level Indicator
3 2K478 Brake Master Cylinder
Reservoir
4 3E764 Power Steering Pump
Auxiliary Reservoir
5 17618 Windshield Washer
Reservoir
6 9601 Engine Air Cleaner Element
7 6714 Oil Bypass Filter
(Continued)
Pa r t
I t e m Nu mb e r De s c r i p t i o n
8 6766 Oil Filler Cap
9 10653 Battery
10 8A080 Radiator Coolant Recovery
Reservoir
11 6730 Engine Oil Pan Drain Plug
A Keep Fluid in this Range at
Normal Operating
Temperature
B Normal Level when Vehicle
Has Not Been Driven
C Keep Oil in this Range
00- 03- 11 Maintenance and Lubr i cat i on 00- 03- 11
LUBRICATION (Cont i nued)
Servi ce PointsChassis
Cha ssi s Lubri cat i on Poi nt s
LUBRICATION POINT
VIEW A
V I E W !
VIEWC
PARKING BRAKE LINKAGE
LUBRICATE CABLE GUIDES, LEVERS, AND
LINKAGE AS REQ'D
VIEWE
VIEW A
BALL JOINTS
NOTE: BALL JOINTS A
REQUIRING LUBRICATION ^
(LOWER ONLY)
VIEWB
STEERING STOP PADS
LUBRICATE SURFACES
VIEWC
IF REQUIRED, FILL AXLE 6.35 mm (1/4 9/16
INCH) BELOW BOTTOM OF FILLER HOLE
VJEWD
Y1119-V
00- 03- 12
SPECIFICATIONS
Maintenance and L u b r i c a t i o n 00- 03- 12
LUBRICANT AND MAINTENANCE MATERIALS SPECIFICATIONS
De s c r i p t i o n P a r t N a me F o r d P a r t d u m b e r | F o r d S p e c i f i c a t i o n
Hi n ge s , Hi n ge C h e c k s a n d
P i v o t s ,
Do o r L a t c h e s
H o o d L a t c h a n d Au x i l i a r y C a t c h
L u g g a g e Co mp a r t me n t Do o r
L a t c h e s
P a r ki n g Br a ke Ca b l e
Mu l t i - P u r p o s e G r e a s e Sp r a y D7 A Z - 19584- A A E SB- M1C106- B
L o c k Cy l i n d e r s L o c k L u b r i c a n t D8A Z - 19587 - A A E SB- M2 C2 0- A
Re a r A x l e ( Al l ) Co n v e n t i o n a l a n d
T r a c t i o n - L o k
Re a r A x l e L u b r i c a n t X Y - 8 0 W 9 0 - QL
a b
WS P - M2 C197 - A
T r a n s mi s s i o n ( 4R7 0W) Mo t o r c r a f t MERCON
A u t o . Tr a n s . Fl ui d
XT- 2 - QDX ME RCON
En gi n e Oi l Fi l t e r L o n g- L i f e Oi l Fi l t e r F1A Z - 67 31- A ( FL - 82 0) E S- F1A E - 67 14- A B
En gi n e Oi l MOTORCRA FT:
5 W3 0 Su pe r P r e mi um
10W30 Supe r Pr e mi um
X O- 5W30- QSP
X O- 10W30- QS P
E SE - M2 C153- E a n d
API Ce r t i f i c a t i o n Ma r k
S p e e d o me t e r Ca b l e S p e e d o me t e r Ca b l e G r e a s e E 6TZ - 19581- A E SF- M1C160- A
En gi n e Co o l a n t P r e mi u m Co o l i n g S y s t e m Fl ui d E 2 F Z - 1 9 5 4 9 - A A o r B E SE - M97 B44- A
Br a ke Ma s t e r Cy l i n d e r Fo r d Hi gh P e r f o r ma n c e DOT
Br a ke Fl ui d
C6A Z - 19542 - A A E SA - M6C2 5- A
Di s c Br a ke Ca l i pe r a n d A n c h o r
P l a t e Sl i d e s
Di s c Br a ke Ca l i p e r G r e a s e D7 A Z - 19590- A
b
E SA - M1C17 2 - A
Ti r e Mo u n t i n g Be a d ( o f Ti r e ) Ti r e Mo u n t i n g L u b e E SR- M99B135- A
Br a ke Ma s t e r Cy l i n d e r P u s h
Ro d a n d Bu s h i n g
Br a ke P e d a l Pi v o t Bu s h i n g
Mo t o r c r a f t SA E 10W- 30 En gi n e
Oi l
X O- 10W30- QSP E SE - M2 C153- E a n d API
Ce r t i f i c a t i o n Ma r k
Fr o n t Su s p e n s i o n Ba l l J o i n t s
St e e r i n g L i n ka g e
St e e r i n g A r m S t o p s
P r e mi um L o n g L i f e G r e a s e XG- 1- C o r X G - 1 - K E SA - M1C7 5- B
a Us e WS P - M2 C197 - A ( X Y- 80W90- QL ) o r e q ui v a l e n t pl u s 59 ml ( 2 o z) of f r i c t i o n mo d i f i e r F3T Z - 19B546- MA o r e q u i v a l e n t me e t i n g Fo r d
s p e c i f i c a t i o n WS P - M2 C196- A f o r t r a c t i o n - l o k r e a r a x l e s ,
b Re a r a x l e l u b e q u a n t i t i e s must b e r e p l a c e d e v e r y 160, 000 km ( 100, 000 mi l e s) or if t h e a x l e h a s b e e n s u b me r g e d i n wa t e r . Ot h e r wi s e , t h e
l ube s h o u l d n o t b e c h e c k e d o r c h a n g e d un l e s s a l e a k i s s u s p e c t e d o r s e r v i c e r e q u i r e d .
REFILL CAPACITIES
C o m p o n e n t U. S. I mp . Me t r i c
C o o l i n g
S y s t e m
( i n c l u d i n g
h e a t e r ) Al l
e n gi n e s
14. 1 q t s . 11. 7 q t s . 13. 3 l i t e r s
E n g i n e O i l
8
( wi t h f i l t e r
c h a n g e )
5. 0 q t s . 4. 2 q t s . 4. 7 l i t e r s
T r a n s m i s s i o n
8
13. 6 q t s 11. 3 q t s . 12. 9 l i t e r s
P o w e r
S t e e r i n g
b
To wn Ca r
Cr o wn
Vi c t o r i a ,
Gr a n d
Ma r q u i s w /
Co o l e r
3. 5 p i n t s
2. 6 p i n t s
3. 0 pi n t s
2. 2 pi n t s
1.7 l i t e r s
1.2 l i t e r s
( Co n t i n u e d )
REFILL CAPACITIES (Cont ' d)
w / o Co o l e r 2. 2 pi n t s 1.8 p i n t s 1.1 l i t e r s
Re a r A x l e
c
8. 8 i n c h r i n g
g e a r
( c o n v e n t i o n a l
a n d
T r a c t i o n - L o k)
3. 7 5 pi n t s 3. 3 pi n t s 1.8 l i t e r s
Fu e l T a n k 2 0. 0 ga l l o n s " 16. 7 ga l l o n s 7 5. 7 l i t e r s
Wi n d s h i e l d
Wa s h e r
Re s e r v o i r
2. 1 q t s . 1.8 q t s . 2. 0 l i t e r s
SPECIFICATIONS (Cont i nued)
REFILL CAPACITIES (Cont 'd)
Ra d i a t o r
P r e s s u r e
C a p
16p s i 1 1 0 k P a
a Di p s t i c k i s u s e d t o d e t e r mi n e t h e e x a c t f i l l r e q u i r e me n t s .
b Fo r p o we r s t e e r i n g pump r e s e r v o i r wi t h c o mb i n a t i o n c a p
a n d d i p s t i c k: P l e a s e n o t e t h e a r r o ws t h a t i n d i c a t e c o r r e c t
f l ui d l e v e l . On e s i d e of t h e d i p s t i c k s h o ws FUL L HOT a n d
t h e o p p o s i t e s i d e s h o w s FUL L COL D. Fl ui d i s a t c o r r e c t
l e v e l if i t l i e s b e t we e n t h e a r r o ws , d e p e n d i n g o n wh e t h e r
f l ui d i s ho t o r c o l d . Fo r r e s e r v o i r wi t h o u t c o mb i n a t i o n c a p
a n d d i p s t i c k: Fl ui d i s a t c o r r e c t l e v e l if i t l i e s b e t we e n MI N
a n d MA X l i n e s. DO NOT OVE RFI L L P OWE R STEERI NG
FLUI D.
c Se r v i c e r e f i l i c a p a c i t i e s a r e d e t e r mi n e d by f i l l i n g t h e r e a r
a x l e 6. 4 mm t o 14. 2 mm (114 i n c h t o 9 / 1 6 i n c h) b e l o w
b o t t o m of f i l l e r h o l e .
d Ve h i c l e ma y be e q u i p p e d wi t h a n 68. 1 l i t e r ( 18. 0 ga l l o n ) f ue l
t a n k.
00- 04- 1 Noise, Vibration and Harshness 0 0 0 4 1
SECTION 00-04 Noise, Vibration and Harshness
SUBJECT PAGE
Di agnost i c Theory 00-04-1
DIAGNOSIS AND TESTING
I nspect i on and Veri f i cat i on 00-04-2
I dent i f yi ng t he Condi t i on 00-04-2
Noi se Di agnost i c Procedure 00-04-2
Road Test 00-04-6
Pi npoi nt Test s 00-04-9
Sy mpt om Chart 00-04-9
SUBJECT PAGE
GLOSSARY OF TERMS
Terms 00-04-19
ADJUSTMENTS
Bal anci ng, Dri veshaf t 00-04-21
Mat ch Mount i ng Ti res 00-04-22
Wheel s, Di st or t ed 00-04-22
SERVICE PROCEDURES
Exhaust Sy st em, Neut ral i zi ng 00-04-22
SPECIAL SERVICE TOOLS/EQUIPMENT 00-04-23
VEHICLE APPLICATION
Town Car, Cr own Vi c t or i a , Gr and Marqui s
Di agnosti c Theory
Di agnosi s is more t han j ust f ol l owi ng a ser i es of
i nt errel at ed st e ps in or der t o f i nd t he sol ut i on t o a
speci f i c condi t i on. It is a wa y of l ooki ng at sy st e ms
t hat ar e not f unct i oni ng t he wa y t hey shoul d and f i ndi ng
out why . Al so it is knowi ng how t he sy st e m shoul d
wo r k and whet her it is wo r ki n g c or r e c t l y .
Ther e ar e basi c rul es f or di agnosi s. If t hese rul es ar e
f ol l owe d, t he cause of t he condi t i on i s usual l y f ound
t he f i rst t i me t hr ough t he sy st e m.
Know the System
Kn o w how t he pa r t s go t oget her.
Kn o w how t he sy st e m ope r a t e s as wel l a s i t s li mi t s
and wha t happens whe n somet hi ng goe s wr o n g.
Somet i mes t hi s means c he c ki ng t he sy st e m agai nst
one t hat i s known t o be wor ki ng pr oper l y.
Know the History of t he System
Ho w ol d or new i s t he sy st e m?
Wha t ki nd of t r eat ment has it had?
Has it been ser vi ced in t he pa st in suc h a manner
t hat mi ght r el at e t o t he present condi t i on?
Wha t i s t he ser vi ce hi st or y ?
A cl ue in any one of t he se a r e a s mi ght sa ve t i me.
Know t h e History of t he Condition
Di d if st ar t suddenl y or di d it a ppe a r gradual l y?
Wa s it r el at ed t o some ot her oc c ur r e nc e l i ke a
col l i si on or previ ous pa r t r epl acement ?
Kn o w how t he condi t i on made i tself kn o wn , it may
be an i mport ant cl ue t o t he c a use .
Know the Probability of Certain Conditions
Developing
Look f or t he si mpl e rat her t han t he compl ex.
For exampl e:
El ect ri cal condi t i ons usually occur at
connect i ons rat her t han in component s.
An engi ne no st a r t i s mor e li kely t o be c a use d by
a l oose wi r e or some component out of
adj ust ment t han a sheared-of f camshaf t .
Know t he di f f erence bet ween i mpossi bl e and
i mprobabl e. Cert ai n f ai l ures in a sy st e m c a n be
i mprobabl e but sti ll happen.
New pa r t s ar e j ust t ha t . It doe s not mean t hey ar e
a l wa y s go o d f unct i oni ng pa r t s.
Do Not Cure the Symptom and Leave the Cause
Lower i ng t he ai r pr essur e in a f r ont t i re may c or r e c t
t he condi t i on of a vehi cl e l eani ng t o one si de, but it
does not c o r r e c t t he ori gi nal c onc e r n.
Be Positive the Cause is Found
Doubl e c he c k f i ndi ngs.
What c a use d a wo r n component .
A l oose t ransmi ssi on or engi ne mount coul d i ndi cat e
t hat ot her mount s ar e al so l oose.
Diagnosis Charts
Char t s ar e si mpl y a wa y of expr essi ng t he rel at i onshi p
bet ween basi c logi c and a physi cal sy st e m of
component s. They hel p corner t he cause of a
condi t i on in t he shor t e st possi bl e amount of t i me.
Di agnosi s c ha r t s combi ne many ar eas of di agnosi s
i nto one vi sual di spl ay:
00- 04- 2 No i se , Vibration and Harshness
00- 04- 2
Probability of certai n things occurri ng in a syst em.
Speed of checki ng certai n components or functi ons,
before ot hers.
Simplicity of performi ng certai n t est s before ot hers.
e Elimination of checki ng huge porti ons of a syst em
by performi ng si mpl e t est s.
Certai nty of narrowi ng down t he search t o a small
porti on before performi ng in-depth testi ng.
The f ast est way t o find a condition is t o work wi t h the
tool s that are avai l abl e. Thi s means worki ng wi th
proven di agnosi s char t s and t he proper special
equipment for t he syst em.
Inspection a n d Ve r i f i c a t i o n
1. Verify the vehi cl e owner' s original concern by
operati ng the vehi cl e t o dupl i cate the condi ti on.
2. If the inspection reveal s obvi ous concern(s) that
can be readily identified, servi ce as requi red.
3. If the concern(s) remai ns after the i nspecti on,
determine the sympt om(s) and proceed t o t he
Sympt om Chart.
How To Use This Di a g n o s t i c P r o c e d u r e S e c t i o n
Noi se, vibration and harshness di agnosi s (NVH in
engineering short hand) is becomi ng more and more
i mportant as vehi cl es are becomi ng more sensitive t o
these vi brati ons. This secti on is desi gned t o aid in
identifying t hese si tuati ons. Thi s secti on is di vi ded into
several subsecti ons, based on t he descri pti on of the
condi ti on. If t he condition occurs at high speed, for
i nstance, the most likely pl ace t o st art is under High
Speed Shake.
The Road Test secti on will tell how t o sort out the
conditions into cat egori es and how t o tell a vibration
f rom a shake.
The secti on will gi ve a f ew hints on quick checks t o
make sure that a cause is either pinpointed or
eliminated.
Use the Gl ossary t o become familiar wi th the t erms.
Name the condi ti on, proceed t o t he secti on
identifying t he condi ti on, and l ocat e the proper
di agnosi s.
Fol l ow the st eps within the sect i on.
Qui ck Checks are descri bed within the st ep, whi l e
more involved t est s and adj ustments are found in
Servi ce Procedures and Adj ustments.
Al ways fol l ow each st ep exact l y and make notes
along the way t o recal l i mportant findings later.
Customer I n t e r v i e w
The road t est and cust omer interview (if available)
provi de information that will help identify the concern
and will provi de di recti on t o the correct starti ng point
for di agnosi s.
I d e n t i f y i n g t h e C o n d i t i o n
Noi se, vi brati on, and harshness (NVH) usually occur in
four areas:
Tires
Engine accessori es
Suspension
Driveline
it is i mportant, t heref ore, that an NVH concern be
i sol ated into its speci fi c area as soon as possi bl e. The
easi est and qui ckest way t o do thi s is t o perform a
road t est as outlined.
No i s e Di a g n o s t i c P r o c e d u r e
No n - A x l e No i se
There are a f ew other condi ti ons that can sound j ust
like axl e noise and have t o be consi dered while
performi ng road t est di agnosi s. The fi ve most common
are exhaust , ti res, roof r acks, tri m mouldings and
transmi ssi on.
Theref ore, ensure that none of the fol l owi ng condi ti ons
are t he cause of t he noise before proceedi ng wi t h an
axl e t eardown and di agnosi s.
1. In certai n condi ti ons, t he pi tch of t he exhaust may
sound very much like gear whi nes. At other ti mes,
it can be mi staken for a wheel beari ng rumble.
2. Ti res, especi al l y snow ti res, can have a
hi gh-pi tched t read whi ne or roar, similar t o gear
noise. Radial ti res, t o some degree, have thi s
charact eri st i c. Al so, any non-standard ti re wi th
an unusual t read constructi on may emit a roar or
whi ne-type noise.
3. Trim and mouldings can al so cause whistling or
whining noise.
4. Clunk may be a metallic noise heard when the
automati c transmi ssi on is engaged in REVERSE
or DRIVE, or it may occur when throttl e is appl i ed
or rel eased. It is caused by backl ash somewhere
in the driveline; it is felt or heard in t he axl e.
5. Beari ng whine is a high-pitched sound similar t o a
whi stl e. It is usually caused by malfunctioning
pinion beari ngs, whi ch are operati ng at dri veshaft
speed. Roller wheel beari ngs may whi ne the
same way if they run compl etel y dry. Bearing
noise occurs at all driving speeds; thi s
distinguishes it f rom gear whi ne, whi ch usually
comes and goes as speed changes.
6. Beari ng rumble sounds like marbl es being
tumbl ed. This condition is usually caused by a
malfunctioning wheel beari ng. The l ower pi tch is
because t he wheel bearing turns at only about
one-third of dri ve shaft speed.
00-04-3 Noise, Vibration and Harshness 00- 04- 3
DIAGNOSIS AND TESTING (Cont i nued)
7. Beari ng noi se. Wheel beari ng noi se mi ght be
mi st aken f or pinion beari ng noi se, so a l wa y s l ook
at t he wheel beari ng caref ul l y bef or e t eari ng
down t he axl e. As not ed earl i er, pinion beari ngs
ma ke a hi gh-pi t ched, whi st l i ng noi se, usually at all
spe e ds. However, if t he r e i s only one pinion
beari ng t hat i s mal f unct i oni ng, t he noi se may va r y
in di f f erent dri vi ng pha se s. If a pinion beari ng i s
suspe c t e d, ref er t o Sect i on 05-02A.
S P A L L E D
S P A L L E D DA MA G E D
ROL L E R ROL L E RS
E3760-E
Rear wheel beari ngs ( 1225) ar e pr e sse d i nt o t he axl e
housi ng, maki ng it mor e di f f i cul t t o c he c k t he m.
However, t he axl e shaf t i s t he inner r a c e f or t he
beari ng. So if t he rear wheel beari ngs ar e da ma ge d,
t he roller sur f ace on t he shaf t wi ll be da ma ge d a s wel l .
The rol l ers run on about t he cent er of t he pol i shed
sur f ace.
E3761-D
Noise Conditions
1. Gear noi se i s t he t y pi cal howl i ng or whi ni ng of t he
ri ng gear and pinion due t o an i mproper gear
pat t er n, gear da ma ge , or i mproper beari ng
pr el oad. It c a n occur at vari ous spe e ds and
dri vi ng condi t i ons or it can be cont i nuous.
2. Chuckl e i s a part i cul ar rat t l i ng noi se t hat sounds
li ke a st i c k agai nst t he spo ke s of a spi nni ng
bi cycl e wheel . If o c c ur s whi l e decel erat i ng f r o m
64 km / h ( 40 mph) and can usually be hear d all
t he wa y t o a st o p. The f r equency vari es wi t h t he
speed of t he vehi cl e.
3. Knoc k i s ve r y si mi lar t o chuckl e; t hough it ma y be
louder and o c c ur s on accel erat i on or
decel er at i on. The t e a r down wi ll di scl ose wha t
has t o be c o r r e c t e d .
4. Chat t er on c or ne r s i s a condi t i on whe r e t he whol e
rear end vi br at es onl y when t he vehi cl e i s movi ng.
The vi brat i on i s plai nly f el t a s wel l a s he a r d, in
convent i onal a xl e s, e x t r a di f f erent i al t hrust
wa she r s c a use a condi t i on of part i al l ockup t hat
c r e a t e s t hi s chat t er . Chat t er noi se on
Tract i on-Lok axl es can usually be t r a c e d t o
er r at i c movement bet ween adj acent cl ut ch
component s and can somet i mes be c o r r e c t e d
wi t h a l ubri cant change and t he addi t i on of a
f ri ct i on modi f i er.
5. Cl i ck at engagement i s a condi t i on when t he axl e
pr oduces a sl i ght noi se, di st i nct f r om a cl unk, t ha t
happens in REVERSE or DRIVE engagement .
Check f or t he pr esence of a pinion oi l sli nger.
6. Axl e shaf t noi se i s si mi lar t o gear noi se and pi ni on
beari ng whi ne. However, rear wheel shaf t beari ng
noi se wi ll normal l y di st i ngui sh i tself f r om gear
noi se by occur r i ng in all dri vi ng modes (dri ve,
c oa st and f l oat ) and wi ll persi st wi t h t ransmi ssi on
in NEUTRAL whi l e vehi cl e i s movi ng at pr obl em
spe e d. If upon ri de eval uat i on, vehi cl e di spl ays
above noi se condi t i on, r emove suspect axl e
shaf t s, r epl ace wheel seal s and install a new set
of axl e shaf t s. Re-eval uat e vehi cl e f or noi se
bef ore removi ng any i nternal component s.
7. Boom i s a condi t i on t hat e xi st s when ri ng gear
t eet h have a runout of mor e t han 0. 10 mm ( 0. 004
i nch).
Any damage t o a gear t o o t h on t he c oa st si de can
cause a noi se i dent i cal t o chuckl e. Even a ver y smal l
t oot h ni ck or ri dge on t he edge of a t oot h is enough t o
cause t he noi se.
Thi s condi t i on can be c o r r e c t e d and t he noi se
el i mi nat ed by cl eani ng up t he gear t oot h ni ck or ri dge
wi t h a small gri ndi ng whe e l . If t he cl eaned up or
da ma ge d ar ea i s l arger t han 3.2 mm ( 1 / 8 i nch), it i s
advi sabl e t o repl ace t he gear set .
If ei t her gear i s sc o r e d or da ma ge d badl y, t he gear set
must be r epl aced. Al so, if met al has br oken l oose, t he
carri er and housi ng must be cl eaned t o r emove
part i cl es t hat coul d cause da ma ge later. Any ot her
damaged pa r t s in t he axl e must be r epl aced.
No i s e , Vibration and Harshness
- T ... v.-.zwz~~
00- 04- 4
T7:T:IT7.~~...WZZ ^..".zzwrrr rr^rrzi
DIAGNOSIS AND TESTING (Conti nued)
To check t he gearset, remove as much lubricant as
possi bl e f rom the gears wi t h clean sol vent. Wi pe the
gears dry or bl ow them dry wi t h compressed air. Look
for scored or damaged t eet h. Al so look for cr acks or
other damage.
Damaged Gear Teet h
E37S4-D
Scor ed Gear Te e t h
E3755-D
When di sassembl i ng t he axl e t o di agnose and correct
gear noise, it is assumed that the ti res, exhaust and
tri m i tems have fi rst been checked and negated as
possi bl e causes.
The noises descri bed under Road Test usually have
speci fi c causes that can be di agnosed by observati on
as the unit is di sassembl ed. The initial cl ues are, of
course, the t ype of noise heard on the road t est and
t he driving condi ti ons.
Knock, whi ch can occur on all driving phases, has
several causes. In most cases, one of the following
condi ti ons has occurred:
8. A gear t oot h damaged on t he dri ve si de is a
common cause of the knock. This can usually be
correct ed by grinding the damaged ar ea.
9. Knock is al so charact eri st i c of excessi ve end
play in t he axl e shafts. Up t o 0. 762 mm ( 0. 030
inch) is al l owed in most axl es. The frequency of
knock will be l ess because the axl e shaft speed is
sl ower than t he dri veshaft ( 4602) .
NOTE: Be sure t o measure t he end pl ay wi th a dial
indicator, not by feel . You can not accuratel y measure
end play by feel .
On t he integral axl e, end pl ay is al l owabl e up t o 0. 762
mm ( 0. 030 inch) but can be reduced t o 0. 127 mm
( 0. 005 i nch). It is control l ed by t he C-washer that
holds the shaft in t he pocket of the si de gear.
Vibration Conditions
Engine or Accessor y Vi brati on, all speeds Refer
to Engine Accessor y Vibration and Tip-in Moan
t est s.
Hi gh-speed shake, 80 k m/ h ( 5 0 mph and up):
1. Refer t o Diagnosis and Testing in Section 04- 04.
2. Refer t o drum, rotor and hub runout checks
contai ned in Secti on 04- 00.
Tip-in Moan Refer t o Tip-in Moan test. If t he
sympt om still exi st s, refer t o the Engine
Accessor y Vi brati on t est or Secti on 03- 05.
Brake Shudder Refer t o Secti on 06- 00.
Leakage Conditions
Most rear axl e l eakage condi ti ons can be correct ed
wi thout a t eardown. However, it is important t o cl ean
the leaking area enough to identify t he exact source.
A pl ugged or sei zed jiggle cap vent will cause
excessi ve fl ange yoke seal lip wear due t o internal
pressure buildup. When a leak occurs, check cap by
pressi ng down on it wi th index finger. If the cap moves
up and down freel y, it is worki ng properl y. If it does not
move freel y, it must be repl aced.
Ensure axl e lubricant level is 6-14 mm ( 1/ 4- 9/ 16 inch)
bel ow bot t om of fill hole.
When the fl ange yoke seal l eaks, it is usually
because it was not installed carefully or properl y, or
because of poor quality on the seal journal surface.
Any damage t o t he seal bore (di ngs, dents, gouges,
et c. ) will di stort the seal casi ng and allow l eakage past
the outer edge of the rear axl e drive pinion seal
( 4676) .
The rear axl e dri ve pinion seal can be torn, cut or
gouged if it is not assembl ed carefully. The spring that
holds the rear axl e dri ve pinion seal against the rear
axl e universal joint flange ( 4851) may be knocked out
and al l ow l eakage past the lip.
The rubber lips can occasi onal l y become hard (like
pl asti c) wi th cr acks at the oil lip cont act point. The
cont act point on the rear axl e universal joint flange is
usually bl ack, indicating excessi ve heat. Marks, ni cks,
gouges or rough surface t ext ure on the seal journal of
the rear axl e universal joint flange will also cause
l eaks. Excessi ve flange yoke seal wear will be noted.
The rear axl e universal joint flange should be repl aced
if any of these conditions exi st.
00- 04- 5 Noi se, Vibration and Harshness 00- 04- 1
Metal chi ps or sand, t rapped at t he sealing lip also
may cause oil l eaks. This can cause a wear groove on
the rear axl e universal joint fl ange and heavy flange
yoke seal wear.
GOUGE
OR
VOID
I N LIP
0.039 mm (0.05 INCH) OR GREATER
INDICATES EXCESSIVE WEAR
VIEW A
E5517-E
On some high mi l eage units, t here have been
i nstances of oil leaking past the t hreads of the pinion
nut. The condition can be cor r ect ed by removing the
nut and appl yi ng Pipe Sealant Wi t h Teflon
D8AZ- 19554- A or equivalent meeti ng Ford
speci fi cati ons WSK- M20G350- AZ and
ESR-M18P7-A on t he t hreads and nut f ace.
NOTE: Be sure t o fol l ow the cor r ect procedure for
setti ng the beari ng prel oad when the nut is installed.
Axl e lubricant level shoul d be 6-14 mm ( 1 / 4 - 9 / 1 6
inch) bel ow bot t om of fill plug hole. Make sure rear
axl e vent is not pl ugged wi th dirt or debri s.
Axl e shaft inner wheel bearing oil seal s ( 1177) are
suscepti bl e t o t he same ki nds of damage as flange
yoke seal s if i mproperl y i nstal l ed. The seal bore
must be clean and t he lip handl ed carefully t o avoi d
cutti ng or teari ng it. Axl e shaft journal surface must
be free of ni cks, gouges and rough surface t ext ure.
Occasi onal l y, t here will be a rear axl e housing leak
t hrough small pocket s in t he met al . These pocket s
(cast i ng l eakage) ar e caused by gas bubbl es in t he
cast i ng pr ocess and are known techni cal l y as a
porous condi ti on or porosi ty.
Because t here is al ways the danger of changi ng the
axl e' s sound charact eri st i cs if torn down t o repl ace
the carri er, servi ce is preferabl e. There are t wo
recommended t ypes of servi ce:
1.
2.
Peen in a small amount of body l ead. Seal the
pocket wi th epoxy sealer that meets Ford
Specification ESB-M3035-A.
In larger pocket s, drill a shal l ow hole and t ap it for
a small set screw. Install the set screw and seal it
over wi th epoxy seal er that meets Ford
Specification ESB-M3035-A.
Most minor wel d l eaks can be correct ed wi t h
epoxy sealer t hat meets Ford speci fi cati on
ESB-M3035-A. This includes the " puddl e" or
fill wel ds that join the axl e shaft tube t o the rear
axl e housing on integral axl es. They
someti mes leak and can be seal ed easily.
Remember, if a wel d is broken, the rear axl e
housing must be repl aced. The alignment is t oo
critical for field servi ce.
CASTING
POROSITY
PUDDLE WELD
SEALED WITH
EPOXY
E 3T 84- D
There have been some occurrences of
lubricant leaking through the rear axle housing
vent ( 4022) . This may be caused by a cl ogged
or sti cki ng axl e vent cap. If this is the case, the
rear axl e housing vent should be repl aced,
using Stud and Bearing E0AZ-19554-BA or
equivalent meeting Ford speci fi cati on
WSK- M2G349- A1, on t hreads t o ensure
retention.
I n o pe r a t i v e Co n d i t i o n s
In t he event the axl e fails t o operate, there will be
obvi ousl y broken or jammed-up part s. It is important t o
t ry t o analyze why t he part s broke to prevent the
condition f rom recurri ng.
Inspect a broken axl e shaft for a twi st in the spline
next t o the break.
Breaks that occur away f rom the spline, or that are not
accompani ed by a t wi st in the spline, may be caused
by forgi ng f l aws and/ or fatigue of t he axl e shaft.
Conditions that can cause a broken axl e shaft include
forgi ng fl aws or excessi ve impact l oad t o the axl e
shaft as a result of a collision, etc.
00- 04- 6 Noi se, Vibration and Har shness 00- 04- 6
The dri ve pinion st em is subj ect t o condi ti ons that
can break it anyti me t he differential pinion beari ng
prel oad is not set up properl y. If t here is no prel oad,
the differential pinion beari ng will turn relative t o the
axl e shaft. Thi s galls the roller shaft and generates
heat, whi ch can draw the temper away f rom t he
shaft.
Too much prel oad al so generat es bearing heat wi t h
the same result. The break normally occurs between
t he t wo differential pinion beari ngs.
Rear axl e housing wel ds, if compl etel y broken, call
for repl acement of the rear axl e housing.
Because of t he severe l oads t hey must handle, rear
wheel beari ngs may require repl acement at high
mileage. If a rear wheel beari ng fails at l ow mileage,
it is often caused by overl oadi ng.
Lock-up or seizure of the axl e shaft is usually
associ at ed wi t h a l ow lubricant condi ti on. The
lubricant prevents friction and helps cool t he part s
as t hey heat up. Wi thout enough lubricant, t he
heated parts get soft and may eventually wel d
together. Check for lubricant l eaks after servi ci ng.
Road Test
A gear-driven unit, especi al l y an automoti ve dri ve axl e,
will produce a certai n amount of noise. Some noise is
accept abl e and may be audible at certai n speeds or
under vari ous driving condi ti ons, for exampl e, as on a
newl y paved bl ackt op road. The slight noise is in no
way detri mental t o the operati on of t he rear axl e and
must be consi dered normal .
NOTE: It is i mportant that the rear axl e noise be
eval uated in di rect dri ve rather than overdri ve.
The road test and customer interview (if avai l abl e)
provi de information needed t o identify the condition
and give direction t o the correct starti ng point for
di agnosi s.
1. Make notes throughout di agnosi s routine. Use a
Road Test f orm that includes space for
comment s. Make sure t o wri t e down even t he
smal l est bit of i nformati on, it may turn out t o be
the most i mportant.
2. Road test the vehi cl e and define the condition by
reproduci ng it several ti mes during the road t est .
3. Perform the Road Test Qui ck Checks as soon as
the condition is reproduced. This will identify the
proper secti on of t he di agnosi s procedure. Run
through the quick checks more than once t o
ensure t hey are providing a usable result.
Remember, the Road Test Qui ck Checks may not
fell where the concern is, but they will tell where it
is not.
4. Do not t ouch anything until a road test and a
thorough visual i nspecti on of t he vehicle have
been perf ormed. Leave t he ti re pressures and
vehicle l oad just where t hey were when t he
condition was first observed. Adjusting ti re
pressures, vehi cl e l oad or making other
adj ustments may reduce the condition' s intensity
t o a point wher e it cannot be identified cl earl y. It
may al so inject somethi ng new into the syst em,
prohibiting proper di agnosi s.
Make a visual inspection as part of the
preliminary di agnosi s routine, wri ti ng down
anythi ng that does not l ook right. Note tire
pressures, but do not adj ust them yet . Note
leaking fluids, l oose nuts and/ or bol ts, or bright
spot s where components may be rubbing agai nst
each other. Check the l uggage compartment or
cargo area for unusual l oads.
00- 04- 7 Noise, Vibration and Harshness 00- 04- 7
ROAD TEST FORM
1. Did condi t i on exi st when vehi cle was new? [ ^ ] Yes [ H| No
How di d condi ti on begin?
I | Gradually occurred Mileage..
I | Suddenly occurred Mileage_
2. NVH between MPH and MPH i n . . gear.
3. Neutral engi ne run-up vi brati on? Yes Q No
4. What dri vi ng condi ti ons affect t he NVH?
| | Light t o medi um accelerat i on
I | Hard accelerati on
I | Decelerati on (foot off accelerat or pedal)
[ | Constant speed
5. If a vi brat i on, where is t he vi brat i on noti ced?
Seat
| | Steeri ng wheel
| | Instrument panel pad
D
F , o o r
| | Hood and f enders
6. If a noise, define as:
Buzz
| | Moan
| | Drone
| | Rumbl e
Q Hum
Other
| | Cli cki ng
Poppi ng
[ | Gri ndi ng
Describe
00- 04- 8 Noi se, Vi br at i on and Har shness 00- 04- 8
DIAGNOSES A N D TESTING (Cont i nued)
Road Tes t Qui c k Ch e c k s
1. 24-80 k m/ h( 15- 50 mph): Wi th light accel erat i on,
a moaning noise is heard and possi bl y a vi brati on
is felt in the fl oorpan. It is usually wor se at a
particular engine speed and at a particular
throttl e setti ng during accel erati on at t hat speed.
It may al so produce a moaning sound, dependi ng
on what component is causing it.
Refer t o Tip-In Moan.
2. 40-72 km / h (25-45 mph): Wi t h st eady t o heavy
accel erati on or decel erati on, a rumbl e-type noise
is heard. It is very intense during heavy
accel erati on or decel erati on and very light during
crui se or neutral coast . The vibration is hard t o
dupl i cate wi th vehicle supported on a hoi st, since
wheel s are coasti ng f ree.
Refer t o Dri veshaft Vi brati on.
3. High Speed: Wi th sl ow accel erati on and
decel erati on or at constant speed, a shake is
someti mes noti ced in the steeri ng wheel / col umn,
seat s, fl oorpan, tri m panels or front end sheet
metal . It is a low frequency vibration (around 9-15
cycl es per second). It may or may not be
i ncreased by appl yi ng brakes lightly.
Refer t o High Speed Shake.
4. High Speed: A vibration is felt in t he fl oorpan or
seat s, wi t h no visible shake, but wi t h an
accompanyi ng sound or rumble, buzz, hum,
drone, or boomi ng noise.
It will exi st in all dri ve modes, but may vary
somewhat in accel erati on, decel erati on, fl oat, or
coast modes. In some cases the driveline
vibration is eliminated in the fl oat mode.
Refer t o Dri veshaft Vi brati on.
5. 0-High Speed: A vibration is felt whenever the
engine reaches a particular rpm. The vi brati on
can be dupl i cated by operati ng t he engine at the
probl em rpm whi l e the vehicle is sitting still. It can
be caused by any component f rom the fan back
t o the torque converter ( 7902) and by anythi ng
t hat turns at engine speed when the vehi cl e is
st opped.
Refer t o Engine Accessor y Vi brati on.
Road Condi t i ons
The road is an i mportant f act or in the road t est . A
smoot h asphal t road that al l ows driving over a range
of speeds is best. The brushed concret e road surface
found on many expr essways and the coarse
aggregat e someti mes found in concret e can mask
many vehi cl e noises and make di agnosi s difficult.
If the customer compl ai ns of a noise or vi brati on on a
particular road and only on a parti cul ar r oad, the
source of t he concern may be t he road surf ace. If
possi bl e, t ry t o t est on the same t ype of surf ace. Thi s
is the only case where a smoot h asphal t road may not
be the best.
Ve h i c l e P r e p a r a t i o n
1. Check and veri fy if vehi cl e is equi pped wi t h
original equipment, t ype, si ze and brand of
wheel s and ti res. If non-original equipment wheel s
and/ or ti res are installed, it may be necessary t o
substi tute original equipment level t i r e/ wheel
assembl i es for di agnosi s.
2. Check and set ti re pressure.
Ho i s t T e s t
After a road t est , but only after a road t est , it is
someti mes useful t o do a similar t est on a hoi st. (Use
an axl e hoi st not a frame hoist. An axl e hoist will not
change t he driveline angl es. If only a f rame hoist is
available, axl e stands shoul d be used.)
1. El evate the rear wheel s slightly, check t o make
sure that both are turning, and run the engine up
wi t h t he vehi cl e in gear.
2. Expl ore t he speed range of interest using t he
dri ve / crui se / coast / f l oat t est s.
3. Perform a coast down in NEUTRAL. If vehicle is
free of vi brati on when operati ng at a st eady
i ndi cated speed and behaves very differently in
dri ve and coast , an axl e concern is likely.
Note, however, that a t est on t he hoist may produce
different vi brati ons and noises than a road t est
because of t he effect of t he hoi st on the rear axl e. It is
not unusual t o find vibrations on t he hoist that were not
found in t he road t est and many ti mes t hese may be
i gnored. If the condition t hat was found on t he road can
be dupl i cated on the hoist, a great deal of ti me can be
saved by doing experi ments on t he hoi st.
0O-O4-9 Noi se, Vi braf "
DI AGNOSI S A N D T E S T I NG (Continued)
Symptom Ch a r t
NOISE, VIBRATION AND HARSHNESS
CONDITION POSSIBLE SOURCE ACTION
High Speed Shake o Suspension/driveshaft.
9 Ti res/wheel s.
Wheel bearings.
Brake rotors.

Engine.
Transmission.
GO to Pinpoint Test A.
@ REFER to Section 03-00.
..ciFER to Section 07-01.
Tip-In Moan Engine air cleaner.
Powertrain.
Engine mounts.
Exhaust system.
GO to Pinpoint Test B.
Engine Accessory Vibration Drive belt / pulleys.
Mounting hardware.
GO to Pinpoint TestC.
Driveshaft Vibration # Driveshaft. GO to Pinpoint Test D.
Tire/Wheel Runout Ti res/wheel s.
Wheel bearings.
GO to Pinpoint Test E.
Axle Gear Noise Differential
Rear axle housing.
Lubricant.
m REFER to Section 06-00.
Pi npoi nt T e s t s
SPECIAL SERVICE TOOL(S) REQUIRED
Description T o o l N u mb e r
Be l t Te n si o n Ga u ge T63L - 862 0- A
It is somet i mes necessary t o remove vari ous
component s of vehi cl e to gain access to the
component to be t est ed. Refer to appl i cabl e secti on
for removal and installation of components. After
veri fyi ng t he condition has been cor r ect ed, ensure all
component s removed have been installed.
These di agnosi s char t s are desi gned to t ake the
technician through a step-by-step diagnosis procedure
t o determine the cause of a condi ti on. It may not
al ways be necessary t o fol l ow the chart to its
conclusion. Perf orm onl y t he Steps necessary to
correct the condi ti on. Then check operati on of the
syst em t o ensure t he cause has been found.
PINPOINT TEST A: HIGH SPEED SHAKE
TEST STEP RESULT ACTION TO TAKE
A1 ROAD TEST
Yes
No
GO to A2.
Vehicle OK.
Accel erat e vehi cle to the speed at which the
customer i ndi cated the shake occurred.
Is a sha ke pr e se nt ?
Yes
No
GO to A2.
Vehicle OK.
00- 04- 10 No i s e , Vi b r a t i o n a n d Ha r s hn e s s 0 0 - 0 4 - 1 0
PINPOINT TEST A: HIGH SPEED SHAKE (Cont i nued)
A2 INSPECT TIRES
Raise vehicle on hoist. Inspect ti res for extreme
wear or damage, cupping or flat spot s.
Are ti res OK?
Yes
No
CUPPED OR
DISHED TREADS
GO to A3.
CHECK suspension
components for
misalignment, abnormal
wear, or damage that may
have contributed to t he
ti re wear. CORRECT
suspension concerns,
and REPLACE damaged
t i res. PERFORM Road
Test.
F7Q35-A
A 3 INSPECT WHEEL BEARINGS
Spin front ti res by hand to check for wheel bearing
roughness. Check bearing end play.
i s end play OK?
Yes
No
GO to A4.
REPLACE bearings as
necessary. PERFORM
Road Test.
F703-B
A4 WHEEL/TIRE RUNOUT ON VEHICLE
Measure wheel /t i re assembly runouts on vehicle
using Rotunda Radial Run Gauge 007-00014 or
equivalent. Assembly runout should be less than
1.14 mm (0.045 inch) radial and lateral. Warm up
ti res prior to taki ng measurement t o eliminate slight
flat spotti ng.
Is measurement in spe c i f i c a t i on?
Yes
No
GO to A9.
GO to A5.
A S WHEEL/TIRE RUNOUT OFF VEHICLE
Measure wheel /t i re assembly from any position that
exceeds 1.14 mm (0.045 inch) radial or lateral.
Before removing wheel /t i re assembly, mark wheel
stud and corresponding bolt hole so assembly can
be installed in same posi ti on. Remove assembly and
mount on wheel balancer. Measure runout as in Step
A4. Assembly runout should be less than 1.14 mm
(0.045 inch) radial and lateral.
Is measurement in spe c i f i c a t i on?
Yes
No
CHECK rotor and bolt
ci rcle runout. GO to AS.
GO to A6.
A6 MATCH MOUNTING
Mark the high runout location on the ti re and also on
the wheel. Break the assembly down and rotate the
ti re 180 degrees (half-way around) on the wheel.
Inflate the tire and measure the runouts.
8s proper bal ance achi eved?
Yes
No
BALANCE assembly and
INSTALL on vehicle.
REFER to Section 04-04.
PERFORM Road Test.
If high spot is not within
101.6 mm (4 inches) of
fi rst high spot on the ti re,
GO to A7.
00- 04- 11 No i s e , Vi b r a t i o n a n d Ha r s h n e s s
00-04-11
A7 WHEEL RUNOUT
Yes
No
LOCATE and MARK low
spot on wheel and
INSTALL ti re matching
high spot on wheel.
PERFORM Road Test.
REPLACE wheel. CHECK
runouts on new wheel. If
new wheel is within limits,
LOCATE and MARK the
low spot. INSTALL t i re,
matching high spot of tire
with low spot of wheel.
INSTALL on vehi cle.
PERFORM Road Test.
Dismount tire and mount wheel on wheel balancer.
Measure runouts on both flanges. Runout should be
less than 1.14 mm (0.045 inch) radial and lateral.
Is t her e proper r unout ?
0
N
' F7043-A
Yes
No
LOCATE and MARK low
spot on wheel and
high spot on wheel.
PERFORM Road Test.
LOCATE and MARK the
PERFORM Road Test.
A8 AXLE /ROTOR AND BOLT CIRCLE RUNOUTS
Yes
No
REPLACE front disc
brake rot or/wheel and
PERFORM Road Test.
REPLACE front di sc
brake rotor (front wheel
posi ti ons) or axle shaft
(rear wheel positions)
and PERFORM Road
Test.
For rear wheel posi t i ons, r
rotor or brake drum and m<
runout (greater than 0.254
ci rcui t runout (greater thar
and brake drum/f ront disc
For front wheel posi ti ons,
flange f ace runout (greate
inch)) and rotor pilot radi a
mm (0.002 inch)).
Are measurement s corre
(A j ROTOR
^ l i ^ PILOT RADIAL
^ ^ M ^ ^ ^ R U N O U T
\ 1/ RO-
x
PIL
emove rear disc brake
sasure axle flange face
mm (0.010 inch)). Bolt
10.397 mm (0.015 inch))
brake rotor pilot radial
mm (0.006 inch)),
measure rotor lateral
mm (0.002 inch)) hub
r than 0.06 mm (0.002
I runout (greater than 0.04
c t ?
SL/^ WHEEL
W -
P I L O T
FOR
0T
F7044-C
Yes
No
REPLACE front disc
brake rot or/wheel and
PERFORM Road Test.
REPLACE front di sc
(rear wheel positions)
and PERFORM Road
Test.
A9 INSPECT WHEELS
Yes
No
GOt o AI O.
INSTALL counterbalance
wheel weight opposi te
locking wheel hub bolt
nut. PERFORM Road
Test.
If wheels are equi pped with locki ng lug nuts, check
t hat proper counterbalance wheel weight is
i nstalled opposi te locking wheel hub bolt nut.
Is wheel wei ght c o r r e c t ?
Yes
No
GOt o AI O.
INSTALL counterbalance
locking wheel hub bolt
nut. PERFORM Road
Test.
A10 FRONT TIRES
Yes
No
BALANCE front wheels.
PERFORM Road Test.
GOt o A 11.
Spin front ti res wi th a wheel balance spinner while
vehi cle is raised on hoi st. Feel for vi brati on in fender
or while seated in vehi cle.
Is vi br at i on f e l t ?
Yes
No
BALANCE front wheels.
PERFORM Road Test.
GOt o A 11.
1995 To wn Ca r , Cr o wn Vi c t o r i a , G r a n d Ma r q u i s Jul y 1994
00- 04- 12 No i se , Vi b r a t i o n a n d Ha r s h n e s s 00- 04- 12
TE ST STEP RESULT ACTION TO TAKE
A11 REAR TIRES
Yes
No
GOt o A12 .
GOt o A14.
Engage drivetrain while vehicle is raised on hoist.
Carefully accelerate the drive wheels while feeling
for vi brati on.
Is vi brat i on f el t ?
Yes
No
GOt o A12 .
GOt o A14.
A12 DRIVETRAIN
Yes
No
GOt o A13.
BALANCE rear wheels.
PERFORM Road Test.
Remove rear wheels, secure brake rotors, if so
equipped by installing lug nut, reversed. Carefully
accelerate the drivetrain while feeling for vibration.
Is vi brat i on f e l t ?
Yes
No
GOt o A13.
PERFORM Road Test.
A13 REAR ROTORS
Yes
No
GO to Driveshaft
Vibration.
REPLACE rear disc brake
rotors. PERFORM Road
Test.
Remove the rear disc brake rotors. Carefully
accelerate the drivetrain while feeling for vi brati on.
Yes
No
GO to Driveshaft
Vibration.
Test.
A14 WHEEL BALANCE
Yes
No
Vehicle OK.
GOt o A15.
Balance all wheels not previously balanced. Road
test vehicle.
Are wheel s bal anced?
Yes
No
Vehicle OK.
GOt o A15.
A15 SUBSTITUTE WHEELS AND TIRES
Yes
No
REFER to Driveshaft
Vi brati on.
INSTALL the original
t i re/wheel assemblies,
one by one, road testi ng
at each st ep, until the
defecti ve ti re(s) is
i denti fi ed. REPLACE
t i re(s) as necessary and
RETEST.
Substitute a known good set of wheels and t i res.
Road t est vehi cle.
Yes
No
REFER to Driveshaft
Vi brati on.
at each st ep, until the
defecti ve ti re(s) is
i denti fi ed. REPLACE
t i re(s) as necessary and
RETEST.
PINPOINT TEST B: TIP-IN MOAN
B1 AIR CLEANER
Yes
No
GOt o B2.
CORRECT condition and
PERFORM Road Test. If
moan persi st s, GO to B2.
Check air cleaner, inlet tube, outlet tube, resonators
and all other components associ at ed with the air
induction system for proper installation and
ti ghtness of all connections.
# Are c ompone nt s pr oper l y i nst al l ed?
Yes
No
GOt o B2.
CORRECT condition and
moan persi st s, GO to B2.
B2 POWERTRAIN RESONANCE
Yes
No
CHANGE or INSTALL
damper as indicated and
RETEST. If moan still
persi st s, GO to B3.
GO to B3.
Loosen all converter housing-to-engine retaining
bolts three-quarter turn and road t est . Tighten bolts
after t est .
Is moan r educed or el i mi nat ed?
Yes
No
CHANGE or INSTALL
damper as indicated and
RETEST. If moan still
persi st s, GO to B3.
GO to B3.
00- 04- 13 No i se , Vi br at i on and Har shness 0 0 - 0 4 - 1 3
PINPOINT TEST B: TIP-IN MOAN (Cont i nued)
B3 ENGINE MOUNTS
Yes
No
Vehicle OK.
GO to B4.
Normalize engine mounts by loosening them and,
with engine running and brake pedal appli ed,
shifting transmission from NEUTRAL to DRIVE and
back to NEUTRAL. Tighten mounting bolts and road
t est .
^ ^ ^ ^ ^ ^ ^ ^
Yes
No
Vehicle OK.
GO to B4.
B4 EXHAUST SYSTEM
Yes
No
Vehicle OK.
REFER to Engine
Accessory Vi brati on.
Warm up system t o normal operating temperature.
Loosen all hanger attachments and reposition
hangers until t hey hang free and strai ght. Then
loosen all flange j oi nts and, wi th engine running, shift
transmission from NEUTRAL to DRIVE and back to
NEUTRAL. Tighten all hanger clamps and flanges.
Road test vehi cle.
EXHAUST
EXHAUST \ y S
P
L
P
~ ^ / \ \ V\ "F7098-A
Yes
No
Vehicle OK.
REFER to Engine
Accessory Vi brati on.
PINPOINT TEST C: ENGINE ACCESSORY VIBRATION
C1 ENGINE RUN-UP
Yes
No i >
GO to C2.
PERFORM stall t est in
DRIVE with brakes
l ocked. If vibration
occurs, GO t o Tip-In
Moan.
Run-up to problem rpm observed in road t est , wi th
vehi cle stationary.
Does vi br at i on o c c ur ?
Yes
No i >
GO to C2.
PERFORM stall t est in
DRIVE with brakes
l ocked. If vibration
occurs, GO t o Tip-In
Moan.
00- 04- 14 Noise, Vibration and Harshness
00- 04- 14
PINPOINT TEST C: ENGINE ACCESSORY VIBRATION (Cont i nued)
02 DRIVE BELTS AND PULLEYS
Yes
No
REPLACE worn or
damaged drive belts or
pulleys. CORRECT belt
tensi on. GO t o C3.
GOt o C3.
With engine st opped, inspect all engine accessory
drive belts and pulleys for wear or damage, and
check belt tensi on, using Belt Tension Gauge
T63L-8620-A.
Automatic drive belt tensioners have belt wear
indicator marks. If the indicator mark is not between
the min and max marks, the drive belt is worn or an
incorrect drive belt is i nstalled.
Are dri ve bel t s or pul l eys wo r n or damaged?
^ ^ ^ ^ ^
\ Vv VP^X GAUGE
M NX \ T63L-8620-A
I l k N \ ^ \ V-RIBBED BELTS
I I l \ \ v \ \ F7099-A
Yes
No
REPLACE worn or
damaged drive belts or
pulleys. CORRECT belt
tensi on. GO t o C3.
GOt o C3.
C3 MOUNTING HARDWARE
Yes
No
GOt o C4.
ALIGN and TIGHTEN
mounting hardware t o
speci f i cat i ons.
CORRECT belt tensi on.
START UP engine and
run-up t o problem rpm. If
vibration still exi st s, GO
t o C6.
Inspect mounting bracket s and adj usting
components for proper alignment and ti ghtness.
Are mount i ng and adj ust i ng c ompone nt s secur e?
Yes
No
GOt o C4.
ALIGN and TIGHTEN
mounting hardware t o
CORRECT belt tensi on.
START UP engine and
run-up t o problem rpm. If
vibration still exi st s, GO
t o C6.
C4 ENGINE IDLING
Yes
No
REPLACE pulley.
GOt o C5.
With engine idling, visually check all accessory
drive belts and pulleys for misalignment, runout or
irregular motion. Maximum runout is 3 mm ( 1/ 8
inch).
Increase engine rpm.
Is t here vi si bl e mi sal i gnment ?
Yes
No
REPLACE pulley.
GOt o C5.
C5 DRIVE BELT ALIGNMENT
Yes
No
REPLACE t hat pulley.
REPLACE belt.
With engine idling, visually check all accessory
drive belts and pulleys for misalignment, runout or
irregular motion. Maximum runout is 3 mm ( 1/ 8
inch).
Increase engine rpm.
Does bel t ri de up and d o wn on pul l ey(s)?
Yes
No
REPLACE t hat pulley.
REPLACE belt.
C6 ACCESSORY DRIVE BELT NOISE
CHECK for misalignment.
CHECK drive belt
tensioner posi ti on.
CHECK for worn belt.
SERVICE /REPLACE as
required.
CHECK drive belt.
REPLACE as required.
GOt o C7 .
Check for "chi r ps" or squeal in a poly-vee belt by
spraying a small amount of water on the grooved
side of the drive belt (use a spray bottle or
equivalent).
Does t he noi se change?
Yes
No
CHECK for misalignment.
CHECK drive belt
tensioner posi ti on.
CHECK for worn belt.
SERVICE /REPLACE as
required.
CHECK drive belt.
GOt o C7 .
00- 04- 15 No i se , Vi b r a t i o n a n d Ha r s h n e s s
0 0 - 0 4 - 1 5
PINPOINT TEST C: ENGINE ACCESSORY VIBRATION (Cont i nued)
07 ACCESSORIES
Yes
No
REPLACE belt. If
vibration still exi st s,
SERVICE or REPLACE
component.
Possible engine
component imbalance.
This situation is possi ble,
but unlikely.
Run-up engine t o problem rpm and, with
st et hoscope-t ype device, check each component.
If the source cannot be det ect ed by probing, remove
each belt, one at a time, until vibration goes away.
Is noi sy component l ocat ed?
Yes
No
REPLACE belt. If
vibration still exi st s,
SERVICE or REPLACE
component.
Possible engine
component imbalance.
This situation is possi ble,
but unlikely.
PINPOINT TEST D: DRIVESHAFT VIBRATION
D1 WHEELS AND TIRES
Yes
No
REFER t o High Speed
Shake for drive-wheel
runout and balance
procedures.
GO t o D2 .
Road test vehicle.
Is hi gh speed shake caused by whe e l s/ t i r e s?
Yes
No
REFER t o High Speed
Shake for drive-wheel
runout and balance
procedures.
GO t o D2 .
D2 DRIVESHAFT
Yes D>
No
CLEAN off undercoating
or REPLACE damaged
driveshaft. If index marks
are misaligned, GO to D6.
CHECK for vibration at
road t est speed. If still
present, GO to D3.
GO to D3.
Inspect driveshaft for undercoating or physi cal
damage. Check index marks (yellow paint daubs) on
rear of driveshaft and rear axle universal j oint
flange.
Are mar ks more t han 90 degrees apar t ?
Yes D>
No
CLEAN off undercoating
or REPLACE damaged
driveshaft. If index marks
are misaligned, GO to D6.
present, GO to D3.
GO to D3.
D3 DRIVESHAFT RUNOUT
Yes
No
GO to D7.
GO t o D4.
With vehi cle on hoist, measure runout at front,
center and rear of driveshaft.
Is runout 0.S9 mm (0. 035 i nch)?
Yes
No
GO to D7.
GO t o D4.
D4 DRIVESHAFT RE-INDEXING AT TRANSMISSION
Yes
No
present, mark rear runout
high point. GO to D5.
GO to D6.
Note or mark indexing of driveshaft to transmission
and rear axle universal j oint flange. Disconnect the
driveshaft, re-index 180 degrees at transmission
only and reconnect. Check runout at front and center
of dri veshaft. Maximum runout is 0.89 mm (0.035
inch).
NOTE: While driveshaft is removed from vehi cle,
manipulate U-joints in each direction of rot at i on. If a
U-joint feels stiff or has a "l umpy", "gr i t t y " feel in
any di rect i on, replace U-joints or driveshaft.
Is runout wi t hi n speci f i cat i on?
Yes
No
present, mark rear runout
high point. GO to D5.
GO to D6.
00- 04- 16 Noise, Vibration and Harshness
00- 04- 16
PINPOINT TEST D: DRIVESHAFT VIBRATION (Cont i nued)
D5 DRIVESHAFT RE-INDEXING AT AXLE
Note or mark indexing of driveshaft to rear axle
U-joint flange. Disconnect the driveshaft. Re-index
180 degrees at axle and connect. Check runout at
rear of driveshaft. Maximum runout is 0.89 mm
(0.035 inch).
Is it wi t hi n speci f i cat i on?
INDEXING REAR AXLE FLANGE
SCRIBE MARKS
DRIVESHAFT
Yes
No
road-test speed. If sti ll
present, GO t o D7 .
GO t o D6.
DRIVESHAFT
CENTERING
SOCKET YOKE
4782
REAR AXLE
UNIVERSAL
JOINT FLANGE
4851
F7S91-B
D6 REAR AXLE U-JOINT FLANGE
Compare the two high points of runout marked in
Test Steps D3 and D4.
Are mar ks wi t hi n 25 mm (1 i nch) of each ot her ?
Yes
No
REPLACE driveshaft.
RECHECK vibration.
REPLACE rear axle
U-joint flange. CHECK
driveshaft runout and
road test for vi brati on. If
sti ll present, GO to D7.
D7 DRIVESHAFT VIBRATION
The driveshaft can be re-indexed at both the rear
axle and transmission t o minimize system
imbalance. Refer to Section 05-00.
Is dri veshaf t bal anced?
Yes
No

Vehicle OK.
GO to D8.
PINPOINT TEST D: DRIVESHAFT VIBRATION (Continued)
D8 DRIVESHAFT BALANCING CLAMP METHOD
Mark rear of driveshaft in four equal parts and
number them 1, 2 , 3 and 4.
Install hose clamp with screw at position No. 1.
Operate driveline at speed at which customer
complained of vibration.
Rotate clamp to each of the other three positions
and check for vibration.
N0.1
Yes
No

GOt o D11.
GO t o D9.
NO. 4
NO. 3
Does vi br at i on change?
NO. 2
F7033-A
D9 INSTALL SECOND CLAMP
Install another clamp, with screw in same position
as first clamp.
Operate vehi cle at speed at which customer
complai ned of vibration.
Is vi br at i on mi ni mal ?
Yes
No

>
Condition correct ed.
GO t o D10.
F7100-A
00- 04- 18 No i s e , Vi b r a t i o n a n d Ha r s hn e s s 00- 04- 18
PINPOINT TEST D: DRIVESHAFT VIBRATION (Cont i nued)
D10 REPOSITION CLAMP
Yes
No
GOt o D11.
Rotate screws of clamps equally away from each
other about 12.7mm (1/ 2 inch).
Operate vehicle at speed at which customer
complained of vibration.
Is vi brat i on mi ni mal ?
ROTATE EACH CLAMP
12.7mm (1/2 INCH) FROM
THE BEST POSITION
^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^
BEST POSITION
F7034-A
NOTE: If vibration is correct ed with the addition of
clamps, the clamps will be left on the driveshaft
permanently. Check clamp clearance after installation
to prevent any contact with floorpan or other parts.
Yes
No
GOt o D11.
D11 ROAD TEST
Yes
No
Install wheels and ti res.
Road test vehicle.
Is vi brat i on mi ni mal ?
NOTE: Vibration felt on hoist may be acceptable
during road test.
Yes
No
PINPOINT TEST E: TIRE/WHEEL RUNOUT
E1 TIRE/WHEEL BEARING INSPECTION
Yes
No
GO to E2.
SERVICE bearings.
REFER t o Section 04-01
(front), 04-02 (rear).
Raise vehi cle, inspect tires and check wheel
bearings.
Are wheel beari ngs OK?
Yes
No
GO to E2.
SERVICE bearings.
(front), 04-02 (rear).
E2 BALANCE TIRES
Yes
No
Vehicle OK.
GO to E3.
Balance tires and place back on vehi cle.
Does vehi cl e f unc t i on pr oper l y ?
Yes
No
Vehicle OK.
GO to E3.
E3 ROTATE TIRES
Yes
No
Vehicle OK.
GO to E4.
Rotate tire and wheel assembly. Front to rear, and
rear to front.
Does vehi cl e f unct i on pr oper l y ?
Yes
No
Vehicle OK.
GO to E4.
E4 CHECK RUNOUT
Yes
No
GO to E6.
GO to E5.
Check total radial runout and t ot al lateral runout of
t i re/wheel assembly.
Is radi al runout less t han 1.01 mm (0. 040 i nch)?
Yes
No
GO to E6.
GO to E5.
PINPOINT TEST E: TIRE /WHEEL RUNOUT (Cont i nued)
TEST STEP RESULT > ACTIOM TO TAKE
E5 INDEX TIRE ON WHEEL
Yes [ >
No t >
Service complet e.
GO to E6.
e Index tire on wheel. Align highest runout point to
wheel low runout point.
Is t ot a l radi al runout less t han 1.01 mm (0.040
i nch)?
Yes [ >
No t >
Service complet e.
GO to E6.
E6 CHECK WHEEL RADIAL RUNOUT
Yes t >
No
REPLACE t i re. BALANCE
ti re. P E R F O R M Road
Test. If s t i l l not OK,
CHECK radial runout.
REPLACE wheel.
BALANCE t i re.
still not OK, CHECK radial
runout.
Check wheel radial runout and ensure it is correct .
NOTE: Although maximum wheel runout shown
exceeds accept able t ot al t i re/wheel assembly
runout, acceptable assembly runout may be
achieved by indexing tire on wheel .
Is wheel runout l ess t han 1.14 mm (0. 045 i nch)?
Yes t >
No
REPLACE t i re. BALANCE
ti re. P E R F O R M Road
Test. If s t i l l not OK,
CHECK radial runout.
REPLACE wheel.
BALANCE t i re.
still not OK, CHECK radial
runout.
GLOSSARY OF TERMS
Terms
Acceleration
Light
Partial throttl e i ncrease in speed such as 0-97 k m/ h
(0-60 mph) in approxi matel y 30 seconds.
Heavy
One-half t o full throttl e i ncrease in speed such as 0-97
k m/ h (0-60 mph) in approxi mat el y 20 seconds.
WOT
Wi de open t hrot t l e.
Ambient Temperature
Surrounding or prevailing temperature. Normal l y, the
temperature in t he servi ce area or out doors,
depending on where testi ng is taki ng pl ace.
Articulation
Verti cal movement of t he front driving or rear axl e
rel ati ve t o t he f rame of the vehicle t o whi ch t hey are
at t ached.
Belt Chirp
An intermittent noi se usually caused by belt
misalignment.
Belt Squeal
A conti nuous hi gh-frequency noise caused by a frozen
accessory or insufficient dri ve belt tensi on.
Boom
A cycl i ng, rhyt hmi c noise often accompani ed by a
sensati on of pressure on t he ear drums.
Bound Up
Ref ers t o a st r essed, rubber-mounted component that
t ransmi t s any NVH whi ch woul d normally be absorbed
by the mount. Refer t o Neutral i ze.
Brakes Applied
When vehi cl e is stati onary, servi ce brakes appl i ed
wi t h enough f orce t o hol d vehi cl e agai nst accel erati on
wi t h transmi ssi on in gear.
Camber
Angle f ormed bet ween front wheel spindle axi s and
horizontal as vi ewed f rom in front of t he vehi cl e.
Caster
Angle f ormed bet ween t he upper and l ower ball joint
centerline axi s of t he kingpin axi s and a verti cal axi s
as vi ewed f rom t he si de of the vehicle. Caster is
consi dered posi ti ve when the t op of the kingpin axi s is
behind t he verti cal axi s.
Chuckle
Refers t o the noise that occurs on the coast driving
phase; usually caused by excessi ve cl earance due t o
differential gear wear or by a damaged t oot h on t he
coast si de of t he final dri ve ring gear or the final dri ve
sun gear.
Clunk
Due t o excessi ve final dri ve ring gear backl ash,
elongation of the differential pinion shaft holes in t he
differential case, or missing si de gear or pinion gear
thrust washers. If none of t hese condi ti ons exi st, clunk
may be caused by a l oose fit of the front wheel dri ve
shaft j oi nts t o the si de gear splines.
Coast / Deceleration
Sl owi ng of vehicle by rel easi ng foot f rom accel erat or
pedal at crui se and allowing engine t o sl ow vehi cl e
wi thout application of brakes.
Coast/Neutral Coast
Engine / transmi ssi on t aken out of gear wi t h
drive-shaft / driveline by pl aci ng transmi ssi on range
sel ector in NEUTRAL.
^C>'CW-0 bt'Aie, Vi br at i on and Har shness
GL OS S A R Y OF T E R MS ( Co n t i n u e d )
00- 04- 20
Cont r ol l ed Rear Sus pens i on Hei ght
The height at whi ch the components of a particular
vehi cl e should be set when driveline angle
measurements are made.
F2713-C
CPS
Cycl es Per Second (Hz).
Cr ui s e
St eady hi ghway speed; neither accel erati ng nor
decel erati ng; even pressure on accel erat or pedal and
shaft ( 9725) on level ground.
De c e l e r a t i o n
Sl owi ng of vehicle by releasing f oot f rom accel erat or
pedal and shaft at crui se and allowing engine t o sl ow
vehi cl e wi thout appl i cati on of brakes.
Dr i v e l i n e Angl es
Di fference of alignment between t he transmi ssi on
output shaft, dri veshaft ( 4602) and rear axl e pinion
centerline.
F2714-C
Dr i v e s h a f t
Rearmost shaft of a driveline whi ch powers the rear
axl e input shaft (pinion shaf t ).
Dr i v e t r a i n
Includes all power transmi tti ng components f rom the
rear of the engine t o the wheel s, including t orque
converter ( 7902) , transmi ssi on, driveline and rear
driving axl es.
Dr i v e t r a i n Da mp e r
A counterwei ght at t ached t o an arm on t he rear of t he
transmi ssi on extensi on housing and desi gned t o " soak
up" or damp unwanted driveline or powertrai n
vi brati ons.
E n g i n e I mb a l a n c e
Some component in the engine whi ch is normally
smoothl y bal anced now causi ng a percepti bl e
vi brati on in t he vehi cl e.
E n g i n e Mi s f i r e
One or more cyl i nders in the engine fails t o fi re at the
proper ti me.
E n g i n e Ru n u p T e s t
Operati on of engine through normal rpm range whi l e
vehi cl e is si tti ng. Used for engine vibration check.
G r a v e l l y Fe e l
A grinding or growl in a component, similar t o the feel
experi enced while driving on gravel .
H a r s h n e s s
A harder than usual behavi or of a component, like
riding a vehi cl e wi t h over-inflated ti res.
Ho s e C l a mp
Screw-Type hose cl amp.
Hz
Hertz (Cycl es Per Second).
I mb a l a n c e ( a l s o Un b a l a n c e )
Out of bal ance; more wei ght on one si de of a rotati ng
component causi ng shake or vi brati on.
I n b o a r d
Towar d the centerline of the vehicle.
I n - P h a s e
The in-line relationship between the f orward coupling
shaft yoke and the dri veshaft slip yoke of a two-pi ece
driveline.
I s o l a t e
Separat e f r om the influence of other component s.
Ne u t r a l i z e ( No r ma l i z e )
To return t o unstressed posi ti on. Used t o descri be
mounts. Refer t o Bound Up.
NVH
Noi se, Vi brati on, Harshness.
00- 04- 2 1 Noise, Vibration and Harshness 00- 04- 21
GLOSSARY OF TERMS (Cont i nued)
Outboard
Towa r d t he out si de of t he vehi cl e, rat her t han t o wa r d
t he cent erl i ne. Ref er t o i nboard.
Pinion Shaft
The input shaf t t o a dri vi ng axl e, usually a part of t he
smal l er dri vi ng or input hypoi d gear of a ri ng gear
( 7 A153) and pinion gearset .
Pumping Feel
A ve r y sl ow vi brat i on t hat resul t s in a movement of
vehi cl e component s si mi lar t o pumpi ng t he servi ce
br a ke s sl i ght l y.
Radial/Lateral
Radi al is in t he plane of rot at i on, whi l e l at eral is at 90
degr ees t o t he f ore-and-af t plane of t he vehi cl e.
Ring Gear
The l arge hypoi d gear, dri ven by t he pinion gear of a
ri ng and pinion dri vi ng axl e gear set .
Road Test
Operat i on of vehi cl e under condi t i ons desi gned t o
r ecr eat e t he condi t i on.
Runout
Out of round or wobbl e.
Shake
Lo w f requency vi brat i on, usually resul t s in vi sual
movement of component s.
Slip Yoke (Slip Spline)
Dri veshaf t coupl i ng devi ce whi c h compensat es f or
changes in shaf t l engt h due t o art i cul at i on of an axl e;
used at one end of dri veshaf t .
Tip-In Moan
A li ght moani ng noi se is hear d when t he vehi cl e is
moder at el y accel er at ed bet ween 40- 64 k m / h (25-40
mph).
TIR
Tot al i ndi cat or runout .
Tire Deflection
Bendi ng of t he body of t he t i re duri ng rot at i on.
Tire Force Vibration
Ti re vi brat i on caused by vari at i ons in t he const ruct i on
of t he t i re, resul t i ng in a vi brat i on when t he t i re r ot at es
agai nst t he pavement . Thi s condi t i on may be present
on per f ect l y round t i res because of vari at i ons in t he
inner const r uct i on.
Ti resFlat Spots
Commonl y c a use d by l et t i ng vehi cl e st and when t i r es
ar e wa r m. Can be c ur e d by oper at i ng vehi cl e until t i r es
ar e wa r m. Thi s concer n is mor e l i kel y t o occur wi t h H,
V, and Z spe e d r a t e d t i res.
Two-Plane Balance
Radi al and l at eral bal ance.
Vibration
Regular movement of a component t hat resul t s in a
sound or f eel of movement .
Typi cal vi brat i on f requenci es, measur ed in c y c l e s per
se c ond (Hz), are:
1. Engi ne a c c e ssor i e s (up t o 160 Hz) (usual l y
c a use d by engi ne f i ri ng pul ses).
2. Engi ne ( 40 Hz); f i ri ng ( 80 Hz) (engi ne f i ri ng
f r equency depends on t he number of cyl i nder s).
3. Pinion ( 47 Hz); ri ng gear, axl e shaf t s ( 13 Hz).
4. Wheel and t i res ( 13 Hz).
5. Dri veshaf t ( 40 Hz); uni versal j oi nt ( 80 Hz).
6. Wheel beari ngs (6 Hz).
7. Tip-in moan ( 120 Hz).
ADJUSTMENTS
Bal anci ng, Dri veshaft
The f i rst c he c k t o be per f or med when dri veshaf t
vi brat i on i s suspect ed is re-i ndexi ng t he dr i veshaf t
( 4602 ) at bot h t he rear axl e and t ransmi ssi on.
A vi brat i on f r e e dri veshaf t can resul t f r om t he
dri veshaf t i ndexi ng pr ocedur e when mi nor dri veshaf t
i mbal ance is cancel l ed by mi nor sy st e m runout s.
1. Rai se vehi cl e on hoi st . Ref er t o Sect i on 00- 02.
Remove rear wheel and t i re assembl i es and rear
di sc br ake rot or ( 2C026) assembl i es. Pl ace f l oor
st ands under suspensi on ar ms t o suppor t rear of
vehi cl e. Not e or mar k i ndexi ng of dr i veshaf t t o
t ransmi ssi on and rear axl e uni versal j oi nt f l ange
(4851).
2. Mar k one hol e posi t i on on dri veshaf t y o ke at rear
of dri veshaf t wi t h t he l et t er A and t he ei ght rear
axl e U-joint f l ange hol es (st art i ng wi t h t he mat i ng
hole wi t h dri veshaf t posi t i on A) f r o m one t hr ough
ei ght . Posi t i on A-1 is consi der ed t he ori gi nal i ndex
posi t i on.
3. Di sconnect dri veshaf t , re-i ndex 180 de gr e e s at
axl e posi t i on A-5. Check f or vi brat i on at r o a d t e st
speed. If vi brat i on is sti ll present , eval uat e
posi t i ons A3 and A7 .
ADJUSTMENTS (Cont i nued)
4. If further improvement is desi red, eval uate
remaining positions that are l ocated bet ween t he
best of the t wo previous positions, A-3 and A-7. If
vehicle t est s sati sfactori l y at any point during thi s
procedure, do not proceed wi th any further st eps.
HOLE POSITION 4851
"A"
F2901-C
5. If re-indexing at axl e is unsuccessful , di sconnect
the dri veshaft, re-index 180 degrees at
transmission only and connect. Check for
vibration at road test speed. If vehi cl e t est s
sati sfactori l y, do not proceed wi t h any further
st eps.
NOTE: Remove dri veshaft f rom vehicle and
manipulate universal joints in each di recti on of rotati on.
If a universal joint feel s stiff or has a " l umpy" , " gr i t t y"
feel in any di recti on, repl ace universal j oi nts.
6. If re-indexing at bot h axl e and transmi ssi on is
unsuccessful , refer t o Dri veshaft Balancing
Secti on 05- 00.
NOTE: Original equipment dri veshaft-to-rear axl e
universal joint flange retaining bol ts ( N- 800594- S100)
are Loct i t e coat ed and do not require a l ockwasher. If
these bol ts are removed, they may be re-installed, if
additional Locti te is appl i ed. New and used bol ts must
be ti ghtened t o 95- 129 N-m (70-95 Ib-ft).
Match Mount i ng Tires
When servi ci ng wheel s or ti res, the following
procedure for matchi ng the ti re and wheel must be
fol l owed t o ensure t hat the best possi bl e ride
charact eri st i cs are maintained.
1. When removi ng a worn ti re f rom a wheel , mark
the val ve location on the ti re prior t o removal .
2. If the original ti re is t o be remounted, index the
val ve mark on t he tire t o the val ve of the original
wheel . Go t o St ep 6.
3. Locat e t he matchi ng point on t he wheel .
Steel wheel s: There is either a chart reuse
sti cker on t he outsi de rim fl ange, or, if the
sti cker is mi ssi ng, a yel l ow paint mark in t he
dropwel l of the rim that must be t ransf erred t o
the outsi de rim fl ange.
Aluminum wheel s: The matchi ng point on
aluminum wheel s is at t he ti re val ve.
4. Locati ng t he matchi ng point on a new ti re:
Many repl acement ti res as wel l as original
equipment ti res are marked for fi rst harmoni c
matchi ng t o t he wheel . These marks vary in t ype
and color. Consult t he ti re deal er for detai l s on
mark identification.
5. Mount the ti re on t he wheel and line up the
chart reuse paint mark or st i cker on the new ti re
si dewal l or t he matchi ng point of t he original ti re
wi t h the mark on t he rim of the steel wheel or t he
ti re valve of the aluminum wheel .
6. Inflate and bal ance t he t i r e/ wheel assembl y.
Wheel s, Di st ort ed
Inspect for Wheel Damage
Inspect the lug nuts ( 1012) and tighten t o 115-142
N-m ( 85- 105 Ib-ft). Loose lug nuts can cause shi mmy
and vi brati on, and may al so di stort the stud holes in
t he wheel s.
Ensure wheel s and hub are cl ean. St ones wedged
bet ween the wheel and rotor or lumps of mud and
grease can unbalance the wheel .
Check for wheel damage. Wobbl e or shi mmy caused
by a damaged wheel will eventually damage t he
beari ngs. Inspect the rims for dents t hat coul d leak air.
Inspect the front hubs and beari ngs whenever t he hubs
are removed, or at regular inspection intervals.
I nst al l Wh e e l
1. Clean all di rt and corrosi on f rom the hub mounting
surface and center pilot hole of t he wheel . Appl y
a thin film of Di sc Brake Caliper Slide Grease
D7AZ-19590-A or equivalent meeting Ford
speci fi cati on ESA-M1C172-A t o the axl e pilot
fl ange to prevent corrosi on.
2. Pl ace wheel on t he hub. Install lug nuts. Tighten
t hem al ternatel y t o draw t he wheel evenly agai nst
t he hub.
3. Lower vehicle. Tighten the lug nuts t o 115-142
N-m (85-105 Ib-ft).
SERVICE PROCEDURES
Exhaust Syst em, Neutralizing
To neutralize exhaust syst em noise, t he following
st eps must be t aken:
00- 04=23 Noi se, Vi br at i on and Har shness 00- 04- 23
SERVICE P ROCE DURE S ( C o n t i n u e d ) S P E CI A L SERVI CE T O O L S / E Q U I P ME N T
1. Loosen muffler inlet pipe and resonators ( 5A289)
t o mani fol ds, the f ast eners at t he flat flanges and
t he U-clamp at muffler inlet pi pe.
2. Place a st and supporti ng muffler ( 5230) . Raise
muffler t o a height so that t he syst em is parallel t o
the f rame and t he muffler pi pe bracket ( 5277) is
unl oaded.
3. Tighten fl at fl anges.
4. Position muffler inlet pipe and resonators t o
manifolds and ti ghten. Ensure that cat al yst heat
shields do not cont act f rame rails.
5. Prior to tightening U-clamp on muffler inlet pipe
and resonator, ensure t hat tail pipe over axl e
assembl y is spaced evenl y bet ween upper rear
suspension upper front arm and bushing ( 5A923)
and rear spri ng ( 5560) . Tighten U-clamp.
6. Wi th compl ete exhaust syst em ti ght (and in col d
condi ti on) the rear hanger st rap should be angling
f or war d, t o al l ow the syst em t o expand rearward,
when heated t o normal running temperature.
SPECIAL SERVI CE TOOL S REQUIRED
Tool Number
De s c r i p t i o n
/
I l l ust r at i on
T 63L - 862 0- A
Be l t Te n si o n Ga uge
SPECI AL SERVI CE TOOL S DESI RED
T o o l Number De s c r i p t i o n
TOOL - 42 01- C Di a l I n d i c a t o r wi t h Br a c ke t r y
ROTUNDA EQUIPMENT
Mo d e l Desert i on
007 - 00014 Ra d i a l Run Ga u ge
SPECIFICATIONS
TORQUE SPECIFICATIONS
Descr i pti on N-m L b - Ft
Dr i v e s h a f t - t o - Re a r Ax l e U- Jo i n t
Fl a n ge Re t a i n i n g Bo l t s
95- 129 7 0- 95
Wh e e l Hub Bo l t Nut s 115- 142 85- 105
Pi n i o n Nut 2 17 160
01- 00- 1
SECTIOM TITLE PAGE
BODY PANELS, FRONT END . 01-02-1
BODYSERVICE .. . . ...01-00-1
BUMPERS . ......... ...... .............01-19-1
DOOR LOCK CONTROL SYSTEM,
ELECTRONI C 01-14B-1
DOORS AND LUGGAGE COMPARTMENT
DOOR - 01-03-1
GLASS, FRAMES AND MECHANISMS 01- 11- 1
HANDLES, LOCKS, LATCHES AND
MECHANISMS 01-14A-1
INSTRUMENT PANEL......... 01-12-1
L i " jam***- "' âmk.
SECTION TITLE PAGE
MIRRORS, REAR VIEW . . . , . . , 01- 09- 1
RESTRAINTS, ACTIVE ..........01-20A-1
RESTRAINTS, PASSIVE SUPPLEMENTAL AIR
BAG SYSTEM . . . . . 01- 2 0B- 1
ROOF PANEL, SLIDING ELECTRIC . . . . . . . . . 0 1 - 1 7 - 1
SEATS AND TRACKS . 01- 10- 1
TRIM, EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01- 08- 1
TRIM, INTERIOR . . . . . 01- 05- 1
UNDERBODY 01-01-1
WIPER AND WASHER SYSTEMS . . . . . . . . . . 01-16-1
ML
SECTION 01-00 BodyService
SUBJECT PAGE
VEHICLE APPLICATION ..01-00-1
Ant i -Corrosi on Pr ot ect i on 01-00-2
Body 01-00-2
Body and Sheet Met al 01-00-2
Body Sealer Types and Appl i cat i on 01-00-2
I nsul at i on 01-00-2
Li f t i ng and Jacki ng 01-00-3
SERVICE PROCEDURES
Body Sealant Locat i ons . 01-00-4
Body Si de St one Pr ot ect i on Vi nyl , Lower ..01-00-4
Coat i ng Spray Procedure 01-00-5
Col or Coat 01-00-6
Equi pment , Suggest ed .01-00-5
Mat eri al s Requi red . 01-00-4
Sheet Metal 01-00-5
Vehi cl e, Maski ng ..01-00-5
Bumper Cover, Pl ast i cFl ai r Moul di ngs 01-00-7
Bumper s, Pol yuret hane, Rim ...01-00-6
SUBJECT PAGE
SERVICE PROCEDURES (Cont 'd. )
Chemi cal or Organi c Damage Repair 01-00-13
Dust and Water Leaks . . . . . . . . . . . 0 1 - 0 0 - 4
Ext eri or Part s, Fl exi bl e Re f i ni shi ng. . . . . . . . . . . 0 1 - 0 0 - 1 0
Panel Servi ce and Spot Repair . . . . . 0 1 - 0 0 - 1 1
Plast i c Component s ..........01-00-6
Rattle El i mi nat i on .....01-00-4
Repai nt i ng ..01-00-13
Wi nd Noi se .............01-00-4
CLEANING AND INSPECTION
Appearance Prot ect i on . . . . . 01- 00- 19
Body Mai nt enance ......01-00-19
Drai n Hol es. . . . . . . . . . . . . 01- 00- 18
Fl oorpan Plugs and Grommet s . . . . . 01- 00- 14
Rat t le El i mi nat i on . . . 01- 00- 18
Tri m .01-00-18
Vi nyl I nsert Moul di ng Care ......01-00-19
ADJUSTMENTS
Body Ser vi ce. . . . . . . . . . . . . . . . . . . . . 0 1 - 0 0 - 2 1
Bump Work 0 1 - 0 0 - 2 1
SPECIAL SERVICE TOOLS/EQUIPMENT ........01-00-21
VEHICLE APPLICATION
01- 00- 2 B o d y S e r v i c e 01- 00- 2
I
B o d y
The body is a unibody open-cowl structure consisting
of the following part s:
Roof panel ( 50202) and body si de panels that are
separat e pi eces wi th a tri m insert at the joints.
Forked frame.
A split three-part l ower dash front crossmember
( 10414) that has gussets at each corner.
B o d y a n d S h e e t Me t a l
The body is const ruct ed of light-weight, all-steel
wel ded material wi th the following servi ceabl e part s:
Bol ted removabl e front fenders ( 16005) .
Hinged front door ( 20124) and rear door ( 24630) .
Hood ( 16612) .
Luggage compartment door ( 40110) .
A n t i - C o r r o s i o n Pr o t e c t i o n
The anti-corrosion syst em includes a combi nati on of
speci al steel s, chemi cal treatment and surface
coati ngs whi ch provi de a barrier agai nst corrosi on.
The syst em provi des the following protecti on:
Zi nc-coated steel s, both single and doubl e-si ded,
that are used in sensitive rust-prone areas such as
body rocker panels ( 10128) , hood ( 16612) , fuel
filler fuel filler door ( 405A26) , and l uggage
compart ment door ( 40110) .
PVC ribbon seal ers between the hem fl anges
around doors, hood and luggage compartment door
prevent t he entry of wat er and minimize el ectrol yti c
acti on.
The entire body is t reat ed in a phosphat e bat h. The
bat h provi des a coati ng whi ch act s as a corrosi on
inhibitor and provi des a mechani cal bond for further
surface coati ngs.
The compl ete body is undercoated using a cathodi c
el ect rocoat process. This process provi des an
el ectromechani cal l y-bonded, corrosi on-resi stant
coati ng whi ch penetrates body j oi nts not reached
by conventional spray or dip techni ques.
Underbody areas, including the front floor pan
( 11135) , rear fl oor pan ( 11218) , quarter
wheel house inner panel ( 27886) and quarter
wheel house outer panel ( 27894) , are coat ed wi th
PVC or bi tumasti c material whi ch resi sts stone
abrasi on.
- Cavi ty wax, a tough petrol eum-based product, is
injected into hard-to-reach areas, including the
l ower interior secti ons of front door ( 20124) , rear
door ( 24630) and the front and rear edges of the
hood and luggage compartment door.
A coati ng of primer surf acer is appl i ed t o all exteri or
panels t o build a prot ect i ve film t hi ckness and
provi de a smoot h surface for further col or coat s.
Exteri or areas subj ect t o stone damage, such as
the front f asci a (front bumper ( 17757) ) and the
l ower fender and door areas, are sprayed wi t h a
tough, abrasi on-resi stant PVC coat i ng.
Weather-resi stant body col or paint is appl i ed t o
compl ete the sheet metal protecti on.
Additional anti -corrosi on protecti on is provi ded by:
Front fender spl ash shields ( 16102) t o prot ect
the wheel house sheet metal f rom stone
damage.
Stone guards fi tted t o the front and rear wheel
arches and adj acent door areas.
I n s u l a t i o n
Insulation is compri sed of urethane, PVC and recycl ed
felt.
Insulation is installed:
Under the roof panel ( 50202) .
Above and bel ow the dash panel ( 01610) .
At the cowl si de panel s ( 02039) .
Over the front and rear tunnel.
Over the front fl oor pan ( 11135) and rear fl oor pan
( 11218) areas.
B o d y S e a l e r T y p e s a n d A p p l i c a t i o n
L i q u i d Bu t y l Se a l e r
Liquid Butyl Seal er C9AZ- 19554- B or equivalent
meeting Ford speci fi cati on ESB-M4G162-A does not
run, is f ast dryi ng and remai ns semi-elastic. The seal er
can be used for seam sealing in such areas as:
Front fl oor pan ( 11135) and rear floor pan ( 11218) .
Quarter wheel house inner panel ( 27886) and
quarter wheel house outer panel ( 27894) .
Dash panel ( 01610) .
Body rocker panels ( 10128) .
Door openi ngs.
Roof si de dri p rail ( 51700) .
It can al so be used t o seal outsi de moulding clip hol es,
and for wi ndshi el d gl ass ( 03100) and back wi ndow
gl ass installation.
C a u l k i n g C o r d
Caulking cor d D6AZ- 19560- A or equivalent meeti ng
Ford speci fi cati on ESB-M4G126-A is commonl y
known as permagum. Appl y wi th a putty knife:
01- 00- 3 Bo d y Se r v i c e
01- 00- 3
On spot wel d hol es.
Around moulding clips.
Bet ween t wo surfaces not properl y seal ed by a
gasket .
Weat her s t r i p Ad h e s i v e
Weatherstri p adhesi ve E8AZ-19552-A or equivalent
meeting Ford speci fi cati on ESB-M2G14-A is designed
t o hold weatherstri ppi ng on:
Front door ( 20124) and rear door ( 24630) .
Body openi ngs.
Hood ( 16612) and l uggage compartment door
( 40110) .
Cowl si de air vent ( 02108) and the surrounding
metal .
Appl yi ng cement to af f ect ed areas of wi ndows and
wi ndshi el d gl ass set in rubber can effecti vel y seal
agai nst l eakage.
Cl ean all grease, dirt and ol d sealer f r om surfaces t o
be cement ed.
Appl y a medium coat of cement t o bot h surfaces.
Immedi atel y press both surf aces firmly together.
Silicone Lubricant
Use thi s lubricant or equivalent on t he rear door and
front door and mini-vent wi ndow weat herst ri ps. Appl y
silicone lubricant t o the weat herst ri ps at every
lubrication peri od t o:
Make front door and rear door easi er t o cl ose.
Avoi d weat herst ri p squeaks.
Ret ard weat herst ri p wear f rom chafi ng between t he
door gl ass upper f rame and t he weat herst ri p.
Help t o retain door wi ndow alignment by reducing
fri cti on bet ween the gl ass f rame and rubber
weat herst ri p.
Li f t i ng and Jacki ng
Refer t o Secti on 00- 02.
Inspect i on and Veri f i cat i on 3. If t he concerns remain after the i nspecti on,
1. Verify the vehi cl e owner' s original concern (SSF
S y m p t o m s a n d g 0 1 0 t h e S
y
m
P
t o m
regardi ng t he body t o duplicate the condi ti on.
2. Inspect to determi ne if any of the following
mechani cal concerns appl y:
Mechanical
Dust L e a k s .
Wa t e r L e a k s .
Sympt om Chart
LEAK ANALYSIS
Dust Leaks Di splaced sealer.
Worn / damaged weatherstri ps.
Damaged body parts.
Mi sadj usted underbody grommet.
Mi sadj usted doors.
Mi sadj usted glass.
PERFORM Dust and Water Leaks
service procedures as outlined.
Water Leaks Di splaced sealer.
Worn /damaged weatherstri ps.
Damaged body parts.
Mi sadj usted underbody grommet.
Mi sadj usted doors.
Mi sadj usted gl ass.
PERFORM Dust and Water Leaks
01- 00- 4
SERVICE PROCEDURES
Dust and Water Leaks
Consider sealer l ocati ons when checki ng for dust or
wat er l eaks. The f or war d motion of the vehicle causes
any unseal ed, small opening in the l ower secti on of the
body t o permit air and dust into the body. Opening the
ventilator air ducts will equalize these pressures. Dust
accumul ates in the rocker panel and may move into
the l uggage compartment.
To eliminate dust l eaks, determi ne the exact point at
whi ch the dust enters.
Under certai n condi ti ons, wat er can enter the body at
any point where dust can enter.
To determi ne the exact location of a dust leak, remove
the following tri m f rom the vehi cl e:
Cowl t op panel ( 020A51) . Refer t o Secti on 01-05.
Quarter tri m panel ( 31012) . Refer to Secti on 01-05.
Rear seat back and rear seat cushi on. Refer t o
Secti on 01-10.
Luggage compart ment cover panel ( 45430) . Refer
t o Secti on 01-05.
Spare ti re. Refer t o Secti on 00- 02.
Center body pillar inside l ower finish panel ( 24346) .
Front door scuff pl ates ( 13208) . Refer t o Secti on
01- 05.
After removi ng the tri m, the location of most l eaks will
be obvi ous. The entrance of dust is usually indicated
by a pointed shaft of dust or silt. Seal these l eaks and
road-test the vehicle on a dusty road t o make sure all
l eaks are seal ed.
After t he road-test, check for indications of a dust
pattern around the door openings, cowl panel, l ower
part of the quarter tri m panel and in the luggage
compart ment .
Someti mes l eaks can be l ocated by putting bright
lights under the vehi cl e, wi th the above components
removed, and checki ng the interior of the body joints
and wel d lines. A light will show through where l eaks
exi st. The Rotunda Vacuum Leak Det ect or 055- 00103
or equivalent, can l ocate dust l eaks, wi nd and wat er
l eaks.
W i n d N o i s e
Air entering or exiting the vehicle through small
openings in the body can result in wi nd noise. Det ect
sources of wi nd noise by driving the vehicle at hi ghway
speeds in four different di recti ons. Listen for sources
of wi nd noise wi th all wi ndows cl osed, radi o chassi s
( 18806) off, bl ower motor ( 18527) turned off and cowl
si de air vents ( 02108) open. Use a st et hoscope t o
pinpoint t he source of the noise.
Most wi nd noise-producing l eaks will occur at the door
and wi ndow seal s or at sheet metal j oi nts in the door or
the door opening in the body.
Seal all l eaks wi t h RTV seal ant and f oam t ape or by
repositioning or repl aci ng the seal s. Road-test the
vehicle t o make sure all l eaks have been seal ed.
An al ternate method of veri fyi ng correct i ve act i ons
involves the use of Rotunda Vacuum Leak Det ect or
055- 00103 or equivalent. After identifying the l eak
point through a road-test, obtai n a meter readi ng by
using t he leak detector. A check wi t h the leak det ect or
after repairing the leak will veri fy t hat the correct i ons
have been effecti ve. A final road-t est may still be
advi sabl e t o make sure that other obj ecti onabl e l eaks,
not noti ced because of a major l eak, do not exi st .
R a t t l e E l i mi n a t i o n
Forei gn obj ects such as nuts, bol ts or small pi eces of
body deadener in the door wel l s, pillars and quarter
panels often cause rattl es. Check door wel l s by
careful l y stri ki ng the undersi de of t he front door
( 20124) and rear door ( 24630) wi t h a rubber mallet.
Inspect all bol ts and scr ews peri odi cal l y. If tightening
the bol ts and scr ews l ocat ed on assembl i es like the
front door and rear door, hood ( 16612) , and l uggage
compart ment door ( 40110) does not eliminate the
rattl es, misalignment is probabl y t he cause. If thi s is
the case, fol l ow the adj ustment and alignment
procedures for t hese assembl i es.
Rattl es and squeaks are somet i mes caused by
weatherstri ppi ng and anti -squeak material that has
sl i pped out of posi ti on. Appl y additional cement or
other adhesi ve.
B o d y S e a l a n t L o c a t i o n s
The body seal ant l ocati ons are:
Front floor pan ( 11135) and rear floor pan ( 11218) .
Quarter wheel house inner panel ( 27886) and
quarter wheel house outer panel ( 27894) .
Dash panel ( 01610) .
Body rocker panel s ( 10128) .
Door openi ngs.
Roof si de dri p rail ( 51700) .
B o d y S i d e S t o n e P r o t e c t i o n Vi n y l , L o w e r
Ma t e r i a l s Re q u i r e d
Abrasi on Resistant Coati ng D9AZ- 19515- A or
ESB-M4G221-A.
Col or Coat Paint Syst em.
Silicone and Wax Remover.
Multi-Purpose Paint Precl eaner (Spray Gun
Clean-Up) VC-542-A.
01- 00- 5 Bo d y Se r v i c e 01- 00- 5
SERVICE PROCEDURES (Cont i nued)
Equi pment , Su g g e s t e d
Rotunda Spray Gun 085- R1626 (No. 63 Air Cap,
No. SS Fluid Tip, No. 363 AN needle) or equivalent.
Rotunda Det ached Pressure Cup 085- R1617,
0. 946 liter (1 quart) (wi th Air Adj usti ng Gauge) or
equivalent.
Rotunda Dual Acti on Sander 107- R1619or
equivalent.
Rotunda Heat Gun 107-R0300 or equivalent.
No. 180-Grit paper.
Lint-free cl ot h.
Tack cl oth.
Regular maski ng t ape.
No. 80 disc for di sc sander.
No. 220/ 240 di sc.
A large area resulting f rom peeling or damage will
require removing the f act ory sprayed-on vinyl coati ng.
The following procedure is suggest ed:
NOTE: Where sheet metal is damaged t o the ext ent '
that fender, door or quarter panel repl acement is
required (or in an initial installation), di sregard St eps 1
and 2.
1. Using Rotunda Heat Gun 107-R0300 or
equivalent or l amp, soften vinyl coati ng until
pliable. Scrape off softened vinyl wi t h putty knife
or similar t ool . If necessary, sand off any hard t o
remove vinyl coati ng using an orbi tal di sc sander
(No. 80 di sc). (The vinyl abrasi on resi stant
coati ng is not suitable for " s pot " correct i ons. )
2. Perform necessary repai rs t o cor r ect sheet metal
damage.
Abrasion Resistant Coati ng D9AZ- 19515- A or
equivalent meeting Ford speci fi cati on ESB-M4G221-A
is available in 0. 947 liter (one quart ) cans.
Approxi matel y 1.89 liters ( t wo quart s) are requi red for
an initial installation on a vehi cl e similar t o a
factory-appl i ed syst em. The speci fi ed dry film
thi ckness of 15 t o 20 ml ( 0. 015 t o 0. 020 inch) requi res
at least three or four coat i ng appl i cati ons, wi th
flash-off time al l owed bet ween coat s. As wi th painting,
spray-coat the compl et e l ower panel .
Because the adherence of thi s coat i ng t o properl y
prepared sheet metal is excel l ent, the necessi ty of
prime painting the sheet metal pri or t o prot ect i ve
coating is el i mi nated.
NOTE: Adhesion will be adversel y af f ect ed unless the
sheet metal area t o be cover ed (ei ther repai red or
new) is prepared in accor dance wi t h the fol l owi ng
procedure:
Vehicle, Masking
Install suitable cover s over t he wheel s ( 1007) . Mask
off all upper exteri or body sheet met al . Remove wheel
opening stone shi el ds and mask moul di ngs.
NOTE: If the vehi cl e has l ower body si de mouldings
305- 355 mm ( 12- 14 inches) above the "t ur n under" of
t he rocker panel , t he moulding can serve as t he upper
margi n of the area t o be coat ed. If the vehi cl e does not
have suitable mouldings, use a scul pture or break line
in the sheet metal . However, the met hod used in
maski ng off the upper coati ng margin line will depend
on the presence or absence of mouldings in thi s area.
Maski ng t ape should be positioned so that the
moulding l ower side is also covered. Do not cover t he
sheet metal immediately bel ow the moulding.
Do not mask off body door openings in the coati ng
area because t hey will be uniformly coat ed where t he
door margi ns al l ow t he coati ng t o enter. However,
t hese door opening areas should be cl eaned t o ensure
coati ng adherence.
S h e e t Me t a l
Sh e e t Me t a l , Se r v i c e d
1. Scuff-sand (No. 180-grit paper) the gl ossy
surface of t he painted areas t o be coat ed.
2. Remove sandi ng dust using a lint-free t ack cl oth
and compressed air.
3. Using a cl ean, lint-free cl ot h, sol vent-wi pe area t o
be coat ed wi t h Multi-Purpose Paint Precl eaner
VC-542-A or equivalent and allow t o flash-off.
S h e e t Me t a l , N e w
1. NOTE: Do not sand through the primer.
Scuff-sand (No. 180-grit paper) the primer.
2. Remove sanding dust using a lint-free t ack cl oth
and compressed air.
3. Using a cl ean, lint-free cl ot h, sol vent-wi pe area t o
be coat ed wi t h Multi-Purpose Paint Precl eaner
VC-542-A or equivalent and al l ow t o flash-off.
C o a t i n g S p r a y P r o c e d u r e
To prot ect the l ower exposed pai nted fender, body
rocker panel ( 10128) , and quarter panel down
fl anges, el evate the vehi cl e high enough so that t he
painter can spray areas effecti vel y. When maki ng an
initial installation, a remote 1.89 liter (t wo quart)
capaci t y pressure cup makes a much more efficient
t ool , because t he spray gun can be used cl oser t o t he
floor. Clean t he spray gun, fluid hose and/ or cup
i mmedi atel y after use. While lacquer thinner can be
used when the suggest ed clean-up material is
unavailable, Multi-Purpose Paint Precleaner, VC-542-A
or equivalent is qui cker and much more efficient. Wi t h
Rotunda Spray Gun 085-R 1626 or an equivalent set at
207 kPa ( 30 psi ) and Rotunda Det ached Pressure Cup
085-R 1617or an equivalent set at 103 kPa ( 15 psi ),
fol l ow this procedure:
1. Appl y a wet , sag-free coat . Al l ow three t o five
minutes flash-off ti me.
2. Appl y a second wet , sag-free coat . Al l ow three t o
five minutes flash-off ti me.
3. Appl y a thi rd wet , sag-free coat . Allow t hree t o
five minutes flash-off ti me.
Body Ser v i c e 01- 00- 6
4. Appl y a final wet , sag-free coat . Al l ow three t o
five minutes flash-off time and pull off fine line
tape, exposi ng raw upper edge of the coati ng.
5. Immediately clean spray equipment using
Multi-Purpose Paint Precleaner VC-542-A or
equivalent.
6. Allow at least t wo hours dryi ng time at
approxi matel y 21 C ( 70F).
Col or Coat
The compl ete coat ed area must be covered wi th col or
coat . Mask off upper margin line wi t h Fine Line Tape
posi ti oned 1.59 mm (1 / 16 inch) above coati ng edge.
Using appropri ate repair paint and appl i cati on
procedures, including both prime and col or coat , finish
paint the protecti ve coati ng.
NOTE: If damaged sheet metal ext ends above the
protecti ve coati ng area, fol l ow the normal pri me/ col or
paint procedures.
Plastic Component s
Cuts and cr acks t o the radi ator grille opening panel
( 8190) or rear bumper cover ( 17K835) where
substrate materi al has not been removed can be
repai red using Instant Adhesi ve E8AZ- 19554 or
equivalent. Gouges, t ears and hol es, where under
surface material has been damaged, can be repai red
using 3M Structural Adhesi ve Tube Kit No. 8101 or
equivalent. Refinish the repai red area using
El astomeri c Addi ti ve mi xed wi th the appropri ate finish
paint.
B u m p e r s , P o l y u r e t h a n e , Ri m
Where substrate material has not been removed, cuts
and cr acks t o the radi ator grille opening panel ( 8190)
or rear bumper covers ( 17K835) can be repai red wi th
3M P.R.O. Fill EZ-Sand (3M Part # 0 5 8 9 5 and
#05896) 3M P.R.O. Fill Automi x (3M Part #05987)
or equivalent.
The following repair procedures can be used for either
the radi ator grille opening panel or the rear bumper
covers.
Three t ypes of damaged bumpers are consi dered
repai rabl e:
A bumper wi th a hole less than 50 mm (1. 97 i nches)
in diameter.
A bumper wi th a cr ack l ess than 100 mm ( 3. 94
inches) in length.
A bumper wi th a cr ack less than 100 mm ( 3. 94
inches) in length that is less than half of t he wi dth of
the bumper.
Al though a bumper damaged beyond this point coul d
also be repai red, repl ace it wi t h a new one. Repair
wor k woul d lessen the beauty and quality of the
bumper because of t he decrease in adhesi ve strength
and other f act ors. Such repai r is al so not consi dered
reasonabl e in t erms of wor k l oad.
Repair pol ypropyl ene bumpers having f l aws that have
reached the surface of t he pol ypropyl ene and are t oo
seri ous t o be rest ored by painting.
1. Cut the rough edges around t he fl aw wi t h a knife
t o make it smoot h. Sand t he area wi t h a sander t o
make an angle of about 45 degrees.
2. CAUTI ON: Di s c o n n e c t t h e n e ga t i v e b a t t e r y
g r o u n d c a b l e b e f o r e u s i n g a n y e l e c t r i c
we l d i n g e q u i p me n t . Da ma ge t o e l e c t r i c a l
c o mp o n e n t s ma y o c c u r .
Wel d damaged ar ea.
For repair of a cr acked ar ea, melt t he crack
together using Rotunda Ai rl ess Pl asti c Wel der
107- 01250 or equivalent.
> For repair of a hole, degrease t he area and the
reverse side of t he damaged ar ea. Install
aluminum t ape on reverse si de of damaged
area.
3. NOTE: Heat only t he shaded area of cr ack or
hole t o melt it.
Melt the pol ypropyl ene wel di ng rod wi t h Rotunda
Ai rl ess Plastic Wel der 107- 01250 or equivalent
and deposi t it in the cr acked ar ea.
Do not melt the wel di ng rod excessi vel y. If the
part is wel ded wi th the wel di ng rod mel ted like
jelly, the wel di ng strength will be l owered.
Operat e a heat gun 2-51 mm (0. 5-2. 0 i nches)
away f rom the part that will be wel ded.
Do not move t he wel di ng rod until the wel ded part
cool s.
4. NOTE: Do not sand part continuously.
Sand the surface of the pol ypropyl ene little by
little because it is easily mel ted even by the
abrasi on heat. If mel ted, remove the mel ted area.
Sand the areas t o whi ch repai r agent will be
appl i ed.
5. Appl y pol ypropyl ene primer uniformly t o an area
larger than the repai red area wi th a brush. It will
t ake about 10 minutes t o dry at 20C ( 68F) .
6. NOTE: When mixing the main and stiffening
agents, do not al l ow bubbles t o f orm.
Mi x the main agent and the stiffening agent in a
ratio of one t o one. Appl y the mi xed repai r agent
t o the damaged ar ea.
Because the repairing agent hardens f ast (about
five minutes), proceed wi t h the wor k i mmedi atel y
after mixing t he agents.
Al l ow about 30 minutes t o dry at 20C ( 68F)
before sandi ng.
0 1 - 0 0 - 7 Bo d y Se r v i c e 0 1 - 0 0 - 7
SERVICE PROCEDURES (Cont i nue d)
7. NOTE: If excessi ve f or ce is appl i ed t o t he ar ea
when sandi ng, t he surf ace will not become
smoot h.
Sand t he ar ea wi t h 180 t o 240-gri t sandpaper.
Mel t any fuzz around t he repai red ar ea by heati ng
it sl i ghtl y wi t h a heat gun.
8. Degr ease t he pai nted surf ace.
9. NOTE: Pol ypropyl ene pri mer will di ssol ve, even
af t er dryi ng, if wi ped wi t h sol vent. Cl ean wi t h
wat er.
Dr y t he part .
10. Add t he sof t ener t o t he uret hane pri mer surf acer
and spr ay it on t he repai r.
11. Ai r-dry at 2 0 C ( 68F) f or ei ght hours.
For ce- dr y at 6 0 C ( 140F) f or one hour.
12. Li ghtl y sand t he ar ea on whi ch t he pri mer
surf acer is spr ayed and t he compl et e surf ace of
t he bumper wi t h 400 t o 600-gri t sandpaper. Do
not expose t he surf ace of t he pol ypropyl ene.
(Wet sandi ng or dr y sandi ng is accept abl e. )
13. Wi pe t he compl et e surf ace of t he bumper wi t h a
degreasi ng agent . Degr ease t he surf ace by
qui ckl y wi pi ng it wi t h a cl ean r ag.
14. NOTE: The pai nt for repai ri ng a pol ypropyl ene
bumper adher es poorl y t o a uret hane bumper.
Use onl y uret hane pri mer f or a urethane bumper
and pol ypropyl ene pri mer f or a pol ypropyl ene
bumper.
Appl y a mat chi ng coat of pai nt t o t he
pol ypropyl ene bumper.
Ot her pai nts f or repai ri ng a pol ypropyl ene
bumper ar e t he same as t hose f or t he urethane
bumper.
15. NOTE: Let t he part ai r-dry when possi bl e
because f orce-dryi ng coul d cause bubbl es in t he
t op coat .
Ai r-dry at 2 0 C ( 68F) f or ei ght hours.
Force-dry at 60C ( 140 F) f or one hour.
Bumper Cover, Pl ast i cFl ai r Moul di ngs
* Procedure 1 Subst rat e Cuts or Cracks
1. Wi pe repai r ar ea wi t h si l i cone and wax remover
t o ensure cl ean surf aces.
2. Not e t he precaut i ons on adhesi ve contai ner.
Appl y a thin coat i ng of Instant Adhesi ve
E8AZ- 19554- A or equi val ent meeti ng Ford
speci f i cat i on WSK- M2G402- A4 t o one surf ace of
t he cut or cr ack. Posi ti on t he surf aces t oget her
ver y qui ckl y in thei r ori gi nal posi t i on. Qui ckl y and
fi rml y pr ess t he t wo sur f aces t oget her f or at l east
one mi nute. Good bond st rengt h is devel oped
af t er one minute but maxi mum st rengt h requi res
t hr ee t o 12 hours t o cure.
3. If t he part di d not have pai nt damage and was
properl y posi t i oned, pai nti ng may not be requi red.
But if pai nti ng is necessary, pr oceed as f ol l ows:
a. Scuff-sand t he repai r ar ea wi t h a sandi ng
bl ock and No. 400 paper. Do not sand
t hrough t he col or coat surf ace. Usual l y
dulling t he surf ace is suffi ci ent. Wi pe off or
cl ean t he repai r ar ea wi t h a cl ean, dr y cl ot h
or an air gun.
b. Wi pe t he sanded surf ace wi t h si l i cone and
wax remover or equi val ent.
c. NOTE: El ast omeri c addi ti ve is f or i ndustri al
use onl y and shoul d onl y be appl i ed by
qual i fi ed personnel . It is not i ntended f or t he
general publ i c. The addi ti ve is not i ntended
f or publ i c use.
Refinish as descr i bed under Ext eri or Par t s,
Fl exi bl e Refi ni shi ng.
Procedure 2Subst r at e Holes, Gouges and
Tears
1. Wi pe damaged ar ea wi t h si l i cone and wax
remover t o ensure cl ean surf aces.
2. Usi ng a gri nder such as Rot unda Dual Act i on
Sander 107- R1619 or equi val ent or a sandi ng
bl ock wi t h No. 36 Di sc or Coar se Abr asi ve
Paper, gri nd or abr ade away suffi ci ent subst r at e
materi al around t he damaged ar ea t o maxi mi ze
adhesi on of repai r mat eri al . Af t er initial gri ndi ng,
t he t hree basi c t ypes of repai r shoul d l ook as
shown:
1995 T o wn Ca r , Cr o wn Vi c t o r i a , G r a n d Ma r q u i s J u l y 1994
01- 00- 8
Bo d y S e r v i c e 01- 00- 8
01- 00- 9 Bo d y Se r v i c e
SERVI CE PROCEDURES (Conti nued)
01- 00- 9
5. Flame-treat the exposed substrate repair area t o
i mprove adhesion. A propane t orch wi th a 25. 4
mm (1-inch) long blue flame should be moved over
the surface until the exposed subst rat e is a light
brown color. Keepi ng the flame moving will
minimize paint damage.
N4484-C
6. Wi pe the underside of the repair area wi th
silicone and wax remover and appl y Auto Body
Repair Tape (3M No. 6930) or equivalent t o
underside of repair area to backup pat ch
material.
7. NOTE: To prevent air bubbl es during mi xi ng, the
components should be scr aped t oget her wi t h
downward pressure and spread thinly on t he
mixing board. Adhesi ve should be used within t wo
minutes after mixing. Observe saf et y precauti ons
when handling adhesi ve.
Using the 3M Structural Adhesi ve Tube Ki t Part
No. 8101 or equivalent, mix t he filler materi al .
Carefully follow the i nstructi ons on t he t ubes and
the kit container t o ensure cor r ect mi xi ng and
application of the pat ch materi al .
8. Appl y mixed adhesi ve t o area wi t h a squeegee in
t wo steps:
M4490-C
a. Appl y a light coat over entire area and
al l ow t o dry.
b. Mi x and appl y second coat if required t o
rest ore the contour.
9. In restori ng the contour, spread f rom edges
t owar d center, filling all low areas. If voi ds,
bubbl es or low areas occur, mix more adhesi ve
and appl y t o servi ce area.
10. Use heat l amps or guns t o speed the drying
process. Because excessi ve heat may damage
the subst rat e, do not use lamps cl oser than 1-1.5
m (4-5 f oot ) t o repai r area or heat guns at
88- 98C ( 190- 210F) for longer than 20
minutes. A cooki ng thermometer can be used.
M44S8-C
01- 00- 10 Body Ser v i c e 01- 00- 10
SERVICE PROCEDURES (Continued)
11. NOTE: The adhesi ve can be sanded after the 20
minutes heat (lamp or gun) cure, or after one hour
at room temperature 22C ( 72F) .
NOTE: Sanding in t wo directions tends to lift
edges and spoil the servi ce.
Grind or bl ock sand down t o correct contour.
Grind wi t h a No. 240 Di sc fol l owed by a No. 320
Paper fol l owed by No. 400 Wet or Dry.
12. NOTE: Spot or glazing putty cannot be used for
el astomeri c (soft) grille opening panel repair.
Examine the finish and fill any bubbl es, holes or
low spot s wi th additional adhesi ve.
N4490-C
13. The entire panel surface must be scuff-sanded
(orbi tal -type di sc or bl ock) wi th No. 320 di sc or
paper.
14. Clean repair area by bl owi ng off wi th an air gun.
N4492-C
15. Wi pe the entire area t o be pai nted wi t h a cl ean,
dry cl oth or t ack cl oth t o ensure cleanliness.
16. Appl y t wo or more pri me paint coat s thinned by
following the di recti ons on the paint can. Al l ow 30
minutes to dry. Finish painting the pri med repair
area for minor cuts and cr acks.
E x t e r i o r Pa r t s , F l e x i b l e Re f i n i s h i n g
WARNI NG: HANDLE THE ADDI TI VE WI TH
CAUTI ON. I TS USE IS RESTRI CTED TO QUALI FI ED
PERSONNEL AND SS NOT I NTENDED FOR THE
GENERAL P UBL I C THE PRODUCT L ABEL
PROVI DES I NFORMATI ON ON RECOMMENDED
SAFETY PRECAUTI ONS AND PROPER
APPLI CATI ON. THE ELASTOMERI C ADDI TI VE
SHOULD NOT BE USED UNTI L THI S I NFORMATI ON
IS READ AND UNDERSTOOD. OBSERVE ALL
APPLI CABLE PRECAUTI ONS.
THE VAPOR AND MI ST SPRAY CAN BE HARMFUL
WHEN MI XED. USE IN A SPRAY BOOTH WI TH
ADEQUATE RESPIRATOR PROTECTI ON. THE
RECOMMENDED PROTECTI ON IS A NATI ONAL
I NSTI TUTE FOR OCCUPATI ONAL SAFETY AND
HEALTH APPROVED POSI TI VE PRESSURE
AI R-SUPPLI ED RESPIRATOR. IF THI S IS NOT
AVAI L ABL E, USE A VAPOR/ PARTI CLE
RESPI RATOR SUCH AS 3M MODEL NO. 6 9 3 4 OR
EQUI VALENT RECOMMENDED BY THE
MANUFACTURER AS EFFECTI VE FOR
I SOCYANATE VAPORS AND MIST. RESPI RATOR
PROTECTI ON IS RECOMMENDED FOR USE
DURI NG THE WHOLE TI ME OF SPRAYI NG AND
UNTI L A L L VAPOR AND MI ST IS GONE. THE 3M
RESPIRATOR PACKAGE HAS SPECI FI C FI TTI NG
AND USE I NSTRUCTI ONS THAT MUST BE
FOL L OWE D TO ENSURE MAXI MUM PROTECTI ON
FROM THE RESPIRATOR.
El astomeri c additive is intended for use wi th Acryl i c
Air Dry servi ce paints or suitable equivalents t o
refinish flexible parts and is not suitable for use on
metal .
01- 00- 11 Body Ser v i c e
SERVI CE P ROCE DURE S (Cont i nued)
This materi al adds flexibility t o air-dry repair paints so
that the same paint wi t h additive can also be used for
repair of soft, non-metallic parts. The use of standard
servi ce automoti ve finishes on flexible parts is
i mpracti cal because t hese finishes form a rigid coati ng
when paint cures. This addi ti ve al l ows paint coati ng to
adhere t o the part when fl exed or compressed and
return t o normal appearance as the part returns or
recovers t o its original shape.
The addi ti ve should be kept away from wat er or moist
air because it may react wi th wat er and form a gel-like
materi al whi ch can make t he product useless.The
coati ng flexibility may be adversel y affected if relative
humidity of air is high during application. The container
must be kept cl osed when not in use.
The useable " p o t " life of a mi xed color is
approxi matel y one hour, after whi ch the mixture will
not dry properl y, To avoi d wasti ng the materi al , mix
only the quantity requi red. Clean all spray equipment
wi t h solvent immediately after use. Allow part to cure
t wo t o four hours after final coat before handling. After
curing for 2 4 hours, the coati ng can be rubbed out by
hand t o i mprove the finish. Do not use a machine for
rubbing; it may cause burri ng.
Sur f ac e Pr epar at i on
If the fl exi bl e part has a coati ng that compl etel y covers
the subst rat e, no speci al priming is requi red. Clean
wi th a silicone and wax remover and scuff-sand wi t h
400-gri t paper t o remove gl oss. The hi gh-bake
el astomeri c coati ng appl i ed in the f act ory requires
sanding t o promot e adhesi on of the air-dry servi ce
paints.
If the coati ng does not cover the subst rat e, Ford
El astomeri c Primer EBP-M18P5-A and Ford
El astomeri c Thinner EBP-1618-B or equivalent must
be used prior t o appl yi ng t he color coat . Follow label
instructions for each product .
Mixing a n d Appl i c at i on
The addi ti ve is highly recommended for use wi th
acryl i c enamel . It may al so be used wi th acryl i c
lacquer for col ors not available in enamel .
Appl y full wet coat s wi t h 10 to 15 minutes flash-time
bet ween coat s.
Enamel : Requi res t hree full wet coat s.
One part El astomeri c Additive (EBP-652-A), 118 ml
(4 ounces)
Four part s acryl i c enamel , 473 ml ( 16 ounces)
Lacquer : Requires si x full wet coat s.
One-half part El astomeri c Addi ti ve (EBP-652-A), 59
ml (2 ounces)
Two part s Acryl i c Lacquer, 236 ml (8 ounces)
Panel Service and Spot Repair
Use a commerci al refinishing syst em and fol l ow
manufacturer' s i nstructi ons.
Pai nt Damage from Airborne Materials
The fol l owi ng information gi ves detai l ed descri pti ons
of paint damage caused by chemi cal or organi c
materi al s. If servi ce is requi red, identify the source of
the damage and fol l ow the recommended servi ce
procedure.
Chemical
The ef f ect s of chemi cal ai rborne materi al s can be
seen as:
Dark bl otches in the paint where the pigment in t he
paint surf ace has been at t acked.
Irregular spot s that are cr acked or et ched around
t he edges and dull in t he centers.
Small orange-col ored spot s caused by iron parti cl es
whi ch may appear on the paint surface.
Materi al s that at t ack a paint film are either acidic or
alkaline.
Sulfuric and nitric aci ds can cause ext reme damage t o
automoti ve paint finishes. Even very small
concentrati ons of the same materials can cause
chemi cal spotti ng damage. Due t o evaporati on and
condensati on, t hese aci ds can creat e severe etchi ng
" s pot s " that may eventually cr ack or lift the paint film
after some ti me in servi ce.
Al though some automoti ve finishes are more resi stant
than ot hers, none are compl etel y immune t o t hese
chemi cal s. The most resi stant paints are t he
urethanes because their resin syst em is l east likely t o
react wi t h chemi cal s. Ai r-dry coati ngs are more
suscepti bl e t o at t ack only when they are f resh. The
longer the paint dri es, t he more resi stant it becomes.
Metallic col ors are less tol erant t o chemi cal s because
aluminum flake is fairly reacti ve wi th either an aci d or
alkali.
The fol l owi ng chart contai ns the most common aci d
materi al s found on automoti ve finishes. The chart
shows a color, the correspondi ng damage
appearance and the chemi cal causal agent. It is not
appl i cabl e for Basecoat / Cl earcoat finishes.
0 1 "00= 12 B o d y S e r v i c e
01- 00- 12
CHEMICAL SPOTTING DAMAGE OF AUTOMOTIVE FINISHES
P a i n t C o l o r Appearance C a u s e d
Ye l l o w Wh i t e s p o t
Da r k b r o wn s p o t ( y e l l o w)
Re d s p o t wi t h f i l m d e g r a d a t i o n
Sp o t b l i s t e r i n g
Hy d r o c h l o r i c or mur i a t i c a c i d
Ni t r i c a c i d
So d i u m h y d r o x i d e ( c a u s t i c )
8
A c e t i c a c i d
No n - me t a l l i c Me d i u m De p t h Bl ue Wh i t e n i n g
Wh i t e n i n g wi t h f i l m d e g r a d a t i o n
Spo t b l i s t e r i n g
Ni t r i c a c i d
8
A c e t i c a c i d
Wh i t e Pi n k
Pi n k c o l o r a t i o n wi t h f i l m d e g r a d a t i o n
Ye l l o wi n g, n o n - a c r y l i c l a c q u e r o n l y
Ni t r i c a c i d
8
A c e t i c a c i d
A mmo n i u m h y d r o x i d e
Me d i u m De p t h Bl ue Sl i ght l i ght bl ue s p o t
Da r k bl ue s p o t
De e p pur pl e s p o t wi t h f i l m d e g r a d a t i o n
Hy d r o c h l o r i c a c i d
Ni t r i c a c i d
8
A c e t i c a c i d
Pa l e Bl ue Me t a l l i c s Sl i ght d a r ke n i n g
Sl i ght y e l l o wi n g
Se v e r e d a r ke n i n g
Se v e r e d a r ke n i n g wi t h f i l m d e g r a d a t i o n
Ni t r i c a c i d
8
A c e t i c a c i d
Si l v e r Me t a l l i c s L i ght s p o t
L i ght s p o t ( e n a me l t ur n s y e l l o w)
Ye l l o wi n g
Da r k, f i l m d e g r a d a t i o n
Ni t r i c a c i d
8
a " C a u s t i c " r e f e r s t o a n y a l ka l i n e s u b s t a n c e t h a t ma y be " h a r s h " or " c o r r o s i v e " d e p e n d i n g on s t r e n gt h o r c o n c e n t r a t i o n .
The following pH chart shows the relationship between
aci di c and alkaline chemi cal s and their correspondi ng
pH values. This chart is provi ded for reference only.
ACI DS/ALKALI S AND pH CHART
pH S c a l e Va l ue E x a mp l e s
2. 0 - Ve r y St r o n g
A c i d s
Hy d r o c h l o r i c , Ni t r i c Sul f ur i c ,
P h o s p h o r i c , Hy d r o f l u o r i c
a n d s o me Wi r e Wh e e l
Cl e a n e r s
3. 0 - St r o n g A c i d s Ci t r i c , Ch r o mi c , Sul f o n i c ,
a n d Huma n Ga s t r i c J u i c e s
4. 0 - A c i d i c Ox a l i c , Gl uc o n i c , Ta r t a r i c
Fa l l o ut Re mo v e r
5. 0- Sl i ght l y Ac i d i c L a c t i c , Ur i c , A c i d Ra i n
6. 0 - Ve r y Sl i ght l y
A c i d i c
Ca r b o n i c
7. 0 - Ne ut r a l Bl o o d , Mo s t Bo d y Fl ui d s,
Di st i l l e d Wa t e r
8. 0 - Ve r y Sl i ght l y
Al ka l i n e
Ur i n e , Wa s h Co n c e n t r a t e
9 . 0 - S l i g h t l y
Al ka l i n e
Ba ki n g So d a
10. 0 - Al ka l i n e So d a A s h , Ca r b - Kl e e n
1 1 . 0 - S t r o n g
Al ka l i n e
Ly e , P o t a s h , Ti r e Cl e a n e r
Or g a n i c
Organi c damage is usually easi er t o identify. Organi c
damage is mostl y due t o t ree sap, bird and insect
droppi ngs, dead i nsects and pollen. Tree sap is easily
identified by clear rai sed drops that may be hard or
st i cky. Bee or bug droppi ng spot s may appear
browni sh or yel l ow in color, about 3.2 mm ( 1 / 8 inch) t o
6. 4 mm (1 / 4 inch) in diameter. Dead and decomposi ng
i nsect bodi es are easily seen. Pollen deposi ts are
small yel l ow cl usters. Each of these i tems is
potentially damagi ng t o any currentl y available paint
syst em. Other noti ceabl e trai ts of organi c damage are
spot s that are rai sed (swel l i ng), mi cro-crazi ng
(cracked) and pitting due t o pollen eati ng into the paint
film. The acti ve ingredients in most organi c
contami nants are tannic and formi c aci ds. These aci ds
are found in berri es and bodily fluids of i nsects and
bi rds.
Because deal ershi p lot lights at t ract i nsects, use " sof t
l i ght s" for display and st orage lot illumination t o
reduce damage. Organi c damage is accel erat ed by
heat. During very hot weat her condi ti ons, it is
i mportant t o wash vehi cl es more often.

Body Ser v i c e 13
SERVICE PROCEDURES ( Co n t i n u e d )
Ch e mi c a l or Or g a n i c Da ma g e Repai r
Iron dust parti cl es may imbed themsel ves into the
paint film. On some light-colored vehicles after some
weatheri ng, tiny dot s of rust st art t o appear. They feel
rough t o the t ouch and are difficult to remove. The best
way to remove these parti cl es is by treati ng the finish
wi th an oxal i c aci d-detergent-water wash. Use the
following procedure t o perform thi s servi ce repai r:
1. NOTE: Oxal i c aci d wash is also pre-packaged in
vari ous strengths under various brand names for
mixing.
Wash and degrease the vehicle first using Ford
Mulfi Purpose Cleaner B8A-19523-B or
equivalent and a suitable wax and grease
remover. If this does not remove all of t he iron
parti cl es, proceed wi th the oxal i c aci d wash.
2. Prepare a quantity of oxal i c aci d-detergent-water
solution as fol l ows:
a. Dissolve six t o eight ounces of oxal i c aci d
(powder) in one gallon of war m water.
b. Add one to t wo tabl espoons full of
non-alkaline detergent such as Ford
Multi-Purpose Cleaner B8A- 19523- B or
ESR-M14P4-A.
3. Appl y this solution liberally t o all af f ect ed
surf aces of the vehicle wi th a l arge sponge. Keep
the surface wet until t he techni ci an can no longer
feel any surface roughness wi th fi ngerti ps. If not
done thoroughl y, staining may redevel op from
remaining iron parti cl es.
4. CAUTI ON: Fa i l ur e t o t h o r o u g h l y r i n s e t hi s
s u r f a c e coul d r esul t i n c o r r o s i o n o f a n o d i z e d
al umi num o r st ai nl ess s t e e l p a r t s w i t h
p r o l o n g e d c o n t a c t .
Rinse the area wi th cl ean water.
5. NOTE: The use of polishing (wi th wax) , sanding
wi t h microfine sandpaper ( 1500 grit or great er)
or buffing wi th very light compound should only be
done as a last resort.
If t he iron parti cl es are not total l y removed after
t wo washi ngs, use one or bot h of the procedures
listed for minor chemi cal contami nati on.
We t Sa n d i n g
1. Clean the exteri or surface of the vehi cl e wi th
Ford Multi Purpose cl eaner B8A- 19523- B or
ESR-M14P4-A t o remove all contami nati on.
2. Appl y 1500-gri t sandpaper t o a rubber padded
sandi ng bl ock t o sand the paint surf ace.
3. NOTE: If the damage has gone deepl y into the
paint film and will not polish or sand out,
refinishing is requi red.
Use a squirt bottl e filled wi t h wat er to l ubri cate
t he 1500-gri t sandpaper as you begi n t o sand
only the damaged areas. Wat er i s both an
abrasi ve and a lubricant in t hi s st ep.
P a i n t Re c o n d i t i o n i n g
Acryl i c enamel single stage or base/ cl ear paint
syst ems should be painted by using t he fol l owi ng
procedure:
1. NOTE: If the damage is t hrough the t op coat
finish and into the pri mers, t he panel must be
sanded down to bare metal or pl asti c and then
refinished.
Wash the vehicle wi th Ford Multi Purpose Cleaner
B8A-19523-B or equivalent meeting Ford
speci fi cati on ESR-M 14P4-A t o remove all organi c
materials.
2. Wash the areas t o be pai nted wi t h wax and
grease remover.
3. Prepare the area as f ol l ows:
a. Neutralize the affected areas wi t h baki ng
soda (sodi um bi carbonate) and wat er.
b. Rinse the surface off wi t h plain wat er.
c. Wash the panel wi t h a mild soapy detergent.
d. Dry the panel compl etel y.
4. NOTE: A fl ex additive may be necessary when
worki ng wi th flexible pl asti cs.
Appl y a self-etching primer for metal surfaces
only.
Then proceed as fol l ows:
a. Let dry per instructions.
b. Appl y a two-component urethane pri mer
surfacer.
c. Sand the surface wi t h 400-gri t sandpaper t o
get proper finish.
d. Finish sanding wi th 600-gri t sandpaper.
5. NOTE: Use acryl i c urethane enamel for this t ype
of repair.
Sol vent-wash the panel wi th wax and grease
remover. Tack-wi pe it.
6. Appl y base coat or t op coat materi al accordi ng t o
appl i cabl e paint syst em.
7. Appl y cl ear acryl i c urethane if using a base / cl ear
paint syst em.
R e p a i n t i n g
Before attempti ng t o repai nt, determi ne the surf ace
and overal l condition of the exi sti ng paint.
Horizontal surf aces usually show the great est surface
deteri orati on. Carefully i nspect t he hood ( 16612) and
roof panel ( 50202) t o determi ne the overall condi ti on
of the paint.
Clean the areas t o be i nspected and look carefully for
any signs of surface deteri orati on, or any other f orm of
film breakdown such as checki ng, cracki ng, or
humidity blistering. In particular, note t he gl oss level.
Low gl oss i ndi cates surface irregularities caused by
such def ect s as checki ng or blistering.
01- 00- 14 Body Ser v i c e 01- 00- 14
Look for evi dence of brittleness, poor adhesi on, or
excessi ve chi ppi ng. To investigate the finish of the
paint, scrape the finish slightly wi th a penknife.
If a compl ete repainting j ob is necessary, plan a
painting sequence bef ore beginning t o spray t o ensure
continuity, avoi d dry joint overl aps and minimize
unnecessary work.
NOTE: Some st at e and local governments have
speci fi c health and saf et y regulations whi ch
recommend using speci al breathing apparat us when
using finishing materi al s containing t oxi c product s.
Fi rst, spray all locations that are not easily accessi bl e
( hood and hood edges, drain channels, door
openi ngs). Keep doors slightly ajar t o prevent sti cki ng
and permit efficient dryi ng. The spray will remove dust
whi ch otherwi se might be blown about and damage
t he finish.
Respray Sequence, Methodical
Once the difficult access areas have been spr ayed,
begin painting the roof panel at the C-pillar, along
the drip rail, to the front body pillar ( 02500) . Paint
f rom the rail i nward t owar d the roof panel center.
Move t o the opposi te side of the body, pick up the
wet paint edge by appl yi ng the paint f rom the center
of the roof panel, continue out ward and along the
dri p rail t o the front body pillar, and finish the roof
panel by sprayi ng the C-pillar.
Extend the coat application down the C-pillar. Paint
the entire body side including the doors and fender
quarter.
Move acr oss t o the front cowl , hood, and top of the
opposi te front fender ( 16005) .
Continue down the front fender and along the body
side t o include the door, quarter panel and C-pillar.
Paint the luggage compartment door ( 40110) and
back panel s.
Drying Paint Repair Work
1. The radi ator grille ( 8200) is made of pl asti c.
Remove or cover the radi ator grille. Al so cover
parki ng l amps ( 13200) , rear l amps ( 13404) , and
outsi de rear vi ew mi rrors ( 17682) when dryi ng
the vehicle at approxi mat el y 90C ( 200F) .
2. If all openings caused by missing wi ndow f rames
and other openings are properl y masked, do not
remove pl asti c part s f rom the interior of t he
vehi cl e, wi th the possi bl e except i on of the radi o
chassi s ( 18806) .
3. Moni tor passenger compart ment t emperat ure. If
the vehicle is equi pped wi t h a radi o t ape pl ayer
digital audio compact di sc player, do not al l ow t he
temperature to exceed 78C ( 170F) .
4. Lat ch doors in the fi rst cat ch t o avoi d di storti on of
the weat herst ri ps.
Floorpan Plugs and Grommet s
Many plugs and grommet s are used in t he front fl oor
pan ( 11135) , rear floor pan ( 11218) and dash panel
( 01610) . The fl oorpan plugs seal the vari ous access
hol es. If any plugs are missing or i mproperl y i nstal l ed,
a dust or wat er leak may result. This al so appl i es t o
the grommet s used on the instrument panel . When
dust or wat er l eaks are evident, t hese plugs and
grommet s should be checked for proper installation.
01- 00- 15 Bo d y Se r v i c e
"1 .-F.-, ._ _
01- 00- 15
CLEANING AND INSPECTION (Conti nued)
Town Car
VIEW B
FRONT OF VEHICLE
I
VI E W A
FRONT OF VEHICLE
V I E W B
N12348-A
Pa r t
1 377935S Plug Button
2 377949S Plug Button
3 111A74 Cover
4 2 0 5 5 2 Insulator
01- 00- 16
CLEANING AND INSPECTION (Cont i nued)
To wn Car
Part Pa r t
I t em Number Descr i pt i on I t e m Nu mb e r De s c r i p t i o n
1 021A46 Cowl Top Panel Seal 4 389515-S Plug Button
2 377949-S Plug Button 5 377356-S Plug Button
3 378770-S Plug Button 6 379286-S Plug Button
(Continued)
7 377936-S Plug Button
01- 00- 17 Bocl vSer vi ce
C L E A N I N G AMD I MSPFCTSON f C o n ! i n u a i )
Cr own i ct or i a, Crane Ma* qui
VIEW A
FRONT OF VEHICLE
CROWN VICTORIA
VIEW A
N12350-A
I t em dumber Descr i pt i on
1 37 7 949- S Pl ug But t o n
2 37 7 935- S Pl ug But t o n
3 37 8444- S Pl ug But t o n
4 N804282-S Pl ug But t o n
I t em
Part
Number Descr i pt i on
5 111A74 Cove r
6 389114- S Pl ug But t o n
7 37 87 7 0- S Pl ug But t o n
8 38962 1-S Pl ug Button
1995 Town Car , Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s Jul y 1994
01- 00- 18 B o d y S e r v i c e 01- 00- 18
Cr o wn Vi c t o r i a , Gr a nd Mar qui s
N12351-A
Par t
I t em Nu mb e r Descr i pt i on
1 G 2 1 A 4 6 C o w l T o p P a n e l S e a l
2 N 3 8 3 6 8 9 - S P l u g B u t t o n
3 N 8 0 6 5 5 7 - S P l u g B u t t o n
4 N807186-S P l u g B u t t o n
I t em
Part
Nu mb e r Descr i pt i on
5 377949-S Pl ug But t o n
( Co n t i n ue d )
Drain Holes
Keep drain holes open t o prevent accumul ati on of
wat er and dirt. Col l ected wat er f rom condensati on will
cause body panel rust through and paint bubbl es.
Rattle Eli mi nati on
Forei gn obj ect s such as nuts, bolts or small pi eces of
body deadener in t he door wel l s, pillars and quarter
panels may cause rattl es. Door wells can be checked
by carefully stri ki ng t he underside of the front door
( 20124) and rear door ( 24630) wi th a rubber mallet.
Inspect all bol ts and scr ews periodically. If tightening
the bol ts and scr ews l ocated on such assembl i es as
the front door and rear door, hood ( 16612) , and
luggage compart ment door ( 40110) does not st op
rattl es, misalignment is probabl y t he reason. If so,
fol l ow the adj ustment and alignment procedures for
these assembl i es.
Weatherstri ppi ng and anti-squeak material that has
slipped out of position may cause rattl es and squeaks.
Appl y additional cement or other adhesi ve.
T r i m
Periodically clean bright metal s wi t h a soft, cl ean c bt h
or sponge and clear water. For very di rty part s, use
Multi-Purpose Cleaner Concentrate B8A- 19523- AA or
equivalent meeting Ford speci fi cati on ESR-M 14P4-A
diluted t o proper concentrati on. Wash, rinse and wi pe
the part s dry. To remove rust or salt corrosi on f rom
chrome-pl ated part s, sparingly use Custom Bri ght
Metal Cleaner 8A-19522-A or equivalent meeting Ford
speci fi cati on ESR-M5B194-B. On aluminum or chrome
finished part s, avoi d scouring wi t h steel wool and
polishing wi th products containing abrasi ves. Use
Custom Silicone Gl oss Polish B7AZ- 19530- AA or
equivalent meeting Ford speci fi cati on ESR-M 11B26-A
for excel l ent protecti on of all bright metal part s.
01- 00- 19 Bo d y Se r v i c e 0 1 - 0 0 - 1 9
OLilLi \!MQ AND INSPECTION ( Opnt f nuecJ)
VinyS I ns er t Moulding Ca r e
CAUTI ON: To avoi d damage t o t he vi nyl i nser t
moul di ngs, use onl y an appr oved For d cl eaner .
Avoi d usi ng st i f f br i st l e br ashes or abr asi ve
mat er i al or cl eaner s-
NOTE: Commerci al hot waxes applied at automati c
car washes may affect the cleaning of vinyl material.
Rinse the vinyl t o remove dirt and gri me. Very di rty
areas should be precl eaned wi th Triple Clean
E0AZ-19526-AA or equivalent meeting Ford
speci fi cati on ESR-M14P4-A or Multi-Purpose Cleaner
Concentrate B8A-19523-AA or equivalent meeting
Ford speci fi cati on ESR-M14P4-A diluted accordi ng t o
label instructions or mild soap solution. Then appl y
Del uxe Leat her and Vi nyl Cleaner F2AZ-19521-WA or
equivalent meeting Ford speci f i cat i on ESR-M14P4-A
fol l owi ng di recti ons.
B o d y Ma i n t e n a n c e
Regular body maintenance preserves the vehi cl e' s
appearance. The following st eps are suggest ed as a
guide for regular body mai ntenance.
1. Vacuum the interior thoroughl y and wash the
vehicle.
2. Check all openings for wat er l eaks and seal
where necessary.
3. Cement all useable l oose weat herst ri ps using
Weatherstri p Adhesi ve E8A2- 19552- A or
ESB-M2G14-A.
4. Repl ace all door and luggage compart ment door
weat herst ri ps that are damaged or worn.
5. Appl y Silicone Lubri cant COAZ-19553-AA or
equivalent meeti ng Ford speci fi cati on
ESR-M13P4-A t o the weat herst ri ppi ng.
6. Repl ace all cr acked, f ogged or chi pped gl ass.
7. Align the hood ( 16612) , front door ( 20124) , rear
door ( 24630) and luggage compart ment door
( 40110) if necessary.
8. Inspect the windshield wi per bl ades ( 17528) and
repl ace t hem if necessary.
9. Tighten front door scuff plate ( 13208) and interior
moulding scr ews. Refer t o Secti on 01- 05.
10. Clean the seat s, door t ri m panels and roof
headlining ( 51916) .
11. Appl y touch-up paint t o chi pped or scr at ched
areas.
12. Drai n holes (l ocated on the undersi de of each
body rocker panel ( 10128) , quarter panel and
door) should be cl eared periodically.
A p p e a r a n c e P r o t e c t i o n
Proper maintenance will help keep the vehicle l ooki ng
new for several years. The following cleaning and care
recommendati ons will prot ect the vehi cl e' s
appearance.
NOTE: Remember t o al ways fol l ow label di recti ons
when using any chemi cal cl eaner or pol i sh. Read all
warni ng and caution statements on label.
Proper exteri or appearance protecti on includes
proper and frequent washi ng (including underside
areas), polishing t o shield paint and bri ght metal
surf aces, touchi ng up ni cks and scrat ches wi t h proper
paint, and keepi ng body drain holes unpl ugged.
Wa s h i n g
Use One St ep Wash and Wax Concentrate
D6AZ-19523-AA or equivalent meeting Ford
speci fi cati on ESR-M14P12-A diluted t o t he proper
concentrati on. Follow wi th a rinse of clear, col d water.
Do not wash vehicle wi th hot water, in di rect sunlight
or whi l e sheet metal is hot.
P o l i s h i n g
Use Cust om Silicone Gl oss Polish B7AZ-19530-AA or
ESR-M 11B26-A, Custom Paste Wax B4A-19534-AA
or equivalent meeting Ford speci fi cati on
ESR-M 11B23-A, Custom Cream Wax
speci fi cati on ESR-M 11B26-A to remove harmful
deposi ts and provide added protecti on on body
surfaces.
U n d e r b o d y
In areas whi ch use road salt or other corrosi ve
materi al s for snow removal or road dust control , flush
and inspect the compl ete underside of the vehicle at
least t wi ce a year.
Pay parti cul ar attention t o cleaning out underbody
members and drain holes where dirt and other foreign
materials may have col l ect ed.
1995 To wn Car, Cr o wn Vi c t o r i a , G r a n d Ma r q u i s Jul y 1994
01- 00- 20
CLEANING AND I NSPECT I ON (Cont i nued)
Ru s t p r o o f i n g
CAUTI ON; The f l exi bl e pl ast i c a n d / o r r u b b e r - l i ke
par t s s u c h as f r ont and r ear pol ycar bonat e
bumper s, pl ast i c cl addi ngs and f ai r i ngs and
ur et hane r ear si ght shi el ds (i f equi pped) may be
damaged by a f t e r ma r ke t r ust pr oof i ng
c ompounds . If r ust pr oof i ng o v e r s p r a y , dr i ps or
r uns ar e al l owed to r emai n on t he f r ont or back
si de of t he not ed pl ast i c par t s, t hey may swel l or
di st or t . To p r e v e n t t hi s, i f t he v e h i c l e has been
af t er mar ket r u s t p r o o f e d , i n s p e c t a n d c l e a n wi t h
E x t r a St r e n g t h Tar a n d Ro a d Oi l Re mo v e r
B7 A - 1952 0- AA o r e q u i v a l e n t me e t i n g Fo r d
s p e c i f i c a t i o n E SR- M5B106- A, o r a
n a p h t h a - we t t e d c l o t h . Wi p e c o mp l e t e l y d r y .
I n s pe c t f r e q u e n t l y , a s r u s t p r o o f i n g ma y r un o r
dr i p f o r s o me t i me a f t e r i n s t a l l a t i o n , e s pe c i a l l y i n
h o t we a t h e r .
C h r o m e a n d Br i g h t Me t a l Ca r e
CAUTI ON: To p r e v e n t p o s s i b l e d a ma g e , pl a s t i c
wh e e l c o v e r s s h o u l d a l wa y s be wa s h e d wi t h mi l d
det er gent and wa t e r i mme d i a t e l y af t er u s i n g a n y
c o mme r c i a l c l e a n e r .
CAUTI ON: Do n o t use s t e e l w o o l , a b r a s i v e - t y p e
c l e a n e r o r s t r o n g d e t e r g e n t s c o n t a i n i n g hi ghl y
a l ka l i n e o r c a u s t i c a ge n t s o n c h r o me - p l a t e d
ma t e r i a l s , a l u mi n u m wh e e l s o r a n o d i z e d
a l u mi n u m par t s b e c a u s e d a ma g e t o t h e
p r o t e c t i v e c o a t i n g a n d d i s c o l o r a t i o n ma y r e sul t .
Cl e a n wi t h On e St e p Wa s h a n d Wa x Co n c e n t r a t e
D6A Z - 1952 3- A A o r e q u i v a l e n t me e t i n g Fo r d
s p e c i f i c a t i o n ESR- M14P12 - A d i l u t e d a c c o r d i n g t o
l a be l d i r e c t i o n s .
WARNI NG: READ THE WARNI NG I NFORMATI ON
ON THE PRODUCT L ABEL .
Frequent washi ng and the use of Custom Bright Metal
Cleaner 8A-19522-A or equivalent meeting Ford
speci fi cati on ESR-M5B194-B, are recommended for
body hardware, chrome-pl ated materials and
aluminum components.
1. Pour some cleaner concentrate onto a cl ean,
damp cl oth and wi pe wax f rom the area t o be
cl eaned. A second application wi th vi gorous
rubbing may be necessary for hard wax areas.
2. For severe wax buildup, pour some metal cleaner
onto a cl ean, damp cl oth and wi pe wax from the
area t o be cl eaned. Minimal effort should be
required t o remove wax. Continue this process
until entire area t o be cl eaned is wax-f ree.
3. To provi de a bright, gl ossy appearance t o
cl eaned area, apply metal cleaner after removing
wax coat i ng. A separat e cl ean, damp cl oth
should be used for this procedure.
Vi n y l T o p a n d P a d d e d Mo u l d i n g Ca r e
CAUTI ON: To a v o i d d a ma g e t o t h e v i n y l i n s e r t
mo u l d i n gs , us e o n l y a n a p p r o v e d Fo r d c l e a n e r .
A v o i d u s i n g s t i f f b r i s t l e b r u s h e s o r a b r a s i v e
ma t e r i a l o r c l e a n e r s .
NOTE: Commerci al hot waxes applied at automati c
car washes may affect t he cleaning of vinyl materi al .
Rinse the vinyl to remove dirt and gri me. Excepti onal l y
di rty areas should be precl eaned wi th Del uxe Leather
and Vinyl Cleaner F2AZ- 19521- WA or equivalent
meeting Ford speci fi cati on ESR-M14P4-A or a mild
soap solution. Then appl y Custom Vinyl Protectant
F2AZ-19530-A or equivalent.
P a i n t
CAUTI ON: Do n o t us e s t e e l w o o l , a b r a s i v e
c l e a n e r s , ga s o l i n e o r s t r o n g d e t e r g e n t s
c o n t a i n i n g hi ghl y a l ka l i n e o r c a u s t i c a g e n t s o n
c h r o me - p l a t e d ma t e r i a l s , a l u mi n u m wh e e l s ,
h e a d l a mp s , b u mp e r s o r a n o d i z e d a l u mi n u m
p a r t s . Da ma ge t o t h e p r o t e c t i v e c o a t i n g a n d
d i s c o l o r a t i o n o r pai nt det er i or at i on ma y o c c u r .
NOTE: Vehicles subj ected t o ai rborne pollen and other
organi c matter and that are exposed to high
t emperat ures and sunshine should be washed as often
as necessary t o keep t hem free of this organi c matter.
Similar precauti ons should be t aken where a vehicle
may be exposed t o chemi cal industrial fallout. Failure
to do so may result in damage t o the exteri or surfaces.
The outsi de finish shoul d be washed frequently. Never
wi pe the painted surface wi th a dry cl oth. Dusting t he
finish when it is dry tends t o rub dust and dirt into the
paint, causi ng scrat ches on the surface. To keep the
finish bright and at t ract i ve, wash the vehicle whenever
it is di rty.
Prot ect t he exteri or wi th frequent washi ng, including
undersi de areas. Use One Step Wash and Wax
Concentrate D6AZ- 19523- AA or equivalent meeting
Ford speci fi cati on ESR-M14P12-A diluted t o proper
concentrati on fol l owed by a rinse wi th clear, col d
water. Do not wash vehicle wi th hot water, in di rect
sunlight or while sheet metal is hot.
Polish paint and bright metal wi th Custom Silicone
Gl oss Polish B7AZ-19530-AA or equivalent meeting
Ford speci fi cati on ESR-M 11B26-A, Custom Paste
Wax B4A- 19534- AA or equivalent meeting Ford
speci fi cati on ESR-M 11B23-A, Custom Cream Wax
speci fi cati on ESR-M 11B26-A t o remove harmful
deposi t s and provi de added protecti on t o body
surf aces, body hardware, and chrome and aluminum
part s. Touch up ni cks and scrat ches wi th proper paint.
Gl a s s
Gl ass should be cl eaned wi th Ultra Clear Spray Gl ass
Cleaner E4AZ-19C507-AA or equivalent meeting Ford
speci fi cati on ESR-M 14P5-A, using a cl ean, soft,
lint-free cl ot h. Fol l ow di recti ons on the container.
01- 00- 21 Bo d y Se r v i c e
01- 00- 2 1
ADJUSTMENTS
B o d y Se r v i c e
NOTE: Perform major body straightening operati ons
wi th body panels at room temperature.
To perform any major body repair effectively, al ways
use repl acement part s that are identical in si ze, shape
and strength t o the original parts and follow the repair
procedures outlined.
NOTE: Fol l ow all repair instructions concerni ng the
location of structural members in load-bearing areas.
The structural members are positioned t o suit the
shape and installation of the mechani cal components
fi tted, such as engine, transaxl e, suspension and other
components.
To avoi d a possi bl e reduction in strength and safety,
restri ct repai rs t o structural members on
acci dent-damaged vehi cl es. To preserve the strength
of the panel, dismantle the panel at the original j oi nts.
Use an assembl y and wel di ng jig for such repai r as
replacing longitudinal members and inner fender
panels. Using a jig ensures a sati sfactory repair and
adherence t o the speci fi ed dimensions.
If repai rs are properl y carri ed out, all repair
procedures using repl acement panels and members
will result in the same st andards of strength whi l e
maintaining operati onal safety.
B u m p W o r k
If t he damage t o outsi de panel s is minimal, bump the
panel s rather than replacing t hem. Bumping reduces
the chance of corrosi on and l eaks at the site of t he
repair.
SPECIAL SERVICE TOOLS/EQUIPMENT
ROTUNDA EQUIPMENT
Mo d e l De s c r i p t i o n
05 5 - 00103 Va c uum L e a k De t e c t o r
05 9 - 00013 Va c uum L e a k De t e c t o r
085- R 1617 De t a c h e d P r e s s u r e Cup
085- R 162 6 Spr a y Gun
107 - R0300 He a t Gun
107 - 012 50 A i r l e s s P l a s t i c We l d e r
107 - R1619 Dua l A c t i o n Sa n d e r
01- 01- 1 Un d e r b o d y 01- 01- 1
SECTION 01-01 Underbody
SUBJECT PAGE
VEHICLE APPLICATION ........01-01-1
DESCRI PTI ON AND OPERATION
Seal ers and Appl i cati on Types ...... 01-01-1
REMOVAL AND INSTALLATION
Exhaust Syst em Shield Assembl y ..01-01-1
Under body Heat Def l ect or s 01-01-1
Under body 01-01-1
SUBJECT PAGE
ADJUSTMENTS
Body Mi sal i gnment Check 01-01-2
Frame Repai rs 01-01-7
St rai ght eni ng Operat i ons 01-01-7
Underbody Mi sal i gnment Check ...01-01-2
Wel di ng 01-01-7
VEHICLE APPLICATION
Sealers and Appl i cat i on Types
Underbody Heat Def l ect ors
Removal
1. Raise t he vehi cl e and secure wi t h Rotunda
Car / Tr uck Stands 077- 00018 or equivalent.
2. Remove all components necessary t o gain
access t o heat defl ectors.
3. Using a correct size drill bit, drill out the heat
defl ector ri vets.
4. Remove the heat defl ectors.
Exhaust Syst em Shield Assembly
Underbody
In geographi c areas using a heavy concentrati on of
road sal t or other corrosi ve materi al s for snow
removal or road dust control , flush and inspect the
compl ete underside of the vehi cl e at least t wi ce a
year.
Installation
1. Align t he heat defl ector rivet holes wi th their
correspondi ng floor hol es.
2. NOTE: Make sure that the floor hol es are
properl y seal ed after ri vets are installed.
Install ri vets using Rotunda Blind Fastener
Installation Tool 107-R0600 or equivalent.
3. Install components that wer e removed t o access
heat defl ectors.
4. Remove the safety stands and l ower the vehicle.
Particular attention should be given to cleaning out
underbody members and drain holes where dirt and
other forei gn materi al s may have col l ected.
0 1 - 0 1 - 2 Under body 0 1 - 0 1 - 2
ADJUSTMENTS
B o d y Misalignment Check
CAUTI ON: Never appl y heat t o t he bumper ener gy
abs or ber s . Heat c oul d c aus e t he mat er i al I nsi de
t h e abs or ber s t o e x p a n d a n d f l o w out of t he
abs or ber s or c r a c k t he met al hous i ng. Al wa y s
r e mo v e t he abs or ber s b e f o r e per f or mi ng b o d y
f r a me s er v i c e near t h e m.
CAUTI ON: Never appl y e x c e s s i v e heat t o b u mp e r
s ur f ac e. Heat c oul d c aus e t he b u mp e r t o di s t or t .
CAUTI ON: Wh e n c ol l ec t i ng ex haus t f umes i n
s er v i c e ar ea, never at t ac h a met al c ol l ec t or t o t h e
ex haus t t ai l pi pe as t he heat c o u l d d a ma g e t h e
bumper .
CAUTI ON: An y a t t e mp t t o c ol d- s t r ai ght en a
s ev er el y bent br ac k et ma y c aus e r upt ur es of t he
we l d s (i f any ) and ma y al so c aus e c r a c k s i n t he
bent par t . Never heat t he ar ea t o mo r e t han a dul l
r ed.
CAUTI ON: Do not a t t e mp t t o c o r r e c t any ser i ous
mi s al i gnment wi t h one j a c k i n g oper at i on.
Damage t o s t r uc t ur e ma y occur .
To align or squar e up body, t ake t wo opposi t e di agonal
measurement s bet ween t he f ront , cent er or rear
pi l l ars. Take t he measurement s bet ween ref erence
poi nt s, such as cr ease lines or wel d j oi nt s, whi ch ar e
di agonal l y opposi t e each ot her on t he t wo pi l l ars bei ng
measur ed. Si nce all measurement s shoul d be made
f r om t he bar e met al , remove all i nteri or t ri m f r om t he
checki ng poi nt s. Refer t o Sect i on 01- 05.
Align each sect i on proport i onat el y, until t he proper
di mensi ons ar e obt ai ned. If f r ame al i gnment is
quest i onabl e, ref er t o Underbody Di mensi ons as
outl i ned.
When checki ng al i gnment of a badl y damaged body,
ensure t hat all necessary f r ame cor r ect i ons have been
made bef ore at t empt i ng t o align t he body.
Rough out badl y damaged ar eas bef ore t aki ng
measurement s f or squari ng up body. Remove t he
gl ass t o prevent br eakage. Refer t o Sect i on 01- 11. In
severe cases, rei nf orcement br acket s and ot her inner
const ruct i on may have t o be r emoved or cut t o permi t
rest orat i on of t he outer shel l and pi l l ars wi t hout
excessi ve strai n on t he par t s. St rai ght en, install and
secure all par t s in pl ace bef ore at t empt i ng t o align t he
body.
In cases of sever e or shar p bends, it may be
necessary t o use heat .
All body wel di ng shoul d be done wi t h a Rot unda MIG
Wi re Feed Wel der 066- 00051 or equi val ent wi t h
wel di ng wi r e meeti ng AWS-E-70 S-6 speci f i cat i on.
U n d e r b o d y Mi s a l i g n me n t C h e c k
The di mensi ons of t he underbody must be r est or ed in
repai ri ng maj or body damage t o provi de cor r ect f ront
and rear wheel geomet r y. Refer t o t he Underbody
Di mensi ons di agr am f or t he underbody di mensi ons. Al l
t he di mensi ons ar e det ai l ed t o t he centerl i ne of
exi st i ng hol es in t he underbody assembl y. Once t he
f rame and suspensi on member s are al i gned, ot her
operat i ons can be perf ormed as outl i ned.
Un d e r b o d y Di me n s i o n s
Underbody di mensi ons are shown in t he i l l ustrati on.
Di mensi ons can be measured using Rot unda Laser
Measuri ng Syst em 073- R0450 or equi val ent.
1995 To wn Ca r , Cr o wn Vi c t o r i a , G r a n d Ma r q u i s J u l y 1994
01- 01- 3 Under body 01- 01- 3
ADJUSTMENTS (Conti nued)
Under body Di mensi ons
N12572-A
Di me n s i o n
mm
12 2 2 . 0
1052 . 0
1311. 0
12 30. 0
1015. 80
1233. 0
1117 . 0
1101. 90
2 4. 10
1103. 10
48. 11
41. 41
51. 61
48. 42
40. 00
48. 54
43. 97
43. 38
0. 94
43. 42
I n c h
( Co n t i n ue d )
Di me n s i o n mm i n c h
L 182 0. 10 7 1. 65 CV, GM
1896. 10 7 4. 64 TC
M 2 52 2 . 10 99. 2 9 CV, GM
2 598. 10 102. 28 TC
N 2 916. 10 114. 80 CV, G M
2 92 2 . 10 115. 04 TC
P 3583. 60 141. 08 CV, GM
3659. 60 144. 07 TC
Q 17 7 . 10 6. 97
01- 01- 4 Under body 0 1 - 0 1 - 4
ADJU8THEN.. .
m
. . ..
Body Mount sTown Car
NO. 1 BODY MOUNT
SECTION A
T" BODY MOUNT
SECTION C SECTION D
_ NO. 4 BODY,
NO. 3 BODY MOUNT
NO. 2 BODY MOUNT
SECTION B
NO. 1B BODY MOUNT
SECTION F SECTION G
NO. 5 BODY MOUNT
NO. 6 BODY MOUNT
"F" BODY MOUNT
SECTION B
NO. 1 AND NO. 1B BODY MOUNT
REAR OF VEHICLE
SECTION C
NO, 2 BODY MOUNT
SECTION D
NO. 3 BODY MOUNT
SECTION E
NO. 4 BODY MOUNT
SECTION F
NO. 5 BODY MOUNT
SECTION G
NO. 6 BODY MOUNT N8531-D
Par t
I t e m d u mb e r Descr i pt i on
1 00145 L o we r Bo d y Mount Shi m (2
Re q' d )
2 00163 Bo d y Bol t Ab s o r b e r Re t a i n e r
(2 Rer/::;
i t em
Par t
Numbe r Descr i pt i on
3 N800898- S2 Bo l t (2 Re q' d )
4 N62 0483- S2 Nut (2 Re q' d )
5 00145 Uppe r Bo d y Mount Shi m ( 2
Re q' d )
( Co n t i n u e d ) ( Co n t i n ue d )
01- 01- 5 Un d e r b o d y 01- 01- 5
Pa r t
I t e m Number Descr i pt i on
6 00396 Upper Body Bolt Absorber (2
Req'd) (No Color Code)
7 00155 Body Bolt Absorber (2
8 N806102-S2 Bolt (4 Req'd)
Req'd) (Color Code: White)
10 00155 Absorber (4 Req'd) (No
Color Code)
11 N806352-S36 Flatwasher (4 Req'd)
12 N806102-S2 Bolt (2 Req'd)
13 00396 Upper Body Bolt*Absorber (2
Pa r t
i t em Number De s c r i p t i o n
15 N806352-S36 Flatwasher (2 Req'd)
16 N800743-S52 Bolt (2 Req'd)
Req'd) (Color Code: Blue)
Req'd) (Color Code: Yellow)
A Tighten to 74.5-95 N-m
(55-70 Lb-Ft)
B Tighten to 47-63 N-m (35-46
Lb-Ft)
C Tighten to 40-54 N-m (30-40
Lb-Ft)
01- 01- 6 Un d e r b o d y
01- 01- 6
Body Mo u n t s Cr o wn Vi c t o r i a , Gr and Mar qui s
NO. 1 BODY MOUNT
SECTION A
SECTION 3 SECTION C
^SE CTI ON D
SE
FJPu
E
H e
" P BODY MOUNT
NO. 1B BODY MOUNT
AND H
NO. 4 BODY MO U N T
NO. 3 BODY MOUNT
NO. 2 BODY MOUNT
SECTION F SECTI ON G
NO. 6 BODY MOUNT
NO. 5 BODY MOUNT
SECTION A
" BODY MOUNT
SECTION B
NO. 1 AND 1B BODY MOUNT
R E A R OF VEHICLE
SECTION C
NO. 2 BODY MOUNT
SECTION D
NO. 3 BODY MO U N T
S E C T I O N E
NO. 4 BODY MO U N T U
7
J
SEDAN ONLY
SECTION F
NO. 5 BODY MOUNT
S E C T I O N G
N O. 6 B O DY MOUNT
S E C T I O N H
NO. 4 BODY MOUNT
P O L I C E ONLY
Par t
1 00145 L o we r Bo d y Mount Shi m (2
Re q' d )
2 00163 Bo d y Bo l t Ab s o r b e r Re t a i n e r
( 2 Re q' d )
Par t
3 N800898- S2 Bol t (2 Re q' d )
4 N62 0483- S2 Nut (2 Re q' d )
5 00145 Uppe r Bo d y Mount Shi m (2
Re q' d
( Co n t i n u e d ) ( Co n t i n u e d )
01- 01- 7 Un d e r b o d y 01- 01- 7
Par t
i t em Number Descr i pt i on
6 00396 U p p e r B o d y B o l t A b s o r b e r (2
Req'd)
( S e d a n N o C o l o r C o d e ,
P o l i c e B r o w n )
7 00155 B o d y B o l t A b s o r b e r (2
8 N806102-S2 Bolt (4 Req'd)
Req'd) (SedanNo Color
Code,
Poli ceOrange)
11 385127-S2 Flatwasher (4 Req'd)
12 N806102-S2 Bolt (2 Req'd)
( Co n t i n ue d )
F r a me Repairs
CAUTI ON: Di s c o n n e c t t h e b a t t e r y g r o u n d c a b l e
b e f o r e u s i n g a n y e l e c t r i c we l d i n g e q u i p me n t as
d a ma g e t o e l e c t r i c a l c o mp o n e n t s ma y o c c u r .
CAUTI ON: If he a t i s n e e d e d t o s t r a i gh t e n a f r a me
me mb e r , ke e p t h e t e mp e r a t u r e b e l o w 650C
( 1200F) . E x c e s s i v e he a t ma y w e a k e n t h e me t a l
i n t h e f r a me me mb e r s a n d c a u s e p e r ma n e n t
d a ma g e .
NOTE: Heat should be kept t o a minimum area so that
t he hardness of t he metal will not be af f ect ed.
El ectri c welding equipment should be used for all
f rame wel di ng.
When a reinforcement is to be wel ded t o a f rame side
member, run the wel ds l engthwi se al ong the si de of the
reinforcement.
If damaged frame member is t o be repl aced, use the
same method of attachment as on t he original f rame
member. New bol ts, required for repl acement of part s,
should be of the same speci fi cati on as the original
bol ts.
Al i gnment
Frame misalignment can affect front and rear wheel
alignment, body alignment, and the operati on of the
chassi s parts. Wi ndow gl ass cr acks, door and wi ndow
opening troubl es, and air or wat er l eaks at t he doors
are often caused by i mproperl y ti ghtened body bol ts
or f rame misalignment.
All the dimensions are detai l ed t o t he centerline of
exi sti ng holes in t he underbody assembl y. Once the
f rame and suspension members are al i gned, the other
operati ons can be performed as outlined.
Pa r t
Req'd) (Color Code:
SedanSilver,
Poli ceOrange)
Req'd) (Color Code: Violet)
Req'd) (Color Code: Orange)
19 00396 Upper Body Bolt Absorber
A Tighten to 74.5-95 N-m
(55-70 Lb-Ft)
Lb-Ft)
c Tighten to 40-54 N-m (30-40
Lb-Ft)
Inspect all f rame members for cr acks, t wi st s or bends.
Check all wel ded connecti ons for cr acks. Inspect the
bol ts and body support bracket s for l ooseness.
Perform any necessary servi ce or make
repl acements.
St rai ght eni ng Operat i ons
Frame strai ghteni ng shoul d be limited t o parts whi ch
are not severel y bent.
Weldi ng
CAUTI ON: Di s c o n n e c t t h e n e ga t i v e b a t t e r y c a b l e
b e f o r e u s i n g a n y e l e c t r i c a l we l d i n g e q u i p me n t a s
d a ma g e t o e l e c t r i c a l c o mp o n e n t s ma y o c c u r .
Perform all wel di ng using Rotunda MIG Wi re Feed
Wel der 066- 00051 or equivalent, and wel di ng wi re
meeting AWS-E-70S speci fi cati ons.
When performi ng oxyacet yl ene wel di ng or brazi ng,
prot ect the adj acent areas wi th heat insulation
compound.
Because more extensi ve panel deformati on resul ts
f rom oxyacet yl ene wel di ng than f rom MIG welding or
spot wel di ng, perform secti onal welding using MIG
wel di ng or spot wel di ng equipment only.
Perform spot wel di ng operati ons in l ocati ons that are
i naccessi bl e wi th spot wel di ng tongs using the hole
wel d met hod. Drill or punch 5 mm (0. 2 inch) holes in
one si de of the flange and wel d and add filler materi al .
01- 01=8 Under body
01- 01- 8
Varying f act or s determine pl ate thi ckness, panel
desi gn, cross-secti onal s and si zes, joining met hod,
wel di ng met hod, and wel di ng l ocati ons during
manufacturi ng. To appl y the most suitable repair
met hod, t heref ore, it is most i mportant t o compl etel y
understand the body desi gn, concept , and
constructi on.
In a monocoque body shell, the structural elements
supporti ng t he transmi ssi on and suspension are
wel ded t o t he bodywork. Every f rame, member, and
outer panel is designed t o offer the maximum
protecti on in t he event of a collision. It is very
i mportant, therefore, that a repai red part meet t he
same st andards as those installed on the new vehi cl e.
It is essential that repair wel ds, particularly on
load-bearing part s or parts contributing t o the strength
of the assembl y, are equivalent t o the originals in si ze,
t ype, and st rengt h.
St eel Co mp o n e n t s , L o w- Al l o y
1. CAUTI ON: Di sconnect t he negat i ve bat t er y
cabl e bef or e usi ng any el ect r i c wel di ng
equi pment as damage t o el ect r i cal
c omponent s may occur .
Because of associ at ed high heat buildup, do not
use oxyacet yl ene when wel di ng high-tensile or
hi gh-strength, low-alloy steel components. Use
spot , MIG, or arc wel di ng. During MIG or arc
wel di ng, use a temperature-i ndi cati ng crayon t o
ensure that the t emperat ure does not exceed
750C( 1400F) .
2. Repl ace spot-wel ded components by spot
wel di ng where possi bl e. If spot wel di ng
equipment is not avai l abl e, or if the location is not
accessi bl e, puddle wel d the panel s.
3. Use MIG welding rather than conventional arc
wel di ng when wel di ng hi gh-strength, high-tensile,
or conventional mild st eel . Use 0.8 mm or 0. 9 mm
di ameter wi re and conf orm t o Cl assi fi cati on AWS
A5. 18-69, E70S-6 or E70S-4. MIG wel di ng is
al so known as GMAW (Gas Metal Arc Wel di ng).
4. Perform conventional ar c wel di ng using 2. 5 mm
(0. 1 inch) di ameter rods conformi ng t o
Classification AS 1552- 1973, E4841 or AWS
A5. 1-78, E7014.
When cutting sal vage or repai rabl e component s, use a
grinding di sc, air chi sel , or metal cutti ng saw.
All welding shoul d be done wi t h a Rotunda MIG Wi re
Feed Wel der 066- 00051 or equivalent, wi t h wel di ng
wi re meeting AWS-E-70S Speci fi cati on.
SPECIFICATIONS
De s c r i p t i o n N-m L b - Ft
Bo d y Mo un t T h r o u gh Bo l t 40- 54 30- 40
Bo d y Mo un t Re t a i n i n g Nut 47 - 63 35- 46
Bo d y Mo un t T h r o u gh Bo l t 7 4. 5- 95 55- 7 0
ROTUNDA EQUIPMENT
066- 00051 MI G Wi r e Fe e d We l d e r
07 3- R0450 L a s e r Me a s u r i n g Sy s t e m
07 7 - 00018 C a r / T r u c k St a n d s
107 - R0600 Bl i n d Fa s t e n e r I n st a l l a t i o n To o l
01- 02 - 1 Bo d y Pa n e l s, Fr o n t En d 01- 02- 1
SECTION 01-02 Body Panels, Front End
SUBJECT PAGE
Body and Sheet Met al ..01-02-1
Hood Component s .01-02-1
Hood Hi nges 01-02-1
Hood Li f t 01-02-1
Radi ator Gri lle 01-02-1
Cowl Vent Screens 01-02-18
Fender and Apron, Front 01-02-8
Gri lle Openi ng Panel 01-02-14
Hood 01-02-6
Hood Hi nge 01-02-7
Hood Insulator .01-02-7
SUBJECT PAGE
REMOVAL AND INSTALLATION (Cont ' d. )
Hood La t c h. . . . . ..01-02-4
Hood Lat ch Cont r ol Handle and Cable 01-02-4
Hood Li f t .01-02-7
Hood Seals 01-02-7
Radi at or Air Def l ect or, Front .....01-02-11
Radi at or Gri lle 01-02-2
Sound Absorber, Front Fender Cowl
Side . , 01-02-14
ADJUSTMENTS
Hood Al i gnme nt . 01-02-19
Hood Lat ch .01-02-19
VEHICLE APPLICATION
Body a n d Sheet Metal
Hood Components
The hood ( 16612) is a front-opening t ype secured by a
st andard double-release hood l atch ( 16700) .
The hood rel ease handle is l ocated bel ow and t o the
left of the steeri ng column.
The hood l atch has a safety l atch, whi ch must be
manually rel eased after the hood l atch control
handle and cabl e ( 16916) have been rel eased.
The hood l atch is mounted t o the radi ator support
( 16138) .
The hood l atch l atches the hood l atch striker, whi ch
is mounted t o the front underside of t he hood.
Hood Hinges
When t he hood ( 16612) is opened, it pi vots on t wo
hood hinges ( 16796) and is propped open by t wo
hood lifts ( 16C826) .
The t wo hood hinges are retai ned t o the body by
t wo bol ts each.
The t wo hood hinges are also retai ned to the hood
wi th t wo bolts each.
Hood Li f t
When t he hood ( 16612) is opened it is support ed by
t wo hood lifts ( 16C826) .
R a d i a t o r Gr i l l e
The radi ator grille ( 8200) is a decorati ve pi ece that is
mounted t o t he radi ator grille opening panel ( 8190) .
01- 02 - 2 Body Panels, Front End 01- 02 - 2
Radiator Grille
Town Car
Removal
NOTE: It may be necessary t o use an ext ensi on on t he
so c ke t wr e nc h t o gai n a c c e ss t o t he ei ght radi at or
gri l l e ret ai ni ng nut s.
Remove ei ght nut and wa she r assembl i es t hat f a st e n
radi at or gri lle ( 82 00) t o radi at or inner gri lle ( 8150) .
Remove radi at or gri l l e.
Installation
Posi t i on radi at or gri lle t o t he r adi at or inner gri lle and
i nstall wi t h ei ght nut and wa she r assembl i es. Ti ght en
t o 5-8 N-m (44-71 Ib-in).
NUT AND WASHER ASSY
N621905-S36
Crown Victoria
Removal
1. Remove bot h headl amps ( 13008) . Refer t o
Sect i on 17 - 01.
2. Remove t wo sc r e ws, one on e a c h si de of t he
headl amp openi ng ret ai ni ng radi at or gri lle t o
radi at or gri lle openi ng panel ( 8190) .
3. Fr om behi nd t he radi at or inner gri l l e, use a f l at
bl ade sc r e wdr i ve r and de pr e ss t he l ocki ng ba r bs
on t he seven ret ai ners a c r o ss t he t o p of t he
radi at or gri lle.
4. Rel ease t he t wo ret ai ners at t he bot t om of t he
radi at or gri lle.
5. Remove t he radi at or gri lle f r o m t he vehi cl e.
Installation
1. Li ne up t he seven ret ai ners a c r o ss the t op of t he
radi at or gri lle t o t he hol es in t he radiator inner
gri lle.
2. Caref ul l y i nsert t he ret ai ners and push in until fully
se a t e d.
3. Push in bot t om of radi at or gri lle t o snap in t he
bot t om t wo ret ai ners.
4. Install t wo sc r e ws, one at e a c h end of t he
radi at or gri lle in t he headl amp openi ng.
5. Install bot h headl amps. Ref er t o Sect i on 17 - 01.
01- 02- 3 Body Panels, Front End 1- 02- 3
- - _^x. _ ~_
_
j f c s . JMK - jam. msrz sm. i
REMOVAL AND INSTALLATION (Cont i nued)
Radi at or Gr i l l e Cr o wn Vi c t o r i a
Pa r t
1 8200 Radiator Grille
2 8190 Radiator Grille Opening Panel
3 N800322-S307 Screw
A Tighten to 1-2 N-m (12-18 Lb-ln)
G r a n d Ma r q u i s
Re mo v a l a n d I n st a l l a t i o n
1. Remove corneri ng l amps ( 15A201) . Refer t o
Secti on 17- 01.
Radi at or Gr i l l e Gr a n d Ma r qui s
N8799-A
2. Remove headl amps. Refer t o Section 17- 01.
3. Remove nine retaining nuts and t wo scr ews
retaining radi ator grille. Remove radi ator grille.
4. To install, reverse Removal procedure.
01- 02 - 4 Body Panels, Front End 0 1 - 0 2 - 4
I t e m
Pa r t
Nu mb e r De s c r i p t i o n
1 8200 Radiator Grille
2 56911-S55 Screw (2 Req'd Each Side)
3 N802376-S Sleeve Nut (1 Req'd Each
Side)
4 N620360-S36
Nut (11 Req'd)
I t e m
Pa r t
5 8190 Radiator Grille Opening
Panel
6 N802387-S2 Nut (4 Req'd)
Panel Moulding
8 N606677-S55 Bolt (4 Req'd)
Hood Latch
Removal
1. Open hood ( 16612) and r emove hood l at ch
cont rol handl e and cabl e ret ai ner. Ref er t o
i l l ust rat i ons f ol l owi ng Hood La t c h Cont rol Handl e
and Cabl e, Removal and Inst allat i on pr oc e dur e s.
2. Di sengage hood l at ch cont rol handle and cabl e
( 16916) f r o m hood l at ch ( 167 00) .
3. Remove hood l at ch ret ai ni ng sc r e ws and r emove
hood l a t c h.
SCREW
387514-S2
LOCATOR
PINS
HOOD LATCH CONTROL
HANDLE AND CABLE
16C656
HOOD LATCH
16700 R7159-D
Installation
1. Posi t i on hood l at ch t o t he vehi cl e and i nstall t wo
ret ai ni ng sc r e ws. Ti ght en hood l at ch ret ai ni ng
sc r e ws t o 9-14 N-m (44-70 Ib-in).
2. Posi t i on hood l at ch cont rol handl e and cabl e t o
hood l at ch and i nstall one ret ai ni ng sc r e w. Ti ght en
t o 2-3 N-m (18-27 Ib-in).
3. Adj ust hood l at ch as out l i ned.
Hood Latch Control Handle and Cable
Removal
1.
2.
4.
5.
Fr om i nsi de t he vehi cl e, open hood ( 16612) .
Remove t he sc r e w ret ai ni ng hood l at ch cont r ol
handl e and cabl e ( 16916) .
Di sengage hood l at ch cont rol handl e and cabl e
f r om hood l at ch ( 16700) .
Remove t he hood l at ch cont rol cl i ps ( 16907 ) .
Fr om i nsi de vehi cl e, remove cabl e mount i ng
br a c ke t ret ai ni ng nuts and caref ul l y pull hood
l at ch cont rol handle and cabl e t hr ough ret ai ni ng
wal l .
1995 T o wn Car , Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s Jul y 1994
01- 02- 5 Body Panel s, Fr ont End 01- 02- 5
REMOVAL AND INSTALLATION (Conti nued)
Town Car
VIEW A
RS3SS-D
Par t
1 387514-S55 S e l f - T a p p i n g S c r e w
2 N623343-S100 J-Nut
3 386132-S C l i p
4 16916 Hood L a t c h R e l e a s e H a n d l e
and C a b l e
5 E x i s t i n g L o c a t o r P i n
( Co n t i n ue d )
I t em
Par t
6 16700 Hood Latch
7 N606689-S36 Screw and Washer Assy (2
Req'd)
8 N620480-S2 Nut
9 56950-S2 Screw and Washer Assy
A Tighten to 9-14 N-m (44-70
Lb-ln)
01- 02 - 6 Bo d y Pa n e l s, Fr o n t E n d
01- 02 - 6
Cr o wn Vi c t o r i a , Gr a nd bar ques
R7158-D
Pa r t
1 383207-S Clip (2 Req'd)
2 16916 Hood Latch Control Handle
and Cable
3 16700 Hood Latch
Req'd)
Pa r t
5 387514-S2 Screw
6 Existing Locator Pin (2
Req'd)
Lb-ln)
Lb-ln)
I n s t a l l a t i o n
1. Posi t i on t he hood l at ch cont r ol handl e and c a bl e
t hr ough t he ret ai ni ng wa l l , seat t he gr ommet
securel y, and i nstall t he cabl e mount i ng br a c ke t
ret ai ni ng nut s.
2. Rout e t he hood l at ch c ont r ol handl e and cabl e
and ret ai n in posi t i on wi t h new hood l at ch cont r ol
cl i ps.
3. Install hood l at ch c ont r ol handl e and cabl e t o t he
hood l at ch.
4. Install t he hood l at ch c ont r ol handl e and cabl e cli p
and t he sc r e w ret ai ni ng hood l at ch cont r ol handl e
and cabl e.
5. Che c k t he hood l at ch c ont r ol handl e and cabl e
rel ease operat i on be f or e cl osi ng t he ho o d .
H o o d
Re mo v a l
1. Open and support hood ( 16612) . Ma r k t he hood
hi nge l ocat i on on t he ho o d .
2. Pr ot e c t t he body wi t h c o ve r s t o prevent damage
t o t he pai nt .
3. Remove t he t wo bol t s ret ai ni ng e a c h hood hi nge
( 167 96) t o t he hood, t aki ng c a r e not t o let t he
hood sl i p when t he bol t s a r e r emoved.
4. Remove t he hood f r o m t he vehi cl e.
1. Posi t i on t he hood t o hood hi nges and i nstall t he
ret ai ni ng bol t s. Remove t he body c ove r s.
2. Adj ust t he hood f or an even f i t bet ween t he
f ender s and a f l ush f i t wi t h t he f ront of t he f r ont
f ender s ( 16006) .
3. Adj ust t he hood l at ch ( 167 00) , if necessar y.
01- 02- 7 Body Panel s, Fr ont End 01- 02- 7
Adj ust hood bumpers ( 16758) on radi ator
support ( 16138) (if necessary) t o flush hood t o
front fenders.
H o o d H i n g e
Re mo v a l
1. Remove hood ( 16612) as outlined.
2. Mark hood hinge location on front fender
( 16005) .
3. Remove the hinge-to-fender rei nforcement
retaining bol ts and remove the hood hinge
( 16796) .
1. Position the hinge-to-fender rei nforcement and
install t he retaining bol ts snug.
2. Install hood as outlined.
3. Adj ust t he hood.
4. Tighten hood hinge retaining bol ts t o 22- 34 N-m
(17-25 Ib-ft).
H o o d S e a l s
Re mo v a l a n d I n s t a l l a t i o n
1. From inside vehi cl e, rel ease hood l atch and open
hood.
2. Pull hood seal strai ght up and away f rom cowl t op
extensi on and cowl vent screen.
3. To install, align hood seal on one end and press
into pl ace.
H o o d I n s u l a t o r
1. From inside vehi cl e, rel ease hood l atch and open
hood.
2. Remove hood insulator retai ners (eleven on Town
Car) (twel ve on Crown Vi ct ori a, Grand Marqui s)
and hood insulator f rom hood.
To install, reverse Removal procedure using new
retai ners.
HOOD
INSULATOR
16738
HOOD
16612
RETAINER
388908-S
12 REQ'D
CROWN VICTORIA AND
GRAND MARQUIS SHOWN
TOWN CAR SIMILAR
N12417-A
H o o d Lift
1.
3.
4.
5.
6.
Open hood ( 16612) and support wi t h prop other
than t he hood lift ( 16C826) .
Di sengage retaining clips that secure hood lift t o
t he hood hinge ( 16796) and ball st ud.
Not e t he position of the hood lift as mounted on
t he hood hinge. Remove the hood lift.
Position hood lift t o hood hinge. Engage retaining
cl i ps.
Remove support used t o hold open hood.
Cycl e hood and check hood lift support syst em
operat i on.
01- 02 - 8 Bo d y Pa n e l s, Fr o n t E n d 0 1 - 0 2 - 8
REMOVAL AND INSTALLATION (Continued)
To wn Car
FRONT
FENDER
16005
R6356-C
Cr o wn Vi c t o r i a , Gr a nd Ma r qui s
N623343-S55
Fender and Apron, Front
Town Car
Removal
1. Re move f ront bumper c o ve r ( 17 D957 ) . Ref er t o
Sect i on 01- 19.
2. Re move ba t t e r y ( 10653) f o r r emoval of RH f r ont
f ender ( 16005) . Ref er t o Sect i on 14- 01.
3. Re move one c o wl seal assembl y-t o-f ender
ret ai ni ng sc r e w.
4. Re move hood ( 16612 ) a s out l i ned.
5. Re move one f ender apr on-t o-f r ame ret ai ni ng
sc r e w (i nsi de wheel openi ng).
6. Remove f r ont f ender apr on a c c e ss hol e c ove r
pl at e ( 16D2 00) ret ai ned by one push pi n i nsi de
rear of f r ont f ender apr on ( 16054) . Remove
cent er f r ont f ender -t o-cowl ret ai ni ng sc r e w (i nsi de
a c c e ss openi ng).
7. Remove si x f ront f ender-t o-radi at or suppor t panel
ret ai ni ng sc r e ws.
8. Remove sc r e w( s) ret ai ni ng f ront f ender apr on t o
radi at or suppor t ( 16138) (t hr ee LH si de or one
RHsi d e ) .
9. Remove t wo nut s and sc r e ws ret ai ni ng ba t t e r y
hol d d o wn cl amp ( 107 18) t o f ront f ender and
radi at or suppor t (RH si de).
10. Remove t hr e e upper and t wo l ower
f ender -t o-cowl ret ai ni ng sc r e ws.
11. Remove f r ont f ender.
12. Remove t wo f ender -t o-bat t er y hol d d o wn cl amp
rei nf orcement br a c e sc r e ws. Remove br a c e (RH
si de).
13. Remove f r ont f ender a pr on.
1. Posi t i on f r ont f ender apr on in f ront f ender and
i nstall t wo sc r e ws (i nsi de t o p of f ront f ender
apr on). Ti ght en t o 9-14 N-m (7-10 Ib-f t ).
2. Posi t i on f ender -t o-bat t er y hol d down cl amp
rei nf orcement br a c e and i nstall t wo sc r e ws.
Ti ght en t o 9-14 N-m (7-10 Ib-f t ).
3. Posi t i on f r ont f ender t o vehi cl e and i nstall t hr e e
upper f r ont f ender -t o-cowl ret ai ni ng sc r e ws.
Ti ght en t wo sc r e ws ent eri ng c o wl t o p t o 34- 51
N-m (25-38 Ib-f t ). Ti ght en one sc r e w ent eri ng
f ront f ender t hr ough f r ont of hood hi nge ( 167 96)
t o 22- 34 N-m (17-25 I b-f t ).
4. Install t wo l ower f r ont f ender -t o-cowl ret ai ni ng
sc r e ws. Ti ght en t o 9-14 N-m (7-10 I b-f t ).
5. Install t wo bat t er y suppor t / hol d-down
br acket -t o-f r ont f ender a pr on nut s and sc r e ws.
Ti ght en sc r e ws t o 9-14 N-m (7-10 Ib-f t ). Then,
t i ght en nut s t o 7-11 N-m (5-8 Ib-f t ).
6. Install sc r e w( s) ret ai ni ng f r ont f ender apr on t o
radi at or suppor t . Ti ght en t o 9-14 N-m (7-10 I b-f t ).
7. Install si x f ender -t o-r adi at or suppor t sc r e ws.
Ti ght en t o 9-14 N-m (7-10 I b-f t ).
8. Install cent er f r ont f ender -t o-cowl sc r e w t hr ough
a c c e ss hol e. Ti ght en t o 9-14 N-m (7-10 Ib-f t ).
Install f r ont f ender apr on a c c e ss hole cover pl at e
wi t h push pi n ret ai ner.
9. Install f ront f ender apr on-t o-f r ame ret ai ni ng
sc r e w. Ti ght en t o 22- 34 N-m (17-25 Ib-f t ).
10. Install one c o wl seal assembl y-t o-f ender ret ai ni ng
sc r e w.
11. Install hood a s out l i ned.
12. Install ba t t e r y (RH si de). Ref er t o Sect i on 14- 01.
13. Install f r ont bumper c ove r . Ref er t o Sect i on
01- 19.
1995 Town Car, Crown Victoria, Grand Marquis Jul y 1994
Town Car
RIGHT SIDE APRON SHOWN
N8207-D
Pa r t
1 16005 F r o n t F e n d e r
2 16B168 F r o n t F e n d e r B a t t e r y
Mo u n t i n g R e i n f o r c e m e n t
3 N803517-S100 U-Nut
4 N800576 S c r e w a n d W a s h e r Assy (2
Req'd)
5 16054 F r o n t F e n d e r Apron
6 16D200 Front Fender Apron Access
Hole Cover Plate
Pa r t
7 388577-S Push Pin
8 10718 Battery Hold Down Clamp
9 16A200 Front Fender Apron Frame
Bracket
10 N800395 Screw and Washer Assy
11 N802744 Screw (2 Req'd)
12 N623342-S100 U-Nut (3 Req'd Each Side)
Req'd Each Side)
Crown Vi ctori a, Grand Marquis
Removal
1. Remove radi ator grille opening panel ( 8190) as
outlined. Remove front bumper cover. Refer t o
Secti on 01- 19.
2. Remove bat t ery for removal of RH front fender.
3. Remove one cowl seal assembl y-to-front fender
retaining screw.
4. Remove hood as outlined.
01- 02 - 10 Body Panel s, Fr ont End 1- 02 - 10
5. Remove t wo front fender-to-radi ator support
panel upper brace retaining scr ews. Remove
brace.
6. Remove one front fender apron-to-frame retaining
scr ew (inside wheel openi ng).
7. Remove front fender apron access hole cover
pl ate retai ned by one push pin inside rear of front
fender apron and remove center front
fender-to-cowl retaining scr ew (inside access
opening). Remove one push pin retaining front
fender apron t o front fender apron ( 16055) (next
t o access opening).
8. Remove fi ve fender-to-radi ator support retaining
scr ews.
9. Remove scr ew( s) retaining front fender apron t o
radi ator support (three LH si de or one RH si de).
10. Remove t wo nuts and scr ews retaining bat t ery
hold down cl amp t o front fender and radi ator
support (RH si de).
11. Remove t hree upper and t wo l ower
fender-to-cowl retaining scr ews.
12. Remove f ront fender.
13. To remove front fender apron, remove t wo
scr ews (inside f op of front fender apron).
14. Remove t wo bat t ery hol d down cl amp
rei nforcement scr ews. Remove front fender
bat t ery mounting rei nforcement ( 16B168) (RH
si de).
15. Remove front fender apron.
1. Position front fender apron in front fender and
install t wo scr ews (inside t op of front fender
apron). Tighten t o 9-14 N-m (7-10 Ib-ft).
2. Position front fender bat t ery mounting
rei nforcement and install t wo scr ews. Tighten t o
9-14 N-m (7-10 Ib-ft).
3. Position front fender t o vehi cl e and install t hree
upper front fender-to-cowl retaining scr ews.
Tighten t wo scr ews enteri ng cowl t op t o 34- 51
Nm ( 25- 38 Ib-ft). Tighten one scr ew entering
front fender apron through front of hood hinge t o
22-34 N-m (17-25 Ib-ft).
4. Install t wo l ower front fender-to-cowf retaining
scr ews. Tighten t o 22-34 N-m (17-25 Ib-ft).
5. Install t wo bat t ery hold down ciamp-to-fender
apron nuts and scr ews. Tighten scr ews t o 9- 14
N-m (7-10 Ib-ft).
6. Install scr ew( s) retaining front fender apron t o
radi ator support . Tighten t o 9-14 N-m (7-10 Ib-ft).
7. Install fi ve front fender-to-radi ator support
scr ews. Tighten t o 9-14 Nm ( 7- 10 Ib-ft).
8. Install center fender-to-cowl scr ew through
access hol e. Tighten t o 9-14 N*m (7-10 Ib-ft).
Install front fender apron access hole cover pl ate
wi t h push pin retainer.
9. Install front fender apron-to-frame retaining
screw. Tighten t o 9-14 N-m (7-10 Ib-ft).
10. Position front fender-to-radi ator support panel
upper br ace. Tighten retaining scr ews t o 9-14
N-m (7-10 Ib-ft).
11. Install one cowl seal assembl y-to-fender retaining
screw.
12. Check fit of front fender t o front door ( 20124) and
hood. Position as requi red.
13. Install hood as outlined.
14. Install bat t ery (RH si de). Refer t o Secti on 14- 01.
15. Install radi ator grille opening panel as outlined.
16. Install front bumper cover. Refer t o Secti on
01- 19.
01- 02 - 11 Body Panels, Front End 01- 02 - 11

VIEW A
N8768-B
Part Pa r t
I t em Number De s c r i p t i o n I t e m Nu mb e r De s c r i p t i o n
1 16758 Hood Bumper 11 387843-S Push Pin
2 N623332-S100 Nut (2 Req'd) 12 388577-S Push Pin
3 N606676-S36 Screw and Washer Assy (2 13 N800395-S36 Screw
Req'd) 14 16A200 Front Fender Apron Frame
4 16B168 Front Fender Battery
Mounting Reinforcement
15 16054
Bracket
Front Fender Apron
5 N606676-S36 Screw and Washer Assy
16 16D200 Front Fender Apron Access
6 10718 Battery Hold Down Clamp Hole Cover Plate
7 16138 Radiator Support 17 N623342-S100 Nut (1 Req'd RH, 3 Req'd LH)
8 N804527-S Push Pin 18 N62332-S100 Nut (2 Req'd)
Req'd)
Lb-Ft)
Req'd RH
f
3 Req'd LH)
Radiator Air Def lect or, Front
Town CarLower
Removal and Installation
1. Raise vehicle on hoi st. Refer t o Secti on 00- 02.
2. Remove t wo push-pins that retain radi ator air
defl ector ( 8327) at t he si des.
3. Remove four scr ew and washer assembl i es at
front radi ator air defl ector and t wo scr ew and
washer assembl i es retaining l ower radi ator air
defl ector t o ski d pl ate.
01- 02 - 12 Bo d y Pa n e l s, Fr o n t End 01- 02 - 12
7JEJL.IZZZZ3D
REMOVAL AMD INSTALLATION (Cont i nued)
4. Remove radi ator air defl ector f rom vehicle.
Separat e front and l ower radi ator air defl ectors
as necessary.
5. To install, reverse Removal procedure. Tighten
si x scr ew and washer assembl i es t o 6-8 N-m
( 53- 71 Ib-in).
Lo we r Radi at or Ai r Def l ect or Town Car
R10998-A
I t e m
Part
1 Front Bumper Cover
2 Skid Plate
3 N800854-S301 J-Nut (2 Req'd)
4 N808589-S307 Screw and Washer (10
Req'd)
5 388930-S Push Pin (2 Req'd)
6 8327 Radiator Air Deflector
(Lower)
7 389358-S Push Pin
(Front)
A Tighten t o 6-8 N-m (53-71
Lb-ln)
T o w n C a r Up p e r
Re mo v a l and i nst al l at i on
1. Remove radi ator ( 8005) . Refer t o Secti on 03- 03.
2. Remove push pins from RH radi ator air defl ector
( 8310) .
3. Remove push pins f rom LH radi ator air defl ector
( 8311) .
Radi at or Ai r Def l ect or Town Car
R10S99-A
I t e m
Par t
Nu mb e r descr i pt i on
1 8A312 Upper Radiator Air Deflector
2 8103 LH Radiator Air Deflector
3 8B407 Lower Radiator Air Deflector
4 N800312 Screw and Washer (4 Req'd
Each Side)
5 382570S Push Pin (3 Req'd Each
Side)
6 8102 RH Radiator Air Deflector
01- 02 - 13 Bo d y Pa n e l s, Fr o n t En d 01- 02 - 13
Par t
It em Number De sc r i pt i on
7 382570S Push Pin (4 Req'd)
Lb-ln)
Cr o wn Vi c t or i a, Gr a n d Mar qui s
Removal and I nst al l at i on
1. Remove radiator. Refer to Secti on 03-03.
Radi at or Air De f l e c t o r sCr o wn Vi ct ori a, Gr and Marqui s
3.
4.
5.
6.
Remove push pins from radiator upper sight
shield ( 8C291) .
Remove push pins from radiator air deflector.
Remove push pins from radiator air deflector.
Remove two sc r e ws from radiator air deflector.
To install, reverse Removal procedure.
ui j r
VIEW A
VIEW SHOWING INSTALLATION OF DEFLECTORS
TO BUMPER ASSY
VIEW
R11000-A
I t e m
Pa r t
2 8C291 Radiator Upper Sight Shield
3 Radiator Support
4 No. 2 Crossmember
5 N800854-S301 J-Nut (6 Req'd)
(Lower)
I t e m
Pa r t
7 N389358-S Push Pin (2 Req'd)
8 N808589-S307 Push Pin (6 Req'd)
(RH-Outer)
(LH-Outer)
11 Bumper Assy
01-02-14 Body Panels, Front End
Sound Absorber, Front Fender Cowl Side
Town Car
Removal end Installation
1. Remove f r ont fender a n d a pr on a s out l i ned.
2 . Remove t wo push pi ns a n d front f ender cowS^kt e
sound a bso r be r f r o m bo d y .
3. To I nst al l , r ever se Removal a n d pr oc e dur e .
Town Car
1. Remove f r ont bumpsr c o v e r ( 17 D957 ) . Ref er t o
Sect i on 01- 19.
2. Re move headl amps ( 13008) a n d pa r ki ng l a mps
( 132 00) . Ref er t o Se c t i on 17 - 01.
3. Remove racEator gri l l e ( 82 00) a s out l i ned.
4. Remove sc r e ws from bo t h si de s of r adi at or
suppor t ( 16138) .
5. Re move sc r e ws from bo t h si de s of r adi at or gr i l e
openi ng panel ( 8190) t o front f ender ( 16005) .
Grills Opening PanelTown Car
6. Remove nut s f r o m hood l a t c h suppor t ( 167 07 ) .
7. Remove s c r e ws f r o m bo t h si des of r adi at or grille
opsni ng panel br a c ke t ( 8B455) .
8. Remove s c r e ws retaining bo t h si des of r adi at or
gri l l e opsni ng panel br a c e ( 8B057 ) t o r adi at or
gri l l e opsni ng panel .
9. To I nst al l , r e ve r se Removal pr oc e dur e .
NOTE: If replacing onl y r adi at or gri l l e opsni ng panel ,
t r ansf er al l ne c e ssa r y pa r t s t o n e w r adi at or gr i l e
openi ng panel .
Pa r t
1 N621905-S36 Nut (2 Req'd)
2 N606676-S36 Screw and Washer
3 N62332-S100 Nut (6 Req'd Each Side)
4 Screw and Washer
( Co n t i n ue d )
Pa r t
Nu mb e r
8190
N606679-S36
Radiator Grille Opening
Panel
Screw and Washer
Tighten to 5-8 N-m (44-71
Lb-ln)
0 1 - 02- 16 Body Panel s, Fr ont End 0 1 - 02- 16
Town Car
1995 Town Car , Cr own Vi c t o r i a , Gr a n d Mar qui s Jul y 1994
Par t Pa r t
I t em Number De s c r i p t i o n I t e m Nu mb e r De s c r i p t i o n
1 8190 Radiator Grilie Opening 12 WG23452-S36 Nut
Panei 13 8200 Radiator Grille
2 N802387-S100 Press Clip
14 388577-S Press Clip
3 8B455 Radiator Grille Opening
Panel Bracket Panel Moulding
4 N621905-S2 Nut 16 N621905-S36 Nut
5 N606676-S36 Screw
17 2C255 Anti-Lock Ring
6 N62332-S100 Press Clip
18 N800319-S36 Stud
7 N800302-S51M Stud
8 N606679-S36 Screw Panel Brace
9 N623332-S100 Screw 20 8A156 Radiator Grille Opening
10 56910-S2 Screw
Panel Moulding
21 N802387-S100 Clip
Panel Extension
C r o w n Vi c t o r i a , G r a n d Ma r q u i s
1. Remove front bumper cover. Refer t o Secti on
01- 19.
2. Remove radi ator grille as outlined.
3. Remove headl amps and parki ng l amps. Refer t o
Secti on 17- 01.
Gri l l e Ope n i n g Panel Cr o wn Vi c t o r i a , Gr a n d Ma r qui s
4. Remove scr ews f rom both si des of radi ator
support.
5. Remove scr ews f rom bot h si des of radi ator grille
opening panel bracket to radi ator grille opening
panel.
6. Remove scr ews f rom both si des of radi ator grille
opening panel t o front fenders.
01- 02 - 18 Bo d y P a n e l s , Fr o n t E n d
01- 02 - 18
I t em
Pa r t
Number De sc r i pt i on I t e m
Par t
Numbe r De s c r i p t i o n
1 16138 Radiator Support 7 N623342-S100 Nut (1 Req'd Each Side)
2 N807316-S3 Bolt 8 N623332-S100 Nut (1 Req'd Each Side)
3 8B455 Radiator Grille Opening 9 16005 (LH) Front Fender
Panel Bracket 16006(RH)
4 N805899-S100 Nut (2 Req'd) A
_
Tighten to 13-15 N-m
(115-133 Lb-ln)
Panel B Tighten to 5-8 N-m (44-71
6 N606678-S55 Bolt
Lb-ln)
Cr o wn Vi c t o r i a Sho wn , Gr and Ma r qui s Si mi l ar
RS81S-B
Pa r t Par t
I t e m Nu mb e r De s c r i p t i o n I t e m Numbe r De s c r i p t i o n
1 16005 Front Fender 6 8200 Radiator Grille
2 16138 Radiator Support 7 N800322-S55 Screw
3 N807316-S36 Screw 8 N807455-S100 Clip
4 8B455 Radiator Grille Opening 9 N803748-S100 Clip
Panel Bracket 10 N606678-S55 Screw
5 N623332-S100 Nut
(Continued)
Panel
Cowl Vent Screens
1. Di sconnect bat t ery ground cabl e ( 14301) .
2. Remove hood pad and wi ndshi el d wi per pivot
arms ( 17526) .
1995 Town Car, Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s Jul y 1994
01- 02- 19 Body Pa n e l s, Fr ont End 01- 02- 19
3. Remove cowl vent screens ( 018A16) . 4. To install, reverse Removal procedure.
Di sconnect wi ndow washer hose ( 17408) f rom
windshield washer nozzle j et and bracket s
( 17603) .
Cowl Vent Scr eens
Par t
1 N 6 1 0 9 5 8 - S 5 5 S c r e w ( 1 R e q ' d )
2 N 6 0 6 6 7 6 - S 5 5 S c r e w ( 1 R e q ' d )
3 018A15(LH) C o w l Ve n t S c r e e n
018A16(RH)
K14970-E
Par t
4 N 8 0 5 7 8 8 - S 1 0 0 S c r e w
5 N805886-S Clip ( 4 R e q ' d )
6 1 7 C 5 6 9 Windshield Wiper Motor and
Linkage Cover
ADJUSTMENTS
Hood Ali gnment
The hood ( 16612) can be adj usted fore-and-aft and
side-to-side by loosening t he hood-to-hood hinge
retaining bol ts and repositioning hood. To rai se or
l ower hood, loosen hood hinge-to-fender
rei nforcement retaining bol ts and rai se or l ower hood
hinge ( 16796) as necessary.
Hood Lat ch
Bef ore adjusting hood l atch mechani sm, make certai n
t he hood ( 16612) is properl y aligned. The hood l atch
( 16700) can be moved side-to-side t o align it wi th t he
opening in the hood inner panel , and up-and-down t o
obtai n a flush fit wi t h front fenders ( 16005) . Refer t o
illustrations following Hood Lat ch Control Handle
Cabl e, Removal and Installation procedures.
1. Loosen the hood l atch retaining bol ts until t hey
are just l oose enough t o move the hood l atch.
01- 02 - 2 0 Bo d y Pa n e l s, Fr o n t E n d 01- 02 - 2 0
2. Move t he hood l at ch si de-t o-si de t o ali gn it wi t h
openi ng in t he hood inner panel .
3. Loosen and l ower t wo hood bumpers.
4. Move hood l at ch up or d o wn as requi red t o obt ai n
a f l ush f i t bet ween t he t o p of t he hood and f ront
f ender s when an upwa r d pr essur e i s appl i ed t o
t he f ront of t he hood. Ti ght en hood l at ch ret ai ni ng
sc r e ws t o 9-14 N-m (7-10 I b-f t ).
5. If c o r r e c t hood l at ch posi t i on is not obt ai nabl e,
r emove t wo l ocat i ng pi ns f r o m beneat h hood
l at ch by t appi ng t he m i nt o t he radi at or suppor t
( 16138) . (They wi ll event ual l y f all f r om t he
vehi cl e. ) Then f ol l ow Hood Adj ust ment
pr ocedur e.
6. If hood cl osi ng ef f or t s and i nsi de hood l at ch
cont r ol handle and cabl e e f f or t s ar e t oo hi gh,
adj ust t he hood l at ch assembl y upwa r d and / o r
t he hood bumpers ( 167 58) d o wn wa r d .
7. Rai se t he t wo hood bumper s t o eli mi nat e any
l ooseness at t he f ront of t he hood when c l ose d.
8. Open and cl ose hood sever al t i mes t o c he c k
oper at i on.
SPECIFICATIONS
De s c r i p t i o n N- m L b - Ft
Ho o d Hi n ge - t o - Fr o n t Fe n d e r Bo l t s 2 2 - 34 17 - 25
Up p e r Fe n d e r - t o - Co wl S c r e ws 34- 51 2 5- 38
L o we r Fe n d e r - t o - Co wl S c r e ws 9- 14 7 - 10
Ba t t e r y Mo u n t i n g
Re i n f o r c e me n t - t o - Fe n d e r A p r o n
S c r e w s
9- 14 7 - 10
TORQUE SPECIFICATIONS (Cont ' d)
Ba t t e r y Mo u n t i n g
Re i n f o r c e me n t - t o - Fe n d e r A p r o n
Nut s
7 - 11 5- 8
Fe n d e r A p r o n - t o - Ra d i a t o r Su p p o r t
S c r e ws
9- 14 7 - 10
Fe n d e r - t o - Ra d i a t o r Su p p o r t
S c r e ws
9- 14 7 - 10
Fe n d e r - t o - Co wi A c c e s s Ho l e
S c r e w
9- 14 7 - 10
Fr o n t Fe n d e r A p r o n - t o - Fr a me
S c r e w
2 2 - 34 17 - 25
Fe n d e r - t o - Ra d i a t o r Su p p o r t Pa n e l
Up p e r Br a c e S c r e w s
9- 14 7 - 10
Ra d i a t o r Gr i l l e Nu t s 5- 8 44- 7 1
( L b- l n )
Ho o d T o p Or n a me n t Nut 4- 7 3- 5
Ho o d L a t c h Re t a i n i n g S c r e ws 9- 14 44- 7 0
( L b- l n )
L o we r Ra d i a t o r Ai r De f l e c t o r
S c r e w s
6- 8 53- 7 1
( L b - l n )
Ra d i a t o r Gr i l l e S c r e w s Cr o wn
Vi c t o r i a / G r a n d Ma r q u i s
1-2 12 - 18
( L b- l n )
Ho o d L a t c h Co n t r o l Ca b l e t o Ho o d
L a t c h S c r e w
2- 3 18- 27
( L b - l n )
Ho o d Hi n ge t o Fe n d e r S c r e w 2 2 - 34 17 - 2 5
Fr o n t Fe n d e r - t o - Co wl S c r e ws 2 2 - 34 17 - 2 5
Ra d i a t o r Gr i l l e Op e n i n g
P a n e l - t o - Ra d i a t o r Su p p o r t Bo l t s
( Up p e r a n d L o w e r )
13- 15 115- 133
( L b - l n )
Ra d i a t o r Gr i l l e Op e n i n g
P a n e l - t o - Ra d i a t o r Su p p o r t Bo l t
( Mi d d l e )
5- 8 44- 7 1
( L b- l n )
1995 To wn Car , Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s J u l y 1994
01-03-1
Doors and Luggage Compartment Door 01-03-1
SECTION 01-03 Doors and Luggage Compartment
Door
SUBJECT PAQE
VEHICLE APPLICATION .01-03-1
Doors 01-03-1
U;ggag* Compartment Door..................................01-03-1
Doors ....................................................................01-03-1
Kings, Door 01-03-2
Luggage Compartment Door..................................01-03-7
Weatherstrip, Luggage Compartment
D&or.................................................................01-03-8
Weatherstrips .01-03-2
SUBJECT PAGE
ADJUSTMENTS
Alignment, Luggage Compartment Door ..............01-03-12
Door Allgnmsnt......................................................01-03-9
Door Inspection .....................................................01-03-9
Torsion Bar Loading .01-03-15
Torsion Bar, Luggage Compartmsnt.....................01-03-13
LUBRICATION
Lubricant .01-03-16
SPECIFICATIONS .01-03-16
SPECIAL SERVICE TOOLS/EQUIPMENT .01-03-16
VEHICLE APPLICATION
Town Car, Cr own Vi c t or i a , Gr and Mar qui s
Doors
The f ront d o o r s ( 2 012 4) and r ear d o o r s ( 24630) :
9 Ar e bol t ed t o f r ont door upper hi nge ( 22800) , f r ont
door l ower hi nge, sl i di ng door hi nge and rol l er
( 2 6800) and r ear door l ower hi nge.
Ar e adj ust abl e vi a t he f r ont door upper hi nge a n d
eli di ng door hi nge and rol l er.
Seal i ng i s by f r ont door openi ng we a t he r st r i p
( 2 07 08) and r ear d o o r we a t he r st r i p ( 2 532 4) a nd
r oof si de rai l we a t he r st r i p ( 512 2 2 ) a nd r e a r d o o r
f r ont we a t he r st r i p.
Requi re regul ar i nspect i on a nd l ubri cat i on of hi nges,
we a t hsr st r i ps and l oc k a nd l a t c h mechani sms.
Luggage Compartment Door
The l uggage compar t ment door ( 40110) :
i s adj ust abl e a nd i s bol t ed t o t he l uggage
compar t ment door hi nge ( 42 7 00) a nd t he hi nge t o
t he vehi cl e.
Is seal ed by a cont i nuous l uggage c ompa r t me nt
d o o r we a t he r st r i p ( 437 2 0) .
Requi res regul ar i nspect i on a n d l ubri cat i on a t t he
hi nges, we a t he r st r i p and l a t c h assembl y .
Doors
F r o n t a n d Re a r
Re mo v a l
1. NOTE: A se c o n d per son i s requi red if Fl exi -Work
Tabl e 156- 00070 i s not avai l abl e.
NOTE: Front d o o r s ( 2 012 4) and r ear d o o r s
(2463G) c a n be r e move d and i nst al l ed usi ng t he
sa me pr oc e dur e .
Suppor t t he f r ont door o r r ear d o o r f or se r vi c e
usi ng Rot unda Fl exi -Work Tabl e 156- 00070 o r
equi val ent .
2 . Di sconnect any wi ri ng har ness c onne c t or s Of
equi pped).
3. Remove hi nge ret ai ni ng bol t s from t he front d o o r
o r r ear d o o r . Remove f r ont door or r ear d o o r .
4. If f r ont d o o r or r ear d o o r i s t o be r e pl a c e d,
t r ansf er t he following component s t o t he new
f r ont d o o r or r ear door if i n usabl e condi t i on: t r i m
panel , wa t e r shi e l d, out si de moul di ngs, c l i ps,
wi n d o w r egul at or s a n d d o o r l at ch c ompone nt s.
1996Town Car, Crown Victoria, Grand Marquis July 1994
01- 03- 2 Door s and Luggage Compar t ment Door 01- 03- 2
I nst al l at i on
1. Position front door or rear door to front door
upper hinge ( 22800) / sl i di ng door hinge and roller
( 26800) or lower ( 22806) door hinge and
parti al l y tighten bol ts.
2. Align front door or rear door and tighten bol ts t o
25-35 N-m (18-26 Ib-ft).
3. If di sconnect ed, connect el ectri cal connectors.
H i n g e , Do o r
Fr o n t a n d Re a r
1. NOTE: Front and rear door hinges can be
. removed and installed using the same procedure.
Support the front door ( 20124) or rear door
( 24630) for servi ce using Rotunda Flexi-Work
Table 156-00070 or equivalent.
2. Mark the location of the front door upper hinge
( 22800) / sl i di ng door hinge and roller ( 26800) or
l ower door hinge ( 22806) on t he front door or
rear door and body.
3. Remove the door hinge-to-body retaining bol ts.
4. Remove the door hinge-to-door retaining bol ts.
Remove front door upper hi nge/sl i di ng door hinge
and roller or l ower ( 22806) door hinge.
5. To install, position the front door upper
hi nge/sl i di ng door hinge and roller or l ower
( 22806) door hinge t o the front door or rear door
and body. Install retaining bol ts.
6. Adj ust the front door or rear door and front door
upper hi nge/sl i di ng door hinge and roller. Tighten
bol ts t o 25-35 N-m (18-26 Ib-ft) and remove t he
support.
Hi n g e C h e c k Do o r , Fr o n t a n d Re a r
Re mo v a l
1. NOTE: Front and rear door hinge checks can be
removed and installed using the same procedure.
NOTE: The door hinge check can be servi ced
wi thout removing the compl ete hinge assembl y.
Perf orm the fol l owi ng procedure:
Open door wi th broken hinge check.
2. Remove exposed hinge-to-body retaining bol t and
retai n.
3. Insert a chi sel , 267 mm (10-112 i nches) long wi th
a 19 mm ( 3 / 4 inch) cutti ng bl ade bet ween hinge
half on body and back side of hinge check.
Hammer until chisel unseats ri vet securi ng hinge
check-t o-body si de hinge.
4. Remove broken hinge check and di scard.
1. Loosel y pl ace new door check and el astomer
rei nforcement into body door hinge.
2. Install door hinge-to-body retaining bolt t o secure
new hinge check and rei nforcement-to-body si de
hinge. Tighten screw and washer t o 25- 35 Nm
(18-26 Ib-ft).
We a t h e r s t r i p s
Re mo v a l
Weat herst ri ps are mechanically retai ned. No adhesi ve
is requi red for retention.
1. Remove interior garnish moulding and loosen
required tri m panels and door scuff pl ates. Refer
t o Secti on 01- 05.
2. Pull front door opening weat herst ri p ( 20708) or
rear door weat herst ri p ( 25324) off wel d flange
around door openi ng.
1. Inspect the wel d flange weat herst ri p mounting
areas for di storti on. Correct any di storti ons using
vi se gri ps or a pair of hammers.
2. Locat e heat-formed corners at upper B-pillar and
C-pillar radii. Begin installing front door opening
weat herst ri p or rear door body weat herst ri p
( 253A10) at point X. Refer t o fol l owi ng
illustrations. For rear doors, install at point Y fi rst,
then compress excess materi al as requi red using
moulded detail as a reference.
3. Continue installing front door opening
around door openi ng. Front door opening
weat herst ri p or rear door body weat herst ri p must
not be st ret ched during installation. End
installation wi th excess front door opening
l ocated at door scuff pl ate.
4. Cut front door opening weat herst ri p or rear door
body weat herst ri p approxi mat el y 6-12 mm
(0. 24-0. 47 inch) longer than needed and butt
ends together. Install door scuff pl ate,
overl appi ng ends of front door opening
weat herst ri p or rear door body weat herst ri p.
5. Begin installing roof si de rail weat herst ri p
( 51222) at point J, continue down front pillar.
Then install f rom point J t o point K and down rear
pillar.
6. Appl y Silicone Lubri cant COAZ-19553-AA or
ESR-M13P4-A as requi red. Wi pe off excess
lubricant.
7. Tighten door scuff pl ates and tri m panels and
install interior garni sh mouldings as necessary.
Refer to Secti on 01- 05.
01- 03- 3
Door s and Luggage Compar t ment Door 01- 03- 3
We a t h e r s t r i ps To wn Car
NOTE: TRIM UP MUST REST
ON TOP OF TRIM PANEL
NOTE: TRIM LIP MUST REST
ON TOP OF TRIM PANEL
.
PI
SECTION i I SECTION C
SECTION C
SECTION B

NOTE: THE PRIMARY SEALS ARE SUPPUED
AS A CONTINUOUS LOOP ALREADY
PLUGGED AND BUTT JOINTED.
THE SEAL IS TO BE ASSEMBLED LOCATING
THE HEAT FORMED CORNERS AT THE
UPPER B-PILLAR C-PILLAR RADIUS*
N8213-D
Par t
1 2 0 7 0 8 Front Door Opening Weatherstrip
2 2 5 3 A 1 0 R e a r D o o r Body W e a t h e r s t r i p
3 1 3 2 0 8 F r o n t D o o r S c u f f P l a t e
4 5 1 9 1 6 R o o f H e a d l i n i n g
01- 03- 4 Door s and Luggage Compar t ment Door
0 1 - 0 3 - 4
Weat her st r i psTown Car
VIEW D
SECTION A SECTION B SECTION C
VIEWD
N12364-A
I t em
Par t
1 2 1 2 2 2
2 1 2 2 3
W e a t h e r s t r i p A s s y R o o f S i d e Ra i l L H
W e a t h e r s t r i p A s s y R o o f S i d e Ra i l R H
1995 Town Car, Cr own Vi ct or i a, Gr and Mar qui s Jul y 1994
01- 03- 5 Do o r s a n d L u g g a g e Co mp a r t me n t Do o r 01- 03- 5
Weat her st r i psCr own Vi ct or i a, Grand Marqui s
CROWN VICTORIA SHOWN
GRAND MARQUIS SIMILAR
NOTE: TRIM LIP MUST
REST ON TOP OF TRIM
PANEL
SECTION A
NOTE: TRIM LIP MUST
REST ON TOP OF TRIM
PANEL
SECTION B
N8796-D
Pa r t
1 51222 Roof Side Rail Weatherstrip
2 20708 Front Door Opening Weatherstrip
3 253A10 Rear Door Body Weatherstrip
4 51752 Roof Side inner Front Moulding
5 02344 Cowl Side Trim Panel
Do o r , Fr o n t and RearTown Car
Town Car has no continuous weat herst ri p on front and
rear doors.
Do o r , Fr o n t and Rear Cr o wn Victoria, G r a n d
Ma r q u i s
Re mo v a l
1. Firmly hold the front door weat herst ri p ( 20530)
at point Z, pull out ward t o remove f rom retention
channel , proceed down t o point X, then t o point Y.
2. Using Rotunda Windshield and Moulding / Trim
Removal Kit 107-R0401 or equivalent position
tool under door weat herst ri p at the push pin and
di sengage each push pin f rom the door.
1 . Install push pins at bot t om half of door beginning
at point Y.
2. Locat e inboard f oot of door weat herst ri p in
C-channel on t op half of door. Align door
weat herst ri p t o corners of door.
3. Starti ng at the corners, press out board f oot of
door weat herst ri p into channel .
Do o r , F r o n t F r o n t E d g e
Re mo v a l a n d I n s t a l l a t i o n T o wn Ca r
1 . NOTE: Refer t o illustration fol l owi ng Front
Weat her st r i pRear Door.
Open front door t o access front door l ower
weat herst ri p ( 20758) .
2. Remove four stud covers.
3. Remove front door l ower weat herst ri p.
Re mo v a l a n d I n s t a l l a t i o n Cr o wn Vi c t o r i a , Gr a n d
Marques
Crown Vi ct ori a and Grand Marqui s have no front door
front weat herst ri p.
01- 03- 6 Do o r s a n d L u gga ge Co mp a r t me n t Do o r
01- 03- 6
Cr o wn Vi ct or i a
(GRAND MARQUIS TYPICAL) REAR DOOR
N8797-B
Pa r t
I t e m Numbe r De sc r i pt i on
1 20530 Front Door Weatherstrip
2 - Front Door Assy
3 25332 Rear Door Front Weatherstrip Assy
4 381500-S Rivet (3 Req'd Each Side)
5 Rear Door Assy
6 25324 Rear Door Weatherstri p
Do o r , R e a r F r o n t E d g e
T o w n C a r Re mo v a l a n d I n st a l l a t i o n
1. Open rear door t o access rear door weat herst ri p.
2. Remove five stud caps retaining upper porti on of
rear door weat herst ri p.
3. Slide l ower portion of rear door weat herst ri p off
door edge.
4. Unsnap bot t om inner edge of rear door
weat herst ri p.
Fr ont Weat her st r i pRear Door
SECTION A
SECTION A
SECTION B
SECTION C
N12363-A
Par t Pa r t
I t em Number Descr i pt i on I t e m Nu mb e r De s c r i p t i o n
1 20758 Weatherstrip AssyFront
Door Lower LH
3 25324 Weatherstrip AssyRear
Door Front LH
20759 Weatherstrip AssyFront
Door Lower RH
25325 Weatherstrip AssyRear
Door Front RH
2 20112 Cap, Stud (9 Req'd) (Part of
20758-9 and 25334-5)
( Co n t i n ue d )
C r o w n Vi ct or i a, Gr and Mar qui s Re mo v a l a n d
I nst al l at i on
1.
2.
3.
NOTE: Ref er t o i llust rat i on f ol l owi ng Door, Front
and Rear f or f ront we a t he r st r i pr e a r door.
For t he f ront of rear door weat her st r i p dri ll out
t hree ret ai ni ng ri vet s.
Remove rear door we a t he r st r i p.
To i nst al l , r ever se Removal pr ocedur e.
Luggage Compart ment Door
1. NOTE: A se c ond per son wi ll be needed f or t hi s
pr ocedur e.
Open l uggage compar t ment door ( 40110) .
2. Cover body panel s surroundi ng l uggage
compar t ment door .
3. Remove l uggage compar t ment door liner (Grand
Marqui s).
4. Remove bol t s ret ai ni ng l uggage compar t ment
door t o l uggage compar t ment door hi nge ( 42 7 00)
on one si de (have se c ond person support t hi s
si de).
01- 03- 8 Door s and Luggage Compar t ment Door
0 1 - 0 3 - 8
Support side still retained t o luggage
compartment door hinge, remove bol ts, and
remove luggage compartment door.
To install, reverse Removal procedure. Adj ust
luggage compartment door as outl i ned. Tighten
bol ts to 5-8.5 N-m (45-75 Ib-in).
We a t h e r s t r i p , L u g g a g e C o m p a r t m e n t Do o r
Re mo v a l
1. NOTE: The luggage compartment door
weat herst ri p ( 43720) may contain a stri ngy
sealer whi ch can sti ck t o the flange when
removed. The l uggage compartment fl oor cover
( 45455) should be covered to prot ect it f rom
contacti ng the sealer.
Luggage compartment door weat herst ri ps are
mechanically retai ned. Adhesi ve is not required
for retenti on.
To wn Car
2. Remove the luggage compart ment door
weat herst ri ps from the trough mounting fl ange.
i n s t a l l a t i o n
1 . Position the continuous l oop luggage
compartment door weat herst ri p over the l uggage
compartment door ( 40110) opening prior t o
installation.
2. Line up weat herst ri p joint at striker,
3. Press the new luggage compart ment door
weat herst ri p on the trough mounting flange 150
mm (6 inches) at a time.
LUGGAGE COMPARTMENT
DOOR WEATHERSTRIP
43720
SECTION A
FRONT
-OF
VEHICLE
LUGGAGE COMPARTMENT
DOOR WEATHERSTRIP
43720
N8239-E
01- 03- 9
Door s and Luggage Compar t ment Door 01- 03- 9
REMOVAL AND I NS T A L L A T I ON ( Co n t i n u e d )
Luggage Compar t ment Door Weat her st r i pCr own Vi ct or i a
BUMPER
390096
LUGGAGE
COMPARTMENT
DOOR
WEATHERSTRIP
43720
LUGGAGE COMPARTMENT
DOOR WEATHERSTRIP 43720
TO REAR _ ^
I "~ OF VEHICLE
r
81
SECTION A
(GRAND MARQUIS SIMILAR)
N879S-D
ADJUSTMENTS
Door Inspection
Check door-to-body gap. Gap should be even and
minimal around entire door edge. Door should open
and cl ose smoothl y and wi th minimum effort.
Door Alignment
NOTE: Do not cover up a poor door alignment wi th a
l atch stri ker adjustment.
The door hinges provide sufficient adjustment t o
correct most door misalignment conditions. The holes
of the hinge and/ or the hinge attachi ng points are
enl arged or el ongated t o provi de for hinge and front
door or rear door alignment.
Refer t o illustrations t o determi ne whi ch hinge
bol ts must be l oosened t o move t he front door
( 20124) or rear door ( 24630) in the desi red
di recti on.
Loosen the hinge bolts just enough t o permit
movement of the front door or rear door wi th a
padded pry bar.
Move front door or rear door t he esti mated
di stance necessary. Tighten the hinge bol ts t o
25-35 N-m (18-26 Ib-ft). Check front door or rear
door fit to ensure there is no bind or i nterference
wi th the adj acent panel.
Repeat the operati on until the desi red fit is
obtai ned. Check the door l atch stri ker tappi ng
pl ate alignment for proper door cl osi ng.
01- 03- 10 Door s and L u g g a g e Compar t ment Door 01- 03- 10
Fr ont and Rear Door Town Car
FRONT
REAR
N8233-C
Par t Pa r t
I t em Number Descr i pt i on I t e m Numbe r De s c r i p t i o n
1 2 4 6 3 0 Rear Door 6 22806 Hinge and Check Assy
2 2 6 8 0 0 Sliding Door Hinge and Roller 7 20124 Front Door
3 N801193-S2 Nut and Washer Assy (1 8 22800 Front Door Hinge
Req'd Each Hinge) A Tighten to 25-35 N-m (18-26
4 2 6 8 6 6 Hinge and Check Assy Lb-Ft)
5 N 8 0 3 4 1 7 - S 2 Screw and Washer Assy (3
Req'd Each Hinge)
01- 03- 11 Do o r s a n d L u gga ge Co mp a r t me n t Do o r 01- 03- 11
Cr o wn Vi c t o r i a , Gr and Ma r q u i s Fr o n t Door
N8788-A
1 2 012 4 Fr ont Door
2 2 2 800 Fr ont Door Uppe r Hi nge
3 N621941- S2 Nut a nd Wa she r Assy (2
Re q' d Ea c h Si d e )
4 N803417 - S2 Sc r e w and Wa she r Assy (6
5 Bo d y Si de Assy
6 2 2 806 Hi nge As s y L o we r
A Ti ght e n t o 25- 35 N-m ( 18- 26
Lb- Ft )
Cr own Vi ct or i a, Grand Marqui s Rear Door
N8790-A
Part
1 2 4630 Re a r Do o r
2 N803417 - S2 Sc r e w a nd Wa she r As s y (4
3 2 6866 Hi nge As s y L o we r
4 2 6800 Sl i di ng Door Hi nge a nd Rol l e r
5 Bo d y Si d e As s y
6 N62 1941- S2 Nut a nd Wa she r As s y (4
A Ti ght e n t o 25- 35 N-m ( 18- 26
Lb- Ft )
01 -03-12 Doors and Luggage Compartment Door
01- 03- 12
Striker, Door Latch
The l atch stri ker should be shimmed t o get the
cl earance bet ween t he stri ker and t he l at ch. To check
this cl earance, clean t he l atch j aws and the stri ker
area. Appl y a thin layer of dark grease such as
Premium Long-Life Grease XG-1-C or equivalent
meeting Ford speci fi cati on ESA-M1C75-B t o the
striker. As t he front door or rear door is opened and
cl osed, a measurabl e pattern will result on the l atch
striker. Use a maxi mum of one shim under the stri ker.
Use Torx Dri ve Bit Set D79P-2100-T or equivalent t o
l oosen. Tighten the l atch stri ker t o 35- 45 N-m (25-32
Ib-ft).
35-45 N-m 22024
(25-32 LB-FT) N6557-F
Al i gnment , Luggage Compartment Door
The luggage compart ment door ( 40110) can be
shi fted fore-and-aft by loosening t he hinge-to-luggage
compart ment door retaining scr ews. The up and down
adj ustment is made by loosening the hinge-to-luggage
compart ment door retaining scr ews and raising or
l oweri ng the luggage compart ment door.
The luggage compartment door shoul d be adj usted for
an even and parallel fit wi t h the l uggage compart ment
door openi ng. The l uggage compart ment door should
al so be adj usted up and down for a flush fit wi t h the
surrounding panel s. Care shoul d be t aken not t o
damage t he l uggage compart ment door or surrounding
body panel s.
Town Car Luggage Compar t ment Door
N8148-C
Part
1 42700 Luggage Compartment Door Hinge
2 4 2 7 4 6 Luggage Compartment Door Hinge Spacer (1 Req'd Each Side)
3 40110 Luggage Compartment Door
4 N803882-S36 Screw and Washer Assy (2 Req'd Each Side)
A Tighten to 5-8.5 N-m (45-75 Lb-ln)
Cr own Vi ct or i a, Grand Mar qui sLuggage
Compar t ment Door
SCREW AND
WASHER ASSY
N803882-S36
LUGGAGE
COMPARTMENT
DOOR
40110
LUGGAGE
COMPARTMENT
DOOR HINGE
42700
N8792-D
T o r s i o n Ba r , L u g g a g e C o m p a r t m e n t
1. Open the luggage compartment door ( 40110) .
Note the pop-up di stance of t he luggage
compart ment door. The luggage compartment
door should have adequate finger cl earance.
2. If the luggage compartment door does not have
adequate finger cl earance, the luggage
compart ment door torsi on bar tension should be
i ncreased.
01- 03- 14 Door s and Luggage Compar t ment Door 01- 03- 14
Town Car Tor si on Bar Loadi ng
SAME SIDE VI E W WI T H LINKAGE
AND RH TORSION BAR REMOVED
TO SHOW POSITION OF LH TORSION
BAR IN LOWER SLOT.
TORSION BAR
ADJUSTING
SLOTS
N8237-B
Pa r t
I t em Nu mb e r De s c r i p t i o n
1 46506 Package Tray Panel
2 42700 Luggage Compartment Door Hinge
3 44891 Luggage Compartment Door/Tai lgat e Hinge Torsion Bar
4 Anti-Rattle Insulator (Part of 44891) (RH Only)
5 44890 Luggage Compartment Door/Tai lgat e Hinge Torsion Bar
Cr o wn Vi c t o r i a , Gr a nd Ma r q u i s To r s i o n Bar
Lo a d i n g
N8793-A
I t e m
Pa r t
1 N8059-S5 Torsion Bar Strap
2 44890 Luggage Compartment
Door/Tai l gat e Hinge Torsion
Bar
3 46506 Package Tray Panel
Hinge
3. If the luggage compart ment door pops open wi th
more f orce than is desi red, the luggage
compartment door torsi on bar tension can be
decreased.
4. WARNI NG: SAFETY GLASSES MUST BE
WORN WHEN PERFORMI NG THI S
OPERATI ON.
WARNI NG: USE CARE WHEN ADJUSTI NG
THE TORSI ON BAR AS IT IS UNDER TENSI ON
AND COULD SPRING OUT OF CONTROL IF
NOT HANDLED PROPERLY*
Support t he luggage compartment door in the full
open position before adjusting the luggage
compart ment door / t ai l gat e hinge torsion bar
( 44890) .
5. To adjust a l uggage compartment door / tailgate
hinge torsi on bar, use a suitable tool designed t o
safel y perform the adj ustment. Then, move the
luggage compart ment door torsion bar end t o
another position (not ch) to increase or decrease
the tensi on.
6. Adjust one l uggage compartment door / tailgate
hinge torsi on bar ( 44891) and check the
adjustment before adj usti ng the other torsi on bar.
01- 03- 15 D o o r s and L u g g a g e C o m p a r t m e n t D o o r 01- 03- 15
7. After luggage compartment door / tai l gate hinge
torsi on bar adjustment, the difference of the
position of the luggage compartment
door / t ai l gat e hinge torsi on bar ends, between
the RH and LH si de, must not be more than one
slot.
Torsi on Bar Loadi ng
1 . W A R N I N G : S A F E T Y G L A S S E S M U S T B E
W O R N W H E N P E R F O R M I N G T H I S
O P E R A T I O N .
W A R N I N G : U S E C A R E W H E N A D J U S T I N G
T H E T O R S I O N B A R A S I T I S U N D E R T E N S I O N
A N D C O U L D S P R I N G O U T O F C O N T R O L I F
N O T H A N D L E D P R O P E R L Y .
Local l y obtain the following materi al s:
Water pipe or steel pipe, 13 mm (1 / 2 inch)
di ameter by 250 mm ( 10 inches) long
3811813- S2 5/ 16- 18 x 1-3/ 4 inch hex head
washer bolt
55736- S2 5 / 1 6 x 1/ 2 inch hex head nut
a.
b.
Steel fl atwasher 1-5/ 8 inch O.D. x 1/ 4 inch I.D. x
1 / 8 inch
Tor si on Bar Ad j ust me n t Tool
1 -
WELD WASHER TO
END OF BOLT
SE CT I ON A
A S S E MB L E D
N5358-E
Pa r t
I t e m Numbe r De s c r i p t i o n
1 3811813-S2 Bo l t 5/ 16x 18x 1 3/ 4 inch
2 55736-S2 Nut
3 Water or Steel Pipe
4

Flatwasher, Steel 1 5/ 8x
1/ 4x 1/8 Inch
A Drill 5 / 1 6 " Diameter Hole
B 159 mm (6 1/4 Inch)
C 254 mm (10 Inch)
D 95 mm (3 3/ 4 Inch)
E 9.5 mm ( 3/ 8 Inch)
F 13 mm ( 1/ 2 Inch)
G 15.8mm (5/ 8I nc h)
A D J U S T ME N T S ( C o n t i n u e d ) L U B R I C A T I O N
Luggage Compar t ment Door Torsi on Bar
Adj ust ment
N5359-E
Par t
1 Uppe r Ba c k Panel
2 42 7 00 L ugga ge Co mpa r t me n t Do o r
Hi nge
3 Tor si on Ba r L o a d e d in Top
No t c h ( Ot he r Ad j ust me n t
No t c he s Ty pi c a l )
4 Hi nge S u p p o r t RH Si d e (LH
Si d e Ty pi c a l )
5 Ha nd Ma d e Tool
6 44891 New Lugga ge Co mpa r t me n t
Do o r / Ta i l ga t e Hi nge To r si o n
Bar t o be L o a d e d
Adjust one luggage compart ment door / t ai l gat e
hinge torsi on bar ( 44891) and check the
adj ustment bef ore adjusting the other l uggage
compart ment door / t ai l gat e hinge torsi on bar.
After l uggage compartment door torsi on bar
adj ustment, the di fference of the position of the
l uggage compart ment door torsi on bar ends
bet ween the RH and LH si de, must not be more
than one slot.
L u b r i c a n t
We a t h e r s t r i p
Use Silicone Lubricant C0AZ- 19553- AA (Jel l y) or
D7AZ- 19553- AA (Spray) or equi val ent meeting Ford
speci fi cati on ESR-M 13P4-A on t he door and wi ndow
weat herst ri ps. It is recommended that silicone
lubricant be applied to the weat herst ri p whenever
necessary. Silicone lubricant hel ps avoi d weat herst ri p
squeaks and ret ards excess weat herst ri p wear f rom
chafi ng bet ween the door gl ass upper f rame and the
weat herst ri p. It also helps t o retai n door wi ndow
alignment by reducing fri cti on bet ween the gl ass f rame
and t he rubber weat herst ri p.
Hi n g e , Do o r
Use Multi-Purpose Grease D7AZ- 19584- AA (Spray)
ESB-M1C93-A t o lubricate door hinges.
LUBRI CATE
BUSHI NGS
AND ROLLER
PIN
N6585-C
Hi n g e , L u g g a g e C o m p a r t m e n t Do o r
Use Multi-Purpose Grease D7AZ- 19584- AA (Spray)
ESB-M1C93-A on luggage compart ment door ( 40110)
and l uggage compartment door hinge ( 42700) . Appl y
an even coat t o all movabl e hinge surfaces when a
binding condition occurs.
SPECIFICATIONS
De s c r i p t i o n N-m Lb-Ft
L a t c h Re t a i n i n g S c r e ws 9- 14 7- 10
Do o r L a t c h St r i ke r 35- 45 2 5- 32
Do o r Hi n ge Re t a i n i n g
S c r e w / Wa s h e r
2 5- 35 18- 26
Hi n ge - t o - L u gga ge Co mp a r t me n t
Do o r S c r e w / Wa s h e r
5-8. 5 45- 7 5
( Lb- l n )
S P E C I A L S E R VI C E T O O L S / E Q U I P ME N T
SPECIAL SERVICE TOOLS DESIRED
T o o l N u m b e r De s c r i p t i o n
D7 9P - 2 100- T Torx Dr i ve Bi t Se t
(Continued)
ROTUNDA EQUIPMENT
156- 0007 0 Fl e x i - Wo r k Ta bl e
107 - R0401 Wi n d s h i e l d a n d Mo u l d i n g / T r i m Re mo v a l
Ki t
01- 05- 1
SUBJECT PAGE
VEHICLE APPLICATION . 01-05-1
Carpets, Floor .01-05-2
Cigar Lighter Knob and El ement... 01-05-2
Headl i ni ng, Roof .......01-05-1
Trim, Interior 01-05-1
Uni versal Transmi tter .......01-05-2
El ectri cal Schemati cs 01-05-3
Pi npoi nt Test .01-05-4
Sympt om Chart . 01-05-3
Ash Recept acl e and Retai ner 01-05-4
Assi st Handl es, Roof . 01-05-31
Carpet , Fl oor . ..01-05-35
Ci gar Li ght er Knob and El ement 01-05-4
Headl i ni ng, Roof . .01-05-27
Lower Panel / Cent er Pillar 01-05-34
Luggage Compar t ment Cover Panel sTown
Car.... .... .....01-05-23
Moul di ngs, I nf eri or. 01-05-6
SUBJECT PAGE
Scuf f Plat es 01-05-32
Tri m Panel 01-05-8
Tri m Panel , Package Tr a y Town Car 01-05-21
Tri m Panel, Qua r t e r Town Car 01-05-19
Tri m Panels, Door 01-05-15
Door El ect ri cal Connect i ons ..01-05-19
Fr o n t To wn Car 01-05-15
Rear Town Car 01-05-18
Vi sor, Auxi l i ary 01-05-6
Vi sor, Insi de 01-05-5
Fabri c. . . . . . ...01-05-37
Saf et y Belt Webbi ng 01-05-37
Spot Cl eani ng 01-05-37
Stain Cleaning 01-05-37
Wi ndow Glass, I nt eri or 01-05-37
Woodgrai n (Si mul at ed), Pl ast i c, Vi nyl and
Leat her ....01-05-37
VEHICLE APPLICATION
This Secti on covers removal and installation of interior
mouldings and tri m compounds.
In most i nstances, one component overl aps another
component.
f this condition is found it will be necessary t o
oosen or remove the overl appi ng component
oefore the removal of the desi red component.
Tri m, I nt er i or
The interior tri m has the following f eat ures:
The door tri m panels are covered wi t h ei ther vinyl or
cl oth and carpet .
Floor carpet ( 13000) covers t he fl oor and l uggage
compart ment .
In Crown Vi ctori a and Grand Marqui s, t he package
t ray tri m panel ( 46668) is made of fi berboard wi th a
sheet metal rei nforcement.
Package t ray tri m panel for Town Car is made of
resi nated cot t on wi th a metal rei nforcement.
The remaining panels are pl asti c.
Many of the interior tri m panel s use conceal ed
fasteners. The installation procedures show t he
location of each fastener.
He a d l i n i n g , Roof
The roof headlining ( 51916) i sa one-pi ece desi gn that
covers the enti re roof.
1995 To wn Car, Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s Jul y , 1994
01- 05- 2 Tr i m, I n t e r i o r 01- 05- 2
DESCRIPTION AND OPERATION (Conti nued)
C a r p e t s , Fl o o r
The floor carpet ( 13000) is a one-piece design that
covers the floor f rom the instrument panel ( 04320) t o
the t op of t he rear floor riser.
C i g a r L i g h t e r K n o b a n d E l e m e n t
The ci gar lighter knob and element ( 15052) has a low
resi stance heating coil whi ch operat es much like the
coil used in a portabl e heater.
When the ci gar lighter knob and element is pushed
compl etel y into the ci gar lighter socket and retainer
( 15055) the circuit is cl osed and current f l ows
through the heating coil t o the ground.
When sufficient heat is generated, the ci gar lighter
knob and element overcomes the spring pressure of
the bi-metal retaining fi ngers and is rel eased.
Ash recept acl es ( 30702) and Cigar lighter knob and
elements are l ocated in the rear door armrest s.
U n i v e r s a l T r a n s m i t t e r
The universal transmi tter provi des a convenient way t o
consol i date t he functions of up t o three individual
hand-held transmi tters into one universal transmi tter.
The universal transmi tter:
Will operat e garage doors, gat es, home/ of f i ce
lighting syst ems, or even securi ty syst ems; nearly
any devi ce that is control l ed by radi o frequency.
Will actually learn and transmi t the radi o frequency
of up t o three of your current hand-held transmi tters
f rom any of the syst ems mentioned above.
Is an integral part of the LH inside visor ( 04100) and
powered by your vehi cl e' s bat t ery and chargi ng
syst em. No batteri es are needed.
UNIVERSAL TRANSMITTER
(PART OF 4100)
INSIDE VISOR
04100 R10886-A
P r o g r a mmi n g
Be f o r e P r o g r a mmi n g
Make sure batteri es in the hand-held transmi tter are
not dead.
Hold hand-held transmi tter in the exact position
descri bed, agai nst the universal transmi tter.
Hold buttons for durati on of the programmi ng,
wi thout interruption.
For best resul ts, pl ace the hand-held transmi tter
end opposi te the bat t ery compart ment agai nst t he
universal transmi tter when programmi ng.
1. CAUTI ON: Dur i n g t h i s p r o c e d u r e t h e s y s t e m
t h a t y o u a r e p r o g r a mmi n g wi l l be ma d e t o
o p e r a t e . Ma ke s u r e t h a t p e o p l e o r o b j e c t s
a r e c l e a r o f t h e ga r a ge d o o r o r g a t e t h a t y o u
a r e p r o g r a mmi n g .
Deci de whi ch one of the three universal
transmi tter channels you want t o program (Button
1, 2, or 3).
2. Hold the end of your hand-held transmi tter button
against the bot t om surf ace of t he universal
transmi tter so that you can still see the red light.
3. Using both hands, push both the hand-held
transmi tter button and the desi red universal
transmi tter button. DO NOT RELEASE EITHER
BUTTON. Continue t o hold both buttons through
step 4.
4. Hold down bot h buttons until you see the red light
on the universal transmi tter fl ash fi rst sl owl y and
then rapidly. This coul d t ake up t o a minute or
more. Rel ease both buttons after light fl ashes
rapidly.
The rapid fl ash means that the universal transmi tter
has been successful l y programmed t o mat ch your
hand-held transmi tter. You can now use the universal
transmi tter i nstead of your hand-held transmi tter.
Op e r a t i o n
To operat e, simply press the appropri at e button on t he
universal transmi tter. The red light illuminates whi l e the
signal is being t ransmi t t ed.
Cl e a r i n g P r o g r a m
To cl ear the universal transmi tter of all previ ousl y
programmed frequenci es, simultaneously hold down
buttons 1 and 3 until the red light begins t o fl ash. This
will cl ear all t hree channel s.
Individual channel s cannot be cl eared, but can be
reprogrammed at any ti me by implementing the
programmi ng procedures as outlined.
1995 To wn Car , Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s Jul y , 1994
01- 05- 3 T r i m, I n t e r i o r 01- 05- 3
Electri cal Schemat i cs
Ci gar Li ght er , To wn Car
I FUSE
'
1 7
. JUNCTION
I PANEL
I
See EVTM for
more details
of this circuit
R9557-B
Inspect i on and Veri f i cat i on
1 . Verify the vehicle owner' s original concern by
operati ng the cigar lighter or garage door
openers t o duplicate the vehi cl e owner' s concern.
2. Inspect t o determi ne if one of the following
mechani cal or el ectri cal concerns appl y:
Me c h a n i c a l E l e c t r i c a l
Bu r n e d out or mi ssi n g c i ga r
l i gh t e r e l e me n t .
Br o ke n or mi ssi n g ga r a ge
d o o r o p e n e r b u t t o n s .
Ci ga r l i gh t e r f u s e mi s s i n g or
b l o wn .
Ga r a ge d o o r o p e n e r f use
mi s s i n g o r b l o wn .
3. If the concern(s) remains after t he i nspecti on,
determi ne the symptom(s) and go t o t he
Sympt om Chart.
Sympt om Chart
REAR DOOR CIGAR LIGHTERS
Cigar Lighter Knob and Element
Inoperative
Short to ground.
Open ground.
Open supply.
Open fuse.
01- 05- 4 Trim, Interior 01- 05 - 4
Pi npoi nt Test
PINPOINT TEST A: CIGAR LIGHTER KNOB AND ELEMENT INOPERATIVE
At CHECK FUSE
Yes
No
GO to A4.
GO to A2.
Ignition swi tch OFF.
Check the 30A CIGAR fuse 10 (Town Car) located in
the instrument panel.
Is f use OK?
Yes
No
GO to A4.
GO to A2.
A2 CHECK SYSTEM
Yes
No
GO to A3.
GOt o A4.
Ignition switch OFF.
Replace the 30A CIGAR fuse 10 (Town Car).
Ignition swi tch in RUN or ACC.
Does f use f ai l agai n?
Yes
No
GO to A3.
GOt o A4.
A3 CHECK FOR SHORT TO GROUND
Yes
No
SERVICE LB/ W wire
between instrument panel
fuse j unction panel and
ci gar lighter knob and
element.
REPLACE 30A CIGAR
fuse 10 (Town Car). GO t o
A4.
Remove the 30A CIGAR fuse 10 (Town Car).
Disconnect cigar lighter connector.
Measure the resi stance of LB/ W wire between RH
terminal of 30A CIGAR fuse 10 (Town Car) holder
and ground.
Is resi st ance less t han 5 ohms?
Yes
No
SERVICE LB/ W wire
element.
REPLACE 30A CIGAR
fuse 10 (Town Car). GO t o
A4.
A4 CHECK POWER SUPPLY TO CIGAR LIGHTER
Yes
No
GO to A5.
SERVICE LB/ W wire
element.
Ignition switch OFF.
Ignition switch in RUN or ACC.
Measure the voltage of the LB/ W wire at the cigar
lighter connector.
Is vol t age great er t han 10 vol t s?
Yes
No
GO to A5.
SERVICE LB/ W wire
element.
A5 CHECK CIGAR LIGHTER GROUND
Yes
No
REPLACE cigar lighter
knob and element.
SERVICE BK wire
between cigar lighter
knob and element and
ground.
Measure the resi stance of the BK wire between the
cigar lighter connector and ground.
Yes
No
knob and element.
SERVICE BK wire
between cigar lighter
knob and element and
ground.
Ash Receptacle and Retainer
1. Access ash receptacl e ( 30702) in wi ndow
regulator swi t ch housing ( 14527) .
2. Pull strai ght upward on ash recept acl e. Remove
ash recept acl e f rom wi ndow regulator swi t ch
housing ( 14528) .
3. To install, align ash recept acl e in wi ndow
regulator swi t ch housing and push into pl ace.
2. Pull ci gar lighter knob and element ( 15052) out of
ci gar lighter socket and retai ner ( 15055) .
3. Carefully pry wi ndow regul ator swi t ch housing
( 14527) f rom differential beari ng shi m ( 4067) .
4. Di sconnect body main wi ri ng ( 14A005) f rom
ci gar lighter socket and retainer.
5. Remove ci gar lighter retai ner f rom ci gar lighter
socket . Remove ci gar lighter socket .
Cigar Li ght er Knob and Element
1. Di sconnect battery ground cabl e ( 14301) .
1995 Town Car, Crown Victoria, Grand Marquis July, 1994
01- 05- 5
T r i m, I n t e r i o r 01- 05 - 5
RH SIMILAR R10884-A
Pa r t
It em Nu mb e r De s c r i p t i o n
1 30702 Ash Receptacle
2 15052 Cigar Lighter Knob and
Element
3 14527 Window Regulator Switch
Housing
4 14529 Window Regulator Control
Switch
5 14A005 Body Main Wiring
6 N807001-S50 Screw (2 Req'd Each Door)
7 27406 Rear Door Trim Panel
8 13466 Miniature Bulb
9 15055 Cigar Lighter Socket and
Retainer
Vi sor, Inside
2. Remove t wo scr ews retaining inside vi sor
( 04100) t o roof panel ( 502B98) .
3. Remove inside visor f rom vi sor arm cl i p ( 04132)
4. Di sconnect court esy or interior l amp swi t ch
wiring ( 13A709) f rom inside vi sor.
6. Remove inside vi sor, sliding auxiliary vi sor
( 04054) f rom visor arm cl i p.
6. Slide auxiliary visor out of inside vi sor.
Vi sor
Pa r t
1 56010 Screw
2 50609 Clip
3 13A709 Courtesy Or Interior Lamp
Switch Wiring (2-Pin
Connector for Town Car
Only)
4 51916 Roof Headlining
5 56010 Screw (2 Req'd)
6 04104 Inside Visor
Vanity Mirror With LampTown Car
Repl ace vi sor t o repl ace vani ty mirror wi t h lamp. Refer
t o Inside Vi sor Removal and Installation.
Vanity Mirror Lamp Lens and Bulbs
1. Remove the cl ear vani ty mirror lamp lens
( 17C706) coveri ng the miniature bulb ( 13465)
using a small screwdri ver.
2. Remove old miniature bulb and install new
miniature bulb.
1995 To wn Ca r , Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s Jul y , 1994
01- 05- 6 Trim, Interior 01- 05- 6
3. Position vanity mi rror lamp lens on inside visor
( 04104) and snap into pl ace.
Pa r t
1 04115 Inside Visor Sleeve
2 17A679 Vanity Mirror
3 Connector (Part of 17A679)
4 17C706 Vanity Mirror Lamp Lens
5 Hi-Lo Switch
VANITY MIRROR
LAMP LENS
17C706
MIRROR LAMP
LENS R6581-C
Visor Arm Clip
1. Di sengage inside visor from visor arm clip.
2. Remove screw retaining visor arm clip t o roof
panel .
3. Slide vi sor arm clip away f rom auxiliary vi sor.
Remove visor arm clip.
Visor, Auxi li ary
1 . Remove visor arm clip ( 04132) as outlined.
2. Slide auxiliary vi sor ( 04054) f rom inside vi sor
( 04100) . Remove auxiliary vi sor.
I t e m
Pa r t
2 4054 Auxiliary Visor, Part of 04104
Visor Assy
3 Lighted Mirror Wiring
Harness
4 N805000-S2 Screw (3 Req'd Each Vi sor)
TR7996B
Mouldi ngs, Interi or
Windshield
The interior tri m Removal and Installation procedures
generally appl y t o all model s. If some of the st eps do
not appl y t o the parti cul ar model being servi ced,
proceed t o the next st ep.
1. Pull front door opening weat herst ri p ( 20708)
l oose at wi ndshi el d si de garni sh moulding
( 03598) .
2. Grasp the wi ndshi el d si de garni sh moulding at t he
t op and gently pull away from A-pillar until all
t hree retai ners rel ease.
3. To install, align wi ndshi el d garni sh moulding
retainer ( 03700) on A-pillar and press wi ndshi el d
si de garni sh moulding into pl ace by hand.
4. Press front door opening weat herst ri p into pl ace.
01- 05- 7 Trim, Interior 01- 05- 7
Town Car
Par t
3 N806482-S G r o m m e t ( 3 R e q ' d E a c h
S i d e )
4 0 4 4 D 7 0 I n s t r u m e n t P a n e l F i n i s h
P a n e l
FRONT OF
" VEHICLE"""
S E C T I O N A
R10885-A
Par t
1 0 3 5 9 8 Windshield Side Garnish
Moulding
2 A-Pillar
( Co n t i n ue d )
Cr own Vi ct ori a, Grand Marquis
SECTION A
R7161-B
Par t
1 03700 Windshield Garnish Moulding Retainer
2

A-Pillar
3 03598 Windshield Side Garnish Moulding
4 56901-S58 Screw
01- 05- 8 Tr i m, I nt er i or 01- 05- 8
Tri m Panel
Cowl Si deTown Car
1. Remove door opening interior front door scuff
pl ate center pillar tri m as outlined.
2. Snap out hood rel ease grommet on dri ver si de.
Town Car
SECTION A
6 ^
SECTION i
SECTION A
3. Remove t wo cowl si de tri m panel retaining
scr ews.
4. Pull cowl side tri m panel ( 02344) r ear war d t o
rel ease retaining push pin. Slip hood rel ease
handle through opening provi ded.
LH SIDE SHOWN
RS338-D
Pa r t
2 N800944-SW Screw
3 Cowl Side Panel
Cowl Si deCrown Vi ctori a, Grand Marquis
1. Remove front door scuff pl ate ( 13209) as
outlined.
2. Snap out hood l atch rel ease cabl e bezel
( 16B999) on LH si de.
3. Remove t wo cowl si de tri m panel push pins using
f abri cat ed tool shown under Scuff Plate Door
Opening Removal and Installation.
4. Pull cowl si de tri m panel rearward t o rel ease
retaining push pin. Slip hood rel ease handle
through opening provi ded.
01- 05- 9 Tr i m, I nt er i or
01- 05- 9
LH Si de, Cr own Vi ct or i a/ Gr and Marqui s
VIEW A
VIEW A
L
SECTION 8
R7171-B
Par t
1
_ -
Plate (Part of 14401)
3 16B999 Hood Latch Release Cable Bezel
4 N805612-S Push Pin
RH Si de, Cr own Vi ct or i a/ Gr and Marqui s
3
VIEW A
SECTION B
SECTION B
INSTALLED
R7172-B
Par t
3 Plate (Part of 14401)
Center Body Pi l l ar, I nsi de Up p e r T o wn Car
Removal and i nst al l at i on
1. Remove front door scuff pl ate as outl i ned.
2. Remove saf et y belt retaining bolt. Refer t o
Secti on 01-20A.
3. Remove front door scuff pl ate starti ng at t op by
gently pulling away f rom B-pillar.
4. Remove push pins from bot t om of center body
pillar inside upper finish panel ( 24356) .
01- 05- 10 T r i m, I nt er i or 0 1 - 0 5 - 1 0
5. Remove center body pillar inside upper finish
panel by gently pushing up.
Uppe r Panel , Ce n t e r Pi l l a r To wn Car
CO
- = - 0
SECTION A
0 - n
SECTI ONB
SECTION B
RS340-C
Pa r t
1
B-Pillar
2 25324 Rear Door Weatherstrip
3 24346 Center Body Pillar Inside
Lower Finish Panel
( Co n t i n ue d )
Pa r t
I t e m Number De s c r i p t i o n
4 24498 Center Body Pillar Inside
Finish Panel Retainer
5 388246-S Push Pin
6 W611624-S2 Washer Head Tapping Screw
(2 Req'd Each Side)
Center Body Pillar, Inside UpperCrown
Victoria, Grand Marquis
1. Remove front door scuff plate as outlined.
2. Remove safety belt retaining bolt. Refer t o
Secti on 01-20A.
panel starti ng at t op by pulling gently away from
B-pillar.
4.
5.
Remove scr ew f rom center body pillar inside
l ower finish panel ( 24346) and remove by gentl y
pulling down.
01- 05- 11
Tr i m, I nt er i or 01- 05 - 11
Cent er Body Pillar, Insi de UpperWi t h Sli di ng
D-Ri ng
SECTION A
R7174-B
Par t
1 N800841-S P u s h - I n N u t ( 1 R e q ' d E a c h
S i d e )
2 2 4 3 9 6 U p p e r T r i m Panel
3 N800943-S58 Screw (1 Req'd Each Side)
4 60262 Front Seat Shoulder Strap
Guide Cover (1 Req'd Each
Side)
5 611B08 Front Safety Belt Retractor
and Tongue
6 2 4 3 4 6 Center Body Pillar Inside
Lower Finish Panel
I t e m
Pa r t
7 B-Pillar
Ce nt e r Bo d y Pi llar, I nsi de Uppe r -
Fr o n t Sa f e t y Bel t Gui de
- Wi t ho ut Sl i di ng
CENTER TRIM
PANEL UPPER
24396
FRONT SEAT
STRAP GUIDE
60262
R7596-A
Upper QuarterTown Car
Removal
1. Remove rear seat cushion and seat back. Refer
2. Remove rear saf et y belt ret ract or and tongue
( 611B68) . Refer t o Secti on 01-20A.
3. Pull rear door weat herst ri p ( 25324) away f rom
upper quarter tri m panel ( 52018) .
4. Pull upper quarter tri m panel out ward t o rel ease
retaining cl i ps.
5. Remove rear seat shoulder st rap opening bezel
( 601B30) f rom upper quarter trim panel by
snapping it out.
6. Slide rear saf et y belt ret ract or and tongue
through slot in upper quarter tri m panel and install
rear seat shoulder st rap opening bezel .
Installation
1. Slide rear saf et y belt ret ract or and tongue
through slot in upper quarter trim panel .
2. Position upper quarter tri m panel t o quarter panel
and press until all retai ners are secure.
3. Install rear saf et y belt ret ract or and tongue. Refer
t o Secti on 01-20A.
4. Install rear seat . Refer t o Secti on 01- 10.
01- 05- 12 T r i m, i n t e r i o r 01- 05- 12
Upper Quart er Trim Panel
REAR SAFETY
BELT RETRACTOR
AND TONGUE
611B68
UPPER
QUARTER
TRIM PANEL
52018
PLASTIC RETAINER
N807247-S
5 REQ'D
SECTION A
SECTION B
R8342-E
Upper QuarterCrown Vi ctori a, Grand
Marquis
Removal
1. Remove rear seat cushion and seat back. Refer
Upper Qua r t e r Cr own Vi ct ori a
SECTION A
2. Remove rear seat shoulder st rap opening bezel
by pryi ng out front t abs fi rst.
3. Remove rear saf et y belt child saf et y belt anchor
tether ( 613D74) . Refer t o Secti on 01-20A.
Ok
SECTION A
0 s
1
SECTION B j
R7176-B
Pa r t
1 51968 Roof Trim Panel
2 611B68 Rear Safety Belt Retractor and Tongue
( Co n t i n ue d )
1995 To wn Car, Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s July, 1994
01- 05- 13 Trim, Interior 01- 05- 13
Par t
3 601B30 R e a r S e a t S h o u l d e r S t r a p O p e n i n g B e z e l
4
_ Tabs (Part o f 601B30)
5 611B68 Rear Safety Beit Retractor and Tongue
Uppe r Qua r t e r Gr a n d Mar qui s
1
TO REAR
DEFROSTER
Qt)-
SECTION A
CO
CO
SECTION B
SECTION B R7175-B
Pa r t
3 601B30 Rear Seat Shoulder Strap Opening Bezel
4 Tabs (Part of 601B30)
4. Pull rear door weat herst ri p l oose at roof tri m
panel ( 51968) .
5. On Crown Vi ctori a, remove scr ew or push pin in
saf et y belt recess. On Grand Marqui s, remove
push pin in safety belt recess.
6. Pull quarter roof tri m panel away from quarter
panel sheet metal until all retai ners rel ease.
01- 05- 14 Tr i m, I n t e r i o r 01- 05- 14
Cr own Vi ct ori a
SECTION A
R7178-B
Pa r t
1 N800841-S Push In Nut
2 51968 Quarter Roof Trim Panel
3 56904-S2 Screw
I t e m
Pa r t
4 611B68 Rear Safety Belt Retractor
and Tongue
5 25324 Rear Door Weatherstrip
6 Retainer (4 Places)
Uppe r Qu a r t e r Gr a n d Mar qui s
Pa r t
I t e m Numbe r Descr i pt i on
3 N807247S Push Pin
4 25324 Rear Door Weatherstri p
5 388577-S Push Pin (1 Req'd Each Side)
01- 05- 15 Tr i m, i nt eri or
01- 05- 15
i nst al l at i on
1. Position quarter roof trim panel t o quarter panel
sheet metal and press until all retainers are
secure.
2. Install push pin (Grand Marqui s) or screw (Crown
Vi ctori a) in saf et y belt recess.
3. Install rear safety belt ret ract or and tongue. Refer
t o Secti on 01-20A.
4. Snap rear seat shoulder st rap opening bezel into
posi ti on.
5. Install rear seat. Refer t o Secti on 01- 10.
Tr i m Pa ne l s, Do o r
Fr o n t To wn Car
Removal
1. CAUTION: To avoi d breakage of door pull
cover(s), i nsert a screwdri ver di agonal l y
bet ween pull st rap and chrome bracket .
Snap out bot h si des t hen remove.
Snap out t wo door pull st rap retaining screw
covers. Remove scr ews.
2. Remove t wo scr ews on front and rear side of
front door tri m panel.
3. The fol l owi ng procedure must be used during
removal and installation of t he door armrest and
tri m panel . Refer t o the appropri ate illustrations
for component and vehicle model identification.
Using the Trim Pad Removing Tool f rom Rotunda
Wi ndshi el d and Moul di ng/ Tri m Removal Ki t
107-R0401 or equivalent, pry the tri m panel
retaining clips f rom the door inner panel .
4. NOTE: Do not use front door tri m panel ( 23942)
t o remove tri m cl i ps f rom door inner panel .
Repl ace any bent, damaged or missing push pins.
Remove wi ndow regulator control swi t ch housing
f rom back of front door tri m panel . Lift up housing
and di sconnect all connect ors.
5. Di sconnect dri ver seat regul ator control
processor swi t ch (driver door onl y) if equi pped.
6. Twi st out interior lamp wi re assembl y.
I nst al l at i on
1. Ensure plastic watershi el d is secured t o door
panel.
2. Position front door tri m panel t o door. Connect
interior lamp wi ri ng.
3. Align door l ock si de to its mating slide on the
sheet metal (front doors onl y).
4. Snap in front door tri m panel. Ensure all retai ners
fit properl y.
5. Install t wo retaining scr ews on front and rear si de
of front door tri m panel.
6. Connect driver seat regulator control processor
( 14C708) (driver door only) if equi pped.
7. Position wi ndow regulator control swi t ch housing
and connect swi t ch connect ors. Install t o front
door tri m panel by snapping in, or by installing the
scr ew at the rear.
8. Install t wo retaining screws and pull st rap covers.
01- 05- 16 Tr i m, I n t e r i o r 01- 05- 16
Tr i m Panel s, Fr o n t Do o r s T o wn Car
R10993-A
Par t Par t
It em Number De sc r i pt i o n I t em Number Descr i pt i on
1

Door 4 N801733-S Rivet (4 Req'd Each Side)
2 37A04-5 Shield Front Door Trim Water 5 23943 Front Door Trim Panel
3 23834 Bracket AssemblyDoor 6 13465 Miniature Bulb
Trim (1 Req'd Each Side)
( Co n t i n ue d )
F r o n t C r o w n Vi c t o r i a , G r a n d Ma r q u i s
Re mo v a l
1. Remove outsi de rear vi ew mirror remote control
unit.
2. Remove wi ndow regul ator control swi t ch housing
by gently pryi ng up, starti ng at the front.
3. Di sconnect all connectors f rom wi ndow regulator
control swi t ch housing.
4. Remove inside door handle cup ( 22634) by
gently pryi ng at screwdri ver slot wi th a
screwdri ver.
5. Remove push pin f rom front door tri m panel upper
front extensi on and remove screw.
6. Remove l ower self-tapping screw retaining front
door tri m panel t o door inner panel.
7. On Grand Marqui s only, pry up screw covers f rom
door pull handle and remove scr ews and handle.
8. Lift front door tri m panel upward and snap out tri m
panel.
9. Di sconnect wi re harnesses f rom door panel as
required and remove front door tri m panel .
1. Connect wi re harnesses to front door tri m panel
as requi red.
2. Install front door tri m panel by pushing in and
down until it snaps into pl ace.
3. Install all self-tapping scr ews retaining front door
tri m panel to door inner panel.
4. On Grand Marquis only, install door pull handle,
ti ghten scr ews and install screw covers.
5. Install push pin coveri ng screw on tri m panel
upper front extensi on.
6. Install inside door handle cup.
7. Install wi ndow regulator control swi t ch housing.
01- 05- 17 Tr i m, I nt eri or
" g a g r ? "ZFMS^r-
0 1 - 0 5 - 1 7
Z3
Tri m Panel s, Fr ont Door sCr own Vi ct or i a, Grand Marqui s
VIEWB
SECTION A
ASSEMBLED VIEWB VIEWC
VIEWD
GRAND MARQUIS SHOWN
CROWN VICTORIA SIMILAR
VIEWE
R10995-A
I t e m
Pa r t
1
2
23942-3
22634-5
Panel Assembly Door Trim
CupDoor Inside Handle
I t e m
Pa r t
3 23774 Cover Front Door Trim Panel
Opening Without Remote
Fuel Filler and Power Lock
Group
( Co n t i n ue d )
01- 05- 18 Tri m, Int eri or 01- 05 - 18
I t em
Par t
4 224A28-9 Support AssemblyFront
Door Pull Handle
5 388047-S101 Rivet (2 Req'd Each Side)
6 238A47 Protector Door Trim Panel
Assembly, LH Side Only
7 3110 Weatherstrip
( Co n t i n ue d )
Pa r t
8 20124 Front Door
9 237A05 Front Door Watershield
10 56912-S58 Screw (2 Req'd)
11 N804592-S58 Screw and Washer (2 Req'd)
12 Trim Plug (2 Req'd Each
Side)
Re a r To wn Car
Removal and Inst al l at i on
1. Snap out t wo door pull st rap retaining screw
covers and remove scr ews.
2. Remove t wo scr ews, one on front side of rear
door tri m panel ( 27406) and one on rear.
3. Remove scr ew retaining rear door inside handle
cup. Remove rear door inside handle cup.
Door Tr i m Panel , Re a r To wn Car
5.
6 .
Using t he tri m pad removi ng tool f rom Rotunda
Windshield and Moul di ng/ Tri m Kit 107-R0401 or
equivalent, pry tri m panel retaining cl i ps f rom rear
door inner panel.
Di sconnect any el ectri cal connecti ons f rom
swi t ches at tri m panel if equi pped, and remove
rear door tri m panel.
R10994-A
Pa r t
1 Rear Door Assembly
2 27458 Shield Rear Door Trim Water
3 238A38 Bracket AssemblyDoor
Trim Panel (1 Req'd Each
Side)
( Co n t i n ue d )
Pa r t
4 N801733-S Rivet (4 Req'd Each Side)
5 2706 Rear Door Trim Panel
01- 05- 19 Tr i m, I nt er i or
01- 05- 19
R e a r C r o w n Vi c t or i a, Gr and Mar qui s
1. Snap out t wo door pull strap retainer screw
covers. Remove screws.
2. Remove one screw from l ower rear door panel.
3. Remove screw retaining rear inside door handle
cup. Remove rear door inside handle cup.
4. Using t he Trim Pad Removing Tool f rom Rotunda
Wi ndshi el d and Moul di ng/Tri m Removal Ki t
107-R0401 or equivalent, pry tri m panel retaining
cl i ps f rom rear door inner panel.
5. Di sconnect any el ectri cal connecti on f rom
swi t ches, if equi pped, and remove rear door tri m
panel .
6. To Install, reverse Removal procedure.
VIEW i
SECTION A INSTALLED
VIEWB
GRAND MARQUIS SHOWN
CROWN VICTORIA SIMILAR VIEWC
R10996-A
I t e m
Pa r t
Nu mb e r De s c r i p t i o n I t e m
Pa r t
1 27406 Rear Door Trim Panel 5 74A30 Rear Door Panel
2 22634 CupDoor Inside Handle 6 56912-S58 Screw (2 Req'd Each Side)
3 224A30 Support AssemblyRear 7 388047-S101 Rivet (2 Req'd Each Side)
Door Pull Handle 8 N806399-S58 Nut (1 Req'd Each Side)
4 253A10 Rear Door Body 9 N804592-S58 Screw (1 Req'd Each Side)
Weatherstrip
10 Trim Plug
( Co n t i n ue d )
Do o r E l e c t r i c a l C o n n e c t i o n s
Refer t o Secti on 01- 11 f or Power Wi ndow, Secti on
01- 09 for Power Mirror, or Section 01- 14B for Power
Door Locks.
T r i m P a n e l , Q u a r t e r T o w n C a r
R e mo v a l a n d I n s t a l l a t i o n
1. Remove f ront door scuff plate ( 13209) as
outl i ned.
2. Remove rear seat cushion and rear seat back.
3. NOTE: Replace any bent, damaged or missing
push pins.
Remove push pins and retaining screw. Remove
quarter trim panel ( 31012) .
01- 05- 20 Tr i m, I nt er i or 01- 05- 2 0
Town Car
SECTION A
R6339-D
Pa r t
1 31136 Quarter Trim Panel
3 N805398-S55 Screw
4 391039-SSW Push Pin (2 Req'd Each
Side)
I t e m
Pa r t
5

Wheelhouse Inner Quarter
Panel
6 27790 Front Quarter Inside Panel
A Tighten to 0.5-2.0 N-m (5-17
Lb-ln)
( Co n t i n ue d )
T r i m P a n e l , Qu a r t e r C r o w n Vi c t o r i a , G r a n d
Ma r q u i s
1. Remove front door scuff plate as outlined.
2. Remove rear seat cushion and rear seat back.
3. Remove rear door weat herst ri p ( 25324) .
4. Remove quarter tri m panel by starti ng f rom t op
and gently pulling away f rom front quarter inside
panel ( 27790) .
01- 05- 21
T r i m, I n t e r i o r 01- 05- 21
Cr o wn Vi c t o r i a / Gr a n d Ma r qui s
REAR DOOR
WEATHERSTRIP
25324
SECTION
k*Y QUARTER TRIM
PANEL
31012
T r i m Panel, Package T r a y T o w n Car
Remov al and I nst al l at i on
1. Remove rear seat. Refer t o Secti on 01- 10.
2. Remove rear speakers. Refer t o Secti on 15-03.
3. Remove t wo screws retaining rear hi-mount lamp
( 13A613) and snap out bulb. Refer t o Secti on
17- 01.
4. Remove retaining scr ew t o rear hi-mount lamp
bracket and remove bracket .
5. Remove t wo push pins on front side of package
t ray tri m panel .
6. Lift package t ray tri m panel ( 46668) upward and
remove.
REAR DOOR
WEATHERSTRIP
25324 1 i f
^QUARTER TRIM
^ PANEL 31012
SECTION A
R7173-B
01- 05- 2 2 Trim, Interior 01- 05- 2 2
Tr i m Panel , Pa c ka ge T r a y T o wn Car
R63S4-C
Part Par t
Stem Number Descr i pt i on I t e m Number Descr i pt i on
1 13A613 High-Mount Stoplamp 4 46668 Package Tray
2 56919-S58 Screw 5 45267-S U-Nut
3 42006 Window 6 56922-S2 Screw
(Continued)
Trim Panel, Package TrayCrown Vi ctori a,
Grand Marquis
1. Remove rear seat. Refer t o Secti on 01-10.
2.
3.
Remove rear radi o speakers ( 18808) if equi pped.
Refer t o Secti on 15-03.
Remove t wo scr ews retaining rear hi-mount lamp
and snap out bulb. Refer t o Secti on 17- 01.
4. Remove roof tri m panels ( 51968) as outlined.
5. Remove retaining screw t o rear hi-mount lamp
bracket and remove bracket .
6. Remove t wo push pins on front si de of package
t ray tri m panel .
7. Lift package t ray tri m panel upward and remove.
01- 05- 23 Trim, interior 0 1 - 0 5 - 2 3
R E MO V A L A N D I N S T A L L A T I O N ( C o n t i n u e d )
PUSH PIN
390018-S
PACKAGE TRAY
TRIM PANEL
46668
REAR SAFETY BELT
RETRACTOR AND TONGUE
611B68
REAR SAFETY BELT
RETRACTOR AND TONGUE
611B68
GRAND MARQUIS SIMILAR
R7182-B
L u g g a g e C o m p a r t m e n t C o v e r P a n e l s T o w n
C a r
1. Remove spare ti re cover ( 45026) as needed for
access.
2. Remove push pins and/ or pushnuts. Remove
luggage compartment carpet or luggage
compartment door tri m panel ( 45594) .
01- 05- 2 4 0 1 - 0 5 - 2 4
REMOVAL AND INSTALLATION (Conti nud)
Lugga ge Co mpa r t me n t Cover P a n e l s To wn Car
R6587-C
Par t
1 68310 Luggage Compartment Cover
2 45026 Spare Tire Cover
3 390018-SSW Push Pin (6 Req'd)
L u g g a g e Compartment Co v e r Pa n e l s Cr o wn
Vi ctori a, Grand Marquis
1 . Remove spare ti re cover.
2. Remove spare ti re.
3. Remove l uggage compart ment door ( 40110) .
01- 05- 25 Tr i m, Int eri or 0 1 - 0 5 - 2 5
Scuf f Pl a t e Cr own Vi ct ori a, Grand Marqui s
LUGGAGE
COMPARTMENT
SCUFF PLATE
PUSH
PIN
N807154-S
Part
Weatherstrip
4. Remove luggage hol d down net ( 55184) .
5. Remove push pins and pushnuts. Remove
l uggage compartment fl oor cover ( 45455) .
R11003-A
Part
1 13144 Luggage Compartment Scuff
Plate (Grand Marquis)
2 13144 Luggage Compartment Scuff
Plate (Crown Vi ctori a)
( Co n t i n ue d )
01- 05- 2 6 T r i m, I n t e r i o r
01- 05- 2 6
Lugga ge Co mpa r t me n t Co v e r i n gCr o wn Vi c t o r i a , Gr a nd Marqui s
2
FRONT OF
VEHICLE
FRONT OF
VEHICLE
VIEW B VIEW D
R7181-C
Par t
1

Fu e l Fi l l e r D o o r R e l e a s e
Handle
2 45455 Luggage Compartment Floor
Cover
Par t
3 391207-SW Push Pin (5 Req'd)
4 390018-SW Push Nut (2 Req'd)
5
Hook Stem Tape Fastener
( Co n t i n ue d )
01- 05- 2 7 Tr i m, I n t e r i o r
01- 05- 2 7
I t em
Par t
Numbe r Descr i pt i on
6 4 5 5 0 0 L u g g a g e C o m p a r t m e n t R e a r
C a r p e t
( Co n t i n ue d )
Par t
7 5 5 0 6 6 L u g g a g e C o m p a r t m e n t H o l d
Down Net
8 4 6 0 0 2 R e t a i n e r ( 2 R e q ' d )
Luggage Compart ment Door Town Ca r
L U G G A G E
COMPARTMENT
DOOR 40110
L U G G A G E
COMPARTMENT
TRIM P A N E L
45594
LATCH COVER
4 3 2 A 3 0
PUSH PIN
390018-S
10 REQ'D
TOWN CAR SHOWN
CROWN VICTORIA, GRAND MARQUIS SIMILAR
R6588-E
Headli ni ng, Roof
These roof headlining ( 51916) Removal and
Installation procedures generally appl y t o all model s. If
some of t he st eps do not appl y to the parti cul ar model
being servi ced, proceed t o t he next st ep.
Town Car
Re mo v a l
1. Remove inside visor ( 04104) assembl i es.
2. NOTE: If equi pped wi t h roof sliding panel , remove
inside retainer (halo moulding f rom around roof
sliding panel opening).
Remove vi sor arm clip ( 04132) .
3. Remove t he assi st handle ( 31406) assembl i es
and coat hook cover ( 29024) , if equi pped, as
outl i ned.
4. Remove t he upper scr ew and l oosen t he l ower
scr ews that retain the center body pillar inside
upper finish panel ( 24356) t o the B-pillar.
5.
7.
8.
9.
10.
11.
12.
Remove roof side inner front moulding ( 51752) as
outlined.
Remove the upper scr ews and loosen t he l ower
scr ews retaining the wi ndshi el d side garni sh
moulding ( 03598) as outlined.
Remove the windshield garni sh moulding
( 03606) .
Remove package t ray tri m panel ( 46668) as
outlined.
Remove roof tri m panel ( 51968) as outlined.
Remove interior lamp ( 13776) . Refer t o Secti on
17-02.
Adjust front seat (s) full f or war d and fol d t he seat s
back.
Pull down si des of roof headlining above door
openings t o expose adhesi ve beads. Using a hot
knife or wi de-bl ade putty knife, cut adhesi ve
beads l engthwi se acr oss roof headlining. Roof
headlining will now be f ree t o remove f rom
vehicle.
13. Remove roof headlining through RH front door
opening.
14. Clean remaining adhesi ve f rom roof sheet metal .
15. Remove any remaining mounting bases or
retaining clips f rom roof sheet metal .
1. NOTE: Folding headlining will require
repl acement wi t h a new headlining.
Carefully position new roof headlining in vehi cl e
wi th fabri c side down. Al l ow roof headlining t o
rest on floor.
2. Appl y adhesi ve meeting Ford speci fi cati on
WSB-M2G355-A across roof headlining in
positions shown using a hand-held adhesi ve gun.
3. CAUTI ON: Use c a r e w h e n l i f t i n g t h e
h e a d l i n i n g i n t o p o s i t i o n t o p r e v e n t g e t t i n g
a d h e s i v e o n s t e e r i n g wh e e l a n d o t h e r
i n t e r i o r p a r t s .
Wi th one person on each si de, raise roof
headlining into posi ti on.
4. Position the roof headlining in the vehi cl e and
install the interior l amp. Refer t o Section 17-02.
5. Reverse Removal procedure except Step 9
(interior l amp).
6. Tighten shoulder harness to speci fi cati on. Refer
t o Section 01-20A.
01- 05- 28 Tr i m, Int eri or 01- 05- 28
Roof Headl i ni ng Wi t h Roof Sl i di ng Panel Town Ca r
SECTION A SECTION D
R6593-C
i t em
Par t
1 52124 Sliding Roof Panel
Headlining Retainer
2 N802734-S
Push Pin (2 Req'd)
4 00014 Warning Label (Passenger
Side)
Pa r t
5 51874 Roof Sliding Panel Housing
Reinforcement
6 00015 Air Bag Warning Label
(Driver Side)
( Co n t i n ue d )
01- 05- 2 9 Trim, Interior 01- 05 - 2 9
Roof Headlining Wi t hout Roof Sli di ng Panel
SECTION E
R6594-E
Par t
i t em Number De sc r i pt i o n
1 N610937-S2 S c r e w (3 Re q ' d )
2 12K703 D o m e L a m p B r a c k e t Assy
5 00015 Warning Label (Passenger
Side)
I t em
Part
6 W5B-M2G355-A Adhesive
A

Lb-ln)
B

509 mm (20.03 Inches)
c 203 mm (7.99 Inches)
D

450 m m (17.71 Inches)
Crown Vi ctori a, Grand Marquis
Removal
2. NOTE: Do not remove scr ews f rom inside vi sors
or assi st handl es.
Remove sun inside vi sors and assi st handl es f rom
mounting base retai ners.
3. Using a sui tabl e tool , pry all mounting cl i ps and
mounting base inserts f rom sheet metal mounting
br acket s around edge of roof headlining.
Remove interior lamp assembl y f r om mounting
bracket and di sconnect court esy lamp feed wi re
( 13B712) . Do not remove mounting bracket f rom
windshield header.
5.
6.
Remove reading lamp ( 13550) assembl i es from
C-pillars and di sconnect court esy lamp feed wi re.
Do not remove mounting br acket s f rom C-pillars.
Carefully pull down front of roof headlining and
di sconnect headlining wiring harness f rom main
wiring harness.
7. Remove trim moulding f rom A-pillars, B-pillars and
C-pillars as outlined.
01- 05- 30 Tr i m, I nt er i or 01- 05- 30
8. Di sengage weat herst ri ps f rom t op half of all door
openings.
9. Remove front seat assembl i es. Refer t o Secti on
01- 10.
10. Pull down si des of roof headlining above door
openings t o expose adhesi ve beads. Using a hot
knife or wi de-bl ade putty knife, cut adhesi ve
beads l engthwi se across roof headlining. Roof
headlining will now be free t o remove f rom
vehi cl e.
11. NOTE: If headlining is fol ded in half for removal , it
must be repl aced wi th a new headlining. Folding
shoul d not be done on installation.
Remove roof headlining through RH front door
opening.
12. Clean remaining adhesi ve f rom roof sheet metal .
13. Remove any remaining mounting bases or
retaining clips f rom roof sheet metal .
I nst al l at i on
1. Carefully position new roof headlining in vehi cl e
wi t h fabri c side down. Allow roof headlining t o
rest on floor.
2. Appl y adhesi ve meeting Ford speci fi cati on
WSB-M2G355-A across roof headlining in
positions shown using a hand-held adhesi ve gun.
3. CAUTION: Use care when l i f t i ng t he roof
headli ni ng i nt o posi t i on t o prevent get t i ng
adhesi ve on st eeri ng wheel and ot her
i nt eri or part s.
Wi t h one person on each si de, raise roof
headlining into position.
4. Align inside vi sor base i nserts wi t h openi ngs in
roof headlining and press inside vi sors into
position by snappi ng vi sor pins into roof mounting
hol es.
5. Tighten out board inside vi sor mounting scr ews.
6. Position assi st handle into roof rail openi ngs and
press retai ners into pl ace.
7. Position rear lamp mounting base into sheet metal
mounting bracket and snap base into pl ace.
8. Pull roof headlining down at wi ndshi el d header
and connect headlining harness connector t o
body harness connector.
9. Position map lamp into mounting base and snap
into pl ace.
10. Insert inside vi sor locating hooks into mounting
bracket s and install retaining scr ews.
11. Tighten assi st handle retaining scr ews. Insert
assi st handle end t abs into assi st handle
depressi ons.
12. Install A-pillar, B-pillar and C-pillar tri m mouldings
as outlined.
13. Install front seat s. Refer t o Secti on 01- 10.
14. Connect bat t ery ground cabl e. Check operati on
of all l amps removed and check operati on of
power seat s if equi pped.
01- 05- 31 Trim, inferior 01- 05- 31
Assi st Handl es, Roof Cr own Vi ct or i a, Grand Marqui s
ADHESIVE
SECTION A SECTION B SECTION C SECTION D
R7160-C
Par t
1 13B712 Courtesy Lamp Feed Wire
2 N802734S Push Pin
3 31406 Assist Handle
As s i s t Handles, Roof
Town Car, Grand Marquis
1. Wi t h narrow screwdri ver, pry up and slide pl asti c
caps on assi st handle ( 31406) . Roll back end of
st rap t o expose retaining scr ews.
2. Remove scr ews and assi st handle. Remove
bezel s.
3. Remove coat hook cover ( 29024) on rear assi st
handle.
01- 05- 32 Trim, Interior 01- 05 - 32
Assist Handles, RoofTown Car
R6584-C
Par t
1 31406 Assist Handle
2

Slide End Cap (Part of 31406)
3 56884 Tapping Screw (2 Req'd)
4 29026 Coat Hook
5

Bezel (Part of 31406)
Crown Victoria
1. Pull assi st handle down t o expose retaining
scr ews.
2. Remove t wo scr ews retaining assi st handle t o
roof panel ( 502B98) . Remove assi st handle.
Scuff Plates
Door OpeningTown Car
1. Drill out five rivets retaining front door scuff pl ate
( 13209) t o body and snap out assembl y.
2. To install, position front door scuff plate to body
and install new ri vets.
01- 05- 33 T r i m, I n t e r i o r
01- 05- 33
Scuf f Pl at esTown Car
RIVET
N805592
5 REQ'D
FRONT DOOR
SCUFF PLATE
13208
SECTION B
SECTION A
BODY
FRONT DOOR
SCUFF PLATE
13208
SECTION A
BODY
FRONT DOOR
SCUFF PLATE
13208
B O D Y - ^ Y
SECTION B
RIVET
N805592
R6585-B
Do o r O p e n i n g C r o w n Vi c t o r i a , G r a n d Ma r q u i s
1 . Gently and evenly pry up on front door scuff plate
using f abri cat ed tool shown or equivalent.
1 INCH X 1/8 INCH STRAP IRON
GRIND TAPER
TOO SHARP)
R7184-A
2. To install, position front door scuff pl ate t o body
and push t o snap in pl ace.
01- 05- 34 T r i m, i nt eri or 01- 05- 34
Sc uf f P l a t e s Cr own Vi ct ori a, Grand Marquis
SECTION C ( 1 J ( 4 ) SECTION B ^ ^ ^ A
2
)
SECTION A TYPICAL
ASSEMBLED
X ) TYPICAL i PLACES EACH SIDE

SECTION B
ASSEMBLED
TYPICAL 5 PLACES EACH SIDE
SECTION C
ASSEMBLED
TYPICAL 3 PLACES EACH SIDE
R7169-A
Par t
1 13209 Front Door Scuff Plate
2 13228 Rear Door Scuff Plate
4 243A52 Center Body Pillar Panel
5 27790 Front Quarter Inside Panel
Lower Panel /Cent er Pillar
1. Remove inserts f rom front door scuff pl ate
( 13209) and rear door scuff pl ates ( 13228) t o
expose scr ews.
2. Remove retaining scr ews.
3. Adj ust front seat as required t o remove front door
scuff pl ate / rear door scuff pl ate.
01- 05- 35 Tr i m, I n t e r i o r
01- 05 - 35
Lo we r Pa n e l / Ce n t e r P i l a r To wn Car
U r n
T / y _ j f ,
R7595-A
Par t
Blem Number Descr i pt i on
1 13256 Front Door Scuff Plate Insert (1 Req'd Each Side)
3 13258 Rear Door Scuff Plate Insert (1 Req'd Each Side)
5 13208 Front Door Scuff Plate
C a r p e t , Fl o o r
Re mo v a l
1. Remove front seat s. Refer t o Secti on 01- 10.
2. Remove rear seat . Refer t o Secti on 01- 10.
5.
6.
Remove center body pillar inside l ower finish
panels ( 24346) as outlined.
Remove cowl si de tri m panels ( 02344) as
outlined.
Remove quarter trim panel ( 31012) as outl i ned.
Remove rear saf et y belt ret ract or and tongue
( 611B68) , as requi red. Refer to Secti on 01- 20A.
Remove pushnut from wel d stud on dash panel
( 01610) (underneath accel erat or pedal Crown
Vi ct or i a/ Gr and Marqui s).
Remove fl oor carpet ( 13000) and front floor mat
( 13086) .
Installation
1. Position floor carpet in vehicle.
2. Install pushnut on wel d stud on dash panel
(underneath accel erator pedal Crown Vi ct ori a,
Grand Marqui s).
3. Install safety bel ts. Refer t o Secti on 01-20A.
4. Install quarter tri m panel as outl i ned.
5. Install cowl side tri m panels as outlined.
6. Install center body pillar inside l ower finish panels
as outlined.
7. Install rear seat. Refer t o Secti on 01- 10.
8. Install front seat s. Refer t o Secti on 01- 10.
01- 05- 36 T r i m, I n t e r i o r 01- 05- 36
Fl oor Ca r pe t To wn Car
SECTION A
TYPICAL 4 PLACES
VIEWB
SECTION A
VIEWB
R6S34-C
Par t
1 13000 Floor Carpet
2 14A099 Wiring Shield
3 388930-SW Push Pin
4 14C712 Seat Control Switch Cover
5 14C708 Seat Regulator Control Processor
Fl oor Ca r p e t Cr o wn Vi c t o r i a , Gr a nd Ma r qui s
FLOOR CARPET
13000
RETAINER
RETAINER R7183-A
01- 05- 37 T r i m, I n t e r i o r
01- 05- 37
Fabric
The following procedure is recommended for the
removal of spot s and stains encountered in servi ce. It
is i mportant that proper cleaning techni ques and
cleaning agents be used t o prevent the stain from
setti ng or affecting the color and/ or fl ame resi stant
properti es of the fabri c.
1. Remove excess staining materi al f rom fabri c by
scrapi ng or wiping wi th a cl ean cl oth (blot if stai n
is wet ).
2. Identify the staining material if possi bl e.
3. NOTE: Using other than recommended cl eaners
or procedures may affect flammability or fabri c
appearance.
Clean the fabri c as outlined.
Spot Cleaning
G r e a s e , Oi l , Ta r , Wa t e r S p o t s , C r a y o n a n d
L i p s t i c k
1. CAUTI ON: Use c a r e wh e n a p p l y i n g t h e s p o t
l i f t e r t o p r e v e n t i t f r o m c o n t a c t i n g v i n y l t r i m.
Spray stain wi t h Ext ra Strength Uphol stery
Cleaner E8AZ-19523-AA or equivalent from a
di stance of 203- 254 mm (8-10 inches) as
di rect ed on the instructions furni shed wi th the
can.
2. Al l ow the spot lifter t o dry compl etel y, formi ng a
whi t e powder on the surface of t he fabri c.
3. Brush and vacuum t he whi te powder from the
surf ace of the fabri c.
4. If the soiled spot is not removed f rom t he fabri c,
repeat Steps 1 through 3 as necessary.
S t a i n C l e a n i n g
G r e a s e , Oi l , Ta r , A d h e s i v e , C r a y o n a n d L i p s t i c k
1. If the stain is still visible after spot cleaning
procedure, blot t he soiled area wi t h a clean
cot t on cl oth sat urat ed wi th Spot and Stain
Remover F3AZ- 19521 -WA.
2. Rub in a circular moti on while continuously
exposi ng clean porti on of cl oth.
3. Gradually wi den area of t he appl i cati on onto
edges of desi gn, pl eat, or biscuit.
4. Repeat Steps 1 through 3 as necessary.
5. Wi pe cleaned ar ea wi t h cl ean damp cl oth t o
remove any residual cleaner.
Di r t , Dr y S o i l , F o o d , a n d B e v e r a g e s
1. NOTE: Spot cleaning as outlined will be sufficient
on f abri cs whi ch are not excessi vel y soi l ed.
However, t o maintain a uniform appearance of t he
seat, the entire seat or insert will have t o be
cl eaned t o prevent a " r i ng" condi ti on.
Appl y Rosenthal or Bi ssel l , or an equivalent
uphol stery cl eaner wi t h clean brush or sponge as
di rected on the instructions furnished wi t h the
container.
2. Rub in a circular moti on until stain is removed.
3. Gradually wi den ar ea of application t o edges of
desi gn, pl eat, or biscuit.
4. Repeat St eps 1, 2 and 3 as necessary.
5. Rub cl eaned area wi t h a damp cl oth t o absorb
residual cleaner.
6. Al l ow t o dry at room temperature.
S a f e t y Be l t W e b b i n g
Clean the belt webbi ng wi t h any mild soap solution
recommended for cleaning uphol stery or carpet s;
fol l ow the instructions provi ded wi th the soap. Do not
bl each or re-dye the webbi ng because thi s may
weaken it. Refer t o Secti on 01-20A.
W o o d g r a i n ( S i m u l a t e d ) , P l a s t i c , Vi n y l a n d
L e a t h e r
Clean soiled simulated woodgrai n surfaces wi t h any
mild househol d detergent or Ford Multi-Purpose
Cleaner B8A-19523-B or equivalent meeting Ford
speci fi cati on ESR-M 14P4-A, diluted per label
instructions ( 3 oz/ gal ) , and a soft cl ot h. Remove mild
abrasi ons such as key marks f rom oil woodgrai ned
surf aces wi t h Ford Custom Silicone Gl oss Polish
B7AZ-19530-AA or equivalent meeting Ford
speci fi cati on ESR-M 11B26-A.
Clean vinyl or leather interior tri m wi th Del uxe Leather
and Vinyl Cleaner F2AZ-19521-WA or equivalent
meeting Ford speci fi cati on ESR-M14P4-A following
labeling instructions.
W i n d o w G l a s s , I n t e r i o r
Clean gl ass wi t h soft dry cl oth and Ultra-Clear Spray
Gl ass Cleaner E4AZ-19C507-AA or equivalent
meeting Ford speci fi cati on ESR-M14P5-A. Inspect
gl ass for cr acks or chi ps. Repl ace gl ass as
necessary.
01- 05- 38 T r i m, I n t e r i o r 01- 05 - 38
SPECIFICATIONS
Do me L a mp Br a c ke t S c r e w 2-6 17- 53
L o we r Qu a r t e r Tr i m Pa n e l S c r e w 0. 5- 2 . 0 5- 17
ROTUNDA EQUIPMENT
107 - R0401 Wi n d s h i e l d a n d Mo u l d i n g / T r i m Re mo v a l
Kit
01- 08- 1 Tr i m, Ext er i or 01- 08- 1
SECTION 01-08 Trim, Exterior
SUBJECT PAGE
VEHICLE APPLICATION ........... .... 01-08-1
Emblems . .... 01-08-1
Moul di ngs, Exteri or ...... 01-08-1
Embl ems . 01-08-1
Moul di ngs, Ext eri or ....01-08-3
SUBJECT PAGE
REMOVAL AND INSTALLATION (Cont 'd. )
Moul di ngs, Wi ndshi el d 01-08-3
Si de Sill . ..01-08-3
SERVICE PROCEDURES
Adhesi ve Removal /Repai r . 01-08-10
VEHICLE APPLICATION
Mouldi ngs, Ext eri or Pressure sensitive adhesi ve t ape.
Body side mouldings are secured to t he body by: Snap-on clips.
Screws.
Emblems
Embl ems are l ogos indicating the t ype or styl e of
vehi cl e.
Emblems
NOTE: The installation area for any adhesi ve name
pl ate ( 8A223) / or nament syst em should be clean and
dry.
1. Heat name plate / ornament evenly t o 29-35 C
(85-95 F).
2. Remove plastic t ape liner.
3. Install name plate / ornament to proper location on
vehicle.
4 . Use roller t o press name pl ate / ornament into final
position.
1995 Town Ca r , Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s Jul y 1994
01- 08- 2 Tr i m, Ext er i or 01- 08- 2
Embl emsTown Car
Par t
1 ESB-M3G89-C-1 Double-Coated Tape
2 16098 Front Fender Name Plate
3 16702 Plate
4 42550-B Luggage Compartment Door Town Car Name Plate
5 42550-A Luggage Compartment Door Lincoln Name Plate
Cr own Vi ct or i a
01- 08- 3 Tr i m, Ext er i or 01- 08- 3
Par t
It em Number Descr i pt i on
1 42528 Luggage Compartment Door Name Plate (Grand Marquis)
2 42528 Luggage Compartment Door Name Plate (Mercury)
3 28032 Quarter Panel Ornament Assy
4 N623422-S36 Hex Nut (3 Req'd Each Side)
Mo u l d i n g s , Wi n d s h i e l d
NOTE: For Removal and Installation of wi ndshi el d,
rear wi ndow and quarter wi ndow mouldings, refer t o
Secti on 01- 11. Wi ndshi el d mouldings are at t ached t o
the windshield gl ass ( 03100) and cannot be removed
unless the wi ndshi el d gl ass is removed.
Mo u l d i n g s , Ex t e r i o r
Exteri or ornaments and mouldings are shown in the
following illustrations. Before removi ng the ext eri or
mouldings, it shoul d be determi ned by the t ype of
retainer used, whet her a respect i ve door, quarter or
l uggage compart ment tri m panel must first be removed
t o provi de access. Refer t o Sect i on 01- 05. If a wel d
st ud is di st ort ed or broken off, it should be repl aced
wi t h an oval head blind rivet (Part No. 383229- S) .
For removal and installation of mouldings retai ned by
double si ded tape, refer t o procedures outlined under
Pressure Sensitive Tape.
Si d e Si l l
T o wn Car
1. Remove pins and l ower quarter moulding
( 29076) .
2. Remove front fender moulding ( 16036) .
3. Remove front and rear door body si de moulding
( 20878) .
4. Remove rocker moulding ( 10176) .
01- 08- 4 Tr i m, E x t e r i o r 01- 08- 4
5. To Install, reverse Removal procedure.
Si de Moul di ngsTown Car
Yf ///
SECTION A
N10472-A
Pa r t Pa r t
I t e m Nu mb e r De s c r i p t i o n I t e m Nu mb e r De s c r i p t i o n
1 20976 Lower Quarter Moulding 4 16003 Front Fender Moulding
2 26666 Rear Door Lower Moulding 5 10176 Rocker Moulding
3 20876(RH) Front Door Lower Moulding 6 ESB-M3G89-C-1 Double-Coated Tape
(Continued)
7 N805592-S100 Rivet (13 Req'd Each Side)
S i d e Si l l , U p p e r C r o w n Vi c t o r i a , G r a n d
Ma r q u i s
1. Raise vehicle on hoist. Refer t o Secti on 00- 02.
2. Remove retaining scr ew f rom rocker panel
moulding.
3. Remove rocker panel moulding.
01- 08- 5 Tr i m, Ext er i or
01- 08- 5
Cr own Vi ct or i a, Gr and Marqui s
SECTION A VIEW B VIEWC
N8S29-C
Par t
1 10176 Moulding
2 10182 Retainer
3 101C48 Moulding
4 N803946-SW Rivet
5 16006 Front Fender
6 31012 Quarter Panel
Si d e Si l l , L o w e r C r o w n Vi c t o r i a , G r a n d
Ma r q u i s
1. Remove ri vets and hood rear moulding ( 16B918) .
2. Remove front fender side l ower moulding
( 16003) .
3. Remove front door outsi de l ower moulding.
4. Remove rear door outsi de l ower moulding
( 25556) .
5. Remove quarter outsi de l ower front moulding.
Do o r Wi n d o w Mo u l d i n g , Fr o n t a n d R e a r T o w n
Ca r
1. Remove nine scr ews and washers and remove
rear door wi ndow moulding.
2. Gently pry front door wi ndow filler rear edge f rom
retai ners.
3. Remove nine scr ews and washers and remove
front door wi ndow moulding.
01- 08- 6 Trim, Exterior 01- 08- 6
VIEW B
I t em
Par t
Number De sc r i pt i on
1 255A34 MouldingRear Door
Window
2 20550 Mouldi ngFront Door
Window
3 214A62 Fi llerFront Door Window
4 20884 Retai nerDoor Outside
Moulding
(Continued)
N12354-A
I t e m
Pa r t
5 384439-S100 Screw and Washer (8 Req'd)
6 N800488-S100 Nut
7 W651015 PlugButton
A

Tighten to 1.4-2 N-m (1-1.5
Lb-Ft)
B
Tighten to 1-1.5 N-m (.75-1.1
Lb-Ft)
1. Remove eight blind ri vets and front door wi ndow
moulding ( 20550) .
2. Remove four blind ri vets and rear door wi ndow
outsi de t op moulding ( 255A60) .
3. Remove eight blind ri vets and rear door wi ndow
outsi de t op moulding (Grand Marqui s only).
01- 08- 7
R E MO V A L A N D I N S T A L L A T I O N (Cont i nued)
(GRAND MARQUIS TYPICAL)
SECTION A
SECTION B
N8827-B
Pa r t
I t em Numbe r De s c r i p t i o n
1 N806242-S Blind Rivet (8 Req'd)
2 N806242-S Blind Rivet (4 Req'd, Crown
Vi ctori a)
3 N806242-S Blind Rivet (8 Req'd, Grand
Marquis)
I t e m
Par t
4 255A60 Rear Door Window Outside
Top Moulding
5 20550 Front Door Window Outside
Top Moulding
6 N806242-S Blind Rivet
7 53700 Roof Outside Cover
B o d y S i d e P r o t e c t i o n
Re mo v a l a n d i n s t a l l a t i o n
1. Remove roof side tri m panel . Refer t o Secti on
01- 05.
2. Remove nuts and roof outsi de rear moulding
( 51728) .
01- 08- 8 Tr i m, Ext er i or 01- 08- 8
Body Si de Pr ot ect i on Moul di ngsCr own Vi ct or i a, Grand Marqui s
SECTION A SECTION B
NS830-B
Part
1 16003 Front Fender Side Lower
Rear Moulding Assy
2 20878 Front Door Outside Lower
Moulding Assy
3 25656 Rear Door Outside Lower
Moulding Assy
I t em
Par t
4 29076 Quarter Outside Lower Front
Moulding Assy
5 16B918 Hood Rear Moulding
6 16612 Hood
7 N804120-S100 Rivet (4 Req'd)
( Co n t i n ue d )
Tape, Pressure Sensitive
To install or servi ce the optional body si de moulding
(ext ruded PVC wi th t wo-way t ape), perform the
fol l owi ng:
Removal
1. NOTE: Heating the moulding namepl ate or sheet
metal will i ncrease adhesi on maki ng it hard t o
remove. Cold temperatures of zero and bel ow
al l ow easi er removal .
Compl etel y clean the sheet metal surface area
around the moulding wi th i sopropyl al cohol and a
cl ean soft cl oth.
2. Before removing the moulding or namepl ate,
mark its location on t op and at each end using
maski ng t ape.
3. When removing mouldings, use a nylon wedge.
Position the nylon wedge between the moulding
and sheet metal and pull the moulding away wi th
st eady tensi on.
4. Remove and repl ace one moulding at a ti me.
5. Once a f ew inches of moulding are f ree, gri p it
wi t h both hands and pull it sl owl y t owar d the front
of the vehi cl e. Be careful not t o damage the paint
or sheet metal .
6. Grip t ape at one end, lifting and pulling away
sl owl y about 1 / 2 inch at a ti me. Small pi eces can
be removed by rolling wi th your thumb across t he
sheet metal surface.
7. All of t he adhesi ve t ape will not come off wi th t he
moulding. The recommended met hod t o remove
the t ape f rom the metal surface is wi t h 3M
Scotch-Brite Moulding Adhesi ve and Stri pe
Removal Di sc, 3M Part No. 07501 or 07502.
I nst al l at i on
1. When all t ape is removed, wi pe area wi th
i sopropyl al cohol and a clean soft cl ot h. Make
sure that all t ape resi due and road di rt is
removed. A clean surface is required for
appl i cati on of new mouldings.
01- 08- 9
2. If paint surface is damaged during moulding
removal , servi ce as requi red.
3. Appl y the new moulding by pulling back adhesi ve
tape protecti ve cover about 75- 100 mm (3 t o 4
i nches) at the front edge of the moulding. Do not
touch or contami nate t ape surface.
4. Align the new moulding wi t h the maski ng t ape
appl i ed during the removal procedure and gently
press, removing the prot ect i ve cover as you
proceed rearward.
5. NOTE: Mouldings should not be installed on
vehi cl es unless sheet metal surface t emperat ures
exceed 80F ( 27C) and the moulding is at 70F
(21 C) minimum.
Be sure that the moulding is lined up correct l y;
once the t ape st i cks, the moulding cannot be
removed.
6. Remove the maski ng t ape and wi pe the ar ea
under t he maski ng t ape wi t h i sopropyl al cohol t o
remove residue.
7. Press the moulding on wi t h a hand roller appl yi ng
a minimum of 138 kPa ( 20 psi) pressure t o make
sure of proper adhesi on.
Roof Si de Mo ul d i n g
N8836-C
1. Remove rear roof side tri m panels ( 52018) . Refer
2. Remove t wo hex st amped nuts and quarter panel
upper pl ate ( 517A20) .
01- 08- 10 Tr i m, E x t e r i o r 0 1 - 0 8 - 1 0
RE MOV A L A N D I NS T A L L A T I ON ( Co n t i n u e d )
Grand Marqui s
QUARTER
PANEL
UPPER
PLATE
517A20
SECTION A
QUARTER PANEL
UPPER PLATE
ASSY 517A20
HEX NUT
SEALER
N623422
3 REQ'D
SE CTI ON A
N8835-C
Preheat Procedure
NOTE: Be sure that any body wax is removed before
using the infrared l amps.
The recommended preheat treatment requires the use
of an infrared lamp bank. The bank should be
positioned approxi matel y 750 mm ( 30 inches) f rom
the desi red location of the body.
Lugga ge Co mpa r t me n t Do o r T o wn Car
LUGGAGE COMPARTMENT
DOOR MOULDING ASSY
42509 RH
42515 LH
N800354-S102
8 REQ'D
TIGHTEN TO
1-2 N-m
(0.75-1.5 LB-FT)
N12355-A
>
\ \\ \ *5y5)^ \\\\
\2J S E CT I ON A
N8S32-B
Pa r t
1 42509 Moulding
3 N805296-S55M Nut (5 Req'd)
SERVICE PROCEDURES
Adhesi ve Removal /Repai r
Body Side Mouldings/Name Plates
In the event of a misapplied moulding or name pl ate,
refer t o Tape, Pressure Sensitive Removal and
Installation for proper cleaning of adhesi ve and proper
installation of moulding or name pl ate.
SPECI F I CAT I ONS
T O R QU E S P E C I F I C A T I O N S
De s c r i p t i o n N*m L b - Ft
Gr i l l e Or n a me n t Nut 4-7 3-5
Ro o f Si d e Mo ul d i n g Nut 2 . 3- 3. 5 1. 7-2. 6
01- 09- 1 Mi rrors, Re a r Vi e w 01- 09- 1
SECTION 01-09 Mirrors, Rear View
SUBJECT PAGE
Aut omat i c Di mmi ng 01-09-1
Memory Mi rror ....01-09-2
Mirror, Inside Rear View ....01-09-2
Mi rror, Out si de Rear Vi ew... 01-09-1
El ect ri cal Schemat i cs 01-09-4
Pi npoi nt Test s ....... 01-09-15
Glass, Out si de Mi rror ....01-09-23
SUBJECT PAGE
Mi rror Br acket , I nsi de Rear Vi ew 01-09-26
Mi rror Co n t r o l Cr o wn Vi ct or i a, Grand
Mar qui s. . . 01-09-24
Mi rror Co n t r o l To wn Car ..01-09-23
Mi rror Mot or 01-09-24
Mi rror, I nsi de Rear Vi ew 01-09-26
Mi rror, Powe r Out si de Rear Vi ew 01-09-22
Mi rrors, Frozen 01-09-27
Mi rrors, Out si de 01-09-27
SPECIflCATIONS 01-09-27
VEHICLE APPLICATION
Mi r r o r , O u t s i d e Re a r V i e w
P o w e r
A RH and LH el ectri cal l y-powered (heated on Town
Car, optional on Crown Vi ct ori a, Grand Marqui s)
outsi de rear vi ew mi rror ( 17682) is st andard. The
outsi de rear vi ew mirror motor ( 17D696) , outsi de rear
vi ew mirror pl ate retai ners ( 17A746) and outsi de rear
vi ew mirror gl ass ( 17K707) are part of t he outsi de
rear vi ew mirror. They can be servi ced separatel y.
The outsi de rear vi ew mirror control ( 17B676) for
controlling outsi de rear vi ew mi rror adj ustments is
l ocat ed in the dri ver' s front door tri m panel ( 23942) .
T o w n Ca r
The automati c dimming outsi de rear vi ew mirror is
opti onal .
The outsi de rear vi ew mirror control has the fol l owi ng
charact eri st i cs:
It operat es bot h RH and LH outsi de rear vi ew
mi rrors. Sel ecti on can be made by moving the
outsi de rear vi ew mirror control t o the LH or RH
position t o control the appropri at e outsi de rear vi ew
mi rror requiring adj ustment.
The outsi de rear vi ew mirror control is desi gned t o
tilt the outsi de rear vi ew mirror up, down, left or ri ght
by pressi ng t he push button on t he arrow indicating
t he desi red di recti on.
The heat ed operati ng mode is turned on when t he
rear wi ndow DEFROST swi t ch is turned on.
One outsi de rear vi ew mirror control operat es bot h RH
and LH outsi de rear vi ew mi rrors. Selection can be
made by rotati ng t he knob in t he cl ockwi se position f or
t he RH outsi de rear vi ew mirror and count ercl ockwi se
f or the LH outsi de rear vi ew mi rror. The outside rear
vi ew mi rror control is desi gned t o tilt t he outsi de rear
vi ew mirror up, down, left or right by moving the knob
f or war d, back, left or right.
A u t o m a t i c D i m m i n g
The LH outsi de rear vi ew mi rror ( 17682) automati c
di mmi ng functi ons same as inside rear vi ew mi rror
( 17700) .
01- 09- 2 Mi r r or s, Rear View 01- 09- 2
DESCRIPTION AND OPERATION ( Co n t i n u e d )
Me mo r y Mi r r o r
This syst em al l ows the automati c positioning of t he
driver seat and outsi de rear vi ew mirror ( 17682) t o
three user-programmabl e posi ti ons. To program
position 1, move the seat s and mi rrors t o the desi red
positions by using the manual control s. Press t he set
button. Within fi ve seconds (before the Light Emitting
Di ode (LED) goes out), press button 1. To program
position 2, repeat the previ ous procedure but use
button 2. To program position 3, repeat the previ ous
procedure but use buttons 1 and 2 simultaneously.
To recall a position, press the appropri ate button or
buttons. A position can only be recal l ed while in PARK
or NEUTRAL. They can be set at any ti me.
Memory is st ored in the dri ver' s seat module. Refer to
Secti on 01- 10 for removal and installation of dri ver' s
seat module.
Programming Mode Interruption
If the el ectri c manual mirror control s are operat ed
while the Processor Assembl y is in the program mode,
the Assembl y will ignore all dat a concerni ng t he
current mirror positions and retain the information
whi ch was in memory prior t o entering t he program
mode.
Initial St art -Up/Low Voltage Conditions
When power is fi rst appl i ed t o t he power f eed input, or
when thi s input is al l owed t o drop bel ow 7 vol ts for
more than 300 milliseconds and again goes above 7
vol ts, the Processor Assembl y will enter the program
mode. It will then store the current positions of the
mi rrors in all three memory positions.
Memory Seat Emergency Stop Mode
The emergency st op mode of t he Memory Seat
Module will al so be implemented wi t h the Processor
Assembl y. If any outside rear vi ew mirror or position
recall swi t ch is act i vat ed whi l e the Processor
Assembl y is in repositioning mode, all outsi de rear
vi ew mirror movement will st op. Repositioning will
resume if t he position recall swi t ch is react uat ed.
Sensors on t he outsi de rear vi ew mi rrors determi ne
movement. If t hese sensors are not connect ed, the
memory or manual syst em will not work.
LED
SEAT REGULATOR
CONTROL SWITCH
14776
NOTE: SWITCH IS LOCATED
IN THE DRIVER'S DOOR
TRIM PANEL
R4999-B
Mirror, Inside Rear Vi ew
Manual
Move the t ab t owar d you for the night position and
away f rom you for the day posi ti on. The speci al swi vel
bracket lets you move the mirror up or down and f rom
side t o si de.
Automatic Dimming
Town Car
The automati c dimming inside rear vi ew mirror
( 17700) has the following charact eri st i cs:
It will change f rom normal t o non-glare when gl are
reaches the inside rear vi ew mi rror.
The inside rear vi ew mirror functi ons mainly at night
wi th limited function at dusk or dawn.
From non-glare, t he inside rear vi ew mirror will
return t o normal after a short del ay. The del ay
st art s when gl are goes away, and prevents
excessi ve changi ng of t he inside rear vi ew mi rror as
traffi c moves behind and around t he vehi cl e or on
rolling hills and curves.
The sensitivity of the inside rear vi ew mirror can be
adj usted by moving the swi t ch bet ween LO and HI.
HI is t he most sensitive setti ng and bri ght
headl amps far away will cause the inside rear
vi ew mirror t o automati cal l y darken.
At the LO setti ng, bright headl amps will have t o
be cl oser t o darken the inside rear vi ew mi rror.
The automati c dimming inside rear vi ew mi rror
measures the bri ghtness of the light f rom t he rear of
the vehi cl e. It automati cal l y makes a correct i on in
the gl are setti ng sel ect ed on t he swi t ch.
The inside rear vi ew mi rror may be turned off by
sliding the swi t ch t o t he OFF posi ti on. It may be
turned off in either t he normal or non-glare set t i ng.
There are t wo light sensors (photocel l s) in thi s
inside rear vi ew mirror.
The sensor that det ect s rear gl are is l ocat ed
inside a wi ndow in the upper RH corner of the
inside rear vi ew mi rror. The second light sensor,
whi ch determi nes outsi de light level, is l ocat ed
on the backsi de of t he inside rear vi ew mi rror
case.
One i mportant saf et y feature is that t he mi rror
automati cal l y l ocks in the normal st at e whenever
the vehi cl e is pl aced in REVERSE. This feature
ensures a bri ght, cl ear vi ew in t he inside rear vi ew
mirror when backi ng up.
01- 09- 3
Mi r r o r s , Re a r Vi e w 01- 09- 3
Town Car, Cr o wn Vi c t o r i a , Gr a nd Ma r qui s
PHOTOCELL
1
ON/OFF LIGHTED
PUSH BUTTON
N7227-B
1995 To wn Ca r , Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s J u l y 1994
01- 09- 4 Mirrors, Rear View
0 1 - 0 9 - 4
Elect ri cal Schemat i cs
Heat ed Power Mi r r or Town Car
HOT AT A L L TI ME S
T O
^ HE A T E D
r BA CK
WI NDOW
OUTSI DE RE A R VI E W
MIRROR CONTROL
2 96
W/ P .Me
L H
MI RROR
S E L E CT
S WI T CH
RH
"Nl
L H
543
1
67 6 I PK/ O
5 ? | B K
DG/ P
541
U/ D
MOT OR
L/ R
MO T O R
LH OUTSIDE
HEATED
REAR VIEW
MIRROR
5 7 | BK
DG
TJ U1 F J
U/D
MOT OR '
L/ R
MOT OR
RH OUTSIDE
HEATED
REAR VIEW
MIRROR
5 7 | BK
See EVTM for more details
of thi s circuit
542
N12574-A
01- 09- 5 Mi r r or s, Rear Vi e w 01- 09- 5
Heat ed Mi r r or Town Car
T O
I NSTRUME NT
CL USTE R
T O
P OWE R
T RA I N
CONT ROL
MODUL E
1 P OWE R
I DISTRIBUTION
1 BOX
^ 7 0 ^ L B / W
17 5
- ' 08- 12
;
> C1- 8 C4- 2
HE A T E D B A C K U T 6 I SO B+
I NDI CATOR OUT P UT B U S
HE A T E D
BA CKL I T E 4 - 1
A N D MI RRORS
BA CKL I T E
C ON T ROL
P O WE B L OG I C P WM S WI T CH
GND G N D DI MMI NG I NP UT
C3- 4 C3- 9 C3<12 C 2 - 1 8
L I G HT I NG
C O N T R O L
MODUL E
(LCM)
* 186
*T FUSE
'-i JUNCTION
P A N E L
5 9 1 DG/ P
BR/ L B
01- 09- 6 Mi r r o r s , Re a r Vi e w 01- 09- 6
He a t e d Powe r Me mo r y Mi r r o r T o wn Car
^ " I N S T R U ME N T
1 3 I P A N E L
* FUSE
J P A N E L
See EV
I of thi s i
> I BK/ L B
I r MAIN
I | LIGHT
! SWITCH
of thi s circuit
i mm
BK/ W
LH FRONT POWER SEAT
POSITION MEMORY MODULE
C3- 2
i
I
I C2 - 2 2 C1- 4 C1- 7 C1- 8 C1- 5 C1*6 C3- 1 02*11 C2 - 2 0 C 2 - 1 2 C2 * 3 C 2 - 1 6 C 2 - 1 5 C 2 - 1 3
7
T
LBW
T | H T
5 7
T
BK
- TB
T O I
5 4 3
I
D G
I 540 I R
5 4 2
1
Y
A M.
I SO L I NK I I I I | "= ="
1
943 I P/O I 940 J D B / O j
I 944 I DG/ O I 942 I R/O 9
1
r u . I R L
1
33
POWER
MIRROR
SWITCH
ASSY
67 6 I I
L OG I C
G ROUN D
W/ P
2 7 0 BR/ O 2 68
2 67 BR/
m
i
LG
W/ P
- _
I I
w/o
MEMORY
SET AND
RECALL
SWITCH
_ l
v
_ j
T
_ |
T
S E T | ;. t f ;;.jf. ""
HOT IN
START
A
I
'6 I I
67 6 I PK/ G
TRANSMISSION
RANGE
SENSOR
2 68 | BK/ O
e h
STARTER
SOLENOID
DRIVER'S
DOOR
MODULE
N12599-A
01- 09- 7 Mi r r o r s , Rear Vi e w
01- 09- 7
DG/ P
LH FRONT
I P OWE R
1 SE A T
1
P OSI TI ON
I ME MORY
, MO DU L E
I
/ C2 - 7 C2 - 6 C2 - 8 C 2 - 1 9 04- 9 C 2 - 1 0 C2- 1 C2 - 2 C 2 - 1 8 C 2 - 1 7 C2 - 4 C2- S C2 - 2 1 C 2 - 1 4 |
540
Y/ R 949 Y/ L B 952
DRIVER'S
MIRROR
ASSY
W/ P
MI RROR
L/R
MI RROR
UP / OOWN
PASSENGER'S
MIRROR
ASSY
of this circuit
) G/ P
LH OUTSIDE
HEATED REAR
VIEW MIRROR
RH OUTSIDE
HEATED REAR
VIEW MIRROR
1
L
N10474-A
01- 09- 8 Mi r r o r s , Rear Vi e w 01- 09- 8
He a t e d Power Mi r r o r Cr o wn Vi c t o r i a , Gr a nd Ma r qui s
HOT AT ALL TIMES
OUTSI DE RE A R VI E W
MI RROR C ON T ROL
67 6
1
DG/ P
541
U/ D
MOTOR
L/R
MOT OR
L H OUT S I DE
H E A T E D
RE A R VI E W
MI RROR
<
PK/ O
5 7 | B K
UVD
MOTOR
L/R
MOTOR
L H OUT SI DE
H E A T E D
RE A R VI E W
MI RROR
>
542
545
of this circuit
N12586-A
01- 09- 9 Mi r r or s, Rear Vi e w 0 1 - 0 9 - 9
Heat ed Mi r r or Cr own Vi ct or i a, Gr and Marqui s
' 1 P OWE R
14 . DISTRIBUTION
I BOX
HOT I N ST A RT OR RUN HOT I N A CC OR RUN
IT"!
10 I R/Y
FUSE
JUNCTION
PANEL
640
640 l R/Y
C1- 9 C M
RUN/START
RUN/ ACC
B+ I NP UT
HEATED
BA C KUT E
CONT ROL
B+ I NP UT
REL AY
OUT P UT
02 - 12 '
L OG I C P WM SWI T CH
G N D G N D DI MMI NG I NP UT
C 3 4
cm _c&tt
1
HEATED
I BACK
! WINDOW
I RELAY
1 FUSE
. JUNCTION
1 PANEL
GY/ L B
BR/ L B |
186 I BR/ L B
BK
}4
llf
0
i
T
1 8 6 1 BR/ L B
484 1 O/ BK
O
1 0 1 0
484 1 O/ BK
DB/ O
59 DG/ P

HEATED
BACK
WINDOW
AND
SWITCH
J
BR/ L B
BRA I DE D
WI RE
SOLID
STATE
ISOLATOR
RADIO
ANTENNA
REAR WINDOW
DEFROST GRID
BRA I DE D
WI RE
57
LH RH
OUTSIDE OUTSIDE
REAR VIEW REAR VIEW
MIRROR MIRROR
HEATER HEATER
. J L-
of this circuit
N12585-A
Aut o ma t i c Di mmi n g Mi r r o r T o wn Car, Cr o wn
Vi c t o r i a , Gr a nd Mar qui s
1 L H
I OUTSIDE
1
HEATED
I REAR
!VIEW
I MIRROR
LB/ W
AUTOMATIC
DIMMING
INSIDE
REAR
VIEW
MIRROR
S e e EVTM f o r
m o r e d e t a i l s
o f t h i s c i r c u i t
LH OUTSIDE REARVIEW
MIRROR ASSY TOWN CAR
WITH COMPASS
N12589-A
P i n
N u mb e r C i r c u i t C i r c u i t F u n c t i o n
1 57 ( BK) Gr o un d
2 59 ( DG / P ) He a t e d E x t e r i o r Mi r r o r Fe e d
WITH COMPASS (Cont ' d)
Pi n
3 5 4 0 ( R ) LH Mi r r o r Le f t ( B- ) / Ri g h t Mo t o r
( B + )
4 947 ( Y/ R) * LH Mi r r o r Le f t / Ri ght Mo t o r
Co mmo n
5 948
( Y/ L B ) '
LH Mi r r o r Up / Do wn Mo t o r Co mmo n
6 541 ( D B ) LH Mi r r o r Up ( B + ) / D o w n Mo t o r
( B - )
7 No t Us e d
8 No t Us e d
9 No t Us e d
10 No t Us e d
* Wi t h Me mo r y Fe a t u r e
WITHOUT MEMORY DRIVER'S SEAT
Pi n
3 540 ( R) LH Mi r r o r Le f t ( B- ) / Ri ght Mo t o r
( B + )
4 542 ( Y) LH Re mo t e Mi r r o r So l e n o i d Co n t r o l
6 541 ( DB) LH Mi r r o r Up ( B + ) / Do w n Mo t o r
( B- )
7
_
No t Us e d
8
__
No t Us e d
9 47 ( L B / W) E l e c t r o c h r o mi c Out put t o O / S
Mi r r o r Co mmo n
10 46 ( P) E l e c t r o c h r o mi c Out put t o O / S
Mo t o r
WITH COMPASS, MEMORY DRIVER'S SEAT AND
HEATED SEATS
Pi n
3 5 4 0 ( R ) LH Mi r r o r Le f t ( B- ) / Ri g h t Mo t o r
( B + )
4 9 4 7 ( Y / R ) LH Mi r r o r L e f t / Ri g h t Mo t o r
Co mmo n
5 9 4 8 ( Y / L B ) LH Mi r r o r Up / Do wn Mo t o r Co mmo n
6 541 ( DB) LH Mi r r o r Up ( B + ) / Do w n Mo t o r
( B- )
7 No t Us e d
8 No t Us e d
9 47 ( L B / W) E l e c t r o c h r o mi c Out put t o O / S
Mi r r o r Co mmo n
10 46 ( P) E l e c t r o c h r o mi c Out put t o O / S
Mi r r o r
01- 09- 11 Mirrors, Rear View 01- 09- 11

o
LH OUTSIDE REAR VIEW
WITHOUT MEMORY FEATURE
N10464-B
Pin
Nu mb e r Ci rcui t Ci rcui t Funct i on
1 542 ( Y) Mo t o r Co mmo n
2 5 4 4 ( P ) Ve r t i c a l Mo t o r Fe e d
3 57 ( BK) He a t e r Gr o un d
4 543 ( DG) Ho r i zo n t a l Mo t o r Fe e d
6 No t Us e d
6 59 ( DG / P ) He a t e r Fe e d
-j<8>nj0
I T
2
<8H
RH OUTSIDE REAR VIEW
WITH MEMORY FEATURE
N10465-B
Pin
Number Ci rcui t Ci rcui t Funct i on
1 542 ( Y) L H Re mo t e Mi r r o r So l e n o i d Co n t r o l
2 5 4 4 ( P ) Ve r t i c a l Mo t o r Fe e d
3 5 4 3 ( DG) Ho r i zo n t a l Mo t o r Fe e d
4 57 ( BK) He a t e r Gr o u n d
5 953 ( W/ P ) Mi r r o r Swi t c h Ve r t i c a l Ri ght
6 59 ( DG / P ) He a t e r Fe e d
LIGHTING CONTROL
MODULE CONNECTOR C1
K2287-A
Pin
Number Ci rcui t Ci rcui t Func t i on
C1- 4 544( P ) Ri ght Ve r t i c a l Mi r r o r
C1- 5 5 4 0 ( R) Le f t Ho r i zo n t a l Mi r r o r
C1- 6 542 ( Y) Ma s t e r Co n t r o l S wi t c h
C1- 7 543 (DG) Ri ght Ho r i zo n t a l Mi r r o r
C1- 8 541
( DB/ Y)
Le f t Ve r t i c a l Mi r r o r
DRIVER SEAT CONTROL
MODULE CONNECTOR C2
K22688-A
DIAGNOSIS AND TESTING (Continued)
Pin
N u m b e r Ci r cui t Ci rcui t Funct i on
C2- 1 952
( W/ L G )
Mi r r o r Le f t
C2- 2 543 ( DG) Mi r r o r Ri ght
C2- 4 544( P) Mi r r o r Do wn
C2- 5 953 ( W/ P ) Mi r r o r Up
C2- 6 9 4 7 C Y/ R) Mi r r o r Ri ght
C2- 7 540 CR) Mi r r o r Le f t
C2- 8 949 ( R / W) Ho r i zo n t a l P o s i t i o n Se n s o r
C2 - 9 9 4 8 C Y/ L B ) Mi r r o r Do wn
C2 - 10 541
( DB / Y)
Mi r r o r Up
C2 - 11 67 6
( P K / O )
P o we r Gr o un d ( L o g i c Gr o un d )
C2- 13 2 7 2 ( W/ O ) LED
C2 - 14 958
( G Y/ R)
Se n s o r Su ppl y
C2- 15 2 68
( B K / O )
Me mo r y 2
C2- 16 2 67
( B R / L G )
Me mo r y 1
C2- 17 957 ( P / W) Ve r t i c a l P o s i t i o n Se n s o r
C2- 18 944
( DG / O)
Ho r i zo n t a l P o s i t i o n Se n s o r
C2 - 19 951
( DB / W)
Ve r t i c a l P o s i t i o n Se n s o r
C2- 20 33 ( W/ P K ) Pa r k Ne ut r a l S wi t c h
C2- 21 955 ( GY) Se n s o r Re t ur n
C2- 22 7 0 ( L B / W) To I SO 9141 Li n k
LIGHTING CONTROL
MODULE CONNECTOR C4
Pin
C3- 1 57 ( BK) Gr o un d
C3- 2 517
( B K / W)
" BA T T " B +
POWER MIRROR SWITCH HARNESS
CONNECTOR ASSY CROWN VICTORIA,
GRAND MARQUIS
Pin
1 54 ( L G / Y) Su ppl y
2
_
No t Us e d
3 5 4 1 ( DB) LH Ve r t i c a l Mo t o r Fe e d
4 5 4 0 ( R) L H Ho r i zo n t a l Mo t o r Fe e d
6 5 4 2 ( Y ) Mo t o r Co mmo n
7 5 4 4 ( P ) RH Ve r t i c a l Mo t o r Fe e d
8 5 4 3 ( DG) RH Ho r i zo n t a l Mo t o r Fe e d
HEATED BACK WINDOW
SWITCH AND LIGHT
CONNECTOR N12591-A
Pi n
1 484
( O / B K )
L i q u i d Cr y s t a l Di s p l a y
3 1010
( DB / O )
688
( G Y/ L B) "
He a t e d Ba c kl i gh t S wi t c h t o
L i gh t i n g Co n t r o l Mo d u l e ( L CM)
I nput
He a t e d Ba c kl i g h t S wi t c h t o Ti me
De l a y Re l a y
4 57 ( BK) Gr o u n d
* Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s
01- 09- 13 Mi r r or s, Rear Vi e w
vwarA' " A i i m a J B W M I V
0 1 - 0 9 - 1 3
RH OUTSIDE REAR VIEW
MIRROR ASSEMBLY CROWN
VICTORIA, GRAND MARQUIS N12592-A
Pin
Nu mb e r Ci rcui t Ci rcui t Funct i on
1 541 ( DB) L H Mi r r o r Up ( B + ) / Do w n Mo t o r
( B- )
3 540 (R) LH Mi r r o r Le f t ( B- ) / Ri g h t Mo t o r
( B + )
5 No t Us e d
L I G HT I NG C O N T R O L
MO DU L E C ON N E C T OR C1
K22687-A
Pin
Number Ci rcui t Ci r cui t Funct i on
1 2 96 ( W/ P ) R U N / A C C B + I nput
2 1034
( B K / W)
Do me L a mp S wi t c h
3 158
( B K / P K )
Key In I gn i t i o n
Pin
4 No t Us e d
5 486
( B R / W)
De c k L i d Aj a r
6 No t Us e d
7 Not Us e d
8 7 0 ( L B / W) Ke y l e s s Ent r y , Me mo r y S e a t s , A BS
9 6 4 0 ( R / Y ) Ru n / S t a r t B + I nput
10 1 0 3 3 ( R / Y) He a d l a mp Swi t c h
11 62 7
( B K / O )
P a s s e n g e r Do o r Aj a r Swi t c h
12 465
( W/ L B )
Do o r Ha n d l e Swi t c h
13 1032
( W/ B K )
Pa r k L a mp Swi t c h
14 3 4 0 ( R / L B ) Pa n i c Al a r m
15 No t Us e d
16 2 2 2
( B R / L G )
A u t o l a mp I n d i c a t o r
T K 2 2 6 8 7 A
DRI VE R S E A T C O N T R O L
MO DU L E C ON N E C T OR C 2
K22688-A
Pin
Number Ci r cui t Ci rcui t FunctH^
1 No t Us e d
2 932
( G Y/ W)
Hi gh Be a m Swi t c h
3
_
No t Us e d
4 6 ( Y / L G ) Ho r n
5 No t Us e e
6 2 2 0 ( P / O ) A u t o l a mp O n / O f f
7 2 1 8 ( W/ P ) A u t o l a mp En a bl e
8 2 17
( DB / O )
A u t o l a mp De l a y
01- 09- 14 Mi r r o r s , Re a r Vi e w 01- 09 - 14
P i n
N u m b e r C i r c u i t Ci r c u i t F u n c t i o n
9 383 ( R / W) ' Ha za r d I n d i c a t o r
10 344
( B K / Y )
Do o r Aj a r Wa r n i n g I n d i c a t o r
11 867 ( DB) Dr i v e r Do o r Aj a r Swi t c h
12 688
( DB / O )
He a t e d Ba c kl i t e Re l a y
13

No t Us e d
14 183 ( T / Y) ' E l e c t r o n i c I n st r ume n t Cl ust e r To n e
Re q u e s t
15 1036
( B R / W)
He a d l a mp Di mme r Swi t c h I nput
16 1 0 3 5 ( D/ R ) He a d l a mp Di mme r Swi t c h I nput
17 85
( B R / L B )
Se a t Be l t Swi t c h
18 1010
( DB / O )
Ba c kl i t e Swi t c h
19

No t Us e d
2 0

No t Us e d
2 1

No t Us e d
2 2

No t Us e d
* No t u s e d in Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s .
T K 2 2 6 8 8 A
LIGHTING CONTROL
MODULE CONNECTOR C3 K22689-A
Pin
1 7 05
( L G / O )
De ma n d L i gh t i n g
2 1 9 ( L B / R ) Va r i a bl e Di mmi n g Out put t o
A c c e s s o r i e s
3 117
( P K / B K )
Al l Do o r s L o c k Si gn a l
4 57 ( BK) P o we r Gr o un d
5 53
( B K / L B )
Co u r t e s y L a mp s
6 195 ( T / W) Ba t t e r y Vo l t a ge I nput t o L CM a n d
He a d l a mp Di mme r Swi t c h
7 No t Us e d
Pin
8 450
( B K / L G )
Se a t Be l t Wa r n i n g I n d i c a t o r
9 57 ( BK) L o g i c Gr o un d
10 1 3 ( R / B K ) L o w Be a m He a d l a mp s a n d
Co r n e r i n g L a mp s
11 54 ( L G / Y) Ba t t e r y Vo l t a ge I nput
12 484
( O / B K )
P ul s e Wi d t h Mo d u l a t e d I l l umi n a t i o n
Out put
13 4 4 ( L B) T u r n / Ha z a r d
14 14( BR) Pa r k L a mp s
15 385 ( W/ R ) Fl a s h e r P o we r
16 2 2 1 ( O / W) Ba t t e r y Vo l t a ge I nput
TK22689A
H
LIGHTING CONTROL
MODULE CONNECTOR 04 K22690-A
Pi n
1 12
( L G / B K )
Hi - Be a m He a d l a mp s
2 196
( DB / O )
Ba t t e r y Vo l t a ge I nput
TK22690A
I nspect i on and Veri f i cat i on
1. Inspect t he components of t he power rear vi ew
mi rror syst em.
Mechani cal El ect r i cal
Da ma g e d mi r r o r s .
Da ma g e d o u t s i d e r e a r v i e w
mi r r o r c o n t r o l .
Bl o wn f us e .
Da ma ge t o wi r i n g h a r n e s s .
L o o s e o r c o r r o d e d
c o n n e c t i o n s .
2. Fl ex t he harness and connect ors at t he control
swi t ch and mi rrors. Look for obvi ous si gns of
opens or short s.
3. Operat e t he power mirror swi t ch and determi ne
condi ti on.
4. If t he inspection reveal s obvi ous concerns t hat
5. If t he concerns remain after the i nspecti on,
determi ne the sympt oms and go t o the Sympt om
Chart .
0 1 - 09- 15 Mi r r or s, Rear Vi ew 0 1 - 09- 15
S y mp t o m Ch a r t
Use Rotunda Digital Vol t-Ohmmeter 014- 00407 or
equivalent for di agnosi s of Pinpoint Tests.
Usi ng NGS
Di agnosti cs f or thi s secti on require use of the New
Generation STAR (NGS) Tester, Rotunda 007- 00500
or equivalent. The module controlling the syst em being
di agnosed communi cates wi th t he Dat a Link
Connector l ocat ed beneath t he instrument cluster.
MIRRORS, REAR VIEW
Both RH and LH Mirrors Inoperative Circuits.
Outside rear view mirror control.
Outside rear view mirror motors.
GO t o Pinpoint Test A for Crown
Vi ct ori a, Grand Marquis.
GO t o Pinpoint Test B for Town Car.
Single Mirror Inoperative Circuit.
Outside rear view mirror cont rol.
Outside rear view mirror motor.
GO to Pinpoint Test C for Crown
GO t o Pinpoint Test B for Town Car.
Single Mirror Does Not Function
With Switch Logic
Circuit.
Outside rear view mirror motor
connection.
GO to Pinpoint Test D for Crown
GO to Pinpoint Test B for Town Car.
Automatic Dimming Out si de/ Inside
Mirror Does Not Switch
Automatically
Blown fuse.
Circuitry open.
Damaged outside rear view mirror
or inside rear view mirror.
Damaged backup lamp swi t ch.
Heated Outside Mirror Does Not
Defrost
Open / short ed circuitry.
Blown fuse.
Damaged outside rear view mirror.
Damaged heated back window
swi tch and light control.
GO to Pinpoint Test F.
Memory Mirror Function
Inoperative
Circuit.
Damaged mirror.
Driver seat module.
GO to Pinpoint Test G.
Pi npoi nt Test s
PINPOINT TEST A: BOTH RH AND LH MIRRORS INOPERATIVE CROWN VICTORIA, GRAND MARQUIS
A1 CHECK MIRROR SUPPLY
Yes
No
GO to A6.
GO to A2.
Remove outsi de rear vi ew mirror control as outlined.
Disconnect outside rear view mirror control harness
connector.
Using a voltmeter, connect one lead to Circuit 54
(LG/ Y) and Circuit 57 (BK) at outside rear view
mirror control connector.
Is bat t er y vol t age pr e se nt ?
Yes
No
GO to A6.
GO to A2.
A2 CHECK GROUND CONTINUITY
Yes D>
No
GO to A3.
SERVICE Circuit 57 (BK)
for open. RESTORE
vehi cle. RETEST system.
Connect an ohmmeter between Circuit 57 (BK) and
known good ground. Measure resi stance.
Is resi st ance 5 ohms or l ess?
Yes D>
No
GO to A3.
for open. RESTORE
A3 CHECK SUPPLY
Yes
No
GO t o A6.
GO t o A4.
Using voltmeter, measure voltage at Circuit 54
(LG/ Y) and a known good ground.
Yes
No
GO t o A6.
GO t o A4.
Connect the OBDI I styl e communi cati on cabl e t o t he
NGS. At t ach t he NGS and communi cati on cabl e t o t he
DLC beneath t he instrument cl uster. Sel ect t he proper
vehi cl e model and year f rom t he NGS menu. You may
then access the testi ng area of t he NGS menu
requi red t o di agnose this vehi cl e syst em.
01- 09- 16 Mi r r o r s , Re a r Vi e w
01- 09- 16
PINPOINT TE ST A: BOTH RH AND LH MIRRORS INOPERATIVECROWN VICTORIA, GRAND MARQUIS (Cont i nued)
A4 CHECK SUPPLY FOR SHORT TO GROUND
Using an ohmmeter connected to a known good
ground, connect second lead to Circuit 54 (LG/ Y).
Measure resi stance.
Yes
No
SERVICE Circuit 54
(LG/Y) for short to
ground. RESTORE
vehi cle. RETEST syst em.
GO to AS.
AS CHECK SUPPLY CIRCUIT CONTINUITY
Check continuity of Circuit 54 (LG/Y) between
outside rear view mirror control and Fuse 17 (10A)
(Town Car), Fuse 4 (15A) (Crown Vi ct ori a, Grand
Marquis).
Yes
No
REPLACE Fuse 17(10A)
(Town Car), Fuse 4 (15A)
(Crown Vi ct ori a, Grand
Marquis). GO to A6.
SERVICE Circuit 54
(LG/Y) for open.
RESTORE vehi cle.
RETEST syst em.
A6 CHECK MIRROR SWITCH OPERATION
Using a j umper wire, jump Circuit 54 (LG/ Y) t o
appropri ate circuit.
Connect a second j umper wire to Circuit 542 (Y) and
a known good ground.
Observe operation of each outside rear view mirror
as j umper is appli ed.
Di d mi rrors oper at e pr oper l y ?
Yes
No
REPLACE outside rear
view mirror cont rol.
RESTORE vehi cle.
RETEST syst em.
GOt o A7.
A7 CHECK SWITCH OUTPUT FOR SHORT TO GROUND
ground, measure resi stance of each circuit per
chart below.
LEFT OUTSIDE REAR VIEW MIRROR
Yes
No

Ci rcui t Funct i on
541 ( DB) UP
5 4 2 ( Y) DOWN
5 4 2 ( Y) RI GHT
5 4 0 ( R ) LEFT
RESTORE vehi cle.
RETEST syst em.
SERVICE suspect circuit
for short. RESTORE
RIGHT OUTSIDE REAR VIEW MIRROR
Ci rcui t Funct i on
5 4 4 ( P ) UP
545 ( W) DOWN
545 ( W) RI GHT
543 ( DG) LEFT
Is resi st ance 100K ohms or more?
PINPOINT TEST B: BOTH RH AND LH MIRRORS INOPERATIVETOWN CAR
B1 CHECK DRIVER AND PASSENGER MIRRORS
Yes
No
MANUAL motions are
operating properly.
ENSURE that mirror is not
loose in frame, which
would cause it t o change.
If mirrors are OK, GO t o
Pinpoint Test G and t est
memory operati on.
GO to B2.
Press driver's mirror verti cal and horizontal swi t ch,
note motion of driver's mirror.
Press passenger's mirror verti cal and horizontal
swi t ch; note motion of passenger's mirror.
Do all mi rrors move as e xpe c t e d?
Yes
No
MANUAL motions are
operating properly.
ENSURE that mirror is not
loose in frame, which
would cause it t o change.
If mirrors are OK, GO t o
Pinpoint Test G and t est
memory operati on.
GO to B2.
01- 09- 17
r x.
Mi r r o r s , Re a r Vi e w 01- 09 - 17
PINPOINT TEST B: BOTH RH AND LH MIRRORS INOPERATIVETOWN CAR (Cont i nued)
B2 CHECK FOR DRIVER'S OR PASSENGER'S MIRROR
INOPERATIVE
Yes
No
GO to B4. TEST only for
motions which do not
operat e.
GO to B3.
f Operate both mirrors horizontally and vertically.
Did bot h mi rrors move properl y?
Yes
No
GO to B4. TEST only for
motions which do not
operat e.
GO to B3.
B3 DRIVER'S AND PASSENGER'S MIRROR INOPERATIVE
Yes
No
If driver's seat module
has j ust been i nstalled,
double check that part
number of DSM is correct .
CHECK fuse 8. GO t o
A12.
GO to B4.
Both mirrors do not move horizontally or vertically.
No mot i on of ei t her mi rror?
Yes
No
If driver's seat module
has j ust been i nstalled,
double check that part
number of DSM is correct .
CHECK fuse 8. GO t o
A12.
GO to B4.
B4 CHECK DRIVER'S MIRROR VERTICAL MOVEMENT
Yes
No
CHECK Circuit 541 (DB)
and Circuit 947 (Y/ R) for
opens, shorts to ground
o r B+ . If Circuits OK,
REPLACE driver's seat
module.
GO to B5.
Connect New Generation STAR Tester to data link
connector.
Command driver's mirror verti cal movement.
Does dri ver' s mi rror not move up and down?
Yes
No
CHECK Circuit 541 (DB)
and Circuit 947 (Y/ R) for
o r B+ . If Circuits OK,
module.
GO to B5.
B5 CHECK DRIVER'S MIRROR HORIZONTAL MOVEMENT
Yes
No
CHECK Circuit 540 (R)
and 948 (Y/ LB) for
o r B+ . If circuits OK,
module.
GO to B6.
Command driver's mirror horizontal movement.
Does dri ver' s mi rror not move l ef t and ri ght ?
Yes
No
CHECK Circuit 540 (R)
and 948 (Y/ LB) for
o r B+ . If circuits OK,
module.
GO to B6.
B6 CHECK PASSENGER'S MIRROR VERTICAL
MOVEMENT
Yes
No
CHECK Circuits 544 (P)
and 957 (P/W) for open
circuit or short to ground
or B+ . If all checks out
OK, REPLACE driver's
seat module. RETEST
system.
GO to B7.
Command passenger's mirror verti cal movement.
Does passenger' s mi rror not move up and down?
Yes
No
CHECK Circuits 544 (P)
and 957 (P/W) for open
circuit or short to ground
or B+ . If all checks out
OK, REPLACE driver's
seat module. RETEST
system.
GO to B7.
B7 CHECK PASSENGER'S MIRROR HORIZONTAL
MOVEMENT
Yes
No
SERVICE Circuits 543
(DG) and 952 (W/LG) for
open circuit or short to
ground or B+ . If all
checks out OK, REPLACE
driver's seat module.
GO to B8.
Command passenger's mirror horizontal movement.
Does passenger' s mi rror not move l ef t or ri ght ?
Yes
No
(DG) and 952 (W/LG) for
ground or B+ . If all
checks out OK, REPLACE
GO to B8.
B8 CHECK SWITCH INPUT PIDS
Yes
No
CHECK ci rcui ts for short
to B+ . CHECK for stuck
swi t ch. RETEST system.
GO to B9.
Mirror swi tch in neutral posi ti on.
Request power mirror swi tch status PIDs.
Does da t a i ndi cat e any mi rror swi t c h act i ve?
Yes
No
CHECK ci rcui ts for short
to B+ . CHECK for stuck
GO to B9.
B9 CHECK SWITCH INPUTS
Yes
No
module. RETEST syst em.
GO t o B10.
While moving mirror swi t ch, request power mirror
swi t ch status PIDs.
Does da t a i ndi cat e all mi rror swi t ches act i ve?
Yes
No
GO t o B10.
01- 09- 18 Mi r r o r s , Re a r Vi e w 01- 09 - 18
PINPOINT TEST B: BOTH RH AND LH MIRRORS INOPERATIVETOWN CAR (Cont i nued)
T E S T S T E P RESULT ACTION TO TAKE
B10 CHECK SWITCH INPUT CIRCUITS
Yes
No
SERVICE following
ci rcui ts for open:
Driver's Lef t /Ri ght :
Circuit 540 (R).
Driver's Up/Down:
Circuit 541 (DB/ Y).
Passenger's Lef t /Ri ght :
Circuit 543 (DG).
Passenger's Up/Down:
Circuit 544 (P).
GO t o B11.
While moving mirror swi t ch, request power mirror
s w i t c h s t a t u s P I D.
Repeat for all mirror swi tch posi ti ons.
Does dat a i ndi cat e any one swi t ch not act i ve?
Yes
No
SERVICE following
ci rcui ts for open:
Driver's Lef t /Ri ght :
Circuit 540 (R).
Driver's Up/Down:
Circuit 541 (DB/ Y).
Passenger's Lef t /Ri ght :
Circuit 543 (DG).
Passenger's Up/Down:
Circuit 544 (P).
GO t o B11.
B11 CHECK SWITCH SUPPLY
Yes
No
SERVICE Circuit 296
(W/ P) feeding B+ t o
swi t ch, Circuit 676 (W/ P)
feeding ground to swi t ch
and Circuit 945 (Y/ BK)
for open.
GO t o B12 .
While holding mirror swi t ch, request power mirror
swi tch status PID.
Does dat a i ndi cat e no swi t ches act i ve?
Yes
No
SERVICE Circuit 296
(W/ P) feeding B+ t o
swi t ch, Circuit 676 (W/ P)
feeding ground to swi t ch
and Circuit 945 (Y/ BK)
for open.
GO t o B12 .
B12 TEST MODULE POWER
Yes
No
GO t o B13.
CHECK for open in Circuit
296 (W / P) or blown fuse
and short to ground on
Circuit 296 (W/ P).
RETEST system.
Check for voltage on Pin G2-12 of driver's seat
module.
Does vol t age read B+ ?
Yes
No
GO t o B13.
296 (W / P) or blown fuse
and short to ground on
Circuit 296 (W/ P).
RETEST system.
B13 TEST MODULE GROUND
Yes
No
676 (PK/G). RETEST
system.
Check for continuity from Pin 02-11 of driver's seat
module to vehicle ground.
Is t here cont i nui t y ?
Yes
No
676 (PK/G). RETEST
system.
PINPOINT TEST C: SINGLE MIRROR INOPERATIVECROWN VICTORIA, GRAND MARQUIS
C1 CHECK MIRROR UP/DOWN OPERATION
Yes
No
GO to C2.
GO to C3.
Remove outside rear view mirror glass from
inoperative outside rear view mirror as outlined.
Carefully probe wires and connect t est lamp
between up/down ci rcui ts:
LEFT MIRROR: 541 (DB), 542 (Y)
RIGHT MIRROR: 544 (P), 545 (W)
Di d t est l amp i l l umi nat e?
Yes
No
GO to C2.
GO to C3.
C2 CHECK MIRROR LEFT/RIGHT OPERATION
Yes
No
REPLACE motor
assembly. RESTORE
GO to C3.
Connect t est lamp between left / right ci rcui ts:
LEFT MIRROR: 540 (R), 542 (Y)
RIGHT MIRROR: 543 (DG), 545 (W)
Yes
No
REPLACE motor
assembly. RESTORE
GO to C3.
C3 CHECK SUSPECT CIRCUIT FOR VOLTAGE
Yes
No
view mirror wiring
harness. RESTORE
from front door to outside
rear view mirror cont rol .
RESTORE vehi cle.
RETEST system.
Remove front door trim panel as outlined.
Disconnect outside rear view mirror harness
connector.
Connect t est lamp between suspect circuit and a
known good ground.
Actuate outside rear view mirror control in
inoperative di recti on.
Di d t est lamp i l l umi nat e?
Yes
No
view mirror wiring
harness. RESTORE
from front door to outside
rear view mirror cont rol .
RESTORE vehi cle.
RETEST system.
01- 09- 19 Mi r r o r s , Re a r Vi e w
01- 09 - 19
PINPOINT TEST D: SINGLE MIRROR DOES NOT FUNCTION WITH SWITCH LOGICCROWN VICTORIA, GRAND MARQUIS
D1 CHECK POWER MIRROR SYSTEM LOGIC
Yes
No
REPLACE outsi de rear
view mirror. RESTORE
GO to D2.
Remove front door tri m panel on vehicle side
experiencing malfunction.
Using voltmeter, verify circuit logic at harness
connector.
Actuate outside rear view mirror control.
Is ci r cui t l ogi c OK?
Yes
No
REPLACE outsi de rear
GO to D2.
D2 CHECK SUSPECT CIRCUIT LOGIC
Yes
No
for crossed wi res.
RESTORE vehi cle.
RETEST syst em.
view mirror control.
RESTORE vehi cle.
RETEST system.
Remove outside rear view mirror control. Leave
harness connected to outside rear view mirror
cont rol.
Back probe outside rear view mirror control harness
connector while actuating outside rear view mirror
control.
Test suspect circuit at outside rear view mirror
control connector.
Is ci r cui t l ogi c OK?
Yes
No
for crossed wi res.
RESTORE vehi cle.
RETEST syst em.
view mirror control.
RESTORE vehi cle.
RETEST system.
PINPOINT TEST E: AUTOMATIC DIMMING OUTSIDE/INSIDE MIRROR DOES NOT SWITCH AUTOMATICALLY
E1 CHECK SUPPLY TO MIRROR
Turn ignition swi tch to the RUN posi ti on.
Gain access to mirror wiring connector as outlined.
Using a t est lamp connected to a known good
ground, check Circuit 298 (P/ O) (Crown Vi ct ori a,
Grand Marquis), 640 (R/ Y) (Town Car) for voltage.
Yes
No

AUTOMATIC DIMMING
MIRROR
ELECTRICAL
CONNECTOR N11297-B
Pi n Number Ci rcui t Ci rcui t Func t i on
1 140
( B K / P K )
Ba c k u p L a mp s
2 57 ( BK) Gr o u n d
3 2 98
( P / 0 ) ( C r o w n
Vi c t o r i a ,
Gr a n d
Ma r q u i s )
6 4 0 ( R / Y )
( To wn Ca r )
Fu s e d 12 Vo l t Fe e d
Di d t e st l amp i l l umi nat e?
GO t o E2 .
SERVICE Circuit 298
(P/ O) (Crown Vi ct ori a,
Grand Marquis), 640
(R/ Y) (Town Car) for
open circuit. RESTORE
E2 CHECK MIRROR GROUND CIRCUIT
Using an ohmmeter connected t o a known good
ground, connect second lead to Circuit 57 (BK) at
mirror connector. Measure resi stance.
Is r esi st ance 5 ohms or l ess?
Yes
No

GO to E3.
for open. RESTORE
01- 09- 2 0 Mi r r o r s , Re a r Vi e w 01- 09- 2 0
PINPOINT TEST E: AUTOMATIC DIMMING OUTSIDE/INSIDE MIRROR DOES NOT SWITCH AUTOMATICALLY (Cont i nued)
E3 CHECK AUTOMATIC DIMMING MIRROR
Yes
No
System is OK. GO t o
Cleaning in thi s sect i on.
RESTORE vehi cle.
RETEST syst em.
GOt o E4.
Gearshift lever must be in PARK for the following
t est s.
Cover photocell at backsi de of mirror case with a
clot h.
Using a flashli ght, shine light on photocell at window
in upper right corner of inside rear view mirror.
Di d i nsi de rear vi ew mi rror cycl e t o non-gl are?
Yes
No
System is OK. GO t o
Cleaning in thi s sect i on.
RESTORE vehi cle.
RETEST syst em.
GOt o E4.
E4 CHECK CIRCUIT 140 (BK/PK)
Yes
No
SERVICE Transmission
Range Sensor, REFER t o
Section 07-14.
REPLACE inside rear
Using test lamp, check Circuit 140 (BK/PK) for
voltage.
Yes
No
SERVICE Transmission
Range Sensor, REFER t o
Section 07-14.
REPLACE inside rear
PINPOINT TEST F: HEATED OUTSIDE MIRROR DOES NOT DEFROST
F1 CHECK INOPERATIVE MIRROR
Yes
No
REPLACE mirror glass as
outlined. RESTORE
GOt o F2 .
Remove outside rear view mirror glass from
inoperative outside rear view mirror as outlined.
Disconnect heated outside rear view mirror
connectors.
Connect test lamp between heated outside rear
view mirror connectors Circuit 59 (DG/P) and 57
(BK).
Turn ignition swi tch t o RUN posi ti on.
Turn heated back window swi tch and light to ON
position.
Di d t est l amp i l l umi nate?
Yes
No
REPLACE mirror glass as
outlined. RESTORE
GOt o F2 .
F2 CHECK CIRCUIT 59 (DG / P) FOR VOLTAGE
Yes
No
SERVICE Circuit 57 (BK).
RESTORE vehi cle.
RETEST system.
GOt o F3.
Turn ignition swi tch t o RUN posi ti on.
Turn heated back window swi tch and light to the ON
position. Connect t est lamp to Circuit 59 (DG/P) and
known good ground.
Yes
No
RESTORE vehi cle.
RETEST system.
GOt o F3.
F3 CHECK CIRCUIT 59 (DG / P) FOR SHORT
Yes
No
SERVICE Circuit 59
(DG/P) for short.
REPLACE fuse.
RESTORE vehi cle.
RETEST system.
GOt o F4.
Turn ignition swi tch to OFF posi ti on.
Connect Rotunda Digital Volt-Ohmmeter 014-00407
or equivalent to Circuit 59 (DG/P) and a known good
ground.
Yes
No
SERVICE Circuit 59
(DG/P) for short.
REPLACE fuse.
RESTORE vehi cle.
RETEST system.
GOt o F4.
F4 CHECK CIRCUIT 59 FOR OPEN
Yes
No
REPLACE damaged fuse
5 10A. RESTORE vehi cle.
RETEST system.
SERVICE Circuit 59
(DG/P) for open.
RESTORE vehi cle.
RETEST system.
Remove fuse 5 10A and inspect.
Connect j umper wire t o Circuit 59 (DG / P) at mirror
connector and known good ground.
Connect ohmmeter t o known good ground and
output side of fuse 5 10A cavity.
Yes
No
REPLACE damaged fuse
5 10A. RESTORE vehi cle.
RETEST system.
SERVICE Circuit 59
(DG/P) for open.
RESTORE vehi cle.
RETEST system.
01- 09 - 2 1 Mi r r o r s , Rear Vi e w 0 1 - 0 9 - 2 1
PINPOINT TEST G: MEMORY MIRROR TESTTOWN CAR
G1 SET MEMORY POSITIONS
Yes >
No >
GO to G2.
GO to Pinpoint Test B8
and execute through all.
RETURN t o G1 after
addressi ng swi tch
concerns.
S i t d o w n i n d r i v e r ' s s e a t and close b o t h f r o n t d o o r s .
N o t e p o s i t i o n o f b o t h d r i v e r ' s and p a s s e n g e r ' s s i d e
m i r r o r s .
P r e s s m e m o r y s e t b u t t o n .
Wi t h i n 5 s e c o n d s , p r e s s M e m o r y 1 b u t t o n .
U s i n g m i r r o r s w i t c h , m o v e mirrors t o a s e c o n d
posi ti on. Make sure there's movement on both
mirrors, verti cally and horizontally.
Press memory set button.
Within 5 seconds, press Memory 2 button.
Do mi r r or s move wi t h swi t c h?
Yes >
No >
GO to G2.
GO to Pinpoint Test B8
and execute through all.
RETURN t o G1 after
addressi ng swi tch
concerns.
G2 CHECK MEMORY POSITION LED
Yes
No
GO to Section 01-10 to
SERVICE memory swi t ch.
GO to G3.
Press memory set swi t ch.
Within 5 seconds, press Memory 1 button.
Does memor y LED t urn on?
Yes
No
GO to Section 01-10 to
SERVICE memory swi t ch.
GO to G3.
G3 CHECK MEMORY RECALL OF PROGRAMMED
POSITION
Yes
No
PRESS Memory 2 and 1
swi tch several ti mes to
ensure that operation is
consi stent. SYSTEM is
operating normally.
GOt o G4.
Press Memory 1 button.
Do mi r r or s move t o exact posi t i on as set i n st ep
G1?
Yes
No
PRESS Memory 2 and 1
swi tch several ti mes to
ensure that operation is
consi stent. SYSTEM is
operating normally.
GOt o G4.
G4 CHECK MEMORY RECALL
Yes
No
GO to Section 01-10t o
service memory recall.
GO t o G5.
Press Memory 1 button.
Do mi rrors move at all?
Yes
No
GO to Section 01-10t o
service memory recall.
GO t o G5.
G5 CHECKING POTENTIOMETER FEEDBACK CIRCUITS
Yes
No
CHECK Circuit 958
(GY/R) for open to
driver's seat module, or
short to ground. RETEST
system.
GOt o G6.
Back probe connector C2 of driver's seat module at
potentiometer inputs for motion whi ch di d not work.
Driver's verti cal:
Circuit 949 (R/W) Pin C2-8
Driver's horizontal:
Circuit 951 (DB/W)Pi n C2-19
Passenger's verti cal:
Circuit 957 (P/ W) Pin C2-17
Passenger's horizontal:
Circuit 954 (DG/W) Pin C2-18
Are all readi ngs l ess t han 0.5 vol t s?
Yes
No
CHECK Circuit 958
(GY/R) for open to
driver's seat module, or
system.
GOt o G6.
G6 POTENIOMETER CIRCUITS VOLTAGE LOW
Yes
No
CHECK Circuit 958
(GY/R) for open circuit to
affected mirror. RETEST
system.
GOt o G7.
Follow st eps in B5.
Are bot h ci r cui t s f or one mi rror l ess t han 0.5
vol t s?
Yes
No
CHECK Circuit 958
(GY/R) for open circuit to
affected mirror. RETEST
system.
GOt o G7.
G7 POTENTIOMETER CIRCUITS VOLTAGE HIGH AND LOW
Yes
No
CHECK af f ect ed circuit
for open or bad
potentiometer. RETEST
system.
GO to G8.
Follow steps in B5.
Is any ci r cui t l ess t han 0.5 vol t s?
Yes
No
CHECK af f ect ed circuit
for open or bad
potentiometer. RETEST
system.
GO to G8.
G8 POTENTIOMETER CIRCUIT VOLTAGE CONSTANT
Yes
No
REPLACE mirror. RETEST
system.
GO to G9.
Follow steps in B5.
Is any one ci r cui t const ant and be t we e n 0.5 and
4.5 vol t s?
Yes
No
REPLACE mirror. RETEST
system.
GO to G9.
01- 09- 2 2 Mi r r o r s , Re a r Vi e w 01- 09- 2 2
PINPOINT TEST G: MEMORY MIRROR TESTTOWN CAR (Cont i nued)
G9 P O T E N T I O ME T E R C I R C U I T V O L T A G E H I G H
Y e s
N o
C H E C K C i r c u i t 9 55 ( G Y )
f o r o p e n c i r c u i t . R E T E S T
s y s t e m .
GO t o G10.
F o l l o w s t e p s i n B5 .
Do all ci rcui ts have 4.5 volts but not more than 5
vol t s?
Y e s
N o
C H E C K C i r c u i t 9 55 ( G Y )
f o r o p e n c i r c u i t . R E T E S T
s y s t e m .
GO t o G10.
G10 P O T E N T I O ME T E R C I R C U I T V O L T A G E B+
Y e s
No w>
D I S C O N N E C T
connectors from driver's
seat module. CHECK all
potentiometer Circuits:
445 ( 0/ L B) , 449
(BR/PK), 452 (GY/R),
443 (LG/R), 442 (LG/O),
444 (LG/BK), 447 (O/R)
and 446 (O/ W).
To s e a t potentiometer,
and ci rcui ts:
949 (R/ W), 951 (DB/W),
954 (DG/W), 955 (GY),
957 (P/ W) and 958
(GY/R).
To mirror potentiometer
for short to B+ .
NOTE that any of these
circuits shorted to B + will
cause all motors to
operate improperly during
memory operation and all
seat motors to "j o g"
during manual motion.
RETEST system.
module. RETEST system.
Follow steps in B5.
Do all ci rcui ts have more than 5 vol t s?
Y e s
No w>
D I S C O N N E C T
connectors from driver's
seat module. CHECK all
potentiometer Circuits:
445 ( 0/ L B) , 449
(BR/PK), 452 (GY/R),
443 (LG/R), 442 (LG/O),
444 (LG/BK), 447 (O/R)
and 446 (O/ W).
To s e a t potentiometer,
and ci rcui ts:
949 (R/ W), 951 (DB/W),
954 (DG/W), 955 (GY),
957 (P/ W) and 958
(GY/R).
To mirror potentiometer
for short to B+ .
NOTE that any of these
circuits shorted to B + will
cause all motors to
operate improperly during
memory operation and all
seat motors to "j o g"
during manual motion.
RETEST system.
Mi r r o r , P o w e r O u t s i d e Re a r V i e w
Re mo v a l
2. Remove front door tri m panel ( 23942) . Refer t o
Secti on 01- 05.
3. Remove push pin f rom rear vi ew mi rror mounting
hole cover ( 17K709) . Remove scr ew under push
pi n. Remove rear vi ew mirror mounting hole
cover.
4. Remove necessary wi ri ng gui des.
5. Remove the three outsi de rear vi ew mi rror
retaining nuts and remove t he outsi de rear vi ew
mi rror ( 17682) guiding the wi ri ng and connect ors
t hrough t he hole in the front door ( 20124) .
OUTSIDE
REAR VIEW
MIRROR
17682
CROWN VICTORIA/
GRAND MARQUIS
17683 TOWN CAR
NUT AND
WASHER ASSY
3 REQ'D
EACH SIDE
TIGHTEN TO
8-10 N-m
. (71-88 LB-IN)
LH SHOWN RH SIMILAR N8763-1
1
2.
3.
Guide wiring and connectors through the hole in
the front door. Position outsi de rear vi ew mirror t o
the front door and install the three retaining nuts.
Tighten t o 8-10 N-m (71-88 Ib-in).
Position and install all wiring gui des.
Connect outsi de rear vi ew mirror assembl y wiring
at its connect ors.
01- 09- 23 Mi r r or s, Rear Vi e w 1 - 0 9 - 2 3
4. install rear vi ew mirror mounting hole cover.
Install retaining scr ew and push pin.
5. Install front door tri m panel.
6. Connect all el ectri cal connect ors t o wi ndow
regul ator swi t ch pl ate ( 14524) . Install wi ndow
regul ator swi t ch pl ate to armrest .
7. On LH front door, install outsi de rear vi ew mirror
remote control nut ( 17B732) t o outsi de rear vi ew
mirror control ( 17B676) .
8. Connect bat t ery ground cabl e.
Glass, Outsi de Mi rror
Removal
1.
2.
CAUTION: It is necessary t o break the mirror
glass to remove it from the mirror housing.
Use proper safety precautions when
performing this operation.
Carefully break the outsi de rear vi ew mi rror gl ass
( 17K707) and remove the pi eces t o gain access
t o the center hol es of the gl ass mounting back.
Carefully pry t he t wo clips off t he cross-tee
through t he t wo hol es in t he gl ass mounting back
and di scard t he cl i ps. The cl i ps are not used
when installing the repl acement outsi de rear vi ew
mi rror gl ass.
PRY OUT TWO
CLIPS
OUTSIDE REARVIEW MIRROR GLASS
MOUNTING BACK (PART OF 17682)
N11265-A
3. Push t he inner edge of t he gl ass mounting back
into t he outsi de rear vi ew mi rror ( 17682) .
4. Grasp t he outer edge of t he gl ass mounting back
and pull out until it snaps out of t he outsi de rear
vi ew mi rror mot or ( 17D696) .
5. On Town Car, di sconnect heater wi res or remove
termi nal s f r om connector.
Installation
1. Connect wi r es on heated mi rror (Town Car) t o
termi nal s on outsi de rear vi ew mi rror gl ass.
Line up the t wo outsi de rear vi ew mi rror pl at e
retai ners ( 17A746) and the cross-t ee on t he
gl ass mounting back t o t he hol es and snap t abs
on t he outsi de rear vi ew mi rror mot or.
OUTSIDE REAR
VIEW MIRROR GLASS
17K707
OUTSIDE REARVIEW
MIRROR PLATE
RETAINER 17A746
N11294-A
Firmly push t he outside rear vi ew mi rror gl ass into
pl ace wi t h t he pal m of the hand until it l ocks.
PRY OUT TWO
CLIPS
OUTSIDE REARVIEW MIRROR GLASS
MOUNTING BACK (PART OF 17682)
N11265-A
Mi rror Cont r ol Town Car
2. Remove wi ndow regulator swi t ch pl ate retaining
screw.
3. Lift wi ndow regul ator swi t ch housing ( 14527)
from armrest and di sconnect el ectri cal connector
from outsi de rear vi ew mirror control ( 17B676) .
4. Push outside rear vi ew mirror control out of
wi ndow regul ator swi t ch housing.
5. Using a putty knife or similar t ool , pry front door
tri m panel retaining clips f rom front door tri m
panel ( 23942) . Tilt front door tri m panel away
from front door ( 20124) and di sconnect outsi de
rear vi ew mi rror control connector. Remove front
door tri m panel .
01- 09- 2 4 Mi r r o r s , Re a r Vi e w 01- 09 - 2 4
To wn Car
N8231-C
Par t
Plate
Switch
3 17B676 Outside Rear View Mirror
Control
5 Door Trim Panel Armrest
(Part of 23942)
Switch
7 N807001-S58 Screw (6 Req'd)
8 14A701 Seat Regulator Control
Switch
Mi r r o r C o n t r o l C r o w n V i c t o r i a , G r a n d
Marquis
1. Remove outsi de rear vi ew mi rror remot e control
nut ( 17B732) f rom outsi de rear vi ew mirror
control ( 17B676) .
2.
4.
Gentl y pry up front porti on of wi ndow regul ator
swi t ch pl ate ( 14524) .
Gently pry up si des and rear of wi ndow regul ator
swi t ch pl ate from the armrest cavi ty.
Di sconnect outside rear vi ew mirror control
connect or and remove outsi de rear vi ew mirror
cont rol .
N8764-B
Pa r t
Remote Control Nut
Plate
3 23942 Front Door Trim Panel
Control
5

Connector (Part of 17B676)
6 4A630 Window Regulator Jumper
Wire
Mi r r o r Mo t o r
Re mo v a l
When repl aci ng outside rear vi ew mirror motor
( 17D696) , it is necessary t o install a new outsi de rear
vi ew mi rror gl ass ( 17K707) .
1. Remove outside rear view mirror gl ass and gl ass
mounting back as outlined in this secti on.
2. Observe outside rear vi ew mirror motor position
and wi re routing in outsi de rear vi ew mirror
( 17682) .
01- 09- 25 Mi r r or s, Rear Vi e w 01- 09- 25
3. Remove three scr ews retaining outsi de rear vi ew
mirror motor t o outsi de rear vi ew mirror. Retain
the scr ews.
ATTACHMENT
SCREWS
OUTSIDE REAR VIEW
MIRROR MOTOR
17D696 LH SIDE SHOWN
RH SIDE OPPOSITE N11267-B
4. Pull outsi de rear vi ew mi rror motor and wi res out
of the outsi de rear vi ew mi rror and label t he wi res
No. 1, No. 2, No. 3 and No. 4 using maski ng t ape.
Mark No. 1 wi re l ocati on on t he ol d outsi de rear
vi ew mi rror motor. Numberi ng t he wi res is
requi red t o install t he new outsi de rear vi ew
mirror motor.
OUTSIDE REAR VIEW
MIRROR 17682
NUMBERED
MASKING
TAPE
CUT WIRES
HERE
OUTSIDE REARVIEW
MIRROR MOTOR
17D696
N11269-A
5. Cut t he wi res as cl ose t o t he outsi de rear vi ew
mirror motor as possi bl e, maki ng sure that t he
numbers st ay on the wi res that are left in t he
outsi de rear vi ew mi rror.
1. Stri p 5 / 1 6 inch of insulation f rom the wi res in t he
outsi de rear vi ew mirror and f rom the wi res on the
new outsi de rear vi ew mirror motor.
WIRING
CONNECTOR
14487
REPLACEMENT
OUTSIDE REARVIEW
MIRROR MOTOR
17D696
N11270-A
Using seal i ng-type butt spl i ce connect ors,
connect the four wi res t oget her (outsi de rear
vi ew mirror motor t o outsi de rear vi ew mi rror) as
numbered during outsi de rear vi ew mirror motor
removal .
INSTALLATION INSTRUCTIONS
x
1. STRIP WIRES 7.6mm (0.3") INSERT INTO
CRIMP BARREL.
2. CRIMP USING CRIMP TOOL FOR
PREINSULATED CRIMPS.
3. HEAT SPLICE WITH HEAT GUN UNTIL
TUBING SHRINKS AND ADHESIVE
FLOWS FROM EACH END.
K19462-A
Position the wi res and outsi de rear vi ew mirror
motor in the outsi de rear vi ew mirror as noted
during removal . Install and hand-tighten the t hree
retaining scr ews.
Install outside rear vi ew mirror gl ass and gl ass
mounting back as outlined in thi s secti on.
Mirror, Inside Rear View
Manual
SPECI AL SERVI CE TOOL(S) REQUIRED
Description Tool Number
Re a r v i e w Mi r r o r Re mo v e r T91T- 17 7 00- A
Removal
1. Whi l e holding inside rear vi ew mi rror ( 17700)
fi rml y, insert Inside Mi rror Removal Tool
T91T-17700-A into sl ot until button is cont act ed.
SLIDE IN THIS
DIRECTION
REAR VIEW
MIRROR
REMOVER
T91T-17700-A
PUSH IN THIS
DIRECTION
N9314-C
2. Remove the inside rear vi ew mi rror assembl y by
pushing inside rear vi ew mi rror upward and away
f rom inside rear vi ew mi rror bracket ( 17698) .
At t ach inside rear vi ew mi rror t o t he inside rear vi ew
mi rror bracket and push into pl ace.
A u t o m a t i c Di mmi n g
Re mo v a l
1. Di sconnect wi ri ng connector at inside rear vi ew
mi rror.
2. Loosen t he inside rear vi ew mi rror assembl y t o
inside rear vi ew mirror bracket set screw.
3. Remove t he inside rear vi ew mi rror assembl y by
sliding upward and away f rom the inside rear vi ew
mi rror bracket .
1. Position the inside rear vi ew mi rror assembl y t o
t he inside rear vi ew mi rror br acket by sliding
downwar d t owar d t he inside rear vi ew mirror
bracket .
2. Tighten t he inside rear vi ew mi rror assembl y t o
inside rear vi ew mi rror br acket set scr ew t o
1.7-2.3 N-m (15-20 Ib-in).
3. Connect the wi ri ng connector at t he inside rear
vi ew mirror.
4. To ensure performance of inside rear vi ew mi rror,
perform compl et e Di agnosi s procedure as
outlined.
Mi r r o r B r a c k e t , I n s i d e Re a r V i e w
Re mo v a l
1. Remove inside rear vi ew mi rror ( 17700) as
outlined and mark location of inside rear vi ew
mirror bracket ( 17698) on t he outsi de of
wi ndshi el d gl ass ( 03100) .
2. Appl y l ow heat f rom Rotunda Heat Gun
107-R0301 or equivalent until the inside rear vi ew
mirror wi ndshi el d pad ( 17A720) softens. Peel
inside rear vi ew mirror bracket off the wi ndshi el d
gl ass.
1. Make sure windshield gl ass, inside rear vi ew
mirror bracket and adhesi ve kit Rear Vi ew Mi rror
Adhesi ve D9AZ-19554-CA or equivalent meeting
Ford speci fi cati on ESB-M2G176-A are at least at
room temperature: 18- 24C (65-75 F) .
2. Locat e and mark the inside rear vi ew mirror
bracket location on the outsi de surface of the
windshield gl ass.
3. Thoroughl y cl ean bonding surf aces of wi ndshi el d
gl ass and inside rear vi ew mirror bracket t o
remove old adhesi ve. Use mild abrasi ve cl eaner
on windshield gl ass and fine sandpaper on inside
rear vi ew mirror bracket t o lightly roughen
surface. Wi pe cl ean wi th al cohol -moi stened cl ot h.
4. Crush accel erator vial (part of Rear Vi ew Mi rror
Adhesi ve D9AZ-19554-CA or equivalent meeting
Ford speci fi cati on ESB-M2G176-A) and appl y
accel erator t o bonding surface of inside rear vi ew
mirror bracket and wi ndshi el d gl ass. Let dry for
three minutes.
5. Appl y t wo drops of Rear Vi ew Mi rror Adhesi ve
D9AZ-19554-CA or equivalent meeting Ford
speci fi cati on ESB-M2G176-A t o t he mounting
surface of the inside rear vi ew mirror bracket .
Using a clean toothpi ck or wooden mat ch, qui ckl y
spread the adhesi ve evenly over t he mounting
surface of the inside rear vi ew mirror bracket .
6. Qui ckl y position the inside rear vi ew mirror
bracket on the windshield gl ass. The 9. 5 mm
( 3 / 8 inch) circular depressi on in t he inside rear
vi ew mirror bracket must be t owar d the bot t om
edge and t owar d the inside of the passenger
compartment. Press t he inside rear vi ew mirror
bracket firmly against t he wi ndshi el d gl ass for
one minute.
01- 09- 27 0 1 - 0 9 - 2 7
7. Al l ow the bond t o set for fi ve minutes. Remove
any excess bonding materi al f rom the wi ndshi el d
gl ass wi th an al cohol -moi stened cl ot h.
INSIDE REAR VIEW
MIRROR 17700
WINDSHIELD GLASS
03100
L7629-C
Mi r r o r s , O u t s i d e
CAUTI ON: Ou t s i d e r e a r v i e w mi r r o r gl a s s e s
( 17 K7 07 ) s h o u l d n o t b e c l e a n e d wi t h a d r y c l o t h
o r a b r a s i v e c l e a n i n g p o w d e r s . Do n o t r e mo v e i c e
w i t h a s c r a pe r . T h e o u t s i d e r e a r v i e w mi r r o r gl a s s
s h o u l d o n l y b e c l e a n e d w i t h a s o f t , c l e a n c l o t h
a n d mi l d d e t e r g e n t a n d wa t e r o r Ul t r a Cl e a r Sp r a y
Gl a ss Cl e a n e r E 4A Z - 19C507 - A A o r e q u i v a l e n t
me e t i n g Fo r d s p e c i f i c a t i o n ESR- M14P5- A,
o t h e r wi s e d a ma g e t o t h e r e f l e c t i v e s u r f a c e ma y
r e s u l t .
SPECIflCATIONS
TORQUE SPECIflCATIONS
Descr i pt i on N-m Lb-l n
E l e c t r o n i c Da y / N i g h t Mo u n t i n g
Br a c ke t S e t s c r e w
1. 7-2. 3 15- 20
Mi r r o r - t o - Do o r 8- 10 7 1- 88
Tool Numbe r /
De sc r i pt i on I l l ust r at i on
T 91T - 17 7 00- A
Re a r v i e w Mi r r o r Re mo v e r
T91T-17700-A
ROTUNDA EQUIPMENT
Model Descr i pt i on
007 - 00500 Ne w Ge n e r a t i o n STAR T e s t e r
014- 00407 Di gi t a l Vo l t - Oh mme t e r
107 - R0301 He a t Gun
Mi r r o r s , F r o z e n
CAUTI ON: To p r e v e n t d a ma g i n g t h e i n t e r n a l
me c h a n i s m o r o u t s i d e r e a r v i e w mi r r o r gl a s s
( 17 K7 07 ) , o u t s i d e ma n u a l r e mo t e mi r r o r s w h i c h
a r e f r o z e n mu s t b e t h a w e d pr i o r t o f u n c t i o n i n g .
DO NOT a t t e mp t t o f r e e - u p t h e o u t s i d e r e a r v i e w
mi r r o r ( 17 682 ) b y p r e s s i n g a ga i n s t t h e o u t s i d e
r e a r v i e w mi r r o r gl a s s .
01- 10- 1
Se a t s a n d T r a c ks 01- 10- 1
SECTION 01-10 Seats and Tracks
SUBJECT PAGE
Head Rest rai nt s . 01-10-4
Heat ed Seat s 01-10-5
Lumbar Support Syst em 01-10-4
Recl i ner.... 01-10-3
Seat Back Cont r ol Swi t ch and Housi ng 01-10-5
Seat Cover Desi gn 01-10-5
Seat Tracks, Manual 01-10-1
Seat Tri m 01-10-5
Seat , Rear 01-10-5
Seat s, Front . 01-10-2
Component Te st s. . . ............01-10-28
Swi t ch Test 01-10-28
Pi npoi nt Te st sTo wn Car 01-10-19
Head Rest rai nt s 01-10-37
Heat ed Se a t sTown Car 01-10-38
Programmabl e Memory 01-10-34
Seat Back Cont r ol Swi t ch and Housi ng 01-10-34
Recli ner, Manual 01-10-36
SUBJECT PAGE
Recli ner, Power ..01-10-37
Seat Regul at or Cont r ol Processor 01-10-35
Seat Regul at or Cont r ol Swi t ch 01-10-33
Po we r Si x- Wa y To wn Car 01-10-33
Seat Track ..01-10-32
Seat Track, PowerSi x-Way ..01-10-33
Seat , Dri ver or Passenger Manual Seat 01-10-31
Seat , Dri ver or Passenger Power Seat.. ..01-10-30
Seat , Rear Bench 01-10-32
DISASSEMBLY AND ASSEMBLY
Arm Rest Cover ..01-10-57
Arm Rest, Front Seat Cent er 01-10-57
Seat Back Frame, Pad and Tri m Cover ....01-10-47
Seat Back Pad Adj ust er, Front . . . ..01-10-46
Seat Back Pad Adj ust i ng Pump, Front 01-10-47
Seat Cushi on Spr i ng, Frame, Pad and Tri m
Cover Assembl i es 01-10-53
Seat , Bench ..01-10-39
Sensor Swi t ch and Wi re, Dri ver Seat ..01-10-38
ADJUSTMENTS
Lat ch, Seat Back 01-10-59
SPECIFICATIONS ..01-10-59
VEHICLE APPLICATION
S e a t T r a c k s , Ma n u a l
The manual seat t r acks have t he fol l owi ng features:
The front seat cushion extensi on handle ( 603A86)
is l ocated at the front of the seat.
Pulling t he front seat cushion extensi on handle
al l ows the seat t o move f orward or r ear war d.
Manual seat t r acks are retai ned t o the fl oorpan by
st uds wi th nut and washer assembl i es and washer
head-type scr ews. The nuts and scr ews retaining
t he seat t r acks are removed f rom inside the vehicle.
01- 10- 2 Seat s and Tr ac k s 01- 10- 2
DESCRIPTION AND OPERATION (Continued)
Spl i t Bench
RH SHOWN
LH TYPICAL
RS602-D
Par t
1 62900 Front Seat Cushion Cover
2 61705 L H F r o n t S e a t T r a c k
3 N801078-S58 Bolt (4 Req'd)
4 61828 Front Seat Track Assi st
Spring
I t e m
Pa r t
5 603A86 Front Seat Cushion
Extension Handle
6 61705 RH Front Seat Track
A Tighten t o 17-23 N- m (13-17
Lb-Ft)
Seat s, Front
Power, Six-Way
The si x-way power seat has the fol l owi ng f eat ures:
Hori zontal , verti cal and tilt adj ustments.
A seat regulator motor ( 14547) and gear housing.
Seat regul ator control swi t ch ( 14A701) .
Vertical gear dri ves.
Horizontal rack-and-pinion dri ves.
The syst em operat es as fol l ows:
The mechani cal portion of the seat t rack in t he
horizontal dri ve consi sts of a rack and pinion on
each t rack.
The pinion housing and seat regul ator motor is
at t ached t o the movabl e secti on of the t rack.
When the seat regul ator control swi t ch is act uat ed,
the center armature is energi zed and the horizontal
dri ve units are act i vat ed.
The seat is then moved f orward or rearward by the
pinion gears traveling in a rack in each l ower t rack
secti on.
In the verti cal dri ve, wor m gear reducers and sect or
gear mechani sms are used.
The dri ve units are l ocated in the front and rear of
the transmission case.
When the seat regul ator control swi t ch is act uat ed,
t he front and rear armatures are energized
simultaneously and the verti cal dri ve units are
act i vat ed.
The seat is then moved up or down by the sect or
gears.
When the front tilt porti on of the seat regulator
control swi tch is act uat ed, t he front armature dri ves
t he front verti cal wor m gear and moves the seat t o
t he desi red posi ti on.
01- 10- 3 Seat s a n d T r a c ks 01- 10- 3
When the rear tilt portion of the seat regul ator
control swi t ch is act uat ed, the rear armature dri ves
t he rear verti cal wor m gear and moves the seat t o
t he desi red posi ti on.
The main components of the syst em are servi ced as
f ol l ows:
The seat regulator mot ors and transmi ssi on are
servi ced as a unit.
The seat regulator control swi t ch and housing
assembl y are servi ced separatel y.
C i r c u i t P r o t e c t i o n
The power seat circuit is prot ect ed by circuit breakers
mounted in each seat regul ator motor armature.
P r o g r a mma b l e
T o w n Ca r , C r o w n Vi c t o r i a LX
Town Car' s memory seat syst em al l ows automati c
positioning of t he dri ver' s seat t o t hree programmabl e
posi ti ons:
To program position 1, move dri ver' s seat t o
desi red position using seat regul ator control s
( 14776) . Press t he SET but t on. Within fi ve seconds,
(bef ore the LED goes out) press button 1.
To program position 2, repeat t he previ ous
procedure using button 2.
To program position 3, repeat the previ ous
procedure but press buttons 1 and 2
simultaneously.
To recall position 1, press button 1. To recall
posi ti on 2, press button 2. To recall position 3,
press buttons 1 and 2 simultaneously.
Programmabl e seat s have t he following f eat ures:
A position can only be recal l ed when the
transmi ssi on is in PARK or NEUTRAL.
A position may be programmed at any ti me.
When power is first appl i ed t o t he vehi cl e, t he
current position of t he dri ver' s seat is st ored in all
t hree memory l ocati ons.
The seat regul ator control is wi red through t he seat
regul ator control processor ( 14C708) . If t he seat
regul ator control processor is not installed, or not
functi onal , the memory or seat regul ator control will
not wor k.
Sensors on t he seat t r ack determi ne movement. If
t hese sensors are not connect ed, t he seat regul ator
control processor and seat regul ator control will not
wor k.
Re c l i n e r
Ma n u a l
The manual seat back recliner syst em operat es as
fol l ows:
The seat back is reclined rearward for opti mum
occupant comf ort .
The reclining seat back is adj usted by a front seat
back adjusting handle ( 61198) on the out board side
of t he seat cushion.
To recline t he seat back, rot at e the front seat back
adjusting handle upward and push the seat back t o
t he desi red position and rel ease the front seat back
adjusting handle.
Spri ng acti on will return the seat back t o i ts full-up
position when the front seat back adjusting handle is
rot at ed upward and occupant back pressure is
removed.
The modular front seat back pad adjuster ( 65500) ,
used on all flight and split bench seat s, is l ocated on
t he out board rear corner of the front seat assembl y.
Thi s mechani sm provi des t he seat back pi vot.
The front seat back pad adj uster is rel eased by a
front seat back adjusting handle provi ded by a
remot e cabl e/ br acket assembl y on the front
out board si de of the front seat cushion f rame and
spri ng ( 63100) .
P o w e r
The power recliner has the following features:
To move t he seat back f orward or backwar d, press
t he seat control swi t ch ( 14C715) on the si de of the
seat cushi on.
If a front seat back pad adj uster is i noperati ve, the
entire front seat back pad adj uster assembl y must
be repl aced.
The front seat back pad adj uster is a modular
design and the individual components cannot be
servi ced or repl aced independently.
LED
SEAT REGULATOR
CONTROL SWITCH
14776
NOTE: SWITCH IS LOCATED
IN THE DRIVER'S DOOR
TRIM PANEL
R4S99-B
01- 10- 4 Seat s and Tr ac k s 01- 10- 4
Recl i ner , Fr ont Seat
POWER SEAT MODELS WITH
RECLINER SHOWN
R2335-0
I t em
Par t
1 N 8 0 0 4 7 6 - S 2 S c r e w
2 6 1 0 1 8 F r o n t S e a t B a c k F r a m e
3 F r o n t S e a t B a c k A s s e m b l y
4 6 2 6 4 8 F r o n t S e a t B a c k
L a t c h P o w e r
5 6 2 6 4 8 F r o n t S e a t B a c k
L a t c h M a n u a l
I t em
Par t
6 N802919-S2 S c r e w
7 6 3 1 0 0 F r o n t S e a t C u s h i o n F r a m e
a n d S p r i n g
A T i g h t e n t o 2 3 - 3 2 N-m (16-24
Lb-Ft)
Lumbar Support Syst em
CAUTI ON: T h e l o n ge r n i p p l e o n t h e s w i t c h
( l o c a t e d a t t h e c e n t e r o f t h e s w i t c h b o d y ) s h o u l d
a l wa y s b e c o n n e c t e d t o t h e h o s e l e a d i n g t o t h e
l u mb a r s u p p o r t . T h e s h o r t e r n i ppl e o n t h e s w i t c h
b o d y c o n n e c t s t o t h e a i r p u mp o u t l e t . If t h i s o r d e r
i s r e v e r s e d , t h e l umba r b a g wi l l n o t h o l d ai r
p r e s s u r e .
The lumbar support syst em consi st s of the fol l owi ng
component s:
Pad adj uster seat control swi t ch ( 14C715) .
Front seat back pad adj uster ( 65500) .
Front seat back pad adj usti ng pump ( 65530) .
Seat back control wiring ( 14B719) .
Front seat back pad adj usti ng t ube ( 65512) .
Except for the front seat back pad adj uster, all
component s are generally l ocat ed at or under t he front
seat cushion f rame and spri ng ( 63100) .
During the inflate mode:
The front seat back pad adjusting pump pumps air
through a front seat back pad adjusting tube t o t he
pad adjuster seat control swi t ch.
Air is then routed through a front seat back pad
adjusting tube t o the front seat back pad adjuster
l ocated in the seat back.
The pad adjuster seat control swi t ch performs t hree
functions:
Turns on front seat back pad adjusting pump.
Act s as a one-way check val ve for air passage t o
front seat back pad adjuster. Once inflated, t he pad
adjuster seat control swi t ch is returned t o its normal
mode and t he check valve cl oses. This maintains air
pressure in the front seat back pad adjuster.
When defl ated, the check val ve opens t o defl ate the
front seat back pad adjuster. In thi s mode, the f ront
seat back pad adjusting pump does not operat e.
Head Restrai nts
Each front seat is equi pped wi t h dual-post design front
seat back head restrai nt ( 611 A O S ) .
01- 10- 5 S e a t s a n d T r a c ks 01- 10- 5
The front seat back head restrai nt is installed as
f ol l ows:
It t ravel s on dual post s whi ch have notches t o
engage a spri ng-l oaded cat ch in t he guide.
The front seat back spri ng assembl y retains t he
front seat head rest guide rod sl eeve ( 610A 16).
FRONT SEAT
HEAD
RESTRAINT
GUIDE ROD
RETAINER
610A18
R7018-B
The front seat back head restrai nt is adjustable
f r om i ts normal posi ti on t o a rai sed position of
approxi mat el y 25 mm ( 1 i nch).
Pull up on t he front seat back head restrai nt t o rai se
it. Pushing down will return it t o its normal position.
Head Re st r a i n t Ad j ust me n t
RAISED
R4073-F
S e a t B a c k C o n t r o l S w i t c h a n d H o u s i n g
The seat control swi t ch ( 14C715) control s the mot ors
whi ch adj ust seat back position and l ateral back
support as f ol l ows:
Press the pad adj uster seat control swi t ch f or war d
t o inflate t he front seat back pad adj uster ( 65500) .
Press the pad adj uster seat control swi t ch rearward
t o defl ate the front seat back pad adj uster.
Move the pad adj uster seat control swi t ch upward
t o rai se the seat back .
Move the pad adj uster seat control swi t ch
downwar d t o l ower t he seat back.
S e a t , Re a r
C o n v e n t i o n a l Re a r
The rear seat is a bench styl e that consi sts of:
Rear seat cushion cover ( 63804) .
Rear seat cushion pad and frame ( 600A88) .
Rear seat cushion f rame ( 63160) .
Rear seat back cover ( 66600) .
Rear seat back pad ( 66800) .
Rear seat back pad and f rame ( 672A18) .
Rear seat center arm rest (optional).
S e a t T r i m
The front and rear seat tri m is at t ached t o t he seat
f rames wi th retai ners and hog rings.
S e a t C o v e r De s i g n
The seat tri m is available in vinyl, cl oth or leather.
H e a t e d S e a t s
Heated seat s:
Are available on Town Car.
Will operat e wi th the ignition swi t ch ( 11572) in RUN
position only.
Provi de heat to RH and LH front seat back and
cushi on.
Are control l ed separatel y from a swi t ch l ocat ed on
front door tri m panels.
Have adjustable heat range.
Elements are made into the front seat back cover
and front seat cushion cover.
01- 10- 6 Se a t s a n d T r a c ks 01- 10- 6
Electri cal Schemat i cs
Dr i ver Se a t Cr o wn Vi c t o r i a / Gr a n d Ma r qui s
HOT AT A L L TI ME S
1 POWER
SEAT J UfTRIBUTION
^ ?
T O R
i (CROWN VICTORIA,
I GRAND MARQUIS ONLY)
of t hi s ci rcui t
FRONT OF SEAT
DO WN
JB> UP
ENTIRE S SEAT
,w , ^ ,
1
. . A > K >k
I I I I I
RWO N I j n "** DOWN ,>
FWD I I UP
LH SEAT
REGULATOR
CONTROL
SWITCH
REAR OF SEAT
D O W N
I I
Y/LB 981
(TOWN
CA R)
R/W 980
T
Y/W
57 | B K
R/LG 982 Y/LG
LH
SEAT
REGULATOR
MOTOR
FRONT
M \ HEIGHT
' MOTOR
y \ FWD/RWD
M 1
MOTOR
REAR
M 1 HEIGHT
1
MOTOR
R9547-B
01- 10- 7 Se a t s a n d T r a c ks 01- 10- 7
Connect or En d Vi ews Dr i ver Se a t with Power
Recl i ner
P O W E R S E A T MO T O R C O N N E C T O R
( WI T H O U T P O WE R RECLINER/LUMBAR)
( DRI VE R' S ) R9886- B
P A S S E N G E R S E A T M O T O R C O N N E C T O R
Pin
N u m b e r Ci rcui t Ci r cui t Func t i on
1 986 ( Y / W) Ho r i zo n t a l Se a t
Re g u l a t o r - Ba c kwa r d I nput
2 989
( R / L G )
Ve r t i c a l Se a t Re gu l a t o r - Re a r Up
3 988
( Y/ L G )
Ve r t i c a l Se a t Re gu l a t o r - Re a r
Do wn
4 987 ( R / W) Ho r i zo n t a l Se a t Re gu l a t o r - Fo r wa r d
I nput
5 9 8 4 ( Y / L B ) Ve r t i c a l Se a t Re gu l a t o r - Fr o n t
Do wn
6 9 8 5 ( R / L B ) Ve r t i c a l Se a t Re gu l a t o r - Fr o n t Up
D R I V E R S E A T M O T O R C O N N E C T O R
Pin
N u m b e r Ci rcui t Ci rcui t Func t i on
1 9 8 0 ( Y / W) Ho r i zo n t a l Se a t
2 983
( R / L G )
3 982
( Y/ L G )
Do wn
4 9 8 1 ( R / W) Ho r i zo n t a l Se a t Re g u l a t o r - Fo r wa r d
I nput
5 9 9 0 ( Y / L B ) Ve r t i c a l Se a t Re gu l a t o r - Fr o n t
Do wn
6 9 7 9 ( R / L B ) Ve r t i c a l Se a t Re gu l a t o r - Fr o n t Up
SEAT CONTROL SWI TCH
R11028-A
Pin
1 981 ( R / W)
987 ( R / W)
Se a t Mo t o r Fo r wa r d Out put
2 983
( R/ L G )
989
( R/ L G )
Re a r He i ght Mo t o r Up Out put
Re a r He i ght Mo t o r Up Out put
3 9 7 9 ( R / L B )
9 8 5 ( R / L B )
Fr o n t He i ght Mo t o r Up Out put
4

No t Us e d
5 9 1 8 ( G Y) Re c l i n e r Mo t o r Fo r wa r d Out put
6 517
( B K / W)
B +
7 980 ( Y / W)
986 ( Y / W)
Se a t Mo t o r Re a r wa r d Ou t pu t
Se a t Mo t o r Re a r wa r d Out put
8 982
( Y/ L G )
988
( Y/ L G )
Re a r He i ght Mo t o r Do wn Out put
9 9 9 0 ( Y / L B )
9 8 4 ( Y / L B )
Fr o n t He i ght Mo t o r Do wn Out put
10

No t Us e d
11 919
( G Y/ B K )
Re c l i n e r Mo t o r Re a r wa r d Out put
12 57 ( BK) Gr o un d
01- 10- 8 Seat s and Tr ac k s 0 1 - 1 0 - 8
Cr own Vi ct or i a, Grand Marqui s
1 ) 1 2 ) 1 3 ) I 4
5 ) 1 6 ) ( 7 ) ( 8
SEAT CONTROL SWITCH
R l 1 0 2 9
^
Pa sse nge r Se a t Cr o wn Vi c t o r i a , Gr a nd Ma r qui s
Pi n
Number Ci r c ui t Ci r cui t Func t i on
1 986 ( Y / W ) Se a t Mo t o r Re a r w a r d Ou t p u t
2 985 ( R / L B ) Fr o n t He i ght Mo t o r Up Ou t pu t
3 9 8 4 ( Y / L B ) Fr o n t He i ght Mo t o r Do wn Ou t p u t
4 517
( B K / W )
B +
5 989
( R / L G )
Re a r He i ght Mo t o r Up Ou t p u t
6 9 8 8
( Y / L G )
Re a r He i gh t Mo t o r Do wn Ou t p u t
7 987 ( R / W) Se a t Mo t o r Fo r wa r d Out put
HOT AT A L L T I ME S
SE AT
FRON T O F SE AT
> - DOWN
U P
I POWER
DISTRIBUTION
M O T O R
B 0 X
C. B |
2 0A I
I
of this circuit
517 i BK/ W
RH SEAT REGULATOR
CONTROL SWITCH
E NTI RE T SEAT
RWD N I o
^ F W D I I
REAR O F SE A T
I I I
W I
57 | B I
R/ LG 988 Y/ LG
RH SEAT
REGULATOR
MOTOR
ASSY
FRONT
M } HE I GHT
' MOT OR
y v FWD/ RWD
M 1
MO T O R
RE A R .
M 1 HE I G HT
* MO T O R
R9548-B
01- 10- 9 Se a t s a n d T r a c ks 01- 10- 9
Co n n e c t o r End Vi e ws P a s s e n ge r Seat

o
E
o
SEAT REGULATOR MOTOR
ASSY (RIGHT)
CONNECTOR ON
14A005 WIRING ASSY
R9894-A
Pin
1 987 ( R / W) Ho r i zo n t a l Se a t Re gu l a t o r - Fo r wa r d
I nput
2 986 ( Y / W) Ho r i zo n t a l Se a t
3 984 ( Y / L B ) Ve r t i c a l Se a t Re gu l a t o r - Fr o n t
Do wn
4 989
( R / L G )
5 985 ( R / L B ) Ve r t i c a l Se a t Re gu l a t o r - Fr o n t Up
6 9 88
( Y/ L G )
Do wn
SEAT CONTROL SWITCH
R11023-A
Pin
1 981 ( R / W)
987 ( R / W)
2 9 8 3
( R / L G )
9 8 9
( R / L G )
Re a r He i ght Mo t o r Up Ou t pu t
Re a r He i ght Mo t o r Up Ou t pu t
3 9 7 9 ( R / L B )
9 8 5 ( R / L B )
Fr o n t He i ght Mo t o r Up Ou t pu t
Pi n
4 No t Us e d
5 918 ( GY) Re c l i n e r Mo t o r Fo r wa r d Out put
6 517
( B K / W)
B +
7 980 ( Y / W)
986 ( Y / W)
8 982
( Y/ L G )
988
( Y/ L G )
9 9 9 0 ( Y / L B )
9 8 4 ( Y / L B )
10 No t Us e d
11 919
( G Y/ B K )
Re c l i n e r Mo t o r Re a r wa r d Out put
12 57 ( BK) Gr o un d

(DRIVER'S)
POWER SEAT
CONTROL SWITCH CONNECTOR
R9S98-B
Pin
1 171
( B K / W)
Ci r c ui t Br e a ke r t o Se a t L a t c h
Re l a y
2 57 ( BK) Gr o un d Ci r c ui t
o n o
LH AND RH SEAT
CONTROL SWITCHES
R9899-B
Pin
1 690 ( GY) Se a t Re c l i n e Co n t r o l
2 67 9
( G Y/ B K )
Se a t Re c l i n e Co n t r o l
3 171
( B K / W)
Ci r c ui t Br e a ke r t o Se a t Ba c k L a t c h
Re l a y
01- 10- 10 Se a t s a n d T r a c ks 01- 10- 10
Dr i ver a n d Pa sse nge r Se a t s wi t h Lumba r Suppo r t
Sy st e m
HOT AT AL L TI MES
490
, POWER
K
I DISTRIBUTION
- BOX
20A '
L
b
_ l
517 I BK/ W
517 i BK/W 517 I BK/W
FRONT SEAT
BACK PAD
ADJUSTING
PUMP
FRONT SEAT
BACK PAD
ADJUSTING
PUMP
SEAT BACK
CONTROL
SWITCH
AND HOUSING
SEAT BACK
CONTROL
SWITCH
AND HOUSING
R11018-A
01- 10- 11 Se a t s a n d T r a c ks 01- 10- 11
Power Recl i ni ng Seat s, Town Car
HOT AT A L L T I ME S HOT A T A L L T I ME S
2 96 I W/ P I
POV | S E E P O WE R S E A T S
-H* UP
m DO WN
SE A T BA C K
L E FT
SEAT
RECLINER
SWITCH I
I
I C 3 - 1 4
452
C 1 - 1 0
C3- 16 C3- 3
C1- 9
C3- 6
- m m poWER
| RECLINING
I S E A T S
1 ( TOWN CA R)
J
BK
I
GY/ R T 445 j O/ LB T 9 1 9 J GY/ BK
449 I BK/ P K I 9 1 8 I G Y I
PASSENGER'S
SEAT
RECLINER
MOTOR
of this circuit
R11027-A
Connect or End Vi e w
1
0
^ 5
4 ) {BJ 16
SEAT RECLINER SWITCH
DRIVER SEAT RECLINER SWITCH
R11025-A
Pin
N u m b e r Ci r cui t Ci rcui t Func t i on
1 57 ( BK) Gr o u n d
2 919
( G Y/ B K )
Se a t Re gu l a t o r S wi t c h t o Re c l i n e r
Mo t o r Do w n
DRIVER SEAT RECLINER SWITCH (Cont 'd)
Pin
3 No t Us e d
4 2 96 ( W/ P ) P o we r
5 9 1 8 ( G Y) Se a t Re gu l a t o r S wi t c h t o Re c l i n e r
Mo t o r U p
PASSENGER SEAT RECLINER SWITCH
Pin
2 919
( G Y/ B K )
Se a t Re gu l a t o r S wi t c h t o Re c l i n e r
Mo t o r Do w n
3 No t Us e d
4 517
( B K / W)
P o we r
5 918 ( GY) Se a t Re gu l a t o r S wi t c h t o Re c l i n e r
Mo t o r U p
01- 10- 12 S e a t s a n d T r a c ks
01- 10- 12
Dri ver' s Se a t Pr ogr ammabl eTown Ca r
01- 10- 13 S e a t s a n d T r a c ks 01- 10- 13
LH SEAT MODULE
CONNECTOR C1 (TOWN CAR)
K22854-A
TOWN CAR
Pin
N u mb e r C i r c u i t Ci rcui t Funct i on
1 No t Us e d
2 No t Us e d
3 No t Us e d
4 943 ( P / O ) Mi r r o r S wi t c h Ve r t i c a l Ri ght
5 942 ( R / O ) Mi r r o r Swi t c h Ho r i zo n t a l L e f t
6 945 ( Y / B L ) Mi r r o r S wi t c h Co mmo n
7 944
( DG / O )
Mi r r o r S wi t c h Ho r i zo n t a l Ri ght
8 940
( DB / O )
Mi r r o r Swi t c h Ve r t i c a l L e f t
9 919
( G Y/ B L )
Re c l i n e r Mo t o r ( Do wn )
10 918 ( GY) Re c l i n e r Mo t o r ( Up )
11 9 7 9 ( R / L B ) Se a t Swi t c h t o Fr o n t Mo t o r - L H
( Up)
12 9 7 8 ( Y / L B ) Se a t S wi t c h t o Fr o n t Mo t o r - L H
( Do wn )
13 9 8 1 ( R / W) Se a t S wi t c h t o Ho r i zo n t a l
Mo t o r - L H ( Fo r wa r d )
14 9 8 0 ( Y / W) Se a t S wi t c h t o Ho r i zo n t a l
Mo t o r - L H ( Re a r wa r d )
15 983
( R / L G )
Se a t S wi t c h t o Re a r Mo t o r - L H
( Do wn )
16 982
( Y/ L G )
Se a t S wi t c h t o Re a r Mo t o r - L H ( Up)
TK22854A
LH SEAT MODULE
V
' K22855-A
TOWN CAR
Pin
C2 - 1 952
( W/ L G )
RH Mi r r o r Ho r i zo n t a l Mo t o r
Co mmo n
C2 - 2 543 ( DG) RH Mi r r o r Ho r i zo n t a l Fe e d ( B +
Ri ght )
C2 - 3 2 7 0
( B R / O )
Me mo r y Se a t Swi t c h - Se t
C2 - 4 5 4 4 ( P ) RH Mi r r o r Ve r t i c a l Fe e d ( B + Up)
C2 - 5 953 ( W/ P ) RH Mi r r o r Ve r t i c a l Mo t o r Co mmo n
C2 - 6 947 ( Y/ R ) LH Mi r r o r Ho r i zo n t a l Mo t o r
Co mmo n
C2 - 7 5 4 0 ( R ) LH Mi r r o r Ho r i zo n t a l Fe e d ( B +
Ri ght )
C2 - 8 949 ( R / W) LH Mi r r o r Ho r i zo n t a l P o s i t i o n
Se n s o r
C2 - 9 9 4 8 ( Y / L B ) L H Mi r r o r Ve r t i c a l P o s i t i o n Se n s o r
C2 - 10 541
( DB / Y)
LH Mi r r o r Ve r t i c a l Mo t o r Fe e d
Se n s o r ( B + Up)
C2 - 11 67 6
( P K / O )
P o we r Gr o un d ( L o gi c Gr o un d )
C2 - 12 2 96 ( W/ P ) Fu s e d A c c e s s o r y Fe e d
C2 - 13 2 7 2 ( W/ O ) Me mo r y Se a t Swi t c h LED Dr i ve
C2 - 14 958
( G Y/ R)
Mi r r o r P o s i t i o n Se n s o r Su ppl y
C2 - 15 2 68
( B K / O )
Me mo r y Se a t Swi t c h P o s i t i o n 2
C2 - 16 2 67
( BR/ L G )
C2 - 17 957 ( P / W) RH Mi r r o r Ve r t i c a l P o s i t i o n Se n s o r
C2 - 18 954
( DG / O)
RH Mi r r o r Ho r i zo n t a l P o s i t i o n
Se n s o r
C2 - 19 951
( DB / W)
L H Mi r r o r Ve r t i c a l P o s i t i o n Se n s o r
01- 10- 14 Se a t s a n d T r a c ks 0 1 - 1 0 - 1 4
TOWN CAR (Cont ' d)
Pin
N u mb e r Ci rcui t Ci rcui t Funct i on
C2 - 2 0 33 ( W/ P K ) P a r k / N e u t r a l S wi t c h
C2 - 2 1 955 ( GY) Mi r r o r P o s i t i o n Se n s o r Co mmo n
C2 - 2 2 7 0 ( L B / W) To I SO 9141 Li nk
T K 2 2 8 5 5 A

a a

DRIVER'S SEAT MODULE
CONNECTOR C3
R11021-A
Pin
1 980 ( Y / W) Se a t Re gu l a t o r Swi t c h t o
Ho r i zo n t a l Mo t o r LH
2 442
( L G / O )
Ho r i zo n t a l Se n s o r t o L F Se a t
Mo d u l e
3 4 4 5
( O / L B )
Re c l i n e r Se n s o r t o L F Se a t Mo d u l e
4 981 ( R / W) Se a t Re gu l a t o r S wi t c h t o
Ho r i zo n t a l Mo t o r L H
5 447 ( O / R ) L CM t o Se a t P o s i t i o n Se n s o r (-)
6 918 ( GY) Se a t Re gu l a t o r Swi t c h t o Re c l i n e r
Mo t o r Up
7 97 9 ( R / L B ) Se a t Re gu l a t o r Swi t c h t o Fr o n t
Mo t o r L H
8 9 8 3
( R / L G )
Se a t Re gu l a t o r Swi t c h t o Re a r
Mo t o r LH
9 4 4 4
( L G / B K )
Re a r Se n s o r t o LF Se a t Mo d u l e
10 9 82
( Y/ L G )
Se a t Re gu l a t o r Swi t c h t o Re a r
Mo t o r L H
11 919
( G Y/ B K )
Se a t Re gu l a t o r Swi t c h t o Re c l i n e r
Mo t o r Do wn
12 9 7 8 ( Y / L B ) Se a t Re gu l a t o r Swi t c h t o Fo r n t
Mo t o r L H
13 No t Us e d
( Co n t i n ue d )
DRIVER'S SEAT MODULE (Cont ' d)
Pin
Number Ci rcui t Ci r c ui t Funct i on
14 452
( G Y/ R )
L CM t o Se a t P o s i t i o n S e n s o r
( Re c l i n e r S e n s o r -)
15 443
( L G / R)
Fr o n t Se n s o r t o L F Se a t Mo d u l e
16 449
( B R / P K )
Se a t P o s i t i o n Se n s o r t o L F Se a t
Mo d u l e ( Re c l i n e r Se n s o r + )
17 446 (O/W) Se a t P o s i t i o n Se n s o r t o L F Se a t
Mo d u l e ( S e n s o r + )
T R 1 1 0 2 1 A
LIGHTING CONTROL MODULE
CONNECTOR C4 R11022-A
Pin
1 186
( B R / L B )
He a t e d Re a r Wi n d o w Out put
2 175
( B K / Y )
Re l a y Fe e d
Co n n e c t o r End Vi e ws Dr i v e r s Se a t ,
Pr o gr a mma bl e
MEMORY SEAT SWITCH
R9883-A
Pin
1 2 96 ( P / W) Co mmo n P o we r
2
__
Not Us e d
3 2 67
( B R / L G )
Me mo r y 1
4 2 68
( B K / O )
Me mo r y 2
( Co n t i n ue d )
01- 10- 15
Se a t s a n d T r a c ks 01- 10- 15
Pin
N u m b e r C i r c u i t C i r c u i t F u n c t i o n
5
_
No t Us e d
6 2 7 0
( B R / O )
Se t '
7
__
No t Us e d
9 2 7 2 ( W/ O ) LED In
10 No t Us e d
SEAT CONTROL SWITCH
CONNECTOR
R7989-D
Pin
1 517
( B K / W)
P o we r
2 54 ( L G / Y) I n t e r i o r L a mp S wi t c h Fe e d
3 3 2 ( R / L B ) St a r t e r Ci r c ui t I nput
4 No t Us e d
5 60
( B K / L G )
Gr o un d
7 2 7 2 ( W/ O ) Me mo r y Se a t S wi t c h L a mp Dr i v e
8 2 7 1
( L G / W)
Me mo r y Se a t S wi t c h L a mp En a bl e
9 2 7 0
3R/ 0)
Me mo r y Se a t S wi t c h Se t
10 2 68
( B K / O )
Me mo r y Se a t S wi t c h P o s i t i o n 2
11 2 67
( B R / L G )
12 2 66 ( P / W) Me mo r y Se a t S wi t c h En a bl e
0
1
-
1
0
-
1
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01- 10- 17
Seat s and Tr ac k s 01- 10- 17
LH SEAT MODULE
K22854-A
P i n
N u mb e r Ci rcui t Ci r cui t Funct i on
1 No t Us e d
2 No t Us e d
3 No t Us e d
4
_
Not Us e d
5 Not Us e d
6 Not Us e d
7
_
No t Us e d
8 Not Us e d
9 919
( G Y/ B L )
Re c l i n e r Mo t o r ( Do wn )
10 9 18 ( GY) Re c l i n e r Mo t o r ( Up)
11 9 7 9 ( R / L B ) Se a t S wi t c h t o Fr o n t Mo t o r - L H
( Up)
12 9 9 0 ( Y / L B ) Se a t S wi t c h t o Fr o n t Mo t o r - L H
13 981 ( R / W) S wi t c h t o Ho r i zo n t a l Mo t o r - L H
14 9 8 0 ( Y / W ) S wi t c h t o Ho r i zo n t a l Mo t o r - L H
15 9 8 3
( R/ L G )
S wi t c h t o Re a r Mo t o r - L H
16 9 82
( Y/ L G )
S wi t c h t o Re a r Mo t o r - L H
T K 2 2 8 5 4 B
LH SEAT MODULE
K22855-A
Pin
Number C i r c u i t Ci rcui t Funct i on
1 No t Us e d
2 No t Us e d
3 2 7 0
( B R / O )
Me mo r y Se a t Swi t c h - Se t
4 No t Us e d
5 No t Us e d
6 No t Us e d
7 No t Us e d
8 No t Us e d
9 No t Us e d
10 No t Us e d
11 57 ( BK) Gr o un d
12 7 85
( B K / L G )
Ba t t e r y Suppl y
13 2 7 2 ( W/ O ) Me mo r y Se a t Swi t c h LED Dr i v e
14 No t Us e d
15 2 68
( B K / O)
16 2 67
( B R / L G )
17 No t Us e d
18 No t Us e d
19 No t Us e d
2 0 33 ( W/ P K ) To P a r k/ Ne u t r a l Swi t c h
2 1 No t Us e d
2 2 7 0 ( L B / W) To I SO 9141 Li n k
T K 2 2 8 5 5 B
01- 10- 18 Se a t s a n d T r a c ks 01- 10- 18
0
0 0 0 0
CONNECTOR C3
R11021-A
Pin
N u m b e r Ci rcui t Ci r cui t Funct i on
1 980 ( Y / W) Ho r i zo n t a l Mo t o r Fo r wa r d
2 442
( L G / O )
Dr i v e r ' s Se a t F WD/ R WD Se n s o r
3 445
( O / L B )
Re c l i n e r Se n s o r
4 981 ( R / W) Ho r i zo n t a l Mo t o r Re a r wa r d
5 447 ( O / R ) Co mmo n
6 918 ( GY) Re c l i n e r Mo t o r Fo r wa r d
7 9 7 9 ( R / L B ) Fr o n t Mo t o r Do wn
8 983
( R / L G )
Re a r Mo t o r Do wn
9 444
( L G / B K )
Dr i v e r ' s Se a t Re a r U p / Do w n
Se n s o r
10 982
( Y/ L G )
Re a r Mo t o r Up
11 919
( G Y/ B K )
Re c l i n e r Mo t o r Re a r wa r d
12 9 7 8 ( Y / L B ) Fr o n t Mo t o r Up
13 No t Us e d
14 452
( G Y/ R)
Re c l i n e r Se n s o r Co mmo n
15 443
( L G / R )
Dr i v e r ' s Se a t Fr o n t U p / Do w n
Se n s o r
16 449
( B R / P K )
Re c l i n e r Se n s o r Suppl y
17 446 ( O / W) P o t e n t i o me t e r Suppl y
T R 1 1 0 2 1 B
LIGHTING CONTROL MODULE
CONNECTOR C4
R11022-A
Pin
1 12
( L B / B K )
2 196
( DB / O )
4 ) I 5 j (
6
MEMORY SWITCH CONNECTOR C5
R11024-A
Pin
1 54 ( L G / Y) B +
2 2 67
( B R / L G )
Me mo r y # 1
3 2 68
( B K / O )
Me mo r y # 2
4 2 7 0
( B R / O )
Se t Swi t c h
6 2 7 2 ( W/ O ) Swi t c h I l l umi n a t i o n
I n s p e c t i o n a n d Ve r i f i c a t i o n
1. Verify the vehicle owner' s original concern by
operati ng the power seat(s) t o dupl i cate the
condition.
2. Inspect t o determine if one of the following
mechanical or el ectri cal concerns appl y:
01- 10- 19 Se a t s a n d T r a c ks
01- 10- 19
Me c h a n i c a l E l e c t r i c a l !
Se a t t r a c k s o b s t r u c t e d .
Se a t a t l i mi t ( s) of t r a v e l .
Da ma g e d l umba r s u p p o r t
h o s e .
Da ma g e d l umba r s u p p o r t
s wi t c h a n d v a l v e .
Op e n h i gh c ur r e n t f u s e
pa n e l f use n umbe r " K " ,
40A.
Op e n i n st r ume n t pa n e l f u s e
n umbe r " 8 " , 15A.
Op e n i n-l i ne f use " P o we r
A n t e n n a / Me mo r y Se a t " ,
10A.
L o o s e , c o r r o d e d o r
d a ma g e d c o n n e c t o r s .
Da ma g e d s wi t c h e s .
Da ma g e d mo t o r s .
3. If t he i nspecti on reveal s obvi ous concern(s) t hat
can be readi l y identified, servi ce as requi red. If
t he concern(s) remai ns after t he i nspecti on,
determi ne the sympt om(s) and go t o t he
Sympt om Chart.
Sympt om Chart
Use Rotunda 73 Digital Multimeter 105-00051 or
equivalent t o perform el ectri cal pinpoint t est s.
SEATS AND TRACKS
Power Seat Completely
Inoperati ve(Base Standard
Power Seats Only)
Circuitry open / short ed.
Damaged Swi tch.
Damaged motor assembly.
GOt o Pinpoint Test A.
Forward/Backward Sliding
Operation Does Not Work Properly
Circuitry open / shor t ed.
Damaged swi t ch.
Up/Down Tilting Operation Does
Not Work Properly
Circuitry open/short ed.
Damaged swi t ch.
GOt o Pi npoi nt Test C.
Up/Down Lifting Operation Does
Not Work Properly
Circuitry open / short ed.
Damaged swi t ch.
GO to Pinpoint Test D.
Power Lumbar / Bolster Support
Does Not Work Properly
Circuitry open / shor t ed.
Damaged swi t ch.
Mot or/pump damaged.
Air bar or hose damaged.
Power Lumbar/Bol st er Support
Does Not Work Properly
(Pneumati c)(Base Standard
Power Seats Only)
Damaged pump.
Damaged hose.
Damaged pad.
Memory Seat Does Not Work
Properly
Damaged memory seat swi t ch.
Damaged memory seat module.
Damaged memory seat sensors.
Pi npoi nt Te st sTown Car
PINPOINT TEST A: POWER SEAT COMPLETELY INOPERATIVE
A1 TEST MOTORS
Yes
No
SYSTEM is operating
normally.
GO t o A2 .
Press driver's seat forward swi tch for 2 seconds.
Press driver's seat rearward switch for 2 seconds.
Press driver's seat forward swi tch for 2 seconds.
Repeat for driver's seat front up/ down, rear
up/down and recline.
Does seat move as e xpe c t e d f or as l ong as t he
swi t c h is hel d?
Yes
No
SYSTEM is operating
normally.
GO t o A2 .
01- 10- 2 0 Se a t s a n d T r a c ks 0 1 - 1 0 - 2 0
PINPOINT TEST A: POWER SEAT COMPLETELY INOPERATIVE (Cont i nued)
A2 T E S T R E S U L T S I N O N E M O T O R F A I L U R E
Ye s
N o
GO t o A16.
GO to A3.
T e s t p e r f o r m e d a s i n A1.
Does one motor not move or only moves in one
di rect i on?
Ye s
N o
GO t o A16.
GO to A3.
A3 MO T O R S T O P S B E F O R E S W I T C H I S R E L E A S E D
Yes [ >
No
GO t o A16.
GO t o A4.
Does one or more motor move for one second
then st ops before swi t ch is r el eased?
Yes [ >
No
GO t o A16.
GO t o A4.
A4 NOT MOTOR MOVEMENT
Yes
No
CHECK Fuse 8 and circuit
breaker 14. If good, GO to
A5.
REPEAT A 1.
Do no motors move?
Yes
No
CHECK Fuse 8 and circuit
breaker 14. If good, GO to
A5.
REPEAT A 1.
A5 T E S T M O D U L E
Yes
No
GO t o A12 .
GO t o A6.
P r e s s a n y s e a t s w i t c h .
Do relays in module c l i c k?
Yes
No
GO t o A12 .
GO t o A6.
A6 C H E C K F U S E
Yes
No
GO t o A10.
GO to A7.
T e s t f u s e m o u n t e d i n s i d e o f d r i v e r ' s s e a t m o d u l e .
Is f use good?
Yes
No
GO t o A10.
GO to A7.
A7 R E P L A C E F U S E
Yes
No
module. Make sure that
the floor of vehicle is
completely dry before
installing new module.
RETEST system.
GO to A8.
D i s c o n n e c t c o n n e c t o r s P1 a n d P3 f r o m f r o n t o f
d r i v e r ' s s e a t m o d u l e .
R e p l a c e f u s e .
R e c o n n e c t m o d u l e .
Does f use blow?
Yes
No
module. Make sure that
the floor of vehicle is
completely dry before
installing new module.
RETEST system.
GO to A8.
A8 T E S T S E A T F O R W A R D A N D U P
Yes
No
SERVICE circuit
associ at ed with motor
which caused fuse t o
blow for short to ground:
Horizontal Forward:
Circuit 981
Front Up: Circuit 979
Rear Up: Circuit 983
Recline Forward: Circuit
918
Also, CHECK for bad
motor.
GO to A9.
T e s t f o w a r d a n d u p s w i t c h f o r e a c h m o t o r .
N o t e a f t e r e a c h s w i t c h i f f u s e b l o w s .
Does f use blow?
Yes
No
SERVICE circuit
associ at ed with motor
which caused fuse t o
blow for short to ground:
Horizontal Forward:
Circuit 981
Front Up: Circuit 979
Rear Up: Circuit 983
Recline Forward: Circuit
918
Also, CHECK for bad
motor.
GO to A9.
A9 TEST SEAT REARWARD AND DOWN
Yes
No
CHECK following ci rcui ts
for short to ground:
Horizontal Rearward:
Circuit 980
Front Down: Circuit 978
Rear Down: Circuit 982
Recline Rearward: Circuit
919
Note that these are t i ed
together internally to the
DSM. Any one shorted to
ground will cause any of
the others to blow fuse.
RETEST system.
T e s t r e a r w a r d a n d d o w n s w i t c h f o r a n y m o t o r .
N o t e i f f u s e b l o w s .
Does f use blow?
Yes
No
CHECK following ci rcui ts
for short to ground:
Horizontal Rearward:
Circuit 980
Front Down: Circuit 978
Rear Down: Circuit 982
Recline Rearward: Circuit
919
Note that these are t i ed
together internally to the
DSM. Any one shorted to
ground will cause any of
the others to blow fuse.
RETEST system.
01- 10- 2 1 Se a t s a n d T r a c ks 01- 10- 2 1
A10 TEST FOR POWER
Yes
No
GO t o A 11.
SERVICE Circuit 517.
RETEST system.
Test for voltage on Pin 1 of connector P3 t o driver's
seat module.
Is vol t age readi ng B+ ?
Yes
No
GO t o A 11.
RETEST system.
A11 TEST FOR GROUND
Yes
No
SERVICE Circuit 57.
RETEST system.
Check for continuity from Pin 2 of connector P3 of
driver's seat module to ground.
Yes
No
SERVICE Circuit 57.
RETEST system.
A12 TEST FOR POWER
Yes
No
GO t o A13.
RETEST system.
Test for voltage on Pin B12 of connector P2 to
Yes
No
GO t o A13.
RETEST system.
A13 TEST FOR GROUND
Yes
No
GO t o A14.
RETEST system.
Check for continuity from Pin B11 of connector P2 of
driver's seat module to ground.
Is t her e c ont i nui t y ?
Yes
No
GO t o A14.
RETEST system.
A14 TEST SWITCH STATUE WITH NEW GENERATION STAR
(NGS) TESTER
Yes
No
SERVICE circuit for stuck
swi tch or short to B+ .
RETEST system.
GO t o A15.
Connect New Generation Star Tester to Data Link
Connector.
Request driver's seat swi tch status PID.
Does dat a i ndi cat e swi t c h act i ve?
Yes
No
swi tch or short to B+ .
RETEST system.
GO t o A15.
A15 TEST ALL SWITCHES STATUS
Yes
No
SERVICE Circuit 296 to
seat swi tches. RETEST
system.
While holding seat swi t ch, request driver's seat
swi tch status PID.
Repeat for each swi t ch.
Does dat a i ndi cat e swi t ches act i ve?
Yes
No
seat swi tches. RETEST
system.
A16 TEST SWITCH
Yes
No
GO to A17.
REPEAT A15.
Press swi t ch for forward motion on motor which
does not move.
Press swi t ch for rearward motion on motor which
does not move.
Is t her e any mot i on? Do rel ays " c l i c k" ?
Yes
No
GO to A17.
REPEAT A15.
A17 TEST FOR SEAT OR RELAY OPERATION
Yes
No
GO to A20.
GOt o A18.
Test performed as in A16.
Does rel ay c l i c k or seat move in one di r e c t i on,
but not t he ot he r ?
Yes
No
GO to A20.
GOt o A18.
A18 TEST FOR FAILURE OF SEAT TO MOVE
Yes
No
SERVICE both circuits to
motor for open circuit.
SERVICE motor.
SERVICE seat t rack for
sti cki ng. RETEST system.
GO to A19.
Does rel ay cl i ck i n bot h di r ect i ons but seat does
not move?
Yes
No
SERVICE both circuits to
motor for open circuit.
SERVICE motor.
SERVICE seat t rack for
sti cki ng. RETEST system.
GO to A19.
A19 TEST FOR FAILURE OF BOTH SEAT AND RELAY
Yes
No
GO to A20.
REPEAT A16.
Does rel ay f ai l t o cl i ck and seat f ai l t o move?
Yes
No
GO to A20.
REPEAT A16.
A20 TEST DRIVER'S SEAT SWITCH
Yes
No
switch or short to B+ .
RETEST system.
GO to A21.
Connect New Generation Star Tester t o Data Link
Connector.
Request driver's seat swi tch status PID.
Does dat a i ndi cat e swi t ch act i ve?
Yes
No
switch or short to B+ .
RETEST system.
GO to A21.
01- 10- 22 Se a t s a n d T r a c ks 01- 10- 22
T E ST STEP RESULT ACTION TO TAKE
A21 TEST SWITCHES
Yes
No
SERVICE Circuit 296 t o
seat swi t ches. RETEST
syst em.
W h i l e h o l d i n g s e a t s w i t c h , request d r i v e r ' s s e a t
s w i t c h s t a t u s P I D.
R e p e a t f o r e a c h s w i t c h .
Does data indicate swi t ches act i ve?
Yes
No
SERVICE Circuit 296 t o
seat swi t ches. RETEST
syst em.
A22 TEST POTENTIOMETER FEEDBACK
Yes
No
GO to A23.
Read voltage on potentiometer input on connector
P1 of driver's seat module for motor(s) with
problem:
Horizontal:
Circuit 442 on Pin 2
Front Up/Down:
Rear Up/Down:
Recline:
Is vol t age readi ng on all ci r cui t s l ess t han 0.5
vol t s?
Yes
No
GO to A23.
A23 TEST FOR RECLINE CIRCUIT VOLTAGE
Yes
No
and 449 for open circuit
or s h o r t t o ground.
RETEST system.
GO to A24.
Is recl i ne ci r cui t readi ng less t han 0.5 vol t s?
Yes
No
and 449 for open circuit
or s h o r t t o ground.
RETEST system.
GO to A24.
A24 TEST FOR VOLTAGE READING (EXCEPT RECLINE)
Yes
No
SERVICE Circuit 447 for
ground. RETEST system.
GO to A25.
Is readi ng f or all ci r cui t s except recl i ne less t han
0.5 vol t s?
Yes
No
GO to A25.
A25 TEST FOR ANY CIRCUIT VOLTAGE READING (EXCEPT
RECLINE)
Yes
No
(Front Up/Down), 444
(Rear Up / Down), or 442
(Horizontal) and Circuit
447 into individual
potentiometer for open
circuit or short to ground.
RETEST system.
GO to A26.
Is readi ng f or any ci r cui t e xc e pt recl i ne less t han
0.5 vol t s?
Yes
No
(Front Up/Down), 444
(Rear Up / Down), or 442
(Horizontal) and Circuit
447 into individual
potentiometer for open
circuit or short to ground.
RETEST system.
GO to A26.
A26 TEST FOR POTENTIOMETER FUNCTION
Yes
No
SERVICE potentiometer.
BE sure that entire
potentiometer is seated
properly on rear of motor.
RETEST system.
GO to A27.
Is vol t age readi ng an i nput of pot ent i omet er
bet ween 0.5 and 4.5 vol t s?
Yes
No
SERVICE potentiometer.
BE sure that entire
potentiometer is seated
properly on rear of motor.
RETEST system.
GO to A27.
A27 TEST FOR ANY/ALL VOLTAGES (EXCEPT RECLINE)
Yes
No
open circuit. RETEST
system.
GOt o A28.
Are any or all vol t age readi ngs e xc e pt recl i ne
bet ween 4.5 and 5 vol t s?
Yes
No
system.
GOt o A28.
A28 TEST FOR VOLTAGE ON RECLINE CIRCUIT
Yes
No
system.
GOt o A29.
Is vol t age readi ng on recl i ne ci r cui t bet ween 4.5
and 5 vol t s?
Yes
No
system.
GOt o A29.
01- 10- 2 3 Se a t s a n d T r a c ks 01- 10- 2 3
A29 TEST FOR VOLTAGE ON ALL CIRCUITS
Yes
No
DISCONNECT connector
from driver's seat
module. TEST all
potentiometer Circuits
445, 449, 452, 443, 442,
444, 447 and 446 to seat
potentiometers and (for
Town Car only), Circuit
949, 951, 954, 955, 957
and 958 t o mirror
adj ustment
potentiometers for short
t o B+. NOTE that any of
these ci rcui ts shorted to
B+ will cause all motors
t o operate improperly
during memory operati on,
and all seat motors to
"j o g" during manual
motion. RETEST system.
REPEAT A22.
Does voltage reading on all ci rcui ts exceed 5
vol t s?
Yes
No
DISCONNECT connector
from driver's seat
module. TEST all
potentiometer Circuits
445, 449, 452, 443, 442,
444, 447 and 446 to seat
potentiometers and (for
Town Car only), Circuit
949, 951, 954, 955, 957
and 958 t o mirror
adj ustment
potentiometers for short
t o B+. NOTE that any of
these ci rcui ts shorted to
B+ will cause all motors
t o operate improperly
during memory operati on,
and all seat motors to
"j o g" during manual
motion. RETEST system.
REPEAT A22.
PINPOINT TEST B: FORWARD /BACKWARD SLIDING OPERATION DOES NOT WORK PROPERLY
B1 CHECK SEAT MOTOR FORWARD / BACKWARD
OPERATION
Yes
No
LEAVE jumper wires
connected to supply,
being careful to not touch
ground. GO to B2.
REPLACE power seat
motor assembly.
RESTORE vehi cle.
RETEST system.
Disconnect power motor connector.
Using a j umper wire connected t o battery posi ti ve,
connect other end to Pin 1, Circuit 981 (R/ W) driver,
Pin 1, Circuit 987 (R / W) passenger. Refer t o
connector end vi ews.
Using a second j umper wi re, connect one end t o Pin
2, Circuit 980 (Y/ W) driver, Pin 2, Circuit 986 (Y/ W)
passenger, momentarily connect other end to a
known good ground.
Observe motor operation as j umper wire is
grounded.
Reverse j umper wi res and observe motor operati on.
Di d seat move pr oper l y ?
Yes
No
LEAVE jumper wires
ground. GO to B2.
REPLACE power seat
motor assembly.
RESTORE vehi cle.
RETEST system.
B2 CHECK POWER SEAT FORWARD/BACKWARD
CIRCUITS
Yes
No
TEST power seat swi t ch.
RESTORE vehicle.
RETEST system.
for open. RESTORE
Reconnect power seat motor.
Using a j umper wire connected t o battery posi ti ve,
connect other end to Pin 1, Circuit 981 (R/ W) driver,
Pin 1, Circuit 987 (R/ W) passenger, of swi tch
connector. Refer to connector end views.
Using a second j umper wi re, connect one end to Pin
6, Circuit 980 (Y/ W) driver, Pin 6, Circuit 986 (Y/ W)
passenger, of swi tch connector, momentarily
connect other end to a known good ground.
grounded.
Yes
No
RESTORE vehicle.
RETEST system.
for open. RESTORE
01- 10- 24 Seat s and Tr acks 0 1 - 1 0 - 2 4
PINPOINT T E ST C: UP/DOWN TILTING OPERATION DOES NOT WORK PROPERLY
C1 CHECK SEAT MOTOR UPWARD / DOWNWARD
OPERATION
Yes
No
LEAVE j umper wires
connected t o supply,
ground. GO to C2.
REPLACE power seat
motor assembly.
RESTORE vehicle.
RETEST system.
Disconnect power motor connector.
U s i n g a j u m p e r w i r e c o n n e c t e d t o b a t t e r y p o s i t i v e ,
connect other end to Pin 3, Circuit 978 ( Y/ LB)
driver, Pin 3, Circuit 984 ( Y/ LB) passenger, of
swi tch connector. Refer to connector end views.
5, Circuit 979 (R/ LB) driver, Pin 5, Circuit 985
(R/ LB) passenger, momentarily connect other end
of swi tch connector to a known good ground.
Yes
No
LEAVE j umper wires
connected t o supply,
ground. GO to C2.
REPLACE power seat
motor assembly.
RESTORE vehicle.
RETEST system.
C2 CHECK POWER SEAT MOTOR TILTING CIRCUITS
Yes
No
RESTORE vehicle.
RETEST system.
for open. RESTORE
Using a jumper wire connected to battery posi ti ve,
connect other end to Pin 2, Circuit 979 (R/ LB)
driver, Pin 2, Circuit 985 (R/ LB) passenger.
4, Circuit 978 (Y/ LB) driver, Pin 4, Circuit 984
(Y / LB) passenger, refer to connector end vi ews,
momentarily connect other end to a known good
ground.
Observe motor operati on as j umper wire is
grounded.
Di d seat move pr ope r l y ?
Yes
No
RESTORE vehicle.
RETEST system.
for open. RESTORE
PINPOINT TEST D: UP/DOWN LIFTING OPERATION DOES NOT WORK PROPERLY
D1 CHECK SEAT MOTOR UPWARD / DOWNWARD
OPERATION
Yes
No
LEAVE j umper wires
ground. GO t o D2 .
REPLACE power seat
motor assembly.
RESTORE vehicle.
RETEST system.
Disconnect power motor connecti on.
Using a j umper wire connected to battery positive,
connect other end t o Pin 4, Circuit 983 (R / LG)
driver, Pin 4, Circuit 989 (R/LG) passenger. Refer to
connector end vi ews.
Using a second j umper wi re, connect one end t o Pin
6, Circuit 982 (Y/LG) driver, Pin 6, Circuit 988
(Y / LG) passenger, momentarily connect other end
to a known good ground.
grounded.
Reverse j umper wires and observe motor operati on.
Yes
No
LEAVE j umper wires
ground. GO t o D2 .
REPLACE power seat
motor assembly.
RESTORE vehicle.
RETEST system.
D2 CHECK POWER SEAT MOTOR TILTING CIRCUITS
Yes
No
RESTORE vehicle.
RETEST system.
for open. RESTORE
vehicle. RETEST system.
Using a j umper wire connected to battery posi ti ve,
connect other end t o Pin 7, Circuit 983 (R / LG)
driver, Pin 7, Circuit 989 (R/LG) passenger, of
swi t ch connector, refer to connector end views.
8, Circuit 982 (Y/ LG) driver, Pin 8, Circuit 988
(Y/ LG) passenger, momentarily connect other end
t o a known good ground.
grounded. Reverse j umper wires per chart and
observe motor operati on.
Di d seat move pr ope r l y ?
Yes
No
RESTORE vehicle.
RETEST system.
for open. RESTORE
01- 10- 2 5 Se a t s a n d T r a c ks
01- 10- 2 5
PINPOINT TEST E: POWER LUMBAR/BOLSTER SUPPORT DOES NOT WORK PROPERLY
E1 CHECK GROUND CIRCUIT AT PUMP
Yes
No
GOt o E2 .
RESTORE vehi cle.
RETEST system.
Disconnect connector at front seat back pad
adj usting pump.
Using a multimeter, connect one lead of ohmmeter
to Circuit 57 (BK) at connector and the other lead to
a known good ground.
Read resi stance.
Yes
No
GOt o E2 .
RESTORE vehi cle.
RETEST system.
E2 CHECK SUPPLY AT FRONT SEAT BACK PAD
ADJUSTING PUMP
Yes
No
GOt o E7 .
GOt oES.
With pump di sconnected, connect one lead of
voltmeter to Circuit 490 (R) and the other lead t o a
known good ground.
Acti vate seat regulator control swi tch to inflate
posi ti on.
Measure voltage.
Is vol t age 10.5v or more?
Yes
No
GOt o E7 .
GOt oES.
E3 CHECK CIRCUIT 490 AT SWITCH
Yes
No
SERVICE Circuit 490 (R).
RESTORE vehi cle.
RETEST system.
GOt o E4.
Remove seat regulator control swi t ch.
Connect harness to seat regulator control swi t ch.
Using a test lamp, back-probe Circuit 490 (R) and
connect other lead to known good ground.
Acti vate swi tch t o inflate posi ti on.
Di d l amp i l l umi nat e?
Yes
No
SERVICE Circuit 490 (R).
RESTORE vehi cle.
RETEST system.
GOt o E4.
E4 CHECK POWER SUPPLY TO SEAT REGULATOR
CONTROL SWITCH
Yes
No
REPLACE seat lumbar
regulator control swi t ch.
RESTORE vehi cle.
RETEST syst em.
GO to E5.
Wi th seat regulator control removed, connect t est
lamp between Circuit 517 (BK/ W) and a known
good ground.
Disconnect seat regulator control swi tch harness.
Did t est l amp i l l umi nat e?
Yes
No
REPLACE seat lumbar
RESTORE vehi cle.
RETEST syst em.
GO to E5.
E5 CHECK CONTINUITY OF CIRCUIT 517 (BK/ W)
Yes
No
GO to E6.
SERVICE open in Circuit
517 (BK/ W). RESTORE
Locat e and remove circuit breaker for seat
Using an ohmmeter, connect one lead to Circuit 517
at seat and other lead at fuse panel seat circuit
breaker output.
Read resi st ance.
Yes
No
GO to E6.
517 (BK/ W). RESTORE
E6 CHECK SUPPLY FROM FUSE PANEL
Yes
No
SERVICE circuit from fuse
panel to seat regulator
control swi t ch. RESTORE
SERVICE circuit from
battery to fuse panel.
RESTORE vehi cle.
RETEST system.
Locat e and remove circuit breaker for seat
Connect test lamp between known good ground and
battery side of circuit breaker cavity.
Yes
No
SERVICE circuit from fuse
panel to seat regulator
control swi t ch. RESTORE
SERVICE circuit from
battery to fuse panel.
RESTORE vehi cle.
RETEST system.
E7 CHECK AIRFLOW AT FRONT SEAT BACK PAD
ADJUSTING PUMP
Yes
No
GO to E8.
REPLACE pump.
RESTORE vehi cle.
RETEST syst em.
Remove front seat back pad adj usting hose from
pump.
Acti vate seat regulator control swi tch to inflate
posi ti on.
Air should be felt at pump opening.
Was air f el t c omi ng f r om pump openi ng?
Yes
No
GO to E8.
REPLACE pump.
RESTORE vehi cle.
RETEST syst em.
01- 10- 2 6 Se a t s a n d T r a c ks
01- 10- 2 6
PINPOINT TEST E: POWER LUMBAR/BOLSTER SUPPORT DOES NOT WORK PROPERLY (Cont i nued)
E8 CHECK AIRFLOW AT SEAT REGULATOR CONTROL
SWITCH
Yes
No
GO t o E9.
SERVICE front seat back
pad adj usting hose.
RESTORE vehi cle.
RETEST system.
R e c o n n e c t front s e a t b a c k p a d a d j u s t i n g h o s e t o
pump.
D i s c o n n e c t f r o n t s e a t b a c k p a d a d j u s t i n g h o s e a t
s e a t r e g u l a t o r c o n t r o l s w i t c h f r o m f r o n t s e a t b a c k
pad adj usting pump.
A c t i v a t e s e a t r e g u l a t o r c o n t r o l s w i t c h t o i n f l a t e
posi t i on.
A i r s h o u l d b e f e l t f r o m o p e n h o s e .
Was air f el t at open hose ?
Yes
No
GO t o E9.
SERVICE front seat back
pad adj usting hose.
RESTORE vehi cle.
RETEST system.
E9 CHECK SYSTEM FOR LEAKS
Yes
No E>
SYSTEM OK. RESTORE
GOt o EI O.
R e c o n n e c t f r o n t s e a t b a c k p a d a d j u s t i n g h o s e a t
seat regulator control swi t ch.
Disconnect front seat back pad adj usting hose at
front seat back pad adj uster and connect an in-line
pressure gauge.
Act i vat e seat regulator control swi t ch to inflate
posi ti on until gauge reads 3447 kPa.
System should hold pressure for three hours.
Af t er t hree hours, is readi ng 32. 41 kPa or mor e?
Yes
No E>
SYSTEM OK. RESTORE
GOt o EI O.
FRONT SEAT BACK
PAD ADJUSTING PUMP
65630 / X
SEAT BACK _
L
tT^f
CONTROL SWITCH ~ ~ JL^JJ
. AND HOUSING 14C715
1
C i n ^ W F R O N T S E A T
l 4 l ^ 3 ^ W 0 ^ BACK PAD
j ^ ^ N k ^ X ^ ADJUSTER 65500
I T
FRONT SEAT BACK { j I ^ SU
PAD ADJUSTING I
HOSE 65528 ^ < ^ J J y
^ S N . < f ^ V IN-LINE
N \ PRESSURE
X V YY GAUGE
R9 8 6 5 - A
E10 CHECK FRONT SEAT BACK PAD ADJUSTER FOR
LEAKS
Yes
No
REPLACE seat regulator
control swi tch. RESTORE
REPLACE front seat back
pad adj uster. RESTORE
Remove in-line pressure.
Insert hand pump into front seat back pad adj uster.
Inflate front seat back pad adj uster to 34.47 k P a (5
psi ).
Front seat back pad adj uster should hold pressure
for three hours.
Af t er t hree hours, i s readi ng 32. 41 kPa or more?
Yes
No
REPLACE seat regulator
control swi tch. RESTORE
REPLACE front seat back
pad adj uster. RESTORE
PINPOINT TEST F: MEMORY SEAT DOES NOT WORK PROPERLY
F1 TEST SET LED
Yes
No
COMMAND LED off. GO
t o F2 .
CHECK Fuse No. 8. IF
fuse is good, GO to F10.
Connector. Put ignition to RUN.
Command set LED on.
Does set l i ght i l l umi nat e?
Yes
No
COMMAND LED off. GO
t o F2 .
CHECK Fuse No. 8. IF
01- 10- 2 7 Se a t s a n d T r a c ks 01- 10- 2 7
PINPOINT TEST F: MEMORY SEAT DOES NOT WORK PROPERLY (Cont i nued)
F2 TEST SWITCHES
Yes
No
short t o battery or stuck
GOt o F3.
N o t e t h a t w h e n t h e i g n i t i o n i s i n R u n , Accessory o r
during Delayed Accessory period, the memory 1 and
memory 2 swi tch PIDs will toggle on and off. This is
normal and can be avoided by turning the ignition off
and opening any door. If no message is sent within
two minutes after the ignition is turned off, the
module will not respond to the tester. Cycle the
ignition and try again.
With driver's door ajar, turn ignition to run, then off.
Request memory set and recall swi tch PID.
Is set swi t c h act i ve?
Yes
No
short t o battery or stuck
GOt o F3.
F3 TEST FOR " 1 " SWITCH CONDITION
Yes
No .
short to battery or stuck
GO to F4.
Test performed as in G2.
Is " 1 " swi t ch act i ve?
Yes
No .
GO to F4.
F4 TEST FOR "2" SWITCH CONDITION
Yes
No
GO to F5.
Test performed as in G2.
Is " 2 " swi t ch act i ve?
Yes
No
GO to F5.
F5 TEST SET SWITCH
Yes
No
GO to F6.
open circuit or bad
With driver's door ajar, turn ignition to run, then off.
While holding set swi t ch, request memory set and
recall swi tch PID.
Does dat a i ndi cat e set swi t c h act i ve?
Yes
No
GO to F6.
open circuit or bad
F6 TEST"1" SWITCH
Yes
No
GO t o F7 .
open circuit or bad
Turn ignition to run, then off.
While holding " 1 " swi t ch, request memory set and
recall swi tch PID.
Does dat a i ndi cat e " 1 " swi t ch act i ve?
Yes
No
GO t o F7 .
open circuit or bad
F7 TEST "2" SWITCH
Yes B>
No t>
GO to F8.
open circuit or bad
. Turn ignition to run, then off.
While holding set swi t ch, request memory set and
recall switch PID.
Does dat a i ndi cat e " 2 " swi t ch act i ve?
Yes B>
No t>
GO to F8.
open circuit or bad
F8 TEST FOR MEMORY
Yes
No
SYSTEM operating
normally.
GOt o F9.
NOTE that if battery or
driver's seat module has
been di sconnected, or if
DSM has been in
Diagnostic Mode, no
memory recall will occur.
GO to A7.
Move seat and mirrors to desi red posi t i on.
Press set button.
Within 5 seconds, press " 1 " swi t ch.
Move seat and mirrors to seconds posi t i on.
Press set button.
Within 5 seconds, press "2" swi t ch.
Press " 1 " swi t ch.
Press "2" swi t ch.
Does seat recal l t o set posi t i ons?
Yes
No
SYSTEM operating
normally.
GOt o F9.
NOTE that if battery or
driver's seat module has
been di sconnected, or if
DSM has been in
Diagnostic Mode, no
memory recall will occur.
GO to A7.
F9 TEST PARK/NEUTRAL INPUT
Yes
No
system.
Connector.
Request Park/ Neutral swi tch PID.
Does PID i ndi cat e Park or Neut ral ?
Yes
No
system.
01- 10- 2 8 Se a t s a n d T r a c ks 01- 10- 2 8
PINPOINT TEST F: MEMORY SEAT DOES NOT WORK PROPERLY (Cont i nued)
F10 TEST DSM POWER
Yes
No
GOt o F11.
Town Car, Circuit 785 for
Crown Vi ct ori a, Grand
Marquis. RETEST
system.
D i s c o n n e c t c o n n e c t o r B f r o m d r i v e r ' s s e a t m o d u l e .
T e s t f o r v o l t a g e o n P i n B12.
Is vol t age r eadi ng B+ ?
Yes
No
GOt o F11.
Town Car, Circuit 785 for
Marquis. RETEST
system.
F11 TEST LED OUTPUT
Yes
No
RECONNECT module. GO
t o F12.
Using a j umper wi re, short pins B12 to B13.
Does memory LED i l l umi nat e?
Yes
No
RECONNECT module. GO
t o F12.
F12 TEST CIRCUIT 272
Yes
No
GOt o F13.
RETEST syst em.
Disconnect memory set swi t ch.
Command memory set LED on.
Read voltage on Circuit 272 into set swi t ch.
Is vol t age r eadi ng B+ ?
Yes
No
GOt o F13.
RETEST syst em.
F13 TEST GROUND
Yes
No
REPLACE set swi t ch.
RETEST syst em.
SERVICE Circuit 57.
RETEST syst em.
Test for continuity to ground on Circuit 57 into set
swi t ch.
Is t here c ont i nui t y ?
Yes
No
REPLACE set swi t ch.
RETEST syst em.
SERVICE Circuit 57.
RETEST syst em.
J 4
Q
SEAT BACK
CONTROL SWITCH
SEAT REGULATOR
CONTROL 14A701 SWITCH
R7498-C
C o m p o n e n t T e s t s
S w i t c h T e s t
NOTE: These t est s are t o be performed only when
di rected by a pinpoint t est .
To test when separat ed f rom connector, using
sel f-powered t est lamp or ohmmeter such as Rotunda
73 Digital Multimeter 105-00051 or equivalent.
01- 10- 29 Seat s and Tr acks 01- 10- 29
Se a t Regulat or Cont rol Swi t c hTo wn Ca r
REARWARD
SWITCH ASSY
14A701
REAR TILT
FRONT TILT
N12447-A
SWITCH TERMINALS
SWITCH POSITIONS N12448-A
4- Wa y
Knob Rear Ti lt Fr ont Ti lt Cont i nui t y
Ne ut r a l Ne ut r a l Ne ut r a l 1- 2 - 4- 5- 6- 7 - 8- ( #3
i s o l a t e d )
Fo r wa r d Ne ut r a l Ne ut r a l 2- 3, 1-4-5-6-7-8
Re a r wa r d Ne ut r a l Ne ut r a l 3- 8, 1-2-4-5-6-7
Up Ne ut r a l Ne ut r a l 3- 4- 6, 1-2-4-6-8
Do wn Ne ut r a l Ne ut r a l 3- 5- 7 , 1-2-4-6-8
Ne ut r a l Up Ne ut r a l 3- 6, 1-2-4-5-7-8
Ne ut r a l Do wn Ne ut r a l 3- 7 , 1-2-4-5-6-8
Ne ut r a l Ne ut r a l Up 3- 4, 1-2-5-6-7-8
Ne ut r a l Ne ut r a l Do wn 3- 5, 1-2-4-6-7-8
Vol t age Test
CONNECTOR ATTACHED TO SWITCH
TO TEST SWITCH WHILE STILL
ATTACHED TO CONNECTOR
TERMINAL NO. 1 IS ALWAYS GROUNDED
AND TERMINAL NO. 3 IS ALWAYS POWER
N2469-K
4-Way
Knob Rear Ti l t Front Ti lt Power Ground
Ne ut r a l Ne ut r a l Ne ut r a l 3 Onl y 1- 2- 3- 4- 5- 6- 7- 8
Fo r wa r d Ne ut r a l Ne ut r a l 2- 3 1-4-5-6-7-8
Re a r wa r d Ne ut r a l Ne ut r a l 3-8 1-2-4-5-6-7
Up Ne ut r a l Ne ut r a l 3- 4- 6 1-2-5-7-8
Do wn Ne ut r a l Ne ut r a l 3- 5- 7 1-2-4-6-8
Ne ut r a l Up Ne ut r a l 3-6 1-2-4-5-7-8
Ne ut r a l Do wn Ne ut r a l 3-7 1-2-4-5-6-8
Ne ut r a l Ne ut r a l Up 3-4 1-2-5-6-7-8
Ne ut r a l Ne ut r a l Do wn 3-5 1. 2-4-6-7-8
01- 10- 30 Se a t s a n d T r a c ks 01- 10- 30
REMOVAL A N D INSTALLATION
Se a t , Dr i v er o r P a s s e n g e r P o w e r Se a t
1. NOTE: If some of t he removal and installation
st eps do not appl y t o t he parti cul ar vehi cl e being
servi ced, proceed t o t he next st ep and revi ew t he
appropri ate illustrations shown. Unless ot herwi se
not ed, the illustrations shown are t ypi cal of split
bench front seat assembl i es, arm rest s (front and
rear), and rear seat cushion and back
assembl i es.
Remove front seat t rack t o floor insulators
( 61748) (if so equi pped) t o expose nuts and
washer s and/ or bol ts.
Seat , Dr i ver a nd Passenger
4.
Remove nuts and washers and / or bol ts retaining
seat t r ack assembl y to f ront f l oor pan ( 11135) .
Lift t he seat up enough t o di sconnect t he seat
harness connect or and di sconnect connect or (if
so equi pped). Remove the seat and t r ack
assembl y f rom t he vehicle.
NOTE: When installing, ti ghten t he retaining bolts
and t he out board nut t o 17-23 N-m (13-17 Ib-ft).
Tighten t he i nboard nut t o 68- 92 N-m ( 50- 68 Ib-ft).
PASSENGER SEAT SHOWN
DRIVER SIDE TYPICAL
R6396-E
Pa r t
1 61748 Front Seat Track to Floor
Insulator
2 61202 Front Safety Belt Buckle End
3 N621945-S2 Nut and Washer Assy (1
Req'd)
4 N802919-S2 Screws (2 Req'd)
5 61710 Seat Track
I t e m
Pa r t
6 N802863-S2 St ud(1 Req'd)
Req'd)
8 N802351-S2 St ud(1 Req'd)
Lb-Ft)
Lb-Ft)
01- 10- 31
Se a t s and Tr acks 01- 10- 31
Se a t , Dr i v er or PassengerManual Se a t
Re mo v a l a n d I nst al l at i on
i . CAUTI ON: Use car e w h e n handl i ng seat and
t r ac k assembl y. Dr oppi ng assembl y or si t t i ng
on seat not secur ed i n vehi cl e may r esul t i n
damaged component s-
Remove front seat t r ack t o fl oor insulator
retaining ri vets and front seat t rack t o fl oor
insulators ( 61748) f rom front and rear of t r acks.
Seat , Spl i t Be n c h Ma n u a l
Remove t he seat t r ack retaining scr ews and nuts
f r om inside t he vehi cl e. Move seat ful l -forward t o
rel ease front seat t r ack assi st spri ng ( 61828)
and lift seat and seat t r ack assembl y f rom t he
vehi cl e.
To install, reverse Removal procedure. Tighten
retaining bol ts and out board retaining nut t o
17-23 N-m (13-17 Ib-ft). Tighten i nboard retaining
nut t o 68- 92 N-m ( 50- 68 Ib-ft).
Check operati on of seat .
R7903-B
Pa r t
1 N803946-S Push Pin (4 Req'd Each
Seat)
Insulator (3 Req'd Each
Seat)
3 N621945-S58 Nut and Washer (1 Req'd
Each Seat)
4 N802351-S58 Stud (1 Req'd Each Seat)
5 Seat Assy
6 Seat Track Assy
Pa r t
7 N802188-S2 Screw (2 Req'd Each Seat)
Insulator (1 Req'd Each
Seat)
9 N802863-S2 Stud (1 Req'd Each Seat)
Each Seat)
Lb-Ft)
Lb-Ft)
01- 10- 32 S e a t s a n d T r a c k s 01- 10- 32
Se a t , Rear B e n c h
Remov al
1. Appl y knee pressure t o t he l ower front porti on of
rear seat cushion assembl y. Push r ear war d t o
di sengage rear seat cushi on pad and f rame
( 600A88) f rom rear seat cushion f ront retai ners
( 63370) .
2. Remove t he rear saf et y belt ret ract or and tongue
( 611B68) and rear seat back pad and f rame
l ower retaining nuts.
3. Grasp t he seat back assembl y at the bot t om and
lift up t o di sengage t he hanger wi re f rom t he
retainer bracket s.
4. Remove the seat back assembl y f r om t he
vehicle.
Seat , Rear Be n c h
WIRE MUST BE FULLY REAR SEAT
SEATED IN RETAINER CUSHION FRONT
RETAINERS
63370 R6569-C
1. Position t he seat back assembl y into t he vehi cl e
so that t he hanger wi re is engaged wi t h t he
retaining br acket s.
2. Install the rear saf et y belt ret ract or and tongue
and rear seat back pad and f rame retainer nuts.
Tighten t o 40- 55 N-m ( 30- 41 Ib-ft).
3. Position t he seat cushion assembl y into the
vehicle.
4. Appl y knee pressure t o the l ower porti on of t he
seat cushi on assembl y. Push rearward and down
t o l ock the rear seat cushi on pad and f rame into
posi ti on.
5. Check rear seat cushi on pad and f rame t o ensure
it is secured into rear seat cushi on front retai ner.
Se a t , Rear Be n c h
VIEW A
R6570-B
Pa r t
1 Hanger Brackets
2 Rear Seat Back Assy
and Tongue
5 Stud (1 Req'd Each Side)
Lb-Ft)
S e a t T r a c k
Ma n u a l
1. Remove seat and seat t rack as outlined.
01- 10- 33 Seats and Tracks 01- 10- 33
2. Pl ace t he seat and t rack assembl y upside down
on a clean bench.
3. NOTE: To ease front seat t rack assi st spri ng
( 61828) removal and installation, adjust seat t o
full f or war d posi ti on.
Di sconnect front seat t rack assi st spri ng.
4. Remove the seat track-to-front seat cushion
f rame and spri ng retaining screws and remove
t he seat t rack assembl y.
5. If t he seat t rack is being repl aced, transfer the
front seat cushion extensi on handle ( 603A86) t o
t he new seat t rack assembl y.
t he seat track-to-front seat cushion f rame and
spri ng retaining scr ews t o 17-23 Nm (13-17
Ib-ft).
Seat Track, PowerSi x-Way
1. Remove seat and t r ack assembl y as outlined.
2. Pl ace t he seat and t rack assembl y upside down
on a cl ean bench.
3. Di sconnect seat regul ator control swi t ch
( 14A701) f rom t r ack assembl y at connect ors.
4. Remove front seat t rack l ower shield ( 62126)
f rom t he out board si de of the t rack assembl y, if
so equi pped.
5. Remove four bol ts retaining t he t rack assembl y t o
t he front seat cushi on f rame and spri ng ( 63100) .
6. Remove nut retaining front safety belt buckl e end
( 61202) t o t he t r ack assembl y. Remove center
occupant belt f rom mounting slot. Remove the
t r ack assembl y f rom the front seat cushi on f rame
and spri ng.
7. To install, reverse Removal procedure. Ti ghten
seat t rack t o front seat cushion f rame and spri ng
retaining bol ts t o 17-23 N-m (13-17 Ib-ft).
8. Check operati on of the seat.
FRONT SEAT
CUSHION FRAME
AND SPRING
63100
POWER FRONT
SEAT TRACK ASSY
TO POWER
SEAT SWITCH
PASSENGER SEAT SHOWN
DRIVER SEAT TYPICAL
SCREW
N801078-S2
4 REQ'D EACH SEAT
TIGHTEN TO
12-24 N-m
(9-18 LB-FT)
R6597-B
Seat Regulator Cont rol Swi t ch
PowerSi x-WayTown Car
2. Gently pry up on the front of the wi ndow regulator
swi t ch housing ( 14527) .
3. Unhook rear edge of wi ndow regul ator swi t ch
housing and remove wi ndow regulator swi t ch
housing f rom front door trim panel ( 23942) .
4. Remove t wo scr ews retaining el ectri cal
connector t o wi ndow regul ator swi t ch housing.
5. Carefully pry seat regulator control swi t ch
( 14A701) f rom connector wi th a small
screwdri ver. Take care not t o damage the
connector pins.
6. To install, position seat regul ator control swi t ch t o
connector and carefully press into pl ace.
7. To compl ete installation, reverse Removal
procedure.
PowerSi x WayCrown Vi ctori a, Grand
Marquis
1. Di sconnect bat t ery ground cabl e.
2. Remove t wo scr ews retaining seat regul ator
control swi t ch t o seat regul ator control mounting
bracket ( 14A705) .
3. Remove seat regul ator control swi t ch and
di sconnect el ectri cal connector. Remove swi t ch.
1995 To wn Car, Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s July 1994
01- 10- 34 Se a t s a n d T r a c k s 0 1 - 1 0 - 3 4
Seat Re gul a t or Co n t r o l S wi t c h Cr o wn Vi c t o r i a ,
Gr a nd Ma r qui s
FRONT OF
VEHICLE
X
MUST BE INSTALLED WITH
"UP" ON THE TOP SIDE OF
SWITCH
POWER DRIVER SEAT SHOWN
POWER PASSENGER SEAT SIMILAR
R6599-C
Pa r t
1 14B691 Seat Regulator Control
Mounting Bracket
3 63100 Front Seat Cushion Frame
and Spring
Switch
5 N610130-S9 Screw (2 Req'd)
P r o g r a m m a b l e Me m o r y
T o w n Ca r , C r o w n Vi c t o r i a
1.
4.
5.
Remove one inside door handle cup retaining
screw. Using a screwdri ver, di sengage retaining
studs f rom front door tri m panel ( 23942) and
remove inside door handle cup ( 22635) .
Remove t wo scr ews retaining seat regul ator
control ( 14776) t o inside door handle cup.
To gain access t o seat regul ator control
connector, remove the wi ndow regulator swi t ch
housing ( 14527) mounted in t he arm rest. Refer
t o Seat Regul ator Control Swi t ch ( 14A701) ,
Power Si x- Way, Removal and Installation.
Di sconnect seat regul ator control connector and
remove seat regul ator cont rol .
Pr o gr a mma bl e Me mo r y Seat Regul at or Co n t r o l
I n st a l l a t i o n
SECTION A
LH DOOR
SECTION A
R6600-B
Pa r t
2 22635 Inside Door Handle Cup
3 14776 Seat Regulator Control
4 N610017-S2 Screw
S e a t Ba c k C o n t r o l S w i t c h a n d H o u s i n g
Re mo v a l
1. Remove seat control swi t ch ( 14C715) f rom seat
by pulling off snap-on bezel , then removi ng t wo
screws l ocated on seat regul ator control swi t ch.
SEAT BACK
CONTROL SWITCH
AND HOUSING
14C715
FROM FRONT
SEAT BACK
PAD ADJUSTING
PUMP
TO FRONT SEAT
BACK PAD
ADJUSTER
R7114-B
2. Release connector retaining t abs wi t h a
flat-bladed tool and slide connector apart .
01- 10- 35 Se a t s a n d T r a c ks 01- 10- 35
REMOVAL A N D INSTALLATION (Cont i nued)
3. To remove seat control swi t ch, use a
small-bladed screwdri ver and insert in holes on
si de of seat regul ator control swi t ch bezel
( 14A706) . Depress metal clips whi l e pulling seat
control swi t ch from seat regul ator control swi t ch
bezel.
1. NOTE: The seat regul ator control swi t ch bezel is
keyed and can only be installed one way.
Snap seat control swi t ches into seat regul ator
control swi t ch bezel by pressi ng firmly.
Mat e connect ors t o seat control swi t ches by
aligning and pressi ng firmly until connect ors snap
into pl ace.
Connect hoses t o seat control swi t ch. (Longer
and f at t er nipple t o front seat back pad adj uster
( 65500) ; shorter and thinner nipple t o front seat
back pad adjusting pump ( 65530) . )
Install t wo scr ews and seat regul ator control
swi t ch. Snap bezel into pl ace.
S e a t R e g u l a t o r C o n t r o l P r o c e s s o r
T o w n Ca r
1. Remove seat and t rack assembl y as outlined.
2. Remove t wo nuts retaining seat regul ator control
mounting bracket ( 14B691) t o front fl oor pan
( 11135) .
Seat Re gul a t or Co n t r o l Pr o c e sso r
Di sconnect all connect ors and remove seat
regul ator control processor ( 14C708) .
nuts t o 2. 0-4. 0 N-m (18-35 Ib-in).
R6601-C
I t e m
Par t
Pa r t
1

To Seat Accessory 4 To Seat Regulator Motor
Connector 5 616A80 Power Seat Cross Drive
2

To Seat Back Control Switch Shaft
and Housing 6

Locators
3

To Seat Position Sensor 7

Seat Torsion Bar (Part of
Connector 61710 Seat Track Assy)
01- 10- 36

Se a t s a n d T r a c ks 0 1 - 1 0 - 3 6
Par t Pa r t
I t em Number Descr i pt i on I t em Number De s c r i p t i o n
8 Locator Clips 12 13000 Floor Carpet
9 14A005 Body Main Wiring 13 N800319-S36 Stud (2 Req'd)
10 14C708 Seat Regulator Control 14 N621906-S36 Nut (2 Req'd)
Processor
15 61710 Seat Track Assy
11 Insulator
A Tighten to 2.0-4.0 N-m (18-35
(Continued)
Lb-ln)
Re c l i n e r , Ma n u a l
B e n c h , Sp l i t
1. The front seat back l atch ( 62648) requi res no
cleaning or maintenance.
Remove spri ng clip and front seat back adjusting
handle ( 61198) . Retain the part s for installation.
Di sconnect " J " and arrow retai ners at out board
right rear corner and " J " retai ner f rom cushi on
f rame si de. Pull back tri m cover.
2.
3.
Remove push pins f rom recliner cover at rear and
left off recliner cover. Al so di sengage lumber tube
(if present). (Power only: Di sconnect el ectri cal
connector.)
Remove t wo front seat back l atch t o front cushi on
f rame retaining scr ews (on out board si de) and
the pi vot bolt on the inboard si de. Remove front
seat back assembl y.
Di sengage " J " t o " J " cl osure at bot t om of front
seat back assembl y and pull up seat back cover.
Remove t wo scr ews retaining f ront seat back
l atch t o front seat back f rame ( 61018) and
remove front seat back l at ch.
Recl i ner, Manual
Pa r t
1

Front Seat Cushion Assy
2 Front Seat Back Assy
3 389443-S Push Pin
4 62648 Front Seat Back Latch
5 N663109-S Front Seat Control Wire
Retainer
Pa r t
6 N803463-S2 Bolt (2 Req'd Each Seat)
7 Hog Rings (2 Req'd Each
Seat)
8 617K45 Front Seat Control Wire
A . Tighten to 44-60 N-m (32-44
Lb-Ft)
01- 10- 37
Seat s and Tr acks 01- 10- 37
8. NOTE: Check front seat back l atch for proper
operati on pri or t o positioning front seat back
cover ( 64416) and front seat back ( 64810) .
front seat back l atch t o front seat cushion f rame
and spring scr ews t o 44- 60 N-m (32-44 Ib-ft) and
front seat back l atch t o front seat back f rame
scr ews t o 22-32 N-m (16-24 Ib-ft).
Recl i ner, Manual
0
R4799-F
Par t
1 N800476
(Power Seat)
N806420
(Manual Seat)
Screw
2 N802919 Screw
3 65500 Seat Back Assy
4 619A74 Adj uster Assy (Power Seat)
5 619A74 Adj uster Assy (Manual Seat)
Lb-Ft)
Re c l i n e r , P o w e r
1. The front seat back l atch ( 62648) requi res no
cleaning or mai ntenance.
2. Remove spri ng clip. Retain the spri ng clip for
installation.
3. Di sconnect " J " and arrow retai ners at out board
right rear corner and " J " retainer f rom cushion
f rame si de. Pull back tri m cover.
4. Remove push pins f rom recliner cover at rear and
left off recliner cover. Al so di sengage lumber tube
(if present ). Di sconnect el ectri cal connector.
5. Remove t wo front seat back l atch t o front cushion
f rame retaining scr ews (on out board si de) and
t he pi vot bolt on t he i nboard si de. Remove front
6. Di sengage " J " t o " J " cl osure at bot t om of front
seat back assembl y and pull up seat back cover.
7.
8.
Remove t wo scr ews retaining front seat back
l atch t o front seat back f rame ( 61018) and
remove front seat back l atch.
seat back-to-seat cushion M10 (l ower) retaining
bol ts t o 44- 60 N-m ( 32- 44 Ib-ft). Tighten center
arm rest-to-seat back retaining bolt t o 16-27 N-m
( 12- 20 Ib-ft).
H e a d R e s t r a i n t s
Re mo v a l
1. Unscrew front seat head rest guide rod retai ners
( 61 OA 18).
2. Pull up on front seat back head restrai nt
( 611A08) . Compress f oam in area of front seat
head rest guide rod sl eeves ( 61 OA 16).
3. Remove front seat back head restrai nt
positioning spri ngs. Pull front seat back head
restrai nt up and out.
1. Slide front seat head rest guide rod retai ners onto
front seat back head restrai nt post s.
2. Compress f oam in front seat head rest guide rod
sl eeve area. Install positioning spri ngs on front
seat head rest guide rod sl eeves.
3. Insert front seat back head restrai nt post s
(notches on post s faci ng rearward) into front seat
head rest guide rod sl eeves and push down t o
engage positioning spri ng.
4. Tighten front seat head rest guide rod retai ners
onto front seat head rest guide rod sl eeves.
01- 10- 38 Se a t s a n d T r a c k s 0 1 - 1 0 - 3 8
NOTE: Front seat back head restrai nt must operat e
smoothl y throughout its range of t ravel , must remai n in
any fi xed posi ti on, and must not be freel y removabl e
f rom t he seat back. If any of t hese condi ti ons are not
met, check for proper installation of positioning spri ng
onto front seat head rest guide rod sl eeve.
5. Adj ust front seat back head restrai nt by appl yi ng
hand pressure, either up or down, t o center area
of front seat back head restrai nt.
Head Re st r a i nt s
FRONT SEAT
HEAD
RESTRAINT
GUIDE ROD
RETAINER
610A18
R7018-B
H e a t e d S e a t s T o w n C a r
1. Remove seat as outl i ned.
NOTE: Heating el ement is built-in as part of each seat
cover. There is not separat e Removal and Installation
procedure for heati ng el ements.
2. Di sconnect el ectri cal connect ors f rom heat seat
module.
3. Drill out t wo ri vets ( 378527- S) and remove
heated seat modul e.
4. To install, reverse Removal procedure using t wo
new ri vets.
S e n s o r S w i t c h a n d Wi r e , Dr i v e r S e a t
1. Remove seat and seat t r ack assembl y as
outlined.
2. Remove seat t r ack from front seat cushion f rame
and spri ng ( 63100) .
3. Di sconnect front seat back pad adjusting tube
( 65512) f r om front seat back pad adjusting pump
( 65530) .
4. Di sconnect " J " retainer holding front of front seat
cushion cover t o front seat cushion f rame and
spri ng.
5. Separate t he front seat cushion cover and front
seat cushi on pad f rom the front seat cushion
f rame and spri ng enough t o access the seat
occupi ed sensor swi t ch and wi re.
01- 10- 39 Seat s and Tr ac k s 01- 10- 39
DISASSEMBLY AND ASSEMBLY (Conti nued)
Seat Occupi ed Sensor Swi t ch and Wi re
REAR OF SWITCH
ON 2ND WIRE
FROM BACK
SEAT OCCUPIED
SENSOR SWITCH
14A501
6 WIRES BETWEEN
CONNECTORS
FRONT SEAT
CUSHION
FRAME AND
SPRING 63100
TUCK FRONT
UNDER 1ST
WIRE
R9S39-A
Di sconnect seat occupi ed sensor swi t ch
connector and remove swi t ch f rom front seat
cushi on f rame and spri ng.
To install, reverse Removal procedure. Verify
seat occupi ed sensor swi t ch and wi re are
posi ti oned in center of front seat cushion f rame
and spri ng and function smoothl y. Tuck nose of
swi t ch underneath fl exi l ator wi re if necessary.
Tighten front seat t rack to front seat cushion
f rame and spri ng nuts t o 17-23 N-m (13-17 Ib-ft).
S e a t , B e n c h
S e a t C u s h i o n C o v e r
1. Remove the rear seat cushion assembl y as
outl i ned.
4.
5.
Cut t he hog rings retaining rear seat cushion
cover ( 63804) t o rear seat cushion pad and
f rame ( 600A88) and/ or di sengage the pl asti c
retai ners f rom t he seat cushi on fl ange. Remove
t he rear seat cushion cover.
Transfer all bol ster ti edown wi res t o their
respect i ve listings in t he new rear seat cushion
cover.
To install, position the rear seat cushion cover
over t he rear seat cushion pad and f rame. Secure
the pl asti c retai ners t o t he seat fl ange assembl y,
if equi pped.
Install the necessary hog rings, buttons and (new)
retai ners. Install the rear seat cushion assembl y
into t he vehi cl e.
01- 10- 40 Seat s and Tr ac k s 0 1 - 1 0 - 4 0
DISASSEMBLY AND ASSEMBLY (Continued)
Town Car
BASE CLOTH/LEATHER SEAT TRIM
CARTIER CLOTH SEAT TRIM
SECTION B
1334H- P
Par t
1 6 3 8 0 4 R e a r Seat C u s h i o n C o v e r
2 Bolster Wire
3 H o g R i n g ( 1 2 R e q ' d E a c h
S i d e )
4 600A88 R e a r S e a t C u s h i o n P a d a n d
F r a m e
Par t
5

Hog Ring ( 4 Req'd Each
Side)
6 Hog Ring ( 3 Req'd Each
Side)
01- 10- 41 Seat s and Tr acks 01- 10- 41
DISASSEMBLY AND ASSEMBLY (Cont i nued)
Cr own Vi ct ori a, Grand Marquis
) MARQUIS/CROWN
SECTION A
m
(Vj
SECTION B SECTION C
CROWN VICTORIA DC
SEAT TRIM
SECTION D
CROWN VICTORIA/GRAND MARQUIS
BASE CLOTH/VINYL SEAT TRIM SHOWN -
CROWN VICTORIA LX CLOTH SEAT TRIM
SIMILAR
R289S-K
01- 10- 42 Se a t s a n d T r a c ks
Par t Par t
I t em Number De sc r i pt i o n I t em Number Descr i pt i on
1 63804 R e a r S e a t C u s h i o n C o v e r
5 Bolster Wire
2 600A88 R e a r S e a t C u s h i o n P a d a n d
F r a m e
6 Hog Ring (8 Req'd Each
Side)
3 Hog Ring (7 Req'd Along
R e a r E d g e )
7
8
Hog Ring (6 Req'd)
Hog Ring (4 Req'd Each
4 H o g R i n g (23 R e q ' d A l o n g Side)
F r o n t E d g e )
(Continued)
S e a t B a c k C o v e r
1. Remove t he rear seat cushi on assembl y and rear
seat back assembl y f rom t he vehi cl e. Remove
the center arm rest assembl y, if so equi pped,
f rom t he rear seat back assembl y as outlined.
2. Wi t h the front si de of rear seat back assembl y
faci ng down, cut t he hog rings t hat retain t he rear
seat back cover ( 66600) t o the rear seat back
pad and f rame ( 672A18) and/ or di sengage t he
pl asti c retai ners f rom the spri ng fl ange assembl y.
3. Remove the rear seat back cover f rom t he rear
seat back pad and f rame.
Seat Back Cover
4.
5.
Transfer all bol ster t i edown wi res t o their
respecti ve listings in the new rear seat back
cover.
To install, position t he rear seat back cover over
the rear seat back pad and f rame. Position t he
pl asti c retai ner(s) over the spri ng fl ange
assembl y.
6. Install the necessary hog rings. Install the center
arm rest assembl y t o the seat back assembl y, if
equi pped.
7. Install t he rear seat back assembl y and rear seat
cushion into t he vehi cl e as outlined.
01- 10- 43 Se a t s a n d T r a c ks 01- 10- 43
Part
1 66600 Rear Seat Back Cover
2 Hog Ring (4 Req'd Each Side)
3 672A18 Rear Seat Back Pad and Frame
4 Bolster Wire
Seat Back Cover
SECTION C
SECTION A
SECTION C
R24S3-E
Pa r t
1 Hog Ring (3 Req'd)
Top and Sides)
3 672A18 Rear Seat Back Pad and
Frame
Par t
4
Hog Ring (17 Req'd Along
Bottom)
5 Hog Ring (3 Req'd)
6 Hog Ring (7 Req'd Each
Side)
7 66600 Rear Seat Back Cover
01- 10- 44 Seat s and Tr ac k s 01- 10- 44
Seat Back Cover
GRAND MARQUIS "
BASE CLOTH TRIM
R23SS-N
01- 10- 45 Se a t s a n d T r a c ks 01- 10- 45
Par t Par t
I t em Number Descr i pt i on I t em Number Descr i pt i on
1

8

Hog Ring (2 Req'd)
Side) 9

2

Bolster Wire (1 Req'd Each Side)
Side) 10 Hog Ring (5 Req'd Each
3

Bolster Wire (1 Req'd Each Side)
Side) 11

Bolster Wire (2 Req'd)
4

Side)
12

Corner)
5 66600 Rear Seat Back Cover 13

6 672A18 Rear Seat Back Pad and Bolster Wire)
Frame 14 Bolster Wire (3 Req'd Each
7

Hog Ring (13 Req'd Along Side)
Top) 15

Hog Ring (3 Req'd)
01- 10- 46 Seat s and Tr ac k s 0 1 - 1 0 - 4 6
Seat Back Cower
SECTION B
CROWN VICTORIA LX
LEATHER SEAT TRIM
GRAND MARQUIS LS
CLOTH/LEATHER SEAT
TRIM
CROWN VICTORIA LX
CLOTH SEAT TRIM
SECTION C
R7128-B
Par t
1 B o l s t e r Wi r e (4 R e q ' d E a c h
S e a t )
2 H o g R i n g (4 R e q ' d E a c h
S i d e )
3 H o g R i n g (4 R e q ' d E a c h
S i d e )
I t em
Part
4

H o g R i n g (4 R e q ' d E a c h
S i d e )
Bottom)
6 6 7 2 A 1 8 Rear Seat Back Pad and
Frame
7 6 6 6 0 0 Rear Seat Back Cover
Seat Back Pad Adj ust er, Front
Removal
1. Remove t he seat and t r ack assembl y as outlined.
Pl ace t he seat on a cl ean surf ace.
2. Remove the front seat back cover ( 64416) and
front seat back ( 64810) as outlined.
3. Disconnect inflating front seat back pad adj usti ng
tube ( 65512) f rom the front seat back pad
adjuster ( 65500) .
01- 10- 47
Seat s a n d T r a c ks 01- 10- 47
DISASSEMBLY AND ASSEMBLY ( C o n t i n u e d )
4. Unhook front seat back pad adj uster f rom the
hol es in the front seat back f rame.
Installation
1. Clip retaining wi res into hol es on front seat back
frame.
Pa r t
1 61018 Front Seat Back Frame
2 Retaining Wire
3 Retaining Tab
4 65500 Front Seat Back Pad
Adj uster
2. Connect front seat back pad adjusting t ube t o
front seat back pad adj uster.
3. Install t he front seat back and front seat back
cover as outlined.
4. Check t he manual seat back l atch for proper
operat i on.
5. Install t he seat and t rack assembl y in t he vehicle
as outlined.
6. Check t he seat t r acks and saf et y bel ts for proper
operat i on.
S e a t B a c k P a d A d j u s t i n g P u m p , F r o n t
Re mo v a l
1. Remove front seat as outlined.
2. Remove the ri vets retaining the pump and motor
assembl y t o t he cushion frame.
3. Di sconnect t he inflating tube and el ectri cal
connector f rom t he pump and motor and remove
the pump/ mot or .
Installation
1. Connect the inflating tube and el ectri cal
connect or t o the pump and motor assembl y.
2. Install the pump / motor on the f rame wi t h t he t wo
retaining ri vets.
3. Install front seat as outlined.
S e a t B a c k F r a m e , Pad a n d T r i m C o v e r
1. Remove the seat and t rack assembl y as outlined.
2. (Manual ) Remove spri ng clip and front seat back
adjusting handle ( 61198) . Retain the part s for
installation.
(Power) NOTE: Power recliners have no seat
back adjusting handle. Go t o st ep 3.
3. Di sconnect " J " and arrow retai ners at out board
right rear corner and " J " retainer f rom cushion
frame si de. Pull back tri m cover.
4. Remove push pins f rom recliner cover at rear and
left of recliner cover. Di sconnect lumbar tube if
necessary. For power seat s, di sconnect
el ectri cal connector.
5. Remove t wo front seat back l atch t o front cushion
frame retaining scr ews (on outboard si de) and
the pi vot bolt on the inboard si de. Remove front
01- 10- 48 S e a t s and T r a c ks 0 1 - 1 0 - 4 8
6. Di sconnect " J " retai ners at bot t om of front seat
back and pull up seat back liner.
Fr ont Se a t Back Cent er Arm Re st
FRONT
S E A T
B A C K
A S S Y
R3335-F
DRIVER SIDE SHOWN
PASSENGER SIDE SIMILAR
Pa r t
2 N800541-S Spacer
Handle Bezel
4 62915-S9 Screw
5 61198 Front Seat Back Adj usting
Handle
R2896-E
7. Remove front seat back robe cor d end covers
( 62808) and t wo retaining scr ews and remove
front seat back assi st cord ( 62800) , if so
equi pped.
Assi st Co r d , Fr o n t Seat Ba c k
DE S I G N E R C A R T I E R S E A T T R I M
SIGNATURE SERIES SEAT TRIM R431S-C
Pa r t
1 62802 Robe Cord Retainer
2 62808 Front Seat Back Robe Cord End Cover
3 62800 Front Seat Back Assist Cord
01- 10- 49 S e a t s a n d T r a c ks 01- 10- 49
8. Remove front seat back head restrai nt ( 611A08)
as outlined.
FRONT SEAT
BACK HEAD
RESTRAINT
611A08
9. Unscrew head restrai nt guide retai ners f rom t he
head restrai nt gui des.
10. Peel front seat back cover from bot t om t o t op,
whi l e di sengagi ng hook fastener t i edowns.
11. Installation is the reverse of Removal procedure.
FRONT SEAT
HEAD
RESTRAINT
GUIDE ROD
RETAINER
610A18
R7018-B
Fr o n t Seat Ba c k Cove r Asse mbl y
BASE SEAT CLOTH/LEATHER TRIM
CARTIER CLOTH SEAT TRIM
R4318-D
Pa r t
1 64416 Front Seat Back Cover
2
Bolster Wire
3 Bolster Wire
Pa r t
4 64810 Front Seat Back
5 J-Retainers (Part of Front
Seat Back Cover)
01- 10- 50 Se a t s a n d T r a c ks
0 1 - 1 0 - 5 0
Si gna t ur e Se r i e s Seat Tr i m
SECTION A
SIGNATURE SERIES SEAT TRIM
RW34-C
Par t
I t em Number De sc r i pt i o n
1
Bolster Wire
2 64416 Front Seat Back Cover
(Continued)
Par t
1
|
3
J-Retainers (Part of Front
Seat Back Cover)
4 64810 Front Seat Back |
1995 Town Car , Cr own Victoria, Grand Mar qui s Jul y 1994
01- 10- 51 Se a t s a n d T r a c ks 01- 10- 51
Fr o n t Seat Ba c k Pad Asse mbl y
It em
Part
Nu mb e r De sc r i pt i o n
(Without Front Seat Back
Pad Adj uster)
3 Bend Tabs Over to Retain
Front Seat Back Pad
Adj uster
( Co n t i n ue d )
I t e m
Pa r t
(With Front Seat Back Pad
Adj uster)
6 64810 Front Seat Back (With Front
Seat Back Outer Pad)
6 64800 Front Seat Back Outer Pad
1995 To wn Ca r , Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s July 1994
01- 10- 52 Se a t s a n d T r a c ks 0 1 - 1 0 - 5 2
Fr o n t Seat Ba c k Ad j ust i n g Handl e
2
I t em
Par t
Handle Bezel
4 52915-S9 Screw
6 61198 Front Seat Back Adj usting
Handle
R3335-F
I t em
Par t
Number De s c r i p t i o n
1
2
62900
N800541-S
Front Seat Cushion Cover
Spacer
( Co n t i n ue d )
Spl i t Be nc h Seat Ba c k, Fr o n t
SPLIT BENCH
NON-RECLINER MODELS
VIEW A
R2809-K'
01- 10- 53 Se a t s a n d T r a c ks 01- 10- 53
Par t
1

Front Seat Back Assy
2 Front Seat Cushion Assy
3 389443-S Push Pin
4 N803463-S2 Screw (2 Req'd Each Seat)
Part
5 N663109-S Front Seat Control Wire
Retainer
6 617K45 Front Seat Control Wire
Lb-Ft)
Fr ont Seat Back Cover
FRONT SEAT
BACK HEAD
RESTRAINT
611A08
HOG RING
AREA
HOG RING
AREA
COVER
ZIPPER
R7501-B
S e a t C u s h i o n S p r i n g , F r a m e , P a d a n d T r i m
C o v e r A s s e m b l i e s
1. Remove seat and t rack assembl y as outl i ned.
2. Remove tri mmed seat back assembl y f rom
cushi on assembl y as outlined.
Remove arm rest assembl y and bracket cover.
Di sengage " J " retainer on out board si de at seat
l ower edge.
Di sengage pl asti c J-strip f rom front rail of front
seat cushion f rame and spri ng ( 63100) .
Peel front seat cushion cover ( 62900) f rom front
t o rear disengaging hook f ast eners as front seat
cushi on cover is being removed.
Remove front seat cushion cover.
Remove front seat cushi on pad ( 632A22) if
requi red.
Remove any mechani sm retaining part s if front
seat cushion f rame and spri ng must be repl aced.
01- 10- 54 Seat s and Tr acks 0 1 - 1 0 - 5 4
DISASSEMBLY A N D ASSEMBLY (Cont i nued)
Spl i t Bench Seat Cushi o n Cover Assembl y, Fr ont
SECTION B
SIGNATURE SEAT TRIM SHOWN
BASE AND CARTIER SEAT TRIM SIMILAR
VIEW C
VI EWC
R3338-G
Pa r t Pa r t
It em Number De s c r i p t i o n I t e m Numbe r De s c r i p t i o n
1
Wire
4 389443-S Push Pin
2 62900 Front Seat Cushion Cover 5 Wire
3 63100 Front Seat Cushion Frame 6 632A22 Front Seat Cushion Pad
and Spring 7 J-Retainer (Part of Front
(Continued)
Seat Cushion Cover)
01- 10- 55 Seat s and Tr acks 01- 10- 55
Spl i t Bench Seat Cushi on and Pad Assembl i es, Front
CARTIER SEAT TRIM
BASE SEAT TRIM
SECTION A
R333S-0
Pa r t
1 632A22 Front Seat Cushion Pad
2 63100 Front Seat Cushion Frame and Spring
01- 10- 66
Seat s and Tr acks
0 1 - 1 0 - 5 6
Spl i t Be nc h Se a t Cushi on Cove r Assembl y
VIEW A
GRAND MARQUIS
BASE CLOTH SEAT TRIM
CROWN VICTORIA
LX CLOTH SEAT TRIM
VIEW A
VIEW A
SECTION F
C Ft OWH VICTORIA/GRAND MARQUIS
BASE VINYL SEAT TRIM
VIEW A
SECTION 8
CROWN VICTORIA LX LEATHER SEAT TRIM
GRAND MARQUIS LS CLOTH/LEATHER
SEAT TRIM
SECTION G
VIEWE SECTION F SECTION G
R3SS4-H
01- 10- 57 Se a t s a n d T r a c ks 01- 10- 57
Pa r t
1 63426 Wire
2 63348 Wire
3 66426 Wire
4 65446 Wire
I t e m
Pa r t
Number De sc r i pt i o n
5 389443-S Push Pin
7 Front Seat Cushion Frame
8 Front Seat Cushion Cover
9 J-Retainer
Spl i t Be n c h Seat Ce n t e r Ar m Rest Fr o n t
FRONT
SEAT
BACK
ASSY
DRIVER SIDE SHOWN
PASSENGER SIDE SIMILAR
R2896-E
Pa r t
1 644A18 Front Seat Back Center Arm
Rest Cover
Rest Spacer
3 Front Seat Back Assembly
4 65478 Front Seat Back Center Arm
Rest Pad
5 N806347-S100 Pivot Bolt
Rest Pad Bushing
Lb-Ft)
A r m Re s t , F r o n t S e a t C e n t e r
1. Remove center arm rest upper bracket covers to
expose t he arm rest pin.
2. Remove push nut f rom end of arm nut pin and
remove ar m rest pin f rom bracket .
3. Remove arm rest and retain pin and bracket
cover s for installation.
R7994-A
Pa r t
1 Front Seat Back Assy
2 Li d, (Part of 644A22 Front
Seat Center Arm Rest)
3 644A22 Front Seat Center Arm Rests
Rest Pad Bushing
6 13562 Utility Tray Beverage Holder
7 19A384 Mobile Telephone Holder
Cradle and Swivel
8 654A76 Front Seat Center Arm Rest
Spacer
Lb-Ft)
A r m Re s t C o v e r
Fr o n t C e n t e r
1. Remove arm rest assembl y as outlined.
2. Unhook the hook fastener and remove the front
seat back center arm rest cover ( 644A18) .
01- 10- 58 Seat s and Tr acks 0 1 - 1 0 - 5 8
3. Slip the new front seat back center arm rest
cover over t he front seat back center arm rest
pad ( 65478) and zip the zipper.
4. To install arm rest assembl y, reverse Removal
procedure. Tighten the pivot bolt t o 16-27 N-m
(12-20 ib-ft).
Re a r C e n t e r
1. Remove the rear seat cushi on assembl y and rear
seat back assembl y as outl i ned.
Ar m Rest Cover
2. Remove t he four nuts that retai n t he rear arm rest
and br acket assembl y t o t he rear seat back
f rame.
3. Remove t he t wo pi vot scr ews t hat retai n t he ar m
rest t o the bracket .
4. Remove t he ar m rest cover.
5. Slip new t ri m cover over ar m rest . To install,
reverse Removal procedure.
Pa r t
1 Rear Seat Back Assy
2 Part of Rear Seat Back
Cover
3 67204 Rear Seat Back Center Arm
Rest Base
Rest Cover
I t e m
Par t
Rest Link and Vertical
Strainer
7 N621906-S2 Nuts
Lb-Ft)
01- 10- 59 Seat s and Tr acks 01- 10- 59
ADJUSTMENTS
Lat ch, Seat Back
The front seat back l atch ( 62648) is modular and does
not require adj ustments. However, proper lubrication
of a hesitant front seat back l atch is permi tted using
Multi-Purpose Grease D0AZ- 19584- AA or equivalent
meeti ng Ford speci fi cati on ESB-M1C93-A.
The only authori zed servi ce permi tted on either front
seat back l atch is t he fol l owi ng:
Tightening of all retaining scr ews as outlined.
Repl acement (in enti rety) of a damaged or
non-functional front seat back l atch.
Removal of any forei gn materi al , such as tie st raps,
pi eces of f oam and t ri m.
If a front seat back l atch or component is
non-functional or damaged, t he enti re front seat back
l atch must be repl aced.
SPECIFICATIONS
Descr i pt i on N-m Lb-Ft
Fr o n t Se a t Ba c k L a t c h - t o - Fr o n t
Se a t Ba c k Fr a me
2 2 - 32 16- 24
Fr o n t Se a t Ba c k L a t c h - t o - Fr o n t
Se a t Cu s h i o n Fr a me a n d Sp r i n g
S c r e ws
44- 60 32 - 44
Se a t T r a c k- t o - Fl o o r Nu t - Ou t b o a r d 17 - 23 13- 17
TORQUE SPECIFICATIONS (Cont 'd)
Se a t T r a c k- t o - Fl o o r Nut - I n bo a r d 68- 92 50- 68
Re a r Sa f e t y Be l t Re t r a c t o r a n d
Re a r Se a t Ba c k Re t a i n i n g Nut
40- 55 30- 41
Fr o n t Se a t Ce n t e r Ar m Re st Pi v o t
Bo l t
16-27 12- 20
Se a t T r a c k- t o - Fr o n t Se a t Cu s h i o n
Fr a me a n d Spr i n g
12- 24 9- 18
Se a t T r a c k- t o - Fl o o r p a n S c r e w 17- 23 13-17
Se a t Re gu l a t o r Co n t r o l P r o c e s s o r
Br a c ke t Nu t s
2. 0- 4. 0 18- 35
( Lb- l n )
Se a t A d j u s t e r S c r e w 19-27 14- 20
Re a r Se a t Ba c k Ar m Re st Li n k a n d
Ve r t i c a l St r a i n e r t o Re a r Se a t
Ba c k P a d a n d Fr a me Nut s
11- 14 8- 11
Re a r Se a t Ba c k Ce n t e r Ar m Re s t
Pi v o t Bo l t s
16-27 12- 20
ROTUNDA EQUIPMENT
007 - 00001 Di gi t a l Vo l t Oh mme t e r
105- 00051 7 3 Di gi t a l Mu l t i me t e r
01- 11- 1 Gl a s s , Fr a me s a n d Me c h a n i s ms 0 1 - 1 1 - 1
SECTION 01-11 Glass, Frames and Mechanisms
SUBJECT PAGE
Swi t ch and Light, Heated Back Wi ndow 01-11-2
Wi ndow Glass, Back * 01-11-2
Wi ndow Glass, Door. .. 01-11-2
Wi ndow Glass, Rear Quart er . 01-11-2
Wi ndow Regulat or Cont r ol Swi t ch 01-11-1
Wi ndow, Heat ed Back . 01-11-2
Wi ndow, One-Touch Dri ver's Si de .... 01-11-1
Wi ndshi el d Glass . 01-11-1
Component Test s 01-11-24
Swi t ch Test s, Wi ndow ....... 01-11-24
El ect ri cal Schemat i cs ...01-11-3
Heat ed Back Wi ndow Swi t ch and Li ght 01-11-25
Sy mpt om Chart ....01-11-17
Back Wi ndow Glass 01-11-36
Door Glass Run Retai ner 01-11-45
Door Glass Top Run 01-11-46
Door Wi ndow Glass . 01-11-25
Gl ass, St at i onar y Rear Door 01-11-48
Heat ed Back Wi ndow Swi t ch and Li ght 01-11-52
Modul e, Dri vers Door 01-11-41
Rear Door 01-11-29
SUBJECT PAGE
Rear Door 01-11-44
Relay, Wi ndow Regul at or Saf et y 01-11-41
Weat herst ri p, Door Glass Bel t 01-11-39
Wi ndow Glass, Rear Quart er 01-11-50
Wi ndow Regul at or Cont r ol Swi t ch ....01-11-40
Wi ndow Regul at or Cont r ol Swi t ch Connect i on
Wi re 01-11-41
Wi ndow Regul at or El ect ri c Dr i ve. ...01-11-42
Wi ndow Regulat or, Power . . . . 01-11-27
Wi ndshi el d Glass . 01-11-32
SERVICE PROCEDURES
Gri d Wi re, Back Wi ndow Gl a ssMe t hod
I 01-11-52
Gri d Wi re, Back Wi ndow Gl a ssMe t hod
II 01-11-53
Lead Wi ndow Termi nal Se r vi c e Me t hod
I 01-11-54
Lead Wi ndow Termi nal Se r vi c e Me t hod
II . 01-11-55
LUBRICATION
Wi ndow Regulat or, Front Door Power... 01-11-56
ADJUSTMENTS
Door Wi ndow Glass 01-11-56
SPECIAL SERVICE TOOLS/EQUIPMENT .........01-11-57
VEHICLE APPLICATION
Wi n d s h i e l d G l a s s
The wi ndshi el d gl ass ( 03100) is standard saf et y
glass-plastic-laminate sandwi ched bet ween t wo
sheet s of gl ass.
Urethane seal ant bonds the windshield gl ass t o t he
wi ndow opening fl ange.
W i n d o w R e g u l a t o r C o n t r o l S w i t c h
The wi ndow regulator control swi t ches ( 14529) :
Are l ocat ed in door armrest s.
Include a master wi ndow regul ator control swi t ch on
the LH front door armrest and can be used t o
act i vat e any or all of t he power wi ndows.
Are l ocated on all passenger door armrest s where
the wi ndow regulator control swi t ches act i vat e the
power wi ndow for individual doors only.
W i n d o w , O n e - T o u c h Dr i v e r ' s S i d e
The LH front wi ndow regul ator control swi t ch ( 14529) :
Has the one-touch feature.
Al l ows the front door wi ndow gl ass ( 21410) t o
move downwar d by momentarily pressi ng the LH
front si de wi ndow regulator control swi t ch.
Will st op the front door wi ndow gl ass after
momentarily touching the button.
1995 To wn Car , Cr o wn Vi c t o r i a / Gr a n d Ma r q u i s Jul y 1994
01- 11- 2 Gl a ss, Fr ames a n d Me c h a n i s ms 01- 11- 2
Will st op the front door wi ndow gl ass when the
wi ndow regulator control swi t ch is pressed for more
than one-half second.
W i n d o w G l a s s , Do o r
Up and down movement of the door wi ndow is
provi ded by a cabl e. The wi ndow gl ass is mounted t o
the slider bracket . When the regul ator motor is
act i vat ed, the cabl e moves the wi ndow up or down t o
t he desi red position.
W i n d o w G l a s s , Re a r Qu a r t e r
The quarter wi ndow gl ass ( 29710) is standard saf et y
gl ass. Urethane sealant bonds quarter wi ndow gl ass
t o opening fl ange.
W i n d o w G l a s s , B a c k
The back wi ndow gl ass ( 42006) is t empered gl ass.
The back wi ndow gl ass is retai ned in position wi th
urethane adhesi ve. The back wi ndow upper garni sh
mouldings ( 42430) are installed wi t h the back wi ndow
gl ass and cannot be repl aced wi thout removi ng the
back wi ndow gl ass.
W i n d o w , H e a t e d B a c k
NOTE: The radi o antenna is l ocat ed on the wi ndow
gl ass and is servi ced wi t h t he back wi ndow gl ass
( 42006) as an assembl y.
The heated back wi ndow consi sts of:
A seri es of gri d lines baked on the inside surface of
the back wi ndow gl ass and syst em wi ri ng whi ch
includes heated back wi ndow ground wi re
( 18C620) and heated back wi ndow f eed wiring
( 18C619) .
The gri d lines consi st of t wo l ayers. The fi rst is
brown as vi ewed f rom the exteri or, and the second
is silver as vi ewed f rom t he interior.
Power for the back wi ndow gl ass gri ds, the outside
rear vi ew mirror and the indicator is supplied from
t he power distribution box through a high current
fuse whi ch prot ect s the circuit.
S w i t c h a n d L i g h t , H e a t e d B a c k W i n d o w
The heat ed back wi ndow defroster syst em consi sts of
the fol l owi ng component s:
A heat ed back wi ndow swi t ch and light ( 18C621)
mounted on the instrument panel ( 04320) .
The heat ed back wi ndow swi t ch and light has a
push button spri ng-l oaded to neutral position t o turn
t he syst em on or off. A timer-controlled relay turns
off after approxi mat el y 10 minutes of operati on. If
more ti me is needed, the heated back wi ndow
swi t ch and light can be reacti vated for another 10
minutes by pushing the button. Repeat as requi red.
Pushing in the heated back wi ndow swi t ch and light
el ectri cal l y cl ose the normally open cont act s in the
heat ed back wi ndow swi t ch and light. The cont act s
provi de power f rom bat t ery ( 10653) t o t he back
wi ndow gl ass gri ds, indicator, heated outsi de mirror
and tri gger the timing circuit. The cont act will remain
cl osed until the timer turns it off, t he heated back
wi ndow swi t ch and light is pushed or the ignition
swi t ch ( 11572) is turned t o OFF.
Power for the control timer comes f rom the
accessor y terminal of the ignition swi t ch and is
avai l abl e when the ignition swi t ch is in the RUN
posi ti on. The circuit is prot ect ed by a fuse in the
fuse panel .
For individual wiring harness appl i cati ons, refer t o
Secti on 18- 01.
1995 To wn Ca r , Cr o wn Vi c t o r i a / Gr a n d Ma r q u i s Jul y 1994
01- 11- 3 Gl a ss, Fr a me s a n d Me c h a n i s ms 01- 11- 3
E l e c t r i c a l S c h e m a t i c s
Po we r Wi n d o ws T o wn Car
HOT A T A L L T I ME S
P OWE R
[ BUS 1 DI ST RI BUT I ON
BAR" BOX
ROOF
I SLI D9NG
I P A N E L
I S WI T CH
LH
FRONT
WINDOW
L B/ BK RE G UL A T OR
CONTROL
SWITCH
'# y \
RH
FRONT
WINDOW
REGULATOR
ELECTRIC
DRIVE
N10901-B
1995 To wn Ca r , Cr o wn Vi c t o r i a / G r a n d Ma r q u i s Jul y 1994
01- 11- 4
Gl a ss, Fr a me s a n d Me c h a n i s ms 01- 11- 4
To wn Car ( Cont i nue d)
" \ J " ^wiffiOmOCKSWTOH LEFT RE AR SWITCH . RIGHT REAR SWITCH I
\ -akl JL m 2212 mwJL - * . - mm, *m> -2
1
Jr J!
1
iSF22fiikJ 1. J
| LH
! FRONT
I WINDOW
REGULATOR
CONTROL
SWITCH
T T
!0 I R/ BK I 3 1 9 I Y/
1 JH LH
REAR
WINDOW
REGULATOR
CONTROL
SWITCH
PUP - ]
^ - + * D O W N ^
>
RH
REAR
WINDOW
REGULATOR
CONTROL
SWITCH
LH
REAR
WINDOW
REGULATOR
ELECTRIC
DRIVE
of this circuit
RH
REAR
WINDOW
REGULATOR
ELECTRIC
DRIVE
N10902-B
Co n n e c t o r End Vi e ws T o wn Car
DRIVER DOOR MODULE CONNECTOR C1
N12602-A
Pin
Number Circuit Circuit Function
1 12 3( R) Do o r L o c k S wi t c h 5
2 120
( P K / L G )
Do o r L o c k S wi t c h
3 118
( P K / O )
Do o r L o c k Mo t o r
4 57 ( B K )
a
67 6
( P K / O )
Gr o un d
L o g i c Gr o un d
5 1 6 3 ( R / O ) Do o r L o c k Ou t pu t
6 84 ( P / Y) L u g g a g e Co mp a r t me n t Do o r L o c k
So l e n o i d Fe e d
7 84 <P / Y)
a
L u g g a g e Co mp a r t me n t Re mo t e
Co n t r o l L o c k S wi t c h Out put
8 117
( P K / B K )
Do o r L o c k Mo t o r
9 121
( Y/ B K )
Do o r L o c k S wi t c h 3
10 119
( P K / Y)
( Co n t i n ue d )
01- 11- 5 Gl a s s , Fr a me s a n d Me c h a n i s ms 0 1 - 1 1 - 5
Pin
Number Circuit Ci r cui t Func t i on
11 2 68
( B K / 0 )
Me mo r y Se a t Swi t c h 2
12 2 67
(BR/LG)
Me mo r y Se a t Swi t c h 1
13 2 6 ( W/ P ) An t i - The f t ( To L u g g a g e
Co mp a r t me n t Do o r )
14

No t Us e d
16

No t Us e d
17 No t Us e d
18 No t Us e d
a Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s
N12603-A
Pin
Number Ci r cui t Ci rcui t Funct i on
1 7 0 ( L B / W) I SO Li n k
2 2 2 6
( W/ B K )
2 2 7 ( Y)
a
Wi n d o w Re gu l a t o r Mo t o r
3 340
( R / L B )
a
2 4 ( D B / O )
An t i - The f t S wi t c h
4 No t Us e d
5 1 2 2 ( Y) Do o r L o c k S wi t c h 4
6 66 ( L B) Do o r L o c k Swi t c h I l l umi n a t i o n
7 465
( W/ L B )
Mo d u l e t o S wi t c h
3 177 ( W) Se a t S wi t c h Se n s o r
9 344
( B K / Y )
Do o r Aj a r S wi t c h
10 1050
( L G / P )
8
33 ( W/ P K )
P o we r I gn i t i o n St a r t
St a r t e r I n t e r l o c k
11 7 8 ( L B / Y ) Do o r L o c k Swi t c h 1
12 7 9 ( L G / R ) Do o r L o c k S wi t c h 2
DRIVER DOOR MODULE
CONNECTOR 03
TOWN CAR
N12604-A
Pin
Number Ci rcui t Ci r cui t Func t i on
1 2 2 6
( W/ B K )
2 9 0 3 ( R ) Re l a y t o Mo t o r Do wn
3 400
( L B / B K )
Wi n d o w Re gu l a t o r S wi t c h Fe e d
4 517
( B K / W)
B+
Pin
1 407 ( T / BK) Dr i v e r ' s Wi n d o w Do wn I nput
2 2 2 7 ( Y) Dr i v e r ' s Wi n d o w Do wn Ou t pu t
3 193
( Y/ L G )
I gn i t i o n ( Ho t in A CC o r RUN)
4 517
( B K / W)
B + t o Mo d u l e
MASTER WINDOW REGULATOR
CONTROL SWITCH N10903-B
Pin
1 1 7 0 ( R / L B ) Wi n d o w L o c k Co n t r o l Si gn a l
2 400
( L B / B K )
P o we r
4 2 2 6
( W/ B K )
Le f t Fr o n t Wi n d o w On e - To uc h
Wi n d o w Re gu l a t o r Co n t r o l
5 2 2 7 ( Y) Le f t Fr o n t Wi n d o w Mo t o r
6 313 ( W/ Y ) Ri ght Fr o n t Wi n d o w Co n t r o l
( Co n t i n ue d )
1995 To wn Car , Cr o wn Vi c t o r i a / G r a n d Ma r q u i s Jul y 1994
01- 11- 6 Gl a s s , Fr a me s a n d Me c h a n i s ms 01- 11- 6
Pin
7 314 ( T / L B) Ri ght Fr o n t Wi n d o w Co n t r o l
8 317
( G Y/ O )
L e f t Re a r Wi n d o w Co n t r o l
9 316 ( Y/ L B ) Le f t Re a r Wi n d o w Co n t r o l
10 319
( Y / B K )
Ri ght Re a r Wi n d o w Co n t r o l
11 32 0
( R / B K )
Ri ght Re a r Wi n d o w Co n t r o l
WINDOW REGULATOR CONTROL SWITCH
N10906-A
Pin
1 3 1 3 ( W / Y ) Wi n d o w Re gu l a t o r Co n t r o l S wi t c h
2 3 3 3 ( Y / R ) Wi n d o w Re gu l a t o r E l e c t r i c
Dr i v e - Do wn I nput
3 1 7 0 ( R / L B ) Wi n d o w Re gu l a t o r Co n t r o l S wi t c h
Fe e d
4 314 (T/ LB) Wi n d o w Re gu l a t o r Co n t r o l S wi t c h
5 3 3 4 ( R / Y ) Wi n d o w Re gu l a t o r E l e c t r i c
Dr i v e - Up I nput
6 No t Us e d
RH Rear
N10905-A
Pin
1 32 0
( R / B K )
Wi n d o w Re gu l a t o r Co n t r o l Swi t c h
3 No t Us e d
4 319
( Y/ B K )
Wi n d o w Re gu l a t o r Co n t r o l S wi t c h
6 3 3 4 ( R / Y ) Wi n d o w Re gu l a t o r E l e c t r i c
Fe e d
5 1 ( 4
N10910-A
Pin
1 317
( G Y/ O )
Wi n d o w Re gu l a t o r Co n t r o l Swi t c h
2 334 ( R / Y) Wi n d o w Re gu l a t o r E l e c t r i c
Fe e d
4 3 1 6 ( Y / L B ) Wi n d o w Re gu l a t o r Co n t r o l Swi t c h
6 No t Us e d
Po we r Wi n d o ws Cr o wn Vi c t o r i a , Gr a nd Mar qui s
HOT I N A C C OR RUN
FUS E
JUNCTION
P A N E L
RH
FRONT
WINDOW
RE G UL A T OR
E L E CT RI C
DRI VE
1995 To wn Car, Cr o wn Vi c t o r i a / G r a n d Ma r q u i s J u l y 1994
01- 11- 8 G l a s s , Fr ames and Mechani sms
01- 11- 8
Cr own Vi ct ori a, Grand Marqui s (Cont i nued)
TO l/P
I LLUMI NATI ON
" \ | WfNDOW LOCK SWITCH
WI RE TAPED BACK
WI TH POLI CE OPTI ON
i
t
LH
REAR
WINDOW
REGULATOR
CONTROL
SWITCH
3 3 4 1 R / Y
LH
REAR
WINDOW
REGULATOR
ELECTRIC
DRIVE
RH
REAR
WINDOW
REGULATOR
ELECTRIC
DRIVE
of this circuit
N10909-B
01- 11- 9 Gl a ss, Fr a me s a n d Me c h a n i s ms 0 1 - 1 1 - 9
Connect or En d Vi ewsCr own Vi ct or i a, Grand
Marqui s
WINDOW/DOOR LOCK CONTROL
SWITCH (MASTER)
N10393-B
Pin
1 484
( O / B K )
L i gh t i n g Di s p l a y
3 119
( P K / Y)
5 517
( B K / W)
B +
7 120
( P K / L G )
8 2 2 6
( W/ B K )
LH Re gu l a t o r Mo t o r
9 3 1 3 ( W / Y ) RH Re gu l a t o r Mo t o r
10 407 ( T / BK) Li mi t S wi t c h
11 314 ( T / L B) RH Re gu l a t o r Mo t o r
12 484
( O / B K )
15 3 1 6 ( Y / L B ) LH Re gu l a t o r Mo t o r
16 319
( Y/ B K )
RH Re gu l a t o r Mo t o r
17 317
( G Y/ O )
LH Re gu l a t o r Mo t o r
18 32 0
( R / B K )
RH Re gu l a t o r Mo t o r
Pin
Number Ci r cui t Ci r cui t Func t i on
19 193
( Y/ L G )
Re g u l a t o r Re l a y Fe e d
2 0 1 7 0 ( R / L B ) Re g u l a t o r S wi t c h Fe e d
D
JTH
5
ONE TOUCH WINDOW
REGULATOR CONTROL
N10904-A
Pi n
1 2 2 7 ( Y) Wi n d o w Re gu l a t o r E l e c t r i c
2 407 ( T / BK) On e - To u c h Wi n d o w Re gu l a t o r
Co n t r o l - Do wn I nput
3 193
( Y/ L G )
On e - To u c h Wi n d o w Re gu l a t o r
Co n t r o l Fe e d
4 2 2 6
( W/ B K )
Wi n d o w Re gu l a t o r E l e c t r i c
RH Fr ont
1
WINDOW/DOOR LOCK
CONTROL SWITCH (RIGHT FRONT)
m m
$
4
B
1995 To wn Car, Cr o wn Vi c t o r i a / Gr a n d Ma r q ui s Jul y 1994
Pi n
1 484
( O / B K )
3 3 3 4 ( R / Y ) Re gu l a t o r Mo t o r
4 314 0 7 L B ) L H Fr o n t Wi n d o w Re gu l a t o r
5 1 7 0 ( R / L B ) Re gu l a t o r S wi t c h
6 3 1 3 ( W / Y ) RH Re gu l a t o r Mo t o r
7 333 ( Y/ R ) Re gu l a t o r Mo t o r
8 118
( P K / O )
Do o r L o c k Ou t pu t
9 119
( P K / Y)
Do o r Un l o c k Gr o un d
10 517
( B K / W)
L o c k Swi t c h P o we r
11 120
( P K / L G )
Do o r L o c k Gr o u n d
12 117
( P K / B K )
Do o r Un l o c k Ou t pu t
13 57 ( BK) Gr o un d
14 484
( O / B K )
L i gh t i n g Di s pl a y
RH Rear
0
LEFT AND RIGHT REAR
WINDOW CONTROL SWITCH
N12612-A
Pin
1 3 3 4 ( R / Y ) Wi n d o w Up Ou t pu t
2 316
( Y/ L B ) '
Wi n d o w Do wn I nput
319
( Y/ BK) ' "
Wi n d o w Do wn I nput
3 1 7 0 ( R / L B ) Wi n d o w L o c k- Ou t Swi t c h
4 317
( G Y/ O) '
32 0
( R / B K ) "
Wi n d o w Up I nput
5 333 ( Y/ R ) Wi n d o w Do wn Out put
7 484
( O / B K )
Wi n d o w Co n t r o l S wi t c h I l l umi n a t i o n
L e f t Re a r Wi n d o w Co n t r o l Swi t c h
Ri ght Re a r Wi n d o w Co n t r o l S wi t c h
01- 11- 11
Gl ass, Fr ames and Mechani sms 0 1 - 1 1 - 1 1
Heat ed Ba c k Wi ndowTown Ca r
HOT AT A L L TI MES
T O
I NST RUME NT
CL US T E R
T O
P OWE R
T RA I N
C O N T R O L
MODUL E
1
1 P OWE R
. DISTRIBUTION
1 BOX
| t
7 0 1 L B/ W
I 1
40A J
L . - J
BK/ Y
- 0 3 - 1 2 CI - 8
HE A T E D BACKL I TE I SO
I NDI CA TOR OUT P UT B U S
HEATED
BACKLITE C4- 1
HEATED AND MIRRORS
BACKL I TE
CONT ROL
POWER LOGIC PWM S WI T CH
GND GND DIMMING INPUT
C3-4 C3- 9 C 3 - 1 2 C 2 - 18
LIGHTING
CONTROL
MODULE
(LCM)
186
" .FUSE
*3 I JUNCTION
;j P A N E L
tJ2*-J
BR/ L B
5 9 1
BR/ L B
of thi s circuit
Connect or End Vi ewsTown Car
HEATED BACK WINDOW
SWITCH AND LIGHT
CONNECTOR N12591-A
Pin
N u m b e r Ci rcui t Ci rcui t Funct i on
1 484
( O / B L )
Cl us t e r Di s pl a y
2 59 ( DG / P ) He a t e d Ou t s i d e Re a r Vi e w Mi r r o r
Fe e d
3 1010
( DB / O )
He a t e d Ba c k L i ght Swi t c h t o
L i gh t i n g Co n t r o l Mo d u l e ( L CM)
I nput
LIGHTING CONTROL
MODULE CONNECTOR C1
K22687-A
Pin
1 2 96 ( W/ P ) R u n / A c e B + I nput
2 1034
( B K / W)
3 158
( B K / P K )
Ke y In I gn i t i o n
4 No t Us e d
5 486
( B R / W)
L u g g a g e Co mp a r t me n t Do o r Aj a r
Pin
6 Not Us e d
7 No t Us e d
8 7 0 ( L B / W) Ke y l e s s En t r y , Me mo r y Se a t s , A BS
9 6 4 0 ( R / Y ) RUN/ S T A RT B + I nput
10 1 0 3 3 ( R / Y) He a d l a mp S wi t c h
11 62 7
( B K / O )
P a s s e n g e r Do o r Aj a r S wi t c h
12 465
( W/ L B )
13 1032
( W/ B K )
14 3 4 0 ( R / L B ) Pa n i c Al a r m
15 No t Us e d
16 2 2 2
( B R / L G )
DRIVER SEAT CONTROL
MODULE CONNECTOR C2
K22688-A
Pin
1
_
St a r t e r I n t e r r upt Re l a y
2 932
( G Y/ W)
Hi gh Be a m Swi t c h I nput
3 No t Us e d
4 6 ( Y/ L G ) Hor n Re l a y
5 No t Us e d
6 2 2 0 ( P / O ) A u t o l a mp On / Of f
8 2 17
( DB / O )
Au t o l a mp De l a y
9 383 ( R / W) Ha za r d I n d i c a t o r ( Cr o wn Vi c t o r i a ,
Gr a n d Ma r q u i s )
Tr a n s mi s s i o n Co n t r o l I n d i c a t o r
L a mp ( To wn Ca r )
Pin
10 344
( B K / Y )
11 867 ( DB) Dr i v e r Do o r Aj a r S wi t c h
12 688
( G Y/ L B )
He a t e d Ba c k Wi n d o w Re l a y
13
_
No t Us e d
14 183 ( T / Y) E l e c t r o n i c I n st r ume n t Cl us t e r To n e
Re q u e s t / P o l i c e Da r k Ca r
15 1036
( B R / W)
He a d l a mp Di mme r S wi t c h I nput
( Do wn )
16 1035
( O / R )
( Up)
17 85
( B R / L B )
Sa f e t y Be l t S wi t c h
18 1010
( DB / O )
He a t e d Ba c k Wi n d o w S wi t c h
19
_
No t Us e d
2 0

No t Us e d
2 1

No t Us e d
2 2

No t Us e d
LIGHTING CONTROL
Pin
1 7 05
( L G / O )
2 1 9 ( L B / R ) Va r i a b l e Vo l t a ge Di mmi n g Out put
t o A c c e s s o r i e s
( Co n t i n ue d )
Pin
3 117
( P K / B K )
4 57 ( BK) P o we r Gr o u n d
5 53
( B K / L B )
6 195 ( T / W) Ba t t e r y Vo l t a g e I nput t o L CM a n d
He a d l a mp Di mme r S wi t c h
7 No t Us e d
8 450
( DG / L G )
S a f e t y Be l t Wa r n i n g I n d i c a t o r
11 5 4 ( L G / Y) Ba t t e r y Vo l t a ge I nput
12 484
( O / B K )
Pul se Wi d t h Mo d u l a t o r ( P WM)
I l l umi n a t i o n Ou t pu t
13 44 ( L B) T u r n / Ha z a r d
14 14 ( BR) Pa r k L a mp s
15 385 ( W/ R ) Fl a s h e r P o we r
LIGHTING CONTROL
Pin
1 12
( L G / B K )
186
( B R / L B )
2 196
( DB / O )
175
( B K / Y)
1995 To wn Car, Cr o wn Vi c t o r i a / G r a n d Ma r q u i s Jul y 1994
01- 11- 14 Gl a ss, Fr a me s a n d Me c h a n i s ms
01- 11- 14
He a t e d Ba c k Wi n d o wCr o wn Vi c t o r i a , Gr a nd Ma r qui s
HOT A T A L L TI ME S
* I P OWE R
14 . DISTRIBUTION
1 BOX
HOT I N S T A RT OR RUN HOT I N A C C OR RUN
FUSE
JUNCTION
P A N E L
1 FUSE
. JUNCTION
I PANEL
.-ct* . - C1- 1
RUN/ STA RT RUN/ A CC
B+ I NP UT B+ I NP UT
RELAY
OUT P UT
ca-12
HE A T E D
BA CKL I TE
C ON T ROL
P OWE R L OG I C P WM S WI T CH
mo
G N D DI MMI NG I NP UT
C3- 4 C 3 - 1 2 . 02 * 18-
57
BK
% I O/ BK I j
0 10101 DB/ O I
8
1
0 K
1 1
L
o
L
t i
57 BK
HEATED
BACK
WINDOW
AND
SWITCH
of thi s circuit
N12585-A
01- 11- 15 Gl ass, Fr ames and Mec hani s ms
01- 11- 15
Connect or End Vi e ws Cr own Vi ct or i a, Grand
Marqui s
HEATED BACK WINDOW
SWITCH AND LIGHT
CONNECTOR
N12591-A
Pi n
1 484
(O/BL)
L i q u i d Cr y s t a l Di s p l a y
2 59 ( DG / P ) He a t e d Ou t s i d e Re a r v i e w Mi r r o r
Fe e d
3 6 8 8
(GY/ LB)
He a t e d Ba c k Wi n d o w S wi t c h t o
Ti me De l a y Re l a y
LIGHTING CONTROL
MODULE CONNECTOR C1
K22687-A
Pin
1 2 96 ( W/ P ) R u n / A C C B + I n p u t
2 1034
( B K / W)
3 158
( B K / P K )
4
No t Us e d
5 486
( B R / W)
L u gga ge Co mp a r t me n t Do o r Aj a r
Pi n
Number Ci r cui t Ci rcui t Fun c t i o n
6

No t Us e d
7

No t Us e d
8 7 0 ( L B / W ) Ke y l e s s En t r y , Me mo r y S e a t s , A BS
9 6 4 0 ( R / Y ) RUN/ S T A RT B + I n put
11 62 7
( B K / O )
P a s s e n ge r Do o r Aj a r S wi t c h
12 4 6 5
( W/ L B )
Do o r Ha n d l e S wi t c h
13 1032
( W/ B K )
Pa r k L a mp S wi t c h
14 3 4 0 ( R / L B ) Pa n i c Al a r m
15

Not Us e d
16 2 2 2
( B R / L G )
DRIVER SEAT CONTROL
MODULE CONNECTOR C2
K22688-A
Pin
1

Not Us e d
2 932
( G Y/ W)
3 Not Us e d
4 6 ( Y/ L G ) Hor n
5
_ ^
Not Us e d
6 2 2 0 ( P / O ) Au t o l a mp On / Of f
8 2 17
( DB/ O)
9 383 ( R / W) Ha za r d I n d i c a t o r ( Cr o wn Vi c t o r i a ,
10 344
( B K / Y)
( Co n t i n ue d )
1995 To wn Car, Cr o wn Vi c t o r i a / Gr a n d Ma r q u i s Jul y 1994
Pin
N u m b e r C i r c u i t Ci rcui t Funct i on
12 688
( DB / O )
13
No t Us e d
14 183 ( T / Y) E l e c t r o n i c I n st r ume n t Cl ust e r To n e
Re q u e s t
15 1036
( B R / W)
16 1035
( O / R )
17 85
( B R / L B )
Sa f e t y Be l t Swi t c h
18 1010
( DB / O )
Re a r Wi n d o w Swi t c h
19 No t Us e d
2 0
No t Us e d
"21
No t Us e d
2 2
No t Us e d
LIGHTING CONTROL
Pin
1 7 05
( L G / O )
2 1 9 ( L B / R ) Va r i a bl e Di mmi n g Out put t o
3 117
( P K / B K )
5 53
( B K / L B )
7 _ No t Us e d
8 450
( B K / L G )
Sa f e t y Be l t Wa r n i n g I n d i c a t o r
Pin
12 484
( O / B K )
Pul se Wi d t h Mo d u l a t o r ( P WM)
I l l umi n a t i o n Out put
13 44 ( L B) T u r n / Ha z a r d
15 385 ( W/ R ) Fl a s h e r P o we r
n
LIGHTING CONTROL
Pin
1 12
( L G / B K )
2 196
( DB / O )
i n s p e c t i o n a n d Ve r i f i c a t i o n
1. Verify t he vehicle owner' s original concern by
operati ng the power wi ndows/ heat ed back
wi ndow t o dupl i cate the condition.
Fr o n t d o o r p o we r wi n d o w
r e gu l a t o r d a ma g e d .
Fr o n t wi n d o w run d a ma g e d .
Fr o n t d o o r wi n d o w gl a s s out
of wi n d o w r un.
Fr o n t d o o r wi n d o w g l a s s
b r o ke n .
Ci r c ui t s o p e n / s h o r t e d .
L o o s e , c o r r o d e d
c o n n e c t o r s .
Da ma g e d wi n d o w r e gu l a t o r
c o n t r o l s wi t c h .
Da ma g e d wi n d o w r e gu l a t o r
e l e c t r i c d r i v e .
Fu s e .
I n-l i ne c i r c ui t b r e a ke r .
S c r a t c h e d Gr i d .
3. If the inspection reveal s obvious concerns that
4. If the concerns remain after the i nspecti on,
Chart.
S y mp t o m Chart
equivalent for di agnosi s of pinpoint t est s.
Us i n g NGS
Di agnosti cs for thi s secti on require use of Rotunda
Generati on STAR TESTER 007- 00500 or equivalent
The module controlling the syst em bei ng di agnosed
communi cates wi t h t he dat a link connect or l ocat ed
beneath t he instrument panel .
GLASS, FRAMES AND MECHANISMS
Power Windows Completely
Inoperative
Supply open or shorted.
Ground open.
Window regulator control swi tch
inoperative.
Circuits open or short ed.
Window regulator electri c drive
inoperative.
Driver's door module.
Single Power Window Inoperative Window regulator electri c drive
ci rcui ts.
Window regulator electri c drive.
Window regulator control swi tch
ci rcui t s.
Window regulator control swi t ch.
One Touch Down Feature
Inoperative
Supply open /shor t ed.
Circuits open/short ed.
One touch down module
inoperative.
Ground open.
GO to Pinpoint Test C.
Window St uck/Bi ndi ng Window t racks.
Front door window regulator.
Rear Window Will Not Defrost Supply open / shorted.
Ground open.
Circuits open/short ed.
Window regulator control swi t ch.
Rear Window Defroster Will Not
Shut Off Automatically
Circuit.
Heated back window swi tch and
light
Heated back window control relay
P i n p o i n t T e s t s
PINPOINT TEST A: POWER WINDOWS COMPLETELY INOPERATIVE
A1 CHECK DELAYED ACCESSORY IN RUN
Yes
No
System operating
normally.
GO t o A2.
Turn ignition swi tch to RUN.
Test all wi ndows.
Do wi n d o ws oper at e?
Yes
No
System operating
normally.
GO t o A2.
A2 CHECK ACCESSORY DRIVER'S WINDOW
INOPERATIVE
Yes
No
GO t o A5.
GO t o A3.
After repeati ng steps in A1.
Do all wo r k except dri ver' s wi ndow?
Yes
No
GO t o A5.
GO t o A3.
Connect t he OBDII st yl e communi cati on cabl e t o t he
NGS. At t ach t he NGS and communi cati on cabl e t o the
DLC beneath t he instrument panel . Sel ect t he proper
vehi cl e model and year f rom t he NGS menu. You may
then access t he testi ng area of t he NGS menu
requi red t o di agnose thi s syst em.
1995 Town Car, Cr o wn Vi c t o r i a / Gr a n d Ma r q u i s Jul y 1994
01- 11- 18 Gl a s s , Fr a me s a n d Me c h a n i s ms
01- 11- 18
PINPOINT TEST A: POWER WINDOWS COMPLETELY INOPERATIVE (Cont i nued)
A3 CHECK ACCESSORY PASSENGERS WINDOW
INOPERATIVE
Yes
No
CHECK speci fi c
passenger's window
circuit. RETEST system.
GO to A4.
After repeating steps in A1.
Do any passenger wi ndows wo r k?
Yes
No
CHECK speci fi c
passenger's window
circuit. RETEST system.
GO to A4.
A4 CHECK ACCESSORY NO WINDOWS WORK
Yes
No
CHECK Circuit 14 (BR).
CHECK Circuit 193
(Y/LG). RETEST system.
GO to AS.
After repeating steps in A1.
Do all wi ndows not wo r k?
Yes
No
CHECK Circuit 14 (BR).
CHECK Circuit 193
(Y/LG). RETEST system.
GO to AS.
A5 TEST DRIVER'S WINDOW DOWN SWITCH
Yes
No
GOt o A6.
SERVICE driver's window
down swi tch and Circuit
407 (T/BK) from swi tch t o
DDM. RETEST system.
Connect Rotunda New Generation Star Tester
007-00500 or equivalent to Data Link Connector.
While holding driver's window down swi t ch, request
DDM Window Switch Status PID.
Does PID i ndi cat e dri ver' s wi n d o w swi t ch down?
Yes
No
GOt o A6.
down swi tch and Circuit
407 (T/BK) from swi tch t o
DDM. RETEST system.
AS BYPASS DRIVER'S DOOR MODULE
Yes
No
REPLACE driver's door
Circuit 226 (W/ BK).
RETEST system.
Remove connector C3 from DDM.
Jumper pin C3-1 and C3-2 together.
Using window swi t ch, run window up and down.
(Note that one touch down will not work.)
Does wi ndow oper at e?
Yes
No
Circuit 226 (W/ BK).
RETEST system.
PINPOINT TEST B: SINGLE POWER WINDOW INOPERATIVE
B1 CHECK WINDOW OPERATION
Yes
No
GOt o B2.
Operate all windows from driver swi t ch.
Do all wi ndows oper at e pr oper l y ?
Yes
No
GOt o B2.
B2 CHECK INDIVIDUAL WINDOW OPERATION
Yes
No
ADVISE customer of the
lockout feature.
GOt o B3.
Turn ignition swi t ch to RUN.
Turn off window lockout on driver door swi t ch.
Operate windows from all passenger (not drivers)
swi t ches.
Do all wi ndows oper at e pr oper l y ?
Yes
No
ADVISE customer of the
lockout feature.
GOt o B3.
B3 CHECK INDIVIDUAL WINDOW PID
Yes
No
Go to Pinpoint Test A.
SERVICE window down
swi tch and Circuit 407
(T/BK) from switch to
driver door module.
RETEST system.
Connect Rotunda New Generation STAR Tester
007-0500 or equivalent to data link connector.
While holding passenger window down swi t ch,
request driver door module window status PID.
Does PID i ndi cat e wi ndow swi t c h down?
Yes
No
Go to Pinpoint Test A.
SERVICE window down
swi tch and Circuit 407
(T/BK) from switch to
driver door module.
RETEST system.
PINPOINT TEST C: ONE TOUCH DOWN FEATURE INOPERATIVE
C1 TEST ONE TOUCH DOWN
Yes
No
GOt o C5.
GOt o C2.
Depress driver's window down swi t ch for less than
480 ms.
m Does dri ver' s wi ndow move all t he way down?
Yes
No
GOt o C5.
GOt o C2.
PINPOINT TEST C: ONE TOUCH DOWN FEATURE INOPERATIVE (Cont i nued)
TEST STEP - RESULT ACTION TO TAKE
C2 TEST WINDOW POWER TO DDM
Yes
No
GO t o C3.
SERVICE window power
Circuit 193 (Y/ LG) t o
driver's door module for
open ci rcui t. RETEST
system.
C o n n e c t R o t u n d a N e w G e n e r a t i o n S t a r T e s t e r
007-00500 t o data link connector.
Put ignition swi tch in RUN.
Request DDM ignition swi tch status PID.
Does i gni t i on swi t c h st at us PID i ndi cat e
Accessor y ?
Yes
No
GO t o C3.
SERVICE window power
Circuit 193 (Y/ LG) t o
driver's door module for
system.
C3 TEST DDM LOGIC GROUND
Yes
No
RECONNECT module and
battery. GO to C4.
SERVICE dri ver's door
module logic ground
Circuit 57 (BK). RETEST
system.
Turn ignition swi tch OFF. Disconnect battery.
Disconnect connector C1 from driver's door module.
Test continuity from Pin C1-15t o ground.
Yes
No
RECONNECT module and
battery. GO to C4.
SERVICE dri ver's door
module logic ground
Circuit 57 (BK). RETEST
system.
C4 TEST WINDOW OPERATION FOR STICKING
Yes
No
SERVICE window
mechanism. MAKE SURE
that nothing is blocki ng
the path of the window.
RETEST syst em.
Run driver's window up and down several times and
observe motion of window.
Does wi ndow move smoot hl y, wi t hout j er ki ng or
st i c ki ng?
Yes
No
SERVICE window
mechanism. MAKE SURE
that nothing is blocki ng
the path of the window.
RETEST syst em.
C5 TEST CANCEL WITH UP SWITCH
Yes
No
System operati ng
normally.
GO to C6.
Run window up.
Press window down swi tch for less than 480 ms.
While window is in motion, depress driver's window
up swi t ch.
Does wi ndow mot i on st op?
Yes
No
System operati ng
normally.
GO to C6.
C6 TEST WINDOW UP SWITCH INPUT TO DDM
Yes
No
REPLACE driver's
window. RETEST syst em.
up switch input t o module.
RETEST system.
007-00500 or equivalent to dat a link connector.
While holding driver's window up swi t ch, request
D D M window swi tch status PID.
Does PID i ndi cat e dri ver' s wi ndow swi t c h up?
Yes
No
REPLACE driver's
window. RETEST syst em.
up switch input t o module.
RETEST system.
PINPOINT TEST D: WINDOW STUCK/BINDING
D1 WINDOW REGULATOR ELECTRIC DRIVE RUNS
SLOWLY
Yes
No
REMOVE obstructi on.
CLEAN and LUBRICATE
glass run. RESTORE
vehicle. RETEST syst em.
GOt o D2 .
Remove trim panel at suspect window.
Actuate window regulator control swi tch in DOWN
posi ti on.
Observe window in glass runs.
Is t here obst r uc t i on i n gl ass runs?
Yes
No
REMOVE obstructi on.
CLEAN and LUBRICATE
glass run. RESTORE
GOt o D2 .
D2 CHECK WINDOW REGULATOR OPERATION
Yes
No
GO to D3.
ADJUST regulator and
guides as outlined.
RESTORE vehicle.
RETEST syst em.
Actuate window regulator control swi tch in UP
posi ti on. Observe regulator operati on.
Does regul at or ski p or bi nd?
Yes
No
GO to D3.
ADJUST regulator and
guides as outlined.
RESTORE vehicle.
RETEST syst em.
01- 11- 2 0 Gl a ss, Fr a me s a n d Me c h a n i s ms 01- 11- 2 0
PINPOINT TEST D: WINDOW STUCK/BINDING (Cont i nued)
D3 CHECK REGULATOR AND WINDOW REGULATOR
ELECTRIC DRIVE
Yes
No
REPLACE rear door
electri c window regulator
or front door window
regulator as outlined.
RESTORE vehicle.
RETEST system.
REPLACE window
regulator electri c drive as
outlined. RESTORE
Remove window regulator electric drive as outlined.
Carefully inspect window regulator electri c drive
and regulator gears.
Is t here damage t o gears at regul at or?
Yes
No
REPLACE rear door
electri c window regulator
or front door window
regulator as outlined.
RESTORE vehicle.
RETEST system.
REPLACE window
regulator electri c drive as
outlined. RESTORE
PINPOINT TEST E: REAR WINDOW WILL NOT DEFROSTTOWN CAR
E1 CHECK FUSE 13
Yes
No
GO t o E7 .
CHECK fuse D in power
distribution box and fuse
j unction panel Fuse 13.
Note that Fuse 13 will
only have power when
rear defroster is acti ve. If
fuse is good, GO to E2.
Put ignition swi t ch in run.
Press heated back window swi tch and light.
Read voltage at fuse j unction panel No. 13.
Is t here vol t age at t he f use?
Yes
No
GO t o E7 .
CHECK fuse D in power
fuse is good, GO to E2.
E2 TEST HEATED BACK WINDOW SWITCH
Yes
No
SERVICE heated back
window switch and light
for stuck swi tch.
SERVICE Circuit 688
(GY/LB) for short t o
GO to E3.
Request heated backli t e swi t ch status PID.
Does PID i ndi cat e heat ed back wi ndow swi t ch
and l i ght act i ve?
Yes
No
SERVICE heated back
window switch and light
for stuck swi tch.
SERVICE Circuit 688
GO to E3.
E3 TEST HEATED BACK WINDOW SWITCH
Yes
No
GO to E4.
SERVICE heated back
window switch and light.
SERVICE Circuit 688
(GY/LB) for open circuit.
RETEST system.
While holding heated back window swi tch and light,
request heated back window swi tch status PID.
Yes
No
GO to E4.
SERVICE heated back
SERVICE Circuit 688
(GY/LB) for open circuit.
RETEST system.
E4 TEST IGNITION STATUS
Yes
No
GOt o E5.
CHECK Fuses 6 and 9. If
both fuses are good,
(W/ LB) and 640 (R/ Y).
RETEST system.
Request ignition swi tch status PID.
Does PID i ndi cat e i gni t i on i n run?
Yes
No
GOt o E5.
(W/ LB) and 640 (R/ Y).
RETEST system.
E5 TEST HEATED BACK WINDOW FEED
Yes
Yes
GOt o E6.
SERVICE Circuit 175
(BK/ Y). RETEST system.
Remove connector C4 from LCM.
Read voltage at Pin 2 of connector.
Yes
Yes
GOt o E6.
SERVICE Circuit 175
(BK/ Y). RETEST system.
E6 TEST HEATED BACK WINDOW OUTPUT
Yes
No
REPLACE lighting control
SERVICE Circuit 186
(BR/LB). RETEST
system.
Using a j umper wi re, short pins 1 and 2 on LCM
connector C4 together.
Read voltage at Fuse 13.
Yes
No
SERVICE Circuit 186
(BR/LB). RETEST
system.
01- 11- 21 Gl a s s , Fr ames and Mechani sms
01- 11- 21
PINPOINT TEST E: REAR WINDOW WILL NOT DEFROSTTOWN CAR (Continued)
E ? TEST HEATED BACK WINDOW INDICATOR
Yes
No
GO to E8.
SERVICE heat ed back
window swi t ch and light.
RETEST syst em.
M a k e s u r e that w i n d o w defroster i s s t i l l o n .
Is window defroster Indicator lit?
Yes
No
GO to E8.
SERVICE heat ed back
window swi t ch and light.
RETEST syst em.
E 8 TEST VOLTAGE ON CIRCUIT 186 (BR / LB)
Yes
No
GO to E9.
SERVICE C i r c u i t 186
(BR/LB). RETEST
system.
M a k e s u r e t h a t w i n d o w defroster i s s t i l l o n .
Read voltage o n connector t o radio isolator module
C i r c u i t 186 ( B R / L B ) .
Is voltage reading B+ ?
Yes
No
GO to E9.
SERVICE C i r c u i t 186
(BR/LB). RETEST
system.
E 9 TEST RADIO ISOLATOR MODULE INPUT
Yes
No
GO t o E10.
SERVICE radio isolator
M a k e s u r e t h a t w i n d o w defroster i s s t i l l o n .
R e a d voltage o n o u t p u t o f r a d i o isolator m o d u l e t o
w i n d o w g r i d .
Is voltage reading B+ ?
Yes
No
GO t o E10.
E 1 0 TEST GROUNDS
Yes
No
GO t o E 11.
RETEST syst em.
Check for continuity from vehicle ground t o Circuit
57 (BK) of radio isolator module.
Yes
No
GO t o E 11.
RETEST syst em.
E11 TEST RADIO ISOLATOR MODULE GROUND
Yes
No
REPLACE rear window.
RETEST syst em.
REPLACE radio isolator
Check for continuity to ground through t he radio
isolator module from the ground output to the
window defroster.
Yes
No
REPLACE rear window.
RETEST syst em.
PINPOINT TEST F: REAR WINDOW WILL NOT DEFROSTCROWN VICTORIA, GRAND MARQUIS
F 1 TEST FUSE 17
Yes
No
Go to F9.
CHECK Fuse 14 in power
Put ignition swi tch in RUN.
Read voltage at fuse j unction panel Fuse 17.
Is t here vol t age at t he f use?
Yes
No
Go to F9.
CHECK Fuse 14 in power
F2 TEST HEATED BACK WINDOW OUTPUT
Yes
No
GO to F6.
GOt o F3.
Probe back of connector C2 Pin C2-12 of lighting
control module.
Test for continuity with ground.
Yes
No
GO to F6.
GOt o F3.
F3 TEST HEATED BACK WINDOW SWITCH PID WITH
SWITCH INACTIVE
Yes
No
SERVICE swi tch for stuck
swi t ch. SERVICE Circuit
1010 ( D B / O ) for short to
GOt o F4.
007-00500 to dat a link connector.
Request heated backli te swi tch status PID.
Does PID i ndi cat e swi t ch act i ve?
Yes
No
SERVICE swi tch for stuck
swi t ch. SERVICE Circuit
1010 ( D B / O ) for short to
GOt o F4.
F4 TEST HEATED BACK WINDOW SWITCH P I D WITH
SWITCH ACTIVE
Yes
No
G O to PS-
S E R V I C E heated back
window swi tch and light.
SERVICE Circuit 1010
(DB / 0) for open ci rcui t.
RETEST system.
While holding heated b a c k l i t e swi t ch, request
heated backli te swi tch status PID.
Yes
No
G O to PS-
S E R V I C E heated back
window swi tch and light.
(DB / 0) for open ci rcui t.
RETEST system.
01- 11- 22 Gl ass, Fr ames and Mechani sms 01- 11- 22
PINPOINT TEST F: REAR WINDOW WILL NOT DEFROSTCROWN VICTORIA, GRAND MARQUIS (Cont i nued)
F5 TEST IGNITION STATUS
Yes >
No
(W/P) and 640 (R/ Y).
RETEST system.
Request ignition swi tch status PID.
Does PID i ndi cat e i gni t i on in RUN?
Yes >
No
(W/P) and 640 (R/ Y).
RETEST system.
F6 TEST HEATED BACKLITE RELAY CIRCUIT
Yes
No
GOt o F7 .
SERVICE circuit. RETEST
system.
Turn ignition swi tch off, then to RUN.
Check for continuity at input to heated back window
relay Circuit 688 (GY/LB) with ground.
Yes
No
GOt o F7 .
system.
F7 TEST HEATED BACKLITE FEED
Yes
No
GO to F8.
SERVICE B+ ci rcui t.
RETEST system.
Disconnect connector from heated back window
relay.
Read voltage at Circuit 185 (BK) on connector (2
places).
Yes
No
GO to F8.
SERVICE B+ ci rcui t.
RETEST system.
F8 TEST HEATED BACKLITE OUTPUT
Yes
No
REPLACE relay. RETEST
system.
system.
Using a jumper wi re, short Circuits 185 (BK) and 186
(BR / LB) on relay connector together.
Read voltage at Fuse 17.
Is vol t age readi ng B+?
Yes
No
REPLACE relay. RETEST
system.
system.
F9 TEST HEATED BACK WINDOW INDICATOR
Yes
No
GOt o FI O.
SERVICE heated back
RETEST system.
Ensure that heated backli te is still on.
Is heat ed backl i t e i ndi cat or l i t ?
Yes
No
GOt o FI O.
SERVICE heated back
RETEST system.
F10 TEST VOLTAGE ON CIRCUIT 186 (BR / LB)
Yes
No
TO t o F11.
system.
Ensure that rear defroster is still on.
Read voltage on connector to hidden antenna
module Circuit 186 (BR/LB).
Yes
No
TO t o F11.
system.
F11 TEST HIDDEN ANTENNA MODULE
Yes
No
GOt o F12.
Ensure that rear defroster is still on.
Read voltage on output of hidden antenna module to
heated back window.
Yes
No
GOt o F12.
F12 TEST GROUNDS
Yes
No
GOt o F13.
RETEST system.
Check for continuity from vehicle ground to Circuit
57 (BK) of radio isolator module.
Yes
No
GOt o F13.
RETEST system.
F13 TEST RADIO ISOLATOR MODULE
Yes
No
REPLACE back window
glass. RETEST system.
Check for continuity to ground through the radio
isolator module from the ground output to the
heated back window.
Yes
No
REPLACE back window
glass. RETEST system.
PINPOINT TEST G: REAR WINDOW DEFROSTER WILL NOT SHUT OFF AUTOMATICALLY TOWN CAR
G1 TEST MIRROR CIRCUIT
Yes
No
SERVICE Circuit 59
(DG/P) for short to B+ .
RETEST system.
GOt o G2.
Remove Fuse 13.
Test on output side of fuse for voltage.
Yes
No
SERVICE Circuit 59
(DG/P) for short to B+ .
RETEST system.
GOt o G2.
0 1 - 1 1 - 23 Gl ass, Fr ames a n d Mechani sms 01- 11 - 23
PINPOINT TEST G: REAR WINDOW DEFROSTER WILL NOT SHUT OFF AUTOMATICALLYTOWN CAR (Continued)
G2 TEST BACKLITE CIRCUIT
Yes
No
GO to G3.
module. REFER to
Section 15-02.
Test for voltage on input side o'f Fuse 13.
# Is voltage reading B+ ?
Yes
No
GO to G3.
module. REFER to
Section 15-02.
G3 TEST LIGHTING CONTROL MODULE
Yes
No
GO to G4.
Disconnect connector C4 from lighting control
module.
Test for voltage on input side of Fuse 13.
Yes
No
GO to G4.
G4 TEST ANTENNA ISOLATOR MODULE
Yes
No
SERVICE Circuit 186
(BR/LB) for short to B+ .
RETEST system.
module. REFER to
Section 15-02.
Remove heated backli te relay.
Yes
No
SERVICE Circuit 186
(BR/LB) for short to B+ .
RETEST system.
module. REFER to
Section 15-02.
PINPOINT TEST H: REAR WINDOW DEFROSTER WILL NOT SHUT OF AUTOMATICALLYCROWN VICTORIA, GRAND
MARQUIS
H1 TEST MIRROR CIRCUIT
Yes
No
SERVICE Circuit 59
(DG/P) for short to B+.
RETEST system.
GOt o H2.
Remove Fuse 17.
Test on output side of fuse for voltage.
Yes
No
SERVICE Circuit 59
(DG/P) for short to B+.
RETEST system.
GOt o H2.
H2 CHECK FUSE 17
Yes
No
GO to H3.
module. REFER to
Section 15-02.
Yes
No
GO to H3.
module. REFER to
Section 15-02.
H3 TEST LIGHTING CONTROL MODULE
Yes
No
GO to H4.
Disconnect connector B from lighting control
module.
Yes
No
GO to H4.
H4 TEST RELAY INPUT
Yes
No
GO to H6.
GO to H5.
Remove heated backli te relay.
Yes
No
GO to H6.
GO to H5.
H5 TEST RELAY GROUND
Yes
No
SERVICE Circuit 688
ground RETEST system.
REPLACE heated back
window relay. RETEST
system.
Test for continuity between Circuit 688 (GY / LB) at
the heated backli te relay and ground.
Is t here cont i nui t y?
Yes
No
SERVICE Circuit 688
ground RETEST system.
REPLACE heated back
window relay. RETEST
system.
H6 TEST ANTENNA ISOLATOR MODULE
Yes
No
SERVICE Circuit 186
(BR/LB) for short t o B- f .
RETEST system.
module. REFER to
Section 15-02.
Disconnect connector from antenna isolator module.
Yes
No
SERVICE Circuit 186
(BR/LB) for short t o B- f .
RETEST system.
module. REFER to
Section 15-02.
1995 To wn Car , Cr o wn Vi c t o r i a / Gr a n d Ma r q u i s J u l y 1994
01- 11- 2 4 Gl a s s , Fr a me s a n d Me c h a n i s ms 01- 11- 2 4
H38
C o mp o n e n t T e s t s
Swi t c h T e s t s , Wi n d o w
Ma s t e r S wi t c h
Testing the master wi ndow regulator control swi t ch
( 14529) should be performed wi th the wi ndow
regul ator control swi t ch removed from the vehi cl e.
Use a sel f-powered test lamp or an ohmmeter such as
Rotunda Digital Volt-Ohmmeter 014- 00407 or
equivalent.
1. Clip one test lead probe on Pin 3, whi ch is
grounded.
2. Wi t h all wi ndow regul ator control swi t ches in the
NEUTRAL posi ti on, Pins 7 through 8 should have
continuity t o Pin 3.
3. Push all four wi ndow regul ator control swi t ches
f orward and hold in that position (t oward front of
vehi cl e when in installed position). Pins 5, 9, 11
and 7 should lose continuity t o Pin 3.
rearward and hold in that position ( t owar d rear of
vehicle when in installed position). Pins 4, 8, 10
and 6 should lose continuity t o Pin 3.
5. Remove the t est l ead f rom Pin 3 and connect it t o
Pin 2 (hot f eed pin). Wi t h all wi ndow regul ator
control swi t ches in t he NEUTRAL posi ti on, only
Pin 1 should have continuity t o Pin 2.
f or war d and hold in that posi ti on. Pins 5, 9, 11
and 7 should have continuity t o Pin 2.
7. Pull all four wi ndow regul ator control swi t ches
rearward and hold in that posi ti on. Pins 4, 8, 10
and 6 should have continuity t o Pin 2.
8. Push the lock-out swi t ch t o its detent posi ti on. Pin
2 shoul d not have continuity wi th any other pin.
9. If any wi ndow regul ator control swi t ch does not
t est as st at ed, repl ace the compl ete wi ndow
regul ator control swi t ch.
To wn Car
SWITCHES SHOWN
IN NEUTRAL
POSITION
LEFT REAR LEFT FRONT
RIGHT REAR RIGHT FRONT
LOCK-OUT SWITCH
PUSH UP FOR LOCK
OUT OPERATION
" " " " " " ; i o j
N8886-C
PIN IDENTIFICATION
Pin(s) Description
1 L o c ko u t S wi t c h Pi n
2 Ho t Fe e d Wh e n I gn i t i o n Swi t c h i s in " R U N "
3 Gr o un d Pi n
5 AND 4 Wi n d o w Re gu l a t o r E l e c t r i c Dr i v e L e f t Re a r
9 AND 8 Wi n d o w Re gu l a t o r E l e c t r i c Dr i v e L e f t Fr o n t
11 AND 10 Wi n d o w Re gu l a t o r E l e c t r i c Dr i v e Ri g h t
Fr o n t
7 AND 6 Wi n d o w Re gu l a t o r E l e c t r i c Dr i v e Ri g h t Re a r
S i n g l e S w i t c h
NOTE: Refer t o Connector End Vi ews while
performi ng test.
1. Use a sel f-powered t est lamp or an ohmmeter
such as Rotunda Digital Volt-Ohmmeter
014- 00407 or equivalent, to test the wi ndow
regul ator control swi t ch.
2. Wi th wi ndow regul ator control swi t ch in the
NEUTRAL posi ti on, there should be continuity
bet ween terminals 1 and 3, 2 and 5, and 4 and 6.
01- 11- 25 Gl ass, Fr ame
5.
Wi th wi ndow regul ator control swi t ch pushed
downwar d, there shoul d be continuity bet ween
termi nal s 2, 4 and 5, and 1 and 3. Terminal 6
should not have continuity wi t h any other
termi nal .
Wi th wi ndow regul ator control swi t ch pushed
upward, t here shoul d be continuity bet ween
terminals 2, 3 and 5, and 4 and 6. Terminal 1
should not have continuity wi t h any other
termi nal .
If the wi ndow regul ator control swi t ch does not
test as outlined, repl ace the wi ndow regul ator
control swi t ch.
Wi t h t he negati ve lead of t he meter grounded,
t ouch each gri d line of t he heat ed rear wi ndow at
its midpoint wi t h the posi ti ve l ead. A readi ng of
approxi mat el y 6 vol ts i ndi cates that t he line is
good. A readi ng of zero vol t i ndi cates that t he line
is broken bet ween the mi dpoi nt and t he B + side
of the gri d line. A readi ng of 12 vol ts i ndi cates
that t he circuit is broken bet ween t he midpoint of
t he gri d line and ground.
Heated Back Wi ndow Swi t ch and Li ght
1. Ground Pin 4 and connect a j umper wi re bet ween
Pins 2 and 3.
2. Appl y power t o Pin 2. The indicator should not
light.
3. Momentari l y actuate t he heated back wi ndow
swi t ch and light ( 18C621) t o ON. The i ndi cator
should come on and st ay on after the heated
back wi ndow swi t ch and light returns t o the
normal posi ti on.
4. The i ndi cator should go off under any one or more
of the following condi ti ons:
Heat ed back wi ndow swi t ch and light is moved
t o OFF.
Jumper wi re bet ween Pins 3 and 2 is removed.
Approxi mat el y 10 minutes has el apsed.
Heated Back Window Grid Wire Test
1. Using a strong lamp inside the vehi cl e, i nspect the
wi re gri d f rom the outsi de. A broken gri d wi re will
appear as a brown spot .
2. Run t he engine at idle. Set the heated back
wi ndow swi t ch and light t o ON. The i ndi cator
should come on.
3. Worki ng inside the vehi cl e wi th a 12-volt DC
vol tmeter such as Rotunda Digital Vol t-Ohmmeter
014- 00407 or equivalent, cont act t he broad
red-brown stri ps on t he rear wi ndow posi ti ve lead
t o bat t ery si de and negati ve lead t o ground si de.
The meter should read 10-13 vol ts. A l ower
vol tage readi ng i ndi cates a loose heat ed back
wi ndow ground wi re (pigtail) connecti on at the
heated back wi ndow ground wi re attachi ng
screw.
4. Contact a good ground point wi th the negati ve
lead of t he meter. The vol tage readi ng shoul d not
change.
Door Wi ndow Glass
Fr o n t
Re mo v a l
1. Remove front door trim panel ( 23942) and front
door tri m shield ( 237A04) . Refer to Secti on
01- 05.
2. Loosen front door gl ass run front retainer
retaining scr ew and position front door gl ass run
front retainer ( 21572) f or war d.
3. CAUTI ON: Do n o t a t t e mp t t o p r y o u t t h e
r i v e t s a s d a ma g e t o t h e f r o n t d o o r w i n d o w
gl a ss ( 2 1410) c o u l d r e s u l t .
NOTE: Prior t o removing the rivet center pins, it is
necessary t o pl ace a suitable bl ock support
between t he door outer panel and the front door
wi ndow channel bracket ( 23288) to stabi l i ze the
front door wi ndow gl ass during rivet removal .
Lower front door wi ndow gl ass t o gain access t o
t wo front door wi ndow channel bracket ri vets and
remove the center pins f rom ri vets using a drift
punch. Using a 1 / 4-inch di ameter drill, drill out
remainder of ri vets.
4. Remove front door wi ndow gl ass.
DOOR WINDOW
GLASS CHANNEL
BRACKET
RETAINER ASSY
DOOR WINDOW
GLASS BRACKET
SPACER
234A44
RIVET
385323-S100
FRONT WINDOW
REGULATOR ASSY
23200
NS853-B
Installation
1. Insert front door wi ndow gl ass into front door
( 20124) between front door belt line outsi de
weatherstri p ( 21452) and inner panel.
4.
5.
Position front door wi ndow gl ass into door f rame
and l ower front door wi ndow gl ass t o align wi t h
front door wi ndow channel bracket .
Install t wo 1 / 4-inch ri vets using Rotunda Blind
Fastener Installation Tool 107-R0600 or
equivalent (use of 1 / 4- 20 X 1-inch screw and
washer assembl i es and 1 / 4-i nch-20 nut and
washer assembl i es is opti onal ). Torque must not
exceed 9-14 N-m (7-10 Ib-ft). Equivalent metri c
f ast eners may al so be used.
Adj ust front door wi ndow gl ass as outlined.
Install front door tri m shield and front door tri m
panel . Refer t o Secti on 01- 05.
Re a r
Re mo v a l
1. Remove rear door tri m panel ( 27406) and
wat ershi el d. Refer t o Secti on 01- 05.
2. CAUTI ON: Do n o t a t t e mp t t o p r y o u t t h e
r i v e t s a s d a ma g e t o t h e r e a r d o o r w i n d o w
gl a s s ( 25712) c o u l d r e s u l t . Pr i o r t o r e mo v i n g
r i v e t c e n t e r p i n s , i t i s n e c e s s a r y t o p l a c e a
sui t abl e b l o c k s u p p o r t b e t w e e n d o o r o u t e r
pa n e l a n d r e a r d o o r w i n d o w c h a n n e l b r a c ke t
t o st a bi l i ze r e a r d o o r w i n d o w gl a s s d u r i n g
r i v e t r e mo v a l .
Remove rear door gl ass run front l ower retainer
( 25796) as outlined.
3. Lower rear door wi ndow gl ass t o gain access t o
t he t wo rear door wi ndow channel bracket
retaining ri vets and remove center pins f r om
ri vets using a drift punch. Using a 6. 35 mm
(1 / 4-inch) di ameter drill, drill out the remainder of
t he ri vets.
4. Remove rear door wi ndow gl ass.
DOOR WINDOW
GLASS CHANNEL
BRACKET
RETAINER
234A46
RIVET
38S323-S100
DOOR WINDOW
GLASS BRACKET
SPACER
234A44
REAR DOOR
ELECTRIC WINDOW
REGULATOR
27008
NS852~i
1. Insert rear door wi ndow gl ass into rear door
( 24631) bet ween rear door gl ass outsi de
weat herst ri p ( 25596) and inner panel .
2. Position rear door wi ndow gl ass into rear door
f rame and l ower rear door wi ndow gl ass t o align
wi t h rear door el ectri c wi ndow regulator ( 27008) .
3. Install t wo 6. 35 mm (1 / 4-i nch) ri vets using
Rotunda Blind Fastener Installation Tool
107-R0600 or equivalent (use of 1 / 4- 20 x 1 inch
bol ts is opti onal ). Torque must not exceed 9-14
Nm (7-10 Ib-ft). Equivalent metri c f ast eners may
al so be used.
4. Install rear door gl ass run front l ower retainer as
outlined.
5. Adj ust rear door wi ndow gl ass as outlined.
6. Install rear door tri m panel and watershi el d. Refer
0 1 - 1 1 - 2 7 Gl a s s , Fr a me s a n d Me c h a n i s ms 0 1 - 1 1 - 2 7
Rear Door Gl ass
s = - < 7 ) 0

NSS23-C
Par t
I t em Number Des c r i pt i on
1 25712 Rear Door Wi ndow Glass
Req'd)
3 N621906-S36 Nut (2 Req'd)
4 802034-S36 Rivet (5 Req'd)
P a r t
i t e m Nu mb e r De s c r i p t i o n
5 27008 Rear Door Elect ri c Wi ndow
Regulator
6 25860 Rear Door Glass Inside
Weat herst ri p
Lb-Ft )
W i n d o w R e g u l a t o r , P o w e r
F r o n t D o o r T o w n Ca r
Re mo v a l
1. CAUTI ON: Wh e n s e r v i c i n g f r o n t d o o r p o w e r
w i n d o w r e g u l a t o r mi n u s m o t o r ( 2 3 2 0 8 ) ,
r e g u l a t o r c a b l e t e n s i o n mu s t n o t b e a l t e r e d .
Ca b l e t e n s i o n i s p r e s e t a t p r o d u c t i o n .
I mp r o p e r a d j u s t me n t ma y r e s u l t i n p r e ma t u r e
f r o n t d o o r p o w e r w i n d o w r e g u l a t o r f a i l u r e o r
e r r a t i c o p e r a t i o n .
CA UTI ON: Be c a r e f u l n o t t o dr i l l t h r o u g h t h e
w i n d o w r e g u l a t o r b e h i n d i n n e r d o o r p a n e l .
A d d i t i o n a l r e p a i r s ma y b e n e c e s s a r y .
If front door wi ndow gl ass ( 21410) is in t he down
posi ti on and is i noperabl e, t he fol l owi ng st eps
must be t aken; if front door wi ndow gl ass is
operat i onal , pr oceed t o St ep 2.
a. Remove front door t ri m panel ( 23942) and
f ront door t ri m shi el d ( 237A04) . Refer t o
Sect i on 01- 05.
1995 T o wn Ca r , Cr o wn Vi c t o r i a / G r a n d Ma r q u i s J u l y 1994
b. Mark inner door panel and drill three hol es
12.7 mm (0. 5 inch) as shown.
mm&B
c. CAUTI ON: Be car ef ul not t o st r i ke or
scr at ch f r ont door wi ndow gl ass-
Remove front door power wi ndow regulator
retaining scr ews through hol es.
d. Remove front door power wi ndow regulator
minus motor off mounting bracket through
access hol e.
e. Remove wi ndow regul ator el ectri c dri ve
( 23394) f rom front door power wi ndow
regul ator minus mot or.
f. Raise front door wi ndow gl ass t o full up
position by hand and secure wi t h a cl amp.
g. Proceed t o St ep 4.
2. Remove front door tri m panel and front door tri m
shi el d. Refer t o Secti on 01- 05.
3. Remove front door wi ndow gl ass as outlined.
4. Di sconnect wi ndow regul ator el ectri c dri ve wiring
connector.
5. NOTE: Use care not t o enlarge sheet metal hol es
in the door inner panel .
Remove t hree 1 / 4-inch rivets retaining wi ndow
regul ator el ectri c dri ve t o inner panel and t wo
6. 35 mm (1 / 4-inch) ri vets retaining l ower bracket
of front door power wi ndow regulator minus
motor t o inner panel . Use drift punch t o knock out
center pins for each rivet. Using a 6. 35 mm
( 1 / 4-inch) di ameter drill, drill out remainder of
rivet.
6. Remove t wo upper front door power wi ndow
regul ator retaining nuts.
7. Remove front door power wi ndow regulator minus
motor f rom front door ( 20124) .
1. Lubri cate front door power wi ndow regulator
minus motor wi t h Teflon Lubricant
E7FZ-19590-A or equivalent meeting Ford
speci fi cati on ESB-M1C111-A as outlined.
2. Install front door power wi ndow regulator minus
motor into access hole in inner panel .
3. Position front door power wi ndow regulator minus
motor using upper front door power wi ndow
regulator studs and t abs on wi ndow regulator
el ectri c dri ve mounting bracket .
4. Install ri vets attachi ng front door power wi ndow
regul ator minus motor t o door inner panel (1 / 4- 20
X 112 inch screw and 1 / 4- 20 nut and washer
assembl i es or equivalent metric fasteners may be
used as al ternates).
5. Install t wo upper front door power wi ndow
regulator retaining nuts.
6. Install front door wi ndow gl ass as outlined.
7. Adj ust front door wi ndow gl ass as outlined.
8. Install front door tri m shield and front door tri m
Fr o n t D o o r C r o w n Vi c t o r i a , G r a n d Ma r q u i s
Re mo v a l
1. If front door wi ndow gl ass is in the down position
and is inoperable, the following st eps must be
t aken; if front door wi ndow gl ass is operati onal ,
proceed t o St ep 2.
a. Remove front door tri m panel and front door
tri m shi el d. Refer t o Secti on 01-05.
b. Di sconnect battery ground cabl e ( 14301) .
Unhook wi ndow regulator el ectri c drive
wi res.
c. CAUTI ON: Be c a r e f u l n o t t o s t r i ke o r
s c r a t c h f r o n t d o o r w i n d o w gl a ss b e c a u s e
i t c o u l d b r e a k.
Remove wi ndow regulator el ectri c dri ve
d. Remove wi ndow regulator el ectri c dri ve from
front door power wi ndow regulator minus
motor.
01- 11- 29
e. Rai se front door wi ndow gl ass to full up
posi ti on by hand and secure wi th a cl amp.
f. Pr oceed t o St ep 5.
Fr ont
RH DOOR SHOWN NUT
LH DOOR TYPICAL N621906-S36
3. Remove front door wi ndow gl ass as outlined.
4. Di sconnect wi ndow regulator el ectri c dri ve wi ri ng
connector.
5. NOTE: Use car e not t o enl arge sheet metal hol es
in t he door inner panel .
Remove t wo 6. 35 mm ( 1/ 4- i nch) rivets retaining
l ower bracket of front door power wi ndow
regul ator minus motor t o inner panel. Use drift
punch t o knock out center pins for each rivet.
Using a 6. 35 mm ( 1 / 4-inch) di ameter drill, drill out
remai nder of ri vet.
6. Remove t hree wi ndow regulator electric dri ve
retaining scr ews f rom inside door t o remove
wi ndow regul ator el ectri c dri ve f rom front door
power wi ndow regul ator minus motor.
7. Remove t wo upper front door power wi ndow
8. Remove front door power wi ndow regul ator minus
motor f rom front door.
1. Lubri cate regulator mechani sm wi th
Multi-Purpose Grease D0AZ-19584-AA or
ESB-M1C93-A as outlined.
2. Install front door power wi ndow regul ator minus
motor into access hole in inner panel .
3. Position front door power wi ndow regul ator minus
motor using upper front door power wi ndow
regulator studs and t abs on wi ndow regulator
electric drive mounting bracket .
4. Install rivets attachi ng front door power wi ndow
regulator minus motor t o door inner panel ( 1 / 4- 20
X 112 inch screw and 1 / 4- 20 nut and washer
assemblies or equivalent metric fasteners may be
used as al ternates).
5. Install t wo upper front door power wi ndow
6. Install wi ndow regulator electric dri ve. Do not
overti ghten screws.
7. Install front door wi ndow gl ass as outlined.
8. Adjust front door wi ndow gl ass as outlined.
9. Install front door tri m shield and front door tri m
panel. Refer to Secti on 01-05.
Re a r Do o r
Re mo v a l
1. CAUTI ON: Wh e n s e r v i c i n g r e a r d o o r e l e c t r i c
wi n d o w r e gul a t o r ( 2 7 008) a s s e mb l y ,
r e gul a t o r c a bl e t e n s i o n mu s t n o t b e a l t e r e d .
Ca bl e t e n s i o n i s pr e s e t a t p r o d u c t i o n .
I mpr o pe r a d j u s t me n t ma y r e sul t i n p r e ma t u r e
r e a r d o o r e l e c t r i c w i n d o w r e gu l a t o r f a i l ur e o r
e r r a t i c o p e r a t i o n .
If rear door wi ndow gl ass ( 25712) is in the down
position and is inoperable, the following st eps
must be taken; if rear door wi ndow gl ass is
operational, proceed to Step 2.
1995 Town Car, Cr o wn Vi c t o r i a / G r a n d Ma r q u i s Jul y 1994
01- 11- 30 Glass, Frames and Mechanisms 01- 11- 30
Remove rear door tri m panel ( 27406) and
VIEW A
DRILL THREE 12.7mm (0.5 INCH)
DIAMETER HOLES
87.32mm (3.44 INCH)
41.94mm (1.65 INCH)-
35.98mm (1.42 INCH'
69.24mm (2.73 INCH)'
27.46mm
(1.08 INCH)
_ J * - ? * - ÊXI STI NG WINDOW REGULATOR
(0.27 INCH) ELECTRIC DRIVE MOUNTING
BRACKET ATTACHMENT HOLES
VIEW A N8488-B
b. CAUTI ON: Be c a r e f u l n o t t o d r i l l t h r o u g h
t h e me c h a n i s m b e h i n d i n n e r d o o r pa n e l .
CAUTI ON: Be c a r e f u l n o t t o s t r i ke o r
s c r a t c h r e a r d o o r w i n d o w gl a s s ( 2 57 13) .
Mark inner door panel and drill t hree hol es
12.7 mm ( 1 / 2 inch) as shown.
3.
4.
5.
6.
7.
c. CAUTI ON: Be c a r e f u l n o t t o s t r i ke o r
s c r a t c h r e a r d o o r w i n d o w gl a s s .
Remove rear door el ectri c wi ndow regul ator
d. Remove rear door el ectri c wi ndow regulator
off mounting bracket through access hole.
e. Remove wi ndow regul ator el ectri c dri ve
( 23394) from housing and cover.
f. Raise rear door wi ndow gl ass t o full up
position by hand and secure wi t h a cl amp.
g. Proceed t o St ep 4.
Remove rear door tri m panel and wat ershi el d.
Remove rear door wi ndow gl ass as outlined.
Di sconnect wi ndow regul ator el ectri c dri ve wiring
connector.
Remove three 6. 35 mm (1 / 4-inch) ri vets retaining
motor bracket t o inner panel and t wo 6. 35 mm
(1 / 4-inch) ri vets retaining l ower bracket of rear
door el ectri c wi ndow regul ator t o inner panel. Use
drift punch t o knock out center pins for each rivet.
Using a 6. 35 mm (1 / 4-i nch) di ameter drill, drill out
remai nder of rivet. Use care not t o enlarge sheet
metal holes in the door inner panel.
Remove t wo upper rear door el ectri c wi ndow
regul ator retaining nuts.
Remove rear door el ectri c wi ndow regul ator.
01- 11- 31 Gl ass, Fr ames and Mechani sms 0 1 - 1 1 - 3 1
Wi ndow Regulat or, Rear
VIEWC
VIEWC
N9631-B
Par t
I t em Number De sc r i pt i on
1 25712 Rear Door Window Glass
Weatherstrip
3 24630 Rear Door
4 27008 Rear Door Electric Window
Regulator
Req'd)
I t e m
Pa r t
6 N385189-S100 Rivet (5 Req'd)
7 N621906-S36 Nut (2 Req'd)
8 234A46 Retainer (2 Req'd)
9 234A44 Spacer (2 Req'd)
10 385232-S100 Rivet (2 Req'd)
Lb-Ft)
1.
3.
Lubri cate rear door el ectri c wi ndow regul ator
wi t h Teflon Lubri cant E7FZ-19590-A or
ESB-M1C111-A as outlined.
Install rear door el ectri c wi ndow regul ator into
access hole in inner panel .
Position rear door el ectri c wi ndow regul ator using
upper rear door el ectri c wi ndow regul ator st uds
and t abs on wi ndow regul ator el ectri c dri ve
mounting bracket .
4. Install rivets retaining rear door electric wi ndow
regulator t o door inner panel ( 1 / 4- 20 x 112 inch
bolt and 1 / 4- 20 nut and washer assembl i es or
equivalent metri c fasteners may be used as
al ternates).
5. Install t wo upper rear door el ectri c wi ndow
regulator retaining nuts. Tighten t o 9-14 Nm
(7-10 Ib-ft).
6. Install rear door electric wi ndow regul ator as
outlined.
7. Adjust rear door wi ndow gl ass as outlined.
01- 11- 32 Gl ass, Fr a me s and Mechani sms 01- 11- 32
8. Install watershi el d and rear door tri m panel. Refer
Wi n d s h i e l d G l a s s
Re a r v i e w Mi r r o r Re mo v e r T91T- 17 7 00- A
Re mo v a l
1. CAUTI ON: Wh e n r e p l a c i n g u r e t h a n e i n s t a l l e d
gl a s s p a r t s , t h e v e h i c l e s h o u l d n o t b e d r i v e n
un t i l t h e u r e t h a n e ha s c u r e d . Thi s i s n o r ma l l y
a mi n i mu m o f 2 4 h o u r s . Thi s wi l l p r e v e n t t h e
wi n d s h i e l d gl a s s ( 03100) f r o m b e i n g j a r r e d
o u t o f p o s i t i o n .
For wi ndshi el d gl ass removal , remove windshield
wi per pivot arms ( 17526) .
2. Remove cowl vent screen ( 018A16) and finisher
porti on of wi ndshi el d outside moulding ( 03144)
by zipping it out of moulding sl ot. For Town Car,
remove finisher porti on of wi ndshi el d outsi de
moulding by cutting it away wi t h a utility knife.
3. Using Rearvi ew Mi rror Remover T91T-17700-A,
remove inside rear vi ew mirror ( 17700) and
inside rear vi ew mirror bracket ( 17698) .
4. Di sconnect hidden antenna wi re f rom terminal
l ocat ed at t op of wi ndshi el d.
5. WARNI NG: SAFETY GLASSES AND GLOVES
MUST BE WORN. FAI LURE TO DO SO MAY
RESULT IN PERSONAL I NJURY.
Use Rotunda Knife wi th Offset Bl ade 107-R1511
or Rotunda Interior Gl ass Cut-Out Knife Kit
163- 00005 or equivalent t o cut sealer. Refer t o
manufacturer' s instructions when using this t ool .
ROTUNDA KNIFE
N9628-B
6. Remove the windshield gl ass f rom vehicle using
suitable suction t ool .
7. NOTE: Trim urethane left on the flange wi t h a
utility knife or razor bl ade until surface is smooth
and free of cut s. If the urethane has cured, it is
not necessary t o remove all the urethane whi ch
remains on the flange. However, at no point
should exi sti ng urethane material exceed 1.2 mm
( 0. 05 inch).
Remove any excess urethane, using care not t o
smear urethane on component part s, crash pad
and vinyl roof.
8. Check flange sealing area for damaged sheet
metal or forei gn obj ects whi ch may have caused,
or may cause, gl ass breakage. Servi ce metal if
necessary.
01- 11- 33 Gl a s s , Fr ames and Mechani sms 01- 11- 33
REMOVAL AND INSTALLATION ( Co n t i n u e d )
I nst al l at i on
1. CAUTI ON: Al l ow al l gl ass par t s i nst al l ed wi t h
ur et hane ampl e t i me to c u r e . If ampl e t i me i s
not al l owed, i t ma y r esul t i n t he wi ndshi el d
gl ass l ooseni ng o r l eaki ng.
NOTE: Trim urethane left on the flange wi t h a
utility knife or razor bl ade until surf ace is smoot h
and f ree of cut s. If the urethane has cured, it is
remai ns on the fl ange. However, at no point
shoul d the exi sti ng urethane material exceed 1.2
mm ( 0. 05 inch).
NOTE: Thoroughl y mix urethane metal primer t o
ensure uniform pigment of mix before use.
NOTE: A minimum of 30 minutes is requi red for
primer surface t o dry.
If pai nted sheet metal has been exposed
anywhere al ong t he fl ange, use a cl ean brush and
appl y Urethane Metal Primer WSB-M2G234-C or
equivalent t o windshield opening fl ange. Appl y t he
urethane metal primer only t o exposed
met al / pai nt ed surfaces. Do not appl y over
exi sti ng urethane.
2. Install f oam dam (wi th self-adhesive backi ng)
around windshield gl ass opening at end of metal
fl ange, and at uppermost side of seal area.
3. Pl ace wi ndshi el d gl ass and moulding assembl y on
a l ow, stabl e wor k surface, inside up.
If moulding is al ready on gl ass, proceed t o Step
4.
If moulding needs t o be installed, use the following
procedure:
Align " V " notch in cerami c paint and wi ndshi el d
outsi de moulding at t op center. Fully seat
wi ndshi el d outsi de moulding along t he t op edge of
wi ndshi el d gl ass then wor k along si des and
bot t om edges of the windshield gl ass.
4. Properl y align windshield gl ass t o body.
a. Pl ace windshield gl ass into openi ng. Center it
t op and bot t om, side t o si de.
b. Using maski ng tape or crayon, make
alignment marks at points on four si des of
bot h windshield gl ass and wi ndshi el d gl ass
openi ng.
5. Remove wi ndshi el d gl ass from vehi cl e and pl ace
it back on wor k tabl e.
6. Clean wi ndshi el d gl ass.
7. NOTE: Wi pe off i mmedi atel y after appl i cati on
because it fl ash-dri es.
Using a lint-free cl ot h, wi pe inside surf ace of
wi ndshi el d gl ass around peri phery in f rom edge of
t he wi ndshi el d outsi de moulding wi t h Urethane
Gl ass Wi pe WSB- M5B280- C2 or equivalent as
f ol l ows:
21. 0 mm ( 0. 80 inch) al ong t op and si des, 70. 0
mm ( 2. 75 inches) along bot t om.
8. Thoroughl y shake and sti r Urethane Gl ass Primer
WSB- M2G314- B or equivalent t o ensure uniform
pi gment mixing.
9. NOTE: Allow a minimum of five minutes f or gl ass
primer t o dry.
Using a clean brush, appl y primer t o inside
wi ndshi el d gl ass edge 21 mm ( 0. 8 inch) wi de
along t op and si des and 70 mm ( 2. 75 i nches)
wi de along bot t om windshield gl ass.
10. If exi sti ng (fully cured) urethane remains on metal
fl ange, appl y fresh urethane on t op of exi sti ng
materi al t o a total height of 14 mm ( 0. 55 inch)
above fl ange.
Appl y an even bead of urethane WSB-M2G316-B
around entire sheet metal flange next t o f oam
dam using an air pressure cartri dge gun. (Ai r line
pressure should be around 275. 8 kPa ( 40 psi ).
The bead should be triangular in shape, 14 mm
(0. 55 inch) hi gh, and 8. 0 mm ( 0. 33 inch) at base.
11. NOTE: This must be done within 10 minutes of
appl yi ng urethane.
Install wi ndshi el d gl ass onto vehicle, taki ng care
t o align marks on windshield gl ass and body f rom
Step 4b.
12. Install windshield wi per mounting arm and pivot
shaft ( 17566) , inside rear vi ew mirror bracket
and inside rear vi ew mirror and cowl vent screen.
13. CAUTI ON: Use onl y u r e t h a n e t o se a l a l l ai r
a n d wa f e r l e a ks af t er se a l ha s b e e n ma d e .
Connect hidden antenna wi re at top of wi ndshi el d.
01- 11- 34 Glass, Fr a me s and Mechanisms 01- 11- 34
CAUTI ON: Al l ow al l gl ass par t s i nst al l ed wi t h
ur et hane ampl e t i me to cur e. If ampl e t i me i s not
al l owed, wi ndshi el d gl ass may c o me l oose or
l eak.
Wi ndshi el d-Town Car
Par t
1 M2G316 High Vi scosi ty Urethane Adhesive (Part of 19562)
2 03100 Windshield Glass
3 03606 Windshield Garnish Moulding
A 8.0 mm (0.31 inch)
B 33.5 mm (1.31 inch)
C 59.0 mm (2.32 inch)
Wi ndshi e l dCr own Vi ct ori a, Gr and Marqui s
N8854-C.
Par t
2

U r e t h a n e G l a s s W i p e ( P a r t
of 1 9 5 6 2 )
3

U r e t h a n e G l a s s P r i m e r ( P a r t
of 1 9 5 6 2 )
4

U r e t h a n e Me t a l Primer ( P a r t
of 1 9 5 6 2 )
Par t
5

U r e t h a n e A d h e s i v e ( P a r t of
1 9 5 6 2 )
6 Foam Dam
8 Stop (2 Req'd)
9 381500-S Rivet (2 Req'd)
01- 11- 36
Gl ass, Fr a me s a n d Me c ha n i s ms 01- 11- 36
B a c k W i n d o w G l a s s
Re mo v a l
1. CAUTI ON: When r epl aci ng ur et hane i n s t a l l e d
gl a s s par t s, t he vehi cl e shoul d not b e dr i ven
un t i l t h e u r e t h a n e ha s c u r e d . Th i s i s n o r ma l l y
a mi n i mu m of 24 hour s. Thi s wi l l p r e v e n t t he
b a c k w i n d o w gl a s s ( 42006) f r om b e i n g
j a r r e d out o f posi t i on.
Di sconnect defroster and hidden antenna
terminals if equi pped for back wi ndow gl ass
removal .
2. WARNI NG: SAFETY GLASSES AND GLOVES
MUST BE WORN. FAI LURE TO DO SO MAY
RESULT IN PERSONAL I NJURY.
Use Rotunda Knife wi t h Offset Bl ade 107-R1511
or Rotunda Interior Auto Gl ass Cut-Out Knife Kit
163- 00001 or equivalent t o cut sealer. Refer t o
manufacturer' s instructions when using this t ool .
ROTUNDA KNIFE
N9628-B
3. Remove the back wi ndow gl ass f rom vehicle
using suitable sucti on t ool .
4. NOTE: Trim urethane left on the flange wi t h a
utility knife or razor blade until surface is smoot h
and f ree of cut s. If the urethane has cured, it is
not necessary t o remove all t he urethane whi ch
should existing urethane material exceed 1.2 mm
( 0. 05 inch).
Remove any excess urethane, using care not t o
smear urethane on component part s, crash pad
and vinyl roof.
5. Check flange sealing area for damaged sheet
metal or forei gn obj ects whi ch may have caused,
or may cause, gl ass breakage. Servi ce metal if
necessary.
1. CAUTI ON: A l l o w al l gl a s s p a r t s i n s t a l l e d wi t h
u r e t h a n e a mp l e t i me t o c u r e . If a mp l e t i me i s
n o t a l l o we d , b a c k w i n d o w gl a s s ma y c o me
l o o s e o r l e a k.
NOTE: Trim urethane left on the flange wi th a
utility knife or razor blade until surface is smoot h
and free of cuts. If the urethane has cured, it is
should the exi sti ng urethane material exceed 1.2
mm ( 0. 05 inch).
NOTE: Thoroughly mix urethane metal primer t o
ensure uniform pigment of mix before use.
NOTE: A minimum of 30 minutes is required for
primer surface to dry.
If painted sheet metal has been exposed
anywhere along the flange, use a clean brush and
appl y Urethane Metal Primer WSB-M2G234-C or
equivalent t o back wi ndow gl ass opening fl ange.
Appl y the urethane metal primer only to exposed
metal / painted surfaces. Do not appl y over
exi sti ng urethane.
01-11-37 Gl a ss, Fr a me s a n d Me c h a n i s ms 01-11-37
2. Install f oam dam (wi th sel f-adhesi ve backi ng)
around back wi ndow gl ass opening at end of
metal fl ange, and at uppermost si de of seal area.
3. Pl ace back wi ndow gl ass on a low, stabl e wor k
surf ace, inside up.
If moulding is al ready on gl ass, proceed t o Step
4.
If moulding needs t o be installed, use the fol l owi ng
procedure:
Align " V " notch in cerami c paint and moulding
( 42404) at t he t op and bot t om center, fully seat
moulding al ong t op edge of back wi ndow gl ass,
then along the t wo si des.
4. Properl y align back wi ndow gl ass t o body.
a. Pl ace back wi ndow gl ass into openi ng.
Center it t op and bot t om, side-to-side (adj ust
back wi ndow l ower st ops ( 42308) if
necessary).
b. Using maski ng t ape or crayon, make
alignment marks at poi nts on four si des of
bot h back wi ndow gl ass and back wi ndow
gl ass openi ng.
5. Remove back wi ndow gl ass f rom vehi cl e and
pl ace it back on wor k tabl e.
6. Clean back wi ndow gl ass.
7. NOTE: Wi pe off i mmedi atel y after appl i cati on
because it fl ash-dri es.
Using a lint-free cl ot h, wi pe inside surface of gl ass
around peri phery in f rom edge of the moulding
wi t h Urethane Gl ass Wi pe WSB-M5B280-C2 as
fol l ows:
Back Wi ndow Gl ass21. 0 mm ( 0. 80 inch) along
t op and si des, 30. 0 mm ( 1. 20 inches) al ong
bot t om.
8. Thoroughl y shake and stir Urethane Gl ass Primer
WSB- M2G314- B or equivalent t o ensure uniform
pigment mi xi ng.
9. NOTE: Al l ow a minimum of five minutes f or gl ass
primer t o dr y.
Using a cl ean brush, appl y primer t o inside back
wi ndow gl ass edge 30 mm ( 1. 20 i nches) wi de
along bot t om back wi ndow gl ass.
10. If exi sti ng (fully cured) urethane remai ns on metal
fl ange, appl y f resh urethane on t op of exi sti ng
materi al t o a t ot al height of 14 mm (0. 55 inch)
above fl ange.
Appl y an even bead of urethane WSB- M2G316- B
around enti re sheet metal fl ange next to f oam
dam using an air pressure cart ri dge gun. (Ai r line
pressure shoul d be around 275. 8 kPa ( 40 psi ).
The bead shoul d be triangular in shape, 14 mm
(0. 55 inch) hi gh, and 8.0 mm ( 0. 33 inch) at base.
11. NOTE: Thi s must be done within 10 minutes of
appl yi ng urethane.
Install back wi ndow gl ass onto vehicle, taki ng
care t o align marks on gl ass and body f rom St ep
4b. Tuck finisher stri p on wi ndow moulding along
the si de under the di tch moulding.
12. Connect wi res t o rear wi ndow defroster and
hidden antenna.
1995 To wn Car, Cr o wn Vi c t o r i a / Gr a n d Ma r q u i s Jul y 1994
Rear Wi n d o wT o wn Car
N8236-D
Par t
1 42006 Back Window Glass
2 Jig Drilled Hole, 2 Places
3 42308 Back Window Lower Stop
4 382413-S55X Screw (2 Req'd)
5 Moulding Assy
6 Urethane Glass Wipe (Red)
(Part of 19562)
Urethane Glass Primer
(Black) (Part of 19562)
7 Urethane Adhesive (Part of
19562)
Pa r t
8 Outer Quarter Panel Assy
9 502B98 Outer Roof Panel Assy
Assy
11

Package Tray Panel Assy
A

14.002.0 mm (0.550.07
inches)
B

8.0 mm (0.31 inches)
C

2.0 mm (0.07 inches)
D

18.0mm (0.70 inches)
01- 11- 39 Gl a ss, Fr a me s a n d Me c h a n i s ms 0 1 - 1 1 - 3 9
Ba c k Wi n d o wCr o wn Vi c t o r i a , Gr and Mar qui s
N8855-C
I t e m
Par t
1 42308 Back Window Lower Stop
2 381500-S Rivet (2 Req'd)
3 Moulding Assy
4 42006 Back Window Glass
5 Urethane Adhesive (Part of
19662)
6 Urethane Glass Wipe (Part
of 19562)
I t e m
Pa r t
7
Urethane Glass Primer (Part
of 19562)
8 Foam Dam
9 Urethane Metal Primer (Part
of 19562)
A 25 mm (0.98 inch)
We a t h e r s t r i p , Do o r G l a s s Be l t
1. Remove door tri m panel and wat ershi el d. Refer t o
Secti on 01- 05.
2. Remove door belt line outsi de weat herst ri p
retenti on nut(s) and remove door belt line outsi de
weat herst ri p by di sengagi ng cl i ps.
3. Remove belt line inside weat herst ri p by gentl y
pulling from door flange.
01-11-40 Gl ass, Fr ames a n d Mechani sms 01-11-40
4. To install, reverse Removal procedure, tighten
nuts to 1.4-2.3 N-m (12-20 Ib-in).
MOULDING ASSY MUST BE DRIVEN DOWN
UNTIL ATTACHING CLIPS FULLY SEAT
THEMSELVES ON BOTTOM OF SLOTS
OUTER DOOR BELT
WEATHERSTRIP
25596
TIGHTEN TO
1-2 N-m
Fr o n t D o o r s T o w n Ca r
2. Remove t he front retaining screw and gently pry
up t he front portion of the wi ndow regulator
swi t ch housing ( 14527) .
3. Unhook the rear edge of the wi ndow regul ator
swi t ch housing and remove the wi ndow regulator
swi t ch housing f rom the armrest cavi ty.
4. Remove t he t wo scr ews retaining the connector
t o t he wi ndow regul ator swi t ch housing.
5. Carefully pry the wi ndow regul ator control swi t ch
( 14529) f rom the connector wi t h a small
screwdri ver. Take care not t o damage the
el ectri cal cont act pins.
N8231-C
Pa r t
Housing
2 Switch Assy (Door Lock
Front LH)
Control
Switch
7 N807001-S58 Screw (6 Req'd)
Switch
Fr o n t D o o r s C r o w n Vi c t o r i a , G r a n d Ma r q u i s
2. Remove nut f rom outsi de rear vi ew mirror control
( 17B676) .
3. Pry up gently on t he wi ndow regul ator swi t ch
housing starti ng at the front.
4. Remove the t wo scr ews retaining t he connector
t o the wi ndow regul ator swi t ch housing.
f rom the connector wi t h a small screwdri ver.
Take care not t o damage the el ectri cal contact
pins.
0 1 - 1 1 - 4 2 Glass, Frames a n d Mechanisms 0 1 - 1 1 - 4 2
To remove a wi re f rom the connector, insert a
needle-like tool in t he edge of the pin hole and bend the
termi nal in. Pull t he wi re and termi nal f rom the
connector. To install the terminal in the connector,
open the termi nal and insert it into the wi re hole.
I SWITCH PIN
\ HOLE
N2316-C
W i n d o w Re g u l a t o r E l e c t r i c Dr i v e
Fr o n t D o o r T o w n Ca r
Re mo v a l
1. Remove front door tri m panel ( 23942) and front
door tri m shield ( 237A04) . Refer t o Secti on
01- 05.
Di sconnect wi ndow regul ator el ectri c dri ve wi res
at multiple connector.
3. Remove three 6. 35 mm (1 / 4-i nch) ri vet s retai ni ng
wi ndow regulator el ectri c dri ve br acket t o inner
panel . Use drift punch t o knock out the center
pins f rom each rivet. Using a 6. 35 mm ( 1 / 4-i nch)
di ameter drill, drill out remai nder of ri vet. Use
care not t o enl arge sheet metal hol es in t he door
inner panel.
4. Worki ng through access hole, remove wi ndow
regul ator el ectri c drive bracket f rom inner panel
and rot at e t o gain access t o three wi ndow
regul ator el ectri c dri ve retaining scr ews.
5. Remove wi ndow regul ator el ectri c dri ve retaining
scr ews using a No. 2 Scrul ox bit and separat e
wi ndow regulator el ectri c dri ve ( 23394) f rom
front door power wi ndow regul ator minus mot or
( 23208) .
6. Remove wi ndow regul ator el ectri c dri ve f rom
inside front door ( 20124) .
1. Position wi ndow regul ator el ectri c dri ve t o front
door power wi ndow regul ator minus motor. Install
three wi ndow regulator el ectri c dri ve scr ews.
Tighten to 4-5 N-m (36-44 Ib-in).
2. Install ri vets retaining front door power wi ndow
regulator minus motor t o inner panel (1 / 4- 20 X
1/ 2 inch scr ew and 1 / 4- 20 nut and washer
assembl i es or equivalent metri c f ast eners may be
used).
3. Connect wi ndow regul ator el ectri c dri ve wi ri ng
and bat t ery ground cabl e.
4. Check front door wi ndow gl ass ( 21410)
operati on. Install front door tri m shield and front
door tri m panel . Refer t o Secti on 01- 05.
0 1 - 1 1 - 4 1 Gl ass, Fr ames and Mechani sms 01- 11- 41
Rear D o o r s T o w n Car
Removal and i nst al l at i on
1. Remove the front retaining screw (l ocated under
the ash receptacl e cover) and gently pry up the
front portion of the wi ndow regulator swi t ch
housing.
2. Unhook the rear edge of the wi ndow regul ator
swi t ch housing and remove the wi ndow regul ator
swi t ch housing f rom the armrest cavi ty.
3. Remove the t wo scr ews retaining the connector
t o t he wi ndow regulator swi t ch housing.
4. Carefully pry the wi ndow regulator control swi t ch
f rom t he connector wi th a small screwdri ver.
Take care not t o damage the el ectri cal cont act
pins.
To wn Car
N8232-C
I t e m
Pa r t
1 30702 Ash Receptacle
2 N610130-S2 Screw
3 Bulb
Switch
6 56922-S58 Screw (6 Req'd)
Par t
Switch
Housing
Re a r D o o r s C r o w n Vi c t o r i a , G r a n d Ma r q u i s
Re mo v a l and I n st a l l a t i o n
1. Gently pry up the front porti on of the wi ndow
regulator swi t ch housi ng.
2. Remove the t wo scr ews retaining t he connector
t o the wi ndow regul ator swi t ch housi ng.
f rom the connector wi t h a small screwdri ver.
Take care not to damage the el ectri cal cont act
pins.
Re l a y , W i n d o w R e g u l a t o r S a f e t y
Locat e the wi ndow regul ator saf et y rel ay
( 14677) in the RH l ower A-pillar behind the RH
cowl side tri m panel ( 02344) .
2. Di sconnect connector f rom t he wi ndow regul ator
safety relay and remove the retaining nut.
Remove wi ndow regul ator saf et y rel ay.
Mo d u l e , Dr i v e r s Do o r
1. Remove LH front door tri m panel ( 23942) . Refer
to Section 01- 05.
2. Di sconnect wi re harness t o dri vers door module.
3. Remove scr ews retaining dri vers door module t o
front door ( 20125) . Remove dri vers door module.
C o n n e c t i o n Wi r e
If the wi ndow regulator control swi t ch connector or a
wi re leading to the connector is repl aced, the wi re(s)
can be removed f rom the connect or wi thout
di sassembl i ng the connector.
01- 11- 43 Gl ass, Fr ames a n d Mechani sms 0 1 - 1 1 - 4 3
Wi ndow Regul at or El e c t r i c Dri ve, Front Door Town Ca r
FRONT DOOR BELT INNER
WATER SHIELD ASSY
N8442-B
Par t
It em Number De sc r i pt i on
1 21410 Front Door Window Glass
2 N621906-S36 Nut (2 Req'd)
3 N800510-S36 Screw and Washer Assy (2 Req'd)
4 N802034-S36 Rivet (5 Req'd)
5 23200 Front Door Window Regulator
A Tighten to 9-14 N-m (7-10 Lb-Ft)
Fr o n t D o o r C r o w n Vi c t o r i a , G r a n d Ma r q u i s
Re mo v a l
2. Di sconnect bat t ery ground cabl e. Di sconnect
wi ndow regul ator el ectri c dri ve wi res at multiple
connector.
scr ews using a Torx Dri ve Bit Set D79P-2100-T
or equivalent and separat e wi ndow regulator
el ectri c dri ve f rom front door power wi ndow
regul ator minus motor.
4. Remove wi ndow regulator el ectri c dri ve f rom
inside f ront door.
1. Position wi ndow regulator el ectri c dri ve t o front
door power wi ndow regul ator minus motor. Install
three wi ndow regul ator el ectri c dri ve scr ews.
Tighten t o 5.6-6.8 H*m (50-60 Ib-in).
2. Connect wi ndow regulator el ectri c dri ve wiring
3. Check front door wi ndow gl ass operati on. Install
front door tri m shield and front door tri m panel .
01- 11- 44
G l a s s , Fr a me s a n d Me c ha n i sms 01- 11- 44
Wi ndow Regulator El ect r i c Dri ve, Front
Door Cr own Vi ct ori a, Grand Marquis
RH DOOR SHOWN NUT
LH DOOR TYPICAL N621906-S36
Rear Door
Remov al
wat ershi el d. Refer to Secti on 01- 05.
Di sconnect wi ndow regul ator el ectri c dri ve wi res
at multiple connector.
3. NOTE: Use care not t o enl arge sheet metal holes
in the door inner panel .
Remove three 6. 35 mm (1 / 4-inch) ri vets
attachi ng the wi ndow regul ator el ectri c dri ve
bracket t o inner panel . Use drift punch t o knock
out the center pins f rom each rivet. Using a 6. 35
mm (1 / 4-inch) di ameter drill, drill out t he
remainder of the rivet.
4. Worki ng through access hole, remove wi ndow
regul ator el ectri c dri ve bracket f rom inner panel
and rot at e t o gain access t o three wi ndow
regul ator el ectri c dri ve retaining scr ews.
scr ews and separat e wi ndow regul ator el ectri c
dri ve ( 23394) f rom rear door el ectri c wi ndow
regul ator ( 27008) .
6. Remove wi ndow regul ator el ectri c dri ve.
1. Position wi ndow regul ator el ectri c dri ve t o rear
door el ectri c wi ndow regul ator and wi ndow
regul ator el ectri c dri ve mounting bracket . Install
three wi ndow regul ator el ectri c dri ve scr ews.
Tighten t o 5.5-7.0 N-m (49-61 Ib-in).
2. Install ri vets retaining wi ndow regul ator el ectri c
dri ve mounting bracket t o inner panel (1 / 4- 20 x
112 inch bolt and 1 / 4- 20 nut and washer
assembl i es or equivalent metric fasteners may be
used).
3. Connect wi ndow regul ator el ectri c dri ve wiring
4. Check rear door wi ndow gl ass ( 25713)
operati on, install watershi el d and rear door tri m
panel. Refer t o Secti on 01- 05.
Wi n d o w Re gul a t o r El e c t r i c Dr i v e Re a r Door
N5S23-C
It em
Par t
1 25712 Rear Door Window Glass
Req'd)
3 N621906-S36 Nut (2 Req'd)
4 802034-S36 Rivet (5 Req'd)
( Co n t i n ue d )
Pa r t
i t e m Numbe r De s c r i p t i o n
Regulator
Weatherstrip
A

Lb-Ft)
Do o r G l a s s Ru n Re t a i n e r
Fr o n t
1. Remove front door trim panel ( 23942) . Refer t o
Secti on 01- 06.
2. Remove bol ts retaining front door gl ass run front
retainer ( 21672) and front door gl ass hinge si de
run ( 21546) t o front door ( 20124) . Remove front
door gl ass run front retainer and front door gl ass
hinge si de run.
Re a r
1. Raise rear door wi ndow gl ass ( 25713) t o the full
up position.
2. Remove screw and washer attachi ng rear door
gl ass run front l ower retainer ( 25796) t o door
inner panel . Remove rear door gl ass run front
l ower retainer.
3. To install, reverse Removal procedure. Adj ust
rear door wi ndow gl ass as outlined.
1995 To wn Ca r , Cr o wn Vi c t o r i a /Grand Ma r q u i s Jul y 1994
Rear Door Gl ass Run Retai ner
VIEW C
VIEW C
N9S31-8
i t em
Par t
Number Descr i pt i on I t em
Par t
1 25712 Rear Door Window Glass 7 N621906-S36 Nut (2 Req'd)
2 25766 Rear Door Glass Run 8 234A46 Door Window Glass Channel
3 24630 Rear Door
Bracket Retainer (2 Req'd)
9 234A44 Door Window Glass Bracket
27008
Regulator
Spacer (2 Req'd)
10 385232-S100 Rivet (2 Req'd)
Req'd) A Tighten to 7-12 N-m (5-9
6 N385189-S100 Rivet (5 Req'd) Lb-Ft)
Do o r G l a s s T o p Ru n
Fr o n t
Re mo v a l
1. Remove front door tri m panel ( 23942) and front
door tri m shield ( 237A04) . Refer t o Secti on
01- 05.
2. Remove front door belt line inside weat herst ri p
( 21456) .
3. Remove front door wi ndow gl ass ( 21410) as
outlined.
4. Remove front door wi ndow garni sh moulding
( 20890) (Crown Vi ct ori a, Grand Marqui s onl y).
5. Remove front door gl ass t op run retaining screw.
6. Remove front door gl ass t op run ( 21596) f rom
front door ( 20124) .
1. Install front door gl ass t op run into door f rame.
2. Push front door gl ass t op run onto door flange
starti ng at upper B-pillar corner.
3. Continue down B-pillar and then acr oss t op of
door frame and down A-pillar.
4. Install front door gl ass t op run retaining scr ew and
washer assembl y. Ti ghten retaining scr ew t o
9-14 N-m (7-10 Ib-ft).
5. Install front door gl ass run front retainer ( 21572)
wi t h upper bracket l ocked into front door.
6. Install front door wi ndow garni sh moulding (Crown
Vi ctori a, Grand Marqui s onl y).
Fr o n t Door Gl ass Ru n s T o wn Car
7. Install front door wi ndow gl ass.
8. Install front door bel t line inside weat herst ri p.
9. Adj ust front door wi ndow gl ass as outl i ned.
10. Install front door t ri m shi el d and front door tri m
panel . Refer t o Sect i on 01- 05.
SECTION A
NS441-C
Pa r t
1 222A00 Front Door Glass Run Latch Side Retainer
2 N800510-S36 Screw and Washer Assy (2 Req'd)
4 21596 Front Door Glass Top Run
5 Window Outside Moulding (Part of 21596)
1995 To wn Car , Cr o wn Vi c t o r i a / G r a n d Ma r q u i s J u l y 1994
01- 11- 48
Gl ass, Fr a me s a n d Me c h a n i s ms 01- 11- 48
REMOVAL AND INSTALLATION ( C o n t i n u e d )
Front Door Gl a s s Cr o wn Vi ct ori a, Grand Marquis
FRONT DOOR
GLASS TOP
RUN 21596
SECTION A
GARNISH
MOULDING
20890
\ FRONT DOOR
)) WINDOW
/ / GARNISH
If MOULDING
L 20890
FRONT DOOR ^
GLASS TOP
RUN 21596
SECTION A
N8850-B
G l a s s , S t a t i o n a r y R e a r Do o r
Re mo v a l
2. Remove rear door gl ass inside weat herst ri p
( 25860) .
3. Remove rear door wi ndow gl ass ( 25713) as
outlined.
4. Remove rear door wi ndow garni sh moulding
( 25560) on Crown Vi ctori a, Grand Marqui s.
5. Remove rear door stati onary wi ndow gl ass
retaining bolt.
6. Remove rear door stati onary wi ndow gl ass
( 26870) .
1. Install rear door stati onary wi ndow gl ass into
door frame.
2. Push rear door stati onary wi ndow gl ass onto
door flange starti ng at upper C-pillar corner.
3. Continue down C-pillar and then acr oss t op of
door f rame and down B-pillar.
4. Install rear door stati onary wi ndow gl ass scr ew
and washer assembl y. Tighten t o 9-14 N-m (7-10
Ib-ft).
5. Install rear door wi ndow garni sh moulding.
6. Install rear door wi ndow gl ass as outlined.
7. Install rear door gl ass inside weat herst ri p.
8. Adj ust rear door wi ndow gl ass as outlined.
9. Install watershi el d and rear door tri m panel. Refer
Rear Door Gl assTown Car
N8S03-C
Pa r t
1 26870 Rear Door Stationary Window Glass
3 25560 Rear Door Window Garnish Moulding
4 25796 Rear Door Glass Run Front Lower Retainer - Town Car Only
01- 11- 50
Gl a s s , Fr a me s a n d Me c h a n i s ms 0 1 - 1 1 - 5 0
Rear Door Gl a ss- Cr o wn Vi ct ori a, Grand Marquis
SECTION A
REAR DOOR
STATIONARY/
WINDOW
GLASS
26870
REAR DOOR>
WINDOW
GARNISH
MOULDING
25560
REAR DOOR ZD
STATIONARY M
WINDOW / / \
GLASS JY ))
26870 f If
REAR DOOR
WINDOW
GARNISH
MOULDING
25560
SECTION A
NS851-1
W i n d o w G l a s s , Re a r Qu a r t e r
1. Remove quarter tri m panel ( 31012) . Refer t o
Secti on 01- 05.
2. From inside vehicle, remove rear quarter wi ndow
gl ass retaining nuts and push quarter wi ndow
gl ass ( 29710) out of openi ng.
3. Remove all f oam core butyl f rom sheet metal
fl ange and quarter wi ndow gl ass if quarter
wi ndow gl ass will be put back in.
4. If t he new quarter wi ndow gl ass has a butyl seal
as part of the assembl y, remove the backi ng
paper f rom the seal . If the quarter wi ndow gl ass is
being reused, oil does not have a butyl seal as
part of t he assembl y. Install butyl servi ce t ape t o
the seal surface of the quarter wi ndow gl ass.
Overl ap the butyl servi ce t ape at the bot t om of
the wi ndow t o prevent wat er l eaks.
5. Position quarter wi ndow gl ass in opening and
install four retaining nuts. Tighten t o 1-2 Nm (9-18
Ib-in).
6. Install quarter tri m panel .
Qua r t e r Wi n d o w Gl a s s T o wn Car
Par t
1 2 9 7 2 6 Quarter Window Opening Sight Shield
2 2 7 8 4 0 Qu a r t e r P a n e l
3 2 7 7 9 0 Front Quarter Inside Panel
4 N620360-S36 Nut and Sealer
A Tighten t o 1 - 2 N-m ( 9- 18 Lb-ln)
01- 11- 52
Gl a ss ~ 1 " ~ - 1 1 - 5 2
Qua r t e r Wi n d o w Gl a s s Cr o wn Vi c t o r i a
o
SECTION A
N8857-B
Pa r t
1 N621901-S2 Nut
2 297A28 Seal Foam Core Butyl
3 29726 Quarter Window Opening
Sight Shield
Lb-ln)
H e a t e d B a c k W i n d o w S w i t c h a n d L i g h t
1. Remove center instrument panel finish panel
( 044D70) .
2. Remove heated back wi ndow swi t ch and light
( 18C621) by pressi ng metal mounting clips on
each si de while pulling gentl y on the swi t ch
button.
3. Di sconnect el ectri cal connector.
HEATED BACK
WINDOW SWITCH
AND LIGHT
18C621
K14570-D
SERVICE PROCEDURES
G r i d Wi r e , B a c k W i n d o w G l a s s M e t h o d I
NOTE: There are 2 methods for repairing terminal
separati on f rom gl ass and/ or gri d breaks. Met hod I
involves soldering the terminal t o the gl ass and
Met hod II uses an epoxy adhesi ve.
A single break or any breaks that total 25 mm (1 inch)
in one grid cannot be servi ced. The back wi ndow gl ass
( 42006) must be repl aced. For breaks less than 25
mm (1 inch) l ong, use t he following procedure:
NOTE: If the fi rst layer of the heated back wi ndow
gl ass gri d (brown) is damaged or missing, it will be
necessary to appl y brown Acryl i c Lacquer Touch-Up
Paint AL81-5477-B or equivalent meeting Ford
speci fi cati on ESR-M2P100-B on the gl ass prior t o
appl yi ng the Rear Wi ndow Defroster Repair
D8AZ-19562-AA or equivalent meeting Ford
speci fi cati on ESB-M4J58-A.
Inoperative grid wi res on back wi ndow gl ass should
now be servi ced by using Rear Wi ndow Defroster
Repair D8AZ-19562-AA or equivalent meeting Ford
speci fi cati on ESB-M4J58-A or equivalent.
S u r f a c e P r e p a r a t i o n
1. The vehicle should be brought inside and warmed
t o 16C( 60F) or above.
2. CAUTI ON: Do n o t use scr aper s, shar p
i n s t r u me n t s , o r a b r a s i v e w i n d o w c l e a n e r s o n
t h e i n t e r i o r s u r f a c e o f t h e b a c k w i n d o w gl a s s
a s t hi s ma y c a u s e d a ma g e t o t h e gr i d l i n e s.
Clean the entire gri d line servi ce area wi t h Ul tra
Clear Spray Gl ass Cleaner E4AZ-19C507-AA or
ESR-M14P5-A t o remove all dirt, wax, grease, oil
or other foreign matter. It is i mportant that the
repair area be cl ean and dry.
01-11-53 Gl ass, Fr ames and Mechani sms 0 1 - 1 1 - 5 3
SERVICE PROCEDURES (Conti nued)
Mi x i ng
The bottl e of Rear Wi ndow Defroster Repai r
D8AZ- 19562- AA or equivalent meeti ng Ford
speci fi cati on ESB-M4J58-A and touch-up paint (if
needed) must be at room t emperat ure. Shake bottl e
for at least one minute for thorough mi xi ng. Shake
frequently during use.
A p p l i c a t i o n
1. Mark l ocati on of break on the outsi de of the back
wi ndow gl ass.
2. Using cellulose t ape, mask off the area di rectl y
above and bel ow gri d break. The break area
shoul d be at the cent er of the mask and t ape gap
must be no wi der than the exi sti ng gri d line.
APPLY BROWN TOUCH-UP PAI NT TO THI S
AREA FIRST WHEN BROWN LAYER OF
GRI D IS DAMAGED OR MI SSI NG
BRUSH
APPLI CATOR <
GRID
TAPE
BREAK
APPLY COATI NG AT LEAST 6.35 mm
(1/4 INCH) ON BOTH SI DES OF BREAK
USING CELLULOSE TAPE, MASK OFF THE
AREA DIRECTLY ABOVE AND BELOW THE
GRID BREAK. THE BREAK AREA SHOULD
BE AT THE CENTER OF THE MASK AND
THE GAP MUST BE NO WIDER THAN THE
EXISTING GRID LINE.
K3787-E
3. NOTE: If the brown layer of the gri d is not broken
or mi ssi ng, appl y only the silver gri d repair
compound t o the break.
Appl y t he correct coati ng in several smoot h
conti nuous st rokes (allowing t hree t o fi ve minutes
dryi ng ti me bet ween coat s) across the break
ar ea using t he brush appl i cator in t he cap. Extend
t he servi ce coati ng at least 6. 35 mm ( 1 / 4 inch)
on bot h si des of t he break area.
If bot h brown and silver l ayers of the gri d are
broken or mi ssi ng, appl y a coati ng of the brown
touch-up paint acr oss the break area fi rst. Two
coat s may be necessary t o obtai n the proper
color. Al l ow the touch-up paint t o dry then appl y
t hree coat s of gri d repair compound allowing
t hree t o fi ve minutes dryi ng time bet ween coat s.
The coat i ng of t he gri d repair compound should
ext end at least 6. 35 mm ( 1 / 4 inch) on both si des
of the break area.
4. Al l ow t o dr y for fi ve minutes then remove t he
mask.
5. CAUTI ON: Be c a r e f u l n o t t o d a ma g e g r i d l i n e
w i t h r a zo r b l a d e . A d d i t i o n a l r e p a i r s ma y b e
n e c e s s a r y .
After removi ng t he mask, check t he outsi de
appearance of t he gri d repai r compound. If t he
repai r compound i s visible above or bel ow t he
gri d, this excess shoul d be removed. Thi s can be
done by placing a single-edge razor bl ade on t he
back wi ndow gl ass parallel t o gri d and scrape
gentl y t owar d gri d.
C u r i n g
The servi ce coati ng will ai r-dry in approxi mat el y one
minute and can be energi zed within t hree minutes.
Opti mum hardness and adhesi on occurs after
approxi matel y 24 hours. At that ti me, t he servi ced
area may be cl eaned wi t h a mild wi ndow cleaner.
G r i d Wi r e , B a c k W i n d o w G l a s s M e t h o d II
NOTE: There are 2 met hods for repai ri ng termi nal
separati on f rom gl ass and/ or grid breaks. Met hod I
involves sol deri ng the termi nal to the gl ass and
Met hod II uses an epoxy adhesi ve.
Use a rear wi ndow defroster servi ce kit t o repai r
pigtail connecti ons, and gri d line breaks.
The servi ce kit is available f rom:
Marketi ng East Company
# 1 0 Li berty Street
North Andover, Massachuset t s 01845
Telephone: ( 508) 689- 9565
Any break in the gri d longer than 25 mm ( 1 inch)
cannot be servi ced. The back wi ndow gl ass ( 42006)
must be repl aced. For breaks less than 25 mm (1 inch)
l ong, use t he following procedure:
1. The vehicle should be brought inside and war med
t o 16C( 60F) or above.
2. CAUTI ON: Do n o t use s c r a p e r s , s h a r p
i n s t r u me n t s o r a b r a s i v e c l e a n e r s o n t h e
i n t e r i o r s u r f a c e o f t h e b a c k w i n d o w gl a s s a s
t h i s ma y c a u s e d a ma g e t o t h e g r i d l i n e s .
Clean entire gri d line repair area wi th Ultra-Clear
Spray Gl ass Cleaner E4AZ-19C507-AA or
ESR-M14P5-A t o remove all dirt, wax, grease, oil
or other forei gn matter. It is i mportant that repair
area be cl ean and dry.
01- 11- 54
Gl a s s , Fr a me s a n d Me c ha n i sms 01-11-54
Appl i c at i on
1. Mark location of break on outsi de of back wi ndow
gl ass.
BA CK WI N DO W
G L A S S 42 006
BROKE N G RI D WI RE
2.
N12581-A
Pl ace maski ng t ape (provi ded in ki t), over break
in gri d wi re, aligning hol es in maski ng t ape wi t h
gri d wi re.
Prepare servi ce kit t wo-part epoxy.
a. Check expi rati on dat e of package. If
hardener has crystal l i zed, pl ace package in
hot wat er until t he hardener softens.
b. Remove pl asti c cl amp f rom package
separati ng resin and hardener.
c. Knead package until resin and hardener are
thoroughl y mi xed.
d. Cut corner of package t o open.
Appl y t wo-part epoxy, wi t h sti ck provi ded, t o wi re
gri d break t hrough cut-out in maski ng t ape.
BA C K WI N DO W
G L A S S 42 006
N12582-A
5. Carefully remove maski ng t ape f rom grid wi re
repai r area.
6. NOTE: Care shoul d be t aken whi l e using heat gun
around interior t ri m.
Using Rotunda Heat Gun 107-R0300 or
equivalent, heat gri d wi re repai r area for one t o
t wo minutes.
ROT UN DA
HE A T
G U N
107 - R0300
B A C K WI N DOW G L A S S RE P A I RE D
42 006 G RI D WI RE
N12583-A
7. NOTE: Heat ed back wi ndow is now operati onal .
Two-part epoxy will thoroughl y cure in 24 hours.
St art engine, turn heated back wi ndow swi t ch
and light ( 18C621) on, and leave on for five
minutes. Inspect gri d wi re repai r area.
Lead Wi ndow Terminal Servi ceMet hod I
NOTE: There are 2 met hods for repairing terminal
separati on f rom gl ass and/ or grid breaks. Met hod I
involves soldering the terminal t o the gl ass and
Met hod II uses an epoxy adhesi ve. Al so, gri d line
repai r procedures are different.
1. Al l ow the back wi ndow gl ass ( 42006) t o war m up
t o room t emperat ure for one-half hour t o an hour.
2. Clean the bus bar in the area t o be servi ced using
fine steel wool ( 3 / 0 to 4 / 0 grade).
3. Restore the area where the bus bar terminal was
originally at t ached by applying three coat s of
Rear Wi ndow Defroster Repair D8AZ- 19562- AA
ESB-M4J58-A. Allow approxi matel y 10 minutes
dryi ng time bet ween coat s.
4. Worki ng as qui ckl y as possible t o avoi d
overheati ng the back wi ndow gl ass, tin the bus
bar wi th sol der in t he area where the terminal will
be reat t ached.
5. Using Rotunda Heat Gun 107-R0300 or
equivalent, preheat the back wi ndow gl ass in the
sol der area t o 6 7
0
- 8 3
0
C ( 120 -150 F) j ust prior
to soldering the terminal on.
01- 11- 55 Gl ass, Fr ames and Mechani sms
SERVICE PROCEDURES (Continued)
6. Position the terminal on the bus bar in the area
t hat was tinned and hold it in pl ace wi th an i ce
pi ck or screwdri ver.
T Y P I C A L L 2 4 4 W
7. CAUTI ON: To a v o i d d a ma g i n g t h e b u s ba r ,
r e mo v e t h e s o l d e r i n g g u n o r i r o n a s s o o n a s
t h e s o l d e r f l o w s .
Appl y soldering heat t o t he pad of the terminal
until the sol der f l ows.
8. St art t he vehi cl e. Turn the heat ed back wi ndow
swi t ch and light ( 18C621) ON and leave it on for
five minutes. Inspect the termi nal and appl y Rear
Wi ndow Defroster Repair D8AZ- 19562- AA or
ESB-M4J58-A t o t he requi red area.
L e a d W i n d o w T e r mi n a l S e r v i c e M e t h o d II
Use a rear wi ndow defroster servi ce kit t o repair
pigtail connecti ons, and gri d line breaks.
The servi ce kit is available f rom:
Market i ng East Company
# 1 0 Li berty Street
Nort h Andover, Massachuset t s 01845
Tel ephone: ( 508) 689- 9565
1. Al l ow back wi ndow gl ass ( 42006) t o war m up t o
room t emperat ure for one-half hour t o an hour.
2. Clean bus bar in area t o be repai red using fine
steel wool ( 3 / 0 t o 4 / 0 grade).
3. Appl y maski ng t ape t o bus bar around bus bar
terminal l ocati on.
4. Prepare servi ce kit to-part epoxy.
a. Check expi rati on dat e of package. If
hardener has crystal l i zed, pl ace package in
hot wat er until the hardener softens.
b. Remove pl asti c cl amp f rom package
separati ng resin and hardener.
c. Knead package until resin and hardener are
thoroughl y mi xed.
d. Cut corner of package to open.
5. Appl y t wo-part epoxy, wi t h sti ck suppl i ed, t o bus
bar terminal location of bus bar.
6. Using a screwdri ver, position bus bar terminal t o
bus bar.
01- 11- 56
Gl ass, Fr ames and Mechani sms 01- 11- 56
SERVICE PROCEDURES (Cont i nued) LUBRICATION
7. NOTE: Care should be t aken whi l e using heat gun
around interior tri m.
Using Rotunda Heat Gun 107-R0300 or
equivalent, heat bus bar terminal and t wo-part
epoxy for one t o t wo minutes whi l e holding bus
bar terminal in posi ti on.
BUS BAR TERMINAL
BACK WINDOW GLASS
42006
ROTUNDA
HEAT GUN
107-R0300
SCREWDRIVER
N12579-A
8.
9.
Carefully remove maski ng t ape.
Carefully install wi re t o termi nal . Heated back
wi ndow is now operati onal . Two-part epoxy will
thoroughl y cure in 24 hours.
BACK
WINDOW
GLASS 42006
HEATED BACK
WINDOW GLASS WIRE
BUS BAR
TERMINAL
10.
N12580-A
St art engine, turn heated back wi ndow swi t ch and
light ( 18C621) on, and l eave it on for fi ve minutes.
Inspect bus bar terminal repair.
W i n d o w R e g u l a t o r , F r o n t Do o r P o w e r
The front door power wi ndow regul ator minus motor
( 23208) should be well l ubri cated t o provi de ease of
operati on. The front door power wi ndow regul ator
minus motor should be l ubri cated whenever t he front
door gl ass t op run ( 21596) or front door power
wi ndow regul ator minus motor is removed, or
excessi ve effort is required t o operat e the wi ndows.
To lubricate a front door power wi ndow regul ator
minus motor, appl y an even coati ng of Teflon
Lubri cant D2AZ-19590-A or equivalent meeting Ford
speci fi cati on ESB-M1C111-A or equivalent t o t he
wi ndow regul ator arm rollers ( 23240) , shafts and
entire length of the wi ndow regul ator equalizer arm
bracket s ( 23230) .
APPLY AN EVEN COATING OF MULTI-
PURPOSE GREASE D0AZ-19584-AA TO ALL
WINDOW REGULATOR ROLLERS, SHAFTS
AND THE ENTIRE LENGTH OF ROLLER
GUIDES AS ILLUSTRATED BY THE SHADED
AREAS
N1007-K
ADJUSTMENTS
Do o r W i n d o w G l a s s
NOTE: Before maki ng any adj ustments, remove the
front door tri m panel ( 23942) and front door tri m shield
( 237A04) . Refer t o Section 01- 05.
1. Loosen, but do not remove, upper front door
power wi ndow regulator retaining nuts.
2. Raise front door wi ndow gl ass ( 21410) t o full up
position and tighten nuts t o 9-14 Nm (7-10 Ib-ft).
3. Loosen, but do not remove, front door gl ass run
front retainer bolt (Town Car onl y).
4. Lower front door wi ndow gl ass t o full down
position and tighten retainer bolt to 9-14 N-m
(7-10 Ib-ft).
01- 11- 57 Gl a s s , Fr a me s a n d Me c h a n i s ms 01- 11- 5 7
SPECIFICATIONS
WINDOW REGULATOR EL ECTRI C DRIVE CURRENT
DRAW
Descr i pt i on S p e c i f i c a t i o n
No L o a d 5 a mp e r e s o r l e s s a t 12. 8 v o l t s
De s c r i p t i o n N- m Lb-Ft
Fr o n t Do o r Wi n d o w Cha n n e l
Br a c ke t
9- 14 7- 10
Do o r E l e c t r i c Wi n d o w Re gu l a t o r
Nut s
9- 14 7- 10
Re a r Do o r Re gu l a t o r E l e c t r i c Dr i v e
t o Re gu l a t o r S c r e ws
5. 6- 6. 8 50- 60
( Lb- l n )
Do o r G l a s s Run Fr o n t Re t a i n e r
S c r e ws
9- 14 7 - 10
Re a r Qu a r t e r Wi n d o w Gl a s s Nu t s 1-2 9- 18
( L b- l n )
Fr o n t Do o r Re gu l a t o r E l e c t r i c Dr i v e
t o Re gu l a t o r S c r e ws
4- 5 36- 44
( Lb- l n )
SPECI AL SERVI CE TOOLS REQUIRED
Tool Numbe r /
Descr i pt i on i l l ust r at i on
T91T- 17 7 00- A
Re a r v i e w Mi r r o r Re mo v e r
T91T-17700-A
SPECI AL SERVI CE TOOLS DESI RED
Tool Number Description
D7 9P - 2 100- T Torx Dr i v e Bi t Se t
ROTUNDA EQUIPMENT
Model Description
107 - R0600 Bl i n d Fa s t e n e r I n s t a l l a t i o n To o l
107 - R0300 He a t Gun
107 - R1511 Kn i f e wi t h Of f s e t Bl a d e
163- 00001 I n t e r i o r A u t o Gl a s s Cut - Out Kn i f e Ki t
01- 12 - 1 I n s t r u me n t Pa n e l 01- 12 - 1
SECTION 01-12 Instrument Panel
SUBJECT P A G E
V E H I C L E A P P L I C A T I O N 01- 12 - 1
C i g a r L i g h t e r a n d Ash R e c e p t a c l e 01-12-1
I n s t r u m e n t Panel 01-12-1
SERVICE PRECAUTIONS
D e p l o y e d A i r Bags 01-12-2
G e n e r a l I nst r uct i ons 01-12-2
L i v e A i r B a g s 01- 12 - 2
PARTS R E P L A C E M E N T
A i r B a g S y s t e m . . . . . . . 01- 12 - 2
S t e e r i n g C o l u m n T u b e 01-12-2
D I A G N O S I S AND TESTING
I n s p e c t i o n a n d V e r i f i c a t i o n .........01-12-3
Pi npoi nt Test 01-12-4
S U B J E C T P A G E
D I A G N O S I S A N D T E S T I N G ( Cont ' d . )
Sy mpt om C h a r t . . . .....01-12-3
Ash Recept acl e a n d Retai ner 01- 12 - 5
Ci gar Li ght er 01- 12 - 6
Finish P a n e l , I n s t r u m e n t P a n e l 01-12-9
G l o v e C o m p a r t m e n t . . . . 0 1 - 1 2 - 1 0
I nst rument Cl ust er 01-12-9
I nst rument Cl ust er Fi ni sh Panel 01-12-9
I nst rument Panel 01-12-6
St eeri ng Col umn Openi ng Cover Assembl y and
R e i n f o r c e m e n t .01-12-9
VEHICLE APPLICATION
I n s t r u m e n t P a n e l
The instrument panel ( 04320) houses the control s for
most of t he vehi cl e' s el ectri cal syst ems.
The gl ove compart ment ( 06010) is l ocat ed in l ower
RH si de of t he instrument panel .
C i g a r L i g h t e r a n d A s h R e c e p t a c l e
The ci gar lighter knob and element ( 15052) has a
l ow-resi stance heating coi l whi ch operat es much like
t he coi l used in a portabl e heater.
When t he ci gar lighter knob and element is pushed
compl etel y into t he ci gar lighter socket and retainer
( 15055) , t he circuit is cl osed and current f l ows
t hrough t he heati ng coi l t o t he ground.
SERVICE PRECAUTIONS
The LH si de of t he instrument panel f rames t he
steeri ng column tube ( 3514) and houses:
the instrument cluster ( 10849) .
the instrument panel .
Refer t o Secti on 13-01 for instrument panel finish
panel information and Removal and Installation
procedures.
When sufficient heat is generat ed, the ci gar lighter
knob and element overcomes the spri ng pressure of
the bi-metal retaining fi ngers and is rel eased.
NOTE: Cigar lighter knob and el ements (for Town Car)
are found in Secti on 01- 05.
Ash recept acl es ( 30702) and ci gar lighter knob and
elements are l ocated in t he center of the instrument
panel ( 04320) and in t he rear armrest s.
WARNI NG: SAFE HANDLI NG OF AI R BAG
MODULES REQUI RES FOLLOWI NG THE
PROCEDURES DESCRI BED BELOW FOR BOTH
LI VE AND DEPLOYED AI R BAGS.
ALWAYS WEAR SAFETY GLASSES WHEN
SERVI CI NG AN AIR BAG VEHI CLE, AND WHEN
HANDLI NG AN AIR BAG.
01- 12 - 2 i n s t r u me n t Pa n e l 01- 12 - 2
SERVICE PRECAUTIONS (Cont i nued)
Li ve Air Bags
WHE N CARRYI NG A LI VE AI R BA G , MAKE SURE
THE BA G AND TRI M COVER ARE POI NTED
AWAY FROM YOUR BODY. I N THE UNLI KELY
EVENT OF A N ACCI DENTAL DEPLOYMENT,
THE BA G WI L L THEN DEPLOY WI TH MI NI MAL
CHANCE OF I NJURY.
IN ADDI TI ON, WHE N PLACI NG A LI VE AI R BAG
ON A BENCH OR OTHER SURFACE, ALWAYS
FACE THE BA G AND TRI M COVER UP, AWAY
FROM THE SURFACE. THI S WI L L REDUCE THE
MOTI ON OF THE MODULE IF I T I S
ACCI DENTALLY DEPLOYED.
Air Bag Sy st em
Pri or t o a t t e mpt i ng di agnost i c prove-out on a se r vi c e d
vehi cl e, t hor oughl y c he c k all se nsor s a nd wi ri ng f or
da ma ge a n d pi nch condi t i on whi c h ma y cause t he ai r
ba g di agnost i c moni t or i nt ernal f use t o bl ow.
Depl oyed Air Bags
SAFE TY PRECAUTI ONS MUST A L SO BE
OBSERVED WHE N HANDLI NG A DEPLOYED AI R
BA G .
AFTE R DEPLOYMENT, THE AI R BAG SURFACE
MAY CONTAI N DEPOSI TS OF SODI UM
HYDROXI DE, A PRODUCT OF THE GAS
GENERANT COMBUSTI ON THAT I S I RRI TATI NG
TO THE SKI N.
AL WAYS WE AR GLOVES AND SAFETY
GL ASSE S WHEN HANDLI NG A DEPLOYED AI R
BA G .
WA SH YOUR HANDS WI TH MI LD SOAP AND
WATER AFTERWARDS.
General I nst ruct i ons
Ref er t o Sect i on 01- 20B.
PARTS REPLACEMENT
St eeri ng Column Tube
If t he col l i si on i nvol ved an ai r bag depl oyment , t he
st eer i ng col umn t ube ( 3514) may have been l oaded
suf f i ci ent l y t o de f or m st eeri ng col umn br a c ke t
i nsul at or ( 3682) or damage st eeri ng col umn t ube
wi r i ng. An i nspect i on shoul d be made of t he st eeri ng
col umn t ube st r uct ur e and c l oc kspr i ng wi ri ng t o ensure
t hat any da ma ge d component s a r e r e pl a c e d. Ref er t o
Sect i on 11-04.
El ect ri cal Schemat i cs
Ci gar Li ght e r , To wn Car
HOT AT AL L TI MES
I C I
1
I FUSE
, JUNCTION
I PANEL
See EVTM for
more details
of thi s circuit
R9557-B
01- 12 - 3
I n s t r u me n t Pa n e l 01- 12 - 3
Ci ga r Li ght e r , Cr o wn Vi c t o r i a , Gr a nd Ma r qui s
HOT AT ALL TIMES
POWER
POINT
1. Verify t he vehi cl e owner' s original concern by
operati ng t he ci gar lighter t o dupl i cate t he
condi ti on.
2. Inspect t o determi ne if one of the fol l owi ng
Da ma g e d c i ga r l i ght e r
s o c k e t a n d r e t a i n e r .
Da ma g e d c i g a r l i ght e r kn o b
a n d e l e me n t .
Bl o wn f us e .
Ci r c ui t r y o p e n / s h o r t e d .
3. If t he inspection reveal s obvi ous concerns that
determi ne t he sympt oms and go t o t he Sympt om
Chart.
Sympt om Chart
Use Rotunda Digital Volt-Ohmmeter 014- 00407 or
equivalent t o perform el ectri cal pinpoint t est s.
01- 12- 4 i nst r ument Panel 01- 12- 4
Ci gar Lighter
C i g a r L i g h t e r S h o r t t o g r o u n d .
O p e n g r o u n d .
Open supply.
O p e n f u s e .
C i g a r l i g h t e r s o c k e t a n d r e t a i n e r .
C i g a r l i g h t e r k n o b a n d e l e m e n t .
GO t o Pinpoint Test A 1.
Pi n p o i n t T e s t
PINPOINT TEST A: CIGAR LIGHTER
A1 CHECK FUSE
Yes
No
GO to A4.
GO to A2.
C h e c k t h e 20A C I G A R F u s e 8 C r o w n V i c t o r i a , G r a n d
Ma r q u i s , 3 0 A F u s e 16 T o w n C a r l o c a t e d i n t h e
instrument panel.
Is f use OK?
Yes
No
GO to A4.
GO to A2.
A2 CHECK SYSTEM
Yes >
No
GO to A3.
GO to A4.
Replace t he 20A CIGAR Fuse 8, Crown Vi ct ori a,
Grand Marquis, 30 A Fuse 16, Town Car.
Yes >
No
GO to A3.
GO to A4.
Yes
No
SERVICE Circuit 40
LB/ W wire between
instrument panel fuse
j unction panel and ci gar
lighter knob and element.
REPLACE 20A CIGAR
Fuse 8 Crown Vi ct ori a,
Grand Marquis, 30A Fuse
10 Town Car. GO to A4.
Remove t he 20A CIGAR Fuse 8 Crown Vi ct ori a,
Grand Marquis, 30A Fuse 16 Town Car.
Measure the resi stance of circuit 40 LB/ W wire
between RH terminal of 20A CIGAR Fuse 8 Crown
Vi ct ori a, Grand Marquis, 30A Fuse 16 Town Car
holder and ground.
Is resi st ance l ess t han 5 ohms?
Yes
No
SERVICE Circuit 40
LB/ W wire between
j unction panel and ci gar
REPLACE 20A CIGAR
Fuse 8 Crown Vi ct ori a,
Grand Marquis, 30A Fuse
10 Town Car. GO to A4.
A4 CHECK POWER SUPPLY TO CIGAR LIGHTER
Yes
No
GO to AS.
SERVICE Circuit 40
LB/ W wire between
j unction panel and cigar
Measure the voltage of the circuit 40 LB/ W wire at
the cigar lighter connector.
Yes
No
GO to AS.
SERVICE Circuit 40
LB/ W wire between
j unction panel and cigar
AS CHECK CIGAR LIGHTER GROUND
Yes
No
knob and element.
SERVICE Circuit 57 BK
wire between cigar
lighter knob and element
and ground.
Measure t he resi stance of circuit 57 BK wire
between t he cigar lighter connector and ground.
Yes
No
knob and element.
SERVICE Circuit 57 BK
wire between cigar
lighter knob and element
and ground.
01- 12- 5
Ash Receptacle and Retainer
Re mo v a l
1. Pull instrument panel ash recept acl e ( 04810) out
t o t he st op.
TOP VIEW ASH RECEPTACLE
04810
ASH RECEPTACLE
RETAINER
(PART OF 04810)
PUSH DOWN ON
SPRINGS TO
RELEASE DRAWER
R9 8S 2 - A
2.
3.
NOTE: Do not di sconnect t he radi o wi ri ng or radi o
antenna lead in cabl e ( 18812) f rom t he radi o
chassi s ( 18806) in St ep 2.
Grand Marqui s Onl yDi sengage radi o chassi s
and pull away f rom the instrument panel ( 04320)
about fi ve inches t o di sengage f rom t he
instrument panel ash recept acl e.
Remove t wo scr ews attachi ng t he ash recept acl e
retai ner t o t he instrument panel .
R E T A I N I N G C L I P S 2 RE Q' D l ^ J R U M E N T
P A N E L 04320
SCREWS
2 REQ'D
rfKASH RECEPTACLE
REMOVED FOR
C L A R I T Y
R9863-B
5.
6.
Lower rear of instrument panel ash recept acl e.
Careful l y slide instrument panel ash recept acl e
t owar d front of vehi cl e t o di sengage retaining
cl i ps.
Di sconnect ash recept acl e wi ri ng at connector.
Remove wiring f rom ash recept acl e bracket .
Reach in wi t h a fl at-bl ade screwdri ver and lift up
on t he t wo spri ng st ops t o rel ease t he instrument
panel ash recept acl e f rom t he ash recept acl e
retainer.
TOP VIEW ASH RECEPTACLE
04810
ASH RECEPTACLE
RETAINER
(PART OF 04810)
PUSH DOWN ON
SPRINGS TO
RELEASE DRAWER
R9S62-A
7. Remove ci gar lighter knob and element ( 15052)
f rom instrument panel ash recept acl e.
ASH
RECEPTACLE
WIRING
INSTRUMENT PANEL
ASH RECEPTACLE
04810
R11026-A
1. Install ci gar lighter knob and element into
instrument panel ash recept acl e. Install
instrument panel ash recept acl e into ash
recept acl e bracket and position wi ri ng harness.
2. Position the ash recept acl e cl i ps retainer t o the
instrument panel and install t he t wo retaining
scr ews. Tighten the scr ews t o 2. 0-2. 9 N-m
(17-25 Ib-in).
3. Connect wi ri ng.
4. Grand Marqui s Onl yInstal l ash recept acl e
retainer maki ng sure t he guide bracket on t he
radi o chassi s engages t he t op of t he ash
recept acl e retainer.
01- 12- 6 I nst r ument Panel 01- 12 - 6
Ash Re c e pt a c l e and Ret ai ner
ASH
RECEPTACLE
WIRING
INSTRUMENT PANEL
ASH RECEPTACLE
04810 R11028-A
Ci gar Li ghter
1. Di sconnect t he bat t ery ground cabl e (14301).
2. Remove ci gar lighter knob and element ( 15052) .
3. Unscrew t he socket f rom t he retainer and push
t he socket out of instrument panel ash
recept acl e.
ASH
RECEPTACLE
WIRING
INSTRUMENT PANEL
ASH RECEPTACLE
04810 R1 1 0 2 6 - A
Inst rument Panel
1. Position wheel s strai ght ahead.
3. Rai se vehi cl e on hoist. Refer t o Sect i on 00- 02.
4. Remove wheel and ti re assembl y.
5. Remove retaining nut in radi ator cool ant recovery
reservoi r assembl y.
6. Remove retai ni ng bol t in front fender spl ash
shi el d.
7. Position front fender spl ash shi el d out of t he way.
8. Lower vehi cl e.
9. Tag and remove wi ri ng connect ors.
Pa r t
1 3530 Steering Column Shroud
(Upper)
2 11572 Ignition Switch
3 390345S36 Bolt (2 Req'd)
4 13K359 Multi-Function Switch
01- 12 - 7 I n s t r u me n t Pa n e l 01- 12 - 7
Par t
5 3 F 6 0 9 Tilt Wheel Handle and Shank
6 3530 Steering Column Shroud
(Lower)
7 5 5 9 2 9 - S 2 Bolt (3 Req'd)
8 7 2 0 2 Shift Control Selector Lever
and Housing
A Tighten to 2.1-2.9 N-m (19-25
Lb-ln)
B Tighten to 3.5-5.0 N-m (31-44
Lb-ln)
C Tighten to 0.68-1.13 N-m
(7-10 Lb-ln)
18. Di sconnect upper steeri ng column shroud ( 3530) .
19. Remove retaining bolt.
10. Remove retaining scr ew in parki ng brake control
( 2780) .
11. Remove parki ng brake cont rol .
12. Remove retaining scr ew in instrument panel finish
panel ( 04338) .
13. Remove retaining scr ew in the instrument panel
finish panel in t he l ower instrument panel ( 04320) .
14. Remove retaining scr ew in t he steeri ng column
opening rei nforcement.
15. Remove retaining scr ew in the steeri ng gear
housing ( 3548) .
16. Remove tilt wheel handle and shank ( 3F609) .
17. Remove ignition swi t ch ( 11572) .
St e e r i n g Co l umn
FRONT OF
VEHICLE
/
R7622-A
20. Di sconnect ignition swi t ch assembl y.
2 1 . Tag and remove el ectri cal connector.
22. Di sconnect vacuum hose.
FRONT OF
^VE HI C L E
VIEW A
R7481-B
I t e m
Pa r t
1
2
3514
13K359
Steering Column Tube
Multi-Function Switch
I t e m
Pa r t
3

To Headlamp Dimmer and
Washer Switch (13K359)
( Co n t i n ue d )
01- 12 - 8 I n s t r u me n t Pa n e l 0 1 - 1 2 - 8
I t e m
Pa r t
4

To Turn Signal and
Windshield Wiper Switch
(13K359)
5 To Ignition Switch (11572)
6 To Steering Wheel Position
Electronic Steering Sensor
(18B015)
I t e m
Pa r t
7 14401 Main Wiring
8 To Driver Side Air Bag
Module (043B13)
9 To Horn and Speed Control
Actuator Swi tch (9C888)
23. Remove retaining nut in t he steeri ng column
assembl y.
24. Lower steeri ng column t ube ( 3514) assembl y.
25. Di sconnect shift cabl e assembl y.
26. Remove steeri ng column shroud retaining screw.
27. Remove retai ni ng scr ews f r om multi-function
swi t ch ( 13K359) .
28. Position t he multi-function swi t ch out of t he way.
NUT
N806423-S56
TIGHTEN TO
21-28 N-m
(16-20 LB-FT)
STEERING
COLUMN
TUBE
3514
R6389-C
29
30.
Remove retai ni ng screw f r om the cowl si de tri m
panel ( 02345) .
Remove l ower panel door t ri m.
3 1 . Remove retai ni ng screw in t he l ower panel door
t ri m.
32. Posi ti on t he l ower panel door tri m out of t he way.
33. Tag and di sconnect wi ri ng connect ors.
34. Remove ground wi re assembl y.
35. Remove retai ni ng scr ew on t he cowl si de (RH)
panel .
36. Remove l ower panel door t ri m.
37. Remove retaining scr ew in t he l ower panel door
tri m.
38. Position l ower panel door tri m out of t he way.
39. Tag and di sconnect wiring connect ors.
40. Remove ground wi re assembl y.
4 1 . Remove retaining rivet in the passenger si de of
42. Di sconnect t he generator (GEN)( 10346).
43. Di sconnect t he radi o f eed of the wi re assembl y.
44. Unsnap the panel on the instrument panel finish
panel, center and RH.
45. Unsnap t hel / Pf i ni sh center (LH) on the panel
assembl y.
46. Remove the radi o chassi s.
47. Remove retaining screw in the instrument panel
finish panel .
48. Position the instrument panel finish panel out of
the way.
49. Tag and di sconnect the wiring connect ors.
50. Remove retaining screw in the air bag restraining
module assembl y.
5 1 . Di sconnect the air bag restraining module
assembl y.
52. Remove and di sconnect the instrument panel
defroster opening grille.
53. Remove instrument panel t o cowl brace retaining
scr ew.
54. Remove instrument panel finish panel retaining
screw.
55. Remove retaining nut on the instrument LH l ower
finish panel .
56. Remove retaining brace.
57. Di sconnect vacuum hose on t he harness
assembl y.
58. If instrument panel is being repl aced, transfer all
parts t o the new instrument panel .
60. Check air bag indicator operati on. Refer t o
Section 01- 20B.
01-12-9 I n s t r u me n t Pa n e l 01-12-9
I n s t r u m e n t Cl u s t e r Fi ni s h Pa n e l
C r o w n Vi c t o r i a
1. Di sconnect time only cl ock and heat ed rear
defrost swi t ch.
2. Remove RH instrument panel upper moulding
( 04268) and LH instrument panel moulding
( 04389) f rom instrument panel ( 04320) by pulling
away f rom instrument panel and snappi ng out of
retai ners.
3. Remove radi o chassi s ( 18806) .
4. Remove eight scr ews retaining instrument panel
finish panel ( 044D70) t o instrument panel .
5. Pull instrument panel finish panel away f rom
instrument panel while unsnapping RH and LH
upper corner retai ners and di sconnect wi ri ng.
Remove instrument panel finish panel f rom
vehi cl e.
7. Verify that air bag warni ng indicator operat es.
T o w n Ca r , G r a n d Ma r q u i s
1. Di sconnect ti me only cl ock and heat ed rear
def rost swi t ch.
2. Remove RH instrument panel upper moulding and
LH instrument panel moulding f rom instrument
panel by pulling away f rom instrument panel and
snappi ng out of retai ners.
3. On Town Car, remove 13 scr ews (si x at t op and
seven at bot t om) retaining instrument panel finish
panel t o instrument panel . On Grand Marqui s,
remove eight scr ews (four t op and four bot t om)
retaining instrument panel finish panel t o
instrument panel .
4. Remove air bag. Refer t o Secti on 01- 20B.
5. Pull instrument panel finish panel away f rom
instrument panel and di sconnect wi ri ng. Remove
instrument panel finish panel f rom vehi cl e.
7. Verify that air bag warni ng indicator operat es.
I n s t r u m e n t C l u s t e r
F i n i s h P a n e l , I n s t r u m e n t P a n e l
RH a n d LH
1. Remove instrument panel finish panel ( 04338) by
snappi ng it out of retai ners.
2. To install, align retai ners and press into
instrument panel ( 04320) .
Up p e r
1. Pull up t o unsnap instrument panel upper finish
panel ( 044A90) .
2. To install, align cl i ps and press instrument panel
upper finish panel into instrument panel .
S t e e r i n g C o l u m n O p e n i n g C o v e r A s s e m b l y
a n d R e i n f o r c e m e n t
1. Snap out RH and LH instrument panel moulding
( 04389) .
2. Remove five retaining scr ews at instrument panel
steeri ng column cover ( 04459) (three f rom
behind instrument panel moulding and t wo f rom
under instrument panel steeri ng column cover
assembl y).
3. Remove t wo bol ts and instrument panel
rei nforcement ( 04545) f rom under steeri ng
column tube ( 3514) .
01- 12 - 10 I n s t r u me n t Pa n e l 0 1 - 1 2 - 1 0
St e e r i n g Co l umn Ope n i n g Cove r a n d Re i n f o r c e me n t
R9560-A
I t em
Par t
1 04320 Instrument Panel
2 04269 RH Instrument Panel
Moulding
3 N606675-S3 Bolt (5 Req'd)
4 04459 Instrument Panel Steering
Column Cover
I t em
Pa r t
5 04269 LH Instrument Panel
Moulding
Lb-ln)
G l o v e C o m p a r t m e n t
1. Remove t hree retaining scr ews at gl ove
compart ment door hinge ( 06050) .
2. Open gl ove compart ment ( 06010) .
3. Press in on si des t o rel ease st ops and remove
gl ove compart ment .
GLOVE COMPARTMENT
DOOR ASSY
INSTRUMENT
PANEL
RH SIDE
BOLT
N803876-S36B
3 REQ'D
TIGHTEN TO
2.0-2.9 N-m
(18-25 LB-IN)
R56tA
01- 12- 11 I nst r ument Panel 0 1 - 1 2 - 1 1
L o c k , G l o v e Co mp a r t me n t
1. Open gl ove compart ment and remove l ock cover.
Remove cl i p securi ng l ock cylinder.
2. Remove l ock cyl i nder f rom gl ove compart ment .
SPECIFICATIONS
Descr i pt i on N-m Lb-ln
St e e r i n g Co l umn Op e n i n g Co v e r
Bo l t s
9- 14 7 - 10
( L b - Ft )
St e e r i n g Co l umn Op e n i n g
Re i n f o r c e me n t Bo l t s
9- 14 7 - 10
( L b - Ft )
St e e r i n g Co l u mn - t o - l n s t r u me n t
Pa n e l Re t a i n i n g Nut s
2 1- 2 8 16- 2 0
( L b - Ft )
Br a c e - t o - l n s t r u me n t Panel
Re t a i n i n g Bo l t s
9- 14 7 - 10
( L b - Ft )
I n st r ume n t Pa n e l Re t a i n i n g Bo l t 45- 7 0 34- 51
( L b - Ft )
I n st r ume n t Pa n e l Re t a i n i n g S c r e w 2 - 2 . 9 18- 2 5
I n st r ume n t Pa n e l Re t a i n i n g Bo l t 2 2 - 34 17 - 2 5
( L b - Ft )
Cl u s t e r Re t a i n i n g S c r e w s 2 - 2 . 9 18- 2 5
A / C Co n t r o l Re t a i n i n g S c r e ws 2- 2. 9 18- 2 5
L i gh t S wi t c h Br a c ke t Re t a i n i n g
S c r e ws
2. 5- 3. 2 2 3- 2 8
A u t o l a mp Se n s o r Re t a i n i n g
S c r e ws
2- 2. 9 18- 2 5
R H I / P Fi n i s h P a n e l Re t a i n i n g
S c r e ws
2 - 2 . 9 18- 2 5
Co u r t e s y L a mp Re t a i n i n g S c r e w 2 - 2 . 9 18- 2 5
Gl o v e Co mp a r t me n t Hi n ge
Re t a i n i n g S c r e ws
2 - 2 . 9 18- 2 5
De sc r i pt i on N-m Lb-l n
A s h Re c e p t a c l e Tr a c k Re t a i n i n g
S c r e ws
2- 2. 9 18- 25
Cl u s t e r Fi n i sh Pa n e l Re t a i n i n g
S c r e w s T o w n Ca r
2 . 7 - 4. 0 2 4- 35
Re l a y Mo un t i n g Br a c ke t Bo l t 7 . 6- 10. 4 68- 92
Fu s e Pa n e l Br a c ke t S c r e w 2 . 7 - 4. 0 2 4- 35
St e e r i n g Co l umn Tube
Re i n f o r c e me n t Bo l t
6. 0- 9. 0 54- 7 9
Tur n Si gn a l S wi t c h S c r e w 2. 1- 2. 9 19- 25
Ti l t Wh e e l Ha n d l e 3. 5- 5 31- 44
Co v e r S c r e w 0. 68- 1. 13 7- 10
Cl u s t e r Fi n i sh Pa n e l Re t a i n i n g
S c r e w s C r o w n Vi c t o r i a , Gr a n d
Ma r q u i s j
2- 2. 9 18-25
RH Pa n e l Re gi s t e r Re t a i n i n g
S c r e ws
2- 2. 9 18- 25
I n st r ume n t Pa n e l Re t a i n i n g S c r e w s 2 - 2 . 4 18- 21
Ce n t e r L o we r I n st r ume n t Pa n e l
Fi n i s h Pa n e l A s s y
2 . 7 - 4. 0 2 4- 35
I n st r ume n t Pa n e l Br a c e - t o - Co wl
Bo l t
9- 14 7 - 10
( L b - Ft )
I n st r ume n t P a n e l - t o - Co wl Si d e Bo l t 2 2 - 34 17-25
( L b - Ft )
I n st r ume n t P a n e l - t o - Co wl
2- 2. 9 18-25
ROTUNDA EQUIPMENT
01- 14A- 1 Handl es, Loc k s , Lat c hes a n d Mechani sms 1 - 14A- 1
SECTION 01-14A Handles, Locks, Latches and
Mechanisms
SUBJECT PAGE
VEHICLE APPLICATION . .01-14A-1
Door Locks. . .01-14A-1
Fuel Filler Door Remote Release,
El ectri c ....01-14A-2
Lock, Chi l d Saf et y ....01-14A-2
Luggage Compar t ment Remot e Cont r ol Lock
Swi t c h .01-14A-2
Component Test s 01-14A-26
Door Lock Ac t ua t or . . . . . 01-14A-27
Door Lock Swi t ch 01-14A-26
El ect ri cal Schemat i cs. . . . . ...01-14A-3
I nspect i on and Veri f i cat i on 01-14A-14
Pi npoi nt Test s ..01-14A-15
Sy mpt om Chart 01-14A-14
Act uat or , Luggage Compar t ment Door
Loc k 01-14A-40
Act uat or , Power Door Lock 01-14A-36
Bel l crank and Li nk, Rear Door 01-14A-35
Cont r ol Processor, El ect roni c Door
Loc k 01-14A-37
Fuel Fi ller Door . 01-14A-37
Handl e, Insi de Door 01-14A-37
Handl e, Out si de Do o r Cr o wn Vi ct or i a, Grand
Marqui s 01-14A-37
Handl e, Out si de Do o r To wn Car. . . . 01-14A-37
Lat ch and Loc k, Luggage Compar t ment
Do o r Cr o wn Vi ct or i a. . 01-14A-39
SUBJECT PAGE
Lat ch and Lock, Luggage Compa r t me nt
Do o r Gr a n d Marqui s 01-14A-40
Lat ch and Lock, Luggage Compar t ment
Do o r To wn Car.. . . 01-14A-38
La t c h, Door ....01-14A-27
Fuel Fi l l er . . . . 01-14A-34
La t c h, Gl ove Compar t ment ......01-14A-38
Lock Cyl i nder, Door . . 01-14A-35
Lock Cyl i nder, Gl ove Compar t ment . 01-14A-38
Luggage Compar t ment Door Remot e Cont r ol
Loc k Swi t c h 01-14A-40
Remot e Cont r ol Assembl y . . . . 01-14A-35
St r i ker Pl at e, Door Lat ch 01-14A-35
St ri ker, Luggage Compar t ment Door 01-14A-40
Swi t c h, Door L o c kCr o wn Vi ct or i a, Grand
Marqui s. 01-14A-36
Swi t c h, Door L o c kTo wn Car 01-14A-36
Swi t c h, Fi ller Door Lock 01-14A-37
ADJUSTMENTS
Lat ch and St ri ker, Luggage Compar t ment
Door 01-14A-41
St ri ker, Door Lat ch 01-14A-41
LUBRICATION
Door Lat ches 01-14A-41
Lock Cyl i nder Lubri cant ...01-14A-41
SPECIFICATIONS ..01-14A-41
SPECIAL SERVICE TOOLS/EQUIPMENT 01-14A-41
VEHICLE APPLICATION
Do o r L o c k s
P o w e r
The power door l ock syst em consi st s of:
Door l atch remot e control and links.
Door l atches.
Door l atch control rod knobs ( 21850) .
Door handle ( 22404) .
Door l atch actuati ng rods.
Door l ock cyl i nders ( 21985) .
Front door l atch control cylinder rods ( 22134)
Door l atch st ri ker pl ate ( 22008) .
Front doors ( 20124) .
Rear doors ( 24630) .
Door l ock swi t ches ( 14028) in t he front door tri m
panel ( 23942) .
Power door lock act uat or ( 218A42) inside each
front door.
Dri ver' s door module.
Circuit wiring and circuit protecti on.
In t he at-rest position, each terminal of t he power door
l ock actuator is connected t o ground through the
dri ver' s door module. Power is suppl i ed t o the syst em
through fuse junction panel circuit breaker and Circuit
517 ( BK/ W) ( Town Car) / 1 7 1 (BK / W)(Crown Vi ct ori a,
Grand Marqui s). The ci rcui t breaker is hot at all ti mes.
When t he rai sed portion of either door lock swi t ch
rocker knob (marked L) is pressed:
01- 14A - 2 Ha n d l e s, Loc k s , Lat c hes and Mechani sms 01- 14A - 2
Power f l ows through the door l ock swi t ch t o t he
dri ver' s door module, whi ch powers t he " l oc k "
termi nal on the power door l ock act uat or.
ALL doors l ock.
When t he depressed portion of either door l ock swi t ch
rocker knob (marked U) is pressed:
Power f l ows through the door l ock swi t ch t o t he
dri ver' s door module, whi ch powers t he " unl ock"
termi nal on the power door l ock act uat or.
ALL doors unlock.
L o c k , C h i l d S a f e t y
The chi l d saf et y l ock, when act i vat ed, prevent s t he
rear door ( 24630) f rom being opened f rom inside the
vehicle regardl ess of t he position of t he rear door l atch
push button rod ( 26460) .
The chi l d saf et y l ock has been desi gned into t he
rear door l atch ( 26412) .
A decal on the rear door l ock f ace shows the
l ocati on of the lever.
The l ever is manually moved up t o l ock and down t o
unlock the child saf et y l ock syst em.
Once t he syst em is put into the l ocked posi ti on and
t he rear door is cl osed, t he rear door can only be
opened f rom outsi de the vehi cl e.
The chi l d saf et y l ock does not l ock t he rear door
f rom t he outsi de.
It is still necessary t o push t he door l ock knob down
or press the door l ock swi t ch ( 14028) t o l ock t he
rear door f rom outsi de.
REAR
DOOR
LATCH
26412
CHI LD SAFETY
LOCK DECAL
CHI LD
SAFETY
LATCH
N6601-D
L u g g a g e C o m p a r t m e n t R e m o t e C o n t r o l L o c k
S w i t c h
The l uggage compart ment remote control lock swi t ch
( 19C542) is mounted on the driver si de front door tri m
panel ( 23942) .
It inputs a signal t o dri ver' s door module, whi ch
act uat es a solenoid integral t o the luggage
compart ment door l atch ( 43200) .
Fu e l Fi l l e r Do o r R e m o t e Re l e a s e , E l e c t r i c
Fuel filler door l ock swi t ch ( 9B242) is l ocated in t he
front door tri m panel ( 23942) next t o the l uggage
compart ment remote control l ock swi t ch ( 19C542) .
The fuel filler door l ock swi t ch act uat es a solenoid
integral t o t he fuel filler door l atch ( 28610) .
Cr o wn Vi c t o r i a , Gr a nd Ma r qui s Sho wn , To wn Car
Si mi l ar
LUGGAGE COMPARTMENT
REMOTE CONTROL LOCK
SWI TCH 19C542
FUEL FILLER
DOOR LOCK
SWI TCH
9B242
DRI VER'S DOOR HARNESS
14631 (TOWN CAR)
BODY MAI N WI RI NG
14A005 (CROWN VI CTORI A, GRAND MARQUIS)
N 8 7 7
o - C
1995 Town Car, Crown Vi ct ori a, Grand Marquis July 1994
01- 14A - 3 Ha n d l e s , L o c k s , L a t c h e s a n d Me c h a n i s ms 01- 14A - 3
El ect ri cal Schemat i cs
Door L o c k Co n t r o l s T o wn Car
HOT A T
A L L T I ME S HOT AT A L L T I ME S
" ! P OWE R
I DISTRI-
BUTION
I BOX
2 7 6 BR
2 7 6 BR
1
| S$A 1$ Aj
* 1 FUSE
. JUNCTION
1 P A N E L
1
S T A RT E R
I NT E RRUP T
RE L A Y
1 8 7 J |
B 85 J 86 1
1 IwI I
2
I B4 > ^ - O C K j
| ^ I OFF
/ RUN I
1
*M*
I START STA '
" i IGNITIOI
1
SWITCH
of this circuit
120 j f
i :
PK/ LG
\ mf
12 01
119 PK/Y
PK/ LG
W/ P
57
BK
5/6
9 / 1 0
l
BACK LIGHTING
KEYLESS
ENTRY
KEYPAD
LG/ R
>
Y/ BK
>
>
123
57
BK
5 1 7 1 BK/ W
1
T O
L I GHTI NG
CONT ROL
MODUL E
( L CM)
67 6
PK/ O "
W/ PK
C1-2
C1-10
SOLID
STATE
C 2 - 1 1
C2 - 12
REMOTE
C2-5
C1 1
CMS
C3-4
C 2 - 1 0
DRIVER'S
DOOR
MODULE
K22802-A
01- 14A - 4 Handl es, Loc k s , Lat ches and Mechani sms
DIAGNOSIS A N D TESTING (Cont i nued)
01- 14A - 4
Door Loc k Cont r ol sTown Car (Cont i nued)
DRIVER'S
DOOR
MODULE
C I - 1 1
0 1 - 1 2
C2 8
01* 6
C2- 9
C2- 3
C2- 7
C2-.1
S OL I D
ST A T E
C I ' 3
C1-8
C1 5
C1- 13
See E VT M for more details
of this circuit
LH FRONT SEAT
SENSOR SWITCH
JA
mm* mm J DRIVER'S
J SEAT
mm MODULE
ST A T E - - I
BR/LG
(
I ST A T E I
LUGGAGE COMPARTMENT
DOOR RELEASE MOTOR
84
r
BK B f
1
! SUSPENSION/
I I B K ^ I S OL I D 'ggggS
110
# I J STATE i ^ | f
c
l
L E
I I I STEERING
I
5
" "
J
MODULE
! f | HEADLAMP
" ^ ^ t. , I SWITCH
S OL I D ;
ST A T E I
465 I W/LB
- 465
! K u a n s
W/LB
465
W/LB
1
70 I LB/W
LH
INTERIOR
LAMP
SWITCH
RH
INTERIOR
LAMP
SWITCH
TO ISO
91 41
LINK
117 PK/BK I R/ 0
PK/O
117
PK/BK
163
R/O
LUGGAGE
COMPARTMENT
DOOR RELEASE
SWITCH
RH FRONT
DOOR LOCK
I LR
I DOOR LOCK
I 118 + . ^ _
PK/O
118 ,
PK/O
^ ^ ( ^ y m m ^ l
PK/BK I
RR
DOOR LOCK
V* - * ^ PK/BK |
LF
DOOR LOCK
163
R/O PK/BK
K22803-A
Lugga ge Co mpa r t me n t Co n t r o l s T o wn Car
Z INSTRUMENT
I CLUSTER
rr--r.
I \ 2GA f 1
im cS m^Jgpz
' I FUSE
. JUNCTION
1 PANEL
5 1 7 BK /W
See EVTM f or more details
of this ci rcui t
2 96
r
#
W/P
T O L I GHT I NG
C ON T ROL MODUL E ( L CM)
t
FUEL FILL DOOR
RELEASE SWITCH
s
DECKLID
PULLDOWN/
MOTOR AND
SWITCH
DRIVER'S
DOOR MODULE
C3~4
01- 6
C M 3
5 1 7 I BK/ W DECKLID
RELEASE MOTOR
P/Y
DECKLID
RELEASE SWITCH
57 I BK
57 | pSK ^
2 6 j W/ P
2 6 I W/ P
FUEL FILLER
DOOR RELEASE
SOLENOID
W/ BK 5 7 I BK
K22801-A
J UNCT I ON
j PANEL
S e e EVTM f o r
m o r e d e t a i l s
of t h i s c i r c u i t
FUEL FILLER
DOOR LOCK
SWITCH
CLOSED WITH
BUTTON
DEPRESSED
482 I W/ BK
FUEL
FILLER
DOOR
SOLENOID
5 7 | B K
#
I
N12613- A
01- 14A - 7 Handl es, Loc k s , Lat c hes and Mec hani s ms
01- 14A - 7
Door Lock Cont r ol sCr own Vi c t o r i a , Gr and Marqui s (Wi t h El ect r oni c Door Lock Cont r ol Sy st e m)
DOOR HANDLE I
C2-3 I
PANIC A L A RM J
S e e EVTM f o r m o r e d e t a i l s
of this circuit
K22796-A
01- 14A - 8 Handl es, Look s , Lat ches and Mechani sms 01- 14A - 8
Door Lock Cont r ol sCr own Vi c t o r i a , Grand Marqui s (Wi t h El ect r oni c Door Lock Cont r ol Sy st e m) (Cont i nue d)
T O
L UG G A G E
COMP A RT -
ME NT DOOR
RE L E A SE
2 6
W/ P "
T O L I GHTI NG
CONT ROL MODUL E
( L CM) A N D
I NST RUME NT
CL US T E R
T O ME MORY .
SE A T S
SEAT OCCUPIED
SWITCH
of thi s circuit
C 1 - 1 3
C1-6
DRI VE R DOOR
UNL OCK
A L L DOORS
L OC K
C2-12
01- 3
3 DOORS
UNL OCK
KE YL E SS
I NP UTS
C2 - 5
o w
C1- 7
Cf c* -
DO O R
A J A R
C1-8
C2 - 1
91 41
0 1 - 1 2
L I NK
ME MORY
L I NK
NO. 1
C1- 11
ME MORY
NO. 2
C2 - 8
SE A T
S WI T CH
L OG I C P OWE R
G RD G RD
0 1 4 C 1 - 1 5
57 1 BK
r
Jt
57 I BK
57
< I
J
#
BK
1

1
1
57 1 BK
57 I BK
1
DRIVER'S
DOOR 117
MODULE
PASSENGER
DOOR
LOCK
MOTOR
T O L UG G A G E
COMP A RT ME NT
DOOR RE L E A SE
T O ME MORY
SE A T S
K22797-A
01- 14A - 9 Ha n d l e s , L o c k s , L a t c h e s a n d Me c h a n i s ms 0 1 - 1 4 A - 9
Lugga ge Co mpa r t me n t Co n t r o l s Cr o wn Vi c t o r i a ,
Gr a nd Ma r qui s
HOT AT ALL TIMES
I T^T- ^"! FUS E
1
\
1 4
I J UNCT I ON
| \ . P A N E L
20A
C1*4
" \ DRI VE R
. DOOR
I MODUL E
C2-13 C2-7
L U G G A G E
C OMP A RT ME N T
DOOR
L OC K
MOT OR
L
L U G G A G E
C OMP A RT ME N T
RE MOT E C ON T ROL
L O C K S WI T CH
CL OS E D WI T H
BUT T ON DE P RE SSE D
T
57 I BK
Co n n e c t o r End Vi e ws
Door L o c k Swi t c h A c t u a t o r T o wn Car
KEYLESS ENTRY KEYPAD CONNECTOR
N12551-A
Pi n
1 7 9 ( L G / R ) 3 / 4 S w i t c h t o P r o c e s s o r
2 7 8 C L B / Y) 1 / 2 S wi t c h t o P r o c e s s o r
3 57 ( BK) Gr o u n d f o r A c t u a t o r i l l umi n a t i o n
4 12 3( R) 9 / 0 S wi t c h t o P r o c e s s o r
5 2 96 ( W/ P ) Fu s e d A c c e s s o r y Fe e d
6 66 ( L B) Fe e d f o r A c t u a t o r I l l umi n a t i o n
7 12 2 ( Y) 7 / 8 S wi t c h t o A c t u a t o r
8 121
( Y / B K )
5 / 6 S wi t c h t o A c t u a t o r

O O
O O
3 C
o o

KEYLESS ENTRY
PAD
N10917-B
Pi n
1 7 9 ( L G / R) 3 / 4 Swi t c h t o P r o c e s s o r
2 7 8 ( L B / Y ) 1 / 2 S wi t c h t o P r o c e s s o r
3 57 ( BK) Gr o un d f o r A c t u a t o r I l l umi n a t i o n
4 12 3( R) 9 / 0 Swi t c h t o P r o c e s s o r
5 121
( Y/ B K )
5 / 6 S wi t c h t o P r o c e s s o r
6 122 ( Y) 7 / 8 Swi t c h t o P r o c e s s o r
7 6 6 ( L B ) Fe e d f o r A c t u a t o r I l l umi n a t i o n
8 12 4( BR) Swi t c h Co mmo n
0 1 - 1 4 A - 1 0 Ha n d l e s , L o c k s , L a t c h e s a n d Me c h a n i s ms 01- 14A - 10
N12609-A
Dri ver Door Module Connect or C1
P i n
1 12 3( R) A c t u a t o r Bu t t o n 9 / 0 I nput
2 12 0
( P K / L G )
Do o r L o c k S w i t c h U n l o c k
3 118
( P K / O )
Un l o c k Al l P a s s e n g e r Do o r s
4 57 ( B K )
a
67 6
( P K / 0 )
b
Gr o un d
L o g i c Gr o u n d
5 1 6 3 ( R / O ) Dr i v e r ' s Do o r Un l o c k
6 84 ( P / Y ) L u g g a g e Co mp a r t me n t Do o r L o c k
So l e n o i d Ou t pu t
7 84 ( P / Y )
a
b
L u g g a g e Co mp a r t me n t Do o r L o c k
No t Us e d
8 117
( P K / B K )
L o c k Al l Do o r s
9 12 1
( Y / B K )
A c t u a t o r Bu t t o n 5 / 6 i n put
10 119
( P K / Y)
Do o r L o c k S w i t c h L o c k
11 2 68
( B K / O )
12 2 67
( B R / L G )
13 2 6 ( W/ P ) L u g g a g e Co mp a r t me n t Do o r
Re l e a s e S wi t c h
14 No t Us e d
15 57 ( BK) Gr o un d
16
_
No t Us e d
17
No t Us e d
Dri ver Door Modul e Connect or C1 (Cont 'd)
Pi n
18 No t Us e d
b To wn Ca r
N12610-A
Dri ver Door Module Connect or 02
Pin
1 7 0 ( L B / W) I SO Li n k
2 2 2 6
W / B K )
a
L H Fr o n t Do o r Wi n d o w
S w i t c h U P
2 2 7 ( Y)
b
3 340
( R / L B )
a
Pa n i c Si gn a l Out put
2 4 ( D B / 0 )
b
P e r s o n a l Se c u r i t y Al a r m
4 No t Us e d
5 1 2 2 ( Y) A c t u a t o r Bu t t o n 7 / 8 I nput
6 66 ( L B) A c t u a t o r I l l umi n a t i o n
7 465
( W/ L B )
I l l umi n a t e d En t r y S wi t c h e s
8 177 ( W) L e f t Fr o n t Se a t Oc c u p i e d I nput
9 344
( B K / Y )
Do o r Aj a r
10 33
( W / P K )
a
I gn i t i o n St a r t I nput
1050
( L G / P )
b
11 7 8 ( L B / Y ) A c t u a t o r Bu t t o n 1/ 2 I nput
12 7 9 ( L G / R ) A c t u a t o r Bu t t o n 3 / 4 I nput
b To wn Ca r
N12608-A
Dri ver Door Module Connect or C3To wn Car
Pin
1 9 0 3 ( R ) Dr i v e r ' s Wi n d o w Do wn i n put
2 2 2 6
( W/ B K )
Dr i v e r ' s Wi n d o w Do wn Out put
3 400
( L B / B K )
Sa f e t y Re l a y t o Wi n d o w Re gu l a t o r
S wi t c h Fe e d
Dri ver Door Modul e Conne c t or C3To wn Car (Cont ' d)
Pin
4 517
( B K / W)
Ba t t e r y Fe e d
Dri ver Door Modul e Connect or C3Cr o wn Vi ct or i a,
Grand Marqui s
Pin
1 407 ( T / B K ) Dr i v e r ' s Wi n d o w Do wn I nput
2 2 2 7 ( Y) Dr i v e r ' s Wi n d o w Do wn Out put
3 193
( Y/ L G )
I gn i t i o n ( Ho t i n A CC or RUN)
4 517
( B K / W)
B + t o Mo d u l e
Po we r Door L o c k s C r o w n Vi c t o r i a / Gr a n d Ma r qui s ( Wi t ho ut El e c t r o n i c Door L o c k Co n t r o l Sy st e m)
HOT AT ALL TIMES
! \ SSSPiSSSL ' DISTRIBUTION
I \ SEAT MOTORS j B 0 X
N10878-B
01- 14A - 13 Ha n d l e s, Loc k s , Lat c hes a n d Mec hani s ms 01- 14A - 13
DIAGNOSIS AND TESTING ( C o n t i n o e d )
Wire Har ness Conne c t or En d Vi e ws
SWITCH (MASTER)
N10393-B
Pi n
1 4 8 4
( O / B K )
S wi t c h L i gh t i n g
3 119
( P K / Y)
Do o r L o c k S wi t c h - L o c k
5 517
( B K / W)
Ba t t e r y Fe e d
7 12 0
( P K / L G )
Do o r L o c k S wi t c h - Un l o c k
8 407 ( T / BK) Wi n d o w Re gu l a t o r Li mi t S wi t c h
9 313 ( W/ Y) RH Fr o n t Wi n d o w Mo t o r
10 2 2 6
( W/ B K )
L H Fr o n t Wi n d o w Mo t o r
11 314 ( T / L B) RH Fr o n t Wi n d o w Mo t o r
Pin
Number Ci r cui t Ci r cui t Fun c t i o n
12 484
( O / B K )
S w i t c h L i gh t i n g
13 5 7 ( BK) Gr o u n d
14 5 7 ( BK) Gr o u n d
15 3 1 6 ( Y / L B ) L H Re a r Wi n d o w Mo t o r
16 319
( Y / B K )
RH Re a r Wi n d o w Mo t o r
17 317
( G Y/ O )
L H Re a r Wi n d o w Mo t o r
18 32 0
( R / B K )
RH Re a r Wi n d o w Mo t o r
19 193
( Y/ L G )
Wi n d o w Re l a y Fe e d
2 0 1 7 0 ( R / L B ) Wi n d o w S wi t c h Fe e d
i eft
s~* u
DOOR LOCK SWITCH-RIGHT
(WITHOUT ELECTRONIC DOOR LOCK
CONTROL SYSTEM) N10880-A
Pin
1 119
( P K / Y)
LH Do o r L o c k S w i t c h L o c k
2 117
( P K / B K )
Do o r L o c k Mo t o r L o c k
3 171
( B K / W)
P o we r
4
__
Not Us e d
5 118
( P K / O )
Do o r L o c k Mo t o r U n l o c k
6 120
( P K / L G )
LH Do o r L o c k S w i t c h U n l o c k
0 1 - 1 4 A - 1 4 Ha n d l e s , L o c k s , L a t c h e s a n d Me c h a n i s ms 01- 14A - 14
Fuel Filler Door Lock Swi t chCrown Vi ctori a,
Grand Marquis
Z POWER
I DISTRIBUTION
. BOX
1
See EVTM for
more details
of this circuit
FUEL FILLER
I
DOOR LOCK
I
SWITCH
I .
CL OSE D WI T H
BUT T ON DE P RE SSE D
I
I
482 1
W/ P K
FUEL FILLER
DOOR LATCH
57 I BK
N10887-B
1. Veri fy t he cust omer' s original concern by
operati ng t he power door l ocks t o dupl i cate t he
condi ti on.
Inspect t o determi ne if one of the fol l owi ng
Mechanical Electrical
Do o r a l i gn me n t .
L a t c h d a ma g e .
L a t c h bi n d i n g.
Fa i l e d c i r c ui t b r e a ke r
Co r r o d e d c o n n e c t o r s .
L o o s e c o n n e c t i o n s .
3.
4.
If t he inspection reveal s obvi ous concern(s) t hat
If t he concern(s) remains after the i nspecti on,
determi ne the sympt om(s) and go t o t he fol l owi ng
Sympt om Chart.
NOTE: Bef ore starti ng el ectri cal di agnosi s, check for
mechani cal bi nds by manually operati ng door l ocks.
Operat e l ock syst em several ti mes f rom each swi t ch,
whi l e observi ng t he operati on of all door l ocks. Be sure
bat t ery is fully charged.
S y m p t o m C h a r t
Use Rotunda 73 Digital Multimeter 105- 00051 or
equivalent for t he following el ectri cal t est s.
Us i n g NG S
Di agnosti cs for thi s secti on require use of t he Rotunda
New Generati on STAR (NGS) Tester 007- 00500 or
equivalent. The module controlling the syst em being
di agnosed communi cates wi t h t he dat a link connector
l ocat ed beneath t he instrument panel .
Connect t he OBDI I styl e communi cati on cabl e t o t he
NGS. At t ach the NGS and communi cati on cabl e t o t he
DLC beneath the instrument panel . Sel ect the proper
vehi cl e model and year f rom the NGS menu. You may
then access t he testi ng area of the NGS menu
requi red t o di agnose this syst em.
01- 14A - 15 Ha n d l e s , Loc k s , L a t c h e s and Mechani sms 0 1 - 1 4 A - 1 5
HANDLES, LOCKS, LATCHES AND MECHANISMS
C O N D I T I O N POSSIBLE SOURCE ACTION
O n e D o o r L o c k O p e r a t i v e Circuitry.
Power door lock actuator.
GO t o Pinpoint Test A.
All Door Locks Operative Locks circuit breaker open.
Battery / power ci rcui t .
Poor ground.
Circuitry.
Door lock swi t ch.
Driver's Door Module.
GO t o Pinpoint Test B, with keyl ess
entry.
GO t o Pinpoint Test C, without
keyless entry.
All Locks Work From One Switch
Only
Power to door lock swi t ch.
Door lock swi t ch.
Circuitry.
GO t o Pinpoint Test D.
Door Locks Operate One Way Only Circuitry.
a Poor ground.
Left door lock swi t ch.
Door Locks Work With Engine
Running Only
Battery di scharged. GO to Pinpoint Test F.
Door Locks Work Intermittently Battery partially charged.
Connections loose, opening or
shorting.
Intermittent door lock swi tch or
power door lock actuator.
GO t o Pinpoint Test G.
Luggage Compartment Release
Switch Inoperative
Circuitry.
Luggage compartment door lock
solenoi d.
Luggage compartment remote
control lock swi t ch.
GO to Pinpoint Test H.
Power Pull-Down Inoperative
Circuit.
Sensor.
Swi t ch.
GO to Pinpoint Test J.
Fuel Filler Door Release
Inoperative
Power fuse or circuit breaker.
Poor ground.
Fuel filler door lat ch.
Circuitry.
GO to Pinpoint Test K.
PINPOINT TEST A: ONE DOOR LOCK INOPERATIVE
A1 CHECK OPERATION OF SUSPECT DOOR LOCK
Yes
No
GO to Lubrication.
SERVICE as required.
GO to A2.
Manually operate inoperative door lock.
Check for binding or stuck condi ti on.
Is l ock st uck or bi ndi ng?
Yes
No
GO to Lubrication.
GO to A2.
A2 CHECK SUSPECT POWER DOOR LOCK ACTUATOR
LOCK OPERATION
Yes -
No
GO to A3.
(PK/BK) (Town Car) or
118 (PK/O) (Crown
Vi ct ori a, Grand Marquis)
for open circuit.
RESTORE vehicle.
RETEST system.
Gain access to suspect power door lock actuator as
outlined.
Disconnect power door lock actuator.
Using a test lamp connected to a known good
ground, check Circuits 117 (PK/BK) (Town Car) or
118 (PK/O) (Crown Vi ct ori a, Grand Marquis) at
harness connector while actuating door lock
swi t ches in the lock posi ti on.
Yes -
No
GO to A3.
(PK/BK) (Town Car) or
118 (PK/O) (Crown
for open circuit.
RESTORE vehicle.
RETEST system.
01- 14A - 16 Handles, Locks, Latches and Mechanisms 01- 14A - 16
PINPOINT TEST A: ONE DOOR LOCK INOPERATIVE (Cont i nued)
A3 CHECK POWER DOOR LOCK ACTUATOR FOR
UNLOCK OPERATION
Remove t est lamp from lock circuit and connect it to
Circuits 118 (P/ O) (Town Car) or 117 (PK/BK)
(Crown Vi ct ori a, Grand Marquis).
Actuate door lock swi t ch in the unlock posi ti on.
Yes
No

GO to A4.
(P/ O) (Town Car) or 117
(P/O) (Crown Vi ct ori a,
Grand Marquis) for open
ci rcui t. RESTORE
A4 CHECK DOOR LOCK ACTUATOR
Using two 10 gauge jumper wi res connected to
battery positive ( + ) and negative (-), at t ach j umpers
to power door lock actuator connector (reverse
polarity for opposi te di recti on).
Di d power door l oc k act uat or oper at e c or r e c t l y ?
Yes
No
GO to AS.
REPLACE power door
lock actuator. RESTORE
A S CHECK ACTUATOR CURRENT DRAW
Using Rotunda 73 Digital Multimeter 105-00051 or
equivalent, check actuator current draw.
Yes
No

POWER SOURCE
(12 VOLT)
ROTUNDA 73
DIGITAL
MULTIMETER
105-00081
Is cur r ent draw 6 amps or l ess?
V
POWER
DOOR
LOCK
ACTUATOR
N11508-A
RECONNECT power door
lock actuator. REFER to
Lubrication.
REPLACE power door
PINPOINT TEST B: ALL DOOR LOCKS INOPERATIVE TOWN CAR
B1 TEST DRIVER'S DOOR LOCK SWITCH
Yes
No
GO to B2.
CHECK Fuse 8 (15A) and
circuit breaker 14 (20A).
CHECK for B+ at Pin C3-4
of driver's door module. If
all are good, GO to B5.
Press driver's door lock swi t ch.
Do all door s l oc k?
Yes
No
GO to B2.
CHECK Fuse 8 (15A) and
circuit breaker 14 (20A).
CHECK for B+ at Pin C3-4
of driver's door module. If
all are good, GO to B5.
B2 ISOLATE INOPERATIVE DOOR LOCK
Yes
No
SERVICE Circuit 118
(PK/O) for open circuit.
RETEST system.
GO to B3.
Ensure all doors are unlocked.
Press driver's door lock swi t ch to lock posi ti on,
e Di d dri ver' s door l oc k, and passenger door s
remai n unl ocked?
Yes
No
SERVICE Circuit 118
(PK/O) for open circuit.
RETEST system.
GO to B3.
B3 ISOLATE INOPERATIVE PASSENGER DOOR LOCK
Yes
No
GOt o B4.
(PK/O) and 117 for open.
RETEST system.
Check all passenger doors.
Are all passenger door s l oc ke d?
Yes
No
GOt o B4.
(PK/O) and 117 for open.
RETEST system.
PINPOINT TEST B: ALL DOOR LOCKS INOPERATIVETOWN CAR (Cont i nued)
B4 CHECK CIRCUIT 163 (R/O)
Yes
No >
GO t o B6.
SERVICE Circuit 163
(R / 0 ) for open ci rcui t.
RETEST syst em.
U s i n g a Di g i t a l Volt-Ohmmeter o r e q u i v a l e n t , c h e c k
continuity of Circuit 163 (R/ O) from driver's door
module t o LH front door lock actuator.
Yes
No >
GO t o B6.
SERVICE Circuit 163
(R / 0 ) for open ci rcui t.
RETEST syst em.
B5 TEST PASSENGER'S DOOR LOCK SWITCH - DRIVER'S
DOOR OK
Yes
No
GO to B7.
SERVICE passenger's
door swi t ch and wiring
Circuit 296 (W/ P) feeding
power to t he swi t ch and
Circuit 119 (PK/ Y) to the
driver's door module.
RETEST syst em.
Press passenger's side door lock swi t ch.
Do door s l oc k?
Yes
No
GO to B7.
SERVICE passenger's
door swi t ch and wiring
Circuit 296 (W/ P) feeding
power to t he swi t ch and
Circuit 119 (PK/ Y) to the
RETEST syst em.
B6 TEST PASSENGER'S DOOR LOCK SWITCH - DRIVER'S
DOOR NOT OK
Yes
No
SERVICE driver's door
swi tch and wiring Circuit
296 (W/ P) feedi ng power
t o the swi t ch and Circuit
119 (PK/ Y) to the
RETEST syst em.
GOt o B27.
Press passenger's side door lock swi t ch.
Yes
No
296 (W/ P) feedi ng power
t o the swi t ch and Circuit
119 (PK/ Y) to the
RETEST syst em.
GOt o B27.
B7 TEST DRIVER'S DOOR UNLOCK SWITCH
Yes
No
GO to B8.
GO to B9.
Press driver's door unlock swi t ch.
Do all door s unl ock?
Yes
No
GO to B8.
GO to B9.
B8 TEST PASSENGER'S DOOR UNLOCK SWITCH -
DRIVER'S DOOR OK
Yes
No
GOt o BI O.
SERVICE passenger's
door swi tch and wiring
Circuit 120 (PK/LG) from
the swi tch t o the driver's
door module. RETEST
system.
Press passenger's side door unlock swi t ch.
Do door s unl ock?
Yes
No
GOt o BI O.
SERVICE passenger's
door swi tch and wiring
Circuit 120 (PK/LG) from
the swi tch t o the driver's
door module. RETEST
system.
B9 TEST PASSENGER'S DOOR UNLOCK SWITCH -
DRIVER'S DOOR NOT OK
Yes
No
120 (PK/LG) from the
swi tch t o the driver's
door module. RETEST
system.
GO to B30.
Press passenger's side door unlock swi t ch.
Do door s unl ock?
Yes
No
120 (PK/LG) from the
swi tch t o the driver's
door module. RETEST
system.
GO to B30.
B10 TEST REMOTE KEYLESS ENTRY REMOTE
TRANSMITTER
Yes
No
GOt o B11.
GO to B24.
Press Remote Keyless Transmitter LOCK button.
Within five seconds press UNLOCK button.
Did door s unl ock?
Yes
No
GOt o B11.
GO to B24.
B11 CHECK REMOTE KEYLESS ENTRY LOCK FUNCTION
Yes
No
GO t o B13.
GOt o B12.
Press Remote Keyless Entry lock button.
Di d door s l oc k?
Yes
No
GO t o B13.
GOt o B12.
TEST STEP RESULT O ACTION TO TAKE
B12 ISOLATE INOPERATIVE CONDITION
Yes E>
No
SERVICE Circuit 117
<PK / BK) for open ci rcui t.
RETEST system.
GOt o B13.
Manually unlock all doors.
Press R e m o t e Keyless Entry l o c k b u t t o n .
Within five seconds, press Remote Keyless Entry
unlock button.
Did passenger door s operat e t he opposi t e of t he
dri ver' s door ?
Yes E>
No
SERVICE Circuit 117
<PK / BK) for open ci rcui t.
RETEST system.
GOt o B13.
B13 CHECK LUGGAGE COMPARTMENT DOOR LOCK
OPERATION
Yes
No
GO t o B14.
GO to B25.
Within five seconds press luggage compartment
unlock button t wi ce.
Di d l uggage compar t ment unl ock?
Yes
No
GO t o B14.
GO to B25.
B14 CHECK ALARM FUNCTION
Yes
No
GOt o B15.
GO to B26.
Press alarm button t wi ce.
Does al arm sound?
Yes
No
GOt o B15.
GO to B26.
B15 TEST KEYLESS ENTRY KEYPAD FACTORY CODE
Yes
No
GO t o B16.
GOt o B17 .
Using keypad, enter factory code to unlock driver's
door.
Within five seconds, press 3/ 4 swi tch to unlock
passenger's doors.
Does dri ver' s door unl ock, and do passenger' s
door s unl ock?
Yes
No
GO t o B16.
GOt o B17 .
B16 TEST KEYLESS LOCKING
Yes
No
System OK.
GO t o B17 .
Press 7 / 8 and 9/ 0 swi tches at the same time.
Yes
No
System OK.
GO t o B17 .
B17 CHECK KEYLESS ENTRY KEYPAD
Yes
No
GO t o B18.
GO t o B2 2 .
Depress 1/2 swi t ch.
Does i l l umi nat ed ent r y t ur n on t he cour t esy
l amps?
Yes
No
GO t o B18.
GO t o B2 2 .
B18 CHECK KEYPAD 3/ 4 BUTTON OPERATION
Yes D>
No ^
GOt o B19.
system.
Lock vehicle by pressing the keypad 7/ 8 and 9/ 0
buttons at same time.
Press the keypad 3/ 4 button.
Di d i l l umi nat ed ent r y t urn on?
Yes D>
No ^
GOt o B19.
system.
B19 CHECK KEYPAD 5 / 6 BUTTON OPERATION
Yes
No
GO to B20.
system.
Lock vehicle by pressing the keypad 7 / 8 and 9/ 0
buttons at the same time.
Press the keypad 5/ 6 button.
Di d i l l umi nat ed ent ry t urn on?
Yes
No
GO to B20.
system.
B20 CHECK KEYPAD 7 / 8 BUTTON OPERATION
Yes
No
GO to B2 1.
system.
Press the keypad 7 / 8 button.
Yes
No
GO to B2 1.
system.
B21 CHECK KEYPAD 9/ 0 BUTTON OPERATION
Yes
No
GO to B22.
Press the keypad 9 / 0 button.
Yes
No
GO to B22.
B22 TEST POWER TO KEYLESS ENTRY KEYPAD
Yes
No
REPLACE keyless entry
keypad. GO to B23.
SERVICE Circuit 296
(W / P) for open circuit.
RETEST system.
Read voltage on Circuit 296 into keyless entry
keypad.
Yes
No
keypad. GO to B23.
SERVICE Circuit 296
(W / P) for open circuit.
RETEST system.
01- 14A - 19 " ~ ~ "" '
a
PINPOINT TEST B: ALL DOOR LOCKS INOPERATIVETOWN CAR (Conti nued)
B23 TEST TRANSMITTER LOCK BUTTON
Yes
No
module. PROGRAM new
keyless entry
transmi tters to new
module. REFER to
Section 01-14B. RETEST
system.
PROGRAM replacement
keyless entry
transmi tters to vehi cle.
REFER to Section
01-14B. GOt o B2 4.
Connect Rotunda New Generation Star t est er
007-00500 or equivalent t o data link connector.
Press LOCK button on keyless entry transmitter.
Request PID for last RKE transmission dat a.
Does dat a i ndi cat e l ock r ecei ved?
Yes
No
module. PROGRAM new
keyless entry
transmi tters to new
module. REFER to
system.
PROGRAM replacement
keyless entry
transmi tters to vehi cle.
REFER to Section
01-14B. GOt o B2 4.
B24 TEST TRANSMITTER UNLOCK BUTTON
Yes
No
module. PROGRAM
keyless entry transmitter
to new module. REFER to
system.
PROGRAM replacement
to vehi cle. REFER to
Section 01-14B. GO to
B25.
007-00500 or equivalent t o data link connector.
Press unlock button on keyless entry transmitter.
Does dat a i ndi cat e unl ock recei ved?
Yes
No
module. PROGRAM
to new module. REFER to
system.
PROGRAM replacement
to vehi cle. REFER to
B25.
B25 TEST TRANSMITTER LUGGAGE COMPARTMENT
RELEASE BUTTON
Yes
No
GO t o Pinpoint Test H.
PROGRAM replacement
to vehicle. REFER to
B26.
007-00500 or equivalent t o Data Link Connector.
Does dat a i ndi cat e l ock recei ved?
Yes
No
PROGRAM replacement
B26.
B26 TEST RKE ALARM BUTTON
Yes
No
GOt o Section 13-11.
PROGRAM replacement
system.
Does dat a i ndi cat e al arm recei ved?
Yes
No
PROGRAM replacement
system.
B27 TEST DRIVER'S DOOR UNLOCK SWITCH
Yes
No
GOt o B28.
GO to B30.
Press driver's door unlock swi t ch.
Do all door s unl ock?
Yes
No
GOt o B28.
GO to B30.
B28 TEST LOCK SWITCH INPUT
Yes
No
SERVICE Circuit 119
(PK/Y) for short to
battery. CHECK for stuck
swi t ch. RETEST syst em.
GOt o B29.
Request PID for Lock Switch Status.
Does dat a i ndi cat e l ock but t on pr essed?
Yes
No
SERVICE Circuit 119
(PK/Y) for short to
swi t ch. RETEST syst em.
GOt o B29.
01- 14A - 2 0 Ha n d l e s, L o c k s , L a t c h e s a n d Me c h a n i s ms 01- 14A - 2 0
B29 TEST LOCK SWITCH INPUT WITH NEW GENERATION
STAR TESTER
Yes
No
module. PROGRAM
keyless entry
transmitters to new
module. REFER to
system.
SERVICE Circuit 119
(PK/Y) for open circuit or
bad swi t ch. ENSURE that
Circuit 296 (W/ P) is
feeding power to
swi tches. RETEST
system.
C o n n e c t R o t u n d a N e w G e n e r a t i o n S t a r t e s t e r
Hold driver's door lock button.
Does dat a i ndi cat e l ock but t on pressed?
Yes
No
module. PROGRAM
keyless entry
transmitters to new
module. REFER to
system.
SERVICE Circuit 119
(PK/Y) for open circuit or
bad swi t ch. ENSURE that
Circuit 296 (W/ P) is
feeding power to
swi tches. RETEST
system.
B30 TEST UNLOCK SWITCH INPUT WITH NEW
GENERATION STAR TESTER
Yes
No
SERVICE Circuit 120
(PK/LG) for short to
swi t ch. GOt o B2.
GO to B31.
Does dat a i ndi cat e unl ock but t on pressed?
Yes
No
SERVICE Circuit 120
(PK/LG) for short to
swi t ch. GOt o B2.
GO to B31.
B31 TEST DRIVER'S DOOR UNLOCK SWITCH INPUT
Yes
No
module. PROGRAM
keyless entry
transmitters to new
module. REFER to
system.
SERVICE Circuit 120
(PK/LG) for open circuit
or bad swi t ch. GO to B2.
Hold driver's door unlock button.
Does dat a i ndi cat e unl ock but t on pressed?
Yes
No
module. PROGRAM
keyless entry
transmitters to new
module. REFER to
system.
SERVICE Circuit 120
(PK/LG) for open circuit
or bad swi t ch. GO to B2.
B32 TEST REMOTE KEYLESS ENTRY TRANSMITTER
Yes
No
System is operational at
this time.
RECHECK Circuit 517
(BK/W) to Pin C3-4 of
DDM for B+. Also,
CHECK Circuit 676
(PK/O) to Pi nC1-4 and
Circuit 57 (BK) to P i n
C1 -15 o f DDM for ground.
If both are good,
module. PROGRAM NEW
keyless entry
transmitters to new
module. REFER to
system.
Press remote keyless entry transmitter LOCK
button.
Press transmitter UNLOCK button.
Within 5 seconds press transmitter UNLOCK button.
Do door s l ock and unl ock as e xpe c t e d?
Yes
No
this time.
RECHECK Circuit 517
(BK/W) to Pin C3-4 of
DDM for B+. Also,
CHECK Circuit 676
(PK/O) to Pi nC1-4 and
Circuit 57 (BK) to P i n
C1 -15 o f DDM for ground.
If both are good,
module. PROGRAM NEW
keyless entry
transmitters to new
module. REFER to
system.
PINPOINT TEST C: ALL DOOR LOCKS INOPERATIVEWITHOUT KEYLESS ENTRY
C1 CHECK SUPPLY TO DOOR LOCK SWITCH
Yes
No
GO to C4.
GO to C2.
Partially remove master door lock swi tch as
outlined.
Using voltmeter, check Circuit 171 (BK/ W) Pin K at
swi t ch connector for voltage.
Is bat t er y vol t age pr esent ?
Yes
No
GO to C4.
GO to C2.
01- 14A - 2 1 Ha n d l e s , L o c k s , L a t c h e s a n d Me c h a n i s ms
0 1 - 1 4 A - 2 1
PINPOINT TEST C: ALL DOOR LOCKS INOPERATIVEWITHOUT KEYLESS ENTRY (Cont i nued)
C2 CHECK CIRCUIT 171 (BK/ W) FOR OPEN
Yes
No
GO t o C3.
SERVICE Circuit 171
(BK/ W) for open.
RESTORE vehi cle.
RETEST syst em.
Disconnect seat / lock Circuit Breaker (30A) at
Power Distribution Box.
Disconnect master door lock swi t ch.
Using an ohmmeter, check resi stance of Circuit 171
(BK/ W) from door lock swi tch connector to output
side of se a t / l oc k Circuit Breaker (30A) cavi ty.
Yes
No
GO t o C3.
SERVICE Circuit 171
(BK/ W) for open.
RESTORE vehi cle.
RETEST syst em.
C3 CHECK CIRCUIT 517 (BK/ W) FOR SHORT
Yes
No
SERVICE Circuit 171
(BK/ W) for short.
RESTORE vehi cle.
RETEST syst em.
REPLACE se a t / l oc k
circuit breaker (30A).
RESTORE vehi cle.
RETEST system.
Using ohmmeter connected t o a known good
ground, connect second lead to Circuit 171 at door
lock swi tch connector.
Yes
No
SERVICE Circuit 171
(BK/ W) for short.
RESTORE vehi cle.
RETEST syst em.
REPLACE se a t / l oc k
circuit breaker (30A).
RESTORE vehi cle.
RETEST system.
C4 CHECK CIRCUIT 57 (BK)
Yes
No
GOt o C5.
for open. RESTORE
ground, connect second lead to Circuit 57 (BK) Pin
G at door lock swi t ch connector.
Yes
No
GOt o C5.
for open. RESTORE
C5 CHECK DOOR LOCK SWITCH OUTPUT
Yes
No
GO t o C6.
REPLACE master door
lock swi t ch. RESTORE
Reconnect master door lock swi t ch.
Using a voltmeter, check Circuit 120 (PK/ LG) at
door lock swi tch connector Pin J for voltage as door
lock swi tch is act uat ed to the lock posi ti on.
Is bat t er y vol t age present ?
Yes
No
GO t o C6.
REPLACE master door
C6 CHECK DOOR LOCK SWITCH UNLOCK OUTPUT
Yes
No
GOt o C7.
REPLACE master door
Disconnect ohmmeter from Circuit 120 (PK/LG).
Connect lead t o Circuit 119 (PK/ Y) Pin L at door
lock swi tch connector.
Measure voltage as door lock swi tch is actuated to
unlock posi ti on.
Yes
No
GOt o C7.
REPLACE master door
C7 CHECK CIRCUIT 117 (PK / BK)
Yes
No
SERVICE Circuit 117
(PK/BK) for open ci rcui t.
RESTORE vehi cle.
RETEST system.
SERVICE Circuit 118
(PK/O) for open ci rcui t.
RESTORE vehicle.
RETEST system.
Gain access to master keyless entry keypad as
outlined.
Disconnect keyless entry keypad.
Using a test lamp, check for voltage at Circuit 118
(PK/O) in harness connector as swi tch is actuated
to the lock posi t i on.
Yes
No
SERVICE Circuit 117
(PK/BK) for open ci rcui t.
RESTORE vehi cle.
RETEST system.
SERVICE Circuit 118
(PK/O) for open ci rcui t.
RESTORE vehicle.
RETEST system.
PINPOINT TEST D: ALL LOCKS WORK FROM ONE SWITCH ONLY
D1 CHECK SUSPECT POWER DOOR LOCK SWITCH
Yes
No
GOt o D2.
REPLACE door lock
swi t ch. RESTORE
Remove suspect swi tch as outlined.
Perform Door Lock Switch component t est .
Di d swi t c h t est OK?
Yes
No
GOt o D2.
REPLACE door lock
swi t ch. RESTORE
D2 CHECK SUPPLY TO POWER DOOR LOCK SWITCH
Yes
No
GOt o D3.
SERVICE Circuit 171
(BK/W) for open ci rcui t.
RESTORE vehicle.
RETEST system.
Using a t est lamp, check Circuit 517 (BK/ W) at Pin 5
for master door lock swi tch or Pin 3 for RH switch for
volt age.
Yes
No
GOt o D3.
SERVICE Circuit 171
(BK/W) for open ci rcui t.
RESTORE vehicle.
RETEST system.
01- 14A - 2 2 Ha n d l e s , L o c k s , L a t c h e s a n d Me c h a n i s ms 01- 14A - 2 2
PINPOINT TEST D: ALL LOCKS WORK FROM ONE SWITCH ONLY (Cont i nued)
D3 CHECK CIRCUIT 119 (PK/Y)
Yes
No
GO to D4.
SERVICE Circuit 119
(PK/ Y) for open.
RESTORE vehicle.
RETEST system.
Remove opposi te door lock swi t ch.
Using an ohmmeter, check Circuit 119 (PK / Y) from
Pin 3 at master power door lock swi tch connector to
Pin 3 at RH power door lock swi tch connector for
continuity.
Yes
No
GO to D4.
SERVICE Circuit 119
(PK/ Y) for open.
RESTORE vehicle.
RETEST system.
D4 CHECK CIRCUIT 120 (PK/LG)
Yes >
No >
REPLACE opposi te door
lock swi tch. RESTORE
vehi cle.
SERVICE Circuit 120
(PK/LG) for open.
RESTORE vehi cle.
RETEST system.
Using ohmmeter, check Circuit 120 (PK/ LG) from
Pin 7 at master power door lock swi tch connector to
Pin 4 at RH power door lock swi tch connector for
continuity.
Yes >
No >
lock swi tch. RESTORE
vehi cle.
SERVICE Circuit 120
(PK/LG) for open.
RESTORE vehi cle.
RETEST system.
PINPOINT TEST E: DOOR LOCKS OPERATE ONE WAY ONLY
E1 CHECK LOCK OPERATION
Yes
No
GO to E4.
GO t o E2 .
Actuate power door locks to the lock posi ti on.
Di d door s l oc k?
Yes
No
GO to E4.
GO t o E2 .
E2 CHECK MASTER POWER DOOR LOCK SWITCH
Yes
No
GOt o E3.
REPLACE damaged door
Remove master door lock swi tch as outlined.
Perform Door Lock Switch Component Test.
Di d swi t c h t est OK?
Yes
No
GOt o E3.
E3 CHECK POWER DOOR LOCK ACTUATOR CURRENT
DRAW
Yes
No
REPLACE power door
vehi cle. RETEST system
Partially remove power door lock act uat ors. Leave
actuators in vehi cle. Disconnect act uat ors.
equivalent, check power door lock actuator current
draw at each door.
Yes
No
REPLACE power door
i r
Yes
No
REPLACE power door
I
i r
/
POWER
DOOR
LOCK
ACTUATOR
N11508-A
Yes
No
REPLACE power door
POWER SOURCE
(12 VOLT)
ROTUNDA 73
DIGITAL
MULTIMETER
105-00051
Is cur r ent draw 6 amps
I LfefiasjHij
i U 2 f l
I | UataJt-tSfcilfnl
I assnta.
or l ess?
/
POWER
DOOR
LOCK
ACTUATOR
N11508-A
Yes
No
REPLACE power door
E4 CHECK RH POWER DOOR LOCK DOOR SWITCH
Yes
No
GOt o E3.
Remove RH door swi tch as outlined.
Perform Door Lock Switch Component Test.
Di d swi t c h t e st OK?
Yes
No
GOt o E3.
PINPOINT TEST F: DOOR LOCKS WORK WITH ENGINE RUNNING ONLY
TEST STEP RESULT E> ACTION TO TAKE
F1 CHECK SUPPLY CIRCUIT
Yes
No
GO to F2.
Using a voltmeter check vehicle battery volt age.
Is vol t age 10 vol t s or more?
Yes
No
GO to F2.
F2 CHECK LATCH/LINKAGE
Yes
No
GOt o F3.
REFER t o Lubrication and
SERVICE as necessary.
Manually l ock/ unlock door.
Does l at ch operat e easi l y?
Yes
No
GOt o F3.
F3 CHECK POWER DOOR LOCK SWITCH CONNECTOR
Yes
No
RESTORE vehi cle.
SERVICE as requi red.
RESTORE vehi cle.
RETEST syst em.
Partially remove master door lock swi t ch as
outlined.
Inspect connector for corrosion or damaged / loose
connection.
Is c onne c t or OK?
Yes
No
RESTORE vehi cle.
RESTORE vehi cle.
RETEST syst em.
PINPOINT TEST G: DOOR LOCKS WORK INTERMITTENTLY
G1 CHECK CONNECTORS
Yes
No
GO to G2.
RESTORE vehicle.
RETEST syst em.
Partially remove door lock swi t ches as outlined.
Check connectors for corrosion and ti ghtness.
Are c onne c t or s OK?
Yes
No
GO to G2.
RESTORE vehicle.
RETEST syst em.
G2 CHECK GROUND CIRCUIT AT EACH SWITCH
Yes
No
PERFORM Door Lock
Switch Component Test.
for open ci rcui t.
RESTORE vehicle.
RETEST syst em.
each door lock swi t ch.
Measure resi stance of each ci rcui t.
Yes
No
PERFORM Door Lock
Switch Component Test.
for open ci rcui t.
RESTORE vehicle.
RETEST syst em.
PINPOINT TEST H: LUGGAGE COMPARTMENT RELEASE SWITCH INOPERATIVE
H1 CHECK OPERATION
Yes
No
this time.
GO t o H2.
Depress luggage compartment remote control lock
swi t ch.
Does l uggage compar t ment door open?
Yes
No
this time.
GO t o H2.
H2 CHECK LUGGAGE COMPARTMENT DOOR RELEASE
OUTPUT
Yes
No
GO t o H7.
GO to H3.
Connect Rotunda New Generation Star (NGS) t est er
Send Command Decklid Release.
Does l uggage compar t ment door open?
Yes
No
GO t o H7.
GO to H3.
H3 CHECK MECHANICAL RELEASE
Yes
No
SERVICE mechanical
operation of luggage
compartment door
release mechanism.
CHECK for sti cki ng
luggage compartment
door.
GO to H4.
Send Command Decklid Release as in J2.
Does l uggage compar t ment door make a noi se?
Yes
No
SERVICE mechanical
operation of luggage
compartment door
release mechanism.
CHECK for sti cki ng
luggage compartment
door.
GO to H4.
PINPOINT TEST H: LUGGAGE COMPARTMENT RELEASE SWITCH INOPERATIVE (Cont i nued)
H4 CHECK LUGGAGE COMPARTMENT DOOR RELEASE
OUTPUT OF DRIVER'S DOOR MODULE
Yes
No
GO to H5.
Check Pin C1 -6 of driver's door module for voltage
when Decklid Release Command is sent.
Is vol t age moment ari l y B+ when command i s
sent ?
Yes
No
GO to H5.
H5 CHECK CONTINUITY TO SOLENOID
Yes
No
GO to H6.
CHECK for short to
ground or open circuit on
Circuit 84.
Check Circuit 84 (P / Y) of the luggage compartment
door release solenoid for voltage when Decklid
Release Command is sent.
Is vol t age moment ari l y B+ when command i s
sent ?
Yes
No
GO to H6.
CHECK for short to
Circuit 84.
HS CHECK FOR CONTINUITY ON GROUND TO SOLENOID
Yes
No
REPLACE luggage
compartment door l at ch.
RETEST system.
to ground. RETEST
system.
Check Circuit 57 (BK) of the luggage compartment
door release solenoid for continuity t o ground.
Is t here cont i nui t y t o gr ound?
Yes
No
REPLACE luggage
compartment door l at ch.
RETEST system.
to ground. RETEST
system.
H7 CHECK LUGGAGE COMPARTMENT REMOTE
CONTROL LOCK SWITCH CIRCUIT
Yes
No
GOt o H8.
Read the Decklid Release swi tch PID.
Close the luggage compartment door.
Does t he Deckl i d Release swi t c h PID change?
Yes
No
GOt o H8.
H8 CHECK FOR LUGGAGE COMPARTMENT REMOTE
CONTROL LOCK RELEASE SWITCH STUCK
Yes
No
SERVICE luggage
compartment remote
control lock switch for
stuck swi tch or Circuit 26
(W/ P) for short to
GO to H9.
With luggage compartment remote control lock
swi t ch not pressed, read the Deckli d Release
swi tch PID.
Does t est er i ndi cat e swi t c h is act i ve?
Yes
No
SERVICE luggage
compartment remote
control lock switch for
stuck swi tch or Circuit 26
(W/ P) for short to
GO to H9.
H9 CHECK FOR CONTINUITY FROM MODULE TO SWITCH
Yes
No
GOt o H10.
CHECK for open circuit on
luggage compartment
remote control lock
swi tch Circuit 26 (W/ P).
RETEST system.
Check Circuit 26 (W / P) of the luggage compartment
remote control lock swi t ch for continuity with Pin
C1-13 of the driver's door module.
Yes
No
GOt o H10.
luggage compartment
remote control lock
swi tch Circuit 26 (W/ P).
RETEST system.
H10 CHECK FOR CONTINUITY OF GROUND OF SWITCH
Yes
No
REPLACE luggage
compartment remote
control lock swi tch.
RETEST system.
to ground. RETEST
system.
Check Circuit 57 (BK) of the luggage compartment
remote control lock swi t ch for continuity to ground.
Yes
No
REPLACE luggage
compartment remote
control lock swi tch.
RETEST system.
to ground. RETEST
system.
PINPOINT TEST J: LUGGAGE COMPARTMENT DOOR POWER PULL DOWN INOPERATIVE
J1 CHECK FUSE
Yes
No
GOt o J2.
REPLACE fuse. RETEST
system.
Check Fuse 8 (t 5A) of fuse j unction panel.
Is f use go o d ?
Yes
No
GOt o J2.
REPLACE fuse. RETEST
system.
0 1 - 1 4 A - 2 5 Ha n d l e s , L o c k s , L a t c h e s a n d Me c h a n i s ms
PINPOINT TEST J: LUGGAGE COMPARTMENT DOOR POWER PULL DOWN INOPERATIVE (Conti nued)
J2 CHECK POWER FEED
Yes ~
No
GO to J3.
SERVICE Circuit 296
( W/ P) f o r open.
Gain access to luggage compartment door lock
actuator as outlined.
Disconnect electri cal connector.
Using a volt-ohmmeter measure voltage at Circuit
296 (W/ P).
Is vol t age great er than 10 vol t s?
Yes ~
No
GO to J3.
SERVICE Circuit 296
( W/ P) f o r open.
J3 CHECK GROUND
Yes
No
GO to J4.
for open.
Disconnect elect ri cal connector.
Using a volt-ohmmeter check continuity between
Circuit 57 (BK) and known good ground.
Yes
No
GO to J4.
for open.
J4 CHECK MOTOR
Yes
No
REPLACE luggage
compartment door lock
actuator.
SERVICE Circuit 665
(O/ Y) for open.
Disconnect electri cal connector.
Using a volt-ohmmeter check continuity of Circuit
665 ( 0/ Y) between luggage compartment door lock
actuator and trunk lid aj ar swi t ch.
Yes
No
REPLACE luggage
compartment door lock
actuator.
SERVICE Circuit 665
(O/ Y) for open.
PINPOINT TEST K: FUEL FILLER DOOR RELEASE INOPERATIVE
TESTSTEP RESULT ACTION TO TAKE
K1 CHECK SUPPLY TO SWITCH
Yes
No
GOt o K2.
SERVICE Circuit 517
(BK/ W) (Town Car) or
171 (BK/W) (Crown
for open. RESTORE
Partially remove fuel filler door lock swi t ch.
Using a t est lamp, check Circuit 517 (BK/ W) (Town
Car) or 171 (BK/ W) (Crown Vi ct ori a, Grand
Marquis) for voltage.
Yes
No
GOt o K2.
SERVICE Circuit 517
(BK/ W) (Town Car) or
171 (BK/W) (Crown
for open. RESTORE
K2 CHECK SWITCH OUTPUT
Yes
No
GOt o K3.
REPLACE fuel filler door
Disconnect test lamp from Circuit 517 (BK/ W)
(Town Car) or 171 (BK/ W) (Crown Vi ctori a, Grand
Marquis), and connect it to Circuit 482 (W/ PK) at
fuel filler door lock swi t ch.
Press fuel filler door lock swi t ch.
Yes
No
GOt o K3.
K3 CHECK CIRCUIT 482 (W / PK)
Yes "
No
GO to K6.
GO to K4.
Open luggage compartment door.
Disconnect fuel filler door l at ch.
Connect t est lamp to Circuit 482 (W /PK) at fuel filler
door latch solenoid connector and a good ground.
Press fuel filler door lock swi t ch.
Yes "
No
GO to K6.
GO to K4.
K4 CHECK CIRCUIT 482 (W/ PK) FOR OPEN
Yes "
No _
GO to K5. Leave
ohmmeter connected.
SERVICE Circuit 482
(W/PK) for open circuit.
RESTORE vehicle.
RETEST system.
Disconnect fuel filler door lock swi t ch.
Using a j umper wire, connect one end t o Circuit 482
(W/PK) at fuel filler door lock solenoid connector
and other end to a known good ground.
ground, connect second lead to Circuit 482 (W/ PK)
at fuel filler door lock swi t ch connector.
Yes "
No _
GO to K5. Leave
ohmmeter connected.
SERVICE Circuit 482
(W/PK) for open circuit.
RESTORE vehicle.
RETEST system.
1995 To wn Car , Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s July 1994
PINPOINT TEST K: FUEL FILLER DOOR RELEASE INOPERATIVE (Cont i nued)
K5 CHECK CIRCUIT 482 (W/ BK) FOR SHORT
Yes
No
SERVICE Circuit 482
(W/PK) for short to
ground. RESTORE
REPLACE damaged
seat / l ock circuit breaker.
RESTORE vehicle.
RETEST system.
Disconnect j umper wire at fuel filler door l at ch.
Is resi st ance 5 ohms or l e ss?
Yes
No
SERVICE Circuit 482
(W/PK) for short to
ground. RESTORE
REPLACE damaged
seat / l ock circuit breaker.
RESTORE vehicle.
RETEST system.
K6 CHECK FUEL FILLER DOOR LATCH SOLENOID
GROUND
Yes i
No
latch. RESTORE vehicle.
RETEST system.
for open circuit.
RESTORE vehicle.
RETEST system.
fuel filler door latch solenoid connector.
Is resi st ance 5 ohms or less?
Yes i
No
latch. RESTORE vehicle.
RETEST system.
for open circuit.
RESTORE vehicle.
RETEST system.
Do o r L o c k S w i t c h
Ma s t e r S w i t c h
Testi ng t he mast er wi ndow regul ator control swi t ch
( 14529) shoul d be perf ormed wi t h the swi t ch removed
f rom t he vehi cl e. Use a sel f-powered test lamp or an
ohmmeter.
1. Clip one t est l ead probe on Terminal 2 (ground).
2. Wi t h all wi ndow regul ator control swi t ches in t he
NEUTRAL posi ti on, no termi nal should have
continuity t o Terminal 2.
f or war d and hol d in t hat posi ti on ( t owar d rear of
vehi cl e when in installed posi ti on). Terminals 8, 9,
15 and 16 shoul d l ose continuity t o Terminal 2.
rearward and hold in t hat position ( t owar d rear of
vehi cl e when in installed posi ti on). Terminals 10,
11, 17 and 18 shoul d l ose continuity t o Terminal
2.
5. Remove t he t est lead f rom Terminal 2 and
connect it t o Terminal 19 (power).
6. Wi t h l ockout wi ndow regul ator control swi t ch in
neutral posi ti on, t here should be continuity
bet ween Terminals 20 and 19. Wi t h l ockout
wi ndow regul ator control swi t ch in unlock
posi ti on, no continuity should be between
Terminals 20 and 19.
f or war d and hold in that posi ti on. Terminals 8, 9,
17 and 16 should have continuity t o Terminal 19.
8. Pull all four wi ndow regul ator control swi t ches
r ear war d and hold in t hat position. Terminals 10,
11, 17 and 18 should have continuity t o Terminal
19.
9. Push t he l ockout wi ndow regulator control swi t ch
t o its detent posi ti on. Terminal 19 should not have
continuity wi th any other termi nal .
10. Remove test lead f rom Terminal 19 and connect
t o Terminal 5.
11. Act i vat e door l ock swi t ch ( 14028) t o unlock.
Continuity shoul d show between Terminals 7 and
5.
12. Act i vat e door l ock swi t ch t o l ock. Continuity
shoul d show between Terminals 5 and 3.
01- 14A - 2 7 Handl es, Loc k s , Lat ches and Mechani sms 01- 14A - 2 7
13. If any swi t ch does not t est a s st at ed, repl ace the
compl et e swi t ch assembl y.
SWITCH (MASTER)
N10393-B
Door Loc k Swi t c h RH
1. Use a sel f -powered test l amp or an ohmmeter to
t est the door l ock swi t ch.
2. Wi t h the door l ock swi t ch in t he NEUTRAL
posi ti on, t here shoul d be continuity bet ween
terminals 1 and 2 and termi nal s 5 and 6. Terminal
4 shoul d be di sconnected f rom all other termi nal s.
3. When the rai sed porti on of t he door l ock swi t ch
rocker knob (marked " L " ) is pushed, there
should be continuity bet ween termi nal s 3 and 1
and termi nal s 3 and 2.
4. When the depressed porti on of t he door l ock
swi t ch rocker knob (marked " U" ) is pushed,
t here shoul d be continuity bet ween terminals 3
and 5 and termi nal s 3 and 6.
5. If t he door l ock swi t ch assembl y does not t est as
st at ed, repl ace t he entire door l ock swi t ch,
housing and wi ri ng assembl y.
Do o r L o c k Swi t c h Co n n e c t o r Te st i n g Poi nt s
DOOR LOCK SWITCH-RIGHT
(WITHOUT ELECTRONIC DOOR LOCK
CONTROL SYSTEM) N10880-A
Pi n
1 119
( P K / Y)
L H Do o r L o c k S w i t c h L o c k
2 117
( P K / B K )
Do o r L o c k Mo t o r L o c k
3 171
( B K / W)
P o we r
4 No t Us e d
5 118
( P K / O )
Do o r L o c k Mo t o r U n l o c k
6 12 0
( P K / L G )
L H Do o r L o c k S w i t c h U n l o c k
Do o r L o c k A c t u a t o r
Appl y 12 vol ts di rectl y t o t he power door lock act uat or
termi nal s (reverse pol ari ty for opposi t e di recti on). The
power door l ock act uat or rod shoul d finish its t ravel in
l ess than one second.
equivalent, the power door l ock actuator current dr aw
(stal l t est ) shoul d not exceed 6 amps. Reverse t he
pol ari ty t o the connector and retest.
L a t c h , Do o r
Fr o n t
1. Remove front door tri m panel ( 23942) and
watershi el d. Refer t o Secti on 01- 05.
2. Check all connecti ons on front door l atch ( 21812)
and front door latch remote control and link
( 21818) and servi ce if necessary.
3. Remove one screw retaining front door l atch
remote control and link t o front door ( 20124) and
front door l atch remote control and link retaining
cl i p. Remove front door l atch remote control and
link.
4. Remove clip retaining front door l atch control
cylinder rod ( 22134) t o door l ock cylinder
( 21985) .
01- 14A - 2 8 Ha n d l e s , L o c k s , Lat c hes and Me c h a n i s ms
01- 14A - 2 8
5. Remove clip from power door l ock actuator
( 218A42) .
6. Remove clip retaining door l atch control rod knob
( 21850) t o front door l at ch.
7. Remove clip retaining front door l atch actuati ng
rod ( 22152) t o front door l at ch.
8. Remove t hree scr ews retaining front door l atch t o
front door.
9. Remove front door l atch (wi th front door l atch
control cylinder rod) and anti-theft shield f rom
front door cavi ty.
10. Transfer bushings and retaining cl i ps along wi th
front door l atch control cyl i nder rod and anti-theft
shi el d t o new front door l at ch.
11. To install, reverse Removal procedure and tighten
f ront door l atch retaining bol ts t o 4-8 N-m ( 35- 70
Ib-in).
01- 14A- 29 Handi es
9
Loc k s , Lat c hes and Mechani sms 01- 14A- 29
Pa r t
1 21818 Front Door Latch Remote
Control and Link
2 55929-S2 Screw (2 Req'd)
3 218A42 Power Door Lock Actuator
4 388047-S102 Rivet
5 377934-S Plug Button
6 21850 Door Latch Control Rod
Knob
7 14A626 Keyless Entry Keypad
8 220050 Lock and Key Set
9 22404 Door Handle
10 22023 Door Lock Cylinder Retainer
11 22152 Front Door Latch Actuating
Rod
13 21812 Front Door Latch
Pa r t
14 N621906-S36 Nut and Washer Assy
15 14A667 Door Lock Switch Retainer
16 21978 Door Latch Shield
17 386656-S Bushing
18 22134 Front Door Latch Control
Cylinder Rod
19 22008 Door Latch Striker Plate
20 N804243-S Shim
21 27840 B-Pillar
Lb-ln)
Lb-ln)
Lb-Ft)
D Tighten to 33-45 N-m (24-33
Lb-Ft)
Fr o n t Door L o c k a n d L a t c h Cr o wn Vi c t o r i a , Gr a nd Mar qui s
VIEW D
VIEWC
N8774-B
0 1 a t c h \ Me *
1
f s
Pa r t Pa r t
(tern Number De s c r i p t i o n I t e m Nu mb e r De s c r i p t i o n
1 56929-S2 Screw and Washer 9 22152 Front Door Latch Actuating
2 21818 Front Door Latch Remote
Control and Link
10 22023
Rod
Door Lock Cylinder Retainer
3 21940 Front Door Lat ch Remote
Control Link
11
12
21985
N805653-S100
Door Lock Cylinder
Screw (3 Req'd)
4 21850 Door Latch Control Rod 13 377934 Button Plug
5 22134
Knob
Front Door Lat ch Control
Cylinder Rod
Door Handle
Rivet (2 Req'd)
Front Door Lat ch
14
15
N805995-S100
218A42
Rivet
Power Door Lock Actuator
6
7
8
22404
388047-S100
21812
Knob
Front Door Lat ch Control
Cylinder Rod
Door Handle
Rivet (2 Req'd)
Front Door Lat ch
16
17
A
N805583-S
22008
Shim (Max. 1 Each Side)
Door Lat ch Striker Plate
Tighten t o 4-8 N-m (35-70
Lb-ln)
Re a r
1. Remove rear door tri m panel ( 27406) and wat er
2. Remove rear door l atch shield ( 26562) from rear
door l atch ( 26412) and check all connecti ons of
rear door l atch remote control link ( 26442) and
rods. Servi ce as necessary.
3. Remove t hree scr ews retaining rear door l atch t o
rear door ( 24630) .
4. Remove rear door l atch bel l crank ( 26448) as
outl i ned.
5. Remove one scr ew retaining rear door l atch
remot e control link (wi th link retaining cl i p).
Remove rear door l atch remot e control link.
6. Remove rear door l atch rod retaining clip f rom
rear door l at ch.
7. Remove ri vet f rom rear door el ectri c l atch
actuator ( 26594) and di sconnect harness,
8. Remove rear door l at ch, rear door el ectri c l atch
actuator and rear door l atch control rod as an
assembl y f rom rear door.
9. Transfer bushi ngs and retaining cl i ps al ong wi th
rear door el ectri c l atch act uat or and rear door
l atch control rod t o new rear door l atch.
10. To install, reverse Removal procedure and ti ghten
rear door l atch retaining bolts t o 4-8 N-m (35-70
Ib-in).
01- 14A - 32 Ha n d l e s , L o c k s , L a t c h e s a n d Me c h a n i s ms
01- 14A - 32
Rear Door Lo c k a n d L a t c h T o wn Car
Par t
1 2 6 4 4 8 Rear Door Latch Bellcrank
2
2 6 4 2 0 Rear Door Latch Control Rod
Link
VIEWD
N8219-D
I t e m
Pa r t
3 26442 Rear Door Latch Remote
Control Link
4 26594 Rear Door Electric Latch
Actuator
Pa r t
5 377934-S Plug
6 388047-S102 Rivet
7 56929-S2 Screw (2 Req'd)
Control and Link
9 N802034-SG Rivet
10 26604 Rear Door Outside Handle
11 26696 Rear Door Latch Actuating
Rod
12 26412 Rear Door Latch
13 N801053-S103 Screw (2 Req'd)
14 N805654-S100 Screw
Pa r t
15 N621905-S361 Nut and Washer (2 Req'd)
16 386656-S Bushing
17 22008 Door Lat ch Striker Plate
18

Panel
19 N804243-S Shim
A

Lb-ln)
B

Lb-ln)
C

Lb-Ft)
D

Tighten t o 35-45 N-m (26-33
Lb-Ft)
Rear Door L o c k a n d L a t c h Cr o wn Vi c t o r i a , Gr a n d Ma r qui s
VIEWD
VIEWD
NS778-C
I t e m
Pa r t
1 56929-S2 Screw
Control and Link
3 N802034-SG Rivet
Par t
4 26448 Bushing
5 264B14 Bellcrank and Link
6 26442 Rear Door Lat ch Remote
Control Link
( Co n t i n ue d )
Part Pa r t
I t em Numbe r De sc r i pt i o n I t e m Nu mb e r De s c r i p t i o n
7 26640 Rear Door Outside Handle 12 377934-S Button Plug
Pad 13 N805995-S100 Rivet
8 388047-S100 Rivet (2 Req'd)
14 26594 Rear Door Electric Lat ch
9 26596 Rear Door Latch Actuating Actuator
Rod 15 22008 Door Lat ch Striker Plate
10 N805653-S100 Screw (3 Req'd)
16 N805583-S Shim (Max. 1 Each Side)
11 26412 Rear Door Latch
Lb-ln)
Fu e l Fi l l e r
1. Open the l uggage compartment, push t he
overri de handle through the slit in the l uggage
compart ment tri m and pull back t he tri m panel .
2. Open the fuel filler door and remove t wo scr ews
retaining t he fuel filler door l atch ( 28610) t o t he
housing assembl y.
Fuel Fi l l er Door a nd La t c h
3. Remove fuel filler door l atch f rom the housing
assembl y through the fuel door openi ng.
4. Di sconnect the wiring harness connector f rom the
fuel filler door l atch sol enoi d.
5. To install, reverse t he Removal procedure.
VIEW A
VIEW C
N8513-E
01- 14A - 35 Ha n d l e s , L o c k s , L a t c h e s a n d Me c h a n i s ms 0 1 - 1 4 A - 3 5
Pa r t Pa r t
I t em Nu mb e r De s c r i p t i o n I t e m Nu mb e r De s c r i p t i o n
1 N 8 0 5 0 6 2 - S 5 5 Screw and Washer 8 N806376-S Bumper (2 Req' d)
2 N802371-S55 Screw and Washer (2 Req'd) 9 N602708-S2 Screw and Washer (4 Req'd)
3 405A20 Fuel Filler Door Hinge Shim 10 405A24 Fuel Filler Door Hinge Spring
(As Req'd Max 2) 11 390855-S Bumper
4 405A26 Fuel Filler Door 12 9008 Vent Hose Relief Discharge
5 28608 Fuel Filler Door Latch Seal
Retainer 13 28610 Fuel Filler Door Latch
6 405C28 Housing and Latch 14 N602704-S36 Screws (2 Req'd)
7 Quarter Panel
A Tighten t o 3.2-3.7 N-m (28-33
(Continued)
Lb-ln)
S t r i k e r P l a t e , Do o r L a t c h
NOTE: This procedure appl i es t o front and rear. Refer
t o appropri ate illustration under Lat ch, Door Fr ont
or Rear.
1. Remove door l atch stri ker pl ate ( 22008) and
washer using correct si ze bit f rom Torx Dri ve Bit
Set D79P-2100-T or equivalent.
2. Install door l atch stri ker pl ate and washer.
3. Adj ust door l atch stri ker pl ate as outlined under
Adj ustments. Tighten door l atch stri ker pl ate t o
33- 45 N-m ( 24- 33 Ib-ft).
DOOR LATCH
STRIKER PLATE
22008
TIGHTEN TO
33-45 N-m
( 2 4- 33 LB-FT)
N7039-B
4. Transfer bushing and retaining clips t o new rear
door l at ch bel l crank.
5. To install, reverse Removal procedure. Use
Heavy Duty Ri veter D80L- 23200- A or equivalent
t o install rivet retaining rear door l atch bel l crank
t o rear door ( 24630) .
R e m o t e C o n t r o l A s s e m b l y
Do o r L a t c h
NOTE: Procedure cover s front and rear door.
1. Remove door tri m panel and watershi el d. Refer t o
Secti on 01- 05.
2. Remove the retaining screw. Di sengage the
retaining t ab.
3. Rotate t he front door l atch remot e control and link
( 21818) cl ockwi se on the RH door and
count ercl ockwi se on t he LH door whi l e movi ng it
f orward t o di sconnect t he front door l atch remot e
control and link f rom front door l atch remote
control link ( 21940) or rear door l atch remote
control link ( 26442) and t he door.
B e l l c r a n k a n d L i n k , Re a r Do o r
watershi el d. Refer t o Secti on 01- 05.
2. Remove the rivet retaining t he rear door l atch
bellcrank ( 26448) t o t he door inner panel .
Di sconnect t he rear door l atch bel l crank f rom t he
rear door l at ch control rod link ( 26420) by
unclipping t he retainer.
3. Remove the rear door l atch push button rod
( 26460) f rom the rear door l atch bel l crank.
Remove rear door l atch bel l crank.
L o c k C y l i n d e r , Do o r
When a door lock cylinder ( 21985) must be repl aced,
repl ace both the door and ignition l ocks as a set t o
avoi d carryi ng an ext r a key whi ch f i t s only one l ock.
Refer t o Secti on 11-05 for ignition key l ock cylinder
procedure.
1. Remove tri m panel and position the wat ershi el d
away from the access hol es. Refer t o Secti on
01-05.
2. Disconnect the door l ock cylinder f rom t he front
door l atch control cylinder rod ( 22134) .
01- 14A~36 Ha n d l e s, L o c k s , L a t c h e s a n d Me c h a n i s ms 01- 14A - 36
3. Remove the door l ock cylinder retainer ( 22023)
and remove t he door l ock cylinder f rom t he front
door ( 20124) .
4. Transfer the l ock cylinder arm t o the new door
l ock cyl i nder. Repl ace the rod retainer if it shows
any wear or warpage.
A c t u a t o r , P o w e r Do o r L o c k
NOTE: Thi s procedure covers front and rear. Refer t o
appropri at e illustration under Removal and Installation
Lat ch, Door.
Secti on 01- 05.
2. Remove pop-rivet retaining power door l ock
act uat or ( 218A42) or rear door el ectri c l atch
act uat or ( 26594) t o door.
3. Di sconnect wi ri ng at connector. Remove power
door l ock actuator or rear door el ectri c l atch
actuator.
4. Remove rear door l atch ( 26412) or front door
l atch ( 21812) as outlined. Di sconnect act uat or
motor link f rom rear door l atch or front door l at ch.
5. Remove power door l ock actuator or rear door
el ectri c l atch act uat or.
S w i t c h , Do o r L o c k T o w n C a r
1. Gentl y pry up front porti on of t he wi ndow
regul ator swi t ch plate ( 14524) .
2. Unhook rear edge of wi ndow regul ator swi t ch
pl ate and remove wi ndow regul ator swi t ch pl ate
f rom t he armrest cavi ty.
3. Remove t wo scr ews retaining t he connect or t o
t he wi ndow regul ator swi t ch pl ate.
4. NOTE: Take care not t o damage el ectri cal
cont act pins.
Careful l y pry t he wi ndow regul ator control swi t ch
( 14529) f rom connector wi t h a small screwdri ver.
5. Remove wi ndow regul ator control swi t ch.
S w i t c h , Do o r L o c k C r o w n V i c t o r i a , G r a n d
Ma r q u i s
1. Remove t wo scr ews retaining wi ndow regul ator
swi t ch pl ate ( 14524) t o t he front door tri m panel
( 23942) . Rai se front door tri m panel .
2. Di sconnect front wi ndow regul ator wi ri ng ( 14631)
f rom outsi de rear vi ew mirror control ( 17B676) .
Remove outsi de rear vi ew mi rror cont rol .
3. Remove scr ews retaining front wi ndow regul ator
wi ri ng t o wi ndow regul ator swi t ch pl ate. Remove
wi ndow regul ator swi t ch pl ate.
4. Transfer outsi de rear vi ew mi rror control t o new
wi ndow regul ator swi t ch pl ate.
LH FRONT N11505-A
Pa r t
Control
Plate
4 14631 Front Window Regulator
Wiring
( Co n t i n ue d )
01- 14A- 37 Ha n d l e s , L o c k s ,
Par t
I t em Nu mb e r De sc r i pt i o n
5 N803247-S58 Screw (2 Req'd Each Si de)
6 56924-S2 Screw (4 Req'd)
Pa r t
Plate
2 56924-S2 Screw (2 Req'd)
3 14630 Front Window Regulator
Wiring
C o n t r o l P r o c e s s o r , E l e c t r o n i c Do o r L o c k
1. Remove dri ver door tri m panel , refer t o Secti on
01- 05.
2. Remove dri ver door modul e retaining scr ews.
3. Di sconnect wi ri ng f rom dri ver door modul e.
4. Remove dri ver door modul e.
H a n d l e , I n s i d e Do o r
1. Remove door tri m panel . Refer t o Secti on 01 - 05.
2. Remove inside door handle retaining scr ews.
3. Remove inside door handl e.
4. To i nstal l , reverse Removal procedure.
a n d Me c h a n i s ms 0 1 - 1 4 A - 3 7
H a n d l e , Ou t s i d e D o r T o w n C a r
NOTE: Thi s procedure appl i es t o front and rear.
Remov al a n d i ns t al l at i on
1. Remove door t ri m panel and wat ershi el d. Refer t o
Secti on 01- 05.
2. Di sconnect the door l at ch act uat or rod f rom t he
l atch.
3. Remove t wo nuts retaining door handle ( 22404)
or rear door outsi de handl e ( 26604) t o door and
remove door handle or rear door outsi de handle
and rod f rom door.
4. Transfer the act uat or r od to t he new door handle
or rear door outsi de handl e using a new cl i p.
H a n d l e , O u t s i d e Do o r C r o w n V i c t o r i a ,
NOTE: Thi s procedure appl i es to front and rear.
Secti on 01- 05.
2. Di sconnect t he door l at ch actuator rod f rom t he
l at ch.
3. Remove t he t wo ri vets retaining the door handle
( 22404) or rear door outsi de handle ( 26604) t o
t he door. Remove the door handle or rear door
outsi de handle and rod f rom t he door.
4. Transfer the act uat or r od t o t he new door handle
or rear door outsi de handle.
5. To install, reverse Removal procedure. Use
Heavy Duty Riveter D80L-23200-A or equivalent.
Swi tch, Filler Door Lock
1. Remove door tri m panel. Refer t o Secti on 01- 05.
2. Carefully pry out fuel door rel ease swi t ch.
3. Di sconnect fuel door rel ease swi t ch wi ri ng.
Fuel Filler Door
1. Open fuel filler door.
2. Remove t wo retaining scr ews.
3. Remove fuel filler door.
01- 14A - 38 Ha n d l e s, L o c k s , L a t c h e s a n d Me c h a n i s ms 01- 14A- 38
R E MO V A L AND INSTALLATION ( C o n t i n u e d )
L a t c h , G l o v e C o mp a r t me n t
L o c k Cy l i n d e r , Gl o v e C o mp a r t me n t
L a t c h a n d L o c k , L u g g a g e C o m p a r t m e n t
D o o r T o w n C a r
1. Open l uggage compart ment door ( 40110) .
2. Remove l uggage compart ment door l atch
retaining scr ews and di sconnect el ectri cal
connector. Remove l uggage compart ment door
l atch ( 43200) .
3. Drill out t wo ri vets retaining sl eeve and cover of
l uggage compart ment l ock cyl i nder t o l uggage
compart ment door outer panel . Remove sl eeve
and cover.
4. Remove l uggage compart ment l ock cylinder,
l uggage compart ment door l ock retainer clip
( 40182) and luggage compart ment door l ock
support ( 432A48) .
5. Remove pop-rivet retaining l uggage compart ment
l ock cylinder and l uggage compartment door l ock
cylinder retainer ( 43629) .
6. Remove luggage compart ment l ock cylinder and
l uggage compart ment door l ock cylinder retainer.
Lugga ge Co mpa r t me n t La t c h a n d L o c k T o w n Car
retaining scr ews t o 9-14 Nm (7-10 Ib-ft).
8. Adj ust as outlined.
GLOVE/LUGGAGE
COMPARTMENT
LOCK CYLINDER
43507
SLEEVE AND
COVER ASSY
43320
RIVET
388524-S'
2 REQ'D N8517-B
N8216-C
0 1 - 1 4 A - 3 9
Par t Part
I t em Number Descr i pt i on I t e m Nu mb e r I n s c r i p t i o n
1 4 3 2 0 0 L u g g a g e C o m p a r t m e n t D o o r
8 433A28 Luggage Compartment Door
L a t c h Lock Cylinder Retainer Seal
2 4 0 1 8 2 Clip 9 43629 Luggage Compartment Door
3 N602701-S2 S c r e w a n d W a s h e r
Lock Cylinder Retainer
4 4 3 2 A 4 8 L u g g a g e C o m p a r t m e n t D o o r
10 375203-S36 Rivet
L o c k S u p p o r t 11 43627 Luggage Compartment Door
5 2 2 0 A 4 0 Door Lock Cylinder Switch
Lock Cylinder Plate
(Lock Tamper Switch) 12 N606675-S36 Screw and Washer (2 Req'd)
6 4 3 5 0 7 Gl ove/Luggage 13 54404 Luggage Compartment Door
Compartment Lock Cylinder Striker
7 4 3 6 2 5 Luggage Compartment Door 14 N605892-S36 Screw and Washer (2 Req'd)
Lock Cylinder Sleeve Pad A Tighten to 9-14 N-m (7-10
(Continued)
Lb-Ft)
L a t c h a n d L o c k , L u g g a g e C o m p a r t m e n t
D o o r C r o w n V i c t o r i a
1. Open the l uggage compart ment door ( 40110) .
2. Remove screw retaining l uggage compart ment
door l ock cyl i nder cover assembl y t o inner panel
and remove cover assembl y.
3. Remove lever assembl y and l uggage
compart ment door l ock retainer clip ( 40182) . If
worn or damaged, repl ace lever and l uggage
compart ment door l ock retainer clip assembl y.
4. Remove luggage compart ment door l atch
retaining scr ews. Di sconnect el ectri cal
connecti on.
5. Remove l uggage compart ment door l at ch
( 43200) and rod together.
6. Remove luggage compart ment door l ock cylinder
retainer ( 43629) and l uggage compart ment door
l ock cylinder retainer seal ( 433A28) .
7. Remove scr ew and washer assembl y retaining
l uggage compart ment door l ock cyl i nder pl ate
( 43627) to l uggage compart ment door l ock
support ( 432A48) . Remove l uggage
compart ment door l ock cyl i nder pl ate and
luggage compart ment door l ock support .
8. Remove luggage compart ment door l ock cyl i nder
and rod.
l uggage compart ment door l atch retaining scr ews
t o 9-14 N-m (7-10 Ib-ft).
N8784-A
Pa r t
1 43507 Gl ove/Luggage
Compartment Lock Cylinder
Lock Cylinder Sleeve Pad
Lock Support
Lock Cylinder Retainer Seal
Lock Cylinder Retainer
6 375203-S Rivet (2 Req'd)
Lock Cylinder Plate
Lock Retainer Clip
Latch
Req'd)
12 N802319-S36M Screw and Washer Assy (2
Req'd)
( Co n t i n ue d )
I t e m
Par t
Number De sc r i pt i o n
13 404B12 Luggage Compartment Door
Lat ch Striker
A

Lb-Ft)
L a t c h a n d Lock, Luggage Compart ment
Door Gr a n d Marqui s
Re mo v a l a n d Installation
3.
5.
Open t he l uggage compart ment door ( 40110) .
Remove the l uggage compart ment door l atch
retaining scr ews. Di sconnect the el ectri c wi re for
t he solenoid and l uggage compart ment door ajar
swi t ch functi ons, and remove l uggage
compart ment door l atch ( 43200) .
Remove the t wo retaining scr ews t o the
gl ove/ l uggage compart ment l ock cyl i nder
( 43507) and remove t he gl ove/ l uggage
compart ment l ock cyl i nder.
Remove the remot e control cabl e assembl y f rom
t he gl ove/ l uggage compart ment l ock cyl i nder t o
t he l uggage compart ment door l at ch.
l uggage compart ment door l atch retaining scr ews
t o 9-14 N-m (7-10 Ib-ft).
FRONT OF BODY
N8782-A
I t e m
Pa r t
1 43507 Gl ove/Luggage
Compartment Lock Cylinder
2 N605892-S36 Bolt (2 Req'd)
3 43200 or 43282 Luggage Compartment Door
Lat ch
6 404B12 Luggage Compartment Door
Latch Striker
A

Lb-Ft)
S t r i k e r , L u g g a g e C o m p a r t m e n t Do o r
1. Remove t wo scr ews securi ng luggage
compart ment l atch stri ker t o l ower finish panel
and remove luggage compart ment l atch stri ker.
2. To install, position luggage compart ment l atch
stri ker t o l ower finish panel and secure wi t h t wo
retaining scr ews. Tighten scr ews t o 9-14 N-m
(7-10 Ib-ft).
A c t u a t o r , L u g g a g e C o m p a r t m e n t Do o r L o c k
T o w n Ca r
1. Remove t he t hree scr ews retaining l uggage
compartment door l ock actuator ( 432A38) t o t he
l uggage compartment door l ock stri ker mounting
bracket ( 43258) .
2. Di sconnect el ectri cal connecti on and remove t he
l uggage compart ment door l ock actuator.
LUGGAGE COMPARTMENT
DOOR LOCK STRIKER
MOUNTING BRACKET
43258
SCREW AND WASHER
N605892-S36
2 REQ'D
LUGGAGE COMPARTMENT
DOOR LOCK ACTUATOR
432A38
SCREW AND WASHER
N803006-S36
3 REQ'D
N11507-A
L u g g a g e C o m p a r t m e n t Do o r R e m o t e C o n t r o l
L o c k S w i t c h
1. Remove door tri m panel. Refer t o Secti on 01 - 05.
2. Carefully pry out luggage compartment swi t ch.
3. Di sconnect luggage compartment swi t ch wi ri ng.
01- 14A - 41 Handl es, L o c k s , Lat c hes and Mechani sms 0 1 - 1 4 A - 4 1
ADJUSTMENTS
St r i k e r , Do o r L a t c h
NOTE: Do not t r y t o correct a poor door alignment
wi th door l atch stri ker pl ate ( 22008) adj ustments.
Before adjusting door l atch stri ker pl ate, open and
cl ose door t o doubl e-check door l atch stri ker pl ate
alignment.
Loosen door l atch stri ker pl ate wi t h correct bit f r om
Torx Dri ve Bit Set D79P-2100-T or equivalent. Move
door l atch stri ker pl ate up-or-down or f rom side-to-side
as necessary. Tighten door l atch stri ker pl ate t o 33- 45
N-m ( 24- 33 Ib-ft).
L a t c h a n d S t r i k e r , L u g g a g e C o m p a r t m e n t
Do o r
The l uggage compart ment l atch stri ker can be
adj usted up and down and t he l uggage compart ment
door l atch ( 43200) can be adj usted f rom si de-to-si de.
Before adj usti ng t he luggage compart ment door l at ch,
make sure t hat t he luggage compart ment door
( 40110) is properl y aligned. Adj ust the l uggage
compart ment door l atch as f ol l ows:
1. Loosen the retaining scr ews.
2. Move t he l uggage compart ment door l atch as
requi red t o enter t he l i f t gat e/ l uggage
compart ment l atch stri ker ( 404A42) wi thout
defl ecti ng t he l uggage compart ment door
si deways.
3. Tighten the retaining scr ews t o 9-14 N-m ( 7- 10
Ib-ft).
4. Move the liftgate / l uggage compart ment l atch
stri ker up or down as necessary t o provi de
proper l uggage compart ment door seal bet ween
t he l uggage compart ment door and t he lower
back panel .
LUBRICATION
Do o r L a t c h e s
Appl y Multi-Purpose Grease Spray D7AZ- 19584- AA
or equivalent meeti ng Ford speci fi cati ons
ESR-M 1C159-A and ESB-M1C106-B t o all movi ng
door l atch component s.
Use Mul ti -Purpose Grease Spray D7AZ- 19584- AA or
equivalent meeti ng Ford speci fi cati ons
ESR-M 1C159-A and ESB-M 1C106-B t o l ubri cate
luggage compart ment door and hood l at ches.
L o c k C y l i n d e r L u b r i c a n t
Use Lock Lubri cant D8AZ- 19587- AA or equivalent
meeting Ford speci fi cati on ESB-M2C20-A t o eliminate
sti cki ng or binding of all l ock cyl i nders.
SPECIFICATIONS
Description N-m Lb-ln
Fr o n t Do o r L a t c h Re t a i n i n g Bo l t s 4-8 35- 7 0
Re a r Do o r L a t c h Re t a i n i n g Bo l t s 4-8 35- 7 0
Do o r L a t c h St r i ke r 33- 45 2 4- 33
( L b - Ft )
Do o r L a t c h St r i ke r P l a t e 2 7 - 36 2 0- 2 8
( L b - Ft )
Fr o n t Do o r L a t c h Re mo t e Co n t r o l
a n d Li nk Re t a i n i n g S c r e w
1-2 9- 17
Ou t s i d e Do o r Ha n d l e Re t a i n i n g Nut 7- 11 5- 8 ( L b - Ft )
Re a r Do o r L a t c h Re mo t e Co n t r o l
a n d Li n k Re t a i n i n g S c r e w
1-2 9- 17
Fue l Fi l l e r Do o r Re t a i n i n g Nut s 3. 2 - 3. 7 2 8- 33
Cy l i n d e r P l a t e Re t a i n i n g S c r e ws
5-8 45- 7 1
L u g g a g e Co mp a r t me n t Do o r L a t c h
Re t a i n i n g S c r e w s
8- 12 7 1- 106
L u g g a g e Co mp a r t me n t St r i ke r
P l a t e Re t a i n i n g S c r e w s
8- 12 7 1- 106
Re t a i n i n g S c r e w s ( Cr o wn
Vi c t o r i a / G r a n d Ma r q u i s )
9- 14 7 - 10
( L b - Ft )
St r i ke r Re t a i n i n g S c r e w s ( Cr o wn
Vi c t o r i a / G r a n d Ma r q u i s )
9- 14 7 - 10
( L b - Ft )
Tool Number De sc r i pt i on
D7 9P - 2 100- T Torx Dr i v e Bi t Se t
D80L - 2 32 00- A He a v y Dut y Ri v e t e r
ROTUNDA EQUIPMENT
Model De sc r i pt i on
007 - 00500 Ne w Ge n e r a t i o n St a r ( NGS) T e s t e r
1995 T o wn Car, Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s Jul y 1994
01- 14B- 1 Do o r L o c k Co n t r o l S y s t e m, E l e c t r o n i c 01- 14B- 1
SECTION 01-14B Door Lock Control System,
Electronic
S U B J E C T P A G E
VEHICLE A P P L I C A T I O N ..01-14B-1
Aut ol ock . 01-14B-3
Door Lock C o n t r o l System, El ectroni c ....01-14B-1
Ent ry Code .01-14B-3
I nput s and Out put s ..01-14B-2
Keyl ess Ent ry Keypad . 01-14B-3
Memory Seat 01-14B-4
Transmi t t er, Keyl ess Ent ry Remot e ....01-14B-4
El ect ri cal Schemat i cs 01-14B-5
SUBJECT PAGE
DIAGNOSIS AND TESTING (Cont 'd. )
I nspect i on and Veri f i cat i on 01-14B-12
Pi npoi nt Test s 01-14B-13
Sy mpt om Chart 01-14B-12
Ant enna 01-14B-21
Door Lock Swi t ch Act uat or 01-14B-20
Door Modul e, Dri ver ......... 01-14B-20
Transmi t t er Bat t ery 01-14B-21
SPECIFICATIONS 01-14B-21
SPECIAL SERVICE TOOLS/EQUIPMENT ....01-14B-21
VEHICLE APPLICATION
Door Lock Control System, Electronic
The el ectroni c door lock control syst em has t hree
main component s:
The dri ver door module.
The five-button keyl ess entry keypad ( 14A626) on
t he dri ver front door ( 20124) .
The four-button (hand-held) keyl ess entry remote
transmi tter ( 15K601) .
DRIVER'S DOOR
MODULE 13C797
KEYLESS ENTRY
REMOTE TRANSMITTER
15K601
N12339-A
DOOR LOCK:
SWITCH
ACTUATOR
14A626
DOOR LOCK
CYLINDER
21985
DOOR HANDLE
22404
PULL TO OPEN
OR TO ACTIVATE
ILLUMINATED ENTRY 'N849S-C
The dri ver door module will perform the fol l owi ng
functi ons:
Unlock dri ver front door ( 20125) .
Unlock all doors.
Unlock l uggage compartment door ( 40110) .
Lock all doors.
Automati cal l y l ock all doors when all doors are
cl osed, t he ignition swi t ch ( 11572) is in the RUN
posi ti on, someone is seat ed in t he driver seat , and
t he transmi ssi on is shi fted into any f or war d or
reverse gear. Thi s feature is available only on
vehi cl es equi pped wi t h automati c transmi ssi ons.
Arm and di sarm t he anti-theft al arm control
( 19A366) , (if equi pped).
01- 14B- 2 Door Loc k Cont r ol Sy s t e m, El ect r oni c 01- 14B- 2
Provi des a signal t o t he lighting control module
whi ch wi l l :
( 1) Turn on interior l amps ( 13776) , keyl ess entry
keypad and keyhol e illumination after any
button on t he keyl ess entry keypad is pushed or
ei ther front door handle ( 22404) is lifted.
( 2) Turn on interior l amps, and keyhol e illumination
when using t he keyl ess entry remot e
transmi tter.
( 3) Act i vat e and deact i vat e personal securi ty
f eat ure whi ch sounds horn ( 13832) and fl ashes
parki ng l amps ( 13200) .
The el ectroni c door l ock cont rol pr ocessor wi l l al so
accept and st ore an al ternate ent ry code. Either code
will then oper at e the syst em.
Inputs and Outputs
The el ectroni c door l ock control syst em recei ves
signals f rom:
Transmi ssi on range (TR) sensor.
Ignition swi t ch ( 11572) .
Door l ock swi t ches ( 14028) .
Lighting control module ( LCM) (door ajar output).
Keyl ess entry keypad ( 14A626) .
Keyl ess entry remote transmi tters ( 15K601) .
Co mp o n e n t / Co n n e c t o r Lo c a t i o n s
The syst em sends signals t o:
Door l ock swi t ch act uat or illumination.
Power door l ock act uat ors ( 218A42) .
Luggage compart ment door lock solenoid ( 14030) .
Horn rel ay ( 14N089) .
Lighting cont rol module ( LCM) .
Pa r t
1 14A626 Keyless Entry Keypad
2 14A067 Fuse Junction Panel
3

Ignition Switch Wiring to
Steering Column
4 19C542 Luggage Compartment
Remote Control Lock Switch
N4959-H
I t e m
Pa r t
5
6
43200
14A501
Latch
Safety Belt Retractor Sensor
Switch and Wire
01- 14B- 3
Door Loc k Cont r ol Sy s t e m, El ect r oni c 01- 14B- 3
Al arm and Ant enna Connect or
ELECTRONI C DOOR LOCK
CONTROL P R O C E S S O R
CONNECTOR DI AGRAM (LOOKI NG
I NTO CONNECTOR)
N9335-G
PROGRAM CONNECTOR (C4)
Pi n Wi r e No .
Number and Col or Conne c t s t o
1 808 ( W/ Y ) P r o gr a m A
2 809 P r o gr a m B
( G Y/ Y)
Entry Code
The system's permanent entry code is located in four
places:
On the owner's warranty card.
On a label on the inside of the luggage compartment
door (40110).
On an owner's code card.
On the drivers door module electronic door lock
control processor.
VIEW SHOWING ATTACHMENT OF
CODE STRIP TO WARRANTY CARD
CODE
STRIP
WARRANTY
CARD
N6954-B
The electronic door lock control processor is
programmed at the factory with a five-digit entry code.
Replacement electronic door lock control processors
include replacement labels and a new owner's code
card.
Keyless Entry Keypad
To unlock the driver front door (20124), and disarm
the anti-theft alarm control (19A366), (if equipped):
Enter the permanent factory code.
Enter the owner's alternate code.
To unlock the passenger door(s), press the 3/ 4 button
within five seconds of unlocking the driver door or
luggage compartment.
To unlock the luggage compartment door (40110),
press the 5/ 6 button within five seconds of unlocking
driver or passenger door(s).
To turn on the courtesy lamps and light all illuminated
components, lift either front door handle (22404) or
press any button on the keyless entry keypad
( 14A626) .
To lock all doors, press the 7/ 8 and 9/ 0 buttons at
the same time with all doors closed. (It is not
necessary to enter the key code first.)
This will turn off courtesy lamps and arm anti-theft
alarm control (if equipped).
To program an alternate code:
1. Enter the five digit permanent entry code into
keyless entry keypad.
2. Within five seconds of pressing last button of
permanent code, press the 1 / 2 button within five
seconds of pressing the last button of the
permanent code.
3. Enter any alternate five digit code within five
seconds of pressing 1 / 2 button.
Enter a sixth digit as follows to indicate
operator's memory seat setting to be set by
alternate code:
9/0no memory recall
1/2memory seat position 1
3/ 4 memory seat position 2
5/6memory seat position 3
After successful programming, the doors will
signal by locking and then unlocking.
Autolock
All doors will automatically lock after all the following
steps are completed:
The autolock feature is activated.
The driver seat is occupied.
All doors are completely closed.
The ignition switch (11572) is in the RUN position.
The shift control selector lever is moved into any
forward or reverse gear.
After initial lock, ail doors automatically relock when
any door is opened and then closed except if driver
seat is empty or ignition switch is OFF.
To activate the autolock feature:
1. Enter the five-digit permanent entry code into _
keyless entry keypad (14A626).
2. Press and hold the 7/ 8 button on the keyless
entry keypad within five seconds of entering the
code.
01- 14B- 4 Door Loc k Cont r ol S y s t e m, El ect r oni c 01- 14B- 4
3. Press and then rel ease t he 3 / 4 button within fi ve
seconds of pressi ng and holding t he 7 / 8 but t on.
4. Release t he 7 / 8 button on keyl ess entry keypad
within five seconds of releasing t he 3 / 4 button.
To deact i vat e t he aut ol ock, repeat the above
sequence.
T r a n s m i t t e r , K e y l e s s E n t r y R e m o t e
The el ectroni c door l ock control syst em includes a
four-button (hand-held) keyl ess ent ry remot e
transmi tter ( 15K601) . Keyl ess entry remot e
transmi tters are reprogrammabl e and all keyl ess entry
remot e transmi tters for the vehi cl e must be set at t he
same ti me. When troubl eshooti ng t he vehi cl e, one
keyl ess entry remot e transmi tter is essenti al t o
perf orm t est s.
To unlock t he dri ver f ront door ( 20124) , press t he
UNLOCK button on t he keyl ess entry remot e
transmi tter, whi ch is programmed into t he el ectroni c
door l ock control processor once.
Thi s will al so di sarm t he anti-theft al arm control
( 19A366) (if equi pped).
To unlock all doors, press t he UNLOCK button on t he
keyl ess entry remot e transmi tter a second ti me wi thi n
five seconds of t he fi rst unlock.
NOTE: If more than fi ve seconds have el apsed si nce
the fi rst press of the UNLOCK button, pressi ng t he
UNLOCK button agai n will only unlock t he dri ver front
door.
To unlock t he l uggage compart ment door ( 40110) ,
press the TRUNK button on t he keyl ess entry remot e
transmi tter t wi ce. Two depressi ons are requi red t o
prevent i nadvertent trunk operat i on.
To turn on interior l amps ( 13776) and keyhol e
illumination, press any of t he fol l owi ng keyl ess entry
remot e transmi tter buttons- UNLOCK, TRUNK or
PANIC.
To l ock all doors and ar m anti-theft al arm control (if
equi pped), press LOCK button on t he keyl ess entry
remot e transmi tter once.
If the horn chi rp is programmed ON, the vehi cl e horn
will sound t o confi rm t he doors have l ocked.
To act i vat e the personal securi ty al arm, press t he red
PANIC button on t he keyl ess entry remot e transmi tter.
The horn ( 13832) will sound and parki ng l amps
( 13200) will fl ash for a maxi mum of t hree minutes.
To deact i vat e the personal securi ty al arm, press t he
red PANIC button again or turn the ignition swi t ch
( 11572) t o RUN.
NOTE: The el ectroni c door l ock control syst em will not
function when the vehi cl e is in gear.
To program or reprogram transmi tter(s) fol l ow
procedure under " keyl ess entry keypad ( 1 4 A6 2 6 ) "
used t o set a code. In St ep 1, press a button on t he
keyl ess entry remote transmi tter i nstead of enteri ng
the fi ve digit code.
Me m o r y S e a t
Remote keyl ess syst em may control the memory seat
functi on.
Press the keyl ess ent ry remote transmi tter
( 15K601) UNLOCK button once. This will unlock t he
dri ver front door ( 20124) and move t he seat t o i ts
correspondi ng memory seat posi ti on, acti ng as if
the memory seat button has been depressed.
Each transmi tter has a memory recal l 1 or 2
designation and an enabl e swi t ch. The swi t ch must
be in the ON position t o acti vate memory recal l .
01- 14B- 5
Door Look Cont r ol Sy s t em, El ect r oni c 01- 14B- 5
Door Loc k Co n t r o l sTo wn Car
HOT AT
A L L TI MES
DB/ O
, 87A "I
I 85 | 861
1 t v# J |
I 84 >
L O C K
'
| r | O F F *
/ RUN I
*
M
;
"I I GNI TI ON
SWITCH
57
BK
9/10
BA CK L I GHT I NG I
LB
57
BK
5 1 7
BK/W
I ST A RT S T A j
5 1 7 1 BK/W
1
BK/W
T O
L I GHTI NG
CONT ROL
MODUL E
( L CM)
of this circuit
67 6
PK/O '
33 ,
W/PtT
C1- 1
C2 - 6 -
C MS
0 3 - 4
C1-4
C 2 - 1 0
K22802-A
Door Lo c k Co n t r o l s T o wn Car ( Co n t i n ue d )
DRIVERS
DOOR
MODUL E
01-11
CM2
C2-6
C1-6
C2-9
02-3
C2-7
02-1
S0UD
STATE
c i a
01-8
C1-5 !
01-13
of this circuit
L H F RONT S E AT
S E N S OR S W I T CH
267
BR/LG
BK/O H S0UO .
^ ^ ^ | ; - STATE |
I DRI V E R' S
! S E AT
I MODUL E
L U G G AG E COMPART ME NT
DOOR R E L E AS E MOT OR
84 r
BK/Y
<
J A | R
I S US P E NS I ON/
c r a j D 1 E L E C T R ON I C
" JHbj g/ I V ARI AB L E
1 ORI F I CE
I S T E E RI N G
' ^ MODUL E
"I HEADL AMP
I S W I T CH
SOLID
- : i mT i -
^ itw ana ut > K
1
70
70 I LB/W
465 I W/LB
465
| W/LB "
^ W / L B ^
1
L H
I NT ERI OR
L AMP
SWI T CH
RH
I NT ERI OR
L AMP
SW I T CH
TO ISO
91 41
LINK
7 I PK/BK 163
PK/O
117
PK/BK
163
R/O
L U G G AG E
COMPART ME NT
DOOR R E L E AS E
SW I T CH
I
4 ^BK^j
RH F RONT
DOOR L O C K
I L R
I DOOR LOCK
PK/O
PK/O
PK/BK I
RR
DOOR L OC K
PK/BK |
m
L F 1
DOOR L OC K I
R/O * ^ O ^ l ' PK/BK
R/O
K22803-A
01- 14B- 7
Do o r L o c k Co n t r o l S y s t e m, E l e c t r o n i c 01- 14B- 7
Lugga ge Co mpa r t me n t Co n t r o l s T o wn Car
HOT AT ALL TIMES
I FUSE
JUNCTION
PANEL
E
l I
I I
. INSTRUMENT
I CLUSTER
of t hi s circuit 665
DECKLID
PULLDOWN/
AJAR
SWITCH
57 I BK
TO LIGHTING
CONTROL MODULE (LCM)
t
FUEL FILL DOOR
RELEASE SWITCH
DRIVER'S
DOOR MODULE
517 I BK/W
C3-4
C1-6
C1-13
DECKLID
RELEASE MOTOR
DECKLID
RELEASE SWITCH
57
26 W/P
2 6 | W/P
FUEL FILLER
DOOR RELEASE
SOLENOID
DECKLID
PULLDOWN/
MOTOR AND
SWITCH
W/BK 57 B BK
T
K22801-A
01- 14B- 8 Do o r L o c k Co n t r o l S y s t e m, E l e c t r o n i c
01- 14B- 8
Door Lo c k Co n t r o l s Cr o wn Vi c t o r i a , Gr a nd Ma r qui s
HOT AT ALL TIMES
M POWER
7 I DISTRIBUTION
If . BOX
I V 20A .
465
TO
W/LB
LIGHTING
W/LB
> CONTROL
340 MODULE
(LCM)
R/LB
K22796-A
01- 14B- 9 Door Loc k Cont r ol S y s t e m, El ect r oni c 01- 14B- Q
DIAGNOSIS AND TESTING ( Co n t i n u e d )
Door Lock Cont r ol sCr own Vi c t o r i a , Grand Marqui s ( Co n t i n ue d )
TO LIGHTING
CONTROL MODULE
(LCM) AND
INSTRUMENT
CLUSTER
TO MEMORY .
SEATS
LB/W
SEAT OCCUPIED
SWITCH
TO LCM
C1-13
. ct-s
DRIVER DOOR
UNL OCK
C1- 8
C 2 - 1 1 A L L DOORS
02 - - 12
L OCK
-01
3 DOORS
UNLOCK
C1- 9
KE YL E SS
I NPUTS
C2-5
of thi s circuit
C M
C 2 6
V
- C1- 7
cm
DOOR
A J A 8 ,
C1- 6
91 41
C 1 - 1 2
L I NK
ME MORY
L I NK
NO, 1
0 1 - 1 1
MEMORY
NO. 2
SE A T
SWITCH
L OG I C P OWE R
G R D G RD
Ct*15.
57 1 BK T
X
57 1 BK
57
%
j
#
BK
1

1

1
57 1 BK
57 1 BK 1
P/Y
2 57
TO LUGGAGE
COMPARTMENT
DOOR RELEASE
TO MEMORY
SEATS
K22797-A
Q1-14B-10 Door Lock Cont r ol Sy s t e m, El ect r oni c 0 1 - 1 4 B- 1 0
Lugga ge Compart ment Cont r ol sCr o wn Vi ct ori a,
Grand Marqui s
I T t T i FUSE
I % 1 4 I J UN C T I ON
B P A N E L
C1-4
" \ DRI VE R
\ DOOR
I MODUL E
02-13 -
C2*7
LUGGAGE
COMPARTMENT
DOOR
L OC K
MOT OR
I
L UG G A G E
COMPARTMENT
RE MOT E C ON T ROL
L O C K SWI T CH
CLOSED WITH
BUTTON DEPRESSED
T
7 I Bl
N12611- A
Door L o c k Swi t c h A c t u a t o r T o wn Car
KEYLESS ENTRY KEYPAD CONNECTOR
N12551-A
Pi n
N u m b e r Circuit ". -Urcui t Func".
1 7 9 ( L G / R ) 3 / 4 Swi t c h t o P r o c e s s o r
2 7 8 ( L B / Y ) 1/ 2 Swi t c h t o P r o c e s s o r
3 57 ( BK) Gr o u n d f o r A c t u a t o r I l l umi n a t i o n
4 12 3( R) 9 / 0 Swi t c h t o P r o c e s s o r
5 2 96 ( W/ P ) Fu s e d A c c e s s o r y Fe e d
7 1 2 2 ( Y) 7 / 8 Swi t c h t o A c t u a t o r
8 12
( Y / B K )
5 / 6 Swi t c h t o A c t u a t o r
Cr o wn Vi ct or i a, Gr and Marqui s
0 E=Lo~~02

&
o o
- 0
I
- 0
KEYLESS ENTRY
PAD
N10917-B
Pin
Number Circuit Circuit F u n c t i o n
1 7 9 ( L G / R ) 3 / 4 Swi t c h t o P r o c e s s o r
2 7 8 ( L B / Y ) 1/ 2 Swi t c h t o P r o c e s s o r
3 57 ( BK) Gr o un d f o r A c t u a t o r I l l umi n a t i o n
4 123 (R) 9 / 0 Swi t c h t o P r o c e s s o r
5 121
( Y/ B K )
5 / 6 Swi t c h t o P r o c e s s o r
6 122 ( Y) 7 / 8 Swi t c h t o P r o c e s s o r
8 12 4( BR) Swi t c h Co mmo n
1995 To wn Car, Cr o wn Vi c t o r i a , Gr a n d Mar qui s Jul y 1994
N12609-A
Pin
Number Ci r cui t C i r c u i t Functi on
1 12 3( R) A c t u a t o r Bu t t o n 9 / 0 I nput
2 120
( P K / L G )
Do o r L o c k S w i t c h U n l o c k
3 118
( P K / O )
Un l o c k Al l P a s s e n g e r Do o r s
4 57 ( B K )
a
67 6
( P K / O f
Gr o un d
5 163 ( R / O ) Dr i v e r s Do o r Un l o c k
6 8 4 ( P / Y ) L u g g a g e Co mp a r t me n t Do o r L o c k
7 84 ( P / Y )
a
b
No t Us e d
8 117
( P K / B K )
L o c k Al l Do o r s
9 121
( Y / B K )
A c t u a t o r Bu t t o n 5 / 6 I nput
10 119
( P K / Y)
Do o r L o c k S w i t c h L o c k
11 2 68
( B K / O )
12 2 67
( B R / L G )
13 2 6 ( W/ P ) L u g g a g e Co mp a r t me n t Do o r
Re l e a s e S wi t c h
14

No t Us e d
15 57 ( BK) Gr o un d
16

No t Us e d
17

No t Us e d
DRIVER DOOR MODULE CONNECTOR C1 (Cont 'd)
Pin
18 No t Us e d
b To wn Ca r
N12610-A
Pi n
1 7 0 ( L B / W) I SO Li n k
2 2 2 6
( W / B K )
8
LH Fr o n t Do o r Wi n d o w
S w i t c h U P
2 2 7 ( Y)
b
3 340
( R / L B )
a
Pa n i c Si gn a l Out put
2 4 ( D B / 0 )
b
P e r s o n a l Se c u r i t y Al a r m
4 No t Us e d
5 122 ( Y) A c t u a t o r Bu t t o n 7 / 8 I nput
6 66 ( L B) A c t u a t o r I l l umi n a t i o n
7 465
( W/ L B )
I l l umi n a t e d En t r y S wi t c h
8 177 ( W) Le f t Fr o n t Se a t Oc c u p i e d I nput
9 344
( B K / Y)
Do o r Aj a r
10 33
( W/ P K )
a
I gn i t i o n St a r t I nput
1050
( L G / P )
b
11 7 8 ( L B / Y ) A c t u a t o r Bu t t o n 1/ 2 I nput
12 7 9 ( L G / R ) A c t u a t o r Bu t t o n 3 / 4 I nput
b To wn Ca r
01- 14B- 12 Do o r L o c k Co n t r o l S y s t e m, E l e c t r o n i c 0 1 - 1 4 8 - 1 2
N12608-A
DRIVER DOOR MODULE CONNECTOR C3TOWN CAR
Pin
1 903 ( R) Dr i v e r ' s Wi n d o w Do wn i n put
2 2 2 6
( W/ B K )
Dr i v e r ' s Wi n d o w Do wn Ou t pu t
3 400
( L B / B K )
Sa f e t y Re l a y t o Wi n d o w Re gu l a t o r
S wi t c h Fe e d
4 517
( B K / W)
Ba t t e r y Fe e d
DRIVER DOOR MODULE CONNECTOR C3CROWN
VICTORIA, GRAND MARQUIS
Pin
1 407 ( T / BK ) Dr i v e r ' s Wi n d o w Do wn I nput
2 2 2 7 ( Y) Dr i v e r ' s Wi n d o w Do wn Ou t pu t
3 193
( Y/ L G )
I gn i t i o n ( Ho t i n A CC o r RUN)
4 517
( B K / W)
B+ t o Mo d u l e
3. If t he inspection reveal s obvi ous concerns t hat
can be readi l y i denti fi ed, servi ce as requi red.
4. If the concerns remai n after t he i nspecti on,
determi ne the sympt oms and go to t he Sympt om
Chart.
NOTE: Keep the dri ver wi ndow rol l ed down during t he
Pinpoint Tests t o avoi d being l ocked out of the vehi cl e.
Check t hat bat t ery ( 10653) is fully char ged. (If not, t he
bat t ery may be causi ng the concern. )
Di sconnect and reconnect bat t ery t o ensure syst em is
reset.
CAUTI ON: Do n o t r e p l a c e pa r t s un l e s s t e s t
r e s u l t s s a y t h e y s h o u l d b e r e p l a c e d .
Us i n g NG S
Di agnosti cs for thi s secti on require use of the Rotunda
New Generation STAR (NGS) Tester 007- 00500 or
equivalent. The module controlling t he syst em being
di agnosed communi cates wi t h the dat a link connector
l ocat ed beneath t he instrument panel .
Connect t he OBDI I st yl e communication cabl e t o t he
NGS. At t ach t he NGS and communi cati on cabl e t o t he
DLC beneath t he instrument panel. Sel ect the proper
vehi cl e model and year from the NGS menu. You may
then access the testi ng area of the NGS menu
requi red t o di agnose thi s vehicle syst em.
operati ng t he el ectroni c door l ock control syst em
t o dupl i cate t he concern.
Bi n d i n g L a t c h e s Op e n Fu s e s :
To wn Ca r a n d Cr o wn
Vi c t o r i a / G r a n d
Ma r q u i s
P o we r Di s t r i b u t i o n Bo x
- K, 40A ( Ma x i )
I n st r ume n t Pa n e l Fu s e
Pa n e l - 17 ( 10A ) , 10
( 2 0 A ) , 8 ( 1 5 A ) , 5 ( 1 5 A )
a n d 4 ( 1 0 A )
L o o s e Co n n e c t o r s
Co r r o d e d Co n n e c t o r s
01- 14B- 13 Door L o c k Cont r ol 818101115 El ect r oni c 01- 14B- 13
NOTE Vol tage and resi stance readi ngs can be
obtai ned using Rotunda Digital Vol t-Ohmmeter
014- 00407 or Rotunda Dwell-Tach-Volt-Ohms Tester
059- 00010 or equivalent
DOOR LOCK CONTROL SYSTEM, ELECTRONIC
Keyless Entry Keypad Does Not
Work Properly
Circuit *
Keyless entry keypad
Electronic door lock control
processor
0
GO to Pinpoint Test A
Doors Do Not Lock or Unlock Using
Keyless Entry Remote Transmitter
Circuit
processor
0
GO to Pinpoint Test B
m
Illuminated Entry Does Not Work
From Keyless Entry Keypad
Circuit
processor
GO to Pinpoint Test C
Illuminated Entry Djoes Not Work
From Keyless Enjtry Remote 0
Transmitter <,
Swi tches
Circuit
GO to Pinpoint Test D
0
Q - *
Anti-Theft System Does Not Arm or
v
Disarm
Efectronic door lock control
processor
Circuits
Procedure error
GO to Pinpoint Test E
Personal Security Alarm Does Not
Work From Keyless Entry Remote
Transmitter,
processor
Circuits
GO to Pinpoint Test F
^Memory Function Does Not
0
Work
-From Keyless Entry Remote
Transmitter
0
Q
processor
Circuits
GO to Pinpoint Test G
Courtesy Lamps Do Not Turn Off If
Left On
Circuit
Electronic doof l ock control
r processor
GO,to Pinpoint Test H
Aut olocks Does Not Work Properly

Circuit
Swi tches ^ *
GO to Pinpoint Test J
Luggage Compartment Door Will
"Not Unlock
o
P
processor
Circuits
0
GO to Pinpoint Test K
5
P i n p o i n t T e s t s * "
0
PINPOINT TEST A- KEYLESÊNTRY KEYPAD DOES NOT WORK PROPERLY
* " TEST STEP , * RESULT ACTl bN TO TAKE
A1 CHECK LOQK OPERATION
Yes \
No
GO to A2
SERVICE any lock
concerns REFER to
Section 01-14A
,
e
While seated in vehi cle, operate locks from interior
swi t ches ,
Does t he l ock sy st em oper at e pr ope r l y ?
Yes \
No
GO to A2
SERVICE any lock
concerns REFER to
Section 01-14A
A2 CHECK TRANSMITTER OPERATION
Yes ,
No
GOt o A3
SERVICE any lock
concerns GO to Pinpoint
Test B.
While outside of vehicle operate all functions of
<
t
remote transmi tter
Does t he sy st em oper at e pr oper l y ?
Yes ,
No
GOt o A3
SERVICE any lock
concerns GO to Pinpoint
Test B.
A3 TEST KEYLESS ENTRY FACTORY CODE
Yes
No t>
0
GO to A4
GO to AS
Using keyless.entry keypad, ent erf act ory code t o

unlock driver's door
?
Within 5 seconds, press 3/ 4 swi tch t o unlock
passenger's doors
Does dr i ver ' s d o o r unl ock, passenger' s door s
unl oc k?
Yes
No t>
0
GO to A4
GO to AS
, , % 1
6
1995 Town Ca r , Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s Jul y 19|4
01- 14B- 14 Door Look Cont r ol S y s t e m, El ect r oni c 0 1 - 1 4 1 - 1 4
PINPOINT T E S T A: KE YL E SS ENTRY KEYPAD DOES NOT WORK PROPERLY (Continued)
TE ST STE P RESULT ACTION TO TAKE
A4 TEST KEYLESS LOCKING
Yes E>
No
System operati ng
normally.
GO to A5.
Press 7/ 8 and 9 / 0 swi t ches concurrently.
# Do all doors l oc k?
Yes E>
No
System operati ng
normally.
GO to A5.
AS CHECK KEYLESS ENTRY SWITCHES
Yes
No
GO to A6.
open circuit. If circuit is
good, REPLACE keyless
entry swi t ch. RETEST
system.
Depress 1/2 swi t ch.
Does illuminated entry turn on the court esy
l i ght s?
Yes
No
GO to A6.
system.
A6 CHECK 3/ 4 BUTTON OPERATION
Yes
No
GO t o A7 .
system.
Lock vehicle by pressi ng the 7 / 8 and 9/ 0 buttons at
same time.
Press the 3/ 4 but t on.
Di d i l l umi nat ed e nt r y t ur n on?
Yes
No
GO t o A7 .
system.
A7 CHECK 5/ 6 BUTTON OPERATION
Yes
No
GO to A8.
system.
Lock vehi cle by pressi ng the 7 / 8 and 9/ 0 buttons at
the same time
Press the 5/ 6 but t on.
Yes
No
GO to A8.
system.
AS CHECK 7 / 8 BUTTON OPERATION
Yes
No
GO to A9.
system.
the same time.
Press the 7/ 8 button.
Di d I l l umi nat ed e nt r y t ur n o n ?
Yes
No
GO to A9.
system.
A9 CHECK 9 / 0 BUTTON OPERATION
Yes
No
GO t o A10.
the same ti me.
Yes
No
GO t o A10.
A10 TEST POWER TO KEYLESS ENTRY SWITCH
Yes
No
swi t ch.
, system.
Read voltage on Circuit 296 into keyless entry
swi t ch.
Does vol t age r ead B+ ?
Yes
No
swi t ch.
, system.
0
PINPOINT TEST B: DOORS DO NOT LOCK OR UNLOCK USING KEYLESS ENTRY REMOTE TRANSMITTER
B1 CHECK LOCK OPERATION
Yes "
No *
GOt o B2 .
SERVICE any lock
concerns. REFER t o
Section 01-14A.
While, seated in vehi cle, operate locks from interior
swi t ches.
Does t he l ock sy st e m oper at e pr ope r l y ?
Yes "
No *
GOt o B2 .
SERVICE any lock
concerns. REFER t o
Section 01-14A.
B2 TEST REMOTE KEYLESS ENTRY FOB
Yes
No
GO to B3.
GO t o B8.
0
Press Remote Keyless Entry (RKE) lock button.
Within 5 seconds press RKE unlock but t on.
Di d door s unl oc k?
Yes
No
GO to B3.
GO t o B8.
B3 CHECK REMOTE KEYLESS ENTRY LOCK FUNCTION
Yes
No
GO t o B5.
GO t o B4.
Press Remote Keyless Entry (RKE) lock button.
Di d door s l o c k?
Yes
No
GO t o B5.
GO t o B4.
PINPOINT TEST B: DOORS DO NOT LOCK OF? UNLOCK USING KEYLESS E N T R Y R E M O T E TRANSMITTER (Cont i nued)
B4 ISOLATE INOPERATIVE CONDITION
Yes
No
open circuit.
open circuit into driver's
door module. RETEST
system.
Manually unlock ail doors.
P r e s s R e mo t e Keyl ess Entry lock button.
Within 5 s e c o n d s , press R e mo t e Keyless Entry
unlock button.
Di d passenger door s oper at e t he opposi t e of t he
dri ver' s door ?
Yes
No
open circuit.
open circuit into driver's
door module. RETEST
system.
B5 CHECK LUGGAGE COMPARTMENT DOOR LOCK
OPERATION
Yes
N O \
GOt o B6.
GO to B9.
Within 5 seconds press luggage compartment
unlock button t wi ce.
Di d l uggage c ompa r t me nt unl oc k?
Yes
N O \
GOt o B6.
GO to B9.
B6 CHECK ALARM FUNCTION
Yes !>
No f^"
GOt o B7 .
GO t o B10.
Does al arm sound?
Yes !>
No f^"
GOt o B7 .
GO t o B10.
B7 TEST RKE UNLOCK BUTTON
Yes
No "
module. NOTE that
keyless entry remote
transmitter will have to be
programmed to new
PROGRAM replacement
transmitter to vehicle
(see Programming
Keyless Entry Remote
Transmitter).
Connector.
Press unlock button on keyless entry remote
transmitter.
Does dat a i ndi cat e unlock r ecei ved?
Yes
No "
module. NOTE that
transmitter will have to be
programmed to new
PROGRAM replacement
(see Programming
Keyless Entry Remote
Transmitter).
B8 TEST RKE DECKLID BUTTON
Yes "
No \
PROGRAM replacement
(REFER to Transmitter,
Keyless Entry Remote).
Connector.
Press lock button on keyless entry remote
transmitter.
Does dat a i ndi cat e lock r ecei ved?
Yes "
No \
PROGRAM replacement
B9 TEST RKE ALARM BUTTON
Yes
No
GOt o Section 13-11,
PROGRAM replacement
RETEST system.
Connector.
Press lock button on keyless entry remote
transmitter.
Does dat a i ndi cat e alarm r ecei ved?
Yes
No
GOt o Section 13-11,
PROGRAM replacement
RETEST system.
PINPOINT TEST C: ILLUMINATED ENTRY DOES NOT WORK FROM DOOR LOCK SWITCH ACTUATOR
TEST STEP RESULT > ACTION TO TAKE
C1 CHECK LIGHTING OPERATION
Yes
No >
SERVICE any lighting
concerns. REFER to
Section 17-02.
Open driver's door and observe courtesy lighting
operati on.
Does t he cour t esy l i ght i ng sy st em oper at e
pr oper l y ?
Yes
No >
SERVICE any lighting
concerns. REFER to
Section 17-02.
01- 14B- 16 Door L o c k Cont r ol S y s t e m, El ect r oni c 01- 14B- 16
L ' . ' i w n
1
~w m.zzzzr"- ~ZL.ZZ7.TTZ~W -. ~~~~ jag- _.' .-SE. ~ ~mz iMZzzzzr-r.!
PINPOINT TEST D: ILLUMINATED ENTRY DOES NOT WORK FROM KEYLESS ENTRY REMOTE TRANSMITTER
T E ST STE P RESULT ACTION TO TAKE
D1 TEST LAMP CIRCUIT
Yes
No
GO t o Pinpoint Test C.
GO to D2.
Lock vehi cle and allow two minutes for all systems
to reset.
Press unlock button on remote keyless entry remote
transmitter.
Do any i n t e r i o r / e x t e r i o r l amps act i vat e?
Yes
No
GO to D2.
D2 CHECK KEYLESS ENTRY REMOTE TRANSMITTER
Yes
No
GO t o Pinpoint Test B.
Lock vehi cle and allow two minutes for all systems
t o reset.
Enter unlock code into keyless entry keypad.
Do any i nteri or/exteri or l amps act i vat e?
Yes
No
PINPOINT TEST E: ANTI-THEFT SYSTEM DOES NOT ARM OR DISARM
E1 CHECK ALARM FUNCTION
Yes >
No
GOt o E2.
GOt o EI O.
Does al arm sound?
Yes >
No
GOt o E2.
GOt o EI O.
E2 TEST KEYLESS ENTRY FACTORY CODE
Yes
No
GOt o E3.
GOt o E4.
Using keypad, enter f act ory code to unlock driver's
door.
Within 5 seconds, press 3/ 4 swi t ch t o unlock
passenger doors.
Does dri vers door unl ock, passenger' s door s
unl oc k?
Yes
No
GOt o E3.
GOt o E4.
E3 TEST KEYLESS LOCKING
Yes D>
No >
System operating
normally.
GOt o E5.
Press 7 / 8 and 9/ 0 swi t ches concurrently.
Do all door s l o c k?
Yes D>
No >
System operating
normally.
GOt o E5.
E4 CHECK KEYLESS ENTRY SWITCHES
Yes
No
GOt o E5.
system.
Depress 1 / 2 swi t ch.
Does i l l umi nat ed ent r y t ur n on t he cour t esy
l i ght s?
Yes
No
GOt o E5.
system.
E5 CHECK 3/ 4 BUTTON OPERATION
Yes
No
GOt o E6.
system.
Lock vehi cle by pressing the 7 / 8 and 9/ 0 buttons at
same time.
Di d i l l umi nat ed ent ry t ur n on?
Yes
No
GOt o E6.
system.
E6 CHECK 5 / 6 BUTTON OPERATION
Yes
No
GO to E7.
system.
Lock vehicle by pressing the 7 / 8 and 9/ 0 buttons at
the same ti me.
Yes
No
GO to E7.
system.
E7 CHECK 7 / 8 BUTTON OPERATION
Yes
No
GOt o E8.
system.
the same time.
Yes
No
GOt o E8.
system.
E8 CHECK 9/ 0 BUTTON OPERATION
Yes
No
GOt o E9.
t he same time.
Yes
No
GOt o E9.
1995 To wn Car , Cr o wn Vi c t o r i a , Gr a n d Ma r qui s Jul y 1994
PINPOINT TEST E: ANTI-THEFT SYSTEM DOES NOT ARM OR DISARM (Cont i nued)
E9 TEST POWER TO KEYLESS ENTRY SWITCH
Read voltage on Circuit 2 9 6 i n t o k e y l e s s e n t r y
swi t ch.
Yes
No
swi t ch.
system.
E10 TEST ALARM BUTTON
C o n n e c t N e w G e n e r a t i o n S t a r T e s t e r t o Data Link
C o n n e c t o r .
P r e s s l o c k b u t t o n o n k e y l e s s e n t r y r e m o t e
transmi tter.
R e q u e s t P I D f o r l a s t R K E transmission d a t a .
Does data Indi cate al arm recei ved?
Yes
No
GO to Section 13-11.
PROGRAM replacement
transmitter t o vehicle
(REFER t o Transmitter,
RETEST system.
PINPOINT TEST F: PERSONAL SECURITY A L A R M D O E S NOT WORK FROM KEYLESS ENTRY REMOTE TRANSMITTER
F1 CHECK LIGHTING OPERATION
Test other keyless entry remote transmitter
functions.
Does t he keyl ess ent r y r emot e t r ansmi t t er
oper at e pr oper l y ?
Yes
No ^
Go to Pinpoint Test B.
MEMORY FUNCTION DOES NOT WORK FROM KEYLESS ENTRY REMOTE TRANSMITTER
G1 CHECK MEMORY SEAT OPERATION
While seat ed in vehi cle, operate seat memory
functions from door swi t ches.
Does t he seat i ng sy st em oper at e pr ope r l y ?
Yes
No
GO to D2.
SERVICE any seat
concerns. REFER t o
Section 01-10.
G2 CHECK MEMORY SEAT OPERATION
While seat ed in vehi cle, operate mirror memory
functions from door swi t ches.
Does the seat i ng sy st em oper at e pr ope r l y ?
Yes
No
SERVICE any mirror
concerns. REFER to
Section 01-09.
PINPOINT TEST H: COURTESY LAMPS DO NOT TURN OFF IF LEFT ON
H1 LOCK SYSTEM TEST
Unlock door using keyless entry keypad or keyless
entry remote transmitter.
Observe lighting for two minutes.
Do i nt er i or l amps t urn off af t er t wo mi nut es?
Yes ^
No
REFER to Section 17-02
for courtesy lamp
diagnosis.
GOt o Pinpoint Test C.
PINPOINT TEST J: AUTOLOCK DOES NOT WORK PROPERLY
J1 CHECK TR SENSOR
Close all doors.
Occupy driver's seat.
a Put ignition switch in RUN.
Do ail door s l oc k?
Yes
N o
SERVICE TR Sensor
Circuit 33 for open ci rcui t.
RETEST system.
GO to J2.
0 1 - 1 4 8 - 1 8 _ Door L o c k Co n t r o l Sy s t e mÊ I e c t r o n i c _ 01- 14B- 18
PINPOINT TEST J; AUTOLOCK DOES NOT WORK PROPERLY (Conti nued)
J2 TEST AUTOLOCKS
Yes
No
GO t o J8.
MAKE SURE that
autolocks feature is
turned on. See "turning
on aut ol ocks". Toggle
autolocks feature. If
autolocks still do not
engage, GOt o J3.
Put transmission in Reverse or Drive.
o Make sure t hat doors are closed and driver's seat is
occupi ed.
Do all door s Sock?
Yes
No
GO t o J8.
MAKE SURE that
autolocks feature is
turned on. See "turning
on aut ol ocks". Toggle
autolocks feature. If
autolocks still do not
engage, GOt o J3.
J3 TEST DOOR AJAR CIRCUITS
Yes
No
for lighting concern.
GO t o J4.
With all doors closed and light swi t ches off, wait
one minute.
Are cour t esy lights on?
Yes
No
for lighting concern.
GO t o J4.
J4 TEST DOOR AJAR INPUT TO DDM
Yes
No
GO t o J5.
GO t o J6.
Connect New Generation Star Tester t o Data Link
Connector.
With all doors cl osed, read Door Ajar PID.
Does PID i ndi cate Door Aj ar?
Yes
No
GO t o J5.
GO t o J6.
J5 TEST LCM
Yes
No >
short to ground. RETEST .
system.
REPLACE Lighting
Control Module. RETEST
system.
Remove Connector B from Lighting Control Module.
Read Door Ajar PID.
Does PID i ndi cat e Door Aj ar?
Yes
No >
short to ground. RETEST .
system.
REPLACE Lighting
system.
J6 TEST SEAT OCCUPIED CIRCUIT
Yes
No
GO to J7.
open circuit and seat
occupi ed swi t ch. RETEST
system.
With driver's seat occupi ed, read Seat Occupi ed
PID.
Does PID i ndi cat e Seat Occupi ed?
Yes
No
GO to J7.
open circuit and seat
occupi ed swi t ch. RETEST
system.
J7 TEST PARK/NEUTRAL CIRCUIT
Yes i >
No
CHECK for stuck TR
Sensor. RETEST system.
With transmission in Drive or Reverse, read
Park/Neut ral PID.
Does PID i ndi cat e Park or Neut ral ?
Yes i >
No
CHECK for stuck TR
Sensor. RETEST system.
J8 TEST DOOR LOCKS
Yes
No >
GO to J 11.
GO to J9.
Make sure driver's seat is occupi ed.
Open and close driver's door.
Open and close passenger's door.
Do door s look af t er each door ?
Yes
No >
GO to J 11.
GO to J9.
J9 TEST DOOR LOCKS
Yes
No
REPLACE Lighting
system.
GO to J10.
Open door and close which did not tri gger
autolocks.
Do cour t esy l i ghts t urn on and of f when door i s
opened?
Yes
No
REPLACE Lighting
system.
GO to J10.
J10 TEST DOOR AJAR INPUT TO DDM
Yes
No
GO to J 11.
system.
Connector.
With any door open, read Door Ajar PID.
Does PID i ndi cat e Door Aj ar?
Yes
No
GO to J 11.
system.
J11 TEST SEAT OCCUPIED SWITCH
Yes
No . '
short to ground or stuck
System operating
normally.
Remove weight from driver's seat.
Open and close any door.
Do door s lock?
Yes
No . '
short to ground or stuck
System operating
normally.
PINPOINT TEST K: LUGGAGE COMPARTMENT DOOR WILL NOT UNLOCK
K1 CHECK DECKLID RELEASE SWITCH
Yes
No
GO t o K11.
GO to K2.
Depress Decklid R e l e a s e s w i t c h .
Does deckli d open?
Yes
No
GO t o K11.
GO to K2.
K2 CHECK DECKLID RELEASE OUTPUT
Yes
No
GOt o K7.
GO to K3.
Connect N e w G e n e r a t i o n S t a r ( N G S ) T e s t e r t o D a t a
Link Connector (DLC).
Send command Decklid Release.
Does deckli d open?
Yes
No
GOt o K7.
GO to K3.
K3 CHECK MECHANICAL RELEASE
Yes
No
CHECK for and SERVICE
mechanical operation of
deckli d release
mechanism. CHECK for
sti cki ng deckl i d.
GO to K4.
Does d e c kl i d rel ease sol enoi d make a noi se?
Yes
No
CHECK for and SERVICE
mechanical operation of
deckli d release
mechanism. CHECK for
sti cki ng deckl i d.
GO to K4.
K4 CHECK DECKLID RELEASE OUTPUT OF DRIVER'S
DOOR MODULE
Yes
No
GO to K5.
# Check Pin C1-6 or C1-7 of driver's door module for
voltage when Decklid Release command is sent.
Is vol t age moment ari l y B+ when command is
sent ?
Yes
No
GO to K5.
K5 CHECK CONTINUITY TO SOLENOID
Yes
No
GO to K6.
CHECK for short to
deckli d release Circuit
84.
Check Circuit 84 of the deckli d release solenoid for
voltage when Decklid Release command is sent.
Is vol t age moment ari l y B+ when command is
sent ?
Yes
No
GO to K6.
CHECK for short to
deckli d release Circuit
84.
K6 CHECK FOR CONTINUITY ON GROUND OF SOLENOID
Yes
No
REPLACE deckli d
release solenoi d.
RETEST system.
Check Circuit 57 of t he deckli d release solenoid for
continuity to ground.
Yes
No
REPLACE deckli d
release solenoi d.
RETEST system.
K7 CHECK DECKLID RELEASE SWITCH CIRCUIT
Yes
No
GO to K8.
Close the Decklid Release swi t ch.
Does t he Deckl i d Release swi t ch PID change?
Yes
No
GO to K8.
K8 CHECK FOR DECKLID RELEASE SWITCH STUCK
Yes
No
SERVICE Decklid
Release swi tch for stuck
swi tch or Circuit 26 for
system.
GO to K9.
With Decklid Release swi tch not pressed, read the
Decklid Release swi tch PID.
Does t est er i ndi cat e swi t c h is act i ve?
Yes
No
SERVICE Decklid
Release swi tch for stuck
swi tch or Circuit 26 for
system.
GO to K9.
K9 CHECK FOR CONTINUITY FROM MODULE TO SWITCH
Yes
No
GO t o K10.
Decklid Release swi tch
Circuit 26. RETEST
system.
Check Circuit 26 of t he Decklid Release swi tch for
continuity with Pin C1-13 of the driver's door
module.
Yes
No
GO t o K10.
Decklid Release swi tch
Circuit 26. RETEST
system.
K10 CHECK FOR CONTINUITY OF GROUND OF SWITCH
Yes
No
REPLACE Decklid
Release swi t ch. RETEST
system.
SERVICE circuit to
GO t o K11.
Check Circuit 57 of t he Decklid Release swi tch for
continuity t o ground.
Yes
No
REPLACE Decklid
Release swi t ch. RETEST
system.
SERVICE circuit to
GO t o K11.
0 1 - 1 4 8 - 2 0 Door Loc k Cont r ol S y s t e m, El ect r oni c 0 1 - 1 4 8 - 2 0
: Z : . : I ~ J T : ": : : : Z Z Z : - ~ ]
PINPOINT TEST K: LUGGAGE COMPARTMENT DOOR WILL NOT UNLOCK (Cont i nued)
K11 RECHECK DECKLID RELEASE SWITCH
Yes
No
System is operati ng
normally.
CHANGE batteri es in
transmitter and RETEST.
If keyless entry remote
transmitter sti ll fails to
operate, GOt o K12 .
Depress Decklid Release swi t ch on keyless entry
remote transmi tter t wi ce within 5 seconds.
Does de c kl i d open?
Yes
No
System is operati ng
normally.
CHANGE batteri es in
transmitter and RETEST.
If keyless entry remote
transmitter sti ll fails to
operate, GOt o K12 .
K12 CHECK DECKLID RELEASE OUTPUT
Yes *
No
GOt o K13.
GO to K3.
Connect New Generation Star (NGS) Tester to Data
Link Connector (DLC).
Does de c kl i d open?
Yes *
No
GOt o K13.
GO to K3.
K13 CHECK DECKLID RELEASE SWITCH TRANSMISSION
Yes
No
REPLACE RKE trailer
wiring feed wiring.
RETEST system.
Depress Deckli d Release swi t ch on keyless entry
remote transmi tter.
Read the RKE Last Data Transmitted PID.
Does dat a i ndi cat e t he Deckl i d Release swi t c h
was t he last key press?
Yes
No
REPLACE RKE trailer
wiring feed wiring.
RETEST system.
Do o r L o c k S w i t c h A c t u a t o r
Refer t o Secti on 01- 14A.
Do o r Mo d u l e , Dr i v e r
2. Remove LH front door tri m panel ( 23942) . Refer
3. Di sconnect body main wi ri ng ( 14A005) f r om
dri ver' s door modul e.
-FRONT OF
VEHICLE
N12340-A
Pa r t
1 20125 Front Door
2 Screws (2 Req'd)
3 13C797 Driver Door Module
5 Driver Door Module
Retaining Bracket (Part of
20125)
01- 14B- 2 1
Do o r Loc k Co n t r o l Sy s t e m, El ect r oni c 01- 14B- 2 1
REMOVAL AND INSTALLATION (Cont f nyed)
4. Remove t wo scr ews retaining dri ver door module
t o front door ( 20125) . Remove dri ver door
module.
To wn Car, Cr o wn Vi ct or i a/ Gr and Ma r qui s
N9670-A
Pa r t
1 56928-S2 Screw
2 15K602 Electronic Door Lock Control
Processor
3 RH Side Cowl Panel
4 N800319-S36 Stud
5 14B204 Electronic Door Lock Control
Processor Bracket
6 N621905-S36 Nut
A Tighten t o 2-3.4 N-m (18-30
Lb-ln)
Lb-ln)
Lb-ln)
A n t e n n a
1. NOTE: The al arm and l ock syst em antenna used
in thi s vehi cl e is part of t he wi ri ng harness. DO
NOT remove t he exi sti ng al arm and l ock antenna
f rom t he wi ri ng harness.
Di sconnect al arm and l ock antenna connector
f rom el ectroni c door l ock cont rol processor and
move out of the way.
2. Connect new al arm and l ock antenna t o el ectroni c
door l ock control processor.
3. Install new al arm and l ock antenna into vehi cl e,
tapi ng al ong wiring harness pat h fol l owed by old
(unconnected) al arm and l ock antenna. Secure
using proper ti e-wrap or st raps.
T r a n s m i t t e r B a t t e r y
CAUTI ON: Do n o t t a k e t h e f r o n t ha l f o f t h e
t r a n s mi t t e r a p a r t .
The keyl ess entry remote transmi tter ( 15K601) is
power ed by t wo coi n-type, three-volt lithium batteri es.
To repl ace t he bat t eri es, the keyl ess entry remote
transmi tter comes apart by twi sti ng a thin coin
bet ween t he t wo hal ves of the keyl ess entry remote
transmi tter.
Careful l y swi ng the cont act s off the batteri es and
remove t he old bat t eri es. When installing the new
bat t eri es, be sure t o pl ace the posi ti ve si de down as
mar ked. Carefully swi ng the cont act s back onto the
t op of the batteri es. Snap the t wo halves back
together.
FRONT HALF BATTERIES
N12617-A
SPECIFICATIONS
De s c r i p t i o n L b - l n
E l e c t r o n i c Do o r L o c k Co n t r o l
P r o c e s s o r Re t a i n i n g S c r e w
2- 3. 4 18-30
P r o c e s s o r Br a c ke t St u d
7- 11 62 - 97
P r o c e s s o r Br a c ke t Re t a i n i n g Nut
6- 10 54- 88
ROTUNDA EQUIPMENT
059- 00010 Dwe l l - Ta c h - Vo l t - Oh ms Te s t e r
01- 16- 1 Wi p e r a n d Wa s h e r S y s t e ms 01- 16- 1
SECTION 01-16 Wiper and Washer Systems
SUBJE CT P A G E
VEHICLE APPLICATION ....... . ....01-16-1
Fluid Level Sensor, Wi ndshi el d Washer
Reservoir .......... . 01-16-2
Low Washer Fluid Indi cator 01-16-2
Washer Syst em, Wi ndshi el d 01-16-2
Wi per Syst em, Wi ndshi el d 01-16-1
DIAGNOSIS AND TESTI NG
Current Draw 01-16-13
Wi ndshi el d Wi per Swi t c h Test ...01-16-12
El ect ri cal Schemat i cs .... 01-16-3
Pi npoi nt Test s .01-16-6
SUBJECT PAGE
DIAGNOSIS AND TESTING (Cont ' d. )
Sy mpt om Chart ..01-16-5
Mul t i -Funct i on Swi t c h 01-16-19
Washer Nozzle Je t and Br a c ke t . . 01-16-20
Washer Pump and Reservoi r. . . 01-16-20
Washer Pump and Seal Assembl y,
Wi ndshi el d . 01-16-19
Wi ndshi el d Wi per. 01-16-13
ADJUSTMENTS
Park Posi t i on ... 01-16-21
SPECIFICATIONS... . 01-16-22
VEHICLE APPLICATION
Wi per Syst em, Wi ndshi el d
The wi ndshi el d wi per syst em consi sts of the fol l owi ng
component s:
Wi ndshi el d wi per mounting arm and pivot shaft
( 17566) .
Wi ndshi el d washer pump ( 17664) .
Wi ndshi el d wi per control module l ocated in the
instrument panel bet ween the radi o and steeri ng
col umn.
Wi ndshi el d wi per motor ( 17508) at t ached t o the
wi ndshi el d wi per mounting arm and pivot shaft.
A wi ndshi el d wi per motor output arm ( 17A436)
connect s the wi ndshi el d wi per motor di rectl y t o the
wi ndshi el d wi per mounting arm and pivot shaft.
Multi-function swi t ch ( 13K359) , whi ch features a
rot ary wi per swi t ch and a push-type washer
actuator.
Of f / Low/ Hi gh Speed
The t wo-speed, permanent magnet, three brush
el ectri c wi ndshi el d wi per motor operat es in t he
fol l owi ng manner:
A brush rigging permi ts sel ecti on of low or high
speed.
When t he multi-function swi t ch is in LO position:
The common brush and the bl ue/ orange wi re
brush are used.
The wi ndshi el d wi per motor operat es at
l ow-speed.
When t he multi-function swi t ch is in HI posi ti on:
- The common brush and the whi t e wi re brush are
used.
Current bypasses a portion of t he armature
wi ndi ng, causi ng the windshield wi per motor to
run faster.
When t he control sel ector is moved t o t he OFF
posi ti on:
The wi ndshi el d wi per motor will continue at
l ow-speed until the windshield wi per motor
swi t ch outer cont act s open.
The wi ndshi el d wi per motor is si gnal ed t o park,
acti vati ng the depressed park mechani sm
whi ch is part of t he output arm.
The wi ndshi el d wi per motor swi tch is inside the motor
gearbox.
I n t e r v a l
When t he multi-function swi t ch is in the interval (INT)
position:
The wi pers make single wi pes separat ed by
pauses.
The control knob on t he end of the multi-function
swi t ch set s t he length of the pauses (from
approxi mat el y 1 to 17 seconds).
The length of pause decreases as the knob is
rot at ed away f rom OFF and i ncreases as t he knob
is rot at ed t owar d OFF.
01- 16- 2 Wi per and Washer Sy s t ems
01- 16- 2
While in the interval wi per mode, it is normal t o hear
a slight ti cki ng sound at the beginning of each
wi pe/ pause cycl e. Thi s sound is f rom t he wi per
control modul e' s relay.
NOTE: When using interval wi pers, the fi rst wi pe may
not occur until after a pause of up to 17 seconds.
I NTERVAL
WI PER RANGE
INTERVAL WIPER
K13878-C
Washer System, Windshield
The wi ndshi el d washer syst em consi sts of:
Two wi ndshi el d washer nozzle j et and bracket s
( 17603) l ocat ed on t he cowl t op panel .
A wi ndshi el d washer pump ( 17664) . It is act i vat ed
by pushing in on the out board end of t he
multi-function swi t ch ( 13K359) .
The act i vat ed multi-function swi t ch energi zes a
wi ndshi el d washer pump mounted inside a cavi t y in
the wi ndshi el d washer reservoi r ( 17618) .
The wi ndshi el d washer reservoi r is mounted on t he
RH fender apron.
The syst em operat es as fol l ows:
Push the knob of t he multi-function swi t ch t owar d
the center of the steeri ng column tube ( 3514) .
If multi-function swi t ch is in OFF or INT posi ti on:
Wi per will run as long as the rot ary wi per swi t ch
is pushed in.
Washers will st op immediately when washer
swi t ch is rel eased.
Wi pers will continue t o run for t hree t o four
cycl es before returning t o OFF or interval
operati on.
If t he multi-function swi t ch is in LO or HI posi ti on,
washer s operat e wi t h no change in wi ndshi el d
wi per motor operati on.
NOTE: The front wi ndshi el d washer nozzle j et s expel a
single oscillating j et st ream. The spray f orms a wi de,
fan-like pattern on the wi ndshi el d. Only act uat e t he
syst em momentari l y t o avoi d sending more fluid than
needed t hrough the syst em.
OUTLET
FLOW TUBE AT HIGH FREQUENCY APPEARS
FEEDBACK CAUSES AS A SOLID FAN TO THE NAKED
OSCILLATION EYE
K6527-C
The wi ndshi el d washer nozzle j et and bracket is not
adj ustabl e, and is mounted t o t he cowl vent screens
( 018A16) .
Low Washer Fluid Indicator
Vehicles equi pped wi t h a low windshield washer fluid
warni ng indicator syst em have a WASH FLUID
indicator in t he instrument cluster. On Town Car, the
indicator is blue. On Crown Vi ctori a and Grand
Marqui s, t he indicator is red.
When the washer fluid level is approxi matel y
one-fourth full or lower, the windshield washer
reservoi r fluid level sensor swi t ch cont act s cl ose,
illuminating t he low washer fluid indicator.
Fluid Level Se n s o r , Windshield Washer
Reservoir
NOTE: Low washer fluid indicator swi t ch cannot be
servi ced separatel y. If swi t ch needs t o be servi ced,
the wi ndshi el d washer reservoi r ( 17618) must be
repl aced.
The windshield washer reservoi r fluid level sensor
( 17B649) , mounted in the wi ndshi el d washer
reservoi r, consi sts of a fl oat and a magnet
assembl y t hat opens and cl oses a reed-type swi t ch.
When the wi ndshi el d washer pump ( 17664) is
energi zed, current will fl ow f rom the windshield
washer reservoi r fluid level sensor through the
cont act s t o the windshield wi per control module and
illuminates t he warni ng indicator on the instrument
cluster ( 10849) .
01- 16- 3 Wi per and Washer Sy s t ems 01- 16- 3
El e c t r i c a l S c h e ma t i c s
Wi per Ci rcui t
HOT IN ACC OR RUN
~ FUSE
l J UNCT I ON
! PANEL
INT
N
? . M A X
U.OBK ^ OFF
H!
_ _ _ _ _ _ _
MULT
,.
3.3K INT l | S
0 N
OHMS MIN INT I SWITCH
LO MAX
C2-4
993 BR/W
I
! I
f
41 I B
13
2
WASHER 63
CIRCUIT
SOLID STATE ^
3 7 1
DB/O
mm. - W|NDSHI EL0
. WIPER
- . 12 . 10 j CONTROL
BK/PK 61
U
MODULE
57

O
WIPER
MOTOR
SWITCH
0
fC PARKING f> PARI
!
i
RUN
""'I'
1
"
1
M I |^
WINDSHIELD
WIPER
MOTOR
See EVTM for
more d e t a i l s
of this circuit
K16159-D
01- 16- 4 ^ Wi per and Wa she r Systems
DIAGNOSIS AMD TESTING ( Co n t i n u e d )
01- 16- 4
Washer Ci rcui t
INTERVAL WIPER/ 57
more details
of this ci rcui t
K16162-E
Connect or End Vi e ws
WINDSHIELD WIPER CONTROL MODULE
Pin
Number Circuit C i r c u i t F u n c t i o n
1 58 (W) Wi n d s h i e l d Wiper Mo t o r - Hi
2 63 ( R) Wi n d s h i e l d Wi p e r Mo t o r Pa r k
Swi t c h
3 61 ( Y / R ) Co mmo n
4 Not Us e d
Pin
5
_
No t Us e d
6 590
( DB / W)
Mul t i - Fun c t i o n Swi t c h ( I n t e r v a l
Co n t r o l )
7 56 ( DB / O ) Wi n d s h i e l d Wi p e r Mo t o r - L o
8 993
( B R / W)
Mul t i - Fun c t i o n Swi t c h Co mmo n
9 2 8
( B K / P K )
Wi n d s h i e l d Wi p e r Mo t o r Pa r k
Swi t c h
10 57 ( BK) Gr o un d
11 941
( B K / W)
Wi n d s h i e l d Wa s h e r Pump
12 57 ( BK) Gr o un d
13 65 ( DG) Ho t in A CC o r RUN
14 589 ( 0 ) Mul t i - Fun c t i o n Swi t c h ( Wi p e r
Mo d e )
WINDSHIELD WIPER
MOTOR CONNECTOR
K22566-A
Pin
1 65 ( DG) B + Suppl y t o Wi n d s h i e l d Wi p e r
Mo t o r ( PF)
2 2 8
( B K / P K )
Wi n d s h i e l d Wi p e r Co n t r o l Mo d u l e
t o Wi n d s h i e l d Wi p e r Mo t o r Pa r k
Swi t c h ( PR)
3 63 (R) Wi n d s h i e l d Wi p e r Co n t r o l Mo d u l e
t o Wi n d s h i e l d Wi pe r Mo t o r Pa r k
Swi t c h ( GR)
4 57 ( BK) Gr o un d (G)
5 6 1 ( Y / R ) Co mmo n Gr o un d f r o m Wi n d s h i e l d
Wi pe r Co n t r o l Mo d u l e t o
Wi n d s h i e l d Wi p e r Mo t o r ( COM)
6 56 ( DB / O ) Wi n d s h i e l d Wi p e r Mo t o r ( L O)
7 58 ( W) Wi n d s h i e l d Wi p e r Mo t o r (HI )
MULTI-FUNCTION SWITCH
11-PIN CONNECTOR C1
K 1 9 8 8 8 - B
Pi n
1 2 9 8 ( P / O ) Fu s e d Run On l y Fe e d
2 5 ( 0 / L B ) Ri ght Ma r k e r / S t o p / T u r n a n d Pa r k
L a mp s
3 37 9
( B R / W)
Ri ght Co r n e r i n g L a mp s
4 10 (LG/R) S t o p l a mp S wi t c h Fe e d
5 2 ( W/ L B ) Ri ght Tur n I n d i c a t o r a n d L a mp s
6 44 ( L B) Fl a s h e r Out put
7 3 8 0 ( P / Y ) L e f t Co r n e r i n g I nput
8 3 ( L G / W ) L e f t Turn I n d i c a t o r a n d L a mp s
9 511 ( LG) S t o p l a mp I nput
10 9 0- G/ O) Le f t Ma r k e r / S t o p / T u r n a n d Pa r k
L a mp s
11 385 ( W/ R ) Ha z a r d Fl a s h e r I nput
MULTI-FUNCTION
SWITCH 7-PIN CONNECTOR C2
K19923-B
Pi n
N u m b e r C i r c u i t Circuit Function
1 5 8 9 ( O) Wi p e r Mo d e
2 15 ( R/ Y) J Di mme r S wi t c h Fe e d
3 13 (R/BK) | L o w Be a m
4 993
( B R / W)
Co mmo n
5 12
( L G / B K )
Hi Beam
6 590
( DB / W)
I n t e r v a l Co n t r o l
7 2 2 1 ( O / W ) P o we r Fe e d
1. Veri f y t he vehi cl e owne r ' s ori gi nal concer n by
oper at i ng t he wi ndshi
t o dupl i cat e t he condl
I nspect t o det ermi ne
ield wi pe r / wa she r sy st e m
i t i o n .
2. if one of t he f ol l owi ng
mechani cal or el ect ri cal concer ns appl y:

Wi n d s h i e l d wi p e r b l a d e Op e n f use : I n st r ume n t f use
mi s s i n g or d a ma g e d . pa n e l No. 2, 3 0 A f u s e .

Bi n d i n g wi n d s h i e l d wi p e r Da ma g e d wi n d s h i e l d wi pe r
pi v o t a r m. mo t o r .
Bi n d i n g wi n d s h i e l d wi p e r # Da ma g e d wi n d s h i e l d
mo un t i n g a r m a n d pi v o t wa s h e r pump.
sha f t . # Ope n c o n n e c t o r s .

E mpt y wi n d s h i e l d wa s h e r I n o pe r a t i v e mul t i - f un c t i o n
r e se r v o i r . s wi t c h .
m
Ki n ke d o r b r o ke n wi n d s h i e l d Th e r ma l b r e a ke r i n t e r n a l t o
wa s h e r h o s e s . t h e wi p e r mo t o r .
3. If t he concern(s) remains af t er t he i nspect i on,
det ermi ne t he sy mpt om(s) and go t o t he
Sy mpt om Chart .
To perf orm el ect ri cal pinpoint t e st s, use Rot unda
Di gi tal Vol t -Ohmmet er 014- 00407 or equi valent .
1995 To wn Car, Cr o wn Vi c t o r i a , Gr a n d Ma r qui s Jul y 1994
01- 16- 6 Wi per a n d Wa she r S y s t e ms 01- 16- 6
WIPERS AND WASHER SYSTEMS
Windshield Washer Inoperative Low fluid level.
Split, loose, pinched or kinked
windshield washer hose.
Open in wiring or multi-function
swi t ch.
Windshield washer pump.
Windshield wiper control module.
o F I L L as required.
INSPECT washer hose. SERVICE
as required.
Windshield Wipers
Inoperati veAll Control Switch
Positions
Wipers Inoperative at High Speed
Open fuse.
Damaged windshield wiper motor.
Multi-function swi t ch.
Bent or damaged wi ndshi eld wiper
mounting arm and pivot shaft.
Open wire or connector.
Windshield Wipers Inoperative At
High Speed
Windshield wiper motor.
Windshield wiper swi t ch.
Damaged circuitry.
Windshield Wipers Inoperative At
Low Speed
Windshield wiper motor.
Multi-function swi t ch.
Damaged circuitry.
Windshield Wipers Inoperative at
Interval Setting
Windshield wiper mot or.
Open in wi ri ng.
Poor ground to windshield wiper
control module.
GOt o Pinpoint Test D.
Wipers Will Not Park at Proper
Position
Worn or damaged windshield wiper
mot or, multi-function swi tch wiring
or windshield wiper control
module.
Windshield Wipers Continue to Run
When Switch is Turned Off
Damaged windshield wiper motor.
Damaged windshield wiper control
module.
Damaged multi-function swi t ch.
Pi npoi nt Tests
PINPOINT TEST A: WINDSHIELD WASHER INOPERATIVE
A1 WINDSHIELD WASHERS INOPERATIVE
Yes
No
FILL windshield washer
reservoir. RESTORE
GO to A2.
Check fluid level of windshield washer reservoir.
Is wi ndshi el d washer reservoi r e mpt y ?
Yes
No
FILL windshield washer
reservoir. RESTORE
GO to A2.
A2 TURN ON WASHER SWITCH
Yes
No
GO to A3.
GO to A6.
With ignition swi tch in RUN posi ti on, check
operation of windshield washer pump.
Does wi ndshi el d washer pump run?
Yes
No
GO to A3.
GO to A6.
A3 INSPECT WINDSHIELD WASHER NOZZLE JET FOR
BLOCKAGE
Yes
No
CLEAN or REPLACE
windshield washer nozzle
j et. RESTORE vehicle.
RETEST system.
GO to A4.
Inspect windshield washer nozzle j et for blockage,
e Are wi ndshi el d washer nozzle j et bl oc ke d?
Yes
No
CLEAN or REPLACE
windshield washer nozzle
j et. RESTORE vehicle.
RETEST system.
GO to A4.
PINPOINT TEST A: WINDSHIELD WASHER INOPERATIVE (Cont i nued)
TEST STEP RESULT ACTION TO T A KE
A4 I NSPECT HOSE, FI LTER, CHECK VALVE FOR
BL OCKAGE OR KINKS
Ye s
No >
CL EAN, SERVI CE o r
REPLACE a s n e c e s s a r y .
RESTORE v e h i c l e .
RETEST s y s t e m.
GO t o A S.
Inspect hose for blockage or kinks.
Are any b l o c k a g e s or ki nks present ?
Ye s
No >
CL EAN, SERVI CE o r
REPLACE a s n e c e s s a r y .
RETEST s y s t e m.
GO t o A S.
A5 I NSPECT WI NDSHI ELD WASHER PUMP
I NLET/ OUTLET FOR BLOCKAGE
Ye s \
No
REMOVE wi n d s h i e l d
wa s h e r pump f r o m
wi n d shi e l d wa s h e r
r e se r v o i r a n d c l e a n .
RETEST s y s t e m.
REPLACE wi n d s hi e l d
wa s h e r pump. RESTORE
v e hi c l e . RETEST s y s t e m.
I n spe c t wi n d s hi e l d wa s h e r pump i n l e t / o u t l e t f o r
b l o c ka ge .
Is wi ndshi el d wa s h e r pump I n l e t / o u t l e t b l o c k e d
o r o b s t r u c t e d ?
Ye s \
No
REMOVE wi n d s h i e l d
wa s h e r pump f r o m
wi n d shi e l d wa s h e r
r e se r v o i r a n d c l e a n .
RETEST s y s t e m.
A6 CHECK FOR VOLTAGE AT WI NDSHI ELD WASHER
PUMP
Ye s
No
GO t o A 7 .
GO t o A 8.
Using a voltmeter, actuate the windshield washer
switch and check for voltage at windshield washer
pump.
Is battery v o l t a g e present?
Ye s
No
GO t o A 7 .
GO t o A 8.
A7 CHECK WI NDSHI ELD WASHER PUMP GROUND
Ye s S>
No
SERVI CE Ci r c ui t 57 (BK)
f o r o pe n c i r c ui t .
RESTORE v e hi c l e .
RETEST s y s t e m.
Usi ng an o hmme t e r c o n n e c t e d t o a kn o wn go o d
gr o un d , c h e c k gr o un d at wi n d s hi e l d wa s h e r pump
c o n n e c t o r wi t h t he o t he r t e st l e a d .
Is c onne c t or pr oper l y gr ounded wi t h resi st ance
of 5 ohms o r l e s s ?
Ye s S>
No
SERVI CE Ci r c ui t 57 (BK)
RETEST s y s t e m.
A8 TURN ON WI NDSHI ELD WI PERS
Ye s
No
G Ot o A 9.
GO t o Pi npoi nt Test B.
Che c k o pe r a t i o n of wi n d shi e l d wi p e r s .
Do wi pers oper at e?
Ye s
No
G Ot o A 9.
A9 CHECK MULTI -FUNCTI ON SWI TCH RESI STANCE AT
WI PER CONTROL MODULE
Ye s
No
G Ot o A 1 1 .
GOto A10.
Unpl ug c o n n e c t o r f r o m wi pe r c o n t r o l mo d ul e .
De pr e s s wi n d shi e l d wa s h e r s wi t c h on e nd of t he
mul t i - f un c t i o n s wi t c h .
Usi ng an o hmme t e r , c h e c k c o n t i n ui t y be t we e n
Ci r c ui t s 993 ( BR/ W) and 590 ( DB/ W) .
Is t here c o n t i n u i t y ?
Ye s
No
G Ot o A 1 1 .
GOto A10.
A10 CHECK MULTI -FUNCTI ON SWI TCH
Ye s
No
SERVI CE o pe n c i r c ui t
be t we e n mul t i - f unc t i on
swi t c h and wi pe r c o n t r o l
mo d ul e . RESTORE
REPLACE mul t i -f unc t i on
s wi t c h . RESTORE
Unpl ug wi pe r s wi t c h c o n n e c t o r .
De pr e s s mul t i - f un c t i o n s wi t c h .
Ch e c k f o r c o n t i n ui t y be t we e n t e r mi n a l s C 1 - 4 and
C 1 - 6 .
I s t h e r e cont i nui t y?
Ye s
No
be t we e n mul t i - f unc t i on
swi t c h and wi pe r c o n t r o l
mo d ul e . RESTORE
REPLACE mul t i -f unc t i on
A 1 1 CHECK WASHER PUMP CIRCUIT
Ye s
No
REPLACE wi pe r c o n t r o l
mo d ul e . RESTORE
SERVI CE Ci r c ui t 941
( BK / W) f or o pe n c i r c ui t .
RETEST s y s t e m.
Ch e c k c o n t i n ui t y of Ci r c ui t 9 4 1 ( BK/ W) f r o m wi pe r
c o n t r o l mo d ul e t o wi n d shi e l d wa s h e r pump.
is th@re cont i nui t y?
Ye s
No
REPLACE wi pe r c o n t r o l
mo d ul e . RESTORE
( BK / W) f or o pe n c i r c ui t .
RETEST s y s t e m.
01- 16- 8 Wi pe r a n d Wa s h e r S y s t e ms
01- 16- 8
PINPOINT TEST B: WINDSHIELD WIPERS INOPERATIVEALL CONTROL SWITCH POSITIONS
B1 CHECK FOR SUPPLY VOLTAGE AT WINDSHIELD
WIPER MOTOR
Yes
No
RECONNECT wiper
control module. GO to B2.
CHECK for:
Open fuse in fuse
j unction panel.
Open connector.
Open wire Circuit 65
(DG).
Poor ground
connection. SERVICE
as required. RESTORE
vehi cle. RETEST
system.
T u r n i g n i t i o n s w i t c h t o R U N .
T u r n m u l t i - f u n c t i o n s w i t c h t o HI.
U n p l u g w i n d s h i e l d w i p e r m o t o r .
C h e c k for b a t t e r y v o l t a g e a t C i r c u i t 6 5 (DG).
Is battery voltage present ?
Yes
No
RECONNECT wiper
CHECK for:
Open fuse in fuse
j unction panel.
Open connector.
Open wire Circuit 65
(DG).
Poor ground
connection. SERVICE
vehi cle. RETEST
system.
B2 CHECK FOR BATTERY VOLTAGE AT THE WINDSHIELD
WIPER CONTROL MODULE
Yes >
No
RECONNECT wiper
SERVICE open in power
feed to windshield wiper
control module. CHECK
for:
Open wire in Circuit 65
(DG).
Open unseated
connector. SERVICE as
required. RESTORE
vehicle. RETEST
system.
U n p l u g c o n n e c t o r o f w i p e r c o n t r o l m o d u l e .
C h e c k f o r b a t t e r y v o l t a g e a t C i r c u i t 6 5 (DG) P i n 2 o f
connector.
Yes >
No
RECONNECT wiper
SERVICE open in power
feed to windshield wiper
control module. CHECK
for:
Open wire in Circuit 65
(DG).
Open unseated
connector. SERVICE as
required. RESTORE
vehicle. RETEST
system.
B3 CHECK FOR BATTERY VOLTAGE TO WINDSHIELD
WIPER MOTOR WINDINGS
Yes
No
GO to B7.
GO to B4.
T u r n i g n i t i o n s w i t c h t o R U N .
T u r n m u l t i - f u n c t i o n s w i t c h t o HI.
D i s c o n n e c t c o n n e c t o r f r o m w i n d s h i e l d w i p e r m o t o r ,
w i n d s h i e l d w a s h e r p u m p .
C h e c k for b a t t e r y v o l t a g e b e t w e e n C i r c u i t s 6 1
( Y / R ) a n d 5 8 ( W) .
Yes
No
GO to B7.
GO to B4.
B4 CHECK FOR BATTERY VOLTAGE AT WINDSHIELD
WIPER CONTROL MODULE CONNECTOR
Y e s >
No L >
CHECK for:
Open wire Circuits 58
(W) or 6 1 (Y/ R).
Open connector.
Unseated connector.
GO to B5.
C h e c k f o r b a t t e r y v o l t a g e b e t w e e n P i n s 12 a n d 14
( C i r c u i t s 6 1 ( Y / R) a n d 5 8 (W)) of w i n d s h i e l d w i p e r
control module connector with multi-function swi tch
s e t a t HI.
Y e s >
No L >
CHECK for:
Open wire Circuits 58
(W) or 6 1 (Y/ R).
Open connector.
Unseated connector.
GO to B5.
B5 CHECK WIRING BETWEEN WINDSHIELD WIPER
CONTROL MODULE AND WINDSHIELD WIPER SWITCH
Yes
No
REPLACE windshield
wiper control module.
RESTORE vehicle.
RETEST system.
GO to B6.
Disconnect connector from windshield wiper control
module.
Measure resi stance between Circuits 993 (BR/ W)
and 589 (0) with multi-function swi tch .
Is resi st ance less t han one ohm?
Yes
No
REPLACE windshield
RESTORE vehicle.
RETEST system.
GO to B6.
PINPOINT TEST B: WINDSHIELD WIPERS INOPERATIVEALL CONTROL SWITCH POSITIONS (Cont i nued)
B6 CHECK WINDSHIELD WIPER SWITCH CONTINUITY
Yes
No >
CHECK for open wire
between multi-function
switch and windshield
RESTORE vehi cle.
RETEST system.
CHECK for damaged
multi-function swi t ch.
RESTORE vehicle.
RETEST system.
Disconnect harness from the multi-function swi tch .
Check continuity between terminals C2-4 and C2-1
with multi-function swi tch at HI.
Is resi st ance less t han f i ve ohms?
Yes
No >
CHECK for open wire
RESTORE vehi cle.
RETEST system.
CHECK for damaged
RESTORE vehicle.
RETEST system.
B7 PERFORM WINDSHIELD WIPER MOTOR CURRENT
DRAW TEST
Yes
No
CHECK windshield wiper
mounting arm and pivot
shaft. SERVICE as
required. RESTORE
REPLACE windshield
wiper motor. RESTORE
Perform windshield wi per motor current draw as
outlined.
Is cur r ent draw OK?
Yes
No
shaft. SERVICE as
required. RESTORE
REPLACE windshield
PINPOINT TEST C: WINDSHIELD WIPERS INOPERATIVE AT HIGH SPEED
C1 CHECK FOR BATTERY VOLTAGE TO WINDSHIELD
WIPER MOTOR WINDINGS
Yes
No
GO to C5.
GOt o C2.
Turn multi-function swi t ch to LO.
Disconnect connector from windshield wiper motor.
Check for battery voltage between Circuits 61
(Y/ R) and 56 (DB/O).
Is vol t age pr esent ?
Yes
No
GO to C5.
GOt o C2.
C2 CHECK FOR BATTERY VOLTAGE AT WINDSHIELD
WIPER CONTROL MODULE CONNECTOR
Yes
No
CHECK for:
Open in Circuits 56
(DB/O) o r 61 (Y/ R).
o Open connector.
Unseated connector.
RESTORE vehicle.
RETEST system.
GO to C3.
Check for battery voltage between Pins 12 and 8
(Circuits 61 (Y/R) and 56 (DB/O)) of windshield
wi per control module connector with multi-function
swi tch set to LO.
w Is vol t age pr esent ?
Yes
No
CHECK for:
Open in Circuits 56
(DB/O) o r 61 (Y/ R).
o Open connector.
Unseated connector.
RESTORE vehicle.
RETEST system.
GO to C3.
C3 CHECK WIRING BETWEEN WINDSHIELD WIPER
CONTROL MODULE AND MULTI-FUNCTION SWITCH
Yes >
No
REPLACE windshield
RESTORE vehicle.
RETEST system.
GO to C4.
module.
Measure resi stance between Circuits 993 (BR/W)
and 589 ( 0) with multi-function swi tch set to LO.
Is resi st ance 4. 08k ohms?
Yes >
No
REPLACE windshield
RESTORE vehicle.
RETEST system.
GO to C4.
1995 To wn Car , Cr o wn Vi c t o r i a , Gr a n d Ma r q ui s Jul y 1994
PINPOINT TEST C: WINDSHIELD WIPERS INOPERATIVE AT HIGH SPEED (Cont i nued)
C4 CHECK CONTROL LINE SIGNAL AT MULTI-FUNCTION
SWITCH
Yes
No
SERVICE open wire
swi tch and windshield
REPLACE damaged
multi-function swi tch.
RESTORE vehi cle.
RETEST system.
Disconnect harness from the multi-function swi t ch.
Check continuity between terminals for C2-4 and
C2-1 with multi-function swi tch set to LO.
Is resi st ance 4. 08k ohms?
Yes
No
SERVICE open wire
swi tch and windshield
REPLACE damaged
multi-function swi tch.
RESTORE vehi cle.
RETEST system.
C5 PERFORM WINDSHIELD WIPER MOTOR CURRENT
DRAW TEST
Yes
No >
shaf t . SERVICE as
required. RESTORE
SERVICE wiper motor as
required. RESTORE
Perform windshield wiper motor current draw t est as
outlined.
Is current draw OK?
Yes
No >
shaf t . SERVICE as
required. RESTORE
SERVICE wiper motor as
required. RESTORE
PINPOINT TEST D: WINDSHIELD WIPERS INOPERATIVE AT INTERVAL SETTING
D1 CHECK OPERATION
Yes
No
GO t o D2 .
GO t o C1.
Does l ow speed wo r k? Yes
No
GO t o D2 .
GO t o C1.
D2 CHECK MODE SELECT INPUT SIGNAL
Yes
No
GO to D4.
GO to D3.
module.
Measure resi stance between Circuits 993 (BR / W)
and 589 (O) with multi-function swi tch set to INT.
Is resi st ance bet ween 10.5k and 12.0k ohms?
Yes
No
GO to D4.
GO to D3.
D3 CHECK MODE SELECT SIGNAL AT MULTI-FUNCTION
SWITCH
Yes
No
CHECK for open wire
RESTORE vehicle.
RETEST system.
REPLACE multi-function
swi tch. SERVICE as
required. RESTORE
Disconnect harness from the multi-function swi t ch.
Measure resi stance between terminals for C2-4 and
C2-1 with multi-function swi tch set t o INT.
Is resi st ance bet ween 10.5k and 12.0k ohms?
Yes
No
CHECK for open wire
RESTORE vehicle.
RETEST system.
swi tch. SERVICE as
required. RESTORE
D4 CHECK INTERVAL SELECT INPUT SIGNAL
Yes
No
REPLACE windshield
RESTORE vehicle.
RETEST system.
GO t o D5.
Rotate interval control on the multi-function swi tch
from min to max.
Measure resistance between Circuits 590 (DB/W)
and 993 (BR/W).
Is resi st ance 3. 3k-104k ohms?
Yes
No
REPLACE windshield
RESTORE vehicle.
RETEST system.
GO t o D5.
J J " 3 - : "Hp-)[ ' enC ^Vasher S y s t e ms
DIAGNOSIS A N D TESTING (Conti nued)
PINPOINT TEST D: WINDSHIELD WIPERS INOPERATIVE AT INTERVAL SETTING (Conti nued)
D5 CHECK INTERVAL SELECT INPUT SIGNAL AT
MULTI-FUNCTION SWITCH
Yes
No
CHECK for open wi res
between the
multi-function swi t ch and
the windshield wi per
control module. SERVICE
swi t ch. RESTORE
Disconnect harness from multi-function swi t ch.
Rotate interval control on the multi-function swi tch
from min to max.
Measure resistance between terminals C2-6 and
C2-4.
Is resi st ance 3. 3k-104k ohms?
Yes
No
CHECK for open wi res
between the
multi-function swi t ch and
the windshield wi per
control module. SERVICE
swi t ch. RESTORE
PINPOINT TEST E: WINDSHIELD WIPERS WILL NOT PARK AT PROPER POSITION
E1 CHECK FOR WIRE CONTINUITY
Yes
No
GOt o E2.
SERVI CE open in Circuit
57 (BK). RESTORE
Disconnect wiper motor connector. Check ground at
ci rcui t 57 (BK).
Is ground OK?
Yes
No
GOt o E2.
SERVI CE open in Circuit
57 (BK). RESTORE
E2 CHECK FOR POWER AT WIPER MOTOR
Yes
No
GOt o E3.
SERVICE open ci rcui ts.
RESTORE vehi cle.
RETEST system.
Place ignition swi tch at RUN and multi-function
switch at OFF. Check for battery voltage between
Circuits 65 (DG) and 57 (BK) at the motor connector.
Is battery vol t age pr esent ?
Yes
No
GOt o E3.
RESTORE vehi cle.
RETEST system.
E3 CHECK MOTOR CIRCUIT CONTINUITY THROUGH
WINDSHIELD CONTROL MODULE
Yes
No
GO to E5.
GO to E4.
With wiper switch at OFF, check for continuity
between Circuits 28 (BK/ PK) and 56 (DB / 0) , and
between Circuits 61 (Y/ R) and 63 (R).
Is cont i nui t y OK?
Yes
No
GO to E5.
GO to E4.
E4 CHECK CIRCUITS TO WIPER CONTROL MODULE
Yes
No
REPLACE wiper control
module. RESTORE
RESTORE vehicle.
RETEST system.
Disconnect wiper control module connector.
Check continuity of Circuits 28 (BK/PK), 56 (DB/O),
61 (Y/ R), and 63 (R) from the wiper motor to the
Are all ci rcui ts cont i nuous?
Yes
No
module. RESTORE
RESTORE vehicle.
RETEST system.
E5 CHECK WIPER MOUNTING ARM / PIVOT SHAFT
Yes
No
REPLACE windshield
RESTORE vehicle.
RETEST system.
Check that windshield wiper motor mounting arm,
pivot shaft, and linkage is not bent, cracked, or
mis-positioned.
Is a r m/ pi v o t sha f t / l i n ka ge OK?
Yes
No
REPLACE windshield
RESTORE vehicle.
RETEST system.
PINPOINT TEST F: WINDSHIELD WIPERS CONTINUE TO RUN WHEN SWITCH IS TURNED OFF
F1 CHECK CONNECTIONS
Yes
No
GO t o F2 .
RETEST system.
Check that windshield wiper motor and wiper control
module connectors are fully seat ed.
Are connect i ons OK?
Yes
No
GO t o F2 .
RETEST system.
PINPOINT TEST F: WINDSHIELD WIPERS CONTINUE TO RUN WHEN SWITCH IS TURNED OFF (Cont i nued)
F2 CHECK MOTOR CIRCUIT CONTINUITY THROUGH
WINDSHIELD WIPER CONTROL MODULE
Yes
No
REPLACE windshield
GOt o F3.
Disconnect wiper motor connector.
With wiper swi t ch at OFF, check continuity between
Circuits 28 (BK/PK) and 56 (DB/O) and between
Ci rcui t s61 (Y/ R) and 63 (R).
Is c ont i nui t y OK?
Yes
No
REPLACE windshield
GOt o F3.
F3 CHECK CIRCUITS TO WIPER CONTROL MODULE
Yes
No >
GO to F4.
RESTORE vehi cle.
RETEST system.
Disconnect wiper control module connector.
Check continuity of Circuits 28 (BK/PK) and 56
(DB/ O), 61 (Y/ R), and 63 (R) from the wiper motor
to the wi per control module.
Are all ci r cui t s cont i nuous?
Yes
No >
GO to F4.
RESTORE vehi cle.
RETEST system.
F4 CHECK CIRCUITS TO MULTI-FUNCTION SWITCH
Yes
No
module. RESTORE
GO to F5.
With wiper swi t ch at OFF, measure resi stance
between Circuits 589 (0), and 993 (BR/W) at wiper
control module.
Is r esi st ance appr oxi mat el y 45k and 50k ohms?
Yes
No
module. RESTORE
GO to F5.
F5 CHECK MULTI-FUNCTION SWITCH
Yes
No
SERVICE open in Circuits
993(BR/ W) and/or 589
(0). RESTORE vehicle.
RETEST system.
REPLACE wiper swi t ch.
RESTORE vehicle.
RETEST system.
Disconnect multi-function swi tch connector.
With wiper swi tch at OFF, measure resi stance
between terminals C2-1 and C2-4.
Is resi st ance bet ween 45k and 50k ohms?
Yes
No
993(BR/ W) and/or 589
(0). RESTORE vehicle.
RETEST system.
REPLACE wiper swi t ch.
RESTORE vehicle.
RETEST system.
Wi n d s h i e l d Wi p e r S w i t c h T e s t
Refer t o the fol l owi ng illustration and t est t o resol ve
concerns wi t h t he wi per and washer swi t ch ci rcui ts.
Testing shoul d be done wi th an ohmmeter such as
Rotunda Digital Vol t-Ohmmeter 014- 00407 or
equivalent.
K19508-B
NOTE: Terminals 1 4 and 6 are the only ones used for
thi s t est .
WINDSHIELD WIPER SWITCH CONTINUITY TEST
. S w i t c h P o s i t i o n Re s i s t a n c e by P i n N u mb e r
I n t e r v a l Wi p e r / Wa s h e r
S w i t c h i n g :
Wa s h ON Cl o s e d pi n 4 t o pi n 6
Wi p e r OFF Re s i s t a n c e pi n 4 t o pi n 6,
103. 3 K o h ms
Wa s h OFF Re s i s t a n c e pi n 4 t o pi n 1, 47 . 6
K o h ms
Wi p e r I n t e r v a l a t MA X. Re s i s t a n c e pi n 4 t o pi n 1,
11. 33 K o h ms
De l a y ( Cl o s e s t P o s i t i o n t o Re s i s t a n c e pi n 4 t o pi n 6 i i n e a r
OFF) t o MI N. De l a y ( Cl o s e s t d e c r e a s i n g f r o m 103. 3 K ohr r . s
P o s i t i o n t o L O) t o 3. 3 K o h ms
Wi p e r L O Re s i s t a n c e pi n 4 t o pi n 6, 3. 3
K o h ms
Wa s h OFF Re s i s t a n c e pi n 4 t o pi n 1, 4. 08
K o h ms
Wi p e r HI Re s i s t a n c e pi n 4 t o pi n 6, 3. 3
K o h ms
Wa s h OFF Cl o s e d pi n 4 t o pi n 1
01- 16- 13 Wi per and Washer Sy s t ems 1-16-13
Cur r ent Dr aw
Wi ndshi el d Washer Pump
Connect l eads of t he tester, such as Rotunda
Al ternator, Regulator, Bat t ery and St art er Tester
010- 00725, or Rotunda Digital Vol t-Ohmmeter
014- 00407 or equivalent. Current dr aw shoul d not
exceed four amps, or i ndi cate less than t wo amps
while t he wi ndshi el d washer pump ( 17664) is pumping
fluid.
STARTING AND
CHARGING TESTER
078-00005
WINDSHIELD
WASHER PUMP
17664 BATTERY
K6530-E
Wi n d s h i e l d Wi per Mo t e r
CAUTI ON: Do not handl e any wi ndshi el d wi per
mot or ( 17508) abusi vel y wh e n di agnosi ng wi per
oper at i ons, as i t wi l l d a ma g e t he magnet s and
mak e t he wi ndshi el d wi per mot or i noper at i ve.
Rough handl i ng of new r epl acement wi ndshi el d
wi per mot or s may al so damage t he magnet s .
To test the wi ndshi el d wi per motor on t he vehi cl e,
di sconnect t he wi ndshi el d wi per mounting arm and
pi vot shaft ( 17566) f rom the wi ndshi el d wi per mot or
and di sconnect the el ectri cal plug. Connect the green
lead f rom t he t est equipment, such as Rotunda
Al ternator, Regulator, Bat t er y and St art er Tester
010- 00725 or equivalent, t o t he bat t ery posi ti ve ( + )
post. Connect t he posi ti ve (red) l ead f rom the t est er t o
t he common brush termi nal . Connect a ground fi rst t o
t he l ow-speed connecti on and then t o t he hi gh-speed
connecti on at t he connector plug as shown. In ei ther
case, t he current draw shoul d not exceed 3. 5
amperes.
ALTERNATOR, REGULATOR,
BATTERY AND STARTER
TESTER (ARBST) 010-00725
+FEED TO
COMMON
TERMINAL
FOR TEST
GROUND
HI OR LO
TO RUN
GREEN
BATTERY
61 (COM)
28 (PR) J Ui
57(G) \ % g | J
56 (LO)
K12569-D
Wi n d s h i e l d Wi p e r
Mount i ng Ar m and Pi vot Shaf t
1. NOTE: Windshield wi per mounting arms and pivot
shafts are not separatel y servi ceabl e. Windshield
wiper mounting arm and pivot shafts ( 17566)
must be repl aced as an assembl y (l ess
windshield wi per motor ( 17508) ) .
Disconnect bat t ery ground cabl e ( 14301) .
01- 16- 14
*r _ ! I B
Wiper a n d Washer S y s t e ms 01- 16- 14
2. Remove wi ndshi el d wi per arms as outlined.
3. Remove cowl vent screens ( 018A17) . Refer to
Secti on 01- 02.
4. Di sconnect wi ndow washer hose ( 17408) f rom
windshield washer nozzle j et and bracket
( 17603) .
6. Remove wi ndshi el d wi per mounting arm and pivot
shaft retaining bol ts. Lift wi ndshi el d wi per
mounting arm and pivot shaft upward.
Wi n d shi e l d Wi pe r Mo un t i n g Ar m a n d Pi vot Sha f t
6. Di sconnect wi ndshi el d wi per motor output arm.
7. Remove wi ndshi el d wi per motor.
8. To install, transfer windshield wi per motor t o new
wi ndshi el d wi per mounting arm and pivot shaft
and reverse Removal procedure.
K14560-C
Pa r t
1 17566 Windshield Wiper Mounting Arm and Pivot Shaft
2 N606678-S55 Bolt
3 17408 Window Washer Hose
4 N804795-S36 Nut (2 Req'd)
5 N623332-S100 U-Nut (6 Req'd)
A

Tighten to 10-14 N-m (88-123 Lb-ln)
01- 16- 15 Wf pe r a n d Wa s h e r S y s t e ms 01- 16- 15
z_ i : ~
P i v o t A r m
Re mo v a l
1 NOTE: To prevent gl ass and/ or paint damage, do
not pry wi ndshi el d wi per arm f rom wi ndshi el d
wi per mounting ar m and pivot shaft wi t h metal or
sharp t ool .
Raise the wi ndshi el d wi per bl ade end of t he
wi ndshi el d wi per arm off of t he wi ndshi el d.
K16548-C
Pa r t
I t e m Nu mb e r
1 17528
2 17526(RH)
17527(LH)
3 17566
4 16A942
5 18A16(RH)
18A17(LH)
Windshield Wiper Blade
Assy
Windshield Wiper Pivot Arm
Windshield Wiper Mounting
Arm and Pivot Shaft
Hood to Cowl Seal Assy
Cowl Vent Screen
Move the slide l atch away f rom the wi ndshi el d
wi per mounting arm and pivot shaft. This will
unlock t he wi ndshi el d wi per pivot arm ( 17526)
f rom t he wi ndshi el d wi per mounting arm and pivot
shaft.
Hold t he wi ndshi el d wi per bl ade end of the
wi ndshi el d wi per pivot arm off of t he gl ass at t he
same ti me. Pull windshield wi per pivot arm off of
the wi ndshi el d wi per mounting arm and pivot shaft
wi thout t he ai d of any tool s.
WINDSHIELD
WIPER PIVOT
ARM
17526 RH
17527 LH
KEY
KEYWAY
1.
WINDSHIELD
WIPER
MOUNTING
PIVOT
SHAFT
17566
K14976-C
To install, line up key on windshield wi per pivot
arm wi t h keyway slot in wi ndshi el d wi per
mounting arm and pivot shaft.
2. Push wi ndshi el d wi per pivot arm onto windshield
wi per mounting ar m and pivot shaft.
3. Hold t he wi ndshi el d wi per pivot arm head onto the
windshield wi per mounting arm and pivot shaft
while raising the windshield wi per blade end of
the wi ndshi el d wi per pivot arm.
4. Push t he slide l atch into the l ock under the
windshield wi per mounting arm and pivot shaft.
Lower the wi ndshi el d wi per bl ade ( 17528) t o t he
windshield gl ass ( 03100) .
Wi p e r Bl ade
1. Release wi ndshi el d wi per bl ade f rom wi ndshi el d
wi per pivot arm.
2. Push windshield wi per bl ade away f rom
windshield wi per pivot arm. Remove windshield
wi per bl ade.
3. To install, align windshield wi per bl ade t o
windshield wi per pivot arm and snap into pl ace.
WINDSHIELD WIPER
BLADE 17528
WINDSHIELD WIPER
PIVOT ARM
17526
K21015-A
01- 16- 16 Wi per and Washer Sy s t ems 01- 16- 16
REMOVAL A N D INSTALLATION (Conti nued)
Wiper Mot or
1. CAUTI ON: The internal permanent magnets
used in the windshield wiper mot or are a
ceramic (glass-like) material. Care must be
exercised In handling the windshield wiper
motor t o avoid damaging the magnets. The
windshield wiper motor must not be struck or
tapped with a hammer or other object.
Remove wi ndshi el d wi per mounting arm and pi vot
shaft as outlined.
2. Unsnap and remove wi ndshi el d wi per motor and
linkage cover ( 17C569) .
3. Remove wi ndshi el d wi per mounting ar m and pivot
shaft retaining clip f r om wi ndshi el d wi per motor
output arm ( 17A436) by lifting l ocki ng t ab and
pulling clip away f rom pi n.
ADAPTER AND NOTE: HAND PRESS
CONNECTOR ARM TO INSTALL
CLIP K16873-C
4. Remove wi ndshi el d wi per motor retaining scr ews
and remove wi ndshi el d wi per motor.
Co wl Vent Sc r e e n s
K14970-E
Pa r t
1 N 6 1 0 9 5 8 - S 5 5 S c r e w ( 1 R e q ' d )
2 N 6 0 6 6 7 6 - S 5 5
Screw (1 Req'd)
3 018A14(RH) C o w l Ve n t S c r e e n
018A15(LH)
4 N 8 0 5 7 8 8 - S 1 0 0 S c r e w
5 N 8 0 5 8 8 6 - S C l i p (4 R e q ' d )
6 0 2 1 A 3 6 C o w l T o p E x t e n s i o n
Wi n d shi e l d Wi per Mo un t i n g Ar m a n d Pi vot Shaf t
K14560-C
Par t
i t e m Number De sc r i pt i o n
1 021A36 Cowl Top Extension
2 N606678-S55 Bolt (6 Req'd)
3 17408 Window Washer Hose
4 N804795-S36 Nut (2 Req'd)
5 N623332-S100 U-Nut (6 Req'd)
A Tighten to 10-14 N-m (88-123 Lb-ln)
Wi n d s h i e l d Wi p e r C o n t r o l Mo d u l e
2. Remove the steeri ng column shroud cover
retaining scr ews.
3. Separat e the t wo hal ves and di sconnect t he
multiple connector at the rear of t he multi-function
swi t ch ( 13K359) .
4. Di sconnect the multiple connector at main wiring
l oom. Remove the windshield wi per control
module f rom the bracket .
01- 16- 19 Wi per a n d Wa s h e r Sy s t ems 0 1 - 1 6 - 1 9
Town Car
FRONT OF
.VEHICLE
Z7 1 Z7 WINDSHIELD WIPER
CONTROL MODULE
ANTI-LOCK
BRAKE CONTROL '
MODULE 2B373
SAFETY BELT ^
WARNING CHIME
10D840
K14974-D
WINDSHIELD WIPER
CONTROL MODULE 17C476
K14975-D
Mu l t i - F u n c t i o n S w i t c h
2. Remove the steeri ng column shroud cover
retaining scr ews and separat e the t wo hal ves.
3. Remove the t wo multi-function swi t ch retaining
scr ews. Di sconnect the multiple connector at the
rear of t he multi-function swi t ch ( 13K359) .
4. To install, reverse Removal procedure. Check the
operati on of the swi t ch.
FRONT OF
VEHICLE
K16531-D
Pa r t
1 3511 Steering Column Tube
Flange
2

To Turn Signal Switch
4

To Headlamp Dimmer and
Washer Switch
6 3F723 Steering Actuator Housing
Wa s h e r P u m p a n d S e a l A s s e m b l y ,
Wi n d s h i e l d
Remov al
1. Remove windshield washer reservoir ( 17618)
assembl y as outlined.
2. Using a small-blade screwdri ver, pry out
windshield washer pump ( 17664) , being careful
not t o damage pl asti c housing.
3. Remove one-piece seal /fi l ter and inspect for
damage or debri s.
1. Insert seal .
2. Lubri cate inside diameter of seal wi th soapy
solution and insert windshield washer pump into
cavi ty until it is firmly seat ed in the seal .
3. CAUTI ON: Do not oper at e wi ndshi el d washer
pump unt i l f l ui d i s added t o wi ndshi el d
washer r eser voi r .
Connect el ectri cal pl ugs and wi ndow washer
hoses ( 17408) and install windshield washer
reservoir as outlined.
01- 16- 20
5.
Fill wi ndshi el d washer reservoi r sl owl y
(ot herwi se air will be t rapped in wi ndshi el d
washer reservoi r causi ng it t o overf l ow) and
operat e wi ndshi el d washer pump.
Check for l eaks.
Wa s h e r N o z z l e J e t a n d B r a c k e t
1. Remove wi ndshi el d wi per pi vot arm ( 17526) as
outlined.
WINDSHIELD
WIPER PIVOT
ARM
17526 RH
17527 LH
KEY
KEYWAY
WINDSHIELD
WIPER
MOUNTING
PIVOT
SHAFT
17566
K14976-C
2. Remove cowl vent screens ( 018A17) . Refer to
Secti on 01- 02.
3. Remove wi ndshi el d washer nozzle j et and
bracket retaining scr ew and remove wi ndshi el d
washer nozzle j et and bracket ( 17603) .
Wa s h e r P u mp a n d Re s e r v o i r
1. NOTE: The wi ndshi el d washer reservoi r ( 17618)
and cover assembl y, wi ndshi el d washer pump
retaining ring, seal and wi ndshi el d washer pump
impeller are servi ced separatel y.
NOTE: Engine air cl eaner removal may aid in
wi ndshi el d washer reservoi r removal and
installation.
Remove front fender apron ( 16055) .
Remove wi ndshi el d washer reservoir retaining
bol ts and lift assembl y away f rom front fender
apron.
NOTE: Wi ndshi el d washer reservoi r will drain
wi t h wi ndow washer hose ( 17408) di sconnect ed.
Di sconnect ei ectri cai connector and wi ndow
washer hose.
4. To install, reverse Removal procedure. Refill
wi ndshi el d washer reservoi r and check for l eaks
and proper operati on.
2.
3.
To wn Car
K14985-B
Pa r t
1 N800369-S2 Screw (2 Req'd)
2 16055 Front Fender Apron
3 14290 Headlamp Dash Panel
Junction Wire
4 17664 Windshield Washer Pump
5 Windshield Washer
Reservoir Fluid Level Sensor
(Part of Windshield Washer
Reservoir)
Reservoir
Lb-Ft)
K16536-C
I t e m
Pa r t
1
2 56950-S2
Locators
Bolt (2 Req'd)
01- 16- 2 1 Wi p e r a n d Wa s h e r S y s t e ms 01- 16- 2 1
I t e m
Pa r t
3 17K605 Windshield Washer Hose
Assy
4 17664 Windshield Washer Pump
Reservoir
6

Windshield Washer
Reservoir Fluid Level Sensor
(Part of Windshield Washer
Reservoir)
A

Lb-ln)
ADJUSTMENTS
P a r k P o s i t i o n
1. The wi ndshi el d wi per pi vot a r m ( 17 52 6) and
wi ndshi el d wi per bl ade ( 17 52 8) assembl i es are
posi t i oned usi ng a ke y and a ke y wa y . If
adj ust ment i s requi red, r e move wi ndshi el d wi per
pi vot a r m and wi ndshi el d wi per bl ade assembl y
a s out l i ned.
2. Usi ng a smal l f l at -end scr ewdr i ver , r emove pl ast i c
ke y f r o m wi ndshi el d wi per pi vot a r m.
3. NOTE: Pri or t o i nst al l at i on of wi ndshi el d wi per
pi vot a r ms and wi ndshi el d wi per bl ades, ope r a t e
mul t i -f unct i on swi t c h ( 13K359) t o c y c l e
wi ndshi el d wi per mount i ng a r m and pi vot shaf t
( 17 566) t o t he par k posi t i on.
Loc a t e wi ndshi el d wi per bl ade assembl y t o
i nst al l at i on posi t i on.
3 J *
3
SECTION A
v
-
/
SECTION! B
ARMS RAISED ABOVE STOP FOR A DJ U S T S
SECTION A SECTION B
ARMS IN PARK POSITION AFf ER ADJUSTMENT
K16064-B
Pa r t
I t e m Nu mb e r De sc r i pt i o n !
1 018A16 Cowl Vent Screens
2 17526 Windshield Wiper Pivot Arm
4

Stop Ramps (Part of Cowl
Vent Screens)
A Town CarDri ver Side
5.0-20.0 mm (0.19-0.78 inch)
Passenger Side
2.0-17.0 mm (0.07-0.66 inch)
Crown Vi ctori a, Grand
MarquisDriver Side
5.0-33.0 mm (0.19-1.29 inch)
Passenger Side
2.0-26.0 mm (0.07-1.02 inch)
NOTE: Rai se wi ndshi el d wi per pivot ar m sl i ght l y
t o al l ow l at ch t o sl i de under wi ndshi el d wi per
mount i ng a r m and pi vot shaf t .
Install wi ndshi el d wi per pi vot ami on wi ndshi el d
wi per mount i ng a r m and pi vot shaf t and appl y
d o wn wa r d pr essur e on wi ndshi el d wi per pi vot
a r m. Al l ow l at ch t o sli de under windshield wi per
mount i ng a r m and pi vot shaf t and slide l at ch usi ng
f i nger pressure only.
Lowe r wi ndshi el d wi per pi vot ar m t o ramp st o ps.
1995 To wn Car , Cr o wn Victoria, Grand Marquis July 1994
01- 16- 2 2 Wi pe r a n d Wa s h e r S y s t e ms 01- 16- 2 2
Wi pe r Park Po si t i o n Ad j ust me n t
K2878-F
SPECIFICATIONS
WINDSHIELD WIPER MOTOR AND SWITCH TEST CURRENT LIMITS
Motor Type Motor Cur r ent Draw Test
8
Washer
Depressed Park 3. 5 amperes 2-4 amperes
a Mo t o r ma x i mu m c u r r e n t wh e n o p e r a t e d wi t h o u t l i n ka ge a t t a c h e d .
Co wl To p E x t e n s i o n Re t a i n i n g
Bo l t s
10- 14 88- 12 3
Wi n d s h i e l d Wa s h e r Re s e r v o i r Bo l t 3- 5 2 7 - 44
ROTUNDA EQUIPMENT
010- 007 2 5 Al t e r n a t o r , Re gul a t o r , Ba t t e r y a n d
St a r t e r Te s t e r
01- 17 - 1 Ro o f Pa n e l , S l i d i n g E l e c t r i c 01- 17 - 1
SECTION 01-17 Roof Panel, SlidingElectric
SUBJECT PAGE
E l ect r i c Operation 01=17-1
Manual Operation .01-17-1
El ect ri cal Schemat i c 01-17-3
Inspection and Verification 01-17-3
Air Def l ect or, Roof 01-17-10
Drai n Hose 01-17-13
Glass, Sl i di ng Roof 01-17-8
Headl i ni ng, Sl i di ng Roof .. 01-17-8
SUBJECT PAGE
Li f t er Arms. . . 01-17-9
Mot or 01-17-13
Openi ng Shi el d, Sl i di ng Roof Panel 01-17-12
Roof Panel , Sl i di ng 01-17-10
Seal 01-17-9
Swi t c h. . . . 01-17-13
ADJUSTMENTS
Glass Panel .01-17-13
Mot or Synchroni zat i on (Ti mi ng) 01-17-16
Wat er Drai nage Syst em and Wat er Leak
Cor r ect i ons 01-17-14
WEHiCLE APPLICATION
Town Car
E l e c t r i c O p e r a t i o n
The sliding roof panel ( 502B98) :
Is available as an opti on.
Is el ectri cal l y operat ed.
Can be cl osed manually in case of el ectri cal power
failure.
The el ectri c syst em operat es in t he fol l owi ng manner:
When t he roof sliding panel swi t ch ( 15B691) is
r ocked r ear war d, the roof sliding outer gl ass panel
( 502A82) sl i des into t he st orage space bet ween
the roof tri m panel ( 51968) and the roof panel ,
exposi ng an opening over t he front seat s.
Ma n u a l O p e r a t i o n
To manually cl ose the roof sliding outer gl ass panel
( 502A82) :
When t he roof sliding panel swi t ch is rocked
f or war d wi t h the roof sliding outer gl ass panel fully
back in the st orage space, the roof sliding outer
gl ass panel moves f orward f rom the st orage
posi ti on.
The rear portion of the roof sliding outer gl ass panel
moves upward on t wo lifter arms near the end of t he
f orward t ravel , allowing a weather-ti ght seal when
t he roof sliding outer gl ass panel is cl osed.
When t he roof sliding panel swi t ch is rocked
f orward wi t h the roof sliding outer gl ass panel fully
f or war d, t he rear of the roof sliding outer gl ass
panel " pops up" t o VENT position.
Wi th the roof sliding outer gl ass panel in the VENT
posi ti on, rocki ng the roof sliding panel swi t ch
rearward cl oses the roof sliding outer gl ass panel .
01- 17- 2 Roof Panel , Sl i di ngEl ect r i c 01- 17- 2
Remove t he roof headlining access hole cover
( 52076) l ocat ed at t he rear of t he roof headlining
( 51916) .
R O O F H E A DL I N I N G
A C C E S S
H O L E
C O V E R
52076 R6302-C
Remove t he sliding roof panel motor ( 15790) as
outlined t o expose t he splined shaft of the sliding
roof rail and guide ( 502C06) .
Crank t he roof sliding outer gl ass panel cl osed using
a typi cal corporat e door wi ndow regul ator crank
handle properl y set on t he splined shaft.
After performi ng these operati ons, remove crank
handle and reti me as outlined. Refer t o Adj ustments,
Mot or Synchroni zati on (Timing).
Install t he sliding roof panel motor.
Tighten t o 4-6 N-m (36-53 Ib-in) and install roof
headlining access hole cover.
R6301-B
1- 17- 3 : o o f P a n e i , Sl i d i n gE l e c t r i c
' -------_\ i f c J Z I Z Z ^ Z Z Z Z Z ^ -
01- 17- 3
E l e c t r i c a l S c h e ma t i c
Roof Pa ne l , Sl i d i n gEl e c t r i c
WMMWm,
HOT IN ACC OR RUN
' 1 POWER
, DISTRIBUTION
I BOX
f
*| FUSE
I JUNCTION L
P A NE L
294
1
0 A
_ J
of thi s circuit
3
i
400J LB/BK
N
0 LB/B
WINDOW REGULATOR
S A F E T Y R E L A Y
400
400 1 LB/BK LB/BK
400 I LB/BK
POWER
WINDOWS
CLOSE
OPEN
57 ^ BK 692
ROOF
SLIDING
PANEL
SWITCH
692
DB
R9601-B
operati ng t he sliding el ectri c roof panel t o
dupl i cate t he condi ti on.
2. Inspect to determi ne if one of the fol l owi ng
Mechani cal E l e c t r i c a l
Damaged roof pa n e l .
Ob s t r u c t e d r o o f pa n e l .
Gui d e .
Da ma g e d d r i v e c a b l e ( s ) .
Ci r c u i t r y o p e n / s h o r t e d .
Da ma g e d s w i t c h .
Da ma g e d r o o f pa n e l mo t o r .
Da ma g e d c i r c ui t b r e a ke r .
3. If the inspection reveal s an obvi ous concern(s)
t hat can be readily identified, servi ce as requi red.
4. If the concern(s) remains after the i nspecti on,
determi ne t he sympt om(s) and go t o the
Sympt om Chart.
equivalent t o perform el ectri cal Pinpoint Test s.
ROOF PANEL, SLIDINGELECTRIC
Roof Sliding Panel Leaks Improper adj ustment.
Sliding roof panel frame drain hose
bl ocked/damaged.
m Roof sliding panel seal damaged,
or not installed properly.
Damaged roof sliding panel
housing.
o GO to Pinpoint Test A.
Excessive Wind Noise Improper adj ustment.
Roof sliding panel seal damaged
or not installed properly.
Roof Sliding Panel Rattles Improper roof sliding outer glass
panel installation.
Roof sliding panel seal not
properly i nstalled.
Foreign obj ects in roof sliding
panel rail or guide.
Rear lifter assemblies not properly
i nstalled.
Front guides loose / improperly
i nstalled.
Roof sliding panel rail and guide
not properly at t ached.
Roof sliding panel headlining not
properly installed.
GOt o Pi npoi nt Test C.
Roof Sliding Panel Noisy During
Operation
Roof sliding outer glass panel not
installed properly.
Obstructions in roof sliding panel
rail and guide or troughs.
Rear guide pin not installed
properly.
Rear lifter assemblies not installed
properly.
Damaged sliding roof panel motor.
Roof Sliding Panel Does Not Open
or Close
Damaged circuit breaker.
Damaged roof sliding panel swi tch.
Damaged sliding roof panel motor.
GOt o Pinpoint Test E.
Roof Sliding Panel Does Not Open
or Close in Vent Position
Rear lifter assemblies not properly
connected.
Rear guide pin not properly
engaged in cam slot of lifter
assembly.
01- 17- 5 Roof Panel , S l i d i n g E l e c t r i c 0 1 - 1 7 - 5
rzz* a T " Z _ J L T L _ ~ m z z z r ~ _ r - a _ : _ ~
_
~ z i _ JL
Pi n p o i n t T e s t s
PINPOINT TEST A; ROOF SLIDING PANEL LEAKS
A1 CHECK SLIDING ROOF PANEL OPERATION
Yes >
No -
GO to A2.
REFER to Adj ustments.
Cycle roof sliding outer glass panel from full open to
full closed posi ti on.
Observe operation looking for smooth operation
and/ or gaps that could cause leakage.
Does roof sl i di ng out er gl ass panel oper at e
smoot hl y and cl ose t i ght l y ?
Yes >
No -
GO to A2.
A2 CHECK SLIDING ROOF PANEL FRAME DRAIN HOSE
Yes >
No
:
-
SERVICE as outlined in
Adj ustments.
GO to A3.
Gain access to sliding roof panel frame drain hose
as outlined.
Check for blockage or damage t o sliding roof panel
frame drain hose .
Is bl ockage or damage pr esent ?
Yes >
No
:
-
Adj ustments.
GO to A3.
A3 CHECK HOUSING DAMAGE
Yes
No
RESTORE vehi cle.
RETEST system.
GO to A4.
Carefully inspect roof sliding panel housing for
cracks or damage.
Is damage pr esent ?
Yes
No
RESTORE vehi cle.
RETEST system.
GO to A4.
A4 CHECK ROOF SLIDING PANEL SEALS
Yes
No
SERVICE as outlined.
RESTORE vehi cle.
RETEST system.
Actuate roof sliding outer glass panel to the full
open posi ti on.
Inspect all roof sliding panel seals for damage or
proper installation.
Are r oof sl i di ng panel seals OK?
Yes
No
RESTORE vehi cle.
RETEST system.
PINPOINT TEST B: EXCESSIVE WIND NOISE
B1 CHECK ROOF SLIDING PANEL FIT
Yes
No
GO to B2.
REFER t o Adj ustments.
Carefully inspect all roof sliding panel seals for
proper fit and damage.
Are all roof sl i di ng panel seal s OK?
Yes
No
GO to B2.
REFER t o Adj ustments.
B2 CHECK ROOF SLIDING PANEL OPERATION
Yes t >
No
SYNCHRONIZE sliding
roof panel motor as
outlined. RESTORE
Observe roof sliding outer glass panel travel.
Does roof sl i di ng out er gl ass panel t ravel t o f ul l
open and f ul l cl osed posi t i on?
Yes t >
No
SYNCHRONIZE sliding
roof panel motor as
outlined. RESTORE
PINPOINT TEST C: ROOF SLIDING PANEL RATTLES
C1 CHECK ROOF SLIDING PANEL OPERATION
Yes >
No &
REFER to Removal and
Installation for proper
installation. RESTORE
GO to C2.
Observe roof sliding outer glass panel operation for
looseness.
Is r oof sl i di ng out er gl ass panel l oose?
Yes >
No &
GO to C2.
C2 CHECK ROOF SLIDING PANEL RAILS/GUIDES
Yes
No
GO to C3.
Operate roof sliding outer glass panel to full open
posi ti on.
Gain access to roof sliding panel rails as outlined.
Carefully check for proper installation of roof sliding
panel rails.
Are r oof sl i di ng panel rai l s i nst al l ed pr oper l y ?
Yes
No
GO to C3.
01- 17 - 6 01- 17 - 6
PINPOINT TEST C: ROOF SLIDING PANEL RATTLES (Cont i nued)
C3 CHECK ROOF SLIDING PANEL TROUGH
Yes D>
No -
Go to C4.
Gain a c c e ss to roof sliding panel trough as outlined.
Carefully check for foreign obj ects, or loose bolts.
If foreign material is found, remove material.
Is roof sl i di ng panel t rough i nstal l ed securel y?
Yes D>
No -
Go to C4.
C4 CHECK ROOF SLIDING PANEL HEADLINING
Yes
No
REFER t o Removal and
Vehicle. RETEST System.
Check roof sliding panel headlining for looseness.
Is roof sl i di ng panel headl i ni ng securel y
f ast ened?
Yes
No
REFER t o Removal and
PINPOINT TEST D: ROOF SLIDING PANEL NOISY DURING OPERATION
D1 CHECK OPERATION OF ROOF SLIDING PANEL
Yes
No
GO t o D2.
full cl osed posi ti on.
Check roof sliding outer glass panel for looseness.
Is roof sl i di ng out er gl ass panel l oose?
Yes
No
GO t o D2.
D2 CHECK FOR OBSTRUCTIONS
Yes E>
No
GO to D3.
Gain access to roof sliding panel rail as outlined.
Check for foreign materi al, or looseness.
If foreign material is present, remove foreign
material.
Is roof sl i di ng panel rai l pr oper l y i nst al l ed?
Yes E>
No
GO to D3.
D3 CHECK SLIDING ROOF PANEL MOTOR
Yes >
No
CHECK sliding roof panel
motor for proper
installation. If installed
properly REPLACE
sliding roof panel motor.
RESTORE vehicle.
RETEST system.
GO to D4.
full cl osed posi ti on.
Listen carefully to sliding roof panel motor
operati on.
Does sl i di ng roof panel mot or make excessi ve
noi se?
Yes >
No
CHECK sliding roof panel
motor for proper
installation. If installed
properly REPLACE
RESTORE vehicle.
RETEST system.
GO to D4.
D4 CHECK LIFTER ASSEMBLIES
Yes
No
REFER to Adj ustments
for service procedure.
RESTORE vehicle.
RETEST system.
Installation. RESTORE
Gain access t o lifter assemblies as outlined.
Check for proper installation.
Are l i f t er assembl i es i nst al l ed pr oper l y ?
Yes
No
for service procedure.
RESTORE vehicle.
RETEST system.
Installation. RESTORE
PINPOINT TEST E: ROOF SLIDING PANEL DOES NOT OPEN OR CLOSE
E1 CHECK SUPPLY TO SLIDING ROOF PANEL MOTOR
Yes
No
GO to E4.
GO t o E2.
Remove roof sliding panel swi tch as outlined.
Turn ignition swi tch to the RUN posi ti on.
Using a t est lamp, connected to a known good
ground, check Circuit 400 (LB/ BK) at roof sliding
panel swi tch connector for voltage.
Is vol t age pr esent ?
Yes
No
GO to E4.
GO t o E2.
01- 17 - 7 Ro o f P a n e l , S l i d i n g E l e c t r i c
01- 17 - 7
PINPOINT TEST E: ROOF SLIDING PANEL DOES NOT OPEN OR CLOSE (Cont i nued)
TEST STEP RESULT ACTION TO-TAKE
E2 CHECK CIRCUIT 193 (Y/ LG)
Yes
No
SERVICE Ci r c ui t i e s
(Y/ LG) for open.
RESTORE vehi cle.
RETEST syst em.
GOt o E3.
Using t est lamp still connected t o ground, check
Circuit 193 (Y/ LG) at Circuit Breaker F (30A) at
power distribution box.
Is vol t a ge pr esent ?
Yes
No
SERVICE Ci r c ui t i e s
(Y/ LG) for open.
RESTORE vehi cle.
RETEST syst em.
GOt o E3.
E3 CHECK CIRCUIT 193 (Y/ LG) FOR SHORT
Yes
No
SERVICE Circuit 193
(Y/ LG) for short.
RESTORE vehi cle.
RETEST syst em.
REPLACE damaged
Circuit Breaker F (30A).
RESTORE vehi cle.
RETEST syst em.
Remove Circuit Breaker F (30A).
ground, connect second lead t o Circuit 193 (Y/ LG).
Yes
No
SERVICE Circuit 193
(Y/ LG) for short.
RESTORE vehi cle.
RETEST syst em.
REPLACE damaged
Circuit Breaker F (30A).
RESTORE vehi cle.
RETEST syst em.
E4 CHECK ROOF SLIDING PANEL SWITCH GROUND
Yes
No
GO t o 5.
for open ci rcui t.
RESTORE vehi cle.
RETEST system.
ground, connect second lead to Circuit 57 (BK)
Yes
No
GO t o 5.
for open ci rcui t.
RESTORE vehi cle.
RETEST system.
E5 CHECK CIRCUIT 691 (DB)
Yes
No
GOt o ES.
REPLACE damaged roof
sliding panel swi t ch.
RESTORE vehi cle.
RETEST system.
Using t est lamp connected t o ground, back probe
Circuit 691 (DB) at roof sliding panel swi tch
connector.
Toggle roof sliding panel swi tch t o the open
posi ti on.
Yes
No
GOt o ES.
RESTORE vehi cle.
RETEST system.
E6 CHECK CIRCUIT 692 (R / Y)
Yes
No
GOt o E7.
RESTORE vehi cle.
RETEST system.
Using t est lamp, back probe Circuit 692 (R / Y) at
roof sliding panel swi tch connector.
Toggle roof sliding panel swi tch t o the close
posi ti on.
Yes
No
GOt o E7.
RESTORE vehi cle.
RETEST system.
E7 CHECK SLIDING ROOF PANEL MOTOR
Yes
No
GOt o E8.
SERVICE Circuit 691 (DB)
for open. RESTORE
Gain access t o sliding roof panel motor as outlined.
Using t est lamp, back probe Circuit 691 (DB) at
motor connector.
Toggle roof sliding panel swi tch t o the closed
posi t i on.
Di d t e st lamp i l l umi nat e?
Yes
No
GOt o E8.
SERVICE Circuit 691 (DB)
for open. RESTORE
E8 CHECK CIRCUIT 692 (R / Y)
Yes
No
REPLACE damaged
RESTORE vehi cle.
RETEST system.
SERVICE Circuit 692
(R/ Y) for open.
RESTORE vehi cle.
RETEST system.
Using t est lamp, back probe Circuit 692 (R / Y) at
motor connector.
Toggle roof sliding panel swi tch t o the open
posi ti on.
Yes
No
REPLACE damaged
RESTORE vehi cle.
RETEST system.
SERVICE Circuit 692
(R/ Y) for open.
RESTORE vehi cle.
RETEST system.
01- 17- 8 Roof Panel , Sl i di ngEl ect r i c 01- 17- 8
PINPOINT TE ST F: ROOF SLIDING PANEL DOES NOT OPEN OR CLOSE IN VENT POSITION
F1 CHECK REAR LIFTER ASSEMBLIES
Yes
No
GOt o F2.
Installation. SERVICE as
outlined. RESTORE
G a i n a c c e s s t o t h e r e a r l i f t e r a s s e m b l i e s a s
o u t l i n e d .
W i t h r o o f s l i d i n g o u t e r g l a s s p a n e l a t t h e f u l l c l o s e d
posi ti on, turn ignition swi tch to the RUN posi ti on.
T o g g l e t h e r o o f s l i d i n g p a n e l s w i t c h t o t h e CLOSED
position.
Did roof sliding outer gl ass panel pop up?
Yes
No
GOt o F2.
outlined. RESTORE
F2 CHECK ROOF SLIDING PANEL VENT CLOSED
OPERATION
Yes E>
No D>
for Motor Synchronization
(Timing) procedure.
outlined. RESTORE
T o g g l e r o o f s l i d i n g p a n e l s w i t c h t o t h e OPEN
posi ti on.
Observe vent closing operation.
Di d roof sl i di ng out er gl ass panel pul l d o wn ?
Yes E>
No D>
for Motor Synchronization
(Timing) procedure.
outlined. RESTORE
REMOWAL AND INSTALLATION
G l a s s , S l i d i n g R o o f
Re mo v a l
1. Rai se roof sliding outer gl ass panel ( 502A82) t o
t he vent posi ti on.
2. Remove si x scr ews (three each si de) retaining
roof sliding outer gl ass panel t o roof sliding panel
housing ( 502C22) .
ROOF SLIDING PANEL
OPENING SHIELD
50988
ROOF SLIDING PANEL
HEADLINING
519A02
SCREW AND WASHER
N803645-S36B
TIGHTEN TO
0.8-1.5 Nm
(7-13LB-IN)
FRONT OF'
'VEHICLE
R3621-F
3. From outsi de of vehi cl e, lift roof sliding outer
gl ass panel f rom vehi cl e.
1. To install, the help of a second techni ci an will be
needed. Position roof sliding outer gl ass panel t o
roof sliding panel housi ng.
2. Whi l e second techni ci an is holding roof sliding
outer gl ass panel f rom outsi de vehi cl e, install and
ti ghten scr ews retaining roof sliding outer gl ass
panel t o roof sliding panel housi ng.
3. Adj ust roof sliding outer gl ass panel as outl i ned.
H e a d l i n i n g , S l i d i n g R o o f
1.
2.
Open roof sliding outer gl ass panel ( 502A82)
approxi matel y one-third of the way.
Grasp and pull down one of the outsi de corners of
the plastic (snap-on) roof sliding panel opening
shield ( 50988) . Worki ng t owar d the opposi te
si de, remove front of roof sliding panel opening
shield f rom roof sliding outer gl ass panel . Then
cl ose roof sliding outer gl ass panel .
ROOF SLIDING OUTER
TOAfi
PANEL
ROOF SLIDING PANEL
oijdfhod OPENING SHIELD
50988
R6303-B
Raise roof sliding outer gl ass panel t o the full vent
position.
On each si de of the roof sliding panel opening
shi el d, approxi matel y half-way t owar d the rear,
use a wi de-bl ade screwdri ver to press up on
rel ease t abs l ocated on bottom surface (right
above t rack scr ews on each si de).
01- 17 - 9 Roof Pa n e l , Sl i d i n g- - El ect r i c 01- 17 - 9
REMOVAL A N D INSTALLATION ( Co n t i n u e d )
Move rear hooked ends of roof sliding panel
opening shield i nward up over rubber roof sliding
panel headlining bumper s and remove roof sliding
panel opening shi el d f rom vehi cl e.
RE L E A S E T A B
T R A C K S C R E W
R O O F SL I DI NG
P A N E L OP E N I N G
S HI E L D 50988
R6535-B
HA T
S E CT I ON
R O O F SL I DI NG
P A N E L HE A DL I NI NG
f = 5 1 9 A 0 2
6.
10.
R6305-C
Slide roof sliding panel headlining ( 519A02)
hal f-way back.
Whi l e holding down on front of roof sliding panel
headlining, run gl ass past t he roof sliding panel
headlining all t he way t owar d the rear.
Remove small inner t r ack scr ews on each si de.
CAUTI ON: Use c a r e not t o o v e r b e n d r o o f
s l i d i n g pa n e l r a i l ( 5107 0) .
Pull roof sliding panel headlining f or war d, up and
out through opening creat ed by bending up roof
sliding panel rail secti on where scr ews were.
NOTE: Roof sliding panel opening shield is a
" snap- f i t " on si de gui des j ust above t r ack scr ews
whi ch t rap the roof sliding panel headlining. Make
sure an audible cl i ck is heard when pressi ng t he
roof sliding panel opening shield onto the gui de.
Test by tryi ng t o pull off wi thout pressi ng t he
rel ease t ab.
To install, reverse Removal procedure. Make
sure roof sliding panel headlining si de gui des are
fully down in t r acks before sliding roof sliding
panel headlining r e a r wa r d.
S e a l
Re mo v a l
1. Remove roof sliding outer gl ass panel ( 502 A82 )
as outlined.
2. Remove ol d r oof sli di ng panel seal ( 51884) .
3. Remove weat herst ri p adhesi ve f r o m roof sliding
outer gl ass pane! channel .
1. Trim one end of t he new roof sliding panel seal
square. Trim other end of roof sliding panel seal
wi t h minimal 1.0 mm (0. 039 inch) i nterference
wi t h opposi te square end.
2. NOTE: Locat e but t joint of roof sliding panel seal
on passenger' s si de of roof sliding outer gl ass
panel fi rst t o ensure that bumper insert in roof
sliding panel seal is posi ti oned along front of roof
sliding outer gl ass panel.
Appl y Super Weat herst ri p Adhesi ve 3M 08008
or equivalent t o new roof sliding panel seal and
pr e ss roof sliding panel seal ont o roof sliding
outer gl ass panel .
3.
4.
" ROOF SL I DI NG
C H A N N E L P A NE L SE A L
51884
ROOF SL I DI NG
x
OUTER G L A S S P A N E L
502 A82 R6308-C
Install roof sliding outer gl ass panel as outlined.
Adj ust roof sliding outer gl ass panel as outlined.
Li f t er A r ms
Re mo v a l
Open roof sliding outer gl ass panel ( 502A82)
approxi matel y one-quarter of t he way.
Remove roof sliding panel opening shield ( 50988)
as outlined under Headlining, Sliding Roof.
Cl ose and raise roof sli di ng outer gl ass panel t o
full vent position.
Remove t hree sc r e ws retaining each Sifter a r m.
Remove roof sliding out er gl ass panel. Lifter arms
must be in t he vent position.
1- 17- 10 Ro o f Pa n e l , Sl i di ngE l e c t r i c 01- 17- 10
6. Operati ng the roof sliding outer gl ass panel , run
lifter arms t o ret ract ed position and rearward
approxi matel y 15. 25 cm (6 i nches).
LIFTER GUIDE ROOF AIR
ASSY (PART OF DEFLECTOR
502C06) 500A26
7. Grab lifter arms and push gui des si deways out of
t rack t o remove arms.
1. Position lifter arms in t r ack and install guide shoe
into t rack.
2. Slide lifter arm f or war d until it cont act s roof air
defl ector ( 500A26) .
3. Operat e roof sliding outer gl ass panel f or war d,
while holding lifter arm up above cabl e bl ock.
LIFTER ARM
ASSY(PART OF
502C06)
R6310-B
4. Operat e roof sliding outer gl ass panel full
f or war d, until cabl e bl ock is in the vent posi ti on.
5. Insert cabl e bl ock pins into bot t om of ki dney sl ots
in lifter arms.
6. Operat e roof sliding outer gl ass panel rearward
t o t he ret ract ed posi ti on. Push down on front
porti on of lifter t o ensure that lifter arm bl ocks
travel under mechani cal st ops. Snap lifter pins
into t op of ki dney sl ot s.
LIFTER ARM KIDNEY
R6311-B
7. Install roof sliding outer gl ass panel assembl y as
outlined.
Air Def lect or, Roof
1. Fully open roof sliding outer gl ass panel
( 502A82) and remove middle and rear retaining
pins.
R6537-B
2. Remove roof air defl ector ( 500A26) .
4. Check operati on.
Roof Panel, Sli di ng
Removal
NOTE: The roof panel consi sts of the compl ete roof
sliding outer gl ass panel ( 502A82) and roof sliding
panel rail ( 51070) .
1. Operat e roof sliding outer gl ass panel t o the
full-open posi ti on.
2. Remove roof sliding panel rail retaining scr ews
except the scr ews at Position 4 as shown.
01- 17- 11 Ro o f P a n e l , S l i d i n g E l e c t r i c 0 1 - 1 7 - 1 '
'zzYr~zr.zzirr
Roof Sl i di ng Panel Rai l
SCREWS
52787-S55
14 REQ'D
TIGHTEN TO
1-1.5 N-m
(9-13LB-IN)
POSITION 2 POSITION 4
POSITION 1 \ POSITION 3
ROOF SLIDING
PANEL HOUSING
502C22
SLIDING ROOF
RAIL AND GUIDE
502C06
R6539-D
3. Operat e roof sliding outer gl ass panel f or war d,
whi l e holding center down to prevent scrat chi ng
roof sliding outer gl ass panel on roof sliding panel
housing rei nforcement ( 51874) .
4. Remove roof headlining access hole cover
( 52076) .
6. Remove sliding roof panel motor retaining bol ts
and sliding roof panel motor ( 15790) .
7. Remove remaining roof sliding panel rail retaining
scr ews above the sliding roof panel motor.
8. Reachi ng inside vehi cl e, push up underside of
roof sliding outer gl ass panel t o rai se roof sliding
panel rail and roof sliding outer gl ass panel above
openi ng.
9. Bet ween the rear edge of roof sliding outer gl ass
panel and roof panel ( 50202) surf ace, have an
assi stant press t rough down using a scal e or
similar thin obj ect . While pressi ng t rough down,
proceed wi t h St ep 10.
ROOF SLIDING
OUTER GLASS
PANEL 502A82 PUSH DOWN
ROOF PANEL
50202
TROUGH
.FRONT OF.
VEHICLE
R6538-C
10. Lift and slide roof sliding panel rail and roof sliding
outer gl ass panel f or war d, maki ng sure not t o
scrat ch roof panel paint while removi ng it f r om
vehicle.
01- 17- 12 Roof Panel , Sl i di ngEl ect r i c 01- 17 - 12
Roof Sl i d i n g Panel
WATER
TROUGH
ROOF SLIDING
PANEL RAIL
51070
ROOF SLIDING
OUTER GLASS
PANEL 502A82
R8357-C
1. Slide roof sliding panel rail and roof sliding outer
gl ass panel into t he roof sliding panel housi ng,
maki ng sure t rough at rear of roof sliding outer
gl ass panel is pushed down under roof panel .
2. CAUTI ON: Ha n d - t i gh t e n al l b o l t s . Do n o t u s e
a i r t o o l s o n t r ac k r et ai ni ng b o l t s o r d a ma g e
t o h o l e s i n r o o f sl i di ng panel h o u s i n g ma y
o c c u r .
Install roof sliding pane! rail retaining scr ews.
3. Install sliding roof panel motor.
4. Install roof headlining access hole cover.
5. Whi l e appl yi ng constant downwar d pressure t o
prevent scrat chi ng roof sliding outer gl ass panel ,
open roof sliding outer gl ass panel .
6. Check and adjust roof sliding outer gl ass panel
hei ght.
Op e n i n g Shield, Sliding Roof Panel
1. Open roof sliding outer gl ass panel ( 502A82)
approxi mat el y hal f-way.
2. Grasp and pull down one of the outsi de corners of
t he pl asti c (snap-on) roof sliding panel opening
shield ( 50988) . Worki ng t owar d the opposi t e
si de, remove front of roof sliding panel opening
shield f rom roof sliding outer gl ass panel . Then
cl ose roof sliding outer gl ass panel .
ROOF SLIDING OUTER
5Q2A82
P A N E L R 0 0 F
SLIDING PANEL
OPENING SHIELD
50988
R6303-B
Raise roof sliding outer gl ass panel t o the full vent
position.
On each si de of the roof sliding panel opening
shi el d, approxi matel y half-way t owar d the rear,
use a wi de-bl ade screwdri ver t o press up on
rel ease t abs l ocated on bot t om surface (right
above t rack scr ews on each si de).
01- 17 - 13 Ro o f Panel , S l i d i n g E l e c t r i c 1-17-13
R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d )
Move rear hooked ends of roof sliding panel
opening shield i nward up over rubber roof sliding
panel headlining bumpers and remove roof sliding
panel opening shield f rom vehi cl e.
RELEASE TAB
TRACK SCREW
R6535-B
S w i t c h
Remov al
1. Remove roof consol e ( 519A58) . Refer t o Secti on
01- 12.
2. Di sconnect wi ri ng connector on si de of roof
consol e.
3. Carefully spread center wal l s of roof consol e t o
rel ease center ci rcui t pl ate and expose roof
sli di ng panel swi t c h ( 15B691) .
4. Remove wi ri ng assembl y connector by rel easi ng
connect or ret ai ni ng t a b on si de wal l of roof
consol e wi t h a f l at -bl aded scr ewdr i ver and sli di ng
connect or of f of i t s l ocat i ng f i nger.
5. Usi ng a smal l scr ewdr i ver , pr y apar t t he t wo
swi t c h ret ai ni ng t a bs and r emove swi t c h
assembl y.
1. Connect el ect r i cal connect or t o roof sli di ng panel
swi t c h.
2. NOTE: The roof sli di ng panel swi t c h is " ke y e d "
and can onl y be i nst al l ed one wa y .
Snap roof sl i di ng panel swi t c h securel y i nto roof
consol e.
3. Install roof consol e.
5. Lo we r sl i di ng roof panel mot or ( 15790) away
f r o m roof sl i di ng panel rail ( 51070) and
di sconnect el ect ri cal connector.
6. To i nst al l , r e ve r se Removal procedure.
Sy nchr oni ze sliding roof panel motor as outlined
under Adj ust ment s.
Drain H o s e
1. Remove r oof headli ni ng ( 51916) . Refer t o
Sect i on 01- 05.
2. Di sconnect sl i di ng roof panel f rame drain hose
( 502C52) f r o m roof sl i di ng panel housi ng
( 502C22) .
3. Sl i de sli di ng roof panel f r a me drain hose from
c o wl panel or quart er pane! gr ommei Remove
sl i di ng roof panel frame drai n hose,
4. To install, ali gn sliding roof panel frame drai n hose
i nto gr omme t and connect sli di ng roof panel f r ame
drai n hose t o roof sli di ng panel housi ng.
5. Install roof headli ni ng. Ref er t o Secti on 01-05.
ADJUSTMENTS
Mo t o r
R e mo v a l a n d I nst al l at i on
1. Ope r a t e roof sli di ng out er gl ass panel ( 502 A82 )
until rear of r oof sli di ng out er gl ass pane! i s f l ush
wi t h roof panel ( 50202) .
2. Remove roof headli ni ng a c c e ss hole cover
( 5207 6) .
3. Di sconnect ba t t e r y ground cabl e ( 14301) .
4. Remove t wo sliding roof panel mot or ret ai ni ng
bol t s.
Glass P a n e l
He i g h t
The c o r r e c t posi t i on of t he roof sliding outer gl ass
panel ( 502 A82 ) t o t he roof panel ( 50202) is as
f ol l ows:
Front Corners: Fl ush t o 1 mm ( 0. 039 i nch) bel ow roof
panel .
Rear Corners: Fl ush t o 1 mm ( 0. 039 i nch) above roof
panel .
1. Cy cl e roof sliding out er gl ass pane! f rom f ull-open
t o f ul l -cl osed posi t i on.
2. Remove t hr ee roof sliding pane! opening shi el d
ret ai ni ng sc r e ws along f ront of openi ng inside of
vehi cl e and sl i de roof sli di ng panel openi ng shi el d
( 50988) and roof sliding pane! headlining
( 519A02) fully rearward t o expose si x roof sliding
out er gl ass panel retai ni ng sc r e ws (t hree on e a c h
si de).
3. Loosen si x roof sliding out er gl ass panel ret ai ni ng
sc r e ws. Ti ght en so t hat t hey are snug but not
t i ght ened t o speci f i cat i on.
4. To adj ust onl y t he f ront of roof sliding outer gl ass
pane!, l oosen t he cent er and f ront sc r e ws. I f it is
desi r ed t o adj ust only t he back of t he roof sli di ng
out er gl ass panel , only l oosen t he cent er and rear
sc r e ws.
5. To check hei ght set t i ng, open t he roof sliding
out er gl ass panel about 101. 60 mm (4. 0 i nches),
t hen ret urn t o t he cl osed posi t i on.
1995 To wn Car, Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s J u l y 1994
01- 17- 14 Ro o f Pa n e i
5
S l i d i n g El ec t r i c 01- 17- 14
6. Tighten t he gl a ss retaining scr ews t o .8-1.5 N-m
(7-13 Ib-in).
7. Slide roof sliding panel opening shield forward
and repl ace t hree retaining sc r e ws.
8. Cl ose roof sliding panel headlining if desi red.
R O O F S L I DI N G P A N E L S C R E W A N D W A S H E R
O P E N I N G S H I E L D N803645-S36B
50988 TIGHTEN TO
FRONT O F "
VEHICLE
R3621-F
Fo r e - a n d - A f t
1. Operat e roof sliding outer gl ass panel t o t he
full-open posi ti on.
2. Loosen 10 scr ews retaining t he adj ustabl e si de
rail covers.
3. Locat e and use t he seri es of hash mar ks at each
front rail corner. Adj ust roof sliding outer gl ass
panel fore-or-aft as requi red, maki ng sure bot h
si des are uniform t o hash marks.
4. CAUTI ON: Ha n d - t i gh t e n al l s c r e w s . Do n o t
u s e a i r t ool s or d a ma g e t o h o l e s i n r o o f
s l i d i n g pa n e l h o u s i n g ( 502 C2 2 ) ma y o c c u r .
Install all retaining scr ews.
Wa t e r Dr a i n a g e S y s t e m a n d Wa t e r L e a k
C o r r e c t i o n s
Dr a i n H o s e s
The roof panel contai ns a drain trough that enci rcl es
t he roof sliding outer gl ass panel ( 502A82) . At t ached
t o the roof sliding outer gl ass panel are four sliding roof
panel f rame drai n hoses ( 502C52) . One sliding roof
panel f rame drain hose is at t ached at each corner of
t he roof panel ( 50202) . The t wo front sliding roof panel
f rame drain hoses are routed down t he wi ndshi el d
pillars and into the cowl si des exiting at rocker panel
drain hol es. The end of the sliding roof panel frame
drain hoses are not reusabl e. The t wo rear sliding roof
panel f rame drain hoses are routed down the rear
pillars f or war d of the rear wheel base exiting at rocker
panel drai n hol es.
NOTE: Prior t o performi ng any servi ces, veri fy that the
drai nage syst em is not pl ugged or rest ri ct ed. Use a
473 ml ( 16 oz) container and pour wat er into the drain
t rough. Look at the rear of the vehicle t o ensure that
t he wat er drai ns f rom the rocker panels f orward of t he
rear wheel house.
If the wat er fl ow is rest ri ct ed, use compressed air t o
bl ow out any material in the drain hose syst em. Test
by pouring wat er sl owl y into the syst em agai n.
After ensuring that the drai nage syst em is not
rest ri ct ed, veri fy that gaps do not exi st bet ween t he
roof sliding panel seal ( 51884) and the roof panel . If a
gap exi st s, t he gap must be brought t o speci fi cati on
before any further acti on is t aken. Adjust roof sliding
outer gl ass panel as outlined.
Wi t h cl earances within speci fi cati on and roof sliding
outer gl ass panel cl osed, have an assi stant spray
wat er on t he roof sliding outer gl ass panel . Check the
inside area t o see if an excessi ve amount of wat er is
entering the drain t rough. A large volume of wat er
i ndi cates that an excessi ve cl earance exi st s between
t he roof sliding panel seal and the roof panel .
01- 17- 15 Roof Pa n e l , S l i d i n g E l e c t r i c 01- 17- 15
Roof Panel Drai nage Sy st e m
RIGHT REAR
ROOF DRAIN HOSE.
54502
DRAIN VALVE
503A20
VI EWB
R6541-B
Sl i d i n g Ro o f P a n e l
The roof sliding outer gl ass panel has control l ed wat er
leak at t he roof sliding panel seal s. A properl y
adj usted roof sliding outer gl ass panel shoul d result in
a snug fit bet ween t he roof sliding panel seal and the
roof panel around the entire openi ng. The fit can be
checked by using a feel er gauge set at 0. 25 mm ( 0. 01
inch) bet ween t he roof sliding panel seal and roof
panel. If t hese speci fi cati ons are not mai ntai ned, wat er
will overf l ow t he drain troughs and enter the roof
panel, running down into t he passenger compart ment
when t he vehi cl e is st opped abruptl y. Al so, i ncreased
wi nd noise coul d result if roof sliding outer gl ass panel
cl earances are not kept t o t hese speci fi cati ons.
We t H e a d l i n i n g S i d e s
If wat er dri ps f r om t he roof headlining ( 51916) above
the front door ( 20124) or quarter wi ndow, check t o
see if t he sliding roof pane! f rame drain hose are
di sconnected f rom t he roof panel . Appl y Weat herst ri p
Adhesi ve E8AZ-19552-A or equivalent meeting Ford
speci fi cati on ESB-M2G14-A on drai n tube nipple and
insert sliding roof panel f rame drain hose.
Ro o f P a n e l O v e r c r o w n e d
If the roof panel is overcrowned t o the contour of t he
roof sliding outer gl ass panel (at rear of roof sliding
outer gl ass panel ), thi s can cause wi nd noise or wat er
leak condi ti ons.
203-254 mm
(8-10 INCHES)
203-254 mm
(8-10 INCHES)
ROOF TRIM PANEL
51968
ROOF PANEL
50202 R4026-E
CAUTI ON: E x c e s s i v e o v e r b e n d i n g c o u l d d i s t o r t
t h e r o o f pa n e l , r e q u i r i n g c o s t l y me t a l f i n i s h i n g
s e r v i c e . Thi s p r o c e d u r e s h o u l d b e u s e d o n l y a s a
l a st r e s o r t .
Remove roof panel f rom vehicle and carefully
overbend the center of the roof panel by appl yi ng
downward pressure.
Ro o f Pa ne l Un d e r c r o wn e d
A roof sliding outer gl ass panel scrat ch can be caused
by the rear of the roof panel being slightly
undercrowned.
A D J U S T M E N T S ( C o n t i n u e d )
CAUTI ON; Excessi ve o v e r be n d a n g coul d di st or t
t he r oof panel , r equi r i ng cost l y met al f i ni shi ng
ser vi ce. Thi s pr ocedur e shoul d be used onl y as a
l ast r esor t .
Open the roof sliding outer gl ass panel slightly and
compare the contour of roof panel and roof sliding
outer gl ass panel . If the roof panel appears fl attened in
the center, and the roof sliding outer gl ass panel scuffs
on t he underside of t he roof panel , remove the roof
panel f rom t he vehi cl e and arch t he roof panel by
pushing up on underside of roof panel to i ncrease the
roof panel ar ch.
M o t o r Sy n c h r o n i z a t i o n ( Ti mi n g )
The sliding roof panel motor ( 15790) must be
synchroni zed. Any ti me the sliding roof panel motor is
removed f rom t he vehi cl e, it must be checked for
synchroni zati on before it is installed.
1. Operat e roof sliding outer gl ass panel ( 502A82)
until rear of roof sliding outer gl ass panel is flush
wi t h roof panel ( 50202) .
2. Remove roof headlining access hole cover
( 52076) .
4. Remove t wo sliding roof panel motor retaining
bol ts.
R6316-B
5. Lower sliding roof panel motor away f rom sliding
roof rail and guide ( 502C06) .
6. Using roof sliding panel swi t ch ( 15B691) , operat e
sliding roof panel motor until it is shut off by the
mi croswi t ch. Check timing of sliding roof panel
motor. Al so check that t he notch in t he cam for
t he mi croswi t ch and t he mi croswi t ch are aligned.
GEAR HOLE TIMING MICRO
ÂlVf R6317-B
If the sliding roof panel motor is not synchroni zed,
adjust it as fol l ows:
a. Connect bat t ery ground cabl e.
b. Connect sliding roof panel motor wi ri ng
connector t o roof panel wiring connector.
c. Operat e roof sliding panel swi t ch t o advance
sliding roof panel motor until notch in cam and
mi croswi t ch are aligned.
d. Di sconnect sliding roof panel motor wi ri ng
connector f rom roof panel wi ri ng connector.
e. From the ret ract ed posi ti on, crank roof
sliding outer gl ass pane! assembl y flush wi th
roof panel .
7. To ti me roof sliding panel rail ( 51070) , align
yel l ow paint line on t he splined sliding roof panel
motor shaft wi th t he yel l ow paint mark on motor
gear cover pl ate next t o it. When t hese marks are
in alignment, the roof sliding panel rail and the
sliding roof panel motor are both synchroni zed.
8. Install sliding roof panel motor onto roof sliding
panel rail.
9. Install sliding roof panel motor retaining bol ts.
Tighten t o 4-6 N-m (36-53 Ib-in).
10. Install roof headlining access hole cover.
SPECIFICATIONS
Description Lb-ln
Sl i d i n g Ro o f Pa n e l Mo t o r Bo l t s 4- 6 36- 53
Ro o f Sl i d i n g Out e r Gl a s s Pa n e l
2- 4 18- 35
Ro o f Sl i d i n g Pa n e l Ra i l Re t a i n i n g
S c r e ws
1. 0-1. 5 9- 13
Ou t e r Gl a s s Pa n e l Re t a i n i n g Sc r e w . 8- 1. 5 7 - 13
ROTUNDA EQUIPMENT
Mod el Descr i pti on
01- 19- 1 Bu mp e r s 01- 19- 1
SECTION 01-19 Bumpers
SUBJECT
VEHICLE APPLICATION
Bumpers ,
Bumper and Bumper Cower...
PAGE SUBJE CT PAGE
01-19-1 REMOVAL AND INSTALLATION (Cont 'd. )
Isolator and Bracket 01-19-8
,01-19-1 Mount i ng Bracket , Li cense Plate................ ...01-19-8
SPECI FI CATI ONS
,01-19-1 Bumper Height Speci f i cat i ons 01-19-9
VEHICLE APPLICATION
B u m p e r s
CAUTI ON: Ne v e r a p p l y e x c e s s i v e he a t t o b u mp e r
s u r f a c e . He a t c o u l d c a u s e d i s t o r t i o n o f t h e
bumper .
Plastic (pol yurethane) bumper covers are used.
The front bumper ( 17757) and rear bumper ( 17906)
are secured wi t h bolt on front bumper i sol ator and
bracket ( 17754) assembl i es.
B u m p e r a n d B u m p e r C o v e r
F r o n t T o w n Ca r
Re mo v a l
1. CAUTI ON: Ne v e r a p p l y h e a t t o t h e f r o n t
b u mp e r i s o l a t o r a n d b r a c ke t ( 17 7 54) . He a t
c o u l d c a u s e t h e ma t e r i a l i n s i d e t h e f r o n t
b u mp e r i s o l a t o r a n d b r a c ke t t o e x p a n d a n d
f l o w o u t o f t h e f r o n t b u mp e r i s o l a t o r a n d
b r a c ke t o r c r a c k t h e me t a l h o u s i n g . A l wa y s
r e mo v e t h e f r o n t b u mp e r i s o l a t o r a n d
b r a c ke t b e f o r e ma ki n g b o d y f r a me s e r v i c e
n e a r t h e m.
Remove four scr ews and washer s acr oss bot t om
of front bumper cover ( 17D957) . Remove t wo
scr ews (each si de) f r om bot t om of front bumper
cover at front fenders ( 16005) and t hree scr ews
in each wheel openi ng.
2. Remove t wo nuts (each si de), retaining front
bumper cover end t o front fender.
3. Remove front bumper cover f rom vehi cl e.
4. Remove t wo nuts at each front bumper i sol ator
and bracket and remove front bumper ( 17757) .
1. Position front bumper t o front bumper isolator and
bracket .
2. Install t wo nuts at each front bumper isolator and
bracket . Tighten t o 34- 46 N-m ( 25- 34 Ib-ft).
3. Position front bumper cover over front bumper
and align front bumper cover ends at front
fenders.
4. St art scr ews retaining front bumper cover t o front
fenders.
5. Tighten scr ews t o 1-1.5 N-m ( 10- 13 Ib-in).
6. Install t wo nuts (each si de) retaining front bumper
cover t o front fenders.
7. After checki ng front bumper cover alignment,
ti ghten nuts at front fenders t o 8. 9-12. 1 N-m
(79-107 Ib-in).
8. Tighten scr ews al ong bot t om of front bumper
cover t o 1.4-2.0 N-m (12-18 Ib-in).
01- 19- 2 Bu mp e r s 01- 19- 2
Fr o n t Bumpe r Co v e r T o wn Car
Pa r t Pa r t
1 17757 Front Bumper
7 16005 Front Fender
8 17D957 Front Bumper Cover
Req'd) A Tighten to 1.4-2.0 N-m (12-18
3 56912-55 Screw (3 Req'd Each Side) Lb-ln)
4 N621926-S36 Nut, Washer and Sealer (2
B
Tighten to 1.1-1.5 N-m (10-13
Req'd Each Side) Lb-ln)
5 N808720-S307 Screw and Washer Assy (2 C Tighten to 8.9-12.1 N-m
Req'd Each Side) (79-107 Lb-ln)
6 N804765-S Nut Insert (3 Req'd Each
Side)
01- 19- 3 Bu mp e r s 01- 19- 3
Fr o n t Bu mp e r T o wn Car
N8212-D
Pa r t
I t e m Number De sc r i pt i on
1 N606084-S36 Bol t (1 Req'd Each Side)
3 N806830-S100 Rivet (4 Req'd)
4 17C947 Front Bumper Cover Support
6 17754 Front Bumper Isolator and
Bracket
Lb-Ft)
Lb-Ft)
F r o n t C r o w n Vi c t or i a, Gr a n d Mar qui s
1. Remove si de marker l amps.
2. Remove t wo retaining scr ews and remove
parki ng l amps ( 13200) f rom front bumper cover
(Grand Marqui s onl y).
3. Remove t wo retaining screw and washer
assembl i es at upper outboard end of front
bumper cover.
4. Remove t wo retaining screw and washer
assembl i es at the outboard verti cal surface of
front bumper cover t o front fender.
5. Remove six retaining scr ews at wheel opening
fl ange f rom front bumper cover t o front fender.
6. Remove t wo retaining screws and washer
assembl i es attachi ng front bumper cover and
front fender at l ower surface.
7. Remove four retaining scr ews and washer
assembl i es attachi ng front bumper cover and
radi ator support ( 16138) at l ower surface.
8. Drill out t wo ri vets at t op of grille opening
attachi ng front bumper cover and front bumper.
9. Remove front license plate mounting bracket
( 17A385) (if equi pped), drill out ri vets and
transfer front license plate mounting bracket if
repl aci ng front bumper cover.
10. CAUTI ON: Pul l i ng f or war d on f r ont bumper
cover wi t hout pushi ng up t o r el ease t abs may
cause gr i l l e openi ng to cr ack.
Di sengage retention t abs on front bumper cover
surface from radi ator grille opening panel
reinforcement ( 8A284) , push up on t abs and pull
front bumper cover f or war d.
11. Remove six retaining nuts f rom front bumper t o
front bumper isolator and bracket .
front bumper t o front bumper isolator and bracket
retaining nuts t o 46. 7-63. 3 N-m (34-47 Ib-ft).
01=19- 4
\w~
Bumper s 01- 19- 4
Fr ont Bumper and Bumpe r Cover
1
N12587-A
Pa r t
2 16138 Radiator Support
4 N807260-S36 Screw (Grand Marquis) (1
Req'd Each Side)
5 N804765-S Insert Nut (3 Req'd Each
Side)
6 N800854-S100 U-Nut (Grand Marquis)
7 N800854-S100 U-Nut (Crown Vi ctori a)
10 N807260-S36 Screw (Grand Marquis) (1
Req'd Each Side)
I t e m
Pa r t
11 N807260-S36 Screw (Crown Vi ctori a) (1
Req'd Each Side)
13 17A385 Front License Plate
Mounting Bracket
15 17A386 License Plate Hardware
Container
16 N807807-S43 Push P i n (1 Req'd Each
Side)
( Co n t i n ue d )
R e a r T o w n Ca r
Re mo v a l
1 . CAUTI ON: Wh e n c o l l e c t i n g e x h a u s t f u me s i n
s e r v i c e a r e a , n e v e r a t t a c h a me t a l c o l l e c t o r
t o t h e e x h a u s t t a i l pi pe b e c a u s e t h e he a t
c o u l d d a ma g e t h e b u mp e r .
Remove four push pins al ong bot t om of rear
bumper cover ( 17K835) at t abs on rear bumper
( 17906) .
01- 19- 5 Bu mp e r s 01- 19- 5
REMOVAL AMP ir-BTT AL.ATION (Gontl nu
Rear Bumper Cover To wn Car
N8214-D
Par t
I t em umbe r Descr i pt i on
1 17K8C " Rear Bumper Cover
2 N621926-S36 Nut and Washer (12 Req'd)
3 N804765-S Nut (3 Req'd Each Side)
5 388930-S Push Pi n (3 Re q' d Ea c h
S" .
Par t
6 17D942 Rear Bumper Cover
A _ Ti ght e n t o 8.9-12.1 N-m
(79-107 Lb-l n)
B

Ti ght e n t o 1.1-1.5 N-m (10-13
Lb-l n)
2. Remove t hree push pins (each si de) retaining
rear bumper cover t o rear l ower edge of quarter
panel .
3= Through l uggage compar t ment , remove t wo nuts
(each si de) l ocated at end of quarter panel . Al so
loosen (but do not remove) ei ght nuts that retain
t he rear bumper cover mounting rei nforcement
( 17D942) to t he l ower ba c k panel .
4. Remove l i cense pl ate l amps f rom rear bumper
cover.
Remove three scr ews (each si de) retaining rear
bumper cover to quarter panel.
Slightly t wi st rear bumper cover to rel ease it from
f orward edge of rear bumper and remove.
Through l uggage compartment openi ng, remove
8 nut and washer and seal assembl i es and
remove rear bumper cover mounting
rei nforcement.
1995 Town Car, Crown Victoria, Grand Mar qui s Jul y 1994
01- 19- 6 Bumpers 01- 19- 6
Bumpe r Cove r Re i n f o r c e me n t
N8215-D
I t e m
Part
1 N621926-S36 Nut, Washer and Seal (8
Req'd)
2
17906 Rear Bumper
3 17D942 Rear Bumper Cover
A

Tighten to 8.9-12.1 N-m
(79-107 Lb-ln)
Remove three nuts at each rear bumper isolator
and bracket (17787) retaining rear bumper.
Remove rear bumper.
Rear Bu mp e r T o wn Car
N820S-E
Par t
1 N606084-S301 Bolt
2 N800325-S301 Nut
Req'd Each Side)
4 17787 Rear Bumper Isolator and
Bracket
5 17906 Rear Bumper Assy
Lb-Ft)
Lb-Ft)
1. Position rear bumper to rear bumper isolator and
bracket and install three nuts on each side.
Tighten to 34-46 N-m (25-34 Ib-ft).
2. Through luggage compartment opening, install 8
nuts retaining rear bumper cover mounting
reinforcement and tighten to 8-12 N-m (6-9 Ib-ft).
Do not tighten nuts until after bumper cover is
installed.
3. Position rear bumper cover on rear bumper and
rear bumper cover mounting reinforcement. Install
license plate lamps (13550).
4. Install retaining screws at wheel openings.
5. Install two nuts each side, retaining rear bumper
cover at end of quarter panel (through luggage
compartment). Tighten to 8.9-12.1 Nm (79-107
lb-in). Also tighten the eight nuts retaining the rear
bumper cover mounting reinforcement to the
lower back panel to 8.9-12.1 N-m (79-107 lb-in).
6. Install three push pins (each side) at lower
quarter panel edge.
7. Install four push pins to rear bumper cover at
retaining tabs of rear bumper.
01- 19- 7 Bu mp e r s 01- 19- 7
Re a r Cr o wn Vi c t o r i a , Gr a n d Mar qui s
RemovaS and I nst al l at i on
1. Remove si x retaining scr ews f rom rear bumper
cover t o wheel opening fl ange.
2. Remove si x push pins retaining bot t om of rear
bumper cover t o quarter panel and four ri vets
retaining bot t om of rear bumper cover t o rear
bumper.
3. From inside l uggage compart ment , remove 12
rear bumper cover t o body retaining nuts .
4. Remove si x nuts retaining rear bumper t o rear
bumper isolator and bracket .
rear bumper t o rear bumper isolator and bracket
retaining nuts t o 46. 7- 63 N-m (34-47 Ib-ft).
Rear Bumper a n d Bumpe r Co v e r Cr o wn Vi c t o r i a , Gr a nd Ma r qui s
N12588-A
Pa r t
i t em Number De s c r i p t i o n
1 17906 Rear Bumper
Bracket
3 17D755 Rear Bumper Retainer (1
Req'd Each Side)
4 N621927-S36M Nut and Washer
5 N606084-S7 Bol t (1 Req'd Each Side)
6 N804765-S Insert Nut (3 Req'd Each
Side)
8 388930-S Push Pin (3 Req'd Each
Side)
Pa r t
9 17K835 Rear Bumper Cover
Each Side)
A

Lb-ln)
B

(65-87 Lb-Ft)
C

(16-21 Lb-Ft)
01- 19- 8 Bu mpe r s
_ . T T 7 7 T T T
01- 19- 8
" 7 T T T 7 ~ 7 ~ - - ' T T 1
I s o l a t o r a n d Br a c k e t
Remov al
1. CAUTI ON: Never appl y heat t o t h e by mpe r
i sol at or and br acket . Heat coul d c a u s e t he
mat er i al i n si d e t he bumper i sol at or and
br a c ke t t o ex pand a n d l eak. He a t ma y al so
c r a c k t h e me t a l h o u s i n g .
NOTE: Procedure appl i es t o front bumper isolator
and bracket ( 17754) and rear bumper i sol ator
and bracket ( 17787) .
Remove front bumper ( 17757) or rear bumper
2. Remove bol ts retaining bumper isolator and
bracket t o f rame.
3. Remove bumper isolator and bracket .
1. Inspection must be made pri or t o reusing bumper
isolator and bracket .
a. There must be no visible fluid l eakage f rom
bumper isolator and bracket .
There must be no deformati on t o t he inner or
outer cyl i nders.
At ambi ent t emperat ures, it must not be
possi bl e t o turn by hand t he outer cylinder
relative t o the inner cylinder.
Pl ace the bumper isolator and bracket in an
arbor, or equivalent. Press and st roke the
bumper isolator and bracket approxi matel y
13 mm ( 1 / 2 inch) t o determi ne whether it
returns t o its original l ength. If it does not
return t o its original l ength, it should not be
reused. A bumper i sol ator and bracket that
does not return t o its original length may
have devel oped l oss of pressure or fluid that
woul d prevent it f rom functioning correct l y in
subsequent i mpact s.
Minor strai ghteni ng of t he bumper isolator
and br acket is permi ssi bl e provi ded
condi ti ons A through D are met.
Install bumper i sol ator and bracket .
Install bol ts retaining bumper i sol ator and bracket
t o f rame. Tighten front or rear bumper isolator
and bracket t o f rame bol ts t o 87. 5- 118. 5 N-m
(65-87 Ib-ft). Tighten bumper i sol ator and bracket
t o bumper nuts t o 46. 7- 63. 3 N-m (34-47 Ib-ft).
b.
c.
e.
2.
3.
Mo u n t i n g B r a c k e t , L i c e n s e P l a t e
1. Remove license pl ate (if equi pped).
2. Drill out rivets retaining front license pl ate
mounting br acket ( 17A386) to front bumper
( 17757) .
3. Remove front l i cense pl ate mounting bracket .
N11284-A
Part
1 17A385 Front License Plate
Mounting Bracket
3

License Plate
4 17A395 Frame, Front License Plate
Mounting Bracket
5 N806830-S100 Rivet (2 Req'd)
6 17A386 Hardware Front License
Plate Mounting Bracket
01- 19- 9 Bumper s 01- 19- 9
SPECIFICATIONS
Bumper Height Specifications
Town Ca r
SECTION k
SECTION B
SECTION B
N8518-C
Par t
3 17906 Rear Bumper
Part
A

396 m m 25 m m (15.6 1
i n c h ) B u m p e r t o G r o u n d
T h r o u g h I n s p e c t i o n H o l e a t
C e n t e r L i n e
B

394 m m 2 5 m m (15.5 1
i n c h ) B u m p e r to G r o u n d
T h r o u g h I n s p e c t i o n H o l e a t
Center L i n e
01-19-10 Bu mp e r s 01-19-10
Cr own Vi c t o r i a , Gr and Mar qui s
SECTION B
N8862-C
I t em
Par t
2 17754 Front Bumper Isolator
Bracket
6 17906 Rear Bumper
( Co n t i n ue d )
Pa r t
A 396 mm 2 8 mm (15.6 1.1
inches) Crown Vi ctori a
381 mm 2 8 mm (15 1.1
inches) Grand Marquis
Bumper to Ground Through
Inspection Hole at Center
Line
B 380 mm 25 mm (14.96 1
inch) Bumper to Ground
Through Inspection Hole at
Center Line
TORQUE SPECIFICATIONSTOWN CAR
De sc r i pt i on N-m Lb- Ft
Fr o n t Bu mp e r I s o l a t o r a n d Br a c ke t
Nut s
34- 46 2 5- 34
Fr o n t Bu mp e r Co v e r t o Fr o n t
Fe n d e r S c r e ws
1. 1-1. 5 10- 13
( L b- l n )
Fr o n t Bu mp e r Co v e r t o Fr o n t
Fe n d e r Nut s
8. 9- 12 . 1 7 9- 107
( L b- l n )
Fr o n t Bu mp e r Co v e r S c r e ws 1. 4-2. 0 12- 18
( L b- l n )
( Co n t i n ue d )
TORQUE SPECIFICATIONSTOWN CAR (Cont ' d)
Fr o n t Bu mpe r I so l a t o r a n d Br a c ke t
Bo l t
68- 92 50- 68
Re a r Bumpe r t o Re a r Bu mpe r
I s o l a t o r a n d Br a c ke t Nut s
34- 46 2 5- 34
Re a r Bumpe r Co v e r Mo un t i n g
Re i n f o r c e me n t Nut s
8- 12 6- 9
( Co n t i n ue d )
01- 19- 11
H m n H B H n
SPECIFICATIONS (Conti nued)
TORQUE SPECIFICATIONSTOWN CAR (Cont ' d)
Description N-m L b - Ft
Re a r Bu mpe r Co v e r Re t a i n i n g
S c r e ws
1. 1-1. 5 10- 13
( L b- l n )
Re a r Bu mpe r Co v e r Re t a i n i n g Nut s 8. 9- 12 . 1 7 . 9- 107
( L b- l n )
TORQUE SPECIFICATIONSCROWN VICTORIA,
GRAND MARQUIS
Bu mpe r I s o l a t o r a n d
Br a c ke t - t o - Bu mp e r
46. 7 - 63 34- 47
Bu mp e r Co v e r - t o - Fe n d e r S c r e w 1-2 8- 17
( L b- l n )
Fr o n t Bu mp e r Co v e r - t o - Ra d i a t o r
Su p p o r t S c r e w
5- 8 44- 7 0
( L b- l n )
I nner Fe n d e r - t o - Fr o n t Bu mp e r
Co v e r S c r e ws
5-8 44- 7 0
( L b- l n )
01- 19- 11
TORQUE SPECIFICATIONSCROWN VICTORIA,
GRAND MARQUIS (Cont 'd)
Bu mp e r I s o l a t o r a n d Br a c ke t Bo l t s 87 . 5- 118. 5 65- 87
Re a r Bu mp e r Co v e r t o Fe n d e r Nut s 5-8 44- 7 0
( Lb- l n )
Bu mp e r Co v e r
E x t e n s i o n - t o - Fe n d e r S c r e ws
1-2 9- 18
( Lb- l n )
Fr o n t Fe n d e r E x t e n s i o n Fr o n t
Bu mp e r Co v e r Nut s
9- 14 6- 10
Fr o n t Bu mp e r Co v e r Bo t t o m
S c r e ws
5- 8 44- 7 0
( Lb- l n )
Fr o n t Bu mp e r Co v e r t o Uppe r Fr o n t
Fe n d e r
1-2 9- 18
( Lb- l n )
Fr o n t Bu mp e r Co v e r t o L o we r
Ra d i a t o r Su p p o r t Br a c ke t
5- 8 44- 7 0
( Lb- l n )
01- 2 0A - 1 0 1 - 2 0 A - 1
SECTION 01-20A Restraints, Active
SUBJECT PAGE
VEHICLE APPLICATION 01-20A-1
Child Safety Seat, Tether At t achment 01-20A-6
Canadi an Vehicles Only 01-20A-6
Tether Anchor Hardware 01-20A-6
Occupant Restraint System 01-20A-1
Saf et y Belt Buckl e 01-20A-2
Saf et y Belt Extensi on Assembl y 01-20A-6
Saf et y Bel t , La p/ Sho ul d e r Fr o n t 01-20A-2
Saf et y Bel t , Lap Cent er 01-20A-3
Saf et y Bel t , La p/ Sho ul d e r Re a r 01-20A-3
Cr own Vi ct or i a, Grand Mar qui s. 01-20A-4
Town Car 01-20A-3
Shoul der St rap Adj ust er, Front Seat ... 01-20A-6
Unf ast eni ng Saf et y Bel t s wi t h
Ret r act or s 01-20A-6
Warni ng Syst em, Saf et y Bel t . . . 01-20A-6
I nspect i on and Veri f i cat i on 01-20A-7
Sy mpt om Chart 01-20A-7
Chi l d Saf et y Seat 01-20A-16
Chi l d Saf et y Seat Locki ng Cli p ..01-20A-16
Chi l d Saf et y Seat , Tet her At t achment ..01-20A-14
Tet her At t achment 01-20A-15
Wi ndow Tray, Re a r Cr own Vi ct or i a,
Grand Marqui s 01-20A-15
Wi ndow Tray, Re a r Town Car 01-20A-15
Tet her At t achment Locat i on 01-20A-14
Saf et y Bel t s, Fr ont Seat s. . 01-20A-7
Buckl e End 01-20A-9
Ret ract or and Tongue .01-20A-7
SUBJECT PAGE
Saf et y Bel t Asse mbl y Fr o n t 01-20A-8
Saf et y Bel t s, Rear Seat s 01-20A-10
Bel t and Buckl e . 01-20A-12
Ret ract or and Tongue 01-20A-10
Shoul der St rap Adj ust er, Fr ont Seat . . . . 01-20A-13
SERVICE PROCEDURES
Funct i onal Test Procedure 01-20A-21
Saf et y Bel t Procedure Af t er A Col l i si on 01-20A-18
Saf et y Bel t Tongue Rot at ed on Bel t 01-20A-20
Saf et y Bel t Twi st ed at Saf et y Bel t
Gui de 01-20A-20
Saf et y Bel t wi t h Anchor Pl at e Thread
Damage 01-20A-18
Saf et y Bel t wi t h No Anchor Plate Thread
Damage 01-20A-18
Shoul der St rap Adj ust er wi t h St r i pped Weld
Nut s, Front Seat . . . 01-20A-19
Saf et y Bel t Mai nt enance 01-20A-22
Saf et y Bel t Webbi ng 01-20A-22
ADJUSTMENTS
Saf et y Bel t s, La p/ Sho ul d e r Fr o n t and
Rear ...01-20A-22
Lap Port i on Adj ust ment ....01-20A-23
Saf et y Bel t s, Fast eni ng 01-20A-22
Saf et y Bel t s, Unf ast eni ng. . . . 01-20A-22
Shoul der Port i on Adj ust ment 01-20A-23
Shoul der St rap Belt Hei ght Adj ust ment ,
Front 01-20A-24
SPECIFICATIONS. 01-20A-24
VEHICLE APPLICATION
Occupant Restrai nt Syst em
A continuous-loop, si ngl e-retractor act i ve restrai nt
syst em is used for the out board front and outboard
rear l ap/ shoul der saf et y bel ts.
01- 20A- 2 Re s t r a i n t s , A c t i v e 01- 2 0A - 2
DESCRIPTION AMD OPERATION (Cont i nued)
WARNINGS CHI LDREN HAVI NG A SEATI NG
HEI GHT GREATER THAN 7 1 CM ( 2 8 I NCHES)
SHOULD USE THE SAFETY BELTS PROVI DED
WI TH THE VEHI CLE. HOWEVER, THE SHOULDER
BELT PORTI ON OF THE LAP SHOULDER SAFETY
BELT SHOULD MOT BE USED IF I T CONTACTS
THE CHI LD' S FACE, CHI N, NECK OR THROAT. IF
THE SHOULDER PORTI ON OF THE SAFETY BELT
EITHER TOUCHES OR HANGS IN FRONT OF THE
CHI LD' S FACE, CHI N, NECK OR THROAT, MOVE
THE CHI LD CLOSER TO THE CENTER OF THE
VEHI CLE. IF THE SHOULDER BELT STI LL DOES
NOT FIT, MOVE THE CHI LD TO A SEAT WI TH A
LAP BELT ONLY. IF THE SAFETY BELTS ARE NOT
ADJUSTED PROPERLY, THE CHI LD' S CHANCES
OF BEI NG I NJURED IN A COLLI SI ON I NCREASE.
WARNI NG: ALL VEHI CLE OCCUPANTS,
I NCLUDI NG PREGNANT WOME N, SHOULD WE AR
SAFETY BELTS FOR MAXI MUM PROTECTI ON IN
THE EVENT OF A COLLI SI ON. A L L VEHI CLE
OCCUPANTS, I NCLUDI NG PREGNANT WOME N,
SHOULD BE SURE THE LAP SAFETY BELT OR L AP
SAFETY BELT PORTI ON OF THE LAP- SHOULDER
BELT, IS FI TTED SNUGLY AND A S L OW A S
POSSI BLE AROUND THE HI PS, NOT THE WAI ST.
FAILURE TO PROPERLY UTI LI ZE THE SAFETY
BELTS MAY I NCREASE THE CHANCES A N D/ OR
SEVERI TY OF I NJURY IN THE EVENT OF A
COLLI SI ON.
ACCORDI NG TO ACCI DENT STATI STI CS,
PROPERLY RESTRAI NED CHI LDREN ARE SAFER
IN THE REAR SEAT THAN IN THE FRONT SEAT.
FOR YOUNG CHI LDREN, I NFANT AND CHI LD
RESTRAI NTS SHOULD BE OBTAI NED AND USED
IN ACCORDANCE WI TH THE I NSTRUCTI ONS
PROVI DED BY THE MANUFACTURER OF THE
I NFANT AND CHI LD RESTRAI NT. CHI LD
RESTRAI NT USE I S REQUI RED BY LAW.
The l ap/ shoul der saf et y belt assembl y consi sts of:
Belt we bbi ng.
Tongue,
e Retractor.
The ret ract or is desi gned t o let the webbi ng move in or
out freel y except for hard braki ng, corneri ng or
i mpact s of approxi mat el y 8 k m/ h (5 mph) or higher
when t he webbi ng is automati cal l y l ocked by a
mechani cal l y-actuated inertia sensor.
R3404-D
I t e m
Pa r t
1 Belt Spool
2

Mounting Bracket
3

Spool Pin
4

Locking Assy
5

Inertia Sensor
Saf et y Belt Buckle
The front inboard belt buckl e is secured t o the seat
t r ack and the rear i nboard belt buckl e is secured t o t he
front fl oor pan ( 11135) .
Attachi ng t he tongue and buckl e secures t he
out board occupant s wi t h bot h l ower and upper
restrai nts.
This tongue and belt attachment can be
accompl i shed by single, continuous movement.
Saf et y Belt, Lap/ Shoul der Fr ont
The front seat lap / shoulder saf et y belt ext ends
f rom a ret ract or l ocated on vehicle structure
underneath the B-pillar tri m up t o a front saf et y belt
gui de ( 613D 10) l ocated on the B-pillar post .
The webbi ng then ext ends f rom front safety belt
guide above and behind t he occupant ' s shoulder,
di recti ng t he webbi ng at t he proper downward angle
over t he occupant ' s shoulder and chest t o front
saf et y belt buckl e end ( 61203) .
01- 20A- 3 Re s t r a i n t s , A c t i v e 01- 2 0A - 3
@ The l a p/ sho ul d e r saf et y belt has a t ongue t hat
l at ches t o f ront sa f e t y belt buckl e end and cont i nues
t hr ough t he t ongue out boa r d t o t he sill bel ow t he
door openi ng and a c t s as a l ap sa f e t y bel t .
The i nboard dri ver and passenger f r ont sa f e t y bel t
buckl e ends ( 612 02 ) are secur ed t o t he f r ont seat
t r a c k.
At t achi ng t he t ongue and buckl e se c ur e s t he
out boa r d oc c upa nt s wi t h bot h l ower and upper
r est r ai nt s.
Thi s t ongue and belt at t achment c a n be
accompl i shed by a si ngl e, cont i nuous movement .
Pa r t
1 61203 Driver Front Safety Belt
Buckle End
2 61202 Passenger Front Safety Belt
Buckle End
(Continued)
Pa r t
Guide Cover
4 N806773 Front Safety Belt Guide Hex
Flange Retaining Nut
5

B-Pillar
6 613D10 Front Safety Belt Guide
and Tongue
9 611B32 Safety Belt Retractor Cover
Bolt Access Plug
10 61705 Front Seat Track
Lb-Ft)
S a f e t y Be l t , L a p C e n t e r
A f ront seat cent er passenger belt ( 611B60) is
pr ovi ded f or t he cent er f ront seat i ng posi t i on wi t h t he
f ront seat cent er passenger belt se c ur e d t o t he f r ont
f l oor pan ( 11135) under t he seat t r a c k.
S a f e t y B e l t , L a p / S h o u l d e r R e a r
T o w n Ca r
The rear seat out boar d l a p/ sho ul d e r sa f e t y bel t
ext ends f r o m a r e t r a c t or l ocat ed behi nd t he roof
si de rear quart er t r i m panel in t he C-pillar.
The l ap / shoul der saf et y bel t t hen e xt e nds f r o m
above and behi nd t he occupant ' s shoul der at t he
pr oper d o wn wa r d angl e over t he occupant ' s
shoul der and chest t o t he rear sa f e t y belt and
buckl e ( 60044) .
The l ap / shoul der sa f e t y bel t has a t ongue t hat
l at ches t o t he rear saf et y belt and buckl e and
cont i nues t hrough t he t ongue out boa r d t o t he rear
f l oor pan ( 11215) .
01- 2 0A - 4 Re s t r a i n t s , A c t i v e 01- 20A- 4
Town Ca r
R8030-B
Pa r t
1 389370-S100 Rear Safety Belt Retractor
Bolt (2 Req'd)
and Tongue
3 52018 Roof Side Rear Quarter Trim
Panel
4 N800937-S190 Rear Safety Belt Anchor Nut
A
Lb-Ft)
Cr o wn Vi c t o r i a
I t e m
Pa r t
Lb-Ft)
The i nboard rear safety belt and buckl e passes
through t he rear seat cushi on.
Attachi ng the tongue and buckl e secures the
occupant wi t h both l ower and upper restrai nts.
This attachment of the tongue and buckl e can be
accompl i shed by a single, continuous movement.
The rear seat out board l ap/ shoul der safety belt
ext ends f rom a retractor l ocated on vehicle
structure underneath the package t ray tri m panel
( 46668) up t o a rear safety belt guide l ocated on the
C-pillar.
The belt is angled and then ext ends from the rear
saf et y belt guide above and behind the occupant ' s
shoulder, di recti ng the webbi ng at t he proper
downwar d angle over the occupant ' s shoulder and
chest t o the rear saf et y belt and buckl e.
The lap / shoulder belt has a tongue on it that
l atches t o the rear safety belt and buckl e and
continues through the tongue outboard t o the front
floor pan ( 11135) .
The i nboard rear safety belt and buckl e passes
through t he rear seat cushi on.
Attachi ng the tongue and buckl e secures the
occupant wi t h both l ower and upper restrai nts.
This attachment of the tongue and buckl e can be
accompl i shed by a single continuous movement.
R710-C
01- 2 0A - 5 Re s t r a i n t s , A c t i v e 01- 2 0A - 5
Pa r t
It em Nu mb e r De s c r i p t i o n
Panel
2 60044 Rear Safety Belt and Buckle
4 N800937-S190 Rear Center Safety Belt
Anchor Nut (2 Req'd)
6 Rear Seat Cushion
and Tongue
( Co n t i n ue d )
Pa r t
8 38G272-S100 Rear Safety Belt
Anchor-to-Rear Trim Panel
Bolt
Bolt (2 Req'd)
A

Tighten t o 40-55 N-m (30-41
Lb-Ft)
B

Lb-Ft)
Gr and Ma r qui s
Pa r t
1 Rear Seat Cushion
Panel
and Tongue
( Co n t i n ue d )
R71S2-C
I t e m
Pa r t
8 386272-S100 Rear Safety Belt
Anchor-to-Rear Trim Panel
Bolt
Bolt
A

Lb-Ft)
B

Lb-Ft)
Center rear seat is equi pped wi th a lap saf et y belt
assembl y. The center rear lap saf et y belt assembl y
consi sts of:
A safety belt and buckle on the RH side (part of rear
safety belt and buckl e.
A safety belt and tongue on t he LH mie Coart of rear
safety belt and buckl s (60045}},
01- 2 0A - 6 Rest r ai nt s, A c t i v e 01- 20A- 6
The rear saf et y belt and buckle assembl i es are
anchored t o the rear floor pan.
Sh o u l d e r St r a p A d j u s t e r , F r o n t S e a t
Front seat shoulder st rap adj uster ( 602B82) is
at t ached t o t he upper B-pillar structure by t wo bol ts.
The height of the shoulder st rap can be adj usted t o
one of fi ve posi ti ons. Refer t o Adj ustments.
R7494-B
Pa r t
1
Release Button (Part of
602B82)
2 602B82 Front Seat Shoulder Strap
Adj uster
3

B-Pillar
and Tongue
5 20125 Front Door
6 24631 Rear Door
Unfastening Safety Belts wi th Retractors
Push t he rel ease button on the end of the buckl e.
This al l ows the tongue t o unlatch f rom t he buckl e.
While t he belt ret ract s, guide the tongue t o its
original position t o prevent it f rom stri ki ng the
techni ci an or the vehi cl e.
Safety Belt Extension Assembly
A saf et y belt t hat is too short, even when fully
ext ended can be l engthened. Saf et y belt extensi on
( 611C22) assembl y is avai l abl e. Thi s assembl y will
add approxi mat el y 20 cm (8 i nches) t o t he length of
the saf et y belt. Saf et y belt extensi ons are avai l abl e at
no cost f rom any authori zed Ford or Li ncol n-Mercury
Warning S y s t e m, Sa f e t y Be l t
If dri ver' s safety belt is fastened when the ignition
swi t ch ( 11572) is turned t o RUN, the saf et y belt
warni ng indicator lamp ( 10C869) in t he instrument
cl uster ( 10849) will not illuminate.
If the dri ver' s safety belt is not f ast ened when the
ignition swi t ch is turned t o RUN, the safety belt
warni ng indicator lamp will illuminate steadi l y for
approxi mat el y one minute and the saf et y belt warni ng
chi me ( 10D840) will sound for approxi matel y six
seconds. If the driver fastens the saf et y belt whi l e
saf et y belt warni ng indicator lamp is illuminated, t he
saf et y belt warni ng indicator lamp will turn off
immediately.
Ch i l d S a f e t y Se a t , T e t h e r A t t a c h me n t
T e t h e r A n c h o r Ha r d wa r e
If child saf et y belt anchor tether ( 613D74) hardware is
requi red for the child saf et y seat, child safety belt
anchor tether hardware can be obtai ned free f rom any
Ford or Li ncol n-Mercury dealer. At t achment holes at
each rear seati ng position have been provi ded in all
vehi cl es.
Canadi an Ve h i c l e s OnSy
WARNI NG: WHEN USI NG ANY I NFANT OR CHI LD
RESTRAI NT SYSTEM, IT IS I MPORTANT THAT
YOU FOL L OW THE I NSTRUCTI ONS PROVIDED BY
THE MANUFACTURER CONCERNI NG I TS
I NSTALLATI ON AND USE. FAI LURE TO FOL L OW
EACH OF THE RESTRAI NT MANUFACTURER' S
I NSTRUCTI ONS CAN RESULT IN A CHI LD
STRI KI NG THE VEHI CLE' S I NTERI OR DURI NG A
SUDDEN STOP OR COLLI SI ON.
WARNI NG: CHI LDREN HAVI NG A SEATI NG
HEI GHT GREATER THAN 71 CM ( 28 I NCHES)
SHOULD USE THE SAFETY BELTS PROVI DED
WI TH THE VEHI CLE. HOWEVER, THE SHOULDER
BELT PORTI ON OF THE LAP SHOULDER SAFETY
BELT SHOULD NOT BE USED IF IT CONTACTS
THE CHI LD' S FACE, CHI N, NECK OR THROAT. IF
THE SHOULDER BELT CONTACTS OR REMAI NS
IN FRONT OF THE CHI LD' S FACE, CHI N, NECK OR
THROAT, MOVE THE CHI LD TO A SEAT WI TH A
LAP SAFETY BELT ONLY (IF AVAI LABLE) .
FAI LURE TO FOL L OW THI S PRECAUTI ON CAN
I NCREASE THE RISK OR SEVERI TY OF I NJURY IN
THE EVENT OF A COLLI SI ON.
WARNI NG: IT IS I MPORTANT THAT THE
BOL T/ ANCHOR BE SECURELY TI GHTENED TO
SPECI FI CATI ON. OTHERWI SE, THE CHI LD' S
SAFETY SEAT MAY NOT BE PROPERLY
SECURED, AND THE CHI LD COULD BE I NJURED IN
CASE OF A SUDDEN STOP OR COLLI SI ON.
All vehi cl es built for sal e in Canada include a child
safety belt anchor tether hardware kit for use wi th
Canadian child safety seat s.
01- 2 0A - 7 Re st r a i n t s, Act i ve
D E S C R I P T I O N A N D O P E R A T I O N ( C o n t i n u e d )
Some chi l d sa f e t y seat s provi de a t et her st r a p
whi c h goe s over t he back of t he vehi cl e seat and
a t t a c he s t o an anchor in t he f l oor or panel behi nd
t he rear seat .
If a t e t he r e d chi l d' s saf et y seat i s i nst al l ed in t he
f ront seat , it shoul d be i nst alled in t he f ront cent er
seat i ng posi t i on.
o The t et her st r a p must be ho o ke d t o t he we bbi ng of
t he buc kl e d rear cent er lap sa f e t y bel t behi nd t he
chi l d' s sa f e t y seat .
@ At t a c hme nt hol es (at e a c h rear seat i ng posi t i on)
have been provi ded t o a t t a c h t he chi l d sa f e t y bel t
anchor t et her ha r d wa r e ki t .
DIAGNOSIS AND T E S T I N G
1. Veri fy t he vehi cl e owner ' s ori gi nal concer n by
oper at i ng t he act i ve rest rai nt sy st e m t o dupl i cat e
t he condi t i on.
2. I nspect t o det ermi ne if one of t he f ol l owi ng
I n s pe c t s a f e t y b e l t we b b i n g
f o r i n t e gr i t y .
Bu r n e d o ut f us e .
Ba r e , b r o ke n o r
d i s c o n n e c t e d wi r e .
Co n n e c t o r not t i gh t l y
e n g a g e d .
Sa f e t y be l t wa r n i n g
i n d i c a t o r l a mp b u r n e d o ut o r
b r o ke n .
3. If the concer n(s) remai ns af t er t he i nspect i on,
Sy mpt o m Chart .
RESTRAINTS, ACTIVE
Safety Belt Warning Chime Does
Not Operate, Safety Belt Warning
Indicator Lamp OK
Power fuse.
Wiring.
Safety belt warning chime.
REPLACE fuse.
SERVICE wiring.
Safety Belt Warning Indicator
Lamp Does Not Operate, Safety
Belt Warning Chime OK
Power fuse.
@ Burned out bulb.
Wiring.
J Safety belt warning chime.
REPLACE fuse.
REPLACE bulb. REFER to Section
13-00.
SERVICE wiring.
Neither Safety Belt Warning Chime
Nor Safety Belt Warning Indicator
Lamp Operates
Power fuse.
Burned out bulb.
Wiring.
REPLACE fuse.
REPLACE bulb. REFER to Section
13-00.
SERVICE wiring.
Excessive Pressure On Occupant
During Normal Wear
Webbing Cannot Be Extracted
Excessive Slack in Webbing,
Webbing Does Not Retract
Front safety belt retractor and
tongue.
e Rear safety belt retractor and
tongue.
REPLACE if necessary.
m PERFORM Functional Test
Procedure in this secti on.
S a f e t y Be l t s , F r o n t S e a t s
Re t r a c t o r a n d T o n g u e
Se a t Be l t Bo l t Bi t T 7 7 L - 2 100- A
01- 20A- 8 Re st r a i n t s, Ac t i ve 01- 20A- 8
Re mo v a l a n d i nst al l at i on
1. NOTE: Seat Belt Bolt Bit T77L-2100-A (No. 50
TORX) should be used for removal and
installation of all safety belt assembl i es.
Remove front seat shoulder st r a p gui de cover
( 60262) by slipping finger behind front seat
shoulder st rap guide cover t owar d center of
vehicle t o di sl odge f r om front safety belt guide
( 613D 10). Lift front seat shoulder st rap guide
cover t o remove.
2. Insert Seat Belt Bolt Bit T77L-2100-A (No. 50
TORX) and remove the front saf et y belt guide
hex flange retaining nut.
3. Remove front safety belt anchor-to-sill bolt.
To wn Car
5. Remove front safety belt guide screw f rom
B-pillar.
6. Remove front safety belt ret ract or bolt.
7. Remove front safety belt ret ract or and tongue
( 611B08) f rom vehi cl e.
9. Make sure the safety belt webbi ng is not t wi st ed.
If it is, remove the twi st. (Refer t o Adj ustments.)
10. Tighten all anchor bol ts and retaining nuts t o the
requi red speci fi cati on shown for each mounting
posi ti on.
11. Check the restrai nt syst em for proper operati on.
S a f e t y Be l t A s s e m b l y F r o n t
X
FRONT OF
VEHICLE
X
RS3S1-E
Pa r t Pa r t
1 56902-S2 Screw (2 Req'd) 8 64810 Front Seat Back
2 389370-S100 Front Safety Belt Retractor
Bolt
9 N620483-S36 Front Center Safety Belt
Anchor Nut and Washer
and Tongue
Adj uster
Guide Cover
11 N806774-S190 Front Seat Shoulder Strap
Adj uster Bolt
5 N806773-S190 Front Safety Belt Guide Hex
Flange Nut
A

Lb-Ft)
6
_
B-Pillar B

7 386277-S100 Front Safety Belt
Lb-Ft)
Anchor-to-Sill Bolt
Re s t r a i n t s , A c t i v e 01- 2 0A - 9
REMOVAL AND INSTALLATION (Cont i ni
Par t
3 56902-S2 Screw
4 N806773-S190 Front Safety Belt Guide Hex
Flange Retaining Nut
5 B Pillar
and Tongue
7 389370=8100 Front Safety Belt Retractor
Bolt
8 386277-S100 Front Safety Belt
Anchor-to-Siil Bolt
VIEW A
VIEW B
R2339-P
Pa r t
9 611B32 Safety Belt Retractor Cover
Bolt Access Plug
10 N806774-S190 Front Seat Shoulder Strap
Adj uster Bolt :
11
602B82 Front Seat Shoulder Strap
Adj uster
12 N620483-S36 Front Center Safety Belt j
Anchor Nut
A

Lb-Ft)
B

Lb-Ft)
( Co n t i n ue d )
Bu c k l e E n d
1. Remove front t rack end cover.
2. Remove front center saf et y belt buckl e end
anchor nuts and washers (on LH si de di sconnect
saf et y belt buckl e swi t ch wi r e).
Slide the center front saf et y belt assembl i es
through the slots in front seat and remove f rom
vehicle.
1995 Town Car, Cr o wn Vi c t o r i a , Gr a n d Mar qui s Jul y 1994
01- 2 0A - 10 Re s t r a i n t s , A c t i v e 01- 2OA- 1O
front center saf et y belt anchor nuts t o 60- 90 N-m
( 44- 60 Ib-ft).
S a f e t y B e l t s , Re a r S e a t s
Re t r a c t o r a n d T o n g u e
1. Remove rear seat cushion kit ( 60080) . Refer t o
Secti on 01- 10.
2. Remove rear saf et y belt anchor nut.
3. Remove roof si de rear quarter tri m panel. Refer
4. Remove rear saf et y belt opening grommet and
pull rear saf et y belt wi t h tongue through belt
openi ng in the quarter tri m panel .
5. Remove rear saf et y belt ret ract or bol ts.
6. Remove out board rear saf et y belt ret ract or and
tongue ( 611B68) f rom t he vehicle.
8. Make sure the saf et y belt webbi ng is not t wi st ed.
If it is, remove the t wi st . (Refer t o Adj ustments.)
9. Tighten all anchor bol ts and retaining nuts t o the
requi red speci fi cati on shown for each mounting
posi ti on.
10. Check the restraint syst em for proper operati on.
To wn Car
I t e m
Pa r t
Bolt (2 Req'd)
and Tongue
Panel
A

Lb-Ft)
B

Lb-Ft)
01- 2 0A - 11
Rest r ai nt s, A c t i v e 0 1 - 2 0 A - 1 1
Crown Vi c t o r i a
R7190-C
Pa r t
I t em Number De s c r i p t i o n
Panel
5
6
N800937-S190 Rear Safety Belt Anchor Nut
Rear Seat Cushion
and Tongue
Pa r t
Anchor-to-Rear Quarter Trim
Panel Bolt
Bolt (2 Req'd)
A

Lb-Ft)
B

Lb-Ft)
( Co n t i n ue d )
I
01- 2 0A - 12 Re s t r a i n t s , A c t i v e 01- 2 0A - 12
Gr a nd Mar qui s
Pa r t
1
Rear Seat Cushion
Panel
and Tongue
R7192-C
Pa r t
Anchor-to-Rear Quarter Trim
Panel Bolt
Bolt
A

Lb-Ft)
B

Lb-Ft)
Be l t a n d B u c k l e
1. Slide out rear seat cushion t o gain access t o rear
saf et y belt and buckl e ( 60044) at t achment s t o
t he rear fl oor pan ( 11215) at the tunnel. Refer t o
Secti on 01- 10.
2. Remove rear center saf et y belt and buckl e
anchor nuts.
01- 2 0A - 13 Re st r a i n t s, Ac t i v e 01- 2 0A - 13
To wn Car
R10881-A
Pa r t
3

Rear Seat Cushion
4 N800937-S190 Rear Center Safety Belt Anchor Nut (2 Req'd)
5 63370 Rear Seat Cushion Front Retainer
A

Tighten t o 40-55 N-m (30-41 Lb-Ft)
S h o u l d e r S t r a p A d j u s t e r , F r o n t S e a t
Re mo v a l
1. Remove front seat shoulder st rap gui de cover
( 60262) by slipping finger behind front seat
shoul der st rap guide cover t owar d center of
vehi cl e t o di sl odge f rom front saf et y belt guide
( 613D 10). Lift front seat shoulder st rap guide
cover t o remove.
2. Insert Seat Belt Bolt Bit T77L-2100-A (No. 50
TORX) and remove the front saf et y belt guide
hex fl ange retaining nut.
4. Remove front seat shoulder st rap adj uster bolts
and remove front seat shoulder st rap adjuster
( 602B82) .
1. Insert t he front seat shoulder strap adj uster in t he
opening of the upper B-pillar structure. Make sure
that front seat shoulder st rap adjuster knob on
the front seat shoulder st rap adjuster is
posi ti oned above the front safety belt gui de ring
attachment stud. (The fool-proofing t ab is l ocat ed
at the bot t om and is t o be inserted in the hole
provi ded in the B-pillar structure.)
2. Align bot h attachi ng bol ts in the front seat
shoulder strap adjuster t o the wel d nuts in the
B-pillar reinforcement.
3. Hand-start the top attachi ng bolt and ti ghten until
it is snug.
4. Hand-start the bottom attachi ng bolt and tighten
until it is snug.
5. Tighten the t op and bot t om front seat shoulder
strap adjuster bolts t o 30- 40 N-m (22-30 Ib-ft).
01- 20A- 14 Re st r a i n t s, Ac t i ve 01- 2 0A - 14
REMOVAL AND I N S T A L L A T I O N ( C o n t i n u e d )
6. After installation of the front seat shoulder st rap
adj uster, install the center body pillar inside upper
finish panel . Refer t o Secti on 01- 05.
7. NOTE: Knob must be abl e t o travel f rom t op t o
bot t om of slot in the B-pillar upper finish panel .
Function the adj uster knob by squeezing the
rel ease button and sliding the front seat shoulder
st rap adjuster up and down.
8. Position the front safety belt guide t o the B-pillar.
Position and hand-start the front safety belt guide
hex flange retaining nut on the front seat shoulder
st rap adj uster st ud. Tighten t o 30-40 N-m (22-30
Ib-ft).
9. Check t o see that the front saf et y belt guide
rot at es freel y after installation.
10. Install t he front seat shoulder st rap guide cover
over the front saf et y belt guide hex flange
retaining nut and snap it into pl ace.
11. Position the front seat shoulder st rap adjuster
knob in the uppermost posi ti on.
12. Check the restrai nt syst em for proper operati on.
C h i l d Safety Seat, T e t h e r Attachment
The chi l d safety belt anchor t et her ( 613D74) kit can
be obtai ned free f rom any Ford or Li ncol n-Mercury
dealer.
WARNI NG: WHEN USING ANY I NFANT OR CHI LD
RESTRAI NT SYSTEM, IT IS I MPORTANT THAT
YOU FOLLOW THE I NSTRUCTI ONS PROVI DED BY
THE MANUFACTURER CONCERNI NG I TS
I NSTALLATI ON AND USE. FAILURE TO FOLLOW
EACH OF THE RESTRAI NT MANUFACTURER' S
I NSTRUCTI ONS CAN RESULT IN A CHI LD
STRI KI NG THE VEHI CLE' S INTERIOR DURING A
SUDDEN STOP OR COLLI SI ON.
WARNI NG: IT IS I MPORTANT THAT THE
BOLT/ ANCHOR BE SECURELY TI GHTENED TO
SPECI FI CATI ON. OTHERWI SE, THE CHI LD' S
SAFETY SEAT MAY NOT BE PROPERLY
SECURED, AND THE CHI LD COULD BE INJURED IN
CASE OF A SUDDEN STOP OR COLLI SI ON.
To install, fol l ow instructions provi ded wi th the child
saf et y belt anchor tether kit.
T e t h e r A t t a c h m e n t L o c a t i o n
Dimension A is the di stance f rom the centerline of the
vehicle t o the center of t he tether attachment hol es.
Dimension B is t he approxi mat e di stance f rom the
center of the radi o speaker grille opening t o the center
of the tether attachment hol es.
VEHICLE
DIMENSION "A" DIMENSION " B "
Hole Di amet er
Si ze mm (i nches) VEHICLE
Vehi cl e Cent erl i ne
t o
Tet her Ho l e mm
(i nches)
Speaker Gri l l e
Openi ng
t o Tet her Ho l e mm
(i nches)
Hole Di amet er
Si ze mm (i nches)
Ri ght a n d Le f t L o c a t i o n T o w n Ca r 404( 15 . 9 ) 2 2 1 ( 8. 7 ) 9. 0 ( 0. 35)
Ce n t e r L o c a t i o n T o w n Ca r 82 ( 3. 2 3) 2 1 6 ( 8 . 5 ) 9. 0 ( 0. 35)
Ri ght L o c a t i o n C r o w n Vi c t o r i a 152 ( 6. 0) 4 1 9 ( 1 6 . 5 ) 9. 0 ( 0. 35)
Le f t L o c a t i o n C r o w n Vi c t o r i a 2 5 4( 10. 0) 3 9 4 ( 1 5 . 5 ) 9. 0 ( 0. 35)
Ce n t e r L o c a t i o n C r o w n Vi c t o r i a 0 4 0 6 ( 1 6 . 0 ) 9. 0 ( 0. 35)
Ri ght L o c a t i o n G r a n d Ma r q u i s 2 9 2 ( 11. 5 ) 2 5 4 ( 1 0 . 0 ) 9. 0 ( 0. 35)
Le f t L o c a t i o n G r a n d Ma r q u i s 45 7 ( 18. 0) 178 ( 7 . 0) 9. 0 ( 0. 35)
Ce n t e r L o c a t i o n G r a n d Ma r q u i s 0 4 8 3 ( 1 9 . 0 ) 9. 0 ( 0. 35)
01- 2 0A - 15 Rest r ai nt s, Act i ve 01- 2 0A - 15
Tet her At t a c h me n t
Wi ndow Tr ay, Rear Town Car
From inside t he luggage compart ment looking
underneath the metal panel structure behind the rear
seat, l ocate one of t he three exi sti ng 9 mm ( 0. 35 inch)
di ameter holes identified by the letter " T " . Each
out board hole is l ocat ed approxi matel y 404 mm ( 15. 9
inches) out board f rom t he centerline of the vehi cl e and
along a line 221 mm (8.7 i nches) rearward f rom the
center of the rear seat radi o speaker ( 18808) . The
out board holes are l ocated above t he oval cl earance
holes in t he sheet metal . The center passenger tether
hole is l ocat ed 137 mm (5. 4 inches) out board t owar d
t he passenger side of vehicle f rom t he centerline of t he
vehicle and 99 mm (3. 9 inches) rearward f rom t he
center line of the rear seat radi o speaker.
To wn Car
NOTE: UNDERSIDE VIEW FROM
INSIDE LUGGAGE COMPARTMENT.
PASSENGER SIDE SHOWN DRIVER
SIDE SIMILAR.
Ri04C
Par t
1 Existing 9 mm (0.35 inch)
Child Restraint Tether Holes
in Metal Structure (Behind
Rear Seat) are Marked by
the Letter "T" Stamped Next
to the Hole
2 Outboard Occupant Hole
(Passenger Side Shown,
Driver Side Symmetrically
Opposite)
3

Oval Clearance Hole
Part
4

Rear Seat Speaker
Assembly
5

Center Occupant Hole
Wi n d o w Tr ay, Re a r Cr o wn Vi ct or i a, Gr and
Mar qui s
Three 9 mm ( 0. 35 inch) di ameter hol es are provi ded in
t he rear package t ray sheet metal structure for
at t achi ng the child safety belt anchor tether. For easy
i denti fi cati on, these holes are marked wi t h the letter
" T " st amped next t o t he hol e.
Cr o wn Vi c t o r i a
LEFT SIDE
TETHER HOLE
LOCATION
RIGHT SIDE
7 O ^ A ? , O M
L E
CENTER TETHER
LOCATION HOLE LOCATION
LEFT AND RIGHT SPEAKER
GRILLE OPENING
R718S-A
The right outboard hole is l ocated approxi matel y 152
mm (6 i nches) from center of the package t ray tri m
panel ( 46668) and approxi matel y 419 mm (16. 5
i nches) rearward from the right speaker grille openi ng.
The center hole is l ocated at the approxi mat e center
line of the vehicle, 38 mm (1. 5 inches) rearward from
t he center of the package t ray and is approxi matel y
406 mm (16 inches) away from the right speaker grille
openi ng.
The left outboard hole is l ocated approxi matel y 254
mm ( 10 inches) f rom center of t he package t ray panel
( 46506) and approxi matel y 394 mm ( 15. 5 inches)
rearward f rom the left speaker grille openi ng.
01- 2 0A - 16 Re st r a i n t s, Ac t i v e 01- 2 0A - 16
R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d )
Gr a nd Ma r qui s
CENTER TETHER RIGHT SIDE
HOLE LOCATION TETHER HOLE
LOCATION
REAR SEAT
SPEAKER
EMBOSSED
L E T T E R T'
RIGHT SIDE AND CENTER TETHER
HOLE LOCATIONS GRAND MARQUIS
(VIEW FROM INSIDE LUGGAGE COMPARTMENT)
R7186-A
Gr a nd Marques
LEFT SPEAKER EMBOSSED
GRILLE OPENING LETTER T'
LEFT SIDE
TETHER HOLE
LOCATION
LEFT S I DE T E T H E R HOLE LOCATIONS
GRAND MA R QU I S ( VI E W FFtOH INSIDE
LUGGAGE COMPARTMENT)
R7187-A
The right outboard hole is l ocated approxi matel y 292
mm ( 11. 5 i nches) from center of the package t ray
panel and approxi matel y 254 mm ( 10 inches)
rearward f rom right speaker grille openi ng.
The center hole is l ocated at t he approxi mat e center
line of t he vehi cl e, 457 mm ( 18 inches) rearward f rom
center of the package t ray panel and is approxi matel y
483 mm ( 19 i nches) from right speaker grille openi ng.
The left out board hole is l ocat ed approxi matel y 457
mm ( 18 i nches) f rom center of the package t ray panel
and approxi matel y 178 mm (7 inches) rearward f rom
left speaker grille openi ng.
C h i l d Safety Seat
WARNI NG: ALWAYS KEEP THE BUCKLE RELEASE
BUTTON POI NTI NG UPWARD AND AWAY FROM
THE CHI LD SAFETY SEAT, WI TH THE TONGUE
BETWEEN THE CHI LD SAFETY SEAT AND THE
RELEASE BUTTON AS SHOWN IN THE
FOLLOWI NG I LLUSTRATI ON. FAILURE TO
FOL L OW THESE I NSTRUCTI ONS COULD RESULT
IN ACCI DENTAL UNBUCKLI NG OF THE SAFETY
BELT IF THE CHI LD SAFETY SEAT HI TS THE
RELEASE BUTTON. RELEASE OF THE SAFETY
BELT COULD RESULT IN SERI OUS I NJURI ES.
Use a chi l d' s safety seat that is recommended for t he
si ze and wei ght of the chi l d. Al ways fol l ow the child' s
saf et y seat manufacturer' s instructions when installing
and using the child' s saf et y seat. When installing a
chi l d' s safety seat be sure to use the correct safety
belt buckl e for that seati ng position and make sure t he
tongue is securel y fastened in the buckl e (as shown in
t he fol l owi ng illustration).
NOTE: End rel ease buckl e shown, side rel ease buckl e
t ypi cal .
LOCKING
CLIP
61248
KEEP TONGUE
BETWEEN CHILD
SEAT AND RELEASE
BUTTON
DO NOT USE
THIS BUCKLE -
TONGUE SLOT
ÔN WRONG SIDE
R1
C h i l d Safety Seat L o c k i n g C l i p
The locking clip must be used t o secure a child safety
seat when your vehicle has a shoulder and lap belt
wi t h a sliding tongue. Every seat belt that requires a
l ocki ng clip is identified on the belt, wi th the label as
shown in the following illustration. The l ocki ng clip is
installed on a sampl e pi ece of belt webbi ng t o show
proper installation.
If you do not use a locking clip, injuries coul d result
f rom the child saf et y seat tipping over during normal
vehicle braki ng or corneri ng.
The Locki ng Clip Kit ( F03Z5461248) can be obtai ned
free from any Ford or Lincoln-Mercury dealer.
01- 2 0A - 17 Re s t r a i n t s , A c t i v e 0 1 - 2 0 A - 1 7
Sa f e t y Bel t Locki ng Cl i p a nd La be l Lo c a t i o n
A WARNING
CHILD SEAT
PORTEBEBE
LABEL
LOCATION
R9819-B
To install t he l ocki ng clip:
1. Thread the saf et y belt webbi ng through the
child' s saf et y seat accordi ng t o the child saf et y
seat manufacturer' s i nstructi ons.
2. Buckl e saf et y belt.
3. Pull on shoul der porti on of the saf et y belt t o make
the lap porti on fit snugly. Keepi ng lap saf et y belt
snug, hold lap and shoulder belt porti ons of t he
webbi ng t oget her next t o slip tongue and
unbuckle saf et y belt (as shown in the fol l owi ng
illustration).
LAP BELT
SHOULDER
BELT
SLIDING
TONGUE
4. Slide either corner of l ocki ng cl i p slot that is
cl osest t o t he tongue over bot h l ayers of belt
webbi ng (as shown in t he fol l owi ng illustration).
LAP BELT
SHOULDER
BELT
LOCKING CLIP
SLIDING
TONGUE
R7056-E
5. Pinch both opposi t e edges of belt webbi ng
together and insert into l ocki ng clip slot (as
shown in the fol l owi ng illustration).
LAP BELT
SHOULDER BELT
LOCKING CLIP
PINCH BOTH OPPOSITE
EDGES OF BELT WEBBING
TOGETHER AND INSERT
INTO LOCKING CLIP SLOT R7057-E
6. Pinch both l ayers of belt webbi ng together and
insert into other sl ot of locking clip (as shown in
the following illustration).
LOCKING CLIP
INSERT BOTH LAYERS
OF BELT WEBBING
INTO OTHER SLOT OF
LOCKING CLIP
R7059-E
HOLD THE LAP AND
SHOULDER BELT HERE
END RELEASE BUCKLE SHOWN
OTHER BUCKLES SIMILAR
R7609*B
01- 2 0A - 18
Rest r ai nt s, Act i ve 01- 20A- 18
7. Rebuckl e saf et y belt. Forci bl y tilt the chi l d' s
saf et y seat f rom si de t o si de and al so tug it
f or war d t o see if it is held securel y in pl ace (as
shown in the following illustration). If excessi ve
movement occurs, repeat St eps 2 through 7 or
properl y install chi l d' s saf et y seat in a different
seati ng position in the vehi cl e.
VIEW OF FINAL INSTALLATION
FORCIBLY TILT THE
SEAT FROM SIDE TO
SIDE AND ALSO TUG
IT FORWARD TO
SEE IF IT IS HELD
SECURELY IN PLACE
R10959-A
SERVICE PROCEDURES
The seat and shoul der saf et y bel ts are
factory-i nstal l ed in their proper l ocati ons. If the belts
are removed for any reason, t hey should be installed
as outlined in Removal and Installation. The 7/ 16-inch
x 20 TORX head anchor bol ts must be hand-started
and then ti ghtened t o 30- 40 N-m (22-30 ib-ft).
Saf et y Belt wi t h No Anchor Plate Thread
Damage
1. Remove damaged bolt f rom anchor rei nforcement
and di scard.
2. Install a new bolt by hand. Refer t o Speci fi cati ons
for part number. Tighten t o 30- 40 N-m (22-30
Ib-ft).
S a f e t y Be l t w i t h A n c h o r P l a t e T h r e a d
Da m a g e
1. Remove broken or stri pped bolt and di scard.
2. Drill out t he internal threads in saf et y belt anchor
pl ate wi th a 27 / 64-inch drill (shoulder belt
13/ 32-i nch drill).
3. Rethread anchor plate wi th a 1/ 2-13 t ap (saf et y
bel t ).
4. Bl ow out the chi ps.
5. Install attachment parts in proper sequence
shown in the appl i cabl e illustration. Tighten the
repl acement bolt t o 30-40 N-m (22-30 Ib-ft).
Original part s are t o be repl aced wi th servi ce
part s i ndi cated in Speci fi cati ons.
6. When servicing a multiple belt and attachment,
install nut ( 382599- S100) t o the bolt in the tunnel
area from the underside of the rear floor pan
( 11215) . Tighten t o 30-40 N-m (22-30 Ib-ft).
S a f e t y Be l t P r o c e d u r e A f t e r A C o l l i s i o n
WARNI NG: ALL SAFETY BELT ASSEMBLI ES
I NCLUDI NG RETRACTORS, BUCKLES, FRONT
SEAT BELT BUCKLE SUPPORT ASSEMBLI ES
(SLI DE BAR) , IF EQUI PPED, CHI LD SAFETY SEAT
TETHER BRACKET ASSEMBLI ES (IF EQUIPPED)
AND ATTACHI NG HARDWARE SHOULD BE
I NSPECTED AFTER ANY COLLI SI ON. ALL SAFETY
BELT ASSEMBLI ES SHOULD BE REPLACED
UNLESS A QUALI FI ED TECHNI CI AN FI NDS THAT
THE ASSEMBLI ES SHOW NO DAMAGE AND
OPERATE PROPERLY. SAFETY BELT
ASSEMBLI ES NOT IN USE DURING A COLLI SI ON
SHOULD ALSO BE I NSPECTED AND REPLACED IF
EITHER DAMAGE OR IMPROPER OPERATI ON IS
NOTED.
Before installing the new saf et y belt assembl y, the
saf et y belt attachi ng areas must be i nspected for
damage and di storti on. If the attachi ng points are
damaged and di st ort ed, the sheet metal must be
wor ked back t o its original shape and structural
integrity.
Install the new saf et y bel t(s) using the Removal and
Installation procedures as outlined. Perform Functional
Test Procedure.
01- 2 0A - 19 Rest r ai nt s, Act i ve 0 1 - 2 0 A - 1 9
S E R V I C E P R O C E D U R E S ( C o n t i n u e d )
S h o u l d e r S t r a p A d j u s t e r w i t h S t r i p p e d W e l d
N u t s , F r o n t S e a t
1. NOTE: If the t wo hex-head attachi ng bol ts on the
front seat shoulder st rap adjuster ( 602B82) are
not st ri pped, install t he front seat shoul der st rap
adj uster t o the body structure as outlined in
Removal and Installation. If the front seat
shoulder st rap adj uster attachi ng bol ts are
st ri pped, repl ace the front seat shoul der st rap
adj uster and install it t o the body structure as
outlined in Removal and Installation.
Wi t h t he B-pillar interior tri m panel removed (refer
t o Secti on 01- 05) , drill out the damaged t hreads
in the upper B-pillar structure using t he 1 / 2-inch
drill provi ded in the Rotunda D Ring Installation Kit
DRILL OUT OLD THREADS
USING 1/2 DRILL (PILOTED
WITH INTEGRAL STOP)
B- PILLAR
STRUCTURE
R8032-B
3.
NOTE: The dri ve " k e e s " on t he insert will act as an
automati c st op.
Sel ect one of the t hread i nserts provi ded in t he
Rotunda D Ring Installation Ki t 134- 00018 or
equivalent and hand-screw if into t he ret apped hole
until it is slightly bel ow the surf ace of the hol e.
Appl y a suitable lubricant t o the t hreads of the
M1 4 x 1.5 t ap provi ded in the Rotunda D Ring
Installation Ki t 134- 00018 or equivalent and t ap
new t hreads.
NOTE: After each rotati on, back t ap off slightly t o
remove new cutti ngs and be sure t o bl ow out any
chi ps before performi ng Step 3.
THREAD
INSERT
"KEES"
B- PILLAR
STRUCTURE
R8034-B
4. After insertion of the t hread insert, use a
12-ounce hammer to lightly t ap the installation
tool (provi ded in the ki t) several ti mes t o dri ve
down t he insert " k ees " .
THREAD
INSERT
"KEES"
THREAD INSERT
INSTALLATION TOOL
B- PILLAR
STRUCTURE
R8035-B
M14X 1.5 TAP
(WITH INTEGRAL STOP)
B- PILLAR
"^STRUCTURE
R8033-B
01- 20A- 20 Re s t r a i n t s , A c t i v e 01- 20A- 20
Safety Belt Twisted at Safety Belt Guide
1. Grasp belt webbi ng at the front safety belt guide
( 613D 10).
B-PILLAR
FRONT SAFETY
BELT GUIDE
613D10
BELT
WEBBING
R8036-D
2. Rot at e and fol d belt webbi ng over itself as
requi red t o remove the twi st.
3. Feed the fol d portion of t he belt through the front
saf et y belt guide.
4. When compl et ed, saf et y belt tongue should f ace
out ward.
S a f e t y Be l t T o n g u e R o t a t e d o n Be l t
1. Grasp belt tongue and pull down on belt webbi ng
t o f orm a l oop through the upper (narrow and
l onger) slot in the tongue.
UPPER (NARROWER AND LONGER)
SLOT IN SAFETY BELT TONGUE
SAFETY BELT
TONGUE
B-PILLAR
SAFETY BELT
WEBBING
R8038-A
2.
3.
Worki ng within the upper slot, rot at e and fold belt
webbi ng over itself as required t o remove the
t wi st .
Pull the excess belt webbi ng back through the
upper slot in the tongue.
01- 2 0A - 2 1 Re s t r a i n t s , A c t i v e 0 1 - 2 0 A - 2 1
Repeat t he above t hree st eps t o compl et e t he
removal of t he t wi st at the l ower (wi der and
l arger) slot in t he tongue.
B-PILLAR
SAFETY BELT
WEBBING
LOWER (WIDER AND SHORTER) *
SLOT IN SAFETY BELT TONGUE R8039-A
When compl et ed, saf et y belt tongue should f ace
out ward.
FRONT SAFETY
BELT GUIDE
613D10
SAFETY BELT
WEBBING
-SAFETY BELT
TONGUE
.LOWER
B-PILLAR
R7143-C
F u n c t i o n a l T e s t P r o c e d u r e
Determi ne the t ypes of saf et y belt assembl i es t hat
have been repl aced. Then t est t he new saf et y belt
assembl y using the appropri at e procedure.
1. NOTE: The RH front and rear shoul der saf et y belt
shoul d not be fully ext ended. Thi s prevents the
possi bi l i ty of fal se feeling (full extensi on versus
l ockup).
When passenger is not avai l abl e, t he RH front
passenger belt may be t est ed if the dri ver has t he
ability t o grasp t he RH front shoul der saf et y belt
and ext end it approxi matel y 66cm ( 26 i nches)
wi thout j eopardi zi ng saf e driving.
2. NOTE: If t he ret ract or of a new saf et y belt
assembl y has been bol ted into a damaged or
di st ort ed mounting ar ea, the new ret ract or coul d
be war ped and may not function properl y.
Reshape t he sheet metal back t o i ts original f orm
and structural integrity and install a new saf et y
belt assembl y.
Dri ver will buckl e up and proceed t o a saf e t est
ar ea. If t he RH front or rear passenger lap safety
belt must be t est ed, a passenger shoul d be
buckl ed into the RH front or rear out board seat.
3. After reachi ng a saf e area t o perf orm sudden
st ops, accel erat e t he vehicle t o approxi matel y 8
k m/ h (6 mph). The dri ver should inform the
passenger (if appl i cabl e) that he is prepari ng t o
make a severe st op. At this ti me, bot h dri ver and
passenger should grasp their shoul der harness
and prepare t o lean slightly f orward at the
moment the brake is applied.
4. The dri ver will make a maxi mum brake
appl i cati on wi thout ti re ski d. (The maxi mum brake
appl i cati on should be on dry concret e or
equivalent hard road surface; never on a wet or
gravel road.) The driver and passenger should
lean f orward slightly into the shoulder harness. At
thi s instant, the bel ts should l ock up wi th minimal
webbi ng extensi on.
5. WARNI NG: THE DRIVER AND PASSENGER
MUST BE PREPARED TO BRACE
THEMSELVES IF THE RETRACTOR DOES
NOT LOCK.
If t here is a l ockup of both shoulder st raps, the
saf et y belt assembl i es are functioning properl y.
Should either or both ret ract ors fail t o l ock up at
the 8 k m/ h (5 mph) speed, the test should be
repeated at a constant 24 km / h ( 15 mph) speed.
(This test must be performed wi th a RH front or
rear passenger if the RH front or rear outboard
bel ts are t o be t est ed. )
6. If either or both shoulder bel ts do not l ock up at
the 24 km / h (15 mph) test, servi ce
malfunctioning safety bel ts. Remove the ret ract or
and rework the sheet metal back t o its original
shape and structural integrity in the ret ract or' s
mounting surface. Install the retractor assembl y
and t est the safety belt assembly.
01- 2 0A - 2 2 Re st r a i n t s, Ac t i ve
01- 20A- 22
_ J
Sa f e t y Bel t Ma i n t e n a n c e
WARNI NG: A L L SAFETY BELT ASSEMBLI ES,
I NCLUDI NG RETRACTORS, BUCKLES, FRONT
SEAT BELT BUCKLE SUPPORT ASSEMBLI ES
(SLI DE BAR) , IF EQUI PPED, CHI LD SAFETY SEAT
TETHER BRACKET ASSEMBLI ES (IF SO
EQUI PPED) AND ATTACHI NG HARDWARE
SHOULD BE I NSPECTED AFTER ANY COLLI SI ON.
A L L SAFETY BELT ASSEMBLI ES SHOULD BE
REPLACED UNLESS A QUALI FI ED TECHNI CI AN
FI NDS THAT THE ASSEMBLI ES SHOW NO
DAMAGE AND OPERATE PROPERLY. SAFETY
BELT ASSEMBLI ES NOT IN USE DURI NG A
COLLI SI ON SHOULD AL SO BE I NSPECTED AND
REPLACED IF EI THER DAMAGE OR I MPROPER
OPERATI ON IS NOTED.
Safety belt assembl i es should be periodically
i nspected t o ensure t hat t hey have not become
damaged and that t hey remain in proper operati ng
condi ti on, particularly if t hey have been subj ected t o
severe st ress such as a collision.
Before installing t he new saf et y belt assembl y, the
saf et y belt attachi ng areas must be i nspected for
damage and di storti on. If t he attachi ng points are
damaged and di st ort ed, the sheet metal must be
r ewor ked back t o its original shape and structural
integrity.
Install t he new saf et y belts and then perform
Functional Test Procedure as outlined.
Safety Belt Webbing
WARNI NG: DO NOT BL E ACH OR RE-DYE THE
WEBBI NG, A S WEBBI NG MAY WE A KE N.
Clean belt webbi ng only wi th a mild soap solution
recommended for cleaning uphol stery or carpet s.
Fol l ow instructions provi ded wi th soap.
1. Pull the lap / shoulder saf et y belt f rom the
retractor so t hat the shoulder portion of the belt
crosses t he shoulder and chest .
2. Insert t he saf et y belt tongue into t he proper
buckl e until a snap is heard and a l atch is felt.
TONGUE
ASSY
R7644-A
S a f e t y Be l t s , Un f a s t e n i n g
To unfasten t he saf et y belt:
1. Push the rel ease button on the buckl e. This
al l ows the tongue t o unlatch from the buckl e.
2. Guide the tongue to its original position while the
safety belt ret ract s. If the tongue is not gui ded, it
may stri ke the techni ci an, a passenger or part of
the vehicle.
ADJUSTMENTS
S a f e t y B e l t s , L a p / S h o u l d e r F r o n t a n d Re a r
S a f e t y Be l t s , Fa s t e n i n g
After entering vehi cl e, adjust the front seat t o obtai n
the best position for driving comf ort , access t o
control s and visibility. Then use the following
procedure for fasteni ng front and rear out board bel ts.
01- 2 0A - 2 3 Rest r ai nt s, A c t i v e 0 1 - 2 0 A- 2 3
Shoul der Por t i on Ad j u s t me n t
WARNI NG: IF THE SHOULDER BELT IS OFF YOUR
SHOULDER OR ON YOUR UPPER ARM, THERE IS A
GREATER RISK OF SEVERE INJURY IN A
COLLI SI ON.
The shoul der belt height can be adj usted to one of fi ve
posi ti ons. Pinch t he rel ease button and slide it up or
down until t he belt rest s on the techni ci ans shoulder
near the neck. Rel ease the button and make sure t he
adj uster is firmly in one of the five posi ti ons.
=DR(VER'S SIDE SHOWN
=
PASSENGER'S SIDE SIMILAR
R74S4-B
Pa r t
1
Release Button (Part of
602B82)
Adj uster
3
_
B-Pillar
and Tongue
5 20125 Left Front Door
6 24631 Left Rear Door
SQUEEZE THE RELEASE BUTTON
AND SLIDE THE STRAP
ADJUSTER UP OR DOWN
DRIVERS SIDE SHOWN
PASSENGER'S SIDE SIMILAR
R7495-B
WARNI NG: DO NOT I NTRODUCE SLACK I NTO THE
SAFETY BELT SYSTEM BECAUSE THE BELT
LOCKS UPON I MPACT WHERE I T IS POSI TI ONED.
USE THE SHOULDER SAFETY BELT ON THE
OUTSI DE SHOULDER ONLY. NEVER WEAR THE
SHOULDER BELT UNDER THE A RM. NEVER
SWI NG I T AROUND THE NECK OVER THE INSIDE
SHOULDER. NEVER USE A SI NGLE BELT FOR
MORE THAN ONE PERSON. ENSURE THE LAP
PORTI ON OF THE BELT I S FI TTED SNUGLY AND
AS LOW AS POSSI BLE AROUND THE HI PS, NOT
ON THE WAI ST. FAILURE TO FOLLOW THESE
PRECAUTI ONS COULD I NCREASE THE CHANCE
AND/ OR SEVERI TY OF I NJURY IN A COLLI SI ON.
The shoulder restrai nt porti on of t he saf et y belt
adj usts automati cal l y t o a snug posi ti on.
L a p Por t i on Ad j u s t me n t
WARNI NG: EACH SEATI NG POSI TI ON IN THE
VEHI CLE HAS A SPECI FI C SAFETY BELT
ASSEMBLY WHI CH CONSI STS OF ONE BUCKLE
AND ONE TONGUE. THE SAFETY BELT
ASSEMBLY I S DESI GNED TO BE USED AS A PAIR
AND IS NOT TO BE USED ACROSS SEATI NG
POSI TI ONS.
WARNI NG: ENSURE THE LAP PORTI ON OF THE
BELT IS FI TTED SNUGLY AND A S LOW AS
POSSI BLE AROUND THE HI PS, NOT AROUND THE
WAI ST. FAI LURE TO DO SO MAY I NCREASE THE
CHANCE OF I NJURY IN THE EVENT OF A
COLLI SI ON.
The vehicle is equi pped wi th a manually-adjusted lap
belt for the center-front and center-rear seat occupant.
Insert the belt tongue into the proper buckl e until a
snap is heard. Pull on both sides of belt to ensure the
buckl e is l atched. Pull up on the end of t he belt t o
tighten the lap porti on t o a snug fit. Ensure the belt is
as low on the hips as possi bl e.
RELEASE
BUTTON
TONGUE
ASSY
BUCKLE
ASSY VIEW A
R7109-B
01- 2 0A - 2 4 Re s t r a i n t s , A c t i v e 01- 2 0A - 2 4
1
Sh o u l d e r St r a p Bei t He i g h t A d j u s t me n t , Fr o n t
To adjust front seat shoulder st rap adjuster ( 602B82) ,
squeeze the rel ease button on the adjuster knob and
slide the adj uster up or down.
SPECIFICATIONS
PARTS REPLACEMENT CHARTSAFETY BELT WITH
DAMAGED WELD NUT ANCHOR PLATE THREADS
PART
NUMBE R
CODE
L E T T E R
8
PART NA ME
3862 7 3- S 100 1A B o l t 7 / 1 6 - 2 0 x 1.38 Pa n
He a d Ta ppi n g
3862 7 4- S 100 1B B o l t 7 / 1 6 - 2 0 x 1.75 Pa n
He a d Ta ppi n g (0. 50 Sh o u l d e r )
382 580- S 100 7 / 1 6 F l a t Wa s h e r
382 62 9- S 100 Wa s h e r . 4 6 3 / . 4 4 3 ID P l a t e
( 1. 80 Di a . , 0. 190 T h i c k)
382 383- S 100 Wa s h e r 1 / 2 S e r r a t e d (0. 18
T h i c k)
3862 7 2 - S 100 1F B o l t 7 / 16- 2 0 x 0. 88 Pa n
He a d Ta ppi n g
3862 7 6- S 100 1L B o l t 7 / 1 6 - 2 0 x 1.75 Pa n
Sh o u l d e r Ta ppi n g (0. 75
Sh o u l d e r )
3862 7 7 - S 100 1K B o l t 7 / 1 6 - 2 0 x 1.38 Pa n
Sh o u l d e r Ta ppi n g ( 0. 50
Sh o u l d e r )
386392 - S 100 1G B o l t 7 / 1 6 - 2 0 x 2 . 1 5 P a n
He a d Ta p p i n g
384966- S 100 V B o l t 7 / 1 6 - 2 0 X 1. 7 5P a n
He a d Ta p p i n g
383531- S 36 X B o l t 1 / 2 - 1 3 x 1.38 Pa n He a d
L o c ki n g
3837 53- S 36 Y B o l t 1 / 2 - 1 3 x 1.75 Pa n He a d
L o c ki n g (. 50 Sh o u l d e r )
382 552 - S 100 1 / 2 F l a t Wa s h e r
382 552 - S 100 W a s h e r 1 / 2 Fl a t ( 1. 30 Di e \
0. 190 T h i c k)
382 553- S 100 Wa s h e r 9 / 1 6 Fl a t ( 0. 2 5
T h i c k)
383437 - S 36 w B o l t 1 / 2 x 13 Pa n He a d
L o c ki n g
3837 54- S 36 Z B o l t 1 / 2 - 1 3 x 2. 25 Pa n He a d
L o c ki n g (. 88 Sh o u l d e r )
3857 09- S 36 T B o l t 1 / 2 - 1 3 x 1.38 Pa n He a d
Sh o u l d e r L o c ki n g
3837 54- S 36 Z B o l t 1 / 2 - 1 3 x 2. 25 Pa n He a d
Sh o u l d e r L o c ki n g
PARTS REPLACEMENT CHARTSAFETY BELT WITH
DAMAGED WELD NUT ANCHOR PLATE THREADS
(Cont 'd)
P A RT
NUMBE R
CODE
L E T T E R
8
P ART NA ME
383531- S 36 X B o l t 1 / 2 - 1 3 x 1.38 Pa n He a d
L o c ki n g
N8067 7 3- S 190 N u t M1 0 x 1.5 Fl a n ge L o c k
N8067 7 4- S 190 B o l t 1 . 5 x 2 1 . 5 S o c ke t He a d
Ca p
a I d e n t i f i c a t i o n l e t t e r on t i p of bo l t h e a d o r f a c e of s p a c e r .
Fr o n t Sa f e t y Be l t Re t r a c t o r Bo l t 30- 40 2 2 - 30
Fr o n t Sa f e t y Be l t An c h o r - t o - Si t l
Bo l t
30- 40 2 2 - 30
Fr o n t Se a t Sh o u l d e r St r a p
A d j u s t e r Bo l t
30- 40 2 2 - 30
Fr o n t Ce n t e r Sa f e t y Be l t A n c h o r
Nut
60- 90 44- 60
Fr o n t Sa f e t y Be l t Gui d e He x
Fl a n ge Re t a i n i n g Nut
30- 40 2 2 - 30
Re a r Sa f e t y Be l t Re t r a c t o r Bo l t 30- 40 2 2 - 30
Re a r Sa f e t y Be l t A n c h o r Nut 40- 55 30- 41
Re a r Ce n t e r Sa f e t y Be l t A n c h o r
Nut
40- 55 30- 41
Re a r Sa f e t y Be l t A n c h o r - t o - Re a r
Tr i m Pa n e l Bo l t
40- 55 30- 41
SPECIAL SERVICE TOOLS REQUIRED
T o o l N u m b e r /
De s c r i p t i o n i l l u s t r a t i o n
T 7 7 L - 2 100- A
Se a t Be l t Bo l t Bi t
T77L-2100-A
ROTUNDA EQUIPMENT
134- 00018 D Ri ng I n st a l l a t i o n Ki t
01- 2 0B- 1 Rest r ai nt s, Passi weSuppl ement al Asr Bag Sy s t em 1=206- 1
SECTION 01-20B Restraints, P r "
Air Bag System
SUBJECT PAGE SUBJECT
VEHICLE APPLICATION..... 01-20B-2
Ai r Bag Di agnosti c Moni tor 01-20B-4
Ai r Bag Modul e, Dri ver Si de. . 01-20B-3
Ai r Bag Modul e, Passenger Si de 01-20B-4
Air Bag Sy st em Func t i ons. . 01-20B-5
El ect ri cal Syst em .01-20B-6
Rest rai nt s, Passi veSuppl ement al Ai r Bag
Syst em 01-20B-2
St eeri ng Col umn Wheel and Ai r Bag Sl i di ng
Cont act 01-20B-6
Warni ng Label s .01-20B-7
PARTS REPLACEMENT
Air Bag Modul es. 01-20B-9
Ai r Bag Syst em 01-20B-10
Servi ce of Ai r Bag Equi pped Vehi cl es I nvol ved
in Col l i si ons 01-20B-9
SERVICE PRECAUTIONS
Ai r Bag I nst r uct i ons 01-20B-11
Air Bags, Depl oyed 01-20B-10
Air Bags, Li ve 01-20B-10
Ai r Bag Syst em Component Locat i on .....01-20B-13
Air Bag Syst em Reconnect Check Li st . . . 01-20B-13
Deact i vat i on Procedure 01-20B-11
Di agnosi ng Cust omer Concer ns Wi t h Hard
Di agnost i c Troubl e Codes 01-20B-11
Di agnost i c Troubl e Code Cl eari ng 01-20B-91
El ect ri cal Schemat i c 01-20B-14
Gl ossary 01-20B-12
Pi npoi nt Test s ...01-20B-22
Cont i nuous Ai r Bag I ndi c a t or Di a gnost i c
Troubl e Code Ti med Out , or Di agnost i c
Moni t or Di sconnect ed or I noperat i ve, or No I gni t i on
Vol t age t o Di agnost i c Moni t or 01-20B-24
Di agnost i c Troubl e Code 14 Pri mary
Crash Sensor Ci rcui t Short ed t o
Ground . .01-20B-35
Di agnost i c Troubl e Code 21 Di agnost i c
Moni t or Not Mount ed t o Vehi cle
Properl y ..01-20B-39
Di agnost i c Troubl e Code 22 Sat i ng
Sensor Out put Ci rcui t Shor t ed t o Bat t er y
Vol t age. . ..01-20B-41
Di agnost i c Troubl e Code 23 Memory
Clear Ci rcui t I mproperl y Grounded 01-20B-45
Di agnost i c Troubl e Code 24 Syst em
Di sarm Fai lure or I nt ernal Di agnost i c Moni t or
Fault 01-20B-46
Di agnost i c Troubl e Code 32 Dri ver Si de
Air Bag Ci rcui t High Resi st ance or
Open . . 01-208-48
Di agnost i c Troubl e Code 33 Passenger
Si de Ai r Bag Ci rcui t Hi gh Resi st ance or
Open .01-20B-51
Di agnost i c Troubl e Code 34 Dri ver Si de
Air Bag Ci rcui t Low Resi st ance or
Shor t ed ......01-208-53
Di agnost i c Troubl e Code 35 Passenger
Si de Ai r Bag Ci rcui t Low Resi st ance or
Shor t ed 01-208-56
Di agnost i c Trouble Code 41 RH Radi at or
Pri mary Crash Sensor Fe e d/ Re t ur n Ci rcui t
Open 01-208-58
PAGE
Di agnost i c Troubl e Code 42 LH Radi at or
Pri mary Crash Sensor Fe e d / Re t ur n Ci rcui t
Open 01-208-60
Di agnost i c Troubl e Code 44 RH Radi at or
Pri mary Crash Sensor Not Mount ed t o
Vehi cle Properl y .... . 01-20B-62
Di agnost i c Troubl e Code 45 LH Radi at or
Pri mary Crash Sensor Not Mount ed to
Vehi cle Properl y . . . . . . . 01-208-65
Di agnost i c Troubl e Code 52 Intermi ttent
or Repai red Lost Bat t er y Feed , . 01-208-68
Di agnost i c Troubl e Code 53 I nt er mi t t ent
or Repai red Ai r Bag Ci rcui t Short ed t o
Ground .....01-20B-69
or Repai red Pri mary Crash Sensor Ci rcui t
Short ed t o Ground . 01-20B-71
Di agnost i c Troubl e Code 6 1 i nt er mi t t ent
or Repai red Di agnost i c Moni t or Not
Mount ed t o Vehi cle Properl y 01-208-72
Di agnost i c Troubl e Code 62 I nt ermi t t ent
or Repai red Saf i ng Sensor Out put Ci rcui t
Short ed t o Bat t ery Vol t age. 01-208-74
or Repai red Memory Clear Circuit
I mproperl y Gr ounded. . . . 01-20B-76
or Repai red Syst em Di sarm Failure or
I nt ernal Di agnost i c Moni t or Fault ......01-208-77
or Repai red Dri ver Si de Air Bag Circuit
High Resi st ance or Open 01-208-78
or Repai red Passenger Si de Air Bag Ci rcui t
High Resi st ance or Open 01-208-80
or Repai red Dri ver Si de Air Bag Circuit Low
Resi st ance or Short ed ................................01-201-81
Di agnost i c Trouble Code 75 Intermi ttent
or Repai red Passenger Si de Air Bag Ci rcui t
Low Resi st ance or Short ed . ....01-208-82
or Repai red RH Radi at or Pri mary Crash
Sensor Fe e d/ Re t ur n Ci rcui t Open. . . . .....01-208-84
or Repai red LH Radi at or Pri mary Crash
Sensor Fe e d/ Re t ur n Ci rcui t Open ...01-208-85
or Repai red RH Radi ator Pri mary Crash
Sensor Not Mount ed t o Vehicle
Properl y ....01-20B-87
or Repai red LH Radi at or Primary Crash
Sensor Not Mount ed t o Vehicle
Properl y ...01-20B-88
No Air Bag I ndi cat or Inoperati ve Indi cator
Ci rcui t 01-208-22
Rapid Cont i nuous Fl ashi ng of Air Bag
I ndi c a t or Bot h Pri mary Crash Sensors
Di sconnect ed .01-208-90
Di agnost i c Moni t or, Air Bag ...............................01-201-92
Modul e, Dri ver Side Air l ag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-201-93
Modul e, Passenger Si de Air Bag . ......01-20B-94
01- 2 0B- 2 Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m 01- 2 0B- 2
SECTION 01-20B Restraints, PassiveSupplemental
Air Bag System
S U B J E C T PAGE
Sensor and Bracket, Front 01-20B-91
Sliding Contact, Air Bag 01-20B-95
DISPOSAL PROCEDURES
Air Bag Di sposal 01-20B-96
Air Bag Di sposal Recommendati on 01-20B-95
SUBJECT PAGE
DISPOSAL PROCEDURES (Cont 'd.)
Ai r Bag, Undepl oyed Faulty 01-20B-96
Ai r Bags, Depl oyed 01-20B-95
Scr apped Vehi cle 01-20B-96
SPECIFICATIONS 01-20B-96
SPECIAL SERVICE TOOLS/EQUIPMENT 01-20B-97
VEHICLE APPLICATION
R e s t r a i n t s , P a s s i v e S u p p l e m e n t a l A i r B a g
S y s t e m
The Supplemental Air Bag Restrai nt Syst em is
desi gned t o provi de i ncreased collision protecti on for
front seat occupant s IN ADDI TI ON TO that provi ded
by t he t hree point saf et y belt syst em.
Saf et y belt use is necessary t o obtai n the best
occupant protecti on and t o recei ve t he full
advant ages of t he suppl emental air bag.
FORD RECOMMENDS THE USE OF SAFETY
BELT SYSTEMS FOR ALL VEHI CLE
OCCUPANTS.
Refer t o Secti on 01-20A for information on t he
Saf et y Belt Restraint Syst em.
The Supplemental Air Bag Restraint Syst em consi sts
of t wo basi c subsyst ems:
Dri ver side air bag module ( 043B13) and passenger
si de air bag module ( 044A74) .
El ectri cal syst em, including RH pri mary crash front
air bag sensor and bracket ( 14B004) , LH pri mary
cr ash front air bag sensor and bracket ( 14B005)
and air bag di agnosti c monitor ( 14B056) .
01- 20B- 3 Re s t r a i n t s , Pas s i v eSuppl ement al Ai r Bag Sy s t em
m. 'ML &EL M * r V
01- 2 0B- 3
Co mpo n e n t L o c a t i o n
R6563-F
I t e m
P a r t
N u m b e r De s c r i p t i o n L o c a t i o n
1 0 4 3 B1 3 Dr i v e r Si d e Ai r
Ba g Mo d u l e
Ce n t e r o f
St e e r i n g Wh e e l
2 14B005
L H
14B004
RH
Pr i ma r y Cr a s h
Fr o n t Ai r Ba g
Se n s o r a n d
Br a c ke t
LH a n d RH
Ra d i a t o r
Su p p o r t s
3 14B056 Ai r Ba g
Di a gn o s t i c
Mo n i t o r
Ri ght of Gl o v e
Co mp a r t me n t
4 0 4 4 A 7 4 P a s s e n ge r Si d e
Ai r Ba g Mo d u l e
A b o v e Gl o v e
Co mp a r t me n t
5 Di a gn o s t i c
" Tr o ubl e Co d e
Cl e a r "
Co n n e c t o r
Un d e r Gl o v e
Co mp a r t me n t
6
_
Ai r Ba g Wa r n i n g
I n d i c a t o r
I n st r ume n t
Cl u s t e r
A i r B a g Mo d u l e , Dr i v e r S i d e
NOTE: The dri ver si de air bag module ( 043B13) is
servi ced as a compl et e assembl y. Perform proper
di sposal procedure as outlined.
The dri ver si de air bag module is mounted in the center
of t he steeri ng wheel ( 3600) . The dri ver si de air bag
modul e consi sts of t he following component s:
Inflator.
Air bag.
Mounting plate and retainer ring (Crown Vi ctori a,
Grand Marqui s).
Modul e housing and attachi ng bracket (Town Car).
Steeri ng wheel tri m cover.
I n f l a t o r
The inflator assembl y is not a servi ceabl e i tem.
When the sensors cl ose, signaling a cr ash,
el ectri cal energy f l ows t o the air bag inflator.
Inside the inflator, an igniter converts the el ectri cal
signal t o thermal energy (heat), causing the ignition
of t he inflator gas generant.
Thi s ignition reacti on combust s the sodium
azi de/ cupr i c oxi de (Crown Vi ctori a, Grand Marqui s)
or sodi um azi de/ pot assi um nitrate (Town Car) gas
generant in the inflator, produci ng nitrogen gas,
whi ch inflates the air bag.
Ai r Ba g
The dri ver side air bag:
Is const ruct ed of nylon.
Is 673 mm (26. 5 inches) in diameter (Town Car) 648
mm (25. 5 inches) in di ameter (Crown Vi ctori a,
Grand Marqui s).
01- 2 0B- 4 Re st r a i n t s, P a s s i v e S u p *
hyp., j .
- 2 0B- 4
Fills t o a volume of about 0. 057 cubi c meter ( 2. 0
cubi c f eet ) in approxi matel y 40 milliseconds.
It is not a servi ceabl e i tem.
Mo u n t i n g P l a t e a n d Re t a i n e r Ri n g
The mounting pl ate and retainer ring:
At t ach and seal the air bag assembl y t o t he inflator.
Al so at t ach the tri m cover and mount the entire
driver side air bag module t o t he steeri ng wheel .
Are components of the dri ver si de air bag module
and cannot be servi ced.
S t e e r i n g Wh e e l T r i m C o v e r
The steeri ng wheel trim cover:
Encases dri ver si de air bag module and horn swi t ch.
Has moul ded in t ear seams that separat e t o al l ow
inflation of t he bag.
Is a component of the dri ver si de air bag module and
is servi ceabl e on the Town Car, but not on t he
Crown Vi ct ori a, Grand Marqui s.
Must not be repai nted for any reason.
Ai r Ba g Modul e , Dr i ver Si d e Cr o wn Vi c t o r i a , Gr a nd
Mar qui s
DRIVER SIDE
AIR BAG
MODULE
043B13
AIR BAG
SLIDING CONTACT
14A664
STEERING
WHEEL
3600
R7580-C
Air B a g Mo d u l e , P a s s e n g e r S i d e
NOTE: The passenger si de air bag module ( 044A74)
is servi ced as a compl ete assembl y. Perform proper
di sposal procedure as outlined.
The passenger si de air bag module is mounted in t he
RH position of t he instrument panel ( 04320) above the
gl ove compart ment ( 06010) . The passenger si de air
bag module consi sts of t he fol l owi ng component s:
Inflator.
Air bag.
Reacti on housing wi th mounting hardware.
Trim cover.
i n f l a t o r
The passenger air bag inflator operat es as fol l ows:
An igniter inside the inflator converts el ectri cal
energy t o thermal energy (heat), causing ignition of
the gas generant.
The ignition reacti on causes combusti on of the
potassi um nitrate gas generant produci ng nitrogen
t o fill t he bag.
e Since the passenger si de air bag module is much
l arger than the driver si de air bag module ( 043B13) ,
it contai ns more gas generant in a different inflator
configuration t o produce more nitrogen gas.
It is a component of the passenger side air bag
module and is not servi ceabl e.
A i r Ba g
The passenger side air bag module:
Is const ruct ed of ri pstop nylon.
Fills t o a volume of approxi matel y 0. 180 cubi c
meter (6. 4 cubi c feet)(Crown Vi ctori a, Grand
Marqui s) 0. 170 cubi c meter (6. 0 cubi c f eet ) (Town
Car).
Is not a servi ceabl e i tem.
Reac t i on Ho u s i n g
The steel reacti on housing:
Supplies support for the inflator.
Provi des a reacti on surface for t he passenger side
air bag module.
Is used t o at t ach the tri m cover.
Contains mounting bracket s that at t ach the
passenger side air bag module t o t he instrument
panel.
@ Is not a servi ceabl e i tem.
Tr i m C o v e r
The thermo-pl asti c tri m cover:
Is t ext ured and painted t o match the surface of the
instrument panel.
e Is constructed wi th a moulded-in tear seam that
separat es when the air bag inflates, and hinges out
of the way during depl oyment.
@ Retains the air bag in the reacti on housing during
vehicle operati on.
Is not a servi ceabl e or repaintable i tem.
Ai r B a g Di a g n o s t i c Mo n i t o r
The air bag di agnosti c monitor (14BQ56) continually
moni tors all air bag syst em components and wiring
connecti ons for possible faults when the ignition
swi t ch ( 11572) is in RUN.
01- 2 0B- 5 Rest r ai nt s, Pas s i v eSuppl ement al Ai r Bag Sy s t em 01- 2 0B- 5
If t he air bag di agnosti c moni tor det ect s a fault in t he
air bag syst em, a Di agnosti c Trouble Code (DTC)
will be wri tten t o t he air bag di agnosti c moni tor' s
Non-Volatile Random Access Memory (NVRAM).
Thi s di agnosti c troubl e code will then be di spl ayed
on the air bag indicator l amp.
After servi ci ng, t he di agnosti c troubl e code may
then be cl eared f rom NVRAM.
Performi ng syst em di agnosti cs is the main purpose
of t he air bag di agnosti c monitor.
THE air bag di agnosti c monitor DOES NOT
DEPLOY THE AIR BAGS IN THE EVENT OF A
COLLISION.
The crash sensors are " har d- wi r ed" t o t he air bags.
Thus the crash sensors determi ne when t he air bag
will be depl oyed.
Several i mportant features of the air bag di agnosti c
monitor and its functi ons within t he syst em are
descri bed below. It is necessary t hat t hese key
features and functi ons are well underst ood.
Air Bag System Functions
The air bag di agnosti c monitor ( 14B056) illuminates
t he air bag i ndi cator for approxi mat el y si x seconds
when t he ignition swi t ch ( 11572) is turned t o RUN
and then turns t he air bag i ndi cator off. This
i ndi cates that t he air bag i ndi cator is operati onal . If
t he air bag i ndi cator does not illuminate at all, st ays
on continuously, or fl ashes at any ti me, then a fault
has been det ect ed by t he air bag di agnosti c
monitor.
Di agnosti c troubl e codes, if present, will begin
flashing within 30 seconds after the ignition swi t ch
has been turned t o RUN. Thi s is the amount of ti me it
t akes the air bag di agnosti c monitor t o perform all
t est s and veri fy syst em faul ts, if present.
Di agnosti c troubl e codes are di spl ayed as a seri es
of fl ashes and pauses of t he air bag indicator.
Di agnosti c troubl e codes are two-di gi t numbers.
Exampl e: A DTC 32 is di spl ayed as fol l ows:
fl ash f l ash fl ash - ( t wo second pause) -
fl ash fl ash - (five second pause)...
flash fl ash fl ash - ( t wo second pause) -
fl ash fl ash - (five second pause)...
Di agnosti c troubl e codes are pri ori ti zed numerically
so that if t wo or more faul ts occur at the same ti me,
t he di agnosti c troubl e code wi t h t he hi ghest pri ori ty
will be di spl ayed.
After the DTC is di spl ayed five ti mes, the air bag
i ndi cator will illuminate continuously until the ignition
swi t ch is cycl ed.
The air bag di agnosti c monitor i ncorporat es
Non-Volatile Random Access Memor y (NVRAM) t o
st ore di agnosti c troubl e codes and retai n t hem
indefinitely. The air bag di agnosti c monitor will
al ways fl ash t he hi ghest pri ori ty di agnosti c troubl e
code st ored in NVRAM. Di agnosti c troubl e codes
may be cl eared f rom the air bag di agnosti c monitor
after t he fault condi ti ons are servi ced (see
Di agnosti c Trouble Code Cl eari ng procedure for
detai l s).
The air bag di agnosti c monitor distinguishes
bet ween hard and intermittent (or repai red) fault
conditions.
Each di agnosti c troubl e code number 1 2 - 4 5
represents a hard fault (a fault t hat is still
present ). Hard di agnosti c troubl e codes are
higher pri ori ty than intermittent di agnosti c
troubl e codes, and may not be cl eared f rom
NVRAM.
Each of these hard di agnosti c troubl e codes
has an equivalent di agnosti c troubl e code
whi ch is the sum of the di agnosti c troubl e code
number plus 40. This equivalent di agnosti c
troubl e code will indicate that an intermittent
condition exi st s, or that a hard condition has
been repai red.
Only the intermittent (repai red) di agnosti c
troubl e codes, numbers 52 - 85, may be
cl eared f rom the air bag di agnosti c monitor.
(See Di agnosti c Trouble Code Clearing
procedure.)
Exampl e: A Di agnosti c Trouble Code 32
i ndi cates that high resi stance in t he dri ver si de
air bag circuit has been, and still is, present. A
DTC 72 (32 + 40) i ndi cates t hat high
resi stance in the driver si de air bag circuit
exi st ed at one ti me, but no longer exi sts due t o
an intermittent condition, or a repai r made t o
the circuit.
If a syst em fault exi st s and the Air Bag Warning
Indicator is not functioning, an audible tone will be
heard indicating a need for servi ce. The tone is a
seri es of five set s of five beeps. This DOES NOT
indicate a di agnosti c trouble code 55 or any other
diagnostic troubl e code. The Air Bag Warning
Indicator must be servi ced before di agnosti c troubl e
codes can be determi ned.
WARNI NG: UNDER NO CI RCUMSTANCES
SUBSTI TUTE ANOTHER FUSE VALUE FOR THE
10A BATTERY FUSE. ANY FUSE OTHER THAN
10A MAY CAUSE DI SARMI NG FAI LURE AND MAY
RESULT IN DANGER TO THE OCCUPANTS OF THE
VEHI CLE. DO NOT ATTEMPT TO REPLACE THE
10A BATTERY FUSE UNTI L THE AI R BAG SYSTEM
FI RST HAS BEEN DEACTI VATED (SEE
DEACTI VATI ON PROCEDURE FOR DETAI LS).
If a fault exi sts that makes unwanted air bag
depl oyment possi bl e, the air bag di agnosti c monitor
will attempt to remove deployment power by turning
on a solid st at e swi t ch t o blow the 10A battery fuse.
01- 2 0B- 6 Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m
If the 10A bat t ery fuse has successful l y been bl own
by t he air bag di agnosti c monitor, the air bag
di agnosti c monitor will not attempt t o bl ow it again
until t he proper fault has been servi ced and cl eared
(see Di agnosti c Trouble Code Clearing procedures
for detai l s). The air bag di agnosti c monitor will st ore
both the unwanted depl oyment di agnosti c troubl e
code and the l oss of depl oyment power di agnosti c
troubl e code. The l oss of depl oyment power
di agnosti c troubl e code is the hi ghest priority.
WARNI NG: THE BACK- UP POWER SUPPLY
ENERGY MUST BE DEPLETED BEFORE ANY AI R
BAG COMPONENT SERVI CE IS PERFORMED. TO
DEPLETE THE BACK- UP POWER SUPPLY
ENERGY, DI SCONNECT THE NEGATI VE BATTERY
CABLE AND WAI T ONE MI NUTE TO AVOI D
ACCI DENTAL DEPLOYMENT AND POSSI BLE
PERSONAL INJURY.
The air bag di agnosti c monitor includes an internal
back-up power suppl y. This feature provi des
sufficient back-up power t o depl oy t he air bags in
the event that the bat t ery ( 10653) or bat t ery cabl es
are damaged in a collision before the crash sensors
are act i vat ed. The back-up power suppl y will
depl ete its st ored energy approxi matel y one minute
after t he negati ve bat t ery cabl e is di sconnect ed.
The air bag di agnosti c monitor i ncorporat es an
internal safing sensor. Proper mounting of the air
bag di agnosti c monitor and bracket assembl y is
cri ti cal t o the function and performance of the air
bag syst em.
The air bag di agnosti c monitor and bracket
assembl y is non-serviceable and must be repl aced
as a unit in the event of failure.
Ai r Ba g I n d i c a t o r L a mp Cr own Vi ct or i a, Grand
Mar qui s
AIR BAG WARNING LAMP
ELECTRONIC CLUSTER
R6553-D
Ai r Bag I ndi cat or LampTown Car
AIR BAG
WARNING LAMP
- J -
B R A K E ÂIR
"AI R- U
: e A e - i l l
R10960-A
St e e r i n g Co l u mn Wheel a n d A i r B a g S l i d i n g
Co n t a c t
The steeri ng column has an air bag sliding cont act
( 14A664) t o transfer el ectri cal signals f rom the
steeri ng column t o the steeri ng wheel ( 3600) for the
air bag syst em. Refer t o Secti on 11-04.
E l e c t r i c a l System
The air bag syst em is powered di rectl y f rom the
bat t ery. The syst em can function wi th the ignition
swi t ch ( 11572) in any posi ti on, including OFF and
LOCK. The syst em can al so function when the dri ver
or passenger seat s are unoccupi ed. The el ectri cal
syst em perf orms three main functi ons:
Det ect s an i mpact.
Carri es el ectri c current t o the igniter(s).
Moni tors t he syst em t o determi ne readi ness.
The el ectri cal syst em components include:
Air bag di agnosti c monitor ( 14B056) wi th i ntegrated
back-up power supply and safing sensor.
Air bag warni ng indicator.
Wiring harness and air bag sliding cont act
( 14A664) .
m RH pri mary crash front air bag sensor and bracket
( 14B004) , LH pri mary crash front air bag sensor
and bracket ( 14B005) .
The igniter within the dri ver side air bag module
( 043B13) and passenger si de air bag module
( 044A74) .
Sensors
The sensor is an el ectri cal swi t ch whi ch operat es as
fol l ows:
It react s t o i mpacts accordi ng t o direction and
f orce.
It di scri mi nates between i mpacts that require air
bag inflation and i mpacts that do not require air bag
inflation.
When an i mpact occurs that requires air bag
inflation, the sensor cont act s cl ose, compl eti ng the
el ectri cal circuit necessary for syst em operati on.
01- 2 0B- 7 Reat i ai nl s, PassSweSuppl ement al A i r Bag Sy s t em 01- 2 0B- 7
D E S C R I P T I O N A N D O P E R A T I O N ( Cont r aed)
Three sensors are mounted in t he vehicle. Their
l ocati ons are as follows:
A pri mary crash front air bag sensor and bracket at
the RH front radi ator support ( 16138) .
A pri mary cr ash front air bag sensor and bracket at
t he LH front radi ator support.
A sati ng sensor inside t he air bag di agnosti c
moni tor.
$ The saf ing and one of t he pri mary crash sensors
must be act i vat ed simultaneously to inflate t he air
bag.
AIR BAG FIRING CIRCUIT DIAGRAM
AIR BAG DIAGNOSTIC MONITOR
t i l
t
AID D i i r S O *<>. V-"e
BATTERY (+) / AIR BAGS
SAFING SENSOR
GROUND (-)
PRIMARY CRASH SENSORS
R10979-A
The air bag syst em is desi gned to:
Operat e in frontal or front-angl ed collisions.
Act i vat e t he air bags in a crash wi t h severe frontal
decel erat i on, more severe than hitting a parked car
of similar si ze and wei ght head-on at about 45 km / h
( 28 mph).
Sense t he severi ty of the crash rather than vehi cl e
speed, thus some frontal collisions at speeds above
45 km / h ( 28 mph) may not be severe enough t o
requi re air bag i nf l at i on.
The sensors in t he vehi cl e determi ne if air bag inflation
i s requi red in t he f ol l owi ng manner:
1. Duri ng severe frontal decel erati on caused by an
i mpact that decel erat es the vehi cl e in t he f or war d
di recti on, both a pri mary crash sensor and a
sat i ng sensor will act i vat e.
2. When a pri mary and saf ing sensor are cl osed at
t he same time, el ectri cal current will f l ow igniting
t he dri ver side air bag modul e and passenger si de
air bag modul e.
The pri mary sensors measure t he cr ash severi ty while
t he safi ng sensor confi rms the cr ash. The sati ng
sensor is used to prevent i nadvertent depl oyments
possi bl y caused by a mal functi on in t he pri mary crash
sensor ci rcui t s or crash sensors.
Sensor Asse mbl y
CAN
FRONT OF
VEHICLE
BIAS MAGNET
R1
Wa r n i n g L a b e l s
Typi cal warni ng labels f or the air bags are shown in the
fol l owi ng illustrations:
1- 20B- 8 Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m 01- 20B- 8
A I R BAG
S M O t f M r S M *
ON DRIVER'S AND PASSENGER'S SUN VISORS
DO NOT TAMPER WITH OR DISCONNECT THE AI R BAG SYSTEM
WIRING. You could inflate t he bag(s) or make it inoperative which may
result in injury. See Shop Manual.
\ ^ ^ , _ J
NE PAS MANIPULER Nl DlsBRANCHER LE Ci BLAGE EUECTHSQUE
DU DiSPOSSTIF D'UN SAO GONFLABLE Ceia pourrait gonfler - -
le sac gonflable ou le mettre hors service et entrainer des Uessures.
^ Voir le manuel de reparation. ROB-S4OOOI4-AA
ON HOOD LATCH SUPPORT
MISE EN C3ARDE POUR EVITER DES SIESSURES GRAVES :
> Pour obtanir tin protection maxi mum dana tea cotfistera do
t o n s genres, touj our* bouder s a ccifituro de s i o t i r f t i *
> Mm pas ut i l Mf da eieoos pour enfanta tournos vera rafriere
sur mm avant.
> Na paa s' asssoi r nl s'appuyer inutHemertt pros du sac gonflable.
> Na pas di poser dobiet* au-desaus dt rs*e eonffabla nl antra
la sac gonflable at soi -mt me.
Pd ur d e p l u s a mp l e r e i i e e l gi i e r i i e r i t s, e o n i u t l i r to G y M f pmfiMmim.
LABEL ON HEADUNER ABOVE DRIVER'S AND PASSENGER'S SUN VISORS CANADA ONLY
" | IB
C A U T I O N TO AVOI D SERI OUS INJURY:
For maximum safety protection in all types of crashes, you
must always wear yai r safety W t
Do not install mr war #t eci ng child seats in any front
passenger seat position*
Do not sit or lean unnecessarily close t o the air tag.
Do not place any objects over the air bag or toetien the
air bag and yourself.
See ttw Own e r Manual f o r farter I nf ormat t of t a n d mpl a n a t i o n s.
LABEL ON BACK SIDE OF DRIVER'S AND PASSENGER'S SUN VISORS
R9S57-B
_____ - x ^t f t KETF
1- 208- 9
PARTS REPLACEMENT
A i r B a g Mo d u l e s
NOTE: When repl aci ng a dri ver side air bag module
( 043B13) or passenger si de air bag module
( 044A74) , a prepai d return post card is provi ded wi t h
the repl acement dri ver side air bag module or
passenger si de air bag module. The seri al number f or
the new part and vehi cl e identification number (VIN)
must be recorded and sent t o Ford Mot or Company.
Dr i ver Si d e Cr o wn Vi c t o r i a , Gr and Ma r qui s
AIR BAG SERIAL NUMBER
V F04B-54043B13-i *EB5CY
R7586-B
Passenger Si de
AIR BAG MODULE VERIFICATION
VEHICLE
f
SERIAL NO. I
ATTENTION INSTALLER
Please complete and mail this postcard with the Air Bag Modulo
Serial Number (shown on sample) and the Vehicle Identification
Number (VIN) of the vehicle in which you are installing this module.
AIR BAG MODULE
SERIAL NO.
R10961-A
The various major assembl i es in the dri ver si de air bag
module and passenger side air bag module have been
desi gned t o be tamper-resi stant and are not t o be
di sassembl ed for servi ce.
CAUTI ON: C o mp o n e n t a s s e mb l i e s ma y be
r e mo v e d a n d r e p l a c e d w h e n d i r e c t e d b y t h e
Di a gn o s i s a n d T e s t i n g s e c t i o n t o a v o i d
u n n e c e s s a r y s e r v i c i n g .
Information on proper handling and st orage of ai r bag
assembl i es is provi ded in thi s secti on. Refer t o
Removal and Installation.
Servi ce of Air Bag Equi pped Vehicles
Involved in Colli si ons
Whi l e servi ci ng an air bag equi pped vehi cl e t hat has
been involved in a collision, check RH pri mary crash
front ai r bag sensor and bracket ( 14B004) , LH
pri mary crash front air bag sensor and br acket
( 14B005) , air bag di agnosti c monitor ( 14B056) , and
wi ri ng.
S e n s o r s
Vehicle sensor orientation is cri ti cal for proper air bag
syst em operati on. If a vehi cl e equi pped wi t h a dri ver
si de air bag module ( 043B13) or passenger si de air
bag module ( 044A74) is involved in a cr ash wher e t he
f enders or grille area have been damaged, ensure t hat
body structure in the area of the sensor mounting is
rest ored t o i ts original condi ti on. Inspect t he air bag
sensor mounting bracket s and air bag sensor wi re
harness pigtail for damage.
Damaged air bag sensors should be repl aced
whet her or not the dri ver si de air bag modul e or
passenger side air bag module is depl oyed.
Undamaged air bag sensors wi ll reset automati cal l y
after a collision and can be reused.
Damaged Wiring
CAUTI ON: Be f o r e a t t e mp t i n g d i a gn o s t i c p r o v e
o u t , c h e c k f o r wi r i n g s h o r t s t h a t c o u l d c a u s e t h e
d i a gn o s t i c mo n i t o r t o b l o w t h e 10 a mp ai r b a g
b a t t e r y f e e d f u s e , t o a v o i d u n n e c e s s a r y
s e r v i c i n g.
Inspect the air bag sensor wiring and t he wiring
harness for any damage that may have occurred due
t o the collision. Repl ace any damaged wi ri ng,
termi nal s, insulation or connectors as requi red.
Spl i ces are required in adj acent wi ri ng; t he spl i ces
should be st aggered approxi matel y 50 mm (2 inches)
f rom each other. Servi ce as f ol l ows:
A wat erproof butt-splice connector should be used on
all wiring servi ced in t he engine compart ment . A heat
shrink nylon splice prevents water, salt, condensati on
and heat f rom affecti ng the servi ced wi ri ng.
PARTS REPLACEMENT (Cont i nued)
The inner wal l of t he spl i ce connect or is li ned wi t h an
adhesi ve t hat mel t s whe n he a t e d wi t h a heat gun and
f l o ws under pr essur e f r o m t he t ubi ng, seal i ng t he
spl i ce. The c onne c t or s can be c r i mpe d wi t h a
st a nda r d i nsul at ed connect or cri mpi ng t ool . The
spl i ces ar e c ol or -c ode d f or gauge i dent i f i cat i on and
a r e t r anspar ent t o al l ow i nspect i on of t he f i ni shed
spl i ce.
INSTALLATION INSTRUCTIONS
1. STRIP WIRES 7.6 mm (0.3 INCH)
INSERT INTO CRIMP BARREL.
2. CRIMP USING CRIMP TOOL FOR
PRE-INSULATED CRIMPS.
3. HEAT SPLICE WITH HEAT GUN UNTIL
TUBING SHRINKS AND ADHESIVE
FLOWS FROM EACH END.
R6719-B
Part Number Part Name Class
E 6FZ - 14488- A But t Co n n e c t o r
Ga u ge : 18- 2 2 ,
Co l o r : Re d
C
E 6FZ - 14488- B But t Co n n e c t o r
Ga u ge : 14- 16,
Co l o r : Bl ue
C
E 6FZ - 14488- C But t Co n n e c t o r
Ga u ge : 10- 12 ,
Co l o r : Ye l l o w
c
Steering Column and Air Bag Sliding Contact
If t he col l i si on i nvol ved dri ver si de ai r ba g modul e or
passenger si de ai r ba g modul e depl oyment , t he
st eeri ng col umn may have been l oaded suf f i ci ent l y t o
de f or m st eer i ng col umn mount i ng br a c ke t s or da ma ge
col umn wi r i ng. An i nspect i on shoul d be made of t he
col umn st r uct ur e and ai r ba g sl i di ng c ont a c t wi ri ng t o
ensure t hat any da ma ge d component s ar e r e pl a c e d.
Ref er t o Sect i on 11-04.
Ai r Bag Syst em
Pri or t o at t empt i ng di agnost i c pr ove out on a ser vi ced
vehi cl e, t horoughl y c he c k RH pri mary c r a sh f ront ai r
ba g sensor and br a c ke t ( 14B004) , LH pri mary c r a sh
f r ont ai r bag sensor and br a c ke t ( 14B005) , ai r bag
di agnost i c moni t or ( 14B056) and wi ri ng f or da ma ge d
or pi nched wi r e s whi c h may cause t he ai r ba g
di agnost i c moni t or t o bl ow t he 10 a mp ai r bag bat t er y
f e e d f use.
Af t er all ser vi ce, v e r i f y t h e ai r b a g wa r n i n g
i n d i c a t o r . Thi s means t urn t he i gni ti on swi t c h ( 1157 2)
t o RUN and count t he f l ashes. If t he ai r bag warni ng
i ndi cat or c o me s on cont i nuousl y f or si x se c onds and
t hen goe s out , and if no DTCs f l ash wi t hi n 30 se c onds,
t he ai r ba g sy st e m is f unct i oni ng pr oper l y and all
mal f unct i ons have been ser vi ced. Ref er t o Di agnosi s
and Test i ng.
SERVICE PRECAUTIONS
WARNI NG: ALWAYS WE AR SAFETY GL ASSES
WHE N SERVI CI NG A N AI R BAG VEHI CLE AND
WHE N HANDLI NG A N AI R BAG TO AVOI D
PERSONAL INJURY.
Saf e handli ng of ai r ba gs requi res f ol l owi ng t he
pr oc e dur e s descr i bed bel ow f or bot h li ve and
de pl oy e d ai r ba gs:
A i r B a g s , L i v e
CARRY A LI VE AI R BA G WI TH THE BA G AND
TRI M COVER POI NTED AWAY FROM YOUR
BODY. A N ACCI DENTAL DEPLOYMENT WI LL
THEN DEPLOY WI TH A MI NI MAL CHANCE OF
INJURY.
PLACE A LI VE AI R BA G ON A BENCH OR OTHER
SURFACE WI TH THE TRI M COVER UP, AWAY
FROM THE SURFACE. Thi s wi l l r e d u c e t h e
mo t i o n o f t h e ai r b a g i f It Is a c c i d e n t a l l y
d e p l o y e d .
A i r Bags, De p l o y e d
SAFETY PRECAUTI ONS MUST A L SO BE
OBSERVED WHEN HANDLI NG A DEPLOYED AI R
BA G .
WE AR GLOVES AND SAFETY GL ASSES WHEN
HANDLI NG A DEPLOYED AI R BA G.
AFTER DEPLOYMENT, THE AI R BA G SURFACE
MAY CONTAI N DEPOSI TS OF SODI UM
HYDROXI DE, A PRODUCT OF THE GAS
GENERANT COMBUSTI ON, THAT 88 I RRI TATI NG
TO THE SKI N.
WA SH YOUR HANDS WI TH MI LD SOAP AND
WATER AFTERWARDS.
01- 2 0( 8- 11 Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m 01- 2 0B- 11
SERVICE PRECAUTIONS (Cont i nued) DIAGNOSIS AMD TESTING
A i r B a g I n s t r u c t i o n s
WARMI NG: SERVI CE I S MADE BY REPLACEMENT
ONLY. DO NOT ATTEMPT REPAIR OF:
CRASH SENSORS.
AI R BAG SLI DI NG CONTACT ( 14A 664) .
AI R BAG DI AGNOSTI C MONI TOR ( 14B056) .
AI R BAG MODULES.
NOTE: IF A PART IS REPLACED AND THE NEW
PART DOES NOT CORRECT THE CONDITION,
INSTALL THE ORIGINAL PART AND PERFORM THE
DIAGNOSTIC PROCEDURE AGAIN.
WARNI NG: THE DRI VER AND PASSENGER AI R
BA G MODULES WI TH DI SCOLORED OR
DAMAGED TRI M COVER DEPLOYMENT DOORS
MUST BE REPLACED, NOT REPAI NTED. ANY
AP P UE D PAI NT MAY DAMAGE THE COVER
MATERI AL. THI S COULD AFFE CT AI R BAG
PERFORMANCE DURI NG DEPLOYMENT AND
MAY I NCREASE THE RI SK OF I NJURY DURI NG A
COLLI SI ON.
WARNI NG: NEVER PROBE THE CONNECTORS
ON THE AI R BAGS. DOI NG SO MAY RESULT IN
AI R BAG DEPLOYMENT WHI CH COULD RESULT
IN PERSONAL I NJURY.
WARNI NG: A L L COMPONENT REPLACEMENTS
AND WI RI NG BEI NG SERVI CED MUST BE MADE
WI TH THE NEGATI VE BATTERY CABLE
DI SCONNECTED FOR A MI NI MUM OF ONE
MI NUTE BEFORE SERVI CE OR REPLACEMENT
I S ATTEMPTED.
NOTE: THE INSTRUCTION " DI SCONNECT"
ALWAYS REFERS TO A CONNECTOR. NEVER
DETACH A COMPONENT FROM THE VEHICLE
WHEN INSTRUCTED TO "DI SCONNECT. "
WARNI NG: VEHI CLE SENSOR ORI ENTATI ON I S
CRI TI CAL FOR PROPER SYSTEM OPERATI ON.
IF A VEHI CLE EQUI PPED WI TH AN AI R BAG
SYSTE M I S I NVOLVED IN A CRASH WHERE THE
FENDERS OR GRI LLE AREA HAVE BEEN
DAMAGED, I NSPECT THE SENSOR MOUNTI NG
BRACKE TS FOR DEFORMATI ON. IF DAMAGED,
THE SENSOR SHOULD BE REPLACED
WHETHER OR NOT THE AI R BAG IS DEPLOYED.
M ADDI TI ON, ENSURE THAT BODY
STRUCTURE I N THE AREA OF SENSOR
MOUNTI NG I S RESTORED TO I TS ORI GI NAL
CONDI TI ON.
Di agnosi ng Customer Concerns Wi t h Hard
Di agnosti c Trouble Codes
Most air bag syst em di agnosti c procedures will
require the use of the Syst em Deacti vati on and
Syst em Reacti vati on Procedures outlined in thi s
sect i on. These procedures allow t he removal of t he
dri ver si de air bag module ( 043B13) and passenger
si de air bag module ( 044A74) f rom t he vehi cl e t hereby
removi ng the risk of air bag depl oyment whi l e
di agnosti cs are performed.
NOTE: The Rotunda Air Bag Si mul ator 105- 00010 for
1995 vehi cl es has a different connect or than previ ous
si mul ators. The new simulator will onl y mate wi t h 1993
vehi cl es and beyond. Li kewi se, Rotunda Air Bag
Simulator 105-00008 will only mat e wi t h 1992 and
previ ous model year vehi cl es.
ROTUNDA
AIR BAG
SIMULATOR
105-00010
R9217-A
Rotunda Air Bag Simulator 105- 00010 or equivalent is
requi red to perform diagnosis and testi ng of t he air
bag syst em. The air bag simulator is a 2-ohm resi stor
used t o simulate an air bag connecti on t o the syst em.
It is not accept abl e t o short circuit t he air bag
connecti on wi t h a zero-ohm jumper wi re. If a zero-ohm
j umper wi re is used t o short circuit t he air bag
connecti on, an appropri ate di agnosti c troubl e code will
be di spl ayed accordi ng to the pri ori ty scheme.
Deact i vat i on Procedure
1. Record pre-set radi o frequenci es for
reprogrammi ng following compl eti on of servi ce
procedure.
BAG COMPONENT SERVI CE I S PERFORMED. TO
DEPLETE BACK- UP POWER SUPPLY ENERGY,
DI SCONNECT THE NEGATI VE BATTERY CABL E
AND WAI T ONE MI NUTE TO AVOI D ACCI DENTAL
DEPLOYMENT AND POSSI BLE PERSONAL
INJURY.
3. Wait one minute. This is the ti me requi red for
back-up power supply in air bag di agnosti c
monitor t o depl ete its st ored energy.
0 1 - 2 0 8 - 1 2 Re s t r a i n t s , P a s s i v e Su p p l e me n t a S Ai r Ba g Sy s t em 01- 2 0B- 12
WARNI NG: DO NOT P L ACE THE AI R BAG WI TH
THE TRI M COVER FACI NG DOWN, A S THE
FORCES OF THE DEPLOYI NG AI R BAG MAY
CAUSE I T TO RI COCHET AND CAUSE PERSONAL
INJURY.
4. Remove dri ver si de air bag module ( 043B13)
f rom vehi cl e as outlined.
Connect Rotunda Air Bag Simulator 105- 00010
or equivalent t o vehi cl e harness at t op of steeri ng
column.
Ro t un d a Ai r Ba g Si mul a t or Co n n e c t i o n -
Vi c t o r i a , Gr and Ma r qui s
-Cr own
ROTUNDA
AIR BAG
SIMULATOR
105-00010
R9222-B
5. Remove passenger si de air bag module
( 044A74) as outlined. Install Rotunda Air Bag
Simulator 105- 00010 or equivalent on vehicle
harness connect or in pl ace of passenger si de air
bag modul e.
6. Reconnect bat t ery ground cabl e.
Re a c t i v a t i o n P r o c e d u r e
WARNI NG: THE AI R BA G SI MULATOR MUST BE
REMOVED AND THE AI R BAG RECONNECTED
WHEN THE SYSTE M I S REACTI VATED TO AVOI D
NON- DEPLOYMENT IN A COLLI SI ON RESULTI NG
IN POSSI BLE PERSONAL I NJURY.
2. Wai t one minute for back-up power suppl y in air
bag di agnosti c monitor t o depl ete st ored energy.
3. Remove Rotunda Air Bag Simulator 105- 00010
or equivalent f rom vehi cl e harness connector at
t op of steeri ng col umn.
4. Install dri ver si de air bag module as outlined.
5. Remove air bag si mul ator f rom vehi cl e harness
connector on passenger si de. Reconnect and
install passenger si de air bag module as outlined.
7. Prove out syst em.
8. Reprogram radi o frequenci es and set cl ock.
G l o s s a r y
A i r B a g S i mu l a t o r
Rotunda Air Bag Simulator 105-00010 or equivalent is
used t o simulate air bag connecti on t o syst em.
Di s c o n n e c t C o m p o n e n t
"DI SCONNECT COMPONENT" means di sconnect
component connector and vehi cl e harness connector.
It does not mean remove component. A di sconnected
part shoul d not be reconnected unless i nstructed t o do
so.
De a c t i v a t e S y s t e m
"DEACTI VATE SYSTEM" means t o perform the
Deacti vati on Procedure as outlined.
P r o v e Ou t S y s t e m
" PROVE OUT SYSTEM" means t o turn the ignition
swi t ch ( 11572) f rom OFF t o RUN and visually monitor
t he air bag indicator wi t h t h e a i r b a gs i n s t a l l e d . The
air bag indicator will light continuously for
approxi mat el y si x seconds and then turn off. If an air
bag syst em fault is present, t he air bag indicator will
either:
Fail t o light
Remain lit continuously or
Fl ash.
The flashing may not occur until approxi matel y 30
seconds after the ignition swi t ch has been turned f rom
OFF t o RUN. This is the time requi red for the air bag
di agnosti c monitor t o compl ete testi ng of t he air bag
syst em. If t he air bag indicator is inoperative and an air
bag syst em fault exi st s, a tone will sound in a pattern
of fi ve set s of five beeps. If this occurs, the air bag
indicator will need t o be servi ced before di agnosi s can
be conti nued.
Re a c t i v a t e S y s t e m
WARNI NG: THE AI R BAG SI MULATOR MUST BE
REMOVED AND THE AI R BAG RECONNECTED TO
AVOI D NON- DEPLOYMENT IN A COLLI SI ON
RESULTI NG IN POSSI BLE PERSONAL INJURY.
"REACTIVATE SYSTEM" means t o perform the
Reacti vati on Procedure outlined.
R e c o n n e c t S y s t e m
"RECONNECT SYSTEM" means t o reconnect all
syst em component s. Refer t o Air Bag Syst em
Reconnect Check Li st.
Re p l a c e C o m p o n e n t
"REPLACE COMPONENT" means t o remove the
exi sti ng component and repl ace it wi th an authori zed
repl acement part obtai ned f rom Ford Customer
Servi ce Division. Al so, the repl acement component
should be installed on vehicle and all necessary
el ectri cal connecti ons should be compl et ed.
Ve r i f y S y s t e m
"VERI FY SYSTEM" means t o prove out syst em wi th
Rotunda Air Bag Simulator 105- 00010 or equivalent in
pl ace of the air bags.
01- 2 0B- 13 Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m 0 1 - 2 0 B- 1 3
Air B a g S y s t e m Reconnect Check Li st
The check list bel ow should be compl et ed fol l owi ng
di agnosi s or servi ce of any air bag syst em concern.
1. Are all cr ash sensors connect ed and mounted t o
the vehi cl e?
2. Is bl ack 3-way connect or at base of steeri ng
col umn connect ed?
3. Are the air bags or air bag si mul ators connect ed?
4. Is air bag di agnosti c monitor ( 14B056)
connect ed?
5. Is vehi cl e bat t ery connect ed?
A i r B a g S y s t e m C o m p o n e n t L o c a t i o n
1. LH Radi ator Pri mary Crash Front Air Bag Sensor
and Bracket ( 14B005) LH si de of radi ator
support .
2. RH Radi ator Pri mary Crash Front Ai r Bag Sensor
and Br acket ( 14B004) RH si de of radi ator
support.
3. Safi ng SensorI nt egral wi t h air bag di agnosti c
monitor ( 14B056) .
4. Dri ver Side Air Bag Modul e ( 043B13) St eer i ng
wheel ( 3600) .
5. Passenger Side Air Bag Modul e
( 044A74) Above gl ove compart ment ( 06010) .
6. Air Bag Sliding Cont act ( 14A664) Behi nd
steeri ng wheel .
7. Air Bag Di agnosti c Moni tor and Br acket To t he
ri ght of t he gl ove compart ment .
8. Air Bag Di agnosti c "Troubl e Code Cl ear "
Connect orBehi nd gl ove compart ment .
INSTRUMENT
PANEL
04320
AIR BAG DIAGNOSTIC G L O V E C O MP A R T ME N T
SERVICE CONNECTOR 0 6 0 1 0 .
14489
CIRCUIT 57 (BK)
S
JL
R109S4-A
.CIRCUIT 631 (T/R)
"TROUBLE CODE CLEAR"
CONNECTOR
R10966-A
DIAGNOSIS AND TESTING (Cor
Elect ri cal S c h e ma t i c
Ai r Ba g Sy s t e mCr o wn Vi c t o r i a , Grand Marqui s
HOT IN START ORRUN
FUSE JUNCTION
PANEL (WARNING: NO FUSE SUBSTITUTIONS)
AIR BAG SLIDING
CONTACT WI NDI NG
0.2-0.35O
PER LEG
DENOTES AIR BAG
DEPLOYMENT CIRCUITS
SHORTS TERMINALS
TOGETHER WHEN
CONNECTOR IS DISCONNECTED
DENOTES HARNESS CONNECTOR
ALL SENSORS WIRING HARNESS
ARE 14401 EXCEPT WHERE
NOTED
R9677-B
Re s t r a i n t s , P a s s i v e f
Ai r Bag Syst emTown Car
HOT IN START I HOT IN
OR RUN | RUN
"T FUSE
| JUNCTION
n PANEL
| (WARNING: NO FUSE
1 5 ^j SUBSTITUTIONS)
AIR BAG SLIDING
CONTACT WINDING
0. 2- 0. 35Q
PER LEG
AIR BAG
DIAGNOSTIC
SERVICE CONNECTOR
\ 1 /
/
1
DENOTES AIR BAG
DEPLOYMENT CIRCUITS
SHORTS TERMINALS
TOGETHER WHEN
CONNECTOR IS DISCONNECTED
A\ DENOTES HARNESS CONNECTOR
^ ALL SENSORS WIRING HARNESS
ARE 14401 EXCEPT WHERE
NOTED
R10937-A
01- 2 0B- 16 Re s t r a i n t s , P a s s i v e S u p p ' 01- 2 0B- 16
(J)
J E L
AI R BAG DI AGNOSTI C MONI TOR
CONNECTOR (GRAY) C1
CONNECTOR (BLACK) C2
R10939-A
P i n
N u m b e r C i r c u i t Ci r cui t F u n c t i o n
1 No t Us e d
2 614
( G Y/ O )
Dr i v e r Ai r Ba g Fe e d
3 615
( G Y/ W)
Dr i v e r Ai r Ba g Re t ur n
4 616
( P K / B K )
P a s s e n g e r Ai r Ba g Re t ur n
5 607
( L B / O )
P a s s e n g e r Ai r Ba g Fe e d
6 964
( DB / L G )
I gn i t i o n
2 95
( L B/ P K) "
I gn i t i o n
7
_
No t Us e d
8 No t Us e d
9
_
No t Us e d
10 57 ( BK) Gr o un d
11 608
( B K / Y )
Ai r Ba g I n d i c a t o r Co n t r o l
Pin
N u m b e r Ci r cui t Circuit Function
2 No t Us e d
13 937 ( R / W) Ba t t e r y
14 937 ( R / W) Ba t t e r y
15 619
( P K / W)
LH Ra d i a t o r Pr i ma r y Cr a s h Se n s o r
Fe e d
16 617
( P K / O )
RH Ra d i a t o r Pr i ma r y Cr a s h Se n s o r
Fe e d
17 631 ( T / R) Me mo r y Cl e a r
18 57 ( BK) Gr o un d
19 6 4 0 ( R / Y )
1003
( GY/ Y) "
L a mp I gni t i on
L a mp I gn i t i o n
2 0 6 2 0 ( P / L B ) L H Ra d i a t o r Pr i ma r y Cr a s h Se n s o r
Gr o un d Mo n i t o r
2 1 6 1 8 ( P / L G ) RH Ra d i a t o r Pr i ma r y Cr a s h Se n s o r
Gr o un d Mo n i t o r
2 2 No t Us e d
2 3 62 5
( Y/ L G )
LH Ra d i a t o r Pr i ma r y Cr a s h Se n s o r
Mo n i t o r
2 4 62 4 ( Y / W) RH Ra d i a t o r Pr i ma r y Cr a s h Se n s o r
Mo n i t o r
To wn Ca r
ELECTRONIC INSTRUMENT
CLUSTER CONNECTOR C1
K22562-A
Pi n
Number C i r c u i t C i r c u i t F u n c t i o n
1 506 (R) E n g l i s h / Me t r i c I nput
2

No t Us e d
3 143 ( L B / Y) Swi t c h Mo d u l e I nput
4 39 ( R / W) En gi n e Co o l a n t Te mp e r a t u r e ( ECT)
Se n s o r I nput
5

No t Us e d
6 2 9 ( Y / W) Fue l L e v e l I nput
~K ~ ' P P
01- 2 0B- 17
Pin
N u m b e r Ci rcui t Ci r cui t Func t i on
7 7 97 ( L G / P ) Ba t t e r y Fe e d t o St e r e o
8 6 7 6
( P K / O )
P o we r Gr o u n d
9 2 95
( L B / P K )
S wi t c h e d P o we r ( Ho t in RUN)
10 8 2 ( P K / Y ) L o w Wa s h e r Fl ui d L e v e l I n put
11 2 05
( DB / L G )
Fl ui d Fl o w Ra t e I nput
12 67 9
( G Y/ B K )
Ve h i c l e S p e e d Se n s o r ( VSS)
Vo l t a ge I nput
13 1 9 ( L B / R ) No n P WM Di mmi n g I nput
14 911
( W/ L G )
T r a n s mi s s i o n Co n t r o l I n d i c a t o r
L a mp
15 7 02
( W/ B K )
C o mp a s s Da t a B +
16 7 03 ( W/ O ) Co mp a s s Da t a B-
17 344
( B K / Y )
Do o r Aj a r I nput Fr o m L C M
18 No t Us e d
19 183 ( T / Y) L i gh t i n g Co n t r o l Mo d u l e To n e
Re q u e s t
2 0

No t Us e d
ELECTRONIC INSTRUMENT CLUSTER
CONNECTOR C2 K19973-B
Pi n
2 1
No t Us e d
2 2

No t Us e d
2 3 152
( L B / W)
Swi t c h Mo d u l e I nput
2 4

No t Us e d
2 5 419
( DG / L G )
Ai r Su s p e n s i o n I nput
2 6 2 03
( O / L B )
Sp e e d Co n t r o l I nput
( Co n t i n ue d )
Pin
Number Circuit Circuit F u n c t i o n
2 7 486
( B R / W)
Tr un k Li d Aj a r I nput
2 8 No t Us e d
2 9 No t Usee!
30 No t Us e d
31
_
No t Us e d
32 No t Us e d
33 No t Us e d
34
_
No t Us e d
35 No t Us e d
36 No t Us e d
Pin
1 67 6
( P K / O )
Gr o un d
2 2 95
( L B / P K )
S wi t c h e d P o we r I nput
3 484
( O / B K )
P WM Di mmi n g I nput
4 932
( G Y/ W)
Hi gh Be a m I nput
5
_
No t Us e d
6

Not Us e d
7 489
( P K / B K )
I gn i t i o n Swi t c h
8
Not Us e d
9 658
( P K / L G )
Ma l f un c t i o n I n d i c a t o r L a mp ( Ch e c k
En gi n e ) I nput
10 904
( L G / R )
Ch a r ge I n d i c a t o r I nput
11

Not Us e d
12

Not Us e d
INDICATOR PANEL (RH)
CONNECTOR C1
R1Q94S-A
Pin
1 2 ( W/ L B ) RH Tur n Si gn a l
2 5 1 2 ( T / L G ) Br a ke I n d i c a t o r I nput ( Wi t h
Ha r n e s s )
3 608
( B K / Y)
Ai r Ba g I n d i c a t o r
4 450
( DG / L G )
Sa f e t y Be l t I n d i c a t o r
5

No t Us e d
6 No t Us e d
8 1003
( G Y/ Y)
Fu s e d I gn i t i o n I nput
INDICATOR PANEL (LH)
CONNECTOR C2
R10944-A
Pin
1 31 ( W/ R ) Oi l P r e s s u r e I n d i c a t o r I nput
2 343
( DB / L G )
Wa r n i n g L a mp t o An t i - Th e f t Mo d u l e
3 6 0 3 ( DG) Fa i l ur e Wa r n i n g L i gh t
4 3 ( L G / W ) LH Turn Si gn a l
5
___
No t Us e d
6
_
No t Us e d
8 2 95
( L B / P K )
Co n n e c t o r End Vi e ws Cr o wn Vi c t o r i a , Gr a nd
Ma r qui s
K22562-A
Pin
1 5 0 6 ( R ) En gl i sh / Me t r i c I nput
2 No t Us e d
3 143 ( L B / Y) S wi t c h Mo d u l e I nput
Se n s o r I nput
5 No t Us e d
8 67 6
( P K / O )
P o we r Gr o un d
9 2 95
( L B / P K )
S wi t c h e d P o we r ( Ho t in RUN)
10 82 ( P K / Y) L o w Wa s h e r Fl ui d L e v e l I nput
11 2 05
( DB / L G )
Fl ui d Fl o w Ra t e I nput
12 67 9
( G Y/ B K )
Ve hi c l e S p e e d Se n s o r ( VSS)
Vo l t a ge I nput
14 911
( W/ L G )
L a mp
15 7 02
( W/ B K )
Co mp a s s Da t a B +
16 7 03 ( W/ O ) Co mp a s s Da t a B-
17 344
( B K / Y )
Do o r Aj a r I nput Fr o m L CM
18
__
No t Us e d
Re q u e s t
2 0 No t Us e d
CONNECTOR C2
K19973-B
Pin
2 1 No t Us e d
2 2 No t Us e d
2 3 152
( L B / W)
S wi t c h Mo d u l e I nput
2 4
_
No t Us e d
2 5 419
( DG / L G )
2 6 2 03
( O / L B )
S p e e d Co n t r o l E n g a g e d I nput
2 7 486
( B R / W)
Tr un k Aj a r I n d i c a t o r I nput
2 8
_
No t Us e d
2 9 No t Us e d
30

No t Us e d
31

No t Us e d
32 No t Us e d
33

No t Us e d
34 No t Us e d
35 No t Us e d
36

No t Us e d
9 ) I S ) I 7
CONNECTOR 03 K19974-B
P i n
N u m b e r C i r c u i t Circuit F u n c t i o n
1 6 7 6
( P K / O )
Ve h i c l e Sp e e d Se n s o r ( VSS)
Gr o u n d
2 9 6 4
( DB / L G )
S wi t c h e d P o we r I nput ( Ho t i n RUN)
3 4 8 4
( O / B K )
4 9 32
( G Y/ W)
Hi gh Be a m I nput
5 2 ( W / L B ) RH Turn Si gn a l
6 3 ( L G / W) L H Turn Si gn a l
7 88 ( B K / W) B+ i n RUN i n put
9 65 8
( P K / L G )
P CM I nput
10 9 0 4
( L G / R )
11 4 5 0
( B K / L G )
12 6 0 8
( B K / Y )
12) (w) (V) (T) (^T) (^2
13) (u) (9^) ( j y (5^ ( j T ) (1
INSTRUMENT CLUSTER
CONNECTOR C1
(CROWN VICTORIA/GRAND MARQUIS)
R10S42-A
P i n
1 2 9 ( Y / W) Fue l P ump ( FP ) Mo d u l e I n put
2 67 6
( P K / O )
Ve hi c l e S p e e d Se n s o r ( VSS) (B-) .
3 6 4 0 ( R / Y ) Wa r n i n g L a mp s Fe e d j
4
_
No t Us e d !
5 658
( P K / L G )
Ma l f u n c t i o n I n d i c a t o r L a mp ( MI L )
Fe e d
6 No t Us e d
7 No t Us e d
8 450
( DG / L G )
Se a t Be l t Wa r n i n g I n d i c a t o r L a mp
9 67 6
( P K / O )
Ve hi c l e S p e e d Se n s o r ( VSS) (B-)
10 3 ( L G / W) LH Fr o n t Tur n Si gn a l L a mp
( Co n t i n ue d )
01- 2 0B- 2 0 Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m 01- 2 0B- 2 0
Pin
11 88 ( B K / W) I n st r ume n t Pa n e l L a mp S wi t c h e d
Fe e d
12 904
(LG/R)
Ch a r g e I n d i c a t o r
13 No t Us e d
14 67 9
( G Y/ B K )
Ve h i c l e S p e e d Se n s o r ( VSS) ( B + )
15 419
( DG / L G )
Ai r Su s p e n s i o n Ma l f u n c t i o n
Wa r n i n g L a mp
16 1053
( L B / P K )
Ai r Su s p e n s i o n Fu s e d Bat t er y -
Fe e d
INSTRUMENT CLUSTER
CONNECTOR 02
R10943-A
Pin
1 484
( O / B K )
L i q ui d Cr y s t a l I l l umi n a t i o n Di s p l a y
3 640 ( R / Y) Wa r n i n g L a mp s Fe e d
4 67 6
( P K / O )
Ve h i c l e S p e e d Se n s o r ( VSS) ( B- )
I nput
6 67 6
( P K / O )
Ve h i c l e S p e e d Se n s o r ( VSS) (B-)
7

No t Us e d
8

No t Us e d
9 603 ( DG) A BS Wa r n i n g L a mp
10 2 ( W/ L B ) RH Fr o n t Turn Si gn a l L a mp
11 911
( W/ L G )
O / D OFF I n d i c a t o r L a mp
12 932
( G Y/ W)
Hi gh Be a m I n d i c a t o r
13 97 7 ( P / W) Br a ke Wa r n i n g L a mp
14 31 ( W/ R ) Oi l P r e s s u r e Wa r n i n g L a mp
15 67 6
( P K / O )
16 608
( B K / Y)
Ai r Ba g Di a gn o s t i c L a mp Dr i v e r
AIR BAG DIAGNOSTIC MONITOR TYPICAL PIN VOLTAGES WITH SYSTEM CONNECTED AND ENGINE RUNNING
"CHARGING SYSTEM VOLTAGE"
Pi n 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 14.5 15.0 15.5 16.0
1 NC NC NC NC NC NC NC NC NC NC NC NC NC NC NC
2 1.5 1.6 1.7 1.8 1.9 2 . 0 2. 1 2. 2 2 . 3 2. 4 2. 5 2. 6 2. 7 2. 8 2. 9
3 1.5 1.6 1.7 1.8 1.9 2 . 0 2. 1 2. 2 2. 3 2. 4 2. 5 2. 6 2. 7 2. 8 2. 9
4 1.5 1.6 1.7 1.8 1.9 2 . 0 2. 1 2. 2 2. 3 2. 4 2. 5 2. 6 2. 7 2. 8 2. 9
5 1.5 1.6 1.7 1.8 1.9 2 . 0 2. 1 2. 2 2 . 3 2. 4 2. 5 2. 6 2. 7 2. 8 2. 9
6 9. 0 9. 5 10. 0 10. 5 11. 0 11.5 12. 0 12. 5 13. 0 13. 5 14. 0 14. 5 15. 0 15. 5 16. 0
10 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0
11 9. 0 9. 5 10. 0 10. 5 11. 0 11. 5 12. 0 12. 5 13. 0 13. 5 14. 0 14. 5 15. 0 15. 5 16. 0
13 9. 0 9. 5 10. 0 10. 5 11. 0 11. 5 12. 0 12. 5 13. 0 13. 5 14. 0 14. 5 15. 0 15. 5 16. 0
14 9. 0 9. 5 10. 0 10. 5 11. 0 11. 5 12. 0 12. 5 13. 0 13. 5 14. 0 14. 5 15. 0 15. 5 16. 0
15 8. 6 9. 1 9. 6 10. 1 10. 6 11. 1 11. 6 12. 1 12. 6 13. 1 13. 6 14. 1 14. 6 15. 1 15. 6
16 8. 6 9. 1 9. 6 10. 1 10. 6 11. 1 11. 6 12. 1 12. 6 13. 1 13. 6 14. 1 14. 6 15. 1 15. 6
17 5. 0 5. 0 5. 0 5. 0 5. 0 5. 0 5. 0 5. 0 5. 0 5. 0 5. 0 5. 0 5. 0 5. 0 5. 0
18 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0
19 9. 0 9. 5 10. 0 10. 5 11. 0 11.5 12. 0 12. 5 13. 0 13. 5 14. 0 14. 5 15. 0 15. 5 16. 0
01- 2 0B- 2 1 " Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m 0 1 - 2 0 B- 2 1
* * " w_ w ^ ~ _ _ ~ ~ r _ ~ T T _ _ _ _ T I - ' ^ '. i
AIR BAG DIAGNOSTIC MONITOR TYPI CAL PIN VOLTAGES WITH SYSTEM CONNECTED AMD ENGINE RUNNING
"CHARGING SYSTEM VOLTAGE" (Cont ' d)
Pi n 9.0 9,5 10.0 10 5 11.0 11.5 12.0 12 . 5 13. 0 13. 5 14. 0 14. 5 15.0 15.5 16.0
2 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0
2 1 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0 0. 0
2 2 NC NC NC NC NC NC NC NC NC NC NC NC NC NC NC
2 3 8. 6 9 1 9. 6 10. 1 10. 6 11. 1 11. 6 12. 1 12. 6 13. 1 13. 6 14. 1 14. 6 15. 1 15. 6
2 4 8.6 9. 1 9.6 10. 1 10. 6 11. 1 11. 6 12. 1 12. 6 13. 1 13. 6 14. 1 14. 6 15. 1 15. 6
NC = No harness connect i on
:ic T r o u b l e C o d e Re t r i e v a l An intermittent fault has occurred and t he fault is no
longer present. The di agnosti c moni tor may be
programmed t o fl ash "i nt ermi t t ent " DTCs 61- 85
that are st ored in NVRAM. Use t he following
procedure t o access t he st ored DTC(s).
(1) Locat e t he air bag di agnosti c servi ce connector
containing Circuit 631 ( T/ R) . This is a grey
connector under t he gl ove compart ment .
(2) Wi t h t he ignition key OFF, short Circuit 631 t o
t he ground contai ned in the servi ce connector
or another good ground.
(3) Turn the ignition key t o RUN and observe the si x
second air bag i ndi cator prove-out.
(4) Within t wo seconds after indicator prove-out,
remove the short on Circuit 6 3 1 .
(5) St ored DTCs will be di spl ayed. After servi ce,
repeat st eps 1-4 and clean t he DTCs using the
DTC Clearing Procedure.
AIR BAG DIAGNOSTIC MONITOR DIAGNOSTIC TROUBLE CODE PRIORITY TABLE
Pri ori t y Code Co mpo n e n t / Fault Descr i pt i on
Hi gh e s t
_
No Ai r Ba g I n d i c a t o r - I n o pe r a t i v e I n d i c a t o r Ci r c ui t
Co n t i n u o u s Ai r Ba g I n d i c a t o r - Di a gn o s t i c Tr o ubl e Co d e Ti me d Out , Di a gn o s t i c
Mo n i t o r Di s c o n n e c t e d o r I n o pe r a t i v e , o r No I gn i t i o n Vo l t a ge t o Di a gn o s t i c
Mo n i t o r .
12 L o s t Ba t t e r y Fe e d
13 Ai r Ba g Ci r c ui t Sh o r t e d t o Gr o un d
14 Pr i ma r y Cr a s h Se n s o r Ci r c ui t Sh o r t e d t o Gr o u n d
2 1 Di a gn o s t i c Mo n i t o r Not Mo u n t e d t o Ve hi c l e P r o p e r l y
2 2 Sa f i n g Se n s o r Out put Ci r c ui t Sh o r t e d t o Ba t t e r y Vo l t a ge
2 3 Me mo r y Cl e a r Ci r c ui t I mpr o pe r l y Gr o un d e d
2 4 S y s t e m Di sa r m Fa i l ur e o r I n t e r n a l Di a gn o s t i c Mo n i t o r Faul t
32 Dr i v e r Si d e Ai r Ba g Ci r c ui t Hi gh Re s i s t a n c e o r Ope n
33 P a s s e n ge r Si d e Ai r Ba g Ci r c ui t Hi gh Re s i s t a n c e or Op e n
34 Dr i v e r Si d e Ai r Ba g Ci r c ui t L o w Re s i s t a n c e o r Sh o r t e d
35 P a s s e n g e r Si d e Ai r Ba g Ci r c ui t L o w Re s i s t a n c e or Sh o r t e d
41 RH Ra d i a t o r Pr i ma r y Cr a s h Se n s o r Fe e d / Re t ur n Ci r c ui t Op e n
42 LH Ra d i a t o r Pr i ma r y Cr a s h Se n s o r Fe e d / Re t ur n Ci r c ui t Op e n
44 RH Ra d i a t o r Cr a s h Se n s o r Not Mo u n t e d t o Ve h i c l e P r o p e r l y
45 LH Ra d i a t o r Cr a s h Se n s o r Not Mo u n t e d t o Ve hi c l e P r o p #T ^
52 I n t e r mi t t e n t or Re p a i r e d L o s t Ba t t e r y Fe e d
P r o c e d u r e t o Re t r i e v e S t o r e d Di a gn o s t i c T r o u b l e
Co d e s f r o m Di a gn o s t i c Mo n i t o r No n - Vo l a t i l e
Ra n d o m A c c e s s Me mo r y
Some Di agnosti c Trouble Codes (DTCs) f or
intermittent probl ems (61-85) may not automati cal l y
fl ash on the air bag indicator and may require retri eval .
If an air bag DTC has been report ed on a vehi cl e but is
not currentl y fl ashi ng, thi s may be due t o t wo reasons:
A chargi ng syst em concern has been identified by
t he di agnosti c monitor and a DTC 12 i ndi cated. DTC
12 will not be st ored in t he air bag di agnosti c
moni tor' s Non-Volatile Random Access Memory
(NVRAM) under t hese ci rcumst ances. Correcti on of
t he chargi ng syst em probl em will eliminate t he DTC.
1- 208- 22 Rest r ai nt s, Pas s i v eSuppl ement al Ai r Bag S y s t e m 01- 2 0B- 2 2
DIAGNOSIS AMD TESTING (Conti nued)
AIR BAG DIAGNOSTIC MONITOR DIAGNOSTIC TROUBLE CODE PRIORITY TABLE (Cont ' d)
P r i o r i t y C o d e C o m p o n e n t / F a u l t De s c r i p t i o n
53 I n t e r mi t t e n t o r Re p a i r e d Ai r Ba g Ci r c ui t S h o r t e d t o Gr o un d
54 I n t e r mi t t e n t o r Re p a i r e d P r i ma r y Cr a s h Se n s o r Ci r c ui t S h o r t e d t o Gr o un d
61 I n t e r mi t t e n t o r Re p a i r e d Di a gn o s t i c Mo n i t o r No t Mo u n t e d t o Ve h i c l e P r o pe r l y
62 I n t e r mi t t e n t o r Re p a i r e d Sa t i n g Se n s o r Ou t pu t Ci r c ui t S h o r t e d t o Ba t t e r y Vo l t a ge
63 I n t e r mi t t e n t o r Re p a i r e d Me mo r y Cl e a r Ci r c ui t I mpr o pe r l y Gr o u n d e d
64 I n t e r mi t t e n t o r Re p a i r e d S y s t e m Di s a r m Fa i l ur e o r I n t e r n a l Di a gn o s t i c Mo n i t o r
Faul t
72 I n t e r mi t t e n t o r Re p a i r e d Dr i v e r Si d e Ai r Ba g Ci r c ui t Hi gh Re s i s t a n c e o r Ope n
7 3 I n t e r mi t t e n t o r Re p a i r e d P a s s e n g e r Si d e Ai r Ba g Ci r c ui t Hi gh Re s i s t a n c e o r Op e n
7 4 I n t e r mi t t e n t o r Re p a i r e d Dr i v e r Si d e Ai r Ba g Ci r c ui t L o w Re s i s t a n c e o r Sh o r t e d
75 I n t e r mi t t e n t o r Re p a i r e d P a s s e n g e r Si d e Ai r Ba g Ci r c ui t L o w Re s i s t a n c e or
S h o r t e d
81 I n t e r mi t t e n t o r Re p a i r e d RH Ra d i a t o r P r i ma r y Cr a s h Se n s o r Fe e d / Re t u r n Ci r c ui t
Op e n
82 I n t e r mi t t e n t o r Re p a i r e d LH Ra d i a t o r Pr i ma r y Cr a s h Se n s o r Fe e d / Re t u r n Ci r c ui t
Op e n
84 I n t e r mi t t e n t o r Re p a i r e d RH Ra d i a t o r Pr i ma r y Cr a s h Se n s o r No t Mo u n t e d t o
Ve h i c l e P r o p e r l y
85 I n t e r mi t t e n t o r Re p a i r e d L H Ra d i a t o r Pr i ma r y Cr a s h Se n s o r No t Mo u n t e d t o
Lowes t

Ra pi d Co n t i n u o u s Fl a s h i n g o f Ai r Ba g I n d i c a t o r - Bo t h Pr i ma r y Cr a s h Se n s o r s
Di s c o n n e c t e d - A s s e mb l y Pl a n t Mo d e
P i n p o i n t Tests
equivalent t o obtai n vol tage and resi stance readi ngs
for the fol l owi ng Pinpoint Tests.
No Ai r Bag I ndi cat or Inoperative I ndi cat or
Ci r cui t
Normal Operation
The air bag indicator is desi gned t o light for si x ( t wo)
seconds when the ignition swi t ch ( 11572) is turned t o
RUN. Thi s initial si x seconds of air bag i ndi cator
illumination is consi dered normal operati on and is
cal l ed " pr oveout " of the air bag indicator. If t here is an
open in t he air bag i ndi cator ci rcui t at Pin 11, a no air
bag i ndi cator fault will occur and thi s proveout will not
be seen.
If the comput er in t he air bag di agnosti c monitor
( 14B056) det ect s an open in the air bag indicator
ci rcui t and if another syst em fault exi st s, then the air
bag di agnosti c monitor will turn on its internal tone
generator (beeper). The beep pattern is fi ve set s of
fi ve beeps. The pattern is repeat ed every 30 minutes
whi l e t he ignition swi t ch is in RUN. The fi ve beeps do
not i ndi cate a code 55 or any other code. The
i ndi cator ci rcui try must be servi ced before the
di agnosti c trouble code can be read.
The air bag di agnosti c monitor requires power at Pin 6
t o energi ze t he air bag indicator circuit properl y. Loss
of ignition vol t age at Pin 6 due t o open circuit or short
t o ground will result in a continuous air bag indicator
(see Continuous Air Bag Indicator descri pti on for
detai l s) due t o t he ignition vol tage appl i ed t o Pin 19.
If the air bag di agnosti c monitor is di sconnected or not
firmly pl ugged in, a shorti ng bar in the bl ack air bag
di agnosti c monitor harness connector short s Pins 10
and 11, turning the lamp on continuously (see
Continuous Air Bag Indicator descri pti on for detai l s).
P o s s i b l e C a u s e s
An i noperati ve air bag indicator circuit can be caused
by:
A b u r n e d o u t b u l b o r o p e n wi r i n g i n t h e ai r b a g
i n d i c a t o r c i r c u i t .
01- 2 0B- 2 3 Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m
El e c t r i c a l Sc he ma t i c No Ai r Ba g I n d i c a t o r
HOT IN START OR RUN
"* FUSE
I JUNCTION
" PANEL
1003
15A"
GY/Y*
1
^ J
LB/PK*

964j ^DB/LG*
1
' AIR BAG I
| INDICATOR j
NOTE THE SHORTING BAR IN
THE BLACK AIR BAG DIAGNOSTIC
MONITOR HARNESS CONNECTOR. THIS
SHORTING BAR SHORTS PINS 11
AND 10 TOGETHER WHENEVER
THE BLACK CONNECTOR IS NOT
FIRMLY PLUGGED INTO THE
AIR BAG DIAGNOSTIC MONITOR.
WHEN PINS 11 AND 10 ARE SHORTED
TOGETHER, THE AIR BAG INDICATOR
WILL BE ON CONTINUOUSLY.
* TOWN CAR
** CROWN VICTORIA, GRAND MARQUIS
AUTOMATIC INDICATOR CIRCUIT
IF THE IGNITION SWITCH
IS IN RUN AND THERE IS NO
RESPONSE FROM THE
COMPUTER, THEN TURN
ON THE INDICATOR DRIVER
CONTINUOUSLY.
IF THE IGNITION SWITCH IS IN
RUN AND THERE IS NO
IGNITION VOLTAGE AT PIN 6,
THEN TURN ON THE
INDICATOR DRIVER
CONTINUOUSLY.
. . C O M P U T E R
IF THE IGNITION
SWITCH IS IN RUN
THEN TURN ON
INDICATOR DRIVER
CIRCUIT FOR
SIX SECONDS.
THEN FLASH
DIAGNOSTIC TROUBLE
CODE(S) IF
ANY EXIST.
IF THE INDICATOR
CIRCUIT IS NOT
INTACT, AND
ANOTHER SYSTEM
FAULT EXISTS,
THEN ACTIVATE
THE INTERNAL
TONE (BEEPER).
AIR mm :mmm$m mmwmm
PINPOINT TEST A: NO AIR BAG INDICATORINOPERATIVE INDICATOR CIRCUIT
A1 UNDERSTAND FUNCTION
Yes
No
GO to A2.
RE-EXAMINE appropri ate
descri pti ons and
schemati cs. Failure to
understand air bag
system functions will
result in needless
replacement of system
components and repeat
service.
Read the normal operati on descri pti on for NO AIR
BAG INDICATOR.
Examine the diagnostic trouble code schemati c.
Is di agnost i c t r oubl e c ode oper at i on wel l
unde r st ood?
Yes
No
GO to A2.
descri pti ons and
understand air bag
result in needless
service.
A2 CHECK FOR OPEN LAMP CIRCUIT
Yes
No
REPLACE air bag
diagnostic monitor and
bracket. RECONNECT
system. VERIFY system.
REACTIVATE system.
GO to A3.
Deactivate syst em.
Disconnect air bag di agnosti c monitor.
Is ai r bag i ndi cat or on?
Yes
No
REPLACE air bag
bracket. RECONNECT
REACTIVATE system.
GO to A3.
01- 2 0B- 2 4 I s s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m 01- 2 0B- 2 4
PINPOINT TEST A: NO AIR BAG INDICATORINOPERATIVE INDICATOR CIRCUIT (Cont i nued)
A3 CHECK FOR ELECTRONIC INSTRUMENT CLUSTER
Yes
No
GO to A4.
LOCATE and SERVICE
open circuit in air bag
indicator circuitry or
burned out bulb.
RECONNECT system.
VERIFY syst em.
REACTIVATE system.
Check for electroni c instrument cluster.
Is t he air bag i ndi cat or ope r a t e d by an el ect r oni c
i nst rument cl ust er ?
Yes
No
GO to A4.
LOCATE and SERVICE
open circuit in air bag
indicator circuitry or
burned out bulb.
RECONNECT system.
VERIFY syst em.
REACTIVATE system.
A4 CHECK INSTRUMENT CLUSTER
Yes
No
SERVICE instrument
cluster. REFER to
Section 13-01A or
13-01B. RECONNECT
REACTIVATE system.
CHECK connectors on
instrument cluster.
REPLACE instrument
cluster if connections are
OK. REFER to Section
13-01A or 13-01B.
RECONNECT system.
VERIFY system.
REACTIVATE system.
Remove plasti c locking wedge from black air bag
diagnostic monitor harness connector.
Measure voltage between Pins 11 ( + ) and 10(-).
Is vol t age equal t o ba t t e r y vol t age?
Yes
No
SERVICE instrument
cluster. REFER to
Section 13-01A or
13-01B. RECONNECT
REACTIVATE system.
CHECK connectors on
instrument cluster.
REPLACE instrument
cluster if connections are
OK. REFER to Section
13-01A or 13-01B.
RECONNECT system.
VERIFY system.
REACTIVATE system.
C o n t i n u o u s Ai r B a g i n d i c a t o r Di a g n o s t i c
Tr oubl e C o d e T i me d Ou t , o r Di a g n o s t i c Mo n i t o r
Di s c o n n e c t e d o r I n o p e r a t i v e , o r No I g n i t i o n
Vo l t a g e t o Di agnos t i c Mo n i t o r
No r ma l Op e r a t i o n
The air bag indicator is desi gned t o light for six ( t wo)
seconds when the ignition swi t ch is turned t o RUN.
Thi s initial si x seconds of air bag i ndi cator illumination
is consi dered normal operati on and is cal l ed
" pr oveout " of the air bag indicator. If the air bag
di agnosti c monitor has det ect ed any faul ts in t he air
bag syst em, it will fl ash t he air bag i ndi cator a seri es of
ti mes t o i ndi cate the hi ghest pri ori ty code st ored in
memory.
The di agnosti c troubl e codes are t wo di gi ts.
The fi rst digit is di spl ayed by a seri es of fl ashes at a
rat e of one per second. A t wo second pause f ol l ows
t he fi rst digit.
The second digit is then di spl ayed by a seri es of
fl ashes at a rate of one per second. A fi ve second
pause fol l ows t he second digit.
The code then repeat s, starti ng wi t h t he fi rst digit.
After t he code has f l ashed compl etel y fi ve ti mes, t he
air bag indicator will light continuously until the ignition
swi t ch is cycl ed. If t he air bag indicator comes on
when t he ignition swi t ch is turned t o RUN and
i mmedi atel y st ays on f or more than ei ght seconds
continuously, then a fault exi st s in t he air bag i ndi cator
ci rcui t.
The air bag di agnosti c monitor i ncorporates a solid
st at e ci rcui t whi ch short s t he air bag indicator line
(Circuit 608, BK/ Y) t o ground t o turn on t he air bag
indicator. When t he bl ack air bag di agnosti c monitor
harness connector is unplugged f rom t he air bag
di agnosti c monitor, a shorti ng bar within t he harness
connect or short s Pin 11 (air bag i ndi cator) and Pin 10
(ground) together, causi ng a continuous l amp. This
shorti ng bar may be removed for servi ci ng purposes
by removi ng the bl ack spacer (l ocki ng wedge) in the
bl ack air bag di agnosti c monitor harness connector.
The air bag di agnosti c monitor requires power at Pin 6
t o energi ze the air bag indicator circuit properl y. Loss
of ignition vol tage at Pin 6 due t o open circuit or short
t o ground will result in a continuous air bag indicator
due t o t he ignition vol tage appl i ed t o Pin 19. An open or
short t o ground in the l amp circuit at Pin 11 will result in
no air bag indicator (refer t o No Air Bag Indicator
descri pti on).
Continuous air bag indicator illumination can be caused
by:
A d i a gn o s t i c t r o u b l e c o d e ha s f l a s h e d f i v e
t i me s a f t e r t h e i gn i t i o n s w i t c h wa s t u r n e d t o
RUN ( a f t e r p r o v e - o u t ) a n d ha s t i me d o u t .
Re c y c l i n g t h e i gn i t i o n s wi t c h wi l l r e d i s pl a y t h e
DTCs.
01- 20B- 25 Rest r ai nt s, P a s s i v e S u p p l e me n t a l Ai r Bag S y s t e m 0 1 - 2 0 8 - 2 5
A di s c onnec t ed or poor l y c onnec t ed ai r bag
di agnost i c moni t or may not push t he short i ng bar
bet ween Pins 10 and 11 into its fully ret ract ed
posi ti on. This short s t he air bag indicator line t o
ground and causes the air bag indicator t o gl ow
continuously.
El e c t r i c a l Sc he ma t i c Co n t i n uo us Ai r Ba g I n d i c a t o r
A d a ma g e d a i r b a g d i a g n o s t i c mo n i t o r .
S h o r t e d ai r b a g i n d i c a t o r wi r i n g .
L o s s o f i gn i t i o n v o l t a g e a t Pi n 6 o f t h e ai r b a g
d i a g n o s t i c mo n i t o r .
HOT IN START OR RUN
f
1 5A*
1003
640
GY/Y*
R/Y**
L r - 1
> 1
MSA J
295 LB/PK*
i 1
DB/LG**
Y
FUSE
INSTRUMENT
CLUSTER
NOTE THE SHORTING BAR IN
THE BLACK DIAGNOSTIC MONITOR
HARNESS CONNECTOR. THIS
SHORTING BAR SHORTS PINS 11
AND 10 TOGETHER WHENEVER
THE BLACK CONNECTOR IS NOT
FIRMLY PLUGGED INTO THE
DIAGNOSTIC MONITOR CONNECTOR.
WHEN PINS 11 AND 10 ARE SHORTED
TOGETHER, THE AIR BAG INDICATOR
WILL BE ON CONTINUOUSLY.
*TOWN CAR
"CROWN VICTORIA, GRAND MARQUIS
AUTOMATIC INDICATOR CIRCUIT
IF THE IGNITION SWITCH IS
ON AND THERE IS NO
RESPONSE FROM THE
COMPUTER, THEN TURN ON THE
INDICATOR DRIVER
CONTINUOUSLY.
IF THE IGNITION SWITCH IS
ON AND THERE IS NO
IGNITION VOLTAGE AT PIN 6,
THEN TURN ON THE
INDICATOR DRIVER
CONTINUOUSLY.
SOLID STATE
LAMP DRIVER
CIRCUIT
IF THE IGNITION
SWITCH IS ON
THEN TURN ON
INDICATOR DRIVER
CIRCUIT FOR
SIX SECONDS.
THEN FLASH
FAULT CODE(S) IF
ANY EXIST.
R10969-A
PINPOINT TEST B: CONTINUOUS AIR BAG INDICATORDIAGNOSTIC TROUBLE CODE TIMED OUT, OR DIAGNOSTIC
MONITOR DISCONNECTED OR INOPERATIVE, OR NO IGNITION VOLTAGE TO DIAGNOSTIC MONITOR
B1 UNDERSTAND FUNCTION
Yes
No
GO to B2.
descriptions and
schemati cs. Failure t o
understand air bag
result in needless
service.
Read the normal operation descri pti on for
Continuous Air Bag Indicator.
Examine the fault code schematic.
Is f aul t code oper at i on wel l under st ood?
Yes
No
GO to B2.
descriptions and
understand air bag
result in needless
service.
01- 2 0B- 2 6
DIAGNOSIS AND TESTING ( C o n t i n u e d )
PINPOINT TEST B: CONTINUOUS AIR BAG INDICATORDIAGNOSTIC TROUBLE CODE TIMED OUT, OR DIAGNOSTIC
MONITOR DISCONNECTED OR INOPERATIVE, OR NO IGNITION VOLTAGE TO DIAGNOSTIC MONITOR (Continued)
B2 CHECK FOR DIAGNOSTIC TROUBLE CODE TIMED OUT
Yes
No >
COUNT diagnostic
trouble code number.
PROCEED to appropri ate
diagnostic trouble code
descri pti on and pinpoint
t est s.
GOt o B3.
Cycl e I gni ti on swi t ch to OFF a nd t hen t o RUN.
Does a di agnosti c troubl e code start fl ashi ng
after a six second (dbtwo) i ndi cator pr ove-out ?
Yes
No >
COUNT diagnostic
trouble code number.
PROCEED to appropri ate
descri pti on and pinpoint
t est s.
GOt o B3.
B3 CHECK IF DIAGNOSTIC MONITOR IS CONNECTED
Yes
No
GO t o B4.
Firmly MATE connectors
to air bag diagnostic
monitor. PROVE OUT
system.
Inspect connectors on air hag diagnostic monitor.
Are c onne c t or s f ul l y pushed t oge t he r ?
Yes
No
GO t o B4.
Firmly MATE connectors
to air bag diagnostic
monitor. PROVE OUT
system.
B4 CHECK FOR IGNITION VOLTAGE
Yes ~
No .
GOt o B5.
LOCATE and SERVICE
open circuit in "HOT IN
RUN" Circuit 295
(LB/PK) Town Car 964
(DB/LG) All others from
fuse panel. CHECK the
fuse, connectors, cri mps,
etc. CHECK for proper
ground on Pin 18 of the air
bag diagnostic monitor
harness connector.
RECONNECT system.
VERIFY system.
REACTIVATE system.
Deactivate system.
Measure voltage between Pins 6 ( + ) and 18 (-) of
the air bag diagnostic monitor harness connector.
Is vol t age measured equal t o bat t er y vol t age?
Yes ~
No .
GOt o B5.
LOCATE and SERVICE
open circuit in "HOT IN
RUN" Circuit 295
(LB/PK) Town Car 964
(DB/LG) All others from
fuse panel. CHECK the
fuse, connectors, cri mps,
etc. CHECK for proper
ground on Pin 18 of the air
harness connector.
RECONNECT system.
VERIFY system.
REACTIVATE system.
B5 CHECK FOR SHORTED INDICATOR WIRING
Yes ^
No
SERVICE short to ground
in Circuit 608 (BK/ Y)
between air bag indicator
and air bag diagnostic
monitor. RECONNECT
REACTIVATE system.
GO to B6.
Remove plasti c locking wedge from t he black air
bag diagnostic monitor harness connector.
Turn ignition switch t o RUN.
Is air bag i ndi cator on?
Yes ^
No
in Circuit 608 (BK/ Y)
between air bag indicator
and air bag diagnostic
monitor. RECONNECT
REACTIVATE system.
GO to B6.
B6 INSPECT SHORTING BAR
Yes
No
REPLACE air bag
bracket. RECONNECT
REACTIVATE system.
REPLACE plastic locking
wedge. MAKE sure the
replacement has shorting
bars on the locking
wedge. RECONNECT
REACTIVATE system.
Inspect shorting bars on plasti c locking wedge for
proper operati on.
Are shor t i ng bars i n good wo r ki n g or der ?
Yes
No
REPLACE air bag
bracket. RECONNECT
REACTIVATE system.
REPLACE plastic locking
wedge. MAKE sure the
replacement has shorting
bars on the locking
wedge. RECONNECT
REACTIVATE system.
01- 2 0B- 2 7 Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba g Sy s t em 0 1 - 2 0 B- 2 7
Di agnos t i c Tr oubl e Co d e 12 L o s t Ba t t e r y
Fe e d
The air bag di agnosti c monitor measures t he vol tage
at Pin 14 of the air bag di agnosti c monitor connector.
Vol tage at Pin 14 shoul d be equal t o bat t ery vol tage. If
the vol tage at Pin 14 drops t o l ess than 8 vol ts, t he air
bag di agnosti c moni tor will fl ash out on the air bag
indicator a DTC 12. If the vol tage at Pin 14 drops t o
l ess than 5 vol ts, t he air bag di agnosti c monitor will
al so st ore a DTC 12 in memory. Should t he loss of
bat t ery vol tage at Pin 14 be intermittent or repai red,
the air bag di agnosti c monitor will fl ash out a DTC 52
(or higher pri ori ty code if one exi st s) on the next
ignition swi t ch cycl e.
Low vol tage at air bag di agnosti c monitor Pin 14 can
be caused by:
WARNI NG: UNDER NO CI RCUMSTANCES
SUBSTI TUTE ANOTHER FUSE VALUE. ANY FUSE
OTHER THAN 10A MAY CAUSE DI SARMI NG
FAI LURE AND MAY RESULT IN DANGER TO THE
OCCUPANTS OF THE VEHI CLE. DO NOT
ATTEMPT TO REPLACE THE 10A FUSE UNLESS
THE AI R BAG SYSTE M FI RST HAS BEEN
DEACTI VATED (SEE DEACTI VATI ON PROCEDURE
FOR DETAI LS) .
NOTE: If a short t o ground exi st s on any of t he Ci rcui ts
607 ( LB/ Q) , 614 ( GY/ O) , 615 ( GY/ W) , or 616
(PK / BK) leading t o a DTC 13 or 53, or similarly a '
short t o ground exi st s on any of Ci rcui ts 617 ( PK/ O) ,
619 ( PK/ W) , 624 ( Y/ W) , 625 ( Y/ LG) leading t o a
DTC 14 or 54, the air bag di agnosti c monitor will
act i vat e a solid st at e swi t ch at Pin 13 of t he air bag
di agnosti c monitor. This causes the 10 amp bat t ery
fuse t o bl ow, thus di sarmi ng t he air bag syst em and
preventi ng i nadvertent air bag depl oyment. If the 10
amp fuse junction panel (or power distribution in some
vehi cl es) bat t ery fuse has bl own, it must be repl aced
by a 10A fuse.
A n o p e n i n t h e b a t t e r y c i r c u i t that woul d prevent
bat t ery vol tage f rom reachi ng air bag di agnosti c
monitor Pin 14.
Af t er t he air bag di agnosti c monitor has di sarmed the
ai r bag syst em, it will not be enabl ed t o di sarm agai n
until t he appropri ate condi ti on (DTC 13, 14, 53, or 54)
has been servi ced and cl ear ed (refer to DTC 13, 14,
53, and 54 and Di agnosti c Trouble Code Cl eari ng
descri pti ons for further detai l s).
A s h o r t to g r o u n d o n t h e b a t t e r y f e e d ci r cui t
bet ween t he fuse and Pin 13 or Pin 14 of the air bag
di agnosti c monitor.
A c onc er n i n t he char gi ng s y s t em causi ng
bat t ery vol tage t o dr op bel ow 8 vol t s.
El e c t r i c a l Sc he ma t i c Di a gn o st i c Tr o ubl e Co d e 12
HOT AT ALL TIMES
A CODE 13 OR 14
CONDITION MAY
CAUSE THE DIAGNOSTIC
MONITOR TO DISARM THE
SYSTEM BY BLOWING
THIS FUSE.
SEE CODE 13 AND 14
DESCRIPTIONS FOR DETAILS.
SHORTS TO GROUND
ON THESE CIRCUITS
MAY CAUSE
FUSE TO
BLOW
I T -
POWER*
DISTRIBUTION
BOX
FUSE**
i JUNCTION
I PANEL
(NO
SUBSTITUTIONS)
R/W
7^
BRACKET
GROUND
* TOWN CAR
1 3
FUSE
BLOW
14
SOLID
STATE
SWITCH
SAFING
mmon
BACK UP
POWER SUPPLY
32-34 VOLTS
IF THE VOLTAGE AT PIN 14
IS LESS THAN 8 VOLTS
DUE TO BLOWN FUSE
OR FOR ANOTHER REASON
THEN FLASH CODE 12. IF THE
VOLTAGE AT PIN 14 IS LESS
THAN 5 VOLTS, THEN
STORE CODE 12
COMPUTER
- A\H SJMS DiAQNOgfIC MONITOR
REFERENCE
GROUND
R10970-A
DTC 12: LOST BATTERY FEED
12-1 UNDERSTAND FUNCTION
Yes
No
NOTE: This is a hard
fault. The fault condition
is sti ll present. This fault
may not be cleared until it
is servi ced and flashes
out as a DTC 52.
GOt o 12-2.
RE-EXAMINE appropriate
descri pti ons and
understand air bag
result in needless
service.
Cycle the ignition swi tch to OFF and then t o RUN
and confirm that DTC 12 is flashing on the air bag
indicator.
Read the normal operation descri pti on for DTC 12.
Examine the di agnosti c trouble code schemati c.
Is t he di agnost i c t r oubl e c ode oper at i on wel l
under st ood?
Yes
No
out as a DTC 52.
GOt o 12-2.
descri pti ons and
understand air bag
result in needless
service.
01- 2 0B- 2 9 Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r l a g S y s t e m
01- 2 0B- 2 9
DTC 12: LOST BATTERY FEED (Conti nued)
12-2 CHECK CHARGING SYSTEM
Yes
No >
GOt o 12 - 3.
SERVICE vehicle
charging system. CYCLE
ignition swi tch.
PROCEED to t he
descri pt i on, schemati c,
and pinpoint t est s of the
di agnosti c trouble code
that is flashi ng.
Measure charging system voltage.
Is vol t age greater than 8 vol t s?
Yes
No >
GOt o 12 - 3.
SERVICE vehicle
charging system. CYCLE
ignition swi tch.
PROCEED to t he
that is flashi ng.
12-3 CHECK BATTERY FEED
Yes
No
REPLACE air bag
di agnosti c monitor and
bracket . RECONNECT
syst em. VERIFY system.
REACTIVATE system.
GO to 12 - 4.
Deactivate system.
Disconnect air bag di agnosti c monitor
Turn ignition swi tch from OFF t o RUN.
Measure voltage between air bag di agnosti c
monitor harness connector Pins 14 ( + ) and 18 (-).
Is vol t age on Pin 14 equal t o bat t er y vol t a ge ?
Yes
No
REPLACE air bag
bracket . RECONNECT
syst em. VERIFY system.
REACTIVATE system.
GO to 12 - 4.
12-4 CHECK BATTERY FUSE
Yes >
No l >
GOt o 12-5.
LOCATE and SERVICE
open Circuit 38 (BK/ O) or
937 (R/ W) between
positive ( + ) terminal of
battery and Pin 14 of the
air bag diagnostic
monitor harness
connector. Check in-line
connectors, crimps, etc.
CONNECT air bag
CYCLE ignition swi t ch.
PROCEED to the
that is flashi ng.
Check 10A battery fuse feeding air bag di agnosti c
monitor harness connector Pins 14 and 13.
Check power distribution fuse feeding the 10A fuse.
Is ei t her f use bl own?
Yes >
No l >
GOt o 12-5.
LOCATE and SERVICE
open Circuit 38 (BK/ O) or
937 (R/ W) between
positive ( + ) terminal of
battery and Pin 14 of the
air bag diagnostic
monitor harness
connector. Check in-line
connectors, crimps, etc.
CONNECT air bag
PROCEED to the
that is flashi ng.
12-5 CHECK FOR SHORT IN HARNESS
Yes
No
LOCATE and SERVICE
short t o ground in Circuit
38 (BK/O) or 937 (R/W)
between fuse and Pin 13
or Pin 14 of the air bag
di agnosti c monitor
harness connector.
CONNECT air bag
diagnostic monitor.
PROCEED to the
descri pt i on schemati c,
that is flashing.
GOt o 12 - 8.
WARNING: CERTAIN FAULT CONDITIONS
(DIAGNOSTIC CODE 13/ 53 OR 14/ 54) MAY CAUSE
THE AIR BAG DIAGNOSTIC MONITOR TO
INTENTIONALLY BLOW THE 10A BATTERY FUSE TO
DISARM THE AIR BAG SYSTEM. DO NOT
SUBSTITUTE ANOTHER FUSE VALUE FOR THE 10A
BATTERY FUSE. ANY OTHER FUSE VALUE MAY
CAUSE FUTURE DISARMING FAILURE AND MAY
VEHICLE. ONCE THE AIR BAG DIAGNOSTIC
MONITOR HAS DISARMED THE SYSTEM, IT WILL
NOT ATTEMPT TO DO SO AGAIN UNTIL THE
APPROPRIATE DIAGNOSTIC TROUBLE CODE
( 13/ 53 OR 14/ 54) HAS BEEN CLEARED. THUS DO
NOT REACTIVATE SYSTEM UNTIL ALL DIAGNOSTIC
TROUBLE CODES HAVE BEEN REPAIRED AND
CLEARED.
Replace blown fuse. NO SUBSTITUTIONS.
Does f use bl ow agai n?
Yes
No
LOCATE and SERVICE
38 (BK/O) or 937 (R/W)
between fuse and Pin 13
or Pin 14 of the air bag
harness connector.
CONNECT air bag
diagnostic monitor.
PROCEED to the
descri pt i on schemati c,
that is flashing.
GOt o 12 - 8.
01- 2 0B- 30
ras
Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m 01- 2 0B- 30
DTC 12: LOST BATTERY FEED (Cont i nued)
12-6 CONFIRM CONDITION
Y e s
No
REPLACE a i r b a g
b r a c k e t . REPLACE fuse,
NO SUBSTITUTIONS.
RECONNECT s y s t e m .
VERIFY s y s t e m .
REACTIVATE s y s t e m .
PROCEED to the
descri pti on, schemati c,
that is flashing.
Reconnect air b a g d i a g n o s t i c m o n i t o r
Does fuse blow agai n?
Y e s
No
REPLACE a i r b a g
b r a c k e t . REPLACE fuse,
NO SUBSTITUTIONS.
RECONNECT s y s t e m .
VERIFY s y s t e m .
REACTIVATE s y s t e m .
PROCEED to the
that is flashing.
Di a g n o s t i c T r o u b l e C o d e 13 Ai r Ba g Ci r c u i t
S h o r t e d t o G r o u n d
The air bag di agnosti c monitor measures the vol t age
at Pins 2, 3, 4, and 5 of t he air bag di agnosti c monitor
connector. The vol tage at these pins is set by t he air
bag di agnosti c monitor and vari es wi t h chargi ng
syst em vol tage (the expect ed vol tages are shown in
the fol l owi ng t abl e). If t he air bag di agnosti c monitor
det ect s l ow vol tage on any of t hese pins, the air bag
di agnosti c monitor will st ore in memory and fl ash out
on t he air bag indicator a DTC 13 t o indicate a possi bl e
short t o ground on t hese ci rcui ts.
At t he same ti me t he air bag di agnosti c monitor begi ns
flashing out DTC 13, it at t empt s t o di sarm the air bag
syst em t o prevent i nadvertent depl oyment of t he air
bag(s) by bl owi ng t he 10A bat t ery fuse feedi ng air bag
di agnosti c monitor Pins 13 and 14. It at t empt s t o bl ow
the fuse by acti vati ng a sol i d st at e swi t ch whi ch short s
the bat t ery f eed at Pin 13 t o sheet metal ground at t he
air bag di agnosti c moni tor' s bracket .
The air bag di agnosti c monitor will make up t o t hree
at t empt s t o bl ow thi s fuse, spaced one minute apart .
If t he air bag di agnosti c monitor has bl own t he fuse
and thus removed bat t ery vol tage at Pin 14, a DTC
12 will be st or ed (refer t o DTC 12 and 52
descri pti on f or further detai l s).
If t he air bag di agnosti c monitor at t empt s t o bl ow
the 10A bat t ery fuse three ti mes and fails each
ti me, a DTC 24 will be st ored (refer t o DTC 24 and
64 descri pti on for further detai l s).
After t he 10A fuse is bl own or t hree at t empt s t o
bl ow it fai l , t he air bag di agnosti c monitor will not
at t empt t o di sarm again until the DTC 13 condition
has been servi ced and cl eared (refer t o Di agnosti c
Troubl e Code Clearing descri pti on for further
detai l s).
Shoul d t he short on Pins 2 , 3 , 4 , or 5 be intermittent
or repai red, t he air bag di agnosti c monitor will fl ash
out a DTC 53 (or a higher pri ori ty DTC such as DTC
12 if one exi st s) on t he next ignition swi t ch cycl e.
AIR BAG DIAGNOSTIC MONITOR TYPICAL PIN VOLTAGES WITH SYSTEM CONNECTED AND ENGINE RUNNING
Pin 9. 0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 14.5 15.0 15.5 16.0
2 1.5 1.6 1.7 1.8 1.9 2. 0 2. 1 2. 2 2. 3 2 . 4 2. 5 2. 6 2. 7 2 . 8 2. 9
3 1.5 1.6 1.7 1.8 1.9 2 . 0 2. 1 2. 2 2 . 3 2 . 4 2 . 5 2. 6 2. 7 2. 8 2. 9
4 1.5 1.6 1.7 1.8 1.9 2. 0 2. 1 2. 2 2 . 3 2 . 4 2. 5 2. 6 2. 7 2 . 8 2. 9
5 1.5 1.6 1.7 1.8 1.9 2. 0 2. 1 2. 2 2. 3 2 . 4 2. 5 2. 6 2. 7 2 . 8 2. 9
0 1 - 2 0 B- 3 1
WARNI NG: SERVI CI NG A DTC 13 WI LL USUALLY
OCCUR AFTER SERVI CI NG OF A DT C 12 HAS
BEEN COMPLETED. UNDER NO CI RCUMSTANCES
RESULT I N DANGER TO THE OCCUPANTS OF THE
VEHI CLE. DO NOT ATTE MP T TO REPLACE THE
10A BATTERY FUSE UNLESS THE AI R BA G
SYSTE M FI RST HAS BEEN DEACTI VATED (SEE
L o w vol t age at ai r ba g di agnost i c moni t or Pins 2 , 3 , 4 ,
or 5 can be c a use d by:
A s h o r t t o g r o u n d o n Ci r c u i t s 6 0 7 (LB/O), 6 1 4
( G Y/ O) , 6 1 5 ( G Y/ W) , o r 6 1 6 ( P K/ BK) causi ng
t he di agnost i c vol t age t o d r o p.
e Re s i s t a n c e t o gr ound on Ci r cui t s 6 1 7 ( PK/ O) ,
6 1 9 ( PK/ W) , 6 2 4 ( Y / W) , 6 2 5 ( Y/ L G) o r i n t e r n a l
r e s i s t a n c e t o gr ound i n e i t h e r of t he r a d i a t o r
p r i ma r y c r a s h sensor s may act i vat e an ai r ba g
di agnost i c moni t or ci rcui t whi ch may c a use t he
vol t age t o d r o p.
A n i n t e r n a l shor t t o gr ound wi t h i n t h e a i r b a g
s l i d i n g c o n t a c t ( 14A 664) causi ng t he dri ver si de
ai r bag ci r cui t (s) t o be sho r t e d t o gr ound.
e A n i n t e r n a l s h o r t t o c a s e gr ound wi t h i n t h e
d r i v e r s i d e ai r h a g mo d u l e ( 043B13) or
p a s s e n ge r s i d e a i r b a g mo d u l e ( 044A 7 4) .
01- 2 0B- 32 Rest r ai nt s, Pas s i v eSuppl ement al Ai r Bag Sy s t em 01- 2 0B- 32
El e c t r i c a l Sc he ma t i c , Cr own Vi ct or i a, Grand Mar qui s Di agnost i c Trouble Co d e 13
HOT IN RUN 1 HOT AT A L L TI MES
| FUSE J UNCT I ON
, P A N E L
1 (NO SUBSTITUTIONS)
IF A SHORT TO GROUND ON f
PINS 2, 3, 4, OR 5
OCCURS, OR RESISTANCE |
TO GROUND ON
PINS 15, 16, 23, OR 24
OCCURS, THEN BLOW
THE 10A FUSE
AND STORE CODE 13
IF THE VOLTAGE AT PIN 14 !
DUE TO BLOWN FUSE
OR FOR ANOTHER REASON 1
THEN STORE CODE 12.
IF THE ATTEMPT TO BLOW
THE 10A FUSE FAILS THREE I
TIMES DUE TO WRONG FUSFJ
OR FOR ANOTHER REASON |
THEN STORE CODE 24
COMPUTER
TO FUS E -
BL OW
REFERENCE
GROUND
km mm mmmmcmmirm
AIR BAG SLIDING
CONTACT WINDING
0.2-0.35Q
PER LEG
GY/O
Q
0971-A
01- 2 0B- 33 Rest r ai nt s, Pas s i v eSuppl ement al Ai r Bag S y s t e m 0 1 - 2 0 B- 3 3
El ect r i cal Sc he ma t i c , Town Ca r Di agnost i c Troubl e Co d e 13
i FUSE JUNCTION
PANEL
1 (NO SUBSTITUTIONS)
AIR BAG SLIDING
CONTACT WINDING
0.2-0.35O
PER LEG
% 9
}
i
h
R10940-A
1995 Town Car , Cr own Vi ct or i a, Gr and Mar qui s Jul y 1994
01- 20B- 34
DTC 13: AIR BAG CIRCUIT SHORTED TO GROUND
TEST STEP R E S U L T ACTION T O T A K E
Yes
No O
out as a DTC 53. Under
normal circumstances a
DTC 12 will have j ust
been servi ced.
GO to 13-2.
descri pti ons and
schemat i cs. Failure to
understand air bag
result in needless
service.
Cycle the ignition switch to OFF and then to RUN
and confirm that DTC 13 is flashing on t he air bag
indicator.
m Is the di agnosti c troubl e code oper at i on wel l
under st ood?
Yes
No O
normal circumstances a
been servi ced.
GO to 13-2.
descri pti ons and
understand air bag
result in needless
service.
13-2 CHECK FOR SHORTED AIR BAG(S)
Yes
No
GO to 13-3.
GO to 13-7.
Deactivate system. Carefully disconnect air bags
during deacti vati on.
9 Turn ignition swi tch from OFF to RUN.
Is DTC 13 sti l l fl ashi ng?
Yes
No
GO to 13-3.
GO to 13-7.
13-3 CHECK DRIVER CIRCUIT FOR SHORTS
Yes -
No
LOCATE and SERVICE
short to ground in Circuit
614 (GY/O), Circuit 615
(GY / W), or air bag sliding
contact wiring.
RECONNECT system.
PROCEED to the
that is flashing.
GO to 13-4.
Disconnect air bag diagnostic monitor.
Examine wiring and connector where air bag sliding
contact mates t o main vehicle harness underneath
steering column.
Check for pinched and / or chafed wi res.
Measure resi stance between air bag diagnostic
monitor harness connector Pin 2 (Circuit 614,
GY/O) and Pin 18 (Circuit 57, BK).
Is Pin 2 shor t ed t o gr ound?
Yes -
No
LOCATE and SERVICE
short to ground in Circuit
614 (GY/O), Circuit 615
(GY / W), or air bag sliding
contact wiring.
RECONNECT system.
PROCEED to the
that is flashing.
GO to 13-4.
13-4 CHECK PASSENGER CIRCUIT FOR SHORTS
Yes
No
LOCATE and SERVICE
607 (LB/ O) or Circuit 616
(PK/BK). RECONNECT
system. CYCLE ignition
swi t ch. PROCEED to the
that is flashi ng.
GO to 13-5.
monitor harness connector Pin 5 (Circuit 607, LB/ O)
and Pin 18 (Circuit 57, BK).
Is Pin 5 shor t ed t o gr ound?
Yes
No
LOCATE and SERVICE
607 (LB/ O) or Circuit 616
(PK/BK). RECONNECT
that is flashi ng.
GO to 13-5.
13-5 CHECK PRIMARY SENSORS
Yes
No
REPLACE air bag
bracket. RECONNECT
REACTIVATE system.
GO to 13-6.
Measure resistance between air bag diagnostic
PK/ W) and Pin 18 (Circuit 57, BK).
PK/ O) and Pin 18 (Circuit 57, BK).
Are resi stance readi ngs i nf i ni t e (open)?
Yes
No
REPLACE air bag
bracket. RECONNECT
REACTIVATE system.
GO to 13-6.
01- 2 0B- 35 Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m 01- 20B- 3S
DTC 13: AIR BAG CI RCUI T SHORTED TO GROUND (Continued)
13-6 DETERMINE IF SENSOR OR WIRE IS SHORTED
Yes
No
LOCATE and SERVICE
resi stance t o ground in
wiring harness on
af f ect ed ci rcui ts.
RECONNECT system.
PROCEED t o the
that is flashi ng.
REPLACE respecti ve
radi ator primary crash
sensor. RECONNECT
syst em. CYCLE ignition
that is flashi ng.
Disconnect radiator primary crash sensor
correspondi ng to the circuit wi th resi stance to
ground found in Step 13-5.
Measure resistance across normally open cont act s
of radiator primary crash sensor at the sensor
connector.
Is resi st ance reading infinite (open)?
Yes
No
LOCATE and SERVICE
resi stance t o ground in
wiring harness on
af f ect ed ci rcui ts.
RECONNECT system.
PROCEED t o the
that is flashi ng.
REPLACE respecti ve
radi ator primary crash
sensor. RECONNECT
that is flashi ng.
13-7 DETERMINE WHICH AIR BAG MODULE IS SHORTED
Yes
No
REPLACE driver side air
bag module.
RECONNECT system.
CYCLE ignition swi tch.
PROCEED to the
that is flashing.
REPLACE passenger
side air bag module.
RECONNECT system.
PROCEED to the
that is flashi ng.
Make sure that shorting bar is properly installed in
passenger side air bag connector.
WARNING: USE A HAND-HELD DIGITAL
OHMMETER WITH L E SS THAN 10MA
SHORT-CIRCUIT CURRENT ON THE LOWEST
RESI STANCE SCALE POSSI BLE (TYPICALLY 200
OHMS SETTING)- FAILURE TO USE A METER OF
THIS TYPE MAY CAUSE PERSONAL INJURY DUE
TO AIR BAG DEPLOYMENT.
Measure resi stance between either of the terminals
in the passenger side air bag connector and the
metal case of the passenger side air bag module.
Yes
No
bag module.
RECONNECT system.
PROCEED to the
that is flashing.
REPLACE passenger
RECONNECT system.
PROCEED to the
that is flashi ng.
Di a g n o s t i c T r o u b l e C o d e 14 P r i ma r y C r a s h
S e n s o r C i r c u i t S h o r t e d t o G r o u n d
The ai r bag di agnosti c monitor measures the vol tage
at Pins 23 and 24 of t he air bag di agnosti c monitor
connector. The vol t age at these pins vari es wi t h
chargi ng syst em vol tage (the expect ed vol tages are
shown in t he fol l owi ng fabl e). If t he air bag di agnosti c
moni tor measures a vol tage of less t han 5 vol ts on
ei ther of t hese pins, the air bag di agnosti c monitor will
st ore in memory and fl ash out on t he air bag indicator a
DTC 14 t o i ndi cate a possi bl e short t o ground on t hese
ci rcui ts.
At the same ti me the air bag di agnosti c monitor begins
flashing out DTC 14, it at t empt s t o di sarm the air bag
syst em t o prevent inadvertent depl oyment of the air
bag(s) by blowing t he 10A battery fuse feedi ng air bag
di agnosti c monitor Pins 13 and 14. It at t empt s t o bl ow
t he fuse by acti vati ng a solid st at e swi t ch that short s
t he bat t ery f eed at Pin 13 t o the sheet metal ground at
the air bag di agnosti c moni tor' s bracket .
The air bag di agnosti c monitor will make up t o three
at t empt s t o bl ow thi s fuse, spaced at one minute
apart .
If the air bag di agnosti c monitor has bl own the fuse
and thus removed battery vol tage at Pin 14, a DTC
12 will be st ored (refer t o DTC 12 and 52 for further
detai l s).
If the air bag di agnosti c monitor at t empt s t o bl ow
t he 10A battery fuse three ti mes and fails each
ti me, a DTC 24 will be st ored (refer t o DTC 24 and
64 for further detai l s).
01-20B-36 Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m 01- 20B- 36
After the 10A fuse is blown or three attempts to
blow it fail, the air bag diagnostic monitor will not
attempt to disarm again until the DTC 13 condition
has been serviced and cleared (refer to Diagnostic
Trouble Code Clearing for further details).
Should the short on Pins 23 or 24 be intermittent or
repaired, the air bag diagnostic monitor will flash out
a DTC 54 (or a higher priority DTC such as DTC 12
if one exists) on the next ignition switch cycle.
CHARGING SYSTEM VOLTAGE
Pin 9.0 9. 5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 14.5 15.0 15.5 16.0
2 3 8. 6 9. 1 9. 6 10. 1 10. 6 11. 1 11. 6 12. 1 12. 6 13. 1 13. 6 14. 1 14. 6 ' 15. 1 15. 6
2 4 8. 6 9. 1 9. 6 10. 1 10. 6 11. 1 11. 6 12. 1 12. 6 13. 1 13. 6 14. 1 14. 6 15. 1 15. 6
WARNI NG: SERVI CI NG A DTC 14 WI LL USUALLY
OCCUR AFTER SERVI CI NG OF A DTC 12 HAS
BEEN COMPLETED. UNDER NO CI RCUMSTANCES
VEHI CLE. DO NOT ATTEMPT TO REPLACE THE
10A BATTERY FUSE UNLESS THE AI R BAG
SYSTE M FI RST HAS BEEN DEACTI VATED (SEE
Low voltage at diagnostic monitor Pins 23 or 24 can
be caused by:
A s h o r t t o g r o u n d o n Ci r c u i t s 617 ( P K/ O) , 6 1 9
( P K / W) , 6 2 4 ( Y/ W) , o r 6 2 5 ( Y/ L G ) causing the
diagnostic voltage to drop.
A n i n t e r n a l s h o r t t o c a s e g r o u n d wi t h i n e i t he r
o f t h e r a d i a t o r p r i ma r y c r a s h s e n s o r s .
01- 2 0B- 37 s t r a i n t s , P a s s i v e S u p p l e me n t a l Air Ba g S y s t e m 01- 2 0B- 37
El e c t r i c a l Sc he ma t i c Di agnost i c Troubl e Code 14
HOT A T A L L T I ME S
10A
R/W
*"" P OWE R*
I DI STRI BUTI ON
: BOX
J FUSE**
. J UNCT I ON
I P A N E L
' (NO
SUBSTI TUTI ONS)
BACK-UP
POWER
SUPPLY
32-34 VOLTS ~
T
* T OWN CA R
** C ROWN VI CTORI A, G R A N D MA RQUI S
t
IF A SHORT TO GROUND ON
PI NS 15, 16, 23, OR 24 OCCURS
THEN BLOW 10A FUSE
AND STORE CODE 14.
IF THE VOLTAGE AT PI N 14
DUE TO BLOWN FUSE
THEN STORE CODE 12.
IF THE ATTEMPT TO BLOW
THE 10A FUSE FAI LS THREE
TI MES DUE TO WRONG FUSE
THEN STORE CODE 24.
AOT BAG DIAGNOSTIC
HIONfTOB' " "
P/LG
r _ ---wmt amar -v^mmsr ~^^mmsttmw wmMuv* : T W O B M B W
1
DTC 14: PRIMARY CRASH SENSOR CIRCUIT SHORTED TO GROUND
Yes
No
normal ci rcumstances a
been servi ced.
GOt o 14-2.
descri pti ons and
understand air bag
result in needless
service.
Cycle the ignition swi tch to OFF and then to RUN
indicator.
Is t he di agnost i c t roubl e code oper at i on wel l
under st ood?
Yes
No
normal ci rcumstances a
been servi ced.
GOt o 14-2.
descri pti ons and
understand air bag
result in needless
service.
14-2 DETERMINE WHICH CIRCUIT IS SHORTED
Yes
No >
REPLACE air bag
bracket. RECONNECT
REACTIVATE system.
GO to 14-3.
Deactivate system.
Set ohmmeter to 200,000 ohm scale or AUTO.
Measure resistance between Pin 18 (Circuit 57, BK)
of the air bag diagnostic monitor harness connector
and all of the following:
Pin 15 (Circuit 619, PK/ W)
Pin 16 (Circuit 617, PK/O)
Pin 23 (Circuit 625, Y/ LG)
Pin 24 (Circuit 624, Y/ W)
Are all t he resi st ance readi ngs i nf i ni t e (open)?
Yes
No >
REPLACE air bag
bracket. RECONNECT
REACTIVATE system.
GO to 14-3.
Yes >
No [
LOCATE and SERVICE
short to ground in wiring
harness on affected
ci rcui ts. RECONNECT
that is flashing.
REPLACE primary crash
sensor. RECONNECT
that is flashi ng.
Disconnect primary crash sensor corresponding to
the shorted circuit found in Step 14-2.
Measure resistance across normally open contacts
of primary crash sensor at the sensor connector.
Is resi st ance readi ng i nf i ni t e (open)?
Yes >
No [
LOCATE and SERVICE
short to ground in wiring
harness on affected
ci rcui ts. RECONNECT
that is flashing.
REPLACE primary crash
sensor. RECONNECT
that is flashi ng.
01- 20B- 39 Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m 0 1 - 2 0 B- 3 9
Di a g n o s t i c T r o u b l e C o d e 2 1 D i a g n o s t i c
Mo n i t o r N o t Mo u n t e d t o Ve h i c l e P r o p e r l y
The ai r ba g di agnost i c moni t or measur es t he
r esi st ance be t we e n t he gr ound connect i on at i t s
br a c ke t and t he r ef er ence gr ound at Pin 18. If t he ai r
ba g di agnost i c moni t or measur es a di f f erence of more
t han 3. 0 ohms be t we e n t he gr ound at Pin 18 and t he
gr ound at i t s br a c ke t , t he ai r bag di agnost i c moni t or
wi ll st or e in memor y and f l ash out a DTC 21 on t he ai r
ba g i ndi cat or. Shoul d t he di f f erence in r esi st ance
be t we e n Pi ns 18 and ai r bag di agnost i c moni t or
br a c ke t gr ound be ser vi ced or ot her wi se r educed t o
l ess t han 3. 0 ohms, t he ai r ba g di agnost i c moni t or wi ll
f l ash out a DTC 61 (or a hi gher pri ori t y DTC if one
e xi st s) on t he next i gni ti on swi t c h c y c l e .
Pos s i bl e Ca u s e s
A high resi stance readi ng at t he air bag di agnosti c
moni tor bracket ground can be caused by:
A poor at t ac hment o f t he a i r b a g d i a g n o s t i c
moni t or due t o l oose mount i ng, d i r t , o r
cor r osi on a t t he ai r b a g d i a g n o s t i c mo n i t o r
br ac k et mount i ng sur f ace( s ) .
A poor reference ground at Pins 10 and 18 of t he air
bag di agnosti c monitor in Circuit 57 (BK).
HOT AT ALL TIMES
10**
10A
"T POW E R*
| DI ST RI B UT I ON
! B OX
I F US E * *
i J UNCT I ON
. I P ANE L
(NO
SUBSTITUTIONS)
BRACKET GROUND IS LOCATED AT THE
DIAGNOSTIC MONITOR BRACKET
ATTACHMENT TO SHEET METAL.
GROUNDING SCREW TORQUE MUST BE
10.2-13.8 N.m(8-10LB-FT)
FUSE
BLOW
* T OWN C AR
** CROW N VI CT ORI A, GRAND MARQUI S
SOLID
STATE
SWITCH
REFERENCE ^
ABOUND < 57
BK
IF THE RESISTANCE DIFFERENCE
BETWEEN BRACKET GROUND AND
THE REFERENCE GROUND AT
PIN 18 IS MORE THAN
3 OHMS THEN STORE CODE 21
C OMP UT E R
AIR B A Q D? A G HOS T H: MONI T OR
R1097 3- A
DTC 2 1: DIAGNOSTIC MONITOR NOT MOUNTED TO VEHICLE PROPERLY
Yes
No
out as a DTC 61.
GO to 21-2.
descri pti ons and
understand air bag
result in needless
servi ce.
indicator.
Read the normal operation descri pti on for DTC 2 1.
Is t he di agnost i c t r oubl e code oper at i on wel l
under st ood?
Yes
No
out as a DTC 61.
GO to 21-2.
descri pti ons and
understand air bag
result in needless
servi ce.
21-2 MEASURE RESISTANCE
Yes
No
REMOVE air bag
bracket assembly from
the vehi cle. Thoroughly
CLEAN the mounting
surfaces. REMOUNT air
with grounding screw
ti ghtened to 10.2-13.8
N-m (8-10 Ib-ft). GO t o
21-3.
GO to 21-4.
Deactivate syst em.
Disconnect negative battery cable.
Set ohmmeter to lowest scale (200 ohms or AUTO).
"Zero" ohmmeter by touching leads together and
record resi stance reading.
Measure resi stance between air bag di agnosti c
monitor bracket and a nearby good sheet metal
ground. Subtract the reading found when zeroing
ohmmeter.
Is t he resi st ance great er t han 3 ohms?
Yes
No
REMOVE air bag
the vehi cle. Thoroughly
CLEAN the mounting
with grounding screw
ti ghtened to 10.2-13.8
N-m (8-10 Ib-ft). GO t o
21-3.
GO to 21-4.
21-3 RECHECK RESISTANCE
Yes
No
REPLACE air bag
bracket. RECONNECT
system. VERIFY syst em.
REACTIVATE system.
CONNECT air bag
PROCEED to the
that is flashing.
monitor bracket and a nearby good sheet metal
ground. Subtract the reading found when zeroing
ohmmeter.
Is t he resi st ance great er t han 3 ohms?
Yes
No
REPLACE air bag
bracket. RECONNECT
REACTIVATE system.
CONNECT air bag
PROCEED to the
that is flashing.
1995 T o wn Ca r , Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s Jul y 1994
01- 2 0B- 41 Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m ^ 01- 2 0B- 41
DTC 2 1: DIAGNOSTIC MONITOR NOT MOUNTED TO VEHICLE PROPERLY (Cont i nued)
21-4 CHECK REFERENCE GROUND
Yes
No
CORRECT poor
grounding on Circuit 57
(BK). If necessary, add a
ground strap from Circuit
57 (BK) t o one of t he
mounting fasteners.
CONNECT air bag
PROCEED to the
descri pt i on, schemati c
that is flashi ng.
REPLACE air bag
bracket. RECONNECT
REACTIVATE syst em.
Visually inspect attachment of ground connecti ons
and spli ces in Circuit 57 (BK) feeding the diagnostic
Are any poor c onne c t i ons f ound?
Yes
No
CORRECT poor
57 (BK) t o one of t he
mounting fasteners.
CONNECT air bag
PROCEED to the
that is flashi ng.
REPLACE air bag
bracket. RECONNECT
REACTIVATE syst em.
Di a g n o s t i c T r o u b l e C o d e 2 2 S a f i n g S e n s o r
Ou t p u t Ci r c u i t S h o r t e d t o B a t t e r y Vo l t a g e
The air bag di agnosti c monitor measures t he vol tage
at Pins 2, 3, 4, and 5 of t he air bag di agnosti c monitor
connector. The vol tage at these pins is set by the air
bag di agnosti c moni tor and vari es wi t h chargi ng
syst em vol tage (the expect ed vol t ages are shown in
the fol l owi ng t abl e). If the air bag di agnosti c monitor
measures a vol tage of more than 5 vol t s on any of
t hese pins, t he air bag di agnosti c monitor will st ore in
memory and fl ash out on t he air bag i ndi cator a DTC
22. Should the unexpect ed high vol tage on Pins 2, 3,
4, or 5 be repai red or intermittent, t he air bag
di agnosti c monitor will fl ash out a DTC 62 (or a higher
pri ori ty DTC if one exi st s) on the next ignition swi t ch
cycl e.
CHARGING SYSTEM VOLTAGE
Pin 9. 0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 14.5 15.0 15.5 16.0
2 1.5 1.6 1.7 1.8 1.9 2. 0 2. 1 2. 2 2. 3 2. 4 2. 5 2. 6 2. 7 2. 8 2. 9
3 1.5 1.6 1.7 1.8 1.9 2. 0 2. 1 2. 2 2. 3 2 . 4 2. 5 2. 6 2. 7 2. 8 2. 9
4 1.5 1.6 1.7 1.8 1.9 2. 0 2. 1 2. 2 2. 3 2. 4 2. 5 2. 6 2. 7 2. 8 2. 9
5 1.5 1.6 1.7 1.8 1.9 2. 0 2. 1 2. 2 2. 3 2. 4 2. 5 2. 6 2. 7 2. 8 2. 9
High vol t age at air bag di agnosti c moni tor Pins 2, 3, 4,
or 5 can be caused by:
A s h o r t t o b a t t e r y o r I gni t i on on Ci r c u i t s 6 0 7
( L B/ O) , 6 1 4 ( G Y/ O) , 6 1 5 ( G Y/ W) , o r 6 1 6
( P K / BK ) causi ng t he di agnosti c vol t age t o ri se.
A s h o r t i n t h e ai r b a g s l i d i n g c o n t a c t bet ween
Circuits 614or 615 and some of the horn or speed
control wi ri ng.
A n i n t e r n a l ai r b a g d i a gn o s t i c mo n i t o r f a i l ur e
such as a short acr oss the normally open cont act s
of the safing sensor.
01- 20B- 42 Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m 01- 2 0B- 42
El ect r i cal Schemat i c, Cr own Vi ct or i a, Grand Mar qui s Di agnost i c Tr oubl e Code 22
HOT IN RUN | HOT AT ALL TIMES
SAFING SENSOR

BACK-UP
POWER I
SUPPLY r
1
-
32-34 VOLTS
T
I
IF THE VOLTAGE ON PINS
2, 3, 4, OR 5 IS
GREATER THAN 5 VOLTS,
THEN STORE CODE 22.
COMPUTER
REFERENCE
GROUND
MU BAG DIAGNOSTIC MONI TOR
AIR BAG SLIDING
CONTACT WINDING
0.2-0.35O
PER LEG
AIR BAG SLIDING
CONTACT WINDING
0.2-0.35Q
PER LEG
01- 2 0B- 43 Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m 01- 20B- 43
DIAGNOSIS AND TESTING (Cont i nyed)
El ect ri cal Sc he ma t i c , Town Ca r Di agnost i c Troubl e Code 22
A . FUSE
8 J JUNCTION
j PANEL
1 >_ 15AJ
DB/LG
HOT AT ALL TIMES
T"!
POWER
DISTRIBUTION
BOX
< C
i t
P O WE R HP >
I SUP P L Y *=ir <
> 3?-34 VOLTS ~ S
S A FI NG SENSOR
IF THE VOLTAGE ON PINS
2,3, 4, OR 5 IS
GREATER THAN 5 VOLTS,
THEN STORE CODE 22.
MB BAG DIAGNOSTIC MONITOR
AIR BAG SLIDING
CONTACT WINDING
0.2-0.35Q
PER LEG
P I P i I f 1
PK/BK
AIR BAG SLIDING
CONTACT WINDING
0.2-0.35Q
PER LEG
1995 Town Gar, Cr own Vi ct or i a, Gr and Mar qui s Jul y 1994
DTC 22: SAFING SENSOR OUTPUT CIRCUIT SHORTED TO BATTERY VOLTAGE
Yes
No
is still present. This fault
out as a DTC 62.
GO to 22-2.
descri pti ons and
understand air bag
result in needless
service.
indicator.
under st ood?
Yes
No
out as a DTC 62.
GO to 22-2.
descri pti ons and
understand air bag
result in needless
service.
22-2 MEASURE DRIVER SIDE VOLTAGE
Yes
No
LOCATE and SERVICE
wire to wire short on
Circuit 614 (GY/O) or
Circuit 615 (GY/W).
RECONNECT air bag
diagnostic monitor.
PROCEED to the
that is flashi ng.
GOt o 22-3.
Deactivate syst em. Inspect driver side air bag
harness wi res for potential shorts to speed control
or horn wiring.
monitor harness connector Pins 2 (Circuit 614,
GY/O) and 18 (Circuit 57, BK).
Is vol t age measured great er t han zero?
Yes
No
LOCATE and SERVICE
Circuit 614 (GY/O) or
Circuit 615 (GY/W).
RECONNECT air bag
diagnostic monitor.
PROCEED to the
that is flashi ng.
GOt o 22-3.
22-3 MEASURE PASSENGER SIDE VOLTAGE
Yes
No
LOCATE and SERVICE
Circuit 607 (LB/ O) or
Circuit 616 (PK/BK).
RECONNECT air bag
diagnostic monitor.
PROCEED to the
that is flashi ng.
REPLACE air bag
bracket. RECONNECT
REACTIVATE system.
LB/ O) and 18 (Circuit 57, BK).
Is vol t age measured great er t han zero?
Yes
No
LOCATE and SERVICE
Circuit 607 (LB/ O) or
Circuit 616 (PK/BK).
RECONNECT air bag
diagnostic monitor.
PROCEED to the
that is flashi ng.
REPLACE air bag
bracket. RECONNECT
REACTIVATE system.
I
I
I
Di agnos t i c Tr oubl e Co d e 2 3 Me m o r y Cl e a r
Ci r cui t I mpr oper l y Gr o u n d e d
Nor mal Oper at i on
The air bag di agnosti c monitor records air bag syst em
di agnosti c troubl e codes in its non-volatile random
access memory (NVRAM). Upon servi ci ng and
correcti on of t he faul ts, t he di agnosti c troubl e codes
may be cl eared f rom the air bag di agnosti c moni tor' s
NVRAM. Under normal ci rcumst ances, t he air bag
di agnosti c moni tor expect s an open ci rcui t on Pin 17 of
the air bag di agnosti c monitor.
During Di agnosti c Trouble Code Clearing (refer t o
Di agnosti c Trouble Code Cl eari ng procedure for
detai l s), t he circuit on Pin 17 will be temporari l y
short ed t o ground.
If DTC cl eari ng procedure is perf ormed i mproperl y,
or if Pin 17 is i mproperl y short ed t o ground in
another fashi on, the air bag di agnosti c moni tor will
st ore in memory and fl ash out on t he air bag
i ndi cator a DTC 23.
Shoul d the short on Pin 17 t o ground be repai red or
intermittent, t he air bag di agnosti c moni tor will fl ash
out a DTC 63 (or a higher pri ori ty DTC if one exi st s)
on t he next ignition swi t ch cycl e.
Improper grounding of t he Memory Cl ear ci rcui t can be
caused by:
A s h o r t t o g r o u n d o n Ci r c u i t 6 3 1 ( T/ R) can
cause i mproper Memory Clear groundi ng.
I mp r o p e r Di a gn o s t i c Tr o u b l e Co d e Cl e a r i n g
p r o c e d u r e p e r f o r ma n c e can cause i mproper
Memory Clear grounding (refer t o Di agnosti c
Trouble Code Clearing procedure for detai l s).
El e c t r i c a l Sc he ma t i c Di a gn o st i c Tr o ubl e Co d e 2 3
AIR BAG T/R
DIAGNOSTIC
"TROUBLE CODE
CLEAR" CONNECTOR
57
BK
i
COMPUTER
IF AN INTERMITTENT
DIAGNOSTIC TROUBLE CODE
IS FLASHING, AND
THE VOLTAGE ON PIN 17
DROPS BELOW 5 VOLTS
AND THEN RETURNS
TO 5 VOLTS WITHIN
25 SECONDS, THEN
CLEAR THE DIAGNOSTIC
TROUBLE CODE
THAT WAS FLASHING.
IF THE VOLTAGE ON PIN 17
IS BELOW 5 VOLTS AT ANY
OTHER TIME FOR
MORE THAN 25 SECONDS,
THEN STORE CODE 23.
AIR BAG DIAGNOSTIC
MONITOR
R9688-B
DTC 23: MEMORY CLEAR CIRCUIT IMPROPERLY GROUNDED
Yes
No \ >
out as a DTC 63.
GOt o 23-2.
descri pti ons and
understand air bag
result in needless
servi ce.
Cycle the ignition swi tch t o OFF and then t o RUN
and confirm that DTC 23 is flashi ng on t he air bag
indicator.
Is t he di agnost i c t roubl e code ope r a t i on wel l
under st ood?
Yes
No \ >
out as a DTC 63.
GOt o 23-2.
descri pti ons and
understand air bag
result in needless
servi ce.
DTC 23: MEMORY CLEAR CIRCUIT IMPROPERLY GROUNDED (Cont i nued)
23-2 ME A S U R E R E S I S T A N C E
Y e s
N o >
R E P L A C E a i r b a g
d i a g n o s t i c m o n i t o r a n d
b r a c k e t . R E C O N N E C T
s y s t e m . V E R I F Y s y s t e m .
R E A C T I V A T E s y s t e m .
L O C A T E a n d S E R V I C E
s h o r t t o g r o u n d o n C i r c u i t
6 3 1 (T/R). R E C O N N E C T
a i r b a g d i a g n o s t i c
m o n i t o r . C Y C L E i g n i t i o n
s w i t c h . P R O C E E D t o t h e
d e s c r i p t i o n , s c h e m a t i c ,
a n d p i n p o i n t t e s t s o f t h e
d i a g n o s t i c t r o u b l e c o d e
t h a t i s f l a s h i n g .
D e a c t i v a t e s y s t e m .
D i s c o n n e c t a i r b a g d i a g n o s t i c m o n i t o r .
S e t o h m m e t e r t o 2 0 0 , 0 0 0 s c a l e o r A U T O .
Me a s u r e r e s i s t a n c e b e t w e e n a i r b a g d i a g n o s t i c
m o n i t o r h a r n e s s c o n n e c t o r P i n s 17 ( C i r c u i t 6 3 1 ,
T / R) a n d 18 ( C i r c u i t 5 7 , BK).
Y e s
N o >
R E P L A C E a i r b a g
d i a g n o s t i c m o n i t o r a n d
b r a c k e t . R E C O N N E C T
s y s t e m . V E R I F Y s y s t e m .
R E A C T I V A T E s y s t e m .
L O C A T E a n d S E R V I C E
s h o r t t o g r o u n d o n C i r c u i t
6 3 1 (T/R). R E C O N N E C T
a i r b a g d i a g n o s t i c
m o n i t o r . C Y C L E i g n i t i o n
s w i t c h . P R O C E E D t o t h e
d e s c r i p t i o n , s c h e m a t i c ,
a n d p i n p o i n t t e s t s o f t h e
d i a g n o s t i c t r o u b l e c o d e
t h a t i s f l a s h i n g .
Di a g n o s t i c T r o u b l e C o d e 2 4 S y s t e m Di s a r m
Fa i l u r e o r I n t e r n a l Di a g n o s t i c Mo n i t o r Fa u l t
The air bag di agnosti c monitor measures t he vol t age
at Pins 2, 3, 4, 5, 23 and 24 of t he air bag di agnosti c
monitor connector.
If t he air bag di agnosti c monitor measures l ow
vol t age on Pins 2, 3, 4, or 5 (or a vol tage of l ess
than 5 vol ts on Pins 23 or 24) , t he air bag di agnosti c
moni tor will fl ash out a DTC 13 (or 14) on t he air bag
i ndi cator t o i ndi cate a possi bl e short t o ground on
t hese ci rcui ts (refer t o DTC 13 and 53 or DTC 14
and 54 for detai l s).
WARNI NG: UNDER NO CI RCUMSTANCES SHOULD
ANOTHER FUSE VALUE BE SUBSTI TUTED FOR
THE 10A BATTERY FUSE. ANY FUSE OTHER
T HA N 10A MAY CAUSE DI SARMI NG FAI LURE AND
MAY RESULT IN DANGER TO THE OCCUPANTS
OF THE VEHI CLE. DO NOT ATTEMPT TO
REPLACE THE 10A BATTERY FUSE UNLESS THE
AI R BA G SYSTEM FI RST HAS BEEN
FOR DETAI LS) .
At t he same ti me the air bag di agnosti c monitor
begi ns flashing out t he DTC 13 or 14, it at t empt s t o
di sarm t he air bag syst em t o prevent i nadvertent
depl oyment of t he air bag(s) by bl owi ng t he 10A
bat t ery fuse feedi ng di agnosti c monitor Pins 13 and
14. It at t empt s t o bl ow t he fuse by acti vati ng a sol i d
st at e swi t ch whi ch short s t he bat t ery f eed at Pin 13
t o sheet metal ground at t he air bag di agnosti c
moni tor' s bracket .
The air bag di agnosti c monitor will make up t o t hree
at t empt s t o bl ow thi s fuse, spaced one minute apart .
If t he air bag di agnosti c moni tor has bl own t he fuse
and t hus removed bat t ery vol tage at Pin 14, a DTC
12 will be st ored (refer t o DTC 12 and 52
descri pti ons f or further detai l s).
If t he air bag di agnosti c monitor at t empt s t o bl ow
t he 10A bat t ery fuse t hree ti mes and fails each
t i me, a DTC 24 will be st ored.
After t he 10A f use is bl own or t hree at t empt s t o
bl ow it fai l , the air bag di agnosti c moni tor will not
at t empt t o di sarm again until the DTC 13or 14
condi ti on has been servi ced and cl eared (refer t o
Di agnosti c Trouble Code Clearing descri pti on for
further detai l s).
If a DTC 24 is st ored in thi s manner, due t o a syst em
di sarm failure, t he next ignition swi t ch cycl e will
produce a DTC 64 (or a higher pri ori ty DTC if one
exi st s).
The air bag di agnosti c monitor al so perf orms several
on-board di agnosti cs every ti me t he ignition swi t ch is
turned t o RUN.
If any of these t est s fai l , t he air bag di agnosti c
moni tor will fl ash DTC 24.
If any of these condi ti ons later resumes normal
operat i on, the next ignition swi t ch cycl e will produce
a DTC 64 (or a higher pri ori ty DTC if one exi st s).
Syst em di sarm failure or internal di agnosti c failure can
be caused by:
WARNI NG: THE BATTERY FUSE MUST BE
REPLACED WI TH A 10A FUSE. UNDER NO
CI RCUMSTANCES SUBSTI TUTE ANOTHER FUSE
VALUE FOR THE 10A BATTERY FUSE. ANY FUSE
OTHER THAN 10A MAY CAUSE DI SARMI NG
FAI LURE AND MAY RESULT IN DANGER TO THE
OCCUPANTS OF THE VEHI CLE. DO NOT
ATTEMPT TO REPLACE THE 10A BATTERY FUSE
UNLESS THE AIR BAG SYSTEM FI RST HAS BEEN
FOR DETAI LS) .
A n i mp r o p e r f u s e v a l u e i n t h e b a t t e r y c i r c u i t
f e e d i n g a i r b a g d i a gn o s t i c mo n i t o r Pi n s 13 a n d
14.
Excessi ve r esi st ance o r o p e n s i n t h e b a t t e r y
f e e d ci r cui t due t o c o r r o s i o n , p o o r c r i mp s , e t c .
The excess resi st ance coul d occur in t he wiring at
the air bag di agnosti c monitor harness Pin 13, t he
10A battery fuse termi nal , or el sewhere in the
bat t ery f eed ci rcui t .
A v e h i c l e c h a r g i n g s y s t em c o n c e r n coul d
prevent the air bag di agnosti c monitor f r om drawi ng
enough current t o perf orm i ts di sarm.
A n i n t e r n a l ai r b a g d i a g n o s t i c mo n i t o r f a i l ur e o n
o n - boar d d i a g n o s t i c o r s y s t e m d i s a r m.
Resi stance t o ground in the normally open pri mary
cr ash sensor f eed Ci rcui ts 617 (PK / O), 619
(PK / W) , 624 (Y / W) and 625 (Y / LG).
El e c t r i c a l Sc he ma t i c Di a gn o st i c Tr o ubl e Co d e 2 4
SEE CODE 13 AND 14
DESCRIPTIONS FOR DETAILS.
HOT AT ALL TIMES
POWER*
I DISTRIBUTION
1
BOX
I FUSE"
l JUNCTION
I PANEL
(NO
SUBSTITU-
TIONS)
937 R/W
AN INCORRECT
FUSE VALUE OR
OPENS
ON THIS CIRCUIT
MAY CAUSE
DISARMING FAILURE
r
BRACKET
GROUND
IF A CODE 13 OR 14
CONDITION OCCURS, THEN
ATTEMPT TO BLOW THE
10A BATTERY FUSE.
IF THREE ATTEMPTS TO
BLOW THE 10A FUSE FAIL
OR AN INTERNAL
DIAGNOSTIC
MONITOR TEST FAILS,
THEN STORE CODE 24.
C OMP UT E R
FUSE
B L O W
]
1 4
MB BAG DIAGNOSTIC MONITOR
* TOWN CAR
** CROWN VICTORIA, GRAND MARQUIS R10975-A
DTC 24: SYSTEM DISARM FAILURE OR INTERNAL DIAGNOSTIC MONITOR FAULT
Yes
No I >
is serviced and flashes
out as a DTC 64.
GO to 24- 2.
descriptions and
understand air bag
result in needless
service.
indicator.
Is the di agnost i c t r oubl e c ode oper at i on wel l
unde r st ood?
Yes
No I >
out as a DTC 64.
GO to 24- 2.
descriptions and
understand air bag
result in needless
service.
24-2 CHECK PRIMARY SENSOR FEEDS
Yes
No
GOt o 24-4.
GO to 24-3.
Deactivate syst em.
Set Multimeter t o highest resi stance scale (200,000
ohms or AUTO).
Measure resi stance from diagnostic monitor
harness connector Pins 15 (Circuit 619 (PK/W))
and Pin 23 (Circuit 625 (Y/LG)) to Pin 18 (Circuit 57,
(BK)).
Measure resi stance from di agnosti c monitor
harness connector Pins 16 (Circuit 617 ( PK/ 0) ) and
Pin 24 (Circuit 624 (Y/ W)) to Pin 18 (Circuit 57,
(BK)).
Are resi st ance readi ngs infinite (open) so t hat
t he meter does not j ump at al l ?
Yes
No
GOt o 24-4.
GO to 24-3.
DTC 24: SYSTEM DISARM FAILURE OR INTERNAL DIAGNOSTIC MONITOR FAULT (Cont i nued)
Yes
No
LOCATE and SERVICE
resi stance to ground in
wiring harness on
af f ect ed circuit.
RECONNECT system.
PROCEED to the
descri pt i on, schematic,
a n d pinpoint t est s of the
that is flashing.
REPLACE front air bag
sensor and bracket.
PROCEED to the
that is flashing.
D i s c o n n e c t f r o n t a i r b a g s e n s o r a n d b r a c k e t
corresponding t o the circuit with resi stance to
ground found i n step 24-2.
Measure resi stance across normally open cont act s
of front air bag sensor and bracket at the sensor
connector.
Is resi st ance readi ng i nf i ni t e?
Yes
No
LOCATE and SERVICE
resi stance to ground in
wiring harness on
af f ect ed circuit.
RECONNECT system.
PROCEED to the
a n d pinpoint t est s of the
that is flashing.
REPLACE front air bag
sensor and bracket.
PROCEED to the
that is flashing.
24-4 CHECK FOR INCORRECT WIRING
Yes
No
CORRECT improper
wiring. RECONNECT air
bag diagnostic monitor.
PROCEED to the
descri pti ons, schemati c,
that is flashing.
REPLACE air bag
bracket. RECONNECT
REACTIVATE system.
Examine air bag diagnostic monitor harness
connector Pin 22. Pin 22 should not be connect ed.
Is a wi re c onne c t e d at Pin 22?
Yes
No
CORRECT improper
wiring. RECONNECT air
PROCEED to the
descri pti ons, schemati c,
that is flashing.
REPLACE air bag
bracket. RECONNECT
REACTIVATE system.
Di a g n o s t i c T r o u b l e C o d e 3 2 Dr i v e r S i d e A i r
B a g Ci r c u i t Hi g h Re s i s t a n c e o r O p e n
Whi l e t he ignition swi t ch is in the RUN posi ti on, t he air
bag di agnosti c monitor runs peri odi c checks on the
resi st ance of t he dri ver and passenger air bag ci rcui ts.
Normal resi stance f r om Pin 2 (Dri ver Air Bag Feed)
t o Pin 3 (Dri ver Air Bag Return) is bet ween 1.4 ohms
and 2. 0 ohms. Thi s resi stance total resul ts f rom t he
sum of t he component s in t he ci rcui t: t he air bag
modul e (approxi matel y 1 ohm) and t he air bag
sliding cont act ( 0. 20 ohm t o 0. 35 ohm per wi ndi ng,
2 wi ndi ngs total ) plus a small amount of resi stance
due t o t he wi re itself, cri mps, et c.
If the resi stance acr oss t hese t wo pins exceeds 3. 5
ohms, t he air bag di agnosti c monitor will i nterpret
thi s as high resi st ance and t he air bag di agnosti c
monitor will st ore in memory and fl ash out on t he air
bag i ndi cator a DTC 32.
If t he high resi stance is later servi ced or ot herwi se
falls into t he normal range, t he next ignition swi t ch
cycl e will produce a DTC 72 (or a higher pri ori ty
DTC if one exi st s).
NOTE: The air bag connector, air bag di agnosti c
monitor harness connector, and t he air bag sliding
cont act connector have metal spri ng clips that act as
shorti ng bars. These shorti ng bars are built into t he
pl asti c hardshel l connect ors. The shorti ng bars are
desi gned t o short Ci rcui ts 6 1 4 ( GY/ O) and 615
( GY/ W) t oget her when t he connect ors are not mat ed.
DO NOT at t empt t o remove the air bag shorting bar
and measure t he resi stance of t he air bag.
The air bag sliding cont act shorti ng bar may be
removed t o measure t he air bag sliding cont act
resi stance. Li kewi se, t he shorti ng bar (s) in the air bag
di agnosti c monitor harness connector may be
removed by removi ng the bl ack spacer (locking
wedge) f rom t he connector. Use ext reme caution
when reinstalling t he shorti ng bars t o ensure they are
installed correct l y.
Excessi ve resi stance acr oss Pins 2 and 3 can be
caused by:
A p o o r c o n n e c t i o n or c or r os i on whe r e t he ai r
b a g sl i di ng c o n t a c t c onnec t s i nt o t he ma i n
wi r i n g h a r n e s s . The air bag sliding cont act
connector at the base of t he steeri ng column may
have excessi ve resi stance bet ween t he mal e and
femal e termi nal s in the connector. Al so, corrosi on
may occur on t he terminal cri mps on bot h t he air
bag sliding cont act termi nal s and the main wi ri ng
harness termi nal s.
A n o p e n c i r c u i t o r hi gh r e s i s t a n c e i n t h e a i r b a g
s l i d i n g c o n t a c t wi n d i n g s i n s i d e t h e air bag
sliding cont act .
El e c t r i c a l Sc he ma t i c Di a gn o st i c Tr oubl e Co d e 32
A n o p e n c i r c u i t o r h i gh r e s i s t a n c e i n t h e wi r i n g
h a r n e s s i n e i t h e r Ci r c u i t 6 1 4 ( G Y/ O) o r Ci r c u i t
6 1 5 ( G Y/ W) .
A n o p e n c i r c u i t o r h i gh r e s i s t a n c e i n t h e d r i v e r
s i d e a i r b a g mo d u l e . DO NOT at t empt a di rect
resi stance measurement of the ai r bag. Fol l ow t he
di agnosti c procedure t o det ermi ne if t he air bag
module resi st ance is higher t han normal .
IF THE RESISTANCE
ACROSS PINS 2 AND
3 EXCEEDS 3.5 OHMS,
THEN STORE CODE 32.
NOTE: THERE ARE THREE
SHORTING BARS IN THE
DRIVER AIR BAG SYSTEM
WIRING. ONE SHORTING
BAR IS LOCATED INSIDE
THE AIR BAG SLIDING
CONTACT CONNECTOR
THAT MATES TO
THE MAIN VEHICLE
HARNESS. ANOTHER
SHORTING BAR IS
LOCATED ON THE
DRIVER AIR BAG
CONNECTOR THAT MATES
WITH THE AIR BAG SLIDING
CONTACT. THE
THIRD IS LOCATED
IN THE GREY AIR BAG
DIAGNOSTIC MONITOR
HARNESS CONNECTOR.
SHORTING BARS SHORT
TWO CIRCUITS TOGETHER
WHEN THE CONNECTORS
ARE NOT MATED.
; COMPUTER
. Am, Bmmmmmmc MONITOR
GY/O
AIR BAG SLIDING
CONTACT WINDING
0.2-0.35Q
PER LEG
r-"
1
AIR BAG DIAGNOSTIC
MONITOR GREY
HARNESS CONNECTOR
SHORTING BAR
AIR BAG
SLIDING
CONTACT
SHORTING
BAR
AIR BAG
SHORTING
BAR
I DRIVER
f AIR BAG
I 1.0Q
GY/W
L_ _ J
AIR BAG SLIDING
CONTACT WINDING
0.2-0.35Q
PER LEG
R9690-A
DTC 32: DRIVER SIDE AIR BAG CIRCUIT HIGH RESISTANCE OR OPEN
Yes
No
out as a DTC 72.
GOt o 32-2.
descri pti ons and
understand air bag
result in needless
service.
indicator.
Is t he di agnost i c t r oubl e c ode operat i on wel l
unde r st ood?
Yes
No
out as a DTC 72.
GOt o 32-2.
descri pti ons and
understand air bag
result in needless
service.
DTC 32: DRIVER SIDE AIR BAG CIRCUIT HIGH RESISTANCE OR OPEN (Cont i nued)
Yes
No
MAKE SURE that locking
wedge has been removed
from gray harness
connector. MAKE SURE
to use 2 ohm air bag
simulator and not a
j umper wire. TRY turning
the steeri ng wheel while
making the measurement.
If these conditions have
been met, GO to 32-3.
GOt o 32-4.
D i s c o n n e c t a i r b a g d i a g n o s t i c m o n i t o r .
S e t o h m m e t e r t o l o w e s t s c a l e (200 o h m s o r AUTO).
r e c o r d r e s i s t a n c e r e a d i n g .
R e m o v e p l a s t i c l o c k i n g w e d g e f r o m g r a y h a r n e s s
c o n n e c t o r .
Me a s u r e r e s i s t a n c e b e t w e e n a i r b a g d i a g n o s t i c
GY/ 0) and 3 (Circuit 615, GY/ W). Subtract t h e
reading found when zeroing ohmmeter.
Is resul t l ess t han 3.0 ohms?
Yes
No
from gray harness
simulator and not a
j umper wire. TRY turning
the steeri ng wheel while
making the measurement.
If these conditions have
been met, GO to 32-3.
GOt o 32-4.
32-3 CHECK FOR DTC 32
Yes
No
REPLACE air bag
bracket . RECONNECT
syst em. REACTIVATE
syst em.
GOt o 32-5.
Reconnect air bag diagnostic monitor.
Turn ignition swi tch from OFF to RUN.
Is DTC 32 st i l l f l ashi ng?
Yes
No
REPLACE air bag
bracket . RECONNECT
syst em. REACTIVATE
syst em.
GOt o 32-5.
32-4 ISOLATE RESISTANCE
Yes
No
REPLACE air bag sliding
cont act . RECONNECT
that is flashing.
LOCATE and SERVICE
open circuit or high
resi stance in Circuit 614
(GY/O) or 615 (GY/W).
RECONNECT system.
PROCEED to the
that is flashing.
Disconnect air bag sliding contact at base of
steering column.
Install air bag simulator on main wiring harness at
base of steering column.
GY/ 0) and 3 (Circuit 615, GY/ W). Subtract the
Is resul t equal t o 2 ohm 0.2 ohm?
Yes
No
cont act . RECONNECT
that is flashing.
LOCATE and SERVICE
(GY/O) or 615 (GY/W).
RECONNECT system.
PROCEED to the
that is flashing.
32-5 CHECK FOR DAMAGED AIR BAG MODULE
Yes
No
DEACTIVATE system.
bag module. CYCLE
ignition swi t ch.
PROCEED to the
that is flashing.
PROCEED to the
that is flashing.
Reactivate syst em.
Cycle ignition swi t ch t o OFF then RUN.
is di agnost i c t r oubl e code 32 f l ashi ng?
Yes
No
DEACTIVATE system.
bag module. CYCLE
ignition swi t ch.
PROCEED to the
that is flashing.
PROCEED to the
that is flashing.
01- 2 0B- 51 e s t r a i n t s , P a s s i v e Suppl ement al Ai r Bag S y s t e m 0 1 - 2 0 B- 5 1
Di agnos t i c Tr oubl e Co d e 3 3 Pa s s e n g e r Si de
Ai r Ba g Ci r c ui t Hi gh Re s i s t a n c e o r Op e n
NOTE: The ai r bag connector a nd t he ai r ba g
di agnosti c monitor harness connect or have metal
spri ng cl i ps t ha t act a s shor t i ng ba r s. These short i ng
bars are built into t he pl asti c hardshel l connect ors.
The shorti ng bars are desi gned t o short Ci rcui ts 607
( LB/ O) and 616 ( PK/ BK) t oget her when t he
connect ors are not mat ed. DO NOT at t empt t o remove
the air bag shorti ng bar and measure t he resi stance of
the air bag.
The shorti ng bar(s) in the air bag di agnosti c monitor
harness connect or may be removed by removi ng the
bl ack spacer (l ocki ng wedge) f r om t he connector. Use
ext reme cauti on when reinstalling t he spacers t o
ensure they are installed correct l y.
Whi l e t he ignition swi t ch is in t he RUN posi ti on, t he air
resi stance of t he driver and passenger air bag ci rcui ts.
Normal resi stance f rom Pin 5 (Passenger Air Bag
Feed) t o Pin 4 (Passenger Ai r Bag Return) is
bet ween 0. 9 ohm and 1.2 ohms. Thi s resi stance
consi sts of t he passenger air bag modul e
resi stance (approxi matel y 1.0 ohm) plus a smal l
amount of resi stance due t o t he wi re itself, cri mps,
et c.
If the resi st ance acr oss Pin 5 and 4 exceeds 3
ohms, t he air bag di agnosti c monitor will st or e in
memory and fl ash out on the air bag indicator a DTC
33.
If the high resi st ance is l ater servi ced or ot herwi se
falls into t he normal range, t he next ignition swi t ch
Excessi ve resi st ance acr oss Pins 2 and 3 can be
caused by:
A n o p e n c i r c u i t o r h i gh r e s i s t a n c e i n t h e wi r i n g
h a r n e s s i n e i t h e r Ci r c u i t 6 0 7 ( L B/ O) o r Ci r c u i t
6 1 6 ( PK/ BK)
B
A n o p e n c i r c u i t o r h i gh r e s i s t a n c e i n t h e
p a s s e n ge r s i d e a i r b a g mo d u l e . DO NOT
a t t e mp t a d i r e c t r e s i s t a n c e me a s u r e me n t o f
t h e a i r b a g . Fo l l o w t h e d i a g n o s t i c p r o c e d u r e t o
d e t e r mi n e i f t h e a i r b a g r e s i s t a n c e i s h i gh e r
t h a n n o r ma l .
IF THE RESISTANCE
ACROSS PINS 5 AND
4 EXCEEDS 3 OHMS,
THEN STORE CODE 33.
NOTE: THERE ARE TWO
PASSENGER AIR BAG
SYSTEM WIRING.
ONE IS LOCATED INSIDE
THE CONNECTOR ON THE
BACK OF THE PASSENGER
SIDE AIR BAG.
ANOTHER SHORTING BAR
IS LOCATED IN THE
GREY AIR BAG
DIAGNOSTIC MONITOR
HARNESS CONNECTOR.
SHORTING BARS SHORT
WHEN THE CONNECTORS
ARE NOT MATED.
A I R B A G D I A 0 N O S F I C MONI TOR
607
LB/O
AIR BAG DIAGNOSTIC
MONITOR GREY
HARNESS CONNECTOR
SHORTING BAR
616
C- I22Q
1 PASSENGER
I AIR BAG
I 1.0Q
R9691-A
DTC 33: PASSENGER SIDE AIR BAG CIRCUIT HIGH RESISTANCE OR OPEN
Yes
No
out as a DTC 73.
GO to 33-2.
descri pti ons and
understand air bag
result in needless
servi ce.
Cycle the ignition swi tch t o OFF and then to RUN
indicator.
under st ood?
Yes
No
out as a DTC 73.
GO to 33-2.
descri pti ons and
understand air bag
result in needless
servi ce.
Yes
No
from gray harness
simulator and not a
j umper wi re. If these
conditions have been
met, GOt o 33-3.
LOCATE and SERVICE
(LB/ O) or 616 (PK/BK).
RECONNECT system.
PROCEED to the
that is flashing.
Deactivate system.
Set ohmmeter to lowest scale (200 ohms or AUTO).
"Zero" ohmmeter by touchi ng leads t oget her and
record resi stance readi ng.
Remove plastic locking wedge from gray harness
connector.
L B/ 0) and 4 (Circuit 616, PK/ BK). Subtract the
Is resul t l ess t han 3.0 ohms?
Yes
No
from gray harness
simulator and not a
j umper wi re. If these
conditions have been
met, GOt o 33-3.
LOCATE and SERVICE
(LB/ O) or 616 (PK/BK).
RECONNECT system.
PROCEED to the
that is flashing.
Yes
No
REPLACE air bag
bracket. RECONNECT
REACTIVATE syst em.
GO to 33-4.
Reconnect air bag di agnosti c monitor.
Turn ignition swi tch from OFF to RUN.
Is Di agnost i c Troubl e Code 33 st i l l f l ashi ng?
Yes
No
REPLACE air bag
bracket. RECONNECT
REACTIVATE syst em.
GO to 33-4.
33-4 CHECK FOR DAMAGED AIR BAG MODULE
Yes
No
DEACTIVATE syst em.
REPLACE passenger
PROCEED to the
that is flashing.
DEACTIVATE system.
PROCEED to the
that is flashing.
Reacti vate system.
Cycle ignition swi tch to OFF then RUN.
Is DTC 33 f l ashi ng?
Yes
No
DEACTIVATE syst em.
REPLACE passenger
PROCEED to the
that is flashing.
DEACTIVATE system.
PROCEED to the
that is flashing.
01- 20B- 53 Rest r ai nt s, P a s s i v e Suppl ement al Ai r Bag S y s t e m 0 1 - 2 0 B- 5 3
Di a g n o s t i c T r o u b l e Co d e 3 4 Dr i v e r S i d e Ai r
B a g Ci r c u i t L o w Re s i s t a n c e o r Sh o r t e d
Whi l e the ignition swi t ch is in the RUN posi ti on, t he air
bag di agnosti c moni tor runs peri odi c checks on the
resi stance of t he dri ver and passenger air bag ci rcui ts.
Normal resi stance f rom Pin 2 (Dri ver Air Bag Feed) t o
Pin 3 (Dri ver Air Bag Return) is bet ween 1.4 ohms and
2. 0 ohms.
Thi s resi stance t ot al resul ts f rom t he sum of t he
component s in the ci rcui t: t he air bag module
(approxi mat el y 1 ohm) and the air bag di agnosti c
moni tor ( 0. 20 ohm t o 0. 35 ohm per wi ndi ng, 2
wi ndi ngs total ) plus a small amount of resi stance
due t o t he wi re itself, cri mps, et c.
If t he resi stance acr oss t hese t wo pins is l ess than 1
ohm, t he air bag di agnosti c monitor will interpret thi s
as a low resi stance and t he air bag di agnosti c
monitor will st ore in memory and fl ash out on the air
bag indicator a DTC 34.
If t he l ow resi stance is later servi ced or ot herwi se
ri ses into the normal range, the next ignition swi t ch
NOTE: The air bag connector, air bag di agnosti c
moni tor harness connector, and t he air bag sliding
cont act connect or have metal spri ng cl i ps t hat act as
shorti ng bars. These shorti ng bars are built into the
pl asti c hardshel l connect ors. The shorti ng bars are
desi gned t o short Ci rcui ts 614 ( GY/ O) and 615
( GY/ W) t oget her when t he connect ors are not mat ed.
DO NOT at t empt t o remove the air bag shorti ng bar
and measure t he resi stance of t he air bag module.
The air bag sliding cont act shorti ng bar may be
removed t o measure t he air bag sliding cont act
resi stance. Li kewi se, t he shorti ng bar(s) in the air bag
di agnosti c monitor harness connector may be
removed by removi ng t he bl ack spacer (l ocki ng
wedge) f r om t he connector. Use ext reme caution
when reinstalling the shorti ng bars t o ensure they are
installed correct l y.
Low resi stance across Pins 2 and 3 can be caused by:
A p o o r l y ma t e d a i r b a g c o n n e c t o r , ai r b a g
d i a g n o s t i c mo n i t o r h a r n e s s c o n n e c t o r , o r a i r
b a g s l i d i n g c o n t a c t c o n n e c t o r may not push t he
short i ng bars back into their fully ret ract ed posi ti on.
A d a ma g e d o r w o r n s h o r t i n g ba r may short
Ci rcui ts 614 ( GY/ O) and 615 ( GY/ W) .
A s h o r t i n t h e a i r b a g s l i d i n g c o n t a c t wi n d i n g s
o r h a r n e s s wi r e s bet ween Ci rcui ts 614 ( GY/ O)
and 615 ( GY/ W) .
A s h o r t c i r c u i t o r l o w r e s i s t a n c e i n t h e d r i v e r
s i d e a i r b a g mo d u l e . DO NOT at t empt a di rect
resi st ance measurement of t he air bag module.
Fol l ow t he di agnosti c procedure t o determi ne if t he
air bag module resi stance is l ower than normal .
2
IF THE RESISTANCE
ACROSS PINS 2 AND 3
IS LESS THAN 1.05 OHMS
THEN STORE CODE 34.
NOTE: THERE ARE THREE
DRIVER AIR BAG SYSTEM
WIRING. ONE SHORTING
BAR IS LOCATED INSIDE
THE AIR BAG SLIDING
CONTACT CONNECTOR
THAT MATES TO THE MAIN
VEHICLE HARNESS.
IS LOCATED ON THE
DRIVER AIR BAG
CONNECTOR THAT MATES
WITH THE AIR BAG
SLIDING CONTACT. THE
THIRD IS LOCATED
IN THE GREY AIR BAG
DIAGNOSTIC MONITOR
HARNESS CONNECTOR. 3
SHORTING BARS SHORT
WHEN THE CONNECTORS
ARE NOT MATED.
COMPUTER
DTC 34: DRIVER SIDE AIR BAG CIRCUIT LOW RESISTANCE OR SHORTED
Yes
No
out as a DTC 74.
GO to 34-2.
descri pti ons and
understand air bag
result in needless
service.
Cycle the ignition swi t ch to OFF and then to RUN
indicator.
under st ood?
Yes
No
out as a DTC 74.
GO to 34-2.
descri pti ons and
understand air bag
result in needless
service.
Yes
No
GO to 34-3.
GO to 34-4.
Deactivate system. Leave driver side air bag
harness connector empty (DO NOT install air bag
simulator).
Remove plasti c locki ng wedge from gray harness
connector.
GY/ 0) a n d 3 (Ci rcui t 615, GY/ W).
Is t he resi st ance r eadi ng i nf i ni t e (open)?
NOTE: Try turning steering wheel while making the
measurement.
Yes
No
GO to 34-3.
GO to 34-4.
AIR BAG SLIDING
CONTACT WINDING
0.2-0.35Q
PER LEG
GY/O
AIR BAG DIAGNOSTIC
MONITOR GREY
HARNESS CONNECTOR
SHORTING BAR
AIR BAG
SLIDING
CONTACT
SHORTING
BAR
AIR BAG
SHORTING
BAR
>
L J
AIR BAG SLIDING
CONTACT WINDING
0.2-0.35Q
PER LEG
1 DRIVER
! AIR BAG
1 1.0Q
OQRQO. A
01- 2 0B- 55 Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m 01- 2 0B- 5 5
DTC 34: DRIVER SIDE AIR BAG CIRCUIT LOW RESISTANCE OR SHORTED (Cont i nued)
34-3 CHECK FOR DAMAGED AIR BAG DIAGNOSTIC
MONITOR
Install air bag simulator onto air bag sliding contact
connector at steering wheel.
Yes
No
REPLACE air bag
bracket . RECONNECT
syst em. VERIFY syst em.
REACTIVATE system.
NOTE: Examine air bag
sliding contact to main
harness connector for an
example of a normal
shorting bar.
EXAMINE shorting bars
on driver side air bag
connector and di agnosti c
monitor harness
connector locking wedge
for proper operation.
bag module if shorting
bars are normal. CYCLE
ignition swi tch.
PROCEED to the
that is flashing.
34-4 CHECK FOR HARNESS SHORT
Disconnect air bag sliding contact at base of
steering column where it mates wi th vehicle
harness.
GY/ O) and 3 (Circuit 615, GY/W).
Is t he resi st ance readi ng i nf i ni t e (open)?
Yes
No
EXAMINE shorting bar in
air bag sliding contact
main harness connector
for proper function.
contact if shorting bar is
normal. RECONNECT
that is flashing.
LOCATE and SERVICE
short across Circuit 614
(GY/O) and 615 (GY/W).
RECONNECT system.
INSPECT air bag
diagnostic monitor
harness connector and
air bag sliding contact
harness connector for
shorted terminals.
PROCEED to the
descri pti on, schematic,
and pinpoint t est s of t he
that is flashi ng.
Di a g n o s t i c Tr oubl e Co d e 3 5 P a s s e n g e r Si de
Ai r B a g Ci r c ui t L o w Res i s t anc e or Sh o r t e d
Whi l e the ignition swi tch is in t he RUN posi ti on, t he air
resi stance of t he driver and passenger air bag ci rcui ts.
Normal resi stance f rom Pin 5 (Passenger Air Bag
Feed) t o Pin 4 (Passenger Ai r Bag Return) is
bet ween 0. 9 ohm and 1.2 ohms.
Thi s resi stance consi sts of t he passenger air bag
module resi stance (approxi matel y 1.0 ohm) plus a
small amount of resi stance due t o the wi re itself,
cri mps, et c.
If the resi stance across Pins 5 and 4 is l ess than 0.7
ohm, the air bag di agnosti c monitor will i nterpret thi s
as a l ow resi stance and t he air bag di agnosti c
monitor will store in memory and fl ash out on t he air
bag i ndi cator a DTC 35.
If the low resi stance is later servi ced or ot herwi se
ri ses into t he normal range, t he next ignition swi t ch
NOTE: The air bag connector and t he air bag
di agnosti c moni tor harness connector have metal
spri ng cl i ps t hat act as shorti ng bars. These shorti ng
bars are built into t he pl asti c hardshel l connect ors.
The shorti ng bars are desi gned t o short Ci rcui ts 607
( LB/ O) and 616 (PK / BK) t oget her when t he
connect ors are not mat ed. DO NOT at t empt t o remove
t he air bag shorti ng bar and measure t he resi stance of
t he air bag modul e.
The shorti ng bar(s) in the air bag di agnosti c monitor
harness connect or may be removed by removing the
bl ack spacer (l ocki ng wedge) f rom the connector. Use
ext reme cauti on when reinstalling the spacers t o
ensure t hey are installed correct l y.
Low resi stance acr oss Pins 5 and 4 can be caused by:
A p o o r l y ma t e d a i r b a g c o n n e c t o r o r a i r b a g
d i a g n o s t i c mo n i t o r h a r n e s s c o n n e c t o r may not
push t he shorti ng bars back into their fully ret ract ed
posi ti on.
A d a ma g e d o r w o r n s h o r t i n g ba r may short
Circuit 607 ( LB / O) and 6 1 6 (PK / BK) .
A s h o r t i n t h e h a r n e s s wi r e s bet ween Circuits
607 (LB / O) and 616 (PK / BK) .
A s h o r t c i r c u i t o r l o w r e s i s t a n c e i n t h e
p a s s e n ge r s i d e a i r b a g mo d u l e . DO NOT at t empt
a di rect resi stance measurement of t he air bag
module. Fol l ow the di agnosti c procedure t o
determi ne if the air bag module resi stance is l ower
than normal .
IF THE RESISTANCE
ACROSS PINS 5 AND 4
IS LESS THAN 0.7 OHMS,
THEN STORE CODE 35.
NOTE: THERE ARE TWO
PASSENGER AIR BAG
SYSTEM WIRING.
ONE IS LOCATED INSIDE
THE CONNECTOR ON THE
BACK OF THE PASSENGER
SIDE AIR BAG.
IS LOCATED IN THE
GREY AIR BAG
DIAGNOSTIC MONITOR
HARNESS CONNECTOR.
SHORTING BARS SHORT
WHEN THE CONNECTORS
ARE NOT MATED.
C OMP UT E R
km BAG DIAGNOSTIC MONITOR
607
LB/O
AIR BAG DIAGNOSTIC
MONITOR GREY
HARNESS CONNECTOR
SHORTING BAR
PK/BK
| PASSENGER
J AIR BAG
I 1.0Q
R9693-A
DTC 35: PASSENGER SIDE AIR BAG CIRCUIT LOW RESISTANCE OR SHORTED
Yes
No
out as a DTC 75.
GOt o 35-2.
descri pti ons and
understand air bag
result in needless
servi ce.
and confirm that DTC 35 is flashi ng on the air bag
indicator.
Read the normal operation descri pt i on for DTC 35.
Is t he di agnost i c t r oubl e c o d e oper at i on wel l
under st ood?
Yes
No
out as a DTC 75.
GOt o 35-2.
descri pti ons and
understand air bag
result in needless
servi ce.
Yes
No
GO to 35-3.
LOCATE and SERVICE
(LB/ O) and 616 (PK/ BK).
RECONNECT syst em.
INSPECT air bag
diagnostic monitor
shorted terminals.
PROCEED to the
that is flashing.
Deacti vate syst em. Leave passenger side air bag
simulator).
Remove plasti c locking wedge from gray harness
connector.
Measure resi stance between di agnosti c monitor
harness connector Pins 5 (Circuit 607, LB/ O) and 4
(Circuit 616, PK/BK).
Yes
No
GO to 35-3.
LOCATE and SERVICE
(LB/ O) and 616 (PK/ BK).
RECONNECT syst em.
INSPECT air bag
diagnostic monitor
shorted terminals.
PROCEED to the
that is flashing.
Yes
No
REPLACE air bag
bracket. RECONNECT
REACTIVATE syst em.
example of a normal
shorting bar.
on passenger side air
bag connector and air
harness connector
locking wedge for proper
operati on. REPLACE
passenger side air bag
module if shorting bars
are normal. CYCLE
ignition swi t ch.
PROCEED t o the
that is flashing.
Install air bag simulator onto passenger side air bag
harness connector.
Yes
No
REPLACE air bag
bracket. RECONNECT
REACTIVATE syst em.
example of a normal
shorting bar.
on passenger side air
bag connector and air
harness connector
locking wedge for proper
operati on. REPLACE
passenger side air bag
module if shorting bars
are normal. CYCLE
ignition swi t ch.
PROCEED t o the
that is flashing.
01- 2OB- S8 Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m 01- 2OB- S8
Di agnos t i c Tr oubl e Co d e 4 1 RH Radi at or
Pr i mar y Cr as h Sens or F e e d / Re t u r n Ci r cui t
Op e n
The vol tage at Pin 16 and Circuit 617 ( PK/ O) is set by
the air bag di agnosti c monitor t o be slightly l ess than
bat t ery vol tage. Circuit 617 is connect ed t o Circuit
624 ( Y/ W) inside RH radi ator pri mary crash sensor.
Therefore, the vol tage at Circuit 624 and air bag
di agnosti c monitor Pin 24 shoul d be the same as t he
vol tage at air bag di agnosti c monitor Pin 16.
The air bag di agnosti c monitor periodically pulls the
vol tage at Pin 16 l ow t o verify the connecti on t o Pin 24.
If the vol tage at Pin 24 does not pull low as a result of
this t est , the air bag di agnosti c monitor will st ore in
memory and fl ash out on t he air bag indicator a DTC
4 1 . If t he connecti on bet ween Pins 16 and 24 is later
servi ced, the next ignition swi t ch cycl e will produce a
DTC 81 (or a higher pri ori ty DTC if one exi st s).
Failure t o get l ow vol tage at Pin 24 during the t est can
be caused by:
A n o p e n c i r c u i t i n t h e wi r i n g h a r n e s s in ei ther
Circuit 617 ( PK/ O) or Circuit 624 ( Y/ W) .
A n o p e n c i r c u i t i n s i d e RH r a d i a t o r p r i ma r y
c r a s h s e n s o r acr oss Circuit 617 ( PK/ O) or Circuit
624 ( Y/ W) .
A s h o r t t o b a t t e r y o r i gn i t i o n v o l t a g e i n a n y o f
t h e Ci r c u i t s 6 1 7 ( P K/ O) , 6 1 9 ( P K / W) , 6 2 4
( Y/ W) , 6 2 5 ( Y/ L G ) .
M POWER*
I DISTRIBUTION
" BOX
1 FUSE**
| * 10A I JUNCTION
I PANEL
(NO
SUBSTITUTIONS)
COMPUTER
PERIODICALLY PULL
VOLTAGE AT PIN
16 LOW. IF VOLTAGE
AT PIN 24 DOES
NOT PULL LOW,
THEN STORE
CODE 41.
18.
REFERENCE
GROUND
21
* TOWN CAR
PK/O
THE VOLTAGE ON THESE
TWO CIRCUITS SHOULD
i ^ BE THE SAME IN A
\ ^ NORMAL SYSTEM.
RH
RADIATOR
PRIMARY
CRASH
SENSOR
P/LG
R10976-A
01- 2 0B- 59 Re s t r a i n t s , P a s s i v e S u p p l e me n t a l A i r Ba g S y s t e m 01- 2 0B- 5 9
DTC 4 1 : RH RADIATOR PRIMARY CRASH SENSOR FEED/RETURN CIRCUIT OPEN
Yes
No
out as a DTC 81.
GO to 41-2.
descri pti ons and
understand air bag
result in needless
service.
and confirm that DTC 41 is flashi ng on the air bag
indicator.
Examine the di agnosti c trouble code schemat i c.
under st ood?
Yes
No
out as a DTC 81.
GO to 41-2.
descri pti ons and
understand air bag
result in needless
service.
Yes
No
GO to 41-3.
GO to 41-4.
Deactivate syst em.
Set ohmmeter t o 200 ohm scale or AUTO.
PK / O) and 24 (Circuit 624, Y/ W) . Subtract the
Is t he resul t l ess t han 2 ohms?
Yes
No
GO to 41-3.
GO to 41-4.
41-3 CHECK FOR SHORTS TO BATTERY
Yes
No
LOCATE and SERVICE
short to high voltage on
appropriate ci rcui t.
PROCEED to the
that is flashing.
REPLACE air bag
bracket. RECONNECT
REACTIVATE system.
With air bag diagnostic monitor di sconnected, cycle
ignition swi tch t o RUN.
Measure t he voltage between the following air bag
diagnostic monitor harness pins and ground:
Pin 15(619, PK/W)
Pin 16(617, PK/O)
Pin 23 (625, Y/ LG)
Pin 24(624, Y/ W)
Is t he vol t age great er t han zero on any of t hese
wi res?
Yes
No
LOCATE and SERVICE
short to high voltage on
appropriate ci rcui t.
PROCEED to the
that is flashing.
REPLACE air bag
bracket. RECONNECT
REACTIVATE system.
DTC 41: RH RADIATOR PRIMARY CRASH SENSOR FEED/RETURN CIRCUIT OPEN (Cont i nued)
41-4 MEASURE RESISTANCE IN SENSOR CONNECTOR
Yes
No
LOCATE and SERVICE
open circuit in the wiring
harness between air bag
RH radiator primary crash
front air bag sensor and
bracket in either Circuit
617 ( P K/ 0) o r Circuit 624
(Y/ W). INSPECT all
interconnections
including cri mps. CYCLE
ignition swi t ch.
PROCEED to the
that is flashing.
REPLACE RH radiator
primary crash front air
bag sensor and bracket.
PROCEED to the
that is flashi ng.
Locate RH radiator primary crash front air bag
sensor and bracket.
Disconnect RH radiator primary crash sensor from
harness.
Measure resi stance between PK/ O and Y/ W wi res
in sensor connector.
Is t he resi st ance readi ng less t han 2 ohms?
Yes
No
LOCATE and SERVICE
617 ( P K/ 0) o r Circuit 624
(Y/ W). INSPECT all
interconnections
ignition swi t ch.
PROCEED to the
that is flashing.
REPLACE RH radiator
PROCEED to the
that is flashi ng.
Di a g n o s t i c T r o u b l e C o d e 4 2 L H Ra d i a t o r
P r i ma r y Cr a s h S e n s o r F e e d / R e t u r n C i r c u i t
O p e n
The vol tage at Pin 15 and Circuit 6 1 9 (PK / W) is set by
t he air bag di agnosti c monitor t o be slightly l ess than
ba t t e r y vol t age. Circuit 619 is connect ed t o Circuit
625 ( Y/ LG) inside LH radi ator pri mary cr ash sensor.
Theref ore, the vol tage at Circuit 625 and air bag
di agnosti c monitor Pin 23 shoul d be t he same as t he
vol tage at air bag di agnosti c monitor Pin 15.
The air bag di agnosti c monitor peri odi cal l y pulls t he
vol tage at Pin 15 l ow t o veri fy the connecti on t o Pin 23.
If the vol tage at Pin 23 does not pull low as a result of
thi s t est , air bag di agnosti c monitor will st ore in
memory and fl ash out on the air bag i ndi cator a DTC
42. If t he connecti on bet ween Pins 15 and 23 is later
servi ced, the next ignition swi t ch cycl e will produce a
DTC 82 (or a higher pri ori ty DTC if one exi st s).
Failure t o get l ow vol tage at Pin 23 during t he test can
be caused by:
A n o p e n c i r c u i t i n t h e wi r i n g h a r n e s s in either
Circuit 6 1 9 (PK / W) or Circuit 625 (Y / LG) .
A n o p e n c i r c u i t i n s i d e l e f t r a d i a t o r p r i ma r y
c r a s h s e n s o r acr oss Circuit 619 ( PK/ W) or Circuit
625 ( Y/ LG) .
A s h o r t t o b a t t e r y o r i gn i t i o n v o l t a ge i n a n y o f
t h e Ci r c u i t s 6 1 7 ( P K/ O) , 6 1 9 ( PK/ W) , 6 2 4
( Y/ W) , 6 2 5 ( Y/ L G ) .
01- 2 0B- 61 Re s t r a i n t s , P a s s i v e S u p p l e me n t a l A i r Ba g S y s t e m 01- 2 0B- 61
HOT AT ALL TIMES
J w
* POWER*
I DISTRIBUTION
* * i
B 0 X
FUSE**
t#A- 1 JUNCTION
mm* 1 PANEL
(NO
SUBSTITUTIONS)
937
R/W
-C <r
23,
COMPUTER
15.
PERIODICALLY PULL
VOLTAGE AT PIN
15 LOW. IF VOLTAGE
AT PIN 23 DOES
NOT PULL LOW,
THEN STORE
CODE 42.
REFERENCE
GROUND
* TOWN CAR
619
THE VOLTAGE ON THESE
TWO CIRCUITS SHOULD
BE THE SAME IN A
NORMAL SYSTEM.
DTC 42: LH RADIATOR PRIMARY CRASH SENSOR FEED/RETURN CIRCUIT OPEN
Cycle t he ignition swi tch t o OFF and then to RUN
indicator.
Read the normal operation descri pti on f or DTC 42.
Is t he di agnost i c t roubl e c o d e oper at i on wel l
unde r st ood?
Yes
No
out as a DTC 82.
GO to 42-2.
descri pti ons and
understand air bag
result in needless
service.
DTC 42: LH RADIATOR PRIMARY CRASH SENSOR FEED/RETURN CIRCUIT OPEN (Cont i nued)
4 2 - 2 MEASURE RESISTANCE
Yes
No [ >
REPLACE air bag
bracket. RECONNECT
REACTIVATE syst em.
GO to 42-3.
D i s c o n n e c t air b a g d i a g n o s t i c m o n i t o r .
Set ohmmeter to 200 ohm scale or AUTO.
PK/ W) and 23 (Circuit 625, Y/ LG). Subtract the
Is t he resul t less t han 2 ohms?
Yes
No [ >
REPLACE air bag
bracket. RECONNECT
REACTIVATE syst em.
GO to 42-3.
Yes
No
LOCATE and SERVICE
LH radiator primary crash
619 (PK/W) or Circuit
625 (Y/LG). INSPECT all
interconnections
ignition swi t ch.
PROCEED to the
that is flashing.
REPLACE LH radiator
PROCEED to the
that is flashing.
Locate LH radiator primary crash front air bag
sensor and bracket .
Disconnect LH radiator primary crash front air bag
sensor and bracket from wire harness.
Measure resi stance between PK/W and Y/ LG wi res
in sensor connector.
Is t he resi st ance readi ng less t han 2 ohms?
Yes
No
LOCATE and SERVICE
LH radiator primary crash
619 (PK/W) or Circuit
625 (Y/LG). INSPECT all
interconnections
ignition swi t ch.
PROCEED to the
that is flashing.
REPLACE LH radiator
PROCEED to the
that is flashing.
Di a g n o s t i c T r o u b l e C o d e 4 4 RH Ra d i a t o r
P r i ma r y C r a s h S e n s o r No t Mo u n t e d t o Ve h i c l e
P r o p e r l y
NOTE: Circuit 618( P/ LG) is ri veted t o t he si de of t he
RH radi ator pri mary cr ash sensor case and t he case
of t he sensor is grounded t o the vehicle at its mounting
point.
The air bag di agnosti c monitor measures the
resi stance bet ween Pin 21 and the reference ground
at Pin 18. If t he air bag di agnosti c monitor measures a
di fference of more than 3.0 ohms bet ween t he ground
at Pin 18 and t he ground at Pin 2 1 , t he air bag
di agnosti c monitor will st ore in memory and fl ash out
on t he air bag i ndi cator a DTC 44. Shoul d t he
di fference in resi stance bet ween Pin 18 and Pin 21 be
servi ced or ot herwi se reduced t o l ess than 3. 0 ohms,
t he air bag di agnosti c monitor will fl ash out a DTC 84
(or a higher pri ori ty DTC if one exi st s) on t he next
A high resi stance reading on Pin 21 t o ground can be
caused by:
A p o o r a t t a c h me n t o f RH r a d i a t o r p r i ma r y c r a s h
f r o n t a i r b a g s e n s o r a n d b r a c ke t d u e t o l o o s e
mo u n t i n g , d i r t , o r c o r r o s i o n at its mounting
l ocati on.
A n o p e n o r d a ma g e d wi r e in Circuit 618 ( P/ LG) .
A n o p e n wi r e o r l o o s e r i v e t i n s i d e RH r a d i a t o r
p r i ma r y c r a s h f r o n t ai r b a g s e n s o r a n d b r a c ke t .
A poor reference ground at Pins 10 and 18 of t he air
bag di agnosti c monitor in Circuit 57 (BK).
A I R SAG DIAGNOSTIC
COMPUTER
IF THE DIFFERENCE
BETWEEN PIN 21 AND
THE REFERENCE GROUND
IS MORE THAN 3 OHMS,
THEN STORE CODE 44.
DTC 44: RH RADIATOR PRIMARY CRASH SENSOR NOT MOUNTED TO VEHICLE PROPERLY
Yes
No
out as a DTC 84.
GO to 44-2.
descriptions and
understand air bag
result in needless
service.
indicator.
unde r st ood?
Yes
No
out as a DTC 84.
GO to 44-2.
descriptions and
understand air bag
result in needless
service.
Yes
No
GO to 44-3.
GO to 44-5.
Deactivate system.
"Zer o" ohmmeter by touching leads together and
Measure resistance between air bag diagnostic
monitor harness connector Pins 18 (Circuit 57, BK)
and 21 (Circuit 618, P/LG). Subtract the reading
found when zeroing ohmmeter.
Is t he resul t great er t han 3 ohms?
Yes
No
GO to 44-3.
GO to 44-5.
NiTOR
.ENCE
3.
P/LG
RH
RADIATOR
PRIMARY
CRASH
SENSOR
SHEET METAL
ATTACHMENT
POINT GROUNDS
CASE OF CRASH
SENSOR
DTC 44: RH RADIATOR PRIMARY CRASH SENSOR NOT MOUNTED TO VEHICLE PROPERLY (Cont i nued)
44-3 CHECK CRASH SENSOR GROUND
Yes
No
LOCATE and SERVICE
resistance in Circuit 618
(P/LG) between air bag
bracket. INSPECT all
interconnections
including crimps.
RECONNECT system.
PROCEED to the
that is flashing.
REMOVE screws
retaining RH radiator
CLEAN mounting surface
of RH radiator primary
crash front air bag sensor
and bracket and chassi s.
INSTALL RH radiator
TIGHTEN screws to
proper speci fi cati on. GO
to 44-4.
Locate RH radi ator primary crash front air bag
Disconnect RH radiator primary crash sensor from
harness.
Measure resi stance between P/LG wire in sensor
connector and a good, nearby chassi s ground.
Subtract the reading found when zeroing ohmmeter.
Yes
No
LOCATE and SERVICE
(P/LG) between air bag
bracket. INSPECT all
interconnections
including crimps.
RECONNECT system.
PROCEED to the
that is flashing.
REMOVE screws
of RH radiator primary
INSTALL RH radiator
TIGHTEN screws to
proper speci fi cati on. GO
to 44-4.
Yes
No
RECONNECT system.
PROCEED to the
that is flashing.
REPLACE RH radiator
RECONNECT system.
PROCEED to the
that is flashing.
Measure resi stance between P/LG wire in RH
radiator primary crash sensor connector and a
good, nearby chassi s ground. Subtract t he reading
Yes
No
RECONNECT system.
PROCEED to the
that is flashing.
REPLACE RH radiator
RECONNECT system.
PROCEED to the
that is flashing.
DTC 44: RH RADIATOR PRIMARY CRASH SENSOR NOT MOUNTED TO VEHICLE PROPERLY (Cont i nued)
Yes
No
CORRECT poor
ground st rap from Circuit
57 (BK) t o one of the
mounting f ast eners.
CONNECT air bag
PROCEED to the
descri pt i on, schemat i c
t hat is flashi ng.
REPLACE air bag
bracket. RECONNECT
REACTIVATE syst em.
Visually inspect attachment of ground connections
and splices in Circuit 57 (BK) feeding the diagnostic
Are any poor connect i ons f ound?
Yes
No
CORRECT poor
ground st rap from Circuit
57 (BK) t o one of the
mounting f ast eners.
CONNECT air bag
PROCEED to the
descri pt i on, schemat i c
t hat is flashi ng.
REPLACE air bag
bracket. RECONNECT
REACTIVATE syst em.
Di a g n o s t i c T r o u b l e C o d e 4 5 L H Ra d i a t o r
P r i ma r y C r a s h S e n s o r N o t Mo u n t e d t o Ve h i c l e
P r o p e r l y
The air bag di agnosti c moni tor measures the
resi stance bet ween Pin 20 and t he reference ground
at Pin 18. If the air bag di agnosti c monitor measures a
di fference of more than 3.0 ohms bet ween t he ground
at Pin 18 and the ground at Pin 20, t he ai r bag
di agnosti c monitor wi l l st ore in memory and f l ash out
on the air bag i ndi cator a DTC 45. Should the
di fference in resi stance bet ween Pin 18 and Pin 20 be
servi ced or ot herwi se reduced t o l ess than 3. 0 ohms,
the air bag di agnosti c moni tor will fl ash out a DTC 85
(or a higher pri ori ty DTC if one exi st s) on t he next
NOTE: Circuit 620 (P / LB) is ri veted t o t he si de of t he
LH radi ator pri mary crash sensor case and t he case
of t he sensor is grounded t o t he vehicle at its mounting
point.
A high resi stance readi ng on Pin 20 t o ground can be
caused by:
A p o o r a t t a c h me n t o f L H r a d i a t o r p r i ma r y c r a s h
f r o n t a i r b a g s e n s o r a n d b r a c ke t d u e t o l o o s e
mo u n t i n g , d i r t , o r c o r r o s i o n at its mounting
l ocati on.
A n o p e n o r d a ma g e d w i r e in Circuit 620 ( P/ LB) .
A n o p e n wi r e o r l o o s e r i v e t i n s i d e L H r a d i a t o r
p r i ma r y c r a s h f r o n t ai r b a g s e n s o r a n d b r a c ke t .
A poor reference ground at Pins 10 and 18 of the ai r
bag di agnosti c monitor in Circuit 57 ( BK) .
01- 2 0B- 66
El ect r i cal Schemat i c Di agnost i c Tr o ubl e Code 45
23
REFERENCE _
GROUND >
COMPUTER
IF THE DIFFERENCE
BETWEEN PIN 20 AND
THE REFERENCE GROUND
IS MORE THAN 3 OHMS,
THEN STORE CODE 45.
Y/LG
PK/W
LH
RADIATOR
PRIMARY
CRASH
SENSOR
SHEET METAL
ATTACHMENT
POINT GROUNDS
CASE OF CRASH
SENSOR
P/LB
R9802-B
DTC 45: LH RADIATOR CRASH SENSOR NOT MOUNTED TO VEHICLE PROPERLY
Yes
No
out as a DTC 85.
GO to 45-2.
descri pti ons and
understand air bag
result in needless
service.
indicator.
Examine t he di agnosti c trouble code schemati c.
unde r st ood?
Yes
No
out as a DTC 85.
GO to 45-2.
descri pti ons and
understand air bag
result in needless
service.
Yes
No
GOt o 45-3.
GO to 45-5.
Deacti vate syst em.
Disconnect air bag di agnosti c moni t or.
monitor harness connector Pins 18 (Circuit 57, BK)
and 20 (Circuit 620, P / LB). Subtract the reading
Is t he resul t gr eat er t han 3 ohms?
Yes
No
GOt o 45-3.
GO to 45-5.
DTC 45: LH RADIATOR CRASH SENSOR NOT MOUNTED TO VEHICLE PROPERLY (Cont i nued)
45-3 CHECK CRASH SENSOR GROUND
Yes
No >
LOCATE and SERVICE
open ci rcui t or high
resi st ance in Circuit 620
( P/ LB) between air bag
di agnost i c monitor and
LH radi at or primary crash
bracket . INSPECT all
i nterconnecti ons
including cri mps.
RECONNECT syst em.
PROCEED to the
di agnost i c trouble code
t hat is flashi ng.
REMOVE screws
retaining LH radiator
of LH radi ator primary
INSTALL LH radiator
TIGHTEN screws to
proper speci f i cat i on. GO
t o 45-4.
Locate LH radiator primary crash front air bag
Disconnect LH radi ator primary crash front air bag
sensor and bracket from harness.
Measure resistance between P / LB wire in sensor
connector and a good, nearby chassi s ground.
Subtract the reading found when zeroing ohmmeter.
Yes
No >
LOCATE and SERVICE
open ci rcui t or high
resi st ance in Circuit 620
( P/ LB) between air bag
di agnost i c monitor and
LH radi at or primary crash
bracket . INSPECT all
i nterconnecti ons
including cri mps.
RECONNECT syst em.
PROCEED to the
di agnost i c trouble code
t hat is flashi ng.
REMOVE screws
retaining LH radiator
of LH radi ator primary
INSTALL LH radiator
TIGHTEN screws to
t o 45-4.
Yes
No
RECONNECT system.
PROCEED to the
that is flashing.
REPLACE LH radiator
RECONNECT system.
PROCEED to the
and pinpoint t est s, of the
that is flashing.
Measure resi stance between P/LB wire in LH
radiator primary crash sensor connector and a
good, nearby chassi s ground. Subtract t he reading
Yes
No
RECONNECT system.
PROCEED to the
that is flashing.
REPLACE LH radiator
RECONNECT system.
PROCEED to the
and pinpoint t est s, of the
that is flashing.
DTC 45: LH RADIATOR CRASH SENSOR NOT MOUNTED TO VEHICLE PROPERLY (Cont i nued)
Yes
No
CORRECT poor
57 (BK) to one of the
diagnostic monitor
mounting fasteners.
CONNECT air bag
diagnostic monitor.
PROCEED to the
descri pti on, schemati c
that is flashing.
REPLACE air bag
bracket. RECONNECT
REACTIVATE system.
and spli ces in Circuit 57 (BK) feedi ng the di agnosti c
Are any poor connect i ons f ound?
Yes
No
CORRECT poor
diagnostic monitor
mounting fasteners.
CONNECT air bag
diagnostic monitor.
PROCEED to the
descri pti on, schemati c
that is flashing.
REPLACE air bag
bracket. RECONNECT
REACTIVATE system.
Di a g n o s t i c T r o u b l e C o d e 5 2 I n t e r mi t t e n t o r
Re p a i r e d L o s t B a t t e r y Fe e d
Refer t o Di agnosti c Trouble Code 12. Return t o DTC
52 for Pinpoint Tests.
P o s s i b l e Ca u s e s
52 for Pinpoint Test s.
DTC 52: INTERMITTENT OR REPAIRED LOST BATTERY FEED
Yes
No
NOTE: This is an
intermittent or repaired
is no longer present.
GO to 52- 2.
descriptions and
understand air bag
result in needless
service.
indicator.
Read the pinpoint t est for DTC 12 as a reference.
Look for areas where intermittent faults may occur.
under st ood?
Yes
No
NOTE: This is an
GO to 52- 2.
descriptions and
understand air bag
result in needless
service.
52-2 CHECK IF REPAIRED
Yes
No
GO to 52-3.
GO to 52-4.
Deactivate system.
Has a DTC 12 j ust been ser vi ced and repai red?
Yes
No
GO to 52-3.
GO to 52-4.
E l e c t r i c a l Sc h e ma t i c Di a gn o s t i c Tr o u b l e Co d e
5 2
01- 2 0B- 69 Re st r a i n t s, P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m ^ 01- 2 0B- 69
DTC 2: INTERMITTENT OR REPAIRED LOST BATTERY FEED (Cont i nued)
52-3 CLEAR AND CHECK FOR OTHER DTCS
Yes
No
PROCEED to the
DTC that is flashi ng.
REACTIVATE syst em.
Check battery fuse feeding air bag di agnosti c
monitor Pins 13 and 14. Fuse should be 10A, NO
SUBSTITUTIONS.
Clear DTC 52 (refer t o Diagnostic Trouble Code
Clearing procedure).
Does anot her di agnost i c t r oubl e c ode st ar t
f l ashi ng?
Yes
No
PROCEED to the
DTC that is flashi ng.
REACTIVATE syst em.
52-4 CHECK CHARGING SYSTEM
Yes
No
SERVICE chargi ng
system concern. GO t o
52-3.
GOt o 52-5.
NOTE: An intermittent charging system or battery
concern could lead t o a DTC 52.
Examine charging system.
Has a char gi ng sy st em c onc e r n been r e por t e d or
not i c e d on t he vehi cl e?
Yes
No
SERVICE chargi ng
system concern. GO t o
52-3.
GOt o 52-5.
52-5 CHECK BATTERY FEED
Yes
No
SERVICE concerns in
battery f eed. GO t o 52-3.
RE-EXAMINE di agnosti c
trouble code descri pti on
and schemati c. LOOK for
causes of intermittent low
battery voltage at Pin 13.
ATTEMPT t o recreate
hard faults by driving
vehicle, flexing wire
harnesses, et c., cycli ng
ignition swi tch frequently.
SERVICE any intermittent
concerns if found. GO to
52-3.
Visually inspect all cri mps, terminals, fuses, wi res,
et c. in the battery circuit feeding Pins 13 and 14 of
the air bag di agnosti c monitor. Look for poor
connecti ons, pinched wi res, et c.
NOTE: An intermittent open in the battery circuit
could lead to a DTC 52.
Are any concer ns not i ced?
Yes
No
SERVICE concerns in
battery f eed. GO t o 52-3.
causes of intermittent low
battery voltage at Pin 13.
ATTEMPT t o recreate
52-3.
Re p a i r e d A i r B a g Ci r c u i t S h o r t e d t o G r o u n d
E l e c t r i c a l S c h e ma t i c Di a g n o s t i c T r o u b l e
C o d e 5 3
DTC 53: INTERMITTENT OR REPAIRED AIR BAG CIRCUIT SHORTED TO GROUND
Yes
No
NOTE: This is an
GO to 53- 2.
descri pti ons and
understand air bag
result in needless
servi ce.
indicator.
Read the normal operation description for DTC 13.
Read the pinpoint t est s for DTC 13 as a reference.
under st ood?
Yes
No
NOTE: This is an
GO to 53- 2.
descri pti ons and
understand air bag
result in needless
servi ce.
Yes
No
GOt o 53-3.
GO to 53-4.
Deactivate system.
Has a DTC 13 j ust been servi ced and repai red?
Yes
No
GOt o 53-3.
GO to 53-4.
Yes
No
PROCEED to the
that is flashi ng.
REACTIVATE system.
Check battery fuse feeding diagnostic monitor Pins
13 and 14. Fuse should be 10A, NO
SUBSTITUTIONS.
Clear DTC 53 (refer to Diagnostic Trouble Code
Does anot her di agnost i c t roubl e code st ar t
f l ashi ng?
Yes
No
PROCEED to the
that is flashi ng.
REACTIVATE system.
53-4 CHECK FOR INTERMITTENT SHORTS
Yes
No
SERVICE wiring concern.
GO to 53-3.
GO to 53-5.
Visually inspect the wiring in the following ci rcui ts:
614( GY/ 0)
607 (LB/ O)
615 (GY/W)
616 (PK/BK)
Look for pinched or chafed wi res.
NOTE: An intermittent short to ground on the above
wires could lead to a DTC 53.
Are any concer ns not i c e d?
Yes
No
GO to 53-3.
GO to 53-5.
53-5 CHECK AIR BAG SLIDING CONTACT
Yes
No
GO to 53-3.
GO to 53-6.
Visually inspect air bag sliding contact wiring at
harness connector.
Visually inspect wiring in steering wheel hub where
air bag sliding cont act mates to driver air bag
connector.
Visually inspect wiring where passenger air bag
mates to harness connector.
NOTE: An intermittent short to ground on the above
wires could lead to a DTC 53.
Yes
No
GO to 53-3.
GO to 53-6.
DTC 53: INTERMITTENT OR REPAIRED AIR BAG CIRCUIT SHORTED TO GROUND (Cont i nued)
53-6 CHECK PRIMARY CRASH SENSORS
Yes
No
REPLACE respecti ve
radiator primary crash
sensor if significant
corrosion is found.
SERVICE wiring
concerns. GO t o 53-3.
causes of intermittent
shorts or resi stance to
ground on the
appropriate ci rcui t s.
ATTEMPT to recreate
vehi cle, flexing wire
ignition swi t ch frequently.
concerns, if found. GO t o
53-3.
Visually inspect primary crash sensors and
associ at ed ci rcui t s:
617 ( PK/ O)
619( PK/ W)
624 (Y/ W)
625 (Y/ LG)
Look for signs of corrosi on of resi stance to ground.
NOTE: Intermittent resi stance to ground in the
above wi res or corrosi on in a primary sensor could
lead t o a DTC 53.
Are any c onc e r ns not i c e d?
Yes
No
REPLACE respecti ve
corrosion is found.
SERVICE wiring
concerns. GO t o 53-3.
ground on the
appropriate ci rcui t s.
ATTEMPT to recreate
ignition swi t ch frequently.
concerns, if found. GO t o
53-3.
Re p a i r e d P r i ma r y C r a s h S e n s o r C i r c u i t S h o r t e d
t o G r o u n d
54 f or Pinpoint Test s.
Refer t o Di agnosti c Troubl e Code 14. Return t o DTC
C o d e 5 4
DTC 54: INTERMITTENT OR REPAIRED PRIMARY CRASH SENSOR CIRCUIT SHORTED TO GROUND
Yes
No
NOTE: This is an
GOt o 54-2.
descri pti ons and
understand air bag
result in needless
servi ce.
indicator.
under st ood?
Yes
No
NOTE: This is an
GOt o 54-2.
descri pti ons and
understand air bag
result in needless
servi ce.
Yes
No
GOt o 54-3.
GO t o 54-4.
Deactivate syst em.
Yes
No
GOt o 54-3.
GO t o 54-4.
DTC 54: INTERMITTENT OR REPAIRED PRIMARY CRASH SENSOR CIRCUIT SHORTED TO GROUND (Cont i nued)
Yes
No
PROCEED to the
that is flashing.
REACTIVATE system.
Check battery fuse feeding di agnosti c monitor Pins
13 and 14. Fuse should be 10A, NO
SUBSTITUTIONS.
Clear DTC 54 (Refer to Diagnostic Trouble Code
f l ashi ng?
Yes
No
PROCEED to the
that is flashing.
REACTIVATE system.
54-4 CHECK PRIMARY CRASH SENSORS
Yes
No [ >
REPLACE respecti ve
corrosi on is found.
SERVICE wiring
concerns. GO to 54-3.
RE-EXAMINE diagnostic
trouble code description
ground on the
appropri ate ci rcui ts.
ATTEMPT to recreate
harnesses, etc., cycling
concerns, if found. GO to
54-3.
Visually inspect primary crash sensors and
associ at ed ci rcui ts:
617 (PK/O)
619 (PK/W)
624 (Y/ W)
625 (Y/LG)
Look for signs of corrosi on of resi stance t o ground.
NOTE: Intermittent resi stance t o ground in the
above wires or corrosi on in a primary sensor could
lead t o a DTC 54.
Yes
No [ >
REPLACE respecti ve
SERVICE wiring
concerns. GO to 54-3.
ground on the
appropri ate ci rcui ts.
ATTEMPT to recreate
54-3.
Re p a i r e d Di a g n o s t i c Mo n i t o r No t Mo u n t e d t o
Refer t o Di agnosti c Trouble Code 2 1 . Return t o DTC
C o d e 6 1
DTC 61: INTERMITTENT OR REPAIRED DIAGNOSTIC MONITOR NOT MOUNTED TO VEHICLE PROPERLY
Yes
No
NOTE: This is an
i ntermi ttent or repaired
GO to 61-2.
descri pt i ons and
understand air bag
syst em functions will
result in needless
servi ce.
Cycle the ignition swi tch t o OFF and then to RUN
and confirm that DTC 61 is flashing on t he air bag
indicator.
under st ood?
Yes
No
NOTE: This is an
i ntermi ttent or repaired
GO to 61-2.
descri pt i ons and
understand air bag
syst em functions will
result in needless
servi ce.
Yes
No
GO to 61-3.
GO to 61-4.
Deactivate syst em.
Has a DTC 21 j ust been servi ced and r epai r ed?
Yes
No
GO to 61-3.
GO to 61-4.
Yes
No
PROCEED to the
that is flashing.
REACTIVATE system.
Does anot her di agnost i c t r oubl e code st ar t
f l ashi ng?
Yes
No
PROCEED to the
that is flashing.
REACTIVATE system.
61-4 CHECK FOR CORROSION
Yes
No
REPLACE air bag
bracket if significant
VERIFY system.
REACTIVATE system.
GO to 61-5.
Visually inspect air bag diagnostic monitor bracket
and mounting surfaces. Look for signs of corrosi on
or poor contact.
NOTE: High resistance in the air bag di agnosti c
monitor mount can lead to a DTC 61.
Is si gni f i cant cor r osi on f ound?
Yes
No
REPLACE air bag
bracket if significant
VERIFY system.
REACTIVATE system.
GO to 61-5.
DTC 61: INTERMITTENT OR REPAIRED DIAGNOSTIC MONITOR NOT MOUNTED TO VEHICLE PROPERLY (Cont i nued)
Yes >
No
CORRECT poor
diagnostic monitor
mounting fasteners.
CONNECT air bag
diagnostic monitor. GO to
61-3.
REMOVE air bag
the vehicle. Thoroughly
CLEAN the mounting
and bracket with
grounding screw
tightened to 10.2-13.8
N-m (8-10 Ib-ft).
causes of high resistance
in the air bag diagnostic
monitor bracket ground.
ATTEMPT to recreate
61-3.
and spli ces in Circuit 57 (BK) feeding the di agnosti c
NOTE: A poor reference ground can lead t o FALSE
ground readings and a diagnostic trouble code 61.
Yes >
No
CORRECT poor
diagnostic monitor
mounting fasteners.
CONNECT air bag
61-3.
REMOVE air bag
the vehicle. Thoroughly
CLEAN the mounting
and bracket with
grounding screw
tightened to 10.2-13.8
N-m (8-10 Ib-ft).
causes of high resistance
in the air bag diagnostic
monitor bracket ground.
ATTEMPT to recreate
61-3.
Re p a i r e d S a f i n g S e n s o r Ou t p u t Ci r c u i t S h o r t e d
t o Ba t t e r y Vo l t a g e
C o d e 6 2
01- 2 0B- 7 5 e s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m
DTC 62: INTERMITTENT OR REPAIRED SAFING SENSOR OUTPUT CIRCUIT SHORTED TO BATTERY VOLTAGE
Yes
No
NOTE: This is an
intermittent or repai red
fault. The fault condi t i on
GOt o 62-2.
descri pti ons and
schemat i cs. Failure t o
understand air bag
result in needless
replacement of syst em
servi ce.
indicator.
underst ood?
Yes
No
NOTE: This is an
fault. The fault condi t i on
GOt o 62-2.
descri pti ons and
schemat i cs. Failure t o
understand air bag
result in needless
replacement of syst em
servi ce.
Yes
No
GO t o 62-3.
GO t o 62-4.
Deactivate system.
Yes
No
GO t o 62-3.
GO t o 62-4.
Yes
No
PROCEED to the
that is flashing.
REACTIVATE system.
Does anot her di agnost i c t r oubl e code st art
f l ashi ng?
Yes
No
PROCEED to the
that is flashing.
REACTIVATE system.
62-4 CHECK FOR STEERING COLUMN SHORTS
Yes
No
SERVICE any wiring
concerns found. GO t o
62-3.
GO t o 62-5.
Visually inspect driver side air bag harness wires for
potential shorts to speed control or horn wiring.
NOTE: An intermittent short to battery voltage on
the air bag harness wires could lead t o a Diagnostic
Trouble Code 62.
Are any concerns not i ced?
Yes
No
SERVICE any wiring
concerns found. GO t o
62-3.
GO t o 62-5.
62-5 CHECK FOR INTERMITTENT WIRE SHORTS
Yes
No
SERVICE any wiring
concerns found. GO to
62-3.
and schematic. LOOK for
shorts to battery voltage
on t he appropriate
ci rcui ts. ATTEMPT to
recreate hard faults by
driving vehicle, flexing
wire harnesses, etc.,
cycli ng ignition swi tch
frequently. SERVICE any
intermittent concerns, if
found. GO to 62-3.
Visually inspect the wires on the following ci rcui ts:
614 (GY/O)
607(LB/ O)
615 (GY/W)
616 (PK/BK)
Look for potential wire-to-wire shorts.
NOTE: An intermittent short to battery voltage on
the above circuits could lead to a DTC 62.
Yes
No
SERVICE any wiring
62-3.
shorts to battery voltage
on t he appropriate
found. GO to 62-3.
0 1 - 2 0 B- 7 5
r^
7
! T'.TT.
1
01- 2 0B- 7 6 Rest r ai nt s, Pas s i v eSuppl ement al Ai r Bag Sy s t em
Di agnos t i c Tr oubl e Co d e S3 I nt er mi t t ent or
Repai r ed Me mo r y Cl ear Ci r cui t I mpr oper l y
Gr o u n d e d
DTC 63: INTERMITTENT OR REPAIRED MEMORY CLEAR CIRCUIT IMPROPERLY GROUNDED
Yes >
No I >
NOTE: This is an
GOt o 63-2.
descri pti ons and
understand air bag
result in needless
service.
indicator.
Examine the diagnostic trouble code schemat i c.
Is t he di agnost i c t r oubl e c ode ope r a t i on wel l
under st ood?
Yes >
No I >
NOTE: This is an
GOt o 63-2.
descri pti ons and
understand air bag
result in needless
service.
Yes
No
GO to 63-3.
GO to 63-4.
Deactivate system.
Yes
No
GO to 63-3.
GO to 63-4.
Yes
No
PROCEED to the
that is flashing.
REACTIVATE system.
f l ashi ng?
Yes
No
PROCEED to the
that is flashing.
REACTIVATE system.
63-4 CHECK FOR MEMORY CLEAR FAULT
Yes
No
READ the Diagnostic
Code Clearing
procedure. GO to 63-3.
GO to 63-5.
NOTE: A short to ground on Circuit 631 (T/R) for more
than 25 seconds will lead to a DTC 23. If the short is
released, a DTC 63 will result on the next ignition swi tch
cycl e.
Has t he Di agnost i c Troubl e Code Cl eari ng
pr ocedur e been pe r f or me d i mpr oper l y ?
Yes
No
READ the Diagnostic
Code Clearing
procedure. GO to 63-3.
GO to 63-5.
C o d e 6 3
01- 2 0B- 7 7 Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m O1- 2 0B- 7 7
DTC 63: INTERMITTENT OR REPAIRED MEMORY CLEAR CIRCUIT IMPROPERLY GROUNDED (Cont i nued)
63-5 CHECK FOR INTERMITTENT WIRE SHORTS
Yes
No
SERVICE any wiring
63-3.
and schemati c. LOOK f or
causes of shorts t o
ground on the Circuit 631
(T/R). ATTEMPT t o
wire harnesses, et c.,
intermittent concerns if
found. GO t o 63-3 .
Visually inspect wiring on Circuit 631 {11R). Look for
signs of pinched or chaf ed wires leading t o an
intermittent short to ground.
Yes
No
SERVICE any wiring
63-3.
and schemati c. LOOK f or
causes of shorts t o
ground on the Circuit 631
(T/R). ATTEMPT t o
found. GO t o 63-3 .
Re p a i r e d S y s t e m Di s a r m Fa i l u r e o r I n t e r n a l
Di a g n o s t i c Mo n i t o r Fa ul t
C o d e 6 4
DTC 64: INTERMITTENT OR REPAIRED SYSTEM DISARM FAILURE OR INTERNAL DIAGNOSTIC MONITOR FAULT
Yes
No r>
NOTE: This is an
GO t o 64-2.
descri pti ons and
understand air bag
result in needless
servi ce.
Cycle the ignition swi t ch to OFF and then to RUN
indicator.
under st ood?
Yes
No r>
NOTE: This is an
GO t o 64-2.
descri pti ons and
understand air bag
result in needless
servi ce.
Yes
No
GO t o 64-3.
GO t o 64-4.
Deactivate system.
Yes
No
GO t o 64-3.
GO t o 64-4.
Yes
No
PROCEED to the
that is flashing.
REACTIVATE system.
f l ashi ng?
Yes
No
PROCEED to the
that is flashing.
REACTIVATE system.
01- 2 0B- 7 8 Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m
01- 2 0B- 7 8
DTC 64: INTERMITTENT OR REPAIRED SYSTEM DISARM FAILURE OR INTERNAL DIAGNOSTIC MONITOR FAULT
(Cont i nued)
64-4 CONFIRM BATTERY CONNECTION
Yes
No
GO t o 64-5.
LOCATE and SERVICE
open circuit on HOT AT
ALL TIMES circuit.
RECONNECT air bag
GO to 64-3.
Deactivate system.
monitor harness connector Pins 13 ( + ) (HOT AT ALL
TIMES) and 18 (-) (Circuit 67, BK).
Is vol t age measured equal t o char gi ng syst em
vol t age?
Yes
No
GO t o 64-5.
LOCATE and SERVICE
open circuit on HOT AT
ALL TIMES circuit.
RECONNECT air bag
GO to 64-3.
64-5 CHECK FUSE
Yes
No
GOt o 64-6.
REPLACE fuse wi th
correct value (10A). NO
SUBSTITUTIONS.
RECONNECT air bag
GO t o 64-3.
Inspect HOT AT ALL TIMES fuse feeding air bag
diagnostic monitor Pins 13 and 14.
WARNING: CERTAIN FAULT CONDITIONS (SEE
DIAGNOSTIC TROUBLE CODE 13/ 53 OR 14/ 54)
MAY CAUSE THE AIR BAG DIAGNOSTIC MONITOR
TO INTENTIONALLY BLOW THE 10A BATTERY
FUSE TO DISARM THE AIR BAG SYSTEM. DO NOT
SUBSTITUTE ANOTHER FUSE VALUE FOR THE
10A BATTERY FUSE. ANY OTHER FUSE VALUE
MAY CAUSE FUTURE DISARMING FAILURE AND
MAY RESULT IN DANGER TO THE OCCUPANTS
OF THE VEHICLE. ONCE THE AIR BAG
DIAGNOSTIC MONITOR HAS DISARMED THE
SYSTEM, IT WILL NOT ATTEMPT TO DO SO
AGAIN UNTIL THE APPROPRIATE DIAGNOSTIC
TROUBLE CODE ( 13/ 53 OR 14/ 54) HAS BEEN
CLEARED. THUS DO NOT REACTIVATE SYSTEM
UNTIL ALL DIAGNOSTIC TROUBLE CODES HAVE
BEEN REPAIRED AND CLEARED.
Is f use val ue c or r e c t (10A)?
Yes
No
GOt o 64-6.
REPLACE fuse wi th
correct value (10A). NO
SUBSTITUTIONS.
RECONNECT air bag
GO t o 64-3.
64-6 CHECK FOR SHORT TO BATTERY
Yes
No
REPLACE 10Afuse. NO
SUBSTITUTIONS.
REPLACE air bag
RECONNECT system.
VERIFY system.
REACTIVATE system.
LOCATE and SERVICE
short to battery on HOT
AT ALL TIMES circuit
connected to Pin 13 of
the air bag diagnostic
monitor. RECONNECT air
GO to 64- 3.
Remove 10A HOT AT ALL TIMES fuse feeding air
bag diagnostic monitor Pins 13 and 14.
monitor harness connector Pins 13 ( + ) (HOT AT ALL
TIMES) and 18 (-) (Circuit 57, BK).
Is vol t age readi ng zero?
Yes
No
REPLACE 10Afuse. NO
SUBSTITUTIONS.
REPLACE air bag
RECONNECT system.
VERIFY system.
REACTIVATE system.
LOCATE and SERVICE
short to battery on HOT
AT ALL TIMES circuit
connected to Pin 13 of
the air bag diagnostic
monitor. RECONNECT air
GO to 64- 3.
Re p a i r e d Dr i v e r S i d e A i r Ba g Ci r c u i t Hi g h
Re s i s t a n c e o r O p e n
C o d e 7 2
01- 2 0B- 7 9 Re s t r a i n t s , Passi veSuppl e me nt a l Ai r Ba g S y s t e m 01- 2 0B- 7 9
DTC 72; INTERMITTENT OR REPAIRED DRIVER SIDE AIR BAG CIRCUIT HIGH RESISTANCE OR OPEN
Yes
No
NOTE: This is an
GOt o 7 2 - 2 .
descri pti ons and
understand air bag
result in needless
service.
indicator.
. Is t he di agnost i c t roubl e c ode ope r a t i on wel l
under st ood?
Yes
No
NOTE: This is an
GOt o 7 2 - 2 .
descri pti ons and
understand air bag
result in needless
service.
Yes
No
GOt o 72-3.
GOt o 72-4.
Deactivate system.
Has a DTC 32 j ust been servi ced and r epai r ed?
Yes
No
GOt o 72-3.
GOt o 72-4.
Yes
No
PROCEED to the
that is flashi ng.
REACTIVATE system.
f l ashi ng?
Yes
No
PROCEED to the
that is flashi ng.
REACTIVATE system.
72-4 CHECK AIR BAG CONNECTIONS
Yes
No
contact or driver side air
bag module if significant
wiring concerns are
found. GO t o 72-3.
GO to 72-5.
Visually inspect wiring at driver side air bag
connector where it mates to air bag sliding contact.
Look for signs of corrosi on in connectors. Also look
for poor crimps or bad connections.
NOTE: High resi stance in t hese connections may
lead to a DTC 72.
Yes
No
bag module if significant
wiring concerns are
found. GO t o 72-3.
GO to 72-5.
Yes
No
contact if any significant
concerns are found. GO
to 72-3.
GO to 72-6.
Visually inspect connector where air bag sliding
contact mates wiring harness. Look for signs of
corrosi on, poor crimps, etc.
Are any c onc e r ns not i ced?
Yes
No
contact if any significant
to 72-3.
GO to 72-6.
72-6 CHECK WIRES
Yes
No
SERVICE any wiring
72-3.
high resistance or open
circuits in the appropri ate
driving vehi cle, flexing
cycling ignition swi tch
found. GO to 72-3.
Visually inspect the wiring and connections in the
following ci rcui t s:
614 (GY/O)
615 (GY/W)
Look for poor cri mps, corrosi on, et c. that may cause
high resi stance.
Yes
No
SERVICE any wiring
72-3.
circuits in the appropri ate
cycling ignition swi tch
found. GO to 72-3.
01- 20B- 80 Rest r ai nt s, Pas s i v eSuppl ement al Ai r Bag Sy s t em 01- 20B- 80
Di agnos t i c Tr oubl e Co d e 7 3 I nt er mi t t ent or
Repai r ed Pas s enger Si de Ai r Ba g Ci r cui t Hi gh
Res i s t anc e or Op e n
7 3 for Pinpoint Test s.
Pos s i bl e Ca u s e s
7 3 for Pinpoint Test s.
El ec t r i c al Sc h e ma t i c Di agnos t i c Tr oubl e
C o d e 7 3
Refer t o Di agnosti c Trouble Code 33. Ret urn t o DTC
7 3 f or Pinpoint Test s.
DTC 73; INTERMITTENT OR REPAIRED PASSENGER SIDE AIR BAG CIRCUIT HIGH RESISTANCE OR OPEN
Yes
No
NOTE: This is an
GOt o 73-2.
descri pti ons and
understand air bag
result in needless
service.
indicator.
under st ood?
Yes
No
NOTE: This is an
GOt o 73-2.
descri pti ons and
understand air bag
result in needless
service.
Yes
No
GO to 73-3.
GOt o 73-4.
Yes
No
GO to 73-3.
GOt o 73-4.
Yes
No
PROCEED to the
that is flashing.
REACTIVATE system.
f l ashi ng?
Yes
No
PROCEED to the
that is flashing.
REACTIVATE system.
73-4 CHECK AIR BAG CONNECTIONS
Yes
No
REPLACE passenger
side air bag module if
significant wiring
to 73-3.
GO to 73-5.
Visually inspect wiring at passenger side air bag
connector where it mates to harness. Look for signs
of corrosi on in connectors. Also look for poor crimps
or bad connecti ons.
NOTE: High resi stance or opens in these
connections may lead t o a DTC 73.
Yes
No
REPLACE passenger
side air bag module if
significant wiring
to 73-3.
GO to 73-5.
l i i i i i i i i ^ ^ i ^^^^mmmimwmmi^^^^^^^mmmwmmWmV' "^MB****** '^F^JS,^'
DTC 73: INTERMITTENT OR REPAIRED PASSENGER SIDE AIR BAG CIRCUIT HIGH RESISTANCE OR OPEN (Cont i nued)
73-5 CHECK WIRES
Yes
No
SERVICE any wiring
73-3.
trouble code descri pt i on
hi gh resistance or open
ci rcui t s in the appropri at e
ci rcui t s. ATTEMPT t o
recreat e hard faults by
driving vehi cle, flexi ng
wi re harnesses, et c.,
cycli ng ignition swi t ch
found. GO to 73-3.
Visually inspect t he wiring and connections in the
following ci rcui ts:
607 ( LB/ O)
616(PK/ BK)
Look for poor cri mps, corrosi on, etc. that may cause
high resi stance.
Yes
No
SERVICE any wiring
73-3.
hi gh resistance or open
ci rcui t s in the appropri at e
ci rcui t s. ATTEMPT t o
recreat e hard faults by
wi re harnesses, et c.,
found. GO to 73-3.
Re p a i r e d Dr i v e r S i d e Ai r B a g C i r c u i t L o w
Re s i s t a n c e o r S h o r t e d
C o d e 7 4
DTC 74: INTERMITTENT OR REPAIRED DRIVER SIDE AIR BAG CIRCUIT LOW RESISTANCE OR SHORTED
Yes
No
NOTE: This is an
GO to 74-2.
descri pti ons and
understand air bag
result in needless
service.
indicator.
unde r st ood?
Yes
No
NOTE: This is an
GO to 74-2.
descri pti ons and
understand air bag
result in needless
service.
Yes
No i >
GO to 74-3.
GO to 74-4.
Deactivate system.
Yes
No i >
GO to 74-3.
GO to 74-4.
01- 2 0B- 82 Re s t r a i n t s , Passi ve-
' S u p p l e me n t a l Ai r Ba g S y s t e m 01- 2 0B- 82
DTC 74: INTERMITTENT OR REPAIRED DRIVER SI DE AIR BAG CI RCUI T LOW RESI STANCE OR SHORTED (Cont i nued)
Yes
No >
PROCEED to the
that is flashing.
REACTIVATE system.
Does another di agnosti c trouble code start
flashi ng?
Yes
No >
PROCEED to the
that is flashing.
REACTIVATE system.
74-4 CHECK SHORTING BARS
Yes
No
SERVICE any concerns if
found. GO to 74-3.
GOt o 74-5.
Visually inspect shorting bars in driver side air bag,
air bag sliding contact connector at main wiring
harness, and air bag di agnosti c monitor gray
harness connector. Look for signs of poor operati on
of these shorting bars.
NOTE: Intermittent shorting bar malfunction may
lead t o a DTC 74.
Yes
No
found. GO to 74-3.
GOt o 74-5.
Yes
No
contact if the resi stance
reading j umps while
turning the steering
wheel. GO to 74-3.
RECONNECT system. GO
to 74-6.
Deactivate syst em. Leave driver side air bag
simulator).
Remove plasti c locki ng wedge from gray harness
connector.
Turn steering wheel while measuring resi stance
between air bag di agnosti c monitor harness
connector Pins 2 (Circuit 614, GY/ O) and 3 (Circuit
615, GY/W).
Yes
No
contact if the resi stance
reading j umps while
turning the steering
wheel. GO to 74-3.
RECONNECT system. GO
to 74-6.
74-6 CHECK WIRES
Yes
No
SERVICE any wiring
concerns found.
bag module if air bag
sliding contact or driver
air bag wires are
damaged. GO to 74- 3.
shorts between the
appropriate ci rcui ts.
ATTEMPT to recreate
harnesses, etc., cycli ng
74-3.
614 (GY/O)
615 (GY/W)
Look for areas of potenti al intermittent shorts
between these ci rcui t s.
Similarly examine air bag sliding cont act wires
where air bag sliding contact mates t o main
harness.
Similarly examine air bag sliding cont act and driver
air bag wires where air bag sliding cont act mates t o
driver side air bag module.
Yes
No
SERVICE any wiring
concerns found.
bag module if air bag
sliding contact or driver
air bag wires are
damaged. GO to 74- 3.
shorts between the
appropriate ci rcui ts.
ATTEMPT to recreate
harnesses, etc., cycli ng
74-3.
Re p a i r e d P a s s e n g e r S i d e A i r B a g Ci r c u i t L o w
Re s i s t a n c e o r S h o r t e d
P o s s i b l e Ca u s e s
C o d e 7 5
DTC 75: INTERMITTENT OR REPAIRED PASSENGER SIDE AIR BAG CIRCUIT LOW RESISTANCE OR SHORTED
Yes
No '
NOTE: This is an
fault. The fault condi ti on
GOt o 75- 2.
RE-EXAMINE appropri at e
descri pti ons and
understand air bag
system functions wi ll
result in needless
servi ce.
Cycle t he ignition swi t ch t o OFF and then to RUN
and confirm t hat DTC 75 i s flashi ng on the air bag
indicator.
Read the normal operati on descri pt i on for DTC 35.
Read t he pinpoint t est s for DTC 35 as a reference.
unde r st ood?
Yes
No '
NOTE: This is an
fault. The fault condi ti on
GOt o 75- 2.
RE-EXAMINE appropri at e
descri pti ons and
understand air bag
system functions wi ll
result in needless
servi ce.
Yes
No
GOt o 75-3.
GOt o 75-4.
Deactivate syst em.
Yes
No
GOt o 75-3.
GOt o 75-4.
Yes
No
PROCEED to the
that is flashing.
REACTIVATE syst em.
f l ashi ng?
Yes
No
PROCEED to the
that is flashing.
REACTIVATE syst em.
Yes
No
found. GO to 75-3.
GOt o 75-5.
Visually inspect shorting bars in passenger side air
bag module and air bag di agnosti c monitor gray
harness connector. Look for signs of poor operation
of these shorting bars.
NOTE: Intermittent shorting bar malfunction may
lead t o DTC 75.
Yes
No
found. GO to 75-3.
GOt o 75-5.
75-5 CHECK WIRES
Yes
No
SERVICE any wiring
concerns found.
REPLACE passenger
side air bag module if air
bag wires are damaged.
GOt o 75-3.
and schematic. LOOK f or
ci rcui ts in the appropri at e
ci rcui t s. ATTEMPT to
found. GO to 75-3.
607 (LB/ O)
616 (PK/BK)
Look for areas of potential intermittent shorts
between these ci rcui t s.
Similarly examine air bag wires where passenger
side air bag module connects t o harness.
Yes
No
SERVICE any wiring
concerns found.
REPLACE passenger
side air bag module if air
bag wires are damaged.
GOt o 75-3.
and schematic. LOOK f or
ci rcui ts in the appropri at e
ci rcui t s. ATTEMPT to
found. GO to 75-3.
01- 2 0B- 84 Rest r ai nt s, P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m 01- 2 0B- 84
Diagnostic Trouble C o d e 8 1 I nt er mi t t ent o r
Repaired RH Radiator Primary Crash S e n s o r
Feed/Return Circuit Open
Normal Operation
Ref er t o Di agnost i c Troubl e Code 4 1 . Return t o DTC
81 f or Pi npoi nt Test s.
Possible Causes
Ref er t o Di agnost i c Troubl e Code 4 1 . Ret urn t o DTC
C o d e 8 1
Ref er t o Di agnost i c Troubl e Code 4 1 . Ret urn t o DTC
DTC 81: INTERMITTENT OR REPAIRED RH RADIATOR PRIMARY CRASH SENSOR FEED/RETURN CIRCUIT OPEN
Yes
No
NOTE: This is an
GO to 81-2.
descri pti ons and
understand air bag
result in needless
servi ce.
Cycle the ignition switch to OFF and then t o RUN
indicator.
unde r st ood?
Yes
No
NOTE: This is an
GO to 81-2.
descri pti ons and
understand air bag
result in needless
servi ce.
Yes
No
GO to 81-3.
GO to 81-4.
Deacti vate system.
Has a DTC 41 j ust been ser vi ced and r epai r ed?
Yes
No
GO to 81-3.
GO to 81-4.
Yes
No
PROCEED to the
that is flashing.
REACTIVATE system.
f l ashi ng?
Yes
No
PROCEED to the
that is flashing.
REACTIVATE system.
81-4 CHECK WIRES
Yes
No
found. GO to 81-3.
GO to 81-5.
Visually inspect the wi res, cri mps, connectors, etc.
on t hese Circuits:
617 (PK/ O)
624 ( Y/ W)
Look for signs of poor connecti ons.
NOTE: An intermittent open in these ci rcui ts may
lead t o a DTC 81.
Yes
No
found. GO to 81-3.
GO to 81-5.
DTC 81: INTERMITTENT OR REPAIRED RH RADIATOR PRIMARY CRASH SENSOR FE E D/ RE TURN CI RCUI T OPEN
(Cont i nued)
Yes
No
found. GOt o 81-3.
GO to 81-6.
Visually inspect wi res on Circuits:
617(PK/ O)
619(PK/ W)
624 (Y/ W)
625 ( Y/ LG)
Look for signs of wi re-to-wi re or other shorts t o
battery, ignition, or another higher voltage.
NOTE: An intermittent short to battery or ignition on
any of these wires may cause a DTC 81 and DTC 82.
Yes
No
found. GOt o 81-3.
GO to 81-6.
81-6 CHECK RH PRIMARY CRASH SENSOR
Yes
No
REPLACE RH radiator
bag sensor and bracket if
significant corrosi on is
not i ced. GO to 81-3.
high resi stance or open
ci rcui ts in the appropriate
found. GO to 81-3.
Locate and visually inspect RH radiator primary
crash front air bag sensor and bracket. Look for
signs of corrosi on.
Yes
No
REPLACE RH radiator
not i ced. GO to 81-3.
high resi stance or open
ci rcui ts in the appropriate
found. GO to 81-3.
Re p a i r e d L H Ra d i a t o r P r i ma r y C r a s h S e n s o r
F e e d / R e t u r n C i r c u i t O p e n
C o d e 8 2
DTC 82: INTERMITTENT OR REPAIRED LH RADIATOR PRIMARY CRASH SENSOR FEED/ RETURN CIRCUIT OPEN
Yes
No
NOTE: This is an
GO to 82-2.
descri pti ons and
understand air bag
result in needless
servi ce.
indicator.
under st ood?
Yes
No
NOTE: This is an
GO to 82-2.
descri pti ons and
understand air bag
result in needless
servi ce.
Yes
No
GO to 82-3.
GOt o 82-4.
Deactivate syst em.
Yes
No
GO to 82-3.
GOt o 82-4.
Yes
No
PROCEED to the
that is flashing.
REACTIVATE system.
f l ashi ng?
Yes
No
PROCEED to the
that is flashing.
REACTIVATE system.
82-4 CHECK WIRES
Yes
No
found. GO to 82-3.
GO to 82-5.
Visually inspect the wi res, cri mps, connectors, et c.
on these Circuits:
619 (PK/ W)
626( Y/ LG)
Look for signs of poor connections.
NOTE: An intermittent open in t hese ci rcui ts may
lead t o a DTC 82.
Yes
No
found. GO to 82-3.
GO to 82-5.
Yes
No
found. GO to 82-3.
GO to 82-6.
Visually inspect wires on Circuits:
617 (PK/O)
619 (PK/ W)
624 (Y/ W)
625 (Y/ LG)
Look for signs of wire-to-wire or other shorts to
battery, ignition, or another higher voltage.
NOTE: An intermittent short to battery or ignition on
any of these wi res may cause a DTC 81 and a DTC
82.
Yes
No
found. GO to 82-3.
GO to 82-6.
DTC 82: INTERMITTENT OR REPAIRED LH RADIATOR PRIMARY CRASH SENSOR FEED/RETURN CIRCUIT OPEN
(Cont i nued)
82-6 CHECK LH PRIMARY CRASH SENSOR
Yes
No
REPLACE LH radiator
not i ced. GOt o 82-3.
ci rcui ts in the appropri ate
ci rcui ts. ATTEMPT t o
found. GO to 82-3.
Locate and visually inspect LH radiator primary
signs of corrosion.
Are any concerns not i ced?
Yes
No
REPLACE LH radiator
not i ced. GOt o 82-3.
ci rcui ts in the appropri ate
ci rcui ts. ATTEMPT t o
found. GO to 82-3.
Re p a i r e d RH Ra d i a t o r P r i ma r y C r a s h S e n s o r
No t Mo u n t e d t o Ve h i c l e P r o p e r l y
C o d e 8 4
DTC 84: INTERMITTENT OR REPAIRED RH RADIATOR PRIMARY CRASH SENSOR NOT MOUNTED TO VEHICLE PROPERLY
Yes
No
NOTE: This is an
GOt o 84-2.
descri pti ons and
understand air bag
result in needless
service.
indicator.
under st ood?
Yes
No
NOTE: This is an
GOt o 84-2.
descri pti ons and
understand air bag
result in needless
service.
Yes
No
GOt o 84-3.
GO to 84-4.
Deactivate system.
Yes
No
GOt o 84-3.
GO to 84-4.
DTC 84: INTERMITTENT OR REPAIRED RH RADIATOR PRIMARY CRASH SENSOR NOT MOUNTED TO VEHICLE PROPERLY
(Cont i nued)
TE ST STEP RESULT

ACTION TO TAKE
f l ashi ng?
Yes

PROCEED to the
that is flashi ng.
No

REACTIVATE system.
Visually inspect the wi res, cri mps, in-line
connectors, etc. on Circuit 618 (P/LG).
Yes

found. GO to 84-3.
No

GOt o 84-5.
NOTE: An intermittent open or high resi stance in thi s
circuit may lead to a DTC 84.
84-5 CHECK RH PRIMARY CRASH SENSOR
Locate and visually inspect RH radi ator primary
signs of corrosi on.
Yes

REPLACE RH radiator
significant corrosion is
noti ced. GO to 84-3.
No

GO to 84-6.
and spli ces in Circuit 57 (BK) feeding the di agnosti c
NOTE: A poor reference ground can lead to FALSE
ground readings and a di agnosti c trouble code 84.
Yes

CORRECT poor
diagnostic monitor
mounting fasteners.
CONNECT air bag
84-3.
No

REMOVE screws
bag sensor and bracket .
Clean mounting surface
of sensor and chassi s.
Install RH radiator
Tighten screws to proper
speci fi cati ons. GO to
84-3.
Re p a i r e d L H Ra d i a t o r P r i ma r y C r a s h S e n s o r
No t Mo u n t e d t o Ve h i c l e P r o p e r l y
C o d e 8 5
01- 2 0B- 89 ' Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba ~ ~- - - -
c
~" i
-m imzzzizzrizzzzzi. m I ZTZZI TI Z. JÊ . . -
1
.' : zmz- ~& ~i
DTC 85: INTERMITTENT OR REPAIRED LH RADIATOR PRIMARY CRASH SENSOR NOT MOUNTED TO VEHICLE PROPERLY
Yes .
>
No
NOTE: This is an
GOt o 85-2.
descri pti ons and
understand air bag
result in needless
service.
indicator.
unde r st ood?
Yes .
>
No
NOTE: This is an
GOt o 85-2.
descri pti ons and
understand air bag
result in needless
service.
Yes
No
GO to 85-3.
GO to 85-4.
Yes
No
GO to 85-3.
GO to 85-4.
Yes
No
PROCEED to the
that is flashing.
REACTIVATE system.
f l ashi ng?
Yes
No
PROCEED to the
that is flashing.
REACTIVATE system.
Yes
No
REPLACE LH radiator
GO to 85-5.
Visually inspect the wi res, cri mps, in-line
connectors, etc. on Circuit 620( P/ LB) .
NOTE: An intermittent open or high resi stance in this
ci rcui t may lead t o a DTC 85.
Locat e and visually inspect LH radiator primary
crash front air bag sensor and bracket.
Yes
No
REPLACE LH radiator
GO to 85-5.
Yes
No " >
CORRECT poor
diagnostic monitor
mounting fasteners.
CONNECT air bag
diagnostic monitor. GOt o
85-3.
REMOVE screws
retaining LH radi ator
of LH radiator primary
INSTALL LH radi ator
TIGHTEN screws to
t o 85-3.
and spli ces in Circuit 57 (BK) feeding the diagnostic
NOTE: A poor reference ground can lead t o FALSE
ground readings and a diagnostic trouble code 85.
Are any poor c o n n e c t i o n s f ound?
Yes
No " >
CORRECT poor
diagnostic monitor
mounting fasteners.
CONNECT air bag
diagnostic monitor. GOt o
85-3.
REMOVE screws
retaining LH radi ator
of LH radiator primary
INSTALL LH radi ator
TIGHTEN screws to
t o 85-3.
01- 20B- 90 Rest r ai nt s, Passi veSuppl ement al Ai r Bag Sy s t em 01- 20B- 90
Ra p i d C o n t i n u o u s Fl a s h i n g o f A i r B a g
I n d i c a t o r B o t h P r i ma r y Cr a s h S e n s o r s
Di s c o n n e c t e d
Each pri mary crash sensor has t hr ee wi r e s.
The first wi re is used for air bag depl oyment.
The second wi re is used t o monitor the sensor' s
connecti on t o the air bag di agnosti c monitor. (Refer
t o Di agnosti c Trouble Codes 41 / 8 1 and 4 2 / 8 2 for
detai l s.)
The thi rd is used t o monitor t he mounting (ground) of
t he sensor t o sheet metal . (Refer t o Di agnosti c
Trouble Codes 4 4 / 8 4 and 45/8*5 for detai l s.)
If t he air bag di agnosti c monitor det ect s that BOTH
pri mary crash sensors are di sconnect ed AND both
pri mary crash sensors are not mounted, the air bag
di agnosti c monitor will fl ash t he air bag indicator
continuously at a rapi d rat e.
In t he assembl y plant, thi s will not result in any
st ored Di agnosti c Trouble Codes.
Outsi de t he assembl y plant, however, Di agnosti c
Trouble Codes 4 1 , 42, 44, and 45 will be st ored.
These will fl ash out as Di agnosti c Trouble Codes
8 1 , 8 2 , 8 4 , 8 5 on t he next ignition swi t ch cycl es if
t he condi ti on is servi ced.
Rapi d Continuous Flashing of the air bag indicator can
be caused by:
Bo t h p r i ma r y c r a s h s e n s o r s d i s c o n n e c t e d f r o m
wi r i n g h a r n e s s .
Ma i n wi r i n g h a r n e s s n o t c o n n e c t e d t o e n gi n e
c o mp a r t me n t wi r i n g har ness. ,
El e c t r i c a l Sc he ma t i c Rapi d Co n t i n uo us Fl ashi ng o f Ai r Bag I n d i c a t o r
AT ALL TIMES
POWER*
K* I DISTRIBUTION
i t o * !
B 0 X
. I FUSE**
' 1GA JUNCTION
, I PANEL
(NO SUBSTITUTIONS)
AIR BAG DIAGNOSTIC
MONITOR
COMPUTER
IF PINS 16 AND 24
ARE NOT CONNECTED,
AND PINS 15 AND 23
ARE NOT CONNECTED
AND
IF THE DIFFERENCE
BETWEEN PINS 20 AND 21
AND THE REFERENCE
GROUND IS MORE THAN
2 OHMS,
THEN STORE CODES
41,42,44, AND 45,
AND FLASH THE AIR BAG
INDICATOR AT A
RAPID RATE.
24
* TOWN CAR
624
Y/LG
PK/W
1
P/LG
R10978-A
P i n p o i n t T e s t
Refer t o Pinpoint Tests for Di agnosti c Trouble Codes
41, 42, 44, and 45.
Di a g n o s t i c T r o u b l e C o d e C l e a r i n g
P r o c e d u r e t o Cl e a r Di a g n o s t i c T r o u b l e C o d e s
f r o m Di a g n o s t i c Mo n i t o r No n - Vo l a t i l e R a n d o m
A c c e s s Me mo r y .
The air bag di agnosti c monitor ( 14B056) continually
checks t he air bag syst em f or readi ness. When a fault
condi ti on is det ect ed, the DTC associ at ed wi th that
fault i s st ored in t he air bag di agnosti c moni tor' s
Non-Volatile Random Access Memory (NVRAM). After
wri ti ng t he DTC t o NVRAM, t he air bag di agnosti c
moni tor signals the fault by fl ashi ng t he appropri at e
di agnosti c troubl e code on t he air bag indicator.
The di agnosti c troubl e code wri tten t o NVRAM is
permanentl y st ored in the air bag di agnosti c monitor
until cl eared by the di agnosti c troubl e code clearing
procedure.
Upon each cycl e of the ignition swi t ch ( 11572) , the
air bag di agnosti c monitor checks for di agnosti c
troubl e codes wri tten in NVRAM. If any di agnosti c
troubl e codes exi st in NVRAM, t he air bag
di agnosti c monitor will then check t o see if these
fault condi ti ons are still present.
If t he condi ti ons of the di agnosti c troubl e code in
NVRAM are still present, then t he air bag di agnosti c
moni tor will use the air bag indicator t o fl ash out t he
di agnosti c troubl e code number t hat was wri tten in
memory.
If t he condi ti ons of the di agnosti c troubl e code are
not still present (indicating an intermittent or
servi ced faul t), t he air bag di agnosti c monitor will
use t he air bag i ndi cator t o fl ash out a DTC whi ch is
t he sum of t he di agnosti c troubl e code in NVRAM
plus 40.
Exampl e: Due t o corrosi on, high resi stance devel ops
on t he dri ver si de air bag ci rcui t. The air bag
di agnosti c monitor st ores a di agnosti c troubl e code 32
in NVRAM. Upon each cycl e of the ignition swi t ch, t he
air bag di agnosti c monitor checks t he resi stance of
t he dri ver air bag ci rcui t.
If t he resi stance is still hi gh, the air bag di agnosti c
monitor causes t he air bag indicator t o fl ash out a
DTC 32.
If t he resi stance falls within the normal range due t o
servi ce or an intermittent condi ti on, t he air bag
di agnosti c monitor causes DTC 72 t o be fl ashed on
t he air bag indicator.
Once a fault has been servi ced, t he associ at ed
di agnosti c troubl e code may be cl eared f r om NVRAM.
Onl y di agnosti c troubl e codes that t he air bag
di agnosti c moni tor sees as repai red or intermittent
may be cl eared (di agnosti c troubl e codes 52 and
above). In no ci rcumst ances can hard fault condi ti ons
(di agnosti c troubl e codes 45 and bel ow) be cl eared.
1. Fol l ow t he di agnosti c procedures as outl i ned t o
servi ce the fault condi ti on fl ashi ng on t he air bag
indicator.
2. Cycl e t he ignition swi t ch t o OFF and then t o RUN.
3. Obser ve air bag i ndi cator prove-out (si x t wo
seconds) f ol l owed by di agnosti c troubl e code
( 52- 85) flashing compl et el y one ti me.
4. Locat e the Di agnosti c ' Tr oubl e Code Cl ear' '
Connector l ocat ed underneath the gl ove
compart ment ( 06010) containing Ci rcui ts 631
( T/ R) and 57 ( BK) .
5. Use a j umper wi re t o short Circuit 631 (T/ R) t o
Circuit 57 ( BK) or t o another good ground. Thi s
short must be made after the di agnosti c troubl e
code fl ashes compl etel y one ti me, but bef ore the
warni ng light st ays on continuously.
6. Hold short until air bag di agnosti c monitor tone
sounds (approxi matel y five seconds).
7. Rel ease short on Circuit 631 ( T/ R) t o Circuit 57
( BK) . Thi s short must be rel eased wi thi n 25
seconds after the di agnosti c monitor tone
sounds.
Di agnosti c troubl e code is now cl eared f rom NVRAM.
Next hi ghest pri ori ty di agnosti c troubl e code st ored in
NVRAM (if one exi st s) will begin fl ashi ng.
S e n s o r a n d B r a c k e t , F r o n t
Re mo v a l
WARNI NG. THE ELECTRI CAL CI RCUI T
NECESSARY FOR SYSTE M DEPLOYMENT IS
POWERED DI RECTLY FROM THE BATTERY. TO
AVOI D ACCI DENTAL DEPLOYMENT AND
POSSI BLE PERSONAL INJURY, THE NEGATI VE
BATTERY CABL E MUST BE DI SCONNECTED
PRIOR TO SERVI CI NG OR REPLACI NG ANY
SYSTEM COMPONENTS.
reprogrammi ng fol l owi ng compl eti on of servi ce
procedures.
3. Wait one minute f or back-up power suppl y energy
t o be depl et ed.
4. Remove radi ator upper sight shield ( 8C291) .
5. Di sconnect RH or LH pri mary crash sensor
el ectri cal connector.
01- 2 0B- 92 Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Ba g S y s t e m 01- 20B- 92
6. Remove three scr ews retaining RH pri mary c r a sh
front air bag sensor and bracket ( 14B004) or LH
pri mary crash front air bag sensor and bracket
( 14B005) at front of radi ator support ( 16138)
and remove RH pri mary crash front air bag
sensor and bracket or LH pri mary crash front air
To wn Car
PRIMARY CRASH FRONT
AIR BAG SENSOR AND
BRACKET 14B004
SCREW
N806327-S190
3 REQ'D
TIGHTEN TO
10.2-13.8 N-m
(8-10 LB-FT)
HEADLAMP DASH
PANEL JUNCTION
^ P q o LH SHOWN
, #
^
u
RH SIMILAR
Cr o wn Vi c t o r i a , Gr a n d Ma r qui s
RH SHOWN
LH SIMILAR
R76S5-C
SCREW
N806327-S190
3 REQ'D
TIGHTEN TO
11.4-15.6 N-m
(9-11 LB-FT)
RH PRIMARY CRASH
FRONT AIR BAG SENSOR
AND BRACKET
14B004
FRONT OF
VEHICLE -
R71S6-D
2. Connect RH or LH pri mary crash sensor wi re l ead
connector t o wi ri ng assembl y connector and
secure wi ri ng retainer.
4. Prove out air bag syst em.
5. Install radi ator upper sight shi el d. Refer t o
Secti on 01- 02.
6. Reprogram radi o frequenci es and set cl ock.
Di a g n o s t i c Mo n i t o r , A i r B a g
Re mo v a l
BAG COMPONENT SERVI CE IS PERFORMED- TO
DEPLETE BACK- UP POWER SUPPLY ENERGY,
DI SCONNECT THE NEGATI VE BATTERY CABLE
AND WAI T ONE MI NUTE TO AVOI D ACCI DENTAL
DEPLOYMENT AND POSSI BLE PERSONAL
INJURY.
WARNI NG: THE ELECTRI CAL CI RCUI T
NECESSARY FOR SYSTEM DEPLOYMENT IS
POWERED DIRECTLY FROM THE BATTERY. TO
POSSI BLE PERSONAL INJURY, THE NEGATI VE
BATTERY CABLE MUST BE DI SCONNECTED
SYSTEM COMPONENTS.
reprogrammi ng fol l owi ng compl eti on of servi ce
procedures.
3. Wait one minute for back-up power suppl y energy
t o be depl et ed.
4. Remove RH cowl si de tri m panel ( 02344) . Refer
5. Open gl ove compart ment door ( 06024) and
depress si des t o rel ease retaining t abs and al l ow
gl ove compart ment door t o drop down.
6. Move RH cowl si de insulation paddi ng t o i mprove
access t o air bag di agnosti c monitor ( 14B056) .
7. Di sconnect air bag di agnosti c monitor el ectri cal
wiring connect ors.
1. Position RH pri mary crash front air bag sensor
and bracket or LH pri mary cr ash front air bag
sensor and bracket in vehi cl e and secure RH
pri mary crash front air bag sensor and bracket or
LH pri mary cr ash front air bag sensor and
br acket t o RH or LH front of radi ator support wi t h
retaining scr ews. Tighten scr ews t o 10. 2-13. 8
N-m ( 8- 10 Ib-ft) on Town Car or 11. 4-15. 6 N-m
(9-111b-ft) on Crown Vi ct ori a, Grand Marqui s.
01- 2 0B- 03 Re s t r a i n t s , P a s s i v e S u p p l e me n t a l Ai r Bag S y s t e m 01- 2 0B- 9 3
8. Remove screws retaining air bag diagnostic
monitor to the RH upper cowl and remove air bag
diagnostic monitor from vehicle.
R10936-A
Pa r t
1 14B056 Air Bag Diagnostic Monitor
2
_
RH Upper Cowl
3

Wire Harness Connector
(Part of 14401)
4

Bolt (2 Req'd)
5

Screw
1. Install air bag diagnostic monitor on the RH upper
cowl and secure with three retaining screws.
2. Connect electrical wiring connectors to the air
3. Reposition RH cowl side insulation padding.
4. Close glove compartment ( 06010) by pushing in
on retaining tabs.
5. Install RH cowl side trim panel. Refer to Section
01- 05.
6. Reconnect battery ground cable.
7. Prove out air bag system.
8. Reprogram radio frequencies and set clock.
Mo d u l e , Dr i v e r S i d e A i r B a g
NOTE: If the driver side air bag module ( 043B13) did
not deploy in a collision, it may not have been needed.
Complete all diagnostics before replacing the driver
Re mo v a l
NECESSARY FOR SYSTEM DEPLOYMENT I S
POSSI BLE PERSONAL I NJURY, T HE NEGATI VE
BATTERY CABL E MUST BE DI SCONNECTED
PRI OR TO SERVI CI NG OR REPLACI NG ANY
SYSTE M COMPONENTS.
1. Record pre-set radio frequencies for
reprogramming following completion of service
procedures.
2. Disconnect battery ground cable (14301).
3. Wait one minute for back-up power supply energy
to be depleted.
4. On Town Car, remove two steering wheel spoke
covers ( 3L518) .
5. Remove four nut and washer assemblies (two
bolts on Town Car) retaining driver side air bag
module to steering wheel ( 3600) .
6. On Town Car, disconnect the horn switch
connector.
7. WARNI NG: PL ACE AI R BAG MODULE ON
BENCH WI TH TRI M COVER FACI NG UP.
Disconnect the air bag electrical connector from
air bag sliding contact connector. Remove driver
Dr i ve r s Si de Ai r Ba g Mo d u l e Cr o wn Vi c t o r i a ,
Gr a n d Mar qui s
NUT AND
WASHER ASSY
N805572-S36
4 REQ'D
TIGHTEN TO
2.7-3.7 N-m
(24-33 LB-IN)
STEERING WHEEL
3600
DRIVER SIDE
AIR BAG
MODULE
043B13
R10092-A
01- 20B- 94 Rest r ai nt s, PassiveSupplemental Ai r Bag Sy s t em 01-20B-94
Dri vers Si de Air Bag Modul eTown Car
STEERING WHEEL
3600
DRIVER SIDE
AIR BAG MODULE
043B13
AH
BOLT AND WASHER
ASSY 2 REQ'D
TIGHTEN TO
10.2-13.8 N-m
(8-10 LB-FT)
STEERING WHEEL
SPOKE COVER
3L518 2REQ'D
R10997-A
1. Connect ai r bag el ect ri cal connect or t o ai r bag
sli di ng cont act connect or.
2. On Town Car, connect t he horn swi t c h connect or.
3. Posi t i on dri ver si de ai r ba g modul e t o st eeri ng
wheel and secur e wi t h f our nut and wa she r
assembl i es t i ght ened t o 2. 7-3. 7 Nm (24-33 lb-in)
on Cr own Vi ct or i a, Grand Marqui s or t wo bol t s
and wa she r s t i ght ened t o 10. 2-13. 8 N-m (8-10
Ib-ft) on Town Car.
4. On Town Car, i nstall t wo st eeri ng wheel spo ke
c o ve r s.
5. Re-connect bat t er y ground cabl e.
6. Pr ove out ai r bag sy st e m.
7. Repr ogr am radi o f requenci es and set c l o c k.
Module, Passenger Side Air Bag
NOTE: If t he passenger si de ai r ba g modul e ( 044A7 4)
di d not depl oy in a col l i si on, it may not have been
needed. Compl et e all di agnost i cs bef ore repl aci ng t he
passenger si de ai r ba g modul e.
Re mo v a l
NECESSARY FOR SYSTE M DEPLOYMENT I S
POSSI BLE PERSONAL I NJURY, THE NEGATI VE
BATTERY CABLE MUST BE DI SCONNECTED
SYSTE M COMPONENTS.
1. Re c or d pre-set radi o f requenci es f or
r epr ogr ammi ng f ol l owi ng compl et i on of ser vi ce
pr oc e dur e s.
2. Di sconnect bat t er y gr ound cabl e ( 14301) .
3. Wai t one mi nute f or back-up power suppl y ener gy
t o be depl et ed.
4. NOTE: The i nst rument panel upper moul di ng
( 042 68) i s ret ai ned by snap-i n t a bs.
On Cr own Vi ct or i a, Grand Marqui s, r emove
i nst rument panel upper moul di ng.
5. On Town Car, remove i nst rument panel f i ni sh
panel ( 044D7 0) . Ref er t o Sect i on 01-12.
6. Open gl ove compar t ment ( 06010) , pr e ss si des
i nwar d and l ower gl ove compar t ment t o f l oor.
7. Thr ough gl ove compar t ment openi ng, r emove
t wo l ower passenger ai r ba g modul e ret ai ni ng
sc r e ws.
WARNI NG: PLACE AI R BAG MODULE ON BENCH
WI TH TRI M COVER FACI NG UP TO AVOI D
POSSI BLE PERSONAL I NJURY.
8. Remove t wo remai ni ng passenger ai r bag modul e
ret ai ni ng sc r e ws, di sconnect el ect ri cal connect or
and r emove passenger si de ai r bag modul e.
Air Bag Module, Passenger Side Town Car
SCREW
N807122-S411
2 REQ'D
TIGHTEN TO
2.1-2.9 N-m
(19-25 LB-IN)
PASSENGER SIDE
AIR BAG MODULE
044A74
SCREW
N806115-S36
2 REQ'D
TIGHTEN TO
7.6-10.4 N-m
(6-8 LB-FT)
R10963-A
01- 2 0B- 95 Rest r ai nt s, Passi veSuppl ement al Ai r Ba g System 0 1 - 2 0 8 - 9 5
REMOVAL AND INSTALLATION (Conti nued) DISPOSAL PROCEDURES
Cr own Vi ct or i a, Gr and Ma r qui s
SCREW N807 12 2 - S411
2 REQ'D
TIGHTEN TO
2. 1-2. 9 N-m
(19-25 LB- I N)
PASSENGER SIDE AIR BAG
MODUL E 044A 7 4
SCREW N806115-S36
w
o
A
S
J 5
U M E N T
2 REQ' D P A NE L
TIGHTEN TO 7.6-10.4 N.m (6-8 LB-FT)
0 4 3 2 0
R10962- A
I nst al l at i on
NOTE: Fill out and ret urn ai r ba g t raceabi l i t y po st c a r d
f or new air ba g wi t h VIN number s and not e di agnost i c
t roubl e c ode .
1. Connect el ect ri cal c onne c t or t o passenger si de
air bag modul e and posi t i on passenger si de ai r
bag modul e in i nst rument panel (04320).
2. Install t wo upper ret ai ni ng sc r e ws. Ti ght en t o
2. 1-2. 9 N-m (19-25 lb-i n).
3. Install t wo l ower modul e ret ai ni ng bol t s. Ti ght en t o
7. 6-10. 4 N-m (6-8 Ib-f t ).
Ret urn gl ove compar t ment t o c or r e c t posi t i on.
On Cr own Vi c t or i a , Gr and Mar qui s, i nstall
i nst rument panel upper moul di ng by snappi ng i nto
pl ace on t he i nst rument panel .
On Town Car, i nstall i nst rument panel f i ni sh panel .
Ref er t o Sect i on 01- 12.
Reconnect ba t t e r y gr ound cabl e.
Prove out ai r bag sy st e m.
Repr ogr am radi o f r equenci es and set c l oc k.
4.
5.
7.
8.
S l i d i n g C o n t a c t , A i r B a g
A i r B a g Di s p o s a l R e c o m m e n d a t i o n
Se ve r a l si t uat i ons may ari se whi ch requi re some f or m
of di sposa l a c t i on: scrappi ng a vehi cl e cont ai ni ng a
d e pl o y e d ai r ba g, scrappi ng a vehi cl e wi t h a live ai r
ba g, di sposa l of a live but el ect ri cal l y i noperat i ve ai r
ba g modul e or scr appi ng a depl oy ed modul e. Di sposal
r e c omme nda t i ons f or t hese si t uat i ons are shown in t he
f ol l owi ng c ha r t and di scussed in det ai l bel ow:
A I R BA G DI SPOSA L RECOMMEND A T I ONS
Co n d i t i o n On st n i Ct l o n S
Ve h i c l e t o b e S c r a p p e d ; Li v e
Ai r Ba g s .
E l e c t r i c a l l y De p l o y
Ve h i c l e t o be S c r a p p e d ;
De p l o y e d Ai r Ba g s .
Sc r a p Ve h i c l e i n t h e Usua l
Ma nne r .
Mo d u l e Re p l a c e d ; Da ma g e d
b u t L i v e Ai r Ba g s .
P a c ka g e a n d L a b e l P r o pe r l y .
Re t ur n t o Fo r d .
Mo d u l e R e p l a c e d ; De p l o y e d
A i r Ba g s .
Sc r a p Ai r Ba g s i n t h e Usua l
Ma nne r .
A i r B a g s , D e p l o y e d
To se r vi c e a vehi cl e in whi ch t he air ba g has depl oy ed,
t he d e pl o y e d ai r bag must be r epl aced wi t h a new ai r
ba g modul e. The depl oyed ai r bag can be di sposed of
in t he sa me manner as any part t o be sc r a ppe d.
STE E RI NG
WHE E L
3600
DE P L OYE D
A I R BAG
R6566-B
01- 20B- 9S Re s t r a i n t s , P a s s i v e Suppl ement al Ai r Ba g Sy s t em 01- 20B- 96
DISPOSAL PROCEDURES (Conti nued)
Air Bag, Undepl oyed Faulty
NOTE: AH faul ty live air bags have been pl aced on t he
Mandat ory Return Li st. All di scol ored or damaged
modul es shoul d be t r e a t e d t he same as any faul ty live
air bag being returned.
In the event that an air bag is di agnosed as i noperati ve
(refer t o Di agnosi s and Testi ng), the i noperati ve air
bag must be repl aced by a new air bag. The
i noperati ve air bag CANNOT BE DI SPOSED OF IN
THE USUAL MANNER. It must be returned i ntact t o
For d Mot or Company for proper di sposal . Return the
cart on t o t he fol l owi ng address for warrant y cl ai m
credi t:
WARRANTY PARTS RETURN CENTER
1 2 8 5 S. MI LL STREET
PLYMOUTH, Ml 4 8 1 7 0
The air bag must be packaged and shi pped accordi ng
t o the U.S. Department of Transportati on regul ati ons.
Retain packagi ng used for repl acement air bag,
including t he labeling. Do not depl oy ai r bag.
Properl y package the module in t he original servi ce
repl acement cart on and securel y t ape shut, wi t h t he
Fl ammabl e Sol i d label and shi ppi ng exempti on affi xed
t o it.
STEERI NG
WHEEL
3600
UNDEPLOYED
AIR BAG
RS567-B
Ai r B a g Di s p o s a l
Ai r Ba g De p l o y me n t , Re mo t e
WARNI NG: REMOTE DEPLOYMENT IS TO BE
PERFORMED OUTDOORS WI TH ALL PERSONNEL
AT LEAST 6 M ( 20 FEET) AWAY TO ENSURE
PERSONAL SAFETY AND DUE TO THE LOUD
REPORT WHI CH OCCURS WHEN DRIVER AND
PASSENGER AI R BAGS ARE DEPLOYED,
1. Remove the dri ver si de air bag module ( 043B13)
and passenger si de air bag module ( 044A74)
f r om t he vehi cl e as outlined.
2. Cut t he t wo module connector wi res and stri p 25
mm ( 1 inch) of insulation f rom t he ends. Obtai n
t wo wi res at least 6 m ( 20 f eet ) l ong. Connect one
end of each wi re t o each of the air bag module
wi res.
WARNI NG: DO NOT PLACE THE AIR BAG WI TH
THE TRI M COVER FACI NG DOWN, AS THE
FORCES OF THE DEPLOYI NG AIR BAG MAY
CAUSE IT TO RI COCHET AND CAUSE PERSONAL
INJURY.
3. Pl ace t he air bag wi th t he tri m cover faci ng
upward on a flat surface in a remote ar ea such as
a parki ng lot or fi el d.
4. Remaining at least 6 m ( 20 f eet ) away f rom the
air bag, depl oy it by touchi ng the other ends of
t he t wo wi res t o the termi nal s of a 12-volt vehi cl e
bat t ery.
5. If successf ul , a loud report will be heard and t he
air bag materi al will be visible. Al l ow at l east 10
minutes bef ore approachi ng t he air bags t o allow
for cool i ng.
The air bags are now depl oyed and may be
scr apped in accordance wi t h scrap metal
procedures.
SPECIFICATIONS
Scrapped Vehicle
Some vehi cl es that are damaged or i noperabl e t o the
point that servi ce cannot be made may contai n
undepl oyed air bags. Thi s condi ti on coul d occur by
si de or rear i mpact, rollover or if the vehi cl e is si mpl y
past its useful lifetime. THE AI R BAGS SHOULD BE
DEPLOYED USING THE FOLLOWI NG
PROCEDURE.
COMPONENT PART NUMBERS
P a r t N u m b e r C o m p o n e n t
043B13- A Dr i v e r Si d e Ai r Ba g Mo d u l e
0 4 4 A 7 4 P a s s e n g e r Si d e Ai r Ba g Mo d u l e
14B004 RH Ra d i a t o r Pr i ma r y Cr a s h Fr o n t Ai r Ba g
Se n s o r a n d Br a c ke t
14B005 L H Ra d i a t o r Pr i ma r y Cr a s h Fr o n t Ai r Ba g
Se n s o r a n d Br a c ke t
14B056 Ai r Ba g Di a gn o s t i c Mo n i t o r
14A664 Ai r Ba g Sl i d i n g Co n t a c t
De s c r i p t i o n N-m L b - l n
Dr i v e r Ai r Ba g Mo d u l e - t o - St e e r i n g
Wh e e l Bo l t s ( To wn Ca r )
10. 2 - 13. 8 8- 10
( L b - Ft )
Dr i v e r Ai r Ba g Mo d u l e - t o - St e e r i n g
Wh e e l Nut s ( Cr o wn Vi c t o r i a , Gr a n d
Ma r q u i s )
2. 7 - 3. 7 2 4- 33
P a s s e n g e r Ai r Ba g Mo d u l e
Re t a i n i n g S c r e w s ( To wn Ca r )
2. 1- 2. 9 19- 2 6
Re t a i n i n g Bo l t s ( To wn Ca r )
7 . 6- 10. 4 6- 8 ( L b - Ft )
Re t a i n i n g S c r e w s F r o n t ( Cr o wn
Vi c t o r i a , G r a n d Ma r q u i s )
7 . 6- 10. 4 67 - 92
Re t a i n i n g S c r e w s Re a r ( Cr o wn
Vi c t o r i a , G r a n d Ma r q u i s )
2. 1- 2. 9 19- 2 6
RH a n d L H P r i ma r y Cr a s h Se n s o r
t o - Ra d i a t o r S u p p o r t S c r e ws ( To wn
Ca r )
10. 2 - 13. 8 8- 10
( L b - Ft )
RH a n d LH P r i ma r y Cr a s h Se n s o r
t o - Ra d i a t o r Su p p o r t S c r e ws
( Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s )
11. 4- 15. 6 9- 11
( L b - Ft )
I n sul a t o r S c r e ws 1.5-3 13-27
ROTUNDA EQUIPMENT
105- 00010 Ai r Ba g Si mu l a t o r
105- 00053 88 Di gi t a l Mu l t i me t e r
02 - 03- 1
GROUP
FRAME AND
MOUNTING /
( 6000)
02-03 Engine and Transmission Mounting
SUBJECT PAGE
VEHI CLE APPLICATION . 02-03-1
Engi ne and Transmi ssi on Mounting .. 02-03-1
Suppor t Insulator, Rear Engi ne 02-03-5
SUBJECT PAGE
REMOVAL AND INSTALLATION (Cont'd.)
Support Insulators, Front Engi ne ....02-03-1
SPECI FI CATI ONS 02-03-6
VEHICLE APPLICATION
Engine and Transmission Mo u n t i n g The rear engine support insulator ( 6068) :
The front engine support insulators ( 6038) :
Is l ocated at the rear of the transmi ssi on.
Are l ocated on each si de of the cyl i nder bl ock At t aches the transmi ssi on to t he No. 3
( 6010) . crossmember.
At t ach t he engine t o t he No. 2 crossmember
( 5025) .
Support Insul at ors, Front Engine
Removal
2. Remove air cl eaner outlet tube ( 9B659) . Refer t o
Secti on 03- 12.
3. Drain engine cool i ng syst em and remove cooling
fan bl ade ( 8600) and fan shroud ( 8146) . Refer t o
Secti on 03- 03.
4. Relieve fuel syst em pressure and di sconnect fuel
lines f r om fuel injection suppl y manifold ( 9F792) .
Refer t o Sect i on 10- 01.
5. Remove upper radi ator hose ( 8260) .
6. Remove windshield wi per motor ( 17508) and
windshield wi per motor mounting bracket
( 17496) . Refer t o Secti on 01- 16.
7. Recover air conditioning syst em. Refer t o Secti on
12-00.
8. Di sconnect A / C manifold and tube ( 19D734) at
A / C compressor ( 19703) and remove bolt
retaining A / C manifold and tube assembl y t o RH
coil bracket .
9. Remove 42-pin engine harness connector f rom
wiring bracket ( 14536) on power brake booster
( 2005) .
02 - 03- 2
E n gi n e a n d T r a n s mi s s i o n Mo u n t i n g 02 - 03- 2
10. Di sconnect 42-pin connector and transmi ssi on
harness connector.
VIEW A
A14801-B
Pa r t
i 14536 Wiring Bracket
2 2005 Power Brake Booster
3 42-Pin Engine Wire Harness
Connector (Part of 12A581)
4 Transmission Wire Harness
11. Di sconnect heater wat er hose ( 18472) .
12. Remove upper stud bolt and loosen l ower bolt
retaining heater wat er hose t o RH cylinder head
( 6049) and position out of t he way.
HEATER WATER
HOSE 18472
REMOVE
-THI S STUD BOLT
RH CYLI NDER-
HEAD 6049
REMOVE THI S
BOLT
A13672-D
13. Remove heater bl ower motor swi t ch resi stor
( 18591) .
14. Remove upper bolt retaining RH front engine
support insulator ( 6038) t o front engine mount
insulator support ( 6K060) .
15. Di sconnect vacuum hoses f rom EGR control
val ve ( 9D473) and EGR val ve t o exhaust manifold
tube ( 9D477) .
16. Remove t wo bol ts retaining EGR control val ve t o
i ntake manifold ( 9424) .
BOLT
2 REQ'D
TIGHTEN TO
20-30 N-m
(15-22 LB-i
EGR VALVE TO EXHAUST
MANIFOLD TUBE 9D477
LINE NUT
2 REQ'D
TIGHTEN
35-45 N-m
(26-33 LB-FT)
FRONT OF
ENGINE -
A13674-B
17. Di sconnect both heated oxygen sensors
( H02SX9F472) .
18. Raise vehicle on a hoist. Refer t o Secti on 00- 02.
19. NOTE: Two through-bol ts requi red for LH front
engine support insulator and one through-bol t
requi red for RH front engine support insulator.
Remove front engine support insulator
through-bol ts.
20. Remove EGR valve t o exhaust manifold tube line
nut f rom RH exhaust manifold ( 9430) and remove
EGR control val ve and EGR val ve t o exhaust
manifold tube.
2 1 . Di sconnect exhaust syst em f rom RH exhaust
manifold and LH exhaust manifold.
02 - 03- 3 Engi ne and Tr ansmi ssi on Mount i ng 02- 03- 3
22. Lower exhaust syst em and wi re t o No. 3
crossmember ( 5025) in posi ti ons shown.
NO. 3 CROSSMEMBER
WIRE
23. Position a sui tabl e j ack and a wood bl ock under
oil pan ( 6675) , r ear war d of oil pan drain plug
( 6730) .
24. Raise engine approxi mat el y 100 mm (4 i nches).
25. Install a wood bl ock under oil pan and l ower
engine ont o wood bl ock.
26. Remove t hree retaining bol ts f rom both RH front
engine support insulator and LH f ront engine
support insulator and remove front engine support
insulators.
NOTE: WIRE BOTH RH AND LH
PIPE TO NO. 3 CROSSMEMBER
Fr o n t Engi ne Suppo r t I nsul a t or s
A13631-B
VIEW A
A14938-E
Pa r t
1 6K060 RH Front Engine Mount
Insulator Support
2 6038 RH Front Engine Support
Insulator
I t e m
Pa r t
3 6038 LH Front Engine Support
Insulator
4 6K061 LH Front Engine Mount
Insulator Support
( Co n t i n ue d )
02- 03- 4 En gi n e a n d Tr a n s mi s s i o n Mount i ng 02- 03- 4
I t e m
Pa r t
5 N806198-S301 Bolt (3 Req'd)
6 N806216-S101 Bolt (6 Req'd)
7 5025 No. 2 Crossmember
8 N807218-S101 Bolt (6 Req'd)
( Co n t i n ue d )
Pa r t
9 N806473-S102 Bolt
Lb-Ft)
Lb-Ft)
1. Position front engine support insulators on engine,
install retaining bol ts and tighten t o 60-81 N-m
( 44- 60 Ib-ft).
2. Raise engine and remove wood bl ock.
3. Lower engine and front engine support insulators
onto RH front engine mount insulator support and
LH front engine mount insulator support ( 6K061) .
4. NOTE: Loosen line nut at EGR control val ve prior
t o installing assembl y into vehi cl e. This will al l ow
enough movement t o align EGR control valve
retaining bol ts.
Position and connect EGR control val ve and EGR
val ve t o exhaust manifold tube t o exhaust
mani fol d. Tighten line nut t o 35- 45 N-m (26-33
Ib-f t ).
5. NOTE: Two through-bol ts requi red on LH front
engine support insulator and one through-bol t
requi red on RH front engine support insulator.
Install front engine support insulator through bol ts
and ti ghten to 47- 63 N-m (35-46 Ib-ft).
6. NOTE: Ensure exhaust syst em cl ears No. 3
crossmember. Adj ust as necessary.
Cut wi re and posi ti on exhaust syst em t o the
exhaust manifolds. Install four nuts and ti ghten t o
27- 41 N-m ( 20- 30 Ib-ft).
7. Lower vehi cl e.
8. Connect both heated oxygen sensors.
9. Install upper bolt retaining RH front engine
support insulator t o front engine mount insulator
support . Tighten t o 47- 63 N-m (35-46 Ib-ft).
10. Install a new gasket on EGR control val ve and
posi ti on t o i ntake mani fol d.
11. Install t wo bol ts retaining EGR control val ve t o
i ntake manifold and ti ghten t o 20-30 N-m (15-22
I b4t ).
12. Tighten EGR val ve t o exhaust manifold tube line
nut at EGR control val ve t o 35- 45 N-m (26-33
Ib-f t ).
BOLT
2 REQ'D
TIGHTEN
20-30 N-m
(15-22 LB-
MANIFOLD TUBE 9D477
LINE NUT
2 REQ'D
TIGHTEN TO
35-45 N-m
(26-33 LB-FT)
FRONT OF
ENGINE "
A13674-B
13. Connect vacuum hoses t o EGR control val ve and
EGR valve t o exhaust manifold tube.
14. Install heater bl ower motor swi t ch resi stor wi t h
t wo retaining scr ews.
15. Position heater wat er hose, install upper stud and
ti ghten upper stud and l ower bolt t o 20-30 Nm
(15-22 Ib-ft). Install ground st rap onto stud and
ti ghten nut t o 20-30 N-m (15-22 Ib-ft).
16. Connect heater wat er hose.
17. Connect 42-pin connector and transmi ssi on
harness connector.
02 - 03- 5 E n gi n e a n d T r a n s mi s s i o n Mo u n t i n g 02- 03- 5
18. Install 42-pi n engine harness connect or to wi ri ng
bracket on power brake booster.
A14801-B
Pa r t
1 14536 Wiring Bracket
3

42-Pin Engine Wire Harness
4

Transmission Wire Harness
19. Connect A / C manifold and tube t o A / C
compressor and install bolt retaining A / C
manifold and tube t o RH coil bracket .
20. Install heater wat er hose.
2 1 . Connect fuel lines t o fuel injection suppl y manifold.
22. Install wi ndshi el d wi per mot or mounting bracket
and wi ndshi el d wi per motor. Refer t o Secti on
01- 16.
23. Evacuate and recharge air conditioning syst em.
24. Install cool i ng fan bl ade and fan shroud. Fill and
bl eed cool i ng syst em. Refer t o Secti on 03- 03.
26. Install air cl eaner outlet t ube. Refer t o Secti on
03- 12.
27. Start engine and check for l eaks.
S u p p o r t I n s u l a t o r , Re a r E n g i n e
1.
2.
3.
NOTE: The rear engine support insulator ( 6068)
is l ocat ed at the transmi ssi on extensi on housi ng
( 7A039) .
Support the automati c transmi ssi on wi t h a j ack
and wood bl ock and remove t he t wo nuts
retaining t he rear engine support insulator t o t he
No. 3 crossmember ( 5025) .
Remove the t wo bol ts retaining the rear engine
support insulator t o the aut omat i c transmi ssi on.
Raise t he automati c transmi ssi on wi t h the j ack.
Remove t he rear engine support insulator.
CAUTI ON: Wh e n e v e r s e l f - l o c ki n g mo u n t i n g
b o l t s a n d n u t s a r e r e mo v e d , t h e y mu s t b e
r e p l a c e d w i t h n e w s e l f - l o c ki n g b o l t s a n d n u t s
o r p o s s i b l e d a ma g e o r p e r s o n a l i n j ur y ma y
o c c u r .
retaining bol ts to 77- 103 N-m (57-76 Ib-ft).
Tighten retaining nuts to 26- 34 N-m ( 19- 25 Ib-ft).
A14936-D
Pa r t
1 7000 Automatic Transmission
2 6068 Rear Engine Support
Insulator
3 5025 No. 3 Crossmember
4 N620482-S427 Nut (2 Req'd)
5 387174-S301 Bolt (2 Req'd)
A

Lb-Ft)
B

Tighten to 77-103 N-m (57-76
Lb-Ft)
02 - 03- 6 Engi ne and Tr ansmi ssi on Mount i ng 02 - 03- 6
SPECIFICATIONS
Description L b - Ft
Fr o n t En gi n e Su p p o r t
I n s ul a t o r - t o - E n gi n e Bo l t s
60- 81 44- 60
EGR Va l v e L i n e Nut 35- 45 2 6- 33
Fr o n t En gi n e Su p p o r t I n sul a t o r
T h r o u gh Bo l t s
47 - 63 35- 46
RH Fr o n t En gi n e Su p p o r t
I n s u l a t o r - t o - Su p p o r t Bo l t
47 - 63 35- 46
Fr o n t En gi n e Su p p o r t
I n s u l a t o r - t o - Cr o s s me mb e r Bo l t s
47 - 63 35- 46
( Co n t i n ue d )
EGR Va l v e - t o - l n t a ke Ma n i f o l d 2 0- 30 15-22
He a t e r Wa t e r Ho s e Re t a i n e r s 2 0- 30 15-22
Gr o u n d St r a p Re t a i n i n g Nut 2 0- 30 15- 22
Re a r En gi n e Su p p o r t
I n s u l a t o r - t o - Tr a n s mi s s i o n Bo l t s
7 7 - 103 57 - 7 6
Re a r En gi n e Su p p o r t
I n s u l a t o r - t o - Cr o s s me mb e r Nut s
2 6- 34 19- 25
E x h a u s t Ma n i f o l d Re t a i n i n g Nut s 2 7 - 41 2 0- 30
03- 00- 1
GROUP
ENGINE
7T ~W7.
SECTION TITLE PAGE
AIR INTAKE SYSTEM 03-12-1
DRIVE BELTS, ACCESSORY .03-05-1
ENGINE CONTROLS, ELECTRONIC 03-14-1
ENGINE COOLING . . ......... 03-03-1
ENGINE EMISSION CONTROL. . ..03-08-1
ENGINE, 4.6L . 03-01-1
SECTION TITLE
ENGINE SERVICE 03-00-1
EVAPORATIVE EMISSIONS 03-13-1
FUEL CHARGING AND CONTROLS4. 6L 03-04-1
IGNITION, ELECTRONIC .... . 03-07-1
STARTING SYSTEM 03-06-1
SECTION 03-00 EngineService
SUBJECT PAGE
Engi ne I dent i f i cat i on 03-00-3
Emi ssi on Cal i brat i on Number Label 03-00-3
Vehi cle Cer t i f i cat i on Label 03-00-3
Exhaust Emi ssi on Cont r ol Syst em 03-00-3
I nt r oduct i on ..03-00-2
SERVICE PROCEDURES
Camshaf t a n d / o r Cyl i nder Head
Jour na l s. . 03-00-25
Cl eani ng ....03-00-25
I nspect i on 03-00-25
Camshaf t End Play 03-00-14
Camshaf t Lobe Li f t ..03-00-12
Hydraul i c Valve Ta ppe t . . 03-00-13
Le a kdown Te st i ng. .03-00-13
Camshaf t Runout . 03-00-25
Cam Lobe Li f t ..03-00-25
Cam Lobes 03-00-25
Camshaf t End Play 03-00-26
Camshaf t Journal Oil Cl earance ..03-00-26
Camshaf t Journal s Di amet er 03-00-26
Camshaf t Spr ocket 03-00-26
Compr essi on Test ...03-00-7
Compressi on Gauge Check ..03-00-7
Compressi on Re a di ngsI nt e r pr e t i ng 03-00-8
Exampl e Readi ngs. . . . 03-00-8
Test Result s .... 03-00-7
Connect i ng Rod Bushi ng Inner Di amet er. . . 03-00-25
Connect i ng Rod Bendi ng Cl earance 03-00-25
Connect i ng Rod Side Cl earance .....03-00-14
Connect i ng Rods ..03-00-24
Cl eani ng 03-00-24
Piston Pin Cl earance 03-00-24
Cr ankshaf t ...03-00-19
Cl eani ng 03-00-19
Crankshaf t End Play 03-00-19
SUBJECT PAGE
SERVICE PROCEDURES (Cont ' d. )
Crankshaf t Mai n Journal and Connect i ng
Rod Journal s 03-00-20
Crankshaf t Runout 03-00-19
Crankshaf t Spr ocket 03-00-20
I nspect i on . 03-00-19
Journal s, Ref i ni shi ng 03-00-20
Crankshaf t End Play 03-00-14
Crankshaf t Mai n and Connect i ng Rod
Beari ngs 03-00-18
Cl eani ng 03-00-18
Crankshaf t Mai n or Connect i ng Rod
Be a r i ngsFi t t i ng 03-00-19
Pl ast i gage Met hod 03-00-19
Cyl i nder Bl o c k. 03-00-15
Cleani ng and I nspe c t i on. . . . 03-00-15
Cyl i nder Bl ock Di st or t i on 03-00-15
Sand Holes or Porous Engi ne
Cast i ngsSer vi ce 03-00-15
Cyl i nder Heads 03-00-27
Cl eani ng 03-00-27
Cyli nder Head Fl at ness 03-00-28
Spark Plug Thread Servi ce 03-00-27
Valve Gui de Inner Di amet er 03-00-31
Valve Seat Cont act Wi dt h 03-00-31
Valve Seat Runout 03-00-29
Valve Seat s, Ref aci ng 03-00-30
Valve Spri ng Lengt h I nspect i on 03-00-32
Valve Spri ng Squareness 03-00-32
Valve Spri ng Tensi on 03-00-32
Valve St em Di amet er 03-00-31
Valve Sfem-to-Vai ve Guide Clearance 03-00-29
Valves 03-00-30
Valves, I nspect i on 03-00-30
Valves, Ref aci ng .....03-00-30
Valves, Sel ect Fi t t i ng 03-00-29
Cyl i nder Leakage Det ect or 03-00-8
Cyl i nder Walls, Ref i ni shi ng .03-00-16
Cleani ng 03-00-16
03- 00- 2 E n g i n e S e r v i c e 03- 00- 2
SECTION 03-00 EngineService
SUBJECT PAGE
SERVICE PROCEDURES (Cont' d.)
Cyl i nder Bore 03-00-16
Cyl i nder Bore Taper 03-00-16
Cylinder Out -of -Round 03-00-16
I nspe c t i on. . . 03-00-16
Engine Bl ock Plugs 03-00-17
Cup-Type 03-00-17
Expansion-Type 03-00-18
Engine Oil Consumpti on, Excessi ve 03-00-10
Oil Consumpti on Test . 03-00-10
Oil Pressure Test 03-00-11
Engine Oil Leaks 03-00-6
Fl uorescent Oil Addi t i ve Met hod 03-00-6
Pressure Met hod . 03-00-6
Test i ng Procedure 03-00-6
Exhaust Mani f ol d 03-00-33
Cl eani ng 03-00-33
Fl ywheel I nspect i on 03-00-33
Transmi ssi on, Aut omat i c ...03-00-33
Hydraul i c Valve Tappet s ...03-00-26
Cl eani ng 03-00-26
Valve, Ball Ti pTappet Wear ..03-00-27
I nt ake Mani f ol d. . . . . . . . ...03-00-33
Cl eani ng ...03-00-33
I nt ake Mani f ol d Vacuum Test 03-00-8
Vacuum Gauge
Re a di ngsI nt e r pr e t a t i on 03-00-9
Leakage Poi nt s 03-00-6
Under Engi ne wi t h Vehi cle on Hoi st ....03-00-7
Oil Leak and Valve Gui de Seal Test 03-00-8
Oil Pan 03-00-27
Cl eani ng 03-00-27
Oil Pump 03-00-27
SUBJECT PAGE
SERVICE PROCEDURES (Cont 'd. )
Cl eani ng 03-00-27
Pressure Regul at or Valve I nspect i on 03-00-27
Pi st on Pin 03-00-24
Pi st on Pin Hole Di amet er 03-00-24
Pi st on Pin Di amet er 03-00-24
Pi st ons, Pi st on Pins and Pi st on Rings 03-00-20
Cl eani ng 03-00-20
Pi st on Out er Di amet er 03-00-23
Pi st on Pi n-t o-Pi st on Cl earance 03-00-23
Pi st on Ring End Gap 03-00-23
Pi st on Ri ng-t o-Groove Cl earance 03-00-23
Pi st on Rings 03-00-23
Pi st on Ri ngsFi t t i ng 03-00-22
Pi st on-t o-Cyl i nder Cl earance 03-00-21
Pi st o n sFi t t i n g 03-00-21
Posi t i ve Crankcase Vent i l at i on (PCV) Syst em,
Cl osed-Type 03-00-6
Rocker Arm 03-00-33
Cl eani ng 03-00-33
Servi ce Li mi t Speci f i cat i ons 03-00-15
Valve Trai n Anal y si sDy nami c 03-00-12
Posi t i ve Rot at or and Valve Spri ng Ret ai ner
Ke y s. 03-00-12
Rocker Arm 03-00-12
Valves and Cyl i nder Head .03-00-12
Valve Trai n Ana l y si sSt a t i c (Engi ne
Off) 03-00-12
Rocker Arms and Valve Tappet s, Overhead
Camshaf t 03-00-12
Valve Cover Removed 03-00-12
VEHICLE APPLICATION
Introduction
WARNI NG: TO AVOI D THE POSSI BI LI TY OF
PERSONAL I NJURY OR DAMAGE TO THE
VEHI CLE, DO NOT OPERATE THE ENGI NE WI TH
THE HOOD ( 16612 ) OPEN UNTI L THE FAN BLADE
( 8600) HAS FI RST BEEN EXAMI NED FOR
POSSI BLE CRACKS AND SEPARATI ON.
Thi s secti on covers the fol l owi ng i nformati on:
Vari ous adj ustments.
Servi ce procedures.
Cleaning and inspection procedures.
For engine removal , di sassembl y, assembl y,
installation, adjustment procedures and speci fi cati ons,
refer t o Secti on 03- 01.
The engine i ncorporates:
A cl osed-type posi ti ve crankcase ventilation (PCV)
syst em.
An exhaust emission control syst em.
All engi ne/ emi ssi on control syst ems are covered in
t he Powertrai n Cont rol / Emi ssi ons Diagnosis Manual .
1
To maintain the requi red exhaust emi ssi on levels, the
following components must be kept in good operati ng
condition and meet recommended adjustment
speci fi cati ons:
Engine.
Fuel syst em.
Ignition syst em.
1 P u r c h a s e d s e p a r a t e l y , r e f e r t o t h e e n d of t h i s Se c t i o n f o r v e h i c l e a p p l i c a t i o n s .
03- 00- 3 E n g i n e S e r v i c e 0 3 - 0 0 - 3
When perf ormi ng t est s, adj ustment or servi ce t o t he
engine, syst em or fuel ignition syst em, fol l ow the
procedures and speci fi cati ons in the appropri at e
Secti on in thi s manual and in the Powertrai n
Cont rol / Emi ssi ons Di agnosi s Manual .
2
Make sure that the fol l owi ng component s are not
servi ceabl e before repl aci ng:
Crankshaft ( 6303) .
Cylinder heads ( 6049) .
Valve guides.
Exhaust val ves ( 6505) .
Intake val ve ( 6507) .
Camshafts ( 6250) .
Cylinder bl ock ( 6010) .
E n g i n e I d e n t i f i c a t i o n
Ve h i c l e C e r t i f i c a t i o n L a b e l
For qui ck engine identification, refer t o t he vehicle
certi fi cati on label. The label is mounted on the LH front
door l ock f ace panel . Find the engine code (letter or
number) on the l abel , then refer t o t he engine
identification chart t o determi ne t he engine t ype and
size. An engine identification label is al so at t ached t o
the engine. The symbol code on the identification label
identifies each engine for determining part s usage; for
i nstance, engine di spl acement and model year. Engine
code information is l ocat ed in Secti on 03- 01.
Vehi cl e Ce r t i f i c a t i o n La be l
1FABP43F9S3100001
V E H I C L E I DE N T I FI C A T I ON NUMBER
MFD. BY FORD MOTOR CO. IN U.S.A.
DATE: 5-94 GVWR: 5347 LB - 2425 KG
FRONT GAWR: 2714 LB REAR GAWR: 2663 LB
1231 KG 1216KG
THIS VEHI CLE CONFORMS TO A L L APPLICABLE FEDERAL MOTOR VEHI CLE SAFETY AND
BUMPER STANDARDS IN E FFE CT ON THE DATE OF MANUFACTURE SHOWN ABOVE.
VEH. I 0ENT. NO. 1FABP43F9S3100001
TYPE PASSENGER
ENGINE CODE
(8th CHARACTER)
MODEL
YEAR
A6972-F
Al ways refer to thi s label when:
Repl acement part s are requi red.
Checki ng engine cal i brati ons.
Engine part s often differ within a saf et y certi fi cati on
label family. Verification of identification codes ensures
that t he proper part s are obtai ned. The codes contain
all pertinent information relating t o:
Dat es.
Optional equipment.
Revisions.
The Ford Mast er Part s Cat al og contai ns a compl et e
listing of the codes and their appl i cati on.
E mi s s i o n C a l i b r a t i o n N u mb e r L a b e l
The emission cal i brati on number label is l ocat ed on t he
LH si de door or LH front door ( 20124) post pillar. It
identifies:
Engine.
Revision level.
These numbers are used t o determi ne if part s are
unique t o speci fi c engines.
CALI BRATI ON
ETALONNAGE
C A L I BRA C I ON
A-20F-F 0 0 E9AE- 6E061-ABY
CALIBRATION
REVISION NUMBER
A15276-B
E x h a u s t E m i s s i o n C o n t r o l S y s t e m
The Powertrai n Cont rol / Emi ssi ons Di agnosi s Manual
2
covers the following information on the exhaust
emission control devi ces used on this engine:
Description and Operati on.
Diagnosis and Testi ng.
Refer t o Section 03- 08 or 03- 14 for Removal and
Installation procedures.
DI A G N O S I S A N D T E S T I N G
operating the engine t o dupl i cate t he condi ti on.
2. Inspect to determi ne if any of the fol l owi ng
mechanical concerns appl y:
Mechanical
En gi n e c o o l a n t l e a ks .
En gi n e oi l l e a ks .
Da ma ge d a n d / o r s e v e r e l y wo r n p a r t s .
L o o s e mo un t i n g b o l t s , s t u d s a n d n ut s.
03- 00- 4 Engi neSer v i c e 03- 00- 4
3. If the concerns remain after the i nspecti on,
Chart.
ENGINE DIAGNOSIS
Difficult Starting Malfunctioning starter system.
Malfunctioning charging system /
battery.
Burnt valve.
Worn pi ston.
Worn piston ri ng(s).
Worn cylinder.
Damaged cylinder head gasket.
Malfunctioning or damaged fuel
system.
Malfunctioning or damaged ignition
system.
REFER to Group 14.
REPLACE valve.
REPLACE pi ston.
Replace piston ring(s).
SERVICE or REPLACE cylinder
block.
REPLACE cylinder head gasket.
REFER to the Powertrain
Control/Emi ssi ons Diagnosis
Manual.
3
Manual.
3
Poor Idling Damaged hydraulic valve tappet.
Worn valve stem guide.
Improper valve-to-valve seat
contact.
system.
system.
system.
system.
Leaking intake manifold gasket.
REPLACE hydraulic valve tappet.
REPLACE valve stem guide.
REPLACE valve and / or valve seat.
Manual.
3
Manual.
3
REPLACE intake manifold gasket.
Abnormal Combustion Damaged hydraulic valve tappet.
Worn hydraulic valve guide.
Burnt or sti cki ng valve.
Weak or broken valve spring.
Carbon accumulation in
combustion chamber.
system.
system.
Leaking intake manifold gasket.
REPLACE hydraulic valve tappet.
REPLACE valve stem guide.
SERVICE or REPLACE valve.
REPLACE valve spring.
ELIMINATE carbon buildup.
Manual.
3
Manual.
3
REPLACE intake manifold gasket.
Excessi ve Oil Consumption Worn piston ring groove.
Sticking piston ring(s).
Worn piston or cylinder.
Worn valve stem seal.
Worn valve stem or valve guide.
Leaking oi l.
Plugged or restri cted air intake
system.
REPLACE pi ston.
SERVICE or REPLACE piston
ring(s).
SERVICE and/or REPLACE piston
or cylinder block.
REPLACE valve stem seal.
REPLACE valve stem and guide.
SERVICE oil leakage.
SERVICE or REPLACE air intake
components as required.
3 Purchased separately, refer to the end of this section for vehicle applications.
03- 00- 5 E n g i n e S e r v i c e 03- 00- 5
ENGINE DIAGNOSIS (Cont i nued)
Engine Noise

Excessive main bearing oil

REPLACE crankshaft main Engine Noise
clearance. bearing.

S e i z e d or heat d a m a g e d

REPLACE crankshaft main bearing
crankshaft main beari ng. a nd/ or crankshaft.

Excessive crankshaft end play.

REPLACE crankshaft thrust Excessive crankshaft end play.
washer, crankshaft thrust main
bearing a nd/ or crankshaft.
Excessive connecting rod bearing

REPLACE connecting rod bearing
oil c l e a r a n c e . and/ or connecting rod a nd/ or
crankshaft.

Heat damaged connecting rod

REPLACE connecting rod bearing
bearing. and/ or crankshaft.

Damaged connecting rod bushing.

REPLACE connecting rod bushing.

Worn cylinder.

SERVICE or REPLACE cylinder
block.

Worn piston or piston pin.

REPLACE piston or piston pin.

Damaged piston ri ng(s).

REPLACE piston ring(s).
#
Bent connecting rod.

REPLACE connecting rod.

Malfunctioning hydraulic valve

REPLACE hydraulic valve t appet .
tappet.

Excessive hydraulic valve tappet
#
ADJUST clearance or REPLACE
clearance. hydraulic valve tappet guide.

Broken valve spri ng.


Excessive valve guide clearance.

SERVICE clearance or REPLACE
valve gui de/st em.

Malfunctioning or damaged cooling

REFER to Secti on 03-03.
system.


system. Control/Emi ssi ons Diagnosis
Manual.
4

Leaking exhaust syst em.

SERVICE exhaust leakage.

Improper drive belt tension.


Malfunctioning generator bearing.


Loose timing chain.

ADJUST or REPLACE timing chain.

Damaged timing chain tensioner.

REPLACE timing chain tensioner.

Malfunctioning water pump

bearing.

Malfunctioning or damaged

exhaust gas recirculation (EGR) Control/Emi ssi ons Diagnosis
system. Manual .
4
Insufficient Power

Malfunctioning hydraulic valve o REPLACE hydraulic valve tappet.
tappet.

Damaged hydraulic valve tappet

REPLACE hydraulic valve tappet
guide. guide.
G
Compression leakage at valve

SERVICE or REPLACE valve, valve
seat. seat and/or cylinder head.

Seized valve stem.

REPLACE valve stem.

Weak or broken valve spring.



Cracked or di storted cylinder

REPLACE cylinder head.
head.

Damaged, worn or sti cki ng piston

SERVICE or REPLACE piston
ri ng(s). ring(s).

Worn or damaged pi ston.

REPLACE pi ston.
#

system. Control/Emi ssi ons Diagnosis system.
Manual .
4


system. Control/Emissions Diagnosis
Manual .
4
Slipping transmission.


Dragging brakes.


Incorrect tire size.

Restri cted exhaust system.

4 P u r c h a s e d s e p a r a t e l y , r e f e r t o t h e e n d o f t h i s Se c t i o n f o r v e h i c l e a p p l i c a t i o n s .
03- 00- 6 Engi neSer v i c e 03- 00- 6
SERVICE PROCEDURES
P o s i t i v e Crankcase Ve n t i l a t i o n (PCV)
S y s t e m, Closed-Type
CAUTI ON: The r emoval o f t h e p o s i t i v e cr ankcase
vent i l at i on s y s t em f r om t he engi ne wi l l adver sel y
af f ect t he f uel ec onomy and engi ne vent i l at i on as
wel l as shor t en engi ne l i f e.
A malfunctioning cl osed posi ti ve crankcase ventilation
syst em may be indicated by loping or rough engine
idle. Do not compensat e for this condition by
di sconnecti ng the crankcase ventilation syst em and
maki ng an idle speed adj ustment.
To determi ne whet her the loping or rough idle condition
is caused by a malfunctioning posi ti ve crankcase
ventilation syst em, refer t o the Powertrai n
5
E n g i n e Oi l L e a k s
When diagnosing engine oil l eaks, the source and
location of the leak must be identified prior t o servi ce.
The following procedure is very effecti ve and requi res
a minimum of equipment. Before using thi s procedure,
it is i mportant t o cl ean the cyl i nder bl ock ( 6010) ,
cylinder heads ( 6049) , val ve covers ( 6582) , oil pan
( 6675) and fl ywheel ( 6375) wi th a suitable solvent t o
remove all t r aces of oi l .
For an oil leak di agnosi s using Rotunda Oil Leak
Det ect or 112-R0030 or equivalent, perform the
following procedure.
ROTUNDA OIL LEAK
DETECTOR
112-R0030
A15068-B
Fl u o r e s c e n t Oi l A d d i t i v e Me t h o d
1. Clean engine wi th a suitable solvent t o remove all
t races of oil.
2. Drain engine oil f rom crankcase and refill wi th
recommended oil, premi xed wi t h Fl uorescent Oil
Addi ti ve ESE-M99C103-A or equivalent. Use a
minimum 14.8 ml (112 ounce) t o a maxi mum 29. 6
ml (1 ounce) of fl uorescent addi ti ve t o all engines.
If oil is not premi xed, fl uorescent addi ti ve must
fi rst be added t o crankcase.
3. Run engine for 15 minutes. St op engine and
inspect all seal and gasket areas for l eaks using
Rotunda Oil Leak Detector 112-R0030 or
equivalent. A clear bright yel l ow or orange area
will identify leak. For extremel y small l eaks,
several hours may be requi red for the leak t o
appear.
4. If necessary, pressuri ze main oil gallery syst em
t o l ocate l eaks due t o i mproperl y seal ed, l oose or
cocked plugs. If fl ywheel bol ts leak oil, look for
sealer on t hreads.
5. Servi ce all l eaks as requi red.
P r e s s u r e Me t h o d
The crankcase can be pressuri zed t o l ocate oil l eaks.
The following materi al s are requi red t o fabri cate the
tool t o be used:
Air suppl y and air hose.
Air pressure gauge that regi sters pressure in one
psi i ncrements.
Air line shutoff val ve.
Appropri at e fittings t o at t ach above parts t o oil fill,
crankcase ventilation grommet ( 6A892) and
crankcase ventilation tube ( 6758) .
Appropri at e plugs t o seal any openings leading t o
crankcase.
A solution of liquid detergent and wat er appl i ed wi th
a suitable appl i cator such as a squirt bottl e or
brush.
Fabri cate the air suppl y hose t o include the air line
shutoff val ve and the appropri ate adapter t o permit
the air to enter the engine through the crankcase
ventilation tube. Fabri cate the air pressure gauge t o a
suitable adapt er for installation on the engine at the oil
fill openi ng.
T e s t i n g P r o c e d u r e
1. Open air suppl y val ve until pressure gauge
maintains 34 kPa (5 psi ).
2. Inspect seal ed and/ or gasket ed areas for l eaks
by appl yi ng " Snoop Pressure Check" or a
solution of liquid detergent and wat er over areas
for formati on of bubbl es, whi ch indicates l eakage.
L e a k a g e P o i n t s
Examine the following areas for oil l eakage:
U n d e r h o o d
Valve cover gasket s ( 6584) .
Crankcase ventilation grommet ( 6A892) .
Head gasket s ( 6051) .
Oil bypass filter ( 6714) and oil filter adapter ( 6881) .
Oil filter adapt er gasket ( 6840) .
Oil level indicator tube ( 6754) (di psti ck) connecti on.
Oil pressure sensor ( 9278) .
5 P u r c h a s e d s e p a r a t e l y , r e f e r t o t h e e n d of t h i s s e c t i o n f o r v e h i c l e a p p l i c a t i o n s .
03- 00- 7 E n g i n e S e r v i c e 03- 00- 7
NOTE: Light foami ng equally around val ve cover bol ts
and crankshaf t seal s is not detri mental and no
correct i ons are requi red.
Oil l eaks at cri mped seams in sheet metal part s and
cr acks in cast or st amped par t s can be det ect ed when
pressuri zi ng the cr ankcase.
Side bol ts.
Wi t h T r a n s mi s s i o n a n d Fl y w h e e l R e m o v e d
NOTE: Air l eakage in area around a crankshaf t rear oil
seal does not necessari l y indicate a crankshaf t rear oil
seal l eak. However, if no other cause can be found for
oil l eakage, assume that crankshaf t rear oil seal is
causi ng the oil leak.
Crankshaft rear oil seal .
Crankshaft rear oil seal retainer.
Pipe plugs at the end of oil passages.
Un d e r E n g i n e w i t h Ve h i c l e o n Ho i s t
Oil pan gasket ( 6710) .
Oil pan front and oil pan rear seal s ( 6723) .
Crankshaft front seal ( 6700) .
Crankshaft rear oil seal ( 6701) .
C o m p r e s s i o n T e s t
C o m p r e s s i o n G a u g e C h e c k
1. Make sure oil in crankcase is of the correct
vi scosi ty and at proper level, and bat t ery
( 10653) is properl y charged. Operat e vehi cl e
until engine is at normal operati ng t emperat ure.
Turn ignition swi t ch ( 11572) t o OFF, and remove
all spark plugs ( 12405) .
2. Set throttl e plate in wi de-open posi ti on.
3. Install a compressi on gauge such as Rotunda
Compressi on Tester 059- R0009 or equivalent in
No. 1 cylinder.
4. Install an auxiliary st art er swi t ch in starti ng
ci rcui t. Wi th ignition swi t ch in OFF and using
auxiliary starter swi t ch, crank engine a minimum
of five compressi on st rokes and record hi ghest
readi ng. Note the approxi mat e number of
compressi on st rokes requi red t o obtai n the
highest readi ng.
5. Repeat test on each cylinder, cranki ng t he engine
approxi matel y the same number of compressi on
st rokes.
T e s t Re s u l t s
The i ndi cated compressi on pressures are consi dered
within speci fi cati on if the l owest reading cylinder is
within 75 percent of the highest readi ng. Refer t o t he
Compressi on Pressure Limit Chart.
COMPRESSION PRESSURE LIMIT CHART
Maxi mum
PSI
Mi ni mum
PSI
Maxi mum
PSI
Mi ni mum
PSI
Maxi mum
PSI
Mi ni mum
PSI
Maxi mum
PSI
Mi ni mum
PSI
134 101 164 123 194 145 2 2 4 168
136 102 166 124 196 147 2 2 6 169
138 104 168 126 198 148 2 2 8 171
140 105 170 127 2 00 150 2 30 172
142 107 172 129 2 02 151 2 32 174
144 108 174 131 2 04 153 2 34 175
146 110 176 132 2 06 154 2 36 177
148 111 178 133 2 08 156 2 38 178
150 113 180 135 2 10 157 2 40 180
152 114 182 136 2 12 158 2 42 181
154 115 184 138 2 14 160 2 44 183
156 117 186 140 2 16 162 2 46 184
158 118 188 141 2 18 163 2 48 186
160 120 190 142 2 2 0 165 2 50 187
162 121 192 144 2 2 2 166
03- 00- 8
E n g i n e S e r v i c e 03- 00- 8
S E R VI C E P R O C E DU R E S ( C o n t i n u e d )
If one or more cyl i nders reads low, squirt
approxi mat el y one tabl espoon of clean engine oil
XO-20W50-QR or equivalent meeting Ford
speci fi cati on ESR-M2C179-A on top of the pistons
( 6108) in the low-reading cyl i nders. Repeat
compressi on pressure check on these cyl i nders.
C o m p r e s s i o n R e a d i n g s I n t e r p r e t i n g
1. If compressi on i mproves consi derabl y, piston
rings are faulty.
2. If compressi on does not i mprove, val ves are
sti cki ng or seati ng poorly.
3. If t wo adj acent cyl i nders indicate low
compressi on pressures and squirting oil on
pi stons does not increase compressi on, a head
gasket ( 6051) may be leaking between cyl i nders.
Engine oil and/ or cool ant in cyl i nders coul d result.
Use the Compressi on Pressure Limit Chart when
checki ng cylinder compressi on so that the l owest
reading number is 75 percent of the highest
readi ng.
E x a mp l e Re a d i n g s
If, after checki ng the compressi on pressures in all
cyl i nders, the hi ghest reading was 1351 kPa ( 196 psi)
and t he l owest pressure reading was 1069 kPa ( 155
psi ), the engine is within speci fi cati on and the
compressi on is consi dered sati sfactory.
C y l i n d e r L e a k a g e De t e c t o r
When a cylinder produces a low readi ng, the Rotunda
Pressuri zati on Kit 014- 00705 or equivalent, helps
pinpoint the exact cause.
The l eakage det ect or is inserted in the spark plug
hol e, t he pi ston ( 6108) is brought up t o top dead
center on the compressi on st roke and compressed air
is admi t t ed.
Once t he combusti on chamber is pressuri zed, a
speci al gauge will read the percentage of l eakage.
Leakage exceedi ng 20 percent is excessi ve.
Whi l e the air pressure is retained in the cylinder, listen
for the hiss of escapi ng air. A leak by the intake val ve
( 6507) will be heard in the throttl e body ( 9E926) . A
leak by the exhaust val ve ( 6505) can be heard at the
tail pi pe. Leakage past the rings will be audible at the
posi ti ve crankcase ventilation (PCV) connecti on. If air
is passi ng through a bl own gasket to an adj acent
cylinder, the noise will be evident at the spark plug
hole of the cyl i nder into whi ch the air is leaking.
Cr acks in the cyl i nder bl ock ( 6010) or gasket l eakage
into t he cool i ng syst em may be det ect ed by a st ream
of bubbl es in the radi ator ( 8005) .
ROTUNDA PRESSURIZATION KIT
014-00705
A23313-A
Oi l L e a k a n d Va l v e G u i d e S e a l T e s t
The cylinder l eakage det ect or t est s for engine oil
l eaks and checks the val ve st em seal s ( 6571) for
l eakage.
1. Plug all crankcase openings except the one used
for connecti ng the l eakage det ect or.
2. Connect the det ect or t o a crankcase opening (an
oil level indicator tube ( 6754) is conveni ent).
Adjust the air pressure t o approxi matel y 34 kPa
(5 psi ).
3. Using a solution of liquid soap and water, brush
the solution along the gasket sealing surf aces
and bearing seal s. Look for bubbl es or f oam.
4. Remove the spark plugs ( 12405) and rot at e the
engine sl owl y wi th a wrench. Check for large
amounts of air escapi ng into the cyl i nders as
each exhaust valve ( 6505) and intake val ve
( 6507) opens.
5. The spark plugs on the leaking cyl i nders will
probabl y show deposi ts of burned oil.
I n t a k e Ma n i f o l d V a c u u m T e s t
Bring t he engine t o normal operati ng temperature.
Connect Rotunda Vacuum/ Pressure Tester
059- 00008 or equivalent t o the i ntake manifold
( 9424) . Run the engine at the speci fi ed idle speed.
03- 00- 9 E n g i n e S e r v i c e 03- 00- 9
The vacuum gauge shoul d read bet ween 51- 74 kPa
(15-22 in-Hg) inches depending upon the engine
condition and the altitude at whi ch the t est is
perf ormed. Subtract 4. 0193 kPa (one inch) f rom the
speci fi ed reading for every 304. 8 m ( 1, 000 f t ) of
elevation above sea level.
The readi ng should be quite st eady. If necessary,
adjust t he gauge damper control (where used) if the
needle is fluttering rapidly. Adj ust the damper until the
needle moves easily wi thout excessi ve flutter.
Va c u u m G a u g e R e a d i n g s I n t e r p r e t a t i o n
A careful study of the vacuum gauge readi ng whi l e the
engine is idling will help pinpoint troubl e areas. Al ways
conduct other appropri at e t est s before arriving at a
final di agnosti c deci si on. Vacuum gauge readi ngs,
al though helpful, must be i nterpreted carefully.
Most vacuum gauges have a NORMAL band i ndi cated
on t he gauge f ace.
ROTUNDA VACUUM/PRESSURE TESTER
059-00008
A23314-A
The fol l owi ng are potenti al gauge readi ngs. Some are
normal ; ot hers should be i nvesti gated further.
A23315-A
1. NORMAL READING: Needle bet ween 51 -74 kPa
( 15 and 22 in-Hg) and holding st eady.
2. NORMAL READING DURING RAPID
ACCELERATION AND DECELERATION: When
the engine is rapi dl y accel erat ed (dot t ed needl e),
the needle will drop t o a low (not t o zero) readi ng.
When the throttl e is suddenly rel eased, the
needle will snap back up to a higher than normal
readi ng.
3. NORMAL FOR HIGH-LIFT CAMSHAFT WITH
LARGE OVERLAP: Needle will regi ster as l ow as
51 kPa (15 in-Hg) but will be relatively steady.
Some oscillation is normal .
4. WORN RINGS OR DILUTED OIL: When the
engine is accel erat ed (dotted needle), the needle
drops t o 0 kPa ( 0 in-Hg). Upon decel erati on, the
needle runs slightly above 74 kPa (22 in-Hg).
5. STICKING VALVES: When the needle (dot t ed)
remains steady at a normal vacuum but
occasi onal l y fl i cks (sharp, fast movement) down
and back about 13 kPa (4 in-Hg), one or more
val ves may be sti cki ng.
6. BURNED OR WARPED VALVES: A regular,
evenl y-spaced, downscal e flicking of t he needle
indicates one or more burned or war ped val ves.
Insufficient hydraulic lash adjuster cl earance will
al so cause this reacti on.
7. POOR VALVE SEATING: A small but regular
downscal e flicking can mean one or more val ves
are not seati ng.
03- 00- 10
E n g i n e S e r v i c e 03- 00- 10
8. WORN VALVE GUIDES: When the needle
osci l l ates (swi ngs back and f ort h) over a 13 kPa
(4 in-Hg) range at idle speed, the val ve gui des
coul d be worn. As engine speed i ncreases, the
needle will become st eady if the guides are
responsi bl e.
9. WEAK VALVE SPRINGS: When the needle
oscillation becomes more violent as engine rpm is
i ncreased, weak valve spri ngs ( 6513) are
i ndi cated. The reading at idle coul d be relatively
st eady.
10. LATE VALVE TIMING: A st eady but low reading
coul d be caused by late val ve timing.
11. IGNITION TIMING RETARDING: Retarded ignition
timing will produce a st eady but low readi ng.
12. INSUFFICIENT SPARK PLUG GAP: When plugs
are gapped t oo cl ose, a regular, small pulsation of
the needle can occur.
13. INTAKE LEAK: A low, st eady readi ng can be
caused by an i ntake manifold or throttl e body
mounting flange gasket leak.
14. BLOWN HEAD GASKET: A regular drop of fair
magnitude can be caused by a bl own head
gasket ( 6051) or war ped head-to-bl ock mounting
surf ace.
15. RESTRICTED EXHAUST SYSTEM: When t he
engine is fi rst st art ed and is idled, t he readi ng
may be normal . But, as the engine rpm is
i ncreased, the back-pressure caused by a
cl ogged muffler ( 5230) , ki nked tail pipe or other
concerns will cause t he needle t o sl owl y drop t o
zero. The needle then may sl owl y ri se. Excessi ve
exhaust cl oggi ng will cause the needle t o drop t o
a l ow point even if the engine is only idling.
When vacuum l eaks are i ndi cated, search out and
correct the condi ti on. Excess air leaking into the
syst em will upset the fuel mi xture and cause condi ti ons
such as rough idle, missing on accel erati on or burned
val ves. If the leak exi st s in an accessor y unit, the unit
will not function correct l y. ALWAYS FIX VACUUM
LEAKS.
E n g i n e Oi l C o n s u m p t i o n , E x c e s s i v e
The amount of oil an engine uses will vary wi t h the way
the vehi cl e is driven in addition t o normal
engine-to-engine vari ati on. This is especi al l y true
during the fi rst 16, 100 km( 10, 000 miles) when a new
engine is being broken in or until certai n internal engine
component s become condi ti oned. Vehicles used in
heavy-duty operati on may use more oil. The following
are exampl es of heavy-duty operat i on:
Trailer-towing appl i cati ons.
Severe loading appl i cati ons.
Engines need oil t o l ubri cate t he following internal
component s:
Cylinder bl ock ( 6010) cyl i nder wal l s.
Pi stons ( 6108) and piston rings.
Intake and exhaust valve st ems.
Intake and exhaust val ve gui des.
All internal engine components.
When the pi stons move downwar d, a thin film of oil is
left on the cylinder wal l s. The oil is burned away on t he
firing st roke during combusti on. If an engine burned a
drop of oil during each firing st roke, oil consumpti on
woul d be about one quart for every mile travel ed.
Fortunatel y, modern engines use much less oil than
this exampl e. However, even efficient engines will use
some oil or they woul d quickly wear out. As the vehicle
is operat ed, some oil is al so drawn into the combusti on
chambers past the i ntake and exhaust val ve st em
seal s ( 6571) and burned.
Many different condi ti ons can affect oil consumpti on
rat es. The fol l owi ng is a partial list of these i tems:
Engine size.
Operat or driving habi ts.
Ambi ent t emperat ure.
Quality and vi scosi ty of the oil.
Operati on under varyi ng conditions can frequently be
mi sl eadi ng. A vehi cl e that has been run for several
thousand miles of short tri ps or below-freezing
ambi ent t emperat ures may have consumed a
" nor mal " amount of oil. However, when checki ng the
engine oil level, it may measure up t o the full mark on
t he oil level di psti ck ( 6750) due t o dilution
(condensati on and fuel) in the engine crankcase. The
vehi cl e then might be driven at high speeds on the
hi ghway where the condensati on and fuel boil off. The
next ti me t he engine oil is checked, it may appear that
a quart of oil was used in about 160 km ( 100 miles).
Thi s percei ved 160 km ( 100 miles) per quart oil
consumpti on rate causes customer concern even
though the actual rate was about 2400 km ( 1500
miles) per quart.
Make sure the sel ected engine oil meets the
recommended API performance cat egory " S G" and
SAE vi scosi ty grade as shown in the vehicle Owner
Guide. Engine oil must be changed at the intervals
speci fi ed for the typi cal operati ng conditions. Refer t o
Secti on 00- 03.
Oi l C o n s u m p t i o n T e s t
The following di agnosti c procedure is used t o
determi ne the source of excessi ve internal oil
consumpti on:
1. NOTE: Oil use is normally greater during the fi rst
16, 100 km ( 10, 000 miles) of servi ce. As mileage
i ncreases, oil usage generally decreases. The
average vehi cl e should get at least 1450 km ( 900
miles) per quart after 16, 100 km ( 10, 000 miles)
of servi ce. High speed dri vi ng, towi ng, high
ambient temperature and similar f act ors may
result in greater oil use.
Define excessi ve oil consumpti on, such as, how
many miles are driven per quart of oil, the owner' s
driving habi ts, sustai ned high speed operati on,
t owi ng, ext ended idle and other consi derati ons.
03- 00- 11 Engi neSer vi ce
SERVICE PROCEDURES ( C o n t i n u e d )
0 3 - 0 0 - 1 1
2. Verify engine has no external oil leak as outlined
under Engine Oil Leaks.
3. Verify engine has correct engine oil level di psti ck.
4. Verify that the engine is NOT being run in an
overfilled condi ti on. Check the oil level at least
five minutes after a hot shutdown wi t h the vehi cl e
parked on a level surf ace. The level should never
be above t he top of cross-hat ch area and " F " in
FULL. If significantly overfi l l ed, perform St eps 5a
through 5d.
5. Perform an oil consumpti on t est :
a. Drain engine oil, remove oil bypass filter
( 6714) and refill wi t h one quart less than the
recommended oil.
b. Run t he engine for t hree minutes ( 10 minutes
if col d), then allow oil t o drai n for at least five
minutes wi th vehi cl e on level surface.
c. Remove engine oil level di psti ck and wi pe
cl ean. (Do not wi pe wi th anythi ng
contami nated wi th silicone compounds.)
Reinstall oil level di psti ck and seat the oil
level di psti ck firmly in t he oil level indicator
tube ( 6754) . Remove t he oil level di psti ck
and dr aw a mark on the back (unmarked)
surf ace at the indicated oil level. (This level
shoul d be about t he same as the ADD mark
on the f ace of the oil level di psti ck.)
d. Add one quart of oi l . Restart the engine and
al l ow t o idle for at l east t wo minutes. Shut off
t he engine and allow oil t o drain back for at
l east fi ve minutes. Mark t he oil level di psti ck
using t he procedure above. (Thi s level may
range f rom slightly bel ow t he t op of t he
cross-hat ched area t o slightly bel ow the
l e t t e r " F" i n FUL L )
e. Record vehi cl e' s mi l eage.
f. Instruct the owner t o dri ve the vehicle as
usual and:
(1) Check the oil level regularly at intervals
of 160-240 km ( 100 t o 150 miles).
(2) Return t o the servi ce point when the oil
level drops bel ow t he l ower (ADD)
mark on the oil level di psti ck.
(3) Add only full quart s of the same oil and
note t he mileage at whi ch the oil is
added in an emergency.
g. Check t he oil level under the same condi ti ons
and at t he same l ocati on as in St eps c and d.
(1) Measure the di stance f rom t he oil level
t o the UPPER mark on t he oil level
di psti ck and r ecor d.
(2) Measure the di stance between the t wo
marks and r ecor d.
(3) Divide the fi rst measurement by the
second.
( 4) Di vi de the di st ance dri ven during t he oil
t est by the result. Thi s quanti ty i s the
approxi mat e oil consumpti on rat e in
ki l ometers per liter (KPL) or miles per
quart (MPQ).
h. If t he oil consumpti on rate is unacceptabl e,
go t o St ep 6.
6. Check PCV syst em. Make sure syst em is not
pl ugged.
7. Check for pl ugged oil drai n-back hol es in cyl i nder
heads ( 6049) and cyl i nder bl ock.
8. If the condi ti on still exi sts after performi ng the
above t est s, go t o St ep 9.
9. Perform a cyl i nder compressi on test as outlined,
and/ or perf orm a Cylinder Leak Detecti on Test
wi th Rotunda Pressuri zati on Kit 014- 00705 or
equivalent. Thi s can help t o determi ne the source
of oil consumpti on, such as val ves, pi ston rings or
other areas.
10. NOTE: If it is determi ned t hat part s should be
repl aced, make sure t o use correct repl acement
parts.
Check valve gui des for excessi ve guide
cl earance. Repl ace all val ve st em seal s after
verifying val ve guide cl earance.
11. Worn or damaged internal engine components
can cause excessi ve oil consumpti on. Small
deposi ts of oil on tip of spark plugs ( 12405) can
be a clue t o internal oil consumpti on. If internal oil
consumpti on still persi sts, proceed as fol l ows:
a. Remove engine f rom vehi cl e and pl ace it on
an engine wor k st and. Remove i ntake
manifolds ( 9424) , cylinder heads , oil pan
( 6675) and oil pump ( 6600) . Refer t o Secti on
03- 01.
b. Check pi ston ring cl earance, ring gap and
ring ori entati on. Servi ce as requi red.
c. Check for excessi ve bearing cl earance.
Servi ce as requi red.
12. Perform Oil Consumption Test as outlined t o
confirm oil consumpti on concern has been
resol ved.
Oi l P r e s s u r e T e s t
De s c r i p t i o n T o o l N u mb e r
En gi n e Oi l P r e s s u r e Ga u ge T 7 3L - 6600- A
1. Di sconnect and remove the oil pressure sensor
( 9278) f rom the engine.
2. Connect an Engine Oil Pressure Gauge
T73L-6600-A and Transmission Test Adapt er
D87C-77000-A or equivalent, t o the oil pressure
sender oil galley port.
3. Run the engine until normal operati ng temperature
is reached.
03- 00- 12 E n g i n e S e r v i c e 03- 00- 12
4. Run the engine at 3, 000 rpm and record the
gauge readi ng.
5. The oil pressure should be:
138-310 kPa (20-45 psi) at 3, 000 rpm.
6. If the pressure is not within speci fi cati on, check
the following possi bl e sources:
a. Insufficient oil.
b. Oil l eakage.
c. Worn or damaged oil pump.
d. Oil pump screen cover and tube ( 6622) .
e. Excessi ve main bearing cl earance.
f. Excessi ve connecti ng rod beari ng
cl earance.
Va l v e T r a i n A n a l y s i s S t a t i c ( E n g i n e Of f )
Va l v e C o v e r R e m o v e d
NOTE: Refer t o Secti on 03- 01 for the Removal and
Installation of the val ve cover ( 6582) .
Check for damaged and/ or severel y worn part s, and
correct assembl y. Make sure correct part s are used
by performi ng t he stati c engine anal ysi s.
Ro c k e r A r m s a n d Va l v e T a p p e t s , Ov e r h e a d
C a ms h a f t
Check for l oose mounting bol ts, studs and nuts.
Check for pl ugged oil f eed in t he fol l owers or
cylinder head ( 6049) .
C a m s h a f t O v e r h e a d C a ms h a f t E n g i n e s
Check for broken or damaged part s.
Va l v e S p r i n g s
Check for broken or damaged part s.
Va l v e S p r i n g Re t a i n e r a n d Va l v e S p r i n g
Re t a i n e r K e y s
Check for proper seati ng of val ve spri ng retainer keys
( 6518) on val ve st em and in val ve spri ng retainer
( 6514) .
P o s i t i v e Ro t a t o r a n d K e y s
Check for proper seati ng in the posi ti ve rotator and on
val ve st em.
Va l v e s a n d C y l i n d e r He a d
Check the head gasket ( 6051) for proper
installation.
Check for pl ugged oil drain back hol es.
Check for worn or damaged val ve ti ps.
Check for missing or damaged guide-mounted val ve
st em seal ( 6571) .
Check col l apsed val ve t appet gap.
Check installed val ve spri ng ( 6513) height.
Stati c checks (engine off) are t o be made on t he
engine prior t o the dynami c procedure.
Va l v e T r a i n A n a l y s i s D y n a m i c
Start the engine and, while running at idle, check for
proper operati on of all part s. Check the fol l owi ng.
Ro c k e r A r m
Loose mounting bol ts, studs and nuts.
Plugged oil f eed in the fol l owers or cylinder head
( 6049) .
P o s i t i v e Ro t a t o r a n d Va l v e S p r i n g Re t a i n e r
K e y s
Check for proper seati ng in t he posi ti ve rotator and on
val ve st em.
Va l v e s a n d Cy l i n d e r He a d
Check for:
Plugged oil drain back hol es.
Missing or damaged valve st em seal s ( 6571) .
Plugged oil metering hole in cylinder head oil
reservoir.
If insufficient oiling is suspect ed, check for bl ocked oil
passages and accel erate the engine to 1200 rpm wi th
t he transmi ssi on in NEUTRAL and the engine at normal
operati ng temperature. Oil should spurt f rom the
rocker arm oil holes so that val ve ti ps and rocker arms
( 6564) are well-oiled. Wi th the val ve cover ( 6582) off,
some oil spl ash may overshoot rocker arms.
C a m s h a f t L o b e L i f t
Check the lift of each lobe in consecuti ve order and
make a note of the readi ngs.
1. Remove val ve covers ( 6582) .
2. Remove rocker arms ( 6564) .
3. Make sure val ve t appet ( 6500) is seat ed. Install
Dial Indicator wi th Bracket ry TOOL-4201-C or
equivalent so that the Cup Shaped Adapter
TOOL-6565-AB or equivalent of indicator is on
t op of val ve t appet and on the same plane as
val ve t appet .
4. Remove spark plugs ( 12405) .
5. Connect an auxiliary st art er swi t ch in starti ng
circuit. Crank engine wi th ignition swi t ch ( 11572)
in OFF posi ti on. Bump crankshaft ( 6303) over
until val ve t appet is on base circle of camshaft
l obe. At thi s point, the val ve t appet will be in its
l owest posi ti on. If checki ng during engine
assembl y, turn crankshaft using a socket and
ratchet.
6. Zero the dial indicator. Continue t o rotate
crankshaft sl owl y until val ve t appet is in
fully-raised position (hi ghest indicator readi ng).
Se r v i c e 0 3 - 0 0 - 1 3 03- 00- 13 Engi ne'
7. NOTE: If lift on any lobe is bel ow speci fi ed servi ce
limits, camshaft ( 6250) and val ve t appet
operati ng on worn l obes must be repl aced, as
wel l as any valve t appet showi ng pitting or a worn
or concave contact f ace. Refer t o i nspecti on of
camshaf t and hydraulic val ve t appet .
Compare total lift recorded on i ndi cator wi t h
speci fi cati ons. (Refer t o Secti on 03- 01. )
8. To check accuracy of original i ndi cator readi ng,
continue t o rotate crankshaf t until i ndi cator reads
zero.
9. Remove dial indicator, adapter and auxi l i ary
st art er swi t ch.
10. CAUTI ON: A f t e r i n s t a l l i n g r o c ke r a r ms , d o
n o t r o t a t e c r a n ks h a f t un t i l v a l v e t a p p e t s
h a v e h a d s u f f i c i e n t t i me t o b l e e d d o w n .
Ot h e r wi s e s e r i o u s v a l v e d a ma g e ma y r e sul t .
Ma n ua l l y b l e e d i n g d o w n wi l l r e d u c e wa i t i n g
t i me .
Install rocker arms.
11. Install val ve covers.
12. Install spark plugs.
Hy d r a u l i c Va l v e T a p p e t
Hydraul i c val ve t appet noise may be caused by any of
t he fol l owi ng:
1. Excessi ve col l apsed val ve t appet gap.
2. Sti cki ng val ve t appet plunger.
3. Val ve t appet check val ve not functioning
properl y.
4. Air in lubrication syst em.
5. Leakdown rate too rapi d.
6. Excessi ve val ve gui de wear.
Excessi ve col l apsed val ve t appet gap may be caused
by a worn val ve t appet , roller val ve t appet s or val ve
ti p. Wi t h val ve t appet col l apsed, check gap between
val ve ti p and fol l ower t o determi ne if any other valve
trai n part s are damaged, worn or out of adj ustment.
A sti cki ng val ve t appet plunger may be caused by dirt,
chi ps or varni sh inside the val ve tappet. Correct the
sti cki ng by repl aci ng wi t h a new valve tappet.
Air bubbl es in the lubrication syst em will prevent the
val ve t appet f rom supporti ng t he val ve spring ( 6513)
l oad and may be caused by t oo high or low an oil level
in the oil pan ( 6675) . It may al so be caused by air
drawn into t he syst em through a hole, crack or leaking
gasket on the oil pump screen cover and tube ( 6622) .
If t he l eak-down ti me is bel ow t he speci fi ed time for
used val ve t appet s, noisy operati on may result. If no
other cause for noisy val ve t appet s can be found, the
l eak-down rat e shoul d be checked and any val ve
t appet s outsi de the speci fi cati on should be repl aced.
Assembl ed val ve t appet s can be t est ed wi t h Hydraulic
Tappet Leakdown Tester TOOL-6500-E or equivalent
t o check t he l eak-down rat e. The l eak-down rate
speci fi cati on is t he ti me in seconds for the plunger t o
move a speci fi ed di st ance of its travel while under a
22. 7 kg ( 50 lb) l oad. Test the val ve t appet s as fol l ows.
L e a k d o w n T e s t i n g
1. NOTE: Do not mix parts f r om di fferent val ve
t appet s. Parts are sel ect-fi tted and are not
i nterchangeabl e.
Pl ace val ve t appet in t est er wi t h plunger faci ng
upward. Pour hydraul i c t est er fluid into cup t o a
level that will cover val ve t appet . The fluid can be
purchased f rom manufacturer of tester. Using
kerosene or any other fluid will not provi de an
accurat e test.
2. NOTE: Valve t appet s cannot be checked wi t h
engine oil in t hem. Only testi ng fluid can be used.
Pl ace a 7. 94 mm ( 5 / 16-inch) steel ball provi ded
wi th tester in plunger cap.
HYDRAULIC TAPPET
3. Adjust length of ram so t hat pointer is 1.59 mm
(1 / 16 inch) bel ow starti ng mark when ram
cont ract s val ve t appet plunger t o faci l i tate timing
as pointer passes St art Timing mark.
HYDRAULIC TAPPET
LEAKDOWN TESTER
TOOL-6500-E
Use center mark on pointer scal e as Stop Timing
point i nstead of original Stop Timing mark at t op
of scal e.
Work val ve t appet plunger up and down until
valve t appet fills wi t h fluid and all t races of air
bubbles have di sappeared.
03- 00- 14 E n g i n e S e r v i c e 03- 00- 14
5. Al l ow ram and wei ght t o f orce val ve t appet
plunger downwar d. Measure exact time it t akes
for pointer t o travel f rom Start Timing t o Stop
Timing marks of tester.
6. A sat i sf act ory valve t appet must have a
l eakdown rate (time in seconds) within minimum
and maximum limits.
7. If val ve t appet is not within speci fi cati on, repl ace
it wi th a new val ve t appet . Do not di sassembl e
and clean new val ve t appet s before testi ng
because oil contai ned in new val ve t appet s is t est
fluid.
8. Remove fluid f rom cup and bleed fluid from val ve
t appet by worki ng plunger up and down. Thi s st ep
will aid in depressi ng val ve t appet plungers when
checki ng val ve cl earance.
C a m s h a f t E n d P l a y
1. CAUTI ON: P r y i n g a ga i n s t t h e c a ms h a f t
s p r o c k e t ( 62 56) wi t h t h e v a l v e t r a i n l o a d o n
t h e c a ms h a f t s p r o c k e t c a n b r e a k o r d a ma g e
t h e c a ms h a f t ( 62 50) .
NOTE: Dial indicator may al so be installed on rear
of engine wi t h indicator point pl aced on flat area
of camshaft end.
Push camshaf t t owar d rear of engine. Install Dial
Indicator wi th Bracket ry TOOL-4201-C or
equivalent so indicator point is on camshaft
sprocket bolt.
2. Zero the dial indicator. Pull camshaft f orward and
rel ease it. Compare dial i ndi cator reading wi t h
speci fi cati ons. If end pl ay is t oo ti ght, check for
binding or forei gn materi al in camshaf t thrust
beari ng. If end play is excessi ve, check for worn
camshaf t thrust plate ( 6269) and repl ace
cylinder head ( 6049) as requi red.
3. Remove dial indicator.
C r a n k s h a f t E n d P l a y
1. Force crankshaft ( 6303) t owar d rear of engine.
2. Install Dial Indicator wi th Bracket ry TOOL-4201-C
or equivalent so cont act point rest s agai nst
crankshaf t flange and indicator axi s is parallel t o
crankshaf t axi s.
INDICATOR
STYLUS AGAINST
AND PARALLEL
TO CRANKSHAFT
PRY CRANKSHAFT
REARWARD, ZERO
INDICATOR AND
THEN PRY FORWARD A5848-C
3. Zero t he dial indicator. Push crankshaft f orward
and note reading on di al .
4. If the end play exceeds the wear limit listed in
Secti on 03- 01, repl ace the lower crankshaft
thrust main bearing ( 6337) . Inspect t he
crankshaft for damage t o the thrust f ace before
installing the new beari ng. If the end play is less
than the minimum limit, inspect t he thrust bearing
f aces for scrat ches, burrs, ni cks or dirt. If t he
thrust f aces are not damaged or di rty, they
probabl y were not aligned properl y. Lubri cate
and install the l ower crankshaft t hr ust main
bearing and crankshaft thrust washer ( 6334) ,
align the f aces following Crankshaft Main Bearing
procedure in Secti on 03- 01.
C o n n e c t i n g R o d S i d e C l e a r a n c e
1. Install Dial Indicator wi th Bracket ry TOOL-4201 -C
or equivalent so that the contact poi nts rest s
against the connecting rod cap.
2. Pull connecti ng rod cap t oward front of engine
and zero the dial indicator.
3. Push the cap t owar d rear of engine and observe
amount of side cl earance on dial indicator.
4. If side cl earance exceeds speci fi cati on, repl ace
connecti ng rod ( 6200) and cap. Refer t o Secti on
03-01 for speci fi cati ons.
03- 00- 15
E n g i n e S e r v i c e
03- 00- 15
5. If si de cl earance is l ess than speci fi cati on,
remove connecti ng rod and cap and i nspect for
scr at ches, burrs, ni cks or dirt bet ween
crankshaf t ( 6303) and connecti ng rod.
S e r v i c e L i mi t S p e c i f i c a t i o n s
Servi ce limit speci fi cati ons are only a guide t o use
when overhauling or reconditioning an engine or engine
component. The speci fi cati ons can help determi ne
whet her a component should be repl aced while the
engine is di sassembl ed.
C y l i n d e r B l o c k
Cl e a n i n g a n d I n s p e c t i o n
If the engine is di sassembl ed, thoroughl y cl ean the
cyl i nder bl ock ( 6010) wi t h solvent. Remove old gasket
materi al f rom all machi ned surfaces. Remove all plugs
that seal oil passages and clean out all t he passages.
Bl ow out all passages, bolt holes and other openings
wi th compr essed air. Ensure t hreads in t he cylinder
head bolt holes are cl ean. Dirt in the t hreads may
cause binding and result in a fal se t orque readi ng. Use
a tap t o true-up t hreads and t o remove all deposi ts.
Thoroughl y cl ean the grooves in t he crankshaf t
beari ngs and bearing retai ners.
Check all machi ned surfaces for burrs, ni cks,
scr at ches and scor es. Remove minor i mperfecti ons
wi t h an oil stone.
Repl ace all plugs that show evi dence of l eakage.
Inspect t he cylinder wal l s for scori ng, roughness or
other si gns of wear.
C y l i n d e r B l o c k Di s t o r t i o n
Check the cylinder bl ock ( 6010) for fl atness of t he
head gasket surface following the procedure and
speci fi cati ons recommended for the cylinder bl ock.
The cyl i nder bl ock can be machined t o bring the head
gasket surf ace within t he fl atness speci fi cati ons listed
in Secti on 03- 01, but not t o exceed 0. 254 mm ( 0. 010
inch) st ock removal f rom the original head gasket
surf ace.
S a n d Ho l e s o r P o r o u s E n gi n e
C a s t i n g s S e r v i c e
Ca st I r o n
Porosi ty or sand hol es, whi ch will cause oil seepage or
l eakage, can occur wi t h modern casti ng processes.
Make a compl et e inspection of engine and
transmi ssi on. If t he l eak is caused by a porous cylinder
bl ock or sand hol es, servi ce wi th an epoxy sealer
meeti ng Ford speci fi cati on M3D35-A(E). Do not
servi ce cr acks wi th thi s materi al . Servi ce wi th thi s
metallic pl asti c must be confined t o cast iron engine
component surf aces where the inner wal l surface is
not exposed t o engine cool ant pressure or oil
pressure. For exampl e:
a. Surf aces of cyl i nder bl ock extendi ng al ong the
l ength of the cyl i nder bl ock, upwar d f r om t he oil
pan rail t o the cyl i nder wat er j acket but not
including machi ned ar eas.
b. Lower rear f ace of t he cyl i nder bl ock.
The fol l owi ng procedure shoul d be used t o servi ce
porous areas or sand hol es in cast i ron:
/
FRONT OF ENGINE
f A23532-A
1. Clean surface t o be servi ced by grinding or
rotary-filing t o a cl ean, bright metal surf ace.
Chamfer or undercut hole or porosi ty t o a great er
dept h than rest of cl eaned surface. Sol i d metal
must surround hole. Openi ngs larger than 6. 35
mm (11A inch) should not be servi ced using an
epoxy seal er meeting Ford speci fi cati on
M3D35-A(E). Openings in excess of 6. 35 mm
( 1 / 4 inch) can be drilled, t apped and pl ugged
using common tool s. Clean servi ce ar ea
thoroughl y. An Epoxy sealer meeting Ford
speci fi cati on M3D35A( E) will not st i ck t o a di rty
or oily surface.
2. Mi x an epoxy sealer meeting Ford speci fi cati on
M3D35-A(E) base and hardener as di rect ed on
container. Stir thoroughl y until uniform.
3. Appl y an epoxy seal er meeting Ford speci fi cati on
M3D35-A(E) wi th a suitable clean tool (such as
putty knife or wood spoon), forci ng epoxy into
hole or porosi ty.
4. Al l ow servi ce mi xture to harden. Two met hods
can be used. Heat-cure wi t h a 250-wat t lamp (as
per direction on contai ner) pl aced 254 mm ( 10
inches) from servi ced surface, or ai r-dry for
10-12 hours at temperatures above 10C
( 50F) .
5. Sand or grind servi ced ar ea t o blend wi th general
contour of surrounding surface.
6. Paint the surface t o mat ch t he rest of the cyl i nder
bl ock.
03- 00- 16 E n g i n e S e r v i c e 03-00-16
C y l i n d e r Wa l l s , R e f i n i s h i n g
CAUTI ON: If t h e s e p r o c e d u r e s a r e n o t f o l l o w e d ,
r u s t i n g o f t h e c y l i n d e r b o r e s ma y o c c u r .
Cl e a n i n g
After any cylinder bore servi ce operati on, such as
honing or degl azi ng, clean the bores wi th soap or
detergent and water. Then thoroughl y rinse the bores
wi t h cl ean wat er t o remove the soap or detergent and
wi pe the bores dry wi th a cl ean, lint-free cl ot h. Finally,
wi pe the bores wi th a clean cl oth di pped in clean
engine oil XO-10W30-QSP or -DSP or equivalent
meeting Ford speci fi cati on ESE-M2C153-E.
I n s p e c t i o n
After the cylinder bl ock ( 6010) has been thoroughl y
cl eaned, check it for cr acks. Invisible cr acks may be
det ect ed by coati ng the suspect ed area wi t h a mi xture
of 25 percent kerosene and 75 percent light engine oi l .
Wi pe the part dry and immediately appl y a coati ng of
zinc oxi de di ssol ved in wood al cohol . Do not use
rubbing al cohol as a substi tute. If cr acks are present,
the coati ng will become di scol ored at the damaged
area. Repl ace the cylinder bl ock if it is cr acked.
Cy l i n d e r Bo r e
Measure the bore wi t h a bore gauge following the
instructions of the manufacturer.
Cy l i n d e r Bo r e T a p e r
Measure the cylinder bores at points A and C as
shown:
CYLINDER
BORE TAPER
CYLINDER WALLS
A14471-A
If the di fference bet ween measurements A and C
exceeds t he maxi mum taper value as speci fi ed in
Secti on 03- 01 rebore the cylinder t o oversi ze.
C y l i n d e r Ou t - o f - Ro u n d
Measure the cylinder boxes in the di recti ons as
shown:
CYLINDER BLOCK
6010
O <Z> ^ Q
(7
CYLINDER,
BORE
[/
h
A
W
V
\ \
\ \
/)
/
/ /
V
A23317-A
If the di fference between measurements exceeds t he
maxi mum out-of-round value as speci fi ed in Section
03- 01 under Speci fi cati ons, rebore the cylinder t o
oversi ze.
C y l i n d e r Bo r e Di a me t e r
Measure the di ameter of each cylinder bore at the t op,
middle and bot t om wi th the gauge pl aced at right
angl es and parallel t o the centerline of the engine. Use
only the measurements obtai ned at 90 degrees t o the
engine centerline when calculating the
piston-to-cylinder bore cl earance.
C y l i n d e r Wa l l H o n i n g
Descr i pt i on Tool Number
En gi n e Cy l i n d e r Ho n e Se t T 7 3L - 6011- A
Honing is recommended only for refinishing cylinder
wal l s when no cross-hat ch pattern is visible on
cylinder wal l s, or for fitting pistons ( 6108) t o the
speci fi ed cl earance. The grade of hone is determi ned
by the amount of metal t o be removed. Fol l ow the
instructions of t he hone manufacturer. If coarse stones
are used t o st art the honing operati on, leave enough
materi al so that all hone marks can be removed wi th
the finishing hone t o obtain the proper piston
cl earance. After honing, thoroughl y cl ean cylinder
bores wi th a detergent and wat er solution.
03- 00- 17 E n g i n e S e r v i c e 0 3 - 0 0 - 1 7
NOTE: Only experi enced techni ci ans should be
al l owed t o perf orm this work.
NOTE: Before any cylinder is refinished, all main
beari ng caps must be in pl ace and ti ghtened t o the
proper torque so t hat the crankshaf t beari ng bores will
not become di st ort ed f rom the refinishing operati on.
Cylinder wal l s that are severel y marred and/ or worn
beyond the speci fi ed limits should be refinished. Hone
only the cylinder or cyl i nders that require refinishing.
All pistons are the same wei ght, bot h standard and
oversi ze; t heref ore, vari ous si zes of pi stons can be
used wi thout upsetting engine bal ance. Refinish the
cyl i nder wi th t he most wear fi rst t o determi ne t he
maxi mum oversi ze. If the cylinder will not clean up
when refinished for the maxi mum oversi ze piston
recommended, repl ace the cyl i nder bl ock.
Refinish the cylinder to within approxi mat el y 0. 038
mm ( 0. 0015 inch) of the requi red oversi ze diameter.
Thi s will al l ow enough st ock for the final st ep of honing
t o obtai n t he correct surface finish and pattern. For t he
proper use of the refinishing equi pment, fol l ow t he
manufacturer' s instructions.
Using a motor-dri ven, spring pressure-t ype Engine
Cylinder Hone Set T73L-6011-A, hone at a speed of
300- 500 rpm. Hones of grit si zes 180-220 will
normally provi de t he desi red bore surf ace finish of
18-38 AA.
CAUTI ON: A f t e r t h e f i n a l o p e r a t i o n i n e i t he r o f t h e
t w o r e f i n i s h i n g me t h o d s d e s c r i b e d a n d pr i o r t o
c h e c k i n g t h e p i s t o n f i t , t h o r o u g h l y c l e a n wi t h a
d e t e r g e n t a n d wa t e r s o l u t i o n a n d t h e n oi l t h e
c y l i n d e r wa l l s o r r u s t i n g o f c y l i n d e r b o r e s ma y
o c c u r .
When honing the cylinder bores, use a lubricant
mi xture of equal part s of kerosene and cl ean engine oil
XO-10W30-QSP or -DSP or equivalent meeting Ford
speci fi cati on ESE-M2C153-E. Operat e t he hone t o
produce a cross-hat ch finish on t he cyl i nder bore. The
cross-hat ch pattern should be at an angle of
approxi mat el y 30 degrees t o t he cyl i nder bore. Mark
t he pi stons t o correspond to t he cyl i nders in whi ch
t hey are t o be installed. When the refinishing of the
appropri at e cyl i nders has been compl et ed and all
pi stons are f i t t ed, thoroughl y cl ean t he entire cylinder
bl ock and oil the cylinder wal l s.
Refinish cyl i nders that are deepl y scor ed,
out-of-round, and/ or if taper exceeds speci fi cati on. If
t he cylinder wal l s have minor surf ace i mperfecti ons,
but the out-of-round and taper are within limits, t ry t o
remove the i mperfecti ons by honing the cylinder wal l s
and installing new servi ce piston rings if t he piston
cl earance is within speci fi cati on. For Speci fi cati ons,
CENTER LINE OF ENGINE
/
V
A
AT RIGHT ANGLE
TO
CENTER LINE OF
ENGINE
B
PARALLEL
TO CENTER LINE
OF ENGINE
k
i
1. OUT-OF-ROUND = DIFFERENCE
BETWEEN A AND B
2. TAPER = DIFFERENCE BETWEEN THE A
MEASUREMENT AT TOP OF CYLINDER
BORE AND THE A MEASUREMENT AT
BOTTOM OF CYLINDER BORE.
M m Q
E n g i n e B l o c k P l u g s
De s c r i p t i o n T o o l N u m b e r
I mp a c t Sl i d e Ha mme r T 59L - 100- B o r
T50T- 100- A
To remove a large core plug, drill a 12. 70 mm
( 1 / 2-inch) hole in the center of the plug and remove
wi t h an Impact Slide Hammer T59L-100-B or
T50T-100-A or pry it out wi th a l arge drift punch. On a
small core pl ug, drill a 6. 35 mm (1 / 4-inch) hole in t he
center of the plug and pry it out wi t h a small pin punch.
Clean and inspect t he plug bore.
Prior t o installing a core plug, the plug bore should be
i nspected for any damage that woul d interfere wi t h t he
proper sealing of the pl ug. If the bore is damaged, t rue
t he surface by boring for the next speci fi ed oversi ze
pl ug.
Oversi ze plugs are identified by the OS st amped in t he
fl at l ocated on the cup si de of the pl ug.
Coat the plug and/ or bore lightly wi th an oil-resistant
(oil galley) Stud and Bearing Mount E0AZ- 19554- BA
WSK- M2G349- A1 or Threadl ock 262 E2FZ- 19554- B
WSK-M2G351-A6 and install it following the
procedure for cup-type or expansi on-type bel ow.
C u p - T y p e
Cup-type core plugs are installed wi t h the fl anged
edge out ward. The maximum di ameter is l ocated at
t he outer edge of the flange. The flange on cup-type
plugs flares out ward wi th the largest di ameter of t he
outer (sealing) edge.
03- 00- 18 E n g i n e S e r v i c e 03- 00- 18
CAUTI ON; It i s i mp o r t a n t t o push o r d r i v e t he pl ug
i nt o t he machi ned bor e b y usi ng a pr oper l y
d e s i g n e d tool. Do not dr i ve t h e pl u g i nt o t he bor e
u s i n g a t o o l t h a t c o n t a c t s t h e f l a n ge . Thi s wi l l
d a ma g e t h e s e a l i n g e d g e a n d r e sul t i n l e a ka ge
a n d / o r p l u g b l o wo u t .
NOTE: If the core plug replacing tool has a dept h
seati ng surf ace, do not seat the tool against a
non-machined (casti ng) surface.
When installed, the fl anged (trailing) edge must be
bel ow the chamfered edge of the bore t o effecti vel y
seal the pl ugged bore.
SEALING
EDGE
BEFORE
INSTALLATION
CUP TYPE
PLUG
CUP TYPE CORE
PLUG REPLACER
TOOL
A23318-A
E x p a n s i o n - T y p e
Expansi on-type core plugs are installed wi t h the fl ange
edge i nward. The maxi mum di ameter of thi s plug is
l ocat ed at the base of the flange wi th the flange flaring
i nward.
CAUTI ON: It i s i mp e r a t i v e t o p u s h o r d r i v e t h e
p l u g i n f o t h e ma c h i n e d b o r e u s i n g a p r o p e r l y
d e s i g n e d f o o l . Do n o t d r i v e t h e pl u g u s i n g a f o o l
t h a t c o n t a c t s t h e c r o w n e d p o r t i o n o f t h e p l u g.
Th i s wi l l e x p a n d t h e pl u g pr i o r t o i n s t a l l a t i o n a n d
ma y d a ma g e t h e p l u g a n d / o r pl u g b o r e .
NOTE: If t he core plug replacing tool has a dept h
seati ng surf ace, do not seat the tool agai nst a
non-machined (casti ng) surface.
When installed, the trailing (maxi mum) di ameter must
be bel ow t he chamf ered edge of the bore t o effecti vel y
seal the pl ugged bore.
SEALING
EDGE
BEFORE
INSTALLATION
Y
EXPANSION TYPE PLUG
EXPANSION TYPE CORE
PLUG REPLACER TOOL
A23319-A
C r a n k s h a f t Ma i n a n d C o n n e c t i n g R o d
B e a r i n g s
Cl e a n i n g
Identify reusable beari ngs so they can be installed in
their original l ocati ons.
CAUTI ON: Do n o t s c r a p e g u m o r v a r n i s h d e p o s i t s
f r o m t h e b e a r i n g she l l s o r d a ma g e t o b e a r i n gs
ma y o c c u r .
Clean the bearing inserts and caps thoroughl y in
solvent and dry them wi th compressed air.
I n s p e c t i o n
Inspect each bearing carefully. Repl ace beari ngs wi th
a scor ed, chi pped or worn surface. Typi cal exampl es
of unsati sfactory beari ngs and their causes are shown
in the following illustration. The copper lead bearing
base may be visible through the beari ng overl ay. If the
base showi ng is less than 20 percent of the total area,
the bearing is not excessi vel y worn. It is not necessary
t o repl ace the bearing if the bearing cl earance is within
recommended limits. Check the cl earance of beari ngs
that appear t o be sati sfactory wi th Pl asti gage
D81L-6002-B as outlined.
CRATERS OR POCKETS
FATIGUE FAILURE
BRIGHT (POLISHED)
SECTIONS
IMPROPER SEATING
SCRATCHES
DIRT IMBEDDED
INTO BEARING MATERIAL
SCRATCHED BY DIRT
OVERLAY
WIPED OUT
LACK OF OIL OR
IMPROPER CLEARANCE
OVERLAY GONE
FROM EDGES
HOURGLASSING
RADIUS RIDE
RADIUS RIDE
A-
03- 00- 19 Engi ne- Ser vi ce 03- 00- 19
C r a n k s h a f t Ma i n o r C o n n e c t i n g R o d
B e a r i n g s F i t t i n g
Pl as t i gage Me t h o d
1. Clean crankshaft j ournal s. Inspect journals and
thrust f aces for ni cks, burrs or roughness t hat
woul d cause premature beari ng wear.
2. CAUTI ON: Do not posi t i on j ack under
cr ankshaf t pul l ey ( 6312 ) . Cr ankshaf t post
damage wi l l r esul t .
If fitting crankshaft main beari ng ( 6333) in
vehi cl e, position a j ack under counterwei ght
adjoining crankshaft main beari ng whi ch is being
checked. Support crankshaft ( 6303) wi t h j ack so
its wei ght will not compress Pl asti gage and
provi de an erroneous readi ng.
Pl ace a pi ece of Pl asti gage D81L-6002-B or
equivalent on bearing surface acr oss full wi dt h of
beari ng cup and about 6. 35 mm ( 1 / 4 inch) off
center.
Install cap and tighten bol ts t o speci fi cati on as
outlined in Secti on 03- 01. Do not turn crankshaft
whi l e Pl asti gage is in pl ace.
Remove cap. Using Pl asti gage scal e, check
wi dt h of Pl asti gage at wi dest point t o get
minimum cl earance. Check at narrowest point t o
get maxi mum cl earance. Difference bet ween
readi ng is taper of j ournal s.
CHECK WIDTH
OF PLASTIGAGE
PLACE PLASTIGAGE
FULL WIDTH
OF JOURNAL ABOUT
6.35 mm (1/4 INCH)
INSTALLING
PLASTIGAGE
MEASURING
PLASTIGAGE
A2868-D
6. If crankshaft journals are damaged or if bearing
cl earance exceeds the speci fi ed limits, refinish
crank journal to 0. 254 mm ( 0. 010 inch) undersize
and use t he appropri ate undersize beari ng.
8.
After bearing has been fi tted and cl eaned, appl y a
light coat of cl ean engine oil XO-10W30-QSP or
-DSP or equivalent meeti ng Ford speci fi cati on
ESE-M2C153-E t o j ournal and beari ngs. Install
beari ng cap. Tighten cap bol ts t o speci fi cati on.
Repeat procedure f or remaining beari ngs t hat
require repl acement.
C r a n k s h a f t
Cl e a n i n g
CAUTI ON: Ha n d l e t he c r a n ks h a f t ( 6303) c a r e f u l l y
t o a v o i d d a ma g e t o t he f i n i s h e d s u r f a c e s .
Clean the crankshaf t wi th sol vent and then bl ow out all
oil passages wi t h compressed air.
I ns pec t i on
Inspect the main and connecti ng rod ( 6200) journals
for cr acks, scr at ches, grooves, scores or rough finish.
Inspect the crankshaf t oil seal surface for ni cks, sharp
edges or burrs that might damage the crankshaft rear
oil seal ( 6701) during installation or cause premature
seal wear.
C r a n k s h a f t Ru n o u t
Set the . crankshaft on V-bl ocks and use Dial Indicator
wi t h Bracket ry TOOL-4201-C or equivalent t o
measure the crankshaft runout.
CRANKSHAFT
6303
DIAL INDICATOR
WITH BRACKETRY
TOOL-4201-C
A14473-D
Maxi mum crankshaft runout is 0. 03 mm (0. 0012 inch).
If the crankshaf t runout exceeds speci fi cati on, repl ace
the crankshaft.
C r a n k s h a f t E n d Pl a y
1. Install crankshaf t into cylinder bl ock ( 6010) as
outlined in Section 03- 01.
03- 00- 20 E n g i n e S e r v i c e 03- 00- 2 0
2. Pry agai nst No. 2 main bearing cap and check
crankshaf t end play in both di recti ons as shown.
PRYBAR
CRANKSHAFT END PLAY
NOTE: PRY CRANKSHAFT IN
DIRECTIONS OF ARROWS AND
NOTE TOTAL END PLAY
DIAL INDICATOR
WITH BRACKETRY
TOOL-4201-C
A230S3-A
3. If end play exceeds speci fi cati ons as outlined in
Secti on 03- 01, grind the crankshaf t and install an
oversi ze crankshaf t thrust main bearing ( 6337)
or repl ace crankshaft and crankshaf t thrust main
beari ng.
C r a n k s h a f t Ma i n J o u r n a l a n d C o n n e c t i n g Ro d
J o u r n a l s
Inspect the main journal and connecti ng rod journal
di ameters. Measure the di ameter of each journal at
t wo different points in the di recti ons as shown.
JOURNAL
A14474-A
If a main journal or connecti ng rod journal di ameter is
l ess than the speci fi cati ons as listed in Secti on 03- 01,
grind the journal t o mat ch an undersi ze beari ng.
J o u r n a l s , Re f i n i s h i n g
Dress minor i mperfecti ons such as scores, ni cks or
burrs wi th an oil stone. If the j ournal s are severel y
marred or exceed the servi ce limit, refinish t o size for
t he next undersize beari ng.
If requi red, machine the journals t o gi ve the proper
cl earance wi t h t he next undersize beari ng. If the
j ournal s will not cl ean up to maxi mum undersize
beari ng avai l abl e, repl ace the crankshaf t .
Al ways reproduce t he same journal shoulder radius
that exi st ed originally. Too small a radius will result in
fati gue failure of the crankshaft. Too l arge a radius will
result in beari ng failure due to radius ride of the
beari ng.
After refinishing the j ournal s, chamfer the oil hol es.
Polish t he journal wi th a No. 500 grit polishing cl oth
and engine oil (crocus cl oth may also be used) t o
obtai n a smoot h finish. Remove all grinding dust f rom
oil passages wi t h compressed air.
C r a n k s h a f t S p r o c k e t
CAUTI ON: Ha n d l e c r a n ks h a f t s p r o c ke t ( 6306)
w i t h c a r e t o a v o i d p o s s i b l e d a ma g e t o t h e
f i n i s h e d s u r f a c e s .
Inspect crankshaft sprocket for ni cks, burrs or
roughness that woul d cause premature wear. If
crankshaf t sprocket is worn or damaged, repl ace
crankshaf t sprocket as outlined in Secti on 03- 01.
P i s t o n s , P i s t o n P i n s a n d P i s t o n Ri n g s
Cl e a n i n g
CAUTI ON: Do n o t us e a c a u s t i c c l e a n i n g s o l u t i o n
o r a wi r e b r u s h t o c l e a n p i s t o n s ( 6108) o r
p o s s i b l e d a ma g e ma y o c c u r .
Using a gasket scraper, remove deposi ts f rom t he
pi ston surf aces. Clean gum or varni sh f rom the piston
ski rt, pi ston pins ( 6135) and piston rings wi th solvent.
A15056-A
Clean the ring grooves wi th Piston Ring Groove
Cleaner D81L-6002-D or equivalent or a broken piston
ring. Make sure oil ring sl ots (or holes) are cl ean.
PISTON RING GROOVE
CLEANER
D81L-6002-D
A15059-C
03- 00- 21 EngineService
0 3 - 0 0 - 2 1
Inspection
Carefully inspect the pistons for fractures at the ring
lands, ski rt s, oil ring sl ot corners, and pin bosses. Al so
inspect for scuf f ed, rough or scored ski rts. If the l ower
inner porti on of t he ring grooves have a high st ep,
repl ace the pi ston. The st ep will i nterfere wi th ring
operati on and cause excessi ve ring si de cl earance.
Spongy, eroded areas near the edge of the t op of t he
piston are usually caused by detonati on or pre-ignition.
A shiny surface on the thrust surface of the pi ston,
offset from the centerline bet ween the piston pin hol es,
can be caused by a bent connecti ng rod ( 6200) .
Replace pi stons showi ng si gns of excessi ve wear,
wavy ring lands or f ract ures or damage f rom
detonation or pre-ignition.
Check the piston-to-cylinder bore cl earance by
measuring the pi ston and bore di ameters. Refer to
Speci fi cati ons in Secti on 03- 01 for t he proper
cl earance. Refer t o Cylinder Bl ock Inspection for t he
bore measurements procedure. Measure t he outsi de
diameter (OD) of t he pi ston and check the pi ston ring
side cl earance as outlined under Fitting Piston Rings.
Replace pi stons showi ng signs of f ract ure, etchi ng or
wear. Check the pi ston pin fit in the pi ston and
connecting rod as outlined.
P i s t o n s F i t t i n g
En gi n e Cy l i n d e r Ho n e Se t T 7 3L - 6011- A
The standard-si ze pi stons are col or-coded red, blue
and yel l ow. Oversi ze shown in Secti on 03- 01 under
Speci fi cati ons.
PISTON DIAMETER
C o l o r mm I n c h
Re d 90. 167 - 90. 180 3. 5499- 3. 5504
Bl ue 90. 180- 90. 193 3. 5504- 3. 5509
Ye l l o w 90. 193- 90. 2 06 3. 5509- 3. 5514
Measure the cylinder bore and sel ect t he piston t o
ensure the proper cl earance. When the bore diameter
is in the l ower one-third of the speci fi ed range, use a
red pi ston. When the bore diameter is in the middle
one-third, use a blue pi ston. When the bore di ameter is
in the upper one-thi rd, use a yellow pi ston.
P i s t o n - t o - C y l i n d e r C l e a r a n c e
NOTE: Cylinder bore must be cl ean and dr y and
cyl i nder bl ock ( 6010) must remain at room
t emperat ure (21 C/ 7 0 F) for eight hours bef ore
taki ng cyl i nder measurements.
A
\ CENTERLINE OF
VJ
j CRANKSHAFT"
A - AT RIGHT ANGLE TO CENTER LINE OF ENGINE
B - PARALLEL TO CENTER LINE OF ENGINE
A23320-A
Measure cylinder bore di ameter in t wo di recti ons, A
andB.
Measure cylinder bore di ameter in both di recti ons at
12. 70 mm (112 inch) bel ow t op of cylinder bl ock deck.
Measure cylinder bore di ameter in both di recti ons at
12. 70 mm ( 1 / 2 inch) above t op of the pi ston wi th the
piston at its l owest point of travel in the cylinder bl ock
bore.
The cyl i nder bore servi ce limit equals the average of
measurements A and B when measured at t he center
of the piston travel .
The cylinder bore taper equals the di fference between
measurements A at t op and B at bottom of cylinder
bore.
The cylinder bore out of round equals the di fference
between measurements A and B when measured at
the center of the piston travel .
Refer t o Speci fi cati ons as outlined at the end of
Secti on 03- 01.
Measure the piston outer di ameter as outlined t o make
sure the specific cl earance is obtai ned. If may be
necessary t o use another pi ston periodically (within
the same grade size) that is slightly larger or smaller
t o achi eve the speci fi ed cl earance.
If the taper, out-of-round and piston-to-cylinder bore
cl earance conditions of the cylinder bore ar e within
specified limits, new piston rings will wor k wel l .
03- 00- 2 2 E n g i n e S e r v i c e 03- 00- 2 2
Cy l i n d e r Bor e Di a me t e r Gauge
CENTRALIZING
PLUNGERS
CENTRALIZING
PLUNGERS
TYPICAL
CYLINDER BORE
MICROMETER
EXTENSIONS
FURNISHED
WITH EACH
SHE DIAMETER BORE GAUGE
RANGE
EXTENSION
REFERENCE
CONTACT
POSITIVE CENTRALIZATION
CENTRALIZING PLUNGERS AUTOMATICALLY
LOCATE THE GAUGING-CONTACTS CENTRALLY ON
THE BORE DIAMETER EVEN WHEN THE GAUGE IS
INSERTED AT AN ANGLE.
A23321-A
If installing new rings in a used cyl i nder that has not
been refinished, remove the cylinder wall glaze using
only spring-loaded Engine Cylinder Hone Set
T73L-6011-A. Remove only if t here is no visible sign of
cross-hat ch marki ngs on the cylinder wal l s. (Refer t o
Cylinder Bl ock, Cylinder Walls, Refinishing.) Al ways
cl ean the cylinder bore thoroughl y wi th detergent and
wat er solution.
1. NOTE: After any refinishing operati on, al l ow
cylinder bore t o cool . Make sure pi ston and bore
are clean and dry before checki ng piston fit.
Calculate the si ze of pi ston t o be used by taki ng a
cylinder bore check. Fol l ow procedures outlined
previously.
2. Sel ect proper si ze piston t o provi de desi red
cl earance. Measure piston di ameter in-line wi t h
centerline of pi ston pin and at 90 degrees t o
pi ston pin axi s.
3. Make sure pi ston and cylinder bl ock are at room
t emperat ure, 21 C ( 70F) .
P i s t o n R i n g s F i t t i n g
1. NOTE: Al ways use a pi ston ring expandi ng tool t o
install rings on a pi ston.
Sel ect proper pi ston ring set for size of cylinder
bore.
2. CAUTI ON: Use c a r e wh e n i n st a l l i n g p i s t o n
r i n g t o a v o i d p o s s i b l e d a ma g e t o p i s t o n r i n g
o r c y l i n d e r b o r e .
Position piston ring in correspondi ng cylinder
bore.
3. Insert piston ring into cylinder bore. Using a
pi ston, push piston ring slightly beyond bot t om of
pi ston ring travel , 115 mm (4. 5 inches) f rom
cylinder bl ock deck f ace.
4. Verify position of piston ring in bore is square wi t h
cylinder wall and check piston ring end gap as
outlined.
A15061-A
03- 00- 23 E n g i n e S e r v i c e 0 3 - 0 0 - 2 3
P i s t o n Ri n g E n d G a p
1. Measure end gap of all pi ston rings wi th Feeler
Gauge D81L-4201-A or equivalent.
FEELER
GAUGE
D81L-4201-A
A15062-B
Piston ring end gap:
Top ring: 0. 23-0. 49 mm ( 0. 009- 0. 019 inch)
2nd ring: 0. 23-0. 49 mm ( 0. 009- 0. 019 inch)
Oil ring rail: 0. 25-0. 77 mm ( 0. 010- 0. 030 inch)
Servi ce limit:
Top ring: 1.00 mm max ( 0. 039 inch max)
2nd ring: 1.00 mm max ( 0. 039 inch max)
Oil ring rail: 1.25 mm max ( 0. 049 inch max)
2. If end gap is greater than servi ce limit, repl ace
pi ston ring. If end gap exceeds servi ce limit after
new pi ston ring is installed, rebore cylinder bl ock.
3. Piston rings should be st aggered on the piston t o
make sure the piston ring end gaps are NOT
aligned.
P i s t o n P i n - t o - P i s t o n C l e a r a n c e
1. Measure inner di ameter of pi ston pin bore in
piston as outlined.
2. Measure outer di ameter of pi ston pin as outlined.
3. Cal cul ate pi ston pin cl earance by subtracti ng pin
di ameter f rom pin bore di ameter.
Standard pi ston pin t o pi ston cl earance is
0. 005- 0. 010 mm ( 0. 0002- 0. 0004 inch).
4. If cl earance exceeds speci fi cati on, repl ace piston
and pi ston pin.
P i s t o n Ou t e r Di a me t e r
Measure the pi ston outer di ameter using a mi crometer.
Measure pi ston ski rt di ameter at 90 degrees t o piston
pin center axi s, 42 mm (1. 62 inch) from t op of pi ston. It
may be necessary periodically t o use another piston
(within the same grade size) that is either slightly
larger or smaller t o achi eve the speci fi ed cl earance.
RED, BLUE
OR YELLOW COLOR
42mm
(1.62 INCH)
A15058-A
P i s t o n Ri n gs
CAUTI ON: P i s t o n r i n gs s h o u l d n o t b e t r a n s f e r r e d
f r o m o n e p i s t o n t o a n o t h e r , r e ga r d l e s s o f
mi l e a ge . P i s t o n r i n g f a i l ur e ma y o c c u r .
Repl ace all piston rings that are scor ed, broken,
chi pped or cr acked. Check the end gap and side
cl earance as outlined.
P i s t o n Ri n g - t o - G r o o v e C l e a r a n c e
1. NOTE: If l ower lands have high st eps, piston
should be repl aced.
Check side cl earance of compressi on rings wi t h
Feeler Gauge D81L-4201-A or equivalent by
inserting it bet ween piston ring and its l ower l and.
Gauge should slide freel y around entire piston
ring ci rcumference wi thout binding.
A8514-C
Piston ring side cl earance:
T o p r i n g: 0. 040- 0. 090 mm ( 0. 0016- 0. 0035 inch)
2 n d r i n g: 0. 030- 0. 080 mm ( 0. 0012- 0. 0031 inch)
Servi ce limit:
T o p r i n g: 0. 15 mm max ( 0. 006 inch max)
2 n d r i n g: 0. 15 mm max ( 0. 006 inch max)
2. If cl earance is greater than servi ce limit, repl ace
piston ring. If cl earance exceeds servi ce limit
after new piston ring is installed, repl ace pi ston.
03- 00- 24
E n g i n e S e r v i c e 03- 00- 24
Pi ston Pin
P i s t o n Pi n Ho l e Di a me t e r
Measure each piston pin hole di ameter at the four
poi nts shown.
T E L E S COP I NG
A14483-B
Repl ace piston ( 6108) that is not within speci fi cati ons.
For Speci fi cati ons, refer t o Secti on 03- 01.
P i s t o n P i n Di a m e t e r
Use a mi crometer t o inspect the piston pin di ameter in
the X and Y di recti ons at points A, B, C and D as
shown.
x
A14484-A
Repl ace piston pin ( 6135) that is not within
speci fi cati ons. For Speci fi cati ons, refer t o Secti on
03- 01.
C o n n e c t i n g R o d s
P i s t o n P i n C l e a r a n c e
1. Measure pi ston pin di ameter as outlined.
2. Measure connecti ng rod bushing inner di ameter
as outlined.
3. Calculate piston pin cl earance t o connecti ng rod
bushing by subtracti ng pin di ameter f rom
connecti ng rod bushing inner diameter.
Standard piston pin cl earance is 0. 015- 0. 040 mm
( 0. 0006- 0. 0016 inch).
4. If cl earance exceeds speci fi cati on, repl ace
connecti ng rod ( 6200) or piston pin ( 6135) as
requi red.
Cl e a n i n g
CAUTI ON: Do n o t use a c a u s t i c c l e a n i n g s o l u t i o n .
Da ma ge t o c o n n e c t i n g r o d s ma y o c c u r .
Remove the beari ngs f rom the connecti ng rod and
cap. Identify each connecti ng rod bearing location if
t hey are t o be reused. Clean the connecti ng rod in
solvent, including the rod bore and the back of the
connecti ng rod bearings ( 6211) . Bl ow out all
passages wi th compressed air.
I n s p e c t i o n
CAUTI ON: It i s n o t n e c e s s a r y t o r e a m o r h o n e t h e
p i s t o n pi n b o r e i n t h e c o n n e c t i n g r o d . Re pl a c e
d a ma g e d c o n n e c t i n g r o d n u t s a n d b o l t s o r
p o s s i b l e e n gi n e d a ma g e ma y o c c u r .
Inspect the connecti ng rods for signs of f ract ures and
the bearing bores for out-of-round and taper. If the
bore exceeds the recommended limits and/ or if the
connecti ng rod is f ract ured, it should be repl aced.
Check the inside di ameter (ID) of the connecti ng rod
piston pin bore. If the piston pin bore in the connecti ng
rod is larger than speci fi cati on, install a 0. 025 mm
( 0. 001 inch) oversi ze piston pin. Prefit the oversi ze
piston pin to t he piston pin bore by reaming or honing
t he piston ( 6108) t o provi de 0. 007- 0. 013 mm
( 0. 0003- 0. 0005 inch) cl earance (light slip fi t).
Assembl e the pi ston, piston pin and connecti ng rod as
outlined.
The connecti ng rods and rel ated part s should be
carefully i nspected and checked so they conform t o
speci fi cati ons. For Speci fi cati ons, refer t o Secti on
03- 01. Various f orms of engine wear caused by these
part s can be readily identified.
A shiny surface on either pin boss inside of the piston
usually indicates that a connecti ng rod is bent.
Abnormal connecti ng rod bearing wear can be caused
by a bent connecti ng rod, worn or damaged crankpi n
or a tapered connecti ng rod bore.
Twi sted connecti ng rods can creat e an identifiable
piston skirt wear pattern, but badl y t wi st ed connecti ng
rods will di sturb the acti on of the entire pi ston, piston
rings and connecti ng rod assembl y. Twi sted rods may
also cause excessi ve oil consumpti on.
03- 00- 25 E n g i n e S e r v i c e 03- 00- 25
Co n n e c t i n g Ro d Bu s h i n g I nner Di a me t e r
Use a t el escope gauge to i nspect the connecting rod
bushing inner di ameter.
TELESCOPING
GAUGE
A16635-B
Repl ace connecti ng rod ( 6200) that is not within
speci fi cati ons as outlined in Secti on 03- 01.
C o n n e c t i n g Ro d Be n d i n g C l e a r a n c e
Check t he connecti ng rods for bend or t wi st on a
suitable alignment fi xture. Fol l ow the instructions of
the fi xture manufacturer. If the bend and/ or t wi st
exceeds speci fi cati on, the connecti ng rod must be
repl aced.
C a m s h a f t a n d / o r C y l i n d e r H e a d J o u r n a l s
Cl e a n i n g
Clean t he camshaft ( 6250) in sol vent and wi pe it dry.
Remove light scuffs, scores or ni cks from t he
camshaf t machi ned surf aces wi t h a smoot h oil stone.
NOTE: If camshaf t journals are excessi vel y wor n or
scor ed, repl ace the camshaft. The cylinder head
beari ng j ournal s can be refinished t o accommodat e
0. 5 mm ( 0. 020 inch) oversi ze camshaf t . If t he cylinder
head journals cannot be bored out 0.5 mm ( 0. 020
i nch), repl ace the cylinder head ( 6049) .
I n s p e c t i o n
Check camshaf t bores for si ze, taper, roundness,
alignment and finish. If any of t hese exceed t he limits
given in Speci fi cati ons as outlined in Secti on 03- 01,
rebore cylinder head t o accept oversi ze camshaf t or
repl ace cylinder head.
C a m s h a f t R u n o u t
Inspect t he camshaft runout by setti ng the No. 1 and
No. 4 journals on V-bl ocks and using Dial Indicator wi th
Bracket ry TOOL-4201-C or equivalent.
DIAL
INDICATOR WITH BRACKETRY
TOOL-4201-C
CAMSHAFT
6250
A23528-A
Maxi mum runout of the camshaf t ( 6250) is 0. 05 mm
( 0. 002 i nch).
C a m L o b e s
Inspect t he camshaf t lobes f or scori ng and si gns of
abnormal wear. Lobe pitting (except in the general
ar ea of t he lobe t oe) will not hinder operati on of t he
camshaf t . The camshaft shoul d not be repl aced unless
t he lobe lift l oss has exceeded speci fi cati on, or pitting
has occurred in the lobe lift ar ea.
C a m L o b e L i f t
The lift of the camshaft l obes can be checked wi t h the
camshaf t installed in the engine or on cent ers.
To measure the camshaft lobe lift, proceed as fol l ows:
1. Measure di stance bet ween major (A-A) and minor
(B-B) di ameters of each cam lobe wi th a Vernier
caliper and record readi ngs. The di fference in
readi ngs on each camshaf t di ameter is lobe lift.
2. If readi ngs do not meet speci fi cati on, repl ace
camshaft. For Speci fi cati ons, refer t o Secti on
03- 01.
6.35 mm 6.35 mm
1/4 INCH 1/4 INCH
NO PITTING
ALLOWED IN
THIS AREA
DIMENSION A MINUS
DIMENSION B EQUALS
THE CAM LOBE LIFT
A23322-A
03- 00- 2 8
03- 00- 2 6
C a ms h a f t J o u r n a l Oi l C l e a r a n c e
1. Remove all forei gn materi al and oil from the
camshaft j ournal s and cylinder head bearing
surfaces.
2. Set the camshaf t into the cylinder head ( 6049) .
3. Position Pl asti gage D81L-6002-B or equivalent
on t op of the journals in the axi al di recti on.
4. Install cylinder head journal caps as outlined in
Secti on 03- 01.
5. Loosen the cylinder head journal cap bol ts as
outlined in Secti on 03- 01.
6. Remove cylinder head journal caps as outlined in
Secti on 03- 01.
7. Measure t he camshaft oil cl earance.
The st andard camshaf t oil cl earance should be
0. 025- 0. 076 mm ( 0. 0010- 0. 0029 inch).
Maxi mum servi ce limit is 0. 121 mm ( 0. 0048 inch).
C a ms h a f t J o u r n a l s Di a me t e r
Measure the journal di ameters in the X and Y
di recti ons at points A and B as shown.
CAMSHAFT
JOURNAL
A16624-B
Repl ace the camshaf t if not within speci fi cati ons as
C a ms h a f t E n d P l a y
1. CAUTI ON: P r y i n g a ga i n s t t h e camshaf t
s pr oc k et ( 62 56) wi t h t h e v a l v e t r a i n l o a d o n
t h e camshaf t s pr oc k et c a n b r e a k o r d a ma g e
t h e camshaf t .
NOTE: Dial Indicator may al so be installed on rear
of engine wi t h indicator point pl aced on fl at area
of camshaf t end.
Push camshaf t t owar d rear of engine. Install Dial
Indicator wi t h Bracket ry TOOL-4201-C or
equivalent so indicator point is on camshaf t
sprocket bol t.
2. Zero the dial indicator. Pull camshaft f orward and
rel ease it. Compare dial indicator reading wi th
speci fi cati ons. If end play is t oo tight, check for
binding or forei gn material in camshaft thrust
beari ng. If end play is excessi ve, check for worn
camshaf t thrust plate ( 6269) and repl ace cylinder
head as requi red.
3. Remove dial indicator.
C a ms h a f t S p r o c k e t
Inspect the camshaft sprocket for warpi ng or
abnormal wear. Inspect the sprocket teeth for wear,
deformati on, chipping or other damage. If necessary,
repl ace the crankshaft sprocket s ( 6306) as outlined in
Secti on 03- 01.
H y d r a u l i c Va l v e T a p p e t s
CAUTI ON: If a n y pa r t o f t h e v a l v e t a p p e t
a s s e mb l y n e e d s r e p l a c i n g, r e pl a c e t h e e n t i r e
v a l v e t a p p e t ( 6500) . I n t e r n a l t o l e r a n c e s f o r t h e
v a l v e t a p p e t s a r e v e r y c r i t i c a l . Mi x i n g
c o mp o n e n t s f r o m d i f f e r e n t v a l v e t a p p e t s ma y
u p s e t t h e s e t o l e r a n c e s , r e s u l t i n g i n i mp r o p e r
v a l v e t a p p e t o p e r a t i o n a n d po s s i b l e e n gi n e
d a ma g e .
Keep valve t appet s in proper sequence so that they
can be installed in their original position. Inspect and
test each valve t appet separatel y t o avoi d a mi xup. If a
valve t appet is worn, repl ace all valve t appet s and
rocker arms ( 6564) .
Cl e a n i n g
Thoroughl y clean all the parts in clean solvent and
wi pe t hem wi th a cl ean, lint-free cl oth.
mSL^ " M L T Z
03- 00- 2 7
I n s p e c t i o n
Inspect the parts and di scard the entire valve tappet if
any part shows pitting, scori ng or excessi ve wear.
Repl ace the entire val ve t appet if the plunger is not
free in t he body. The plunger should drop t o the bot t om
of the body by its own wei ght when assembl ed dry.
Assembl e the val ve t appet and check for f reeness of
operati on by pressi ng down on the plunger. The val ve
t appet s can al so be checked wi t h a hydraul i c tester t o
t est the l eakdown rat e. Fol l ow the i nstructi ons of the
test unit manufacturer or the procedure under
Camshaft Lobe Lift, Hydraul i c Valve Tappet and
Leakdown Testi ng.
Va l v e , Ba l l T i p T a p p e t We a r
The val ve t appet ti p is bal l -shaped wi t h an oil hole in
the t op. Light radial scuffing is accept abl e. Repl ace if
medium t o heavy scuffi ng, pitting, galling or metal
transfer is found. Al so check parent rocker arm in ball
socket area for similar condi ti ons.
Oi l P u m p
C l e a n i n g
Wash all parts in a solvent and dry t hem thoroughl y
wi t h compressed air. Use a brush t o cl ean the inside of
the pump housing and t he pressure relief val ve
chamber. Make sure all dirt and metal parti cl es are
removed.
I n s p e c t i o n
Check t he inside of the oil pump housing and gears for
damage or excessi ve wear.
Repl ace the oil pump ( 6600) if housing and/ or gears
are excessi vel y worn, scored or grooved. Inspect
gears for ni cks, burrs or score marks. Remove minor
i mperfecti ons wi th an oil stone.
P r e s s u r e Re g u l a t o r Va l v e I n s p e c t i o n
NOTE: Do not servi ce internal component s. If any
component is out of speci fi cati on, t he compl ete oil
pump assembl y must be repl aced.
Inspect the relief val ve spri ng t o see if it is col l apsed or
wor n. Check t he relief val ve spring tensi on. If the valve
spri ng tension is not within speci fi cati on and/ or the
val ve spri ng is worn or damaged, repl ace the oil pump.
Check t he relief val ve pi ston for free operati on in the
bore.
Oi l P a n
C l e a n i n g
CAUTI ON: Do n o t d a ma g e t h e l o w o i l l e v e l s e n s o r
( 6C62 4) (i f e q u i p p e d ) w h e n c l e a n i n g t h e o i l pa n
( 667 5) .
Scrape any dirt or metal parti cl es f rom the inside of
t he oil pan. Scrape all old gasket materi al f rom the
gasket surface. Wash the oil pan in a sol vent and dry it
thoroughl y. Make sure all forei gn parti cl es are
removed.
I n s p e c t i o n
Check t he oil pan for cr acks, hol es or damaged drain
plug t hreads. Check the gasket surface f or damage
caused by over-ti ghtened bol ts. Replace wi t h a new oil
pan gasket ( 6710) and oil pan if it cannot be servi ced.
C y l i n d e r H e a d s
Repl ace the cylinder head ( 6049) if it is cr acked.
Remove all burrs or scrat ches wi t h an oil stone.
Cl e a n i n g
CAUTI ON: Wi t h t h e v a l v e s i n s t a l l e d t o p r o t e c t t h e
v a l v e s e a t s , r e mo v e d e p o s i t s f r o m t h e
c o mb u s t i o n c h a mb e r s a n d v a l v e h e a d s wi t h a
s c r a p e r a n d a wi r e b r u s h . Do n o t d a ma g e t h e
h e a d g a s ke t s u r f a c e o r l e a ka ge ma y o c c u r u p o n
r e a s s e mb l y .
After the val ves are removed, clean the val ve guide
bores. Use cleaning solvent t o remove dirt, grease and
other deposi ts from the val ves wi th a fine wi re brush or
buffing wheel .
I n s p e c t i o n
Inspect the cylinder heads for cr acks or excessi vel y
burned areas in the exhaust outlet port s.
Check t he cylinder head for cr acks and inspect the
head gasket surface for burrs and ni cks. Small
imperfections can be dressed down using an oil stone.
Replace the cylinder head if it is cr acked.
The following inspection procedures are for a
compl ete overhaul of the cylinder head. For individual
servi ce operati ons, use only the appropri ate
inspection procedure.
S p a r k P l u g T h r e a d S e r v i c e
Damaged spark plug t hreads in the cylinder head can
be servi ced using Rotunda Tapersert Installation Kit
107-R0901 or equivalent.
03- 00- 2 8 E n g i n e S e r v i c e 03- 00- 2 8
1. NOTE: The use of power or air-driven tool s is not
approved for the installation of t apersert s. The
procedure involves cutti ng new t hreads in t he
spark plug ( 12405) hole. After rethreadi ng
operati on, a t apered sl eeve will be installed in the
cylinder head. The sl eeve is t hreaded on t he
inside and outsi de. The outsi de t hreads into the
cylinder head whi l e the inside provi des new
t hreads for the spark pl ug. This servi ce is
permanent and will have no effect on the life of the
cylinder head or spark plug.
CAUTI ON: Th e c y l i n d e r h e a d mu s t b e
r e mo v e d f r o m c y l i n d e r b l o c k ( 6010) b e f o r e
i n s t a l l i n g a t a p e r s e r t . T h e s e r v i c e p r o c e d u r e
i n c l u d e s a t h r e a d - c u t t i n g p r o c e s s w h i c h
p r o d u c e s me t a l c h i p s . P e r f o r mi n g t h i s
p r o c e d u r e wh i l e t h e c y l i n d e r h e a d i s o n t h e
c y l i n d e r b l o c k wi l l c a u s e me t a l c h i p s t o f a l l
i n t o t h e c y l i n d e r . On c e i n t h e c y l i n d e r , t h e s e
c h i p s c a n d a ma g e t h e c y l i n d e r wa l l w h e n t h e
e n gi n e i s s t a r t e d .
TAP MANDREL
ROTUNDA TAPERSERT INSTALLATION KIT
107-R0901
A 6
651- E .
Thoroughl y cl ean spark plug count erbore, seat
and t hreads of all di rt or other forei gn materi al .
2. Start t ap into spark plug hole and keep it properl y
aligned.
As t ap begins cutti ng new t hreads, appl y
aluminum cutti ng oil t o t ap.
Continue cutting t hreads and appl yi ng oil until
st op ring bot t oms agai nst spark plug seat.
3. Remove t ap. Remove all metal chi ps using
compressed air.
4. Coat t hreads of mandrel wi th cutti ng oil. Thread
t apersert onto mandrel until one t hread of
mandrel ext ends beyond t apersert .
TAPERSERT
ONE THREAD
EXTENDING
BEYOND
TAPERSERT A6470-D
5. NOTE: A properl y installed t apersert will be flush
t o 1.0 mm (. 254 inch) bel ow spark plug gasket
seat .
Thread t apersert into t apped spark plug hole
using a torque wrench. Continue tightening
mandrel until torque wrench indicates 61 Nm (45
Ib-ft).
6. To loosen mandrel for removal , hold mandrel
stati onary and turn mandrel body approxi matel y
one-half turn. Remove mandrel .
C y l i n d e r He a d Fl a t n e s s
When a cylinder head is removed because of gasket
l eaks, check the fl atness of the head gasket t o make
sure it conf orms t o speci fi cati on using Strai ght Edge
D83L- 4201 -A and Feeler Gauge D81L- 4201 -A or
equivalent. For Speci fi cati ons, refer t o Secti on 03- 01.
Repl ace cylinder head if it is necessary t o refinish the
head gasket surface.
Cy l i nde r Head Fl a t ne ss Me a sur e me n t Ty pi c a l
STRAIGHT EDGE D83L-4201-A
A23325-A
03- 00- 29 E n gi n e -
Z = Z Z = 2 L "
- Se r v i c e 03- 00- 2 9
Va l v e Se a t Ru n o u t
Check the val ve seat runout wi th Valve Seat Runout
Gauge D81P-6002-E or equivalent as illustrated
bel ow. Fol l ow the instructions of the gauge
manufacturer. If t he runout exceeds t he wear limit,
ref ace the val ve and valve seat. For Speci fi cati ons,
VALVE SEAT
RUNOUT GAUGE
D81P-6002-E
A7275-D
Va l v e S t e m- t o - Va l v e G u i d e C l e a r a n c e
Check the val ve stem-to-val ve guide cl earance of
each val ve in its respecti ve val ve guide wi t h Dial
Indicator wi t h Bracket ry TOOL-4201-C and Valve
St em Cl earance Tool TOOL-6505-E or equivalent. Use
a flat-end i ndi cator point.
Install the tool on t he valve st em until it is fully seat ed
and firmly ti ghten t he knurled set screw. Permit the
val ve t o drop away from its seat until the tool cont act s
the upper surface of the valve guide.
DIAL INDICATOR
WITH BRACKETRY
TOOL-4201-C
VALVE STEM
CLEARANCE TOOL
TOOL-6505-E
A15092-C
Position Rotunda Dial Indicator wi th Bracket ry
TOOL-4201-A or equivalent wi th its flat tip agai nst the
center portion of the tool ' s spheri cal secti on at
approxi matel y 90 degrees to the valve st em axi s.
Move the tool back and f ort h in line wi th the indicator
st em. Take a reading on the dial indicator wi thout
removing the tool f rom the valve guide upper surface.
Divide the reading by t wo, whi ch is the division f act or
for the tool . If valve stem-to-valve guide cl earance
exceeds the wear limit, ream the valve guide for the
next oversi ze val ve stem as outlined.
Va l v e s , S e l e c t Fi t t i n g
If the valve stem-to-valve guide cl earance exceeds the
servi ce cl earance, repl ace the valve guide. Ream the
valve guide to the st andard di ameter of 7. 02-7. 04 mm
(0. 276-0. 277 inch). Al ways reface the val ve seat after
the valve guide has been repl aced.
In the case of valve stem-to-valve guide cl earance, t he
servi ce cl earance is only intended as a di agnosti c aid
for engine noise. The cl earance does not consti tute a
failure or indicate need for servi ce. However, when
overhauling or reconditioning a cylinder head regard
the servi ce cl earance as having a practi cal worki ng
value and use as an aid for installing a new guide.
03- 00- 30 E n g i n e S e r v i c e 03- 00- 30
CAUTI ON: The i nt er f er ence angl e o f t he val ve
and seat shoul d not be l apped out . Remove al l
gr oov es or s c or e mar ks f r o m t he end of t he val ve
s t em and chamf er i t as necessar y. Do not r emov e
mor e t han 0. 2 54 mm ( 0. 010 i nch) f r o m t he end of
t he val ve s t em or excessi ve val ve l a sh may
o c c u r .
If the val ve f ace runout is excessi ve and/ or t o remove
pi ts and grooves, ref ace the val ves t o a true
45-degree angle. Remove only enough st ock t o
correct the runout or t o clean up t he pits and grooves.
If the edge of the val ve head is l ess than 0. 794 mm
(1 / 32-i nch) thi ck after grinding, repl ace the valve
because the val ve will run t oo hot in the engine.
If the val ve and/ or val ve seat has been ref aced, check
the cl earance between the rocker arm pad and t he
val ve st em wi t h the valve train assembl y installed in
t he engine and repl ace the val ve st em seal ( 6571) .
Va l v e S e a t s , Re f a c i n g
Measure the val ve seat wi dt h. Reface t he valve seat s
if the wi dt h is not within speci fi cati ons. Refer t o
Secti on 03- 01 for Speci fi cati ons.
Refer t o Engine Servi ce in the Rotunda Tool catal og for
a descri pti on of the various val ve seat gri nders and
cut t ers available.
Refaci ng the val ve seat should be cl osel y coordi nated
wi th t he refaci ng of the valve f ace so t hat the finished
seat and val ve f ace will be concentri c and the
speci fi ed i nterference angle will be maintained. Thi s is
i mportant so that the valve and seat will have a
compressi on-ti ght fit. Make sure refacer grinding
wheel s are properl y dressed.
Grind t he val ve seat s t o a true 45-degree angle.
Remove only enough st ock t o cl ean up pi ts and
grooves or t o correct the valve seat runout. After the
seat has been ref aced, measure valve seat cont act
wi dt h as outl i ned.
The finished val ve seat should cont act t he
approxi mat e center of the val ve f ace. Determi ne
where the val ve seat cont act s t he f ace.
To do thi s, coat t he seat wi th Prussian Blue and set the
valve in pl ace. Rotate the val ve wi t h light pressure. If
the blue is t ransf erred to the center of the valve f ace,
t he cont act is sati sfactory. If t he blue is t ransf erred t o
t he t op edge of the val ve f ace, l ower the val ve seat. If
the blue is t ransf erred t o the bot t om edge of the val ve
f ace, rai se the val ve seat.
Va l v e s
The cri ti cal inspection points and tol erances of the
val ve are i l l ustrated. Refer t o Speci fi cati ons in Secti on
03- 01 f or servi ce limits.
Va l v e s , I n s p e c t i o n
Inspect the val ve st em for bends and the end of the
st em for grooves or scori ng.
Inspect t he val ve f ace and the edge of t he val ve head
f or pi ts, grooves or scores. Inspect the st em for a
bend condition and t he end of the st em for grooves or
scor es. Check t he val ve head for signs of burning or
erosi on, warpi ng and cracki ng. Minor pi ts, grooves
and other abrasi ons may be removed. Di scard
severel y damaged val ves.
Inspect t he val ve spri ng ( 6513) , val ve spring retai ners
( 6514) and val ve spri ng retainer keys ( 6518) . Di scard
any damaged part s.
Va l v e s , Re f a c i n g
CAUTI ON: Di s c a r d a n y e x c e s s i v e l y w o r n o r
d a ma g e d v a l v e t r a i n p a r t s .
Minor pits or grooves may be removed. Di scard
severel y damaged val ves if the f ace runout cannot be
correct ed by refinishing or if stem cl earance exceeds
speci fi cati on. Refer t o Secti on 03-01 for
Speci fi cati ons.
Refer t o Engine Servi ce in the Rotunda Tool catal og for
a descri pti on of val ve resurfaci ng equipment.
The valve refaci ng operati on should be cl osel y
coordi nat ed wi t h the valve seat refaci ng operati ons so
that the finished angles of the valve f ace and valve
seat will meet speci fi cati ons and provi de a
compressi on-ti ght fit.
Make sure refacer grinding wheel s are properl y
dr essed. Refer t o the illustration for critical valve
dimensions.
VALVE TYPICAL,
FOR DIMENSIONS REFER
TO SPECIFICATIONS
CHECK FOR THIN (WORN)
s
LANDS BETWEEN
KEEPER GROOVES
(MULTIPLE BEAD VALVES)
VALVE
FACE
ANGLE
0.794 mm (1/32 INCH)
MINIMUM
, CHECK FOR
BENT STEM
DIAMETER
THIS LINE
PARALLEL WITH
VALVE HEAD
A23526-A
03- 00- 31 E n g i n e S e r v i c e 03- 00- 31
Va l v e S e a t C o n t a c t Wi d t h
Using a seat-wi dth scal e or a machi ni st' s scal e,
measure t he seat wi dt h. Narrow t he seat , if
necessary, t o bring it within speci fi cati on. Refer t o
Secti on 03- 01 for speci fi cati ons.
SEAT WIDTH SCALE
A6802-C
If the val ve seat wi dt h exceeds the maxi mum limit,
remove enough st ock f rom t he t op and / or bot t om
edge of the seat t o reduce t he wi dt h t o speci fi cati on.
On the i ntake and exhaust seat s, use a 60-degree
angle grinding wheel t o remove st ock f rom t he bot t om
of the seat (rai se the seat s). A 30-degree angle wheel
is used t o remove st ock f rom the t op of t he seat s
(l ower the seat s).
TO REMOVE STOCK FROM
BOTTOM OF SEAT, USE
THE FOLLOWING WHEEL:
INT 60 DEGREES
EXH 60 DEGREES
TO REMOVE STOCK FROM
TOP OF SEAT
USE 30 DEGREE WHEEL
45 DEGREES
VALVE
SEAT
WIDTH
A23533-A
Va l v e G u i d e I n n e r Di a me t e r
Measure the inner di ameter of t he val ve gui des at the
points shown.
VALVE
GUIDE
(CROSS-SECTION)
TELESCOPING
GAUGE
A14465-B
If valve guide is not within speci fi cati ons as listed in
Secti on 03- 01, ream the val ve gui de and install a val ve
wi t h an oversi ze st em.
Va l v e S t e m Di a me t e r
Measure t he di ameter of each val ve at the points
shown.
MICROMETER
VALVE
HEAD
A23529-A
If the st em di ameter is not within speci fi cati ons as
outlined in Secti on 03- 01, repl ace the val ve.
03- 00- 32 Engi neSer v i c e 03- 00- 32
Val ve Spr i ng L e n g t h I ns pec t i on
Inspect each val ve spri ng for cr acks or damage and
repl ace as necessary. Measure the free length of each
val ve spri ng as shown.
If a val ve spring is not within speci fi cati ons as outlined
in Secti on 03- 01, repl ace the val ve spri ng.
Va l v e S p r i n g T e n s i o n
Inspect the val ve spri ng, val ve spring retai ners, and
valve spri ng retainer keys for wear or damage.
Di scard any damaged part s.
NOTE: Make sure the val ve spri ngs are reassembl ed
t o their OWN ORIGINAL DAMPERS by pushing
damper on the val ve spri ng. DO NOT OPEN damper
wi t h any kind of tool t o reassembl e.
Check the val ve spri ngs for proper pressure at the
speci fi ed spring l engths using Valve Clutch Spring
Tester TOOL-6513-DD or equivalent. Weak val ve
spri ngs cause poor engine performance. Repl ace any
val ve spri ng not within speci fi cati on. For
speci fi cati ons, refer t o Secti on 03- 01. Manually
rotati ng the valve spri ng whi l e installed in the engine
will not determi ne condition of valve spri ngs.
APPLY TORQUE UNTIL
A8516-C
Va l v e S p r i n g S q u a r e n e s s
Check each val ve spri ng for squareness using a steel
square and a flat surface. Stand the val ve spring and
square on end of the flat surface. Slide the val ve spri ng
up t o the square. Revolve the val ve spring sl owl y and
observe the space between the t op coil of the val ve
spri ng and the square. Refer t o the following
illustration.
CHECK
SPECIFICATION
CLOSED COIL END DOWNWARD A8517-B
03- 00- 33 E n g i n e S e r v i c e 03- 00- 33
NOTE: Make sure t he (col or-coded) proper val ve
spring is installed.
NOTE: Make sure t he val ve spri ngs are reassembl ed
to their OWN ORIGINAL DAMPERS by pushing
damper on the val ve spri ng. DO NOT OPEN damper
wi th any kind of tool t o reassembl e.
Refer t o Speci fi cati ons in Secti on 03- 01 for
out-of-square limits. Fol l ow the same procedure to
new valve spri ngs bef ore installation.
R o c k e r A r m
Cl e a n i n g
Clean all part s thoroughl y using sol vent. Make sure all
oil passages are open.
I n s p e c t i o n
Inspect t he pad at the val ve end of the rocker arm
( 6564) for indications of scuffing or abnormal wear. If
the pad is grooved, repl ace the rocker arm. Inspect
the val ve t appet -t o-rocker arm bore for ni cks,
scrat ches, scores or scuffs. Repl ace all damaged
components.
Inspect roller for abnormal wear. Rotate roller t o check
for beari ng wear. If any wear or damage is found,
repl ace rocker arm and i nspect camshaf t ( 6250) as
outlined.
I n t a k e Ma n i f o l d
Cl e a n i n g
Remove all gasket materi al f rom the machi ned
surfaces of the i ntake manifold ( 9424) . Clean the
intake manifold in a suitable solvent and dry it wi th
compressed air.
CAUTI ON: Re mo v e a l l f i l i n gs a n d f o r e i g n ma t t e r
t h a t ma y h a v e e n t e r e d t h e i n t a ke ma n i f o l d a s a
r e s ul t o f s e r v i c e o r d a ma g e t o e n gi n e ma y o c c u r .
CAUTI ON: Ch e c k a n d ma ke sur e t h a t al l
p r e s s e d - i n c o r e pl u gs a n d t u b e s a r e f ul l y s e a t e d
a n d t i g h t o r d a ma g e t o t h e e n gi n e ma y o c c u r .
I n s p e c t i o n
Inspect the i ntake manifold for cr acks, damaged
gasket surf aces or other damage that woul d make it
unfit for further servi ce. Clean the EGR and PCV
syst em t ubes/ hoses.
E x h a u s t Ma n i f o l d
Cl e a n i n g
Remove all gasket or forei gn material f rom all inlet and
outlet sealing surf aces of t he exhaust manifold ( 9430) .
I n s p e c t i o n
Inspect the cylinder head joining flanges of the exhaust
manifold for evi dence of exhaust gas l eaks.
Inspect t he exhaust manifold f or cr acks, damaged
gasket surf aces or other damage that woul d make
them unfit f or further servi ce. War ped or cr acked
exhaust mani fol ds must be repl aced.
F l y w h e e l I n s p e c t i o n
T r a n s mi s s i o n , A u t o m a t i c
Inspect the fl ywheel ( 6375) f or cr acks or other
damage that woul d make it unfit for further servi ce.
Inspect the fl ywheel ring gear for worn, chi pped or
cr acked t eet h. If t he t eet h are damaged, repl ace t he
fl ywheel .
SPECIFICATIONS
POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS
MANUALVEHICLE APPLICATIONS
OBDI I 3. 8L Mu s t a n g , 4. 6L To wn Car, Cr o wn Vi c t o r i a ,
Gr a n d Ma r q u i s , Co n t i n e n t a l , T h u n d e r b i r d ,
Co u ga r
OBDI Al l Ot he r Ve h i c l e s
TA1000B
De s c r i p t i o n I l l u s t r a t i o n
T50T- 100- A
I mpa c t Sl i d e Ha mme r
T50T-100-A
T 59L - 100- B
T59L-100-B
T 7 3L - 6011- A
En gi n e Cy l i n d e r Ho n e Se t
T73L-6011-A
T 7 3L - 6600- A
Engi ne Oi l Pr e ssur e Ga uge
T73L-68O0-A T73L-68O0-A
03- 00- 34 E n g i n e S e r v i c e 03- 00- 34
(Conti nued)
D81L - 42 01- A Fe e l e r Ga u ge
D81L - 6002 - B P l a s t i ga ge
D81L - 6002 - D P i s t o n Ri ng Gr o o v e Cl e a n e r
D81P - 6002 - E Va l v e Se a t Run o ut Ga u ge
D83L - 42 01- A St r a i gh t E d ge
D87 C- 7 7 000- A Tr a n s mi s s i o n Te st A d a p t e r
T OOL - 42 01- C Di a l I n d i c a t o r wi t h Br a c ke t r y
T OOL - 6500- E Hy d r a ul i c T a p p e t L e a k d o w n Te s t e r
T OOL - 6505- E Va l v e St e m Cl e a r a n c e To o l
T OOL - 6513- DD Va l v e Cl u t c h Spr i n g T e s t e r
T OOL - 6565- A B Cup S h a p e d A d a p t e r
ROTUNDA EQUIPMENT
014- 007 05 P r e s s ur i za t i o n Ki t
05 9 - 00008 Va c uum / P r e s s u r e Te s t e r
059- R0009 Co mp r e s s i o n Te s t e r
107 - R0901 Ta pe r s e r t I n st a l l a t i o n Ki t
112 - R0030 Oi l L e a k De t e c t o r
03- 01- 1 E n gi n e , 4. 6L ( 2 V) 03- 01- 1
SUBJECT PAGE
VEHICLE APPLICATION . ....03-01-1
Camshaft. ...03-01-3
Crankshaft 03-01-3
Dri ve Bel t Syst em ....03-01-6
Emi ssi on Cal i brat i on Label 03-01-2
Engi ne 03-01-1
Engi ne Code I nf ormat i on ...03-01-2
Engi ne Cool i ng Syst em 03-01-5
Engi ne I dent i f i cat i on 03-01-1
Engi ne Lubri cati on Syst em 03-01-4
Exhaust Emi ssi on Cont rol Sy st em. . . . ....03-01-2
I nduct i on Syst em 03-01-3
Posi t i ve Crankcase Vent i l at i on Syst em 03-01-3
Valve Trai n 03-01-3
IN-VEHICLE SERVICE
Camshaf t Ti mi ng Chai ns and Tensi oners .03-01-19
Camshaf t s 03-01-23
Connect i ng Rod Beari ngs 03-01-55
Crankshaf t Pulley and Crankshaf t Front Oil
Seal .03-01-15
Crankshaf t Rear Oil Seal 03-01-57
Cyl i nder Heads .03-01-29
Engi ne Component s ...03-01-7
Engi ne Fr ont Cover 03-01-16
Exhaust Mani f ol d 03-01-39
Fl ywheel . . . 03-01-56
I nt ake Mani f ol d 03-01-37
Oil Bypass Fi l t er and Adapt er . . . .03-01-57
SUBJECT PAGE
IN-VEHICLE SERVICE (Cont ' d. )
Oi l Level I ndi cat or Tube 03-01-59
Oi l Pan and Oil Pump Screen Cover and
Tube ....03-01-44
Oil Pump 03-01-51
Pi st ons and Connect i ng Rods ...03-01-51
Rocker Arm ..03-01-13
Sensors 03-01-59
Ti mi ng Spr oc ke t s 03-01-22
Valve Cover and Gasket . . . .03-01-10
Valve Spr i ng, Ret ai ner and Valve Stem
Se a l . 03-01-14
Valve Tappet , Hydraul i c 03-01-13
Wat er Pump 03-01-37
Crankshaf t 03-01-62
Crankshaf t Mai n Bear i ngs. . 03-01-72
Engi ne 03-01-59
Cyl i nder Bl ock Assembl y .03-01-93
Cyl i nder Bl ock Bore 03-01-93
Engi ne. . ....03-01-73
Hydraul i c Valve Tappet 03-01-92
Subassembl i es 03-01-89
Cyl i nder Head 03-01-89
Pi st on Ri ngs 03-01-92
VEHICLE APPLICATION
Engine
WARNI NG: DO NOT OPERATE THE ENGI NE WI TH
THE HOOD OPEN UNTI L THE FAN HAS BEEN
FI RST EXAMI NED FOR POSSI BLE CRACKS AND
SEPARATI ON.
The4. 6L-
fol l owi ng:
-2V ( 281 CD) is a V-8 engine wi t h t he
Single overhead camshaf t s ( 6250) (OHC).
Two val ves per cylinder.
Sequential Multi-port Fuel Injection (SFI).
An aluminum intake manifold ( 9424) .
Aluminum cylinder heads ( 6049) .
A cast iron, 90 degree V-cylinder bl ock ( 6010) .
The el ectroni c ignition syst em has t wo ignition coi l s
( 12029) . The ignition control module (I CM)(12K072) is
mounted t o t he LH inner front fender ( 16005) . Thi s
high-energy ignition syst em is requi red for fast-burn
combusti on.
Engine Identification Engine build dat e.
It is i mperati ve that the engine codes and the Engine plant code.
cal i brati on number be used when orderi ng part s or
Engine code.
maki ng inquiries about t he engine.
Engine code.
The engine code information label, l ocat ed on t he front
of the engine, contai ns:
03- 01- 2 E n gi n e , 4. 6L ( 2 V) 03- 01- 2
Engine Code Information
ENGINE
CODES
5G812AA
TYPICAL
ROMEO
ENGINE
PLANT
. 1 1 - 1 2 - 9 4 ,
r
BUILD DATE
A14872-F
E m i s s i o n C a l i b r a t i o n L a b e l
The Vehicle Emission Control Information (VECI) label,
l ocated on the upper radi ator si ght shi el d, identifies:
Engine cal i brati on number.
Engine code number and revision l evel .
These numbers are used t o determi ne if part s are
unique t o speci fi c engi nes.
49 St a t e s
FORD VOI D* COMPANY
VEHICLE EMISSION CONTROL INFORMATION
THIS VEHICLE 18 EQUIPPED WITH ELECTRONIC FUEL INJECTION. I6NITI0N TIMING.
IDLE MIXTURE. COLD ENGINE IOLE SPEED AND COLO ENGINE FUEL ENRICHMENT
ARE NOT ADJUSTABLE.
SET PARKING BRAKE AND BLOCK WHEELS. DISCONNECT AUTOMATIC PARKING BRAKE
RELEASE. IF SO EQUIPPED. EOUIPPED. MAKE ALL ADJUSTMENTS WITH EN6INE AT
NORMAL OPERATING TEMPERATURE ANO ACCESSORIES OFF,
Ca l i f o r n i a
VEHICLE EMISSION CONTROL INFORMATION
THIS VEHICLE IS EQUIPPED WITH ELECTRONIC FUEL INJECTION. IfiNITION TIMING. IDLE
MIXTURE. COLD ENGINE I CU SPEED AHO COLD ENGINE FUEL ENRICHMENT ARE NOT
ADJUSTABLE.
SET PARKING BRAKE AND BLOCK WHEELS. OISC0NNECT AUTOMATIC PARKING BRAKE RELEASE.
IF SO EOUIPPED. MAKE ALL ADJUSTMENTS WITH ENGINE AT NORMAL OPERATING TEMPERATURE
AND ACCESSORIES OFF.
THIS ENGINE IS EOUIPPED WITH AUTOMATIC SPEED CONTROL. IDLE RPM IS NOT ADJUSTABLE.
IF NOT WITHIN SPECIFIED RPM RANGE. SEE SHOP MANUAL.
AUTO. TRANS. 18 ORIVEi 3SO RPM
USE SAE SW-30 OIL API SERVICE
SO - ENERGY CONSERVING I I .
THIS VEHICLE CONFORMS TO U.S.
EPA AND CALIFORNIA REGULATIONS
APPLICABLE TO 1991 MODEL YEAR
NEW MOTOR VEHICLES INTRODUCED
INTO COMMERCE SOLELY FOR SALE
IN CALIFORNIA.
M NOSE SQUTI HS
TTti CATALYST I KKXTZ
A14874-B
Exhaust Emission Control System
Operati on and requi red maintenance of the exhaust
emission control devi ces used on this engine are
covered in the Powertrai n Cont rol / Emi ssi ons
Di agnosi s Manual .
1
THIS ENGINE IS EOUIPPED WITH AUTOMATIC v
IDLE SPEED CONTROL. IDLE RPM IS NOT MUUM N01E 0U TI BS
ADJUSTABLE. IF NOT WITHIN SPECIFIED
RPM RANGE. SEE SHOP MANUAL.
AUTO. TRANS. IN DRIVE: 560 RPM
USE SAE 5W-30 OIL API SERVICE
SG - ENERGY CONSERVING I I .
J
J L
j
I
THIS VEHICLE CONFORMS TO U.S. EPA
REGULATIONS APPLICABLE TO I99I MODEL
a
YEAR NEW MOTOR VEHICLES.
mm* mm*
a"cT I CATALYST I aBBST
A14873-B
03- 01- 3 E n gi n e , 4. 6L ( 2 V) 0 3 - 0 1 - 3
Induct i on Syst em
Sequential Multi-port Fuel Injection (SFI) provi des t he
f uel / ai r mi xture needed f or burning in the cyl i nders.
Eight sol enoi d-operated fuel i nj ectors ( 9F593) ,
mounted in t he l ower i ntake manifold ( 9424) , meter
fuel into the air i ntake st ream in accordi ng t o engine
demand.
The eight fuel i nj ectors ar e:
Posi ti oned so t hat their t i ps di rect fuel j ust ahead of
the engine i ntake val ves ( 6507) .
Connected in parallel wi t h t he fuel pressure
regulator.
Fuel:
Is suppl i ed f r om the vehi cl e' s fuel tank ( 9002) by a
hi gh-pressure el ectri c fuel pump ( 9350) mounted in
the fuel tank.
Is fi l tered and sent t o t he fuel injection suppl y
manifold ( 9F792) .
A fuel pressure regul ator ( 9C968) on thi s fuel injection
suppl y manifold control s t he fuel-delivery pressure at a
constant 269 kPa ( 39 psi ).
Excess fuel suppl i ed by t he fuel pump, but not needed
by the engine, is returned t o t he vehi cl e fuel t ank by a
fuel return line.
Crankshaft
The crankshaft ( 6303) :
Is support ed on the bot t om of the cylinder bl ock
( 6010) by five st eel -backed, over-pl ated aluminum
crankshaft main beari ngs ( 6333) .
Connects wi t h t he camshaf t s ( 6250) by t wo
spr ocket s and t wo timing chai ns.
The rear crankshaf t thrust main bearing ( 6337) limits
crankshaft end pl ay and absorbs thrust l oads appl i ed
t o the crankshaf t ends.
Camshaft
The camshaf t s ( 6250) are individually chain-driven
wi th an automati c hydraulic timing chain tensi oner
( 6L266) on each timing chai n.
Valve Train
The confi gurati on of the val ve train consi st s of:
A hydraul i c val ve t appet ( 6500) providing automati c
lash adj ustment.
The camshaf t lobe t ransf ers i ts up-and-down motion t o
the rocker arms ( 6564) .
The camshaf t s ( 6250) :
Ar e seat ed in j ournal bores on t op of t he cyl i nder
head ( 6049) .
The val ves:
Ar e arranged al ternatel y - intake val ve
( 6507) / exhaust val ve ( 6505) .
Positive Crankcase Ventilation System
All engines are equi pped wi t h a posi ti ve cl osed-t ype
crankcase ventilation syst em recycl i ng t he cr ankcase
vapors t o t he i ntake manifold ( 9424) .
Q37 31- A
Pa r t
1 6853 Crankcase Ventilation Hose
2 6A666 Positive Crankcase
Ventilation Valve
3 9424 Intake Manifold
4 6582 Valve Cover
5 To Fuel Vapor and Brake
Tube
6 9A228 Fuel Tank Vent Tube
7 To 9C915
8 9447 Carburetor Gasket
03- 01- 4 E n gi n e , 4
B
6 L ( 2 ) 03- 01- 4
Engine L u b r i c a t i o n S y s t e m
The lubrication syst em of t he 4. 6L2V engine is
desi gned t o provi de opti mum oil fl ow t o cri ti cal
component s of the engine through its entire operati ng
range.
Engi ne Lubr i c a t i o n Sy st e m
METERED OIL TRAVELS
THROUGH VALVE TAPPET
AND ROCKER ARM AND
IS SPLASHED ONTO CAM LOBE,
ROLLER BEARINGS IN ROLLER
FOLLOWER, AND VALVE TIP.
VALVE STEM IS LUBRICATED
BY METERED LEAKAGE PAST
LIP OF VALVE STEM SEAL.
A14937-D
Pa r t
1

Valve Tappet Vent Gallery
(Open to Crankcase) (Part of
6049)
2

Valve Tappet and Camshaft
Bearing Feed Gallery
(Reduced Pressure) (Part of
6049)
3 Orifice and Strainer (Part of
6049)
4 RH Head Gallery Oil
Reservoir (Part of 6049)
5

Primary Main Gallery
Pressure (Not Restri cted)
(Part of 6010)
6

LH Head Gallery Oil
Reservoir (Part of 6049)
7 Orifice and Strainer (Part of
6049)
Pa r t
8 6049 Cylinder Head
9

Oil Drain to Sump (Part of
6049)
10

To Hydraulic Timing Chain
Tensioner (6L266)
11

From Left Bank Cylinder
Block (Part of 6010)
13 9278 Oil Pressure Sensor
14 6881 Oil Filter Adapter
15

Oil Pump Integral Relief
Valve (Part of 6010)
16

Bypass (Part of 6010)
17 6600 Oil Pump
18

To LH Cylinder Head (Part of
6049)
19

Oil Drain to Sump (Part of
6010)
Oil is drawn into the oil pump ( 6600) through t he oil
pump screen cover and tube ( 6622) in t he sump.
Oil is pumped through t he oil bypass filter ( 6714) on
t he left front si de of t he cylinder bl ock ( 6010) .
Oil enters the main oil gallery where it is di stri buted
t o the crankshaft main journals and t o both cylinder
heads ( 6049) .
From the main j ournal s, t he oil is:
03- 01- 5 E n gi n e , 4 . 6 L ( 2 V) 03- 01- 5
Routed through cross-dri l l ed passages in t he
crankshaft ( 6303) t o t he crankpi ns f or connecti ng
rod bearing l ubri cati on.
Control l ed l eakage t hrough the crankshaf t main
beari ng ( 6333) and connecti ng r od beari ngs ( 6211) i s:
Slung radially out ward t o cool and l ubri cate t he
cyl i nder wal l s as wel l as t he enti re connecti ng rod
( 6200) , pi ston ( 6108) and pi ston ring assembl i es.
The left cylinder head is:
Fed f rom a drilling into t he l ateral suppl y passage
feedi ng the main gal l ery at t he front of t he cylinder
bl ock.
The ri ght cylinder head i s:
Fed f rom a drilling into the rear of t he main gallery.
Mai n gal l ery pressure is reduced as it enters the
cyl i nder head galleries through t he use of fi xed .
servi ceabl e ori fi ces l ocat ed at t he upper part of t he
f eed passages.
Thi s reduced pressure in the cyl i nder head galleries
f eeds t he:
Camshaft j ournal s.
The val ve t appet s ( 6500) .
The hydraulic timing chai n tensi oners ( 6L266) .
The cam l obes and rocker arms ( 6564) whi ch are
l ubri cated by spl ash creat ed through val ve trai n
operati on.
Oi l P u mp
The oil pump has t he fol l owi ng charact eri st i cs:
It is a positive di spl acement internal gear pump
using t op seal rot ors (known generi cal l y as a
G-rotor oil pump).
It is mounted on t he front f ace of t he cylinder bl ock.
The inner rotor is pi l oted on the crankshaft post and
is driven through fl ats on t he crankshaf t .
Syst em pressure is limited by an i ntegral ,
i nternal l y-vented relief val ve whi ch di rect s t he
bypass oil back t o the inlet si de of t he oil pump.
Oil pump di spl acement has been sel ect ed t o provi de
adequat e vol ume t o ensure proper oil pressure bot h
at hot idle and maxi mum speed.
Relief val ve cal i brati on prot ect s t he syst em f rom
excessi ve pressure during high vi scosi t y condi ti ons,
yet is desi gned t o provi de adequat e l ubri cati on
under hi gh-temperature and hi gh-speed condi ti ons.
Oi l P a n
The oil pan ( 6675) :
Is a st amped steel or mol ded aluminum part t hat
bol ts t o t he bot t om of t he engine bl ock.
Act s as a reservoi r holding lubrication t hat is
pumped through the engine by the oil pump after
st art up.
E n g i n e C o o l i n g S y s t e m
The engine cool ant:
Fl ows through t he radi ator t ubes and is cool ed by
air passi ng over the cool i ng fins assi st ed by t he
cool i ng fan motor and fan blade ( 8600) as
necessary.
Is then ci rcul ated f rom the radi ator outlet tank
( 8054) through the radi ator cool ant recovery
reservoi r ( 8A080) whi ch is pressuri zed t o
continuously separat e the air f rom the cool i ng
syst em.
Fl ows f rom t he radi ator cool ant recovery reservoi r
through t he engine, heater core ( 18476) and wat er
pump ( 8501) . The cool ant then returns t o the
radi ator ( 8005) through t he wat er hose connecti on
( 8592) .
03- 01- 6
E n gi n e , 4. 6L ( 2 V) 03- 01- 6
Engi ne Co o l i n g Sy st e m
COOLANT FLOW DIRECTION
Q3012-C
I t e m
Pa r t
Pa r t
1 8A080 Radiator Coolant Recovery 7 6881 Oil Filter Adapter
Reservoir 8 8260 Upper Radiator Hose
2 8100 Pressure Relief Cap 9 8005 Radiator
3 18476 Heater Core
10 8501 Water Pump
4 18472 Heater Water Hose 11 8592 Water Hose Connection
5 6010 Cylinder Block
12 8286 Lower Radiator Hose
6 6049 Cylinder Head 13 8075 Radiator Overflow Hose
Dr i v e Be l t S y s t e m
The 4. 6L2V OHC engines are equi pped wi t h dri ve
bel ts ( 8620) t o ensure maxi mum life. When repl aci ng
dri ve bel ts, they shoul d be of t he same t ype as
originally installed.
Engines equi pped wi t h an automati c dri ve belt
tensi oner ( 6B209) will not require any dri ve belt
tensi on adj ustment for the life of t he dri ve belt.
Loose dri ve bel ts will result in sl i ppage whi ch may
cause a noise compl ai nt or i mproper accessor y
operat i on.
Loose dri ve bel ts may result in operati onal
probl ems like generators not delivering proper
charge or other concerns.
Overti ghteni ng the dri ve belts will pl ace a severe
l oad on accessory beari ngs.
Refer t o Secti on 03- 03 for servi ce procedures.
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03- 01- 9 E n gi n e , 4. 6L ( 2 V) 03- 01- 9
IN-VEHICLE SERVICE (Continued)
Pa r t
1 N806155-S2 Bolt
2 9D930 Fuel Charging Wiring
3 9723 Accelerat or Cable Bracket
4 N804394-S8M Bolt
5 9F792 Fuel Inj ection Supply
Manifold
6 9F593 Fuel Inj ector (8 Req'd)
7 N806178-S2 Nut
8 8592 Water Hose Connection
9 391107-S O-Ring
10 8575 Water Thermostat
11 9461 Intake Manifold Gasket
12 10884 Water Temperature Indicator
Sender Unit
13 12A648 Engine Coolant Temperature
Sensor
14 9F485 EGR Valve Tube to Manifold
Connector
15 9D477 EGR Valve to Exhaust
Manifold Tube
16 N804073-S8 Bolt
17 9D475 EGR Valve
18 9D476 EGR Valve Gasket
20 9E926 Throttle Body
21 9E936 Throttle Body to Intake
Manifold Gasket
22 9A589 Throttle Body Adapter
23 N806154-S2 Bolt
24 9H486 Intake Manifold Upper
Gasket
25 9J472 EGR Vacuum Regulator
Bracket
27 N804958-S2 Bolt
28 9F715 Idle Air Control Valve
29 N806155-S2 Bolt
30 9F670 IAC Valve Gasket
31 N806156-S2 Bolt
33 9A450 Core Plug
Ventilation Valve
35 6A892 Crankcase Ventilation
Grommet
36 N806183-S2 Bolt
37 6C518 Valve Cover Bolt or Stud
Seal
38 6020 Engine Front Cover Gasket
39 6C324 Crankcase Vent Connector
and Hose
40 19703 A/ C Compressor
41 N806184-S2 Bolt
42 N606502-S36 Bolt
43 12029 Ignition Coil
44 6B209 Drive Belt Tensioner
45 N804178-S2 Nut
46 10300 Generator
Pa r t
48 10153 Generator Rear Mounting
Bracket
49 N806200-S2 Bolt
50 N806155-S2 Bolt
51 6C315 Crankshaft Position Sensor
52 6700 Crankshaft Front Seal
53 N806155-S2 Bolt
54 6019 Engine Front Cover
55 6B288 Camshaft Position Sensor
56 N806300-S2 Stud
58 8509 Water Pump Pulley
59 N806177-S2 Bolt
60 8501 Water Pump
61 3Z728 O-Ring
62 6584 Valve Cover Gasket
63 6582 Valve Cover (RH)
64 6345 Crankshaft Main Bearing
Cap Bolt
66 7007 Engine Rear Plate
67 6375 Flywheel
68 N806168-S Bolt
70 6582 Valve Cover (LH)
Seal
72 N806183-S2 Bolt
73 6A648 Fitting
75 N806356-S2 Stud
Seal
77 6051 Head Gasket
78 N806456-S Dowel
79 6890 Oil Filter Mounting Insert
80 6840 Oil Filter Adapter Gasket
83 9D290 Oil Pressure Sensor
84 N806514-S2 Stud
85 N806156-S2 Bolt
87 N606523-S Bolt
88 6710 Oil Pan Gasket
89 12280 Ignition Wires
90 N806155-S2 Bolt
91 12257 Ignition Coil Bracket
92 12297 Ignition Wire Separator
93 W701624-S Stud
95 N606502-S36 Bolt
96 3A733 Power Steering Pump Pulley
97 3A674 Power Steering Pump
98 N806176-S2 O-Ring
( Co n t i n ue d )
03- 01- 10
E n gi n e , 4. 6L ( 2 V) 03- 01- 10
Pa r t
99 6687 Oil Pan Baffle
100 6675 Oil Pan
101 6734 Oil Pan Drain Plug Gasket
102 6730 Oil Pan Drain Plug
103 W701240-S309 Bolt (6 Req'd)
104 W701575S Nut
105 9430 Exhaust Manifold
106 N806139-S2 Bolt
107 N806164-S Washer
108 6256 Camshaft Sprocket
109 6265 Camshaft Sprocket Spacer
110 6B280 Camshaft Bearing Cap
(Front)
111 6B280 Camshaft Bearing Cap
(Rear)
112 N806070-S Bolt
113 6250(LH)
6250 (RH)
Camshaft
114 6065 Cylinder Head Bolt
115 6750 Oil Level Dipstick
116 N806155-S2 Bolt
Cap Bolt
119 18472 Heater Water Hose
120 N806070-S Bolt
121 6K297 Timing Chain Guide
122 8555 Water Bypass Tube
123 N806040-S Dowel
124 6L253 Timing Chain Tensioner Arm
126 N806070-S Bolt
127 6K297 Timing Chain Guide
128 N806040-S Dowel
Cap Stud
130 6335 Crankshaft Rear Oil Seal
Retainer
132 N806155-S2 Bolt
133
Orifice and Strainer (Part of
6049)
134 12405 Spark Plug
135 6500 Valve Tappet
136 6564 Rocker Arm
137 6518 Valve Spring Retainer Key
138 6514 Valve Spring Retainer
Pa r t
139 6513 Valve Spring
140 6571 Valve Stem Seal
141 N804811-S Core Plug
142 6L266 Timing Chain Tensioner
143 N606543-S2 Bolt
144 6507 Intake Valve
145 6505 Exhaust Valve
146 6334 Crankshaft Thrust Washer
148 9448 Exhaust Manifold Gasket
149 6150 Piston Compression Ring
150 6152 Piston Compression Ring
151 6159 Oil Ring Rail
152 6161 Oil Ring Expander
153 6159 Oil Ring Rail
154 6108 Piston
155 6135 Piston Pin
156

Not Used
157 6200 Connecting Rod
158 6211 Connecting Rod Bearing
159

Not Used
160 6214 Connecting Rod Bolt
161 N806180-S Stud Spacer
162 N605904-S Bolt
163 6622 Oil Pump Screen Cover and
Tube
164 6600 Oil Pump
165 N606021-S Bolt
166 N605892-S2 Bolt
167 6268 Timing Chain
168 87038-S96 O-Ring
169 6306 Crankshaft Sprocket
170 12A227 CKP Sensor Pulse Wheel
171 6312 Crankshaft Pulley
172 6378 Crankshaft Pulley Retaining
Washer
173 6A340 Crankshaft Pulley Bolt
174 N806201-S Woodruff Key
175 6303 Crankshaft
176 6337 Lower Crankshaft Thrust
Main Bearing
177 6333 Lower Crankshaft Main
Bearing (4 Req'd)
178

Main Bearing Cap (5 Req'd,
Part of 6010)
Cap Stud
180 8678 Belt Idler Pulley
Va l v e C o v e r a n d G a s k e t
RH S i d e
Re mo v a l
2. Di sconnect positive battery cabl e at battery
( 10653) and at power distribution box.
03- 01- 11 E n gi n e , 4 . 6 L ( 2 ) 0 3 - 0 1 - 1 1
IN-VEHICLE SERVICE (Conti nued)
3. Remove retaining bolt f rom positive bat t ery cabl e
bracket l ocat ed on t he si de of RH cylinder head
( 6049) .
BOLT CABLE A14806-B
4. Di sconnect fuel chargi ng wi ri ng ( 9D930) f rom
crankshaf t position sensor (CKP
sensor)(6C315), A / C cl utch ( 2884) and
evaporat i ve emission cani ster purge val ve (EVAP
cani ster purge val ves)(9C915). Position harness
out of t he way.
6. Di sconnect vent hose f rom evaporati ve emission
cani ster purge val ve and position posi ti ve bat t ery
cabl e out of t he way.
6. CAUTI ON: Do n o t pul l o n t h e i gn i t i o n wi r e s a s
i t ma y s e p a r a t e f r o m t h e c o n n e c t o r i n t h e
i gn i t i o n wi r e b o o t .
Di sconnect ignition wi res f rom spark plugs
( 12405) . Refer t o Secti on 03- 07.
7. Remove ignition wi re and bracket s ( 12280) from
val ve cover studs and move ignition wi res out of
t he way.
8. Remove positive crankcase ventilation val ve
(PCV val ve)(6A666) f rom crankcase ventilation
grommet ( 6A892) and move out of t he way.
9. Remove bol ts and stud bol ts retaining val ve cover
( 6582) t o cylinder head. Remove val ve cover.
1. Clean sealing surf aces of cylinder head and val ve
cover wi th Metal Surface Cleaner
F4AZ-19A536-RA or equivalent meeting Ford
speci fi cati on WSE-MSB392-A. Appl y Silicone
Gasket and Sealer F1AZ-19562-A or equivalent
meeti ng Ford speci fi cati on WSE-M4G320-A2 in
bot h pl aces where engine front cover ( 6019)
meet s cylinder head.
2. Position and, using Gasket and Trim Adhesi ve
D7AZ- 19B508- B or equi val ent meeti ng Ford
speci fi cati on ESR-M 11P17-A and ESE-M2G52-A,
glue new val ve cover gasket ( 6584) into val ve
cover and install onto cylinder head.
3. Install bol t s and stud bol ts into valve cover.
Tighten studs and bol ts t o 8-12 Nm ( 71- 106
lb-in).
4. Install posi ti ve crankcase ventilation valve into
cr ankcase ventilation grommet .
5. Install ignition wi re br acket s on st uds and connect
ignition wi res t o spark pl ugs. Refer t o Secti on
03- 07.
6. Connect fuel chargi ng wi ri ng t o evaporati ve
emi ssi on cani ster purge val ve, A / C cl utch and
crankshaf t position sensor.
7. Position positive bat t ery cabl e harness on RH
cyl i nder head.
8. Install bolt retaining bat t ery cabl e bracket t o
cyl i nder head.
9. Connect positive bat t ery cabl e at power
distribution box and harness ( 14516) and
bat t ery.
10. Connect battery ground cabl e.
L H S i d e
Re mo v a l
1. Remove air cleaner outlet tube ( 9B659) .
lines. Refer t o Secti on 10- 01.
4. Raise vehicle on a hoi st. Refer t o Secti on 00- 02.
5. Di sconnect fuel chargi ng wi ri ng from el ectroni c
vari abl e orifice (EVO) sensor and oil pressure
sensor ( 9278) .
6. Position fuel chargi ng wi ri ng out of way.
7. Lower vehicle.
harness connector f rom fuel chargi ng wi ri ng.
03- 01- 12 E n gi n e , 4. 6L ( 2 V) 03- 01- 12
retaining bracket on power brake boost er
( 2005) , and move out of the way.
Pa r t
3
.
Connector (Part of 9D930)
4 Transmission Wire Harness
10. Remove wi ndshi el d wi per governor ( 17C476) .
11. CAUTI ON: Do n o t pul l o n t h e i gn i t i o n wi r e s a s
i t ma y s e p a r a t e f r o m t h e c o n n e c t o r i n t h e
Di sconnect ignition wi res f rom spark plugs. Refer
12. Remove ignition wi re and bracket s f rom studs and
move ignition wi res out of the way.
13. Remove bol ts and st ud bol ts retaining val ve cover
t o cyl i nder head. Remove val ve cover.
FRONT OF
ENGINE
APPLY SILICONE
GASKET SEALER
NOTE: LH SIDE SHOWN
RH SIDE TYPICAL
A13663-B
Pa r t
1 6582 RH Valve Cover
3 N806356-S2 Stud (LH 3 Req'd, RH 2
Req'd)
5 N806183-S2 Bolt (LH 8 Req'd, RH 9
Req'd)
6 6582 LH Valve Cover
7 6049 LH Cylinder Head
A

Lb-ln)
1 Remove all t races of dirt, oil or previously applied
sealant f rom t he engine front cover and cylinder
head sealing surf aces. Clean all sealing surfaces
wi t h Metal Surface Cleaner F4AZ-19A536-RA or
WSE-MSB392-A. Sealing surf aces must be clean
and dry before appl yi ng sealant.
Appl y Silicone Gasket and Sealer F1AZ-19562-B
WSE-M4G320-A2 in both pl aces where engine
front cover meet s cylinder head.
03- 01- 13 E n gi n e , 4 . 6 L ( 2 ) 03- 01- 13
Position and, using Gasket and Trim Adhesi ve
D7AZ- 19B508- B or equivalent meeting Ford
speci fi cati on ESR-M 11P17-A and ESE-M2G52-A,
glue new valve cover gasket onto val ve cover.
Install val ve cover onto cyl i nder head.
Install bol ts and st uds bol t s into val ve cover.
Tighten studs and bol ts t o 8-12 N-m ( 71- 106 Ib-in)
no later than four minutes after compl eti ng St ep
3.
Install ignition wi re bracket s on studs and connect
ignition wi res t o spark pl ugs. Refer t o Secti on
03- 07.
Install wi ndshi el d wi per governor. Refer t o
Secti on 01- 16.
Connect fuel chargi ng wi ri ng at 42-pin connect or
and transmi ssi on harness connector.
B. Install 42-pin connector on retaining bracket .
9. Raise vehi cl e.
10. Position and connect fuel chargi ng wiring t o t he
EVO sensor and oil pressure sensor.
11. Lower vehi cl e.
12. Connect fuel lines. Refer to Secti on 10- 01.
Connect bat t ery ground cabl e.
St art engine and check for l eaks.
13
14
R o c k e r A r m
Va l v e Spr i n g Co mp r e s s o r
Va l v e Spr i n g S p a c e r
T 91P - 6565- A
T 91P - 6565- A H
Re mo v a l
1. Remove val ve cover s ( 6582) as outlined.
2. Position pi ston ( 6108) of cylinder being servi ced
at t he bot t om of i ts st roke and camshaft l obe at
base ci rcl e.
3. CAUTI ON: If Va l v e Sp r i n g Sp a c e r
T 91P - 6565- A H i s n o t u s e d , v a l v e s p r i n g
r e t a i n e r ( 6514) wi l l hi t v a l v e s t e m se a l ( 657 1)
a n d d a ma g e t h e v a l v e s t e m s e a l .
Install Valve Spri ng Spacer T91P-6565-AH
bet ween val ve spri ng coils t o prevent val ve st em
seal damage.
4. Install Valve Spri ng Compressor T91P-6565-A
under camshaf t ( 6250) and on t op of val ve spri ng
retai ner.
VIEW A
VALVE SPRING
SPACER
T91P-6565-AH
VALVE SPRING
COMPRESSOR
T91P-6565-A
VALVE SPRING SPACER
T91P-6565-AH
VIEW A
A15052-B
5. Compress val ve spri ng ( 6513) and remove
rocker arm ( 6564) .
6. Remove val ve spri ng compressor and spacer.
7. Repeat St eps 2 through 6 until all necessary
rocker arms are removed.
1. Appl y clean engine oil t o valve st em and ti p,
rocker arm roller cont act surfaces and val ve
t appet ( 6500) .
2. Install Valve Spring Spacer T91P-6565-AH
between val ve spri ng coi l s.
3. NOTE: Piston must be at the bottom of its st r oke
and camshaft at base ci rcl e.
Compress val ve spri ng using Valve Spring
Compressor T91P-6565-A and install roller
follower.
4. Remove val ve spring compressor and spacer.
5. Repeat St eps 1 through 4 until all rocker arms are
installed.
6. Install valve cover, as outlined.
Va l v e T a p p e t , H y d r a u l i c
Re mo v a l
1. Remove rocker arms ( 6564) as outlined.
2. Remove val ve t appet s ( 6500) f rom cylinder
heads (6049).
03- 01- 14 E n gi n e , 4. 6L ( 2V)
03- 01- 14
3. Clean and inspect valve t appet s as outlined in
Secti on 03- 00.
1. Appl y clean engine oil t o val ve st em and ti p,
rocker arm roller cont act surf aces and val ve
t appet s and cylinder head val ve t appet bore.
2. NOTE: Valve t appet s must have no more than 1.5
mm ( 0. 059 inch) of plunger travel prior t o
installation.
Install valve t appet s into cylinder heads.
3. Install rocker arms as outlined.
Valve Spring, Retainer and Valve Stem Seal
Va l v e Sp r i n g Co mp r e s s o r
Va l v e Sp r i n g S p a c e r
Va l v e S t e m Se a l Re p l a c e r
T 91P - 6565- A
T 91P - 6565- A H
T 91P - 657 1- A
Re mo v a l
1. Remove val ve covers ( 6582) and rocker arms
2. Remove spark plug ( 12405) f rom appl i cabl e
cylinder. Refer t o Secti on 03- 07.
3. Position pi ston ( 6108) at t op of st roke wi t h bot h
exhaust val ve ( 6505) and i ntake val ve ( 6507)
cl osed.
4. NOTE: Failure of air pressure t o hold the exhaust
val ve and i ntake val ve cl osed whi l e performi ng
t he fol l owi ng st eps is an indication of val ve
and/ or val ve seat damage and requi res removal
of cyl i nder head ( 6049) .
Install an air line wi t h an adapt er in the spark plug
hole and turn air suppl y ON.
5. Install Valve Spring Spacer T91P-6565-AH
bet ween val ve spri ng coi l s.
6. Compress val ve spri ng ( 6513) using Valve Spring
Compressor T91P-6565-A.
VIEW A
VALVE SPRING
SPACER
T91P-6565-AH
VALVE SPRING
COMPRESSOR
T91P-6565-A
VALVE SPRING SPACER
T91P-6565-AH
VIEW A
A15052-B
CAUTI ON: If a i r p r e s s u r e ha s f o r c e d t h e
p i s t o n t o t h e b o t t o m o f t h e c y l i n d e r , a n y l o s s
o f a i r p r e s s u r e wi l l a l l o w t h e v a l v e ( s) t o f a l l
i n t o t h e c y l i n d e r . A r u b b e r b a n d , t a p e o r
s t r i n g w r a p p e d a r o u n d t h e e n d o f t h e v a l v e
s t e m wi l l p r e v e n t t h i s f r o m h a p p e n i n g a n d
st i l l a l l o w e n o u g h t r a v e l t o c h e c k t h e v a l v e
f o r b i n d s a n d e x c e s s i v e gu i d e t o v a l v e s t e m
c l e a r a n c e .
Remove val ve spri ng retainer keys ( 6518) , val ve
spri ng retainer ( 6514) and val ve spri ng.
Using l ocki ng pl i ers, remove val ve st em seal
( 6571) .
Repeat St eps 2 through 8 until all necessary
val ve stem seal s are removed.
NOTE: RH CYLINDER HEAD SHOWN
LH CYLINDER HEAD SIMILAR
LOCKING
PLIERS
VALVE STEM
SEAL 6571
A13630-B
03- 01- 15 E n gi n e , 4. 6L ( 2 V) 03- 01- 15
1. NOTE: Piston must be at t op dead center (TDC)
of cyl i nder being servi ced.
Remove air pressure f rom spark plug adapter.
Inspect t he val ve st em for damage. Rotate the
val ve and check t he val ve st em ti p for eccentri c
movement during rotati on. Move the val ve up and
down through normal t ravel in t he val ve guide and
check t he st em for bi nds.
2. CAUTI ON: If t h e v a l v e ha s b e e n d a ma g e d , i t
wi l l b e n e c e s s a r y t o r e mo v e t h e c y l i n d e r
h e a d f o r s e r v i c e . Re f e r t o S e c t i o n 03- 00.
If t he condi ti on of t he val ve is sat i sf act ory, appl y
cl ean engine oil t o the val ve st em and hold t he
val ve cl osed. Appl y the air pressure within t he
cylinder.
Install new val ve st em seal using Valve St em Seal
Repl acer T91P-6571-A.
VALVE SPRING
COMPRESSOR
T91P-6565-A
VALVE STEM
SEAL
REPLACER
T91P-6571-A
A15053-A
4. Position val ve spri ng and val ve spri ng retainer
over val ve st em.
5. Install Valve Spring Spacer T91P- 6565- AH
bet ween val ve spring coi l s.
6. Compress val ve spring using Val ve Spri ng
Compressor T91P-6565-A and install val ve
spri ng retai ner key.
7. ' Remove val ve spring compressor and spacer.
8. Turn air suppl y OFF and remove adapt er f rom
spark plug hol e.
9. Install spark plug.
10. Install rocker arms and val ve cover s as outlined.
Crankshaf t Pulley and Crankshaf t Front Oil
Seal
Cr a n ks h a f t Da mp e r Re mo v e r
Cr a n ks h a f t Da mp e r Re p l a c e r
Fr o n t Co v e r Se a l Re mo v e r
Cr a n ks h a f t Se a l R e p l a c e r / C o v e r
Al i gn e r
T 58P - 6316- D
T 7 4P - 6316- B
T 7 4P - 67 00- A
T88T- 67 01- A
Re mo v a l
2. Release dri ve bel t tensi oner ( 6B209) and remove
dri ve belt ( 8620) . Refer t o Secti on 03- 05.
3. Rai se vehi cl e on hoist. Refer t o Secti on 00- 02.
4. Remove crankshaf t pulley bol t ( 6A340) and
crankshaf t pulley retaining washer ( 6378) f rom
crankshaf t ( 6303) .
5. Install Crankshaf t Damper Remover
T58P-6316-D on crankshaft pulley ( 6312) and
pull crankshaf t pulley from crankshaf t .
CRANKSHAFT DAMPER
REMOVER
T58P-6316-D
A13668-B
6. Using Front Cover Seal Remover T74P-6700-A,
remove crankshaf t front seal ( 6700) .
1. Lubri cate seal bore in engine front cover ( 6019)
and seal lip wi t h cl ean engine oi l .
2. Using Crankshaft Seal Repl acer/ Cover Aligner
T88T-6701-A, install crankshaft front seal .
CRANKSHAFT SEAL
REPLACER/COVER ALIGNER
T88T-6701-A
A14815-E
03- 01- 16
E n gi n e , 4 6L ( 2 V) 03- 01- 16
IN-VEHICLE SERVICE ( C o n t i n u e d )
Using Crankshaft Damper Repl acer
T74P-6316-B, install crankshaft pulley.
CRANKSHAFT
DAMPER REPLACER
T74P-6316-B
A13662-B
Appl y Silicone Gasket and Seal ant
F1AZ- 19562- B or equivalent meeting Ford
speci fi cati on WSE-M4G320-A2 t o end of keyway
of damper as shown.
CRANKSHAFT
PULLEY 6312
VIEW A
SEALER
KEYWAY
SEALER
CRANKSHAFT
PULLEY 6312
KEYWAY
^ ^ ^ ^ ^ ^ ^
VIEW A
A18921-B
5. NOTE: Make sure key on crankshaf t aligns wi t h
keyway of crankshaf t pulley.
Install crankshaf t pulley bolt and crankshaf t
pulley retaining washer. Tighten t o 155-166 N-m
( 114- 121 Ib-ft).
6. Lower vehi cl e.
7. Install dri ve belt. Refer t o Secti on 03- 05.
9. St art engine and check for l eaks.
E n g i n e F r o n t C o v e r
T 58P - 6316- D
T 7 4P - 6316- B
Re mo v a l
1. CAUTI ON: T h e v a l v e c o v e r s ( 6582 ) , o i l p a n
( 667 5) a n d o i l pa n g a s ke t ( 67 10) mu s t b e
r e mo v e d pr i o r t o t h e e n gi n e f r o n t c o v e r
( 6019) o r p o s s i b l e e n gi n e d a ma g e a n d / o r
l e a ka ge ma y o c c u r u p o n r e a s s e mb l y .
Remove fan blade ( 8600) and fan shroud ( 8146) .
2. Loosen wat er pump pulley bol ts.
3. Remove dri ve belt ( 8620) . Refer t o Secti on
03- 05.
4. Remove wat er pump pulley ( 8509) .
6. NOTE: The front l ower bolt on the power steeri ng
pump ( 3A674) will not come all t he way out.
Remove bol ts retaining power steeri ng pump t o
cyl i nder bl ock ( 6010) and engine front cover.
7. Wi re power steeri ng pump out of way.
8. Remove oil pan and oil pan gasket as outlined.
9. Remove crankshaft pulley bolt ( 6A340) and
crankshaft ( 6303) .
10. Install Crankshaft Damper Remover
pull crankshaft pulley f rom crankshaft.
CRANKSHAFT DAMPER
REMOVER
T58P-6316-D
A13668-B
12. Remove bolt retaining air conditioner
hi gh-pressure line t o RH ignition coil bracket .
13. Remove both RH and LH val ve covers as
outlined.
both ignition coils ( 12029) and camshaft position
sensor (CMP sensor)(6B288).
03- 01- 17 E n gi n e , 4* 6L ( 2 V) 0 3 - 0 1 - 1 7
15. Remove t hree bol ts retaining RH ignition coil
bracket t o engine front cover. Position power
steeri ng hoses out of way.
16. Remove t hree nuts retaining LH ignition coil
bracket t o engine front cover.
17. Slide bot h ignition coil br acket s and ignition wi res
off mounting st uds and lay assembl y on t op of
engine. Remove bol ts retaining belt idler pulley;
then remove pulley.
18. Di sconnect fuel chargi ng wi ri ng f rom crankshaf t
position sensor (CKP se nsor ) ( 6C315) and then
remove crankshaf t position sensor.
19. If equi pped, remove retai ners for oil cool er
( 6A642) f rom engine front cover retaining stud
bol ts and position oil cool er out of the way.
20. Remove stud bol ts and bol ts retaining engine front
cover t o engine.
2 1 . Remove engine front cover.
A PPLY WSE-M4G320-A 2
SEA LER
Pi ONTOF
EiGINE
VIEW A
TYPICAL 4 PLACES
A13659-C
Pa r t
6 W807753 Bolt
7 N806300-S2 Stud
8 N806040-S Dowel (2 Req'd)
(Lb-Ft)
1 Remove all t r aces of di rt, oil or previously appl i ed
sealant f rom the engine front cover and cylinder
bl ock seal i ng surf aces. Clean all sealing surf aces
wi th Metal Surface Cleaner F4AZ- 19A536- RA or
equivalent meeting Ford speci fi cati ons
WSE-M5B392-A. Sealing surf aces must be cl ean
and dry before appl yi ng seal ant.
03- 01- 18
E n gi n e , 4.6L (2V)
03- 01- 18
IN-VEHiCLE SERVICE (Cont i nued)
3.
4.
8.
9.
10.
11.
12.
Repl ace cr ankshaf t f ront seal ( 67 00) , and engi ne
front cover gasket (three each).
Appl y an 8-12 mm ( 0. 32- 0. 47 inch) bead of
Silicone Gasket Sealant F1AZ- 19562- B or
WSE- M4G320- A2, in l ocati ons shown in
illustration fol l owi ng Removal , St ep 2 1 .
Install engine front cover on engine no more than
four minutes after appl yi ng seal ant.
Install studs and bol ts retaining engine front cover
t o engine in l ocati on shown fol l owi ng Removal ,
St ep 2 1 . Tighten t o 20- 30 N-m (15-22 Ib-ft) no
more than four minutes after appl yi ng seal ant.
If equi pped, install oil cool er onto engine front
cover retaining stud bol ts.
Install crankshaf t position sensor and at t ach t he
fuel chargi ng wi ri ng t o the crankshaf t position
sensor.
Position ignition coil bracket s and ignition wi res
as an assembl y onto mounting st uds.
Position power steeri ng hose and install seven
nuts retaining coil bracket s t o engine front cover.
Tighten nuts t o 20-30 N-m ( 15- 22 Ib-ft).
Connect fuel chargi ng wi ri ng t o bot h ignition coi l s
and camshaft position sensor.
Install val ve covers as outlined.
Position air conditioner hi gh-pressure line on RH
ignition coil bracket and install bol t.
13. Raise vehi cl e.
14. Appl y Silicone Gasket and Seal ant
speci fi cati on WSE- M4G320- A2 t o end of the
keyway and crankshaf t pulley.
CRANKSHAFT
PULLEY 6312
VIEW A
SEALER
KEYWAY
SEALER
CRANKSHAFT
PULLEY 6312
KEYWAY
VIEW A
A18921-B
15. Position crankshaft pulley on crankshaft. Make
sure crankshaft key and keyway are aligned.
16. Using Crankshaft Damper Repl acer
T74P-6316-B, install crankshaft pulley.
17. Install crankshaf t pulley bolt and crankshaft pulley
retaining washer. Tighten t o 155-165 N-m
( 114- 121 Ib-ft).
18. Install oil pan wi t h new oil pan gasket as outlined.
19. Position power steeri ng pump on engine and
install four retaining bol ts. Tighten t o 20- 30 N-m
(15-22 Ib-ft).
20. Lower vehicle.
0 3 - 0 1 - 1 9 Engi ne, 4. 6L ( 2V) 03- 01- 19
21. Install water pump pulley with four bolts. Tighten
to 20-30 N-m (15-22 Ib-ft).
22. Install drive belt. Refer to Section 03-05.
23. Install fan blade and fan shroud. Refer to Section
03-03.
24. Start engine and check for leaks.
Camshaf t Ti mi ng Chains and Tensi oners
Ca m P o s i t i o n i n g To o l
Ca m P o s i t i o n i n g To o l A d a p t e r s
Cr a n ks h a f t Ho l d i n g To o l
T 91P - 62 56- A
T 92 P - 62 56- A
T 93P - 6303- A
Re mo v a l
1. CAUTI ON: A t n o t i me , wh e n t h e t i mi n g
c h a i n ( s ) a r e r e mo v e d a n d t h e c y l i n d e r h e a d s
( 6049) a r e i n s t a l l e d , ma y t h e c r a n ks h a f t
( 6303) a n d / o r c a ms h a f t s ( 62 50) b e r o t a t e d .
Fa i l ur e t o f o l l o w t h e s e d i r e c t i o n s wi l l r e s ul t i n
v a l v e a n d / o r p i s t o n d a ma g e .
NOTE: Because this is not a free-wheeling
engine, and if "jumps time," there will be damage
to the valves and/or pistons (6108) and will
require the removal of the cylinder heads. The
camshaft sprockets (6256) should only be
disassembled from the camshafts when one of
the components is to be replaced.
Remove valve covers (6582), oil pan (6675) and
engine front cover (6019) as outlined.
2. Remove crankshaft position sensor pulse wheel.
3. Rotate engine to No. 1 top dead center (TDC).
90 DE G RE E S 90 DE G RE E S
A14820-B
4. NOTE: This will prevent accidental rotation of the
camshafts.
NOTE: Cam Positioning Tool Adapters
T92P-6256-A and Cam Positioning Tool
T91P-6256-A must be installed on camshaft to
prevent camshaft from rotating.
Install Cam Positioning Tool Adapters
T91P-6256-A on flats of camshaft.
A15294-B
5. Remove two bolts retaining RH timing chain
tensioner (6L266) to cylinder head and remove
timing chain tensioner.
6. Remove RH timing chain tensioner arm (6L253).
7. Remove two bolts retaining RH timing chain guide
(6K297) to cylinder head and remove timing
chain guide.
8. Remove RH timing chain from camshaft sprocket
and crankshaft sprocket (6306).
9. NOTE: Cam Positioning Tool Adapters
T91P-6256-A must be installed on camshaft to
prevent camshaft from rotating.
Remove two bolts retaining LH timing chain
tensioner to cylinder head and remove timing
chain tensioner.
10. Remove LH timing chain tensioner arm.
11. Remove two bolts retaining LH timing chain guide
to cylinder head and remove timing chain guide.
12. Remove LH timing chain from camshaft sprocket
and crankshaft sprocket.
13. If necessary, remove camshaft sprockets and
crankshaft sprockets as outlined.
14. CAUTION: Do not rotate crankshaft and/or
camshafts or possible engine damage may
occur.
Inspect the plastic running face on timing chain
tensioner arms and timing chain guides. If worn or
damaged, remove and clean oil pan and oil pump
screen cover and tube (6622).
03- 01- 20 En gi n e , 4. 6L ( 2 V) 0 3 - 0 1 - 2 0
Installation
1. NOTE: if engine has ' ' jumped t i me, ' ' ensure that
ail repai rs t o engine components and/ or val ve
trai n have been made. Then rotate engine
count ercl ockwi se 45 degrees. Thi s will position
all pi stons bel ow t op of deck f ace. Install cylinder
heads as outlined.
NOTE: Cam Positioning Tool Adapt ers
T91P-6256-A must be installed on camshaft, t o
prevent camshaf t s f rom rotati ng.
Install timing chai n gui des (both si des). Install
timing chain guide retaining bol ts. Tighten t o 8-12
N-m (71-106 lb-in).
2. If removed, position LH camshaft sprocket
spacer ( 6265) and camshaft sprocket on
camshaf t .
3. Install washer and camshaf t sprocket retaining
bol t. Do not tighten at this ti me.
4. If removed, position RH camshaf t sprocket
spacer and camshaft sprocket on camshaft.
5. Install washer and camshaf t sprocket retaining
bolt. Do not tighten at thi s ti me.
Pa r t
I t e m Nu mb e r Descr i pt i on
1 6250 Camshaft
2 6303 Crankshaft
3 6K297 Timing Chain Guide (LH)
4 6306 Crankshaft Sprocket (2
Req'd)
5 N806070-S Bolt (2 Req'd Each Side)
6 6K297 Timing Chain Guide (RH)
7 N806139-S2 Bolt (1 Req'd Each Side)
8 N806164-S Washer (1 Req'd Each Side)
9
6268 Timing Chain (RH)
I t e m
Pa r t
10 6256 Camshaft Sprocket
11
6265 Camshaft Sprocket Spacer
(1 Req'd Each Side)
A

Lb-ln)
B

(81-95 Lb-Ft)
6. NOTE: Crankshaft sprocket s are identical. They
may only be installed one way. Refer t o t he
fol l owi ng illustration for proper crankshaft
sprocket installation.
VIEW A
I NCORRECT I NCORRECT I NSTALLATI ON
* Q A T I M I N G
f wx T V* J M A R K S
V J ^ A ^ A L I G N E D
K E Y W A Y S ^
A L I G N E D
VIEW A
A14824-B
NOTE: Make sure t apered part of crankshaft sprocket
f aces away f rom cylinder bl ock ( 6010) .
If, removed, install LH crankshaft sprocket .
NOTE: WITH EITHER CHAIN POSITIONED
AS SHOWN, MARK EACH END AND USE
MARKS AS TIMING MARKS
7. NOTE: If copper links of timing chain are not
visible, split both timing chai ns in half and mark
t he t wo opposi ng links as shown.
Install LH timing chain on camshaft sprocket .
Make sure copper link of timing chai n lines up wi t h
timing mark of camshaft sprocket .
8. Install LH timing chain on crankshaft sprocket .
timing mark of crankshaft sprocket .
03- 01- 21 E n gi n e , 4. 6L ( 2 V) 0 3 - 0 1 - 2 1
10.
11.
NOTE: Make sure t apered part of crankshaft
sprocket f aces t owar d cylinder bl ock.
If removed, install RH crankshaf t sprocket .
Install RH timing chai n on camshaf t sprocket .
Make sure copper link of timing chai n lines up wi th
timing mark of camshaf t spr ocket .
Install RH timing chain on crankshaf t sprocket .
timing mark of crankshaf t spr ocket .
A14823-C
Pa r t
1

RH Camshaft Timing Chain
Mark
2 RH Camshaft Sprocket Mark
3

LH Camshaft Timing Chain
Mark
4
RH Camshaft Sprocket Mark
5

Crankshaft Sprocket Mark
6 Crankshaft Timing Chain
Mark
7 6306 Crankshaft Sprocket
8 Crankshaft Keyway Center
Line
12. Install RH and LH timing chain tensioner and
secure wi th t wo bol ts on each. Tighten bol ts t o
20- 30 N-m (15-22 Ib-ft).
13. Install Crankshaft Holding Tool T93P-6303-A over
crankshaf t and engine front cover alignment
dowel t o position crankshaft.
NfJAl XTOOL CRANKSHAFT HOLDING
C O VE R A S G N ME N T T OOL T 93P - 6303- A
DOWEL
NOTE: ALIGN CRANKSHAFT
WOODRUFF KEY WITH
KEYWAY ON TOOL
A16254-B
14. Lubri cate timing chai n tensioner arm cont act
surf aces wi t h cl ean engine oil and install RH and
LH timing chai n tensioner arms on their dowel s.
NOTE: DO NOT REMOVE
TENSIONER LOCK PINS
UNTIL CHAIN GUIDES
HAVE BEEN INSTALLED
FRONT OF
ENGINE
NOTE: LUBRICATE TENSIONER
ARM CONTACT SURFACES WITH
ENGINE OIL PRIOR TO ASSY
A14822-C
Pa r t
1 6049 Cylinder Head (RH)
2 6049 Cylinder Head (LH)
3 N806040-S Dowel
(LH)
5 6L266 Timing Chain Tensioner (LH)
6 N606543-S2 Bolt (2 Req'd)
7

Lock Pin (Part of 6L266)
8 6L266 Timing Chain Tensioner (RH)
( Co n t i n ue d )
03- 01- 2 2 E n gi n e , 4. 6L ( 2 V) 03- 01- 2 2
Pa r t
(RH)
Lb-Ft)
15.
16.
17
19.
Wi t h a suitable C-clamp around t he timing chain
tensi oner arm and timing chain guide, remove all
sl ack f rom timing chain while using caution not t o
bend t he timing chai n guide.
Remove l ock pins f rom timing chain tensi oners
and make sure all timing marks are aligned.
NOTE: USE C-CLAMP TO REMOVE SLACK
FROM CAMSHAFT TIMING CHAIN
A16255-B
Using Cam Positioning Tool Adapt ers
T91P-6256-A t o align camshaf t , ti ghten camshaf t
spr ocket bolt t o 110-130 N-m (81-95 Ib-ft).
18. NOTE: If not at maxi mum lift, loosen camshaf t
spr ocket bolt and repeat Steps 12-15.
Install Rotunda Dial Indicator wi th Bracket ry
014- 00282 or equivalent in cylinder 1 spark plug
hol e. Check that camshaf t is at maxi mum lift f or
t he i ntake val ve ( 6507) at 114 degrees after t op
dead center (TDC).
Remove Cam Positioning Tool Adapt ers
T92P-6256-A, Cam Positioning Tool
T91P-6256-A and Crankshaft Positioning Tool
T93P-6256-A.
20. Install engine front cover, oil pan and val ve covers
as outlined.
2 1 . St art engine and check for l eaks and proper
operati on.
T i m i n g S p r o c k e t s
T 91P - 62 56- A
T 92 P - 62 56- A
Re mo v a l
1. Remove camshaf t timing chai ns and timing chain
tensi oners ( 6L266) as outlined.
2. Remove crankshaf t spr ocket s ( 6306) f rom
3. NOTE: Cam Positioning Tool Adapt ers
T91P-6256-A must be installed on camshaf t s
( 6250) t o prevent camshaf t s f rom rotati ng.
Remove camshaf t sprocket retaining bol ts,
washer s, camshaf t spr ocket s ( 6256) and
camshaf t sprocket spacer s ( 6265) .
4. CAUTI ON: Do n o t r o t a t e c r a n ks h a f t a n d / o r
c a ms h a f t s o r p o s s i b l e d a ma g e t o e n gi n e
ma y o c c u r .
Inspect crankshaf t spr ocket s and camshaf t
spr ocket s for wear or damage and repl ace as
requi red.
1. NOTE: Cam Positioning Adapt ers T92P-6256-A
and Cam Positioning Tool T91P-6256-A must be
installed on camshaf t s t o prevent camshaf t s f rom
rotati ng.
Position camshaft sprocket spacers and
camshaf t spr ocket s on camshaf t s.
2. Install washer s and camshaf t sprocket retaining
bol ts. Do not tighten at thi s ti me.
03- 01- 2 3 En gi n e , 4* 6L ( 2 V) 0 3 - 0 1 - 2 3
3. NOTE: Crankshaf t spr ocket s are identical. They
may only be installed one way.
Install crankshaf t spr ocket s onto crankshaft.
Refer t o t he fol l owi ng illustration for proper
crankshaf t spr ocket installation.
VIEW A
CORRECT
INCORRECT INCORRECT INSTALLATION
TI MI NG
fwxtLi MARKS
^ V S ^ 7 A L I G NE D
K E Y W A Y S ^
A L I G N E D
VIEW A
A14824-B
4. Install camshaf t timing chai ns and timing chai n
tensi oners as outl i ned.
C a m s h a f t s
Ca m P o s i t i o n i n g T o o l
Va l v e Spr i n g C o mp r e s s o r
T58P - 6316- D
T91P - B2 56- A
T7 4P - 6316- B
T92 P - 62 56- A
T91P - 6565- A
T91P - 6565- A H
Re mo v a l
1
2
Di sconnect bat t ery ground cabl e ( 14301) .
Remove fan bl ade ( 8600) and fan shroud ( 8146) .
4. Remove air cl eaner outl et tube ( 9B659) . Refer t o
Secti on 03- 12.
6. Release dri ve belt tensi oner ( 6B209) and remove
drive belt ( 8620) . If necessary, refer t o Secti on
03-05.
7. CAUTI ON: Do n o t pul l o n i gn i t i o n wi r e a s i t
ma y s e pa r a t e f r o m t h e c o n n e c t o r i n t h e
i gn i t i o n wi r e boot .
Di sconnect eight ignition wi res f rom spark pl ugs
( 12405) . Refer t o Section 03- 07.
8. Di sconnect ignition wi re and bracket s ( 12280)
f r om valve cover studs.
9. Remove t wo bol ts retaining ignition wi re
separator ( 12297) to ignition coil bracket s.
10. Remove bolt retaining air conditioner high
pressure line t o RH ignition coil bracket .
11. Di sconnect fuel chargi ng wiring ( 9D930) from
bot h ignition coils ( 12029) and camshaf t posi ti on
12. Remove three nuts retaining RH ignition coil
bracket to engine front cover ( 6019) .
13. Remove three nuts retaining LH ignition coil
bracket to engine front cover.
14. Slide ignition coil bracket s and ignition wi re and
bracket assembl y off mounting st uds and remove
f rom vehicle.
16. Di sconnect positive battery cabl e at power
distribution box.
17. Remove retaining bolt f rom posi ti ve bat t ery cabl e
bracket l ocated on the side of RH cylinder head
( 6049) .
18. Di sconnect fuel vapor hose f rom evaporati ve
emission cani ster purge val ve (EVAP cani ster
purge val ves)(9C915) and posi ti on posi ti ve
bat t ery cabl e out of the way.
19. Di sconnect fuel vapor hose f rom posi ti ve
crankcase ventilation valve (PCV val ve)(6A666)
and remove positive crankcase ventilation val ve
f rom valve cover (6582).
retaining bracket on power brake boost er ( 2005) .
2 1 . Di sconnect fuel chargi ng wi ri ng at 42-pin
connector and transmission harness connector
and move out of the way.
22. Di sconnect crankshaft position sensor (CKP
sensor)(6C315), A/ C cl utch ( 2884) and
evaporati ve emission cani ster purge val ve.
24. NOTE: The front lower bolt on t he power steeri ng
cylinder bl ock ( 6010) and engine front cover.
25. Wi re the power steeri ng pump out of the way.
26. Remove oil pan gasket ( 6710) and oil pan ( 6675)
as outlined.
crankshaft pulley retaining washer ( 6378) f rom
crankshaft ( 6303) .
03- 01- 2 4 E n gi n e , 4. 6L ( 2 V) 03- 01- 2 4
pull crankshaf t pulley f rom crankshaf t .
CRANKSHAFT DAMPER
REMOVER
T58P-6316-D
A13668-B
29. Position drai n pan under oil bypass filter ( 6714)
and remove oil bypass filter.
30. Di sconnect power steeri ng control val ve act uat or
( 3783) and oil pressure sensor ( 9278) .
3 1 . Remove oil filter adapt er ( 6881) and position fuel
chargi ng wi ri ng out of t he way.
33. Remove nine bol ts and t wo st ud bol ts retaining
RH val ve cover t o cyl i nder head and remove
val ve Gover.
34. Remove ei ght bol ts and t hree stud bol ts retaining
LH val ve cover t o cylinder head and remove val ve
cover.
FRONT OF
ENGINE
APPLY SILICONE
GASKET SEALER
NOTE: LH SIDE SHOWN
RH SIDE TYPICAL
A13663-B
Pa r t
3 N806356-S2 Bolt
5 N806183-S2 Bolt (LH 8 Req'd RH 9 Req'd)
A

Lb-ln)
03- 01- 2 5 E n gi n e , 4. 6L ( 2 V) 03- 01- 2 5
IN-VEHiCLE SERVICE (Conti nued)
35. Remove seven stud bol ts and four bol ts retaining
engine front cover t o engine. Remove engine front
cover.
APPLY WSE-M4G320-A2
SEALER
0 -

A13659-C
Pa r t
6 W807753 Bolt
7 N806300-S2 Stud
A

Tighten t o 20-30 N-m (15-22
(Lb-Ft)
36. Remove timing chai ns as outlined.
37. CAUTI ON: Cr a n ks h a f t mu s t b e i n t h i s
p o s i t i o n p r i o r t o r o t a t i n g c a ms h a f t s ( 62 50) o r
d a ma g e t o p i s t o n s ( 6108) a n d / o r v a l v e t r a i n
wi l l r e s u l t .
Rot at e crankshaft count ercl ockwi se 45 degrees
f rom t oe.
C CRANKSHAFT
6303
39.
CRANKSHAFT
KEYWAY
A13655-B
38. NOTE: This ensures that all pi stons are bel ow the
t op of t he cylinder bl ock deck f ace.
Install Valve Spring Compressor T91P-6565-A
under camshaf t and on t op of val ve spri ng
retai ner ( 6514) .
NOTE: Valve Spring Spacer T91P- 6565- AH must
be installed bet ween val ve spri ng coi l s. Camshaft
must be at base ci rcl e before compressi ng val ve
spri ng ( 6513) . Rotate camshaf t as requi red until
all r ocker arms ( 6564) are removed.
VIEW A
VALVE SPRING
SPACER
T91P-6565-AH
VALVE SPRING
COMPRESSOR
T91P-6565-A
VALVE SPRING SPACER
T91P-6565-AH
VIEW A
A15052-B
Compress val ve spring far enough t o remove
rocker ar m.
03- 01- 2 6 E n gi n e , 4. 6L ( 2 V) 03- 01- 2 6
IN-VEHICLE SERVICE (Cont i nued)
40. Repeat St eps 38 and 39 until all rocker arms are
removed.
4 1 . Remove 14 bol ts retaining camshaf t beari ng caps
( 6B280) t o cyl i nder head.
CAMSHAFT BEARING
CAP 6B280
p 0 o B o 0 o,
TAP HERE
7
CYLINDER HEAD 6049
A14949-B
42. Tap upward on camshaft beari ng caps at posi ti on
shown and gradual l y lift camshaf t bearing caps
f rom cyl i nder head.
43. Remove camshaf t strai ght upward t o avoi d
bearing damage.
FRONT OF
ENGINE
NOTE: VALVE TAPPET MUST
BE PUMPED UP BEFORE
INSTALLATION
NOTE: LH SHOWN
RH TYPICAL
A14818-B
Pa r t
1 Front 6B280 Camshaft Bearing Cap
2 6L293 Bolt (14 Req'd)
3 6B280 Rear Camshaft Bearing Cap
4 6250 Camshaft
Pa r t
5 6564 Rocker Arm (8 Req'd)
6 6500 Valve Tappet (8 Req'd)
A

Lb-ln)
44. St eps 38 t hrough 43 will remove only one
camshaf t . If both camshaf t s are being servi ced,
repeat St eps 38 through 43 t o remove t he other
camshaf t .
1. Clean and i nspect val ve cover, engine front cover
and cyl i nder head sealing surf aces.
2. Position camshaf t on cylinder head. Appl y cl ean
engine oil t o j ournal s and l obes of camshaft.
3. NOTE: Each camshaf t beari ng cap is ti ghtened
individually.
Install and seat camshaf t beari ng caps.
Hand-start 14 bol ts.
4. Tighten camshaf t beari ng cap retaining bol ts in
sequence t o 8-12 N-m ( 71- 106 lb-in).
I n st a l l a t i o n Se que n c e
CAMSHAFT BEARING CAMSHAFT BEARING
CAP 6B280 | CAP 6B280
5.
6.
A14817-C
Loosen 14 camshaf t bearing cap retaining bol ts
approxi mat el y t wo turns or until head of bolt is
free.
NOTE: Camshaft should turn freel y wi th a slight
drag.
Reti ghten all bol ts in sequence t o 8-12 N-m
( 71- 106 lb-in).
7. Check camshaf t end play using Rotunda Dial
Indicator wi t h Bracket ry 014- 00282 or
equivalent.
If necessary, install Cam Positioning Tool
Adapt ers T92P-6256-A and Cam Positioning Tool
T91P-6256-A on fl ats of camshaf t and install
camshaf t sprocket spacer ( 6265) and camshaft
sprocket ( 6256) . Install bolt and washer and
ti ghten t o 110-130 N-m (81-95 Ib-ft).
8
03- 01- 2 7 E n gi n e , 4. 6L ( 2 V)
" ? K Z - Z I Z I ! a E J 3 K
03- 01- 2 7
9. NOTE: Val ve Spri ng Spacer T91P- 6565- AH must
be installed bet ween val ve spri ng coi l s and t he
camshaf t must be at base ci rcl e pri or t o
compressi ng val ve spri ng. Rotate camshaf t as
necessary until all rocker arms are i nstal l ed.
Install Valve Spri ng Compressor T91P-6565-A
under camshaf t and on t op of val ve spri ng
retai ner. Install val ve t appet ( 6500) .
10. Compress val ve spri ng f ar enough t o install
rocker arm.
11.
12.
13.
14.
15.
16.
NOTE: St eps 2 through 11 will install only one
camshaf t . If both camshaf t s are being servi ced,
repeat St eps 2 through 11 to install t he other
camshaf t .
Repeat St eps 8 through 10 until all rocker arms
are installed. Remove Valve Spri ng Spacer f rom
val ve spri ng.
CAUTI ON: Cr a n ks h a f t mu s t o n l y b e r o t a t e d i n
t h e c l o c k w i s e d i r e c t i o n a n d o n l y a s f a r a s t o p
d e a d c e n t e r ( TDC) .
NOTE: This will position crankshaft at t op dead
center (TDC).
Rotate crankshaf t cl ockwi se 45 degrees.
C CRANKSHAFT
6303 . . .
CRANKSHAFT
KEYWAY
A13658-B
CAUTI ON: T i mi n g c h a i n p r o c e d u r e s mu s t b e
f o l l o w e d e x a c t l y o r d a ma g e t o v a l v e s a n d / o r
p i s t o n s wi l l r e s u l t .
Install timing chai n as outlined.
Inspect and repl ace crankshaft front seal ( 6700)
and engine front cover gasket ( 6020) as
necessary.
NOTE: Remove all t races of di rt, oil or previ ousl y
appl i ed seal ant. Clean all sealing surf aces wi th
Metal Surface Cleaner F4AZ- 19A536- RA or
WSE- M5B392- H. Sealing surf aces must be cl ean
Appl y an 8-12 mm (0. 32-0. 47 inch) bead of
Silicone Gasket and Sealant F1AZ- 19562- B or
equivalent meeti ng For d speci fi cati on
WSE- M4G320- A2 in l ocati ons shown.
APPLY WSE-M4G320-A2
SEALER
0

A13659-C
Pa r t
6 W807753 Bolt
7 N806300-S2 Stud
A

Tighten t o 20-30 N-m (15-22
(Lb-Ft) !
17. Install engine front cover on engine.
18. Install engine front cover stud bol ts and eight
bol ts retaining engine front cover t o engine.
Tighten t o 20-30 N-m (15-22 Ib-ft).
03- 01- 2 8 E n gi n e , 4. 6L ( 2 V) 03- 01- 2 8
!N-EHlCLE SERVICE (Conti nued)
19. NOTE: Remove all t races of di rt, oil or previ ousl y
appl i ed seal ant. Clean all sealing surf aces wi t h
Met al Surface Cleaner F4AZ-19A536-RA or
WSE-M5B392-A. Sealing surfaces must be cl ean
Appl y Silicone Gasket and Sealant
speci fi cati on WSE-M4G320-A2 both pl aces
engine front cover meets cyl i nder head.
20. Position and using Silicone Gasket and Sealant
speci fi cati on WSE-M4G320-A2, secure gasket s
into val ve covers and install val ve covers onto
cyl i nder heads.
2 1 . Install bol ts and stud bol ts into RH val ve cover.
Tighten all bol ts t o 8-12 N-m (71-106 Ib-in).
22. Install bol ts and stud bol ts into LH val ve cover.
Tighten all bol ts t o 8-12 N-m ( 71- 106 Ib-in).
FRONT OF
ENGINE
APPLY SILICONE
GASKET SEALER
NOTE: LH SIDE SHOWN
RH SIDE TYPICAL
A13663-B
Pa r t
3 N806356-S2 Stud (LH 3 Req'd RH 2
Req'd)
I t e m
Pa r t
A

Lb-ln)
23. Rai se vehi cl e.
24. Connect fuel chargi ng wi ri ng t o t he power
steeri ng control val ve act uat or and oil pressure
sensor.
25. Appl y Silicone Gasket and Sealant
F1 AZ- 19562- B or equivalent meeting Ford
speci fi cati on WSE-M4G320-A2 in keyway of
crankshaf t pulley as shown.
CRANKSHAFT
PULLEY 6312
VIEW A
SEALER
KEYWAY
SEALER
CRANKSHAFT
PULLEY 6312
KEYWAY
VIEW A
A18921-B
26. Position crankshaf t pulley on crankshaf t . Make
sure crankshaft key and keyway are al i gned.
03- 01- 29 E n gi n e , 4. 6L ( 2 V) 0 3 - 0 1 - 2 9
T74P- 6316- B, install crankshaf t pulley.
CRANKSHAFT
DA MP E R R E P L A C E R
T 7 4P - 6316- B
A13662-B
28 Install crankshaf t pulley bol t and crankshaf t pulley
( 114- 121 Ib-ft).
29. Install oil pan wi t h new gasket as outlined.
install four retaining bol ts. Tighten t o 20- 30 N-m
(15-22 Ib-ft).
3 1 . Lower vehi cl e.
32. Connect fuel chargi ng wi ri ng t o the A / C cl ut ch,
crankshaft posi ti on sensor and evaporati ve
emission cani ster purge val ve.
33. Connect 42-pi n engine harness connector and
transmi ssi on harness connector.
34. Install 42-pi n connector on retaining bracket on
power br ake boost er.
A14S01-B
Pa r t
3

4

35. Install posi ti ve crankcase ventilation val ve in RH
val ve cover and front vapor hose.
36. Position posi ti ve bat t ery cabl e harness on RH
cyl i nder head.
37. Install bol t retaining bat t ery cabl e br acket t o
cyl i nder head.
38. Connect front vapor hose t o evaporati ve emi ssi on
cani ster purge val ve.
39. Connect posi ti ve bat t ery cabl e at power
di stri buti on box and harness ( 14516) and bat t ery
( 10653) .
40. Install wat er pump pulley and ti ghten bol t s t o
20- 30 N-m (15-22 Ib-ft).
4 1 . Position ignition coil bracket s and ignition wi re
and bracket s assembl y onto mounting st uds.
42. Install seven nuts retaining ignition coil br acket s t o
engine front cover. Tighten t o 20- 30 N-m ( 15- 22
Ib-ft).
43. Connect fuel chargi ng wiring t o both ignition coi l s
and camshaf t posi ti on sensor.
44. Position air conditioner hi gh-pressure line on RH
ignition coi l bracket and install bolt.
45. Connect ignition wi res t o spark pl ugs. Refer t o
Secti on 03- 07. Install bracket s onto val ve cover
studs.
46. Install dri ve bel t. Refer t o Secti on 03- 05.
47. Install wi ndshi el d wi per governor. Refer t o
Secti on 01- 16.
48. Connect fuel lines. Refer t o Secti on 10- 01.
49. Install fan bl ade and fan shroud. Fill cool i ng
syst em. Refer t o Secti on 03- 03.
50. Install air cl eaner outlet tube. Refer t o Secti on
03- 12.
5 1 . Connect bat t ery ground cabl e.
52. Start engine and check for l eaks. Check and add
oil as needed.
C y l i n d e r H e a d s
De s c r i p t i o n T o o l Number
T58P - 6316- D
T 7 4P - 6316- B
T 91P - 62 56- A
T 92 P - 62 56- A
Re mo v a l
2. Drain cooling syst em and remove fan bl ade
( 8600) and fan shroud ( 8146) . Refer t o Secti on
03-03.
03- 01- 30 E n gi n e , 4. 6L ( 2V) 03- 01- 30
4. Remove air cleaner outlet tube ( 9B659) . Refer t o
Secti on 03- 12.
6. Release dri ve belt tensioner ( 6B209) and remove
7. CAUTI ON: Do not pul l on i gni t i on wi r e as i t
may separ at e f r om t he connect or i n t he
i gni t i on wi r e boot .
Di sconnect eight ignition wi res f rom spark pl ugs
( 12405) . Refer t o Secti on 03- 07.
8. Di sconnect ignition wi re and bracket s ( 12280)
f rom val ve cover studs.
9. Remove t wo bol ts retaining ignition wi re
separat or ( 12297) t o ignition coil bracket s.
10. Remove bolt retaining air conditioner
hi gh-pressure line t o RH ignition coil bracket .
both ignition coi l s ( 12029) and camshaft position
sensor (CMP sensor ) ( 6B288) .
12. Remove three nuts retaining RH ignition coil
bracket t o engine front cover ( 6019) .
13. Remove four nuts retaining LH ignition coi l
bracket t o engine front cover.
14. Slide ignition coil bracket s and ignition wi re and
bracket assembl y off mounting studs and remove
f rom vehi cl e.
16. Di sconnect generator wi ri ng harness f rom
junction bl ock, front fender apron ( 16054) and
generator (GEN)( 10346) .
17. Remove t wo bol ts retaining generator mounting
bracket ( 10153) t o i ntake manifold ( 9424) .
18. Remove t wo bol ts retaining generator t o cyl i nder
bl ock ( 6010) and remove generator.
19. Di sconnect posi ti ve bat t ery cabl e at power
distribution box and harness ( 14516) .
20. Remove retaining bolt f rom posi ti ve bat t ery cabl e
bracket l ocat ed on t he si de of RH cyl i nder head
( 6049) .
2 1 . Di sconnect front vapor hose f rom evaporat i ve
emi ssi on cani ster purge val ve (EVAP cani ster
purge val ves)(9C915) and move posi ti ve bat t ery
cabl e out of t he way.
22. Di sconnect front vapor hose f rom posi ti ve
crankcase ventilation val ve (PCV val ve) ( 6A666)
and remove posi ti ve crankcase ventilation val ve
f rom val ve cover ( 6582) .
retaining bracket on power brake boost er ( 2005) ,
di sconnect and move out of t he way.
24. Di sconnect fuel chargi ng wi ri ng f rom the
crankshaf t position sensor (CKP
sensor)(6C315), A / C cl utch ( 2884) and
evaporat i ve emi ssi on cani ster purge val ve.
25. Rai se vehi cl e on hoi st. Refer t o Secti on 00- 02.
26. NOTE: The front l ower bolt on t he power steeri ng
cyl i nder bl ock and engine front cover.
27. Secure the power steeri ng pump out of t he way
wi t h wi re.
28. Remove oil pan ( 6675) and oil pan gasket ( 6710)
as outl i ned.
29. Remove crankshaf t pulley bolt ( 6A340) and
T58P-6316-D on crankshaf t pulley ( 6312) and
pull crankshaf t pulley f rom crankshaf t .
CRANKSHAFT DAMPER
REMOVER
T58P-6316-D
A13668-B
3 1 . Di sconnect fuel chargi ng wi ri ng f rom t he power
steeri ng control val ve act uat or ( 3783) and oil
pressure sensor ( 9278) .
32. Position fuel chargi ng wi ri ng out of the way.
33. Di sconnect EGR val ve t o exhaust manifold tube
( 9D477) f rom RH exhaust manifold ( 9430) .
34. Di sconnect three way cat al yt i c converter
( TWCX5E212) f rom RH and LH exhaust
manifolds.
35. Lower exhaust syst em and secure t o
crossmember in posi ti ons shown wi t h wi re.
NO. 3 CROSSMEMBER
A13631-B
03- 01- 31 E n gi n e , 4. 6L ( 2V) 3- 01- 31
36. Remove bolt retaining st art er wi ri ng harness t o
rear of RH cyl i nder head.
38. Remove bol ts and st ud bol ts retaining RH val ve
cover t o cyl i nder head and remove val ve cover.
39. Remove bol ts and st ud bol ts retaining LH val ve
cover t o cyl i nder head and remove val ve cover.
40. Di sconnect accel erat or cabl e ( 9A758) and speed
control actuator ( 9A825) using a screwdri ver or
similar t ool .
A C C E L E R A T O R C A B L E
9 A 7 5 8 / S P E E D C O N T R O L
A C T U A T O R 9 A 8 2 5
S C R E W D R I V E R
4 1 .
42.
43.
44.
45.
A13634-C
Remove accel erat or cabl e bracket ( 9723) f rom
i ntake manifold and position out of t he way.
Di sconnect vacuum hose f rom throttl e body
adapt er vacuum port. .
Di sconnect bot h heat ed oxygen sensors
( H02SX9F472) .
Di sconnect heater wat er hose ( 18472) .
NOTE: Two wat er outlet connecti on retaining
bol ts al so retain i ntake mani fol d.
Remove t wo bol ts retaining wat er hose
connecti on ( 8592) t o i ntake manifold and position
upper radi ator hose ( 8260) and wat er hose
connecti on out of t he way.
W A T E R O U T L E T
C O N N E C T I O N
8 5 9 2
U P P E R R A D I A T O R
H O S E N
8 2 6 0
B O L T
2 R E Q ' D
T I G H T E N T O
2 0 - 3 0 N-m
( 15- 2 2 L B - F T )
A13633-C
46. Remove nine bol ts retaining i ntake mani fol d t o
cylinder heads and remove i ntake mani fol d.
47. Remove i ntake manifold gasket s ( 9461) .
48. Remove seven st ud bol ts and four bol t s retaining
engine f ront cover t o engine. Remove engine front
cover.
APPLY WSE-M4G320-A2
SEALER
0 -
0
A13659-C
Pa r t
6 W807753 Bolt
7 N806300-S2 Stud
A - Tighten to 20-30 N-m (15-22
(Lb-Ft)
03- 01- 32
E n gi n e , 4 . 6 L ( 2 V) 03- 01- 32
50. NOTE: The l ower rear bolt cannot be removed
due t o i nterference wi th t he power brake boost er.
Use a rubber band or similar item t o hold bolt
away f rom cylinder bl ock (as shown).
Remove 10 bol ts retaining LH cylinder head t o
cylinder bl ock.
LOWER REAR
A13636-B
5 1 . NOTE: Cylinder head must not be set on head
f ace. If val ves are open, damage may occur.
Remove LH cylinder head.
52. Remove ground st rap and one st ud and one bolt
retaining heater wat er hose t o RH cylinder head.
53. NOTE: The l ower rear bolt cannot be removed
due t o i nterference wi t h t he A / C evaporat or
housing ( 19850) . Use a rubber band or similar
item t o hold bolt away f r om cyl i nder bl ock as
shown.
Remove 10 bol ts retaining RH cyl i nder head t o
cyl i nder bl ock.
LOWER REAR
RH CYLINDER HEAD BOLT RUBBER
A13635-B
54. Remove RH cyl i nder head.
55. If cyl i nder heads are t o be repl aced and / or
servi ced, refer t o Cylinder Head Di sassembl y and
Assembl y.
1. Clean cyl i nder head, i ntake manifold, valve cover
and cylinder bl ock sealing surfaces as outlined
under Di sassembl y and Assembl y. If necessary,
check cyl i nder head and cylinder bl ock fl atness,
2. NOTE: Thi s ensures that all pi stons ( 6108) are
bel ow t op of cyl i nder bl ock deck f ace.
Rotate crankshaf t count ercl ockwi se 45 degrees.
CRANKSHAFT
KEYWAY A13655-B
3. Inspect cylinder head f ace surface for scrat ches
near cool ant passage and combusti on chambers.
4. Rotate crankshaf t t o a stabl e position where
val ves do not ext end bel ow cylinder head f ace.
5. Position new head gasket ( 6051) on cylinder
bl ock.
6. CAUTI ON: Cy l i n d e r h e a d b o l t s mu s t be
r e p l a c e d w i t h n e w b o l t s . T h e y a r e
t o r q u e - t o - y i e l d d e s i g n e d a n d c a n n o t be
r e u s e d .
Install l ower rear cylinder head bol ts and retain in
position wi t h rubber bands or similar items as
outlined.
0 3 - 0 1 - 3 3 - ^ ^ ^ E n gi n e , 4. 8 L ( 2V ) ^ _ _ _ 0 o ^ i
7. NOTE: Take care not t o score t he surface of the
cyl i nder head f ace.
Position LH cyl i nder head on cyl i nder head t o
bl ock dowel s ( 6A008) .
8. Appl y clean engine oil t o all head bolt spot -f aces.
9. Remove rubber band f rom l ower rear bolt and
install nine remaining bol ts. Hand-ti ghten.
10. Tighten LH cyl i nder head bol ts as fol l ows:
a. Tighten 10 bol t s, in sequence, t o 30- 40 N-m
(22-30 Ib-f t ).
b. Rotate 10 bol ts, in sequence, 85- 95 degrees.
c. Rotate 10 bol ts, in sequence, an additional
85-95 degrees.
s r r
a
RH CYLINDER
HEAD 6049
LH CYLINDER
HEAD 6049
CYLINDER HEAD TIGHTENING SEQUENCE
I
FRONT OF
ENGINE
i A13657-C
11. Position RH cyl i nder head on cyl i nder head t o
bl ock dowel .
12. Appl y cl ean engine oil t o all head bolt spot -f aces.
13. Remove rubber band f rom l ower rear bolt and
install the nine remaining bol ts. Hand-tighten.
14. Tighten RH cyl i nder head bol ts as fol l ows:
a. Tighten 10 bol ts, in sequence, t o 30- 40 N-m
(22-30 Ib-ft). Refer t o illustration following
St ep 10.
15.
16.
17.
b. Rot at e 10 bol ts, in sequence, 85- 95 degrees.
c. Rot at e 10 bol t s, in sequence, an addi ti onal
85- 95 degrees.
Position heat er wat er hose on cyl i nder head and
install t wo bol ts.
Rotate camshaf t s ( 6250) using f l at s mat ched at
center of camshaf t until both are in ti me and install
Cam Positioning Tool Adapt er s T92P-6256-A and
Cam Positioning Tool T91P-6256-A on f l at s of
camshaf t . Thi s will prevent the camshaf t s f r om
rotati ng.
CAUTI ON: Cr a n ks h a f t mu s t o n l y b e r o t a t e d i n
t h e c l o c k w i s e d i r e c t i o n a n d o n l y a s f a r a s
TDC.
NOTE: This will position crankshaft at TDC No 1.
Rot at e crankshaf t cl ockwi se 45 degrees.
q_ CRANKSHAFT
6 3 0 3
s u b
18.
19.
CRANKSHAFT
KEYWAY
A13658-B
CAUTI ON: T i mi n g c h a i n p r o c e d u r e s mu s t b e
f o l l o w e d e x a c t l y o r d a ma g e t o v a l v e s a n d / o r
p i s t o n s wi l l r e s u l t .
Install timing chai ns as outlined.
Inspect and repl ace crankshaft front seal ( 6700)
and engine front cover gasket ( 6020) as
necessary.
03- 01- 34 E n gi n e , 4. 6L ( 2 V) 03- 01- 34
20. NOTE: Remove all t races of di rt, oil or previ ousl y
appl i ed seal ant. Clean all sealing surfaces wi t h
Met al Surface Cleaner F4AZ-19A536-RA or
and dry before appl yi ng sealant.
Appl y an 8-12 mm (0. 32-0. 47 inch) bead of
Silicone Gasket and Sealant F1AZ- 19562- B or
WSE- M4G320- A2, in locations shown.
APPLY WSE-M4G320-A2
A 1 3 6 5 9 - C
Pa r t
6 W807763 Bolt
7 N806300-S2 Stud
(Lb-Ft)
2 1 . Install engine front cover on engine.
22. Install seven st ud bol ts and eight bol ts retaining
engine front cover t o engine. Tighten t o 20- 30
N-m (15-22 Ib-ft).
23. NOTE: Bef ore installation, i nspect intake manifold
f or ni cks and cut s.
NOTE: Make sure alignment t abs on i ntake
manifold gasket s are aligned wi t h holes in
cyl i nder heads.
Position new i ntake manifold gasket s on cylinder
heads.
24. Position i ntake manifold on cylinder heads.
25. Install and ti ghten nine bol ts in sequence shown t o
20- 30 N-m (15-22 Ib-ft).
A14812-B
26. Install wat er t hermost at ( 8575) and new O-ring
then position wat er hose connecti on and upper
radi ator hose and install t wo bol ts. Tighten t o
20- 30 N-m (15-22 Ib-ft).
UPPER RADIATOR
A13633-C
03- 01- 35 E n gi n e , 4. 6L ( 2 V) 0 3 - 0 1 - 3 5
28
29
30.
31
Connect fuel chargi ng wi ri ng t o bot h heated
oxygen sensors.
Connect vacuum hose t o t hrot t l e body adapt er
vacuum port .
Install accel erat or cabl e bracket on intake
manifold and connect accel erat or cabl e and
speed control act uat or t o t hrot t l e body ( 9E926) .
NOTE: Remove all t races of di rt, oil or previ ousl y
appl i ed seal ant. Clean all sealing surfaces wi t h
and dry bef ore appl yi ng seal ant.
Appl y Silicone Gasket and Seal ant
speci fi cati on WSE- M4G320- A2 bot h pl aces
wher e engine front cover meet s cylinder head.
Position and using Gasket and Trim Adhesi ve
D7AZ- 19B508- B or equivalent meeting Ford
speci fi cati ons ESR-M 11P17A and
ESE-M2G52-A, secure new val ve cover gasket s
( 6584) into val ve covers and install valve covers
onto cyl i nder heads.
Install bol ts and stud bol ts into RH valve cover.
Tighten all bol ts to 8-12 N-m ( 71- 106 Ib-in).
34. Install bol ts and stud bol ts into LH valve cover.
Tighten all bol ts t o 8-12 N-m ( 71- 106 Ib-in).
32
33
APPLY SILICONE
GASKET SEALER
NOTE: LH SIDE SHOWN
RH SIDE TYPICAL
A13663-B
Pa r t
Req'd)
A

Lb-ln)
35. Raise vehicle.
36. Position starter wiring harness t o RH cyl i nder
head and install retaining bolt.
37. Cut wi re and position exhaust manifold t o RH and
LH exhaust manifolds.
38. NOTE: Make sure exhaust syst em cl ears No. 3
crossmember. Adjust as necessary.
Install four nuts and tighten t o 27- 41 N*m ( 20- 30
Ib-ft).
39. Connect EGR val ve t o exhaust mani f ol d tube t o
RH exhaust manifold and t i ght en nut t o 35-45 Nm
(26-33 Ib-ft),
03- 01- 36
E n gi n e , 4. 6L ( 2 V) 03- 01- 36
40. Connect fuel chargi ng wiring t o t he power
steeri ng control valve act uat or and oil pressure
sensor.
4 1 . Appl y Silicone Gasket and Seal ant
F1AZ- 19562- B or equivalent meeti ng Ford
speci fi cati on WSE-M4G320-A2 in keyway of
crankshaf t pulley as shown.
CRANKSHAFT
PULLEY 6312
VIEW A
SEALER
KEYWAY
SEALER
CRANKSHAFT
PULLEY 6312
KEYWAY
VIEW A
A18921-B
42. Position crankshaf t pulley on crankshaf t . Make
sure crankshaf t key and keyway are al i gned.
T74P- 6316- B, install crankshaf t pulley.
CRANKSHAFT
DAMPER REPLACER
T74P-6316-B
A13662-B
44. Install crankshaf t pulley bolt and crankshaf t pulley
( 114- 121 Ib-ft).
45. Install oil pan wi th new oil pan gasket as outlined.
install four retaining bol ts. Tighten t o 20-30 N-m
( 15- 22 Ib-f t ).
48. Connect fuel chargi ng wiring t o the A / C cl ut ch,
crankshaf t position sensor and evaporati ve
emi ssi on cani ster purge val ve.
49. Connect 42-pin engine harness connector and
50. Install 42-pi n connector on retaining bracket on
power brake booster.
5 1 . Install posi ti ve crankcase ventilation val ve in RH
52. Position posi ti ve bat t ery cabl e harness on RH
cyl i nder head.
53. Install bolt retaining bat t ery cabl e bracket t o
cyl i nder head.
54. Connect front vapor hose t o evaporati ve emission
55. Connect posi ti ve bat t ery cabl e at power
di stri buti on box and harness and bat t ery
( 10653) .
56. Position generator and install t wo retaining bol ts.
Tighten t o 20- 30 N-m (15-22 Ib-ft).
57. Install t wo bol ts retaining generator rear mounting
bracket t o i ntake manifold and ti ghten t o 8-12
N-m ( 71- 106 lb-in).
58.
59.
Install wat er pump pulley and tighten bol ts t o
20- 30 N-m (15-22 Ib-ft).
Position ignition coil bracket s and ignition wi re
and bracket onto mounting studs.
60. Install seven nuts retaining ignition coil bracket s t o
engine front cover. Tighten t o 20- 30 N-m (15-22
Ib-f t ).
6 1 . Install t wo bol ts retaining ignition wi re separat or
t o ignition coil bracket . Tighten t o 8-12 N-m
( 71- 106 lb-in).
62. Connect fuel chargi ng wi ri ng t o both ignition coils
and camshaf t position sensor.
63. Position air conditioner hi gh-pressure line on RH
ignition coil bracket and install bolt.
64. Connect ignition wi res t o spark plugs. Refer t o
Secti on 03- 07. Install br acket s onto val ve cover
studs.
Install dri ve bel t. Refer t o Secti on 03- 05. 65
66 Install wi ndshi el d wi per governor. Refer t o
Secti on 01- 16.
68. Install fan bl ade and fan shroud. Fill cooling
69. Install air cl eaner outlet tube. Refer t o Secti on
03- 12.
03- 01- 37 E n gi n e , 4. 6L ( 2 V) 03- 01- 37
(N-VEWCLE SERVICE (Conti nued)
7 1 . Check and add engine oil as needed.
Wa t e r P u m p
Re mo v a l
1. Drain cool i ng syst em, remove fan bl ade ( 8600)
and fan shroud ( 8146) . Refer t o Secti on 03- 03.
2. Rel ease dri ve belt tensi oner ( 6B209) and remove
3. Remove four bol ts retaining wat er pump pulley
( 8509) t o wat er pump ( 8501) and remove wat er
pump pulley.
4. Remove four bol ts retaining wat er pump t o engine
and remove wat er pump.
WATER PUMP
HOUSING GASKET
8507 X v
WATER PUMP
8501
BOLT
4 REQ'D
TIGHTEN TO
20-30 N-m
(15-22 LB-FT) A14810-D
1. Repl ace O-ring t ype wat er pump housing gasket
( 8507) and cl ean sealing surf ace of cyl i nder
bl ock ( 6010) .
2. Lubri cate wat er pump housing gasket wi t h Ford
Premium Cooling Syst em Fluid E2FZ-19549-AA
(in Canada, Mot orcraf t CXC-8-B) or equivalent
meeti ng Ford speci fi cati on and ESE-M97B44-A.
3. Position wat er pump on engine and install four
retaining bol ts. Tighten t o 20- 30 N-m (15-22 Ib-ft).
4. Position wat er pump pulley on wat er pump and
install four retaining bol ts. Tighten bol ts t o 20- 30
N-m ( 15- 22 Ib-f t ).
5. Install dri ve bel t. Refer t o Secti on 03- 05.
6. Install fan bl ade, fan shroud and fill cool i ng
7. Check for l eaks.
Re mo v a l
2. Drai n engine cool i ng syst em.
5. Remove ai r cl eaner outl et t ube ( 9B659) . Refer t o
Secti on 03- 12.
6. Rel ease dri ve belt tensi oner ( 6B209) and remove
7. CAUTI ON: Do n o t pul l o n i gn i t i o n wi r e a s i t
ma y s e p a r a t e f r o m t h e c o n n e c t o r i n t h e
Di sconnect all ignition wi res f rom spar k plugs
( 12405) . Refer t o Secti on 03- 07.
8. Di sconnect ignition wi re and br acket s ( 12280)
f rom val ve cover studs.
both ignition coi l s ( 12029) and camshaf t posi ti on
10. Di sconnect all ignition wi res f rom bot h ignition
coi l s. Refer t o Secti on 03- 07.
11. Remove ignition wi re and bracket .
12. Remove bol ts retaining ignition coi l s t o ignition coil
bracket s.
13. Di sconnect generator wiring harness f rom power
distribution box at front fender apron ( 16054) and
f rom generator (GEN)( 10300).
14. Remove t wo bol ts retaining generator mounting
bracket ( 10153) t o i ntake manifold ( 9424) .
15. Remove t wo bol ts retaining generat or
(GEN)( 10346) t o cylinder bl ock ( 6010) and
remove generator.
16. Raise vehi cl e on a hoi st. Refer t o Secti on 00- 02.
17. Di sconnect fuel chargi ng wi ri ng f rom oil pressure
sensor ( 9278) and power steeri ng control val ve
actuator ( 3783) and move fuel chargi ng wi ri ng out
of the way.
18. Di sconnect EGR val ve t o exhaust manifold tube
( 9D477) f r om RH exhaust manifold ( 9430) .
20. Remove 42-pi n engine harness connector f rom
retaining bracket on power brake booster ( 2005) .
2 1 . Di sconnect 42-pi n connector.
22. Di sconnect fuel chargi ng wi ri ng f rom A / C cl utch
( 2884) , crankshaf t position sensor (CKP
sensor)(6C315) and evaporati ve emission
cani ster purge val ve (EVAP cani ster purge
val ves)(9C915).
23. Remove posi ti ve crankcase ventilation val ve
(PCV val ve)(6A666) f rom val ve cover ( 6582) and
front vapor hose f rom posi ti ve crankcase
ventilation val ve.
03- 01- 38 E n gi n e , 4. 6L ( 2V) 03- 01- 38
control act uat or ( 9A825) f rom throttl e body
(9E926) using a screwdri ver or similar t ool .
A C C E L E R A T O R C A B L E
9 A 7 5 8 / S P E E D C O N T R O L
A C T U A T O R 9 A 8 2 5
S C R E W D R I V E R
25.
26.
27.
28.
A13634-C
Remove accel erat or cabl e bracket ( 9723) f rom
i ntake manifold and move out of the way.
Di sconnect vacuum hose f rom throttl e body
adapt er vacuum port.
Di sconnect fuel chargi ng wi ri ng f rom bot h heat ed
oxygen sensors ( HQ2S) ( 9F472) .
Di sconnect heater wat er hose ( 18472) .
29. NOTE: Two wat er outlet connecti on retaining
bol ts al so retai n i ntake mani fol d.
Remove t wo bol ts retaining wat er hose
connecti on ( 8592) t o i ntake manifold and move
upper radi ator hose ( 8260) and wat er hose
connecti on out of the way.
W A T E R O U T L E T
C O N N E C T I O N
8 5 9 2
U P P E R R A D I A T O R
H O S E N
8 2 6 0
B O L T
2 R E Q ' D
T I G H T E N T O
2 0 - 3 0 N-m
( 1 5 - 2 2 L B - F T )
A13633-C
30. Remove nine bol ts retaining i ntake manifold t o
cyl i nder heads ( 6049) and remove i ntake
manifold.
3 1 . Remove i ntake manifold gasket s ( 9461) .
1. NOTE: If a new i ntake manifold is being i nstal l ed,
transfer all necessary components ont o new
i ntake mani fol d.
Clean sealing surf aces of i ntake manifold and
cylinder heads.
2. Position new i ntake manifold gasket s on cylinder
heads.
3. Position i ntake manifold on cylinder heads.
4. NOTE: Make sure alignment t abs on i ntake
manifold gasket are aligned wi th hol es in cylinder
heads.
Install and ti ghten nine bol ts in sequence shown t o
20- 30 N-m (15-22 Ib-ft).
5.
A14812-B
Repl ace O-ring seal on wat er hose connecti on.
Position wat er hose connecti on and upper
radi ator hose and install t wo bol ts and ti ghten t o
20- 30 N-m (15-22 Ib-ft).
Connect heater wat er hose.
Connect fuel chargi ng wiring t o both heated
oxygen sensors.
Connect vacuum hose t o throttl e body adapt er
vacuum port .
Install accel erat or cabl e bracket on intake
manifold and connect accel erat or cabl e and
speed control act uat ors t o throttl e body.
10. Install posi ti ve crankcase ventilation val ve in
11. Connect fuel chargi ng wi ri ng t o the A / C cl utch,
crankshaf t position sensor and evaporati ve
emission cani ster purge val ve.
12. Connect 42-pi n engine harness connector.
13. Install 42-pin connector on retaining bracket on
power brake booster.
14. Rai se vehi cl e.
15. Connect EGR val ve t o exhaust manifold tube t o
RH exhaust manifold and ti ghten nut t o 35- 45 N-m
( 26- 33 Ib-f t ).
03- 01- 39 E n gi n e , 4. 6L ( 2 V) 0 3 - 0 1 - 3 9
16. Connect fuel chargi ng wi ri ng t o the power
steeri ng control val ve act uat or and oil pressure
sensor.
17. Lower vehicle.
18. Position generat or and install t wo retaining bol t s.
19. Install t wo bol ts retaining generator mounting
bracket t o i ntake manifold and ti ghten t o 8-12
N-m ( 71- 106 lb-in).
20. Connect generat or wi ri ng harness t o generator,
RH front fender apron and power distribution box.
2 1 . Position ignition wi re and bracket assembl y on
engine and install bol ts retaining ignition coi l s t o
ignition coi l br acket s. Tighten bol ts t o 8-12 N-m
( 71- 106 lb-in).
22. Connect eight ignition wi res t o ignition coi l s in
posi ti ons shown.
NOTE: POSITION
NO. 8 WIRE AGAINST
NO. 7 RETAINER
RH IGNITION
COIL 12029
LH IGNITION
COIL 12029
NOTE: ENSURE RETAINER
CLIP IS FULLY ENGAGED
ON COIL TOWER
A14813-B
23. Connect all ignition wi res t o spark pl ugs. Refer t o
Secti on 03- 07.
24. Connect ignition wi re bracket s on val ve cover
st uds.
25. Connect fuel chargi ng wi ri ng t o bot h ignition coi l s
and camshaft posi ti on sensor.
03- 12.
28. Install windshield wi per governor. Refer t o
Secti on 01- 16.
3 1 . Fill and bl eed engine cool i ng syst em. Refer t o
Secti on 03- 03.
32. Check and fill oil t o speci fi ed level.
33. St art engine and check f or l eaks.
E x h a u s t Ma n i f o l d
T o w n Ca r
Re mo v a l
Secti on 03- 12.
3. Drai n engine cool i ng syst em and remove fan
bl ade ( 8600) and fan shroud ( 8146) . Refer t o
Secti on 03- 03.
5. Remove upper radi at or hose ( 8260) .
6. Remove wi ndshi el d wi per governor ( 17C476)
and support bracket . Refer to Secti on 01- 16.
7. Recover air condi ti oni ng syst em. Refer t o Secti on
12-00.
8. Di sconnect A / C compressor t o condenser
di scharge line ( 19972) at A / C compressor
( 19703) and remove bolt retaining hose t o RH
ignition coil bracket .
9. Remove 42-pin engine harness connect or f rom
retaining bracket on power brake boost er
( 2005) .
10. Di sconnect 42-pi n connect or and transmi ssi on
harness connector.
11. On LH exhaust mani fol d ( 9430) , remove bolt
retaining oil level indicator tube ( 6754) .
13. Remove nut retaining ground st rap t o RH cyl i nder
head ( 6049) .
14. Remove upper stud bol t and l ower bolt retaining
heater wat er hose t o RH cyl i nder head and
position out of t he way.
HEATER WATER
HOSE 18472
REMOVE
THIS STUD BOLT
RH CYLINDER
HEAD 6049
REMOVE THIS
BOLT
A13672-D
( 18591) .
16. Remove bolt retaining RH front engine support
insulator ( 6038) t o front sub-frame ( 5C145) .
17. Di sconnect vacuum hoses from EGR val ve (EGR
val ve)(9D475) and EGR val ve tube t o manifold
connector (9F485).
03- 01- 40 E n gi n e , 4. 6L ( 2 V) 03- 01- 40
18. Remove t wo bol ts retaining EGR val ve t o i ntake
manifold ( 9424) .
BOLT
2 REQ'D
TIGHTEN
20-30 N-m
(15-22 LB-
MANIFOLD TUBE 9D477
LINE NUT
2 REQ'D
TIGHTEN
35-45 N-m
(26-33 LB-FT)
FRONT OF
"ENGINE -
A13674-B
19. Di sconnect both heated oxygen sensors
( H02SX9F472) .
2 1 . NOTE: Two through-bol ts are requi red for LH
front engine support insulator and one
through-bol t is required f or RH front engine
support insulator.
through-bol ts.
22. Remove EGR val ve t o exhaust manifold t ube line
nut f r om RH exhaust manifold and remove EGR
val ve t o exhaust manifold tube ( 9D477) .
23. Di sconnect t hree way cat al yt i c convert er
( TWCX5E212) f rom RH and LH exhaust
manifold.
24. Lower t hree way catal yti c convert er and secure
t o crossmember in posi ti ons shown wi t h wi re.
NO. 3 CROSSMEMBER
WIRE
A13631-B
25. Position a suitable j ack and a bl ock of wood under
oil pan ( 6675) , rearward of oil drain hole.
26. Rai se engine approxi matel y 100 mm ( 4 i nches).
27. For LH exhaust manifold, remove front engine
support insulator f rom cylinder bl ock ( 6010) and
remove ei ght nuts retaining exhaust mani fol d.
28. Remove LH exhaust manifold and t wo exhaust
manifold gasket s ( 9448) .
NUT
8 REQ'D
LH EXHAUSTS
MANIFOLD
9430
BOLT
3 REQ'D
NOTE: LH EXHAUST MANIFOLD SHOWN
RH EXHAUST MANIFOLD TYPICAL
LH FRONT
ENGINE
SUPPORT
INSULATOR
6038
A14805-C
29. For RH exhaust manifold, remove eight nuts
retaining exhaust manifold t o cyl i nder head and
st uds and remove exhaust manifold and exhaust
manifold gasket .
1. If exhaust manifolds are being repl aced, transfer
heated oxygen sensors and ti ghten t o 37- 45 N-m
( 27- 33 Ib-ft). Al so, for RH exhaust mani fol d,
transfer EGR val ve tube t o manifold connector
and ti ghten t o 45- 65 N-m (33-48 Ib-ft).
2. Clean mati ng surf aces of exhaust manifolds and
cylinder head.
03- 01- 41 E n gi n e , 4. 6L ( 2V) 0 3 - 0 1 - 4 1
3. Position exhaust manifold gasket and LH exhaust
manifold t o cylinder head and st uds and install
eight retaining nuts. Tighten in sequence t o 18-22
N-m (13-16 Ib-ft).
I nst a l l a t i on Se que n c e
NOTE: ENGINE SHOWN REMOVED
FOR CLARITY
RH EXHAUST MANIFOLD SIMILAR A13673-B
Position t wo exhaust manifold gasket s and LH
exhaust manifold t o cyl i nder head and studs and
install eight nuts. Tighten in sequence t o 18-22
N-m (13-16 Ib-ft). Refer t o illustration following
St ep 3.
NOTE: Loosen line nut at EGR val ve prior t o
installing assembl y into vehi cl e. Thi s will al l ow
enough movement t o align EGR val ve retaining
bol ts.
Position and connect EGR val ve t o exhaust
manifold tube t o exhaust mani fol d. Tighten line nut
t o 36-45 N-m ( 26- 33 Ib-ft).
Install LH f ront engine support insulator on
cylinder bl ock and ti ghten bol ts t o 20-30 N-m
(15-22 Ib-ft).
Lower engine ont o front engine support insulator
and remove j ack.
8.
9.
NOTE: Two through-bol ts are requi red on LH
f ront engine support insulator and one
through-bol t is requi red on RH front engine
support insulator.
Install front engine support insulator through-bol ts
and tighten t o 20- 30 N-m (15-22 Ib-ft).
NOTE: Make sure exhaust syst em cl ears No. 3
Remove wi re and position t hree way catal yti c
convert er. Install four nuts and ti ghten t o 27-41
N-m (20-30 Ib-ft).
11. Connect bot h heat ed oxygen sensors.
12. Install bolt retaining RH front engine support
insulator t o f ront sub-frame. Tighten t o 20- 30 N-m
(15-22 Ib-ft).
13. Install a new EGR val ve gasket ( 9D476) on EGR
val ve and posi ti on t o i ntake mani fol d.
14. Install t wo bol t s retaining EGR val ve t o i ntake
manifold and ti ghten t o 20- 30 N-m (15-22 Ib-ft).
15. Tighten EGR val ve t o exhaust manifold t ube line
nut at EGR val ve t o 35- 45 N-m ( 26- 33 Ib-ft).
BOLT
2 REQ'D
TIGHTEN TO
20-30 N-m
(15-22 LB-FT)
MANIFOLD TUBE 9D477
LINE NUT
2 REQ'D
TIGHTEN TO
35-45 N-m
(26-33 LB-FT)
FRONT OF
ENGINE "
A13674-B
16. Connect vacuum hoses t o EGR val ve and EGR
val ve t o exhaust manifold tube.
18. Position heater wat er hose. Install upper stud and
l ower bolt, ti ghten upper stud and l ower bolt t o
20- 30 N-m (15-22 Ib-ft). Install ground st rap ont o
stud and ti ghten nut t o 20-30 N-m (15-22 Ib-ft).
20. If removed, install oil level indicator tube retaining
bol t.
2 1 . Connect 42-pin connector and transmi ssi on
harness connector.
22. Install 42-pin engine harness connector t o
retaining bracket on power brake boost er.
23. Connect A / C compressor t o condenser
di scharge line t o A / C compressor and install bolt
retaining hose assembl y t o RH ignition coil
bracket .
24. Install upper radi ator hose.
26. Install windshield wi per governor and retaining
bracket . Refer t o Secti on 01- 16.
28. Install fan blade and fan shroud. Fill and bl eed
cooling syst em. Refer t o Secti on 03- 03.
30. Install air cleaner outlet tube. Refer t o Secti on
03- 12.
3 1 . Start engine and check for l eaks.
03- 01- 42 E n gi n e , 4. 6L ( 2 V) 03- 01- 42
Re mo v a l
2. Remove air cleaner outl et tube. Refer t o Secti on
10- 01.
3. Drain cool i ng syst em and remove fan bl ade and
fan shroud. Refer t o Secti on 03- 03.
5. Remove upper radi ator hose.
6. Remove wi ndshi el d wi per governor and support
12-00.
di scharge line at A / C compressor and remove
bolt retaining hose t o RH ignition coi l bracket .
9. Remove 42-pi n engine harness connector f rom
retaining bracket on power brake booster.
10. Di sconnect 42-pin connect or and transmi ssi on
harness connector.
11. Di sconnect heater wat er hose.
12. Remove nut retaining ground st rap t o RH cyl i nder
head.
13. Remove upper stud bolt and l ower bolt retaining
heater wat er hose t o RH cylinder head and move
out of t he way.
HEATER WATER
HOSE 18472
REMOVE
THIS STUD BOLT
RH CYLINDER
HEAD 6049
REMOVE THIS
BOLT
A13672-D
14. Remove heater bl ower motor swi t ch resi stor.
insulator-to-front sub-frame.
BOLT
2 REQ'D
TIGHTEN TO
20-30 N-m
(15-22 LB-FT)
MANIFOLD TUBE 9D477
LINE NUT
2 REQ'D
TIGHTEN TO
35-45 N-m
(26-33 LB-FT)
FRONT OF
ENGINE -
A13674-B
16. Di sconnect both heated oxygen sensors.
17. Raise vehi cl e on a hoist. Refer t o Secti on 00- 02.
18. NOTE: Two through-bol ts are required for LH
through-bol t is required for RH front engine
support insulator.
through-bol ts.
19. Remove EGR val ve t o exhaust manifold tube nut
f rom RH exhaust manifold.
20. Di sconnect t hree way catal yti c converter f rom
RH and LH exhaust manifolds.
2 1 . Lower exhaust and secure t o crossmember in
posi ti ons shown wi th wi re.
NO. 3 CROSSMEMBER
WIRE
A13631-B
03- 01- 43 E n gi n e , 4. 6L ( 2V) 03- 01- 43
22. For LH exhaust manifold, remove front engine
support insulator f rom cyl i nder bl ock and remove
eight nuts retaining exhaust manifold.
23. Remove LH exhaust manifold and t wo exhaust
manifold gasket s.
24. Position a screw-t ype j ackst and and a bl ock of
wood under oil pan, r ear war d of oil drai n hol e.
25. Raise engine approxi mat el y 100 mm (4 i nches).
RH EXHAUST MANIFOLD TYPICAL A14805-C
26. For RH exhaust manifold, remove eight nuts
retaining exhaust manifold t o cylinder head and
retaining studs and remove exhaust manifold and
exhaust manifold gasket .
1. If exhaust manifolds are being repl aced, transfer
heated oxygen sensors and ti ghten t o 37- 45 N-m
( 27- 33 ib-ft). Al so, for RH exhaust mani fol d,
transfer EGR val ve t o exhaust manifold tube and
ti ghten t o 45- 65 N-m ( 33- 48 Ib-ft).
2. Clean mating surf aces of exhaust manifolds and
cyl i nder heads.
3. Position exhaust manifold gasket and RH exhaust
manifold t o cylinder head and studs and install
eight retaining nuts. Tighten in sequence t o 18-22
N-m (13-16 Ib-ft).
NOTE: ENGINE SHOWN REMOVED
FOR CLARITY
RH EXHAUST MANIFOLD SIMILAR A13673-B
4. Position t wo exhaust manifold gasket s and LH
exhaust manifold t o cylinder head and st uds and
install ei ght retaining nuts. Tighten in sequence t o
18-22 N-m ( 13- 16 Ib-ft). Refer t o illustration
fol l owi ng St ep 3.
5. Position and connect EGR val ve t o exhaust
manifold t ube t o exhaust manifold. Tighten line nut
t o 35- 45 N-m (26-33 Ib-ft).
6. Install LH front engine support insulator on
cyl i nder bl ock and ti ghten bol ts t o 20- 30 N-m
(15-22 Ib-ft).
7. Lower engine onto front engine support insulator
and remove j ack.
8. NOTE: Two through-bol ts are requi red on LH
support insulator.
9. NOTE: Make sure exhaust syst em cl ears No. 3
Remove wi re and position three way catal yti c
converter. Install four nuts and tighten t o 27- 41
N-m ( 20- 30 Ib-f t ).
11. Connect fuel chargi ng wiring ( 9D930) t o bot h
heated oxygen sensors.
03- 01- 44 E n gi n e , 4. 6L ( 2 V) 03- 01- 44
insulator t o front sub-frame. Tighten t o 20- 30 N-m
(15-22 Ib-ft).
BOLT
2 REQ'D
TIGHTEN TO
20-30 N-m
(15-22 LB
MANIFOLD TUBE 9D477
LINE NUT
2 REQ'D
TIGHTEN TO
35-45 N-m
(26-33 LB-FT)
FRONT OF
'ENGINE -
A13674-B
13.
14
Install heater bl ower motor swi t ch resi stor wi th
Position heater wat er hose. Install upper stud and
l ower bolt and ti ghten upper stud and l ower bolt t o
20- 30 N-m (15-22 Ib-ft). Install ground st rap onto
st ud and ti ghten nut t o 20- 30 N-m ( 15- 22 Ib-ft).
harness connector.
17. Install 42-pi n engine harness connect or t o
retaining hose t o RH ignition coil bracket .
2 1 .
22.
Install wi ndshi el d wi per governor and retaining
Evacuate and recharge air conditioning syst em.
23. Install fan bl ade and fan shroud. Fill and bl eed
cool i ng syst em. Refer t o Secti on 03- 03.
03- 12.
Oi l Pa n a n d Oi l P u mp S c r e e n Co v e r a n d T u b e
T o w n Ca r
Re mo v a l
Secti on 03- 12.
3. Drai n cool i ng syst em and remove fan bl ade
( 8600) and fan shroud ( 8146) . Refer t o Secti on
03- 03.
5. Remove upper radi ator hose ( 8260) .
6. Remove wi ndshi el d wi per governor ( 17C476)
and support bracket . Refer t o Secti on 01- 16.
12-00.
di scharge line ( 19972) at A / C compressor
( 19703) and remove bolt retaining hose t o RH
ignition coil bracket .
retaining bracket on power brake booster
( 2005) .
harness connector.
12. Remove nut retaining ground st rap t o RH cylinder
head ( 6049) .
13. Remove upper stud bolt and l ower bolt retaining
out of way.
HEATER WATER
HOSE 18472
REMOVE
THIS STUD BOLT
RH CYLINDER
HEAD 6049
REMOVE THIS
BOLT
A13672-D
( 18591) .
insulator ( 6038) t o front sub-frame ( 5C145) .
16. Di sconnect vacuum hoses f rom EGR val ve (EGR
val ve)(9D475) and EGR val ve t o exhaust
manifold tube ( 9D477) .
17. Remove t wo bol ts retaining EGR val ve t o i ntake
manifold ( 9424) . Loosen EGR tube t o exhaust
manifold nut and remove EGR val ve.
03- 01- 45 E n gi n e , 4 . 6 L ( 2 ) 0 3 - 0 1 - 4 5
18.
19.
20.
2 1 .
22.
23.
Raise vehi cl e on a hoi st. Refer t o Secti on 00- 02.
Drain engine oil.
NOTE: Two through-bol ts are requi red for LH
through-bolt is requi red for RH front engine
support insulator.
Remove front engine support insulator through
bol ts.
Remove EGR val ve t o exhaust manifold tube nut
f rom RH exhaust manifold ( 9430) and remove
EGR val ve t o exhaust manifold tube.
Di sconnect t hree way cat al yt i c converter
( TWCX5E212) f rom RH and LH exhaust manifold.
Lower exhaust and secure t o crossmember in
posi ti ons shown wi t h wi re.
NO. 3 CROSSMEMBER
WIRE
A13631-B
wood under oil pan ( 6675) , rearward of oil drain
hole.
25. Rai se engine approxi mat el y 100 mm (4 i nches).
26. Insert t wo wood bl ocks approxi mat el y 60-70 mm
( 2. 5- 2. 75 inches) t hi ck under each front engine
support insulator.
27. Lower engine onto wood bl ocks and remove j ack
f r om under oil pan.
28. NOTE: It may be necessary t o l oosen (DO NOT
REMOVE) t he t wo nuts on rear engine support
insulator ( 6068) . Wi t h a screw-t ype j ackst and,
rai se t he extensi on housing ( 7A039) of the
transmi ssi on slightly t o remove oil pan.
Remove bol ts retaining oil pan t o engine. Remove
oil pan.
OIL PAN
, BOLTS
16 REQ'D
WOODEN
BLOCKS A13647-B
29. If necessary, remove t wo bol ts retaining oil pump
screen cover and t ube ( 6622) t o oil pump ( 6600)
and remove bolt retaining oil pump screen cover
and tube t o main beari ng stud spacer. Remove oil
pump screen cover and tube.
BOLT
2 REQ'D
TIGHTEN TO
8-12 N-m
(71-106 LB-IN)
BOLT
TIGHTEN TO
20-30 N-m
(15-22 LB-FT)
MAIN BEARING
STUD SPACER
N806180-S
OIL PUMP
6600
A13648-C
1. Clean oil pan and i nspect for damage.
2. NOTE: Remove all t r aces of dirt, oil or previ ousl y
appl i ed sealant. Clean all sealing surf aces wi t h
WSE-M5B392-A. Sealing surfaces must be cl ean
Clean sealing surfaces of engine front cover
( 6019) , crankshaft rear oil seal and retai ner
( 6K301) and cyl i nder bl ock ( 6010) .
3. Inspect oil pump screen cover and t ube and
repl ace if necessary.
4. If removed, position oil pump screen cover and
tube on oil pump and hand-start t wo bol t s.
03- 01- 46 E n gi n e , 4. 6L ( 2 V) 03- 01- 46
6. Hand-tighten bolt retaining oil pump screen cover
and tube t o main beari ng stud spacer.
6. Tighten oil pump screen cover and tube-to-oil
pump bol ts t o 8-12 N-m ( 71- 106 Ib-in). Tighten oil
pump screen cover and tube t o main beari ng stud
spacer bolt t o 20- 30 N-m ( 15- 22 Ib-ft).
BOLT
2 REQ'D
TIGHTEN TO
TIGHTEN TO MAIN BEARING OIL PUMP
20-30 N-m STUD SPACER 6600
(15-22 LB-FT) N806180-S
A 1 3 6 4 8
_
c
7. Position new oil pan gasket ( 6710) on oil pan.
8. Appl y Silicone Gasket and Seal ant
speci fi cati on WSE- M4G320- A2 where engine
front cover meet s cyl i nder bl ock and crankshaf t
rear oil seal and retai ner meet cylinder bl ock.
Position oil pan on engine and install retaining
bol ts. Tighten bol ts in sequence t o 25-35 Nm
(18-26 Ib-ft) in no more than four minutes after
appl yi ng sealer.
^ ) TIGHTEN BOLTS IN SEQUENCE
Pa r t
1 6675 Oil Pan
4 W701240-S309 Bolt (16 Req'd)
A

Lb-Ft)
B

Lb-Ft)
9. Position screw-t ype j ackst and and bl ock of wood
under oil pan rearward of oil drain hole.
03- 01- 47 E n gi n e , 4. 6L ( 2 ) 03- 01- 47
iN-VEHiCLE SERVICE (Conti nued)
10. Raise engine enough t o remove wood bl ocks.
OIL PAN
BOLTS
13
18
19
WOODEN
BLOCKS A13647-B
11. Lower engine onto front engine support insulator
and remove j ack.
through-bol t is required on RH front engine
support insulator.
Install front engine support insulator through-bol ts
and ti ghten t o 20-30 N-m (15-22 Ib-ft).
NOTE: Loosen nut at EGR val ve pri or t o installing
assembl y into vehicle. Thi s will al l ow enough
movement t o align EGR val ve retaining bol ts.
Position EGR val ve t o exhaust manifold tube in
vehi cl e and connect t o exhaust manifold. Tighten
nut t o 35- 45 N-m (26-33 Ib-ft).
Remove wi re and position exhaust syst em t o bot h
27-41 N-m ( 20- 30 Ib-ft).
Repl ace oil bypass filter ( 6714) as outlined.
insulator t o front sub-frame. Tighten t o 20- 30 N-m
(15-22 Ib-ft).
Install a new EGR valve gasket ( 9D476) on EGR
val ve and position on i ntake manifold.
Install t wo bol ts retaining EGR val ve t o i ntake
20. Tighten EGR val ve t o exhaust manifold tube nut at
EGR val ve t o 35-45 N-m ( 26- 33 Ib-ft).
14
15.
BOLT
2 REQ'D
TIGHTEN
20-30 N-m
(15-22 LB-
MANIFOLD TUBE 9D477
LINE NUT
2 REQ'D
TIGHTEN TO
35-45 N-m
(26-33 LB-FT)
FRONT OF
ENGINE "
A13674-B
2 1 . Connect vacuum hoses t o EGR val ve and EGR
22. Install heater bl ower motor swi t ch resi stor wi th
23. Position heater wat er hose. Install upper stud
bolt and l ower bol t. Tighten upper stud bolt and
l ower bolt t o 20- 30 N-m (15-22 Ib-ft). Install
ground st rap on stud and tighten nut t o 20- 30 N-m
(15-22 Ib-ft).
Connect heater wat er hose. 24.
harness connector.
26. Install 42-pin engine harness connector t o
Connect fuel lines. Refer t o Secti on 10- 01. 29.
30.
3 1 .
32.
33.
Install windshield wi per governor and retaining
Fill crankcase wi t h cl ean engine oil t o speci fi ed
level.
Evacuate and recharge air conditioning. Refer t o
Secti on 12-00.
Install fan blade and fan shroud and fill cool i ng
34. Connect battery ground cabl e.
03- 12.
Re mo v a l
03- 01- 48 E n gi n e , 4. 6L ( 2 V)
03- 01- 48
2. Remove air cl eaner outlet tube. Refer t o Secti on
03- 12.
3. Drain cool i ng syst em and remove fan bl ade and
fan shroud. Refer t o Secti on 03- 03.
5. Remove upper radi ator hose.
6. Remove wi ndshi el d wi per governor and support
12-00.
di scharge line at A / C compressor and remove
bolt retaining hose t o RH ignition coil bracket .
Remove 42-pin engine harness connector f rom
Di sconnect 42-pin connector and transmi ssi on
harness connector.
Di sconnect heater wat er hose.
9.
10.
11.
12.
13.
Remove nut retaining ground st rap t o RH cyl i nder
head.
Remove upper stud bolt and l ower bolt retaining
out of way.
HEATER WATER
HOSE 18472
REMOVE
THIS STUD BOLT
RH CYLINDER-
HEAD 6049
REMOVE THIS
BOLT
A13672-D
14. Remove heater bl ower motor swi t ch resi stor.
insulator t o front sub-frame.
16. Di sconnect t hree way catal yti c convert er f rom
RH and LH exhaust manifold.
17. Lower exhaust and secure t o crossmember in
posi ti ons shown wi t h wi re.
NO. 3 CROSSMEMBER
WIRE
A13631-B
wood under oil pan rearward of oil drain hole.
19. Raise engine approxi matel y 100 mm (4 i nches).
20. Insert t wo wood bl ocks approxi matel y 60- 70 mm
(2. 5-2. 75 inches) thi ck under each front engine
support insulator.
2 1 . Lower engine ont o wood bl ocks and remove j ack
f rom under oil pan.
22. NOTE: It may be necessary t o loosen (DO NOT
REMOVE) the t wo nuts on rear engine support
insulator. Wi t h a screw-t ype j ackst and, rai se the
extensi on housing of the transmi ssi on slightly t o
remove oil pan.
Remove bolts retaining oil pan t o engine. Remove
oil pan.
OIL PAN
, BOLTS
WOODEN
BLOCKS A13647-B
03- 01- 49 E n gi n e , 4. 6L ( 2 V)
: : . : : i 7: ; : : - r: :
23. If necessary, remove t wo bol ts retaining oil pump
screen cover and t ube t o oil pump and remove
bolt retaining oil pump screen cover and tube t o
main beari ng stud spacer. Remove oil pump
screen cover and t ube.
BOLT
2 REQ'D
TIGHTEN TO
8-12 N-m
(71-106 LB-IN)
BOLT
TIGHTEN TO
20-30 N-m
(15-22 LB-FT)
MAIN BEARING
STUD SPACER
N806180-S
OIL PUMP
6600
A13648-C
1. Clean oil pan and i nspect for damage.
2. NOTE: Remove all t r aces of di rt, oil or previ ousl y
Clean sealing surf aces of engine front cover,
crankshaf t rear oil seal and retainer and cylinder
bl ock.
3. Inspect oi ! pump screen cover and t ube and
repl ace O-rsng.
4. If removed, position oil pump screen cover and
tube on oil pump and hand-start t wo bol ts.
5. Hand-ti ghten bolt retai ni ng oil pump screen cover
and t ube t o main beari ng stud spacer.
6. Tighten oil pump screen cover and tube-to-oil
pump bol ts t o 8-12 N-m ( 71- 106 lb-in). Tighten oi l
pump screen cover and t ube t o main beari ng st ud
spacer bolt t o 20- 30 N-m (15-22 Ib-ft).
BOLT
2 REQ'D
TIGHTEN TO
8-12 N-m
(71-106 LB-IN)
BOLT'
TIGHTEN TO MAIN BEARING OIL PUMP
20-30 N-m STUD SPACER 6600
(15-22 LB-FT) N806180-S
7. Position new oil pan gasket on oil pan.
A13648-C
03- 01- 50
E n gi n e , 4. 6L ( 2 ) 03- 01- 50
8. Appl y Silicone Gasket and Sealant
speci fi cati on WSE-M4G320-A2 where engine
front cover meets cylinder bl ock and crankshaf t
rear oil seal and retainer meets cylinder bl ock.
Position oil pan on engine and install retaining
bol ts. Tighten bol ts in sequence t o 25- 35 N-m
(18-26 Ib-ft) in no more than four minutes after
appl yi ng sealer.
o
TIGHTEN BOLTS IN SEQUENCE
REFER TO LEGEND
A14940-C
Pa r t
1 6675 Oil Pan
4 W701240-S309 Bolt (16 Req'd)
A

Lb-Ft)
B

Lb-Ft)
9 Position screw-t ype j ackst and and bl ock of wood
under oil pan rearward of oil drai n hole.
10. Rai se engine enough t o remove wooden bl ocks.
OIL PAN
, BOLTS
16 REQ'D
11.
12.
13.
14.
15.
16.
17.
18.
19.
WOODEN
BLOCKS A13647-B
Lower engine onto front engine support insulator
and remove j ack.
NOTE: Two through-bol ts are required on LH
support insulator.
NOTE: Loosen nut at EGR val ve prior t o installing
assembl y into vehi cl e. This will al l ow enough
movement t o align EGR val ve retaining bol ts.
Position EGR valve t o exhaust manifold tube in
vehi cl e and connect t o exhaust manifold. Tighten
nut t o 35- 45 N-m ( 26- 33 Ib-ft).
Remove wi re and position exhaust syst em t o both
27-41 N-m (20-30 Ib-ft).
Repl ace oil bypass filter as outlined.
Lower vehi cl e.
Install bolt retaining RH front engine support
insulator t o l ower front sub-frame. Tighten t o
20- 30 N-m (15-22 Ib-ft).
Install a new EGR val ve gasket on EGR val ve and
position on i ntake manifold.
Install t wo bol ts retaining EGR val ve t o i ntake
03- 01- 5 1 E n gi n e , 4. 6L ( 2 V) 0 3 - 0 1 - 5 1
!N-EHlCLE SERVICE (Conti nued)
20. Tighten EGR val ve-to-exhaust manifold tube nut at
EGR val ve t o 35- 45 N-m ( 26- 33 I b-f t ).
BOLT
2 REQ'D
TIGHTEN TO
20-30 N-m
(15-22 LB-I
MANIFOLD TUBE 9D477
LINE NUT
2 REQ'D
TIGHTEN'
35-45 N-m
(26-33 LB-FT)
FRONT OF
"ENGINE "
A13674-B
21 Connect vacuum hoses t o EGR val ve and EGR
23. Position heater wat er hose. Install upper stud bolt
and l ower bolt and ti ghten upper st ud bolt and
l ower bolt t o 20-30 N-m (15-22 Ib-ft). Install
ground st rap on stud and ti ghten nut t o 20-30 N-m
(15-22 Ib-ft).
25.
26
Connect 42-pi n connect or and transmi ssi on
harness connector.
Install 42-pi n engine harness connector t o
retaining bracket on power brake booster.
Install upper radi ator hose.
Connect fuel lines. Refer t o Secti on 10- 01.
28
29
30 Install wi ndshi el d wi per governor and retaining
3 1 . Fill crankcase wi th cl ean engine oil t o speci fi ed
l evel .
32. Evacuat e and recharge air conditioning. Refer t o
Secti on 12-00.
33. Install fan bl ade and fan shroud and fill cooling
03- 12.
36. St art engine and check f or l eaks.
Oi l P u m p
Re mo v a l
1
2.
3.
Remove valve cover s ( 6582) , engine front cover
( 6019) , oil pan ( 6675) and oil pump screen cover
and t ube ( 6622) as outl i ned.
Remove timing chai n as outl i ned.
Remove four bol ts retaining oil pump ( 6600) t o
cyl i nder block ( 6010) . Remove oil pump.
OIL PUMP
6600
BOLT
4 REQ'D
TIGHTEN TO
8-12 N-m
(71-106 LB-IN)
FRONT OF
ENGINE
CYLINDER BLOCK
6010
A14816-D
1. Rot at e inner rotor of oil pump t o align wi t h fl ats on
crankshaf t ( 6303) and install oil pump flush wi th
cyl i nder bl ock.
2. Install four retaining bol ts and ti ghten t o 8-12 N-m
( 71- 106 Ib-in).
3. Repl ace oil filter ( 6731) as outlined.
4. Install timing chain as outlined.
5. Install engine front cover, oil pan, oil pump screen
cover and tube and val ve covers as outlined.
6. Fill engine wi th cl ean oil t o speci fi ed level.
7. Start engine and check f or l eaks.
P i s t o n s a n d C o n n e c t i n g R o d s
Re mo v a l
1. Remove RH and LH cylinder heads ( 6049) as
outlined.
2. Remove and di scard head gasket s ( 6051) .
3. If cyl i nder heads are t o be servi ced, refer t o
Subassembl i es, Cylinder Head Di sassembl y and
Assembl y.
03- 01- 52 E n gi n e , 4. 6L ( 2 V)
03- 01- 52
4. Remove oi l pan ( 667 5) and oil pan ga ske t ( 67 10)
a s out l i ned.
Pa r t
1 W701240-S309 Bolt (16 Req'd)
3 6675 Oil Pan
A

Lb-Ft)
B

Lb-Ft)
5. Remove oil pump scr een c ove r and t ube ( 6622) .
Pa r t
2 N605904-S Bolt
Tube
Cap Stud
6 N606021-S Bolt (4 Req'd)
7 6600 Oil Pump
8 3Z728 O-Ring
9 N805892-S2 Bolt (2 Req'd)
A

Lb-Ft)
B

Lb-ln)
03- 01- 53 E n gi n e , 4. 6L ( 2 V) 0 3 - 0 1 - 5 3
IN-VEHSCLE SERVICE ( C o n t i n u e d )
6.
8.
NOTE: Pistons ( 6108) , connecti ng rods ( 6200)
and connecti ng rod beari ngs ( 6211) should be
numbered t o ensure t hey are assembl ed in thei r
original posi ti ons.
NOTE: Before removi ng pi stons, i nspect the t op
of the cylinder bores. If necessary, remove the
ri dge and/ or carbon deposi t s f rom each cylinder
using Rotunda Cylinder Ri dge Reamer
014- 00292 or equivalent as outlined in Secti on
03- 00.
Turn crankshaf t ( 6303) until pi ston t o be removed
is at the high point of i ts t ravel . If more than one
pi ston is being removed, identify t he pi stons,
connecti ng rods and connecti ng rod caps for
cyl i nder posi ti on.
CAUTI ON: Car e shoul d be t ak en not t o
damage t he f r act ur ed r od and cap j oi nt f ac e
sur f aces or possi bl e damage t o engi ne may
occur .
NOTE: Connecti ng rod bol ts ( 6214) are retai ned
in the bolt hole wi t h a light press fit. The
connecti ng rod bol ts have been t orqued t o yi el d
at least t wi ce and must be di scarded. Use a
hammer and punch t o dri ve connecti ng rod bol ts
f r om connecti ng rod cap.
Remove t he connecti ng rod cap and l ower
connecti ng rod beari ng. Keep cap and l ower
connecti ng rod beari ng together. Push t he pi ston,
connecti ng rod assembl y and upper connecti ng
rod beari ng through the t op of the cylinder bore.
Use care t o prevent damage t o the beari ng and
cyl i nder bore surf aces. Keep upper connecti ng
rod beari ng and connecti ng r od together.
DRIVE BOLTS OUT
USING HAMMER AND PUNCH
SUPPORT BEARING
CAP WHILE
REMOVING BOLTS
A15051-B
Using a new connecti ng rod bol t, at t ach cap and
l ower connecti ng rod beari ng t o connecti ng rod
and upper beari ng t o prevent mixing parts and
damagi ng the f ract ured joint f ace surf aces.
9. Clean and inspect pi ston, connecti ng rod,
connecti ng rod beari ngs and cyl i nder bl ock bores
as outlined in Secti on 03- 00.
10. If requi red, di sassembl e pi ston f rom connecti ng
rod as outl i ned.
11. If requi red, repl ace pi ston ri ngs as outlined.
1 Coat pi ston bor es, pi stons and ri ngs, crankshaf t
j ournal and beari ng surf aces wi t h cl ean engine oil.
CAUTI ON: Be s u r e n o t t o s c r a t c h c y l i n d e r
wa l l o r c r a n ks h a f t j o u r n a l wi t h c o n n e c t i n g
r o d . P us h p i s t o n d o w n un t i l c o n n e c t i n g r o d
b e a r i n g s e a t s o n c r a n ks h a f t j o u r n a l .
NOTE: Ma ke sure pi ston ring gaps are rot at ed 30
degr ees apart .
NOTE: Not ch on pi ston t o front of engine.
Turn crankshaf t until the crankshaf t t hr ow is at
bot t om of st r oke. Install correct l y numbered
pi ston and connecti ng rod assembl i es wi t h Pi ston
Ring Groove Cleaner D81L- 6002- D or equivalent
and a sui tabl e connecti ng rod gui de t ool .
NOTCH TOWARD -
FRONT OF ENGINE
A13639-B
Part
1 6214 Connecting Rod Bolt (16
Req'd)
2

Cap (8 Req'd) (Part of 6200)
3 6211 Connecting Rod Bearing
Lower (8 Req'd)
4 6303 Crankshaft
5 6211 Upper Connecting Rod
Bearing (8 Req'd)
6 6108 Piston (8 Req'd)
7 6200 Connecting Rod (8 Req'd)
8 D81L-6002-C Piston Ring Compressor Tool
9
Connecting Rod Guide Tool
Lb-Ft), Then rotate an
additional 85-95 degrees
03- 01- 54 E n gi n e , 4 . 6 L ( 2 V)
03- 01- 54
NOTE: Due t o t he use of a cr acked connecti ng
rod joint f ace surface, t he connecti ng rod cap
must be properl y aligned t o t he connecti ng r od.
The connecti ng rod and connecti ng rod cap
beari ng t angs should be l ocat ed on the same si de
of the connecti ng rod.
Al ternatel y ti ghten new connecti ng rod cap bol ts
in several passes t o obtai n 40- 45 N-m (29-34
Ib-ft) and rot at e connecti ng rod bol ts an additional
85- 95 degrees. After installation, rot at e
crankshaft t o ensure smoot h operat i on.
Check connecti ng rod si de cl earance using
Rotunda Dial Indicator wi t h Br acket r y 014- 002 82
or equivalent. Cl earance shoul d be 0. 15-0. 45 mm
( 0. 006- 0. 0177 i nch). If si de cl earance is great er
than maxi mum servi ce limit of 0. 50 mm ( 0. 020
i nch), repl ace connecti ng rods and/ or
crankshaf t .
ROTUNDA DIAL
INDICATOR
WITH BRACKETRY
014-00282
CONNECTING
ROD 6200,
A15093-C
NOTE: Install new O-ring then st art all bol ts on oil
pump ( 6600) and oil pump screen cover and tube
bef ore ti ghteni ng.
Install oil pump screen cover and tube.
A13652-B
Pa r t
2 N605904-S Bolt
Tube
Cap Stud
6 N606021-S Bolt (4 Req'd)
7 6600 Oil Pump
8 3Z728 O-Ring
9 N605892-S2 Bolt (2 Req'd)
A

Lb-ln)
B

Lb-ln)
03- 01- 55 E n gi n e , 4 . 6 L ( 2 V) 03- 01- 5 5
Pa r t
1 W701240-S309 Bolt (16 Req'd)
3 6675 Oil Pan
Lb-Ft)
Lb-Ft)
7. If cyl i nder heads are t o be servi ced, refer t o
Assembl y.
8. CAUTI ON: Do n o t u s e s a n d p a p e r c o a r s e r
t h a n 6 0 0 gr i t .
NOTE: Clean cylinder head gasket surf ace wi th a
tol uene-based pai nt thinner or gasket remover. If
gasket materi al remai ns on head af t er cl eani ng,
use a 600 gri t sandpaper t o remove remaining
materi al .
9. NOTE: RH and LH head gasket s are not
i nterchangeabl e.
Position new head gasket s on cylinder head.
10. CAUTI ON: Fa i l ur e t o p o s i t i o n c r a n ks h a f t a s
s h o w n wi l l c a u s e d a ma g e t o p i s t o n s a n d / o r
v a l v e t r a i n c o mp o n e n t s .
NOTE: Wi t h crankshaf t in thi s posi ti on, no pi ston
will be at t op dead center (TDC).
Rotate crankshaft t o position as shown.
CRANKSHAFT
KEYWAY A13655-B
11. CAUTI ON: Use c a r e w h e n p o s i t i o n i n g
c y l i n d e r h e a d s . Da ma ge t o c y l i n d e r b l o c k
( 6010) a n d / o r c y l i n d e r h e a d s ma y r e sul t .
Install cylinder heads as outlined.
C o n n e c t i n g R o d B e a r i n g s
Re mo v a l
1. Remove oil pan ( 6675) and oil pump screen cover
and tube ( 6622) as outlined.
03- 01- 56 E n gi n e , 4. 6L ( 2 V) 03- 01- 56
3.
NOTE: Connecting rod caps, connecti ng rods
( 6200) and connecti ng rod beari ngs ( 6211)
should be numbered t o ensure they are
assembl ed in their original posi ti ons.
Turn crankshaft ( 6303) until connecti ng rod
beari ng t o be removed is accessi bl e. If more than
one connecti ng rod beari ng is being removed,
identify the connecti ng rod caps, connecti ng rods
and connecti ng rod beari ngs for cylinder posi ti on.
Remove the connecti ng rod cap, l ower
connecti ng rod bearing and upper connecti ng rod
beari ng. Keep cap and connecti ng rod beari ngs
together. Use care t o prevent damage t o t he
beari ng and cylinder bore surfaces.
CAUTI ON: Ca r e s h o u l d b e t a ke n n o t t o
d a ma g e t h e f r a c t u r e d r o d a n d c a p j o i n t f a c e
s u r f a c e s o r p o s s i b l e d a ma g e t o e n gi n e ma y
o c c u r .
Connecti ng rod bol ts ( 6214) are retai ned in the
connecti ng rod cap hole wi th a light press fit. The
connecti ng rod bol ts have been t orqued t o yield
at l east t wi ce and must be di scarded. Use a
hammer and punch t o dri ve connecti ng rod bol ts
f rom connecti ng rod cap.
DRIVE BOLTS OUT
SUPPORT BEARING
CAP WHILE
REMOVING BOLTS
A15051-B
Inspect the connecti ng rods, connecti ng rod caps
and crankshaf t as outlined in Secti on 03- 00.
1 Clean crankshaf t connecti ng rod j ournal s wi th a
clean cl ot h.
Lubri cate crankshaf t and connecti ng rod beari ng
surf aces wi t h clean engine oi l .
CAUTI ON: Be s u r e n o t t o s c r a t c h c y l i n d e r
wa l l o r c r a n ks h a f t j o u r n a l w i t h c o n n e c t i n g
r o d . Pul l p i s t o n ( 6108) d o w n un t i l c o n n e c t i n g
r o d b e a r i n g s e a t s o n c r a n ks h a f t j o u r n a l .
Install upper connecti ng rod beari ngs in t he
connecti ng rod caps. Align retaining tang of
connecti ng rod bearing wi t h not ch in connecti ng
rod.
4. NOTE: Due t o the use of a cr acked connecti ng
rod joint f ace surface, the connecti ng rod cap
must be properl y aligned t o t he connecti ng rod.
beari ng t angs should be l ocated on t he same si de
of the connecti ng rod.
Install l ower connecti ng rod beari ngs in the
connecti ng rod caps. Align retaining t ang of
connecti ng rod beari ng wi th notch in connecti ng
rod cap.
5. Install connecti ng rod caps and al ternatel y ti ghten
new connecti ng rod cap bol ts in several passes
t o obtai n 40- 46 N-m (29-34 Ib-ft) and rot at e
connecti ng rod bol ts an additional 85- 95 degrees.
Af t er installation, rotate crankshaft t o ensure
smoot h operati on.
6. Check connecti ng rod si de cl earance using
Rotunda Dial Indicator wi th Bracket ry 014- 00282
or equivalent. Cl earance should be 0. 15-0. 45 mm
( 0. 006- 0. 0177 i nch). If si de cl earance is greater
crankshaf t .
ROTUNDA DIAL
INDICATOR
WITH BRACKETRY
014-00282
CONNECTING
ROD 6200
J
A15093-C
7. Install oil pump screen cover and tube and oil
panwi th new oil pan gasket ( 6710) as outlined.
F l y w h e e l
Re mo v a l
1. Remove transmi ssi on. Refer t o Secti on 07- 01.
03- 01- 57 E n gi n e , 4 . 6 L ( 2 V) 0 3 - 0 1 - 5 7
2. Remove si x bol ts retai ni ng f l ywheel ( 6375) t o
crankshaft ( 6303) and remove f l ywheel .
CYLINDER BLOCK
6010
BOLT
6 REQ'D
TIGHTEN TO
73-87 N-m
(54-64 LB-FT)
1
CRANKSHAFT
6303
FROI f f OF
ENGINE
/
FLYWHEEL
6375
A14809-O
2.
3.
Position fl ywheel on crankshaf t and install six
retaining bol ts. Tighten in al ternati ng sequence t o
73- 87 N-m ( 54- 64 Ib-ft).
Check fl ywheel runout. Refer t o Secti on 03- 00.
Install transmi ssi on. Refer t o Secti on 07- 01.
C r a n k s h a f t Re a r Oi l S e a l
Re a r Ma i n Se a l Re p l a c e r
Re a r Cr a n k Se a l R e p l a c e r / A d a p t e r s
T 82 L - 67 01- A
T 91P - 67 01- A
Re mo v a l
1 Remove transmi ssi on f rom vehi cl e. Refer t o
Secti on 07- 01.
2. Remove fl ywheel ( 6375) .
3. Remove crankshaf t rear oil seal retainer.
4. CAUTI ON: Use c a r e t o a v o i d d a ma g i n g
r e t a i n e r w h e n r e mo v i n g se a l o r p o s s i b l e
e n gi n e o i l l e a ka ge ma y o c c u r u p o n
r e a s s e mb l y .
Wi t h crankshaft rear oil seal retainer support ed
securel y and, using a punch, remove crankshaft
rear oil seal ( 6701) f rom retainer.
1. NOTE: Remove all t r aces of dirt, oil or previously
Met al Surf ace Cleaner F4AZ-19A536-RA or
WSE- M5B392- A. Sealing surfaces must be clean
and dr y before appl yi ng sealant.
Cl ean and inspect crankshaf t rear oil seal retainer
( 6335) and retainer-to-cylinder bl ock mati ng
surf aces.
3.
Appl y a 1.5 mm ( 0. 06 inch) continuous bead of
Silicone Gasket and Seal er F1 AZ- 19562- B or
equivalent meeti ng For d speci fi cati on
WSE- M4G320- A2 t o cylinder bl ock ( 6010) as
shown.
CYLINDER BLOCK
6010
SILICONE GASKET
AND SEALANT
F1AZ-19562-B
MEETING FORD
SPECIFICATION
WSE-M4G320-A2
A13644-C
Install crankshaf t rear oil seal retai ner and ti ghten
bol ts in sequence shown t o 8-12 N-m ( 71- 106
Ib-in).
A13645-B
4. Install new crankshaft rear oil seal using Rear
Mai n Seal Repl acer T82L-6701-A and Rear
Crank Seal Repl acer Adapt ers T91P-6701-A.
5. Install fl ywheel .
6. Install transmi ssi on. Refer t o Section 07- 01.
Oi l B y p a s s Fi l t e r a n d A d a p t e r
Re mo v a l
2. Position a drain pan under oil bypass filter area.
3. Unscrew the oil bypass filter ( 6714) f rom oil filter
adapt er ( 6881) using an oil-filter wrench.
03- 01- 58 E n gi n e , 4. 6L ( 2V) 03- 01- 58
4. Clean the oil bypass filter sealing surface of oil
filter adapter.
AFTER SEAL CONTACT
A 1 4 m
^
5. If removal of the oil filter adapt er is requi red,
proceed wi th t he fol l owi ng:
a. On trailer t ow and pol i ce opti on equi pped
vehi cl es, di sconnect the oil suppl y and return
hoses f rom t he oil cool er ( 6A642) at t he oil
filter adapt er.
b. Di sconnect t he engine control sensor wi ri ng
( 12A581) f rom t he oil pressure sensor
( 927 8) .
c. Drain t he cool i ng syst em as outlined in
Secti on 03- 03.
d. Di sconnect t he l ower radi ator hose ( 8286)
f rom the oil filter adapt er. Refer t o Secti on
03- 03.
e. Remove t he oil filter adapt er retaining bol ts,
oil filter adapt er and oil filter adapter gasket
( 6840) .
f. Clean and inspect t he sealing surfaces of the
oil filter adapt er gasket and cylinder bl ock
( 6010) .
Tr ai l er To w a n d Pol i c e Opt i o n Sho wn , Non-Trai l er
To w a n d Non-Pol i c e Si mi l ar
FRONT OF ENGINE
A23536-A
Pa r t
3

Bolt (4 req'd)
5

To Oil Cooler (6A642)
A

Tighten 3/ 4 Turn After Seal
Contact
B

Lb-Ft)
1. If only the oil bypass filter was removed, proceed
t o St ep 2. If removal of the oil filter adapter was
requi red, proceed wi th t he fol l owi ng:
2. Install new oil filter adapt er gasket , oil filter
adapter and retaining bol ts.
a. Tighten bol ts t o 20-30 N-m (15-22 Ib-ft).
b. Install the l ower radi ator hose onto the oil
filter adapter. Install the hose cl amp securel y.
c. Connect t he engine control sensor wiring t o
the oil pressure sensor.
d. On trailer t ow and police option equi pped
vehi cl es, connect the oil suppl y and return
hoses f rom the oil cool er t o t he oil filter
adapter.
03- 01- 59 E n gi n e , 4. 6L ( 2 V) 03- 01- 5 9
1N-EHICLE SERVICE (Conti nued)
3. NOTE: The oil by pa ss filter has a 22 mm metri c
t hread and an anti-drain back val ve. Make sure
the repl acement oil bypass filter is equi pped wi t h
a 22 mm metri c t hread and the anti-drain back
val ve.
Coat rubber seal of oil bypass filter wi t h cl ean
engine oi l .
4. Install oil bypass filter on oil filter adapt er until
rubber seal cont act s sealing surface of oil filter
adapt er.
5. Tighten an addi ti onal three-quarter turn after seal
cont act .
6. Lower vehi cl e.
7. Check oil level and fill t o speci fi ed level.
8. If requi red, fill cool i ng syst em as outlined in
Secti on 03- 03.
9. Start engine and check f or l eaks.
Oi l L e v e l I n d i c a t o r T u b e
Re mo v a l
1. Remove LH front engine support insulator ( 6038)
as outl i ned.
2. Remove bolt retaining oil level i ndi cator tube
( 6754) t o cyl i nder head ( 6049) and remove oil
level i ndi cator t ube.
OIL LEVEL
INDICATOR
TUBE 6754
BOLT
TIGHTEN TO
20-30 N-m
(15-22 LB-FT)
BOLT
3 REQ'D
LH FRONT ENGINE
SUPPORT INSULATOR
6038
A14875-D
1. Inspect O-ring, lube wi th cl ean engine oil and
repl ace as needed.
2. Route oil level indicator tube t hrough exhaust
manifold ( 9430) and into cyl i nder bl ock ( 6010) .
3. Fully seat tube into cylinder bl ock and install
retaining bol t. Tighten t o 20- 30 N-m ( 15- 22 Ib-ft).
4. Install LH front engine support insulator as
outl i ned.
S e n s o r s
Oi l P r e s s u r e S e n s o r
The oil pressure sensor (9278) is l ocat ed on t he LH
si de of t he cyl i nder bl ock (6010) in t he oil filter adapt er
( 6881) . When installing, tighten t o 16-24 N-m ( 12- 18
Ib-ft).
E n g i n e
Sp r i n g L o c k Co upl i n g Di s c o n n e c t Tool
( 3 / 8 i n c h )
Sp r i n g L o c k Co upl i n g Di s c o n n e c t Tool
( 1 / 2 i n c h)
T 81P - 1962 3- G 1
T 81P - 1962 3- G 2
Re mo v a l
2. Remove hood ( 16612) . Refer t o Secti on 01 -02.
3. Drai n engine cooling syst em. Refer t o Secti on
03- 03.
12-00.
5. Remove fan blade ( 8600) , fan shroud ( 8146) and
radi ator ( 8005) . Refer t o Secti on 03- 03.
lines. Refer t o Section 10- 01.
7. Remove windshield wi per governor ( 17C476)
and support bracket . Refer t o Secti on 01- 16.
8. Remove air cleaner outlet tube ( 9B659) . Refer t o
Secti on 03- 12.
9. Remove 42-pin connector from retaining bracket
on power brake booster ( 2005) .
03- 01- 60 E n gi n e , 4 . 6 L ( 2 V) 03- 01- 60
10. Di sconnect 42-pin connecter and transmi ssi on
harness connector and move out of t he way.
A14801-B
Pa r t
3

4

control act uat or ( 9A825) wi th a screwdri ver or
similar t ool .
ACCELERATOR CABLE
9A758/SPEED CONTROL
ACTUATOR 9A825
SCREWDRIVER
12.
A13634-C
Di sconnect fuel chargi ng wi ri ng ( 9D930) and front
vapor hose f rom evaporat i ve emission cani ster
purge val ve (EVAP cani ster purge
val ves)(9C915).
13. Di sconnect posi ti ve bat t ery cabl e f rom power
di stri buti on box.
14. Di sconnect vacuum suppl y hose f rom throttl e
body adapter vacuum port.
15. Di sconnect heater suppl y and return hoses.
VACUUM
SUPPLY
HOSE
SUPPLY
HOSE
THROTTLE
BODY
ADAPTER
9A589-
17
RETURN
HOSE
A13670-B
16. Di sconnect generator harness f rom front fender
apron ( 16054) and power distribution box.
Di sconnect air conditioning compressor inlet and
outl et hoses f rom A / C compressor ( 19703) using
Spri ng Lock Coupling Di sconnect Tool
T81P-19623-G1 ( 3 / 8 inch) and T81P-19623-G2
( 1 / 2 inch).
INLET
HOSE
SPRING LOCK OUTLET
COUPLING DISCONNECT
H
0SE
TOOL
T81P-19623-G1 AND
T81P-19623-G2 A14802-B
18. Di sconnect fuel chargi ng wiring f rom power
steeri ng control val ve actuator ( 3783) on power
steeri ng pump ( 3A674) .
19. Di sconnect body ground st rap from dash panel
( 01610) .
2 1 . Drain engine oil.
03- 01- 61 E n gi n e , 4. 6L ( 2 V) 0 3 - 0 1 - 6 1
22. Di sconnect t hree way cat al yt i c converter
( TWCX5E212) from RH and LH exhaust manifold
( 9430) and support wi t h wi re on crossmember in
posi ti ons shown.
NO. 3 CROSSMEMBER
WIRE
A13631-B
23. Remove retaining nut f rom transmi ssi on line
bracket and remove t hree bol ts and stud retaining
engine t o transmi ssi on case t o cyl i nder bl ock
front bracket ( 7E234) .
24. Remove st art er motor ( 11002) . Refer t o Secti on
03- 06.
25. Remove four bol ts retaining power steeri ng pump
t o cyl i nder bl ock ( 6010) and move out of t he way.
26. Remove transmi ssi on housing cover ( 7986) f rom
cylinder bl ock t o access torque converter
retaining nuts. Rotate crankshaf t ( 6303) until
each nut (four required) is accessi bl e and remove
nuts.
27. Remove si x bol ts retaining transmi ssi on t o
engine.
front engine support insulator ( 6038) and one
through-bol t is required on RH front engine
support insulator.
Remove engine insulator through-bol ts.
30. Support transmi ssi on wi th Rotunda Servi ce Jack
3 1 . Remove bolt retaining RH front engine support
insulator t o front sub-frame ( 5C145) .
32. Install Rotunda Engine Lift Bracket Set
014- 00334 or equivalent on side of LH cyl i nder
head ( 6049) at front as shown. At t ach Rotunda
Engine Lift Bracket Set 014- 00334 or equivalent
using t wo M- 12x 1. 75x20 mm bol ts. Install
Rotunda Engine Lift Bracket Set 014- 00334 or
equivalent on side of RH cylinder head at rear.
ROTUNDA
ENGINE LIFT
BRACKET
014-00334
USE TWO
,M12X 1.75X20 mm
' BOLTS
A15060-E
33
34
35
36
37,
Connect Rotunda Floor Crane 077- 00043 or
equivalent t o the Rotunda Engine Lift Bracket s
Raise engine slightly and careful l y separat e
engine f rom transmi ssi on.
Carefully lift engine out of engine compartment.
Position engine on a wor k st and.
Remove engine-lifting equipment.
1. Install Rotunda Engine Lift Bracket Set
014- 00334 or equivalent in posi ti ons shown in
illustration following Step 33.
2. Connect floor crane t o lifting bracket s and
remove engine from work st and.
3. Carefully l ower engine into engine compartment.
4. NOTE: Make sure studs on torque converter
( 7902) align wi th holes in fl ywheel ( 6375) .
Start torque converter pilot into fl ywheel and align
paint marks on fl ywheel and torque converter.
5. Fully engage engine t o transmi ssi on and l ower
onto front engine support insulators.
Remove engine-lifting equipment.
Install bolt retaining RH front engine support
insulator to front sub-frame.
Raise vehicle.
Install six bolts retaining engine t o transmi ssi on
and tighten t o 40-60 N-m ( 30- 44 Ib-ft).
NOTE: Two through bol ts required on LH front
engine support insulator and one through bolt on
RH front engine support insulator.
Install front engine support insulator through
bol t s. Ti ghten t o 20-30 N-m (15-22 Ib-f t ).
6.
7.
8.
9.
10.
03- 01- 62 E n gi n e , 4. 6L ( 2 V) 03- 01- 62
11. NOTE: Rotate crankshaf t until each nut (four
requi red) is accessi bl e.
Install four t orque converter retaining nuts.
Tighten t o 30- 35 N-m (22-25 Ib-ft).
12. Install transmi ssi on housing cover t o cylinder
bl ock.
13. Position power steeri ng pump on cylinder bl ock
and install four retaining nuts. Tighten t o 20- 30
N-m (15-22 Ib-ft).
14. Install st art er motor. Refer t o Secti on 03- 06.
15. Position transmi ssi on line bracket t o transmi ssi on
case t o cyl i nder bl ock bracket stud and install
retaining nut. Tighten t o 20- 30 N-m (15-22 Ib-ft).
16. NOTE: Make sure t hree way catal yti c converter
cl ears No. 3 crossmember. Adj ust as necessary.
Remove wi re and position exhaust syst em t o bot h
27-41 N-m ( 20- 30 Ib-ft).
18. Connect fuel chargi ng wi ri ng t o the power
steeri ng control val ve act uat or.
19. Connect inlet and outlet hoses t o A / C
compressor.
20. Connect generator harness f rom front fender
apron and power distribution box.
2 1 . Connect heater suppl y and return hoses.
22. Connect vacuum suppl y hose t o throttl e body
adapt er vacuum port.
VACUUM
SUPPLY
HOSE
SUPPLY
HOSE
THROTTLE
BODY
ADAPTER
9A589-
RETURN
HOSE
A13670-B
23.
24.
25.
26.
27.
28.
Connect posi ti ve bat t ery cabl e t o power
distribution box and harness ( 14516) .
Connect fuel chargi ng wi ri ng and front vapor hose
t o evaporat i ve emission cani ster purge val ve.
Connect accel erat or cabl e and speed control
act uat ors.
Connect 42-pin engine harness connector and
Install 42-pin connector t o retaining bracket on
power brake boost er.
Install wi ndshi el d wi per governor and support
30. Install radi ator, fan bl ade and fan shroud. Refer t o
Secti on 03- 03.
3 1 . Install air cl eaner outlet tube. Refer t o Secti on
03- 12.
32. Fill and bl eed engine cool i ng syst em. Refer t o
Secti on 03- 03.
34. Install hood. Refer t o Secti on 01- 02.
36. Fill engine wi t h oil.
37. St art engine and check for cool ant, oil and fuel
l eaks.
Crankshaft
Re a r Cr a n k Se a l Re p l a c e r A d a p t e r
T58P - 6316- D
T 7 4P - 6316- B
T 82 L - 67 01- A
T91P - 67 01- A
Re mo v a l
1. NOTE: This procedure will remove and install the
crankshaft ( 6303) wi th the engine removed f rom
t he vehi cl e.
Remove ignition wi res as outlined in Secti on
03- 07.
2. Remove six fl ywheel retaining bol ts and remove
fl ywheel ( 6375) f rom crankshaft.
3. Remove accessory dri ve belt ( 8620) . Refer t o
Secti on 03- 05.
5. Remove dri ve belt idler pulley ( 8679) and dri ve
belt tensioner ( 6B209) wi th ignition coils ( 12029) .
6. Remove oil bypass filter ( 6714) as outlined.
OIL BYPASS
FILTER
6714
NOTE: LUBRICATE SEAL
WITH CLEAN ENGINE OIL
AND TIGHTEN 3/4 TURN
AFTER SEAL CONTACT
A14808-C
03- 01- 63 E n gi n e , 4 . 6 L ( 2 V)
03- 01- 63
7. Remove RH and LH val ve cover s ( 6582) f rom
cylinder heads ( 6049) .
FRONT OF
ENGINE
APPLY SILICONE
GASKET SEALER
NOTE: LH SIDE SHOWN
RH SIDE TYPICAL
A13663-B
Pa r t
Req'd)
Lb-ln)
crankshaf t pulley retaining washer ( 6378) .
9. Using Crankshaft Damper Remover
T58P-6316-D, pull crankshaf t pulley ( 6312) f rom
crankshaf t .
CRANKSHAFT DAMPER
REMOVER
T58P-6316-D
A13668-B
crankshaf t position sensor (CKP sensor)(6C315)
and camshaf t position sensor (CMP
sensor)(6B288).
11. Remove crankshaft posi ti on sensor and camshaf t
position sensor f rom engine front cover ( 6019) .
FRONT OF
ENGINE
Pa r t
2

Bolt (4 Req'd)
4

Bolt
5
_
Bolt
A

Lb-Ft)
B

Lb-ln)
03- 01- 64 En gi n e , 4. 6L ( 2V) 03- 01- 64
12. Remove oil pan ( 6675) and oil pan gasket ( 6710) .
Pa r t
I t e m d u mb e r De s c r i p t i o n
1 W701240-S309 Bolt (16 Req'd)
3 6675 Oil Pan
A

Tighten t o 25-35 N-m (18-26
Lb-Ft)
B

Lb-Ft)
13. Remove engine front cover.
APPLY WSE-M4G320-A2

A 1 3 6 5 9 - C
Pa r t
' I t e m Nu mb e r De s c r i p t i o n
6 W807753 Bolt
7 N806300-S2 Stud
A

Lb-Ft)
14. NOTE: Thi s will position all pi stons ( 6108) bel ow
t op of cylinder bl ock deck f ace.
Position crankshaf t on t op dead center (TDC) No.
1.
16. Remove camshaf t s ( 6250) as outlined.
03- 01- 65 ' E n gi n e , 4. 6L ( 2V) 03- 01- 65
17. Remove oil pump screen cover and t ube ( 6622)
and oil pump ( 6600) .
Pa r t
2 N605904-S Bolt
Tube
Cap Stud
6 N606021-S Bolt (4 Req'd)
7 6600 Oil Pump
8 3Z728 O-Ring
9 N805892-S2 Bolt (2 Req'd)
A

Lb-Ft)
B

Lb-ln)
18. Remove crankshaf t rear oil seal retainer ( 6335) .
A1S669-B
I t e m
Pa r t
2 6303 Crankshaft
Retainer
5 Bolt (6 Req'd)
A

Lb-ln)
19. NOTE: Connecting rods ( 6200) , connecti ng rod
caps and connecti ng rod bearings ( 6211) shoul d
be numbered t o ensure they are assembl ed in
their original posi ti ons.
Turn crankshaft until connecti ng r od c a p t o be
removed is accessi bl e. Identify t he connecti ng
rods, connecti ng rod caps and connecti ng rod
beari ngs for cylinder posi ti on.
20. Remove the connecti ng rod cap and l ower and
upper connecti ng rod beari ngs. Keep cap and
connecti ng rod beari ngs together. Use care t o
prevent damage t o the bearing and cylinder bore
surfaces.
03- 01- 66 Engi ne, 4. 6L ( 2V) 03- 01- 66
2 1 . CAUTI ON: Car e shoul d be t ak en not t o
damage t he f r act ur ed rod and cap j oi nt f ace
sur f aces or possi bl e engi ne damage may
occur .
Connecti ng rod bol ts ( 6214) are retai ned in the
bolt hole wi t h a light press fit. The connecti ng rod
bol ts have been t orqued t o yield at least t wi ce
and must be di scarded. Use a hammer and punch
t o dri ve connecti ng rod bol ts f rom connecti ng rod
cap.
DRIVE BOLTS OUT
SUPPORT BEARING
CAP WHILE
REMOVING BOLTS A15051-A
22. Remove horizontal main cap si de bol ts f rom
cyl i nder bl ock ( 6010) .
23. Loosen crankshaf t main bearing cap adjusting
scr ews ( 6C360) on beari ng main caps.
24. Remove bearing main cap retaining bol ts. These
are torque-to-yi el d bol ts, and should not be
reused.
25. NOTE: The l ocati on of t he main beari ng caps and
t he crankshaf t main beari ngs ( 6333) shoul d be
identified. When t he engine is assembl ed,
crankshaf t main beari ngs whi ch are t o be reused
shoul d be installed in thei r original posi ti ons.
Remove each main beari ng cap and l ower
crankshaf t main beari ng and crankshaf t thrust
main beari ng ( 6337) . Keep each cap, l ower
crankshaf t main beari ng and crankshaf t thrust
main beari ng together.
A13637-B
I t e m
Pa r t
1 6C360 Crankshaft Main Bearing
Cap Adj usting Screw
Cap Bolt
Cap Stud
Main Bearing
Bearing
6 6303 Crankshaft
7 6337 Upper Crankshaft Main
Thrust Bearing
Bearing
26. CAUTI ON: Wh e n r e mo v i n g t h e c r a n ks h a f t ,
use c a r e n o t t o d a ma g e a n y o f t h e b e a r i n g
s u r f a c e s o n t h e c r a n ks h a f t .
Remove crankshaf t .
27. If requi red, repl ace crankshaf t main beari ngs,
crankshaft thrust main beari ng and crankshaf t
thrust washer ( 6334) as outlined.
03- 01- 67
I f
E n gi n e , 4. 6L ( 2 V) 03- 01- 67
1. NOTE: All sealing surf aces must be cl ean and
free of chi ps, dirt, paint and forei gn materi al . Al so
make sure oil passages are clear.
Lubri cate and install crankshaf t main beari ngs
into cyl i nder bl ock. Install crankshaf t main
beari ngs and crankshaft thrust main beari ng into
main beari ng caps.
Install crankshaft into cylinder bl ock.
Push crankshaft rearwards. Lubri cate and install
upper crankshaft thrust washer by rolling t he
crankshaft thrust washer onto machi ned shelf
between rear si de of No. 5 bul khead and thrust
surface of crankshaf t . Make sure coat ed si de of
crankshaft thrust washer wi t h three 5 mm wi de
oil grooves f aces the crankshaf t thrust surf ace.
NOTE: ASSEMBLE
CAPS WITH ARROW
POINTING FORWARD,
CAPS ARE STAMPED
1 THROUGH 5 FRONT
TO REAR
FRONT OF
ENGINE
A13637-C
I t e m
Pa r t
Cap Bolt
Cap Stud
I t e m
Pa r t
Thrust Bearing
Bearing
6 6303 Crankshaft
Cap Side Bolt
Bearing
4. NOTE: Crankshaft main beari ng cap adjusting
scr ews must be bot t omed on main beari ng caps
prior t o installation of main beari ng caps.
Install main beari ng caps. Tap main beari ng caps
wi t h a brass hammer t o seat caps properl y.
NOTE: ALL MAIN BEARING CAPS
MUST BE TAPPED INTO POSITION
PRIOR TO TIGHTENING. FAILURE
TO DO SO MAY RESULT IN
IMPROPER TORQUE.
BRASS HAMMER
MAIN BEARING
CAP
5.
A13641-B
Push crankshaf t f or war d using a pry bar or
similar tool t o seat crankshaft thrust main beari ng
and crankshaf t thrust washer.
TORQUE
WRENCH
NOTE: PUSH CRANKSHAFT IN DIRECTION
OF ARROW TO FULLY SEAT THRUST
BEARING. LEAVE PRYBAR IN POSITION
UNTIL ALL MAIN BEARING BOLTS ARE
TIGHTENED.
r
03- 01- 68 E n gi n e , 4. 6L ( 2 V)
03- 01- 68
6. NOTE: No. 5 main bearing cap must be seat ed
until t he main beari ng cap bol ts are fully ti ghtened
as outlined bel ow.
Wi t h crankshaf t pushed f or war d, install prybars
or similar tool s t o push both RH and LH front
edges of No. 6 main bearing cap rearward and
posi ti on the l ower crankshaft thrust main beari ng
rear f ace properl y agai nst the thrust f ace of t he
crankshaf t .
7. CAUTI ON: Ma i n b e a r i n g b o l t s mu s t b e
r e p l a c e d wi t h n e w b o l t s . T h e y a r e
t o r q u e - t o - y i e l d d e s i g n a n d c a n n o t b e r e u s e d .
Tighten new main beari ng cap bol ts in t wo st eps
as f ol l ows:
a. Tighten bol ts in sequence to 30- 35 N-m
(22-25 Ib-ft).
b. Rotate bol ts in sequence 85- 95 degrees.
NOTE: ITEMS 1 THROUGH 10 ARE
MAIN BEARING CAP BOLTS, 11
THROUGH 18 ARE CRANKSHAFT MAIN
BEARING CAP ADJUSTING SCREWS, AND
19 THROUGH 26 ARE CRANKSHAFT
MAIN BEARING CAP BOLTS.
A13638-C
Tighten crankshaf t main beari ng cap adj usti ng
scr ews in t wo st eps as fol l ows:
a. Tighten crankshaft main beari ng cap
adjusting scr ews in sequence t o 5 N-m ( 44
lb-in).
b. Tighten crankshaft main beari ng cap
adjusting scr ews in sequence to 9-11 N-m
(80-97 lb-in).
Tighten main beari ng cap bol ts in t wo st eps as
f ol l ows:
a. Tighten main beari ng cap bol ts in sequence t o
10 N-m (7 Ib-ft).
b. Tighten main beari ng cap bol ts in sequence t o
19-23 N-m (14-17 Ib-f t ).
10. NOTE: Pry agai nst number t wo main beari ng cap.
Check crankshaft end pl ay in both di recti ons as
shown.
PRYBAR
CRANKSHAFT END PLAY
0.130-0.251 mm
(0.005-0.010 INCH)
ROTUNDA DIAL
INDICATOR
WITH BRACKETRY
014-00282
NOTE TOTAL END PLAY
A13643-D
11. Appl y a 1.5 mm ( 0. 06 inch) continuous bead of
Silicone Gasket and Sealant F1AZ-19562-B or
WSE-M4G320-A2 t o cylinder bl ock as shown.
CYLINDER BLOCK
- ^6010
SILICONE GASKET
AND SEALANT
F1AZ-19562-B
MEETING FORD
SPECIFICATION
WSE-M4G320-A2
A13644-C
12. Install crankshaft rear oil seal retainer t o cylinder
bl ock and tighten six bol ts in sequence t o 8-12
N-m ( 71- 106 lb-in).
A13645-B
03- 01- 69 E n gi n e , 4
B
6 L ( 2 )
03- 01- 69
13. If removed, using Rear Seal Repl acer Adapt er
T91P-6701-A and Rear Mai n Seal Repl acer
T82L-6701-A, install crankshaf t rear oil seal
( 6701) .
REAR MAIN
SEAL REPLACER
T82L-6701-A
REAR CRANK
SEAL REPLACER
ADAPTERS
T91P-6701-A
A15054-C
14. Turn crankshaf t until t he crankshaft t hr ow is at
bot t om of st roke. Install upper connecti ng rod
beari ng onto connecti ng rod. Lubri cate
connecti ng rod beari ng and crankshaft wi t h cl ean
engine oi l .
15. CAUTI ON: Be s u r e n o t t o s c r a t c h c y l i n d e r
r o d . Pul l p i s t o n d o w n un t i l c o n n e c t i n g r o d
NOTE: Due t o t he use of a cr acked connecti ng
rod joint f ace surf ace, t he connecti ng rod cap
must be properl y aligned t o the connecti ng rod.
beari ng t angs should be l ocated on t he same si de
of t he connecti ng r od.
Install connecti ng rod cap and l ower connecti ng
rod beari ng and al ternatel y tighten new
connecti ng rod cap bol ts in several passes t o
obtai n 40- 45 N-m ( 25- 34 Ib-ft) and rot at e
connecti ng rod bol ts an additional 85- 95 degrees.
After installation, rot at e crankshaft t o ensure
smoot h operat i on.
Rotunda Dial Indicator wi t h Bracket ry 014- 00282
or equi val ent. Cl earance should be 0. 15-0. 45 mm
( 0. 006- 0. 0177 inch). If si de cl earance is greater
crankshaf t .
ROTUNDA DIAL
INDICATOR
WITH BRACKETRY
014-00282
CONNECTING
ROD 6200
A1S093-C
17. NOTE: Install new O-ring then st art all bol ts on oil
pump and oil pump screen cover and tube before
ti ghteni ng.
Install oil pump and oil pump screen cover and
t ube.
A13652-B
Par t
2 N605904-S Bolt
( Co n t i n ue d )
03- 01- 7 0
E n gi n e , 4 . 6 L ( 2 V)
03- 01- 7 0
Pa r t
Tube
Cap Stud
6 N606021-S Bolt (4 Req'd)
7 6600 Oil Pump
8 3Z728 O-Ring
9 N605892-S2 Bolt (2 Req'd)
A

Lb-ln)
B

Lb-ln)
18. CAUTI ON: Fa i l ur e t o p o s i t i o n c r a n ks h a f t a s
NOTE: Wi th crankshaf t in thi s posi ti on, no pi ston
Rotate crankshaft t o position as shown.
CRANKSHAFT
KEYWAY A13655-B
19. CAUTI ON: Cr a n ks h a f t mu s t o n l y b e r o t a t e d i n
t h e c l o c k w i s e d i r e c t i o n a n d o n l y a s f a r a s t o p
d e a d c e n t e r ( TDC) No . 1.
Rot at e crankshaf t cl ockwi se 45 degrees. This
will position crankshaf t at t op dead center (TDC)
No. 1.
KEYWAY A13658-B
20. Install camshaf t s as outlined.
2 1 . Install timing chai ns as outlined.
2 2 . Repl ace crankshaf t front seal ( 67 00) in engine
f ront cover if requi red.
2 3. Install engine front cover as outlined.
APPLY WSE-M4G320-A2
A13659-C
Pa r t
6 W807753 Bolt
7 N806300-S2 Stud
A

Lb-Ft)
24. Install crankshaft position sensor and camshaft
position sensor into engine front cover and tighten
retaining bol ts t o 8-12 N-m (71-106 Ib-in).
03- 01- 71 E n gi n e ,
4. . 6L ( 2 V) 0 3 - 0 1 - 7 1
25. Reconnect fuel chargi ng wi ri ng t o crankshaft
position sensor and camshaf t position sensor.
A13661-E
Pa r t
2

Bolt (4 Req'd)
4

Bolt
5

Bolt
A

Lb-Ft)
B

Lb-ln)
26. Install oil pan wi t h new oil pan gasket . Tighten
bol ts t o 25-35 N-m (18-26 Ib-ft) in no more than
four minutes after appl yi ng sealer.
Pa r t
1 W701240-S309 Bolt (16 Req'd)
3 6675 Oil Pan
A

Lb-Ft)
B

Lb-Ft)
27. NOTE: Silicone Gasket and Sealant
speci fi cati on WSE-M4G320-A2 must be appl i ed
t o crankshaft keyway prior t o installing
crankshaft pulley.
Install crankshaft pulley using Crankshaft Damper
Repl acer T74P-6316-B.
28. Install crankshaft pulley bolt and crankshaf t pulley
retaining washer. Tighten to 155-165 N-m
( 114- 121 Ib-ft).
03- 01- 7 2 E n gi n e , 4. 6L ( 2V) 03- 01- 72
29. Install RH and LH val ve cover gasket s ( 6584) .
Tighten studs and bol ts t o 8-12 N-m ( 71- 106
Ib-in).
APPLY SILICONE
GASKET SEALER
NOTE: LH SIDE SHOWN
RH SIDE TYPICAL
A136S3-B
Pa r t
Req'd)
Req'd)
A

Lb-ln)
30. Install new oil bypass filter as outlined.
OIL BYPASS
FILTER
6714
NOTE: LUBRICATE SEAL
AND TIGHTEN 3/4 TURN
AFTER SEAL CONTACT
A14S0S- C
3 1 . Install dri ve belt idler pulley and dri ve belt
tensi oner wi t h ignition coils and ti ghten seven nuts
t o 20- 30 N-m (15-22 Ib-ft).
32. Install wat er pump pulley and ti ghten bol ts t o
20- 30 N-m (15-22 Ib-ft).
33. Install accessor y dri ve belt. Refer t o Secti on
03- 05.
34. Install fl ywheel and tighten si x bol ts t o 73-87 N-m
( 54- 64 Ib-ft).
35. Install ignition wi res as outlined in Secti on 03- 07.
36. Install engine as outlined.
C r a n k s h a f t Ma i n B e a r i n g s
Re mo v a l
1. Remove engine f rom vehicle as outlined.
2. Remove crankshaf t ( 6303) as outlined.
3. Clean and i nspect cylinder bl ock ( 6010) ,
crankshaf t , crankshaf t main beari ngs ( 6333) ,
crankshaf t thrust main bearing ( 6337) and
crankshaf t thrust washer ( 6334) as outlined in
Secti on 03- 00.
1. Fit crankshaf t main beari ngs as outlined in
Secti on 03- 00.
2. Install upper crankshaft main beari ng and
crankshaf t thrust washer into cylinder bl ock.
Install l ower crankshaf t main beari ngs and
crankshaf t thrust main bearing into main beari ng
caps.
3. Install crankshaf t as outlined.
4. Install engine into vehicle as outlined.
03- 01- 7 3 En gi n e , 4 . 6 L ( 2 V) 03- 01- 7 3
E n g i n e
De s c r i p t i o n Tool N u m b e r
Re a r Cr a n k Se a l Re p l a c e r A d a p t e r
C a m P o s i t i o n i n g To o l A d a p t e r s
T58P - 6316- D
T 7 4P - 6316- B
T 82 L - 67 01- A
T 91P - 67 01- A
T 91P - 62 56- A
T 92 P - 62 56- A
Di s a s s e mb l y
1. NOTE: Thi s procedure will di sassembl e and
assembl e a compl et e engine wi t h t he engine
removed f rom t he vehi cl e.
Remove ignition wi res and spark plugs ( 12405) .
el ectroni c engine control s, fuel i nj ectors ( 9F593)
and ignition coi l s ( 12029) and remove fuel
chargi ng wi ri ng.
A13667-C
Pa r t
1
_
To Idle Air Control (IAC)
Valve (Part of 9D930)
2

To EGR Valve Position (EVP)
Sensor (Part of 9D930)
3 To EGR Vacuum Regulator
(EVR) Sensor (Part of
9D930)
4

To LH H02S (Part of 9D930)
5

To 12A581 Harness (Part of
9D930)
6

To Fuel Inj ectors (8 Places,
Part of 9D930)
7

To Throttle Position (TP)
8 To Engine Coolant
Temperature (ECT) Sensor
(Part of 9D930)
9

To LH Ignition Coil (Part of
9D930)
10

To Power Steering Pump
(Part of 9D930)
11

To Oil Pressure Switch (Part
of 9D930)
12
To Camshaft Position (CMP)
( Co n t i n ue d )
03- 01- 7 4 E n gi n e , 4. 6L ( 2 V) 03- 01- 7 4
Pa r t
14 To Crankshaft Position
(CKP) Sensor (Part of
9D930)
15

To Power Distribution Box
(Part of 9D930)
16

To A/ C Compressor (Part of
9D930)
18

To RH Ignition Coil (Part of
9D930)
19 To Water Temperature
Indicator Sender Unit (Part of
9D930)
20 N806155-S2 Screw (3 Req'd)
21

To 9C915 (Part of 9D930)
22

To RH H02S (Part of 9D930)
A

Lb-ln)
3. Remove si x fl ywheel retaining bol ts and remove
fl ywheel ( 6375) f rom crankshaf t ( 6303) .
4. Remove crankcase vent connect or and front
vapor hose and posi ti ve cr ankcase ventilation
val ve (PCV val ve)(6A666).
5. Remove generator mounting bracket ( 10153)
and t wo bol ts retaining generat or (GEN)( 10300)
t o cyl i nder bl ock ( 6010) .
7. Remove A / C compressor ( 19703) .
8. Remove dri ve belt idler pulley ( 8679) and dri ve
belt tensioner ( 6B209) wi t h ignition coi l s.
9. Remove RH and LH exhaust manifolds ( 9430) .
10. Remove oil bypass filter ( 6714) and oil filter
adapt er ( 6881) .
NOTE: LUBRICATE SEAL WITH
Pa r t
6 N806514-S2 Stud
7 N806156-S2 Bolt (3 Req'd)
A

Lb-Ft)
11. Remove wat er hose connecti on ( 8592) , wat er
t hermost at ( 8575) and O-ring.
12. Remove nine bol ts retaining intake manifold
( 9424) t o cylinder heads ( 6049) and remove
i ntake manifold.
13. If necessary di sassembl e i ntake manifold as
fol l ows:
a. Remove throttl e body ( 9E926) and throttl e
body adapter.
b. Remove idle air control valve (IAC
val ve)(9F715).
c. Remove engine cool ant temperature sensor
(ECT sensor)(12A648) and wat er
temperature indicator sender unit ( 10884) .
d. Remove four bol ts retaining fuel injection
suppl y manifold ( 9F792) and remove fuel
injection supply manifold and fuel injectors.
03- 01- 7 5 E n gi n e , 4. 6L ( 2 V)
^mmr ~ XEET -jmr <*mwmr- *mam**
03- 01- 7 5
14. Remove RH and LH val ve covers ( 6582) .
GASKET SEALER NOTE: LH SIDE SHOWN
UAbKf c : I b b A L f c H
R H s |
p
E
TYPICAL
A13663-B
Pa r t
Req'd)
A

Lb-ln)
15. Remove crankshaf t pulley bolt ( 6A340) and
crankshaf t pulley retaining washer ( 6378) .
16. Using Crankshaft Damper Remover
T58P-6316-D, pull crankshaf t pulley ( 6312) f rom
crankshaf t .
CRANKSHAFT DAMPER
REMOVER
T58P-6316-D
A13668-B
17. Remove crankshaf t posi ti on sensor (CKP
sensor)(6C315) and camshaf t posi ti on sensor
(CMP sensor)(6B288) f r om engine front cover
( 6019) .
A13661-E
Pa r t
2

Bolt (4 Req'd)
4

Bolt
5

Bolt
A

Lb-Ft)
B

Lb-ln)
03- 01- 7 6
E n gi n e , 4 . 6 L ( 2 V) 03- 01- 7 6
18. Remove oil pan ( 6675) and oil pan gasket ( 6710) .
Pa r t
1 W701240-S309 Bolt (16 Req'd)
3 6675 Oil Pan
A

Lb-Ft)
B

Lb-Ft)
19. Remove heater wat er hose ( 18472) .
20. Remove wat er pump ( 8501) .
Pa r t
1 6049 RH Cylinder Head
3 N806155-S2 Bolt (2 Req'd)
6 N606021-S Bolt (4 Req'd)
7 8501 Water Pump
8 3Z728 O-Ring
A

Lb-Ft)
03- 01- 7 7 E n gi n e , 4. 6L ( 2V) 03- 01- 77
DISASSEMBLY A N D ASSEMBLY (Conti nued)
2 1 . Remove engine front cover.
APPLY WSE-M4G320-A2
A13659-C
I t e m
Pa r t
6 W807753 Bolt
7 N806300-S2 Stud
I t e m
Pa r t
A

Tighten t o 20-30 N-m (15-22
Lb-Ft)
22. NOTE: Thi s will position all pi stons ( 6108) bel ow
t op of cyl i nder bl ock deck f ace.
Position crankshaft on t op dead cent er (TDC) No.
1 cylinder.
KEYWAY A13658-B
23. Remove timing chai ns as outl i ned.
24. Rotate crankshaf t count ercl ockwi se 45 degrees.
CRANKSHAFT
KEYWAY A13655-B
25. Remove RH and LH cylinder heads. Di scard all
head bol ts.
26. Remove and di scard head gasket s ( 6051) .
27. If cylinder heads are t o be servi ced, refer t o
Assembl y.
03- 01- 7 8
E n gi n e , 4 . 6 L ( 2 V) 03- 01- 7 8
28. Remove oil pump ( 6600) and oil pump screen
cover and tube ( 6622) .
Pa r t
2 N605904-S Bolt
Tube
Cap Stud
6 N606021-S Bolt (4 Req'd)
7 6600 Oil Pump
8 3Z728 O-Ring
9 N805892-S2 Bolt (2 Req'd)
A

Lb-Ft)
B

Lb-ln)
29. Remove crankshaf t rear oil seal retainer ( 6335) .
A13669-B
I t e m
Pa r t
2 6303 Crankshaft
Retainer
5

Bolt (6 Req'd)
A

Tighten t o 8-12 N-m (71-106
Lb-ln)
30. NOTE: Pi stons, connecti ng rods ( 6200) and
connecti ng rod beari ngs ( 6211) shoul d be
numbered t o ensure they are assembl ed in their
NOTE: Before removing pi stons, inspect the t op
of the cyl i nder bores. If necessary, remove the
ri dge and/ or carbon deposi ts f rom each cylinder
using Rotunda Cylinder Ridge Reamer
014- 00292 or equivalent as outlined in Secti on
03- 00.
Turn crankshaft until pi ston t o be removed is at
the high point of its t ravel . If more than one piston
is being removed, identify the pi stons, connecti ng
rods and connecti ng rod caps for cylinder
position.
3 1 . Remove t he connecti ng rod cap and l ower
connecti ng rod beari ng. Keep cap and l ower
connecti ng rod bearing together. Push t he pi ston,
connecti ng rod and upper connecti ng rod bearing
through the t op of t he cylinder bore. Use care t o
prevent damage to the beari ng and cylinder bore
surf aces. Keep upper connecti ng rod bearing and
connecti ng rod together.
03- 01- 7 9 E n gi n e , 4. 6L ( 2 V) 03- 01- 7 9
32. CAUTI ON: Car e shoul d be t ak en not t o
damage t he f r ac t ur ed r od and c ap j oi nt f ac e
sur f aces or possi bl e engi ne damage may
occur .
NOTE: Connecti ng rod bol ts ( 6214) are retai ned
in the connecti ng rod cap wi t h a light press fi t.
The connecti ng rod bol ts have been t orqued t o
yi el d at least t wi ce and must be di scarded. Use a
hammer and punch t o drive connecti ng rod bol ts
f rom connecti ng rod cap.
DRIVE BOLTS OUT
33.
34.
36.
SUPPORT BEARING
CAP WHILE
REMOVING BOLTS
A15051-B
Using new connecti ng rod bol ts, at t ach
connecti ng rod cap and l ower connecti ng rod
beari ng t o connecti ng rod and upper connecti ng
rod beari ng t o prevent mixing part s and damagi ng
t he f ract ured joint f ace surfaces.
NOTE: Any pi ston rings that are removed f r om
pi ston shoul d be di scarded and repl aced wi t h
new pi ston ri ngs.
If pi ston ring repl acement is requi red, use a
suitable pi ston ring expander. Remove t wo
compressi on ri ngs. Remove t wo oil ring rails and
expander by hand.
Mark connecti ng rod cap t o ensure reassembl y
wi th same pi ston and installation in same
cyl i nders f rom whi ch they wer e removed.
NOTE: The pi ston and pi ston pin ( 6136) are a
mat ched set. Keep pi stons, pi ston pin, pi ston
rings, connecti ng rods and connecti ng rod
beari ngs t oget her in proper cyl i nder order.
Using Piston Pin Tool D81L- 6135- A or equivalent,
press pi ston pin f rom pi ston and connecti ng r od.
REMOVAL
PRESS
PLATES
PIN
PUSHER
PISTON
PIN
6135
RECEIVING
TUBE
A8121-C
36.
37.
38.
39.
Remove horizontal main cap si de bol ts f rom
cyl i nder bl ock.
Loosen crankshaf t main beari ng cap adjusting
scr ews ( 6C360) on main beari ng caps.
Remove beari ng main cap retaining bol ts. These
are torque-to-yi el d bol ts, and shoul d not be
reused.
NOTE: The l ocati on of t he main beari ng caps and
t he main beari ng inserts shoul d be identified.
When the engine is assembl ed, beari ngs whi ch
ar e t o be reused should be installed in their
Remove each main bearing cap and l ower
crankshaft main bearing ( 6333) and crankshaft
thrust main beari ng ( 6337) . Keep each cap,
l ower crankshaft main beari ng and crankshaft
thrust main beari ng together.
CAUTI ON: Wh e n r e mo v i n g t h e c r a n ks h a f t ,
us e c a r e n o t t o d a ma g e a n y o f t h e b e a r i n g
s u r f a c e s o n t h e c r a n ks h a f t .
Remove crankshaft.
Clean and i nspect crankshaft and cylinder bl ock.
Repl ace worn or damaged component s as
requi red.
A s s e mb l y
1. NOTE: Before assembl i ng cylinder bl ock, all
sealing surfaces must be cl ean and free of chi ps,
dirt, paint and forei gn materi al . Al so make sure
cool ant and oil passages are clear.
Lubri cate and install crankshaf t main beari ngs
into cylinder bl ock. Install crankshaf t main
beari ngs and crankshaft thrust main bearing into
main beari ng caps.
2. Install crankshaft into cylinder bl ock.
40.
4 1 .
03- 01- 80 Engi ne, 4. 6L (2V)
03- 01- 80
Push crankshaft r ear war d. Lubri cate and install
upper crankshaft thrust washer ( 6334) by rolling
t he crankshaft thrust washer onto machi ned shelf
between rear si de of No. 5 bul khead and thrust
surface of crankshaf t . Ensure coat ed si de of
crankshaft thrust washer wi th three 5 mm wi de
oil grooves f aces t he crankshaft thrust surface.
NOTE: ASSEMBLE
CAPS WITH ARROW
POINTING FORWARD,
CAPS ARE STAMPED
1 THROUGH 5 FRONT
TO REAR
FRONT OF
ENGINE
A13637-C
Pa r t
Cap Bolt
3 6 3 4 5 Crankshaft Main Bearing
Cap S t u d
Main Bearing
Bearing
6 6303 Crankshaft
Bearing
I t e m
Pa r t
4. NOTE: Crankshaft main bearing cap adjusting
scr ews must be bot t omed on main beari ng cap
prior t o installation of main bearing cap.
Install main beari ng caps. Tap main beari ng caps
wi t h a brass hammer t o seat caps properl y.
NOTE: ALL MAIN BEARING CAPS
MUST BE TAPPED INTO POSITION
PRIOR TO TIGHTENING. FAILURE
TO DO SO MAY RESULT IN
IMPROPER TORQUE.
BRASS HAMMER
MAIN BEARING
CAP
5.
A13641-B
Push crankshaf t f orward using a prybar or similar
tool t o seat crankshaft thrust main bearing and
crankshaf t thrust washer.
TORQUE
WRENCH
NOTE: PUSH CRANKSHAFT IN DIRECTION
OF ARROW TO FULLY SEAT THRUST
BEARING. LEAVE PRYBAR IN POSITION
UNTIL ALL MAIN BEARING BOLTS ARE
TIGHTENED.
A13642-B
NOTE: No. 5 main bearing cap must be seated
until the main bearing cap bol ts are fully ti ghtened
as outlined below.
Wi t h crankshaft pushed f or war d, install prybars
or similar tool s t o push both RH and LH front
edges of No. 5 main bearing cap rearward and
position the l ower crankshaft thrust main bearing
rear f ace properl y against t he thrust f ace of the
crankshaft.
03- 01- 81 Engi ne, 4. 6L ( 2V) 0 3 - 0 1 - 8 1
7. CAUTI ON: Ma i n bear i ng bol t s mu s t b e
r epl aced wi t h new bol t s. They ar e
t o r q u e - t o - y i e l d des i gned and cannot be
r eused.
Tighten new main bearing cap bolts in two steps
as follows:
a. Tighten bolts in sequence to 30-3*5 N-m
(22-25 Ib-ft).
b. Rotate bolts in sequence 85-95 degrees.
I nst a l l a t i on Se que n c e
NOTE: ITEMS 1 THROUGH 10 ARE
MAIN BEARING CAP BOLTS, 11
THROUGH 18 ARE CRANKSHAFT MAIN
BEARING CAP ADJUSTING SCREWS, AND
19 THROUGH 26 ARE CRANKSHAFT
MAIN BEARING CAP BOLTS.
A13638-C
8. Tighten crankshaft main bearing cap adjusting
screws in two steps as follows:
a. Tighten crankshaft main bearing cap
adjusting screws in sequence to 5 N-m (44
Ib-in).
b. Tighten crankshaft main bearing cap
adjusting screws in sequence to 9-11 N-m
(80-97 Ib-in).
9. Tighten main bearing cap bolts in two steps as
follows:
a. Tighten main bearing cap bolts in sequence to
10 N-m (7 Ib-ft).
10.
b. Tighten main bearing cap bolts in sequence to
19-23 N-m (14-17 Ib-ft).
NOTE: Pry against number two main bearing cap.
Check crankshaft end play in both directions as
shown.
P RYBA R
CRANKSHAFT END PLAY
0.130-0.251 mm
(0.005-0.010 INCH)
ROTUNDA DIAL
INDICATOR
WI TH BRACKETRY
014-00282
NOTE TOTAL END PLAY
A13643-D
11. Apply a 1.5 mm (0.06 inch) continuous bead of
Silicone Gasket and Sealant F1AZ-19562-B or
equivalent meeting Ford specification
WSE-M4G320-A2 to cylinder block as shown.
CYLI NDER BLOCK
6010
SI LI CONE GASKET
AND SEALANT
F1AZ-19562-B
MEETI NG FORD
SPECI FI CATI ON
WSE-M4G320-A2
A13644-C
12. Install crankshaft rear oil seal retainer to cylinder
block and tighten six bolts in sequence to 8-12
N-m (71-106 Ib-in).
A 1 3 6 4 5 - B
0 3 - 0 1 - 8 2 Engi ne, 4. 6L (2V) 03- 01- 82
13. Usi ng Rear Seal Repl acer Ada pt e r s
T91P-6701-A and Rear Mai n Seal Repl acer
T82L-6701-A, i nstall cr ankshaf t rear oil seal
( 6701) .
REAR MAIN
SEAL REPLACER
T82L-6701-A
REAR CRANK
SEAL REPLACER
ADAPTERS
T91P-6701-A
A15054-C
14. Coat pi st on bor es, pi st ons, pi st on ri ngs,
cr ankshaf t j ournal s and beari ng sur f aces wi t h
cl ean engi ne oi l .
15. NOTE: Ma ke sure pi st on ri ng ga ps a r e r ot at ed 30
degr ees apart .
NOTE: Not ch on pi st on t o f ront of engi ne.
Turn cr ankshaf t until t he cr ankshaf t t hr o w is at
bot t om of st r oke . Install c or r e c t l y numbered
pi st on, connect i ng r od and upper connect i ng rod
beari ng assembl i es wi t h Pi st on Ring Compr essor
D81L-6002-C or equi val ent and a sui t abl e
connect i ng r od gui de t ool .
16. CAUTI ON: Be s u r e n o t t o s c r a t c h c y l i n d e r
r o d . Push p i s t o n d o w n un t i l c o n n e c t i n g r o d
NOTE: Due t o t he use of a c r a c ke d connect i ng
r od j oi nt f a c e sur f ace, t he connect i ng r od c a p
must be pr oper l y al i gned t o t he connect i ng r o d .
The connect i ng r od and connect i ng r od c a p
beari ng t angs shoul d be l ocat ed on t he sa me si de
of t he connect i ng r o d .
Install connect i ng r od c a p and l ower connect i ng
r od beari ng and al t ernat el y t i ght en new
connect i ng r od c a p bol t s in several pa sse s t o
obt ai n 40-45 N-m ( 29- 34 Ib-f t ). Rot at e connect i ng
r od bol t s an addi t i onal 85-95 de gr e e s. Af t er
i nst al l at i on, r ot at e cr ankshaf t t o ensure smoot h
oper at i on.
NOTCH TOWARD -
FRONT OF ENGINE
A13639-B
Pa r t
1 6214 Connecting Rod Bolt (16
Req'd)
2

Cap (8 Req'd) (Part of 6200)
3 6211 Lower Connecting Rod
Bearing (8 Req'd)
4 6303 Crankshaft
5 6211 Upper Connecting Rod
Bearing (8 Req'd)
6 6108 Piston (8 Req'd)
7 6200 Connecting Rod (8 Req'd)
8 D81L-6002-C Piston Ring Compressor Tool
9

Connecting Rod Guide Tool
Lb-Ft), Then rotate an
additional 85-95 degrees
03- 01- 83 E n gi n e , 4. 6L ( 2V)
03- 01- 83
Rotunda Dial Indicator wi t h Br acket r y 014- 00282
or equivalent. Cl earance shoul d be 0. 15-0. 45 mm
( 0. 006- 0. 0177 inch). If si de cl earance is greater
crankshaf t .
ROTUNDA DIAL
INDICATOR
WITH BRACKETRY
014-00282
CONNECTING
ROD 6200
J
A15093-C
18. NOTE: Install new O-ring then st art all bol ts on oil
pump and oil pump screen cover and t ube before
ti ghteni ng.
Install oil pump and oil pump screen cover and
tube.
A13S52-B
Pa r t
2 N606904-S Bolt
Tube
Cap Stud
6 N606021-S Bolt (4 Req'd)
7 6600 Oil Pump
8 3Z728 O-Ring
9 N605892-S2 Bolt (2 Req'd)
Lb-ln)
B Tighten t o 8-12 N-m (71-106
Lb-ln)
19. NOTE: Make sure cylinder heads are installed in
their original posi ti ons.
If cylinder heads are t o be servi ced, refer t o
Assembl y.
03- 01- 84 E n gi n e , 4. 6L ( 2 V) 03- 01- 84
20. CAUTI ON: Do n o t u s e s a n d p a p e r c o a r s e r
t h a n 6 0 0 gr i t o r d a ma g e t o s e a l i n g s u r f a c e s
ma y o c c u r .
NOTE: Clean cyl i nder head gasket surf ace wi th a
tol uene-based paint thinner or gasket remover. If
gasket materi al remai ns on head after cleaning,
use a 600-gri t sandpaper t o remove remaining
materi al .
2 1 . NOTE: RH and LH head gasket s are not
i nterchangeabl e.
Position new head gasket s on cylinder head.
LH HEAD
GASKET
6051
22.
RH HEAD
GASKET
6051
A13654-B
CAUTI ON: Fa i l ur e t o p o s i t i o n c r a n ks h a f t a s
NOTE: Wi th crankshaf t in thi s posi ti on, no pi ston
Rot at e crankshaf t t o position as shown.
< CRANKSHAFT
CRANKSHAFT
KEYWAY A13S55-B
23. CAUTI ON: Use c a r e w h e n p o s i t i o n i n g
c y l i n d e r h e a d s . Da ma ge t o c y l i n d e r b l o c k
a n d / o r c y l i n d e r h e a d s ma y r e s u l t .
Position cylinder heads on cylinder bl ock. Use
Cam Positioning Tool Adapt ers T92P-6256-A and
Cam Positioning Tool T91P-6256-A t o prevent
crankshaf t s f rom rotati ng.
RH CYLINDER
HEAD 6049
LH CYLINDER
HEAD 6049
CYLINDER
BLOCK 6010
CRANKSHAFT
KEYWAY
CRANKSHAFT <
6303
A13656-B
24. CAUTI ON: Cy l i n d e r h e a d b o l t s mu s t b e
r e p l a c e d wi t h n e w b o l t s . T h e y a r e
t o r q u e - t o - y i e l d d e s i g n e d a n d c a n n o t b e
r e u s e d .
NOTE: Appl y clean engine oil t o all head bolt
spot -f aces.
Tighten new cylinder head bol ts as f ol l ows:
a. Tighten head bol ts in sequence t o 30- 40 N-m
( 22- 30 Ib-ft).
b. Rotate head bol ts in sequence 85- 95
degrees.
c. Rotate head bol ts in sequence an additional
85- 95 degrees.
w4
RH CYLINDER
HEAD 6049
LH CYLINDER
HEAD 6049
CYLINDER HEAD TIGHTENING SEQUENCE
I
FRONT OF
ENGINE
I A13657-C
03- 01- 85 E n gi n e , 4. 6L ( 2 V) 0 3 - 0 1 - 8 5
25. CAUTI ON: Cr ankshaf t must onl y b e r o t a t e d i n
t h e c l oc k wi s e di r ect i on and o n l y as f ar a s t o p
d e a d c e n t e r (TDC) No . 1 c y l i n d e r .
Rot at e crankshaf t cl ockwi se 45 degrees. Thi s
will posi ti on crankshaft at t op dead center (TDC)
No. 1.
KEYWAY A13658-B
26. Install timing chai ns as outlined.
27. Repl ace crankshaft front seal ( 6700) in engine
front cover if requi red.
28. Install engine front cover as outlined.
APPLY WSE-M4G320-A2
A13659-C
Pa r t
6 W807763 Bolt
7 N806300-S2 Stud
A

Lb-Ft)
03- 01- 86
E n gi n e , 4. 6L ( 2 V) 03- 01- 86
Tighten bol ts t o 25-35 N-m (18-26 Ib-ft) in no more
than four minutes after appl yi ng sealer.
A136S3-B
Pa r t
1 W701240-S309 Bolt (16 Req'd)
3 6675 Oil Pan
A

Lb-Ft)
B

Lb-Ft)
30. Install wat er pump and ti ghten retaining bol ts t o
20- 30 N-m (15-22 Ib-ft).
3 1 . Install heater wat er hose.
NOTE: LUBRICATE O-RING WITH
CLEAN ANTIFREEZE
' 2
A13660-B
Pa r t
1 6049 RH Cylinder Head
3 N80665-S2 Bolt (2 Req'd)
6 N606021-S Bolt (4 Req'd)
7 8501 Water Pump
8 3Z728 O-Ring
A

Lb-Ft)
03- 01- 87 E n gi n e , 4. 6L ( 2 V) 03- 01- 87
32. Install crankshaf t position sensor and camshaft
posi ti on sensors into engine front cover and
ti ghten retaining bol ts to 8-12 N-m ( 71- 106 lb-in).
A13661-E
Pa r t
2 Bolt (4 Req'd)
4

Bolt
5

Bolt
A

Lb-Ft)
B

Tighten to 8-12 N-m (71 -106
Lb-ln)
33. NOTE: Silicone Gasket and Seal er
F1AZ- 19562- B or equivalent meeti ng Ford
speci fi cati on WSE- M4G320- A2 must be applied
t o crankshaf t keyway prior t o installing
crankshaf t pulley.
Install crankshaft pulley using Crankshaft Damper
Repl acer T74P-6316-B.
CRANKSHAFT
DAMPER REPLACER
T74P-6316-B
A13662-B
34. Install crankshaft pulley bolt and crankshaft pulley
( 114- 121 Ib-ft).
35. Install RH and LH val ve cover gasket s ( 6584) .
Tighten studs and bol t s t o 8-12 N-m ( 71- 106
lb-in).
FRONT OF
ENGINE
APPLY SILICONE
GASKET SEALER
NOTE: LH SIDE SHOWN
RH SIDE TYPICAL
A13663-B
Pa r t
Req'd)
Req'd)
A

Tighten t o 8-12 N-m (71-106
Lb-ln)
36. If i ntake manifold was di sassembl ed, assembl e
as fol l ows:
a. Install fuel injector o-rings ( 9C991) on fuel
injectors wi t h cl ean engine oil prior t o
assembl y.
b. Install fuel injection suppl y manifold and fuel
i nj ectors and ti ghten four bol ts t o 8-12 N-m
( 71- 106 lb-in).
03- 01- 88 E n gi n e , 4. 6L ( 2 V) 03- 01- 88
c. Install engine cool ant temperature sensor and
wat er temperature indicator sender unit and
ti ghten t o 16-24 N-m (12-17 Ib-ft).
d. Install idle air control val ve and tighten bol ts
t o 8-12 N-m ( 71- 106 lb-in).
e. Install throttl e body and throttl e body
adapter. Tighten bol ts t o 8-12 N-m ( 71- 106
lb-in).
37. NOTE: Align t abs on i ntake manifold gasket
( 9461) wi th holes in cylinder head.
Position i ntake manifold gasket on cylinder head.
38. Install i ntake manifold wi th nine bol ts and ti ghten
t o 20- 30 N-m (15-22 Ib-ft).
39. NOTE: Water outlet connecti on retaining bol ts are
al so i ntake manifold retaining bol ts.
Install wat er outlet connecti on O-ring and wat er
hose connecti on. Tighten bol ts t o 20- 30 N-m
(15-22 Ib-ft).
40. Install oil filter adapt er and tighten bol ts t o 20- 30
N-m (15-22 Ib-ft).
4 1 . Install oil bypass filter.
NOTE: LUBRICATE SEAL WITH
Pa r t
Pa r t
6 N806514-S2 Stud
7 N806516-S2 Bolt (3 Req'd)
A

Tighten t o 20-30 N-m (15-22
Lb-Ft)
42. Install LH exhaust manifold and ti ghten bol ts t o
20- 30 N-m (15-22 Ib-ft).
43. Install RH exhaust manifold and ti ghten bol ts t o
20- 30 N-m (15-22 Ib-ft).
44. Install dri ve belt idler pulley and dri ve belt
tensioner wi t h ignition coi l s and ti ghten seven nuts
t o 20- 30 N-m (15-22 Ib-ft).
45. Install A / C compressor and ti ghten t hree bol ts t o
20- 30 N-m (15-22 Ib-ft).
CRANKSHAFT
KEYWAY A13S55-B
46. Install wat er pump pulley and ti ghten bol ts t o
20- 30 N-m (15-22 Ib-ft).
47. Install generator and ti ghten generator-to-cyl i nder
bl ock retaining bol ts t o 20-30 N-m (15-22 Ib-ft).
48. Install generator mounting bracket and ti ghten t o
8-12 N-m (71-106 lb-in).
49. Install posi ti ve crankcase ventilation val ve and
front vapor hose.
50. Install fl ywheel t o crankshaft and ti ghten si x bol ts
t o 73-87 N-m (54-64 Ib-ft).
03- 01- 89 En gi n e , 4. 6L ( 2 V) 0 3 - 0 1 - 8 9
5 1 . Install fuel chargi ng wi ri ng and connect all
appl i cabl e wi ri ng connect ors.
A13867-C
I t e m
Pa r t
1

To Idle Air Control (IAC)
Valve (Part of 9D930)
2 . To EGR Valve Position (EVP)
3 To EGR Vacuum Regulator
(EVR) Sensor (Part of
9D930)
4

To LH H02S (Part of 9D930)
5 To 12A581 Harness (Part of
9D930)
6

To Fuel Inj ectors (8 Places,
Part of 9D930)
7 To Throttle Position (TP)
8 To Engine Coolant
Temperature (ECT) Sensor
(Part of 9D930)
9 To LH Ignition Coil (Part of
9D930)
( Co n t i n ue d )
Par t
10 To Power Steering Pump
(Par t of 9D930)
11

To Oil Pressure Switch (Part
of 9D930)
12

To Camshaft Position (CMP)
14 To Crankshaft Position
(CKP) Sensor (Part of
9D930)
15

To Power Distribution Box
(Part of 9D930)
16

To A/ C Compressor (Part of
9D930)
18

To RH Ignition Coil (Part of
9D930)
19 To Water Temperature
Indicator Sender Unit (Part of
9D930)
20 N806155-S2 Screw (3 Req'd)
21

To 9C915 (Part of 9D930)
22

To RH H02S (Part of 9D930)
A

Lb-ln)
52. Install spark pl ugs. Tighten t o 9-20 N-m (7-15
Ib-f t ).
53. Install ignition wi res as outlined in Secti on 03- 07.
S u b a s s e m b l i e s
C y l i n d e r He a d
Dr i v e r Ha n d l e
Va l v e S t e m Se a l Re p l a c e r
T80T- 4000- W
T91P - 657 1- A
T91P - 6565- A
T 91P - 6565- A H
Di s a s s e mb l y
1. NOTE: Camshaft ( 6250) must be at base ci rcl e
before compressi ng val ve spri ng ( 6513) . Rot at e
camshaf t as requi red until all rocker arms ( 6564)
are removed.
Install Valve Spring Compressor T91P-6565-A
under camshaft and on t op of val ve spri ng
retainer ( 6514) .
03- 01- 90 E n gi n e , 4. 6L ( 2V) 0 3 - 0 1 - 9 0
Install Val ve Spri ng Spacer T91P-6565-AH
VIEW A
VALVE SPRING
SPACER
T91P-6565-AH
VALVE SPRING
COMPRESSOR
T91P-6565-A
VALVE SPRING SPACER
T91P-6565-AH
VIEW A
A15052-B
3. Compress val ve spri ng f ar enough t o remove
rocker arm.
Repeat St eps 1 through 3 until all rocker arms are
removed.
4. Remove all val ve t appet s ( 6500) .
5. Further compress val ve spri ng and remove val ve
spri ng retainer keys ( 6518) , val ve spri ng retai ner
and val ve spri ng.
A14878-B
Pa r t
1 6507 Intake Valve
2 6505 Exhaust Valve
3 6571 Valve Stem Seal
4 6513 Valve Spring
5 6514 Valve Spring Retainer
6 6518 Valve Spring Retainer Key
6. Remove val ve st em seal ( 6571) using locking
pl i ers and remove i ntake val ves ( 6507) and
exhaust val ves ( 6505) .
VALVE
STEM
SEAL
A14876-B
7. Remove 14 bol ts retaining camshaf t bearing caps
( 6B280) t o cyl i nder head ( 6049) .
03- 01- 91 E n gi n e , 4. 6L ( 2 V) 0 3 - 0 1 - 9 1
8. Tap upward on camshaf t beari ng c a ps t o
gradual l y lift camshaft beari ng caps f rom cyl i nder
head. Remove camshaft.
NOTE: VALVE TAPPET MUST
BE PUMPED UP BEFORE
INSTALLATION
NOTE: LH SHOWN
RH TYPICAL
A14818-B
Pa r t
1 6B280 Front Camshaft Bearing Cap
2 6L293 Bolt (14 Req'd)
3 6B280 Rear Camshaft Bearing Cap
4 6250 Camshaft
5 6564 Rocker Arm (8 Req'd)
6 6500 Valve Tappet (8 Req'd)
A

Tighten t o 8-12 N-m (71-106
Lb-ln)
A s s e m b l y
1. Position camshaft on cyl i nder head. Appl y oil t o
j ournal s and l obes of camshaf t .
2. Install and seat camshaf t beari ng caps.
Hand-start 14 bol ts.
3. NOTE: Each camshaf t beari ng cap is ti ghtened
individually.
Tighten camshaft beari ng cap retaining bol ts in
sequence t o 8-12 N-m ( 71- 106 Ib-in).
CAMSHAFT BEARING CAMSHAFT BEARING
4.
6.
7.
10.
11.
12.
13.
CAP 6B280 \ CAP 6B280
A14817-C
Loosen 14 camshaft beari ng cap retaining bol t s
approxi matel y t wo turns or until head of bolt is
f ree.
Reti ghten all bol ts in sequence t o 8-12 N-m
(71-106 Ib-in).
NOTE: A knot t ed rag or similar item must be
posi ti oned under i ntake val ve or exhaust val ve t o
hol d it in the UP posi ti on.
Install val ve into cylinder head.
Install new val ve st em seal s using Valve St em
Seal Repl acer T91P-6571-A and Driver Handl e
T80T-4000-W.
DRIVER HANDLE
T80T-4000-W
VALVE STEM
SEAL REPLACER
T91P-6571-A
A15055-A
Position val ve spri ng and val ve spring retainer
onto val ve.
Install Valve Spring Compressor T91P-6565-A,
under camshaft and on t op of valve spring
retainer.
Install Valve Spri ng Spacer T91P-6565-AH
Compress val ve spri ng f ar enough t o install val ve
spri ng retainer key.
Repeat St eps 6 through 11 until all i ntake val ves
and exhaust val ves are installed.
NOTE: Camshaft must be at base ci rcl e prior t o
compressi ng val ve spri ng. Rotate camshaft as
necessary until all rocker arms are installed.
Compress val ve spri ng using Valve Spring
Compressor T91P-6666-A or equivalent far
enough t o install rocker ar m.
03- 01- 92
E n gi n e , 4. 6L ( 2 V) 03- 01- 92
P i s t o n s a n d P i s t o n P i n s
Di s a s s e mb l y
1. Using Piston Pin Tool D81L-6135-A or equivalent,
press piston pin ( 6135) through piston ( 6108)
and connecti ng rod ( 6200) .
2. Clean and i nspect pi ston and connecti ng rods.
Check pi ston and pi ston pin fit. Refer t o Secti on
03- 00.
A s s e m b l y
1. Appl y a light coat of cl ean engine oil t o all part s.
2. Verify that all part s to be assembl ed are for same
cylinder. Assembl e piston t o connecti ng rod.
3. Start pi ston pin in pi ston and connecti ng rod. Thi s
may requi re a very light t ap wi t h a mallet. Using
Piston Pin Tool D81 L-6135-A or equivalent, press
pi ston pin through pi ston until piston pin is
cent ered in pi ston. After assembl y, make sure
connecti ng rod swi ngs smoothl y.
A8122-C
P i s t o n Ri n g s
Di s a s s e mb l y a n d A s s e mb l y
1. Remove pi ston rings using a piston ring expander.
2. Clean and i nspect pi ston as outlined in Secti on
03- 00.
3. Verify pi ston ring end gap as outlined in Secti on
03- 00.
4. Install oil ring expander and t wo rails by hand.
Position oil ring rail and expander gaps as shown.
UPPER SIDE ^ *
FRONT MARK
RAIL * A15063-A
5. Using a pi ston ring expander, install t wo
compressi on rings as shown. Fol l ow instructions
on the pi ston ring package.
H y d r a u l i c Va l v e T a p p e t
The internal part s of each hydraulic valve t appet
( 6500) are mat ched set s. Do not intermix the part s.
Keep the valve t appet s intact until they are t o be
cl eaned. Valve t appet s should al ways be t est ed after
assembl y. Refer t o the Servi ce procedures in Secti on
03- 00.
Di s a s s e mb l y
Di sassembl e and assembl e each val ve t appet
separatel y. Identify the valve t appet s so they can be
installed in their original bores.
1. Grasp the l ock ring wi th needlenose pliers t o
rel ease it f rom the groove. It may be necessary t o
press the plunger t o fully rel ease l ock ring.
2. Remove the push rod ball, metering val ve (di sc),
plunger and spri ng.
3. Remove the plunger, the check val ve and t he
check val ve retainer and plunger spri ng. Carefully
remove the plunger spri ng, the check val ve
retainer and the check val ve di sc f rom the
plunger.
A s s e m b l y
1. Place the plunger upside down on a cl ean wor k
bench.
2. Place the check valve (di sc or ball check) in
position over t he oil hole on the bot t om of t he
plunger. Set the check val ve spri ng on t op of the
check val ve (di sc or ball check) .
3. Position the check valve retainer over the check
val ve and spri ng and push the retainer down into
pl ace on t he plunger.
03- 01- 93 E n gi n e , 4. 6L ( 2 V) 03- 01- 93
5.
6
Pl ace t he plunger spri ng and then the plunger
(open end up) into t he val ve t appet body.
Position t he meteri ng val ve (di sc) in t he plunger,
and then pl ace the push rod cup in t he plunger.
Press the plunger and position t he cl osed end of
t he l ock ring in the groove of t he val ve t appet
body. Wi t h the plunger still pressed, position t he
open ends of the l ock ring in t he groove. Rel ease
t he plunger and then press it agai n t o fully seat
t he l ock ri ng.
7. Use t he Hydraulic Tappet Lockdown Tester
TOOL-6500-E or equivalent t o fill t he val ve
t appet s wi t h t est fluid.
C y l i n d e r B l o c k A s s e m b l y
Di s a s s e mb l y
1. Mount the engine in a wor k stand and remove all
part s not furnished wi th t he new cyl i nder bl ock
( 6010) fol l owi ng the procedures in Removal and
Installation.
2. Remove t he cylinder head t o bl ock dowel s
( 6A008) and the cylinder bl ock drain pl ugs.
3. Remove t he used cylinder bl ock f rom the wor k
st and.
A s s e m b l y
1. Cl ean t he gasket and seal surf aces of all
servi ceabl e part s and assembl i es.
2. Position t he new cylinder bl ock in a wor k stand
and install t he cylinder head t o bl ock dowel and
cyl i nder drain plugs.
3. Transfer all servi ceabl e part s removed f rom the
used cyl i nder bl ock fol l owi ng t he procedures in
Removal and Installation.
4. Check all assembl y cl earances and correct as
necessary.
C y l i n d e r B l o c k B o r e
Bef ore repl aci ng a cyl i nder bl ock ( 6010) , determi ne if
it is servi ceabl e. Servi ce as necessary. Refer t o
Secti on 03- 00.
Di s a s s e mb l y
1. Compl etel y di sassembl e the used engi ne,
fol l owi ng t he procedures in Di sassembl y and
Assembl y.
2. Remember t o ri dge ream the cyl i nder bores
bef ore removi ng pi ston ( 6108) .
3. Remove t he cyl i nder head t o bl ock dowel s
( 6A008) and the cyl i nder bl ock drai n plugs.
A s s e m b l y
1. Clean the gasket and seal surf aces of all
servi ceabl e part s and assembl i es.
2. Position t he new cyl i nder bl ock in a wor k stand
and install the cyl i nder head t o bl ock dowel and
the cyl i nder bl ock drai n plugs.
3. Transfer all servi ceabl e part s removed f rom the
used cyl i nder bl ock, fol l owi ng the procedures in
Di sassembl y and Assembl y.
4. Check all assembl y cl earances and correct as
necessary.
SPECIFICATIONS
OBDI I 3. 8L Mu s t a n g , 4. 6L To wn Ca r , Cr o wn Vi c t o r i a ,
Co u ga r
OBDI Al l Ot h e r Ve h i c l e s
TA1000B
03- 01- 94
E n gi n e , 4. 6L ( 2 ) 03- 01- 94
En gi n e Specifications
GENERAL SPECIFICATIONS
DISPLACEMENT 4.6L(281 CID)
NUMBER OF CYLINDERS 8
BORE AND STROKE . 90.2 x 90.0mm
FIRING ORDER 1-3-7-2-6-5-4-8
OIL PRESSURE (HOT 1500 RPM) 138-310 kl
DRIVE BELT TENSION 0
CYLINDER HEAD AND VALVE TRAI N
COMBUSTION CHAMBER VOLUME (cc) 50 1
VALVE SEATS
Width - Intake 1.9-2.1
Width - Exhaust 1.9-2.1
Angle 45
Runout (TI.R.) Max 0.025
VALVE ARRANGEMENT (Front-to-Rear) (Left Hand) E-l-E-l-E-l-E-l
.(Right Hand) l-E-l-E-l-E-l-E
VALVE STEM TO GUIDE CLEARANCE
Intake 0.020-0.069
Exhaust 0.046-0.095
VALVE HEAD DIAMETER
Intake 44.5
Exhaust 34.0
Gauge Diameters 42.5 and 32.0
VALVE FACE RUNOUT LIMIT 0.05
VALVE FACE ANGLE 45.5
VALVE STEM DIAMETER (Std.)
Intake 6.995-6.975
Exhaust 6.970-6.949
(0.015 Oversize)
Intake 7.376-7.356
Exhaust 7.351-7.330
(0.030 Oversize)
Intake 7.757-7.737
Exhaust 7.732-7.711
VALVE SPRINGS
Compression Pressure (N @ Spec. Length)
Intake 587,14 N @ 28.02
Exhaust 587.14 N @ 28.02
Free Length (Approximate)
Intake 49.55
Exhaust 49.55
Installed Pressure (N @ Spec. Length)
Intake 244.64 @ 40.0
Exhaust 244.64 @ 40.0
Service Limit 10% Pressure Loss @ 28.02
Out of Square Limit 2
ROCKER ARM
Ratio 1.75:1
VALVE TAPPET
Diameter (Std.) 16.000-15.988
Clearance to Bore 0.018-0.069
Service Limit _ 0.016
Hydraulic Leakdown R a t e 5-25 seconds
Collapsed Valve Tappet Gap Desired 0.85-0.45
CAMSHAFT
LOBE LIFT
Intake
Exhaust
Allowable Lobe Lift Loss
THEORETICAL VALVE LIFT @ ZERO LASH
Intake
Exhaust . . .
END PLAY
Service Limit
JOURNAL TO BEARING CLEARANCE
Service Limit
JOURNAL DIAMETER (ALL)
BEARING INSIDE DIAMETER (ALL)
FRONT BEARING LOCATION
6.58939
6.58939
12.0
12.0
, . . 0.025-0.165
0.190
. . 0.025-0.076
0.121
26.962-26.936
. 27.012-26.91
C4
CYLINDER BLOCK
Head Gasket Surface
Head Gasket Surface Finish
MAIN BEARING BORE DIAMETER , 72.402-72.42
CRANKSHAFT AND FLYWHEEL
MAIN BEARING JOURNAL DIAMETER . .
CONNECTING ROD JOURNAL
Diameter
CRANKSHAFT FREE END PLAY' . ' . ' . "*".
CRANKSHAFT RUNOUT TO REAR FACE
OF BLOCK
CONNECTING ROD BEARINGS
Clearance to Crankshaft Desired
Allowable ^
Bearing Wall Thickness ( S t d . )
MAIN BEARINGS
Clearance to Crankshaft Desired
Allowable .
. 67.483-67.503
. 52.988-53.003
0.130-0.301 mm
. . . . 0.050MAX
. 0. 027-0. 069
. . 0.027-0.069
. . 2.444-2.452
Bearing Wall Thickness ( S t d . )
CONNECTING ROD, PISTON AND
CONNECTING ROD
Piston Pin Bore Diameter
Crankshaft Bearing Bore Diameter
. 0.027-0.065
. 0.027-0.065
. 1.920-1.928
RINGS
Length (Center to Center) . .
ALIGNMENT (BORE-TO-BORE MAX. DI FF)
.21.959-21.979
. 56.756-56.876
150.7
Twi st.
Band
SIDE CLEARANCE (ASSEMBLED TO CRANK)
Standard
Service Limit
. 0.050 PER 25
. 0.038 PER 25
. 0.015-0.45
. 0.50 MAX
CYLINDER BORE AND PISTON
CYLINDER BORE
Diameter
Surface Finish (RMS)
Out-of-Round Limit
Out-of-Round Service Limit . . .
Taper Service Limit
PISTON ^
DiameteKD
Coded Red 1
Coded Blue 2
Coded Yellow 3
PISTON-TO-BORE CLEARANCE.
PIN BORE DIAMETER
RING GROOVE WIDTH
Compression (Top)
Compression (Bottom)
Oil Ring
PISTON PIN
Length
DIAMETER
PIN TO PISTON CLEARANCE . . .
PIN TO ROD CLEARANCE
PISTON RINGS
Ring Gap
Compression (Top)
OIL RING
Side Clearance
Compression (Top)
Oil Ring
Service Umit
Ring G a p
Compression (Top)
Oil Ring (Steel Rail)
CD
. 0.2-0.6 microns
0.015
0.020
0.006
. . 90.167-90.180
. . 90.180-90.193
, . 90.193-90.206
. . . . 0.008-0.016
. 22.0015-22.004
. 1.530-1.550
.1.520-1.530
. 6.996-7.224
. . . 61. 93-62. 05
.21.994-21.999
. . . 0.005-0.010
. . . 0.015-0.040
. . 1. 0 MAX
. . 1. 0 MAX
1.25 MAX
. 0.040-0.090
. 0.030-0.080
Snug Fit
. . 0.015 MAX
. 0.23-0.49
. 0.23-0.49
. 0.15-0.66
LUBRICATION SYSTEM
OIL CAPACITY (QUARTS U.S.) 5 0.25
DRIVE BELT TENSION
Belts have differing tension specifications depending on whether they are
Newly Installed ( y o r Used (more than ten minutes of engine operation).
When belts are round to be below the allowable minimum, they must be
"RESET" (adjusted). Specifications for these situations are shown on next
page:
CAM880-F
03- 01- 95 E n gi n e , 4 . 6 L ( 2 ) 03- 01- 9 5
BELT TYPE
6 Rib (Fixed)
BELT TENSION IN LBS.
110-120
NOTE: "FIXED" refers to systems with manually-adjusted centers
which are bolted in place and considered fixed.
(T) Newly Installed Refers to the condition of the "NEW" drive belt
before the engine has made no more than one rotation and before
the belt has had a chance to stretch or seat into the pulley
grooves.
(5) Head Gasket Surface WT = 10.0 Minus 2.5 Microns
Head Gasket Surface Finish-RZU - 13.5 0.8 TPI 63% MIN.
Ra 3.0-3.5 J.80. This ID is obtained using a hand held profilometer.
(5) Time required for plunger to leak down 1.6mm of travel with 222 N
force and leak down fluid in tappet.
( ?) Distance front edge of bearing is installed below front face of
cylinder block.
0.050 Undersize add 0.025 to standard thickness.

Pin bore and crank bearing bore must be parallel and in same
vertical plane within the specified total difference when measured
at the ends of a 203mm bar, 101.5mm on each side of rod cen-
terline.
( ?) Piston Bore Diameter
Red-90. 200-90. 213
Bl ue-90. 213-90. 226
Yellow - 90.226-90.239
(D Measured 42mm from dome of piston, 90 degrees to the pin.
Piston diameter includes 0.02-0.03mm of coating. Piston-to-bore
fit measurements must be done by measuring bore and matching
corresponding bore color with the same piston color.
Specification in gauge.
CA14879-F
Cr a n ks h a f t Ma i n Be a r i n g Ca p
Ad j u s t i n g S c r e ws
( 1) ( 1)
Ma i n Be a r i n g Ca p Si d e Bo l t s ( 2 ) ( 2 )
Ca ms h a f t S p r o c k e t b o l t 110- 130 81- 95
Co n n e c t i n g Ro d Bo l t ( 3) ( 3)
En gi n e Fr o n t Co v e r Bo l t 2 0- 30 15- 2 2
Cy l i n d e r He a d Bo l t ( 4) ( 4)
Pul l e y t o Cr a n ks h a f t b o l t 155- 165 114- 12 1
EGR Va l v e t o I n t a ke Ma n i f o l d 2 0- 30 15- 22
E x h a u s t Ma n i f o l d t o Cy l i n d e r He a d
Nut
18- 22 13- 16
Fl y wh e e l t o Cr a n ks h a f t Bo l t 7 3- 87 54- 64
I n t a ke Ma n i f o l d To Cy l i n d e r He a d
Bo l t ( 5)
2 0- 30 15- 22
Ma i n Be a r i n g Ca p - Bo l t ( 6) ( 6)
Oi l Fi l t e r A d a p t e r Bo l t 2 0- 30 15- 22
Oi l By p a s s Fi l t e r t o A d a p t e r ( 7 ) ( 7 )
Oi l I nl et Tube t o Oi l Pump Bo l t 8- 12 7 1- 106
Oi l Pa n Dr a i n Pl ug 11- 16 8- 12
Oi l Pa n To Cy l i n d e r Bl o c k - Bo l t 2 5- 35 18- 26
( L b - Ft )
Oi l P r e s s u r e S e n d e r / S e n s o r 16- 2 4 12 - 18
Oi l Pump t o Cy l i n d e r Bl o c k - Bo l t 8- 12 7 1- 106
( L b- l n )
Oi l I nl et Tube t o Ma i n Be a r i n g Ca p -
Nut
2 0- 30 15- 22
Wa t e r Pump To Pul l e y - Bo l t 2 0- 30 15- 22
S p a r k Pl ug t o Cy l i n d e r He a d 9- 2 0 7 - 15
G e n e r a t o r t o Cy l i n d e r Bl o c k 2 0- 30 15- 22
Va l v e Co v e r Bo l t / St u d Bo l t 8- 12 7 1- 106
Wa t e r Out l e t Co n n e c t i o n Bo l t 2 0- 30 15- 22
Wa t e r Pump t o Cy l i n d e r Bl o c k Bo l t 2 0- 30 15-22
H 0 2 S 37 - 45 2 7 - 33
EGR Tube Co n n e c t o r 45- 65 33- 48
EGR Va l v e t o E x h a u s t Ma n i f o l d
T u b e - T o - Co n n e c t o r
35- 45 2 6- 33
E x h a u s t Ma n i f o l d - t o - Du a l
Co n v e r t e r a n d P i pe Nut s
2 7 - 41 2 0- 30
Fr o n t En gi n e Su p p o r t I n s ul a t o r s 2 0- 30 15-22
Fr o n t En gi n e Su p p o r t I n sul a t o r
T h r o u g h Bo l t s
2 0- 30 15-22
P o we r St e e r i n g Pump t o En gi n e 2 0- 30 15-22
I gn i t i o n Wi r e Se p a r a t o r - T o - Co i l
Br a c k e t s
8- 12 7 1- 106
( L b- l n )
Oi l L e v e l I n d i c a t o r Tube t o Bl o c k 8- 12 7 1- 106
( L b- l n )
Fue l I n j e c t i o n Su p p l y Ma n i f o l d
8- 12 7 1- 106
( L b- l n )
Cr a n ks h a f t Re a r Oi l Se a l Re t a i n e r
Bo l t s
8- 12 7 1- 106
( L b- l n )
He a t e r Wa t e r Ho s e Re t a i n i n g Bo l t s
a n d St u d Bo l t
2 0- 30 15- 22
Ca ms h a f t Be a r i n g Ca p t o Cy l i n d e r
He a d
8- 12 7 1- 106
( L b- l n )
Re a r En gi n e Su p p o r t I n sul a t o r t o
T r a n s mi s s i o n Re t a i n i n g b o l t s
40- 60 30- 44
To r q ue Co n v e r t e r Re t a i n i n g Nut s 30- 35 2 2 - 2 5
E n gi n e - To - Tr a n s mi s s i o n Br a c e s 2 5- 43 18- 31
Tr a n s mi s s i o n Li n e Br a c ke t 2 0- 30 15- 22
Ti mi n g Ch a i n Te n s i o n e r b o l t s 2 0- 30 15- 22
Ti mi n g Ch a i n Gui d e Bo l t s 8- 12 7 1- 106
( L b- l n )
A / C Co mp r e s s o r Re t a i n i n g b o l t s 2 0- 30 15-22
CKP a n d CMP Se n s o r Re t a i n i n g
Bo l t s
8- 12 7 1- 106
( L b- l n )
I AC Va l v e Bo l t s 8- 12 7 1- 106
( L b- l n )
Wa t e r T e mp e r a t u r e I n d i c a t o r
Se n d i n g Uni t
16- 24 12-17
3- 01 - 96 E n gi n e , 4. 6L ( 2 V) 03- 01 - 96
TORQUE SPECIFICATIONS (Cont' d)
Descr i pti on L b - l n
Thr ot t l e Body and Adapt er Bol t s 8- 12 7 1- 106
( L b- l n )
Ca b l e Br ac k et Ret ai ni ng bol t 8- 12 7 1- 106
( L b- l n )
(1) Ti ghten in 2 St eps: Fi rst st ep 5 N-m (44 Lb-ln)
Second st ep 9-11 N-m (80-97 Lb-l n).
(2) Ti ghten in 2 st eps: Fi rst st ep 10N.m (7 Lb-Ft )
Second st ep 19-23 N-m (14-17 Lb-Ft ).
(3) Ti ghten in 2 st eps: Fi rst st ep 40-45 N-m (29-34
Lb-Ft ) Second st ep Rot at e 85-95 degrees.
(4) Ti ghten in 3 st eps: Fi rst st ep 30-40N-m (22-30
Lb-Ft ) Second st ep Rot at e 85-95 degrees.
(5) Af t er assembl y, ret i ght en wi t h engine hot .
(6) Ti ghten in 2 st eps: Fi rst st ep 30-35 N-m (22-25
Lb-Ft ), Second st ep Rot at e 85-95 degrees.
(7) 1 / 2 turn af t er gasket cont act s seal i ng surf ace.
(8) Measure 42 mm f rom dome of pi st on, 90 degrees t o
t he pi n. Pi ston di amet er i ncl udes 0.02-0.03 mm of
coat i ng. Pi st on-t o-bore fi t measurement s must be done
by measuri ng bore and mat chi ng correspondi ng bore
col or wi t h t he same pi st on col or.
T58P - 6316- D
T58P-6316-D
T 7 4P - 6316- B
T74P-6316-B
T 7 4P - 67 00- A
Fr o n t Co v e r Se a l Re mo v e r
T74P-6700-A
T 80T - 4000- W
Dr i ve r Ha n d i e
TS0T-4WW-W
T 81P - 1962 3- G 1
Spr i n g L o c k Co u p l i n g
Di s c o n n e c t To o l ( 3/ 8 i n c h)
T81P-19623-G1
SPECIAL SERVICE TOOLS REQUIRED (Cont ' d)
Tool Numbe r /
Descr i pt i on I l l ust r at i on
T 81P - 1962 3- G 2
Sp r i n g L o c k Co upl i n g
Di s c o n n e c t To o l ( 1 / 2 i n c h)
T81P-19623-G2
T 82 L - 67 01- A
T82L-6701-A
T 88T - 67 01- A
Cr a n ks h a f t Se a l
R e p l a c e r / C o v e r Al i gn e r
T88T-6701-A
T 91P - 62 56- A
C a m P o s i t i o n i n g To o l
T91P-6256-A
T 91P - 6565- A
T91P-6565-A
T 91P - 6565- A H
T91P-6565-AH
T 91P - 657 1- A
Va l v e St e m Se a l Re p l a c e r
T91P-6571-A
T 91P - 67 01- A
Re a r Cr a n k Se a l Re p l a c e r
A d a p t e r s
T91P-6701-A
T 92 P - 62 56- A
^^^^S^ T92P-625 6-A
T 93P - 6303- A
Cr a n ks h a f t Ho l d i n g To o l
TWP- S303- A
Tool Number Descr i pt i on
D81L - 6135- A P i s t o n Pi n To o l
03- 01- 97 E n gi n e , 4. 6L ( 2 V) 0 3 - 0 1 - 9 7
(Conti nued)
ROTUNDA EQUIPMENT
014- 002 82 Di a l I n d i c a t o r wi t h Br a c ke t r y
014- 002 90 P i s t o n Ri n g Co mp r e s s o r
014- 002 92 Cy l i n d e r Ri d ge Re a me r
ROTUNDA EQUIPMENT (Cont ' d)
014- 00334 En gi n e Li f t Br a c k e t Se t
07 7 - 00042 Se r v i c e J a c k
07 7 - 00043 Fl o o r Cr a n e
03- 03- 1 E n gi n e Co o l i n g 03- 03- 1
SECTION 03-03 Engine Cooling
SUBJECT PAGE
VEHICLE APPLICATION ......03-03-1
Cool ant Recovery System 03- 03- 4
Cool i ng Fan and Fan Cl ut ch 03- 03- 4
Cool i ng Fan, El ectri c 03- 03- 4
Cool i ng System 03-03-1
El ect ri cal Syst em 03-03-4
Engi ne Bl ock Heater 03-03-5
Radi at or 03-03-4
Ther most at , Water 03-03-5
Component Test s ...03-03-10
Fan Cl ut ch Test 03-03-12
Maxi mum Speed Fan Cl ut ch Requi rement
Test ...03-03-13
Mi ni mum Speed Fan Cl ut ch Requi rement
Te st Co l d ...03-03-12
Pressure Reli ef Cap Pressure Test . 03-03-11
Pressure Test 03-03-10
Radi at or Leak Test , Removed From
Vehi cl e ...03-03-12
Ther most at , Water ...03-03-12
Cabl e, El e c t r i c En gi n e Bl ock Heat er ...03-03-17
Cool i ng Fan Bl ade and Fan Cl ut ch,
Mechani cal 03-03-16
Cool i ng Fan Mot or, Fan Bl ade and Fan Shroud
Assembl y, El ect ri cal . ...03-03-17
SUBJECT PAGE
Engi ne Bl ock Heater .03-03-18
Engi ne Cool ant Temperat ure Sensor 03-03-17
Fan Shroud 03-03-17
Fi t t i ngs 03-03-15
Radi at or 03-03-15
Radi at or Cool ant Recovery Reservoi r 03-03-15
Radi at or Drai ncock . 03-03-17
Radi at or Hoses 03-03-14
Ther most at , Water .03-03-13
Wat er Pump 03-03-14
Wat er Temperat ure I ndi cat or Sender
Uni t .03-03-17
SERVICE PROCEDURES
Radi at or Core 03-03-19
Transmi ssi on Oil Cool er Connect i on
Leaks 03-03-19
Cool ant Condi t i on Check 03-03-20
Cool i ng Syst em Hoses and Cl amps 03-03-20
Cool i ng Syst em, Cl eani ng 03-03-21
Cool i ng Syst em, Drai ni ng, Fi l l i ng and
Bl eedi ng ...03-03-20
Fan Blade 03-03-22
Pressure Relief Cap ....03-03-21
Radi at or 03-03-22
Radi at or Cool ant Level Check 03-03-19
SPECIFICATIONS
Cool ant Mi xt ure 03-03-22
WEHiCLE APPLICATION
Town Car, Cr own Vi ct ori a, Grand Marqui s
C o o l i n g S y s t e m
"Wal t er C. Avr ea, t he owner of patents 3, 6 0 1 , 181
and RE 27, 965, has grant ed Ford Mot or Company
ri ghts wi t h respect t o cool i ng syst ems covered by
t hese pat ent s. "
03- 03- 2 E n gi n e Co o l i n g 03- 03- 2
WARNI NG: NEVER REMOVE THE PRESSURE
RELI EF CAP UNDER ANY CONDI TI ONS WHI LE
THE ENGI NE I S OPERATI NG. FAI LURE TO
FOLLOW THESE I NSTRUCTI ONS COUL D RESULT
IN DAMAGE TO THE COOLI NG SYSTEM OR
ENGI NE A N D/ OR PERSONAL I NJURY. TO AVOI D
HAVI NG SCALDI NG HOT COOL ANT OR ST E A M
BLOW OUT OF THE COOLI NG SYSTE M, USE
EXTREME CARE WHEN REMOVI NG THE
PRESSURE RELI EF CAP FROM A HOT RADI ATOR
COOLANT RECOVERY RESERVOI R ( 8A 080) .
WAI T UNTI L THE ENGI NE HAS COOLED, THEN
WRAP A THI CK CL OTH AROUND THE PRESSURE
RELI EF CAP AND TURN I T SLOWLY ONE TURN
( COUNTERCLOCKWI SE) . STEP BA CK WHI LE THE
PRESSURE I S RELEASED FROM THE COOLI NG
SYSTEM. WHE N CERTAI N A L L THE PRESSURE
HAS BEEN RELEASED, REMOVE PRESSURE
RELI EF CAP ( STI LL WI TH A CLOTH) .
WARNI NG: TO AVOI D THE POSSI BI LI TY OF
VEHI CLE, DO NOT OPERATE THE ENGI NE WI TH
THE HOOD ( 16612 ) OPEN UNTI L THE FAN BLADE
( 8600) HAS BEEN EXAMI NED FI RST FOR
This secti on covers cool i ng syst em di agnosi s and
servi ce, cool i ng syst em component removal ,
di sassembl y, assembl y, installation, servi ce
procedures and speci fi cati ons.
The cool ant syst em oper at es in t he fol l owi ng manner:
Cool ant f l ows through t he radi ator t ubes and is
cool ed by air passi ng over the cool i ng fins assi st ed
by the mechani cal cool i ng fan bl ade, and auxi l i ary
el ectri c cool i ng fan motor and fan bl ade.
Cool ant is then ci rcul ated f rom t he radi at or outlet
t ank through t he wat er inlet (in t he oil filter adapt er
(6881)) t o the wat er pump ( 8501) and into t he
cyl i nder bl ock ( 6010) and cylinder heads ( 6049) .
The cool ant t hen returns t o the radi at or ( 8005)
through the radi ator inlet tank t o compl et e t he
ci rcui t.
03-03-3
E n gi n e Co o l i n g 03-03-3
En gi n e Co o l i n g Sy st e m
Q3009-F
Pa r t
Stem Nu mb e r De s c r i p t i o n
1 8005 Radiator
2 N807283-S56 Clip (4 Req'd)
3 8260 Upper Radiator Hose
4 8075 Radiator Overflow Hose
5 8A080 Radiator Coolant Recovery
Reservoir
6 8100 Pressure Relief Cap
7 N621907-S2 Nut (3 Req'd)
8 8146 Fan Shroud
9 N606676-S56 Screw (2 Req'd)
10 8286 Lower Radiator Hose
11 8592 Water Hose Connection
12 8K651
8146
8600
Cooling Fan Mot or/Fan
Blade and Fan Shroud
Pa r t
13 N807283-S56 Clip (3 Req'd)
14 N606676-S56 Screw (2 Req'd)
15 19712 A/ C Condenser Core
16 N606676-S56 Screw (2 Req'd)
A

Tighten to 5.5-7.0 N-m (4-5
Lb-Ft)
B

Tighten to 2.7-5.4 Nm (24-48
Lb-ln)
C

Lb-ln)
D

Lb-ln)
03- 03- 4 E n gi n e Co o l i n g 03- 03- 4
E l e c t r i c a l S y s t e m
NOTE: Wi t h A / CON, the auxi l i ary cool i ng fan mot or
will run continuously. Auxi l i ary cooling fan motor will
not cycl e ON and OFF wi t h A / C cl utch ( 2884) .
NOTE: An except i on t o thi s is when vehicle speed is
over 72 k m/ h ( 45 mph) and cool ant t emperat ure is
bel ow 104C ( 220F) . The auxiliary cooling fan motor
will then automati cal l y shut off.
The auxi l i ary cool i ng fan motor is mounted wi thi n a fan
shroud ( 8146) behind t he radi ator ( 8005) . The
powert rai n control modul e ( PCM) ( 12A650) act uat es
t he auxi l i ary cooling fan motor when:
The cool ant reaches a speci fi ed t emperat ure.
When t he engine reaches a speci fi ed speed.
When t he A / C cl ut ch is act i vat ed (if so equi pped).
Coolant Recovery Syst em
NOTE: When t he wat er t hermost at ( 8575) is cl osed
t here is no f l ow t hrough t he reservoi r syst em.
The cool ant recovery syst em operat es in t he fol l owi ng
manner:
Trapped air in the cool i ng syst em must be removed.
A pressuri zed reservoi r syst em is used whi ch
continuously separat es t he air from the cool i ng
syst em.
When t he wat er t hermost at is open, engine cool ant
f l ows through a small hose f rom the t op of t he
radi ator outlet t ank t o t he radi ator cool ant recovery
The radi ator cool ant recovery reservoi r separat es
any entrapped air f rom the cool ant and repl eni shes
t he syst em through its outlet t o the l ower radi ator
hose ( 8286) .
The radi ator cool ant recovery reservoi r serves as
t he l ocati on for servi ce fill, cool ant expansi on during
war m up, syst em pressuri zati on f rom the pressure
relief cap ( 8100) and air separati on during
operat i on.
The radi ator cool ant recovery reservoi r is desi gned
t o have approxi mat el y 0. 5 to 1 liter ( 0. 53- 1. 06 qt s)
of air when col d t o al l ow for cool ant expansi on.
The radi ator outlet tank on the RH si de of t he
radi ator contai ns a transmi ssi on oil cool er for
cool i ng t he transmi ssi on fluid.
The crossf l ow radi ator used is an aluminum core
wi t h nylon t anks.
The aluminum radi ator requi res speci al servi ce
procedures that are different f rom copper / br ass
radi at ors.
Cool i ng Fan and Fan Cl ut ch
The fan cl utch ( 8A616) permi ts use of a powerful
fan bl ade ( 8600) wi thout power l oss or noise.
It is a temperature-control l ed fluid coupling that
regul ates fan bl ade speed accordi ng t o t he
t emperat ure of the air comi ng through t he radi ator
cor e and fl owi ng around the bi-metal cont rol val ve
l ocat ed on the f orward f ace of the fan cl ut ch.
Pulley rati os and t est speeds are listed in
Speci fi cati ons.
BI-METAL SPRING
FAN CLUTCH
8A616
B1932-E
Radiator
Aluminum Core, Crossflow
NOTE: Whenever l eaks or damage to radi ator ( 8005)
are found, the entire radi ator must be repl aced as an
assembl y.
The radi ator is of t he tube and louvered-fin-core
t ype wi t h the t ubes arranged horizontally for
crossf l ow of t he engine cool ant.
Two t anks, one on each side of the radi ator, provi de
uniform distribution of t he cool ant t o the crossf l ow
t ubes.
Cool i ng Fan, Electri c
The cool i ng fan syst em functi ons as fol l ows:
The syst em consi sts of a fan blade ( 8600) and a
t wo-speed cooling fan motor l ocated behind the
radi ator ( 8005) .
The cooling fan motor is wi red t o operat e only when
the ignition swi t ch ( 11572) is in the RUN position
and prevents the cooling fan motor f r om operati ng
after t he ignition swi t ch is turned t o t he OFF
posi ti on.
03- 03- 5 E n gi n e Co o l i n g 03- 03- 5
DESCRIPTION AND OPERATION (Cont i nued) DIAGNOSIS AND TESTING
T h e r m o s t a t , Wa t e r
When t he cool ant is col d, the wat er t hermost at ( 8575)
is in the cl osed position and the engine cool ant fl ow is
rest ri ct ed t o the:
Cylinder block ( 6010) .
Intake manifold ( 9424) .
Cylinder heads ( 6049) .
As the engine cool ant t emperat ure i ncreases:
The wat er t hermost at opens allowing a porti on of
t he cool ant t o pass into t he radi ator ( 8005) .
Simultaneously, the bypass passage internal t o t he
i ntake manifold, cyl i nder head and cyl i nder bl ock is
cl osed off by the dual-acting wat er t hermost at .
E n g i n e B l o c k H e a t e r
The bl ock heater ( 6A051) consi sts of an el ectri cal
heati ng element installed in one of t he cor e plug
openi ngs in the cylinder bl ock ( 6010) and an el ectri cal
cabl e whi ch plugs into a st andard 110-volt AC
el ectri cal outl et. It is desi gned t o keep t he engine
cool ant war m during col d weat her t o ai d in col d
st art i ng.
E l e c t r i c a l S c h e m a t i c
Co o l i n g Fan Mo t o r T o wn Car
HOT AT ALL TIMES
POWER
DISTRIBUTION
BOX
TO
POWERTRAIN
CONTROL
MODULE (PCM)
See EVTM for
more details
of this circuit
I
M.
Q3732-A
03- 03- 6 Engi ne Cool i ng 03- 03- 6
i l l i M^
Co o l i n g Fan Mot or Cr o wn Vi c t o r i a , Gr a nd Marqui s
RELAY
CENTER
HOT AT ALL TIMES
. - p 0 W E R
COOLING. DISTRIBUTION
) FAN I BOX
1
"* """IPOWERTRAIN
; CONTROL
1
1 MODULE (PCM) i
8? j P OWE R RE L A Y *
See EVTM for
more details
of this circuit
TO
POWERTRAIN
CONTROL
MODULE (PCM)
1. Verify t he cust omer' s concern by operati ng t he
engine cool i ng syst em t o dupl i cate t he concern.
2. Inspect t o determi ne if one of t he fol l owi ng
Da ma g e d h o s e s . Da ma g e d c o o l i n g f a n mo t o r .
L o o s e / d a m a g e d h o s e Un p l u gge d c i r c ui t
c l a mp s . c o n n e c t o r s .
Da ma g e d w a t e r t h e r mo s t a t . Op e n f u s e s .
Da ma g e d c y l i n d e r h e a d
g a s k e t s .
Da ma g e d i n t a ke ma n i f o l d
g a s ke t .
Da ma g e d wa t e r pump.
Da ma g e d r a d i a t o r .
Da ma g e d r a d i a t o r c o o l a n t
r e c o v e r y r e s e r v o i r .
Da ma g e d h e a t e r c o r e .
If the concerns remain after t he i nspecti on,
determi ne t he sympt oms and go t o t he Sympt om
Chart.
03- 03- 7 E n gi n e Co o l i n g 03- 03- 7
Symptom Chart
COOLING SYSTEM
Loss of Coolant Damaged radiator.
Loose / damaged radi ator hoses.
Loose/damaged heater hoses.
Damaged heater core.
Damaged engine gasket s.
Damaged radiator coolant
recovery reservoir.
Damaged oil cooler (pol i ce/t rai l er
tow only).
Damaged oil cooler lines.
Engine Overheats Damaged water thermostat.
Damaged water pump.
Internal engine coolant leak.
Cooling fan inoperative.
Plugged radiator.
Plugged heater core.
Engine Does Not Reach Normal
Operating Temperature
Damaged water thermostat.
Cooling fan.
Low engine coolant.
Block Heater Does Not Operate
Properly
Block heater power cable.
Block heater.
GO t o Pinpoint Test D.
Cooling Fan Runs Continuously Circuit.
Powertrain control module.
Engine coolant temperature
sensor.
Control/Emi ssi on Diagnosis
Manual
1
.
Cooling Fan Does Not Run Circuit.
Cooling fan motor.
REFER t o the Powertrain
Control/Emi ssi on Diagnosis
Manual.
1
Pinpoint Tests
PINPOINT TEST A: LOSS OF COOLANT
A1 CHECK COOLANT LEVEL
Yes
No
GO t o A2.
REFILL as outlined. GO to
A7.
NOTE: If engine is hot, allow engine to cool down before
proceedi ng.
Check coolant level at radiator coolant recovery
reservoir.
Is cool ant l evel OK?
Yes
No
GO t o A2.
A7.
A2 CHECK FOR VISIBLE LEAKAGE
Yes
No
RETEST system.
GO t o A3.
Engine coolant has an added dye color t hat makes
t he coolant an excellent leak detector.
Check entire cooli ng system for visible leakage.
Is t her e vi si bl e l eakage?
Yes
No
RETEST system.
GO t o A3.
A3 CHECK PRESSURE RELIEF CAP
Yes
No
GO t o A4.
REPLACE damaged
pressure relief cap.
RETEST system.
Using Rotunda Radi at or/Heat er Core Pressure
Tester 021-00012 or equivalent, test pressure relief
cap as outlined in Component Testing.
Di d pressure rel i ef cap t e st OK?
Yes
No
GO t o A4.
REPLACE damaged
RETEST system.
03- 03- 8 En gi n e Co o l i n g 03- 03- 8
PINPOINT TEST A: LOSS OF COOLANT (Cont i nued)
A4 CHECK COOLANT FOR INTERNAL LEAKAGE
Yes
No
If engine oil is evident, GO
to Secti on 03-00. If
transmission oil is
evident, SERVICE as
outlined in Section 07-01.
GO to AS.
Inspect coolant in radiator coolant recovery
reservoir for signs of transmission or engine oi l.
Is oi l evi dent i n c ool a nt ?
Yes
No
If engine oil is evident, GO
to Secti on 03-00. If
transmission oil is
evident, SERVICE as
GO to AS.
A5 CHECK ENGINE AND TRANSMISSION FOR COOLANT
Yes
No
If coolant is in engine, GO
t o Section 03-00. If
coolant is in
transmission, SERVICE
as outlined in Secti on
07-01.
GO to A6.
Remove oil level di pst i cks from engine and
transmi ssi on.
Carefully inspect oil level di pst i ck for evidence of
coolant.
Is cool ant evi dent ?
Yes
No
If coolant is in engine, GO
t o Section 03-00. If
coolant is in
transmission, SERVICE
as outlined in Secti on
07-01.
GO to A6.
A6 PRESSURE TEST COOLING SYSTEM
Yes
No
RETEST syst em.
Cooling system is
operational at t hi s ti me.
RETEST system.
Using Rotunda Radi at or/Heat er Core Pressure
Tester 021 -00012 or equivalent, pressurize cooli ng
system as outlined in Service Procedures.
Check for any signs of visible leakage.
NOTE: Check inside vehicle for possi ble heater
core leakage.
Is t her e l eakage?
Yes
No
RETEST syst em.
Cooling system is
operational at t hi s ti me.
RETEST system.
A7 CHECK COOLANT RECOVERY
Yes
No
GO to AS.
REFER to Cleaning and
Inspection. SERVICE as
outlined.
Allow engine t o cool . Remove pressure relief cap
and inspect cap for foreign material between
sealing gasket and di aphragm.
Is cap OK?
Yes
No
GO to AS.
REFER to Cleaning and
Inspection. SERVICE as
outlined.
A8 CHECK RADIATOR OVERFLOW HOSE
Yes
No
GO to A9.
SERVICE radiator
overflow hose as
required. RESTORE
vehicle.
Remove radiator overflow hose.
Inspect hose for obstructi on, cracks or cuts.
Is hose c ondi t i on OK?
Yes
No
GO to A9.
SERVICE radiator
overflow hose as
required. RESTORE
vehicle.
A9 CHECK RESERVOIR
Yes
No
REPLACE radiator
coolant recovery
reservoir. RESTORE
vehicle.
REFER to Pressure Test,
Component Tests.
Replenish coolant in radiator coolant recovery
reservoir to FULL COLD level as outlined.
Inspect radi ator coolant recovery reservoir for
leaks.
Is t her e l eakage at radi at or c ool a nt recovery
reservoi r?
Yes
No
REPLACE radiator
coolant recovery
reservoir. RESTORE
vehicle.
REFER to Pressure Test,
Component Tests.
PINPOINT TEST B: ENGINE OVERHEATS
B1 CHECK ENGINE COOLANT LEVEL
Yes
No
GO to B2.
Pinpoint Test A.
NOTE: If engine is hot, allow engine t o cool down before
proceedi ng.
Remove pressure relief cap and check engine
coolant level at radiator coolant recovery reservoir.
Is engi ne c ool a nt l evel OK?
Yes
No
GO to B2.
Pinpoint Test A.
B2 CHECK COOLANT CONDITION
Yes
No
GO to B3.
FLUSH system as
outlined. RETEST
system.
Check coolant for contaminants such as rust or
corrosi on. Also check for color di scolorati on.
Is cool ant c o n d i t i o n OK?
Yes
No
GO to B3.
FLUSH system as
outlined. RETEST
system.
03- 03- 9 E n gi n e Co o l i n g 03- 03- 9
PINPOINT TEST B: ENGINE OVERHEATS (Cont i nued)
B3 CHECK FOR AIR FLOW OBSTRUCTION
Yes >
No
REMOVE obstruction and
CLEAN A/ C condenser
core and radiator as
outlined. RETEST
system.
GO to B4.
Inspect A/ C condenser core and radiator for
obstructi ons such as leaves or bugs.
Is t her e any obst r uc t i on?
Yes >
No
REMOVE obstruction and
CLEAN A/ C condenser
core and radiator as
outlined. RETEST
system.
GO to B4.
B4 CHECK HEATER CORE OPERATION
Yes
No
GO to B5.
TURN engine OFF. Before
it overheats. SERVICE
heater core as outlined in
Section 12-03A. RETEST
system.
Install pressure relief cap.
Start engine and allow to run.
As engine starts to warm up, feel the inlet and outlet
heater water hoses. They should feel the same after
t hree or four minutes.
Is out l et heat er wat er hose t he same t emper at ur e
as t he i nl et heat er wat er hose?
Yes
No
GO to B5.
TURN engine OFF. Before
it overheats. SERVICE
heater core as outlined in
Section 12-03A. RETEST
system.
B5 CHECK WATER THERMOSTAT OPERATION
Yes
No >
REPLACE water
thermostat as outlined.
RETEST system.
LEAVE engine RUNNING.
GO t o B6.
Allow engine to run for 10 minutes.
Feel the inlet and outlet heater water hoses and the
underside of the upper radiator hose.
Are t he upper radi at or hose and heat er wat er
hoses col d?
Yes
No >
REPLACE water
RETEST system.
LEAVE engine RUNNING.
GO t o B6.
B6 CHECK COOLING FAN CLUTCH
Yes
No
GO t o Section 03-00 for
Engine Service
Procedure.
REPLACE fan clutch as
outlined in thi s Secti on.
RETEST system.
Check for proper cooli ng fan clutch operation as
outlined under Component Tests.
Di d c ool i ng f an c l ut c h oper at e OK?
Yes
No
GO t o Section 03-00 for
Engine Service
Procedure.
REPLACE fan clutch as
outlined in thi s Secti on.
RETEST system.
PINPOINT TEST C: ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE
C1 CHECK ENGINE TEMPERATURE
Yes
No
REPLACE water
RETEST system.
GO to Section 13-01A
(Electronic Instrument
Cluster) or 13-01B
(Conventional Instrument
Cluster) for proper
temperature gauge
diagnosis.
Start engine and allow to run for 15 minutes.
Feel inlet and outlet heater water hoses and
underside of upper radi ator hose.
Are upper radi at or hose and heat er wat er hoses
c ol d?
Yes
No
REPLACE water
RETEST system.
GO to Section 13-01A
(Electronic Instrument
Cluster) or 13-01B
(Conventional Instrument
Cluster) for proper
temperature gauge
diagnosis.
03- 03- 10 Engi ne Cool i ng 03- 03- 1
IB8ESM
PINPOINT TEST D: ENGINE BLOCK HEATER DOES NOT OPERATE PROPERLY
D1 C H E C K P O W E R C A B L E
C h e c k c o n t i n u i t y o f C i r c u i t s 1, 2 a n d 3 i n p o w e r
c a b l e u s i n g R o t u n d a 7 3 Di g i t a l Mu l t i m e t e r
1 0 5 - 0 0 0 5 1 o r e q u i v a l e n t .
Is there continuity in Ci rcui ts 1, 2 and 3?
Y e s
No

R E P L A C E b l o c k h e a t e r .
R E T E S T s y s t e m .
R E P L A C E p o w e r c a b l e .
R E T E S T s y s t e m .
POWER CABLE CONNECTORS
L8998-B
Pr es s ur e Tes t
1. Turn the engine off.
2. WARNI NG: NEVER REMOVE THE PRESSURE
THE ENGINE I S OPERATI NG. FAI LURE TO
FOL L OW THESE I NSTRUCTI ONS COULD
RESULT IN DAMAGE TO THE COOLI NG
SYSTEM OR ENGI NE A N D/ OR PERSONAL
I NJURY. TO AVOI D HAVI NG SCALDI NG HOT
COOLANT OR STEAM BLOW OUT OF THE
COOLI NG SYSTE M, USE EXTREME CARE
WHEN REMOVI NG THE PRESSURE RELI EF
CAP FROM A HOT RADI ATOR COOLANT
RECOVERY RESERVOI R ( 8A 080) . WAI T
UNTI L THE ENGI NE HAS COOLED, THEN
WRAP A THI CK CL OTH AROUND THE
PRESSURE RELIEF CAP AND TURN IT
SLOWLY ONE TURN
( COUNTERCLOCKWI SE) . STEP BA CK WHI LE
THE PRESSURE I S RELEASED FROM THE
COOLI NG SYSTE M. WHEN CERTAI N A L L THE
PRESSURE HAS BEEN RELEASED, REMOVE
PRESSURE RELI EF CAP ( STI LL WI TH A
CLOTH) .
Check engine cool ant level as outlined.
3. Di sconnect t he el ectri cal connect or f rom t he
wat er t emperat ure i ndi cator sender unit ( 10884) .
Remove t he wat er t emperat ure indicator sender
unit f rom the engine.
Wi t h the pressure relief cap installed and t he
cool i ng syst em pressure rel i eved, only a small
amount of cool ant will be l ost when t he wat er
t emperat ure i ndi cator sender unit is removed.
4. Install t he adapt er fitting f rom Rotunda |
Radi ator / Heater Core Pressure Tester
021- 00012 or equivalent (male t hread on one end
and a hose connector on the other end t o
accommodat e the t est er hose) ti ghtl y into t he
i ntake manifold ( 9424) in pl ace of t he wat er
temperature indicator sender unit.
5. Di sconnect t he radi ator overfl ow hose ( 8075)
f rom the radi ator cool ant recovery reservoi r.
Install a separat e hose, maki ng sure hose is fi rml y
installed on the reservoi r overfl ow nipple. Al so
make sure it is in good condi ti on. Insert the free
end of the hose into a container of water.
6. If the pressure relief cap does not hold pressure,
remove and wash the pressure relief cap in cl ean
wat er t o di sl odge all foreign parti cl es f rom t he
gasket s. Check t he sealing surface in t he
radi ator cool ant recovery reservoi r filler neck.
Then i nspect the cam l ock fl anges on both si des
of the filler neck for maxi mum pressure relief cap
engagement.
03-03-11 Engi ne Cool i ng 03-03-11
7. CAUTI ON: If t he pr essur e dr ops , c hec k f or
l e a ks a t t h e e n gi n e t o h e a t e r c o r e h o s e s ,
e n gi n e - t o - r a d i a t o r hoses, wat er val ve hose
(i f appl i cabl e) , wat er hose connect i on gas k et
( 8255) , r adi at or ( 8005) and h e a t e r c o r e
( 18476) , et c. A l s o r e f e r t o Se c t i o n 03- 00,
Ser vi ce Pr ocedur es i f a l eak cannot be
l ocat ed i n cool i ng s y s t em. Any l eaks w h i c h
ar e f ound must be c or r ec t ed and s y s t em
r ec hec k ed.
Pressurize the engine cool i ng syst em as outlined
in St ep 6 (using a pressure relief cap that
operat es within the speci fi ed upper and l ower
pressure limits). Observe the gauge reading for
approxi mat el y t wo minutes. Refer t o
Speci fi cati ons. Pressure shoul d not drop during
thi s ti me.
If t he syst em hol ds pressure, proceed t o St ep 8.
8. Rel ease syst em pressure by loosening the
pressure relief cap and remove the adapter.
Install t he wat er t emperat ure indicator sender
unit, check cool ant level and repl eni sh, if
necessary, wi t h t he correct engine cool ant
mi xture.
P r e s s u r e Re l i e f C a p P r e s s u r e T e s t
1. Remove pressure relief cap f rom t he radi ator
cool ant recovery reservoi r filler neck fol l owi ng
outlined precauti ons.
2. NOTE: The adapt er is desi gned t o accept bot h
deep and shal l ow neck pressure relief caps.
Use wat er t o cl ean the pressure relief cap in t he
area of the rubber seal and t he vacuum relief
val ve. Refer t o Cleaning and Inspection for
procedure. Immerse t he pressure relief cap in
wat er and install on the shal l ow filler neck of t he
Rotunda Radi at or / Heat er Core Pressure Tester
021- 00012 and Rotunda Radi ator Cap Adapt er
for Mark VI I I 021- 00066 or equivalent.
3. NOTE: The filler neck seal is reversi bl e so that it
may be used on either a deep or shal l ow filler
neck. It will al so fit ei ther end of the radi ator cap
pressure t est adapter.
Immerse t he filler neck seal in wat er and install in
t he filler neck adapter.
4. Install t he filler neck adapt er wi t h filler neck seal
on t he deep filler neck end t o t he radi ator cap
pressure t est adapter.
5. Connect t he femal e qui ck-connect fitting of t he
pressure t est pump t o t he male qui ck-connect
fitting of the filler neck adapter.
6. NOTE: If the plunger of t he pump is depressed
t oo f ast , an erroneous pressure readi ng will
result.
Sl owl y depress the plunger of t he pressure t est
pump until the pressure gauge readi ng st ops
i ncreasi ng and note t he hi ghest pressure readi ng
obt ai ned.
7. Rel ease t he pressure by turning the pressure
relief scr ew count ercl ockwi se. Then ti ghten t he
pressure relief screw and repeat Step 6 (at least
t wi ce) t o ensure the pressure t est readi ng is
repeat abl e within the accept abl e gauge readi ng
limits of t he pressure relief cap. Al so make sure it
is not errati c. Refer t o Speci fi cati ons.
8. If the pressure t est gauge readi ngs are not within
t he accept abl e gauge reading limits, repl ace the
pressure relief cap. If t he pressure test gauge
readi ngs are within t he accept abl e gauge readi ng
limits, perform the Cooling Syst em Pressure Test.
Ro t un d a Ra d i a t o r / He a t e r Co r e Pr essur e Te st e r
02 1- 00012
Pa r t
1 8100 Pressure Relief Cap
2 021-00066 Radiator Cap Adapter for
Mark VIII
3

Filler Neck Seal (Part of
021-00012)
4

Filler Neck Adapter (Part of
021-00012)
5

Quick Disconnect Fittings
(Part of 021-00012)
6

Pump and Gauge Assy (Part
of 021-00012)
7

Pressure Relief Screw (Part
of 021-00012)
03- 03- 12 Engi ne Cool i ng 03- 03- 12
WARNI NG: NEVER REMOVE THE PRESSURE
THE ENGINE IS OPERATI NG. FAILURE TO
FOL L OW THESE I NSTRUCTI ONS COULD RESULT
I N DAMAGE TO THE COOLI NG SYSTE M OR
ENGI NE A N D/ OR PERSONAL INJURY. TO AVOI D
HAVI NG SCALDI NG HOT COOLANT OR STE AM
BL OW OUT OF THE COOLI NG SYSTE M, USE
EXTREME CARE WHEN REMOVI NG THE
PRESSURE RELIEF CAP FROM A HOT RADI ATOR
COOL ANT RECOVERY RESERVOI R. WAI T UNTI L
THE ENGI NE HAS COOLED, THEN WRAP A THI CK
CL OTH AROUND THE PRESSURE RELI EF CAP
AND TURN I T SLOWLY ONE TURN
( COUNTERCLOCKWI SE) . STEP BACK WHI LE THE
PRESSURE IS RELEASED FROM THE COOLI NG
SYSTEM. WHE N CERTAI N ALL PRESSURE HAS
BEEN RELEASED, REMOVE PRESSURE RELI EF
CAP ( STI LL WI TH A CL OTH) .
When investigating a concern of overheati ng or an
insufficient heat er / def r ost er performance, perform
t he fol l owi ng.
1. Check and servi ce any l eaks in t he:
Pressure relief cap.
Heater wat er hoses ( 18472) .
Radi ator hoses.
Water hose connecti on ( 8592) .
Head gasket ( 6051) .
Water pump housing gasket ( 8507) .
2. Check the col d engine cool ant level in t he radi ator
cool ant recovery reservoi r.
a. If t he level is bel ow the col d fill l evel , fill t o t he
col d fill level wi t h a 5 0 / 5 0 mi xture of Ford
b.
Ra d i a t o r L e a k T e s t , R e m o v e d F r o m Ve h i c l e
Clean t he radi ator before l eak-testi ng t o prevent
contami nati ng t he t est tank. Leak-test t he radi ator in
cl ean wat er wi th 138 kPa ( 20 psi) air pressure. Do not
l eak-test an aluminum radi ator in t he same wat er t hat
copper / br ass radi at ors are t est ed in. Flux and caust i c
cl eaners may be present in the cleaning tank and t hey
will damage aluminum radi ators. If condi ti ons do not
al l ow a separat e tank for aluminum radi ator
l eak-testi ng, thoroughl y clean the t est tank each ti me
before testi ng an aluminum radi ator in t he tank.
Al ways install plugs in the oil cool er fi tti ngs bef ore
l eak-testi ng or cleaning any radi ator.
Fa n C l u t c h T e s t
Spin the f an bl ade ( 8600) . A light resi stance shoul d be
felt. If t here is no resi stance or very high resi st ance,
the minimum and maxi mum fan speeds must be
checked as fol l ows.
Premium Cooling Syst em Fluid
E2FZ- 19549- AA or -B (in Canada, Mot orcraf t
CXC-8-B) or equivalent meeting Ford
speci fi cati on ESE-M97B44-A and wat er.
If t he engine cool ant drops bel ow t he col d fill
l evel , add cool ant t o bri ng level back t o t he
col d fill level. Repeat t he above procedure
until all t he air is purged f rom t he engine
cool i ng syst em.
When thi s procedure has been compl et ed,
feel t he heater inlet and outlet hoses and the
undersi de of t he upper radi ator hose ( 8260) .
The wat er t hermost at ( 8575) shoul d be
removed only if t hese hoses are col d after 10
minutes of operati on.
Mi n i mu m S p e e d Fa n Cl u t c h Re q u i r e me n t
T e s t C o l d
1. Using a suitable marker, mark t he wat er pump
pulley ( 8509) , one of t he fan bl ade retaining bol ts
and t he crankshaf t pulley ( 6312) .
2. Connect a tachometer t o t he engine.
3. Install a throttl e adjusting t ool .
4. Connect a Sun Strobe Light or equivalent. Thi s
can be an SLT-1 or SLT-2 St robot ach or an STA-1
St robe Trigger adapter for t he Sun Di stri butor
Test St and. A Rotunda Digital Photoel ectri c
Tachometer 055- 00108 or equivalent may al so
be used for thi s t est .
5. WARNI NG: TO AVOI D THE POSSI BI LI TY OF
VEHI CLE, DO NOT OPERATE THE ENGI NE
UNTI L THE FAN BLADE HAS BEEN FI RST
EXAMI NED FOR POSSI BLE CRACKS AND
SEPARATI ON.
Start t he engine and run it at approxi matel y 1500
rpm until engine temperature has normalized.
6. Adjust the engine t o the speci fi ed engine testi ng
speed.
03- 03- 13 Engi ne Cool i ng 03- 03- 13
7. Operat e the st robe light at 3000 rpm and aim it at
t he wat er pump pulley. Adj ust t he engine speed
until t he light fl ashes and t he wat er pump pulley
marks are synchroni zed.
8. Ai m t he timing light at the fan bl ade retaining
bol ts. Adj ust t he st robe light until it is
synchroni zed wi t h the marked fan bl ade retaining
bolt (fan bl ade appears t o st and still).
9. The fan bl ade speed must not be greater than the
speci fi ed fan bl ade t est speed at 3000 wat er
pump rpm.
10. Turn t he engine off.
11. If the fan bl ade speed was great er than the
speci fi ed fan bl ade t est speed, repl ace the fan
cl utch ( 8A616) .
If the part s are not t he correct ones, repl ace t he
part s and perform t he t est agai n.
12. If t he maxi mum speed fan cl utch requirement t est
is goi ng t o be perf ormed, do not remove the
t achomet er, st robe light or throttl e adjusting t ool .
13. If a Maxi mum Speed Fan Cl utch Requirement Test
is not goi ng t o be perf ormed, remove t he
t achomet er, st robe light and throttl e adjusting
t ool .
Ma x i mu m S p e e d Fa n Cl u t c h Re q u i r e me n t Te s t
1. If the Minimum Speed Fan Cl utch Requirement
Test was not perf ormed, fol l ow St eps 1 through 5
under Minimum Speed Fan Dri ve Requirement
Test.
2. NOTE: The t emperat ure shoul d be above 82 C
( 180F) for maxi mum fan speed.
Bl ock off areas on each si de of t he radi ator in t he
engine compart ment and t he front of t he radi ator
grille ( 8200) . Thi s will rai se the temperature of
t he air stri ki ng the fan cl utch and shoul d cause
t he fan bl ade t o operat e at maxi mum speed.
3. Pl ace t he air conditioning sel ector in t he
MAXI MUM position and t he bl ower swi t ch in the
HIGH posi ti on.
4. Adj ust t he st robe light t o 3000 rpm.
PERSONAL INJURY OR DAMAGE TO THE
WI TH THE HOOD ( 16612 ) OPEN UNTI L THE
FAN BLADE HAS BEEN FI RST EXAMI NED FOR
St art the engine and adj ust it until the wat er pump
pulley is synchroni zed wi t h t he st robe light. Thi s
will be near the engine testi ng speed given in
Speci fi cati ons.
6. Synchroni ze the timing light wi th t he fan
blade-to-fan cl utch retaining bolt.
7. The fan bl ade speed must meet or exceed t he
speci fi ed maxi mum fan bl ade t est speed at 3000
wat er pump rpm.
8. If t he fan bl ade speed was less than the speci fi ed
fan bl ade t est speed, repl ace the fan cl utch.
Re mo v a l
RELIEF CAP UNDER ANY CONDI TI ONS WHI LE
THE ENGINE IS OPERATING- FAILURE TO
FOLLOW THESE I NSTRUCTI ONS COULD
SYSTEM OR ENGINE AND/ OR PERSONAL
INJURY. TO AVOI D HAVI NG SCALDI NG HOT
COOLANT OR STEAM BLOW OUT OF THE
COOLI NG SYSTEM, USE EXTREME CARE
WHEN REMOVI NG THE PRESSURE RELIEF
CAP FROM A HOT RADIATOR COOLANT
RECOVERY RESERVOIR ( 8A080) . WAI T
UNTI L THE ENGINE HAS COOLED, THEN
WRAP A THI CK CLOTH AROUND THE
PRESSURE RELIEF CAP AND TURN IT
SLOWLY ONE TURN
( COUNTERCLOCKWI SE) . STEP BACK WHI LE
THE PRESSURE IS RELEASED FROM THE
COOLI NG SYSTEM. WHEN CERTAI N ALL THE
PRESSURE HAS BEEN RELEASED, REMOVE
PRESSURE RELIEF CAP (STI LL WI TH A
CLOTH) .
Partially drain t he engine cooling syst em so that
the engine cool ant level is bel ow the wat er
t hermost at ( 8575) .
2. Di sconnect the upper radi ator hose ( 8260) from
the wat er hose connecti on ( 8592) .
3. Remove the t wo wat er outlet connection retaining
bol ts.
4. Remove the wat er hose connecti on gasket
( 8255) and wat er t hermost at from the i ntake
manifold ( 9424) . Inspect wat er hose connecti on
gasket for damage and repl ace if necessary.
0 3 - 0 3 - 1 4
\mmmmMmtmmmmzf
E n gi n e Co o l i n g 03- 03- 14
1. Install t he wat er t hermost at , wat er hose
connecti on gasket and wat er hose connecti on as
shown.
WATER OUTLET
CONNECTION
8592
WATER OUTLET
CONNECTION
GASKET 8255
BYPASS
POPPET
DOWN
WATER
THERMOSTAT
8575
Q3007-D
2. Install and al ternatel y ti ghten the t wo retaining
bol ts. Tighten bol ts t o 20- 30 N-m (15-22 Ib-ft).
3. Connect t he upper radi ator hose t o t he wat er
hose connecti on.
4. Fill t he engine cooling syst em wi t h a 5 0 / 5 0
mi xture of Ford Premium Cooling Syst em Fluid
E2FZ-19549-AA or -B (in Canada, Mot orcraf t
CXC-8-B) or equivalent t hat meets Ford
speci fi cati on ESE-M97B44-A and wat er.
5. Start t he engine and check all hoses and
connecti ons for l eaks. Al l ow the engine t o war m
up so t hat t he wat er t hermost at opens and t op off
radi ator cool ant recovery reservoi r as requi red t o
maintain minimum col d fill level.
Wa t e r P u m p
Re mo v a l
1.
2.
4.
Drain engine cooling syst em. Remove fan bl ade
( 8600) and fan shroud ( 8146) .
Rel ease dri ve belt tensioner ( 6B209) and remove
dri ve belt ( 8620) .
Remove four bol ts retaining wat er pump pulley
( 8509) t o wat er pump ( 8501) and remove wat er
pump pulley.
Remove four bol ts retaining wat er pump t o
cylinder bl ock ( 6010) and remove wat er pump.
WATER PUMP
HOUSING GASKET
8507
WATER PUMP
8501
BOLT
4 REQ'D
TIGHTEN TO
20-30 N-m
(15-22 LB-FT) A14810-D
1. Repl ace wat er pump housing gasket ( 8507) and
cl ean sealing surface of cylinder bl ock.
2. Lubri cate wat er pump housing gasket wi t h cl ean
Ford Premium Cooling Syst em Fluid
E2FZ-19549-AA or -B (in Canada CXC-8-B) or
equivalent meeting Ford Speci fi cati on
ESE-M97B44-A.
3. Position wat er pump on cyl i nder bl ock and install
four retaining bol ts. Tighten to 20-30 N-m (15-22
Ib-ft).
4. Position wat er pump pulley on wat er pump and
install four retaining bol ts. Tighten bol ts t o 20- 30
Nm (15-22 Ib-ft).
6. Install fan bl ade and fan shroud.
7. Fill engine cool i ng syst em wi th a 5 0 / 5 0 mi xture
of Ford Premium Cooling Syst em Fluid
speci fi cati on ESE-M97B44-A and wat er as
outlined. Check for l eaks.
R a d i a t o r H o s e s
Re mo v a l
NOTE: Radi ator hoses should be checked as di rect ed
in the appl i cabl e Maintenance Schedul e. Refer t o
Secti on 00- 03. Repl ace whenever hoses become
cr acked, rot t ed or have a tendency t o col l apse.
Drain the radi ator ( 8005) and slide the cl amps onto
hose at each end of the hose to be removed. Slide t he
hose off t he radi ator connection and the wat er hose
connection ( 8592) (upper radi ator hose ( 8260) ) or t he
wat er pump connecti on (l ower radi ator hose ( 8286) ) .
03- 03- 16 Engi ne Cool i ng 03- 03- 15
I nst al l at i on
1. CAUTI ON: Ma ke s ur e t h e h o s e c l a mp s a r e
b e y o n d t he bead a n d pl aced i n t h e cent er of
t h e c l a mp i n g s u r f a c e o f t h e c o n n e c t i o n s .
Position the hose cl amps at least 3.2 mm (1 IB
inch) f rom each end of the hose. Coat the
connecti on areas wi th an approved
water-resi stant sealer and slide the hose on the
connecti ons.
2. Fill the radi ator wi th a 5 0 / 5 0 mi xture of Ford
Premium Cooling Syst em Fluid E2FZ-19549-AA
or -B (in Canada, Mot orcraf t CXC-8-B) or
ESE-M97B44-A and water. Operat e the engine
for several minutes then check the hoses and
connecti ons for l eaks.
R a d i a t o r
Re mo v a l
1. Remove fan shroud ( 8146) as outlined.
2. NOTE: When di sconnecti ng the transmi ssi on oil
cool er inlet and outlet lines, loosen t he
transmi ssi on oil cool er lines while holding radi ator
fitting wi t h a back-up wrench.
Di sconnect the transmi ssi on oil cool er inlet and
outlet lines.
3. Drain engine cool i ng syst em as outlined.
4. Di sconnect upper radi ator hose ( 8260) and l ower
radi ator hose ( 8286) and de-aerati on hose f rom
the radi ator ( 8005) .
5. Remove t wo upper A / C condenser
core-to-radi ator retaining bol ts.
6. Remove radi ator upper support retaining bol ts
and remove support s.
7. Lift A / C condenser core ( 19712) sufficiently t o
di sengage l ower retaining clips on radi ator.
Remove radi ator f rom vehi cl e.
1. If installing a new radi ator on vehi cl es equi pped
wi t h automati c transmi ssi on, transfer the oil
cool er line connect ors t o t he new radi ator, using
Pipe Sealant wi th Teflon D8AZ-19554-A or
equivalent oil resi stant seal er meeting Ford
speci fi cati ons WSK- M2G350- A2.
2. Position the radi ator into t he vehi cl e. Install A / C
condenser core into l ower retaining cl i ps on
radi ator.
3. Install upper support s and secure wi t h bol ts.
4. Install t wo upper A / C condenser core-to-radi ator
retaining bol ts. Tighten t o 8-11 N-m (71-97 lb-in).
5. Connect the oil transmi ssi on cool er lines while
using a back-up wrench t o hold fi tti ng.
6. Connect the upper radi ator hose, l ower radi ator
hose and de-aerati on hoses.
7. Cl ose the radi ator drai ncock ( 8115) .
8. Install fan shroud as outlined.
9. Fill t he engine cooling syst em wi th a 5 0 / 5 0
mi xture of Ford Premium Cooling Syst em Fluid
speci fi cati on ESE-M97B44-A and water.
VEHI CLE, DO NOT OPERATE THE ENGINE
FAN BLADE ( 8600) HAS BEEN FI RST
EXAMI NED FOR CRACKS AND SEPARATI ON.
Operat e the engine and check for l eaks at the
hose connecti ons and the transmi ssi on oil cool er
lines. Check the automati c transmi ssi on fluid.
11. Turn the engine off and check radi ator and
cool ant recovery reservoi r engine cool ant levels.
R a d i a t o r C o o l a n t R e c o v e r y R e s e r v o i r
Re mo v a l
1. Drai n radi ator ( 8005) until engine cool ant is out of
radi ator cool ant recovery reservoi r ( 8A080) .
Di sconnect radi ator overfl ow hose ( 8075) at
radi ator cool ant recovery reservoi r.
2. Remove l ower radi ator hose ( 8286) and cl amp
f rom radi ator cool ant recovery reservoi r.
Remove radi ator cool ant recovery reservoi r
retai ners and remove radi ator cool ant recovery
reservoi r.
1. Position radi ator cool ant recovery reservoi r in
vehi cl e and install retaining nuts. Tighten retaining
nuts securel y.
2. Connect l ower radi ator hose and cl amp t o
radi ator cool ant recovery reservoi r.
3. Connect radi ator overfl ow hose t o radi ator
cool ant recovery reservoi r.
4. Fill and bleed engine cooling syst em as outlined.
Check for cool ant l eaks and proper engine
cool ant level after engine reaches normal
operati ng temperature.
F i t t i n g s
When installing a new radi ator ( 8005) , transfer t he
transmission oil cool er line fittings f rom t he old radi ator
and install them in the new radi ator, using Pipe Sealant
wi th Teflon D8AZ-19554-A or equivalent oil resi stant
sealer meeting Ford speci fi cati on WSK- M2G350- A2.
When installation of the radi ator is compl ete, check
the transmi ssi on oil cool er line connecti ons for l eaks.
Check the transmi ssi on fluid level and fill, if necessary.
03- 03- 16 E n gi n e Co o l i n g 03- 03- 16
C o o l i n g Fa n B l a d e a n d Fa n C l u t c h ,
Me c h a n i c a l
Remov al
SEPARATI ON.
Di sconnect (pull apart ) t he el ectri c cooling fan
motor wiring connect or at t he RH si de of t he fan
shroud ( 8146) .
2. Remove the l ower fan shroud from the upper fan
shroud.
3. Loosen the fan shroud f rom its radi ator mounting
and remove t he l ower radi ator hose ( 8286) f rom
the fan shroud.
4. Lift the fan shroud out of the vehi cl e.
5. Remove the fan cl utch mounting shaft f rom the
wat er pump pulley hub.
Me c ha n i c a l Fan Bl ade a n d Cl ut c h
6. Remove t he four fl anged-head mounting bol ts and
separat e the fan bl ade f r om the fan cl utch
( 8A616) .
1. Position t he fan bl ade on the fan cl utch and install
the fl anged hex head mounti ng bol t s. Tighten t he
bol ts evenly and al ternatel y t o 20- 27 N-m ( 15- 20
Ib-f t ).
2. Mount the fan cl utch shaf t t o t he wat er pump
pulley hub and ti ghten t o 50- 62 N-m (37-46 Ib-ft).
3. Install the fan shroud into the vehi cl e.
4. Install the fan shroud into the radi at or' s l ower
mounting cl i ps. Install and ti ghten t he fan shroud
retaining scr ews t o 2. 7-5. 4 N-m ( 24- 48 lb-in).
5. Install the l ower radi ator hose into t he fan shroud
mounting retainer.
6. Connect t he el ectri c cool i ng motor wi ri ng
connectors together and secure t he wiring t o t he
fan shroud.
7. Install the l ower fan shroud onto the upper fan
shroud.
Q3014-D
I t e m
Pa r t
2 N807271 Bolt (4 Req'd)
3 8600 Fan Blade
4 8A616 Fan Clutch
A

Lb-Ft)
B
Tighten t o 50-62 N-m (37-46
Lb-Ft)
I t e m
Pa r t
C When installed and water
pump shaft is rotated and fan
clutch is held stationary,
maximum runout of the fan
blade mounting surface to be
within 0.203 mm (0.008
inch).
03- 03- 17 En gi n e Co o l i n g 03- 03- 17
C o o l i n g Fa n Mo t o r , Fa n B l a d e a n d Fa n S h r o u d
A s s e m b l y , E l e c t r i c a l
Re mo v a l
1. Di sconnect (pull apar t ) t he cooling fan motor
wiring connector at the si de of the fan shroud
( 8146) .
2. Remove fan shroud as outlined.
3. Remove retaining scr ews, cooling fan motor and
fan bl ade ( 8600) f rom fan shroud.
cool i ng fan motor and fan bl ade retaining scr ews
t o 3-6 N-m (27-53 Ib-in). Tighten fan shroud
retaining scr ews t o 2.7-5.4 N-m (24-48 Ib-in).
Tighten fan cl utch shaft to the wat er pump pulley
hub t o 50-62 N-m ( 37- 46 Ib-ft).
Fa n S h r o u d
Re mo v a l
SEPARATI ON.
Turn the l ower fan shroud ( 8146) in the upper fan
shroud t o al l ow cl earance for removal of fan
shroud.
2. Di sconnect (pull apart ) the el ectri c cooling fan
motor wi ri ng connector at the RH si de of the fan
shroud.
3. Remove t he radi ator upper si ght shield ( 8C291) .
4. Loosen the fan shroud f rom its radi ator mounting
and remove the l ower radi ator hose ( 8286) f rom
the support s on the fan shroud.
5. Lift t he fan shroud out of the vehi cl e.
6. Remove el ectri c cool i ng fan motor and fan bl ade
f rom fan shroud (if requi red) as outlined.
1. If removed, install el ectri c cooling fan motor and
fan bl ade onto fan shroud. Tighten retaining
scr ews t o 3-6 N-m (27-53 Ib-in).
2. Install the fan shroudi nto the vehi cl e.
3. Install the fan shroud into the radi ator' s l ower
mounting cl i ps. Install and ti ghten t he fan shroud
retaining scr ews t o 2.7-5.4 N-m (24-48 Ib-in).
4. Position t he l ower radi ator hose onto t he
support s on the fan shroud.
5. Connect t he el ectri c cool i ng fan motor wiring
connect ors t oget her and secure the wiring t o the
fan shroud.
6. Turn t he l ower fan shroud in the upper fan shroud
t o the cl osed posi ti on.
7. Install the radi ator upper sight shi el d.
R a d i a t o r Dr a i n c o c k
A l u m i n u m C o r e Ra d i a t o r
Re mo v a l
1. Turn t he radi ator drai ncock ( 8115)
count ercl ockwi se t o unscrew. When the radi ator
drai ncock is unscrewed t o the end of the t hreads,
pull t he radi ator drai ncock partially out f rom the
radi ator inlet tank ( 8079) .
2. Remove the radi ator drai ncock f rom the radi ator
( 8005) by squeezing the si des together wi th a
pair of needlenose pliers. Then pull the radi ator
drai ncock from the radi ator.
1. Ma ke sure O-ring is in groove on st em of radi ator
drai ncock.
2. Water-saturate radi ator drai ncock in order t o wet
O-ring.
3. Push the loosely assembl ed radi ator drai ncock
into t he opening until it snaps into pl ace.
4. Tighten the radi ator drai ncock by turning
cl ockwi se to 0.7-1.4 N-m (6-12 Ib-in).
O- RI NG v r <
II
STEM '
J
M2174-B
Wa t e r T e m p e r a t u r e I n d i c a t o r S e n d e r Un i t
1. Drain engine cooling syst em as outlined.
2. Di sconnect engine control sensor wiring
( 12A581) f rom wat er temperature indicator
sender unit ( 10884) .
3. Remove wat er temperature indicator sender unit
f rom upper intake manifold ( 9424) .
wat er temperature indicator sender unit t o 16-24
N-m (12-17 Ib-ft).
E n g i n e C o o l a n t T e m p e r a t u r e S e n s o r
C a b l e , E l e c t r i c E n g i n e B l o c k H e a t e r
03- 03- 18 Engi ne Cool i ng 03- 03- 18
2. Di sconnect bl ock heater power cabl e f rom bl ock
heater ( 6A051) .
3. Lower vehi cl e.
4. Di sconnect bl ock heater power cabl e retai ner (if
equi pped) and remove bl ock heater power cabl e
f rom vehi cl e.
5. To install, reverse Removal procedure. Make
sure power cabl e is routed and secured away
f rom rotati ng or hot components.
E n g i n e B l o c k H e a t e r
Re mo v a l
1. Open hood ( 16612) and install protecti ve fender
covers.
3. Position drain pan bel ow radi ator ( 8005) .
THE ENGI NE IS OPERATI NG. FAI LURE TO
FOL L OW THESE I NSTRUCTI ONS COULD
SYSTEM OR ENGINE AND/ OR PERSONAL
INJURY. TO AVOI D HAVI NG SCALDI NG HOT
COOL ANT OR STE AM BL OW OUT OF THE
RADI ATOR, USE EXTREME CARE WHEN
REMOVI NG THE PRESSURE RELI EF CAP
FROM A HOT COOLI NG SYSTEM. WAI T UNTI L
THE ENGI NE HAS COOLED, THEN WRAP A
THI CK CL OTH AROUND THE PRESSURE
RELI EF CAP AND TURN I T SLOWLY TO THE
FI RST STOP. STEP BACK WHI LE THE
PRESSURE IS RELEASED FROM THE
COOLI NG SYSTE M. WHEN IT IS CERTAI N A L L
THE PRESSURE HAS BEEN RELEASED,
PRESS DOWN ON THE PRESSURE RELI EF
CAP ( STI LL WI TH A CLOTH) , TURN AND
REMOVE.
Remove pressure relief cap following outlined
precauti ons. At t ach 9.5 mm (0.4-inch) hose t o
drain tube and open radi ator drai ncock ( 8115) .
Drain radi ator t o a correspondi ng level bel ow
bl ock heater ( 6A051) . Cl ose radi ator drai ncock.
5. Di sconnect bl ock heater power cabl e f rom bl ock
heater.
6. Loosen retaining screw and pry bl ock heater f rom
cylinder bl ock ( 6010) while moving retaining
screw f rom si de to side t o di sengage cl amp
strap.
7. Remove bl ock heater while noting the position of
heating element.
8. Remove bl ock heater power cabl e.
1. Clean t he inside di ameter of the cylinder bl ock
hole machi ned surface and hold entrance.
Remove any burrs at the hole entrance t o avoi d
damage t o the O-ring.
2.
3.
4.
5.
6.
Appl y a liberal coati ng of Premi um Long Li fe
Grease XG-1-C or equivalent meeting Ford
speci fi cati on ESA-M1C75-B t o bl ock heater
O-ring and cyl i nder bl ock openi ng.
Insert bl ock heater in cyl i nder bl ock hole in t he
same posi ti on as if was removed.
Tighten scr ew t o 1.6-1.8 N-m ( 14- 16 lb-in).
Connect bl ock heater power cabl e t o bl ock
heater.
Install bl ock heater power cabl e. Make sure
power cabl e is routed and ti e-strapped away
f rom rotati ng or hot component s.
Refill cool i ng syst em wi th a 5 0 / 5 0 mi xture of
Ford Premium Cooling Syst em Fluid
speci fi cati on ESE-M97B44-A and wat er as
outlined.
8 Connect bat t ery ground cabl e.
10. Check engine cool ant level as requi red.
11. Remove fender covers and cl ose hood.
BLOCK HEATER
6A051
POWER CABLE
JNDER BLOCK I PI _
0 f ^
CYLINDER
601
BLOCK HEATER
6A051
O-RING
CYLINDER BLOCK
6010
L8999-A
03- 03- 19 Engi ne Cool i ng
03- 03- 19
SERVICE PROCEDURES
Radiator Core
NOTE: Wi t h the i ntroducti on of a new radi ator braze
process, there is no longer an approved servi ce
method for repairing radi ator core l eaks. Due t o the
t ype of flux used during brazi ng, the t wo component
epoxy materi al previ ousl y used will not adhere t o the
aluminum radi ator core. If the radi ator core l eaks, the
radi ator ( 8005) should be repl aced.
Transmi ssi on Oil Cooler Connect i on Leaks
Check t o see that the fitting nut is fully ti ghtened. If the
leak persi st s, appl y a thi n, even coat of Dow Corning
1200 primer or equivalent using a brush. Al l ow t o dry
for 10 minutes at room temperature. Appl y Dow
Corning Silastic 734 RTV or equivalent in undiluted
f orm around t he leaking connecti on and allow it t o dry
for one hour.
Radiator Coolant Level Check
Check engine cool ant level in the radi ator cool ant
recovery reservoi r ( 8A080) at least once a month.
Wi th a col d engine, t he engine cool ant level must be
maintained at or above the FULL COLD mark.
At normal engine operati ng t emperat ure, the engine
cool ant level shoul d be at the FULL HOT mark. If
engine cool ant level in t he radi ator cool ant recovery
reservoi r is l ess than t he above i ndi cated levels, a
5 0 / 5 0 mi xture of Ford Premium Cooling Syst em Fluid
E2FZ-19549-AA or B (in Canada, Mot orcraf t
CXC-8-B) or equivalent meeting Ford speci fi cati on
ESE-M97B44-A and wat er should be added t o t he
radi ator cool ant recovery reservoi r t o the speci fi ed
levels.
If no engine cool ant is observed in the radi ator cool ant
recovery reservoi r or when a cool ant level change
does not occur, check the syst em as fol l ows:
1. Wi t h the engine col d, remove the pressure relief
cap and i nspect the filler neck sealing gasket for
forei gn materi al bet ween the gasket and
pressure relief cap di aphragm. Refer t o Pressure
Relief Cap Cleaning and Inspection. Rinse
pressure relief cap in cl ean water.
The pressure relief cap used on thi s syst em is
unique, repl ace only wi t h the proper pressure
relief cap.
2. Remove the radi ator overfl ow hose ( 8075) at the
radi ator connecti on. Remove radi ator cool ant
recovery reservoi r f rom front fender apron
( 16054) and flush wi th cl ean water.
3. Inspect the radi ator overfl ow hose for
obstructi on, cr acks or cut s. Repl ace if
necessary.
4. Install radi ator cool ant recovery reservoi r and
connect overfl ow hose at the radi ator connecti on.
5. Replenish the engine cool ant in the radi ator
( 8005) and add cool ant t o radi ator cool ant
recovery reservoi r as requi red.
6. Install the pressure relief cap.
A low engine cool ant level in the radi ator can
cause poor heater and def rost er performance. If
this condition exi st s, perform t he fol l owi ng:
a. Wi th col d engine, remove pressure relief
cap.
b. Wi th a 5 0 / 5 0 mi xture of Ford Premium
Cooling Syst em Fluid E2FZ-19549-AA or -B
(in Canada, Mot orcraf t CXC-8-B) or
ESE-M97B44-A solution and water, fill
radi ator cool ant recovery reservoi r t o
i ndi cated level and repl ace pressure relief
cap.
c. Start the engine and run until the wat er
t hermost at ( 8575) opens.
d. Observe the level of engine cool ant in the
radi ator cool ant recovery reservoi r. The
minimum level should be as speci fi ed in Step
2. If not, adjust engine cool ant level by
adding 5 0 / 5 0 mi xture of Ford Premium
Cooling Syst em Fluid E2FZ-19549-AA or -B
(in Canada, Mot orcraf t CXC-8-B) or
ESE-M97B44-A and water.
e. Check for l eakage at:
o All hoses and hose connecti ons.
o Radi ator seams, radi ator core and
radi ator drai ncock ( 8115) .
All cylinder bl ock core plugs and drain
plugs.
Edges of all cooling syst em gasket s.
Transmission oil cool er fittings.
Vehicle heating syst em components.
Water pump ( 8501) .
f. Examine oil level di psti ck ( 6750) for
evi dence of engine cool ant in engine oil.
g. Check radi ator for evi dence of oil in cool ant.
Install cooling syst em analyzer t o assi st in testi ng
the cooling syst em. Follow the manufacturer' s
recommended connecti ons and testi ng
procedures.
03- 03- 20 E n gi n e C o o l i n g 03- 03- 2 0
Coolant Condi t i on Check
1. NOTE: Use only a permanent-type cool ant such
as Ford Premium Cooling Syst em Fluid
E2FZ-19549-AA (in Canada, Mot orcraf t
speci fi cati ons ESE-M97B43-A and
ESE-M97B44-A.
Check engine cool ant for di rty or rusty
appearance. Di rty or rusty cool ant requi res
repl acement t o prot ect the cooling syst em from
corrosi on damage. Repl ace the cool ant. Refer t o
Cooling Syst em, Draining, Filling and Bl eedi ng.
2. If cool ant condi ti on is sat i sf act ory, check cool ant
concentrati on for proper protecti on level. Use a
Rotunda Bat t ery and Anti freeze Tester
021- 00046 or equivalent, or a Hydromet er for
t est i ng. Maintain a protecti on level of at l east
-30 C (-20 F) t o preserve anti-rust corrosi on
protecti on and ensure proper engine operati ng
t emperat ure.
If concentrati on level is l ow, partially drain the
cool i ng syst em by opening t he radi ator drai ncock
( 8115) or by partially removi ng t he l ower radi ator
hose ( 8286) , secure the radi ator drai ncock or
hose cl amp and add 100 percent concentrati on
of Ford Premium Cooling Syst em Fluid
E2FZ-19549-AA (in Canada, Mot orcraf t
CXC-8-B) or equivalent meeti ng Ford
speci fi cati on ESE-M97B44-A t o obtai n t he
recommended protecti on level. Wet the rubber
sealing surf ace of the pressure relief cap before
installing the pressure relief cap ti ghtl y on
radi ator cool ant recovery reservoi r ( 8A080) .
Cool i ng Syst em Hoses and Clamps
1. Inspect cooling syst em hoses and cl amped hose
connecti ons f or l eaks or excessi ve deteri orati on.
Servi ce or repl ace as requi red.
2. Inspect radi ator core and t anks for l eaks. Servi ce
or repl ace as requi red.
3. Inspect cool i ng syst em hose routing t o ensure
sufficient cl earance t o engine compart ment
component s. Reposition hoses if requi red.
4. Check radi ator supports and br acket s for firm
radi ator retenti on. Correct as requi red. The
radi ator ( 8005) is installed wi t h rubber isolation
mounts.
Cooli ng Syst em, Drai ni ng, Filling and
Bleedi ng
1. Wi t h t he engine OFF and sufficiently cool , remove
pressure relief cap, open radi ator drai ncock
( 8115) and remove the cyl i nder bl ock drain plugs
and al l ow cool ant to drai n.
2. Cl ose radi ator drai ncock. Hand-ti ghten.
3. Check all hose cl amps for proper ti ghtness and
l ocati on. Make sure radi ator drai ncock is cl osed
and cylinder drai n pl ugs are installed.
4. Remove heat er wat er hose ( 18472) f r om heater
outlet t ube at rear of RH cyl i nder head ( 6049) .
5. NOTE: Its i mportant t o maintain engine cool ant
concentrati on between 40 percent, - 24C
(-11 F) and 60 percent, -52 C (-62 F)
dependi ng on cl i mate condi ti ons. Bel ow 40
percent, t here is a l oss of freeze prot ect i on.
Above 60 percent, t he engine may overheat on a
war m day. Outsi de thi s range, protecti on agai nst
rust and corrosi on may be greatl y reduced.
Fill radi ator cool ant recovery reservoi r ( 8A080)
wi th a 5 0 / 5 0 mi xture of Ford Premium Cooling
Syst em Fluid E2FZ-19549-AA or -B (in Canada,
Mot orcraf t CXC-8-B) or equivalent meeti ng Ford
speci fi cati on ESE-M97B44-A and wat er until t he
mi xture f l ows out of the heater outlet tube.
6. Install heater wat er hose t o heater outlet tube.
Install hose cl amp securel y.
7. Fill radi ator cool ant recovery reservoi r t o bel ow
t he filler neck seat wi t h a 5 0 / 5 0 mi xture of
cool ant and water.
8. Place heater temperature sel ector in MAXI MUM
heat posi ti on.
VEHI CLE, DO NOT OPERATE ENGINE WI TH
HOOD ( 16612) OPEN UNTIL FAN BLADE
( 8600) HAS BEEN FI RST EXAMI NED FOR
Install t he pressure relief cap and run engine until
wat er t hermost at ( 8575) opens (cool ant fl owi ng
through upper radiator hose ( 8260) becomes
hot).
10. Stop engine and allow t o cool . Carefully remove
11. Add a 5 0 / 5 0 mi xture of Ford Premium Cooling
Syst em Fluid E2FZ-19549-AA or -B (in Canada,
Mot orcraf t CXC-8-B) or equivalent meeting Ford
speci fi cati on ESE-M97B44-A and wat er t o the
FULL COLD mark on the radiator cool ant
recovery reservoir through the filler opening at
the top of the radiator cool ant recovery reservoi r.
12. Install pressure relief cap. Check for l eaks.
03- 03- 2 1 E n gi n e Co o l i n g 03- 03- 2 1
CLEANING A N D INSPECTION (Conti nued)
C o o l i n g S y s t e m , C l e a n i n g
C o o l i n g S y s t e m Fl u s h P r o c e d u r e
Ra d i a t o r I n st a l l e d
To remove rust, sludge and other forei gn material f rom
t he cool i ng syst em, use Premium Cooling Syst em
Flush F1AZ- 19A503- A or equivalent meeting Ford
speci fi cati on ESR-M 14P7-A that is safe for use wi th
aluminum radi ators ( 8005) . Remove the wat er
t hermost at ( 8575) prior t o pressure-flushing. This
cleaning restores cool i ng efficiency and helps prevent
overheati ng. A pulsating or reversed di recti on of
flushing wat er will l oosen sediment more quickly than a
st eady fl ow in the normal cool ant fl ow di recti on. In
severe cases where cleaning sol vents will not properl y
cl ean t he cooling syst em for efficient operati on, use
t he pressure flushing method using Rotunda Cooling
Syst em Flusher 106-00010 or equivalent. Di spose of
ol d cool ant and flushing wat er contami nated wi th
anti freeze and cleaning chemi cal s in accordance wi th
l ocal , st at e and federal l aws.
Ra d i a t o r Re mo v e d
1. CAUTI ON: Ra d i a t o r i n t e r n a l p r e s s u r e mu s t
n o t e x c e e d 138 kPa ( 2 0 ps i ) . Da ma ge ma y
r e s ul t .
Back-fl ush radi ator. Position a high-pressure
wat er hose in l ower radi ator hose location and
back-fl ush.
2. Remove wat er hose connecti on ( 8592) and wat er
t hermost at as outlined.
3. Back-fl ush engine. Position hi gh-pressure hose
into engine through wat er t hermost at location and
back-fl ush engine.
He a t e r C o r e Ba c k - Fl u s h i n g
CAUTI ON: T h e h e a t e r c o r e ( 1847 6) mu s t b e
b a c k- f l u s h e d s e p a r a t e l y f r o m t h e e n gi n e c o o l i n g
s y s t e m f o r p r o p e r b a c k- f l u s h wa t e r f l o w d i r e c t i o n
t h r o u g h t h e h e a t e r c o r e .
All engine cool i ng syst em flushing and back-flushing
procedures must include a separat e back-flushing of
t he heater core after the flushing or back-flushing of
t he engine cooling syst em Thi s will prevent engine
cool i ng syst em parti cl es f rom cl oggi ng the heater core
t ubes and reducing (or eliminating) cool ant fl ow
through the heater core.
The correct heater core back-flushing procedure is as
f ol l ows.
1. Di sconnect the heater core outlet heater wat er
hose ( 18472) f rom the return fitting and install a
femal e garden hose-end fitting adapt er in the end
of the outlet heater wat er hose. Secure wi th a
hose cl amp.
2. Connect the femal e garden hose end of the outlet
heater wat er hose t o the male end of a wat er
suppl y garden hose.
3. Di sconnect the heater core inlet heater wat er
hose f rom the i ntake manifold fi tti ng. Al l ow t o
drain into a suitable container.
4. If a wat er valve is installed in t he heater core inlet
heater wat er hose, check t o be certai n the wat er
val ve is open (no vacuum).
5. Turn t he wat er suppl y val ve on and off several
ti mes so that the surge acti on will help t o di sl odge
larger stubborn parti cl es f rom the heater core
tubes. Al l ow full wat er pressure t o fl ow for
approxi matel y five minutes.
6. If a wat er valve is installed in t he heater core inlet
heater wat er hose, appl y vacuum t o the wat er
val ve vacuum motor t o ensure proper operati on
of the wat er val ve and proper cl osure wi t h no
wat er l eakage. Repl ace the wat er val ve if
requi red.
7. Remove the hose cl amp and femal e garden
hose-end adapt er from t he end of the outlet
heater wat er hose and reconnect the outlet
heater wat er hose onto the wat er pump fitting
and heater return fitting.
8. Connect the inlet heater wat er hose onto t he
cylinder bl ock fitting and i ntake manifold fi tti ng.
9. Fill the engine cooling syst em as outlined, using a
5 0 / 5 0 mi xture of Ford Premium Cooling Syst em
Fluid E2FZ-19549-AA or -B (in Canada,
Mot orcraf t CXC-8-B) or equivalent meeting Ford
speci fi cati on ESE-M97B44-A and water.
10. Test the syst em for proper heater performance
wi th the speci fi ed engine cool i ng syst em
condi ti ons.
P r e s s u r e Re l i e f C a p
1. Inspect the areas under the vacuum valve and
rubber seal for rust or dirt parti cl es.
2. Using war m t ap water, rai se the vacuum val ve
and rubber seal and thoroughl y flush away l oose
rust or t rapped dirt parti cl es.
3. Inspect and remove any loose or i mbedded rust
or dirt parti cl es on the sealing surfaces of t he
rubber seal .
03- 03- 2 2 E n gi n e Co o l i n g 03- 03- 2 2
4. NOTE: If paint is observed on t he filler neck
sealing surf ace, remove it using paint thinner.
Inspect the radi ator cool ant recovery reservoi r
filler neck opening for dirt parti cl es on t he sealing
surf ace at the bot t om of the filler neck openi ng.
Use a cl ean cl oth and wi pe t he sealing surface t o
remove any dirt parti cl es.
INSPECT/CLEAN
UNDER RUBBER
SEAL
SEALING
SURFACE
RADIATOR COOLANT RECOVERY
RESERVOIR 8A080 (FILLER
NECK OPENING)
Q32S3-B
R a d i a t o r
NOTE: Wi t h t he introduction of a new radi ator braze
process, t here is no longer an approved servi ce
met hod for repairing radi ator core l eaks. Due t o the
t ype of flux used during brazi ng, the t wo component
epoxy materi al previously used will not adhere t o the
aluminum redi ator core. If the radi ator core l eaks, the
radi ator ( 8005) should be repl aced.
E x t e r n a l
Install steel or brass plugs in the transmi ssi on oil
cool er fi tti ngs before cleaning and keep t hem installed
during t he entire servi ce operati on.
NOTE: Do not use a metal brush to cl ean an aluminum
core. Use only horsehair, bristle or nylon brushes.
Clean outsi de of aluminum core wi th a soft bristle
brush, war m wat er and a mild househol d liquid
detergent. Rinse wi t h cl ear water.
I n t e r n a l
NOTE: Do not use causti c cleaning solutions or
copper / br ass radi ator cleaning agents on aluminum
radi at ors.
To cl ean internal aluminum tubes use soni c cleaning
equi pment. Rinse the core wi th cl ean wat er when
compl et ed.
Fa n B l a d e
WARNI NG: DO NOT ATTEMPT TO STRAI GHTEN
OR REPAIR A FAN BLADE ( 8600) . REPLACE FAN
BLADE IF HUB OR BLADES ARE DAMAGED.
Check fan bl ade for cr acks or damage. Repl ace as
outlined.
SPECIFICATIONS
COOLING SYSTEM REFILL CAPACITIES
8
Liters Quarts
13. 3 14. 1
a To convert t o i mperi al measure, multi ply U.S. quart s
shown by 0.83.
b Capaci t i es shown i nclude radi at or cool ant recovery
reservoi r (8A080) f i l l ed t o FULL COLD mark.
COOLING SYSTEM PRESSURE SPECIFICATIONS
De s c r i p t i o n P r e s s u r e
Ra d i a t o r P r e s s u r e Te st 138 kP a ( 2 0 p s i )
P r e s s u r e Re l i e f Ca p P r e s s u r e 1 1 0 k P a ( 1 6 p s i ) + 1 4 k P a (2
ps i )
2 1 kP a ( 3 psi )
C o o l a n t Mi x t u r e
Servi ce refill recommendati ons are 5 0 / 5 0 mix of
wat er and permanent cool ant / ant i f reeze fluid such as
Ford Premium Cooling Syst em Fluid E2FZ-19549-AA
or -B (in Canada, Mot orcraf t CXC-8-B) or equivalent
meeting Ford speci fi cati on ESE-M97B44-A.
All figures shown are actual but may vary 15
percent due t o syst em vari ati ons.
Most servi ce refills will only t ake 80 percent of
capaci t y listed because some engine coolant does not
drai n.
WATER THERMOSTAT OPENING TEMPERATURE
St a r t s t o Op e n 8 9 - 9 3 C ( 1 9 2 - 1 9 9 F )
Ful l y Ope n 1 0 4 C ( 2 1 9 F )
03- 03- 2 3 E n gi n e Co o l i n g 03- 03- 2 3
SPECIFICATIONS (Continued)
FAN CLUTCH SPECIFICATIONS
Fan Test Speed Wat er Pump a t 3000 RPM
Vehi cl e
Cool i ng
Opt i on
Wat er Pump
Pulley Ratio
Engi ne RPM
Required to Run
Water Pump
at 3000 RPM
Mi n. Speed
Test Col d
Fan Max. RPM
Max. Speed
Test Hot
Fan Min.-RPM
To wn Ca r Ba s e 1.3 2 300 1500 2 2 00
To wn Ca r Cl a s s 3
Tr a i l e r To w
1.3 2 300 1500 2 2 00
Cr o wn Vi c t o r i a ,
Gr a n d Ma r q u i s
Base 1.3 2 300 1500 2 2 00
Cr o wn Vi c t o r i a ,
Gr a n d Ma r q u i s
Cl a s s 3
Tr a i l e r To w
1.3 2 300 1500 2 2 00
Descr i pt i on Lb-Ft
Fa n Sh r o u d - t o - Ra d i a t o r Bo l t s 2 . 7 - 5. 4 2 4- 48
( L b- l n )
A / C Co n d e n s e r Co r e - t o - Ra d i a t o r
Bo l t s
8- 11 7 1- 97
( Lb- l n )
Nut Fi t t i n g 2 4- 31 18- 23
Wa t e r Out l e t Co n n e c t i o n Bo l t s 2 0- 30 15- 22
Fa n Bl a d e - t o - Fa n Cl u t c h 2 0- 2 7 15- 20
Fa n Cl u t c h - t o - Wa t e r P ump Pul l e y
Hub
50- 62 37 - 46
Ra d i a t o r Dr a i n c o c k . 7 - 1. 4 6- 12
( L b- l n )
Tr a n s mi s s i o n Oi l e r Co o l e r Li n e
Co n n e c t o r s - t o - Ra d i a t o r
2 4. 4- 2 8. 5 18-21
Ra d i a t o r Co o l a n t Re c o v e r y
Re s e r v o i r Re t a i n i n g Nut
5. 5- 7 . 0 4- 5
Wa t e r P u mp - t o - Cy l i n d e r Bl o c k 2 0- 30 15- 22
Wa t e r Pump P ul l e y - t o - Hub 2 0- 2 7 15- 20
Bl o c k He a t e r Re t a i n i n g S c r e w 1. 6-1. 8 14- 16
( L b- l n )
E l e c t r i c Co o l i n g Fa n Mo t o r a n d Fa n
Bl a d e - t o - Fa n Sh r o u d S c r e ws
3-6 2 7 - 53
( Lb- l n )
Wa t e r Te mp e r a t u r e I n d i c a t o r
Se n d e r Uni t
16- 24 12-17
ROTUNDA EQUIPMENT
02 1- 00012 Ra d i a t o r / He a t e r Co r e P r e s s u r e Te s t e r
02 1- 00046 Ba t t e r y a n d An t i f r e e ze Te s t e r
02 1- 00066 Ra d i a t o r Ca p A d a p t e r Se t
055- 00108 Di gi t a l P h o t o e l e c t r i c T a c h o me t e r
106- 00010 Co o l i n g S y s t e m Fl us he r
03- 04- 1 Fue l Ch a r gi n g a n d C o n t r o l s 4 . 6 L ( 2V) 0 3 - 0 4 - 1
SECTION 03-04 Fuel Charging and Controls4.6L
(2V)
SUBJECT PAGE
A / C Compressor Cl ut ch Control Relay 03-04-5
Air Induction Syst em 03-04-2
Fuel Charging Wiring 03-04-4
Fuel I nj ect i on Supply Mani f ol d 03-04-3
Fuel I nj ect i on Ti mi ng 03-04-2
Fuel I nj ect ors ..03-04-3
Fuel Pressure Regul at or.. 03-04-4
Fuel Pressure Relief Valve 03-04-4
Fuel Pump Relay 03-04-5
Fuel Syst em . ..03-04-1
I nert i a Fuel Shut of f (IFS) Swi t ch ...03-04-4
I nt ake Mani f ol d 03-04-2
Sequent i al Mul t i port Fuel I nj ect i on (SFI) 03-04-2
Thr ot t l e Body 03-04-2
Fuel Chargi ng and Cont rol s ..03-04-5
SUBJECT PAGE
Fuel Chargi ng Syst em ...03-04-5
Fuel Chargi ng Wi ri ng 03-04-11
Fuel I nj ect i on Suppl y Mani f ol d 03-04-9
Fuel I nj ect or 03-04-8
Fuel Pressure Regul at or 03-04-10
Fuel Pressure Relief Valve 03-04-9
Spri ng Lock Coupl i ng 03-04-6
Fuel I nj ect or 03-04-11
Thr ot t l e Body . . 03-04-11
ADJUSTMENTS
Idle Speed 03-04-12
VEHICLE APPLICATION
Fu e l S y s t e m
WARNI NG: DO NOT SMOKE, CARRY LI GHTED
TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKI NG ON OR NEAR ANY FUEL-RELATED
COMPONENT HIGHLY FLAMMABLE MI XTURES
ARE ALWAYS PRESENT AND MAY BE I GNI TED,
NOTE: When t he bat t ery ( 10653) has been
di sconnected and reconnect ed, some abnormal dri ve
sympt oms may occur whi l e the powertrai n control
module ( PCM) ( 12A650) rel earns its adapti ve
st rat egy. The vehicle may need t o be driven 18 km ( 10
miles) or more t o relearn the st rat egy.
An on-board vehicle powertrai n control module:
Accept s signals f rom vari ous engine electronic
sensors t o comput e the requi red fuel fl ow rate
necessary t o maintain a prescri bed ai r/ f uel rati o
throughout the entire engine operati onal range.
Sends a command t o the fuel i nj ectors ( 9F593) t o
meter t he appropri ate quanti ty of fuel.
Determi nes and compensat es for the age of the
vehi cl e and its uniqueness.
Automati cal l y senses and compensat es for
changes in altitude (for exampl e, f rom sea level to
mountains).
The fuel delivery subsyst em consi sts of:
A high-pressure, in-tank mounted, fuel pump ( 9350) .
A fuel filter / reservoi r delivering fuel f rom the fuel
tank ( 9002) through a 20-micron fuel filter ( 9155) t o
a fuel injection suppl y manifold ( 9F792) .
The fuel injection supply manifold whi ch
i ncorporates el ectri cal l y-actuated fuel injectors
mounted di rectl y above each of the engine' s i ntake
port s.
The fuel injectors whi ch, when energi zed, spray a
metered quantity of fuel into the i ntake air st ream.
A constant fuel pressure drop is maintained across t he
fuel injectors by a fuel pressure regulator ( 9C968)
whi ch is:
Connected in seri es wi th the fuel i nj ectors.
Positioned downst ream from fuel i nj ectors.
Excess fuel supplied by the fuel pump, but not requi red
by the engine, passes through t he fuel pressure
regulator and returns to the fuel tank through a fuel
return line.
1995 To wn Car , Cr o wn Vi c t o r i a , Gr a n d Ma r qui s J u l y 1994
03- 04- 2 Fue l Ch a r gi n g a n d C o n t r o l s 4 . 6 L ( 2V) 03- 04- 2
Fu e l I n j e c t i o n T i m i n g
For fuel injection ti mi ng:
Each fuel injector ( 9F593) is energi zed once every
other crankshaft revolution in sequence wi t h ignition
firing order.
The peri od of ti me that the fuel i nj ectors are
energi zed (injector " on t i me" or pulse wi dt h) is
control l ed by the vehi cl e' s powertrai n control
module (PCM)(12A650).
Air entering the engine is moni tored by fl ow,
pressure and temperature sensors.
The signals of t he el ectroni c engine control sensors
are processed by the powertrai n control modul e.
The powertrai n control module determi nes the
needed injector pulse wi dt h and sends a command
t o t he fuel injectors t o meter the exact quanti ty of
fuel .
S e q u e n t i a l Mu l t i p o r t Fu e l I n j e c t i o n ( SFI )
The sequenti al multiport fuel injection (SFI) syst em is
cl assi fi ed as:
Multi-point.
Pulse ti me.
Mass air f l ow control l ed.
Fuel is met ered into each i ntake port in sequence wi th
the ignition firing order accordi ng t o engine demand
through the fuel injector ( 9F593) mounted on a tuned
T h r o t t l e B o d y
The throttl e body ( 9E926) functions as f ol l ows:
The throttl e body provi des control of engine airflow.
A cam lever and accel erator cabl e ( 9A758) rotates
t he throttl e shaft f rom idle t o wi de open throttl e
(WOT) posi ti on.
The pl ate position at idle is f act ory set by the lever
contacti ng a throttl e return control (TRC) screw.
The head of the screw is removed t o make the idle
pl ate set permanent. DO NOT attempt t o adjust
i dl e/mi ni mum plate setti ng wi th the TRC screw.
Refer t o the Powertrai n Cont rol / Emi ssi ons
Di agnosi s Manual .
1
The throttl e body ai rfl ow is f act ory set by the idle air
adj ust needle (trim scr ew) within the throttl e body
cast i ng. DO NOT attempt t o adjust. Refer t o the
Powertrai n Cont rol / Emi ssi ons Diagnosis Manual .
1
Throttl e body idle ai rfl ow provi des minimum engine
airflow, while the idle air control valve (IAC
val ve)(9F715) provi des supplemental engine ai rfl ow
t o maintain the desi red engine idle speed.
Other features of the throttl e body include:
The WOT plate position whi ch is obtai ned when the
lever cont act s the throttl e body casti ng.
Throttl e Position Sensor (TP sensor)(9B989) whi ch
provi des an el ectri cal signal whi ch is used as an
input t o the powertrai n control module
( PCMX12A650) .
A seal ant is applied t o the downst ream si de of the
throttl e body plate and bore, t o reduce pl ate-to-bore
l eakage and the sealant should NOT be removed by
cleaning.
A i r I n d u c t i o n S y s t e m
The air induction syst em supplies fi l tered air t o the
engine t o mix wi th t he fuel for combusti on purposes
and consi st s of the fol l owi ng:
Engine air cleaner (ACL)(9600) wi t h an i ntake air
t emperat ure sensor (IAT sensor)(12A697).
Air cl eaner element (ACL el ement )(9601).
Mass air fl ow sensor ( MAF sensor)( 12B579) .
Air cl eaner outlet tube ( 9B659) .
Throttl e body ( 9E926) .
Upper and l ower i ntake manifolds ( 9424) .
The i ntake manifold ( 9424) :
Is a one-piece aluminum casti ng.
Runner lengths are tuned t o optimize engine torque
and power output.
Pocket s for the fuel injectors ( 9F593) are machi ned
t o prevent both air and fuel l eakage.
Pocket s, in whi ch the fuel injectors are mounted,
are posi ti oned t o di rect the fuel injector fuel spray
i mmedi atel y in front of each engine i ntake val ve
( 6507) .
V9846-A
Pa r t
2 9B989 Throttle Position Sensor
3 9C968 Fuel Pressure Regulator
4 9F593 Fuel Inj ector
Manifold
Fu e l I n j e c t o r s
The eight fuel i nj ectors ( 9F593) are:
El ectro-mechani cal devi ces whi ch bot h meter and
atomi ze fuel del i vered t o t he engine.
Mounted in t he l ower i ntake manifold ( 9424) and are
posi ti oned so t hat their ti ps di rect fuel just ahead of
t he engine i ntake val ves ( 6507) .
The fuel injector bodi es consi st of:
Sol enoi d.
Needl e and val ve assembl y.
Di r ect or / met er i ng pl ate.
An el ectri cal cont rol signal f rom the powertrai n control
module (PCM)( 12A650) act i vat es t he fuel injector
sol enoi d, al l owi ng fuel t o fl ow. Si nce the fuel injector
fl ow ori fi ce is f i xed and the fuel pressure drop across
the injector ti p is constant:
Fuel fl ow to t he engine is regul ated by t he l ength of
ti me the solenoid is energi zed.
Atomi zati on is obtai ned at the di r ect or / met er i ng
pl ate.
I t e m
Pa r t
1

Outer O-Ring Seal (Upper)
(Part of 9F593)
2 Integral Filter (Part of
9F593)
3 Coil (Part of 9F593)
4 Armature (Part of 9F593)
5 Outer O-Ring Seal (Lower)
(Part of 9F593)
6 Stainless Steel Valve Body
(Part of 9F593)
7

End Cap (Part of 9F593)
8 Stainless Steel Needle (Part
of 9F593)
9 Washer (Part of 9F593)
10 Coil Terminal Blade (Part of
9F593)
Fu e l I n j e c t i o n S u p p l y Ma n i f o l d
The fuel injection supply manifold ( 9F792) delivers
high-pressure fuel f rom the vehicle fuel supply line t o
the eight fuel injectors ( 9F593) . The fuel injection
suppl y manifold consi sts of:
Tubular fuel rail.
Eight fuel injector connectors.
A mounting fl ange to t he fuel pressure regulator
( 9C968) .
Mounting at t achment s whi ch l ocate the fuel injection
suppl y manifold and provi de fuel injection retenti on.
Fuel inlet and outlet connecti ons whi ch have push
connect (CCD) fi tti ngs.
Fu e l P r e s s u r e R e g u l a t o r
The fuel pressure regul ator ( 9C968) :
Is at t ached t o the fuel injection supply manifold
( 9F792) downst ream of the fuel injectors ( 9F593) .
Regul ates the fuel pressure supplied t o the fuel
i nj ectors.
Is a di aphragm-operated relief val ve in whi ch one
si de of the di aphragm senses fuel pressure and the
other si de is subj ected t o intake manifold vacuum.
Nominal fuel pressure is establ i shed by a spri ng
prel oad appl i ed t o the di aphragm.
Bal ances one side of t he di aphragm wi t h manifold
pressure t o maintain a constant fuel pressure drop
acr oss the fuel i nj ectors.
Bypasses and returns excess fuel t o t he fuel tank
( 9002) .
Fuel Pr e ssur e Re gul a t or
I t e m
Pa r t
1

Engine Vacuum Reference
Tube (Part of 9C968)
2 Ball Seat (Part of 9C968)
3

Spring (Part of 9C968)
4 Upper Housing (Part of
9C968)
Pa r t
5 Diaphragm (Part of 9C968)
6

Lower Housing (Part of
9C968)
7

Fuel Outlet (Return) Tube
(Part of 9C968)
8

Fuel Inlet (Supply) Tube (Part
of 9C968)
9

O-Ring Grooves (Part of
9C968)
10

Mounting Plate (Part of
9C968)
11

Fuel Filter Screen (Part of
9C968)
12

Spring Seat (Part of 9C968)
13

Valve Assembly (Part of
9C968)
Fu e l P r e s s u r e Re l i e f Va l v e
The fuel pressure relief val ve ( 9H321) :
Is used t o relieve fuel pressure f rom the fuel delivery
syst em.
Is l ocated on the fuel injection suppl y manifold
( 9F792) .
For fuel syst em pressure relief procedures, refer t o
Secti on 10- 01.
Fu e l C h a r g i n g Wi r i n g
The fuel chargi ng wiring ( 9D930) :
Connects the engine control sensor wiring
( 12A581) t o each fuel injector ( 9F593) and other
el ectroni c engine control s such as throttl e position
sensor (TP sensor)(9B989) and idle air control
val ve (IAC val ve)(9F715).
Recei ves fuel injector signals f rom the powertrai n
control module ( PCM) ( 12A650) and transfers the
signals t o the fuel i nj ectors.
The signals f rom the powertrai n control module
determi ne the fuel injection sequence and duration
each fuel injector will st ay open t o allow fuel into the
combusti on chambers.
I n e r t i a Fu e l S h u t o f f ( I FS) S w i t c h
The inertia fuel shutoff swi t ch (IFS swi t ch)(9341):
Is used in conjunction wi th an el ectri c fuel pump
( 9350) .
Shuts off the fuel pump in the event of a collision.
Consi sts of a steel ball held in pl ace by a magnet.
When a sharp impact occurs:
03- 04- 5 Fue l Ch a r g i n g a n d C o n t r o l s 4 . 6 L ( 2 V) 03- 04- 5
DESCRIPTION AND OPERATION (Cont i nued) REMOVAL AND INSTALLATION
The ball breaks l oose f rom t he magnet, rolls up a
ramp and stri kes a t arget pl ate whi ch opens t he
el ectri cal cont act s of the inertia fuel shutoff swi t ch.
Thi s shuts off the fuel pump.
Once open, it must be manually reset bef ore
restarti ng t he vehicle.
POSITION FOR
OPEN SWITCH
RESET BUTTON
(SWITCH CLOSED)
A20827-A
Fu e l P u m p Re l a y
The fuel pump relay ( 14N089) suppl i es power t o t he
fuel pump ( 9350) when the powert rai n control module
( PCM) ( 12A650) grounds the rel ay during START and
engine running condi ti ons.
A / C Compressor Clut ch Cont rol Relay
The A / C compressor cl utch control relay ( 14N089)
i mproves idle smoothness after engine start-up and
al so i mproves accel erati on performance. The A / C is
cut off f or approxi matel y five seconds under the
fol l owi ng condi ti ons:
Just after t he engine is st art ed.
When t he throttl e position sensor (TP
sensor)(9B989) indicates a full throttl e condi ti on.
Fu e l C h a r g i n g S y s t e m
P r e - S e r v i c e P r o c e d u r e s
The fuel chargi ng syst em consi st s of the fuel injection
suppl y manifold ( 9F792) , fuel i nj ectors ( 9F593) , fuel
pressure regul ator ( 9C968) and t he i ntake manifold
( 9424) . Prior t o servi ce or removal of t he fuel chargi ng
syst em, the fol l owi ng st eps must be t aken:
2. Remove fuel t ank filler cap ( 9030) and rel ease
fuel tank pressure.
3. WARNI NG: THE FUEL SYSTEM IS NORMALLY
PRESSURI ZED TO 2 7 6 KPA ( 40 PSI ). USE
CARE WHE N SERVI CI NG THE FUEL SYSTEM
OR PERSONAL I NJURY MAY OCCUR.
Rel ease pressure f rom fuel syst em. Refer t o
Secti on 10-01 for fuel syst em pressure relief
procedures. A fuel pressure relief val ve ( 9H321)
on t he fuel injection suppl y manifold is provi ded
for thi s procedure.
P o s t - S e r v i c e P r o c e d u r e s
After the servi ce is compl et e and the fuel chargi ng
syst em is installed t o engine, the following st eps must
be t aken:
1. Install fuel tank filler cap at fuel tank ( 9002) .
3. Add engine coolant if requi red.
4. WARNI NG: THE FUEL SYSTEM IS NORMALLY
CARE WHEN SERVI CI NG THE FUEL SYSTEM
OR PERSONAL I NJURY MAY OCCUR.
NOTE: Check all connecti ons at fuel injection
supply manifold, fuel injectors and fuel line push
connect fi tti ngs, etc.
Turn ignition swi tch ( 11572) ON/ OFF several
ti mes wi thout starting engine t o check for fuel
l eaks.
5. Start engine and warm t o operati ng temperature.
Check for engine cool ant leak if cool ant was
removed.
Fuel Chargi ng and Cont rol s
Refer t o t he Powertrai n Control / Emissions Di agnosi s
Manual
2
for Di agnosi s and Testing Procedures of the
4. 6L SFI engine.
03- 04- 6 Fue l Ch a r gi n g a n d C o n t r o l s 4 . 6 L ( 2 V) 03- 04- 6
Perform Powertrai n Control Modul e (PCM)
Self-Test t o check syst ems functi on. Refer t o the
Powertrai n Cont rol / Emi ssi ons Di agnosi s
Manual .
3
Spri ng Lock Coupli ng
The spri ng l ock coupling is a fuel line coupling held
t oget her by a gart er spri ng inside a ci rcul ar cage.
When the coupling is connect ed, t he f l ared end of the
femal e fitting slips behind the gart er spri ng inside t he
cage of the male fi tti ng. The gart er spri ng and cage
then prevent t he fl ared end of the male fitting f rom
pulling out of t he cage. As a redundant l ocki ng feature,
a horseshoe-shaped retaining clip is i ncorporated t o
i mprove the retaining reliability of t he spri ng l ock
coupl i ng.
MALE
FITTING
CUP/TETHER ASSY
FEMALE FITTING
SPRING-LOCK
COUPLING
V7329-B
Re mo v a l
1
3.
WARNI NG: THE FUEL SYSTEM IS NORMALLY
CARE WHEN SERVI CI NG THE FUEL SYSTEM
OR PERSONAL INJURY MAY OCCUR.
Rel ease fuel syst em pressure. Refer t o Secti on
10-01 f or fuel syst em pressure relief procedures.
A fuel pressure relief val ve ( 9H321) on the fuel
injection suppl y manifold ( 9F792) is provi ded for
thi s procedure.
Remove retaining cl i p f rom spri ng l ock coupling
by hand only. Do not use any sharp tool or
screwdri ver because it may damage t he spri ng
l ock coupl i ng.
Twi st fitting t o free it f rom any adhesi on at t he
O-ring seal s.
Fit Spring Lock Coupling Di sconnect Tool
D87L-9280-A ( 3 / 8 inch) or D87L- 9280- B (112
inch) or equivalent t o coupl i ng.
5. Cl ose t ool and push into open si de of cage t o
expand gart er spri ng and rel ease femal e fi tti ng.
6. After gart er spri ng is expanded, pull fittings apart .
7. Remove tool f rom di sconnected coupling.
1. Make sure that gart er spri ng is in cage of male
fi tti ng. If gart er spri ng is missing, install a new
spri ng by pushing it into cage openi ng. If garter
spri ng is damaged, remove it f rom cage wi th a
small wi re hook (do not use a screwdri ver) and
install a new spri ng.
2. Clean all di rt or forei gn material f rom both pi eces
of coupl i ng.
3. WARNI NG: USE ONLY THE SPECI FI ED
O-RI NGS AS THEY ARE MADE OF A SPECI AL
MATERI AL. THE USE OF ANY O-RING OTHER
THAN THE SPECI FI ED O-RI NG MAY A L L OW
THE CONNECTI ON TO LEAK
I NTERMI TTENTLY DURI NG VEHI CLE
OPERATI ON.
Repl ace missing or damaged O-rings. Use only
O-rings l i sted in the following spri ng lock coupling
illustration.
Lubri cate male fitting and O-rings and inside of
femal e fi tti ng wi th clean engine oil
XO-10W30-QSP or -DSP or equivalent meeting
Ford speci fi cati on ESE-M2C153-E.
4. Fit femal e fitting t o male fitting and push until
garter spri ng snaps over fl ared end of femal e
fi tti ng.
5. Make sure of coupling engagement by pulling on
fitting and checki ng t o make sure garter spring is
over f l ared end of femal e fi tti ng.
6. NOTE: All vehi cl es require the l arge bl ack clip t o
be installed on the supply-side fuel line and the
small gray clip t o be installed on the return-side
fuel line.
Position retaining clip over metal portion of spring
l ock coupl i ng. Firmly push retaining clip onto
spri ng l ock coupl i ng. Make sure that horseshoe
portion of clip is over the coupling. Do not install
retaining clip over rubber fuel line.
03- 04- 7 Fue l Ch a r gi n g a n d C o n t r o l s 4 . 6 L (2V) 03- 04- 7
Spr i ng Lock Coupl i ng
TO DISCONNECT COUPLING
CAUTION RELIEVE FUEL PRESSURE
BEFORE DISCONNECTING COUPLING
TO CONNECT COUPLING
0
CLIP'
REMOVE CLIP FROM COUPLING
FEMALE MALE
0
CAGE
FLARE
O-RINGS SPRING
USE SPECIFIED
TOOL OR
EQUIVALENT
SPRING LOCK COUPLING
DISCONNECT TOOL:
D87L-9280-A 3/8 INCH
D87L-9280-B1/2 INCH

CAGE'
OPENING
FIT TOOL TO COUPLING SO THAT TOOL
CAN ENTER CAGE OPENING TO RELEASE
THE GARTER SPRING.
PUSH TOOL INTO
CAGE OPENING
NOTE: SPECIFIED
TOOL WILL FIT
AROUND RUBBER
COVERED FUEL LINE.

PUSH THE TOOL INTO THE CAGE
OPENING TO RELEASE THE FEMALE
FITTING FROM THE GARTER SPRING.
USE ONLY SPECIFIED FUEL
RESISTANT O-RINGS
(COLOR: BROWN)
REPLACEMENT O-RINGS
390846- S96 (3/8 INCH DIA<
2 PER FITTING)
390847- S96 (1/2 INCH DIA.
2 PER FITTING)
CHECK
FOR
CORROSION
LUBRICATE O-RINGS
CLEAN FITTINGS WITH SOLVENT. CHECK
FOR MISSING OR DAMAGED O-RINGS.
REPLACE MISSING O-RINGS. IF EITHER
O-RING IS DAMAGED, REPLACE BOTH O-RINGS.
REPLACEMENT GARTER SPRINGS:
3/8-INCH E1ZZ-19E576-A
1/2-INCH E1ZZ-19E576-B

PULL THE COUPLING MALE AND FEMALE
FITTINGS APART
GARTER SPRING

TO ENSURE COUPLING ENGAGEMENT.
PULL ON FITTING AND VISUALLY CHECK
TO BE SURE GARTER SPRING IS OVER
FLARED END OF FEMALE FITTING.
^ F U E L LINE
0
YES
TETHER
CLAMPED

REMOVE THE TOOL FROM THE
DISCONNECTED SPRING LOCK COUPLING
f RUBBER WRONG WHEN FLARE OR
FEMALE HOSE O-RINGS ARE SHOWING
V7332-C
Throt t l e Body
Removal
1. Remove ai r cl eaner out l et tube ( 9B659) f r om
throttl e body ( 9E926) .
2. Di sconnect t hrot t l e position sensor (TP
sensor)(9B989) f rom fuel chargi ng wi ri ng
( 9D930) and accel erat or cabl e ( 9A758) at t he
throttl e lever.
5.
1.
Remove four t hrot t l e body retaining bol ts.
Carefully separat e throttl e body f rom throttl e
body-to-i ntake manifold spacer.
Remove and di scard t hrot t l e body gasket
bet ween throttl e body and throttl e body-to-i ntake
manifold spacer.
NOTE: If scrapi ng is necessary, do not damage
gasket surf aces or al l ow materi al t o drop into
manifold.
Clean gasket mati ng surf aces.
Install throttl e body, new throttl e body gasket and
four bol ts t o t he throttl e body-to-i ntake manifold
spacer. Tighten retaining bol ts t o 8-12 N-m
( 71- 106 lb-in).
Connect throttl e position sensor t o fuel chargi ng
wi ri ng and accel erat or cabl e at t he throttl e lever.
Install air cl eaner outl et tube. Tighten engine air
cl eaner tube cl amps ( 9C632) t o 2.5-3.2 N-m
( 22- 28 lb-in).
3.
THROTTLE
BODY 9E926
THROTTLE BODY
GASKET 9E936
BOLT
4 REQ'D
TIGHTEN
TO
8-12 N-m
(71-106
LB-IN)
FRONT'OF^
ENGINE
THROTTLE
BODY-TO-INTAKE MANIFOLD
SPACER 9A589
V9847-A
Fu e l I n j e c t o r
Re mo v a l
1. Perform St eps 1 through 3 under Fuel Chargi ng
Syst em, Pre-Servi ce Procedures.
2. Remove fuel injection suppl y manifold ( 9F792) as
outlined.
3. Carefully remove connect ors f rom fuel chargi ng
wi ri ng ( 9D930) t o individual fuel injectors ( 9F593)
as requi red.
FUEL CHARGING
WIRING 9D930
ELECTRICAL
CONNECTOR
5.
FUEL
INJECTOR 9F593
V5059-B
4. Graspi ng fuel injector body, pull up whi l e gently
rocki ng fuel injector f rom si de t o si de.
FRONT OF ; ^ & l
ENGINE T S I at
V7602-B
Inspect fuel injector O-rings (t wo per fuel injector)
for signs of deteri orati on. Repl ace as requi red.
6. Inspect fuel injector end cap, body and washer for
signs of di rt and deteri orati on.
O-RING
WASHER-
END CAP-
O-RING
V3928-F
03- 04- 9 Fue l Ch a r g i n g a n d C o n t r o l s 4 . 6 L ( 2 V) 03- 04- 9
1. CAUTI ON: Newer use si l i cone gr ease. It wi l l
c l o g t h e f u e l i nj ect or s.
Lubri cate new O-rings wi th cl ean engine oil
XO-10W30-QSP or -DSP or equivalent meeti ng
Ford speci fi cati on ESE-M2C153-E.
2. Install fuel i nj ectors using a light, twi sti ng-pushi ng
moti on.
3. Install fuel injection supply manifold as outlined.
4. Install connect ors f rom fuel chargi ng wi ri ng t o fuel
injectors.
5. Perform St eps 1 through 6 of Fuel Chargi ng
Syst em Post-Servi ce Procedures.
Fuel Pressure Relief Valve
E FI / CFI Fue l P r e s s u r e Ga u ge T 80L - 997 4- B
Removal
1
2.
If fuel injection supply manifold ( 9F792) is
mounted t o engine, remove fuel t ank filler cap
( 9030) . Then rel ease pressure f rom syst em at
fuel pressure relief val ve ( 9H321) on fuel injection
suppl y manifold using EFI / CFI Fuel Pressure
Gauge T80L- 9974- B.
NOTE: Fuel pressure relief val ve cap ( 9H323) on
fuel pressure relief val ve must be removed.
Using an open-end wrench or suitable deep-wel l
socket , remove fuel pressure relief val ve.
FRONT OF ENGINE
V9240-A
Pa r t
Manifold
3 9F593 Fuel inj ector
4 N804394-S8M Bolt (4 Req'd)
5 9H321 Fuel Pressure Relief Valve
6 9H323 Fuel Pressure Relief Valve
Cap
Lb-ln)
B

Tighten t o 7.75 N-m (69
Lb-ln)
C

Tighten to 0.6 N-m (5.3 Lb-ln)
Install fuel pressure relief val ve and fuel pressure relief
val ve cap. Tighten fuel pressure relief val ve t o 7. 75
N-m ( 69 Ib-in) and the fuel pressure relief valve cap t o
0.6 N-m ( 5. 3 Ib-in).
Fuel Injection Supply Manifold
Removal
1. Perform Steps 1, 2 and 3 under Fuel Charging
Syst em, Pre-Service Procedures.
2. Remove air cleaner outlet tube ( 9B659) f rom
throttl e body (9E926).
3. Di sconnect vacuum line at fuel pressure regulator
( 9C968) .
4. Remove spri ng l ock coupling retainer clip f rom
fuel inlet and return fittings.
03- 04- 10 Fue l Ch a r gi n g a n d C o n t r o l s 4 . 6 L ( 2 V) 03- 04- 10
5. NOTE: The fol l owi ng items shoul d be noted when
servi ce is requi red:
Use speci fi ed tool or equivalent.
Inspect for missing or damaged O-rings.
Use t he speci fi ed fuel resi stant O-rings
(Brown).
Lubri cate t he O-ring wi t h cl ean engine oi l .
Make sure that t he fitting is l ocked.
Using Spring Lock Coupling Di sconnect Tool
D87L-9280-A ( 3 / 8 inch) or D87L- 9280- B ( 11 2
inch) or equivalent, di sconnect t he fuel suppl y and
return hoses f rom t he fuel injection suppl y
manifold ( 9F792) as outlined.
6. Di sconnect fuel chargi ng wiring ( 9D930) f r om fuel
i nj ectors ( 9F593) .
7. Remove four fuel injection suppl y manifold
retaining bol ts ( t wo on each si de).
8. NOTE: It may be easi er t o remove fuel i nj ectors
wi t h t he fuel injection supply manifold as an
assembl y.
Carefully di sengage fuel injection suppl y manifold
f rom fuel i nj ectors and remove fuel injection
suppl y manifold.
9. Use a rocki ng, side-to-side moti on whi l e lifting t o
remove fuel i nj ectors f rom fuel injection suppl y
mani fol d.
BOLT FUEL INJECTION
N804394-S8M SUPPLY MANIFOLD
4 REQ'D 9F792
1. CAUTI ON: Wh e n i n s t a l l i n g f u e l i n j e c t i o n
s u p p l y ma n i f o l d p a y p a r t i c u l a r a t t e n t i o n t o
p r o p e r s e a t i n g o f f u e l i n j e c t o r O- r i n gs t o
ma k e s u r e t h a t n o f u e l l e a ks e x i s t .
Push fuel injection suppl y manifold down t o make
sure all fuel i nj ector O-rings are fully seat ed in the
fuel injection suppl y manifold cups and i ntake
manifold ( 9424) .
2. Install retaining bol ts while holding down fuel
injection suppl y manifold. Tighten retaining bol ts
t o 8-12 N-m ( 71- 106 lb-in).
3. Install spri ng lock coupling as outlined.
4. Connect vacuum line t o fuel pressure regul ator.
5. Wi t h fuel chargi ng wi ri ng di sconnected, turn
ignition swi t ch ( 11572) t o t he RUN position t o
al l ow t he fuel pump ( 9350) t o pressuri ze the
syst em.
6. Using a cl ean t owel , check for fuel l eaks.
7. Connect fuel chargi ng wiring t o fuel i nj ectors.
8. Install air cl eaner outlet tube. Tighten engine air
cl eaner t ube cl amps ( 9C632) t o 2.5-3.2 N-m
( 22- 28 lb-in).
9. Run vehi cl e at idle for t wo minutes. Turn engine off
and i nspect for l eaks.
Fu e l P r e s s u r e R e g u l a t o r
Re mo v a l
Syst em, Pre-Servi ce Procedures if removing fuel
pressure regul ator ( 9C968) while fuel injection
suppl y manifold ( 9F792) is installed on engine.
2. Remove air cl eaner outlet tube ( 9B659) f rom
3. Remove vacuum line at fuel pressure regul ator.
4. Remove t wo Allen-head retaining scr ews f rom
fuel pressure regul ator housing and di scard.
5. Remove fuel pressure regulator, return seal and
O-rings. Di scard fuel pressure regulator return
seal and O-rings.
6. If scrapi ng is necessary, do not damage fuel
pressure regul ator or fuel injection supply
manifold sealing surfaces.
1. CAUTI ON: Ne v e r u s e s i l i c o n e gr e a s e . It wi l l
c l o g t h e f u e l i n j e c t o r s ( 9F593) .
Lubri cate new fuel pressure regulator O-rings
wi t h cl ean engine oil XO-10W30-QSP or -DSP or
ESE-M2C153-E.
2. Make sure sealing surf aces of fuel pressure
regul ator and fuel injection supply manifold are
cl ean.
3. Install new fuel pressure regulator O-rings and
new return seal on fuel pressure regulator.
4. Using new Allen-head retaining scr ews, install fuel
pressure regulator on fuel injection supply
mani fol d. Tighten retaining screws t o 3.0-4.5 N-m
( 27- 40 lb-in).
5. Install vacuum line t o fuel pressure regulator.
6. Install air cleaner outlet tube. Tighten engine air
cleaner tube cl amp ( 9C632) to 2.5-3.2 N-m
( 22- 28 lb-in).
03- 04- 11 Fue l Ch a r g i n g a n d C o n t r o l s 4 . 6 L ( 2V) 03- 04- 11
Syst em, Post-Servi ce Procedures.
Fu e l C h a r g i n g Wi r i n g
1. Remove air cl eaner outl et tube ( 9B659) f rom
2. Di sconnect fuel chargi ng wi ri ng ( 9D930) f r om fuel
injectors ( 9F593) and el ectroni c engine cont rol s.
3. Di sconnect fuel chargi ng wi ri ng f rom engine
control sensor wi ri ng ( 12A581) .
4. Remove fuel chargi ng wi ri ng retaining bol ts and
fuel chargi ng wiring f rom i ntake manifold ( 9424) .
5. To install, reverse Removal procedure. Ti ghten
fuel chargi ng wiring retaining bol ts t o 8-12 N-m
(71-106 Ib-in). Tighten engine air cl eaner t ube
cl amp ( 9C632) t o 2. 5-3. 2 N-m ( 22- 28 Ib-in).
Verify all el ectri cal connecti ons.
2. Locat e fuel pump rel ay ( 14N089) , l ocat ed in t he
engine compart ment power distribution center,
and remove fuel pump rel ay.
WARNI NG: DO NOT SMOKE OR CARRY LI GHTED
WORKI NG I N OR NEAR ANY FUEL- RELATED
COMPONENT. HIGHLY FL A MMA BL E MI XTURES
ARE A L WA YS PRESENT AND MAY BE I GNI TED,
CAUTI ON: T h e t h r o t t l e b o d y ( 9E 92 6) f o r t h i s
v e h i c l e i s a s l u d ge - r e s i s t a n t d e s i g n wi t h a c o a t i n g
o n t h e b o r e a n d pl a t e . Sl u d ge a c c u mu l a t i o n wi l l
n o t a f f e c t t h e t h r o t t l e b o d y a i r f l o w . A n y a t t e mp t
t o c l e a n t h e b o r e a n d pl a t e a r e a wi l l i mpa i r t h e
e f f e c t i v e n e s s o f t h e c o a t i n g . DO NOT c l e a n t h e
b o r e a n d p l a t e a r e a o f t h e t h r o t t l e b o d y .
Fu e l I n j e c t o r
T e s t i n g / C l e a n i n g
CAUTI ON: T h e f u e l i n j e c t o r s ( 9F593) f o r t h i s
v e h i c l e h a v e a d e p o s i t - r e s i s t a n t d e s i g n a n d
s h o u l d NOT be c l e a n e d o r f a i l u r e o f t h e f u e l
i n j e c t o r s ma y o c c u r .
Test fuel i nj ectors using Rotunda Fuel Injector
Test er/ Cl eaner 113-00001 or equivalent. Fol l ow tool
manufacturer' s operati ng i nstructi ons.
ADJUSTMENTS SPECIAL SERVICE TOOLS/EQUIPMENT
Idle Speed
NOTE: The throttl e body ( 9E926) for thi s vehi cl e
cannot be adj usted.
Refer t o the Powertrai n Cont rol / Emi ssi ons Di agnosi s
Manual .
4
SPECIFICATIONS
OBDI i 3. 8L Mu s t a n g , 4. 6L To wn Ca r , Cr o wn Vi c t o r i a ,
Co u ga r
TA1000B
En gi n e Ai r Cl e a n e r Tube Cl a mp s 2 . 5- 3. 2 2 2 - 2 8
T h r o t t l e Bo d y - t o - i n t a ke Ma n i f o l d
S p a c e r
8- 12 7 1- 106
Fue l P r e s s u r e Re l i e f Va l v e t o Fue l
I n j e c t i o n Su p p l y Ma n i f o l d
7 . 7 5 69
Fue l P r e s s u r e Re gu l a t o r - t o - Fu e l
I n j e c t i o n Su p p l y Ma n i f o l d
3- 4. 5 2 7 - 40
Fue l I n j e c t i o n Su p p l y
Ma n i f o l d - t o - l n t a ke Ma n i f o l d
8- 12 7 1- 106
Fue l P r e s s u r e Re l i e f Va l v e Ca p 0. 6 5. 3
Fue l Ch a r gi n g Wi r i n g t o I n t a ke
Ma n i f o l d Bo l t s
8- 12 7 1- 106
Tool Numbe r /
De s c r i p t i o n I l l ust rat i on
T 80L - 997 4- B
E FI / C FI Fu e l P r e s s u r e Ga uge
T80L-9974-B
D87 L - 92 80- A Spr i n g L o c k Co upl i n g Di s c o n n e c t To o l
( 3 / 8 I n c h)
D87 L - 92 80- B Spr i n g L o c k Co upl i n g Di s c o n n e c t To o l
( 1 / 2 I n c h)
ROTUNDA EQUIPMENT
113- 00001 Fue l I n j e c t o r T e s t e r / Cl e a n e r
4 P u r c h a s e d s e p a r a t e l y , r e f e r t o t h e e n d o f t h i s S e c t i o n f o r v e h i c l e a p p l i c a t i o n s .
03- 05- 1 Dr i ve Be l t s , A c c e s s o r y 03- 05- 1
SECTION 03-05 Drive Belts, Accessory
SUBJECT PAGE
Drive Bel t s, Accessory 03-05-1
Component Tests ....03-05-3
Drive Belt Tensioner, Aut omat i c. . . 03-05-3
Inspecti on and Veri fi cati on 03-05-2
Sy mpt om Chart . 03-05-2
SUBJECT PAGE
Dri ve Bel t Repl acement 03-05-3
Dri ve Bel t , Serpent i ne .....03-05-3
Dri ve Bel t Tensi oner, A u t o ma t i c . . . . 03-05-4
ADJUSTMENTS
Dri ve Bel t Tensi on Adj ust ment 03-05-4
Dri ve Bel t Tensi oner, Aut omat i c 03-05-4
SPECIFICATIONS .03-05-5
VEHICLE APPLICATION
Dr i v e B e l t s , A c c e s s o r y
NOTE: Dri ve belts ( 8620) wi t h automati c drive belt
tensi oners ( 6B209) do not require adj ustment.
NOTE: When a dri ve belt is repl aced or reinstalled
after a servi ce procedure, the dri ve belt does not fully
seat into pulley grooves until engine has run for several
minutes.
Thi s vehi cl e is equi pped wi t h:
A " V' - r i bbed serpentine accessor y dri ve belt.
An automati c drive belt tensi oner.
Repl acement dri ve bel ts should be of t he same t ype as
originally installed.
The dri ve belt condition should be checked:
At 96, 000 km ( 60, 000 miles).
Then every 24, 140 k m( 15, 000 miles).
Q2258-B
Dri ve belt chi rp is a regularly occurri ng " chi r pi ng"
noise t hat occurs due t o:
Pulley misalignment.
Excessi ve pulley runout.
It can be a result of a damaged pulley or an improperly
repl aced pulley that was not properl y aligned.
To cor r ect dri ve belt chi rp:
Determi ne the area where the noise comes f rom.
Check each of the pulleys in that area wi th a
st rai ght edge t o the crankshaft pulley ( 6312) .
Look for the accessory pulley t o be out of position in
the f or e/ af t di recti on or at an angle t o the
strai ghtedge.
Dri ve belt squeal is an intermittent noise that occurs
when the dri ve belt slips on a pulley during certai n
condi ti ons such as:
Engine start-up.
Rapid engine accel erati on.
A/ C cl utch engagement.
Drive belt squeal can occur under the following
condi ti ons:
If the A / C di scharge pressure goes above 2895
kPa ( 420 psi ). This can occur if:
The A / C syst em is overcharged.
The A/ C condenser ai rfl ow is bl ocked.
The engine cooling fan is not engaging fully at
idle.
If any of the accessori es are damaged, have a worn
or damaged bearing or internal torsi onal resi stance
above normal for any reason. All of the accessori es
should be rotatabl e by hand in the unloaded
condi ti on. If any are not, t he accessory should be
i nspected.
If fluids get on the dri ve belt. This woul d include
power steeri ng fluid, engine cool ant, engine oil and
air conditioning syst em lubricant.
If fluid does get on the dri ve belt during servi ce,
clean the dri ve belt wi th soap and wat er and
thoroughl y rinse wi th clean water. The drive belt
does not have to be repl aced if no apparent damage
has occurred.
03- 05- 2 Dr i v e Be i t s , A c c e s s o r y 03- 05- 2
If t he dri ve belt is t oo long, it woul d allow the arm on
the dri ve belt tensioner t o go all the way t o drive belt
tensioner arm travel stop under certai n load
condi ti ons, whi ch will remove the tension on the
dri ve belt. If the drive belt tensioner is resting on the
st op, repl ace the dri ve belt.
NOTE: The dri ve belt tensioner arm should rotate
freel y wi thout binding. If the drive belt is worn or
damaged, repl ace the dri ve belt.
Inspection and Verification
1. Verify t he vehicle owner' s original concern by
operati ng the engine to dupl i cate the condi ti on.
2. Inspect t o determi ne if any of the following
Mechanical
Dr i v e be l t n o i s e or s q u e a l .
Pul l e y mi s a l i gn me n t o r e x c e s s i v e pul l e y r un o ut .
3. Inspect for dri ve belt cracki ng / chunki ng / wear as
outl i ned.
4. If t he concerns remain after the inspections,
determi ne the sympt oms and go to the Sympt om
Chart.
Dr i v e Be l t C r a c k i n g / C h u n k i n g / We a r
Under severe operati ng condi ti ons (high
t emperat ures, low humidity), dri ve belt rib cracki ng
can occur at less than 80, 000 km ( 50, 000 miles).
Dri ve belt rib cracki ng ( cr acks across backi ng):
Is not a reason for concern.
Has no detri mental effect on dri ve belt performance.
However, cr acks running wi th backi ng are not
accept abl e.
The dri ve belt ( 8620) is still perfectl y functional until rib
" chunki ng" occurs. Drive belt " chunki ng" is where
the rubber materi al actually chunks out between the
cr acks. The drive belt should be repl aced if chunking
occurs.
" V" Ri bbe d Se r pe n t i n e Dri ve Bel t Wi t h Cr a c ks
Ac r o ss Ba c ki n g
CRACKS ACROSS RIBS ARE ACCEPTABLE.
CRACKS PARALLEL TO BACKING ARE NOT.
Q2059-C
"V" Ri bbe d Se r pe n t i n e Dri ve Bel t Wi t h Chun ks of
Rib Mi ssi ng
CHUNKS OF RIBS MISSING ARE
NOT ACCEPTABLE
Q3243-C
Symptom Chart
ACCESSORY DRIVE BELTS
Drive Belt Cracking Drive belt. System OK.
Drive Belt Chunking Drive belt. REPLACE drive belt as outlined.
Drive Belt Noise or Squeal Drive belt.
Pulley(s).
DETERMINE what area of the
pulley(s) the noise is coming from,
then CHECK that area with a
strai ghtedge and LOOK for the
accessory pulley(s) to be out of
position in the f ore/af t direction or
at an angle to the strai ghtedge.
Dr i v e Be i t s , A c c e s s o r y 03- 05- 3
Dr i ve Bel t Tens i oner , Au t o ma t i c
The automati c dri ve belt tensioner ( 6B209) can be
checked as f ol l ows:
1. Wi th t he engine running, observe dri ve belt
tensi oner movement. The drive belt tensioner
should move (respond) when the A / C
compressor cycl es or when the engine is
accel erat ed rapi dl y. If t he drive belt tensioner
movement is constant and excessi ve, a pulley or
shaft is probabl y bent or a pulley is out of round.
In rare cases, excessi ve dri ve belt rideout
(uneven dept h of grooves in drive belt ( 8620) )
can cause excessi ve dri ve belt tensioner
movement. Thi s condi ti on can be checked by
repl aci ng the suspect dri ve belt wi t h a new dri ve
belt and repeati ng the observati on.
2. Wi t h engine off, check f or proper routing of t he
dri ve belt. Refer t o the illustrations under Removal
and Installation. Servi ce as requi red.
3. Inspect the dri ve belt tensioner wear indicator as
outlined under Dri ve Belt Tensioner, Automati c in
Adj ustments, t o ensure the drive belt is withing
operati ng range. Repl ace the drive belt as
requi red.
4. Rotate the dri ve belt tensioner and check for a
binding or frozen condi ti on. Repl ace components
as requi red.
Dr i v e Be l t R e p l a c e m e n t
Dr i v e Be l t , S e r p e n t i n e
WARNI NG: DO NOT A L L OW DRIVE BELT
TENSI ONER ( 6B2 09) TO SNAP BA CK AS DAMAGE
TO DRI VE BELT TENSI ONER OR PERSONAL
I NJURY COULD RESULT
NOTE: Minor cr acks in the " V" - gr ooved porti on of t he
dri ve belt ( 8620) are consi dered normal and
accept abl e. If the dri ve belt has chunks missing f rom
the ri bs, the dri ve belt should be repl aced.
Conditions requiring drive belt repl acement are rib
chunk-out, severe glazing, f rayed cords or other
concerns. Repl ace any drive belt exhibiting one of
t hese condi ti ons.
1. Rot at e dri ve belt tensioner away f rom dri ve belt
wi t h a breaker bar installed in the 1 / 2-inch
square hole in dri ve belt tensi oner arm.
2. Lift dri ve belt over generator pulley fl ange and
remove.
3. NOTE: Make sure dri ve belt is properl y installed
on each pulley.
NOTE: When installing dri ve belt on pul l eys,
ensure that all grooves make proper cont act wi t h
pulleys.
To install, position drive belt over pul l eys. Make
sure t hat all "V"- gr o o v e s make proper cont act
wi t h pulley as shown.
DRIVE BELT
8620
PULLEY
Q1834-C
03- 05- 4 Dr i v e Be l t s , A c c e s s o r y 03- 05- 4
Dr i ve Bel t Rout i ng
Q3003-C
I t e m
Pa r t
1 10300 Generator
3 3A733 Power Steering Pump Pulley
4 6312 Crankshaft Pulley
5 19703 A/ C Compressor
6 8620 Drive Belt
7 6B209 Drive Belt Tensioner
8 8678 Belt Idler Pulley
Dr i v e Be l t T e n s i o n e r , A u t o m a t i c
1. Remove serpenti ne dri ve belt ( 8620) as outlined.
2. Remove RH ignition coil ( 12029) f rom dri ve belt
tensioner ( 6B209) and engine front cover ( 6019)
as outlined in Secti on 03- 07.
3. Remove dri ve belt tensioner retaining nut and
bol ts and drive belt tensioner f rom engine front
cover.
dri ve belt tensioner retaining nut and bol ts t o
20- 30 N-m (16-22 Ib-ft).
NUT
TIGHTEN
TO
20-30 N-m
(15-22 LB-FT)
BOLT
2 REQ'D
TIGHTEN TO
20-30 N-m
(15-22 LB-FT)
DRIVE BELT
TENSIONER
6B209
ENGINE FRONT
LOWER 6019
Q3730-A
ADJUSTMENTS
Dr i v e Be l t T e n s i o n A d j u s t m e n t
S e r p e n t i n e Dr i v e Be l t
Dri ve bel ts ( 8620) have an automati c dri ve belt
tensioner ( 6B209) and do not require adjustment.
Dr i v e Be l t T e n s i o n e r , A u t o m a t i c
NOTE: The dri ve belt tensioner indicator mark
i nspecti on is done wi th the engine OFF at 96, 000 km
( 60, 000 mile) intervals.
Automati c dri ve belt tensi oners ( 6B209) are
spri ng-l oaded devi ces whi ch set and maintain the dri ve
belt tensi on. The dri ve belt ( 8620) should not require
tension adjustment for the life of the dri ve belt. The
dri ve belt is worn or an i ncorrect drive belt has been
installed if the tab is resting against a st op.
03- 05- 5 Dr i v e Be l t s , A c c e s s o r y 03- 05- 5
Locat e the t ab on t he mounting pl ate of dri ve belt
tensioner. The t ab should be approxi matel y bet ween
the st ops of the dri ve belt tensi oner arm.
SPECIFICATIONS
Description N-rn Lb-Ft
Dr i v e Be l t Te n s i o n e r Re t a i n i n g Nut
a n d Bo l t s
2 0- 30 15- 22
03- 06- 1 St a r t i n g S y s t e m 03- 06- 1
SECTION 03-06 Starting System
SUBJECT PAGE
Sequence of Operati on 03-06-2
Starter .......03-06-2
Starter System ..03-06-1
Component Tests .......03-06-7
Armat ure .....03-06-12
Starter 03-06-7
Starter Sol enoi d 03-06-12
El ectri cal Schemat i c. . . ...03-06-3
Pinpoint Tests 03-06-5
Symptom Chart 03-06-5
Starter Mot or. ....03-06-13
SUBJECT PAGE
Armature Repl acement, Starter Motor 03-06-16
Bushings 03-06-16
Starter Drive Repl acement . 03-06-15
Starter Motor...... 03-06-14
SERVICE PROCEDURES
Jump St art i ng 03-06-16
Road Servi ce 03-06-16
Armature Coi l , Starter Motor..................... 03-06-17
Bushings ...........03-06-18
Starter Drive and Fl ywheel Ring Gear
Inspecti on 03-06-18
Starter Frame and Magnet 03-06-18
VEHICLE APPLICATION
S t a r t e r S y s t e m
The st art er syst em operat es as f ol l ows:
The functi on of the starti ng syst em is t o crank t he
engine at a speed f ast enough t o permi t t he engine
t o st art .
Heavy cabl es, connect ors and swi t ches are used in
t he starti ng syst em because of the l arge current
requi red by t he st art er motor ( 11002) whi l e it is
cranki ng the engine.
The amount of resi st ance in t he starti ng ci rcui t must
be kept t o an absol ute minimum t o provi de maxi mum
current for st art er motor operati on.
A di scharged or damaged bat t ery ( 10653) , l oose or
cor r oded connecti ons or partially broken cabl es will
result in sl ower than normal cranki ng speeds. These
concerns may even prevent t he st art er motor f rom
cranki ng the engine.
In case of starti ng syst em difficulty, t he operat or
may have di scharged t he bat t ery bef ore calling for
assi st ance.
A road servi ce procedure is outlined in thi s secti on
t o ai d t he servi ce techni ci an in such cases of a
di scharged bat t ery.
The starti ng syst em includes:
The permanent magnet gear-reducti on st art er
motor wi t h a sol enoi d-actuated dri ve.
The bat t ery.
A remot e control st art er swi t ch (part of t he ignition
swi t ch ( 11572) ) .
The transmi ssi on range (TR) sensor.
Heavy circuit wi ri ng.
STARTER MOTOR
11002
J4488-B
Vehicles equi pped wi th an automati c transmission
have a transmi ssi on range (TR) sensor in the starter
control ci rcui t. This sensor prevents operati on of the
starter motor unless the sel ector lever is in the
NEUTRAL or PARK posi ti on.
03- 06- 2 S t a r t i n g S y s t e m 03- 06- 2
Starter
The st art er mot or ( 11002) is a 12-volt unit that has
a st art er sol enoi d ( 11390) mounted on t he dri ve end
housi ng.
The motor is energi zed when the st art er solenoid
cont act s are cl osed.
Thi s engages t he starter dri ve ( 11350) wi t h the
f l ywheel ring gear and st art s t he engi ne.
An overrunning cl utch in t he st art er dri ve prot ect s
t he st art er mot or f rom excessi ve speed when t he
engine st art s.
The current f l ows through t he sol enoi d energizing
coi l until t he sol enoi d plunger is at the end of its
t ravel .
The plunger then cl oses a set of cont act s that
bypass the energizing coi l , letting the holding coil
keep t he st art er dri ve engaged and passi ng starti ng
current t o the st art er motor.
S e q u e n c e o f O p e r a t i o n
1. The ignition swi t ch ( 11572) is turned t o t he
START posi ti on.
2. Vol tage is provi ded t o t he st art er sol enoi d
( 11390) . The st art er solenoid is energi zed
di rectl y f rom the ignition ci rcui try. A magneti c field
is creat ed in the solenoid coi l .
3. The iron plunger cor e is drawn into t he sol enoi d
coi l .
4. A lever connect ed t o t he st art er dri ve ( 11350)
engages t he dri ve pinion gear t o t he f l ywheel ring
gear.
5. When t he iron plunger core is all t he way into the
coi l , its cont act di sc cl oses the ci rcui t bet ween
t he bat t ery ( 10653) and the st art er mot or
termi nal s.
6. The current f l ows t o t he motor. The st art er dri ve
gear cr anks t he fl ywheel ( 6375) and t he engine
7. As current f l ows to t he motor, t he sol enoi d pull-in
coil is bypassed.
8. The hold-in coil keeps the st art er dri ve engaged
wi t h t he f l ywheel .
9. The st art er dri ve remains engaged until the
ignition swi t ch is rel eased from t he START
posi ti on.
An overrunning cl utch in t he st art er dri ve prot ect s the
st art er motor ( 11002) f rom excessi ve speeds during
t he brief peri od before t he driver rel eases t he ignition
swi t ch f rom t he START position (as t he engine st art s).
03- 06- 3
S t a r t i n g S y s t e m 03- 06- 3
Electrical Schematic
St a r t e r Sy st e m
HOT AT ALL TIMES
POWER
DISTRIBUTION
BOX |
""IGNITION
| | SWITCH
TRANSMISSION
RANGE (TR)
R/LB
STARTER
MOTOR/
SOLENOID
1+ 1 BATTEI
T
57 1 BK
POWER
DISTRIBUTION
of this circuit
TRANSMISSION RANGE (TR)
SENSOR CONNECTOR
K21039-B
Pin
3 140
( B K / P K )
Ba c k- u p L a mp
4 33 ( W/ P K ) St a r t e r Co n t r o l t o I n t e r l o c k Mo d u l e
5 No t Us e d
6 199 ( L B / Y ) Tr a n s mi s s i o n Ra n ge Se n s o r t o
P CM
7 359
( G Y/ R )
Se n s o r Si gn a l Re t ur n
8 Not Us e d
Pin
1 3 2 ( R / L B ) St a r t e r Co n t r o l
2 2 98 ( P / O ) Fu s e d Run On l y Fe e d
1995 To wn Ca r , Cr o wn Vi c t o r i a , Gr a n d Ma r q ui s Jul y 1994
03- 06- 4 St a r t i n g S y s t e m
~ ~ Y Z
0 3 - 0 6 - 4
K3) ( A2) ^T /
IGNITION SWITCH CONNECTOR
K22549-A
Pi n
12 No t Us e d
B1 37 ( Y) Ba t t e r y I nput
A 1 2 97
( B K / L G )
Hot i n RUN o r A CC Out put
A 3 687
( G Y/ Y)
Ho t in RUN
11 1 6 ( R / L G ) Ho t i n START o r RUN
A 4 687
( G Y/ Y)
Ho t i n RUN
STA 33 ( W/ P K ) Ho t in START |
A 2 2 62
( B R / P K )
Ho t i n RUN
P 2 97 7 ( P / W) Gr o u n d e d i n START
GND 57 ( BK) Gr o un d I nput
P 1 No t Us e d
1. WARNI NG: WHEN SERVI CI NG STARTER
MOTOR ( 11002 ) OR PERFORMI NG OTHER
UNDERHOOD WORK IN THE VI CI NI TY OF THE
STARTER MOTOR, BE AWARE THAT THE
HEAVY GAUGE BATTERY I NPUT L E AD AT
THE STARTER SOLENOI D ( 11390) IS
"ELECTRI CALLY HOT " A T A L L TI MES.
A PROTECTI VE CAP OR BOOT IS PROVI DED
OVER THI S TERMI NAL THAT MUST BE
REPLACED AFTER SERVI CI NG. BE SURE T O
DI SCONNECT BATTERY GROUND CABL E
( 14301) BEFORE SERVI CI NG STARTER.
WARNI NG: WHEN WORKI NG I N AREA OF THE
STARTER, BE CAREFUL TO AVOI D
TOUCHI NG HOT EXHAUST COMPONENTS.
CAUTI ON: Wh e n d i s c o n n e c t i n g t h e pl a s t i c
h a r d s h e l l c o n n e c t o r a t t h e s o l e n o i d
S- t e r ml n a l , gr a s p t h e pl a s t i c c o n n e c t o r a n d
pul l l e a d o f f . DO NOT pul l s e p a r a t e l y o n l e a d
wi r e .
Veri f y t he vehi cl e owner ' s ori gi nal concer n by
oper at i ng t he st ar t er sy st e m t o dupl i cat e t he
condi t i on.
2. I nspect t o det ermi ne if any of t he mechani cal or
el ect ri cal concer ns appl y:
St a r t e r mo t o r mo un t i n g
mi s a l i g n e d .
Fl y wh e e l r i n g ge a r t o o t h
d a ma g e .
Co n n e c t i o n s l o o s e ,
d a ma g e d o r s h o r t i n g.
Da ma g e d b a t t e r y .
If the concerns remain after the i nspecti on,
Chart.
1995 To wn Car, Cr o wn Vi c t o r i a , Gr a n d Ma r q ui s Jul y 1994
03- 06- 5 Starting System 03- 06- 5
Sympt om Chart
STARTER SYSTEM DIAGNOSIS
CONDITION P O S S I B L E S O U R C E ACTION
Engine Cranks Slowly Low b a t t e r y .
Ground not secure.
Connections loose.
Inoperative starter motor.
Shorted fuse or ignition swi t ch.
Engine Does Not Crank Low battery.
Open fuse.
Open ignition swi t ch.
Shorts to ground.
Fuel syst em.
Engine syst em.
Unusual Starter Noise Starter motor.
Flywheel ring gear tooth damage
or excessi ve ring gear runout.
Inoperative components.
PINPOINT TEST A: ENGINE CRANKS SLOWLY
A1 CHECK FOR VOLTAGE TO STARTER
Yes
No
GO to A2.
CHECK wire connections
between battery and
starter solenoid. CHECK
ground connections at
battery to ground and
starter solenoid t o ground
for an open, short or
security. If secure,
and check battery
charging system.
NOTE: Hoist vehicle (if necessary) to access starter
solenoid terminals.
NOTE: Remove plastic safety cap on starter solenoid
and di sconnect hardshell connector at starter solenoid
"S" terminal as descri bed under Removal and
Installation in this sect i on.
Ignition swi tch OFF. Transmission in PARK or
NEUTRAL.
Using Rotunda Digital Volt-Ohmmeter 014-00407 or
equivalent, check for voltage from starter " B + "
terminal to starter drive end housing (ground).
Does vol t met er i ndi cat e 12 t o 12.45 vol t s DC?
Yes
No
GO to A2.
CHECK wire connections
between battery and
starter solenoid. CHECK
ground connections at
battery to ground and
starter solenoid t o ground
for an open, short or
security. If secure,
and check battery
charging system.
A2 MANUALLY CRANK STARTER
Yes
No
GOt o A3.
REPLACE starter motor.
Installation procedures in
thi s secti on. RETEST new
starter motor.
Ignition swi tch OFF. Transmission in PARK or
NEUTRAL.
Connect one end of a j umper wire to the starter
" B+ " terminal and momentarily touch t he other end
to solenoi d "S" terminal.
Does st ar t er mot or cr ank and cr ank qui c kl y ?
Yes
No
GOt o A3.
REPLACE starter motor.
Installation procedures in
thi s secti on. RETEST new
starter motor.
A3 CHECK CIRCUITRY TO STARTER
Yes
No ^
t o check ignition switch
for shorts. CHECK
ignition fuse for short to
ground.
REPLACE ISO-starter
relay as required.
SERVICE or REPLACE
ci rcui t(s) that are open or
shorted as required.
Check Circuit 37 (Y) for open between ignition fuse
and starter motor. Check ISO-starter relay. Check
for short to ground.
Check Circuit 33 (W / PK) and 32 (R / LB) for open
between ignition swi tch and starter motor. Check for
short (s) t o ground.
Does t he ci r cui t r y f r o m st art er mot or ret ai n
c ont i nui t y and have no short s t o gr ound?
Yes
No ^
t o check ignition switch
for shorts. CHECK
ignition fuse for short to
ground.
REPLACE ISO-starter
relay as required.
SERVICE or REPLACE
ci rcui t(s) that are open or
shorted as required.
03- 06- 6 S t a r t i n g S y s t e m 03- 06- 6
PINPOINT T E ST B: ENGINE DOES NOT CRANK
TE ST STEP RESULT A CT I ON T O T A KE
B1 CHECK FOR VOLTAGE TO STARTER
Ye s
No
GO t o B2.
CHECK wi r e c o n n e c t i o n s
b e t we e n ba t t e r y a n d
st a r t e r s o l e n o i d . CHECK
gr o un d c o n n e c t i o n s at
ba t t e r y t o gr o un d a n d
st a r t e r so l e n o i d t o gr o un d
f or an o pe n , sho r t o r
se c ur i t y . If s e c u r e ,
REFER t o Se c t i o n 14-00
a n d c h e c k ba t t e r y
c ha r gi n g s y s t e m.
NOTE: Ho i st v e hi c l e (i f n e c e s s a r y ) t o a c c e s s s t a r t e r
so l e n o i d t e r mi n a l s.
NOTE: Re mo v e pl a st i c sa f e t y c a p on st a r t e r s o l e n o i d
a nd d i s c o n n e c t ha r d she l l c o n n e c t o r at s o l e n o i d " S "
t e r mi n a l a s d e s c r i b e d under Re mo v a l a nd I n st a l l a t i o n in
t hi s s e c t i o n .
I gni t i on s wi t c h OFF. Tr a n smi ssi o n in PARK or
NEUTRAL.
Usi n g Ro t un d a Di gi t a l Vo l t - Ohmme t e r 014-00407 or
e qui va l e n t , c h e c k f o r v o l t a ge f r o m st a r t e r " B + "
t e r mi n a l t o st a r t e r d r i ve e n d ho usi n g ( gr o un d ) .
Does voltmeter indicate 12 to 12.45 volts DC?
Ye s
No
GO t o B2.
CHECK wi r e c o n n e c t i o n s
b e t we e n ba t t e r y a n d
st a r t e r s o l e n o i d . CHECK
gr o un d c o n n e c t i o n s at
ba t t e r y t o gr o un d a n d
st a r t e r so l e n o i d t o gr o un d
f or an o pe n , sho r t o r
se c ur i t y . If s e c u r e ,
a n d c h e c k ba t t e r y
c ha r gi n g s y s t e m.
B2 MANUALLY CRANK STARTER
Ye s
No
GO t o B3.
REPLACE st a r t e r mo t o r .
REFER t o Re mo v a l a n d
I n st a l l a t i o n p r o c e d u r e s i n
t hi s s e c t i o n . RETEST n e w
st a r t e r mo t o r .
I gni t i on s wi t c h OFF. Tr a n smi ssi o n in PARK or
NEUTRAL.
Co n n e c t one e n d of a j umpe r wi r e t o t he s t a r t e r
" B + " t e r mi n a l a nd mo me n t a r i l y t o u c h t he o t he r e n d
t o so l e n o i d " S " terminal.
Does starter motor crank and crank qui ckl y?
Ye s
No
GO t o B3.
REPLACE st a r t e r mo t o r .
REFER t o Re mo v a l a n d
I n st a l l a t i o n p r o c e d u r e s i n
t hi s s e c t i o n . RETEST n e w
st a r t e r mo t o r .
B3 CHECK CI RCUI TRY TO STARTER
Ye s
No
GO t o B4.
REPLACE I SO- st a r t e r
r e l a y a s r e qui r e d .
SERVI CE or REPLACE
c i r c ui t ( s) t ha t a r e o pe n o r
s h o r t e d a s r e qui r e d .
Ch e c k Ci r c ui t 37 ( Y) f or o pe n be t we e n i gn i t i o n f use
a n d st a r t e r mo t o r . Ch e c k I SO- st a r t e r r e l a y . Ch e c k
f o r sho r t t o gr o un d .
Ch e c k Ci r c ui t 33 ( W / PK) a nd 32 (R / LB) f o r o pe n
b e t we e n i gni t i on s wi t c h a n d st a r t e r mo t o r . Ch e c k f o r
s h o r t ( s ) t o gr o un d .
Does the circuitry f r om starter motor retain
continuity and have no shorts to ground?
Ye s
No
GO t o B4.
REPLACE I SO- st a r t e r
r e l a y a s r e qui r e d .
SERVI CE or REPLACE
c i r c ui t ( s) t ha t a r e o pe n o r
s h o r t e d a s r e qui r e d .
B4 CHECK I GNI TI ON FUSE
Ye s
No
GO t o B5.
GO t o B6.
Ch e c k i gni t i on f use in t he e ngi ne c o mpa r t me n t
po we r d i st r i but i o n bo x .
Is ignition f use open?
Ye s
No
GO t o B5.
GO t o B6.
B5 CHECK FOR GROUNDED POWER FEED
Ye s
No
SERVI CE or REPLACE
sho r t t o gr o un d .
REPLACE i gni t i on f use
a n d RETEST st a r t e r
s y s t e m.
s y s t e m.
Ch e c k Ci r c ui t 37 ( Y) f r o m t h e i gni t i on f use s o c ke t t o
gr o un d .
Does continuity exi st ?
Ye s
No
SERVI CE or REPLACE
s y s t e m.
s y s t e m.
B6 CHECK FOR I GNI TI ON SWI TCH FEED
Ye s
No
GO t o B7.
SERVI CE or REPLACE
o pe n or s h o r t e d c i r c ui t a s
r e qui r e d . RETEST s t a r t e r
s y s t e m.
Ch e c k v o l t a ge t o t h e i gni t i on s wi t c h .
Does voltmeter indicate 10-12 volts DC?
Ye s
No
GO t o B7.
SERVI CE or REPLACE
o pe n or s h o r t e d c i r c ui t a s
r e qui r e d . RETEST s t a r t e r
s y s t e m.
B7 CHECK I GNI TI ON SWI TCH FOR OPEN
Ye s
No
CHECK f uel s y s t e m.
REFER to Se c t i o n 10-00.
CHECK e ngi ne s y s t e m.
REFER t o Se c t i o n 03-01.
I gni t i on swi t c h i s o pe n .
REPLACE as r e qui r e d .
RETEST st a r t e r s y s t e m.
Re i n st a l l st a r t e r s y s t e m.
Wi t h i gn i t i o n s wi t c h in t he START po si t i o n , c h e c k
v o l t a ge f r o m t he " ST " t e r mi n a l on t he i gni t i on swi t c h
t o gr o un d .
Does voltmeter indicate 10t o 12 volts DC?
Ye s
No
CHECK f uel s y s t e m.
REFER to Se c t i o n 10-00.
CHECK e ngi ne s y s t e m.
I gni t i on swi t c h i s o pe n .
REPLACE as r e qui r e d .
RETEST st a r t e r s y s t e m.
03- 06- 7 St a r t i n g S y s t e m 03- 06- 7
PINPOINT TEST C: UNUSUAL STARTER NOISE
C1 CHECK STARTER MOUNTING
Yes
No B>
GO to C 2 .
SERVICE or REPLACE
wiring or component
mountings as required.
RETEST starting system
for noises.
Check starter motor mounting to be flushed (not
cocked). Check that all connections are secure.
Refer to Removal and Installation for mounting
information.
Check other necessary components related t o the
starting system to be securely mounted (ignition
swi t ch, di stri butor, battery and transmission
swi t ches).
Check wiring connections for damage or shorting
due to corrosi on or stray wi res.
Are t he st a r t i ng sy st e m c ompone nt s and wi r i ng
secure and undamaged?
Yes
No B>
GO to C 2 .
SERVICE or REPLACE
wiring or component
mountings as required.
RETEST starting system
for noises.
C 2 CRANK ENGINE
Yes
No
REPLACE starter
solenoid.
If noise sounds like
shorting or sparki ng,
check grounded feeds to
battery or starter motor.
knocking, REFER to
Section 03-01 for engine
inoperation diagnosis.
Put ignition swi tch in START then RUN posi ti on. As
engine is "st art i ng, " listen to individual components
for noise due t o gear t oot h damage, shorti ng,
sparking or knocki ng.
Pinpoint noise to component.
Is noi se due t o ri ng gear t o o t h damage?
Yes
No
REPLACE starter
solenoid.
shorting or sparki ng,
check grounded feeds to
battery or starter motor.
knocking, REFER to
Section 03-01 for engine
inoperation diagnosis.
S t a r t e r
L o a d Te s t
Conduct thi s t est if t he st art er motor ( 11002) cr anks
sl owl y and al so t o compare t he current t o
speci fi cati ons.
1. Connect Rotunda Starti ng and Chargi ng Tester
(VAT-40) 078- 00005 or equivalent. Make sure
t hat current is not fl owi ng through ammeter and
heavy-duty carbon pile rheost at porti on of ci rcui t
(rheost at at maxi mum count ercl ockwi se
posi ti on).
2. NOTE: Make sure ignition swi t ch ( 11572) is in
OFF position and S-terminal connector has been
removed so engine does not start.
Pl ace transmi ssi on in NEUTRAL or PARK. Crank
engine wi t h ignition swi t ch OFF and determi ne
exact reading on voltmeter. This test is
accompl i shed by di sconnecti ng push-on
connector S at starter solenoid ( 11390) and
connecti ng a remote-control starter swi t ch f rom
posi ti ve battery terminal t o S-terminal of st art er
sol enoi d.
03- 06- 8 St a r t i n g Sy s t em 0 3 - 0 6- 8
3. St op cranki ng engine. Reduce resi stance of
carbon pile until voltmeter indicates same reading
as that obtained while starter motor cranked the
engine. The ammeter will indicate starter current
draw under load. Check this with value listed in
Starter Specifications.
J4487-D
03- 06- 9 St a r t i n g S y s t e m 03- 06- 9
ROT UN DA S T A RT I NG
A N D C H A RG I N G
T E S T E R ( VAT- 40)
J 4 4 8 5 - C
Vol t age Dr op Test s
If t he st a r t e r mot or c r a nks sl owl y and t he ba t t e r y
( 10653) i s sat i sf act or y , t he r e may be a mal f unct i on of
t he st a r t e r mot or or in t he cr anki ng ci rcui t wi ri ng. To
det ermi ne if t he probl em is in t he wi r i ng, a vol t age d r o p
t e st must be per f or med.
These t e st s are per f or med t o det ermi ne if t her e is
e xc e ssi ve resi st ance in t he st a r t e r mot or ci rcui t .
Al wa y s make t he vol t -ohmmet er connect i ons at t he
component t ermi nal rat her t han at t he cabl e wi ri ng end
connect or. Maki ng a connect i on at t he wi ri ng end
connect or coul d resul t in f al se readi ngs because t he
met er wi ll not pi ck up a hi gh r esi st ance bet ween t he
wi ri ng connect or and t he component .
Mo t o r Fe e d Ci r c ui t
1. Prevent t he engi ne f r o m st ar t i ng by di sconnect i ng
t he ignition coi l ( 12029) .
2. Connect a r emot e st ar t er swi t c h bet ween t he
st a r t e r sol enoi d S-t ermi nal and t he bat t er y
posi t i ve ( + ) t ermi nal .
3. Connect Rot unda Di gi t al Vol t -Ohmmet er
014- 00407 or equi valent posi t i ve l ead t o t he
ba t t e r y posi t i ve ( + ) post . Connect Rot unda
Di gi t al Vol t -Ohmmet er 014- 00407 or equi valent
negat i ve l ead t o t he st ar t er sol enoi d M-t ermi nal .
4. Engage t he r emot e st ar t er swi t c h. Read and
r e c or d t he vol t age. The vol t age readi ng shoul d be
0. 5 vol t or l ess.
5. If t he vol t age readi ng is hi gher t han t hi s,
i ndi cat i ng e xc e ssi ve resi st ance, move t he
vol t -ohmmet er negat i ve l ead t o t he st ar t er
sol enoi d B-termi nal and repeat t he t est . If t he
vol t age readi ng at t he B-termi nal is l ower t han 0. 5
vol t , t he concer n i s ei t her in t he connect i ons at
t he sol enoi d or in t he sol enoi d c ont a c t s.
6. Remove t he cabl es f r om sol enoi d B-, S-, and
M-t ermi nal s. Clean t he cabl es and connect i ons
and rei nst al l t he cabl es t o t he proper t ermi nal s.
Repeat St eps 1 t hr ough 5 above. If t he vol t age
d r o p readi ng i s sti ll hi gher t han 0. 5 vol t s when
c he c ke d at t he M-termi nal or l ower when
c he c ke d at t he B-t ermi nal , t he concern is in t he
sol enoi d c o n t a c t s. Remove and repl ace t he
st a r t e r mot or or st ar t er sol enoi d if avai l abl e.
7. If t he vol t age readi ng t aken at t he sol enoi d
B-t ermi nal is still hi gher t han 0. 5 vol t af t er
cl eani ng t he cabl es and connect i ons at t he
st a r t e r sol enoi d, t he concern is ei t her in t he
posi t i ve ( + ) ba t t e r y cabl e connect i on or in t he
posi t i ve ba t t e r y cabl e i tself.
8. By movi ng t he vol t -ohmmet er negat i ve l ead
t o wa r d t he ba t t e r y and checki ng each
mechani cal connect i on poi nt , t he excessi ve
vol t age d r o p can be l ocat ed. When t he hi gh
readi ng di sappear s, t he l ast mechani cal poi nt
t hat wa s c he c ke d is t he concer n.
03- 06- 10 St a r t i n g S y s t e m 0 3 - 0 6 - 1 0
Mo t o r Fe e d Ci r c ui t
5
. REMOTE STARTER
SWITCH
S-TERMINAL
B-TERMINAL
ROTUNDA DIGITAL
VOLT-OHMMETER
014-00407
M-TERMINAL
T
J4575-B
Mo t o r G r o u n d Ci r c u i t
A sl ow cranki ng condi ti on can be caused by
resi stance in the ground or return porti on of the
cranki ng ci rcui t. Check t he vol tage drop in t he ground
circuit as f ol l ows:
1. Prevent the engine f r om starti ng by di sconnecti ng
t he ignition coi l .
2. Connect a remote st art er swi t ch between t he
st art er sol enoi d S-terminal and t he bat t ery
posi ti ve ( + ) termi nal .
3. Connect a Rotunda Digital Volt-Ohmmeter
014- 00407 or equivalent posi ti ve l ead t o the
st art er motor housing (connecti on must be cl ean
and f ree of rust or grease). Connect Rotunda
Digital Vol t-Ohmmeter 014- 00407 or equivalent
negati ve l ead t o t he negati ve (-) bat t ery terminal.
Engage the remote st art er swi t ch and crank the
engine. Read and record t he vol t-ohmmeter
readi ng. The readi ng shoul d be 0.2 vol t or l ess.
If the vol tage drop is more than 0.2 vol t, cl ean the
negati ve cabl e connecti ons at t he bat t ery and
body connecti ons and ret est . If t he vol tage drop
is still t oo hi gh, perform t he following t est :
03- 06- 11 St a r t i n g S y s t e m
03- 06- 11
Mot or Gr ound Ci rcui t
REMOTE
I n d i v i d ua l Cabl e
The resistance of any cable can be checked in the
same manner by using Rotunda Digital Vol t-Ohmmeter
1. Determi ne whi ch way the current is fl owi ng in t he
cabl e. Connect Rotunda Digital Vol t-Ohmmeter
014- 00407 or equivalent posi ti ve l ead t o the end
of the cabl e nearest bat t ery posi ti ve.
2. Connect Rotunda Digital Vol t-Ohmmeter
014- 00407 or equivalent negati ve l ead t o t he
terminal at t he ot her end of the cabl e.
3. Crank t he engine and observe Rotunda Digital
Vol t-Ohmmeter 014- 00407 or equivalent. The
vol tage readi ng should be 0. 2 vol t or lower. If t he
vol tage drop is t oo hi gh, cl ean t he termi nal ends.
Retest, and if still hi gh, repl ace t he cabl e.
Mo t o r Pi n i o n Te s t
1. Remove st art er motor as outl i ned.
2. Di sassembl e st art er dri ve ( 11350) f rom st art er
motor as outlined.
3. Turn t he st art er dri ve pinion by hand and hold t he
overruning cl ut ch. Repl ace t he st art er dri ve if t he
pinion turns in bot h di recti ons or does not turn.
R O T U N D A D I G I T A L
V O L T - O H M M E T E R
0 1 4 - 0 0 4 0 7 ^
PINION
J4581-A
No L o a d Te st
CAUTI ON: Ma ke s u r e t h a t t h e s t a r t e r mo t o r i s
s e c u r e l y mo u n t e d i n b e n c h v i s e wh i l e e n e r gi zi n g,
a s s t a r t e r mo t o r wi l l mo v e o r j u mp .
The st art er no-load t est will uncover such conditions
as open or short ed wi ndi ngs, or rubbing starter motor
armature ( 11005) . The starter motor can be t est ed at
no-load, on the t est bench only.
03- 06- 12 St a r t i n g S y s t e m 03-06-12
NOTE: A remote control st art er swi t ch should be
used in the S circuit for turning t he starter motor
ON and OFF during testi ng.
Make t est connecti ons wi t h Rotunda Starti ng and
Chargi ng Tester (VAT-40) 078- 00005 or
equivalent cabl es connect ed t o st art er motor,
l arge enough t o carry high current (the same as in
t he vehi cl e). The starter motor will run at no-load.
Be sure that no current is fl owi ng through
ammeter (rheostat at maxi mum count ercl ockwi se
position). Determine exact readi ng on voltmeter.
ROTUNDA STARTING AND CHARGING
TESTER (VAT-40) 078-00005
POSITIVE
LEADS NEGATIVE
LEADS
(CONVENIENT GROUND ON STARTER MOTOR
SUCH AS MOUNTING EAR ON CASTING)
l i r M
^ _
' J5467-A
2. Di sconnect starter motor f r om bat t ery. Then
reduce resi stance of rheost at until vol tmeter
i ndi cates same reading as t hat obtai ned while
st art er motor was running. The ammet er will
indicate starter motor no-load current draw. Refer
t o Starter Speci fi cati ons at t he end of thi s section
f or a comparat i ve value.
3. If current exceeds speci fi cati on, check for
rubbing starter motor armat ure, bent output
shaft ( 11355) , binding bushi ngs, or short s in
st art er motor armature or brush hol der ( 11061) .
A r m a t u r e
Op e n Ci r c ui t Te st
An open circuit starter motor armat ure may
someti mes be det ect ed by exami ni ng t he commutator
for evi dence of burning. A burn spot on t he
commutator is caused by an ar c f or med every ti me the
commut at or segment, connect ed t o t he open circuit
wi ndi ng, passes under a brush.
G r o u n d e d Ci r c ui t Te s t
Thi s t est will determi ne if t he wi ndi ng insulation has
been damaged, permi tti ng a conduct or t o t ouch the
st art er f rame and magnet ( 11075) or armat ure core.
To determi ne if the armature wi ndi ngs are grounded,
check wi th a Rotunda Digital Vol t-Ohmmeter
014- 00407 or equivalent. Infinite resi st ance indicates
a normal condi ti on.
ROTUNDA DIGITAL
VOLT-OHMMETER
014-00407
J3411-D
S t a r t e r S o l e n o i d
Make sure that the st art er sol enoi d is i sol ated
el ectri cal l y f rom the st art er motor. Using a Rotunda
Digital Volt-Ohmmeter 014- 00407 or equivalent,
check for continuity bet ween S-terminal and
M-terminal, and bet ween S-terminal and ground
(starter frame and magnet). If t here is no continuity,
the fol l owi ng conditions may exi st:
1. Open wi re; repl ace st art er sol enoi d.
2. Ice, dirt or other forei gn materi al preventi ng
cont act ; servi ce as necessary.
J3390-A
So l e n o i d S- Te r mi n a l Ci r c u i t Re s i s t a n c e
Using Rotunda Digital Vol t-Ohmmeter 014- 00407 or
equivalent, check the resi stance of the entire
S-terminal circuit, including all the swi t ches, wi res and
connecti ons. Resi stance should be l ess than 0. 08
ohm.
So l e n o i d M- Te r mi n a l
1. Using Rotunda Digital Vol t-Ohmmeter 014- 00407
or equivalent, check f or continuity between t he
starter solenoid M-terminal and t he starter
solenoid housing.
03- 06- 13 St ar t i ng Sy s t e m 03- 06- 13
2. If t here is no continuity, repl ace t he starter
sol enoi d.
ROTUNDA DIGITAL
VOLT-OHMMETER "
014-00407
J4582-B
S t a r t e r Mo t o r
Re mo v a l
1. WARNI NG: WHEN SERVI CI NG STARTER
MOTOR ( 11002) OR PERFORMI NG ANY
MAI NTENANCE IN THE AREA OF THE
STARTER MOTOR, NOTE THE HEAVY GAUGE
I NPUT LEAD CONNECTED TO THE STARTER
SOLENOI D ( 11390) IS HOT AT ALL TI MES.
MAKE SURE THE PROTECTI VE CAP IS
I NSTALLED OVER THE TERMI NAL AND IS
REPLACED AFTER SERVI CE.
NOTE: When t he bat t ery has been di sconnected
and reconnect ed, some abnormal dri ve
sympt oms may occur while t he powert rai n
cont rol module ( PCM) ( 12A650) rel earns its
adapt i ve st rat egy. The vehi cl e may need t o be
dri ven 10 miles or more t o rel earn t he st rat egy.
Di sconnect the bat t ery ground cabl e ( 14301) .
2. Rai se t he vehicle on a hoist. Refer t o Secti on
00- 02.
3. CAUTI ON: Wh e n d i s c o n n e c t i n g h a r d s h e l l
c o n n e c t o r a t S- t e r mi n a l , g r a s p t h e pl a s t i c
she l l a n d pul l o f f . Do n o t pul l o n wi r e . Be
c a r e f u l t o pul l s t r a i gh t o f f t o p r e v e n t d a ma g e
t o t h e c o n n e c t o r a n d S- t e r mi n a l . If a n y p a r t
o f t h e c o n n e c t i o n i s d a ma g e d , r e p l a c e t h e
d a ma g e d c o mp o n e n t s .
Di sconnect st art er cabl e and push-on connector
f rom st art er sol enoi d.
4. Remove upper bol t.
5. Remove l ower bol t and st art er motor.
1.
2.
3.
4.
6.
7.
8.
Position starter motor t o engine and install upper
and l ower bol ts finger-tight.
Tighten the upper bolt t o 20-27 N-m ( 15- 20 Ib-ft).
Tighten t he l ower bolt t o 20-27 N-m (15-20 Ib-ft).
Connect st art er solenoid connector. Be careful t o
push strai ght on and make sure connector l ocks
in posi ti on wi th a notable cl i ck or detent.
Install starter cabl e nut t o st art er solenoid
B-terminal. Tighten t o 9-14 N-m ( 80- 124 Ib-in).
Repl ace red st art er solenoid saf et y cap.
Lower vehi cl e t o floor.
03- 06- 14 St a r t i n g S y s t e m 03- 06- 14
S t a r t e r Mo t o r
NOTE: Al t hough di sassembl y and servi ce pr ocedur es
are shown f or t he st a r t e r mot or ( 11002) in t hi s
sect i on, it is r ecommended t ha t t he st ar t er mot or be
ret urned t o For d Ret urn Par t s Cent er f or anal ysi s and
revi ew.
St art er Mot or Di s a s s e mb l e d Vi e w
J44S6-A
I t e m
Pa r t
1 N805403 Terminal Nut
2 11390 Starter Solenoid
3 11A171 Housing Seal Assy
4 11135 Bushing Bearing
5 11130 Drive End Housing
6 N806405 Solenoid Screw (2 Req'd)
7 11002 Starter Motor
8 11067 Drive Lever and Pin
9 11360 Starter Drive
10 11223 Stop Ring Retainer
11 11222 Starter Drive Stop Ring
Pa r t
12

Magnet Retainer (6 Req'd)
(Part of 11075)
13 11075 Starter Frame and Magnet
14 11061 Brush Holder
15 11059 Brush Spring
16

Bushing (Part of 11049)
17 11049 Brush End Plate and Bushing
18 N805406 Brush Plate Bolt (2 Req'd)
19 N805428 Through-Bolt (2 Req'd)
20 11A196 Drive Seal Ring
21 11005 Starter Motor Armature
( Co n t i n ue d )
( Co n t i n ue d )
03- 06- 15 S t a r t i n g S y s t e m 03- 06- 15
I t em
Pa r t
22 11A172 Armature Thrust Ball
23 11K190 Planet Gear
24 11A165 Stationary Gear
25 N805404 Truarc E-Ring
26 11180 Drive End Housing Seal
I t e m
Pa r t
27

Magnet Pole Piece (6 Req'd)
(Part of 11075)
28

Pole Shunt (6 Req'd) (Part of
11075)
29 11036 Pinion Thrust Washer
30 11355 Output Shaft
31 11A167 Planet Gear Retainer
Di s a s s e mb l y
1.
3.
Remove posi ti ve brush connector f rom st art er
solenoid M-terminal.
Remove st art er solenoid retaining scr ews and
st art er solenoid ( 11390) .
Remove through-bol ts and separat e dri ve end
housing f rom st art er f rame and magnet ( 11075) .
Remove seal ( 11A171) f rom dri ve end housi ng.
Remove st art er solenoid and gear assembl y f rom
dri ve end housi ng.
Remove dri ve lever and pin ( 11067) from st art er
dri ve ( 11350) .
5.
6.
Remove st art er dri ve st op ring ( 11222) and st op
ring retainer ( 11223) f rom output shaft ( 11355) ,
then remove st art er dri ve f rom output shaft.
Push E-ring off output shaft and separat e gear
assembl y f rom output shaft.
7. Remove brush pl ate bol ts and brush end pl ate
and bushing ( 11049) f rom st art er f rame and
magnet.
8. Remove brush holder ( 11061) and push st art er
motor armat ure ( 11005) out of st art er f rame and
magnet.
A s s e m b l y
1. NOTE: Seal er materi al meeting Dow formulation
Silastic 737 or GE Silicone RTV 123 or equivalent
meeti ng For d speci fi cati on ESA-M4G294-A
should be repl aced on st art er mot or during
reassembl y.
Install st art er motor armature in st art er f rame and
magnet. Appl y a thin coati ng of Syncol ube (PTFE)
Low Temperature Grease or equivalent meeti ng
Ford speci fi cati on ESF-M1C218-A on bot h ends
of armature shaf t and spline. Install brush holder
whi l e maki ng sure brushes fit over commutator.
Appl y grease t o bushing bore in brush end pl ate
and bushing. Push back grommet onto st art er
f rame and magnet and at t ach brush end wi t h
brush pl ate bol t s. Tighten t o 2-3 N-m (18-27 lb-in).
2. Appl y grease t o output shaft spline and pl ace
stati onary gear ( 11A165) over output shaft.
Install armat ure thrust washer and push E-ring
onto output shaft. Pl ace st art er dri ve onto output
shaft and install st art er dri ve st op ring and st op
ring retainer. At t ach dri ve lever t o st art er dri ve.
3. Grease and install planet gears ( 11K190) .
4. Appl y grease into dri ve end housing bushing bore
(approxi matel y one-quarter full). Install st art er
dri ve gear assembl y into housi ng, maki ng sure t o
line up bolt hol es in gear assembl y and housing.
Pl ace planet gear retainer ( 11A167) over gear
assembl y. Install housing seal into dri ve end
housing.
5. Position st art er f rame and magnet t o housing and
install through-bol ts. Tighten t o 5-10 N-m ( 45- 89
lb-in).
6. Position st art er solenoid t o housing. Make sure
t hat solenoid plunger is at t ached through dri ve
lever (bot t om st art er solenoid M-terminal should
have a metal stri p at t ached t o i t). Tighten st art er
solenoid scr ews t o 5-10 N-m (45-89 lb-in).
7. At t ach posi ti ve brush connector t o starter
solenoid (bot t om terminal). Tighten nut t o 9-14
N-m ( 80- 124 lb-in).
8. Check that st art er motor no-load current dr aw is
within speci fi cati on. Refer t o Component Tests
under Di agnosi s and Testi ng.
S t a r t e r Dr i v e R e p l a c e m e n t
1. Remove posi ti ve brush connector f rom st art er
solenoid M-terminal. Remove starter solenoid
retaining scr ews and remove starter solenoid
( 11390) .
2. Remove through-bol ts and separat e motor
assembl y f rom dri ve end housing. Remove
housing seal f rom dri ve end housing. Remove
st art er dri ve gear assembl y f rom housing and
det ach dri ve lever and pin ( 11067) .
3. Remove st art er dri ve st op ring ( 11222) and st op
ring retainer ( 11223) f rom output shaft ( 11355)
and then remove starter dri ve assembl y.
4. Appl y a thin coati ng of Syncol ube (PTFE) Low
Temperature Grease or equivalent meeting Ford
speci fi cati on ESF-M1C218-A on output shaft
spline. Install new st art er dri ve gear assembl y on
output shaft. Install new st art er dri ve st op ring
and st op ring retainer. At t ach dri ve lever and pin.
5. Partially fill dri ve end housing bushing bore wi t h
grease (approxi matel y one-quarter full). Install
starter dri ve gear assembl y in housing, maki ng
sure t o line up bolt holes in starter dri ve gear
assembl y and housi ng.
03- 06- 16 St ar t i ng Sy s t em 0 3 - 0 6 - 1 6
6.
7.
Install lever support and housing seal in dri ve end
housi ng.
Position st art er f rame and magnet ( 11075) t o
housing and install through-bol ts. Tighten t o 5-10
N-m ( 45- 89 Ib-in).
Install st art er sol enoi d. Refer t o St art er Motor,
Assembl y.
A r m a t u r e R e p l a c e m e n t , S t a r t e r Mo t o r
1. Remove posi ti ve brush connector f r om starter
sol enoi d M-terminal.
2. Remove through-bol ts and separat e motor f rom
st art er dri ve gear assembl y and dri ve end
housing.
3. Remove brush end pl ate scr ews, brush end pl ate
and bushing ( 11049) and brush holder ( 11061)
f r om st art er f rame and magnet ( 11075) . Remove
st art er motor armat ure ( 11005) f rom st art er
f rame and magnet.
4. Install new st art er motor armature in st art er
f rame and magnet. Appl y a thin coati ng of
Syncol ube (PTFE) Low Temperature Grease or
equivalent meeting For d speci fi cati on
ESF-M1C218-A on bot h ends of armat ure shaft
and pinion.
5. Install brush holder. Make sure t hat brushes fit
over commutator. Push bl ack grommet onto
f rame. Appl y grease t o bushing bore in brush end
pl ate and bushing and at t ach t o st art er f rame and
magnet.
6. Position starter f rame and magnet t o st art er dri ve
gear assembl y and dri ve end housi ng. Install
through-bol ts. Tighten to 5-10 N-m ( 45- 89 Ib-in).
7. At t ach posi ti ve brush connector t o st art er
sol enoi d (M-Terminal). Tighten nut t o 9-14 N*m
( 80- 124 Ib-in).
8. Check that st art er motor no-load current draw is
within speci fi cati on. Refer t o Component Testing
under Di agnosi s and Testi ng.
B u s h i n g s
Di s a s s e mb l y a n d A s s e m b l y
1. The bushings can be pressed or t apped out of
thei r housing using a dri ver of t he appropri at e
si ze. Be sure t he housing is well support ed.
2. Immerse new bushings in engine oil ( SAE30 or
40) for at least 20 minutes before installation.
3. NOTE: Do not ream t he bushings after installation
si nce t he self-lubricating qualities of t he bushing
may be damaged.
Press or t ap the new bushing into position using a
driver.
BU SHI NG
(PART OF
11049)
DRI VE END
HOU SI NG
11130
BRU SH END
PLA TE A ND
BU SHI NG
11049
BU SHI NG
11135
J3732-C
SERVICE PROCEDURES
R o a d S e r v i c e
For cases of a st art er motor ( 11002) that cranks t he
engine very sl owl y, connect a 12-volt boost er bat t ery
t o the syst em.
J u m p S t a r t i n g
WARNI NG: HYDROGEN AND OXYGEN GASES ARE
PRODUCED DURING NORMAL BATTERY
OPERATI ON. THI S GAS MI XTURE CAN EXPLODE
IF FLAMES, SPARKS OR LI GHTED TOBACCO ARE
BROUGHT NEAR THE BATTERY. WHEN
CHARGI NG OR USING A BATTERY IN AN
ENCLOSED SPACE, ALWAYS PROVIDE
VENTI LATI ON AND SHI ELD YOUR EYES.
WARNI NG: KEEP OUT OF REACH OF CHI LDREN.
BATTERI ES CONTAI N SULFURI C ACI D. AVOI D
CONTACT WI TH SKI N, EYES OR CLOTHI NG.
ALSO, SHI ELD YOUR EYES WHEN WORKI NG
NEAR THE BATTERY TO PROTECT AGAI NST
POSSI BLE SPLASHI NG OF THE ACI D SOLUTI ON.
IN CASE OF ACI D CONTACT WI TH SKI N, EYES OR
CLOTHI NG, FLUSH IMMEDIATELY WI TH WATER
FOR A MI NI MUM OF FI FTEEN MI NUTES. IF ACI D IS
SWALLOWED, DRINK LARGE QUANTI TI ES OF
MI LK OR WATER, FOLLOWED BY MI LK OF
MAGNESI A, A BEATEN EGG, OR VEGETABLE OI L.
CALL A PHYSI CI AN IMMEDIATELY.
CAUTI ON: Do n o t d i s c o n n e c t t h e b a t t e r y o f t h e
v e h i c l e t o b e s t a r t e d . Di s c o n n e c t i n g t h e b a t t e r y
c o u l d d a ma g e t h e v e h i c l e ' s e l e c t r o n i c s y s t e m.
To avoi d damage t o the vehicle and bat t ery or t he
possibility of personal harm, fol l ow instructions and
precauti ons.
3- 06- 17 St ar t i ng Sy s t em 03- 06- 17
Negat i v e Gr o u n d e d Ba t t e r y
WARNI NG: TO AVOI D ANY POSSI BI LI TY OF
INJURY, USE P A R T I C U L A R CARE WHEN
C O N N E C T I N G A BOOSTER BATTERY TO A
DI S C H A R G E D BATTERY.
WARNI NG: WHEN SERVI CI NG THE STARTER
MOTOR ( 11002 ) OR P E R F O R MI N G OTHER
UNDERHOOD WORK IN THE VI CI NI TY OF THE
STARTER MOTOR, BE AWARE THAT THE HEAVY
GAUGE BATTERY I NPUT LEAD AT THE STARTER
SOLENOI D ( 11390) IS " ELECTRI CALLY HOT" AT
ALL TI MES*
A P R O T E C T I V E CAP OR BOOT IS PROVI DED
O V E R THI S T E R MI N A L THAT MUST BE REPLACED
AFTER S E R VI C I N G . BE SURE TO D I S C O N N E C T
BATTERY GROUND CABLE ( 14301) BEFORE
S E R VI C I N G STARTER MOTOR.
1. Position vehi cl es so j umper cabl es will reach,
being careful that vehi cl es do not t ouch.
2. Turn bl ower motor ( 18527) of vehi cl e t o be
st art ed ON (set control on DEFROST for vehi cl es
equi pped wi t h automati c t emperat ure control ).
Turn other swi t ches and l amps OFF.
3. WARNI NG: MAKI NG THE FI NAL CABLE
C O N N E C T I O N C O U L D C A U S E A N
E L E C T R I C A L SPARK NEAR THE BATTERY
AND C O U L D C A U S E AN E X P L O S I O N - REFER
TO WARNI NG AT THE BEGI NNI NG OF THE
JUMP STARTI NG PROCEDURE-
Make j umper cabl e connecti ons.
Connect one end of fi rst j umper cabl e t o t he
bat t ery posi ti ve vol tage ( + ) termi nal of
di scharged bat t ery and other end t o the
bat t ery posi ti ve vol tage ( + ) termi nal of boost er
battery.
WARNI NG: MAKE THE FI NAL CABL E
CONNECTI ON TO AN ENGI NE BOLT HEAD
OR GOOD METALLI C CONTACT SPOT ON
ENGI NE OF VEHI CLE TO BE S T A R T E D , NOT
TO BATTERY N E G A T I V E V O L T A G E (-)
T E R MI N A L , OR POSSI BLE P E R S O N A L
INJURY MAY OCCUR.
Connect one end of second j umper cabl e t o
bat t ery negati ve vol tage (-) termi nal of boost er
bat t ery. Connect other end t o an engine bol t
head or good metallic cont act spot on engine
of vehi cl e t o be st art ed.
JUMP STARTING
MAKE CONNECTIONS IN NUMERICAL
ORDER (DISCONNECT IN REVERSE
ORDER 4, 3, 2, 1)
DISCHARGED
BATTERY
MAKE SURE VEHICLES
DO NOT TOUCH
J5468-A
4.
Make sure j umper cabl es are not in way of
movi ng engine part s.
St art engine of vehicle wi th good battery. Run
engine at a moderat e speed.
St art engine of vehicle wi th di scharged
battery. Fol l ow starti ng instructions in the
Owner Guide.
Leave all swi t ches EXCEPT bl ower motor OFF.
Reduce engine speed t o idle on both vehi cl es
t o prevent possi bl e damage t o vehicle
el ectri cal syst ems.
Remove cabl es in exact REVERSE sequence.
Begin by removi ng cabl e from engine of vehicle
t hat had di scharged battery ( 10653) .
If t he starter motor does not turn the engine over,
even wi th t he booster battery at t ached, refer t o
St art er Syst em Diagnosis and Testing in this
secti on.
CLEANING A N D INSPECTION
Armature Coil, Starter Motor
1. Inspect st art er motor armature windings for
broken or burned insulation and unwel ded or open
connecti ons.
2. Check st art er motor armature ( 11005) for open
ci rcui ts, short s and grounds. Check for rubs on
pole or magneti c shunts.
03- 06- 18 St a r t i n g S y s t e m 03- 06- 18
3. Check commut at or for runout. Inspect armature
shaft and t wo bushings for scori ng and excessi ve
wear wi t h Dial Indicator D87L- 4201- A and
Magneti c Base D87L-4201-B or equivalent, if
commut at or is rough, or more than 0. 12 mm
( 0. 005 inch) out of round, it must be repl aced.
COMMUTATOR RUNOUT CHECK
DIAL INDICATOR
D87L-4201-A
ROTATE ARMATURE
SHAFTS ON
BEARING SURFACES
MAGNETIC
BASE
D87L-4201-B
"V" BLOCKS
J5478-A
S t a r t e r F r a m e a n d Ma g n e t
1. Check the st art er f rame and magnet ( 11075) for
damage and repl ace as necessary.
STARTER
FRAME
AND MAGNET
11075
J4S77-B
B u s h i n g s
Inspect the self-lubricating br onze/ i r on armature
bushings in t he dri ve housing and brush end pl ate
and bushing ( 11049) . Repl ace bushings
whenever excessi ve starter mot or armat ure
shaft si de-pl ay is evident (maxi mum al l owabl e 0. 2
mm, ( 0. 008 i nch)).
Repl ace bushings if worn or scor ed. Check the
output shaft ( 11355) for wear if the bushings are
excessi vel y scor ed or wor n. Servi ce or repl ace
output shaft as necessary.
S t a r t e r Dr i v e a n d F l y w h e e l Ri n g G e a r
I n s p e c t i o n
1. CAUTI ON: The s t a r t e r d r i v e ( 11350) i s
p a c k e d w i t h gr e a s e a n d s e a l e d , a n d s h o u l d
n o t be wa s h e d i n s o l v e n t .
CAUTI ON: Do n o t wa s h t h e s t a r t e r d r i v e
b e c a u s e t h e s o l v e n t wi l l w a s h o u t t h e
l u b r i c a n t c a u s i n g s t a r t e r d r i v e t o s l i p. Use a
b r u s h o r c o mp r e s s e d ai r t o c l e a n t h e s t a r t e r
d r i v e , s t a r t e r mo t o r a r ma t u r e ( 11005) ,
b r u s h , ge a r a s s e mb l i e s , d r i v e e n d h o u s i n g,
p o l e pi e c e s a n d pl a n e t g e a r s ( 11K190) .
Wa s h al l o t h e r p a r t s i n s o l v e n t a n d d r y .
Examine gears and spline on output shaft
( 11355) , and dri ve pinion for chi pped, broken or
worn conditions. Repl ace if requi red.
03- 06- 19
p?"*- MM
St a r t i n g S y s t e m 03- 06- 19
CLEANING AND INSPECTION (Continued)
St art er Drive and Fl y wheel Ri ng Gear Wear
PINION AND RING GEAR WEAR PATTERNS
NORMAL WEAR PATTERN
2. Inspect the entire ci rcumference of the fl ywheel
ring gear for damage when the st art er dri ve gear
t eet h are damaged. The fl ywheel ring gear
pattern will usually be found in t wo pl aces around
t he fl ywheel ring gear. If t he starter dri ve gear or
fl ywheel ring gear show si gns of excessi ve wear
or milling, they must be repl aced.
SMALL WEAR PATTERN
MILLED GEARS J5469-A
SPECIFICATIONS
STARTER SPECIFICATIONS
St ar t er Mot or
Max. Load No Load
St art er Brushes
Mot or
Di amet er
Cur r ent Draw
Under Normal
Load
Normal
Engi ne
Cr a nki ng
Speed
Min. St al l
Tor que @ 5
Vol t s Max. Load No Load Mf g. Lengt h
Spr i ng
Tensi on
7 8 mm ( 3
I n c h e s )
130- 2 2 0 A mp s 140- 2 2 0 RP M 14. 7 N-m ( 11. 0
L b - Ft )
8 0 0 A mp s 7 0 10 A mp s 14. 0 mm ( 0. 55
I n c h)
1 8 N ( 6 4 o z)
Maxi mum commut at or runout is 0. 12 mm (0.005 i nch). Maxi mum st art i ng ci rcui t vol t age drop (bat t ery posi t i ve t ermi nal t o
st ar t er t ermi nal ) at normal engi ne t emperat ure is 0.5 vol t .
03- 06- 2 0 St a r t i n g S y s t e m 03- 06- 2 0
TORQUE SPECI FI CATI ONS
Description N-m Lb-ln
So l e n o i d S c r e ws 5- 10 45 89
M- Te r mi n a l Nut 9- 14 80- 12 4
B- Te r mi n a l Nut 9- 14 80- 12 4
T h r o u g h - Bo l t s 5- 10 45- 89
Mo u n t i n g Bo l t s 2 0- 2 7 15-20
( L b - Ft )
Br u s h P l a t e Bo l t s 2- 3 18-27
SPECI AL SERVI CE TOOLS DESI RED
D87 L - 42 01- A Di a l I n d i c a t o r
D87 L - 42 01- B Ma g n e t i c Ba s e
ROTUNDA EQUIPMENT
07 8- 00005 St a r t i n g a n d Ch a r gi n g Te s t e r ( VAT- 40)
03- 07- 1
I gn i t i o n , E l e c t r o n i c 03- 07- 1
SECTION 03-07 Ignition, Electronic
SUBJECT PAGE
Crankshaft Position Sensor 03-07-1
Igni ti on Coil 03-07-1
Igni ti on Components, El e c t r o n i c . 03-07-1
Igni ti on Control Modul e. . ....03-07-2
I gni t i on. 03-07-3
Br acket , I gni t i on Coi l ..03-07-4
Crankshaf t Posi t i on Sensor 03-07-3
I gni t i on Coi l 03-07-3
SUBJECT PAGE
I gni t i on Cont r ol Module 03-07-5
I gni t i on Wi res 03-07-5
Radio I gni t i on I nt erf erence Capaci t or 03-07-7
Spark Plugs 03-07-7
I gni t i on Coi ls 03-07-9
I gni t i on Wi res 03-07-9
Spark Plugs 03-07-9
ADJUSTMENTS
Spark Plugs 03-07-9
VEHICLE APPLICATION
DESCRIPTION A N D OPERATION
Igni ti on Component s, Elect roni c
The el ectroni c ignition (El) syst em for the 4. 6L-2V
engine consi sts of the following component s:
Crankshaft position sensor (CKP sensor)(6C315).
Ignition control module ( I CM) ( 12K072) .
Ignition coils ( 12029) .
Desi red spark angle signal f rom the powertrai n
control module (PCM)(12A650).
Rel ated wi ri ng.
Crankshaf t Posi ti on Sensor
The crankshaf t position sensor (CKP
sensor)(6C315) is a vari abl e rel uctance sensor
t ri ggered by a 36-minus-1 t oot h tri gger pulse wheel
l ocat ed inside the engine front cover ( 6019) .
The sine wave t ype signal generat ed f rom t he
crankshaf t position sensor provi des t wo t ypes of
i nformati on. One is the position of the crankshaf t
( 6303) in 10-degree i ncrements. The other is the
crankshaf t speed (rpm).
The ignition control module (I CM)(12K072) uses
thi s information wi th the spark advance information
f rom the powertrai n control module ( PCM) ( 12A650)
t o determi ne ignition coil turn ON and turn OFF ti me.
Base ignition timing is referenced t o the position of
the crankshaf t position sensor and is set at 10 2
degrees before t op dead center (BTDC) and is not
adj ustabl e.
Igni ti on Coil
The four ignition coils ( 12029) each contai n t wo
separat e ignition coils whi ch are control l ed by t he
ignition control module ( I CM) ( 12K072) through t wo
coi l l eads for each ignition coi l .
Each ignition coil acti vates t wo spark plugs ( 12405)
simultaneously, one spark plug on t he compressi on
st roke and one spark plug on the exhaust st roke.
The maj ori ty of the energy is used by the spark plug
on the compressi on st roke. The spark plug fi red on
t he exhaust st roke uses very little of t he ignition
coi l s st ored energy.
Since t hese t wo spark plugs are connected in
seri es, the firing vol tage of one spark plug will be
negative wi t h respect t o ground, while the vol tage of
the other spark plug will be posi ti ve wi t h respect t o
ground.
Refer t o the Powertrai n Control / Emissions
Diagnosis Manual
1
for additional information on
spark plug polarity.
The ignition coils are mounted on the ignition coil
mounting bracket s whi ch are at t ached t o the engine
front cover ( 6019) .
03- 07- 2 I gn i t i o n , E l e c t r o n i c 0 3 - 0 7 - 2
There are t wo cyl i nder numbers on each ignition coil
termi nal t o allow the ignition coils to be
i nterchangeabl e.
VIEW A
B4485-B
I g n i t i o n C o n t r o l Mo d u l e
The ignition control module ( I CM) ( 12K072) :
Recei ves crankshaf t position and speed information
from t he crankshaft posi ti on sensor (CKP
sensor)(6C315), and desi red spark advance
information f rom the powert rai n control module
( PCMX12A650) .
Uses t he information t o di rect whi ch ignition coil
( 12029) to fi re, and cont rol s t he turn ON and OFF
ti mes of the ignition coil t o achi eve the correct dwel l
and spark advance.
Synthesi zes a profile ignition pi ckup (PIP) signal and
an ignition di agnosti c monitor (IDM) signal for use by
the powert rai n control modul e.
Sends information on syst em failures through t he
IDM signal t o the powert rai n control module whi ch
st ores information for use during di agnosti c t est
mode.
The ignition di agnosti c monitor (IDM) al so provi des
the signal t o drive the t achomet er.
Is l ocat ed at the rear of the LH front fender ( 16005)
in the engine compart ment .
) 1
IGNITION
CONTROL
MODULE
( o
12K072
( o
<~ ,
B4484-8
03- 07 - 3 I gn i t i o n , E l e c t r o n i c 03- 07 - 3
DIAGNOSIS A N D TESTING
I g n i t i o n
Refer t o the Powertrai n Cont rol / Emi ssi ons Diagnosis
Manual .
2
Crankshaft P o s i t i o n Sensor
Re mo v a l
2. Remove serpenti ne dri ve belt ( 8620) . Refer t o
Secti on 03- 05.
4. Di sconnect crankshaf t position sensor (CKP
sensor)(6C315) and A / C compressor ( 19703)
f rom the engine control sensor wiring ( 12A581) .
5. Recover A/ C syst em and remove A / C
compressor. Refer t o Secti on 12-00.
6. Remove crankshaf t position sensor retaining
scr ew and remove crankshaft position sensor.
CRANKSHAFT POSITION
SENSOR (CKP)
6C315 B4487-C
1. Make sure crankshaf t position sensor mounting
surface is clean and that crankshaft posi ti on
sensor O-ring is in proper location on crankshaft
position sensor.
2. CAUTI ON: Do n o t o v e r t i g h t e n c r a n ks h a f t
p o s i t i o n s e n s o r r e t a i n i n g s c r e w o r d a ma g e
t o c r a n ks h a f t p o s i t i o n s e n s o r ma y o c c u r .
Position crankshaf t position sensor and install
retaining screw. Tighten to 8-12 Nm (71-106
Ib-in).
3. Install A / C compressor. Evacuate and recharge
A / C syst em. Refer t o Secti on 12-00.
4. Properl y route engine control sensor wiring and
connect el ectri cal connectors t o A / C
compressor and crankshaft position sensor.
5. Lower vehicle.
6. Install serpentine dri ve belt. Refer t o Secti on
03- 05.
SHOWN ASSEMBLED
B4478-B
Pa r t
2 12A227 CKP Pulse Wheel
3 N806155-S2 Screw
A

Tighten t o 8-12 N-m (71-106
Lb-ln)
I g n i t i o n C o i l
Re mo v a l
( 12A581) from ignition coils ( 12029) and radi o
ignition interference capaci t ors ( 18801) .
03- 07- 4 I gn i t i o n , E l e c t r o n i c 03- 07 - 4
2. Di sconnect ignition wi res by squeezi ng locking
t abs and twi sti ng while pulling upwar d.
SQUEEZE
LOCKING TABS
TO REMOVE
B4400-B
3. Remove four ignition coil retaining scr ews and
remove ignition coi l s and radi o ignition
i nterference capaci t ors. Save radi o ignition
i nterference capaci t ors for reinstallation wi t h
ignition coi l s.
1. Position ignition coils and radi o ignition
i nterference capaci t ors t o mounting bracket .
2. Install retaining scr ews and ti ghten t o 5-7 Nm
(40-61 Ib-in).
3. Appl y Silicon Di el ectri c Compound
D7AZ- 19A331 -A (Mot orcraf t WA-10) or
ESE-M1C171-A t o all ignition wi re spark plug
boot s.
4. Install each ignition wi re connector t o the proper
terminal on t he ignition coi l . Make sure boot s are
fully seat ed.
5. Connect ignition coi l s and radi o ignition
i nterference capaci t ors t o the engine control
sensor wi ri ng.
VIEW A
B5153-A
Pa r t
2 12043 Ignition Coil Mounting
Bracket (2 Req'd)
3 Radio Ignition Interference
Capaci tor Connector (Part of
12A581)
4

Ignition Coil Connector (Part
of 12A581)
5 N606502-S36M Screw (8 Req'd)
6 18801 Radio Ignition Interference
Capacitor (2 Req'd)
A

Lb-ln)
B r a c k e t , I g n i t i o n C o i l
1. Remove ignition coi l s ( 12029) as outlined.
2. Remove ignition coil mounting bracket retainers
and ignition coil mounting bracket s f rom engine
front cover ( 6019) .
ignition coil mounting bracket retai ners t o 20-30
N-m (15-22 Ib-ft).
03- 07- 5
Igni t i on, El e c t r o n i c 03- 07- 5
I g n i t i o n C o n t r o l Mo d u l e
Re mo v a l
1.
2.
Di sconnect ignition control module el ectri cal
connector by pushing down on the connector
finger ends while graspi ng the connector body
and pulling away f rom the ignition control module
( I CMX12K072) .
Remove t wo ignition control module retaining
scr ews and remove ignition control module.
SPEED CONTROL
SERVO 9C735
LH FRONT
FENDER
16005
IGNITION
CONTROL
MODULE
12K072
SCREW
N800770-S36
2 REQ'D
TIGHTEN TO
3-4 N-m
(24-35 LB-IN)
B4488-E
1. Position ignition control module t o front fender
( 16005) and install retaining scr ews. Tighten t o
3-4 N-m (24-35 lb-in).
2. Connect ignition control module el ectri cal
connector by pushing until connector fi ngers are
l ocked over l ocki ng wedge feature on ignition
control module. Locki ng the connector is
i mportant t o ensure sealing of the connector and
ignition control module i nterface.
I g n i t i o n Wi r e s
Re mo v a l
1. CAUTI ON: Do n o t pul l o n t h e i gn i t i o n wi r e
d i r e c t l y , t h e wi r e ma y s e p a r a t e f r o m t h e
c o n n e c t o r i n s i d e t h e b o o t .
Di sconnect ignition wi re f rom spark plug ( 12405)
by graspi ng the boot and twi sti ng slightly in both
di recti ons t o free it.
2. CAUTI ON: Do n o t pul l o n t h e i gn i t i o n wi r e
d i r e c t l y , t h e wi r e ma y s e p a r a t e f r o m t h e
c o n n e c t o r i n s i d e t h e b o o t .
Di sconnect the ignition wi re f rom t he ignition coil
( 12029) by squeezi ng the locking t abs and
twi sti ng while pulling upward.
SQUEEZE
LOCKING TABS
TO REMOVE
B4400-B
3. Remove three ignition wi re separat ors ( 12297)
f rom val ve cover retaining studs, open ignition
wi re separat ors and remove ignition wi re.
1. CAUTI ON: P r o pe r i n st a l l a t i o n of i gn i t i o n
wi r e s i s c r i t i c a l t o v e h i c l e o p e r a t i o n . If a n y
i gn i t i o n wi r e i s n o t p r o p e r l y i n s t a l l e d o n
s p a r k p l u g o r i gn i t i o n c o i l b o t h s p a r k pl u gs
c o n n e c t e d t o t h a t i gn i t i o n c o i l ma y n o t
o p e r a t e un d e r l o a d .
Whenever an ignition wi re is removed for any
reason f rom a spark plug or ignition coi l , or a new
ignition wi re is installed, coat the entire interior
surface of the boot s wi th Silicone Di el ectri c
Compound D7AZ- 19A331- A (Mot orcraf t WA-10)
ESE-M1C171-A using a small clean tool prior t o
installation.
2. Install each ignition wi re t o the proper terminal on
the ignition coi l s. The terminals on the ignition
coi l s are numbered. Make sure the boot s are fully
seat ed and that both ignition coil boot locking
t abs are engaged.
3. Route ignition wi re through ignition wi re separator
and cl ose ignition wi re separat ors. Install ignition
wi re separat ors onto val ve cover retaining studs.
4. NOTE: Ignition wi re spark plug boot must be
posi ti oned 45 degrees f rom crankshaft centerline
(outboard and f orward) to make sure the boot
seal is fully seat ed.
Connect ignition wi re to spark plug.
03- 07 - 6
I gn i t i o n , E l e c t r o n i c
03- 07 - 6
I gni t i on Wi re I nst al l at i on
TO STUD
VIEW 0
NOTE: ENSURE WIRE
SEPARATOR IS FULLY
ENGAGED ON STUD
B4477-E
03- 07 - 7
I gn i t i o n , E l e c t r o n i c 03- 07 - 7
Pa r t
Stem Numbe r De s c r i p t i o n
1 12297 Ignition Wire Separator
2 12286 Ignition Wire (8 Req'd)
4 12405 Spark Plug (8 Req'd)
5 12029 LH Ignition Coil
Pa r t
Capaci tor (2 Req'd)
7 12029 RH Ignition Coil
A

Lb-Ft)
( Co n t i n ue d )
R a d i o i g n i t i o n I n t e r f e r e n c e C a p a c i t o r
( 12A581) f rom radio ignition i nterference
capaci t ors ( 18801) .
Remove ignition coil and radio ignition
i nterference capaci t or retaining scr ews and radi o
ignition i nterference capaci t ors f rom mounting
bracket .
retaining scr ews t o 5-7 N-m (40-61 lb-in).
VIEW A
NOTE: RH IGNITION
COIL SHOWN;
LH IGNITION COIL
SIMILAR
B5153-A
Par t
2 12043 Ignition Coil Mounting
Bracket (2 Req'd)
3

Radio Ignition Interference
Capaci tor Connector (Part of
12A581)
I t e m
Pa r t
4

Ignition Coil Connector (Part
of 12A581)
5 N606502-S36M Screw (8 Req'd)
Capacitor (2 Req'd)
A

Lb-ln)
S p a r k P l u g s
1. Di sconnect ignition wi res f rom spark plugs
2. Loosen spark plugs 1 / 4 turn and remove any dirt
or foreign materi al f rom spark plug areas of
cylinder heads ( 6049) wi th compressed air.
3. NOTE: Three different styl es of platinum
enhanced spark plugs are produced for the
4. 6L2 V engine. Each plug has a different part
number, and use. AWSF-32P spark plugs have a
platinum enhanced center el ectrode and are used
in cyl i nders 4, 5 and 6. AWSF-32PG spark plugs
have a platinum enhanced ground (si de)
el ectrode, and are used in cyl i nders 1, 2 and 3. If
any spark plug is removed and re-installed, it
MUST be installed in the same cylinder f rom
whi ch it was removed. If any spark plug is
repl aced, use only spark plugs wi th part number
AWSF-32PP (as listed on the VECI label). This
repl acement spark plug has double platinum
enhancement on both the center and ground
el ectrode and may be used in all eight cyl i nders.
Remove spark plugs.
4. NOTE: Refer t o the Spark Plug Inspection Chart
t o determine the condition of spark plugs.
Check and adjust spark plug gap as outlined.
spark plugs t o 9-20 N-m (7-15 Ib-ft).
03- 07 - 8 I gn i t i o n , E l e c t r o n i c 03- 07- 8
Spark Pl ug I nspect i on Chart
GAP BRIDGED
I DE N T I FI E D B Y DE P O S I T B U I L D -
U P CLOSING GAP BETWEEN
ELECTRODES.
C A U S E D BY O I L O R C A R B O N
FOULING. REPLACE SPARK PLUG
CARBON FOULED
IDENTIFIED BY BLACK, DRY FLUFFY
CARBON DEPOSITS ON INSULATOR
TIPS, EXPOSED SHELL SURFACES
AND ELECTRODES.
CAUSED BY TOO COLD A PLUG,
DIRTY AIR CLEANER, DEFECTIVE
FUEL PUMP, TOO RICH A FUEL
MIXTURE, IMPROPERLY OPERATING
HEAT RISER OR EXCESSIVE IDLING.
REPLACE SPARK PLUG.
OIL FOULED
IDENTIFIED BY WET BLACK
DEPOSITS ON THE INSULATOR
SHELL BORE ELECTRODES.
CAUSED BY EXCESSIVE OIL
ENTERING COMBUSTION CHAMBER
THROUGH WORN RINGS AND
PISTONS, EXCESSIVE CLEARANCE
BETWEEN VALVE GUIDES AND
STEMS, OR WORN OR LOOSE
BEARINGS. CORRECT OIL
PROBLEM. REPLACE SPARK PLUG.
NORMAL
IDENTIFIED BY LIGHT TAN OR GRAY
DEPOSITS ON THE FIRING TIP.
PRE-IGNITION
IDENTIFIED BY MELTED ELECTRODES
AND POSSIBLY BLISTERED INSULATOR.
METALLIC DEPOSITS ON INSULATOR
INDICATE ENGINE DAMAGE.
CAUSED BY TOO COLD A PLUG,
DIRTY AIR CLEANER, DEFECTIVE
FUEL PUMP, TOO RICH A FUEL
MIXTURE, IMPROPERLY
OPERATING HEAT RISER OR
EXCESSIVE IDLING. REPLACE
SPARK PLUG.
OVERHEATING
IDENTIFIED BY A WHITE OR LIGHT
GRAY INSULATOR WITH SMALL
BLACK OR GRAY BROWN SPOTS
AND WITH BLUISH-BURNT
APPEARANCE OF ELECTRODES.
CAUSED BY ENGINE OVER-
HEATING, WRONG TYPE OF
FUEL, LOOSE SPARK PLUGS, TOO
HOT A PLUG, LOW FUEL PUMP
PRESSURE OR INCORRECT
IGNITION TIMING. REPLACE
SPARK PLUG.
FUSED SPOT DEPOSIT
IDENTIFIED BY MELTED OR SPOTTY
DEPOSITS RESEMBLING BUBBLES OR
BLISTERS.
CAUSED BY SUDDEN ACCELERATION
REPLACE SPARK PLUG.
B40S4-G
03- 07- 9 I gn i t i o n , E l e c t r o n i c 03- 07- 9
Spark Plugs
Cleaning spark plugs ( 12405) is not recommended.
Inspect the el ect rodes and outer surface. Refer t o
Spark Plug Inspection Chart. Repl ace spark plugs if
t hey are worn or damaged.
I g n i t i o n C o i l s
Wi pe t he ignition coil t ower s wi th a cl ean cl oth
dampened wi t h soap and water. Remove any.soap film
and dry wi th compressed air. Inspect ignition coil
( 12029) for cr acks, carbon tracki ng and dirt.
I g n i t i o n Wi r e s
Wi pe t he ignition wi res wi th a cl ean, damp cl oth prior
t o i nspecti on. Wi thout removing the ignition wi res f rom
t he spark plugs ( 12405) or ignition coils ( 12029) ,
i nspect the ignition wi res for visible damage such as
cut s, pi nches, cr acks or torn boot s. Repl ace only
damaged ignition wi res.
ADJUSTMENTS
S p a r k P l u g s
Using a suitable spark plug gap t ool , adjust spark plug
gap t o 1.3-1.4 mm ( 0. 052- 0. 056 inch) following tool
manufacturer' s i nstructi ons.
SPECIFICATIONS
MANUAL VEHICLE APPLICATIONS
Co u ga r
TA1000B
IGNITION SYSTEM SPECIFICATIONS
Descr i pt i on Speci f i cat i on
Sp a r k Pl ug Ty pe A WSF- 32 P P *
r
Sp a r k Pl ug Ga p 1. 31- 1. 41 mm ( 0. 052 - 0. 056
I n c h)
Fi r i n g Or d e r 1- 3- 7- 2- 6- 5- 4- 8
I gn i t i o n Ti mi n g 1 0 2 De gr e e s BT DC ( No t
A d j u s t a b l e )
a
Three different styl es of platinum-enhanced spark
plugs are produced for the 4. 6L2V engine. Each plug
has a different part number, and use. AWSF-32P spark
plugs (12405) have a platinum enhanced center
el ectrode and are used in cylinders 4, 5 and 6.
AWSF-32PG spark plugs have a platinum-enhanced
ground (side) el ectrode, and are used in cylinders 1, 2
and 3. If any spark plug is removed and re-i nstal l ed, it
MUST be installed in the same cylinder from whi ch it
was removed. If any spark is repl aced, use only spark
plugs wi th part number AWSF-32PP (as l i sted on the
VECI l abel ). This replacement spark plug has double
platinum enhancement on both the center and ground
el ectrode and may be used in all eight cyl i nders.
Descr i pt i on Nm Lb-l n
Cr a n ks h a f t P o s i t i o n Se n s o r S c r e w 8- 12 7 1- 106
I gn i t i o n Co n t r o l Mo d u l e S c r e ws 3-4 2 4- 35
I gn i t i o n Co i l S c r e w s 5-7 40- 61
I gn i t i o n Co i l Mo u n t i n g Br a c ke t
Re t a i n e r s
2 0- 30 15- 22
( L b - Ft )
Sp a r k Pl ugs 9- 2 0 7 - 15
( L b - Ft )
Ca p a c i t o r Re t a i n i n g S c r e w 5-7 40- 61
03- 08- 1 *. E n gi n e E mi s s i o n Co n t r o l 03- 08- 1
SECTION 03-08 Engine Emission Control
SUBJECT PAGE
Exhaust Gas Reci rcul at i on (EGR) System 03-08-1
Posi t i ve Crankcase Vent i l at i on (PCV)
Syst em . 03-08-1
Engi ne Emi ssi on Cont r oL. . . . .
0
. .03-08-2
IN-VEHICLE SERVICE
EGR Cont r ol Sol enoi d 03-08-5
EGR Pressure Sensor . 03-08-4
EGR Val ve... 03-08-3
SUBJECT PAGE
EGR Valve t o Exhaust Mani f ol d Tube .03-08-4
PCV Hoses ... 03-08-3
PCV Valve 03-08-3
EGR Cont r ol Sol enoi d .... 03-08-5
EGR Valve .03-08-5
PCV Valve 03-08-5
VEHICLE APPLICATION
P o s i t i v e C r a n k c a s e Ve n t i l a t i o n ( P CV) S y s t e m
CAUTI ON: Do n o t r e mo v e t h e PCV s y s t e m f r o m
t h e e n gi n e . Op e r a t i n g e n gi n e wi t h o u t PCV
s y s t e m wi l l r e d u c e b o t h f u e l e c o n o my a n d e n gi n e
v e n t i l a t i o n . Th i s wi l l w e a k e n e n gi n e p e r f o r ma n c e
a n d s h o r t e n e n gi n e l i f e .
The posi ti ve cr ankcase ventilation (PCV) syst em
cycl es crankcase gases back through the engine
where t hey are burned. The posi ti ve cr ankcase
ventilation val ve (PCV val ve)(6A666):
Regul ates t he amount of ventilating air and bl ow-by
fuel vapor t o the i ntake manifold ( 9424) .
Prevents backf i re f rom travel i ng into the crankcase.
Is mounted in a verti cal posi ti on.
Ty pi c a l PCV Ai r Fl ow Di a gr a m
A18842-B
Par t
1 6582 Valve Cover
2 To Air Cleaner Outlet Tube
3 6758 Crankcase Ventilation Tube
Ventilation Valve
Exhaust Gas R e c i r c u l a t i o n ( E GR) Syst em
The exhaust gas reci rcul ati on (EGR) syst em is
desi gned t o:
Rei ntroduce exhaust gas into the combusti on cycl e.
Lower combusti on t emperat ures.
Reduce t he formati on of nitrous oxi de (NOX).
The amount of exhaust gas rei ntroduced and the
timing of the cycl e vari es by cal i brati on. Timing and
volume are control l ed by:
Engine rpm.
Engine vacuum.
08- 08- 2 Engi ne Emi ssi on Cont r ol 03- 08- 2
Exhaust syst em back pressure.
Engine cool ant t emperat ure.
Throttl e posi ti on.
The EGR val ve (EGR val ve)(9D475) is vacuum
act uat ed. The vacuum hose routing di agram is shown
on t he Vehicle Emission Control Information (VECI)
decal .
The EGR is a differential pressure f eedback EGR
(DPFE) syst em. DPFE is a subsoni c cl osed loop EGR
syst em. The DPFE syst em:
Moni t ors EGR fl ow rate by the pressure drop
acr oss the meteri ng ori fi ce.
Uses an EGR pressure sensor ( 9J460) as t he
f eedback devi ce.
Control l ed pressure is vari ed by the val ve
movement using vacuum output of the EGR vacuum
regul ator control ( 9J459) .
Uses the EGR val ve only as a pressure regulator,
rat her than a fl ow meteri ng devi ce.
Al l ows for a more accurat e assessment of EGR fl ow
requi rements.
EGR (DPFE) Fl ow Di a gr a m
ANALOG VOLTAGE
INPUT
[
DUTY
CYCLE OUTPUT
DPFE
SENSOR
CONTROLLED
PRESSURE
INPUT
EGR
k
FLOW
INTAKE ,
VACUUM
EXHAUST
PRESSURE
INPUT
METERING
ORIFICE
EXHAUST PRESSURE
EXHAUST
FLOW
A14906-C
E x h a u s t E mi s s i o n C o n t r o l S y s t e m
Ve hi c l e E mi s s i o n Co n t r o l I n f o r ma t i o n De c a l
Vacuum hoses on the engine use a col or stri pe t o aid in
hose routing checks. The stri pe will usually be the
same col or as on the Vehicle Emission Control
Information decal , but t he correct vacuum hose routing
must be veri fi ed by using the correct component
connecti ons shown on t he VECI decal .
Ty pi c a l VECI Decal
FORD MOTOR COMPANY
VE HI CL E EMI SSI ON CONT ROL I NFORMATI ON
TMto VOMOM Is osti^ppod wMt otoctronlc OMJI M control WMMM> <
To efttek wiglm timing Mi paffOftgJsfito and Mo@i whitta. Engta mtat to at
"~ *" *" in MutnJ, mini MX^ MMI M off.
(1)*Rsifiotf
ft Dfteonnset Hit ta-flnt
spots! Qmmm? i *m %
ft i@-sM pt@toiis%
wMintdnip nolnt.
(4) Vwlfy tttat fit ignition
timing lo 10BTDC if
not M@ shop HMMML
ft 1km tugta off ani fwtMt
use SAE mm m m taf
S<itrgj? C O# MI V ^ 11
Thto wMdo conforms to
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sppttoaote to 1HS mocM
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A18895-A
E n g i n e E m i s s i o n C o n t r o l
Manual
1
for di agnosi s of the engine emission control
syst ems.
IN-VEHICLE SERVICE
PCV Valve
1. Remove air cl eaner outlet t ube ( 9B659) as
Di sconnect crankcase vent connector and hose
( 6C324) f r om posi ti ve cr ankcase ventilation
val ve (PCV val ve)(6A666).
Remove posi ti ve crankcase ventilation val ve f rom
grommet ( 14603) in RH val ve cover ( 6582) .
Inspect posi ti ve crankcase ventilation val ve and
grommet for deteri orati on. Repl ace as
necessary.
To install, reverse Removal procedures.
FRONT OF
ENGINE
A23534-A
I t e m
Pa r t
d u mb e r De s c r i p t i o n
Ventilation Valve
3 14603 Grommet (2 Req'd)
4 6C324 Crankcase Vent Connector
and Hose
5

To Throttle Body (Part of
6C324)
P C V H o s e s
C r a n k c a s e Ve n t i l a t i o n T u b e
1.
2.
Remove air cl eaner outlet t ube ( 9B659) as
outlined in Sect i on 03- 12.
Remove crankcase ventilation tube ( 6758) f rom
LH val ve cover grommet ( 14603) .
3. Inspect grommet and cr ankcase ventilation t ube
for deteri orati on. Repl ace as necessary.
C r a n k c a s e Ve n t i l a t i o n H o s e
1. Remove air cl eaner outlet tube as outlined in
Secti on 03- 12.
2. Di sconnect cr ankcase vent connect or and hose
( 6C324) f rom posi ti ve crankcase ventilation
valve (PCV val ve)(6A666).
3. Di sconnect cr ankcase vent connect or and hose
f rom throttl e body adapt er vacuum fi tti ng.
E G R Va l v e
Re mo v a l
1. Remove air cleaner outlet tube ( 9B659) as
2. Raise vehi cl e on hoist. Refer t o Secti on 00- 02.
3. CAUTI ON: Use c a r e n o t t o d a ma g e EGR v a l v e
t u b e t o ma n i f o l d c o n n e c t o r ( 9F485) .
NOTE: Hold EGR val ve tube t o manifold
connector wi th a wrench whi l e di sconnecti ng
EGR val ve t o exhaust manifold tube ( 9D477) .
Di sconnect EGR val ve t o exhaust manifold tube
from EGR val ve (EGR val ve)(9D475) and EGR
valve tube t o manifold connector.
4. Lower vehicle.
5. Di sconnect EGR pressure sensor hoses f rom
EGR val ve t o exhaust manifold tube.
6. Di sconnect vacuum hose f rom EGR val ve.
7. Remove t wo EGR val ve retaining bol ts.
03=08- 4
Engi ne Emi ssi on Cont r ol 03- 08- 4
8. Remove EGR val ve, EGR val ve gasket ( 9D47 6)
and EGR val ve t o exhaust manifold tube f rom
vehicle.
NOTE: EXHAUST MANIFOLD /
SHOWN REMOVED FOR CLARITY
PURPOSES ONLY A13675-B
Pa r t
1 N804073-S8 Bolt (2 Req'd)
2 9430 RH Exhaust Manifold
3 9F485 EGR Valve Tube to Manifold
Connector
4 9D477 EGR Valve to Exhaust
Manifold Tube
5 9D475 EGR Valve
A

Tighten t o 20-30 N-m (15-22
Lb-Ft)
B

Tighten t o 45-65 N-m (33-48
Lb-Ft)
C

Lb-Ft)
1. Glean i ntake manifold sealing surface wi t h a
pl asti c-ti pped scraper t o remove any residual
EGR val ve gasket materi al .
2. NOTE: Do not tighten EGR val ve t o exhaust
manifold tube nut on EGR val ve at this ti me.
Position EGR val ve t o exhaust manifold tube into
EGR val ve and loosely connect EGR val ve t o
exhaust manifold tube nut t o EGR val ve.
3. Position EGR val ve gasket , EGR val ve and EGR
val ve t o exhaust manifold tube into vehi cl e.
4. Install t wo bol ts retaining EGR val ve t o i ntake
manifold ( 9424) . Tighten bol ts t o 20-30 N-m
(15-22 Ib-ft).
5. Connect vacuum hose t o EGR val ve.
6. Connect EGR pressure sensor hoses t o EGR
7. Raise vehi cl e.
8. NOTE: Hol d EGR val ve tube t o manifold
connector wi t h a wrench while tightening EGR
val ve t o exhaust manifold tube nut.
Connect EGR val ve t o exhaust manifold tube t o
EGR val ve tube t o manifold connector. Tighten
EGR val ve t o exhaust manifold tube nuts t o 35- 45
N-m ( 26- 33 Ib-ft).
9. Lower vehi cl e.
10. Install air cl eaner outlet tube as outlined in Secti on
03- 12.
E G R Va l v e t o E x h a u s t Ma n i f o l d T u b e
Refer t o EGR Valve In-Vehicle Servi ce procedures for
removal and installation of EGR val ve t o exhaust
manifold tube ( 9D477) .
E G R P r e s s u r e S e n s o r
EGR pressure sensor ( 9J460) .
2. Di sconnect EGR pressure sensor hoses f rom
EGR pressure sensor.
3. Remove EGR pressure sensor retaining bol ts and
EGR pressure sensor f rom transducer mounting
bracket ( 9J432) .
EGR pressure sensor retaining bolts to 5-7 Nm
( 40- 61 Ib-in).
Pa r t
1 N611037-S2 Bolt (2 Req'd)
2 9J460 EGR Pressure Sensor
3 N620479-S50 Nut
4 9J459 EGR Vacuum Regulator
Control
5 N606676-S36 Bolt
6 9J432 Transducer Mounting
Bracket
7 9D761 EGR Pressure Sensor Hoses
A

Lb-ln)
B

Tighten to 8 - 1 2 N-m (71-106
Lb-ln)
EGR Cont rol Solenoi d
1. Di sconnect fuel chargi ng wiring ( 9D930) f rom
EGR vacuum regul ator control ( 9J459) .
2. Di sconnect main emission vacuum control
connector ( 9E498) f rom EGR vacuum regulator
cont rol .
3. Remove retaining nut and EGR vacuum regulator
control f rom transducer mounting bracket l ocated
at rear of lower i ntake manifold ( 9424) .
retaining nut for EGR vacuum regul ator control t o
5-7 N-m (40-61 Ib-in).
PCV Valve
Cleaning of the positive cr ankcase ventilation val ve
(PCV val ve) ( 6A666) is not recommended. Refer t o
Secti on 00- 03 for the recommended posi ti ve
cr ankcase ventilation val ve mai ntenance mi l eage
i nterval . The posi ti ve cr ankcase ventilation val ve
shoul d be repl aced at the speci fi ed mileage i nterval s.
Shake posi ti ve crankcase ventilation val ve and
careful l y i nspect for splits or cr acks. If posi ti ve
cr ankcase ventilation val ve does not rattl e or is
damaged, repl ace posi ti ve crankcase ventilation
val ve.
EGR Va l v e
Inspect t he EGR valve (EGR val ve)(9D475) for
bl ockage or contami nati on. Clean EGR val ve using
Rotunda EGR Valve Cleaner 021- 0056A or equivalent
fol l owi ng manufacturer' s i nstructi ons. Inspect EGR
val ve for vacuum l eakage and repl ace if necessary.
EGR Cont rol Solenoi d
1. Di sconnect the vacuum hoses f rom the EGR
vacuum regulator control ( 9J459) .
2. Lightly bl ow air into t he EGR vacuum regul ator
control and verify t hat air does not fl ow.
3. Di sconnect the fuel chargi ng wiring ( 9D930) f rom
the EGR vacuum regulator control .
4. Appl y bat t ery vol tage and a ground t o the EGR
vacuum regulator control at the connector.
5. Lightly bl ow air into t he EGR vacuum regul ator
control and verify that air does not fl ow through
the EGR vacuum regulator control .
6. If air does not blow through the EGR vacuum
regul ator control , repl ace t he EGR vacuum
regul ator control as outlined.
SPECIFICATIONS
OBDI I 3.8L Mu s t a n g , 4. 6L To wn Ca r , Cr o wn Vi c t o r i a ,
Co uga r
TA1000B
EGR Va l v e Bo l t s SO-30 15-22
EGR Va l v e t o E x h a u s t Ma n i f o l d
Tube Nut s
35- 45 2 6- 33
TORQUE SPECIFICATIONS (Cont' d)
Description N-m Lb-Ft
EGR P r e s s u r e Se n s o r Bo l t s 5-7 40- 61
( Lb- l n )
T r a n s d u c e r Mo u n t i n g Br a c k e t Bo l t 8- 12 7 1- 106
( L b- l n )
EGR Va l v e Tube t o Ma n i f o l d
Co n n e c t o r
45- 65 33- 48
ROTUNDA EQUIPMENT
Model Description
02 1- 0056A EGR Va l v e Cl e a n e r
03- 12 - 1 ASr I n t a ke Sy s t em 03- 12 - 1
SECTION 03-12 Air Intake System
SUBJECT PAGE
Air Cleaner El ement 03-12-1
Air Inducti on System 03-12-1
Air Intake System .... 03-12-1
SUBJECT PAGE
REMOVAL AND INSTALLATION (Cont' d.)
Air Cleaner Outl et Tube .03-12-3
Engine Air Cleaner 03-12-3
Air Cleaner Element 03-12-3
Engi ne Air Cleaner 03-12-3
VEHICLE APPLICATION
Air Induct i on Syst em
NOTE: All engines are equi pped wi t h a repl aceabl e
dry-t ype air cleaner element (ACL el ement )(9601).
The air induction syst em performs t he fol l owi ng
functi ons:
Supplies clean air t o the throttl e body ( 9E926) .
Outsi de air enters f rom an opening in t he LH front
fender apron ( 16054) into the engine air cleaner
( ACL) ( 9600) where it is fi l tered by the air cl eaner
element.
Thi s fi l tered air then travel s t hrough the mass air
fl ow sensor ( MAF sensor ) ( 12B579) , air cl eaner
outlet tube ( 9B659) and into the t hrot t l e body.
The posi ti ve crankcase ventilation (PCV) syst em is
al so suppl i ed clean air through a fi tti ng on t he air
cleaner outlet tube.
Air induction noise is effecti vel y eliminated by means
of a seal ed and tuned resonator chamber l ocated in
the air cleaner cover.
Air Cleaner Element
The air cl eaner element (ACL el ement )(9601) is a:
Dry-t ype air cleaner element.
Chemi cal l y t reat ed, pl eated paper air filtering
element whi ch permi ts air fl ow through t he air
induction syst em, filtering out unwanted dust, dirt
and debri s.
Air Intake Syst em
Refer t o t he Powertrai n Cont rol / Emi ssi ons Di agnosi s
Manual
1
f or di agnosi s and testi ng procedures.
Air Cleaner Element
Refer t o Secti on 00- 03 for the Emissions Schedul ed
Mai ntenance for f requency of i nspecti on and/ or
repl acement of t he air cl eaner element (ACL
el ement )(9601).
Removal
1. Loosen engine air cleaner tube cl amp ( 9C632) at
air cl eaner outlet tube ( 9B659) t o mass air fl ow
sensor ( MAF sensor)(12B579) and remove air
cl eaner outlet tube f rom mass air fl ow sensor.
03- 12- 2
Ai r I n t a ke S y s t e m 03- 12- 2
2. Di sconnect engine control sensor wi ri ng
( 12A 581) f rom t he mass air fl ow sensor and
i ntake air temperature sensor (IAT
sensor ) ( 12A697) .
3. Unfasten retaining clips t o remove the air cl eaner
cover.
4. Remove air cleaner el ement.
1. Clean all inside surfaces of t he engine air cl eaner
( ACLX9600) as outlined.
Air I nt ake Syst em
2. Install t he air cl eaner element.
3. Position air cl eaner cover on t he air cl eaner body
and secure retaining cl i ps.
4. Connect engine control sensor wi ri ng t o the
i ntake air temperature sensor and engine control
sensor wi ri ng.
5. Install air cleaner outlet tube t o mass air fl ow
sensor and ti ghten engine air cl eaner tube cl amp
t o 3. 4-4. 6 N-m (30-41 lb-in).
V7612-C
Pa r t Pa r t
1 9H308 Idle Air Control Valve Inlet
Tube
9 9P686 Engine Air Cleaner Support
Insulator
2 6758 Crankcase Ventilation Tube 10 N623332-S2 Nut
3 9C632 Engine Air Cleaner Tube
11 16044 LH Front Fender Apron
Clamp 12

Idle Air Control Valve Inlet
4 9B659 Air Cleaner Outlet Tube (Part of 9424)
5 N621907-S2 Nut (5 Req'd)
6 12A697 Intake Air Temperature
14 9723 Accelerator Cable Bracket
Sensor 15 W611102-S2 Bolt
7 9600 Engine Air Cleaner A

Tighten to 3.4-4.6 N-m (30-41
8 12B579 Mass Air Flow Sensor Lb-ln)
03- 12- 3 Ai r I nt ake S y s t e m 03- 12- 3
I t em
Par t
B

Tighten to 2.3-3.4 N-m (20-30
Lb-ln)
I t em
Pa r t
c

Lb-ln)
En g i n e Ai r Cl e a n e r
Remov al a n d I nst al l at i on
1. Loosen engine air cleaner tube cl amp ( 9C632) at
mass air f l ow sensor (MAP sensor)(12B579).
2. Remove air cleaner outlet t ube ( 9B659) f rom
mass air f l ow sensor.
( 12A581) f rom mass air f l ow sensor and i ntake
air t emperat ure sensor (IAT sensor)(12A697).
4. Remove engine air cleaner retaining nuts and
engine air cleaner ( ACL) ( 9600) .
5. To install, reverse removal procedure. Tighten
engine air cleaner retaining nuts t o 2.3-3.4 N-m
( 20- 30 Ib-in). Tighten engine air cleaner tube
cl amp t o 3.4-4.6 N-m ( 30- 41 Ib-in).
A i r C l e a n e r O u t l e t T u b e
1. Loosen engine air cleaner tube cl amps ( 9C632)
and remove air cleaner outlet tube retaining bolt.
2. Di sconnect crankcase ventilation tube ( 6768)
and idle air control val ve inlet tube ( 9H308) f rom
air cl eaner outlet tube ( 9B659) and remove air
cl eaner outlet tube.
3. To install, reverse removal procedure. Tighten air
cl eaner outlet tube retaining bolt t o 2-3 N-m
(18-27 Ib-in). Tighten engine air cl eaner tube
cl amps t o 3.4-4.6 N-m (30-41 Ib-in).
A i r C l e a n e r E l e m e n t
CAUTI ON: Cl e a n i n g t h e ai r c l e a n e r e l e me n t ( ACL
e l e me n t ) ( 9601) i s n o t r e c o mme n d e d .
Refer t o Secti on 00- 03 for the recommended air
cl eaner el ement maintenance mileage interval. The air
cl eaner element should be repl aced at the speci fi ed
mileage i nterval s.
Visually inspect t he air cl eaner element for si gns of
dust or dirt leaking through hol es in t he filter medi a or
past the sealing edges. Pl ace a light on t he bot t om
(cl ean si de) of the air cleaner el ement and l ook
through the filter medi a at the light. Even t he smal l est
hole is cause for repl acement.
Al so check the air cl eaner element for def ormed seal s
or for charred (burned) or brittle spot s that coul d fail
under engine operati on and cause a hole.
Di scol orati on only is not a cause for repl acement.
E n g i n e A i r C l e a n e r
Clean the air cl eaner body and the cover wi th a sol vent
or compressed air. Wi pe the air cleaner body and
cover dry if a sol vent is used. Inspect the air cl eaner
body and cover f or di storti on or damage at the gasket
mating surfaces. Repl ace cover or body if t hey are
damaged beyond servi ce.
SPECIFICATIONS
MANUAL VEHICLE APPLICATIONS
OBDI I 3. 8L Mu s t a n g, 4. 6L To wn Car, Cr o wn Vi c t o r i a ,
Co u ga r
OBDI Al l Ot he r Ve h i c l e s
TA1000B
Descr i pt i on N m Lb- l n
En gi n e Ai r Cl e a n e r Tube Cl a mp 3. 4-4. 6 30- 41
En gi n e Ai r Cl e a n e r Re t a i n i n g Nut 2. 3- 3. 4 2 0- 30
Ai r Cl e a n e r Out l e t Tube Re t a i n i n g
Bo l t
2-3 18-27
03- 13- 1
SECTION 03-13 Evaporative Emissions
SUBJE CT PAGE
Evaporati ve Emi ssi on Cani st er 03-13-2
Evaporati ve Emi ssi on Cani st er Purge
Valve 03-13-2
Evaporati ve Emi ssi on Control Syst em .03-13-1
Evaporati ve Emi ssi on Hose ..03-13-2
Evaporati ve Emi ssi on Tube Shut Off Valve... 03-13-3
Evaporati ve Emi ssi on Valve 03-13-4
Fill Cont rol /Vent Syst em ..03-13-1
Pressure and Vacuum Relief Syst em 03-13-3
Syst em Components ...03-13-2
Evaporati ve Emi ssi ons 03-13-4
SUBJECT PAGE
Inspection and Verification .03-13-4
Pinpoint Test 03-13-5
Evaporat i ve Emi ssi on Cani st er 03-13-5
Evaporat i ve Emi ssi on Cani st er Purge
Valve 03-13-6
Evaporat i ve Emi ssi on Hose .03-13-6
Evaporat i ve Emi ssi on Tube Shut Off Valve.. 03-13-7
Evaporat i ve Emi ssi on Valve 03-13-7
VEHICLE APPLICATION
Evaporat i ve Emi ssi on Cont rol Syst em
As a part of t he fuel syst em, all vehi cl es are equi pped
wi t h fuel vapor evaporat i ve emission control syst ems
t o meet Federal requi rements in effect at t he ti me of
producti on.
The fuel tank evaporat i ve emission syst em al l ows for
control l ed rel ease of fuel tank pressure through t he
evaporat i ve emi ssi ons cani ster (EVAP
cani st er)(9D653). Under normal operati ng condi ti ons,
thi s syst em will al l ow sufficient venting t o prevent a
build-up of internal fuel t ank pressure.
Some operati ng condi ti ons may cause t emporary
build-up of internal fuel tank pressure. Some of t hese
condi ti ons are:
On war m or hot days, parki ng t he vehi cl e after filling
t he fuel tank ( 9002) , t he fuel is cool f rom
underground st orage and vapori zes rapidly when
war med.
Parki ng after driving over rough roads, washboar d,
or other harsh surf aces, after filling t he fuel t ank.
Agi tati on of fuel i ncreases vapori zati on.
Climbing long grades, especi al l y whi l e towi ng a
trailer or while fully l oaded.
Parki ng after driving long di stances in high
temperature condi ti ons.
A normally-functioning fuel tank evaporati ve emission
syst em will relieve t he pressure build-up.
No servi ce is requi red if t hese condi ti ons caused the
concern. A bl ocked fuel tank evaporati ve emission
syst em can cause abnormal fuel tank pressure and
must be servi ced. Refer t o Inspection and Verification
as outlined.
Most components of t he evaporati ve emission control
syst em are servi ced by a simple nut, bolt or scr ew for
part removal and installation.
If push pins are removed, they must be repl aced wi th
new pins. Refer t o syst em illustration in Removal and
Installation.
Fi l l C o n t r o l / V e n t Syst em
Fill cont rol is accompl i shed by t he fol l owi ng met hod:
A venting line integral t o the fuel tank filler pi pe
( 9034) ext ends inside t he fuel tank ( 9002) .
The evaporati ve emission tube shut off val ve
( 9G332) senses fuel tank filler cap ( 9030) removal
by a change in pressure of t he fuel tank. The
evaporati ve emission tube shut off val ve cl oses the
fl ow path f rom the evaporati ve emission val ve
( 9B593) t o the evaporati ve emi ssi ons cani sters
(EVAP cani st er)(9D653) during refueling t o prevent
overfilling of the fuel t ank.
03- 13- 2 E v a p o r a t i v e E mi s s i o n s 03- 13- 2
e The vent syst em is desi gned t o provi de an air
space, approxi matel y 15 percent of t he fuel t ank
vol ume, above t he fuel level in the fuel t ank.
The air space al l ows for thermal expansi on of fuel
and provi des cl earance bet ween the fuel and t he
evaporati ve emission val ve, whi ch is mounted in the
t op panel of the fuel t ank.
The cl earance is sufficient t o al l ow fuel vapor
venting through t he evaporati ve emi ssi on val ve
under all stati c and most dynami c vehi cl e
conditions.
S y s t e m C o m p o n e n t s
Fu e l T a n k E v a p o r a t i v e E mi s s i o n S y s t e m
Thi s syst em consi st s of:
Seal ed fuel tank ( 9002) and fuel tank filler pi pe
( 9034) .
Pr essur e/ vacuum relief fuel tank filler cap ( 9030) .
Evaporati ve emission val ve ( 9B593) .
e Evaporati ve emission tube shut off val ve ( 9G332) .
Evaporati ve emission and brake tube ( 9S294) .
Evaporati ve emissions cani ster (EVAP
cani st er)(9D653).
E n g i n e E v a p o r a t i v e E mi s s i o n S y s t e m
Thi s syst em consi sts of:
Evaporati ve emission cani ster purge val ve (EVAP
cani ster purge val ves)(9C915).
Evaporati ve emissions cani ster.
Syst em control and operati on are accompl i shed
through four separat e basi c functi ons in t he syst em:
1. Fill control vent syst em.
2. Fuel tank vapor venting and st orage syst em.
3. Fuel vapor purge syst em.
4. Pressure and vacuum relief syst em (fuel tank filler
cap) .
E v a p o r a t i v e E m i s s i o n C a n i s t e r
Fuel vapor emi tted through t he evaporat i ve emission
valve ( 9B593) is st ored in t wo evaporati ve emissions
cani sters (EVAP cani st er)(9D653).
TO EVAPORATIVE EMISSION CANISTER
PURGE VALVE 9C915
EVAPORATIVE EMISSION CANISTER
9 0 6 5 3
VS844-A
E v a p o r a t i v e E m i s s i o n H o s e
The fuel tank vent tube ( 9A228) transmi ts st ored fuel
vapor f rom t he evaporati ve emi ssi ons cani sters (EVAP
cani st er)(9D653) and evaporati ve emission and brake
tube ( 9S294) through t he evaporati ve emission
cani ster purge val ve (EVAP cani ster purge
val ves)(9C915) and to t he engine.
E v a p o r a t i v e E m i s s i o n C a n i s t e r P u r g e Va l v e
The evaporati ve emission cani ster purge val ve (EVAP
cani ster purge val ves)(9C915):
Is in-line wi t h the evaporati ve emissions cani sters
(EVAP cani st er)(9D653).
Controls t he fl ow of fuel vapors out of the
evaporati ve emissions cani sters.
Cl oses off vapor fl ow f rom t he evaporati ve
emissions cani sters when t he engine is not running.
After the engine i s st art ed, in response to a signal from
the powertrai n control module ( PCM) ( 12A650) , the
evaporati ve emission cani ster purge valve opens and
cl oses t o al l ow fuel vapors t o fl ow f rom the
evaporati ve emi ssi ons cani ster t o the engine.
TO POWERTRAIN
CONTROL MODULE
v
12A650
TO VACUUM
SOURCE
TO EVAPORATIVE EMISSION *
CANISTERS 9D653
EVAPORATIVE EMISSION
CANISTER PURGE VALVE
9C915
TO ENGINE
PORT
V9842-A
Pressure and Vacuum Relief Syst em
Fuel Tank Filler Cap
The fuel tank filler cap ( 9030) is a seal ed cap wi t h a
built-in pressure-vacuum relief val ve and:
Fuel syst em vacuum relief is provi ded after
negati ve 2 kPa ( 0. 28 psi ).
Provi des pressure relief above 14 kPa (2 psi ).
Under normal operati ng condi ti ons, t he fuel t ank
filler cap operat es as a check val ve, allowing air t o
enter t he fuel tank ( 9002) as fuel is used, whi l e
preventi ng fuel vapors f rom escapi ng t he fuel t ank
through t he fuel t ank filler cap.
Evaporat i ve Emi ssi on Tube Shut Off Valve
The evaporat i ve emission tube shut off val ve ( 9G332)
is l ocat ed in-line bet ween the evaporati ve emission
val ve ( 9B593) and the evaporati ve emissions cani ster
(EVAP cani st er)(9D653). The evaporati ve emission
t ube shut off val ve control val ve is mounted on t he fuel
t ank ( 9002) by an integral bracket . The evaporati ve
emi ssi on tube shut off val ve cl oses the fl ow path f rom
t he evaporat i ve emi ssi on val ve t o t he evaporati ve
emi ssi ons cani ster during refueling t o prevent
overfilling of the fuel t ank.
VIEW A
TUBE SHUT OFF
VALVE 9G332
PRESSURE SENSING PORT
TO FUEL TANK FILLER PIPE
9034
TO EVAPORATIVE
EMISSION CANISTERS
9D653
FROM EVAPORATIVE
EMISSION VALVE
VIEW A
V9843-A
1995 To wn Ca r , Gr o wn Vi c t o r i a , Gr a n d Ma r q u i s Jul y 1994
Evaporat i ve Emi ssi on Valve
Fuel vapor in t he fuel t ank ( 9002) is vented t o t he
evaporati ve emi ssi ons cani ster (EVAP
cani st er)(9D653) t hrough the evaporati ve emi ssi on
val ve ( 9B593) and t he evaporat i ve emission t ube shut
off val ve ( 9G332) . The evaporat i ve emission val ve is
mounted in a rubber grommet at a central l ocati on in
the upper surface of t he fuel tank. A vapor space
bet ween t he fuel level and the fuel t ank upper surf ace
is combi ned wi t h an ori fi ce and fl oat shut-off val ve in
the evaporat i ve emi ssi on val ve t o prevent liquid fuel
f r om passi ng t o t he evaporat i ve emission tube shut off
val ve and t he evaporat i ve emi ssi ons cani sters. The
vapor space al so al l ows for thermal expansi on of t he
fuel .
VIEW A
TO FUEL
TANK
9002
VALVE 9B593
TUBE SHUT OFF
VALVE 9G332 VIEW A
V9840-A
Evaporat i ve Emi ssi ons
Manual
1
for di agnosi s of Engine Evaporati ve Emission
Syst em.
1. Veri fy t he vehi cl e owner' s original concern by
removi ng the fuel filler cap t o dupl i cate the
condi ti on.
2. Inspect t o determi ne if any of t he fol l owi ng
If t he concern(s) remain after the i nspecti on,
determi ne the sympt oms and go t o t he Sympt om
Chart.
Mechanical
Hi s s i n g s o u n d o r r e l e a s e o f p r e s s u r e a s t h e f ue l t a n k f i l l e r
c a p i s r e mo v e d f r o m t h e f ue l t a n k f i l l e r p i p e .
Sympt om Chart
EVAPORATIVE EMISSIONS DIAGNOSIS
Fuel Tank Pressure Abnormal Evaporative emission hoses,
valves or inlets blocked.
Tubes or hoses kinked or pi nched.
1995 To wn Car, Cr o wn Vi c t o r i a , Gr a n d Ma r qui s Jul y 1994
03- 13- 5 E v a p o r a t i v e E mi s s i o n s
03- 13- 5
Pi npoi nt Test
PINPOINT TEST A: FUEL TANK PRESSURE ABNORMAL
A1 FUNCTIONAL TESTVAPOR SUPPLY LINE
DISCONNECTED
Yes
No
GO t o A3.
GO t o A2.
With the fuel level below 1/2, disconnect
evaporative emission and brake tube at fuel vapor
canister.
Plug the evaporative emission and brake tube.
Using Rotunda Fuel Tank Leak Tester 134-00003,
pressurize the fuel system through the t est fuel tank
filler cap.
Remove plug from the evaporative emission and
brake tube.
Di d t he f uel sy st em pressure decay?
Yes
No
GO t o A3.
GO t o A2.
A2 CANISTER INLET AND VAPOR TUBE BLOCKAGE TEST
Yes
No
REMOVE blockage or
REPLACE component.
VERIFY service.
GO to A3.
Inspect canister inlet nipple and evaporative
emission and brake tube for bl ockage.
Are i nl et or evaporat i ve emi ssi on and brake t ube
bl oc ke d?
Yes
No
REMOVE blockage or
REPLACE component.
VERIFY service.
GO to A3.
A3 FUNCTIONAL TESTEVAPORATIVE EMISSION
CONTROL VALVE SIGNAL LINE DISCONNECTED
Yes
No
REPLACE the
evaporative emission
tube shut off valve.
VERIFY service.
GO t o A4.
Disconnect the evaporati ve emission control valve
signal line from t he fuel tank filler pipe.
Plug t he signal line at t he fuel tank filler pi pe.
Plug t he evaporati ve emission supply line at fuel
vapor canister.
Pressurize the fuel syst em.
Remove plug from the evaporative emission supply
line.
Di d t he f uel sy st em pressure decay?
Yes
No
REPLACE the
evaporative emission
tube shut off valve.
VERIFY service.
GO t o A4.
A4 FUNCTIONAL TESTEVAPORATIVE EMISSION TUBE
DISCONNECTED
Yes
No
System OK, no servicing
required.
REPLACE fuel vapor
valve and grommet.
VERIFY service.
Remove evaporative emission tube from fuel vapor
valve at evaporati ve emission tube shut off valve.
Di d t he f uel t ank sy st e m pressure decay?
Yes
No
System OK, no servicing
required.
REPLACE fuel vapor
valve and grommet.
VERIFY service.
E v a p o r a t i v e E m i s s i o n C a n i s t e r
2. Remove evaporat i ve emi ssi on cani ster retaining
bol ts.
3. Partially l ower evaporati ve emi ssi ons cani sters
(EVAP cani st er)(9D653) and di sconnect
evaporat i ve emi ssi on and br ake tube ( 9S294)
f rom evaporat i ve emi ssi ons cani st ers.
evaporat i ve emission cani ster retaining bol ts t o
5. 2-7. 2 N-m ( 46- 63 Ib-in). Perform syst em leak
check as f ol l ows:
a. Di sconnect and plug fuel tank filler pipe shield
( 9A097) leading t o the evaporat i ve
emi ssi ons cani ster at t he evaporat i ve
emi ssi on cani ster purge val ve (EVAP cani ster
purge val ves)(9C915).
b. Plug vent at the evaporati ve emissions
cani ster.
c. Using Rotunda Fuel Tank Leak Tester
134-00003, pressuri ze t he fuel syst em
through the test fuel tank filler cap.
d. Verify that the pressure within the syst em
does not decay.
e. If pressure does decay, determi ne the cause
of the leak and repair.
f. Remove plugs and reconnect fuel tank filler
pipe shield t o the evaporati ve emission
E v a p o r a t i v e E m i s s i o n H o s e
1. Di sconnect fuel tank vent t ube ( 9A228) f rom
evaporat i ve emission and br ake tube ( 9S294) at
RH si de of f rame ( 5005) .
2. Di sconnect ignition wi re separat ors ( 12297) f rom
RH val ve cover stud bol ts and position ignition
wi res out of t he way.
3. Di sconnect fuel tank vent t ube f rom t he
evaporat i ve emission cani ster purge val ve (EVAP
4. Di sconnect fuel tank vent t ube f rom throttl e body
adapt er port and remove fuel tank vent tube f rom
vehi cl e.
5. To install, reverse Removal procedures. Perform
syst em l eak check as f ol l ows:
a. Di sconnect and plug fuel t ank filler pipe shield
( 9A097) leading t o the evaporat i ve
emi ssi ons cani ster (EVAP cani st er)(9D653)
at t he evaporat i ve emi ssi on cani ster purge
val ve.
b. Plug vent at the evaporat i ve emi ssi ons
cani ster.
134- 00003, pressuri ze t he fuel syst em
through t he t est fuel t ank filler cap.
d. Verify t hat t he pressure within the syst em
does not decay.
e. If pressure does decay, determi ne t he cause
of t he l eak and repair.
f. Remove plugs and reconnect fuel t ank filler
pi pe shi el d t o t he evaporat i ve emission
E v a p o r a t i v e E m i s s i o n C a n i s t e r P u r g e Va l v e
1. Di sconnect main emission vacuum control
connector ( 9E498) f rom connector port on
evaporati ve emi ssi on cani ster purge val ve (EVAP
2. Di sconnect fuel t ank vent t ube ( 9A228) f r om t he
evaporat i ve emi ssi on cani st er purge val ve.
3. Di sconnect t he engine cont rol sensor wi ri ng
( 12A581) f rom t he evaporat i ve emission cani ster
purge val ve.
4. Remove evaporat i ve emi ssi on cani ster purge
val ve retai ni ng nuts and evaporat i ve emission
cani ster purge val ve f rom bracket l ocat ed on RH
si de of the dash panel ( 01610) .
evaporat i ve emission cani ster purge val ve
retaining nuts t o 7. 6-10. 4 N-m ( 67- 92 lb-in).
Perform syst em l eak check as fol l ows:
a. Di sconnect and plug fuel tank filler pi pe shield
( 9A097) leading t o t he evaporati ve
emi ssi ons cani ster (EVAP cani st er)(9D653)
at the evaporati ve emission cani ster purge
val ve.
b. Plug vent at t he evaporati ve emi ssi ons
cani ster.
134- 00003, pressuri ze t he fuel syst em
through t he t est fuel tank filler cap.
d. Verify t hat t he pressure within the syst em
does not decay.
e. If pressure does decay, determi ne t he cause
of the l eak and repair.
f. Remove plugs and reconnect fuel tank filler
pipe shield t o the evaporati ve emission
Fuel Vapor Cani st er Ve nt i ng Sy st e m
1
FRONT OF VEHICLE
/
VIEWX
V7573-D
I t e m
Pa r t
1 9A228 Fuel Tank Vent Tube
2

To Fuel Vapor and Brake
Tube(9S294)
4 9A589 Throttle Body Cover
5

To Fuel Tank Vent Tube
(9A228)
I t e m
Pa r t
6 5005 Frame
7 9D653 Evaporative Emissions
Canister (2 Req'd)
8 9S294 Evaporative Emission and
Brake Tube
Evaporat i ve Emi ssi on Tube Shut Off Valve
The evaporat i ve emission tube shut off val ve ( 9G332)
is servi ced as an assembl y wi t h the evaporat i ve
emission val ve ( 9B593) . Refer t o Secti on 10-01 for
Removal and Installation procedures.
E v a p o r a t i v e E mi s s i o n Ca n i s t e r
Re t a i n i n g Bo l t
E v a p o r a t i v e E mi s s i o n Ca n i s t e r
Pur ge Va l v e Re t a i n i n g Nut s
5. 2- 7 . 2
7 . 6- 10. 4
L b - l n
46- 63
67 - 92
Evaporat i ve Emi ssi on Valve
Refer t o Secti on 10-01 for Removal and Installation
procedures.
SPECIFICATIONS
ROTUNDA EQUIPMENT
Mo d e l
134- 00003
Fue l Ta n k L e a k Te s t e r
OBDI I 3. 8L Mu s t a n g, 4. 6L To wn Ca r , Cr o wn Vi c t o r i a ,
Co u ga r
TA1000B
03- 14- 1 En gi n e Co n t r o l s , E l e c t r o n i c 03- 14- 1
SECTION 03-14 Engine Controls, Electronic
SUBJECT PAGE
Camshaft Position (CMP) Sensor .03-14-3
Engine Control Syst ems, El ect roni c .03-14-1
Engi ne Coolant Temperature (ECT)
Sensor 03-14-2
Heated Oxygen Sensor (H02S) 03-14-2
idle Air Control (IAC) Valve 03-14-2
Intake Air Temperature (IAT) Sensor ...03-14-2
Mass Air Flow (MAF) Sensor 03-14-2
Power Steeri ng Pressure (PSP) Swi t ch 03-14-3
Powertrain Control Module (PCM) ........03-14-1
Throttle Position (TP) Sensor ...03-14-2
Vehi cle Speed Sensor (VSS) 03-14-3
Engi ne Cont r ol s, El ect r oni c 03-14-3
Camshaf t Posi t i on (CMP) Sensor 03-14-5
SUBJECT PAGE
Engi ne Cool ant Temperat ure (ECT)
Sensor 03-14-4
Heat ed Oxygen Sensor (H02S) 03-14-5
Idl e Ai r Cont r ol (IAC) Valve 03-14-4
I nt ake Ai r Temper at ur e (IAT) Sensor ...03-14-4
Mass Air Fl ow (MAF) Sensor 03-14-4
Power St eeri ng Pressure (PSP) Swi t ch .....03-14-5
Power t r ai n Cont r ol Module (PCM) ...03-14-3
Saf eguards 03-14-3
Thr ot t l e Posi t i on (TP) Sensor 03-14-4
Vehi cle Speed Sensor (VSS) 03-14-6
Idle Ai r Cont r ol (IAC) Valve 03-14-6
ADJUSTMENTS
Thr ot t l e Posi t i on (TP) Sensor 03-14-6
VEHICLE APPLICATION
E n g i n e C o n t r o l S y s t e m s , E l e c t r o n i c
WORKI NG ON OR NEAR ANY FUEL- RELATED
COMPONENT HIGHLY FLAMMABLE MI XTURES
The sequenti al multiport fuel injection (SFI) syst em is
cl assi fi ed as a multi-point, pulse ti me, mass air fl ow,
fuel injection syst em.
To maintain t he requi red exhaust emission l evel s, the
fuel meteri ng syst em must be kept in good operati ng
condi ti on and adj usted t o t he speci fi cati ons l i sted
i n/ on t he fol l owi ng sources:
The appl i cabl e secti on of t he Powertrai n
1
The appl i cabl e secti on of thi s group.
The Engine / Emissions Fact s Book.
The Vehicle Emission Control Information (VECI)
decal .
Additional engine performance checks are requi red t o
keep the exhaust emissions at the speci fi ed minimum
pollutant level. Refer t o Secti on 00- 03 for t hese
performance checks and their recommended
intervals.
Al ways refer t o the Mast er Parts List Catal og f or part s
usage and interchangeability before replacing a
throttl e body ( 9E926) or a component part of a throttl e
body.
P o w e r t r a i n C o n t r o l Mo d u l e ( P CM)
The powert rai n control modul e ( PCM) ( 12A650)
perf orms t he fol l owi ng functi ons:
Accept s information f r om vari ous engine sensors t o
comput e t he requi red fuel f l ow rate necessary t o
maintain a prescri bed ai r / f uel ratio throughout the
entire engine operati onal range.
Sends out a command t o the fuel injectors ( 9F593)
t o meter t he appropri ate quantity of fuel .
Determi nes and compensates for the age of t he
vehicle and its uniqueness.
Automati cal l y senses and compensat es for
changes in altitude (for exampl e, f rom sea level t o
mountains).
T h r o t t l e P o s i t i o n ( T P ) S e n s o r
The throttl e position sensor (TP sensor)(9B989) is:
A potenti ometer t hat provi des a signal t o the
powertrai n control module ( PCM) ( 12A650) that is
di rectl y proporti onal t o the throttl e pl ate position.
Mounted t o t he throttl e body ( 9E926) and is
connect ed t o t he throttl e pl ate shaft.
En gi n e Co n t r o l s, El e c t r o n i c
Pa r t
2 9B989 Throttle Position Sensor
3 9C968 Fuel Pressure Regulator
4 9F593 Fuel Inj ector
Manifold
7 9F715 Idle Air Control Valve
8 9D475 EGR Valve
Mass Air Flow (MAF) Sensor
The mass air fl ow sensor ( MAF sensor)(12B579) has
t he fol l owi ng charact eri st i cs:
It is mounted on t he corner of t he engine air cleaner
( ACLX9600) .
Uses a hot wi re sensi ng element t o measure the
amount of air enteri ng the engine. Air passi ng over
t he hot wi re causes it t o cool .
It then sends out an anal og vol tage signal t o the
PCM ( 12A650) t o determi ne t he i ntake air mass.
The PCM will then cal cul ate the requi red fuel
injector pulse wi dth t o provi de the desi red ai r/ f uel
rati o.
The mass air f l ow sensor hot wi re sensing element and
housing are cal i brated as a unit and must be servi ced
as a compl et e assembl y.
Intake Air Temperat ure (IAT) Sensor
The i ntake air temperature sensor (IAT
sensor ) ( 12A697) changes resi stance in response t o
i ntake air t emperat ure. The IAT sensor resi stance
decreases as the surrounding air temperature
i ncreases. Thi s provi des a signal t o t he PCM
( 12A650) indicating temperature of the incoming
i ntake air.
Idle Air Cont rol (IAC) Valve
The idle air control val ve (IAC val ve)(9F715) control s
engine idle speed. The idle air control val ve is mounted
on t he intake manifold ( 9424) and al l ows air t o bypass
t he throttl e pl ate. The amount of air al l owed t o bypass
is determi ned by the powertrai n control module
( PCM) ( 12A650) and control l ed by a duty cycl e signal.
Engine Coolant Temperature (ECT) Sensor
The engine cool ant temperature sensor (ECT
sensor ) ( 12A648) :
Changes resi stance in response t o t he engine
cool ant temperature.
Resi stance decreases as the surrounding
t emperat ure i ncreases, providing a signal t o the
powertrai n control module ( PCM) ( 12A650) that
i ndi cates engine cool ant temperature.
Heated Oxygen Sensor (H02S)
The heated oxygen sensors ( H02S) ( 9F472) are
l ocated in the exhaust pi pes bel ow the exhaust
manifolds. The heated oxygen sensors react wi t h the
oxygen in the exhaust gases and generate a vol tage
based on this reacti on.
A low vol tage indicates t oo much oxygen or a lean
condi ti on.
A high vol tage indicates not enough oxygen or a rich
condi ti on.
03- 14- 3 En gi n e C o n t r o l s , E l e c t r o n i c 03- 14- 3
C a m s h a f t P o s i t i o n ( CMP ) S e n s o r
The camshaf t position sensor (CMP sensor)(6B288)
is a vari abl e rel uctance sensor whi ch is tri ggered by
the high-point mark on t he camshaf t sprocket ( 6256) .
Power St eeri ng Pressure (PSP) Swi t ch
The power steeri ng pressure swi t ch (PSP
swi t ch) ( 3N824) is a normally cl osed swi t ch that opens
as pressure i ncreases. It i s used t o send a signal t o t he
powert rai n control module (PCM)( 12A650) t o adjust
idle speed t o compensate for the additional l oad on t he
engine.
Vehi cle Speed Sensor (VSS)
The vehi cl e speed sensor ( VSSX9E731) is a magneti c
pi ckup t hat sends a signal t o the powert rai n control
module ( PCM) ( 12A650) . Thi s VSS signal transmi ts t he
vehi cl e speed t o t he powertrai n control module.
D10198-C
Engine Cont rol s, El ect roni c
Manual
2
.
Safeguards
1. Al ways di sconnect bat t ery ground cabl e ( 14301)
before servi ci ng or repl aci ng el ectroni c engine
control s.
2. Fol l ow Di agnosti c Procedures as outlined in the
Powertrai n Cont rol / Emi ssi ons Di agnosi s
Manual
2
.
3. Di sconnect el ectroni c engine cont rol s f rom wi re
harness before measuri ng for continuity,
resi stance or energizing using a 12-volt source.
4. Never measure vol t age or resi stance di rectl y at
the powertrai n cont rol module ( PCM) ( 12A650) .
Powert rai n Cont rol Module (PCM)
Removal
2. Loosen engine cont rol sensor wi ri ng ( 12A581) t o
PCM connector retainer bolt.
3. Remove engine control sensor wi ri ng connector
f rom PCM( 12A650) .
4. Remove powert rai n control module bracket clip
( 12B518) f rom powertrai n control module
bracket (PCM br acket ) ( 12A659) and powertrai n
control modul e.
5. Remove PCM.
engine control sensor wiring connector retainer
bolt t o 3.7 N-m ( 32 Ib-in).
V9272-A
I t e m
Par t
1 N8047-S36B Nut (2 Req'd)
2 12A696 Powertrain Control Module
Seal
Bracket
5 12B518 Powertrain Control Module
Bracket Clip
6 01610 Dash Panel
T h r o t t l e Po s i t i o n ( TP) Se n s o r
Remov al
2. Di sconnect throttl e position sensor (TP
sensor)(9B989) f rom engine control sensor
wi ri ng ( 12A581) .
3. Remove t wo throttl e position sensor retaining
scr ews.
4. Remove throttl e position sensor.
I nst al l at i on
1. To install throttl e position sensor, reverse
Removal procedure.
2. Tighten retaining scr ews t o 2.8-3.8 N-m (25-34
Ib-in).
THROTTLE BODY SHOWN
UPSIDE DOWN FOR CLARITY
THROTTLE
BODY 9E926
SCREW
2 REQ'D
TIGHTEN TO
2.8-3.8 N-m
(25-34 LB-IN)
THROTTLE
POSITION (TP)
SENSOR 9B989
V9271-B
Ma s s A i r F l o w ( MA F) S e n s o r
CAUTI ON: T h e ma s s ai r f l o w h o t wi r e s e n s i n g
e l e me n t a n d h o u s i n g a r e c a l i b r a t e d a s a un i t a n d
mu s t b e s e r v i c e d a s a c o mp l e t e a s s e mb l y . Do n o t
d a ma g e t h e s e n s i n g e l e me n t ( i n t e r n a l t o h o u s i n g)
o r p o s s i b l e f a i l ur e o f t h e ma s s a i r f l o w s e n s o r
( MAF s e n s o r ) ( 12 B57 g) ma y o c c u r .
2. Di sconnect engine control sensor wi ri ng
( 12A581) f r om mass air fl ow sensor.
3. Loosen engine air cl eaner tube cl amps ( 9C632)
on air cl eaner outlet tube and throttl e body inlet
t ube. Di sconnect t ubes f rom mass air fl ow
sensor.
4. Remove mass air f l ow sensor t o mass air f l ow
sensor bracket retaining bol ts and remove mass
air fl ow sensor bracket ( MAF sensor
br acket ) ( 9B961) .
mass ai rfl ow sensor retaining bol ts t o 4. 7-5. 0
N-m ( 42- 46 Ib-in). Tighten engine air cl eaner tube
cl amps t o 1.4-2.5 N-m (12-22 Ib-in).
I n t a k e A i r T e m p e r a t u r e ( I AT) S e n s o r
( 12A581) f rom intake air temperature sensor (IAT
sensor)(12A697).
3. Remove intake air temperature sensor f rom
i ntake air temperature sensor t o 8-13 N-m (6-8
Ib-ft).
i dl e Air Cont rol (IAC) Valve
Re mo v a l
2. Di sconnect t he idle air control val ve (IAC
val ve)(9F715) f rom the engine control sensor
wiring ( 12A581) .
3. Remove the t wo idle air control val ve retaining
scr ews.
4. Remove the idle air control val ve and idle air
control val ve gasket .
1. NOTE: If scrapi ng is necessary, do not damage
idle air control valve or intake manifold idle air
control val ve gasket surfaces, or drop material
into i ntake manifold ( 9424) .
Clean idle air control valve gasket mating
surfaces.
2. To install idle air control val ve, reverse Removal
procedure.
3. Tighten retaining scr ews t o 9.5 N-m (7 Ib-ft).
E n g i n e C o o l a n t T e m p e r a t u r e ( E CT ) S e n s o r
1. Partially drain engine cooling syst em. Refer t o
Secti on 03- 03.
( 12A581) from engine coolant temperature
sensor (ECT sensor)(12A648).
4. Remove engine cool ant temperature sensor f rom
engine cool ant temperature sensor t o 8-13 N-m
(6-8 Ib-ft). Refill cooling syst em as outlined in
Secti on 03- 03.
03- 14- 5 E n gi n e Co n t r o l s , E l e c t r o n i c 03- 14- 5
Heated Oxygen Sensor (H02S)
Ox y ge n Se n s o r Wr e n c h T 94P - 947 2 - A
NOTE: The 4. 6L-2V engine uses four heated oxygen
sensors ( H02S) ( 9F472) for the engine control
syst em. The heat ed oxygen sensors are l ocat ed in t he
dual converter Y pi pe ( 5F250) .
2. Di sconnect heat ed oxygen sensors f rom engine
control sensor wiring ( 12A581) .
3. Raise vehi cl e on hoist. Refer t o Secti on 00- 02.
4. NOTE: If excessi ve f orce is needed t o remove
heated oxygen sensors, l ubri cate heated oxygen
sensors wi t h penetrati ng oil prior t o removal .
Remove heat ed oxygen sensors f rom dual
converter Y pi pe using Oxygen Sensor Wr ench
T94P-9472-A.
heated oxygen sensors t o 36- 46 N-m (26-34
Ib-ft).
RH SIDE SHOWN
LH SIDE SIMILAR
HEATED OXYGEN
SENSOR (H02S) 9F472
TIGHTEN TO 36-46 N.m
(26-34 LB-FT)
FRONT OF ENGINE
DUAL CONVERTER
AND PIPE
5F250
RH EXHAUST
MANIFOLD 9430
V9826-A
Camshaft Posi t i on (CMP) Sensor
Removal
1.
2. Di sconnect engine cont rol sensor wi ri ng
( 12 A581) f r o m camshaf t posi ti on sensor (CMP
sensor ) ( 6B288) .
3. Remove camshaf t posi ti on sensor retaining
scr ew and remove camshaf t position sensor f rom
engine front cover ( 6019) .
Make sure camshaf t position sensor mounting
surf ace is cl ean and that camshaft posi ti on
sensor O-ring is in proper l ocati on on camshaf t
posi ti on sensor.
CAUTI ON: Do n o t o v e r t i g h t e n c a ms h a f t
p o s i t i o n s e n s o r r e t a i n i n g s c r e w o r d a ma g e
t o c a ms h a f t p o s i t i o n s e n s o r ma y o c c u r .
Position camshaf t position sensor and install
retaining screw. Tighten t o 8-12 Nm ( 71- 106
lb-in).
Connect engine control sensor wi ri ng t o camshaf t
position sensor.
SCREW
TIGHTEN TO
8-12 N-m
(71-106 LB-IN)
ENGINE FRONT
COVER 6019
^ J
CAMSHAFT
POSITION (CMP)
SENSOR 6B288
V9273-B
Power Steeri ng Pressure ( P SP ) Swi t ch
Refer to Section 11-02 for Power Steeri ng Pressure
(PSP) Swi t ch Removal and Installation procedure.
03- 14- 6 ngl ne Co n t r o l s , E l e c t r o n i c 03- 14- 6
Ve h i c l e S p e e d S e n s o r (VSS)
Refer t o Secti on 07- 01 for Removal and Installation
procedures of the vehicle speed sensor
( VSSX9E731) .
Idle Air Cont rol (IAC) Valve
CAUTI ON: Do n o t use Ca r b u r e t o r Tun e - Up
Cl e a n e r D9A Z - 1957 9- BA ( ESR- M14P9- A) o r a n y
o t h e r t y p e o f s o l v e n t o r d a ma g e t o t h e v a l v e
i n f e r n a l c o mp o n e n t s ma y r e s ul t .
The idle air control val ve (IAC val ve)(9F715) cannot
be cl eaned. The idle air control val ve must be
repl aced.
De s c r i p t i o n L b - Ft
MA F S e n s o r - t o - Br a c ke t Bo l t s 4. 7 - 5. 0 42 - 46
( Lb- l n )
En gi n e Ai r Cl e a n e r Tube Cl a mp s 1. 4-2. 5 12-22
( Lb- l n )
IAT Se n s o r 8- 13 6-8
I dl e Ai r Co n t r o l Va l v e t o I n t a ke
Ma n i f o l d
9. 5 7
ECT Se n s o r 8- 13 6-8
H02 S - t o - Co n v e r t e r 36- 46 2 6- 34
Ca ms h a f t P o s i t i o n
Se n s o r - t o - E n gi n e Fr o n t Co v e r
8- 12 7 1- 106
( Lb- l n )
ADJUSTMENTS
Throt t l e Posi t i on (TP) Sensor
The throttl e position sensor (TP sensor)(9B989)
cannot be adj usted and must be repl aced.
SPECIFICATIONS
OBDI I 3. 8L Mu s t a n g, 4. 6L To wn Car , Cr o wn Vi c t o r i a ,
Co u ga r
TA1000B
T 94P - 947 2 - A
Ox y g e n Se n s o r Wr e n c h
En gi n e Co n t r o l Se n s o r Wi r i n g
Co n n e c t o r - t o - P CM Bo l t
3. 7 32 ( L b- l n )
T h r o t t l e P o s i t i o n Se n s o r t o
T h r o t t l e Bo d y S c r e ws
2. 8- 3. 8 2 5- 34
( L b- l n )
04- 00- 1
G ROUP
SUSPENSION
f
' oOOO c 5 000)
SECTION TITLE PAGE SECTION TITLE PAGE
SUSPENSION AND WHEEL HUBS, FRONT . 04-01-1 SUSPENSIONSERVICE . ..04-00-1
SUSPENSI ON AND WHEEL HUBS, REAR 04-02-1 WHEELS AND TIRES 04-04-1
SUSPENSION, COMPUTER CONTROLLED 04-05-1
" m$%w w ~ ^mm' *&m*r *&mp ~ ^ ^ J O T T I
SECTION 04-00 SuspensionService
SUBJECT PAGE
Component Repl acement 04-00-2
Suspensi on, Front 04-00-2
Suspensi on, Rear 04-00-4
Ball Joi nt s 04-00-14
Lower Arm and Bushi ng. . . . 04-00-14
Ball Joi nt , Lo we r I n spe c t i o n 04-00-8
Ball Joi nt , Uppe r I nspe c t i on 04-00-7
Front End ....04-00-7
Road Test 04-00-7
Engi ne Speed Sensi t i ve ....04-00-7
Torque Sensi t i ve ....04-00-7
Vehi cle Speed Sensi t i ve. . . 04-00-7
Shock Absorber and Air Spri ng Assembl y
Checks 04-00-8
Bench Test 04-00-9
Hoi st Check 04-00-8
Vehi cle I nspect i on 04-00-8
Shock Absorber Checks 04-00-8
Suspensi on, Rear ...04-00-9
SUBJECT PAGE
Ti re Wear. ...04-00-6
Vi brat i on and Roughness 04-00-7
Pi npoi nt Test s ..04-00-10
Sympt om Chart 04-00-9
ADJUSTMENTS
Al i gnment Procedure 04-00-18
Al i gnment , Fr ont . 04-00-15
Beari ng, Front Wheel ...04-00-18
Equi pment I nst al l at i on .....04-00-15
Ref erence Def i ni t i ons. 04-00-16
Ti re Lead 04-00-17
Ti re Wear Condi t i on Chart 04-00-17
Toe ...04-00-15
Wheel / Ti r e Runout 04-00-17
Al i gnment , Rear.. 04-00-22
Cent eri ng St eeri ng Wheel . . . . 04-00-20
Dr i v e s h a f t - P i n i o n Angle Checki ng 04-00-21
Ride Hei ght Cor r ect i on. . . . . . . . 04-00-18
St eeri ng Angl e Check 04-00-21
Toe and St eeri ng Wheel Spoke Posi t i on ..04-00-19
Wheel Turni ng Angl e, Fr ont . . 04-00-20
VEHICLE APPLICATION
04- 00- 2 S u s p e n s i o n S e r v i c e 04- 00- 2
1
C o m p o n e n t R e p l a c e m e n t
S u s p e n s i o n , Fr o n t
CAUTI ON: Al l s u s p e n s i o n f a s t e n e r s a r e i mp o r t a n t
a t t a c h i n g p a r t s i n t h a t t h e y c o u l d a f f e c t t he
p e r f o r ma n c e of v i t a l p a r t s and s y s t e ms , a n d / o r
c o u l d r e s ul t i n ma j o r s e r v i c e e x p e n s e . A n y p a r t
mu s t b e r e p l a c e d wi t h o n e o f t h e s a me pa r t
n u mb e r or wi t h a n e x a c t e q u i v a l e n t pa r t i f
r e p l a c e me n t b e c o me s n e c e s s a r y . Do not u s e a
r e p l a c e me n t pa r t o f l e sse r q u a l i t y o r s u b s t i t u t e
d e s i g n . T o r q u e v a l u e s mu s t b e u s e d a s s p e c i f i e d
d u r i n g a s s e mb l y t o e n s u r e p r o p e r f u n c t i o n .
Never at t empt t o heat, quench or strai ghten any front
suspensi on part. Repl ace wi th a new part.
The fol l owi ng front suspensi on components may be
repl aced either individually or as an assembl y:
Front shock absorbers may be repl aced
individually. (They do not need t o be repl aced in
pai rs.)
Front coil spri ngs ( 5310) may be repl aced
individually.
Front wheel spi ndl es ( 3105) may be repl aced
individually.
Front suspension arm bushing joint ( 3084) and front
suspension upper ball joint ( 3049) may be repl aced
individually.
Lower ball joint and front suspension l ower arm
( 3078) may be repl aced as an assembl y.
Front wheel hub ( 1104) and bearing may be
repl aced as an assembl y.
Front stabilizer bar ( 5482) may be repl aced
individually.
Stabilizer bar link ( 5K484) may be repl aced
individually.
Fr o n t Suspe n si o n
F7092-E
Pa r t Pa r t
I t em Numbe r De s c r i p t i o n I t e m Numbe r De s c r i p t i o n
1 3084 Front Suspension Arm
13 5415 Front Spring Insulator
Bushing 14 5310 Front Coil Spring (2 Req'd)
2 N 8 0 6 7 9 8 - S 4 2 8 Bolt (4 Req'd)
15 3079 Front Suspension Lower Arm
3 N 8 0 5 4 7 6 - S 3 0 1 Nut (4 Req'd) 16 N801224-S Washer (2 Req'd)
4 N806579-S428 Bolt (2 Req'd) 17 N800980-S301 Bolt (4 Req'd)
5 N805475-S428 Nut (2 Req'd) 18 N620468-S60 Nut (2 Req'd)
6

Frame
19 3020 Front Suspension Bumper (2
7 N 8 0 5 4 7 6 - S 3 0 1 Nut (4 Req'd) Req'd)
8 5K484 Stabilizer Bar Link (2 Req'd) 20 N808509-S428 Nut (2 Req'd)
9 3108 Front Wheel Spindle
A

10 N805474-S60 Nut (4 Req'd)
(109-148 Lb-Ft)
11 5 4 8 2 Front Stabilizer Bar
B

(107-129 Lb-Ft)
12 N808487-S428 Nut (4 Req'd)
(107-129 Lb-Ft)
Pa r t
C

Lb-Ft)
D

(83-113 Lb-Ft)
Pa r t
E

Tighten t o 34-47 N-m (26-34
Lb-Ft)
F

Tighten to 87-119 N-m (64-88
Lb-Ft)
S u s p e n s i o n , Re a r
The fol l owi ng rear suspensi on components may be
Shock absorbers ( 18080) may be repl aced
individually. (They do not have t o be repl aced in
pai rs.)
Rear spri ngs ( 5560) may be repl aced individually.
Rear suspensi on arm and bushings ( 5500) must be
repl aced in pai rs.
Rear suspension l ower arms ( 5A649) must be
repl aced in pai rs.
Upper suspension arm rear spri ng upper retaining
seat ( 5781) must be repl aced in pai rs.
Rear stabilizer bar ( 5A772) may be repl aced
individually.
Rear stabilizer bar link may be repl aced individually.
Pa r t
1 18192 Nut and Insulator Assembly
(2 Req'd)
2 5536 Rear Spring Insulator (2
Req'd)
3 5560 Rear Spring (2 Req'd)
4 4730 Rear Axle Bumper (2 Req'd)
5 N805479-S60 Nut (2 Req'd)
6 5A649 Rear Suspension Lower Arm
(2 Req'd)
7 N800169-S428 Nut (2 Req'd)
8 W701642-S60 Nut (2 Req'd)
9 N802891-S50 Bolt (2 Req'd)
10 N802891-S60 Bolt (2 Req'd)
11 N621941-S428 Nut (4 Req'd)
12 5A772 Rear Stabilizer Bar
13 18080 Shock Absorber (2 Req'd)
14 18171 Washer (2 Req'd)
15 5500 Rear Suspension Arm and
Bushing
Pa r t
16 N804655-S171 Bolt (2 Req'd)
17 5A638 Bushing (2 Req'd)
18 N808043-S60 Bolt (2 Req'd)
19 4A047 Bracket (2 Req'd)
20 N605907-S60 Screw (2 Req'd)
21 5493 Bushing (8 Req'd)
22 5K484 Stabilizer Bar Link
A

Lb-Ft)
B

(56.4-76.3 Lb-Ft)
C

(103-132 Lb-Ft)
D

(119-149 Lb-Ft)
E

Lb-Ft)
F

Lb-Ft)
T i r e We a r
Inspect ti res for wear. Abnormal or excessi ve wear
may be caused by i ncorrect wheel alignment,
wheel / t i r e i mbal ance, or i mproper ti re pressure.
Ty pi c a l Wear Pa t t e r n s
Vi b r a t i o n a n d R o u g h n e s s
Vi brati on, roughness, t ramp, shi mmy and thump may
be caused by excessi ve tire or wheel runout, worn or
cupped t i res, or wheel and ti re unbalance.
These condi ti ons may al so be caused by rough or
undulating road surf aces. Driving the vehi cl e on
different t ypes of road surfaces will indicate if the road
surf aces are actual l y causi ng the condi ti on.
Do not i mmedi atel y suspect the ti res when attempti ng
t o di agnose a vi brati on concern. Other sources of
vibration include:
Loose or worn wheel beari ngs.
Loose or worn suspensi on or steeri ng component s.
Worn or damaged dri veshaft slip yoke ( 4841) j oi nts.
Excessi ve front di sc brake rotor ( 1125) runout.
Loose engine or transmi ssi on support s.
e Engine dri ven accessori es.
This secti on covers those vi brati ons rel ated t o t he
suspensi on, ti res and wheel s.
For di agnosti c procedures and servi ce for other t ypes
of vi brati on, refer t o Secti on 00- 04.
Road Tes t
NOTE: A compl et e road t est procedure is provi ded in
Secti on 00- 04.
A ti re vibration di agnosti c procedure al ways begins
wi th a road t est . The road t est and cust omer interview
(if avai l abl e) will provi de much of t he information
needed t o find t he source of a vi brati on.
During the road t est , dri ve the vehicle on a road t hat is
smoot h and f ree of undulations. If vi brati on is apparent,
note and record the fol l owi ng:
The speed at whi ch the vi brati on occurs.
9 What t ype of vibration occurs in each speed
rangemechani cal or audible.
How the vibration is af f ect ed by changes in engine
torque, vehi cl e speed and engine speed.
Type of vi brati on sensi t i vi t yt orque sensitive,
vehicle speed sensitive, or engine speed sensitive.
Use the fol l owi ng expl anati on of t erms t o help isolate
the source of the vi brati on.
If the road t est i ndi cates t he vibration is rel ated t o the
ti res or wheel s, use the Tire Wear Condition Chart t o
help pinpoint the cause of t he concern. If t he road test
indicates that t here is ti re whi ne, but no shake or
vibration, the noise ori gi nates wi th the cont act
between t he ti re and the road surface.
Tor que Sensi t i ve
Thi s means that the condition can be i mproved or
worsened by accel erati ng, decel erati ng, coast i ng,
maintaining a st eady vehi cl e speed and appl i cati on of
engine torque.
Ve h i c l e S p e e d Se n s i t i v e
Thi s means t hat the vi brati on al ways occurs at the
same vehi cl e speed and is not a f f e c t e d by engine
t orque, engine rpm, or transmi ssi on range sel ecti on.
E n gi n e S p e e d Se n s i t i v e
Thi s means t hat the vi brati on occurs at varyi ng vehi cl e
speeds when a different transmi ssi on range is
sel ect ed. It can somet i mes be i sol ated by i ncreasi ng
or decreasi ng engine speed wi th t he transmi ssi on in
NEUTRAL, or by stall testi ng wi t h the transmi ssi on in
gear. If t he condition is engine-speed sensi ti ve, the
condi ti on is not rel ated t o t i res.
To veri fy t hat tire noise is not associ at ed wi t h shake
or vi brati on, inflate the ti res one at a ti me and check
for a change in t he sound. The pi tch or whi ne will
change as t he i ncreased pressure changes t he ti re
frequency.
Fr o n t E n d
Do n o t c h e c k a n d a d j u s t f r o n t - wh e e l a l i gn me n t
wi t h o u t f i r s t ma k i n g t h e f o l l o wi n g i n s p e c t i o n f o r
f r o n t - e n d d a ma g e o r we a r :
1. Check for speci fi ed air pressure in all four t i res.
2. Raise front of vehi cl e off the floor. Refer t o
Secti on 00- 02. Graspi ng upper and l ower
surfaces of the ti re, shake each front wheel t o
check for worn wheel beari ng. Check front
suspension l ower arm ball joint ( 3050) and
mounts for l ooseness, wear and damage. Check
brake backi ng plate mountings. Tighten all l oose
nuts and bol ts t o speci fi cati on. Repl ace all worn
part s. Refer to Secti on 04- 01.
3. Check steeri ng gear mountings and all steeri ng
linkage connecti ons for l ooseness. Tighten all
mountings t o speci fi cati on. If any of t he linkage is
worn or bent, repl ace the part s. Refer t o Secti on
11-03.
4. NOTE: Any noticeable wheel bearing play can
only be correct ed by wheel hub ( 1104) and wheel
bearing repl acement.
Grasp upper and l ower surf aces of ti re and shake
each wheel t o check wheel beari ng end pl ay. If
any in-and-out free play is noti ced, repl ace worn
or damaged wheel hub. Refer t o Secti on 04- 01.
5. Check the acti on of the front shock absorbers
( 18124) , and the condition of their at t achment s.
Refer to Shock Absorber Checks. A sti cki ng or
binding front shock absorber may not al l ow t he
vehicle to settl e in a normal , level position,
possibly affecti ng the front-wheel alignment.
Ba l l J o i n t , U p p e r I n s p e c t i o n
Before performing any ball joint i nspecti on, check the
wheel bearings. Refer to Secti on 04- 01.
04- 00- 8
S u s p e n s i o n S e r v i c e 04- 00- 8
1. Raise vehi cl e and pl ace fl oor j acks beneath the
front suspension lower arms ( 3078) .
F2505-C
2. Have an assi stant grasp t he l ower edge of t he ti re
and move the wheel in and out.
3. Whi l e the wheel is being moved, observe the
upper end of the front wheel spindle ( 3105) and
t he front suspension upper arm ( 3083) . Any
movement between t he upper end of the front
wheel spindle and the upper suspension arm
i ndi cates abnormal ball joint wear.
4. If any such movement is observed, install new
front suspension upper ball joint ( 3049) . Refer t o
Secti on 04- 01 f or repl acement procedure.
Ba l l J o i n t , L o w e r I n s p e c t i o n
Bef ore performi ng any bail joint i nspecti on, check the
front wheel beari ngs. Refer t o Secti on 04- 01.
1. Support the vehicle in normal driving posi ti on,
wi t h bot h ball j oi nts l oaded.
2. Have an assi stant grasp t he l ower edge of ti re
and move t he wheel in and out.
3. Observe l ower end of t he front wheel spindle and
t he front suspension l ower arm while wheel is
being moved. Any movement bet ween the front
wheel spindle and the front suspensi on l ower arm
i ndi cates abnormal wear.
4. If any such movement is observed, repl ace front
suspension l ower arm. Refer t o Secti on 04- 01.
S h o c k A b s o r b e r C h e c k s
These vehi cl es are equi pped wi t h gas-pressuri zed
hydraul i c shock absorbers. These shock absorbers
are not adj ustabl e or refillable and cannot be servi ced.
1. Oil Leak: A light film of oil (weepage) on t he upper
porti on of t he shock absorber is permi ssi bl e and
is a result of proper shock lubrication. Weepage
is a condi ti on in whi ch a thin film of oil may be
deposi t ed on the shock absorber outer tube
(body) and is normally noti ced due t o the
col l ecti on of dust in thi s ar ea. Shock absorbers
whi ch exhi bi t thi s weepage condition are
functional units and should not be repl aced.
Leakage is a condition in whi ch t he entire front
shock absorber body is covered wi th oil and the
oil will dri p f rom t he shock absorber onto t he
pavement.
If thi s condi ti on exi st s:
a. Make sure that fluid observed is not f rom
sources other than t he shock absorber.
b. Repl ace the worn or damaged shock
absorber.
2. Vehicle Sag: Many ti mes shock absorbers are
repl aced in an effort t o sol ve a vehicle sag
concern. Shock absorbers by design are
hydraul i c dampi ng units only, and unlike
suspensi on spri ngs, do not support any
suspensi on l oads. Therefore, repl aci ng a shock
absorber will not correct a vehicle sag concern.
3. Repl acement in Pai rs: In t he past it was
recommended that shock absorbers be repl aced
in pai rs if one unit became unservi ceabl e.
Improved sealing (due t o new materials and
design and i mproved rod machining and
hardening techni ques al ong wi th i mproved
manufacturing quality checks) have added t o the
functional reliability of shock absorbers.
Theref ore, shock absorbers no longer need t o be
repl aced in pai rs when only one unit is not
servi ceabl e.
S h o c k A b s o r b e r a n d A i r S p r i n g A s s e m b l y
C h e c k s
Ve hi c l e I n s p e c t i o n
1. Check all ti res for proper inflation pressure.
2. Check ti re condition t o confi rm proper front end
alignment, ti re bal ance and overall tire condition
such as separati on or bul ges.
3. Check t he vehi cl e for optional suspension
equipment such as heavy duty handling or trailer
t ow suspensi ons. These suspensi ons will have a
firmer ride feeling than st andard suspensi ons.
4. Check vehi cl e atti tude for evi dence of possi bl e
overl oad or saggi ng. Check luggage
compartment area.
5. Road t est vehicle t o confi rm customer concern
after performi ng St eps 1 through 4.
Ho i s t Ch e c k
1. Noi se: Noise can be caused by l oose suspension
or front shock absorber at t achment s. Verify that
all at t achment s or the suspension components
and shock absorbers are ti ght. Repl ace any
shock absorber that has a damaged integral
l ower mounting bushing. Check shock absorbers
for external damage.
2. Bot t om / Hoppi ng: Check condition of the rubber
suspension travel st ops (front suspensi on bumper
( 3020) / r ear axl e bumper ( 4730) ) . Repl ace if
worn or missing. Exami ne for evi dence of
previ ous overl oad or damaged component s.
3. Force-Check: Support front suspensi on l ower
arm or rear axl e housing ( 4010) , and remove
l ower shock absorber at t achment . St roke shock
absorber body using as much t ravel as possi bl e.
The acti on should be smoot h and uniform
throughout each st roke. Dampi ng f or ces should
be equivalent on both si des of t he vehi cl e.
4. Repl ace only the worn or damaged shock
absorbers. Shock absorbers do not require
repl acement in pai rs, unless bot h units are wor n
or damaged.
Bench Test
Wi th t he shock absorber ri ght si de up (as installed in
vehi cl e), ext end it fully. Then turn t he shock absorber
upside down and fully compress it. Repeat thi s
procedure at least t hree ti mes t o make sure that any
t rapped air has been expel l ed. Now pl ace the shock
absorber right side up in a vi se and hand st roke t he
shock absorber. Check the front shock absorber
insulators for damage and wear.
Install a new shock absorber if any of t he fol l owi ng
abnormal condi ti ons are met:
If t he shock absorber i s properl y pri med, in its
installed posi ti on and t here is a l ag or a ski p
occurri ng near mi d-stroke of t he shaft reverse travel
di recti on.
If there is any seizing duri ng t he shaf t full travel ,
except at either end of t he t ravel .
If upon t he shaft f ast , reverse st r oke, t here is any
noise encountered ot her than a faint swi sh, such as
a cl i cki ng sound.
If there are excessi ve fluid l eaks and / or the front
shock absorber acti on remai ns errat i c after purging
air.
At regular i nterval s, the fol l owi ng rear suspension
checks shoul d be made:
1. Check f or evi dence of fluid l eaks on rear shock
absorbers ( 18080) . (A light film of fluid is
permi ssi bl e. Verify fluid is not f rom other
sources. )
2. Check shock absorber operati on.
3. Check condi ti on of upper and l ower rear
suspensi on arm bushings ( 5A638) and rear
suspensi on tension st rut and bushings ( 5A952) .
Repl ace any damaged or worn components as
outlined.
SUSPENSIONSERVICE
Drift Left or Right Excessive si de-to-si de difference
in caster or camber.
Excessive positive caster.
Excessive negative caster.
Unequal toe setti ng
wheel-to-wheel.
Poor lubrication or wear of front
suspension lower arm ball j oint.
Incorrect vehicle attitude (front or
rear either high or low).
Steering gear or linkage worn or
damaged.
Unequal tire pressure.
Damaged or unbalanced wheels
and ti res.
Brake drag or brake system.
CHECK for abnormal loading,
spring sag, or non-standard
springs.
CHECK steering syst em. REFER to
Section 11-00.
CHECK ti res and wheels.
REBALANCE if required. REPLACE
if required. REFER to Section
04-04.
CHECK brakes. REFER to Section
06-00.
Steering Wheel Off Center Wheels not aligned.
Wheel s/t i res not same size.
Steering system malfunction.
Tracks Improperly Incorrect caster.
Rear suspension damage.
Rough Ride Damaged shock absorbers. GO to Pinpoint Test D.
04- 00- 10
S u s p e n s i o n S e r v i c e 04- 00- 10
SUSPENSIONSERVICE (Cont i nued)
Excessive Noise Loose / broken front shock
absorber mount bolts.
Loose / broken front shock
absorber bolts to front suspension
arm bushing j oint.
Damaged/worn stabilizer bar, link,
insulators.
Improper Tire Wear Excessive t oe.
Excessive positive or negative
camber.
Incorrect ti re pressure.
Vibration Wheel bearings.
Wheel /t i re runout.
Wheel balance.
Brakes rotor runout.
Drive line balance.
PINPOINT TEST A: DRIFT LEFT OR RIGHT
A1 CHECK VEHICLE ALIGNMENT
Yes
No
GO to A2.
ADJUST alignment as
necessary.
Place vehicle on an alignment rack.
Check vehicle alignment.
Is al i gnment wi t hi n speci f i cat i on?
Yes
No
GO to A2.
ADJUST alignment as
necessary.
A2 CHECK STEERING LINKAGE
Yes
No
SERVICE or REPLACE
worn or damaged
components as
necessary.
GOt o A3.
Raise vehicle on hoist. Refer to Section 00-02.
Check steering linkage for indications of excessi ve
wear or damage.
Is t here i ndi cat i on of excessi ve wear or damage?
Yes
No
SERVICE or REPLACE
worn or damaged
components as
necessary.
GOt o A3.
A3 CHECK TIRES
Yes
No >
REPLACE t i res.
GO to Pinpoint Test Step
B1.
Inspect ti res for excessi ve wear or damage.
Are t i r es excessi vel y wor n or damaged?
Yes
No >
REPLACE t i res.
B1.
PINPOINT TEST B: STEERING WHEEL OFF CENTER
B1 CHECK CLEAR VISION
Yes
No
GOt o B2.
ADJUST clear vision.
REFER to Speci fi cati ons.
Place vehicle on alignment rack.
Is cl ear vi si on wi t hi n speci f i cat i ons?
Yes
No
GOt o B2.
ADJUST clear vision.
REFER to Speci fi cati ons.
B2 INSPECT STEERING COMPONENTS
Yes
No
REPLACE or SERVICE
worn components.
or 04-01.
C1.
Inspect steering components for excessi ve wear or
damage.
Are st eer i ng c ompone nt s excessi vel y wor n or
damaged?
Yes
No
REPLACE or SERVICE
worn components.
or 04-01.
C1.
PINPOINT TEST C: TRACKS IMPROPERLY
C1 CHECK CASTER
Yes t>
No
GO to C2.
ALIGN vehicle.
Place vehicle on alignment rack.
Is cast er wi t hi n spe c i f i c a t i on?
Yes t>
No
GO to C2.
ALIGN vehicle.
PINPOINT TEST C: TRACKS IMPROPERLY (Conti nued)
C2 CHECK REAR SUSPENSION
Yes
No
GO t o Pinpoint Test Step
D1.
INSPECT rear suspension
components for wear or
damage. SERVICE or
REPLACE worn or
damaged components
are requi red. REFER t o
Secti on 04-02.
Measure vehicle wheel base LH and RH.
Compare measurements.
Are measurements the same?
Yes
No
GO t o Pinpoint Test Step
D1.
INSPECT rear suspension
components for wear or
damage. SERVICE or
REPLACE worn or
damaged components
are requi red. REFER t o
Secti on 04-02.
PINPOINT TEST D: ROUGH RIDE
D1 CHECK FRONT SHOCK ABSORBERS
Yes
No
REPLACE front shock
absorbers. REFER t o
Section 04-01.
GO to D2.
Rai se vehicle on hoist. Refer to Section 00-02.
Inspect front shock absorbers for oil leaks or
damage.
Are f ront shock absorbers l eaki ng?
Yes
No
REPLACE front shock
absorbers. REFER t o
Section 04-01.
GO to D2.
D2 CHECK REAR SHOCK ABSORBERS
Yes
No
REPLACE rear shock
absorber. REFER to
Section 04-02.
Vehicle OK.
With vehicle on hoist, inspect rear shock absorber
for oil leak or damage.
Are rear shock absorbers l eaki ng or damaged?
Yes
No
REPLACE rear shock
absorber. REFER to
Section 04-02.
Vehicle OK.
PINPOINT TEST E: EXCESSIVE NOISE
E1 INSPECT SUSPENSION
Yes
No
TIGHTEN/REPLACE
shock absorber mount
bolts. REFER to Section
04-01 (front) or 04-02
(rear).
GO t o E2 .
Rai se vehicle on hoist. Refer to Section 00-02.
Inspect shock absorber mount bolts.
Are mounti ng bol ts l oose or broken?
Yes
No
TIGHTEN/REPLACE
shock absorber mount
bolts. REFER to Section
04-01 (front) or 04-02
(rear).
GO t o E2 .
E2 INSPECT SPRINGS
Yes
No
REPLACE springs.
(front) or 04-02 (rear).
GO t o E3.
With vehicle on hoist, inspect springs for damage.
Are spri ngs damaged?
Yes
No
REPLACE springs.
(front) or 04-02 (rear).
GO t o E3.
E3 INSPECT FRONT SUSPENSION LOWER ARM
BUSHINGS
Yes
No
REPLACE front
suspension lower arm
bushings. REFER to
Section 04-01.
Vehicle OK.
Inspect front suspension lower arm bushings for
excessi ve wear or damage.
Are f r ont suspensi on l ower arm bushi ngs wor n or
damaged?
Yes
No
REPLACE front
suspension lower arm
bushings. REFER to
Section 04-01.
Vehicle OK.
PINPOINT TEST F: IMPROPER TIRE WEAR
F1 INSPECT TIRES
Yes
No
ALIGN vehicle. REPLACE
tires if badly worn.
GO t o F2 .
Raise vehicle on hoist. Refer t o Section 00-02.
Inspect ti res for uneven wear on inner or outer
- shoulder.
Is t here uneven f i re wear ?
Yes
No
ALIGN vehicle. REPLACE
tires if badly worn.
GO t o F2 .
PINPOINT TEST F: IMPROPER TIRE WEAR (Cont i nued)
F2 UNEVEN TIRE WEAR
Yes
No
ALIGN vehi cle. ROTATE
ti res. REPLACE fi res if
badly worn.
GO t o F3.
With vehicle on hoist, inspect ti res for sawtooth
pattern.
Do ti res have sa wt oot h pat t er n?
Yes
No
ALIGN vehi cle. ROTATE
ti res. REPLACE fi res if
badly worn.
GO t o F3.
F3 CHECK FOR CUPPED TIRE
Yes
No
BALANCE and ROTATE
t i res. REFER to Section
04-04.
Vehicle OK.
With vehicle on hoist, inspect ti res for cupping or
dishing.
Are t i res cupped or di shed?
Yes
No
BALANCE and ROTATE
t i res. REFER to Section
04-04.
Vehicle OK.
PINPOINT TEST G: VIBRATION
G1 ROAD TEST
Yes
No
GO t o G2 .
Vehicle OK.
Accelerate vehicle to the speed which the customer
indicated the vibration occurred.
is a vi br at i on present ?
Yes
No
GO t o G2 .
Vehicle OK.
G2 INSPECT FRONT WHEEL BEARINGS
Yes
No S>
GO to G3.
PERFORM road t est .
Rock each front tire by gripping the top and bottom
then alternately push/pul l the tire in and out. Feel
for excess looseness of the bearings.
Spin each front wheel by hand checking for
roughness.
Are t he beari ngs l oose or rough?
Yes
No S>
GO to G3.
PERFORM road t est .
G3 FRONT WHEEL BEARING END PLAY
Yes >
No
Wheel bearing OK. GO to
G4.
REPLACE wheel hub as
necessary. PERFORM
Road Test.
Remove wheel and tire assembly and the disc brake
caliper.
Position Dial Indicator with bracketry TOOL-4201 -C
or equivalent against the wheel hub. Push and pull
the wheel hub in axial direction and measure the end
play of the wheel hub and front wheel bearing
assembly. Themaximum allowable end play is 0.05
mm (0.002 inch).
Is t he end play wi t hi n l i mi t s?
Yes >
No
Wheel bearing OK. GO to
G4.
REPLACE wheel hub as
necessary. PERFORM
Road Test.
G4 WHEEL/TIRE RUNOUT ON VEHICLE
Yes
No
GO to G9.
GO to G5.
Measure wheel /t i re assembly runouts on vehicle
using Rotunda Radial Run Out Gauge 007-00014 or
equivalent. Assembly runout should be less than
1.14 mm (0.045 inch) radial and lateral. Warm up
ti res prior to taki ng measurement to eliminate slight
flat spotti ng.
Is measurement in speci f i cat i on?
Yes
No
GO to G9.
GO to G5.
G5 WHEEL/TIRE RUNOUT OFF VEHICLE
Yes
No
CHECK rotor drum and
bolt ci rcle runout. GO to
G8.
GO to G6.
Measure wheel /t i re assembly from any position that
exceeds 1.14 mm (0.045 inch) radial or lateral.
Before removing wheel /t i re assembly, mark wheel
stud and corresponding bolt hole so assembly can
be installed in same posi ti on. Remove assembly and
mount on wheel balancer. Measure runout as in Step
G3. Assembly runout should be less than 1.14 mm
(0.045 inch) radial and lateral.
Is measurement in speci f i cat i on?
Yes
No
CHECK rotor drum and
bolt ci rcle runout. GO to
G8.
GO to G6.
G6 MATCH MOUNTING
Yes
No
INSTALL on vehicle.
PERFORM Road Test.
first high spot on the ti re,
GO t o G7 .
Mark the high runout location on the ti re and also on
the wheel. Break the assembly down and rotate the
ti re 180 degrees (half-way around) on the wheel.
Inflate the tire and measure the runouts.
Are t i r e s/ whe e l bal anced?
Yes
No
INSTALL on vehicle.
PERFORM Road Test.
first high spot on the ti re,
GO t o G7 .
PINPOINT TEST G: VIBRATION (Cont i nued)
G7 WHEEL RUNOUT
Yes
No
LOCATE and MARK low
spot on wheel and
high spot on wheel.
PERFORM Road Test.
LOCATE and MARK the
PERFORM Road Test.
Dismount tire and mount wheel on wheel balancer.
Measure runouts on both flanges. Runout should be
less than 1.14 mm (0.045 inch) radial and lateral.
Is t here proper runout?
N X
F7043-A
Yes
No
LOCATE and MARK low
spot on wheel and
high spot on wheel.
PERFORM Road Test.
LOCATE and MARK the
PERFORM Road Test.
G8 AXLE, ROTOR AND BOLT CIRCLE RUNOUTS
Yes
No
REPLACE rear di sc brake
rotor and PERFORM
Road Test.
REPLACE front disc
(rear wheel posi ti ons)
and PERFORM Road
Test.
For rear wheel posi ti ons,
and measure hub flange U
0.254 mm (0.010 inch)). B
than 0.08 mm (0.003 inch)
(greater than 0.05 mm (0.<
For front wheel posi ti ons,
ci rcle runout at rotor outer
to rear hub (greater than C
rotor pilot radial runout (g
(0.002 inch)).
Are measurement s c o r n
qL | ROTOR
PILOT RADIAL
rh 1 nOm RUNOUT
\ 1/ RO
%
PIL
remove front disc brake
ice runout (greater than
olt ci rcle runout (greater
) and pilot radial runout
302 inch)).
measure rotor lateral
mm (0.002 inch)) bolt
diameter while mounted
).06 mm (0.002 inch)) and
r
eat ert han 0.05 mm
*ct ?
TOR
OT
F7044-C
Yes
No
REPLACE rear di sc brake
rotor and PERFORM
Road Test.
REPLACE front disc
(rear wheel posi ti ons)
and PERFORM Road
Test.
G9 INSPECT WHEELS
Yes
No
GOt o G12.
INSTALL counter balance
locking lug nut.
PERFORM Road Test.
GO t o G10.
If wheels are equipped with locking lug nuts, check
that proper counter balance wheel weight is
installed opposi te lug nut.
Is wheel wei ght c o r r e c t ?
Yes
No
GOt o G12.
INSTALL counter balance
locking lug nut.
PERFORM Road Test.
GO t o G10.
G10 FRONT TIRES
Yes
No
BALANCE front wheel(s).
PERFORM Road Test.
GO t o G 11.
GO t o G12 .
Spin front ti res wi th a wheel balance spinner while
vehi cle is raised on hoi st. Feel for vibration in front
fender or while seat ed in vehi cle.
Yes
No
BALANCE front wheel(s).
PERFORM Road Test.
GO t o G 11.
GO t o G12 .
PINPOINT TEST G: VIBRATION (Cont i nued)
G11 REAR TIRES
Yes
No
GO t o G13.
GOt o G15.
Engage drivetrain while vehicle is raised on hoi st.
Carefully accelerate the drive wheels while feeling
for vi brati on.
Yes
No
GO t o G13.
GOt o G15.
G12 DRIVETRAIN
Yes
No
GO t o G14.
PERFORM Road Test.
Remove rear wheels, secure brake drums, if so
equipped by installing lug nuts, reversed. Carefully
accelerat e the drivetrain while feeling for vi brati on.
Yes
No
GO t o G14.
PERFORM Road Test.
G13 REAR ROTORS
Yes
No
REFER to Driveshaft
Vibration Diagnosis in
Section 00-04.
Test.
Remove the rear disc brake rotors. Carefully
accelerat e the drivetrain while feeling for vi brati on.
Yes
No
REFER to Driveshaft
Section 00-04.
Test.
G14 WHEEL BALANCE
Yes
No
Vehicle OK.
GOt o G15.
Balance all wheels not previously balanced. Road
t est vehi cle.
Are wheel s bal anced?
Yes
No
Vehicle OK.
GOt o G15.
G15 SUBSTITUTE WHEELS AND TIRES
Yes
No
REFER to Driveshaft
Section 00-04.
at each step, until the
defecti ve tire(s) is
identified. REPLACE
ti re(s) as necessary and
RETEST.
Substitute a known good set of wheels and t i res.
Road t est vehi cle.
Yes
No
REFER to Driveshaft
Section 00-04.
at each step, until the
defecti ve tire(s) is
identified. REPLACE
ti re(s) as necessary and
RETEST.
Ba l l J o i n t s
1. Check for front suspension l ower arm ball joint
( 3050) wear by raising the vehicle until the wheel
is cl ear of the floor.
2. Support t he front suspension l ower arm ( 3078)
so t hat t here is no l oad on the suspensi on strut.
3. Try t o rock t he wheel t op-t o-bot t om; if any wobbl e
is fel t, l ook for movement bet ween t he front
suspensi on l ower arm and front wheel spindle
( 3105) and front wheel knuckl e ( 3K186) .
4. If t he front suspensi on l ower arm ball joint
appears ti ght, check the wheel beari ng.
Ot herwi se, any movement present i ndi cates front
suspensi on l ower arm ball joint wear.
Si nce t he front suspensi on l ower arm ball joint is
i ntegrated into t he front suspensi on l ower arm, t he
front suspensi on l ower arm must be repl aced. Refer t o
Secti on 04- 01 for servi ce procedure.
L o we r A r m a n d Bu s h i n g
Check the front suspension l ower arms ( 3079) and the
front stabilizer bar ( 5482) for signs of damage and
possi bl e deformati on due t o curb i mpacts, improper
hoisting, et c. If any such damage is evident, carefully
measure and compare the component wi th its
opposi te-si de counterpart t o det ect any di fferences.
Check all front and rear suspension rubber bushings
for wear or deteri orati on whi l e supporti ng the vehicle
and the component so that the bushing carri es no
l oad. If any unrestrai ned motion (free pl ay) is apparent
in a shake t est , the bushing should be repl aced.
Test all rubber-bushed suspension mounting and
connecti ng poi nts for free play in the unloaded
condi ti on. Use a j ack or lever t o raise the vehicle or
suspension component t o unload the bushing for
shake testi ng. Refer t o Secti on 00-02 for lifting
procedure. Some restrai ned relative motion is
permissible as the bushing is st ressed in testi ng, but if
free play is evident at any point, the bushing should be
repl aced.
ADJUSTMENTS
A l i g n m e n t , F r o n t
1. NOTE: Do not at t empt t o check and adj ust
front-wheel alignment wi thout fi rst maki ng a
preliminary i nspecti on of the front end part s.
Check all t he f act ors affecti ng front-wheel
alignment adj ustments. Check the front-wheel
alignment under t he following curb l oad
condi ti ons:
Oil level and radi ator ( 8005) filled t o speci fi cati on.
2. Spare ti re, wheel , j ack and j ack handle in
posi ti on.
3. Front seat s in rearmost posi ti on.
4. All other loading removed.
5. All ti res inflated t o speci fi ed pressure (col d).
6. All excessi ve mud, dirt and road deposi t
accumul ati on removed f rom chassi s and
underbody.
Refer t o Speci fi cati ons for front wheel alignment
speci fi cati ons.
E q u i p me n t I n s t a l l a t i o n
Equipment used for front-wheel alignment i nspecti on
must be accurat e. All wheel alignment readi ngs must
be perf ormed on an alignment rack level t o within 1.59
mm (1 / 16 inch) side-to-side and front-to-rear. The
instrumentation used must have a means of
compensati ng for wheel runout.
Install t he wheel alignment equipment on t he vehi cl e
and fol l ow t he installation and inspection i nstructi ons
provi ded by the equipment manufacturer.
Ca s t e r a n d C a mb e r
The cast er is the f or war d or rearward tilt of t he top of
the front wheel spindle ( 3105) (RH). If t he t op of the
front wheel spindle tilts t o t he rear, cast er is posi ti ve. If
the t op of t he front wheel spindle tilts t o t he front,
cast er is negati ve. For correct cast er angle or tilt,
refer t o Speci fi cati ons.
The maxi mum cast er di fference (si de-to-si de) is
shown in Speci fi cati ons.
Camber is t he amount the centerline of t he wheel is
ti l ted i nward or out ward f r om t he true vert i cal . If a
wheel tilts out war d away f rom t he vehi cl e, camber is
posi ti ve. If t he t op of a wheel tilts i nward t owar d the
vehi cl e, camber is negati ve. For correct camber
angl e, refer t o Speci fi cati ons.
The maxi mum camber di fference (si de-to-si de) is
shown in Speci fi cati ons.
I | POSITIVE
| CAMBER
NEGATIVE
CASTER
POSITIVE
CASTER
Q.OF TIRE
CAMBER
ANGLE
FRONT OF
VEHICLE
F1216-C
T o e
NOTE: Toe should only be checked and adj usted after
t he cast er and camber have been adj usted t o
speci fi cati on.
Check t he t oe wi th the front wheel s in the
strai ght-ahead position. Run the engine, so t hat t he
power steeri ng control val ve will be in t he center
(neutral) posi ti on, and lock the steeri ng wheel ( 3600)
in pl ace using a steeri ng wheel holder. Measure t he
di stance bet ween the ext reme front wheel s and al so
between t he ext reme rear of bot h front wheel s. The
di fference between these t wo di stances is t he t oe in or
t oe out.
Correct toe-in setti ng, the i nward pointing of bot h front
wheel s is shown in Speci fi cati ons.
Re f e r e n c e Definitions
CAMBER
-
s
ANGLE
f TRUE
PIVOT
CENTERLINE
WHEEL
CENTERLINE
POSITIVE
CAMBER
/ VERTICAL
SCRUB RADIUS
TOE t
FRONT OF
I vTRUE FORE AND AFT VEHICLE
I I
A
FOR POSITIVE (TOE-IN) A IS LESS THAN B
FOR NEGATIVE (TOE-OUT) A IS GREATER THAN B
CASTER
TRUE
VERTICAL
POSITIVE
CASTER
ANGLE
STRUT/BALL JOINT
CENTERLINE (KPI)
KI NG
PI N
FRONT OF VEHICLE
CLEAR VISION
POSITION OF STEERING WHEEL
SPOKE RELATIVE TO HORIZONTAL
3 DEGREES CCW
3 DEGREES CW
CROWN VICTORIA/ _ _ _
k I
A
_
l w
_
l 4 f f c I
GRAND MARQUIS J SN E ^T I VE TOWN CAR
-1.2 3 DEGREES
C W , S
POSITIVE 1.4 DEGREES
SIDE-TO-SIDE
SIDE-TO-SIDE MEANS THE VALUE OF THE LEFT
SIDE MINUS THE VALUE OF THE RIGHT SIDE
EXAMPLE:
LEFT CAMBER = + 3/4 DEGREES
RIGHT CAMBER = + 1/4 DEGREES
SIDE-TO-SIDE = 3/4 DEGREES
1/4 DEGREES = + 1/2 DEGREES
EXAMPLE:
LEFT CAMBER = + 1/4 DEGREES
RIGHT CAMBER = +3/4 DEGREES
SIDE-TO-SIDE = 1/4 DEGREES -3/4 DEGREES =
+1/2 DEGREES
NOMINAL
THE NOMINAL VALUE IS THE
PREFERRED VALUE
TOLERANCE
THE TOLERANCE IS THE RANGE OF ACCEPTABLE VALUES
AROUND THE NOMINAL VALUE
EXAMPLE:
S-S CAMBER = -1/2 DEGREES (NOM.) 3/4 DEGREES
(TOL.) MEANS THAT VALUES BETWEEN -1-1/4 DEGREES
AND +1/4 DEGREES ARE ACCEPTABLE.
F7803-B
04- 00- 17 Sus pens i onS e r v i c e
0 4- 00- 17
Wh e e l / T i r e Runout
Check wheel and tire runout wi th t he ti res inflated t o
the normal l oad inflation pressure. To ensure accurat e
resul ts, make t he checks wi th a di al indicator, or
Rotunda Radial Runout Gauge 007- 00014 or
equivalent, i mmedi atel y after the r oad t est . If ti me is
al l owed t o pass bet ween the r oad t est and t he runout
checks, t he ti res may devel op sl i ght fl at spot s, whi ch
can affect the accur acy of t he ti re runout checks.
Measure ti re radial runout at the center and outsi de
ribs of the t read f ace. It may be necessary t o put t ape
on t he ti re t read t o keep the dial i ndi cator roller f rom
falling into t read bl ock grooves in t he t r ead. Measure
the lateral runout just above the l etters identifying t he
ti re si ze.
Measure wheel radial runout at t he wheel rim along t he
inside edge of t he fl ange.
Ti r e L e a d
" L e a d " is t he movement or wander of t he vehicle f rom
a strai ght path on a level road wi t h no pressure on t he
steeri ng wheel .
Lead is usually caused by:
Incorrect wheel alignment.
Uneven brake adj ustment.
Uneven or i ncorrect tire inflation pressures.
Damaged or wor n ti re constructi on.
The way a ti re is const ruct ed can produce ti re l ead. An
exampl e of thi s is pl acement of the radi al bel ts.
Off-center bel ts on a radi al ti re can cause t he ti re t o
devel op a si de f or ce whi l e rolling strai ght down t he
r oad. If one side of the ti re is a little l arger di ameter
than t he other, t he ti re will t end t o roll t o one si de. Thi s
will devel op a si de f orce whi ch can produce ti re l ead.
Ti r e We a r C o n d i t i o n Ch a r t
SUSPENSI ON
CONDI TI ON POSSI BL E SOURCE A CTI ON
Ra pi d We a r At The Sho ul d e r s Ti r es un d e r i n f l a t e d .
Wo r n suspe n si o n c o mpo n e n t s , i .e.,
bal l j o i n t s, uppe r st r ut mo un t s,
l o we r c o n t r o l a r m bushi n gs.
E x c e s s i v e c o r n e r i n g s p e e d s .
I NFLATE t i r e s t o r e c o mme n d e d
pr e s s u r e ROTATE t i r e s.
REPLACE wo r n c o mpo n e n t s .
ROTATE t i r e s.
Ra pi d We a r At Ce n t e r Of Tr e a d Ti r es o v e r i n f l a t e d . I NFLATE t i r e s t o r e c o mme n d e d
pr e s s u r e ROTATE t i r e s .
We a r At One Sho ul d e r Toe out of a d j ust me n t .
Ca mbe r out of s pe c i f i c a t i o n .
Bent f r o n t suspe n si o n l o we r a r ms.
Be nt f r ont s h o c k a b s o r b e r s .
Bent f r ont spr i n g and s h o c k t o we r .
ADJUST t o e t o s pe c i f i c a t i o n .
CHECK f or wo r n or d a ma ge d
suspe n si o n c o mpo n e n t s .
REPLACE f r ont suspe n si o n l o we r
a r ms.
REPLACE f r ont s h o c k a b s o r b e r s .
REPLACE f r ont spr i n g a n d s h o c k
t o we r .
Fe a t he r Edge Toe out a d j ust me n t .
Be nt or wo r n t i e r o d e n d s.
Da ma ge d whe e l hub.
ADJUST t o e t o s pe c i f i c a t i o n s .
REPLACE t i e r o d e n d s.
REPLACE whe e l hub.
Ba l d Spo t s or Ti re Cuppi n g Un ba l a n c e d whe e l .
Ex c e ssi v e r a d i a l runout .
Fr ont s h o c k a bso r be r wo r n .
BALANCE t i r e a n d wh e e l .
CHECK r unout a n d REPLACE t i r e if
n e c e ssa r y .
REPLACE f r ont s h o c k a bso r be r .
Ti re Sc a l l o pe d Toe out a d j ust me n t .
Ca mbe r out of s pe c i f i c a t i o n .
Wor n suspe n si o n c o mpo n e n t s , i .e.,
ba l l j o i n t s, we a k st r ut s.
ADJUST t o e t o s pe c i f i c a t i o n .
CHECK f or wo r n or d a ma ge d
suspe n si o n c o mp o n e n t s .
REPLACE wo r n suspe n si o n
c o mpo n e n t s .
Ve hi c l e Sp e e d Se n si t i v e Vi br a t i o n .
Vi br a t i o n at Spe e d s Abo v e 88
k m / h (55 mph) .
Ti re a nd whe e l l a t e r a l r unout . REPLACE t i r e ( s ) . ROAD TEST
v e hi c l e .
Sp e e d Re qui r e d t o Ca use
Vi br a t i o n I n c r e a se s a s Runout
De c r e a s e s . Ve hi c l e Spe e d
Se n si t i v e Vi br a t i o n . Vi br a t i o n a t
Sp e e d s Abo v e 32 k m / h ( 2 0 mph) .
Ti re a nd whe e l r a di a l r unout . REPLACE t i r e ( s ) . ROAD TEST
v e hi c l e .
04- 00- 18 SuspensionService 04- 00- 18
SUSPENSION (Cont i nued)
Up-down Movement in Steering
Wheel and Instrument Panel Along
With Mechani cal Vi brati on. Most
Noticeable Between 3 2 - 6 4 km/ h
( 2 0 - 4 0 mph). Vehicle Speed
Sensitive Vi brati on.
Wheel hop.
Caused by t i res having radial
runout of more than 1 . 1 4 mm
( 0 . 0 4 5 inch). Do not attempt t o
correct by balanci ng.
REPLACE t i re(s). ROAD TEST
vehicle.
Steering Vibration Vehicle Speed
Sensitive
Tire balance. Stati c unbalance not
a cause of vibration below 4 8 km/ h
( 3 0 mph). Dynamic unbalance not a
cause under 6 4 km/ h ( 4 0 mph).
BALANCE t i res. ROAD TEST
vehicle.
Tire Wear
May also generate whine at high
speed changing to growl at low
speed. Vehicle speed sensitive
noise.
Worn /damaged suspension
components or t i res. Vehicle out of
alignment. Tires out of balance.
BALANCE t i res. SERVICE tires and
vehicle as required. ROAD TEST
vehicle.
Bearing, Front Wheel
Front wheel beari ngs ( 1215) that need repl aci ng may
be i ndi cated by a noise that occurs only when turning.
To di agnose t he wheel beari ngs:
1. Road t est t he vehi cl e on a smoot h road. Make
sharp turns t o t he right and left.
If t he vehi cl e makes noises on right turns, t he
left f ront wheel beari ngs may need t o be
repl aced.
If t he vehi cl e makes noises on the left turns, t he
right front wheel beari ngs may need t o be
repl aced.
2. NOTE: Be careful not t o confuse l ower ball joint
l ooseness wi t h wheel beari ng l ooseness.
Raise t he front of t he vehi cl e and check for l oose
wheel beari ngs by rocki ng the ti res at t op and
bot t om.
3. Spin the ti re qui ckl y by hand and make sure t he
ti re turns smoothl y wi thout noise f rom t he wheel
beari ngs.
4. Remove the wheel and di sc brake cal i per
(2B120).
5. Position Dial Indicator wi t h Bracket ry
TOOL-4201-C or equivalent agai nst t he wheel
hub, then push and pull t he wheel hub. Measure
t he end pl ay of the wheel hub and wheel beari ng
assembl y. The maxi mum al l owabl e end play i s:
0. 0002 mm ( 0. 01 i nch). If t he end play exceeds
t he speci fi ed limit, repl ace the wheel beari ng.
Ride Height Correction
Exami ne t he vehi cl e for indications of abnormal
atti tude, such as t he front or rear end being higher or
l ower than normal . Any heavy i tems in l uggage or
passenger compart ment s shoul d be removed before
checki ng wheel alignment.
If vehi cl e atti tude is not normal and no unusual l oad is
present, check for si gns of damage, or nonstandard
repl acement suspension part s.
Alignment Procedure
C a s t e r / C a mb e r A d j u s t me n t To o l s T7 9P - 3000- A
On Town Car, Crown Vi ctori a and Grand Marqui s
adj usti ng cams are provi ded for cast er and camber
adj ustment.
OPPOSITE
F7093-C
1. Check cast er and camber and record the
readi ngs.
3.
4.
5.
6 .
NOTE: A vehi cl e within the minimum t o maxi mum
tol erances may requi re alignment adj ustment t o
t he nominal setti ng (zero), because side-to-side
setti ng is out of speci fi cati on and must be
cor r ect ed.
Compare camber and cast er readi ngs wi th
nominal speci fi cati ons on appropri at e chart
(dependi ng on vehi cl e) to determi ne if adj ustment
is requi red t o bring vehi cl e t o nominal setti ng.
Maxi mum cast er di fference between wheel s (left
minus ri ght) t o be within - 3 / 4 degree t o + 3 / 4
degree wi t h cast er set t o speci fi cati on.
Maxi mum camber di fference between wheel s
(left minus ri ght) t o be within - 3 / 4 degree t o
+ 3 / 4 degree wi t h camber set t o speci fi cati on.
If adj ustment is requi red, loosen t wo nuts on t op
of adj usti ng cams.
Turn hex cams as requi red t o obtai n desi red
val ve.
After proper cast er and camber setti ngs have
been set , hol d each cam and ti ghten nuts t o
145-175 N-m ( 107- 129 Ib-ft).
Check toe-in and steeri ng wheel spoke position
and adj ust bot h (as required) at t he same ti me.
Toe and St eeri ng Wheel Spoke Posi ti on
After adjusting cast er and camber, check the steeri ng
wheel spoke posi ti on wi t h the front wheel s in
strai ght-ahead posi ti on. If the spokes are not in their
normal posi ti on, t hey can be properl y adj usted whi l e
toe is being adj ust ed.
1. Loosen t he t wo cl amp bol t s on each spi ndl e
connecti ng rod sl eeve.
T U R N DO WN WA R D T O
DE C RE A S E ROD L E NGT H
T U R N U P WA R D
T O I NCRE A S E
ROD L E NG T H
L H S L E E VE
T URN
DO WN WA R D
T O I NCRE A SE
ROD L E NG T H
T URN UP WA RD T O
DE C RE A S E ROD L E NG T H
RH S L E E VE
F1433-F
2. Adjust t oe. if the steeri ng wheel spokes are in
their normal posi ti on, lengthen or shorten bot h
rods equally t o obtain correct t oe. If t he steeri ng
wheel spokes are not in thei r normal posi ti on,
make the necessary rod adj ustments t o obtai n
correct t oe and steeri ng wheel spoke alignment.
WH E N TOE I S CORRECT
T U R N B O T H C O N N E C T I N G R O D
S L E E VE S D O W N W A R D
T O A DJ U S T WH E N T O E I S C O R R E C T
S P O K E P OSI T I ON T U R N B O T H C ON N E C T I N G R O D
S L E E VE S U P WA R D T O
A DJ U S T S P O K E P OSI T I ON
WH E N T O E I S
N O T C O R R E C T
L E N G T H E N L E FT R O D
T O DE C R E A S E T OE - I N
S H O R T E N RI G HT R O D
T O I N C RE A S E TOE-IN
WH E N T O E I S
N O T C O R R E C T
S H O R T E N L E F T R O D
T O I N C RE A S E T OE - I N
L E N G T H E N RI G H T R O D
T O DE C R E A S E T OE - I N
A DJ U S T B O T H R O DS E QU A L L Y .
T O MAINTAIN N O R MA L S P O K E P OS I T I ON
F1434- E
3. When t oe and the steeri ng wheel spoke position
are both correct , l ubri cate cl amp, bol ts and nuts.
Tighten t he cl amp bol ts on bot h connecti ng rod
sl eeves t o 27- 30 N-m ( 20- 22 Ib-ft). The sl eeve
position shoul d not be changed when t he cl amp
bol ts are ti ghtened for proper cl amp bolt
ori entati on.
H O R I Z O N T A L FRON T O F VE H I C L E -
VE RT I CA L
A F T E R T O E SE T T I NG, T H E T WO C L A MP
B O L T S O N E A C H SI DE O F VE HI CL E MUS T
B E P OSI T I ONE D WI T HI N L I MI TS S H O WN ,
WI T H T H R E A DE D E N D O F B O L T S T O WA R D
FR O N T O F VE HI C L E
F2 7 7 9- C
C e n t e r i n g S t e e r i n g Wh e e l
1. Shift the power steeri ng short rack ( 3L547) back
t o t he equal angle setti ng.
2. Wi th the wheel s strai ght ahead, remove and shift
the steeri ng wheel ( 3600) on the column
serrati ons as cl ose as possi bl e t o the centered
position.
3. Install the wheel ( 1007) and fine tune t he power
steeri ng short rack position as outlined in Steps 1
and 2.
4. NOTE: If t he toe-in is t o be checked, do not
tighten t he front wheel spindle connecti ng rod or
end j am nuts at this ti me.
Tighten the j am nuts.
5. Position t he tie rod ends in the undercuts on the
tie rod ends ( 3A130) , and secure wi th the boot
clips.
Wh e e l T u r n i n g A n g l e , F r o n t
When t he inside wheel is turned 20 degrees, the
turning angle of t he outsi de wheel should be as
speci fi ed. The turning angle cannot be adj usted
di rectl y, because if is a result of the combination of
caster, camber and toe adj ustments and shoul d,
therefore, be measured only after these adj ustments
have been made. If the turning angle does not measure
t o speci fi cati on, check the suspensi on, front
sub-frame ( 50145) or steeri ng parts for a bent
condi ti on.
The front suspension is fully adjustable for caster,
camber and t oe. After front wheel alignment f act ors
have been checked, make the necessary
adj ustments. Do not attempt t o adjust front wheel
alignment by bending the suspension or steeri ng parts.
04- 00- 21 S u s p e n s i o n S e r v i c e 0 4- 0 0 - 2
c
S t e e r i n g A n g l e C h e c k
NOTE: Perform the steeri ng angle check bef ore toe-in
measurement (if any steeri ng angle correct i ons have
been made).
Check the wheel steeri ng angles at full right and left
posi ti ons. If t he angles are not within speci fi cati on as
outlined, t he tie rod ends ( 3A130) must be adj usted t o
the right or left until the steeri ng angl es are equal .
Adjustment of tie rod end af f ect s t he centeri ng of t he
steeri ng wheel ( 3600) in t he strai ght-ahead posi ti on.
Adj ustments can be fine-tuned by shifting t he tie rod
ends a small amount away f rom the equal angle
setti ng. If the steeri ng wheel cannot be cent ered wi th
the steeri ng angl es within speci fi cati on, check for
i mproper assembl y or installation of the fol l owi ng
steeri ng component s:
Steeri ng gear ( 3504) .
Steeri ng column tube ( 3514) .
e Steeri ng col umn l ower yoke ( 3N725) .
Steeri ng wheel .
Refer t o Secti on 11-00 f or steeri ng syst em servi ci ng.
Adjust t he steeri ng angl es as f ol l ows:
1. Wi th paint or marki ng pen, mark bot h tie rod ends
and j am nuts in their original posi ti ons. These
reference marks will help in equalizing right and
left adj ustments.
2. Remove the ti e rod boot cl i ps and free t he boot s
t o prevent t hem f rom being t wi st ed when t he tie
rods are turned.
3. Loosen and back off the tie rod end j am nuts.
4. To avoi d toe-in change, turn one tie rod into, and
the ot her out of, t he ti e rod ends, by equal
amounts. Thi s shortens one tie rod and lengthens
t he other, shifting t he power steeri ng short rack
( 3L547) right or left until the rack t eet h are
cent ered on the pinion, and rack travel f rom the
cent ered position is equal in bot h di recti ons. This
equal i zes t he wheel steeri ng angl es, but al so
rot at es t he pinion and steeri ng wheel .
5. Position the wheel s strai ght ahead and check t he
steeri ng wheel centeri ng. If cl ose t o cor r ect , shift
t he power steeri ng short rack and ti e rod ends
left or right wi thout turning the wheel s, t o center
the steeri ng wheel . A shift t o the left will turn the
wheel cl ockwi se, and a shift t o the right will turn
it, count ercl ockwi se, as seen from the dri ver
seat.
6. Verify that t he wheel steeri ng angl es are still
within speci fi cati on. If not within speci fi cati on, t he
steeri ng wheel can be removed and shi fted on t he
column t o center it. Thi s is preferabl e t o
attempti ng an overhaul of t he steeri ng gear and
steeri ng column t ube, whi ch may have been
previ ousl y di sassembl ed wi thout marki ng for
correct assembl y.
D r i v e s h a f t P i n i o n A n g l e C h e c k i n g
Descr i pti on T o o l Number
Pi ni on A n gl e L e v e l Ga u ge T 68P - 4602 - A
1. NOTE: A l oad must be appl i ed t o attai n a curb
height as shown on the pinion angle chart . Thi s
height is measured f rom t he t op of t he rear axl e
housing tube to the rear suspensi on j ounce
bumper bracket on t he bot t om of the si de rai l .
Position the V-magnet part of Pinion Angl e Level
Gauge T68P-4602-A on the dri veshaft ( 4602)
away from wel ds and bal ance wei ght s.
2. NOTE: The snap ring must be removed and
installed after the readi ng is compl et ed.
From LH si de of the vehi cl e, position Pinion Angl e
Level Gauge T68P-4602-A on the V-magnet wi t h
t he adjusting scr ew t o the left. Adj ust the dial on
t he tool until the LH edge of t he bubbl e is exact l y
on the zero line.
3. Position the magneti zed tool on t he beari ng cap
wi t h t he tool in the same relative position as it
was on the V-magnet.
4. Read t he position of the bubbl e' s LH edge on the
scal e t o determi ne t he dri veshaft pinion angl e.
Compare wi t h the pinion angle speci fi cati on.
If the pinion angle is not within speci fi cati on, install
servi ce upper rear suspensi on arm and bushi ngs
( 5500) (may not be available for all vehi cl es,
check wi th your deal er) equi pped wi t h cams.
Adjust pinion angle as fol l ows:
5. Remove the rear suspension arm and bushings as
outlined.
6. NOTE: If the cam (l ocat ed in the bushing inner
sl eeve) appears t o be rusty, t ap the cam wi t h a
drift t o remove the rust, so t he cam will rot at e.
Using a wi de and flat obj ect like a l arge
screwdri ver, insert the t ool in t he slot in the
eccentri c inner sl eeve. If is accessi bl e t hrough
t he hole f rom where the retaining bolt was
removed.
7. NOTE: LH and RH rear suspensi on arm and
bushings must have same setti ng.
Rotate the cam inside t he inner sl eeve cl ockwi se
or countercl ockwi se t o rai se or l ower t he pinion
nose angle t o speci fi cati on.
8. After the adj ustment is perf ormed, install t he rear
suspension arm and bushings as outlined.
ECCENTRIC BUSHING ON UPPER
FRONT OF ARM ASSEMBLY AND ITS AFFECT
VEHICLE ON PINION ANGLE
INSTALLED DECREASE INCREASE
POSITION PINION PINION
ANGLE ANGLE
F2953-C
A l i g n m e n t , Re a r
1. Check t he ti re pressure and adj ust as necessary.
2. Inspect the rear wheel beari ng pl ay and correct
as necessary. Refer t o Secti on 05-02A.
3. NOTE: Make sure the vehi cl e is on level ground
and has no l uggage or passenger load before
performi ng the fol l owi ng procedure.
Verify that t he di fference in the rear ride height
between the left and right si des is within 10 mm
( 0. 4 inch). To check thi s, measure f rom t he
center of the rear wheel t o the hi ghest point on
t he wheel openi ng.
Rear wheel camber and toe-in are not adj ustabl e.
Camber or toe-in out of speci fi cati on i ndi cates
collision damage or i mproper hoisting. To correct
rear camber or toe-in out of speci fi cati on (other
than a lateral adj ustment) requi res repl acement
of the rear suspension l ower arm ( 5A649) and
rear suspension arm and bushing ( 5500) for
vehi cl es equi pped wi th coil spri ngs, or rear
suspensi on arm and bushing and rear suspension
arm and bushing for vehi cl es equi pped wi th air
spri ng. Refer t o Secti on 04- 02.
SPECIFICATIONS
WHEEL BASE AND TREAD WIDTH FRONT WHEEL TURNING ANGLE
I
Wheel Base
Tread Wi dt h
I
Wheel Base Front Rear
CM Inch CM I nch CM I nch
2 90. 3 114. 3 159. 5 62 . 8 160. 7 63. 3
BALL JOINTSRADIAL PLAY
Vehi cle
Turni ng Angl e
of Out si de
Wheel Wi t h
I nsi de Wheel
Turned 20
Degrees
To wn Car , Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s 18. 51 d e g r e e s
De sc r i pt i on Radi al Pl a y Ma x. Al l owabl e
L o we r Ba l l
Jo i n t
We a r I n d i c a t o r Re p l a c e t h e Fr o n t
Su s p e n s i o n L o w e r A r m if t h e r e i s e x c e s s i v e
l o o s e n e s s .
Up p e r Ba l l
Jo i n t
Re p l a c e t h e ba l l j o i n t if
p e r c e p t i b l y l o o s e .
NOTE: If sensi ti ve steeri ng condition still exi st s after
maki ng the adj ustments, refer t o Steering Syst em
Di agnosti cs in Secti on 11-00.
FRONT WHEEL ALIGNMENT SPECIFICATIONS-TOWN CAR (CURB HEIGHT WITH 1/ 2 TANK OF FUEL)
I t em
Al i gnme nt Fact or s
I t em Nomi nal Mi ni mum Maxi mum
Ca mb e r - 0. 50 d e g r e e s - 1. 2 5 d e g r e e s + 0 . 2 5 d e g r e e s
Ca mb e r Di f f e r e n c e ( l e f t mi n us
r i gh t )
+ 0 . 0 0 d e g r e e s - 0. 7 5 d e g r e e s + 0 . 7 5 d e g r e e s
0 4 - 0 0 - 2 3 S u s p e n s i o n S e r v i c e 0 4 - 0 0 - 2 3
FRONT WHEEL ALIGNMENT SPECIFICATIONS-TOWN CAR (CURB HEIGHT WITH 1 / 2 TANK OF FUEL) (Cont ' d)
I t e m
Alignment Fact or s
I t e m Nomi nal Mi ni mum Maxi mum
Ca s t e r + 6 . 0 d e g r e e s + 5 . 2 5 d e g r e e s + 6 . 7 5 d e g r e e s
Ca s t e r Di f f e r e n c e ( l e f t mi n us
r i gh t )
T o t a l To e De g r e e
3
- 0. 12 5 d e g r e e s t o e - o u t - 0. 37 5 d e g r e e s + 0 . 1 2 5 d e g r e e s
To t a l To e I n c h
3
- 0. 063 i n c h - 0. 188 i n c h + 0 . 0 6 3 i n c h
To t a l To e m m
3
- 1. 6 mm - 4. 8 mm + 1.6 mm
Cl e a r Vi s i o n
b
- 1. 4 d e g r e e s - 4. 4 d e g r e e s + 1.6 d e g r e e s
a P o s i t i v e v a l ue s p e c i f i c a t i o n f o r t o e i s t o e - i n , n e ga t i v e v a l u e s p e c i f i c a t i o n f o r t o e i s t o e - o u t .
b Ne ga t i v e v a l ue s p e c i f i c a t i o n f o r c l e a r v i s i o n i s c o u n t e r c l o c k w i s e .
FRONT WHEEL ALIGNMENT SPECIFICATIONS-CROWN VICTORIA/GRAND MARQUIS (CURB HEIGHT WITH 1 / 2 TANK OF
FUEL)
I t em
Al i gnment Fact or s
I t em Nomi nal Mi ni mum Maxi mum
Ca mb e r - 0. 50 d e g r e e s - 1. 2 5 d e g r e e s + 0 . 2 5 d e g r e e s
Ca mb e r Di f f e r e n c e ( l e f t mi n us
r i gh t )
Ca s t e r + 5 . 5 d e g r e e s + 4 . 7 5 d e g r e e s + 6 . 2 5 d e g r e e s
Ca s t e r Di f f e r e n c e ( l e f t mi n us
r i gh t )
To t a l To e De g r e e
3
- 0. 12 5 d e g r e e s t o e - o u t - 0. 37 5 d e g r e e s + 0 . 1 2 5 d e g r e e s
To t a l To e I n c h
3
- 0. 063 i n c h - 0. 188 i n c h + 0 . 0 6 3 i n c h
To t a l To e m m
3
- 1. 6 mm - 4. 8 mm + 1.3 mm
Cl e a r Vi s i o n
b
- 1. 2 d e g r e e s - 4. 2 d e g r e e s + 1.8 d e g r e e s
a P o s i t i v e v a l ue s p e c i f i c a t i o n f o r t o e i s t o e - i n , n e ga t i v e v a l u e s p e c i f i c a t i o n f o r t o e i s t o e - o u t .
b Ne g a t i v e v a l ue s p e c i f i c a t i o n f o r c l e a r v i s i o n i s c o u n t e r c l o c k wi s e .
DRIVESHAFTPINION ANGLE SPECIFICATION
Axl e Angl e
Cont r ol l e d Hei ght
Axl e Angl e m m I nches
8. 8 i n c h 2 d e g r e e s 152 . 9 6. 02
Up p e r A r m- t o - Fr a me Re t a i n i n g
Bo l t s
136- 190 101- 140
Ca m Re t a i n i n g Nut s 145- 17 5 107 - 12 9
Ti e Ro d Sl e e v e Cl a mp Bo l t s 2 7 - 30 2 0- 2 2
Up p e r St a bi l i ze r Ba r L i n k Pi n c h
Bo l t
40- 55 30- 40
L o we r Ba l l Jo i n t Nut 108- 162 80- 119
Up p e r Ba l l Jo i n t P i n c h Bo l t 7 6- 104 55- 7 7
Tool Numbe r /
T 68P - 4602 - A
Pi n i o n An gl e L e v e l Ga uge
T6BP-4602-A
T OOL - 42 01- C Di al I n d i c a t o r wi t h Br a c ke t r y
ROTUNDA EQUIPMENT
007 - 00014 Ra d i a l Run o ut Ga u ge
04- 01- 1 Su s p e n s i o n a n d Wh e e l Hu b s , Fr o n t 04- 01- 1
SECTION 04-01 Suspension and Wheel Hubs, Front
SUBJECT PAGE
Component Replacement 04- 01- 3
Component s 04-01-1
Fasteners, Suspensi on . 04- 01- 3
Shock Absorber 04- 01- 3
Suspensi on 04-01-1
Wheel Beari ng and Wheel Hub 04-01-4
Suspensi on and Wheel Hubs, Front 04-01-4
Ar m, Lower 04-01-7
Ar m, Upper ... ....04-01-g
Ball Joi nt 04-01-7
Coi l Spri ng 04-01-g
SUBJECT PAGE
Hub and Rotor, Wheel Grease Seal, Bearing
Cones and Cups 04-01-5
Sensor I ndi cat or, Ant i -Lock Brake .04-01-6
Shock Absorber, Front .............. 04-01-6
St abi l i zer Bar 04-01-12
Br acket 04-01-12
St abi l i zer Bar Li nk Assembl y 04-01-12
Wheel Hub Bol t .....04-01-6
Wheel Spi ndl e, Front 04-01-4
ADJUSTMENTS
Wheel Al i gnment 04-01-13
SPECIAL SERVICE TOOLS/EQUIPMENT . 04-01-13
VEHICLE APPLICATION
Suspension
The front suspensi on is desi gned so t hat it al l ows an
individual wheel t o compensat e for changes in t he
road' s surf ace level wi thout consi derabl y affecti ng the
opposi t e wheel .
Components
Each wheel is independently connected t o the f rame
by front wheel spindles ( 3105) , ball joint assembl i es
front suspensi on upper arm ( 3083) and front
suspensi on l ower arm ( 3078) .
The front wheel spi ndl es are speci fi cal l y desi gned
and posi ti oned t o al l ow t he steeri ng front wheel
spi ndl es t o move in a prescri bed t hree dimensional
arc.
The upper porti on of each front shock absorber
ext ends through the spri ng housing and is secured
wi t h t wo grommet s, t wo grommet retai ners and a
nut.
Side roll of the front suspension is control l ed by a
spring steel front stabilizer bar ( 5482) . Front
stabilizer bar is mounted in rubber l ower suspension
arm stabilizer bar insulators ( 5493) held t o the
f rame si de rails by stabilizer bar bracket s ( 5486) .
- The front wheel s are held in proper relationship t o
each other by t wo tie rod ends ( 3A130) that are
connect ed t o steeri ng arms on the front wheel
spi ndl es and t o a steeri ng sect or shaft arm drag link
( 3304) .
_ Front coi l spri ngs ( 5310) are mounted bet ween the
spri ng housings on t he f rame and t he front
suspensi on l ower arms.
Ride control is provi ded by doubl e, di rect acti ng
front shock absorbers ( 18124) mounted inside t he
front coi l spri ng and at t ached t o t he front
suspensi on l ower arms by bol ts.
The ends of the front stabilizer bar are connected
by ball joint links t o the front wheel spindle.
The front suspension l ower arm is at t ached t o the
f rame through isolating rubber bushings.
The front suspension upper arm bushings are bol ted
t o f rame bracket s.
A non-loaded ball joint is bol ted t o the outer end of
the front suspension upper arm and cl amped t o the
front wheel spindle by a pinch bolt and nut.
The inner ends of the front suspension l ower arm
have pressed-in and fl ared bushings whi ch are
bol ted t o the f rame bracket s.
Bol ts, passi ng through t he front suspension upper
arm bushings, at t ach the front suspension l ower
arm t o t he f rame.
04- 01- 2
-T::ZZTSL~ j
The l ower ball joint assembl y is a press fit in the Pol yurethane front suspensi on arm ball joint dust
front suspensi on l ower arm and at t aches t o the front seal s ( 3A105) are provi ded at t he ball socket
wheel spindle wi th a nylon prevailing torque nut. assembl i es t o keep dirt and moi sture f rom enteri ng
the joint, whi ch coul d damage beari ng surf aces.
Steel snap ri ngs provi de a posi t i ve cl osure syst em
for t he ball j oi nts.
Suspensi on, Fr ont
F7092-E
I t e m
Pa r t
Pa r t
1 3084 Front Suspension Arm 7 N805476-S301 Nut (4 Req'd)
Bushing 8 5K484 Stabilizer Bar Link (2 Req'd)
2 N806798-S428 Bolt (4 Req'd) 9 3108 Front Wheel Spindle
4 N806579-S428 Bolt (2 Req'd) 11 5482 Front Stabilizer Bar
6

Frame
13 5415 Front Spring Insulator
04- 01- 3
Su s p e n s i o n a n d Wh e e l Hu b s , Fr o n t 04- 01- 3
Pa r t
14 5310 Front Coil Spring (2 Req'd)
16 N801224-S Washer (2 Req'd)
17 N800980-S301 Bolt (4 Req'd)
18 N620468-S60 Nut (2 Req'd)
Req'd)
20 N808509-S428 Nut (2 Req'd)
A

(109-148 Lb-Ft)
Pa r t
B Tighten to 145-175 N-m
(107-129 Lb-Ft)
C

Lb-Ft)
D

(83-113 Lb-Ft)
E

Lb-Ft)
F

Tighten to 87-119 N-m (64-88
Lb-Ft)
The front wheel beari ngs are of a wheel hub ( 1104)
unit design and are pregreased, seal ed and require
no schedul ed mai ntenance.
The wheel beari ngs are preset and cannot be
adj usted.
If a wheel beari ng repl acement is requi red for any
servi ce, the wheel hub must be repl aced as an
assembl y.
The wheel beari ngs cannot be di sassembl ed f rom
the wheel hub and cannot be servi ced separatel y.
No individual servi ce seal s, roller or races are
avai l abl e.
The front axl e wheel hub retainer ( 3B477) torque of
255- 345 N-m ( 188- 254 Ib-ft) restri cts wheel hub
rel ati ve movement and maintains axi al position of
t he wheel hub.
S h o c k A b s o r b e r
The front shock absorbers provi de motion and f orce
and dampi ng between the sprung and unsprung
masses of the vehicle when traveling over irregular
road surf aces.
The front shock absorber consi sts of a twi n tube
gas-pressuri zed structure providing dampi ng in both
the rebound (UP) and compressi on (DOWN)
di recti ons.
This dampi ng is accompl i shed by driving a dual
(rebound and compressi on) acti ng piston through a
fluid environment.
The motion resi stant f orces are control l ed by a
vel oci ty sensitive variable orifice piston assembl y
within the front shock absorber.
F a s t e n e r s , S u s p e n s i o n
CAUTI ON: Al l f r o n t s u s p e n s i o n f a s t e n e r s a r e
i mp o r t a n t a t t a c h i n g p a r t s i n t h a t t h e y c o u l d a f f e c t
t h e p e r f o r ma n c e o f v i t a l p a r t s a n d s y s t e ms ,
a n d / o r c o u l d r e s u l t i n ma j o r s e r v i c e e x p e n s e .
A n y pa r t mu s t b e r e p l a c e d w i t h o n e o f t h e s a me
p a r t n u mb e r o r w i t h a n e x a c t e q u i v a l e n t pa r t i f
r e p l a c e me n t b e c o me s n e c e s s a r y . Do n o t us e a
r e p l a c e me n t p a r t o f l e sse r q u a l i t y o r s u b s t i t u t e
d e s i g n . T o r q u e v a l ue s mu s t b e u s e d a s s p e c i f i e d
d u r i n g a s s e mb l y t o e n s u r e p r o p e r r e t e n t i o n o f
t h i s p a r t .
Never at t empt t o heat, quench or strai ghten any front
suspensi on part. Repl ace wi th a new part.
04- 01- 4 Su s p e n s i o n a n d Wh e e l Hu b s , Fr o n t 0 4 - 0 1 - 4
Wh e e l B e a r i n g a n d Wh e e l H u b
Each front wheel is bol ted t o a wheel hub ( 1104)
assembl y. The wheel beari ng is an integral part of the
wheel hub assembl y and is servi ced as a wheel hub. A
front axl e wheel hub retai ner ( 3B477) and washer
at t ach the wheel hub t o t he front wheel spindle ( 3105)
assembl y.
Pa r t
1 1125 Front Disc Brake Rotor
2 1N135 Front Hub Gap Grease Seal
3 3B477 Front Axle Wheel Hub
Retainer
4 1104 Wheel Hub
5 2C182 Front Brake Anti -Lock
Sensor Indicator
A

(188-254 Lb-Ft)
S u s p e n s i o n a n d Wh e e l H u b s , F r o n t
Refer t o Secti on 04-00 or 00- 04.
Wh e e l S p i n d l e , F r o n t
Re mo v a l
1. Rai se the front of the vehi cl e and position saf et y
st ands under bot h si des of t he f rame j ust behind
the front suspension l ower arm ( 3078) . Refer t o
Secti on 00-02.
2. Remove wheel and t i re.
3. Remove the front di sc brake rotor ( 1125) , di sc
brake caliper ( 2B120) , front di sc brake rotor
shield ( 2K005) and f ront brake anti-lock sensor
( 2C204) , if equi pped. Di scard cal i per mounting
bol ts. Refer to Sect i on 06- 03.
4. Di sconnect the ti e rod end ( 3A130) f rom the front
wheel spindle ( 3105) using Tie Rod End Remover
TOOL-3290-D or equivalent.
5. Loosen the nylon ring nut f rom l ower ball joint st ud
nut and loosen t he nut one or t wo turns. Do not
remove the nut at this ti me.
6. Wi th a hammer, sharpl y hit t he front wheel spindle
near t he stud t o l oosen the stud f rom the front
wheel spindle.
7. Loosen front stabilizer bar link nut at front wheel
spindle until nut is above t hread on ball st ud.
Using a hammer, st ri ke the nut t o di spl ace the
stabilizer bar link ( 5K484) f rom the front wheel
spindle. Remove and di scard nut.
8. Remove pinch bolt f rom upper ball joint and
stabilizer ball link joint at front wheel spindle.
9. CAUTI ON: The j a c k wi l l s u p p o r t t h e s p r i n g
l o a d o n t h e f r o n t s u s p e n s i o n l o we r a r m.
Position a floor j ack under the front suspensi on
l ower arm at the lower ball joint area, and rai se
j ack t o support front suspensi on l ower ar m.
10. Remove the l ower ball joint st ud nut. Remove the
front wheel spindle. Pry the slot wi t h a suitable
pry bar at the upper ball joint t o separat e f rom
front wheel spindle.
1. Position front wheel spindle on upper ball joint
stud. Install pinch bolt and loosely install nut.
04- 01- 5 Su s p e n s i o n a n d Wh e e l Hubs , Fr o n t 04- 01- 5
REMOVAL A N D I N S T A L L A T I O N ( C o n t i n u e d )
2. Position front wheel spindle and front suspension
l ower arm and insert stabilizer bar link into
t apered hole in front wheel spindle. Install nut.
3. NOTE: Skirt can be removed f rom nut provi ded
sufficient l oad, 889 N ( 200 lb) can be generated
between ball joint stud and spindle taper.
Position the front wheel spindle on the lower ball
joint stud, and install a new ski rt ed nylon ring nut.
Tighten the nut t o 113-153 N-m ( 83- 113 Ib-ft) wi t h
an air tool until ski rt curls on the outsi de of the nut.
Rai se the front suspensi on l ower arm and gui de
t he upper ball joint stud into the front wheel
spindle. Install the pi nch bolt and nut.
4. Tighten the upper ball joint pinch bolt nut t o
87- 119 N-m (64-87 Ib-ft) and remove floor j ack.
5. Connect the tie rod end to the front wheel spindle.
Install the nut and ti ghten t o 47- 63 N-m (35-46
Ib-ft). Continue t o tighten until slot for cotter pin is
al i gned. Refer t o Secti on 11-03. Install a new
cot t er pin.
6. Install the front di sc brake rotor shield , disc
brake caliper, and front brake anti-lock sensor if
equi pped. Use new cal i per mounting bol ts. Refer
7. Install the wheel and ti re assembl y.
8. Remove the saf et y st ands and l ower the vehi cl e.
9. Check caster, camber and t oe. Adj ust as
requi red. Refer t o Secti on 04- 00.
H u b a n d Ro t o r , Wh e e l G r e a s e S e a l , B e a r i n g
C o n e s a n d C u p s
Fr o n t Hub Re mo v e r / Re p l a c e r T81P - 1104- C
Re mo v a l
1. Rai se vehicle on hoi st. Refer t o Secti on 00- 02.
3. Remove front hub cap grease seal ( 1N135) f rom
wheel hub ( 1104) and di scard.
4. Remove t wo di sc brake cal i per l ocati ng pins
( 2B296) f rom di sc brake cal i per ( 2B120)
assembl y and di scard.
5. CAUTI ON: Do not l e t d i s c b r a ke c a l i pe r h a n g
b y t he f r ont br ak e hose ( 2 07 8) . Da ma ge t o
f r o n t b r a ke hose ma y r e s ul t .
Remove di sc brake cal i per assembl y and
suspend by wi re.
6. Remove front di sc brake rotor ( 1125) . If f act ory
push on nuts are i nstal l ed, remove cl i ps fi rst.
7. Remove front axl e wheel hub retainer ( 3B477)
and di scard.
8. Remove wheel hub assembl y. If assembl y cannot
be removed by hand, use Front Hub
Remover / Repl acer T81P-1104-C.
WHEEL HUB 1104
1. Install wheel hub.
2. Install new front axl e wheel hub retainer and
ti ghten t o 255- 345 N-m ( 188- 254 Ib-ft).
F5163-B
3. Install front di sc brake rotor and push on nuts.
4. Install new front hub cap grease seal . Use
appropri ate tool so as not t o damage or di stort
front di sc brake rotor.
5. Position di sc brake caliper t o front di sc brake
rot or and front wheel spindle ( 3105) .
04- 01- 6 Su s p e n s i o n a n d 04- 01- 6
REMOAL AND INSTALLATION (Conti nued)
6. Install new disc brake caliper locating pins.
Tighten t o 88 N-m ( 65 Ib-ft).
7. Install wheel and tire assembl y. Tighten lug nuts
( 1012) t o 115-142 N-m ( 85- 105 Ib-ft).
8. Lower vehicle.
S e n s o r I n d i c a t o r , A n t i - L o c k B r a k e
Re mo v a l
3. Remove di sc brake caliper ( 2 B120) , front di sc
brake rotor ( 1125) and wheel hub ( 1104)
assembl i es. Di scard cal i per mounting bol ts. Refer
t o Secti ons 04- 01 and 06- 03.
4. Using a Pulley Puller D81P- 19703- B or
equivalent, remove front brake anti-lock sensor
indicator ( 2C182) f rom wheel hub.
1. Support center of wheel hub so that wheel hub
bol ts ( 1107) do not rest on wor k surface.
2. CAUTI ON: E n s ur e f r o n t b r a ke a n t i - l o c k
s e n s o r i n d i c a t o r i s p r e s s e d o n s t r a i gh t t o
p r e v e n t d a ma g e .
Position front brake anti-lock sensor indicator on
wheel hub. Place flat pl ate on t op of ring and
press until flush wi t h t op of wheel hub.
3. Install wheel hub, front di sc brake rotor and di sc
brake caliper assembl i es. Use new caliper
mounting bol ts. Refer t o Secti ons 04- 01 and
06- 03.
4. Install wheel and ti re assembl y. Tighten lug nuts
( 1012) to 115-142 N-m ( 85- 105 Ib-ft).
H6519-B
Pa r t
1
Hydraulic Ram
2 1104 Wheel Hub
3 Spacer
Pa r t
4 2C182 Front Brake Anti-Lock
Sensor Indicator
5

Flat Steel Plate
S h o c k A b s o r b e r , F r o n t
Re mo v a l
WARNI NG: A L L VEHI CLES ARE EQUI PPED WI TH
GAS-PRESSURI ZED FRONT SHOCK ABSORBERS
WHI CH WI L L EXTEND UNASSI STED. DO NOT
APPLY HEAT OR FLAME TO THE PROMT SHOCK
ABSORBER TUBE.
For Inspection procedure, refer t o Secti on 04- 00.
1. Remove the front spri ng insulator ( 5415)
assembl y f rom the front shock absorber upper
end.
2. Raise the vehi cl e on a hoi st. Refer to Secti on
00- 02.
3. Remove the t wo scr ews attachi ng the front shock
absorber ( 18124) t o the front suspension l ower
arm ( 3078) , and remove the front shock
absorber. Li ghtl y wi re brush the shock studs t o
remove rust, oil or corrosi on.
4. Remove front shock absorber.
1. Properl y pri me t he new front shock absorbers.
Refer t o Shock Absorber Checks in Secti on
04- 00.
2. Pl ace a front spri ng insulator on the front shock
absorber t op stud and position t he front shock
absorber inside the front coil spri ng ( 5310) . Install
the scr ews. Tighten to 13-17 N-m (10-12 Ib-ft). If
the t hreads in t he front suspension lower arm
become st ri pped or damaged, the removed
scr ews should be reused, along wi th 5/ 16- 18
l ocknuts. Tighten to 13-17 N-m (10-12 Ib-ft) as
when scr ews wer e originally secured di rectl y t o
the front suspension l ower arm.
3. Remove the saf et y stands and l ower the vehicle.
4. Place a nut / washer assembl y on the front shock
absorber t op st ud, and start nut. Tighten t o 34- 46
N-m (25-34 Ib-ft).
Wh e e l H u b B o l t
Re mo v a l
1. Raise vehicle on hoist. Refer to Secti on 00- 02.
3. Remove di sc brake caliper ( 2B120) , and front
disc brake rotor ( 1125) . Di scard caliper mounting
bol ts. Refer t o Secti on 06-03.
4. Position wheel hub bolt ( 1107) t o cl ear front
wheel knuckl e ( 3K185) .
5. Remove from wheel hub ( 1104) .
WHEEL
HUB BOLT
1107
WHEEL HUB
1104
F8511-A
1. Install wheel hub bolt into wheel hub.
2. Using a lug nut ( 1012) , seat wheel hub bolt into
wheel hub.
3. Install front di sc brake rotor and di sc brake
cal i per. Use new caliper mounting bol ts. Refer t o
Secti on 06- 03.
4. Install wheel and tire assembl y. Refer t o Secti on
04- 04.
Ba l l J o i n t
Re mo v a l
1. Raise the front of the vehi cl e, position saf et y
stands under t he f rame behind front suspension
l ower arm ( 3078) . Refer t o Secti on 00- 02.
3. CAUTI ON: T h e f l o o r j a c k wi l l s u p p o r t t h e
s p r i n g l o a d o n t h e f r o n t s u s p e n s i o n l o we r
a r m.
Position a floor j ack under front suspensi on l ower
arm at t he l ower ball joint area and rai se j ack t o
support front suspension l ower arm.
4. Remove retaining nut and pinch bolt f rom upper
ball joint st ud.
5. Mark the position of alignment cams. When
repl aci ng front suspension upper ball joint ( 3049)
thi s will approxi mat e current alignment.
6. Remove t wo nuts retaining front suspension
upper ball joint t o front suspension upper arm
( 3083) .
7. Remove front suspension upper ball joint and
spread slot wi th suitable pry bar t o separat e t he
ball joint stud f rom front wheel spindle ( 3105) .
NOTE: Upper front suspension upper ball joint can be
used on either si de of vehicle.
1. Position ball joint assembl y on front suspension
upper arm and insert ball stud into front wheel
spindle.
2. Install pinch bolt and retaining nut. Tighten t o
87- 119 N-m (64-87 Ib-ft).
3. Install alignment cams t o t he approxi mat e
posi ti on at removal . If not marked, position t o
neutral posi ti on.
4.
5.
6.
7.
8.
REFERENCE
MARK INCREASE
DECREASE
CAMBER ADJUST
REFERENCE
MARK
FRONT OF
VEHICLE
CASTER ADJUST
BALL JOINT
RH ID ON ARM
FORGING
RH SHOWN
LH SYMMETRICALLY
OPPOSITE
F7093-C
Install t wo nuts attachi ng front suspension upper
ball joint t o front suspension l ower arm. Hold
cams and ti ghten nuts t o 145-175 N-m ( 107- 129
Ib-ft).
Remove fl oor j ack from front suspension l ower
arm.
Install ti re and wheel assembl y. Refer t o Secti on
04- 04.
Remove saf et y stands and l ower vehicle.
Check and adjust front wheel alignment. Refer t o
Secti on 04- 00.
A r m , L o w e r
Re mo v a l
1. Raise the front of the vehicle and position saf et y
stands under bot h si des of the frame just behind
the front suspensi on lower arms ( 3078) . Refer t o
Secti on 00- 02. Remove t he wheel and ti re.
2. Remove di sc brake cal i per ( 2B120) , front di sc
brake rotor ( 1125) and front brake anti-lock
sensor ( 2C204) if equi pped. Di scard di sc brake
caliper l ocati ng pins ( 2B296) . Refer to Secti on
06- 03.
3. Remove the front suspensi on bumper ( 3020) ;
i nspect and save for installation if in good
condi ti on.
4. Remove front shock absorber ( 18124) as
outlined.
5. Di sconnect t he steeri ng sect or shaft arm drag
link ( 3304) f rom the pitman arm. Refer t o Section
11-03.
6. CAUTI ON: Do n o t r e mo v e t h e n u t f r o m t h e
ba l l j o i n t s t u d a t t hi s t i me t o p r e v e n t i n j ur y .
Loosen the l ower ball joint st ud nut one or t wo
turns.
Pa r t
1 N805477-S60 Ski rted Nylon Ring Nut (2
Req'd)
4 N620468-S56 Nut (2 Req'd)
Req'd)
6 N800980-S101 Bolt (4 Req'd)
7 N805965-S60 Nut (4 Req'd)
7. Tap t he front wheel spindle ( 3105) sharpl y, near
t he l ower st ud, wi th a hammer t o l oosen t he stud
in the front wheel spindle.
8. Place a fl oor j ack under the front suspensi on
l ower arm.
9. Install the coi l spri ng compr essor as descri bed
under Coil Spri ng Removal , and remove t he front
coil spri ng ( 5310) .
10. Remove t he ball joint nut and remove front
suspensi on l ower arm assembl y.
11. Remove f ast eners at f rame bracket s and remove
front suspensi on l ower arm.
1. Position front suspensi on l ower arm in f rame
bracket s and loosely assembl e fasteners.
2. NOTE: Ski rt can be removed f rom nut provi ded
sufficient l oad 889N ( 200 lb) can be generat ed
bet ween ball joint and spindle taper.
Position t he front suspensi on l ower arm ball joint
stud into t he front wheel spindle, and install t he
new ski rt ed nylon ring nut. Tighten nut t o 113-153
N-m ( 83- 113 Ib-ft) wi th a pneumatic tool until ski rt
curls on outsi de of nut.
3. NOTE: Ensure that the pigtail of the l ower coi l of
the front coil spring is in the proper location of the
front spri ng insulator ( 5414) on t he front
suspension l ower arm, bet ween the t wo hol es.
Position the front coil spri ng into the upper spri ng
pocket , and rai se the front suspensi on l ower arm
aligning the holes in t he arm wi t h the holes in t he
crossmember. Install bol ts and nuts wi th washer
installed on the front bushi ng. Do not ti ghten at
this ti me.
4. Remove t he coil spri ng compressor.
5. Connect t he steeri ng center link at the pi tman arm
and install t he nut. Tighten t o 59- 63 N-m ( 44- 46
Ib-ft). Refer to Secti on 11-03. Continue t o ti ghten
until slot for cot t er pin is aligned. Install a new
cot t er pin.
6. Install front shock absorber as outlined.
7. Install the front suspensi on bumper. Tighten front
suspension l ower arm-to-frame bracket bol ts t o
136-190 N- m( 101- 140 Ib-ft).
8. Install front disc brake rotor shield ( 2K005) , front
disc brake rotor and di sc brake cal i per. Install
front brake anti-lock sensor, if equi pped. Use new
caliper mounting bol ts. Refer t o Secti on 06- 03.
9. Install wheel and ti re.
10. Wi th t he vehicle supported on the wheel s and
ti res at normal curb height, ti ghten the front
suspension lower arm-to-crossmember bol ts and
nuts t o 136-190 N-m ( 101- 140 Ib-ft).
11. Check caster, camber and t oe. Adj ust as
A r m , U p p e r
Re mo v a l
1. Raise the front of the vehicle, and position saf et y
stands under both si des of the f rame just behind
front suspension l ower arm ( 3078) . Refer t o
Secti on 00- 02.
2. Remove the wheel and ti re.
3. CAUTI ON: T h e f l o o r j a c k wi l l s u p p o r t t h e
s p r i n g l o a d o n t h e f r o n t s u s p e n s i o n l o we r
a r m.
Position floor j ack under the front suspension
l ower arm, and raise j ack t o support front
suspension l ower arm.
4. Remove retaining nut f rom upper ball joint stud t o
front wheel spindle pinch bolt.
5. Tap pinch bolt t o remove f rom front wheel spindle
( 3105) .
6. Wi t h a suitable pry bar, spread slot t o allow ball
joint stud t o rel ease out of front wheel spindle.
7. Remove the front suspension upper arm retaining
bol ts and remove front suspension upper arm
( 3083) assembl y.
1. Use reference marks f rom camber and cast er
cams as initial setti ngs.
OPPOSITE
F7093-C
2. Position the front suspension upper arm t o the
frame bracket and install the t wo retaining bol ts
and nuts. Tighten t o 136-190 N-m ( 101- 140 Ib-ft).
3. Connect the upper ball joint stud t o the front
wheel spindle and install the retaining pinch bolt
and nut. Tighten the nut t o 87- 119 N-m (64-87
Ib-ft).
4. Install the wheel and ti re.
5. Remove saf et y stands and l ower front of vehi cl e.
6. Check caster, camber and t oe. Adjust as
C o i l S p r i n g
Re mo v a l
Remove wheel and tire assembl y.
2. Remove the t wo bol ts retaining the front shock
absorber ( 18124) t o the front suspension l ower
arm ( 3078) .
3. Remove the upper nut, retainer and grommet
from t he front shock absorber. Remove the front
shock absorber.
4. Remove steeri ng center link f rom pitman arm.
5. Support the vehicle wi th saf et y stands under the
j acki ng pads and l ower the hoist but maintain
sufficient worki ng room.
6. Using Coil Spring Compressor D78P-5310-A or
equivalent, install one pl ate wi th the pivot ball
seat faci ng downward into the coils of the front
coil spri ng ( 5310) . Rotate the pl ate so that it is
flush wi th the upper surface of the front
suspension l ower arm.
7. Install the other pl ate wi th the pivot ball seat
faci ng upward into the coils of the front coil
spri ng. Insert t he upper ball nut through the coils
of the front coil spri ng so that nut rests in the
upper pl ate.
8. NOTE: This pin can only be i nserted one way into
the upper ball nut because of a st epped hole
desi gn.
Insert the compressi on rod into the opening in the
front suspension l ower arm, through the upper
and l ower plate and upper ball nut. Insert the
securi ng pin through the upper ball nut and
compressi on r od.
04- 01- 10 Su s p e n s i o n a n d Wh e e l Hu b s , Fr o n t 0 4 - 0 1 - 1 0
9. Wi th the upper ball nut secured, turn the upper
pl ate so that it wal ks up the coil until it cont act s
the upper front spri ng insulator ( 5415) . Then
back-off one-half t urn.
I t e m
Pa r t
1 Upper Ball
2

Compression Rod
3

Forcing Nut
4

Thrust Washer
5 Lower Ball Nut
6 Plate
7

Pin
10. Install the lower ball nut and thrust washer on the
compressi on rod and screw on t he forci ng nut.
w
F2785-E
04- 01- 11
Su s p e n s i o n a n d Wh e e l Hu b s , Fr o n t 04- 01- 11
11. Tighten the forci ng nut until the front coil spring is
compressed enough so that it is free in its front
spri ng insulator.
COIL SPRING
COMPRESSOR
D78P-5310-A
F2956-C
12. Remove the t wo front suspensi on l ower arm pi vot
bol t s, di sengage the front suspension l ower arm
f rom the f rame crossmember and remove the
front coil spri ng.
13. If a new front coil spri ng is t o be installed:
a. Mark t he position of the upper and lower
pl ates on t he front coil spri ng wi th chal k.
b. Wi t h an assi stant, compress a new front coil
spri ng for installation, measure the
compressed length and the amount of
curvature of the old front coil spri ng.
14. Loosen the forci ng nut t o relieve spring tensi on,
and remove the t ool s f rom t he front coil spri ng.
CHALK
MARKS
F2708-C
1. Assembl e the coil spring compressor and l ocate
in the same position as i ndi cated in Removal ,
St ep 13a.
2. Before compressi ng t he front coil spri ng, ensure
that the upper ball nut securi ng pin is i nserted
properl y.
3. Compress front coil spring until spring height
reaches the dimension obtai ned in Removal , Step
13b.
4. Position the front coil spring assembl y into the
front suspension lower arm ( 3079) .
CHALK MARK
/ f
F2786-E
5. To install front coil spri ng, reverse Removal
procedure.
04- 01- 12 Su s p e n s i o n a n d Wh e e l Hu b s , Fr o n t 0 4 - 0 1 - 1 2
6. The tail of the front coi l spri ng must be posi ti oned
as shown.
F7095-C
Pa r t
1 N808487-S428 Nut (4 Req'd)
2 5415 Front Spring Insulator (2
Req'd)
3 5310 Front Coil Spring (2 Req'd)
5 N801224-S Washer (2 Req'd)
6 N800980-S301 Bolt (4 Req'd)
A

(101-140 Lb-Ft)
S t a b i l i z e r Ba r
St a b i l i z e r Ba r L i n k A s s e m b l y
Re mo v a l
1. Raise the vehicle on hoi st. Refer t o Secti on
00- 02.
2. Remove retaining nuts f rom stabilizer bar links
( 5K484) at front stabilizer bar ( 5482) .
3. Loosen front stabilizer link nut at front wheel
spindle ( 3105) until nut is above t hread on ball
st ud. Using a hammer, stri ke the nut t o di spl ace
t he ball stud f rom front wheel spindle. Remove
and di scard nut.
4. Remove stabilizer bar links f rom front stabilizer
bar.
Pa r t
2 N805474-S60 Nut (4 Req'd)
3 5482 Front Stabilizer Bar
5

Ball Stud
1. Position stabilizer bar links into end of front
stabilizer bar wi t h retaining nut. Do not ti ghten nut
at this time.
2. Position stabilizer bar link studs t o front wheel
spindle. Install new nut. Tighten nuts t o 26- 35 N-m
(19-26 Ib-ft).
3. Tighten stabilizer bar link-to-stabilizer bar nuts t o
26-35 N-m (19-26 Ib-ft). Lower vehicle.
Br a c k e t
1. Pry locking tab away from f rame and slide stud
out, t ap stud if necessary.
2. Clean area around slot.
3. Slide stud into slot until spring l ocks.
04- 01- 13
Su s p e n s i o n a n d Wh e e l Hubs , Fr o n t 04- 01- 13
ADJUSTMENTS
Wheel Alignment
SPECIFICATIONS
Fr o n t Su s p e n s i o n L o we r
A r m- t o - Fr a me
136- 190 101- 140
Fr o n t Su s p e n s i o n Up p e r
A r m- t o - Fr a me
136- 190 101- 140
St a bi l i ze r Ba r L i n k- t o - Fr o n t Wh e e l
Spi n d l e
2 6- 35 19- 26
Fr o n t Su s p e n s i o n Ba l l
J o i n t - t o - Fr o n t Wh e e l Spi n d l e
Up p e r
87 - 119 64- 87
Fr o n t Su s p e n s i o n Ba l l
J o i n t - t o - Fr o n t Wh e e l Spi n d l e
L o we r
113- 153 83- 112
Fr o n t St a bi l i ze r Ba r - t o - Fr a me 59- 81 44- 59
S h o c k A b s o r b e r Up p e r A t t a c h me n t 34- 46 2 5- 34
S h o c k A b s o r b e r - t o - Fr o n t
Su s p e n s i o n L o we r A r m
13-17 10- 12
St a bi l i ze r Ba r L i n k- t o - Fr o n t
St a b i l i ze r Ba r
2 6- 35 19- 26
Up p e r Ba i l J o i n t - t o - Fr o n t
Su s p e n s i o n Up p e r A r m
145- 17 5 107 - 12 9
Fr o n t A x l e Wh e e l Hub Re t a i n e r 2 55- 345 189- 2 54
Fr o n t Di s c Br a ke Ca l i pe r Mo u n t i n g
Bo l t s
17 0- 2 30 12 6- 17 0
Pi t ma n Ar m Nut 59- 63 44- 46
P i n c h Bo l t a n d Nut 51- 67 38- 49
L ug Nut s 115- 142 85- 105
S h o c k A b s o r b e r To p St ud Nut 34- 46 2 5- 34
Ti e Ro d - t o - Fr o n t Wh e e l Spi n d l e 47 - 63 35- 46
Ca l i p e r L o c a t i n g Pi n 88 G5
T 81P - 1104- C
Fr o n t Hub Re mo v e r / Re p l a c e r
T81P-1104-C
D7 8P - 5310- A Co i l Spr i n g Co mp r e s s o r
TOOL - 32 90- D Ti e Ro d End Re mo v e r
D81P - 197 03- B Pul l e y Pul l e r
04- 02 - 1 Su s p e n s i o n a n d Wh e e l Hu b s , Re a r 04- 02 - 1
SECTION 04-02 Suspension and Wheel Hubs, Rear
SUBJECT PAGE
Components 04-02-1
SuspensIon
s
Rear 04-02-1
Suspensi on and Wheel Huns, Rear 04-02-4
Arm 04-02-6
Lower 04-02-6
Upper. . 04-02-6
Bushi ng, Axl e Housi ng-t o-Upper Ar m. . . . 04-02-7
SUBJECT PAGE
Shock Absor ber 04-02-5
Spri ng ..04-02-4
St abi l i zer. . 04-02-8
Bar. 04-02-8
Wheel Hub Bol t 04-02-8
ADJUSTMENTS
Al i gnment 04-02-9
Dri veshaf t -Pi ni on Angl e Checki ng
Procedure ..04-02-9
SPECIFICATIONS. .04-02-10
VEHICLE APPLICATION
Town Car, Crown Vi ct or i a, Grand Marqui s
There are t hree major t ypes of components in t he rear
suspension syst em:
Rear suspensi on l ower arms ( 5A649) .
Rear spri ngs ( 5560) .
Rear shock absorbers ( 18080) .
The rear axl e housing ( 4010) is suspended f rom the
vehi cl e f rame as f ol l ows:
Two short rear suspension arm and bushings
( 5500) control the side-to-side sway of the vehi cl e.
Two longer rear suspension l ower arms manage t he
f or war d and rearward movement of t he rear axl e
housings.
C o m p o n e n t s
Re a r S p r i n g
Two rear spri ngs ( 5560) are connect ed bet ween the
rear axl e and f rame. Each rear spri ng is mounted t o an
upper seat i ntegral wi t h the f rame, and a l ower seat
wel ded t o t he rear axl e housing ( 4010) .
S h o c k A b s o r b e r , Re a r
The other suspension part s linking t he rear axl e
housing t o the f rame are the t wo shock absorbers
( 18080) . Both shock absorbers are mounted bet ween
t he upper seat s of the rear spri ngs and t he t wo shock
bracket s wel ded t o the rear axl e tube assembl y.
WARNI NG: TURN OFF REAR SUSPENSI ON
LEVELER COMPRESSOR SWI TCH LOCATED ON
THE RIGHT SIDE OF THE LUGGAGE
COMPARTMENT (IF EQUI PPED).
CAUTI ON: Rear suspensi on f ast ener s ar e
i mpor t ant par t s because t h e y c o u l d a f f e c t t h e
per f or mance of v i t a l c omponent s and s y s t ems
a n d / o r coul d r esul t i n maj or ser vi ce expense.
They mu s t be r epl aced wi t h t he same par t
number or wi t h an equi val ent par t i f r epl acement
bec omes necessar y. Do n o t use a r epl acement
par t of l esser qual i t y or subst i t ut e desi gn. Tor que
val ues must be used as speci f i ed dur i ng
r eassembl y t o ensur e pr oper r et ent i on of t hi s
par t .
NOTE: Ori entati on of fasteners is i mportant on upper
rear suspension arm and bushing ( 5500) t o axl e joint.
Ensure f ast eners are installed in the same di recti ons
as when removed.
Upper rear suspension arm and bushing is repl aced
as an assembl y. The upper rear suspension arm and
bushings shoul d be repl aced in pai rs.
The upper suspension arm-to-axl e housing bushings
may be repl aced individually.
The rear spri ngs ( 5560) may be repl aced
individually.
The shock absorber ( 18080) may be repl aced
individually.
The rear suspension l ower arms ( 5A649) are
repl aced as an assembl y and in pai rs.
The rear stabilizer bar ( 5A772) , stabilizer bar link
( 5K484) and l ower suspension arm stabilizer bar
insulator ( 5493) may be repl aced individually.
The fol l owi ng rear suspension components may be
04- 02 - 3
Su s p e n s i o n a n d Wh e e l Hu b s , Re a r
04- 02 - 3
04- 02 - 4 Su s p e n s i o n a n d Wh e e l Hubs, Rear 04- 02 - 4
Pa r t
1 18A192 Nut and Insulator Assy (2
Req'd)
2 5 5 3 6 Rear Spring Insulator (2
Req'd)
3 5560 Rear Spring (2 Req'd)
4 5 5 6 0 Rear Spring (Air) (2 Req'd)
5 4730 Rear Axle Bumper (2 Req'd)
6 N805479-S60 Nut (2 Req'd)
7 5 A 6 4 9 Rear Suspension Lower Arm
(2 Req'd)
8 N800169-S428 Nut (2 Req'd)
9 N802891-S60 Bolt (2 Req'd)
10 N802891-S60 Bolt (2 Req'd)
11 N621941-S428 Nut (4 Req'd)
12 5A772 Rear Stabilizer Bar
14 5500 (Coil Rear Suspension Arm and
Spring) Bushing
5A803 LH (Air
Spring)
5500 RH (Air
Spring)
Pa r t
15 N804655-S60 Bolt (2 Req'd)
16 5A638 Bushing (2 Req'd)
17 N808043-S60 Bolt (2 Req'd)
18 4A047 Bracket (2 Req'd)
19 N605907-S60 Screw (2 Req'd)
22 W701642-S60 Nut (2 Req'd)
A

Lb-Ft)
B

(56-76 Lb-Ft)
C

(103-132 Lb-Ft)
D

(119-149 Lb-Ft)
E

Tighten to 21 -29 N-m (16-21
Lb-Ft)
F

Lb-Ft)
Wh e e l A s s e m b l y
The rear wheel assembl y is installed as f ol l ows:
The rear wheel beari ng ( 12 2 5) and inner wheel
beari ng oil seal ( 117 7 ) are pressed into t he axl e
tube assembl y.
The semi-floating axl e shaft ( 4234) are held in the
rear axl e housing ( 4010) by the u-washer ( 4N237)
posi ti oned in a sl ot on the axl e shaft splined end.
The wheel and ti re assembl y is bol ted t o the axl e
shaft fl ange by t he wheel hub bolt ( 1107 ) and lug nut
( 1012) .
Each rear wheel ( 1007 ) is bol ted t o rear hub ( 1109)
assembl y.
S u s p e n s i o n a n d Wh e e l H u b s , Re a r
S p r i n g
A i r
Re a r
Re mo v a l
1. Position a hoist under t he rear axl e housing, and
rai se t he vehi cl e. Refer t o Secti on 00- 02. Pl ace
j ackst ands under f rame side rails.
2. Remove rear stabilizer bar ( 5A7 7 2) as outlined.
3. Di sconnect t he l ower studs of the t wo shock
absorbers ( 18080) f rom the mounting bracket s
on the rear axl e assembl y ( 4006) .
4. Unsnap t he parki ng brake rear cabl e and conduit
( 2A635) f rom upper arm retainer before l oweri ng
t he rear axl e housing ( 4010) .
5. Lower the hoist and axl e housing until t he rear
spri ngs ( 5560) are r el eased.
6. Remove rear spri ng and rear spri ng center
mounting insulators ( 5741) f rom vehi cl e.
1. Position the rear spring in t he upper and l ower
seat s wi th rear spri ng center mounting insulator
bet ween upper end of rear spri ng and f rame seat .
2. Raise the hoi st and rear axl e assembl y housing
wi t h t he rear spri ngs in posi ti on. Connect the
l ower studs of the rear shock absorbers t o their
mounting bracket s on the axl e tube. Install new
retaining nuts. Tighten t o 76. 5- 103. 5 N-m (56-76
Ib-ft).
3. Snap the parki ng brake rear cabl e and conduit
into t he upper arm retainer.
4. Install rear stabilizer bar as outlined.
5. Remove the j ackst ands, and l ower the vehi cl e.
S h o c k A b s o r b e r
R e mo v a l
For inspection procedure, refer t o Secti on 04- 00.
1. WARNI NG: A L L VEHI CLES ARE EQUI PPED
WI TH GAS- PRESSURI ZED SHOCK
ABSORBERS WHI CH WI L L EXTEND
UNASSI STED. DO NOT APPLY HEAT OR
FL AME TO THE SHOCK ABSORBER TUBE.
Rai se the vehi cl e on a hoi st. Refer t o Secti on
00- 02. If f r a me cont act hoi st is used, support t he
rear axl e housing ( 4010) .
2. To assi st in removi ng the upper at t achment on
shock absorbers ( 18080) using a plastic dust
tube, pl ace an open end wr ench on t he hex
st amped into t he dust t ube' s metal cap. For
shock absorbers wi t h a steel dust tube, simply
grasp the tube t o prevent st ud rotati on when
loosening t he retaining nut.
F2952-D
3. Remove the shock absorber retaining nut,
washer, and insulator assembl y f rom the stud on
the upper side of the f rame. Di scard nut.
Compress the shock absorber t o clear the hole in
the f rame, and remove the inner insulator and
washer f rom the upper retaining st ud.
4. Remove the self-locking retaining nut, and
di sconnect the shock absorber l ower stud f rom
the mounting bracket on t he rear axl e tube.
5. NOTE: Repl ace shock absorbers individually as
requi red. It is not necessary to repl ace in pai rs.
Perform Shock Absorber Checks. Refer t o
Secti on 04-00 t o determi ne performance of
shock absorbers.
1. Properl y prime the new shock absorber. Refer t o
Secti on 04- 00, Shock Absorber Checks.
2. Position the shock absorber so t hat the upper
retaining stud enters the hole in t he frame. While
holding the shock absorber in thi s position, install
a new nut and insulator assembl y on the upper
side of the upper f rame. Be sure t o seat the
shock absorber in the frame attachi ng hole.
Tighten nut to 34- 46 N-m (25-34 Ib-ft).
3. Extend the shock absorber, and pl ace the l ower
stud in the mounting bracket hole on the rear axl e
assembl y ( 4006) housing. Install a new
self-locking retaining nut. Tighten nut to
76. 5-103. 5 N-m (56-76 Ib-ft).
4. Lower vehicle.
04- 02 - 6 Suspensi on and Wh e e l Hubs, Rear 04- 02 - 6
A r m
L o we r
Removal
Refer t o the Rear Suspensi onExpl oded Vi ew
illustration in Descri pti on and Operati on.
1. WARNI NG: TURN REAR SUSPENSI ON
LEVELER COMPRESSOR SWI TCH OFF (IF SO
EQUI PPED).
NOTE: To i mprove rear axl e assembl y noise and
vi brati on concerns, the rear suspension should be
f ast ened t o the f rame and rear axl e assembl y
( 4006) at the curb height posi ti on.
NOTE: If one rear suspension l ower arm ( 5A649)
requi res repl acement, al so repl ace t he opposi t e
rear suspension l ower arm.
NOTE: If both rear suspension arm and bushings
( 5500) and both rear suspension l ower arms are
t o be removed at the same ti me, remove both
rear spri ngs ( 5560) as outlined under Rear Spri ng
Removal . For air spri ng removal , refer t o Secti on
04- 05.
Mark rear suspensi on shock absorber ( 18080)
rel ati ve t o protecti ve sl eeve wi t h t he vehi cl e in a
st at i c, level ground condi ti on.
2. Remove rear stabilizer bar ( 5A772) as outlined.
3. Rai se t he vehi cl e on a hoi st, and pl ace j ackst ands
under t he rear axl e assembl y. Refer t o Secti on
00- 02.
4. Lower t he hoist until t he shock absorbers are
fully ext ended t o relieve rear spri ng pressure.
5. Support rear axl e assembl y under differential
pinion nose as wel l as under rear axl e assembl y.
6. Remove and di scard t he l ower arm pi vot bolt and
nut f rom t he axl e bracket . Then, di sengage t he
rear suspensi on l ower arm f rom t he bracket .
7. Remove and di scard t he pi vot bolt and nut f rom
t he f rame bracket , and remove the rear
suspensi on l ower arm.
1. NOTE: The rear suspensi on l ower arms are
i nterchangeabl e si de-to-si de.
Position t he rear suspensi on l ower arm in the
bracket on the f rame si de rai l . Install a new pi vot
bolt and new nut. Insert the bolt so t hat nut f aces
out board. Do not ti ghten t he nut at thi s ti me.
2. Position t he rear suspensi on l ower arm t o the
axl e bracket , and install a new bolt and new nut.
Do not ti ghten t he nut at thi s ti me.
3. Raise t he rear axl e assembl y t o position that
compresses shock absorbers t o previ ousl y
establ i shed alignment marks.
4. Tighten t he rear suspensi on l ower arm-to-axl e
pi vot bol t t o 140-180 N-m ( 103- 132 Ib-ft) and t he
rear suspensi on l ower arm-to-frame pivot bolt t o
162-203 Nm ( 119- 149 Ib-ft).
5. Install rear stabilizer bar as outlined.
6. Remove j ackst ands and lower vehi cl e.
Up p e r
Fo r c i n g S c r e w T 7 9P - 5638- A 1
Re c e i v i n g Cup T 7 9P - 5638- A 2
Bu s h i n g Re mo v e r T 7 9P - 5638- A 5
Re c e i v i n g Cup T 86P - 5638- A H1
Bu s h i n g Re p l a c e r T 86P - 5638- A H2
Re a r Bu s h i n g S p a c e r T 86P - 5638- A H3
Re mo v a l
1. CAUTI ON: Rear s u s p e n s i o n f a s t e n e r s a r e
i mp o r t a n t r e t a i n i n g p a r t s i n t h a t t h e y c o u l d
a f f e c t t h e p e r f o r ma n c e o f v i t a l c o mp o n e n t s
a n d s y s t e ms a n d / o r c o u l d r e s ul t i n ma j o r
s e r v i c e e x p e n s e . T h e y mu s t b e r e p l a c e d
w i t h o n e o f t h e s a me pa r t n u mb e r o r wi t h a n
e q u i v a l e n t pa r t i f r e p l a c e me n t b e c o me s
n e c e s s a r y . Do n o t use a r e p l a c e me n t pa r t o f
l e s s e r q u a l i t y o r s u b s t i t u t e d e s i g n . To r q u e
v a l u e s mu s t b e u s e d a s s p e c i f i e d d u r i n g
r e a s s e mb l y t o e n s u r e p r o p e r r e t e n t i o n o f
t h i s pa r t .
WARNI NG: TURN OFF REAR SUSPENSI ON
LEVELER COMPRESSOR SWI TCH (IF SO
EQUI PPED).
NOTE: If one rear suspension arm and bushing
requi res repl acement, al so repl ace the opposi te
rear suspension arm and bushing.
and both rear suspension l ower arms are t o be
removed at the same ti me, remove both rear
spri ngs as outlined. For air spring removal refer t o
Secti ons 04- 05.
NOTE: Refer t o Lower Arm Procedure t o
neutralize arm bushings and t o i mprove rear axl e
assembl y NVH charact eri st i cs.
are t o be repl aced, remove and repl ace one rear
suspension arm and bushing at a ti me. This must
be done t o prevent the axl e from rolling or slipping
si deways. Rolling or slipping might occur wi th
bot h rear suspension arm and bushings removed,
maki ng repl acement difficult.
Rai se the vehi cl e, and support the f rame si de
rails wi th j ackst ands. Refer t o Secti on 00- 02.
2. Support the rear axl e assembl y.
3. Lower the rear axl e assembl y, and support the
rear axl e assembl y under differential pinion nose
as well as under rear axl e assembl y.
4. Unsnap parki ng brake rear cabl e and conduit
( 2A635) f rom upper arm retainer.
5. Remove and di scard the nut and bolt retaining the
rear suspension arm and bushing t o t he rear axl e
assembl y housing. Di sconnect the rear
suspension arm and bushing from t he housing.
6. Remove and di scard t he nut and bolt that secures
t he rear suspensi on arm and bushing t o t he frame
bracket , and remove t he rear suspension ar m
and bushi ng.
POSITION TOOLS AS SHOWN AND TIGHTEN FORCING
SCREW UNTIL BUSHING IS PULLED OUT OF AXLE EAR
F4708-B
Pa r t
1 5A638 Rear Suspension Arm
Bushing
2 T86P-5638-AH3 Rear Bushing Spacer
3 T86P-5638-AH1 Receiving Cup
4 T79P-5638-A1 Forcing Screw
5

Rear Axle Ear (Part of 4010)
6 T79P-5638-A5 Bushing Remover
1. Hold t he rear suspensi on ar m and bushing in
pl ace on t he front arm bracket , and install a new
retaining bol t and a new self-locking nut. Do not
ti ghten t he nut at thi s ti me.
2. Secure t he rear suspension arm and bushing t o
the rear axl e assembl y wi th new retaining bol ts
and nuts. Bol ts must be poi nted t owar d front of
vehi cl e.
3. Raise the suspensi on wi th hoi st, until rear
suspensi on arm and bushing rear pi vot hole is in
position wi t h hole in axl e bushi ng. Install a new
pivot bolt and nut wi th nut faci ng i nboard.
4. Tighten t he rear suspension arm and
bushing-to-axle pivot bol ts t o 140-180 N-m
( 103- 132 Ib-ft) and t he rear suspensi on arm and
bushing-to-frame pivot bol ts t o 162-203 N-m
( 119- 149 Ib-ft).
6. Snap parki ng brake rear cabl e and condui t into
rear suspensi on arm and bushing retainer.
6. Remove support s f rom f rame and rear axl e
assembl y, and lower vehi cl e.
B u s h i n g , A x l e H o u s i n g - t o - U p p e r A r m
Re a r Bu s h i n g S p a c e r
Re c e i v i n g Cup
Bu s h i n g Re p l a c e r
Fo r c i n g S c r e w
Bu s h i n g Re mo v e r
Re p l a c e r Re c e i v i n g Cup
T 86P - 5638- A H3
T 86P - 5638- A H1
T 86P - 5638- A H2
T 7 9P - 5638- A 1
T 7 9P - 5638- A 5
T 7 9P - 5638- A 2
Re mo v a l
1. Remove upper rear suspension arm and bushing
( 6500) as outl i ned.
2. Pl ace the upper arm rear bushing remover tool in
posi ti on, and pull bushing out.
F4708-B
Pa r t
Bushing
3 T86P-5638-AH1 Receiving Cup
5

6 T79P-5638-A5 Bushing Remover
I nst al l at i on
1. Using Forci ng Scr ew T79P-5638-A1 and
Receiving Cup T79P- 5638- A2 install bushing
assembl y into bushing ear of rear axl e housing
( 4010) .
POSITION TOOLS AS SHOWN AND TIGHTEN
FORCING SCREW UNTIL BUSHING
REPLACER IS AGAINST SPACER
F4709-B
I t e m
Pa r t
1 T86P-5638-AH3 Spacer
2 T86P-5638-AH2 Bushing Replacer
4

Rear Axle Ear
5 T79P-5638-A2 Receiving Cup
6 5A638 Bushing
2. Install upper rear suspension arm and bushing as
outlined.
S t a b i l i z e r
Ba r
Re mo v a l
1. WARNI NG: TURN OFF REAR SUSPENSI ON
EQUI PPED).
Raise vehi cl e on hoi st, and pl ace j ackst ands
under the f rame si de rails. Refer t o Secti on
00- 02.
2. Lower t he hoi st and rear axl e assembl y ( 4006)
housing until t he shock absorbers ( 18080) are
fully ext ended.
3. Di sconnect rear stabilizer bars ( 5A772) f rom rear
stabilizer bar link and bushing ( 5C488) . Remove
bol ts and stabilizer bar bracket ( 5486) retaining
rear stabilizer bar t o rear axl e assembl y.
1. Install t wo stabilizer bar bracket s onto l ower
suspension arm stabilizer bar insulators ( 5493)
and hook both bracket s into T-slot of rear axl e
bracket . Install t wo retaining bol ts and tighten t o
21-29 N-m (16-21 Ib-ft).
2. Connect rear stabilizer bar eyes t o rear stabilizer
bar link and bushings using l ower suspension arm
stabilizer bar insulators and nut and washer
assembl y. Tighten t o 17-23 N-m (13-17 Ib-ft).
Link
EQUI PPED).
Raise vehicle on hoist. Refer to Secti on 00- 02.
2. Di sconnect stabilizer bar link ( 5K484) and l ower
suspension arm stabilizer bar insulator f rom rear
stabilizer bar.
3. Di sconnect stabilizer bar link and l ower
suspension arm stabilizer bar insulator body.
nuts t o 17-23 N-m (13-17 Ib-ft).
I n s u l a t o r
Re mo v a l
EQUI PPED).
Raise vehicle on hoi st. Refer t o Secti on 00- 02.
2. Remove bolt, stabilizer bar bracket and l ower
suspension arm stabilizer bar insulator.
3. Remove l ower suspension arm stabilizer bar
insulator f rom rear stabilizer bar.
2. Tighten bol ts t o 21- 29 N-m (16-21 Ib-ft).
Wh e e l H u b B o l t
Re mo v a l
3. Remove rear di sc brake rotor ( 2C026) . Refer t o
Secti on 06- 04.
4. Using a punch, dri ve wheel hub bolt ( 1107) out of
axl e flange.
1. Position wheel hub bolt into axl e flange.
2. Using a reversed lug nut ( 1012) , seat wheel hub
bolt into axl e fl ange. Di scard lug nut after use.
04- 02 - 9 Su s p e n s i o n a n d Wh e e l Hu b s , Re a r 04- 02- 9
ADJUSTMENTS
A l i g n m e n t
Driveshaft-Pinion A n g l e C h e c k i n g P r o c e d u r e
Descr i pti on Tool N u m b e r !
Pi ni on Angl e Level Gauge T 68P - 4602 - A
A l oad must be appl i ed t o curb height. Thi s height is
measured verti cal l y f rom t he t op of t he rear axl e
assembl y housi ng tube t o t he out board edge of t he
f rame si de rail. Refer t o Speci fi cati ons.
Co n t r o l l e d He i ght (Curb)
FRONT OF
VEHICLE
FRAME
MEASURE DIMENSION VERTICALLY FROM
AXLE TUBE TO FRAME RAIL (LOCATION
FOR CHECKING CONTROLLED HEIGHT)
F2795-D
1. Position t he V-magnet (Part of Pinion Angl e Level
Gauge T68P- 4602- A) on t he dri veshaft slip yoke
( 4841) away f rom wel ds and bal ance wei ght s.
2. Remove universal joint snap ring f rom rear axl e
universal joint fl ange ( 4851) .
3. From LH si de of the vehi cl e, position Pinion Angl e
Level Gauge T68P-4602-A on the V-magnet wi t h
the adj usti ng scr ew t o the left. Adj ust t he dial on
the t ool until the LH edge of t he bubbl e is exact l y
on t he zero line.
PINION
ANGLE
LEVEL
GAUGE
T68P-4602-A
ADJUSTING
SCREW
F2796-C
4. Position t he magneti zed tool on t he beari ng cap
of t he rear axl e universal joint fl ange wi t h t he tool
in t he same relative position as it was on the
V-magnet.
V-MAGNET
PINION
ANGLE
LEVEL
GAUGE
T68P-4602-A
F2797-D
Read the position of the bubbl e' s LH edge on the
scal e t o determine the dri veshaft pinion angl e.
Compare wi th the Dri veshaft Pinion Angle
Speci fi cati on chart.
Install universal joint snap ri ng.
If the pinion angle is not within speci fi cati on, install
servi ce upper arms (may not be available for all
vehi cl es, check wi th your deal er) equi pped wi t h
rear suspension arm adjusting cam ki ts ( 5K751) .
Adjust the pinion angle as f ol l ows:
Remove the rear suspension arm and bushings
04- 02- 10 Su s p e n s i o n a n d Wh e e l Hu b s , Re a r 04- 02- 10
8. Using a wi de and fl at obj ect like a l arge
screwdri ver, insert t he tool in t he slot in the
eccentri c inner sl eeve. The slot is accessi bl e
through the hole f rom where the retaining bolt
was removed.
ECCENTRIC BUSHING ON UPPER
FRONT OF ARM ASSEMBLY AND ITS AFFECT
VEHICLE ON PINION ANGLE
INSTALLED DECREASE INCREASE
POSITION PINION PINION
ANGLE ANGLE
F2953-C
9. NOTE: If t he rear suspensi on arm adjusting cam
(l ocat ed in the bushing inner sl eeve) appears t o
be rusty, t ap t he rear suspensi on arm adjusting
cam wi th a drift t o remove the rust, so t he rear
suspensi on arm adjusting cam will rot at e.
Rot at e t he rear suspensi on arm adjusting cam
inside the inner sl eeve cl ockwi se or
count ercl ockwi se t o rai se or l ower t he pinion
nose angl e t o speci fi cati on.
10. NOTE: LH and RH rear suspensi on arm and
bushi ngs must have same set t i ng.
After t he adj ustment is perf ormed, install t he rear
suspensi on arm and bushing as outl i ned.
11. If vehi cl e is equi pped wi th rear air suspensi on,
remove bracket and retaining hardware t o LH
servi ce ar m. Set rear air suspensi on height as
SPECiFiCATiONS
DRIVESHAFT-PINION ANGLE SPECIFICATION
Axl e Angl e
Cont r ol l e d Hei ght
Axl e Angl e m m I nches
8. 8 i n c h 2 d e g r e e s 18
Mi n u t e s
152. 9 6. 02
S h o c k A b s o r b e r - t o - Up p e r Mo u n t
Nut
34- 46 2 5- 34
Up p e r A r m- t o - Fr a me 162 - 2 03 119- 149
De sc r i pt i on N-m Lb-Ft
Uppe r A r m- t o - A x l e 140- 180 103- 132
S h o c k A b s o r b e r - t o - A x l e Br a c ke t 7 6. 5- 103. 5 56- 7 6
St a b i l i ze r L i n k- t o - Fr a me 17 - 23 13- 17
L o we r A r m- t o - A x l e 140- 180 103- 132
L o we r A r m- t o - Fr a me 162 - 2 03 119- 149
St a b i l i z e r - t o - A x l e 2 1- 2 9 16- 2 1
Re a r A x l e Wh e e l Hub Re t a i n e r 2 55- 345 188- 2 54
Tool Numbe r /
De sc r i pt i on I l l ust rat i on
T 68P - 4602 - A
Pi n i o n An gl e L e v e l Ga u ge
T 6 8 P - 4 6 0 2 - A
T 7 9P - 5638- A Su s p e n s i o n
Bu s h i n g Se r v i c e Se t
Co n s i s t s
o f : T 7 9P - 5638- A 1
T 7 9P - 5638- A 2
T 7 9P - 5638- A 5
T 7 9 P - 5 6 3 8 - A
T 86P - 5638- A H Re a r Ax l e
Co n t r o l A r m Bu s h i n g To o l Se t
Co n s i s t s of :
T 86P - 5638- A H1
T 86P - 5638- A H2
T 86P - 5638- A H3
Re a r Bu s h i n g S p a c e r
^ÊÂH2
T J
\ ^ C V T A H 3
T 8 6 P - 5 6 3 8 - A H
T 7 1P - 462 1- B
Pi n i o n Be a r i n g Co n e Re mo v e r
T 7 1 P - 4 B 2 1 - B
T 89P - 5493- B
Pi v o t Bu s h i n g Re p l a c e r
( i
T 8 9 P - 5 4 9 3 - 8
04- 04- 1 Wh e e l s a n d Ti r e s 04- 04- 1
SECTION 04-04 Wheels and Tires
SUBJECT PAGE
Lug Nuts .............04-04-4
Safety 04-04-4
Tire, Temporary Spare 04-04-2
Ti res ....04-04-2
Wheel and Tire Assembl i es 04-04-1
Wheel Assembl y 04-04-3
Wheel Hub Caps 04-04-3
Wheels 04-04-2
Inspecti on and Verification .04-04-4
Road Test 04-04-5
Hoi st i ng 04-04-9
Lug Nut Torque Requi rement . . . . 04-04-12
Ti re Repl acement 04-04-10
Ti re Servi ce 04-04-11
Wheel and Ti re 04-04-9
Wheel Ornament s 04-04-11
Leaks 04-04-13
SUBJECT PAGE
CLEANING AND INSPECTION (Cont ' d. )
Mai nt enance and Pr ot ect i on in Corrosi ve
Envi ronment s 04-04-14
Saf et y Precaut i ons 04-04-17
St r ai ght eni ng Wheels, Rims or
Component s 04-04-14
Ti re I nf l at i on 04-04-15
Ti re Mai nt enance 04-04-15
Ti re Rot at i on 04-04-15
Ti re Si zes 04-04-12
Ti re, Spare ...04-04-12
Tread Wear I ndi cat ors ...04-04-16
Valves 04-04-14
Wheel and Ti re I ndexi ng 04-04-16
Wheel Hub Caps, Wheel Ornament at i on 04-04-13
Wheel Mai nt enance 04-04-14
Wheel s ...04-04-12
ADJUSTMENTS
Opt i onal Lug Adapt er 04-04-19
Tire and Wheel Balance 04-04-17
SPECIFICATIONS
Ti re I nf l at i on Pressures 04-04-20
VEHICLE APPLICATION
Wh e e l a n d T i r e A s s e m b l i e s
The f act ory installed ti res and wheel s ( 1007) are
desi gned t o operat e sati sfactori l y wi th l oads up to and
including the full rat ed load capaci t y when inflated t o
the recommended inflation pressures.
Correct tire pressures and driving techni ques have
an i mportant influence on tire life.
Heavy corneri ng, excessi vel y rapi d accel erati on
and unnecessary sharp braki ng i ncrease tire wear.
04- 04- 2 Wheel s and Ti r es 04- 04- 2
T i r e , Temporary Spare
WHEEL OFF THE GROUND SUCH AS WHEN
CHANGI NG A TI RE, THE WHEEL STI LL ON THE
WARNI NG: THE TEMPORARY SPARE IS
PROVI DED ONLY FOR TEMPORARY EMERGENCY
USE. DO NOT USE AS A REGULAR TI RE. SERVI CE
AND REPLACE THE REGULAR TIRE AS SOON AS
POSSI BLE. ANY CONTI NUOUS ROAD USE OF
THI S TEMPORARY, EMERGENCY TIRE MAY
RESULT IN TIRE FAI LURE, LOSS OF VEHI CLE
CONTROL, AND POSSI BLE INJURY TO VEHI CLE
OCCUPANTS.
CAUTI ON: Because t he t empor ar y spar e i s a
smal l er di amet er t han t he st andar d t i r e, gr ound
cl ear ance i s r educ ed. Use car e when a t empor ar y
spar e i s bei ng used and avoi d any obst acl es t hat
may c o me i n c ont ac t wi t h t he under si de of t he
vehi cl e.
A hi gh-pressure 415 kPa ( 60 psi) t emporary spare ti re
and wheel is st andard equipment.
The hi gh-pressure t emporary spare tire is desi gned t o
provi de more luggage room and a lightweight,
easy-to-install spare ti re.
TIRE TRIM COVER
F8475-A
Di r ec t i ons f or Use
1. The spare ti re is for t emporary, emergency use
only and not for continuous use as a road wheel .
Do not exceed 80 k m/ h ( 50 mph) under any
ci rcumst ances. Repl ace wi th a regular ti re as
soon as possi bl e.
2. Do not use ti re chai ns wi t h t emporary spare.
Check col d inflation pressure monthly and when
used, maintain the col d inflation pressure as
speci fi ed on the vehicle ti re pressure decal .
3. Avoi d driving over road hazards such as
pothol es. Carefully read the Owner Guide before
using this emergency spare. When t read wear
i ndi cators appear on the ti re, repl ace wi th same
t ype t emporary emergency spare.
4. Do not exceed t he vehicle maxi mum l oad rating
noted on the ti re decal .
5. Do not attempt t o servi ce or remove t he
t emporary spare f rom its wheel .
6. Do not attempt t o use the wheel for any other
t ype of ti re.
Ti r e s
WARNI NG: DO NOT MIX DIFFERENT TYPES OF
TI RES ON THE SAME VEHI CLE, SUCH AS RADI AL,
BI AS, AND BI AS- BELTED TI RES EXCEPT IN
EMERGENCI ES (TEMPORARY SPARE USAGE) ,
BECAUSE VEHI CLE HANDLI NG MAY BE
SERIOUSLY AFFECTED AND MAY RESULT IN
LOSS OF CONTROL.
When repl aci ng ti res, only ti res of the size, speed
rati ng, l oad range, and constructi on t ype originally
installed on the vehicle are recommended. Use of any
other ti re size or t ype may seriously affect the
fol l owi ng:
Ride.
Handling.
Speedometer / odomet er cal i brati on.
Vehicle ground cl earance.
Tire cl earance t o the body and chassi s.
Consi der the following when replacing ti res:
1. To achi eve best all around vehicle performance,
ti res of different constructi on should not be mi xed
on t he same vehi cl e.
2. It is recommended that new ti res be installed in
pai rs on t he same axl e.
3. When replacing only one ti re, it should be pai red
wi th the ti re having the most t read t o equalize
braki ng tracti on.
4. Snow ti res should be of a size and t ype equivalent
t o other ti res on the vehicle as recommended on
the tire decal .
Wh e e l s
NOTE: All Crown Vi ctori a, Grand Marqui s and Town
Cars (except limousine) are equi pped wi th rear di sc
brakes.
Wheel s ( 1007) must be repl aced under any of t he
following condi ti ons:
Bent, dented or heavily rusted.
Have air l eaks (aluminum wheel s can, in most
cases, be servi ced using the procedure under
Mai ntenance).
04- 04- 3 Wh e e l s a n d Ti r e s 04- 04- 3
Have el ongated bolt hol es.
Have excessi ve lateral or radial runout. Wheel s wi t h
a lateral or radial runout great er than the
recommended speci fi cati on may cause an
obj ecti onabl e, high-speed vehi cl e vi brati on.
Repl acement wheel s must be equal t o t he original
equipment wheel s in all of the following paramet ers:
Load capaci t y.
Diameter.
Wi dt h.
Offset and mounting confi gurati on.
An i mproper wheel may affect the fol l owi ng:
Wheel and beari ng life.
Ground and ti re cl earance.
Speedomet er and odometer cal i brati ons.
Fr o n t
Each front wheel is bol ted t o the wheel hub ( 1104) and
front di sc brake rotor ( 1125) assembl y.
A seal ed front wheel beari ng is part of the wheel
hub assembl y.
The wheel hub assembl y is at t ached t o t he front
wheel spindle ( 3105) by a front axl e wheel hub
retainer ( 3B477) .
Re a r
The rear wheel rear di sc brake rotor ( 2C026) is
at t ached t o wheel hub bol ts ( 1107) on the rear axl e
shaft hub fl ange.
The wheel and ti re mounts on t he same wheel hub
bol ts and is held agai nst the hub fl ange and rear
di sc brake rotor by the lug nuts ( 1012) .
The rear wheel bearing ( 1225) is pressed into the
outer axl e t ube housing.
The entire assembl y is held in the rear axl e housing
( 4010) by retaining the axl e shaft ( 4234) in the rear
axl e housing U-washer ( 4N237) .
Wh e e l H u b C a p s
O r n a me n t A p p l i q u e Re p l a c e me n t
If a wheel cover ( 1130) is not damaged, but is missing
its wheel cover applique ( 1137) , the wheel cover
applique should be repl aced using the fol l owi ng
procedure:
CAUTI ON: Do n o t s o a k o r a l l o w s o l v e n t t o r e ma i n
o n t h e s u r f a c e o f t h e wh e e l c o v e r o r i t ma y
d a ma g e t h e f i n i s h o r we a ke n t h e s t r u c t u r e .
1. Remove any old adhesi ve present in t he wheel
cover s appl i que cavi ty.
2. Thoroughl y cl ean the cont act area on t he wheel
cover wi th Ext ra Strength Spot and Stain
Remover B7A- 19521- AA meeti ng Ford
speci fi cati on ESR-M5B197-A or equivalent.
3. Appl y three di me-si zed daubs of Bl ack Non-Aci d
Cure Silicone Rubber E7TZ-19562-A or
ESL-M4G273-A t o the wheel cover or wheel
cover applique.
4. Install the wheel cover appl i que wi th a slight
twi sti ng pressure t o ensure proper seati ng. Ideal
curing time bef ore installing t he wheel cover is 24
hours.
CLEAN SURFACE
THOROUGHLY WITH
FORD EXTRA STRENGTH
SPOT AND STAIN
REMOVER B7A-19521 -AA
WHEEL COVER
APPLIQUE
1141, 1137
PRESS APPLIQUE
INTO POSITION WITH
APPLY THREE DAUBS OF TWISTING MOTION TO
SILICONE SEALER SEAT COMPLETELY
E7TZ-19562-A F3045-E
A n t i - T h e f t Wi r e
Optional locking (anti-theft) wheel covers are
available.
A pedestal cup is at t ached t o the wheel ( 1007) wi th
fl anged lug nuts ( 1012) .
A speci al bolt reaches through the center of t he
wheel cover to a pi erce nut on t op of t he pedestal
cup.
A center wheel cover applique snaps onto the wheel
cover, hiding the head of the l ock bolt.
Use care when installing or removi ng.
A key wrench is used to lock t he wheel cover t o the
pedestal cup and t o remove t he wheel cover
applique.
A decal on the underside of the luggage
compartment door next t o t he j acki ng i nstructi ons
contains the lock bolt regi strati on number.
A customer warni ng card and regi strati on car d are
al so provi ded.
04- 04- 4 Wh e e l s a n d Ti r e s 04- 04- 4
The owner must fill out the card and mail it t o
McGard Incorporated. Then, should the key wrench
assembl y be lost, the owner can purchase a new
assembl y wi th the correct key pattern by
presenti ng the regi strati on number.
To allow vehicle servi ce in the event the key has
been mi spl aced, a Rotunda Locki ng Wi re
Wheel cover Mast er Key Set 013- R0002 or
equivalent is available at most Ford and
Li ncol n/ Mercury dealer servi ce depart ment s.
The key has a ci rcul ar keyway that is at t ached t o
the femal e slot in the anti-theft lock bolt.
Remove or install the anti-theft l ock bolt as fol l ows:
1. Insert the key into the slot of the lock bolt.
2. Appl y pressure on the key and remove or install
the lock bolt.
COVER MUST BE
Pa r t
1 1012 Lug Nut (5 Req'd)
2 1130 Wheel Cover
3 1W063 Wheelcover Bolt
4 1137 Wheel Cover Applique
5 178000 Wheelcover Locki ng Key
Assy
6 1A113 Wheelcover Locki ng
Pedestal
A

(85-105 Lb-Ft)
L u g N u t s
A n t i - T h e f t
Aluminum wheel s ( 1007) are equi pped wi t h anti-theft
lug nuts ( 1012) (one per wheel ) that are installed
during vehi cl e pre-delivery.
The key is at t ached t o the wheel lug wr ench,
st owed wi t h the spare ti re.
To allow vehi cl e servi ce in the event the cust omer' s
key has been mi spl aced, a Rotunda Locki ng Wheel
Mast er Servi ce Tool Set 013- R0006 or equivalent is
available only at most Ford and Li ncol n/ Mercury
deal er servi ce depart ment s.
The key has a circular keyway that is mat ched t o
t he femal e slot in the anti-theft lug nut.
Remove or install the anti-theft lug nuts as fol l ows:
CAUTI ON: Ma ke s u r e t h e ke y i s he l d s q u a r e t o t h e
l ug n u t s . If t h e ke y i s o n a n a n gl e , i t ma y d a ma g e
t h e ke y a n d t h e a n t i - t h e f t l ug n u t s . DO NOT us e a
p o w e r i mp a c t w r e n c h o n t h e wh e e l h u b b o l t n ut
ke y .
1. Insert the key into the slot of the lug nuts.
2. Pl ace the lug nuts wrench on the key.
3. Whi l e appl yi ng pressure on the key, remove or
install t he lug nuts.
S a f e t y
Do not exceed the recommendati ons of l oad rati ng
capaci t y speci fi ed on the vehicle safety certi fi cati on
decal l ocated on door pillar.
A j ack is provi ded for wheel and ti re maintenance
only.
Never run engine when vehicle is supported by a
j ack.
To maxi mi ze ti re performance, inspect them for signs
of i mproper inflation and uneven wear whi ch may
indicate a need for balancing, rotati on, or front
suspension alignment. Tires should al so be checked
frequentl y for cut s, stone brui ses, abrasi ons, bl i sters,
and for obj ects that may have become i mbedded in
the t read. More frequent inspections are
recommended when rapi d or ext reme temperature
changes occur, or where road surfaces are rough or
occasi onal l y littered wi th debri s.
As a further visible check of ti re condi ti on, t read wear
i ndi cators are moulded into the bot t om of the t read
grooves. The tire should be repl aced when t hese
indicator bands become visible.
Wh e e l a n d Ti r e C h e c k i n g P r o c e d u r e
Ti r e We a r Di a gn o s i s
Inspect ti res for wear. Abnormal or excessi ve wear
may be caused by i ncorrect wheel alignment,wheel
and tire i mbal ance, or i mproper tire pressure.
04- 04- 5 Wh e e l s a n d Ti r e s 04- 04- 5
Typi cal Wear Pat t er ns
Ro a d T e s t
NOTE: A compl et e road t est procedure is provi ded in
Secti on 00- 04.
A ti re vi brati on di agnosti c procedure al ways begins
wi th a road t est . The road t est and customer interview
(if available) will provi de much of the information
needed t o find t he source of a vi brati on.
During the road t est , dri ve t he vehi cl e on a road that is
smoot h and free of undulations. If vi brati on is apparent,
note and record the fol l owi ng:
The speed at whi ch the vi brati on occurs.
What t ype of vi brati on occurs in each speed range
mechani cal or audible.
How t he vi brati on is af f ect ed by changes in vehi cl e
speed, engine speed, and engine t orque.
Type of vi brati on sensi ti vi ty: torque sensi ti ve,
vehi cl e speed sensi ti ve, or engine speed sensitive.
The fol l owi ng expl anati ons help i sol ate the source of
the vi brati on.
T o r q u e S e n s i t i v e
This means that the condition can be i mproved or
made wor se by accel erat i ng, decel erati ng, coast i ng,
maintaining a st eady vehi cl e speed or appl yi ng engine
torque.
Ve h i c l e S p e e d S e n s i t i v e
This means that the vibration al ways occurs at the
same vehicle speed and is not affected by engine
torque, engine rpm, or the transmi ssi on gear sel ect ed.
E n g i n e S p e e d S e n s i t i v e
This means that the vibration occurs at varyi ng vehicle
speeds when a different transmi ssi on gear is sel ect ed.
It can someti mes be isolated by increasing or
decreasi ng engine speed wi t h the transmi ssi on in
NEUTRAL, or by stall testi ng wi th the transmi ssi on in
gear. If the condi ti on is engine speed sensitive, the
cause is probabl y not related t o the ti res.
If the road t est indicates that t here is tire whi ne, but no
shake or vi brati on, t he noise ori gi nates wi t h the
contact bet ween the ti re and t he road surface.
A thumping noise usually means that the ti re is flat
or has soft spot s making a noise as they sl ap the
roadway. Tire whi ne can be distinguished f rom axl e
noise. Axl e noise diminishes or changes accordi ng
to load or speed. Tire whi ne remains t he same over
a range of speeds.
CAUTI ON: Be s ur e t o d e f l a t e t i r e s t o t h e i r p r o p e r
p r e s s u r e s a f t e r t hi s c h e c k i s c o mp l e t e d .
Ov e r i n f l a t e d t i r e s wi l l a d v e r s e l y a f f e c t v e h i c l e
ha n d l i n g.
To verify that the tire noise is not associ at ed wi th
shake or vi brati on, inflate t he ti res one at a ti me t o
345 kPa ( 50 psi) and check for a change in the
sound. The pi tch or whine will change as the
i ncreased pressure changes the ti re frequency.
04- 04- 6 Wh e e l s a n d Ti r e s 04- 04- 6
Symptom Chart
WHEELS AND TIRES
Tires Show Excess Wear on Edge
of Tread
Under-inflated t i res.
Vehicle overloaded.
High-speed cornering.
Incorrect toe setti ng.
ADJUST air pressure in ti res.
CORRECT as required.
SET toe to speci fi cati on. REFER to
Section 04-00.
Tires Show Excess Wear in Center
of Tread
Tires over-inflated. ADJUST air pressure in ti res.
Other Excessive Tire Wear
Problems
Improper tire pressure.
Incorrect t i re/wheel usage.
Loose or leaking front shock
absorber and rear shock absorber.
Front end out of alignment.
Loose, worn or damaged
suspension components, bushings
and ball j oi nts.
Wheels and tires out of balance.
Excessive lateral or radial runout
of wheel or tire.
Tires need rotati ng.
INSTALL correct tire and wheel
combination.
TIGHTEN or REPLACE as
necessary. REFER to Section
04-01 (Front) or 04-02 (Rear).
ALIGN front end. REFER to Section
04-00.
INSPECT, SERVICE or REPLACE
as required.
BALANCE wheels and ti res.
CHECK, SERVICE or REPLACE as
required. Use dial indicator to
accurately determine runout.
ROTATE ti res.
Wheel Mounting is Difficult Improper application or
mismatched part s, including wheel
hub bolts and lug nuts.
Corroded, worn or damaged part s.
Follow manufacturers'
speci fi cati ons.
CLEAN or REPLACE.
Wheel Rust or Corrosion Poor maintenance. Keep clean and PROTECT with
paint.
Wobble or Shimmy Affecting Wheel
Runout
Damaged wheel (eventually
damaged front wheel bearing outer
cone and roller bearings and
uneven tire wear).
INSPECT wheel rims for dents.
SERVICE or REPLACE as required.
Excessive Vehicle Vibration,
Rough Steering
Loose suspension components. TIGHTEN or REPLACE.
04- 04- 7 Wh e e l s a n d Ti r e s 04- 04- 7
WHEELS AND TIRES (Conti nued)
Vehicle Vibrations from Wheels
and Tires
Wheel or tire imbalance.
Front di sc brake rotor / rear disc
brake rotor imbalance.
Excessive radial runout of wheel or
t i re.
Excessive lateral runout of wheel
or tire.
Loose or damaged wheel hub bolt,
lug nut or enlarged stud holes.
Bent wheel.
Inflation pressure too high or low.
Damaged front wheel bearing.
Ti re/wheel mismatch.
Uneven tire wear.
Improperly seated tire bead.
Debris between wheel mounting
face and hub mounting surface.
Water in ti res.
BALANCE tire and wheel
assembly.
CHECK front di sc brake rot or/rear
disc brake rotor fins for mud or
debri s. If no damage or debri s is
seen, front di sc brake rot or/rear
disc brake rotor may have a heavy
spot. Substitute a good front di sc
brake rot or/rear disc brake rotor
and road t est agai n. If vibration
st ops, REPLACE front disc brake
rot or/rear disc brake rotor.
Use a dial indicator to CHECK the
radial runouts of both the wheel
and the ti re. If either the tire or
wheel is out of speci f i cat i on, also
CHECK the radial runout of t he
wheel hub bolt. REPLACE
components whi ch are out of
speci fi cati on.
Use a dial indicator to check the
lateral runouts of both the wheel
and the ti re. If either the tire or
wheel is out of speci f i cat i on, also
CHECK the lateral runout of t he
wheel hub. REPLACE components
which are out of speci f i cat i on.
necessary.
REPLACE wheel. Attempts t o
straighten a wheel can cause
fractures in the wheel and weaken
the wheel's strength.
REPLACE front wheel bearing.
INSTALL correct t i r e/ wheel
combination.
REFER to tire wear conditions
chart. REPLACE tire if necessary
to correct vibration.
SPIN tire and wheel assembly on
vehicle. EXAMINE area where the
tire and the wheel meet. If that
section of the tire appears to
waver while being rotated, the tire
bead may not be seated on the
wheel. DISMOUNT the tire and
clean bead seat areas on both
wheel and tire. REMOUNT tire
using liquid soap meeting Ford
speci fi cati on ESA-M99B135-A.
CLEAN mounting surface.
REMOVE water.
04- 04- 8 Wh e e l s a n d Ti r e s 04- 04- 8
WHEELS AND TIRES (Cont i nued)
Vehicle Vibrations from Driveline
Which May be Mistaken as Wheels
and Tires
Loose or worn transmission and
engine mounts.
Excessive driveshaft runout or
imbalance or driveshaft damage.
Loose or worn driveline or
suspension components.
Improper vehi cle suspension
alignment.
Improper pinion angle.
necessary.
BALANCE or REPLACE driveshaft
as necessary.
IDENTIFY location of vibration
carefully as it may be transmitted
through frame. Vibrations coming
from rear of vehicle may appear as
though they are coming from the
front. TIGHTEN, SERVICE or
REPLACE loose or worn parts.
ALIGN vehicle suspension.
REALIGN pinion angle to
speci fi cati ons. If damaged,
REPLACE differential ring gear and
pinion.
Cracked or broken wheel di scs
(center portion of wheel). Cracks
develop in the wheel front disc
brake rotor from hand hole to hand
hole, from hand hole to rim, or from
hand hole to wheel hub bolt. Wheel
hub bolt holes become worn,
elongated or deformed. Metal
builds up around wheel hub bolt
hole edges, cracks develop from
wheel hub bolt hole to wheel hub
bolt hole. Related driver
complai nts; unusual operating
noise or vibration and on the road
failures.
Metal fatigue resulting from
abusive handling.
REPLACEwheel. CHECK position
of wheel on vehicle for working
load speci fi cati ons.
REPLACE wheel and CHECK for:
Installation of correct wheel
hub bolts and lug nuts, and
recommended exact
speci fi cati ons.
Cracked or broken wheel hub
bolts, and replace.
Worn wheel hub face.
Replace if severe.
Broken or cracked wheel hub
barrel, replace.
Worn stud grooves, replace or
install recommended serrated
bolts.
Clean mounting surfaces and
retorque lug nuts periodically.
Rust streaks fanning out from
wheel hub bolts holes are a
sure indication that the lug
nuts are or have been loose.
Cracks Develop in Rim Base Back
(Rim Bead Seat) or the Gutter Area
(Drop Well Radii)
Overloading or abusive use.
Improper use of t ool s.
REPLACE wheel. CHECK loading
and operating conditions. Avoid
over inflation of t i res. CHECK
specs for rim load capaci ty,
working loads, ti re size, ply rating
and tire constructi on.
CHECK mounting, demounting, and
maintenance procedures.
Damaged Wheel Hub Bolt Threads Sliding wheel across wheel hub
bolts during assembly.
REPLACE wheel hub bolts. Follow
proper wheel installation
procedure.
Broken Wheel Hub Bolts Loose lug nuts.
Overloading.
REPLACE wheel hub bolts. Follow
proper torque procedure.
REPLACE wheel hub bolts.
COMPARE actual load against
vehicle load ratings.
Stripping Threads Excessive torque. REPLACE wheel hub bolts. Follow
Rust Streaks From Wheel Hub Bolt
Holes
Loose lug nuts. CHECK complete assembly.
REPLACE damaged parts. Follow
Damaged Lug Nuts Loose wheel assembly.
Over tightened lug nuts.
REPLACE lug nuts. Follow proper
torque procedure.
04- 04- 9 Wh e e l s a n d Ti r e s 04- 04- 9
ZZ - L_Jf = " J L J . . .. ^ J f - _ L - ' Z TZZ ^ ^3L ZZZ JL L. _ 1 ~ HZ ~ZL ZS JL_ _J
WHEELS AND TIRES (Cont i nued)
Frozen Lug Nuts Corrosion or galling.
Overloading.
If corrosi on is sli ght, wire brush
away corrosi on. If corrosi on is
excessi ve, REPLACE wheel hub
bolt s and lug nuts. If condition
persi st s, LUBRICATE first three
threads of each wheel hub bolt
wi th a graphi t e-based lubricant.
CAUTION: Do not permi t
l ubr i cant t o get on cone seat s of
st ud hol es or on cone angl e of
l ug nut s.
REDUCE weight.
H o i s t i n g
Incorrect hoisting can damage steeri ng linkage
components and front-end suspensi on struts. Refer t o
Secti on 00- 02.
Wh e e l a n d T i r e
WARNI NG: NEVER RUN THE ENGI NE WI TH ONE
WHEEL OFF THE GROUND, SUCH A S WHEN
NOTE: Extended use of other than conventional spare
ti res on a Tracti on-Lok rear axl e coul d result in a
permanent reducti on in effecti veness. This l oss of
effecti veness does not affect normal driving and
should not be noti ceabl e t o the driver.
Re mo v a l
1. Remove the wheel cover ( 1130) by inserting end
of wheel lug wrench and pryi ng agai nst wheel rim
fl ange. Loosen, but do not remove, the lug nuts
( 1012) .
2. Raise the vehi cl e until the ti re cl ears the floor.
3. CAUTI ON: Do n o t use h e a t t o r e mo v e a
f r o z e n wh e e l b e c a u s e h e a t c a n s h o r t e n t h e
l i f e o f t h e wh e e l a n d / o r d a ma g e t h e wh e e l
b e a r i n gs .
Remove the lug nuts. Remove the wheel f rom the
wheel hub ( 1104) .
4. If corrosi on has f ormed around the center pilot
hole so that the wheel ( 1007) cannot be removed
by hand, use a wheel puller t o remove the frozen
wheel .
ALUMINUM
1. Clean all dirt and corrosi on from the wheel hub
mounting surface and center pilot hole of the
wheel . Appl y a thin coat of Disc Brake Caliper
Slide Grease D7AZ-19590-A or equivalent
meeting Ford speci fi cati on ESA-M1C172-A t o the
axl e pilot flange t o reduce corrosi on.
04- 04- 10 Wheel s and Ti r es 04- 04- 10
2. Pl ace the wheel on the hub. Install the l ocki ng
wi re hubcap pedestal (if used) and the lug nuts.
Tighten t hem al ternatel y t o draw the wheel evenly
agai nst the wheel hub.
3. Lower the vehicle. Tighten the lug nuts t o
115-142 N-m ( 85- 105 Ib-ft). Refer t o Secti on
00- 02.
4. Install wheel cover t o wheel .
Bot h t he base and bri ght wi re wheel covers are full
pl asti c wheel covers wi t h integral pl asti c l atches
whi ch retain t o the undercut in the wheel at the saf et y
bead. Use care t o line up t he cover wi ndow whi ch has
the indentation (al so identified on the backsi de of t he
cover wi t h val ve st em l ogo) wi t h t he val ve and cap
( 1700) when installing the wheel cover. When
installing t hese wheel covers, do not f orce or hammer
on the f ace of the wheel cover, t hey can be installed
by hand.
T i r e R e p l a c e m e n t
NOTE: If the ti re is t o be reinstalled on an original
equipment wheel ( 1007) , mark the ti re at the val ve
st em hole so that t hey can be reassembl ed in the
same rel ati ve posi ti on.
CAUTI ON: Do n o t r e mo v e t h e h i gh - p r e s s u r e
t e mp o r a r y s p a r e t i r e f r o m t h e wh e e l . Do n o t
s e r v i c e t e mp o r a r y s p a r e .
Use t he Rotunda Tire Changer 006- 02100 or
equivalent t o mount or dismount ti res. Follow the
equipment manufacturer' s i nstructi ons. Do not use
hand tool s or tire irons alone t o change ti re as this may
cause damage to the ti re beads or wheel rim. Clean
rim bead seat s as outlined under Cleaning and
Inspection.
After mounting, inflate the ti re until the beads are
compl etel y seat ed. Install the valve and cap ( 1700)
and inflate the ti re t o the proper inflation pressure.
Ti r e R e p l a c e me n t P r e c a u t i o n s
WHEEL OFF THE GROUND, SUCH AS WHEN
1. Fol l ow the saf et y procedures descri bed in this
manual and obtai n safety literature from the
wheel and rim manufacturer, NHTSA or OSHA. If
you have any questi ons, consult the di stri butor or
manufacturer di rectl y. The load carryi ng
requi rements of each vehicle should al so be
determi ned bef ore sel ecti ng the proper
t i r e/ wheel combi nati on.
2. Al ways remember the weakest wei ght carryi ng
component of the vehicle (such as ti re, wheel ,
axl e or beari ngs) determi nes its overall maxi mum
and saf e l oad carryi ng capaci t y for the vehi cl e.
3. NOTE: Use of i mproper repl acement wheel s and
t i res may adversel y affect ride, handling, load
carryi ng capaci t y, wheel beari ng life, ti re
cl earance t o body and chassi s components,
vehi cl e ground cl earance, vehicle wi dt h and
brake cool i ng.
When replacing ti res, use the same si ze, l oad
range and constructi on t ype (bi as, bias bel ted or
radi al ) as originally installed on the vehi cl e, or a
t ype that meets Ford speci fi cati ons for the
vehi cl e.
4. When replacing wheel s, use original equipment
manufacturer' s wheel s or equivalent available
f r om your Ford dealer wi t h equivalent capaci t y,
wi dt h, offset and mounting configuration as t hose
originally installed on your vehicle.
When changi ng ti res, remove the wheel and
ti re f rom the vehicle.
In servi ci ng of all ti res use cauti on not to drop
t hem (or the wheel or assembl i es) on the feet,
hands or body, or heavily on the floor.
Pract i ce good methods of lifting; use your legs
as well as your arms and your body. This will
help t o prevent painful, internal injury.
When carryi ng ti res or wheel s don' t st ep in oil
or grease. Keep the floor clean and dry.
When deflating a ti re, reduce the pressure as
much as you possi bl y can by pushing the val ve
core plunger. Only then should you remove the
val ve core. Keep your eyes away f rom the
val ve.
Use only standard tire mounting tool s and
equipment. The use of makeshi ft tool s,
screwdri vers or pliers t o f orce ti res on or off
wheel s is dangerous. This can help prevent
cut s on hands and wri st s and will make it
unnecessary t o use a mallet for unseating the
ti re beads.
Al ways lubricate tire beads to ensure sealing
of tire beads on rim wi th a rubber lubricant
meeting Ford speci fi cati on ESA-M1B6-A.
The Rotunda Del uxe Tire Changer 104- 00110
or equivalent includes a bead seat er/ i nf l at or
using an automati cal l y adjustable inflation ring,
whi ch ai ds in properl y seati ng the bead for
inflation. To properl y operat e the Rotunda ti re
changer, fol l ow the instructions provi ded.
Inspect ti re and perform necessary servi ce. A
Rotunda Tire Spreader 104-00111 or
equivalent is very helpful, but use care when
worki ng around it. Keep the spreader arms
cl osed when the machine is idle.
Inspect and repl ace damaged or corroded part s.
Abuse during road operati ons or in mounting ti res can
cause damage that may weaken the part s. Parts that
are excessi vel y corroded are weakened. Al ways
inspect for and repl ace damaged or heavily rusted
parts.
04- 04- 11 Wh e e l s a n d Ti r e s 04- 04- 1"
zrr:
Inspect and remove light rust and other forei gn matter.
Accumul ati on of such materi al on t he engagement
surfaces of the rim base and side can prevent the
proper fit of t hese part s. Use of a rust preventati ve
during mounting will minimize rust.
Tires and rims often require a buffing operati on before
being mounted once the regular servi ces have been
made.
CAUTI ON: A l wa y s we a r s a f e t y g o g g l e s , o r a f a c e
s h i e l d w h e n p e r f o r mi n g a n y b u f f i n g o p e r a t i o n t o
p r o t e c t t h e f a c e a n d e y e s f r o m f o r e i g n o b j e c t s .
made.
Avoi d hammeri ng rims wi t h steel hammers. Small
bits of steel may be broken off t he hammer or rim,
flying into the eyes (wear saf et y goggl es), f ace or
body. Use rubber-covered, steel -headed hammers
wherever possi bl e. Rubber mallets only should be
used on ti res; al though wi t h modern tire changi ng
equipment no pounding is necessary.
Stand as far as possi bl e f rom the val ve st em while
inflating ti res. Avoi d a position where the f ace or
body is i mmedi atel y over t he wor k being done on
any tire in whi ch t here is pressure.
Al ways use a saf et y cage, such as Rotunda Inflation
Chamber 104- 00104 or equivalent, or portabl e
safety devi ce while inflating ti res. Protect yoursel f
f rom possi bl e i mproper assembl y, inadvertently
mi s-matched part s and other assembl y errors.
Use only accurat e, t est ed gauges to ensure proper
air pressure as speci fi ed on the Certification Label
at t ached t o t he vehicle. Check all gauges regularly
wi t h a mast er gauge.
T i r e S e r v i c e
WARNI NG: TI RE SEALANTS THAT ARE I NJECTED
THROUGH THE VALVE STEM ARE NOT TO BE
USED TO SERVI CE PUNCTURED TIRES BECAUSE
THEY CAN PRODUCE WHEEL RUST AND TIRE
I MBALANCE.
Punctured ti res should be removed from the wheel
( 1007) and permanentl y servi ced from the inside using
a combi nati on servi ce plug and vulcanized pat ch.
When servi ci ng a puncture, al ways follow t he
manufacturer' s instructions for use of the servi ce kit.
Servi ce punctures in the t read area only. Never
attempt t o servi ce punctures in the tire shoul ders or
si dewal l s. In addi ti on, do not servi ce any tire that has
sustai ned the following damage:
Bulges or bl i sters.
Ply separat i on.
Broken or cr acked beads.
Fabri c cr acks or cut s.
Ti res worn t o t he fabri c, or if wear i ndi cators are
visible.
Punctures larger than 6. 35 mm ( 1 / 4 inch) di ameter.
rSERVICEABLE AREA-
\ L
)
F2891-D
Wh e e l O r n a m e n t s
Install the center wheel cover appl i que ( 1137) on the
wheel ( 1007) and be sure it is snapped into pl ace all
the way around using the palm of the hand or a rubber
mallet.
WHEEL
1007
WHEEL
COVER
APPLIQUE
1137
F7202-C
To remove center wheel cover applique on 16-inch
wheel s, the wheel is removed fi rst and the center
wheel cover applique is pushed out from brake si de.
04- 04- 12 Wh e e l s a n d Ti r e s 04- 04- 12
Install the center wheel cover applique on the wheel
and be sure it is snapped in pl ace using the palm of the
hand or a rubber mallet.
F7812-A
Lug Nut Torque Requirement
All lug nuts ( 1012) must be ti ghtened t o 115-142 N-m
( 85- 105 Ib-ft).
Wh e e l s
Inspect the lug nuts ( 1012) and ti ghten t o 115-142
N-m (85-105 Ib-ft). Loose lug nuts can cause shi mmy
and vi brati on, and may al so di stort t he stud hol es in
the wheel s ( 1007) .
Ensure wheel s and wheel hubs ( 1104) are cl ean.
Stones wedged bet ween the wheel and front di sc
brake rotor ( 1125) or rear brake drum ( 1126) or
lumps of mud and grease can unbalance the wheel .
Check the wheel pilot hole for rust. Rust in this area
coul d prevent easy removal , so it should be cl eaned
before repl aci ng the wheel .
Check for wheel damage. Wobbl e or shi mmy caused
by a damaged wheel will eventually damage the
beari ngs. Inspect the ri ms for dents that coul d leak air.
Inspect the front wheel hubs and lug nuts whenever the
hubs are removed or at regular inspection intervals.
S t e e l
Rim bead seat s on steel wheel s shoul d be cl eaned
wi t h a wi re brush or coarse steel wool t o remove
l ubri cants, old rubber and light rust.
Wheel servi ces that use wel di ng, heating or peening
are not approved. An inner tube is not an accept abl e
servi ce for l eaky wheel s or ti res.
A l u mi n u m
CAUTI ON: Do n o t us e s t e e l w o o l , a b r a s i v e - t y p e
c l e a n e r o r s t r o n g d e t e r g e n t s c o n t a i n i n g hi ghl y
a l ka l i n e o r c a u s t i c a ge n t s a s d a ma g e t o t h e
p r o t e c t i v e c o a t i n g a n d d i s c o l o r a t i o n ma y r e s ul t .
NOTE: Automati c car wash ti re brushes may damage
aluminum and st yl ed road wheel protecti ve coati ngs.
Before using such a servi ce, be sure abrasi ve-type
brushes are not being used.
Aluminum wheel rim bead seat s should be cl eaned
wi t h a non-abrasive cleaner t o remove ti re mounting
lubricants and ol d rubber. Before mounting or
dismounting a ti re, the bead area should be wel l
l ubri cated wi th a ready-to-use liquid soap that meets
Ford speci fi cati on (ESA-M1B6-A) or equivalent.
On 15-inch wheel s remove the center wheel cover
appl i que ( 1137) f rom the wheel wi th the t apered end
of the wheel nut wrench by inserting under the rai sed
not ch, and rotati ng the handle whi l e pryi ng against the
wheel .
Mo u n t i n g A r e a
Corrosi on buildup can result in wheel s sti cki ng t o the
axl e or front di sc brake rotor flange after extensi ve
servi ce. To prevent this from recurring once the
wheel s are removed, use the following procedure:
1. Clean the axl e / f ront disc brake rotor flange and
wheel bore of corrosi on wi t h a wi re brush, steel
wool or other suitable materi al .
2. Coat wheel bore wi th Di sc Brake Caliper Slide
Grease D7AZ-19590-A or equivalent meeting
Ford speci fi cati on ESA-M1C172-A. Do not appl y
grease t o wheel hub bolt nut seats or wheel hub
bolt ( 1107) .
3. Install wheel on vehicle.
T i r e S i z e s
It is mandatory t o use only the ti re si zes recommended
on the tire chart at t ached t o the vehicle. Larger or
smaller ti res can damage the vehicle and affect
durability and may require changing the speedometer
dri ve gears ( 7G237) . Verify wheel size and offsets
mat ch those recommended for the tire in use. Refer t o
Speci fi cati ons.
T i r e , S p a r e
The spare tire and j ack are st owed under the rear load
floor. Refer t o Secti on 00- 02.
T e mp o r a r y S p a r e Ti r e
The t emporary spare tire is lightweight and is for
limited mileage, emergency use only. It should be used
only until the regular ti re is servi ced. This tire is
identified by the wordi ng TEMPORARY USE ONLY
moulded into the ti re.
04- 04- 13 Wh e e l s and Ti r e s 04- 04- 13
Wheel Hub C a p s , Wheel Ornament at i on
Cl eani ng
CAUTI ON: Do not use st eel wo o l , abr asi ve- t ype
cl eaner or s t r ong det er gent s cont ai ni ng hi ghl y
al kal i ne or caust i c agent s as damage t o t he
pr ot ect i ve coat i ng and di scol or at i on may r esul t .
NOTE: Automati c car wash ti re brushes may damage
aluminum and st yl ed road wheel prot ect i ve coati ngs.
Before using such a servi ce, be sure abrasi ve-type
brushes are not being used.
To cl ean wheel s ( 1007) , wheel cover s ( 1130) and
wheel cover appl i ques ( 1137) , use a mild soap and
wat er solution, and rinse thoroughl y wi t h cl ean water.
L e a k s
NOTE: Wheel servi ces that use wel di ng, heating or
peening are not approved. An inner tube is not an
accept abl e servi ce for leaking wheel s ( 1007) or ti res.
If t he air pressure in an aluminum wheel is found t o be
low, the following procedure should be perf ormed
bef ore consi deri ng wheel repl acement.
1. Remove t he ti re and wheel assembl y, and inspect
the wheel for structural damage. If none exi st s,
go t o Step 2. If t he wheel is damaged, repl ace it.
2. Wi t h the ti re mounted on t he wheel , l ocate t he air
l eak using a wat er bat h or equivalent met hod, and
mark the l ocati on. Check t he compl et e wheel for
possi bl e additional l eaks. When l eaks are
marked, di smount ti re. Mark the val ve location on
the tire for proper i ndexi ng.
3. On the ti re side of the wheel , thoroughl y cl ean the
leaking area wi t h Professi onal Choke and
Li nkage Cleaner E8AZ- 19A501- AA or equivalent
meeting Ford speci fi cati on ESR-M 14P10-A, or
use sandpaper of approxi mat el y 80-gri t t o
remove all contami nati on. Using t he sandpaper,
score the surface of t he wheel t o i mprove
adhesi on of t he sealer. Adequat e area around the
leak should be prepared t o ensure coveri ng the
l eak. If the val ve and cap ( 1700) is cl ose t o the
ar ea, remove it.
4. Use a cl ean cl oth t o remove all cl eaner or sanding
dust.
5. NOTE: Do not use a t or ch containing
oxyacet yl ene.
Heat the prepared area wi th Rotunda Heat Gun
107-R0300 or equivalent or a propane t or ch until
Aluminum Wheel Repair Compound
E7AZ-19554-A or equivalent meeti ng Ford
speci fi cati on ESA-M4G280-A f l ows. Appl y the
hot melt materi al over the prepared area using a
liberal fl ow and wi pi ng acti on t o ensure coverage
of the leaking ar ea. Servi ce is most effecti ve
when heat is appl i ed t o the brake si de of t he rim
and sealer is mel ted by heat in t he metal ri m.
Ti re Si de of Wheel
Br ake Si de of Wheel
F4855-F
6. Appl y only enough heat t o melt the sealer, then
remove heat source. After servicing the l eak,
al l ow the wheel t o cool until it can be handled
safely.
7. CAUTI ON: Use c a u t i o n wh e n mo u n t i n g t h e
t i r e s o a s n o t t o d a ma g e t h e se a l e r .
Index and assembl e ti re and wheel indexing ti re
mark t o the val ve. Inflate tire to the recommended
pressure as indicated on the ti re pressure decal .
8. Repeat Step 2 t o verify servi ce.
9. When the servi ce is compl et ed, inflate properl y,
bal ance the assembl y and install on vehicle.
04- 04- 14 Wh e e l s
CLEANING AND INSPECTION ( C o n t i n u e d )
S t r a i g h t e n i n g Wh e e l s , Ri ms o r C o m p o n e n t s
Do not heat wheel s ( 1007) in an attempt t o soften
t hem for strai ghteni ng to repair damage f rom stri ki ng
curbs, et c. The speci al alloy used in these wheel s is
heat -t reat ed, and uncontrolled heating from wel di ng
af f ect s the properti es of the materi al . Do not wel d the
wheel s for any reason.
Va l v e s
Repl acement wheel s ( 1007) may need t o have a valve
and cap ( 1700) installed. If it becomes necessary t o
repl ace a val ve and cap, use 19 N-m ( 14 Ib-ft) of
t orque on the hex nut, on t hose wheel s equi pped wi th
brass val ve and caps. On wheel s equi pped wi th
rubber val ve and caps, the rubber valve and cap must
be fully seat ed in the hole in the wheel .
Ma i n t e n a n c e a n d P r o t e c t i o n i n C o r r o s i v e
E n v i r o n m e n t s
Aluminum wheel s ( 1007) have a protecti ve coati ng t o
resi st corrosi on. Care should be t aken t o avoi d
damagi ng the wheel or corrosi on may occur. Washi ng
t hem (do not use highly alkaline cleaning agents) when
washi ng the rest of the vehicle will be enough t o keep
wheel s looking good for many years. Certain
envi ronments, as creat ed by some operati ons, can
l ead t o corrosi on. Some of t hese are: l i vestock
hauling, salt, chl ori de compounds used for snow
removal , dust control and highly alkaline materi al s.
When t hese condi ti ons are encountered, the fol l owi ng
pract i ce is recommended:
1. Clean frequentl y wi th st eam or hi gh-pressure
wat er f rom a hose. Use of a mild detergent will
speed up the cleaning process.
2. When ti res are removed, the entire wheel shoul d
be cl eaned and i nspected. For maxi mum
prot ect i on, there are vari ous t ypes of coati ngs
whi ch give good resul ts. The following procedure
is suggest ed:
1. Remove all the soil and oil f rom the wheel surface
wi t h either hi gh-pressure st eam or solvent. A
suitable sol vent woul d be mineral spi ri ts.
2. Remove any adherent soil or oxi dati on product s
by using a soft bristle brush.
3. Clean the surf ace again wi t h sol vent, using
mineral spi ri ts t o remove l oose product s.
Wh e e l Ma i n t e n a n c e
Du r i n g Ti r e I n s p e c t i o n
1. WARNI NG: EXCESSI VELY CORRODED OR
CRACKED KI US CAN BE DANGEROUS.
DEFLATE TI RES PRIOR TO THE REMOVAL
FROM THE WHEELS.
Check all metal surfaces thoroughl y whi l e maki ng
ti re i nspecti ons, including areas on i nboard si de of
wheel . Wat ch for:
Excessi ve rust or corrosi on build-up.
Cracks in metal .
Bent fl anges, resulting f rom road obstructi ons.
Loose, missing or damaged lug nuts ( 1012) .
Bent or stri pped wheel hub bol ts ( 1107) .
2. Remove damaged wheel s ( 1007) .
3. Mark damaged or hazardous areas wi th chal k so
that part will be removed f rom servi ce.
4. Coat wheel pilot area wi th Di sc Brake Caliper
Slide Grease D7AZ-19596-A or equivalent
meeting Ford speci fi cati on ESA-M1C172-A. Do
not appl y grease to lug nut seat s or wheel hub
bolt.
5. Repl ace parts as requi red.
6. Inflate ti res only t o recommended air pressures.
7. Check the lug nut torque and reti ghten the lug
nuts as outlined.
Du r i n g Ti r e C h a n g e s
WARNI NG: AL L OYS OR METAL SURFACES WI TH
CRACKS ARE VERY DANGEROUS. THESE
COMPONENTS COULD FAI L WI THOUT WARNI NG
DURI NG I NFLATI ON OR LATER ON THE VEHI CLE.
DESTROY A L L PARTS THAT ARE CRACKED.
CAUTI ON: Ma ke s u r e t h a t r e p l a c e me n t s a r e ma d e
wi t h t h e p r o p e r si ze s a n d t y p e s o f wh e e l s .
I mp r o p e r r e p l a c e me n t wh e e l s c a n a d v e r s e l y
a f f e c t v e h i c l e h a n d l i n g r e s u l t i n g i n t h e l o s s o f
c o n t r o l .
1. Check ail metal surfaces. Wat ch particularly for
the following i tems:
Cracks in the rim bead seat or drop well radii
areas. These are caused by deep rim tool
marks, overl oadi ng and overinflating ti res or
using larger than recommended tire si zes.
Cracks in the wheel di sc, bet ween the stud
holes or hand hol es. These are caused by
loose lug nuts, i mproper installation
procedures or the use of i ncorrect si zes or
t ypes of attachi ng part s.
2. Repl ace the parts as necessary.
3. Thoroughl y remove rust, dirt and other forei gn
materials f rom all surfaces. Hand or el ectri c wi re
brushes, sand blasting or chemi cal bat hs may be
used. Bead seat areas of rim should be free of
rust and rubber deposi ts.
04- 04- 15 Wh e e l s a n d Ti r e s 04- 04- 15
4. Paint ri m by brush or spray wi th a fast-dryi ng
metal primer. Surfaces should be clean and dry
prior t o painting. Make sure bare metal areas on
t he outsi de or ti re side of rim are covered.
5. Lubri cat e t he ti re side of the rim base just prior t o
mounting ti re.
NOTE: Avoi d t he use of any lubricant whi ch contai ns
wat er or solvent that is injurious t o rubber such as
WD40. A combi nati on lubricant and rust-preventi ve
compound is preferabl e such as a ready-to-use liquid
soap that meet s Ford speci fi cati on ESR-M99B135-A
or equivalent. This protecti ve measure is of parti cul ar
i mportance wi th drop-center tubel ess rims as the air in
the ti re is contai ned by the tire-side rim surf ace.
6. CAUTI ON: Wh e n mo u n t i n g a t i r e o n a wh e e l ,
d o n o t i n f l a t e t o mo r e t h a n 2 7 6 kP a ( 40 psi ) ;
t h e n d e f l a t e t i r e .
Inflate ti re t o recommended air pressure.
NOTE: If t he ti re is t o be reinstalled on the same
wheel , mark the ti re and wheel so t hey can be
reassembl ed in the same position.
WARNI NG: AFTERMARKET AEROSOL TIRE
SEALANTS ARE EXTREMELY FLAMMABLE.
ALWAYS QUESTI ON CUSTOMER TO MAKE SURE
THESE PRODUCTS HAVE NOT BEEN USED.
Punctured ti res shoul d be removed f rom the wheel and
permanentl y servi ced from t he inside using a
combi nati on repair plug and vulcanized pat ch. When
servicing a puncture, al ways fol l ow the manufacturer' s
instructions for using t he servi ce ki t.
Punctures in the t read area only are servi ceabl e.
Never at t empt t o servi ce punctures in the tire
shoul ders or si dewal l s. In addi ti on, do not servi ce any
tire that has sustai ned the following damage:
Bulges or bl i sters.
Ply separat i on.
Broken or cr acked beads.
Fabric cr acks or cut s.
Tires worn t o t he fabri c, or if wear i ndi cators are
visible.
Punctures larger than 6. 35 mm ( 1 / 4 inch) diameter.
T i r e Ma i n t e n a n c e
To clean ti res, use a mild soap and wat er solution only,
and rinse thoroughl y wi th clear water. Do not use any
causti c solutions or abrasi ve materi al s. Do not use
steel wool , wi re brushes, gasoline, paint thinner or
similar materi al s havi ng a mineral oil base. These
materi al s are harmful t o the ti res and will eventually
di scol or the whi tewal l s and rai sed l etters.
T i r e I n f l a t i o n
WARNI NG: OVER- OR UNDER-I NFLATED TI RES
CA N REDUCE TI RE LI FE, ADVERSELY AFFE CT
VEHI CLE HANDLI NG, AND POSSI BLY L E AD TO
SUDDEN FAI LURE THAT COULD RESULT I N THE
L OSS OF VEHI CLE CONTROL WI THOUT
WARNI NG.
The ti re inflation pressure is careful l y cal cul ated to
gi ve the vehicle sat i sf act ory ride and steeri ng
charact eri st i cs wi thout compromi si ng long ti re t read
life.
A ti re chart (refer t o Owner Guide for l ocati on) gi ves
t he recommended col d ti re inflation pressure. The col d
ti re inflation pressure can be measured after the
vehi cl e has been parked for t hree hours or has been
driven less t han 5 km (3 miles).
A higher tire inflation pressure than recommended can
cause a hard ri de, ti re bruising, car cass damage, and
rapi d wear at t he center of the ti re. Low ti re pressure
can produce ti re squeal , hard steeri ng, rim dents, high
t emperat ures, and rapi d wear on the outer edges of
the ti res. Unequal inflation pressures in ti res using t he
same axl e can cause uneven braki ng and reduced
handling.
T i r e R o t a t i o n
CAUTI ON: If t h e v e h i c l e i s e q u i p p e d wi t h a
t e mp o r a r y s p a r e t i r e , d o n o t i n c l u d e i t i n t h e
r o t a t i o n o f t h e o t h e r f o u r t i r e s .
To equalize ti re wear, ti res may be rot at ed, but not until
t he cause of unusual or uneven tire wear is determi ned
and cor r ect ed.
Front and rear ti res perform different j obs and can
wear differently depending on t he t ype of vehicle and
driving habi ts.
To equalize wear and optimize tire life, rot at e ti res as
defi ned bel ow. For convenience, tire rotati on schedul e
coi nci des wi th the appropri ate oil change schedul e.
For oil change Schedul e A, rotate ti res at
approxi matel y 9, 500 km ( 6, 000 miles) and every
14, 500 km ( 9, 000 miles) thereafter.
For oil change Schedul e B, rot at e ti res at
approxi matel y 8, 000 km ( 5, 000 miles) and every
16, 000 km ( 10, 000 miles) thereafter.
Refer t o Section 00- 03.
04- 04- 16 Wh e e l s a n d Ti r e s 04- 04- 16
WARNI NG: DO NOT USE TEMPORARY SPARE FOR
ROTATI ON OR A S A REGULAR TI RE. THE
TEMPORARY SPARE IS PROVI DED FOR
TEMPORARY USE ONLY. ANY CONTI NUED ROAD
USE OF THE TEMPORARY SPARE MAY RESULT IN
TI RE FAI LURE, LOSS OF VEHI CLE CONTROL AND
POSSI BLE I NJURY TO VEHI CLE OCCUPANTS.
WARNI NG: DO NOT MI X STEEL WHEELS ( 1007 )
WI TH ALUMI NUM WHEELS. USE FOUR WHEELS
OF THE SAME DESI GN. VEHI CLE HANDLI NG
COULD BE AFFECTED.
If abnormal wear is det ect ed, find and correct t he
cause, and rot at e the ti res following the di agram t o
al l ow more even wear.
FOUR TIRE ROTATION FIVE TIRE ROTATION
F4724-C
T r e a d We a r I n d i c a t o r s
The original equipment ti res have built-in t read wear
i ndi cators t o show when ti res need repl acement.
These i ndi cators will appear as 12.7 mm ( 1 / 2 inch)
wi de bands when the ti re t read dept h becomes 1.6
mm ( 1 / 1 6 i nch). When t he i ndi cators appear in t wo or
more adj acent grooves, at t hree locations around the
ti re, or when cor d or fabri c is exposed, ti re
repl acement due t o t read wear is recommended.
F2S90-D
Wh e e l a n d T i r e I n d e x i n g
When servi ci ng wheel s ( 1007) or ti res, the following
procedure for matchi ng the ti re and wheel must be
fol l owed to ensure that the best possi bl e ride
charact eri st i cs are maintained:
1. When removing a worn ti re f rom a wheel , mark
the val ve and cap location on the ti re prior t o
removal .
2. If the original tire is t o be remounted, index the
valve mark on the tire t o the val ve and cap ( 1700)
of the original wheel . Go t o Step 6.
If a new wheel is being installed, l ocat e the ti re
matchi ng point based on the valve position on the
original wheel relative to its matchi ng point
descri bed in Step 3.
3. Locat e t he matchi ng point on t he wheel .
Steel wheel s: There is either a chartreuse sti cker
on the outside rim flange, or, if the sti cker is
missing, a yel l ow paint mark in the dropwel l of the
rim that must be transferred t o the outsi de rim
flange.
Aluminum wheel s: The matchi ng point on
aluminum wheel s is at the tire val ve and cap.
4. Locati ng the matchi ng point on a new ti re:
Many repl acement ti res as well as original
equipment ti res are marked for fi rst harmonic
matchi ng t o the wheel . These marks vary in t ype
and color. Consult the tire dealer for detai l s on
mark identification.
5. Mount the tire on the wheel and line up the
chartreuse paint mark or sti cker on the new ti re
si dewal l or the matchi ng point of the original ti re
wi th the mark on the rim of the steel wheel or the
tire val ve of the aluminum wheel .
6. Inflate and bal ance the ti re / wheel assembl y.
04- 04- 17 Wh e e l s a n d Ti r e s 04- 04- 17
S a f e t y P r e c a u t i o n s
WHEEL OFF THE GROUND, SUCH AS WHE N
1. Fol l ow the safety procedures descri bed in this
manual and obtai n safety literature f rom t he
wheel and rim manufacturer, NHTSA or OSHA. If
you have any questi ons, consult the di stri butor or
manufacturer di rectl y. The load carryi ng
requi rements of each vehi cl e should also be
determi ned bef ore sel ecti ng the proper
t i r e/ wheel combi nati on.
2. Al ways remember the weakest wei ght carryi ng
component of the vehi cl e (such as ti re, wheel
( 1007) or axl e, beari ngs) determi nes its overal l
maxi mum and safe load carryi ng capaci t y for t he
vehicle.
3. When replacing ti res, use the same si ze, l oad
range and constructi on t ype (bi as, bi as bel ted or
radial) as originally installed on the vehi cl e, or a
t ype that meets Ford speci fi cati ons for t he
vehicle.
4. NOTE: Use of i mproper repl acement wheel s and
ti res may adversel y affect ride, handling, l oad
carryi ng capaci t y, wheel beari ng life, ti re
cl earance t o body and chassi s component s,
vehicle ground cl earance, vehicle wi dt h and
brake cool i ng.
When replacing wheel s, use original equipment
manufacturer' s wheel s or equivalent available
f rom your Ford dealer wi t h equivalent capaci t y,
wi dt h, offset and mounting configuration as t hose
originally installed on your vehicle.
When changi ng ti res, remove the wheel and
tire f rom the vehi cl e.
In servi ci ng of all ti res use caution not t o drop
them (or the wheel s or assembl i es) on the feet,
hands or body, or heavily on the floor.
Practi ce good met hods of lifting; use your legs
as well as your arms and your body. Thi s will
help to prevent painful, internal injury.
When carryi ng ti res or wheel s, don' t st ep in oil
or grease. Keep the fl oor clean and dry.
When deflating a ti re, reduce the pressure as
much as you possi bl y can by pushing t he val ve
core plunger. Only then should you remove the
val ve core. Keep your eyes away f rom the
val ve.
NOTE: If the ti re is t o be reinstalled on an original
equipment wheel , mark the ti re at the valve st em hole
so that they can be reassembl ed in the same relative
position.
Use only st andard ti re mounting tool s and
equipment. The use of makeshift t ool s,
screwdri vers or pliers t o f orce ti res on or off
rims or wheel s is dangerous. This can help
prevent cuts on hands and wri st s and will make
it unnecessary t o use a mallet for unseating the
tire beads.
Al ways lubricate ti re beads t o ensure seal i ng
of ti re beads on rim wi t h a ready-to-use liquid
soap t hat meets For d speci fi cati on
ESR-M99B135-A or equi val ent.
The Rotunda Del uxe Tire Changer 104- 00110
or equivalent includes a bead seat er/ i nf l at or
using an automati cal l y adj ustabl e inflation ring,
whi ch ai ds in properl y seati ng the bead for
inflation. To properl y operat e t he Rotunda ti re
changer, fol l ow the i nstructi ons provi ded.
Inspect ti re and perf orm necessary servi ce. A
Rotunda Tire Spreader 104- 00111 or
equivalent is very helpful, but use care when
worki ng around it. Keep the spreader arms
cl osed when the machi ne is idle.
Inspect and repl ace damaged or corroded part s.
Abuse during road operati ons or in mounting ti res can
cause damage that may weaken the part s. Part s that
are excessi vel y corroded are weakened. Al ways
inspect for and repl ace damaged or heavily rusted
part s.
Inspect and remove light rust and other foreign matter.
Accumul ati on of such materi al on the engagement
surf aces of t he rim base and si de can prevent t he
proper fit of t hese parts. Use of a rust preventati ve
during mounting will minimize rust.
CAUTI ON: A l wa y s we a r s a f e t y g o g g l e s , o r a f a c e
s h i e l d wh e n p e r f o r mi n g a n y b u f f i n g o p e r a t i o n t o
p r o t e c t t h e f a c e a n d e y e s f r o m f o r e i g n o b j e c t s .
made.
Avoi d hammeri ng rims wi th steel hammers. Small
bits of steel may be broken off the hammer or ri m,
flying into the eyes (wear saf et y goggl es), f ace or
body. Use rubber-covered, steel -headed hammers
wherever possi bl e. Rubber mallets only should be
used on ti res; although wi th modern tire changi ng
equipment no pounding is necessary.
Stand as far as possible f rom the valve stem while
inflating ti res. Avoi d a position where the f ace or
body is immediately over the work being done on
any tire in whi ch there is pressure.
Al ways use a safety cage, such as Rotunda Inflation
Chamber 104-00104 or equivalent, or portabl e
safety devi ce while inflating ti res. Protect yoursel f
from possible improper assembl y, inadvertently
mi smatched part s and other assembl y errors.
Use only accurat e, t est ed gauges to ensure proper
air pressure as speci fi ed on the Certification Label
at t ached to the vehicle. Check all gauges regularly
wi th a master gauge.
ADJUSTMENTS
T i r e a n d Wh e e l B a l a n c e
There are t wo t ypes of wheel and tire bal ance: stati c
and dynami c.
04- 04- 18 Wh e e l s a n d Ti r e s 04- 04- 18
S t a t i c Ba l a n c e
A stati c balance is the equal distribution of wei ght
around t he wheel ( 1007) . Wheel s that are stati cal l y
unbalanced cause a bouncing acti on called wheel
t ramp. This condition will eventually cause uneven ti re
wear.
WHEEL TRAMP i
CENTERLINE
t',' OF SPINDLE
HEAVY SPOT ~ t -
i
ADD BALANCE WEIGHTS HERE
CORRECTIVE
WEIGHTS
F2896-D
Dy n a mi c Ba l a n c e
A dynami c bal ance is the equal distribution of wei ght
on each side of t he centerline, so that when the ti re
spins there is no tendency for the assembl y t o move
f rom side-to-side. Wheel s that are dynami cal l y
unbal anced may cause wheel shimmy.
WHEEL SHIMMY
CENTERLINE
OF SPINDLE
ADD BALANCE
WEIGHTS HERE ,
CORRECTIVE WEIGHTS
F2892-D
Deposi t s of mud, etc. must be cl eaned f rom the inside
of t he ri m. St ones should be removed from the t read in
order t o avoi d operator injury during spin balancing
and t o obtain a good bal ance. Inspect the tire for any
damage, then bal ance accordi ng to the equipment
manufacturer' s explicit instructions.
Of f Ve h i c l e
When performi ng an off-vehicle wheel bal ance on
vehi cl es equi pped wi th aluminum wi re spoke wheel s,
use one of t he following el ectroni c bal ancers t o
provi de the proper wheel bal ance:
When balancing wheel s off the vehicle, use a bal ancer
that pilots the wheel by its center hole. If the wheel
t ramp and vehi cl e vibration is not correct ed by the
off-vehicle bal ance, an on-vehicle balance may be
needed.
Aluminum wheel s have thi cker rim flanges and require
specially desi gned bal ance wei ghts. Wheel wei ghts
for aluminum wheel s are coat ed t o prevent corrosi on
and should be installed wi th a plastic mallet.
CLIP RIM CLIP
STEEL WHEEL
BALANCE WEIGHT
RIM
ALUMINUM WHEEL
BALANCE WEIGHT F7082-B
1. Remove center wheel cover ( 1130) and loosen
lug nuts ( 1012) of wheel s t o be bal anced. Raise
up front or rear of vehicle, as requi red.
2. Remove wheel to be bal anced. Mount wheel t o
bal ance machine. Lock hub adapter into spindle.
3. The bal ance equipment should have been
cal i brated by f act ory approved technicians within
the last 90 days.
4. The equipment mounting surfaces, cones, cone
spri ngs, wi ng nuts, and mounting cups must be
cl ean and wi thout def ect s.
5. All tire labels, stones, dirt, and any other foreign
material must be removed from the t i r e/ wheel
assembl y. Particular attention should be paid to
ensuring that the wheel mounting f ace and pilot
hole are cl ean and free from foreign materi al .
6. The tire / wheel assembl y must be mounted on the
machi ne using a back mounted cone. Front
coning of the assembl y is not permi tted.
7. The machi ne must be operat ed in the DYNAMIC
mode only.
8. The f act ory balance wei ghts should not be
removed f rom the wheel before checki ng the
bal ance st at us.
9. Spin the ti re / wheel assembl y on the machine in
accordance wi th the balance equipment
manufacturer' s instruction.
04- 04- 19 Wh e e l s a n d Ti r e s
10. NOTE: Ti r e/ wheel rebal anci ng shoul d not be
requi red when rotati ng ti res.
Any t i r e/ wheel assembl y t hat shows a machine
readi ng of 0. 50 ounces or l ess in the DYNAMI C
mode cannot be consi dered outsi de of f act ory
speci fi cati ons when checked on field accurat e
bal ance equipment.
11. If dynami c correcti on is requi red, remove and
di scard t he f act ory bal ance wei ght s. Re-spin the
t i r e/ wheel assembl y and add new correcti on
wei ghts in accordance wi th t he bal ance
equipment manufacturer' s i nstructi ons. Never add
more than 85 g (3 ounces) t o ei ther rim flange.
Al ways recheck bal ance after wei ght is added.
12. Remove t he tire / wheel assembl y f rom t he
machi ne and mount ont o t he vehi cl e.
13. Lower the vehi cl e to t he ground. Tighten the lug
nuts t o 115-142 N-m ( 85- 105 Ib-ft), install t he
center cap.
On Ve h i c l e
On-vehicle balancing requi res t he use of Rotunda
El ectroni c St robe Bal ancer 006- 01400 and Rotunda
Wheel Spinner 006- 01580 or equivalent. Fol l ow t he
i nstructi ons supplied by t he manufacturer.
Optional Lug Adapter
For a more consi stent wheel bal ance, optional lug
adapt ers and wheel pilot col l ars shoul d be used. This
additional equipment ensures proper wheel position on
the bal ance equipment. Thi s equipment is available for
all Rotunda off-vehicle wheel bal ancers.
WHEEL PILOT COLLAR DIMENSIONS
OUTSIDE
DIAMETER
63.2 mm
(2.48
INCHES)
COLLAR
THICKNESS
12 mm
(1/2 INCH)
INSIDE DIAMETER AS NECESSARY
TO FIT BALANCER SHAFT
TYPICAL COLLAR INSTALLATION
A-BALANCE SHAFT
B-LUG ADAPTER
C-WHEEL
D-ADAPTER PLATE BOLT
E-COLLAR
F3460-C
SPECIFICATIONS
WHEEL AND TIRES
C o d e C o l o r / S t y l e
Wh e e l
Si ze
N o . o f
Bo l t s
Bo l t Ci r c l e
Di a me t e r Of f s e t Ti r e Us a g e
DP Re d Vi o l e t 1 5 x 6 . 5 5 4. 5 . 35 P 2 2 5 / 7 0 R1 5 - 1 0 0 15
A l u m. C a s t L a c y Sp k 1 5 x 6 . 5 5 4. 5 . 35 P 2 1 5 / 7 0 R 1 5 B a s e 15
PL Ye l l o w 1 5 x 6 . 5 5 4. 5 . 35 P 2 1 5 / 7 0 R1 5 15
FC Or a n g e / S t e e l 1 6 x 4 5 4. 5 . 76 T 1 2 5 / 8 0 R 1 6
1
16
A l u mC a s t Ra d i a l Sp k 1 5 x 6 . 5 5 4. 5 . 45 P 2 1 5 / 7 0 R1 5
P 2 2 5 / 7 0 R1 5 - 1 0 0 S
15
15
A l u mC a s t 1 6 x 7 5 4. 5 1.00 P 2 2 5 / 6 0 R1 6 16
1 S p a r e Ti r e
04- 04- 20 Wh e e l s a n d Ti r e s 04- 04- 20
WHEEL RIM RUNOUT AND BALANCE SPECIFICATIONS
Type Wheel
Max. Radial
Runout
Max.
Lateral
Runout
Max. Bal ance
Weight
Al umi n um 1.5 mm
( 0. 06 i n c h)
2. 0 mm
( 0. 08 i n c h)
5. 0 o z. p e r wh e e l
3. 0 o z. pe r s i d e
St e e l 1.5 mm
( 0. 06 i n c h)
2. 5 mm
( 0. 10 i n c h)
5. 0 o z. pe r wh e e l
3. 0 o z. pe r s i d e
TIRE RUNOUT SPECIFICATIONS
Type Wheel
Max. Radi al
Runout
Max. Lat eral
Runout
Al umi n um 1.5 mm
( 0. 06 i n c h)
2. 0 mm
( 0. 08 i n c h)
St e e l 1.5 mm
( 0. 06 i n c h)
2. 5 mm
( 0. 10 i n c h)
Tire Inflation Pressures
When checki ng tire inflation pressures, refer t o ti re
inflation pressure chart on door pillar.
Lug Nu t s 115- 142 85- 105
ROTUNDA EQUIPMENT
006- 01400 E l e c t r o n i c S t r o b e Ba l a n c e r
006- 01580 Wh e e l Spi n n e r
006- 02 100 Ti r e Ch a n ge r
013- R0002 Ma s t e r Ke y Se t
013- R0006 Ma s t e r Se r v i c e To o l Se t
104- 00104 I n f l a t i o n Ch a mb e r
104- 00110 De l u x e Ti r e Ch a n ge r
104- 00111 Ti r e S p r e a d e r
107 - R0300 He a t Gun
04- 05- 1 Su s p e n s i o n , C o mp u t e r Co n t r o l l e d 0 4 - 0 5 - 1
SECTION 04-05 Suspension, Computer Controlled
SUBJECT PAGE
Air Compressor Assembl y. 04-05-7
Air Spri ng Assembl y . . 04-05-9
Air Suspensi on Height Sensor 04-05-10
Air Suspensi on Servi ce Swi tch 04-05-10
Compressor Relay ... 04-05-8
Cont r ol Modul e 04-05-11
Cont r ol Modul e Power and Gr ound. . . . 04-05-6
Cont r ol Valve Act uat or (EVO), Power St eeri ng
Assi st . ..04-05-10
Door Court esy Lamp Swi t ch Input 04-05-7
Dual Act i on Sy st em. . . . . . . ..04-05-1
I gni t i on Swi t ch I nput ...04-05-6
Sol enoi d Valve Ai r Spri ng 04-05-9
Sol enoi d Valve Vent ...04-05-9
Vehi cl e Speed Sensor 04-05-11
Wei ght Added 04-05-6
Wei ght Removed. 04-05-6
Di agnost i c I nst r uct i ons 04-05-17
Aut o Test Di agnost i cs 04-05-19
Dri ve Cycl e Di agnost i cs 04-05-17
Funct i onal Test s 04-05-21
Sy mpt om Chart . . . .04-05-16
Ai r Compr essor and Dryer Assembl y 04-05-69
Ai r Li ne, Nyl on-Servi ce 04-05-72
SUBJECT PAGE
Ai r Spri ng 04-05-68
Ai r Spri ng Connect or Repair Ki t 04-05-73
Ai r Spri ng Fi l l . . 04-05-67
Ai r Spri ng Pi st on Ret ai ner Cli p 04-05-69
Ai r Spri ng Suspensi on 04-05-64
Ai r Spri ng Syst em Component s 04-05-65
Ai r Suspensi on Hei ght Sensor 04-05-71
Ai r Suspensi on Servi ce Swi t ch 04-05-71
Compr essor Relay 04-05-72
Cont r ol Modul e 04-05-72
Dr y e r Ai r Compressor 04-05-70
EVO Power St eeri ng Cont r ol Valve
Act uat or 04-05-64
Hoi st i ng and Body Support 04-05-63
Hoi st i ng, Li f t i ng, Ja c ki ng and Towi ng
Rest ri ct i ons 04-05-63
Mount i ng Br acket , Air Compressor 04-05-71
Shock Repl acement 04-05-64
Sol enoi d O-Ring 04-05-73
Sol enoi d Valve, Ai r Spri ng 04-05-65
Suspensi on Fast eners 04-05-63
Warni ng I ndi cat or . 04-05-72
SERVICE PROCEDURES
Ai r Leaks . . 04-05-74
Qui ck Checks Wi t hout Star Test er 04-05-73
ADJUSTMENTS
Ride Hei ght . . 04-05-74
VEHICLE APPLICATION
Dual A c t i o n S y s t e m
The rear air suspensi on:
Is an ai r-operated, mi croprocessor-control l ed,
suspensi on syst em.
Repl aces t he conventional rear coil spring
suspensi on.
Provi des l ow spri ng rat es for i mproved ride and
automati c rear l oad leveling.
Is st andard equipment on the Town Car.
Is avai l abl e as optional equi pment on Crown Vi ctori a
and Grand Marqui s.
The rear air suspension syst em has the following
f eat ures:
The syst em is operati onal wi t h t he ignition swi t ch in
t he RUN posi ti on.
Aut omat i c rear l oad leveling has limited operati on
for one hour after ignition swi t ch is turned t o OFF.
The air suspension swi t ch, l ocated on t he right si de
of the luggage compartment, must be turned OFF
when the vehicle is on a hoist, being t owed or jump
st art ed.
The Air Suspension warni ng i ndi cat ori s l ocated in
the instrument panel, t o the right of the
speedometer.
The warning indicator fl ashes five ti mes and
then st ays on wi th ignition swi t ch ( 11572) ON or
when a syst em malfunction is det ect ed.
The rear leveling syst em operat es by addi ng or
releasing air in the spri ngs t o maintain t he level of
the vehicle at a predetermi ned rear suspensi on D
ride height dimension, and is control l ed by a control
module ( 5A919) . (Refer t o Adj ustments.)
The rear air suspension control module al so
control s the electronic vari abl e ori fi ce (EVO) power
steeri ng.
Refer t o Section 11-02 for Descri pti on and
Operati on of the EVO power steeri ng syst em.
04- 05- 2 Su s p e n s i o n , Co mp u t e r Co n t r o l l e d
04- 05- 2
Air requi red for leveling t he vehi cl e is di stri buted
f rom t he air compressor t o the rear air spri ngs by a
nylon air line whi ch runs f rom the compressor air
dri er ( 5346) through a Y-fitting t o each individual air
spri ng.
04- 05- 3
Su s p e n s i o n , Co mp u t e r Co n t r o l l e d
04- 05- 3
04- 05- 4 Su s p e n s i o n , C o mp u t e r Co n t r o l l e d 04- 05- 4
Pa r t
1 9C392 Compressor Relay Power
Junction Block
2 5A897 Air Line (Attached to
Brake/Fuel Bundle)
3 5319 Air Compressor With
Regenerative Air Dryer and
Vent Solenoid
4 5A897 Air Line to Compressor
5

Quick Connect
6

To LH Air Spring
Pa r t
7 From Compressor
8

Y-Fitting (Part of 5A911)
9 To RH Air Spring
10 5A908 Heat Shield
11 5A966 Spring Retainer Clip
12 5560 Rear Spring
13 5359 Rear Air Suspension Height
Sensor
14 5A919 Control Module
15 14018 Air Spring Solenoid
04- 05- 5 Su s p e n s i o n , Co mp u t e r Co n t r o l l e d 04- 05- 5
Suspe n si o n , Co mput e r Co n t r o l l e d Cr o wn Vi c t o r i a a n d Gr a nd Ma r qui s
04- 05- 6
Su s p e n s i o n , Co mp u t e r Co n t r o l l e d 04- 05- 6
Pa r t
1 9C392 Compressor Relay Power
Junction Block
2 5A897 Air Line (Attached to
Brake/Fuel Bundle)
3 5319 Air Compressor
4 5346 Regenerative Air Dryer
5 5A987 Air Line to Compressor
6 5A919 Control Module
7

Quick Connect
Pa r t
8 To LH Air Spring
9

From Compressor
10

Y-Fitting (Part of 5A911)
11

To RH Air Spring
12 5A908 Heat Shield
13 5A966 Spring Retainer Clip
14 5560 Rear Spring
15 5359 Air Suspension Height
Sensor
16 14018 Air Spring Solenoid
We i g h t A d d e d
When wei ght is added t o t he vehi cl e:
The air suspension height sensor ( 5359) length is
reduced f rom tri m l ength, sending a " r ear is l ow"
signal t o t he control module ( 5A919) .
The control module then turns t he compressor on by
grounding t he compressor rel ay control Circuit 420.
Thi s rest ores the rear of t he vehi cl e t o tri m posi ti on.
Bat t ery vol tage is provi ded t o t he rel ay coil by
Circuit 1053.
The control modul e opens t he spri ng sol enoi d
val ves ( 5311) by swi tchi ng Ci rcui ts 1071 and 1072
t o ground. Thi s al l ows pressuri zed air t o enter t he
spri ngs.
Bat t ery vol tage is provi ded t o t he air spri ng
solenoid val ves by Circuit 1053.
Compressed air f l ows f rom t he compressor,
through the compressor air dri er ( 5346) air lines
and spri ng solenoid val ves into t he rear spri ngs
( 5560) .
As the rear spri ngs rai se t he rear body hei ght, t he
air suspension height sensor i ncreases in length
until t he preset tri m height is reached.
The control module then turns off t he compressor
(through the rel ay) and cl oses t he air spri ng
sol enoi d val ves.
Compressed air f l ows f rom rear spri ngs ( 5560) ,
through the air spri ng solenoid val ves, air lines,
compressor air dri er ( 5346) , and out the vent
sol enoi d val ve.
As t he body l owers, the air suspension height
sensor length decreases until t he preset tri m height
is reached.
The control module then cl oses the vent and
sol enoi d val ves.
C o n t r o l Mo d u l e P o w e r a n d G r o u n d
The control module ( 5A919) has the following
features:
Power is provi ded by Circuit 1053 and is control l ed
by t he air suspension swi t ch.
The air suspension swi t ch is powered through a
15 amp fuse in Circuit 296 in Town Car.
AIR SUSPN PUMP (30A MAXI ) fuse provi des
thi s power through Circuit 1053 in Crown
Vi ctori a and Grand Marqui s.
Control module ground is provi ded through control
module wi re harness Pins 6 and 2 1 , t o the RH inner
quarter panel sheet metal , near the control module.
We i g h t R e m o v e d
When wei ght is removed:
The air suspensi on height sensor ( 5359) length is
i ncreased f rom t he tri m l ength, sending a " r ear is
hi gh" signal t o the control modul e ( 5A919) .
The control module then opens t he vent sol enoi d
val ve (l ocat ed in the compressor assembl y) by
swi tchi ng Circuit 421 t o ground and opens t he
sol enoi d val ves ( 5311) by swi tchi ng Ci rcui ts 1071
and 1072 t o ground. Thi s rest ores the rear of t he
vehi cl e t o tri m posi ti on.
I g n i t i o n S w i t c h I n p u t
Syst em responds t o ignition swi t ch ( 11572) input as
fol l ows:
The control module ( 5A919) st ays powered for one
hour after t he ignition swi t ch is turned t o the OFF
position in order t o perform leveling correcti ons
after occupant s and l uggage are removed f rom the
vehicle.
When the ignition swi t ch is turned t o RUN, Circuit
298 is supplied bat t ery vol tage.
If t here is an open in Circuit 1053 in or its feed
ci rcui ts, t he control module will be inoperative and
di agnosti cs cannot be entered.
5-7 Su s p e n s i o n , C
o r
~"
Do o r C o u r t e s y L a m p S w i t c h I n p u t
Syst em responds t o lamp swi t ch ( 13713) as fol l ows:
The control module ( 5A919) uses t he door court esy
lamp swi t ch input for t wo different functi ons:
Preventi ng vent s when a door is open t o avoi d
the possi bi l i ty of t he vehi cl e l oweri ng and t he
door cat chi ng on an obstructi on.
Servi ci ng a correct i on immediately, if needed.
The control module cannot sense whi ch doors are
open, only t hat one or more doors are open, or all
doors are cl osed.
If a damaged door l amp swi t ch (al ways open) or a
short t o bat t ery in Circuit 159 (dri ver door) or Circuit
24 (passenger door) exi st s, t he control module will
i nterpret that a door is open and not vent unless
vehi cl e speed is above 24 k m/ h ( 1 5 mph).
Above 24 k m/ h ( 1 5 mph) the control module
di sregards all door signals.
A i r C o m p r e s s o r A s s e m b l y
NOTE: The compressor motor contai ns a thermal
overl oad circuit breaker. The circuit breaker
automati cal l y reset s if tri pped by excessi ve heat.
The air compressor assembl y:
Consi sts of t he compr essor and vent sol enoi d;
neither is servi ceabl e.
Is mounted in t he engine compart ment on the LH
fender apron bel ow t he engine air cl eaner
( ACLX9600) .
Is a single-cylinder el ectri c motor-dri ven unit whi ch
provi des pressuri zed air as requi red.
Is power ed by a rel ay, control l ed by t he control
modul e ( 5A919) .
Passes pressuri zed ai r through t he compressor air
dri er ( 5346) whi ch contai ns silica gel ( a dryi ng
agent ).
Moi sture is then removed f rom t he compressor air
drier when vent ed air passes out of t he syst em
during vent operat i on.
The compressor air dri er may be servi ced
separatel y.
A four-pin connect or is used on the compressor
assembl y:
The or ange/ r ed wi re supplies power.
The bl ack wi re grounds the compressor motor.
The blue and green wi res operat e the vent sol enoi d.
Co mpr e sso r Ai r Dryer Asse mbl y
F6336-G
I t e m
Pa r t
Pa r t
1 5346 Compressor Air Dri er
1
8

Brush (Part of 5319)
2

Air Line Release Button (Part 9

Connecting Rod (Part of
of 5346) 5319)
3 Air Line Fitting (Part of 5346) 10
_____
Piston (Part of 5319)
4 5319 Compressor Assembly 11 Intake Valve (Part of 5319)
5

Armature(Part of 5319) 12 Discharge Valve (Part of
6

Magnets (Part of 5319)
5319)
7

Commutator (Part of 5319)
13

O-Ring Seal (Part of 5319)
C o m p r e s s o r Re l a y
The air suspensi on compressor rel ay and bracket
( 9C392) is needed because the control module cannot
di rectl y provi de the high current needed t o run the
compressor motor. It operat es as f ol l ows:
e The control module ( 5A919) grounds Circuit 420 t o
energize the relay coi l .
1 E x c e p t f o r t h e c o mp r e s s o r a i r d r i e r , t h e Ai r Co mp r e s s o r A s s e mb l y i s s e r v i c e d a s a uni t .
04- 05- 9 S u s p e n s i o n , Co mp u t e r Co n t r o l l e d 04- 05- 9
When energi zed, the coil creat es a magneti c field
whi ch cl oses t he rel ay cont act s, connecti ng Circuit
1053 t o Circuit 538.
High current t hen f l ows f r om bat t ery t o t he
compressor motor.
COMPRESSOR
RELAY
9C392
Air Spri ng Assembl y
Two air spri ngs:
Repl ace t he conventi onal steel spri ngs.
Support t he vehi cl e l oad at t he rear wheel s ( 1007) .
Are mounted bet ween t he axl e spri ng seat s and t he
f rame upper spri ng seat s, similar t o t he
conventional rear steel spri ng syst em.
Sol enoi d Valve Vent
CAUTI ON: T h e v e n t s o l e n o i d v a l v e h a s a n i n t e r n a l
d i o d e f o r e l e c t r i c a l n o i s e s u p p r e s s i o n a n d
t h e r e f o r e i s p o l a r i t y s e n s i t i v e . Ca r e mu s t b e
t a k e n n o t t o s w i t c h t h e b a t t e r y f e e d a n d g r o u n d
c i r c u i t s , o r c o mp o n e n t d a ma g e wi l l r e s u l t .
The vent sol enoi d val ve:
Al l ows air t o escape f rom the syst em during venting
correct i ons.
Is l ocat ed above t he air compressor cylinder head.
Is encl osed in the cylinder head cast i ng, whi ch
1
f orms an integral val ve housing that al l ows t he val ve
ti p t o enter t he pressuri zed si de of t he syst em.
Has an O-ring seal whi ch prevents air l eakage past
the val ve ti p.
Opens when the rear is high and the control module
( 5A919) determi nes lowering is requi red. |
Provi des an escape route for pressuri zed air when
opened.
The vehicle will not l ower unless the air spri ng '
sol enoi d val ves ( 5311) ar e al so opened t o al l ow air
t o l eave t he spri ngs.
Air is exhaust ed f rom t he spri ngs and vented I
through the compressor air dryer.
Is not a servi ceabl e i tem.
I
Sol enoi d Valve Air Spri ng
WARNI NG: NEVER ROTATE AN AI R SPRING
SOLENOI D VALVE TO THE RELEASE SLOT IN THE
END CAP FI TTI NG UNTI L A L L PRESSURI ZED AI R
HAS ESCAPED FROM THE SPRING TO PREVENT
DAMAGE OR INJURY.
The air spring solenoid valve ( 5311) :
Al l ows air t o enter and exi t the air spring during
leveling correct i ons.
Is el ectri cal l y operat ed and control l ed by the control
module ( 5A919) .
Because t he spring solenoid val ves are airtight,
connecti ng air lines are not requi red t o be compl etel y
ai rti ght. The air lines only contai n pressuri zed air
during vent and compress operati ons.
Removal of the solenoid valve has a t wo-st age
pressure relief syst em similar t o a radi ator cap:
Fi rst remove the air spri ng solenoid retainer ( 5308) .
Then rot at e t he sol enoi d val ve out of the seat t o
rel ease air f rom the spri ng.
Then r emove the solenoid val ve.
F6333- D
Pa r t
1 Electri cal Connector (Part of
5311)
2

Coil (Part of 5311)
3

O-Ring Seals (Part of 5311)
4

Air Line Fitting (Part of 5311)
5 Valve (Part of 5311)
6

Environmental O-Ring (Part
of 5311)
Air Suspensi on Servi ce Swi t ch
NOTE: The air suspension swi t ch must be turned t o
the OFF position when t he vehi cl e is hoi sted, j acked,
t owed, j ump st art ed or rai sed off the ground t o avoi d
unnecessary operati on of t he syst em and/ or possi bl e
damage t o its components.
The air suspensi on swi t ch provi des power t o the
control module ( 5A919) in the ON position only. The
swi t ch is l ocat ed on the RH si de of the l uggage
compart ment .
F6340-B
Cont rol Valve Act uat or (EVO), Power
St eeri ng Assi st
The EVO control val ve actuator is l ocated on t he
steeri ng pump bel ow the engine on the LH si de.
Air Suspensi on Height Sensor
The air suspensi on height sensor ( 5359) sends signals
t o the control module ( 5A919) through Ci rcui ts 427
and 428. There are three possi bl e condi ti ons that the
control modul e i nterprets f rom signals f rom t he air
suspensi on height sensor:
Vehicle is at tri m height.
Vehicle is bel ow tri m height.
Vehicle is above tri m height.
The air suspension height sensor is installed and
operat es as fol l ows:
Is connect ed t o the f rame crossmember at one end
and at t he LH rear upper arm at the other end.
The air suspension height sensor get s shorter when
the rear of t he vehi cl e l owers and longer when the
rear of t he vehicle ri ses.
Magnet s mounted in the l ower slide porti on of the air
suspensi on height sensor move relative t o t he air
suspension height sensor housing.
This movement generates a signal that is sent t o the
control module through t wo small Hall effect
swi t ches at t ached t o the air suspension height
sensor housing.
The signal generated by movement of the magnets
determi nes swi t ch opening and closing as fol l ows:
At tri m height, the swi t ches remain cl osed and the
control module recei ves a tri m signal.
Upward movement of the magnets will open one
swi t ch t o indicate a high condi ti on.
Downwar d movement of t he magnets will open the
other swi t ch t o indicate a low condi ti on.
BALL STUD
ATTACHING POINTS
AIR SUSPENSION HEIGHT SENSOR 5359
F6425-C
04- 05- 11 Su s p e n s i o n , C o mp u t e r Co n t r o l l e d
DESCRIPTION A N D OPERATION (Conti nued)
Ve h i c l e S p e e d S e n s o r
The vehi cl e speed sensor (VSS)(9E731) is installed
and functi ons wi t h t he EVO steeri ng syst em as
fol l ows:
Vehicle speed sensor is l ocat ed on t he
transmi ssi on.
Used t o establ i sh vehi cl e speed.
The output current t o the power steeri ng control
val ve act uat or ( 3783) is a function of vehi cl e speed
and t he steeri ng wheel rotati on rate.
When vehi cl e speed is less than 16 km / h ( 10 mph)
t he output current is l ess than 100 mA, and full
power steeri ng assi st is provi ded.
As vehi cl e speed i ncreases, t he current i ncreases
t o approxi mat el y 600 mA. The current then remains
constant at approxi mat el y 600 mA for vehi cl e
speeds greater than approxi mat el y 144 k m/ h ( 90
mph). Conversel y, as vehi cl e speeds decrease, the
current decreases linearly.
A sel ector swi t ch at the dri ver' s LH si de al l ows the
Town Car dri ver t o sel ect t he rat e at whi ch power
steeri ng assi st is reduced wi t h vehi cl e speed. The
selection is for a low, normal or high rate of decrease.
VEHICLE SPEED
SENSOR 9E731
VEHICLE SPEED
SENSOR
CONNECTOR
K6267-D
C o n t r o l Mo d u l e
The Rear Air Suspensi on/ EVO Control Modul e
( 5A919) servi ces both t he rear air suspensi on syst em
and t he EVO steeri ng syst em.
The wi ri ng harness connect s t o t he control module
using t wo separat e push button rel ease connectors.
The connect ors are keyed so that t hey cannot be
installed i ncorrectl y.
CONTROL
MODULE
5A919
CONNECTORS F6416-C
Control modul e operat es as f ol l ows:
In general t he control modul e uses a 45-second
averagi ng interval t o determi ne when compress and
vent operati ons are needed.
However, door l amp swi t ch ( 13713) inputs can
overri de t he 45-second averagi ng interval so
compress and vent operati ons can begin
i mmedi atel y, if needed.
The 45-second averagi ng interval is used t o keep
the control module f rom maki ng unneeded
correct i ons.
When a vehi cl e at the correct rear tri m height hits a
bump, the air suspension height sensor output will
read l ow and high in addi ti on to tri m until the
oscillations die out.
If the control module was t o correct for these
" bump induced r eadi ngs", syst em duty cycl e woul d
i ncrease unnecessarily.
The 45-second averagi ng interval not only
eliminates correct i ons due t o bumps, but al so
eliminates unneeded correct i ons resulting f rom
braki ng, accel erat i ng, and turning. The control
module tabul ates the air suspension height sensor
readi ngs, and does not begin a compress or vent
operati on until t he air suspension height sensor
( 5359) reads low or high f or 45 seconds nearly
consi stentl y.
Vent operati ons are more restri cted wi th t he ignition
on. Compress operati ons are more restri cted after
the ignition is off.
To eliminate the chance of catchi ng a door on a curb
as the vehi cl e vents down, the control module will
not allow any venting t o occur when a door is open.
The control module does not allow any vent
operati ons for t he fi rst 45 seconds after t he ignition
swi t ch ( 11572) has been turned t o RUN.
Even if a vehicle is extremel y high in the rear,
DO NOT expect it to vent until the ignition swi t ch
has been turned t o RUN for 45 seconds.
04- 05- 12 Suspension, Computer Controlled 04- 05- 12
Suspension, Computer Cont rol l edTown Car
HOT AT AL L TI MES
HOT AT A L L TI MES
1 POWER
u
I DISTRIBUTION
I BOX
1 POWER
COMPRESSOR l | u N
RELAY | ggJ
0 N
4 15A J 2 5A
jj 295 | LB/PK
296j^W/P I
1
I FUSE
I JUNCTION
I PANEL
AIR
SUSPENSION
POWER 1 HEIGHT
HEIGHT OUTPUTS INPUT GROUM31 SENSOR
. INSTRUMENT
1 CLUSTER
"CHECK AIR J
USPENSION"!
INDICATOR
AIR
SUSPENSION
DATALINK
CONNECTOR
11 mmmm OUTPUT 4 I tGNmoN
DIAGNOSTIC ON INPUT
^ 2 1 S S
:
i m i T
y O 0 U L E GROUND "
HEIGHT INPUTS
ACTUATOR OUTPUT
14 26 18
AIR
SUSPENSION
DATALINK
CONNECTOR
1 AIR
1 SUSPENSION/
1
EVO CONTROL
I MODULE
19 ROTATION RATE INPUT I
22 POWER 8 GROUND
OUTPUT
5 7
6761 PK /O
! 6| GY / 0 T 663 j R T
87 J T / Y I 6 3 4 | B
ELECTRONICALLY VARIABLE
ORIFICE (EVO) POWER STEERING
See EVTM f o r mor e det ai l s
of t hi s c i r c ui t
04- 05- 13
Su s p e n s i o n , C o mp u t e r C o n t r o l l e d
04- 05- 13
Cr o wn Vi c t o r i a a n d Gr a nd Ma r qui s
l iK l l i_ l i_ _ J
L L
15
_
HOT A T A L L TI ME S
* F U S E
I J UNCT I ON
. P ANE L
A 1 E 3
5
I P OW E R
*
, f
? DI ST RI B UT I ON
) S US P N BOX
1
t
A I R S US P E NS I ON
SWI T CH
7 RH
RE A R
AIR S PRI NG
S OL E N OI D
V AL V E
X
I 1 6 13
I GNI TI ON SOL E NOI D
1 RUN CONT ROL
| I NP UT I NP UT
2 5 S OL E N OI D
C ON T ROL
OUT P UT
of thi s circuit
EVO
P OWE R ST E E RI NG
X 1
, 3
1
63
X
18 19
1 I NST RUMENT
| C L U S T E R
RC
S0l
OH
E VO A C T UA T OR
M7fl OUT P UT
I NP UT G ROUN D ' <-* >
1 fi 26 14
5 DO O R O P E N I NP UT
S OL I D ST A T E
G R O U N D DI AGNOSTI C
21 I NP UT 4
I NDI CATOR OUT P UT 11
P OWE R
Bmum OUT P UT
8 22
HE I GHT
I NP UTS
| AI R
S US P E NS I ON/
1 E V O C ON T R OL
| MODUL E
T/Y
i
GY/ O
E VO
P O WE R
ST E E RI NG
A I R
SUSP E NSI ON
DATA LI NK
CONNE CT OR
n T T
I
4 2 9
1
P
K / L G I 4281 O
" B K / P K " ? W JL W
1 T Y I
W I 427 I PK/ BKj j
432 T B K / P K I A "
v , T B K T H T
DB
T
D
AI R
S US P E NS I ON
HE I GHT
S E N S OR
04- 05- 14 Suspension, Computer Controlled 04- 05- 14
Connect or End Vi ews
A I R S US P E NS I ON/ E L E CT RONI C
VARI ABLE ORIFICE (EVO) CONTROL
MODULE CONNECTOR (WHITE) C1
F7816-C
P i n
Nu mb e r C i r c u i t Ci rcui t Func t i on
1 418
( DG / Y)
Ba t t e r y P o s i t i v e Vo l t a ge ( B + )
2 No t Us e d
3 42 8
( O / B K )
Re a r Ai r Su s p e n s i o n He i gh t Se n s o r
I nput ( L o w I n d i c a t o r )
4
a
844
( G Y / R )
b
No t Us e d
Da t a Li n k Co n n e c t o r ( Di a gn o s t i c
I n put )
5 344
( B K / Y)
Co u r t e s y L a mp S wi t c h I nput
7 67 9
( G Y/ B K )
Ve h i c l e S p e e d Se n s o r I nput ( + )
15 418
( DG / Y)
( B + )
16 2 95
( L B / P K )
2 98 ( P / 0 )
a
I gn i t i o n RUN I nput
17 42 7
( P K / B K )
I nput ( Hi gh I n d i c a t o r )
18 633 ( R )
b
a
8 3 4 ( R / Y )
St e e r i n g Wh e e l Ro t a t i o n Ra t e
I nput
19 634 ( B R )
b
835
( R / W )
a
St e e r i n g Wh e e l Ro t a t i o n Ra t e
I nput
2 0 67 6
( P K / 0 )
b
359
( G Y / R )
a
Ve h i c l e S p e e d Se n s o r I nput (-)
a Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s ,
b To wn Ca r On l y .
AIR SUSPENSION/ELECTRONIC
VARI ABLE ORIFICE (EVO) CONTROL
F7815-C
Pi n
8 432
( B K / P K )
Re a r Ai r Su s p e n s i o n He i ght Se n s o r
Gr o un d An d Di a gn o s t i c Gr o un d
9 844
( G Y/ R)
I nput )
10

No t Us e d
11 419
( DG / L G )
Wa r n i n g I n d i c a t o r Out put
12
a
635 ( Y)
b
No t Us e d
St e e r i n g Mo d e Se l e c t
13 107 1
( B R / P K )
L H Ai r Spr i n g So l e n o i d Co n t r o l
14 86 ( G Y/ O ) EVO A c t u a t o r Co n t r o l Out put
2 1

No t Us e d
2 2 4 2 9 ( P / L G ) Re a r Ai r Su s p e n s i o n He i ght Se n s o r
P o we r Out put
2 3 42 0
( DB / Y)
Co mp r e s s o r Re l a y Co n t r o l
2 4 42 1 ( P K) Ve n t So l e n o i d Co n t r o l
2 5 107 2
( T / W)
RH Ai r Spr i n g So l e n o i d Co n t r o l
2 6 87 ( T / Y) E VO A c t u a t o r Fe e d b a c k
a Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s ,
b To wn Car .
04- 05- 15 S u s p e n s i o n , Co mp u t e r C o n t r o l l e d 04- 05 - 15
INSTRUMENT CLUSTER
CONNECTOR C2
R10943-A
Pin
Number Ci r cui t Ci rcui t Func t i on
1 484
( O / B K )
L i q u i d Cr y s t a l I l l umi n a t i o n Di s p l a y
3 640 ( R / Y) Wa r n i n g L a mp s Fe e d
4 67 6
( P K / O )
I nput
6 67 6
( P K / O )
7

No t Us e d
8

No t Us e d
9 6 0 3 ( DG) A BS Wa r n i n g L a mp
10 2 ( W/ L B ) RH Fr o n t Turn Si gn a l L a mp
11 911
( W/ L G )
O / D OFF i n d i c a t o r L a mp
12 932
( G Y / W)
Hi gh Be a m I n d i c a t o r
13 97 7 ( P / W) Br a ke Wa r n i n g L a mp
14 31 ( W/ R ) Oi l P r e s s u r e Wa r n i n g L a mp
15 67 6
( P K / O )
16 608
( B K / Y )
Ai r Ba g Di a gn o s t i c L a mp Dr i v e r
INSTRUMENT CLUSTER
CONNECTOR C1
R1W42-A
Pin
1 2 9 ( Y / W ) Fue l Pump ( FP ) Mo d u l e I nput
2 67 6
( P K / O )
3 640 ( R / Y ) Wa r n i n g L a mp Fe e d
4

No t Us e d
5 658
( P K / L G )
Fe e d
6

No t Us e d
7

No t Us e d
8 450
( DG / L G )
Se a t b e l t Wa r n i n g I n d i c a t o r L a mp
9 67 6
( P K / O )
Ve h i c l e S p e e d Se n s o r ( VSS) (B+)
10 3 C L G / W) L H Fr o n t Turn Si gn a l L a mp
11 88 ( B K / W) I n st r ume n t Pa n e l L a mp S wi t c h e d
Fe e d
12 904
( L G / R )
Ch a r ge I n d i c a t o r
13

No t Us e d
14 67 9
( G Y/ B K )
Ve hi c l e S p e e d Se n s o r ( VSS) ( B + )
15 419
( DG / L G )
Ai r Su s p e n s i o n Ma l f un c t i o n
Wa r n i n g L a mp
16 1053
( L B / P K )
Ai r Su s p e n s i o n Fu s e d Ba t t e r y
Fe e d
04- 06- 16
Su s p e n s i o n , Co mp u t e r Co n t r o l l e d 04- 05- 16
4 J I 5 J I 6
DATA LINK CONNECTOR
F7820-C
Pin
N u m b e r C i r c u i t Ci r cui t Func t i on
1

No t Us e d
2 432
( B K / P K )
Gr o un d
3 413 ( L G) DLC- A
4 419
( DG / L G )
STO Out put
5 844
( G Y/ R)
STI I nput
6 412
( O / L B )
DL C- B
operati ng t he vehi cl e t o dupl i cate t he condi ti on.
2. Inspect t o determi ne if one of the fol l owi ng
Mechani cal El ect ri cal
S h o c k a b s o r b e r f a i l ur e O p e n Fu s e s :
L e a k f r o m a i r l i n e ( s) To wn Ca r
L e a k f r o m a i r s p r i n g( s ) P o we r Di s t r i but i o n Bo x
Ru pt u r e d ai r s p r i n g( s ) Fu s e U ( 30A MAXI )
He i ght s e n s o r d a ma g e d Fu s e Jun c t i o n Pa n e l Fus e
He i ght s e n s o r of f ba l l s t u d s 1 ( 15A )
Cr o wn Vi c t o r i a / G r a n d
Ma r q u i s
P o we r Di s t r i but i o n Bo x
Fu s e AI R SUSP N P UMP
( 30A MAXI )
Fu s e J u n c t i o n Pa n e l Fus e
1 ( 1 5 A )
L o o s e Co n n e c t o r s
C o r r o d e d Co n n e c t o r s
3. If the concern(s) remai ns after t he i nspecti on,
determi ne t he sympt om(s) and go t o t he
Sympt om Chart.
equivalent f or the fol l owi ng El ectri cal Tests.
The Air Suspension Syst em di agnosti cs require the
use of Rotunda SUPER STAR II Tester 007- 0041B or
equivalent.
AIR SUSPENSION DIAGNOSIS
Rear Suspension Does Not
Respond to Load Changes
Ci rcui ts.
Compressor.
Control Module.
Height Sensor.
GO to Auto Test AA.
Rear Rides Low/Hi gh Ci rcui ts.
Control Module.
Spring Solenoid Valves.
Height Sensor.
GO to Auto Test AA.
Unable to Enter Auto Test Super Star II Fault.
Procedural error.
Circuits.
Control module.
GO to Pinpoint Test N.
Poor Ride Quality Air springs.
Ci rcui ts.
GO to Auto Test AA.
AIR SUSPENSION DIAGNOSIS (Cont i nued)
Air Suspension Warning Indicator
ON
Air suspension service swi t ch OFF.
Air suspension system concern.
Instrument panel cluster concern.
CHECK swi tch in luggage
compartment.
GO t o Auto Test AA.
GO t o Section 13-01A (Electroni c)
or 13-01B (Conventional).
Di a g n o s t i c I n s t r u c t i o n s
NOTE: Rot unda SUPER STAR Test er 007 - 00019
ma y n o t be used.
Thi s part of di agnost i cs is di vi ded i nto t hr e e a r e a s:
Dri ve Cy c l e Di agnost i cs
Aut o Test Di agnost i cs
Funct i onal Test s
Dr i v e C y c l e Di a g n o s t i c s
To assi st t he t echni ci an in c or r e c t i ng i nt ermi t t ent
ai r-suspensi on e r r or s, 1995 Ai r-Suspensi on sy st e ms
have t he abi l i t y t o st or e DTC. When t he warni ng li ght
ha s been a c t i va t e d, t he cont r ol modul e wi ll st o r e t ha t
DTC f or 80 i gni ti on c y c l e s. If t her e i s no repeat of t he
sa me er r or duri ng t hese 80 i gni ti on c y c l e s, t he cont r ol
modul e wi ll e r a se t he DTC. The t echni ci an can ret ri eve
t he st or e d DTC by perf ormi ng DRIVE CYCLE
DI AGNOSTI CS.
04- 05- 18
Dri ve Cy c l e s Di a gn o st i c s Te st Pr ocedur e
NOTE: Used t o retrieve error codes from Non-volatile memory and to help diagnose
intermittent conditions that cannot be detected in Service Bay diagnostics.
WHILE DRIVING THE VEHICLE THE
MESSAGE CENTER ACTIVATES THE
CHECK AIR SUSPENSION LIGHT
VEHICLE PASSES SERVICE BAY TESTS, BUT
CUSTOMER COMPLAINT WAS THAT THE
CHECK AIR SUSPENSION LIGHT WAS ON.
PREPARE VEHICLE
Park vehicle
Turn Ignition OFF
PREPARE VEHICLE
Drive vehicle over 25 MPH to
test vehicle speed sensor.
Park vehicle and turn ignition
OFF.
i
RETRIEVE STAR CODES
SUPER STAR II at EEC/MCU setting.
FAST codes.
TEST button UP (HOLD)
Connect to Diagnostic Test connector
Turn tester power switch to ON.
Wait at least 3 seconds
Depress STAR tester button (TEST)
1 f f
CODE 15 ALL OTHER STAR CODES
No errors were detected
or stored in Non-volatile
memory
Record Error codes from
Non-volatile memory
Refer to Air Suspension STAR
CODE chart and perform
pinpoint tests indicated.
K
TO EXIT DRIVE CYCLE TEST
K
Release STAR tester button
HOLD
Disconnect SUPER STAR II
from Diagnostic connector
Release STAR tester button
HOLD
Disconnect SUPER STAR II
from Diagnostic connector
TO ERASE ERROR CODES AFTER REPAIR IS MADE
Perform Drive Cycle Diagnostics as shown above.
Release STAR tester button (HOLD)
Wait two seconds
Depress STAR tester button (TEST)
CODE 35 will be displayed meaning error codes
erased from Non-volatile memory.
EXIT by Releasing STAR tester button (HOLD), module
will exit Drive Cycle Test sequence automatically.
F4825-A
04- 05- 19 Suspensi on, Comput er Cont r ol l ed 04- 05- 19
Au t o Tes t Di agnos t i c s
At t he beginning of t he aut omat i c porti on of t he test,
the control modul e ( 5A919) checks for damaged
control module (DTC 70) , for unstabl e bat t ery vol tage
(DTC 80) , then for short ed or open condi ti ons that
woul d creat e DTCs 39 t hrough 46, and 68 through 7 1 .
If short s or opens are det ect ed, the automati c porti on
of t he t est is ended and a DTC 13 (Auto Test Failed)
will be di spl ayed on the SUPER STAR II tester. If no
short s or opens are det ect ed, t he automati c portion of
t he t est conti nues. The control modul e at t empt s t o
rai se and l ower t he vehi cl e t o veri fy that all t hree air
suspension height sensor st at es (tri m, hi gh, and l ow)
can be reached. A properl y functioning vehi cl e will be
at tri m height at t he end of the Auto Test. If all t hree
st at es are not reached, t he Aut o Test will end and
agai n a DTC 13 will be di spl ayed. A DTC 12 will be
di spl ayed at t he end of t he Aut o Test only if everythi ng
checked t o this point is functi onal .
After the DTC 12 (or DTC 13) is di spl ayed, t he control
modul e is ready t o check for manual inputs. The
manual inputs check the steeri ng sensor and t he door
court esy lamp swi t ch ci rcui ts. During the manual t est ,
the module continually moni tors the door Circuit 344
and t he steeri ng sensor Ci rcui ts 633 and 634 for
acti vi ty. To pass t he manual t est t he control module
must det ect t hat all four doors have been opened and
cl osed, and t hat the steeri ng wheel has been turned at
least 1/ 4 turn in each di recti on. In the Town Car, t he
EVO steeri ng sel ect swi t ch must be cycl ed through all
t hree posi ti ons. After t he manual t est , the STAR tester
button must be t oggl ed, or t he control module will
continue t o monitor the manual t est inputs indefinitely.
Either a DTC 11 (Ai r Suspensi on OK) or other DTCs
will be di spl ayed at thi s ti me.
After t he Aut o/ Manual t est s, the DTCs wi l l be
di spl ayed aut omat i cal l y. Each DTC det ect ed will be
di spl ayed f or about 15 seconds. The code di spl ay will
conti nue until all DTCs have been di spl ayed. The
di spl ay will repeat the DTC until the STAR t est button
is rel eased (up). Wri t e down all DTCs, then rel ease
pr essed t est er but t on. DO NOT di sconnect or turn
OFF t he tester. The t est er is ready t o enter t he
Functi onal Test, if a DTC II has been di spl ayed.
04- 05- 2 0 Su s p e n s i o n , C o mp u t e r Co n t r o l l e d 04- 05- 2 0
AUTO TEST DIAGNOSTICS
AA1 CHECK FOR DTCs
Yes
No
GO t o AA2.
CHECK t est er
connections. RETEST
syst em.
SUPER STAR SB Tester 007-0041B must be used
f or thi s procedure. SUPER STAR Tester
007-00019 may not be used.
Remove all ext ra loads from luggage and passenger
compartments.
Set STAR Tester as follows:
STAR: EEC/MCU Setting
SUPER STAR II: EEC/MCU Setting, FAST codes
Turn ignition swi tch OFF.
Turn air suspension swi tch (RH side of luggage
compartment) OFF, then ON.
Remove RH luggage compartment trim panel. Refer
to Section 01-05.
Connect STAR Tester to data link connector.
NOTE: Ensure STAR t est button is in HOLD (up)
position before connecting to vehi cle.
N:
^^=========^^ SYSTEM
\ \ \-~A U SYSTEM DATA LINK
\ \ \ CONNECTOR (DLC)
\ \ \ FOR STAR TESTER
\ \ \ F7204-D .
If battery is weak, connect battery charger to
maintain battery level and turn ignition swi t ch to
RUN.
Wait at least two seconds, then press STAR Tester
button so it remains in the TEST (down) posi ti on.
Within 20 seconds, a DTC 10 should be di splayed.
Is t her e any code di spl ayed?
Yes
No
GO t o AA2.
CHECK t est er
connections. RETEST
syst em.
AA2 CHECK FOR DTC 10
Yes
No
System is in AUTO Test
Mode. GO t o AA4.
GO to AA3.
Check the t est er display for DTC.
Is DTC 10 di spl ayed?
Yes
No
System is in AUTO Test
Mode. GO t o AA4.
GO to AA3.
Yes
No
GO t o M1.
GO to AA1.
Check the t est er display for DTC.
Yes
No
GO t o M1.
GO to AA1.
04- 05- 2 1 Su s p e n s i o n , C o mp u t e r Co n t r o l l e d 0 4 - 0 5 - 2 1
AUTO TEST DIAGNOSTICS (Conti nued)
Yes
No >
Vehicle passes. EXIT
Auto Test by
di sconnecti ng STAR
t est er and turning ignition
swi t ch off.
RECORD DTCs. REFER
t o Air Suspension DTC
chart for Pinpoint Tests
for DTCs di splayed. DO
NOT disconnect or turn
off STAR Tester, ignition
swi t ch or air suspension
swi t ch. GO to Pinpoint
Tests for DTCs
di splayed.
DTC 10 will be displayed for up to two minutes.
DO NOT put any weight on vehicle while DTC 10
is di spl ayed.
When Auto Test is complete a DTC 12 (Auto Test
passed) or DTC 13 (Auto Test failed) will be
di splayed.
With DTC 12 or 13 displayed:
Open and close all four doors.
Turn steering wheel 1 / 4 turn in both directions.
Cycle steering select switch through 3 positions
(Town Car only).
NOTE: The above manual inputs can be done in any
sequence.
Release STAR TEST button to HOLD (up) position.
Wait two seconds and press button to TEST (down)
posi ti on.
Within 20 seconds DTCs will be displayed.
NOTE: The DTCs will be displayed for about 15
seconds each. After all DTCs have been displayed,
the DTCs will be repeat ed. The DTCs will continue to
repeat as long as the STAR t est er button is in the
TEST (down) posi ti on.
Yes
No >
Vehicle passes. EXIT
Auto Test by
di sconnecti ng STAR
t est er and turning ignition
swi t ch off.
RECORD DTCs. REFER
t o Air Suspension DTC
chart for Pinpoint Tests
for DTCs di splayed. DO
NOT disconnect or turn
off STAR Tester, ignition
swi t ch or air suspension
swi t ch. GO to Pinpoint
Tests for DTCs
di splayed.
Fu n c t i o n a l T e s t s
CAUTI ON: Fu n c t i o n a l t e s t i s r u n o n l y i f d i a g n o s i s
d o e s n o t i d e n t i f y c o n c e r n . E x c e s s i v e use o f t h e
f u n c t i o n a l t e s t c o u l d o v e r h e a t t h e c o mp r e s s o r o r
d a ma g e s y s t e m e l e c t r o n i c s .
These t est s are run at t he end of t he Aut o/ Manual t est
procedure, and are used as an ai d t o di agnose t he
syst em. The only way t o enter the Functional Test is
by fi rst running t he Aut o/ Manual t est . During t he
Functional Test the control module will at t empt t o
cycl e the component s as fol l ows:
DTC 2 3: Vent Rear - During thi s t est t he control
modul e will at t empt t o open the vent solenoid val ve
and air spring sol enoi d val ves ( 5311) a s long as t he
STAR t est er button is pressed. The rear of the vehi cl e
will lower.
NOTE: DTC 26 is normally used t o inflate the air spri ng
after installation.
DTC 2 6: Compress Rear - During thi s t est the cont rol
modul e will at t empt t o energize t he compressor and
open t he spri ng solenoid val ves as long as t he STAR
t est er button is pressed. The rear of t he vehi cl e will
ri se.
NOTE: The ext ended use of thi s t est can cause the
sel f-resetti ng circuit breaker in the compressor t o
open. If thi s happens, al l ow the compressor t o cool
down for 15 minutes. Then, restart the di agnosti c
procedures.
DTC 3 1 : Air Compressor Relay Toggle - During thi s
t est , the control module will at t empt t o cycl e t he
compressor relay ON for one second and OFF f or one
second repeatedl y. Thi s cycl e will repeat for as long
as t he STAR tester button is pressed. The compressor
will be heard cycl i ng ON and OFF if this test is
successful .
DTC 32 : Vent Solenoid Valve Toggle - During thi s t est ,
t he vent solenoid val ve is opened for one second, then
cl osed for one second. This cycl e will repeat f or as
long as the STAR t est er button is pressed. The vent
solenoid val ve in t he air compressor will be heard
cycl i ng ON and OFF if thi s test is successful .
DTC 33: Air Spring Solenoid Valve Toggl e - During thi s
t est , both air spring solenoid val ves will be opened f or
one second, then cl osed for one second repeatedl y.
This cycl e will repeat for as long as the STAR t est er
button is pressed. The control module cannot turn one
spri ng solenoid val ve on wi thout turning the other
solenoid valve on (Circuits 416 and 429 are t i ed
together inside the control modul e). To veri fy that both
solenoid val ves operat e, raise the vehi cl e on a hoist.
Refer t o Section 00- 02. Do not turn the air suspension
swi t ch OFF. Remain in Functional Test DTC 33. Then,
touch each solenoid val ve t o verify that it is cycl i ng ON
and OFF.
FUNCTIONAL TESTS
AB1 CHECK FOR DTCs
Functional Tests are used in some of the DTC
Pinpoint Tests to aid in system di agnosi s.
The Functional Test mode can only be entered after
Auto Test has been performed. A DTC 11 or any
other DTCs must be di splayed before the Functional
Test mode can be entered.
Are DTCs di spl ayed?
Yes
No

GO to AB2.
REPEAT Auto Test. If Auto
Test cannot be entered,
GOt o Pinpoint Test N.
AB2 CHECK FOR FUNCTIONAL TEST DTCs
Release STAR Tester button to the HOLD (up)
posi ti on.
Wait at least 20 seconds.
Press STAR Tester button to the TEST (down)
position.
DTC 23 should be di splayed, then DTCs 2 6, 31, 32
and 33 will be di splayed in order. Each DTC will be
di splayed for about 15 seconds. After all the DTCs
are di splayed, they will be repeated as long as the
STAR Test button is in TEST (down) posi ti on.
Are f unct i onal t e st DTCs di spl ayed?
Yes
No

GO to AB3.
RELEASE STAR Tester
button to HOLD (up)
posi ti on. Wait 20
seconds and press
button t o TEST (down)
posi ti on. If Functional
Test DTCs are still not
di splayed, REPEAT Auto
Test.
AB3 PERFORM FUNCTIONAL TESTS
The following chart lists the Functional Test DTCs:
DT C De s c r i p t i o n
2 3 Ve n t Re a r
2 6 C o mp r e s s Re a r
31 To ggl e C o mp r e s s o r o n a n d o f f r e p e a t e d l y
32 To ggl e v e n t s o l e n o i d v a l v e o n a n d o f f r e p e a t e d l y
33 To ggl e a i r s p r i n g s o l e n o i d v a l v e s o n a n d o f f
r e p e a t e d l y
Yes
No
Within four seconds after the desi red Functional
Test DTC is di splayed, release the STAR Tester
button to the HOLD (up) posi t i on.
NOTE: Waiting longer than four seconds will cause
the next Function Test t o be entered.
As long as the STAR Tester button is in t he HOLD
(up) posi ti on, the Functional Test will continue.
NOTE: The STAR Tester may or may not display the
DTC for the Functional Test sel ect ed.
Example: Functional Test DTC 32 is sel ect ed. STAR
Tester may display DTC 31, even though Functional
Test 32 is being run.
To exi t a Functional Test, depress the STAR Tester
button to the TEST (down) posi t i on.
The Functional Test DTCs will be di splayed. The
DTCs will be di splayed for about 15 seconds each
and will cycl e. The Functional Tests may be entered
and exi ted as often as desi red.
Are all Funct i onal Test s successf ul ?

If di rected here from
Pinpoint Test, RETURN to
original t est .
REFER to Air Suspension
Diagnostic Trouble
Codes and Pinpoint Test
Index.
04- 05- 2 3 S u s p e n s i o n , Co mp u t e r Co n t r o l l e d 04- 05- 2 3
DT C C o d e s I n d e x
AIR SUSPENSION DIAGNOSTIC TROUBLE CODES AND PINPOINT TEST INDEX
DTC
P i n p o i n t
Test De s c r i p t i o n
S e r v i c e
P r i o r i t y
10 Di a g n o s t i c s E n t e r e d , A u t o Te st in P r o g r e s s
11 Ve h i c l e P a s s e s
3
12 A u t o T e s t e d P a s s e d , P e r f o r m Ma n ua l I n put s
13 A u t o Te st Fa i l e d , P e r f o r m Ma n ua l I n put s
15 No Dr i v e Cy c l e Er r o r s De t e c t e d
16

E VO Di a gn o s t i c Tr o ubl e Co d e ( Re f e r t o Se c t i o n 11 - 00)
17 E VO Di a gn o s t i c Tr o ubl e Co d e ( Re f e r t o Se c t i o n 11- 00)
18
_
E VO Di a gn o s t i c Tr o ubl e Co d e ( Re f e r t o S e c t i o n 11- 00)
23
b
Fu n c t i o n a l Te st , Ve n t Re a r
26
b
Fu n c t i o n a l Te st , Co mp r e s s Re a r
28 P St e e r i n g Se l e c t S wi t c h No t De t e c t e d ( To wn Ca r On l y ) 4t h
31 Fu n c t i o n a l Te st , Ai r C o mp r e s s o r Re l a y T o ggl e
32
b
Fu n c t i o n a l Te st , Ve nt So l e n o i d To ggl e
33
b
Fu n c t i o n a l Te st , Ai r Sp r i n g So l e n o i d T o ggl e
35 Dr i v e Cy c l e Er r o r Co d e s E r a s e d OK
39 A C o mp r e s s o r Re l a y Co n t r o l Ci r c ui t Sh o r t t o Ba t t e r y 2 n d
40 A C o mp r e s s o r Re l a y Co n t r o l Ci r c ui t Sh o r t t o Gr o u n d . 2 n d
42 B Ai r Sp r i n g So l e n o i d Va l v e Sh o r t t o Gr o un d 2 n d
43 C Ai r Sp r i n g So l e n o i d Va l v e Sh o r t t o Ba t t e r y 2 n d
44 D Ve n t So l e n o i d Va l v e Sh o r t t o Ba t t e r y 2 n d
45 E Sh o r t in Ve n t So l e n o i d Va l v e Ci r c ui t 2 n d
46 F Ai r Su s p e n s i o n He i ght Se n s o r Su ppl y Ci r c ui t S h o r t e d 2 n d
51 G Un a b l e t o De t e c t L o we r i n g of Re a r 3r d
54 H Un a b l e t o De t e c t Ra i s i n g of Re a r 3r d
6 8 J Sh o r t i n Re a r Ai r Su s p e n s i o n He i ght Se n s o r Ci r c ui t 2 n d
70

Re p l a c e Co n t r o l Mo d u l e
7 1 K Ai r Su s p e n s i o n He i ght Se n s o r Ci r c ui t Op e n 3r d
72 L Di d No t De t e c t 4 Op e n a n d Cl o s e d Do o r Si gn a l s 4t h
7 4 E VO Di a gn o s t i c Tr o ubl e Co d e ( Re f e r t o S e c t i o n 11- 00)
8 0 M Co n t r o l Mo d u l e De t e c t s L o w Ba t t e r y Vo l t a ge 1st !

N Un a b l e t o En t e r Aut o Te st Di a gn o s t i c s o r Wa r n i n g L i gh t Re ma i n s
On A f t e r Ve h i c l e P a s s e s ( Co d e 11)
a If v e h i c l e i s st i l l l o w o r hi gh i n r e a r , c h e c k r i d e h e i g h t a s o u t l i n e d ,
b Fu n c t i o n a l t e s t s a f t e r d ur i n g A u t o Ma n ua l Te st .
04- 05- 2 4 Su s p e n s i o n , Co mp u t e r Co n t r o l l e d 04- 05- 2 4
PINPOINT TE ST A: DTC 39 COMPRESSOR RELAY CONTROL CIRCUIT SHORT TO BATTERY/GROUND
A1 CHECK COMPRESSOR RELAY
NOTE: The horn circuit and air suspension system use
the same type of relay. Press horn pad to ensure horn is
operating.
Remove horn relay and install compressor relay in
its place.
Repeat Auto Test.
Yes
No
HORN
RELAY
COMPRESSOR
RELAY
INSTALL relays in original
posi ti ons. If horn sounds,
GO to A2; otherwise,
REPLACE compressor
relay and REPEAT Auto
Test.
INSTALL horn relay in
original posi ti on.
REPLACE compressor
relay. REPEAT Auto Test.
0 0 0 0 D 1 D 0 O
DO JOT
TOWN CAR
OD00DD0DD
oooooo n [ [ y
POWER DISTRIBUTION BOX
DIRECTLY BEHIND BATTERY
F7661-B
COMPRESSOR
RELAY
POWER
DISTRIBUTION
BOX DIRECTLY
BEHIND BATTERY
30 AMP FUSE
AIR SUSPENSION PUMP
CROWN VICTORIA AND GRAND MARQUIS
F720S-C
04=05- 2 5 Su s p e n s i o n , C o mp u t e r C o n t r o l l e d 0 4 - 0 5 - 2 5
PINPOINT TEST A: DTC 39 COMPRESSOR RELAY CONTROL CIRCUIT SHORT TO BATTERY/GROUND (Cont i nued)
A2 CHECK FOR HARNESS SHORT
Turn air suspension switch OFF.
Disconnect control module connectors.
Remove compressor relay from power di stri buti on
box.
Yes
No

REPLACE control
module. REPEAT Auto
Test.
GO to A3.
HORN
RELAY
COMPRESSOR
RELAY
DDDDDlDDffl
O CD D
O D D
TOWN CAR
F7661-B
HORN
RELAY
DOQDDDODD
.COMPRESSOR
RELAY
POWER
DISTRIBUTION
BOX DIRECTLY
BEHIND BATTERY
30 AMP FUSE
AIR SUSPENSION PUMP
F7206-C
Turn air suspension swi tch ON.
Measure voltage between Pins 23 and 6 on harness
side of control module connectors.
Does t he met er i ndi cat e zero vol t s?
V
WHITE
MODULE CONNECTOR
WHITE
MODULE CONNECTOR
F7208-B
A3 CHECK THE METER READING
Check the meter reading.
Does t he met er i ndi cat e 12 vol t s?
Yes
No
SERVICE short to battery
in Circuit 420. REPEAT
Auto Test.
GO t o A 1.
04- 05- 2 6 Su s p e n s i o n , C o mp u t e r Co n t r o l l e d
04- 05- 2 6
PINPOINT TEST B: DTC 42 AIR SPRING SOLENOID VALVE SHORTED TO GROUND
B1 CHECK CIRCUIT 429 (P / LG) FOR SHORT TO GROUND
Turn air suspension swi tch OFF.
Measure voltage between Pin 13 and 6 of control
module connectors.
Yes
No

GO t o B3.
GO t o B2.
WHITE
MODULE CONNECTOR
WHITE
MODULE CONNECTOR
F7210-B
NOTE: If Circuit 1072 (T/ W)or 1071 (BR/PK) is shorted
t o ground, the corresponding spring solenoid valve will
always be open, even with the ignition swi tch OFF.
B2 CHECK THE METER READING
Does the met er i ndi cat e zero vol t s?
Yes
No
Circuit 1071 (BR/PK) has
possi ble short to ground.
GO t o B3 before
servicing Circuit 1071
(BR/PK).
GO to B1.
04- 05 - 2 7 S u s p e n s i o n , C o mp u t e r Co n t r o l l e d 04- 05- 2 7
PINPOINT TEST B: DTC 42 AIR SPRING SOLENOID VALVE SHORTED TO GROUND (Cont i nued)
B3 CHECK 30 AMP FUSE
Remove and inspect 30 amp fuse for Circuit 1053
(LB/PK) (locat ed in power di stri buti on box).
30 AMP FUSE
FOR CIRCUIT 1053 LB/PK
Yes
DtmiDtn
TOWN CAR
No
DIRECTLY BEHIND BATTERY F7664-C
.COMPRESSOR
RELAY
OD0D0D
5V
POWER
DISTRIBUTION
BOX DIRECTLY
BEHIND BATTERY
30 AMP FUSE
AIR SUSPENSION PUMP
F7206-C
Is f use bl own?
SERVICE short t o ground
in Circuit 1053 (LB/ PK).
REPLACE 30 amp fuse.
NOTE: Circuit 1053
LB / PK) feeds power to
the spring solenoid
valves, vent solenoid and
compressor relay.
CHECK for shorts at the
compressor assembly.
REPEAT Auto Test.
GO to B4.
B4 CHECK CIRCUIT 416 FOR SHORT TO GROUND
Measure voltage between Pins 25 and 6 of control
module connect ors.
Yes
No
WHITE
MODULE CONNECTOR
WHITE
MODULE CONNECTOR
F7211-B
REPLACE control
module. REPEAT Auto
Test.
GOt o B5.
B5 CHECK THE VOLTMETER READING
Check the meter readi ng.
Yes
No
in Circuit 1072 (T/W)
and/ or Circuit 1071
(BR/PK). REPEAT Auto
Test.
GO to B4.
04- 05- 2 8 Su s p e n s i o n , C o mp u t e r Co n t r o l l e d
04- 05- 2 8
PINPOINT TEST C: DTC 43 AIR SPRING SOLENOID VALVE SHORT TO BATTERY
C1 CHECK LH AIR SPRING SOLENOID CIRCUIT
NOTE: The resistance measurements in this procedure
check the condition of the air spring solenoid valve coi l
and diode. A digital ohmmeter will not pass enough
current through the diode to check its condition. Use
Rotunda Inductive Dwell-Tach-Volt-Ohm Tester
059-00010 or equivalent analog (needle-type) meter.
NOTE: Air suspension swi tch must be ON for thi s
t est .
Measure resi stance between Pins 13 and 1 on
control module connectors.
Reverse leads and measure resistance again
between Pins 13 and 1.
Meter should indicate 15 to 18 ohms one way, and 5
to 10 ohms less the other way.
Are t he met er readi ngs as i ndi cat ed above?
Yes
No

Solenoid valve and wiring
OK. GO to 02 .
SERVICE LH air spring
valve or wiring.
WHITE
MODULE CONNECTOR
WHITE
MODULE CONNECTOR
F7220-B
04- 05- 2 9
: : ; zi : : r r : zzr : : j
PINPOINT TEST C: DTC 43 AIR SPRING SOLENOID VALVE SHORT TO BATTERY (Conti nued)
C2 CHECK RH AIR SPRING SOLENOID VALVE CIRCUIT
416 (LB/ BK)
Air suspension swi tch must be ON for thi s t est .
Meter should indicate 15 to 18 ohms.
Are t he met er readi ngs as i ndi cat ed above?
Yes
No
REPLACE control
module. REPEAT Auto
Test.
GO to C3.
C3
F7258-B
CHECK FOR SHORT TO BATTERY AND REVERSED
CIRCUITS
Air suspension swi tch must be ON and control
module connectors di sconnected.
Raise vehicle on hoi st. Refer to Section 00-02.
Disconnect air spring solenoid valve connector.
Inspect connector to ensure that Circuit 1053
(LB/PK) and 1072 (T/W) or 1053 (LB/ PK) and 1071
(BR/PK) are not reversed in the connector.
If ci rcui t s are reversed install ci rcui ts in the correct
terminals and repeat Auto Test.
Yes
No
REPLACE air spring
solenoid valves. REPEAT
Auto Test.
in Circuit 1072 (T/W)
and/ or 1071 (BR/PK).
REPEAT Auto Test.
CIRCUIT 1071 (LH) F7213-B
Measure voltage between Circuit 1072 (T/W) and
ground and/or Circuit 1071 (BR/PK) and ground.
o Measure voltage between Circuit 1053 (LB/PK) and
ground.
Meter should indicate battery voltage.
Are t he met er readi ngs as speci f i ed?
Su s p e n s i o n , C o mp u t e r Co n t r o l l e d
04- 05- 30
PINPOINT TEST D: DTC 44 VENT SOLENOID VALVE SHORT TO BATTERY
01 CHECK HARNESS CONNECTOR
NOTE: The resistance measurements in thi s procedure
check the condition of the vent solenoid valve coil and
diode. A digital ohmmeter will not pass enough current
through the diode to check its condition. Use Rotunda
Inductive Dwell-Tach-Volt-Ohm Tester 059-00010 or
equivalent analog (needle-type) meter.
Remove air cleaner assembly and plasti c shield
protecti ng air compressor assembly as outlined.
Disconnect air compressor connector.
Inspect connector for obvious damage or corrosi on.
Ensure that wire terminals are locat ed correctly and
fully seated in connector.
CIRCUIT 421 (PK) v CIRCUIT (1053 LB/PK)
Yes
No

GO t o D2 .
CIRCUIT 57 W \ ^
COMPRESSOR HARNESS CONNECTOR
CIRCUIT (538 GY/R
TOWN CAR)
F7666-C
Inspect air compressor assembly connector to
ensure it is wired correct ly.
COMPRESSOR
ASSY
CONNECTOR
COMPRESSOR
ASSY
Are harness c onne c t or s f unct i onal ?
F7215-A
04- 05- 31 Su s p e n s i o n . . Co mp u t e r Co n t r o l l e d 04- 05 - 31
PINPOINT TE ST D: DTC 44 VENT SOLENOID VALVE SHORT TO BATTERY (Continued)
D2 CHECK HARNESS CIRCUIT 1053 (LB/PK)
Disconnect vent solenoid connector.
Turn air suspension switch ON.
Measure voltage between Circuit 1053 (LB/ PK) and
ground at harness connector.
Measure voltage between Circuit 421 (PK) and
ground at harness connector.
Meter should indicate zero volts.
Are the meter readi ngs a s speci f i ed?
Yes
No

GO to D5.
GO to D3.
F7216-C
D3 CHECK THE READINGS
Check the voltage readings.
Is Ci rcui t 421 (PK) at ba t t e r y vol t age and Ci rcui t
1053 (LB/ PK) at zero vol t s?
Yes
No

INSTALL circuits in
correct terminals.
GO to D4.
D4 CHECK THE METER
Check the voltmeter readings.
Are Ci rcui t s 1053 (LB/ PK) and 421 (PK) at
bat t er y vol t age?
Yes
No
in Circuit 421 (PK).
REPEAT Auto Test.
GO to D2.
PINPOINT TE ST D: DTC 44 VENT SOLENOID VALVE SHORT TO BATTERY (Continued)
D5 CHECK RESISTANCE OF VENT SOLENOID
Measure resistance between blue wire and green
wire on compressor assembly connector.
Reverse leads and measure resi stance again
between blue and green wi res.
Meter should indicate 25 t o 35 ohms one way, less
than 25 ohms the other way.
Is t he ohmmet er readi ng as speci f i ed?
Yes
No
REPLACE control
module. REPEAT Auto
Test.
GO to D6.
COMPRESSOR ASSY
F7217-A
D6 CHECK THE OHMMETER READING
Check the meter readings.
Are bot h readi ngs l ess t han 25 ohms?
Yes
No
REPLACE compressor
assembly. REPEAT Auto
Test. If DTC 44 is
repeated, REPLACE
control module. REPEAT
Auto Test.
GO to D5.
04- 05 - 33 Su s p e n s i o n , Co mp u t e r C o n t r o l l e d 04- 05 - 33
PINPOINT TE ST E: DTC 45 VENT SOLENOID SHORT TO GROUND
E1 CHECK CIRCUIT 420 FOR SHORT TO GROUND
NOTE: If Circuit 420 (DB/Y) (compressor) or 421 (PK)
(vent solenoid valve) is shorted to ground, that
component will always be ON, even wi th the ignition
swi tch OFF.
module connectors.
Meter should indicate 12 volts.
Yes
No

GO to E3.
GOt o E2.
v
WHITE
MODULE CONNECTOR
WHITE
MODULE CONNECTOR
F7208-B
E2 CHECK THE METER READING
Yes
No
Circuit 420 has short to
possi ble ground. GO to
E3 before servicing
Circuit 420.
GO t o E 1.
E3 CHECK 30 AMP AIR SUSPENSION FUSE
Remove and inspect 30 amp fuse in power
distribution box.
Is t he f use bl own?
Yes
No
in Circuit 1053 (LB/PK).
REPEAT Auto Test.
GO to E4.
E4 CHECK CIRCUIT 421 FOR SHORT TO GROUND
module connectors.
Meter should indicate 12 vol t s.
Yes
No
REPLACE control
module. REPEAT Auto
Test.
Go to E5.
WHITE
MODULE CONNECTOR
WHITE
MODULE CONNECTOR
F7248-B
04- 05- 34 Su s p e n s i o n , C o mp u t e r Co n t r o l l e d 04- 05 - 34
PINPOINT TEST E: DTC 45 VENT SOLENOID SHORT TO GROUND (Cont i nued)
E5 VERIFY METER READING
Yes
No
in Circuit 420 and/ or
Circuit 421. REPEAT Auto
Test. If DTC 45 is
repeated, REPLACE
Auto Test.
GOt o E4.
Verify meter reading.
Does the meter i ndi cate zero vol ts?
Yes
No
in Circuit 420 and/ or
Test. If DTC 45 is
repeated, REPLACE
Auto Test.
GOt o E4.
PINPOINT TEST F: DTC 46 AIR SUSPENSION HEIGHT SENSOR SUPPLY CIRCUIT SHORTED
F1 CHECK SENSOR
Yes
No
GOt o F2.
REPLACE air suspension
height sensor. REPEAT
Auto Test. If DTC 46 is
again recei ved,
REPLACE control
module. REPEAT Auto
Test.
Turn air suspension swi t ch OFF.
Disconnect air suspension height sensor electri cal
connector.
Lower vehi cle.
Perform Auto Test.
Ignore all DTCs except Code 46.
Is DTC 46 recei ved?
Yes
No
GOt o F2.
Auto Test. If DTC 46 is
again recei ved,
REPLACE control
module. REPEAT Auto
Test.
F2 CHECK CIRCUIT 431 FOR SHORT TO BATTERY
Yes
No
GO to F4.
GO to F3.
module connectors.
Meter should indicate zero volts.
Yes
No
GO to F4.
GO to F3.
V
4 -
Yes
No
GO to F4.
GO to F3.
^
u
^- u ^ ^ u u
WHITE WHITE
MODULE CONNECTOR MODULE CONNECTOR
F7223-B
Yes
No
GO to F4.
GO to F3.
F3 CHECK THE METER READING
Yes w>
No
in Circuit 429 (P/LG).
REPEAT Auto Test.
GO t o F2 .
Yes w>
No
REPEAT Auto Test.
GO t o F2 .
04- 05- 35 Su s p e n s i o n , C o mp u t e r Co n t r o l l e d 0 4 - 0 5 - 3 5
PINPOINT TE ST F: DTC 46 AIR SUSPENSI ON HEIGHT SENSOR SUPPLY CI RCUI T SHORTED (Continued)
F4 CHECK CIRCUIT 431 FOR SHORT TO GROUND
Measure resistance between Pins 22 and 6 of
Meter should indicate greater than 10,000 ohms.
Does meter read more than 10,000 ohms?
Yes
No
REPLACE control
module. REPEAT Auto
Test.
REPEAT Auto Test.
WHITE
MODULE CONNECTOR
WHITE
MODULE CONNECTOR
F7223-B
PINPOINT TEST G: DTC 51 UNABLE TO DETECT LOWERING OF REAR
G1 PERFORM FUNCTIONAL TEST
NOTE: This test must be performed in a quiet
environment.
Perform Functional Test 32. Refer t o Functional
Procedure.
During Functional Test 32, the vent solenoid valve
locat ed in compressor assembly should cycle ON
and OFF repeatedly (one second ON, one second
OFF) during the t est . As the valve cycl es, a cli cki ng
noise can be heard by listening at the front of the LH
front wheel opening.
Does valve c y c l e ?
Yes
No

GO to G5.
GO t o G2 .
G2 CHECK HARNESS
Remove air cleaner intake tube and air compressor
plasti c shield as outlined.
Inspect compressor for obvious signs of water
entry.
Disconnect compressor connector. Inspect
connector for corrosi on or obvious damage. Ensure
terminals are fully seat ed in connector.
Measure voltage between Circuit 421 (PK) in
harness connector and a good chassi s ground.
Meter should pulse between zero volt s and battery
voltage (during Functional Test 32).
Does vol t age pul se?
Yes
No
REPLACE compressor
Test.
GO to G3.
GOOD
CHASSIS
GROUND
F7225-A
PINPOINT TEST G: DTC 51 UNABLE TO DETECT LOWERING OF REAR (Cont i nued)
G3 CHECK VENT SOLENOID VALVE CIRCUIT 1053
(LB/ PK)
Measure voltage between Circuit 1053 (LB/PK) at
harness connector and a good chassi s ground.
Is t here bat t ery vol t age?
Yes
No

GOt o G4.
1053 (LB/PK). REPEAT
Auto Test.
GOOD
CHASSIS
GROUND
F7226-A
G4 CHECK CIRCUIT 421 (PK) FOR OPEN
Measure resistance between Circuit 421 (PK) at
compressor connector and Pin 24 of control module
connector.
Meter should indicate less than 10 ohms.
Yes
No
REPLACE control
module. REPEAT Auto
Test.
421 (PK). REPEAT Auto
Test.
WHITE
MODULE CONNECTOR
F7227-B
G5 CHECK AIR SPRING SOLENOID VALVES
Enter Functional Test 33. Refer to Functional Test
Di agnosti cs.
Leave air suspension swi tch ON and raise vehicle
on hoi st. Refer to Section 00-02.
Feel each spring solenoid valve to check for ON and
OFF cycli ng. A cli cki ng noise will be heard when
they cycl e, but each solenoid valve must be felt to
ensure both are operati ng.
Are bot h val ves cy cl i ng?
Yes
No
GO t o G11.
DO NOT EXIT Functional
Test 33. GO to G6.
G6 CHECK AIR SPRING SOLENOID VALVE HARNESS AND
CONTROL MODULE
Disconnect inoperative air spring solenoid valve
connector.
Measure voltage between both ci rcui ts in solenoid
valve connector.
Meter should pulse between zero volts and battery
voltage.
Are t her e vol t age pul ses?
Yes
No

REPLACE inoperative air
spring solenoid valve.
REPEAT Auto Test.
EXIT Functional Test 33.
GO t o G7 .
F7259-A
G7 CHECK AIR SPRING SOLENOID VALVE BATTERY FEED
CIRCUIT 1053 (LB/PK)
Measure voltage between Circuit 1053 (LB/PK) at
air spring solenoid valve connector and a good
chassi s ground.
Is t here 11 vol t s or more?
Yes
No
GO to G8.
1053(LB/PK). REPEAT
Auto Test.
PINPOINT TE ST G: DTC 51 UNABLE TO DETECT LOWERING OF REAR (Cont i nued)
G8 CHECK CONTINUITY OF SPRING SOLENOID VALVE
CONTROL CIRCUITS
Measure resi stance of spring solenoid control
circuit between solenoid valve connector and black
control module connector as shown.
Yes
No
GO to G9.
between control module
and solenoid valve
connector. REPEAT Auto
Test.
LH AIR SPRING
SOLENOID VALVE
WHITE MODULE CONNECTOR
LH SPRING
SOLENOID
CONNECTOR
RH AIR SPRING
SOLENOID VALVE
WHITE
MODULE CONNECTOR
RH SPRING
SOLENOID
CONNECTOR
F7228-B
PINPOINT TEST G: DTC 51 UNABLE TO DETECT LOWERING OF REAR (Continued)
G9 CHECK LH AIR SPRING SOLENOID CIRCUITS
The resistance measurements in this procedure
check the condition of the air spring solenoid valve
coi l .
NOTE: Air suspension swi tch must be ON for thi s
t est .
module connectors (checking LH).
Meter should indicate 15 to 18 ohms one way, and 5
to 10ohms less the other way.
Is t he met er readi ng f or the sol enoi d valve as
speci f i ed?
Yes
No
GO t o G10.
REPLACE damaged
REPEAT Auto Test.
F7220-B
G10 CHECK RH AIR SPRING SOLENOID CIRCUITS
Reverse leads and measure resi stance again
between Pins 25 and 1 (RH solenoid valve).
Meter should indicate 15 to 18 ohms one way, 5 to
10 ohms less the other way.
Is t he met er readi ng as speci f i ed f or t he sol enoi d
val ve?
Yes
No
GO t o G13.
GO t o G 11.
WHITE
MODULE CONNECTOR
WHITE
MODULE CONNECTOR
F7258-B
PINPOINT TEST Q: DTC 51 UNABLE TO DETECT LOWERING OF REAR (Cont i nued)
G11 CHECK HEIGHT SENSOR INSTALLATION
Yes
No
REPLACE control
module. REPEAT Auto
Test. If DTC 51 occurs
again, GOt o G14.
GO t o G12.
Leave STAR Tester in Functional Test mode, but do
not select a Pinpoint Test (STAR Tester button
should be pressed down).
Leave air suspension switch ON.
Making sure that STAR t est er is accessi bl e, raise
vehicle on hoist. Refer to Section 00-02.
Check that air suspension height sensor is at t ached
to both ball studs.
Check upper and lower air suspension height sensor
mounting bracket s for obvious damage.
Are air suspensi on hei ght sensor at t achment s
OK?
f j j \ BALL STUD
| 3 y)ATTACHING POINTS
AIR SUSPENSION HEIGHT SENSOR 5359 F6425-C
Yes
No
REPLACE control
module. REPEAT Auto
again, GOt o G14.
GO t o G12.
G12 INSPECTION OF HEIGHT SENSOR FITTED TO BALL
STUDS
Yes
No
PUSH air suspension
height sensor onto ball
studs. ENSURE air
suspension height sensor
fits securely on both ball
studs. If not, REPLACE air
suspension height
sensor. LOWER vehi cle.
REPEAT Auto Test.
GO t o G13.
Are one or bot h ends of f bal l st uds?
Yes
No
PUSH air suspension
studs. ENSURE air
suspension height
REPEAT Auto Test.
GO t o G13.
G13 CHECK HEIGHT SENSOR MOUNTING BRACKETS FOR
DAMAGE
Yes
No
SERVICE bracket s.
LOWER vehicle. REPEAT
Auto Test.
GO t o G11.
Check upper and lower air suspension height
Are t he air suspensi on hei ght sensor
at t achment s bent or damaged?
Yes
No
SERVICE bracket s.
Auto Test.
GO t o G11.
G14 CHECK AIR FLOW THROUGH SPRING SOLENOID
VALVES
Yes
No
CONNECT solenoid valve
air lines and heat shi elds.
GO t o G15.
REPLACE inoperative
RESUME Function Test
33. If cycled solenoid
does not release air,
REPLACE control
module. REPEAT Auto
Test.
CAUTION: Rear of vehi cl e must be suppor t e d by
f r ame. If rear is suppor t ed by axl e, rear of vehi cl e
wi l l l ower dur i ng t hi s t est .
NOTE: Some air must be in each air rear spring to
perform thi s t est .
Disconnect air lines at both spring solenoid valves.
Remove air spring solenoid heat shi elds, if so
equi pped.
Enter Functional Test 33 to cycle air spring solenoid
valve. Refer to Auto Test.
Does ai r f l ow f r om each air spr i ng sol enoi d valve
when i f i s c y c l e d open?
Yes
No
CONNECT solenoid valve
air lines and heat shi elds.
GO t o G15.
REPLACE inoperative
RESUME Function Test
33. If cycled solenoid
does not release air,
REPLACE control
module. REPEAT Auto
Test.
04- 05- 41 S u s p e n s i o n , C o mp u t e r Co n t r o l l e d 04- 05- 41
G15 CHECK FOR ADEQUATE SPRING PRESSURE
Yes E>
No
GOt o G17 .
GOt o G16.
Lower Vehicle. There should be nothing supporting
vehicle except the wheels.
Cycle ignition swi tch (RUN-OFF-RUN) and driver
side door to start automatic trim height adjustment.
Allow vehi cle to est abli sh automatic trim height.
Measure distance between center of lip rear wheel
opening and bottom of wheel (not bottom of t i re).
Measurement should be a minimum of 610-635mm
(24-26 inch). This is vehi cle trim height.
Is t he vehi cl e hi gher?
Yes E>
No
GOt o G17 .
GOt o G16.
G16 CHECK FOR VEHICLE LOW
Yes
No
GO to G20.
GO t o G15.
Measurement should be a minimum of 610-635mm
(24-25 inch). This is vehi cle trim height.
Is t he vehi cl e l ow?
Yes
No
GO to G20.
GO t o G15.
G17 CHECK AIR FLOW THROUGH LINES
Yes
No
EXIT Functional Test 23
before rear of vehicle
becomes t oo low. GO to
G13.
GO t o G18.
CAUTION: Rear of vehi cl e may d r o p rapi dl y once
Funct i onal Test 23 is e nt e r e d.
Remove air cleaner assembly and plasti c shield
from compressor assembly as outlined.
Disconnect air line at compressor dryer.
Enter Functional Test 23vent rear. Refer t o
Functional Tests. Air should flow from di sconnected
air line and vehicle should drop about 25.4 mm (1.0
inch) in 10-20 seconds.
Does t he air f l ow f r o m ai r li ne and vehi cl e dr op?
Yes
No
EXIT Functional Test 23
before rear of vehicle
becomes t oo low. GO to
G13.
GO t o G18.
G18 CHECK AIR FLOW THROUGH LINES
Yes
No
SERVICE air line from
compressor to solenoid
valves for blockage or
ki nks. REPEAT Auto Test.
GO t o G19.
Check air flow through lines.
Is t here l i t t l e or no air f l o wi n g, vehi cl e does not
l ower or l owers very sl owl y ?
Yes
No
SERVICE air line from
compressor to solenoid
valves for blockage or
ki nks. REPEAT Auto Test.
GO t o G19.
G19 CHECK AIR FLOW THROUGH COMPRESSOR AIR
DRYER
Yes
No
REPLACE compressor air
drier. INSTALL
REPEAT Auto Test.
REPLACE air compressor
Test.
Remove compressor air drier from compressor as
outlined.
Connect air line to compressor air drier.
Enter Functional Test 23vent rear.
Is t her e l i t t l e or no ai r f l ow t hr ough c ompr e ssor
ai r dr y e r ?
Yes
No
drier. INSTALL
REPEAT Auto Test.
REPLACE air compressor
Test.
G20 INFLATE REAR SPRINGS
Yes
No
GOt o G17 .
GOt o G21.
Enter Functional Test 26compress rear. Refer to
Functional Tests.
Exit Functional Test 26 when rear of vehi cle is
rai sed about 50mm (2 inch) above tri m height.
Distance should be about 660-685mm (26-27 inch)
from bottom of wheel (not bottom of t i re) and center
of rear wheel lip opening.
Does t he rear of vehi cl e rai se?
Yes
No
GOt o G17 .
GOt o G21.
G21 COMPRESSOR RUNS, REAR OF VEHICLE DOES NOT
RAISE
Yes !>
No
EXIT Function Test 26.
GO to G23.
GOt o G22.
Is t he compr essor runni ng but t he rear of t he
vehi cl e not rai si ng?
Yes !>
No
GO to G23.
GOt o G22.
G22 COMPRESSOR DOES NOT RUN
Yes
No
GOt o G20.
Is t he compr essor not runni ng and t he rear of t he
vehi cl e does not rai se?
Yes
No
GOt o G20.
G23 CHECK FOR AIR FLOW FROM AIR COMPRESSOR
Yes
No
SERVICE blocked or
kinked air line. REPEAT
Auto Test.
GO to G24.
CAUTION: Support rear of vehi cl e on f rame. If rear of
vehi cl e i s suppor t ed by axl e, air spri ngs wi l l be
damaged duri ng thi s t est .
Raise rear of vehi cle. Refer to Section 00-02.
Disconnect air line from compressor air drier.
Enter Functional Test 26compress rear.
Air should flow from compressor air drier while
compressor is running.
Does air f l ow f r o m compr essor air dr y er ?
Yes
No
SERVICE blocked or
kinked air line. REPEAT
Auto Test.
GO to G24.
G24 CHECK AIR FLOW WITH COMPRESSOR AIR DRYER
REMOVED
Yes
No
drier. REPEAT Auto Test.
CAUTION: Ent er
Funct i onal Test 26 whi l e
i n Funct i onal Test and
f i l l air spri ngs f or about
90 seconds bef or e
l oweri ng rear of vehi cl e
t o prevent damage t o
vehi cl e or component s.
REPLACE compressor
Test.
CAUTION: Ent er
f i l l ai r spri ngs f or about
90 seconds bef or e
vehi cl e or c ompone nt s.
Remove compressor air drier from air compressor
as outlined.
Air should flow from compressor air dryer fitting on
compressor while compressor is running.
Does air f l ow f r o m compr essor ai r dr y er ?
Yes
No
drier. REPEAT Auto Test.
CAUTION: Ent er
f i l l air spri ngs f or about
90 seconds bef or e
vehi cl e or component s.
REPLACE compressor
Test.
CAUTION: Ent er
f i l l ai r spri ngs f or about
90 seconds bef or e
vehi cl e or c ompone nt s.
PINPOINT TEST H: DTC 54 UNABLE TO DETECT RAISING OF REAR
H1 PERFORM COMPRESSOR FUNCTIONAL TEST
Yes
No
GO to H9.
Test 31. GO t o H2.
Enter Functional Test 31 compressor relay t oggle.
Refer to Auto Test /Funct i onal Test.
Compressor should cycle ON and OFF repeatedly
(one second ON, one second OFF) during thi s t est .
Cycling of the compressor can be heard from the LH
front wheel well.
Does compr essor c y c l e ?
Yes
No
GO to H9.
Test 31. GO t o H2.
PINPOINT TEST H: DTC 54 UNABLE TO DETECT RAISING OF REAR (Cont i nued)
TEST STEP RESULT

ACTION TO TAKE
H2 MEASURE VOLTAGE AT COMPRESSOR
Remove air cleaner assembly and compressor
plasti c shield as outlined.
Disconnect compressor electri c connector.
Measure voltage between Circuits 538 (GY/ R) and
57 (BK) of compressor harness connector.
Meter should pulse between battery voltage and
zero volts (during Functional Test 31).
Does t he met er pul se bet ween bat t er y vol t age
and zero vol t s?
Yes

CONNECT compressor
connector. WAIT 10
minutes for compressor
internal circuit breaker to
cool down and cl ose.
Circuit breaker may have
opened due to excessi ve
compressor run-time
during di agnost i cs. If
compressor does not
start to cycle on and off
after 10 minutes,
REPLACE compressor.
REPEAT Auto Test.
Test 31. GO to H3.
0)
V
+
? f
No

CONNECT compressor
connector. WAIT 10
minutes for compressor
internal circuit breaker to
cool down and cl ose.
Circuit breaker may have
opened due to excessi ve
compressor run-time
during di agnost i cs. If
compressor does not
start to cycle on and off
after 10 minutes,
REPLACE compressor.
REPEAT Auto Test.
Test 31. GO to H3.
Q
CIRCUIT- T \ V <
57 BK I X ;
& -
CIRCUIT
^ - 538 GY/R
F7233-D
H3 CHECK COMPRESSOR RELAY
Compressor relay should cycle ON and OFF (one
second ON, one second OFF) during this test. As
the relay cycles a cli cki ng noise will be heard.
Does rel ay cycl e?
Yes
No

GO t o H7.
GO to H4.
H4 CHECK COMPRESSOR RELAY REPLACEMENT
The horn circuit and the air suspension system use
the same type of relay. Press horn pad to ensure
horn is operating.
Remove compressor relay and install horn relay in
its place.
Repeat Auto Test.
Yes
No

INSTALL relays in original
positions. GO to H5.
INSTALL horn relay in
original position.
REPLACE compressor
relay. REPEAT Auto Test.
H5 CHECK RELAY BATTERY FEED CIRCUIT 1053 (LB/ PK)
Measure voltage between Circuit 1053 (LB / PK) at
relay terminal and a good chassi s ground.
Is t here 11 vol t s or mor e?
Yes
No

GO to H6.
(LB/PK) for open.
REPEAT Auto Test.
TOWN CAR
n m
D D D D D 1 D D D 1
IDDDoDDD
DoO

O D D
a a a
GOOD
CHASSIS
GROUND
DIRECTLY BEHIND BATTERY F7670-B
CROWN VICTORIA AND
GRAND MARQUIS
oooooo oQ /
GOOD
CHASSIS
GROUND
F7235-C
H6 CHECK RELAY CONTROL CIRCUIT 420 (DB/ Y)
Disconnect control module connect ors.
Measure resi stance of Circuit 420 (DB/Y) between
power distribution box and Pin 23 of control module
black connector.
Is r esi st ance l ess t han "lOohms?
Yes
No
REPLACE control
module. REPEAT Auto
Test.
420 (DB/ Y). REPEAT
Auto Test.
TOWN CAR

DDDDDSDDtl
IDQDoODD
WHITE
MODULE CONNECTOR
F7671-C
CROWN VICTORIA
AND
GRAND MARQUIS
oooooo oQ /
WHITE
MODULE CONNECTOR
F7236-C
H7 CHECK CIRCUIT 417 ( P / 0) FOR CONTINUITY
Remove air compressor relay from power
distribution box.
Disconnect air compressor connector.
Measure resi stance of Circuit 417 (P/O) between
power distribution box and compressor connector.
Resistance should be less than 5 ohms.
Yes
No

GOt o H8.
538 (GY/R). REPEAT
Auto Test.
COMPRESSOR
CONNECTOR
TOWN CAR
538 GY/R
san
UDDDIDDDi
BHUTU
05 0

F7672-C
CROWN VICTORIA AND
GRAND MARQUIS
COMPRESSOR
CONNECTOR
C I R C U I T
538 GY/R POWER DISTRIBUTION BOX
F7237-C
04- 05- 47
S u s p e n s i o n , Co^p^M Qw&to&<&
04- 05- 47
PINPOINT TEST H: DTC 54 UNABLE TO DETECT RAISING OF REAR (Conti nued)
H8 CHECK GROUND CIRCUIT 57 (BK)
Measure resistance between Circuit 67 (BK) at
compressor connector and a good chassi s ground.
Is resi st ance less than 5 ohms?
Yes
No
GOOD
CHASSIS
GROUND
57 BK
F7261-A
REPLACE compressor
Test.
57. REPEAT Auto Test.
H9 CHECK AIR SPRING SOLENOID VALVES
Enter Functional Test DTC 33. Refer to Pinpoint Test
AB.
Leave air suspension swi t ch ON and raise vehicle
on hoi st. Refer to Secti on 00-02.
Feel both spring solenoid valves t o see if they are
cycling ON and OFF. A cli cki ng noise will be heard
when they cycl e, but each solenoid valve must be
felt to ensure that both are operati ng.
Are bot h sol enoi d val ves cy cl i ng?
Yes
No

f >
GO t o H15.
Test 33. GO t o H10.
H10 CHECK AIR SPRING SOLENOID VALVE HARNESS AND
CONTROL MODULE CIRCUITS
Disconnect inoperative spring solenoid valve
connector.
Measure voltage between both circuits in
connector.
Meter should pulse between zero volts and battery
voltage.
Are t her e met er pul ses?
Yes
No
F7259-A
>
REPLACE inoperative
REPEAT Auto Test.
GO t o H11.
04- 05- 48
H11 CHECK AIR SPRING SOLENOID VALVE BATTERY FEED
CIRCUIT 1053 L B/ P K)
Yes
No l >
GO t o H12.
SERVICE open in circuit
Auto Test.
Measure voltag
spring solenoid
ground.
Meter should in
Is there 11 volt
105
e between ^
valve conne
dicate batte
s or more?
H
TT1
M l
/J U l
114 ( O/ R) circuit at
j ct or and a good chassis
>ry voltage.
\ GOOD
CHASSIS
"T" GROUND
F7260-C
Yes
No l >
GO t o H12.
SERVICE open in circuit
Auto Test.
PINPOINT TE ST H: DTC 54 UNABLE TO DETECT RAISING OF REAR (Conti nued)
H12 CHECK CONTINUITY OF SPRING SOLENOID VALVE
CONTROL CIRCUITS
Turn air suspension swi tch off.
Measure resi stance of spring solenoid valve control
circuit between solenoid valve connector and
control module connector as shown.
LH AIR SPRING
SOLENOID VALVE
Yes
No

GO t o H13.
SERVICE open in ci rcui t
between control module
and solenoid valve
connector. REPEAT Auto
Test.
WHITE MODULE CONNECTOR
RH AIR SPRING
SOLENOID VALVE
LH SPRING
SOLENOID
CONNECTOR
WHITE
MODULE CONNECTOR
RH SPRING
SOLENOID
CONNECTOR
F7228-B
H13 CHECK LH AIR SPRING SOLENOID CIRCUITS
NOTE: Air suspension swi tch must be ON for this
test.
control module connectors (checki ng LH).
Is t he met er readi ng as speci f i ed?
Yes
No

GO t o H14.
REPLACE damaged
REPEAT Auto Test.
WHITE WHITE
F7220-B
H14 CHECK RH AIR SPRING SOLENOID VALVE CIRCUITS
Is t he met er readi ng f or t he spr i ng sol enoi d valve
as speci f i ed?
Yes
No

GO t o H15.
REPLACE damaged
REPEAT Auto Test.
WHITE WHITE
F7258-B
04- 05- 51 S u s p e n s i o n , C o mp u t e r Co n t r o l l e d 0 4 - 0 5 - 5 1
PINPOINT TEST H: OTC 54 UNABLE TO DETECT RAISING OF REAR (Cont i nued)
TEST STEP RESULT t > ACTION TO TAKE
H15 CHECK HEIGHT SENSOR INSTALLATION
Yes
No
REPLACE control
module. REPEAT Auto
again, GOt o H20.
GO t o H16.
Leave STAR Tester in Functional Test mode, but do
not select a Functional Test (STAR t est er button
should be pressed down).
Leave air suspension swi tch ON.
Raise vehicle on hoist. Refer t o Section 00-02.
Check that air suspension height sensor is at t ached
to both ball st uds.
Check that upper and lower mounting bracket s are
not bent or damaged.
Are air suspensi on hei ght sensor at t achment s
OK?
Il l } \ BALL STUD
j j = | ÂTTACHING POINTS
AIR SUSPENSION HEIGHT SENSOR 5359
F 6
425-C
Yes
No
REPLACE control
module. REPEAT Auto
again, GOt o H20.
GO t o H16.
H16 INSPECTION OF HEIGHT SENSOR FITTED TO BALL
STUDS
Yes
No
PUSH air suspension
studs. ENSURE air
suspension height
REPEAT Auto Test.
GO t o H17.
Are one or bot h ends of f bal l st uds?
Yes
No
PUSH air suspension
studs. ENSURE air
suspension height
REPEAT Auto Test.
GO t o H17.
H17 CHECK HEIGHT SENSOR MOUNTING BRACKETS FOR
DAMAGE
Yes
No
SERVICE bracket s.
Auto Test.
GOt oH18.
Are t he air suspensi on hei ght sensor
at t achment s bent or damaged?
Yes
No
SERVICE bracket s.
Auto Test.
GOt oH18.
H18 CHECK FOR AIR FLOW FROM AIR COMPRESSOR
Yes
No
CONNECT air line to
compressor air drier. GO
to H20.
GO t o H19.
Lower and support rear of vehi cle. Refer to Section
00-02.
CAUTION: Support rear of vehi cl e on f rame. If
rear of vehi cl e is suppor t ed by axl e, air spri ngs
wi l l be damaged duri ng t hi s t est .
Disconnect air line from compressor air drier.
Air should flow from compressor air drier while
compressor is running.
Does t he air f l ow f r om compr essor air dryer?
Yes
No
CONNECT air line to
compressor air drier. GO
to H20.
GO t o H19.
H19 CHECK AIR FLOW WITH COMPRESSOR AIR DRYER
REMOVED
Yes
No
drier.
CAUTION: Enter
Funct i onal Test 26 as
out l i ned in Funct i onal
Test Procedure and f i l l
air spri ngs f or about 90
seconds bef ore
l ower i ng rear of vehi cl e
vehi cl e and
component s.
REPEAT Auto Test.
REPLACE compressor
assembly.
CAUTION: Enter
seconds bef ore
vehi cl e and
component s.
REPEAT Auto Test.
Remove compressor air drier from air compressor
as outlined.
Air should flow from compressor air dryer fi tti ng on
compressor while compressor is running.
Does t he air f l ow f r om compr essor air dr y e r ?
Yes
No
drier.
CAUTION: Enter
seconds bef ore
l ower i ng rear of vehi cl e
vehi cl e and
component s.
REPEAT Auto Test.
REPLACE compressor
assembly.
CAUTION: Enter
seconds bef ore
vehi cl e and
component s.
REPEAT Auto Test.
H20 CHECK FOR AIR LEAKS IN LINES AND SPRINGS
Yes
No
SERVICE leaks in air lines
and/or REPLACE rear
spring(s). REPEAT Auto
Test.
GO t o H2 1.
Raise rear of vehi cle. Refer to Section 00-02.
NOTE: Support rear of vehicle on frame, not on axle.
Supporting vehicle by the frame allows full
extension of air rear springs for leak det ect i on.
Enter Functional Test 26compress rear. Refer to
Functional Test Procedure.
Check air lines and air rear springs for leaks.
NOTE: The air lines are routed along the LH rocker
panel along with the fuel and brake lines.
Are l eaks de t e c t e d?
Yes
No
SERVICE leaks in air lines
and/or REPLACE rear
spring(s). REPEAT Auto
Test.
GO t o H2 1.
H21 CHECK FOR BLOCKED AIR LINES
Yes
No
REPLACE control
module. REPEAT Auto
Test.
GOt o H22.
Disconnect air lines at both air spring solenoid
valves. Remove air spring solenoid heat shi elds, if
equi pped.
Support rear of vehicle on frame to prevent vehicle
from lowering during functional t est . Refer t o
Section 00-02.
Air should flow from both air lines and from both air
spring solenoid valves.
Does air f l ow f r om bot h air l i nes and f r om bot h air
spr i ng sol enoi d val ves?
Yes
No
REPLACE control
module. REPEAT Auto
Test.
GOt o H22.
H22 CHECK FOR NO AIR FLOW FROM REAR AIR
SPRING(S)
Yes
No
SERVICE blocked air
lines. REPEAT Auto Test.
SERVICE air spring
solenoids. REPEAT Auto
Test.
Check ai rf l ow.
Is t her e air f l ow f r om rear spri ng(s)?
Yes
No
SERVICE blocked air
lines. REPEAT Auto Test.
SERVICE air spring
solenoids. REPEAT Auto
Test.
04- 05 - 5 3 Su s p e n s i o n , Co mp u t e r Co n t r o l l e d 04- 05- 53
PINPOINT TE ST J : DTC 68 SHORT IN REAR AIR SUSPENSION HEIGHT SENSOR CIRCUIT
J1 CHECK FOR DTC 71
Disconnect rear air suspension height sensor
elect ri cal connector.
Perform Auto Test.
Yes
No
Auto Test.
GOt o J2 .
J2 CHECK FOR DTC 68
Check the display for DTC 68.
Yes
No

GOt o J3.
GOt o J 1 .
J3 CHECK CIRCUIT 428 FOR SHORT TO GROUND
Measure resistance between Pins 6 and 3 of white
control module connector.
Meter should indicate more than 10,000 ohms.
Is resi st ance more t han 10,000 ohms?
Yes
No
WHITE
MODULE CONNECTOR
F7241-B

GOt o J4.
Circuit 428 has short to
ground. GO t o J4 before
servicing short in Circuit
428.
J4 CHECK CIRCUIT 427 FOR SHORT TO GROUND
Measure resistance between Pins 6 and 17 of white
Meter should indicate more than 10,000 ohms.
Does t he met er i ndi cat e more t han 10,000
ohms?
Yes
No

REPLACE control
module. REPEAT Auto
Test.
in Circuit 427 and/or
Test.
WHITE
MODULE CONNECTOR
F7266-B
04- 05- 54
PINPOINT TEST K: DTC 71 AIR SUSPENSION HEIGHT SENSOR CIRCUIT OPEN
K1 VISUAL INSPECTION
Enter Functional Test mode. Refer to Functional
Test procedure. DO NOT select a Functional Test at
this ti me. STAR tester button should remain in TEST
(down) position.
NOTE: If the control module is not in the functional
test mode, the voltages in the following test steps
will be i ncorrect.
Ensure that air suspension height sensor electri cal
connector is connected and that connector and
wiring have no obvious damage.
Are c onne c t or a n d / o r wi r i ng wor n or damaged?
Yes
No
SERVICE connector
and/or wiring as
necessary. REPEAT Auto
Test.
GOt o K2,
K2 CHECK CIRCUITS 427 (PK/ BK) AND 428 (O/BK)
Disconnect air suspension height sensor.
Measure voltage between Circuits 427 (PK/BK) and
428 (O/ BK) and a good chassi s ground.
Meter should indicate 4 volts for each circuit.
Does t he met er i ndi cat e 4 vol t s f or each ci r cui t ?
HEIGHT SENSOR
HARNESS CONNECTOR
Yes
No

GO to K4.
GO to K3.
CIRCUIT 427
CIRCUIT 428
GOOD
CHASSIS
GROUND
F7242-A
K3 ISOLATE OPEN IN CIRCUITS 427 (PK/BK) AND/OR
428 (O/ BK) OR CONTROL MODULE
Measure resistance of damaged circuits between
air suspension height sensor connector and control
module connector.
Yes
No
REPLACE control
module. REPEAT Auto
Test.
LOCATE and SERVICE
open in Circuit 427
(PK/BK) and/or 428
(O/BK). REPEAT Auto
Test.
HEIGHT SENSOR
HARNESS CONNECTOR
CIRCUIT
428 O/BK
CIRCUIT
427 (PK/BK)
CIRCUIT
427 PK/BK
XT
WHITE
MODULE CONNECTOR
F7243-C
0 4 - 0 5 - 5 5 S u s p e n s i o n , C o mp u t e r C o n t r o l l e d 0 4 - 0 5 - 5 5
PINPOINT TEST K: DTC 71 AIR SUSPENSION HEIGHT SENSOR CIRCUIT OPEN (Cont i nued)
K4 CHECK CIRCUIT 432 (BK/ PK)
Measure resi st ance bet ween Circuit 432 (BK/ PK) in
air suspension hei ght sensor connect or and a good
ground.
Meter should i ndi cat e less than 10 ohms.
Is r e si st a nc e l ess t han 10 o hms?
Yes
No

GO t o K6.
GOt o K5.
CIRCUIT 432 HEIGHT SENSOR
HARNESS CONNECTOR
GOOD
CHASSIS
GROUND
F7244-A
K5 ISOLATE OPEN IN CIRCUIT 432 (BK/ PK) OR CONTROL
MODULE
Turn air suspensi on swi t ch OFF.
Di sconnect cont rol module connect ors.
Measure resi st ance of Circuit 432 (BK/ PK)
between the air suspensi on hei ght sensor
connect or and cont rol module connector.
Resi st ance should be less than 10 ohms.
Is r esi st ance l ess t han 10 ohms?
Yes
No
REPLACE cont rol
module. REPEAT Auto
Test.
LOCATE and SERVICE
open in Circuit 432
(BK/ PK). REPEAT Auto
Test.
CIRCUIT
432 BK/PK
CIRCUIT
432 BK/PK
HEIGHT SENSOR
HARNESS CONNECTOR
WHITE
MODULE CONNECTOR
F7245-B
K6 CHECK CIRCUIT 429 ( P/ LG)
Measure volt age between Circuit 429 (P/ LG) and a
good chassi s ground.
Meter should pulse bet ween 4 and 6 vol t s.
Does t he met er pul se be t we e n 4 and 6 vol t s?
CIRCUIT
429 P/LG
Yes
No

Circuit 429 (P/ LG) OK,
REPEAT Auto Test.
GO to K7.
HEIGHT SENSOR
HARNESS CONNECTOR
GOOD
CHASSIS
GROUND
F7246-B
1995 T o wn Ca r , C r o w n Vi c t o r i a , G r a n d Ma r q u i s J u l y 1994
04- 05- 56
PINPOINT TE ST K: DTC 71 AIR SUSPENSI ON HEIGHT SENSOR CIRCUIT OPEN (Continued)
K7 ISOLATE OPEN IN CIRCUIT 420 (P / LG) OR CONTROL
MODULE
Measure resistance of Circuit 429 (P / LG) between
air suspension height sensor connector and control
module connector.
Is resi st ance l ess than 10 ohms?
CIRCUIT
429 P/LG
Yes
No
REPLACE control
module. REPEAT Auto
Test.
LOCATE and SERVICE
open in Circuit 429
(P/LG). REPEAT Auto
Test.
CIRCUIT
429 P/LG
WHITE
MODULE CONNECTOR F7247-B
PINPOINT TEST L: DTC 72 DID NOT DETECT 4 OPEN AND CLOSE DOOR SIGNALS
L1 CHECK DOOR CIRCUITS
Measure voltage between Pins 5 and 6 of gray
NOTE: Leave meter connected during entire
pinpoint test.
Open and close each door.
Meter should indicate battery voltage with doors
open, zero volts with doors cl osed.
Does t he met er i ndi cat e bat t er y vol t age at al l ?
Yes
No

GOt o L2.
LEAVE meter connected.
GO to L4.
WHITE
MODULE CONNECTOR
F7267-B
L2 CHECK VOLTAGE READING
Open and close each door.
Does t he met er i ndi cat e bat t ery vol t age wi t h
door open and zero vol t s wi t h door cl osed?
Yes
No

GO to L3.
GO to L7.
04- 05- 57 Su s p e n s i o n , C o mp u t e r Co n t r o l l e d 04- 05 - 5 7
PINPOINT TEST L: DTC 72 DID NOT DETECT 4 OPEN AND CLOSE DOOR SIGNALS (Cont i nued)
L3 REPEAT AUTO TEST
Yes
No
REPLACE control
module. REPEAT Auto
Test.
System OK.
Repeat Auto Test.
During manual tests, forcefully open and close
doors.
Observe diagnostic trouble codes.
Does DTC 72 act i vat e?
Yes
No
REPLACE control
module. REPEAT Auto
Test.
System OK.
L4 CHECK DOOR COURTESY LAMP SWITCH
Yes
No
ADJUST door courtesy
lamp swi t ch. REPEAT
Auto Test.
GO to L5.
Open each door not indicating battery voltage one
at a time.
Manually press door courtesy lamp switch several
ti mes while observing meter.
Does met er i ndi cat e bat t er y vol t age wi t h swi t c h
r el eased, zero vol t s wi t h swi t c h pr essed?
Yes
No
ADJUST door courtesy
Auto Test.
GO to L5.
L5 CHECK DOOR HARNESS
Yes
No
GO to L6.
54 (LG/Y) between door
courtesy lamp swi tches
and fuse j unction panel.
REPEAT Auto Test.
Disconnect door switch connector.
Measure volt age at connector between Circuit 54
(LG/Y) and a good chassi s ground.
Is t here ba t t e r y vol t age?
Yes
No
GO to L6.
54 (LG/Y) between door
courtesy lamp swi tches
and fuse j unction panel.
REPEAT Auto Test.
L6 JUMPER DOOR HARNESS
Yes
No
REPLACE door courtesy
Auto Test.
24 (DB/O) between door
courtesy lamp swi tch and
Auto Test.
Connect a fused jumper between Circuit 54 (LG / Y)
and Circuit 159 (R/PK) (driver's door) or 24 (DB/ O)
(other doors) and observe meter.
Yes
No
Auto Test.
24 (DB/O) between door
courtesy lamp swi tch and
Auto Test.
L7 CHECK FOR SHORT TO BATTERY
Yes
No
Auto Test.
GO to L8.
Disconnect door courtesy lamp swi t ches one at a
time and leave di sconnect ed.
Observe meter each time a swi tch is di sconnect ed.
Does t he met er dr op t o zero vol t s when a swi t c h
is di sc onne c t e d?
Yes
No
Auto Test.
GO to L8.
L8 BATTERY VOLTAGE WITH ALL SWITCHES
DISCONNECTED
Yes E>
No
in Circuit 159 (R/PK) for
driver door Circuit or 24
(DB/O) for other doors.
REPEAT Auto Test.
GOt o L7.
Check meter readi ng.
Is met er st i l l r eadi ng bat t ery vol t age wi t h all f our
swi t ches di sconnect ed?
Yes E>
No
in Circuit 159 (R/PK) for
driver door Circuit or 24
(DB/O) for other doors.
REPEAT Auto Test.
GOt o L7.
04- 05- 58
PINPOINT TE ST M: DTC 80 CONTROL MODULE DETECTS LOW BATTERY VOLTAGE
Mi MEASURE SYSTEM VOLTAGE
Turn air suspension service switch OFF.
Turn air suspension service switch ON.
module connector.
Connect test lamp between Pins 1 and 6 of control
module connector.
Does the meter indicate zero voi t s?
Yes
No
WHITE
MODULE CONNECTOR F7758-B

GO to M8.
GO t o M2 .
M2 CHECK THE METER READING
Does t he met er i ndi cat e bet ween zero and 11
vol t s?
Yes
No
CHECK and SERVICE
charging system. REFER
to Section 14-00, then
REPEAT Auto Test.
GO to M3.
M3 CHECK VOLTMETER READING
Does t he met er i ndi cat e at l east 11 vol t s?
Yes
No

GO to M4.
GO t o M1.
M4 CHECK THE TEST LAMP
Check the test lamp to determine whether it is very
dim or bright.
Is t he t est l amp very di m?
Yes
No

GO to N6.
GO to MS. *
M5 CHECK AIR SUSPENSION SERVICE SWITCH
Check air suspension service swi t ch.
Was air suspensi on servi ce swi t ch i ni t i al l y o f f ?
Yes
No
TURN air suspension
service swi tch ON and
REPEAT Auto Test.
GOt o M6.
PINPOINT TE ST M: DTC 80 CONTROL MODULE DETECTS LOW BATTERY VOLTAGE (Conti nued)
M6 CHECK IGNITION SWITCH SENSE CIRCUIT
Measure voltage between Pin 16 of control module
white connector and a good chassi s ground.
Meter should indicate bat t ery voltage.
Is t here bat t er y vol t age?
Yes
No

GOt o M7 .
LOCATE and SERVICE
open in Circuit 295
(LB/ PK) Town Car, 298
(P/ O) Crown Vi ctori a and
Grand Marquis or open
fuses. CHECK ignition
swi t ch. Also check for
damage or pinching of
489. REPEAT Auto Test.
GOOD
CHASSIS
GROUND
WHITE
MODULE
CONNECTOR
F7250-B
M7 CHECK CONTROL MODULE GROUNDS
Measure resi stance between Pin 6 and a good
chassi s ground.
Does met er i ndi cat e l ess t han 5 ohms?
Yes
No
If DTC 80 was generated,
REPLACE control
module. REPEAT Auto
Test. If unable to enter
di agnosti cs with new
control module, GO to N2.
or SERVICE ground
terminals. REPEAT Auto
Test.
WHITE
MODULE CONNECTOR
GOOD
CHASSIS
GROUND
WHITE
MODULE CONNECTOR
F7251-B
PINPOINT TEST M: DTC 80 CONTROL MODULE DETECTS LOW BATTERY VOLTAGE (Cont i nued)
M8 CHECK AIR SUSPENSION SWITCH
Yes
No
swi t ch. REPEAT Auto
Test.
REMOVE jumper.
GO to M9.
Disconnect air suspension swi t ch.
Connect a fused jumper between Circuit 1053
(LB/PK)Town Car, 37 (Y) Crown Vi ctori a and Grand
Marquis and 418 (DG/Y) Town Car, 418 (DG/Y)
Crown Vi ct ori a and Grand Marquis at connector.
Read meter.
Are t here 11 vol t s or more?
FUSED
JUMPER^V
I Sl F7257-A
Yes
No
swi t ch. REPEAT Auto
Test.
REMOVE jumper.
GO to M9.
M9 CHECK BATTERY CIRCUIT
Yes
No
418 (DG/Y) between
switch and control
module. REPEAT Auto
Test.
CHECK feed fuses or
1053 (LB/PK) between
switch and fuse panel.
Measure volt
Town Car, 41
Marquis of ai
good chassis
Read meter.
Are t here 11
age betj
4( 0/ R)
r susper
5 ground
vol t s Ol
O}
V
V
ween Circuit 1053 (LB/PK)
Crown Vi ctori a and Grand
ision switch connector and a
r mor e?
- GOOD
CHASSIS
GROUND F7252-A
Yes
No
418 (DG/Y) between
switch and control
module. REPEAT Auto
Test.
CHECK feed fuses or
1053 (LB/PK) between
switch and fuse panel.
PINPOINT TEST N: UNABLE TO ENTER AUTO TEST DIAGNOSTICS
N1 CHECK POWER AND GROUND
Yes
No
REPEAT Auto Test.
GO to N2.
If another SUPER STAR II Tester is available,
attempt t o rerun Auto Test.
If still unable to enter Auto Test, Go to Pinpoint Test
M to check control module power and ground.
Is concer n de t e c t e d and servi ced dur i ng Pi npoi nt
Test M?
Yes
No
REPEAT Auto Test.
GO to N2.
PINPOINT T E ST N: UNABLE TO ENTER AUTO T E ST DIAGNOSTICS (Continued)
N2 CHECK DATA LINK CONNECTOR CIRCUITS FOR
CONTINUITY
Check continuity of Circuits 419 (DG/LG), 432
(BK/PK) and 844 (GY/R) between control module
connectors and data link connector.
Is t here cont i nui t y i n all ci r cui t s?
Yes
No

GO t o N3.
SERVICE open in ci rcui ts
as necessary. REPEAT
Auto Test.
WHITE
MODULE CONNECTOR
WHITE
MODULE CONNECTOR
419 432
DG/LG BK/PK
844
GY/R
STAR TESTER
DATA LINK CONNECTOR
LOCATED NEAR MODULE
F7255-C
N3 CHECK FOR SHORT TO BATTERY
Measure voltage between data link connector
Circuit 419 (DG/LG) and a good ground.
Measure voltage between data link connector
Circuit 844 (GY/R) and a good ground.
Does met er i ndi cat e zero vol t s at bot h ci r cui t s?
Yes
No

GO to N4.
Auto Test.
F7256-C
04- 05- 62
PINPOINT TEST N: UNABLE TO ENTER AUTO TEST DIAGNOSTICS (Cont i nued)
N4 CHECK CIRCUITS FOR SHORT TO GROUND
Measure resi stance between data link connector
Circuit 419 (DG / LG) and a good ground.
Measure resi stance between dat a link connector
Circuit 844 (GY/R) and a good ground.
Does met er i ndi cat e more t han 10,000 ohms f or
each ci r cui t ?
STAR TESTER
DATA LINK CONNECTOR
LOCATED NEAR MODULE
Yes
No

GOt o N5.
Auto Test.
844 GY/R
419 DG/LG "
GOOD
CHASSIS
GROUND
F7256-C
N5 CHECK SUSPENSION WARNING INDICATOR
Turn service swi tch OFF in luggage compartment.
Turn ignition swi tch t o RUN.
Observe suspension warning indicator on instrument
panel.
Is war ni ng l i ght on?
Yes
No
SERVICE the instrument
cluster. REFER to Section
13-01A (Electronic) or
13-01B (Conventional).
REPEAT Auto Test.
GOt o N6.
N6 MEASURE RESISTANCE OF POWER FEED
NOTE: Look for bad connections at control module
harness connectors.
Disconnect positive battery cable.
Measure resi stance between Pin 1 on control
module connector and positive battery terminal.
Yes
No
REPLACE control
module. REPEAT Auto
Test.
SERVICE open or bad
connection on Circuits
1053 (LB/PK) and 38 or
418 (DG/Y). REPEAT
Auto Test.
PINPOINT TEST P: STEERING SELECT SWITCH NOT DETECTED (TOWN CAR ONLY)
P1 CHECK SELECT SWITCH INPUT
Yes
No
REPLACE control
module. REPEAT Auto
Test.
GO to P2.
Disconnect air suspension / EVO control module
white connector C1.
Turn the select swi tch on the driver's left to the high
posi ti on.
Turn the ignition swi tch to the RUN posi ti on.
Using a voltmeter (059-00010), measure voltage
between Pin 6 and Pin 12.
Yes
No
REPLACE control
module. REPEAT Auto
Test.
GO to P2.
P2 CHECK CIRCUIT 635 (GY/R)
Yes
No
LEAVE ohmmeter
connected. GO to P3.
SERVICE Circuit 635
(GY/R) for open. REPEAT
Auto Test.
Turn ignition swi tch t o OFF posi ti on.
Turn the select swi tch t o the LOW posi ti on.
Using an ohmmeter (059-00010) or equivalent,
measure resistance between Pin 6 and Pin 12.
Is resi st ance 1 ohm or l ess?
Yes
No
LEAVE ohmmeter
connected. GO to P3.
SERVICE Circuit 635
(GY/R) for open. REPEAT
Auto Test.
04- 05- 63 Su s p e n s i o n , Co mp u t e r Co n t r o l l e d 04- 05 - 63
PINPOINT TEST P: STEERING SELECT SWITCH NOT DETECTED (TOWN CAR ONLY) (Conti nued)
P3 CHECK SELECT SWITCH RESISTANCE
Yes
No FR -
REPLACE control
module. REPEAT Auto
Test.
REPLACE select switch.
REPEAT Auto Test.
Turn the select switch to the middle position.
Measure the resistance between Pin 6 and Pin 12.
Is resi st ance 10,000 ohms or great er?
Yes
No FR -
REPLACE control
module. REPEAT Auto
Test.
REPLACE select switch.
REPEAT Auto Test.
Ho i s t i n g , Li f t i ng, Jacki ng and Towi ng
Re s t r i c t i o n s
WARNI NG: THE ELECTRI CAL POWER SUPPLY TO
THE AIR SUSPENSI ON SYSTEM MUST BE SHUT
OFF PRIOR TO HOI STI NG, JACKI NG OR TOWI NG
A N AIR SUSPENSI ON VEHI CLE. THI S CAN BE
ACCOMPLI SHED BY DI SCONNECTI NG THE
BATTERY OR TURNI NG OFF THE AIR
SUSPENSI ON SWI TCH LOCATED IN THE
LUGGAGE COMPARTMENT ON THE RH SI DE.
FAILURE TO DO SO MAY RESULT IN UNEXPECTED
I NFLATI ON OR DEFLATI ON OF THE AI R SPRI NGS
WHI CH MAY RESULT IN SHI FTI NG OF THE
VEHI CLE DURING THESE OPERATI ONS.
Hoi st i ng and Body Support
1. CAUTI ON: T h e f o l l o w i n g h o i s t r e s t r i c t i o n s
mu s t b e o b s e r v e d :
Position vehicle over hoist. Refer t o Secti on
00- 02. Turn ignition swi t ch ( 11572) t o OFF
position and turn off air suspension swi t ch l ocat ed
in luggage compart ment on RH si de.
2. A body hoist is the recommended met hod for
vehicle hoisting. When thi s hoist is used, rai se
vehicle using st andard support procedures.
Suspension will be support ed in rebound by front
and rear shock absorbers after vehi cl e is l i fted.
Al so support vehi cl e at four corners wi t h
j ackst ands as a saf et y precauti on. Do not use
suspension hoi sts.
3. If a body hoi st is not avai l abl e, an al ternate
method approved f or vehi cl e hoi sti ng is t o use a
st andard hydraul i c fl oor j ack. Rai se front of
vehicle at No. 2 crossmember until ti res are
above floor. Refer t o Secti on 00- 02.
Support vehicle body wi t h j ackst ands at each
front corner and then l ower fl oor j ack so t hat front
suspension is in full rebound. Repeat this
procedure for rear air suspensi on, except rai se
body at rear j acki ng l ocati on. Refer t o Secti on
00- 02.
Component Replacement
WARNI NG: BEFORE SERVI CI NG ANY AI R
SUSPENSI ON COMPONENTS, DI SCONNECT
POWER TO THE SYSTE M BY TURNI NG AI R
SUSPENSI ON SWI TCH OFF OR BY
DI SCONNECTI NG BATTERY GROUND CABL E TO
PREVENT VEHI CLE DAMAGE OR PERSONAL
I NJURY.
WARNI NG: DO NOT REMOVE AN AI R SPRI NG
UNDER ANY CI RCUMSTANCES WHEN THERE IS
PRESSURE IN THE AI R SPRI NG. DO NOT REMOVE
ANY COMPONENTS SUPPORTI NG AN AI R SPRI NG
WI THOUT EI THER EXHAUSTI NG THE AI R OR
PROVI DI NG SUPPORT FOR THE AI R SPRI NG TO
INJURY.
Suspensi on Fasteners
Suspension fasteners ar e i mportant retaining part s in
that they coul d affect perf ormance of vital components
and syst ems and/ or coul d result in major servi ce
expense. They must be repl aced wi th fasteners of the
same part number, or wi t h an equivalent part, if
repl acement becomes necessary. Do not use a
repl acement part of lesser quality or substitute desi gn.
Torque values must be used, as speci fi ed, during
assembl y t o ensure proper retention of parts. New
fasteners must be used whenever ol d fasteners are
loosened or removed and when new component part s
are installed. Refer t o Speci fi cati ons for torque val ues.
Air Spri ng Suspensi on
Rear
The following rear suspensi on components may be
repl aced individually.
Ai r compressor (l ess dr yer ) , regenerati ve
compressor air drier ( 5346) and O-ring are all
servi ced as separat e component s.
Ai r suspension height sensor ( 5359) , control
module ( 5A919) and air suspension swi t ch are
repl aceabl e.
Rear spri ngs ( 5560) are repl aceabl e as assembl i es
(includes solenoid val ves ( 5311) ) . It is not
necessary t o repl ace in pai rs.
Air spring solenoid val ves and external solenoid
o-rings ( 5312) are repl aceabl e.
Air lines are repl aceabl e. However, qui ck connect
unions and bulk tubing are avai l abl e t o mend a
damaged air line.
The collet and O-ring of qui ck connect fittings are
repl aceabl e wi th air spri ng connector repai r kit
( 5B321) .
Gas-filled shock absorbers ( 18080) must be
repl aced as assembl i es. They are not servi ceabl e.
Repl ace only the damaged shock absorber. It is not
necessary t o repl ace in pai rs.
Rear suspensi on l ower arms ( 5A649) , including
bot h end bushi ngs, are repl aceabl e as assembl i es.
They must be repl aced in pai rs.
Rear suspension arm and bushi ngs ( 5500) ,
including body end bushi ng, are repl aceabl e as
assembl i es. They must be repl aced in pai rs.
Rear stabilizer bar ( 5A772) is repl aceabl e wi t h
stabilizer bar-to-axl e stabilizer bar link ( 5K484)
included.
Stabilizer bar-to-frame bushings are repl aceabl e.
E VO P o w e r S t e e r i n g C o n t r o l Va l v e A c t u a t o r
Refer t o Secti on 11-02 for Removal and Installation
procedure.
S h o c k R e p l a c e m e n t
Re mo v a l
1. WARNI NG: ALL VEHI CLES ARE EQUI PPED
WI TH GAS PRESSURI ZED SHOCK
ABSORBERS ( 18080) WHI CH WI LL EXTEND
UNASSI STED. DO NOT APPLY HEAT OR
FLAME TO THE SHOCK ABSORBER TUBE.
WARNI NG: TURN AI R SUSPENSI ON SWI TCH
OFF TO PREVENT VEHI CLE DAMAGE OR
I NJURY.
Raise vehi cl e on hoi st. Refer t o Secti on 00- 02. If
f rame cont act hoi st is used, support rear axl e.
2. To assi st in removi ng the upper attachments on
shock absorbers, using a pl asti c dust tube, pl ace
an open end wrench on the hex stamped into dust
t ube' s metal cap. For shock absorbers wi th a
steel dust tube, si mpl y grasp tube t o prevent stud
rotati on when loosening retaining nut.
STUD
PLASTIC
DUST TUBE
SHOCK
ABSORBER
18080
3.
5.
F2952-D
Remove shock absorber retaining nut, washer,
and insulator from stud on upper si de of f rame.
Di scard nut. Compress shock absorber t o cl ear
hole in f rame, and remove inner insulator and
washer f rom upper retaining stud.
Remove and di scard self-locking retaining nut.
Di sconnect shock absorber l ower stud from
mounting bracket on rear axl e tube.
Perform Shock Absorber Checks. Refer t o
Secti on 04- 00 t o determi ne shock absorber' s
performance.
1. Properl y prime new shock absorber. Refer t o
Secti on 04- 00.
2. Pl ace inner washer and insulator on upper
retaining st ud, and position shock absorber so
that upper stud enters hole in frame. While
holding shock absorber in thi s position, install
outer insulator, washer, and a new stud nut on the
upper side of upper frame. Be sure t o seat
insulator pilot in f rame connecting hole. Tighten
nut t o 19-35 N-m (15-25 Ib-ft).
3. Extend shock absorber, and pl ace l ower stud in
mounting bracket hole on rear axl e housing.
Install a new self-locking nut. Tighten nut to
70- 115 N-m (52-85 Ib-ft).
4. Lower vehi cl e.
5. Turn air suspension swi t ch ON.
04- 05- 65 Su s p e n s i o n , C o mp u t e r Co n t r o l l e d 04- 05 - 65
A i r S p r i n g S y s t e m C o m p o n e n t s
REAR AIR SPRING
APPEARANCE
PRIOR TO VEHICLE
INSTALLATION
CORRECT
L = APPROXIMATELY
50.0mm
(2.0 INCHES)
CORRECT APPEARANCE
OF REAR SPRING MEMBRANE
NO FOLDS OR
CREASE FOR
360 DEGREES
AROUND CYLINDER
MEMBRANE ROLLED
OVER PISTON FOR
360 DEGREES
F6344-C
CAUTI ON: P o we r t o t h e ai r s y s t e m mu s t b e s h u t
o f f b y t u r n i n g t h e a i r s u s p e n s i o n s w i t c h (i n
l u gga ge c o mp a r t me n t ) o f f o r b y d i s c o n n e c t i n g
t h e b a t t e r y w h e n s e r v i c i n g a n y a i r s u s p e n s i o n
c o mp o n e n t s t o p r e v e n t v e h i c l e d a ma g e o r
p e r s o n a l i n j ur y .
WARNI NG: DO NOT ATTEMPT TO I NSTALL OR
I NFLATE ANY REAR AI R SPRI NG THAT HAS
BECOME UNFOLDED TO PREVENT VEHI CLE
DAMAGE OR PERSONAL I NJURY.
FAI LURE TO OBSERVE THE FOLLOWI NG
PROCEDURES MAY RESULT IN A SUDDEN
FAI LURE OF THE AI R SPRI NG OR SUSPENSI ON
SYSTE M.
ANY REAR SPRI NG WHI CH IS UNFOLDED MUST
BE REFOLDED A S SHOWN, PRIOR TO BEI NG
I NSTALLED IN A VEHI CLE.
THE AIR SPRI NG REFOLDI NG PROCEDURE
SHOULD ONLY BE USED TO SERVI CE A N AI R
SPRI NG WHI CH HAS NEVER SUPPORTED THE
VEHI CLE' S WEI GHT WHI LE IN THE
I MPROPERLY FOLDED POSI TI ON.
I MPROPERLY FOLDED AIR SPRI NGS FOUND ON
VEHI CLES DURI NG PRE-DELI VERY I NSPECTI ON
OR AFTER USE MUST BE REPLACED.
DO NOT ATTEMPT TO I NFLATE ANY AI R
SPRI NG WHI CH HAS BEEN COLLAPSED WHI LE
UNI NFLATED FROM THE REBOUND HANGI NG
POSI TI ON TO THE JOUNCE STOP.
WHEN I NSTALLI NG A NEW AI R SPRI NG, CARE
MUST BE TAKE N NOT TO APPLY A LOAD TO
THE SUSPENSI ON UNTI L SPRI NGS HAVE BEEN
I NFLATED USI NG THE AIR SPRI NG FI LL
PROCEDURE.
AFTER I NFLATI NG AN AIR SPRING IN HANGI NG
POSI TI ON, I T MUST BE I NSPECTED FOR
PROPER SHAPE.
S o l e n o i d Va l v e , A i r S p r i n g
Re mo v a l
The air spring solenoid valve ( 5311) has a t wo-st age
sol enoi d valve pressure relief fitting similar t o a
radi ator cap:
Fi rst remove air spri ng solenoid retainer ( 5308) .
Then rotate the solenoid valve out of the spri ng to
rel ease air f rom the assembl y.
Remove the solenoid val ve as fol l ows:
1. Turn air suspension swi t ch off.
Suspension must be at full rebound.
3. Remove heat shield if equi pped.
4. Di sconnect solenoid val ve el ectri cal connector
and then di sconnect air line.
ELECTRICAL CONNECTOR
AIR LINE
SPRING
SOLENOID
VALVE
5311
F634S-C
Rel ease Qui ck Co n n e c t
PUSH DOWN AND HOLD
PLASTIC RELEASE RING
SPRING SOLENOID
VALVE 5311
DISCONNECT
PULL TO REMOVE
NYLON TUBE
APPROXIMATELY
18 mm (0.71 INCH)
CONNECT
PUSH NYLON
TUBING IN UNTIL
SEATED AGAINST
OUTER TUBE
DISCONNECT/CONNECT FROM AIR SPRING
SOLENOID SHOWN SAME PROCEDURE
FOR AIR LINE DISCONNECT/CONNECT
FROM AIR COMPRESSOR DRYER F3656-E
5. Remove air spri ng solenoid retai ner.
6. Rot at e solenoid val ve count ercl ockwi se t o fi rst
st op.
7. Pull solenoid val ve strai ght out sl owl y to second
st op t o bl eed air f rom syst em.
8. CAUTI ON: Do n o t f ul l y r e l e a s e s o l e n o i d v a l v e
u n t i l ai r i s c o mp l e t e l y b l e d f r o m t h e a i r s p r i n g
t o p r e v e n t i n j ur y .
Af t er air is fully bl ed f rom syst em, rotate solenoid
val ve count ercl ockwi se t o thi rd st op and remove
sol enoi d val ve f rom solenoid val ve housing.
AIR SPRING
SOLENOID
RETAINER
5308
AIR SPRING
SOLENOID VALVE
5311
AIR SPRING END
CAP (PART OF
SPRING ASSY)
1ST STOP 2ND STOP
STOP ON
SOLENOID
VALVE
3RD STOP SOLENOID
0
. O-RING
3
) 5312
DO NOT REMOVE
UNTIL AIR IS EXHAUSTED
FROM SPRING
REMOVAL SHOWN REVERSE SEQUENCE
FOR SOLENOID INSTALLATION
F6347-C
Remove l arge solenoid o-ring ( 5312) f rom
solenoid housing.
SOLENOID O-RING
5312
SOLENOID VALVE
HOUSING
SECTION A
SOLENOID
HOUSING
LARGE O-RING
IN INSTALLED
POSITION
SECTION A
F6348-C
04- 05- 67 Su s p e n s i o n , Co mp u t e r Co n t r o l l e d 04- 05 - 67
> H 3 3
1. Check sol enoi d o-rings for abrasi on or cut s.
Repl ace sol enoi d o-rings as requi red. Lightly
grease O-ring area of solenoid and larger
solenoid housing sol enoi d o-ring wi t h Silicone
Dielectric Compound D7AZ- 19A331- A or
ESE-M1C171-A.
PUCKER THE SOLENOID RUBBER
O-RINGS BY PUSHING TO ONE SIDE
WITH THUMB AND INDEX FINGER,
INSTALL TWO SMALL O-RINGS AND
LIGHTLY COAT WITH SILICONE DIELECTRIC
COMPOUND D7AZ-19A331-A (ESE-M1C171-A)
OR EQUIVALENT
5312 BETWEEN O-RINGS F4766-C
2. Insert sol enoi d val ve into air spri ng end cap and
rot at e cl ockwi se t o thi rd st op, push into second
st op, then rot at e cl ockwi se t o fi rst st op.
3. Install air spri ng solenoid retainer.
4. Inspect wi re harness connector and ensure
rubber gasket is in pl ace at bot t om of connector
cavi ty.
5. Connect air line and el ectri cal connector.
6. Install heat shield.
7. Lower hoist as requi red, but do not appl y a l oad
t o the suspensi on.
8. Refill air spri ng(s) as fol l ows using Functional Test
26.
A i r S p r i n g Fi l l
1. CAUTI ON: Wh e n I n st a l l i n g def l at ed ai r
s p r i n gs o n t h e v e h i c l e , l ower t h e ho i s t
p r o gr e s s i v e l y a s r equi r ed. DO NOT a p p l y a n y
l o a d t o t h e s u s p e n s i o n u n t i l t h e s p r i n gs h a v e
b e e n i n f l a t e d f o r a t l e a s t 9 0 s e c o n d s t o
p r e v e n t p e r s o n a l i n j ur y .
Support f rame so rear wheel s are off ground wi t h
no load appl i ed t o rear suspensi on.
2. Air suspensi on swi t ch must be ON.
3. Ignition swi t ch ( 11572) must be in RUN posi ti on.
A bat t ery charger should be connect ed t o bat t ery
t o reduce bat t ery drai n.
4. Fol d back RH l uggage compart ment tri m panel
carpet and connect Rotunda SUPER STAR II
Tester 007- 0041B or equivalent, t o air
suspension dat a link connect or ( 14489) .
5. Set SUPER STAR II tester to EEC-IV / MCU mode.
Al so set SUPER STAR II tester t o FAST mode.
Release STAR t est er button t o HOLD (up)
position and turn tester ON.
6. Press STAR Tester button t o TEST (down)
position. A DTC 10 will be di spl ayed. Within t wo
minutes a DTC 13 will be di spl ayed. After DTC 13
is di spl ayed, rel ease tester button t o HOLD (up)
position, wai t t wo seconds and press tester
button to TEST (down) posi ti on. Ignore any DTCs
di spl ayed.
7. Release tester button to the HOLD (up) posi ti on.
Wait at least 20 seconds, then press tester
button t o the TEST (down) posi ti on. Within 10
seconds, the following DTCs will start t o be
di spl ayed in t he order shown:
DT C De s c r i p t i o n
2 3 Ve nt Re a r
2 6 Co mp r e s s Re a r
31 Cy c l e Co mp r e s s o r On a n d Of f Re p e a t e d l y
32 Cy c l e Vent So l e n o i d Va l v e Ope n a n d C l o s e d
Re p e a t e d l y
33 Cy c l e Spr i n g So l e n o i d Va l v e s Ope n a n d
Cl o s e d Re p e a t e d l y
04- 05- 68 Suspensi on, Comput er Cont r ol l ed
04- 05- 68
8. Within four seconds after DTC 26 is di spl ayed,
rel ease t est er button t o the HOLD (up) posi ti on.
(Waiting longer than four seconds may result in
Functional Test 31 being entered.) The
compressor will fill the air spri ngs wi th air as long
as the t est button is in the HOLD (up) posi ti on. To
st op filling the air spri ngs, press the tester button
t o the TEST (down) posi ti on.
9. NOTE: It is possi bl e t o overheat the compressor
during thi s operati on. If the compressor
overheat s, the self-resetting circuit breaker in the
compressor will open and remain open for about
15 minutes. This al l ows the compressor t o cool
down.
To exi t Functional Test 26, di sconnect the STAR
t est er and turn the ignition swi t ch OFF.
A i r S p r i n g
Ai r Sp r i n g Re mo v e r T90P - 5310- A
Re mo v a l
1. Turn air suspension swi t ch OFF.
2. Rai se vehi cl e on a hoist as outlined. Suspension
must be fully down wi th no l oad.
3. Remove heat shield as requi red.
4. Remove spri ng retainer clip.
5. WARNI NG: DO NOT REMOVE AN AIR SPRI NG
UNDER ANY CI RCUMSTANCES WHEN THERE
IS PRESSURE IN THE AIR SPRI NG. DO NOT
REMOVE ANY COMPONENTS SUPPORTI NG
AN AIR SPRI NG WI THOUT EITHER
EXHAUSTI NG THE AIR OR PROVIDING
SUPPORT FOR THE AIR SPRING TO PREVENT
PERSONAL INJURY.
Remove air spri ng solenoid val ve ( 5311) as
outlined.
HEAT SHIELD
'5A908
SPRING
RETAINER
CLIP 5A966
AIR SPRING
WITH INTEGRAL
SOLENOID 5560
F6349-D
6. Remove spri ng piston-to-axle spri ng seat .
Insert Air Spring Remover T90P-5310-A
between axl e tube and spri ng seat on f orward
si de of axl e.
Position tool so that its flat end rests on air
spri ng piston knob. Push downwar d, forci ng
piston and retainer clip off of axl e spring seat.
AIR SPRING
REMOVER
T90P-5310-A
PUSH
DOWNWARD
F6361-C
7. Remove rear spring ( 5560) .
1. Install air spring solenoid val ve as outlined.
2. Install air spring into f rame spri ng seat, taki ng
care t o keep solenoid valve air and el ectri cal
connecti ons clean and free of damage.
04- 05- 69 S u s p e n s i o n , C o mp u t e Cx V i \ .
A
V0 5 - 6 9
7.
Connect push-on ring spri ng retainer clip t o knob
of spri ng cap f rom t op si de of f rame spri ng seat .
Connect air line and el ectri cal connector t o
solenoid val ve assembl y.
Install heat shield t o f rame rear spri ng seat , if
requi red.
Align air rear spri ng pi ston t o axl e seat s. Squeeze
to i ncrease pressure and push downwar d on
pi ston, snappi ng pi ston t o axl e seat at rebound
and support ed by shock absorber ( 18080) .
CAUTI ON: Ai r r e a r s p r i n g s ma y b e d a ma g e d
i f s u s p e n s i o n i s a l l o we d t o c o mp r e s s b e f o r e
s p r i n g i s i n f l a t e d .
Refill air rear spri ngs as outl i ned.
POSITION 1 INCH SOCKET
OVER PISTON KNOB AND
PUSH DOWNWARD UNTIL
CLIP IS FULLY SEATED
F6351-D
A i r S p r i n g P i s t o n R e t a i n e r C l i p
Re mo v a l
1. CAUTI ON: Re t a i n e r c l i p ma y be d i s t o r t e d .
Vi sua l l y i n s p e c t f o r b e n t f i n ge r s a t o u t e r
d i a me t e r o f c l i p o r d i s t o r t i o n a c r o s s r e t a i n e r
c l i p . If t h e s e c o n d i t i o n s a r e p r e s e n t , r e p l a c e
r e a r a i r s p r i n g r e t a i n e r ( 5A 966) .
Using needl enose pl i ers, bend each of four
prongs (holding rear air spri ng retainer t o pi ston
knob) out war d.
PISTON
KNOB
BEND ALL FOUR
TABS UPWARD
BEND ALL FOUR
TABS UPWARD
F6350-D
2. Remove and di scard rear air spri ng retai ner from
air spri ng pi ston.
1. Align new retainer clip over pi ston knob.
2. CAUTI ON: Do n o t c l a mp a n y p o r t i o n o f t h e
r e a r s p r i n g p i s t o n t o p r e v e n t d a ma g e t o
v e h i c l e .
Position a one-inch di ameter socket on rear air
spri ng retainer and push clip downwar d until clip
is fully seat ed on piston knob.
A i r C o m p r e s s o r a n d Dr y e r A s s e m b l y
1. WARNI NG: TURN AI R SUSPENSI ON SWI TCH
OFF.
Di sconnect bat t ery ground cabl e.
2. Remove engine air cl eaner ( ACL) ( 9600) . Refer t o
Secti on 03- 12.
3. Remove windshield washer reservoi r ( 17618)
assembl y. Refer t o Secti on 01- 16.
4. Remove compressor spl ash shield and push pins.
I / ( / ^ FRONT OF.
L
^ ' VEHICLE
REMOVE TWO
PUSH PINS
F6352-C
Remove air line f rom compressor air drier ( 5346)
by pushing retainer i nward and pulling out air line.
04- 05- 70 Suspensi on, C o mp u t e r Cont r ol l ed 04- 05- 70
6. Di sconnect compressor el ect ri cal connector.
FRONT OF
VEHICLE
AND PULL OUT
AIR LINE F6353-C
7. If necessary, rai se vehi cl e on hoist. Refer t o
Secti on 00- 02.
8. Remove t hree retaining nuts securi ng
compressor t o fender apron.
9. Lower vehi cl e.
10. Remove compressor and compressor air dri er
assembl y.
D r y e r A i r C o m p r e s s o r
Re mo v a l
PERSONAL INJURY.
Di sconnect bat t ery ground cabl e.
2. Remove air compressor ( 5319) and compressor
air drier ( 5346) assembl y as outlined.
3. Remove compressor air dryer-to-compressor
retaining screw.
F6354-E
4. Twi st compressor air drier cl ockwi se t o
di sengage f rom air compressor.
5. Remove compressor air drier and O-ring seal .
Di scard O-ring seal .
O-RING
0 4 - 0 5 - 7 1 Su s p e n s i o n , C o mp u t e r Co n t r o l l e d 04- 05 - 7 1
1. Install new O-ring on compressor air drier t o
ensure it is properl y seat ed on compressor air
dryer end.
Install compressor air drier into air compressor
and twi st count ercl ockwi se.
Install compressor air dryer-t o-compressor
retaining screw. Tighten t o 1.6-2.8 N-m (15-25
Ib-in).
Install compressor and compressor air dri er
assembl y, as outlined.
Mo u n t i n g B r a c k e t , A i r C o m p r e s s o r
Re mo v a l
1. Turn air suspension servi ce swi t ch OFF.
2. Remove air compressor and compressor air
dryer assembl y as outlined.
3. Remove three nuts retaining mounting bracket t o
body si de apron.
1. Position mounting bracket t o body side apron
wi t h t wo locating t abs.
2. Secure three nuts retaining bracket t o body si de
apron.
3. Install air compressor and compressor air dryer
assembl y as outlined.
4. Turn air suspension servi ce swi t ch ON.
A i r S u s p e n s i o n H e i g h t S e n s o r
Re a r
Re mo v a l
PERSONAL INJURY.
Hoist vehi cl e. Refer t o Secti on 00- 02. Suspension
must be at full rebound.
3. NOTE: Before removi ng air suspension height
sensor ( 5359) f rom ball st uds, observe dept h of
studs in air suspensi on height sensor.
Di sconnect bot t om and then t op end of air
suspension height sensor f rom ball studs by
depressi ng spri ng clip and pulling air suspension
height sensor away f rom ball st ud.
AIR SUSPENSION
HEIGHT SENSOR
MOUNTING BALL
STUD (TYPICAL)
PUSH SPRING
CLIP ON AIR
SUSPENSION
HEIGHT SENSOR
BACK
AIR SUSPENSION
HEIGHT SENSOR
, (TOP OR BOTTOM
V ATTACHMENT)
CAUTION:
WHEN REMOVING OR INSTALLING
AIR SUSPENSION HEIGHT SENSOR,
GRASP BODY OF AIR SUSPENSION
HEIGHT SENSOR AS CLOSE AS
POSSIBLE TO THE ATTACHING ENDS.
DO NOT USE A BENDING FORCE NEAR
THE CENTER OF THE AIR SUSPENSION
HEIGHT SENSOR BODY OR DAMAGE TO
THE AIR SUSPENSION HEIGHT SENSOR
MAY OCCUR.
PULL AIR
SUSPENSION
HEIGHT
SENSOR FROM
MOUNTING BALL
STUD WHILE
HOLDING SPRING
CLIP BACK
F3673-D
PUSH AIR SUSPENSION
HEIGHT SENSOR ONTO
MOUNTING BALL STUD
UNTIL SPRING CLIP
SNAPS IN PLACE INSTALLATION
1. Connect t op and then bot t om end of air
suspension hei ght sensor t o ball studs. Make
sure that ball studs are fully seat ed in air
suspension hei ght sensor ball stud retainer
housings.
2. Connect air suspension height sensor el ectri cal
connector.
3. Lower vehi cl e.
4. Turn air suspensi on swi t ch ON.
A i r S u s p e n s i o n S e r v i c e S w i t c h
1. Depress retaining clips retaining swi t ch t o br ace,
and remove swi t ch.
3. Push swi t ch into position in brace. Ensure
retaining clips are fully seat ed.
4. Connect el ectri cal connector.
04- 05- 7 2
Su s p e n s i o n , C o mp u t e r Co n t r o l l e d 04- 05- 7 2
C o m p r e s s o r Re l a y
1.
2.
Remove cover from power distribution box
(l ocated at rear of bat t ery) and remove
compressor relay.
Install new rel ay in power distribution box and
install cover.
TOWN CAR
COMP RE SSOR REL AY
, POWER
DI STRI BUTI ON
BOX
DI RECTL Y
BEHIND
BATTERY
RELAY " l ^ g Q Q ^
DDODODD
F6423-C
. COMP RE S S OR
RELAY
POWER
DISTRIBUTION
BOX DI RECTLY
BEHIND BATTERY
30 AMP FUS E
AIR SUSPENSI ON PUMP
F7206-C
Warni ng Indi cat or
Refer t o Secti on 13-01A (El ectroni c Cl uster) or
13-01B (Conventional Cl uster) for Removal and
Installation procedure.
2. Remove control module f rom snap-in fingers on
bracket behind the gl ove box.
3. Pull control module ( 5A919) out t o gain access t o
control module connect ors.
4. Di sconnect each control module connector by
pushing control module connector rel ease button
and pulling connect ors f rom control module.
Installation
1.
2.
3.
Connect control module el ectri cal connectors t o
control module.
At t ach control module t o bracket snap-in fingers
behind gl ove box.
Install gl ove compart ment . Refer t o Secti on
01- 12.
CONTROL
MODULE
FRONT OF
VEHICLE _
F8462-A
4. Turn air suspension swi t ch ON. Refer t o Secti on
01- 12.
Cont rol Module
Town Car
Removal
PERSONAL I NJURY.
Remove gl ove compart ment ( 06010) . Refer t o
Secti on 01- 12.
Air Li ne, Nyl onServi ce
If a leak is det ect ed in an air line, it can be servi ced by
carefully cutti ng the line wi th a sharp knife t o ensure a
good, cl ean, strai ght cut. Trim back outer sleeve
16-20 mm (0. 63-0. 78 inch). Then, install a servi ce
fitting. Wr ap union wi th el ectri cal t ape t o prot ect . If
more tube is requi red, it can be obtai ned in bulk.
04- 05- 7 3 Su s p e n s i o n , C o mp u t e r Co n t r o l l e d 54- 05- 7 3
REMOVAL A N D INSTALLATION (Continued)
NOTE: A soap and wat er solution can be appl i ed to
the air lines t o veri fy the l ocati on of air l eaks.
SERVICE OF LEAKS IN AIR LINE
X-ACTO KNIFE.
16-20 mm
(0.63-0.78 INCH)
REMOVE 16-20 mm (0.63-0.78 INCH)
OF SLEEVING MATERIAL
SERVICE UNION
SERVICE KIT NO 5B322
REPLACEMENT AIR LINE (IF REQUIRED)
4.70 mm DIAMETER NYLON 11 OR 12
^ TUBE SERVICE KIT NO. 5A911
TO SEAT, PUSH IN APPROXIMATELY
15 mm (0.59 INCH)
F5131-E
Air Spring Connector Repair Kit
If a gross leak is det ect ed in any of t he qui ck connect
fi tti ngs, it can be servi ced using an air spri ng
connect or repai r ki t ( 5B321) contai ni ng a new O-ring,
col l et, rel ease ring and O-ring removal t ool . The outer
housing of the fitting cannot be servi ced. Refer t o
illustration fol l owi ng Air Line, Nyl onSer vi ce. Minor
air seepage is accept abl e.
To remove t he col l et and O-ring, insert a scr ap piece of
air line, grasp t he air line firmly (do not use pliers) and
pull strai ght out. ( DO NOT use t he rel ease button.) A
f or ce of 130-220 N (30-50 l bs) is requi red t o remove
t he col l et. After t he collet is removed, use the servi ce
tool t o remove t he ol d O-ring.
To servi ce, fi rst ensure the seal ar ea is free of di rt.
Insert t he new O-ring and seat if in t he bot t om of the
fi tti ng housi ng. Insert the new col l et, verifying t he end
wi t h four prongs is i nserted. Press t he col l et into
posi ti on wi t h finger pressure. Install the new rel ease
button.
REMOVAL OF QUICK CONNECT FITTING
(AT SOLENOIDS OR AIR COMPRESSOR)
COLLET
INSTALLATION OF QUICK CONNECT FITTING
FITTING
PLASTIC WASHER
HOUSING O-RING RELEASE RING
jN COLLET
SERVICE KIT NO. 5B321
F8517-A
Solenoid O-Ring
The areas that have O-ring seal s that can be servi ced
are:
Air compressor head t o dryer: One O-ring.
Air spring solenoid t o end cap: Two O-rings each
solenoid. One larger O-ring in the solenoid housi ng.
(This O-ring does not affect air l eakage.)
Qui ck connect fi tti ng: One O-ring at dryer and one
O-ring at each spri ng.
If air l eaks are det ect ed in these areas, the
components can be removed following the procedures
outlined, and new O-rings can be installed.
SERVICE PROCEDURES
Qu i c k C h e c k s Wi t h o u t Star T e s t e r
The air suspension syst em el ectri cal harness routing
illustration shows the approxi mate routing of the
harnesses and location of the i nterconnects used by
t he air suspension syst em. To l ocate and di agnose
concerns inspect t he wiring and connect ors. A brief
descri pti on of each harness fol l ows:
14A435: Connects di rectl y t o the Air Suspension
Control Module ( 5A919) and Air Suspension Swi t ch.
Connects to the 12614 harness in the front center
of the luggage compartment. Connects t o the
14401 and 14290 harness in the RH front cowl
panel area.
04- 05- 74 Su s p e n s i o n , Co mp u t e r Co n t r o l l e d 0 4- 0 5 - 7 4
12614: Rear under vehi cl e harness that di rectl y
connect s t o t he Air Spring Solenoid Val ves ( 5311)
and t he Air Suspension Height Sensor ( 5359) .
1 4 4 0 1 : Di rectl y connects t o the ignition swi t ch,
instrument cl uster ( "Check Air Suspensi on"
Indicator) and fuse junction panel .
14290: Engine compartment harness that connect s
di rectl y t o t he Power Distribution Box and Harness
( 14516) , Air Compressor, and Air Compressor
Relay. This harness al so provi des t he compressor
ground.
The EVO line connects t o the steeri ng pump under
the engine.
14A005: Di rectl y connect s t o all lamp swi t ches
( 13713) and feeds the door open / cl osed
information t o the Control Modul e through t he
14401 and 14A435 harnesses.
A i r L e a k s
To servi ce for air l eaks, i nspect syst em for damaged
lines f rom the compressor t o t he rear air spring
assembl i es. Servi ce or repl ace damaged parts as
necessary.
ADJUSTMENTS
Ri d e Height
Di me n s i o n G a u g e R i d e Se n s o r T 90P - 5995- B
I The rear suspension ride height D dimension is
adj usted by moving the rear air suspensi on height
sensor mounting bracket up or down based on t he LH
rear suspensi on upper arm posi ti on. A sl ot adj ustment
nut is provi ded on the bracket t o adjust up or down as
requi red. A one index mark change t o t he air
suspensi on height sensor mounting bracket will yi el d
approxi mat el y 9 mm ( 0. 35 inch) change (up or down)
t o t he verti cal D dimension.
Rear Ai r Suspe n si o n Lo we r Mo un t i n g Br a c ke t a n d
Ad j ust me n t s
< RAISE
1
I LOWER -
VEHICLE I VEHICLE
VIEW A
F6358-C
Pa r t
1 Clip (Part of 5359)
Bushing
3

Nut (Part of 5359)
4

Clip (Part of 5359)
5 Bracket (Part of 5359)
WARNI NG: THE SUSPENSI ON HEIGHT D
DI MENSI ONS ARE FOR REFERENCE ONLY. THE
VEHI CLE ATTI TUDE MUST BE CONTROLLED BY
THE DI MENSI ONS SHOWN TO PREVENT VEHI CLE
DAMAGE.
Improper suspension ride height D dimension may be
caused by an Air Suspension syst em that is not set
properl y. Check the suspension D dimension ride
height as fol l ows:
1. Position the vehicle on a level surface over an
open servi ce pit or equivalent.
2. Open luggage compartment door ( 40110) and
ensure that the air suspension swi t ch is ON. Then
open the dri ver' s door only and turn ignition
swi t ch ( 11572) t o RUN.
3. Add wei ght t o rear bumper. Rear of vehicle will
rise t o tri m position.
4. After reachi ng tri m (air compressor st ops),
remove wei ght and cl ose dri ver' s door. Vehicle
will l ower t o correct ride height.
5. Rock the vehicle si deways to remove the effect
of suspension fri cti on, and allow it t o settl e.
6. Turn OFF air suspension swi t ch t o prevent
actuati on of air suspension syst em.
7. Remove wel d fl ash as required f rom i nboard
f rame reinforcement rail surface.
04- 05- 7 5 Suspensi on, Comput er Cont r ol l ed
~Z7~. AZZ
04- 05- 7 5
i
8. Measure dimension verti cal l y from axl e tube t o
f rame i nboard rei nforcement rail.
REAR SUSPENSION
FRAME
I NBOARD
FRAME
REI NFORCEMENT
DIMENSION D
EQUALS
TOWN CAR
%
126.8 7mm
(4.99 0.28 IN.)
CROWN VI CTORI A/
GRAND MARQUI S
BASE VEHI CLE / X"
139.8 + 8 mm (f i f
(5.50 0.31 IN.) V
REAR AXLE
TOURI NG PACKAGE
129.8 8mm
(5.11 0. 31 IN.)
9. From the LH si de of vehi cl e, posi ti on t he
Dimension GaugeRi de Sensor T90P-5995-B
on t he axl e tube so gauge post will cont act f rame
i nboard rei nforcement rail in a verti cal posi ti on.
10. Hol d gauge in pl ace and rel ease thumb screw.
Slide t he post up until gauge cont act s f rame
i nboard rei nforcement rai l , hand ti ghten thumb
scr ew and remove gauge by rolling it rearward off
t he axl e tube.
1 1 . WARNI NG: BEFORE ADJUSTI NG AI R
SUSPENSI ON HEI GHT SENSOR, TURN AI R
SUSPENSI ON SWI TCH OFF TO PREVENT
VEHI CLE DAMAGE.
If D ride height dimension is not within
speci fi cati on, adjust by movi ng t he rear air
suspensi on height sensor attachi ng bracket up or
down. Movi ng the bracket one index mark up or
down will change the verti cal D dimension
approxi mat el y 9mm ( 0. 35 inch).
1 2 . After t he adjustment is made, repeat St eps 6
through 10.
REAR AXLE
^ FRONT OF
VEHICLE
MEASURE D DIMENSION VERTICALLY
FROM AXLE TUBE TO FRAME INBOARD
REINFORCEMENT RAIL
F6359-F
Ri de He i ght Ad j ust me n t
REMOVE WELD
FLASH AS
REQUI RED
i
i t
READD
^DIMENSION
VI EW A
F6360-E
Pa r t
1 T90P- 5995- B He i ght Ch e c ki n g Ga uge
2

Fr a me Rai l
3

Sl i di ng Po st a n d Sc a l e (Par t of T90P- 5995- B)
4

Se t Sc r e w ( Pa r t of T90P- 5995- B)
5

Ga uge Ho usi n g ( Pa r t of T90P- 5995- B)
04- 05- 7 6 Su s p e n s i o n , Co mp u t e r Co n t r o l l e d 04- 05- 7 6
SPECIFICATIONS
T ORQU E SPECI FI CA T I ONS
Fr o n t N u t C o mp r e s s o r Mo un t i n g
Br a c ke t LH Fe n d e r A p r o n
5. 4- 8. 1 4- 6
Re a r N u t C o n t r o l Mo d u l e
Mo un t i n g Br a c ke t
5-6 45- 53
( Lb- l n )
Re a r B o l t R e a r Ai r Su s p e n s i o n
Se n s o r Mo un t i n g Br a c ke t t o No . 4
Cr o s s me mb e r
8. 1- 17 . 6 6- 13
Re a r N u t L o w e r Ai r Su s p e n s i o n
Se n s o r Mo un t i n g Br a c ke t t o LH
Uppe r Co n t r o l A r m
8- 14 6- 10
Re a r B o l t H e a t Sh i e l d t o Fr a me
Up p e r Spr i n g Se a t
8. 1- 17 . 6 6- 13
Re a r S h o c k A b s o r b e r Up p e r N u t 19- 35 15- 25
Re a r S h o c k A b s o r b e r
L o w e r S t u d a n d Nut
7 0- 115 52 - 85
Ai r Co mp r e s s o r Dr y e r t o
C o m p r e s s o r S c r e w
1. 6-2. 8 15- 25
( Lb- l n )
U p p e r / L o w e r Co n t r o l Ar m t o A x l e
P i v o t B o l t
140- 180 103- 133
U p p e r / L o w e r Co n t r o l Ar m t o
Fr a me P i v o t B o l t
162 - 2 03 119- 150
St a bi l i ze r Ba r Br a c k e t s 16-27 12- 20
St a bi l i ze r Ba r t o Li n k 17 - 24 13- 18
SPECI A L SERVI CE T OOLS REQU I RED
Tool N u m b e r /
T 90P - 5310- A
Ai r Spr i n g Re mo v e r
T90P-S310-A
T 90P - 5995- B
Di me n s i o n G a u g e R i d e
Se n s o r
T90P-599S-B
ROT U ND A EQU I PMENT
007 - 0041B SUPER STAR II Te s t e r
059- 00010 I n d uc t i v e Dwe l l - Ta c h - Vo l t - Oh ms Te s t e r
05 - 00- 1
G ROUP
SECTION TI TLE PAGE SECTION TI TLE PAGE
AXLE AND DRI VESHAFTSERVI CE 05-00-1 AXLE, TRACTION-LOK LIMITED SLIP
AXLE, INTEGRAL CARRI ER8. 8 INCH RING DI FFERENTI AL8. 8 INCH RING GEAR....... 05-02B-1
GEAR 05-02A-1 DRI VESHAFT... 05-01-1
SECTION 05-00 Axle and DriveshaftService
I
SUBJECT PAGE
Axl e I dent i f i cat i on Tag 05-00-1
Brake Sy st em, Anti -Lock. 05-00-4
D ri veshaf t 05-00-2
Dri vi ng Axl e 05-00-3
Component Test s ..05-00-15
Tractl on-Lok Di fferenti al .05-00-15
Universal Joi nt Flange Runout Check, Rear
Axl e 05-00-16
Analysis of Inoperati ve Condi ti ons 05-00-14
Anal ysi s of Leakage 05-00-8
Anal ysi s of Vi brati on ..........................05-00-9
SUBJECT PAGE
Preliminary Diagnosis 05-00-6
Inspecti on after Disassembly of the Axle........ 05-00-23
I nspect i on Bef ore Di sassembl y of t he
Axle 05-00-19
ADJUSTMENTS
Axle Al i gnme nt / I nspe c t i on ... 05-00-24
Ring Gear Backl ash Adj ust me nt . . 05-00-28
LUBRICATION
Drai ni ng and Fi lli ng 05-00-28
SPECIAL SERVICE TOOLS/EQUIPMENT ..05-00-30
VEHICLE APPLICATION
Axl e Ident i f i cat i on Tag
The Plant Code on the axl e identification t ag is the
official servi ce identifier.
The Plant Code for a particular rear axl e housing
( 4010) assembl y will not be dupl i cated.
The Plant Code will not change as long as that
particular rear axl e housing assembl y never
undergoes an external design change.
PLANT CODE
BUILD DATE
YEAR MONTH DAY
O
S052B
.3.08
CONVENTIONAL RATIO
(3L08 TRACTION-LOK)
RING GEAR
' DIAMETER (INCHES)
E5515-G
05- 00- 2 A x l e a n d Dr i v e s h a f t S e r v i c e 05- 00- 2
But if an internal desi gn change t akes pl ace in the
same axl e during the producti on life of t he axl e and
t hat internal change af f ect s servi ce parts*
interchangeability, a dash and numerical suffix will
be added to the Plant Code.
INTERCHANGEABILITY AFFECTED
INTERNALLYv BUILD DATE
YEAR MONTH DAY
The Vehicle Certification Label (V.C. Label ) is
affi xed on the LH front door l ock panel or door pillar.
The V.C. Label contai ns the axl e ID code in the
l ower RH corner.
CONVENTIONAL RATIO RING GEAR
(3L08 TRACTION-LOK) DIAMETER (INCHES)
E5516-G
MFD. BY FORD MOTOR CO. I N U.S.A.
DATE: 07/94 GVWR: 5347 LB - 2425 KG
FRONT GAWR: 2714 LB REAR GAWR: 2683 LB
1231 KG
1216 KG
THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY AND
BUMPER STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE.
VEH. IDENT. NO. 1LNLM83W9PY777000
IF0276
TYPE PASSENGER
IR0141
3H
482450
i DSO
BODY I VR I MLOG. I INT. TRIM I A/C 1 R 1 S I AX I TR
CA4 HD G60 DD A 2 B Y XBBBB
CODE
CONVENTIONAL RATIO
8<M*) 2.73:1
Y( T ) 3.08:1
5<E*) 3.27:1
2(K*) 3.55:1
*TftACTON L0IC
AXLE ID CODE
E1917-U
Dr i v e s h a f t
Re a r
NOTE: All dri veshaft ( 4602) assembl i es are bal anced;
if the vehi cl e is t o be undercoat ed, cover t he
dri veshaft and dri veshaft centeri ng socket yoke
( 4782) t o prevent appl i cati on of any undercoati ng
materi al .
The dri veshaft is a tubular shaft used t o transfer
engine torque f rom the transmi ssi on output shaft
( 7060) t o the differential in t he rear axl e housing
( 4010) , whi ch in turn transmi ts t orque through the axl e
shaft ( 4234) t o the dri ve wheel s.
The dri veshaft assembl y consi sts of:
Two single cardan rear axl e shaft universal j oi nts
( 4249) .
A dri veshaft slip yoke ( 4841) .
A wel ded aluminum tube assembl y.
Dri veshaft centeri ng socket yoke.
The dri veshaft slip yoke permits the dri veshaft t o
move f or war d and rearward on the transmi ssi on
output shaft during drivetrain movement and during
dri veshaft removal and installation.
Dr i ve sha f t Asse mbl y
E8389-A
Stem
Pa r t
1 Needle Rollers (Part of
4635)
2

Grease Seal (Part of 4635)
3

Bearing Cup (Part of 4635)
4

Thrust Washer (Part of 4635)
5

Spider (Part of 4635)
6 4249 Rear Axle Shaft Universal
Joint
7 4841 Driveshaft Slip Yoke
8

Snap Ring (8 Req'd) (Part of
4249)
Pa r t
9 4602 Driveshaft
10 4782 Driveshaft Centering Socket
Yoke
11 4851 Rear Axle Universal Joint
Flange
12 N800574-S100 Bolt (4 Req'd)
13 4249 Rear Axle Shaft Universal \
Joint (Rear)
14 End Yoke (Part of 4635)
A
Tighten to 93-130 N-m (71 -95
Lb-Ft)
Dr i v i n g A x l e
Re a r
The rear dri ve axl e operat es as f ol l ows:
Recei ves power f rom the engine through the
transmi ssi on and dri veshaft ( 4602) .
The pinion gear rot at es the differential case ( 4204)
t hrough engagement wi th the ring gear whi ch is
bol ted t o t he differential case outer flange.
Inside t he differential case, t wo differential pinion
gear s ( 4215) are mounted on t he differential pinion
shaft ( 4211) whi ch is pinned t o t he differential case.
These differential pinion gears are engaged wi t h t he
differential side gear ( 4236) t o whi ch the axl e
shafts ( 4234) are splined.
The differential case then turns and rotates the axl e
shafts and rear wheel assembl i es.
When it is necessary for one wheel and axl e shaft t o
rotate faster than the other, the f ast er turning
differential side gear causes the differential pinion
gear t o roll on the sl ower turning differential si de
gear t o allow differential acti on between the t wo
axl e shafts.
n
B r a k e S y s t e m , A n t i - L o c k
4 - Wh e e l
The Town Car is equi pped wi th a four-wheel anti-lock
brake syst em (ABS) wi t h Traction Assi st (TA) as an
opti on. The Crown Vi ct ori a, Grand Marqui s offers ABS
wi t h TA as optional equipment.
The syst em prevents wheel l ockup by automati cal l y
modulating the brake pressure during an emergency
st op.
By not locking t he wheel s, the dri ver can maintain
steeri ng control and st op the vehicle in the short est
possi bl e di stance under most condi ti ons.
The brake pedal f orce required t o engage the ABS
function may vary wi t h the road surface condi ti ons.
A dry surface requi res a higher f orce while a
sl i ppery surface requi res much less f orce.
During the ABS operat i on, the dri ver will sense a
pulsation in the brake pedal ( 2455) accompani ed by
a slight up and down movement in the pedal height
and a clicking sound.
The pedal effort and pedal feel during normal
braki ng are similar t o that of a conventional power
brake syst em.
Certai n rear axl e and driveline concerns are al so
common t o the engine, transmi ssi on, wheel beari ngs,
ti res and other part s of the vehicle. For thi s reason,
make sure that the cause of the troubl e is in the rear
axl e before adj usti ng, servi ci ng or replacing any of t he
part s.
Rear axl e concerns can be di agnosed and correct ed
qui ckl y by following t he proper procedures. Being able
t o perform a good di agnosi s is necessary in order t o
eliminate guesswork and save ti me.
Thi s Secti on defines vari ous possi bl e rear axl e
condi ti ons and t est s for identifying the cause and the
servi ce procedure. The four rear axl e condi ti ons t o be
revi ewed are:
1. Leakage Condi ti ons:
a. Rear Axl e Dri ve Pinion Seal ( 4676)
b. Drive Pinion Nut
c. Inner Wheel Beari ng Oil Seal s ( 1177)
d. Casti ng Porosi ty
e. Wel d Leaks
f. Rear Axl e Housing Vent ( 4022)
2. Vi brati on Condi ti ons:
a. Tires
b. Driveline Angl e
c. U-Joint Wear
d. Axl e Shaft Runout
e. Dri ve Pinion St em and Rear Universal Joint
Flange
f. Wheel Flange Runout
3. Noi se Conditions:
a. Non-Axl e Noi se
b. Axl e Noi se
(1) Gear Noise
( 2) Knock
( 3) Clunk
(4) Bearing Noi se
(5) Beari ng Prel oad Check
( 6) Bent Axl e Housi ngAnal ysi s
(7) Axl e Alignment Inspecti onRear
4. Inoperative Conditions:
a. Broken Axl e Shaft ( 4234)
b. Broken Pinion Stem
c. Broken Wel ds
d. Wheel Bearing Malfunctions
e. Axl e Lock-up
The di agnosti c material deal s wi th sympt om anal ysi s
whi ch di scovers the original cause of a concern so
that repeat servi ce can be avoi ded. However, t he
purpose of thi s Secti on is t o provi de information on
servi ce st eps of speci al i mportance.
U- J o i n t I n s p e c t i o n
1. Remove dri veshaft ( 4602) . Refer t o Secti on
05- 01.
2. Mani pul ate rear axl e shaft universal joint ( 4249)
in each di recti on of rotati on. If U-joint feel s stiff or
has a " l umpy, " " gr i t t y" feel in any di recti on,
repl ace rear axl e shaft universal j oi nts. Refer t o
Secti on 05- 01.
A l i g n me n t I n s p e c t i o n , Re a r A x l e
1. Rai se the vehicle on a hoist t o allow the rear axl e
housing ( 4010) t o be freel y suspended. Refer t o
Secti on 00- 02.
2. Using whi t e chal k or paint, mark a small area at
the center of each rear ti re and draw a verti cal
line on it.
CHALK LINE HERE
(CENTER OF EACH REAR TIRE)
E3942-C
Adjust bot h wheel s so that the marki ngs f ace the
front of t he vehi cl e. Using a t ape measure,
measure t he di stance between marks and record
this readi ng (front readi ng).
MEASURE CHALK LINK
TO CHALK LINE
.FRONT OF
VEHICLE
MEASURE
HERE
E6192-B
4. Rotate t he rear wheel s so that the marki ngs are
di rectl y underneath the vehicle. Measure t he
di stance bet ween the marks and record thi s
reading (bot t om readi ng).
MEASURE CHALK LINE
TO CHALK LINE
FRONT OF
VEHICLE
MEASURE
HERE
E6193-B
5. Rotate t he rear wheel s so the marki ngs f ace the
rear of the vehicle. Measure and record the
di stance bet ween marks (rear readi ng).
9.
MEASURE CHALK LINE
TO CHALK LINE
FRONT OF
VEHICLE '
MEASURE
HERE
E61S4-B
The di fference between t he front and rear
readi ngs is the toe-out or toe-in condition of the
housing (St eps 3 and 5).
Exampl e:
Front Readi ng: 157.9 cm ( 62- 3/ 16 inch)
Rear Readi ng: 157.6 cm (62-1 / 16 inch)
Toe-Out: 3.1 mm( 1/ 8i nc h)
Toe-in occurs when the front readi ng is less than
t he rear readi ng.
To determi ne camber, find t he average of the
front and rear readings (obtai ned in Steps 3 and
5) . Then subtract the bot t om readi ng from thi s
(obtai ned in Step 4) .
Exampl e:
Average of Front and Rear Readi ngs: 158. 1 cm
( 62- 1/ 8 inch)
Bot t om Reading: 158. 1cm (62-1 / 8 inch)
Di fference or Camber: 0 mm ( 0 inch)
Positive ( + ) camber is when t he bottom readi ng
is less than the average of t he front and rear
readi ngs. Negative (-) camber is when the bot t om
reading is greater than the average of the front
and rear readi ngs.
Results of the measurements t aken must conf orm
t o the following speci fi cati ons:
Camber 0 3.9 mm (0 5 / 3 2 inch)
Toe-in 0 - 1 . 5 8 mm ( 0- 1/ 16 inch)
Toe-Out 0 - 4 . 7 mm ( 0- 3/ 16 inch)
If the rear axl e assembl y does not meet this
speci fi cati on, it must be repl aced.
If rear axl e is repl aced, repeat St eps 2 through 7.
05-00-6 A x l e a n d Dr i v e s h a f t S e r v i c e 05-00-6
No i s e A c c e p t a b i l i t y
A gear-driven unit, especi al l y an automoti ve dri ve axl e,
under vari ous driving conditions such as a newly
paved bl ackt op road. The slight noise is not
detri mental t o operati on of t he rear axl e and must be
consi dered normal .
Wi t h t he Tracti on-Lok limited slip differential axl e,
slight chatter noise on sl ow turns after ext ended
hi ghway driving is consi dered accept abl e and has no
detri mental effect on the l ocki ng axl e functi on.
P r e l i mi n a r y Di a g n o s i s
Qu e s t i o n t h e Cu s t o me r
The preliminary di agnosi s begins wi t h the servi ce
techni ci an aski ng the customer enough di agnosti c
questi ons; especi al l y for condi ti ons of noi sy operati on
and/ or vi brati on.
Al ways ask the customer about:
1. The exact nature of the sympt om. If it is a
vi brati on, how is it fel t? If a noise, what kind? Is it
hi gh-pi tched, a rumbling noise or some other
concern?
2. The driving condi ti ons in whi ch the sympt oms
appear: road speed, drive or coast , on turns or on
a grade only.
3. Whet her the condition is constant or vari abl e.
Does a noise i ncrease in pi tch wi th speed or
some other f act or?
All information should be wri tten on the servi ce order
so t hat the techni ci an will know where t o st art l ooki ng.
The techni ci an doing the di agnosi s must be abl e t o
identify t he axl e concern f rom what is wri tten on t he
order fol l owi ng the road test.
It is, of course, preferabl e t o have the customer
demonst rat e the sympt oms in a road test whenever
possi bl e.
A x l e Di a gn o s i s Ch e c k She e t
If t here is enough reason t o suspect an axl e concern,
the servi ce techni ci an should al so initiate an Axl e
Di agnosi s Check Sheet.
T : MKfc ' ' ,7 JHSmU I J f f i L i r jmSSmi - L " -2HBBK- a W C * Z f c . I
NVH ROAD TEST FORM
1. Did condition exist when vehicle was new? Q Yes Q No
How did condition begin?
| | Gradually occurred Mileage
| | Suddenly occurred Mileaae
2. Neutral engine run-up NVH? Q Yes Q No
3. Vehicle NVH between MPH and MPH
4. What driving conditions affect the NVH?
| | Light to medium acceleration
| | Hard acceleration
| | Deceleration (foot off accelerator pedal)
| | Constant speed
5. If a vibration, where is the vibration noticed?
Seat
| | Steering wheel
| I Instrument panel pad
Floor
| | Hood and fenders
6. If a noise, define as:
Buzz
| | Moan
[ [ Drone
| | Rumble
D
H u m
| | Other Describe:
CF34~P
05- 00- 8
A x l e a n d Dr i v e s h a f t S e r v i c e
_ r~ T Y . .
T
05- 00- 8
It is most important t o record all the information rel ated
t o the concern t o di agnose it accuratel y and qui ckl y.
Ro a d Te st
A road test is mandatory for any customer concern of
noise and/ or vi brati on that is not eliminated by t he
on-hoist check of chassi s components. The Di agnosi s
Check Sheet is arranged t o record the conditions that
may be heard or felt during this t est .
The Di agnosi s Check Sheet lists four operati ng
condi ti ons or modes in whi ch some axl e noises come
and go: Drive, Crui se, Coast and Fl oat.
Mode Conditions
DRI VE A c c e l e r a t i n g t h e v e h i c l e ; a
d e f i n i t e t h r o t t l e d e p r e s s i o n
a p p l y i n g e n gi n e t o r q u e .
CRUI SE Ma i n t a i n i n g a c o n s t a n t s p e e d
wi t h t h e t h r o t t l e a p p l i e d .
COA ST De c e l e r a t i n g wi t h t h e t h r o t t l e
c l o s e d .
FL OAT Co n t r o l l e d d e c e l e r a t i o n ;
b a c ki n g t h e t h r o t t l e
c o n t i n u a l l y t o pr e v e n t e i t h e r
b r a ki n g o r a c c e l e r a t i n g t o r q u e
f r o m t h e e n gi n e .
To perform a good di agnosti c check it is i mportant t o
operat e the vehi cl e in all four modes and check off
t hose in whi ch t he noise occurs. The modes are
defi ned in the precedi ng chart. Wri t e down the
ki l ometers-per-hour (miles-per-hour) range at whi ch
both noise and vibration occur. On vehi cl es equi pped
wi t h overdri ve transmi ssi ons eval uate rear axl e noise
wi t h t he transmi ssi on in DIRECT DRIVE and not in
OVERDRIVE. Transmi ssi on noise can be mi staken for
rear axl e noise when in overdri ve.
A n a l y s i s o f L e a k a g e
Most rear axl e l eakage condi ti ons can be correct ed
wi thout a t eardown. However, it is i mportant t o cl ean
t he leaking area enough t o identify t he exact source.
A pl ugged or sei zed jiggle cap rear axl e housing vent
will cause excessi ve fl ange yoke seal lip wear due t o
internal pressure buildup. When a leak occurs, check
cap by pressi ng down on it wi t h index finger. If t he cap
moves up and down freel y, it is worki ng properl y. If it
does not move freel y, it must be repl aced.
Check axl e lubricant level. Adj ust as required t o j ust
bel ow bot t om of fill plug hole.
Fl a n ge Yo ke Se a l
When t he rear axl e dri ve pinion seal l eaks, it may be
t hat it was not installed properl y, or because of rough
t ext ure or damage on the seal journal surface.
Any damage t o the seal bore (di ngs, dents, gouges or
other i mperfecti ons) will di stort the seal casi ng and
al l ow l eakage past the outer edge of the rear axl e
dri ve pinion seal .
The rear axl e dri ve pinion seal can be torn, cut or
gouged if it is not assembl ed carefully. The spring that
hol ds the rear axl e drive pinion seal against the rear
axl e universal joint flange ( 4851) may be knocked out
and al l ow l eakage past the lip.
The rubber lips can occasi onal l y become hard (like
pl asti c) wi th cr acks at the oil lip cont act point. The
cont act point on the rear axl e universal joint flange is
usually bl ack, indicating excessi ve heat. Mar ks, ni cks,
gouges or rough surface t ext ure on the seal journal of
the rear axl e universal joint flange will al so cause
l eaks. Excessi ve rear axl e dri ve pinion seal wear will
be noted. The rear axl e universal joint flange should be
repl aced if any of t hese conditions exi st.
Metal chi ps or sand t rapped at the sealing lip al so may
cause oil l eaks. Thi s can cause a wear groove on the
rear axl e universal joint flange and heavy flange yoke
seal wear.
GOUGE
OR
VOID
IN LIP
CONTACT AREA
VIEW A
0.039 mm (0.05 INCH) OR GREATER
INDICATES EXCESSIVE WEAR
VIEW A
E5517-E
Dr i ve Pi n i o n Nut
CAUTI ON: Re mo v i n g t h e pi n i o n n ut d i s t u r b s
pi n i o n b e a r i n g p r e l o a d . Re f e r t o Se c t i o n 05- 02 A
( n o n t r a c t i o n - l o k a x l e ) o r 05- 02 B ( t r a c t i o n - l o k
a x l e ) f o r r e mo v a l a n d i n s t a l l a t i o n o f pi n i o n n ut
b e f o r e p e r f o r mi n g t h i s p r o c e d u r e .
On some high-mileage units, there have been
instances of oil leaking past t he t hreads of the pinion
nut. The condition can be correct ed by installing a new
nut or removing t he nut and appl yi ng Pipe Sealant Wi t h
Teflon D8AZ- 19554- A or equivalent meeting Ford
speci fi cati on WSK- M20G350- AZ on the t hreads and
nut f ace.
NOTE: Be sure t o fol l ow the correct procedure for
setti ng t he beari ng prel oad when the nut is installed.
Axl e lubricant level should be 1 / 4 - 9 / 1 6 inch bel ow
bot t om of fill plug hol e. Make sure rear axl e housing
vent hose is not pl ugged wi th dirt or debri s.
A x l e Sh a f t Se a l s
Axl e shaft inner wheel bearing oil seal s are suscepti bl e
t o the same ki nds of damage as rear axl e dri ve pinion
seal s if i mproperl y installed. The seal bore must be
cl ean and t he lip handled carefully t o avoi d cutting or
teari ng it. Axl e shaft journal surface must be free of
ni cks, gouges and rough surface t ext ure.
Occasi onal l y, t he spi ral machining l ead on the axl e
shaft seal j ournal can cause an oil pumping acti on past
the seal . If an inner wheel bearing oil seal l eaks after it
is repl aced, especi al l y on the passenger si de, the
spi ral machining l ead may be t he probl em. If this
occurs, repl ace t he suspect axl e shaft.
Ca s t i n g P o r o s i t y ( Ho l e s i n Ca s t i n g)
Occasi onal l y t here will be a rear axl e housing leak
through small pocket s in the metal . These pocket s
(casti ng l eakage) are caused by gas bubbl es in the
casti ng process and are known techni cal l y as a
porous condi ti on or porosi ty.
Because t here is al ways the danger of changing the
axl e' s sound charact eri st i cs if torn down t o repl ace
the carri er, servi ce is preferabl e. There are t wo
recommended t ypes of servi ce:
1. Peen in a small amount of body l ead. Seal the
pocket wi t h epoxy sealer that meet s Ford
Speci fi cati on ESB-M3035-A.
2. In larger pocket s, drill a shal l ow hole and t ap it for
a small set screw. Install the set scr ew and seal it
over wi t h epoxy sealer that meet s Ford
Speci fi cati on ESB-M3035-A.
We l d L e a ks
Most minor wel d l eaks can be correct ed wi t h epoxy
seal er that meet s Ford Manufacturi ng St andard
M3D35-A(E). Thi s includes the " puddl e" or fill wel ds
that join the axl e shaft tube t o the rear axl e housing on
integral axl es. They someti mes l eak and can be
seal ed easily. If a wel d is broken, t he rear axl e housing
must be repl aced. The alignment is t oo critical for field
servi ce.
CASTING
POROSITY
PUDDLE WELD
SEALED WITH
EPOXY
E3764-D
A x l e Ve n t
There have been some occurrences of lubricant
leaking through the rear axl e housing vent hose. Thi s
may be caused by a cl ogged or sti cki ng axl e vent cap.
The rear axl e housing vent should then be repl aced,
using Stud and Bearing Mount E0AZ-19554-BA or
WSK- M2G349- A1 on t hreads t o ensure retenti on.
A n a l y s i s o f Vi b r a t i o n
Few vi brati on condi ti ons are caused by the rear axl e
assembl y ( 4006) . On a vibration concern, fol l ow t he
di agnosi s procedure in Secti on 00- 04 unless t here is a
good reason t o suspect the axl e.
Most vi brati on in the rear end is caused by ti res or
driveline angle.
05- 00- 10
A x l e a n d Dr i v e s h a f t S e r v i c e 05 - 00- 10
T r a c t i o n - L o k Di f f e r e n t i a l
WARNI NG: NEVER RUN ENGI NE WI TH ONE
WHEEL OFF THE GROUND. A VEHI CLE EQUI PPED
WI TH A TRACTI ON- LOK DI FFERENTI AL WI L L
AL WAYS HAVE BOTH WHEELS DRI VI NG. IF,
WHI LE THE VEHI CLE IS BEI NG SERVI CED, ONLY
ONE WHEEL I S RAI SED OFF THE FLOOR AND THE
REAR AXL E I S DRI VEN BY THE ENGI NE, THE
WHEEL ON THE FLOOR COULD DRI VE THE
VEHI CLE OFF THE STAND OR J A CK. BE SURE
BOTH REAR WHEELS ARE OFF THE FLOOR.
Ti r e s
WARNI NG: DO NOT BAL ANCE THE REAR WHEEL S
AND TI RES WHI LE THEY ARE MOUNTED ON THE
VEHI CLE. POSSI BLE TI RE DI SI NTEGRATI ON
A N D/ OR DI FFERENTI AL FAI LURE COULD
RESULT, CAUSI NG PERSONAL I NJURY A N D/ OR
EXTENSI VE COMPONENT DAMAGE. USE
OFF- VEHI CLE WHEEL AND TI RE BAL ANCE R
ONLY.
CAUTI ON: S o me v e h i c l e s a r e e q u i p p e d w i t h
d i r e c t i o n a l t i r e s ( se e t i r e r o t a t i o n a r r o w s o n t i r e
s i d e wa l l ) . I f a d i r e c t i o n a l t i r e i s r e mo v e d f o r
s e r v i c e , i t mu s t b e r e mo u n t e d i n i t s o r i gi n a l
l o c a t i o n .
Vi brat i on i s a def i ni t e concer n wi t h moder n,
hi gh-mi l eage t i res if t he y ar e not " t r u e " bot h radi al l y
and l at eral l y. They ar e more suscept i bl e t o vi brat i on
around t he li mi ts of radi al and l at eral runout of t he t i r e
and wheel assembl y. They al so requi re mor e a c c ur a t e
bal anci ng. Wheel and t i re runout c he c ks, t rui ng and
bal anci ng ar e normal l y done bef or e axl e i nspect i on.
Somet i mes a vi brat i on concer n can be c o r r e c t e d by
pr oper l y rot at i ng or i nflati ng t he t i r es. The b e s t t i r e s
shoul d be o n t h e r e a r t o mi ni mi ze vi br at i on, especi al l y
on vehi cl es wi t h rear spri ngs ( 5560) .
Dr i v e l i n e A n gl e
An ^c o r r e c t dri veli ne (pi ni on) angl e c a n of t en be
d e t e c t e d by t he dri vi ng condi t i on when vi brat i on
o c c ur s.
1. A vi brat i on duri ng coast i ng f r o m 7 2 t o 56 km / h
( 45 t o 35 mph) i s of t en c a use d by a hi gh pinion
angl e.
2. A vi brat i on duri ng accel er at i on, agai n around 56
t o 7 2 k m / h ( 35 t o 45 mph), may i ndi cat e a l ower
t han speci f i ed pi ni on angl e. Ref er t o Sect i on
00- 04 f or pinion angl e pr ocedur e.
Whe n it i s cert ai n t ha t t he t i r es and dri vel i ne angi e
a r e not t he cause, i nspect t he axl e and rear axl e
shaf t uni versal j oi nt s. Ref er t o Sect i on 00- 04.
A x l e Sh a f t Run o ut
Runout of t he axl e shaf t at ei t her end i s an i nf requent ,
but possi bl e, cause of rear end vi br at i on. It i s
advi sabl e t o c he c k t he axl e shaf t f or runout of t he :
1. Pi lot (radi al )
2. Fl ange f a c e (l at eral )
3. Bol t ci r cl e (radi al )
Ref er t o Sect i on 00- 04 f or t he checki ng pr oc e dur e s
and speci al ser vi ce t ool f or axl e shaf t runout .
NOTE: If t he axl e shaf t assembl y is r e move d, c he c k
runout of t he shaf t i t self . The f or ge d (unmachi ned) part
of t he shaf t i s al l owed t o have a s much as 3. 0 mm
( 0. 120 i nch) runout . Thi s al one wi ll not cause a
vi brat i on condi t i on.
Dr i v e Pi n i o n S t e m a n d Re a r Un i v e r sa l J o i n t
Fl a n ge
Rear a xl e uni versal j oi nt f l ange runout shoul d be
c he c ke d when all ot her c he c ks have f ai l ed t o sho w
t he c a use of vi brat i on.
Anot her c a use of excessi ve rear axl e uni versal j oi nt
f l ange runout i s i mproper i nst allat i on of t he rear axl e
dri ve pi ni on seal . If t he spri ng on t he seal lip i s
di sl odged, it wi l l j a m up and c o c k t he f l ange. Check
t hat possi bi l i t y bef ore repl aci ng t he di f f erent i al ri ng
gear and pinion ( 4209) because of e xc e ssi ve rear axl e
uni versal j oi nt f l ange runout .
A x l e No i s e
The f ol l owi ng i s a gl ossar y of axl e noi se t e r ms:
1. Ge a r n o i s e i s t he t ypi cal "ho wl i n g" or "whi n i n g"
of t he ri ng gear and pinion due t o an i mproper
gear pat t er n, gear damage or i mproper beari ng
pr e l oa d. It can occur at vari ous speeds and
dri vi ng condi t i ons or it can be cont i nuous.
2. Ch u c kl e i s a pa r t i c ul a r ' ' r a t t l i n g" noi se t hat
sounds li ke a st i ck agai nst t he spo ke s of a
spi nni ng bi cycl e wheel . It oc c ur s whi l e
decel er at i ng f r om 64 k m/ h ( 40 mph) and can
usually be hear d all t he wa y t o a st op. The
f r equency vari es wi t h t he speed of t he vehi cl e.
3. K n o c k i s ver y si mi lar t o chuckl e, t hough it may
be l ouder and oc c ur s on accel erat i on or
decel er at i on. The t e a r down wi ll di scl ose wha t
has t o be c o r r e c t e d .
4. Cl u n k may be a met al l i c noi se heard whe n t he
aut omat i c t ransmi ssi on i s engaged in REVERSE
or DRI VE, or it may occur when t hr ot t l e i s appl i ed
or r el eased. It is c a use d by backl ash some whe r e
in t he dri vel i ne or l oose suspensi on component s.
It i s "f e l t " or heard in t he axl e.
No n - A x l e No i s e
Ther e a r e a f e w ot her condi t i ons t hat can sound j ust
li ke axl e noi se and have t o be consi dered in
pre-di agnosi s.
The t hr ee most common are exhaust , t i res and t ri m
moul di ngs.
1. In cert ai n condi t i ons, .he pi t ch of t he exhaust may
sound ve r y much li ke gear whi ne. At ot her t i mes,
it can be mi st aken f or a wheel beari ng rumbl e.
2. Ti r e se spe c i a l l y snow t i r e s c a n have a
hi gh-pi t ched t r e a d whi ne or roar si mi lar t o gear
noi se. Radi al t i r es, t o some degr ee, have t hi s
char act er i st i c. Any non-st andard t i re wi t h an
unusual t r e a d const r uct i on may al so emi t a roar
or whi ne-t ype noi se.
05-00-11 A x l e a n d Dr i v e s h a f t S e r v i c e 05- 00- 11
3. Trim, grille and mouldings can al so cause
whistling or whining noi ses.
Make sure that none of t hese are the cause of t he
noise before proceedi ng wi t h an axl e t eardown and
di agnosi s.
A n a l y s i s o f G e a r No i s e
Ge a r Ho wl a n d Wh i n e
Before di sassembl i ng t he axl e t o di agnose and correct
gear noise, eliminate t he ti res, exhaust , trim i tems,
roof racks and axl e shaf t s / rear wheel beari ngs
( 1225) as possi bl e causes.
The noises descri bed under Road Test usually have
speci fi c causes that can be di agnosed by observati on
as t he unit is di sassembl ed. The initial clues are, of
course, the t ype of noise heard on the road test and
the driving condi ti ons.
Beari ng malfunctions will normally be obvi ous at
di sassembl y. As noted earlier, differential pinion
beari ngs ( 4630) make a hi gh-pi tched, whistling noise,
usually at all speeds. However, if there is only one
differential pinion beari ng that is malfunctioning, t he
noise may vary in different driving phases.
Differential pinion beari ngs are frequentl y repl aced
unnecessarily on axl es wi t h l ow mileage under 24, 139
km ( 15, 000 miles) when correct i ng gear noise. They
shoul d not be repl aced unless t hey are actual l y scor ed
or damaged, or there is a speci fi c differential pinion
beari ng noise. Exami ne t he l arge end of the rol l ers for
wear. If the differential pinion beari ngs original blend
radius has wor n t o a sharp edge, the differential pinion
beari ng should be repl aced.
Remember that the l ow-pi tched rumble of a
malfunctioning wheel beari ng can al so be caused by
t he exteri or l uggage rack or t i res.
Rear wheel beari ng noise might be mi staken for pinion
beari ng noise. Look at t he rear wheel bearing careful l y
before teari ng down the axl e.
SPALLED
SPALLED DAMAGED
ROLLER ROLLERS
E3780-E
Rear wheel beari ngs are pressed into the axl e housi ng
t ubes, making t hem more difficult t o check. However,
t he axl e shaft is t he inner race for t he beari ng. If t he
beari ng is damaged, the roller surf ace on the axl e
shaf t may al so be damaged. The rol l ers run
approxi mat el y on t he center of the pol i shed surf ace.
E3761-D
Ch u c kl e
Chuckl e that occurs on the coast driving phase is
usually caused by excessi ve cl earance between the
differential gear hub and the differential case bore. It
can al so be caused by a damaged t oot h on the coast
si de of the pinion or ring gear.
Any damage t o a gear t oot h on the coast si de can
cause a noise identical t o chuckl e. Even a very small
t oot h nick or ri dge on the edge of a t oot h is enough t o
cause the noise.
You can often correct thi s condi ti on and eliminate the
noise simply by cleaning up t he gear t oot h nick or ri dge
wi t h a small grinding wheel . If t he cl eaned up or
damaged area is larger than 3. 2 mm (1 IB inch), it is
advi sabl e t o repl ace the gearset .
To check the differential ring gear and pinion, remove
as much lubricant as possi bl e f rom t he gears wi th
cl ean solvent. Wi pe the gears dry or bl ow them dry
wi th compressed air. Look for scor ed or damaged
t eet h. Al so look for cr acks or other damage.
If either gear is scored or damaged badl y, the
differential ring gear and pinion must be repl aced. If
there is metal broken l oose, t he rear axl e housing must
al so be cl eaned t o remove parti cl es t hat coul d cause
damage later. Any other damaged part s in the rear
axl e housing must be repl aced.
05- 00- 12
A x l e a n d Dr i v e s h a f t S e r v i c e 05- 00- 12
Da ma ge d Gear Te e t h
E3754-D
Sc o r e d Gear Te e t h
Kn o c k
Knock, whi ch can occur on all driving phases, has
several causes. In most cases, the techni ci an will
di scover one of the fol l owi ng condi ti ons:
1. A gear t oot h damaged on the dri ve si de is a
common cause of t he knock. Thi s can usually be
correct ed by grinding the damaged area.
Da ma ge d Te e t h or Ge a r se t
E3756-E
Dr i ve Si de Kn o c k
E3757-E
2. Occasi onal l y, the rear axl e differential gear case
bol ts ( 4216) will knock against the inside of the
rear axl e housing cast i ng. The cause may be t oo
little cl earance due t o casti ng fl ash or bumps. In
this case, the differential case ( 4204) can be
removed and the i nterference points ground out.
Another possibility is simply that one or more rear
axl e differential gear case bol ts are slightly
backed-out. Remove, repl ace and properl y
ti ghten the rear axl e differential gear case bol ts
using Stud and Beari ng Mount E0AZ-19554-BA
WSK- M2G349- A1 on the t hreads.
1
I
3. NOTE: Be sure t o measure t he end pl ay wi t h a
dial indicator and not by feel . Guessing is
i naccurate.
Knock is al so charact eri st i c of excessi ve end
pl ay in the axl e shaf t s. Up t o 0. 762mm ( 0. 030
inch) is al l owed in most axl es. The frequency of
knock will be less because the axl e shaft speed is
sl ower than the dri veshaft.
Cl un k
Co mp a n i o n Fl a n ge Ho l d i n g To o l T 7 8P - 4851- A
Clunk is due t o backl ash in the driveline or l oose rear
suspensi on components. To determi ne whet her
driveline clunk is caused by t he axl e, make a check of
the total axl e backl ash as fol l ows.
1. Rai se t he vehi cl e on a f rame or twi n post hoi st so
t hat t he wheel s are f ree. Refer t o Secti on 00- 02.
2. To maintain driveline bal ance, mark rear
dri veshaft centeri ng socket yoke ( 4782) and rear
axl e universal joint fl ange so they may be installed
in their original posi ti ons.
3. Remove bol ts and di sconnect dri veshaft f rom t he
rear axl e universal joint flange. Support
dri veshaft.
4. Install Compani on Fl ange Holding Tool
T78P-4851-A bet ween the rear axl e universal
joint flange and a part of t he f rame or body so that
t he rear axl e universal joint fl ange cannot move.
5. Lock t he LH rear wheel t o keep it f rom turni ng.
6. Us i n g a t o r q u e w r e n c h a n d l o c a t i n g o n o n e o f
t h e wh e e l n u t s , rot at e RH wheel sl owl y t o a
t orque of 6.8-8.1 N-m (5-6 Ib-ft). Hol d a chal k
marker on si de of ti re 304. 8 mm ( 12 i nches) f rom
center of wheel .
E3759-G
7. Rot at e wheel sl owl y in opposi t e di recti on t o a
t orque of 6.8-8.1 N-m (5-6 Ib-ft).
8. Measure t he length of t he chal k mark whi ch is the
total axl e backl ash. Total axl e backl ash should
be 25. 4 mm (1 inch) or l ess.
If the backl ash is within thi s limit, t he clunk will not
be eliminated by di sassembl i ng the axl e.
Check for t hese conditions if the backl ash is
excessi ve.
E l o n ga t i o n of the differential pinion shaft hol es in
t he differential case.
Mi s s i n g differential case or differential si de gear
thrust washer ( 4228) .
Ga l l i n g of the differential pinion shaft ( 4211) and
bore.
If none of t hese conditions are present, there may be a
l oose fit of t he axl e shafts t o the si de gear splines. You
should continue as fol l ows until the correcti on is mac
9. Install new differential si de gears ( 4236) and
check the backl ash.
10. Install t wo new axl e shafts.
11. Repl ace the differential case.
12. Install the dri veshaft so the index mark on the
dri veshaft slip yoke ( 4841) is in-line wi t h the index
mark on t he dri veshaft centeri ng socket yoke.
Thi s ensures original driveline bal ance. If vibration
exi st s after installation, refer t o Secti on 00- 04.
13. Tighten all rear axl e universal joint fl anges t o
95- 130 N-m (70-95 Ib-ft).
Be a r i n g Wh i n e
Beari ng whine is a high-pitched sound similar t o a
whi stl e. It is usually caused by malfunctioning pinion
beari ngs, whi ch are operati ng at dri veshaft speed.
Beari ng noise occurs at all driving speeds. This
distinguishes it from gear whine whi ch usually comes
and goes as speed changes.
C h a t t e r o n C o r n e r s
Chatter on corners is a condition where t he whol e rear
end vi brates only when the vehicle is movi ng. The
vi brati on is plainly felt and heard. In conventional
axl es, ext r a differential thrust washers cause a
condi ti on of partial l ockup that creat es this chatter.
Chatter noise on Tracti on-Lok axl es can usually be
t r aced t o errati c movement bet ween adj acent cl utch
pl ates and can be correct ed wi th a lubricant change
that includes friction modifier addi ti ve.
Cl i c k a t E n g a g e me n t
Click at engagement is a condition on axl es of a slight
noise, distinct f rom a " cl unk, " that happens in
REVERSE or DRIVE engagement. It can be correct ed
by installing a rear axl e dri ve pinion shaft oil slinger
( 4670) bet ween the rear axl e universal joint flange and
differential pinion beari ng ( 4621) .
A x l e S h a f t No i s e
Axl e shaft noise is similar t o gear noise and differential
pinion beari ng whi ne. However, axl e shaft beari ng
noise will normally distinguish itself f rom gear noise by
occurri ng in all driving modes (dri ve, coast and fl oat),
and will persi st wi t h transmi ssi on in NEUTRAL whi l e
vehi cl e is moving at probl em speed. If t he vehi cl e
makes thi s noise, remove suspect axl e shaf t s, repl ace
rear wheel beari ngs and install a new set of axl e
shaf t s. Re-evaluate vehi cl e for noise bef ore removi ng
any internal components.
Be a r i n g Ru mb l e
Beari ng rumble sounds like marbl es being tumbl ed.
Thi s condi ti on is usually caused by a malfunctioning
wheel beari ng. The l ower pi tch is because the wheel
beari ng turns at only about one-third of dri veshaft
speed. Wheel beari ng noise al so may be hi gh-pi tched,
similar t o gear noise, but will be evi dent in all four
driving modes.
A n a l y s i s o f I n o p e r a t i v e C o n d i t i o n s
If t he axl e fails t o operat e, there will be broken or
j ammed-up part s. Anal yze why the part s have broken
t o prevent the condition f rom recurri ng.
Br o k e n A x l e Sha f t
Inspect a broken axl e shaft for a twi st in the spline next
t o t he break.
Breaks that occur away from the spline or that are not
accompani ed by a t wi st in the spline may be caused
by forgi ng f l aws and / or fatigue of the axl e shaft.
Condi ti ons that can cause a broken axl e shaft include
forgi ng f l aws or excessi ve i mpact l oad t o the axl e
shaft as a result of a collision or other f act ors.
Br o ke n Pi n i o n S t e m
The dri ve pinion st em can break at any ti me if the
differential pinion beari ng prel oad is not set up
properl y. If t here is no prel oad, the differential pinion
beari ng will turn rel ati ve t o the axl e shaft. This galls t he
roller shaft and generates heat whi ch can draw the
t emper away f rom the shaft.
Too much prel oad al so generates beari ng heat wi th
the same result. The break normally occurs between
the t wo differential pinion bearings.
Br o k e n We l d s
Rear axl e housing wel ds, if compl etel y broken, call for
repl acement of the rear axl e housing.
Wh e e l Be a r i n g Ma l f u n c t i o n s
Because of the severe l oads they must handle, rear
wheel beari ngs may require repl acement at high
mi l eage. If a rear wheel bearing fails at l ow mileage, it
is often caused by overl oadi ng. '
Axl e L o c k- Up
Lock-up or seizure of the axl e shaft usually indicates
i nadequate lubrication. The lubricant prevents friction
and hel ps cool the part s as they heat up. Wi thout
enough lubricant, the heated part s get soft and may
eventually wel d together. Check for lubricant l eaks
after servi ci ng.
REAR AXLE DIAGNOSIS
Excessive Rear Axle Noise Differential carrier. ROAD TEST vehi cle to ensure
concern is rear axle noise rather
than other system noise. Refer to
Road Test. SERVICE and
REPLACE parts as required.
Loud "Clunk" in Driveshaft When
Shifting from REVERSE to DRIVE
Driveshaft.
Rear axle shaf t s.
RAISE vehi cle, ROTATE driveshaft
by hand to i solate concern as a
driveshaft or rear axle concern.
SERVICE or REPLACE as required.
REMOVE and INSPECT. SERVICE
as required.
Limited-Slip or Traction-Lok Axle
Does Not Work in Snow, Mud or on
Ice
Differential. PERFORM Traction-Lok
Differential Component Test as
outlined. SERVICE as required.
On Turns, the Rear Axle Has a
High-Pitched Chattering Noise
(Limited-Slip or Traction-Lok Axles
Only). Slight Chatter Noise on Slow
Turns after Extended Highway
Driving is Considered Accept able
and Has No Detrimental Effect on
the Locki ng Axle Function
Lubricant.
Differential.
ROAD TEST vehi cleDRIVE
vehi cle in ti ght ci r cl es5
clockwi se and 5 counterclockwi se.
If chatter is still evident, flush axle
and REPLACE with Motorcraft
Premium Rear Axle Lubricant
XY-80W90-QL or -KL or equivalent
meeting Ford speci fi cati on
WSP-M2C197-Aplus 13.5 ml (4
oz) of F3TZ-19B546-MA Friction
Modifier or equivalent meeting
Ford speci fi cati on
WSP-M2C196-A.
REMOVE di fferenti al, service as
required.
T r a c t i o n - L o k Di f f e r e n t i a l
Rai se up one rear wheel and remove t he wheel cover
( 1130) . Install adapt er f rom Tracti on Lock Torque Tool
T59L-4204-A on the wheel hub bol ts ( 1107) .
Tr a c t i o n - L o k To r q u e To o l T59L- 42 04- A
WHEEL OFF THE GROUND. A VEHI CLE EQUI PPED
WI TH A TRACTI ON- LOK DI FFERENTI AL WI L L
ALWAYS HAVE BOTH WHEELS DRI VI NG. IF,
WHI LE THE VEHI CLE I S BEI NG SERVI CED, ONLY
ONE WHEEL I S RAI SED OFF THE FLOOR AND THE
REAR AXL E IS DRI VEN BY THE ENGI NE, THE
WHEEL ON THE FLOOR COULD DRI VE THE
VEHI CLE OFF THE STAND OR J A CK. BE SURE
BOTH REAR WHE E L S ARE OFF THE FLOOR.
A Tract i on-Lok di f f erent i al can be c he c ke d f or pr oper
operat i on wi t hout removi ng it f r om t he rear axl e
housi ng ( 4010) .
05- 00- 16 A x l e a n d Dr i v e s h a f t S e r v i c e
05- 00- 16
Using a torque wrench wi th the capaci t y of at least
271 N-m ( 200 Ib-ft), rot at e the axl e shaft ( 4234) . Be
sure that the transmi ssi on is in NEUTRAL, one rear
wheel is on the floor and the other rear wheel is rai sed
off the floor. The breakaway torque required t o st art
rotation should be at least 27 N-m ( 20 Ib-ft). The initial
breakaway torque may be higher than the continuous
turning torque but thi s is normal . The axl e shaft should
turn wi t h even pressure throughout the check wi thout
slipping or binding. If the torque readi ng is less than
speci fi ed, check the differential case ( 4204) for
internal damage.
TRACTION-LOK
TORQUE TOOL
T59L-4204-A
TORQUE WRENCH
E1897-F
Un i v e r s a l J o i n t Fl a n g e Ru n o u t C h e c k , Re a r
A x l e
Co mp a n i o n Fl a n ge Run o ut Ga u ge
Cl a mp P l a t e
T 92 L - 4851- B
T 92 L - 4851- C
CAUTI ON: Th i s o p e r a t i o n d i s t u r b s t h e pi n i o n
b e a r i n g p r e l o a d . Pi n i o n b e a r i n g p r e l o a d mu s t b e
r e s e t i f t h e pi n i o n n ut ha s b e e n l o o s e n e d o r
r e mo v e d f o r r e a r a x l e un i v e r s a l j o i n t f l a n ge
( 4851) r e - i n d e x i n g o r r e p l a c e me n t .
1. Raise the vehicle on a hoist that supports the rear
axl e (twi n post hoi st). Refer t o Secti on 00- 02.
2. Remove the dri veshaft ( 4602) assembl y. Refer t o
Secti on 05- 01.
3. Inspect the rear axl e universal joint flange for
damage.
Position Companion Flange Runout Gauge
T92L- 4851- B on rear axl e universal joint fl ange.
E8356-B
I t e m
Par t
1
_
Pilot (Part of 4851)
2 Pinion Nut
3 T92L-4851-B Companion Flange Runout
Gauge
4 Bolts (2 Req'd)
5 T92L-4851-C Clamp Plate
Flange
5. Install Cl amp Plate T92L- 4851 -C on runout
gauge.
COMPANION FLANGE
RUNOUT GAUGE
T92L-4851-B
CLAMP PLATE
T92L-4851-C
E8357-A
05- 00- 17 A x l e a n d Dr i v e s h a f t S e r v i c e 0 5 - 0 0 - 1 7
DIAGNOSES AND TESTING ( Co n t i n u e d )
Align holes in cl amp pl ate wi th holes in rear axl e
universal joint flange and install bol ts. Snug bol ts
evenly.
CLAMP PLATE
T92L-4851-C
COMPANION FLANGE
RUNOUT GAUGE
T92L-4851-B E8358-A
7. NOTE: Refer t o Secti on 05- 02A for rear axl e
universal joint fl ange Removal and Installation
procedures.
Turn compani on fl ange runout gauge as shown t o
l ocate and mark high spot on rear axl e universal
joint fl ange. If fl ange runout exceeds 0. 010 i nch,
remove rear axl e universal joint flange, re-index
180 degrees on pinion and re-install. Check
runout agai n. If necessary, rotate rear axl e
universal joint fl ange until an accept abl e runout is
obtai ned. If fl ange runout is still more than 0. 010
inch, repl ace rear axl e universal joint fl ange.
VIEW A
DIAL INDICATOR/
MAGNETIC BASE
D78P-4201-B
VIEW A
8.
E8359-B
If excessi ve runout is still evident after
repl acement of the rear axl e universal joint fl ange,
repl ace the rear axl e housing. Repeat the above
checks until runout is within speci fi cati ons. Install
the dri veshaft assembl y as outlined in Secti on
05- 01. Tighten bol ts t o 95- 130 N-m (70-95 Ib-ft).
05- 00- 18 Axl e and Dr i v e s h a f t Ser v i c e 05- 00- 18
T o o t h Co n t a c t Pat t er ns Ch e c k o f Ge a r s e t
1. Set up ring gear t o creat e a pattern as fol l ows:
a. The final pinion position will be veri fi ed by
using the gear cont act pattern met hod
descri bed as f ol l ows:
TOP LAND PROFILE
ROOT
RING GEAR TOOTH
E8231-B
Pa r t
1

Profile
2

Lengthwise Bearing Arc
3 Toe
4 Heel
5

Root
6

Top Land
2.
b. WARNI NG: GEAR TEETH MAY HAVE
SHARP EDGES. WHEN HANDLI NG
GEARS, USE CARE TO AVOI D PERSONAL
I NJURY.
NOTE: When making changes, note t hat t wo
vari abl es are involved. For exampl e, if you
have the backl ash set correct l y t o
speci fi cati ons and you change t he pinion
posi ti on shi m, you may have t o readj ust the
backl ash t o the correct speci fi cati on bef ore
checki ng the pattern. Refer t o pattern
i nterpretati on.
The t oe of the gear t oot h is the porti on of t he
t oot h surface at t he end t owar d the center.
The heel of the gear t oot h is t he porti on of the
t oot h surface at t he outer end. The t op land
of a gear t oot h is the surf ace of the t op of the
t oot h. Every gear has a charact eri st i c
pat t ern. The illustrations show typi cal
pat t erns only, and expl ai ns how patterns shift
as gear location is changed. When maki ng
pinion position changes, shi ms shoul d be
changed in the range of . 05mm (. 002 inch) t o
. 10mm (. 004 inch) until correct pattern has
been obtai ned.
When a change in backl ash is requi red,
backl ash shims should be changed in the
range of 1-1/2 ti mes the amount of backl ash
requi red t o bring t he gears into speci fi cati on.
For exampl e, if the backl ash needed t o be
changed b y . 10mm (.004 inch), the shi m
pack should be changed by .15mm (. 006
inch) as a starti ng point. The actual amount of
backl ash change obtai ned will vary
dependi ng upon t he ratio and gear si ze.
High backl ash is correct ed by movi ng the
ring gear cl oser t o t he pinion. Low backl ash
is correct ed by moving the ring gear away
f rom the pinion. These correct i ons are made
by swi tchi ng shims f rom one si de of the
differential case t o t he other.
c. Paint ring gear t eet h wi th a marki ng
compound t o both t he dri ve and coast si de.
Rotate ring gear one compl et e revolution in bot h
di recti ons whi l e load is being appl i ed wi th a l arge
screwdri ver or similar tool bet ween the carri er
casti ng and differential case fl ange.
3. Interpret t he pattern left on ring gear as fol l ows:
Normal or desi rabl e pat t ern. The dri ve pattern
shoul d be cent ered on the t oot h. The coast
pattern should be cent ered on t he t oot h, but
may be slightly t owar d the t oe. There shoul d
be some cl earance between t he pattern and
t he t op of the t oot h.
DRIVE SIDE
HEEL ^ TOE
COAST SIDE
TOE HEEL
E4233-A
Backl ash correct . Thinner pinion position shi m
requi red.
DRIVE SIDE
HEEL TOE
COAST SIDE
TOE HEEL
E4234-A
Backl ash correct . Thi cker pinion position shim
requi red.
DRIVE SIDE
HEEL _ TOE
COAST SIDE
TOE HEEL
E4235-A
Pinion position shim correct . Decrease
backl ash.
DRIVE SIDE
HEEL TOE
COAST SIDE
TOE HEEL
E4236-A
Pinion posi ti on shi m correct . Increase
backl ash.
DRIVE SIDE
HEEL ' TOE
COAST SIDE
TOE HEEL
E4237-A
Cont act Pat t er n Loc at i on
4. The fol l owi ng summari zes how pinion and ring
gear movements will obtai n sat i sf act ory roll
patterns:
a. Decreasi ng backl ash moves t he ring gear
cl oser t o t he pinion.
Dr i ve pat t er n (convex side of gear) moves
slightly l ower and t owar d t oe.
Coast pat t er n (concave si de of gear) moves
l ower and t owar d t he t oe.
b. Increasing backl ash moves t he ring gear
away from t he pinion.
Dr i ve pat t er n moves slightly higher and
t owar d the heel .
Coast pat t er n moves higher and t owar ds
t he heel .
c. Thi cker pinion position shi m wi t h the
backl ash const ant moves the pinion cl oser t o
t he ring gear.
Dr i ve pat t er n moves deeper on t he t oot h
(flank cont act ) and slightly t owar d t he t oe.
Coast pat t er n moves deeper on t he t oot h
and t owar d t he heel .
d. Thinner pinion position shim wi t h t he
backl ash constant moves the pinion farther
f rom t he ring gear.
Dr i ve pat t er n moves t owar d t he t op of t he
t oot h (face cont act ) and t owar d t he heel .
Coast pat t er n moves t owar d the t op of the
t oot h and slightly t owar d t he t oe.
I n s p e c t i o n B e f o r e Di s a s s e m b l y o f t h e A x l e
A x l e Ba c k l a s h C h e c k
Co mp a n i o n Fl a n ge Ho l d i n g To o l T 7 8P - 4851- A
1. Raise the vehi cl e on a frame or twi n post hoi st so
that the wheel s are f ree. Refer t o Secti on 00- 02.
2. To maintain driveline bal ance, mark rear
dri veshaft centering socket yoke ( 4782) and rear
axl e universal joint flange ( 4851) so t hey may be
installed in their original posi ti ons.
05- 00- 2 0
A x l e a n d Dr i v e s h a f t S e r v i c e
05- 00- 20
3. Remove bol ts and di sconnect dri veshaft ( 4602)
from the rear axl e universal joint flange. Support
dri veshaft.
4. Install Companion Flange Holding Tool
T78P-4851-A between t he rear axl e universal
joint flange and a part of the frame or body so that
the rear axl e universal joint flange cannot move.
5. Lock the LH rear wheel t o keep it f rom turning.
6. Using a torque wrench and locating on one of the
wheel nuts rotate RH wheel sl owl y to a torque of
6.8-8.1 N-m (5-6 Ib-ft). Hold a chal k marker on
si de of ti re 304. 8 mm ( 1 2 i nches) from center of
wheel .
E3759-G
7. Rotate wheel sl owl y in opposi te di recti on t o a
torque of 6. 8-8. 1 N-m (5-6 Ib-ft).
8. Measure the length of the chal k mark whi ch is the
total axl e backl ash. Total axl e backl ash should
be 25. 4 mm ( 1 inch) or l ess.
I n t e g r a l Ca r r i e r
Pi n i o n De p t h Ga u ge T 7 9P - 402 0- A
Inspect t he differential case ( 4204) assembl y and
drive pinion before t hey are removed f rom the rear
axl e housing ( 4010) . These inspections can help find
the cause of the troubl e and determi ne the correcti on
needed.
1. Wi pe the lubricant f rom the internal worki ng part s
and visually i nspect the part s for wear and/ or
damage.
2. Rotate the gears t o see if there is any roughness
whi ch woul d i ndi cate worn or damaged beari ngs
or gears.
3. Check the ring gear t eet h for signs of scori ng,
abnormal wear, ni cks or chi ps.
4. Set up Dial Indicator wi th Bracket ry
TOOL-4201-C or equivalent, and check ring gear
backl ash and ring gear backf ace runout.
5. Proper gearset assembl y must be checked using
the Pinion Dept h Gauge T79P-4020-A whi ch
shows correct dri ve pinion bearing adj ustment
shi m ( 4663) requi red t o ensure accept abl e
running condi ti on.
05- 00- 21 A x l e a n d Dr i v e s h a f t S e r v i c e 0 5 - 0 0 - 2 1
mmmiiifmmmm
Di f f e r e n t i a l Ri ng Gear a n d Pi ni on Cl e a r a nc e Che c k
-iiimimi Q ni l i . ' i i i i ni i -
E4152-G
Pa r t
1 T79P-4020-A9 Screw
2 4621 Differential Pinion Bearing
3 T79P-4020-A11 Handle
4

Assembled Tool
5 T79P-4020-A3 Aligning Adapter
Pa r t
6 T79P-4020-A10 Gauge Block (1.700 Thick)
7 T79P-4020-A19 Gauge Tube (3.063 OD 8.8
Inch)
7 T80T-4020-F49 Gauge Tube (2.892 OD 7.6
Inch)
Ri n g Me a s u r e me n t P r o c e d u r e a n d P i n i o n
Ba c k l a s h C h e c k
Thi s measurement procedure indicates runout
condi ti ons that will not show up in other t est s. Remove
the dri ve pinion bearing adj ustment shi m. Refer t o
Secti on 05-2A. Measure ring gear backl ash on 30
consecuti ve ring gear t eet h using Dial Indicator wi th
Bracket ry TOOL-4201-C or equivalent. Note the
vari ati on bet ween the high and low readi ngs. If over
0. 10mm ( 0. 004 inch), repl ace the differential ring gear
and pinion ( 4209) . Install the axl e housing cover
( 4033) .
DIAL INDICATOR
WITH BRACKETRY
TOOL-4201-C
F2689-F
Ri n g G e a r Ru n o u t C h e c k
If t he ring gear runout check (before di sassembl y)
exceeds speci fi cati on, t he condition may be caused
by a war ped ring gear, a damaged rear axl e housi ng,
loss of differential beari ng prel oad or debri s bet ween
t he ring gear back f ace and t he case fl ange. To
determi ne the cause of excessi ve runout, proceed as
fol l ows.
1. Wi t h the pinion removed, pl ace differential
case/ gear subassembl y wi t h differential
beari ngs ( 4221) and differential beari ng cups
( 4222) in rear axl e housi ng.
E4411-C
2. Install a 6. 25 mm (0.265-i nch) differential bearing
shim ( 4067) on the LH si de of subassembl y.
6.25 mm
(0.265 IN)
DIFFERENTIAL
BEARING SHI M'
4067
E4412-E
3. Install the LH beari ng cap finger-tight.
E4413-C
4. Install progressi vel y larger differential beari ng
shi ms on the RH si de until t he l argest differential
beari ng shi m sel ect ed can be assembl ed wi t h a
slight drag feel .
NOTE: APPLY PRESSURE
TOWARD LEFT SIDE TO
ENSURE BEARING CUP
DIFFERENTIAL BEARING
SHIM 4067
E4414-D
5. Install the RH si de beari ng cap. Install beari ng cap
bol ts. Tighten t o 95- 115 N-m (70-85 Ib-ft).
ARROWS
OUTBOARD
E4415-C
6. Rotate t he assembl y t o ensure f ree rotati on.
E4416-C
7. Install Dial Indicator wi th Bracket ry TOOL-4201-C
or equivalent. Check and note ring gear runout.
DIAL INDICATOR WITH
BRACKETRY TOOL-4201-C
8. If the runout is within speci fi cati on, the original out
of speci fi cati on runout was caused by insufficient
differential bearing prel oad. If the runout exceeds
speci fi cati on, proceed t o Step 9.
05- 00- 2 3 A x l e a n d Dr i v e s h a f t S e r v i c e 05- 00- 23
9. Remove differential c a s e from the rear axle
housing.
10. Remove ring gear using a drift that will bot t om in
ring gear bolt hol es. Stri ke at al ternate hol es
around gear.
11. Install differential case assembl y in rear axl e
housing wi t h o u t ring gear.
12. Check differential case runout agai n. If the runout
is now within limits, the ring gear was out of
speci fi cati on and should be repl aced. If the runout
is still excessi ve, the differential case is damaged
and should be repl aced.
I n s p e c t i o n a f t e r Di s a s s e m b l y o f t h e A x l e
WARNI NG: AL WAYS WEAR SAFETY GOGGLES. IF
SOLVENT OR COMPRESSED AI R GETS IN EYES,
SEVERE I RRI TATI ON OR PERMANENT I NJURY
SUCH A S BLI NDNESS COULD RESULT. SEEK
MEDI CAL ATTENTI ON IMMEDIATELY.
Thoroughl y clean all part s. Syntheti c seal s must not be
cl eaned, soaked or washed in cleaning sol vents.
Al ways use cl ean solvent when cleaning beari ngs. Oil
the beari ngs i mmedi atel y after cleaning to prevent
rusti ng. Inspect the part s for wear or damage. Clean
the inside of the carri er before rebuilding it.
When a scored differential ring gear and pinion ( 4209)
is repl aced, the rear axl e housing ( 4010) should be
washed thoroughl y and steam cl eaned. This can only
be done effecti vel y if t he axl e shafts ( 4234) and inner
wheel bearing oil seal s ( 1177) are removed f rom the
housing. Inspect individual part s as outlined bel ow.
G e a r s
Examine the differential ring gear and pinion gear t eet h
for scori ng or excessi ve wear. Worn gears cannot be
rebuilt to correct a noisy condi ti on. Gear scori ng is t he
result of excessi ve shock loading or t he use of an
i ncorrect lubricant. Scored gears cannot be reused.
Examine the t eet h and thrust surf aces of the
differential side gears ( 4236) . Wear on the hub of the
differential side gear can cause a chucki ng noise
known as chuckl e when the vehicle is driven at low
speeds. Wear of splines, thrust surf aces or thrust
washers can contri bute t o excessi ve driveline
backl ash.
Be a r i n g Cu p s a n d C o n e a n d Ro l l e r A s s e mb l i e s
Check bearing cups for rings, scores, galling or
excessi vel y worn wear patterns. Pinion cups must be
solidly seat ed. Check for seati ng by attempti ng t o
insert a 0. 04 mm ( 0. 0015 inch) feeler bet ween these
cups and the bot t oms of their bores.
When operat ed in the bearing cups, cone and roller
assembl i es must turn wi thout roughness. Examine the
l arge roller ends for wear. If the original blend radius
has worn t o a sharp edge, the beari ng shoul d be
repl aced.
If inspection reveal s either a worn beari ng cup or a
worn cone and roller assembl y, both part s should be
repl aced t o avoi d damage.
Un i v e r s a l J o i n t Fl a n g e , Re a r A x l e
Make sure that the surfaces of t he rear axl e universal
joint flange ( 4851) have not been damaged in
removing the dri veshaft ( 4602) or in removi ng the
dri veshaft centering socket yoke ( 4782) f rom the rear
axl e universal joint flange. The end of t he rear axl e
universal joint flange that cont act s t he rear axl e dri ve
pinion shaft oil slinger ( 4670) must be smoot h. Polish
these surfaces if necessary. Roughness aggravat es
backl ash noises and causes wear of t he rear axl e
universal joint flange and pinion nut, causi ng a l oss in
differential pinion bearing prel oad.
Dr i v e s h a f t C e n t e r i n g S o c k e t Yo k e
Make sure that the surfaces of the dri veshaft
centeri ng socket yoke have not been damaged in
removi ng t he dri veshaft or in removing the dri veshaft
centeri ng socket yoke f rom t he rear axl e universal
joint flange. The end of the dri veshaft centeri ng socket
yoke that cont act s the rear axl e universal joint flange
must be smoot h. Polish t hese surf aces, if necessary.
Ca r r i e r H o u s i n g
Make sure that the differential bearing bores are
smoot h (if appl i cabl e). Remove any ni cks or burrs f rom
the mounting surfaces of the carri er housing.
Di f f e r e n t i a l Ca s e
Make sure that the hubs where the differential bearing
( 4221) mount are smoot h. Carefully exami ne the
differential beari ng shoul ders whi ch may have been
damaged when the beari ngs were removed. The
differential beari ngs assembl i es will fail if t hey do not
seat firmly agai nst the shoul ders. Check t he fit (free
rotati on) of the differential si de gears in their
counterbores.
T r a c t i o n - L o k Di f f e r e n t i a l P a r t s
CAUTI ON: Pl a t e s s h o u l d b e r e p l a c e d a s a s e t
o n l y . E x a mi n e al l t h r u s t s u r f a c e s a n d h u b s f o r
we a r . A b n o r ma l we a r o n t h e s e s u r f a c e s c a n
c o n t r i b u t e t o a n o i s y a x l e o n c o n e - t y p e
T r a c t i o n - L o k d i f f e r e n t i a l .
Inspect the cl utch pl ates for uneven or ext reme wear.
The tanged cl utch pl ates must be free f rom burrs,
ni cks or scrat ches whi ch coul d cause excessi ve or
errati c wear t o the internally splined cl utch pl ates. The
internally splined cl utch pl ates should be i nspected for
condition of the materi al , and wear. Repl ace the pl ates
if their thi ckness is less than 1.5 mm ( 0. 058 inch) or if
the materi al is scored or badl y worn. Inspect the plate
internal t eet h for wear. Repl ace them if excessi ve
wear is evident.
ADJUSTMENTS
Axle Al i gnment/Inspecti on
1. Raise the vehi cl e on a hoist t o al l ow t he rear axl e
housing ( 4010) t o be freel y suspended. Refer t o
Secti on 00- 02.
2. Using whi te chal k or paint, mark a small area at
t he center of each rear ti re and dr aw a verti cal
line on it.
CHALK LINE HERE
(CENTER OF EACH REAR TIRE)
E3942-C
3. Adj ust both wheel s so that the marki ngs f ace t he
front of the vehicle. Using a t ape measure,
measure the di stance between marks and record
thi s reading (front readi ng).
MEASURE CHALK LINK
TO CHALK LINE
.FRONT OF
VEHICLE
MEASURE
HERE
E6192-B
05- 00- 2 5 A x l e a n d Dr i v e s h a f t S e r v i c e 0 5 - 0 0 - 2 5
4. Rotate t he rear wheel s so t hat t he marki ngs are
di rectl y underneath the vehicle. Measur e t he
di stance bet ween the marks and record this
reading (bot t om readi ng).
MEASURE CHALK LINE
TO CHALK LINE
FRONT OF
VEHICLE
MEASURE
HERE
E6193-B
5. Rotate t he rear wheel s so the marki ngs f ace the
rear of the vehi cl e. Measure bet ween scri be
marks (rear readi ng).
MEASURE CHALK LINE
TO CHALK LINE
FRONT OF
VEHICLE "
MEASURE
HERE
E6194-B
6. The di fference bet ween t he front and rear
readi ngs is the toe-out or toe-in condi ti on of the
housing (St eps 3 and 5).
Exampl e:
Front Readi ng: 157. 9 cm (62-3 / 1 6 inch)
Rear Readi ng: 157. 6 cm (62-1 / 1 6 inch)
Toe-Out: 3. 1 mm ( 1 / 8 inch)
Toe-in occurs when the front readi ng is less than
the rear readi ng.
7. To determi ne camber, find the average of the
front and rear readi ngs (obtai ned in St eps 3 and
5) . Then subt ract t he bot t om readi ng f rom thi s
(obtai ned in St ep 4) .
Exampl e:
Average of Front and Rear Readi ngs: 158. 1cm
( 62- 1/ 8 inch)
Bot t om Readi ng: 158. 1 cm (62-1 IB inch)
Di fference or Camber: 0 mm (0 inch)
Positive ( + ) camber is when t he bot t om readi ng
is less than the average of the f ront and rear
readi ngs. Negati ve (-) camber is when t he bot t om
reading is greater than the average of the front
and rear readi ngs.
8. Results of the measurements t aken must conf orm
to the following speci fi cati ons:
Camber 0 3. 9 mm (0 5 / 3 2 inch)
Toe-In 0 - 1 . 5 8 mm ( 0- 1/ 16 inch)
Toe-Out 0 - 4 . 7 mm ( 0- 3/ 16 inch)
If t he rear axl e assembl y does not meet thi s
speci fi cati on, it must be repl aced.
9. If rear axl e is repl aced, repeat St eps 2 through 7.
Dr i v e s h a f t Ba l a n c i n g
Vi brati on or shudder whi ch is noti ceabl e either on fast
accel erati on, when coasti ng or when using the engine
for braki ng, may be caused by the rear axl e housing
being l oose on the rear suspensi on, i mproper ti re
bal ance, improper driveline installation or bal ance.
If dri veshaft ( 4602) components are repl aced and
shaft vibration is encountered after installation,
di sconnect the dri veshaft and remove the dri veshaft
slip yoke ( 4841) . Rotate the dri veshaft slip yoke 180
degrees. Then reconnect the dri veshaft t o the
dri veshaft slip yoke and reinstall in vehi cl e. If the
vibration persi sts, di sconnect the dri veshaft at t he
rear axl e universal joint flange ( 4851) . Rotate the
flange 180 degrees and reconnect t he dri veshaft t o
the rear axl e universal joint flange .
If rotati ng the dri veshaft 180 degrees does not
eliminate vibration, t he shaft may be bal anced using
the following procedure.
1. Raise the vehicle on a hoist so that rear axl e is
safel y supported wi t h wheel s free t o rotate at
normal ride height.
2. Wi th the transmi ssi on in gear, i ncrease the
vehicle speed t o maxi mum vibration level. Not e
and record the speed of thi s vibration peri od as a
baseline speed.
3. WARNI NG: USE CAUTI ON WHEN CHECKI NG
THE DRI VESHAFT NEAR THE BALANCE
WEI GHTS TO PREVENT INJURY TO THE
HANDS.
Wi th t he transmi ssi on in gear, run the vehi cl e wi th
the dri veshaft rotati ng at a speed of 64-80 k m/ h
(40-50 mph). Have an assi stant carefully bring a
crayon, pi ece of chal k or col ored pencil up until it
just barel y cont act s t he rear end, center and front
end of t he dri veshaft. The chal k marks will
indicate the heavy si de of the shaft.
E4238-A
4. Install t wo screw-t ype hose cl amps on the
dri veshaft so that their heads are l ocated 180
degrees f rom the chal k mark, starti ng at t he rear
axl e universal joint fl ange end of the dri veshaft.
Tighten the cl amps.
5. CAUTI ON: To p r e v e n t o v e r h e a t i n g , d o n o t
r u n t h e v e h i c l e o n t h e h o i s t f o r a n e x t e n d e d
p e r i o d .
Accel erat e the vehi cl e up t o t he baseline speed. If
vi brati on is still evi dent, rot at e the cl amps
approxi mat el y 45 degrees away f rom each other
and t est for correct i on of vi brati on.
6. If necessary, continue t o rot at e the cl amps apart
in smaller increments until the vibration becomes
reduced or eliminated.
7. If the vibration is not compl etel y eliminated,
repeat t he above procedure and bal ance t he front
end of t he dri veshaft, checki ng for elimination or
reducti on of the vi brati on.
8. Remove the vehicle f rom the hoist and perform a
road t est .
CHALK MARK
ROTATING CLAMPS E4240-A
A l t e r n a t e P r o c e d u r e
1. Road t est Evaluate and record road speed at
whi ch vi brati on occurs.
2. Raise vehi cl e on a f rame cont act hoist.
Re-evaluate by starti ng the engine, engaging the
transmi ssi on and accel erati ng t o the i ndi cated
speeds at whi ch the vi brati on was most severe
during the road t est . Suspending the rear axl e
( 4001) makes the driveline more sensitive t o
vi brati on.
3. Mark one of the driveshaft centering socket yoke
mounting bolt holes " A" , and number the rear
axl e universal joint flange holes 1 through 8,
starti ng wi t h t he one mati ng wi t h " A" . The original
position can then be identified as " A - 1 " . Re-index
the shaft 180 degrees t o " A- 5 " and road t est . If
not sat i sf act ory, repeat for positions " A- 3 " and
" A- 7 " and, if necessary, bet ween the best t wo of
the previ ous four t est ed until t he vibration st ops
or t he best position is found.
DRIVESHAFT
CENTERING
SOCKET YOKE
4782
HOLE POSITION A
REAR AXLE
COMPANION
FLANGE
4851
E8489-A
A vehicle is more sensitive t o excessi ve
i mbal ance and/ or runout at the rearward end of
the dri veshaft. Therefore, l ocat e the heavy si de
of t he dri veshaft by the use of t he st robe light and
transducer f rom Rotunda El ectroni c St robe
Bal ancer 006- 01400 or equivalent as f ol l ows:
Remove rear wheel s and t i res.
Reinstall all t he lug nuts ( 1012) in reverse, flat
si de t owar d t he rear di sc brake rotor ( 2C026)
t o avoi d lug nut i mbal ance and t o prevent rear
di sc brake rotor f rom di sl odgi ng.
w Draw an axi al chal k line at any radial l ocati on
approxi mat el y 101.6 mm (4 inches) long at the
rear of t he dri veshaft.
Locat e t he transducer on the bot t om si de of
the rear axl e housing, and secure it in pl ace.
Run t he engine at t he wor st vi brati on speed
noted and wat ch t he posi ti on of the chal k line
using the st robe light.
Thi s provi des a starti ng point f or the initial
l ocati on of t he cl amps.
CHALK LINE
E4241-A
LOCATING TRANSDUCER
TRANSDUCER
5.
E4242-A
Stop the engine and rotate t he dri veshaft so t hat
the chal k line is in the same location as seen
under the st robe light.
05- 00- 28 Axl e a n d Dr i veshaf t Ser vi ce 05- 00- 28
6. Install t wo stainless steel hose cl amps on the
dri veshaft. Position t he cl amp heads 180
degrees from the transducer and tighten the
cl amps.
7. CAUTI ON: Do n o t r u n t h e engi ne on t he hoi st
wi t h t he t r ansmi ssi on e n g a g e d f or ex t ended
p e r i o d s d u e t o t h e d a n ge r o f o v e r h e a t i n g t h e
e n gi n e o r t r a n s mi s s i o n .
Run the engine through t he speed range. If no
vi brati on is felt, remove the lug nuts, install the
wheel s and ti res and reinstall the lug nuts in the
correct position and go t o Step 9.
However, if any vibration still exi st s, t he
combi ned wei ght of the t wo hose-cl amp heads
may be in excess. To reduce this excess
wei ght, rot at e the cl amp heads away f rom
each other approxi matel y 15 degrees (one
each way from the original posi ti on). Run the
engine and note if the vibration has been
reduced.
8. Continue t o rotate the cl amp heads apart in
smaller angular i ncrements until the vehi cl e feel of
bal ance (vibration) is best . At this point, install the
wheel s and ti res and road test the vehi cl e t o
determi ne the actual degree of i mprovement.
If sat i sf act ory i mprovement has been obtai ned,
proceed t o Step 9.
9. When t he bal ance has been correct ed t o a
sat i sf act ory level, ti ghten the cl amps securel y.
Clean thoroughl y wi th lacquer thinner and spray
the cl amps wi th a commerci al l y available bl ack
paint for a finished appearance.
Ring Gear Backlash Adjustment
Two separat e adj ustments affect pinion and ring gear
t oot h cont act . They are pinion location and backl ash.
Individual di fferences in matchi ng the rear axl e housing
( 4010) and t he differential pinion bearings ( 4630)
require t he use of shims to l ocate the pinion for correct
contact wi th the ring gear. Refer t o Secti on 05-02A for
shi m sel ecti on procedures.
E1476-F
I t e m
Pa r t
Flange
2 4859 Drive Pinion Oil Seal
Deflector
3 4662 Differential Drive Pinion
Bearing Spacer
4 4663 Drive Pinion Bearing
Adj ustment Shim
5 4067 Differential Bearing Shim
LUBRICATION
Draining and Filling
8.8-Inch Axle
1. Raise vehi cl e. Refer t o Secti on 00- 02.
2. Clean all dirt from area of axl e housing cover
( 4033) .
05- 00- 2 9 A x l e a n d Dr i v e s h a f t S e r v i c e 05 - 00- 2 9
LUBRICATION (Conti nued) SPECIFICATIONS
3. Drain rear axl e lubricant by removi ng axl e
housing cover.
Fi l l i n g
1. CAUTI ON: Ma ke sur e ma c h i n e d s u r f a c e s o n
b o t h a x l e h o u s i n g c o v e r a n d r e a r a x l e
h o u s i n g ( 4010) a r e c l e a n b e f o r e i n s t a l l i n g
t h e n e w s i l i c o n e se a l a n t . I n si d e o f r e a r a x l e
h o u s i n g mu s t b e c o v e r e d w h e n c l e a n i n g t h e
ma c h i n e d s u r f a c e t o p r e v e n t a x l e
c o n t a mi n a t i o n . Ti gh t e n t h e a x l e h o u s i n g
c o v e r b o l t s ( 4346) i n a c r o s s wi s e p a t t e r n t o
e n s u r e u n i f o r m d r a w on c o v e r .
NOTE: Axl e housing cover assembl y must be
installed within 15 minutes of t he silicone rubber
appl i cati on or new silicone rubber must be
appl i ed.
Appl y Silicone Rubber D6AZ- 19562- AA or -BA or
ESB-M4G92-A or WSE- M4G323- A1. Install axl e
housing cover and ti ghten axl e housing cover
bolts t o 27-37 N-m (20-27 Ib-ft).
AXLE HOUSING COVER
4033
2.
3.18-4.76 mm (1/8-3/16 INCH)
WIDE CONTINUOUS BEAD
OF SILICONE RUBBER
(D6AZ-19562-AA OR -BA,
ESB-M4G92-A OR ESE-M4G195-A)
OR EQUIVALENT MEETING FORD SPECIFICATION
F2667-H
Add Mot orcraf t Premium Rear Axl e Lubri cant
XY- 80W90- QL or -KL or equivalent meeti ng Ford
speci fi cati on WSP-M2C197-A until it is 6-14 mm
( 0. 250- 0. 562 inch) bel ow bot t om of fill hol e. Add
118 ml (2 oz) of Ford Addi ti ve Fri cti on Modifier
F3TZ- 19B546- MA or equivalent meeti ng Ford
speci fi cati on WSP-M2C196-A t o Tracti on-Lok
axl es. Install fill plug and tighten t o 20- 41 Nm
( 15- 30 Ib-f t ).
AXLE SHAFT ENDPLAY
De sc r i pt i on m m I nch
A x l e Sh a f t E n d p l a y ( Ma x . ) 0. 7 62 0. 030
LUBRICANT CAPACITIES
De sc r i pt i on Liters Pi nt s
P r e mi u m Re a r A x l e L u b r i c a n t
X Y- 80W9 0- QL o r - KL o r e q ui v a l e n t
me e t i n g Fo r d s p e c i f i c a t i o n
WS P - M2 C197 - A
1.7 3. 7 5
Fr i c t i o n
Mo d i f i e r F3 T Z - 1 9 B5 4 6 - MA
( WS P - M2 C196- A )
0. 118 . 25
DRIVE PINION BEARING PRELOAD
Descr i pt i on N-m Lb-ln
Mi n i mum To r q u e Re q u i r e d t o
Ti ght e n Pi ni on Fl a n ge Nut t o Ob t a i n
Co r r e c t Pi n i o n Be a r i n g P r e l o a d
190
a
140 ( L b - Ft )
Pi n i o n Be a r i n g
P r e l o a d ( C o l l a p s i b l e Sp a c e r )
Us e d Be a r i n g s
b
0. 9- 1. 5 8- 14
Ne w Be a r i n gs 1. 8-3. 2 16- 29
a If pi n i o n b e a r i n g p r e l o a d e x c e e d s s p e c i f i c a t i o n b e f o r e t h i s
t o r q u e i s o b t a i n e d , i n st a l l a n e w c o l l a p s i b l e s p a c e r ,
b Wi t h o i l s e a l .
RING GEAR BACKLASH
Descr i pt i on mm I nches
Ba c k l a s h Be t we e n Ri n g Ge a r a n d
Pi n i o n Te e t h
. 2 03- . 4 . 008- . 015
Ma x i mu m Ba c kl a s h Va r i a t i o n
Be t we e n Te e t h
. 1016 . 004
RING GEAR RUNOUT
Ma x i mu m Run o ut of Ba c k f a c e of
Ri ng Ge a r
. 07 62 . 004
IRQUE SPECIFICATIONS
Descr i pt i on N-m L b- Ft
Dr i v e s h a f t t o Re a r A x l e U-Joi nt
Fl a n ge Bo l t s
95- 130 7 0- 95
Di f f e r e n t i a l Si d e Be a r i n g Ca p Bo l t s 95- 115 7 0- 85
Pi ni on Nut 2 17 160
A x l e Ho usi n g Co v e r Re t a i n i n g
Bo l t s
2 7 - 37 2 0- 2 7
Fi l l e r Pl ug 2 8- 40 2 0- 30
Tool Numbe r /
Descr i pt i on I l l ust rat i on
T 59L - 42 04- A
T r a c t i o n - L o k To r q ue To o l
T59L-4204-A
T 7 8P - 4851- A
Co mp a n i o n Fl a n ge Ho l d i n g To o l
T78P-4851-A
T 7 9P - 402 0- A
Pi n i o n De p t h Ga u ge
Co n s i s t s of :
T 7 9P - 402 0- A 9 S c r e w
T 7 9P - 402 0- A 11 Ha n d l e
T 7 9P - 402 0- A 3 Al i gn i n g A d a p t e r
T 7 9P - 402 0- A 10 Ga u ge Bl o c k
( 1. 7 00 T h i c k)
T79P-4020-A
Tool Numbe r /
T 92 L - 4851- B
Co mp a n i o n Fl a n ge Run o ut
Ga u ge
T92L-4851-B
T 92 L - 4851- C
Cl a mp P l a t e
T92L-4851-C
D7 8P - 42 01- B Di a l I n d i c a t o r / Ma g n e t i c Ba s e
D80T- 402 9- F49 Ga uge Tube
ROTUNDA EQUIPMENT
006- 01400 E l e c t r o n i c St r o b e Ba l a n c e r
05- 01- 1 Dr i v e s h a f t 05- 01- 1
SECTION 05-01 Driveshaft
SUBJECT PAGE
Driveshaft 05-01-1
Uni versal Jo i n t s. . 05-01-2
Dri veshaf t 05-01-2
SUBJECT PAGE
Dri veshaf t ..05-01-2
Dri veshaf t , Si ngl e Cardan Uni versal Joi nt 05-01-3
EHi CLE APPLICATION
Dr i v e s h a f t
The dri veshaft ( 4602) equi pped wi th single cardan
universal j oi nts provi de the following f eat ures:
Dri veshaft is a tubular shaft used t o transfer engine
t orque f rom t he transmi ssi on output shaft t o t he
differential in the rear axl e housing ( 4010) whi ch, in
turn, transmi ts t orque through the axl e shaf t s
( 4234) t o t he dri ve wheel s.
Dr i ve sha f t E x p l o d e d Vi e w
The dri veshaft assembl y consi st s of t wo single
cardan universal j oi nts, a dri veshaft slip yoke
( 4841) , a wel ded tube assembl y and dri veshaft
centeri ng socket yoke ( 4782) .
The spl i ned dri veshaft slip yoke permi ts t he
dri veshaft t o move f or war d and rearward on the
transmi ssi on output shaft during dri vetrai n
movement and during dri veshaft removal and
installation.
E2096-T
Pa r t
1 N800594-S100 Bolt (4 Req'd)
Joint
3 4602 Driveshaft Assy
IPsirit
4

5

Needle Rollers (Part of
4249)
6

05- 01- 2 Dr i v e s h a f t 05- 01- 2
Pa r t
7 Thrust Washer (Part of 4249)
8

9 4841 Slip Yoke Assy
10

Snap Ring (4 Req'd) (Part of
4249)
I t e m
Pa r t
11 4782 Driveshaft Yoke
Flange
A

Tighten to 95-130 N-m (71-95
Lb-Ft)
U n i v e r s a l J o i n t s
NOTE: Other t ype universal j oi nts should not be used
in pl ace of thi s t ype. Dri veshaft i mbal ance and
vibration may result.
The dri veshaft universal j oi nts are:
Lube-for-life desi gn.
Equi pped wi t h nylon thrust washer s, l ocated at
each base of the beari ng cup, whi ch control end
pl ay, position the needle beari ngs and i mprove
grease movement.
E7S73-E
I t e m
Pa r t
Joint
2

3

32 Needle Rollers (Part of
4249)
4

5

Thrust Washer (Part of 4249)
6

A

Series 1310 82.55 mm
(3.250 inch)
Series 1330 92.07 mm
(3.625 inch)
I t e m
Pa r t
B 26.98 mm (1.0625 inch)
NOTE: Span measurements are made wi th beari ng
cups fully seat ed on spider.
Vehi cl es are equi pped wi th size 1330 universal j oi nts
wi t h a 92. 07 mm ( 3- 5/ 8 inch) span and 26. 98 mm
(1-1 / 1 6 inch) bearing cups.
Dr i v e s h a f t
Dr i v e s h a f t
Re mo v a l
1. To maintain driveline bal ance, mark the dri veshaft
yoke and rear axl e universal joint flange ( 4851)
so they may be installed in their original posi ti ons.
2. Remove the four rear flange bol ts and di sconnect
t he dri veshaft ( 4602) from t he rear axl e universal
joint fl ange. Pull t he dri veshaft t owar d the rear of
t he vehicle until t he dri veshaft slip yoke cl ears the
transmi ssi on extensi on housing and seal . Mark
t he dri veshaft slip yoke index in relation to
transmi ssi on output shaft during removal , and
temporari l y install the appropri at e plug in the
extensi on housing t o prevent lubricant l eakage.
1. Lubri cate the dri veshaft slip yoke ( 4841) splines
wi t h Premium Long-Life Grease XG-1-C or
ESA-M1C75-B. Remove t he plug f rom the
transmi ssi on extensi on. Inspect the housing seal
for damage; repl ace if requi red.
2. Align dri veshaft slip yoke index mark wi th the
transmi ssi on output shaft mark and install the
dri veshaft assembl y. Do not al l ow the dri veshaft
slip yoke assembl y t o bot t om on the output shaft
wi t h excessi ve f orce.
05- 01- 3 Dr i v e s h a f t 05- 01- 3
3. NOTE: When installing a new dri veshaft
assembl y, align the f act ory-made yel l ow paint
mark at the rear of t he dri veshaft t ube wi th the
f act ory-made yel l ow paint mark on t he rear axl e
universal joint fl ange. If paint marks are not
visible, refer t o Secti on 05- 00, Dri veshaft
Bal anci ng.
Install the dri veshaft so the index mark on the
dri veshaft yoke is in-line wi th the index mark on
the rear axl e universal joint fl ange. Thi s ensures
original driveline bal ance. If vi brati on exi sts after
installation, refer t o Secti on 05- 00.
4. Tighten the four dri veshaft yoke bol ts t o 95- 130
N-m (71-95 Ib-ft).
Dr i v e s h a f t , S i n g l e C a r d a n U n i v e r s a l J o i n t
U- Jo i n t To o l T 7 4P - 4635- C
Di s a s s e mb l y
CAUTI ON: Un d e r n o c i r c u ms t a n c e s i s t h e
d r i v e s h a f t a s s e mb l y t o b e c l a mp e d i n t h e j a ws o f
a v i s e o r si mi l a r h o l d i n g f i x t u r e . De n t i n g o r
l o c a l i ze d f r a c t u r e o f t h e t u b e ma y r e s u l t c a u s i n g
d r i v e s h a f t f a i l ur e d u r i n g v e h i c l e o p e r a t i o n .
1. Pl ace dri veshaft ( 4602) on a sui tabl e wor k
bench. Be careful not t o damage t ube.
2. Prior t o di sassembl y, mark t he posi ti ons of the
dri veshaft components relative t o the dri veshaft
t ube. All components must be reassembl ed in t he
same relationship t o maintain proper bal ance.
3. Cl amp U-Joint Tool T74P-4635-C in vise.
4. Remove the four snap rings that retai n the
beari ng cups.
5. Position the dri veshaft slip yoke ( 4841) in U-Joint
Tool T74P-4635-C and press out beari ng cup. If
beari ng cup cannot be pressed all t he way out of
t he dri veshaft slip yoke, remove if wi t h vi se grip
or channel l ock pliers.
E7586-B
Be a r i n g Cup Removal
6. Reposi ti on the dri veshaft slip yoke in U-Joint Tool
T74P-4635-C 180 degrees t o press on the spider
and remove t he remaining beari ng cup from the
opposi t e si de.
7. Remove dri veshaft slip yoke f rom the spider.
8. Remove the remaining bearing cups and spi ders
f rom t he dri veshaft in the same manner.
9. Clean all foreign matter from t he dri veshaft slip
yoke areas of the dri veshaft.
10. Repeat St eps 1 through 9 to remove dri veshaft
yoke.
A s s e mb l y
NOTE: Rear axl e shaft universal joint servi ce ki ts are
t o be installed as compl ete assembl i es only. Do not
mix components f rom other universal j oi nts.
1. Start a new beari ng cup into t he dri veshaft slip
yoke of t he dri veshaft.
05- 01- 4 Dr i v e s h a f t 05- 01- 4
2. Position the new spi der in t he dri veshaft slip yoke
and press the beari ng cup 6. 3 mm ( 1 / 4 inch)
bel ow the yoke surface using U-Joint Tool
T74P-4635-C.
3. Remove U-Joint Tool T74P-4635-C and install a
new snap ring.
4. St art a new beari ng cup into t he opposi te si de of
t he dri veshaft slip yoke. Check needles for
proper posi ti on.
5. Position dri veshaft in U-Joint Tool T74P-4635-C
and press on the beari ng cup until the opposi te
beari ng cup cont act s t he snap ri ng.
6. NOTE: Assembl e universal joint using the yel l ow
snap rings supplied in t he kit. If difficulty is
encountered wi t h yel l ow snap rings, install the
bl ack snap rings suppl i ed in the kit.
Remove t he dri veshaft f r om tool and install a new
snap ring. Check snap ring for proper seati ng.
SNAP
RING
7. Install the dri veshaft slip yoke, remaining beari ng
cups, spider, dri veshaft yoke and snap rings in
t he same manner.
8. Check universal j oi nts for f reedom of movement.
If binding has resul ted f rom misalignment during
assembl y, a sharp rap on the dri veshaft slip
yokes wi t h a brass or plastic hammer will seat
beari ng cups. Take care t o support the shaft end
and do not stri ke the beari ngs during thi s
procedure. Ensure universal j oi nts are f ree t o
rot at e easily wi thout binding before installing
dri veshaft.
E7590-B
Seat i ng Beari ng Cups
E7591-C
SPECIFICATIONS
Re a r Dr i v e s h a f t Ce n t e r i n g S o c ke t
Yo ke Bo l t s
95- 130 7 1- 95
05- 01- 5 Dr i v e s h a f t 05 - 01- 5
T 7 4P - 4635- C
U-Joi nt To o l
T74P-4635-C
05- 02 A - 1 A x l e , I n t e gr a l Ca r r i e r 8. 8- I n c h Ri n g Ge a r 05- 02 A - 1
SECTION 05-02A Axle, Integral Carrier 8.8-Inch
Ring Gear
SUBJECT PAGE
VEHI CLE APPLICATION 05-02A-1
Brake Syst em, Ant i -LockRear 05-02A-4
Description 05-02A-1
Noise Acceptability 05-02A-5
Operati on. - ...05-02A-4
Axle, Integral Carrier 05-02A-5
Axl e Housi ng t o Upper Cont rol Arm
Bushi ng 05-02A-13
Axl e Shaf t 05-02A-5
Axl e Vent . . . 05-02A-21
Cover 05-02A-14
Fl ange Yoke Seal a n d / o r Uni versal Joi nt
Fl ange, Rear Axl e 05-02A-10
Seal a n d / o r Beari ng Repl acement 05-02A-9
Sensor I ndi cat or, Ant i -Lock Brake .... 05-02A-8
Axl e Assembl y. . . . 05-02A-31
Axle Shaf t I nst al l at i on ..05-02A-39
Di f f erent i al Case I nst al l at i on 05-02A-35
Drive Pi ni on and Fl ange Yoke Seal
I nst al l at i on ...05-02A-33
SUBJECT PAGE
DISASSEMBLY AND ASSEMBLY (Cont 'd.)
Dri ve Pi ni on Shi m Sel ect i on 05-02A-31
Pi ni on Beari ng Cup I nst al l at i on .......... 05-02A-31
Wheel Beari ng and Oil Seal
I nst al l at i on 05-02A-35
Axl e Di sassembl y 05-02A-22
Axl e Shaf t Removal . 05-02A-24
Sensor, Ant i -Lock Brake ...05-02A-22
Uni versal Joi nt Fl ange and Fl ange Yoke Seal
Removal ...05-02A-22
Cover I nst al l at i on . 05-02A-40
Sensor, Ant i -Lock Brake 05-02A-40
Wheel Beari ng and Oil Seal Removal 05-02A-26
Di f f erent i al Case Removal 05-02A-26
Di f f erent i al Case Runout Check. ...05-02A-29
I nspect i on Af t er Di sassembl y of
Carri er 05-02A-41
I nspect i on Bef ore Di sassembl y of
Carri er ....05-02A-40
SPECIFICATIONS 05-02A-41
SPECIAL SERVICE TOOLS/EQUIPMENT....... ....05-02A-42
VEHICLE APPLICATION
Description
The rear axl e assembl y contai ns the following
features:
An i ntegral -type housing hypoi d gear design wi th
the centerline of the pinion set bel ow the centerline
of the ring gear.
A hypoi d gearset whi ch consi sts of a 224 mm
(8.8-i nch) di ameter ring gear and an overhung dri ve
pinion whi ch is supported by t wo opposed
differential pinion beari ngs ( 4621) .
Pinion bearing prel oad is maintained by a differential
dri ve pinion collapsible spacer ( 4662) on the pinion
shaft and adj usted by the pinion nut.
The rear axl e housing ( 4010) assembl y consi sts of
a cast center secti on wi th integral cast suspension
attachi ng ears, t wo steel tube assembl i es and a
steel axl e housing cover ( 4033) .
The axl e housing cover uses a silicone seal ant
rather than a gasket .
The differential case ( 4204) is a one-piece desi gn
wi th t wo openings to al l ow for assembl y of internal
components and lubricant fl ow.
The differential pinion shaft ( 4211) is retai ned by a
differential pinion shaft l ock pin ( 4241) assembl ed
t o the differential case.
The differential case is mounted in the rear axl e
housing bet ween t wo opposed t apered roller
differential beari ngs ( 4221) .
The differential bearing cups ( 4222) are retai ned in
the rear axl e housing by removabl e bearing caps.
Differential bearing prel oad and ring gear backl ash
are adj usted by the differential bearing shim ( 4067)
l ocated bet ween the differential bearing cup and the
carri er housi ng.
Using bot h the hypoi d shim gauge and the
differential shi m gauge is requi red for proper
gearset adj ustment.
The semi-floating axl e shafts ( 4234) are held in the
housing by u-washers ( 4N237) posi ti oned in a slot
on the axl e shaft splined end.
These u-washers al so fit into a machi ned recess in
the differential si de gears ( 4236) within the
differential case.
05- 02 A - 2 A x l e , I n t e gr a l Ca r r i e r 8. 8- I n c h Ri n g Ge a r
05- 02 A - 2
DESCRIPTION AND OPERATION (Conti nyed)
Axl e, Rear Expl oded Vi ew
Pa r t
1 4033 Axle Housing Cover
2 I.D.Tag
3 4346 Axle Housing Cover Bolt
4 4628 Rear Axle Pinion Bearing
Cup
6 4663 Drive Pinion Bearing
Adj ustment Shim
7

Drive Pinion (Part of 4209)
8 4221 Differential Bearing (RH)
9 4222 Differential Bearing Cup
11 Ring Gear (Part of 4209)
12 4241 Differential Pinion Shaft Lock
Pin
13 4228 Differential Side Gear Thrust
Washer
14 4236 Differential Side Gear
15 4230 Differential Pinion Thrust
Washer
16 4215 Differential Pinion Gear
17 4211 Differential Pinion Shaft
18 4215 Differential Pinion Gear
19 4230 Differential Pinion Thrust
Washer
20 4236 Differential Side Gear
21 4228 Differential Side Gear Thrust
Washer
22 4221 Differential Bearing
24 4221 Differential Bearing (LH)
25 4216 Rear Axle Differential Gear
Case Bolt
26 4204 Differential Case
27 4010 Rear Axle Housing
28 46108S Bolt
Pa r t
29

Differential Bearing Cap
(Part of 4010)
30 Shipping Plug
31 4N237 U-Washer
32 4A332 Rear Axle Shaft O-Ring
33 1225 Rear Wheel Bearing
34 2C189 Rear Brake Anti-Lock
Sensor Indicator
35 4234 Axle Shaft
36 1107 Wheel Hub Bolt
37 3910317-5190 Nut
38 2C220 Rear Wheel Disc Brake
Adapter
39 1177 Inner Wheel Bearing Oil Seal
40 390317-S190 Bolt
41

Fill Plug
Bearing Cup
Collapsible Spacer
45 4670 Rear Axle Drive Pinion Shaft
Oil Slinger
46 4676 Rear Axle Drive Pinion Seal
Flange
48 389546-S100 Drive Pinion Nut
A Tighten To 38-52 N-m (28-38
Lb-Ft)
B

Lb-Ft)
c

Tighten to 95-115 N-m (70-85
Lb-Ft)
Lb-Ft)
E Tighten to 21 -40 N-m (15-30
Lb-Ft)
05- 02 A - 4 Axl e, I nt egr al Car r i er - ~ -
Axl e Asse mbl y , Rear Sect i onal Vi e w
0
I t em
Par t
1 42 36 Di f f e r e n t i a l Si d e Ge a r
2 42 04 Di f f e r e n t i a l Ca se
3 Ri ng Ge a r (Pa r t of 42 09)
4 4067 Di f f e r e nt i a l Be a r i n g Shi m
5 42 2 1 Di f f e r e n t i a l Be a r i n g
6 Pi ni on (Pa r t of 42 09)
7 4630 Rear Ax l e Pi ni on Be a r i n g
Co n e a nd Rol l e r
8 462 1 Di f f e r e n t i a l Pi ni on Be a r i n g
9 467 6 Fl a n ge Yo ke Se a l
10 4851 Re a r Ax l e Un i ve r sa l Joi nt
Fl a n ge
E8278-D
Pa r t
11 4662 Dri ve Pi ni on Be a r i n g
Ad j ust me n t Shi m (Under
Re a r Ax l e Pi ni on Be a r i ng
Cone a nd Ro l l e r )
12 2 2 51 Rear Ax l e Br a ke Li ne Clip
13 2 C190 Rear An t i - L o c k Br a ke
Condui t and Wi r e
14 N806900- S2 Br a c ke t Bol t
15 2 860 Br a c ke t
16 2 A635 Pa r ki n g Br a ke Rear Ca bl e
a nd Condui t
17 4010 Ax l e Ho usi n g
A Ti ght e n t o 16-27 N-m ( 12- 20
Lb- Ft )
O p e r a t i o n
The rear dri ve axle operat es in the following manner:
Rear axl e drive pinion, whi ch recei ves its power
f rom t he engine through the transmi ssi on and
dri veshaft (4602).
The pinion gear rotates the differential case ( 4204)
t hrough engagement wi th the ring gear, whi ch is
bol ted t o the differential case outer fl ange.
Inside the differential case, t wo differential pinion
gears ( 4215) are mounted on a differential pinion
shaft ( 4211) which is secured to t he differential
case by a differential pinion shaft l ock pin (4241).
B r a k e S y s t e m , A n t i - L o c k R e a r
The rear anti-lock brake components consi st of the
fol l owi ng features:
Rear brake anti-lock sensor ( 2C190) whi ch is
at t ached t o the rear di sc brake cal i per anchor plate
( 2B582) and is not adj ustabl e. Refer t o Secti on
06- 09.
Rear brake anti-lock sensor indicator ( 2C189) ,
whi ch is pressed onto the axl e shaft ( 4234) .
Removal and Installation procedures are outlined in
thi s sect i on.
05- 02A- 5 A x l e , I n t e gr a l Ca r r i e r 8. 8- I n c h Ri n g Ge a r 05- 02 A - 5
These differential pinion gears are engaged wi th the
differential side gears ( 4236) t o whi ch axl e shafts
( 4234) are splined.
As the differential case turns, it rotates the axl e
shafts and rear wheel s.
When it is necessary for one wheel and axl e shaft t o
rot at e faster than the other, t he faster turning
differential side gear causes the differential pinion
gears t o roll on the slower-turning differential side
gear t o allow differential acti on bet ween the t wo
axl e shafts.
N o i s e A c c e p t a b i l i t y
A gear-dri ven unit, especi al l y an automoti ve dri ve axl e,
under vari ous driving condi ti ons, for exampl e, on a
newl y-paved bl acktop road. The slight noise is not
detri mental t o operati on of the rear axl e and is
consi dered normal .
NOTE: Whenever replacing the rear axl e lubricant,
use Premium Rear Axl e Lubricant XY-80W90-QL or
KL or equivalent meeting Ford speci fi cati on
WSP-M2C197-A.
A x l e S h a f t
Re mo v a l
1. CAUTI ON: Th e r e a r b r a ke a n t i - l o c k s e n s o r
( 2 C190) mu s t be r e mo v e d b e f o r e t h e a x l e
s h a f t s ( 42 34) a r e r e mo v e d t o p r e v e n t
d a ma g e t o t h e r e a r b r a ke a n t i - l o c k s e n s o r o r
r e a r b r a ke a n t i - l o c k s e n s o r i n d i c a t o r
( 2 C189) . Th e r e a r b r a ke a n t i - l o c k s e n s o r i s
b o l t e d o n t h e r e a r d i s c b r a ke c a l i pe r a n c h o r
pl at e ( 2 B582 ) .
Raise vehicle t o desi red worki ng height. Refer t o
Secti on 00- 02. Remove rear wheel and tire
assembl y. Remove rear di sc brake cal i pers
( 2552) and rear di sc brake rot ors ( 2C026) . Refer
A x l e , I n t e g r a l C a r r i e r
05- 02 A - 6 A x l e , I n t e gr a l Ca r r i e r 8. 8- I n c h Ri n g Gear 0 5 - 0 2 A - 6
REMOVAL A N D INSTALLATION ( C o n t i n u e d )
E7578-C
I t e m
Pa r t
1 2 552 Rear Di sc Br a ke Ca l i pe r
2 2 B582 Rear Di sc Br a ke Ca l i pe r
An c ho r Pl a t e
3 2C026 Rear Di sc Br a ke Rot or
( Co n t i n ue d )
Par t
4 42 34 Ax l e Sha f t
5 2C189 Re a r Br a ke An t i - L o c k
Se n so r i n d i c a t o r
6 2C190 Re a r Br a ke An t i - L o c k
Se n so r
2. Clean all di rt f rom area of axl e housing cover
( 4033) wi th a wi re brush or cl oth.
3. Drain rear axl e lubricant by removing the axl e
housing cover.
4. Remove differential pinion shaft lock pin ( 4241)
and differential pinion shaft ( 4211) .
DI FFERENTI AL PI NI ON SHAFT
LOCK PIN 4241
TI GHTEN TO
20-41 N-m
(15-30 LB-FT)
DI FFERENTI AL
PI NI ON SHAFT
4211
E3856-G
5. Push fl anged end of the axl e shaft t owar d the
center of the vehicle and remove the u-washer
( 4N237) and rear axl e shaft o-ring ( 4A332) from
the button end of the axl e shaft.
AXLE SHAFT 4234
REAR AXLE SHAFT
RETAINING U-WASHER
4N237
E3857-E
Remove axle shaft from the rear axl e housing
( 4010) . Do not damage the inner wheel beari ng
oil seal (1177) and rear brake anti-lock sensor
indicator.
05- 02 A - 7 Axl e, I n t e gr a l Ca r r i e r 8. 8- I n c h Ri n g Gear 05- 02 A - 7
1. CAUTI ON: Do n o t l et spl i nes o n axl e s h a f t
damage oi l seal or bear i ng assembl y.
NOTE: Check for presence of rear axl e shaft
o-ring on the spline end of t he shaft and install if
not present.
Carefully slide axl e shaft into rear axl e housing
wi thout damagi ng rear wheel beari ng ( 1225) or
rear brake anti-lock sensor indicator. Start
splines into si de gear and push firmly until the
button end of t he axl e shaft can be seen in the
differential case ( 4204) .
2. Install the u-washer on the button end of t he axl e
shaft splines. Pull the shaft outboard until the
u-washer seat s in the counterbore of the
differential si de gear ( 4236) .
3. CAUTI ON: Di f f e r e n t i a l pi n i o n s h a f t l o c k pi n
;
mu s t b e t i g h t e n e d t o s p e c i f i c a t i o n u s i n g
St u d a n d Be a r i n g Mo u n t E 0A Z - 19554- BA o r
e q u i v a l e n t me e t i n g Fo r d s p e c i f i c a t i o n
WS K- M2 G 3 4 9 - A 1 .
Position the differential pinion shaft through the
differential case and differential pinion gears
( 4215) , aligning the hole in the differential pinion
shaft wi th the l ock bolt hole. Appl y Stud and
Beari ng Mount E0AZ-19554-BA meeting Ford
speci fi cati on WSK- M2G349- A1 or equivalent t o
differential pinion shaft l ock pin. Install differential
pinion shaft lock pin and ti ghten t o 20-41 N-m
(15-30 Ib-ft).
DIFFERENTIAL PINION SHAFT
LOCK PIN 4241
TIGHTEN TO
20-41 N-m
PINION SHAFT
4211 E3856-G
4. NOTE: Axl e housing cover must be installed
wi thi n 15 minutes of application of the silicone
rubber or new silicone rubber must be appl i ed.
CAUTI ON: Ma ke s ur e ma c h i n e d s u r f a c e s o n
h o u s i n g a r e c l e a n b e f o r e i n s t a l l i n g t h e n e w
s i l i c o n e s e a l a n t . I n si d e o f a x l e mu s t b e
c o v e r e d w h e n c l e a n i n g t h e ma c h i n e d
s u r f a c e t o p r e v e n t a x l e c o n t a mi n a t i o n .
T i gh t e n t h e c o v e r b o l t s i n a c r o s s wi s e
p a t t e r n t o e n s u r e u n i f o r m d r a w o n a x l e
h o u s i n g c o v e r .
Appl y Silicone Rubber D6AZ- 19562- AA or BA or
ESB-M4G92-A or ESE-M4G195-A. Install axl e
housing cover and tighten retaining bol ts t o 38-52
N-m ( 28- 38 Ib-ft).
AXLE HOUSING COVER
4033
3.18-4.76 mm (1/8-3/16 INCH)
OF SILICONE RUBBER
F2667-H
5. Add Premium Rear Axl e Lubricant XY- 80W90- QL
or -KL or equivalent meeting Ford speci fi cati on
WSP-M2C197-A until it is 6-14 mm (. 250-. 562
inch) bel ow bot t om of fill hole. Add 118.3 ml (2
oz) of Ford Addi ti ve Friction Modifier
F3TZ-19B546-MA (WSP-M2C196-A) or
equivalent t o Traction-Lok axl es. Install filler plug
and tighten t o 20-41 N-m (15-30 Ib-ft).
6. Install rear brake anti-lock sensor. Tighten
retaining bolt t o 4.5-6.8 N-m (40-60 lb-in).
7. Install rear di sc brake caliper and rear di sc brake
rotor. Refer t o Section 06- 04.
8. Install wheel s and ti res.
Description Tool N u m b e r
Pi ni on Be a r i n g Cup Re p l a c e r
A x l e Be a r i n g Se a l Re mo v e r
Se n s o r Ri n g Re p l a c e r
A x l e Be a r i n g Se a l Re mo v e r
T85T- 4616- A
T7 5L - 116S- B
T 94P - 2 02 02 - A
T 7 5L - 1165- B
Re mo v a l
1. Remove axl e shaft ( 4234) as outlined and
position on a wor k bench.
2. CAUTI ON: Use o n l y a c o l d c h i s e l , n o t a
s c r e wd r i v e r . E x t r e me c a r e s h o u l d b e t a ke n
n o t t o s c r a t c h o r n i c k r e a r wh e e l b e a r i n g a n d
se a l j o u r n a l a n d r e a r b r a ke a n t i - l o c k s e n s o r
i n d i c a t o r j o u r n a l .
NOTE: Prior t o installation of new rear br ake
anti-lock sensor indicator ( 2C189) , remove any
burrs or ni cks f rom journal.
Using a thin-blade col d chisel bet ween rear brake
anti-lock sensor indicator and axl e shaft, st ri ke
chisel evenly around flange forci ng rear brake
anti-lock sensor indicator off rear brake anti-lock
sensor i ndi cator journal. Di scard rear brake
anti-lock sensor indicator.
REAR ANTI-LOCK
SENSOR INDICATOR
2C189
AXLE SHAFT
4234 E7579-B
1. Position Sensor Ring Repl acer T94P- 20202- A on
press as shown.
SENSOR RING
REPLACER
T94P-20202-A
AXLE BEARING SEAL
REMOVER
T75L-1165-B
i J
1 1
u
E8477-B
Pl ace new rear brake anti-lock sensor indicator
over Sensor Ring Repl acer T94P-20202-A.
REAR ANTI-LOCK BRAKE
SENSOR INDICATOR
2C189
SENSOR RING REPLACER
T94P-20202-A
E8478-B
3. Insert axl e shaf t t hrough t ool .
BRAKE SENSOR
INDICATOR
2C189
E8479-A
4. Pl ace Pinion Beari ng Cup Repl acer T85T-4616-A
over hub end of axl e shaf t .
5. Press axl e shaf t until it bot t oms out on axl e
f l ange.
6. Install axl e shaf t as out l i ned.
S e a l a n d / o r B e a r i n g R e p l a c e m e n t
A x l e Tube Se a l Re p l a c e r
Ax l e Tube Be a r i n g Re p l a c e r
Pul l e r A t t a c h me n t
Wh e e l Be a r i n g a n d Se a l Re mo v e r
T50T- 100- A
T7 8P - 117 7 - A
T7 8P - 12 2 5- A
T 58L - 101- B
T 85L - 12 2 5- A H
1. Remove axl e shaf t s ( 4234) as out l i ned.
2. Insert Rear Axl e Beari ng Remover
T85L-1225-AH in bore and posi t i on it behi nd rear
wheel beari ng ( 1225) so t angs on t ool engage
beari ng out er race. Remove rear wheel beari ng
and inner wheel beari ng oil seal ( 1177) as a unit,
using I mpact Sli de Hammer T50T-100-A.
05- 02 A - 10 A x l e , i n t e gr a l Ca r r i e r 8. 8- I n c h Ri n g Ge a r 05 - 02 A - 10
REMOVAL AND INSTALLS (Conti nued)
Rear Di sc Br a ke Cal i per An c ho r Pl ate
IMPACT SLIDE
HAMMER
T50T-100-A
PARKING BRAKE
2 C 2 2 0
PULLER
T58L-101-B
REAR AXLE BEARING
REMOVER T85L-1225-AH
REAR DISC BRAKE
CALIPER ANCHOR PLATE
2B582
E7597-D
Lubri cate the rear wheel beari ng wi t h speci fi ed
rear axl e lubricant.
4.
E3936-D
CAUTI ON: i n s t a l l a t i o n o f r e a r wh e e l b e a r i n g
o r i n n e r wh e e l b e a r i n g o i l se a l a s s e mb l y
w i t h o u t p r o p e r t o o l ma y r e sul t i n a n e a r l y
b e a r i n g o r se a l f a i l u r e . If i n n e r wh e e l b e a r i n g
o i l se a l b e c o me s c o c k e d i n b o r e d u r i n g
i n s t a l l a t i o n , r e mo v e i t a n d i n st a l l a n e w o n e .
Install rear wheel beari ng into the housing bore
using Axl e Tube Beari ng Repl acer T78P-1225-A.
AXLE TUBE
BEARING REPLACER
T78P-1225-A
5.
E7598-B
Install t he inner wheel beari ng oil seal using Axl e
Tube Seal Repl acer T78P-1177-A. Use Premium
Long-Li fe Grease XG-1-C or K or equivalent
meeti ng Ford speci fi cati on ESA-M1C75-B
bet ween the lips of the inner wheel beari ng oil
seal .
AXLE TUBE
SEAL REPLACER
T78P-1177-A
6. Install axl e shafts as outlined.
E7592-B
F l a n g e Y o k e S e a l a n d / o r U n i v e r s a l J o i n t
Fl a n g e , Re a r A x l e
Co mp a n i o n Fl a n ge Re mo v e r
Pi ni on Se a l Re p l a c e r
T 65L - 4851- B
T7 8P - 4851- A
T7 9P - 467 6- A
Re mo v a l
Replacement of rear axl e drive pinion seal ( 4676)
involves removal and installation of only the pinion nut
and rear axl e universal joint flange ( 4851) .
05- 02 A - 11 A x l e , I n t e gr a l Ca r r i e r 8. 8- I nch Ri ng Gear 05- 02 A - 11
1. CAUTI ON: Thi s o p e r a t i o n d i s t u r b s t h e pi ni on
bear i ng pr el oad. Thi s p r e l o a d mu s t b e
car ef ul l y r eset w h e n a s s e mb l i n g.
Rai se the vehi cl e and install saf et y st ands. Refer
t o Secti on 00- 02. Remove the rear wheel s and
rear di sc brake rot ors ( 2C026) . Refer t o Secti on
06- 04.
2. NOTE: If rear axl e universal joint fl ange is being
repl aced, it is not necessary to mark the
dri veshaft centeri ng socket yoke ( 4782) .
Mark the dri veshaft centeri ng socket yoke and
rear axl e universal joint flange t o ensure proper
position of t he dri veshaft ( 4602) during assembl y.
Di sconnect the dri veshaft f rom t he rear axl e
universal joint fl ange. Remove the dri veshaft f rom
the transmi ssi on extensi on housing. Install an oil
seal repl acer tool in the transmi ssi on extensi on
housing t o prevent oil l eakage.
3.
SCRIBE MARKS
SCRIBE MARKS
REAR AXLE UNIVERSAL
JOINT FLANGE 4851
DRIVESHAFT CENTERING
SOCKET YOKE 4782
E6691-C
Install a N*m (lb-in) torque wrench on the pinion
nut. Record the torque required to maintain
rotati on of the pinion through several revol uti ons.
REAR AXLE
UNIVERSAL JOINT
FLANGE 4851
TORQUE WRENCH
N-m (LB-IN)
F2669-E
4. Whi l e holding rear axl e universal joint flange wi th
Compani on Flange Holding Tool T78P-4851-A,
remove pinion nut.
COMPANION
FLANGE HOLDING TOOL
T78P-4851-A
REAR AXLE
UNIVERSAL
JOINT FLANGE
4851
F2670-G
5.
6.
Clean area around the rear axl e drive pinion seal .
Pl ace a drain pan under rear axl e drive pinion seal
or rai se front of vehicle higher than rear.
Mark rear axl e universal joint flange in relation to
pinion shaft so rear axl e universal joint flange can
be installed in same position.
MARK REAR AXLE UNIVERSAL
JOINT FLANGE 4851
IN RELATION TO PINION
F2671-D
05 - 02 A - 12 A x l e , I n t e gr a l Ca r r i e r 8. 8- I n c h Ri n g Ge a r 05- 02 A - 12
7. CAUTI ON; Newer s t r i ke t h e r e a r a x l e
un i v e r sa l j o i n t f l a n ge wi t h a h a mme r t o
p r e v e n t d a ma ge t o t h e r e a r a x l e un i v e r sa l
j o i n t f l a n ge o r d r i v e pi n i o n b e a r i n g
a d j u s t me n t s hi m ( 4663) .
Remove rear axle universal joint flange using
Companion Flange Remover T65L- 4851- B.
F2672-E
8. CAUTI ON: Do n o t d a ma ge h o u s i n g wh i l e
r e mo v i n g se a l .
Position screwdri ver under fl ange of rear axl e
dri ve pinion seal and carefully stri ke wi th hammer
t o wedge screwdri ver blade bet ween metal
flange of rear axl e drive pinion seal and rear axl e
housing (4010).
9. Pry up on metal flange of rear axl e dri ve pinion
seal . Install gripping pliers and stri ke wi th hammer
until rear axl e drive pinion seal is removed.
GRIPPING
PLIERS
E7554-D
1. CAUTI ON: I n s t a l l a t i o n wi t h o u t p r o p e r t o o l
ma y r e sul t i n e a r l y r e a r a x l e d r i v e pi n i o n se a l
f a i l u r e . If r e a r a x l e d r i v e pi n i o n se a l b e c o me s
c o c k e d d u r i n g i n s t a l l a t i o n , r e mo v e a n d
r e p l a c e wi t h n e w s e a l .
Clean the flange yoke seal seat surface and
install rear axle dri ve pinion seal on Pinion Seal
Repl acer T79P-4676-A. Appl y Premium
Long-Life Grease XG-1-C or K or equivalent
meeti ng Ford speci fi cati on ESA-M1C75-B
bet ween seal lips (if not pregreased).
0S- 02 A - 13 A x l e , I nt egr al Car r i er 8. 8- I n c h Ri n g Gear 05- 02 A - 13
PINION SEAL REPLACER
T79P-4676-A
F2674-F
2. NOTE: Check rear axl e universal joint flange for
burrs. Remove burrs as necessary.
Make sure splines on t he pinion shaft are free of
burrs. If burrs are evi dent, remove t hem by using
a fine crocus cl ot h. Worki ng in a rotati ng moti on,
wi pe the pinion cl ean.
3. Install rear axl e dri ve pinion seal in t o rear axl e
housing.
4. Appl y a small amount of speci fi ed rear axl e
lubricant t o rear axl e universal joint fl ange splines.
5. CAUTI ON: Th e r e a r a x l e un i v e r s a l j o i n t f l a n ge
mu s t n e v e r be h a mme r e d o n o r a s s e mb l e d
wi t h p o we r t o o l s .
Align mark on rear axl e universal joint flange wi th
mark on the pinion shaft. Install rear axl e
universal joint fl ange.
6. Install a new pinion nut on pinion shaft (appl y a
small amount of lubricant on the washer side of
nut).
7. Hold the rear axl e universal joint fl ange wi th
Compani on Flange Holding Tool T78P-4851-A
while tightening the nut.
FLANGE HOLDING TOOL
T78P-4851-A F2670-G
8. Tighten pinion nut. Rotate differential ring gear
and pinion ( 4209) occasi onal l y t o ensure proper
bearing seati ng. Take frequent differential pinion
bearing torque prel oad readings until the original
recorded prel oad reading is obtai ned.
9. If the original recorded prel oad is less than
speci fi cati on, tighten until a rotational torque of
0.9-1.5 N-m (8-14 Ib-in) prel oad is obtai ned. If the
prel oad is higher than speci fi cati on, ti ghten t o
original reading as recorded.
Never back off the pinion nut t o reduce prel oad. If
reduced prel oad is requi red, a new differential
drive pinion collapsible spacer ( 4662) and pinion
nut must be installed.
10. Remove oil seal repl acer tool from the
transmi ssi on extensi on housing. Install the front
end of the dri veshaft on the transmi ssi on output
shaft.
11. Connect the rear end of the dri veshaft t o the rear
axl e universal joint fl ange, aligning the marks on
the dri veshaft and rear axl e universal joint fl ange.
Tighten rear axl e universal joint flange bolts t o
95- 130 N-m (70-95 Ib-ft).
12. CAUTI ON: Ov e r f i l l i n g a x l e c a n c a u s e r e a r
a x l e h o u s i n g v e n t o r se a l l e a ka ge .
Fill axl e wi th Premium Rear Axl e Lubricant
XY-80W90-QL or -KL or equivalent meeting Ford
speci fi cati on WSP-M2C197-A until fluid level is
within 6-14 mm (. 250-. 562 inch) bel ow bottom of
filler hole wi th the axl e in operati ng position. Add
118 ml (2 oz) of Addi ti ve Friction Modifier
F3TZ-19B546-MA or equivalent meeting Ford
speci fi cati on WSP-M2C196-A. Refer t o
Speci fi cati ons. Install filler plug. Tighten t o 20-41
N-m (15-30 Ib-ft).
13. Make sure rear axl e housing vent ( 4022) is not
plugged wi th debri s.
A x l e H o u s i n g t o U p p e r C o n t r o l A r m B u s h i n g
Re mo v a l
Su s p e n s i o n Bushi n g Se r v i c e Se t
Re a r Ax l e Co n t r o l Ar m Bus hi n g To o l Se t
T 7 9P - 5638- A 1. A 2
a n d A 5
T 86P - 5638- A H
1. Raise the vehicle on a hoist and position safety
stands under the rear frame crossmember. Refer
2. Support the rear axl e housing ( 4010) and pinion
nose.
3. Remove the upper rear suspension arm and
bushing ( 5500) . Refer to Secti on 04- 02.
05- 02 A - 14 A x l e , I n t e gr a l Ca r r i e r 8. 8- I n c h Ri n g Ge a r
4. Usi ng Suspensi on Bushi ng Servi ce Set
T79P-5638-A and Rear Axl e Control Arm Tool
Set T86P- 5638- AH, remove rear suspension arm
bushing ( 5A638) .
F4708-B
I t e m
Pa r t
Bushing
3 T86P-5638-AH1 Remover, Receiving Cup
5

1. Using Suspension Bushing Servi ce Set
T79P-5638-A, install rear suspensi on arm
bushing into bushing ear of rear axl e housi ng.
POSITION TOOLS AS SHOWN AND TIGHTEN
FORCING SCREW UNTIL BUSHING
REPLACER IS AGAINST SPACER
F4709-B
Pa r t
4

Rear Axle Ear
5 T79P-5638-A2 Replacer Receiving Cup
6 5A638 Bushing
2. Install the upper rear suspension arm and
bushing. Refer t o Section 04- 02.
C o v e r
Re mo v a l
1. Raise vehicle t o desi red worki ng height. Refer to
Section 00- 02.
2. Clean all dirt f rom area of axl e housing cover
( 4033) wi th a wi re brush or cl oth.
3. Drain rear axl e lubricant by removing the axl e
housing cover.
05- 02A- 1S A x l e , I nt egr al Car r i er 8. 8- I n c h Ri ng Gear 05- 02 A - 15
I nst al l at i on
1. CAUTI ON: Make sur e machi ned sur f aces o f
bot h axl e housi ng cover and r ear axl e
housi ng ( 4010) ar e f r ee of ol d gas k et
mat er i al bef or e appl yi ng new si l i cone
seal ant . I nsi de of axl e must be c ov er ed when
cl eani ng t he machi ned sur f ace t o pr event
axl e cont ami nat i on. Ti ght en axl e housi ng
cover bol t s i n a cr osswi se pat t er n t o ensur e
uni f or m dr aw on axl e housi ng cover .
NOTE: Axl e housing cover must be installed
within 15 minutes of appl i cati on of seal er or new
seal er must be appl i ed.
Install axl e housing cover using Silicone Rubber
D6AZ- 19562- AA or BA or equivalent meeting
Ford speci fi cati ons ESB-M4G92-A and
ESE-M4G195-A. Tighten retaining bol ts t o 38-52
N-m (28-38 Ib-ft).
AXLE HOUSING COVER
4033
3.18-4.76 mm (1/8-3/16 INCH)
OF SILICONE RUBBER
F2667-H
2. CAUTI ON: Ov e r f i l l i n g a x l e c a n c a u s e r e a r
a x l e h o u s i n g v e n t ( 402 2 ) a n d se a l l e a ka ge .
XY- 80W90- QL or -KL or equivalent meeting Ford
within 6-14 mm (. 250-. 562 inch) bel ow bot t om fill
hole. Add 118 ml (2 oz) of Addi ti ve Friction
Modi fi er F3TZ-19B546-MA or equivalent meeting
Ford speci fi cati on WSP-M2C196-A. Make sure
t hat the axl e is in operati ng position. Install filler
pl ug. Tighten t o 20-41 N-m (15-30 Ib-ft).
3. Make sure rear axl e housing vent is not plugged
wi t h debri s.
A x l e H o u s i n g
A x l e Tube Be a r i n g Re p l a c e r
T7 8P - 117 7 - A
T7 8P - 12 2 5- A
Re mo v a l
1. Raise vehicle on a hoist and position safety
stands under the rear frame crossmember. Refer
2. Drain lubricant f rom the rear axl e housing by
removi ng axl e housing cover.
3. CAUTI ON: T h e r e a r b r a ke a n t i - l o c k s e n s o r
( 2 C190) mu s t be r e mo v e d b e f o r e t h e a x l e
s h a f t s ( 42 34) a r e r e mo v e d . Th e r e a r b r a ke
a n t i - l o c k s e n s o r i s b o l t e d t o t h e r e a r d i s c
b r a ke c a l i pe r a n c h o r pl a t e ( 2 B582 ) .
Remove wheel s, rear di sc brake rot ors ( 2C026)
and rear di sc brake cal i pers ( 2552) . Refer t o
Secti on 06- 04.
05- 02 A - 16 A x l e , I n t e gr a l Ca r r i e r 8. 8- I n c h Ri n g Ge a r 0 5 - 0 2 A - 1 6
Pa r t
1 2552 Rear Disc Brake Caliper
2 2B582 Rear Disc Brake Caliper
Anchor Plate
3 2C026 Rear Disc Brake Rotor
E7578-C
I t e m
Pa r t
4 4234 Axle Shaft
5 2C189 Rear Brake Anti -Lock
Sensor Indicator
Sensor
4. Remove differential pinion shaft l ock pin ( 4241)
f rom the differential pinion shaft ( 4211) and
remove the differential pinion shaft.
LOCK PIN 4241
TIGHTEN TO
20-41 N-m
(15-30 LB-FT)
DIFFERENTIAL
PINION SHAFT
4211
E3856-G
Push axl e shafts i nward to remove u-washers
( 4N237) .
AXLE SHAFT 4234
REAR AXLE SHAFT
RETAINING U-WASHER
4N237
E3857-E
6. Remove axl e shafts.
7. Remove RH and LH di sc brake adapter bracket s,
bol ts and J-nuts.
RH Br a c ke t
BOLT
TIGHTEN TO
27-54 N-m
(20-39 LB-FT)
J-NUT
REAR DISC BRAKE
CALIPER ANCHOR
PLATE 2B582
DISC BRAKE
ADAPTER BRACKET
BOLT
TIGHTEN TO
27-54 N-m
(20-40 LB-FT)
E7593-C
LH Br acket
REAR DISC BRAKE
CALIPER ANCHOR
PLATE 2B582
J-NUT
DISC BRAKE
ADAPTER
BRACKET
BOLTS
TIGHTEN TO
27-54 N-m
(20-40 LB-FT) E7594-D
8. Remove four retaining nuts f rom each rear di sc
brake cal i per anchor plate and wire the rear di sc
brake cal i per anchor pl ates t o underbody.
9. Di sconnect dri veshaft ( 4602) at the rear axl e
universal joint flange ( 4851) and wi re it to the
underbody.
10. Support rear axl e housing wi th j ackst ands or a
hoist.
11. Di sengage brake line from clips that retain the line
t o t he rear axl e housing.
12 WARNI NG: REMOVAL OF AI R SPRI NGS IS
REQUI RED BEFORE AXLE IS REMOVED. DO
NOT REMOVE AN AI R SPRI NG UNDER ANY
CI RCUMSTANCES WHEN THERE IS
PRESSURE IN THE AI R SPRI NG. DO NOT
REMOVE ANY COMPONENT SUPPORTI NG OR
BEI NG SUPPORTED BY AN AI R SPRI NG
WI THOUT EXHAUSTI NG THE AI R PRESSURE,
REFER TO SECTI ON 04 05,
Remove air spri ng. Refer t o Secti on 04- 05.
13. Di sconnect rear axl e housing vent f rom rear axl e
housing.
14. Di sconnect l ower rear shock absorber studs f rom
the mounting bracket s on the rear axl e housing.
15. Remove retaining nut and bolts and di sconnect
the rear suspension arm and bushings ( 5500)
f rom the mountings on the rear axl e housing ear
bracket s.
16. Lower rear axl e housing assembl y until the
spri ngs are rel eased. Lift out spri ngs.
17. Remove nuts and bol ts that connect rear
suspension arm and bushings t o rear axl e
housing. Di sconnect both rear suspension arm
and bushings from the rear axl e housing.
18. Lower rear axl e housing and remove it from the
vehicle.
05- 02 A - 18 A x l e , I n t e gr a l Ca r r i e r 8. 8- l n c h Ri n g Ge a r
i _jm& ~ i S i E r - a t JmVC
05- 02 A- 11
Ax l e , Rear Expl oded Vi ew
E38S9-K
i t e m
Pa r t
1 18041 Washer (2 Req'd)
2 384485-52 Nut (2 Req'd)
3 18198 Cushion (2 Req'd)
4 5536 Cap (2 Req'd)
5 5560 Spring (2 Req'd)
6 4730 Cushion (2 Req'd)
8 N800424 Nut (2 Req'd)
9 N8005262-5100 Nut (2 Req'd)
10 N800523-5100 Bolt (4 Req'd)
11 N800166-5100 Nut (4 Req'd)
( Co n t i n ue d )
Pa r t
12 Bushing (4 Req'd)
13 N800414-5100 Bolt (4 Req'd)
16 5500 Upper Suspension Arm and
Bushing
Bushing
18 4032 Vent
19

Hose
20 376545 Clamp
21

Y Fitting
1. Transfer all components from old rear axl e
housing t o new rear axl e housing and make the
necessary adj ustments t o backl ash and prel oad
as outlined. Install rear axl e housing vent.
RH SHOWN
LH SIMILAR
Pa r t
1 2860 Brake Hose Clip
2 N804725-S100 Bracket (2 Req'd)
Sensor
4 N605520-S100 Bolt (2 Req'd)
5 N802191-S56 Bracket Bolt (2 Req'd)
6 2C218 Anti-Lock Brake Sensor
Wiring Retainer
7 2A635 Parking Brake Rear Cable
and Conduit
A Tighten to 4.5-6.8 N-m (40-60
Lb-ln)
B
Lb-Ft)
Install new rear wheel beari ngs ( 1225) into new
rear axl e housing using Axl e Tube Beari ng
Repl acer T78P-1225-A.
AXLE TUBE
BEARING REPLACER
T78P-1225-A
E7598-B
Install inner wheel bearing oil seal ( 1177) using
Axl e Tube Seal Replacer T78P-1177-A. Appl y
Premium Long-Life Grease XG-1-C or K or
ESA-M1C75-B between the lips of the inner
wheel bearing oil seal .
AXLE TUBE
SEAL REPLACER
T78P-1177-A
E7592-B
4. Position new rear axl e housing under vehicle and
rai se rear axl e housing wi th a hoist or j ack.
Connect the rear suspension arm and bushings t o
their mounting bracket s on rear axl e housing. (Do
not ti ghten bol ts and nuts at this point.)
Position rear spri ngs ( 5560) in area provi ded.
Rai se rear axl e housing into posi ti on.
Connect rear suspension arm and bushings t o the
vehi cl e. Install bol ts and retaining nuts and ti ghten
t o 140-180 N-m ( 103- 133 Ib-ft). Tighten rear
suspensi on arm and bushing to axl e retaining
bol ts t o 140-180 N-m ( 103- 133 Ib-ft).
Position brake lines on the rear axl e housing and
secure wi th retaining clips. Position and secure
brake junction bl ock to the housing cast boss.
Connect air spring lines. Refer to Section 04-05.
10. Install rear disc brake caliper anchor plates on
axl e housing fl anges (no gasket s requi red).
Tighten nuts and bolts to 27-40 N-m (20-29 Ib-ft).
11. Install RH and LH di sc brake adapter bracket s,
bol ts and J-nuts. Tighten bolts t o 27-54 Nm
( 20- 40 Ib-ft).
8.
9.
05- 02A- 20 Axl e, I nt egr al Car r f
REMOVAL AND INSTALLATION f Cont i nued)
RH Br a c ke t
BOLT REAR DISC BRAKE
TIGHTEN TO CALIPER ANCHOR
27-54 N m PLATE 2B582
(20-39 LB-FT)
J-NUT
DISC BRAKE
ADAPTER BRACKET
LH Br acket
BOLT
TIGHTEN TO
27-54 N-m
(20-40 LB-FT) E7593-C
REAR DISC BRAKE
CALIPER ANCHOR
PLATE 2B582
DISC BRAKE
ADAPTER
BRACKET
BOLTS
TIGHTEN TO
27-54 N-m
(20-40 LB-FT)
J-NUT
E7594-0
12. Connect rear shock absorber l ower studs t o the
mounting bracket on the rear axl e housing. Install
the retaining nuts and ti ghten t o 70- 115 N-m
(52-85 Ib-ft).
13. Connect dri veshaft t o rear axl e uni versal joint
flange. Install retaining bol ts. Tighten t o 95- 130
N-m (70-95 Ib-ft).
SCRIBE MARKS
SCRIBE MARKS
REAR AXLE UNIVERSAL
JOINT FLANGE 4851
SOCKET YOKE 4782
E6691-C
14.
15.
CAUTI ON; Do n o t d a ma g e i n n e r wh e e l
bear i ng oi l seal o r r e a r b r a ke a n t i - l o c k s e n s o r
i ndi cat or ( 2 C189) .
Slide axl e shafts into the rear axl e housing until
the splines enter the differential si de gear ( 4236) .
Push axl e shafts at the fl ange i nward, and install
the u-washer at the end of each shaft spline. Pull
shafts out board until each u-washer enters the
recess in the differential side gears.
AXLE SHAFT 4234
REAR AXLE SHAFT
RETAINING U-WASHER
4N237
E3857-E
05- 02 A - 2 1 A x l e , I n t e gr a l Ca r r i e r 8. 8- l n c h Ri n g Ge a r 05- 02 A - 2 1
16. Appl y St ud and Beari ng Mount E0AZ-19554-BA
( WSK- M2G349- A1) or equivalent t o differential
pinion shaft l ock pin and install differential pinion
shaft and differential pinion shaft lock pin. Tighten
t o 20-41 N-m (15-30 Ib-ft).
LOCK PIN 4241
TIGHTEN TO
20-41 N-m
PINION SHAFT
4211 E3856-G
17. Install rear di sc brake rot ors and rear di sc brake
cal i pers. Refer t o Secti on 06- 04.
18. Install rear brake anti-lock sensor. Tighten
retaining bolt t o 4. 5-6. 8 N-m (40-60 Ib-in).
19. Install wheel s and ti res. Tighten lug nut s ( 1012) t o
115-142 N-m ( 85- 105 Ib-ft).
20. CAUTI ON: Ma ke s u r e ma c h i n e d s u r f a c e s o f
h o u s i n g a r e f r e e o f o l d g a s ke t ma t e r i a l
b e f o r e a p p l y i n g n e w s i l i c o n e s e a l a n t . I n si d e
o f a x l e mu s t b e c o v e r e d w h e n c l e a n i n g t h e
ma c h i n e d s u r f a c e t o p r e v e n t a x l e
c o n t a mi n a t i o n . Ti gh t e n a x l e h o u s i n g c o v e r
b o l t s i n a c r o s s wi s e p a t t e r n t o e n s u r e
u n i f o r m d r a w o n a x l e h o u s i n g c o v e r .
NOTE: Axl e housing cover must be installed
within 15 minutes of appl i cati on of sealer or new
seal er must be appl i ed.
Install axl e housing cover using Silicone Rubber
D6AZ- 19562- B or equivalent and tighten axl e
housing cover bol ts ( 4346) t o 38-52 N-m (28-38
Ib-ft).
AXLE HOUSING COVER
4033
3.18-4.76 mm (1/8-3/16 INCH)
OF SILICONE RUBBER
F2667-H
2 1 . CAUTI ON: Ov e r f i l l i n g a x l e c a n c a u s e r e a r
a x l e h o u s i n g v e n t a n d se a l l e a ka ge .
within 6-14 mm (. 250-. 562 inch) bel ow bot t om fill
hole. Add 118 ml (2 oz) of Addi ti ve Friction
Modifier F3TZ-19B546-MA or equivalent meeting
Ford speci fi cati on WSP-M2C196-A. Be sure that
the rear axl e housing is in operati ng posi ti on.
Install filler pl ug. Tighten t o 20-41 N-m (15-30
Ib-ft).
22. Make sure rear axl e housing vent is not plugged
wi th debri s.
23. Road test vehicle.
A x l e Ve n t
Re mo v a l
05- 02 A - 2 2
r22T :zr
A x l e , i n t e gr a l Ca r r i e r 8. 8-Snch Ri n g Ge a r 05 - 02 A - 2 2
2. Remove rear axl e housing vent ( 4022) f rom rear
axl e housing ( 4010) .
Y FITTING
HOSE CLAMP
376545
REAR AXLE VENT
4022
E9159-A
1. Install rear axl e housing vent into rear axl e
housi ng.
2. Lower vehicle.
Axle Disassembly
Servi ce operati ons on the differential case ( 4204) and
the differential ring gear and pinion ( 4209) can be
perf ormed wi th the axl e housing in the vehicle.
S e n s o r , A n t i - L o c k Br a k e
RH SHOWN
LH SIMILAR
Pa r t
Stem Nu mb e r De s c r i p t i o n
1 2860 Rear Cover Bracket
Sensor
4 N605520-S100 Sensor Bolt (2 Req'd)
6 2C218 Parking Brake Bracket
7 2A635 Parking Brake Cable
A Tighten to 4.5-6.8 N-m (40-60
Lb-ln)
Lb-Ft)
1. Raise vehicle to desi red worki ng height. Refer to
Secti on 00- 02.
2. Remove cabl e from brake hose clip ( 2860) and
parki ng anti-lock brake sensor wiring retainer
( 2C218) .
3. Remove bolt and bracket f rom rear axl e housing
( 4010) .
4. Remove bolt and rear brake anti-lock sensor
( 2C190) .
Un i v e r s a l J o i n t Fl a n g e a n d Fl a n g e Yo k e Se a l
Re mo v a l
SPECIAL SERVICE TOOL(S) REOUIRED
Co mpa n i o n Fl a n ge Re mo v e r
Co mpa n i o n Fl a n ge Ho l d i n g Tool
Pi ni on Se a l Re p l a c e r
T 65L - 4851- B
T7 8P - 4851- A
T 7 9P - 467 6- A
05- 02A- 23 A x l e , I n t e gr a l Ca r r i e r 8. 8- I n c h Ri n g Ge a r 05 - 02 A - 2 3
3.
NOTE: Repl acement of rear axl e drive pinion seal
( 4676) involves removal and installation of only
the pinion nut and rear axl e universal joint fl ange
( 4851) .
CAUTI ON: Th i s o p e r a t i o n d i s t u r b s t he pi ni on
bear i ng pr el oad. Thi s pr el oad must be
car ef ul l y r eset when assembl i ng.
Raise the vehi cl e and install saf et y stands. Refer
t o Secti on 00- 02. Remove the rear wheel s and
rear di sc brake rot ors ( 2C026) . Refer t o Secti on
06- 04.
NOTE: If rear axl e universal joint flange is being
repl aced, it is not necessary t o mark the
dri veshaft centeri ng socket yoke ( 4782) .
Mark the dri veshaft centeri ng socket yoke and
rear axl e universal joint flange t o ensure proper
position of the dri veshaft ( 4602) during assembl y.
Di sconnect the dri veshaft f rom the rear axl e
universal joint fl ange. Remove the dri veshaft f rom
t he transmi ssi on extensi on housing. Install an oil
seal repl acer tool in the transmi ssi on extensi on
housing t o prevent oil l eakage.
SCRIBE MARKS
SCRIBE MARKS
REAR AXLE UNIVERSAL
JOINT FLANGE 4851
SOCKET YOKE 4782
E6691-C
Install a N-m (lb-in) torque wrench on the pinion
nut. Record the torque requi red to maintain
rotati on of the pinion through several revolutions.
REAR AXLE
UNIVERSAL JOINT
FLANGE 4851
TORQUE WRENCH
N-m (LB-IN)
F2669-E
4. Whi l e holding rear axl e universal joint flange wi t h
Compani on Flange Holding Tool T78P-4851-A,
remove pinion nut.
COMPANION
FLANGE HOLDING TOOL
T78P-4851-A
REAR AXLE
UNIVERSAL
JOINT FLANGE
4851
F2670-G
Clean area around the rear axl e dri ve pinion seal .
Pl ace a drain pan under rear axl e dri ve pinion seal
or rai se front of vehicle higher than rear.
Mark rear axl e universal joint flange in relation t o
pinion shaft so rear axl e universal joint fl ange can
be installed in same position.
MARK REAR AXLE UNIVERSAL
JOINT FLANGE 4851
IN RELATION TO PINION
F2671-D
05- 02 A - 2 4 A x l e , i n t e gr a l Ca r r i
DISASSEMBLY AND ASSEMBLY ( Co n t i n u e d )
7. CAUTI ON: Newer st r i ke t he r ear axl e
uni ve r sa l j oi nt f l ange wi t h a hammer to
pr event damage to r ear axl e uni ve r sa l j oi nt
f l ange or dri ve pi ni on be a r i ng a dj ust me nt
shi m ( 4663) .
Remove rear axle universal joint flange using
Companion Flange Remover T65L- 4851- B.
F2672-E
8. CAUTI ON: Do n o t d a ma g e h o u s i n g wh i l e
r e mo v i n g s e a l .
Position screwdri ver under fl ange of rear axl e
dri ve pinion seal . Carefully st ri ke wi t h hammer t o
wedge screwdri ver bl ade bet ween metal flange
of rear axl e dri ve pinion seal and rear axl e
housing.
9. Pry up on metal fl ange of rear axl e dri ve pinion
seal . Install gri ppi ng pliers and stri ke wi th hammer
until rear axle dri ve pinion seal is removed.
GRIPPING
PLIERS
E7554-D
NOTE: Whenever repl aci ng the rear axl e lubricant,
use Premium Rear Axl e Lubri cant XY-80W90-QL or
-KL or equivalent meeting Ford speci fi cati on
WSP-M2C197-A.
A x l e Sh a f t Re mo v a l
1. CAUTI ON: The r ear b r a ke a n t i - l o c k s e n s o r
mu s t be r emov ed b e f o r e t h e a x l e s h a f t s
( 42 34) ar e r e mo v e d . Th e r e a r b r a ke a n t i - l o c k
s e n s o r i s bol t ed on t h e r e a r d i s c b r a ke
c a l i pe r anchor pl a t e ( 2 B582 ) .
Raise vehicle t o desi red worki ng height. Refer t o
Secti on 00-02. Remove rear wheel and ti re
assembl y. Remove rear di sc brake cal i pers
( 2552) and rear di sc brake rot ors. Refer t o
Secti on 06- 04.
05- 02 A - 2 5 A x l e , I n t e gr a l Ca r r i e r 8. 8- I n c h Ri n g Gear 05- 02 A - 2 5
DISASSEMBLY A N D ASSEMBLY ( Co n t i n u e d )
E7578-C
Pa r t
1 2 5 5 2 Re a r Di sc Br a ke Ca l i pe r
2 2 B 5 8 2 Re a r Di sc Br a ke Ca l i pe r
An c ho r Pl a t e
3 2 C 0 2 6 Re a r Di sc Br a ke Rot or
Pa r t
4 42 34 Ax l e Sha f t
5 2 C189 Re a r Br a ke An t i - Lo c k
Se n so r I n d i c a t o r
6 2 C190 Re a r Br a ke An t i - Lo c k
Se n so r
2. Clean all dirt f rom area of axl e housing cover
( 4033) wi th a wi re brush or cl ot h.
3. Drain rear axl e lubricant by removi ng the axl e
housing cover.
4. Remove differential pinion shaft l ock pin ( 4241)
and differential pinion shaft ( 4211) .
DI FFERENTI AL PI NI ON SHAFT
LOCK PIN 4241
TI GHTEN TO
20-41 N-m
(15-30 LB-FT)
DI FFERENTI AL
PI NI ON SHAFT
4211
E3856-G
5. Push fl anged end of the axl e shafts t owar d the
center of the vehi cl e and remove the u-washer
( 4N237) f rom the button end of the axl e shaft.
AXLE SHAFT 4234
REAR AXLE SHAFT
RETAI NI NG U-WASHER
4N237
E3857-E
6. Remove axl e shaft from the rear axl e housing. Be
careful not to damage the inner wheel bearing oil
seal ( 1177) and rear brake anti-lock sensor
indicator ( 2C189) .
05- 02 A - 2 6 A x l e , I nt egr al Car r i er 8. 8- I n c h Ri ng Gear 05- 02 A - 2 6
W h e e l B e a r i n g a n d O i l S e a l R e m o v a l
Descr i pti on T o o l N u m b e r
I mp a c t Sl i d e Ha mme r
A x l e Tube Be a r i n g Re p l a c e r
Re a r A x l e Be a r i n g Re mo v e r
T50T- 100- A
T7 8P - 117 7 - A
T 7 8P - 12 2 5- A
T 85L - 12 2 5- A H
1. Remove axle shafts (4234) as outlined.
2. Insert Rear Bearing Remover T85L-1225-AH in
bore and position it behind rear wheel bearing
(1225) so tangs on tool engage bearing outer
race. Remove rear wheel bearing and inner wheel
bearing oil seal (1177) as a unit, using Impact
Slide Hammer T50T-100-A.
Rear Di sc Br ake Cal i per Anchor Pl at e
IMPACT SLIDE
HAMMER
T50T-100-A
PARKING BRAKE
2C220
PULLER
T58L-101-B
REAR AXLE BEARING
REMOVER T85L-1225-AH
REAR DISC BRAKE
2B582
E7597-D
Di f f e r e n t i a l C a s e Re mo v a l
Pi n i o n Be a r i n g Co n e Re p l a c e r
Di f f e r e n t i a l Si d e Be a r i n g Re p l a c e r
Di f f e r e n t i a l Si d e Be a r i n g Re mo v e r
Pi n i o n Be a r i n g Cup Re p l a c e r
Pi n i o n Be a r i n g Co n e Re mo v e r
Pi n i o n Se a l Re p l a c e r
T53T- 462 1- C
T 57 L - 42 2 1- A 2
T65L- 4851- B
T 7 0P - 42 2 1- A
T 7 1P - 4616- A
T 7 1P - 462 1- B
T 7 8P - 4851- A
T 7 9P - 467 6- A
1. Raise vehicle and place jackstands under rear
frame crossmember. Refer to Section 00-02.
Lower the hoist so that the rear axle housing
(4010) is at suitable working height.
2. Remove axle housing cover (4033) from the rear
axle housing and drain lubricant.
3. Perform the inspection before disassembly. Refer
to Cleaning and Inspection.
4. Remove rear wheel, rear disc brake calipers
(2552) and rear disc brake rotors (2C026). Refer
to Section 06-04.
5. Remove rear brake anti-lock sensor (2C190)
located in rear disc brake caliper anchor plate
(2B582).
6. Working through axle housing cover, remove
differential pinion shaft lock pin (4241) and
remove the differential pinion shaft ( 4211) and
differential pinion gears (4215).
LOCK PIN 4241
TIGHTEN TO
20-41 N-m
(15-30 LB-FT)
DIFFERENTIAL
PINION SHAFT
4211
E 3 8 5 6 - G
7. Push axle shaft inward until u-washers (4N237)
at button end of the axle shaft are clear of the
differential side gear recess.
05- 02 A - 2 7 Axl e, I nt egr al Car r i er 8. 8- I n c h Ri ng Gear 05- 02 A - 2 7
8. CAUTI ON: Do not damage wheel seal s or
r ear br ake ant i - l o c k sensor i ndi cat or
( 2C189) when r emovi ng axl e shaf t s f r o m
r ear axl e housi ng. In addi t i on, axl e shaf t s
shoul d be compl et el y r emov ed f r om r ear
axl e housi ng.
Remove u-washers and pull axl e shafts out of the
rear axl e housing.
AXLE SHAFT 4234
9.
REAR AXLE SHAFT
RETAINING U-WASHER
4N237
E3857-E
Mark the dri veshaft centeri ng socket yoke
( 4782) and rear axl e universal joint fl ange ( 4851)
t o ensure proper alignment at assembl y.
Di sconnect dri veshaft ( 4602) f rom rear axl e
universal joint fl ange. Remove dri veshaft
assembl y f rom vehi cl e. Insert an oil seal
repl acement tool in the transmi ssi on extensi on
housing t o prevent l eakage.
SCRIBE MARKS
SCRIBE MARKS
REAR AXLE UNIVERSAL
JOINT FLANGE 4851
SOCKET YOKE 4782
E6691-C
10. CAUTI ON: Be a r i n g c a p s MUST be i n s t a l l e d i n
t he i r o r i gi n a l p o s i t i o n s d u r i n g a s s e mb l y . No t e
d i r e c t i o n o f a r r o ws o n c a p s .
Mark one differential beari ng cap t o help position
the caps properl y during assembl y.
ARROW CAST INTO
BEARING CAP
E3860-D
11. Loosen differential beari ng cap bolts and bearing
caps.
12. Pry differential case ( 4204) , differential bearing
cups ( 4222) and differential bearing shi ms ( 4067)
out until they are loose in the bearing caps.
Remove beari ng caps and remove differential
case f rom rear axl e housing.
E3861-D
05- 02A- 28 A x l e , I n t e gr a l Ca r r i e r 8. 8- I n c h Ri n g Ge a r 05- 02A- 28
13. Inspect the differential beari ngs ( 4221) and
differential bearing cups for damage. If damaged,
remove the differential beari ngs using Differential
Si de Beari ng Remover T70P-4221-A.
D I F F E R E N T I A L S I D E
B E A R I N G R E M O V E R
E664S-C
14. Install differential beari ngs using Differential Side
Beari ng Repl acer T57L- 4221- A2.
F3779-D
Dr i v e P i n i o n Re mo v a l
1. Remove differential case as outlined.
2. NOTE: If a new differential ring gear and pinion
( 4209) is being installed, t he rear axl e universal
joint flange need not be marked.
Mark rear axl e universal joint flange in relation t o
the pinion shaft. Hold the rear axl e universal joint
fl ange wi th Companion Flange Holding Tool
T78P-4851-A and remove the pinion nut.
3. Remove rear axl e universal joint flange wi t h
Compani on Flange Remover T65L- 4851- B.
F2672-E
4. Wi th a soft-faced hammer, drive pinion out of front
differential dri ve pinion beari ng cup ( 4616) and
remove through rear of rear axl e housing.
5. Remove rear axl e drive pinion seal ( 4676) as
outlined.
05- 02 A - 2 9 A x l e , I n t e gr a l Ca r r i e r 8. 8- I nch Ri ng Ge a r 0 5 - 0 2 A - 2 9
6 . To remove and install the differential pinion
beari ng ( 4630) , use Pinion Bearing Cone
Remover T71P-4621-B and Pinion Bearing Cone
Repl acer T53T-4621-C.
P R E S S
RAM
PINION BEARI NG
4630 F 2 6 7 7 - F
7. NOTE: Measure the dri ve pinion bearing
adj ustment shi m ( 4663) , whi ch is found under the
differential pinion bearing wi th a mi crometer and
record the t hi ckness. Thi s is used as a reference
t o compare the shim gauge reading prior t o
installing t he differential pinion beari ng.
Remove the dri ve pinion beari ng adj ustment shim
f rom the dri ve pinion.
RE AR A X L E DI FFERENTI AL
BEARI NG
ADJUSTMENT
SHIM 4663
E m ? 3 m C
P i n i o n Be a r i n g C u p Re mo v a l
1. NOTE: To ensure proper seati ng, clean bores
before installing rear axl e pinion bearing cups
( 4628) .
Inspect rear axl e pinion beari ng cups and, if
damaged, remove f rom rear axl e housing casti ng
by tappi ng al ternatel y (wi t h a brass drift of
suitable length) on each si de of the rear axl e
pinion beari ng cups t o prevent rear axl e pinion
beari ng cups f rom cocki ng in the bore.
Di f f e r e n t i a l Ca s e Ru n o u t C h e c k
If t he ring gear runout check (before di sassembl y)
exceeds speci fi cati on, the condition may be caused
by a war ped ring gear, a damaged rear axl e housing,
l oss of differential bearing prel oad or debri s between
the ring gear back f ace and the case flange. To
determi ne the cause of excessi ve runout, proceed as
f ol l ows:
1. Wi t h the pinion removed, place differential
case/ r i ng gear subassembl y wi th differential
beari ngs and differential bearing cups in rear axl e
housing.
2. Install a 0.265-i nch differential bearing shim on
the LH side of subassembl y.
.265 INCH
0 5 - 0 2 A - 3 0
Axle, Integral Carrier 8.8-inch Ri n g Ge a r 0&- G 2 A - 50
DISASSEMBLY AND ASSEMBLY (Cont i nue d)
3. Inst all t he LH bear i ng c a p f i nger -t i ght .
E4413-C
4. Inst all pr ogr e ssi ve l y l ar ger di f f er ent i al be a r i ng
shi ms o n t he RH si de unti l t he l a r ge st di f f erent i al
be a r i ng shi m se l e c t e d c a n be a sse mbl e d wi t h a
sl i ght d r a g f e e l .
NOTE: APPLY PRESSURE ni rccncMTi Ai Q C A D I M O
TOWARD LEFT SIDE TO S H . M ? ^ BEARING
ENSURE BEARING CUP
S H , M 4 0 6 7
4222 IS SEATED
E4414-D
5. Inst all t he RH si de bear i ng c a p. Inst al l bear i ng c a p
bo l t s. Ti ght en t o 95- 115 N-m ( 7 0- 85 I b-f t ).
ARROWS
OUTBOARD
E4415-C
6. Ro t a t e t he a sse mbl y t o ensur e f r e e r o t a t i o n .
E4416-C
7. Inst al l Di al I ndi cat or wi t h Br a c ke t r y TOOL- 42 01- C
or equi val ent . Che c k a n d not e ri ng ge a r runout .
DIAL INDICATOR WITH
BRACKETRY TOOL-4201-C
8. If t he runout i s wi t hi n spe c i f i c a t i on, t he ori gi nal
. out -of -spe c i f i c a t i on runout wa s c a use d by
i nsuf f i ci ent di f f erent i al bear i ng pr e l o a d . If t he
runout e x c e e d s spe c i f i c a t i on, pr o c e e d t o St e p 9.
9. Re move di f f erent i al c a se f r o m t he r e a r axJe
housi ng.
E4411-C
05- 02 A - 31 A x l e , I nt egr al Car r i er 8. 8- I n c h Ri ng Gear 05- 02 A - 31
10. Remove ring gear using a drift that will bottom in
ring gear bolt hol es. Strike at al ternate holes
around gear.
NOTE: REMOVE ANY
BURRS OR DEBRIS
FROM MATING
SURFACES OF RING
GEAR BACK FACE
AND DIFFERENTIAL
CASE FLANGE
RING GEAR
BACK FACE
DIFFERENTIAL
CASE FLANGE
E6262-C
11.
12.
Install differential case in carri er wi thout ring gear.
Check differential case runout agai n. If the runout
is now within limits, the ring gear was out of
speci fi cati on and should be repl aced. If the runout
is still excessi ve, the differential case is damaged
and should be repl aced.
Axle Assembly
Pinion Bearing C u p I n s t a l l a t i o n
Description T o o l N u m b e r
Pi n i o n Be a r i n g Cup Re p l a c e r T7 1P - 4616- A
Install the new cups wi th Pinion Beari ng Cup
Replacer T71P-4616-A. Make sure the rear axl e
pinion bearing cup (4628)/ di f f erent i al pinion
bearing ( 4621) are properl y seat ed in their bores.
If a 0. 038 mm (0. 0015-i nch) feel er gauge can be
i nserted bet ween a cup and the bot t om of its bore
at any point around the cup, the cup is not
properl y seat ed. Whenever the rear axl e pinion
beari ng cup/ di f f erent i al pinion beari ng is
repl aced, the differential pinion beari ng shoul d
al so be repl aced.
F2679-D
Dr i v e P i n i o n S h i m S e l e c t i o n
Pi n i o n De p t h Ga uge Se t T 7 9P - 402 0- A
A dri ve pinion bearing adjustment shi m ( 4663) 0. 254
mm t o 0. 965 mm ( 0. 010 t o 0. 038 inch) is used
between the differential pinion bearing ( 4630) and
pinion head. The correct dri ve pinion beari ng
adjustment shim size will l ocate t he pinion for proper
t oot h contact wi th ring gear. Selecting correct dri ve
pinion bearing adjustment shim when installing a new
dri veshaft ( 4602) can be done by using Pinion Depth
Gauge Set T79P-4020-A as outlined.
1. Refer t o illustration and assembl e the appropri ate
aligning adapter, gauge di sc and gauge bl ock t o
the screw.
05-02A -32 A x l e , I n t e gr a l Ca r r i e r 8. 8- I n c h Ri n g Ge a r
Rear Axl e Pi ni on De pt h GaugeT79P- 4020- A
D
|I TOnmrO^mnmi

E3S62-G
Pa r t Pa r t
1 T79P-4020-9 Screw 6 T79P-4020-A3 Alignment Adapter (1.612
2 T79P-4020-A11 Handle
OD)
3 4621 Front Differential Pinion
7 T79P-4020-A18 Gauge Disc ( 1. 884 Thi ck)
Bearing 8 T79P-4020-A10 Gauge Block (1.700 Thi ck)
4

Assembled Tool 9 T79P-4020-A Gauge Tube (3.063 OD)
5 4622 Rear Differential Pinion
Bearing
( Co n t i n ue d )
2. NOTE: The gauge bl ock must be offset t o obtai n
an accurat e readi ng.
Pl ace differential pinion beari ng (new, or used if in
good condi ti on) over aligning di sc and insert into
rear axl e pinion beari ng cup. Pl ace front
differential pinion bearing into the differential dri ve
pinion beari ng cup ( 4616) and assembl e the tool
handle into screw. Tighten to 2. 26 N-m ( 20 Ib-in).
F2693-D
Make sure that the gauge handle adapter screw,
aligning adapter, gauge di sc and gauge bl ock
assembl y are securel y mounted between the
front differential pinion bearing and rear
differential pinion beari ng. Check the tool handle
torque prior t o gauging to ensure that beari ngs
are properl y seat ed. This can affect final shi m
selection when improperly assembl ed. Clean
bearing cups and differential pedestal surf aces
thoroughly. Appl y only light oil film on beari ng
assembl i es prior t o gaugi ng.
The gauge bl ock should then be rot at ed several
half-turns to ensure rollers are properl y seat ed in
bearing cups. Rotational torque on the gauge
assembl y should be 2.2 N*m (20 Ib-in) wi t h new
bearings. Final position should be approxi mat el y
45 degrees across gauge tube to make sure t hat
gauge block is in-line wi th gauge tube high point.
This area should be used for pinion shim
sel ecti on. Selection of drive pinion beari ng
adjustment shim wi th gauge block not lined up
wi th tube high point will cause i mproper shim
selection and may result in axl e noise.
/V<1c
3
B
r?t3cr/sfl Gamer 8. 8- I n c h Ri n g Ge a r
0 5 0 2 A- 3 3
6.
NOTE: Dri ve pinion bearing adjustment shims
must be flat. Do not use di rty, bent, ni cked or
mutilated dri ve pinion beari ng adj ustment shims
as a gauge.
Use dri ve pinion bearing adjustment shims as the
gauge for shi m sel ecti on. This will minimize errors
in attempti ng t o st ack feeler gauge st ock
together. It will also minimize simple addition
errors in calculating correct shim thi ckness.
NOTE: The same differential pinion bearing used
in this procedure must be used in final assembl y
of the axl e.
It is i mportant t o feel a slight drag on the dri ve
pinion beari ng adjustment shim for correct
sel ecti on. Do not at t empt to f orce the dri ve pinion
bearing adj ustment shim bet ween the gauge
bl ock and the gauge tube. This will minimize
sel ecti on of a drive pinion beari ng adjustment
shirn thi cker than requi red whi ch resul ts in a deep
t oot h cont act in final assembl y of the axl e.
Place the dri ve pinion beari ng adj ustment shi ms
on pinion shaft. Press differential pinion bearing
until firmly seat ed on shaft.
I NCREASE
SHI M BY
3 SHI M SIZES
+ 0.006 INCH
I NCREASE
SHI M BY
3 SHI M SI ZES
+ 0.006 I NCH
E4455-D
Dr i v e P i n i o n a n d Fl a n g e Yo k e Se a l I n s t a l l a t i o n
Pi ni on Seal Repl acer
Compani on Fl ange Hol di ng Tool
Pi ni on Bear i ng Cone Repl acer
T79P- 4676- A
T78P- 4851- A
T53T- 4621- C
NOTE: The same differential pinion bearing used
in this procedure must be used in final assembl y
of the axl e.
Place the dri ve pinion beari ng adj ustment shi ms
on the pinion and press the differential pinion
beari ng assembl y until it is firmly seat ed on the
shaft.
PRESS
RAM
DRIVE PINION
BEARING
ADJUSTMENT
SHIM 4663
PINION BEARING CONE
REPLACER T53T-4621-C
DIFFERENTIAL
PINION BEARING
4630
F2678-G
2. Make sure splines on pinion st em are free of
burrs. If burrs are evident, remove using a fine
crocus cl ot h, worki ng in a rotational moti on. Wi pe
pinion cl ean.
Pl ace a new differential dri ve pinion collapsible
spacer ( 4662) on pinion stem against pinion st em
shoulder.
COLLAPSIBLE
SPACER
4662
E5 889-D
1995 Town Car, Cr own Vi ct or i a, Gr and Ma r qui s Jul y 1994
05- 02 A - 34 0 5 - 0 2 A - 3 4
3. NOTE: Clean the oil seal surface before installing
t he rear axl e drive pinion seal ( 4676) in t he
housing bore. Coat lips of seal wi t h Long Life
Grease XG-1-C or equivalent meeting Ford
speci fi cati on ESA-M1C75-B.
Install t he differential pinion bearing and rear axl e
dri ve pinion shaft oil slinger ( 4670) in housing
bore and install the rear axl e dri ve pinion seal on
t he Pinion Seal Repl acer T79P- 4676A.
DIFFERENTIAL PINION
BEARING 4630
REAR AXLE DRIVE
PINION SHAFT OIL
SLINGER 4670
FLANGE YOKE
SEAL 4676
PINION SEAL
REPLACER
T79P-4676-A
E8290-C
4. CAUTI ON: I n st a l l a t i o n wi t h o u t t h e p r o p e r t o o l
ma y r e s ul t i n e a r l y s e a l f a i l ur e . If r e a r a x l e
d r i v e p i n i o n se a l b e c o me s c o c k e d d u r i n g
i n s t a l l a t i o n , r e mo v e i t a n d i n st a l l a n e w o n e .
Install rear axl e dri ve pinion seal .
PINION SEAL REPLACER
T79P-4676-A
F2674-F
5. From rear of rear axl e housing ( 4010) , install
dri ve pinion assembl y (dri ve pinion, dri ve pinion
beari ng adj ustment shi ms, rear axl e pinion
beari ng cup and differential dri ve pinion
col l apsi bl e spacer into the housing pinion shaft
bore.
DRIVE PINION ASSY
E4251-A
6. Appl y a small amount of Premium Rear Axl e
Lubri cant XY- 80W90- QL or -KL or equivalent
meeting Ford speci fi cati on WSP-M2C197-A t o
rear axl e universal joint fl ange ( 4851) splines.
7. NOTE: If a new rear axl e universal joint fl ange is
being installed, di sregard t he mark on the pinion
stem.
CAUTI ON: T h e r e a r a x l e u n i v e r s a l Joi nt flange
mu s t n e v e r be h a mme r e d o n o r i n s t a l l e d w i t h
p o we r t o o l s .
Align mark on rear axl e universal joint fl ange wi th
mark on the pinion shaft.
8. Wi th dri ve pinion in pl ace in rear axl e housing,
install rear axl e universal joint flange using
Companion Flange Repl acer Tool -4858-E or
equivalent.
9. Install a new pinion nut on pinion shaft (appl y a
small amount of lubricant on the washer si de of
nut).
10. Hold t he rear axl e universal joint flange wi t h
Companion Flange Holding Tool T78P-4851-A
while tightening the nut.
COMPANION
FLANGE HOLDING TOOL
T78P-4851-A
REAR AXLE
UNIVERSAL
JOINT FLANGE
4851
F2670-G
05- 02 A - 35 A x l e , I n t e gr a l Ca r r i e r 8. 8- I n c h Ri ng Ge a r
DISASSEMBLY A N D ASSEMBLY ( C o n t i n u e d )
0S- 02 A - 35
11. NOTE: Never back off the pinion nut t o reduce
prel oad. If reduced prel oad is requi red, install a
new differential dri ve pinion collapsible spacer
and pinion nut.
Tighten pinion nut. Rotate pinion occasi onal l y t o
ensure bearing seat s properl y. Take frequent
pinion bearing torque prel oad readi ngs until the
original recorded prel oad readi ng is obtai ned.
Wh e e l Bear i ng a n d Oi l Seal I nst al l at i on
Descr i pti on T o o l N u mb e r
Ax l e Tube Se a l Re p l a c e r
T 7 8P - 12 2 5- A
T7 8P - 117 7 - A
1. Lubri cate the rear wheel beari ng ( 1225) wi th
speci fi ed rear axl e lubricant.
E3936-D
2. CAUTI ON: I nst al l at i on of r e a r wh e e l bear i ng
or i n n e r wh e e l bear i ng oi l se a l ( 117 7 )
assembl y wi t h o u t p r o p e r t o o l ma y r e s ul t i n
an e a r l y bear i ng o r se a l f ai l ur e, i f i n n e r wh e e l
bear i ng oi l seal b e c o me s c o c k e d i n b o r e
dur i ng i nst al l at i on, r emove i t and i nst al l a
new o n e ,
Install rear wheel bearing into the housing bore
using Axl e Tube Bearing Repl acer T78P-1225-A.
3. Install the inner wheel beari ng oil seal using Axl e
Tube Seal Repl acer T78P-1177-A. Use Premium
Long-Life Grease XG-1-G or K or equivalent
meeting Ford speci fi cati on ESA-M1C75-B
between the lips of the inner wheel bearing oil
seal .
Di f f e r e n t i a l Ca s e I n s t a l l a t i o n
Co n d i t i o n 1
Fol l ow this procedure when only repl acement of
dri veshaft is required and the differential bearings
( 4221) and differential case ( 4204) do not require
repl acement.
1. Remove the differential caps and bolts. Identify
the RH cap, RH differential bearing cup ( 4222)
and differential bearing shims ( 4067) to keep
these components as RH and LH sets.
2. Remove the differential case subassembl y using
the pry bar met hod. Reasonabl e effort will be
required t o remove subassembl y if prel oad is
within speci fi cati on range. If subassembl y can be
removed by hand, use Condition 2 for assembl y.
3. Repl ace the differential ring gear and pinion
members using the differential bearing shims from
the original assembl y and sel ect the drive pinion
bearing adj ustment shim as outlined. (Shims may
be reused wi th the excepti on of drive pinion
bearing adj ustment shim whi ch will require
regauging t o speci fi cati on before assembl y.)
Co n d i t i o n 2
Fol l ow this procedure when original differential bearing
shi ms are not available or when rear axl e housing,
differential case or differential bearing repl acement is
requi red.
* - 36
1. Wi t h pinion depth set and pinion installed, place
the differential case/ gear subassembl y wi th
differential beari ngs and differential bearing cups
in rear axl e housing.
E4418-C
2. Install a 0.265-i nch differential beari ng shi m on
the LH si de.
.265 INCH
DIFFERENTIAL
BEARING SHIM
4067
E4412-D
3. Install LH bearing cap finger-tight.
E4419-C
4. Install differential beari ng shi ms progressi vel y on
t he RH side until the l argest di fferenti al bearing
shi m sel ect ed can be assembl ed wi t h a slight
drag f eel .
NOTE: APPLY PRESSURE
TOWARD LEFT SIDE TO
ENSURE BEARING CUP
4222
DIFFERENTIAL BEARING
SHIM 4067
E4414-D
5. Install RH si de bearing cap and di f f erent i al
beari ng cap bol ts. Tighten to 95- 115 Nm (70-85
Ib-f t ).
ARROWS
OUTBOARD
E4421-C
6. Rotate the assembl y t o ensure free operati on.
E4422-C
05- 02 A - 37 A x l e , I n t e gr a l Ca r r i e r 8. 8- i n c h Ri n g Ge a r 05- 02 A - 37
Check gear and pinion ba c kl a sh. If backl ash is
within speci fi cati on, go t o Step 14. If backl ash is
not within speci fi cati on, go t o Step 10. If zero
backl ash is measured, proceed wi th Step 8.
BACKLASH SPEC 0.203-0.381 mm
(0.008-0.015 INCH) PREFERRED
RANGE 0.305-0.381 mm
(0.012-0.015 INCH)
8.
E4423-D
If a zero backl ash occurs, add 0. 020 inch t o the
RH si de and subtract 0. 020 inch f rom the LH side
t o allow backl ash indication.
SUBTRACT
- 0.020 INCH
ADD
+ 0.020 INCH
E4424-D
9. Check backl ash. Repeat Step 7.
10. If backl ash is not t o speci fi cati on, correct
backl ash by increasing t hi ckness of one
differential beari ng shim and decreasi ng
t hi ckness on the other differential bearing shi m by
the same amount. Refer t o the following
illustrations for approxi mat e shim change.
Ad j ust i n g Ba c kl a sh
MORE BACKLASH
DECREASE
FOR MORE
BACKLASH
LEFT SIDE
INCREASE +
FOR MORE
BACKLASH
RIGHT SIDE
LESS BACKLASH.
INCREASE +
FOR LESS
BACKLASH
DECREASE-
FOR LESS
BACKLASH
E4451-D
DIFFERENTIAL SHIM SIZE CHART
B a c k l a s h C h a n g e Re q u i r e d T h i c k n e s s C h a n g e Re q u i r e d
mm I n c h mm I n c h
0. 02 5 0. 001 0. 050 0. 002
0. 050 0. 002 0. 050 0. 002
0. 07 6 0. 003 0. 101 0. 004
0. 101 0. 004 0. 152 0. 006
0. 12 7 0. 005 0. 152 0. 006
0. 152 0. 006 0. 2 03 0. 008
0. 17 7 0. 007 0. 2 54 0. 010
0. 2 03 0. 008 0. 2 54 0. 010
0. 2 2 8 0. 009 0. 304 0, 012
0. 2 54 0. 010 0. 355 0. 014
0. 2 7 9 0. 011 0. 355 0. 014
0. 304 0. 012 0. 406 0. 016
0. 330 0. 013 0. 457 0. 018
0. 335 0. 014 0. 457 0. 018
0. 381 0. 015 0. 508 0. 02 0
05- 02A- 38 A x l e , I n t e gr a l Ca r r i e r 8. 8- l n c h Ri ng Ge a r 0 5 - 0 2 A - 3 8
MHl Ml l t t i l l MMa
r - PAINT STRIPES ARE APPROXIMATELY
.25 WIDE AND .25 APART
2.963
-.08
.03
X45 DEGREES
E4156-D
DIFFERENTIAL SHIM SIZE CHART
N u m b e r s o f
S t r i p e s a n d C o l o r
C o d e
2 C- COAL
1 C- COAL
5 B L U
4BLU
3 BL U
2 BL U
5 P I NK
4 PI NK
3 PI NK
2 P I NK
1 PI NK
5 GRN
4 GRN
3 G R N
2 GRN
1 G R N
5 WH
4 W H
3 WH
2 WH
Di m e n s i o n A
7 . 7 9 7 8 -
7 . 7 4 7 0 -
7 . 6 9 6 2 -
7 . 6 4 5 4 -
7 . 5 9 4 6 -
7 . 5 4 5 8 -
7 . 4 4 2 2 -
7 . 3914-
7 . 3406-
7 . 2 898-
7 . 2 390-
7 . 1 8 8 2 -
7 . 137 4-
7 . 0863-
7 . 0358-
8 . 9 8 5 -
6 . 93 42-
6. 8834-
6. 832 6-
6. 7 813-
- 7 . 8105
- 7 . 7 597
- 7 . 7 089
- 7 . 6581
- 7 . 607 3
- 7 . 5565
- 7 . 4549
- 7 . 4041
- 7 . 3533
- 7 . 302 5
- 7 . 2 517
- 7 . 2 009
- 7 . 15 01
- 7 . 0 9 9 3
- 7 . 0 4 8 5
7 . 0485
- 6 9 469
- 6 . 8 9 6 1
- 6 . 8 4 5 3
- 6 . 7 9 4 5
I n c h
0 . 3 0 7 0 -
0 . 3 0 5 0 -
0 . 3 0 3 0 -
0 . 3 0 1 0 -
0 . 2 9 9 0 -
0 . 2 9 7 0 -
0 . 2 9 3 0 -
0 . 2 9 1 0 -
0 . 2 8 9 0 -
0 . 2 8 7 0 -
0 . 2 8 5 0 -
0 . 2 8 3 0 -
0 . 2 8 1 0 -
0 . 2 7 9 0 -
0 . 2 7 7 0 -
0 . 2 7 5 0 -
0 . 2 7 3 0 -
0 . 2 7 1 0 -
0 . 2 6 9 0 -
j 0 . 2 6 7 0 -
0. 307 5
0. 3055
0. 3035
0. 3015
0. 2 995
0. 2 97 5
0. 2 935
- 0. 2 915
- 0. 2 895
- 0. 2 87 5
- 0. 2 855
- 0. 2 835
- 0. 2 815
- 0. 2 7 95
- 0. 2 7 7 5
- 0. 2 7 55
- 0. 2 7 35
- 0. 2 7 15
- 0. 2 695
- 0. 2 67 5
DIFFERENTIAL SHIM SIZE CHART (Cont' d)
Di m e n s i o n A
N u m b e r s o f
S t r i p e s a n d Color
C o d e mm Inch
1 w:-; 6 . 7 3 1 - 6. 7 437 0. 2 650 0 . 2 6 5 5
5 - Y E L . 6 . 6 8 0 2 - - 6 . 6 9 2 9 0. 2 630 0 . 2 6 3 5
4 YEL 6 . 6 2 9 4 - - 6 . 6 4 2 1 0. 2 610 - 0 . 2 6 1 5
3 - Y E L 6 . 5 7 8 6 - - 6 . 5 9 1 3 0. 2 590 0 . 2 5 9 5
2 - Y E L 6 . 5 2 7 8 - - 6 . 5 4 0 5 0. 2 57 0 0. 2 5 7 5
1 - Y E L 6 . 4 7 7 0 - - 6 . 4 8 9 7 0. 255C - 0 . 2 5 5 5
5 ORNG 6 . 4 2 6 2 - - 6 . 4 3 8 9 0. 2 530 - 0 2 535
4 ORNG 6 . 3 7 5 4 - - 6 . 3 8 8 1 0. 2 510 - 0 . 2 5 1 5
3 ORNG ' 6 . 3 2 4 6 - - 6 . 3 3 7 3 0. 2 490 0. 2 495
2 - O R N G 6 . 2 7 3 8 - - 6 . 2 8 6 5 0. 2 47 0 0. 2 47 5
1 ORNG 6 . 2 2 2 3 - - 6 . 2 3 5 7 0. 2 450 0. 2 455
2 RED 6 . 1 7 2 2 - - 6 . 1 8 4 9 0. 2 430 0. 2 335
1 RED 0 . 2 4 1 0 - - 0 . 2 4 1 5 6. 12 14 6. 1341
11. Install differential beari ng shim and bearing caps.
Tighten cap bol ts t o 95- 115 N-m (70-85 Ib-ft).
ARROWS
OUTBOARD
E4421-C
12. Rotate assembl y several ti mes.
E442S
13. Recheck backl ash. If backl ash is within
speci fi cati on, proceed t o Step 14. If not, repeat
Step 10.
BACKLASH SPEC 0.203-0.381 mm
(0.008-0.015 INCH) PREFERRED
RANGE 0.305-0.381 mm
(0.012-0.015 INCH)
14.
15.
E4423-D
Increase both LH and RH differential bearing shim
si zes by 0. 006 inch and install for correct
differential bearing prel oad. Make sure the shims
are fully seat ed and the assembl y turns freel y.
Use a whi te marki ng compound t o obtai n a t oot h
mesh cont act pattern in t he assembl y. Pattern
legibility can be i mproved by connecti ng the
dri veshaft and rotati ng bot h ti res in the dri ve and
coast di recti on.
INCREASE
SHIM BY
3 SHIM SIZES
+ 0.006 INCH
INCREASE
SHIM BY
3 SHIM SIZES
+ 0.006 INCH
E4455-D
A x l e S h a f t I n s t a l l a t i o n
1. NOTE: Check f or presence of rear axl e shaft
o-ring ( 4A332) on the spline end of the shaft and
install if mi ssi ng.
CAUTI ON: Do n o t l e t a x l e s h a f t s pl i n e s
d a ma g e o i l se a l o r b e a r i n g a s s e mb l y .
Carefully sl i de axl e shaft ( 4234) into rear axl e
housing wi t hout damagi ng rear wheel beari ng,
inner wheel beari ng oil seal or rear brake anti-lock
sensor i ndi cator ( 2C189) . Start splines into
differential si de gear ( 4236) and push firmly until
t he button end of axl e shaft can be seen in the
differential c a se .
2. Install the u-washer ( 4N237) on the button end of
the axl e shaft splines. Pull t he shaft out board until
the u-washer seat s in the counterbore of the
differential side gear.
3. CAUTI ON: Di f f e r e n t i a l pi n i o n s h a f t l o c k pi n
( 42 41) mu s t b e t i g h t e n e d t o s p e c i f i c a t i o n
u s i n g St u d a n d Be a r i n g Mo u n t
E 0A Z - 19554- BA o r e q ui v a l e n t me e t i n g Fo r d
s p e c i f i c a t i o n WS K- M2 G 349 - A 1.
Position the differential pinion shaft ( 4211)
through the differential case and differential pinion
gears ( 4215) , aligning the hole in the differential
pinion shaft wi th the l ock bolt hole. Appl y
Premium Rear Axl e Lubricant XY- 80W90- QL or
-KL or equivalent meeting Ford speci fi cati on
WSP-M2C197-A t o differential pinion shaft l ock
pin. Install differential pinion shaft l ock pin and
tighten t o 20-41 N-m (15-30 Ib-ft).
LOCK PIN 4241
TIGHTEN TO
20-41 N-m
(15-30 LB-FT)
DIFFERENTIAL
PINION SHAFT
4 2 1 1
E3856-G
Install axl e housing cover ( 4033) as outlined.
05 - 02 A - 40 A x l e , I n t e gr a l Ca r r i e r 8. 8- I n c h Ri n g Ge a r 0 5 - 0 2 A - 4 0
Co we r I n s t a l l a t i o n
1. NOTE: Axl e housing cover ( 4033) must be
installed wi thi n 15 minutes of appl i cati on of t he
silicone rubber or new silicone rubber must be
appl i ed.
CAUTI ON: Ma ke s u r e ma c h i n e d s u r f a c e s o n
h o u s i n g ( 4010) a r e c l e a n b e f o r e i n s t a l l i n g
t h e n e w s i l i c o n e s e a l a n t . I n si d e o f a x l e mu s t
b e c o v e r e d w h e n c l e a n i n g t h e ma c h i n e d
s u r f a c e t o p r e v e n t a x l e c o n t a mi n a t i o n .
Ti gh t e n t h e c o v e r b o l t s i n a c r o s s wi s e
p a t t e r n t o e n s u r e u n i f o r m d r a w o n a x l e
h o u s i n g c o v e r .
Appl y Silicone Rubber D6AZ- 19562- AA or BA or
ESB-M4G92-A or ESE-M4G195-A. Install axl e
housing cover and tighten axl e housing cover bolt
( 4346) t o 38- 52 N-m ( 28- 38 Ib-ft).
AXLE HOUSING COVER
4033
3.18-4.76 mm (1/8-3/16 INCH)
OF SILICONE RUBBER
F2667-H
. Add Premium Rear Axl e Lubri cant XY- 80W90- QL
or -KL or equivalent meeti ng Ford speci fi cati on
WSP-M2C197-A until it is 6-14 mm ( 1 / 4 - 9 / 1 6
inch) bel ow bot t om of fill hol e. Add 59 ml (2 oz) of
Ford Addi ti ve Fri cti on Modi fi er F3TZ- 19B546- MA
(WSP-M2C196-A) or equivalent t o Tracti on-Lok
axl es. Install filler plug and ti ghten t o 20- 41 N-m
(15-30 Ib-ft).
Sensor, Anti-Lock Brake
Installation
1. Install rear brake anti-lock sensor ( 2C190) and
bolt. Ti ghten bolt t o 4. 5-6. 8 N-m ( 40- 60 Ib-in).
2. Secure anti-lock br ake sensor wi ri ng harness t o
rear axl e housing ( 4010) wi th bracket and bol t.
Tighten bolt t o 16-27 N-m (12-19 Ib-ft).
3. Clip anti-lock brake sensor wi ri ng harness into
parki ng brake br acket .
Sensor, An t i - Lo c k Br ake
RH SHOWN
LH SIMILAR
Pa r t
1 2086 Rear Cover Bracket
Sensor
4 N605520-S100 Sensor Bolt (2 Req'd)
6 2C218 Parking Brake Bracket
and Conduit
A Tighten t o 4.6-6.8 N-m (40-60
Lb-ln)
B Tighten t o 16-27 N-m (12-19
Lb-Ft)
Inspection Before Disassembly of Carrier
Pi n i o n De p t h Ga u ge Se t T7 9P - 402 0- A
Inspect differential case ( 4204) assembl y and
differential ring gear and pinion ( 4209) before
removing the rear axl e housing ( 4010) . These
i nspecti ons may help det ect t he cause and determi ne
t he solution.
1. Wi pe lubricant f rom internal worki ng part s and
inspect par t s for wear and / or damage.
2. Rotate gear s t o see if t here is any roughness
whi ch woul d indicate worn or damaged beari ngs
or gears.
3. Check ri ng gear t eet h f or si gns of sc or i ng,
abnormal wear, ni cks or chi ps.
4. Set up Di al Indi cat or Wi t h Br a c ke t r y
TOOL -4201-C or equi valent and c he c k ri ng gear
backl ash and ri ng gear ba c kf a c e runout as
out l i ned. Ref er t o Speci f i cat i ons.
I n s p e c t i o n A f t e r Di s a s s e m b l y o f C a r r i e r
Thoroughl y cl ean all par t s. Al wa y s use new sol vent
when cl eani ng beari ngs. Do not spi n dr y beari ngs wi t h
c ompr e sse d air. Oil t he beari ngs i mmedi at el y wi t h
speci f i ed rear axl e lubri cant t o prevent rust i ng. I nspect
pa r t s f or damage. Clean t he i nsi de of t he housi ng
bef ore rebui l di ng. When a sc or e d or chi pped gear set
i s r epl aced, t he axl e housi ng must be wa she d
t horoughl y. I nspect i ons of i ndi vi dual pa r t s ar e out l i ned
bel ow.
S e n s o r , A n t i - L o c k Br a k e
The rear br a ke ant i -l ock sensor ( 2C190) must be
cl ean and f r ee of all unnecessary mat eri al such as
r oa d di rt , undercoat i ng and wa st e br a ke mat eri al .
The rear br a ke ant i -l ock sensor i ndi cat or ( 2C189)
must be cl ean and f r ee of ni cks, dent s and mi ssi ng
segment s. Removal and Inst allat i on pr ocedur es ar e
out l i ned.
G e a r s
Exami ne di f f erent i al ri ng gear and pinion t eet h f or
scor i ng, e xc e ssi ve wear, ni cks a n d / o r chi ppi ng.
Wor n, sc o r e d and damaged ge a r s cannot be rebui l t t o
c o r r e c t a noi sy condi t i on.
Be a r i n g C u p s
Check beari ng c ups f or deep sc o r e s, galli ng or
spel l i ng If a 0, 038 mm (0, 0015-i nch) f eel er gauge can
be i nsert ed be t we e n a cup and t he bot t om of i t s bor e
at any poi nt around t he cup, t he c up must be r e se a t e d.
Un i v e r s a l J o i n t Fl a n g e , Re a r A x l e
Ma ke sure t hat t he sur f aces of t he rear axl e uni versal
j oi nt f l ange ( 4851) have not been da ma ge d in
removi ng t he dri veshaf t ( 4602) or in removi ng t he rear
axl e uni versal j oi nt f l ange f r o m t he di f f erent i al ri ng gear
and pinion ( 4209) . The end of t he rear axl e uni versal
j oi nt f l ange t hat c ont a c t s t he beari ng cone a s wel l a s
t he nut count er bor e and f l ange y o ke seal sur f a c e must
be smoot h and f r e e of ni cks
C o n e a n d Ro l l e r A s s e mb l i e s
When ope r a t e d in t he c ups, beari ng rol l ers must t urn
wi t hout roughness. Exami ne t he l arge end of t he
rol l ers f or we a r (pi t t i ng, sc or i ng, galli ng or spal l i ng). If
i nspect i on r eveal s ei t her a d a ma ge d cup or a
da ma ge d cone and roller assembl y , r epl ace bot h
pa r t s
Ca r r i e r H o u s i n g
Ma ke sur e t hat t he di f f erent i al beari ng bor e s are
smo o t h. Remove any ni cks or bur r s f r o m t he mount i ng
sur f a c e s of t he rear axl e housi ng ( 4010) .
Di f f e r e n t i a l C a s e
Ma ke sur e t hat t he hubs whe r e t he di f f erent i al
bear i ngs ( 4221) mount ar e smoot h. Caref ul l y exami ne
t he di f f erent i al beari ng shoul ders, whi ch may have
been da ma ge d when t he di f f erent i al beari ngs we r e
r e move d. The beari ng assembl i es wi ll f ai l if t hey do not
seat f i rml y agai nst t he shoul ders. Check t he f i t (f ree
r ot at i on) of t he di f f erent i al si de gear s ( 4236) in t hei r
count er bor es.
SPECIFICATIONS
CLEARANCE, TOLERANCE AND ADJUSTMENTS
Descr i pt i on mm i nches
Ma x i mu m Run o ut o f Ba c k f a c e of
Ri n g Ge a r
. 07 62 . 004
Di f f e r e n t i a l Si d e Ge a r Th r u s t
Wa s h e r T h i c kn e s s
. 7 62 - . 812 . 030- . 032
Di f f e r e n t i a l Pi ni on Ge a r Thr us t
Wa s h e r T h i c kn e s s
. 7 62 - . 812 . 030- . 032
Ma x i mu m Di f f e r e n t i a l Ca s e Run o ut . 07 6 . 003
No mi n a l Pi n i o n L o c a t i n g Shi m . 7 62 . 030
Pi n i o n Te e t h
. 2 03- . 4 . 008- . 015
Ma x i mu m Ba c kl a s h Va r i a t i o n
. 1016 . 004
Ma x i mu m Ra d i a l Run o ut of
Co mp a n i o n Fl a n ge in A s s e mb l y
. 2 5T I R . 010 TI R
A v a i l a b l e Pi n i o n Ge a r Sh i ms i n
S t e p s of :
. 02 54 mm ( 0. 001 i n c h )
2 2 4 mm ( 8. 8 i n c h) a n d 191 mm
. 2 54- . 965 . 010- . 038
LUBRICANT CAPACITIES
Li t ers Pi nt s
1.8 3 . 7 5
a b
a Al l c o n v e n t i o n a l a x l e s use Pr e mi um Re a r A x l e L u b r i c a n t
X Y- 80W90- QL o r - KL o r e q ui v a l e n t me e t i n g Fo r d
Sp e c i f i c a t i o n WSP - M2 C197 - A . Se r v i c e r e f i l l c a p a c i t i e s a r e
d e t e r mi n e d by f i l l i n g a x l e 1 / 4 i n c h t o 9 / 1 6 i n c h b e l o w
b o t t o m o f f i l l e r h o l e . Ve h i c l e must b e l e v e l wi t h gr o u n d .
b Fo r Tr a c t i o n - L o k e q u i p p e d v e h i c l e s , a d d 59 ml ( 2 o z. ) o f
A d d i t i v e Fr i c t i o n Mo d i f i e r F3T Z - 19B546- MA o r e q ui v a l e n t
me e t i n g Fo r d s p e c i f i c a t i o n WSP - M2 C196- A .
Descr i pt i on N*m Lb-Ft
Di f f e r e n t i a l Be a r i n g Ca p Bo l t 95- 115 7 5- 90
Di f f e r e n t i a l Pi n i o n Sh a f t L o c k Bo l t 2 0- 41 15- 30
Ri n g Ge a r Re t a i n i n g B o l t s
3
95- 115 7 0- 85
A x l e Ho usi n g Co v e r Bo l t s 38- 52 2 8- 38
Oi l Fi l l e r Pl ug 2 0- 41 15- 30
T ORQU E SPECI FI CA T I ONS (Cont' d)
Di sc Br a ke A n c h o r P l a t e Bo l t s a n d
Nut s
2 7 - 40 2 0- 40
Di sc Br a ke A d a p t e r Br a c k e t Bo l t s 2 7 - 54 2 0- 40
Uppe r Su s p e n s i o n A r m- t o - A x l e 140- 180 103- 133
L o we r Su s p e n s i o n A r m- t o - A x l e 140- 180 103- 133
Br a ke J u n c t i o n Bl o c k 14- 2 4 10- 18
S h o c k A b s o r b e r Nut 7 0- 115 52 - 85
Un i v e r sa l Jo i n t Fl a n ge Bo l t s 95- 130 7 0- 95
Wh e e l L u g Nu t s 115- 142 85- 105
Br a ke A n t i - L o c k Se n s o r Re t a i n i n g
Bo l t
4. 5- 6. 8 40- 60
( L b- l n )
Re a r P a r ki n g Br a ke a n d Co n d ui t
Br a c ke t Bo l t
16- 27 12- 20
a Use St ud and Bear i ng Mount E 0A Z - 19554- BA or equi val ent
meet i ng For d speci f i cat i on WS K- M2 G 349- A 1.
R OT A T I ONA L T ORQU E
De sc r i pt i on N-m Lb- l n
Pi n i o n Be a r i n g
P r e l o a d ( C o l l a p s i b l e S p a c e r )
Us e d B e a r i n g s
8
0. 9- 1. 5
b
8- 14
b
Ne w Be a r i n gs 1. 8-3. 2 16- 29
a If pi n i o n b e a r i n g p r e l o a d e x c e e d s s p e c i f i c a t i o n b e f o r e t h i s
t o r q u e i s o b t a i n e d , i n st a l l a n e w c o l l a p s i b l e s p a c e r ,
b Wi t h f l a n ge y o ke s e a l i n s t a l l e d .
Tool Numbe r /
T50T- 100- A
T50T-100-A
T53T- 462 1- C
Pi ni on Be a r i n g Co n e Re p l a c e r
T53T-4621-C
T 57 L - 42 2 1- A 2
Di f f e r e n t i a l Si d e Be a r i n g
T57L-4221-A2
Tool Numbe r /
De sc r i pt i on
T 7 9P - 5638- A Su s p e n s i o n
Bu s h i n g Se r v i c e Se t
Co n s i s t s
of :
T 7 9P - 5638- A 1
T 7 9P - 5638- A 2
T 7 9P - 5638- A 5
T 86P - 5638- A H Re a r Ax l e
Co n t r o l Ar m Bu s h i n g To o l Se t
Co n s i s t s of :
T 86P - 5638- A H1
T 86P - 5638- A H2
T 86P - 5638- A H3
S p a c e r
T 58L - 101- B
Pul l e r
T 65L - 4851- B
T 7 0P - 42 2 1- A
Di f f e r e n t i a l Si d e Be a r i n g
Re mo v e r
T 7 1P - 4616- A
T 7 1P - 462 1- B
Pi ni on Be a r i n g Co n e Re mo v e r
T 7 5L - 1165- B
Ax l e Be a r i n g / S e a l P l a t e
T7 8P - 117 7 - A
Ax l e Tube Se a l Re p l a c e r
I l l ust r at i on
T71P-4621-B
T7SL- 11M- B
( Co n t i n ue d )
05- 02 A - 43 A x l e , I n t e gr a ! Ca r r i e r 8. 8- I n c h Ri n g Ge a r 05- 02 A - 43
(Conti nued)
SPECIAL SERVICE TOOLS REQUIRED (Cont' d)
T 7 8P - 12 2 5- A
T78P-1225-A
T 7 8P - 4851- A
T78P-4851-A
T 7 9P - 467 6- A
Pi n i o n Se a l Re p l a c e r
T79P-4676-A
T 85L - 12 2 5- A H
Re a r Ax l e Be a r i n g Re mo v e r
( Us e wi t h I mpa c t Sl i d e Ha mme r
T50T- 100- A)
T85L-1225-AH
T85T- 4616- A H
TSSf-4i1SAH
SPECIAL SERVICE TOOLS REQUIRED (Cont 'd)
Tool Numbe r /
T 7 9P - 402 0- A
Pi ni on De p t h Ga u ge Se t
n
T79P-4020-A
T 94P - 2 02 02 - A
Se n s o r Ri n g Re p l a c e r
T34P-20202-A
TOOL - 4858- E Co mp a n i o n Fl a n ge Re p l a c e r
0 5 - 0 2 1 - 1 Di f f e r e n t i a l , T r a c t i o n - L o k L i mi t e d S l i p 8 . 8 - I n c h Ri n g Ge a r 05- 02 B- 1
E T : zj r r ~Tr ~: : i 3" ^ ^
SECTION 05-02B Differential, Traction-Lok Limited
Slip8.8-Inch Ring Gear
SUBJECT PAGE
VEHICLE APPLICATION .05-02B-1
Descr i pt i on 05-02B-1
Noi se Accept abi l i t y 05-02B-2
Operat i on 05-02B-2
Di f f er ent i al , Tract i on-Lok Li mi t ed Sli p 05-02B-3
Di f f er ent i al , Tract i on-Lok Li mi t ed Slip . 05-02B-3
SUBJECT PAGE
Di f f er ent i al Case 05-02B-3
ADJUSTMENTS
Bench Torque Test 05-02B-12
Cl ut ch Pack Prel oad Adj ust me nt 05-02B-10
In-Vehi cle Ad j ust me n t s. . .... 05-02B-6
SPECIFICATIONS . 05-02B-13
SPECIAL SERVICE TOOLS/EQUIPMENT 05-02B-13
VEHICLE APPLICATION
Descri pt i on
WARNI NG: TO AVOI D INJURY, NEVER RUN THE
ENGI NE WI TH ONE WHEEL OFF THE GROUND,
FOR I NSTANCE, WHEN CHANGI NG A TI RE. THE
WHEEL STI LL ON THE GROUND COULD CAUSE
THE VEHI CLE TO MOVE.
The Tracti on-Lok axl e assembl y, except for the
differential case ( 4204) and its internal component s, is
identical t o the conventi onal axl e.
The Tracti on-Lok differential empl oys t wo set s of
multiple di sc differential cl utch packs ( 4947) t o
cont rol differential acti on.
The differential si de gear mounting di stance is
control l ed by seven pl ates (four st eel , t hree fri cti on)
and one steel shi m by sel ect si ze t o control
differential si de gear posi ti on.
The pl ates are st acked on t he differential side gear
hub and housed in t he differential case.
Al so l ocat ed in t he differential case, between the
differential si de gear ( 4236) , is a one-piece
di fferenti al cl utch spri ng ( 4214) , whi ch applies an
initial f or ce t o t he differential cl utch packs.
Addi ti onal cl ut ch capaci t y is del i vered f rom the side
gear s' thrust l oads.
The four steel pl ates are st acked in pai rs bet ween
t he t hree t anged fri cti on pl ates and are splined t o
t he differential si de gear hub whi ch, in turn, is
spl i ned t o t he hal fshaft.
The fri cti on pl ates are t anged t o the differential
case; t heref ore, t he differential cl ut ch packs are
al ways engaged.
DIFFERENTIAL
CLUTCH SPRING
4214
DIFFERENTIAL
SIDE GEAR
4236
DIFFERENTIAL CLUTCH PACK
4947 (INCLUDES THREE
STEEL, FOUR FRICTION AND
ONE REAR AXLE DIFFERENTIAL
CLUTCH SHIM 4A324)
. DIFFERENTIAL
PINION GEAR
4215
ES477Ê
05- 02B- 2 Di f f e r e n t i a l , T r a c t i o n - L o k L i mi t e d S l i p 8. 8- I n c h Ri n g Ge a r 06- 02B- 2
Tr a c t i o n - Lo k Di f f e r e n t i a l E x pl o d e d Vi e w
E3953-D
I t e m
Pa r t
Pa r t
1 4204 Differential Case 6 4214 Differential Clutch Spring
2 4A324 Rear Axle Differential Clutch 7 4236 Differential Side Gear
Shim 8 4211 Differential Pinion Shaft
3 4947 Differential Clutch Pack
9 4241 Differential Pinion Shaft Lock
4 4230 Differential Pinion Thrust Pin
Washer A

5 4215 Differential Pinion Gear Lb-Ft)
O p e r a t i o n
Differential acti on is accompl i shed as fol l ows:
The pressure bet ween cl utch pl ates opposes
differential acti on at all ti mes.
When the vehi cl e turns a corner, the differential
cl utch pack ( 4947 ) sl i ps, allowing normal differential
acti on t o t ake pl ace.
Under adverse weat her condi ti ons, where one or
bot h wheel s may be on a l ow-tracti on surface such
as snow, i ce or mud, the friction bet ween the cl utch
pl ates will transfer a portion of the usable torque t o
the wheel wi t h the most t ract i on. Thus, the wheel
that is on i ce or snow will have a tendency t o
operat e wi t h t he opposi t e wheel in a combi ned
driving effort.
CAUTI ON: E x t e n d e d us e o f o t h e r t h a n ma t c h i n g
si ze s p a r e t i r e s o n a T r a c t i o n - L o k r e a r a x l e c o u l d
r e s ul t i n r e d u c t i o n i n e f f e c t i v e n e s s ( bi a s t o r q u e ) .
Th i s l o s s o f e f f e c t i v e n e s s d o e s n o t a f f e c t n o r ma l
d r i v i n g a n d s h o u l d n o t b e n o t i c e a b l e t o t h e d r i v e r .
Ho we v e r , e x t e n d e d us e wi l l r e d u c e t h e a bi l i t y o f
t h e a x l e t o p r o v i d e a d d e d t r a c t i o n o n s l i p p e r y
s u r f a c e s .
Noise Acceptability
Gear-driven units, such as automoti ve drive axl es, will
produce a certai n amount of noise. Some noise is
accept abl e and may be heard at certai n speeds or
under various driving condi ti ons, such as on a newly
paved bl acktop road. The slight noise is not harmful t o
rear axl e operati on and is normal .
05- 02 B- 3 I f f e r e n t i a l , T r a c t i o n - L o k L i mi t e d S l i p 8 . 8 - i n c h Ri n g Ge a r 05- 02 B- 3
NOTE: Vehicles equi pped wi th a Tracti on-Lok
differential may exhibit a slight stick-slip noise on ti ght
turns after ext ended hi ghway dri vi ng. This is
consi dered accept abl e and has no detri mental ef f ect .
Di f f erent i al , Tract i on-Lok Li mi t ed Slip
Di f f erent i al , Tract i on-Lok Li mi t ed Slip
Refer t o Secti on 05-02A.
Di fferenti al Case
Tr a c t i o n - L o k To r q u e To o l
Ge a r Ro t a t o r
Tr a c t i o n - L o k Cl u t c h Ga uge
T 59L - 42 04- A
T 80P - 42 05- A
T 80P - 4946- A
Disassembly
1. NOTE: It is not necessary t o remove the
differential cone and roller assembl i es f rom t he
case j ournal s unless t hey are damaged. If t he
beari ngs remain on the differential case ( 4204)
during servi ce, keep t hem cl ean and free f rom
forei gn materi al .
Remove and di scard t he 10 bol ts securi ng t he
ring gear t o the differential case.
2. Remove the ring gear by tappi ng the gear wi t h a
soft-faced hammer or press the gear f rom the
differential case.
3. Remove t he differential pinion shaft l ock pin
( 4241) and remove the differential pinion shaft
( 4211) .
6.
7.
WARNI NG: USE CARE WHE N REMOVI NG THE
DI FFERENTI AL CL UTCH SPRI NG BECAUSE
OF SPRI NG TENSI ON.
Wi th a suitable drift, dri ve out the S-shaped
differential cl utch spri ng ( 4214) .
DIFFERENTIAL
CLUTCH SPRING
4214
E5484-C
Using differential Gear Rotator-Tracti on-Lok
T80P-4205-A, rotate t he differential pinion gears
( 4215) until the differential pinion gears and
differential pinion thrust washer s ( 4230) can be
removed.
Remove the differential side gears ( 4236) ,
differential cl utch packs ( 4947) and rear axl e
differential cl utch shims ( 4A324) f rom the RH and
LH cavi ti es and t ag them " R H " and " L H" .
NOTE: Do not use cleaning sol vents on fri cti on
plate surf aces. Wi pe cl ean only.
Clean and inspect all parts for wear or damage.
Repl ace as necessary.
05- 02 B- 4
Di f f e r e n t i a ! , T r a c t i o n - L o k L i mi t e d S l i p 8. 8- I n c h Ri n g Ge a r 05- 02 B- 4
Tr a c t i o n - Lo k Di f f e r e n t i a l Di sa sse mbl y
E3061-G
8. Adj ust cl ut ch pa c k pr el oad as out l i ned.
05- 02 B- S Di f f e r e n t i a l , T r a c t i o n - L o k L i mi t e d S l i p 8 . 8 - i n c h Ri n g Ge a r 05- 02 B- 5
A s s e m b l y
1. Lubri cate all part s wi th Premium Rear Axl e
Lubri cant XY-80W90-QL or -KL or equivalent
meeti ng Ford specification WSP-M2C197-A prior
t o assembl y. Lubri cate all clutch pl ates wi t h
Addi ti ve Fri cti on Modifier F3TZ-19B546-MA or
equivalent meeting Ford specification
WSP-M2C196-A prior to assembl y.
Tract i on-Lok Di f f erent i al -Assembl y
2. Mount the differential case in a soft-j aw vi se and
pl ace the differential cl utch packs and differential
si de gears in their proper cavi ti es in t he
differential case.
3. Pl ace t he differential pinion gears and differential
pinion thrust washer s on t he differential side
gears.
DIFFERENTIAL
PINION GEAR
4215
DIFFERENTIAL
PINION THRUST
WASHER 4230
GEAR ROTATOR
T80P-4205-A
E7S45-E
05- 02 B- 6 Di f f e r e n t i a l , T r a c t i o n - L o k L i mi t e d S l i p 8 . 8 - I n c h Ri n g Ge a r
-__ r r r sr ~__ _ __: ~ ~ zrsnr i _^t r pr - - --- -
05- 02 B- 6
DISASSEMBLY AND ASSEMBLY (Conti nued) ADJUSTMENTS
4. Install Gear Rotator T80P-4205-A in the
differential case.
5. Rotate the differential pinion gears until the bores
in the differential pinion gears are aligned wi t h the
differential pinion shaft holes in the differential
case. Remove the tool from the differential case.
6. Wi th a soft-faced hammer, install the differential
cl utch spring in the differential case. If necessary,
compl ete the installation of differential cl utch
spri ng wi th a brass drift.
7. NOTE: Inspect the differential cl utch spring for
damage.
DIFFERENTIAL
CLUTCH SPRING
4214
8.
ES484-C
NOTE: Do not tighten the differential pinion shaft
l ock pin at this point. The differential pinion shaft
and differential pinion shaft lock pin will be
removed t o install the axl e shafts. Once the axl e
shafts and retaining washers are installed, then
t he differential pinion shaft and differential pinion
shaft lock pin may be installed and ti ghtened t o
speci fi cati on.
Clean the t apped holes in the differential ring gear
and pinion ( 4209) wi th a suitable sol vent. If t he
new bol ts t o be used show a green coati ng over
approxi matel y 12.7 mm ( 1 / 2 inch) of the
t hreaded area, use as is. If not coat ed, appl y a
small amount of Stud and Bearing Mount
E0AZ-19554-BA or equivalent meeting Ford
speci fi cati on WSK- M2G349- A1. Tighten t o
95- 115 N-m (70-85 Ib-ft).
In-Vehicle Adjustments
In-vehicle adj ustments are possi bl e on this unit wi thout
removi ng t he differential case ( 4204) from the rear
axl e assembl y ( 4200) . If the testi ng check was not t o
speci fi cati on, use t he following procedure t o correct
the condi ti on:
Ge a r Ro t a t o r
T r a c t i o n - L o k Cl u t c h Ga u ge
T80P - 42 05- A
T80P - 4946- A
2.
4.
5.
NOTE: Whenever replacing the rear axl e
lubricant, use Premium Rear Axl e Lubricant
speci fi cati on WSP-M2C197-A and Addi ti ve
Fri cti on Modi fi er F3TZ-19B546-MA or equivalent
meeting Ford speci fi cati on WSP-M2C196-A.
Raise the vehi cl e on a hoist and install saf et y
st ands. Refer t o Secti on 00- 02. Remove rear
wheel s, rear di sc brake cal i pers ( 2552) and rear
di sc brake rot ors ( 2C026) .
Remove axl e housing cover ( 4033) f rom
differential case f ace and drain lubricant.
3. Perform t he inspection before di sassembl y.
Worki ng through the cover openi ng, remove the
differential pinion shaft lock pin ( 4241) and
remove t he differential pinion shaft ( 4211) .
Push axl e shaf t s i nward until the u-washers
( 4N237) at the button end of shafts are clear of
the differential si de gear recess.
CAUTI ON: Do n o t d a ma g e t h e wh e e l se a l s
w h e n r e mo v i n g t h e a x l e s h a f t s f r o m t h e a x l e
h o u s i n g . T h e a x l e s h a f t s mu s t a l so b e
c o mp l e t e l y r e mo v e d f r o m t h e a x l e h o u s i n g .
Remove the U-washers and pull the axl e shafts
( 4234) out of the rear axl e housing ( 4010) .
05- 02 8- 7 Di f f e r e n t i a l , T r a c t i o n - L o k Li mi t ed S l i p 8 . 8 - i n c h Ri n g Ge a r 05- 02 B- 7
ADJUSTMENTS ( C o n t i n u e d )
Cl ut c h Spr i ng Re mova l
REAR AXLE SHAFT
RETAINING U-WASHER
7. WARNI NG: USE CARE WHEN REMOVI NG THE
DI FFERENTI AL CLUTCH SPRI NG BECAUSE
OF SPRI NG TENSI ON.
Wi t h a suitable dri ft, dri ve t he S-shaped
differential cl utch spri ng ( 4214) hal f-way out of
the differential case. Rotate t he differential case
180 degrees.
DIFFERENTIAL
CLUTCH SPRING
4214
8. Hold the differential cl ut ch spri ng wi t h a pair of
pliers and t ap the differential cl ut ch spri ng until it
is removed f rom t he di fferenti al case.
9. NOTE: A 304. 8 mm (12-i nch) extensi on is
requi red to rot at e the di fferenti al pinion gear
( 4215) for removal .
Using Gear Rot at or T80P- 4205- A, rot at e the
differential pinion gear s until t he differential pinion
gears can be removed f rom t he differential case.
GEAR ROTATOR
T80P-4205-A
10. Remove t he RH and LH differential side gear
( 4236) and differential cl utch pack ( 4947) wi t h
the rear axl e differential cl utch shim ( 4A324) and
t ag them " RH" and " L H" .
11. NOTE: Do not use cleaning solution on cl utch
pl ate surfaces. Wi pe cl ean only.
Inspect the differential cl utch packs for wear and
repl ace parts as necessary.
12. Install Tracti on-Lok Cl utch Gauge T80P-4946-A
on each of the differential si de gear differential
cl utch packs without the rear axl e differential
cl utch shi m. Tighten t o 6.7 N-m ( 60 lb-in).
05- 02 B- 8 Di f f er ent i al , Tr act i on- Lok Li mi t ed S l i p 8 . 8 - l n c h Ri ng Gear 05- 02 B- 8
Cl ut c h Pack Pr e l oa d Ad j ust me n t
E3957-H
05- 02 B- 9 Di f f e r e n t i a l , T r a c t i o n - L o k L i mi t e d S l i p 8 . 8 - I n c h Ri n g Ge a r 05 - 02 B- 9
13. Usi ng a f eel er bl ade, sel ect t he t hi ckest bl ade
t hat wi ll ent er be t we e n t he t ool and t he di f f erent i al
cl ut ch pa c k. Thi s readi ng wi ll be t he t hi ckness of
t he rear a xl e di f f erent i al cl ut ch shi m.
14. NOTE: Lubr i cat e f ri ct i on pl at es wi t h Addi t i ve
Fri ct i on Modi f i er F3TZ- 19B546- MA or equi val ent
meet i ng Fo r d speci f i cat i on WSP-M2C196-A pri or
t o r eassembl y .
Install t he LH di f f erent i al si de gear, di f f erent i al
cl ut ch pa c k and rear axl e di f f erent i al cl ut ch shi m
i nt o t he c a vi t y in t he di f f erent i al case. Repeat t hi s
st e p f or t he RH si de.
TRACTION-LOK
CLUTCH GAUGE
15. Pl ace t he di f f erent i al pinion ge a r s and di f f erent i al
pi ni on t hr ust wa she r s ( 42 30) 180 degr ees apar t
on t he di f f erent i al si de ge a r s.
16. NOTE: A 304. 8 mm (12-i nch) ext ensi on is
requi red t o i nst all t he di f f erent i al pinion ge a r s.
Install Gear Rot at or T80P-4205-A in di f f erent i al
c a se .
E3953-G
17. Rot at e t he t ool until t he di f f erent i al pi ni on ge a r s
ar e al i gned wi t h t he di f f erent i al pi ni on shaf t hol e.
Remove t he t ool f r o m t he di f f erent i al c a se .
GEAR ROTATOR
T80P-4205-A
18. NOTE: I nspect t he di f f erent i al c l ut c h spri ng f or
damage.
Hol d t he di f f erent i al cl ut ch spri ng up t o t he
di f f erent i al c a se wi ndow and wi t h a sof t -f aced
hammer, hammer t he di f f erent i al cl ut ch spri ng i nt o
posi t i on.
19. Install t he axl e shaf t s and u-washers i nt o posi t i on.
Push t he axl e shaf t out boar d a s f ar as possi bl e.
05- 02B- 10 Di f f e r e n t i a l , T r a c t i o n - L o k L i mi t e d S l i p 8. 8- I n c h Ri ng Ge a r
0S- 02B- 10
20. NOTE: Differential pinion shaft l ock pin should be
repl aced wi th a new pin. If a new differential pinion
shaft l ock pin is not available, coat t hreads wi th
Stud and Bearing Mount E0AZ-19554-BA or
WSK- M2G349- A1 and ti ghten t o speci fi cati on.
Install the differential pinion shaft and differential
pinion shaft l ock pin. Tighten t he differential pinion
shaft l ock pin t o 20-41 N-m ( 15- 30 Ib-ft).
2 1 . Install the rear di sc brake rot ors, rear disc brake
cal i pers and wheel s. Perform the Tracti on-Lok
Operati onal Check as outlined in Secti on 05- 00 t o
make sure that the unit is within speci fi cati on.
22. CAUTI ON: Ma ke s ur e c a r r i e r f a c e a n d a x l e
h o u s i n g c o v e r a r e c l e a n a n d f r e e o f o l d
se a l a n t b e f o r e i n s t a l l i n g n e w s i l i c o n e
s e a l a n t . A x l e h o u s i n g c o v e r mu s t b e i n s t a l l e d
wi t h i n 15 mi n u t e s o f a p p l y i n g s e a l a n t .
Using Silicone Rubber D6AZ-19562-BA or
ESE-M4G195-A, install t he rear axl e housing
cover assembl y and bol ts. Tighten t o 34-47 Nm
(25-35 Ib-ft).
23. Fill wi th Premium Rear Axl e Lubri cant
speci fi cati on WSP-M2C197-A, 6 t o 14 mm ( 1 / 4
to 9 / 1 6 inch) f rom the bot t om of the fill hole wi t h
the axl e in the running posi ti on. Add 118 ml (2 oz)
of Addi ti ve Friction Modifier F3TZ- 19B546- MA or
WSP-M2C196-A. Install the oil filler plug. Tighten
t o 20- 41 N-m ( 15- 30 Ib-ft).
CLUTCH
2. Assembl e differential Traction-Lok Cl utch Gauge
T80P-4946-A on differential side gear differential
cl utch pack.
C l u t c h P a c k P r e l o a d A d j u s t m e n t
1. Assembl e the differential cl utch pack ( 4947) on
the differential side gear ( 4236) (no rear axl e
differential cl utch shi m ( 4A324) requi red at this
poi nt). However, all pl ates must be pre-l ubri cated
wi t h Addi ti ve Fri cti on Modifier F3TZ- 19B546- MA
WSP-M2C196-A.
05- 02 B- 11 Di f f er ent i al , Tr act i on- Lok Li mi t ed S l i p 8 . 8 - I n c h Ri ng Gear 0 5 - 0 2 B - 1 1
Cl ut ch Pack Prel oad Adj ust ment
i
3 E3957-H
05- 02 B- 12 Di f f e r e n t i a l , T r a c t i o n - L o k L i mi t e d S l i p 8. 8- I n c h Ri n g Ge a r 05- 02 B- 12
3. Using a feel er gauge t ool , sel ect the t hi ckest
feel er bl ade that will enter between the tool and
the differential cl utch pack.
TRACTION-LOK
CLUTCH GAUGE
T80P-4946-A
E3958-F
NOTE: Do not mix t he cl utches or shi ms.
Not e the t hi ckness; thi s will be t he shim requi red
for that differential cl utch pack.
Repeat St eps 1 through 4 for the opposi te
differential cl utch pack.
B e n c h T o r q u e T e s t
Ge a r Ro t a t o r
T 59L - 42 04- A
T 80P - 42 05- A
1. Prior t o installation of the l ocki ng differential into a
vehi cl e, a bench-torque check must be made.
Wi t h Tracti on-Lok Torque Tool T59L-4204-A,
check the t orque requi red t o rot at e one
differential si de gear ( 4236) whi l e the other is
held stati onary.
GEAR ROTATOR
T80P-4205-A
TRACTION-LOK TORQUE TOOL
T59L-4204-A
E3984-E
The initial br eakaway torque shoul d be no l ess
than 27 N-m ( 20 Ib-ft). The rotati ng torque
requi red t o keep the differential si de gear turning
wi t h new differential cl utch packs ( 4947) may
fl uctuate.
BREAKAWAY TORQUE SPECIFICATIONS
T r a c t i o n - L o k Te st On - Ve h i c l e o r
Be n c h wi t h Ne w o r Ol d Cl u t c h
P a c k s ( Mi n i mum)
2 7 2 0
TORQUE WRENCH
OF AT LEAST 271 N-m
(200 LB-FT) CAPACITY
TRACTION-LOK
TORQUE TOOL
T59L-4204-A
E3983-E
05- 02 B- 13 Di f f e r e n t i a l , T r a c t i o n - L o k L i mi t e d S l i p 8 . 8 - I n c h Ri n g Ge a r 05 - 02 B- 13
SPECIFICATIONS
LUBRICANT CAPACITY
3
De s c r i p t i o n Li t ers Pi nt s
Re a r Ax l e L u b r i c a n t P r e mi u m
Re a r Ax l e L ubr i c a n t X Y- 80W90- QL
o r - K L o" e q ui v a l e n t me e t i n g Fo r d
s p e c i f i c a t i o n WS A - M2 C197 - A
1.8 3. 7 5
Ad d i t i v e Fr i c t i o n
Mo d i f i e r F3T Z - 19 B5 46- M A
WSP - M2 C196- A
0. 059 0. 12 5
a
Refer to Section 05-02A for fill procedures.
BACKLASH BETWEEN RING GEAR AND PINION
Pi n i o n Te e t h
. 2 03- . 040 . 008- . 015
Ma x i mu m Ba c k l a s h Va r i a t i o n
. 010 . 004
Oi l Fi l l e r Pl ug 2 0- 41 15- 30
Ri ng Ge a r Re t a i n i n g Bo l t s 95- 115 7 0- 85
Ax l e Ho u s i n g Co v e r Bo l t s 34- 47 2 5- 35
Cl u t c h P a c k Ga u ge 6. 7 60 ( L b - l n )
SPECIAL SERVICE TOOLS/EQUI PMENT
Tool Numbe r /
T 59L - 42 04- A
T59L-4204-A
T 80P - 42 05- A
Ge a r Ro t a t o r
TS0JM20S-A
T 80P - 4946- A
T r a c t i o n - L o k Cl u t c h Ga u ge
T80P-4946-A
06- 00- 1
G R O U P
BRAKE SYSTEM ^'B
SECTION TITLE PAGE
BRAKE SYSTEM, ANTI-LOCK 06-09-1
BRAKE SYSTEM, HYDRAULIC . 06-06-1
BRAKE SYSTEM, PARKING . 06-05-1
BRAKE SYSTEM, POWER.... 06-07-1
SECTION TITLE PAGE
BRAKE SYSTEM SERVICE . ......06-00-1
BRAKES, FRONT DISC .........06-03-1
BRAKES, REAR DISC ...06-04-1
Service
SUBJECT PAGE
Brake Boost er ..06-00-12
Brakes, Disc 06-00-12
Hydraul i c Sy st e m. ...06-00-12
Parki ng Brake 06-00-12
Servi ce Precaut i ons. . .....06-00-12
ADJUSTMENTS
Brake Fl ui d Level Check 06-00-14
Brake Pedal Free Hei ght Measurement s. . ....06-00-13
Brake Pedal Travel Measurement ...06-00-13
Brake Rotor, Di sc . 06-00-14
Brakes Fr o n t Di sc 06-00-14
Brakes RearDi sc 06-00-14
Ref i ni shi ng ...06-00-15
SPECIFICATIONS
Brake Syst em Component
Speci f i cat i ons 06-00-16
SECTION 06-00 Brake Syst em
SUBJECT PAGE
Brake Combi nat i on Valve 06-00-2
Brake Syst em, Ant i -Lock ....06-00-3
Brake Syst em, Hydraul i c 06-00-2
Brake Syst em, Parki ng 06-00-2
Brakes, Front Di sc 06-00-2
Br akes, Rear Disc 06-00-2
Mast er Cyli nder, Dual ....06-00-2
Component Test s ...06-00-9
I nspect i on and Veri f i cat i on ....06-00-3
SERVICE PROCEDURES
Brake Hose 06-00-11
Brake Tubing 06-00-11
Hydraul i c Leak Test 06-00-11
VEHICLE APPLICATION
06- 00- 2 Br a ke S y s t e mS e r v i c e 06- 00- 2
DESCRIPTION A N D O P E R A T I O N
Master Cylinder, Du a !
WARMI NG: BRAKE FLUI D CONTAI NS
POLYGLYCOL ETHERS AMD POLYGLYCOLS.
AVOI D CONTACT WI TH EYES. WASH HANDS
THOROUGHLY AFTER HANDLI NG. IF BRAKE
FLUI D CONTACTS EYES, FLUSH EYES WI TH
RUNNI NG WATER FOR 15 MI NUTES. GET
MEDI CAL ATTENTI ON IF I RRI TATI ON PERSI STS.
IF TAKEN I NTERNALLY, DRI NK WATER AND
INDUCE VOMI TI NG. GET MEDI CAL ATTENTI ON
I MMEDI ATELY.
The brake master cylinder ( 2140) has the fol l owi ng
features:
A common plastic brake master cylinder reservoi r
( 2K478) and fluid level indicator combi ned in one
assembl y.
The dual hydraulic brake syst em is a conventi onal ,
pedal -actuated syst em wi t h the following features:
Brake master cylinder.
Brake pressure control val ve ( 2B091) .
- Brake tubes and hoses.
B r a k e C o m b i n a t i o n Va l v e
The brake pressure control val ve ( 2B091) :
Regul ates the hydraulic pressure in the rear brake
syst em.
Is l ocated between the rear brake syst em' s inlet
port s and the master cylinder outlet port s.
Operati on is as fol l ows:
When the brake pedal ( 2455) is appl i ed, the full,
rear brake fluid pressure passes through the
proporti oni ng val ve t o the rear brake syst em until
the val ve' s split point is reached.
Above its split point, the proporti oni ng valve begi ns
t o reduce the hydraulic pressure t o the rear brakes,
creati ng a bal anced braki ng condition between the
front and rear wheel s t o minimize rear wheel
ski ddi ng during hard braki ng.
B r a k e System, H y d r a u l i c
This vehicle is equi pped wi t h a pedal act uat ed
hydraulic dual brake syst em. The syst em consi sts of
the fol l owi ng:
Power brake boost er ( 2005) .
Brake master cylinder ( 2140) .
Brake pressure control val ve ( 2B091) .
Necessar y brake t ubes and hoses.
The dual hydraulic syst em wi t h or wi thout ABS is
front-to-rear split. Bot h front brakes compri se one
circuit and bot h rear brakes the other circuit.
B r a k e s , F r o n t Di s c
Front di sc brakes have the fol l owi ng features:
Pin sl i der-type bolt on anchor bracket caliper
assembl i es wi th 291 mm ( 10. 2 inch) full cast
composi t e front di sc brake rot ors ( 1125) .
The di sc brake cal i per ( 2B120) has a steel cal i per
pi ston ( 2196) wi t h a piston seal and a press-in t ype
dust boot.
The di sc brake cal i per assembl y is at t ached t o t he
front suspension front wheel spindle ( 3105) wi th
t wo M14 bol ts.
The di sc brake cal i per is mounted t o t wo slide pins
whi ch, once l ubri cated and assembl ed in the front
di sc brake cal i per anchor pl ate ( 2B292) , provi de
"seal ed for l i f e" perf ormance.
B r a k e s , Re a r Di s c
The rear di sc brakes have the following features:
A drum-in-hat styl e solid full cast rear di sc brake
rotor ( 2C026) .
Hydraulically act i vat ed rear di sc brake cal i pers
( 2553) wi th integral mechanically (cabl e) operat ed
parki ng brake mechani sms.
Except for the parki ng brake mechani sm, the rear
di sc brake cal i per assembl y is similar t o the pin
slider di sc brake cal i per ( 2B120) .
The added parki ng brake lever on the back of the
rear di sc brake cal i per is cabl e-operated by the
parki ng brake control ( 2780) l ocated bel ow the
dash panel, similar t o rear drum brake installations.
The caliper parki ng brake mechani sm is adj usted
manually.
B r a k e S y s t e m , P a r k i n g
The parki ng brake syst em has the following features:
It is control l ed by an independent foot-operated
parki ng brake control ( 2780) whi ch actuates the
rear wheel brake shoes and linings ( 2001) through
a cabl e syst em.
The parki ng brake warni ng indicator can be
act uat ed by the parki ng brake control . It warns the
driver t o rel ease t he parki ng brake control before
driving the vehi cl e. If the indicator remains lit, a
brake malfunction has occurred.
The automati c vacuum-type parki ng brake syst em has
the following f eat ures:
The vacuum power unit is snapped onto the
mounting bracket of the parki ng brake control
assembl y.
The vacuum-actuated di aphragm within the unit is
connected by a rod t o the l ower end of the rel ease
lever.
Hoses connect the vacuum motor to the engine
manifold through a vacuum rel ease swi t ch at t he
steeri ng column.
The vacuum motor is act uat ed t o rel ease the
parki ng brake whenever the engine is running and
the transmi ssi on is in a f orward driving gear.
To manually rel ease the automati c vacuum-type
parki ng brake, a parki ng brake rel ease handle
ext ends f rom the l ower porti on of the dash panel
( 01610) , left of the steeri ng col umn. Pulling on thi s
handle rel eases the parki ng brake.
B r a k e S y s t e m , A n t i - L o c k
The ABS is a four-wheel syst em whi ch prevents wheel
lock-up by automati cal l y modul ati ng the brake
pressure during an emergency st op. By not locking the
wheel s, it enabl es the dri ver t o maintain steeri ng
control and st op in t he shortest possi bl e di stance
under most condi ti ons.
During normal braki ng, the ABS and non-ABS brake
pedal feel will be the same. During ABS operati on, a
pulsation can be felt in the brake pedal ( 2455) ,
accompani ed by a " cl i cki ng" sound.
Vehicles wi t h ABS are equi pped wi t h a pedal act uat ed
dual brake syst em. The hydraul i c syst em consi sts of
the fol l owi ng:
ABS control and module.
Power brake boost er ( 2005) .
Brake master cylinder ( 2140) .
Brake pressure control val ves ( 2B091) .
Necessary brake tubes and hoses.
Ro a d T e s t
Perform a road t est t o compare actual vehi cl e braki ng
performance wi t h the perf ormance st andards
expect ed by the driver. The ability of the test driver t o
make valid compari sons and det ect performance
deficiencies will depend on experi ence.
The driver should have a t horough knowl edge of brake
syst em operati on and accept ed general performance
guidelines in order t o make good compari sons and
det ect performance concerns.
An experi enced brake techni ci an will al ways establ i sh
a route that will be used f or all brake di agnosi s road
t est s. The road sel ected will be reasonabl y smoot h
and level. Gravel or bumpy r oads are not sui tabl e
because the surf ace does not al l ow the ti res t o gri p
the road equally. Cr owned roads should be avoi ded
because of t he large amount of wei ght shi fted t o the
l ow set of wheel s on this t ype of road. Once t he route
is establ i shed and consi stentl y used, the road surf ace
vari abl e can be eliminated f rom the test resul ts.
Before a road test, get a compl et e descri pti on of the
customer concerns or suspect ed condi ti on. Fr om the
descri pti on, t he techni ci an' s experi ence will al l ow the
techni ci an to mat ch possi bl e causes wi th sympt oms.
Certai n component s will be t agged as possi bl e
suspect s whi l e ot hers will be eliminated by the
evi dence. More i mportantl y, the cust omer' s
descri pti on can reveal unsafe condi ti ons whi ch shoul d
be checked or correct ed bef ore the road t est . The
descri pti on will also help f or m t he basi c approach t o
the road test by narrowi ng the concern t o speci fi c
components, vehi cl e speed or condi ti ons.
Begin the road test wi th a general brake perf ormance
check. Keepi ng the descri pti on in mind, test t he
brakes at different vehi cl e speeds using both light and
heavy pedal pressure.
Avoi d locking t he brakes and sliding the ti res. Locked
brakes and sliding ti res do not indicate brake
efficiency. A heavily braked and turning wheel will st op
the vehicle in less di stance than l ocked brakes. If the
condition becomes evi dent during this check, make
sure it fits the descri pti on given before the road t est . If
the condition is not evi dent, at t empt t o dupl i cate t he
condition using the information f rom the descri pti on.
If a concern exi st s, use the Brake Syst em Sympt om
Chart in order t o isolate it t o a speci fi c subsyst em and
condition descri pti on. From this descri pti on, a list of
possible sources can be used t o further narrow t he
cause to a speci fi c component or condition.
NOTE: LIMD ONLY: To determine if the probl em is in
the front or rear braki ng syst em, first use the brake
pedal ( 2455) , then use the parki ng brake. If the
condition (i.e., pull, vi brati on, pulsation) occurs only
wi t h the parki ng brake, the concern is in the rear
syst em. If the condition occurs when the brake pedal
is depressed, the concern is in the front syst em.
06- 00- 4
Br a ke S y s t e mS e r v i c e 06- 00- 4
Sympt om Chart
BRAKE SYSTEM
Brakes Pull or Drift Unequal air pressure in t i res.
Grease or fluid on brake shoe and
lining; glazed linings.
Stuck or seized cali pers.
INFLATE ti res to correct pressure.
REPLACE. REFER to Section
06-03 or 06-04.
Brake Warning Indicator Always
ON
Hydraulic system.
Shorted indicator ci rcui t.
Vibration When Brakes are Applied Grease or fluid on brake shoe and
lining; glazed linings.
Front di sc brake rot or/rear disc
brake rotor.
06-03 or 06-04.
Pedal Goes Down Fast Air in system.
Malfunctioning brake master
cylinder.
BLEED system. REFER to Section
06-06.
Pedal Eases Down Slowly Air in system.
Malfunctioning brake master
cylinder.
BLEED system. REFER to Section
06-06.
Pedal is Low or Feels Spongy Brake shoe and lining.
Hydraulic syst em.
06-03 or 06-04.
Brake Lock-up During Light Brake
Pedal Force
Tires worn or incorrect pressure.
Glazed or worn brake shoe and
lining.
INFLATE tires to proper pressure.
REPLACE worn t i res.
06-03 or 06-04.
Excessive and / or Erratic Pedal
Travel
Worn brake shoe and lining.
Disc brake rotors.
06-03 or 06-04.
Brakes Drag Power brake booster.
Brake pressure control valve.
Excessi ve Brake Pedal Effort Power brake booster inoperative.
Worn or contaminated brake shoes
and linings.
PERFORM Power Brake Booster
Function Test outlined in this
secti on.
06-03 or 06-04.
Brake Noise Brake shoe and lining.
Power brake booster.
06-03 or 06-04.
GO to Pinpoint Test L.
Slow or Incomplete Brake Pedal
Return
Power brake booster.
Brake master cylinder.
GO to Pinpoint Test M.
Pi npoi nt Tests
PINPOINT TEST A: BRAKES PULL OR DRIFT
TEST STEP RESULT " ACTION TO TAKE
A1 ROAD TEST VEHICLE
Yes
No
GO to A2.
Vehicle OK.
Road t est vehi cle and apply brake pedal.
Does vehi cl e pul l or dr i f t ?
Yes
No
GO to A2.
Vehicle OK.
A2 TIRE INSPECTION
Yes
No
GO to A3.
INFLATE ti res to proper
pressure. REPLACE
excessi vely worn t i res.
REPEAT Test St e p At .
Check for excessi ve wear or improper ti re pressure.
Are t i r es good?
Yes
No
GO to A3.
INFLATE ti res to proper
pressure. REPLACE
excessi vely worn t i res.
REPEAT Test St e p At .
PINPOINT TEST A: BRAKES PULL OR DRIFT (Cont i nued)
A3 BRAKE PAD INSPECTION
Yes
No
GO t o A4.
REPEAT Test Step A 1.
Inspect brake shoe and lining for grease or fluid on
linings and/ or wear concerns.
Are brake pads OK?
Yes
No
GO t o A4.
REPEAT Test Step A 1.
A4 PRESSURE CONTROL VALVE TESTFRONT TO
REAR SPLIT SYSTEM
Yes
No
INSPECT cali pers and
REPLACE RH rear brake
pressure control valve.
Install pressure gauges in the LH front and RH rear
bleeder screws. Apply 6895 kPa (1000 psi) in front
brake syst em. The RH rear brake pressure must be
between 3751-4647 kPa (544-674 psi ).
Is rear brake pressure bet ween 3751-4647 kPa
(544-674 psi )?
Yes
No
PINPOINT TEST B: BRAKE WARNING INDICATOR ALWAYS ON
B1 BRAKE FLUID LEVEL
Yes
No
GOt o B3.
GOt o B2.
Check brake master cylinder reservoir fluid level.
Is f l ui d level good?
Yes
No
GOt o B3.
GOt o B2.
B2 BRAKE SYSTEM LEAKAGE
Yes
No
SERVICE as necessary,
ADD fluid and BLEED
system.
FILL brake master
cylinder reservoir. GO to
B3.
Check brake master cylinder reservoir sealing
points and external brake system for leakage.
(Refer t o Hydraulic Leak Test and Non-Pressure
Leaks.)
Does syst em l eak?
Yes
No
ADD fluid and BLEED
system.
FILL brake master
cylinder reservoir. GO to
B3.
B3 IGNITION WIRING CHECK
Yes
No
GOt o B4.
REROUTE wiring as
necessary.
Check that ignition wiring is not within a 50.8mm (2
inch) radius of the reed swi tch Fluid Level Indicator
(FLI) assembly.
Is i gni t i on wi r i ng OK?
Yes
No
GOt o B4.
REROUTE wiring as
necessary.
B4 FLOAT ASSEMBLY CHECK
Yes
No
CHECK if ignition prove
out circuit is working
properly.
REPLACE brake master
cylinder reservoir
assembly.
Check if float is stuck or magnet is dislodged from
float.
Is f l oat f unct i onal ?
Yes
No
CHECK if ignition prove
out circuit is working
properly.
REPLACE brake master
cylinder reservoir
assembly.
PINPOINT TEST C: VIBRATION WHEN BRAKES ARE APPLIED
C1 ROAD TEST
Yes
No
to service thi s condition
first. REPEAT Step.
GOt o C2.
Road test vehicle without applying brakes 40-80
km/ h (25-50 mph).
Is a vi brat i on present ?
Yes
No
to service thi s condition
first. REPEAT Step.
GOt o C2.
C2 FRONT BRAKE VIBRATION
Yes
No
CHECK front and rear
disc brake rotors for
excessive runout or
cracks. REFER to
Section 06-04 for disc
brake rotor procedures.
REPEAT Step C2.
Vehicle OK.
Road test vehicle with light and medium application
on the brake pedal.
Was a vi br at i on present ?
Yes
No
CHECK front and rear
disc brake rotors for
excessive runout or
cracks. REFER to
Section 06-04 for disc
brake rotor procedures.
REPEAT Step C2.
Vehicle OK.
PINPOINT TEST D: PEDAL GOES DOWN FAST
D1 PEDAL FEEL
Yes
No
Vehicle OK.
GOt o D2.
Road test vehicle and apply brake pedal.
Was brake pedal ef f ort normal?
Yes
No
Vehicle OK.
GOt o D2.
D2 BRAKE FLUID LEVEL
Yes
No
GOt o D3.
CHECK brake master
cylinder reservoir sealing
points (Non-Pressure
Leaks), ADD fluid and
BLEED system. REPEAT
Test St e p DI .
Is f l ui d level accept abl e?
Yes
No
GOt o D3.
CHECK brake master
points (Non-Pressure
Leaks), ADD fluid and
Test St e p DI .
D3 PRESSURIZE SYSTEM
Yes
No
CHECK rear brake
adj ustment and ADJUST
if necessary. If condition
still exi st s, BLEED
system for air. REPEAT
Test St e p DI .
GOt o D4.
Pump brake pedal rapidly (five ti mes).
Does t he brake pedal hei ght bui l d up and t hen
hol d?
Yes
No
CHECK rear brake
if necessary. If condition
still exi st s, BLEED
system for air. REPEAT
Test St e p DI .
GOt o D4.
D4 BRAKE SYSTEM LEAKS
Yes
No
ADD fluid and BLEED
system. REPEAT Test
St e p DI .
GOt o D5.
Check for external brake system leaks (use
Hydraulic Leak Test).
Any l eaks f ound?
Yes
No
ADD fluid and BLEED
system. REPEAT Test
St e p DI .
GOt o D5.
D5 MASTER CYLINDER BYPASS TEST
Yes
No
REPLACE damaged
parts, ADD fluid and
Test Step D1.
System OK.
Test for brake master cylinder bypass (use Bypass
Condition Check).
Was a concer n f ound?
Yes
No
REPLACE damaged
Test Step D1.
System OK.
PINPOINT TEST E: PEDAL EASES DOWN SLOWLY
E1 CHECK BRAKE PEDAL OPERATION
Yes
No
No action required.
(REFER to Normal
Condition No.1.)
GOt o E2.
Check if condition occurs during actual stoppi ng
appli cati on by applying the brake pedal while the
vehi cle is moving.
Does c ondi t i on occur wi t h vehi cl e st at i onar y?
Yes
No
No action required.
(REFER to Normal
Condition No.1.)
GOt o E2.
E2 BRAKE SYSTEM LEAKS
Yes
No
ADD fluid and BLEED
system. REPEAT Test
St e p E I .
GOt o E3.
Check for external brake system leaks. (Refer to
Hydraulic Leak Test.)
Were any l eaks f ound?
Yes
No
ADD fluid and BLEED
system. REPEAT Test
St e p E I .
GOt o E3.
E3 BRAKE MASTER CYLINDER BYPASS TEST
Yes
No >
REPLACE damaged
Test St e p E I .
System OK.
Test for brake master cylinder bypass. (Refer to
Bypass Condition Check.)
Was a pr obl em f ound?
Yes
No >
REPLACE damaged
Test St e p E I .
System OK.
06- 00- 7
PINPOINT TEST F: PEDAL IS LOW OR FEELS SPONGY
F1 SPONGY PEDAL
Yes
No
Vehicle OK.
GOt o F2 .
Road test vehicle and apply brake pedal.
Was brake pedal ef f ort normal ?
Yes
No
Vehicle OK.
GOt o F2 .
F2 BRAKE FLUID LEVEL CHECK
Yes
No
GOt o F3.
CHECK brake master
poi nts. (Non-Pressure
Leaks) ADD fluid and
BLEED syst em.
Is fl ui d level accept abl e?
Yes
No
GOt o F3.
CHECK brake master
poi nts. (Non-Pressure
Leaks) ADD fluid and
BLEED syst em.
F3 FILLER CAP VENT CHECK
Yes
No
CLEAN as necessary.
REPEAT Test S t e p FI .
GO t o F4.
Check if filler cap vent holes are clogged or dirty.
Was a c onc e r n f ound?
Yes
No
CLEAN as necessary.
REPEAT Test S t e p FI .
GO t o F4.
F4 BLEED BRAKE SYSTEM
Yes
No
GOt o F5.
Vehicle OK.
Bleed brake system as descri bed in thi s Secti on.
Is c ondi t i on st i l l pr esent ?
Yes
No
GOt o F5.
Vehicle OK.
F5 FRONT HUB NUT CHECK
Yes
No
REPLACE with new nut
and st ake. Do not reuse
t he f r o n t axl e wheel hub
ret ai ner. REPEAT Test
St e p FI .
CHECK rear brake
if necessary. REPEAT
Test S t e p FI .
Check front axle wheel hub retainer nut for
looseness, (refer to Section 04-01).
Was hub nut l oose?
Yes
No
REPLACE with new nut
and st ake. Do not reuse
t he f r o n t axl e wheel hub
ret ai ner. REPEAT Test
St e p FI .
CHECK rear brake
if necessary. REPEAT
Test S t e p FI .
PINPOINT TEST G: BRAKE LOCKUP DURING LIGHT BRAKE PEDAL FORCE
G1 BRAKE LOCK UP TEST
Yes
No
GO to G4.
GOt o G2.
Road t est vehicle and apply brake pedal lightly.
Do br akes l ock up?
Yes
No
GO to G4.
GOt o G2.
G2 TIRE INSPECTION
Yes
No
GOt o G3.
SUBSTITUTE known good
ti res if worn. INFLATE t o
proper pressure. REPEAT
Test St e p GL
Check for excessi ve ti re wear or improper ti re
pressures.
Are t i r es good?
Yes
No
GOt o G3.
SUBSTITUTE known good
ti res if worn. INFLATE t o
proper pressure. REPEAT
Test St e p GL
G3 BRAKE PAD INSPECTION
Yes
No
GO t o G4.
REPEAT Test St e p G L
Inspect brake shoes and linings for grease or fluid
on linings and / or wear concerns.
Are t her e concer ns?
Yes
No
GO t o G4.
REPEAT Test St e p G L
G4 PRESSURE CONTROL VALVE TESTFRONT
Yes
No
Install pressure gauges in t he LH front and RH rear
bleeder screws. Apply 6895 kPa (1000 psi) in front
brake syst em. The RH rear brake pressure must be
between 3751-4647 kPa (544-647 psi ).
Is rear br ake pressure be t we e n 3751-4647 kPa
(544-647 psi )?
Yes
No
PINPOINT TEST H: EXCESSIVE AND/OR ERRATIC PEDAL TRAVEL
H1 ROUGH ROAD TEST
Yes
No
Vehicle OK.
GO t o H2 .
Road test vehicle under rough road conditions.
Apply brakes slowly.
Are brakes good?
Yes
No
Vehicle OK.
GO t o H2 .
H2 WHEEL BEARING CHECK
Yes
No
REPLACE front wheel
bearing if damaged.
TIGHTEN front wheel
bearing assembly to
speci fi cati on. REPEAT
Test St e p HI .
CHECK front disc brake
rotor for thi ckness
variances. (REFER to
Section 06-03.)
Check for loose front wheel bearings .
Are f r ont wheel beari ngs l oose?
Yes
No
REPLACE front wheel
bearing if damaged.
TIGHTEN front wheel
bearing assembly to
speci fi cati on. REPEAT
Test St e p HI .
CHECK front disc brake
rotor for thi ckness
variances. (REFER to
Section 06-03.)
PINPOINT TEST J: BRAKES DRAG
J1 CHECK FLUID CONTROL VALVE
Yes
No
Vehicle OK.
INSPECT fluid control
valve for contamination.
(REFER to Brake
Pressure Control Valve
procedure in Section
06-06.) GO to J2.
Road test vehicle and apply brakes.
Are brakes f unct i onal ?
Yes
No
Vehicle OK.
INSPECT fluid control
valve for contamination.
(REFER to Brake
Pressure Control Valve
procedure in Section
06-06.) GO to J2.
J2 CHECK POWER BRAKE BOOSTER
Yes
No
Vehicle OK.
CHECK power brake
booster push rod
adj ustment.
Road test vehicle and apply brakes.
Are brakes f unct i onal ?
Yes
No
Vehicle OK.
CHECK power brake
booster push rod
adj ustment.
PINPOINT TEST K: EXCESSIVE BRAKE PEDAL EFFORT
K1 CHECK BRAKE APPLICATION
Yes
No
GOt o K2.
GOt o K4.
With engine off, apply and release brake pedal five
times to deplete all vacuum from power brake
booster. Depress brake pedal, hold with light
pressure. Start engine.
Does t he brake pedal hol d?
Yes
No
GOt o K2.
GOt o K4.
K2 VACUUM BOOSTER LEAK TEST
Yes
No
Vehicle OK.
GO to K3.
Run engine to medium idle, release accelerator
pedal and shaft and turn engine off. Wait 90 seconds
and apply brakes. Two or more applications should
be power assi st ed.
Does power brake boost er wo r k?
Yes
No
Vehicle OK.
GO to K3.
K3 POWER SECTION CHECK VALVE TEST
Yes
No
INSTALL new power
brake booster check
valve and REPEAT Step
K2.
REPLACE power brake
booster. REPEAT Step
K1.
Disconnect vacuum hose for power brake booster
check valve at manifold. Blow into hose attached to
power brake booster check valve.
Does air pass t hr ough val ve?
Yes
No
INSTALL new power
brake booster check
valve and REPEAT Step
K2.
REPLACE power brake
K1.
06- 00- 9

Br a ke S y s t e m S e r v i c e 06- 00- 9
PINPOINT TEST K: EXCESSIVE BRAKE PEDAL EFFORT (Cont i nued)
K4 POWER SECTION TEST
Yes ^
No >
REPLACE power brake
K1.
SERVICE or REPLACE
vacuum hose and vacuum
fi tti ngs. Also TUNE or
SERVICE engine as
required. REPEAT Step
K1.
Disconnect vacuum hose from power brake booster
check valve. Run engine at idle. Check vacuum
supply with a vacuum gauge.
Is pressure above 40.5 kPa (12 in-Hg) wi t h brake
booster non-operat i onal ?
Yes ^
No >
REPLACE power brake
K1.
SERVICE or REPLACE
vacuum hose and vacuum
fi tti ngs. Also TUNE or
SERVICE engine as
required. REPEAT Step
K1.
PINPOINT TEST L: BRAKE NOISE
L1 PEDAL NOISE
Yes
No
GOt o L2.
Vehicle OK.
Run engine at fast idle for 10 seconds or longer.
Apply brake pedal and listen for noise. Compare
results with known good system.
Was a noi se present ?
Yes
No
GOt o L2.
Vehicle OK.
L2 PUSH ROD ADJUSTMENT
Yes
No
BLEED brake syst em.
REPLACE power brake
L 1.
Check and adj ust power brake booster push rod.
Is push r od adj ust ment OK?
Yes
No
BLEED brake syst em.
REPLACE power brake
L 1.
PINPOINT TEST M: SLOW OR INCOMPLETE BRAKE PEDAL RETURN
M1 BRAKE PEDAL RETURN
Yes
No
Vehicle OK.
GOt o M2 .
Run engine at fast idle while making several brake
appli cati ons. Pull brake pedal rearward with
approxi mately 44.5 N (10 lbs) f orce. Release the
brake pedal and measure the di stance to the toe
board. Make a hard brake appli cati on. Release the
brake pedal and measure the brake pedal t o toe
board di stance. The brake pedal should return to its
original posi ti on.
Di d brake pedal ret urn t o ori gi nal posi t i on?
Yes
No
Vehicle OK.
GOt o M2 .
M2 BRAKE PEDAL BINDING
Yes
No
REPLACE power brake
booster.
CORRECT any sti cki ng or
binding. REPEAT M2.
Check brake pedal to be sure it is operating freely.
Is t he brake pedal oper at i ng f r eel y ?
Yes
No
REPLACE power brake
booster.
CORRECT any sti cki ng or
binding. REPEAT M2.
Br a k e B o o s t e r Fu n c t i o n a l T e s t
Br a ke Bo o s t e r Op e r a t i o n Ch e c k
1. Check t he hydraul i c brake syst em for l eaks or
insufficient fluid.
2. Wi t h t he transmi ssi on in PARK, st op the engine.
Depress t he brake pedal ( 2455) several ti mes t o
exhaust all vacuum in the syst em.
3. Wi th the engine turned off and all vacuum in t he
syst em exhaust ed, depress t he brake pedal , and
hold it in the applied posi ti on. St art the engine. If
the vacuum syst em is operati ng, the brake pedal
will move downward under constant foot
pressure. If no motion is felt, t he vacuum power
brake booster ( 2005) syst em is not functioning.
4. Remove t he vacuum hose f r o m t he power br ake
boost er c he c k val ve. Mani f ol d vacuum shoul d be
avai l abl e at t he c he c k val ve end of t he hose wi t h
the engine at idle spe e d and t he t ransmi ssi on in
NEUTRAL. Ensure t hat all unused vacuum out l et s
are pr oper l y c a ppe d , hose connect or s ar e
properl y se c ur e d, and vacuum hoses ar e in good
condi t i on.
When it is est abl i shed t hat mani f ol d vacuum is
avai l abl e t o t he powe r br a ke boost er, connect
the vacuum hose t o t he powe r br ake boost er ,
and repeat St ep 3. If no d o wn wa r d movement of
t he br ake pedal is f el t , r epl ace t he powe r br ake
boost er .
5. Ope r a t e t he engi ne a mi ni mum of 10 seconds at
f ast i dle. St op t he engi ne, and let t he vehi cl e
st and f or 10 mi nut es. Then, appl y t he br a ke pedal
wi t h appr oxi mat el y 89 N ( 20 l bs) of f o r c e . The
pedal fee! (br a ke appl i cat i on) shoul d be t he same
as t hat not ed wi t h t he engi ne oper at i ng. If t he
br a ke pedal f eel s har d (no powe r assi st ), repl ace
the c he c k val ve, t hen r epeat t he t est . If t he br a ke
pedal feel s ha r d, r epl ace t he power br ake
boost er .
If t he br a ke pedal movement f eel s spongy, bl eed
t he hydraul i c sy st e m t o r emove air f r om t he
sy st e m. Ref er t o Hydraul i c Sy st e m Bl eedi ng,
Sect i on 06- 06.
Br ak e Boost er
I nspect ail hoses and connect i ons. All unused vacuum
c onne c t or s shoul d be c a ppe d . Hoses and t hei r
connect i ons shoul d be pr oper l y secur ed in good
condi t i on wi t h no hol es or no col l apsed a r e a s. Inspect
t he powe r br a ke boost er c he c k val ve ( 2366) on t he
po we r brake boost e r f or damage.
B r a k e Ma s t e r C y l i n d e r
Usual l y t he f i rst and st r ongest i ndi cat or of anyt hi ng
wr o n g in t he br a ke sy st e m is a f eel i ng t hr ough t he
br a ke pedal .
f o r ma l Condi t i ons
The f ol l owi ng condi t i ons ar e consi der ed normal and
ar e not i ndi cat i ons t hat t he br a ke mast er cyl i nder
( 2 140) is in need of ser vi ce.
Condi t i on 1
1
A s l i gh t t u r b u l e n c e i n t h e b r a ke
ma s t e r c y l i n d e r r e s e r v o i r fSuid o c c u r r i n g w h e n
tfo b r a ke p e d a l i s r e l e a s e d . Turbul ence oc c ur s as
br a ke flui d ret urns t o t he br a ke mast er cyl i nder af t er
rel easi ng t he br a ke s.
Co n d i t i o n 2: A t r ac e of b r a ke f l u i d e x i s t s o n
boos t er shel l bel ow t h e b r a ke ma s t e r c y l i n d e r
mount i ng f l a n ge . Thi s condi t i on resul t s f r o m t he
l ubri cat i ng act i on of t he mast er cyl i nder wi pi ng seal .
Co n d i t i o n 3: Flui d love! wi l l decrease wi t h lining wear.
A b n o r ma l Co n d i t i o n s
Changes in br a ke pedal f eel or t ravel are i ndi cat ors
t hat somet hi ng coul d be wr o n g in t he br a ke sy st e m.
The di agnosi s pr oc e dur e s and t echni ques in t hi s
Sect i on use br a ke pedal f eel , t he warni ng i ndi cat or
i llumi nati on, and br a ke flui d level as i ndi cat ors in
di agnosi ng br a ke sy st e m concer ns.
Co n d i t i o n 1: Br a ke pedal goe s down f ast . Thi s coul d
be c a use d by an ext ernal or i nternal l eak.
Co n d i t i o n 2: Br a ke pedal eases down sl owl y. Thi s
coul d be c a use d by an ext ernal or i nternal l eak.
Co n d i t i o n 3: Br a ke pedal is l ow and / or f eel s spongy.
Thi s condi t i on may be c a use d by no flui d in t he br a ke
mast er cyl i nder reservoi r ( 2K47 8) , reservoi r c a p vent
hol es c l ogge d, rear br a ke s out of adj ust ment , or ai r in
t he hydraul i c sy st e m.
Co n d i t i o n 4: Br a ke pedal ef f ort e xc e ssi ve . Thi s may
be c a use d by a bi nd or obst r uct i on in br ake pedal
l i nkage, or i nsuffi ci ent powe r br a ke boost er vacuum.
Co n d i t i o n 5: Rear br a ke l ock-up duri ng li ght br ake
pedal f o r c e . Thi s may be c a use d by wr ong t i re
pr essur e, gr ease or flui d on linings / d a ma ge d li ni ngs,
i mproperl y adj ust ed parki ng br a ke s, or
d a ma ge d / c o n t a mi n a t e d br ake pressure cont rol val ve
( 2B091) .
Co n d i t i o n 6: Errat i c br ake pedal ef f ort . Thi s condi t i on
coul d be caused by powe r br a ke boost er mal f unct i on,
e xt r e me cal i per pi st on "kn o c k ba c k" or i mproperl y
i nst al l ed di sc br ake shoe and lining ( 2001) .
Co n d i t i o n 7: Br a ke warni ng i ndi cat or ON. Thi s may
be c a use d by l ow f lui d l evel , ignition wi r e rout i ng t oo
cl ose t o flui d level i ndi cat or assembl y, or f l oat
assembl y damage.
NOTE: Pri or t o perf ormi ng any di agnosi s, ensure t he
br ake sy st e m warni ng i ndi cat or is f unct i onal .
By p a s s Co n d i t i o n Ch e c k
1. Check fluid in br a ke mast er cyl i nder. Fill br a ke
mast er cyl i nder reservoi r if l ow or empt y .
2. Obse r ve flui d level in br a ke mast er cyl i nder
reservoi r. If af t er several br ake appl i cat i ons t he
flui d level remai ns t he same, measure wheel
t urni ng t or que requi red t o r ot a t e wheel s wi t h
br a ke s appl i ed as f ol l ows:
Pl ace t ransmi ssi on in NEUTRAL and rai se
vehi cl e on hoi st . Ref er t o Sect i on 00- 02.
Appl y br a ke s sl owl y t o a minimum of 445 N
( 100 l bs) and hol d f or appr oxi mat el y 15
se c onds. Wi t h br a ke s sti ll appl i ed, e xe r t
t or que on f ront wheel s t o 101 N-m ( 7 5 Ib-ft)
(wi t h ABS). On vehi cl es wi t hout ABS exer t
t or que on one f ront and one rear wheel . If ei t her
wheel r ot a t e s, i nspect i nternal component s of
br a ke mast er cyl i nder and repl ace da ma ge d
pa r t s.
No n - P r e s s u r e L e a ks
An empt y br ake mast er cyl i nder reservoi r condi t i on
may be caused by t wo t y pe s of non-pressure ext ernal
l eaks.
06- 00- 11 Br a ke S y s t e m S e r v i c e 06- 00- 11
T y p e 1: An ext ernal l eak ma y oc c ur at t he br a ke
mast er cyl i nder reservoi r c a p be c a use of i mproper
posi t i oni ng of t he ga ske t and c a p. Reposi t i on c a p and
ga ske t .
T y p e 2 : An ext ernal l eak ma y oc c ur at t he br a ke
mast er cyl i nder reservoi r mount i ng gr omme t s. Ser vi ce
suc h a l eak by i nstalli ng new gr omme t s.
SERVICE PROCEDURES
Hydrauli c Leak Test
It i s possi bl e t hat all evi dence of flui d l eakage may
have wa she d off if t he vehi cl e ha s been ope r a t e d in
rai n or snow, as br a ke f lui d is wat er -sol ubl e. Refill
sy st e m, bl eed and appl y t he br a ke s sever al t i mes.
Exami ne t he sy st e m t o ver i f y t hat t he br a ke mast er
cyl i nder reservoi r ( 2 K47 8) f lui d level i s act ual l y
dr oppi ng. Lo c a t e and c o r r e c t t he ext ernal l eak. If f lui d
level d r o ps and no ext er nal l eak c a n be f ound, c he c k
f or a br a ke mast er cyl i nder bor e end seal l eak.
Brake Pedal Reserve Check
Whe r e a l ow br ake pedal ( 2 455) or t he f eel of a
bot t omed-out condi t i on e xi st s, c he c k f or br a ke pedal
r eser ve.
1. Ope r a t e engi ne a t i dl e wi t h t he t ransmi ssi on in
ei t her PARK or NEUTRAL.
2. Appl y br a ke pedal l i ght l y t hr e e t o f our t i mes.
3. Al l ow 15 se c onds f or vacuum t o repl eni sh powe r
br a ke boost er ( 2 005) .
4. NOTE: Thi s i ncr eased r esi st ance may f eel l i ke
somet hi ng has bo t t o me d out .
Appl y br a ke pedal until it st ops movi ng d o wn wa r d
or an i ncreased r esi st ance t o t he br a ke pedal
t r avel o c c ur s.
5. Hol d br a ke pedal in appl i ed posi t i on and rai se t he
engi ne speed t o appr oxi mat el y 2, 000 r pm.
6. NOTE: The addi t i onal movement of t he br a ke
pedal is t he resul t of t he i ncr eased engi ne
mani f ol d vacuum whi c h e xe r t s mor e f o r c e on t he
br a ke boost er duri ng engi ne r undown. Thi s
means t hat addi t i onal st r o ke i s avai l abl e in t he
br a ke mast er cyl i nder ( 2140) , and t he br a ke
sy st e m is not bot t omi ng out .
Rel ease accel er at or pedal and o bse r ve t hat
br a ke pedal moves d o wn wa r d a s engi ne ret urns
t o i dle spe e d.
B r a k e T u b i n g
WARNI NG: COPPER TUBI NG SHOULD MOT BE
USED IN A HYDRAULI C SYST E M. WHE N BENDI NG
BRAKE TUBI NG TO FI T UNDERBODY OR REAR
A X L E CONTOURS, BE CARE FUL NOT JO KI NK OR
CRACK THE TUBE.
Doubl e-wal l st eel t ubi ng i s use d t hroughout t he br a ke
sy st e m wi t h t he e xc e pt i on of t he f r ont br a ke hose s
( 2 07 8) and f ront br a ke ho se a t t he f ront wheel s and at
t he rear axl e housi ng br a ke t ube connect i on.
Al wa y s bl eed t he appl i cabl e pr i mar y or se c onda r y
br a ke sy st e m af t er pr i mar y or se c onda r y brake
sy st e m hose or line r epl acement .
All br a ke t ubi ng shoul d be pr ope r l y f l ar ed usi ng ei t her
an I.S.O. Fl are or a 45-de gr e e Doubl e Fl are t o pr ovi de
go o d l eakpr oof connect i ons. Cl ean t he br a ke t ubi ng by
f l ushi ng wi t h cl ean br a ke f l ui d bef or e i nst al l at i on.
When connect i ng a t ube t o a hose, t ube connect or or
br a ke cyl i nder, t i ght en t he t ube f i t t i ng nut t o
speci f i cat i on.
If a sect i on of t he br ake t ubi ng be c ome s da ma ge d, t he
ent i re sect i on shoul d be r e pl a c e d wi t h t ubi ng of t he
same t y pe , si ze, shape a nd l engt h.
Al wa y s bl eed appl i cabl e pr i ma r y or se c onda r y br a ke
sy st e m af t er hose or line repl acement .
When connect i ng a t ube t o a br a ke hose, t ube
connect or or br ake wheel cyl i nder, t i ght en t he t ube
f i t t i ng nut t o speci f i cat i on wi t h Lb-l n Torque Wr e nc h
D81L-600-A or equi val ent .
Brake Hose
A br a ke hose shoul d be r epl aced if it sho ws si gns of
sof t eni ng, cr acki ng or ot her damage.
When i nstalli ng a new br a ke hose , t wo new seal i ng
wa she r s shoul d be used, Posi t i oni ng of hose t o br a ke
cal i per i s cont rol l ed by a sel f -i ndexi ng br a ss bl ock.
When securi ng br ake hose connect i on t o cal i per,
t i ght en bol t t o 40-60 N-m (30-45 Ib-ft). I nspect posi t i on
of i nst al l ed hose f or cl ear ance t o ot her chassi s
component s. Posi t i oni ng of br a ke hose is cont r ol l ed by
sel f -i ndexi ng end f i t t i ngs.
Servi ce Precauti ons
1. Gr ease or any ot her f orei gn mat eri al must be kept
off t he lining sur f aces of t he f ront di sc br a ke r ot or
( 1125) and ext ernal sur f aces of the wheel hub
( 1104) duri ng servi ce operat i ons. In handl i ng t he
f ront di sc br ake r ot or and di sc br a ke cal i per
( 2B120) assembl i es, avoi d def ormat i on of t he
f ront di sc br ake r ot or and ni cki ng or sc r a t c hi ng of
br a ke shoes and linings (2001).
2. If a cal i per pi st on ( 2196) is rer/rovec' for any
r eason, t he pi st on seal must be r e pl a c e d.
3. During removal and installation of a wheel
assembl y, exerci se care not t o interfere wi th the
front disc brake rotor shield ( 2K005) or t he wheel
cylinder bl eeder screw.
4. Front wheel bearing end play is critical and must
be within speci fi cati on.
5. To avoi d bending or damagi ng the front di sc
brake rotor shield on full RH or LH wheel turns,
the vehicle must be centered on the hoist before
servi ci ng any front end components.
6. Do not attempt t o clean or rest ore any oil or
grease-soaked brake shoes and linings. When
contami nated linings are found, they must be
repl aced in compl ete axl e set s.
7. When replacing front disc brake rotor after either
machining or new part repl acement, make sure
hub surface is clean and free of contami nants
before installation.
B r a k e s , Di s c
Fr o n t a n d Re a r
2. Remove the wheel and ti re f rom the front di sc
brake rotor ( 1125) and rotor.
3. Inspect brake shoes and linings ( 2001) for wear.
If t he lining is worn t o within 3 mm (1 / 8 inch) of
the shoe, repl ace all (four) brake shoes and
linings (compl ete axl e set) on front wheel s as
requi red.
4. Visually check t he di sc brake cal i per(s). If the
cal i per housing is leaking, it should be repl aced. If
a seal is l eaki ng, t he caliper must be
di sassembl ed and new seal s installed. If a piston
is sei zed in the bore, a new cal i per housing is
requi red.
5. Lower vehicle.
Refer t o Secti ons 06- 03 and 06- 04 for di sc brake
rotor Servi ce procedure.
B r a k e Ma s t e r Cy l i n d e r
When in the brake master cylinder area, check the
brake lines and brake master cylinder mounting. The
brake lines and attachi ng nuts must be ti ght. The
brake line fittings must not show any signs of l eakage.
Tighten t he brake lines at the brake master cylinder
( 2140) t o 14-20 N. m(10-15 Ib-ft).
The fol l owi ng condi ti ons are consi dered normal and
are not indications that the brake master cylinder is in
need of servi ce:
Low fluid level det ect ed wi thout signs of l eakage.
This condition is caused by di spl acement of fluid
f rom the brake master cylinder reservoi r into the
rear di sc brake cal i pers ( 2552) , the di sc brake
cal i pers ( 2B120) , and/ or the rear wheel cyl i nders
( 2261) t o compensat e for normal brake wear. Add
fluid as needed.
A momentary or slight squirt of brake fluid from the
brake master cylinder reservoir upon application of
the brake pedal ( 2455) . This condition is caused by
fluid di spl acement through the brake master
cyl i nder reservoi r compensati ng port as the brake
master cylinder pi stons move f orward in the bore
when the brakes are appl i ed.
Slight turbulence in the brake master cylinder
reservoi r fluid when the brake pedal is rel eased.
Turbulence occurs as brake fluid returns t o the
brake master cylinder after releasing the brakes.
A t race of brake fluid found on the outside of the
power brake booster ( 2005) bel ow the brake
master cylinder mounting flange. This condition
results f rom the lubricating action of the master
cylinder wiping seal .
Br a k e T u b i n g
Inspect the brake tubes under the vehi cl e for damage
and proper routi ng. Check the hoses connecti ng the
brake tubes t o the di sc brake cal i pers, t o the rear
wheel cyl i nders and/ or t o the rear di sc brake cal i pers
for any signs of damage, cracki ng or softeni ng. The
hose fittings must be tight wi thout signs of l eakage.
B r a k e B o o s t e r
Check the power brake booster ( 2005) operati on as
outlined under Brake Booster Functional Test. If the
power brake boost er is damaged or i noperati ve,
repl ace it wi th a new power brake booster.
H y d r a u l i c S y s t e m
An i nspecti on of the brake hydraul i c syst em begins
wi th a fluid level check. If the fluid level is bel ow the line
in the brake master cylinder reservoi r ( 2K478) , add
the requi red amount of fluid. Use High Performance
DOT-3 Brake Fluid C6AZ- 19542- AA or Dot 3
equivalent meeting Ford speci fi cati on ESA-M6C25-A.
P a r k i n g B r a k e
1. Check the parki ng brake rear cabl e and conduits
( 2A635) for damage and proper routing. If the
parki ng brake rear cabl e and conduit are
damaged, they must be repl aced. Refer t o
Secti on 06- 05.
2. Operat e the parki ng brake control ( 2780) and
check for conditions that may cause binding,
groani ng, or an incomplete rel ease of the parki ng
brake.
3. Ensure that the parking brake components are in
good condition and that all the cabl es and the
cabl e housing cl amps are lubricated and in good
condi ti on. Check the front parki ng brake cabl e
and conduit adjustment. Refer t o Secti on 06-05.
ADJUSTMENTS
B r a k e P e d a l F r e e H e i g h t Me a s u r e m e n t s
1. Wi th the engine running for full power brake
operati on and the parki ng brake fully rel eased,
measure the brake pedal f ree height.
2. Insert a slender, sharp-poi nted prod through the
floor carpet ( 13000) and sound deadener t o the
dash panel metal . Measure t he di stance to the
center on t op accel erat or pedal side of the brake
pedal pad.
3. If the position of the brake pedal ( 2456) is not
within speci fi cati on, check the brake pedal for
mi ssi ng, worn or damaged bushi ngs, or loose
retaining bol ts and repl ace if requi red.
4. If the brake pedal free height is still out of
speci fi cati on, check the brake pedal , power
brake boost er ( 2005) or brake mast er cylinder
( 2140) t o be sure the cor r ect part s are installed.
Repl ace the worn or damaged part s as
necessary.
90 DEGREES
TRAVEL TEST TO BE MADE WITH
PARKING BRAKE IN RELEASED POSITION
H8034-A
NOTE: " A " Dimension t o be measured t o sheet metal
f rom center of pad on t he accel erat or pedal side of the
brake pedal pad.
" B " Dimension t o be measured parallel t o the verti cal
center line of the steeri ng column wi t h a 111.2 N ( 25
lb) l oad appl i ed t o t he center line of the brake pedal
pad. (Checks on power brake vehi cl es made wi th
engine running.)
VEHICLE
BRAKE PEDAL FREE
HEIGHT " A " (REF. ONLY)
MAXIMUM
BRAKE
PEDAL
TRAVEL
(INCHES)
"! " VEHICLE MAX. MIN.
MAXIMUM
BRAKE
PEDAL
TRAVEL
(INCHES)
"! "
S t a n d a r d 2 10 mm
( 8. 3 I n c he s )
191 mm
( 7 . 5 I n c h e s )
7 6. 2 mm
( 3. 5 I n c h e s )
P o l i c e 2 2 1 mm
( 8. 7 I n c he s )
2 04 mm
( 8. 0 I n c h e s )
7 6. 2 mm
( 3. 5 I n c h e s )
Brake Pedal Travel Measurement
1. Wi t h engine running and transmi ssi on in PARK or
NEUTRAL, bl ock wheel s and rel ease parki ng
brake control ( 2780) .
2. Install t he Rotunda Effort Gauge 021 - 00001 or
equivalent on t he br ake pedal ( 2455) and check
as f ol l ows:
ROTUNDA EFFORT GAUGE
021-00001
H3669-D
3. Hook a steel measuri ng t ape t o t he brake pedal .
Measure and record the di stance f rom the brake
pedal f ree height position t o the reference point,
whi ch is at the six o' cl ock posi ti on on the steeri ng
wheel ri m.
STEERING WHEEL RIM
GAUGE SURFACE
4. Wi th the steel t ape still hooked t o t he brake
pedal , apply the brake pedal by pressi ng
downward on the brake pedal effort gauge. Appl y
a 111 N (25 lb) load t o the center of t he br ake
pedal . Maintain the brake pedal l oad and
measure the di stance f rom t he brake pedal t o the
fi xed reference point on the steeri ng wheel rim
parallel t o the centerline of the steeri ng col umn.
5. The di fference between the brake pedal f ree
height and t he depressed pedal measurement
under a 111 N ( 25 lb) load shoul d be 124 mm (3. 5
i nches) maxi mum.
6. If the brake pedal travel is more than the
maxi mum dimension speci fi cati on, make several
reverse st ops wi t h a f orward st op before each.
Move the vehi cl e in REVERSE and f orward for
approxi mat el y 10 feet. Then appl y the brakes
holding the brake pedal down until the vehi cl e is
compl etel y st opped. This will act uat e the brake
pedal sel f-adj usters. If t hese st ops do not bring
the brake pedal travel within speci fi cati on, make
several additional f or war d and reverse st ops as
outlined above.
7. If the above st eps do not bring the brake travel
within speci fi cati on, bleed the brake syst em.
Br a k e s F r o n t D i s c
Br a k e s Re a r Di s c
Brake Fl ui d Level Check
Al ways check the fluid level in the master cylinder
bef ore performi ng t he test procedures. If the fluid level
is not t o 4 mm ( 0. 16 inch) bel ow t he MAX line of t he
brake master cyl i nder reservoi r ( 2K478) , add High
Performance DOT-3 Brake Fluid C6AZ- 19542- AA or
DOT-3 equivalent meeting Ford speci fi cati on
ESA-M6C25-A.
B r a k e R o t o r , Di s c
Ru n o u t
NOTE: Whenever t he brake rotor has been separat ed
f rom wheel hub f ace, cl ean any rust or forei gn materi al
f rom mati ng surf ace on wheel hub f ace and brake
rotor. Failure t o do this may result in i ncreased lateral
runout of the brake rotor and brake pulsation.
Install t he brake rot ors on wheel hubs and hold in pl ace
by using i nverted lug nuts and washer t o seat the
brake rot ors t o hubs. Tighten wheel lug nuts to 115
N-m ( 85 Ib-ft).
Using a dial indicator, measure di sc brake rotor lateral
runout as shown. The dial indicator should be cent ered
on braki ng surf ace. Rotate di sc brake rotor while
measuri ng runout. If runout is greater than 0. 08 mm
( 0. 003 i nch), di sc brake rotor must be reposi ti oned
(i ndexed) on hub t o obtai n t he l owest possi bl e runout.
CHECK
ROTOR
H7803-A
If l ateral runout of di sc brake rotor is above 0. 08 mm
( 0. 003 inch) after repositioning (indexing), the wheel
hub ( 1104) / r ear hub ( 1109) and beari ng assembl y
must be i nspected. Using a dial indicator, measure
wheel hub/ r ear hub and bearing assembl y f ace
runout. Wheel hub runout must be less than 0. 06 mm
( 0. 002 inch). If wheel hub f ace runout is greater than
0. 06 mm ( 0. 002 inch), a new wheel hub/ r ear hub must
be installed.
NOTE: If rotor lateral runout remains greater than 0. 08
mm ( 0. 003 inch) after the following servi ce
procedures, thi s indicates that the brake lathe
requi res servi ce:
Di sc brake rotor machining.
Di sc brake rotor repositioning (indexing).
Verifying wheel hub f ace runout is less than 0. 06
mm (0. 002 inch).
DIAL RUNOUT
INDICATOR CHECK
H7804-A
P a r a l l e l i s m
Parallelism is the vari ati ons in the thi ckness of the di sc
brake rotor. If the t wo rubbing surf aces of the di sc
brake rotor are not parallel, the di sc brake rotor may
cause excessi ve brake pedal travel , a pulsating brake
pedal , or noise.
Two met hods can be used t o check if t he t wo f aces of
a di sc brake rotor are paral l el . A mi crometer can be
used t o measure t he di sc brake rotor t hi ckness at 12
points approxi mat el y 30 degrees apart and 25. 4 mm
(1 inch) f rom the outer edge of the di sc brake rotor.
The other met hod is t o measure the di sc brake rotor
on a preci si on l athe desi gned for machining di sc brake
rotor. At t ach t wo dial i ndi cators, one on each si de of
the di sc brake rotor, so that the styl us of each
indicator cont act s the rubbing surface, di rectl y
opposi te each other, approxi mat el y 25. 4 mm (1 inch)
from t he outer edge of the di sc brake rotor.
Zero both i ndi cators and rotate t he di sc brake rotor
while wat chi ng bot h dials. If the t ot al readi ngs of both
i ndi cators exceed the speci fi ed limit for parallelism,
the di sc brake rot or must be refinished or repl aced.
R e f i n i s h i n g
A simplified met hod of measuring maxi mum al l owabl e
st ock removal using a standard hand mi crometer
eliminates the need for speci al t ool s as on previ ous
rear di sc rot ors. However, a Rotunda Rotor Mounting
Adapt er 054- 00032 or equivalent will be requi red for
use on t he brake l athe for refinishing.
All di sc brake rotor refinishing must adhere t o the rule
that equal amounts of disc brake rotor st ock are
removed f rom each braki ng surf ace each ti me a rear
di sc brake rot or ( 2C026) is refi ni shed.
The minimum al l owabl e overall di sc brake rotor
thi ckness conti nues t o be st amped on the rear di sc
brake rotor and must not be exceeded.
1. Wi th a sui tabl e mi crometer, measure the overal l
t hi ckness of the di sc brake rotor braki ng surface
at four equal l y-spaced poi nts around the rear di sc
brake rotor.
2. NOTE: Using a mi crometer t o measure di sc
brake rotor t hi ckness simplifies previ ous di sc
brake rotor measurement procedure, but it is
mandat ory t hat an equal amount of materi al be
removed f rom each side of t he di sc brake rotor
each time t he di sc brake rotor is resurf aced.
Using the l owest reading f rom St ep 1, subt ract
t he minimum al l owabl e t hi ckness st amped into
t he rear di sc brake rotor. The di fference, if any,
represent s t he total amount of materi al avai l abl e
for machining. A thi ckness readi ng less than the
minimum rear di sc brake rotor thi ckness requi res
di sc brake rotor repl acement.
3. After measuri ng t he di sc brake rotor, the di sc
brake rot or should be installed in the lathe arbor
using t he speci al adapt er that is required f or
proper di sc brake rotor alignment. Never use a
lathe t hat cut s only one f ace of t he di sc br ake
rotor at a ti me; it must be a simultaneous st raddl e
cut . Install a dial i ndi cator t o read rotor l ateral
runout near t he center of t he di sc brake rot or
f ace. If runout is 0. 05 mm ( 0. 002 inch) or bel ow,
pr oceed t o machi ne di sc brake rotor. If runout is
over 0. 05 mm ( 0. 002 i nch), loosen di sc brake
rotor on the arbor and rot at e the di sc brake rot or
90 degrees. Read the runout, and if it is bel ow
0. 05 mm ( 0. 002 i nch), proceed t o machi ne t he
di sc brake rotor. If runout is still over 0. 05 mm
( 0. 002 i nch), again l oosen the di sc brake rotor,
and rot at e it an additional 90 degrees. Check t he
runout. If runout is 0. 05 mm ( 0. 002 inch) or l ess,
proceed t o machi ne the di sc brake rotor. If t he
runout still exceeds 0. 05 mm ( 0. 002 inch), return
t he di sc brake rotor t o t he best runout position
obt ai ned. If t he di sc brake rotor runout can be
brought bel ow 0. 05 mm ( 0. 002 inch), proceed t o
machi ne the di sc brake rotor. If t he di sc brake
rotor cannot be brought bel ow 0. 05 mm ( 0. 002
inch) runout, it must be repl aced.
4. Set the cutti ng tool t o j ust cont act the high spot s
on the di sc brake rotor, then adjust the cutti ng
tool t o t he minimum depth requi red t o cl ean up the
di sc brake rotor f ace. Equal material must be
removed f rom each si de. Do not exceed the
al l owabl e st ock removal . Clean all cutti ngs and
chi ps f rom the disc brake rotor before installing it
t o the axl e.
SPECIFICATIONS
B r a k e S y s t e m C o m p o n e n t S p e c i f i c a t i o n s
FRONT DISC BRAKE
De s c r i p t i o n S p e c i f i c a t i o n
Li n i n g Ma t e r i a l B a s e
P o l i c e
BBA - 2 001T B FF I n t e gr a l l y
Mo l d e d
BBA 2 003MFF I n t e gr a l l y
Mo l d e d
Li n i n g We a r Li mi t ( Fr o m Sh o e
Su r f a c e )
3. 17 5 mm ( 0. 12 5 i n c h)
Ca l i pe r Cy l i n d e r Bo r e
Di a me t e r
66. 02 5 mm ( 2 . 599 i n c h)
Br a ke P i s t o n Ou t s i d e
Di a me t e r
65. 92 5 mm ( 2 . 595 i n c h)
Fr o n t Di sc Br a ke Ro t o r
No mi n a l T h i c kn e s s
2 6. 0 mm ( 1. 02 4 i n c h e s )
Fr o n t Di s c Br a ke Ro t o r
Mi n i mum T h i c k n e s s
8
2 4. 7 5 mm ( 0. 97 4 i n c h)
Di a me t e r
2 91 mm ( 11. 45 i n c h e s )
A l l o wa b l e Runout on Ve hi c l e
0. 08 mm ( 0. 003 i n c h)
( Co n t i n ue d )
FRONT DISC BRAKE (Cont ' d)
Description Spe c i f i c a t i on
Fr o n t Di s c Br a ke Ro t o r Fi n i sh 0. 40- 3. 2 mi c r o me t e r s ( 10- 80
mi c r o - i n c h )
T h i c k n e s s Ma x i mu m
0. 009 mm ( 0. 00035 i n c h)
a Mi n i mum Sa f e T h i c kn e s s i s s h o wn o n e a c h f r o n t d i s c b r a ke
r o t o r .
REAR DISC BRAKE
Compone nt Spe c i f i c a t i on
L i n i n g Ma t e r i a l Nut ur n NTB- FF
L i n i n g Si ze I nner a n d Out e r 124 x 40 x 10 mm
( 4 x 1 . 5 x 0 . 3 9 i n c h)
L i n i n g We a r Li mi t
( f r o m s h o e s u r f a c e )
3. 17 5 mm ( 0. 12 5 i n c h)
Ca l i p e r Cy l i n d e r Bo r e
Di a me t e r
48 mm ( 1. 89 i n c h)
Ro t o r No mi n a l T h i c kn e s s 12. 5 mm ( 0. 50 i n c h)
Ro t o r Mi n i mum T h i c kn e s s
8
11. 25 mm ( 0. 44 i n c h)
Ro t o r Di a me t e r 2 90 mm ( 11. 4 i n c h e s )
Ro t o r A l l o wa b l e Run o ut
Of f Ve h i c l e
0. 08 mm ( 0. 003 i n c h)
REAR DISC BRAKE (Cont 'd)
Compone nt Speci f i cat i on
Ro t o r Fi n i s h 0. 40- 3. 2 mi c r o - me t e r s
( 10- 80 mi c r o - i n c h e s )
Ro t o r T h i c kn e s s Va r i a t i o n 0 . 0 1 3 mm ma x . ( 0. 0005 i n c h )
a Mi n i mum s a f e t h i c k n e s s i s s h o wn o n e a c h r o t o r .
De sc r i pt i on N-m L b - Ft
Br a ke Ho s e Co n n e c t i o n t o Ca l i pe r 40- 60 30- 45
To r q ue o n Fr o n t Wh e e l s 101 7 5
L u g Nut s 115 85
Br a ke Li n e Nu t s 14- 20 10- 15
ROTUNDA EQUIPMENT
02 1- 00001 Ro t u n d a Ef f o r t Ga u ge
054- 00032 Ro t o r Mo un t i n g A d a p t e r
06- 03- 1 Br a ke s , Fr o n t Di sc 06- 03- 1
SECTION 06-03 Brakes, Front Disc
SUBJECT PAGE
Anchor Bracket ..06-03-4
Brake Shoes and Linings 06-03-3
Brake Syst em, Disc 06-03-1
Caliper 06-03-3
Rotor .06-03-3
Rotor Shi eld 06-03-3
Wheel Hubs and Beari ngs 06-03-3
Brake, Front Disc 06-03-4
Brake Shoe and Li ni ng 06-03-5
Cali per ... ...06-03-4
Removal 06-03-4
Rot or. . . 06-03-7
Rot or Shi eld 06-03-8
Servi ce Precaut i ons 06-03-4
SUBJECT PAGE
Anchor Br a c ke t 06-03-9
Cal i per 06-03-9
Si ngl e Pi st on 06-03-9
SERVICE PROCEDURES
Rot or Servi ce 06-03-10
Anchor Br acket 06-03-11
Brake Shoe and Li ni ngs ....06-03-11
Cal i per 06-03-11
Rot or 06-03-11
ADJUSTMENTS
Hydraul i c Syst em Bl eedi ng 06-03-12
Rot or and Brake Shoe Li ni ng Hand
Sandi ng 06-03-12
YEHiCLE APPLICATION
Town Car, Cr own Vi ct or i a, Gr and Marqui s
B r a k e S y s t e m , Di s c
WARNI NG: BRAKE FLUI D CONTAI NS
POLYGLYCOL ETHERS AND POLYGLYCOLS.
AVOI D CONTACT WI TH EYES. WA SH HANDS
FLUID CONTACTS EYES, FLUSH EYES WI TH
RUNNING WATER FOR 15 MI NUTES. GET
MEDI CAL ATTENTI ON IF IRRITATION PERSI STS.
IF TAKEN INTERNALLY, DRI NK WATER AND
INDUCE VOMI TI NG. GET MEDI CAL ATTENTI ON
IMMEDIATELY.
Front di sc br a ke s ar e st a nda r d on ail vehi cl es.
NOTE: Brake fri cti on materi al s inherently generate
noise and heat t o di ssi pate energy. As a result,
occasi onal squeal is possi bl e and it is aggravat ed by
severe environmental condi ti ons such as col d, heat,
wet , snow, sal t, mud and other condi ti ons.
Fr o n t Di sc Br a ke Si n gl e Pi st on
I t e m
Pa r t
Numbe r De s c r i p t i o n I t e m
Pa r t
1 2B120(RH) Disc Brake Caliper 12 N802191-S56 Bolt
2B121(LH) 13 2C224 Bracket
2 N808237-S100 Bolt (4 Req'd)
3 N808229-S100 Rivet (3 Req'd) Sensor Assy
4 1104 Wheel Hub with ABS 15

Body
5 3B477 Front Axle Wheel Hub 16 3105 Front Wheel Spindle
Retainer 17 E865401-S Retainer
6 1N135 Dust Cup
A

7 W62485-S2 Washer (4 Req'd, 2 Each Lb-Ft)
Side) B

8 1125 Front Disc Brake Rotor (188-254 Lb-Ft)
9 1104 Wheel Hub Without ABS C

Tighten to 4.5-6.8 N-m (40-60
10 2K004(RH) Front Disc Brake Rotor
Lb-ln)
2K005(LH) Shield D

11 N805151-S100 Bolt Lb-Ft)
Rotor
The full-cast front di sc brake rot or ( 1125) is of the
venti l ated-type, i ncorporati ng non-directional cooling
fins.
The front di sc brake rotor is mounted on t he front
wheel hub( 1104) .
The di sc brake cal i per ( 2B120) / front di sc brake
caliper anchor pl ate ( 2B292) must be removed t o
servi ce the front di sc brake rot ors.
Wh e e l H u b s a n d B e a r i n g s
R o t o r S h i e l d
Front di sc brake rot or shields ( 2K005) are steel .
The front di sc brake rotor shi el ds are at t ached t o t he
vehi cl e' s front wheel spindle ( 3105) by t hree ri vets on
each si de and are not i nterchangeabl e side-to-side.
C a l i p e r
The front di sc brakes use a pin sl i der-type di sc brake
cal i per ( 2B120) / front di sc brake cal i per anchor pl ate
( 2B292) assembl y wi t h 291 mm ( 11. 45 inch) full cast
front di sc brake rot ors ( 1125) .
The di sc brake cal i per has a steel cal i per piston
( 2196) wi th a pi ston seal and press in-type dust
boot .
The di sc brake cal i per / front di sc brake cal i per
anchor plate assembl y is at t ached t o the front
wheel spindle ( 3105) wi th t wo 14 mm hex-head
bol ts.
The di sc brake cal i per slides on l ubri cated front di sc
brake cal i per anchor pl ates t hat are seal ed f rom t he
el ements by rubber boot s.
The front di sc brake cal i per anchor pl ates are
at t ached t o t he di sc brake cal i per by t wo caliper pin
bol ts.
NOTE: DO NOT
REMOVE FOR
CALIPER
REPLACEMENT
H8094-C
I t e m
Pa r t
1 2W303 Lower Caliper Brake Bolt
2 2B393 Front Caliper Sleeve
3 2A492 Insulator
4 2B302 Caliper
2B294
5 2B164 Disc Brake Pad Anti-Rattle
Clip
6 2196 Wheel Cylinder Piston
7 2B115 Piston Seal
8 2207 Dust Boot
9 2018 Brake Shoe
10 2B292 Front Disc Brake Caliper
Anchor Plate
11 2B296 Upper Caliper Bolt
A

Tighten to 88 N-m (65 Lb-Ft)
B r a k e S h o e s a n d L i n i n g s
The brake shoes and linings ( 2001) have the following
f eat ures:
Are marked LH and RH and have directional ar r ows
pai nted on their inner edges t o indicate direction of
f orward vehicle movement.
Brake shoes and linings used in police appl i cati ons
are i nterchangeabl e (no inner, outer, left or ri ght).
The fl anges on both inner and outer brake shoes
and linings slide on machined surfaces of the di sc
brake caliper locating pin ( 2B296) .
Use a si ngl e-purpose br a ke shoe hol d-down spri ng
( 2068) whi ch holds the brake shoe and lining
agai nst the di sc brake caliper l ocati ng pin t o prevent
shoe and lining rattl e.
The brake shoes and linings use a
pressure-sensi ti ve insulator materi al f or noise
suppressi on. Remove the prot ect i ve paper f rom thi s
insulator before installing new brake shoes and
linings.
Anchor Bracket
The di sc brake caliper locating pin ( 2B296) is
at t ached t o the front wheel spindle ( 3105) by t wo M14
x 2. 0 x 28 mm propert y cl ass 10.9 bol ts. Using a
longer bolt will damage the front di sc brake rot or
( 1125) . The di sc brake caliper l ocati ng pin contai ns
t he front di sc brake caliper anchor pl ates ( 2B292)
whi ch permi t caliper movement as t he brake shoe and
lining ( 2001) wear in servi ce.
Brake, Front Disc
Servi ce Precauti ons
1. Grease or any other forei gn materi al must be kept
off lining surfaces and braki ng surf aces of front
di sc brake rotor ( 1125) and external surf aces of
wheel hub ( 1104) during servi ce operati on. In
handling front di sc brake rotor and di sc br ake
cal i per ( 2B120) assembl i es, avoi d deformati on,
nicking or scrat chi ng of brake shoes and linings
( 2001) and front di sc brake rotor.
2. If a cal i per pi ston ( 2196) is removed for any
reason, piston seal and dust boot must be
repl aced.
3. During removal and installation of a wheel
assembl y, exerci se care not t o interfere wi t h or
damage front di sc brake rotor shield ( 2K005) or
t he wheel cyl i nder bleeder scr ew ( 2208) .
4. Vehicle must be cent ered on hoist bef ore
servi ci ng any front end components t o avoi d
bending or damagi ng front di sc brake rotor shi el d
on full right or left wheel turns. Refer t o Secti on
00- 02.
5. Do not at t empt t o cl ean or rest ore oil or
grease-soaked brake shoes and linings. When
contami nated brake shoes and linings are f ound,
brake shoes and linings must be repl aced in
compl et e axl e set s and front di sc brake rot or
braki ng surf aces wi ped cl ean.
6. The LH and RH di sc brake cal i pers must be
installed on the correct si de of t he vehi cl e t o be
sure wheel cylinder bleeder scr ew is in the
t opmost position for proper purging of air from the
front brake syst em during bleeding.
Caliper
Removal
2. Remove the wheel and ti re assembl y. Use care t o
avoi d damage t o, or interference wi t h, the wheel
cylinder bleeder scr ew ( 2208) during removal .
3. Mask di sc brake cal i per ( 2B120) assembl y t o
make sure it is installed on correct front wheel
spindle ( 3105) during installation.
4. Use a 10 cm (4 inch) C-clamp t o seat cal i per
pi ston ( 2196) in its bore and provi de cl earance
for cal i per assembl y removal f rom front di sc
brake rotor ( 1125) . (Avoi d brake fluid overfl ow in
master cylinder reservoi r.)
5. Di sconnect front brake hose ( 2078) f rom di sc
brake caliper. Remove hollow retaining bolt that
connects front brake hose t o di sc brake caliper.
Remove front brake hose f rom di sc brake caliper
and plug front brake hose.
Pa r t
1

Brake Line
2 N802191-S56 Screw
3 2B121(RH)
2B120(LH)
Disc Brake Caliper
4 N808832-S Sealing Washer (4 Req'd)
5 2078 Front Brake Hose
6 N808236-S36 Bolt
A

Lb-Ft)
B

Lb-Ft)
C

Lb-Ft)
6. Remove upper and l ower caliper l ocati ng pin
bol ts.
7. Lift di sc br ake cal i per f rom t he front di sc br ake
cal i per anchor pl ate ( 2B292) . Hold brake shoes
and linings ( 2001) whi l e lifting di sc brake cal i per
t o prevent t hem f rom falling off once the di sc
brake cal i per is removed f rom the front di sc
brake cal i per anchor pl ate.
Pa r t
1 2W303 Lower Caliper Brake Bolt
2 2B393 Front Caliper Sleeve
3 2A492 Insulator
4 2B302
2B294
Caliper
5 2B164 Disc Brake Pad Anti-Rattle
Clip
6 2196 Wheel Cylinder Piston
7 2B115 Piston Seal
8 2207 Dust Boot
9 2018 Brake Shoe
10 2B292 Front Disc Brake Caliper
Anchor Plate
11 2B296 Upper Caliper Bolt
A

Tighten to 88 N-m (65 Lb-Ft)
1. Use a 10 cm ( 4 inch) C-clamp and wood bl ock 70
mm x 25 mm (2 3 / 4 x 1 inch), approxi mat el y 19
mm ( 3 / 4 inch) thi ck t o seat t he cal i per pi ston in
its bore. Thi s must be done t o provi de cl earance
for the di sc brake caliper t o fit over t he front di sc
brake rot or during installation.
2. Install repl acement di sc brake cal i per, or correct
di sc brake cal i per as mar ked during removal , by
sliding it downwar d over front di sc br ake cal i per
anchor pl ate wi t h the brake shoes and linings
i nstal l ed. Align pin mounting bosses on di sc brake
cal i per wi th t he di sc brake cal i per l ocati ng pins
( 2B296) in t he front di sc brake cal i per anchor
pl ate.
3. Install bot h upper and l ower l ocati ng pin bol ts.
Tighten t o 24- 36 N-m ( 18- 26 Ib-ft).
4. Remove plug and install front brake hose on di sc
brake cal i per wi t h new sealing washers on each
si de of t he fi tti ng. Install retaining bolt through
fitting and washer s. Tighten t o 40- 60 N-m ( 30- 45
Ib-ft).
5. Bl eed brake syst em. Refer t o Secti on 06- 06.
6. Install wheel and ti re. Tighten lug nuts ( 1012) t o
115-142 N-m (85-105 Ib-ft).
7. Lower vehi cl e. Pump brake pedal ( 2455) several
ti mes t o position brake shoes and linings.
8. Road t est vehi cl e.
B r a k e S h o e a n d L i n i n g
Re mo v a l
1. Check fluid level in brake master cylinder
reservoi r ( 2K478) . Remove brake fluid until brake
master cylinder reservoi r is half-full.
3. NOTE: It is not necessary t o di sconnect hydraul i c
connecti ons.
Remove wheel and tire. Use care t o avoi d
damage or interference wi th wheel cylinder
bl eeder screw ( 2208) during removal .
4. Use a 10 cm (4 inch) C-clamp and wood bl ock 70
mm x 25 mm ( 2 3 / 4 x 1 inch) and approxi matel y
19 mm ( 3 / 4 inch) thi ck t o seat the caliper piston
( 2196) in its bore. This must be done to provi de
cl earance for the disc brake cal i per ( 2B120) t o fit
over the front di sc brake rotor ( 1125) during
installation.
5. Remove t wo caliper anchor bracket mounting
bol ts.
6. Li ft di sc br a ke c a l i pe r / f ront di sc br a ke cal i per
anchor pl at e ( 2B292) a wa y f r om f ront di sc br a ke
r ot or usi ng a rot at i ng mot i on.
7. Remove out er br a ke shoe and lining ( 2001)
assembl y f r om di sc br a ke cal i per assembl y by
sli di ng br a ke shoe and lining in f ront di sc br a ke
cal i per anchor pl at e a wa y f r om out er leg t o
di sengage it f r om t he f r ont di sc br a ke cal i per
anchor pl at e. Remove out er br ake shoe and
li ni ng.
8. Remove inner br a ke shoe and lining assembl y
f r om di sc br a ke cal i per assembl y by sli di ng br a ke
shoe and lining in f r ont di sc br a ke cal i per anchor
pl at e a wa y f r o m cal i per pi st on di sengagi ng it f r om
t he f r ont di sc br a ke cal i per anchor pl at e. Remove
inner br a ke shoe and li ni ng.
9. Suppor t t he di sc br a ke cal i per assembl y in a
manner t hat wi ll not st r e t c h or damage t he f r ont
br a ke hose ( 2078) .
10. I nspect bot h di sc br a ke rot or braki ng sur f aces.
Mi nor scor i ng or bui ldup of br a ke shoe and lining
mat eri al doe s not requi re machi ni ng or
repl acement of t he f r ont di sc br a ke r ot or .
Hand-sand gl aze of f bot h f ront di sc br ake r ot or
braki ng sur f aces usi ng garnet paper 100A
(medi um gri t ) or alumi num oxi de 150-J (medi um
gr i t ).
1. Use a 10 c m ( 4 i nch) C-cl amp and wo o d bl ock 7 0
mm x 25 mm ( 2 3 / 4 x 1 i nch) and appr oxi mat el y
19 mm ( 3 / 4 i nch) t hi ck t o seat cal i per pi st on in i t s
bor e. Thi s must be done t o provi de cl earance f or
di sc br a ke cal i per assembl y t o fi t over f ront di sc
br a ke r ot or duri ng i nst al l at i on.
2. NOTE: Di sc br ake cal i per has provi si on t o al l ow
br a ke shoe hol d-down spri ng ( 2068) t o be
i nst alled onl y one wa y . Ri ght and left br ake shoe
hol d-down spri ngs ar e i dent i cal but i nst alled in
opposi t e di rect i ons.
Cl ean f ront di sc br a ke cal i per l egs and br ake
shoes and linings a s necessary. Ma ke sure br a ke
shoe hol d-down spri ng is seat ed in cal i per lining
i nspect i on openi ng. Br ake shoe hol d-down spri ng
must be i nst alled f r om t he lining si de.
3. NOTE: Pol i ce a ppl i c a t i o n sBr a ke shoes and
linings ar e i nt erchangeabl e.
Br a ke shoes and linings ar e ma r ke d LH and RH.
A di rect i onal a r r ow is pai nt ed on t he l ower edge
of e a c h br ake shoe and lining. Thi s ar r ow, when in
c o r r e c t posi t i on, wi ll poi nt t o wa r d f ront of vehi cl e.
4. Peel pr ot ect i ve paper f r om i nsulat or on t he br ake
shoe and lining assembl y. The i nsulator is bl ack in
col or when paper is r emoved. Thi s
pressure-sensi t i ve adhesi ve i nsulator f unct i ons t o
r educe noi se. Care shoul d be exer ci sed t o avoi d
cont ami nat i on of t he adhesi ve surf ace pri or t o
i nst allat i on of t he br a ke shoes and li ni ngs.
5. Engage t he br ake shoe and lining in t he f ront di sc
br a ke cal i per anchor pl at e by f i rst engagi ng t he
si de opposi t e t he br ake shoe hol d-down spri ng.
Pr ess t he ot her end of t he br ake shoe and lining
t o c ompr e ss t he br a ke shoe hol d-down spri ng
and engage t he br a ke shoe and lining in t he f ront
di sc br ake cal i per anchor pl at e. Bot h inner and
out er br ake shoes and linings are i nst alled in t he
same manner.
6. I nspect di sc br ake cal i per / f ront di sc br ake
cal i per anchor pl at e assembl y t o make sure
br a ke shoes and linings are properl y i nst alled and
t hat a r r o ws ar e poi nt i ng t o wa r d f ront of vehi cl e,
and t hat br a ke shoe and lining f a c e s f ront di sc
br a ke r ot or .
7. NOTE: If is i mport ant t o use c or r e c t bol t ( M14 x
2. 0 x 28 mm l ong).
Posi t i on di sc br ake cal i per / f ront di sc br ake
cal i per anchor pl at e assembl y over f ront di sc
br ake r ot or . Install t wo di sc br ake cal i per anchor
br a c ke t mount i ng bol t s. Ti ght en t o 170-230 N-m
( 125- 170 Ib-f t ).
8. Install wheel and t i re assembl y. Ti ght en lug nuts
( 1012) t o 115-142 N-m ( 85 -105 Ib-f t ).
9. Lowe r vehi cl e.
10. Pump br ake pedal ( 2455) several t i mes t o
posi t i on br ake shoes and li ni ngs. Refill br ake
mast er cyl i nder ( 2140) as necessar y. Ref er t o
Sect i on 06-06.
06- 03- 7 Br a ke s , Fr ont Di s c 06- 03- 7
R o t o r
Re mo v a l
1. CAUTI ON: Ha n d l e t he f r ont d i s c b r a ke r ot or
( i 12 5) and f r o n t di sc br ake c a l i pe r ( 2 B12 0)
assembl i es i n such a wa y as t o a v o i d damage
t o t he f r ont di sc br ak e r ot or a n d n i c ki n g ,
scr at chi ng, or cont ami nat i on of t h e br ake
s h o e a n d l i n i n g ( 2 001) .
Remove t he wheel ( 1007 ) and t i re f r o m t he wheel
hub ( 1104) . Be caref ul t o avoi d da ma ge t o or
i nt erf erence wi t h t he wheel cyl i nder bl eeder
sc r e w ( 2208) and f r ont di sc br a ke r ot or shi el d
( 2 K004) .
2. Remove t he f r ont di sc br a ke cal i per / f r ont di sc
br a ke cal i per anchor pl at e ( 2B292) assembl y
f r om t he f ront wheel spi ndl e ( 3105) and t he f ront
di sc br a ke r ot or . Ma r k t he f r ont di sc br a ke rot or
and wheel hub bolt ( 1107 ) t o ai d assembl y. If t he
f ront di sc br a ke cal i per doe s not requi re
servi ci ng, it is not ne c e ssa r y t o di sconnect t he
f ront br a ke hose ( 2078) . Posi t i on t he f r ont di sc
br a ke cal i per out of t he wa y , and suppor t it wi t h a
wi r e t o avoi d damagi ng t he di sc br a ke cal i per or
st r et chi ng t he f ront br a ke hose. Insert a cl ean,
c a r d bo a r d spacer be t we e n t he br a ke shoe s and
li ni ngs t o prevent t he inner br a ke shoe a nd lining
f r om comi ng out of t he f ront di sc br a ke cal i per
and bei ng da ma ge d by f al l i ng on t he f l oor.
3. NOTE: If e xc e ssi ve f o r c e must be used duri ng
f ront di sc br a ke r ot or r emoval , t he f r ont di sc
br a ke r ot or shoul d be c he c ke d f or l at eral runout
pri or t o i nst al l at i on.
Remove f ront di sc br a ke r ot or assembl y f r om
wheel hub.
If addi t i onal f o r c e i s requi red t o r emove f ront di sc
br a ke r ot or , appl y Rust Penet rant and Inhi bi tor
F2 AZ- 19A501 - A A (ESR-M99C56-A) or
equi val ent on f ront and rear di sc br a ke r o t o r / hub
mat i ng sur f a c e s. Fi rst , st r i ke f ront di sc br a ke
r ot or be t we e n st uds wi t h a pl ast i c hammer. If t hi s
doe s not wo r k, a t t a c h 3-Jaw Puller D80L-1013-A
or equi val ent and r emove f r ont di sc br a ke r ot or .
1. NOTE: If t he f ront di sc br a ke r ot or i s not bei ng
r e pl a c e d, cl ean t he hub mount i ng sur f ace of t he
f ront di sc br a ke r ot or a s wel l a s t he hub mount i ng
sur f a c e f or rust , sc a l e or di rt . The cont ami nat i on
wi ll not al l ow f r ont di sc br a ke r ot or t o si t f l at t o t he
hub sur f a c e .
If t he f r ont di sc br a ke r ot or is bei ng r epl aced,
r e move t he pr ot ect i ve coat i ng f r om t he new f ront
di sc br a ke r ot or wi t h Car bur et or Tune-Up Cl eaner
D9AZ- 1957 9- AA (ESR-M 14P9-A) or equi val ent .
2. Install t he f ront di sc br a ke r ot or assembl y on t he
wheel hub.
3. Mount t he f ront di sc br a ke cal i per assembl y on
t he f r ont wheel spi ndl e a s out l i ned.
4. Pump br a ke pedal ( 2455) several t i mes t o
posi t i on br a ke shoe s and li ni ngs.
REMOYAL AND INSTALLATION ( C o n t i n u e d )
Rotor Shield
Removal
2. Remove wheel and ti re assembl y, di sc brake
cal i per ( 2B120) , front di sc brake cal i per anchor
pl ate ( 2B292) assembl y and front di sc brake
r ot or ( 1125) as outl i ned. It is not necessary t o
di sconnect hydraul i c connecti ons.
3. NOTE: Remove ri vets by punching out mandrel
l ocat ed in center of rivet. Wi t h a chi sel , cut off
ri vet at front wheel spindle ( 3105) and punch out
ri vet remaining in hole.
Remove t hree ri vets retaining front di sc brake
rotor shield ( 2K005) t o front wheel spindle and
remove front di sc brake rotor shi el d.
1. Locat e front di sc brake rotor shield until shield
at t achment surf aces cont act knuckl e mounting
bosses and hol es in knuckl e bosses are aligned
wi t h mounting hol es in front di sc brake rotor
shi el d.
2. Install new ri vets using Heavy-Duty Riveter
D80L- 23200- A or equivalent (three per front di sc
brake rotor shield) through attachi ng holes in
front di sc brake rotor shield and front wheel
spindle. The rivet body head should cl amp front
di sc brake rotor shield securel y t o spindle
bosses.
3. Install brake front di sc brake rotor, disc brake
cal i per, front disc brake cal i per anchor plate
assembl y and wheel and ti re assembl y as
outlined.
4. Make certai n front di sc brake rotor shield does
not cont act front di sc brake rotor. Rotate wheel
t o visually inspect for cont act .
5. Pump brake pedal ( 2455) prior t o moving t he
vehi cl e t o position brake shoes and linings
( 2001) .
6. Road test vehi cl e.
Ca l i p e r
Si ngl e Pi s t on
Di sassembl y
1. Remove front di sc brake cal i per ( 2B120) / front
di sc brake cal i per anchor pl ate ( 2B292)
assembl y as outlined. Do not use screwdri ver or
similar tool t o pry cal i per pi ston ( 2196) back into
cyl i nder bore. Use a C-clamp.
2. CAUTI ON: Use l a y e r s o f s h o p t o w e l s t o
c u s h i o n p o s s i b l e i mp a c t o f t h e wh e e l c a l i pe r
p i s t o n a ga i n s t t h e f r o n t d i s c b r a ke c a l i pe r
i r o n w h e n wh e e l c a l i pe r p i s t o n c o me s o u t o f
t h e p i s t o n b o r e . Do n o t u s e a s c r e wd r i v e r o r
si mi l a r t o o l t o p r y wh e e l c a l i pe r p i s t o n o u t o f
t h e b o r e , a s d a ma g e t o t h e wh e e l c a l i pe r
p i s t o n may r e s u l t . If t h e wh e e l c a l i pe r p i s t o n
i s s e i z e d a n d c a n n o t b e f o r c e d f r o m t h e d i s c
b r a ke c a l i pe r , t a p l i ght l y a r o u n d t h e p i s t o n
wh i l e a p p l y i n g ai r p r e s s u r e . Use c a r e
b e c a u s e t h e wh e e l c a l i pe r p i s t o n c a n
d e v e l o p c o n s i d e r a b l e f o r c e f r o m p r e s s u r e
b u i l d u p .
If further di sassembl y is requi red t o servi ce wheel
cal i per pi ston, di sconnect front di sc brake cal i per
f rom hydraul i c syst em, and bl ow out t he wheel
cal i per pi ston using Air Nozzl e Assembl y
TOOL-7000-DE or equivalent.
DISC BRAKE CALIPER
2B120
CLOTH
FIBER
BLOCK
APPLY AIR
PRESSURE
H9036-A
3. Remove the dust boot from the front di sc brake
cal i per assembl y.
4. Remove the rubber piston seal f r om the cyl i nder
and di scard it.
A s s e m b l y
1. When assembl i ng front di sc brake cal i per,
exami ne wheel cal i per pi ston for surf ace
irregularities, pi tti ng, scori ng, wear, or corrosi on
of t he chrome pl ated surf ace. Repl ace wheel
cal i per pi ston if damaged. Be sure t o cl ean
forei gn materi al f rom wheel cyl i nder pi ston
surf aces and l ubri cate wi th brake fluid before
inserting into front di sc brake cal i per. Al ways
install new seal and dust boot .
3.
When installing wheel cal i per pi ston back into
bore, use wood bl ock or another flat st ock, like
an ol d br ake shoe and lining ( 2001) assembl y,
bet ween C-clamp and wheel cal i per pi ston. Do
not appl y C-clamp di rect l y t o wheel cylinder
pi ston surf ace. This can result in damage to
wheel cal i per pi ston. Be sure wheel caliper piston
is not cocked.
Ensure dust boot is ti ght in boot groove on wheel
cal i per pi ston and in f ront di sc brake caliper.
Install front di sc brake cal i per assembl y as
outl i ned.
A n c h o r B r a c k e t
Di s a s s e mb l y
1. Remove di sc brake cal i per ( 2B120) / front di sc
brake cal i per anchor pl ate ( 2B292) assembl y as
outl i ned. Do not use screwdri ver or similar tool t o
pry cal i per piston ( 2196) back into bore as
damage to t he anti-rattle spri ng may occur. Use a
C-clamp.
2. Remove di sc brake cal i per l ocati ng pin ( 2B296)
f rom t he front di sc brake caliper anchor pl ate.
3. Remove dust boot f rom each front di sc brake
cal i per anchor pl at e/ anchor bracket mounting
point and di scard.
NOTE: DO NOT
REMOVE FOR
CALIPER
REPLACEMENT
H8094-C
06- 03- 10 Brakes, Front Di sc 06- 03- 10
A s s e mb l y
1. When assembl i ng f ront di sc br a ke cal i per anchor
pl at e, exami ne pin sur f ace i rregul ari t i es, pi t t i ng,
sc or i ng, we a r or cor r osi on of t he sur f ace.
Repl ace t he f ront di sc br a ke cal i per anchor pl at e
if da ma ge d. Be sure t o cl ean f orei gn mat eri al f r o m
pin sur f aces and l ubri cat e wi t h Di sc Br a ke
Cal i per Sl i de Gr ease D7AZ- 19590- A or
equi val ent meet i ng Fo r d speci f i cat i on
ESA-M1C172 bef or e i nsert i ng i nt o f ront di sc
br a ke cal i per anchor pl at e. Al wa y s i nstall a new
dust boot .
2. Ma ke sure bot h dust boot s a r e t i ght l y seat ed in
bot h t he boot gr oove on f ront di sc br ake cal i per
anchor pl at e and in t he si mi lar gr oove in t he f r ont
di sc br a ke cal i per anchor pl at e.
3. Install di sc br a ke cal i per / f r ont di sc br a ke cal i per
anchor pl at e assembl y as out l i ned.
SERVICE PROCEDURES
R o t o r Servi ce
Ref er t o Sect i on 06- 00 Di agnosi s and t o t he f ol l owi ng
i nf ormat i on f or servi ci ng and condi t i ons requi ri ng f r ont
di sc br a ke r ot or ref i ni shi ng.
Br a ke pul sat i on (br a ke roughness) t hat i s present
duri ng br ake appl i cat i on i s caused by ei t her f orei gn
mat eri al bui ld-up or cont ami nat i on on t he f ront di sc
br a ke r ot or braki ng sur f ace or uneven f ront di sc br a ke
rot or t hi c kne ss.
If t her e i s a f orei gn mat eri al bui ld-up or cont ami nat i on
f ound on f ront di sc br a ke r ot or or br a ke shoe and lining
sur f a c e s, hand sand br a ke shoes and linings ( 2 001)
and f r ont di sc br a ke r ot or s ( 1126) .
Uneven f ront di sc br a ke r ot or t hi ckness (t hi ckness
vari at i on) may be c a use d by t he f ol l owi ng:
@ Front di sc br a ke r ot or l at eral runout in e x c e ss of
0. 06 mm ( 0. 003 i nch) when f r ont di sc br a ke r ot or i s
mount ed on wheel hub ( 1104) .
e Front di sc br a ke cal i per d r a g.
Abr a si ve act i on of br a ke shoe and lining.
If br a ke pul sat i on (br a ke roughness) i s present ,
a t t e mpt st oppi ng vehi cl e wi t h t ransmi ssi on in t he
NEUTRAL posi t i on. If t he pul sat i on (roughness) i s
gone, t he dri vet rai n shoul d be i nspect ed. If pul sat i on
(roughness) remai ns, st o p vehi cl e f r o m 48 k m / h ( 30
mph) usi ng parki ng br a ke cont r ol ( 27 80) . If pul sat i on
remai ns, i nspect rear br a ke s. If pul sat i on is gone,
i nspect f r ont br a ke s.
Ro t o r Mi n i mu m Thickness
Front di sc br a ke r ot or minimum t hi ckness must not be
l ess t han 24. 7 6 mm ( 0. 97 4 i nch) or l ess t han number
c a st on i nsi de of t he f ront di sc br a ke r ot or af t er
ref i ni shi ng.
Rotor Machining
Do not machi ne, cut or t r ue up new f ront di sc br a ke
r ot or s pri or t o i nst al l at i on on vehi cl e. Maki ng a light cut
on a new f ront di sc br a ke r ot or may cause excessi ve
runout and resul t in br a ke shudder several t housand
mi les lat er. It i s best t o cl ean oil fi lm of f new f ront di sc
br a ke r ot or wi t h Car bur et or Tune-up Cl eaner
D9AZ- 1967 9- AA or equi val ent meet i ng For d
speci f i cat i on ESR-M 14P9-A and i nstall it on vehi cl e.
Never use a br a ke l at he t hat c ut s only one f a c e of t he
f ront di sc br a ke r ot or at a t i me. It must be a
si mul t aneous st r addl e cut . All f ront di sc br a ke rot or
ref i ni shi ng must r emove equal amount s of f ront di sc
br a ke r ot or st o c k f r o m e a c h braki ng sur f ace each t i me
a f ront di sc br a ke r ot or i s ref i ni shed.
On-vehi cl e br a ke l at hes machi ne t he f ront di sc br ake
r ot or whi l e it i s on t he wheel hub and i s t urni ng on t he
same a xi s a s t he wheel hub. Thi s pr ocedur e reduces
f ront di sc br a ke r ot or l at eral runout t o near zero by
cut t i ng t he f r ont di sc br a ke r ot or perpendi cul ar t o t he
axi s of t he wheel hub, t he r e by cancel l i ng t he ef f ect of
st a c ke d t ol erance of t he wheel hub f ront di sc br ake
r ot or and f ront wheel spi ndl e ( 3106) . Fol l ow t he
on-vehi cl e br a ke l at he manuf act urer' s i nst ruct i ons on
machi ni ng pr oc e dur e s.
A bench-mount ed di sc br ake l at he machi nes t he f ront
di sc br a ke r ot or t o t he axi s of t he l at he arbor. Thi s
t y pe of ser vi ce wi ll not reduce t ot al l at eral runout
a ssoc i a t e d wi t h st a c ke d t ol er ances of t he wheel hub,
f ront di sc br a ke r ot or and f ront wheel spi ndl e. Fol l ow
manuf act urer' s i nst ruct i ons on machi ni ng pr ocedur es.
Wi t h bot h t y pe s of br a ke l at hes, set cut t i ng t ool t o j ust
c ont a c t t he hi gh spo t s on t he f ront di sc br ake r ot or ,
t hen adj ust cut t i ng t ool t o t he mi ni mum dept h requi red
t o cl ean up t he f ront di sc br ake r ot or f a c e . Best resul t s
ar e obt ai ned wi t h a f i r st cut t hat t ot al l y r emoves t he
ol d r ot or sur f aces f ol l owe d by a se c ond light f i ni sh cut .
The t ot al mat eri al r e move d (combi nat i on of bot h si des)
must not e xc e e d t he mi ni mum di sc a r d t hi ckness t hat i s
ma r ke d on t he i nsi de of t he f ront di sc br ake r ot or .
To i mprove initial br a ke pedal f eel and sur f ace f i ni sh on
a machi ned f ront di sc br a ke r ot or , li ght ly sand f ront
di sc br a ke r ot or sur f ace wi t h 120 gri t paper pri or t o
r oa d t est i ng.
Runout Check
NOTE: Whenever f r ont di sc br ake r ot or has been
se pa r a t e d f r o m wheel hub f a c e , cl ean any rust or
f orei gn mat eri al f r om mat i ng sur f ace on wheel hub
f a c e and f ront di sc br a ke r ot or . Fai lure t o do t hi s may
resul t in i ncreased l at eral runout of t he f ront di sc br ake
r ot or and br a ke pul sat i on.
Install f ront di sc br a ke r ot or s on wheel hubs and hol d in
pl ace by usi ng i nvert ed lug nut s ( 1012) and wa she r s t o
seat f ront di sc br ake r o t o r s t o wheel hubs. Ti ght en lug
nuts t o 116-142 N-m ( 85- 105 Ib-ft).
Measur e f ront di sc br a ke r ot or runout a s f ol l ows:
Usi ng a di al i ndi cat or, measure f ront di sc br ake
r ot or l at eral runout a s shown.
The di al i ndi cat or shoul d be cent er ed on braki ng
sur f ace.
06- 03- 11 Br a ke s , Fr o n t Di sc 0 6 - 0 3 - 1 1
Rot at e f ront di sc br ake r ot or whi l e measuri ng
runout .
If runout i s gr eat er t han 0. 08 mm ( 0. 003 i nch), f ront
di sc br a ke r ot or must be reposi t i oned (i ndexi ng) on
wheel hub t o obt ai n t he l owest possi bl e runout .
CHECK
ROTOR
H7803-A
If l at eral runout of f ront di sc br a ke r ot or i s a bo ve
0. 08 mm ( 0. 003 i nch) af t er reposi t i oni ng (i ndexi ng),
t he wheel hub and beari ng assembl y must be
i nspect ed.
Usi ng a di al i ndi cat or, measur e wheel hub and
beari ng assembl y f a c e runout as shown.
Wheel hub runout must be l ess t han 0. 06 mm ( 0. 002
i nch).
If wheel hub f a c e runout is gr eat er t han 0. 06 mm
( 0. 002 i nch), a new wheel hub must be i nst al l ed.
NOTE: If f ront di sc br a ke r ot or l at eral runout remai ns
gr eat er t han 0. 08 mm ( 0. 003 i nch) af t er t he f ol l owi ng
ser vi ce pr oc e dur e s, t hi s i ndi cat es t hat t he br a ke l at he
requi res servi ce:
Front di sc br a ke r ot or machi ni ng.
Front di sc br a ke r ot or reposi t i oni ng (i ndexi ng).
Veri f yi ng wheel hub f a c e runout i s l ess t han 0. 06
mm ( 0. 002 i nch).
DIAL RUNOUT
INDICATOR CHECK
H7804-A
Cali per
1. Cl ean all met al pa r t s wi t h i sopr opy l al cohol . The n ,
cl ean out and d r y t he gr oove s and pa ssa ge wa y s
wi t h c o mpr e sse d air. Ensure t ha t f ront di sc br a ke
cal i per bor e and component pa r t s are t hor oughl y
cl ean.
2. Che c k cyl i nder bor e and cal i per pi st on ( P196) f or
d a ma ge or e xc e ssi ve wear . Repl ace t he cal i per
pi st on if it i s pi t t e d, sc o r e d , c o r r o d e d or t he
pl at i ng i s wo r n of f .
3. Vi sual l y c he c k di sc br a ke cal i per ( 2B120) . If
cal i per housi ng i s l eaki ng, it shoul d be r e pl a c e d If
a seal i s l eaki ng, di sc br a ke cal i per must be
di sassembl ed and new seal s a nd dust boot
i nst al l ed. If cal i per pi st on i s sei zed in t he bo r e , a
new di sc br a ke cal i per is r equi r ed.
Anchor Bracket
1. Cl ean all met al pa r t s wi t h i sopr opy l al cohol . The ,
cl ean out and dr y gr oove s and pi n bo ss hol es,
ma ke sure pin bo ss bor es and component pa r t s
ar e t hor oughl y cl ean.
2. Che c k pin bo ss bor es and pi ns f or damage o r
e xc e ssi ve wear.
3. Vi sual l y c he c k f r ont di sc br a ke cal i per a nc hor
pl at e ( 2B292) . If pi n i s sei zed in bor e , a new front
di sc br a ke cal i per anchor pl at e i s requi red.
Che c k t he pin bores and pi ns for damage or
e xc e ssi ve wear. Repl ace t he pi ns if they are
pi t t e d, sc o r e d or c o r r o d e d .
Brake Shoe and Li ni ngs
I nspect br ake shoe and lining ( 2001) f or wear . If lining
i s wo r n t o wi t hi n 3. 17 6 mm ( 1 / 8 i nch) of shoe, repl ace
all f our br a ke shoes and linings (compl et e axl e set ) as
necessar y .
Rotor
Remove pr ot ect i ve coat i ng f rom new f ront di sc br a ke
r ot or ( 1125) wi t h Carburet or Tune-up Cleaner
D9AZ- 19579- AA or equi valent meet i ng Ford
speci f i cat i on ESR-M 14P9-A. If ori gi nal f ront di sc br a ke
r ot or i s bei ng i nst al l ed, make sure r ot or braki ng and
mount i ng surf aces ar e cl ean. Appl y a smal l amount of
Si li cone Di el ect ri c Compound D7 AZ- 19A331- A or
equi val ent meet i ng Ford speci f i cat i on ESE- M1C171- A
t o pi lot di amet er of f ront di sc br a ke r ot or ,
NOTE: Ma ke sure f ront di sc br a ke r ot or t o hub
mount i ng surf aces ar e f ree f r o m rust and scal e. If not ,
r emove rust wi t h wi r e br ush, Sc ot c h Brite, or
sandpaper, f r om hub f a c e and r ot or f a c e . Make sure
ma r ke d st ud and ma r ke d rot or hol s line up t o ensure
l owest rot or runout .
ADJUSTMENTS
H y d r a u l i c System Bleeding
Rotor a n d B r a k e Shoe Li ni ng Hand Sandi ng
NOTE: Minor scori ng or buildup of lining materi al does
not require machining or repl acement of front di sc
brake rotor ( 1125) .
Hand sand gl aze f rom both rotor braki ng surf aces
using garnet paper 100A (medium-grit) or aluminum
oxi de 150J (medi um).
SPECIFICATIONS
BRAKE LINING AND ROTOR DIMENSIONS
Compone nt Spe c i f i c a t i on
Li n i n g Ma t e r i a l B a s e BBA - 2 001T BFF I n t e gr a l l y
Mo u l d e d
Li n i n g Ma t e r i a l P o l i c e BBA - 2 003MFF I n t e gr a l l y
Mo u l d e d
Li n i n g We a r Li mi t ( Fr o m Sh o e
Su r f a c e )
3 . 1 7 5 mm ( 0. 12 5 i n c h )
Ca l i pe r Cy l i n d e r Bo r e
Di a me t e r
66. 02 5 mm ( 2 . 599 i n c h e s )
Br a ke P i s t o n Ou t s i d e
Di a me t e r
65. 92 5 mm ( 2 . 595 i n c h e s )
No mi n a l T h i c kn e s s
2 6. 0 mm ( 1. 02 4 i n c h e s )
Mi n i mum T h i c kn e s s
a
2 4. 7 5 mm ( 0. 97 4 i n c h)
Di a me t e r
2 91 mm ( 11. 45 i n c h e s )
A l l o wa b l e Run o ut o n Ve h i c l e
0. 08 mm ( 0. 003 i n c h)
Fr o n t Di sc Br a ke Ro t o r Fi n i sh 0. 40- 3. 2 mi c r o me t e r s
( 10- 80 mi c r o - i n c h )
T h i c kn e s s Ma x i mu m
0. 009 mm
( 0. 00035 i n c h)
a Mi n i mum Sa f e T h i c kn e s s i s s h o wn o n e a c h f r o n t d i s c b r a ke
r o t o r .
FLUID SPECIFICATION
Br a ke Fl ui d Hi gh P e r f o r ma n c e DOT- 3 Br a ke Fl ui d
C6A Z - 19542 - A A or DOT- 3 Equi v a l e n t
Me e t i n g Fo r d Sp e c i f i c a t i o n
E SA- M6C2 5- A
Descr i pt i on N-m Lb- Ft
Fr o n t Di s c Br a ke Ca l i pe r L o c a t i n g
Pi n s
2 4- 36 18-26
Fl e x i b l e Br a ke Ho s e - t o - Ca l i p e r 40- 60 30- 45
Br a k e Tu b e - t o - Ho s e Fi t t i n g 14- 20 10-15
L u g Nut s 115- 142 85- 105
Ca l i p e r A n c h o r Br a c ke t t o Spi n d l e 17 0- 2 30 12 5- 17 0
Wh e e l Cy l i n d e r Bl e e d e r S c r e w 17- 24 13- 18
Br a ke Ho s e Br a c ke t - t o - Fr a me 16-27 12-20
Fr o n t Br a ke A n t i - L o c k Se n s o r
A s s y - t o - Sp i n d l e Bo l t
4. 5- 6. 8 40- 60
( L b- l n )
Fr o n t A x l e Wh e e l Hub Re t a i n e r 2 55- 345 188- 2 54
All hydraul i c lines must be ti ghtened t o the speci fi c
t orque value and be f ree of l eakage.
D80L - 2 32 00- A He a v y Dut y Ri v e t e r
T OOL - 7 000- DE Ai r No zzl e A s s e mb l y
ROTUNDA EQUIPMENT
054- 00080 Di s c Br a ke L a t h e
06- 04- 1 Br a ke s , Re a r Di sc 06- 04- 1
SECTION 06-04 Brakes. Fte
SUBJECT PAGE
VEHICLE APPLICATION . .................06-04-1
Brake Shoe and Li ni ng 06-04-2
Brakes, Rear Disc ... ... 06-04-1
Cali per . . . . . . . . . . 06-04-2
Hubs and Bear i ngs. . 06-04-3
Rotor 06-04-2
Support Br acket ....06-04-3
Brakes, Rear Di sc 06-04-3
Brake Shoe and Li ni ng ...06-04-4
Cali per ...06-04-3
Rotor .. 06-04-5
SUBJECT PAGE
REMOVAL AND INSTALLATION (Cont ' d, )
Servi ce Precauti ons. .....06-04-3
Shi e l d. . 06-04-6
Support Br a c ke t 06-04-5
Cal i per 06-04 7
SERVICE PROCEDURES
Rot or Ref i ni shi ng. . . . .......... . . . . . . . .
t
.06-04-8
Brake Shoe and Li ni ng . ....06-04-9
Cal i per 06-04-9
VEHICLE APPLICATION
Brakes, Rear Disc
IF TAKE N I NTERNALLY, DRI NK WATER AND
I NDUCE VOMI TI NG. GET MEDI CAL ATTENTI ON
I MMEDI ATELY.
The rear di sc brakes consi st of the fol l owi ng
component s:
e A pin si i der-type rear di sc brake cal i per ( 2553)
assembl y.
A 290 mm (11. 4 inch) cast iron drum-in-hatrear di sc
brake rot or ( 2C026) bol ted to the rear axl e shaft
fl ange.
Rear di sc brake caliper has a phenolic rear di sc
brake pi ston and adj usters ( 2B588) wi th a seal and
a press-in t ype dust boot.
06- 04- 2 Br a ke s , Re a r Di sc 06- 04- 2
Rear Di sc Br a ke E x p l o d e d Vi e w
H7376-C
I t em
Par t
2 4234 LH Axle Shaft
4 383609-S Pushnut (2 Req'd Each Side)
Sensor Indicator
6 3912205-56 Nut (4 Req'd)
Adapter
Pa r t
9 390317-S190 Bolt (4 Req'd)
11 2B296 Disc Brake Caliper Locating
Pin
A

Lb-Ft)
B

Lb-Ft)
( Co n t i n ue d )
R o t o r
The rear disc brake rot ors ( 2C026) are solid full cast
drum-in-hat t ype. The rear di sc brake rotor is mounted
on the axl e fl ange.
C a l i p e r
The rear disc brake cal i per ( 2552) assembl y consi st s
of:
Phenolic rear di sc brake pi ston and adjuster
( 2B588) .
Rubber O-ring seal posi ti oned in a groove in t he rear
di sc brake cal i per housing.
Press in t ype dust boot.
Rear disc brake caliper is at t ached t o the rear di sc
brake caliper anchor pl ate ( 2B582) by t wo hex
head disc brake caliper l ocati ng pins ( 2B296) .
Rubber insulators isolate the di sc brake caliper
locating pins f rom the rear di sc brake caliper.
B r a k e S h o e a n d L i n i n g
Brake shoe and lining assembl i es are installed as
fol l ows:
The inner brake shoes and linings ( 2001) are
i nterchangeabl e left to right and use a three-finger
clip that fi ts inside the rear di sc brake piston and
adjuster ( 2B588) .
06- 04- 3 Br a ke s , Rear Di sc 06- 04- 3
The out er brake shoes and linings are
i nt erchangeabl e left t o ri ght and use a dual -purpose
cli p whi ch hol ds t he br ake shoes and linings on t he
rear di sc br a ke cal i per ( 2552) and al so prevent s
cal i per rat t l e.
The f l anges on bot h inner and out er br a ke shoes
and linings sl i de on machi ned sur f aces.
Pa r t
1 2 B595 Pi st o n Se a l
2

Dust Bo o t (Pa r t of 2 B595)
3 2001 Inner Br a ke Sho e a nd Li ni ng
Assy ( Must be Fi r ml y Se a t e d
Aga i n st Pi st o n )
4 2 553 Rear Di sc Br a ke Ca l i pe r
5 2 001 Out e r Br a ke Sho e a nd Li ni ng
Assy ( Must be Se a t e d
Aga i n st Ho usi n g)
6 2 B2 96 Di sc Br a ke Ca l i pe r L o c a t i n g
Pin
S u p p o r t B r a c k e t
The rear di sc br ake cal i per anchor pl at e ( 2B582) :
Transmi t s braki ng t or que f r om t he inner and out er
br ake shoes and linings ( 2001) t o t he rear axl e
housi ng ( 4010) .
Provi des a mount i ng f or t he parki ng br a ke
assembl y.
H u b s a n d Be a r i n g s
B r a k e s , Re a r Di s c
Service Precautions
1. Ke e p gr e a se or any ot her f orei gn mat eri al of f
lining sur f a c e s and braki ng sur f a c e s of rear di sc
br a ke r ot or ( 2C026) , and ext er nal sur f a c e s of
axl e f l ange duri ng ser vi ce oper at i on. In handli ng
rear di sc br a ke r ot or and rear di sc br a ke cal i per
( 2553) , avoi d def or mat i on, ni cki ng or scr at chi ng
of br a ke shoe s and linings ( 2 001) and rear di sc
br a ke r o t o r s.
2. If a rear di sc br a ke pi st on and adj ust er ( 2B588)
i s r emoved f or any r eason, r epl ace pi st on seal
and dust boot . Be caref ul not t o da ma ge pl ast i c
rear di sc br a ke pi st on and adj ust er; pr ot e c t it
f r o m c ont a c t wi t h any met al or shar p-edged
obj ect s.
Do not a t t e mpt t o cl ean or r est or e oil or
gr e a se -soa ke d br ake shoes and li ni ngs. When
cont ami nat ed linings ar e f ound, r epl ace br ake
shoe s and linings in compl et e axl e se t s and wi pe
rear di sc br a ke rot or braki ng sur f a c e s cl ean.
C a l i p e r
Re mo v a l
2. Remove wheel and t i re assembl y.
3. Di sconnect f l exi bl e rear brake hose ( 2282) f r om
rear di sc br ake cal i per ( 2553) . Remove br a ke
f i t t i ng ret ai ni ng bolt f r om rear di sc br a ke cal i per.
Plug hose and cal i per f i t t i ng.
4. Remove di sc br ake cal i per l ocat i ng pi ns ( 2B296) .
5. Li ft rear di sc br ake cal i per off rear di sc br a ke
cal i per anchor pl at e ( 2B582) usi ng a rot at i ng
mot i on.
1. CAUTI ON: Do n o t pr y d i r e c t l y a ga i n s t p l a s t i c
r e a r d i s c b r a ke p i s t o n o r d a ma g e t o p i s t o n
wi l l o c c u r .
Ret r act rear di sc br ake pi st on fully in pi st on bor e
and posi t i on rear di sc brake cal i per assembl y
above rear di sc br ake rot or ( 2C026) wi t h
ant i -rat t l e spri ng l ocat ed on l ower adapt er
suppor t a r m. Install rear di sc br ake cal i per over
rear di sc br ake rot or wi t h rot at i ng mot i on. Ma ke
sure inner br ake shoe and lining ( 2001) is
properl y posi t i oned.
2. CAUTI ON: Th e d i s c b r a ke c a l i pe r l o c a t i n g
pi n s mu s t b e i n s e r t e d a n d s t a r t e d by h a n d .
Install di sc br ake cal i per l ocat i ng pi ns. Clean inner
sur f ace of cal i per bushi ngs and l ubri cat e di sc
br ake cal i per l ocat i ng pins wi t h Si li cone Di el ect ri c
Compound D7AZ-19A331-A (Mot or cr af t WA-10)
or equi valent meet i ng Ford speci f i cat i on
ESE-M1C171-A.
3. Ti ght en di sc br ake cal i per l ocat i ng pi ns t o 29- 41
N-m (22-30 Ib-ft).
06- 04- 4 Br a ke s , Re a r Di sc 06- 04- 4
4. Remove plug and install rear wheel brake hose
( 2A442) on rear disc brake caliper wi t h new
gasket on each side of fitting outlet. Insert
retaining bol t through washers and fi tti ngs.
Tighten bol ts t o 40- 54 N-m (30-40 Ib-ft).
5. Bl eed brake syst em. Refer t o Secti on 06- 06.
Al ways repl ace rubber rear di sc brake bl eeder
scr ew cap after bleeding.
6. Fill brake mast er cylinder ( 2140) as requi red.
7. Install wheel and ti re assembl y. Tighten lug nuts
( 1012) t o 115-142 N-m (85-105 Ib-ft). Lower
vehi cl e.
8. Pump brake pedal ( 2455) prior t o moving vehicle
t o position brake shoes and linings.
o
H7756-C
Pa r t
1 2208 Bleeder Screw
2 4200 Rear Axle Assy
3 2B582 Rear Disc Brake Caliper
Anchor Plate
4 2B296 Locating Pin (2 Req'd)
5 2552 RH
2553 LH
Rear Disc Brake Caliper
Lb-Ft)
B

Lb-Ft)
Brake Shoe and Li ni ng
Removal
1. Remove brake master cylinder cap and check
fluid level in brake mast er cyl i nder reservoi r
( 2K478) . Remove brake fluid until brake master
cyl i nder reservoi r is half full. Di scard removed
fl ui d.
4. Remove rear di sc brake caliper locating pins
( 2B296) .
5. Lift rear di sc brake cal i per ( 2553) assembl y f rom
rear di sc brake cal i per anchor pl ate ( 2B582) and
rear di sc brake rot or ( 2C026) using a rotati ng
moti on.
6. CAUTI ON: Do n o t p r y d i r e c t l y a ga i n s t pl a s t i c
r e a r d i s c b r a ke p i s t o n a n d a d j u s t e r ( 2 B588)
o r d a ma g e t o pi st on wi l l o c c u r .
Remove inner and outer brake shoe and lining
( 2001) assembl i es.
7. Inspect both rear di sc brake rotor braki ng
surf aces. Minor scori ng or buildup of lining
material does not requi re machining or
repl acement of rear di sc brake rotor. Hand sand
gl aze f rom both rear di sc brake rotor braki ng
surfaces using garnet paper 100-A (medium gri t)
or aluminum oxi de 150-J (medi um).
8. Suspend rear di sc brake caliper wi th wi re. Use
care not t o damage rear di sc brake caliper or
st ret ch rear wheel brake hose ( 2A442) .
1. CAUTI ON: Ext r a car e must be t a ke n d u r i n g
t h i s p r o c e d u r e t o p r e v e n t d a ma g e t o pl a s t i c
c a l i pe r p i s t o n ( 2 196) . Me t a l o r s h a r p o b j e c t s
c a n n o t c o me i n t o d i r e c t c o n t a c t wi t h p i s t o n
s u r f a c e o r d a ma g e wi l l r e s ul t .
Use a 4-inch C-clamp and wood bl ock 70 mm x
25 mm ( 2- 3/ 4- i nch x 1-inch) and approxi matel y
19 mm ( 3 / 4 inch) thi ck t o seat hydraulic caliper
pi ston in its bore. Thi s provi des necessary
cl earance for rear di sc brake caliper ( 2552)
assembl y t o fit over rear disc brake rotor during
installation.
2. Remove all rust buildup f rom inside of outer shoe
cont act area.
3. Install inner brake shoe and lining in caliper pi ston
and outboard surface of caliper. Do not bend
shoe cl i ps during installation in caliper piston or
di storti on and rattl es can occur.
REAR
DISC
BRAKE
ROTOR
2C206
REAR DISC BRAKE
2B582
LOCATE SPRING ON LOWER
ADAPTER SUPPORT ARM
AS SHOWN
REAR DISC BRAKE
CALIPER
RH 2552
LH 2553
H7757-B
Install correct outer brake shoe and lining. Make
sure clips are properl y seat ed.
06- 04- 5 Br a k e s , Re a r Di sc 06- 04- 5
5. Install rear di sc br ake cali per over rear di sc
br a ke r ot or . Ref er t o Cali per, Installati on.
6. Install wheel and t i re assembl y. Ti ghten lug nut s
( 1012) t o 115-142 N-m (85-105 Ib-ft). Lowe r
vehi cl e.
7. Top off br a ke flui d wi t h Heavy-Dut y Br ake Fl ui d
C6AZ- 19542- A, AA or DOT-3 equi valent meet i ng
For d speci f i cat i on ESA-M6C25-A.
8. Pump br a ke pedal (2455) pri or t o movi ng vehi cl e
t o posi t i on br a ke shoes and linings.
R o t o r
Re mo v a l
1. Rai se vehi cl e on hoi st . Refer t o Sect i on 00- 02 .
2. CAUTI ON: Ha n d l e r e a r d i s c b r a ke r o t o r
( 2 C02 6) a n d r e a r d i s c b r a ke c a l i pe r ( 2 553)
a s s e mb l y i n s u c h a wa y a s t o p r e v e n t
d e f o r ma t i o n o f r o t o r , a n d n i c ki n g , s c r a t c h i n g
o r c o n t a mi n a t i o n o f b r a ke s h o e s a n d
l i n i n g s / r o t o r s u r f a c e s .
Remove whe e l and t i re assembl y. Remove r e a r
di sc br a ke cal i per assembl y f r om rear di sc br a ke
rot or a s out l i ned. If rear di sc br ake cal i per d o e s
not requi re servi ci ng, it is not necessary t o
di sconnect rear wheel br ake hose ( 2A442) or
remove rear di sc br ake cal i per f r om vehi cl e.
Posi t i on rear di sc br ake cal i per out of t he wa y
and suppor t it wi t h a l engt h of wi r e t o avoi d
damagi ng t he rear di sc br ake cal i per.
3. NOTE: If addi t i onal f or c e is requi red t o r e move
rot or, appl y Rust Penet rant and Inhibitor
F2AZ- 19A501- AA or equi valent meet i ng Fo r d
speci f i cat i on ESR-M99C56-A on r o t o r / f l a n ge
mat i ng sur f ace. Install 3-Jaw Puller D80L- 1013- A
or equi val ent and remove rear di sc br a ke r ot or .
CAUTI ON: If e x c e s s i v e f o r c e mu s t b e u s e d
d u r i n g r e mo v a l o f r e a r d i s c b r a ke r o t o r , t h e
r e a r d i s c b r a ke r o t o r s h o u l d b e c h e c k e d f o r
l a t e r a l r u n o u t pr i o r t o i n s t a l l a t i o n . Re f e r t o
Se r v i c e P r o c e d u r e s .
Remove rear di sc br ake rot or ret ai ni ng pushnut s
and rear di sc br a ke rot or.
1. If rear di sc brake r ot or i s bei ng r e pl a c e d, r emove
prot ect i ve coat i ng f r o m new rear di sc br a ke r ot or
wi t h Carburet or Tune-Up Cl eaner
D9AZ-19579-AA or equi val ent meet i ng Fo r d
speci f i cat i on ESR-M 14P9-A. If ori gi nal r ear di sc
br ake r ot or is bei ng i nst al l ed, ma ke sure rear di sc
br ake r ot or braki ng and mount i ng sur f aces ar e
cl ean.
2. Install rear di sc br a ke r ot or . Pushnut s d o not need
t o be r epl aced.
3. Install rear di sc br a ke cal i per as out l i ned.
4. Install wheel and t i re assembl y . Ti ght en lug nut s
(1012) t o 115-142 N-m ( 85- 105 Ib-f t ).
5. Lower vehi cl e. Pump br ake pedal ( 2455) pri or t o
movi ng vehi cl e t o posi t i on br a ke shoes and linings
(2001).
Support B r a c k e t
Remov al
2. Remove rear di sc br a ke r ot or ( 2C026) and rear
di sc br ake cal i per ( 2 553) a s out l i ned.
3. Remove axl e shaf t ( 4234) . Ref er t o Sect i on
05-02A.
4. Remove f our rear di sc br a ke cal i per anchor pl at e
mounti ng bol t s and nut s.
5. Remove rear di sc br a ke cal i per anchor pl at e
(2B582).
06- 04- 6 Br akes, Rear Di sc 06- 04- 6
Rear Di sc Br a ke E x p l o d e d Vi ew
H7376-C
Pa r t Pa r t
Stem Nu mb e r De s c r i p t i o n I t e m Nu mb e r De s c r i p t i o n
1 2553 Rear Disc Brake Caliper 8 1177 Inner Wheel Bearing Oil Seal
2 4234 LH Axle Shaft 9 390317-S190 Bolt (4 Req'd)
3 2C026 Rear Disc Brake Rotor 10 1225 Rear Wheel Bearing
4 383609-S Pushnut (2 Req'd Each Side) 11 2B296 Disc Brake Caliper Locating
Sensor Indicator A
Pin
6
7
3912205-56
2C220
Nut (4 Req'd)
Rear Wheel Disc Brake
Adapter
B
Lb-Ft)
Lb-Ft)
Installation
1. Position rear disc brake caliper anchor plate on
rear axle housing (4010).
2. Install four caliper anchor plate mounting bolts
and nuts. Tighten nuts to 27-54 N-m (20-40 Ib-ft).
3. Install axle shaft. Refer to Section 05-02A.
4. Install rear disc brake rotor and rear disc brake
caliper as outlined.
Sh i e l d
Removal
1. Raise vehicle on hoist. Refer to Section 00-02.
2. Remove three screws and one nut to remove rear
wheel disc brake shield (2C028).
Installation
1. Position rear wheel disc brake shield on rear disc
brake caliper anchor plate (2B582).
06- 04- 7 Br a ke s , Re a r Di sc
0 6 - 0 4 - 7
2. Install t hr ee sc r e ws.
H8201-A
C a l i p e r
Di s a s s e mb l y
1. Remove rear di sc br a ke cal i per ( 2 653) assembl y
as out l i ned. Remove out er br ake shoe and lining
( 2001) by sl i ppi ng d o wn cal i per leg until cl i p i s
di sengaged. Remove inner br a ke shoe and lining
by pulli ng it st r ai ght out of pi st on.
2. CAUTI ON: Do n o t u s e a s c r e wd r i v e r o r a n y
si mi l a r t o o l t o pr y r e a r d i s c b r a ke p i s t o n a n d
a d j u s t e r ( 2 B588) o u t o f b o r e . I t wi l l r e s u l t i n
d a ma g e t o r e a r d i s c b r a ke p i s t o n a n d
a d j u s t e r . Cu s h i o n p i s t o n ' s i mp a c t a ga i n s t
r e a r d i s c b r a ke c a l i pe r w h e n b l o wi n g i t o u t o f
b o r e b y p l a c i n g s h o p t o w e l s b e t w e e n r e a r
d i s c b r a ke p i s t o n a n d a d j u s t e r a n d c a l i p e r
b r i d g e .
Appl y ai r pr e ssur e t o t he flui d por t in t he rear di sc
br a ke cal i per wi t h Ai r Nozzl e Assembl y
TOOL-7000-DE or equi val ent t o r emove rear di sc
br ake pi st on and adj ust er. If t he rear di sc br a ke
pi st on a nd adj ust er i s sei zed and cannot be
f o r c e d f r o m rear di sc br a ke cal i per, r ear di sc
br a ke cal i per assembl y must be r e pl a c e d.
Pa r t
1 2B595 Piston Seal
2

Dust Boot (Part of 2B595)
3 2001 Inner Brake Shoe and Lining
Assy (Must be Firmly Seated
Against Piston)
5 2001 Outer Brake Shoe and Lining
Assy (Must be Seated
Against Mousing)
6 2B296 Disc Brake Caliper Locating
Pin
A s s e m b l y
1. When assembl i ng rear di sc br a ke cal i per,
exami ne rear di sc br a ke pi st on f or sur f ace
i rregul ari t i es or small chi ps and c r a c ks. Repl ace
cal i per pi st on ( 2196) if da ma ge d. Be sure t o
cl ean f orei gn mat eri al f r o m pi st on sur f aces and
l ubri cat e wi t h br ake flui d bef ore i nsert i ng i nt o rear
di sc br a ke cal i per. Al wa y s i nstall new seal and
dust boot .
2. CAUTI ON: Do n o t a ppl y C- c l a mp d i r e c t l y t o
p i s t o n s u r f a c e . Thi s c a n r e s ul t i n d a ma g e t o
c a l i pe r p i s t o n . Be s u r e c a l i pe r p i s t o n i s n o t
c o c k e d .
When i nstalli ng cal i per pi st on ba c k i nt o bor e , use
a wo o d bl ock or anot her f l at st o c k, li ke an ol d
br ake shoe and lining assembl y, bet ween
C-cl amp and cal i per pi st on.
3. Ma ke sure t hat dust boot is t i ght in boot gr oove
on cal i per pi st on and in rear di sc br a ke cal i per.
06- 04- 8 Br a ke s , Re a r Di sc 06- 04- 8
To install inner brake shoe and lining wi th
three-finger clip at t ached to shoe into pi ston,
grab each end of shoe, making it square wi th
cal i per pi ston. Push firmly until shoe clip snaps
into pi ston. Do not allow shoe or clip tangs t o
cock during installation.
P HE N OL I C P I ST ON
I NSP E CT I ON
MI N O R S U R F A C E
I M P E R F E C T I O N S A R E
A L L O W A B L E , P R O V I D E D
T H E Y D O N O T E N T E R T H E
D U S T B O O T G R O O V E A R E A
N O C R A C K S , C H I P S , G O U G E S ,
O R A N Y O T H E R S U R F A C E
D A M A G E O N P I S T O N O D
I S A C C E P T A B L E
C R A C K S C O M P L E T E L Y
A C R O S S P I S T O N F A C E N O T
A C C E P T A B L E
B O T T O M O F D U S T
B O O T G R O O V E
5. Install rear di sc brake caliper as outlined.
H3656- D
SERVICE PROCEDURES
Rotor R e f i n i s h i n g
Refer t o Di agnosi s and Testing in Secti on 06- 00 and
the fol l owi ng information for servicing and condi ti ons
requiring refinishing of rear disc brake rotor ( 2C026) .
Brake roughness (vibration or pedal pulsation) that is
present during servi ce brake application may be
caused by rotor thi ckness variation or corrosi on
contami nati on buildup on the rotor braki ng surfaces.
This t hi ckness variation can occur wi th rear di sc brake
rotor wear in excess of 19, 311 ki l ometers ( 12, 000
miles) of use. Rotor turning may thus be necessary
beyond the warrant y peri od. As a last resort, repl ace
heavily scor ed or damaged rear disc brake rot ors.
If brake pedal pul sates, attempt stoppi ng the vehicle in
NEUTRAL. If roughness is gone, the dri vetrai n should
be i nspected. If the roughness remai ns, inspect the
brakes. Refer t o Secti on 06-00.
Use Rotunda Di sc Brake Lathe 054- 00080 or
equivalent t o refinish rear disc brake rot ors.
1. Wi t h a suitable mi crometer, measure the overal l
thi ckness of the rear disc brake rotor braki ng
surface at four equally spaced points around t he
rear di sc brake rotor.
2. NOTE: Remove an equal amount of material f rom
each side of the rear disc brake rotor each ti me
the rear disc brake rotor is turned.
Using the l owest reading f rom Step 1, subtract
t he minimum al l owabl e thi ckness cast into the
rear di sc brake rotor 11.25 mm ( 0. 44 inch).
The di fference, if any, represents the total
amount of material available for machining.
A thi ckness reading less than the minimum rear
di sc brake rotor thi ckness requi res
repl acement of rear disc brake rotor.
3. NOTE: Never use a lathe that cuts only one f ace
of t he rear di sc brake rotor at a ti me; it must be a
simultaneous straddl e cut.
After measuring the rear di sc brake rotor, install
the rear di sc brake rotor in the lathe arbor using
t he adapter that is required for proper rear di sc
brake rotor alignment.
Install a dial indicator t o read lateral runout of
the rear di sc brake rotor near the center of the
rear di sc brake rotor f ace.
If runout is 0. 05 mm ( 0. 002 inch) or below,
machine rear di sc brake rotor.
If runout is over 0. 05 mm ( 0. 002 inch), loosen
rear di sc brake rotor on the arbor and rot at e
the rear disc brake rotor 72 degrees.
Read the runout. If it is bel ow 0. 05 mm ( 0. 002
inch), machine the rear di sc brake rotor.
If runout is still over 0. 05 mm ( 0. 002 inch),
again loosen the rear di sc brake rotor and
rotate it an additional 72 degrees.
Check the runout. If runout is 0. 05 mm ( 0. 002
inch) or l ess, machine the rear di sc brake rotor.
If the runout still exceeds 0. 05 mm (0. 002
inch), return the rear di sc brake rotor t o t he
best runout position obtai ned.
If the rear di sc brake rotor runout can be
brought bel ow 0. 13 mm ( 0. 005 inch), proceed
t o machine the rear disc brake rotor.
If the runout cannot be brought bel ow 0. 13 mm
(0. 005 inch), repl ace rear di sc brake rotor as
outlined.
4. Set the cutting tool to just cont act the high spot s
on the rear di sc brake rotor, then adjust the
cutti ng tool t o the minimum dept h required t o
clean up the rotor f ace.
Equal material must be removed from each
side.
> Do not exceed the al l owabl e st ock removal .
Clean all cutti ngs and chi ps f rom the rear di sc
brake rotor before installing it t o the rear axl e
assembl y ( 4200) .
06- 04- 9 Br a ke s , Re a r Di sc 06- 04- 9
Caliper
Clean all met al pa r t s wi t h i sopr opy l al cohol . Then
cl ean out and dr y gr oove s and pa ssa ge wa y s wi t h
c ompr e sse d air. Ma ke sure cal i per bor e and
component pa r t s ar e t hor oughl y cl ean.
Che c k cyl i nder bor e and cal i per pi st on ( 2 196) f or
damage or e xc e ssi ve wear.
Vi sually c he c k rear di sc br a ke cal i per ( 2 663) . If
cal i per housi ng is l eaki ng, it shoul d be r epl aced. If a
seal is l eaki ng, rear di sc br a ke cal i per must be
di sassembl ed and new seal s and dust boot i nst al l ed. If
a cal i per pi st on is sei zed in t he bor e, a new cal i per
pi st on is requi red. Car e must be t a ke n whi l e removi ng
pl ast i c cal i per pi st on.
Brake Shoe and Li ni ng
1. Remove wheel ( 1007 ) and t i re f r om rear hub
( 1109) and rear di sc br a ke r ot or ( 2C026) .
2. I nspect br a ke shoes and linings ( 2001) f or wear.
If lining i s wo r n t o wi t hi n 3. 17 5 mm (1 / 8 i nch) of
shoe , repl ace all f our br a ke shoes and li ni ngs.
SPECIFICATIONS
BRAKE DIMENSIONS
Component Specification
Li n i n g Ma t e r i a l Nut ur n NT8- FF
Li n i n g Si ze I nner a n d Ou t e r 1 2 4 x 4 0 x 10 mm
( 4 x 1 . 5 x 0 . 3 9 i n c h)
Li n i n g We a r Li mi t
( f r o m s h o e s u r f a c e )
3. 17 5 mm ( 0. 12 5 i n c h)
Ca l i p e r Cy l i n d e r Bo r e
Di a me t e r
48 mm ( 1. 89 i n c h)
Ro t o r No mi n a l T h i c kn e s s 12. 5 mm ( 0. 50 i n c h)
Ro t o r Mi n i mu m T h i c kn e s s
8
11. 25 mm ( 0. 44 i n c h)
Ro t o r Di a me t e r 2 90 mm ( 11. 4 i n c h e s )
Ro t o r A l l o wa b l e Run o ut
Of f Ve h i c l e
0. 08 mm ( 0. 003 i n c h)
Ro t o r Fi n i s h 0. 40- 3. 2 mi c r o - me t e r s
( 10- 80 mi c r o - i n c h e s )
Ro t o r T h i c k n e s s Va r i a t i o n 0. 013 mm ma x . ( 0. 00005 i n c h)
a Mi n i mu m s a f e t h i c k n e s s i s s h o wn on e a c h r o t o r .
FLUID SPECIFICATIONS
L u b r i c a n t S p e c i f i c a t i o n
Br a ke Fl ui d DOT- 3, C6AZ-19542-AA o r
equi val ent me e t i n g Fo r d
s p e c i f i c a t i o n E S A - M6C2 5- A
Di s c Br a ke Ca l i p e r Sl i d e
G r e a s e
D7 A Z - 19590- A or e q u i v a l e n t
E S A - M1C17 2 - A
Si l i c o n e Di e l e c t r i c C o mp o u n d D7 A Z - 19A 331 -A o r e q u i v a l e n t
E SE - M1C17 1- A
Description L b - Ft
Ca l i pe r Bl e e d e r S c r e w 8- 13 6-9
Ca l i pe r L o c a t i n g Pi n 2 9- 41 2 2 - 30
Br a ke Ho s e - t o - Ca l i p e r Re t a i n i n g
Bo l t
40- 54 30- 40
Hy d r a u l i c T u b e Co n n e c t i o n s 14- 2 0 10- 15
L u g Nu t s 115- 142 85- 105
Re a r Di s c Br a ke Ca l i pe r A n c h o r
P l a t e Mo u n t i n g Nut s
2 7 - 5 4 2 0- 40
NOTE: All hydraul i c lines must be ti ghtened to the
speci f i c t or que val ue and be f ree of fluid l eakage.
Tool Number De s c r i p t i o n
D80L - 1013- A 3- J a w Pul l e r
T OOL - 7 000- DE Ai r No zzl e A s s e mb l y

ROTUNDA EQUIPMENT
Model Description
054- 00080 Di s c Br a ke L a t h e
06- 05- 1 Br a ke S y s t e m, P a r ki n g 06- 05- 1
SECTION 06-05 Brake System, Parking
SUBJECT PAGE
Control Assembl i es . 06-05-1
Parki ng Brake Warni ng Syst em 06-05-2
Pi npoi nt Tests 06-05-3
Brake Shoe and Li ni ng Assembl y 06-05-11
SUBJECT PAGE
Cable and Condui t 06-05-9
Cont r ol 06-05-5
I ndi cat or Bul b, Brake Syst em Warni ng 06-05-12
Brakes, Rear 06-05-12
ADJUSTMENTS
Cable Adj ust ment 06-05-12
Cable Tensi on, Release 06-05-13
SPECIFICATIONS.. ....06-05-13
VEHICLE APPLICATION
MEDI CAL ATTENTI ON IF IRRITATION PERSI STS.
IF TAKEN I NTERNALLY, DRI NK WATER AND
I MMEDI ATELY.
The parki ng brake syst em is cabl e-actuated and
control l ed by an independent f oot -operat ed parki ng
brake control ( 2780) .
C o n t r o l A s s e m b l i e s
Ca b l e A c t u a t e d Re a r Wh e e l P a r k i n g Br a k e
An independent f oot -operat ed parki ng brake control
( 27 80) act uat es the rear wheel brake shoes and
linings ( 2001) through a cabl e syst em.
To appl y parki ng brake, press parki ng brake control
downwar d.
H6916- A
On vehi cl es equi pped wi th rear di sc brakes, the
parki ng brake is a drum-type design mounted in t he
hub of the rear di sc brake rotor (2C026).
Pa r ki n g Br a ke Sy st e m
H7376-C
I t e m
Pa r t
2 4234 Axle Shaft
4 383609-S Pushnut (2 Req'd Each Side)
Sensor Indicator
6 3912205-56 Nut (4 Req'd)
Adapter
Pa r t
9 390317-S190 Bolt (4 Req'd)
11 2B296 Disc Brake Caliper Locati ng
Pin
A

Tighten t o 27-54 N-m (20-40
Lb-Ft)
B

Lb-Ft)
The automati c (vacuum) rel ease-type is st andard
equipment on all vehi cl es.
The automati c vacuum-type parki ng brake syst em
contai ns the following f eat ures:
A parki ng brake rel ease cont rol motor ( 2A843) wi t h
mounting bracket at t ached t o the parki ng brake
cont rol .
The vacuum-actuated di aphragm within the parki ng
brake rel ease cont rol mot or whi ch is connect ed by
a rod t o t he upper end of the parki ng brake rel ease
vacuum hose ( 2B653) .
The parki ng brake rel ease vacuum hose whi ch
connect s the parki ng brake rel ease control motor t o
t he engine manifold t hrough a vacuum rel ease
swi t ch at the steeri ng col umn tube ( 3514) .
The parki ng brake rel ease control motor whi ch is
act uat ed t o rel ease t he parki ng brake whenever t he
engine is running and t he transmi ssi on is in a
forward-dri vi ng gear.
A manual rel ease feature that rel eases the parki ng
brake control when t he parki ng brake rel ease
handle ( 2760) , l ocated on the l ower left si de of the
instrument panel, is pulled out.
P a r k i n g B r a k e Wa r n i n g S y s t e m
The parki ng brake warning indicator:
Can be act uat ed by t he parki ng brake control
( 2780) .
Warns the driver to rel ease the parki ng brake
control before driving the vehi cl e.
Indicates that a brake malfunction has occurred if
the indicator remains on.
Inspection and Ve r i f i c a t i o n
operati ng t he parki ng brake syst em t o dupl i cate
the condi ti on.
2. Inspect t o determi ne if one of t he following
Da ma g e d p a r ki n g b r a ke
c o n t r o l .
B i n d i n g / d a ma g e d p a r ki n g
b r a ke c a b l e s .
Da ma g e d v a c u u m p a r ki n g
b r a k e r e l e a s e c o n t r o l
mo t o r .
Da ma g e d o r d i s c o n n e c t e d
p a r ki n g b r a ke r e l e a s e
h a n d l e .
P a r ki n g b r a ke wa r n i n g
i n d i c a t o r s wi t c h ( r e f e r t o
Se c t i o n 13- 01) .
Chart.
BRAKE SYSTEM, PARKING
Parking Brake Will Not Apply Damaged parking brake cont rol .
Bi ndi ng/damaged parking brake
cables.
Parking Brake Will Not Release Bi ndi ng/damaged parking brake
cables.
Damaged parking brake control.
Damaged parking brake release
control motor.
Damaged or di sconnected parking
brake release handle.
PINPOINT TEST A: PARKING BRAKE WILL NOT APPLY
A1 CHECK PARKING BRAKE CONTROL
Yes
No w>
REFER to adj ustments in
this Section. SERVICE as
required.
GOt o A2.
Raise vehicle on a hoist with parking brake fully
released.
Actuate parking brakes by pressing parking brake
pedal downward.
Did par ki ng brakes appl y?
Yes
No w>
REFER to adj ustments in
this Section. SERVICE as
required.
GOt o A2.
A2 CHECK PARKING BRAKE CABLES
Yes
No
SERVICE parking brake
cables as required.
REPLACE parking brake
control.
Loosen tensioner as outlined.
Actuate parking brake control as outlined in Test A1.
Di d par ki ng brake c ont r ol act uat e?
Yes
No
SERVICE parking brake
cables as required.
control.
PINPOINT TEST B: PARKING BRAKE WILL NOT RELEASE
B1 CHECK PARKING BRAKE CONTROL
Yes
No
GOt o B2.
GO to B4.
Apply parking brake.
Release parking brake by pulling out parking brake
release handle.
Di d par ki ng brake rel ease?
Yes
No
GOt o B2.
GO to B4.
06- 05- 4 Br a ke S y s t e m, P a r ki n g 06- 05 - 4
PINPOINT TEST B: PARKING BRAKE WILL NOT RELEASE (Cont i nued)
B2 CHECK PARKING BRAKE RELEASE CONTROL MOTOR
Yes
No
control as outlined.
GO to B3.
NOTE: All checks of parking brake release control
motor and vacuum hoses are to be performed wi th the
engine running at idle speed.
NOTE: Vacuum is available at the parking brake release
control motor when the transmission select or is in D
range.
Check for vacuum at the parking brake release
control motor.
Is vacuum 34 kPa (10 inhg mi ni mum)?
Yes
No
GO to B3.
B3 CHECK SYSTEM VACUUM HOSES FOR LEAKS
Yes
No
RETEST syst em.
GO to B4.
NOTE: This test may require two techni ci ans.
Start engine and run at idle speed.
Depress brake pedal and shift transmission
selector into D range.
Follow routing at vacuum hoses, listening for a
"hi ssi ng" sound along routing.
Are any vacuum l eaks f ound?
Yes
No
RETEST syst em.
GO to B4.
B4 DEPRESS PARKING BRAKE
Yes
No
VERIFY that parking
brake release handle is
installed to parking brake
control and steering
column correctly. If not,
correct the installation. If
installation is correct ,
release handle.
GO to B5.
Start vehicle. While holding down brake pedal, shift
transmission into D range.
Di d par ki ng brake rel ease?
Yes
No
VERIFY that parking
brake release handle is
installed to parking brake
control and steering
column correctly. If not,
correct the installation. If
installation is correct ,
release handle.
GO to B5.
B5 CHECK PARKING BRAKE CONTROL
Yes
No
GO to B6.
Remove parking brake control as outlined.
Connect parking brake release handle to parking
brake control with parking brake control and parking
brake release handle not at t ached to vehicle or
steering column.
Depress pedal on parking brake control.
Using caution to avoid injury during pedal return, set
the parking brake control down and pull the parking
brake release handle.
Di d t he pedal r et ur n?
Yes
No
GO to B6.
B6 CHECK FRONT PARKING BRAKE CABLE
Yes
No
REPLACE front parking
brake cable and conduit
as outlined.
GO to B7.
Disconnect front parking brake cable and conduit
from parking brake rear cable and conduit at
connector.
Move transmission selector lever to the NEUTRAL
posi ti on.
Rotate rear wheels by hand.
Do wheel s t urn f r eel y ?
Yes
No
REPLACE front parking
brake cable and conduit
as outlined.
GO to B7.
B7 CHECK REAR PARKING BRAKE CABLES
Yes
No
lever. RETEST syst em.
for proper service
procedure. SERVICE as
required.
Disconnect parking brake levers, one at a time.
Rotate wheel af f ect ed by di sconnected parking
brake lever.
Di d wheel t urn f r eel y ?
Yes
No
lever. RETEST syst em.
for proper service
procedure. SERVICE as
required.
Co n t r o l
Remov al
2. Fully rel ease parki ng brake.
3. Raise vehi cl e partially on hoi st. Refer t o Secti on
00- 02.
4. Rel ease cabl e tension as outlined.
5. Separat e front parki ng brake cabl e and condui t
( 2853) f rom parki ng brake rear cabl e and
condui ts ( 2A635) at t he connector.
PARKING
BRAKE REAR
CABLE AND
CONDUIT 2A635
FRONT PARKING
BRAKE CABLE
AND CONDUIT
2853
CONNECTOR ASSY
H6917-B
6. Lower vehi cl e.
7. Partially remove scuff pl ate and partially remove
front door l ower weat herst ri p ( 20758) .
COWL SIDE
TRIM PANEL
02344
H6918-B
8. Remove parki ng brake rel ease handle mounting
scr ew f rom instrument panel steeri ng column
cover ( 04459) . Slide parki ng brake rel ease
handle ( 2760) back and down t o remove f rom
instrument panel steeri ng column cover.
9.
INSTRUMENT
PANEL STEERING
COLUMN COVER
04459
SCREW
-4
PARKING BRAKE RELEASE
HANDLE 2B658
HS037-A
Remove center instrument panel mouldings
( 04389) (RH and LH) t o gain access t o
instrument panel steeri ng column cover.
10. Remove instrument panel steeri ng column cover
retaining bol ts and remove instrument panel
steeri ng column cover.
LOWER STEERING
COLUMN COVER
04459
H6919-B
11.
12.
13.
14.
15.
16.
Remove steeri ng column-to-parking brake control
shake brace.
Remove powertrai n control module
( PCMX12A650) .
Remove parki ng brake release vacuum hose
( 2B653) f rom parki ng brake rel ease control
motor ( 2A843) .
Remove LH cowl side tri m panel ( 02345) .
Remove fuse panel retaining nuts and move fuse
panel asi de t o gain worki ng room.
NOTE: Pull and retain t he instrument panel
( 04320) rearward slightly by installing a small
bl ock of wood or similar tool between the
instrument panel and the body.
Remove LH l ower instrument panel retaining
bol ts.
17. Remove parki ng brake control retaining bol ts.
18. Lower parki ng brake control ( 2780) . Di sconnect
the front parki ng brake cabl e and conduit from
parki ng brake control reel .
DOOR
WEATHERSTRIP
20758
WOOD BLOCK
RELEASE PARKING BRAKE CONTROL
HANDLE 2780
BUSHINGS
k . ^ / /
PARKING BRAKE
RELEASE HANDLE
\ \ [/
2B658 \ \ ^<~s
VIEW A
H9039-A
19. Remove parki ng br a ke rel ease handl e f r o m
par ki ng br a ke cont rol by snappi ng t he t wo
r el ease handl e bushi ngs out of t he par ki ng br a ke
c ont r ol rel ease lever.
0
6
-
0
5
-
7

B
r
a
k
e

S
y
s
t
e
m
,

P
a
r
k
i
n
g

0
6
-
0
5
-
7

1
9
9
5

T
o
w
n

C
a
r
,

C
r
o
w
n

V
i
c
t
o
r
i
a
,

G
r
a
n
d

M
a
r
q
u
i
s

J
u
l
y

1
9
9
4

Pa r t
1

Sound Deadener
2 2853 Front Parking Brake Cable
and Conduit
3 2780 Parking Brake Control
and Conduit (RH)
and Conduit (LH)
Sensor
7 2B653 Parking Brake Release
Vacuum Hose From Steering
Column Switch
Bracket
9 4006 Rear Axle Assembly
10 16B920 Clip
Pa r t
11 5500 LH Rear Suspension Arm and
Bushing
12 5486 Stabilizer Bar Bracket
13 N803585-S2 Bolt (3 Req'd)
14 01610 Cowl
Handle
16 Frame
17 2860 Brake Hose Clip
18 N806900-S2 Bolt
19 2K865 Retainer
20

Screw
21 N611196-S56 Screw (2 Req'd)
A

Lb-Ft)
B

Tighten to 12-17N-m (9-12
Lb-Ft)
1. At t ach parki ng brake rel ease handle t o parki ng
brake control by snapping t wo parki ng brake
handle bushings into parki ng brake control
rel ease lever.
2. Position parki ng brake control and connect front
parki ng brake cabl e and conduit.
3. Install parki ng brake control -to-body si de cowl
and install three retaining bol ts. Tighten t o 25-35
N-m (17-25 Ib-ft).
4. Remove wood bl ock f rom instrument panel and
install l ower instrument panel retaining bol ts.
DOOR
WEATHERSTRIP
20758
WOOD BLOCK
H6920-B
5.
6.
7.
Install powertrai n control module.
Install steeri ng col umn-to-parki ng brake control
shake brace.
At t ach parking brake rel ease vacuum hose t o
parki ng brake rel ease control motor.
8. Install fuse panel retaining nuts.
9. Install LH cowl si de tri m panel.
10. Install lower instrument panel steeri ng column
cover except l ower LH screw, and install center
instrument panel moul di ngs.
| LOWER STEERING
m COLUMN COVER
^ 04459
H6919-B
11. Position door weat herst ri p and push into pl ace.
06- 05- 9
Br a ke S y s t e m, P a r ki n g 06- 05- 9
12. Position scuff pl ate and install retaining scr ews.
13.
COWL SIDE
TRIM PANEL
02344
H6918-B
NOTE: If the rel ease handle l ocator t ab is not f ed
through the column cover locating hole, t he
parki ng brake rel ease handle will not fit properl y
t o the instrument panel steeri ng column cover.
At t ach parki ng brake rel ease handle t o
instrument panel steeri ng column cover by
inserting handle l ocator t ab through t he cover' s
locating hole, sliding t he parki ng brake rel ease
handle f or war d. Install parki ng brake rel ease
handle mounting screw. Tighten t o 1-2 N-m (9-18
Ib-in).
INSTRUMENT
PANEL STEERING
COLUMN COVER
04459
SCREW PARKING BRAKE RELEASE
HANDLE 2B658
H9037-A
14. Raise vehi cl e. Refer t o Secti on 00- 02. Connect
front parki ng brake cabl e and conduit t o parki ng
brake rear cabl e and condui t.
PARKING
BRAKE REAR
CABLE AND
CONDUIT 2A635
FRONT PARKING
BRAKE CABLE
AND CONDUIT
2853
CONNECTOR ASSY
H6917-B
15. Adj ust parki ng brake cabl e tension as outlined.
16. Lower vehicle and connect bat t ery ground cabl e.
17. Check operati on of parki ng brake control as
outlined.
Cable and Condui t
Front
Removal
2. Release parking brake cabl e tension as outlined.
3. Di sconnect front parki ng brake cabl e and conduit
( 2853) from LH parki ng brake rear cabl e and
conduit ( 2A635) at cabl e connector.
4. Using a 13 mm box-end wrench t o press retaining
t abs, remove parki ng brake cabl e and conduit
retainer from frame. At front fender apron
( 16055) , remove scr ew holding pl asti c inner front
fender apron t o frame.
5. Pull back front fender apron t o expose front
parki ng brake cabl e and conduit.
6. Pull parki ng brake rear cabl e and conduit through
f rame and let it hang in wheel housing.
7. Lower vehicle and, inside passenger
compartment, remove t he cover of sound
deadener from front parki ng brake cabl e and
conduit at the dash panel ( 01610) . Di sconnect
front parking brake cabl e and conduit f rom
parki ng brake control ( 2780) at cl evi s.
8. Using a 13 mm box-end wrench, press retaining
t abs and remove front parki ng brake cabl e and
condui t from parki ng brake control .
9. Push front parki ng brake cabl e and conduit down
through dash panel and remove front parki ng
brake cabl e and conduit f rom inside wheel
housing.
Installation
1. St art front parki ng brake cabl e and conduit
through opening in the dash panel inside
passenger compartment.
0 6 - 0 5 - 1 0 Br ake Sy s t e m, P a r ki n g
2. Connect end of front parki ng brake cabl e and
condui t t o parki ng brake control cl evi s. Press
t abbed condui t retainer into parki ng brake
cont rol . Install sound deadener cover pat ch at
dash panel .
3. Raise vehi cl e. Refer t o Secti on 00- 02. Insert front
parki ng brake cabl e and condui t through f rame
member t owar d rear of vehi cl e. Press t abbed
condui t retainer into f rame hole.
4. Connect front parki ng brake cabl e and conduit t o
parki ng brake rear cabl e and condui t connector.
H6917-B
5. Adj ust parki ng brake cabl e tension as outl i ned.
6. Lower vehi cl e.
7. Check operat i on of parki ng brake as outlined
under Adj ustments.
Re a r
Re mo v a l
1. Rai se vehi cl e. Refer t o Secti on 00- 02.
2. Rel ease parki ng brake cabl e tension as outlined.
3. Di sconnect front parki ng brake cabl e and condui t
f rom parki ng brake rear cabl e and condui t at
connector.
4. Di sconnect parki ng brake cabl e retainer at
f rame.
5. Di sconnect LH parki ng brake rear cabl e and
conduit f rom RH parki ng brake rear cabl e and
condui t at connector.
LH CABLE TO GO
' UNDER RH CABLE
H9040-A
Pa r t
1
_
Frame
2 2A635 Parking Brake Rear Cable and Conduit, LH
3 2A635 Parking Brake Rear Cable and Conduit, RH
4 Connector
5 2B599 Parking Brake Cable Adj uster
6 2B666 Cable Retainer
6. Rel ease parki ng brake rear cabl e and conduit RH
t abbed condui t retai ner f rom f rame using a 13 mm
box-end wr ench.
Remove RH cabl e tie-strap f rom rear stabilizer
bar ( 5A772) , wi re retainer on LH axl e bracket ,
and di sconnect parking brake rear cabl e and
conduit from retainer on RH rear axl e housing
( 4010) by removi ng bolt and retainer.
06- 05- 11
Br a ke S y s t e m, P a r ki n g 06- 05 - 11
8. Remove cabl e ret ai ni ng E-ciip and cabl e eyel et
f r o m rear parki ng br a ke cabl e. Pull par ki ng br a ke
r ear cabl e and condui t out of rear wheel di sc
br a ke adapt er boss.
9. Remove parki ng br a ke rear cabl e and condui t s
f r o m vehi cl e.
1. I nsert parki ng br ake rear cabl e and condui t
t hr ough mount i ng bo ss and connect it t o rear
par ki ng br a ke lever.
2. Push rear parki ng br a ke cabl e t hr ough mount i ng
bo ss and i nstall ret ai ni ng cl i p.
3. At t a c h rear parki ng br a ke cabl e RH t o axl e
ret ai ni ng cl i p, t hr ough wi r e ret ai ner. Pr ess t a bbe d
ret ai ner i nt o c r ossme mbe r hol e until l oc ke d i nto
pl ace.
4. Rout e rear parki ng br a ke cabl e LH under RH
cabl e bet ween st abi l i zer bar st ud and shoc k
absor ber . Connect RH cabl e end t o connect or
assembl y (part of parki ng br a ke rear cabl e and
condui t LH).
5. At t a c h t i e-st rap on RH parki ng br a ke rear cabl e
and condui t t o rear st abi l i zer bar.
6. Connect parki ng br a ke rear cabl e and condui t
c onne c t or t o f ront parki ng br a ke c a bl e and
condui t .
7. Adj ust parki ng br a ke cabl e t ensi on a s out l i ned.
8. Lo we r vehi cl e. Che c k oper at i on as out l i ned.
B r a k e S h o e a n d L i n i n g A s s e m b l y
R e mo v a l
1. Remove axl e shaf t ( 42 34) assembl y . Ref er t o
Sect i on 05- 02.
2. Di sconnect parki ng br a ke rear c a bl e and condui t
( 2A635) f rom rear parki ng br a ke cabl e.
3. Remove br a ke shoe hol d d o wn spr i ngs ( 2 B454)
and br a ke shoe hol d d o wn spri ng pi ns ( 2069) .
4. Se t br a ke shoe adj ust ment sc r e w ( 2 046) t o
shor t e st l engt h.
5. Sl i ght l y pull parki ng brake shoe and linings
( 2 N7 12) a wa y f r o m parki ng br a ke suppor t pl at e
( 23636) and spread enough t o r emove br a ke
shoe adj ust ment sc r e w assembl y.
6. Remove upper br a ke shoe adj ust i ng sc r e w spri ng
( 2 043) .
7. CAUTI ON: Mak& $ u r $ r e a r p a r ki n g b r a ke
cabl e d o e s n o t d a ma g e b o o t o r pul l b o o t o u t
o f p o s i t i o n .
Li f t par ki ng i r ak e &hoe and linings over suppor t
and remove perki ng br a ke shoe and li ni ngs and
rear parki ng br a ke cabl e as an assembl y .
3. Di sassembl e parki ng br a ke shoe and li ni ngs,
par ki ng br a ke l ever (2A637) and par ki ng br a ke
return spri ngs ( 2466) .
H7375-B
Pa r t
1 2046 Brake Shoe Adj ustment
Screw
2 2B454 Brake Shoe Hold Down
Spring
3 2A637 Rear Parking Brake Cable
4 2L642 Lower Return Springs
5 2049 Brake Shoe Adj usting Screw
Spring
6 2N712 Parking Brake Shoe and
Lining (2 Req'd)
1. Install l ower parki ng br a ke ret urn spri ng and rear
par ki ng br a ke cabl e t o parki ng br ake shoe and
lining assembl i es.
2. Ma ke sure parki ng br a ke lever boot ( 2404) is
pr oper l y posi t i oned in parki ng br a ke suppor t
pl at e. Install parki ng br ake shoe and lining
assembl i es by f i rst i nsert i ng rear parki ng br a ke
cabl e t hr ough boot , l oweri ng shoes i nt o posi t i on.
REAR DISC REAR WHEEL DISC
POSITIONED H7377-
3. Install upper br a ke shoe adj ust i ng sc r e w spr i ng.
4. Install br a ke shoe adj ust ment sc r e w assembl y.
REMOVAL AND INSTALLATION (Conti nued) ADJUSTMENTS
6.
7.
Install brake shoe hold down spri ngs and brake
shoe hol d down spri ng pi ns.
Connect parki ng brake rear cabl e and conduit t o
rear parki ng brake cabl e.
Install axl e shaft assembl y. Refer t o Secti on
05- 02.
179.65mm MAX
(7.072 INCH)
179.45mm MIN
(7.065 INCH)
179.65mm MAX
(7.072 INCH)
179.45mm MIN
(7.065 INCH)
H7824-A
8. Center parki ng brake shoe and linings on parki ng
brake support pl ate and, using an 8-inch
mi crometer, gauge parki ng brake shoe and linings
t o di mensi ons shown.
Indicator Bulb, Brake System Warning
Brakes, Rear
Appl y t he br ake pedal ( 2 455) a f ew ti mes and veri fy
that t he rear brakes do not drag when rear wheel s
rotate.
2.
Cable A d j u s t m e n t
1. CAUTI ON: Wi t h t he par ki ng b r a ke c ont r ol
( 2780) i n OFF posi t i on, t he r ear par ki ng
b r a ke shoe and l i ni ng ( 2 N7 12 ) must not dr ag.
Ch e c k f or mov ement of t he par ki ng br ak e
r e a r c a bl e a n d c ondui t s ( 2A635) f r o m t hei r
c o n d u i t s when t h e par ki ng br ake
i n t e r me d i a t e cabl e ( 2 A 62 0) i s def l ec t ed wi t h
a f o r c e of 45 - 65 N ( 1 0 - 1 5 l bs) .
Appl y parki ng brake wi t h 445 N-m ( 100 l b) f oot
pedal effort. Rel ease parki ng brake cont rol .
Repeat appl i cati on and rel ease.
Pl ace transmi ssi on in NEUTRAL (N). Rai se
vehi cl e on an axl e-type hoi st. Refer t o Secti on
00-02.
Wi t h parki ng brake control in the off posi ti on,
grasp tensioner around housi ng. Using a tool
similar t o one shown, hook the end into t he
rounded end at cl i p bet ween clip and housi ng.
Unlock clip by pulling downwar d wi t h t he tool and
support tensioner. Tensioner spri ng will t ake up
cabl e sl ack and prel oad cabl es. Whi l e holding
tensioner, l ock t he clip by pushing up on bot t om of
clip. If clip does not slide up, move assembl y
slightly t o align cl osest groove on adj uster rod t o
the cl i p.
31.75 mm (1.25 INCHES)
4.
5.
6.
101.6 mm
(4.0 INCHES)
101.6 mm ,
(4.0 INCHES) H7382-B
Examine tensioner for remaining cabl e t ake-up
capability. If none is present, check all cabl es,
parki ng brake control and bracket s for possi bl e
damage or defl ecti on. Repl ace damaged par t s
and tension by using initial installation adj ustment
procedure.
Insert LH parki ng brake rear cabl e and condui t
into bl ack pl asti c retainer whi ch hangs under
fl oorpan.
Snap retainer shut.
I n i t i a l I n s t a l l a t i o n A d j u s t me n t
1. Install parki ng brake control tensi oner and ail
cabl es wi th routing clips. Connect all cabl es
together wi th tensioner. (Be sure t o i nst all cor r ect
adjuster for rear brake usage).
2. Pl ace t ransmi ssi on in NEUTRAL (N). Rai se
vehi cl e on an axl e-t ype hoi st . Ref er t o Sect i on
00- 02.
3. Wi t h parki ng br ake cont rol in OFF posi t i on, gr a sp
t ensi oner around housi ng, t hen usi ng a t ool si mi lar
t o t he one sho wn , hook end i nto rounded end of
cli p bet ween cl i p and housi ng. Unl ock cl i p by
pulling d o wn wa r d wi t h t he t ool and support
t ensi oner, t ensi oner spri ng will f a ke up cabl e
sl ack and pr el oad cabl es. Whi l e holdi ng
t ensi oner, l ock t he cl i p by pushi ng up on bot t om of
cl i p. If cl i p does not sl i de up, move assembl y
sl i ght l y t o ali gn cl osest gr oove on adj ust er r od t o
t he cl i p.
4. Appl y parki ng br a ke cont r ol fully ON wi t h 445
N-m ( 100 lb) f oot pedal ef f ort . Rel ease parki ng
br a ke cont r ol . Repeat appl i cat i on and rel ease
t wi c e .
5. Repeat st e p 3 t o t a ke up any addi t i onal sl ack.
6. Snap ret ai ner shut .
Cabie Tension, Release
1. Fully rel ease t he parki ng br ake.
2. Rai se vehi cl e on an axl e-t ype hoi st . Ref er t o
Sect i on 00- 02.
3. Remove parki ng br a ke rear cabl e and condui t
( 2 A635) f rom bl ack pl ast i c cabl e ret ai ner under
f l oorpan by unsnappi ng ret ai ner and pulling out
parki ng brake rear cabl e and conduit.
4. Removal of cabl e tension requi res t wo peopl e t o
di sengage and rel oad t he t ensi oner. One person
is t o unl ock t he t ensi oner by pulling d o wn wa r d on
t he cl i p. Whi l e cl i p is di sengaged, t he second
person is t o appl y t he parki ng br a ke cont rol
( 27 80) fully t o t he last not ch posi t i on. The
t ensi oner spri ng wi ll c ompr e ss al l owi ng cabl e
sl ack t o r et ur n.
5. Lo c k t he t ensi oner by pushi ng up on t he cl i p.
Ma ke sure l ocki ng lever is secur e by rot at i ng it
t o wa r d t hr eaded r od. Wr a p t a pe or wi r e around
t he l ocki ng lever and t hr eaded r od t o prevent
acci dent al rel ease.
6. Rel ease t he parki ng br ake c ont r ol . Cabl es,
t ensi oner and parki ng br ake cont r ol may be
r emoved.
SPECIFICATIONS
P a r ki n g Br a ke Co n t r o l
A s s e mb l y - t o - Bo d y Bo l t s
2 5- 35 17 - 2 5
A d a p t e r A s s e mb l y - t o - Re a r A x l e
Tube Fl a n ge Nut s
2 7 - 54 2 0- 40
Di s c Br a ke Ca l i pe r L o c a t i n g Pi n s 2 6- 35 19- 2 6
Re l e a s e Ha n d l e Mo u n t i n g S c r e w 1-2 9- 18
( L b - l n )
Fr o n t P a r ki n g Br a ke Ca b l e a n d
Co n d ui t Re t a i n e r
12- 17 9- 12
06- 06- 1 Br a ke S y s t e m, Hy d r a u l i c 06- 06- 1
SECTION 06-06 Brake System, Hydraulic
SUBJE CT PAGE
Brake System 06-06-1
Brake Syst em, Ant i -Lock 06-06-4
Stopl i ght Swi tch 06-06-2
Brake Syst em . . 06-06-4
Brake Mast er Cyl i nder 06-06-4
Brake Mast er Cyl i nder Reservoi r 06-06-5
Brake Pedal and Bracket .. 06-06-4
Brake Pressure Cont rol Valve 06-06-6
Cal i per Hose, Front 06-06-7
Cal i per Hose, Rear 06-06-7
St opl i ght Swi t ch . 06-06-6
SUBJECT PAGE
Br ake Mast er Cyl i nder 06-06-7
SERVICE PROCEDURES
Hydraul i c Li ne Repair 06-06-9
Hydraul i c Syst em Bl eedi ng 06-06-10
Br ake Fl ui d Leakage . .... 06-06-11
Br ake Li nes and Hoses 06-06-11
ADJUSTMENTS
Brake Boost er t o Master Cyl i nder Push
Rod 06-06-12
VEHICLE APPLICATION
Town Car, Cr own Vi ct or i a, Gr and Mar qui s
B r a k e S y s t e m
WARNI NG; BRAKE FLUI D CONTAI NS
AVOI D CONTACT WI TH EYES. WA SH HANDS
I MMEDI ATELY.
Thi s vehi cl e is equi pped wi t h a br a ke pedal act uat ed
dual br a ke sy st e m. The sy st e m consi st s of t he
f ol l owi ng:
Powe r br a ke boost er ( 2005) .
Br a ke mast er cyl i nder ( 2 140) .
Br a ke pressure cont r ol val ves ( 2B091) .
Di sc br a ke cal i pers ( 2B120) . Rear di sc br a ke
cal i per s (2553).
Br a ke t ubes and hoses.
B r a k e Ma s t e r Cy l i n d e r
The br a ke mast er cyl i nder is a dual pi st on t y pe . The
br a ke ma st e r cyl i nder ope r a t e s as f ol l ows:
Whe n t he br ake pedal ( 2455) is d e pr e sse d ,
pr e ssur e i s appl i ed by mechani cal l i nkage t o t he
pr i mar y and secondar y pi st ons.
Br a ke mast er cyl i nder pi st ons appl y hydraul i c
pr e ssur e t o t he t wo o ppo se d hydraul i c ci r cui t s.
The br a ke mast er cyl i nder consi st s of:
Br a ke mast er cyl i nder reservoi r ( 2K47 8) .
Pri mary a nd secondar y pi st ons.
Br a ke mast er cyl i nder body .
B r a k e s , Re a r
The rear di sc br ake sy st e m i ncludes:
Si ngle pi st on rear di sc br a ke cal i pers ( 2552) .
Rear di sc br ake cal i per anchor pl at es ( 2B582) .
Br a ke shoe s and linings (2001).
Rear di sc br ake r ot or s (2C026).
Rear wheel brake hoses ( 2A442) .
B r a k e s , Fr o n t
The f ront di sc brake sy st em i ncludes:
Di sc br a ke cal i per assembl i es.
Front di sc br ake r ot or s ( 1125) .
Br a ke shoe s and linings.
Front br a ke hoses (2078).
Dua l Hy d r a u l i c Br a k e S y s t e m
The dual hydraul i c sy st em is a convent i onal , pedal
act uat ed sy st e m. The sy st e m consi st s of:
Br a ke mast er cyl i nder.
Br a ke pr essur e cont rol val ve.
Di sc br a ke cal i per and rear di sc br ake cal i per s.
Br a ke t ubes and hoses.
The dual hydraul i c sy st em wi t h and wi t hout ABS is
f ront -t o-rear spli t . Bot h f ront br akes compr i se one
ci rcui t and bot h rear br akes t he ot her ci rcui t .
S t o p l i g h t S w i t c h
B r a k e C o n t r o l Va l v e s a n d P r e s s u r e S w i t c h
The br a ke pressure cont r ol val ve ( 2B091) assembl y
c onsi st s of t he f ol l owi ng f eat ur es:
When t he br a ke pedal ( 2466) i s appl i ed, t he full rear
br a ke flui d pr essur e pa sse s t hr ough t he
proport i oni ng val ve t o t he rear br a ke sy st e m until
t he val ve spl i t poi nt is r e a c he d.
The proport i oni ng val ve begi ns t o r educe t he
hydraul i c pr essur e t o t he rear br a ke s, above i t s
spl i t poi nt , creat i ng a bal anced br aki ng condi t i on
be t we e n t he f ront and rear wheel s.
The proport i oni ng val ve' s spl i t poi nt and sl ope
per f or mance ar e l i st ed in Speci f i cat i ons.
On Cr own Vi ct or i a, Grand Marqui s equi pped wi t h
ABS t r act i on c ont r ol , t he br a ke pr essur e cont r ol
val ve i s mount ed on t he out boa r d si de of t he mast er
cyl i nder. The val ve pr opor t i ons pr essur e t o bot h
rear br a ke s.
On vehi cl es equi pped wi t h ABS l ess t r act i on cont r ol
and non ABS, t he br a ke pr essur e and cont r ol val ve
i s i nst al l ed in t he mast er cyl i nder. Thi s val ve
pr opor t i ons pressure t o t he rear br a ke t hr ough a
j unct i on bl ock on t he f r a me .
Ad a pt e r Asse mbl y ( Jun c t i o n Bl o c k) a n d Pr essur e
S wi t c h T o wn Car Less Tr a c t i o n Assi st
PRESSURE
SWITCH
BRAKE PRESSUE CONTROL
VALVE ASSY
H7S08-1
06- 06- 3
7L.Z7~JRZ~
Br a ke S y s t e m, Hy d r a u l i c
~
06- 06- 3
Adapt er Assembl y ( Junct i on Bl ock) - Town Car
Wi t h ABS and Wi t hout Spe e d Cont r ol
BRAKE PRESSURE CONTROL
VALVE ASSY
PRESSURE
SWITCH
i
H6946-D
Adapt er Assembl y ( Junct i on Bl o c k) Cr own
Vi c t o r i a , Grand Marqui s Wi t h ABS and Tr act i on
Cont r ol
H9030-A
Pa r t
1 2140 Brake Master Cylinder
2
2B253 Brake Master Cylinder Outlet
Rear Tube
3 2A040 Brake Master Cylinder
Connector Tube
4 2B091 Brake Pressure Control
Valve
Valve Outlet Tube
6 2L477 Brake Pressure Control
Valve Outlet Tube
7 2B260 Brake Pressure Differential
Valve Bracket
8 N605904-S301 Bolt (4 Req'd) 19-26 N-m
(13-20 Lb-Ft)
06- 06- 4
Br a ke Sy s t em, Hy d r a u l i c 06- 06- 4
Ad a pt e r Asse mbl y ( Jun c t i o n Bl o c k) a n d Pr essur e
S wi t c h Cr o wn Vi c t o r i a , Gr a nd Mar qui s Wi t ho ut
ABS a nd Wi t h Spe e d Co n t r o l
P R E S S U R E
S W I T C H .
B R A K E P R E S S U E C O N T R O L
VALVE ASSY
H 7 8 0 8 - B
B r a k e S y s t e m , Anti-Lock
The ABS f our-wheel syst em:
Prevents wheel l ockup by automati cal l y modulating
t he brake pressure during an emergency st op.
ft Enables the dri ver t o maintain steeri ng control and
st op in the shortest possi bl e di stance under most
condi ti ons.
ft Refer t o Secti on 06- 09.
B r a k e P e d a l a n d B r a c k e t
Re mo v a l
2. Di sconnect the stopl i ght swi t ch wi re connector
f rom the stopl i ght swi t ch ( 13480) .
3. Loosen the boost er retaining nuts approxi matel y
6. 35 mm ( 1 / 4 inch) at the pedal support bracket
( 01508) . Remove the push rod retainer and
brake master cylinder push rod spacer ( 2B129) .
Slide the stopl i ght swi t ch outboard along the
brake pedal pin just far enough for the outer hole
of t he stopl i ght swi t ch f rame t o clear the pin.
Remove the stopl i ght swi t ch by sliding it
downwar d. Remove the brake master cyl i nder
push rod bushing ( 247 4) f rom the push rod.
4. Slide the push rod off t he pedal pin.
5. Remove t he prevailing torque nut and then
remove the pivot bolt, brake pedal ( 2455) , brake
pedal support mounting spacer ( 2B180) , and
brake master cylinder push rod bushing f rom the
pedal support bracket .
1. Appl y a coati ng of engine oil t o the brake master
cylinder push rod bushing. Locat e bushings and
brake pedal support mounting spacer in the brake
pedal hub.
2. Position the brake pedal assembl y in the pedal
support bracket and install t he pivot bolt. Install
the prevailing torque nut. Tighten the nut t o 14-27
N-m (10-20 Ib-ft).
3. Install the brake master cylinder push rod, and
the brake master cylinder push rod bushing on
the brake pedal pin. Position the stoplight swi t ch
so that it st raddl es t he push rod wi th the slot on
the pedal pin and the swi t ch outer frame hole just
cl eari ng the pin. Slide the stopl i ght swi t ch upward
onto t he pin and push rod. Slide the assembl y
i nboard t owar d the brake pedal arm. Install the
outer brake master cylinder push rod spacer and
the push rod retainer. Lock retainer securel y.
4. Tighten the booster retaining nuts t o 21 -29 N-m
(16-21 Ib-ft).
5. Connect t he stoplight swi t ch wi re t o the stoplight
swi t ch.
B r a k e S y s t e m
Re mo v a l
1. Press the brake pedal ( 2455) several ti mes t o
exhaust all vacuum in the syst em.
2. Remove brake tubes f rom pri mary and secondary
outlet ports of brake master cylinder ( 2140) .
3. Di sconnect the brake warni ng indicator swi t ch
connector.
06- 06- 5
4. For vehi cl es wi t h ABS plus tracti on assi st,
remove t he t wo bol ts whi ch at t ach the
proporti oni ng val ve bracket t o t he br ake master
cylinder. Secure t he proporti oni ng val ve and
brake t ubes in a position t o prevent damage or
loss of brake fluid.
5. Remove t wo nuts retaining brake mast er cylinder
t o power brake boost er ( 2005) assembl y.
6. Slide br ake master cyl i nder f or war d and upward
f rom vehi cl e.
1. Position br ake mast er cyl i nder assembl y on studs
on boost er assembl y.
2. Install retaining nuts. Tighten retaining nuts t o
21- 29 N-m (16-21 Ib-ft).
3. Fasten the proporti oni ng val ve bracket t o the
mast er cylinder. Tighten the t wo bol ts t o 19-26
N-m ( 14- 19 Ib-ft).
4. Install pri mary and secondary brake t ubes t o
brake mast er cylinder outlet port s. Tighten t o
14-20 N-m (10-15 Ib-ft).
5. Connect br ake warni ng i ndi cator swi t ch
connector.
6. Fill brake master cylinder wi t h speci fi ed brake
fluid t o MAX line t o 4. 0 mm ( 0. 16 inch) bel ow on
brake mast er cyl i nder reservoi r ( 2K478) . Use
High Performance DOT-3 Brake Fluid
C6AZ- 19542- AA or DOT-3 equivalent fluid
meeti ng For d speci fi cati on ESA-M6C25-A.
7. Bl eed br ake syst em as outl i ned.
8. Operat e br akes several t i mes, then check f or
external hydraul i c l eaks.
2. Remove brake mast er cyl i nder filler cap ( 2162)
f rom br ake mast er cyl i nder reservoi r.
3. On vehi cl es wi th ABS, di sconnect the HCU suppl y
hose f rom t he brake mast er cylinder reservoi r
fi tti ng and secure in a posi ti on to prevent l oss of
brake fluid.
4. Remove pri mary reservoi r port f rom brake
mast er cylinder by pryi ng upward wi th rod or long
screwdri ver. For vehi cl es wi t h ABS remove t he
front l ocati ng pin and r ock t he brake mast er
cyl i nder reservoi r up and away f rom the rear
l ocati ng pi n.
5. Remove secondary br ake master cylinder port in
same manner and di scard compl et e brake master
cyl i nder reservoi r assembl y.
6. Remove grommet s f r om br ake master cyl i nder.
1. Wet grommet s wi t h cl ean brake fluid and press
into br ake mast er cyl i nder.
2. Wet br ake mast er cyl i nder reservoi r in cl ean
brake fluid and press new reservoi r assembl y into
grommet s. For vehi cl es wi t h ABS, assembl e
reservoi r retaining l egs on pins whi l e pressi ng
reservoi r port s into grommet s.
3. Connect fluid level i ndi cator swi t ch.
4. Fill brake mast er cyl i nder reservoi r wi th speci fi ed
brake fluid t o MAX line t o 4. 0 mm ( 0. 16 inch)
bel ow. Use High Performance DOT-3 Brake Fluid
C6AZ- 19542- AA or DOT-3 equivalent fluid
meeti ng For d speci fi cati on ESA-M6C25-A.
5. Check for l eaks.
B r a k e Ma s t e r C y l i n d e r R e s e r v o i r
Re mo v a l
NOTE: Whenever the brake mast er cylinder reservoi r
( 2K478) is removed f rom t he brake master cyl i nder
( 2140) , new grommet s must be installed.
1. Di sconnect fluid level i ndi cator swi t ch.
06- 06- 6
Br a ke S y s t e m, Hy d r a u l i c 06- 06- 6
VIEW A
VIEW B
PIN MUST BE LOCKED
IN PLACE AS SHOWN
VIEW C
H6947-E
i t e m
Pa r t
1 N800538-S10G Nut
2

Inner Cowl
3 385759-S2 Nut (4 Req'd)
4 N606689-S2 Bolt
5 01610 Dash Panel
6 2B196 Booster Without ABS
7 2B450 Spacer
8 2450 Assy
9 13480 Stoplight Switch Assy
Pa r t
10 2B129 Master Cylinder Push Rod
Spacer
11
2A309 Bushing
12 Push Rod (Part of 2B195)
13 380699-S100 Pin
A
-
Lb-Ft)
B

Lb-Ft)
B r a k e P r e s s u r e C o n t r o l Va l v e
ABS t ract i on assi st vehi cl es have a redundant speed
control deacti vati on control swi t ch added t o t he
proporti oni ng val ve. For non ABS and vehi cl es wi t h
ABS l ess tracti on assi st, a junction bl ock is used.
Re mo v a l
1. NOTE: The brake pressure control val ve ( 2B091)
assembl y is servi ced only as an assembl y.
Di sconnect the brake inlet t ubes and t he out l et
t ubes f rom t he brake pressure control val ve,
2. Remove the bolt that retai ns the brake pressure
control val ve assembl y on t he control val ve
bracket . Remove the assembl y f rom the vehi cl e.
1. Position the brake pressure control val ve
assembl y on the control val ve bracket whi ch is
at t ached t o the master cylinder. Install the
retaining bolts t o secure t he val ve t o t he bracket .
2. Connect the rear brake outlet tubes t o t he brake
pressure control val ve. Tighten the tube nut t o
14-20 N-m (10-15 Ib-ft).
3. Connect the inlet tubes t o t he brake pressure
control val ve. Tighten the tube nut t o 14-20 N-m
(10-15 Ib-ft).
4. Bl eed the brake syst em as outlined.
Stoplight Switch
C a l i p e r H o s e , F r o n t
Re mo v a l
1. Rai se vehi cl e on hoi st . Refer t o Sect i on 00- 02.
2. Remove t he wheel and t i re assembl y f r om t he
wheel hub ( 1104) . Use car e t o avoi d damage t o ,
or i nt erf erence wi t h t he cyl i nder bl eeder sc r e w
f i t t i ng duri ng removal .
3. Di sconnect t he f l exi bl e f ront br a ke hose ( 207 8)
f r om t he di sc br a ke cal i per ( 2B120) as f ol l ows:
a. Loosen t he t ube f i t t i ng t hat c onne c t s t he
f ront br a ke hose t o t he br a ke t ube at t he
br a c ke t on t he f r ame.
b. Plug t he br a ke t ube.
c. Di sconnect f ront hose br a c ke t f r om f r ame
by removi ng a scr ew.
d. Remove t he hol l ow bolt t hat a t t a c he s t he
f ront br a ke hose assembl y t o t he di sc br a ke
cal i per.
e. Mar k t he LH and RH di sc br a ke cal i per and
f ront br a ke hose assembl i es wi t h chal k pri or
t o removal f r o m t he vehi cl e so t hey can be
posi t i oned c o r r e c t l y duri ng i nst al l at i on.
1. Install t he f l exi bl e f ront br ake hose t o t he di sc
br a ke cal i per wi t h hol l ow bolt N808236- S36 and
t wo new seali ng wa she r s N808832- S. Ti ght en
f r ont br ake hose f i t t i ng t o 40- 60 N-m (30-46 Ib-f t ).
2. NOTE: Do not t wi st t he f ront br a ke hose.
Secur e t he br a c ke t t o f r ame by a sc r e w. Remove
t he pl ug f r om t he br a ke t ube. Connect t he br a ke
t ube t o t he f ront br a ke hose wi t h t he t ube f i t t i ng
nut . Ti ght en t o 14-20 N-m (10-15 Ib-f t ).
3. Bl eed t he br ake sy st e m and cent ral i ze t he br a ke
pr essur e di f f erent i al val ve ( 2B257 ) .
4. Fill t he br ake mast er cyl i nder reservoi r ( 2 K47 8)
t o t he FULL mark e mbosse d on t he br a ke mast er
cyl i nder reservoi r.
5. Install t he wheel and t i re assembl y. Ti ght en lug
nut s ( 1012) t o 115-142 N-m ( 85- 105 Ib-f t ).
C a l i p e r H o s e , Re a r
Re mo v a l
2. Remove wheel and t i r e assembl y.
3. Di sconnect f l exi bl e br a ke hose f r om rear di sc
br a ke cal i per ( 2553) . Remove br a ke f i t t i ng
ret ai ni ng bol t f r om rear di sc br ake cal i per. Pl ug
hose and cal i per f i t t i ng.
1. Remove pl ug and i nstall rear whe e l br a ke hose
( 2 A442 ) on rear di sc br a ke cal i per wi t h new
ga ske t on e a c h si de of f i t t i ng out l et . Insert
ret ai ni ng bol t t hr ough wa she r s a nd f i t t i ngs.
Ti ght en bol t s t o 40- 60 N-m ( 30- 45 Ib-ft).
2. Bl eed br a ke sy st e m. Ref er t o Sect i on 06-06.
Al wa y s repl ace rubber rear di sc br a ke bl eeder
sc r e w c a p af t er bl eedi ng.
3. Fill br a ke mast er cyl i nder ( 2140) a s requi red.
4. Install wheel and t i re assembl y . Ti ght en lug nuts
( 1012) t o 115-142 N-m ( 85- 105 Ib-f t ). Lowe r
vehi cl e.
B r a k e L i n e Re p l a c e me n t
If a sect i on of br a ke line is d a ma ge d , t he ent i re sect i on
must be r epl aced wi t h a line of t he same t y pe , si ze,
sha pe and l engt h.
CAUTI ON: Ne v e r us e c o p p e r t u b i n g . I t i s s u b j e c t
t o f a t i g u e , c r a c k i n g a n d c o r r o s i o n w h i c h c o u l d
r e s u l t i n b r a ke l i n e f a i l u r e .
Doubl e-wal l st eel t ubi ng is used t hroughout t he br ake
hydraul i c sy st e m. All br ake line f i t t i ngs must be
pr oper l y doubl e-f l ared t o provi de st r ong l eakpr oof
connect i ons. When bendi ng t ubi ng t o f i t t he underbody
or rear axl e cont our s, be caref ul not t o ki nk or c r a c k
t he li ne.
Repl ace a br ake line a s f ol l ows:
1. NOTE: The out si de di amet er of t he line is used t o
speci f y si ze.
Obt ai n t he r ecommended line and st eel f i t t i ng of
t he c or r e c t si ze.
2. NOTE: Cor r e c t l engt h may be det ermi ned by
measuri ng t he line t o be r epl aced usi ng a l engt h of
c o r d and t hen addi ng 3. 175 mm ( 1 / 8 i nch) f or t he
f l ar es.
Use a t ubi ng cut t er t o cut t he t ubi ng t o l engt h.
3. NOTE: Ma ke sure t he f i t t i ngs are i nst al l ed and
ori ent ed cor r ect l y bef ore f l ari ng bot h ends of t he
li ne.
Use a sui t abl e f l ari ng t ool t o make met ri c i so
f l ares at t he ends of t he line. Fol l ow t he
i nst ruct i ons i ncl uded wi t h t he t ool .
4. Bend t he line t o t he necessar y cont our s and
connect . Cl earance of 19. 05 mm ( 3 / 4 i nch) must
be mai nt ai ned bet ween t he line and all movi ng or
vi brat i ng pa r t s.
On vehi cl es equi pped wi t h ABS and t r act i on cont r ol ,
t he br a ke mast er cyl i nder ( 2140) must not be
overhaul ed, because of i nternal adj ust ment s whi ch
requi re ext ensi ve speci al t ool s and f i xt ur es.
On vehi cl es wi t h ABS wi t hout t r act i on cont rol or
wi t hout ABS, t he br a ke mast er cyl i nder is ser vi ced a s
f ol l ows.
Di s a s s e mb l y
NOTE: If br a ke mast er cyl i nder i s t o be put i nt o a vi se
t o ai d in di sassembl y, mount i nt o vi se by f l ange only t o
avoi d damage t o bor e or hydraul i c cont r ol unit
reservoi r ar eas.
1. Clean t he out si de of t he br a ke mast er cyl i nder
t horoughl y. Remove t he br a ke mast er cyl i nder
filler c a p ( 2162) and ga ske t . Al wa y s di sc a r d
used br a ke f l ui d.
2. Remove st o p bol t and pr essur e cont rol val ve by
unscrewi ng f r om br a ke mast er cyl i nder. The
br ake mast er cyl i nder i nt ernal s cannot be
removed unless t he st o p bol t and pr essur e
cont rol val ve are r e move d.
3. Depr ess t he pri mary pi st on, and remove snap
ri ng f r om ret ai ni ng gr oove at t he open end of t he
bor e.
Br a ke Ma st e r Cy l i nde r
Pa r t Pa r t
i t e m Nu mb e r De s c r i p t i o n I t e m Nu mb e r De s c r i p t i o n
1 2162 Brake Master Cylinder Filler
Cap
Valve
2 2K478 Brake Master Cylinder
Reservoir
7

Secondary Piston Assy (Part
of 2140)
3 2L074 Secondary Master Cylinder
Reservoir Seal
8

Primary Piston Assy (Part of
2140)
4

Secondary Outlet (Part of 9

Snap Ring (Part of 2140)
2140) 10 2L074 Primary Master Cylinder
5

Stop Bolt (Part of 2140) Reservoir Seal
Remove t he pr i mar y pi st on and secondar y pi st on
assembl i es f r o m br a ke mast er cyl i nder. Tap open
end of br a ke mast er cyl i nder on bench t o r emove
pi st ons. If se c onda r y pi st on doe s not readi l y
c o me out , appl y ai r pr essur e t o se c onda r y out l et
por t t o assi st r emoval .
A s s e m b l y
1. Dip repl acement pi ston assembl i es in High
Performance DOT-3 Brake Fluid
C6AZ- 19542- AA or DOT-3 equivalent meeti ng
Ford speci fi cati on ESA-M6C25-A for lubrication
prior t o assembl y into brake master cyl i nder.
Attempti ng t o assembl e pi ston assembl i es wi t h
dry seal s can ruin t hem.
2. install secondary (smal l er) pi ston assembl y into
bore, spri ng end fi rst.
3. Install pri mary piston assembl y, spring end fi rst.
4. Depress pri mary pi ston and install snap ring.
5. Install pressure control val ve into brake mast er
cyl i nder. Tighten t o 13-24 N-m ( 10- 18 Ib-ft). Install
st op bolt and ti ghten t o 1-4 N-m (9-35 Ib-in).
6. Fill and bl eed brake mast er cyl i nder.
7. Install cap and gasket on brake master cyl i nder
reservoi r ( 2K478) .
SERVICE PROCEDURES
H y d r a u l i c L i n e Re p a i r
WARNI NG: COPPER TUBI NG SHOULD NOT BE
USED IN A HYDRAULI C SYSTE M.
Certai n brake t ube bundles are servi ced as compl et e
assembl i es. If not servi ced, t he fol l owi ng servi ce
procedure should be used:
1. Obtai n the recommended bulk 3/ 16- i nch
double-wall steel brake tubing and t he correct
st andard t ube nuts for 3 / 16-inch tubi ng.
2. Cut tubing t o length requi red. Clean burrs after
cutti ng. The correct length may be obtai ned by
measuring t he removed tube wi t h a stri ng and
addi ng 1.2 mm ( 1 / 8 inch) for each fl are.
3. Pl ace tube nut onto tube into correct di recti on and
fl are t he end of the tube wi t h an SAE i nverted
fl are or the metri c ISO f l are as requi red, using
Brake Line Flaring Tool D81L- 2269- A, or
equivalent.
4. Repeat on t he opposi t e end of t he tube.
5. Bend t he repl acement t ube t o mat ch t he removed
tube using a tubing bender. When t he
repl acement brake tube is installed, maintain
adequate cl earance t o metal edges and movi ng
or vi brati ng part s.
6. Install brake t ube and t orque tube nuts t o 14-20
N-m ( 10- 15 Ib-ft) wi t h Lb-ln Torque Wrench
D81L-600-A or equivalent.
7. Bl eed t he servi ced pri mary or secondary ci rcui t.
Sf ei ther end of the Tube-to-Tube Connecti on requi res
repl acement, repl ace bot h ends wi t h t he SAE doubl e
45-degree union connecti on.
All br ake tubing shoul d be f l ared properl y t o provi de
good l eakproof connecti ons. Clean brake tubing by
flushing wi th cl ean brake fluid bef ore installation.
When connecti ng a t ube t o a hose, tube connect or or
brake cylinder, ti ghten t he t ube fitting nut t o
speci fi cati on wi th Lb-ln Torque Wr ench D81L-600-A or
equivalent.
Commonl y used t ypes of brake line fl ared connecti ons:
SAE double 45-degree fl are.
7/16 WRENCH CHAMFER
3/8 - 24
OR THREAD
7/16-24 H7816-A
ISO Metri c fl are.
13mm WRENCH
RADIUS
OR THREAD
M12x 1 H7817-A
Tube to tube connecti on.
H7818-A
SAE doubl e 45 Union (repai r).
H7819-A
H y d r a u l i c S y s t e m B l e e d i n g
When any part of t he hydraul i c syst em has been
di sconnect ed for servi ce or repl acement, air may
enter the syst em causi ng a spongy pedal acti on. Bleed
t he hydraul i c syst em, after it has been properl y
connect ed, t o ensure that all air is expel l ed.
A n t i - L o c k B r a k e S y s t e m Bl e e d i n g
Ne w Ge n e r a t i o n STAR ( NGS) Te s t e r 007 - 00500
Anyti me servi ce is perf ormed on the ABS val ve bl ock
or pump and motor assembl y, a speci al bl eed
procedure must be fol l owed t o make sure no air is
t rapped in t he ABS control and modul ator assembl y. If
thi s procedure is not done, the customer coul d
experi ence a spongy pedal after he act uat es ABS.
Using the New Generation STAR (NGS) Tester:
(1) Bl eed entire syst em conventionally using a manual
or pressure bleed procedure as outlined.
(2) Hook up New Generati on STAR (NGS) Tester t o
the underdash serial dat a link connector as though
retrieving codes.
( 3) Make sure ignition is in the RUN posi ti on.
(4) Fol l ow i nstructi ons on t he NGS screen. Choose
correct vehi cl e and model year, go t o "Di agnost i c
Dat a Li nk" menu i tem, choose ABS Modul e,
choose "Funct i on Test s" , and choose "Ser vi ce
Bl eed" .
(5) The NGS will prompt you t o depress the brake
pedal . MAKE SURE YOU PUSH HARD ON THE
BRAKE PEDAL. You will need t o hold down the
brake pedal for approxi matel y 5 seconds whi l e
the NGS opens t he outlet val ves in the brake
pressure control val ve bl ock. When t he outlet
val ves are opened, you should i mmedi atel y feel
t he pedal drop. Make sure you push the pedal ALL
THE WAY TO THE FLOOR (very i mportant). The
NGS will then instruct you t o rel ease the brake
pedal . After you rel ease the brake pedal , t he NGS
will run t he ABS hydraul i c pump motor for
approxi mat el y 15 seconds.
(6) Repeat St ep (5) t o make sure all air is fl ushed from
t he ABS unit. Upon compl eti on, t he NGS will
di spl ay "Ser vi ce Bl eed Procedure Compl et ed" .
( 7) Repeat t he conventional syst em bleed using a
manual or pressure bl eed procedure as outlined.
Ma n u a l Bl e e d i n g
The pri mary and secondary (front and rear) hydraulic
brake syst ems are individual syst ems and are bled
separatel y. Bleed the longest line fi rst on the individual
syst em being servi ced. During the compl et e bleeding
operati on, DO NOT allow the brake master cylinder
reservoi r ( 2K478) t o run dry. Keep the master cylinder
reservoi rs filled wi th High Performance DOT-3 Brake
Fluid C6AZ- 19542- AA or DOT-3 equivalent meeting
Ford speci fi cati on ESA-M6C25-A. Never reuse brake
fluid that has been drai ned from the hydraulic syst em
or has been al l owed t o stand in an open container for
an ext ended peri od of ti me.
NOTE: Non-ABS vehi cl es have t he brake master
cylinder ( 2140) mounted at an angle t o the hori zontal ,
bleeding may be better performed if the vehicle is
posi ti oned so that t he brake master cylinder is
hori zontal .
1. To bl eed the brake syst em, position a suitable
box wrench on the bleeder fitting on the brake
wheel cylinder. At t ach a rubber drain tube t o the
bl eeder fi tti ng. The end of the tube should fit
snugly around the bleeder fi tti ng.
2. Submerge the free end of the tube in a contai ner
partially filled wi th cl ean brake fluid, and loosen
the bl eeder fitting approxi matel y three-quarters
of a turn.
3. Have an assi stant push the brake pedal ( 2455)
down sl owl y through its full t ravel . Cl ose t he
bl eeder fi tti ng, then return t he brake pedal t o
full-release posi ti on. Repeat thi s operati on until
air bubbl es cease t o appear at the submerged
end of the bleeder tube.
4. When the fluid is compl etel y free of air bubbl es,
secure the bleeder fitting and remove the bl eeder
tube.
5. Repeat this procedure at the brake wheel
cylinder on the opposi te si de. Refill the brake
master cylinder reservoi r after each wheel
cylinder is bl ed, and install the master cylinder
cap and gasket . Ensure the di aphragm-type
gasket is properl y posi ti oned in the master
cylinder cap. When t he bleeding operati on is
compl et ed, t he fluid level should be at t he MAX
line t o 4. 0 mm (0. 16 inch) bel ow.
6. If t he pri mary (front brake) syst em is t o be bl ed,
repeat St eps 2 through 5 at t he right front brake
cal i per and ending at the left front brake caliper.
Bleed the brake master cylinder at the bleed
screw after all cal i pers are bl ed.
7. After di sc brake servi ce, ensure that the di sc
brake pi stons are returned t o their normal
positions and the shoe and lining assembl i es are
properl y seat ed. This is accompl i shed by
depressi ng t he brake pedal several ti mes until
normal pedal travel is establ i shed.
8. Check pedal feel . If brake pedal feel s " spongy"
repeat bleed procedure, or use the Vacuum
method as outlined in Secti on 06- 09, but bl eed
both rear cal i pers fi rst.
SERVICE PROCEDURES (Conti nued) CLEANING AND INSPECTION
P r e s s u r e Bl e e d i n g
For pressure bleeding, use a bl adder-type bl eeder
tank only, such as Rotunda Brake Bl eeder 104- 00064
or equivalent.
Bleed the l ongest lines fi rst. The bleeder tank shoul d
contai n enough new brake fluid t o compl et e t he
bleeding operati on. Use High Performance DOT-3
Brake Fluid C6AZ- 19542- AA or DOT-3 equivalent fluid
meeting Ford speci fi cati on ESA-M6C25-A. Never
reuse brake fluid that has been drai ned f rom the
hydraulic syst em. The tank shoul d be charged wi th
approxi matel y 69- 206 kPa( 10-30 psi) of air pressure.
CAUTI ON: Ne v e r e x c e e d 3 4 4 kP a ( 50 psi )
p r e s s u r e .
1. Clean all di rt f rom t he master cyl i nder reservoi r
cover.
2. Remove t he brake master cyl i nder reservoi r
cover. Fill the master cyl i nder reservoi r wi t h t he
speci fi ed brake fluid. Install the pressure bl eeder
adapt er tool t o the brake master cyl i nder, and
at t ach t he bl eeder tank hose t o t he fitting on the
adapter. Mast er cylinder pressure bl eeder
adapt er tool s can be obtai ned f rom vari ous
manufacturers. Fol l ow t he i nstructi ons of the
manufacturer t o install t he adapter.
3. If the rear wheel cyl i nders (the secondary brake
syst em) are t o be bl ed, use a sui tabl e box wrench
on the bl eeder fitting at the right, rear brake
wheel cylinder. At t ach a bl eeder t ube snugly
around the bl eeder fi tti ng.
4. Open the val ve on the bl eeder tank t o admi t
pressuri zed brake fluid into t he brake mast er
cyl i nder reservoi r.
5. Submerge t he free end of t he tube in a contai ner
parti al l y filled wi th cl ean brake fluid, and l oosen
the bl eeder fitting.
6. When air bubbles cease t o appear in t he fluid at
the submerged end of t he bl eeder t ube, cl ose the
bl eeder fi tti ng. Remove t he tube. Repl ace rubber
dust cap on bleeder screw.
7. At t ach a bl eeder tube and repeat St eps 4, 5 and
6 at t he left rear caliper.
8. On front brakes, repeat St eps 4, 5 and 6 starti ng
at t he RH di sc brake cal i per ( 2B120) and ending
at the LH di sc brake cal i per.
9. When the bleeding operati on is compl et ed, cl ose
the bl eeder tank val ve and remove the t ank hose
f rom t he adapt er fi tti ng.
10. After di sc brake servi ce, ensure di sc br ake
pi stons are returned t o thei r normal posi ti ons and
the shoe and lining assembl i es are properl y
seat ed. Thi s is accompl i shed by depressi ng the
brake pedal several ti mes until normal pedal
travel is establ i shed.
11. Remove t he pressure bl eeder adapt er t ool f rom
brake master cylinder. Fill t he brake mast er
cyl i nder reservoi r t o the MAX line t o 4 mm ( 0. 16
i nch) bel ow. Install the brake mast er cyl i nder filler
c a p ( 2162) cap.
CAUTI ON: Bl i s t e r i n g o r s we l l i n g i n d i c a t e s
c o n t a mi n a t i o n o f b r a ke f l u i d b y a
p e t r o l e u m- b a s e d s o l v e n t o r o i l . I n t h a t c a s e , a l l
r u b b e r c o mp o n e n t s i n t h e b r a ke h y d r a u l i c s y s t e m
mu s t be i n s p e c t e d a n d r e p l a c e d , a n d t h e e n t i r e
s y s t e m mu s t b e f l u s h e d w i t h c l e a n b r a ke f l u i d t o
p r e v e n t r e c o n t a mi n a f i o n . Re pl a c e t h e f o l l o wi n g
c o mp o n e n t s :
Front brake cal i per seal s.
Front brake hoses ( 2078) .
Rear wheel br ake hoses ( 2A442) .
Mast er cyl i nder cap gasket .
Br ake pressure control val ves ( 2B091) .
1. Wash brake master cyl i nder body, especi al l y
bore, al ong wi th pri mary pi ston and secondary
pi ston assembl i es in cl ean brake fluid. Denatured
or i sopropyl alcohol can be used i nstead.
2. NOTE: The aluminum body of the brake master
cyl i nder ( 2140) i s anodi zed. Some si gns of bore
wear on t he anodi zed surf ace, as evi denced by
lighter areas of the anodi zed surface, are normal
and not detri mental .
Inspect seal s on pri mary and secondary pi ston
assembl i es for cut s, ni cks, scrat ches or signs of
wear and f or presence of any blistering or
swel l i ng.
3. CAUTI ON: Ho n i n g o f t h e b o r e o n a l u mi n u m
b r a ke ma s t e r c y l i n d e r s i s n o t p e r mi t t e d a s
t h e a n o d i c c o a t i n g a n d h a r d n e s s c o u l d b e
r e mo v e d .
Inspect brake master cylinder bore for pi tti ng,
corrosi on or heavy wear. Heavy wear is
charact eri zed by scori ng or galling of metal .
4. Repl ace if necessary.
B r a k e Lines a n d H o s e s
Inspect t he brake lines and hoses for cr acks, scar s or
other damage and repl ace if necessary.
B r a k e Fluid L e a k a g e
Appl y the brake pedal ( 2455) several ti mes and
i nspect for brake syst em l eakage.
Verify that the fluid level in the brake master cyl i nder
reservoi r ( 2K478) is between t he MAX and MIN lines.
Add brake fluid if the level is bel ow the MAX line.
ADJUSTMENTS
B r a k e B o o s t e r t o Ma s t e r C y l i n d e r Push R o d
The power brake boost er ( 2005) has an adj ustabl e
push rod (output rod) whi ch is used t o compensat e for
dimensional vari ati ons in an assembl ed power brake
booster. The push rod length is adj usted after each
power brake booster power unit has been assembl ed
in producti on. A properl y adj usted push rod that
remai ns wi thi n the power br ake boost er after it was
assembl ed in producti on shoul d never require a
servi ce adjustment.
A power brake boost er that is suspect ed of having an
i mproper push rod length will i ndi cate either of the
fol l owi ng:
A push rod whi ch is t oo long will prevent the brake
master cylinder pi ston f rom compl etel y releasing
hydraulic pressure and cause brakes t o dr ag.
A push rod whi ch is t oo short will i ncrease brake
pedal travel and cause a clunk or groani ng noise
f rom t he power brake boost er.
If necessary, a booster push rod length can be veri fi ed
wi t h a push rod gauge using t he fol l owi ng procedure:
GAUGE DIMENSIONS
76.2 mm (3 INCHES)-
31.75 mm
76.2 mm
(3 INCHES)
25.61 mm
(1.008 INCH)
MINIMUM
25.99 mm
(1.023 INCH)
1. Wi thout di sconnecti ng the brake tubes,
di sconnect the brake master cylinder ( 2140) and
set it away f rom the booster power unit. The
brake master cylinder must be support ed t o
prevent damagi ng the brake tubes.
2. If any booster output rod length adj ustment is
made, make sure that vacuum is appl i ed t o t he
booster check val ve.
3. Wi t h the engine idling, gauge and adjust the push
rod length. A f orce of approxi matel y 22 N (5 lb)
appl i ed t o the push rod wi th the gauge will ensure
t hat the push rod is seat ed wi t h the power brake
booster.
BOOSTER CHECK
VALVE 2365
ADJUST PUSH ROD SCREW TO
PROVIDE A SLIGHT PRESSURE
(APPROXIMATELY 22.24 N (5 LBS)
AGAINST THE GAUGE
POWER BRAKE
BOOSTER 2005
PUSH ROD ADJUSTMENT BENDIX *
H 1
87 1 -G
Install t he brake master cylinder on t he power
unit. Gradually al ternate the tightening of the
retaining nuts t o 21-29 N-m (16-21 Ib-ft).
MAXIMUM
H6S45-C
SPECIFICATIONS
CONTROL VALVE SPECIFICATIONS
De sc r i pt i on Type
Pressure
Di f f erent i al Met er i ng
Pr opor t i oni ng
Spl i t / Sl o pe
Wi t h A BS Wi t h Tr a c t i o n Co n t r o l Re mo t e No No 300 ( 0. 43)
Wi t h A BS L e s s Tr a c t i o n Co n t r o l : No n A BS Ma s t e r Cy l i n d e r No No 300 ( 0. 43)
06- 06- 13 Br a k e S y s t e m, Hy d r a u l i c 0 6 - 0 6 - 1 3
Wi t h ABS Wi t hout ABS
Description N-m Lb-Ft Lb-Ft
Ma s t e r Cy l i n d e r t o Bo o s t e r 2 1- 2 9 16- 2 1

Bo o s t e r t o Da s h P a n e l 2 1- 2 9 16- 2 1

Wh e e l Cy l i n d e r Bl e e d e r S c r e w 10- 2 0 7 . 5- 15

Ca l i pe r Bl e e d e r S c r e w 8- 2 0 6- 15 8- 2 0 6- 15
Br a ke Ho s e Co n n e c t i o n t o Ca l i p e r 40- 60 30- 45 40- 60 30- 45
Hy d r a ul i c Tube Co n n e c t i o n s
a
Al l 14- 2 0 10- 15 14- 2 0 10- 15
3 / 8 x 2 4

14- 2 0 10- 15
Br a ke P e d a l Pi v o t Sha f t Nut 14- 2 7 10- 20
P r e s s u r e Co n t r o l Va l v e - t o - Ma s t e r Cy l i n d e r Ho u s i n g

13- 2 4 10- 18
P r o p o r t i o n i n g Va l v e Br a c k e t - t o - Ma s t e r Cy l i n d e r 19- 2 6 14- 19
_
St o p Bo l t - t o - Ma s t e r Cy l i n d e r Ho u s i n g

1-4 9- 35
( L b- l n )
P e d a l Su p p o r t Br a c ke t - t o - Co wl Nut 18- 2 7 13- 20
_
Wh e e l Hub Bo l t Nut 115- 142 85- 105

a Al l h y d r a u l i c l i n e s must b e t i g h t e n e d t o t h e s p e c i f i c t o r q u e v a l u e a n d b e f r e e o f f l ui d l e a ka g e .
D81L - 2 2 69- A Br a ke L i n e Fl a r i n g To o l
D81L - 600- A L b - l n To r q u e Wr e n c h
ROTUNDA EQUIPMENT
104- 00064 Br a ke Bl e e d e r
06- 07 - 1 Br a ke S y s t e m, P o we r 06- 07 - 1
SECTION 06-07 Brake System, Power
SUBJECT PAGE
Brake Booster, Power. . 06-07-1
Brake System, Power 06-07-1
Brake Booster Check Valve...... ..06-07-2
Brake Booster, Power ...06-07-1
SUBJECT PAGE
Vacuum Hose and Check Valve 06-07-3
ADJUSTMENTS
Brake Booster to Master Cylinder Push
Rod. . . . . .06-07-3
SPECIFICATIONS ....06-07-4
VEHICLE APPLICATION
Brake Booster, Power
I MMEDI ATELY.
The di aphragm-type brake power brake booster
( 2005) :
Brake System, Power
Brake Booster, Power
Removal
2. Exhaust residual vacuum by appl yi ng brake pedal
( 2455) four t o fi ve ti mes.
3. Remove brake master cylinder ( 2140) f rom
power brake booster ( 2005) . Set it asi de wi thout
di sturbi ng hydraul i c lines. It is not necessary t o
di sconnect brake lines, but be careful not t o kink
brake lines. Kinking of brake lines can lead t o
tube damage.
4. Di sconnect manifold vacuum hose f rom power
brake boost er check val ve ( 2365) .
Is sel f-contai ned.
Is mounted on the engine side of the dash panel .
Uses engine i ntake manifold vacuum and
atmospheri c pressure for its power.
Adj ustment of t he push rod (non-ABS only) and
repl acement of t he check val ve are the only
servi ces permi tted on the power brake booster.
Must be repl aced wi th a new power brake boost er if
it becomes damaged or i noperati ve.
5. Worki ng inside vehi cl e bel ow instrument panel
( 04320) , remove stopl i ght swi t ch connector.
Remove stopl i ght swi t ch retaining pin. Slide
stoplight swi t ch ( 13480) off f rom brake pedal pin
just far enough f or outer plate of stoplight swi t ch
t o cl ear pin. Then remove stopl i ght swi t ch f rom
pin. Be careful not t o damage stopl i ght swi t ch
during removal .
6. Remove booster-to-dash panel retaining nuts.
Slide booster push rod and brake master cylinder
push rod bushing ( 2474) off brake pedal pin.
7. Remove power brake booster f rom dash panel by
sliding push rod out f rom engine si de of dash
panel ( 01610) .
Power Brake Syst em
Pa r t
2 2B180 Brake Pedal Support
Mounting Spacer
3 01508 Pedal Support Bracket
4 385759-S2 Nut (4 Req'd)
5 N606689-S2 Bolt
6 01610 Dash Panel
7 2140 Brake Master Cylinder
8 13480 Stoplight Switch
Pa r t
9 380699-S100 Retainer Clip
10

Push Rod Assy (Part of
2005)
11 2474 Brake Master Cylinder Push
Rod Bushing
12 2B129 Brake Master Cylinder Push
Rod Spacer
A

Lb-Ft)
B

Lb-Ft)
1. Pl ace power brake boost er in position on dash
panel .
2. Worki ng inside vehi cl e, posi ti on boost er push rod
and brake master cylinder push rod bushing on
brake pedal pin. Secure power brake boost er t o
dash panel wi t h self-locking nuts. Tighten t o
21- 29 N-m (16-21 Ib-ft).
3. Position stopl i ght swi t ch so t hat it st raddl es
boost er push rod wi t h swi t ch slot t owar d pedal
bl ade and hole just cl eari ng pi n. Slide stopl i ght
swi t ch compl etel y onto pin. Be careful not t o bend
or deform stopl i ght swi t ch.
4. Install brake mast er cylinder push rod spacer
( 2B129) on pin and secure all part s t o pin wi t h
hairpin retainer. Make sure retainer is fully
installed and l ocked over pedal pin. Install
stopl i ght swi t ch wiring connect or on stopl i ght
swi t ch.
5. Connect manifold vacuum hose t o power brake
boost er check val ve using hose cl amp.
6. Install brake master cyl i nder-to-booster studs.
Tighten retaining nuts t o 21-29 N-m (16-21 Ib-ft).
7. Connect bat t ery ground cabl e. Start engine and
check power brake functi on.
B r a k e B o o s t e r C h e c k Va l v e
Re mo v a l
1. NOTE: The power brake booster check valve
( 2365) is pressed into the hose. An arrow on the
hose i ndi cates the di recti on of vacuum fl ow.
Di sconnect t he check valve vacuum hose f rom
t he vacuum outlet manifold ( 9C490) .
2. Remove power brake booster check valve f rom
power brake boost er ( 2005) .
1. Install power brake booster check val ve into
power brake boost er.
2. Connect c he c k val ve vacuum hose t o vacuum
out l et mani f ol d.
Vacuum Hose and Check Valve
1. Di sconnect t he vacuum hose.
2. Inspect t he hose f or c ut s, abrasi ons and c r a c ks.
3. Appl y bot h vacuum and pr essur e on t he engi ne
si de of t he hose.
4. Veri f y t hat t he ai r f l ows only t o wa r d t he engi ne.
5. NOTE: An a r r o w on t he h o s e / power br a ke
boost er c he c k val ve ( 2365) assembl y i ndi cat es
t he c or r e c t ori ent at i on of hose i nst al l at i on.
If repl acement i s necessar y , repl ace t he hose and
powe r br ake boost er c he c k val ve as an
assembl y.
ADJUSTMENTS
B r a k e B o o s t e r t o Ma s t e r C y l i n d e r P u s h R o d
The vacuum powe r br a ke boost er ( 2005) on non-ABS
vehi cl es has an adj ust abl e push r od (out put r od) whi c h
is used t o c ompe nsa t e f or di mensi onal vari at i ons in an
assembl ed power br a ke boost er . The push r od l engt h
i s adj ust ed af t er e a c h powe r br a ke boost er has been
assembl ed in pr oduct i on. A pr oper l y adj ust ed push r od
t hat remai ns assembl ed t o t he powe r br ake boost er
wi t h whi c h it wa s ma t c he d in product i on shoul d never
requi re a ser vi ce adj ust ment .
A powe r br a ke boost er t hat is suspect ed of havi ng an
i mproper push r od l engt h wi ll i ndi cat e ei t her of t he
f ol l owi ng:
CAUTI ON: Do n o t a d j u s t t o o l o n g o r b r a ke d r a g
c o u l d r e s u l t .
A push r od t hat i s t o o l ong wi ll prevent t he br a ke
mast er cyl i nder pi st on f r o m compl et el y rel easi ng
hydraul i c pr essur e, causi ng t he br a ke s t o d r a g.
A push r od t hat is t oo shor t wi ll i ncrease br a ke
pedal t ravel and cause a groani ng noi se t o c ome
f r om t he power br ake boost er .
NOTE: A l ocal l y-made push r od gauge of t he f ol l owi ng
di mensi ons must be used.
GAUGE DIMENSIONS
- 7 6. 2 mm (3 INCHES)-
31.75 mm
76.2 mm
(3 INCHES)
25.61 mm
(1.008 INCH)
MINIMUM
25.99 mm
(1.023 INCH)
MA X I MU M
H6945-C
If necessar y, boost er push rod l engt h can be veri f i ed
wi t h a push r od gauge by usi ng t he f ol l owi ng
pr ocedur e:
1. Wi t hout di sconnect i ng t he br a ke t ubes,
di sconnect t he br ake mast er cyl i nder ( 2140) , and
move it a wa y f r om t he power br ake boost er . The
br ake mast er cyl i nder must be suppor t ed t o
prevent damagi ng t he br ake t ubes.
2. Wi t h t he engi ne runni ng, gauge and adj ust t he
push r od l engt h f r om t he knurl ed ar ea. A f or c e of
appr oxi mat el y 22 N (5 lb) appl i ed t o t he push r od
wi t h t he gauge wi ll ensure t hat t he push r od is
seat ed wi t hi n t he powe r br ake boost er .
3. Install the brake mast er cyl i nder on t he power
brake boost er. Gradual l y al ternate tightening t he
retaining nuts t o 21-29 N-m ( 16- 21 Ib-ft). Refer t o
Section 06- 06.
SPECIFICATIONS
P o we r Br a ke Bo o s t e r - t o - Da s h
Pa n e l Re t a i n i n g Nut
2 1- 2 9 16- 2 1
Br a ke Ma s t e r Cy l i n d e r - t o - P o we r
Br a ke Bo o s t e r L o c ki n g Nu t s
2 1- 2 9 16- 21
P e d a l Su p p o r t Br a c k e t - t o - Da s h
Pa n e l Bo l t
17-27 14- 2 0
06- 09- 1 Br a ke S y s t e m, A n t i - L o c k 06- 09- 1
SECTION 06-09 Brake System, Anti-Lock
SUBJECT PAGE
Brakes, Ant i -Lock .......06-09-5
Brake Booster, Power ...06-09-2
Brake Master Cyl i nder 06-09-2
Brake Master Cyl i nder and Brake Fluid Level
Swi tch..... 06-09-2
Brake Sensor, Anti -Lock 06-09-4
Brake Syst emAnt i -Lock 06-09-1
Component Locati on 06-09-6
Control Modul e, Anti-Lock Brake.... 06-09-4
Hydraul i c Cont r ol Uni t (HCU) 06-09-2
Hydraulic Schemati c 06-09-3
Tract i on Assi st 06-09-1
On-Board Di agnost i cs 06-09-10
Warni ng Lamp I ndi cat ors 06-09-10
Li nk Communi cat i on, Modul e Not
Respondi ng 06-09-11
SUBJECT PAGE
Qui ck Test s ...06-09-12
Sy mpt om Chart ...06-09-14
Brake Boost er, Power 06-09-25
Brake Mast er Cyl i nder wi t h Fl ui d Level Swi t ch
Reservoi r .06-09-26
Brake Sensors 06-09-26
Cont r ol Modul e, Ant i -Lock Brake. . . . 06-09-26
Cont r ol Valve, Brake Pressure 06-09-26
Hydraul i c Cont r ol Unit (HCU) 06-09-25
Sensor I ndi cat or, Ant i -Lock Br ake. . 06-09-28
ADJUSTMENTS
Brake Mast er Cyl i nder Reservoi r Checki ng and
Fi l l i ng 06-09-28
Brake Syst em Bl eedi ng 06-09-28
VEHICLE APPLICATION
Town Car, Cr own Vi c t or i a , Grand Marqui s
Brake SystemAnti -Lock
I MMEDI ATELY.
The Town Car is equi pped wi t h 4-wheel ant i -l ock
br a ke sy st e m (ABS) wi t h t r act i on assi st (TA) a s
st a nda r d equi pment .
The Cr own Vi c t or i a / Gr and Marqui s of f er s ABS *
t oget her wi t h t r a c t i on assi st a s an opt i on.
The ant i -l ock br a ke sy st e m:
Prevent s wheel l ock-up by aut omat i cal l y modul at i ng
br ake pr essur e duri ng an emergency st op by not
l ocki ng t he wheel s.
Dri ver can mai ntai n st eeri ng cont rol and st o p
vehi cl e in shor t est possi bl e di st ance under most
condi t i ons.
Duri ng ABS oper at i on, dri ver wi ll sense a pul sat i on
in t he br a ke pedal ( 2455) accompani ed by a sl i ght
up and down movement of pedal hei ght and a
cl i cki ng sound.
i Pedal f eel and pedal ef f ort wi ll be si mi lar t o a
convent i onal power br a ke sy st e m.
J Duri ng accel er at i on, if one or bot h rear wheel s l ose
t r act i on and begi n t o spi n, t he TA sy st e m wi ll rapi dl y
appl y and rel ease t he appr opr i at e rear br ake(s).
The i sol at i on val ve will al so cl ose and t he pump
mot or ( 2C256) wi ll run. The i solat i on val ve permi t s
br ake operat i on only t o t he rear br ake ci rcui t by
cl osi ng off t he ret urn pat h t o t he br ake mast er
cyl i nder ( 2140) .
Traction Assist
Tract i on assi st (TA) is desi gned t o cont rol wheel spi n
when accel er at i ng on sl i ppery or l oose sur f a c e s.
The t r act i on assi st sy st e m moni t ors br a ke usage t o
prevent br a ke over heat i ng. It ope r a t e s at vehi cl e
spe e ds up t o a ppr oxi ma t e l y 55 k m/ h ( 34 mph).
The TA sy st e m ope r a t e s a s f ol l ows:
06- 09- 2
If t he brakes are appl i ed during TA operati on, t he
anti-lock brake module ( 2C219) recei ves a signal
f rom the stopl i ght swi t ch ( 13480) and automati cal l y
st ops TA cycl i ng.
If t he tracti on assi st syst em is used continually on
sl i ppery roads, t he anti-lock brake module may shut
off the syst em t o prevent overheati ng of the rear
brakes.
Syst em cycl i ng is moni tored by the anti-lock brake
module. Thi s information is st ored in the keep-alive
memory.
The ABS/ TA consi st s of t he fol l owi ng major
components:
Power brake boost er ( 2005) and brake mast er
cyl i nder assembl y.
Brake pressure control val ve bl ock ( 2C266) .
Pump motor.
Anti-lock brake modul e.
Front brake anti-lock sensor ( 2C204) / rear brake
anti-lock sensor ( 2C190) .
B r a k e B o o s t e r , P o w e r
The di aphragm-type power brake booster ( 2005) :
Is self-contained and is mounted on the engine
compart ment si de of the dash panel ( 01610) .
Uses engine i ntake manifold vacuum and
at mospheri c pressure f or its power.
Must be repl aced wi t h a new power brake booster if
it becomes damaged or i noperati ve.
Is servi ced only as an assembl y (excl udi ng the
power brake boost er check val ve ( 2365) ) .
The br ake master cyl i nder ( 2140) is a Tandem master
cylinder.
The ABS only brake master cyl i nder uses a brake
pressure control val ve ( 2B091) in the pri mary (rear)
circuit t o control hydraul i c pressure t o t he rear
brakes. The secondary ci rcui t (front) supplies t he
front brakes. The brake pressure control val ve is
servi ced separatel y.
The ABS, tracti on assi st brake master cyl i nder
does not use a brake pressure control val ve. The
pri mary (rear) ci rcui t suppl i es t he front brakes. The
secondary circuit suppl i es t he rear brakes.
B r a k e Ma s t e r C y l i n d e r a n d B r a k e Fl u i d L e v e l
S w i t c h
The brake mast er cyl i nder reservoi r ( 2K478) is a cl ear
transl ucent pl asti c contai ner:
, A n t i - L o c k 06- 09- 2
m - w m . ?E" T~
e An i ntegral fluid level swi t ch is part of t he br ake
mast er cyl i nder reservoi r assembl y.
The brake master cyl i nder reservoi r and br ake
mast er cyl i nder filler cap ( 2162) are servi ced
separat el y.
BRAKE MASTER CYLINDER
RESERVOIR 2K478
H8955-A
J
H y d r a u l i c C o n t r o l Un i t ( HCU)
The anti-lock brake hydraulic control unit is l ocated
and operat es as fol l ows:
HCU is l ocated in the front of t he engine
compartment on the LH side bel ow the engine air
cleaner ( ACL) ( 9600) .
It consi sts of a brake pressure control val ve bl ock
(2C266), pump motor ( 2C256) , and anti-lock brake
control module ( 2B373) .
Operati on of the anti-lock brake control module is as
fol l ows:
During normal braki ng, fluid f rom the brake master
cylinder ( 2140) enters through t wo inlet port s at the
top of the pump motor.
The fluid then passes through t hree normally open
inlet val ves, one for each front brake and one f or the
rear brakes (except vehi cl es equi pped wi t h TA,
whi ch has four normally open inlet val ves so t he
rear brakes can be operat ed i ndependentl y).
If the anti-lock brake module ( 2C219) senses t hat a
wheel is about t o l ock, the anti-lock brake control
module cl oses the appropri ate inlet. This prevents
any more fluid from entering the af f ect ed brake.
Br a ke S y s t e m
-zmrrrzr.- : * zr
The ant i -l ock br ake modul e t hen l ooks at t hat wheel
agai n. If it i s sti ll decel er at i ng, t he ant i -l ock br ake
modul e opens t he normal l y cl osed out l et val ve
whi ch de c r e a se s pr essur e by dumpi ng flui d t o a l ow
pr essur e accumul at or in t he pump mot or .
The pump mot or t hen pumps t he flui d in t he
accumul at or back t o t he br a ke mast er cyl i nder.
Thi s pr oduces t he moder at e pul sat i ons in t he br a ke
pedal ( 2455) .
The t r act i on assi st br a ke pr essur e cont rol val ve
bl ock cont ai ns an e x t r a set of inlet and out l et val ves
f or Tract i on Assi st (TA) f unct i on. Ther e is an
i sol at i on val ve f or t he rear ci rcui t . The i sol at i on
val ves cl ose duri ng t r act i on assi st operat i on t o
al l ow t he pump mot or t o bui ld pr essur e t o t he rear
wheel s rat her t han ret urni ng br a ke f lui d t o t he br a ke
mast er cyl i nder.
The br ake pr essur e cont r ol val ve bl ock f or A BS/ T A
cont ai ns a val ve t o al l ow flui d t o be dr a wn f r om t he
br a ke mast er cyl i nder f or t r act i on assi st f unct i on.
The br a ke pr essur e cont r ol val ve bl ock, pump
mot or , and ant i -l ock br a ke modul e ar e ser vi ced
separ at el y. Ot her t han ga ske t s, no i nt ernal par t s
can be ser vi ced.
BRAKE PRESSURE
CONTROL VALVE BLOCK 2C266
PUMP MOTOR 2C256
ANTI-LOCK BRAKE MODULE 2C219
BRAKE TUBES
H8956-A
The ABS onl y ant i -l ock br a ke cont r ol modul e, br a ke
pr essur e cont r ol val ve bl ock and pump mot or (Town
Car Onl y) a r e physi cal l y di f f erent t han t he ABS wi t h
t r a c t i on assi st ant i -l ock br a ke cont r ol modul e, br a ke
pr essur e cont r ol val ve bl ock and pump mot or .
The ABS only br ake pr essur e cont rol val ve bl ock is
f our i nches long and has onl y t hr ee out l et t ube
por t s. The ABS only pump mot or is appr oxi mat el y
t hr ee i nches tall and bot h inlet t ube por t s are at t he
same l evel . The inlet por t is 3 / 16.
The ABS/ Tr a c t i o n Assi st br a ke pr essur e cont rol
val ve bl ock is si x i nches long and has f our out l et
t ube por t s. The ABS/ Tr a c t i o n Assi st pump mot or is
appr oxi mat el y f our i nches tall and has one t ube inlet
por t one i nch above t he ot her por t .
The ABS/ Tr a c t i o n Assi st br ake pressure cont rol
val ve bl ock uses a l arger di amet er t ube ( 6. 35 mm
( 0. 250 i nch)) f r om t he br a ke mast er cyl i nder t o t he
pump mot or assembl y.
H y d r a u l i c S c h e m a t i c
ABS wi t h Tr a c t i o n Assi st
PRIMARY CIRCUIT (FRONT BRAKES)
BRAKE BOOSTER
'2005
BRAKE MASTER
CYLINDER 2140
2B091
BRAKE PRESSURE
CONTROL VALVE
BRAKE
PRESSURE
CONTROL
VALVE BLOCK
2C266
/
6 6 |
E J -
RIGHT
FRONT
LEFT
FRONT
RIGHT
REAR
LEFT
REAR
PUMP MOTOR 2C256
H
9028-A
06- 09 - 4 Br a ke S y s t e m, A n t i - L o c k 06- 09- 4
ABS Onl y
2B091 BRAKE PRESSURE CONTROL VALVE
2005 BRAKE BOOSTER
2140 BRAKE MASTER
CYLINDER
PRIMARY CIRCUIT
" (FRONT BRAKES)
SECONDARY CIRCUIT
(REAR BRAKES)
}
RIGHT
~ FRONT
1_ LEFT
3
FRONT
] - REAR
H9029-A
Control Module, Anti -Lock Brake
The anti-lock brake modul e ( 2C219) is l ocat ed bel ow
t he brake pressure cont rol val ve bl ock ( 2C266) .
It is an on-board di agnosti c non-repairable unit
consi sti ng of t wo mi croprocessors and the necessary
ci rcui try for thei r operat i on. The anti-lock brake
module moni tors syst em operati on during normal
driving as well as during anti-lock braki ng (and tracti on
assi st cycl i ng, if equi pped).
Anti-lock brake modul e operati on is as f ol l ows:
Under normal driving condi ti ons, t he
mi croprocessors produce short t est pulses t o t he
sol enoi d val ves t hat check t he el ectri cal syst em
wi thout any mechani cal reacti on.
Impending wheel l ock condi ti ons tri gger si gnal s f r om
t he anti-lock br ake modul e that open and cl ose t he
appropri ate sol enoi d val ves.
When the pump mot or ( 2C256) st art s t o run, t he
dri ver may hear some noise and will feel moderat e
pulsations in t he br ake pedal ( 2455) .
During normal braki ng, t he brake pedal feel will be
identical t o a st andard brake syst em.
During tracti on assi st operati on, t he anti-lock brake
module operat es as fol l ows:
During accel erat i on, if one or bot h rear wheel s lose
t ract i on or begin t o spi n, the anti-lock brake module
will cl ose t he isolation val ves and operat e the pump
mot or. If the dri ver appl i es the brakes during
cycl i ng, the syst em will automati cal l y shut off.
The anti-lock brake module moni tors tracti on assi st
usage and will shut off t he tracti on assi st f eat ures t o
prevent overheati ng of the rear brakes.
If t he syst em shuts off, there is a cool down peri od
requi red before it becomes functional agai n. Thi s
cool down peri od vari es depending on brake usage
during the cool down peri od.
Anti -l ock braki ng is still fully functional during t he
cool down peri od.
Most malfunctions whi ch occur t o the anti-lock
brake syst em and the tracti on assi st will be st ored
as a di agnosti c troubl e code (DTC) in the keep-alive
memory of t he anti-lock brake modul e. DTC(s) can
be retri eved by following the on-board di agnosti c
procedures. Refer t o Di agnosi s and Testi ng.
Brake S e n s o r , A n t i - L o c k
The anti-lock brake syst em uses four set s of
vari abl e-rel uctance anti-lock brake sensors t o
determi ne the rotati onal speed of each wheel The
front brake anti-lock sensors ( 2 C2 04) / rear brake
anti-lock sensors ( 2C190) operat e on magnetic
induction principle. As the teeth on t he brake anti-lock
sensor i ndi cators rotate past the stati onary brake
anti-lock sensors, a signal proporti onal t o the speed of
the rotati on is generated and sent t o t he anti-lock
brake control module ( 2B373) through a t wi st ed pair
harness.
Fr o n t
The front br a ke ant i -l ock sensors ar e at t ached t o the
front wheel spindles ( 3105) . The front brake anti-lock
sensor i ndi cators (2C182) are pressed onto the wheel
hub ( 1104) assembl i es.
Re a r
The rear brake anti-lock sensors are at t ached t o the
rear wheel di sc brake adapt ers ( 2C220) and t he rear
brake anti-lock sensor i ndi cat ors ( 2C189) are pressed
onto t he axl e shafts ( 4234) .
An t i Lo c k Br a ke Se nsor I nst a l l a t i on
FRONT
REAR
H7389-D
I t em
Par t
Nu mb e r Descr i pt i on I t e m
Pa r t
1 2C204 Front Brake Anti -Lock 7 388835 Screw
Sensor 8 2C026 Rear Disc Brake Rotor
2 2B120 Disc Brake Caliper 9 N803961-S100 Screw
3 2C182 Front Brake Anti -Lock 10 2C190 Rear Brake Anti-Lock
Sensor Indicator Sensor
4 1125 Front Disc Brake Rotor 11 N605520-5428 Screw
5 1104 Wheel Hub A

Tighten to 4.5-6.8 N-m (40-60
6 3105 Front Wheel Spindle Assy Lb-ln)
B r a k e s , A n t i - L o c k
Ant i -l ock br a ke sy st e m (ABS) ope r a t e s a s f ol l ows:
When t he br a ke s are appl i ed, flui d i s f o r c e d f r om
t he br ake mast er cyl i nder out l et por t s t o t he inlet
po r t s.
Thi s pr essur e is t r ansmi t t ed t hr ough f our normal l y
open sol enoi d val ves cont ai ned i nsi de t he br a ke
pr essur e cont r ol val ve bl ock ( 2C266) , t hen t hr ough
t he out l et po r t s of t he br a ke pr essur e cont r ol val ve
bl ock t o e a c h wheel .
If t he ant i -l ock br a ke cont r ol modul e ( 2 B37 3)
senses t hat a wheel is about t o l ock, ba se d on
sensor d a t a , it c l ose s t he normal l y open sol enoi d
val ve f or t hat ci rcui t . Thi s prevent s any mor e flui d
f r om ent eri ng t hat ci rcui t .
The ant i -l ock br a ke modul e ( 2C219) t hen l ooks at
t he sensor si gnal f r om t he af f ect ed wheel agai n.
If t hat wheel i s sti ll decel er at i ng, it opens t he
normal l y c l ose d sol enoi d val ve f or t hat ci rcui t . Thi s
dumps any pr essur e t hat is t r a ppe d be t we e n t he
normal l y open val ve and t he br a ke ba c k t o t he
accumul at or.
Once t he af f ect ed wheel comes back up t o spe e d,
t he ant i -l ock br a ke modul e ret urns t he val ves t o
t hei r normal condi t i on al l owi ng flui d f l ow t o t he
af f ect ed br ake.
The ant i -l ock br ake modul e moni t ors t he
el ect romechani cal component s of t he sy st e m.
Mal f unct i on of t he ant i -l ock br ake sy st e m wi ll cause
t he ant i -l ock br ake modul e t o shut off or inhibit t he
sy st e m. However, normal power assi st ed braki ng
remai ns.
Mal f unct i ons ar e i ndi cat ed by t he ant i -l ock warni ng
i ndi cat or i nsi de t he vehi cl e.
The 4-wheel ant i -l ock br ake sy st e m is self
moni t ori ng. When t he ignition swi t c h ( 1157 2) i s
pl aced in t he RUN posi t i on, t he ant i -l ock br a ke
modul e wi ll per f or m a prel i mi nary sel f -check on t he
ant i -l ock el ect ri cal sy st e m i ndi cat ed by a one t o
t wo-se c ond illumination of t he amber ANTI -LOCK
BRAKE i ndi cat or in t he i nst rument cl ust er ( 10849) .
Duri ng vehi cl e oper at i on, i ncludi ng normal and
ant i -l ock br aki ng, t he ant i -l ock br ake modul e
moni t ors all el ect ri cal ant i -l ock f unct i ons and some
hydraul i c oper at i ons.
Each t i me t he vehi cl e is dri ven, a s soon as vehi cl e
speed r eaches appr oxi mat el y 2 0 k m/ h (13 mph),
t he ant i -l ock br a ke modul e t urns on t he pump mot or
(2C256) f or appr oxi mat el y one-half se c ond. At t hi s
t i me a mechani cal noi se may be hear d. Thi s is a
normal f unct i on of t he sel f -check by t he ant i -l ock
br ake cont rol modul e.
In most mal f unct i ons of t he ant i -l ock br a ke / t r a c t i o n
assi st sy st e m, t he amber ANTI -LOCK BRAKE wi l l
be i l l umi nat ed.
Most mal f unct i ons ar e r e c o r d e d a s a di agnost i c
t roubl e c o d e ( DTC) in t he ant i -l ock br a ke modul e
memor y and a ssi st in pi npoi nt i ng t he component
needi ng ser vi ce.
C o m p o n e n t L o c a t i o n
ABS component l ocat i on i s shown in t he f ol l owi ng
i l l ust rat i on.
H6S48-D
Pa r t Pa r t
1 2C189 Rear Brake Anti-Lock 6 2C204 Front Brake Anti-Lock
Sensor Indicator Sensor
2 4234 Axle Shaft
Sensor Indicator
Sensor 8 3105 Front Wheel Spindle
4

Brake Lines
9 1125 Front Disc Brake Rotor
5

Anti -Lock Brake Hydraulic
Control Unit
0
6
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(m~m~8 mm gy s t t o m, A n t i - L o c k
- 9- 8
HOT AT ALL TIMES
SHORTING
CAP
DATA LINK
CONNECTOR
RE A R
of this circuit
TOWN CAR
Pin
N u m b e r C i r c u i t Ci rcui t Funct i on
1 5 3 3 ( T / R) Ba t t e r y P o we r
2 533 ( T / R) Ba t t e r y P o we r
3 No t Us e d
4

No t Us e d
5 52 1 ( T / O) L H Fr o n t Wh e e l S p e e d Se n s o r
6 52 2 ( T / BK) L H Fr o n t Wh e e l S p e e d Se n s o r
7 5 1 4 ( Y / R ) RH Fr o n t Wh e e l S p e e d Se n s o r
8 516
( Y / B K )
RH Fr o n t Wh e e l S p e e d Se n s o r
9 5 18
( L G / R )
LH Re a r Wh e e l S p e e d Se n s o r
10 519
( L G / B K )
LH Re a r Wh e e l S p e e d Se n s o r
11 52 3
( R / P K )
RH Re a r Wh e e l S p e e d Se n s o r
12 52 4
( P K / B K )
13 530
( L G / Y)
Gr o un d
H8973-A
TOWN CAR (Cont 'd)
Pin
14 530A
( L G / Y)
Gr o un d
15 532
( L B / P K )
I gn i t i o n Fe e d
16

Not Us e d
17 Not Us e d
18 Not Us e d
19

Not Us e d
2 0 511 ( LG) Br a ke L a mp Swi t c h I nput
2 1 603 ( DG) A BS Wa r n i n g L a mp
2 2 57 V ( BK) Wh e e l Sp e e d Se n s o r Gr o un d
2 3 Not Us e d
2 4 No t Us e d
2 5 Not Us e d
2 6

No t Us e d
2 7 Not Us e d
2 8 7 0B
( L B / W)
Di a gn o s t i c Da t a Li nk
P i n
1 601
( L B / P K )
Ba t t e r y P o we r
2 601
( L B / P K )
Ba t t e r y P o we r
CROWN VICTORIA, GRAND MARQUIS (Cont 'd)
Pin
3 No t Us e d
4

No t Us e d
5 52 1 ( T / O) LH Fr o n t Wh e e l Sp e e d Se n s o r
( Co n t i n ue d )
CROWN VICTORIA, GRAND MARQUIS (Cont' d)
Pin
6 52 2 ( T / BK) L H Fr o n t Wh e e l S p e e d Se n s o r
7 5 1 4 ( Y / R ) RH Fr o n t Wh e e l S p e e d S e n s o r
8 516
( Y / B K )
RH Fr o n t Wh e e l S p e e d S e n s o r
9 518
( L G / R )
L H Re a r Wh e e l S p e e d S e n s o r
10 519
( L G / B K )
L H Re a r Wh e e l S p e e d Se n s o r
11 52 3
( R / P K )
RH Re a r Wh e e l S p e e d S e n s o r
12 52 4
( P K / B K )
13 57 ( BK) Gr o un d
14 5 7 ( B K ) Gr o un d
15 88 ( B K / W) 12 Vo l t I gn i t i o n Fe e d
16 No t Us e d
17 No t Us e d
18 No t Us e d
19 No t Us e d
20 511 ( L G) Br a ke L a mp S wi t c h I nput
21 603 ( DG) A BS Wa r n i n g L a mp
22 57 ( BK) Wh e e l S p e e d Se n s o r Gr o u n d
2 3 No t Us e d
24 No t Us e d
25 No t Us e d
26 No t Us e d
27 No t Us e d
28 7 0 ( L B / W) Di a gn o s t i c Da t a Li n k
Wa r n i n g L a m p I n d i c a t o r s
The anti-lock brake syst em uses t wo warni ng
i ndi cators t o alert the dri ver of malfunctions in the
syst em.
The red BRAKE warni ng i ndi cator will come on for only
t wo reasons:
1. If the brake fluid level in the brake mast er cylinder
reservoi r ( 2K478) falls bel ow t he level whi ch is
determi ned by t he set point of t he fluid level
swi t ch (FLS).
2. If the parki ng brake is appl i ed.
The amber CHECK ANTI-LOCK BRAKE warni ng
indicator will come on for numerous reasons. It warns
the dri ver that t he ABS and tracti on-assi st have been
turned off due t o a sympt om that exi st s in the syst em.
Normal power-assi st ed braki ng remai ns but the
wheel s can l ock duri ng a panic st op whi l e the indicator
is on. Certai n procedures must be f ol l owed t o find the
fault in thi s si tuati on. They are expl ai ned in thi s
secti on.
Ensure t he di agnosti c procedures are f ol l owed
step-by-step in order as i ndi cated.
WARNI NG: FOL L OWI NG THE WRONG SEQUENCE
OR BYPASSI NG STEPS WI LL L E A D TO
UNNECESSARY REPLACEMENT OF PARTS,
A N D/ OR I NCORRECT RESOLUTI ON OF THE
SYMPTOM.
O n - B o a r d Di a g n o s t i c s
The anti-lock br ake/ t r act i on assi st syst em anti-lock
brake module ( 2C219) is capabl e of performi ng an
on-board di agnosti c using Rotunda New Generation
Star (NGS) Tester.
The anti-lock br ake module moni tors syst em operati on
and can st ore all defi ned di agnosti c troubl e codes in its
memory. It is i mportant t o understand t hat the anti-lock
brake module CANNOT recogni ze some failures.
Theref ore if a sympt om exi sts and no di agnosti c
troubl e codes ar e st ored by the anti -l ock brake
module, other di agnosti c st eps must be fol l owed.
The anti-lock brake module cannot st ore a di agnosti c
troubl e code if t here is no power t o the anti-lock brake
modul e. This condi ti on can be found by using the Qui ck
Check Sheet.
New Ge n e r a t i o n St ar Te st e r Co n n e c t i o n s
DATA LINK CONNECTOR (DLC)
Pin
1
_
No t Us e d
2 914 ( T / 0 ) J 1850 Da t a Bus
3

No t Us e d
4 57 ( BK) Ch a s s i s Gr o u n d
5 57 0
( B K / W)
Si gn a l Gr o un d
6 No t Us e d
7 7 0 ( L B / W) I SO- 9141 Di a gn o s t i c Li ne
8 No t Us e d
9

No t Us e d
10 915
( P K / L B )
J 1850 Da t a Bus Re t ur n
11 No t Us e d
12

No t Us e d j
Pin
Number Ci r cui t Ci r cui t Functi on
13 67 ( L G / Y) Un r e gu l a t e d Su ppl y
14

No t Us e d
15

No t Us e d
16 554
( Y / B K )
Un s wi t c h Ba t t e r y P o we r
If t he red BRAKE warni ng indicator is on, refer t o
Secti on 06- 00, Brake Syst em Di agnosi s and Testi ng.
. L i n k Co mmu n i c a t i o n , Mo d u l e N o t
Re s p o n d i n g
If you get the above response when tryi ng t o pull
codes, it means the NGS is not abl e t o communi cate
wi t h the anti-lock br ake control module ( 2B373) . IT
DOES NOT MEAN THE anti-lock brake control module
IS DEFECTIVE. Check the following i tems when thi s
message occurs:
(1) Confirm t hat the ignition in RUN posi ti on.
( 2) Check the fuse box f or bl own fuses.
( 3) Check t he NGS connecti on t o t he di agnosti c
connector.
(4) There is an 8-pin connect or on the LH front apron
(by t he power steeri ng fluid reservoi r). Thi s
connector is used by t he assembl y plant. Ensure
that t here is a cap on thi s connector. If the cap is
not in pl ace, power cannot get t o the ABS ECU.
If none of t hese acti ons wi l l rest ore the communi cati on
link, proceed t o Anti -Lock Qui ck Check Sheet t o
check bat t ery power, ignition f eed, and di agnosti c link.
Di a g n o s t i c C o d e s , Re t r i e v i n g
The anti-lock br ake/ t r act i on assi st syst em has
on-board di agnosti c capabi l i ti es vi a the Ford ISO 9141
seri al dat a link. The DTCs can be retri eved in the
fol l owi ng manner:
1. Connect the NGS t est er t o t he serial dat a link
connector under t he dash t o the right of the
steeri ng col umn.
2. Plug the NGS into t he ci garet t e lighter.
3. Make sure the ignition is in t he " RUN" posi ti on.
4. Fol l ow the i nstructi ons on the NGS screen.
(Choose correct vehi cl e and model year, proceed
t o "di agnost i c dat a l i nk" menu i tem, choose
" ABS (Anti -Lock Br ake Modul e) " , choose
" r et r i eve/ cl ear DTCs , press st art ).
5. The NGS will di spl ay any DTCs found, and by
turning t he dial t o highlight each one, will gi ve a
verbal descri pti on of t he code.
6. Wri te down all DTCs .
7. NOTE: If NGS report s " Syst em passed, no
DTCs" , proceed t o the Anti -Lock Qui ck Check
Sheet. If NGS report s "Li nk communi cati on error,
module not respondi ng", see secti on ti tl ed "Li nk
Communication Error Modul e Not Respondi ng".
8. Next , on t he same menu as " r et r i eve/ cl ear
DTCs" will be " on demand self t est " . Run the on
demand self t est .
9. Wri t e down all DTCs.
10. Compare DTCs f rom t he' ' on demand self t est ' ' t o
t he DTCs f rom "ret ri eve codes" . Any codes
given by t he self t est are exi sti ng failures and
must be repai red before codes given by the
"r et r i eve codes" command. Codes given by the
" on demand self t est " are failures that can be
det ect ed wi thout t he car movi ng. St ored codes
t hat are not det ect ed by t he " on demand self
t est " are intermittent failures or failures that only
occur when t he vehi cl e is dri ven.
11. Refer t o t he DTC index t o determi ne whi ch
pinpoint test t o perform for each code.
Di a g n o s t i c T r o u b l e C o d e E r a s i n g
After t he failures have been repai red and you have
confi rmed the vehicle functions properl y, use t he NGS
t o cl ear all troubl e codes f rom the ECU.
The ABS ECU will automati cal l y cl ear codes that have
not recurred after 80 ignition cycl es, provi ded that the
vehicle has reached 15 mph bet ween each ignition
cycl e. (Simply swi tchi ng the ignition off and on 80
ti mes will not clear t he codes).
ON-BOARD DIAGNOSTIC TROUBLE CODE INDEX
Not e: The Next Generat i on Star (NGS) Test er wi l l
aut omat i cal l y gi ve a t r ansl at i on of t he DTC on t he
screen
DT C SOURCE A CT I ON
b 1317 Ba t t e r y Vo l t a ge Hi gh Go t o Pi n po i n t Te st A
D 1 3 4 2 ECU I nt e r na l Fa i l ur e Go t o Pi n po i n t Te st A
C 1 1 9 4 L F Out l e t Va l v e Ci r c ui t
Fa i l ur e
Re p l a c e ECU
C 1 2 1 0 RF Out l e t Va l v e Ci r c ui t
Fa i l ur e
Re p l a c e ECU
C1 242 LR Out l e t Va l v e Ci r c ui t
Fa i l ur e
Re p l a c e ECU
C 1 2 4 6 RR Out l e t Va l v e Ci r c ui t
Fa i l ur e
Re p l a c e ECU
C1198 L F I nl et Va l v e Ci r c ui t
Fa i l ur e
Re p l a c e ECU
C 1 2 1 4 RF I nl et Va l ve Ci r c ui t
Fa i l ur e
Re p l a c e ECU
C 1 2 5 0 LR I nl et Va l ve Ci r c ui t
Fa i l ur e
Re p l a c e ECU
C 1 2 5 4 RR I nl et Va l ve Ci r c ui t
Fa i l ur e
Re p l a c e ECU
C 1 4 0 0 Tr a c t i o n A s s i s t Va l v e
Fa i l ur e
Re p l a c e ECU
C 1 1 4 5 RF Wh e e l S p e e d I nput
Ci r c ui t Fa i l ur e
Go t o Pi n po i n t Te st C
Note: The Next Generati on Star (NGS) Test er will
automatically gi ve a translation of tfee DTC on the
screen (Cont'd)
DTC SOURCE ACTION
C 1 1 5 5 L F Wh e e l S p e e d I nput
Go t o Pi n po i n t Te st B
C 1 1 6 5 RR Wh e e l S p e e d I nput
Go t o Pi n po i n t Te st D
C 1 1 7 5 L R Wh e e l S p e e d I nput
Go t o Pi n po i n t Te st E
C 1 1 4 8 RF Wh e e l Hi gh S p e e d
Co h e r e n c y Fa ul t
C 1 1 5 8 L F Wh e e l Hi gh S p e e d
C 1 1 6 8 RR Wh e e l Hi gh S p e e d
C 1 1 7 8 LR Wh e e l Hi gh S p e e d
Go t o Pi n po i n t Te st E
C 1 2 3 3 L F Wh e e l S p e e d Si gn a l
Mi s s i n g
C 1 2 3 4 RF Wh e e l S p e e d Si gn a l
Mi s s i n g
C 1 2 3 5 RR Wh e e l S p e e d Si gn a l
Mi s s i n g
Not e: The Next Gener at i on St ar (NGS) Test er will
aut omat i cal l y gi ve a t r ansl at i on of the DTC on t he
sc r e e n (Cont ' d)
DTC SOURCE ACTION
C 1 2 3 6 L R Wh e e l S p e e d
Co mp a r i s o n Fa i l ur e
Si gn a l Mi s s i n g
Go t o Pi n po i n t T e s t E
C 1 2 5 8 L F Wh e e l S p e e d
Go t o Pi n po i n t Te s t B
C 1 2 5 9 RF Wh e e l S p e e d
Go t o Pi n po i n t Te s t C
C 1 2 6 0 RR Wh e e l S p e e d
Go t o Pi n po i n t T e s t D
C 1 2 6 1 L R Wh e e l S p e e d
Go t o Pi n po i n t Te s t E
C 1 2 6 7 A BS Fu n c t i o n Di s a b l e d
Te mp o r a r i l y
a
C 1 0 9 5 Hy d r a u l i c P u mp Mo t o r
Go t o Pi n po i n t Te s t L
a Co d e c 12 67 i n d i c a t e s t h e ECU e x p e r i e n c e d a s t r o n g
e l e c t r o ma g n e t i c f i e l d wh i c h t e mp o r a r i l y d i s a b l e d t h e
mo d u l e . Wh e n t h e E CU i s / w a s r e mo v e d f r o m t h e
d i s t u r b a n c e , t h e E CU s h o u l d f u n c t i o n p r o p e r l y wi t h t h e n e x t
i gn i t i o n ke y - o n . Do n o t r e p l a c e t h e ECU wh e n t h i s c o d e
a p p e a r s . Se r v i c e a l l o t h e r c o d e s f i r s t .
( Co n t i n ue d )
Quick Tests
Ant i -Lock Qui ck Check Sheet Usi ng 60-Pi n EEC-IV Breakout Box 014-00322
I t em t o be Test ed I gni t i on Mode
Measure
Be t we e n Pi n
Numbers
Test er
Sc a l e / Ra n ge Speci f i cat i on Test St ep
Ba t t e r y P o we r Of f o r On 1 a n d 13
2 a n d 14
DC Vo l t s
DC Vo l t s
10 V mi n .
10 V mi n .
A
A
I gn i t i o n Fe e d OFF
ON
15 a n d 13
15 a n d 13
DC Vo l t s
DC Vo l t s
O V
10 V mi n.
A
A
L F Se n s o r Re s i s t a n c e OFF 5 a n d 6 K O h m s 0. 8- 1. 4 K o h ms B
RF Se n s o r Re s i s t a n c e OFF 7 a n d 8 K O h m s 0. 8- 1. 4 K o h ms C
LR Se n s o r Re s i s t a n c e OFF 9 a n d 10 K O h m s 0. 8- 1. 4 K o hms E
RR Se n s o r Re s i s t a n c e OFF 11 a n d 12 K O h m s 0. 8- 1. 4 K o h ms D
Se n s o r Co n t i n ui t y
To Gr o u n d
L F OFF 5 a n d 13 Co n t i n ui t y No c o n t i n ui t y B
RF OFF 6 a n d 13 Co n t i n ui t y No c o n t i n ui t y C
LR OFF 7 a n d 13 Co n t i n ui t y No c o n t i n ui t y E
RR OFF 8 a n d 13 Co n t i n ui t y No c o n t i n ui t y D
Se n s o r v o l t a g e : Ro t a t e w h e e l @ o n e r e v o l u t i o n
pe r s e c o n d
LF OFF 5 a n d 6 AC mVo l t s 100- 3500mV B
RF OFF 7 a n d 8 AC mVo l t s 100- 3500mV C
LR OFF 9 a n d 10 AC mVo l t s 100- 3500mV E
RR OFF 11 a n d 12 AC mVo l t s 100- 3500mV D
Br a ke L a mp S wi t c h
P e d a l No t A p p l i e d : ON 2 0 a n d 13 DC Vo l t s OV K
P e d a l A p p l i e d : ON 2 0 a n d 13 DC Vo l t s 10 V mi n. K
Ant i -Lock Qui ck Check Sheet Usi ng 60-Pi n EEC-IV Breakout Box 014-00322 (Cont 'd)
I tem t fee Tested I gni t i on Mode
Me a s u r e
Be t we e n Pi n
Numbers
Test er
Sc a l e / Ra nge Speci f i cat i on Test St ep
Di a gn o s t i c Li n k ON 2 8 a n d 13 DC Vo l t s 10 V mi n .
A BS Wa r n i n g L a mp OFF 2 1 a n d 13 OC Vo l t s OV G
ON 2 1 a n d 13 DC Vo l t s 10 V mi n . G
A BS Br e a ko u t A d a p t e r
Ne w Ge n e r a t i o n STAR ( NGS)
7 3 Di gi t a l Mu l t i me t e r
007 - 00016
007 - 00500
105- 00051
Spe c i a l Se r vi c e Tool s
ROTUNDA 73 DIGITAL
MULTI METER
105-00051
H9067-A
Refer t o the El ectri cal Schemat i c when performi ng t he
Pinpoint Tests t o l ocate wi re ci rcui ts i ndi cated in t he
t est s. Each t est is compl etel y independent of the other
t est s and within each t est are sequences t hat can
identify a condi ti on wi thout requiring compl eti on of t he
enti re t est procedure.
06- 09- 14 Br a ke Sy s *
a
"
a
' "
a i ?: - - I'M : . aw - - A- uaBmmmimmmmmm ; . . . r a r . JET _ r "Z z aE
NOTE: Normal ABS warni ng l amp sequence: Amber
light will come on for 2-3 seconds during sel f-check
when ignition is in the " r u n " posi ti on.
ABS Warning Lamp Stays Lit After
Starting Engine
^ Anti-lock brake control module.
Anti-lock brake warning i ndi cator
on (with brake warning indicator
of f ).
RETRIEVE codes using NGS. If no
codes exi st or NGS reports link
communication error, PROCEED to
Pinpoint Test A.
Normal ABS Warning Lamp
Sequence, Then Light Comes Back
On at 10 mph
LH front sensor and ci rcui t.
RH front sensor and ci rcui t.
RH rear sensor and ci rcui t.
LH rear sensor and ci rcui t.
RETRIEVE codes using NGS. If
c o d e c 1095 appears, PROCEED to
Pinpoint Test L. If a sensor code
exi st s, PROCEED to Pinpoint Test
B, C, D, or E as appropri ate.
Normal ABS Warning Lamp
Sequence; False Cycling of ABS of
Traction Assi st (Can Hear/Feel
ABS During Light Accelerat i on or
Deceleration)
LH front sensor and ci rcui t.
RH front sensor and ci rcui t.
RH rear sensor and ci rcui t.
LH rear sensor and circuit.
RETRIEVE codes using NGS. If a
sensor code exi st s, PROCEED t o
Pinpoint Test B, C, D, or E, as
appropri ate.
Anti-Lock Brake Warning Indicator
On (With Brake Warning Indicator
Off, Parking Brake Released and
Brake Lining Wear Checked)
Brake master cylinder reservoir. REFER to Pinpoint Test F.
No Anti -Lock Brake Indicator On
When Ignition Switch ON
Anti-lock indicator. REFER to Pinpoint Test G.
Spongy Brake Pedal With / Without
Anti-Lock Function (No Warning
Indicator)
Air in system. REFER to Pinpoint Test H.
Poor Vehicle Tracking During
Anti-Lock Function (Warning
Indicator Off)
Air in system.
Brake pressure control valve
block.
REFER to Pinpoint Test J.
Traction Assi st Inoperative
(Normal Warning Lamp Sequence)
Anti -lock brake control module.
Brake pressure control valve
block.
REFER to Pinpoint Test K.
Pinpoint Tests
PINPOINT TEST A: ANTI-LOCK BRAKE WARNING INDICATOR ON (WITH BRAKE WARNING INDICATOR OFF)
A1 CHECK POWER TO ANTI-LOCK BRAKE CONTROL
MODULELOW RANGE
Yes
No
GO to A5.
GO to A3.
Disconnect anti -lock brake wiring plug from
anti-lock brake control module.
Connect 60-Pin Breakout Box 014-00322 and New
Generation STAR Tester 007-00500 or equivalent t o
the Anti-Lock 28-pin plug wiring harness.
Set multi-meter t o read volts DC.
Measure voltage between Breakout Box Pins 15 and
13.
Is vol tage readi ng less t han 10 vol t s?
Yes
No
GO to A5.
GO to A3.
06- 09 - 15 Br a ke S y s t e m, A n t i - L o c k 06- 09- 15
PINPOINT TEST A: ANTI-LOCK BRAKE WARNING INDICATOR ON (WITH BRAKE WARNING INDICATOR OFF) (Cont i nued)
A2 CHECK POWER TO ANTI-LOCK BRAKE CONTROL
MODULEHIGH RANGE
Yes
No
CHECK vehicle charging
syst em. REFER to
Section 14-00.
GO to A3.
Disconnect anti -lock brake wiring plug from
anti-lock brake control module.
Connect 60-Pin Breakout Box 014-00322 and New
Generation STAR Tester 007-00500 or equivalent t o
the Anti-Lock 28-pin plug wiring harness.
Set multimeter to read volts DC.
Turn ignition swi tch t o RUN.
13.
Is vol t age r eadi ng great er t han 10 vol t s?
Yes
No
CHECK vehicle charging
syst em. REFER to
Section 14-00.
GO to A3.
A3 CHECK ANTI-LOCK BRAKE CONTROL MODULE TO
GROUND WIRE
Yes
No
GO to A4.
SERVICE or REPLACE
cable harness 57.
Check continuity between Breakout Box Pin 13 and
body ground.
Is cont i nui t y pr esent ?
Yes
No
GO to A4.
SERVICE or REPLACE
cable harness 57.
A4 CHECK IGNITION TO ANTI-LOCK BRAKE CONTROL
MODULE WIRE
Yes
No
REVERIFY reading at
Test Step A1 or A2.
SERVICE or REPLACE
cable harness Circuit
489, 295 or Fuse 7 for
Town Car. Circuit 489, 88
or Fuse 15 for Crown
CHECK for shorting cap
on 8-pin connector on LH
apron (by power steering
reservoir).
Check for continuity between Breakout Box Pin 15
and ignition swi t ch wire 489.
Yes
No
REVERIFY reading at
Test Step A1 or A2.
SERVICE or REPLACE
489, 295 or Fuse 7 for
Town Car. Circuit 489, 88
or Fuse 15 for Crown
CHECK for shorting cap
on 8-pin connector on LH
apron (by power steering
reservoir).
AS CHECK GROUND
Yes
No
GO to A6.
SERVICE or REPLACE
cable harness Circuit 57.
Check for continuity between Breakout Box Pins 13
and 14.
Yes
No
GO to A6.
SERVICE or REPLACE
cable harness Circuit 57.
AS CHECK BATTERY POWER TO ANTI-LOCK BRAKE
CONTROL MODULE CIRCUIT 601 (LB/PK)
Yes
No
GO to A7.
SERVICE wiring harness
Circuit 601 or Fuse 15 for
Marquis or Circuit 533 or
Fuse B for Town Car.
o Measure voltage between Breakout Box Pins 1 and
13.
Is vol t age r eadi ng over 10 vol t s?
Yes
No
GO to A7.
A7 CHECK REDUNDANT BATTERY POWER TO ANTI-LOCK
BRAKE CONTROL MODULE
Yes
No
GO to A8.
14.
Is vol t age readi ng over 10 vol t s?
Yes
No
GO to A8.
AS ABS MODULE CHECK
Yes
No
REVERIFY that all t est s
have been performed.
REPLACE ABS control
module.
NOTE: Ignition must be in "RUN" posi ti on.
If on-board di agnost i cs, ABS Quick Test, and Test A
di d not find concern, replace ABS anti-lock brake
control module wi th a known good module.
Is ABS war ni ng l amp st i l l on?
Yes
No
REVERIFY that all t est s
have been performed.
REPLACE ABS control
module.
06- 09- 16 Br a ke S y s t e m, A n t i - L o c k 0 6 - 0 9 - 1 6
PINPOINT TEST B: LH FRONT SENSOR AND CIRCUIT
B1 DTCs C1155, C1158, C1233, C1258:
CHECK LH FRONT SENSOR
Yes
r
.
; ;
.
No * '
GO to B3.
GO to B2.
Disconnect anti-lock brake wiring from anti-lock
brake control module.
Connect 60-Pin Breakout Box 014-00322 wi th
Anti -Lock Brake Adapter 007-00116 or equivalent t o
the anti-lock brake wiring connector on wiring
harness.
Measure resistance between Pins 5 and 6.
Is resi st ance bet ween 800 and 1400 ohms?
Yes
r
.
; ;
.
No * '
GO to B3.
GO to B2.
B2 CHECK LH FRONT BRAKE ANTI-LOCK SENSOR
RESISTANCE
Yes
No
SERVICE or REPLACE
cable harness Circuit 521
or 522.
REPLACE LH front brake
anti -lock sensor.
Disconnect LH front brake anti-lock sensor plug.
Measure resistance of front brake anti -lock sensor
at brake anti-lock plug.
LH FRONT BRAKE ANTI-LOCK
u r r r y o n
SENSOR 2C204 H7773-D
Yes
No
SERVICE or REPLACE
or 522.
anti -lock sensor.
VOLTAGE
Yes
No
GO to B4.
CHECK front brake
anti-lock sensor
mounting, air gap or front
brake anti-lock sensor
indicator mounting.
Turn air suspension swi tch OFF, if so equi pped.
Place vehi cle on hoist and raise wheels clear of
ground. Refer to Secti on 00-02.
Set multi-meter to voltage range (2 volt s AC).
Measure voltage between Pins 6 and 6 at breakout
box while spinning LH front wheel at approximately
one revolution per second.
Is vol t age bet ween 0.10 and 3.50 vol t s AC?
Yes
No
GO to B4.
CHECK front brake
anti-lock sensor
indicator mounting.
CIRCUIT CONTINUITY TO GROUND
Yes
No
GOt o B5.
GO to B6.
Check continuity between Breakout Box Pins 5 and
13.
Is c ont i nui t y pr esent ?
Yes
No
GOt o B5.
GO to B6.
B5 CHECK LH FRONT BRAKE ANTI-LOCK SENSOR TO
GROUND
Yes
No
anti-lock sensor.
SERVICE or REPLACE
or 522. RECONNECT
sensor plug.
Disconnect LH front brake anti -lock sensor plug.
Check for continuity between each sensor plug pin
(sensor si de) and vehicle ground.
LH FRONT BRAKE ANTI-LOCK _ _ _ _
n
SENSOR 2C204 H7773-D
Yes
No
anti-lock sensor.
SERVICE or REPLACE
or 522. RECONNECT
sensor plug.
PINPOINT TEST B: LH FRONT SENSOR AND CIRCUIT (Cont i nued)
B6 CHECK ANTI-LOCK BRAKE CONTROL TO GROUND
WIRE
Yes
No
GO to B7.
SERVICE or REPLACE
or 530.
body ground.
Was cont i nui t y present ?
Yes
No
GO to B7.
SERVICE or REPLACE
or 530.
B7 CHECK LH FRONT WHEEL BEARING
Yes >
No
REPLACE
damaged/worn part s.
REVERIFY symptom.
NOTE: Turn air suspension swi tch ON when vehicle is
off hoi st, if so equi pped.
Check front wheel bearing end play.
Inspect front brake anti-lock sensor indicator
visually for damaged t eet h.
Were l oose or damaged part s f ound?
Yes >
No
REPLACE
damaged/worn part s.
REVERIFY symptom.
PINPOINT TEST C: RH FRONT SENSOR AND CIRCUIT
C1 DTCs C1145, C1148, C1234, ORC1259:
CHECK RH FRONT SENSOR
Yes
No
GO to C3.
GO to C2.
Disconnect 55-pin connector from anti-lock brake
control module.
Connect 60-Pin Breakout Box 014-00322 with
Anti -Lock Brake Adapter 007-00116 or equivalent to
the 55-Pin connector on wiring harness.
Measure resi stance between Pins 7 and 8.
Yes
No
GO to C3.
GO to C2.
C2 CHECK RH FRONT BRAKE ANTI-LOCK SENSOR
RESISTANCE
Yes
No
SERVICE or REPLACE
or516.
REPLACE RH front brake
anti-lock sensor.
Disconnect RH front brake anti-lock sensor plug.
Measure resi stance of sensor at brake anti-lock
sensor plug.
Is resi st ance be t we e n 800 and 1400 ohms?
<
RH FRONT BRAKE ANTI-LOCK
U
A n
SENSOR 2C204 H7774-0
Yes
No
SERVICE or REPLACE
or516.
anti-lock sensor.
VOLTAGE
Yes
No
GO to C4.
CHECK front brake
anti-lock sensor
indicator mounting.
Turn air suspension swi t ch OFF, if so equipped.
Place vehicle on hoist and raise wheels clear of
ground. Refer t o Section 00-02.
Set multi-meter to voltage range (2 volts AC).
box while spinning RH front wheel at approximately
Is vol t age be t we e n 0. 10 and 3.5 vol t s AC?
Yes
No
GO to C4.
CHECK front brake
anti-lock sensor
indicator mounting.
CIRCUIT CONTINUITY TO GROUND
No
Yes
GO to C6.
GO to C5.
Check continuity between breakout box Pins 7 and
13.
No
Yes
GO to C6.
GO to C5.
06- 09- 18 Br a ke S y s t e m, A n t i - L o c k ' 06- 09- 18
PINPOINT TEST C: RH FRONT SENSOR AND CIRCUIT (Cont i nued)
C5 CHECK RH FRONT BRAKE ANTI-LOCK SENSOR TO
GROUND
Yes
No
anti -lock sensor.
SERVICE or REPLACE
cabl e harness Circuit 514
or 516. RECONNECT
brake anti -lock sensor
plug.
Disconnect RH front brake anti-lock plug.
Check for continuity between each brake anti-lock
sensor plug pin (sensor si de) and vehicle ground.
RH FRONT BRAKE ANTI-LOCK
U
_
A n
Yes
No
anti -lock sensor.
SERVICE or REPLACE
cabl e harness Circuit 514
or 516. RECONNECT
brake anti -lock sensor
plug.
C6 CHECK ANTI-LOCK BRAKE CONTROL MODULE TO
GROUND WIRE
Yes ^
No
GO to C7.
SERVICE or REPLACE
or 530.
body ground.
Yes ^
No
GO to C7.
SERVICE or REPLACE
or 530.
C7 CHECK RH FRONT WHEEL BEARING
Yes
No
REPLACE
damaged/worn parts.
REVERIFY symptom.
NOTE: Turn air suspension swi tch ON when vehi cle is
Check front wheel bearing end play.
Inspect front brake anti-lock sensor indicator
visually for damaged t eet h.
Were any part s l oose or damaged?
Yes
No
REPLACE
damaged/worn parts.
REVERIFY symptom.
PINPOINT TEST D: RH REAR SENSOR AND CIRCUIT
D1 DTCs C1165, C1168, C1235, OR C1260:
CHECK RH REAR SENSOR
Disconnect anti-lock brake wiring from anti-lock
the 55-pin connector on anti-lock brake wiring
harness.
Yes
No >
GO to D3.
GOt o D2.
D2 CHECK RH REAR BRAKE ANTI-LOCK SENSOR
RESISTANCE
Disconnect RH rear brake anti-lock sensor.
Measure resi stance of brake anti-lock at sensor
plug.
Yes
No

SERVICE or REPLACE
or 524.
REPLACE RH rear rear
brake anti-lock sensor.
u
RH REAR BRAKE H777R-C
ANTI-LOCK SENSOR 2C190
m f m U
PINPOINT TEST D: RH REAR SENSOR AND CIRCUIT (Continued)
D3 CHECK RH REAR BRAKE ANTI-LOCK SENSOR
VOLTAGE
Yes
No
GO t o D4.
CHECK rear brake
anti-lock sensor
mounting, air gap or rear
indicator mounting.
ground. Refer t o Section 00-02.
Measure voltage between Pins 11 and 12 at
breakout box while spinning RH rear wheel at
approxi mately one revolution per second.
Is vol tage bet ween 0.10 and 3.5 vol t s AC?
Yes
No
GO t o D4.
CHECK rear brake
anti-lock sensor
indicator mounting.
D4 CHECK RH REAR ANTI-LOCK BRAKE SENSOR CIRCUIT
CONTINUITY TO GROUND
Yes
No
GO to D5.
GO to D6.
13.
Is cont i nui t y present ?
Yes
No
GO to D5.
GO to D6.
D5 CHECK RH REAR SENSOR TO GROUND
Yes
No
SERVICE or REPLACE
or 524. RECONNECT
sensor plug.
Disconnect RH rear brake anti-lock sensor plug.
Check for continuity between each rear brake
anti -lock sensor plug pin (sensor si de) and vehi cle
ground.
<
RH REAR BRAKE H777S-C
ANTI-LOCK SENSOR 2C190 " ' " ^
Yes
No
SERVICE or REPLACE
or 524. RECONNECT
sensor plug.
D6 CHECK ANTI-LOCK BRAKE CONTROL MODULE TO
GROUND WIRE
Yes
No
GOt o D7 .
SERVICE or REPLACE
or 530.
Check continuity between breakout box Pin 13 and
body ground.
Yes
No
GOt o D7 .
SERVICE or REPLACE
or 530.
D7 CHECK FOR EXCESSIVE AXLE VIBRATION
Yes
No
SERVICE or REPLACE
damaged part s.
REVERIFY symptom.
NOTE: Turn air suspension switch ON when vehicle is
Check rear axle housing for excessi ve play.
Check rear wheel bearings for excessi ve play.
Inspect rear brake anti -lock sensor indicator for
damaged t eet h.
Were any parts l oose or damaged?
Yes
No
SERVICE or REPLACE
damaged part s.
REVERIFY symptom.
PINPOINT TEST E: LH REAR SENSOR AND CIRCUIT
E1 DTCs C1175, C1178, C1236, OR C1261:
CHECK LH REAR BRAKE ANTI-LOCK SENSOR
Yes
No
GO to E3.
GO to E2.
Disconnect anti -lock brake wiring from anti-lock
Anti -Lock Brake Adapter 007-00116 or equivalent t o
the 55-pin connector on anti-lock brake wiring
harness.
Is r esi st ance be t we e n 800 and 1400 ohms?
Yes
No
GO to E3.
GO to E2.
06- 09- 2 0 Br a ke S y s t e m, A n t i - L o c k 06- 09- 2 0
PINPOINT TEST E: LH REAR SENSOR AND CIRCUIT (Cont i nued)
E2 CHECK LH REAR BRAKE ANTI-LOCK SENSOR
RESISTANCE
Yes
No
SERVICE or REPLACE
or 519.
REPLACE LH rear rear
brake anti -lock sensor.
Disconnect LH rear brake anti -lock sensor plug.
Measure resi stance of rear brake anti -lock sensor
at sensor plug.
LH REAR BRAKE ANTI-LOCK
u
- _ e
n
SENSOR 2C190 H777S-D
Yes
No
SERVICE or REPLACE
or 519.
brake anti -lock sensor.
E3 CHECK LH REAR BRAKE ANTI-LOCK SENSOR
VOLTAGE
Yes
No
GOt o E4.
CHECK rear brake
anti-lock sensor
indicator mounting.
CORRECT as requi red.
Turn ignition swi t ch swi tch OFF.
ground. Refer t o Secti on 00-02.
box while spinning LH rear wheel at approxi mately
Is vol t age be t we e n 0. 10 and 3.5 vol t s AC?
Yes
No
GOt o E4.
CHECK rear brake
anti-lock sensor
indicator mounting.
CORRECT as requi red.
E4 CHECK LH REAR BRAKE ANTI-LOCK SENSOR CIRCUIT
CONTINUITY TO GROUND
Yes
No
GO to E5.
GO to E6.
13.
Yes
No
GO to E5.
GO to E6.
E5 CHECK LH REAR BRAKE ANTI-LOCK SENSOR TO
GROUND
Yes
No *
SERVICE or REPLACE
or 519. RECONNECT rear
brake anti-lock plug.
Disconnect LH rear brake anti -lock sensor plug.
Check for continuity between each sensor plug pin
(sensor side) and vehi cle ground.
LH REAR BRAKE ANTI-LOCK
U
_
A n
Yes
No *
SERVICE or REPLACE
or 519. RECONNECT rear
brake anti-lock plug.
E6 CHECK ANTI-LOCK BRAKE CONTROL MODULE TO
GROUND WIRE
Yes
No
GO to E7.
SERVICE or REPLACE
or 530.
body ground.
Is cont i nui t y pr e se nt ?
Yes
No
GO to E7.
SERVICE or REPLACE
or 530.
PINPOINT TEST E: LH REAR SENSOR AND CIRCUIT (Continued)
E7 CHECK FOR EXCESSIVE AXLE VIBRATION
Yes
No
SERVICE or REPLACE
damaged parts.
REVERIFY symptom.
NOTE: Turn air suspension swi tch ON when vehicle is
off hoist, if so equi pped.
Check differential housing for excessi ve play.
Check rear axle bearings for excessi ve play.
Inspect rear brake anti-lock sensor indicator ring for
damaged t eet h.
Were any par t s l oose or damaged?
Yes
No
SERVICE or REPLACE
damaged parts.
REVERIFY symptom.
PINPOINT TEST F: ANTI-LOCK BRAKE WARNING INDICATOR ON (WITH BRAKE WARNING INDICATOR OFF, PARKING
BRAKE RELEASED AND BRAKE LINING WEAR CHECKED)
F1 CHECK BRAKE FLUID LEVEL
Check that brake fluid is no more than 4 mm (0.16
inch) below MAX line l ocat ed on side of brake
master cylinder reservoir.
Is f l ui d l evel l ow?
Yes
No
CHECK system for
external leaks. SERVICE
as required.
GO t o F2 .
F2 CHECK FLUID LEVEL SWITCH
Disconnect 3-pin plug on master cylinder fluid brake
reservoir.
Check for continuity between Pins 1 and 3 on
reservoir.
Yes
No

REPLACE 3-Pin Fluid
Level Swi tch.
GO to F3.
T
Br a ke S y s t e m, A n t i - L o c k 06- 09- 2 2
PINPOINT TEST F: ANTI-LOCK BRAKE WARNING INDICATOR ON (WITH BRAKE WARNING INDICATOR OFF, PARKING
BRAKE RELEASED AND BRAKE LINING WEAR CHECKED) (Conti nued)
F3 CHECK FOR GROUND CONCERN
Check for grounded wire harness, Circuit 977.
Is wi re harness gr ounded?
977 P/W
Yes
No

SERVICE or REPLACE
977.
REVERIFY warning lamp
on.
57 BK-
a
G6
977AP/W
3-PIN FLUID BRAKE MASTER
CYLINDER FILLER CAP
CONNECTOR HARNESS SIDE H7787-E
PINPOINT TEST G: NO ANTI-LOCK BRAKE INDICATOR ON WHEN IGNITION SWITCH ON
G1 CHECK IGNITION FEED AND FUSE
Yes
No
GOt o G2.
SERVICE or REPLACE
603, 640 or Fuse 13
Marquis. Circuit 603, 295
or Fuse 7 Town Car.
Check for 12 volts to lamp socket with ignition
swi tch in RUN.
Is B+ pr esent ?
Yes
No
GOt o G2.
SERVICE or REPLACE
603, 640 or Fuse 13
Marquis. Circuit 603, 295
or Fuse 7 Town Car.
G2 CHECK WARNING INDICATOR BULB
Yes
No
GO t o G3.
REPLACE bulb.
Check warning indicator bulb.
Is bul b good?
Yes
No
GO t o G3.
REPLACE bulb.
G3 CHECK CIRCUIT 603
Yes
No
REVERIFY symptom.
SERVICE or REPLACE
603.
Check continuity between lamp socket and
Breakout Box Pin 21.
Is cont i nui t y present?
Yes
No
REVERIFY symptom.
SERVICE or REPLACE
603.
PINPOINT TEST H: SPONGY BRAKE PEDAL WITH/WITHOUT ANTI-LOCK FUNCTION (NO WARNING INDICATOR)
H1 CHECK COMPONENT MOUNTING
Yes ^
No w>
GOt o H2.
Check for proper brake pedal and power brake
boost er/brake master cylinder attachment.
Bleed brake system as outlined.
Is brake pedal spongy ?
Yes ^
No w>
GOt o H2.
H2 BLEED BRAKE SYSTEM
Yes
No
GOt o J2.
Rebleed brake system.
Is brake pedal spongy ?
Yes
No
GOt o J2.
1995 To wn Ca r , Cr o wn Vi c t o r i a , Gr a n d Ma r qui s Jul y 1994
06- 09- 2 3 ^ ^_ Br a ke S y s t e m, A n t i - L o c k ^ _ 06- 09- 2 3
PINPOINT TEST J: POOR VEHICLE TRACKING DURING ANTI-LOCK FUNCTION (WARNING INDICATOR OFF)
J1 BLEED BRAKE SYSTEM
Yes
No
GO to J2.
Turn rear suspension leveler compressor swi tch
OFF is so equipped.
Bleed brake system as outlined.
Turn rear suspension leveler compressor swi tch
back ON when vehicle is off hoist.
Does vehi cl e t r ack poor l y ?
Yes
No
GO to J2.
J2 CHECK LH ANTI-LOCK VALVE OPERATION
Yes
No
GO to J3.
VERIFY no "ECU internal
fai lure" or "valve circuit
fai lure" codes are stored
by running the
"on-demand self t est ". If
no codes are recei ved,
REPLACE brake pressure
control valve block.
Turn off rear air suspension compressor if so
equi pped.
Turn ignition swi tch to "RUN" position.
Lift vehicle and rotate a!! wheels to ensure they turn
freely, (vehicle must be in "neutral.)
Use NGS to put ABS control module into di agnosti c
mode.
Use NGS to command pump motor to run for four
seconds ("t ri gger" must be pressed twi ce since
each input will run motor for two seconds). This will
ensure t he accumulators are empty.
Apply moderate brake pedal effort and have an
assi stant check that the LF wheel will not turn. If
wheel turns, replace brake pressure control valve
block.
Use NGS t o tri gger all valves to energize.
Have assi stant check LF wheel immediately after
pressi ng tri gger (NGS will only energize valves for
two seconds per tri gger input).
Di d LF wheel t urn f r eel y (wi t h a t wo f o o t l ever
arm such as a t i re i ron) whi l e val ves wer e
energi zed?
Yes
No
GO to J3.
by running the
J3 CHECK RF ANTI-LOCK VALVE OPERATION
Yes
No
GOt o J4.
by running the
seconds ("t ri gger" must be pressed twi ce since
assi stant check that the RF wheel will not turn. If
block.
Use NGS to trigger all valves to energize.
Have assi stant check RF wheel immediately after
pressing tri gger (NGS will only energize valves for
Di d RF wheel t urn f reel y (wi t h a t wo f o o t lever
arm such as a f i re i ron) whi l e val ves wer e
ener gi zed?
Yes
No
GOt o J4.
by running the
J4 CHECK LR ANTI-LOCK VALVE OPERATION
Yes
No
GOt o J5.
by running the
seconds ("t ri gger" must be pressed t wi ce since
ensure the accumulators are empty.
assi stant check that the LR wheel will not turn. If
block.
Use NGS to trigger all valves to energize.
Have assi stant check LR wheel immediately after
Di d LR wheel t urn f reel y (wi t h a t wo f oot lever
arm such as a t i re i ron) whi l e val ves were
ener gi zed?
Yes
No
GOt o J5.
by running the
06- 09 - 2 4 Br a k e S y s t e m, A n t i - L o c k 06- 09- 2 4
PINPOINT TEST J: POOR VEHICLE TRACKING DURING ANTI-LOCK FUNCTION (WARNING INDICATOR OFF) (Cont i nued)
J5 CHECK RR ANTI-LOCK VALVE OPERATION
Use NGS t o command pump motor to run for four
seconds. ("Tri gger" must be pressed t wi ce since
assistant check that the RR wheel will not turn. If
block.
Have assistant check RR wheel immediately after
Di d RR wheel t ur n f r eel y (wi t h a t wo f o o t l ever
arm such as a t i r e i ron) whi l e val ves wer e
energi zed?.
Yes
No
REVERIFY symptom.
by running t he
PINPOINT TEST K: TRACTION ASSIST INOPERATIVE (NORMAL WARNING LAMP SEQUENCE)
Not e: The t r a c t i o n assi st syst em may be i nhi bi t ed by a t her mal model i n t he ant i -l ock br ake c ont r ol modul e. Thi s
t her mal model cal cul at es rear br ake t e mpe r a t ur e s, and i f t he t emper at ur es r each a certai n t hr eshol d, t he ant i -l ock
br ake c ont r ol modul e wi l l i nhi bi t t r a c t i on assi st f un c t i o n t o pr ot e c t t he rear br akes f r o m over heat i ng. Once t he rear
br akes have c ool e d d o wn , t he t r a c t i o n assi st wi l l become f unc t i ona l agai n.
K1 CHECK BRAKE LAMP SWITCH
Connect 60-Pin Breakout Box 014-00322 wi t h
the anti-lock brake wiring connector on the
headlamp dash panel j unction wire harness.
Turn the ignition swi tch to the RUN posi t i on.
Measure voltage between Breakout Box pins 20 and
13.
Yes
No
REPLACE brake lamp
swi tch or SERVICE cable
harness Circuit 511.
GO t o K2.
NOTE: Do not apply brake pedal while performing
thi s test.
Is B+ pr e se nt ?
K2 CHECK TRACTION ASSIST VALVE
Reconnect headlamp dash panel j unction wi re
wiring harness connector t o the anti-lock brake
control module.
Use NGS to retrieve DTCs.
Is c ode C1400 pr esent ?
Yes
No
REPLACE anti-lock brake
control module.
GO to K3.
K3 CHECK TRACTION ASSIST FUNCTION
Turn off air suspension swi t ch.
Raise vehi cle on hoist so that all wheels can rotate
freely. Refer t o Section 00-02.
Start vehi cle and shift to dri ve.
Do rear wheel s st ar t and st o p as t hough t he
br akes are bei ng appl i ed and rel eased?
Yes
No
REVERIFY symptom.
PINPOINT TEST L: HYDRAULIC PUMP MOTOR
L1 CHECK 2-PIN CONNECTOR
Verify t he 2-pin connector from the ABS pump motor
t o the control module is fully seat ed.
Was c o n n e c t o r f ul l y seat ed?
Yes
No
GO to L2
Use NGS to re-run On
Demand Self Test;
VERIFY C1095 no longer
exi sts.
PINPOINT TEST L: HYDRAULIC PUMP MOTOR (Continued)
L2 CHECK PUMP MOTOR OPERATION WITH (NGS)
Yes
No
control module.
GO to L3.
Reconnect 28-Pin connector wiring harness to
anti-lock control module.
Use NGS, put ABS module into diagnostic command
mode. Follow NGS instructions to command pump
motor to run.
Does pump mot or run?
Yes
No
control module.
GO to L3.
L3 CHECK PUMP MOTOR OPERATION
Yes
No
REVERIFY symptom.
REPLACE anti-lock pump
and motor assembly.
Disconnect 2-pin connector on inboard side of
anti-lock brake module.
Ground brown wire and apply 12V to red wi re.
Does pump mot or run?
Yes
No
REVERIFY symptom.
REPLACE anti-lock pump
and motor assembly.
B r a k e B o o s t e r , P o w e r
Hydraulic Control Unit (HCU)
Re mo v a l
2. Remove engine air cl eaner ( ACL) ( 9600) and air
cl eaner outlet tube ( 9B659) .
3. Di sconnect 28-pin connect or attachi ng anti-lock
brake module ( 2C219) t o wi re harness.
4. Remove t wo t ubes f rom inlet port s of t he pump
motor ( 2C256) and t hree ( ABS) , four ( ABS/ TA)
t ubes f rom outlet port s of brake pressure control
val ve bl ock ( 2C266) . Plug each port t o prevent
brake fluid f rom spilling on paint and wi ri ng.
5. Remove 13 mm nut retaining the HCU t o the
mounting bracket . Tip the rear of t he HCU up and
pull rearward t o slide the f or war d mounting pins
out of the retaining grommet s. Remove HCU f rom
vehi cl e.
H8957-A
I t e m
Pa r t
1

Rear Mounting Stud
2 2C266 Brake Pressure Control
Valve Block (ABS/TA)
3 Brake Tubes
4 2C219 Anti-Lock Brake Module
5 2C256 Pump Motor
6 Inlet Ports (Part of 2C256)
1 Insert HCU mounting pins into front grommet s on
mounting bracket . Make sure HCU is fully seat ed
in bracket . Install rear retaining nut. Tighten t o
16-24 N-m (12-18 Ib-ft).
Connect t hree tubes ( ABS onl y) (four tubes,
ABS/ TA) t o outlet port s on si de of brake
pressure control val ve bl ock and t wo tubes t o
inlet port s on t op of pump motor. Tighten tube
fittings t o 14-24 N-m ( 10- 18 Ib-ft).
06- 09- 2 Br ake Sy s t e m, Ant i - Lock
0 6- 0 9 - 2 6
REMOVAL A N D I N S T A L L A T I O N (Conti nued)
5.
6.
Connect 28-pin connector t o anti-lock brake
modul e. Tighten bolt t o 4. 8 Nm ( 42 Ib-in).
Install engine air cleaner and air cl eaner outlet
t ube.
Bl eed brake syst em. Refer t o Secti on 06- 06.
B r a k e Ma s t e r C y l i n d e r w i t h Fl u i d L e v e l
S w i t c h R e s e r v o i r
ANTI -LOCK BRAKE
MODULE 2C219
TORX SCREWS
2 REQ' D
C o n t r o l Va l v e , B r a k e P r e s s u r e
Re mo v a l
1 . Remove HCU as outl i ned.
2. Remove mounting pins f r om brake pressure
control val ve bl ock ( 2C266) .
3. Remove anti-lock brake modul e ( 2C21 9) as
outlined.
4. Remove t hree Torx bol t s. Remove pump motor
( 2C256) and gasket ( 2C254) f rom brake
pressure control val ve bl ock.
1. Install pump motor and gasket on brake pressure
control val ve bl ock wi t h t hree Torx bol ts.
Tighten bol ts t o 27- 32 N-m (20-24 Ib-ft).
2. install mounting pins onto brake pressure control
val ve bl ock. Tighten mounting pins t o 7-9 Nm
( 70- 80 Ib-in).
3. Install anti-lock brake modul e as outlined.
4. Install HCU as outlined.
C o n t r o l Mo d u l e , A n t i - L o c k B r a k e
Re mo v a l
1. Remove HCU as outl i ned.
2. Di sconnect t wo pin connector.
3. Remove t wo Torx Scr ews.
4. Slide anti -l ock brake modul e ( 2C219) off brake
pressure control val ve bl ock ( 2C266) .
1. Position anti-lock br ake module on brake
pressure cont rol val ve bl ock. Connect t wo pin
connector.
2. Install t wo Torx scr ews. Tighten scr ews t o 2
N-m ( 18 Ib-in).
3. Install HCU as outl i ned.
(t 1
tjT - ; -\
I
V
I L ~ ^ - J j I 1 ^ ^ ^ ^ , ^JI t- 1
BRAKE PRESSURE C O N T R O L
VALVE BLOCK 2 C 2 6 6
H8958-A
ANTI -LOCK BRAKE MODULE
2C219
T W O P I N
C O N N E C T O R
BRAKE PRESSURE CONTROL
VALVE BLOCK 2C266
H8960-A
B r a k e S e n s o r s
Fr ont
Re mo v a l
1. From inside engine compartment, di sconnect
front brake anti-lock sensor ( 2C204) assembl y
two-pin connector from wi ri ng harness.
2. Remove pl asti c clip holding sensor wi re to frame.
06- 09- 2 7 Br a ke System, A n t i - L o c k 06- 09- 2 7
REMOAL AND INSTALLATION (Cont i nued)
3. Remove sensor wi re f rom steel routing clip on
f rame and from dust shi el d.
4. Remove sensor retaining bolt from front spindle
and slide front brake anti-lock sensor out of
mounting hole.
1. Install front brake anti-lock sensor into mounting
hole in front wheel spindle (3105) and install
retaining bolt. Tighten to 4.5-6.8 N-m (40-60
lb-in).
2. Insert sensor routing grommets into dust shield
and steel bracket on frame. Route wire into
engine compartment.
3. Install plastic clip that holds sensor wire to frame
into hole in frame.
4. Connect two-pin connector to wire harness.
Br a ke An t i - Lo c k Se n s o r Fr o n t
LH SIDE SHOWN H6959-C
Par t
1 . Frame
3 N605518-S428 Bolt (2 Req'd)
Pa r t
4 E865401 Clip (1 Req'd Each Side)
5 N802191-S56 Bolt (2 Req'd)
6 2C224 Routing Clip
Sensor
A

Tighten to 4.5-6.8 N-m (40-60
Lb-ln)
Lb-Ft)
Re a r
Re mo v a l
1. From inside luggage compartment, disconnect
two-pin sensor connector from wiring harness
and push sensor wire through hole in floor.
2. From below vehicle, remove sensor wire from
routing bracket located on top of rear axle
housing (4010) and remove steel clip holding
sensor wire and brake tube against rear axle
housing.
3. Remove screw from clip holding sensor wire and
brake tube to bracket on rear axle housing.
4. Remove rear brake anti-lock sensor (2C190) to
rear wheel disc brake adapter retaining bolt and
remove rear brake anti-lock sensor.
1. Insert rear brake anti-lock sensor into rear wheel
disc brake adapter (2C220) and install retaining
bolt. Tighten to 4.5-6.8 N-m (40-60 lb-in).
2. Attach clip holding rear brake anti-lock sensor
and brake tube to bracket on rear axle housing
and secure with screw. Tighten to 4.5-6.8 N-m
(40-60 lb-in).
3. Install steel clip around rear axle housing tube
that holds sensor wire and brake tube against
rear axle housing tube, and push spool-shaped
grommet into clip located on top of axle carrier
housing.
4. Push sensor wire connector up through hole in
floor and seat large round grommet into hole.
5. Connect sensor two-pin connector to wiring
harness inside luggage compartment.
06- 09- 2 8 Br a ke System, Ant i -Look 06- 09 - 2 8
Br a ke An t i - Lo c k Se n s o r Re a r
VIEW A
H6960-D
Par t Par t
I t em Number Descr i pt i on I t em Number Descr i pt i on
1 11135 F l o o r P a n 5 2267 RH Brake Tube
2 2C218 Steel Clip 6 2A635 Parking Brake Rear Cable
and Conduit
Sensor 7 2860 Clip
4 2268 LH Brake Tube 8 388835 Bolt (2 Req'd)
9 N605520-S428 Bolt (2 Req'd) j
Sensor Indicator, Anti-Lock Brake
Front
Rear
Ref er t o Sect i on 05- 02A f or 7.5 i nch ri ng gear and
05- 02B f or 8. 8 i nch ri ng gear.
ADJUSTMENTS
Brake System Bleeding
Brake Master Cylinder Reservoir Checking
and Filling
Br ake flui d level in t he br a ke mast er cyl i nder reservoi r
( 2K47 8) shoul d be bet ween 4 mm (0. 16 i nch) bel ow
t he MAX line on t he si de of t he br ake mast er cyl i nder
reservoi r and t he MAX li ne. If br ake flui d is l ow, t he red
BRAKE i ndi cat or wi ll i llumi nate. To add br a ke f l ui d,
clean and r emove br ake mast er cyl i nder filler c a p
( 2162) and pour cl ean br a ke flui d into t he t o p of t he
br ake mast er cyl i nder reservoi r. Fill t o speci f i cat i on
ment i oned above. Use Hi gh Perf ormance DOT 3
Br ake Flui d C6A Z - 19542 - A A , BA (ESA-M6C25-A) or
DOT-3 equi val ent meet i ng For d speci f i cat i on
ESA-M6C25-A. If br ake flui d has t o be a dde d of t en,
c he c k all hydraul i c connect i ons f or l eaks.
SPECIFICATIONS
Description N-m Lb- Ft
Hydr aul i c Cont r ol Uni t - t o- Br acket
Nut
16- 24 12- 18
Br ake Tube Fi t t i ng 14- 24 10 18
( Cont i nued)
TORQUE SPECIFICATIONS (Cont'd)
A n t i - L o c k Br a ke Co n t r o l Mo d u l e 4. 5- 6. 8 40- 60
( L b- l n )
Br a ke A n t i - L o c k Se n s o r Bo l t 4. 5- 6. 8 40- 60
( L b- l n )
Mo u n t i n g Br a c ke t Bo l t 16- 27 12- 20
P ump Mo t o r t o P r e s s u r e Co n t r o l
Bl o c k
2 7 - 32 2 0- 2 4
2 8 Pi n Co n n e c t o r t o A n t i - L o c k
Mo d u l e
4. 8 42 ( L b - l n )
ROTUNDA EQUIPMENT
007 - 00500 Ne w Ge n e r a t i o n St a r ( NGS) Te s t e r
007 - 00116 A BS Br e a ko u t A d a p t e r
014- 0032 2 60- Pi n Br e a ko u t Bo x
Tool Numbe r /
T 85T - 4616- A H
T 8 5 T - 4 6 1 &- A H
0 7 - 0 1 - 1
G R O U P
TRANSMISSION
km
SECTI ON TI TLE PAGE SECTI ON TITLE PAGE
TRANSMISSION RANGE (TR) SENSOR 07-14-1 TRANSMISSION, AUTOMATICEXTERNAL
TRANSMISSION, AUTOMATI C4R70W 07-01-1 CONTROLS . . . .07-05-1
TRANSMISSION, AUTOMATICCOOLING 07-02-1
SECTION 07-01 Transmission, Automatic4R70W
SUBJECT PAGE
VEHICLE APPLICATION .. 07-01-2
4R70W Transmi ssi on . . 07-01-2
Main Component s and Fun c t i o n . . . 07-01-10
Transmi ssi on El ect roni c Cont r ol Syst em 07-01-12
Transmi ssi on Range Sel ect or and Shi ft
Pat t erns ... .. . 07-01-8
Af t er On-Board Di agnost i c 07-01-59
Ai r Pressure Test s.*... .... 07-01-103
Di agnosi s By Sy mpt om Rout i nes 07-01-34
Di agnost i c Rout i nes. . . 07-01-35
Di agnost i c St rat egy 07-01-27
Di rect Cl ut ch Pressure Test 07-01-104
El ect ri cal Schemat i c. 07-01-24
Engi ne Idle Speed Check 07-01-100
High or Low Fl ui d Level 07-01-30
Li ne Pressure Test . . . . . . . . .. 07-01-100
On-Board Di agnost i c Qui ck Test s . 07-01-56
On-Board Di agnost i c Troubl e Code Descri pt i on
Chart . . . . . . .... 07-01-59
Prel i mi nary I nspect i on 07-01-29
Requi red Equi pment : 07-01-27
Rot unda Transmi ssi on Test er 07-01-62
Shi f t Poi nt Checks. . . . . . . 07-01-102
Shift Sol enoi d Fai lure Modes . 07-01-72
St all Speed Test ...... 07-01-101
Torque Convert er Cl ut ch Operat i on
Test aQ ...07-01-102
Transmi ssi on Drive Cycl e Test .07-01-58
Transmi ssi on Flui d Condi t i on Check 07-01-30
Transmi ssi on Fl ui d Cool er Fl ow Check 07-01-34
Transmi ssi on Fl ui d Leakage Checks ..07-01-31
Torque Convert er Leakage Check 07-01-33
Transmi ssi on Flui d Level Check . 07-01-30
Transmi ssi on Range (TR) Sensor
Test i ng Enha nc e me nt 07-01-68
Veri f i cat i on of Condi t i on 07-01-29
IN-VEHICLE SERVICE
Cool er Lines 07-01-122
EPC Sol enoi d. . . . . . . . . . . . 07-01-109
Ext ensi on Housing Seal , Gasket and
Bushi ng. . . . . . . . . . . . . ..07-01-105
SUBJECT PAGE
Mai n Cont r ol Component s 07-01-113
Mai n Cont r ol Valve Body 07-01-106
Manual Cont r ol Lever Shaf t Se a l . . . . . . 07-01-118
Shi f t Li nkage Check 07-01-104
Transmi ssi on Flui d Drai n and Fi ll
Pr oc e dur e . . . ....07-01-104
REMOVAL
Transmi ssi on ... 07-01-122
DISASSEMBLY
Transmi ssi on .07-01-123
DISASSEMBLY AND ASSEMBLY OF
SUBASSEMBLIES
Di rect Cl ut ch Cyl i nder . .... 07-01-162
For war d Cl ut ch Cyl i nder 07-01-152
I nt ermedi at e Cl ut ch Cyl i nder 07-01-146
Mai n Cont r ol Valve Body ....07-01-136
Out put Shaf t and Di rect Cl ut ch Cyl i nder 07-01-160
Pl anet ary Gear Support Assembl y and
Pl anet ary Low One-Way Cl ut ch 07-01-158
Pump and I nt ermedi at e Cl ut ch Pi st o n
Di sassembl y ..07-01-141
Pump and I nt ermedi at e Cl ut ch
Pi st onAssembl y 07-01-144
Pump Bushi ng ...07-01-143
Reverse Cl ut ch .....07-01-148
Reverse Sun Gear Assembl y 07-01-159
Servi ce Not es 07-01-135
Torque Convert er Checks . 07-01-168
ASSEMBLY
Tr ansmi ssi on. 07-01-170
INSTALLATION
Transmi ssi on 07-01-182
Case .07-01-185
Convert er and Cool er ...07-01-184
El ect ri cal Connect or s 07-01-185
For war d, Di rect , I nt ermedi at e, Overdri ve and
Reverse Cl ut ches ....07-01-184
Main Cont rol Valve Body ...07-01-183
One-Way Cl ut c h. . . . 07-01-185
Out put Shaft 07-01-185
Planet Assembl i es ..07-01-185
Thrust Beari ngs 07-01-185
07 - 01- 2 T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W 07 - 01- 2
SECTION 07-01 Transmission, Automatic4R70W
SUBJECT PAGE
CLEANING AND INSPECTION (Cont' d.)
Transmi ssi on 07-01-183
Transmission Cooler and Lines, Backf lushing
and Cleaning 07-01-184
Transmission Fluid Cool er Tube
Leakage ..... 07-01-185
SUBJECT PAGE
SPECIFICATIONS
Checks and Adj ustments 07-01-186
VEHICLE APPLICATION
4 R 7 0 W T r a n s m i s s i o n
The 4R70W transmi ssi on has the following features:
Four speeds.
Rear wheel dri ve.
El ectroni c shift.
Torque converter cl utch control .
Line pressure cont rol s.
Aut o ma t i c Tr a n smi ssi o n
The transmi ssi on uses a Ravigneaux-style
double-pinion compound gearset t o produce four
f orward speeds and reverse. Two bands, t wo one-way
roller cl utches and four friction cl utches are used t o
hold or dri ve vari ous pl anetary gearset members.
D10217-B
T r a n s mi s s i o n I d e n t i f i c a t i o n
All vehi cl es are equi pped wi t h a Vehicle Certi fi cati on
Label , affi xed t o t he LH (dri ver' s) si de door l ock post.
Refer t o t he code in the space marked TR on the
Vehicle Certi fi cati on Label for proper transmi ssi on
identification.
For additional information such as: model , servi ce ID
level or build dat e, refer t o the transmission servi ce ID
t ag whi ch is at t ached t o transmi ssi on case ( 7005) .
07- 01- 3 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 07- 01- 3
Typi cal Tr a n smi ssi o n Servi ce ID Tag
ATTACHED TO PASSENGER SI DE OF CASE
ASSEMBLY NO. MODEL
\
\ CQ O
A S S Y . F 5 A P - B A ^ ^ >
SN-0002951 ' I
s
o
IMIK lllilllHIIIi
C-B0010002S51
.ENGINE
SIZE
SERIAL NO.
D10215-D
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1
9
9
4

I t e m
Pa r t
1 7902 Torque Converter
2 87650-S2 Plug - Converter Drain -
1/8-27 Dryseal
3 7A103 Pump Assy - Front Pump
4 7A248 Front Oil Pump Seal
5 7A248 Front Oil Pump Seal
6 7B258 Bushing - Front Pump
7 N605789-S100 Bo l t - M8- 1. 25X25 Hex Hd
(7-At t 7A103t o 7005)
8
-- Body Assy - Front Pump
(Part of 7A103)
9 7A136 Gasket - Front Pump
10
-
Gear - Front Pump Inner
Gerotor (Part of 7A103)
11

Gear - Front Pump Outer
Gerotor (Part of 7A103)
12 7A108 Front Pump Support
13 N605787-S52 Bo l t - M8- 1. 25X25 Hex Fig
Hd (5 ATT7A108 to 7A103)
14 7D014 Thrust Washer Select Fit No.
j
15 7D020 Reverse Clutch Cylinder
Seal (2 Req'd)
16 7D019 Seal - Forward Clutch
Cylinder (2 Req'd)
17 7F255 Seal - Intermediate Clutch
Piston - Inner
18 7F224 Intermediate Clutch Piston
Outer Seal
19 7E005 Intermediate Clutch Piston
20 7B442 Plate - Interm Clutch External
Spline (Steel) Sel Fit
21 7B164 Plate Assy - Interm Clutch
Internal Spline (Friction)
22 7B066 Plate - Intermediate Clutch
Pressure
23 7F196 Overdrive Band
24 391267-S Ring - 3-21 /64Retai ni ng
Type SU EXT (Ret 7F262 to
7F215)
25 7D191 Retainer - intermediate
One-Way Clutch
26 7F221 Hub - Intermediate Clutch
27 7A089 Clutch Assy - Intermediate
One-Way
28 7D044 Reverse Clutch Drum
29 7D403 Reverse Clutch Piston Outer
Seal
30 7D402 Reverse Clutch Piston
31 7D404 Reverse Clutch Piston Small
Seal
Spring Pressure Ring
33 7B070 Reverse Clutch Piston
Spring
34 7A577 Spring - Reverse Clutch
Piston Spring
35 7B066 Plate - Reverse Clutch Front
Pressure
I t e m
Pa r t
36 7B164 Plate - Reverse Clutch
37 7B442 Plate - Reverse Clutch
External Spline (Steel)
38 7B066 Plate - Reverse Clutch Rear
Pressure
39 7B497 Seal - Input Shaft (2 Req'd)
40 7D483 Retainer - Reverse Clutch
Pressure Plate - Sel Fit
41 7A166 Bearing and Race Assy -
Forward Clutch No. 2
42 7F207 Forward Clutch Cylinder and
Shaft
43 7A548 Seal - Forward Clutch Piston
- Outer
44 7C099 Seal - Forward Clutch Piston
- Inner
45 7A262 Piston - Forward Clutch
46 7A480 Spring - Forward Clutch
Piston Return
47 7A527 Retainer Return Spring -
Forward Clutch
48 388099-S Snap Ring - Retaining -
1-59/64 (Ret 7A529 in
7F207)
49 7E085 Rear Clutch Pressure Spring
50 7B442 Plate - Forward Clutch
External Spline (Steel)
Pressure
53 7D483 Clutch Pressure Plate
Retainer Snap Ring (Select
Fit)
54 7F231 Forward Clutch Hub Front
Bearing No. 3
55 7B067 Hub - Forward Clutch
56 7F351 Shaft - Intermediate Stub
57 7C096 Thrust Bearing - Forward
Clutch Hub No. 4
58 7A019 Gear Assy - Reverse Sun
59 7F244 Bearing and Race Assy -
Forward Clutch Sun Gear No.
5
60 388501-S Retaining Ring - Center
Support - 7-7/92
61 7A399 Gear Assy - Forward Clutch
Sun
62 7A399 Primary Sun Gear
63 7A130 Support Assy - Planetary
Gear
64 7A089 OWC Cage Spring and Roller
Assy - Planetary
65 7A398 Front Planet
66 7D095 Reverse Clutch Band
67 377427-S Retaining Ring - 0.58 Thick
(Locates Rev Bnd During
Assy)
68 7F236 Direct Clutch Hub
( Co n t i n ue d )
07 - 01- 7 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 07 - 01- 7
Pa r t
69 7F243 Direct Clutch Inner Bearing
No. 7
70 7F237 Support - Direct Clutch Inner
Bearing
71 7D483 Retaining Ring - Direct
Clutch Press Plate -Select
Fit
72 7B066 Plate - Direct Clutch
Pressure
73 7B164 Plate - Direct Clutch Internal
Spline (Fri cti on)
74 7B442 Plate - Direct Clutch External
Spline (Steel)
76 388104-S Retaining Ring - 1-19/32
(Ret 7F235t o7F283)
76 7F235 Direct Clutch Support and
Spring
77 7A262 Piston Assy - Direct Clutch
78 7C099 Direct Clutch Inner Seal
79 7A233 Seal - Direct Clutch Piston
Outer
80 7A153 Gear - Output Shaft Ring
81 7F283 Cylinder Assy - Direct Clutch
82 7F274 Output Shaft t o Direct Clutch
Cylinder Seal (2 Req'd)
83 7F240 Direct Clutch Hub Bearing
and Race Outer No. 8
84 7060 Output Shaft
85 7F273 Output Shaft to Case Seal (3
Req'd)
86 87054-S94 Seal - O-Ring (Piloted Output
Shaft Only)
87 7D164 Output Shaft Hub
88 97713-S Snap Ring - 1- 13/ 16
Retaining (Ret 7D164 to
7060)
89 7C122 Snap Ring Retaining (Ret
7D164 t o 7A153)
90 7025 Bushing - Rear Case
91 7F242 Case Rear Bearing No. 9
92 7005 Case
93 7086 Extension Housing Gasket
94 N803747-S100 Bo l t - M8- 1. 25X30 (6 Req'd
Att 7A039 to 7005)
95 7A039 Extension Housing
96 7A034 Extension Housing Bushing
97 7052 Seal Assy - Extension
Housing (Booted)
98 390318-S100 Pipe Plug - 1 /8-27 Dryseal
Tapered (5 Req'd)
99 7F295 Overdrive Band Anchor Pin
100

Pin - Reverse Band Anchor
(Part of 7005)
101 7034 Vent
102 N605771-S2 Bolt - M6-1.0 X 14 Hex Fig Hd
(Att OPS Speed Sensor to
Case)
103 7H103 Output Shaft Speed (OSS)
Sensor
Pa r t
I t e m Nu mb e r De sc r i pt i o n
104 7Z101 Turbine Speed Sensor Seal -
14.0 X 1.78 O-Ring (2 Req'd)
105 N806933-S100 Bolt and Washer Assy -
M6-1. 0X25 MM (2
Req'd)(At t 7F293 t o 7005)
106 7F293 Sensor - Trans Range
107 7A256 Manual Control Lever
108 7B498 Seal Assy - Manual Control
Lever
109 373907-S2 Nut - 1 / 4 Spring (Ret i.D. Tag
t o 7000)
110 -- Tag - Identification (Part of
7005)
111 7D273 Connector Assy - Fluid Tube
(2 Req'd)
112 7N171 Converter Housing Access
Plug
113 7E242 Screen Assy - Fluid
114 7B210 Manual Lever Shaft
Retaining Pin
115 7Z383 Seal - 0.426 X 0.070 O-Ring
116 7Z101 Turbine Speed Sensor Seal -
14.0 X 1.78 O-Ring
117 7G383 Solenoid Valve - Electronic
Pressure Control (EPC)
118 7A441 Parking Pawl
119 7D071 Parking Pawl Shaft
120 -- Cup - Park Rod Guide (Part
of 7A039)
121 7D070 Parking Pawl Return Spring
122 7A232 Parking Lever Actuating Rod
123 7A115 Manual Valve Detent Lever
124 N800287-S51 Nut -M14 X 1.5 Hex-I nt erm
Det Lvr (Att 7A115 t o 7A256)
125 7H188 Piston Assy - Overdrive
Servo
126 7F201 Overdrive Servo Piston
Return Spring
127

Rod - Overdrive Servo
Actuating (Part of 7H188)
128 Washer - Backup Overdrive
Servo Bellville (Part of
7H188)
129 Spring - Bellville Overdrive
Cushion Spring (Part of
7H188)
130 -- Piston Assy - Overdrive
Servo (Part of 7H188)
131
-
Ring - Retaining (Part of
7H188)
132 -- Sleeve Assy - Overdrive
Servo (Part of 7H188)
133 7384 Accumulator Piston
Retaining Ring - 2.85
Retaining Type TVP "H"
Internal (Ret 7H188 t o 7005)
134 7D031 Reverse Band Servo Spring
135 7D189 Reverse Band Servo Piston
and Rod
136 7D036 Reverse Band Servo Cover
( Co n t i n ue d )
07 - 01- 8
T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W
J L . Mk J L #fr ML
07 - 01- 8
Pa r t
137 388215-S100 Retaining Ring - Internal -
3-13/16
138 7F250 Seal - 2-3 Accumulator
Piston - Upper
139 7F251 Piston - 2-3 Shift
Accumulator
140 7F249 Seal - 2-3 Accumulator
Piston - Lower
141 7F285 Spr i ng-2-3 Shift
Accumulator Piston
142 7B264 Ret ai ner-2-3 Shift
Accumulator Spring
143 7F284 Spring - 1-2 Shift
Accumulator (Model
Dependant)
144 7F248 Seal - 1-2 Shift Accumulator
Piston
145 7F251 Piston - 1-2 Shift
Accumulator
146 7F249 Seal - 1-2 Shift Accumulator
Piston - Lower
147 7F284 Spring - 1-2 Shift
Accumulator
148 7H300 Cover and Seal Assy - 1-2
Accumulator
Retaining Ri ng-2-1/ 16
Retaining Type HU Internal
(Ret 7H300 to 7005)
150 N605517-S1000 Bol t -M6-1. 0X 16HexHd
(12-Att7F282 t o7A100,
7A008 and 7G136
151
-
Plate - Valve Body
Reinforcing (Part of 7A100)
152 7C155 Main Control to Case Gasket
- Upper
153

Plate - Control Valve Body
Separator (Part of 7A100)
154 7C155 Main Control to Case Gasket
- Lower
155 7H171 Valve - Converter Drainback
156 7A100 Main Control Valve Body
157 7H173 Gasket - Valve Body Cover
Plate
Pa r t
158
-
Plate - Valve Body Cover
(Part of 7A100)
159 Bol t -M6-1. 0X 18HexHd
(4-Att 7C034 to 7A100)(Part
of 7A100)
160 7A098 Filter and Seal Assy - Fluid
161 7A191 Gasket - Trans Pan
162 7A194 Pan - Trans
163 N605785-S1036 Bol t -M8-1. 25X 18 Hex Fig
Hd (14-Att 7A194 to 7005)
164 -- Magnet - Ceramic Case (Part
of 7A194)
165 7H141 Transmission Fluid
Temperature (TFT) Sensor
166 N806381-S1300 Bol t -M8-1. 25X46 Hex
Shldr Pilot (2-Att 7C034t o
7A100)
167 N807179-S1000 Bolt - M6- 1.0X52 Hex Fig Hd
(12-Att 7A100 to 7005)
168 7H111 Solenoid Retainer
169 7E195 Ball - 1/4 Dia Coast Booster
Valve Shuttle (8 Req'd)
170 7H187 Screen - Solenoid Pressure
Supply
171 N606022-S1000 Bolt - M6- 1. 0X40 Hex Fig Hd
(13-Att 7A100t o 7005)
172 7E332 Manual Valve Detent Spring
173 7Z276 Seal - 0.864 X 0.070 O-Ring
(2 Req'd)
174 7G276 Wiring Connector Bulkhead
175 7Z484 Shift Control Solenoid Seal -
6.07 x 1.70 O-Ring (2 Req'd)
176 7G484 Shift Solenoid
177 7H186 Shift Control Solenoid
Bracket
178 7G136 Solenoid Valve - Torque
Converter Clutch (TCC)
179 7Z136 Seal - 0.489 x 0.070 O-Ring
180 7Z484 Shift Control Solenoid Seal -
0. 176x0. 070 O-Ring
A Intermediate Clutch Assy
B Reverse Clutch Assy
C Forward Clutch Assy
D Direct Clutch Assy
T r a n s m i s s i o n R a n g e S e l e c t o r a n d S h i f t
P a t t e r n s
The t ransmi ssi on range sel ect or has si x posi t i ons:
P,R,N, , 2 a n d 1.
R |
/
2 1
TRANSMISSION
SELECTOR
INDICATOR
D102 2 2 - C
(P) P a r k
There is no power f l ow t hrough t he t ransmi ssi on in
PARK range.
07 - 01- 9 07 - 01- 9
The parki ng pawl ( 7A441) l ocks t he output shaft
( 7060) t o t he case ( 7005) t o prevent the vehicle
f rom rolling.
For safety reasons, the vehi cl e parki ng brake
control ( 2780) shoul d al so be used when the vehi cl e
is parked and not in use.
The engine can be st art ed in the PARK range.
PARK must be sel ect ed before the ignition key can
be removed.
(R) Re v e r s e
Reverse gear enabl es t he vehi cl e t o be operat ed in
a rearward di recti on, at a reduced rati o.
There is engine braki ng in REVERSE.
(N) Ne u t r a l
There is no powerf l ow through the transmi ssi on in
NEUTRAL.
Wheel s are f ree t o move because t he output shaft is
not held by the parki ng pawl .
The engine may be st art ed in NEUTRAL.
Ignition key cannot be removed whi l e the vehicle is
in thi s range.
( ) Ov e r d r i v e
Overdri ve is t he normal sel ector posi ti on for most
f orward driving condi ti ons. This posi ti on provi des:
Automati c shifts (fi rst through f ourt h).
Appl i cati on and rel ease of the t orque converter
cl ut ch.
Maxi mum fuel economy during normal operati on.
( 2 ) S e c o n d
Sel ecti on of t he second gear posi ti on ( 2) provi des
second gear st art and hol d.
Appl i cati on of the torque conver t er cl ut ch may al so
occur in thi s range, dependi ng on transmi ssi on and
vehi cl e condi ti ons.
Thi s position can be sel ect ed when starti ng on
sl i ppery roads f or i mproved t ract i on, or engine
braki ng.
( 1) Ma n u a l L o w
Sel ecti on of Manual 1 or Manual LOW posi ti on at idle
will al l ow fi rst gear operati on only (no upshi fts).
If thi s position is sel ected at normal road speeds,
the transmi ssi on will initially downshi ft into second
gear, then downshi ft into first gear when vehicle
speed falls bel ow approxi mat el y 45 k m/ h ( 28 mph).
The Manual LOW position will provi de engine
braki ng, maki ng it especi al l y useful for descendi ng
st eep grades.
T r a n s mi s s i o n C o n t r o l S w i t c h ( T CS)
Overdri ve may be cancel l ed by pressi ng the
Transmission Control Swi t ch (TCS) on the gear
sel ector lever.
Wi t h overdri ve cancel l ed t he transmi ssi on will allow
automati c shi fts f rom fi rst through thi rd gears only.
Overdri ve shifting though all four gears may be
act i vat ed again by pressi ng the TCS.
Thi s should be done at cl osed throttl e for best shift
response.
07 - 01- 10
07- 01- 10
Main Components and Function
Tr a nsmi ssi on Mai n Co mpo n e n t s- Se c t i o n a l Vi ew
D14697-A
I t e m
Pa r t
Pa r t
1 7B164A Intermediate Clutch 6 7F351 Stub Shaft
2 7B164E Reverse Clutch 7 7060 Output Shaft
3 7B164D Forward Clutch 8 7A089 Planetary One-Way Clutch
4 7B164B Direct Clutch 9 7D095 Reverse Clutch Band
5 7F207 Forward Clutch Cylinder and 10 7F196 Overdrive Band
Input Shaft 11 7A089 Intermediate One-Way
(Continued)
Clutch
T o r q u e C o n v e r t e r
The t ransmi ssi on uses a pressure pl at e-st yl e t or que
convert er ( 7 902) .
C O V E R
P R E S S U R E T U R B I N E S T A T O R I M P E L L E R
P L A T E
D10218-A
0 7 - 0 1 - 1 1 T r a n s mi s s i o n , A u t o m a t i c 4 R7 0 W 07- 01- 11
The torque converter for the transmi ssi on is a
four-element converter. It contai ns t he standard t hree
el ements whi ch transmi t and multiply torque:
Impeller,
e Turbine.
Stator.
Plus a torque converter cl utch for i ncreased fuel
economy in thi rd and fourth gears.
The operati on of the torque convert er components is
as fol l ows:
Rotati on of the converter housing and impeller set
the fluid in moti on.
The turbine react s to the fluid moti on from the
impeller, transferri ng rotati on t o t he geartrai n.
The st at or redi rects fluid goi ng back into the
impeller, allowing for torque multiplication.
The addition of a torque converter cl utch t o t he torque
converter provi des a mechani cal link between the
converter housing and the engine, allowing for di rect
transfer of power f rom the engine t o the geartrai n.
The convert er cl utch pressure plate ( 7B066) is
appl i ed and rel eased by fluid pressure, whi ch is
control l ed by t he powertrai n control module
( PCM) ( 12A650) through an el ectroni c pressure
control (EPC) solenoid in the main control val ve body
( 7A100) .
Torque Co n v e r t e r Se c t i o n a l Vi ew
D11472-A
I t e m
Pa r t
1 Torque Converter Cover
(Part of 7902)
2 Turbine (Part of 7902)
3 Impeller (Part of 7902)
4

Stator (Part of 7902)
5

Torque Converter Clutch
(Part of 7902) j
G e a r t r a i n
Power is transmi tted from the t orque converter t o the
Ravigneaux geartrai n components through t he input
shaft and f orward cl utch cylinder and shaft ( 7F207) .
The geartrai n contains a compound pl anetary set
connected by dual pinion gears.
By holding or driving certai n members of t he
gearset, four f orward rati os and one reverse ratio
are obtai ned and transmi tted t o t he output shaft
( 7060) . The rati os are as fol l ows:
Gear Ra t i o s
1st ge a r 2 . 84 to 1
2 n d ge a r 1. 55 ::> ;
3r d ge a r 1. 00 to 1
4t h ge a r 0. 7 0 ?o "
1
Re v e r s e 2 . 32 <:o ']
Members of the gearset are held or driven by a
seri es of bands or cl utches.
DE S C R I P T I O N A N D O P E R A T I O N ( C o n t i n u e d )
The t ransmi ssi on uses:
Two bands.
Two one-way roller cl utches.
Four fri cti on cl utches.
P l a n e t a r y G e a r s e t
The pl anetary gearset in the transmi ssi on is a
Ravi gneaux-type set consi sti ng of the following
components:
Pri mary sun gear ( 7A399) .
Reverse cl utch gear and shell ( 7A019) .
A pinion carrier.
Long and short pinions.
Ring gear ( 7A153) .
Members are driven or held t o produce four f orward
gear rati os plus one reverse rati o.
I n p u t S h a f t
The f or war d cl utch cylinder and shaft transfers speed
and torque f rom t he converter turbine t o t he geartrai n.
This f orward cl utch cylinder and shaft is splined t o the
turbine shaft ( 7F351) on one end and t o the f orward
sun gear and turbine shaft on the other end.
P l a n e t a r y G e a r s e t
The pl anetary gearset in t he transmi ssi on is a
Ravi gneaux-type set consi sti ng of the following
components:
Forward sun gear.
Reverse cl utch gear and shell.
A pinion carri er.
Long and short pinions.
Ring gear.
Members are driven or held t o produce four f orward
gear rati os piug one reverse rati o.
Fo r wa r d Cl u t c h Cy l i n d e r a n d Sha f t
The f or war d cl utch cylinder and shaft transfers speed
and torque f rom t he converter turbine t o t he geartrai n.
Thi s shaft is splined t o the turbine on one end and t o
t he f or war d cl utch cylinder and stub shaft on t he other
end.
St u b Sh a f t
The stub shaft transfers power f rom the turbine shaft
t o t he planet carri er (through the di rect cl utch) during
thi rd and fourth gear operati on.
Ou t p u t S h a f t
The output shaft provi des t orque t o the propeller shaft
and rear axl e assembl y ( 4200) . It is driven by the ring
gear of the pl anetary gearset .
Hy d r a u l i c S y s t e m
Fl ui d P u mp
The transmi ssi on uses a gerot or design front pump
support and gear ( 7A103) . The pump is more efficient
at l ower engine speeds. It is al so made of aluminum.
OUTER ROTOR
D10219-A
Ma i n Co n t r o l Va l ve Bo d y
The main control val ve body houses four electronic
solenoids:
Two shift solenoids ( 7G484) .
Torque converter cl utch solenoid (TCC
sol enoi d)(7G136).
Electronic pressure control (EPC) solenoid.
T r a n s m i s s i o n E l e c t r o n i c C o n t r o l S y s t e m
The powertrai n control module (PCM)(12A650) and its
i nput / out put network control the following
transmission operati ons:
Shift scheduling.
Line pressure (shift feel ).
Torque converter cl utch.
The transmission control is separat e f rom the engine
control st rat egy in the PCM, al though some of t he
input signals are shared.
DESCRI PTI ON A N D OPERATION (Conti nued)
The powertrai n control module recei ves some input
signals f rom engine-related sensors, including:
Mass air fl ow sensor (MAF sensor)( 12B579).
Engine cool ant temperature sensor (ECT
sensor)(12A648).
Barometri c pressure sensor (BARO sensor).
These signals provi de information t o t he powertrai n
control module about t he load and cl i mate under whi ch
the engine is operati ng. Some other inputs are based
on dri ver inputs, such as accel erator pedal position
whi ch is rel ated t o the powertrai n control module by
the throttl e position sensor (TP sensor)(9B989). Still
other inputs are provi ded by:
e Transmission components.
e Output shaft speed (OSS) sensor.
Transmission range (TR) sensor (control l ed by
dri ver pl acement of the shift l ever).
Transmission fluid temperature sensor (TFT
sensor).
Using all of t hese input signals, t he powertrai n control
module can determi ne when t he ti me and condi ti ons
are right for a shift or torque converter cl utch
appl i cati on. The powertrai n control module can al so
determi ne the line pressure needed t o opti mi ze shift
feel . To accompl i sh t hese functi ons, the powertrai n
control module control s four el ectroni c sol enoi ds:
m Two On / Off shift sol enoi ds ( 7G484) .
One pulse- wi dt h modul ated torque converter cl utch
solenoid (TCC sol enoi d)(7G 136) for t orque
converter cl utch (TCC) control or "cont rol l ed sl i p"
of t he torque converter cl utch.
An el ectroni c pressure control (EPC) sol enoi d for
line pressure cont rol .
The powert rai n control modul e recei ves and sends
el ectri cal signals t hat are used t o make t he
transmi ssi on more responsi ve t o dri ver and vehi cl e
needs.
The dri ver demands are transmi tted t o the powert rai n
control modul e through four components:
T r a n s mi s s i o n r a n ge s e l e c t o r l e v e r The dri ver' s
demand for a parti cul ar gear range is transl ated into
an el ectri cal signal for t he powertrai n control
modul e by t he transmi ssi on range (TR) sensor.
A c c e l e r a t o r p e d a l The dri ver' s demand for
t orque and accel erati on are sent mechani cal l y t o
t he throttl e body ( 9E926) on t he engine. A throttl e
posi ti on sensor then t ransl at es this mechani cal
moti on into an el ectri cal signal and sends it t o t he
powert rai n control modul e.
Br a ke p e d a l A brake on / off (BOO) swi t ch tells
t he powert rai n control module when the brake is
appl i ed, indicating t he dri ver demand t o di sengage
t he t orque converter ( 7902) .
T r a n s mi s s i o n Co n t r o l S w i t c h A momentary
cont act swi t ch, l ocated on the side of t he
transmi ssi on range sel ector that al l ows t he dri ver t o
manually sel ect t hree or four speed operati on.
T r a n s mi s s i o n , Au t o ma t i c 4 R7 0 W 07 - 01- 14
PCM i n put s and Out put s
CONTROL
SWITCH (TCS)
CONTROL
INDICATOR
LAMP (TCIL)
BRAKE ON/OFF
(BOO) SWITCH
IKkMSMlSSflOM
| AW| E| TR)
OUTPUT SHAFT
VEHICLE i
1^PSl i l S&fl W FLU
TERJIPgRATURg
POWERTRAIN
CONTROL
MODULE
{PCM)
m
BGNIT80N CONTROL
MODULI
8GNIT0ON COILS
THROTTLE!
(TP) SEN!
/ / 1
ELECTRONIC
CONTROL ( E P C)
SOLENOID
TORQUE
CONVERTER
CLUTCH (TCC)
SOLENOID J
ENGINE
QGOUMT
TEMPERATURE
(ECT) SENSOR
SHIR" SOLENOID
! ASSEMBLIES (SSI , SS2)
TORQUE
CONVERTER
CLUTCH (TCC)
SOLENOID J
ENGINE
QGOUMT
TEMPERATURE
(ECT) SENSOR
MASS AIR FLOW
{MAF} SENSOR
INTAKE AIR
TEMP
(IAT) i
ME CONDITIONING
CLUTCH (A/C)
D1
1 995 Town Car, Cr own Vi ct or i a, Gr and Mar qui s Jul y 1994
07 - 01- 15
izzr. "7";.. smaaar
07 - 01- 15
Po we r t r a i n Co n t r o l Modul e (PCM) 12A650:
The operat i on of t he t ransmi ssi on i s cont rol l ed by t he
powert rai n cont rol modul e. Many input sensors
provi de i nf ormat i on t o t he powert rai n cont rol modul e.
The powert rai n cont rol module t hen cont rol s
act uat ors whi ch det ermi ne t ransmi ssi on operat i on.
D10130-J*
DTCs: P0605. P1605
Engi ne Co o l a n t Te mpe r a t ur e (ECT) Se nsor 12A648:
The engine cool ant t emperat ure sensor de t e c t s
t emperat ure of engi ne cool ant and suppl i es
i nformati on t o t he powert rai n cont rol modul e. The
engi ne cool ant t emperat ure sensor is i nst al l ed into
t he heat er out l et f i t t i ng or cool i ng passage on t he
engi ne. For engi ne cont rol appl i cat i ons, t he ECT
si gnal is used t o modi f y i gni ti on cont r ol , EGR f l ow and
air- t o-f uel rat i o as a f unct i on of engi ne cool ant
t emperat ure. On el ect roni c i nstrument cl ust er s, t he
ECT output is used t o cont rol t he cool ant t emperat ure
i ndi cat or. The ECT sensor is used t o cont rol t orque
convert er cl ut ch operat i on.
ELECTRICAL
CONNECTOR
I n t a ke Ai r Te mpe r a t ur e (IAT) Se n so r 12A697:
The i nt ake ai r t emperat ure sensor pr ovi des t he
sequent i al f uel i nj ect i on (SFI) sy st e m wi t h mi xt ure
(fuel and air) t emperat ure i nf ormat i on. The i nt ake air
t emperat ure sensor is used bot h as a densi t y
c or r e c t or for air f l ow cal cul at i on and t o proport i on
col d enri chment fuel f l ow. The i nt ake ai r t emperat ure
sensor is i nst al l ed in t he ai r cl eaner out l et t ube and
provi des t he fuel syst em wi t h mi xt ure t emperat ure
i nf ormat i on. The i nt ake air t emper at ur e sensor is
used in det ermi ni ng EPC pr essur e.
TEST PIN 39.
TEST PIN 91 SIG RTN
VEHICLE
HARNESS
CONNECTOR
D14104-A
Sy mpt o ms : I ncorrect EPC pressure, ei t her hi gh or
low, wi l l result in ei t her harsh or sof t shi f t s.
DTCs: P0112, P0113, P0114
TEST PIN 91 0 <
TEST PIN 38
SIG RTN
ECT
VEHICLE
HARNESS
CONNECTOR
D14103-A
Sy mpt o ms: Torque convert er cl ut ch wi ll al ways be
off, resul t i ng in r educed fuel economy.
DTCs: P0117, P0118, P1116, P1117
Transmi ssi on Cont rol Swi t ch ( TCS) and
Tr ansmi ssi on Cont rol Indi cator Lamp (TCI L)
The t ransmi ssi on cont rol swi t ch is a moment ary
cont act swi t ch. When t he swi t ch is pr essed, a si gnal
is sent t o t he powert rai n cont rol module t o allow
aut omat i c shi f t s f rom f i rst t hrough f ourt h gears or f i rst
t hrough t hi rd gears only. The powert rai n cont rol
module energi zes t he t ransmi ssi on cont rol i ndi cat or
lamp (TCIL) when t he swi t ch is off. The TCIL
i ndi cat es overdri ve cancel mode act i vat ed (lamp ON)
and EPC ci rcui t short ed (lamp f l ashi ng) or moni t ored
sensor f ai l ure.
TRANSMISSION CONTROL
INDICATOR LAMP
O/ D
O F F
Tr a n smi ssi o n Co n t r o l Swi t c h (TCS) a n d
Tr a n smi ssi o n Co n t r o l I n d i c a t o r La mp (TCIL) ( Co n t ' d )
Se nsor : Transmi ssi on Cont rol Swi t ch (TCS)
Sy mpt o ms: No overdri ve cancel when swi t ch is
c y c l e d.
DTC: P1780 t e st e d during Key On Engine Off (KOEO)
Sel f -Test .
Ac t ua t o r : Transmi ssi on Control Indi cat or Lamp
(TCIL)
Sy mpt o ms:
FAILED ON:Overdri ve cancel mode al ways
i ndi cat ed, no f l ashi ng for EPC ci rcui t short ed or
moni t ored sensor f ai lure.
FAILED OFFOver dr i ve cancel mode never
i ndi cat ed, no f l ashi ng for EPC ci rcui t short ed or
moni t ored sensor f ai lure.
DTC: TBD
SWITCH
TO IGNITION-
SWITCH
TEST PIN 7 9
T C I L
FUSE , r~^^y
HSCTION
PANEL -
n
TCS
TEST PIN 29 ^
SWITCH HARNESS
CONNECTOR
*TEST PINS LOCATED ON BREAKOUT BOX.
ALL HARNESS CONNECTORS VIEWED INTO
MATING SURFACE.
D14105-A
07 - 01- 17 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W
0 7 - 0 1 - 1 7
Tr ansmi ssi on Flui d Temperat ure (TFT) Se n so r
7 H141:
The t ransmi ssi on flui d t emperat ure (TFT) sensor is
l ocat ed on t he t ransmi ssi on main cont rol val ve body.
It is a t emperat ure sensi t i ve devi ce cal l ed a
t hermi st or. The resi st ance value of t he TFT wi l l vary
wi t h t emperat ure change. The powert rai n cont rol
module moni t ors t he vol t age acr oss t he TFT t o
det ermi ne t he t emperat ure of t he t ransmi ssi on f l ui d.
The powert rai n cont rol module uses t hi s vol t age
si gnal t o det ermi ne whet her a col d st art shi ft
schedul e i s necessary. The shi f t schedul e is
compensat ed when t he t ransmi ssi on f l ui d is col d. The
powert rai n cont rol module al so i nhi bi t s t orque
convert er cl ut ch operat i on at low t ransmi ssi on flui d
t emperat ures and cor r ect s EPC pressures f or
t emperat ure.
D14141-A
Sy mpt o ms : Torque convert er cl ut ch (TCC)
engagement and st abi l i zed shi f t schedul es happen
t oo soon af t er a col d st art .
DTCs: P07 12, P07 13, P17 11, P17 83
Tr a n smi ssi o n Range (TR) Se n so r 7 F293:
The TR sensor sends a si gnal t o t he powert rai n
cont rol modul e t o i ndi cat e t he posi t i on of t he manual
cont rol l ever (P, R, N, , 2, 1). The TR sensor is
l ocat ed on t he out si de of t he t ransmi ssi on at t he
manual cont rol lever. The TR sensor det ermi nes
desi red gear and EPC pressure. The TR sensor al so
cont ai ns ci rcui t s f or Pa r k/ Ne ut r a l and backup l amps.
(1) 32 R/ LB St art er Cont rol
(2) 298 W/ L B Accessor y Feed (Crown Vi ct or i a,
Grand Marqui s)
640 R / Y Accessor y Feed (Town Car)
(3) 140 BK/ PK Back-Up Lamps
(4) 33 W/ P K St art er Cont rol t o Int erl ock Ci rcui t
(5) Not Used
(6) 199 L B/ Y TR Sensor t o PCM
(7) 359 GY/ R PCM Si gnal Return
(8) Not Used
Sy mpt o ms: Engagement concerns, wrong gear, no
shi f t s, i ncrease in EPC pressure.
DTCs: P0707, P0708, P1705
07- 01- 18
T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 07- 01- 18
St o pl i ght Swi t c h 13480:
The brake o n / o f f (BOO) swi t ch t el l s t he powert rai n
control module when the brakes are appl i ed. The
swi tch cl oses when brakes are appl i ed and opens
when they are r el eased. The BOO swi t ch will al so
di sengage t orque convert er cl ut ch when t he brake is
appl i ed.
HOT AT ALL TIMES
FUSE
JUNCTION
PANEL
BRAKE
ON/OFF
SWITCH
TEST PIN 92 O BOO
STOPLAMP
D14106-AI
Sy mpt o ms:
Fai l ed ONt or que convert er cl ut ch wi ll not engage
at l ess t han one-t hi rd t hrot t l e.
Fai l ed OFF or not c o n n e c t e d t o r que convert er
cl ut ch wi ll not di sengage when brake is appl i ed.
DTCs: P0703, P1703
El e c t r o n i c I gn i t i o n (El)
The el ect roni c i gni ti on (El) syst em consi st s of a
crankshaf t posi t i on sensor, i gni ti on cont rol modul e,
t wo f our t ower i gni ti on coi l s and t he powert rai n
cont rol modul e. The i gni ti on cont rol module oper at es
by sendi ng crankshaf t posi t i on i nf ormat i on f rom t he
crankshaf t posi t i on sensor t o t he i gni ti on cont rol
modul e. The i gni ti on cont rol module generat es a
crankshaf t posi t i on (CKP) si gnal (engi ne rpm) and
sends it t o t he powert rai n cont rol module. The
powert rai n cont rol module uses t he CKP si gnal in t he
t ransmi ssi on st rat egy, as well as wi de-open t hr ot t l e
(WOT) shi f t cont r ol , t orque convert er cl ut ch cont rol
and EPC pressure.
IGNITION CONTROL
MODULE 12K072
IGNITION
COILS 12029
CRANKSHAFT POSITION
SENSOR (CKP) 6C315
D10193-C
Sy mpt o ms: Harsh engagement s and shi f t s, l at e WOT
shi f t , no t orque convert er cl ut ch engagement .
DTCs: P0300 t hrough P0308, P0320, P0340, P1351
t hrough P1364
07- 01- 19 T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W 0 7 - 0 1 - 1 9
Ai r Co n d i t i o n i n g Cl ut c h ( A / C Cl ut c h) 2 884:
OEM Fa c t o r y I nst a l l e d
An el ect romagnet i c cl ut ch is energi zed when t he A / C
cycl i ng swi t ch cl oses. The A / C cycl i ng swi t ch is
l ocat ed on t he suct i on a c c umul a t or / dr i e r . The
cl osi ng of t he swi t ch cont act s compl et es t he ci rcui t
t o t he A / C cl ut ch and draws it into engagement wi t h
t he compr essor dri veshaf t . The powert rai n cont rol
module uses t hi s si gnal t o adj ust EPC pressure when
t he air condi t i oni ng cl ut ch is engaged t o compensat e
for addi t i onal load on t he engi ne.
WAC
RELAY
(NORMALLY
OPEN)
TO VPWR
TEST PIN 41
A/C CYCLING [ 1
SWITCH
4 1
TO A/C
DEMAND SWITCH D14107-A
Sy mpt o ms:
Fai l ed ONEPC pressure sl i ght l y low wi t h A / C
OFF.
Fai l ed OFFEPC pressure sl i ght l y hi gh wi t h A / C
ON.
DTC: P1460
Mass Ai r Fl o w (MAF) Se nsor 12B57 9:
The mass air f l ow sensor di rect l y measures t he mass
of air f l owi ng into t he engi ne. The sensor out put is a
DC (anal og) si gnal rangi ng f rom 0.5 vol t t o 5 vol t s
used by t he powert rai n cont rol module t o cal cul at e
f uel i nj ect or pulse wi dt h. For t ransmi ssi on st r at egi es
t hi s mass air f l ow sensor is used for EPC pressure
cont r ol , shi ft and t orque convert er cl ut ch schedul i ng.
The powert rai n cont rol module uses t hi s si gnal f or
EPC pressure cont r ol , shi f t and t orque convert er
cl ut ch schedul i ng.
TEST PIN 88<5>-MAF
TEST PIN 36-MAF ^
TEST PIN 5 1 P 1 l _ r
76,77,103
TEST PIN 60~GND"
TEST PIN 7 1- VPWRT
TEST PIN 97 0
1
VEHICLE HARNESS
CONNECTOR
D14108-A
Sy mpt o ms: Hi gh/ l ow EPC pressure, i ncorrect shi f t
schedul e, i ncorrect convert er engagement
schedul i ng and sympt oms si mi lar t o a t hr ot t l e
posi t i on (TP) sensor mal f unct i on.
DTCs: P0102, P0103, P1100, P1101
07 - 01- 2 0 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 07- 01- 20
Thr o t t l e Po si t i o n (TP) Se nsor 9B989:
The t hrot t l e posi t i on sensor is a pot ent i omet er
mount ed on t he t hrot t l e body. The TP sensor det ect s
t he posi t i on of t he t hrot t l e pl at e and sends t hi s
i nf ormat i on t o t he powert rai n cont rol module as a
varyi ng vol t age si gnal . The powert rai n cont rol module
uses t hi s si gnal t o cont rol shi ft schedul i ng, EPC
pressure cont rol and t orque convert er cl ut ch cont rol .
Sy mpt o ms: Harsh engagement s, firm shi ft f eel ,
abnormal shi ft schedul e, t orque convert er cl ut ch
does not engage, t orque convert er cl ut ch cycl i ng.
DTCs: P0122, P0123, P1120, P1121, P1124, P1125
Out put Sha f t Spe e d Se nsor (OSS) 7H103:
The out put shaf t speed (OSS) sensor is a magnet i c
pi ckup, l ocat ed at t he output shaf t ring gear t hat
sends a si gnal t o t he powert rai n cont rol module t o
i ndi cat e t ransmi ssi on output shaf t speed. The
powert rai n cont rol module uses t hi s si gnal for t orque
convert er cl ut ch cont rol , shi ft schedul i ng, used in
det ermi ni ng EPC pressure.
SRTN
L - O TEST PIN 91
1
0 TEST PIN 84
O S S
D14110-A
Sy mpt o ms : No convert er engagement s, harsh shi f t s,
abnormal shi ft schedul es.
DTC: P0720
Vehi cl e Spe e d Se nsor (VSS) 9E 7 31:
The vehi cl e speed sensor is a magnet i c pi ckup t hat
sends a si gnal t o t he powert rai n cont rol module. Thi s
VSS si gnal t el l s t he powert rai n cont rol module
vehi cl e speed. The powert rai n cont rol module uses
t hi s si gnal t o modi fy upshi ft schedul es.
D14111-A
Sy mpt o ms: Shi ft engagement /di sengagement
(hunti ng) on grades.
DTC: P0500
07 - 01- 2 1 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 07 - 01- 2 1
Shi f t So l e n o i d Asse mbl y , Shi f t Co n t r o l So l e n o i d s 1
a nd 2 (7G484):
Two ON / OFF shift sol enoi ds are used for el ect roni c
shi ft schedul i ng. One unit cont ai ni ng t he t wo shi ft
sol enoi ds is l ocat ed in t he main cont rol valve body.
The shi ft sol enoi ds are two- way, normally open st yl e.
Shift sol enoi ds SS-1 and SS-2 provi de gear sel ect i on
of f i rst t hrough f ourt h gears by cont rol l i ng t he
pressure t o t he t hree shi f t val ves.
VPWFKDTEST PIN 71, 97
5 5 1 TEST PIN 27
552 TEST PIN 1
WHITE
SHIFT SOLENOID
NO. 2 (SS2)
SHIFT SOLENOID
NO. 1 (SS1)
D14112-A
SS-1 Sy mpt o ms: Improper gear sel ect i on dependi ng
on f ai l ure mode and manual lever posi t i on.
Fai l ed ONf i r st and f ourt h gear only.
Fai l ed OFFse c o n d and t hi rd gear only.
DTCs: P0750 *, P0751 * *, P0781 * *, P0782 * *,
P07 83* * , P17 51
SS-2 Sy mpt o ms: Improper gear sel ect i on dependi ng
on f ai l ure mode and manual lever posi t i on.
Fai l ed ONt hi r d and f ourt h gear only.
Fai l ed OFFf i r st and second gear only.
DTCs: P0755*, P0756* * , P07 82 * *, P0783* *,
P 17 33* \ P 17 56
Shi f t So l e n o i d Asse mbl y , Shi f t Co n t r o l So l e n o i d s 1
a n d 2 (7G484): ( Co n t ' d )
SS-1 a n d SS-2 Sy mpt o ms:
Bot h f ai l ed ONf our t h gear only.
Bot h f ai l ed OFFse c o n d gear only.
DTCs: P0750 *, P0751, P0755 *, P0756
* Out put ci rcui t check, generat ed onl y by el ect r i cal
condi t i ons.
* * May al so be generat ed by some non-el ect ri cal
t ransmi ssi on component condi t i on.
To r que Co n v e r t e r Cl ut c h (TCC) So l e n o i d 7 G136:
The t orque convert er cl ut ch sol enoi d is used t o
cont rol t he appl y and rel ease of t he t orque convert er
cl ut ch.
TEST PIN 82 O T C C
TEST PIN 71, 97 -TCC VPWR
GREEN
D14113-A
Sy mpt o ms:
Fai l ed ONengi ne st al l s in second gear (D, 2
range) at low i dle speeds wi t h t he brake appl i ed.
Fai led OFFt or que convert er cl ut ch never
engages.
DTCs: P0741 * *, P 07 43\ P 17 44* *, P 17 41* * ,
P1742, P1743
* Output ci rcui t check, generat ed only by el ect ri cal
condi t i ons.
07- 01- 22 T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W 07- 01- 22
El e c t r o n i c Pr essur e Co n t r o l (EPC) So l e n o i d 7 G383:
The el ectroni c pressure control ( E P C ) solenoid
regulates transmission E P C pressure. E P C valve
pressure is used to control line pressure and the 2-3
backout valve f unct i on.
D14114-A
Sy mpt o ms:
Failed ONMi ni mum EPC pressure (minimum
c a pa c i t y ), limit engi ne t orque (al t ernat e f i ri ng).
Fai led OFFMa x i mum EPC pressure, harsh
engagement s, harsh shi f t s.
El e c t r o n i c Pr essur e Co n t r o l (EPC) So l e n o i d 7G383:
(Cont ' d)
DTCs: P1746, P1747
* Output ci rcui t check, generat ed only by el ect ri cal
condi t i ons.
S o l e n o i d Op e r a t i o n s C h a r t s
Sol enoi ds
Transmi ssi on
Range Sel ect or
Lever Posi t i on
PCM
Commanded
Gear SS-1 SS-2 TCC
P / R / N 1 ON OFF HD

1 ON OFF HD
2 OFF OFF EC

3 OFF ON EC

4 ON ON EC

w/ OD OFF
1 1 ON OFF HD
2 2 OFF OFF EC
3 3 OFF ON EC
Ma n u a l 2 2 OFF OFF EC
Ma n u a l 1 1 ON OFF HD
A
1 2 OFF OFF EC
a Wh e n a ma n ua l pul l - i n o c c u r s a b o v e a c a l i b r a t e d s p e e d t h e
t r a n s mi s s i o n wi l l d o wn s h i f t f r o m t h e h i gh e r ge a r unt i l t h e
v e h i c l e s p e e d d r o p s b e l o w t hi s c a l i b r a t e d s p e e d .
EC = Electronically Controlled
HD = Hydraulically Di sabl ed
Internal Tr ansmi ssi on Co n n e c t o r / Ha r n e ss Di agram
TEST PIN 1
TEST PIN 97
TEST PIN 71 CD-
TEST PIN 2 7
TEST PIN 91
TEST PIN 37
TEST PIN 81
TEST PIN 8 2
TEST PIN 2 4 ^ ^
TEST PIN 84
U V 3
'
W
TEST PIN 64
OUTPUT SHAFT SPEED
SENSOR VEHICLE
HARNESS CONNECTOR
TRANSMISSION
RANGE (TR) SENSOR
VEHICLE HARNESS
CONNECTOR
D14115-A
07 - 01- 2 4 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W
07 - 01- 2 4
El e c t r i c a l S c h e ma t i c
Transmi ssi on El ect roni c Cont r ol Sy st e m
I
36I1TR
T PCM POWER
1 REL AY ( NEXT
8
TO POWER
1 DISTRIBUTION
TO
INTAKE AIR
TEMPERATURE
SENSOR
of thi s circuit
TO THROTTLE TO
POSITION SENSOR STOPLIGHT
(TP) SWITCH
i i i
TO
ENGINE
COOLANT TO
TEMPERATURE MASS AIR
SENSOR FLOW SENSOR VEHICLE
SPEED
IGNITION CONTROL
MODULE
(PROFILE IGNITION
PICKUP SIGNAL)
TO
MASS AIR
FLOW SENSOR
POWERTRAIN CONTROL MODULE
| 2 7
"* A 7T~ ^ "
jjj SS1 ^ J | SS2
T X
:>
- X
^ J J T C C ^ 1 E P C
L J L _
X l
TP EXT
PSP MAF
IAT VSS
D14695-A
ss:
J O O O O O O O O O O O O Ol
o o o o o o o o o o o o on
" O O O O O O O O O O O O o
o o o o o o o o o o o o o p
u o o o o o o o o o o o o o
[ Q O O O O O O O O O O O On
j o o o o o o o o o o o o o
l O O O O O O O O o o o o on
(PCM)CONNECTOR
V9286-A
Pin
Nu mb e r Ci r cui t Ci rcui t Funct i on
1 3 1 5 ( P / 0 ) Shi f t So l e n o i d # 2
2 658
( P K / L G )
3 No t Us e d
4 No t Us e d
5

No t Us e d
6

No t Us e d
7 No t Us e d
8 No t Us e d
9 No t Us e d
10 No t Us e d
11 No t Us e d
12

No t Us e d
13 107 ( P) Da t a L i n k Co n n e c t o r ( DL C)
14 No t Us e d
15 915
( P K / L B )
Da t a L i n k Co n n e c t o r ( DL C)
16 9 14 ( T / O) Da t a Li n k Co n n e c t o r ( DL C)
17 No t Us e d
18 No t Us e d
19

No t Us e d
2 0 No t Us e d
2 1 No t Us e d
22

No t Us e d
23 2 5 9 ( O / R ) I gn i t i o n Gr o u n d
24 57 0
( B K / W)
P o we r Gr o u n d
25 57 ( BK) Ca s e Gr o u n d
26 No t Us e d
2 7 2 37 ( O / Y) Shi f t S o l e n o i d # 1
28 2 2 8 ( DB) L o w S p e e d Fa n Co n t r o l Out put
29 2 2 4 ( T / W) T r a n s mi s s i o n Co n t r o l S wi t c h
30 2 42 ( DG) Oc t a n e Ad j u s t
31 No t Us e d
32

No t Us e d
Pi n
Number Ci rcui t Ci rcui t Fun c t i o n
3 3 67 6
( P K / O )
3 4
_
No t Us e d
35 392
( R / L G )
He a t e d Ox y g e n Se n s o r # 3 ( H 0 2 S )
3 6 968 ( T / L B) Ma s s Ai r Fl o w Se n s o r Re t u r n
37 92 3
( O / B K )
T r a n s mi s s i o n Fl u i d T e mp e r a t u r e
Se n s o r
38 354
( L G / R )
En gi n e Co o l a n t T e mp e r a t u r e ( ECT)
Se n s o r
39 7 43 ( GY) I n t a ke Ai r T e mp e r a t u r e (I AT)
Se n s o r
40 2 38
( DG / Y)
Fue l Pump ( FP) Mo n i t o r
41 347
( B K / Y )
Ai r Co n d i t i o n i n g Cy c l i n g S wi t c h
42

No t Us e d
43 2 05
( DB / L G )
Buf f e r Fue l L e v e l Ou t pu t t o
Tr i pmi n d e r
44

No t Us e d
45

No t Us e d
46 No t Us e d
47 360
( B R / P K )
EGR Va c u u m Re gu l a t o r
48 659 ( O / W) I gn i t i o n Di a g n o s t i c Mo n i t o r
49 395
( G Y/ O )
P r o f i l e I gn i t i o n P i c ku p ( PI P)
50 9 2 9 ( PK) S p a r k ( SP OUT)
51 57 0
( B K / W)
P o we r Gr o u n d
52 No t Us e d j
53
__
No t Us e d
54 92 4
( B R / O )
T r a n s mi s s i o n Co a s t Cl u t c h
So l e n o i d
55 554
( Y / B K )
B + Ke e p Al i v e P o we r
56 191
( L G / B K )
EVAP Ca n i s t e r Pur ge Va l v e
57

No t Us e d
( Co n t i n ue d )
07 - 01- 2 6 T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W 07 - 01- 2 6
P i n
68 67 9
( G Y/ B K )
59
_
Not Us e d
60 7 4
( G Y/ L B )
61 3 9 3 ( P / L G ) He a t e d Ox y g e n Se n s o r # 2 ( H 0 2 S )
62 No t Us e d
63
_
No t Us e d
64 199 ( L B / Y ) Tr a n s mi s s i o n Ra n ge ( TR) Se n s o r
65 352
( B R / L G )
Di f f e r e n t i a l P r e s s u r e Fe e d b a c k
EGR Se n s o r
66 No t Us e d
67 No t Us e d
68

Not Us e d
69 331
( P K / Y)
A / C Cut o ut Re l a y
7 0
_
No t Us e d
7 1 361 ( R) P o we r ( VP WR)
7 2 561 ( T / R) Fue l I n j e c t o r # 7
7 3 559 ( T / BK ) Fue l I n j e c t o r # 5
7 4 557
( B R / Y)
Fue l I n j e c t o r # 3
75 555 ( T) Fue l I n j e c t o r # 1
76 57 0
( B K / W)
P o we r Gr o un d
77 5 7 0
( B K / W)
P o we r Gr o un d
7 8

No t Us e d
7 9 911
( W/ L G )
L a mp Ou t pu t
80 92 6
( L B / O )
Fue l Pump ( FP) Re l a y Ou t pu t
81 92 5 ( W/ Y ) E l e c t r o n i c P r e s s u r e Co n t r o l Out put
( Co n t i n ue d )
P i n
N u mb e r C i r c u i t Circuit F u n c t i o n
82 No t Us e d
83 2 64
( W/ L B )
I dl e Ai r Co n t r o l ( I AC) Va l v e
84 97 0
( DG / W)
Out put Sha f t S p e e d Se n s o r
85 2 82
( DB / O )
Ca ms h a f t P o s i t i o n Se n s o r
86 No t Us e d
87 94 ( R / B K ) He a t e d Ox y g e n Se n s o r # 2 ( H0 2 S )
88 9 6 7 ( L B / R ) Ma s s Ai r Fl o w ( MA F) Se n s o r
89 355
( G Y/ W)
T h r o t t l e P o s i t i o n ( TP) Se n s o r
90 351
( B R / W)
Re f e r e n c e Vo l t a ge
91 359
( G Y/ R )
Si gn a l Re t ur n
92 511 ( LG) St o p l i gh t S wi t c h
93 387 ( R / W) He a t e d Ox y g e n Se n s o r # 1 ( H 0 2 S )
94 388 ( Y / L B ) He a t e d Ox y g e n Se n s o r # 2 ( H0 2 S )
95 389
( W/ B K )
He a t e d Ox y g e n Se n s o r # 3 ( H0 2 S )
96 3 9 0 ( T / Y) He a t e d Ox y g e n Se n s o r # 4 ( H0 2 S )
97 361 ( R) Ve hi c l e P o we r ( VP WR)
98 562 ( L B) Fue l I n j e c t o r # 8
99 560
( L G / O )
100 558
( B R / L B )
101 556 ( W) Fue l I n j e c t o r # 2
102 No t Us e d
103 57 0
( B K / W)
P o we r Gr o un d
104 No t Us e d
07 - 01- 2 7 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 01- 2 7

TRANSMISSION HARNESS CONNECTOR
D12133-A
TOWN CAR
Pin
Number Circuit C i r c u i t Function
1 237 ( O/ Y ) Shi f t So l e n o i d # 1
2 361 (R) Ve h i c l e P o we r
3 924
( B R / O )
T o r q u e Co n v e r t e r Cl u t c h ( TCC)
So l e n o i d
4
_
No t Us e d
5 92 3
( O / B K )
Tr a n s mi s s i o n Fl ui d T e mp e r a t u r e
( TFT) I nput
6 3 1 5 ( P / 0 ) Shi f t So l e n o i d # 2
7 3 6 1 ( R ) Ve h i c l e P o we r
9 359
( G Y/ R)
Si gn a l Re t ur n
10 92 5 ( W/ Y ) E l e c t r o n i c P r e s s u r e Co n t r o l ( EPC)
So l e n o i d
P i n
Number Circuit C i r c u i t F u n c t i o n
1 2 37 ( O / Y ) Shi f t So l e n o i d # 1
2 361 ( R) Ve h i c l e P o we r
3 4 7 3 ( P / Y ) T o r q u e Co n v e r t e r Cl u t c h So l e n o i d
4 No t Us e d
5 92 3
( O / B K )
( TFT) I nput
6 3 1 5 ( P / 0 ) Shi f t So l e n o i d # 2
Pi n
N u m b e r Circuit Ci r cui t Functi on
7 361(R) Ve h i c l e P o we r
8 3 6 1 ( R ) Ve h i c l e P o we r
9 359
( G Y/ R )
Si gn a l Re t ur n
Di a g n o s t i c S t r a t e g y
Troubl eshooti ng an el ectroni cal l y control l ed automati c
transmi ssi on is simplified by using the proven method
of di agnosi s. One of t he most i mportant thi ngs t o
remember is t hat there is a definite procedure t o
follow. DO NOT TAKE SHORT CUTS OR ASSUME
THAT CRI TI CAL CHECKS OR ADJUSTMENTS
HAVE ALREADY BEEN MADE. Fol l ow the
procedures as wri tten t o avoi d missing cri ti cal
components or st eps.
To properl y di agnose a concern, the techni ci an should
have the fol l owi ng publications avai l abl e:
Transmission Reference Manual
Powertrai n Cont rol / Emi ssi ons Di agnosi s Manual
1
Oasi s Messages
Technical Servi ce Bulletins (TSBs)
El ectri cal and Vacuum Troubl eshooti ng Manual
(EVTM)
These publications provi de the information requi red
when diagnosing transmi ssi on concerns.
R e q u i r e d E q u i p m e n t :
Powertrai n Cont rol / Emi ssi ons Di agnosi s Manual
1
Rotunda New Generation Star (NGS) Tester
Rotunda Transmission Tester 007- 0085C or
equivalent
Rotunda Digital Volt-Ohmmeter 014- 00407 or
equivalent
Rotunda Transmission Range (TR) Sensor Cabl e
(MLPS Cabl e) 007- 00086 or equivalent
Transmission Range (TR) Sensor Alignment Tool
(MLPS Alignment Tool) T93P-70010-A
Rotunda 104 Pin Breakout Box 014- 00950 or
equivalent
07 - 01- 2 8
T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 07 - 01- 2 8
Di a gn o si s Fl ow Cha r t
Rectangles are
Action Boxes
Diamonds
are Decision
Boxes
NO
Know and understand the customer's concern
Check fluid level and condition
Verify the concern by operating vehicle
Check for non-factory installeditems and verify
a
roper installation
heck shift linkage adjustment in overdrive
Check TSB's and OAslS for vehicle concern
Perform "Quick Test" both KOEO & KOER
Record all codes
NOTE:
If you f i nd and repair the cause
of the transmission concern at
any point i n t hi s diagnostic flow
chart, "go t o" the last action box.
YES
Fault codes YES
Repair all hard DTC codes.
Follow pinpoint tests in
PC/ED Manual* first, then
Transmission Reference Manual/
Service Manual
NO Pass codes
Clear codes and
perform drive-
cycle test
Repair continuous test memory
codes, follow pin point tests
in the PC/ED Manual* first, then
Transmission Reference Manual/
Service Manual
Go to "Diagnosis by symptom"
section of the Transmission
Reference Manual/
Service Manual
Install the Transmission Tester.
Perform static and drive tests
with Transmission Tester
Go to PC/ED Manual*, intermittent
fault diagnosis section and use
EEC-IV Monitor, B.O.B. or SBDS to
diagnose cause of concern in the
processor, vehicle harness or
external inputs (sensors/switches)
Use "Hydraulic/Mechanical
Routine" to diagnose
and repair concern
X
NO
PC/ED = Powertrain Control/
Emissions Diagnosis
Purchased separately, refer to the end
of the Section for vehicle applications.
Perform final "Quick Test" to
verify no DTC codes are present
Clear memory code
Return vehicle to customer
Get assistance from
Technical Hotline
D1154S-C
07 - 01- 2 9 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 0 7 - 0 1 - 2 9
P r e l i mi n a r y I n s p e c t i o n
The following i tems must be checked before
proceedi ng:
1. Know and Understand the cust omer' s concern.
2. Validate cust omer' s concern (when does it
exi st ?).
a. Upshift
b. Downshi ft
c. Coasti ng
d. Engagement
e. Noi se/ Vi brat i on
NOTE: If Noi se/ Vi brat i on check for dependenci es.
RPM dependent.
Vehicle Speed dependent.
Shift dependent.
Gear dependent.
Range dependent.
Temperature dependent.
3. Vehicle at normal operati ng t emperat ure.
4. Check Fluid Level and Condi ti on.
5. Visually i nspect t he vehicle for t he following
i tems:
Vehicle Modi fi cati ons.
Electronic Add-On i tems.
Leaks.
Proper linkage adj ustments.
6. Check TSBs and Oasi s for Concern Information.
7. Perform the COMPLETE On-Board Di agnosti c
pr ocedur esKey On Engine Off (KOEO) and
Key On Engine Running (KOER).
Ve r i f i c a t i o n o f C o n d i t i o n
Thi s secti on provi des information whi ch must be used
in bot h determining the actual cause of customer
concerns and performi ng the appropri at e servi ce
procedures.
NOTE: Some transmi ssi on condi ti ons may cause
engine concerns. An EPC short ci rcui t may cause
al ternate firing. The t orque converter cl utch not
disengaging will stal l t he engine.
The following procedures must be used when verifying
customer concerns for transmi ssi on:
1. Required equi pment:
Rotunda Transmi ssi on Tester 007- 0085C or
equivalent
New Generati on Star Tester (NGS) 007- 00500
or equi val ent
Rotunda Digital Vol t-Ohmmeter 007- 00001 or
equivalent
Rotunda Transmi ssi on Range (TR) Sensor
Tester Adapt er (MLP Tester Adapt er )
Transmi ssi on Range (TR) Sensor Alignment
Tool ( MLPS Alignment Tool) T93P- 70010- A
Rotunda 104 Pin Breakout Box 014- 00950 or
equivalent
2. Determi ne cust omer concerns rel ati ve t o vehi cl e
usage:
Hot or col d vehi cl e operati ng t emperat ure.
Hot or col d ambi ent temperatures.
Type of terrai n.
Vehicle l oaded/ unl oaded.
Ci t y/ hi ghway dri vi ng.
3. Check fluid level and condition.
4. Road test vehi cl e t o verify customer concern.
NOTE: Inspect vehi cl e for non-Ford approved add-on
devi ces such as:
Air conditioning
Generat ors
Engine turbos
Cellular tel ephones
Cruise control s
CB radi os
Linear boost ers
Backup al arm signals
Computers
These i tems, if not installed properl y, will affect
powertrai n control module or transmi ssi on functi on.
Pay particular attenti on t o add-on wi ri ng spl i ces in
t he powertrai n control module or transmi ssi on
wiring harness, abnormal tire size or axl e ratio
changes.
After a road test, wi th the vehicle war m and before
disturbing any connect ors, perform t he Qui ck Test
using Rotunda New Generation Star Tester
007- 00500 or equivalent. Refer t o the Powertrai n
Cont rol / Emi ssi ons Diagnosis Manual
2
.
T r a n s mi s s i o n Fl ui d L e v e l C h e c k
CAUTI ON: To pr event t r ansmi ssi on damage, do
not dr i ve vehi cl e i f f l ui d l evel i s bel ow t he bot t om
hol e i n f l ui d l evel i ndi cat or .
Tr ans mi s s i on Ho t Op e r a t i n g Te mp e r a t u r e
The aut omat i c t ransmi ssi on shoul d be c he c ke d at an
oper at i ng t emper at ur e of 66 G-77 C ( 150 F-170 F)
(fluid level indicator hot t o t ouch). The operati ng
temperature may be obtai ned by driving 24-32 km
(15-20 miles) of ci ty-type driving wi t h the outsi de
temperature above 10C( 50F) .
CAUTI ON: If v e h i c l e ha s b e e n o p e r a t e d f o r a n
e x t e n d e d p e r i o d a t h i gh s p e e d , i n c i t y t r a f f i c , i n
h o t we a t h e r , o r v e h i c l e i s b e i n g u s e d t o pul l a
t r a i l e r , t h e f l u i d ha s t o c o o l , a p p r o x i ma t e l y 3 0
mi n u t e s a f t e r e n gi n e ha s b e e n t u r n e d o f f t o
o b t a i n a n a c c u r a t e r e a d i n g.
T r a n s mi s s i o n Fl ui d I n d i c a t o r Re a d i n g: Fluid level at
operati ng t emperat ure.
Fluid level on fluid level indicator shoul d be within the
cross-hat ched area.
FLUID LEVEL AT OPERATING
'TEMPERATURE 66C-77C (150F-170F)
FLUID LEVEL AT ROOM TEMPERATURE
21C-35C (70F-95F)
DO NOT DRIVE MARK
DS439-C
T r a n s mi s s i o n C o l d R o o m T e mp e r a t u r e
If the transmi ssi on is not at an operati ng temperature
of 66 C- 7 7 C( 150F- 17 0 F) and it becomes
necessary t o check the fluid level (such as
pre-del i very), the fluid may be checked at room
t emperat ure of 21 C- 35C ( 70F- 95 F) (fluid level
indicator cool t o t ouch).
T r a n s mi s s i o n Fl ui d I n d i c a t o r Re a d i n g: Fluid level at
room t emperat ure.
Fluid level on the fluid level indicator should read
bet ween the holes at room temperature.
NOTE: The fluid level indication on t he fluid level
indicator will be different at operati ng temperature and
room t emperat ure. For the correct fluid level readi ng
on the fluid level indicator, fol l ow the appropri at e
i nstructi ons st at ed previously.
Before addi ng fluid, make sure that t he correct t ype
will be used. Only use fluid that meets or exceeds the
speci fi cati on st amped on the fluid level indicator.
CAUTI ON: Use o f a f l u i d o t h e r t h a n MERCON
Mu l t i - P u r p o s e A u t o ma t i c T r a n s mi s s i o n Fl ui d
XT- 2 - QDX c o u l d r e s ul t i n t r a n s mi s s i o n
ma l f u n c t i o n a n d / o r f a i l u r e .
Check fluid level as fol l ows:
1. Wi t h transmi ssi on in PARK, engine at curb idle
rpm, f oot brakes appl i ed and vehi cl e on level
surf ace, move t he transmi ssi on sel ector lever
through each range. Al l ow time in each range t o
engage transmi ssi on, return t o PARK, appl y
parki ng brake control ( 2780) and bl ock wheel s.
Do n o t t u r n o f f t h e e n gi n e d u r i n g t h e f l u i d
l e v e l c h e c k.
2. Clean all dirt from the transmi ssi on fluid level
i ndi cator cap before removi ng the fluid level
i ndi cator f rom the fluid filler tube.
3. Pull the fluid level indicator out of the fluid filler
tube, wi pe it cl ean, and push all the way back into
the tube. Ma ke s u r e i t i s f ul l y s e a t e d .
4. Pull the fluid level indicator out of t he fluid filler
tube again and check the fluid level.
If necessary, add enough fluid through t he fluid
filler tube t o raise the level t o the correct posi ti on.
Do not overfill the transmi ssi on. This will result in
foami ng, loss of fluid through the vent and
possi bl e transmi ssi on malfunction. If overfill
occurs, excess fluid must be removed.
5. Install t he fluid level indicator, maki ng sure it is
fully seat ed in the fluid filler tube.
If the transmi ssi on fluid level is correct l y
establ i shed at 21 C- 35C ( 70F- 95F) , it will
appear in the cross-hat ch area on the fluid level
i ndi cator when t he transmi ssi on reaches an
operati ng temperature of 66C- 77C
( 150F- 170F) . Do not overfill or underfill.
Underfill can result in transmi ssi on loss of
engagement or slipping. This condition is most
evident in col d weat her or when the vehi cl e is
parked or being driven on a hill.
If the transmi ssi on fluid level is checked when the
fluid is at room t emperat ure, the fluid level
indicator could indicate that fluid should be added
if the fluid level indicator is mi sread. If fluid is
added at this ti me, an overfill condition coul d
result when the fluid reaches operati ng
t emperat ures of 66 C-77 C ( 150 F-170 F)
(fluid level indicator hot t o t ouch).
H i g h o r L o w Fl u i d L e v e l
A fluid level that is too high may cause the fluid t o
become aerat ed due t o the churning acti on of t he
rotati ng part s of the transmi ssi on. Aerat ed fluid will
cause errati c control pressure, and the aerat ed fluid
may be f orced from t he vent.
A fluid level that is too l ow will affect transmi ssi on
operati on. Low level may indicate fluid l eaks t hat may
cause transmi ssi on damage.
T r a n s m i s s i o n Fl u i d C o n d i t i o n C h e c k
1. Make t he normal fluid check as outlined.
07 - 01- 31 0 7 - 0 1 - 3 1
2. Observe col or and odor of the fluid. It should be
dark reddi sh, not brown or bl ack. Odor can
someti mes indicate that t here is an overheati ng
condition or cl utch di sc or band failure.
3. Use an absorbent whi te faci al tissue t o wi pe the
fluid level indicator. Exami ne the stain on ti ssue
for evi dence of solids ( specks of any kind) and for
anti freeze signs (gum or varni sh on fluid level
i ndi cator).
If specks are present in t he fluid or there is
evi dence of anti freeze, t he transmi ssi on pan must
be removed for further i nspecti on. If fluid
contami nati on or transmi ssi on failure is confi rmed
by further evi dence of cool ant or excessi ve sol i ds
in t he transmi ssi on oil pan ( 7A194) , the
transmi ssi on must be di sassembl ed and
compl etel y cl eaned and servi ced. This includes
cleaning t he torque converter ( 7902) and
transmi ssi on cooling syst em. It woul d be a wast e
of ti me t o perf orm any further checks bef ore
cleaning and servi ci ng the transmi ssi on. During
di sassembl y and assembl y, all overhaul checks
and adj ustments of cl earances and end play must
be made. After the transmi ssi on has been
servi ced, all di agnosi s t est s and adj ustments
listed in the Di agnosi s by Sympt om chart must be
compl et ed t o ensure the concern has been
cor r ect ed.
Transmission Fluid Leakage Checks
Check t he vehicle speed sensor (VSS)(9E731), output
shaft speed sensor (OSS) and the connector at
transmi ssi on. Repl ace the rubber seal , if necessary.
NOTE: Fluid f rom other external sources can col l ect
bet ween t he case ( 7005) and pan rail and gi ve the
appearance of a pan t o case gasket l eak. If fluid is
present check the fol l owi ng posi ti ons as outlined.
Check for l eakage at pan t o case gasket .
Leakage at the pan t o case gasket often can be
st opped by tightening t he retaining bol ts t o 12-15 N-m
(9-111b-ft). Do not over-ti ghten transmi ssi on pan bol ts.
If necessary, repl ace the pan t o case gasket .
Check t he fluid filler tube connecti on at the
transmi ssi on case or transmi ssi on pan. If l eakage is
found here, install a new O-ring and press t he fluid filler
tube t o the case. The fluid filler tube bracket shoul d
align properl y and be at t ached t o the transmi ssi on or
engine.
Check t he fluid lines and fittings bet ween the
transmi ssi on and t he transmi ssi on cool er in t he
radi ator tank for l ooseness, wear or damage. When
fluid is found t o be l eaki ng bet ween the case and the
cool er inlet tube or cool er t ube, ti ghten the fitting t o 31
Mm ( 23 Ib-ft).
CAUTI ON: Do n o t t r y t o s t o p t h e f l u i d l e a k b y
i n c r e a s i n g t h e t o r q u e b e y o n d s p e c i f i c a t i o n . Th i s
ma y c a u s e d a ma g e t o t h e c a s e t h r e a d s .
If t he leak conti nues, repl ace t he cool er line fitting and
ti ghten t o 20-26 N-m ( 15- 19 Ib-ft). The same
procedure shoul d be f ol l owed for fluid l eaks bet ween
the transmi ssi on cool er and cool er line fi tti ngs.
Check t he engine cool ant in t he radi ator ( 8005) . If
transmi ssi on fluid is present in the cool ant, t he
transmi ssi on cool er in the radi ator i s probabl y l eaki ng.
The transmi ssi on cool er can be further checked for
l eaks by di sconnecti ng the cool er t ube and cool er inlet
tube f rom the cool er fittings and appl yi ng 345- 517 kPa
( 50- 75 psi) air pressure t o t he fi tti ngs. Remove t he
radi ator cap ( 8100) t o relieve the pressure buildup at
t he exteri or of t he cool er t ank. If t he transmi ssi on
cool er is leaking and/ or will not hol d pressure, t he
transmi ssi on cool er must be repl aced. Refer t o
Secti on 07-02 for transmi ssi on cool er repl acement
procedure.
If l eakage is found at t he manual control lever ( 7A256) ,
repl ace the manual control lever seal .
P i p e P l u gs
The transmi ssi on has five pipe plugs: four on t he RH
si de of t he case and one on t he LH si de. Inspect the
plugs for l eakage. Ensure they are ti ghtened t o 8-16
N-m (6-12 Ib-ft). If tightening does not st op the l eak,
repl ace the plug.
When a converter drain plug l eaks, remove the drai n
plug wi t h a six-point wrench. Coat t he t hreads wi t h
Pipe Sealant wi t h Teflon D8AZ- 19554- A or
WSK- M2G350- AZ and install plug. Tighten the drain
plug t o 28-30 N-m (21-23 Ib-ft). Fluid l eakage f rom the
converter housing may also be caused by engine oil
leaking past the rear main bearing seal , or from oil
galley pl ugs. Verify the exact cause of t he leak before
starti ng servi ce procedures.
C o o l e r T u b e L e a k a g e
When fluid l eakage is found at the transmi ssi on cool er,
the transmi ssi on cool er must be repl aced. Refer t o
Secti on 07-02.
When one or more of t he cool er tubes must be
repl aced, each repl acement cool er tube must be
f abri cat ed from the same size steel tubing as the
original cool er tube.
Using the old cool er tube as a guide, bend the new
cool er tube as requi red. Add the necessary fittings
and install the cool er tube.
After the fittings have been ti ghtened, add fluid as
needed and check for fluid l eaks.
1 T - .
L e a k C h e c k T e s t w i t h Bl a c k L i g h t
Oil soluble aniline or fl uorescent dyes premi xed at the
rate of 2.5ml (1 / 2-t easpoon) of dye powder t o 0. 23
liter ( 1/ 2- pi nt ) of transmi ssi on fluid have proved helpful
in locating t he source of fluid l eakage. Such dyes may
be used t o determi ne whet her an engine oil or
transmi ssi on fluid leak is present, or if the fluid in the oil
cool er l eaks into the engine cool ant syst em. A bl ack
light must be used wi th the fl uorescent dye solution.
Fl u i d L e a k a g e i n T o r q u e C o n v e r t e r A r e a
When internal wear or damage has occurred in the
transmi ssi on, metal parti cl es, cl utch pl ate materi al , or
band materi al may have been carri ed into the torque
converter ( 7902) and transmi ssi on cool er. These
contami nants are a major cause of recurri ng
transmi ssi on troubl es and MUST be removed f rom the
syst em before the transmi ssi on is put back into
servi ce.
Possi bl e Leak Poi nt s
CAUTI ON: Wh e n e v e r a t r a n s mi s s i o n ha s b e e n
d i s a s s e mb l e d t o r e p l a c e w o r n o r d a ma g e d p a r t s
o r b e c a u s e t h e ma i n c o n t r o l v a l v e b o d y ( 7 A 100)
s t i c ks f r o m f o r e i g n ma t e r i a l , t h e ma i n c o n t r o l
v a l v e b o d y , t r a n s mi s s i o n c o o l e r a n d c o o l e r i n l e t
t u b e a n d c o o l e r t u b e MUST b e c l e a n e d a n d
f l u s h e d b y u s i n g t h e Ro t u n d a T o r q u e Co n v e r t e r
Cl e a n e r 0 1 4 - 0 0 0 2 8 o r e q u i v a l e n t . Un d e r NO
c i r c u ms t a n c e s s h o u l d a n a t t e mp t b e ma d e t o
c l e a n t o r q u e c o n v e r t e r by h a n d a gi t a t i o n wi t h
s o l v e n t . Da ma ge t o t o r q u e c o n v e r t e r ma y r e sul t .
In diagnosing and correcti ng fluid l eaks in t he front
pump support and gear and torque converter area, use
t he fol l owi ng procedures t o l ocate the exact cause of
t he l eakage. Leakage at the front of transmi ssi on, as
evi denced by fluid around the torque converter
housing, may have several sources. By careful
observat i on, it is possi bl e, in many i nstances, to
pinpoint the source of leak before removi ng the
transmi ssi on f rom the vehi cl e. The paths whi ch the
fluid t akes t o reach the bot t om of the torque converter
housing are shown in the following illustration.
FRONT
PUMP-TO-CASE
BOLT LEAK
CRANKSHAFT
SEAL LEAK
CONVERTER DRAIN PLUG LEAK OR /
CONVERTER TO FLYWHEEL STUD
WELD LEAK
NOTE: BECAUSE OF A ONE PIECE CASE,
LEAKAGE FROM THE PUMP GASKET WILL
RUN DOWN THE INSIDE OF THE
CONVERTER HOUSING ON AUTOMATIC
OVERDRIVE TRANSMISSION.
D
2871-K
07 - 01- 33
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T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W
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Pa r t
1

Torque Converter Housing (Part of 7902)
2 6375 Flywheel
4 6303 Crankshaft
5

Impeller (Part of 7902)
1. Fluid leaking by the pump gasket lip will tend t o
move along the impeller hub and ont o t he back of
the impeller housing. Except in the case of a total
seal failure, fluid l eakage by the lip of t he pump
gasket will be deposi ted on t he inside of the
torque converter housing only, near the outsi de
di ameter of the housing.
2. Fluid l eakage by t he outsi de di ameter of the pump
gasket and front pump body will fol l ow t he same
path whi ch the l eaks by the front pump seal
follow.
3. Fluid that l eaks by a front pump-to-case bolt will
be deposi t ed on the inside of the t orque converter
housing only. Fluid will not be deposi ted on the
back of t he torque converter.
4. Fluid l eakage from the converter drai n plugs or
converter-to-fl ywheel st ud wel d will appear at the
outsi de di ameter of the t orque convert er on t he
back f ace of the fl ywheel ( 6375) , and in the
converter housing only near the f l ywheel . Fluid
l eaks f rom the torque converter will leave a ring of
fluid around the inside of the torque converter
housi ng.
5. NOTE: Whi t e ti ssue paper may ai d in determining
t he col or (transmi ssi on fluid is red) and source of
t he leaking fluid.
Engine oil l eaks are somet i mes i mproperl y
di agnosed as transmi ssi on pump gasket l eaks.
The fol l owi ng areas of possi bl e l eakage should
al so be checked t o determi ne if engine oil l eakage
is causi ng t he concern.
a. Leakage at the val ve cover gasket ( 6584)
may allow oil t o f l ow over the t orque
convert er housing or seep down bet ween the
t orque converter housing and cyl i nder bl ock
( 6010) causi ng oil t o be present in or at the
bot t om of t he t orque convert er housi ng.
b. Oil galley plug l eaks will allow oil t o fl ow down
t he rear f ace of t he cylinder bl ock t o the
bot t om of t he t orque converter housing.
c. Leakage at t he crankshaf t rear oil seal
( 6701) will wor k back t o the f l ywheel , and
then into the t orque convert er housing.
d. Leakage at oil pressure sensor ( 9278) .
6. Fluid l eakage f rom other areas, such as t he
power steeri ng syst em f or war d of the
transmi ssi on, coul d cause fluid t o be present
around the t orque convert er housing due t o
bl owback or road draft. The following procedures
should be used t o determi ne the cause of the
l eakage bef ore servi ce.
a. Remove t he fluid level indicator and note t he
col or of t he fluid. Original f act ory fill flui d is
dyed red t o aid in determining if l eakage is
f rom the engine or transmi ssi on. However, a
power steeri ng l eak may be mi staken for a
transmi ssi on leak si nce both fluids are dyed
red. Check the power steeri ng syst em for
l eaks that coul d be misidentified as a
transmi ssi on leak. Refer t o Secti on 11-00.
b. Remove the torque converter housing cover.
Clean off any fluid f rom the t op and bot t om of
t he t orque converter housi ng, front of the
case and rear f ace of the engine and oil pan
( 6675) . Clean the torque converter area by
washi ng wi t h a suitable non-flammable
solvent and bl ow dry wi th compressed air.
c. Wash out the torque converter housi ng, t he
front of t he fl ywheel and t he converter drain
plugs. The torque converter housing may be
washed out using cleaning solvent and a
squi rt-type oil can. Bl ow all washed areas dry
wi t h compressed air.
d. St art and run the engine until t he transmi ssi on
reaches its normal operati ng t emperat ure.
Observe the back of the cylinder bl ock and
t op of t he torque converter housing for
evi dence of fluid l eakage. Raise the vehi cl e
on a hoist and run t he engine at fast idle, then
at engine idle, occasi onal l y shifting t o the
OVERDRIVE and REVERSE ranges to
i ncrease pressure within the transmi ssi on.
Observe the front of t he f l ywheel , back of the
cylinder bl ock (in as far as possi bl e), and
inside t he torque converter housing and front
of the case. Run the engine until fluid l eakage
is evi dent and t he probabl e source of l eakage
can be determi ned.
T o r q u e C o n v e r t e r L e a k a g e C h e c k
If wel ds on the torque converter i ndi cate l eakage,
remove the torque converter and make t he fol l owi ng
check:
07 - 01- 34
SZllZ'lZWL
07 - 01- 34
. y 1
Assembl e Rot unda Leak Test Ki t 021- 0054A or
equi val ent t o t he t orque conver t er . Test t or que
conver t er f or l eaks, f ol l owi ng t he di rect i ons suppl i ed
wi t h t he de t e c t or ki t .
ROTUNDA LEAK
TEST KIT 021-0054A D670-B
T r a n s m i s s i o n Fl u i d C o o l e r F l o w C h e c k
NOTE: The t ransmi ssi on l i n ka ge / c a bl e adj ust ment ,
flui d level and line pr essur e must be wi t hi n
speci f i cat i on bef or e perf ormi ng t hi s t est . Ref er t o
Sect i on 07- 05 f or adj ust ment s.
1. Remove flui d level i ndi cat or f r om flui d f i l t er t ube.
2. Pl ace funnel in fluid filler t ube.
3. Rai se vehi cl e on a hoi st and pl ace sui t abl e saf et y
st ands under vehi cl e.
4. Remove cool er ret urn line (rear f i t t i ng) f r om f i t t i ng
on t ransmi ssi on c a se ( 7005) .
5. Connect one end of a hose t o cool er ret urn line
and rout e ot her end of hose up t o a poi nt whe r e it
can be i nsert ed i nto funnel at flui d filler t ube.
6. Remove sa f e t y st ands and l ower vehi cl e. Insert
end of hose i nto f unnel.
7. St ar t engi ne and run at idle wi t h t ransmi ssi on in
NEUTRAL posi t i on.
8. When f lui d f l owi ng f r om hose i s sol i d, a li beral
amount of flui d shoul d be obser ved. "Li be r a l " is
de sc r i be d a s about 0. 5 liter (16 oz) del i vered in
30 se c onds. If li beral f l ow is obse r ve d, t e st is
c ompl e t e d.
9. If f l ow is not l i beral , st op engi ne. Di sconnect hose
f r om cool er ret urn line and connect it t o conver t er
out line f i t t i ng (f ront f i t t i ng) on t ransmi ssi on c a se .
10. Repeat st e ps 7 and 8. If f l ow is now l i beral , ref er
t o t he Cleani ng and I nspe c t i onConve r t e r and
Cool er and Transmi ssi on Cool er and Li nes,
Backf l ushi ng and Cl eani ng. If f l ow is not l i beral ,
ser vi ce pump a n d / o r t orque convert er ( 7 902)
assembl y.
Di a g n o s i s B y S y m p t o m R o u t i n e s
The Di agnosi s by Sy mpt om Char t s gi ve t he servi ce
t echni ci an di agnost i c i nf ormat i on, di rect i on and
possi bl e component s, using a sy mpt om as a st ar t i ng
poi nt .
The Di agnosi s by Sy mpt om Char t s are di vi ded i nto
t wo cat egor i es: El ect ri cal Rout i nes, i ndi cat ed by 2 00
seri es numbers, and Hydraul i c / Mechani cal Rout i nes,
i ndi cat ed by 300 seri es numbers. The El ect ri cal
Rout i nes list t he possi bl e el ect ri cal component s t hat
coul d cause or cont ri but e t o t he sy mpt o m de sc r i be d.
The Hydraul i c / Mechani cal Rout i nes list t he possi bl e
hydraul i c or mechani cal component s t hat coul d cause
or cont ri but e t o t he sy mpt om de sc r i be d.
Di a g n o s i s b y S y m p t o m C h a r t s Di r e c t i o n s
1. Usi ng t he i ndex, sel ect t he concer n / sy mpt o m
t hat best descr i bes t he condi t i on.
2. Turn t o t he rout i ne i ndi cat ed in t he Di agnosi s by
Sy mpt om Index.
3. Al wa y s begi n di agnosi s of a sy mpt om by usi ng
t he f ol l owi ng:
a. Preli mi nary I nspect i ons.
b. Veri f i cat i on of Condi t i on.
c. Check t he Fluid Level .
d. Perf orm Ot her Test Pr ocedur es as Di r ect ed.
4. Then begi n wi t h t he El ect ri cal Routi ne, if
i ndi cat ed. Fol l ow t he ref erence or act i on requi red
st at ement s. Al wa y s per f or m t he On-Board
Di agnost i c Test s as requi red. NEVER SKI P
STEPS. Servi ce as requi red. If t he concer n is sti ll
present af t er el ect ri cal di agnosi s, t hen pr oc e e d
t o t he Hydraul i c / Mechani cal Routi ne l i st ed.
5. NOTE: Not all concer ns and condi t i ons wi t h
el ect ri cal component s will set a Di agnost i c
Troubl e Code (DTC). Be a wa r e t hat t he
component s l i st ed may sti ll be t he cause. Veri f y
pr oper f unct i on of t hose component s pri or t o
proceedi ng t o t he Hydraul i c / Mechani cal Routi ne
l i st ed.
The Hydraul i c / Mechani cal Rout i nes list possi bl e
hydraul i c or mechani cal component s t hat coul d
cause t he concer n. These component s are l i st ed
in t he removal sequence and by most li kely
cause. You must i nspect all component s l i st ed t o
ensure proper servi ce.
07 - 01- 35 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 0 7 - 0 1 - 3 5
DIAGNOSIS BY SYMPTOM INDEX
ROUTINES
HYDRAULI C/
TITLE ELECTRICAL (1) MECHANICAL
E n g a g e m e n t Concerns
No Fo r wa r d 2 01 301
No Re v e r s e 2 02 3 0 2
Ha r s h Re v e r s e 2 03 3 0 3
Ha r s h Fo r wa r d 2 04 3 0 4
De l a y e d / Soft Re v e r s e 2 05 305
De l a y e d / S o f t Fo r wa r d 2 06 306
S h i f t Concerns
S o m e / A l l Sh i f t s Mi s s i n g 2 10 3 1 0
Ti mi n g Co n c e r n s
E a r l y / L a t e 2 11 311
E r r a t i c / H u n t i n g 2 12 312
Fe e l
S o f t / S l i p p i n g 2 13 313
H a r s h 2 14 314
No 1st Gear, E n ga ge s i n Hi gh e r Ge a r 2 15 315
No Ma n u a l 1st Ge a r 2 16 316
No Ma n u a l 2 n d Ge a r 2 17 317
Torque Conver t er Oper at i on Concer ns
No A p p l y 2 40 340
A l wa y s A p p l i e d / S t a l l s Ve h i c l e 2 41 341
C y c l i n g / S h u d d e r / C h a t t e r 2 42 342
Ot her Concer ns
No En gi n e Br a ki n g i n 2 n d Ge a r , Ma n u a l 2 n d o r Ma n u a l 1st P o s i t i o n 2 50 350
Shi f t L e v e r E f f o r t s Hi gh 2 52 352
E x t e r n a l L e a k s 2 51 351
Po o r Ve h i c l e P e r f o r ma n c e 2 53 353
N o i s e / Vi b r a t i o n F o r w a r d o r Re v e r s e 2 54 354
En gi n e Wi l l No t Cr a n k 2 55 355
No PARK Ra n ge 2 56 356
Ov e r h e a t i n g 2 57 357
Ot her Conc e r n: Pressure Ref erence Chart 401
Ot her Conc e r n: Cl ut ch a nd Band Appl i cat i on Chart 601
Ot her Conc e r n: Sol enoi d Appl i c a t i on Chart 7 01
(1) Perform el ectri cal routine first.
Di a g n o s t i c R o u t i n e s
NO FORWARD ENGAGEMENT
Possible Component Re f e r e n c e / Ac t i o n
201 ELECTRICAL ROUTINE
No E l e c t r i c a l Co n c e r n s
301 HYDRAULIC/MECHANICAL ROUTINE
Fl ui d
I mp r o p e r l e v e l
Co n d i t i o n
Ad j u s t f l ui d t o p r o p e r l e v e l .
I n s pe c t a s o ut l i n e d un d e r Tr a n s mi s s i o n Fl ui d Co n d i t i o n Ch e c k.
Shi f t Li nkage
Da ma g e d , o ut of a d j u s t me n t I n s pe c t a n d s e r v i c e a s r e q u i r e d . Ad j us t l i n ka ge a s o u t l i n e d . A f t e r
s e r v i c i n g l i n ka ge , v e r i f y TR s e n s o r i s p r o p e r l y a d j u s t e d . Re f e r t o
Tr a n s mi s s i o n , A s s e mb l y .
NO FORWARD ENGAGEMENT (Cont 'd)
P o s s i b l e C o m p o n e n t Re f e r e n c e / Ac t i o n
Improper P r e s s u r e s
L o w f o r wa r d c l u t c h p r e s s u r e , l o w l i ne p r e s s u r e Ch e c k p r e s s u r e a t l i ne a n d f o r wa r d c l u t c h t a p . Re f e r t o Ot h e r
Co n c e r n : P r e s s u r e Re f e r e n c e Cha r t 401 f o r s p e c i f i c a t i o n . If
p r e s s u r e s a r e l o w, c h e c k t h e f o l l o wi n g p o s s i b l e c o mp o n e n t s :
f l ui d f i l t e r a n d s e a l a s s e mb l y ,
ma i n c o n t r o l s , pump a s s e mb l y ,
f o r wa r d c l u t c h a s s e mb l y .
Fluid Filter a n d S e a l A s s e m b l y
P l u gge d , d a ma g e d
Fi l t e r s e a l d a ma g e d
Re p l a c e f i l t e r a n d s e a l a s s e mb l y .
Ma i n C o n t r o l s
3- 4 shi f t v a l v e , ma i n r e gu l a t o r v a l v e , o r i f i c e c o n t r o l v a l v e , ma n ua l
v a l v e s t u c k , d a ma g e d
Bo l t s out of t o r q u e s p e c i f i c a t i o n
G a s ke t s d a ma g e d
2- 3 a c c u mu l a t o r a n d s e a l s d a ma g e d
I n s pe c t f o r d a ma g e . Se r v i c e a s r e q u i r e d .
Ad j us t b o l t s t o s p e c i f i c a t i o n .
I n s pe c t g a s ke t f o r d a ma g e a n d r e p l a c e .
I n s pe c t p i s t o n , s e a l s a n d b o r e f o r d a ma g e . Se r v i c e a s r e q u i r e d .
Pump Assembl y
P o r o s i t y / c r o s s l e a ks a n d ba l l mi s s i n g or l e a ki n g, p l u gge d ho l e
No . 3 a n d No . 4 s e a l r i n gs d a ma g e d
Ad j u s t b o l t s t o s p e c i f i c a t i o n .
I n s pe c t f o r p o r o s i t y a n d l e a ks . Se r v i c e a s r e q u i r e d .
I n s pe c t s e a l s f o r d a ma g e . Se r v i c e a s r e q u i r e d .
I n s pe c t f o r d a ma g e a n d r e p l a c e .
Fo r wa r d Cl ut ch Assembl y
Se a l s , p i s t o n d a ma g e d
Ch e c k b a l l s d a ma g e d , mi s s i n g, mi s l o c a t e d , n o t s e a t i n g p r o p e r l y
Fr i c t i o n E l e me n t s d a ma g e d o r wo r n
I n s pe c t s e a l s f o r d a ma g e . Se r v i c e a s r e q u i r e d .
I n s pe c t f o r mi s l o c a t i o n , p o o r s e a t i n g, d a ma g e . Re p l a c e c y l i n d e r
a s r e q u i r e d .
Ch e c k f o r a b n o r ma l we a r , d a ma g e . Se r v i c e a s r e q u i r e d .
Low One-Way Cl ut ch Assembl y (Pl anet ary)
Wo r n , d a ma g e d o r mi s a s s e mb l e d I n s pe c t f o r d a ma g e . Se r v i c e a s r e q u i r e d .
Out put Shaf t
Da ma g e d I n s pe c t f o r d a ma g e . Se r v i c e a s r e q u i r e d .
TD10377D
NO REVERSE ENGAGEMENT CONCERN:
Possi bl e Compone nt Re f e r e n c e / Ac t i o n
Fl ui d
Co n d i t i o n
Shi f t Li nkage
Da ma g e d o r o ut of a d j u s t me n t I n s pe c t a n d s e r v i c e a s r e q u i r e d . Ad j us t l i n ka ge a s o u t l i n e d . Af t e r
s e r v i c i n g l i n ka ge , v e r i f y t h a t t h e TR s e n s o r i s p r o p e r l y a d j u s t e d .
Re f e r t o Tr a n s mi s s i o n , A s s e mb l y .
I mpr ope r Pressures
L o w r e v e r s e c l u t c h p r e s s u r e , l o w r e v e r s e b a n d p r e s s u r e , l o w l i ne
p r e s s u r e
Ch e c k p r e s s u r e a t l i ne p r e s s u r e t a p . Re f e r t o Ot h e r Co n c e r n :
P r e s s u r e Re f e r e n c e Cha r t 401 f o r s p e c i f i c a t i o n s . If p r e s s u r e s
a r e l o w, c h e c k t h e f o l l o wi n g p o s s i b l e c o mp o n e n t s :
f l ui d f i l t e r a n d s e a l a s s e mb l y ,
ma i n c o n t r o l s ,
r e v e r s e s e r v o ,
pump a s s e mb l y ,
r e v e r s e c l u t c h a s s e mb l y .
NO REVERSE ENGAGEMENT CONCERN: ( Cont ' d )
Fluid Filter and Seal Assembly
P l u gge d , d a ma g e d Re p l a c e f i l t e r a n d s e a l a s s e mb l y .
Mai n Cont r ol s
No . 6 s h u t t l e b a l l , ma n ua l v a l v e , ma i n r e gu l a t o r v a l v e , 1 -2
a c c u mu l a t o r s e a l s s t u c k or d a ma g e d
Bo l t s o ut of t o r q u e s p e c i f i c a t i o n
G a s ke t d a ma g e d
I n s p e c t f o r d a ma g e . S e r v i c e a s r e q u i r e d .
A d j u s t b o l t s t o s p e c i f i c a t i o n .
I n s p e c t f o r d a ma g e a n d r e p l a c e .
Low Reverse Servo
Se a l s ( p i s t o n a n d c o v e r ) d a ma g e d
Se r v o c o v e r r e t a i n i n g r i ng
A n c h o r pi n s ( c a s e ) d a ma g e d
I n s p e c t f o r d a ma g e . Se r v i c e a s r e q u i r e d .
Pump Assembl y
P o r o s i t y / c r o s s l e a k s / b a l l mi s s i n g o r l e a ki n g, p l u gge d ho l e
No . 1 a n d 2 s e a l r i n gs d a ma g e d
I n s p e c t p u mp a s s e mb l y . Re p l a c e a s r e q u i r e d .
Reverse Cl ut ch Assembl y
Ch e c k ba l l mi s s i n g or d a ma g e d
Fr i c t i o n e l e me n t s d a ma g e d o r wo r n
Low Reverse Band
Ba n d , s e r v o , a n c h o r pi n s d a ma g e d o r wo r n I n s p e c t f o r d a ma g e . Se r v i c e a s r e q u i r e d .
TD10379F
HARSH REVERSE E NGA GE ME NT
Power t r ai n Cont r ol Sy st em
E l e c t r i c a l i n p u t s / o u t p u t s , v e h i c l e wi r i n g h a r n e s s e s , P CM, TFT
s e n s o r , EPC s o l e n o i d
Run Se l f - Te st . Re f e r t o P o we r t r a i n C o n t r o l / E mi s s i o n s Di a gn o s i s
Ma n u a l
3
f o r d i a g n o s i s . P e r f o r m e n ga ge me n t t e s t , EPC t e s t a n d
P i n po i n t T e s t s B a n d E usi n g Ro t u n d a Tr a n s mi s s i o n Te s t e r
007 - 0085C o r e q ui v a l e n t , a s o u t l i n e d . Se r v i c e a s r e q u i r e d . Cl e a r
c o d e s , r o a d t e s t a n d r e r un Se l f - Te st .
Fl ui d
Co n d i t i o n
A d j u s t f l ui d t o p r o p e r l e v e l .
I n s p e c t a s o ut l i n e d un d e r Fl ui d Co n d i t i o n Ch e c k.
Shi f t Li nkage
Da ma g e d o r o ut of a d j u s t me n t I n s p e c t a n d s e r v i c e a s r e q u i r e d . Ad j ust l i n ka ge a s o u t l i n e d . A f t e r
I mpr oper Pressures
Hi gh l i ne p r e s s u r e , h i gh EPC p r e s s u r e C h e c k p r e s s u r e a t l i ne a n d EPC p r e s s u r e t a p s . Re f e r t o Ot h e r
Co n c e r n : P r e s s u r e Re f e r e n c e Cha r t 401 f o r s p e c i f i c a t i o n s . If
h i g h , c h e c k t h e f o l l o wi n g p o s s i b l e c o mp o n e n t s : ma i n c o n t r o l s ,
f l ui d f i l t e r a n d s e a l a s s e mb l y .
Fl ui d Fi l t er and Seal Assembl y
P l u g g e d o r d a ma g e d
Mai n Cont r ol s
No . 6 Shut t l e b a l l , No . 5 c h e c k b a l l , ma n ua l v a l v e , ma i n r e gu l a t o r
v a l v e s t u c k, d a ma g e d o r mi s s i n g
H A R S H R E V E R S E E N G A G E M E N T ( C o n t ' d )
EPC s o l e n o i d s t u c k o r d a ma g e d I n s p e c t f o r d a ma g e , c o n t a mi n a t i o n . P e r f o r m EPC t e s t i n Ro ut i n e
No . 2 03. Se r v i c e a s r e q u i r e d .
L o w Re v e r s e S e r v o
Se r v o c o v e r r e t a i n i n g r i n g a s s e mb l e d wr o n g
Pump Assembl y
Bo l t s o ut o f t o r q u e s p e c i f i c a t i o n
P o r o s i t y / c r o s s l e a ks
No . 1 a n d No . 2 s e a l r i n gs d a ma g e d
I n s p e c t pu mp a s s e mb l y . Re p l a c e a s r e q u i r e d .
Reverse Cl ut ch Assembl y
C h e c k ba l l mi s s i n g o r d a ma g e d
Fr i c t i o n e l e me n t s d a ma g e d , wo r n
Re t ur n s p r i n g p i s t o n d a ma g e d , wo r n
Low Reverse Band
Ba n d , s e r v o , a n c h o r pi n d a ma g e d o r wo r n I n s p e c t f o r d a ma g e . Se r v i c e a s r e q u i r e d .
TD10381C
H A R S H F O R W A R D E N G A G E M E N T
E l e c t r i c a l i n p u t s / o u t p u t s , v e h i c l e wi r i n g h a r n e s s e s , P CM, TFT
s e n s o r , EPC s o l e n o i d
Run Se l f - Te st . Re f e r t o P o we r t r a i n Co n t r o l / E mi s s i o n s Di a gn o s i s
Ma n u a l
4
f o r d i a g n o s i s . P e r f o r m e n g a g e me n t t e s t , EPC t e s t a n d
Pi n po i n t T e s t s B a n d E usi n g Ro t u n d a Tr a n s mi s s i o n Te s t e r
007 - 0085C o r e q u i v a l e n t , a s o u t l i n e d . Se r v i c e a s r e q u i r e d . Cl e a r
c o d e s , r o a d t e s t a n d r e r un Se l f - Te st .
Fl ui d
Co n d i t i o n
I mpr oper P r e s s u r e s
Hi gh f o r wa r d c l u t c h p r e s s u r e , h i gh l i n e p r e s s u r e , h i gh EPC
p r e s s u r e
Ch e c k p r e s s u r e a t l i n e , EPC a n d f o r wa r d p r e s s u r e t a p s . Re f e r t o
Ot h e r Co n c e r n : P r e s s u r e Re f e r e n c e Cha r t 401 f o r
s p e c i f i c a t i o n s . If p r e s s u r e s a r e h i gh , c h e c k t h e f o l l o wi n g
p o s s i b l e c o mp o n e n t s : ma i n c o n t r o l s , pu mp a s s e mb l y .
Mai n C o n t r o l s
Ma i n r e gu l a t o r v a l v e , 2 - 3 b a c ko u t v a l v e , 2- 3 a c c u mu l a t o r
s e a l / r e t a i n e r s t u c k, d a ma g e d
G a s k e t s d a ma g e d
EPC s o l e n o i d s t u c k o r d a ma g e d
I n s p e c t a n d s e r v i c e a s r e q u i r e d .
I n s pe c t f o r d a ma g e o r c o n t a mi n a t i o n . P e r f o r m EPC t e s t in
Ro ut i n e No . 2 04. Se r v i c e a s r e q u i r e d .
Pump A s s e m b l y
I n s pe c t f o r p o r o s i t y / l e a k s . Re p l a c e pu mp a s s e mb l y a s r e q u i r e d .
HARSH FORWARD ENGAGEMENT (Cont ' d)
For war d Cl ut ch Assembl y
Ch e c k b a l l s mi s s i n g or d a ma g e d
Fr i c t i o n e l e me n t d a ma g e d or wo r n
Fo r wa r d c l u t c h wa v e s pr i n g d a ma g e d
Fo r wa r d c l u t c h r e t ur n s pr i n g d a ma g e d
I n s p e c t f o r mi s l o c a t i o n , p o o r s e a t i n g , d a ma g e . Re p l a c e f o r wa r d
c l u t c h c y l i n d e r .
TD10383D
DELAYED/SOFT REVERSE ENGAGEMENT
Fl ui d
Co n d i t i o n
I n s p e c t a s o u t l i n e d un d e r T r a n s mi s s i o n Fl ui d Co n d i t i o n Ch e c k.
Shi f t Li nkage
Da ma g e d , out of a d j u s t me n t I n s p e c t a n d s e r v i c e a s r e q u i r e d . A d j u s t l i n ka ge a s o u t l i n e d . Af t e r
Re f e r t o T r a n s mi s s i o n , A s s e mb l y .
I mproper Pressures
p r e s s u r e
Ch e c k p r e s s u r e a t l i ne t a p . Re f e r t o Ot h e r Co n c e r n : P r e s s u r e
Re f e r e n c e Cha r t 401 f o r s p e c i f i c a t i o n s . If p r e s s u r e s a r e l ow,
c h e c k t h e f o l l o wi n g p o s s i b l e c o mp o n e n t s : ma i n c o n t r o l s , p u mp
a s s e mb l y , r e v e r s e c l u t c h a s s e mb l y , r e v e r s e s e r v o .
P l u g g e d , d a ma g e d
Mai n Cont r ol s
No . 6 s h u t t l e b a l l , 1-2 a c c u mu l a t o r s e a l s , ma n ua l v a l v e , ma i n
r e g u l a t o r v a l v e s t u c k o r d a ma g e d
Low Reverse Servo
Se r v o c o v e r r e t a i n i n g r i n g mi s a s s e mb l e d
I n s pe c t lot d a ma g e . Se r v i c e a s r e q u i r e d .
Pump Assembl y
P o r o s i t y / c r o s s l e a k s / b a l l mi s s i n g o r l e a ki n g
No . 1 a n d No . 2 se a l r i n gs d a ma g e d
Ad j ust b o l t s t o s p e c i f i c a t i o n .
I n s pe c t pu mp a s s e mb l y . Re p l a c e a s r e q u i r e d .
Reverse Cl ut c h Assembl y
S e a l s , p i s t o n d a ma g e d
e C h e c k ba l l mi s s i n g o r d a ma g e d
Re t ur n s p r i n g a n d pi s t o n d a ma g e d , wo r n
Low Re v e r s e Band
Da ma g e d , wo r n I n s pe c t f o r d a ma g e . Se r v i c e a s r e q u i r e d .
TD10385D
DELAYED/ SOFT FORWARD ENGAGEMENT
Pos s i bl e Co mp o n e n t Re f e r e n c e / Ac t i o n
206 ELECTRI CAL ROUTI NE
No El ect r i cal Concer ns
306 HYDRAUL I C/ MECHANI CAL ROUTI NE
Fl ui d
I mpr oper l evel
Co n d i t i o n
I n s p e c t a s o ut l i n e d un d e r Tr a n s mi s s i o n Fl ui d Co n d i t i o n Ch e c k.
Shi f t Linkage
Da ma g e d , o ut of a d j u s t me n t I n s p e c t a n d s e r v i c e a s r e q u i r e d . Ad j u s t l i n ka ge a s o u t l i n e d . Af t e r
I mp r o p e r Pr e s s u r e s
L o w f o r wa r d c l u t c h p r e s s u r e , l o w l i ne p r e s s u r e , l o w EPC
p r e s s u r e
C h e c k p r e s s u r e a t l i n e , f o r wa r d c l u t c h a n d EPC t a p s . Re f e r t o
Ot h e r Co n c e r n : P r e s s u r e Re f e r e n c e Cha r t 401 f o r
s p e c i f i c a t i o n s . If p r e s s u r e s a r e l o w, c h e c k t h e f o l l o wi n g p o s s i b l e
c o mp o n e n t s : f l ui d f i l t e r a n d s e a l a s s e mb l y , ma i n c o n t r o l s a n d
p u mp a s s e mb l y .
P l u gge d , d a ma g e d
Mai n Cont r ol s
3-4 shi f t v a l v e , ma i n r e gu l a t o r v a l v e , o r i f i c e c o n t r o l v a l v e s t u c k o r
d a ma g e d
2-3 o r 1-2 a c c u mu l a t o r , s e a l s , b o r e d a ma g e d o r s t u c k
I n s p e c t a n d s e r v i c e a s r e q u i r e d .
Pump Assembl y
No . 3, No . 4 s e a l r i n gs d a ma g e d
I n s p e c t pu mp a s s e mb l y . Re p l a c e a s r e q u i r e d .
For wa r d Cl ut ch Assembl y
Ch e c k b a l l s mi s s i n g, d a ma g e d
I n s p e c t f o r mi s l o c a t i o n , p o o r s e a t i n g, d a ma g e . Re p l a c e c y l i n d e r
a s r e q u i r e d .
C h e c k f o r d a ma g e . Se r v i c e a s r e q u i r e d .
TD10411C
SHIFT CONCERNS; SOME OR ALL SHI FTS MISSING
Power t r ai n Cont r ol Syst em
E l e c t r i c a l i n p u t s / o u t p u t s , v e h i c l e wi r i n g h a r n e s s e s , p o we r t r a i n
c o n t r o l mo d u l e , shi f t s o l e n o i d s , o u t pu t s h a f t s p e e d ( OSS)
s e n s o r , TR s e n s o r
Ma n u a l
5
f o r d i a g n o s i s . P e r f o r m Pi n po i n t T e s t s A, D a n d F usi n g
Ro t u n d a Tr a n s mi s s i o n Te s t e r ( 007 - 0085C) , a n d Tr a n s mi s s i o n
Ra n ge ( TR) Se n s o r Ca b l e ( ML P S Ca b l e ) ( 007 - 00086) o r
e q ui v a l e n t , a s o u t l i n e d . Se r v i c e a s r e q u i r e d . Cl e a r c o d e s , r o a d
t e s t a n d r e r un Se l f - Te st .
Fl ui d
I mp r o p e r l evel
Co n d i t i o n
Shi f t Li nka ge , TR Sensor
Da ma g e d , o ut of a d j u s t me n t I n s pe c t a n d s e r v i c e a s r e q u i r e d . Ad j us t l i n ka ge a s o u t l i n e d . Af t e r
SHIFT CONCERNS: SOME OR ALL SHIFTS MISSING (Cont ' d)
Re f e r t o t h e f o l l o wi n g s hi f t r o u t i n e ( s ) f o r f ur t he r d i a g n o s i s :
Shi f t 1-2, Rout i ne 2 2 0 / 3 2 0
Shi f t 2- 3, Rout i ne 2 2 1 / 3 2 1
Shi f t 3- 4, Rout i ne 2 2 2 / 3 2 2
Shi f t 4- 3, Rout i ne 2 2 3 / 3 2 3
Shi f t 3- 2 , Rout i ne 2 2 4 / 3 2 4
Shi f t 2 - 1 , Rout i ne 2 2 5 / 3 2 5
TD10387D
SHIFT CONCERNS: SHIFT TIMING EARLY/LATE
c o n t r o l mo d u l e , shi f t s o l e n o i d s , EPC s o l e n o i d , TFT se n so r , OSS
Run Se l f - Te s t . Re f e r t o P o we r t r a i n C o n t r o l / E mi s s i o n s Di a gn o s i s
Ma n u a l
6
f o r d i a gn o s i s . P e r f o r m Pi n po i n t T e s t s A, B, E a n d F us i n g
Ro t u n d a Tr a n s mi s s i o n Te s t e r ( 007 - 0085C) o r e q ui v a l e n t , a s
o u t l i n e d . Se r v i c e a s r e q u i r e d . Cl e a r c o d e s , r o a d t e s t a n d r e r un
Se l f - Te st .
Ot her
Ti r e si ze c h a n ge , a x l e r a t i o c h a n g e Ve r i f y v e h i c l e h a s o r i gi n a l e q u i p me n t . Re f e r t o Ce r t i f i c a t i o n
L a b e l a n d Sa f e t y S t a n d a r d Ce r t i f i c a t i o n L a b e l . Ch a n g e s in t i r e
s i ze , a x l e r a t i o wi l l a f f e c t shi f t t i mi n g.
Fluid
Co n d i t i o n
I n s pe c t a s o ut l i n e d un d e r Fl ui d Co n d i t i o n Ch e c k.
Li n e p r e s s u r e , EPC p r e s s u r e C h e c k p r e s s u r e a t l i ne a n d E P C t a p s . Re f e r t o Ot h e r Co n c e r n :
P r e s s u r e Re f e r e n c e Cha r t 401 f o r s p e c i f i c a t i o n s . If not OK,
c h e c k t h e ma i n c o n t r o l s . If OK, r e f e r t o t h e f o l l o wi n g shi f t
r o u t i n e ( s ) f o r f ur t he r d i a g n o s i s :
Shi f t 1-2, Rout i ne 32 0
Shi f t 2- 3, Rout i ne 32 1
Shi f t 3-2, Rout i ne 32 4
Shi f t 2 - 1 , Rout i ne 32 5
Main Cont r ol s
EPC s o l e n o i d , s t u c k o r d a ma g e d h y d r a u l i c a l l y o r me c h a n i c a l l y
Va l v e s , a c c u mu l a t o r s , s e a l s s t u c k or d a ma g e d or mi s a s s e mb l e d
So l e n o i d s c r e e n (i n v a l v e b o d y ) b l o c k e d o r d a ma g e d
I n s pe c t f o r d a ma g e , c o n t a mi n a t i o n . P e r f o r m EPC t e s t s in Ro ut i n e
No . 2 1 1 . Se r v i c e a s r e q u i r e d .
I n s pe c t f o r d a ma ge . Se r v i c e a s r e q u i r e d .
Cl e a n o r r e p l a c e s c r e e n .
TD10389D
0 7 - 0 1 - 4 1
SHIFT CONCERNS: TIMING ERRATIC/HUNTING
Powe r t r a i n Co n t r o l Syst em
c o n t r o l mo d u l e , s h i f t s o l e n o i d s , TCC s o l e n o i d , TR se n so r , OSS
Ma n u a l
6
f o r d i a gn o s i s . P e r f o r m Pi n po i n t Te s t s A, C, D a n d F u s i n g
Ro t u n d a Tr a n s mi s s i o n Te s t e r ( 007 - 0085C) , a n d T r a n s mi s s i o n
Ra n ge ( TR) Se n s o r Ca b l e ( ML P S Ca b i e ) ( 007 - 00086) o r
e q ui v a l e n t , a s o u t l i n e d . Se r v i c e a s r e q u i r e d . Cl e a r c o d e s , r o a d
t e s t a n d r e r un Se l f - Te st .
SHIFT CONCERNS: TIMINGERRATIC/HUNTING (Cont' d)
312 H YDR A U L I C / ME C H A N I C A L ROUTI NE
Fl ui d
Co n d i t i o n
I n s pe c t a s o u t l i n e d un d e r Tr a n s mi s s i o n Fluid Co n d i t i o n Ch e c k.
Mai n Cont r ol s
Va l v e s , a c c u mu l a t o r s , s e a l s , mi s a s s e mb l e d , s t u c k o r d a ma g e d
Cl e a n or r e p l a c e s c r e e n .
Tor que Conver t er Cl ut ch
To r q ue c o n v e r t e r Re f e r t o Hy d r a u l i c / Me c h a n i c a l Ro ut i n e 342 , Co n v e r t e r
Cy c l i n g / Sh u d d e r / Ch a t t e r .
Spe c i f i c Shi f t s
Re f e r t o t h e f o l l o wi n g shi f t r o ut i n e ( s ) f o r f ur t he r d i a g n o s i s :
Shi f t 1-2, Rout i ne, 32 0
Shi f t 2- 3, Rout i ne, 32 1
Shi f t 2 - 1 , Rout i ne, 32 5
SHIFT CONCERNS: FEEL SOFT/SLIPPING
Powe r t r a i n Cont r ol Sy st em
c o n t r o l mo d u l e , EPC s o l e n o i d , OSS
Ma n u a l
7
f o r d i a g n o s i s . P e r f o r m Pi n po i n t T e s t s E a n d F usi n g
Se l f - Te st .
Fl ui d
Co n d i t i o n
I n s pe c t a s o u t l i n e d un d e r Tr a n s mi s s i o n Fl ui d Co n d i t i o n Ch e c k.
L o w l i ne p r e s s u r e , l o w EPC p r e s s u r e Ch e c k p r e s s u r e s a t l i ne a n d EPC t a p s . Re f e r t o Ot h e r Co n c e r n :
P r e s s u r e Re f e r e n c e Cha r t 401 f o r s p e c i f i c a t i o n s . If p r e s s u r e s
a r e l o w o r a l l s h i f t s a r e so f t / s l i p p i n g, go t o Ma i n Co n t r o l s . If
p r e s s u r e s a r e OK a n d a s p e c i f i c shi f t i s s o f t / s l i p p i n g , r e f e r t o
t h e f o l l o wi n g r o u t i n e ( s ) f o r f ur t he r d i a gn o s i s :
Shi f t 2 - 1 , Rout i ne, 32 5
Mai n Cont r ol s
1-2 a c c u mu l a t o r , 2- 3 b a c k o u t v a l v e , ma i n r e gu l a t o r v a l v e , o r i f i c e
c o n t r o l v a l v e , o v e r d r i v e s e r v o r e gu l a t o r v a l v e s t u c k, d a ma g e d o r
mi s a s s e mb l e d
EPC s o l e n o i d s t u c k o r d a ma g e d
I n s pe c t f o r d a ma g e a n d c o n t a mi n a t i o n . P e r f o r m EPC t e s t s i n
Ro ut i n e No . 2 13. Se r v i c e a s r e q u i r e d .
TD10393E
SHI FT CONCERNS: FE E L HARSH
2 1 4 E L E CT RI CA L ROUTI NE
P o w e r t r a i n C o n t r o l S y s t e m
El ect r i cal i nput s / out put s , vehi cl e wi r i ng har nesses, power t r ai n
cont r ol modul e, EPC sol enoi d, OSS
Run Se l f - Te s t . Re f e r t o P o we r t r a i n C o n t r o l / E mi s s i o n s Di a gn o s i s
Ma n u a l
8
f o r d i a g n o s i s . P e r f o r m Pi n po i n t T e s t s E a n d F usi n g
Ro t u n d a T r a n s mi s s i o n Te s t e r ( 007 - 0085C) or e q ui v a l e n t , a s
Se l f - Te s t .
3 1 4 H YDR A U L I C / ME C H A N I C A L ROUTI NE
Fl ui d
I mpr oper l evel
Condi t i on
I n s p e c t a s o u t l i n e d un d e r Tr a n s mi s s i o n Fl ui d Co n d i t i o n Ch e c k.
I m p r o p e r P r e s s u r e s
Hi gh l i ne pr essur e, hi gh EPC pr essur e Ch e c k p r e s s u r e s a t l i ne a n d EPC t a p s . Re f e r t o Ot h e r Co n c e r n :
P r e s s u r e Re f e r e n c e Ch a r t 401 f o r s p e c i f i c a t i o n s . If p r e s s u r e s
a r e h i gh o r al l s h i f t s a r e h a r s h , go t o Ma i n Co n t r o l s . If p r e s s u r e s
a r e OK a n d a s p e c i f i c shi f t i s h a r s h , r e f e r t o t h e f o l l o wi n g shi f t
r o u t i n e ( s ) f o r f u r t h e r d i a g n o s i s :
Shi f t 2 - 3, Rout i ne, 32 1
Shi f t 4- 3, Rout i ne, 323
Sh i f t 2 - 1, Rout i ne, 32 5
1-2 a c c u mu l a t o r , 2- 3 b a c ko u t v a l v e , ma i n r e gu l a t o r v a l v e , o r i f i c e
c o n t r o l v a l v e , o v e r d r i v e s e r v o r e gu l a t o r v a l v e s t u c k, d a ma g e d o r
E P C s o l e n o i d s t u c k o r d a ma g e d
I n s p e c t f o r d a ma g e , c o n t a mi n a t i o n . P e r f o r m EPC t e s t s i n Ro ut i n e
2 14. Se r v i c e a s r e q u i r e d .
TD10395E
S H I F T C O N C E R N S : NO 1 S T G E A R , E N G A G E S I N H I G H E R G E A R
2 1 5 ELECTRICAL ROUTINE
Power t r ai n Cont r ol Sy st e m
c o n t r o l mo d u l e , shi f t s o l e n o i d s , TR s e n s o r
Ma n u a l
8
f o r d i a gn o s i s . P e r f o r m Pi n po i n t T e s t s A a n d D usi n g
Ro t u n d a Tr a n s mi s s i o n Te s t e r ( 007 - 0085C) , a n d t h e
Tr a n s mi s s i o n Ra n ge ( TR) Se n s o r Ca b l e ( ML P S Ca b l e )
( 007 - 00086) o r e q ui v a l e n t , a s o u t l i n e d . Se r v i c e a s r e q u i r e d .
Cl e a r c o d e s , r o a d t e s t a n d r e r un Se l f - Te st .
3 1 5 HYDRAULIC/MECHANICAL ROUTINE
Shi f t Li nka ge , TR Sensor
Da ma g e d or o ut of a d j u s t me n t I n s pe c t a n d s e r v i c e a s r e q u i r e d . Ad j u s t l i n ka ge a s o ut l i n e d . Af t e r
p r e s s u r e
Ch e c k f o r wh i c h p r e s s u r e s a r e o n a s f o l l o ws a n d c o r r e s p o n d i n g
r o u t i n e s
9
:

Fo r wa r d Of f , I nt er medi at e Of f , Di r ect X
Fo r wa r d Of f , I nt er medi at e X, Di r ect Of f
Fo r wa r d Of f , I nt er medi at e X, Di rect X
Fo r wa r d X, I nt er medi at e Of f , Di rect X
For wa r d X, I nt er medi at e X, Di r ect Of f
For wa r d X, I nt er medi at e X, Di r ect X
Fo r wa r d X, I nt er medi at e Of f , Di rect Of f
e
3 2 4 , 3 0 1
3 2 5 , 3 0 1
3 2 3 , 3 2 4 , 3 2 5 , 3 0 1
32 4
32 5
32 3, 32 4, 32 5
Re f e r t o a p p r o p r i a t e Me c h a n i c a l Di a gn o s i s
Mechani cal
Ba n d s , c l u t c h e s o r s e a l s d a ma g e d o r wo r n Re f e r t o Tr a n s mi s s i o n , Di s a s s e mb l y a n d A s s e mb l y .
9 X = p r e s s u r e s a p p l i e d .
SHIFT CONCERNS: NO MANUAL 1ST GEAR
Powertrain Control System
c o n t r o l mo d u l e , shi f t s o l e n o i d s , TR Se n s o r
Ma n u a l
1 0
f o r d i a gn o s i s . P e r f o r m Pi n po i n t T e s t s A a n d D usi n g
Ro t u n d a Tr a n s mi s s i o n Te s t e r ( 007 - 0085C) , a n d t h e
( 007 - 00086) o r e q ui v a l e n t , a s o u t l i n e d . Se r v i c e a s r e q u i r e d .
Shi f t Li nkage, Cabl e, TR Sensor
Da ma g e d o r o ut of a d j u s t me n t I n s pe c t a n d s e r v i c e a s r e q u i r e d . Ad j u s t l i n ka ge a s o u t l i n e d . Af t e r
p r e s s u r e , l o w EPC p r e s s u r e
Ch e c k p r e s s u r e a t l i ne a n d EPC p r e s s u r e t a p s . Re f e r t o Ot h e r
Co n c e r n : P r e s s u r e Re f e r e n c e Cha r t 401 f o r s p e c i f i c a t i o n s . If
p r e s s u r e s a r e l o w, c h e c k t h e f o l l o wi n g p o s s i b l e c o mp o n e n t s :
f l ui d f i l t e r a n d s e a l a s s e mb l y , ma i n c o n t r o l s , r e v e r s e c l u t c h
a s s e mb l y a n d r e v e r s e s e r v o a s s e mb l y .
P l u gge d o r d a ma g e d Re p l a c e f l ui d f i l t e r a n d s e a l a s s e mb l y .
Mai n Cont r ol s
No . 6 s h u t t l e ba l l , ma n ua l v a l v e , ma i n r e gu l a t o r v a l v e , l o w s e r v o
mo d u l a t o r v a l v e s t u c k, d a ma g e d o r mi s a s s e mb l e d
Low Reverse Servo
Se r v o c o v e r r e t a i n i n g r i n g mi s a s s e mb l e d
TD10399E
SHIFT CONCERNS: NO MANUAL 2ND GEAR
Powe r t r a i n Cont r ol Sy st em
c o n t r o l mo d u l e ( P CM) , shi f t s o l e n o i d s , TR s e n s o r
Ma n u a l
1 0
f o r d i a gn o s i s . P e r f o r m Pi n po i n t Te s t s A a n d D usi n g
Ro t u n d a Tr a n s mi s s i o n Te s t e r ( 007 - 0085C) o r e q ui v a l e n t , a n d t h e
( 007 - 00086) o r e qui v a l e n t , a s o ut l i n e d . Se r v i c e a s r e q u i r e d .
Shi f t Li nkage, Cabl e, TR Sensor
Da ma g e d , o ut of a d j u s t me n t I n s pe c t a n d s e r v i c e a s r e q u i r e d . Ad j u s t l i n ka ge a s o u t l i n e d . Af t e r
Re f e r t o Tr a n s mi s s i o n A s s e mb l y p r o c e d u r e s .
Mai n Cont r ol s
Or i f i c e c o n t r o l v a l v e , 3- 4 shi f t v a l v e , 1-2 a n d 2- 3 shi f t v a l v e , 3- 4
c a p a c i t y mo d u l a t o r v a l v e s t u c k, d a ma g e d or mi s a s s e mb l e d
TD8098D
SHIFT CONCERNS: 1-2 SHIFT (AUTOMATIC)
(Possible Component Re f e r e n c e / Ac t i o n
220 ELECTRI CAL ROU TI NE
Power tr ai n Contr ol Syst em
El ect r i cal i nput s / out put s , vehi cl e wi r i ng har nes s es , power t r ai n
cont r ol modul e, shi f t sol enoi ds, OSS
Run Se l f - Te st . Re f e r t o P o we r t r a i n C o n t r o l / E mi s s i o n s Di a g n o s i s
Ma n u a l
1 1
f o r d i a g n o s i s . P e r f o r m Pi n po i n t T e s t s A a n d F u s i n g
Ro t u n d a Tr a n s mi s s i o n Te s t e r ( 007 - 0085C) o r e q u i v a l e n t , a s
Se l f - Te s t .
320 HYDRAU LI C/MECHANI CAL ROU TI NE
Shift Li nkage, TR Sensor
Damaged or out of adj ust ment I n s p e c t a n d s e r v i c e a s r e q u i r e d . Ad j u s t l i n ka ge a s o u t l i n e d . A f t e r
I nt er medi at e cl ut ch pr essur e, l i ne pr essur e C h e c k p r e s s u r e a t l i ne a n d i n t e r me d i a t e c l u t c h t a p s . Re f e r t o
Ot h e r Co n c e r n : P r e s s u r e Re f e r e n c e Ch a r t 401 f o r
s p e c i f i c a t i o n s . If n o t OK, c h e c k the Ma i n Co n t r o l s .
Main Contr ol s
1 -2 shi f t v a l v e , 1 -2 a c c u mu l a t o r v a l v e s t u c k o r d a ma g e d
Bol t s out of t or que s p e c i f i c a t i o n
SS1 n o t f u n c t i o n i n g p r o p e r l y
No . 8 ba l l n o t s e a t i n g
A c t i v a t e s o l e n o i d usi n g t r a n s mi s s i o n t e s t e r . I f s o l e n o i d o p e r a t i o n
c a n n o t b e f e l t wh e n p l a c i n g h a n d o n s o l e n o i d , r e p l a c e s o l e n o i d .
I n s p e c t O- r i n gs f o r d a ma g e . Se r v i c e a s r e q u i r e d .
I n s pe c t f o r d a ma g e a n d s e r v i c e a s r e q u i r e d .
Pump Asse mbl y
P o r o s i t y / c r o s s l e a ks , b a l l s mi s s i n g , d a ma g e d o r l e a ki n g
I n s p e c t f o r p o r o s i t y / l e a k s , balls missing. Re p l a c e p u mp
a s s e mb l y a s r e q u i r e d .
I nt er medi at e Cl ut ch Assembl y
Se a l s d a ma g e d
P i s t o n d a ma g e d
Fr i c t i o n e l e me n t s d a ma g e d o r wo r n
I n s pe c t f o r d a ma g e . Se r v i c e as r e q u i r e d .
I nt er medi at e One-Way Cl ut ch Assembl y
No t h o l d i n g o r d a ma g e d I n s pe c t f o r d a ma g e . Se r v i c e a s r e q u i r e d .
Low One-Way Cl ut ch Assembl y
Not o v e r r un n i n g o r d a ma g e d i n s p e c t f o r d a ma g e . Se r v i c e a s r e q u i r e d .
TD10401F
SHI FT CONCERNS: 2-3 SHI FT ( A U T OMA T I C)
Possi bl e Co mpo n e n t Re f e r e n c e / Ac t i o n
Powert rai n Co n t r o l Sy st em
E l e c t r i c a l i n p u t s / o u t p u t s , v e h i c l e wi r i n g h a r n e s s e s , P CM, shi f t
s o l e n o i d s , OSS
Ma n u a l
1 1
f o r d i a gn o s i s . Pe r f o r m Pi n po i n t T e s t s A a n d F usi n g
Ro t u n d a Tr a n s mi s s i o n Te s t e r ( 007 - 0085C) or e q ui v a l e n t , a s
o ut l i n e d . Se r v i c e a s r e q u i r e d . Cl e a r c o d e s , r o a d t e s t a n d r e r un
Se l f - Te st .
321 HYDRAULI C/MECHANI CAL ROUTINE
Shi f t Li nkage
Da ma g e d o r o ut of a d j u s t me n t I n s pe c t a n d s e r v i c e a s r e q u i r e d . Ad j us t l i n ka ge a s o u t l i n e d . Af t e r
s e r v i c i n g l i n ka ge , v e r i f y t ha t t h e TR s e n s o r i s p r o p e r l y a d j u s t e d .
( Co n t i n ue d )
07 - 01- 46
T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W 07 - 01- 46
SHIFT CONCERNS: 2 - 3 SHIFT (AUTOMATIC) (Cont ' d)
Possible Component R e f e r e n c e / A c t i o n
Improper Pressures
Di r e c t c l u t c h p r e s s u r e Ch e c k p r e s s u r e a t d i r e c t c l u t c h t a p . Re f e r t o Ot h e r Co n c e r n :
P r e s s u r e Re f e r e n c e Cha r t 401 f o r s p e c i f i c a t i o n s . If not OK,
c h e c k t h e ma i n c o n t r o l s .
Main Controls
2- 3 shi f t v a l v e , c h e c k ba l l No . 1 or No . 3, s o l e n o i d p r e s s u r e
r e gu l a t o r v a l v e , 2- 3 b a c ko u t v a l v e , 2- 3 mo d u l a t o r v a l v e , o r i f i c e
c o n t r o l v a l v e s t u c k, d a ma g e d o r mi s a s s e mb l e d
SS2 not f u n c t i o n i n g p r o p e r l y
Out put s ha f t s e a l s d a ma g e d o r c up pl ug l e a ki n g o r mi s s i n g
2- 3 a c c u mu l a t o r d a ma g e d o r s t u c k
So l e n o i d s c r e e n (i n ma i n c o n t r o l ) b l o c k e d o r d a ma g e d
A c t i v a t e s o l e n o i d usi n g t r a n s mi s s i o n t e s t e r . If s o l e n o i d o p e r a t i o n
I n s pe c t O- r i n gs f o r d a ma g e . Se r v i c e a s r e q u i r e d .
I n s pe c t p i s t o n s e a l a n d b o r e f o r d a ma g e . Se r v i c e a s r e q u i r e d .
I n t e r me d i a t e O v e r r u n n i n g C l u t c h A s s e m b l y
No t o v e r r un n i n g o r d a ma g e d I n s pe c t f o r d a ma g e . Se r v i c e a s r e q u i r e d .
O u t p u t S h a f t
Se a l r i n gs d a ma g e d
Cup pl ug d a ma g e d or mi s s i n g
Di r e c t C l u t c h A s s e m b l y
Se a l s o r p i s t o n d a ma g e d
Fr i c t i o n e l e me n t s wo r n o r d a ma g e d
Ch e c k ba l l not s e a t i n g
Re t ur n s p r i n g a s s e mb l y d a ma g e d
C a s e
Out put s ha f t r e a r s e a l s l e a ki n g or d a ma g e d I n s pe c t f o r d a ma g e . Se r v i c e a s r e q u i r e d . I n s pe c t c a s e f o r
d a ma g e d s e a l a r e a . If d a ma g e d , r e p l a c e c a s e .
TD10403F
SHIFT CONCERNS: 3 - 4 SHIFT (AUTOMATIC)
P o s s i b l e C o m p o n e n t R e f e r e n c e / A c t i o n
2 2 2 E L E CT RI CA L ROUT I NE
Powertrain C o n t r o l S y s t e m
c o n t r o l mo d u l e , shi f t s o l e n o i d s , OSS, t r a n s mi s s i o n c o n t r o l
s wi t c h ( TCS)
Ma n u a l
1 2
f o r d i a g n o s i s . P e r f o r m Pi n po i n t Te s t s A a n d F usi n g
Se l f - Te st .
S h i f t L i n k a g e , TR S e n s o r
Da ma g e d o r o ut o f a d j u s t me n t I n s pe c t a n d s e r v i c e a s r e q u i r e d . Ad j ust l i n ka ge a s o u t l i n e d . Af t e r
I m p r o p e r P r e s s u r e s
Fo r wa r d c l u t c h p r e s s u r e , d i r e c t c l u t c h p r e s s u r e , l i ne p r e s s u r e Ch e c k l i ne , d i r e c t a n d f o r wa r d c l u t c h p r e s s u r e s a t a p p r o p r i a t e
t a p s . Re f e r t o Ot h e r Co n c e r n : P r e s s u r e Re f e r e n c e Cha r t 401 f o r
s p e c i f i c a t i o n s . If p r e s s u r e s a r e out of s p e c i f i c a t i o n , c h e c k ma i n
c o n t r o l s .
Main C o n t r o l s
3- 4 shi f t v a l v e , s o l e n o i d p r e s s u r e r e gu l a t o r v a l v e , OD s e r v o
r e gul a t o r , 3- 4 c a p a c i t y mo d u l a t o r v a l v e , 2- 3 b a c ko u t v a l v e ,
o r i f i c e c o n t r o l v a l v e , 1-2 a n d 2- 3 shi f t v a l v e s s t u c k, d a ma g e d or
I n s pe c t f o r d a ma g e d a n d s e r v i c e a s r e q u i r e d .
12 P u r c h a s e d s e p a r a t e l y , r e f e r t o t h e e n d of t hi s Se c t i o n f o r v e h i c l e a p p l i c a t i o n s .
SHIFT CONCERNS: 3-4 SHIFT (AUTOMATIC) (Cont ' d)
SS1 or SS2 n o t f u n c t i o n i n g p r o p e r l y
OD s e r v o c o v e r , r o d a n d p i s t o n c u s h i o n s pr i n g o r s e a l s d a ma g e d
No ' s 1, 2, 4 a n d 7 c h e c k b a l l s d a ma g e d o r mi s s i n g
So l e n o i d s c r e e n (i n ma i n c o n t r o l ) b l o c k e d or d a ma g e d
A c t i v a t e s o l e n o i d us i n g t r a n s mi s s i o n t e s t e r . If s o l e n o i d o p e r a t i o n
c a n n o t be f e l t wh e n p l a c i n g h a n d o n s o l e n o i d , r e p l a c e s o l e n o i d .
I n s p e c t O- r i n gs f o r d a ma g e . S e r v i c e a s r e q u i r e d .
Pump Assembl y
P o r o s i t y / c r o s s l e a ks , b a l l s mi s s i n g, d a ma g e d or l e a ki n g
I n s p e c t f o r p o r o s i t y / l e a k s , b a l l s mi s s i n g . Re p l a c e p u mp
I n s p e c t f o r d a ma g e . Re p l a c e a s r e q u i r e d .
OD Band
OD b a n d a n d r e v e r s e c l u t c h d r u m a s s e mb l y d a ma g e d , wo r n or
I n t e r me d i a t e o v e r r un n i n g c l u t c h a s s e mb l y d a ma g e d
I n s p e c t f o r d a ma g e a n d s e r v i c e a s r e q u i r e d .
For war d Cl ut ch Assembl y
Fr i c t i o n e l e me n t s wo r n o r d a ma g e d
Ch e c k ba l l s t u c k, d a ma g e d o r n o t s e a t i n g p r o p e r l y
I nput Shaf t
Se a l s d a ma g e d I n s p e c t f o r d a ma g e . Se r v i c e a s r e q u i r e d .
TD10405G
c o n t r o l mo d u l e , shi f t s o l e n o i d s , t r a n s mi s s i o n c o n t r o l s wi t c h
( TCS)
Ma n u a l
1 3
f o r d i a gn o s i s . P e r f o r m Pi n po i n t Te st A us i n g Ro t u n d a
Tr a n s mi s s i o n T e s t e r ( 007 - 0085C) or e q ui v a l e n t , a s o u t l i n e d .
Se r v i c e a s r e q u i r e d . Cl e a r c o d e s , r o a d t e s t a n d r e r un Se l f - Te st .
Fo r wa r d c l u t c h p r e s s u r e , l i ne p r e s s u r e Ch e c k l i ne a n d f o r wa r d c l u t c h a t p r e s s u r e t a p s . Re f e r t o Ot h e r
Co n c e r n : P r e s s u r e Re f e r e n c e Ch a r t 401 f o r s p e c i f i c a t i o n s . If o ut
of s p e c i f i c a t i o n , c h e c k ma i n c o n t r o l s .
Mai n Cont r ol s
3-4 shi f t v a l v e , s o l e n o i d p r e s s u r e r e gu l a t o r v a l v e , OD s e r v o
r e gu l a t o r , 3- 4 c a p a c i t y mo d u l a t o r , o r i f i c e c o n t r o l v a l v e , 2- 3
b a c ko u t v a l v e , 1-2, 2- 3 shi f t v a l v e s s t u c k, d a ma g e d o r
C h e c k b a l l s No . 1, No . 2, No . 7 d a ma g e d , mi s s i n g or not s e a t i n g
p r o p e r l y
SS1 not f un c t i o n i n g p r o p e r l y
OD s e r v o , s e a l , r o d d a ma g e d
So l e n o i d s c r e e n (i n ma i n c o n t r o l ) b l o c k e d o r d a ma g e d
c a n n o t be f e l t wh e n p l a c i n g h a n d on s o l e n o i d , r e p l a c e s o l e n o i d .
I n spe c t O- r i n gs f o r d a ma g e . Se r v i c e a s r e q u i r e d .
I n spe c t f o r d a ma g e . Se r v i c e a s r e q u i r e d .
Cl e a n or r e p l a c e s c r e e n .
Pump Assembl y
P o r o s i t y / c r o s s l e a ks , b a l l s mi s s i n g, d a ma g e d o r l e a ki n g
Se a l r i n gs d a ma g e d .
I n spe c t f o r p o r o s i t y / l e a ks , b a l l s mi s s i n g. Re p l a c e p u mp
I n spe c t f o r d a ma g e . Se r v i c e a s r e q u i r e d .
I n spe c t f o r d a ma g e a n d r e p l a c e .
13 P u r c h a s e d s e p a r a t e l y , r e f e r t o t h e e n d of t h i s S e c t i o n f o r v e h i c l e a p p l i c a t i o n s .
SHIFT CONCERNS: 4-3 SHIFT (AUTOMATIC) (Cont'd)
Possi bl e Component Re f e r e n c e / Ac t i o n
Overdrive Band
OD b a n d a n d r e v e r s e c l u t c h a s s e mb l y d a ma g e d , wo r n o r
I n t e r me d i a t e o v e r r un n i n g c l u t c h a s s e mb l y d a ma g e d
Fowa r d Cl ut ch Assembl y
Ch e c k ba l l s t u c k, d a ma g e d or not s e a t i n g p r o p e r l y
Fo r wa r d c l u t c h p i s t o n a n d r e t ur n s pr i n g d a ma g e d
I nput Shaf t
Se a l s d a ma g e d I n s p e c t f o r d a ma g e . Se r v i c e a s r e q u i r e d .
TD10407G
c o n t r o l mo d u l e , shi f t s o l e n o i d s
Ma n u a l
1 4
f o r d i a gn o s i s . P e r f o r m Pi n po i n t Te st A usi n g Ro t u n d a
T r a n s mi s s i o n T e s t e r ( 007 - 0085C) or e q ui v a l e n t , a s o u t l i n e d .
Di r e c t c l u t c h Ch e c k p r e s s u r e a t d i r e c t c l u t c h t a p . Re f e r t o Ot h e r Co n c e r n :
P r e s s u r e Re f e r e n c e Cha r t 401 f o r s p e c i f i c a t i o n s . If not wi t hi n
s p e c i f i c a t i o n , c h e c k ma i n c o n t r o l s .
Mai n Cont r ol s
2- 3 s hi f t v a l v e s t u c k o r d a ma g e d
Ch e c k b a l l s d a ma g e d or mi s s i n g
SS2 not f un c t i o n i n g p r o p e r l y
I n s pe c t f o r d a ma g e . Se r v i c e a s r e q u i r e d
Ad j u s t b o l t s to s p e c i f i c a t i o n .
I nt er medi at e On e - Wa y Cl ut ch
No t h o l d i n g o r d a ma g e d I n s pe c t f o r d a ma g e . Se r v i c e a s r e q u i r e d .
Di rect Cl ut ch Assembl y
Se a l s or p i s t o n d a ma g e d
Fr i c t i o n e l e me n t d a ma g e d , wo r n
Ch e c k ba l l s t u c k, d a ma g e d or not s e a t i n g p r o p e r l y
TD10409G
Powe r t r a i n Cont r ol Syst em
c o n t r o l mo d u l e , shi f t s o l e n o i d s
Ma n u a l '
4
f o r d i a gn o s i s . P e r f o r m Pi n po i n t Te st A usi n g Ro t u n d a
Tr a n s mi s s i o n Te s t e r ( 007 - 0085C) or e q ui v a l e n t , a s o u t l i n e d .
(Continued)
SHIFT CONCERNS: 2-1 SHIFT (AUTOMATIC) (Cont ' d)
Pos s i bl e Co mp o n e n t Re f e r e n c e / Ac t i o n
3 2 5 HYDRAUL I C/ MECHANI CAL ROUTI NE
I mp r o p e r Pressures
I nt er medi at e cl ut ch C h e c k p r e s s u r e a t i n t e r me d i a t e c l u t c h t a p . Re f e r t o Ot h e r
Co n c e r n : P r e s s u r e Re f e r e n c e Ch a r t 401 f o r s p e c i f i c a t i o n s . If n o t
wi t h i n s p e c i f i c a t i o n s , c h e c k Ma i n Co n t r o l s a n d P u mp A s s e mb l y .
Mai n Co n t r o l s
1 -2 shi f t val ve, 1 -2 accumul at or sol enoi d pr essur e r egul at or
val ve st uck, damaged or mi s as s embl ed
Bol t s out of t or que speci f i cat i on
SS1 not f unct i oni ng pr oper l y
Gas k et s damaged
I n s p e c t O- r i n gs f o r d a ma g e ; s e r v i c e a s r e q u i r e d .
Pu mp As s e mb l y
Gas k et s damaged
Po r o s i t y / c r o s s l eaks
I n s p e c t f o r l e a k / p o r o s i t y . Re p l a c e p u mp a s s e mb l y a s r e q u i r e d .
I nt er medi at e Cl ut ch Assembl y
P i s t o n d a ma g e d
En d c l e a r a n c e i mp r o p e r
I n s p e c t a n d c o r r e c t a s o u t l i n e d un d e r T r a n s mi s s i o n , A s s e mb l y
I nt e r me di a t e One-Way Cl ut ch
Da ma g e d I n s p e c t f o r d a ma g e . Se r v i c e as r e q u i r e d .
Low One-Way Cl ut ch
No t h o l d i n g o r d a ma g e d I n s p e c t f o r d a ma g e . Se r v i c e a s r e q u i r e d .
TD10413F
TORQUE CONVERTER OPERATION CONCERNS: NO APPLY
c o n t r o l mo d u l e , t o r q u e c o n v e r t e r c l u t c h ( TCC) s o l e n o i d , TFT
s e n s o r , OSS
Ma n u a l
1 5
f o r d i a gn o s i s . P e r f o r m Pi n po i n t T e s t s B, C, a n d F usi n g
Se l f - Te st .
Shi f t Li nkage
Da ma g e d , o ut of a d j u s t me n t I n s pe c t a n d s e r v i c e a s r e q u i r e d . A d j u s t l i n ka ge a s o u t l i n e d . Af t e r
L o w l i ne p r e s s u r e , l o w EPC p r e s s u r e Ch e c k p r e s s u r e a t l i ne a n d EPC t a p s . Re f e r t o Ot h e r Co n c e r n :
P r e s s u r e Re f e r e n c e Cha r t 401 f o r s p e c i f i c a t i o n s . If p r e s s u r e i s
l o w, c h e c k EPC a n d ma i n r e gu l a t o r v a l v e . If wi t hi n s p e c i f i c a t i o n ,
c h e c k ma i n c o n t r o l s .
Mai n Cont r ol s
So l e n o i d p r e s s u r e r e gu l a t o r v a l v e , ma n ua l v a l v e , b y p a s s c l u t c h
c o n t r o l v a l v e a n d pl un ge r , c o n v e r t e r p r e s s u r e l i mi t v a l v e , d r a i n
b a c k v a l v e s t u c k, d a ma g e d or mi s a s s e mb l e d
T CC s o l e n o i d not f u n c t i o n i n g p r o p e r l y
I n spe c t f o r d a ma g e a n d s e r v i c e a s r e q u i r e d .
I n spe c t O- r i n gs f o r d a ma g e . Se r v i c e a s r e q u i r e d .
I n spe c t f o r d a ma g e a n d r e p l a c e .
( Co n t i n ue d )
07- 01- 50 Tr a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 07- 01- 50
TORQUE CONVERTER OPERATION CONCERNS: NO APPLY (Cont 'd)
Pump Assembl y
P o r o s i t y / c r o s s l e a ks , b a l l s l e a ki n g
I n s p e c t f o r p o r o s i t y / l e a k s , ba l l mi s s i n g. Re p l a c e pu mp
I nput Shaf t
Se a l s d a ma g e d I n s p e c t f o r d a ma g e . Se r v i c e a s n e c e s s a r y .
Tor que Convert er Assembl y
L e a ka g e , f r i c t i o n ma t e r i a l d a ma g e d , i n t e r n a l s e a l s d a ma g e d I n s p e c t t o r q u e c o n v e r t e r a s o u t l i n e d . Se r v i c e o r r e p l a c e a s
r e q u i r e d .
TD10415F
TORQUE CONVERTER OPERATION CONCERN: ALWAYS APPLIED/STALLS VEHICLE
c o n t r o l mo d u l e , t o r q u e c o n v e r t e r c l u t c h ( TCC) s o l e n o i d , TFT
s e n s o r
Ma n u a l
1 6
f o r d i a gn o s i s . P e r f o r m Pi n po i n t T e s t s B a n d C usi n g
Se l f - Te st .
Ma i n Cont r ol s
Dr a i n b a c k v a l v e , t o r q u e c o n v e r t e r c l u t c h a n d pl un ge r s t u c k,
d a ma g e d or mi s a s s e mb l e d
TCC s o l e n o i d not f u n c t i o n i n g p r o p e r l y
No . 7 ba l l i mp r o p e r s e a t i n g
Pump Assembl y
Ba l l mi s s i n g, l e a ki n g, p o r o s i t y / c r o s s l e a ks
I n s pe c t f o r p o r o s i t y / l e a k s , ba l l s mi s s i n g. Re p l a c e pu mp
I nput Shaf t
Se a l s d a ma g e d I n s pe c t f o r d a ma g e . Se r v i c e a s r e q u i r e d .
Tor que Conver t er Assembl y
No e n d c l e a r a n c e
P i s t o n p l a t e d a ma g e d o r s t u c k t o c o v e r
I n s pe c t c o n v e r t e r a s o ut l i n e d a n d r e p l a c e a s r e q u i r e d .
If c o v e r i s h e a t - s t a i n e d , r e p l a c e t o r q u e c o n v e r t e r .
TD10417E
TORQUE CONVERTER OPERATION CONCERN: CYCLING/SHUDDER/CHATTER
Powe r t r a i n Cont r ol Syst em
c o n t r o l mo d u l e , t o r q u e c o n v e r t e r c l u t c h ( TCC) s o l e n o i d , OSS
Ma n u a l
1 6
f o r d i a g n o s i s . P e r f o r m Pi n po i n t T e s t s C a n d F usi n g
Se l f - Te st .
0 7 - 0 1 - 5 1 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 0 7 - 0 1 - 5 1
TORQUE CONVERTER OPERATION CONCERN: CYCLI NG/SHUDDER/CHATTER (Cont ' d)
Possible C o m p o n e n t Re f e r e n c e / Ac t i o n
342 HYDRAULI C/ MECHANI CAL ROUTINE
Fl ui d
Co n d i t i o n I n s p e c t f l u i d c o n d i t i o n . If bur n t , d r a i n f l u i d a n d c o n v e r t e r . R e p l a c e
f l u i d a n d f i l t e r a s s e mb l y . Br i n g v e h i c l e t o n o r ma l o p e r a t i n g
t e mp e r a t u r e . P e r f o r m T r a n s mi s s i o n Dr i v e C y c l e Te s t as o u t l i n e d .
P e r f o r m Se l f - Te s t . If c o n d i t i o n s t i l l e x i s t s , c o n t i n u e d i a g n o s t i c s .
Main Controls
S o l e n o i d p r e s s u r e r e g u l a t o r v a l v e , No . 7 c h e c k b a l l , b y p a s s
c l u t c h c o n t r o l v a l v e a n d pl u n ge r , c o n v e r t e r p r e s s u r e l i mi t v a l v e
s t u c k , d a m a g e d o r mi s a s s e mb l e d
Bo l t s o u t o f t o r q u e s p e c i f i c a t i o n
S o l e n o i d s c r e e n (i n v a l v e b o d y ) b l o c k e d o r d a ma g e d
T CC s o l e n o i d n o t f u n c t i o n i n g p r o p e r l y
I n s p e c t f o r d a ma g e . S e r v i c e as r e q u i r e d .
A c t i v a t e s o l e n o i d u s i n g t r a n s mi s s i o n t e s t e r . If s o l e n o i d o p e r a t i o n
c a n n o t b e f e l t w h e n p l a c i n g h a n d o n s o l e n o i d , r e p l a c e s o l e n o i d .
I n s p e c t O- r i n gs f o r d a ma g e . S e r v i c e as r e q u i r e d .
Pump Asse mbl y
Bo l t s o u t of t o r q u e s p e c i f i c a t i o n
P o r o s i t y / c r o s s l e a ks , b a l l s mi s s i n g o r l e a ki n g
I n s p e c t f o r p o r o s i t y / l e a k s o r b a l l s mi s s i n g . R e p l a c e p u mp
I nput Shaf t
S e a l s d a m a g e d I n s p e c t f o r d a ma g e . S e r v i c e a s r e q u i r e d .
Tor que Co n ve r t e r
E x c e s s i v e e n d c l e a r a n c e I n s p e c t c o n v e r t e r a s o u t l i n e d . Re p l a c e a s r e q u i r e d .
OTHER CONCERNS: NO ENGINE BRAKING IN 2ND GEAR, MANUAL 2ND OR MANUAL 1ST POSITION
250 ELECTRI CAL ROUTINE
No E l e c t r i c a l C o n c e r n s
350 HYDRAULI C/MECHANI CAL ROUTINE
Shi f t Li n ka ge
Da ma g e d o r o ut of a d j u s t me n t I n s p e c t a n d s e r v i c e a s r e q u i r e d . A d j u s t l i n ka ge a s o u t l i n e d . A f t e r
Main Co n t r o l s
3- 4 s h i f t v a l v e , 1-2 a n d 2 - 3 s h i f t v a l v e , g a s k e t s , o r i f i c e c o n t r o l
v a l v e , 3- 4 c a p a c i t y mo d u l a t o r v a l v e , s t u c k o r d a m a g e d o r
OD s e r v o a s s e mb l y d a ma g e d o r s t u c k
I n s p e c t f o r d a ma g e . S e r v i c e as r e q u i r e d .
I n s p e c t c o v e r , p i s t o n a n d s e a l f o r d a ma g e . S e r v i c e a s r e q u i r e d .
Over dr i ve
OD b a n d , r e v e r s e c l u t c h d r u m a s s e mb l y wo r n o r d a m a g e d
I n t e r me d i a t e o v e r r u n n i n g c l u t c h a s s e mb l y d a ma g e d
I n s p e c t f o r d a ma g e . Se r v i c e as r e q u i r e d .
I n s p e c t f o r d a ma g e . S e r v i c e a s r e q u i r e d .
TD10421F
OTHER CONCERNS: SHIFT LEVER EFFORTS HIGH
Possible Co mpo n e n t Re f e r e n c e / Ac t i o n
351 HYDRAULI C/ MECHANÂL ROUTINE
Shi f t Li n ka ge , TR Sensor
Da ma g e d o r o ut of a d j u s t me n t I n s p e c t a n d s e r v i c e a s r e q u i r e d . A d j u s t l i n ka ge a s o u t l i n e d . A f t e r
OTHER CONCERNS; SHIFT L E V E R EFFORTS HIGH ( C o n t ' d )
Possible C o m p o n e n t R e f e r e n c e / A c t i o n
Manual Lever
Retaining pin damaged, nut l o o s e , d e t e n t s p r i n g be n t o r
damaged or PARK me c h a n i s m d a ma g e d
Main Cont rol s
Manual valve stuck or d a ma g e d
Bolts out of torque s p e c i f i c a t i o n
TD10423F
ER CONCERNS: EXTERNAL LEAKS
P o s s i b l e Component R e f e r e n c e / A c t i o n
23 '--i ECTRI CAL ROUTINE
Powert rai n Cont rol Syst em
Electrical i nput s/out put s, s e n s o r s e a l s l e a ki n g (TR, OSS, VS S o r
transmission connector)
I n spe c t f o r l e a ka g e a n d s e r v i c e a s r e q u i r e d .
352 HYDRAULI C/ MECHANI CAL ROUTINE
Seal s, Gaskets
To r q ue c o n v e r t e r , p u mp a s s e mb l y , p a n , e x t e n s i o n h o u s i n g -
g a s k e t / s e a l , ma n ua l l e ve r , f l ui d l e v e l i n d i c a t o r t u b e
L o c a t e s o u r c e of l e a k. Se r v i c e a s r e q u i r e d .
O t h e r
Co o l e r f i t t i n g, p r e s s u r e t a p s , c o n v e r t e r d r a i n p l u g, b a n d a n c h o r
pi n s , c o o l e r l i n e s, c a s e p o r o s i t y , c a s e c r a c k e d
Ve nt b l o c k e d or d a ma g e d
L o c a t e s o u r c e of l e a k. Se r v i c e a s r e q u i r e d .
Ch e c k v e n t f o r d a ma g e o r b l o c k a g e . Se r v i c e a s r e q u i r e d .
TD10425 F
OTHER CONCERNS: POOR VEHICLE PERFORMANCE
P o w e r t r a i n C o n t r o l S y s t e m
E l e c t r i c a l i n p u t s / o u t p u t s , v e h i c l e wi r i n g h a r n e s s e s , shi f t
s o l e n o i d s , TR s e n s o r , t o r q u e c o n v e r t e r c l u t c h ( TCC) s o l e n o i d ,
t r a n s mi s s i o n oi l t e mp e r a t u r e ( TFT) s e n s o r
Ma n u a l
1 7
f o r d i a gn o s i s . P e r f o r m Pi n po i n t Te s t s A, B, C a n d D
usi n g Ro t u n d a Tr a n s mi s s i o n Te s t e r ( 007 -0085C), a n d
Tr a n s mi s s i o n Ra n ge (TR) Se n s o r Ca b l e ( ML P S Ca b l e )
( 007 -00086) o r e qui v a l e n t , a s o ut l i n e d . Se r v i c e a s r e q u i r e d .
Cl e a r c o d e s , r o a d t e s t a n d r e r un Se l f - Te st . A l s o r e f e r t o Ro ut i n e s
241/341 To r q ue Co n v e r t e r Op e r a t i o n Co n c e r n : A l wa y s A p p l i e d .
S h i f t L i n k a g e , TR S e n s o r
Da ma g e d or out o f a d j u s t me n t I n spe c t a n d s e r v i c e a s r e q u i r e d . Ad j us t l i n ka ge a s o u t l i n e d . Af t e r
Ve r i f y P r o p e r S h i f t S c h e d u l i n g a n d E n g a g e m e n t s
Go t o t h e a p p r o p r i a t e Di a gn o s t i c Ro ut i n e s .
T o r q u e C o n v e r t e r C l u t c h A l w a y s A p p l i e d
Go t o Hy d r a u l i c / Me c h a n i c a l Ro ut i n e 241/ 341.
T o r q u e C o n v e r t e r C l u t c h
Da ma g e d I n spe c t t o r q u e c o n v e r t e r a s o u t l i n e d . Re p l a c e a s o u t l i n e d .
TD10427F
OTHER CONCERNS: N O I S E / V I B R A T I O N F O R W A R D OR REVERSE
2 5 4 E L E CT RI CA L ROUT I NE
17 P u r c h a s e d s e p a r a t e l y , r e f e r t o t h e e n d of t hi s Se c t i o n f o r v e h i c l e a p p l i c a t i o n s .
OTHER CONCERNS: NOISE/VIBRATION FORWARD OR REVERSE (Cont ' d)
Possi bl e Component Re f e r e n c e / Ac t i o n
3S4 HYDRAU LI C/MECHANI CAL ROU TI NE
For No i se s/ Vi br a t i o n s That Chang Wi th Engi ne Speed:
Conver t er c omponent s
Fl ui d l evel ( l ow) pump cavi t at i on
Pump as s embl y
Engi ne dr i ve ac c es s or i es
Co o l e r l i n e s gr o u n d i n g out
Fl y wh e e l
L o c a t e s o u r c e o f d i s t u r b a n c e . S e r v i c e a s r e q u i r e d .
For No i se s/ Vi br a t i o n s That Change Wi t h Vehi cl e Speed:
En gi n e mo u n t s l o o s e o r d a ma g e d
Dr i v e l i n e c o n c e r n s :
u- j o i n t s
r e a r a x l e
s u s p e n s i o n
mo d i f i c a t i o n s
1st Ge a r :
l o w o n e - wa y c l u t c h
g e a r s e t
f r i c t i o n e l e me n t s
2 n d Ge a r :
i n t e r me d i a t e o n e - wa y c l u t c h
i n t e r me d i a t e c l u t c h p i s t o n b l e e d h o l e out o f 12 O' c l o c k
p o s i t i o n
3r d Ge a r :
t o r q u e c o n v e r t e r
a n t i - c l u n k s p r i n g
4t h Ge a r :
g e a r s e t
t o r q u e c o n v e r t e r
Re v e r s e :
g e a r s e t
Out put s h a f t s p l i n e s wo r n o r d a ma g e d
L o c a t e s o u r c e o f d i s t u r b a n c e a n d s e r v i c e a s r e q u i r e d .
Fo r s p e c i f i c shi f t or t o r q u e c o n v e r t e r c o n c e r n s , r e f e r t o t h e
f o l l o wi n g r o ut i n e ( s ) f o r f u r t h e r d i a g n o s i s :
Shift 3- 2, Rout i ne, 32 4
Shi f t 2 - 1 , Rout i ne, 32 5
Torque Convert er Cy cl i ng 2 42 / 342
Ot her No i se s/ Vi br a t i o n s:
Ma i n Co n t r o l s , v a l v e r e s o n a n c e
Shi f t Ca b l e :
v i b r a t i o n
gr o u n d i n g
c o o l e r l i n e s
gr o u n d i n g
L o c a t e s o u r c e of d i s t u r b a n c e a n d s e r v i c e a s r e q u i r e d .
OTHER CONCERNS: ENGINE WI L L NOT CRANK
Power t r ai n Co n t r o l Sy st e m
E l e c t r i c a l i n p u t s / o u t p u t s , v e h i c l e wi r i n g h a r n e s s e s , e n gi n e
s t a r t i n g s y s t e m h a r d wa r e , TR s e n s o r
Ma n u a l
1 8
f o r d i a gn o s i s . P e r f o r m Pi n po i n t Te st D usi n g
( 007 - 00086) or e q ui v a l e n t , a s o u t l i n e d . Se r v i c e a n d a d j us t a s
r e q u i r e d .
( Co n t i n ue d )
OTHER CONCERNS: ENGINE WILL NOT CRANK (Cont'd)
Possi bl e Component R e f e r e n c e / A c t i o n
355 HYDRAU LI C/MECHANI CAL ROU TI NE
Shift Li nkage, TR Sensor
Da ma g e d o r o ut o f a d j u s t me n t I n s pe c t a n d s e r v i c e a s r e q u i r e d . Ad j u s t l i n ka ge a s o u t l i n e d . Af t e r
TD10431E
OTHER CONCERNS: NO PARK RANGE
S h i f t Linkage, TR S e n s o r
Da ma g e d o r o ut of a d j u s t me n t I n s pe c t a n d s e r v i c e a s r e q u i r e d . Ad j u s t l i n ka ge a s o u t l i n e d . Af t e r
P a r k Me c h a n i s m
Out put s h a f t r i n g, p a r k b r a ke p a wl , p a r ki n g p a wl r e t ur n s p r i n g ,
p a r k r o d gu i d e cup, p a r ki n g p a wl s h a f t , p a r ki n g p a wl a c t u a t i n g
r o d , ma n ua l l e ve r , ma n ua l l e v e r d e t e n t s p r i n g d a ma g e d o r
I n s pe c t f o r d a ma g e o r mi s a s s e mb l y a n d s e r v i c e a s r e q u i r e d .
TD10433E
OTHER CONCERNS: TRANSMISSION OVERHEATING
Re f e r t o Ro u t i n e 2 4 0 / 3 4 0 , T o r q u e C o n v e r t e r O p e r a t i o n C o n c e r n :
No A p p l y
Fl u i d
Co n d i t i o n
Ad j us t f l ui d t o p r o p e r l e v e l .
C o o l e r L i n e s
Da ma g e d , b l o c k e d o r r e v e r s e d I n s pe c t f o r d a ma g e a n d p r o p e r i n s t a l l a t i o n . Se r v i c e a s r e q u i r e d .
A u x i l i a r y C o o l e r
Da ma g e d , b l o c k e d o r r e s t r i c t e d o r i mp r o p e r l y i n s t a l l e d I n s pe c t f o r d a ma g e a n d p r o p e r i n s t a l l a t i o n . Se r v i c e a s r e q u i r e d .
Ve h i c l e C o n c e r n s C a u s i n g E n g i n e O v e r h e a t i n g
Re f e r t o Se c t i o n 03- 03
Dr a i n b a c k v a l v e , t o r q u e c l u t c h c o n t r o l v a l v e , c o n v e r t e r l i mi t
v a l v e s t u c k, d a ma g e d o r mi s a s s e mb l e d
T o r q u e C o n v e r t e r
No A p p l y Re f e r t o Ro ut i n e 2 40 / 340.
TD10435C
07- 01- 56 Tr ansmi ssi on, A u t o m a t i c 4 R 7 0 W
0 7 - 0 1 - 5 5
CAUTI ON: Do n o t i n st a l l T r a n s mi s s i o n Te st e r
wh e n ver i f yi ng t hese pr essur es.
NOTE: Vehicle harness must be installed at
transmi ssi on connector t o verify t hese pressures.
NOTE: Pressures may vary wi t h model .
OTHER CONCERN: PRESSURE REFERENCE CHART 401A 3.8L SC/ 4. 6L
P r e s s u r e s A t I d l e
G e a r E P C L i n e F o r w a r d C l u t c h I n t e r m e d i a t e C l u t c h Direct C l u t c h
1M 0- 69 kP a 2 8 2 - 5 1 0 k P a 2 48- 496 kP a 0- 34 kP a 0- 34 kP a
1D ( 0- 9 ps i ) ( 41- 7 4 psi ) ( 36- 7 2 ps i ) ( 0- 5 p s i ) ( 0- 5 psi )
2 M 0- 69 kP a 2 8 2 - 5 1 0 k P a 2 48- 496 k P a 2 48- 496 kP a 0- 34 kP a
2D ( 0- 9 ps i ) ( 41- 7 4 psi ) ( 36- 7 2 ps i ) ( 36- 7 2 ps i ) ( 0- 5 psi )
3 0- 69 kP a 2 8 2 - 5 1 0 k P a 2 48- 496 kP a 2 48- 496 kP a 2 48- 496 kP a !
( 0- 9 ps i ) ( 41- 7 4 ps i ) ( 36- 7 2 ps i ) ( 36- 7 2 ps i ) { 36- 7 2 p s i )
4 0- 69 kP a 2 8 2 - 5 1 0 k P a 0- 34 kP a 2 48- 496 kP a 2 48- 49!
( 0- 9 ps i ) ( 41- 7 4 psi ) ( 0- 5 ps i ) ( 36- 7 2 ps i ) ( 36- 7 2 p s i )
R 0- 69 kP a 462 - 7 51 kP a 0- 34 kP a 0- 34 kP a 0- 34 kP a
( 0- 9 ps i ) ( 67 - 109 ps i ) ( 0- 5 ps i ) ( 0- 5 ps i ) ( 0- 5 psi )
P 0- 69 kP a 2 8 2 - 5 1 0 k P a 0- 34 kP a 0- 34 kP a 0- 34 kP a
( 0- 9 ps i ) ( 41- 7 4 ps i ) ( 0- 5 ps i ) ( 0- 5 p s i ) ( 0- 5 ps i )
N . 0- 69 kP a 2 82 - 510 kP a 0- 34 kP a 0- 34 kP a 0- 34 kP a
( 0- 9 ps i ) ( 41- 7 4 ps i ) ( 0- 5 ps i ) (0-5 ps i ) ( 0- 5 ps i )
P r e s s u r e a t Wi d e O p e n T h r o t t l e ( WOT ) S t a l l
1M 57 2 - 641 k P a 1102 - 1447 kP a 1047 - 1447 kP a 0- 34 kP a 0- 34 kP a
1D ( 83- 93 p s i ) ( 160- 2 10 psi ) ( 152 - 2 10 ps i ) (0-5 ps i ) ( 0- 5 psi )
2 M 57 2 - 641 k P a 1102 - 1447 kP a 1047 - 1447 kP a 1047 - 1447 kPa 0- 34 kP a
( 83- 93 p s i ) ( 160- 2 10 psi ) ( 152 - 2 10 ps i ) ( 15 2 - 2 10p s i ) ( 0- 5 psi )
R 57 2 - 641 kP a 1337 - 17 50 kP a 0- 34 kP a 0- 34 kP a 0- 34 kP a
( 83- 93 p s i ) ( 2 2 0- 2 80 psi ) ( 0- 5 psi ) (0-5 ps i ) ( 0- 5 psi )
OTHER CONCERN: BAND/CLUTCH APPLICATION CHART 601
G e a r
Ov e r d r i v e
B a n d
Low
Re v e r s e
B a n d
F o r w a r d
C l u t c h
Di r e c t
C l u t c h
I n t e r i m
F r i c t i o n
C l u t c h
Re v e r s e
C l u t c h
I n t e r i m
On e - Wa y
C l u t c h
P l a n e t a r y
On e - Wa y
C l u t c h
1s t G e a r Ma n u a l L o w A p p l i e d A p p l i e d Ho l d i n g
2 n d G e a r Ma n u a l L o w A p p l i e d A p p l i e d A p p l i e d Ho l d i n g
1s t G e a r D( OVE RDRI VE ) o r
D( 3)
A p p l i e d Ho l d i n g
2 n d G e a r D ( OVE RDRI VE ) o r
D( 3)
A p p l i e d A p p l i e d Ho l d i n g
3 r d G e a r D ( OVE RDRI VE ) o r
D( 3)
A p p l i e d A p p l i e d A p p l i e d
4 t h G e a r D ( OVE RDRI VE ) A p p l i e d A p p l i e d A p p l i e d
Re v e r s e (R) A p p l i e d Appl i e d
OTHER CONCERN: SOLENOID APPLICATION CHART
701
S o l e n o i d s
T r a n s mi s s i o n
Rang Selector
L e v e r Position
P CM
C o m m a n d e d
G e a r SS-1 SS- 2 T C C

1 ON OFF HD

2 OFF OFF EC

3 OFF ON EC

4 ON ON EC

w / O D OFF
1 1 ON OFF HD
2 2 OFF OFF EC
3 3 OFF ON EC
Ma n u a l 2 2 OFF OFF ' EC
Ma n u a l 1 1 ON OFF '
a
1 2 OFF OFF EC
t r a n s mi s s i o n wi l l d o wn s h i f t f r o m t h e h i gh e r g e a r unt i l t h e
v e h i c l e s p e e d d r o p s b e l o w t h i s c a l i b r a t e d s p e e d .
EC = El ect roni cal l y Cont rol l ed
HD = Hydraul i cal l y Di sabl ed
On-Board Di agnosti c Quick Tests
The Qui ck Tests are in the Powertrai n
Cont rol / Emi ssi ons Di agnosi s Manual
1 9
. These t est s
can be used t o di agnose the powertrai n control
modul e ( PCM) ( 12A650) , sensors and act uat ors of the
4R70W transmi ssi on.
The following is a guide for using the On-Board
Di agnosti c (OBD) Qui ck Tests and the Rotunda New
Generati on Star Tester (NGS) 007- 00500, wi t h some
speci al consi derati ons to remember: '
NOTE: For detai l ed instructions and other di agnosti c
met hods using the NGS, refer t o the Powertrai n
1 9
or NGS
i nstructi on guide.
NOTE: If using a generi c scan t ool , refer t o t he
Powert rai n Cont rol / Emi ssi ons Di agnosi s Manual
1 9
for
i nstructi ons on performi ng OBD procedures.
Quick Test 1. 0
Perf orm the Visual Check and Vehicle Preparati on
procedures as outlined in the Powertrai n
1 9
.
Inspect the fol l owi ng:
Air cleaner and inlet ducti ng.
All engine vacuum hoses for damage: l eaks, cr acks,
bl ockage, proper routi ng, et c.
PCM syst em wi ri ng harnesses for proper
connecti ons, bent or broken pins, corrosi on, l oose
wi res, proper routi ng, et c.
Powertrai n Control Module, sensors and act uat ors
f or physi cal damage.
Engine cool ant for proper level.
Transmission fluid for proper level and condi ti on.
Any NON-factory installed items wi red into the
transmi ssi on or PCM harnesses.
NOTE: Perform all necessary servicing before
continuing wi t h Quick Tests.
Quick Test 2 . 0
007- 00500 or equivalent to dat a link connector (DLC).
The following are procedures t o run OBDII procedures.
Vehicle P r e p a r a t i o n a n d N e w Generation Star
T e s t e r P r e p a r a t i o n
Prepare the vehicle as fol l ows:
Transmission range sel ector lever in PARK.
-"Êngl pato operati ng temperature.
Appl y parki ng brake.
Bl ock wheel s.
Turn OFF all el ectri cal loads including A / C and
defroster. (If A/ C is ON, DTC P1460 will set . )
Prepare the NGS as fol l ows:
LCD SCREEN
PROGRAM CARD
(INSERT INTO BACK OF
CONTROL UNIT)
VEHICLE INTERFACE
MODULE
CONTROL UNIT
POWER CABLE CONNECTOR
D12116-A
Turn ignition swi t ch ( 11572) to the OFF posi ti on.
Verify that t he proper PROGRAM card is i nserted in
the NGS.
Connect J1962 / 1 6 way DCL cabl e adapter t o the
NGS.
Connect NGS DCL cabl e adapter securel y into the
vehi cl e' s dat a link connector.
07- 01- 57 T r a n s mi s s i o n ,
Connect t he NGS powe r suppl y cabl e t o t he vehi cl e
bat t ery power suppl y through ci gar lighter or at t he
battery wi th alligator clip adapter.
Turn t he ignition swi t ch t o t he RUN posi ti on, or st art
vehicle if necessary.
. The NGS is now ready t o communi cate wi th t he
PCM.
NOTE: Do not repl ace parts based on a code, perf orm
Pinpoint Tests fi rst.
Qu i c k T e s t 3. 0 Ke y On , Engi ne Of f ( KOEO)
Some speci al consi derati ons for Key On, Engine Off
Qui ck Test include the fol l owi ng:
The KOEO test provi des
4
' har d" Di agnosti c Trouble
Codes (DTCs) present at the ti me of testi ng.
Al ways servi ce the " h a r d " DTCs fi rst.
P e r f o r mi n g KOEO Qui c k - Tes t
Perform visual inspection and vehi cl e preparati on as
requi red.
Sel ect "Vehi cl e and Engine Sel ect i on" menu.
Sel ect year, engine, model wi t h the appropri ate
qualifier if needed, for exampl e, transmi ssi on or 49
st at e/ Cal .
Sel ect "Di agnost i c Dat a Li nk" menu.
Sel ect "Di agnost i c Test Mode" menu.
Sel ect " KOEO On-Demand Sel f -Test ".
Fol l ow operati ng i nstructi ons f rom the NGS menu
screen.
Record all DTCs di spl ayed.
Servi ce NON-transmi ssi on DTCs fi rst as t hey can
di rectl y affect t he operati on of t he transmi ssi on.
Road test and repeat Qui ck Test t o verify the
servi ce.
Qu i c k T e s t 4. 0 Co n t i n u o u s Me mo r y DT Cs
Continuous DTCs are concerns whi ch were det ect ed
during normal vehi cl e operat i on. These codes are
retai ned for 40 warm-up cycl es.
Some speci al consi derati ons for continuous testi ng
include the fol l owi ng:
The cause of some conti nuous DTCs may have
been eliminated if KOEO and / or KOER DTCs wer e
servi ced. Al ways re-test and servi ce any DTCs that
still remain.
If DTCs are present, go t o the On-Board Di agnosti c
Trouble Code Descri pti on Chart for servi ce
information. Erase DTC, perform the Transmission
Drive Cycl e and repeat all Qui ck Test procedures
after compl eti ng servi ce on t he DTCs.
If the continuous test passes ( P1111) and a concern
is still present, refer t o t he Di agnosi s by Sympt om
routines, OASI S and TSBs for concern di agnosi s.
P e r f o r m i n g C o n t i n u o u s DT C T e s t s
Sel ect year, engine, model wi th t he appropri at e
st at e/ Cal .
Sel ect "Ret ri eve Continuous Codes" menu.
Fol l ow operati ng instructions f rom t he NGS menu
screen.
Perform Transmi ssi on Dri ve Cycl e Test.
Rerun Continuous DTC Test, if DTCs have ret urned,
and servi ce as requi red. Road t est and rerun ail
. DTC test procedures.
Qu i c k T e s t 5. 0 K e y On E n g i n e Ru n n i n g ( KOE R)
The Engine Running Quick-Test provi des " h a r d " DTCs
only.
Some speci al consi derati ons for KOER Qui ck-Test
include the fol l owi ng:
Fol l ow the menu screen instructions as they appear.
If a DTC appears after the KOER test, a malfunction
is present. Refer to the On-Board Di agnosti c
Trouble Code Descri pti on Chart for servi ce
information.
P e r f o r mi n g KOE R S e l f - T e s t
Perform visual inspection and vehi cl e preparati on as
requi red.
Sel ect year, engine, model wi th the appropri at e
st at e/ Cal .
S'elect "Di agnost i c Dat a Li nk" menu.
Select " KOER On-Demand Sel f-Test".
Follow operati ng instructions f rom the NGS menu
screen (exampl e: turn key on, et c. ) and perf orm
Brake On/ Of f and cycl e the Transmission Control
Swi tch (TCS) on and off, if equi pped.
Servi ce all NON-transmission DTCs first as t hey can
di rectl y affect the operati on of t he transmi ssi on.
Road test and repeat Qui ck Test t o verify servi ce.
S p e c i a l NGS T e s t Mo d e s
Output State Diagnostic t est modes.
PCM Reset Mode (Clearing DTCs)
Ou t p u t S t a t e Di a g n o s t i c T e s t Mo d e
The Output State Di agnosti c Test Mode (DTM) ai ds in
servicing output act uat ors associ at ed wi th t he OBDII
syst em. It al l ows the techni ci an t o energize and
de-energize most of the syst em output act uat ors on
command.
07 - 01- 58 Tr ansmi ssi on, A u t o ma t i c 4 R 7 0 W 07 - 01- 58
P e r f o r mi n g t he Out put St at e Di agnost i c Test
Mo d e ( DTM) :
NOTE: You must enter DTM wi t h ignition swi t ch in RUN
and the engine off.
Perform visual inspection and vehicle preparati on as
requi red.
Sel ect year, engine, model wi th the appropri ate
st at e/ Cal .
Enter " Act i ve Test s" .
Enter "Out put Cont r ol " .
Fol l ow operati ng instructions f rom t he NGS menu
screen.
PCM Reset Mo d e ( Cl e a r i n g DT Cs )
The PCM Reset Mode provi des a means for the NGS
t o command t he PCM t o cl ear all DTCs. When
resetti ng the PCM, a DTC P1000 will be set in the
PCM until all OBDII Syst em or components have been
moni tored during OBDII Drive Cycl e.
A PCM reset:
Cl ears the DTCs.
Cl ears the Freeze Frame Dat a.
Cl ears the Oxygen Sensor Test Dat a.
Resets the status of the OBDII Syst em Moni tors.
Sets the DTC P1000.
Pe r f o r mi n g t h e P CM Re s e t
Perform visual inspection and vehicle preparati on as
required.
e Sel ect year, engine, model wi th the appropri at e
st at e/ Cal .
Sel ect "Generi c OBDII Funct i ons" menu.
Sel ect "Cl eari ng ALL Codes" .
Fol l ow operati ng instructions f rom the NGS menu
screen.
m Perform OBDII Drive Cycl eCl ear DTC P1000.
C l e a r i n g DT C P 1 0 0 0 P r o c e d u r e s
Re a d i n e s s f o r I nspect i on/ Mai nt enance T e s t i n g
In some localities it may become a legal requirement t o
pass an Inspection / Mai ntenance (I / M) test of the
OBDII Syst em. If t he vehi cl e' s OBDII syst em or its
bat t ery has j ust been servi ced, the PCM syst em is
reset t o a " not ready for I / M t est i ng" condi ti on. To
prepare the vehi cl e for this test and to cl ear the DTC
P1000, the OBDII Drive Cycl e must be perf ormed.
OBDI I Dr i v e C y c l e
The fol l owi ng st eps MUST BE RUN IN THE ORDER
SHOWN. If st eps 2, 3 or 4 are i nterrupted, repeat the
st ep before proceedi ng. Any safe driving mode is
accept abl e between st eps.
Al ways dri ve vehicle in a safe manner accordi ng t o
traffi c condi ti ons and obey all traffi c l aws.
1. Start engine and dri ve vehicle in typi cal ci ty st op
and go traffi c for at l east 10 minutes after if has
reached normal operati ng temperature.
2. Idle vehi cl e for at l east 45 seconds, then
accel erat e at part throttl e t o near 72 k m/ h ( 45
mph).
3. Cruise and maintain a sel ect speed in t he range of
48 t o 64 k m/ h ( 30 t o 40 mph) on a level road wi th
throttl e held st eady for at least one minute.
4. Cruise and maintain a sel ect speed in the range of
64 t o 105 k m/ h ( 40 t o 65 mph) on a level road
wi t h throttl e held st eady for at least one minute
and 20 seconds.
5. OBDII Dri ve Cycl e has been compl et ed.
Ot h e r NGS T e s t i n g Fe a t u r e s
For further information on other di agnosti c testi ng
features using the NGS or generic scan t ool , refer t o
the Powertrai n Cont rol / Emi ssi ons Di agnosi s
Manual
2 0
.
Other di agnosti c methods include the fol l owi ng:
Parameter Identification (PID) Access Mode, used
t o monitor sensors and act uat ors.
Freeze Frame Dat a Access Mode, used t o vi ew
emission rel ated dat a values f rom speci fi c PIDs.
Oxygen Sensor Monitor Mode, used t o monitor the
Heated Oxygen ( H02S) sensor.
T r a n s m i s s i o n Dr i v e C y c l e T e s t
After performi ng the Qui ck Test, use the following
Transmission Dri ve Cycl e Test for checki ng
transmi ssi on continuous codes:
NOTE: The Transmission Dri ve Cycl e Test must be
fol l owed exact l y. A malfunction must occur four ti mes
consecuti vel y for DTCs 617, 618, 619t o be set, and
five ti mes consecuti vel y for continuous DTC 628.
1. Record and then erase Qui ck Test DTCs.
2. Warm engine to normal operati ng temperature.
3. Make sure transmi ssi on fluid level is correct .
4. Wi th transmission In OVERDRIVE, moderatel y
accel erate f rom st op t o 80 Km / h ( 50 mph). This
al l ows the transmission t o shift into fourth gear.
Hold speed and throttl e open st eady for a
minimum of 15 seconds.
2 0 P u r c h a s e d s e p a r a t e l y , r e f e r t o t h e e n d of t h i s Se c t i o n f o r v e h i c l e a p p l i c a t i o n s .
07- 01- 59 Tr ansmi ssi on, A u t o ma t i c 4 R 7 0 W 07- 01- 5 9
DIAGNOSIS AND TESTI NG (Cont i nued)
5. Wi t h transmi ssi on in OVERDRIVE, press TCS
(TCIL shoul d illuminate) and moderatel y
accel erat e f rom st op t o 64 Km / h ( 40 mph). This
al l ows transmi ssi on to shift into thi rd gear. Hol d
speed and throttl e open st eady for a minimum of
15 seconds ( 30 seconds above 1220 met ers
( 4000 ft)).
6. Press TCS (TCIL should turn off) and accel erat e
f rom 64 Km/ h ( 40 mph) t o 80 Km/ h ( 50 mph).
This al l ows transmi ssi on to shift into fourth gear.
Hold speed and throttl e posi ti on st eady for a
A f t e r O n - B o a r d Di a g n o s t i c Be gi n wi t h n o n - t r a n s mi s s i o n r e l a t e d DTCs , t h e n
After the on-board di agnosti c procedures are
s e r v i c e a n y t r a n s mi s s i o n r e l a t e d DTCs.
compl et ed, servi ce all DTCs.
7. Wi t h transmi ssi on in fourth gear and maintaining
st eady speed and throttl e openi ng, lightly appl y
and rel ease br ake (to operat e st opl amps). Then
hold speed and throttl e st eady for an addi ti onal
five seconds minimum.
8. Brake t o a st op and remain st opped for a
9. Repeat St eps 4 through 8 at least fi ve ti mes.
10. Perform Qui ck Test and record continuous DTCs.
On-Board Di agnost i c Trouble Code
Descri pt i on Chart
Refer t o the On-Board Di agnosti c Trouble Code
Descri pti on Chart for information on Condition and
Sympt oms. Thi s chart will be helpful in referring t o the
proper manual(s) and t o ai d in di agnosi ng internal
transmi ssi on concerns and external non-transmission
inputs. The Pinpoint Test s are used in diagnosing
el ectri cal concerns of t he transmi ssi on. Make sure
that the vehi cl e wi ri ng harness and the powertrai n
control module ( PCM) ( 12A650) are di agnosed as
wel l . The Powertrai n Cont rol / Emi ssi ons Di agnosi s
Manual
2 1
will aid in di agnosi ng non-transmission
el ectroni c component s.
ON-BOARD DIAGNOSTIC TROUBLE CODE DESCRIPTION CHART
"Ma y al so be ge ne r a t e d by some ot her non-el ect r i c t r ansmi ssi on har dwar e sy st e m.
' Out put ci r cui t c he c k, gener at ed onl y by el ect r i cal sy mpt o ms.
Four Di gi t
DTC Compone nt Descr i pt i on Condi t i on Sy mpt om Act i on
P 1111 SYST E M P a s s No ma l f u n c t i o n d e t e c t e d .
Ma l f u n c t i o n not d e t e c t e d by
P CM.
P C / E D
P 0112 IAT
IAT i n d i c a t e s 12 5C
( 2 5 4 F) ( gr o u n d e d )
Vo l t a ge d r o p a c r o s s IAT
e x c e e d s s c a l e s e t f o r
t e mp e r a t u r e 12 5C ( 2 54F) .
P 0113 IAT
IAT i n d i c a t e s - 4 0 C
( - 40F) ( o p e n c i r c u i t )
Vo l t a ge d r o p a c r o s s IAT
e x c e e d s s c a l e se t f o r
t e mp e r a t u r e - 40 C ( - 40F) .
I n c o r r e c t EPC p r e s s u r e . Ei t he r
hi gh o r l o w wh i c h wi l l r e sul t in
h a r s h or so f t s h i f t s .
P C / E D
P 0114 IAT
IAT o ut of o n - b o a r d
d i a g n o s t i c r a n ge
IAT t e mp e r a t u r e hi ghe r or l o we r
t h a n e x p e c t e d d ur i n g KOE O a n d
KOER.
Re r un o n - b o a r d d i a g n o s t i c at
n o r ma l o p e r a t i n g t e mp e r a t u r e .
P C / E D
P 1116 IAT
ECT o ut o f o n - b o a r d
d i a g n o s t i c r a n ge
ECT t e mp e r a t u r e h i gh e r or l o we r
t h a n e x p e c t e d d ur i n g KOE O a n d
KOER.
Re r un o n - b o a r d d i a g n o s t i c a t
n o r ma l o p e r a t i n g t e mp e r a t u r e .
P C / E D
P 0117 ECT
ECT i n d i c a t e s 1 2 5 C
( 2 54 F)
Vo l t a ge d r o p a c r o s s ECT
t e mp e r a t u r e 1 2 5 C ( 2 5 4 F )
( gr o u n d e d ) .
P C / E D
NOTE: The vehi cl e wiring harness, powertrai n control
module and non-transmission sensors may affect
transmi ssi on operati ons. Servi ce these concerns fi rst.
2 1 P u r c h a s e d s e p a r a t e l y , r e f e r t o t h e e n d o f t h i s Se c t i o n f o r v e h i c l e a p p l i c a t i o n s .
07 - 01- 60
Transmi ssi on, Au t o ma t i c 4R7 0W 07 - 01- 60
ON-BOARD DIAGNOSTIC TROUBLE CODE DESCRIPTION CHART (Cont'd)
" May also b g e n e r a t e d b y s o m e o t h e r non-el ect r i c t r a n s m i s s i o n h a r d w a r e s y s t e m .
' Out put c i r c u i t c h e c k , g e n e r a t e d o n l y b y e l e c t r i c a l s y m p t o m s .
Fo u r Di g i t
DT C Component Descr i pt i on Condi t i on Sy mpt om Ac t i on
P 0118 ECT
ECT i n d i c a t e s - 40C
(-40 F)
Vo l t a ge d r o p a c r o s s ECT
t e mp e r a t u r e - 40 C ( - 40F)
( o p e n c i r c u i t ) .
To r que c o n v e r t e r c l u t c h wi l l
a l wa y s be of f , r e s ul t i n g i n
r e d u c e d f ue l e c o n o my .
P C / E D
P 112 4 TP
TP v o l t a g e h i g h / l o w
f o r o n - b o a r d
d i a g n o s t i c .
TP w a s not i n t h e c o r r e c t
p o s i t i o n f o r o n - b o a r d d i a gn o s t i c .
Re r un a t a p p r o p r i a t e t h r o t t l e
p o s i t i o n pe r a p p l i c a t i o n .
P C / E D
P0122,
P0123,
P 112 0,
P 1 1 2 1 ,
P 112 5
TP TP c o n c e r n
P CM h a s d e t e c t e d a n e r r o r . Thi s
e r r o r ma y c a u s e a t r a n s mi s s i o n
c o n c e r n .
Ha r s h e n g a g e me n t s , f i r m shi f t
f e e l , a b n o r ma l shi f t s c h e d u l e ,
t o r q u e c o n v e r t e r c l u t c h d o e s not
e n ga ge . To r que c o n v e r t e r c l u t c h
c y c l i n g .
P C / E D
P0102,
P 0103,
P 1100,
P 1101
MA F MA F c o n c e r n s
MA F s y s t e m h a s a ma l f u n c t i o n
wh i c h ma y c a u s e a t r a n s mi s s i o n
c o n c e r n .
H i g h / l o w EPC p r e s s u r e ,
i n c o r r e c t shi f t s c h e d u l e .
I n c o r r e c t t o r q u e c o n v e r t e r
c l u t c h e n ga ge me n t s c h e d u l i n g.
S y mp t o ms si mi l a r t o a TP f a i l ur e .
P C / E D
P 0300- P 0308
P 032 0,
P 0340
P 1351- P 1364
I CM _ I CM c o n c e r n s
I CM s y s t e m h a s a ma l f u n c t i o n
wh i c h ma y c a u s e a t r a n s mi s s i o n
c o n c e r n .
Ha r s h e n g a g e me n t s a n d s h i f t s ,
l a t e WOT s h i f t s , no t o r q u e *
c o n v e r t e r c l u t c h e n ga ge me n t .
P C / E D
P 0500 VSS
I n suf f i c i e n t i nput f r o m
VSS.
P CM d e t e c t e d a l o s s of v e h i c l e
s p e e d s i gn a l d ur i n g o p e r a t i o n .
To r que c o n v e r t e r c l u t c h
e n g a g e s , shi f t
e n g a g e me n t / d i s e n g a g e me n t
( hun t i n g) on g r a d e s .
P C / E D
P 17 03 BOO
Br a ke not a c t u a t e d
d ur i n g o n - b o a r d
d i a g n o s t i c .
Br a ke not c y c l e d d ur i n g KOER.
Fa i l e d ON o r not
c o n n e c t e d t o r q u e c o n v e r t e r
c l u t c h wi l l not e n ga ge a t l e s s
t ha n 1/ 3 t h r o t t l e .
P C / E D
P 17 03 BOO
BOO s w i t c h c i r c ui t
f a i l e d .
Br a ke O N / O F F c i r c ui t f a i l ur e .
Fa i l e d OFF or not
c o n n e c t e d t o r q u e c o n v e r t e r
c l u t c h wi l l not d i s e n g a g e wh e n
b r a ke i s a p p l i e d .
P C / E D
P 1460 A / C
A / C c l u t c h c y c l i n g
p r e s s u r e s wi t c h e r r o r
A / C or De f r o s t ON c o n d i t i o n
ma y r e sul t f r o m A / C c l u t c h
b e i n g ON d ur i n g o n - b o a r d
d i a gn o s t i c .
DTC s e t d ur i n g o n - b o a r d
d i a g n o s t i c r e r u n wi t h A / C
OFF.
Fa i l e d O N E P C p r e s s u r e
s l i ght l y l o w wi t h A / C OFF.
P C / E D
P 0 7 8 1 * *
SS1 or
i n t e r n a l p a r t s
1-2 shi f t e r r o r
En gi n e r pm d r o p not d e t e c t e d
wh e n 1-2 shi f t wa s c o mma n d e d
by P CM.
I mpr o pe r ge a r s e l e c t i o n
d e p e n d i n g on f a i l ur e o r mo d e
a n d ma n ua l l e v e r p o s i t i o n . Shi f t
e r r o r s ma y a l s o be d ue t o o t h e r
i n t e r n a l t r a n s mi s s i o n c o n c e r n s
( s t u c k v a l v e s , d a ma g e d f r i c t i o n
ma t e r i a l ) .
Re f e r t o
So l e n o i d
On / Of f
Ch a r t s .
Re f e r t o
Pi n po i n t
Te st A.
P 0 7 8 2 * *
SS1 . SS2 or
i n t e r n a l p a r t s
2- 3 shi f t e r r o r
by P CM.
( s t u c k v a l v e s , d a ma g e d f r i c t i o n
ma t e r i a l ) .
Re f e r t o
So l e n o i d
On / Of f
Ch a r t s .
Re f e r t o
Pi n po i n t
Te st A.
P 0 7 8 3 * *
S S 1 , SS2 or
i n f e r n a l p a r t s
3- 4 shi f t e r r o r
by P CM.
( st uck v a l v e s , d a ma g e d f r i c t i o n
ma t e r i a l ) .
Re f e r t o
So l e n o i d
O n / O f f
Ch a r t s .
Re f e r t o
Pi n po i n t
Te st A.
07- 01- 61 Tr ansmi ssi on, Au t o ma t i c 4 R7 0 W 07- 01- 61
ON-BOARD DIAGNOSTIC TROUBLE CODE DESCRIPTION CHART (Cont ' d)
"May a l s o b generated by some other non-electric transmission hardware system.
'Output circuit check, gener a ted onl y by electrical symptoms.
Fo u r Digit
DTC Component Description Condition Symptom Action
P0 7 5 0 * SS1
SS1 sol enoi d ci r cui t
f ai l ur e
SS1 ci r cui t f ai l ed t o pr ovi de
vol t age dr op a c r o s s sol enoi d.
Ci r cui t open or s hor t ed or PCM
dr i ver f ai l ur e dur i ng on- boar d
di agnost i c.
I mpr oper gear sel ect i on
dependi ng on condi t i on mode
and manual l ever posi t i on. See
Sol enoi d On / Of f char t .
Ref er t o
Pi npoi nt
Test A.
P0 7 5 5 * SS2
SS2 sol enoi d ci r cui t
f ai l ur e
SS2 ci r cui t f ai l s t o pr ovi de
vol t age dr op a c r o s s sol enoi d.
Ci r cui t open or s hor t ed or PCM
dr i ver f ai l ur e dur i ng on- boar d
di agnost i c.
I mpr oper gear sel ect i on
dependi ng on condi t i on mode
and manual l ever posi t i on. See
Sol enoi d On / Of f char t .
Ref er t o
Pi npoi nt
Test A.
TCI L TCI L ci r cui t f ai l ur e TCI L ci r cui t open or s hor t ed.
Fai l ed ONOv e r d r i v e cancel
mode on. NO f l ashi ng TCI L f or
EPC f ai l ur e or sensor .
Fai l ed OFFOv e r d r i v e cancel
mode never i ndi cat ed. NO
f l ashi ng TCI L f or EPC sensor
f ai l ur e.
PC/ ED
P1 7 4 7 * * EPC
EPC sol enoi d ci r cui t
f ai l ur e, shor t ed
ci r cui t or out put
dri ver.
Vol t age t hr ough EPC sol enoi d i s
c h e c k e d . An er r or wi l l be not ed if
t ol er ance i s e x c e e d e d .
Shor t Ci r c ui t Caus es mi ni mum
EPC pr essur e ( mi ni mum
c apac i t y ) and l i mi t s engi ne
t or que ( al t er nat e f i r m) .
Ref er t o
Pi npoi nt
Te s t E.
P1 7 4 6 * * EPC
Shor t ed PCM out put
dri ver.
Open Ci r c ui t Caus es maxi mum
EPC pr essur e, har sh
engagement s and shi f t s.
Ref er t o
Pi npoi nt
Test E.
P 0 7 4 1 * * Tr ansmi ssi on
Tr ansmi ssi on
sl i ppage d e t e c t e d .
The PCM pi c k ed up an
ex c es s i v e amount of sl i ppage
dur i ng nor mal vehi cl e oper at i on.
Tr ansmi ssi on s l i ppage/ er r at i c
or no t or que conver t er cl ut ch
oper at i on. Fl ash TCI L.
Ref er t o
Di agnosi s
by
Sy mpt om.
P1780 TCS
TCS not changi ng
s t at es .
TCS not c y c l ed dur i ng sel f - t est .
TCS ci r cui t open or s hor t ed.
Rer un on- boar d di agnost i c and
cycl e swi t ch. No OD cancel
when swi t ch i s c y c l ed.
PC/ ED
P1709 TR Sensor
TR sensor out of
r ange.
I ndi cat ed v ol t age dr op ac r os s
TR sensor e x c e e d s l i mi t s
est abl i shed f or eac h posi t i on.
Har sh engagement s, f i r m shi f t
f eel .
No 3 / 4 shi f t .
Ref er t o
Pi npoi nt
Test D.
P1711 TFT
TFT out of on- boar d
di agnost i c r ange.
Tr ansmi ssi on not at oper at i ng
t emper at ur e dur i ng on- boar d
di agnost i c.
War m vehi cl e t o nor mal
oper at i ng t emper at ur e.
Ref er t o
Pi npoi nt
Test B.
P0713 TFT
- 4 0 C( - 4 0 F )
i ndi cat ed TFT sensor
ci r cui t open.
Vol t age dr op ac r os s TFT sensor
e x c e e d s scal e set f or
t emper at ur e - 4 0 C ( - 40F)
Fi r m shi f t f eel .
Ref er t o
Pi npoi nt
Test B.
P 07 12 TFT
1 5 7 C( 3 1 5 F )
i ndi cat ed TFT sensor
ci r cui t gr ounded.
Vol t age dr op ac r os s TFT sensor
e x c e e d s s c al e set f or
t emper at ur e of 1 5 7 C( 3 1 5 F )
Fi r m shi f t f eel .
Ref er t o
Pi npoi nt
Test B.
P0720 OSS
I nsuf f i ci ent i nput f r om
out put shaf t s p e e d
sensor .
PCM det ec t ed a l oss of OSS
si gnal dur i ng oper at i on.
Har sh shi f t s, abnor mal shi f t
schedul e, no t or que conver t er
cl ut ch act i vat i on.
Ref er t o
Pi npoi nt
Test F.
P0743* TCC
TCC sol enoi d ci r cui t
f ai l ur e dur i ng
on- boar d di agnost i c.
TCC sol enoi d ci r cui t f ai l s t o
pr ovi de vol t age dr op acr oss
sol enoi d. Ci r cui t open or shor t ed
or PCM dr i ve f ai l ur e duri ng
on- boar d di agnost i c.
Shor t ci r cui t Engi ne st al l s in
second ( OD, 2 r ange) at l ow i dl e
s peeds wi t h br ake appl i ed.
Open ci r cui t Tor que conver t er
cl ut ch never engages.
Ref er t o
Pi npoi nt
Test C.
P1705 TR Sensor
TR sensor not
i ndi cat i ng PARK
dur i ng KOEO.
On- boar d di agnost i c not run in
PARK.
Rer un or i - boar d di agnost i c in
PARK
Ref er t o
Pi npoi nt
Test A.
P 1 7 4 1 * * TCC
Ex c es s i v e t or que
conver t er cl ut ch
engagement er r or .
Excessi ve var i at i ons in sl i p
( engi ne s peed sur ge) ac r os s t he
t or que conver t er cl ut ch.
Engi ne RPM osci l l at i on i s
pr esent in 3r d gear .
Ref er t o
Pi npoi nt
Test C.
( Cont i nued)
ON-BOARD DIAGNOSTIC TROUBLE CODE DESCRIPTION CHART (Cont 'd)
" Ma y a l s o b e g e n e r a t e d b y s o m e o t h e r n o n - e l e c t r i c t r a n s m i s s i o n h a r d w a r e system.
"Output c i r c u i t c h e c k , g e n e r a t e d o n l y by e l e c t r i c a l s y m p t o m s .
Fo u r Di g i t
DT C C o m p o n e n t De s c r i p t i o n C o n d i t i o n S y m p t o m A c t i o n
P 17 83 TFT
Tr a n s mi s s i o n
o v e r t e mp c o n d i t i o n
i n d i c a t e d .
Tr a n s mi s s i o n f l ui d t e mp e r a t u r e
e x c e e d e d 12 7 C ( 2 7 0 F) .
I n c r e a s e in EPC p r e s s u r e .
Re f e r t o
Pi n po i n t
Te st B.
P 07 07 TR Se n s o r
TR s e n s o r c i r c ui t
b e l o w mi n i mum
v o l t a ge .
TR s e n s o r , c i r c ui t o r P CM
s h o r t e d o r g r o u n d e d .
Re f e r t o
Pi n po i n t
Te st D.
P 07 08 TR Se n s o r
TR s e n s o r c i r c ui t
a b o v e ma x i mu m
v o l t a ge .
TR s e n s o r , c i r c ui t o r P CM
i n d i c a t e s o p e n .
Re f e r t o
Pi n po i n t
Te st D.
P 07 51 SS1
Shi f t s o l e n o i d # 1
f un c t i o n a l f a i l ur e .
Me c h a n i c a l o r h y d r a u l i c f a i l ur e
of t h e shi f t s o l e n o i d .
I mp r o p e r ge a r s e l e c t i o n
d e p e n d i n g on f a i l ur e mo d e a n d
ma n ua l l e v e r p o s i t i o n .
Re f e r t o
So l e n o i d
On / Of f
Cha r t .
Re f e r t o
Pi n po i n t
Te st A.
P 07 56 S S 2
f un c t i o n a l f a i l ur e .
o f t h e shi f t s o l e n o i d .
I mp r o p e r ge a r s e l e c t i o n
Re f e r t o
So l e n o i d
On / Of f
Cha r t .
Re f e r t o
Pi n po i n t
Te st A.
P 17 42 T CC
TCC s o l e n o i d f a i l e d
ON ( Ca l i f , o n l y ) .
T CC s o l e n o i d h a s f a i l e d ON by
e l e c t r i c , me c h a n i c a l o r h y d r a u l i c
c o n c e r n .
Ha r s h s h i f t s .
Re f e r t o
Pi n po i n t
Te st C.
P 17 43 TCC
TCC s o l e n o i d f a i l e d
ON.
T CC s o l e n o i d h a s f a i l e d ON by
e l e c t r i c , me c h a n i c a l o r h y d r a u l i c
c o n c e r n .
Ha r s h s h i f t s .
Re f e r t o
Pi n po i n t
Te st C.
P 17 44
( Ca l i f o r n i a
o n l y )
s l i p p a g e d e t e c t e d .
T h e P CM p i c k e d up an
e x c e s s i v e a mo un t o f s l i p p a g e
d ur i n g n o r ma l v e h i c l e o p e r a t i o n .
Tr a n s mi s s i o n s l i p p a g e / e r r a t i c
or no t o r q u e c o n v e r t e r c l u t c h
o p e r a t i o n .
Re f e r t o
Di a gn o s i s
by
S y mp t o m.
P 1 7 5 1 * * SS1
f u n c t i o n a l f a i l ur e
( Ca l i f o r n i a o n l y )
Re f e r t o
So l e n o i d
On / Of f
Cha r t .
Re f e r t o
Pi n po i n t
Te st A.
P 1 7 5 6 * * SS2
f u n c t i o n a l f a i l ur e
( Ca l i f o r n i a o n l y )
Re f e r t o
So l e n o i d
On / Of f
Cha r t .
Re f e r t o
Pi n po i n t
Te st A.
PC/ EDPo we r t r a i n Cont r ol / Emi ssi ons Di agnosi s Manual
Rotunda Transmission Tester
Use Rot unda Transmi ssi on Test er 007 - 0085C or
equi val ent t o di agnose el ect roni cal l y cont rol l ed
t r ansmi ssi ons. The f ol l owi ng i nst ruct i ons outli ne t he
set -up and use of t hi s t est er in t he pi npoi nt t e st s f or t he
4R70W.
NOTE: Use t he AODE t ransmi ssi on t est er overl ay t o
di agnose t he 4R7 0W t ransmi ssi on.
T e s t e r J a c k s
1. VPWR Pi n J a c k s ( r e d ) : VPWR t est poi nt s f or
sol enoi d ci rcui t s.
2 2 P u r c h a s e d s e p a r a t e l y , r e f e r t o t h e e n d of t h i s Se c t i o n f o r v e h i c l e a p p l i c a t i o n s
2. So l e n o i d ( MCCC, EPC) Si gn a l Li n e Pi n J a c k s
( b l a c k) : Si gnal line t e st poi nt s f or sol enoi d
ci r cui t s.
NOTE: The t est er overl ay is l abel ed f or t he MCCC
sol enoi d. Thi s is used t o t est t he t or que conver t er
cl ut ch (TCC) sol enoi d.
3. B A T + (red) a n d BAT- ( bl a c k) Pi n J a c k s :
Ba t t e r y ref erence poi nt s when measuri ng ci rcui t s
f or shor t s.
4. TOT Pi n J a c ks : Test poi nt s f or t ransmi ssi on flui d
t emper at ur e sensor (TFT sensor ).
5. OSS Pi n J a c ks : Test poi nt s f or out put speed
shaf t sensor (OSS).
T e s t e r L E Ds a n d C o n t r o l s
1. Ca b l e Co r r e c t l y I n st a l l e d LEDs: When LED is
lit, t he cabl e is i nst al l ed c or r e c t l y .
2. St a t u s LEDs: LED " OFF" whe n not a c t i va t e d by
t est er (sol enoi d not a c t i va t e d, open ci rcui t or
si gnal line shor t t o ground). LED "GREEN" when
act i vat ed by t est er and current d r a w i s c or r e c t .
LED "RED" when act i vat ed by t est er and current
d r a w is e xc e ssi ve (shor t t o Ba t t e r y Posi t i ve
Vol t age ( B+ ) ) . All LEDs light or ange duri ng
Sel f -Test .
3. S o l e n o i d A c t i v a t e Bu t t o n s : Ener gi ze
r e spe c t i ve sol enoi ds duri ng c l i c k t est i ng and
a c t i va t e sel ect ed ci r cui t s duri ng DRI VE mode
t est i ng.
4. B e n c h / Dr i v e S w i t c h : Sel ect s ope r a t i ng mode,
ei t her BENCH or DRIVE.
5. S o l e n o i d S e l e c t / G e a r Se l e c t S w i t c h : Has
t hr e e f unct i ons.
In BENCH MODE: a c t s as shi f t sol enoi d sel ect or
f or cl i ck t est i ng. In DRIVE MODE: a c t s as f o r wa r d
gear sel ect or in pl ace of vehi cl e' s PCM cont rol l ed
shi f t i ng. Hydraul i c sa f e t y mechani sms and
ove r r i de s are built i nto t he t r ansmi ssi on.
In OHMS CHECK: al l ows y ou t o measur e
r esi st ance (ohms).
07 - 01- 64
T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 07 - 01- 64
AODE Overl ay
TRANSMI SSI ON TESTER
LED ON: AODE CABLE CORRECTLY INSTALLED.
o
AODE ]
MCCC
* NOT USED

EPC
O o
VPWR
S T A T |
JS
ACTIVATE
O
SHI FT SOLENOIDS
VPWR

BENCH
I
GREEN | I OFF II OFF |
| GREEN
OFF I
I OFF II GREEN | I GREEN
GEAR SEL ECT
CUCKTEST
SOLENOID SELECT
SS-1 S S - 2 OHMS/
CHECK
'GEAR SELECT
Jt NOT USED

OSS
o o
TOT
o o
E XT P OWE R
o o
BAT-f - BAT
D10502-A
T r a n s mi s s i o n T e s t e r I n s t r u c t i o n s
The Rotunda Transmi ssi on Tester 007- 00085C or
equivalent al l ows a techni ci an t o operat e the el ectri cal
porti on of t he transmi ssi on independent of the vehi cl e
el ectroni cs. Thi s al l ows the techni ci an t o determi ne
transmi ssi on concerns.
T r a n s mi s s i o n T e s t e r Us e
The Transmi ssi on Tester usage is di vi ded in fi ve st eps:
I.
I V.
V.
Preliminary Testing and Di agnosi s
Installing t he Transmission Tester
Stati c Testi ng - Engine OFF
Dynami c Testi ng - Engine Running
Removi ng Transmi ssi on Tester and Clearing
Di agnosti c Trouble Codes
P r e l i mi n a r y T e s t i n g a n d Di a g n o s i s
Before any di agnosti c testi ng is done on vehicle some
preliminary checks must be perf ormed, as outlined
below. Be sure t o wri te down findings, especi al l y any
DTCs found, for future reference.
a. Check transmi ssi on fluid level and condi ti on.
b. Check for add-on items (phones, comput ers, CB
radi o, et c. ).
c. Visually inspect wiring harness and connectors.
d. Check for vehicle modi fi cati ons.
e. Check shift linkage for proper adj ustment.
f. Verify customer concern:
Upshift, Downshi ft, Coasti ng, Engagement,
Noi se/ Vi brat i on
g. Vehicle must be at normal operati ng temperature.
h. Per f or m vehi cl e on-boar d di agnost i c.
i. Re c or d all DTCs.
j . Ser vi ce all non-t ransmi ssi on c o d e s.
T r a n s mi s s i o n T e s t e r I n s t a l l a t i o n ( Se t - Up
P r o c e d u r e )
Installi ng t he t ransmi ssi on t e st e r at t he t ransmi ssi on
connect or al l ows separ at i on of t he vehi cl e el ect roni cs
f r o m t ransmi ssi on el ect r oni cs. Di sconnect i ng normal
vehi cl e el ect r oni cs wi ll set addi t i onal DTCs and cause
f i rm shi f t s. (Di sconnect i ng t he t ransmi ssi on connect or
def aul t s t ransmi ssi on t o maxi mum line pressure).
NOTE: Duri ng t est er usage addi t i onal DTCs may be
set . Ther ef or e, it i s i mport ant t hat all DTCs ar e er ased
af t er se r vi c e has been made. To veri f y eli mi nati on of
all DTCs rerun On-Board Di agnost i c.
NOTE: The f ol l owi ng manual s shoul d be avai l abl e t o
assi st in di agnosi s of el ect roni cal l y cont rol l ed
t ransmi ssi ons:
Power t r ai n Cont rol / Emi ssi ons Di agnosi s
Ma n ua l .
2 3
Transmi ssi on Test er Manual (pr ovi ded wi t h
t e st e r ).
1. CAUTI ON: Do n o t a t t e mp t t o p r y o f f
c o n n e c t o r s wi t h a s c r e wd r i v e r . Th i s wi l l
d a ma g e t h e c o n n e c t o r a n d c o u l d r e s ul t i n
t r a n s mi s s i o n c o n c e r n s .
Di sconnect vehi cl e wi ri ng harness at
t ransmi ssi on connect or.
2. Turn t e st e r Sol enoi d Sel ect swi t c h t o t he OHMS
CHECK posi t i on.
3. CAUTI ON: Ro u t e a l l c a b l e s a wa y f r o m he a t
s o u r c e t o p r e v e n t d a ma g e t o c a b l e s .
Connect appr opr i at e t est er i nt erf ace cabl e and
over l ay t o t ransmi ssi on and t est er.
4. CAUTI ON: Ro u t e g a u g e l i n e a wa y f r o m he a t
s o u r c e s t o p r e v e n t d a ma g e t o l i n e .
Install a line pr essur e gauge i nto line pr essur e t a p
on t r ansmi ssi on.
5. Plug t ransmi ssi on t e st e r power suppl y i nt o ci gar
l i ght er r ecept acl e. At t hi s t i me, all LEDs shoul d
illuminate f or a shor t per i od and t hen t urn of f . Thi s
i s t he t est er i nternal ci rcui t c he c k.
6. Posi t i on Bench / Dri ve swi t c h t o BENCH mode .
S t a t i c T e s t i n g E n g i n e Of f
St at i c t est i ng pr ocedur es al l ow f or shop t est i ng of t he
t ransmi ssi on in t he vehi cl e or on t he bench.
Compl et i on of t hese t e st s pr ove out t ransmi ssi on
el ect r oni cs.
R e s i s t a n c e / C o n t i n u i t y T e s t s
CAUTI ON: Fo r r e s i s t a n c e c h e c k s , b e s u r e t h e
t e s t e r So l e n o i d Se l e c t s w i t c h i s s e t t o t h e OHMS
CHECK p o s i t i o n o r d a ma g e t o t h e o h mme t e r ma y
r e s u l t .
Ref er t o t he appr opr i at e Pinpoint Test t o be
per f or med ba se d on t he DTCs di spl ay ed.
Usi ng a Di gi t al Vol t -Ohmmet er and t he Transmi ssi on
Test er pe r f or m t he Pi npoi nt Test s as i ndi cat ed
ba se d on t he DTCs whi c h we r e di spl ay ed.
Ser vi ce as i ndi cat ed by t he pi npoi nt t e st s. Al wa y s
r et est and r o a d t e st vehi cl e af t er se r vi c e .
T r a n s mi s s i o n S o l e n o i d s a n d Sensors
Re s i s t a n c e T e s t s
EPC So l e n o i d
Set ohmmet er t o 100-200 o hm range.
Connect negat i ve l ead of ohmmet er t o t he EPC j a c k.
Connect posi t i ve l ead of ohmmet er t o t he VPWR
j a c k.
Recor d r esi st ance.
Ref er t o t he f ol l owi ng c ha r t s f or val ues.
If out of speci f i cat i on, ref er t o Pi npoi nt Test E.
S o l e n o i d s ( S S - 1 , S S - 2 , T C C )
Set ohmmet er t o 100-200 ohm range.
Connect posi t i ve l ead of ohmmet er t o t he
appr opr i at e VPWR j a c k f or t he sol enoi d bei ng
t e st e d.
Connect negat i ve l ead of t he ohmmet er t o t he
appr opr i at e sol enoi d j ack ( SS- 1, SS-2, MCCC) and
r e c or d r esi st ance.
Ref er t o f ol l owi ng c ha r t s f or val ues.
If out of speci f i cat i on, ref er t o Pi npoi nt Test A ( SS- 1,
SS-2); Pi npoi nt Test C (TCC).
SOLENOID R E S I S T A N C E
Solenoid O h m s
SS- 1 2 0- 30
SS- 2 2 0- 30
T CC 1. 0-3. 0
EPC 2 . 48- 5. 66
T r a n s mi s s i o n Fl u i d T e mp e r a t u r e ( TFT) S e n s o r
Set ohmmet er t o 1000 ohm scal e.
Connect ohmmet er posi t i ve l ead t o + TOT j a c k.
Connect ohmmet er negat i ve l ead t o -TOT j a c k.
Recor d resi st ance. Resi st ance wi ll var y wi t h
t emperat ure.
Refer t o t he f ol l owi ng char t .
If out of speci f i cat i on, ref er t o Pi npoi nt Test B.
TRANSMISSION FLUID T E MP E R A T U R E
c F
R e s i s t a n c e
( Oh ms )
" 4 0 - 2 0 "40-"4 967 K- 2 84K
"19-"1 "3-31 2 84K- 100K
0- 2 0 32 - 58 100K- 37 K
2 1- 40 59- 104 37 K- 16K
( Co n t i n ue d )
2 3 P u r c h a s e d s e p a r a t e l y , r e f e r t o t h e e n d of t h i s S e c t i o n f o r v e h i c l e a p p l i c a t i o n s .
1995 To wn Car, Cr o wn Vi c t o r i a , Grand Ma r q u i s Jul y 1994
TRANSMISSION FLUID TEMPERATURE (Cont ' d)
c F
Re s i s t a n c e
( Oh ms )
41- 7 0 105- 158 16K- 5K
7 1- 90 159- 194 5K- 2 . 7 K
91- 110 195- 2 30 2 . 7 K- 1. 5K
111- 130 2 31- 2 66 1. 5K- 0. 8K
131- 150 2 67 - 302 0. 8K- 0. 54K
Ou t p u t S h a f t S p e e d S e n s o r ( OSS)
Set ohmmeter t o 1000 ohm (K) range.
Connect t he positive lead of the ohmmeter t o the
+ OSS.
Connect t he negative lead of the ohmmeter t o the
-OSS.
Record resi stance.
OSS should be 450- 750 ohms.
If out of speci fi cati on, refer t o Pinpoint Test F.
S h o r t t o G r o u n d a n d S o l e n o i d Vo l t a g e T e s t s
NOTE: LED will turn GREEN when solenoid acti vates
and turn OFF when deact i vat ed.
LED will turn RED if an a c t i v a t e d solenoid / harness is
short ed t o B + .
LED will remain OFF if an a c t i v a t e d sol enoi d/ harness
is short ed t o ground or no continuity.
1. Set tester Bench / Dr i ve swi t ch t o BENCH mode.
2. Set vol tmeter t o 20 volt DC range.
3. Connect vol tmeter posi ti ve lead t o the
appropri at e sol enoi d. Connect vol tmeter negati ve
lead t o t he appropri ate sol enoi d.
4. NOTE: TCC solenoid cl i ck may or may not be
audible.
Using a VOM, check for vol tage acr oss each
solenoid by acti vati ng t he solenoid swi t ches.
Press t he appropri ate swi t ch. The LED should
illuminate, the vol tage should change and an
audible cl i ck may be heard. If LED does not
illuminate, a short t o ground condi ti on exi st s.
5. Observe and record val ues.
Dy n a mi c T e s t i n g E n g i n e Ru n n i n g
Dynami c testi ng is t he final st ep in the transmi ssi on
t est er usage. It al l ows the transmi ssi on t o be proven
out el ectroni cal l y and hydraulically.
T r a n s mi s s i o n S o l e n o i d C y c l i n g a n d Dr i v e T e s t
P r e l i mi n a r y Se t Up
1. Set Bench / Dri ve swi t ch t o DRIVE mode.
2. Set Gear Sel ect swi t ch t o fi rst gear posi ti on.
3. Pl ace vehi cl e in PARK.
4. St art engine.
EPC S o l e n o i d
1 . Observe line pressure. Record value.
Line pressure should go t o maxi mum. If not, refer
t o the Di agnosi s by Sympt om Routines for
di agnosti c ti ps or Pinpoint Test E concerni ng EPC
sol enoi d.
2. CAUTI ON: Do n o t a t t e mp t t o h o l d t h e EPC
s w i t c h d e p r e s s e d ( mi n i mu m l i n e pr e s s u r e )
a n d st a l l t h e t r a n s mi s s i o n ( ho l d i n g t h e
v e h i c l e wi t h t h e b r a ke wh i l e d e p r e s s i n g t h e
t h r o t t l e w i t h t h e t r a n s mi s s i o n i n ge a r ) , a s
t r a n s mi s s i o n d a ma g e wi l l r e sul t .
Press EPC swi t ch. Line pressure should drop t o a
minimum val ue. Record value. If not, refer t o the
Di agnosi s by Sympt om Routines or Pinpoint Test
E for the EPC sol enoi d.
T r a n s mi s s i o n E n g a g e me n t
1. Verify that Mode swi t ch is in DRIVE mode.
2. Turn GEAR SELECT dial t o 1.
3. Start engine.
4. Depress EPC swi t ch. Line pressure should drop
t o idle pressure.
While holding EPC swi t ch down, shift vehicle f rom
PARK t o REVERSE.
Di d vehi cl e shift into REVERSE?
Was engagement smooth?
Shift vehi cl e f rom REVERSE t o PARK.
5. Depress EPC swi t ch. Line pressure should drop
t o idle pressure.
While holding the EPC swi t ch down, shift vehicle
f rom PARK t o DRIVE.
Did vehi cl e shift into DRIVE?
Was engagement smooth?
Shift vehi cl e from DRIVE t o PARK.
Release EPC swi t ch. Pressure should return t o
maxi mum.
6. Wi th the EPC swi t ch rel eased, repeat st eps 4
and 5, engagements should be fi rm.
Up s h i f t / Do w n s h i f t
NOTE: Upshi fts and downshi fts will be f i r m during this
procedure.
NOTE: Pressure gauges may be removed.
NOTE: These t est s should be performed on the road.
If performed on the hoist, the technician may not feel
all shifts when engaged.
LEDs will turn GREEN when shift solenoids ( 7G484)
are acti vated and turn OFF when deact i vat ed. Refer
t o the appropri ate overl ay for the proper status shift
sequence of t he shift solenoids during upshifts and
downshi fts.
07 - 01- 67 Transmission, A u t o m a t i c 4 R 7 0 W 07 - 01- 67
1. Shi ft vehicle into OVERDRIVE and a c c e l e r a t e t o
2 4 km /h ( 15 mph), sel ect se c ond gear by
rot at i ng Gear Sel ect swi t c h t o second gear
posi t i on.
Di d vehi cl e upshi ft t o second gear ?
Di d appr opr i at e shi ft sol enoi ds
act i vat e / deact i vat e?
2. Ac c e l e r a t e t o 40 k m/ h ( 25 mph) and sel ect t hi rd
gear posi t i on.
Di d vehi cl e upshi ft t o t hi rd gear ?
3. Ac c e l e r a t e t o 56-72 km / h ( 35 / 45 mph) and
sel ect f ourt h gear posi t i on.
Di d vehi cl e upshi ft t o f our t h gear ?
4. Reverse t he order t o downshi f t .
Does vehi cl e downshi f t f r om f ourt h t o t hi r d, t hi rd
t o second, and se c ond t o f i r st ?
T o r q u e C o n v e r t e r C l u t c h E n g a g e me n t
1. NOTE: Thi s t est shoul d be per f or med on t he
r o a d . If per f or med on a hoi st , f eel i ng t he t orque
convert er cl ut ch engage may not be possi bl e.
CAUTI ON: Do n o t d e p r e s s MCCC s w i t c h wi t h
t r a n s mi s s i o n i n ge a r a n d t h e v e h i c l e a t a
s t o p . Da ma ge t o t h e t o r q u e c o n v e r t e r c l u t c h
ma y r e s ul t .
Ac c e l e r a t e and shi ft vehi cl e up i nt o t hi r d gear.
Hol d speed st eady and pr e ss t he MCCC swi t c h.
Does t he t or que convert er engage?
Does t he engi ne rpm dr op?
Di d t or que convert er cl ut ch sol enoi d (TCC
sol enoi d)(7G 136) act i vat e?
O u t p u t S h a f t S p e e d S e n s o r ( OSS) Fu n c t i o n
C h e c k
1. NOTE: Thi s t est may be per f or med on t he hoi st
or on t he r oa d.
Set vol t met er t o 20 vol t s AC.
Connect vol t met er posi t i ve l ead t o t he ( + ) OSS
j a c k.
Connect vol t met er negat i ve l ead t o t he (-) OSS
j a c k.
Sl owl y accel er at e vehi cl e and moni t or vol t met er.
Does vol t age i ncrease wi t h vehi cl e speed?
Af t er y ou fi ni sh t est i ng, cont i nue t o "Transmi ssi on
Test er Removal and Cl eari ng DTCs" if T R/ ML P
t est i ng i s not requi red. If T R/ ML P t est i ng is r equi r ed,
cont i nue.
07 - 01- 68 Tr a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W 07 - 01- 68
Transmission Range (TR) Sensor
TestingEnhancement
TR/ ML P Te st e r I n st r uc t i o n s
T R A N S M I S S I O N T E S T E R
9 9
9
( o O O / / TR/MLP SENSORS
PARK/NEUTRAL
LEO QSEQ I N
PARK OR
NEUTRAL
ONLY
HOLD TO TEST
O
STATUS

BACKUP LAMPS
LED ( SB IN
REVERSE
ONLY
HOLD TO TEST
O
STATUS

LB? PSD IN:
o
Axootl mm STATUS
AX4S I AODE
AX4N I 4R7CW
CME I
HOLD TO TEST
SWITCH TEST
FOR EACH SWITCH TEST:
PRESS AND HOLD EACH SWITCH SUTTON WHILE SHIFTING GEAR
SELECTOR TO ALL GEAR POSITIONS:
LED FOR THE ACTIVE TEST SHOULD LIGHT [Q3D ONLY FOR THE
INDICATED GEAR POSITION.
IF LED FAILS TO LIGHT FOR THAT GEAR POSITION OR IF IT LIGHTS
FOR A DIFFERENT GEAR POSITION:
VERIFY TR/MLP ALIGNMENT PER SHOP MANUAL, AND
RETEST
M NOT
USED

SENSOR TEST
CONNECT OHMMETER TO TR/MLP AND SIG RTN JACKS.
RECORD RESISTANCES IN EACH GEAR POSITION WHILE
SHIFTING GEAR SELECTOR TO ALL POSITIONS.
REFER TO TABLE.
IF VALUES ARE OUT OF RANGE, REFER TO SHOP MANUAL.
BEFORE ATTACHING
OVERLAY SET SWITCH
IN DOWN P08I TI ON.

o
TR/MLP SENSOR TEST
NOT
USED

TR/MLP
GEAR SELECTOR
POSITION
PARK
RESISTANCE O
MIN MAX
3770 4607
MANUAL LEVER P08ITION
O O
TR/MLP SIG RTN
REVERSE 1304 153 MANUAL LEVER P08ITION
O O
TR/MLP SIG RTN
NEUTRAL 660 807
O O
TR/MLP SIG RTN
OVERDRIVE * 361 442
O O
TR/MLP SIG RTN
SECOND/DRIVE t 190 232
O O
TR/MLP SIG RTN
FIRST
76 95
* , f RtFER TO SHOP MANUAL
D14049-A
T r a n s mi s s i o n T e s t e r Us e f o r TR Di a g n o s i s
The Transmission Tester al l ows a technician t o
operat e the el ectri cal porti on of the transmi ssi on
range (TR) sensor. The TR/ MLP Tester usage is
di vi ded into fi ve st eps:
1. Preliminary Testing and Di agnosi s.
2. Transmission Tester Installation (Set-Up
Procedure).
3. Testi ng TR Sensor.
4. Par k/ Neut r al , Backup Lamp and Optional Circuit
Vol tage Test s.
5. Transmission Tester Removal and Clearing
Diagnostic Trouble Codes (DTCs).
P r e l i mi n a r y T e s t i n g a n d Di a g n o s i s
Before any diagnostic testi ng is done on a vehicle,
some preliminary checks must be performed as
outlined below. Be sure t o wri te down your findings,
especi al l y any DTCs found, for future reference.
Check transmission fluid level and condi ti on.
Check for add-on items (phones, comput ers, C B
radi o, et c).
1995 To wn Car , Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s Jul y 1 9 9 4
07 - 01- 69
T r a n s mi s s i o n , A u t o ma t i c 4 R7 0 W
07 - 01- 69
Visually i nspect wi ri ng harness and connect ors.
Check for vehi cl e modi fi cati ons.
Verify that the shift l i nkage is properl y adj usted in
OVERDRIVE.
Verify that TR Sensor is properl y adj usted in
NEUTRAL.
Verify customer concern.
Upshift, Downshi ft, Coasti ng, Engagement,
Noi se/ Vi brat i on
Vehicle must be at a normal operati ng t emperat ure.
Perform vehi cl e On-Board Di agnosti c.
Record all DTCs.
Servi ce all non-transmission DTCs.
T r a n s mi s s i o n T e s t e r I n s t a l l a t i o n ( Se t Up
P r o c e d u r e )
Installing the Transmi ssi on Tester at t he TR Sensor
CONNECTOR al l ows t he separati on of t he vehi cl e
el ectroni cs f rom the TR sensor el ectroni cs.
NOTE: During tester usage additional DTCs may be
set . Theref ore, it is i mportant that all codes are erased
after servi ce has been made. To veri fy elimination of
all DTCs, rerun On-Board Di agnosti c.
NOTE: The following manuals should be available t o
assi st in di agnosi s of el ectroni cal l y-control l ed
transmi ssi ons:
Powertrai n Control / Emissions Di agnosi s Manual
2 4
Transmi ssi on Reference Manual
c o n n e c t o r s w i t h a s c r e wd r i v e r . Th i s wi l l
d a ma g e t h e c o n n e c t o r a n d c o u l d r e s ul t i n a
t r a n s mi s s i o n c o n c e r n .
Di sconnect vehi cl e harness at transmi ssi on TR
Sensor connector.
2. NOTE: For in-vehicle testi ng, use t he
transmi ssi on t est er extensi on cabl e.
CAUTI ON: Ro u t e al l c a b l e s a wa y f r o m HEAT
SOURCES t o p r e v e n t d a ma g e t o c a b l e s .
Set Bench/ Dr i ve swi t ch t o DRIVE mode. Install
TR/ MLP Sensor Overl ay onto tester. Connect
i nterface cabl e t o transmi ssi on t est er and then t o
the TR sensor connector. Refer t o chart for t he
proper cabl e/ appl i cat i on.
TRANSMISSION TESTER CABLE APPLICATION
T r a n s mi s s i o n Mo d e l Ye a r C a b l e I.D.
E 4 0 D 1989- 1993 A
A ODE 1992 ONLY A
A X ODE 1991- 1992 A
A X O DE / A X 4 S 1993 & UP B
A ODE 1993 & UP C
4R7 0W 1993 & UP C
CD4E 1993 & UP D
3. Turn t est sel ect swi t ch t o t he TR / MLP SENSOR
TEST posi ti on.
4. Plug transmi ssi on t est er power suppl y plug into
ci gar lighter.
At this ti me, all LEDs shoul d illuminate for a short
peri od and then turn off. Thi s is t he t est er internal
circuit check.
T e s t i n g TR S e n s o r
Stati c testi ng procedures al l ow for shop testing of the
transmi ssi on in the vehi cl e or on the bench.
Compl eti on of t hese t est s prove out the TR sensor
el ectroni cal l y.
R e s i s t a n c e / C o n t i n u i t y T e s t s
CAUTI ON: Fo r r e s i s t a n c e c h e c k s , b e s ur e t h a t
t h e f e s t e r s e l e c t o r s w i t c h i s s e t t o t h e T R/ ML P
SENSOR TE ST p o s i t i o n o r d a ma g e t o t h e
o h mme t e r ma y r e s ul t .
Using a digital vol t / ohmmet er and the Transmission
Tester, perform Pinpoint Test D as outlined based
on t he DTCs di spl ayed.
Perform servi ces as i ndi cated by the pinpoint t est s.
Al ways retest and road test vehi cl e after any
servi ce.
TR S e n s o r Re s i s t a n c e T e s t s
Set ohmmeter t o 1000 ohm range.
Connect the posi ti ve lead of the ohmmeter t o the
TR/ MLP j ack.
Connect the negative lead of the ohmmeter t o the
SIGRTN j ack.
Move transmi ssi on range sel ector lever into each
gear posi ti on.
Record resi stance at each posi ti on.
Refer to the following chart for val ues.
If out of range, refer to Pinpoint Test D as outlined.
TR S E N S O R R E S I S T A N C E
Ra n g e S e l e c t o r
L e v e r P o s i t i o n
Re s i s t a n c e ( o h ms )
Ra n g e S e l e c t o r
L e v e r P o s i t i o n Mi n i m u m Ma x i mu m
PARK 37 7 0 4607
REVERSE 1304 1593
NEUTRAL 660 807
OVERDRI VE' 361 442
SE COND/ DRI VE " 190 2 32
MA NUA L 1 . 7 8 9 5
Sa me v a l u e s f o r o v e r d r i v e o r O / D CANCE L ( DRI VE) on
e l e c t r o n i c a l l y c o n t r o l l e d t r a n s mi s s i o n s . D a n d Dr i ve ( 0 / D
Ca n c e l l e d ) a r e in t h e s a me t r a n s mi s s i o n r a n ge s e l e c t o r
l e v e r p o s i t i o n .
Sa me v a l u e s f o r SE COND ( e l e c t r o n i c t r a n s mi s s i o n ) or
DRI VE on t r a n s mi s s i o n s wi t h a s e p a r a t e DRI VE a n d
OVERDRI VE p o s i t i o n .
07 - 01- 7 0
07 - 01- 7 0
Vo l t a g e T e s t s P a r k / N e u t r a l , B a c k u p L a m p
a n d Op t i o n a l C i r c u i t s
1. NOTE: LED will turn RED when the circuit cl oses
and turn OFF when the circuit is open.
Tester Sel ect Swi t ch t o the TR/ MLP SENSOR
TEST posi ti on.
2. Press and HOLD each button while moving the
transmi ssi on range sel ector lever through EACH
range.
3. Moni tor each LED.
4. The status LED should indicate RED only in t he
i ndi cated posi ti on. Refer t o overl ay.
5. If the LED does NOT indicate RED in the desi red
posi ti on, or indicates RED in another position,
fi rst veri fy TR sensor alignment and then retest. If
the sensor fails, then repl ace.
T r a n s mi s s i o n T e s t e r Re mo v a l a n d Cl e a r i n g
DT Cs
c o n n e c t o r s wi t h a s c r e wd r i v e r . Thi s wi l l
d a ma g e t h e c o n n e c t o r a n d c o u l d r e sul t i n a
t r a n s mi s s i o n c o n c e r n .
Di sconnect transmi ssi on tester f rom the TR
Sensor connector.
2. Reinstall vehicle wiring harness. Verify
connecti on by pulling up on the harness.
3. Di sconnect transmi ssi on tester power lead f rom
vehicle.
4. Erase all DTCs using the procedures in the
Powertrai n Cont rol / Emi ssi ons Diagnosis
Manual
2 5
.
5. Rerun On-Board Diagnostic Tests t o recei ve a
pass code (P1111-4. 6L).
6. Verify that the customer concern has been
eliminated.
TRANSMISSION INTERNAL HARNESS
VPWR (EPC)
EPC
TFT
TFT RETURN
SS2
SS1
SS VPWR
VPWR TCC
TCC
SS VPWR
SS1
SS2
'TFT
TFT RETURN
D11501-C
NOTE: Prior t o ent eri ng Pi npoi nt Test s, c he c k t he
OBDII sy st e m wi ri ng harness f or pr oper connect i ons,
bent or br oken pi ns, c or r osi on, l oose wi r es, proper
rout i ng, proper seal s and t hei r condi t i on. Check t he
PCM, sensor s and a c t ua t or s f or damage. Refer t o t he
Powert rai n Cont r ol / Emi ssi ons Di agnosi s Ma n u a l .
2 6
NOTE: If el ect ri cal di agnosi s has been per f or med and
a concer n still e xi st s, ref er t o Di agnost i c Rout i nes.
If DTCs are present whi l e per f or mi ng t he On-Board
Di agnost i cs, ref er t o t he On-Boar d Di agnost i c Troubl e
Code Descri pt i on Chart f or t he appr opr i at e ser vi ce
pr ocedur e. Pri or t o ent eri ng Pi npoi nt Test s, ref er t o
any TSBs and Oasi s me ssa ge s f or t ransmi ssi on
concer ns.
NOTE: Pri or t o ent eri ng pi npoi nt t e st s, t he vehi cl e
harness must be c he c ke d f or cont i nui t y and shor t s;
t he power t r ai n cont r ol modul e ( PCM) ( 12A650) must
be c he c ke d f or any concer ns. Ref er t o t he Powert rai n
Cont r ol / Emi ssi ons Di agnosi s Ma n u a l
2 6
f or proper
pr ocedur es.
NOTE: If any non-t ransmi ssi on DTCs appear, ser vi ce
t hose c ode s f i r st . They coul d af f ect t he el ect ri cal
operat i on of t he t ransmi ssi on. Recor d and er ase DTCs
f r om cont i nuous memory af t er ser vi ce has been
per f or med. Af t er servi ci ng any DTCs in t he Qui ck Test ,
repeat t he Qui ck Test .
Use t he f ol l owi ng pi npoi nt t e st s t o di agnose
t ransmi ssi on el ect ri cal concer ns.
P i n p o i n t T e s t A S h i f t S o l e n o i d s
DTCs:
P 07 81, P0782, P07 83 Shi ft Er r or s
P07 50, P07 51 Sol enoi d Ci rcui t Fai lures
P 07 51, P1751 Shi f t Solenoi d No. 1 Mal f unct i on
P0756, P1756 Shi f t Solenoi d No. 2 Mal f unct i on
Thi s Pinpoint Test is i nt ended t o di agnose t he shi f t
sol enoi ds el ect ri cal sy st e m ONLY. To prevent
repl acement of go o d component s, be a wa r e t hat t he
f ol l owi ng ar eas may be at f aul t :
Engine
Perf ormance, Cool i ng, Br a ke s
El ect ri cal
Bat t ery, Input Sensors, Wi ri ng Har nesses
Transmi ssi on
Internal Transmi ssi on Component s, Li nkages,
Cooli ng
Thi s Pinpoint Test is i nt ended t o di agnose t he f ol l owi ng
component s:
Transmi ssi on Wi ri ng Harness, SS1, SS2, VPWR
Powert rai n Cont rol Modul e
TRANSMISSION
VEHICLE HARNESS
CONNECTOR
f SS1 AND SS2 VPWR"
4.6L TEST PIN 27O/Y
TEST PIN 91,97 O- R-
TEST PIN 1 O
-SS1
^FROM PCM
POWER RELAY
SS1
SS VPWR
SS2
WHITE/BLACK STRIPE
SS2
S S 1
SS VPWR
D14116-A
Solenoid
PCM Signal
Output Pin KOEO DTC
SS1
8
27 P 07 50
S S 2
b
1 P 07 55
a SS1 = Shi f t So l e n o i d 1
b SS2 = Shi f t So l e n o i d 2
S o l e n o i d Op e r a t i o n s C h a r t s
Solenoids
Transmission
Range Selector
Lever Position
P CM
Commanded
SS-1 SS-2 TCC

1 ON OFF HD

2 OFF OFF EC

3 OFF ON EC

4 ON ON EC

w / O D OFF
1 1 ON OFF HD
2 2 OFF OFF EC
3 3 OFF ON EC
Ma n ua l 2 2 OFF OFF EC
( Co n t i n ue d )
Solenoids
Transmission
Rang S e l e c t o r
L e v e r Position
PCM
Commanded
G e a r SS-1 SS-2 TCC
Ma n u a l 1 1 ON OFF HD
a
1 2 OFF OFF EC
EC = Electronically Cont rol l ed
HD = Hydraulically Di sabl ed
t r a n s mi s s i o n wi l l d o wn s h i f t f r o m t h e hi ghe r ge a r unt i l t h e
v e h i c l e s p e e d d r o p s b e l o w t h i s c a l i b r a t e d s p e e d .
S h i f t S o l e n o i d Fa i l u r e Mo d e s
Sh i f t S o l e n o i d Fa i l ur e " A l w a y s O n "
Failed ON due t o powertrai n control module
( PCM) ( 12A650) and/ or vehicle wiring concerns, shift
sol enoi d ( 7G484) el ectri cal l y or hydraulically stuck
ON (TCS off).
Transmi ssi on Range Sel ect or Lever Posi t i on
SS-1
ALWAYS ON:
2 1
PCM Gear Act ual Gear
Commanded Obt ai ned
1 1 1 1
2 1 1 1
3 4 2 * 2*
4 4 2 * 2*
* No Engine Braki ng
SS-2
ALWAYS ON:

2 1
PCM Gear
Comma nde d
Act ual Gear
Obt ai ned
1 4 2 * 2*
2 3
2*
2*
3 3 2* 2*
4 4 2* 2*
* No Engine Braki ng
S h i f t S o l e n o i d Fa i l ur e " A l w a y s O f f "
Failed OFF due t o powertrai n control module and/ or
vehi cl e wiring concerns, shift solenoid electrically or
hydraulically stuck OFF (TCS off).
SS-1
ALWAYS
OFF: 2 1
PCM Gear
Commanded
Act ual Gear
Obt ai ned
1 2 2 2
2 2 2 2
3 3 2* 2 *
4 3 2 * 2*
*No Engine Braking
SS-2
ALWAYS
OFF:
2 1
PCM Gear Act ual Gear
Commanded Obt ai ned
1 1 1 1
2 2 2 2
3 2 2 2
4 1 1 1
PINPOINT TEST A: SHIFT SOLENOIDS
A1 ELECTRONIC DIAGNOSTICS
Yes
No >
REMAIN in Output State
DTM. GOt o A2.
PRESS throttle and
release. If vehicle did not
enter Output State DTM,
REFER to Powertrain
Control/Emi ssi ons
Diagnosis Manual
2 7
.
Check to make sure the transmission harness
connector is fully seat ed, terminals are fully
engaged in connector and in good condition before
proceedi ng.
Enter Output State Diagnostic Test Mode (DTM).
Refer to Speci al Test Modes as outlined.
007-00500 or equivalent.
Perform KOEO test until continuous DTCs have been
di splayed.
Press throttle to WOT and release.
Does vehi cl e ent er Out put St at e DTM?
Yes
No >
DTM. GOt o A2.
PRESS throttle and
REFER to Powertrain
Control/Emi ssi ons
Diagnosis Manual
2 7
.
07 - 01- 7 3 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 0 7 - 0 1 - 7 3
PINPOINT TEST A: SHIFT SOLENOIDS (Cont i nued)
A2 CHECK ELECTRICAL SIGNAL OPERATION
Yes
No
GO to A5.
GO to A3.
CAUTION: Do not pry on connect or . Thi s wi l l damage
t he c onne c t or and coul d resul t in a t ransmi ssi on
c o n c e r n . Pull up on t he c onne c t or harness.
Disconnect transmission connector.
Using a mirror, inspect both ends of connector for
damage or pushed out pins, corrosi on, loose wires
and missing or damaged seals.
NOTE: Refer to the schematic and charts preceding
thi s pinpoint t est .
Connect a VOM positive lead to VPWR and the
negative test lead to the solenoid circuit of the
transmission vehicle harness connector.
Place VOM on 20 volt scale.
While observing VOM, press and release throttle to
cycl e solenoid output ON and OFF.
Does t he suspect sol enoi d out put vol t age
change at l east 0.5 vol t ?
Yes
No
GO to A5.
GO to A3.
A3 CHECK CONTINUITY OF SOLENOID SIGNAL AND
VPWR HARNESS CIRCUITS
Yes
No
GO to A4.
SERVICE OPEN ci rcui ts.
REMOVE breakout box.
RECONNECT all
components. REPEAT
Quick Tests.
Turn ignition swi tch to the OFF posi ti on.
Ensure transmission harness connector is
di sconnected.
Disconnect powertrain control module, inspect for
damage or pushed out pins, corrosi on or loose
wi res.
Install Rotunda Breakout Box 014-00950 or
equivalent, leave powertrain control module
di sconnected.
NOTE: Refer to the schematic and chart preceding
Measure resistance between PCM signal test Pins 1
or 27 at breakout box and signal pin at the
transmission harness connector.
Measure resistance between PCM signal test Pin 71
and 97 at breakout box and signal pin at the
Is each resi st ance less t han 5 ohms?
Yes
No
GO to A4.
SERVICE OPEN ci rcui ts.
RECONNECT all
components. REPEAT
Quick Tests.
A4 CHECK SOLENOID HARNESS FOR SHORTS TO
POWER AND GROUND
Yes
No .
GO to A5.
SERVICE short ci rcui t s.
RECONNECT all
components. REPEAT
Quick Tests.
Ensure Rotunda Breakout Box 014-00950 or
equivalent is installed and powertrain control
module di sconnected.
di sconnected.
NOTE: Refer to schematic and charts preceding this
pinpoint t est .
Measure resi stance between PCM signal output
pins and t est Pin 71 and 97 at breakout box.
Measure resi stance between test Pins 51, 76, 77,
103 and 91 at breakout box and chassi s ground.
Is each resi st ance great er t han 10,000 ohms?
Yes
No .
GO to A5.
SERVICE short ci rcui t s.
RECONNECT all
components. REPEAT
Quick Tests.
A5 TRANSMISSION FUNCTIONAL TEST
Yes
No
GO to A6.
GO to A7.
Disconnect vehicle harness at transmission.
CAUTION: Do not at t empt t o pry connect or. This
wi l l damage the connect or and coul d resul t in a
transmi ssi on concern. Depress tab and pull up
on harness connector.
Install Rotunda Transmission Tester 007-0085C or
equivalent to transmission connector.
Using t est s outlined under Transmission Tester
Instructions, perform Transmission Solenoid and
Sensors Resistance Tests.
NOTE: LED will turn GREEN when solenoid acti vates
and turn OFF when deacti vated. LED will turn RED if
an ACTIVATED solenoi d/harness is shorted t o
battery positive. LED will remain off if an ACTIVATED
sol enoi d/harness is shorted to ground or no
continuity (open ci rcui t).
Does sol enoi d (LED GREEN) act i vat e?
Yes
No
GO to A6.
GO to A7.
A6 TRANSMISSION DRIVE TEST
Yes
No
REPLACE PCM. ERASE
all codes and PERFORM
the Drive Cycle Test as
outlined. RE-RUN Quick
Test. If DTCs are still
present, REFER to
Diagnosis by Symptom
Routines.
GOt o A7.
Perform the Transmission Solenoid Cycling and
Drive Test as outlined under Transmission Tester
Instructions, Dynamic TestingEngine Running.
Does t he vehi cl e upshi f t when commanded by
t he t e st e r ?
Yes
No
REPLACE PCM. ERASE
all codes and PERFORM
the Drive Cycle Test as
outlined. RE-RUN Quick
Test. If DTCs are still
present, REFER to
Diagnosis by Symptom
Routines.
GOt o A7.
PINPOINT TE ST A: SHIFT SOLENOI DS (Cont i nued)
A7 CHECK RESISTANCE OF SOLENOID/HARNESS
NOTE: Refer to the Transmission Tester for terminal
locations.
Bench /Drive switch in BENCH mode.
Rotate Gear Select switch to OHMS CHECK
position.
Connect ohmmeter negative lead to SS-1 j ack and
positive lead to VPWR jack on tester. This is to test
SS-1.
Record resistance.
Resistance should be between 20 and 30 ohms.
Connect ohmmeter negative lead to SS-2 j ack and
positive lead to VPWR jack on tester. This is to test
SS-2.
Record resistance.
Is resi st ance f or each sol enoi d bet ween 20 and
30 ohms?
Yes
No

GO to A8.
GO to A9.
NOTE: Out of
specification may be
caused by internal
harness or solenoid
concerns.
SHI FT SOLENOI DS
VPWR
I GREEN If OFF || OFF II GREEN |
O t' OFF ' I FOFFI f cj j j j l l GREEN|
-GEAR SELECT
CONNECT OHMMETER BETWEEN THESE
TWO JACKS FOR EACH SOLENOID
D12032-A
07 - 01- 7 6 Tr a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 07 - 01- 7 6
PINPOINT TEST A; SHIFT SOLENOIDS (Continued)
A8 CHECK SOLENOID /HARNESS FOR SHORT TO
GROUND
Check for continuity between BAT- j ack (engine
ground) and appropriate j ack with an ohmmeter or
other low current tester (less than 200 milliamps).
Yes
No

GO to A9.
GO to Diagnosis by
Symptom Routines.
Solenoid Tester Jack
SS- 1 S S - 1 / VP WR
SS- 2 S S - 2 / VP WR
Connection should show infinite resistance (no
continuity).
SHI FT SOLENOI DS
1 2
GREEN I FOPF
OFFnrofi T HI GREEN'
CONNECT OHMMETER
BETWEEN BAT (-)
JACK AND EACH
SOLENOID JACK
OFF
GEAR SELECT
EXT POWER
o o
D12G33-A
A9 INTERNAL ELECTRONIC DIAGNOSTICS
Drain transmission fluid.
Remove transmission pan.
Check that the internal harness connector is fully
engaged on the shift solenoid assembly.
Check that the internal harness connector terminals
are fully seat ed in the connector.
Inspect the connector for damage.
Are above i n good c ondi t i on?
Yes
No

GOt o AI O.
07 - 01- 7 7 Tr a n smi ssi o n s A u t o m a t i c 4 R 7 0 W 07- 01- 77
PINPOINT TEST A: SHIFT SOLENOIDS (Conti nued)
A10 CHECK INTERNAL HARNESS (CONTINUITY)
Disconnect internal harness from solenoid assembly
(3-wire connector).
CAUTION: Do not probe i nt o c onne c t or
t er mi nal s. Thi s wi l l damage t he c onne c t or and
coul d resul t i n a t ransmi ssi on c o n c e r n .
For SS-1, connect the posi ti ve lead from an
ohmmeter to the tester j ack SS-1 and the negative
lead at the white wire of the 3-wire connector.
Record resi stance. Resistance should be less than
0.5 ohm.
For SS-2, connect the posi ti ve lead from an
ohmmeter to the tester j ack SS-2 and the negative
lead at the black wire of the 3-wire connector.
Record resistance. Resistance should be less than
0.5 ohm.
For VPWR, connect posi ti ve lead to VPWR and the
negative lead to the white / black wire of the 3-wire
connector.
0.5 ohm.
Is resi st ance f or each sol enoi d less t han 0.5
ohm?
Yes
No

GO to A 11.
REPLACE internal
harness. GO t o A12.
A11 CHECK INTERNAL HARNESS (SHORTS TO GROUND)
ground) and the appropri ate wire with an ohmmeter
or other low current t est er (less than 200 milliamps).
Yes
No

REPLACE internal
harness. GO to A12.
GO t o A12 .
S o l e n o i d Wi r e
SS- 1 Wh i t e
SS- 2 Bl a c k
VP WR Wh i t e / B l a c k
Connection should show infinite resi stance (no
continuity).
Does c onne c t i on show c ont i nui t y ?
DIAGNOSES AND TESTING (Conti nued)
A12 CHECK SOLENOID RESISTANCE AT SOLENOID
For SS-1, connect the ohmmeter to the center No. 1
terminal of the solenoid assembly and to the +
terminal.
Record resi stance.
For SS-2, check solenoid resistance by connecting
an ohmmeter at the outboard No. 2 terminal and +
terminal of the solenoid assembly.
Record resi stance.
Yes
No

fr-
GC t o A13.
REPLACE solenoid
assembly.
SS2
SS1
SHIFT SOLENOID
ASSEMBLY CONNECTOR D10233-C
Is resi st ance f or each sol enoi d bet ween 20 and
30 ohms?
A13 CHECK SOLENOID FOR SHORT TO GROUND
ground) and appropri ate terminal wi th ohmmeter or
Yes
No

S o l e n o i d T e r mi n a l
SS-1 1
SS-2 2
PWR +
REPLACE solenoid
assembly.
REFER to Diagnosis by
Symptom Routines.
continuity).
Does connect i on show cont i nui t y ?
P i n p o i n t T e s t B T r a n s m i s s i o n Fl u i d
T e mp e r a t u r e ( TFT) S e n s o r
DTCs:
P1711 TFT Sensor Out of Self-Test Range
POT 13 TFT Sensor Circuit Open
POT 12 TFT Sensor Circuit Short ed
P1783 Transmission Overt emp Indicated
Thi s Pinpoint Test is intended t o di agnose the TFT
sensor el ectri cal syst em ONLY. To prevent
repl acement of good components, be awar e t hat the
fol l owi ng areas may be at fault:
Engine
Cooling
Electrical
Battery, Wiring Harnesses
Transmission
Internal Transmission Components, Cooling,
Fluid
This Pinpoint Test is intended t o di agnose the following
components:
Transmission Wiring Harness, TFT, SIGNAL
RETURN
Powert rai n Cont rol Modul e ( PCM) 12A650 / n f f f l r v
f / o o o j ]
T E S T P I N 3 7 O / B K T F T H o o o o j I
T E S T P I N 9 1 0 G Y / R S I G R T N A X O J > X /
TRANSMISSION
VEHICLE
HARNESS
CONNECTOR
D14117-A
PINPOINT TEST B: TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR
B1 ELECTRONIC DIAGNOSTICS
Yes
No >
GOt o B2.
PERFORM checks.
ERASE codes. REPEAT
Quick Test.
Check to make sure transmission harness
proceedi ng.
Have t he i t ems above been c he c ke d?
Yes
No >
GOt o B2.
PERFORM checks.
ERASE codes. REPEAT
Quick Test.
B2 CHECK ELECTRICAL SIGNAL OPERATION
Yes
No
GOt o B3.
REFER to Powertrain
Control/Emi ssi ons
Diagnosis Manual
2 8
for
diagnosis of NO
Reference Voltage.
CAUTION: DO NOT PRY c onne c t or . Thi s wi l l
damage t he c onne c t or and coul d resul t in a
t ransmi ssi on c o n c e r n . Pull up on vehi cl e harness
c onne c t or .
Using a mirror, inspect both ends of the connector
for damaged or pushed out pins, corrosi on, loose
wi res and missing or damaged seals.
NOTE: Refer to the schemati c preceding thi s
pinpoint t est .
Connect a VOM positive test lead t o TFT circuit and
negative test lead to Signal Return (SIG RTN) circuit
of transmission harness connector.
Turn ignition swi tch to RUN, engine off.
Is vol t age bet ween 4. 75 and 5.25 vol t s?
Yes
No
GOt o B3.
REFER to Powertrain
Control/Emi ssi ons
Diagnosis Manual
2 8
for
diagnosis of NO
Reference Voltage.
07 - 01- 80 Tr a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W ^ ^ ^ 07 - 01- 80
PINPOINT TEST B: TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR (Continued)
B3 CHECK CONTINUITY OF TFT AND SIG RTN CIRCUITS
Yes
No
GO to B4.
RECONNECT all
components. ERASE all
codes. REPEAT Quick
Tests.
Turn ignition switch to the OFF position.
Ensure that the vehicle harness is disconnected at
the transmission connector.
Disconnect powertrain control module. Inspect for
damaged or pushed out pins, corrosion or loose
wires.
equivalent. Leave powertrain control module
di sconnected.
NOTE: Refer to schemati c preceding this pinpoint
test.
Measure resi stance between PCM signal test Pin 37
at breakout box and signal test pin at transmission
harness connector.
at breakout box and signal test pin at transmission
harness connector.
Are bot h resi st ances less t han 5 ohms?
Yes
No
GO to B4.
RECONNECT all
components. ERASE all
codes. REPEAT Quick
Tests.
B4 CHECK TFT CIRCUIT FOR SHORT TO VPWR AND
GROUND
Yes
No
GOt oBS.
SERVICE short ci rcui t (s).
RECONNECT all
components. ERASE
codes. REPEAT Quick
Tests.
di sconnected.
damaged or pushed out pins, corrosi on or loose
wi res.
di sconnected.
NOTE: Refer to schemati c preceding this Pinpoint
Test.
Measure resi stance between TFT test pin and t est
Pins 71 and 97 at breakout box.
Measure resi stance between TFT test pin and
chassi s ground.
i s each resi st ance great er t han 10,000 ohms?
Yes
No
GOt oBS.
RECONNECT all
components. ERASE
codes. REPEAT Quick
Tests.
07- 01- 81 T r a n s mi s s i o n , A u t o ma t i c ' 4R7 0W 0 7 - 0 1 - 8 1
PINPOINT TEST B: TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR (Cont i nued)
B5 CHECK RESISTANCE OF TFT SENSOR /HARNESS
locations.
Vehicle must be at normal operating temperature.
Disconnect vehi cle harness at transmission.
CAUTION: Do not a t t e mpt t o pry connect or . Thi s
wi l l damage t he c onne c t or and coul d resul t i n a
t ransmi ssi on c o n c e r n . Depress t ab and pull up
on harness c onne c t or .
Set Bench/Dri ve swi t ch to BENCH mode.
Rotate Gear Select swi tch to OHMS / DIODE CHECK
position.
Connect ohmmeter negative lead to -TOT j ack and
positive lead t o 4-TOT j ack on tester.
Perform t est s 1 and 2.
NOTE: While performing Test 1 and 2, observe
resi stances. DTC 637 is set if resi stance value
exceeds 869K ohms (OPEN ci rcui t). DTC 638 is set
if resi stance value falls below 597 ohms (short
ci rcui t).
Test 1
Record resi stance.
Resistance should be approximately in the following
ranges:
TRANSMISSION FLUID TEMPERATURE
Test 2
Check for intermittent short or open.
If resi stance was between 0.8K and 100K ohms,
perform followi ng t est . If transmission is warm, allow
transmission t o cool . Check transmission fluid
temperature sensor resi stance again. Compare
resi stance wi th initial resi stance. Resistance should
decrease if transmi ssi on was heated and should
increase if transmi ssi on was allowed t o cool . If
correct change in resi stance occurs, REPEAT
On-Board Di agnosti c.
Is resi st ance i n range?
Yes
No

GO t o B6.
GOt o B7.
c F
R e s i s t a n c e
( Oh ms )
4 0 - 2 0 "40- 4 967 K- 2 84K
' 1 9 - 1 "3-31 2 84K- 100K
0- 2 0 32 - 58 100K- 37 K
2 1- 40 59- 104 37 K- 16K
41- 7 0 105- 158 16K- 5K
7 1- 90 159- 194 5K- 2 . 7 K
91- 110 195- 2 30 2 . 7 K- 1. 5K
111- 130 2 31- 2 66 1. 5K- 0. 8K
131- 150 2 67 - 302 0. 8K- 0. 54K
B6 CHECK TFT SENSOR / HARNESS FOR SHORT TO
GROUND
ground) and appropri ate j ack (-TOT and 4-TOT) wi th
ohmmeter or other low current tester (less than 200
milliamps).
continuity).
Yes
No

GO to B7.
REPLACE PCM.
CONNECT OHMMETER BETWEEN EACH
TOT JACK AND BAT (-) JACK
D12036-A
B7 INTERNAL ELECTRONIC DIAGNOSTICS
Check that internal harness connector is fully
engaged on transmission fluid temperature sensor.
Check that internal harness connector terminals are
fully seat ed in connector.
Are above i n good condi t i on?
Yes
No
GO to B8.
B8 CHECK INTERNAL HARNESS (CONTINUITY)
Disconnect internal harness from transmission fluid
temperature sensor.
CAUTION: Do not probe i nt o c onne c t or
t ermi nal s. Thi s wi l l damage t he c onne c t or and
coul d resul t i n a t ransmi ssi on c onc e r n.
For transmission fluid temperature sensor, connect
the positive lead from an ohmmeter to the tester
+TOT j ack and the negative lead at the whi t e/ r ed
wire of the TFT sensor connector.
0.5 ohm.
Connect the positive lead from an ohmmeter to the
tester -TOT j ack and the negative lead at the red
wire of the TFT wire connector.
0.5 ohm.
Is resi st ance l ess t han 0.5 ohm?
Yes
No

GO to B9.
REPLACE internal
harness. GOt o BI O.
07- 01- 83 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 07 - 01- 83
B9 CHECK INTERNAL HARNESS (SHORTS TO GROUND)
ground) and the appropri ate wire (+T0T and -TOT)
with ohmmeter or other low current tester (less than
200milliamps).
Yes
No
S e n s o r Wi r e
T O T + Wh i t e / R e d
TOT- Re d
continuity).
REPLACE internal
harness. GO t o B10.
GO t oB10.
B10 CHECK TFT SENSOR RESISTANCE
Check sensor resi stance by connecting an
ohmmeter at the terminals of the transmission fluid
temperature sensor assembly.
Record resi stance.
Resistance should be in range of temperature of the
vehi cle.
Resistance should be approxi mately in the following
ranges:
TRANSMISSION FLUID TEMPERATURE
Yes
No
c F
Resistance
(Ohms)
"40-' 20 ' 4 0 - 4 J 967 K- 2 84K
' 1 9 - 1 "3- 31 2 84K- 100K
0- 2 0 32 - 58 100K- 37 K
2 1- 40 59- 104 37 K- 16K
41- 7 0 105- 158 16K- 5K
7 1- 90 159- 194 5K- 2 . 7 K
91- 110 195- 2 30 2 . 7 K- 1. 5K
111- 130 2 31- 2 66 1. 5K- 0. 8K
131- 150 2 67 - 302 0. 8K- 0. 54K
Is resi st ance in range?

GO to 811.
REPLACE transmission
fluid temperature sensor.
B11 CHECK TFT SENSOR FOR SHORT TO GROUND
Check for continuity between engine ground and
appropri ate terminal wi th ohmmeter or other low
current t est er (less than 200 milliamps).
S e n s o r T s r mi n a l
TFT
continuity).
Yes
No
REPLACE transmission
fluid temperature sensor.
RERUN Quick Test i f DTC
is still present. REFER to
the Powertrain
Control/Emi ssi ons
Diagnosis Manual
2 9
t o
diagnose harness or
powertrain control
module concerns.
P i n p o i n t T e s t C T o r q u e C o n v e r t e r C l u t c h
( T CC) S o l e n o i d
DTCs:
P0741 TCC Engagement Error Det ect ed
P0743 TCC Solenoid Circuit Failure
P1741 TCC Excessi ve Slip Det ect ed
P1742, P1743 TCC Solenoid Failure
Thi s Pinpoint Test is intended t o di agnose the TCC
solenoid el ectri cal syst em ONLY. To prevent
repl acement of good components, be awar e that the
following areas may be at fault:
Engine
Performance, Cooling
Electrical
Battery, input Sensors, Wiring Harnesses, BOO
Swi t ch
e Transmission
Internal Transmission Components, Li nkages,
Cooling
Thi s Pinpoint Test is intended t o di agnose the following
components:
Transmission Wiring Harness, TCC, VPWR
@ Powertrai n Control Modul e
Solenoid
PCM Signal
Output Pin KOEO DTC
TCC
a
82 07 43
a TCC = To r que Co n v e r t e r Cl u t c h So l e n o i d
TEST PIN 82 0 -
TEST PIN 71/97R|
4.6L TEST PIN 71/97 -R
TRANSMISSION
VEHICLE HARNESS
CONNECTOR
-TCC-
FROM PCM
POWER RELAY
-TCC VPWR
D14118-A
PINPOINT TEST C: TORQUE CONVERTER CLUTCH (TCC) SOLENOID
C1 ELECTRONIC DIAGNOSTICS
Yes
No
DTM. GO to C2.
PRESS throttle and
refer to the Powertrain
Control/Emi ssi ons
Diagnosis Manual
3 0
.
Check to make sure the transmission harness
proceedi ng.
Enter Output State Diagnostic Test Mode (DTM).
Refer to Special Test Modes as outlined.
# Perform KOEO test until continuous DTCs have been
di splayed.
Press throttle to WOT and release.
m t he vehi cl e enter Out put St at e DTM?
Yes
No
DTM. GO to C2.
PRESS throttle and
refer to the Powertrain
Control/Emi ssi ons
Diagnosis Manual
3 0
.
PINPOINT TEST C: TORQUE CONVERTER CLUTCH (TCC) SOLENOID (Cont i nued)
C2 CHECK ELECTRICAL SIGNAL OPERATION
Yes
No
GO t o C5.
GO to C3.
NOTE: Refer to t he schematic and chart precedi ng
thi s Pinpoint Test.
Connect a VOM positive lead t o VPWR and the
negative t est lead to the solenoid ci rcui t of the
transmission vehi cle harness connector.
While observing VOM, press and release t hrot t le to
cycle solenoid output ON and OFF.
Does t he suspect sol enoi d out put vol t age
change at l east 0.5 vol t ?
Yes
No
GO t o C5.
GO to C3.
C3 CHECK CONTINUITY OF SOLENOID SIGNAL AND
Yes
No
GO to 04.
SERVICE open ci rcui t s.
RECONNECT all
components. REPEAT
Quick Tests.
Turn ignition swi t ch to the OFF posi t i on.
di sconnect ed.
Disconnect powertrain control module, inspect for
wi res.
equivalent, leaving powertrain control module
di sconnect ed.
NOTE: Refer to the schematic and chart preceding
t hi s Pinpoint Test.
at the breakout box and the signal pin at the
Measure resi stance between PCM signal t est Pins
71 and 97 at breakout box and t he signal pin at the
Yes
No
GO to 04.
SERVICE open ci rcui t s.
RECONNECT all
components. REPEAT
Quick Tests.
C4 CHECK SOLENOID HARNESS FOR SHORTS TO
POWER AND GROUND
Yes
No
GO to C7.
RECONNECT all
components. REPEAT
Quick Tests.
module di sconnect ed.
di sconnect ed.
NOTE: Refer to schemati c and chart precedi ng this
Pinpoint Test.
Measure resi stance between PCM signal output
pins and t est Pins 71 and 97 at breakout box.
Measure resi stance between t est Pins 51, 76, 77,
103 and 91 at breakout box and chassi s ground.
Is each resi st ance great er t han 10, 000 ohms?
Yes
No
GO to C7.
RECONNECT all
components. REPEAT
Quick Tests.
07 - 01- 86 T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W
07 - 01- 86
PINPOINT TEST C: TORQUE CONVERTER CLUTCH (TCC) SOLENOID (Continued)
C5 TRANSMISSION FUNCTIONAL TEST
Yes
No
GO to C6.
GO to 07.
Disconnect vehicle harness at transmi ssi on.
CAUTION: Do not pry connect or . Thi s wi l l
t ransmi ssi on c onc e r n. Press t he t ab and pull on
vehi cl e harness connect or.
Using t est s outlined under Tester Instructions,
perform torque converter clutch solenoid function
t est .
NOTE: LED will turn GREEN when torque converter
clutch solenoid acti vates and turn OFF when
deact i vat ed. LED will turn RED if an ACTIVATED
sol enoi d/harness is shorted to battery posi ti ve.
LED will remain off if an ACTIVATED
sol enoi d/harness is shorted to ground or no
continuity (open ci rcui t).
Does MCCC (LED GREEN) act i vat e when t est er
swi t ch i s pressed?
Yes
No
GO to C6.
GO to 07.
C6 TRANSMISSION DRIVE TEST
Yes
No
REPLACE PCM.
GO to C7.
Perform Transmission Drive Test as outlined under
testi ng instructions.
While in second gear press the MCCC swi t ch.
Does t he t or que conver t er cl ut ch sol enoi d
act i vat e (LED GREEN)?
Does t he engi ne rpm dr op?
Yes
No
REPLACE PCM.
GO to C7.
C7 CHECK RESISTANCE OF SOLENOID/HARNESS
Yes
No
GO to C8.
GO to C9.
NOTE: Internal harness or
torque converter clutch
solenoid may be
damaged.
NOTE: Refer to Transmission Tester for terminal
locati ons.
Set Bench / Drive swi tch to BENCH mode.
Rotate Gear Select swi tch to OHMS CHECK
posi ti on.
Connect ohmmeter negative lead to MCCC j ack and
posi ti ve lead to VPWR on tester.
This is to test torque converter clutch solenoi d.
Record resi stance.
Yes
No
GO to C8.
GO to C9.
NOTE: Internal harness or
torque converter clutch
solenoid may be
damaged.
PINPOINT TE ST C: TORQUE CONVERTER CLUTCH (TCC) SOLENOID (Continued)
C8 CHECK SOLENOID/HARNESS FOR SHORT TO
GROUND
ground) and appropri ate j ack wi th an ohmmeter or
other low current t est er (less than 200 milliamps).
TCC MCCC
Yes
No

GO to C9.
Symptom Routines.
Connection should infinite resi stance (no
continuity).
MCCC
P
' ACTIVATE

CONNECT OHMMETER,
BETWEEN EACH OF
THE TCC JACKS
AND BAT (-) JACK
SHI FT SOLENOI DS
STATUS
O r GREEN i r ^ F i ro F F "
VPWR
OFFI PO T FHI QRE E N
GEAR SELECT -
D12038-B
C9 INTERNAL ELECTRONIC DIAGNOSTICS
engaged on t he torque converter clutch solenoid
assembly.
fully seat ed in the connector.
Are above i n good c ondi t i on and engaged
pr oper l y ?
Yes
No
GO t o C10.
PINPOINT TEST C: TORQUE CONVERTER CLUTCH (TCC) SOLENOID (Cont i nued)
1
C10 CHECK INTERNAL HARNESS (CONTINUITY)
Disconnect internal harness from torque converter
clutch solenoid assembly (TCC wire connector).
CAUTION: Do not probe i nt o connect or
t ermi nal s. Thi s wi l l damage t he connect or and
coul d resul t in a t ransmi ssi on c onc e r n.
Connect positive lead from an ohmmeter to tester
MCCC j ack and the negative lead at the green wire
of the TCC connector.
0.5 ohm.
tester VPWR j ack and the negative lead to the
whi t e/green wire of the TCC connector.
0.5 ohm.
Is resi st ance less t han 0.5 ohm?
Yes
No

GO t o C11.
REPLACE internal
harness. GO to C12.
C11 CHECK INTERNAL HARNESS (SHORTS TO GROUND)
Check for continuity between BAT- jack (engine
or other low current t est er (less than 200 milliamps).
Yes
No
S o l e n o i d Wi r e
TCC Gr e e n
Wh i t e / G r e e n
continuity).

REPLACE internal
harness. GO to C12.
GOt o C12.
C12 CHECK SOLENOID RESISTANCE
For TCC, check solenoid resistance by connecting
an ohmmeter to the terminals of the torque
converter clutch solenoid assembly.
Record resi stance.
Yes
No

GOt o C13.
REPLACE torque
converter clutch solenoid
assembly.
C13 CHECK SOLENOID FOR SHORT TO GROUND
ground) and appropri ate solenoid terminals with
ohmmeter or other low current tester (less than 200
milliamps).
Yes
No
S o l e n o i d T e r mi n a l
TCC
continuity).
REPLACE torque
converter clutch solenoid
assembly.
Symptom Routines.
- T r a n s mi s s i o n Ra n g e ( TR) P i n p o i n t T e s t D-
S e n s o r
DTCs: P0707 TR Sensor or Circuit Short ed
P0708 TR Sensor or Circuit Open
P1705 TR Sensor Not Indicating Park During KOEO
Thi s Pinpoint Test is intended t o di agnose the
Transmi ssi on Range (TR) Sensor el ectri cal syst em
ONLY. To prevent repl acement of good components,
be awar e t hat the following areas may be at fault:
Engine
Starter, Starter Relay
El ectri cal
Battery, Ignition Swi t ch, Wi ri ng Harnesses
@ Transmission
Internal Transmission Components, Li nkages
components:
Transmission Wi ri ng Harness, TR Sensor, Signal
Return
Powertrai n Control Modul e
Starter Ci rcui ts, Backup Circuit
Pin
3 140
( B K / P K )
Ba c k- u p L a mp
4 3 3 ( W/ P K ) St a r t e r Co n t r o l t o Co n t r o l Mo d u l e
5 No t Us e d '
6 199 ( L B / Y ) T r a n s mi s s i o n Ra n ge (TR) Se n s o r
t o PCM
7 359
( G Y/ R )
Se n s o r Si gn a l Re t u r n
8 No t Us e d
SENSOR CONNECTOR
Tr a n smi ssi o n Se n so r Co n n e c t o r
K21039-B
32 (R/LB) 298 (W/LB) 199 (LB/Y)
N D
mMmm
P 1
33 (W/PK) 140 (BK/PK) 359 (GY/R)
D12040-A
TRANSMISSION RANGE SENSOR TESTING PROCEDURE
Connect
Sel f -Power ed
Test Lamp or
Ohmmet er t o
To Test Termi nal s Move Swi t c h t o These Posi t i ons A Good Swi t c h Wi l l I n d i c a t
Tr a n s mi s s i o n Ci r c u i t s 359 ( G Y/ R) P a r k 37 7 0- 4507 o h ms
Re v e r s e 1304- 1593 o h ms
a n d Ne u t r a l 660- 807 o h ms
Ov e r d r i v e 361- 442 o h ms
199 ( L B / Y) S e c o n d ( 2 ) 190- 232 o h ms
Fi r s t ( 1) 7 8- 95 o h ms
Ba c k u p L a mp Ci r c ui t 2 94 ( W/ L B ) P a r k Gr e a t e r t ha n 100K o h ms
Re v e r s e Gr e a t e r t h a n 100K o h ms
a n d Ne ut r a l Gr e a t e r t h a n 100K o h ms
Ov e r d r i v e Gr e a t e r t ha n 100K o h ms
140 ( B K / P K ) S e c o n d ( 2 ) L e s s t ha n 5 o h ms
Fi r s t ( 1) Gr e a t e r t h a n 100K o h ms
St a r t e r Relay Ci r c ui t 33 ( W/ P K ) Pa r k L e s s t ha n 5 o h ms
07- 01- 90
T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W 07- 01- 90
TRANSMISSION RANGE SENSOR TESTI NG PROCEDURE (Cont ' d)
T o T e s t
Connect
Self-Powered
Test L a m p o r
Ohmmeter to
T e r mi n a l s Move S w i t c h to These P o s i t i o n s A G o o d S w i t c h Wi l l I n d i c a t e
Re v e r s e Gr e a t e r t h a n 100K o h ms
a n d Ne ut r a l L e s s t ha n 5 o h ms
Ov e r d r i v e Gr e a t e r t h a n 100K o h ms
3 2 ( R / L B ) S e c o n d ( 2) Gr e a t e r t h a n 100K o h ms
Fi r st ( 1) Gr e a t e r t h a n 1 0 0 K o h ms
TR/ MLP Test er 007- 00086
T R A N S M I S S I O N T E S T E R
9
9
( o O O / / TR/MLP SENSORS ]
PARK/NEUTRAL
LEO Q H 3 IN
PARK OR
J * * STATUS
o
HOLD TO TEST
BACKUP LAMPS
LED fREDI IN
REVERSE
ONLY
HOLD TO TEST
O
STATUS

ADDITIONAL
jaaupiEuml ^
Axooel 400 STATUS
AX4S I AODE
AX4N 1 4R70W
C04I
HOLD TO TEST

SWITCH TEST
FOR EACH SWITCH TEST:
PRESS AND HOLD EACH SWITCH BUTTON WHILE SHIFTING GEAR
SELECTOR TO ALL GEAR POSITIONS:
LED FOR THE ACTIVE TEST SHOULD LIGHT HREff! ONLYPOH THE
INDICATED GEAR POSITION.
IF LED FAILS TO LIGHT FOR THAT GEAR POSITION OR IF IT LIGHTS
FOR A DIFFERENT GEAR POSITION:
VERIFY TR/MLP ALIGNMENT PER SHOP MANUAL, AND
RETEST
I t NOT
USED
SENSOR TEST
CONNECT OHMMETER TO TR/MLP AND SIG RTN JACKS.
RECORD RESISTANCES IN EACH GEAR POSITION WHILE
SHIFTING GEAR SELECTOR TO ALL POSITIONS.
REFER TO TABLE.
IF VALUES ARE OUT OF RANGE, REFER TO SHOP MANUAL
BEFORE ATTACHING
OVERLAY 8ET SWITCH
IN DOWN POSITION.

o
TR/MLP SENSOR TEST
NOT
USED

TR/MLP
GEAR SELECTOR
POSITION
PARK
RESISTANCE O
MIN MAX
3770 4607
MANUAL LEVER POSITION
o o
TR/MLP SIG RTN
REVERSE 1304 1593 MANUAL LEVER POSITION
o o
TR/MLP SIG RTN
NEUTRAL 660 807
o o
TR/MLP SIG RTN
OVERDRIVE * 361 442
o o
TR/MLP SIG RTN
SECOND/DRIVE f 190 232
o o
TR/MLP SIG RTN
FIRST 78 fS
#, f MFER TO SHOP MANUAL
D14049-A
07- 01- 91 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 0 7 - 0 1 - 9 1
PINPOINT TE ST D: TRANSMISSION RANGE (TR) SENSOR
Dt TR SENSOR ELECTRONIC DIAGNOSTICS
Yes
No
REMOVE t ool. GOt o D2.
ADJUST sensor as
outlined under
Transmission Assembly.
After adj ustments,
PLACE transmission
range selector lever in
PARK. CLEAR DTC and
REPEAT Quick-Test.
Check to make sure TR sensor harness connector is
fully seat ed, terminals are fully engaged in
connector and in good condition before proceedi ng.
Verify shift linkage adj ustment in the OVERDRIVE
posi ti on.
Apply parking brake.
Place transmission in NEUTRAL.
Verify that Transmission Range (TR) Sensor (Manual
Lever Position Sensor) Alignment Tool
T93P-70010-A or equivalent fi ts in the appropri ate
sl ot s.
Is t he sensor pr oper l y adj ust ed?
Yes
No
REMOVE t ool. GOt o D2.
ADJUST sensor as
outlined under
Transmission Assembly.
After adj ustments,
PLACE transmission
range selector lever in
PARK. CLEAR DTC and
REPEAT Quick-Test.
D2 CHECK ELECTRICAL SIGNAL OPERATION
Yes
No
GOt o D3.
Cont rol/Emi ssi ons
Diagnosis Manual
3 1
for
diagnosis of NO
Reference Voltage.
CAUTION: DO NOT pry on connect or . Thi s wi l l
t ransmi ssi on c o n c e r n . Pull up on vehi cl e harness
connect or .
wires and missing or damaged seals.
NOTE: Refer to the schemati c and chart preceding
Connect a VOM positive test lead to TFT circuit and
negative test lead to Signal Return (SIG RTN) circuit
of transmission harness connector.
Turn ignition swi tch to the ON posi ti on, engine OFF.
Yes
No
GOt o D3.
Diagnosis Manual
3 1
for
diagnosis of NO
Reference Voltage.
D3 CHECK CONTINUITY OF TR SENSOR HARNESS
CIRCUITS
Yes
No
GO to D4.
SERVICE open ci rcui t (s).
RECONNECT all
components. ERASE
codes. REPEAT Quick
Test.
CAUTION: Do not pry connect or . Thi s wi l l
damage t he connect or and coul d resul t in a
transmi ssi on c o n c e r n . Press but t on and pull up
on vehi cl e harness.
Disconnect TR sensor.
Inspect for damage or pushed out pins, corrosi on or
loose wi res.
equivalent. Leave PCM di sconnect ed.
damaged or pushed out pi ns, corrosi on or loose
wi res.
NOTE: Refer to the schemat i cs and chart s
precedi ng thi s Pinpoint Test.
Measure resistance between PCM t est Pin 91 at
breakout box and SIG RTN circuit at TR sensor
vehi cle harness connector.
Measure resistance between PCM test Pin 64 at
breakout box and TR signal circuit at TR sensor
vehi cle harness connector.
Is each resi st ance l ess than 5 ohms?
Yes
No
GO to D4.
RECONNECT all
components. ERASE
codes. REPEAT Quick
Test.
07 - 01=92
07 - 01- 92
PINPOINT TEST D: TRANSMISSION RANGE (TR) SENSOR (Continued)
04 CHECK TR SENSOR CIRCUIT FOR SHORTS TO POWER
AND GROUND
equivalent is installed and PCM di sconnected.
Ensure TR sensor harness connector is
di sconnected.
NOTE: Refer to schemati cs and charts preceding
this pinpoint test.
Measure resi stance between PCM test Pins 64, 71,
97 , 51, 76, 77, 103 a n d 91.
Measure resi stance between PCM test Pin 30 at
breakout box and chassi s ground.
Yes
No

GO to D5.
SERVICE short circuit.
RECONNECT all
components. ERASE
codes. REPEAT Quick
Test.
D5 CHECK OPERATION OF TR SENSOR
Disconnect TR sensor harness connector at the
transmission.
Connect Rotunda Transmission Tester 007-0085C
with Transmission Range (TR) Sensor Cable (MLPS
Cable) 007-00086 or equivalent to TR sensor.
Using procedures provided with tester, verify TR
sensor functions in all posi ti ons.
Check continuity and resi stance in all positions.
Check run/st art , backup lamps and optional swi tch
functions.
TR SENSOR RESISTANCE RANGE
Yes
Ra n g e
S e l e c t o r L e v e r
P o s i t i o n
R e s i s t a n c e
( o h ms )
Ra n g e
Vo l t s
Ra n g e
S e l e c t o r L e v e r
P o s i t i o n Mi n Ma x
Ra n g e
Vo l t s
P 37 7 0 4607 3. 97 - 4. 85
R 1304 1593 3. 2 4- 3. 96
N 6 6 0 807 2 . 55- 3. 11
OD 361 442 1. 88-2. 30
2 190 2 32 1. 23-1. 51
1 7 8 95 0. 61- 0. 7 5
No
Concern not in TR sensor.
If you were di rected here
from Diagnosis by
Symptom, RETURN to
routine. If you were
di rected here diagnosing
a DTC, GO t o the
Powertrain
Control/Emi ssi ons
Diagnosis Manual
3 2
to
diagnose intermittent
operation.
REPLACE TR sensor and
ADJUST. REFER to
transmission assembly
sect i on. ERASE codes
and REPEAT Quick Test.
P i n p o i n t T e s t E E l e c t r o n i c P r e s s u r e C o n t r o l
( EPC) S o l e n o i d
DTCs: P1747 EPC Ci rcui t Fai lure
P17 46 EPC Dri ver Ci rcui t Open in PCM
Thi s pi npoi nt t e st is i nt ended t o di agnose t he EPC
sol enoi d el ect ri cal sy st e m ONLY. To prevent
repl acement of good component s, be a wa r e t hat t he
f ol l owi ng a r e a s may be at f aul t :
Engi ne
Perf ormance
El ect ri cal
Bat t er y, Input Sensors, Wi ri ng Harnesses
Transmi ssi on
Internal Transmi ssi on Component s, Cooli ng
This pinpoint t est is intended t o di agnose the following
components:
Transmission Wiring Harness, EPC, EPC VPWR
S o l e n o i d
P CM
S i g n a l
O u t p u t P i n K O E O DT C
E P C
a
81 P 17 46, P 17 47
a EPC = E l e c t r o n i c P r e s s u r e Co n t r o l So l e n o i d
FROM PCM
POWER RELAY
EPC VPWR-
- TEST PIN 71/97
- O TEST PIN 81
TRANSMISSION
VEHICLE HARNESS
CONNECTOR
EPC VPWR
EPC
BLUE
WHITE/BLUE STRIPE
VPWR (EPC)
EPC
D14119-A
PINPOINT TEST E: ELECTRONIC PRESSURE CONTROL (EPC) SOLENOID
E1 CHECK VPWR TO SOLENOID
Check to make sure transmission harness
engaged and in good condition before proceedi ng.
Turn ignition swi t ch to the OFF position.
CAUTION: Do not pry on connect or . Thi s wi l l
damage t he c onne c t or and coul d resul t i n a
t r ansmi ssi on c o n c e r n . Press but t on and pull up
on vehi cl e harness.
NOTE: Refer to t he schemati c and charts preceding
Turn ignition swi t ch to RUN, engine OFF.
Measure the voltage between EPC VPWR circuit at
transmission harness connector and
chassi s/ bat t er y ground.
m Is vol t age gr eat er t han 10.5 vol t s?
Yes
No

GOt o E2.
SERVICE open in the
harness. RECONNECT all
components. ERASE
codes. REPEAT Quick
Test.
PINPOINT TEST E: ELECTRONIC PRESSURE CONTROL (EPC) SOLENOID (Cont i nued)
E2 CHECK CONTINUITY OF SOLENOID SIGNAL AND
Yes
No
GO to E3.
RECONNECT all
components. ERASE
codes and REPEAT
On-Board Diagnostic
Tests.
Disconnect Powertrain Control Module (PCM).
Inspect for damaged or pushed out pins, corrosi on
or loose wi res.
equivalent. Leave PCM di sconnected.
NOTE: Refer t o the schematic and charts precedi ng
Measure resistance between PCM t est Pins 71 and
97 at breakout box and EPC PWR circuit at
Measure resistance between PCM test Pin 81 at
breakout box and EPC signal pin at transmission
harness connector.
Yes
No
GO to E3.
RECONNECT all
components. ERASE
codes and REPEAT
On-Board Diagnostic
Tests.
E3 CHECK HARNESS FOR SHORT TO POWER AND
GROUND
Yes
No
GO to E4.
RECONNECT all
components. ERASE
codes and REPEAT
On-Board Diagnostic
Tests.
equivalent is installed, PCM is di sconnect ed.
Ensure transmission connector is di sconnected.
NOTE: Refer t o the schematic and charts precedi ng
Measure resistance between EPC circuit PCM test
Pin 81 and Pins 71 and 97 at breakout box.
Measure resistance between EPC circuit PCM test
Pi ns81, 51, 76, 77, 103 and 91 at breakout box.
Yes
No
GO to E4.
RECONNECT all
components. ERASE
codes and REPEAT
On-Board Diagnostic
Tests.
E4 TRANSMISSION FUNCTIONAL TEST
Yes
No
REPLACE powertrain
control module.
GO to E5.
Disconnect vehicle harness at transmi ssi on.
CAUTION: Do not at t empt t o pry t he connect or .
Thi s wi l l damage t he c onne c t or and coul d resul t
i n a t ransmi ssi on c o n c e r n . Depress t ab and pull
up on harness connect or .
Install line pressure gauge at line tap on case.
equivalent t o transmission connector.
Set Bench/ Drive swi tch to DRIVE mode.
Rotate Gear Select swi tch to first gear posi ti on.
Using t est s outlined under Transmisison Tester
Instructions, perform the Transmission Solenoids
and Sensors Resistance Tests.
NOTE: LED will turn GREEN when EPC solenoid
act i vat es and turn OFF when deact i vat ed. LED will
turn RED if an ACTIVATED sol enoi d/harness is
shorted to battery positive voltage (B+). LED will
remain off if an ACTIVATED sol enoi d/harness is
shorted to ground or no continuity (open ci rcui t ).
Does t he EPC (GREEN LED) act i vat e when
EPC swi t c h is pressed?
Observe line pressure on the gauge while
pressing EPC swi tch (engine must be running).
Does t he li ne pressure dr op?
Yes
No
REPLACE powertrain
control module.
GO to E5.
07 - 01- 95 T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W 0 7 - 0 1 - 9 5
I zr-r 1 a . A. X ~ Ji Z r .* A. & Z- - - . A . T T X A. - A .-. - A-:.^^SZ3
E5 CHECK RESISTANCE OF SOLENOID/HARNESS
Yes
No
GOt o E6.
GOt o E7 .
NOTE: Out of
speci f i cat i on may be
caused by internal
harness or EPC solenoi d
concerns.
locati ons.
Set Bench / Drive switch to BENCH mode.
Rotate Gear Select switch to OHMS CHECK
posi ti on.
Connect ohmmeter negative lead to VPWR jack and
positive lead to EPC j ack on tester. This is t o t est
EPC solenoi d.
Record resi stance.
Resistance should be between 2.48 and 5.66 ohms.
i s resi st ance bet ween 2. 48 and 5.66 ohms?
Yes
No
GOt o E6.
GOt o E7 .
NOTE: Out of
speci f i cat i on may be
caused by internal
harness or EPC solenoi d
concerns.
07 - 01- 96
07 - 01- 96
E6 CHECK SOLENOID/HARNESS FOR SHORT TO
GROUND
ground) and appropri ate j ack with an ohmmeter or
Yes
No

GO t oE7.
Symptom Routines.
S o l e n o i d T e s t e r J a c k
EPC EPC
VP WR
continuity).
AODE
EPC
Ck o
VPWR ^STATUS
O
EPC
CONNECT
OHMMETER
BETWEEN EACH
EPC JACK AND
)BAT (-) JACK
2 3 4
OFF
II OFF II GREEN
OFF II GREEN
IIIdil iMU
GEAR SELECT
* NOT USED J
EXT POWER
o o
SAT + i A T -
D12042-A
07 - 01- 97
0 7 - 0 1 - 9 7
E7 INTERNAL ELECTRONIC DIAGNOSTICS
engaged on EPC solenoid assembly.
fully seated in connector.
Inspect connector for damage.
Ar e above pr oper l y engaged and in good
c ondi t i on?
Yes
No

GOt o E8.
E8 CHECK INTERNAL HARNESS (CONTINUITY)
Disconnect internal harness from EPC solenoid
assembly.
t est er EPC j ack and the negative lead at the blue
wire at the EPC wire connector.
0.5 ohm.
Connect the positive lead from an ohmmeter t o the
t est er VPWR j ack and the negative lead at the
whi t e/bl ue wire at the EPC wire connector.
0.5 ohm.
Is resi st ance less t han 0.5 ohm?
Yes
No

GO to E9.
REPLACE internal
harness. GO to E10.
E9 CHECK INTERNAL HARNESS (SHORTS TO GROUND)
or other low current tester (less than 200 milliamps).
Yes
No

REPLACE internal
harness. GO to E10.
GO to E10.
Sol enoi d Wi re
EPC Bl ue ( Si gn a l )
Wh i t e / B l u e ( EPC VP WR)
continuity).
Is t her e cont i nui t y ?
E10 CHECK SOLENOID RESISTANCE
Check solenoid resi stance by connecting an
ohmmeter at the EPC solenoid terminals of the
solenoi d.
Record resi stance.
Resistance should be between 2.48 and 5.66 ohms.
Is resi st ance be t we e n 2. 48 and 5. 66 ohms?
Yes
No

GOt o E 11.
REPLACE EPC solenoi d.
E11 CHECK SOLENOID FOR SHORT TO GROUND
ground) and appropri ate terminal with ohmmeter or
Yes
No

REPLACE EPC solenoi d.
Symptom Routines.
Sol e noi d Termi nal
E P C + /-
conti nui ty).
P i n p o i n t T e s t F O u t p u t S h a f t S p e e d ( OSS) Thi s Pinpoint Test is i nt ended t o di agnose t he OSS
S e n s o r sensor el ect ri cal sy st e m ONLY. To prevent
n j r
. repl acement of good component s, be awar e t hat t he
o s
' f ol l owi ng areas may be at f ault :
P07 20 Insuf f i ci ent Input f or Out put Shaf t Speed
Sensor
El ectri cal
Bat t ery, Input Sensors, Wiring Harnesses
Transmission
Internal Transmi ssi on Components
components:
Transmission Wi ri ng Harness, OSS, SIGNAL
RETURN
OUTPUT SHAFT
SPEED SENSOR
(OSS) VEHICLE
HARNESS CONNECTOR
TEST PIN 84-
TEST PIN 240-
-OSS+
-SIG RTN
*TEST PINS LOCATED ON BREAKOUT BOX.
ALL HARNESS CONNECTORS VIEWED INTO
MATING SURFACE.
D14120-A
PINPOINT TEST F: OUTPUT SHAFT SPEED (OSS) SENSOR
F1 ELECTRONIC DIAGNOSTICS
Yes
No
GOt o F2 .
PERFORM the checks.
ERASE codes. RERUN
On-Board Diagnostic
Tests.
Check that the output shaft speed sensor connector
is fully seat ed, terminals are fully engaged in the
connector and in good condition.
Have t he i t ems above been c he c ke d?
Yes
No
GOt o F2 .
PERFORM the checks.
ERASE codes. RERUN
On-Board Diagnostic
Tests.
F2 CHECK CONTINUITY OF OSS HARNESS CIRCUITS
Yes
No
GO to F3.
SERVICE open ci rcui t(s).
RECONNECT all
components. ERASE
codes. RERUN On-Board
Diagnostic Tests.
Disconnect OSS.
CAUTION: Do not pry on connect or . Thi s wi l l
damage t he c onne c t or and coul d resul t i n a
t r ansmi ssi on c onc e r n. Pull up on vehi cl e
harness.
damaged or pushed out pins, corrosion or loose
wi res.
equivalent, leaving powertrain control module
di sconnect ed.
NOTE: Refer to schemati cs and charts preceding
breakout box and OSS(+) signal circuit at the OSS
harness connector.
breakout box and OSS(-) signal circuit at the OSS
harness connector.
Yes
No
GO to F3.
SERVICE open ci rcui t(s).
RECONNECT all
components. ERASE
codes. RERUN On-Board
Diagnostic Tests.
F3 CHECK OSS CIRCUITS FOR SHORT TO POWER AND
GROUND
Yes
No
GO to F4.
SERVICE short ci rcui t(s).
RECONNECT all
components. ERASE
codes and RERUN
On-Board Diagnostic
t est s.
OSS di sconnected.
Breakout box i nstalled, PCM di sconnected.
Measure resi stance between PCM test Pins 84, 24
and test Pins 71 and 97 at breakout box.
Measure resi stance between PCM test Pins 84, 24,
71, 97, 51, 76, 77 and 103 at breakout box.
Yes
No
GO to F4.
SERVICE short ci rcui t(s).
RECONNECT all
components. ERASE
codes and RERUN
On-Board Diagnostic
t est s.
07 - 01- 99 T r a n s mi s s i o n , A u t o ma t i c - - 4R7 0W 07 - 01- 99
PINPOINT TEST F: OUTPUT SHAFT SPEED (OSS) SENSOR (Continued)
F4 TRANSMISSION FUNCTIONAL TEST
Disconnect vehicle harness at OSS sensor.
CAUTION: Do not at t empt t o pry on t he
connect or . This wi l l damage t he c onne c t or and
coul d resul t in a t r ansmi ssi on c o n c e r n . Pull on
harness connect or .
equivalent onto output shaft speed sensor.
Connect voltmeter positive lead to +OSS and t he
negative lead to -OSS. Set voltmeter to AC.
Perform OSS Function Test. Monitor voltmeter.
Does t he vol t age i ncrease wi t h an i ncrease in
vehi cl e speed?
Yes
No

REPLACE PCM.
GO t o F5.
F5 CHECK RESISTANCE OF OUTPUT SHAFT SPEED
SENSOR
locati ons.
Connect ohmmeter negative lead to +OSS j ack and
positive lead to -OSS j ack on tester. This is to t est
OSS sensor.
Record resi stance. Resistance should be between
450 and 750 ohms.
Yes
No

GO to F6.
REPLACE OSS sensor.
RERUN OSS Function
Test.
F6 CHECK SENSOR FOR SHORT TO GROUND
ground) and appropri ate j ack with an ohmmeter or
OSS +0SS
- o ss
Yes
No
REPLACE OSS sensor.
RERUN OSS Function
Test.
GO t o F7 .
continuity).
OSS
o o
TOT
o o
EXT POWER
o o
BAT + - . BA T* *
CONNECT OHMMETER
BETWEEN EACH OSS
JACK AND BAT(-) JACK D12G44-A
F7 CHECK OSS MAGNETISM
Remove OSS sensor from transmission.
Place OSS sensor against a metal surface to which
a magnet would st i ck. The OSS sensor should be
magnetized and st i ck to the metal surface.
Does OSS st i c k?
Yes
No
GO t o F8.
REPLACE OSS sensor.
RERUN OSS Function
Test.
PINPOINT TEST F: OUTPUT SHAFT SPEED (OSS) SENSOR (Cont i nued)
F8 CHECK OUTPUT SHAFT RING GEAR
Yes
No >
REPLACE OSS sensor.
RERUN OSS Function
Test.
REFER to Disassembly
and Assembly to service
output shaft ring gear.
SERVICE or REPLACE as
required.
With OSS sensor removed and transmission in
NEUTRAL, rotate driveshaft and observe through
the OSS sensor hole in case that all six holes or
indentations in the ring gear are present and free of
foreign material.
Are hol es present and f ree of f or ei gn mat eri al ?
Yes
No >
REPLACE OSS sensor.
RERUN OSS Function
Test.
REFER to Disassembly
and Assembly to service
output shaft ring gear.
SERVICE or REPLACE as
required.
E n g i n e I d l e S p e e d C h e c k
Ref er t o t he Powert rai n Cont rol / Emi ssi ons Di agnosi s
Ma n u a l
3 3
f or t he appr opr i at e pr ocedur e.
L i n e P r e s s u r e T e s t
Thi s t est veri f i es t hat t he line pr essur e is wi t hi n
speci f i cat i on.
1. Connect pr essur e gauge t o line pr essur e t a p.
LINE PRESSURE
TAP
D12119-A
2. St ar t engi ne and c he c k line pr essur es. Ref er t o
Ot her Concern: Pressure Ref erence Char t 401
under Di agnosi s by Sy mpt om Rout i nes t o
det ermi ne if line pressure is wi t hi n speci f i cat i on.
CAUTI ON: P e r f o r m l i n e p r e s s u r e t e s t pr i o r t o
p e r f o r mi n g st a l l s p e e d t e s t . If l i n e p r e s s u r e i s l o w
a t s t a l l , d o n o t p e r f o r m st a l l s p e e d t e s t o r f u r t h e r
t r a n s mi s s i o n d a ma g e wi l l o c c u r . DO NOT
MAI NTAI N WOT i n a n y t r a n s mi s s i o n r a n ge FOR
MORE THAN FI E SECONDS.
CAUTI ON: T r a n s mi s s i o n t e s t e r MUST BE
REMOVED f r o m t h e t r a n s mi s s i o n a n d t h e v e h i c l e
h a r n e s s r e i n s t a l l e d t o v e r i f y t h e s e p r e s s u r e s .
I mp r o p e r p r e s s u r e r e a d i n gs ma y l e a d t o i mp r o p e r
p a r t s r e p l a c e me n t o r i n t e r n a l d a ma g e .
3. If line pr essur e is not wi t hi n speci f i cat i on, c he c k
EPC pr essur e.
4. Connect pressure gauge t o EPC pressure t a p.
EPC
TAP
(MIDDLE)
D12120-A
5. Rest art engi ne and c he c k EPC pressure. Ref er t o
Ot her Concern: Pressure Ref erence Chart 401
under Di agnosi s by Sy mpt om Rout i nes f or
6. If EPC pressure is not wi t hi n speci f i cat i on,
per f or m Pinpoint Test E t o di agnose EPC
operat i on. If EPC operat i on is OK, ref er t o Li ne
Pressure Test Chart f or line pr essur e concer n
causes.
07- 01- 101 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 0 7 - 0 1 - 1 0 1
Li ne Pr e ssur e Test Char t
LINE PRESSURE TEST
LOW AT IDLE
IN ALL POSITIONS
CHECK LOW FLUID LEVEL, RESTRICTED INLET FILTER,
LOOSE MAIN BODY, CASE BOLTS, EXCESSIVE LEAKAGE
IN PUMP, CASE, CONTROL BODIES, STICKING MAIN
REGULATOR VALVE, DAMAGED INLET TUBE SEAL ON INLET
FILTER, DAMAGED GASKETS OR SEPARATOR PLATE.
HIGH AT IDLE
IN ALL POSITIONS
I
CHECK MAIN REGULATOR VALVE, EPC SOLENOID
AND WIRING HARNESS. RUN QUICK TEST REFERRED
TO IN ELECTRICAL DIAGNOSIS IN THIS SECTION.
LINE PRESSURE TEST
LOW ONLY IN
VALVE BODY
LOW REVERSE
SERVO
SEPARATOR
PLATE,
LOW/REVERSE
SERVO OR
VALVE BODIES,
REVERSE
CLUTCH
FORWARD
CLUTCH, VALVE
BODY
FORWARD
CLUTCH,
INTERMEDIATE
CLUTCH, VALVE
BODIES
FORWARD
CLUTCH,
LOW/REVERSE
SERVO OR
VALVE BODY
D12728-A
S t a l l S p e e d T e s t
The st al l spe e d t est c he c ks t orque conver t er cl ut ch
oper at i on and i nst al l at i on, t he holdi ng abi l i t y of t he
f o r wa r d cl ut ch, reverse cl ut ch (t he l ow-r ever se
bands), t he pl anet ary one-way cl ut ch, and engi ne
per f or mance.
Conduct t hi s t est wi t h t he engi ne cool ant and
t ransmi ssi on flui d at proper levels and at normal
Appl y t he servi ce and parki ng br ake cont rol ( 27 80)
f i rml y f or e a c h st al l spe e d t est .
1. Fi nd t he speci f i ed st al l rpm f or t he vehi cl e by
ref erri ng t o Speci f i cat i ons. Use a gr ease penci l t o
ma r k t he r pm on t he di al of a t achomet er .
STALL SPEED
E n g i n e rpm
4. 6L Cr o wn Vi c t o r i a a n d Gr a n d Ma r q u i s 2 001- 2 330
4. 6L P o l i c e 2 007 - 2 358
4. 6L To wn Ca r 2 035- 2 380
2. Connect t a c home t e r t o engi ne.
3. NOTE: If t he r pm r e c or de d by t he t a c home t e r
e xc e e ds t he maxi mum li mi ts gi ven in
Speci f i cat i ons, rel ease t he accel er at or pedal
i mmedi at el y because cl ut ch or band sl i ppage is
i ndi cat ed.
In each of t he f ol l owi ng ranges: , 2 , 1 , R, pr ess
t he accel er at or pedal t o t he f l oor and hol d it j ust
long enough t o let t he engi ne get t o wi de
open-t hrot t l e. Whi l e maki ng t hi s t est , do not hol d
t he t hr ot t l e open f or more t han f i ve seconds at a
t i me.
4. Not e t he resul t s in e a c h range.
5. Af t er e a c h range, move t he sel ect or l ever t o
NEUTRAL and run t he engi ne at 1000 r pm f or
about 15 se c onds t o cool t he t or que conver t er
( 7902) bef or e maki ng t he next t e st .
6. Refer t o t he f ol l owi ng char t f or c or r e c t i ve act i ons.
STALL SPEED OUT OF SPECIFICATION DIAGNOSIS
S e l e c t o r P o s i t i o n S t a l l S p e e d s Hi g h St a l l Speeds L o w

Pl a n e t a r y On e - Wa y Cl u t c h
, 2 a n d 1 Fo r wa r d Cl u t c h o r I n t e r me d i a t e Cl u t c h
STALL SPEED OUT OF SPECIFICATION DIAGNOSIS (Cont 'd)
Selector Position Stall Speeds High Stall Speeds Low
0 , 2 , 1 a n d R P e r f o r m P r e s s u r e Te st To r q ue Co n v e r t e r St a t o r On e - Wa y Cl u t c h o r
En gi n e P e r f o r ma n c e
R Re v e r s e Cl u t c h o r L o w Re v e r s e Ba n d o r
Se r v o
T o r q u e C o n v e r t e r C l u t c h O p e r a t i o n T e s t
Thi s t est veri f i es t hat t he t or que convert er cl ut ch
cont rol sy st e m and t he t orque conver t er are operat i ng
properl y.
1. Perf orm Qui ck Test as out l i ned. Check f or DTCs
628, 652 , and 656. Ref er t o Pinpoint Test C f or
di agnosi s.
2. Connect a t achomet er t o engi ne.
3. Bri ng engi ne t o normal operat i on t emper at ur e by
dri vi ng vehi cl e at hi ghway spe e ds f or
appr oxi mat el y 15 mi nut es in posi t i on.
4. Af t er normal operat i ng t emper at ur e is r e a c he d,
mai nt ai n a const ant vehi cl e speed of about 80
k m/ h ( 50 mph) and t a p br a ke pedal wi t h t he left
f oot .
5. Engine r pm shoul d i ncrease when br ake pedal is
t a ppe d , and de c r e a se about f i ve seconds af t er
pedal is r el eased. If t hi s doe s not occur, ref er t o
Torque Convert er Operat i on Concerns in t he
Di agnosi s by Sy mpt om Rout i nes.
6. If vehi cl e st al l s in or manual 2 at idle wi t h
vehi cl e at a st op, move t ransmi ssi on range
sel ect or l ever t o manual 1 posi t i on. If vehi cl e
st al l s, ref er t o Torque Convert er Operat i on
Concer ns in t he Di agnosi s by Sy mpt om Rout i nes.
Ser vi ce a s requi red. If vehi cl e does not st al l in ,
ref er t o El ect ri cal Di agnosi s f or PCM and Vehi cl e
Harness Di agnosi s in Pi npoi nt Test C.
S h i f t P o i n t C h e c k s
Thi s t e st veri f i es t hat t he shi f t cont rol sy st e m is
oper at i ng pr oper l y.
1. Bri ng engi ne and t ransmi ssi on up t o normal
2. Ope r a t e vehi cl e wi t h t ransmi ssi on range sel ect or
l ever in posi t i on.
3. Appl y mi ni mum t hr ot t l e and obse r ve spe e ds at
whi c h upshi f t oc c ur s and t or que conver t er
engages. (Ref er t o Aut omat i c Transmi ssi on
Speci f i cat i on Bulletin FPS-12180-94. )
AXLE RATIO 2.73
Thr o t t l e Posi t i on Range Shi f t (MPH)
L i gh t T h r o t t l e . D 1-2 9- 12
. D 2- 3 2 2 - 2 6

3- 4 40- 44
AXLE RATIO 2.73 (Cont ' d)
Thr ot t l e Posi t i on Range Shi f t (MPH)
-C. T. 4- 3 3 4 1
, D -
C.T.
3-2 1 4 1
D -
C.T.
2- 1 9 1
Wi d e Op e n T h r o t t l e , D 1-2 44- 49
i D 2- 3 86- 93
, D 3-2 7 8 Ma x .
, D 2- 1 34 Ma x .
Ti re Si zes
P215/ 70R15
C.T.=Cl osed Throttle
Note: D is the same as wi th the transmission control
swi tch acti vated (light on)
AXLE RATIO 3.27 EXCEPT POLICE
L i ght Th r o t t l e , D 1-2 7 - 10
, D 2 - 3 18. 5- 2 1. 5

3- 4 33- 37
-C.T. 4- 3 2 8 1
D -
C.T.
3-2 12 . 51
, D -
C.T.
2-1 7 1
, D 2- 3 7 1- 7 6
, D 3- 2 66 Ma x .
, D 2-1 2 8 Ma x .
Ti re Si zes
P215/ 70R15 Trailer Tow
P225/ 70R15 Handling Tire (Merc.)
P225/ 60R16 Handl i ng/Towi ng Sedan (Crown Vic.)
C.T.=Closed Throttle
Note: D is the same as wi th the transmission control
AXLE RATIO 3.27 POLICE
L i ght T h r o t t l e , D 1-2 7- 10
, D 2- 3 18. 5- 2 1. 5

3- 4 33- 37
( Co n t i n ue d )
AXLE RATIO 3.27 POLICE (Cont ' d)
T h r o t t l e P o s i t i o n Ra n g e S h i f t ( MPH)
-C.T. 4- 3 2 8 1
, D -
C.T.
3-2 12 . 51
, D -
C.T.
2- 1 7 1
, D 2-3 7 1- 7 6
, D 3-2 66 Ma x .
, D 2- 1 2 8 Ma x .
Ti re Si zes
P225/ 70HR15
C.T.=Cl osed Throttle
Note: D is the same as wi th the transmi ssi on control
4. Wi t h vehi cl e in OVERDRIVE (fourth gear), press
transmi ssi on control swi t ch. Transmi ssi on shoul d
downshi ft t o thi rd gear. Remove f oot f rom
accel erator pedal ; engine braki ng shoul d occur.
5. Press accel erat or pedal t o fl oor ( WOT) .
Transmission should shift f rom thi rd to second
gear, or thi rd t o fi rst dependi ng on vehi cl e speed.
Torque converter cl utch shoul d di sengage and
then reappl y.
6. Wi th vehi cl e in position above 80 k m/ h ( 50
mph) and less than half t hrot t l e, move t he
transmi ssi on range sel ector lever f rom
position t o manual 2 position and remove foot
f rom accel erat or pedal . Transmi ssi on should
immediately downshi ft into second gear. Wi t h
vehicle remaining in manual 2 posi ti on, move
transmi ssi on sel ector into manual 1 posi ti on, and
rel ease accel erat or pedal . Transmi ssi on should
downshi ft into fi rst gear at speeds BELOW 48- 56
k m/ h (30-35 mph).
7. If transmi ssi on fails t o upshift / downshi ft or t orque
converter cl utch does not appl y and rel ease,
refer t o Di agnosi s by Sympt om Routi nes.
A i r P r e s s u r e T e s t s
Tr a n s mi s s i o n Te st P l a t e T 92 P - 7 006- A
Re v e r s e C l u t c h
Appl y air pressure t o the reverse cl utch passage in the
Transmission Test Pl ate, T92P-7006-A. A dull thud
can be heard when t he reverse cl utch pi ston ( 7D402)
appl i es. In addi ti on, movement of t he reverse cl utch
drum ( 7D044) may al so be det ect ed.
F o r w a r d C l u t c h Cy l i n d e r
Appl y air pressure t o the f or war d cl utch appl y
passage in the transmi ssi on t est pl ate. A dull t hud can
be heard or movement of the cl utch piston ( 7A262)
can be felt on the case ( 7005) as the cl utch pi ston is
appl i ed.
I n t e r me d i a t e C l u t c h C y l i n d e r
Appl y air pressure t o the i ntermedi ate cl utch passage
in t he transmi ssi on t est pl ate. A dull thud can be heard
or felt when the i ntermedi ate cl utch piston ( 7E005)
appl i es.
Di r e c t C l u t c h Cy l i n d e r
Appl y air pressure t o the di rect cl utch appl y passage.
A dull thud should be heard or fel t on the dri veshaft if
t he cl utch is operati ng.
O v e r d r i v e S e r v o
Appl y air pressure t o the overdri ve ( O/ D) servo appl y
passage in the transmi ssi on t est pl ate. Operati on of
t he band is indicated by the tightening of the band
around the reverse cl utch drum. The O/ D servo will
return t o the rel ease position as a result of f orce f r om
t he overdri ve servo piston return spri ng ( 7F201) . Al so,
when the servo returns to the rel ease posi ti on, a t hud
can be felt on the O/ D servo cover. The band will then
rel ax.
Transmi ssi on Test Pl ate
D10447-A
Item De s c r i p t i o n
1 Co n v e r t e r By p a s s
2 1 -2 A c c u mu l a t o r A p p l y
3 I n t e r me d i a t e Cl u t c h
4 Ov e r d r i v e Se r v o Re l e a s e
6 Re v e r s e Se r v o
6 Ov e r d r i v e Se r v o A p p l y
7 2-3 A c c u mu l a t o r Bo t t o m
8 2-3 A c c u mu l a t o r To p
9 Fo r wa r d Cl u t c h
10 Di r e c t Cl u t c h
07- 01- 104 Tr ansmi ssi on, Au t o ma t i c 4 R 7 0 W 07- 01- 104
L o w - R e v e r s e S e r v o
Appl y air pressure t o the l ow-reverse servo passage
in the transmi ssi on t est pl ate. A dull thud can be heard
when the l ow-reverse band ti ghtens around t he
pl anetary assembl y drum surface. Al so, movement of
the ring gear ( 7A153) can be det ect ed.
2 - 3 A c c u mu l a t o r
Appl y air pressure t o t he 2-3 accumul ator passage.
The accumul ator pi ston ( 7F251) should unseat. This
can be det ect ed by inserting a metal rod into the 2-3
pi ston hole. When the accumul ator piston unseats, the
rod will move. Al so, a thud can be heard when the
accumul ator piston appl i es.
Di r e c t C l u t c h Pressure Test
The di rect cl utch pressure t est will di agnose a
l ow-pressure condition or l eakage in the di rect cl utch
ci rcui t. A di fference of 103 kPa ( 15 psi) or more
bet ween di rect cl utch pressure and line pressure (read
at the f or war d cl utch pressure t ap) will prevent a
normal 3-4 shift.
1. CAUTI ON: Pr essur e gauges af f ect t he shi f t
q u a l i t y of t he t r ansmi ssi on. Car e shoul d be
t a k e n not to accel er at e or decel er at e
r a pi d l y . Possi bl e t r ansmi ssi on f ai l ur e coul d
r esul t .
At t ach 0-2000 kPa (0-300 psi) pressure gauges
t o t he f orward cl utch pressure t ap and t o the
di rect cl utch pressure t ap. Gauges must be
accurat e enough t o distinguish a 103 kPa ( 15 psi)
di fference. (If thi s t est is done in conjunction wi th
a line pressure t est , pressure gauges will be
at t ached t o all pressure t aps. ) Have sufficient
fl exi bl e hose t o read t he gauges in the vehi cl e.
2. Dri ve the vehi cl e. When pressure is appl i ed t o the
di rect cl utch, note t he di fference bet ween the
pressure read at f or war d cl utch pressure t ap and
t he di rect cl utch pressure.
3. If the di fference in pressures is less than 103 kPa
( 15 psi ), the di rect cl utch circuit is OK.
4. If the di fference is great er than 103 kPa ( 15 psi ),
t here coul d be a leak in the di rect cl utch pressure
ci rcui t. If the di fference does not exceed 103 kPa
( 15 psi ), the gauges on the line pressure and
di rect cl utch pressure can be swi t ched t o confi rm
t hat gauge cal i brati on di fference is not the cause.
IN-VEHICLE SERVICE
Transmi ssi on Fluid Drain and Fill Procedure
Normal maintenance and lubrication requi rements do
necessi t at e periodic automati c transmi ssi on fluid
changes. If a major servi ce, such as a cl utch, band,
beari ng, et c. , is requi red, it will have t o be removed for
servi ce. At this time, the torque converter ( 7 902) ,
transmi ssi on cool er and cool er inlet tube and cool er
tube must be thoroughl y fl ushed t o remove any dirt.
When used under continuous or severe condi ti ons, the
transmi ssi on and torque converter should be drai ned
and refilled wi th fluid as speci fi ed.
CAUTI ON: Use o f a f l ui d o t h e r t h a n s p e c i f i e d
c o u l d r e s ul t i n t r a n s mi s s i o n ma l f u n c t i o n a n d / o r
f a i l u r e .
Refer t o the Vehicle Certification Label affi xed t o the
LH front door lock f ace panel or door pillar for the
transmi ssi on code.
When filling a dry transmission and torque converter,
refer t o Speci fi cati ons for capaci t y. Check t he fluid
level.
Procedures for partial drain and refill, due t o in-vehicle
servi ce operati on, are as fol l ows:
1. Raise vehicle on a hoist or j ackst ands. Refer t o
Secti on 00-02.
2. Pl ace drain pan under transmi ssi on.
3. Loosen transmission pan retaining bol ts and drain
fluid from transmi ssi on.
4. When fluid has drai ned t o level of pan fl ange,
remove rest of pan bol ts worki ng f rom t he RH
si de, and allow it t o drop and drain sl owl y.
5. When all fluid has drai ned f rom transmi ssi on,
remove and thoroughl y cl ean transmi ssi on pan.
6. Cl ean, inspect and install pan t o case gasket on
transmi ssi on pan, and install transmi ssi on pan on
transmi ssi on.
7. Lower vehicle.
8. Fill transmission t o proper level wi th Mot orcraf t
MERCON Multi-Purpose Automati c
Transmission Fluid XT-2-QDX or equivalent
MERCON approved fluid.
Shi ft Li nkage Check
Thi s is a CRI TI CAL adj ustment. Be sure the detent
in t he transmi ssi on corresponds exact l y wi t h t he st op
in the steeri ng column tube ( 3514) . Hydraulic l eakage
at the manual control valve can cause del ay in
engagements and/ or slipping while operati ng if the
linkage is not correctl y adj usted.
NOTE: Check for a misadjustment in shift linkage. Do
thi s by matching the detents in t he transmi ssi on range
sel ector lever wi th those in the transmi ssi on. If they
mat ch, the misadjustment is in t he indicator. Do not
adjust t he shift linkage.
Ext ensi on Housing Seal, Gasket and Bushi ng
Re mo v a l
Se a l Re mo v e r
E x t e n s i o n Ho us i n g Bu s hi n g Re mo v e r
E x t e n s i o n Ho us i n g Bu s hi n g Re p l a c e r
E x t e n s i o n Ho us i n g Se a l Re p l a c e r
T 7 4P - 442 48- A
T 7 7 L - 7 697 - A
T 80L - 7 7 034- A
T 61L - 7 657 - B
1. Open hood and di sconnect t he ba t t e r y ground
cabl e ( 14301) .
2. Rai se vehi cl e on a hoi st . Ref er t o Sect i on 00- 02.
3. Remove muffler inlet pi pe and r esonat or ( 5A289) .
4. Drai n t ransmi ssi on flui d a s out l i ned.
5. Remove dri veshaf t . Ref er t o Sect i on 05- 01.
6. Di sconnect and r emove t he vehi cl e spe e d sensor
(VSS)(9E731) f r om t he ext ensi on housi ng
( 7 A039) .
7. Posi t i on a t ransmi ssi on j a c k under t he
t ransmi ssi on and rai se it sl i ght l y.
8. Remove t he engi ne rear suppor t -t o-cr ossmember
bol t s.
9. Remove t he cr ossmember -t o-f r ame si de support
ret ai ni ng bol t s and r emove t he engi ne and
t ransmi ssi on suppor t i nsul at or ( 6F063) and
engi ne and t ransmi ssi on suppor t ( 6F065) and
engi ne damper mount i ng body br a c ke t ( 6F067) .
10. Lowe r t he j a c k under t he t ransmi ssi on and al l ow
t he t ransmi ssi on t o hang.
11. NOTE: The ext ensi on housi ng bol t s have been
c oa t e d wi t h a seal ant . Mo r e br eak t or que may be
requi red t o r emove t hese bol t s.
Usi ng a 13 mm soc ke t , r emove si x ext ensi on
housi ng bol t s. Sli de ext ensi on housi ng off out put
shaf t . Remove and di sc a r d ext ensi on housi ng
ga ske t ( 7086) .
12. Remove ext ensi on housi ng seal usi ng Seal
Remover T74P-77248-A. Ensure seal remover
lips ar e f i rml y seat ed under t he f l ange on t he
ext ensi on housi ng seal .
SEAL REMOVER
T74P-77248-A
D10123-B
13. I nspect ext ensi on housi ng bushi ng ( 7 A034) . If
requi red, r emove t he ext ensi on housi ng bushi ng
usi ng Ext ensi on Housi ng Bushi ng Remover
T77L- 7697- A.
EXTENSION
HOUSING
7A039
1. If r e move d, i nstall new ext ensi on housi ng bushi ng
using Ext ensi on Housi ng Bushi ng Repl acer
T80L-77034-A.
2. Install new ext ensi on housi ng gasket and
ext ensi on housi ng. Ti ght en si x bol t s t o 25-30 N*m
(18-22 Ib-f t ).
3. Install new ext ensi on housi ng seal using
Ext ensi on Housi ng Seal Repl acer T61L-7657-B.
07- 01- 106 T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W 07 - 01- 106
4. Raise the transmi ssi on. Position the engine and
transmi ssi on support insulator and engine and
transmi ssi on support and engine damper
mounting body bracket t o t he frame side
support s and install the retaining bol ts. Refer t o
Secti on 02- 03 for torque speci fi cati ons.
5. Lower the transmi ssi on and install the rear engine
support-to-crossmember nut. Refer t o Secti on
02- 03.
6. Remove the transmi ssi on j ack.
7. Connect the muffler inlet pipe and resonator t o
t he exhaust manifold ( 9430) . Refer t o Secti on
09- 00.
8. Install the vehi cl e speed sensor and connect
wi ri ng.
9. Install the dri veshaft ( 4602) . Refer to Secti on
05- 01.
10. Remove saf et y stands and l ower the vehicle.
Connect the bat t ery ground cabl e.
11. Pour 4. 7 liters (5 quarts) of speci fi ed fluid into
fluid filler tube. St art engine and add fluid as
requi red to achi eve the proper fluid level as
outlined.
12. Check the transmi ssi on, torque converter ( 7902)
assembl y and cool er lines for l eaks.
Main Cont rol Valve Body
Removal
1. Open hood and di sconnect the battery ground
cabl e ( 14301) .
2. Raise vehi cl e on a hoist. Refer t o Secti on 00- 02.
3. Drain transmi ssi on fluid as outlined.
4. Using a 10 mm socket , remove 14 pan retaining
bol ts, transmi ssi on pan and pan t o case gasket .
Di scard pan t o case gasket .
PAN TO
CASE GASKET
7A194 D14050-A
5. Remove pan magnet. Clean transmi ssi on pan and
pan magnet.
PAN
D10254-C
6. NOTE: Al ways use a new filter and grommet.
Never attempt t o cl ean or reuse a di rty filter.
CAUTI ON: If g r o mme t r e ma i n s i n ma i n
c o n t r o l b o r e , us e a sma l l s c r e wd r i v e r t o p r y i t
o u t . Ta ke c a r e n o t t o d a ma ge ma i n c o n t r o l
b o r e .
Using both hands, remove filter by pulling upward.
D14046-A
07 - 01- 107 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 07- 01- 107
CAUTI ON: Do n o t pul l o n wi r e s . Thi s ma y
d a ma g e wi r e s o r c o n n e c t o r a n d c o u l d r e s ul t
i n a t r a n s mi s s i o n c o n c e r n . If r e q u i r e d ,
c a r e f u l l y p r y u p o n l o c ki n g t a b a n d
d i s c o n n e c t t h e c o n n e c t o r .
Grasp connector at each solenoid or sensor and
pull strai ght out to di sconnect.
CONNECTOR
O
D10255-A
9.
Using an 8 mm socket , remove one bolt retaining
manual control valve detent lever spri ng ( 7A261)
t o the main control val ve body ( 7A100) .
Remove EPC solenoid bracket retaining bolt.
Remove bracket .
EPC SOLENOI D
BRA CKET
D10183-C
10. Using an 8 mm socket , remove remaining 24
val ve body-to-case retaining bol t s, the main
control valve body and the val ve-to-body gasket .
D14048-A
1
2.
Position main control val ve body using the t wo
alignment bol ts as a guide. Ensure coasti ng
booster valve shuttle balls ( 7E195) are in t he
correct l ocati ons as outlined under Assembl y.
Install the EPC solenoid bracket . Loosel y install
one long 6 mm bolt.
4
sEPC SOLENOI D
BRA CKET
D10183-C
3. Loosel y install 11 long and 12 short bol ts.
07-01-108
T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W 07-01-108
IN-VEHICLE SERVICE ( Co n t i n u e d )
4. Install manual cont rol val ve det ent lever spri ng
and one bol t .
D10118-B
Mai n Co n t r o l t o Case
INSTALLATION
21 22 23
Ti ght en t he main cont rol val ve body bol t s in t wo
st e ps as f ol l ows:
Ti ght en t he 25 ret ai ni ng bol t s t o c a se t o 9-11
N-m (80-100 lb-i n).
Ret i ght en t he f ol l owi ng bol t s t o t he
speci f i cat i on i ndi cat ed and in sequence as
i ndi cat ed by t he i l l ust rat i on:
2 M8X 1. 25X46 mm gui de pin bol t s t o
18-24 N-m (155-195 lb-i n).
4 M6X 1.0X18 mm cover pl at e bol t s t o
9-11 N-m (80-100 lb-i n).
12 M6X1. 0X52 mm cover pl at e bol t s t o
9-11 N-m (80-100 lb-in)
D12122-B
07- 01- 109 T r a n s mi s s i o n , Au t o ma t i c 4 R7 0 W 0 7 - 0 1 - 1 0 9
I N- VEHI CL E SERVICE (Conti nued)
6. Connect wi ri ng connect ors t o transmi ssi on fluid
t emperat ure sensor (TFT sensor), shift sol enoi ds
( 7G484) and EPC sol enoi d.
TFT SENSOR
CONNECTOR
SOLENOID ELECTRICAL EPC
CONNECTOR CONNECTOR
Install new filter and grommet .
D14047-A
GROMMET
TRANSMISSION
FLUID FILTER
D14046-A
8. Install pan magnet t o transmi ssi on pan.
o / f
PAN
MAGNET
7L027
D10254-C
9. Cl ean, inspect and install pan t o case gasket and
transmi ssi on pan. Tighten all bol ts t o 12-15 N-m
(9-11 Ib-ft).
PAN TO
CASE GASKET
7A191
TRANSMISSION
v
PAN
7A194
D14050-A
EPC So l e n o i d
Remov al
Tr a n s mi s s i o n Ra n ge ( TR) Se n s o r
Al i gn me n t To o l ( ML P S Al i gn me n t To o l )
T 93P - 7 0010- A
1. Open hood and di sconnect t he bat t ery ground
cabl e ( 14301) .
2. Raise vehicle on a hoi st. Refer t o Secti on 00- 02.
3. Drain transmission fluid as outlined.
0 7 - 0 1 - 1 1 0
T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W 0 7 - 0 1 - 1 1 0
PAN TO
CASE GASKET
7A194 D14050-A
5. Remove pan magnet. Clean transmission pan and
pan magnet.
PAN
D10254-C
6. NOTE: Al ways use a new filter and grommet.
Never attempt t o cl ean or reuse a di rty filter.
c o n t r o l b o r e , us e a sma l l s c r e wd r i v e r t o pr y i t
o u t . T a ke c a r e n o t t o d a ma g e ma i n c o n t r o l
b o r e .
Using both hands, remove filter by pulling upward.
D14046-A
7. Using an 8 mm socket , remove one bolt retaining
manual control val ve detent lever spring ( 7A261)
t o the main control val ve body ( 7A100) . Remove
manual control val ve detent lever spri ng.
8. Di sconnect transmi ssi on shift linkage from
manual control lever by removing the nut.
07- 01- 111 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 07 - 01- 111
Using an 8 mm socket , remove t wo bol ts retaining
transmi ssi on range (TR) sensor t o case ( 7005) .
Remove transmi ssi on range (TR) sensor f rom
manual control lever ( 7A256) .
D14698-A
10. NOTE: For cl ari ty, t he following illustrations show
the main control val ve body removed. It is not
necessary t o remove t he main control val ve body
for thi s procedure.
Remove t he EPC solenoid bracket retaining bolt.
Remove t he EPC sol enoi d bracket .
EPC SOLENOID
BRACKET
D10183-C
11. NOTE: Use a shop cl oth t o prot ect pan-to-case
surface.
Remove manual lever shaft retai ni ng pin ( 7B210) .
MANUAL LEVER
SHAFT RETAINING
PIN 7B210
-D8890-B
12. Using a 13/ 16- i nch open-end wr ench on t he inner
nut and a 12 mm wrench on t he manual control
lever shaft fl ats, loosen the inner nut.
MANUAL INNER
CONTROL NUT
LEVER SHAFT ,
7C493
D8891-B
Slide manual control lever partially out of t he case
t o compl et e removal of the inner nut from manual
control lever.
13. Slide manual control lever out of case. Position
manual val ve detent lever ( 7A115) so that EPC
solenoid can be removed. Remove EPC solenoid
connector by graspi ng connect or body and
pulling. Remove el ectroni c pressure control (EPC)
solenoid by sliding it out of the case bore.
1. Lubri cate EPC Solenoid Seal and O-ring wi th a
light coati ng of MERCON Multi-Purpose
Automati c Transmission Fluid XT-2-QDX or
equivalent MERCON approved fluid. Install EPC
solenoid by sliding it into the bore.
2. Install t he EPC solenoid bracket . Install bolt and
ti ghten t o 11-15 N-m ( 100- 130 lb-in).
3. Install connector t o EPC solenoid by pushing
connector body in pl ace.
4. Position manual valve detent lever and parki ng
lever actuati ng rod ( 7A232) into case. Parking
lever actuati ng rod must be positioned over
parki ng pawl ( 7A441) .
5. Slide manual control lever into case and position
through detent. Install nut and tighten t o 26-37
N-m (20-27 Ib-ft).
6. Install manual lever shaft retaining pin.
7. Install TR sensor on manual control lever and t wo
shi ms, then loosely install bol ts.
D14698-A
07 - 01- 113 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 07- 01- 113
NOTE: PARK is the last detent when t he manual
control lever is full f orward. Return t wo detents
t owar d output shaft ( 7060) for NEUTRAL.
Position manual control lever in NEUTRAL.
Insert Transmission Range (TR) Sensor Alignment
Tool (MLPS Alignment Tool) T93P- 70010- A into
sl ot s. Align all t hree sl ots on transmi ssi on range
(TR) sensor wi th t hree t abs on t ool .
TRANSMISSION RANGE
(TR) SENSOR
SENSOR ALIGNMENT TOOL
T93P-70010-A
D14044-A
10. Tighten TR sensor bol ts to 9-11 N-m ( 80- 100
lb-i n).
11. Install manual control val ve detent lever spri ng
and bolt. Tighten bolt t o 11-15 N-m ( 100- 130
lb-i n).
OVERDRIVE BAND
SERVO PISTON
7F200
NYLON CLOTH
D11118-B
12. Cl ean, inspect and install pan t o case gasket .
Tighten all bol ts t o 12-15 N-m (9-111b-ft).
13. At t ach transmi ssi on linkage t o manual control
lever. Tighten adjusting nut t o 19-26 Nm (14-19
Ib-ft).
14. Pour 4. 7 liters ( 5 quart s) of MERCON
Multi-Purpose Aut omat i c Transmi ssi on Fluid
XT-2-QDX or equi val ent MERCON approved
fluid into oil filler tube ( 7A228) .
16. St art t he engine and add speci fi ed fluid as
requi red t o achi eve t he proper fluid level as
outlined.
17. Check t he transmi ssi on f or l eaks.
Main Cont rol Component s
Se r v o P i s t o n Re mo v e r / Re p l a c e r
Se r v o P i s t o n Se l e c t i o n To o l
T 92 P - 7 002 3- A
T 80L - 7 7 030- A
To servi ce the 1-2 or 2-3 accumul at ors or t he
overdri ve or reverse servo assembl i es use the
following procedure:
Re mo v a l
1. Remove the main control val ve body ( 7A100) as
outlined. This illustration shows t he position of the
overdri ve servo, the reverse band servo pi ston
and rod ( 7D189) , 2-3 accumul ator pi ston
( 7F251) and t he 1-2 accumul ator pi ston.
REVERSE BAND FRONT OF
2-3 SERVO PISTON " VEHICLE "
ACCUMULATOR AND ROD
PISTON 7F251 7D189 OVERDRIVE
SERVO
7H188
1-2 ACCUMULATOR
PISTON 7F251
D14043-A
2. Remove the 2-3 accumul ator spring retainer.
-FRONT OF VEHICLE-
2-3 ACCUMULATOR
SPRING RETAINER
7B264
3. Remove 2-3 accumul ator pi ston.
D14042-A
2-3 ACCUMULATOR
PISTON
7F251
.FRONT OF.
VEHICLE
D14041-A
Ove r d r i ve Ser vo
OVERDRIVE SERVO..
PISTON RETAINER
7G280
OVERDRIVE
PISTON
RETURN
SPRING
7F201
OVERDRIVE
SERVO ASSY 7H188
D11503-D
4. NOTE: If tool is not available, ext reme care must
be t aken. Spring pressure will f orce overdri ve
servo piston ( 7F200) assembl y out of case
( 7005) . Case bore damage may result f rom tryi ng
t o pry on overdri ve servo piston retainer
( 7G280) .
Use Servo Piston Remover/ Repl acer
T92P-70023-A t o cont act the overdri ve servo
pi ston return spring ( 7F201) . Use snap-ring pliers
t o remove retainer ring.
!
FRONT OF
VEHICLE
SERVO PISTON
REMOVER/
REPLACER
T92P-70023-A
OVERDRIVE
SERVO
D10121-B
5. Remove pi st on assembl y. Remove over dr i ve
ser vo pi st on ret urn spri ng.
OVERDRIVE
SERVO PISTON
ASSY
OVERDRIVE SERVO
PISTON RETURN
SPRING 7F201
Reverse Band Ser vo
D14Q40-A
REVERSE BAND
SERVO COVER '
7D036
REVERSE BAND
SERVO SPRING
7D031
REVERSE BAND
SERVO PISTON
AND ROD 7D030
RETAINING RING
7384
D10190-C
Use Ser vo Pi st on Re move r / Re pl a c e r
T92P-70023-A t o cont act t he r ever se band ser vo
cover ( 7 D036) and c ompr e ss ret urn spri ng and
remove accumul at or pi st on ret ai ni ng ri ng ( 7384) .
NOTE: The l engt h of t he r od a t t a c he d t o t he
pi st on is gr a de d f or t hr ee di f f erent l engt hs.
Ther ef or e, t hey shoul d not be i nst alled in any
t ransmi ssi on ot her t han t he t ransmi ssi on f r om
whi c h t hey we r e r emoved.
Remove r ever se band servo cover , r ever se band
ser vo pi st on and r od and r ever se band ser vo
spri ng ( 7 D031) .
REVERSE BAND
SERVO COVER
7D281
REVERSE BAND
SERVO PISTON
AND ROD
7D030
REVERSE
BAND
SERVO
SPRING
7D031
D14039-A
8. Appl y d o wn wa r d pr essur e on 1-2 accumul at or
c ove r usi ng Servo Pi st on Remover / Repl acer
T92P-70023-A. Usi ng snap-ri ng pl i ers, remove
1-2 accumul at or pi st on ret ai ni ng ri ng.
1-2 Accumul at or
1-2 ACCUMULATOR
PISTON RETAINING
RING 97632 D14038-A
9. NOTE: Caref ully not e t he l ocat i on of t he 1-2
accumul at or out er spri ng ( 7 G267 ) and assembl e
in t he same posi t i ons. Some model s may use t wo
1-2 accumul at or out er spri ngs. The accumul at or
pi st on may al so var y wi t h appl i cat i ons.
Remove cover and 1-2 accumul at or out er spri ng.
Use reverse snap-ri ng pl i ers t o r emove
accumul at or pi st on and 1-2 shi f t spri ng (7F284).
1. Install reverse band ser vo spr i ng, reverse band
ser vo pi st on and r o d . When pi st on and rod
assembl y repl acement be c o me s necessary,
det ermi ne t he c or r e c t l engt h of t he reverse ser vo
pi st on and r od, pr oceed as f ol l ows:
1995 To wn Car , Cr o wn Vi c t o r i a , Gr a n d Ma r qui s Jul y 1994
NOTE: Thi s is not an ordi nary i nst al l at i on pr ocedur e
and does not compensat e f or band wear.
a. Lubri cat e t he r ever se pi st on seal t o f aci l i t at e
assembl y and t o prevent damage t o t he seal .
b. Install t he reverse ser vo pi st on and ret urn
spri ng. Do not i nstall t he pi st on cover or
ret ai ni ng ri ng.
c. Install Servo Pi st on Sel ect i on Tool
T80L-77030-A. Ti ght en t he band appl y bolt
on Servo Pi st on Sel ect i on Tool
T80L- 77030- A t o 5. 6 N-m ( 50 lb-i n).
SERVO PISTON
SELECTION TOOL
T80L-77030-A
TORQUE
WRENCH
D14037-A
At t a c h Di al Indi cat or wi t h Br a c ke t r y
TOOL-4201-C or equi val ent and posi t i on t he
i ndi cat or st em on t he f l at port i on of t he
pi st on. Zer o t he di al i ndi cat or.
DIAL INDICATOR
WITH BRACKETRY
TOOL 4201-C
D14036-A
e. Thr ead t he bolt out of t he sel ect or t ool until
t he pi st on st o ps agai nst t he bot t om of t he
t ool .
2.
4.
f. Read t he amount of pi st on t ravel on t he di al
i ndi cat or.
If t he t ravel is 2. 845-6. 020 mm
(0. 112-0. 237 i nch), t he pi st on l engt h is
wi t hi n speci f i cat i on.
If t he t ravel is not wi t hi n speci f i cat i on,
sel ect i ve pi st ons are avai l abl e in t he
f ol l owi ng l engt hs:
ID
74. 56 mm ( 2. 936 i nch) 1 gr oove
75. 92 mm ( 2. 989 i nch) 2 gr ooves
77. 29 mm ( 3. 043 i nch) 3 gr oove
Lengt h of r od measured f r om pi st on
surf ace t o end of r o d .
Sel ect t he proper r od t o bri ng t he
servo pi st on t ravel wi t hi n
speci f i cat i on.
g. Lubri cat e t he cover seal t o f aci l i t at e
h. Remove t he servo sel ect i on t ool and di al
i ndi cat or.
Install Ser vo Pi st on Re move r / Re pl a c e r Tool
T92P-70023-A t o t ransmi ssi on c a se .
Ti ght en sc r e w on Servo Pi st on
Re move r / Re pl a c e r Tool T92P-70023-A t o al l ow
enough cl earance t o i nstall retai ni ng ri ng.
Install reverse servo retai ni ng ri ng and remove
t ool .
REVERSE SERVO
RETAINING RING
T92P-70023-A D10171-A
Install over dr i ve band ( 7 F196) over r ever se
cl ut ch assembl y and posi t i on t he poc ke t of t he
over dr i ve band agai nst overdri ve band anchor pin
( 7 F295) . Install over dr i ve ser vo pi st on ret urn
spri ng and over dr i ve ser vo pi st on assembl y.
Veri f y t i p of pi st on assembl y engages t he po c ke t
of over dr i ve band. Usi ng Servo Pi st on
Re mo ve r / Re pl a c e r Tool T92P-70023-A, i nst all
pi st on assembl y i nto t he c a se and c o mpr e ss
over dr i ve se r vo pi st on ret urn spri ng.
SERVO PISTON
REMOVER/REPLACER
T92P-70023-A
D10507-B
OVERDRIVE
PISTON
RETURN
SPRING
7F201
OVERDRIVE SERVO SLEEVE
' AND PISTON ASSY
6. CAUTI ON: Ma ke s u r e r e v e r s e s e r v o r e t a i n i n g
r i n g i s c o mp l e t e l y s e a t e d b e f o r e r e mo v i n g
t o o l
Ma ke sure band anchor and t i p of t he pi st on
assembl y are pr oper l y posi t i oned agai nst band
po c ke t s. Ti ght en t ool f or ci ng sc r e w until pi st on is
bel ow ret ai ni ng ri ng gr oove and i nstall ret ai ni ng
ri ng, r emove t ool .
7. Install t he component s f or 2-3 accumul at or in t he
f ol l owi ng order:
NOTE: Ret ai ner is secur ed by mai n cont r ol .
Upper accumul at or seal ( 7F250) .
Lower accumul at or seal ( 7F249) .
Accumul at or pi st on.
Rear band se r vo spri ng ret ai ner ( 7 B264) .
2-3 ACCUMULATOR
UPPER SEAL 7F250
2-3 SHIFT
ACCUMULATOR
PISTON SPRING
7F285
2-3 SHIFT
ACCUMULATOR
PISTON 7F251
2-3 ACCUMULATOR
PISTON LOWER
SEAL 7F249
2-3 SHIFT
ACCUMULATOR
SPRING RETAINER*
7F252
D10174-A
Assembl e t he component s f o r 1-2 accumul at or in
t he f ol l owi ng order:
Accumul at or pi st on seal ( 7 F2 48) .
Lowe r accumul at or seal .
Accumul at or out er spri ng.
Cover and seal assembl y.
Accumul at or pi st on ret ai ni ng r i ng.
D12755-A
Par t
1 7F248 Accumulator Piston Seal
2 7F251 Accumulator Piston
3 7F249 Lower Accumulator Seal
4 7G267 1-2 Accumulator Spring
5 7H300 Cover and Seal Assy
Retaining Ring
9. Install the 1 -2 accumul ator assembl y and spring
t o case. Install cover and seal assembl y. Install
retaining ring.
D14034-A
10. Install mai n control val ve body as outlined.
11. Install new fluid filter and grommet.
D14046-A
12. Cl ean, i nspect and install pan t o case gasket and
transmi ssi on pan. Tighten all bol ts t o 12-15 Nm
(9-11 Ib-ft).
PAN TO
CASE GASKET
7A194 D14050-A
13. Install transmi ssi on shift linkage t o manual control
lever.
14. Pour 4. 7 liters (5 quarts) of Mot orcraf t MERCON
Multi-Purpose Automati c Transmission Fluid
XT-2-QDX or equivalent MERCON approved
fluid into fluid filler tube.
15. Reconnect battery ground cabl e ( 14301) .
16. St art the engine and add speci fi ed fluid as
required t o achi eve the proper fluid level as
outlined.
17. Check the transmi ssi on for l eaks.
Manual Cont rol Lever Shaft Seal
Shi f t L e v e r Se a l Re p l a c e r
T 7 4P - 7 7 498- A
T 93P - 7 0010- A
Removal
1. Open hood and di sconnect the battery ground
cabl e ( 14301) .
3. Drain transmi ssi on fluid as outlined.
07 - 01- 119 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 0 7 - 0 1 - 1 1 9
5. Di sconnect transmi ssi on shift linkage from
manual control lever by removi ng adjusting nut.
PAN TO
CASE GASKET
7A194 D14050-A
pan magnet.
PAN
D10254-C
7. NOTE: Al ways use a new filter and grommet .
Never at t empt to cl ean or reuse a di rty filter.
c o n t r o l b o r e , use a s ma l l s c r e wd r i v e r t o p r y i t
b o r e .
Using bot h hands, remove filter by pulling upward.
D14046-A
8. Using an 8 mm socket , remove t wo bol t s retaining
transmi ssi on range (TR) sensor t o case ( 7005) .
Remove transmi ssi on range (TR) sensor f rom
manual control lever ( 7A256) .
D14698-A
07 - 01- 12 0 T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W 07- 01- 120
manual control val ve detent lever spri ng ( 7A261)
t o the main control val ve body ( 7A100) .
surf ace.
Remove manual lever shaft retaining pin ( 7B210) .
11. Using a 13/ 16- i nch open-end wrench on t he inner
nut and a 12 mm wrench on the manual control
lever shaft f l at s, loosen the inner nut.
Slide manual control lever partially out of the case
t o compl ete removal of the inner nut f rom manual
control lever. Remove manual control lever f rom
case.
12. NOTE: Do not damage bore wi th the prying t ool .
Using a screwdri ver on the Manual control lever
seal l ower edge, carefully pry manual control
lever seal out of case bore.
1. Install new manual control lever seal using Shift
Lever Seal Replacer T74P-77498-A.
D14033-A
2. Position manual valve detent lever ( 7A115) and
parki ng lever actuati ng rod ( 7A232) into case.
Parking lever actuati ng rod must be posi ti oned
over parki ng pawl ( 7A441) .
3. Slide manual control lever into case and position
through detent. Install nut and tighten t o 26-37
N-m (20-27 Ib-ft).
Install manual lever shaft retaining pin.
07 - 01- 12 1 Tr ansmi ssi on, Au t o ma t i c 4R7 0W 0 7 - 0 1 - 1 2 1
4. Install manual control val ve detent lever spri ng
and one bolt.
5. Install new fluid filter and grommet .
D14046-A
6. Install TR sensor on manual control lever and t wo
shi ms, then loosely install bol ts.
D14698-A
7. NOTE: PARK is t he last detent when t he manual
control lever is full f or war d. Return t wo det ent s
t owar d output shaft ( 7060) for NEUTRAL.
Position manual control lever in NEUTRAL.
8. Insert Transmission Range (TR) Sensor Alignment
Tool (MLPS Alignment Tool) T93P-70010-A into
sl ots. Align all three sl ots on TR sensor wi th t hree
t abs on t ool .
TRANSMISSION RANGE
(TR) SENSOR
T93P-70010-A D14044-A
9. Tighten T R sensor bolts to 9-11 N-m (80-100
lb-in).
Clean, inspect and install pan to case gasket and
transmission pan. Tighten all bolts to 12-15 Nm
(9-11 Ib-ft).
P A N T O
C A S E G A S K E T
7 A 194 D14050-A
10. Install transmission linkage to manual control
lever.
11. Pour 4.7 liters (5 quarts) of Motorcraft MERCON
Multi-Purpose Automatic Transmission Fluid
XT-2-QDX or equivalent MERCON approved
fluid into fluid filler tube.
12. Reconnect battery ground cable.
13. Start the engine and add specified fluid as
required to achieve the proper fluid level as
outlined.
14. Check the transmission for leaks.
Cooler Lines
When one or more of the cooler inlet tube and cooler
tube must be replaced, each replacement tube must
be fabricated from the same size steel tubing as the
original line.
1. Using the old tube as a guide, bend the new tube
as required. Add the necessary fittings and install
the tube.
2. Tighten cooler line-to-case fittings to 20-26 Nm
(15-19 Ib-ft).
3. Tighten cooler fittings to 24-31 N-m (18-23 Ib-ft).
4. After the fittings have been tightened, add
specified fluid as necessary and check for fluid
leaks.
REMOVAL
S P E C I A L S E R VI C E T O O L ( S ) R E QU I R E D
E x t e n s i o n Ho usi n g Se a l Re p l a c e r T 7 4P - 7 7 052 - A
NOTE: After transmission is removed for a major
overhaul, it is important to completely clean all
transmission components, including torque converter
(7902), transmission cooler, cooler inlet tube, main
control valve body (7A100), clutches and all coasting
booster valve shuttle balls (7E195) after any
transmission service that generates contamination.
These contaminants are a major cause for recurring
transmission concerns and must be removed from the
system before the transmission is returned to service.
The cleaning of debris from the direct clutch check ball
is often omitted. This omission can lead to a repeat
servicing of the transmission.
Cleaning and flushing procedures for transmission
components, including the direct clutch check ball, as
outlined under Cleaning and Inspection.
Re mo v a l
1. Open hood and disconnect the battery ground
cable (14301).
2. Raise vehicle on a hoist. Refer to Section 00-02.
3. Drain transmission fluid as outlined.
4. Remove exhaust system as necessary for
transmission removal. Refer to Section 09-00.
5. Remove the converter access cover and adapter
plate bolts from the engine oil pan (6675).
6. CAUTI ON: Ca r e s h o u l d b e t a ke n n o t t o
d a ma g e c o o l e r l i n e s.
NOTE: Never rotate the crankshaft pulley (6312)
in a counterclockwise direction (as viewed from
the front).
Remove the four flywheel-to-converter retaining
nuts by placing a 22 mm socket and breaker bar
on the crankshaft pulley retaining bolt. Rotate the
crankshaft pulley clockwise (as viewed from the
front) to gain access to each of the nuts.
7. Remove driveshaft. Refer to Section 05-01.
8. Disconnect and remove the vehicle speed sensor
(VSSX9E731) from the extension housing
(7A039).
9. Place a drain pan under the torque converter.
With the wrench on the crankshaft pulley
retaining bolt, turn the torque converter to gain
access to the converter housing access plug
(7N171) and remove. After the fluid has been
drained, install the converter housing access
plug.
10. Carefully disconnect shift cable from transmission
manual control lever at transmission by removing
adjusting nut.
11. Disconnect the transmission wiring harness
connectors.
07- 01- 123 T r a n s mi s s i o n , Au t o ma t i c 4 R 7 0 W 07 - 01- 12 3
REMOVAL (Cont i nued)
12. Remove starter-to-converter housing retaining
bol ts and posi ti on st art er motor ( 11002) out of
t he way.
13. Position a transmi ssi on j ack under t he
transmi ssi on and rai se it slightly.
14. Remove the engine rear support-to-crossmember
bol ts.
15. Remove t he crossmember-t o-f rame si de support
retaining bol ts and remove the engine and
transmi ssi on support insulator ( 6F063) and
engine and transmi ssi on support ( 6F065) and
engine damper mounting body bracket ( 6F067) .
16. Lower t he j ack under t he transmi ssi on and al l ow
t he transmi ssi on t o hang.
17. Position a j ack t o the front of t he engine and rai se
t he engine t o gain access t o t he t wo upper
converter housing-to-engine retaining bol ts.
18. Di sconnect the cool er lines at t he transmi ssi on.
Plug all openi ngs t o keep dirt out.
19. Remove the l ower convert er housing-to-engine
retaining bol ts.
20. Remove the transmi ssi on fluid filler t ube.
2 1 . Secure t he transmi ssi on t o the j ack wi t h a saf et y
chai n.
22. NOTE: If t he transmi ssi on is t o be removed for a
peri od of ti me, support the engine wi t h a saf et y
stand and wood bl ock.
Remove t he t wo upper converter
housing-to-engine retaining bol ts. Move the
transmi ssi on t o the rear so it di sengages f rom t he
dowel pins and the t orque converter is
di sengaged f rom t he fl ywheel ( 6375) . Lower the
transmi ssi on f rom t he vehi cl e.
23. Remove t orque converter f rom transmi ssi on.
DISASSEMBLY
Transmission
S P E C I A L S E R VI C E T O O L ( S ) R E QU I R E D
De sc r i pt i on Tool Number
Be n c h Mo u n t e d Ho l d i n g Fi x t u r e
Se r v o P i s t o n R e mo v e r / R e p l a c e r
Se a l Re mo v e r
E x t e n s i o n Ho u s i n g Bu s h i n g Re mo v e r
Pump Pul l e r A d a p t e r s
Be a r i n g Cup Pul l e r
T 57 L - 500- B
T 92 P - 7 002 3- A
T 7 4P - 7 7 2 48- A
T 7 7 L - 7 697 - A
T 59L - 100- B
T89T- 7 0010- A
T 7 7 F- 1102 - A
NOTE: Bef ore beginning Di sassembl y,
per f or m/ i nspect t he fol l owi ng:
The transmi ssi on servi ce area shoul d be kept cl ean,
wel l organi zed and supplied wi t h cl ean, lint-free
shop cl ot hs.
Thorough cl eani ng of t he transmi ssi on ext eri or will
reduce the possi bi l i ty that damagi ng contami nants
mi ght enter the subassembl i es duri ng di sassembl y
and assembl y.
If t he transmi ssi on is being removed for major
overhaul , it is i mportant to compl et el y cl ean all
transmi ssi on component s, including torque
convert er ( 7902) , cool er, cool er inlet t ubes, main
cont rol val ve body ( 7A100) , all cl ut ches and all
coast i ng boost er val ve shuttle bal l s ( 7E195) after
any transmi ssi on servi ci ng that generat es
contami nati on. These contami nants are a major
cause for recurri ng transmi ssi on t roubl es and must
be removed f rom t he syst em bef ore t he
transmi ssi on is returned t o servi ce. The cleaning of
debri s f rom the di rect cl utch check ball is often
omi t t ed. Thi s omi ssi on can l ead t o a repeat
servi ci ng of the transmi ssi on.
Debri s that col l ect s and builds up in the corners of
t he st amped cl utches must be removed.
The pan magnet shoul d be removed f rom
transmi ssi on pan and wi ped cl ean al ong wi th the
transmi ssi on pan.
Whenever a seal is removed f rom a pi ston, shaft or
servo, note the t ype of seal and when appl i cabl e,
t he di recti on of t he sealing lip.
Disassembly
1. Mount transmi ssi on in Bench Mounted Holding
Fi xture T57L-500-B.
07- 01- 124
Tr ansmi ssi on, A u t o ma t i c 4 R 7 0 W 07- 01- 124
DISASSEMBLY (Continued)
2.
Using a 10 mm socket , remove 14 pan retaining
bol ts, transmi ssi on pan and pan to case gasket .
TRANSMISSION
PAN
7A194
PAN TO
CASE GASKET
7A191
D10374-C
pan magnet.
PAN
MAGNET
7L027
010254-C
4. NOTE: Al ways use a new filter and grommet .
Never at t empt t o cl ean or reuse a di rty filter.
CAUTI ON: i f g r o mme t r e ma i n s i n ma i n
c o n t r o l b o r e , u s e a s ma l l s c r e wd r i v e r t o p r y i t
b o r e .
Using bot h hands, remove filter by pulling upward.
GROMMET
D10256-A
CAUTI ON: Do n o t pul l o n wi r e s . Thi s ma y
d a ma g e wi r e s o r c o n n e c t o r s a n d c o u l d r e sul t
i n a t r a n s mi s s i o n c o n c e r n . If r e q u i r e d ,
c a r e f u l l y p r y up o n l o c ki n g t a b a n d
d i s c o n n e c t t h e c o n n e c t o r .
Grasp connector at each solenoid or sensor and
pull strai ght out t o di sconnect.
CONNECTOR
O
D10255-A
DISASSEMBLY (Conti nued)
6. NOTE: Removal of the OSS at t hi s ti me will
prevent sensor damage when removi ng the
output shaft ( 7060) .
Using an 8 mm socket , remove bolt retaining
output shaft speed sensor (OSS) t o case ( 7005)
and remove OSS.
7. Using an 8 mm socket , remove t wo bol ts retaining
transmi ssi on range (TR) sensor t o case. Remove
transmi ssi on range (TR) sensor f rom manual
control lever ( 7 A256) .
D 1 2 7 2 6 - B
manual cont rol val ve det ent lever spri ng ( 7 A261)
t o the main control val ve body.
07- 01- 126 Tr a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W 07- 01- 126
DISASSEMBLY (Cont i nued)
surface.
Remove manual lever shaft retaining pin ( 7B210) .
D889T>6
11. Using a 13/ 16- i nch open-end wrench on the inner
nut and a 12 mm wrench on t he manual control
lever shaft fl ats, loosen the inner nut.
Slide manual control lever partially out of the case
t o compl et e removal of the inner nut f rom manual
control lever.
12. NOTE: Do not damage bore wi th the pryi ng t ool .
Using a screwdri ver on the manual control lever
seal l ower edge, careful l y pry manual control
lever seal out of case bore.
13. Lift manual valve detent lever ( 7A115) and
parki ng lever actuati ng rod ( 7A232) out of the
case.
D1 0 5 4 0 - A
14. Remove el ectroni c pressure control (EPC)
solenoid by sliding it out of the case bore.
07 - 01- 12 7
07 - 01- 12 7
15. This i l l ust rat i on shows the position of the
overdri ve servo, the reverse band servo, 2-3
accumul ator pi ston ( 7F251) and the 1-2
accumul ator pi ston.
1-2 ACCUMULATOR
PISTON 7F251
OVERDRIVE REVERSE BAND ACCUMULATOR
SERVO SERVO PISTON 7F251
7H188 7D189
D10279-D
16. Remove the 2-3 accumul ator spring retainer.
2-3 ACCUMULATOR
SPRING RETAINER
7B264
D10541-B
17. Remove 2-3 accumul ator pi ston.
2-3 ACCUMULATOR
PISTON
7F251
Ove r dr i ve Se r vo
OVERDRIVE SERVO.
PISTON RETAINER
7G280
OVERDRIVE
PISTON
RETURN
SPRING
7F201
OVERDRIVE
SERVO ASSY 7H188
D11503-D
07 - 01- 12 8 T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W 07- 01- 128
18. NOTE: If tool is not avai l abl e, ext reme care must
be t aken. Spring pressure will f orce overdri ve
servo pi ston ( 7 F200) assembl y out of case. Case
bore damage may result f rom tryi ng t o pry on
overdri ve servo piston retainer ( 7G280) .
Use Servo Piston Remover / Repl acer
T92P-70023-A t o compress the overdri ve servo
pi ston return spri ng ( 7F201) . Use snap-ring pliers
t o remove retainer ri ng.
FRONT OF
VEHICLE
SERVO PI STON
REMOVER/
REPLA CER
T92P-70023-A
OVERDRI VE
SERVO
D10121-B
19. Remove pi ston assembl y. Remove overdri ve
servo pi ston return spri ng.
OVERD RI VE SERVO
PI STON RETU RN
SPRI NG 7F201
OVERDRI VE
SERVO PI STON
A SSY
D11504-B
Reverse Band Servo
REVERSE BA ND
SERVO COVER
7D036
REVERSE BA ND
SERVO SPRI NG
7D031
REVERSE BA ND
SERVO PI STON
A ND ROD 7D030
RETA I NI NG RI NG
7384
D10190-C
20.
21.
Use Servo Piston Remover/ Repl acer
T92P-70023-A t o contact the reverse band servo
cover ( 7D036) and compress return spring and
remove servo cover retaining ring.
NOTE: The length of the rod at t ached t o the
pi ston is graded in three different lengths.
Therefore, t hey should not be installed in any
transmi ssi on other than the transmission f rom
whi ch they wer e removed.
Remove reverse band servo cover, reverse band
servo piston and rod ( 7D189) and reverse band
servo spring ( 7D031) .
REVERSE
BA ND
SERVO
SPRI NG
7D031
REVERSE BA ND
SERVO PI STON
A ND ROD
7D030
REVERSE BA ND
SERVO COVER
7D036
D5 S 7 9 - B
22. Appl y downward pressure on 1-2 accumul ator
cover using Servo Piston Remover / Replacer
T92P-70023-A. Using snap-ring pliers, remove
1-2 accumul ator piston retaining ring ( 7384) .
07 - 01- 12 9 T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W 0 7 - 0 1 - 1 2 9
23. Caref ul l y not e t he l ocat i on of t he 1-2 accumul at or
out er spr i ngs ( 7G267) and assembl e in t he same
posi t i ons. Some model s may use t wo 1-2
accumul at or out er spri ngs. The accumul at or
pi st on ma y al so var y wi t h appl i cat i ons. Remove
c ove r and 1-2 accumul at or outer spr i ng. Use
r e ve r se snap-ri ng pl i ers t o remove accumul at or
pi st on and 1-2 shi f t spri ng (7F284).
1-2 ACCUMULATOR
PISTON RETAINING
RING
D10262-C
24. Remove f lui d scr een f r om case.
FLUID
SCREEN
7E242
D10264-C
25. Remove ext ensi on housi ng seal usi ng Seal
Remover T74P-77248-A. Ensure seal remover
li ps ar e f i rml y seat ed under t he f l ange on t he
ext ensi on housi ng seal .
SEAL REMOVER
T74P-77248-A
26.
Dl 123-8
I nspect ext ensi on housi ng bushi ng ( 7 A034) . If
requi red, r emove t he ext ensi on housi ng bushi ng
usi ng Ext ensi on Housi ng Bushi ng Remover
T77L-7697-A.
EXTENSION
HOUSING
7A039
EXTENSION HOUSING
BUSHING REMOVER
T77L-7697-A
D8900-B
07- 01- 130
ZZW-
07- 01- 130
27. NOTE: The extensi on housing bol ts have been
coat ed wi t h a sealant. More break torque may be
requi red t o remove t hese bol ts.
Using a 13 mm socket , remove si x extensi on
housing bol ts. Remove and di scard extensi on
housing gasket ( 7086) .
EXTENSION
HOUSING
7A039
DS903-B
28. The output shaft may have shipping seal still
at t ached. Remove and di scard. Thi s seal is not
requi red f or assembl y.
OUTPUT
SHAFT
SHIPPING
SEAL
D8901-B
29. Slide parki ng pawl shaft ( 7D071) out of the case
and remove parki ng pawl ( 7A441) and parki ng
pawl return spri ng ( 7D070) .
30. Pl ace transmi ssi on in t he verti cal posi ti on wi t h
output shaft t owar d floor.
PARKING QAQi / i K t / >
PAWL PARWNG
SHAFT PAWL
7D071 7A441
PARKING
PAWL
RETURN
SPRING
7D070
m
D10267-B
3 1 . CAUTI ON: E x t r e me c a r e mu s t b e t a ke n
d u r i n g t r a n s mi s s i o n c o n n e c t o r r e mo v a l . Do
n o t pul l o n t h e wi r e s , o r us e a h a mme r o n t h e
c o n n e c t o r b o d y . Thi s wi l l d a ma g e wi r e s o r
c o n n e c t o r a n d c o u l d r e sul t i n a t r a n s mi s s i o n
c o n c e r n .
Remove transmission connector f rom case. Pl ace
a screwdri ver on the flat porti on of the connector
and dri ve the connector out through the bottom of
the case.
TRANSMISSION
CONNECTOR
D10206-A
0 7 - 0 1 - 1 3 1 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 07 - 01- 131
32. Remove f ront pump seal usi ng Seal Remover
TOOL-1175-AC or equi valent and I mpact Sli de
Hammer T59L- 100- B.
IMPACT SLIDE
HAMMER
T59L-100-B
SEAL REMOVER
TOOL-1175-AC
D8905-B
33. NOTE: All bol t s have been c o a t e d wi t h a seal ant .
Mor e br eak t or que mi ght be requi red t o remove
bol t s.
Usi ng a 10 mm soc ke t , remove seven pump body
ret ai ni ng bol t s.
BOLTS
7 REQ'D
D3173-D
34. Remove f r ont pump and suppor t assembl y using
t wo I mpact Sl i de Hammers T59L- 100- B and
Pump Puller Ada pt e r s T89T-70010-A.
IMPACT SLIDE
HAMMERS
B
PULLER ADAPTERS
T89T-70010-A
D10662-C
35.
36.
Remove and d i sc a r d oil pump ga ske t .
CAUTI ON: Re mo v e t h e a s s e mb l y c a r e f u l l y t o
p r e v e n t d a ma g e t o t h e o v e r d r i v e b a n d
f r i c t i o n ma t e r i a l b y t h e r e v e r s e c l u t c h d r i v e
l u gs .
Gr asp t he f o r wa r d cl ut ch cyl i nder and shaf t
( 7 F207 ) f i rml y and pull t he f ol l owi ng component s
out of t he c a se as an assembl y:
I nt ermedi at e cl ut ch pack
I nt ermedi at e one-way cl ut ch
Reverse cl ut ch assembl y
For wa r d cl ut ch assembl y
FORWARD CLUTCH
ASSY
5 ^ 3
REVERSE CLUTCH
ASSY
D11486-A
37. NOTE: Band may be removed wi th assembl y.
Di sengage overdri ve band ( 7F196) f rom
overdri ve band anchor pin ( 7F295) and remove.
OVERDRIVE
BAND
D8910-B
38. Remove f orward cl utch hub and the No. 3 f or war d
cl utch hub front bearing ( 7F231) .
NO. 3 FORWARD
FORWARD CLUTCH CLUTCH
D3178-C
39. Remove intermediate stub shaft.
7C096 D10259-I
40. Rotate reverse cl utch gear and shell ( 7A019) t o
align indent wi th overdri ve band anchor pin.
OVERDRIVE
BAND
ANCHOR PIN
SHELL 7A019 D8S13-D
07 - 01- 133 T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W
07 - 01- 133
4 1 . Remove f orward cl utch sun gear, No. 5 needle
beari ng, reverse cl utch gear and shell and t he No.
4 needle bearing as an assembl y.
NO. 5 NEEDLE
BEARING 7F244 D10S44-B
42. Remove center planet support retaining ri ng. Note
position of retaining ring t abs for assembl y.
TAB
CENTER PLANET
SUPPORT
RETAINING
RING
OVERDRIVE
BAND ANCHOR
PIN 7F295
D3180-E
43. Using needle-nose pl i ers, remove case t o center
support spri ng out f rom bet ween the center
support and t he case. Not e l ocati on f or assembl y.
CASE CENTER SUPPORT
SPRING 7F277
CENTER
SUPPORT
7A130 D10508-B
44. Remove pl anetary gear support and pl anetary as
an assembl y.
PLANETARY GEAR
SUPPORT AND
PLANETARY
D3629-D
45. Remove r ever se band.
RETAINING
RING
D10545-A
47 . Remove output shaft, ring gear ( 7 A153) and
di rect cl utch assembl y as a unit, f rom the front of
the case.
NO. 9 CASE REAR
CLUTCH ASSY D11506-C
48. Remove No. 9 case rear bearing ( 7F242) f rom
rear of t he case.
BEARING
7F242 D3189-E
0 7 - 0 1 - 1 3 5 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 07 - 01- 135
DISASSEMBLY (Continued)
SUBASSEMBLIES
49. Inspect output shaft bushing. If removal is
requi red, use Bearing Cup Puller T77F-1102-A
and Impact Slide Hammer T59L-100-B.
IMPACT SLIDE
HAMMER
T59L-100-B
D8919-A
Service Notes
NOTE: Bef ore beginning Assembl y, per f or m/ i nspect
t he fol l owi ng:
All f ast eners must be t i ght ened to the t orque
i ndi cated in t he t ext . In addi ti on to appeari ng in t he
t ext , the necessary t or ques can be found under
Speci fi cati ons.
When building up subassembl i es, each component
part shoul d be l ubri cated wi t h cl ean Mot orcraf t
MERCON Multi-Purpose Automati c Transmi ssi on
XT-2-QDX or equivalent MERCON approved fl ui d.
It is al so good pract i ce t o l ubri cate the
subassembl i es as t hey are installed in the case
( 7005) .
Needl e beari ngs, thrust washer s and seal s shoul d
be lightly coat ed wi th petrol eum jelly during
subassembl y build up or transmi ssi on assembl y.
Many component s and surf aces in the transmi ssi on
are preci si on machi ned. Careful handling during
di sassembl y, cl eani ng, inspection and assembl y
can prevent unnecessary damage t o machi ned
surfaces.
When building up subassembl i es and assembl i ng the
transmi ssi on, ALWAYS use new gasket s and seal s.
0
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SUBASSEMBLIES (Cont i nued)
Pa r t
I t e m Nu mb e r De s c r i p t i o n I t e m
1 7A100 Main Control Valve Body
Assy
26

2 Valve - Converter Drain Back
(Part of 7A100)
27
3

Valve - Pressure Regulator
(Part of 7A100)
28
4

Spring - Pressure Regulator
Valve (Part of 7A100)
29
5

Plug - Valve Retainer (Part of
7A100)
30
6 Retainer - Valve Plug (Part of
7A100)
31
7

Valve - Capaci ty Modulator
(Part of 7A100)
32
8

Spring - Capaci ty Modulator
33
9 Plate - Spring Retaining (Part
of 7A100)
34
10

Valve - Capaci ty Modulator
(Part of 7A100)
35
11

36
12

Plate - Spring Retaining (Part
of 7A100)
37
13

Valve - 3-4 Shift (Part of
7A100)
38
14 Spring - 3-4 Shift Valve (Part
of 7A100)
39
15
.
7A100)
40

16

Retainer - Valve Plug (Part of
7A100)
41
17 Valve - Capaci ty Modulator
(Part of 7A100)
41
18
42
42
19

43
7A100)
43
20

44
7A100)
44
_
21

Valve - 2-3 Backout (Part of
7A100)
45
22

Spring - 2-3 Backout (Part of
45
_
7A100)
46
23

of 7A100)
46
24

Screen - Solenoid (Part of
47
7A100)
47
25

48
(Part of 7A100)
48
Pa r t
of 7A100)
Valve - Control Manual (Part
of 7A100)
Ring - Retaining (Part of
7A100)
7A100)
Spring - 2-3 Shift Valve (Part
of 7A100)
7A100)
Plug - Valve Retaining (Part
of 7A100)
7A100)
(Part of 7A100)
of 7A100)
Valve - Bypass Clutch
Control (Part of 7A100)
Spring - Bypass Clutch
Control Valve (Part of
7A100)
Plunger - Bypass Clutch
Control Valve (Part of
7A100)
Sleeve - Bypass Clutch
Control Plunger (Part of
7A100)
Plate - Control Valve (Part of
7A100)
Valve - Main Regulator (Part
of 7A100)
Spring - Main Oil Pressure
Regulator Valve (Part of
7A100)
Valve - Main Oil Pressure
Booster (Part of 7A100)
Sleeve - Main Oil Pressure
Booster Valve (Part of
7A100)
7A100)
Check Ball (8 Req'd) (Part of
7A100)
Di s a s s e mb l y
1. Remove retaining bolt and shift solenoid bracket .
07 - 01- 138
07 - 01- 138
DISASSEMBLY A N D ASSEMBLY OF
SUBASSEMBLIES (Continued)
2. Remove shift solenoid ( 7G484) assembl y and
torque converter cl utch sol enoi d (TCC
sol enoi d)(7G136) by pulling strai ght up.
D10573-A
3. Turn main control val ve body ( 7A100) over and
remove 11 bol ts retaining rei nforcement and
separat or pl ates.
D10574-A
4. Remove separat or pl ate and gasket s. Di scard
gasket s.
D10575-A
5. Note location and remove check balls. Remove
solenoid screen.
SUBASSEMBLIES ( Co n t i n u e d )
Check Bai l Locat i ons
CONVERTER
CHECK BALL DRAIN BACK VALVE CHECK BALL
(PART OF 7A100) (PART OF 7A100) (PART OF 7A100)
SOLENOID
SCREEN
(PART OF 7A100) D 1 4 6 4 * *
6. Remove conver t er drai n ba c k val ve.
D10578-B
8. Remove main cont r ol cover ( 7G004) .
07- 01- 140 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W
07- 01- 140
SUBASSEMBLIES (Conti nued)
2. Install t wo guide pin bol ts and four val ve body
cover retaining bol ts. Tighten guide pin bol ts t o
18-24 Nm ( 155- 195 lb-in) and valve body cover
retaining bol ts t o 9-11 N-m (80-100 lb-in) in
sequence shown.
GUIDE PIN BOLTS
D10580-B
3. Install coasti ng booster val ve shuttle balls
( 7E195) , converter drain back valve and solenoid
screen.
4. Install separat or pl ate and new gasket s.
5. Install rei nforcement pl ates. Tighten retaining
bol ts t o 11-15 Nm ( 100- 130 lb-in) in sequence
shown.
6. Inspect O-rings on sol enoi ds for damage. Install
shift solenoid assembl y and torque converter
cl utch sol enoi d.
O-RINGS
D10581-A
7. Install bracket and retaining bolt. Tighten t o 9-11
N-m (80-100 lb-in).
D10582-A
D12776-A
07 - 01- 141
0 7 - 0 1 - 1 4 1
Pump and Intermedi ate Clut ch Pi ston-
Disassembly
Di sa sse mbl e d Vi ew
Pa r t
2 7A248 Front Pump Seal
3 N605789-S100 Bolt (7 Req'd)
4 7A106 Front Pump Assy
5 7H169 Pump Inner Gerotor
6 N605789-S52 Bolt (5 Req'd)
7 7D014 Thrust Washer
8 7D020 Reverse Clutch Cylinder
Seal
9 7D019 Forward Clutch Cylinder
Seals
10 7F222 Intermediate Clutch Retainer
Spring Assy
Pa r t
11 7E005 Intermediate Clutch Piston
Outer Seal
Inner Seal
14 7A108 Front Pump Stator Support
15 7H169 Pump Outer Gerotor
16 7A136 Pump Gasket
17 7B258 Front Pump Bushing
18 7A248 Front Pump Inner Seal
19 87650-S2 Converter Drain Plug
Di s a s s e mb l y
1. Remove t he No. 1 t hrust wa she r ( 7 D014) .
D3833-E
2. Usi ng a 10 mm soc ke t , remove f i ve f ront pump
suppor t bol t s. Separ at e f ront pump suppor t
( 7 A108) and pump assembl y.
016277-B
3. NOTE: The r ever se cl ut ch seal s are l arger t han
t he f o r wa r d cl ut ch seal s.
Remove t wo e a c h of r ever se cl ut ch cyl i nder
seal s ( 7 D020) and f o r wa r d cl ut ch seal s.
REVERSE CLUTCH
SEALS 2 REQ'D
2 REQ'D
D11466-B
4. Remove inner and out er pump ge r ot or s f r om
pump body.
5. Remove spri ng ret ai ner assembl y by caref ul l y
di sl odgi ng t he t abs.
D3194-D
6. Remove i nt ermedi at e cl ut ch pi st on ( 7E005) and
i nt ermedi at e cl ut ch pi st on inner seal ( 7 F2 2 5) and
i nt ermedi at e cl ut ch pi st on out er seal ( 7F224) .
7. Remove f ront pump seal and d i sc a r d .
FRONT PUMP
D3267-E
P u m p B u s h i n g
Oi l Pump Bu s h i n g Re mo v e r
Oi l Pump Bu s h i n g Re p l a c e r
T 80L - 7 7 2 68- B
T80L - 7 7 2 68- A
Di s a s s e mb l y
1. If r equi r ed, remove f ront pump bushi ng usi ng
Pump Bushi ng Remover T80L- 77268- B.
A s s e m b l y
1. To i nst al l , pr ess t he f ront pump bushi ng using
Pump Bushi ng Repl acer T80L-77268-A.
PUMP
D10658-C
P u m p a n d I n t e r m e d i a t e C l u t c h
P i s t o n A s s e m b l y
Fr o n t Pump Se a l Re p l a c e r
I n t e r me d i a t e Cl u t c h P i s t o n Se a l
P r o t e c t o r
T 63L - 7 7 837 - A
T 95L - 7 7 005- A
A s s e m b l y
1. Install t he f ront pump seal usi ng Front Pump Seal
Repl acer T63L- 77837- A.
FRONT PUMP
D10275-A
2. Install new i nt ermedi at e cl ut ch pi st on inner seal
( 7 F2 2 5) and i nt ermedi at e cl ut ch pi st on out er seal
( 7 F2 2 4) on i nt ermedi at e cl ut ch pi st on (7E005).
D10274-B
3. CAUTI ON: T h e p i s t o n b l e e d h o l e mu s t b e
l o c a t e d a t 12 o ' c l o c k p o s i t i o n ( t o wa r d t o p o f
t r a n s mi s s i o n ) . If i n c o r r e c t l y i n s t a l l e d ,
t r a n s mi s s i o n ma y n o t o p e r a t e p r o p e r l y .
NOTE: Pi st on bl eed hole is t he only round hole in
t he i nt ermedi at e cl ut ch pi st on assembl y.
Not e l ocat i on of t he pi st on bl eed hol e.
PISTON BLEED
D10276-A
4.
5.
NOTE: Coat i ntermedi ate cl utch pi ston outer seal
and intermediate cl utch piston inner seal and
pump body sealing area wi th petrol eum jelly.
Install i ntermedi ate cl utch pi ston as f ol l ows:
a. Install i ntermedi ate cl utch pi ston in
Intermediate Cl utch Lip Seal Prot ect or
T80L-77005-A.
PISTON
BLEED
HOLE
INTERMEDIATE
CLUTCH PISTON
SEAL PROTECTOR
T95L-77005-A
D3269-D
Install i ntermedi ate cl ut ch pi ston in pump body
and push i ntermedi ate cl utch pi ston t o t he bot t om
of t he bore by exerti ng even pressure.
D3637-D
6. Snap spri ng retai ner assembl y into pl ace on pump
body.
SPRING RETAINER
APPLY EVEN PRESSURE
TO INSTALL
D3270-C
7. Install the inner and outer pump gerot ors in pump
body.
The fl ats have st eps that must f ace t he pump
body f or ease of installing the t orque converter
( 7902) .
PUMP INNER
GEROTOR
INNER GEROTOR
FLATS
D10251-C
8. Install reverse cl utch cylinder seal ( 7D020) and
2 REQ'D
D11466-B
9. Position pump st at or support t o pump body and
install retaining bol ts. Tighten t o 20- 26 N-m
(15-19 Ib-ft).
Intermediate Clutch Cylinder
NOTE: One-way cl utch must rot at e count ercl ockwi se
when installed on drum.
D10209-D
07- 01- 147 T r a n s mi s s i o n , A u t o m a t i c 4 R7 0 W
22EEET7
0 7 - 0 1 - 1 4 7
SUBASSEMBLIES ( C o n t i n u e d )
Di s a s s e mb l y
1. Remove cl utch retaining ring.
CLUTCH
RETAINING
RING
D1Q246-A
2. Remove one-way cl utch retainer.
ONE WAY CLUTCH
RETAINER
D3231-E
3. Remove cl utch outer race by lifting on the race
whi l e turning count ercl ockwi se.
Carefully lift one-way cl utch f rom reverse cl utch
drum ( 7D044) .
OUTER
RACE
D3232-E
A s s e m b l y
NOTE: For ease in assembl y, t he chamfer on the outer
cl utch race splines should f ace upwar d.
ONE-WAY
CLUTCH
7A089
D8929-B
1. NOTE: One-way cl utch must rot at e
count ercl ockwi se when installed on reverse
cl utch drum.
Install one-way cl utch on reverse cl utch drum.
07 - 01- 148
2. Install cl ut ch out er r ace.
OUTER
RACE
3. Install one-way cl utch retainer and spri ngs.
4. Install cl ut ch retai ni ng ri ng.
ONE WAY CLUTCH
RETAINER
D3231-E
D3232-E
R e v e r s e C l u t c h
13 . 12
11
D10210-B
Pa r t
1 7D044 Reverse Clutch Drum
Spring Pressure Ring
3 7B070 Reverse Clutch Piston
Spring
I t e m
Pa r t
4 7B442 Reverse Clutch External
Spline Clutch Plate
5 7B066 Clutch Pressure Plate
6 7A166 Forward Clutch Bearing
Retainer Snap Ring
( Co n t i n ue d )
i t em
Pa r t
8 7B164 Reverse Clutch Internal
Spline (Friction) Plates
10 7A677 Clutch Pressure Plate
Retainer Snap Ring
Pa r t
11 7D404 Reverse Clutch Piston Small
Seal
13 7D403 Reverse Clutch Piston Outer
Seal
Cl u t c h Spr i n g Co mp r e s s o r
Re v e r s e Cl u t c h Sp r i n g Co mp r e s s o r
Re v e r s e Cl u t c h I nner Se a l P r o t e c t o r
Re v e r s e Cl u t c h Ou t e r Se a l P r o t e c t o r
T 65L - 7 7 515- A
T 80L - 7 7 405- A
T 80L - 7 7 403- B
T 80L - 7 7 403- A
Di s a s s e mb l y
1. Remove No. 2 needle beari ng.
NO. 2
NEEDLE
BEARING
REVERSE CLUTCH
D8584-C
2. Remove cl utch pressure pl ate retai ner snap ring
( 7D483) .
CLUTCH PRESSURE
PLATE RETAINER
SNAP RING
7D483
3. Remove cl utch pack.
CLUTCH PACK
D3225-C
Install Reverse Clutch Spring Compressor
T80L- 77405- A and Clutch Spring Compressor
T65L- 77515- A onto reverse cl utch drum
( 7D044) . Tighten enough t o compress reverse
cl utch piston spri ng ( 7B070) . Remove cl utch
pressure pl ate retainer snap ring ( 7A577) .
REVERSE CLUTCH
SPRING COMPRESSOR
T80L-77405-A
CLUTCH SPRING
COMPRESSOR
T65L-77515-A
D10555-B
D3224-D
NOTE: To ai d in reverse cl ut ch pi st on spri ng
removal , it may be necessar y t o appl y air
pressure t o t he r ever se cl ut ch dr um. Bl ock t he
opposi t e hole wi t h a fi nger.
Remove reverse cl ut ch pi st on ( 7D402) , r ever se
cl ut ch pi st on spri ng and reverse cl ut ch pi st on
spri ng pr essur e ri ng ( 7D256) .
REVERSE CLUTCH
PISTON SPRING
PRESSURE RING
7D256
REVERSE CLUTCH
PISTON SPRING
7B070
D3227-D
6. Remove r ever se cl ut ch pi st on and r ever se cl ut ch
pi st on smal l seal ( 7D404) and r ever se cl ut ch
pi st on out er seal ( 7D403) .
APPLY AIR HERE
D8935-A
A s s e m b l y
1. NOTE: The pi st on c he c k ball must be present and
movi ng f reel y.
NOTE: Coat r ever se cl ut ch pi st on out er seal and
r ever se cl ut ch pi st on small seal , r ever se cl ut ch
dr um, seal i ng ar ea and seal pr ot e c t or wi t h
pet rol eum j el l y.
Install new r ever se cl ut ch pi st on smal l seal and
r ever se cl ut ch pi st on out er seal on r ever se cl ut ch
pi st on. Di rect i on of i nst al l at i on is not i mport ant
because seal s are squar e cut .
NOTE: THE SEALS ARE SQUARE AND
THEREFORE CAN BE INSTALLED IN EITHER
DIRECTION.
REVERSE
CLUTCH
PISTON
OUTER
SEAL
7D403
CHECK
BALL
REVERSE CLUTCH
PISTON SMALL
SEAL 7D404
D5885-C
2. Install r ever se cl ut ch pi st on as f ol l ows:
a. Install Reverse Cl ut ch Inner Seal Pr ot ect or
T80L- 77403- B on t he cl ut ch hub and
Reverse Cl ut ch Out er Seal Pr ot ect or
T80L- 77403- A over t he reverse cl ut ch
pi st on.
b. Posi t i on reverse cl ut ch pi st on and push it t o
t he bot t om of t he r ever se cl ut ch drum usi ng
even t humb pressure.
REVERSE CLUTCH
SEAL PROTECTOR
(INNER)
T80L-77403-B
REVERSE CLUTCH
SEAL PROTECTOR
(OUTER) T80L-77403-A
D10249-A
3. Install r ever se cl ut ch pi st on spri ng pr essur e ri ng
and r ever se cl ut ch pi st on spri ng. The di shed si de
of r ever se cl ut ch pi st on spri ng must f a c e t o wa r d
t he r ever se cl ut ch pi st on.
4. Install r ever se cl ut ch pi st on spri ng pr essur e ri ng
(wi t h poi nt s down) usi ng Reverse Cl ut ch Spri ng
Compr essor T80L- 7 7 405- A and Cl ut ch Spri ng
Compr essor T65L- 77515- A.
5. Install f r ont cl ut ch pr e ssur e pl at e ( 7 B066) , cl ut ch
pa c k and rear cl ut ch pr essur e pl at e. Posi t i on t he
st e ppe d si de of f ront cl ut ch pr essur e pl at e down
wi t h f l at si de t o wa r d cl ut ch pack and rear cl ut ch
pr essur e pl at e f l at si de t o wa r d cl ut ch pa c k.
|
REAR PRESSURE
D10128-B
6. Install cl ut ch pa c k cl ut ch pr essur e pl at e ret ai ner
snap ri ng and c he c k t he cl ear ance bet ween t he
cl ut ch pr essur e pl at e ret ai ner snap ri ng and t he
cl ut ch pr essur e pl at e usi ng a f eel er gauge. Cl ut ch
pr e ssur e pl at e shoul d be hel d d o wn wa r d as
cl ear ance is c he c ke d usi ng Di al I ndi cat or wi t h
Br a c ke t r y TOOL-4201-C or equi val ent .
D10557-B
The cl ear ance shoul d be:
Four pl at e assembl y
1. 01-1. 524 mm ( 0. 040- 0. 060 i nch)
If cl earance i s not wi t hi n speci f i cat i on, i nstall c o r r e c t
si ze ret ai ni ng ri ng and c he c k cl ear ance. Sel ect i ve
retai ni ng ri ngs are avai l abl e in t he f ol l owi ng
t hi cknesses:
Selective Retaining Flings
1. 52- 1. 62 mm ( 0. 060- 0. 064 i n c h)
1. 87- 1. 98 mm ( 0. 07 4- 0. 07 8 i n c h)
2 . 2 3- 2 . 33 mm ( 0. 088- 0. 092 i n c h)
2 . 59- 2 . 69 mm ( 0. 102 - 0. 106 i n c h)
7. Check cl ut ch f or proper operat i on usi ng Ai r
Nozzl e TOOL-7000-DE or equi val ent . The cl ut ch
shoul d be heard and f el t t o wo r k smoot hl y and
wi t hout l eakage.
APPLY AIR HERE
DIAL INDICATOR
WITH BRACKETRY
TOOL-4201-C
D8935-A
D10558-B
Forward C l u t c h C y l i n d e r
D11508-A
07 - 01- 15 3 T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W 07 - 01- 153
i t e m
Pa r t
1
7D483 Reverse Clutch Pressure
Plate Retainer Snap Ring
2 7F207 Forward Clutch Cylinder and
Shaft
3 7A548 Outer Seal
4 7A480 Return Spring
5 7A527 Forward Clutch Piston
Spring Retainer
6 7B442 Forward Clutch External
Spline Clutch Plate
Retainer Snap Ring
8 7B067 Forward Clutch Hub
De s c r i p t i o n JOI N u mb e r
Di r e c t Cl u t c h Spr i n g Co mp r e s s o r
Fo r wa r d Cl u t c h Li p Se a l P r o t e c t o r
( I n n e r )
Fo r wa r d Cl u t c h Li p Se a l P r o t e c t o r
( Out e r )
T 65L - 7 7 515- A
T 81P - 7 02 35- A
T 80L - 7 7 140- A
T 68L - 7 D158- A
Di s a s s e mb l y
1. NOTE: Forward cl utch hub may remai n in shell
during di sassembl y.
Remove f orward cl utch hub and No. 3 f or war d
cl utch hub front beari ng ( 7F231) , if not al ready
removed.
FORWARD CLUTCH
HUB 7B067
D3832-D
Pa r t
9 7F231 Forward Clutch Hub Front
Bearing
11 7B164 Forward Clutch Internal
Spline (Fri cti on) Plates
12 7E085 Forward Clutch Pressure
Spring
13 388099-S Retaining Ring
14 7A262 Clutch Piston
15 7C099 Forward Clutch Inner Seal
16 7A166 Forward Clutch Bearing
17 7B497 Input Shaft Seal
2. NOTE: To aid handling, cl utch may be set in t he
extensi on housing ( 7A039) or a 51 mm (2 inch)
di ameter hole may be cut in t he wor k bench.
Remove cl utch pack cl utch pressure pl ate
retainer snap ring ( 7D483) .
D3236-E
3. Remove cl ut ch pack, cl ut ch pr essur e pl at e
( 7 B066) and f o r wa r d cl ut ch pressure spri ng.
4. Compr ess cl ut ch support and spri ng usi ng Di rect
Cl ut ch Spri ng Compr essor T81P-70235-A.
Pl ace into a shop ar bor pr ess and appl y only
enough pressure t o rel ease spri ng t ensi on on t he
snap ri ng.
Remove snap ri ng and sl owl y rel ease t he pr ess t o
r emove spri ng compr essor .
D10243-C
5. NOTE: Ai r pr essur e may be requi red t o remove
cl ut ch pi st on ( 7 A262) .
Remove cl ut ch pi st on spri ng ret ai ner ( 7 A527 ) ,
ret urn spri ng and cl ut ch pi st on.
6. Remove pi st on di r ect cl ut ch inner seal ( 7C099)
and out er pi st on seal s.
CLUTCH PISTON
D3238-C
7. NOTE: Make sure input shaf t Teflon seal s are
not damaged.
NOTE: Soli d shaf t seal s may be r epl aced wi t h
scar f -cut seal s f or servi ce.
Remove seal s f r om f o r wa r d cl ut ch cyl i nder and
shaf t ( 7F207) .
8. Ma ke sure c he c k ball in cl ut ch cyl i nder are f r ee
and cl ean. Check f or proper seat i ng.
A s s e mb l y
1. NOTE: Coat pi ston seal s and cl utch drum sealing
area wi t h petrol eum jelly.
Install new seal s on cl utch pi ston. Note di recti on
of the sealing lip before installation.
CLUTCH
PISTON
7A262
PISTON SEAL
D10240-B
2. Install cl utch piston as fol l ows:
a. Install For war d Cl utch Lip Seal Prot ect or
(Inner) T80L- 77140- A over cl utch cylinder
hub.
b. Install cl utch pi ston in For war d Cl utch Lip
Seal Prot ect or (Out er), T68P-7D158-A.
FORWARD CLUTCH
LIP SEAL PROTECTOR
(OUTER) T68P-7D158-A
FORWARD CLUTCH
LIP SEAL PROTECTOR
(INNER) T80L-77140-A
D10241-B
3. Position seal prot ect or and cl utch piston in
f orward cl utch cyl i nder and shaft. Push cl utch
pi ston t o the bot t om of the f orward cl utch cyl i nder
and shaft using even thumb pressure. Remove
seal prot ect ors.
FORWARD CLUTCH
LIP SEAL PROTECTOR
(INNER) T80L-77140-A
FORWARD CLUTCH
LIP SEAL PROTECTOR
(OUTER) T68P-7D 158-A
CLUTCH
PISTON
7A262
D8945-B
07 - 0- ^156
4. Install piston return spring and cl utch piston
spring retainer.
D10559-A
Compress pi ston return spri ng using Di rect Cl utch
Spring Compressor T81P-70235-A. Compress
cl utch piston only enough t o al l ow cl earance t o
install snap ring.
DIRECT CLUTCH
SPRING
COMPRESSOR
T81P-70235-A
D10243-C
Install cl utch pack in the fol l owi ng order:
a. Forward cl utch pressure spri ng.
b. Cl utch pack.
c. Cl utch pressure pl ate.
CLUTCH
PACK
FORWARD CLUTCH
PRESSURE
SPRING
7E085
CLUTCH
PRESSURE
PLATE
7B066
D10252-C
7. Install cl utch pack cl utch pressure pl ate retainer
snap ring and check the cl earance bet ween the
cl utch pressure pl ate retainer snap ring and
cl utch pressure plate using Dial Indicator wi t h
Bracket ry TOOL-4201-C or equivalent.
Cl utch pressure pl ate should be held downwar d
as the cl earance is checked.
DIAL INDICATOR
WITH BRACKETRY
TOOL-4201-C
D10560-B
07 - 01- 157 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 07 - 0- W- 57
D10S1-B
If the cl earance is not within speci fi cati on, install
the correct size retaining ring and recheck t he
cl earance. Sel ecti ve retaining rings are avai l abl e
in the following t hi cknesses:
Selective Retaining Ring
1. 52- 1. 62 mm ( 0. 060- 0. 064 i n c h)
1. 87- 1. 98 mm ( 0. 07 4- 0. 07 8 i n c h)
2 . 2 3- 2 . 69 mm ( 0. 086- 0. 092 i n c h)
2 . 59- 2 . 69 mm ( 0. 102 - 0. 106 i n c h)
8. NOTE: Scarf-cut seal s must be installed wi t h
mating surfaces as shown.
Install t wo scarf-cut seal s on t he f orward cl utch
cylinder and shaft if original seal s are damaged or
missing.
CORRECT
The cl earance should be:
1.27-2.26 mm ( 0. 50- 0. 089 inch)
9. Install No. 3 f or war d cl utch hub front beari ng.
Install f or war d cl utch hub into f orward cl utch
cylinder and shaft, ensure f or war d cl utch hub is
agai nst No. 3 f or war d cl ut ch hub front beari ng.
NO. 3 FORWARD
CLUTCH HUB
FRONT BEARING
INCORRECT
D10657-A
07f 0-1?158
Tr ansmi ssi on, Aut oma t i c 4R70W 07 - 01- 158
Pl a n e t a r y Ge a r Su p p o r t A s s e mb l y a n d
P l a n e t a r y L o w O n e - Wa y Cl u t c h
Di sa sse mbl y
PLANETARY
ONE-WAY
CLUTCH
7A089
PLANETARY
GEAR SUPPORT
ASSY 7A130
FRONT PLANET
7A398
D10212-B
1. Remove pl anetary gear support assembl y f rom
f orward pl anetary assembl y. Rotate the
pl anetary gear support assembl y
count ercl ockwi se and lift.
PLANETARY
GEAR SUPPORT
ASSY 7A130
2.
PLANETARY
ASSY
7A398
D10239-C
Carefully remove pl anetary one-way cl utch f rom
f or war d pl anetary assembl y.
PLANETARY
ONE-WAY
CLUTCH 7A089
PLANETARY
ASSY
7A398
D3242-E
A s s e mb l y
1. Inspect cl utch outer race, inner race, band
surface, pinion gears, beari ngs and thrust washer
for roughness.
Inspect planet support bushing for roughness.
Inspect one-way cl utch ( 7A089) , rollers and
spri ngs for damaged rol l ers and broken spri ngs.
D1938-G
Part
Item Number Descri pt i on
1 7A089 Planetary One-Way Clutch
2

Cage (Part of 7A089)
3

Spring (Part of 7A089)
4

Roller (Part of 7A089)
( Co n t i n ue d )
I t e m
Pa r t
5

"Cam Type" Clutch Race
(Part of 7A130)
6

Planetary Carrier (Part of
7A130)
7 7A130 Planet Support
2. Install one-way cl ut ch in f o r wa r d pl anet ary
assembl y.
3. Install pl anet ary gear support assembl y i nto
one-way cl ut ch by rot at i ng t he pl anet ary gear
suppor t assembl y c ount e r c l oc kwi se .
Lubr i cat e cl ut ch r aces and cl ut ch assembl y wi t h
pet rol eum j elly t o ai d in assembl y.
Reverse Sun Gear Assembly
Di sassembl y
NO. 4 THRUST
BEARING
7C096
REVERSE SUN
GEAR ASSY
7A019
FORWARD CLUTCH
SUN GEAR
7A399
NO. 5 THRUST BEARING
7 F 2 4 4
D14963-A
2. NOTE: The f o r wa r d c l ut c h sun gear and r ever se
sun gear a sse mbl y is a sse mbl e d as par t of t he
t r ansmi ssi on a sse mbl y pr oc e dur e .
Re move f o r wa r d c l ut c h sun gear and No. 5 t hr ust
beari ng f r o m r ever se sun gear assembl y.
FORWARD CLUTCH SUN GEAR
7A399
REVERSE SUN
GEAR ASSY
7A019
D4243-E
1. Remove t he No. 4 t hrust beari ng ( 7C096) f r om
r ever se sun gear assembl y.
i yi i ti H P w i i i i i i i i i i i i i
1 1
; >mmmmmh+mmmmmmmmmm in i iiiiiniiiiiiMiiiiiiiii i I I I MI I I I P I mnmwmm MmMmmmmmmmmwmmmiMM mmwmm
Output Shaft and Direct Clutch Cylinder
D14S9S-A
i t e m
Pa r t
1 7F236 Direct Clutch Hub
Washer
4 7A153 Ring Gear
5 7F283 Direct Clutch Cylinder
6 7F274 Output Shaft to Direct Clutch
Cylinder Seal
I t e m
Pa r t
7 7F240 Direct Clutch Bearing and
Race
8 87054-S94 Seal (Piloted Output Shaft
Only)
9 7060 Output Shaft
10 7F273 Output Shaft to Case Seal
11 7D164 Output Shaft Hub
12 7064 Snap Ring
07- 01- 161
07-OT-:161
Di s a s s e mb l y
1. Remove snap ri ng ret ai ni ng t he out put shaf t hub
( 7D164) t o ri ng gear ( 7 A153) .
OUTPUT SHAFT
BEARI NG SNAP
RING
7064
D11510-B
2. Separ at e out put shaf t ( 7 060) f r om ri ng gear .
NO. 8 DIRECT CLUTCH
INNER BEARI NG 7F243
OUTPUT
SHAFT 7060
DIRECT CLUTCH
7F283
D11511-C
3. Remove snap ri ng ret ai ni ng out put shaf t hub.
Sli de out put shaf t hub off rear of out put shaf t .
OUTPUT
SHAFT
8
* "
HUB
7D164
D10247-C
4. NOTE: The i l l ust rat i on sho ws t he c o r r e c t
l ocat i ons f or out put sha f t t o c a se seal s ( 7 F27 3) .
OUTPUT SHAFT
TO CASE SEAL
7F273
3 REQ'D
D10546-C
Remove t hr e e out put shaf t t o c a se seal s and
out put shaf t O-ring seal .
Pi l ot ed Out put Shaf t Onl y
O-RING SEAL
87054-S94
OUTPUT SHAFT
7060 D11512-B
5. Remove t wo out put shaf t t o di rect cl ut ch cyl i nder
seal s ( 7 F27 4) f r om t he out put shaf t . Not e t he
di rect i on of t he out put shaf t t o di r ect cl ut ch
cyl i nder seal s.
OUTPUT SHAFT
TO DIRECT
CLUTCH CYLINDER
SEAL
7F274
2 REQ'D
D10248-D
07 ^01- 162 T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W 07 - 01- 162
Di rect Clut ch Cyli nder
Di sa sse mbl e d Vi e w
Pa r t
Retainer Snap Ring
4 7B442 Direct Clutch External Spline
Clutch Plate
5 388104-S Retaining Ring
6 7F283 Direct Clutch Cylinder
7 7A548 Outer Seal
Cl u t c h Sp r i n g Co mp r e s s o r T65L - 7 7 515- A
Di r e c t Cl u t c h I nner L i p Se a l P r o t e c t o r T 80L - 7 7 2 34- A
Di r e c t Cl u t c h Ou t e r Li p Se a l P r o t e c t o r T 80L - 7 7 2 54- A
Pa r t
8 7C099 Direct Clutch Inner Seal
9 7A262 Clutch Piston
10 7F235 Direct Clutch Retainer and
Spring Assembly
11 7B164 Direct Clutch Internal Spline
(Friction) Plates
Washer
13 7f236 Direct Clutch Hub
07 - 01- 163 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 07- 1i1S3
Di s as s embl y
1. Af t er removi ng di r ect cl ut ch hub, r emove No. 7
di r ect cl ut ch inner beari ng ( 7 F243) and di rect
cl ut ch inner beari ng wa she r ( 7F237) .
NO. 7 DIRECT
CLUTCH INNER
BEARING
7F243
DIRECT CLUTCH
INNER BEARING
WASHER 7F237
D10150-B
2. Remove cl ut ch pr essur e pl at e ret ai ner snap ri ng
( 7 D483) . Remove and i nspect cl ut ch pack. Not e
t he rel at i on of cl ut ch pr essur e pl at es ( 7 B066) f or
assembl y.
CLUTCH
PRESSURE
PLATE
7B066
CLUTCH
PACK
D3285-D
3. Usi ng Cl ut ch Spri ng Compr e ssor T65L- 77515- A
c o mpr e ss t he di r ect cl ut ch suppor t and spri ng
( 7 F2 35) . Remove pi st on ret ai ni ng ri ng using
expandi ng-t y pe snap-ri ng pl i ers.
CLUTCH SPRING
COMPRESSOR
T65L-77515-A
PISTON
RETAINING
RING
388104-S
D10268-C
NOTE: Use air pr essur e if necessar y t o r emove
cl ut ch pi st on ( 7 A262) .
Remove di rect cl ut ch suppor t and spri ng and
cl ut ch pi st on f r om di r ect cl ut ch cyl i nder.
CLUTCH
PISTON
7A262
D3209-E
07 ?t >: i * i 64
07 - 01- 164
5. Remove di rect cl ut ch inner seal ( 7C099) f r om
di rect cl ut ch and out er seal f r om cl ut ch pi st on.
Veri f y pr esence of c he c k ball and t hat it moves
f reel y.
CHECK
BALL
DIRECT CLUTCH
INNER SEAL
7C099
D14964-A
A s s e m b l y
1. NOTE: Lubr i cat e di rect cl ut ch inner seal and seal
pr ot e c t or wi t h pet rol eum j elly.
Install di r ect cl ut ch inner seal on di r ect cl ut ch as
f ol l ows:
a. Posi t i on Di rect Cl ut ch Inner Li p Seal
Pr ot e c t or T80L-77234-A over di r ect cl ut ch
cyl i nder.
b. Posi t i on di r ect cl ut ch inner seal over
pr ot e c t or t ool wi t h t he seal i ng lip f aci ng
d o wn .
DIRECT CLUTCH
INNER SEAL
7C099
DIRECT CLUTCH
INNER LIP SEAL
PROTECTOR
T80L-77234-A
2. NOTE: Coat di rect cl ut ch inner seal and out er
pi st on seal s, cl ut ch cyl i nder seal i ng a r e a and
pi st on inner seal i ng ar ea wi t h pet rol eum j elly.
Install cl ut ch pi st on out er seal . Not e di rect i on of
seal i ng lip bef or e i nst al l at i on. The lip shoul d poi nt
t o wa r d bot t om of cl ut ch cyl i nder.
OUTER PISTON SEAL
NOTE DIRECTION
OF SEAL LIP BEFORE
INSTALLATION
D3272-C
3. Install cl ut ch pi st on as f ol l ows:
a. Install cl ut ch pi st on in Di rect Cl ut ch Out er Li p
Seal Pr ot ect or T80L-77254-A.
DIRECT CLUTCH OUTER
LIP SEAL PROTECTOR
T80L-77254-A
D10547-C
D10269-C
07 - 01- 165 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 07 - 01* 165
b. Position tool in t he di rect cl utch and push the
cl utch pi ston to the bot t om of the di rect
cl utch cylinder using even thumb pressure.
DIRECT CLUTCH
OUTER LIP
SEAL
PROTECTOR
T80L-77254-A
D10273-B
Install di rect cl utch support and spri ng and
retaining ring using Clutch Spri ng Compressor
T65L- 77515- A.
CLUTCH SPRING
COMPRESSOR
T65L-77515-A
PISTON
RETAINING
RING
388104-S
D10268-C
Install cl ut ch pack and cl utch pressure pl ate.
6. NOTE: TOOL-4201-C or equivalent may al so be
used f or cl earance check.
Wi t h cl utch pressure plate retai ner snap ring
i nstal l ed, check cl earance bet ween cl utch
pressure pl ate retainer snap ring and cl utch
pressure pl ate using a feel er gauge.
Cl utch pressure pl ate should be held downwar d
as the cl earance is checked.
FEELER
GAUGE
CLUTCH PRESSURE
PLATE RETAINER
RING 7D483
The cl earance should be:
D3274-C
Six Plate 1.52-2.33 mm ( 0. 065- 0. 082 inch).
If t he cl earance is not wi thi n limits, install
the correct size retaining ring and check
the cl earance. Sel ecti ve retaining rings are
available in the following t hi cknesses:
Selective Retaining Rings
1. 27-1. 37 mm ( 0. 050- 0. 054 i n c h )
1.62- 1.72 mm ( 0. 064- 0. 068 i n c h )
1. 98- 2. 08 mm ( 0. 07 8- 0. 082 i n c h )
2 . 33- 2 . 43 mm ( 0. 092 - 0. 096 i n c h )
D3285-D
07 - 01- 166
0 7 - 0 1 - 1 6 6
8. Install No. 7 di rect cl ut ch inner beari ng washer
(wi t h count er bor e down) and No. 7 di r ect cl ut ch
inner beari ng (bl ack si de up t o wa r d rear cl ut ch
hub).
D10271-C
9. Install di rect cl ut ch hub ( 7F236) .
REAR CLUTCH
HUB 7F236
D14965-A
10. Install t wo out put shaf t t o di r ect cl ut ch cyl i nder
seal s ( 7 F27 4) . Ensure out put shaf t t o di r ect
cl ut ch cyl i nder seal s ar e pr oper l y l apped.
DIRECT CLUTCH
CYLINDER
SEALS 7F274
2 REQ'D
D10548-B
11. Install out put shaf t hub ( 7 D164) . Install snap ri ng.
D10549-A
12. NOTE: Ma ke sure out put shaf t t o c a se seal s
( 7F273) are l apped properl y.
Install t hree out put shaf t t o c a se seal s and out put
shaf t O-ring seal .
07 - 01- 167 T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W 0 7 - t f P 1 6 7
13. Install No. 8 di rect cl utch hub bearing and race
( 7F240) on di rect cl utch cylinder.
NO. 8 DIRECT
CLUTCH HUB
BEARING AND
RACE 7F240
D10551-D
14. NOTE: Di rect cl utch cylinder may be installed
after ring gear ( 7A153) is installed t o output shaft
hub.
Install di rect cl utch cylinder on output shaft
( 7 060) .
NO. 8 DIRECT
CLUTCH HUB
BEARING AND
RACE 7F240
D10552-D
15. Install ring gear and snap ring on output shaft.
OUTPUT SHAFT
BEARING SNAP
RING 7064
m 4 K
B
D11513-B
16. Install fol l owi ng components as an assembl y:
Intermediate one-way cl utch
Reverse cl utch
Forward cl utch
17. Install reverse cl utch assembl y on f or war d cl utch
assembl y.
REVERSE
CLUTCH
FORWARD"
CLUTCH
D11484-B
07 - 01* 168
Torque Convert er Checks
Co n v e r t e r Cl u t c h Ho l d i n g To o l
Co n v e r t e r Cl u t c h To r qui n g To o l
T 7 7 L - 7 902 - R
T 7 6L - 7 902 - C
On e - Wa y C l u t c h C h e c k
1. Insert t he Convert er Cl ut ch Holdi ng Tool
T77L-7902-R in one of t he gr ooves in t he st at or
t hrust washer.
T77L-7902-R
CONVERTER
CLUTCH HOLDING
TOOL
4.
f f
S
Insert t he Convert er Cl ut ch Torqui ng Tool
T76L-7902-C in conver t er pump dri ve hub t o
engage one-way cl ut ch inner r ace.
At t a c h a t or que wr e nc h t o t he conver t er cl ut ch
t orqui ng t ool . Wi t h t he convert er cl ut ch holdi ng
t ool held st at i onary, t urn t he t or que wr e nc h
count er cl ockwi se. The t or que conver t er one-way
cl ut ch shoul d l ock up and hol d a 13 N-m ( 10 Ib-ft)
f o r c e . The t or que convert er one-way cl ut ch
shoul d r ot at e f reel y in a c l oc kwi se di rect i on until
t orqui ng t ool c ont a c t s t he holdi ng t ool . Try t he
cl ut ch f or l ock up and hol d in at l east f i ve di f f erent
l ocat i ons around t he t or que convert er ( 7902) .
If t he cl ut ch f ai ls t o l ock up and hol d a 13 N-m ( 10
Ib-ft) t or que, repl ace t he t orque conver t er .
CONVERTER CLUTCH
TORQUING TOOL
T76L-7902-C
D2877-JC
To r que Co n v e r t e r Cl ut c h Che c ks
TORQUE WRENCH
SPLINED INTO
STATOR CLUTCH
INNER RACE
CONVERTER CLUTCH*
TORQUING TOOL
T76L-7902-C
D454*D
S t a t o r t o I mp e l l e r I n t e r f e r e n c e C h e c k
1. NOTE: Front pump suppor t ( 7 A108) ma y remai n
in f r ont pump suppor t and gear ( 7 A103) duri ng
t hi s t est .
Posi t i on t he f r ont pump suppor t on a bench wi t h
t he spl i ne end of t he shaf t poi nt i ng up.
TORQUE
CONVERTER
7902
D10443-C
2. Mount t or que conver t er on t he f ront pump suppor t
wi t h t he spl i nes on t he one-way cl ut ch inner r ace,
engagi ng t he mat i ng spl i nes of t he f r ont pump
suppor t .
3. Hol d t he f ront pump suppor t st at i onar y, and t r y t o
r ot a t e t he t or que conver t er c ount e r c l oc kwi se .
The t or que conver t er shoul d r ot a t e f r eel y wi t hout
any si gns of i nt erf erence or scr api ng wi t hi n t he
t or que conver t er .
4. If t her e i s an i ndi cat i on of sc r a pi ng, t he t rai l i ng
edges of t he st at or bl ades ma y be i nt erf eri ng wi t h
t he l eadi ng edges of t he i mpeller bl ades. In such
c a se s, r epl ace t he t or que conver t er .
S t a t o r t o T u r b i n e I n t e r f e r e n c e C h e c k
1. NOTE: Front pump suppor t may remai n in f r ont
pump suppor t and gear duri ng t hi s t e st .
Posi t i on t he t or que c onve r t e r on t he be nc h, f ront
si de d o wn .
2. Install f ront pump suppor t t o engage t he mat i ng
spl i nes of t he f ront pump suppor t shaf t .
3. Install t he f o r wa r d cl ut ch cyl i nder and shaf t
( 7 F207 ) , engagi ng t he spl i nes wi t h t he rear cl ut ch
hub( 7 B067 ) .
FRONT PUMP
SUPPORT
TORQUE
CONVERTER
7902 D10445-B
4. Hol d t he st a t or shaf t st at i onary and a t t e mpt t o
r ot a t e t he rear cl ut ch hub wi t h t he f o r wa r d cl ut ch
cyl i nder and shaf t . The t urbi ne and t or que
conver t er cl ut ch assembl i es shoul d r o t a t e in bot h
di rect i ons not exceedi ng maxi mum t or que of 9. 6
N*m (7 Ib-f t ) wi t hout any si gns of met al l i c
i nt erf erence or scr api ng noi se.
6. If i nt erf erence e xi st s, t he st at or f ront t hr ust
wa she r ma y be wo r n , al l owi ng t he st a t or t o hi t
t he t urbi ne. In such c a se s, t he t or que conver t er
must be r epl aced.
The conver t er cr ankshaf t pi lot shoul d be c he c ke d
f or ni c ks or da ma ge d sur f aces t hat coul d cause
i nt erf erence when i nstalli ng t he t or que conver t er
i nto t he cr ankshaf t ( 6303) . Check t he conver t er
f ront i mpeller hub f or ni cks or shar p e dge s t ha t
woul d da ma ge t he pump seal .
E n d P l a y C h e c k
End Pl a y C h e c k i n g To o l T 80L - 7 902 - A
1. Insert End Pl ay Checki ng Tool T80L-7902-A i nt o
t he t or que convert er pump dri ve hub until it
bo t t o ms.
07- 01- 170
T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W 0 7 - 0 1 - 1 7 0
2. Expand t he sleeve in t he turbine spline by
tightening t he threaded inner post until the tool is
securel y l ocked in t o the spline.
3. At t ach Dial Indicator wi t h Bracket ry
TOOL-4201-C or equivalent t o the t ool . Position
t he i ndi cator button on the converter pump dri ve
hub, and set t he dial f ace at 0 (zero).
4. Lift the tool upward as far as it will go and note
t he i ndi cator readi ng. The indicator reading is the
t ot al end pl ay whi ch t he turbine and st at or share.
Repl ace t he torque convert er if the total end play
exceeds t he limits i ndi cated in t he chart bel ow.
5. Loosen t he t hreaded inner post t o free the tool
and remove t he tool f rom the torque converter.
Refer t o t he fol l owi ng chart for t orque converter
end-play speci fi cati ons.
TORQUE CONVERTER END PLAY LIMITS
N e w o r Re b u i l t T o r q u e
C o n v e r t e r Used T o r q u e C o n v e r t e r
1. 2 7 / 1. 96 mm ( 0 . 0 5 / 0 . 0 7 7
i n c h) ma x
2. 5 mm ( 0. 100 i n c h) ma x
ASSEMBLY
E x t e n s i o n Ho us i n g Se a l Re p l a c e r T 61L - 7 657 - A
I mp a c t Sl i d e Ha mme r T50T- 100- A
Se r v o P i s t o n Re mo v e r / Re p l a c e r T 92 P - 7 002 3- A
Ga u ge Ba r T 80L - 7 7 003- A
Shi f t L e v e r Se a l Re p l a c e r T7 4P - 7 7 498- A
E x t e n s i o n Ho us i n g Bu s h i n g Re p l a c e r T 80L - 7 7 034- A
E x t e n s i o n Ho us i n g Se a l Re p l a c e r T 61L - 7 657 - B
Se r v o P i s t o n Se l e c t i o n To o l T 80L - 7 7 030- A
Tr a n s mi s s i o n Ra n ge ( TR) Se n s o r T93P - 7 0010- A
A s s e mb l y
1. If bushing was removed, position repl acement
bushing on Extension Housing Seal Replacer
T61L-7657-A and install in bushing bore through
t he front of the case ( 7005) .
2. Thread Impact Slide Hammer T50T-100-A into
Seal Repl acer through the back of the case.
Install the bushing.
HAMMER
T50T-100-A D10093-B
0 7 - 0 1 - 1 7 1 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 07 - 01- 17 1
ASSEMBLY (Conti nued)
Wi t h t ransmi ssi on in t he vert i cal posi t i on, coat
c a se rear beari ng ( 7F242) wi t h pet rol eum j el l y
and i nstall t he No. 9 c a se rear beari ng on t he
t r ansmi ssi on c a se boss.
NO. 9
CASE REAR
BEARING
7F242 D3189-E
Install out put shaf t ( 7060) , ri ng gear ( 7 A163) and
di r e c t cl ut ch as an assembl y.
NO. 9 CASE REAR
BEARING
7F242
OUTPUT SHAFT
7060, RING
GEAR 7A153
AND DIRECT
CLUTCH ASSY
D11506-C
5. Install ret ai ni ng ri ng t hat suppor t s r ever se band.
D10562-A
Install t he r ever se band. Ensure r ever se band is
se a t e d on anchor pi ns.
D10162-A
7. NOTE: For wa r d pl anet ary assembl y and
pl anet ary gear suppor t assembl y cannot be
i nst alled unless t he not ch cut in t he pl anet ary
gear support assembl y is al i gned wi t h t he
overdri ve band anchor pin ( 7F295) . Top of
pl anet ary gear suppor t assembl y shoul d be
bel ow snap ri ng gr oove .
Install f or wa r d pl anet ary assembl y and pl anet ary
gear support assembl y as a unit.
Ali gn not ch in pl anet ary gear suppor t assembl y
wi t h overdri ve band anchor pi n.
Rot at e t he out put shaf t , if necessar y, t o al i gn t he
planet carri er spl i nes wi t h t he di rect cl ut ch hub
spl i nes.
0 7 - O M 7 2 T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W 07 - 01- 17 2
8. NOTE: Forward pl anetary assembl y and 9. Install center planet support retaining ring.
pl anetary gear support assembl y cannot be Reference retainer ring end t ab t o overdri ve band
installed unless notch cut in pl anetary gear anchor pin.
support assembl y is aligned wi t h overdri ve band
anchor pin.
TAB
07- 01- 173 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 0 7 - 0 1 - 1 7 8
11. Install i ntermedi ate stub shaft.
7C096 D10
12. Install f orward cl utch hub and No. 3 f or war d
cl utch hub front beari ng.
NO. 3 FORWARD
FORWARD CLUTCH CLUTCH
D317B-C
13. Install f or war d cl utch assembl y.
14. NOTE: Wi ggl e the input shaft whi l e engagi ng t he
reverse cl utch spl i nes. Make sure the reverse
cl utch cyl i nder lugs are compl etel y seat ed in t he
notches of the reverse cl utch gear and shell
( 7 A019) .
Install reverse cl utch cylinder assembl y.
0 7 - C . - 1 7 4 T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W 07 - 01- 17 4
15. Install overdri ve band ( 7F196) over reverse
cl utch assembl y and position the pocket of the
overdri ve band agai nst overdri ve band anchor
pin. Install overdri ve servo pi ston return spri ng
( 7 F201) and overdri ve servo pi ston assembl y.
Verify tip of pi ston assembl y engages the pocket
of overdri ve band. Using Servo Piston
Remover/ Repl acer T92P-70023-A, install piston
assembl y into the case and compress overdri ve
servo piston return spri ng.
SERVO PISTON
REMOVER/REPLACER
T92P-70023-A D10507-B
OVERDRIVE SERVO COVER
AND PISTON ASSY
OVERDRIVE
v
r
m PISTON
/ RETURN
/ SPRING
/ 7F201
D3164-D
16. Make sure band anchor and tip of the pi ston
assembl y are properl y posi ti oned agai nst band
pocket s. Tighten tool until pi ston is bel ow
retaining ring groove, install retaining ring, then
remove t ool .
OVERDRIVE
BAND
7F196
OVERDRIVE BAND
ANCHOR PIN
7F295
17. Install i ntermedi ate cl utch as fol l ows:
a. Cl utch pressure pl ate ( 7B066) is the
t hi ckest . Install thi s fi rst wi th chamfer si de
down.
b. Cl utch pl ates.
c. Perform St eps 18 and 19 t o sel ect the proper
i ntermedi ate cl utch sel ecti ve steel pl ate.
CLUTCH
PRESSURE
PLATE
7B066
INTERMEDIATE
CLUTCH ASSY
f D10263-B
18. Wi t h proper i ntermedi ate pl ates sel ected and
i nstal l ed, perform end cl earance check for No. 1
thrust washer using the same tool s.
DEPTH
MICROMETER
D80P-4201-A
D10102-A
07 - 01- 17 5 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W
07 - 01- 17 5
19. NOTE: Mai nt ai n d o wn wa r d pr essur e on cl ut ch
pa c k whi l e measuri ng d e pt h.
Measur e t he i nt ermedi at e cl ut ch cl ear ance usi ng
De pt h Mi cr omet er D80P- 4201- A or equi val ent
and Gauge Bar T80L- 77003- A.
Set t he gauge bar a c r o ss t he pump c a se
mount i ng sur f aces. The dept h at t he i nt ermedi at e
cl ut ch separ at or pl at e i s:
42. 4- 42. 0 mm ( 1. 670- 1. 654 i nch)
Check t he cl earance agai n 180 de gr e e s opposi t e
t o ensure t he aver age de pt h is wi t hi n t ol er ance.
If t he dept h is not wi t hi n t ol er ance, t he f ol l owi ng
si ze sel ect i ve st eel pl at es are avai l abl e:
Sel ect i ve St eel Pl at es
1. 80-1. 7 mm ( 0. 07 1 - 0. 067 i n c h)
2. 05- 1 . 9 5 mm ( 0. 081 - 0. 07 7 i n c h)
2 . 31 - 2 . 2 0 mm ( 0. 091 - 0. 087 i n c h)
2 . 56- 2 . 46 mm ( 0. 101- 0. 097 i n c h)
Install c o r r e c t pl at e and c he c k cl ear ance.
T r a n s mi s s i o n S e l e c t i v e T h r u s t Wa s h e r
P r o c e d u r e
1. Posi t i on t he Dept h Mi cr omet er D80P- 4201 -A or
equi val ent on Gauge Bar T80L- 77003- A so t hat
t he de pt h i s measured at t he r ever se cl ut ch drum
t hrust f a c e . Check t he end pl ay 180 de gr e e s
opposi t e t o det ermi ne t he aver age d e pt h. Ref er
t o Sel ect i ve Thrust Wa she r s under
Speci f i cat i ons.
GAUGE BAR
T80L-77003-A
DEPTH MICROMETER
D80P-4201-A
D10664-A
SELECTIVE THRUST WASHERS
8
Depth Thickness
Color
Code
36. 7 342 - 38. 1838 mm
( 1. 4856- 1. 5033 i n c h)
1. 2 17 - 1. 37 1 mm
( 0. 050- 0. 054 i n c h )
Gr e e n
38. 1864- 38. 641 mm
( 1. 5034- 1. 52 13 i n c h)
1. 7 2 7 - 1. 82 8 mm
( 0. 068- 0. 07 2 i n c h)
Ye l l o w
38. 6436- 39. 07 2 8 mm
( 1. 52 14- 1. 5383 i n c h)
2 . 159- 2 . 2 60 mm
( 0. 085- 0. 089 i n c h)
Na t u r a l
39. 07 54- 39. 5046 mm
( 1. 5384- 1. 5553 i n c h )
2 . 590- 2 . 692 mm
( 0. 102 - 0. 106 inch)
Re d
39. 507 2 - 40. 1396 mm
( 1. 5554- 1. 5803 i n c h)
3. 02 2 - 3. 12 4 mm
( 0. 119- 0. 12 3 i n c h)
Bl ue
a. The t hrust washer is l oc a t e d on t he st at or support
whi ch is at t ached t o t he back of t he pump housi ng.
2. Install No. 1 t hrust wa she r ( 7 D014) on pump
body usi ng pet rol eum j el l y t o hol d in pl ace.
PUMP BODY
NO. 1 THRUST
WASHER
7D014
3.
D3833-E
Install pump gasket . Ma ke sure pump ga ske t is
posi t i oned and case pa ssa ge s are c o ve r e d .
02-O1--176 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W
07 - 01- 17 6
4. To maintain pump-to-case alignment, use a
f abri cat ed M8-1. 25 mm bolt (head removed) as a
guide, install in the 12 o' cl ock position using
petrol eum jelly on pump-to-case seal surfaces t o
ai d pump installation.
5. To ai d assembl y, grasp input shaft and wi ggl e
shaft while pressi ng down on pump.
6. Remove alignment bolt and install pump-to-case
bol ts. Al ternate bolt tightening t o draw the pump
fully into the case. Tighten t o 20-26 N-m (15-19
Ib-ft).
7. Pl ace transmi ssi on in the horizontal posi ti on.
Install parki ng pawl ( 7A441) and parki ng pawl
return spri ng ( 7D070) . Slide parki ng pawl shaft
( 7D071) into case through parki ng pawl .
PARKING PAWL
SHAFT
Install out put shaf t spe e d sensor (OSS). Ti ght en
bol t t o 7-10 N-m (5-7 Ib-f t ).
OUTPUT SHAFT
SPEED SENSOR
7H103
D10266-C
Install manual c ont r ol l ever seal usi ng Shi f t Lever
Seal Repl acer T74P- 77498- A.
SHIFT LEVER
SEAL REPLACER
T74P-77498-A
D3258-E
10. Install EPC sol enoi d.
EPC SOLENOID
7G383
11. If r e move d, i nst al l new ext ensi on housi ng bushi ng
usi ng Ext ensi on Housi ng Bushi ng Repl acer
T80L- 77034- A. Inst al l ne w ext ensi on housi ng
ga ske t ( 7 086) a n d ext ensi on housi ng ( 7 A039) .
Ti ght en bol t s t o 2 5- 30 N-m ( 18- 22 I b-f t ).
12. Install ext ensi on housi ng seal usi ng Ext ensi on
Housi ng Seal Repl acer T61L- 7 657 - B.
EXTENSION
HOUSING
7A039
D8903-B
13. Posi t i on manual val ve det ent l ever ( 7 A115) and
parki ng lever act uat i ng r od ( 7 A2 32 ) i nt o c a se .
Parki ng l ever act uat i ng r od must be posi t i oned
over parki ng pa wl .
PARK LEVER ACTUATING
ROD 7A232 OVER
PARKING PAWL 7A441
D10568-B
14. Sli de manual cont rol lever ( 7 A2 56) i nto c a se and
posi t i on t hrough det ent . Install nut and t i ght en t o
26-37 N-m (20-27 Ib-ft).
15. Install manual lever shaf t ret ai ni ng pin ( 7 B210) .
07 - 01=17 8 T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W 07 - 01- 17 8
16. Install fluid screen into case (head fi rst).
FLUID
SCREEN
7E242
17.
D10264-C
Install reverse band servo spri ng ( 7D031) ,
reverse band servo pi ston and rod ( 7D189) .
When band and/ or pi ston and rod assembl y
repl acement becomes necessary, determi ne the
correct length of the reverse servo pi ston,
proceed as fol l ows:
a. Lubri cate t he reverse piston seal t o faci l i tate
b.
c.
Install the reverse servo piston and return
spri ng. Do not install the piston cover or
retaining ring.
Install Servo Piston Sel ecti on Tool
T80L-77030-A. Tighten the band appl y bolt
on Servo Piston Sel ecti on Tool
T80L- 77030- A t o 5. 6 N-m ( 50 Ib-in).
TORQUE
WRENCH
SERVO PISTON
SELECTION
TOOL T80L-77030-A
D3339-C
d. At t ach Dial Indicator wi th Bracket ry
TOOL-4201-C or equivalent and position the
indicator st em on the fl at porti on of the
pi ston. Zero the dial indicator.
DIAL INDICATOR
WITH BRACKETRY
TOOL 4201-C
D3340-C
e.
Thread the bolt out of the sel ector tool until
the piston st ops agai nst the bot t om of the
tool .
f. Read the amount of pi ston travel on the dial
indicator.
If the travel is 2. 845-6. 020 mm
(0. 112-0. 237 inch), the piston length is
within speci fi cati on.
If the travel is not within speci fi cati on,
sel ecti ve pistons are available in the
following lengths:
ID
74. 56 mm ( 2. 936 inch) 1 groove
75. 92 mm ( 2. 989 inch) 2 grooves
77. 29 mm ( 3. 043 inch) 3 grooves
Length of rod measured f rom piston
surface to end of rod.
Sel ect the proper rod t o bring the
servo piston travel within
speci fi cati on.
g. Remove the servo selection tool and dial
indicator.
h. Lubri cate the cover seal t o faci l i tate
assembl y and t o prevent damage to the seal .
Place servo cover and retaining ring in servo
bore.
07 - 01- 17 9 T r a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W 07- 01 - 1 7 9
18. Ti ght en sc r e w on Ser vo Pi st on
Re mo ve r / Re pl a c e r T92P-70023-A t o al l ow
enough cl earance t o i nstall ret ai ni ng ri ng.
REVERSE SERVO
RETAINING RING
T92P-70023-A D10171-A
19. NOTE: Ret ai ner i s secur ed by mai n cont r ol .
Install t he component s f or 2-3 accumul at or in t he
f ol l owi ng or der :
Upper accumul at or seal ( 7 F2 50)
Lowe r accumul at or seal ( 7 F2 49)
Accumul at or pi st on ( 7 F251)
Accumul at or pi st on spri ng ( 7 F285)
Accumul at or spri ng ret ai ner ( 7 F2 52 )
2-3 ACCUMULATOR
UPPER SEAL 7F250
2-3 SHIFT
ACCUMULATOR
PISTON SPRING
7F285
2-3 SHIFT
ACCUMULATOR
PISTON 7F251
2-3 ACCUMULATOR
PISTON LOWER
SEAL 7F249
2-3 SHIFT
ACCUMULATOR
SPRING RETAINER-
7F252 D10174-A
20. Install t he component s f or 1-2 accumul at or in t he
f ol l owi ng order:
1-2 shi f t spri ng ( 7F284) .
Accumul at or pi st on seal ( 7 F248) .
Lowe r accumul at or seal .
Accumul at or out er spr i ng.
Cover and seal assembl y.
Accumul at or pi st on ret ai ni ng ri ng ( 7 384) .
D10175-B
Pa r t
1 7F284 1-2 Shift Spring
2 7F248 Accumulator Piston Seal
3 7F251 Accumulator Piston
4 7F249 Lower Accumulator Seal
5 7G267 1-2 Accumulator Outer
Spring
6 7G300 Cover and Seal Assy
Retaining Ring
07 - 01- 180
2 1 . NOTE: Tab on connect or is secured by mai n
c ont r ol .
Ali gn and i nstall wi ri ng connect or i nto c a se .
I nspect O-ri ng and r epl ace if requi red.
D10261-B
22. Posi t i on main cont rol val ve body ( 7 A100) using
t he t wo ali gnment bol t s a s a gui de. Ensure
coast i ng boost er val ve shut t l e bal l s ( 7E195) are
in t he c or r e c t l ocat i ons as out l i ned.
23. Install t he EPC sol enoi d br a c ke t . Loosel y install
one long 6 mm bol t .
24. Loosel y install 11 long and 12 shor t bol t s.
25. Install manual cont rol val ve det ent lever spri ng
( 7 A2 61) a n d one bol t .
26. Ti ght en t he main cont rol val ve body bol t s in t wo
st e ps as f ol l ows:
Ti ght en t he 25 ret ai ni ng bol t s t o c a se t o 9-11
N-m (80-100 lb-i n).
Ret i ght en t he f ol l owi ng bol t s t o t he
speci f i cat i on i ndi cat ed and in sequence as
i ndi cat ed by t he i l l ust rat i on:
2 M8X1. 25X46 mm gui de pin bol t s t o
18-24 N-m (155-195 lb-in).
4 M6X 1.0X18 mm cover pl at e bol t s t o
9-11 N-m (80-100 lb-i n).
12 M6X1. 0X52 mm cover pl at e bol t s t o
9-11 N-m (80-100 lb-in).
Mai n Co n t r o l t o Case
INSTALLATION
D12122-B
27. Connect wi ri ng c onne c t or s t o t ransmi ssi on f lui d
t emper at ur e sensor (TFT), shi f t sol enoi ds
( 7 G484) and EPC sol enoi d.
TFT SENSOR
CONNECTOR
SOLENOID ELECTRICAL
CONNECTOR EPC
CONNECTOR D10280-C
28. Install new f i l t er and gr o mme t .
GROMMET
D10570-B
29. Install t ransmi ssi on range (TR) sensor on manual
cont r ol l ever and l oosel y i nstall bol t s.
TRANSMISSION RANGE
(TR) SENSOR
D14966-A
30. NOTE: PARK is t he l ast det ent when t he manual
cont r ol l ever is full f o r wa r d . Ret urn t wo det ent s
t o wa r d out put shaf t f or NEUTRAL.
Posi t i on manual cont r ol l ever in NEUTRAL.
Insert Transmi ssi on Range (TR) Sensor (Manual
Lever Posi t i on Sensor Ali gnment Tool )
T93P-70010-A i nt o sl ot s. Al i gn all t hr ee sl ot s on
t ransmi ssi on range (TR) sensor wi t h t hree t a bs
on t ool .
(MLPS ALIGNMENT TOOL)
T93P-70010-A
TRANSMISSION RANGE
(TR) SENSOR
D11522-B
3 1 . Ti ght en t ransmi ssi on range (TR) sensor bol t s t o
7-10 N-m (62-89 Ib-i n).
32 . Cl ean, i nspect and i nstall pan t o c a se ga ske t and
t ransmi ssi on pan. Ti ght en all bol t s t o 12-16 N-m
(9-11 I b-f t ).
TRANSMISSION
PAN
7A194
TO
CASE GASKET
7A191
D10374-C
INSTALLATION
1. Ti ght en convert er housi ng a c c e ss plug ( 7 N17 1)
t o 28-30 N-m (21-23 Ib-f t ).
2. Proper i nst allat i on of t he t orque conver t er ( 7 902)
requi res full engagement of t he convert er hub in
t he pump gear. To accompl i sh t hi s, t he t or que
conver t er must be pushed and at t he same t i me
r ot at ed t hrough wha t f eel s li ke t wo
1
' n o t c h e s " or
bumps. When fully i nst al l ed, rot at i on of t he t or que
conver t er wi l l usually result in a cl i cki ng noi se
hear d, c a use d by t he convert er sur f ace t ouchi ng
t he housi ng-t o-case bol t s. Thi s shoul d not be a
concer n but rat her an i ndi cat i on of proper t or que
conver t er i nst allat i on si nce, when t he t or que
conver t er is a t t a c he d t o t he engi ne f l ywheel
( 637 5) , it wi ll be pulled sl i ght l y f o r wa r d , a wa y
f r om t he bol t heads. Besi des t he cl i cki ng sound,
t he t or que convert er shoul d r ot at e f reel y wi t h no
bi ndi ng.
DIMENSION A TO BE 10.23-14.43 mm
(7/16-9/16 INCH) APPROXIMATELY
07- 01=183 Tr a n s mi s s i o n , A u t o m a t i c 4 R 7 0 W
INSTALLATION (Conti nued)
3. Wi t h t orque convert er properl y installed, place
transmi ssi on on j ack and secure wi th safety
chai n.
4. Rot at e t he t orque convert er so the dri ve studs
and convert er housi ng access plug are in
alignment wi t h thei r hol es in the fl ywheel .
5. CAUTI ON: Du r i n g t h i s mo v e , t o a v o i d
d a ma g e , d o n o t a l l o w t h e t r a n s mi s s i o n t o ge t
i n t o a n o s e - d o w n p o s i t i o n a s t h i s wi l l c a us e
t h e t o r q u e c o n v e r t e r t o mo v e f o r w a r d a n d
d i s e n g a g e f r o m t h e p u mp ge a r . T h e
c o n v e r t e r h o u s i n g i s p i l o t e d i n t o po s i t i o n b y
d o w e l s i n t h e r e a r o f t h e e n gi n e b l o c k. The
t o r q u e c o n v e r t e r mu s t r e s t s q u a r e l y a ga i n st
t h e f l y w h e e l . T h i s i n d i c a t e s t h a t t h e
c o n v e r t e r pi l o t i s n o t b i n d i n g i n t h e e n gi n e
c r a n ks h a f t ( 6303) .
Align t he orange bal anci ng marks on converter
stud and f l ywheel bol t hole if balancing marks are
present.
6. Wi t h t he transmi ssi on mounted on a transmission
j ack, move t he t orque converter and transmission
assembl y f or war d into position being careful not
t o damage the f l ywheel and the converter pilot.
The t orque convert er f ace must rest squarely
agai nst t he f l ywheel . Thi s indicates that the
convert er pilot is not binding in the engine
crankshaf t .
7. NOTE: Bef ore installing t he torque converter
housi ng-to-fl ywheel retaining nut, a check should
be made t o ensure that the torque converter is
properl y seat ed. The t orque converter should
move freel y wi t h respect t o the fl ywheel . Grasp
the st ud. Movement back and forth should result
in a metallic cl ank noise if the converter is
properl y seat ed. If t he t orque converter will not
move, the transmi ssi on must be removed and the
t orque convert er reposi ti oned so that the impeller
hub is properl y engaged in t he pump gear.
Install t wo convert er housing-to-engine retaining
bol ts at t he engine dowel locations. Tighten t o
55- 68 N-m ( 40- 50 Ib-ft).
8. Install t he remaining converter housing-to-engine
retaining bol ts and ti ghten t o 55- 68 N-m (40-50
Ib-ft).
9. Remove the saf et y chain f rom the automati c
transmi ssi on / t ransaxl e ( A/ T) ( 7 000) .
10. Install t he fluid filler tube and secure it t o the
cyl i nder bl ock ( 6010) wi t h the retaining bolt.
Tighten t he bolt t o 38- 51 N-m (28-38 Ib-ft). If the
fluid filler tube is l oose in t he case, it should be
repl aced.
11. Install t he cool er lines t o t he transmi ssi on case
( 7005) . Tighten lines t o 20- 26 N-m (15-19 Ib-ft).
12. Remove the j ack supporti ng the front of the
engine.
13. Rai se the transmission. Position t he engine and
transmi ssi on support insulator ( 6F063) and
engine and transmission support ( 6F065) and
engine damper mounting body bracket ( 6F067) t o
t he f rame side supports and install the retaining
bol ts. Refer to Section 02- 03.
14. Lower t he transmission and install the rear engine
support-to-crossmember nut. Refer t o Secti on
02- 03.
15. Remove the transmission j ack.
16. Connect the transmission wi ri ng harness.
17. Install the starter motor ( 11002) . Refer t o Secti on
03- 06.
18. Install four flywheel-to-converter retaining nuts.
19. Install converter access cover and cover pl ate
bol ts on engine oil pan ( 6675) . Tighten t o 16-22
N-m (12-16 Ib-ft).
20. Install exhaust syst em. Refer t o Secti on 09- 00.
2 1 . Install the vehicle speed sensor ( VSSX9E731)
and connect wiring.
22. Install the driveshaft ( 4602) . Refer t o Secti on
05- 01.
23. Remove safety stands and l ower the vehicle.
Connect the battery ground cabl e ( 14301) .
24. Fill transmission to speci fi cati on. Start engine and
add fluid as required to achi eve the proper fluid
level as specified.
25. Check t he transmission, torque converter
assembl y and oil cooler lines for l eaks.
Clean all parts wi th suitable solvent and use
moi sture-free air to dry off all part s and clean out fluid
passages.
NOTE: The composition cl utch pl ates, bands and
syntheti c seal s should not be cleaned in a vapor
degreaser or with any t ype of detergent solution.
To cl ean these parts, wipe wi th a lint-free cl ot h. New
cl utch pl ates or bands should be soaked in the
speci fi ed transmission fluid for 15 minutes before
assembl y.
Main Control Valve Body
1. Clean all parts, except non-metallic coasti ng
booster valve shuttle balls (7E195), thoroughl y in
clean solvent and blow dry wi th moisture- free
compressed air.
7- 01- 184 T r a n s mi s s i o n , A u t o ma t i c 4 R 7 0 W 07 - 01- 184
2. NOTE: If necessary, use crocus cloth to polish
valves and plungers. Avoid rounding sharp edges
of valves and plungers with crocus cloth.
Inspect all valve and plunger bores for scores.
Check all fluid passages for obstructions. Inspect
all mating surfaces for burrs and scores.
3. Inspect all springs for distortion. Check all valves
and plungers for free movement in their
respective bores. Valves and plungers, when dry,
must fall from their own weight in their respective
bores.
4. Roll manual control valve on a flat surface to
check for bent condition.
Convert er and Cooler
When internal wear or damage has occurred in the
transmission, metal particles, clutch plate material or
band material may have been carried into the torque
converter (7902) and transmission fluid cooler
(7A095). These contaminants are a major cause of
recurring transmission troubles and must be removed
from the system before the transmission is put back
into service.
Whenever a transmission has been disassembled to
replace worn or damaged parts or because the valve
body sticks from foreign material, the torque converter
and transmission fluid cooler must be cleaned by using
a mechanically agitated cleaner, such as Rotunda
Torque Converter and Oil Cooler Cleaner 014-00028
or equivalent.
Flush the torque converter of the remaining solvent
using this procedure:
1. Thoroughly drain the remaining solvent through
the converter housing access plug (7N171).
2. Add 1.9 liter (2 qt) of clean transmission fluid to
the torque converter. Agitate by hand.
3. Thoroughly drain the solution through the
converter housing access plug.
3.
5.
6.
Connect a tank return hose to the steel
transmission cooler pressure line (shorter line).
Place the outlet end of this hose in the solvent
tank reservoir.
Turn on solvent pump and allow the solvent to
circulate a minimum of five minutes (cycling
switch on and off will help dislodge contaminants
in cooler system).
Switch off the solvent pump and disconnect the
solvent pressure hose from the transmission
cooler return line.
Use compressed air to blow out the cooler(s) and
lines (blow air into the transmission cooler return
line) until all solvent is removed.
Remove the rubber return hose from the
remaining steel cooler line.
COOLER LINES
TO RESERVOIR
PRESSURE
CONNECTION
D12277-A
Transmi ssi on Cooler and Li nes, Backf l ushi ng
and Cleani ng
1. Perform backflushing with a Rotunda Torque
Converter Cleaner 014-00028 or equivalent. Test
your equipment to make sure that a vigorous fluid
flow is present before proceeding. Replace the
system filter if flow is weak or contaminated.
2. To aid in attaching the cleaner to the transmission
steel cooler lines, connect two additional rubber
hoses to the transmission end of the steel
transmission cooler lines as described below.
Connect the cleaner tank pressure line to the
steel transmission cooler return line (longer
line).
Forward, Di rect, Int ermedi at e, Overdri ve and
Reverse Clutches
1. Inspect clutch cylinder thrust surfaces, piston
bore and clutch plate serrations for scores or
burrs. Minor scores or burrs may be removed
with crocus cloth. Replace clutch cylinder if badly
scored or damaged.
2. Check fluid passage in clutch cylinder for
obstructions. Clean out all fluid passages. Inspect
clutch piston for scores and replace if necessary.
Inspect check balls for freedom of movement and
proper seating.
3. Check clutch release spring for distortion and
cracks. Replace spring (including wave spring) if
distorted or cracked.
4. Inspect composition clutch plates, steel clutch
plates and clutch pressure plate for worn or
scored bearing surfaces. Replace all parts that
are deeply scored or burred.
07 - 01- 185 Transmission, Automatic4R70W 0 7 - 0 1 ^ 8 5
5. Check c l ut c h pl at es f or f l at ness and f i t on cl ut ch
hub ser r at i ons. Di sc a r d any pl at e t hat d o e s not
sl i de f reel y on serrat i ons or t ha t i s not f l at .
6. Che c k c l ut c h hub t hr ust sur f aces f or sc or e s and
cl ut ch hub spl i nes f or wear.
One-Way Cl ut ch
1. I nspect out er and inner r a c e s f or sc o r e s or
da ma ge d sur f ace a r e a s whe r e rol l ers or spr a gs
c ont a c t r a c e s.
2. I nspect rol l ers, spr a gs and spr i ngs f or e xc e ssi ve
we a r or damage.
3. I nspect spri ng and c a ge f or bent or da ma ge d
spri ng ret ai ners.
Output Shaft
1. I nspect out put shaf t beari ng sur f a c e s f or sc o r e s.
If e xc e ssi ve cl ear ance or sc o r e s ar e f ound,
r epl ace out put shaf t ( 7 060) and i nspect
c ompone nt s.
2. Che c k spl i nes on out put shaf t f or wear ; repl ace
out put shaf t if spl i nes ar e e xc e ssi ve l y wo r n .
I nspect all bushi ngs.
Elect ri cal Connect ors
Anyt i me an el ect ri cal connect or i s di sconnect ed,
i nspect t he connect or f or t ermi nal condi t i on, cor r osi on
and cont ami nat i on. Al so i nspect t he connect or seal f or
damage. Cl ean, ser vi ce or r e pl a c e a s requi red.
Case
I nspect c a se ( 7 005) f or c r a c ks and st r i pped t hr e a ds.
I nspect ga ske t sur f aces a nd mat i ng sur f aces f or
bur r s. Che c k vent f or obst r uc t i on, and c he c k all flui d
pa ssa ge s f or obst r uct i ons a nd l eakage.
I nspect c a se bushi ng f or sc o r e s. Che c k all parki ng
l i nkage pa r t s f or we a r or d a ma ge .
2. I nspect pi ni on ge a r s f or d a ma ge d or e xc e ssi ve l y
wor n t e e t h.
3. Che c k f or f r e e rot at i on of pi ni on ge a r s.
Thrust Beari ngs
Wa sh t hr ust beari ngs t hor oughl y in cl eani ng sol vent .
Bl ow beari ngs d r y wi t h c o mpr e sse d ai r.
Ma ke cer t ai n bear i ngs a r e cl ean and t hen l ubri cat e
wi t h t r ansmi ssi on f l ui d. Repl ace any beari ngs and
r a c e s whi c h sho w si gns of pi t t i ng or r oughness. Thr ust
beari ngs shoul d not be di sa sse mbl e d. The r e f or e ,
"Pi t t i n g" i s not vi si bl e. If any t hr ust beari ng f eel s r ough
af t er pr ope r cl eani ng and l ubri cat i on, it shoul d be
r e pl a c e d. Di sassembl ed t hr ust beari ngs shoul d never
be r e use d.
Transmi ssi on Flui d Cooler Tube Leakage
When flui d l eakage is f ound at t he t ransmi ssi on f lui d
cool er ( 7 A095) , t he t ransmi ssi on f lui d cool er must be
r epl aced.
When one or mor e of t he oi l cool er inlet t ube (7 A030)
and oi l cool er t ube ( 7 A031) must be r e pl a c e d, e a c h
repl acement t ube must be f a br i c a t e d f r o m t he sa me
si ze st eel t ubi ng a s t he ori gi nal line.
Usi ng t he ol d t ube as a gui de, bend t he new t ube as
requi red. Ad d t he necessar y f i t t i ngs and i nstall t he
t ube.
Af t er t he f i t t i ngs have been t i ght ened, a d d flui d a s
necessar y and c he c k f or flui d l eaks.
SPECIFICATIONS
OBDI I
OBDI
3. 8L Mu s t a n g , 4. 6L To wn Ca r , Cr o wn Vi c t o r i a ,
Co u ga r
A HOt h e r Ve h i c l e s
T A 1 0 0 0 B
AUTOMATIC TRANSMISSION REFILL CAPACITY
Liters
12. 9
Quarts
13. 6
Planet Assembli es
NOTE: Individual pa r t s of t he pl anet assembl i es ar e
not ser vi ceabl e.
1. Check pi ns and sha f t s in pl anet assembl i es f or
l oose f i t and / or c ompl e t e di sengagement . Use
new pl anet a sse mbl y if ei t her condi t i on e xi st s.
H I i i i f i l i l l M M M M ^ ^
STALL SPEED SPECI FI CATI ONS
Vehicle Application Axle Ratio Engine
Converter
K Factor
Stall Speed (rpm)
4
Vehicle Application Axle Ratio Engine Diameter
7902
Assembly K Factor Minimum Maximum
Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s 2 . 7 3 / 3 . 0 8 4. 6L 2V 305 mm
( 12 . 00 i n)
F4VP - A A 140 2 000 2 3 3 0
Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s
P o l i c e
3. 2 7 4. 6L 2V 305 mm
( 12 . 00 i n)
F4VP - A A 140 2 010 2 3 6 0
To wn Ca r 3. 08 4. 6L 2V 305 mm
( 12 . 00 i n)
F4VP - A A 140 2 000 2 330
To wn Ca r Tr a i l e r To w 3. 2 7 4. 6L 2 V 305 mm
( 12 . 00 i n)
F4VP - A A 140 2 035 2 380
a En gi n e t r u n c a t e d a t 2 94 I b- f t f o r st a l l s p e e d p r o j e c t i o n .
Checks and Adj ust ment s
NOTE: Transmi ssi on end pl ay can be adj ust ed usi ng
one of t he sel ect i ve t hrust wa she r s avai l abl e f or
ser vi ce. Af t er measuri ng t he de pt h, i nstall t he requi red
t hr ust washer.
TORQUE CONVERTER END PLAY
New or Rebuilt Used
1.27 / 1 . 9 6 mm ( 0. 050 / 0. 07 7
i n c h)
1.90 mm ( 0. 7 5 i n c h) ma x
SELECTI VE SNAP RI NGS
Clutch Steel Friction Clearance
Selective Snap
a
Rings-Thickness
Fo r wa r d Cl u t c h 5
b
5 1. 27- 2. 38 mm
( 0. 050- 0. 094 i n c h)
1. 88- 1. 98 mm
( 0. 07 4- 0. 07 8 i n)
2 . 2 4- 2 . 34 mm
( 0. 088- 0. 092 i n)
2 . 59- 2 . 69 mm
( 0. 102 - 0. 106 i n)
Re v e r s e Cl u t c h 3 4 1. 02- 1. 91 mm
( 0. 040- 0. 07 5 i n c h)
1. 88- 1. 98 mm
( 0. 07 4- 0. 07 8 i n)
2 . 2 4- 2 . 34 mm
( 0. 088- 0. 092 i n)
2 . 59- 2 . 64 mm
( 0. 102 - 0. 106 i n)
Di r e c t Cl u t c h 6 6 5 P l a t e : 1. 30- 1. 80 mm
( 0. 051- 0. 07 1 i n c h)
6 Pl a t e : 1. 65- 2. 16 mm
( 0. 065- 0. 085 i n c h)
1. 27-1. 37 mm
( 0. 050- 0. 054 i n)
1. 63- 1. 73 mm
( 0. 064- 0. 068 i n)
1. 98- 2. 08 mm
( 0. 07 8- 0. 082 i n)
2 . 34- 2 . 44 mm
( 0. 092 - 0. 096 i n)
I n t e r me d i a t e Cl u t c h 3
C
3
d
41. 504- 41. 808 mm
( 1. 650- 1. 67 0 i n c h)
1. 70- 1. 80 mm
( 0. 067 - 0. 07 1 i n)
1. 96- 2. 06 mm
( 0. 07 7 - 0. 081 i n)
2 . 2 1- 2 . 31 mm
( 0. 087 - 0. 091 i n)
a Se l e c t i v e s t e e l p l a t e s f o r i n t e r me d i a t e c l u t c h ,
b Pl us a w a v e d p l a t e ( i n s t a l l e d n e x t t o p i s t o n ) ,
c I n c l u d e s s e l e c t i v e s t e e l p l a t e s ,
d Mu s t u s e t h r e e f r i c t i o n p l a t e s .
REVERSE SERVO PISTON TRAVEL
mm I nch
2 . 845- 6. 02 0 0. 112 - 0. 2 37
NOTE: Pi st on t r avel can be adj ust ed usi ng one of t he
sel ect i ve se r vo pi st ons avai l abl e f or ser vi ce.
SELECTIVE SERVO PISTONS
Rod Le ngt h* I.D.
7 4. 56 mm ( 2 . 936 i n c h) 1 Gr o o v e
7 5. 92 mm ( 2 . 989 i n c h ) 2 Gr o o v e
7 7 . 2 9 mm ( 3. 043 i n c h ) 3 Gr o o v e
a Me a s u r e d f r o m t h e p i s t o n s u r f a c e t o t h e e n d o f t h e r o d .
SELECTIVE THRUST WASHERS
8
Dept h Thi c kne ss
Col or
Code
36. 7 342 - 38. 1838 mm
( 1. 4856- 1. 5033 i n c h )
1. 2 17 - 1. 37 1 mm
( 0. 050- 0. 054 i n c h)
Gr e e n
38. 1864- 38. 641 mm
( 1. 5034- 1. 52 13 i n c h)
1. 7 2 7 - 1. 82 8 mm
( 0. 068- 0. 07 2 i n c h)
Ye l l o w
38. 6436- 39. 07 2 8 mm
( 1. 52 14- 1. 5383 i n c h)
2 . 159- 2 . 2 60 mm
( 0. 085- 0. 089 i n c h)
Na t u r a l
39. 07 54- 39. 5046 mm
( 1. 5384- 1. 5553 i n c h)
2 . 590- 2 . 692 mm
( 0. 102 - 0. 106 i n c h)
Re d
39. 507 2 - 40. 1396 mm
( 1. 5554- 1. 5803 i n c h)
3. 02 2 - 3. 12 4 mm
( 0. 119- 0. 12 3 i n c h)
Bl ue
a. The t hrust washer is l ocat ed on t he st at or support
whi ch is a t t a c he d t o t he back of t he pump
housi ng.
E x t e n s i o n Ho u s i n g Bo l t s 2 5- 30 18- 2 2
Pa n Re t a i n i n g Bo l t s 12- 15 9- 11
St a t o r S u p p o r t - t o - P u mp Bo d y 2 0- 2 6 15- 19
Ma i n Co n t r o l Bo l t s
Cr o s s me mb e r - t o - T r a n s mi s s i o n 87 - 110 64- 81
Co n v e r t e r - t o - Fl y wh e e l Nut s 2 7 - 46 2 0- 34
Co n v e r t e r Ho u s i n g A c c e s s Pl ug 2 8- 30 2 1- 2 3
Co n v e r t e r Ho u s i n g- t o - E n gi n e Bo l t s 55- 68 40- 50
Co o l e r L i n e s - t o - Ca s e 2 0- 2 6 15- 19
Fr o n t P u mp - t o - Ca s e 2 0- 2 6 15- 19
T CC So l e n o i d - t o - Ma i n Co n t r o l 9- 11 80- 100
( L b - l n )
Re i n f o r c e me n t P l a t e s - t o - Ma i n
Co n t r o l
9- 11 80- 100
( L b - l n )
Co v e r P l a t e - t o - Ma i n Co n t r o l 9- 11 80- 100
( L b - l n )
Ma i n Co n t r o l Gui d e Pi n Bo l t s 18- 24 155- 195
( L b - l n )
P r e s s u r e Ta p P l u gs 8- 16 6- 12
Ou t p u t Sha f t S p e e d Se n s o r 7 - 10 5- 7
Ma n u a l L e v e r - t o - Ca s e 2 6- 37 2 0- 2 7
TR Se n s o r Bo l t s 7 - 10 5-7
Co o l e r Fi t t i n g 2 4- 31 18- 2 3
Re t a i n i n g Bo l t
5-8 44- 7 1
( L b - l n )
Co n v e r t e r A c c e s s Co v e r P l a t e
Bo l t s
2 . 5- 3. 6 2 2 - 32
( L b- l n )
Fl u i d Fi l l e r Tube Bo l t 38- 51 2 8- 38
Ma n u a l Co n t r o l Va l v e De t e n t L e v e r
Sp r i n g Bo l t
11- 15 100- 130
( L b - l n )
Tool Numbe r /
T50T- 100- A
T 57 L - 500- B
T 59L - 100- B
T59L-100-B
T 61L - 7 657 - A
E x t e n s i o n Ho u s i n g Se a l
Re p l a c e r
T61L-7857-B
T 63L - 7 7 837 - A
Fr o n t Pump Se a l Re p l a c e r
T63L-77837-A
T 65L - 7 7 515- A
E
T6SL-77515-A
T 68P - 7 D158- A
L i p Se a l P r o t e c t o r ( Ou t e r )
-A1
T68P-7D15B-A
(Cont i nued)
Tool Number/
Description Illustration
T 7 4P - 7 7 2 48- A
Se a l Re mo v e r
T74P-77248-A
T 7 6L - 7 902 - C
Co n v e r t e r Cl u t c h To r q ui n g To o l
T78L-7902-C
T 7 7 F- 1102 - A
Be a r i n g Cup Pul l e r
T77F-1102-A
T 7 7 L - 7 697 - A
E x t e n s i o n Ho us i n g Bu s h i n g
Re mo v e r
^^^^^^^^^77L^W7-A
T 7 7 L - 7 902 - R
Co n v e r t e r Cl u t c h Ho l d i n g To o l
T 80L - 7 902 - A
En d Pl a y Ch e c ki n g To o l
T80L-7902-A
T 80L - 7 7 003- A
Ga u ge Ba r
T80L-77003-A
T 8 0 L - 7 7 0 3 O A
Se r v o P i s t o n Se l e c t i o n To o l
T80L-77030-A
T 80L - 7 7 034- A
E x t e n s i o n Ho u s i n g Bu s h i n g
Re p l a c e r
TB0L-77034-A
Tool Number/
Description Illustration
T 80L - 7 7 140- A
Fo r w a r d Cl u t c h L i p Se a l
P r o t e c t o r ( I n n e r )
T80L-77140-A
T 80L - 7 7 2 34- A
Di r e c t Cl u t c h I nne r Li p Se a l
P r o t e c t o r
T80L-77234-A
T 80L - 7 7 2 54- A
Di r e c t Cl u t c h Ou t e r L i p Se a l
P r o t e c t o r
T80L-77254-A
T 80L - 7 7 2 68- A
Oi l P u mp Bu s h i n g Re p l a c e r
T80L-77266-A
T 80L - 7 7 2 68- B
Oi l Pump Bu s h i n g Re mo v e r
T80L-77288-B
T 80L - 7 7 403- A
Re v e r s e Cl u t c h Ou t e r Se a l
P r o t e c t o r
T80L-77403-A
T 80L - 7 7 403- B
Re v e r s e Cl u t c h I nner Se a l
P r o t e c t o r
T80L-77403-B
T89T- 7 0010- A
Pump Pul l e r A d a p t e r s
T89T-70010-A
T 92 P - 7 006- A
Tr a n s mi s s i o n Te s t Pl a t e
^^^^5 T92P-7006-A
T 92 P - 7 002 3- A
Se r v o P i s t o n
Re mo v e r / Re p l a c e r
T92P-70023-A
07 - 01- 189
(Continued)
Tool Numbe r /
De s c r i p t i o n I l l ust rat i on
T93P- 70010- A
Tr ansmi ssi on Range Sens or
Al i gnment Tool ( MLPS
Al i gnment Tool )
2)
3P70010A
T95L- 77005- A
I nt er medi at e Cl ut ch Pi st on Seal
Pr ot ect or
TfL-7T-A
ROTUNDA EQUIPMENT
007- 0085C Tr ansmi ssi on Test er
007- 00086 Tr ansmi ssi on Range ( TR) Sensor Cabl e
( MLPS Cabl e)
007- 00500 New Gener at i on St ar ( NGS) Test er
014- 00028 Tor que Conv er t er / Oi l Cool er Cl eaner
014- 00407 Di gi t al Vol t - Ohmmet er
014- 00950 104-Pi n Br eakout Box
021- 0054A Leak Test Ki t
D80P- 4201- A Dept h Mi cr omet er
TOOL- 1175- AC Seal Remover
TOOL- 4201- C Di al I ndi cat or wi t h Br acket r y
TOOL- 7000- DE Ai r Nozzl e Assembl y
1995 Town Car, Cr own Vi ct or i a, Gr and Mar qui s July 1994
07 - 02 - 1 T r a n s mi s s i o n , A u t o ma t i c C o o l i n g 07 - 02 - 1
SECTION 07-02 Transmission, AutomaticCooling
SUBJECT PAGE
Transmi ssi on Fluid Cooler, I nt egral ....07-02-1
Component Tests 07-02-3
Transmi ssi on Fl ui d Fl ow 07-02-3
Sy mpt om Chart ...07-02-3
SUBJECT PAGE
Fl ui d Cool er Tube 07-02-4
Fl ui d Cool er 07-02-4
Fl ui d Cool er Li nes. . . . 07-02-4
SPECIFICATIONS. . 07-02-5
VEHICLE APPLICATION
Town Car, Cr own Vi ct or i a, Grand Marqui s
T r a n s m i s s i o n Fl u i d C o o l e r , I n t e g r a l
The t ransmi ssi on flui d cool er ( 7 A095) is i nt egral t o t he
radi at or ( 8005) . Whenever l eaks or damage t o t he
radi at or are f ound, r epl ace t he ent i re radi at or. Ref er t o
Sect i on 03- 03.
07 - 02 - 2
T r a n s mi s s i o n , A u t o m a t i c C o o l i n g
07 - 02 - 2
07 - 02 - 3 T r a n s mi s s i o n , A u t o ma t i c C o o l i n g 07 - 02 - 3
Part
1 7A031 Oil Cooler Tube
2 7A030 Oil Cooler Inlet Tube
3 372223-S101 Cooler Tube Clip
4 7C410 Transmission Oil Cooler
Tube
5 N809635-S560A Hose
6 376240-S Clamp (3 Req'd)
7 7A095 Transmission Fluid Cooler
8 87944-S8 Tube Nut
9 7D273 Oil Tube Connector
10 N605785-S56 Bolt
Pa r t
11 7N291 Transmission Oil Cooler Line
Clip
12 6007 Engine
13 8005 Radiator
A Tighten to 2.0-3.1 N-m (18-27
Lb-ln)
B Tighten to 17-23 N- m (13-17
Lb-Ft)
Lb-Ft)
Lb-Ft)
( Co n t i n ue d )
When fluid l eakage is found in radi ator ( 8005) ) ,
repl ace radi ator. Refer t o Secti on 03- 03.
AUTOMATIC TRANSMISSION C O O L I N G
C O N DI T I O N POSSIBLE SOURCE A C T I O N
Transmission Overheating Clogged radiator.
System leaks.
INSPECT for plugging. SERVICE as
required.
INSPECT for leaks. SERVICE as
required.
T r a n s mi s s i o n Fl u i d F l o w
To check for proper fluid fl ow, use t he fol l owi ng
procedure:
NOTE: The linkage, fluid and control pressure must be
within speci fi cati ons bef ore performi ng thi s fl ow
check.
1. Remove the transmi ssi on fluid level indicator
( 7A020) f rom the oil filler t ube ( 7A228) . Pl ace a
funnel in the oil filler tube.
2. Raise the vehicle. Refer t o Secti on 00- 02.
3. Remove the cool er return line f rom its fitting in the
case.
4. Connect a hose t o t he cool er return line and
fasten the free end of the hose in the funnel
installed in the oil filler tube.
5. St art the engine and set idle speed at 1000 rpm
wi th t he transmi ssi on in NEUTRAL.
6. Observe the fluid fl ow at the funnel. When the
fl ow is solid (air bleeding has been compl eted),
t he fl ow should be liberal.
7. If there is not a liberal fl ow at 1000 rpm in
NEUTRAL, low front oil pump capaci t y, main
circuit syst em l eakage or cool er syst em
restri cti on is i ndi cated.
Check both metal cool er lines between the
transmi ssi on and radi ator ( 8005) for restri cti ons.
Check for restri cti ons in the metal or rubber
cool er lines t o and f rom the auxiliary cool er (if
equi pped). Check and feel all bends for ki nks,
especi al l y rubber cool er lines, that woul d restri ct
fl ow and coul d result in transmi ssi on overheati ng
or lack of lubrication.
8. To separat e transmi ssi on concerns f rom cool er
syst em concerns, repeat by connecti ng a hose t o
t he cool er inlet line.
07- 02- 4 Tr a n smi ssi o n s A u t o ma t i c - - Co o l i n g 07 - 02 - 4
Fluid C o o l e r T u b e
1. If l eakage is not ed at cool er line f i t t i ng on t he
t ransmi ssi on or radi at or, unscr ew t he t ube nut
whi l e hol di ng t he f i t t i ng in t he t ransmi ssi on or
radi at or wi t h a wr e nc h.
2. Install a 1 / 4x 18 st rai ght t hr e a d connect or i nto
t he t ransmi ssi on c a se ( 7 005) or a 1 / 4x 18
t a pe r e d t hr ead connect or i nt o radi at or ( 8005) ,
usi ng t hr e a d seal er or Teflon t a pe on t he mal e
t hr e a ds of t he connect or. Ti ght en t o 16-20 N-m
(12-15 Ib-f t ).
3. Install t ube nut i nto connect or. Ti ght en t o 16-24
N-m (12-17 Ib-ft).
Fluid Cooler
When i nternal we a r or damage has oc c ur r e d in t he
t ransmi ssi on, met al part i cl es, cl ut ch pl at e mat eri al or
band mat eri al may have been c a r r i e d i nt o t he t or que
convert er ( 7 902) and radi at or ( 8005) . These
cont ami nant s are a maj or cause of recurri ng
t ransmi ssi on t roubl es and must be r e move d f r o m t he
sy st e m bef ore t he t ransmi ssi on is put ba c k i nto
servi ce.
Whenever a t ransmi ssi on has been di sassembl ed t o
repl ace wor n or damaged pa r t s, t he t or que conver t er
and radi at or must be cl eaned by usi ng a
mechani cal l y-agi t at ed cl eaner, suc h a s Rot unda
Torque Convert er / Oil Cool er Cl eaner 014- 0002 8 or
equi valent .
Flush t he t or que conver t er of t he remai ni ng sol vent
using t hi s pr ocedur e:
1. Thoroughl y drai n t he remai ni ng sol vent t hr ough
t he conver t er housi ng a c c e ss pl ug.
2. Ad d 1.9 liter (2 qt . ) of cl ean Mo t o r c r a f t Mercon
Mul t i -Purpose Aut omat i c Transmi ssi on Flui d
E6AZ-19582-B or equi valent meet i ng For d
speci f i cat i on ESR-M2C163-A2 t o t he t or que
convert er. Agi t at e by hand.
3. Thoroughl y drai n t he sol ut i on t hr ough t he
convert er housi ng a c c e ss pl ug.
Fl u i d C o o l e r L i n e s
Inspect cool er li nes and f i t t i ngs f or da ma ge and l eaks.
Ti ght en f i t t i ngs t o speci f i cat i on. If l eak pe r si st s,
repl ace f i t t i ngs and lines as necessar y .
When one or more of t he t ransmi ssi on f lui d cool er li nes
must be r epl aced, e a c h repl acement line must be
f abr i cat ed f r om t he same si ze st eel t ubi ng as t he
ori gi nal line.
Usi ng t he ol d line a s a gui de, bend t he new line as
requi red. Ad d t he necessar y f i t t i ngs and i nst all t he line.
Af t er t he f i t t i ngs have been t i ght ened t o speci f i cat i on,
a d d f lui d a s ne c e ssa r y and c he c k f or flui d l eaks.
Whenever a t r ansmi ssi on has been di sassembl ed t o
r epl ace wo r n or d a ma ge d pa r t s or when flui d
cont ami nat i on i s suspe c t e d, t he f ol l owi ng pr ocedur e
shoul d be used:
1. Conduct backf l ushi ng wi t h a Rot unda Torque
Co n v e r t e r / Oi l Cool er Cl eaner 014- 00028 or
equi val ent . Test your equi pment t o make sure
t hat a vi gor ous f lui d f l ow i s present bef ore
pr oc e e di ng. Repl ace t he sy st e m f i lt er if f l ow is
we a k or cont ami nat ed.
2. To ai d in at t achi ng t he cl eaner t o t he t ransmi ssi on
st eel c ool e r lines, connect t wo addi t i onal rubber
hose s t o t he t ransmi ssi on end of t he st eel
t r ansmi ssi on cool er lines as de sc r i be d bel ow.
Connect t he cl eaner t ank pr essur e line t o t he
st eel t ransmi ssi on cool er ret urn line (l ongest
li ne).
Connect a t ank ret urn hose t o t he st eel
t ransmi ssi on cool er pr essur e line (shor t er line).
Pl ace t he out l et end of t hi s hose in t he sol vent
t ank reservoi r.
3. Turn on sol vent pump and al l ow t he sol vent t o
ci r cul at e a mi ni mum of f i ve mi nut es (cycl i ng
swi t c h on and off wi ll help di sl odge cont ami nant s
in cool er sy st e m).
4. Swi t c h off t he sol vent pump and di sconnect t he
sol vent pressure hose f r om t he t ransmi ssi on
cool er ret urn line.
5. Use c o mpr e sse d ai r t o bl ow out t he cool er (s) and
lines (bl ow ai r into t he t ransmi ssi on cool er ret urn
line) until all sol vent is r emoved.
6. Remove t he rubber ret urn hose f r om t he
remai ni ng st eel cool er line.
COOLER LINES
TO RESERVOIR
PRESSURE
CONNECTION
D12277-A
0 7 - 0 2 - 5 T r a n s mi s s i o n , A u t o ma t i c C o o l i n g
07 - 02 - 5
SPECIFICATIONS
Description N-m Lb- F t
Tr a n s mi s s i o n Co o l e r t o Ra d i a t o r
Out l e t Ta n k Re t a i n i n g Nut s
17- 23 12 . 5- 16. 9
Fl ui d Co o l e r Tube Co n n e c t o r 16- 20 12-15
Fl ui d Co o l e r Tube Nut 16- 24 12-17
Fl ui d Co o l e r Tube Ho s e Cl a mp 2. 0- 3. 1 18-27
( L b- l n )
Co o l e r L i n e Cl i p t o En gi n e Bo l t 40- 56 30- 41
ROTUNDA EQUIPMENT
Model Description
014- 0002 8 To r q u e Co n v e r t e r / Oi l Co o l e r Cl e a n e r
07 - 05- 1 Tr ansmi ssi on, Aut omat i c Ex t er nal Cont r ol s 07 - 05* 1
SECTION 07-05 Transmission, AutomaticExternal
Controls
SUBJECT PAGE
VEHICLE APPLICATION ..07-05-1
Shift Control Linkage 07-05-1
Shi ft I nt erl ock Syst em 07-05-1
Transmission Cont rol Swi t ch ..07-05-1
P i n p o i n t Tests 07-05-6
SUBJECT PAGE
Transmi ssi on Range (TR) Sensor 07-05-10
Transmi ssi on Shi f t Cabl e and Br a c ke t . . . 07-05-8
ADJUSTMENTS
Shi f t Cont r ol Li nkage 07-05-10
Shi f t I ndi cat or Cabl e ....07-05-10
VEHICLE APPLICATION
Shift Cont rol Li nkage
Column mounted range sel ector.
The transmission range sel ector linkage consi sts of: Cabl e connecti ng the range sel ector t o t he
transmi ssi on manual control lever ( 7A256) .
Shift Int erlock Syst em
The brake/ shi f t er interlock syst em has the fol l owi ng
features:
All vehicles use a brake shift i nterl ock mechani sm
consisting of a shift l ock act uat or at t ached t o t he
steering column tube ( 3514) .
This mechani sm prevents shifting the transmi ssi on
out of the PARK position unless t he brake pedal
( 2455) is appl i ed.
Transmission Cont rol Swi t ch
The column range sel ector includes transmi ssi on
control swi t ch (TCS) in the shift lever knob.
The syst em automati cal l y engages t he OVERDRIVE
mode each ti me the ignition swi t ch ( 11572) is
turned t o RUN.
When ignition swi t ch ( 11572) is turned t o t he RUN
posi ti on, the shift l ock actuator is energi zed l ocki ng
shifter in PARK posi ti on.
When brake pedal is appl i ed and the stopl i ght
swi t ch ( 13480) is act i vat ed, the brake shift l ock
actuator is deact i vat ed and the range sel ector can
be moved out of t he PARK posi ti on.
Pressing the transmi ssi on control swi t ch (TCS) wi t h
the ignition swi t ch in RUN l ocks out t he OVERDRIVE
mode; pressi ng the TCS once again engages t he
OVERDRIVE mode.
Tr ansmi ssi on. Aut omat i c Ex t er nal Cont r ol s 07- 05- 2
Electrical Schematics
Shift I nt er l ockTown Ca r
STOPLIGHT
SWITCH
CLOSED WITH
BRAKE PEDAL
APPLIED
^ 1
SOLID STATE
]
a
SHIFT
LOCK
ACTUATOR
S ^ B K
I
See E VT M for more details
of this circuit
A18925-B
Shi f t I n t e r l o c kCr o wn Vi ct ori a, Grand Mar qui s
HOT AT AL L TI MES
I S
1 oi l LG/R
T
S T OP L I G HT
SWITCH
CLOSED WITH
BRAKE PEDAL
DEPRESSED
of this circuit
07 - 05- 3 T r a n s mi s s i o n , A u t o ma t i c E x t e r n a l Co n t r o l s 07 - 05 - 3
Tr a n smi ssi o n Co n t r o l Swi t c h a n d Tr a n smi ssi o n
Co n t r o l I n d i c a t o r L a mp T o wn Car, Cr o wn Vi c t o r i a ,
Gr and Ma r qui s
HOT IN START OR RUN
13, 4*
, F U S E
I J UNCT I ON
. P AN E L
A |
TO TRANSMI SSI ON
CONTROL I NDI CATOR
LAMP IN I NSTRUMENT
CLUSTER
911 W/ LG
T RANSMI SSI ON
CONT ROL
S W I T CH
(res)
911 W/ LG
T/ W
r
I
- 1 POW E RT RAI N
I CONT ROL
I MODUL E
I ( PCM)
J
of thi s ci rcui t
* CROWN VI CTORI A
D12137 - A
loo O O O O O O O O O o pl
o o o o o o o o o o o o o r i
p o o o o o o o o o o o o o l
l o O O O O O O O O O O O O I
L J O O O O O O O O O O O O O l
f O O O O O O O O O O O O O n l
I O O O O O O O O O O O O O J
l o o o o o o o o o o o o o r
(PCM) CONNECTOR
V9286-A
Pin
Number Ci r cui t Ci r cui t Fun c t i o n
1 315 ( P / O ) Shi f t So l e n o i d # 2 ( SS- 2 )
2 6 5 8
( P K / L G )
Ma l f u n c t i o n I n d i c a t o r L a mp
3 No t Us e d
4 2 2 9 ( R / O ) Fa n Co n t r o l Mo n i t o r
5

No t Us e d
Pi n
6

No t Us e d
7

No t Us e d
8

No t Us e d
9

No t Us e d
10

No t Use d
11

No t Us e d
( Co n t i n ue d )
07 - 05- 4
mmmmmmm
T r a n s mi s s i o n , A u t o ma t i c E x t e r n a l Co n t r o l s 07 - 05- 4
P i n
N u mb e r Ci rcui t Ci rcui t Func t i on
12

Not Us e d
13 107 ( P) Da t a Li n k Co n n e c t o r ( DL C)
14
_
No t Us e d
15 915
( P K / L B )
Da t a Li n k Co n n e c t o r ( DL C)
16 914 ( T / O) Da t a Li n k Co n n e c t o r ( DL C)
17 639 ( L G / P ) Hi gh Fan Co n t r o l
18

No t Us e d
19

No t Us e d
2 0

No t Us e d
2 1

No t Us e d
2 2

No t Us e d
2 3 2 59 ( O / R ) I gn i t i o n Gr o un d
2 4 57 0
( B K / W)
P o we r Gr o un d
2 5 57 ( BK) Ca s e Gr o un d
2 6

No t Us e d
2 7 2 37 ( O / Y ) Shi f t So l e n o i d # 1 ( SS- 1)
2 8 No t Us e d
2 9 2 2 4 ( T / W) Tr a n s mi s s i o n Co n t r o l Swi t c h ( TCS)
30 2 42 ( DG) Oc t a n e A d j u s t
31

No t Us e d
32 No t Us e d
33 67 6
( P K / O )
Ve hi c l e S p e e d Se n s o r ( VSS) (-)
34 No t Us e d
35 392
( R / L G )
36 9 6 8 ( T / L B) Ma s s Ai r Fl o w Se n s o r Re t ur n
37 92 3
( O / B K )
( T FT ) S e n s o r
38 354
( L G / R )
En gi n e Co o l a n t Te mp e r a t u r e
Se n s o r
39 7 43 ( GY) I n t a ke Ai r T e mp e r a t u r e Se n s o r
40 7 87
( P K / B K )
Fue l Pump Mo n i t o r
41 883
( P K / L B )
42

No t Us e d
43

Not Us e d
44

No t Us e d
45

No t Us e d
46

No t Us e d
47 360
( B R / P K )
EGR Va c u u m Re gu l a t o r
48 6 5 9 ( O / W) I gn i t i o n Di a gn o s t i c Mo n i t o r
49 395
( G Y/ O )
Pr o f i l e I gn i t i o n P i c ku p (PI P)
50 92 9 ( P K) Sp a r k ( SP OUT)
51 57 0
( B K / W)
P o we r Gr o u n d
Pin
52 __ No t Us e d
53 No t Us e d
54 No t Us e d
55 37 ( Y) B + K e e p Al i v e P o we r
56 No t Us e d
57 No t Us e d
58 67 9
( G Y/ B K )
Ve h i c l e S p e e d Se n s o r ( VSS) ( + )
59 No t Us e d
6 0 7 4
( G Y/ L B )
61 393 ( P / L G ) He a t e d Ox y g e n Se n s o r # 2 ( H0 2 S )
62 No t Us e d
63

No t Us e d
64 1 9 9 ( L B / Y ) Tr a n s mi s s i o n Ra n ge Se n s o r
65 352
( B R / L G )
EGR Se n s o r
66 No t Us e d
67 101
( G Y/ Y)
Ca n i s t e r Pur ge So l e n o i d
68 197 ( T / O) Co o l i n g Fa n s
69 331
( P K / Y)
A / C WOT Cut o ut Re l a y
7 0 4 6 2 ( P ) Wa r n i n g a n d A l a r ms
7 1 3 6 1 ( R ) P o we r ( VP WR)
7 2 561 ( T / R) Fue l I n j e c t o r # 7
7 3 559 ( T / BK) Fue l I n j e c t o r # 5
7 4 557
( B R / Y)
7 5 5 5 5 ( T ) Fue l I n j e c t o r # 1
7 6 57 0
( B K / W)
P o we r Gr o un d
7 7 57 0
( B K / W)
P o we r Gr o un d
7 8
_
No t Us e d
7 9 911
( W/ L G )
L a mp ( TCI L) Ou t pu t
80 92 6
( L B / O )
Fue l Pump Re l a y Out put
81 92 5 ( W/ Y ) E l e c t r o n i c P r e s s u r e Co n t r o l Out put
82 92 4
( B R / O )
To r que Co n v e r t e r Cl u t c h So l e n o i d
83 2 64
( W/ L B )
84 97 0
( DG / W)
Out put Sha f t S p e e d ( OSS) Se n s o r
85 2 82
( DB / O )
86 439 ( T / L G ) A / C He a d P r e s s u r e Swi t c h
87 94 ( R / B K ) He a t e d Ox y g e n Se n s o r # 2 ( H 0 2 S )
88 9 6 7 ( L B / R ) Ma s s Ai r Fl o w ( MA F) Se n s o r
( Co n t i n ue d )
07 - 05- 5
Pin
Number Ci r cui t C i r c u i t F u n c t i o n
Pi n
N u m b e r Ci r cui t C i r c u i t F u n c t i o n
89 355
( G Y/ W)
T h r o t t l e P o s i t i o n ( TP) Se n s o r 97 3 6 1 ( R ) Ve h i c l e P o we r ( VP WR) 89 355
( G Y/ W)
T h r o t t l e P o s i t i o n ( TP) Se n s o r
98 5 6 2 ( L B ) Fue l I n j e c t o r # 8
90 351
( B R / W)
Re f e r e n c e Vo l t a ge
99 560
( L G / O )
91 359
( G Y/ R )
Si gn a l Re t ur n
100 558
( B R / L B )
92 511 ( L G) Br a ke On / Of f ( BOO) S wi t c h
101 556 ( W) Fue l I n j e c t o r # 2
93 387 ( R / W) He a t e d Ox y g e n Se n s o r # 1 ( H 0 2 S )
102 Not Us e d
94 3 8 8 ( Y / L B ) He a t e d Ox y g e n Se n s o r # 2 ( H 0 2 S )
103 57 0
( B K / W)
P o we r Gr o u n d
95 389
( W/ B K )
103 57 0
( B K / W)
P o we r Gr o u n d
95 389
( W/ B K )
104 Not Us e d
96 390 ( T / Y) He a t e d Ox y g e n Se n s o r # 4 ( H 0 2 S )
operati ng t he gearshi ft linkage and brake shift
interlock t o dupl i cate the condi ti on.
2. Inspect t o determi ne if one of t he fol l owi ng
Symptom Chart
Use t he sympt om chart as an ai d in determi ni ng
possi bl e concern sources and necessary servi ce
acti ons for the range sel ector l i nkage.
Da ma g e d or mi s a d j u s t e d
s e l e c t o r l e v e r c a b l e .
Da ma g e d i gn i t i o n ke y
c y l i n d e r .
Op e n ( b l o wn ) f u s e ( s ) .
Da ma g e d b r a ke shi f t
i n t e r l o c k a c t u a t o r .
Da ma g e d wi r i n g h a r n e s s .
L o o s e or c o r r o d e d
3. If t he concern(s) remains after t he i nspecti on,
Chart.
RANGE SELECTOR LINKAGE AND INTERLOCK
Starter Motor Inoperative in PARK
and/ or NEUTRAL
Back-up Lamps Not Operating
Correctly
Transmission range (TR) sensor
worn or damaged.
Circuit.
Shift Interlock System Does Not
Release or Lock Properly
Blown fuse.
Damaged stoplight swi tch.
Damaged shift lock actuator.
PERFORM Pinpoint Test A.
Shift Control Li nkage Binding, Out
of Proper Gear Relationship
Damaged i gni t i on/shi f t er interlock
cable.
Loose ignition / shifter interlock
cable.
Loose retainer bracket.
Shift control linkage misadj usted.
PERFORM Pinpoint Test B.
Transmission Control Switch and
Indicator Lamp Not Operating
Properly
NOTE: Steady flashi ng of indicator
lamp i ndi cates a DTC present and
a transmission concern. Refer to
Section 07-01 for di agnosi s.
Damaged transmission control
swi t ch.
Circuitry open / shorted.
Blown fuse.
Burned-out miniature bulb.
Damaged powertrain control
module.
PERFORM Pinpoint Test C.
07- 05- 6 Tr ansmi ssi on, Aut omat i c Ex t er nal Cont r ol s 07 - 05- 6
Use Rot unda Di gi t al Mul t i met er 105- 00051 or
equi val ent f or di agnosi s of f ol l owi ng Pi npoi nt Test s.
PINPOINT TEST A: SHIFT INTERLOCK SYSTEM DOES NOT RELEASE OR LOCK PROPERLY
A1 CHECK SUPPLY FUSE
Yes
No
GO to A4.
GO to A2.
Check fuse 6 (10A) / 17 (15A)
1
located in fuse
j unction panel.
Is t he f use OK?
Yes
No
GO to A4.
GO to A2.
A2 CHECK SYSTEM
Yes
No
GO to A4.
GO to A3.
Replace fuse 6( 1 OA).
Inspect fuse.
Yes
No
GO to A4.
GO to A3.
Yes
No
GO to A4.
SERVICE circuit between
brake shift lock actuator.
Remove fuse 6 (10A).
Disconnect brake shift lock actuator connector.
Measure resi stance of Circuit 294 (W/ LB)/ 298
( P / O)
1
wire between the right terminal of fuse 6 and
ground.
Is resi st ance great er t han 10, 000 ohms?
Yes
No
GO to A4.
brake shift lock actuator.
A4 CHECK POWER SUPPLY FROM SUPPLY FUSE
Yes
No
GO to A5.
interior fuse panel and
brake shi ft-lock actuator.
Disconnect the brake shift lock relay connector
locat ed to the right of steering column.
Measure the voltage on LG wire at shift lock relay
connector.
Yes
No
GO to A5.
interior fuse panel and
brake shi ft-lock actuator.
AS CHECK WIRE BETWEEN STOPLIGHT SWITCH AND
BRAKE SHIFT LOCK ACTUATOR
Yes
No
GO to A6.
SERVICE Circuit 511 (LG)
between stoplight swi tch
and brake shift lock
actuator.
Apply brake pedal.
Measure voltage on Circuit 511 (LG) at shift lock
actuator connector.
Is vol t age great er t han 10 vol t s wi t h brake pedal
appl i ed and less t han 1 vol t wi t h brake pedal
rel eased?
Yes
No
GO to A6.
SERVICE Circuit 511 (LG)
between stoplight swi tch
and brake shift lock
actuator.
A6 CHECK SHIFT LOCK ACTUATOR GROUND
Yes
No
REPLACE brake shift
lock actuator.
SERVICE BKwi re.
Measure resi stance of BK wire between brake shift
lock actuator and ground.
Yes
No
REPLACE brake shift
lock actuator.
SERVICE BKwi re.
PINPOINT TEST B: SHIFT CONTROL LINKAGE BINDING, OUT OF PROPER GEAR RELATIONSHIP
B1 CHECK SHIFT CONTROL LINKAGE
Yes
No
REPLACE gearshift lever
linkage. RESTORE
GOt o B2.
Gain access to gearshi ft lever linkage as outlined.
Actuate gearshift linkage in all ranges.
Observe all linkage during operati on.
m Is l i nkage damaged?
Yes
No
REPLACE gearshift lever
linkage. RESTORE
GOt o B2.
1 Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s a p p l i c a t i o n .
07 - 05- 7 T r a n s mi s s i o n , A u t o ma t i c E x t e r n a l C o n t r o l s 07 - 65- 7
PINPOINT TE ST B: SHI FT CONTROL LI NKAGE BINDING, OUT OF PROPER GEAR RELATIONSHIP (Continued)
B2 CHECK SHIFT CONTROL CABLE
Yes
No
ADJUST linkage as
outlined in Adj ustments.
GOt o B3.
RESTORE vehi cle.
RETEST syst em.
Check transmission shift cable and bracket
installation and t i ght ness.
Is transmi ssi on shift cabl e and bracket properly
i nst alled?
Yes
No
ADJUST linkage as
outlined in Adj ustments.
GOt o B3.
RESTORE vehi cle.
RETEST syst em.
B3 CHECK LINKAGE/CABLE FOR PROPER GEAR
RELATIONSHIP
Yes
No
SERVICE is complet e.
RESTORE vehi cle.
RETEST syst em.
REPLACE damaged
l i nkage/cabl e. RESTORE
Actuate gearshift lever in all ranges.
Does indicator match gearshift lever sel ect i on?
Yes
No
SERVICE is complet e.
RESTORE vehi cle.
RETEST syst em.
REPLACE damaged
l i nkage/cabl e. RESTORE
PINPOINT T E ST C: TRANSMISSION CONTROL SWITCH AND INDICATOR LAMP NOT OPERATING PROPERLY
C1 CHECK SUPPLY TO TRANSMISSION CONTROL
SWITCH
Yes
No
GO t o C3.
GOt o C2.
Turn ignition swi tch t o the RUN posi ti on.
Using a t est lamp connected t o a known good
ground, check for voltage at output side of fuse 13
(10A) Town Car or fuse 14 (10A) Crown Vi ct ori a,
Grand Marquis.
Did t est lamp illuminate?
Yes
No
GO t o C3.
GOt o C2.
C2 CHECK FUSE
Yes
No
SERVICE Circuit 640
(R / Y) Town Car or Circuit
296 (LB/PK) Crown
for short t o ground.
REPLACE fuse.
RESTORE vehi cle.
RETEST system.
REPLACE damaged
fuse. RESTORE vehi cle.
RETEST syst em.
Remove fuse.
Using an ohmmeter connect ed to a known good
ground, connect second lead to output side of fuse
cavity.
Yes
No
SERVICE Circuit 640
296 (LB/PK) Crown
for short t o ground.
REPLACE fuse.
RESTORE vehi cle.
RETEST system.
REPLACE damaged
RETEST syst em.
C3 CHECK SUPPLY VOLTAGE AT CONTROL SWITCH
Yes
No
GOt o C4.
SERVICE Circuit 640
295 (LB/PK) Crown
for open ci rcui t.
RESTORE vehi cle.
RETEST system.
Using a t est lamp, check Circuit 640 (R / Y) Town Car
or Circuit 296 (LB/PK) Crown Vi ct ori a, Grand
Marquis at transmission control swi t ch for voltage.
Yes
No
GOt o C4.
SERVICE Circuit 640
295 (LB/PK) Crown
for open ci rcui t.
RESTORE vehi cle.
RETEST system.
C4 CHECK TRANSMISSION CONTROL SWITCH
Yes
No
GOt o C5.
REPLACE damaged
transmission control
swi t ch. RESTORE
Actuate the transmission control swi t ch.
Using a t est lamp, check for voltage at Circuit 224
(T/W) at control swi t ch.
Yes
No
GOt o C5.
REPLACE damaged
transmission control
swi t ch. RESTORE
C5 CHECK TRANSMISSION CONTROL SWITCH INPUT TO
POWERTRAIN CONTROL MODULE (PCM)
Yes
No
GOt o C6.
SERVICE Circuit 224
(T/W) for open ci rcui t .
RESTORE vehi cle.
RETEST system.
Gain access to the powertrai n control module as
outli ned.
Actuate transmission control swi t ch.
Using a t est lamp check for voltage at Circuit 224
(T/W) at PCM connector.
Yes
No
GOt o C6.
SERVICE Circuit 224
(T/W) for open ci rcui t .
RESTORE vehi cle.
RETEST system.
07 - 05- 8 T r a n s mi s s i o n , A u t o ma t i c E x t e r n a l Co n t r o l s 07 - 05- 8
PINPOINT T E ST C: TRANSMISSION CONTROL SWITCH AND INDICATOR LAMP NOT OPERATING PROPERLY (Continued)
C6 CHECK POWERTRAIN CONTROL MODULE OUTPUT
TO TRANSMISSION CONTROL INDICATOR LAMP
Yes
No
GO to C7.
REPLACE damaged
powertrain control
module. RESTORE
ground, carefully back-probe Circuit 665 ( 0/ Y) at
PCM connector.
Yes
No
GO to C7.
REPLACE damaged
powertrain control
module. RESTORE
C7 CHECK CIRCUIT 665 (O / Y)
Yes
No
INSPECT connector.
RESTORE vehicle.
RETEST system.
LEAVE j umper wire
connected. GO to C8.
Turn ignition swi tch t o the OFF posi ti on.
Disconnect the powertrain control module.
Turn ignition switch to the RUN posi ti on.
Using a jumper wire connected t o a known good
ground, carefully connect other end t o Circuit 911
(W/ LG).
Did t ransmi ssi on c o n t r o l i ndi cat or l amp
i l l umi nat e?
Yes
No
INSPECT connector.
RESTORE vehicle.
RETEST system.
LEAVE j umper wire
connected. GO to C8.
C8 CHECK CIRCUIT 665 ( 0/ Y) AT INSTRUMENT CLUSTER
Yes
No
GO to C9.
SERVICE Circuit 911
(W/LG) for open circuit.
RESTORE vehicle.
RETEST system.
Gain access t o instrument cluster connectors as
ground, connect second lead to Circuit 911 (W/LG)
at cluster connector.
Yes
No
GO to C9.
SERVICE Circuit 911
(W/LG) for open circuit.
RESTORE vehicle.
RETEST system.
C9 CHECK TRANSMISSION CONTROL INDICATOR LAMP
BULB
Yes ^
No ^
SERVICE instrument
cluster. REFER t o
Section 13-01A
(Electroni c), 13-01B
(Conventional).
REPLACE damaged
miniature bulb. RESTORE
Remove miniature bulb.
Using an ohmmeter, check continuity of miniature
bulb.
Yes ^
No ^
SERVICE instrument
cluster. REFER t o
Section 13-01A
(Electroni c), 13-01B
(Conventional).
REPLACE damaged
miniature bulb. RESTORE
T r a n s m i s s i o n S h i f t C a b l e a n d B r a c k e t
Re mo v a l
1. Fr om under i nst rument panel ( 04320) , r e move
cabl e pl ast i c t ermi nal f r om t he col umn sel ect or
lever pi vot ball by pryi ng wi t h a sc r e wdr i ve r
bet ween cabl e pl ast i c t ermi nal and sel ect or lever.
2. Remove shi f t cabl e and br a c ke t ( 7E395) f r o m t he
st eeri ng col umn t ube.
3. Rai se vehi cl e. Ref er t o Sect i on 00- 02.
4. Remove shi f t cabl e and br a c ke t f r om
t ransmi ssi on shi f t cabl e br a c ke t ( 7 B2 2 9) by
unl ocki ng l ock t a bs and sli di ng cabl e out of
br a c ke t . D10112-A
5. Remove nut at t achi ng cabl e t o t ransmi ssi on
manual cont r ol lever st ud and remove cabl e f r om
st ud.
6. Remove shi f t cabl e and br a c ke t f r om
t ransmi ssi on t or que conver t er housi ng and f r ame
rai l . Lowe r vehi cl e.
07 - 05- 9 T r a n s mi s s i o n , A u t o ma t i c E x t e r n a l Co n t r o l s 07 - 05- 9
7. Fr om engi ne c ompa r t me nt , unseat cabl e
gr ommet f r o m c o wl and shi f t cabl e and br a c ke t
on engi ne c ompa r t me nt si de and pull cabl e out of
c o wl .
Shi f t Co n t r o l s
VIEWY
VIEWZ
D14586-A
I t e m
Pa r t
Pa r t
1 7E364 Control Selector Cable 7 7K391 Clips
Bracket 8 7E364 Control Selector Cable
2 7E395 Shift Cable and Bracket Bracket
3 7B229 Transmission Shift Cable 9 N802212-S100 Bolt
Bracket
A

Tighten t o 23.3-31.7 N-m
4 7H181 Shift Actuator Cable Fitting (17-23 Lb-Ft)
5 N801555-S56 Nut B

Tighten t o 19-26 N-m (14-19
6 N605785-S56 Bolt (2 Req'd)
Lb-Ft)
Installation
1. Fr om engi ne compar t ment , f e e d pl ast i c t ermi nal
end of cabl e t hr ough c o wl .
2. Fr om passenger compar t ment , pull t he rubber
gr ommet on t he t ransmi ssi on range sel ect or
cabl e i nt o da sh panel openi ng and seat it
securel y.
3. Install t ransmi ssi on range sel ect or c a bl e i nt o
st eeri ng col umn t ransmi ssi on shi f t cabl e br a c ke t .
Ensure t hat l ocki ng t a b i s fully se a t e d .
4. Install shi f t cabl e and br a c ke t t o st eeri ng col umn
cast i ng.
07 H) 5- 10 T r a n s mi s s i o n , A u t o ma t i c E x t e r n a l Co n t r o l s 07 - 05- 10
5. NOTE: Appl y small amount of gr ease t o col umn
sel ect or l ever pi vot bal l , or cabl e t ermi nal .
At t a c h cabl e pl ast i c t ermi nal t o col umn sel ect or
lever pi vot bal l . Pl ace range sel ect or in over dr i ve
posi t i on and hang a 1.4 kg (3 lb) wei ght on t he
end.
6. Fr om engi ne compar t ment , rout e t he shi f t cabl e
t o br a c ke t on cr ossmember and t hr ough cl i p on
fuel rail br a c ke t . Insert cl i p on cabl e i nto hol e in
br a c ke t . Posi t i on t he cabl e so t hat t he whi t e band
on cabl e is 2 5. 4 mm (1. 0 i nch) f r om t he gr ommet .
7. Rai se vehi cl e. Install t ransmi ssi on range sel ect or
cabl e in gearshi f t cabl e br a c ke t . Cli p t he
t ransmi ssi on shi f t cabl e into t ransmi ssi on
br a c ke t . Ensure l ocki ng t a bs are fully se a t e d.
8. Pl ace t ransmi ssi on in OVERDRIVE range posi t i on
by rot at i ng t he lever count er c l o c kwi se t o st op.
Rot at e lever c l o c kwi se t wo st ops.
9. Ali gn t ransmi ssi on shi f t cabl e paddl e sl ot on
t ransmi ssi on manual cont rol lever st ud shoul ders
whi l e t i ght eni ng nut t o speci f i cat i on.
11. Remove 1.4 kg (3 lb) wei ght .
Transmission Range (TR) Sensor
ADJUSTMENTS
Transmi ssi on cont r ol li nkage adj ust ment s shoul d be
per f or med in t he order in whi ch t hey appear.
Shift Control Linkage
1. Pl ace range sel ect or lever in (OVERDRI VE)
posi t i on. A wei ght of 1.4 kg (3 lb) shoul d be hung
on t he range sel ect or t o ensure t he l ever is
l ocat ed f i rml y on t he (OVERDRI VE) det ent .
Loosen shi f t cabl e ret ai ni ng nut at manual cont r ol
lever.
2. Move t ransmi ssi on manual cont r ol l ever t o
(OVERDRI VE) posi t i on, second det ent f r om most
f o r wa r d posi t i on.
3. Ti ght en shi f t cabl e ret ai ni ng nut at manual cont r ol
lever t o 13-25 N-m (10-18 Ib-f t ).
4. Check oper at i on of t ransmi ssi on in e a c h sel ect or
lever posi t i on. Ensure t hat par k mechani sm and
t ransmi ssi on range (TR) sensor ar e f unct i oni ng
properl y.
Shift Indicator Cable
1. Remove i nst rument panel l ower t ri m panel .
2. Pl ace st eeri ng col umn sel ect or lever in
OVERDRIVE posi t i on and hol d lever in posi t i on by
pl aci ng a 1.4 kg (3 lb) wei ght on t he lever.
3. Rot at e t he adj ust ment t humbsc r e w l ocat ed on
t he RH si de of t he col umn, t o ali gn t he i ndi cat or
wi t hi n t he l et t er " O" on t he anal og i nst rument
cl ust er adj ust ment .
4. For t he di gi t al i nst rument cl ust er, ali gn t he
i ndi cat or such t hat bot h cal i brat i on d o t s ar e whi t e
when parallel t o t he st eeri ng col umn cent erl i ne.
5. Cy cl e range sel ect or t hr ough all of t he posi t i ons
and c he c k t hat t he t ransmi ssi on range i ndi cat or
c o ve r s t he proper l et t er or number in each
posi t i on.
6. Install t he i nst rument panel l ower t ri m panel .
INDICATOR-
ANALOG
INSTRUMENT
CLUSTER
ADJUSTMENT
ELECTRONIC
(DIGITAL)
CLUSTER
ADJUSTMENT
ADJUSTMENT
TOLERANCE
BAND
INDICATOR
CALIBRATION DOTS
RED FLUORESCENT
PAINT
INDICATOR
D7293-B
SPECIFICATIONS
Tr a n s mi s s i o n Ca bl e t o
Tr a n s mi s s i o n Ra n ge Se l e c t o r
L e v e r Nut
19- 26 14- 19
Tr a n s mi s s i o n Shi f t Ca b l e
Br a c ke t - t o - T r a n s mi s s i o n
2 3. 3- 31. 7 17- 23
ROTUNDA EQUIPMENT
07 - 14- 1 T r a n s mi s s i o n Ra n ge (TR) Se n s o r 07 - 14- 1
SECTION 07-14 Transmission Range (TR) Sensor
SUBJECT PAGE
Transmi ssi on Range (TR) Sensor . 07-14-1
El ectri cal Schemat i cs. . . . 07-14-2
Inspection and Veri fi cati on 07-14-6
Pinpoint Test s 07-14-7
SUBJE CT PAGE
ADJUSTMENTS
VEHICLE APPLICATION
Town Car, Cr own Vi ct or i a, Grand Mar qui s
T r a n s m i s s i o n R a n g e ( TR) S e n s o r Permi t s t he engi ne t o st ar t onl y in t he PARK and
The t ransmi ssi on range (TR) sensor : NEUTRAL posi t i ons.
Ac t i va t e s t he ba c k-up l amps in t he REVERSE
Is t ransmi ssi on-mount ed. posi t i on.
The power t r ai n cont rol modul e ( PCM) ( 12A650)
moni t ors t he vol t age a c r o ss a ser i es of st e p-down
r esi st or s t hat c or r e sponds t o t he posi t i on of t he
manual cont rol l ever ( 7 A256) . The power t r ai n
cont r ol modul e uses t hi s i nf ormat i on in det ermi ni ng
desi r ed gear and el ect roni c pr e ssur e cont rol (EPC)
pr essur e.
Tr a n smi ssi o n Range (TR) Se n s o r T o wn Car
HOT AT ALL TIMES
r
2 1 R/LB
TO ANTENNA
MODULE
I START
1 | LOCK'
1 OFF 1
33Yw/ P K 32
IGNITION
SWITCH
1 POWERTRAIN
lCONTROL
I MODULE (PCM)
O i l '
J ,

33jJj/V/PK
TO MEMORY
SEAT MODULE
# 1
I -
GY/R
TO ELECTRONIC
DOOR LOCK
BK/PK ' CONTROL
TO ELECTRONIC
DAY/NIGHT
BK/PK ' MIRROR
R/LB
TO POWER
DISTRIBUTION
BATTERY
RH
. ... BACKUP
\ ^ / L A M P
l
Lf I I FROM ENGINE
CONTROLS
' 1 TRANSMISSION
SIGNAL ,
RETURN
I
of this circuit
J4608-B
Tr a n smi ssi o n Range (TR) Se n s o r Cr o wn Vi c t o r i a , Gr a nd Ma r qui s
HOT AT ALL TIMES
~-
mmmm
ATJ~
m
IGNIT ION
I I 84 | S W I T CH
I STARJ V AOC j
J ^^VLOCK J
1 OFF I
POW E RT RAI N
' C O N T R O L
| MODUL E ( PCM)
Lsi J ^ "
I B B
"
POWER
DISTRIBUTION
GY/R
CROWN
VICTORIA
GRAND
r
MARQUIS
I
CROWN
VICTORIA
NOT USED
* WITH POLICE
OPTION
il
D J ^ K / P K
-
" " U ^ B I
14OJBK/PK
140
1401 BK/PK
IT
BK/PK
GRAND
MARQUIS
140i BK/PK
NOT USED
5 7 Y B K
1401 BK/PK
I
140
L H
B ACK UP
RH
B ACK UP
L AMP
BK/PK 5 7 1 B K
LH f Z T A R H
B ACK UP I O 1 B AC K UP
L AMP V J ^ /
L A M P
571 BK
T RANSMI SSI ON
57 1 BK
WI T H E L E CT RONI C
DOOR L OCK
C ON T ROL
I
9
SENSOR I
, POWER INPUT SIGNAL J
h FROM PCM RETURN I
POWER RELAY |
.1
TO ELECTRONIC
DAY/NIGHT
MIRROR
TO ELECTRONIC
DOOR LOCK
CONTROL
MODULE
of thi s ci rcui t
J 460 9- B
0?t 4- 4 T r a n s mi s s i o n Ra n ge (TR) Se n s o r 07 - 14- 4
1
27
53
79
o o o o o o o o o o o o i
o o o o o o o o o o o o o n
" O O O O O O O O O O O O O
o o o o o o o o o o o o o
o o o o o o o o o o o o ^
O O O O O O O O O O O Q O n
J O O O O O O O O O O O O O
p o o o o o o o o o o o o n
POWERTRA8N CONTROL MODULE
(PCM) CONNECTOR
26
52
78
104
V9286-A
Pi n
1 315 ( P / O ) Shi f t So l e n o i d # 2
2 658
( P K / L G )
3 No t Us e d
4 No t Us e d
5 No t Us e d
6 No t Us e d
7 No t Us e d
8 No t Us e d
9 No t Us e d
10 No t Us e d
11 No t Us e d
12 No t Us e d
13 107 ( P ) Da t a Li n k Co n n e c t o r ( DL C)
14 No t Us e d
15 915
( P K / L B )
Da t a Li n k Co n n e c t o r ( DL C)
16 914 ( T / O) Da t a Li n k Co n n e c t o r ( DL C)
17 No t Us e d
18 No t Us e d
19

No t Us e d
2 0 No t Us e d
2 1 No t Us e d
2 2 No t Us e d
2 3 2 59 ( 0 / R ) I gn i t i o n Gr o un d
2 4 57 0
( B K / W)
P o we r Gr o un d
2 5 57 ( BK) Ca s e Gr o un d
2 6 No t Us e d
2 7 2 3 7 ( O / Y ) Shi f t So l e n o i d # 1
2 8 2 2 8 ( DB) L o w S p e e d Fan Co n t r o l Out put
2 9 2 2 4 ( T / W) T r a n s mi s s i o n Co n t r o l S wi t c h
30 2 42 ( DG) Oc t a n e Ad j u s t
31 No t Us e d
32 No t Us e d
P i n
33 67 6
( P K / O )
Ve hi c l e Sp e e d Se n s o r ( VSS) ( B- )
34

Not Us e d
35 392
( R / L G )
He a t e d Ox y g e n Se n s o r # 3 ( H0 2 S )
36 968 ( T / L B) Ma s s Ai r Fl o w Se n s o r Re t ur n
37 92 3
( O / B K )
Tr a n s mi s s i o n Fl ui d Te mp e r a t u r e
Se n s o r
38 354
( L G / R )
Engi ne Co o l a n t Te mpe r a t u r e ( ECT)
Se n s o r
39 7 43 ( GY) I n t a ke Ai r Te mpe r a t u r e (I AT)
Se n s o r
40 2 38
( DG / Y)
Fue l Pump ( FP) Mo n i t o r
41 347
( B K / Y)
42

No t Us e d
43 2 05
( DB / L G )
Buf f e r Fue l L e v e l Out put t o
Tr i pmi n d e r
44

No t Us e d
45

Not Us e d
46

No t Us e d
47 360
( B R / P K )
EGR Va c uum Re gu l a t o r
48 659 ( O / W) I gn i t i o n Di a gn o s t i c Mo n i t o r
49 395
( G Y/ O )
Pr o f i l e I gn i t i o n P i c kup (PI P)
50 92 9 ( PK) Spa r k ( SP OUT)
51 57 0
( B K / W)
P o we r Gr o un d
52

No t Us e d
53

No t Us e d
54 9 2 4
( B R / O )
Tr a n s mi s s i o n Co a s t Cl ut c h
So l e n o i d
55 554
( Y / B K )
B + Ke e p Al i v e P o we r
56 191
( L G / B K )
EVAP Ca n i s t e r Pur ge Va l v e
57

No t Us e d
07 - 14- 5 T r a n s mi s s i o n Ra n ge ( TR) S e n s o r 0 7 - K - 5
: z : : : : : z : r ~ : \ ;
Pin
N u m b e r Ci rcui t Ci r cui t F u n c t i o n
58 67 9
( G Y/ B K )
59 __ No t Us e d
60 7 4
( G Y/ L B )
61 3 9 3 ( P / L G ) He a t e d Ox y g e n Se n s o r # 2 ( H 0 2 S )
62

No t Us e d
63

No t Us e d
64 1 9 9 ( L B / Y ) T r a n s mi s s i o n Ra n ge ( TR) Se n s o r
65 352
( B R / L G )
EGR Se n s o r
66
_
No t Us e d
67

No t Us e d
68

No t Us e d
69 331
( P K / Y)
A / C Cut o ut Re l a y
7 0

No t Us e d
7 1 3 6 1 ( R ) P o we r ( VP WR)
7 2 561 ( T / R) Fue l I n j e c t o r # 7
7 3 559 ( T/ BK) Fue l I n j e c t o r # 5
7 4 557
( B R / Y)
7 5 5 5 5 ( T) Fue l I n j e c t o r # 1
7 6 57 0
( B K / W)
P o we r Gr o u n d
7 7 57 0
( B K / W)
P o we r Gr o u n d
7 8

No t Us e d
7 9 911
( W/ L G )
L a mp Ou t pu t
80 92 6
( L B / O )
Fue l Pump ( FP ) Re l a y Ou t pu t
81 92 5 ( W/ Y ) E l e c t r o n i c P r e s s u r e Co n t r o l Ou t p u t
Pin
82 No t Us e d
83 2 64
( W/ L B )
84 97 0
( DG / W)
Out put Sh a f t S p e e d Se n s o r
85 2 82
( DB / O )
86
_
No t Us e d
87 9 4 ( R / B K ) He a t e d Ox y g e n Se n s o r # 2 ( H 0 2 S )
88 967 ( L B / R ) Ma s s A i r Fl o w ( MA F) S e n s o r
89 355
( G Y/ W)
T h r o t t l e P o s i t i o n ( TP) S e n s o r
90 351
( B R / W)
Re f e r e n c e Vo l t a g e
91 359
( G Y/ R)
Si gn a l Re t ur n
92 511 ( LG) St o p l i gh t S wi t c h
93 3 8 7 ( R / W ) He a t e d Ox y g e n Se n s o r # 1 ( H 0 2 S )
94 3 8 8 ( Y / L B ) He a t e d Ox y g e n Se n s o r # 2 ( H 0 2 S )
95 389
( W/ B K )
96 390 ( T / Y) He a t e d Ox y g e n Se n s o r # 4 ( H 0 2 S )
97 361 (R) Ve hi c l e P o we r ( VP WR)
98 562 ( L B) Fue l I n j e c t o r # 8
99 560
( L G / O )
100 558
( B R / L B )
101 556 ( W) Fue l I n j e c t o r # 2
102 No t Us e d
103 57 0
( B K / W)
P o we r Gr o un d
104 Not Us e d
SENSOR CONNECTOR K21039-B
Pin
3 140
( B K / P K )
Ba c k- u p L a mp
4 33 ( W/ P K ) St a r t e r Co n t r o l t o Co n t r o l Mo d u l e
5 Not Us e d
6 1 9 9 ( L B / Y ) Tr a n s mi s s i o n Ra n ge (TR) Se n s o r
t o P CM
7 359
( G Y/ R)
8 Not Us e d
07 - 14- 6
T r a n s mi s s i o n Ra n ge (TR) Se n s o r 07 - 14- 6

TRANSMISSION HARNESS CONNECTOR
D12133-A
TOWN CAR
Pin
N u m b e r Circuit Ci rcui t Funct i on
1 2 37 ( O / Y) Shi f t So l e n o i d # 1
2 3 6 1 ( R ) Ve h i c l e P o we r
3 9 2 4
( B R / O )
To r q ue Co n v e r t e r Cl u t c h ( TCC)
So l e n o i d
4 No t Us e d
TOWN CAR (Cont 'd)
Pin
5 92 3
( O / B K )
( TFT) I nput
6 3 1 5 ( P / 0 ) Shi f t So l e n o i d # 2
7 3 6 1 ( R ) Ve h i c l e P o we r
8 3 6 1 ( R ) Ve h i c l e P o we r
9 359
( G Y/ R )
Si gn a l Re t ur n
So l e n o i d
Pin
1 2 37 ( O / Y) Shi f t So l e n o i d # 1
2 3 6 1 ( R ) Ve h i c l e P o we r
3 4 7 3 ( P / Y ) To r q ue Co n v e r t e r Cl u t c h So l e n o i d
4 No t Us e d
5 92 3
( O / B K )
( TFT) I nput
6 3 1 5 ( P / O ) Shi f t So l e n o i d # 2
7 3 6 1 ( R ) Ve h i c l e P o we r
8 3 6 1 ( R ) Ve h i c l e P o we r
9 359
( G Y/ R )
Si gn a l Re t ur n
1. Vi sual l y i nspect t he sy st e m component s f or
cust omer ' s concer n.
2. Veri f y wi ri ng and connect i ons f or t he t ransmi ssi on
r ange sensor t o f i nd l ooseness, c or r osi on,
da ma ge or ot her obvi ous causes f or a
mal f unct i on.
If an obvi ous cause f or an obse r ve d or r epor t ed
mal f unct i on is f ound, c or r e c t t he cause if possi bl e
bef or e proceedi ng t o t he next st e p.
If t he c a use of t he mal f unct i on cannot be f ound by
sy st e m i nspect i on, go t o Sy mpt om Chart whi ch
ser ves as a gui de f or f urt her di agnosi s t o val i dat e
cust omer ' s concer n.
Symptom Chart
TRANSMISSION RANGE (TR) SENSOR
Engine "No Crank" TR sensor damaged, misadj usted,
not connected, wiring harness
open, damaged.
Ignition swi t ch, wiring harnesses.
Linkages out of adj ustment.
INSPECT for damage and
connection. ADJUST TR sensor as
outlined. PERFORM Pinpoint Test
A. SERVICE as required.
PERFORM ignition swi tch and
harness continuity t est s. REFER to
Section 11-05.
ADJUST per service manual
procedures.
Engine "No Crank" in Either PARK
or NEUTRAL
TR sensor damaged. REFER to Pinpoint Test A.
TRANSMISSION RANGE (TR) SENSOR (Continued)
Engine Cranks With Transmission
Range Selector Lever in Ranges
Other Than PARK or NEUTRAL
Li nkages out of adj ustment.
TR Sensor mi sadj usted.
TR sensor damaged, wiring
harness short ed.
ADJUST per service manual
procedures.
ADJUST TR sensor as outlined.
INSPECT for damage. PERFORM
Pinpoint Test A. SERVICE as
required.
Backup Lamps Inoperative Bulbs damaged, burnt out. Harness
damaged, corroded, loose wi res.
Li nkages out of adj ustment.
TR sensor out of adj ustment,
damaged, wiring harness
damaged, open, corroded.
INSPECT bulbs and harnesses for
damage, corrosi on, looseness.
ADJUST linkage per service
manual procedure.
INSPECT for damage. PERFORM
Pinpoint Test A. SERVICE as
required.
Harsh Shifts, Firm Engagements,
Improper Shift
Harness connector not seat ed
properly; harness damaged,
corroded.
TR sensor mi sadj usted, damaged.
INSPECT for damage. SERVICE as
required.
PERFORM Pinpoint Test A.
NOTE: Pri or t o ent eri ng Pi npoi nt Test s, ref er t o any
TSBs and OASI S messages f o r t ransmi ssi on
concer ns.
NOTE: Pri or t o ent eri ng Pi npoi nt Test s, t he vehi cl e
harness must be c he c ke d f or cont i nui t y and sho r t s;
t he power t r ai n cont rol modul e ( PCM) ( 12A650) must
be c he c ke d f or any concer ns. Ref er t o t he Power t r ai n
Cont r ol / Emi ssi ons Di agnosi s Ma nua l
1
f or pr oper
pr ocedur es.
NOTE: If any non-t ransmi ssi on DTCs appear, ser vi ce
t hose c o d e s f i r st . They coul d af f ect t he el ect ri cal
operat i on of t he t ransmi ssi on. Recor d and er ase
c o d e s f r om cont i nuous memor y af t er ser vi ce has been
per f or med. Af t er servi ci ng any DTCs r ecei ved duri ng
t he Qui ck Test , ref er t o t he Power t r ai n
Cont r ol / Emi ssi ons Di agnosi s Ma nua l
1
; t he Qui ck Test
must be r e pe a t e d.
NOTE: Check power t r ai n cont r ol modul e wi ri ng
harness f or pr oper connect i ons, bent or br oken pi ns,
c or r osi on, l oose wi r e s, pr oper rout i ng, proper seal s
and t hei r condi t i on. Check t he power t r ai n cont r ol
modul e, sensor s and a c t ua t or s f or physi cal da ma ge .
ON-BOARD DIAGNOSTIC TROUBLE CODE DESCRIPTION CHART
DTC Compone nt De sc r i pt i on Condi t i on Sy mpt o m
Ref erence
/ Ac t i o n
P 17 05 TR TR n o t i n PARK Se l f t e s t n o t run i n PARK. Re r un se l f t e s t in PARK. G O t o
Pi n po i n t
Te st A.
P 07 07 TR TR c i r c u i t b e l o w mi n i mum
v o l t a g e
TR s e n s o r , c i r c u i t o r P CM
s h o r t e d o r g r o u n d e d .
I n c r e a s e in EPC p r e s s u r e . GO t o
Pi n po i n t
Te s t A.
P 07 08 TR TR c i r c u i t a b o v e ma x i mu m
v o l t a g e
TR se n so r , c i r c u i t o r P CM
i n d i c a t e s o p e n .
I n c r e a s e in EPC p r e s s u r e . GO t o
Pi n po i n t
Te s t A.
If DTCs ar e pr esent whi l e perf ormi ng t he On-Boar d
Di agnost i c, ref er t o t he On-Boar d Di agnost i c Troubl e
Code Descr i pt i on Chart f or t he a ppr opr i a t e ser vi ce
pr ocedur e.
07 - 14- 8
T r a n s mi s s i o n Ra n ge (TR) Se n s o r 07 - 14- 8
This Pinpoint Test is desi gned t o di agnose t he
Transmission Range (TR) Sensor el ectri cal syst em
ONLY. To prevent repl acement of good components,
note that the following areas may be at fault:
Engine starter motor ( 11002) , starter relay.
El ectri cal bat t ery ( 10653) , ignition swi t ch
( 11572) , wiring harnesses.
Transmission internal transmi ssi on component s,
linkages.
Thi s Pinpoint Test is desi gned t o di agnose t he
following components:
Transmission wiring harness, transmi ssi on range
sensor, signal return.
Powertrai n Control Modul e.
Refer t o t he following schemati c and chart when
performi ng the Pinpoint Test st eps.
P i n
2 640 ( R / Y) Fu s e d Run On l y Fe e d ( To wn Ca r )
3 140
( B K / P K )
Ba c k- u p L a mp
4 33 ( W/ P K ) St a r t e r Co n t r o l t o Co n t r o l Mo d u l e
5 No t Us e d
6 1 9 9 ( L B / Y ) Tr a n s mi s s i o n Ra n ge ( TR) Se n s o r
t o P CM
7 359
( G Y/ R )
8 No t Us e d
298 P/O (CROWN VICTORIA/GRAND MARQUIS)
33 W/PK 640 R/Y (TOWN CAR) 199 LB/Y
32 R/LB 140 BK/PK
of thi s circuit
TRANSMISSION 359 GY/R
RANGE (TR)
SENSOR
SENSOR CONNECTOR K21039-B
P i n
2 2 98 ( P / O ) Fu s e d Run On l y Fe e d ( Cr o wn
Vi c t o r i a , Gr a n d Ma r q u i s )
PINPOINT TEST A: ENGINE NO CRANK
A1 4R70W TR SENSOR ELECTRONIC DIAGNOSTICS
Yes
No
REMOVE t ool . GO to A2.
ADJUST sensor as
outlined. After
adj ustments, PLACE
transmission gear
selector in PARK. CLEAR
DTC and repeat
Quick-Test, refer to the
Powertrain
Control/Emi ssi ons
Diagnosis Manual
2
.
Check to make sure TR sensor harness connector is
fully seat ed, terminals are fully engaged in
connector and in good condition before proceedi ng.
Verify shift linkage adj ustment in the OVERDRIVE
posi ti on.
Apply parking brake control.
Place transmission in NEUTRAL.
Verify that Transmission Range (TR) Sensor
Alignment Tool (MLPS Alignment Tool)
T92P-70010-AH fi ts in the appropri ate sl ot s.
Is t he sensor pr oper l y adj ust ed?
Yes
No
REMOVE t ool . GO to A2.
ADJUST sensor as
outlined. After
adj ustments, PLACE
transmission gear
selector in PARK. CLEAR
DTC and repeat
Quick-Test, refer to the
Powertrain
Control/Emi ssi ons
Diagnosis Manual
2
.
07 - 14- 9 T r a n s mi s s i o n Ra n ge (TR) S e n s o r 07^ f 4* 9
PINPOINT TE ST A: ENGINE NO CRANK (Cont i nued)
A2 CHECK ELECTRICAL SIGNAL OPERATION
Yes
No
GOt o A3.
REFER to Powertrain
Control / Emissions
Diagnosis Ma nua l
3
for
di agnosi s of NO
reference volt age.
CAUTION: Do NOT pry on c onne c t or . Press TAB
and pull up on harness.
NOTE: Refer to the schematic and chart precedi ng
this pinpoint t est .
Connect a VOM positive lead t o TR sensor ci rcui t
and negative test lead to signal return circuit of
Turn ignition swi tch to RUN, engine off.
Yes
No
GOt o A3.
REFER to Powertrain
Control / Emissions
Diagnosis Ma nua l
3
for
di agnosi s of NO
reference volt age.
A3 CHECK CONTINUITY OF TR SENSOR HARNESS
CIRCUITS
Yes
No
GO to A4.
REMOVE Breakout Box.
RECONNECT all
components. ERASE
codes. REPEAT the
Quick Test, refer to
Powertrain
Control/Emi ssi on
Diagnosis Manual
3
.
CAUTION: Do not pry c onne c t or . Press but t on
and pull up on vehi cl e harness.
Disconnect TR sensor.
Inspect for damage or pushed out pins, corrosi on or
loose wi res.
di sconnected.
wires.
NOTE: Refer to the schemati cs and charts
preceding this pinpoint t est .
Measure resi stance between powertrain control
module t est Pin 91 at Breakout Box and SIG RTN
circuit at TR sensor vehicle harness connector.
module test Pin 64 at Breakout Box and TR sensor
signal circuit at TR sensor vehicle harness
connector.
Yes
No
GO to A4.
RECONNECT all
components. ERASE
codes. REPEAT the
Powertrain
Control/Emi ssi on
Diagnosis Manual
3
.
A4 CHECK TR SENSOR CIRCUIT FOR SHORTS TO POWER
AND GROUND
Yes
No l >
GO to A5.
SERVICE short ci rcui t.
RECONNECT all
components. ERASE
codes. REPEAT the
Section Powertrain
Control/Emi ssi on
Diagnosis Manual
3
.
module di sconnect ed.
Ensure TR sensor harness connector is
di sconnected.
NOTE: Refer to schemati cs and chart s precedi ng
module test Pin 64 and test Pins 71/ 97,
51/ 7 6/ 7 7 / 103 and91 at the Breakout Box.
module test Pin 64 at Breakout Box and chassi s
ground.
Yes
No l >
GO to A5.
SERVICE short ci rcui t.
RECONNECT all
components. ERASE
codes. REPEAT the
Section Powertrain
Control/Emi ssi on
Diagnosis Manual
3
.
07 - 14- 10 T r a n s mi s s i o n Ra n ge (TR) Se n s o r 0 7 - 1 4 - 1 0
PINPOINT TEST A: ENGINE NO CRANK (Cont i nued)
A5 CHECK OPERATION OF TR SENSOR
Disconnect TR sensor harness connector at the
transmi ssi on.
Connect Transmission Tester 007-0085-A with
Transmission Range (TR) Sensor Cable (MLP
Cable) 007-00086 to TR sensor.
Using procedures provided wi th tester, verify sensor
functions in all posi ti ons.
Check continuity and resi stance in all posi ti ons.
Check RUN/START, back-up lamps and
optional swi tch function.
Is t he TR sensor OK?
TRANSMISSION CIRCUITS (199 AND 359)
Yes
No
Transmi ssi on Range Sel ect or
Lever Posi t i on
Resi st ance (Ohms)
Vo l t s
1
Transmi ssi on Range Sel ect or
Lever Posi t i on Mi n Max Vo l t s
1
P 37 7 0 4607 4. 41
R 1304 1593 3. 60
N 660 8 0 7 2 . 93
OD 361 4 4 2 2 . 09
D/ 2 190 2 32 1.37
1 7 8 9 5 0. 68
Concern is not in sensor.
If di rected here from
Diagnosis by Symptom,
RETURN t o Routine. If
diagnosing a DTC,
REFER t o the Powertrain
Control/Emi ssi ons
Diagnosis Manual
4
t o
diagnose intermittent
concerns.
REPLACE TR sensor as
outlined. ERASE codes.
REPEAT Quick Test, refer
to Powertrain
Control /Emi ssi on
Diagnosis Manual
4
.
1 Ma y v a r y + / - 1 0 % d u e t o s e n s o r a n d VRE F v a r i a t i o n s .
STARTER CIRCUITS (32 AND 33)
Resi st ance (Ohms)
Key On St ar t
Posi t i on Vol t s
p L e s s t h a n 5. 0 o h ms VBAT
R Gr e a t e r t h a n 100k
o h ms
0
N L e s s t h a n 5. 0 o h ms VBAT
OD Gr e a t e r t h a n 100k
o h ms
0
D/ 2 Gr e a t e r t h a n 100k
o h ms
0
1 Gr e a t e r t h a n 100k
o h ms
0
BACKUP LAMP CIRCUITS (298 AND 140)
Resi st ance (Ohms) Key On Vol t s
p Gr e a t e r t h a n 100k
o h ms
0
R L e s s t h a n 5. 0 o h ms VBAT
N Gr e a t e r t h a n 100k
o h ms
0
OD Gr e a t e r t h a n 100k
o h ms
0
D/ 2 Gr e a t e r t h a n 100k
o h ms
0
1 Gr e a t e r t h a n 100k
o h ms
0
07- 14- 11 T r a n s mi s s i o n Ra n ge (TR) Se n s o r 0 7 - 1 4 - 1 1
T r a n s mi s s i o n Ra n g e ( TR) S e n s o r
T 92 P - 7 0010- A H
Re mo v a l
3. Di sconnect el ect ri cal harness f r om Transmi ssi on
Range sensor.
4. Remove t wo ret ai ni ng bol t s.
5. Remove Transmi ssi on Range sensor.
1. Ensure manual cont rol l ever ( 7 A2 56) is in t he
2. Install Transmi ssi on Range sensor and l oosel y
i nstall t wo ret ai ni ng bol t s.
3. Ali gn TR sensor sl ot s usi ng Transmi ssi on Range
(TR) Sensor Al i gnment Tool (MLPS Al i gnment
Tool ) T92P- 70010- AH.
4. Ti ght en ret ai ni ng bol t s t o 9-12 N-m (7-9 Ib-ft) and
r emove t ool .
5. Connect el ect ri cal har ness t o Transmi ssi on
Range sensor.
6. Lowe r t he vehi cl e.
7. Connect bat t er y ground c a bl e .
8. Che c k f or pr oper oper at i on wi t h par ki ng br a ke
cont r ol ( 2 7 80) engaged. The engi ne shoul d st ar t
onl y in PARK or NEUTRAL.
ADJUSTMENTS
T r a n s m i s s i o n R a n g e ( TR) S e n s o r
T r a n s mi s s i o n Ra n ge ( TR) Se n s o r
T 92 P - 7 0010- A H
1. Remove nut securi ng manual c ont r ol l ever
( 7 A2 56) t o Transmi ssi on Range sensor.
2. Turn manual cont r ol l ever t o NEUTRAL posi t i on.
3. Loosen t wo TR se nsor ret ai ni ng bol t s.
4. Ali gn TR sensor sl ot s usi ng Transmi ssi on Range
(TR) Sensor Al i gnment Tool ( MLPS Al i gnment
To o I ) T92P- 7 0010- AH.
5. Ti ght en ret ai ni ng bol t s t o 9-12 N-m (7-9 Ib-ft).
6. Install nut ret ai ni ng manual cont r ol l ever t o TR
sensor and t i ght en t o 16-22 N-m (12-16 Ib-ft).
SPECIFICATIONS
OBDI I 3. 8L Mu s t a n g , 4. 6L To wn Car , Cr o wn Vi c t o r i a ,
Gr a n d Ma r q u i s , Co n t i n e n t a l , Th u n d e r b i r d ,
Co u ga r
TA1000B
T r a n s mi s s i o n Ra n ge Se n s o r Bo l t s 9- 12 7-9
Ma n u a l Co n t r o l L e v e r Nut 16- 22 12- 16
Tool Numbe r /
De sc r i pt i on I l l ust rat i on
T 92 P - 7 0010- A H
Tr a n s mi s s i o n Ra n ge ( TR)
Se n s o r Al i gn me n t To o l ( ML P S
Al i gn me n t To o l )
T92P-70010-AH
ROTUNDA EQUIPMENT
007 - 00033 Br e a ko u t Bo x
007 - 0085A Tr a n s mi s s i o n Te s t e r
007 - 00086 Tr a n s mi s s i o n Ra n ge ( TR) Se n s o r Ca b l e
(MLP Ca b l e )
09 - 00- 1
EXHAUST SYSTEM
SECTION 09-00 Exhaust System
GROUP
0 9
SUBJECT PAGE
Exhaust Shi elds 09-00-2
Exhaust Syst em 09-00-1
Inspection and Veri fi cati on 09-00-2
Pinpoint Test 09-00-3
Exhaust Hanger I nsul at ors 09-00-6
Exhaust Out l et Pi pe Frame Br acket 09-00-6
Exhaust Shi el ds ... . 09-00-6
SUBJECT PAGE
Muf f l er 09-00-4
Muf f l er Inl et Pi pe 09-00-4
Three-Way Cat al yt i c Convert er (TWC)... 09-00-5
Exhaust Shi el d I nspect i on 09-00-10
Exhaust Syst em 09-00-10
ADJUSTMENTS
Exhaust Syst em Al i gnment 09-00-10
SPECIFICATIONS . 09-00-10
SPECIAL SERVICE TOOLS/EQUIPMENT ...09-00-11
EHiCLE APPLICATION
E x h a u s t S y s t e m
WARNI NG: THE NORMAL OPERATI NG
TEMPERATURE OF THE EXHAUST SYSTEM I S
VERY HI GH. NEVER ATTE MP T TO SERVI CE ANY
PART OF THE SYSTE M UNTI L I T HAS COOLED. BE
ESPECI ALLY CAREFUL WHE N WORKI NG AROUND
THE THREE WAY CATALYTI C CONVERTER
( TWC) ( 5E 2 12 ) THE TEMPERATURE OF THE
THREE WAY CATALYTI C CONVERTER RI SES TO A
HI GH LEVEL AFTER ONLY A FEW MI NUTES OF
ENGI NE OPERATI ON.
CAUTI ON: Wh e n s e r v i c i n g e x h a u s t s y s t e m o r
r e mo v i n g e x h a u s t c o mp o n e n t s , d i s c o n n e c t a l l
h e a t e d o x y g e n s e n s o r s ( H02 S) ( 9F47 2 ) a t t h e
wi r i n g c o n n e c t o r s t o p r e v e n t d a ma g e t o t h e
h e a t e d o x y g e n s e n s o r s a n d wi r i n g h a r n e s s . Re f e r
t o Se c t i o n 03- 14 f o r l o c a t i o n o f t h e h e a t e d
o x y g e n s e n s o r s .
Thi s sect i on c o ve r s t he general exhaust sy st e m
adj ust ment s and ser vi ce pr oc e dur e s.
Al wa y s ref er t o t he Mast er Par t s Cat al og f or pa r t s
usage and i nt erchangeabi l i t y be f or e repl aci ng a
component par t of t he exhaust sy st e m.
The exhaust sy st e ms are equi pped wi t h;
Two t hr ee wa y cat al yt i c c onve r t e r s.
One or t wo muf f l ers ( 5230) (dependi ng on
appl i cat i on).
I nt erconnect i ng exhaust inlet pi pes ( 5246) .
The f act or y-i nst al l ed exhaust sy st e ms shown in t he
i l l ust rat i ons in t hi s sect i on di ffer f r om t he servi ce
repl acement sy st e ms in t he number of pi eces used.
When maki ng a ser vi ce repl acement , ref er t o t he
Mast er Part s Ca t a l og f or t he cur r ent assembl i es.
The exhaust sy st e m must be f r ee of:
Le a ks.
Bi ndi ng.
Groundi ng.
Excessi ve vi br at i ons.
These condi t i ons ar e usually c a use d by l oose, br oke n
or mi sal i gned:
1995 T o wn Car , Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s J u l y 1994
09- 00- 2 E x h a u s t S y s t e m 09- 00- 2
I
Cl amps.
Shields,
Bracket s.
Pipes,
If any of these conditions exi st, check the exhaust
syst em components and alignment. Adj ust or repl ace
as necessary t o maintain the speci fi ed cl earances
(refer t o the illustrations). Repl ace these part s if t hey
are damaged or badl y corroded. Do not at t empt t o
servi ce:
Bracket s.
Cl amps.
Insulators.
Detai l ed illustrations of the exhaust syst ems are
shown.
The Removal and Installation procedures appl y t o all
model s unless otherwi se noted. Refer t o the
appropri ate syst em illustration when servi ci ng t he
exhaust syst em.
T h r e e - Wa y Ca t a l y t i c C o n v e r t e r ( T WC)
The three way catal yti c converter, mounted in t he
engine exhaust st ream:
Pl ays a major role in the emission control syst em.
Works as a gas reactor.
Catal yti c function is t o speed up the heat produci ng
chemi cal reacti on between components of the
exhaust gases in order t o reduce the air pollutants.
Catal yti c materi al inside the converter is made of a
cerami c substrate that is coat ed wi th a high surface
area alumina and i mpregnated wi th catal yti cal l y
acti ve platinum.
The surface of the cat al yst materi al is what pl ays a
major role in the heat produci ng chemi cal react i on.
Pr ec aut i ons
WARNI NG: EXHAUST GASES CONTAI N CARBON
MONOXI DE WHI CH CAN BE HARMFUL TO HEALTH
AND ARE POTENTI ALLY L E THAL . EXHAUST
SYSTEM L E AKS SHOULD BE REPAI RED
I MMEDI ATELY. NEVER OPERATE THE ENGI NE IN
ENCLOSED AREAS.
CAUTI ON, L e a d e d f ue l mu s t n o t be u s e d i n a
v e h i c l e f i t t e d wi t h a t h r e e w a y c a t a l y t i c
c o n v e r t e r t h e l e a d wi l l p o i s o n t h e c a t a l y s t ,
The following precauti ons must be observed when
operati ng a vehicle equi pped wi t h t hree way cat al yt i c
convert ers.
If a vehi cl e is continually mi sfuel ed:
The l ead in the fuel will be deposi t ed in the converter
and compl etel y blanket the cat al yst .
Lead combi nes chemically wi t h platinum t o
" poi son" t he cat al yst .
Continuous use of l eaded fuels can total l y dest roy
the cat al yst , and render the converter usel ess.
The addition of lead t o the converter can al so solidify
the cat al yst , causi ng:
Excessi ve back pressure in the exhaust syst em.
Possible engine damage.
Extremel y high temperatures of 1100C ( 2 012 F) or
over, due t o misfiring or over-ri ch f uel / ai r mi xture, will
cause t he cerami c base t o sinter or burn, destroyi ng
the converter.
The three way catal yti c convert ers have been
desi gned t o provi de a long servi ce life. No
maintenance is necessary for the t hree way catal yti c
convert ers; however the fol l owi ng condi ti ons must be
avoi ded:
Driving downhill wi th the gears engaged and the
ignition swi t ch ( 1157 2) OFF.
Driving wi th misfiring engine.
Running the engine continuously wi t h a misfiring
spark plug ( 12405) . When idling is unstable or when
the engine l acks power, refer t o the Powertrai n
Cont rol / Emi ssi ons Diagnosis Manual .
1
Parki ng or stoppi ng the vehicle over combusti bl e
materi al . If the vehicle is parked or st opped over
combusti bl e material such as dry grass, t he
materi al may be ignited by t he high t emperat ure of
the three way catal yti c converter and muffler.
E x h a u s t S h i e l d s
S e r v i c e a n d / o r Re p l a c e me n t
Exhaust shields, consisting of f ormed metal sheet s,
at t ach t o the exhaust syst em or the catal yti c
converter connecti ons using vari ous methods.
Exhaust shields are not subject t o servi ce other t han:
Replacing missing or damaged shi el ds.
Removal of debri s that may col l ect in t he shield
area.
If an exhaust shield is damaged or shows evi dence of
deteri orati on, it should be repl aced rather than
servi ced.
Converter shields are servi ceabl e by repl aci ng the
shield using cl amps or bol ts. If an exhaust shield is
damaged or shows evi dence of deteri orati on, it should
be repl aced rather than servi ced.
E x h a u s t L e a k a g e o r No i s e
operati ng the engine t o dupl i cate the condi ti on.
2. Inspect t o determine if any of the following
09- 00- 3 E x h a u s t S y s t e m 09- 00- 3
3. External l eaks in the exhaust syst em are often
accompani ed by noi ses and exhaust fumes. A
visual inspection of the exhaust syst em usually
will show the l ocati on of a leak. When checki ng
for exhaust l eakage or noise, i nspect the entire
syst em for burnout hol es, l oose or corroded
cl amps, muffler ( 5230) or exhaust inlet pi pe
( 5246) . Exami ne the underbody for grayi sh-whi te
or bl ack exhaust soot whi ch woul d i ndi cate
exhaust l eakage at that point. On small l eaks,
have an assi stant hold rags over the tail pipe
outlet whi l e listening for t he l eak. Thi s hel ps
magnify the leak.
4. NOTE: In t he event of a t hree-way cat al yt i c
convert er failure, al ways check the muffler t o be
sure convert er debri s has not ent ered muffler.
When testi ng for a rattl e or vi brati on condi ti on, it
is helpful to use a rubber mallet. Tap on t he
exhaust component s to si mul ate the bouncing
acti on of the exhaust whi l e wat chi ng for
exhaust-to-body / chassi s contact. Al so l ook for
l oose or rusted fl ange connecti ons, l oose or
damaged exhaust shi el ds or cl amp, and l oose or
broken exhaust outlet pi pe f rame br acket s
( 5260) .
5. Lightly tappi ng on the muffler and t hree way
cat al yt i c converter (TWC)(5E212) can determi ne
if there are l oose or broken baffles in the muffler
or a loose or broken element in the t hree way
cat al yt i c converter.
6. If the concern(s) remain after t he i nspecti on,
determi ne t he sympt oms and go to t he Sympt om
Chart.
Symptom Chart
EXHAUST SYSTEM
Exhaust Leakage or Noise Exhaust leak.
Misaligned exhaust.
Loose clamps or fasteners.
Restri cted exhaust.
REFER t o Exhaust Leakage or
Noise as outlined under Inspection
and Verification.
Engine Has Lack of Power Fuel syst em.
Ignition system.
Electronic engine controls.
Restri cted exhaust system.
Pinpoint Test
PINPOINT TEST A: RESTRICTED EXHAUST SYSTEM TEST
A1 EXHAUST SYSTEM INSPECTION
Yes
No
GO t o A2.
REPLACE any damaged
or deteri orated exhaust
components. GO to A2
Inspect exhaust system for damage and
deteri orati on.
Is t he exhaust syst em OK?
Yes
No
GO t o A2.
REPLACE any damaged
or deteri orated exhaust
components. GO to A2
A2 VACUUM TEST
Yes >
No >
REFER to Powertrain
Control/Emi ssi ons
Diagnosis Manual
2
.
GO to A3.
o At t ach a Rotunda Vacuum / Pressure Tester
059-00008 or equivalent to the intake manifold
vacuum source.
Hook-up Rotunda Tachometer 059-00007 or
equivalent.
Start engine and gradually increase speed to 2000
rpm with transmission in NEUTRAL.
Is neut ral vacuum above 53. 8 kPa ( 16 i n-Hg)?
Yes >
No >
REFER to Powertrain
Control/Emi ssi ons
Diagnosis Manual
2
.
GO to A3.
09- 00- 4 E x h a u s t S y s t e m 09- 00- 4
PINPOINT TEST A: RESTRICTED EXHAUST SYSTEM TEST (Cont i nued)
A3 VACUUM TESTEXHAUST DISCONNECTED
Yes
No
GO to A4.
GO to A5.
Turn engine OFF.
Support and disconnect exhaust system at exhaust
manifolds.
Repeat vacuum t est .
Is the mani fol d vacuum above 53. 8 kPa (16
in-Hg)?
Yes
No
GO to A4.
GO to A5.
A4 VACUUM TESTCATALYTIC CONVERTER(S) ON,
MUFFLER(S) OFF
Yes
No
REPLACE muffler and
RETEST.
REPLACE three way
catalyti c converter and
INSPECT muffler to be
sure three way catalyti c
converter debris has not
entered muffler.
Turn engine OFF.
Reconnect exhaust system at exhaust manifold.
Disconnect muffler.
Repeat vacuum t est .
Is t he mani f ol d vacuum above 53. 8 kPa (16
in-Hg)?
Yes
No
REPLACE muffler and
RETEST.
REPLACE three way
catalyti c converter and
INSPECT muffler to be
sure three way catalyti c
converter debris has not
entered muffler.
A5 EXHAUST MANIFOLD RESTRICTED
Yes
No
REFER to Powertrain
Control/Emi ssi ons
Diagnosis Manual
3
.
REMOVE casting f lash. If
flash cannot be removed,
REPLACE exhaust
manifolds and RETEST.
Remove the exhaust manifolds. Inspect the ports f or
casti ng flash by dropping a length of chain into each
port. Do not use a wire or light to check ports. The
restri cti on may be large enough for them to pass
through but small enough t o cause excessi ve back
pressure at high engine rpm.
Are exhaust mani f ol ds OK?
Yes
No
REFER to Powertrain
Control/Emi ssi ons
Diagnosis Manual
3
.
REMOVE casting f lash. If
flash cannot be removed,
REPLACE exhaust
manifolds and RETEST.
Mu f f l e r
WARNI NG: THE NORMAL OPERATI NG
TEMPERATURE OF THE EXHAUST SYSTEM IS
VERY HI GH. NEVER ATTEMPT TO SERVI CE ANY
PART OF THE SYSTEM UNTI L IT HAS COOLED. BE
ESPECI ALLY CAREFUL WHEN WORKI NG AROUND
THE THREE WAY CATALYTI C CONVERTER
( TWC) ( 5E 2 12 ) . THE TEMPERATURE OF THE
CONVERTER RISES TO A HIGH LEVEL AFTER
ONLY A FEW MI NUTES OF ENGINE OPERATI ON.
Re mo v a l
1. Raise t he vehi cl e on a hoist that permi ts t he rear
axl e assembl y ( 4200) t o l ower t o the full extent of
its t ravel . Refer t o Secti on 00- 02. This will
provi de t he cl earance necessary t o remove the
muffler.
2. Remove the muffler cl amp at the exhaust inlet
pipe-to-muffler inlet connecti on.
3. Remove exhaust hanger insulators ( 5F262) f rom
exhaust outlet pipe f rame bracket s ( 5260) (three
pl aces on single, six pl aces on dual).
4. Separat e t he muffler ( 5230) f rom the exhaust
inlet pi pe ( 5246) and remove the muffler
assembl y.
1. Slide a new muffler cl amp over the outlet end of
t he exhaust inlet pipe .
2. Position the muffler on the exhaust inlet pipe and
loosely install the muffler cl amp. Ensure that the
t ab is fully inserted into the locating slot and
muffl er.
3. Position the muffler and install the exhaust hanger
insulators. Repl ace any exhaust hanger insulator
showi ng signs of wear or deteri orati on.
4. NOTE: If speci fi ed alignment speci fi cati ons
cannot be obtai ned, the RH and LH exhaust
manifold ( 9430) attachments should be l oosened.
After speci fi cati ons are obtai ned, tighten t he
exhaust manifold retaining nuts t o 34-46 N-m
(26-33 Ib-ft) while holding cl earances.
Align the exhaust syst em t o conform t o the
cl earance speci fi cati on. Refer t o appl i cabl e
illustration.
5. Position and al ternatel y ti ghten the muffler cl amp
nuts to 40-55 N-m (30-41 Ib-ft). Ensure the t ab
and slot are properl y engaged.
6. Check the syst em for l eaks, and l ower the
vehicle.
Mu f f l e r I n l e t P i p e
Re mo v a l
1. Raise vehicle. Refer t o Secti on 00- 02.
09- 00- 5 E x h a u s t S y s t e m 09- 00- 5
2. CAUTI ON: When ser vi ci ng exhaust s y s t e m o r
r emovi ng exhaust c omponent s , d i s c o n n e c t
a l l h e a t e d o x y g e n s e n s o r s ( H02 S) ( 9F47 2 ) a t
t h e wi r i n g c o n n e c t o r s t o p r e v e n t d a ma g e t o
t h e h e a t e d o x y g e n s e n s o r s a n d wi r i n g
h a r n e s s . Re f e r t o Se c t i o n 03- 14 f o r l o c a t i o n
o f t h e h e a t e d o x y g e n s e n s o r s .
Remove t he muffler cl amps at t he muffler ( 5230)
or muffler i nl et s.
3. Remove t he bol t s ret ai ni ng t he exhaust inlet pi pe
f l anges t o t he t hr e e wa y cat al yt i c c onve r t e r s
( TWCX5E212) .
4. Lowe r t he exhaust inlet pi pe ( 52 46) until t he inlet
f l anges cl ear t he t hr ee wa y cat al y t i c conver t er .
To gai n suf f i ci ent cl ear ance, it may be necessar y
t o r emove t he exhaust out let pi pe f r ame br a c ke t
5. When t he exhaust inlet pi pe is l ower ed
suf f i ci ent l y, se pa r a t e t he exhaust inlet pi pe f r om
t he muffler and di sc a r d exhaust conver t er out let
ga ske t ( 5E241) .
6. Wi t h exhaust out l et pi pe f r ame br a c ke t ret ai ni ng
bol t s r e move d, it may be necessar y t o suppor t
t he muffler in posi t i on usi ng wi r e.
1. Remove all exhaust conver t er out l et gasket
mat eri al f r om t he out l et f l anges on t he t hr ee wa y
cat al yt i c c onve r t e r s and exhaust inlet pi pe and
f l anges.
2. Loosen RH and LH t hr ee-way cat al y t i c
conver t er -t o-exhaust mani f ol d ret ai ni ng nut s
enough t o al l ow t hr ee-way cat al y t i c conver t er s
movement wi t hout bi ndi ng.
3. Sli de new muffler cl amps over t he out l et ends of
t he exhaust inlet pi pe .
4. Insert t he e xha ust inlet pi pe i nto t he muffler sli p
j oi nt s and l oosel y se c ur e t he muffler cl amps. The
exhaust inlet pi pe t a b must fully engage t he
muffler al i gnment sl ot .
5. Install new exhaust conver t er out l et ga ske t and
posi t i on t he exhaust inlet pi pe t o t he t hree wa y
cat al yt i c conver t er . Install new ret ai ni ng bol t s. Do
not t i ght en t he bol t s.
6. Install t he e xha ust out l et pi pe f r a me br a c ke t
ret ai ni ng bol t s, if r e move d.
7. Ali gn t he sy st e m t o speci f i cat i on. Ref er t o
appl i cabl e i l l ust rat i on.
8. NOTE: Al t er nat e t i ght eni ng of j oi nt f ast ener s is
requi red t o pr ovi de uni f orm cl ampi ng in or der t o
prevent j oi nt di st or t i on, a maj or c a use of l eaks
and sy st e m mi sal i gnment .
Wi t h t he sy st e m hel d t o ali gnment speci f i cat i on:
Ensure t hat t he exhaust inlet pi pe t a b is fully
engaged i nt o t he muffler al i gnment sl ot .
Al t ernat el y t i ght en t he muffler cl amp nuts t o
40-55 Nm ( 30- 41 Ib-f t ).
Ti ght en t he exhaust out l et pi pe f r a me br a c ke t
bol t s t o 17-23 N-m (13-16 I b-f t ), if r equi r ed.
Ti ght en t he exhaust inlet pi pe-t o-t hr ee-way
c a t a l y t i c conver t er f l ange ret ai ni ng bol t s t o
34- 46 N-m (26-33 Ib-f t ).
w Al t er nat el y t i ght en t he RH and LH e xha ust
mani f ol d nut s t o 34- 46 N-m ( 26- 33 Ib-f t ).
9. Remove ali gnment rest rai nt s and suppor t wi r e.
10. Che c k t he exhaust sy st e m f or l eaks and pr ope r
al i gnment .
T h r e e - Wa y C a t a l y t i c C o n v e r t e r ( T WC )
Re mo v a l
1. CAUTI ON: Wh e n s e r v i c i n g e x h a u s t s y s t e m o r
r e mo v i n g e x h a u s t c o mp o n e n t s , d i s c o n n e c t
al l h e a t e d o x y g e n s e n s o r s ( H02 S) ( 9F47 2 ) a t
t h e wi r i n g c o n n e c t o r s t o p r e v e n t d a ma g e t o
t h e h e a t e d o x y g e n s e n s o r s a n d wi r i n g
h a r n e s s . Re f e r t o Se c t i o n 0 3 - 1 4 f o r l o c a t i o n
o f t h e h e a t e d o x y g e n s e n s o r s .
Rai se vehi cl e. Ref er t o Sect i on 00- 02.
2. Remove t he ret ai ni ng bol t s at each t hr e e -wa y
cat al y t i c conver t er f l ange.
3. Remove t he t hr ee-way cat al yt i c conver t er t o
exhaust mani f ol d ret ai ni ng nut s.
4. Sli de t he exhaust inlet pi pe ( 5246) r e a r wa r d until
t he t hr ee wa y cat al yt i c conver t er s
(TWC)(5E212) can be r emoved. It may be
necessar y t o obt ai n suf f i ci ent cl earance t o
separ at e t he t hree wa y cat al yt i c conver t er at
exhaust mani f ol d connect i on(s).
5. Di sc a r d exhaust convert er out let ga ske t s
( 5E241) and any damaged par t s.
1. Remove exhaust convert er out let ga ske t mat eri al
f r om exhaust inlet pi pe and t he t hree wa y
cat al yt i c c onve r t e r s.
2. Posi t i on t he t hr ee wa y cat al y t i c c onve r t e r s t o t he
exhaust mani f ol ds ( 9430) . Loosel y i nstall
ret ai ni ng nut s.
3. Install new exhaust convert er out l et ga ske t s
bet ween t he t hr ee wa y cat al yt i c c onve r t e r s and
exhaust inlet pi pe f l anges. Posi t i on t he exhaust
inlet pi pe f l ange t o t he t hr ee-way c a t a l y t i c
conver t er out l et f l ange and i nsert new ret ai ni ng
bol t s.
4. NOTE: Al t ernat e t i ght eni ng of t he j oi nt f ast ener is
requi red t o provi de uni f orm cl ampi ng. Thi s wi ll
prevent j oi nt di st ort i on, a maj or cause of sy st e m
l eaks and mi sadj ust ment .
Al t ernat el y t i ght en t he t hree wa y c a t a l y t i c
convert er t o t he exhaust inlet pi pe f l ange
ret ai ni ng bol t s t o 34-46 N-m (26-33 Ib-f t ).
5. Ali gn t he sy st e m t o proper cl ear ance
speci f i cat i on. Ref er to appl i cabl e i l l ust rat i on.
09- 00- 6 E x h a u s t S y s t e m 09- 00- 6
7.
8.
Al ternatel y tighten the exhaust manifold nuts t o
34- 46 N-m (26-33 Ib-ft).
Check the syst em for l eaks.
Lower vehicle.
E x h a u s t S h i e l d s
T h r e e - Wa y C a t a l y t i c C o n v e r t e r ( T WC) Sh i e l d s
The cat al yst wel ded shields are t o be repl aced wi th
cl amp-on servi ce shi el ds.
Removal and Installation procedures involve removing
t he shield at t achment s and shi el d. Installation is the
reverse procedure, using new part s. The illustrations
i ndi cate t he t ypes and proper positioning of exhaust
shi el ds and cl amps.
2. Support exhaust syst em wi th a suitable j ack
st and.
muffler ( 5230) .
4. Remove exhaust outlet pipe f rame bracket
( 5260) .
exhaust outlet pipe f rame bracket retaining bol ts
t o 17-23 N-m (13-16 Ib-ft).
E x h a u s t O u t l e t P i p e F r a m e B r a c k e t
1. Rai se vehicle on hoist. Refer t o Secti on 00- 02.
E x h a u s t H a n g e r I n s u l a t o r s
2. Support exhaust syst em wi th a suitable j ack
st and.
exhaust outlet pipe frame bracket s ( 5260) and
muffler ( 5230) as necessary.
09- 00- 7 E x h a u s t S y s t e m
09- 00- 7
4. 6L E n gi n e 2 V Dual Exhaust Syst em
TIGHTEN BOLTS
ALTERNATELY TO
MAINTAIN
TORQUE AND TO DRAW
FLANGES EVENLY
* END OF STUD BOLT WITH THE
SHORTEST THREAD
LENGTH TO I E SCREWED
INTO EXHAUST MANIFOLD
VIEW A
TI GHTEN NUTS EVENLY
AND ALTERNATELY TO
MAINTAIN TORQUE
RH SIDE SHOWN
LH SIDE SIMILAR
VIEW A
RH SIDE SHOWN
LH SIDE SIMILAR
VIEW B
RH SIDE SHOWN
LH SIDE SIMILAR
VIEWC

RH SIDE SHOWN
LH SIDE SIMILAR
VIEW J
VIEW K
VIEW K
U2115-G
09- 00- 8 E x h a u s t S y s t e m 09- 00- 8
Pa r t Pa r t
1 5E212 Three Way Catalyti c 13 N391188-S100 Nut (4 Req'd)
Converter (2 Req'd) 14 9430 Exhaust Manifold (2 Req'd)
2 5246 Exhaust Inlet Pipe 15 N807988-S100 Stud Bolt (4 Req'd)
3 5230 Muffler (2 Req'd)
16 N806228-S100 Nut (4 Req'd)
4 N802771-S56 Exhaust Clamp (2 Req'd) 17 5025 Crossmember
5 5260 Exhaust Outlet Pipe Frame
Bracket (4 Req'd)
A

Lb-Ft)
6 N802212-S100 Bolt (6 Req'd) B
7 5500 Rear Suspension Arm and Lb-Ft)
Bushing (2 Req'd) C Tighten to 34-46 N-m (26-33
8 5A965 Rear Spring and Shock Lb-Ft)
Absorber (2 Req'd) D 25.5 mm (1.004 inch)
9 5005 Frame
E

37.0 mm (1.457 inch)
10 5E241 Exhaust Converter Outlet
F

0.0-1.0 mm (0.0-0.039 inch)
Gasket (2 Req'd)
G 20.5-28.0 mm (0.807-1.102
11
5F240 Exhaust Damper (2 Req'd) inch)
12 56143-S100 Bolt (4 Req'd) H 19.0 mm (0.748 inch)
09- 00- 9 E x ha us t S y s t e m
09- 00- 9
4. 6L 2 V Engi ne, Si ngl e Ex ha ust Sy st e m
VIEW A
TIGHTEN BOLTS
ALTERNATELY TO
MAINTAIN
TORQUE AND TO DRAW
FLANGES EVENLY
# END OF STUD BOLT WITH THE
SHORTEST THREAD
LENGTH TO BE SCREWED
INTO EXHAUST MANIFOLD
TIGHTEN NUTS EVENLY
AND ALTERNATELY TO
MAINTAIN TORQUE
U2116-G
09- 00- 10 E x h a u s t S y s t e m 09- 00- 10
Pa r t
1 5E212 Three Way Catalyti c
Converter (2 Req'd)
2 5230 Muffler
3 N802771-S56 Exhaust Clamp
4 5246 Exhaust Inlet Pipe
5 9430 Exhaust Manifold (2 Req'd)
6 N807988-S100 Stud Bolt (4 Req'd)
7 N806228-S100 Nut (4 Req'd)
Bushing (2 Req'd)
9 5A966 Rear Spring and Shock
Absorber (2 Req'd)
10 N802212-S100 Bolt (3 Req'd)
11 5005 Frame
12 5260 Exhaust Outlet Pipe Frame
Bracket (2 Req'd)
13 N391188-S100 Nut (4 Req'd)
Pa r t
14 56142-S100 Bolt (4 Req'd)
15 5E241 Exhaust Converter Outlet
Gasket
16 5F240 Exhaust Damper
17 5025 Crossmember
Lb-Ft)
B

Lb-Ft)
C

Lb-Ft)
D

25.5 mm (1.004 inch)
E 37.0 mm (1.457 inch)
F 0.0-1.0 mm (0.0-0.039 inch)
G

20.5-28.0 mm (0.807-1.102
inch)
H 19.0 mm (0.748 inch)
Exhaust Syst em
Inspect t he t hree way cat al yt i c convert ers
( TWCX5E212) , exhaust inlet pi pes ( 5246) and
mufflers ( 5230) for cr acked j oi nts, broken wel ds and
corrosi on damage that woul d result in a leaking
exhaust syst em. Inspect the cl amps, bracket s and
i nsul ators for cr acks and stri pped or badl y corroded
bol t t hreads. When cl amp(s) are l oosened and/ or
removed t o repl ace a muffler or exhaust inlet pi pe,
repl ace t he cl amp(s) if there is reasonabl e doubt t hat
its servi ce life is limited.
Exhaust Shield Inspect i on
Inspect t he exhaust shields for cr acks, broken wel ds,
corrosi on and damage. Repl ace the exhaust shield if
damaged.
ADJUSTMENTS
Exhaust Syst em Al i gnment
A mi sal i gned exhaust syst em is usually i ndi cated by
vi brati on, groundi ng, rattling or binding of syst em
component s. Often the associ at ed noise is hard t o
di sti ngui sh f rom other chassi s noi ses. Look for broken
or l oose cl amps and bracket s. Repl ace or ti ghten as
necessary. It is i mportant that exhaust cl earances and
alignment be maintained.
Perf orm the fol l owi ng procedures t o align t he syst em:
1. Loosen the retaining hardware, cl amp and t he
pi pe support br acket s.
2. Align t he exhaust syst em, beginning at t he front
of t he vehi cl e, t o establ i sh maxi mum cl earance.
3. NOTE: Tighten the flange nuts and the exhaust
manifold nuts evenly and alternately.
Tighten all retai ners to speci fi cati on.
4. NOTE: Three way catal yti c converters
( TWCX5E212) , exhaust inlet pipes ( 5246) ,
mufflers ( 5230) , bracket s, cl amps and insulators
should be repl aced if they are worn or badl y
corroded. Do not attempt t o servi ce these part s.
5. St art the engine and check the exhaust syst em
for l eaks.
SPECIFICATIONS
Co u ga r
TA1000B
Co n v e r t e r - t o - l n l e t P i pe Bo l t s 34- 46 2 6- 33
E x h a u s t Ma n i f o l d Nut s 34- 46 2 6- 33
Muf f l e r Cl a mp Nut s 40- 55 30- 41
E x h a u s t Out l e t Pi pe Fr a me
Br a c k e t Bo l t s
17- 23 13- 16
09- 00- 11 E x h a u s t S y s t e m 09 - 00- 11
ROTUNDA EQUIPMENT
Model Description
059- 00007 T a c h o me t e r
059- 00008 Va c u u m / P r e s s u r e Te s t e r
10- 00- 1
GROUP
FUE S YS T
SECTI ON TI TLE PAGE
ACCELERATOR PEDAL AND LINKAGE 10-02-1
FUEL SYSTEMSERVI CE 10-00-1
FUEL TANK, FI LTERS, LINES AND EL ECTRI C
FUEL PUMP ...10-01-1
SECTI ON TI TLE
SPEED CONTROL SYSTEM.
PAGE
.10-03-1
SECTION 10-00 Fuel System = - - & d ms
SUBJECT PAGE
Fuel Syst em Servi ce ..10-00-1
Fuel Syst em , 10-00-2
Engi ne Ai r Cl eaner . 10-00-2
SUBJECT PAGE
CLEANING AND INSPECTION (Cont 'd. )
Fuel Pump, El ect r i c. 10-00-2
Idle Air Cont rol (IAC) Valve ..10-00-2
ADJUSTMENTS
Fuel Syst em 10-00-3
VEHICLE APPLICATION
Fu e l S y s t e m S e r v i c e
WARNI NG: DO NOT SMOKE OR CARRY LI GHTED
TOBACCO OR OPEN FL AME OF ANY TYPE WHEN
WORKI NG ON OR NEAR ANY FUEL- RELATED
COMPONENT. HI GHLY FL A MMA BL E MI XTURES
When servi ci ng t he fuel syst em, observe t he following
information:
All engines use a cl osed-t ype posi ti ve crankcase
ventilation syst em and an exhaust emi ssi on syst em
t o control engine emi ssi ons within Government
speci fi cati ons.
To maintain t he requi red exhaust emi ssi on levels,
the fuel meteri ng syst em must be kept in good
operati ng condi ti on.
The syst em must be adj usted to speci fi cati ons
listed in the appl i cabl e Secti on of t he Powertrai n
Cont rol / Emi ssi ons Diagnosis Manual
1
.
Additional engine performance checks are required
to keep the exhaust emissions at t he speci fi ed
minimum pollutant level. Refer t o the Pre-Delivery
manual for these performance checks and
recommended i nterval s.
This secti on covers Di agnosi s, Cleaning and
Inspection procedures di rectl y rel ated t o fuel injection.
Al ways refer t o the Mast er Parts Catal og for parts
usage and interchangeability before repl aci ng a
throttl e body ( 9E926) or a component part of a throttl e
body.
10- 00- 2 Fue l S y s t e mS e r v i c e 10- 00- 2
Fu e l S y s t e m
Refer t o t he Powertrai n Control / Emissions Diagnosis
Manual
2
.
E n g i n e A i r C l e a n e r
Clean the air cleaner body and the cover wi th a solvent
or compr essed air. Wi pe t he air cl eaner body and
cover dry if a solvent is used. Inspect the air cleaner
body and cover for di storti on or damage at the gasket
mati ng surf aces. Repl ace cover or body if they are
damaged beyond servi ce.
Al so check the air cleaner element for def ormed seal s
or brittle spot s that coul d fail under engine operati on
and cause a hole.
Di scol orati on only, is not a cause for repl acement.
I d l e Air C o n t r o l (IAC) Va l v e
CAUTI ON: Do n o t use Ca r b u r e t o r Tun e - Up
Cl e a n e r D9A Z - 1957 9- BA o r e q u i v a l e n t me e t i n g
Fo r d s p e c i f i c a t i o n ESR- M14P9- A o r a n y o t h e r
t y p e s o l v e n t o r d a ma g e t o t h e v a l v e i n t e r n a l
c o mp o n e n t s ma y r e s u l t .
The idle air control valve (IAC val ve)(9F715) cannot
be cl eaned. The idle air control valve must be
repl aced.
i
A i r C l e a n e r E l e m e n t
CAUTI ON: Cl e a n i n g t h e ai r c l e a n e r e l e me n t ( ACL
e l e me n t ) ( 9 601) i s n o t r e c o mme n d e d . Cl e a n i n g
t h e a i r c l e a n e r e l e me n t wi l l r e s ul t i n r e s t r i c t e d
a i r f l o w.
Refer t o Secti on 00- 03 for t he recommended air
cl eaner element mai ntenance mileage i nterval . The air
cl eaner element should be repl aced at t he speci fi ed
mi l eage i nterval s.
Visually i nspect t he air cl eaner element for signs of
dust or dirt leaking through holes in the filter medi a or
past t he sealing edges. Pl ace a light on the bot t om
(cl ean si de) of t he air cl eaner element and look
t hrough t he filter medi a at t he light. Even t he smal l est
hole is cause for repl acement.
CAUTI ON: The t h r o t t l e b o d y ( 9E 92 6) i s o f a
s l u d g e r e s i s t a n t d e s i gn a n d s h o u l d n o t be
c l e a n e d .
Fu e l P u m p , E l e c t r i c
Manual
2
.
10- 00- 3
Fue l S y s t e mS e r v i c e
10- 00- 3
ADJUSTMENTS
Fuel System
Refer t o Powertrai n Cont rol / Emi ssi ons Di agnosi s
Ma n ua l
3
.
SPECIFICATIONS
Co u ga r
TA1000B
FUEL PRESSURE SPECIFICATIONS
En gi n e Run n i n g 30- 45 ps i
2 10- 310 kP a
Ke y On En gi n e Of f 35- 40 p s i
2 40- 2 80 kP a
10- 01- 1 Fue l Ta n k, Fi l t e r s , L i n e s a n d E l e c t r i c Fue l P u mp 10- 01- 1
SECTION 10-01 Fuel Tank, Filters, Lines and Electric
Fuel Pump
SUBJECT PAGE
Evaporati ve Emission Tube Shutoff Valve ..10-01-4
Evaporati ve Emission Valve 10-01-4
Fuel Filter 10-01-2
Fuel Gauge 10-01-6
Fuel Inj ected Engines ............................................10-01-1
Fuel Li nes. 10-01-4
Push Connect Fi tti ng 10-01-4
Fuel Pressure Regulator... 10-01-5
Fuel Pump, El ectri c .......10-01-4
Fuel Tank and Fuel Tank Filler Pipe 10-01-2
Fuel Tank Filler Cap 10-01-2
Inerti a Fuel Shutoff (IFS) Swi t ch 10-01-6
Fuel Tank, Fi l ters, Li nes, Valves and El ectri c
Fuel Pump 10-01-7
Evaporati ve Emission Tube Shut-Off
Valve .10-01-12
Evaporati ve Emission Valve .10-01-12
Fuel and Vapor Return Tubes 10-01-12
SUBJECT PAGE
Fuel Drai ni ng 10-01-7
Fuel Fi l l i ng ....10-01-7
Fuel Fi l t er(s) . 10-01-11
In-Tank.. 10-01-11
Fuel Tank 10-01-8
Fuel Tank Fi ller Pipe 10-01-10
Fuel Tank Sendi ng Unit and Fuel Pump 10-01-11
Fuel Tank Support St raps 10-01-10
I nert i a Fuel Shut of f (IFS) Swi t ch 10-01-12
Push Connect Fi t t i ngs 10-01-12
Spri ng Lock Coupl i ng ..10-01-14
Fuel Tanks. . . . . 10-01-16
SERVICE PROCEDURES
Fuel Syst em Pressuri zed 10-01-16
Fuel Syst em Pressure Reli ef 10-01-16
Push Connect Tube Ends, St eel 10-01-18
Push Conne c t or s, Nyl on 10-01-17
SPECIFICATIONS
Fuel Syst em Speci f i cat i ons 10-01-18
SPECIAL SERVICE TOOLS/EQUIPMENT ..10-01-19
VEHICLE APPLICATION
TOBACCO OR AN OPEN FLAME OF ANY TYPE
WHEN WORKI NG ON OR NEAR ANY
FUEL- RELATED COMPONENT. HI GHLY
FL A MMA BL E MI XTURES ARE AL WAYS PRESENT
AND MAY BE I GNI TED, RESULTI NG IN POSSI BLE
PERSONAL INJURY.
Fuel Injected Engines
Fuel i nj ect ed engi nes have t he f ol l owi ng
c ha r a c t e r i st i c s:
Vehi cl es equi pped wi t h f uel i nj ect ed engi nes use an
el ect ri c fuel pump ( 9350) t o pr ovi de hi gh-pressure
fuel t o t he fuel i nj ect ors ( 9F593) .
The f uel pump is l ocat ed i nsi de t he fuel t ank ( 9002) .
The suppl y line whi c h del i vers f uel f r om t he f uel t ank
t o t he engi ne is under pr essur e duri ng vehi cl e
oper at i on.
All f uel i nj ecti on sy st e ms have a ret urn line whi ch
ret urns unused f uel f r o m t he engi ne t o t he fuel t ank.
When fuel i nj ect ed engi nes are t urned of f , t he fuel in
t he f uel suppl y lines remai ns pressuri zed f or long
peri ods of t i me t o provi de qui ck st ar t -ups.
Pr ocedur es f or servi ci ng t hese pressuri zed fuel
sy st e ms are out l i ned in t hi s sect i on.
Fuel Tank and Fuel Tank Filler Pipe
The fuel t ank filler pi pe ( 9034) per f or ms t he f ol l owi ng
f unct i ons:
The r e st r i c t e d openi ng of t he fuel t ank fi ller pi pe
al l ows only a non-l eaded fuel nozzle t o be i nsert ed.
The r est r i ct or consi st s of a narrow openi ng in t he
fuel t ank filler pi pe c ove r e d by a spri ng l oaded st eel
t r a p door.
The smal l er non-l eaded fuel nozzle wi ll f i t t hr ough
t he nar r ow openi ng and push t he t r a p door asi de,
al l owi ng normal f i lli ng. Leaded fuel nozzl es wi ll not f i t
t hr ough t he narrow openi ng. The t r a p door bei ng
cl osed c a use s a f uel ba c kup and aut omat i c nozzle
shut -of f .
The r e st r i c t e d fuel filler is manuf act ured as an
assembl y, and must be ser vi ced by removal and
repl acement wi t h a new fuel t ank fi ller pi pe.
Fuel t ank filler pi pes are not t o be modi f i ed in
a ny wa y .
The f uel t ank filler pi pe desi gn cont r ol s t he amount
of fuel whi c h is per mi t t ed into t he fuel t ank ( 9002) .
The fill li mi ti ng sy st e m is desi gned t o permi t an
a ppr oxi ma t e 10t o 12 percent f uel t ank vol ume ai r
spa c e when t he f uel t ank is fi lled t o c a pa c i t y . Thi s
air spa c e pr ovi des f or t hermal expansi on of fuel a s
wel l as bei ng an ai d t o t he i n-tank vapor vent
sy st e m. The fuel t ank hol ds appr oxi mat el y 7 5. 7 L
( 20 gal ) of usabl e f uel .
Fuel Tank Filler Cap
WARNI NG: FUEL TANK ( 9002 ) MAY BE
PRESSURI ZED. TO REMOVE FUEL TANK FI LLER
CAP ( 9030) , ROTATE OVER ONE HAL F TURN
COUNTERCLOCKWI SE. IF FUEL TANK FI LLER
CAP IS VENTI NG FUEL OR A HI SSI NG SOUND I S
HEARD, WAI T UNTI L CONDI TI ON STOPS BEFORE
CONTI NUI NG TO TURN FUEL TANK FI LLER CAP .
IF THESE PRECAUTI ONS ARE NOT FOL L OWE D,
FUEL MAY SPRAY AND CAUSE PERSONAL
INJURY.
The fuel t ank filler c a p has t he f ol l owi ng
It cont ai ns an i nt egral pr essur e and va c uum reli ef
val ve. The vacuum val ve:
Ac t s a s a se c o n d a r y poi nt f or ai r t o ent er t he
fuel t ank t o r epl ace t he fuel a s it i s use d.
Opens onl y in t he event t hat t he pr i mar y ent ry
poi nt t hr ough t he c a r bo n cani st er and
evapor at i ve emi ssi on val ve ( 9B593) become
r e st r i c t e d. The va c uum relief val ve opens af t er
vacuum in t he fuel t ank reaches -3. 4 kPa (-0.5
psi ).
The pr essur e val ve a c t s as a ba c kup pr essur e
reli ef val ve in t he event t he normal vent i ng
sy st e m i s o ve r c o me by e xc e ssi ve generat i on of
i nt ernal pr essur e or rest ri ct i on of t he normal
vent i ng sy st e m. The pressure reli ef range i s
11. 1-14. 4 kPa (1. 6-2. 1 psi ).
Da ma ge t o t he fuel t ank filler c a p, or cont ami nat i on
t ha t st ops t he pr e ssur e / v a c uum val ve f r om wor ki ng
ma y resul t in def or mat i on of t he fuel t ank. Car e
shoul d a l wa y s be t aken t o use a pr oper fuel t ank
fi ller c a p in good wo r ki n g order.
It is a t hr e a de d sc r e w-on desi gn wi t h a pre-vent
f eat ur e t hat al l ows t he fuel t ank t o vent f or t he f i r st
t hr ee-quar t er t urn bef or e unt hreadi ng.
Al l f uel t ank filler c a ps ar e a t t a c he d t o t he vehi cl e
wi t h a t et her usi ng t he fuel t ank filler pi pe-t o-housi ng
sc r e w at t he t hr ee t o f our o' c l oc k posi t i on.
The fuel t ank filler cap assembl y pr ovi des pr essur e
and vacuum relief f unct i ons and it shoul d be
r epl aced wi t h t he proper fuel t ank fi ller c a p t o
prevent possi bl e sy st e m mal f unct i on.
The fuel t ank filler cap is f i t t ed wi t h a t or que li mi ti ng
r at chet t o prevent di f f i cul t y in removal .
When i nstalli ng t he fuel t ank filler c a p, cont i nue t o
t urn c l oc kwi se until r at chet mechani sm gi ves of f
t hr ee or more l oud " c l i c ks " .
Fuel Filter
Fuel is f i l t ered at t hr ee l ocat i ons.
I n - L i n e
In-line fuel f i lt er and base ( 9B072) has t he f ol l owi ng
char act er i st i cs:
10- 01- 3 Fuel Tank, Fi l t er s, Li nes and El ect r i c Fuel Pump 10- 01- 3
It provi des filtration t o prot ect the small meteri ng
ori fi ces of the injector nozzles.
It is l ocated downst ream of the el ectri c fuel pump
( 9350) and is mounted on a bracket on the
underbody.
It is a one-piece constructi on whi ch cannot be
cl eaned. If it becomes cl ogged, repl ace it.
NOTE: When repl aci ng fuel filter and bases, use the
fuel filter and base speci fi ed for t he engine being
servi ced.
SCREW
W611633-S56
2 REQ'D
FUEL RETURN
TUBE 9L291
FUEL FILTER
AND BASE
9B072
V7586-A
I n - Ta n k
A nylon filter element is mounted on t he fuel pump inlet
inside the fuel tank ( 9002) and is used t o prot ect t he
fuel pump f rom fuel contami nants.
Fu e l I n j e c t o r S c r e e n
An injector filter is l ocat ed at the t op of each fuel
injector ( 9F593) and is not servi ceabl e. If an injector
screen becomes cl ogged, repl ace the compl et e fuel
injector. Refer t o Secti on 03- 04 f or fuel injector
i nformati on.
MFI Fue l I n j e c t o r
V8562-A
I t e m
Pa r t
1

Fuel Inj ection Supply
Manifold O-Ring Seal (Part
of 9F593)
2
Integral Filter Screen (Part of
9F593)
3 Coil (Part of 9F593)
4
_
Armature (Part of 9F593)
5

Intake Manifold O-Ring Seal
(Part of 9F593)
6 End Cap (Part of 9F593)
7 Stainless Steel Needle and
Valve Body (Part of 9F593)
8 Washer (Part of 9F593)
9 Body (Part of 9F593)
10

Coil Terminal Blade (Part of
9F593)
10- 01- 4 Fuel T a n k, Fi l t er s, Li nes and El ect r i c Fuel Pump 10- 01- 4
Evaporati ve Emi s s i o n Valve
The evapor at i ve emi ssi on val ve ( 9B593) is mount ed in
t he t o p sur f ace of t he fuel t ank ( 9002) in t he vapor
dome . Its f unct i on is t o al l ow fuel va por s t o f l ow i nt o
t he remai nder of t he evapor at i ve emi ssi ons sy st e m
whi l e prevent i ng t he f l ow of li qui d i nto t ha t sy st e m
(smal l amount s may e sc a pe due t o vehi cl e
maneuvers) and is used t o vent t r a ppe d fuel va po r s.
The fuel va por s l eave t he val ve and t r avel t hr ough a
vapor line t o t he c a r bon cani st er f or st or a ge until t he y
ar e pur ged t o t he engi ne f or burni ng.
EVAPORATIVE
EMISSION VALVE 9B593
EVAPORATIVE
EMISSION TUBE
SHUT OFF VALVE
9G332
V9851-A
Evaporati ve Emi ssi on Tube Shut of f Valve
The evapor at i ve emi ssi on t ube shut of f val ve ( 9G332)
is mount ed on t he t o p of t he fuel t ank ( 9002) using a
br a c ke t . It is c onne c t e d in ser i es bet ween t he
evapor at i ve emi ssi on val ve ( 9B593) and t he
evapor at i ve emi ssi ons cani st er (EVAP
c a ni st e r )(9D653). A hose c onne c t s t he evapor at i ve
emi ssi on t ube shut off val ve t o t he fuel filler pi pe
sensi ng t ube. The e va por a t i ve emi ssi on t ube shut of f
val ve de t e c t s f uel t ank filler c a p ( 9030) removal by
sensi ng change in fuel t ank pr e ssur e . By cl osi ng when
t he fuel t ank filler c a p i s r e move d, t he evapor at i ve
emi ssi on t ube shut off val ve c l ose s t he f l ow pat h f r om
t he evapor at i ve emi ssi on val ve t o t he evapor at i ve
emi ssi ons cani st er duri ng ref uel l i ng, in order t o prevent
overf i l l i ng t he fuel t ank. The evapor at i ve emi ssi on t ube
shut of f val ve opens whe n t he fuel t ank filler c a p is
r epl aced, t o al l ow normal evapor at i ve emi ssi on
cont r ol .
Fuel Li nes
Spring Lock Coupling
Spr i ng l oc k coupl i ngs ar e used t o connect t he f uel li nes
t o t he engi ne fuel rai l s. The f i t t i ngs c a n be ser vi ced
usi ng t he pr oc e dur e s out l i ned.
Push Connect Fi tti ng
St eel f uel li nes and rubber c ove r e d nylon f uel hose
a sse mbl i e s wi t h push connect f i t t i ngs ar e used wi t h
4. 6L mul t i port fuel i nj ect ed (MFI ) engi nes.
Nyl on push connect f i t t i ngs are used t o make t he f uel
line connect i ons t o t he fuel f i l t er and base ( 9B07 2) .
St eel push connect f i t t i ngs ar e used t o make f uel line
connect i ons t o t he f uel pump ( 9350) in t he fuel t ank
( 9002 ) . The se f i t t i ngs must be ser vi ced usi ng t he
pr o c e d ur e s out l i ned.
Fuel Pump, Elect ri c
The f uel sy st e m has t he f ol l owi ng c ha r a c t e r i st i c s:
It uses a hi gh-pressure in-fuel t ank mount ed el ect r i c
f uel pump ( 9350) .
The f uel pump is a combi ned assembl y wi t h a fuel
ga uge sender.
The f uel t ank ( 9002) is sheet met al and has a fuel
r eser voi r we l de d i nsi de t he sump cavi t y .
The f uel pump is mount ed wi t h i t s inlet at t he bo t t o m
of t he f uel t ank reservoi r. Thi s desi gn permi t s fuel
pump operat i on duri ng ext r eme vehi cl e maneuvers
a nd dri vi ng on st eep hills when t he fuel t ank i s near
e mpt y .
The hi gh-pressure pumpi ng unit is c a pa bl e of suppl yi ng
80. 0L ( 21. 0 gal ) of f uel per hour at a wor ki ng pr essur e
of 2 69. 0 kPa (39 psi ).
The fuel pump:
Ha s an i nternal reli ef val ve t o pr ot e c t t he fuel pump
f r o m overpressuri zi ng if t he fuel f l ow becomes
r e st r i c t e d (cl ogged fi lter, da ma ge d fuel line, e t c . ) .
Ove r pr e ssur e is li mi t ed t o 850 kPa ( 123 psi ) and
r e duc e d fuel f l ow wi ll resul t .
Is pr o t e c t e d at i t s inlet by a nylon pi ck-up scr een
t hat f i l t ers di rt and cont ami nant s whi c h coul d plug or
da ma ge t he i nternal fuel pump component s. The
nylon pi ck-up scr een al l ows pa ssa ge of smal l
quant i t i es of wa t e r whi c h may accumul at e wi t hi n t he
fuel t ank sump.
V9850-A
Pa r t
1 9350 Fuel Pump
2

Seal (Part of 9H307)
3 Electri cal Connector (Part of
9H307)
4

Fuel Gauge Sender (Part of
9H307)
5

Electric Fuel Pump (Part of
9H307)
6

Inlet Filter (Part of 9H307)
7

Fuel Return (Part of 9H307)
8 Sender Float (Part of 9H307)
9

Fuel Return Inlet (Part of
9H307)
10

Fuel Pressure Supply (Part
of 9H307)
The el ect ri cal sy st e m:
Has a f uel pump cont r ol rel ay cont r ol l ed by t he
powe r t r a i n cont rol modul e rel ay (PCM
r e l a y ) ( 12A646) , whi c h pr ovi des po we r t o t he fuel
pump t hr ough an i nert i a fuel shut of f swi t c h (IFS
swi t c h) ( 9341) , whi c h is normal l y c l ose d.
Provi des powe r t o t he fuel pump t hr ough t wo rel ays:
Fuel pump power rel ay.
Power t r ai n cont rol modul e powe r r el ays. The
current pat h i s dependent upon t he operat i ng
condi t i on(s).
When t he i gni ti on swi t c h ( 1157 2) i s in t he OFF
posi t i on:
The c ont a c t s of bot h rel ays ar e ope n.
When t he i gni ti on swi t c h is f i rst t urned t o t he ON
posi t i on:
The power t r ai n cont rol modul e (PCM) power
rel ay is energi zed, cl osi ng i t s c ont a c t s.
Power is pr ovi ded t o bot h t he fuel pump rel ay
and t o a t i mi ng devi ce in t he power t r ai n cont rol
modul e rel ay.
The fuel pump runs t hrough t he c ont a c t s of t he
fuel pump power t r ai n cont rol modul e rel ay.
If t he i gni ti on swi t c h is not t urned t o t he START
posi t i on:
The t i mi ng devi ce in t he power t r ai n cont rol
modul e rel ay wi ll open t he ground Ci rcui t 57
(af t er appr oxi mat el y one second). Openi ng t he
ground ci rcui t de-energi zes t he fuel pump
power t r ai n cont rol module rel ay, openi ng i t s
c ont a c t s, whi c h in t urn de-energi zes t he fuel
pump. Thi s ci rcui t ry provi des f or
pre-pressuri zat i on of t he fuel sy st e m.
When t he ignition swi t c h is t urned t o t he START
posi t i on:
The powert rai n cont rol modul e rel ay oper at es
t he fuel pump powert rai n cont rol module rel ay t o
provi de fuel whi l e cr anki ng.
Af t er t he engi ne st a r t s and t he ignition swi t c h is
" ret urned t o t he ON posi t i on:
Power t o t he fuel pump is agai n suppl i ed
t hrough t he fuel pump power t r ai n cont rol
module rel ay.
The powert rai n cont rol modul e rel ay senses
engi ne speed and shut s off t he fuel pump by
openi ng t he ground ci rcui t t o t he fuel pump
power t r ai n cont rol module rel ay when t he
engi ne st ops, or is bel ow 120 r pm.
Fuel Pressure Regulator
The fuel pr essur e regul at or (9C968):
Is a t t a c he d t o t he fuel i nj ecti on suppl y mani f ol d
( 9F792) downst r e a m of t he fuel i nj ect ors ( 9F593) .
Regul at es t he fuel pressure suppl i ed t o t he fuel
i nj ect ors.
Is a di aphr agm-oper at ed relief val ve in whi ch one
si de of t he di aphragm senses fuel pr essur e and t he
ot her si de is subj ect ed t o i nt ake mani f ol d vacuum.
Nomi nal fuel pressure is est abl i shed by a spri ng
prel oad appl i ed t o t he di aphr agm.
10- 01- 6 Fuel Tank, Fi l t er s, Li nes and El ect r i c Fuel Pump
10- 01- 6
Bal ances one si de of the di aphragm wi t h manifold
pr essur e t o mai nt ai n a const ant f uel pr essur e d r o p
a c r o ss t he fuel i nj ect ors.
By -pa sse s and ret urns e x c e ss fuel t o t he fuel t ank
( 9002) .
For Fuel Pr essur e Regul at or Removal and Inst allat i on
pr oc e dur e s, r ef er t o Sect i on 03- 04.
Pa r t
1 Engine Vacuum Reference
Tube (Part of 9C968)
2

Ball Seat (Part of 9C968)
3 Spring (Part of 9C968)
4

Upper Housing (Part of
9C968)
5 Diaphragm (Part of 9C968)
6

Lower Housing (Part of
9C968)
7

Fuel Outlet (Return) Tube
(Part of 9C968)
8

Fuel Inlet (Supply) Tube (Part
of 9C968)
9

O-Ring Grooves (Part of
9C968)
10

Mounting Plate (Part of
9C968)
11

Fuel Filter Screen (Part of
9C968)
12

Spring Seat (Part of 9C968)
I t e m
Pa r t
13

Valve Assembly (Part of
9C96I ~
Fuel Gauge
Ref er t o Sect i on 13-01A f or el ect r oni c cl ust er or
13-01B for convent i onal cl ust er.
Inertia Fuel Shutoff (IFS) Swi tch
In t he event of a col l i si on, t he el ect r i cal c o n t a c t s in t he
i nert i a f uel shut of f swi t c h (IFS swi t c h) ( 9341) open and
t he fuel pump aut omat i cal l y shut s of f .
The f uel pump wi ll shut off even if t he engi ne d o e s
not st op runni ng. The engi ne, however , wi l l st o p a
f e w seconds af t er t he fuel pump st o ps.
It is not possi bl e t o r est ar t t he engi ne until t he i nert i a
f uel shut of f swi t c h i s manually r eset .
The i nert i a f uel shut of f swi t c h i s l oc a t e d in t he
l uggage compar t ment on t he o ut bo a r d si de of t he
LH hi nge suppor t .
CAUTI ON: Do n o t r e s e t t h e i n e r t i a f u e l s h u t o f f
s w i t c h un t i l t h e c o mp l e t e f ue l s y s t e m h a s b e e n
i n s p e c t e d f o r l e a ks .
To reset t he i nert i a f uel shut of f swi t c h, pr ess but t on on
t o p of swi t c h.
Fu e l T a n k , Fi l t e r s , Lines, Valves a n d El e c t r i c
Fu e l P u mp
Ref er t o t he Powert rai n Cont r ol / Emi ssi ons Di agnosi s
Ma n ua l
1
.
Fu e l Dr a i n i n g
FUEL- RELATED COMPONENT. HIGHLY
FLAMMABLE MI XTURES ARE ALWAYS PRESENT
PERSONAL INJURY.
2. Insert Rotunda Fuel Tanker Adapt er Hose
034- 00012 or equi val ent into f uel tank ( 9002)
t hr ough f uel t ank filler pi pe ( 9034) .
3. Remove fuel f r om fuel t ank wi t h Rot unda Fuel
St or a ge Tanker 034- 00002 or equi val ent .
Fuel Filling
CAUTI ON: En sur e t h a t al l t u b e s a n d v e n t s a r e
p r o p e r l y c o n n e c t e d a n d s e a l e d pr i o r t o r e f i l l i n g
t h e f u e l t a n k.
1. Insert Rot unda Fuel Tanker Adapt er Hose
034- 00012 or equi val ent i nto fuel t ank ( 9002)
t hr ough fuel t ank filler pi pe ( 9034) .
To wn Car Sho wn , Cr o wn Vi c t o r i a , Gr a nd Mar qui s Si mi l ar
2. Transf er fuel f r om Rot unda Fuel St or age Tanker
034- 00002 or equi val ent t o fuel t ank.
3. Connect bat t er y ground cabl e ( 14301) .
Most component s of t he st andar d fuel sy st e m ar e
ser vi ced by a si mpl e nut, bol t or sc r e w part f or
removal and i nst al l at i on. Ref er t o i ndi vi dual sy st e m
i l l ust rat i ons f or speci f i c part ref erences.
V9830-A
Part
1

Fuel Supply Tube (Part of
9S284)
2 9S284 Fuel Return/Supply Tubes
3 LH Frame Rail
4 9L291 Fuel Return and Brake Tube
( Co n t i n ue d )
I t e m
Pa r t
5 Fuel Return Line (Part of
9L291)
6 N802191-S56 Bolt (2 Req'd)
7 9B072 Fuel Filter and Base
A

Lb-ln)
Fuel T a n k
FUEL-RELATED COMPONENT. HIGHLY
PERSONAL I NJURY
WARNI NG: FUEL SUPPLY LI NES ON ALL
VEHI CLES EQUI PPED WI TH FUEL I NJECTED
ENGINES WI LL REMAI N PRESSURI ZED FOR LONG
PERIODS OF TI ME AFTER ENGINE SHUTDOWN.
FUEL SYSTEM PRESSURE MUST BE RELI EVED
PRIOR TO FUEL SYSTEM SERVI CE TO PREVENT
POSSI BLE INJURY. REFER TO FUEL SYSTEM
PRESSURE RELIEF.
WARNI NG: FUEL TANK MAY BE PRESSURI ZED-
REMOVE FUEL TANK FI LLER CAP SLOWLY. IF
FUEL TANK FI LLER CAP I S VENTI NG FUEL OR A
HISSING SOUND IS HEARD, WAI T UNTI L THE
CONDI TI ON STOPS BEFORE REMOVI NG THE
FUEL TANK FI LLER CAP. IF THESE PRECAUTI ONS
ARE NOT FOLLOWED, FUEL MAY SPRAY AND
CAUSE PERSONAL INJURY.
Remov al
1. Depressuri ze t he fuel sy st e m as out l i ned in Fuel
Sy st e m Pressure Relief.
2. Drai n f uel f r o m t he fuel t ank ( 9002 ) pri or t o fuel
t ank removal as out l i ned.
5. Di sconnect fuel hoses and t ubes a s out l i ned.
6. On vehi cl es equi pped wi t h a f uel t a nk fi ller pi pe
ret ai ner ( 9B233) whi c h f ast ens t he fuel t ank fi ller
pi pe ( 9034) t o t he fuel t ank, r emove t he sc r e w
ret ai ni ng t he fuel t ank fi ller pi pe ret ai ner t o t he fuel
t ank f l ange.
7. Di sconnect el ect ri cal connect or t o t he f uel pump
( 9350) .
8. Pl ace a saf et y suppor t under t he fuel t ank.
Remove t he nuts f r om one end of t he f uel t ank
suppor t st r a ps ( 9092) . The f uel t ank suppor t
st r a ps are hi nged and wi ll swi ng out of t he wa y .
9. Remove fuel t ank f r o m t he vehi cl e.
I nst al l at i on
1. Bef or e pr oc e e di ng, c he c k t he f ol l owi ng:
a. Le a k c he c k t he fuel pump.
b. Ensure evapor at i ve emi ssi on val ve ( 9B593)
i s pr oper l y i nst al l ed on t he f uel t ank t o p.
c. Ma ke sur e cl i ps ar e i nst alled pr ope r l y on t ank
f l ange a nd va por li nes are se c ur e d i nt o cl i ps.
d . Ma ke all requi red connect i ons whi c h wi l l be
i naccessi bl e af t er t he fuel t ank i s i nst al l ed.
2. Pl ace t he f uel t ank in i t s proper posi t i on in t he
vehi cl e. For most model s, l ubri cat e t he f uel t ank
filler pi pe wi t h wa t e r base t i re mount i ng l ubri cant .
Install t he f uel t ank ont o t he fuel t ank fi ller pi pe
t hen bri ng t he f uel t ank i nto fi nal posi t i on.
3. Bri ng f uel t ank suppor t st r a ps ar ound t he f uel t ank
and st a r t t he ret ai ni ng nut or bol t . Al i gn f uel t ank
wi t h t he fuel t ank suppor t st r a ps and c he c k
cl ear ance t o f r ame and underbody.
4. Che c k t he hoses and wi ri ng mount ed on t he fuel
t ank t o p t o ensure t hey ar e c o r r e c t l y r out ed and
wi ll not be pi nched bet ween t he f uel t ank and
body.
5. Ti ght en t he fuel t ank support st r a p ret ai ni ng nuts
t o 29- 41 N-m (22-30 Ib-f t ).
6. Fast en fill pi pe ret ai ner, if r e move d. Ti ght en
sc r e ws t o 6. 8-9. 2 N-m (61-81 Ib-in).
7. Reconnect t he fuel hoses and li nes whi c h we r e
di sconnect ed. Ensure t hat t he fuel suppl y, fuel
r et ur n, and vapor vent connect i ons a r e made
c or r e c t l y . Tr ace t he vari ous li nes t o t he engi ne
and ref er t o t he appl i cabl e sy st e m i l l ust rat i ons t o
ensure t he proper lines ar e c onne c t e d.
8. Connect f uel pump el ect ri cal connect or .
10. Repl ace fuel drai ned f r om t he f uel t a nk a s
out l i ned.
11. Connect bat t er y ground cabl e.
12. Che c k all connect i ons f or l eaks.
Fue l Tank
VIEW A VIEWB
BREAK OFF
SHANK AFTER
ASSY
NOTE: ENGINE OIL MEETING FORD SPECIFICATION M2C153-E MAY BE
f
,
USED AS AN ASSEMBLY AID. NO OTHER MATERIAL MAY BE USED. V*)
VIEW C VIEW A
VIEWD
J 0
VIEWE
V9849-A
10- 01- 10 Fue l Ta n k, Fi l t e r s , L i n e s a n d E l e c t r i c Fu e l P u mp 10- 01- 10
Pa r t
1 9002 Fuel Tank
2 N802429-S100 Pin (2 Req'd)
3

Underbody
4 9092 Fuel Tank Support Strap
5 N800478-S190 Nut (2 Req'd)
6 9053 Fuel Tank Support
7 N801111-S190 Bolt (2 Req'd)
8 9G332 Evaporative Emission Tube
Shut Off Valve
9 9B593 Evaporative Emission Valve
10 9034 Fuel Tank Filler Pipe
11 9B233 Fuel Tank Filler Pipe
Retainer
Pa r t
12 N805402-S56 Screw (4 Req'd)
13 9030 Fuel Tank Filler Cap
14

Fuel Filler Housing
15

Fuel Tank Filler Pipe Sensing
Tube Hose
16 W611621-S56 Screw
17

Vapor Supply Line
18 N610957-S56 Screw (4 Req'd)
A

Tighten t o 2.3-3.3 N-m (21-29
Lb-ln)
B

Tighten to 6.8-9.2 N-m (61-81
Lb-ln)
Fu e l T a n k S u p p o r t S t r a p s
Re mo v a l
Fuel t ank support st r a ps ( 9092) may be r emoved
a n d / o r r epl aced wi t hout removi ng t he fuel t ank
( 9002 ) , if each fuel t ank support st r a p is r emoved a nd
i nst al l ed one at a t i me and a suppor t is pr ovi ded under
t he f uel t ank, or by f ol l owi ng t he pr oc e dur e f or fuel
t ank r emoval . The l oop end of t he f uel t ank suppor t
st r a p at t achment hol ds t he f uel t ank support st r a p in
pl ace af t er t he fuel t ank is r e move d.
Al l vehi cl es use a pi n-t ype at t achment t hr ough a l oop
in t he end of t he f uel t ank suppor t st r a p. The body
br a c ke t has a l arge hole in one si de t o i nsert and
r emove t he pi n. Ther e is a small hol e in t he opposi t e
si de of t he br a c ke t t o push t he pin out usi ng a dri f t pi n
or punch.
1. NOTE: Pin must be fully i nst al l ed i nto body
br a c ke t .
To r emove t he fuel t ank suppor t st r a p, push t he
f uel t ank suppor t st r a p up i nt o t he br a c ke t until
t he pin lines up wi t h t he l arge hol e. Ther e is a
gui de and st o p i nsi de t he br a c ke t t o assi st in
ali gni ng t he fuel t ank suppor t st r a p f or removal
and i nstallati on of t he pi n.
2. NOTE: A magnet i zed sc r e wdr i ve r i s helpful t o
d r a w t he pin out of t he l arge openi ng in t he
br a c ke t if t he pin doe s not line up pr oper l y.
Push t he pin out of t he l arge hol e in t he si de of t he
br a c ke t by i nsert i ng a small dri f t pin or punch i nt o
t he small hole in t he opposi t e si de of t he br a c ke t .
1. Push t he f uel t ank suppor t st r a p i nt o t he br a c ke t
openi ng until it is l ocat ed agai nst t he st op and t he
l oop end i s al i gned wi t h t he l arge pi n openi ng in
t he si de of t he housi ng.
2. CAUTI ON: T h e pi n mu s t r e s t f l a t a ga i n s t t h e
b o t t o m o f t h e b r a c ke t . If t h e p i n i s n o t f u l l y
s e a t e d , t h e f u e l t a n k c o u l d b e d a ma g e d . Do
n o t i n s t a l l t h e f u e l t a n k. A t t e mp t t o p o s i t i o n
t h e pi n s o t h a t i t wi l l s e a t p r o p e r l y , i f
u n s u c c e s s f u l , r e mo v e t h e pi n a n d s t r a p .
Ch e c k f o r , a n d r e mo v e a n y o b s t r u c t i o n s t h a t
ma y b e i n s i d e t h e b r a c ke t . Ch e c k t o e n s u r e
t h e pi n i s t h e c o r r e c t l e n g t h .
Insert t he pin t hr ough t he l arge openi ng in t he si de
of t he br a c ke t i nto t he l oop in t he fuel t ank
suppor t st r a p.
3. Pull t he f uel t ank support st r ap down until t he pin
i s fully se a t e d on t he bot t om of t he br a c ke t .
Fu e l T a n k Fi l l e r P i p e
PERSONAL INJURY.
1. Remove f our fi ller neck ret ai ni ng sc r e ws and f uel
t ank fi ller c a p ( 9030) i nsi de fuel fi ller housi ng.
2. Rai se vehi cl e. Ref er t o Sect i on 00- 02.
3. Drai n f uel f r om fuel t ank ( 9002) a s out l i ned. Ma ke
sure t ank is l ess t han 3 / 4 full.
4. Remove sc r e w ret ai ni ng fuel t ank filler pi pe
ret ai ner ( 9B233) t o fuel t ank.
5. Remove left rear wheel and t i re.
6. Remove sc r e ws ret ai ni ng quart er-panel seal t o
body .
7. Remove fuel t ank filler pi pe ( 9034) , fuel t ank fi ller
pi pe ret ai ner and vent hose reli ef di schar ge seal
( 9008) t hr ough wheel house.
8. To i nst al l , r ever se Removal pr ocedur e.
Fuel Fi l l er Door
1. Open t he l uggage compar t ment door ( 40110) ,
push t he over r i de handl e t hr ough t he sli t in t he
l uggage compar t ment t ri m and pull ba c k t he t ri m
panel .
2. Open t he fuel door and r emove t wo sc r e ws
ret ai ni ng t he l at ch assembl y t o t he housi ng
assembl y.
3. Remove l at ch assembl y f r om t he housi ng
assembl y t hr ough t he f uel door openi ng.
4. Di sconnect t he wi ri ng har ness cl i p f r o m t he l at ch
assembl y sol enoi d.
5. To Inst all, r ever se t he Removal pr ocedur e.
Fuel Filter(s)
PERSONAL INJURY.
WARNI NG: BECAUSE OF THE COMBUSTI ON
CHARACTERI STI CS OF GASOLI NE, ALWAYS USE
EXTREME CARE WHEN REMOVI NG AND
I NSTALLI NG ANY FUEL SYSTEM COMPONENT.
I n - Ta n k
1. Remove f uel t ank ( 9002) as out l i ned.
2. Remove fuel pump ( 9350) a s out l i ned.
3. Remove f i l t er mount ed on f uel pump i nlet.
I n - L i n e
Re mo v a l
3. Remove t he push connect f i t t i ngs at bot h ends of
t he fuel f i l t er and base ( 9B07 2) a s out l i ned. Install
new ret ai ner cl i ps in e a c h push connect f i t t i ng.
4. Remove f uel f i l t er and ba se and ret ai ner f r om
met al br a c ke t by removi ng t wo ret ai ner bol t s.
5. Remove f uel f i l t er and ba se f r om t he ret ai ner.
Not e t hat t he di rect i on of t he f l ow a r r o w poi nt s t o
t he open end of t he ret ai ner. Di scar d f uel f i l t er and
base.
6. Remove rubber i nsulat or ri ngs f r om fuel f i l t er and
base.
1. Install t he rubber i nsulat or ri ngs on new f uel f i l t er
and base. Repl ace i nsul at or(s) if fuel f i lt er and
base move s f reel y af t er i nst allat i on of ret ai ner.
2. Pl ace t he f uel f i l t er and base i nto t he fuel f i l t er
ret ai ner wi t h t he f l ow a r r o w poi nt i ng out of t he
open end of t he ret ai ner.
3. Install t he fuel f i lt er ret ai ner on met al br a c ke t .
Ti ght en ret ai ni ng bol t s t o 9-12 N-m ( 80- 106 lb-i n).
4. Install t he push connect f i t t i ngs ont o t he fuel f i lt er
and base ends a s out li ned in Fi t t i ng, Push
Connect .
5. St ar t engi ne and c he c k f or l eaks.
Fuel Tank Sending Unit and Fuel Pump
Re mo v a l
1. Pl ace vehi cl e on hoi st , do not rai se.
2. Depressuri ze fuel sy st e m a s out l i ned in Fuel
3. Drai n f uel f r om fuel t ank ( 9002) a s out l i ned.
5. Di sconnect suppl y line and ret urn line f i t t i ngs.
6. Di sconnect fuel pump ( 9350) el ect ri cal
connect or.
7. Remove any di rt t hat has accumul at ed around t he
fuel pump so t hat it wi ll not ent er t he fuel t ank
duri ng removal and i nst al l at i on.
8. Remove si x bol t s f r om around peri met er of fuel
pump.
9. Remove f uel pump.
1. Clean fuel pump mount i ng f l ange and t he fuel t ank
mount i ng sur f ace.
2. Caref ul l y i nstall fuel pump t o ensure t ha t f i l t er is
not da ma ge d.
3. Install si x bol t s around fuel t ank sensor and pump
peri met er and t i ght en t o 8-10 h kn (71-89 lb-i n).
4. Connect fuel t ank sensor and pump el ect ri cal
connect or.
5. Install fuel line f i t t i ngs as out l i ned.
7. Install a mi ni mum of 38L ( 10 gal ) of f uel and c he c k
f or l eaks.
8. Wi t h EFI / CFI Fuel Pr essur e Gauge T80L- 997 4- B
connect ed t o t he fuel pr essur e relief val ve on t he
fuel suppl y mani f ol d, t urn i gni ti on swi t c h ( 1157 2 )
f r om OFF t o ON posi t i on f or t hr ee se c onds.
Repeat t hi s OFF t o ON swi t chi ng (5 t o 10 t i mes)
until pressure gauge sho ws at l east 2 41 kPa ( 35
psi ).
9. Remove pr essur e gauge, st a r t engi ne, and c he c k
f or l eaks.
I n e r t i a Fu e l S h u t o f f ( I FS) S w i t c h
1. Open l uggage c ompa r t me nt door ( 40110) .
2. Remove sc r e w ret ai ni ng i nert i a f uel shut of f swi t c h
(IFS swi t c h) ( 9341) .
3. Di sconnect wi ri ng har ness connect or f r om i nert i a
fuel shut of f swi t c h and r emove i nert i a fuel shut of f
swi t c h.
4. To i nst al l , r ever se Removal pr oc e dur e .
1. Di sconnect ba t t e r y gr ound c a bl e ( 14301) .
2. Remove powe r di st ri but i on box cover .
3. Remove f uel pump powe r t r a i n cont r ol modul e
rel ay (PCM r e l a y ) ( 12A646) .
4. To i nst all, r ever se Removal pr oc e dur e .
E v a p o r a t i v e E m i s s i o n Va l v e
2. Remove f uel t ank ( 9002) a s out l i ned.
3. Remove e va por a t i ve emi ssi on val ve ( 9B593)
f r om t o p of f uel t ank.
4. Repl ace f uel f i l t er and base ( 9B07 2 ) if d a ma ge d .
5. To i nst al l , r e ve r se Removal pr oc e dur e usi ng SAE
10W-40 f or e a se of i nst al l at i on.
E v a p o r a t i v e E m i s s i o n T u b e S h u t - O f f Va l v e
1. Depressuri ze t he f uel sy st e m a s out li ned in Fuel
Sy st e m Pr essur e Relief.
2. Remove fuel t ank ( 9002) a s out l i ned.
3. Remove e va por a t i ve emi ssi on t ube shut of f val ve
( 9G332) f r om t o p of fuel t ank.
Fu e l a n d Va p o r R e t u r n T u b e s
1. Depressuri ze t he f uel sy st e m a s out li ned in Fuel
Sy st em Pressure Relief.
3. Drai n fuel f r om fuel t ank ( 9002 ) a s out l i ned.
4. Lower fuel t ank and di sconnect fuel suppl y and
vapor t ubes ( 9S2 84) f r om fuel t ank.
5. Di sconnect f uel suppl y and vapor t ubes f r om
engi ne.
6. Remove nine sc r e ws ret ai ni ng fuel suppl y and
vapor t ubes under f r ame.
7. Remove fuel suppl y and vapor t ubes.
P u s h C o n n e c t F i t t i n g s
WARNI NG: FUEL SUPPLY LI NES ON VEHI CLES
EQUI PPED WI TH FUEL I NJECTED ENGI NES WI L L
REMAI N PRESSURI ZED FOR LONG PERIODS OF
TI ME AFTER ENGI NE SHUTDOWN. FUEL SYSTEM
PRESSURE MUST BE RELI EVED PRIOR TO FUEL
SYSTEM SERVI CE TO PREVENT POSSI BLE
INJURY. REFER TO FUEL SYSTEM PRESSURE
RELIEF.
St eel
Fue l Li n e Di s c o n n e c t To o l ( 5 / 1 6 I n c h)
Fue l Li n e Di s c o n n e c t To o l ( 3 / 8 I nc h)
T90T- 9550- B ( Pa r t
of T90T- 9550- S)
T90T- 9550- C ( Pa r t
of T90T- 9550- S)
Thi s f i t t i ng consi st s of a body, spa c e r s, O-ri ngs and a
ret ai ni ng cl i p. The cl i p l ocks t he f i t t i ng t o i t s mat i ng
t ube j unct ure. The f ol l owi ng met hods are t o be
f ol l owed t o di sconnect t he f i t t i ng.
Bef ore at t empt i ng t o di sconnect t he f i t t i ng:
1. Inspect vi si ble i nternal port i on of f i t t i ng f or di rt
accumul at i on. If mor e t han a li ght coat i ng of dust
is present , cl ean t he f i t t i ng bef ore di sassembl y.
10-01-13 Fue l Ta n k, Fi l t e r s , L i n e s a n d E l e c t r i c Fue l P u mp 10-01-13
NOTE: If necessar y , drai n fuel t ank ( 9002 ) a s out l i ned.
2. Some adhesi on bet ween t he seal s in t he f i t t i ng
and t he t ubi ng wi ll occur wi t h t i me. To se pa r a t e ,
t wi st t he f i t t i ng on t he t ube, t hen push and pull t he
f i t t i ng until it moves f reel y on t he t ube.
Re mo v a l
1. To di sengage t he t ube f r om t he f i t t i ng, snap t he
Fuel Li ne Di sconnect Tool T90T-9550-B 5 / 1 6
i nch (Gr ay ) and T90T- 9550- C3/ 8 i nch (Bl ue)
(Part of T90T-9550-S) wi t h ei t her t a b on t he fuel
line t o be di sconnect ed.
FUEL LINE
DISCONNECT TOOL
T90T-9550-B OR
T90T-9550-C
V7615-A
2. NOTE: Some f uel t ubes have a se c onda r y bead
whi c h al i gns wi t h t he out er sur f ace of t he cl i p.
These be a ds can ma ke t ool i nsert i on di f f i cul t .
Push t he di sconnect t ool i nt o t he connect or t o
r el ease t he i nt ernal l ocki ng f i ngers.
3. NOTE: Onl y moder at e ef f or t is requi red if t he t ube
has been pr oper l y di sengaged. Use hands only.
Se pa r a t e f uel line f r om t he connect or. Remove
di sconnect t ool .
FUEL LINE
DISCONNECT TOOL
T90T-9550-B OR
T90T-9550-C
V7616-A
4. Af t er di sassembl y, i nspect and cl ean t he t ube end
seal i ng sur f ace. Tube end shoul d be f r ee of
sc r a t c he s and cor r osi on a s t hey resul t in pat h f or
fuel l eakage. Inspect t he i nsi de of t he f i t t i ng f or
any i nt ernal pa r t s such a s O-ri ngs and spa c e r s
t ha t may have been di sl odged f r om t he f i t t i ng.
Repl ace any da ma ge d connect or.
1. Install new connect or / hose t ube assembl y if
da ma ge wa s f ound.
2. Bef or e i nst alli ng f i t t i ng on t he t ube, wi pe t ube end
wi t h a cl ean c l ot h. I nspect t he i nsi de of t he f i t t i ng
t o ensure it i s f r ee of di rt a n d / o r obst r uc t i ons.
3. To i nst all t he f i t t i ng ont o t he t ube, ali gn t he f i t t i ng
and t ube axi al l y and push t he f i t t i ng ont o t he t ube
end. When t he f i t t i ng is engaged, a def i ni t e cl i ck
wi ll be he a r d. Pull on f i t t i ng t o ensure it is fully
e nga ge d. Appl yi ng a li ght c oa t of engi ne oil t o t he
t ube end wi ll e a se assembl y.
Ny l o n
Push connect f i t t i ngs used t o connect t o 3 / 8 i nch and
5 / 1 6 i nch nomi nal di amet er met al t ubi ng use a hai rpi n
cl i p.
" f ^ ^ SHIPPING TAB
O-RINGS
STEEL LINE
SPACERS
V3587-E
Di sconnect all push connect f i t t i ngs f r om component s
(sender, f i l t er) pri or t o component removal . The push
connect f i t t i ngs t hat connect f l exi bl e fuel lines t o t he
fuel pump modul e cannot be di sconnect ed until t he fuel
t ank is part i al l y l ower ed j ust bef ore removi ng t he fuel
t ank compl et el y.
Re mo v a l
NOTE: If necessar y, drai n fuel t ank as out l i ned.
1. Inspect vi si bl e i nternal port i on of f i t t i ng f or di rt
accumul at i on. If more t han a light coat i ng of dust
is present , cl ean t he f i t t i ng bef ore di sassembl y.
2. Some adhesi on bet ween t he seal s in t he f i t t i ng
and t he t ubi ng wi ll occur wi t h t i me. To separ at e,
t wi st t he f i t t i ng on t he t ube, t hen push and pull t he
f i t t i ng until it moves f reel y on t he t ube.
NOTE: On 90 degr ee el bow connect or s, excessi ve
si de l oadi ng coul d break t he connect or body.
3. CAUTI ON: Do n o t us e a n y t o o l s .
4. Remove hai rpi n cl i p f r om f i t t i ng by f i rst bendi ng
t he shi ppi ng t ab d o wn wa r d so t hat it will cl ear t he
body. Next , (usi ng hands onl y) spr ead t he t wo
cl i p l egs about 3.2 mm ( 1 / 8 i nch) each t o
di sengage t he body and push t he legs i nto t he
f i t t i ng. Compl et e removal is accompl i shed by
li ghtly pulling f r om t he t ri angul ar end of t he cli p
and wor ki ng it cl ear of t he t ube and f i t t i ng.
5. Gr asp t he f i t t i ng and hose assembl y and pull in an
axi al di rect i on t o r emove t he f i t t i ng f r om t he st eel
t ube.
6. When f i t t i ng is r emoved f r om t he t ube end,
i nspect t he f i t t i ng and t ube f or any i nternal par t s
t hat may have been di sl odged f r om t he f i t t i ng.
Any l oose i nternal pa r t s shoul d be i mmedi at el y
i nst al l ed, usi ng t he mat i ng t ube t o i nsert t he par t s.
10- 01- 14 Fue l Tank, Fi l t er s, Li nes and El ect r i c Fuel Pump 10- 01- 14
I nst al l at i on
1. It is r ecommended t ha t t he ori gi nal cl i p not be
reused in t he f i t t i ng. To i nst all t he new cl i p, i nsert
cl i p i nt o any t wo adj acent openi ngs wi t h t he
t ri angul ar port i on poi nt i ng a wa y f r om t he f i t t i ng
openi ng. Install cl i p t o f ul l y engage t he body (l egs
of hai rpi n cl i p l oc ke d on out si de of bo d y ) . Pi loti ng
wi t h an i ndex f i nger is necessar y .
2. Bef or e i nstalli ng f i t t i ng on t he t ube, wi pe t ube end
wi t h a cl ean c l ot h. I nspect t he i nsi de of t he f i t t i ng
t o ensure it is f r ee of di rt a n d / o r obst r uct i ons.
3. To i nstall t he f i t t i ng ont o t he t ube, ali gn t he f i t t i ng
and t ube axi al l y and push t he f i t t i ng ont o t he t ube
end. When t he f i t t i ng i s e nga ge d, a def i ni t e cl i ck
wi ll be hear d. Pull on f i t t i ng t o ensure it is fully
engaged. Appl yi ng a li ght c oa t of engi ne oil t o t he
t ube end wi ll ease assembl y .
Sp r i n g L o c k Co u p l i n g
Fue l Li ne Di s c o n n e c t To o l ( 5 / 1 6 I n c h)
Fue l Li ne Di s c o n n e c t To o l ( 3 / 8 I n c h)
T 90T - 9550- B ( Pa r t
o f T 90T - 9550- S )
T 90T - 9550- C ( Pa r t
o f T90T- 9550- S)
The spri ng l ock coupl i ng is a f uel line coupl i ng hel d
t oget her by a gar t er spri ng i nsi de a ci rcul ar c a ge .
When t he coupl i ng i s c onne c t e d t oget her , t he f l ar ed
end of t he f emal e f i t t i ng sl i ps behi nd t he gar t er spri ng
i nsi de t he c a ge of t he male f i t t i ng. The gar t er spri ng
and c a ge t hen prevent t he f l ar ed end of t he f emal e
f i t t i ng f r om pulling out of t he c a ge . As a redundant
l ocki ng f eat ur e, a hor seshoe sha pe d ret ai ni ng cl i p is
i ncor por at ed t o i mprove t he ret ai ni ng rel i abi l i t y of t he
spri ng l ock coupl i ng.
MALE
FITTING
CUP/TETHER ASSY
FEMALE FITTING
SPRING-LOCK
COUPLING
V7329-B
Re mo v a l
1. Reli eve fuel sy st e m pr essur e a s out l i ned in Fuel
Sy st e m Pressure Reli ef.
2. CAUTI ON: Do n o t u s e a n y s h a r p t o o l o r
s c r e wd r i v e r a s i t ma y d a ma g e t h e s p r i n g
l o c k c o u p l i n g .
Remove ret ai ni ng cl i p f r om spri ng l ock coupl i ng
by hand onl y.
3. Twi st f i t t i ng t o f r e e it f r o m any adhesi on a t t he
O-ri ng seal s.
4. Fit Spri ng Lo c k Coupl i ng Di sconnect Tool
D87L- 9280- A ( 3 / 8 i nch) (Yel l ow), D87L- 9280- B
( 1 / 2 i nch) (Green) or Spri ng Loc k Coupl i ng
Di sconnect Tool T90T- 9550- B ( 5 / 1 6 i nch)
(Gr a y ), T90T-9550-C ( 3 / 8 i nch) (Bl ue) (Part of
T90T-9550-S) or equi val ent t o coupl i ng.
5. Cl ose t ool and push i nt o open si de of c a ge t o
e xpa nd gar t er spr i ng a nd rel ease f emal e f i t t i ng.
6. Af t er gar t er spri ng i s e xpa nde d, pull f i t t i ngs apar t .
7. Remove t ool f r o m di sconnect ed coupl i ng.
1. Ensure t hat ga r t e r spr i ng is in c a ge of mal e f i t t i ng.
If gar t er spri ng is mi ssi ng, i nstall a new spri ng by
pushi ng it i nt o c a ge openi ng. If gar t er spri ng is
da ma ge d, r emove it f r o m c a ge wi t h a smal l wi r e
hook (do not use a sc r e wdr i ve r ) and i nst all a new
spri ng.
2. Clean all di rt or f orei gn mat eri al f r om bot h pi eces
of coupl i ng.
3. WARNI NG: USE ONLY THE SPECI FI ED
O-RI NGS A S THEY ARE MADE OF A SPECI AL
MATERI AL. THE USE OF ANY O-RI NG OTHER
THAN THE SPECI FI ED O-RI NG MAY A L L OW
THE CONNECTI ON TO LEAK
I NTERMI TTENTLY DURI NG VEHI CLE
OPERATI ON. REPLACE MI SSI NG OR
DAMAGED O-RI NGS. USE ONLY O-RINGS
LI STED IN SPRING LOCK COUPLI NG
ILLUSTRATION,,
Lubr i cat e mal e f i t t i ng and O-ri ngs and i nsi de of
f emal e f i t t i ng wi t h cl ean engi ne oil meet i ng For d
speci f i cat i on ESE-M2C153-E or equi val ent .
4. Fit f emal e f i t t i ng t o mal e f i t t i ng and push until
gar t er spri ng snaps over f l ared end of f emal e
f i t t i ng.
5. Ensure coupl i ng engagement by pulling on f i t t i ng
and vi sual l y checki ng t o ensure gar t er spri ng i s
over f l ar ed end of f emal e f i t t i ng.
6. NOTE: All vehi cl es requi re t he l arge, bl ack cl i p t o
be i nst al l ed on t he suppl y si de fuel line and t he
smal l , gr a y cl i p t o be i nst al l ed on t he ret urn si de
fuel li ne.
Posi t i on ret ai ni ng cl i p over met al port i on of spri ng
l ock coupl i ng. Fi rml y push ret ai ni ng cl i p ont o
spri ng l ock coupl i ng. Ensure t hat hor seshoe
port i on of cl i p is over t he coupl i ng. Do not i nstall
ret ai ni ng cl i p over rubber fuel line.
Spr i n g Lo c k Co upl i n g
C A U T I O N RELIEVE FUEL PRESSURE
BEFORE DISCONNECTING COUPLING
TO CONNECT COUPLING

CLIP"
REMOVE CLIP FROM COUPLING
FEMA LE MA LE
o
CAGE
O-RI NGS SPRING
U S E S P E C I FI E D
T O O L O R
E QU I V A L E N T
SPRI NG LOCK COU PLI NG
DI SCONNECT TOOL:
D87 L - 9 2 80- A 3/ 8 I N C H
D8 7 L - 9 2 8 0 - B 1/ 2 I N C H
C A G E '
O P E N I N G
FI T T O O L TO C O U P L I N G S O THAT TOOL
. C A N E N T E R C A G E O P E N I N G TO RELEASE
2
* T H E G A R T E R S P R I N G .

P U S H TOOL I N T O
C A G E O P E N I N G
N O T E : S P E C I FI E D
T O O L WI L L FI T
A R O U N D R U B B E R
C O V E R E D F U E L L I NE .

OPENING TO RELEASE THE FEMALE
FITTING FROM THE GARTER SPRING.
U S E O N L Y S P E C I FI E D FUE L
R E S I S T A N T O- RI N G S
(COLOR: BROWN)
REPLACEMENT O-RINGS
390846- S96 (3/8 INCH DIA.
2 PER FITTING)
390847- S96 (1/2 INCH DIA.
2 PER FITTING)
CHECK
FOR
CORROSI ON
LU BRI CATE O-RI NGS
WI TH CLEA N ENGI NE OI L
CLEAN FITTINGS WITH SOLVENT. CHECK
FOR MISSING OR DAMAGED O-RINGS.
REPLACE MISSING O-RINGS. IF EITHER
O-RING IS DAMAGED, REPLACE BOTH O-RINGS.
REPLACEMENT GARTER SPRINGS:
3/8-INCH E1ZZ-19E576-A
1/2-INCH E1ZZ-19E576-B

FITTINGS APART
GARTER SPRI NG
TO ENSURE COUPLING ENGAGEMENT.
PULL ON FITTING AND VISUALLY CHECK
%
i TO BE SURE GARTER SPRING IS OVER
*
]

. -FU EL LI NE

YES
TETHER
CLA MPED

DISCONNECTED SPRING LOCK COUPLING
RU BBER WRONG WHEN FLARE OR
F E MA L E HOSE O-RINGS ARE SHOWING
V7332-C
1 0 - 0 1 - 1 6 Fue l Tank, Fi l t e r s , L i n e s a n d E l e c t r i c Fue l P u mp 10- 01- 16
Fu e l T a n k s
CAUTI ON: Re mo v e t h e f u e l p u mp ( 9350) pr i o r t o
s t e a mi n g t h e f u e l t a n k ( 9002 ) t o p r e v e n t d a ma g e
t o t h e f u e l p u mp .
REMAI N PRESSURI ZED FOR LONG PERI ODS OF
PRESSURE MUST BE RELI EVED PRI OR TO FUEL
SYSTE M SERVI CE TO PREVENT POSSI BLE
INJURY. REFER TO FUEL SYSTE M PRESSURE
RELI EF.
Fuel t a nks do not requi re speci al ser vi ce pr oc e dur e s.
The only ser vi ce oper at i on is st e a m cl eani ng t o
r emove cont ami nat i on usi ng st a nda r d pr ocedur es.
Af t er st eami ng, al l ow t o t hor oughl y ai r dr y . The
evapor at i ve emi ssi on val ve ( 9B593) and f uel t ank
suppor t st r a p bol t s shoul d al so be r epl aced.
SERVICE PROCEDURES
Fuel Syst em Pressure Relief
I NJURY. REFER TO FUEL SYSTE M PRESSURE
RELI EF.
1. Remove air cl eaner assembl y a s out l i ned in
Sect i on 03- 12.
2. Connect EFI / CFI Fuel Pressure Gauge
T80L- 9974- B t o fuel pr essur e reli ef val ve on t he
fuel suppl y mani f ol d.
3. Open t he manual val ve on t he EFI / CFI Fuel
Pressure Gauge T80L - 997 4- B t o rel i eve fuel
sy st e m pr essur e.
F u e l S y s t e m Pr e s s u r i z e d
Fu e l L i n e s , S t e e l
CAUTI ON: T h e u s e o f c o p p e r t u b i n g i s n o t
r e c o mme n d e d d u e t o f u e l c o n t a mi n a t i o n .
TI ME AFTER ENGI NE SHUTDOWN. FUEL SYSTE M
I NJURY. REFER TO FUEL SYSTE M PRESSURE
RELI EF.
Re mo v a l
1. Depressuri ze t he fuel sy st e m a s out l i ned in Fuel
2. Drai n t he fuel f r om t he fuel t ank ( 9002 ) a s
out l i ned.
3. Di sconnect t he li ne(s) at t he fuel t ank and at t he
engi ne. Remove t he lines f r om t he hol di ng cl i ps
al ong t he underbody. Remove all da ma ge d hoses
and t ube sect i ons.
1. Cut a new sect i on of t ubi ng t o appr oxi mat el y t he
sa me l engt h as t he sect i on t o be r e pl a c e d,
al l owi ng f or t he t hr e a de d connect or s / f a st e n e r s.
2. Bend t he t ube sect i on t o conf or m t o t he cont our
of t he ori gi nal t ube.
3. Square t he ends of t he cut t ubi ng wi t h a f i l e.
Remove bur r s. Bl ow out any part i cl es wi t h
c ompr e sse d air.
4. Posi t i on t he lines in t he underbody cl i ps. Do not
t i ght en at t hi s t i me.
BQllOfQ
V8607-A
5. Assembl e t he f i t t i ng by sli di ng t he nut over t he
t ubi ng wi t h t hr eaded (open) end out .
6. CAUTI ON: Ma ke s ur e t h a t f e r r u l e i s
a s s e mb l e d c o r r e c t l y b e f o r e i n s t a l l i n g i t o n
t u b e .
Sli de t he f errul e on t he t ubi ng wi t h t he cut t i ng
edge out; t he l arge head end shoul d be i nsi de of
t he nut.
7. Lubr i cat e t he f errul e and t he t hr e a ds on t he
f ast ener s wi t h oi l .
8. Bo t t o m t he t ube in t he f i t t i ng, and t i ght en t he nut
until t he f errul e j ust gr i ps t he t ube. When t he t ube
can no longer be t urned by hand, t he f errul e has
st a r t e d t o gri p t he t ube.
10- 01- 17 Fuel Tank, Fi l t e r s , L i n e s a n d E l e c t r i c Fuel Pump 10- 01- 17
9. After the ferrule gri ps the tube, ti ghten t he nut one
full turn.
10. Tighten the fuel line t o the underbody cl i ps t o
secure the fuel lines.
NOTE: Af t er di sassembl y of the fl arel ess fitting joint,
such as at the fuel hose t o fuel line connecti on, t he
fl arel ess fitting can be reassembl ed. To reassembl e,
reconnect the t hreaded fitting and seat t he ferrul e t o
be finger-tight. When the ferrule is seat ed, draw t he
nut up approxi matel y one-sixth t o one-third of a turn
wi t h a wrench t o compl ete the tightening operati on.
11. Fill the fuel tank as outlined, st art engine and
check for l eaks.
12. Pressuri ze lines and check new joint for l eaks.
Fu e l a n d Va p o r Re t u r n T u b e s
TI ME AFTER ENGINE SHUTDOWN. FUEL SYSTEM
PRESSURE MUST BE RELI EVED PRIOR TO FUEL
SYSTEM SERVI CE TO PREVENT POSSI BLE
I NJURY. REFER TO FUEL SYSTEM PRESSURE
RELI EF.
Mul ti port fuel injection (MFI) syst ems are equi pped
wi th an el ectri c fuel pump module that provi des fuel t o
the engine at higher pressure than conventi onal fuel
syst ems. A fuel return syst em is al so provi ded. All fuel
hose/ t ube connecti ons are made wi t h push connect
fi tti ngs, and all hoses are servi ced as assembl i es. The
metal t ubes at t ached t o t he vehi cl e underbody may be
servi ced. The metal underbody tubes must be cut and
f ormed out of rolls of bulk fuel syst em servi ce tubi ng.
A damaged secti on of tubing can be cut out of t he
exi sti ng line and repl aced by a comparabl e servi ce
tubing secti on, spl i ced into the line by means of
t hreaded fasteners and connect ors.
All repl acement hoses must be servi ced as
assembl i es. Refer t o Push Connect Fitting installation
for connecti ng procedure. Bulk fuel hose must not be
used t o servi ce tubing in high pressure fuel syst ems.
S p l i c i n g N y l o n t o N y l o n
1. Depressuri ze the fuel syst em as outlined in Fuel
Syst em Pressure Relief.
2. Drai n fuel tank as outlined, if necessary.
3. Cut a secti on of servi ce tubi ng, Type 11 or 12
nylon 7.9 mm ( 5 / 1 6 inch) di ameter, t o same
length as damaged secti on of tubi ng.
4. Sel ect proper 7.9 mm ( 5 / 1 6 inch) barbed
connect ors for compl eti ng spl i ce. Two
connect ors are requi red for each spl i ce.
5. NOTE: To make hand insertion of barbed
connect ors into nylon easier, tube end must be
soaked in a cup of boiling wat er for one minute
i mmedi atel y before pushing barbed connect ors
into nyl on.
Install barbed connect ors into each end of
repl acement tubing using boiling wat er as
outlined.
6. Install clips onto any tubes whi ch might be difficult
t o access once final spl i ces are compl et ed.
7. Install t wo keyst one cl amps l oosel y onto original
nylon tubi ng.
8. Compl ete spl i ce of repl acement nylon t o original
nylon tubing at both ends.
9. Tighten keyst one cl amps.
10. Install any remaining clips whi ch wer e removed
for thi s servi ce and check that t ubes are secure in
original cl i ps.
11. Fill fuel tank as outlined, st art engine and check
for l eaks.
Push Connect ors, Nylon
NOTE: Damaged push connectors must be di scarded
and repl aced wi t h new push connect ors. If only the
retaining clip is damaged, repl ace the cl i p.
1. Relieve fuel syst em pressure as outlined. Read
cauti onary note prior t o relieving pressuri zed fuel
syst em. If necessary, drain fuel tank ( 9002) as
outlined.
2. Di sconnect t he damaged push connector. Be
sure t o break t he t ab before removi ng retaining
clip.
3. Sel ect the proper size repl acement push
connector and nylon tube assembl y. Refer t o
illustration showi ng Fuel Line Servi ce Parts.
4. Cut out a secti on of the original nylon tube t o the
same length as t he nylon tube at t ached t o the
new push connector.
5. NOTE: To make hand insertion of the barbed
connect ors into the nylon easier, the tube end
must be soaked in a cup of boiling wat er for one
minute immediately before pushing the barbs into
t he nylon. The 5 / 16-inch barbed connector is
used for splicing 5/ 16-inch non-EFI and
5/ 16- i nch EFI tubi ng.
Install proper barbed connector into the
repl acement nylon assembl y.
6. Install t wo keyst one cl amps loosely onto the
original nylon tubing before beginning Step 7.
7. Compl ete t he spl i ce by connecti ng the barbed
connector t o the original nylon.
8. Tighten the cl amps.
9. Connect the new connector assembl y t o the steel
tube end.
10. Check that t he underbody clips are properl y
securi ng the fuel tubes.
11. Fill fuel tank, st art engine and check for fuel l eaks.
10- 01- 18 FueSl T k, F T ^ L' J@S J 3 ^ "ori c" " 1 " "
_ z . . . . . J C . mmE= _Z * '. ... w~ : z z r z r ~ ZZ_ TT - z r i
Fue l Li ne Se r vi c e Part s
7.9mm (5/16 I N C H ) M R C O N N E C T O R
4712-0
P a r t No . P a r t Name and De s c r i p t i o n Qu a n t i t y
N803431 Un i o n 5- Ba r b St e e l 5 / 1 6 I n c h 2
N809613 Tube 5 / 1 6 I n c h Bul k Ny l o n A s
Ne c e s s a r y
37 7 9 31 Cl a mp f o r Uni on Co r r e c t i o n s 2 Pe r Sl i c e
9 2 89 Tube A s s y 5 / 1 6 I n c h P u s h Co n n e c t
wi t h 18 I n c h Ny l o n
1
92 89 Tube A s s y 5 / 1 6 I n c h E l b o w wi t h 18
I nc h Ny l o n
1
SPECIFICATIONS
P O W E R T R A I N C O N T R O L / E M I S S I O N S D I A G N O S I S
M A N U A L V E H I C L E A P P L I C A T I O N S
Co u g a r
TA1000B
Push Connect Tube Ends, St eel
1. Reli eve fuel sy st e m pr e ssur e a s out l i ned. Read
caut i onary not e pri or t o rel i evi ng pr essur i zed f uel
sy st e m. If necessar y, drai n f uel t ank ( 9002) as
out l i ned.
2. NOTE: Al l ow f or adequat e r o o m t o t i ght en a union
wi t h a wr e nc h at t hi s l ocat i on.
Usi ng a t ube cut t er, r e move t he da ma ge d push
connect t ube end at a conveni ent di st ance f r om
t he end.
3. Choose a pr oper r epl acement push connect t ube
end.
4. Sel ect t he pr oper si ze union and a t t a c h t he new
st eel t ube end t o t he ori gi nal t ube .
5. Clean off t he st eel t ube end and r epl ace t he push
connect or ont o t he t ube. (A new ret ai ner cl i p is
r ecommended. )
6. Check t hat t he under body cl i ps ar e pr oper l y
securi ng t he fuel t ube s.
7. Fill fuel t ank, st a r t engi ne and c he c k f or l eaks.
Fuel Syst em Speci f i cat i ons
F U E L C A P A C I T Y
Fu e l T a n k G a l l o n s L i t e r s
St a n d a r d 2 0. 0 7 5. 7
F U E L P R E S S U R E
En gi n e Run n i n g 30- 45 psi
2 10- 310 kP a
Ke y On En gi n e Of f 35- 40 psi
2 40- 2 80 kP a
P U S H C O N N E C T R E T A I N E R S P A R T N U M B E R S
Part Number Component
N802 2 41 ( Bl a c k) Hai r Pi n C l i p
8
3 / 8 I nc h
Co n n e c t o r
N802 2 39 ( Wh i t e ) Ha i r Pi n C l i p
3
5 / 1 6 I nc h
Co n n e c t o r
a Re p l a c e me n t Re q u i r e d Af t e r Co n n e c t o r Re mo v a l
10- 01- 19 Fuel Tank, Fi l t ers, Li nes and El ect ri c Fuel Pump 10- 01- 19
Description N-m Lb-l n
Fue l Fi l t e r a n d Ba s e Re t a i n i n g
Bo l t s
9- 12 80- 106
Fue l Ta n k Su p p o r t St r a p Re t a i n i n g
Nut s
2 9- 41 2 2 - 30
( L b - Ft )
Fi l l e r Ne c k- t o - Bo d y S c r e ws 2. 3- 3. 3 2 1- 2 9
Fue l Ta n k Fi l l e r P i pe Re t a i n e r 6. 8- 9. 2 61- 81
Fue l P r e s s u r e Re gu l a t o r Re t a i n i n g
Bo l t s
9- 12 80- 106
Tool Numbe r /
T 80L - 997 4- B
EFI a n d CFI Fue l P r e s s u r e
Ga u ge
TB0L-9974-B
Fue l Li n e Di s c o n n e c t To o l Se t
T 90T - 9550- S c o n s i s t s of :
T90T- 9550- B
Fue l Li n e Di s c o n n e c t To o l
( 5 / 1 6 - i n c h )
T90T- 9550- C
Fue l L i n e Di s c o n n e c t To o l
( 3 / 8 - i n c h )
T90T-9550-S
D84P - 92 7 5- A Fue l Ta n k Se n d e r Wr e n c h
D87 L - 92 80- A Sp r i n g L o c k Co upl i n g Di s c o n n e c t To o l
( 3 / 8 i n c h )
D87 L - 92 80- B Sp r i n g L o c k Co upl i n g Di s c o n n e c t To o l
( 1 / 2 i n c h)
ROTUNDA EQUIPMENT
034- 00002 Fue l S t o r a g e Ta n ke r
034- 00012 Fue l Ta n ke r A d a p t e r Ho s e
10- 02 - 1 A c c e l e r a t o r P e d a l a n d L i n ka ge 10- 02 - 1
SECTION 10-02 Accelerator Pedal and Linkage
SUBJECT PAGE
V E H I C L E A P P L I C A T I O N ...10-02-1
Accelerat or Pedal a n d L i n k a g e 10-02-1
i nspecti on and Veri fi cati on 10-02-1
S y m p t o m Chart 10-02-1
SUBJ E CT PAGE
Accel erat or Cabl e. . . . . 10-02-2
Accel erat or Cabl e Bracket 10-02-2
Accel er at or Pedal and Shaf t 10-02-2
V E H I C L E APPLICATION
Accel erat or Pedal and Li nkage
The throttl e is control l ed by an accel erat or cabl e
( 9A758) and an accel erat or pedal and shaft ( 9725)
assembl y. The following shoul d be noted when
servi ci ng thi s syst em:
The accel erat or pedal and shaft should travel
smoothl y f rom an idle t o wi de open throttl e position.
Hesi tati on or return and/ or preventi on of return t o
idle position must not occur throughout t he total
travel of the accel erat or pedal and shaft.
Surrounding component s such as wi ri ng, hoses,
sound insulator and floor coveri ng must not cont act
sliding inner member of the accel erator cabl e or the
accel erat or pedal and shaft.
The throttl e assembl y is adjustable for f ree pl ay and
di stance of t ravel .
The sliding inner member of t he accel erat or cabl e
should not be l ubri cated, and it is not servi ceabl e.
1. Visually i nspect accel erat or pedal and shaft
( 9725) and accel erat or cabl e ( 9A758) for
cust omer' s concern.
2. If an obvi ous cause for an observed or report ed
malfunction is found, correct t he cause if possi bl e
before proceedi ng t o the next st ep.
3. If the cause of the malfunction cannot be found by
i nspecti on, proceed t o the Sympt om Chart whi ch
serves as a guide for further di agnosi s t o val i date
cust omer' s concern.
Sympt om Chart
Based on the condi ti on, the fol l owi ng st eps are t o be
used for di agnosi s fol l owi ng di sconnecti on of the
accel erator cabl e ( 9A758) f rom the throttl e body
lever. (If vehicle is equi pped wi th speed cont rol ,
di sconnect t he speed control actuator cabl e from the
accel erator cabl e.)
10- 02 - 2 A c c e l e r a t o r Pe d a l a n d L i n ka ge 10- 02 - 2
ACCELERATOR PEDAL AND SHAFT TO ACCELERATOR CABLE
Accelerator Pedal and Shaft are
Hard to Push Down or Have a
Rough / Raspy or Sticky Feel
Be sure that the di sconnected end
of the accelerator cable or its
accelerator retracti ng spring does
not come into contact wi th any of
the surrounding parts.
Operate the accelerator pedal and
shaft by foot.
If accelerator cable operation is
smooth, accelerator cable is not
damaged. Refer to Powertrain
Manual
1
for other checks.
If the condition recurs (being sure
di sconnected end of accelerat or
cable has not come into contact
with anything), check the
accelerator pedal and shaft for
free operati on.
REPLACE accelerator cable.
High Engine Idle Speed If the socket does not extend
beyond the stud, check the
accelerator pedal and shaft for
free operati on.
REPLACE accelerator cable.
A c c e l e r a t o r C a b l e
1. Usi ng a sui t abl e t ool , push t he accel er at or cabl e
nyl on bushi ng out of t he accel er at or pedal and
shaf t a r m.
2. Remove t he accel er at or cabl e ret ai ner (9E728)
f r o m t he accel er at or cabl e housi ng. The
a c c e l e r a t or cabl e ret ai ner is l ocat ed i nsi de t he
vehi cl e whe r e t he accel er at or cabl e housi ng
pa sse s t hr ough t he dash panel i nto t he
passenger compar t ment .
3. Di sconnect t he accel er at or cabl e ( 9A7 58) at t he
t hr ot t l e body (TB) t hr ot t l e l ever by rot at i ng t he
t hr ot t l e lever t o t he wi de open t hr ot t l e posi t i on
and sl i de cabl e t hr ough sl ot in c a m.
4. Remove t he accel er at or cabl e housi ng t o engi ne
mount i ng br a c ke t ret ai ni ng sc r e w.
5. Remove t he accel er at or cabl e housi ng t o dash
panel ret ai ni ng nut s, wi per modul e suppor t
br a c ke t and housi ng.
6. To i nst al l , r ever se Removal pr ocedur e and ensure
a c c e l e r a t or cabl e ret ai ner is pushed i nto
a c c e l e r a t or cabl e housi ng at l east 6. 35 mm ( 1 / 4
i nch). Al so be sure accel er at or cabl e moves
f reel y.
Ref er t o Di agnosi s and Test i ng f or di agnosi s of t he
a c c e l e r a t or pedal and shaf t ( 97 25) af t er t he
di sconnect i on of t he accel er at or cabl e f r om t he
t hr ot t l e body t hr ot t l e l ever c a m. Di sconnect speed
cont r ol a c t ua t or ( 9A82 5) f r om t he accel er at or cabl e, if
equi pped.
A c c e l e r a t o r P e d a l a n d S h a f t
1. Usi ng a sui t abl e t ool , push t he accel er at or cabl e
nylon bushi ng out of t he accel er at or pedal a r m.
2. Remove t he t wo accel er at or pedal and shaf t t o
da sh panel retai ni ng nut s.
3. To i nst al l , reverse Removal pr ocedur e and t i ght en
accel er at or pedal and shaf t nut s t o 15-20 N- m
(11-15 Ib-f t ). Al so ensure t hat pedal mot i on is not
r e st r i c t e d.
A c c e l e r a t o r C a b l e B r a c k e t
1. Remove accel er at or cabl e housi ng t o accel er at or
cabl e br a c ke t retai ni ng scr ew.
2. Remove t he bol t s ret ai ni ng t he accel er at or cabl e
br a c ke t ( 97 23) t o t he engi ne.
3. Li ft t he accel er at or cabl e housi ng out of t he
accel er at or cabl e br acket . Remove t he
accel er at or cabl e br acket .
4. To i nst al l , reverse Removal pr ocedur e and t i ght en
accel er at or cabl e br acket bol t s t o 8-12 N-m
(71-106 lb-i n).
10- 02 - 3
A c c e l e r a t o r Pe d a l a n d L i n ka ge
10- 02- 3
Accel er at or Cabl e
VIEWC
COLOR CODE FOR ACCELERATOR
CABLE 9A758
ENGINE THROTTLE BODY COLOR CODE
4. 6L S F I NONE
COLOR CODE FOR BRACKET 723
ENGINE THROTTLE BODY COLOR CODE
4.6L SFI BLACK
V74Q3-F
10- 02 - 4 A c c e l e r a t o r Pe d a l a n d L i n ka ge 10- 02 - 4
I t e m
Pa r t
2 9A758 Accelerator Cable
3 9723 Bracket
4 9725 Accelerat or Pedal and Shaft
5 06610 Dash Panel
6 5401670 Body Assembly
7 501670 Insulator
SPECIFICATIONS
P O WE R T R A I N C O N T R O L / E MI S S I O N S DI A G N O S I S
MA N U A L V E H I C L E A P P L I C A T I O N S
Co u ga r
OBDI A l l Ot h e r Ve h i c l e s
T A 1 0 0 0 B
Pa r t
8 N804796-S56 Nut (2 Req'd)
9 N804795-S2 Nut (2 Req'd)
10

Brace
11 N610959-S56 Bolt
A

Tighten to 15-20 N-m (11 -15
Lb-Ft)
B

Lb-ln)
A c c e l e r a t o r P e d a l a n d
Sh a f t - t o - Da s h Nut s
15- 20 11- 15
A c c e l e r a t o r Ca b l e
Br a c ke t - t o - E n gi n e Bo l t s
8- 12 7 1- 106
( Lb- l n )
10- 03- 1 Sp e e d Co n t r o l S y s t e mE l e c t r o n i c 10- 03- 1
SECTION 10-03 Speed Control SystemElectronic
SUBJECT PAGE
Speed Control System 10-03-1
Component Test.......... 10-03-14
Speed Cont rol Act uat or Swi t ch
Assembl y... 10-03-14
El ectri cal Schemati c 10-03-5
Sy mpt om Chart . . . ...10-03-7
Deact i vat or Swi t c h 10-03-21
SUBJECT PAGE
Sl i di ng Cont act , Ai r Bag ....10-03-17
Speed Cont r ol Ac t ua t or 10-03-19
Speed Cont r ol Ac t ua t or Swi t ch
Assembl y 10-03-15
Speed Cont r ol Servo 10-03-18
St opl i ght Swi t ch 10-03-21
Vehi cl e Speed Sensor (VSS) a..... 10-03-21
ADJUSTMENTS
Ac t ua t or Cabl e 10-03-22
Brake Pedal Hei ght 10-03-23
SPECIFICATIONS.... 10-03-24
VEHICLE APPLICATION
Speed Control System
The speed cont r ol sy st e m consi st s of :
Speed cont r ol ser vo ( 9C735) .
Speed cont r ol act uat or ( 9A825) .
Vehi cl e spe e d sensor (VSS)(9E731).
Horn rel ay and br a c ke t ( 13853) .
Spe e d Co n t r o l Co mpo n e n t s
Spe e d cont rol act uat or swi t c h ( 9C888) .
St opl i ght swi t c h ( 13480) .
Deact i vat or swi t c h (Part of 2 B091) .
Br a ke pr essur e cont r ol val ve ( 2B091) .
The sy st e m ope r a t e s i ndependent l y of engi ne vacuum,
t he r e f or e no vacuum li nes are r equi r ed.
L8253-C
Pa r t Pa r t
1 N610959-S56 Screw
2

Actuator Cable Adj uster 5 9C735 Speed Control Servo
Fitting (Part of 9A825) 6 9C809 Speed Control Bracket Plate
3 9A825 Speed Control Actuator A Tighten to 3-4 N-m (27-35
(Continued)
(Lb-ln)
The spe e d cont rol servo:
Is mount ed in t he engi ne compar t ment near t he
powe r br a ke boost er ( 2005) .
Is c onne c t e d t o t he t hr ot t l e l i nkage wi t h t he spe e d
cont r ol a c t ua t or .
The el ect r oni cs are i nt egrat ed into t he speed
cont r ol se r vo, eli mi nati ng t he need f or any ot her
spe e d cont r ol el ect roni c modul es in t he vehi cl e.
The spe e d cont r ol act uat or swi t c h assembl y is
mount ed in t he st eeri ng wheel ( 3600) . It consi st s of:
LH but t ons (ON, OFF).
RH but t ons (RESUME, SET ACCEL, COAST).
Ne c e ssa r y wi r i ng.
L9095-A
LS086-A
The vehi cl e spe e d sensor (VSS):
Is mount ed t o t he t ransmi ssi on.
Is a magnet i c pi ckup dri ven by a gear whi c h is
dri ven by t he t ransmi ssi on.
The VSS si gnal sent t o speed cont rol ser vo is
proport i onal t o vehi cl e speed.
The ai r bag sli di ng cont act :
Is l ocat ed at t he cent er of st eeri ng wheel .
Transf ers el ect ri cal si gnal s f r om t he st eeri ng col umn
wi ri ng t o:
dri ver si de ai r bag modul e ( 043B13)
horn bl ow swi t c h ( 13A87 5)
spe e d cont r ol act uat or swi t c h.
The st opl i ght swi t c h:
Is a normal l y open swi t c h t hat cl oses when t he
br a ke pedal ( 2455) is appl i ed.
Sends an el ect ri cal si gnal t o t he speed cont rol
ser vo t o di sengage t he speed cont rol sy st e m.
When t he br a ke pedal is rel eased, t he st opl i ght
swi t c h ret urns t o i t s open posi t i on.
Ref er t o Sect i on 17-01 f or addi t i onal i nf ormat i on.
The deact i vat or swi t c h:
Is a normal l y cl osed swi t c h and repl aces t he speed
cont rol dump val ve ( 9C727) as a redundant saf et y
f eat ure in t he sy st e m.
An el ect ri cal si gnal f r om t he BOO ci rcui t t o t he The de a c t i va t or swi t c h i s l ocat ed at t he rear br a ke
speed cont rol servo wi l l di sengage t he sy st e m pr e ssur e cont r ol val ve (ant i -l ock br a ke s) or br a ke
when t he br a ke pedal is appl i ed. pr e ssur e swi t c h adapt er ( 2C300) (convent i onal
Under i ncreased brake pedal efforts ( 22. 25- 44. 5 N hydraul i c br akes) bel ow t he power br ake boost er.
(5-10 l bs), engi ne runni ng), t he deact i vat or swi t c h
mount ed in t he br ake line wi l l open and r emove
power t o t he speed cont r ol se r vo, rel easi ng t he
t hr ot t l e f r om speed cont r ol ser vo cont r ol .
De a c t i va t o r Swi t c h
The el ect roni c i nst rument cl ust er ( 10849) c onsi st s of
one mi cr ocomput er -based modul e t hat pr oc e sse s
sensor i nf ormat i on and cont r ol s t he t hr ee vacuum
f l uorescent di spl ays (VFD). The di spl ays i ncl ude:
Speedomet er / odomet er.
El ect roni c fuel and engi ne cool ant t emper at ur e
gauges.
Me ssa ge cent er.
The me ssa ge cent er i ncl udes t he spe e d cont r ol
i ndi cat or. Thi s i ndi cat or:
I ndi cat es t o t he dri ver t hat t he speed cont rol sy st e m
is cont rol l i ng vehi cl e speed.
10- 03- 4 S p e e d Co n t r o l S y s t e mE l e c t r o n i c 10- 03- 4
Illumi nates when t he speed cont rol is a c t ua t e d and
when RESUME is act uat ed.
Turns off when t he br akes are appl i ed a n d / o r when
t he speed cont rol OFF swi t c h is pr e sse d.
ELECTRONIC INSTRUMENT CLUSTER (EIC) SPEED CONTROL
INDICATOR
10- 03- 5
JJFJ ^K:
S p e e d Co n t r o l S y s t e mE l e c t r o n i c
- X - -
-
9. . 1 I T H Z ?
10- 03- 5
To wn Car
HOT AT ALL TIMES
o f t h i s c i r c u i t
I T" !
K i
FUSE
JUNCTION
PANEL
HOT AT ALL TIMES
LG/R
10 LG/R
ELECTRONIC
CLUSTER
DISPLAY
2 0 3 O / L B
DEACTIVATOR
1
SWITCH
h
/
OPEN WITH
I BRAKE PEDAL
APPLIED
STOPLIGHT
SWITCH
CLOSED WITH
BRAKE PEDAL
APPLIED
636j Ô

5 1 1 L G
I F"!
IC 5
460 1 Y/LB
POWER
DISTRIBUTION
BOX
z
HORN
RELAY
1 0 2 7 4
8 1 5 6
JZ L ^f HORN 1
SPEED
CONTROL
SERVO
PK/O
151 I LB/BK
I
T
848 I DG/O
PK/ofc
DEDICATED
LINE: NO
ADDITIONAL
CONNECTIONS
SPEED CONTROL SWITCHES
12 0 OHM
C O A S T
\ OFF I O N
680 OHM
SET/
ACCEL
2 2 00 OHM
HORN
AIR BAG SLIDING CONTACT
L7661-D
Co n n e c t o r End Vi e w
SPEED CONTROL
SERVO CONNECTOR
L7660-D
Pi n
N u m b e r Circuit Circuit F u n c t i o n
1 2 03
(O/LB)
S p e e d Co n t r o l I n d i c a t o r L a mp
Out put
2

No t Us e d
3 67 9
( G Y/ B K )
Ve h i c l e Sp e e d Se n s o r I nput
4 511 ( LG) St o p l i gh t Swi t c h I nput
5 151
( L B / B K )
S p e e d Co n t r o l A c t u a t o r S wi t c h
A s s y I nput
6 848
( DG / O)
Si gn a l Re t ur n
7 2 95
( L B / P K )
Ho t in RUN
( Co n t i n ue d )
Pin
8 No t Us e d
9 636 ( O) De a c t i v a t o r Swi t c h I nput
10 67 6
( P K / O )
Gr o un d
111
of this circuit
I T " I FUSE
I f
7
i JUNCTION
S 1 PANEL
i C 1
ELECTRONIC CLUSTER
DISPLAY
3 I O/LB 636 I O
DEACTIVATOR
1
SWITCH
>
I
OPEN WITH
I
BRAKE PEDAL
APPLIED
STOPLIGHT
SWITCH
CLOSED WITH
BRAKE PEDAL
APPLIED
Y
511 I LG
GY/BK
VEHICLE
SPEED
SENSOR
(VSS)
6 7 6 Y PK/O
NOTE: THE SAME SERVO ASSY IS
USED FOR BOTH ANALOG AND
ELECTRONIC INSTRUMENT CLUSTERS.
DEDICATED
LINE: NO
ADDITIONAL
CONNECTIONS
SPEED CONTROL SWITCHES
\ OFF ON
1 ^ < J
120 OHM . 5 680 OHM . ; 2200 OHM
COAST - : SET/ * : RESUME
ACCEL
. r
HORN
AiR BAG SLIDING CONTACT
L8176-C
Co n n e c t o r End Vi ew
P i n
4 511 ( L G) St o p l i gh t S wi t c h I nput
5 151
( L B / B K )
Si gn a l Re t ur n
6 848
( DG / O )
S p e e d Co n t r o l S wi t c h Gr o u n d
7 2 96 ( W/ P ) Hot i n RUN
8

No t Us e d j
9 6 3 6 (O) De a c t i v a t o r S wi t c h I nput
10 57 ( BK) Gr o un d
S P E E D C O N T R O L
S E R VO C O N N E C T O R
L 7 660- D
P i n
1 2 03
( O/ LB)
S p e e d Co n t r o l I n d i c a t o r L a mp
Out put
2

No t Us e d
3 67 9
( G Y/ B K )
Ve hi c l e S p e e d Se n s o r I nput
NOTE: For Crown Vi ctori a, Grand Marqui s vehi cl es
wi thout speed cont rol , a cap containing a shorti ng bar
is pl aced over t he 10-pin speed control servo ( 9C735)
connector. The bar connects pins 6 and 10 provi di ng
a return t o ground for the horn signal. If this shorti ng
bar is not present on vehi cl es wi thout speed cont rol ,
t he horn ( 13832) will not function. Refer t o connect or
end vi ew and El ectri cal Schemati c.
( Co n t i n ue d )
1. Verify the customer' s original concern by
operati ng speed control syst em to duplicate the
condi ti on.
condi ti on.
condi ti on.
I n s p e c t a n d v e r i f y t ha t :
a c t u a t o r c a b l e i s
a d j u s t e d p r o p e r l y wi t h o u t
h o l d i n g t he t h r o t t l e o p e n
o r i n c r e a s i n g i dl e s p e e d .
t h r o t t l e l i n ka ge o p e r a t e s
f r e e l y a n d s mo o t h l y wh e n
c o n n e c t e d t o t h e a c t u a t o r
c a b l e a n d s p e e d c o n t r o l
s e r v o .
Ve r i f y p r o p e r ho r n
o p e r a t i o n .
Ve r i f y s t o p l i gh t o p e r a t i o n .
Ch e c k c i r c u i t f u s e s .
I n s pe c t a n d v e r i f y t ha t :
c o n n e c t i o n s a r e
c o mp l e t e wi t h n o l o o s e
wi r e s or t e r mi n a l s .
o wi r i n g i s not b r o ke n ,
s h o r t e d o r c o r r o d e d .
wi r i n g i s not mi s r o u t e d .
3. If the concern(s) remain after i nspecti on,
determi ne the sympt om(s) and go t o the
Sympt om Chart.
Use Rotunda 73 Digital Multimeter 105-00051 or
equivalent t o perform electrical Pinpoint Tests.
SPEED CONTROL SYSTEM ELECTRONIC
Speed Control Inoperative Blown fuse.
Circuitry.
Deactivator swi t ch.
Stoplight swi t ch.
Burnt stoplamp bulb.
Speed control actuator swi t ches.
Vehicle speed sensor.
Speed control servo.
SPEED CONTROL SYSTEMELECTRONIC (Cont i nued)
S e t S p e e d F l u c t u a t e s Vehicle speed sensor.
Speed control actuator swi t ches.
Circuitry
Loose binding between speed
control actuator cable and t hrot t le
body.
Engine.
REFER to Powertrain
Manual \ SERVICE engine as
required.
S p e e d C o n t r o l D o e s N o t
D i s e n g a g e W h e n B r a k e s A r e
Applied
Stoplight swi t ch.
Blown fuse.
Circuitry.
S p e e d C o n t r o l I n d i c a t o r D o e s N o t
Turn On
Circuitry.
Instrument cluster.
S p e e d C o n t r o l I n d i c a t o r D o e s N o t
T u r n O F F
Circuitry.
Instrument cluster.
C O A S T S w i t c h I n o p e r a t i v e Speed control actuator swi t ches.
Circuitry.
S E T / A C C E L S w i t c h I n o p e r a t i v e Speed control actuator swi t ches.
Circuitry.
GO t o Pinpoint Test G.
RESUME Switch Inoperative Speed control actuator swi t ches.
Circuitry.
OFF Switch Inoperative Speed control actuator swi t ches.
Circuitry.
GO to Pinpoint Test Step J.
PINPOINT TEST A: SPEED CONTROL INOPERATIVE
A1 VERIFY POWER TO SPEED CONTROL SERVO
Yes
No
* GO to A4.
GO to A2.
Disconnect 14290 harness connector from speed
control servo.
Turn ignition switch to RUN.
With a Rotunda 73 Digital Multimeter 105-00051 or
equivalent, measure voltage between Pin 4 ( B + ,
Circuit 295 (LB/ PK)
2
or 296 (W/ P)
3
) and Pin 1
(GND, Circuit 676 ( PK/ O)
2
or 57 (BK)
3
).
Yes
No
* GO to A4.
GO to A2.
A2 CHECK IGNITION CIRCUIT
Yes
No
GO to A3.
SERVICE ignition fuse 4
2
or 6
3
in instrument panel
or circuit 295 ( LB/ PK)
2
or
296 ( W/ P)
3
as required.
With ignition swi tch in RUN, measure voltage
between Pin 4 ( B + , Circuit 295 ( LB/ PK)
2
or 296
(W/ P)
3
) and a ground on the chassi s.
Yes
No
GO to A3.
SERVICE ignition fuse 4
2
or 6
3
in instrument panel
or circuit 295 ( LB/ PK)
2
or
296 ( W/ P)
3
as required.
A3 CHECK SPEED CONTROL SERVO GROUND CIRCUIT .
Yes
No
REPEAT Step A 1.
SERVICE ground circuit
676 ( PK/ O)
2
or 57 (BK)
3
.
Measure resi stance between Pin 1 (GND, Circuit
676 ( PK/ O)
2
or 57 (BK)
3
) and a ground point on the
chassi s.
Yes
No
REPEAT Step A 1.
SERVICE ground circuit
676 ( PK/ O)
2
or 57 (BK)
3
.
2 To wn Ca r
3 Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s
10- 03- 9 S p e e d Co n t r o l S y s t e mE l e c t r o n i c __ _ 10- 03- 9
PINPOINT TEST ki SPEED CONTROL INOPERATIVE (Continued)
A4 CHECK DEACTIVATOR SWITCH CIRCUIT
Yes
No
GO t o A7 .
GO t o A5.
Leave ignition swi tch in RUN.
With no brakes appli ed, place a 12 Volt Circuit Test
Light between Pin 2 (Circuit 636 (0)) and Pin 1
(GND, Circuit 57 (BK).
Is t he light i l l umi nat ed?
Yes
No
GO t o A7 .
GO t o A5.
A5 VERIFY POWER AT DEACTIVATOR SWITCH HARNESS
CONNECTOR
Yes
No
GO t o A6.
SERVICE blown Fuse 11
or open Circuit 10
(LG/R).
Remove 14401 harness connector from deacti vator
swi t ch.
. Place 12 Volt Circuit Test Light between Circuit 10
(LG/R) of deacti vator swi tch connector and chassi s
ground.
Is t he light i l l umi nat ed?
Yes
No
GO t o A6.
or open Circuit 10
(LG/R).
AS CHECK FOR OPEN CIRCUIT BETWEEN DEACTIVATOR
SWITCH AND SPEED CONTROL SERVO
Yes
No
REPLACE deacti vator
swi t ch.
SERVICE open Circuit
636 ( 0) in harness.
Measure resi stance of Circuit 636 ( 0) from
deacti vator switch connector t o Pin 2 of speed
control servo connector.
Is resi st ance less t han 1 ohm?
Yes
No
swi t ch.
636 ( 0) in harness.
A7 CHECK STOPLIGHT SWITCH CIRCUIT
Yes
No
REPLACE stopli ght
swi t ch.
GO to A8.
With no brakes appli ed, measure voltage between
Pin 7 (BRK, Circuit 511 (LG)) and Pin 1 (GND, Circuit
676 ( PK/ O)
4
o r 57 ( BK)
5
) .
Yes
No
REPLACE stopli ght
swi t ch.
GO to A8.
A8 CHECK STOPLIGHT SWITCH CIRCUITRY
Yes
No
GO to A12.
GO to A9.
With brakes appli ed, measure voltage between Pin
7 (Circuit 511 (LG)) and Pin 1 (Circuit 676 ( PK/ O)
4
or 57 | BK)
5
) .
Yes
No
GO to A12.
GO to A9.
A9 CHECK STOPLIGHT SWITCH
Yes
No
GO t o A10.
REPLACE stoplight
swi tch.
Remove elect ri cal connector from stopli ght swi t ch.
Measure resi stance between two terminals of
stopli ght swi tch wi th brakes appli ed.
Is resi st ance l ess t han f i ve ohms?
Yes
No
GO t o A10.
REPLACE stoplight
swi tch.
A10 VERIFY POWER AT STOPLIGHT SWITCH HARNESS
CONNECTOR
Yes
No
GO to A11.
4
or 7
5
or open in Circuit 10
(LG/R).
Measure voltage between Circuit 10 (LG/ R) of
stoplight swi tch connector and chassi s ground.
Is t here bat t er y vol t a ge ?
Yes
No
GO to A11.
4
or 7
5
or open in Circuit 10
(LG/R).
A11 CHECK FOR OPEN CIRCUIT BETWEEN STOPLIGHT
SWITCH AND SPEED CONTROL SERVO
Yes
No
REPEAT Step A7.
511 (LG).
Measure resi stance of Circuit 511 (LG) from
stopli ght swi t ch connector to Pin 7 of speed control
servo connector.
Is resi st ance less than fi ve ohms?
Yes
No
REPEAT Step A7.
511 (LG).
A12 CHECK FOR STUCK ON SPEED CONTROL ACTUATOR
SWITCH
Yes
No
REPLACE speed control
actuator swi t ch.
GOt o A13.
With no steeri ng wheel swi t ches pressed, measure
voltage between Pin 6 (Circuit 151 (LB/ BK)) and Pin
1 (GND, Circuit 676 ( PK/ O)
4
or 57 (BK)
5
).
Yes
No
actuator swi t ch.
GOt o A13.
A13 CHECK ON SWITCH OPERATION
GOt o A17.
GOt o A14.
With steeri ng wheel ON swi t ch pressed, measure
voltage between Pin 6 (Circuit 151 (LB/ BK)) and Pin
1 (GND, Circuit 676 ( PK/ O)
4
or 57 (BK)
5
).
Yes
No '
GOt o A17.
GOt o A14.
4 To wn Ca r
PINPOINT TEST A: SPEED CONTROL INOPERATIVE (Cont i nued)
A14 VERIFY POWER AT AIR BAG SLIDING CONTACT
CONNECTOR AT BASE OF STEERING COLUMN
Yes 6>
No
GO t o A15.
CHECK fuse in the power
distribution box, Circuit
460 (Y/ LB), horn relay
and bracket and Circuit 1
(DB)
6
or 6 ( Y/ LG)
7
.
Disconnect air bag sliding contact at the base of
steering column.
Measure voltage between Circuit 1 (DB)
6
or 6
(Y / LG)
7
at air bag sliding contact connector and Pin
57 (Circuit 676 ( PK/ O)
6
or 57 (BK)
7
of speed control
servo connector.
Yes 6>
No
GO t o A15.
CHECK fuse in the power
distribution box, Circuit
460 (Y/ LB), horn relay
and bracket and Circuit 1
(DB)
6
or 6 ( Y/ LG)
7
.
A15 CHECK AIR BAG SLIDING CONTACT
Yes
No
GO t o A16.
contact.
Disconnect speed control actuator swi t ch.
Measure resistance across each of the air bag
sliding contact windings between the air bag sliding
contact connector at the base of steering column
and speed control swi tches connector in the
steering wheel.
Is each resi st ance readi ng bet ween 0.25-0.5
ohm?
Yes
No
GO t o A16.
contact.
A16 CHECK FOR OPEN CIRCUIT BETWEEN AIR BAG
SLIDING CONTACT AND SPEED CONTROL SERVO
Yes
No
actuator swi t ch.
151 (LB/ BK) or Circuit
848 (DG/O).
Measure resistance in Circuits 151 (LB / BK) and
848 (DG/O) between air bag sliding contact
connector at base of steering column and speed
control servo.
Is each resi st ance readi ng less t han f i ve ohms?
Yes
No
actuator swi t ch.
151 (LB/ BK) or Circuit
848 (DG/O).
A17 CHECK FOR STUCK COMMAND SWITCHES
Yes
No
GO t o A18.
actuator swi tch.
With no steering wheel swi tches pressed, measure
resistance between Pin 6 (Circuit 151 (LB/BK)) and
Pin 5 (Circuit 848 (DG/O)).
Is resi st ance great er t han 3k ohms?
Yes
No
GO t o A18.
actuator swi tch.
A18 CHECK SET/ACCEL SWITCH OPERATION
Yes
No
GO t o A19.
actuator swi t ch.
With the SET/ACCEL switch pressed, measure
resistance between Pin 6 (Circuit 151 (LB/BK)) and
Pin 5 (Circuit 848 (DG/O)).
Yes
No
GO t o A19.
actuator swi t ch.
A19 CHECK VSS CIRCUIT
Yes
No
GO to A2 1.
GO to A20.
Measure resistance between Pin 3 (Circuit 679
(GY/BK) and Pin 10 (Circuit 676 ( PK/ O)
6
or
57 (BK)
7
).
Yes
No
GO to A2 1.
GO to A20.
A20 CHECK VSS
Yes
No
CHECK for opens or
shorts in Circuit 679
(GY/BK) or 676 (PK/O).
REPLACE vehicle speed
sensor.
Remove VSS connector.
Measure resi stance across VSS terminals.
Yes
No
CHECK for opens or
shorts in Circuit 679
(GY/BK) or 676 (PK/O).
REPLACE vehicle speed
sensor.
A21 CHECK FOR BROKEN OR BINDING CABLE
Yes
No
servo.
actuator.
Remove speed control actuator from speed control
servo.
Check for broken or binding cable by pulling on
cable ball slug to ensure throttle moves freely.
Is cabl e OK?
Yes
No
servo.
actuator.
6 To wn Ca r
10- 03- 11 S p e e d Co n t r o l S y s t e m E l e c t r o n i c 10- 03- 11
PINPOINT TE ST B: S E T SP E E D FLUCTUATES
B1 VERIFY CONDITION OCCURS ONLY WHILE USING
SPEED CONTROL
Yes
No
REFER to Powertrain
Diagnosis Manual
8
.
SERVICE engine as
requi red.
GO t o B2.
Verify that engine is properly tuned.
Verify that condition does not occur when driving
without speed control.
Does condi t i on occur wi t hout speed c o n t r o l ?
Yes
No
REFER to Powertrain
Diagnosis Manual
8
.
SERVICE engine as
requi red.
GO t o B2.
B2 CHECK FOR BINDING IN SPEED CONTROL ACTUATOR
CABLE AND THROTTLE BODY LINKAGE
Yes
No
GO t o B3.
Check for binding or sti cki ng of speed control
actuator cable or t hrot t le linkage and throttle plate.
Make sure t hrot t l e cable bracket and speed control
servo bracket are not loose.
Are c ompone nt s OK?
Yes
No
GO t o B3.
B3 CHECK VSS
Yes
No
CHECK continuity across
Circuit 679 (GY/ BK) and
676 (PK/O). GO to B4.
REPLACE vehi cle speed
sensor.
Remove VSS connector.
Measure resi stance across sensor terminals.
Yes
No
CHECK continuity across
Circuit 679 (GY/ BK) and
676 (PK/O). GO to B4.
REPLACE vehi cle speed
sensor.
B4 CHECK SPEED CONTROL SERVO ASSEMBLY
Yes
No
servo.
CHECK MAP sensor and
EGR valve position
(EVP). REFER to
Powertrain
Control / Emissions
Diagnosis Manual
8
.
Substitute known good speed control servo.
Test vehicle for proper operati on.
Does syst em oper at e pr oper l y ?
Yes
No
servo.
CHECK MAP sensor and
EGR valve position
(EVP). REFER to
Powertrain
Control / Emissions
Diagnosis Manual
8
.
PINPOINT TEST C: SPEED CONTROL DOES NOT DISENGAGE WHEN BRAKES ARE APPLIED
C1 CHECK DEACTIVATOR SWITCH CIRCUIT
Yes
No
GO to C2.
Disconnect 14290 harness connector from the
speed control servo.
With no brakes appli ed, place a 12 Volt Circuit Test
Light between Pin 2 (Circuit 636 ( 0) ) and Pin 1
(GND, Circuit 57 (BK)).
Is t he l i ght i l l umi nat ed?
Yes
No
GO to C2.
C2 CHECK DEACTIVATOR SWITCH OPERATION
Yes
No
GO to C3.
swi t ch.
Leave ignition swi t ch in RUN posi ti on.
Fully apply brakes with the 12 Volt Circuit Test Light
still between Pin 2 (Circuit 636 ( 0) ) and Pin 1 (GND,
Circuit 57 (BK)).
Does t he l i ght t ur n of f ?
Yes
No
GO to C3.
swi t ch.
C3 CHECK STOPLIGHT SWITCH CIRCUIT
Yes
No
GO to C4.
SERVICE stopli ght
swi tch, Fuse 7 or open in
Circuit 511 (LG) or Circuit
10( LG/ R) . RECONNECT
With brakes appli ed, measure voltage between Pin
7 (Circuit 511 (LG)) and Pin 1 (GND, Circuit 57 (BK)).
Yes
No
GO to C4.
SERVICE stopli ght
swi tch, Fuse 7 or open in
Circuit 511 (LG) or Circuit
10( LG/ R) . RECONNECT
PINPOINT TEST C: SPEED CONTROL DOES NOT DISENGAGE WHEN BRAKES ARE APPLIED (Cont i nued)
C4 CHECK FOR BINDS IN SPEED CONTROL ACTUATOR
CABLE AND THROTTLE LINKAGE ATTACHMENT
Yes
No
servo.
RECONNECT speed
control servo.
Remove speed control actuator cable from speed
control servo.
Check for broken or binding cable by pulling on
cable ball slug t o ensure throttle moves freely.
Is cabl e OK?
Yes
No
servo.
RECONNECT speed
control servo.
PINPOINT TEST D: SPEED CONTROL INDICATOR DOES NOT TURN ON
D1 CHECK VOLTAGE AT SPEED CONTROL SERVO
ASSEMBLY CONNECTOR
Yes
No
GO t o D3.
GO t o D2 .
control servo.
With ignition swi tch in RUN, measure voltage
between Pin 10 (Circuit 203 (O/LB)) and Pin 1 (GND
Circuit 676 ( PK/ O)
9
or 57 (BK)
1 0
).
Is vol t age appr oxi mat el y f i ve vol t s?
Yes
No
GO t o D3.
GO t o D2 .
D2 CHECK CIRCUIT CONTINUITY
Yes
No
GO to D3.
203 (O/ LB).
Measure resi stance of Circuit 203 ( 0 / LB) from Pin
10 of speed control servo connector to instrument
cluster connector.
Yes
No
GO to D3.
203 (O/ LB).
D3 DISPLAY TURN ON TEST
Yes
No
servo and REPEAT test.
SERVICE instrument
13-01A or 13-01B.
With ignition swi tch in RUN, connect Pin 10 (Circuit
203 ( 0/ LB) ) to Pin 1 (GND Circuit 676
9
( PK/ 0) or 57
(BK)
1 0
).
Does speed c ont r ol di spl ay t ur n on?
Yes
No
servo and REPEAT test.
SERVICE instrument
13-01A or 13-01B.
PINPOINT TEST E: SPEED CONTROL INDICATOR DOES NOT TURN OFF
E1 CHECK CIRCUIT 203
Yes
No
SERVICE Circuit 203
(O/ LB).
SERVICE instrument
cluster for internal short
to ground. REFER to
Section 13-01A or
13-01B.
Check for short to ground in Circuit 203 ( 0/ L B) .
Is t here a shor t ?
Yes
No
SERVICE Circuit 203
(O/ LB).
SERVICE instrument
cluster for internal short
to ground. REFER to
Section 13-01A or
13-01B.
PINPOINT TEST F: COAST SWITCH INOPERATIVE
F1 CHECK COAST SWITCH OPERATION
Yes
No
GO t o F2 .
actuator swi tch.
RECONNECT speed
control servo.
control servo.
With COAST swi tch pressed, measure resistance
between Pin 6 (Circuit 151 (LB/ BK)) and Pin 5
(Circuit 848 (DG/O)) while rotating steering wheel
through full range.
Yes
No
GO t o F2 .
actuator swi tch.
RECONNECT speed
control servo.
9 To wn Ca r
10- 03- 13 S p e e d Co n t r o l S y s t e mEl e c t r o n i c 10- 03- 13
r
r- : ^ a g y - ^ r a g
1
gâsisy xreaar WTEJSF ~ ~ ~ - y a w s - - wa s
PINPOINT TEST F: COAST SWITCH INOPERATIVE (Cont i nued)
F2 CHECK COMMAND SWITCH RETURN CIRCUIT
Yes
No
servo.
SERVICE short in Circuit
848 (DG/O).
RECONNECT speed
control servo.
Me a s u r e r e s i s t a n c e b e t w e e n P i n 5 ( C i r c u i t 848
(DG/O)) and Pin 1 (GND, Circuit 676 ( PK/ O)
1 1
, 57
(BK)
1 2
).
Is resi st ance great er t han one ohm?
Yes
No
servo.
848 (DG/O).
RECONNECT speed
control servo.
PINPOINT TEST G: SET/ACCEL SWITCH INOPERATIVE
G1 CHECK SET/ACCEL SWITCH OPERATION
Yes
No
GO t o G2 .
actuator swi t ch.
RECONNECT speed
control servo.
control s e r v o .
With SET/ACCEL swi tch pressed, measure
resi stance between Pin 6 (Circuit 151 (LB/ BK)) and
Pin 5 (Circuit 848 (DG/O)) while rotati ng steeri ng
wheel through full range.
Yes
No
GO t o G2 .
actuator swi t ch.
RECONNECT speed
control servo.
G2 CHECK COMMAND SWITCH RETURN CIRCUIT
Yes
No
servo.
848 (DG/O).
RECONNECT speed
control servo.
Measure resi stance between Pin 5 (Circuit 848
(DG/O)) and Pin 1 (GND Circuit 676 ( PK/ O)
1 1
or 57
(BK)
1 2
.
Yes
No
servo.
848 (DG/O).
RECONNECT speed
control servo.
PINPOINT TEST H: RESUME SWITCH INOPERATIVE
H1 CHECK RESUME SWITCH OPERATION
Yes
N o ^
GO t o H2.
actuator swi t ch.
RECONNECT speed
control servo.
control servo.
With RESUME swi t ch pressed, measure resi st ance
(Circuit 848 (DG/O)) while rotati ng steering wheel
through full range.
Yes
N o ^
GO t o H2.
actuator swi t ch.
RECONNECT speed
control servo.
H2 CHECK COMMAND SWITCH RETURN CIRCUIT
Yes I
No
servo.
848 (DG/O).
RECONNECT speed
control servo.
Measure resi stance between Pin 5 (Circuit 848
(DG/O)) and Pin 1 (GND Circuit 676 ( PK/ O)
1 1
or 57
(BK)
1 2
.
Yes I
No
servo.
848 (DG/O).
RECONNECT speed
control servo.
PINPOINT TEST J: OFF SWITCH INOPERATIVE
J1 CHECK OFF SWITCH OPERATION
servo.
actuator swi t ch.
RECONNECT speed
control servo.
control servo.
With OFF swi t ch pressed, measure resi st ance
(Circuit 848 (DG/O)) while rotati ng steeri ng wheel
through full range.
Is resi st ance l ess t han f our ohms?
Yes
No
servo.
actuator swi t ch.
RECONNECT speed
control servo.
11 To wn Ca r
10- 03- 14
Sp e e d Co n t r o l S y s t e mE l e c t r o n i c 10- 03- 14
C o mp o n e n t T e s t
Sp e e d Co n t r o l A c t u a t o r S w i t c h A s s e m b l y
To t est speed cont rol act uat or swi t c h ( 9C888)
pe r f or m t he f ol l owi ng vol t age and resi st ance
measurement s.
Remove 14401 harness connect or f r om spe e d cont rol
ser vo ( 9C735) . Connect t he negat i ve l ead of vol t met er
t o Pin 10 (Ci rcui t 67 6 ( P K / O )
1 3
or 57 ( BK)
1 4
) of
connect or. Measure t he DC or AC vol t age of t he
f ol l owi ng ci rcui t s wi t h posi t i ve l ead of met er.
VOLTAGE MEASUREMENTDC
CIRCUIT NAME PIN CIRCUIT WIRE COLOR TEST CONDITION
APPROXIMATE
VOLTAGE
I gn i t i o n Fe e d 7 2 95
a
2 96
b
L B / P K
3
W / P
b
I gn i t i o n s wi t c h in
RUN
Ba t t e r y v o l t a ge ( 12
v o l t s )
De a c t i v a t o r S wi t c h
Fe e d
9 636 0 No b r a ke s a p p l i e d
Br a ke p e d a l a p p l i e d
0
v o l t s )
L e s s t h a n 0. 5 v o l t
St o p l i gh t S wi t c h
Fe e d
4 511 LG No b r a ke s a p p l i e d
Br a ke p e d a l a p p l i e d
L e s s t ha n 0. 5 v o l t
v o l t s )
Co mma n d Si gn a l
( c o n t r o l l i n e )
5 151 L B / B K No s wi t c h e s
p r e s s e d
P r e s s a n d h o l d ON
s wi t c h
L e s s t h a n 0. 5 v o l t
v o l t s )
E l e c t r o n i c Cl u s t e r
Di s p l a y
1 2 03 O / L B I gn i t i o n s wi t c h in
RUN
5 v o l t s
a To wn Ca r
b Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s
c I n c r e a s e d b r a ke p e d a l e f f o r t s wi l l be r e q u i r e d t o t r i gge r s w i t c h wi t h e n gi n e OFF.
VOLTAGE MEASUREMENTAC
CIRCUIT NAME PIN CIRCUIT
WIRE
COLOR TEST CONDITION
APPROXIMATE
VOLTAGE
VS S Ou t pu t Si gn a l 3 67 9 G Y / B K Ve h i c l e o n r o a d
a b o u t 30 mp h
Ve hi c l e o n r o a d
a b o u t 45 mp h
1.4 v o l t s AC
mi n i mum
1.6 v o l t s AC
mi n i mum
Remove 14401 har ness connect or at spe e d cont r ol
se r vo. Connect an ohmmet er bet ween t he desi gnat ed
ci r cui t s wi t h i gni ti on swi t c h of f .
RESISTANCE MEASUREMENTS
CIRCUIT NAME PIN CIRCUIT
WIRE
COLOR TEST CONDITION
APPROXIMATE
RESISTANCE
St o p l i gh t S wi t c h t o
Gr o un d
4 t o 10 511 t o 67 6
a
o r 5 7
b
L G t o P K / O
a
o r B K
b
Br a ke s n o t a p p l i e d L e s s t h a n 10 o h ms
VS S Si gn a l t o
Gr o un d
3- 10 6 7 9 - 6 7 6
a
o r 5 7
b
G Y / B K t o P K / O
a
o r
B K
b
Ha r n e s s
d i s c o n n e c t e d f r o m
s e r v o
2 00- 300 o h ms
13 To wn Ca r
RESI STANCE MEASU REMENTS
CI RCU I T NAME PI N CI RCU I T
WI RE
COL OR T E S T CONDI T I ON
A P P ROX I MA T E
RE S I S T A NCE
Co mma n d Si gn a l t o
Co mma n d Re t ur n
5 t o 6 151 t o 848 L B / B K t o D G / O No s w i t c h e s
p r e s s e d
P r e s s OFF s wi t c h
P r e s s COA ST s wi t c h
P r e s s A CCE L s wi t c h
P r e s s RE SUME
s w i t c h
G r e a t e r t h a n 3 0 0 0
o h ms
L e s s t h a n 4 o h ms
114- 12 6 o h ms
646- 7 14 o h ms
2 09 0- 2 310 o h ms
Co mma n d Re t ur n t o
Gr o un d
6 t o 10 848 t o 6 7 6
a
o r 57
b
D G / O t o P K / O
a
o r
BK
b
No s w i t c h e s
p r e s s e d
Op e n c i r c u i t
a To wn Ca r
b Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s
Speed Cont rol Act uat or Swi t ch Assembl y
RemovalCrown Vi ctori a, Grand Marquis
1. WARNI NG: THE POSI TI VE BATTERY CABLE
MUST BE DI SCONNECTED BEFORE ANY AI R
BAG COMPONENT IS SERVI CED.
NECESSARY FOR SYSTEM DEPLOYMENT IS
POWERED DIRECTLY FROM THE BATTERY
AND BACKUP POWER SUPPLY. TO AVOI D
PERSONAL INJURY, THE BATTERY POSI TI VE
CABLE MUST BE DI SCONNECTED FOR ONE
MI NUTE TO DE-ENERGI ZE THE BACKUP
POWER SUPPLY PRIOR TO SERVI CI NG OR
REPLACI NG ANY SYSTEM COMPONENTS.
Di sconnect ba t t e r y gr ound c a bl e ( 14301) .
2. Di sconnect posi t i ve ba t t e r y cabl e and wai t one
mi nut e f or ba c kup powe r suppl y t o depl et e i t s
st or e d energy. Ref er t o Sect i on 01- 20B f or
Suppl ement al Ai r Ba g Sy st e m.
3. Remove f our nut and wa she r assembl i es ret ai ni ng
dri ver si de ai r ba g modul e ( 043B13) t o st eeri ng
wheel ( 3600) .
4. Di sconnect ai r ba g el ect r i cal c onne c t or f r o m ai r
bag sli di ng c ont a c t connect or .
5. WARNI NG: PLACE AI R BAG MODULE ON
Remove dri ver si de ai r ba g modul e f r o m st eeri ng
wheel .
NUT AND WASHER ASSY
N805572-S38
4 REQ'D
TIGHTEN TO
2.7-3.7 N-m
(24-33 LB-IN)
R9570-B
6. Pry of f RH and LH spe e d cont rol swi t c h bezel s.
10- 03- 16 10- 03- 16
BEMOWAL AND INSTALLATION (Conti nued)
7. Remove RH and LH bezel s f rom steeri ng wheel .
SPEED CONTROL
SWITCH BEZEL
L6636-B
8. Remove f our Phillips head scr ews ( t wo on each
si de) f r om speed cont rol swi t ch assembl i es.
LS637-B
9. Remove wi r e organi zer f rom steeri ng wheel .
WIRE
ORGANIZER
L6638-B
10. Di sconnect speed cont rol act uat or swi t c h
( 9C888) and horn bl ow swi t c h connect or s.
Remove speed cont rol act uat or swi t c h f r om
st eeri ng wheel .
SPEED CONTROL
SWITCHES AND WIRING
ASSY
L6639-B
I n s t a l l a t i o n C r o w n Vi c t o r i a , G r a n d Ma r q u i s
1. Posi t i on speed cont rol act uat or swi t c h ont o
st eeri ng wheel and install f our Phillips head
sc r e ws.
2. CAUTI ON: Ma ke s u r e wi r e s a r e p o s i t i o n e d s o
t h a t n o i n t e r f e r e n c e i s e n c o u n t e r e d w h e n
i n st a l l i n g ai r b a g mo d u l e .
Connect all harness connect or s and rout e wi ri ng
in st eeri ng wheel cavi t y. Install wi re organi zer.
3. Posi t i on speed cont rol swi t c h bezel s and snap
i nto pl ace.
4. Posi t i on dri ver si de ai r bag modul e on st eeri ng
wheel a nd connect ai r bag sli di ng c ont a c t .
5. Install dri ver si de ai r bag modul e on st eeri ng
wheel and i nstall f our nut and washer assembl i es.
Ti ght en t o 4-5. 6 N-m ( 35- 50 lb-in) f or Town Car
and 2. 7-3. 7 N-m (24-33 lb-in) f or Cr own Vi ct or i a,
Grand Mar qui s.
6. NOTE: Be c a use ba t t e r y vol t age t o t he
power t r ai n cont rol modul e ( PCM) ( 12A650) wa s
i nt errupt ed, per f or mance may be a f f e c t e d until
t he powert rai n cont r ol modul e re-l earns dri vi ng
st r at egy .
Reconnect posi t i ve ba t t e r y cabl e.
7. Reconnect bat t er y gr ound cabl e.
8. Prove out air bag sy st e m. Ref er t o Sect i on
01-20B.
R e m o v a l T o w n Ca r
1. WARNI NG: THE POSI TI VE BATTERY CABL E
BAG COMPONENT I S SERVI CED.
NECESSARY FOR SYSTE M DEPLOYMENT IS
POWERED DI RECTLY FROM THE BATTERY
AND BACKUP POWER SUPPLY. TO AVOI D
PERSONAL I NJURY, THE BATTERY POSI TI VE
CABL E MUST BE DI SCONNECTED FOR ONE
MI NUTE TO DE-ENERGI ZE THE BACKUP
POWER SUPPLY PRIOR TO SERVI CI NG OR
REPLACI NG ANY SYSTE M COMPONENTS.
Di sconnect bat t er y ground cabl e.
2. Di sconnect posi t i ve ba t t e r y cabl e and wa i t one
mi nut e f or ba c kup powe r suppl y t o depl et e i t s
st or e d energy. Ref er t o Sect i on 01- 2 0B f or
Suppl ement al Ai r Bag Sy st e m.
3. Remove t wo ba c k cover pl ugs f r o m st eeri ng
wheel . Remove t wo sc r e w and wa she r
assembl i es ret ai ni ng dri ver si de ai r bag modul e t o
st eeri ng whe e l .
4. Di sconnect air ba g el ect ri cal connect or f r om ai r
ba g sli di ng cont act connect or. Di sconnect r ed
horn connect or f r om st eeri ng wheel assembl y .
5. WARNI NG: PLACE AI R BA G MODULE ON
Remove dri ver si de air ba g modul e f r o m st eeri ng
wheel .
6. Remove ba c k cover f r o m st eer i ng whe e l
assembl y.
7. Di sconnect spe e d cont r ol connect or f r o m ai r ba g
sl i di ng c ont a c t connect or .
8. Sli de 6-way spe e d c ont r ol connect or of f ba c k
cover.
9. Remove ba c k c ove r f r om st eer i ng wheel
assembl y . Pry off RH spe e d cont r ol swi t c h.
10. Fe e d spe e d cont r ol swi t c h t hr ough a c c e ss hole in
t he st eeri ng whe e l .
11. Repeat St eps 9 and 10 f o r LH spe e d cont r ol
swi t c h.
I n s t a l l a t i o n T o w n Ca r
1. Feed LH spe e d cont r ol swi t c h t hr ough LH a c c e ss
hol e l ocat ed in t he ba c k of t he st eeri ng wheel . Do
t he same f or t he RH spe e d cont rol swi t c h. Ensure
t hat spe e d cont rol swi t c h sna ps into t he st eeri ng
wheel .
2. Sli de 6-way connect or ont o ba c k cover.
3. Fast en ba c k cover ont o st eer i ng wheel . Ma ke
sure wi r e s are posi t i oned so t hat no wi r es ar e
pi nched when t he ba c k c ove r is assembl ed t o t he
st eeri ng wheel .
4. Connect speed cont r ol connect or f r om ai r ba g
sli di ng c ont a c t t o 6-way connect or in ba c k cover.
5. Post i i on dri ver si de ai r bag modul e on st eeri ng
wheel and connect ai r bag sli di ng cont act .
Connect red horn connect or .
6. Install dri ver si de air bag modul e on st eeri ng
wheel and i nstall t wo sc r e w and washer
assembl i es. Ti ght en sc r e ws t o 4-5. 6 Nm (35-50
lb-in).
7. Assembl e t wo ba c k cover pl ugs i nto t he st eeri ng
wheel .
8. NOTE: Because bat t er y vol t age t o t he
Power t r ai n Cont rol Modul e wa s i nt errupt ed,
per f or mance may be af f ect ed until t he Power t r ai n
Cont rol Modul e re-l earns dri vi ng st r at egy .
Reconnect posi t i ve ba t t e r y cabl e.
10. Prove out ai r bag sy st e m. Ref er t o Sect i on
01- 20B.
Sl i d i n g Co n t a c t , Air B a g
Speed Cont rol Servo
L7656-B
I t e m
Pa r t
1 9A825 Speed Control Actuator
2

Actuator Cable Cap (Part of
9A825)
3 9C735 Speed Control Servo
4

Cable Ball Slug (Part of
9A825)
5 Cap Locking Tabs (Part of
9A825)
6 Locki ng Arm (Part of 9A825)
7 N621905-S56 Nuts (3 Req'd)
A Tighten to 5-7 N-m ( 44-62
Lb-ln)
Re mo v a l
1. Remove ret ai ni ng cl i p f r om speed cont r ol
act uat or cabl e adj ust er f i t t i ng.
2. Push spe e d cont rol act uat or t ube out of adj ust er
f i t t i ng a t t a c he d t o t hr ot t l e cabl e.
3. Di sconnect 14401 har ness connect or at spe e d
cont r ol ser vo ( 9C7 35) .
4. Remove t hr ee nut s at t achi ng spe e d cont rol ser vo
t o vehi cl e.
5. Remove speed cont rol act uat or cabl e c a p f r om
spe e d cont rol ser vo by depr essi ng c a p l ocki ng
a r m and rot at i ng c a p count er cl ockwi se.
6. Remove speed cont rol act uat or cabl e slug f r om
spe e d cont rol servo pulley. Gent l y push act uat or
cabl e slug past ret ai ni ng spri ng usi ng a small
scr ewdr i ver .
PULLEY WITH METAL.
RETAINING SPRING
L8992-A
7. Remove br a c ke t f r om speed cont rol servo and
ret ai n br a c ke t and sc r e ws f or i nst allat i on on
speed cont rol ser vo.
1. At t a c h br a c ke t t o speed cont rol ser vo wi t h t hr ee
sc r e ws (par t No. W7 01510) . Ti ght en sc r e ws t o
8-11 N-m (6-8 Ib-f t ).
2. Ma ke sure t hat rubber seal i s fully seat ed ont o
speed cont r ol act uat or cabl e c a p.
3. NOTE: I ncorrect wr appi ng of speed cont rol
act uat or cabl e c or e wi r e around speed cont rol
ser vo pulley may result in a hi gh idle condi t i on.
Ensure t hat t hr ot t l e lever is at idle posi t i on af t er
speed cont rol act uat or cabl e i nstallati on and
adj ust ment .
Loc k cabl e ball sl ug into spe e d cont rol ser vo
pulley sl ot .
4. Pull on t hr ot t l e at t achment end of speed cont rol
act uat or cabl e t o d r a w cabl e c a p on t o speed
cont rol ser vo pulley.
5. Insert cabl e cap l ocki ng t a bs i nto speed cont rol
servo sl ot s. Rot at e c a p c l oc kwi se until l ocki ng
a r m engages l ocki ng t a b on speed cont rol se r vo.
6. Posi t i on speed cont rol act uat or ( 9A825) and
speed cont rol ser vo assembl y in vehi cl e. Ti ght en
mount i ng nuts t o 5-7 Nm (44-62 Ib-in)
7. At t a c h 14401 harness connect or t o speed
cont rol ser vo.
10- 03- 19 S p e e d Co n t r o l S y s t e mE l e c t r o n i c
i w w si y ~ :.
10- 03- 19
8. Adj ust spe e d cont r ol act uat or a s out l i ned and
i nst all ret ai ni ng cl i p.
S p e e d Co n t r o l A c t u a t o r
Remov al
1. Remove sc r e w at t achi ng air cl eaner out l et t ube
( 9B659) t o accel er at or cabl e br a c ke t ( 97 23) .
2. Remove t wo hose s f r om air cl eaner out l et t ube.
Loosen ai r cl eaner out l et t ube c l a mp at t hr ot t l e
body ( 9E926) . Pull ai r cl eaner out l et t ube f r om
t hr ot t l e body a nd posi t i on out of t he wa y .
3. Remove sc r e w at t achi ng spe e d c ont r ol act uat or
( 9A82 5) t o accel er at or cabl e br a c ke t .
4. Di sconnect spe e d cont r ol a c t ua t or f r om
a c c e l e r a t or cabl e ( 9A7 58) .
5. Remove spe e d cont r ol act uat or c a bl e c a p f r om
t he spe e d cont r ol se r vo ( 9C7 35) by depressi ng
c a p l ocki ng ar m and rot at i ng t he c a p
c ount e r c l oc kwi se .
L7656-B
Pa r t
2

Actuator Cable Cap (Part of
9A825)
4
.
Cable Ball Slug (Part of
9A825)
5

Cap Locki ng Tabs (Part of
9A825)
6

Locki ng Arm (Part of 9A825)
7 N621905-S56 Nut (3 Req'd)
A

Lb-ln)
10- 03- 2 0 S p e e d Cont roS S y s t e mE l e c t r o n i c 10- 03- 2 0
6. Remove speed control actuator cabl e sl ug from
spe e d cont rol ser vo pulley. Gent l y push act uat or
cabl e sl ug past ret ai ni ng spri ng usi ng a smal l
scr ewdr i ver .
PUSH IN THIS
DIRECTION
CABLE
SLUG
PULLEY WITH METAL.
RETAINING SPRING
RETAINING
SPRING
L8992-A
I nst al l at i on
1. Ma ke sure t hat rubber seal is fully se a t e d ont o
spe e d cont r ol act uat or cabl e c a p.
To wn Car Sho wn , Cr o wn Vi c t o r i a , Gr a n d Ma r qui s Si mi l ar
2. NOTE: I ncorrect wr appi ng of spe e d cont r ol
act uat or cabl e c or e wi r e around speed cont r ol
ser vo pulley may result in a hi gh idle condi t i on.
Ma ke sure t hat t hr ot t l e lever is at idle posi t i on
af t er speed cont rol act uat or i nst allat i on and
adj ust ment .
Lo c k speed cont rol act uat or cabl e ball sl ug i nto
speed cont rol ser vo pulley sl ot .
3. Pull on t hrot t l e body end of spe e d cont rol
act uat or cabl e t o dr a w cabl e c a p ont o speed
cont rol ser vo pulley.
4. Ali gn speed cont rol act uat or cabl e c a p t a bs wi t h
sl ot s in speed cont rol servo housi ng. Insert c a p
i nto t he speed cont rol ser vo and r ot at e c l o c kwi se
until t he l ocki ng a r m engages.
5. Rout e speed cont rol act uat or cabl e behi nd powe r
br ake boost er ( 2005) and al ong val ve c ove r
underneat h fuel li nes. Posi t i on speed cont r ol
act uat or cabl e into ret ai ni ng cl i ps.
6. Snap speed cont rol act uat or cabl e ont o
accel er at or cabl e and i nstall sc r e w ( N610959) at
accel er at or cabl e br a c ke t . Ti ght en t o 3-4 N-m
(27-35 Ib-in).
7. Check speed cont rol act uat or cabl e adj ust ment
a s out l i ned.
8. Connect air cl eaner out l et t ube and hose a s
out li ned in Sect i on 03-12.
L8253-C
Pa r t
1 N610959-S56 Screw
2

Actuator Cable Adj uster
Fitting (Part of 9A825)
Pa r t
( Co n t i n ue d )
10- 03- 2 1
S p e e d Co n t r o l S y s t e mE l e c t r o n i c 10- 03- 2 1
I t em
Par t
6 9C809 Speed Control Bracket Plate
I t em
Par t
Nu mb e r Descr i pt i on
A

Lb-ln)
Re mo v a l
Remove bol t ret ai ni ng VSS mount i ng cl i p t o
t ransmi ssi on.
2. Remove vehi cl e speed sensor (VSS)(9E731) and
dri ven gear f r o m t r ansmi ssi on.
TRANSMISSION
7000
VEHICLE
SPEED
SENSOR
9E731
WIRING
HARNESS
L3921-F
3. Di sconnect el ect ri cal c onne c t or f r om vehi cl e
spe e d sensor.
Remove speedomet er dri ven gear ret ai ner
( 17292) . Remove dri ven gear f r o m vehi cl e spe e d
sensor.
1. Posi t i on dri ven gear t o vehi cl e spe e d sensor.
Install gear ret ai ner.
2. Connect el ect r i cal connect or.
3. Insert vehi cl e spe e d sensor i nt o t ransmi ssi on
housi ng. Install ret ai ni ng bol t . Ti ght en t o 4-6 N-m
(35-53 lb-i n).
2. NOTE: Si nce t he swi t c h si de pl at e nearest t he
br ake pedal ( 2 455) i s sl ot t e d it is not ne c e ssa r y
t o remove t he br a ke mast er cyl i nder push r o d
and one spa c e r wa she r f r o m t he br a ke pedal pi n.
Remove t he hai rpi n ret ai ner. Sli de t he st opl i ght
swi t c h, t he push r od and t he nylon wa she r s and
bushi ng a wa y f r o m t he br a ke pedal , and r emove
t he st opl i ght swi t c h by sli di ng t he st opl i ght swi t c h
up and down.
1. CAUTI ON: Do n o t s u b s t i t u t e o t h e r t y p e s o f
pan r e t a i n e r s , r e p l a c e o n l y wi t h a p r o d u c t i o n
ha i r pi n r e t a i n e r .
Posi t i on st opl i ght swi t c h so t hat t he U-shaped
si de is nearest t he pedal and di rect l y over a nd
under t he pi n. Then sl i de swi t c h down a nd up
t rappi ng t he mast er cyl i nder push r od and bl ack
bushi ng be t we e n t he swi t c h si de pl at es. Push
st opl i ght swi t c h and push r o d assembl y f i rml y
t o wa r d br a ke pedal a r m. Assembl e out si de whi t e
pl ast i c wa she r t o pin and i nstall hai rpi n ret ai ner t o
t r a p whol e assembl y .
2. NOTE: St opl i ght swi t c h wi r e harness must have
suf f i ci ent l engt h t o t ravel wi t h st opl i ght swi t c h
duri ng full st r o ke of st opl i ght swi t c h. If wi r e l engt h
is i nsuf f i ci ent , r er out e harness or ser vi ce as
requi red.
Assembl e t he wi r e harness connect or t o t he
st opl i ght swi t c h.
3. Check st opl i ght swi t c h f or proper oper at i on.
S t o p l i g h t S w i t c h
Re mo v a l
1. NOTE: Loc ki ng t a b on connect or must be l i f t ed
bef or e c onne c t or can be r e mo ve d .
Di sconnect t he wi r e harness at t he connect or
f r o m t he st opl i ght swi t c h ( 13480) .
De a c t i v a t o r S w i t c h
Re mo v a l
1. Remove el ect ri cal connect or f r om deact i vat or
swi t c h.
2. Unscr ew deact i vat or swi t c h and r emove f r om
br a ke pr essur e cont r ol val ve ( 2B091) (vehi cl es
wi t h ant i -l ock br a ke s) or br ake pr essur e swi t c h
adapt er ( 2C300) (vehi cl es wi t h convent i onal
hydraul i c br a ke s).
1. Sc r e w deact i vat or swi t c h i nto br a ke pressure
cont r ol val ve or br a ke pressure swi t c h adapt er.
Ti ght en t o 15-20 N-m(11-15 Ib-ft).
2. At t a c h el ect ri cal connect or.
3. Bl eed br ake lines as outli ned in Sect i on 06-09
(ant i -l ock br a ke s), or Sect i on 06-06 (convent i onal
hydraul i c br a ke s).
10- 03- 22 Speed Cont r ol Sy s t emEl ec t r oni c 10- 03- 22
Br a ke Pr e ssur e Cont rol Val ve Locat i on
WIRING HARNESS
CONNECTOR
FRONT OF
VEHICLE
DE A C T I V A T O R
SWITCH
( P A R T O F 2B091
B R A K E P R E S S U R E
C O N T R O L V A L V E
2 B0 9 1
L7665-D
Junct i on Bl ock Locat i on
B R A K E
P R E S S U R E
S WI T C H
A D A P T E R
2C300
D E A C T I V A T O R
SWITCH
L8140-B
ADJUSTMENTS
Actuator Cable
1. Remove ret ai ni ng cl i p f r om act uat or cabl e
adj ust er at t hr ot t l e body (9E926).
2. Ma ke sure t hr ot t l e is in fully cl osed posi t i on.
3. CAUTI ON: T h e s p e e d c o n t r o l a c t u a t o r c a b l e
mu s t n o t b e pu l l e d t i gh t , o t h e r wi s e s p e e d
c o n t r o l ma y n o t o p e r a t e p r o p e r l y .
Pull on speed cont r ol act uat or cabl e t o t a ke up
sl ack, t hen back off at l east one not ch so t her e is
appr oxi mat el y 3 mm ( 0. 118 i nch) of sl ack in t he
speed cont rol act uat or cabl e.
4. Insert speed cont rol act uat or cabl e ret ai ni ng cl i p
and snap i nto pl ace.
5. Check t hat t hr ot t l e l i nkage oper at es f reel y and
smoot hl y.
10- 03- 2 3 S p e e d Co n t r o l S y s t e mE l e c t r o n i c 10- 03- 2 3
ADJUSTMENTS ( C o n t i n u e d )
To wn Car Sho wn , Cr o wn Vi c t o r i a , Gr a n d Ma r qui s Si mi l ar
Pa r t
1 N610959-S56 Screw
2

Actuator Cable Adj uster
Fitting (Part of 9A825)
( Co n t i n ue d )
I t e m
Pa r t
4 9A758 Accelerat or Cable
6 9C809 Speed Control Bracket Plate
A

Lb-ln)
B r a k e P e d a l H e i g h t
1. Wi t h t he engi ne running f or full powe r br a ke
operat i on and t he parki ng br a ke fully r e l e a se d,
measure t he br a ke pedal ( 2 455) f r ee hei ght .
2. NOTE: " A " Di mensi on t o be measur ed t o sheet
met al f r o m cent er of pa d on t he a c c e l e r a t or pedal
si de of t he br a ke pedal pa d .
" B " Di mensi on t o be measur ed paral l el t o t he
vert i cal cent er line of t he st eeri ng col umn wi t h a
111. 2 N ( 2 5 lb) l oad appl i ed t o t he cent er line of
t he br a ke pedal pa d. ( Che c ks on powe r br a ke
vehi cl es ma de wi t h engi ne runni ng.)
Insert a sl ender, shar p-poi nt ed pr od t hr ough t he
f l oor c a r pe t ( 13000) and sound deadener t o t he
dash panel ( 01610) met al . Measur e t he di st a nc e
t o t he cent er on t o p a c c e l e r a t or pedal si de of t he
br a ke pedal pa d .
3. If t he posi t i on of t he br a ke pedal i s not wi t hi n
speci f i cat i on, c he c k t he br a ke pedal f or mi ssi ng,
wor n or d a ma ge d bushi ngs, or l oose ret ai ni ng
bol t s and r e pl a c e if r equi r ed.
4. If t he br a ke pedal f r ee hei ght i s sti ll out of
speci f i cat i on, c he c k t he br a ke pedal , po we r
br a ke boost e r ( 2 005) or br a ke mast er cyl i nder
( 2140) t o be sur e t he c o r r e c t par t s ar e i nst al l ed.
Repl ace t he wo r n or d a ma ge d pa r t s as
necessar y.
90 DEGREES
B MAX
GAUGED
SURFACE
TRAVEL TEST TO BE MADE WITH
PARKING BRAKE IN RELEASED POSITION
H8034-A
VE HI CL E
BRA KE P E DA L FRE E
HEI GHT " A " (REF. ONLY)
MA X I MUM
BRA KE
P E DA L
T RA VE L
( I NCHE S)
" B"
VE HI CL E MA X. MI N.
MA X I MUM
BRA KE
P E DA L
T RA VE L
( I NCHE S)
" B"
St a n d a r d 2 1 0 m m
( 8. 3 I n c he s )
191 mm
( 7 . 5 I n c h e s )
7 6. 2 mm
( 3. 5 I n c h e s )
Po l i c e 2 2 1 mm
( 8. 7 I n c he s )
2 04 mm
( 8. 0 I n c h e s )
7 6. 2 mm
( 3. 5 I n c h e s )
10- 03- 2 4 S p e e d Co n t r o l S y s t e mE l e c t r o n i c 10- 03- 2 4
SPECIFICATIONS
POWERTRAIN CONTROL/EMI SSI ONS DIAGNOSIS
OBDI I 3. 8L Mu s t a n g , 4. 6L To wn Car, Cr o wn Vi c t o r i a ,
Co u ga r
OBDI A l l Ot h e r Ve h i c l e s
TA1000B
S p e e d Co n t r o l Se r v o Nut 5-7 44- 62
S p e e d Co n t r o l A c t u a t o r
Ca b l e - t o - A c c e l e r a t o r Ca b l e
Br a c k e t S c r e w
3- 4 2 7 - 35
De a c t i v a t o r S wi t c h 15- 20 11- 15
( L b - Ft )
Ai r Ba g Mo d u l e Nut ( To wn Ca r ) 4- 5. 6 35- 50
Ai r Ba g Mo d u l e Nut ( Cr o wn
2. 7 - 3. 7 2 4- 33
Br a c k e t t o S p e e d Co n t r o l Se r v o
S c r e w
8- 11 6- 8 ( L b - Ft )
Ve h i c l e S p e e d Se n s o r Re t a i n i n g
Bo l t
4- 6 35- 53
ROTUNDA EQUIPMENT
11- 00- 1
GROUP
STEERING SYSTEM 11
SECTI ON TI TLE PAGE
STEERING COLUMN .... 11-04-1
STEERING COLUMN SWITCHES 11-05-1
STEERI NG LINKAGE.... 11-03-1
SUBJECT PAGE
I dent i f i cat i on. . . . 11-00-2
EVO Steeri ng Di agnosi s. ........11-00-13
Pinpoint Tests 11-00-14
SERVICE PROCEDURES
Air Purge wi t h Vacuum External Source
Procedure 11-00-28
External Leakage 11-00-25
Fill Procedure 11-00-29
Fluid Leak 11-00-27
Fluid Level Top-Off Procedure 11-00-27
Preliminary Procedures 11-00-23
Pump Flow and Pressure Tests 11-00-25
SECTION TITLE PAGE
STEERING SYSTEM, POWER 11-02-1
STEERING SYSTEMSERVICE 11-00-1
SUBJECT PAGE
SERVICE PROCEDURES (Cont' d.)
Purgi ng Power Steeri ng System of Air 11-00-27
Sensi ti ve Steeri ng Di agnosti c and Service
Procedure 11-00-24
Start-Up Procedure, After Power Steeri ng
Pump or Gear Servi ce 11-00-29
Steeri ng Col umn Beari ng 11-00-27
Steeri ng Pump, Power 11-00-30
Steeri ng Wheel Free Play 11-00-27
Tie Rod Arti cul ati on Torque.... .11-00-27
Turning Effort Check 11-00-23
Flushing 11-00-31
Steeri ng Gear 11-00-31
SECTION 11-00 Steering SystemService
VEHICLE APPLICATION
11- 00- 2 St e e r i n g S y s t e mS e r v i c e 11- 00- 2
I d e n t i f i c a t i o n
S t e e r i n g Ge a r Mo d e l
Steering gears are identified by a servi ce identification
t ag fastened t o the assembl y. Tags contai n
i nf ormat i on as shown in t he i l l ust rat i on.
STEERING GEAR
MODEL CODE
SPA-EY
4 E 7 B
SHIFT CODE
YEAR, MONTH, DAY
BUILD DATE CODE
LOCATION: ON 3548 AT OPPOSITE
END OF INPUT SHAFT G7151-B
The power st eeri ng pump ( 3A67 4) has a servi ce
i dent i f i cat i on t a g t o i dent i f y assembl i es f or servi ce
pur poses.
TAG LOCATION ON PUMP BODY
HBD-AA"
-MODEL
YEAR MONTH SHIFT DAY
G5870-D
P o w e r S t e e r i n g P u mp
The CHI powe r st eeri ng pump has t he f ol l owi ng
f eat ures:
It is a belt dri ven, vane-t ype, power st eeri ng pump.
It i s mount ed di rect l y t o t he engi ne bl ock by f our
An el ect roni c vari abl e ori f i ce (EVO) power st eeri ng
cont rol val ve act uat or ( 37 83) is connect ed t o t he
pump body t o provi de speed sensi t i ve power
st eeri ng assi st .
The el ect ri cal connect or and casi ng are abl e t o
swi vel . Thi s is normal and does not i ndi cat e a l oose
powe r st eeri ng cont rol val ve act uat or assembl y.
The power st eeri ng oil reservoi r ( 3A697 ) f or t he
powe r st eeri ng flui d is mount ed on t he LH apr on.
An i dent i f i cat i on t a g a t t a c he d t o t he power st eeri ng
pump i ndi cat es t he model number and bar c ode .
Ref er t o t hese when a new power st eeri ng pump is
requi red.
POWER STEERING
CONTROL VALVE
ACTUATOR
3783
POWER STEERING
PUMP
3A674 G5S74-D
NOTE: The power st eeri ng pump is ser vi ced a s an
assembl y. If any ser vi ce is requi red, t he ent i re power
st eeri ng pump assembl y must be r epl aced. The only
except i on is if t he EVO power st eeri ng cont rol val ve
act uat or or connect or on t he power st eeri ng pump
assembl y is f ound t o be damaged; t hen repl ace t he
power st eeri ng cont rol val ve act uat or only.
Ref er t o Sect i on 11-02 f or more i nf ormat i on on t he
EVO sy st e m.
In t he event of an el ect ri cal ci rcui t mal f unct i on, such as
ci rcui t open, shor t e d, or cont rol l er f ai l ure, t he power
st eeri ng cont rol val ve act uat or wi ll provi de full powe r
st eeri ng assi st duri ng such f ai lure modes.
Cont i nued operat i on under such condi t i ons may cause
excessi vel y hi gh power st eeri ng flui d t emper at ur e and
damage t he st eeri ng component s.
11- 00- 3
St e e r i n g S y s t e m S e r v i c e 11- 00- 3
El e c t r oni c Vari abl e Ori f i ce (EVO) St eer i ng Sy st e m Cr own Vi ct ori a, Gr and Marquis (Without Ai r Suspe n si o n )
See EVTM f o r mo r e d e t a i l s
of this circuit
E L E CT RONI C VA RI A BL E
ORI FI CE ( EVO) T E S T
CONNE CT OR
844 1 GY/ R
I
x x
6
X
12
SOLID STATE
13
' 1 ELECTRONIC
. VARIABLE
1 ORIFICE (EVO)
1 CONTROL
\ MODULE
I
41XG/LG
432
T
BK/PK
33
X
1 A x 5
BK/ P K 330 | Y/ L G 3 5 3 j ^ L B
86 I GY/ O 87 X T / Y
ELECTRONIC
VARIABLE
ORIFICE
(EVO)
ACTUATOR
T
57 I BK
G7179-B
ELECTRONIC VARIABLE ORIFICE (EVO)
CONTROL MODULE CONNECTOR
G7790-A
Pi n
1 633 ( R) St e e r i n g Wh e e l Ro t a t i o n Ra t e
I nput
2 844
( G Y/ R)
E VO Te st Co n n e c t o r Di a gn o s t i c
I nput
3 419
( DG/ L G)
E VO Te st Co n n e c t o r Di a gn o s t i c
I nput
4 432
( B K / P K )
EVO Te st Co n n e c t o r Gr o un d
6 634 ( BR) St e e r i n g Wh e e l Ro t a t i o n Ra t e
I nput
7 2 9 8 ( P / O ) Ba t t e r y P o we r
8 676
( P K / O )
Ve h i c l e S p e e d I nput (-)
9 67 9
( G Y/ B K )
Ve h i c l e S p e e d I nput ( + )
10 No t Us e d
11 No t Us e d
( Co n t i n ue d )
11- 00- 4 St eer i ng Sy s t e mSe r v i c e 11- 00- 4
Pin
12 837
( Y/ B K )
St e e r i n g Wh e e l Ro t a t i o n Se n s o r
Gr o un d
13 330
( Y/ L G )
E VO A c t u a t o r Co n t r o l B +
14 353 ( L B) E VO A c t u a t o r Co n t r o l B-
Pin
1 No t Us e d
2 432
( B K / P K )
Gr o u n d
3
_
No t Us e d
4 419
( DG / L G )
Di a gn o s t i c I nput
5 844
( G Y/ R)
Di a gn o s t i c I nput
6 No t Us e d
ELECTRONIC VARIABLE ORIFICE
(EVO) TEST CONNECTOR G 7 8 2 0 - A
El e c t r o n i c Var i abl e Or i f i c e (EVO) St e e r i n g C r o w n Vi c t o r i a , Gr a n d Ma r qui s (Wi t h Ai r Suspe n si o n )
r
VEHICLE
SPEED
SENSOR
(VSS)
-I -
I
I JTAI R
I POWER
DISTRIBUTION
r T - - | FUSE
1 t
1 7
i JUNCTION
I \ I PANEL
AIR
SUSPEN-
SION
SWITCH
GY/BK
I
STEERING
WHEEL
ROTATION
SENSOR
418 I DG/Y
I 1 'T
P/O 633
I" - I " T
i i
1 C1-7 C1-1 C1-15 C1-16
SOLID STATE
1 AIR
C1-18 C1-19 i SUSPENSION/
1
ELECTRONIC
1 VARIABLE
! ORIFICE
1 (EVO)
Y/BK
of this circuit
G7789-A
11- 00- 6 Steering S y s t e m
t S e r v i c e 11- 00- 6
El ect r oni c Vari able Ori f i ce (EVO) St eeri ng To wn Ca r
of this circuit
G7791-A
DIAGNOSIS AND TESTING (Conti oyed)
VARIABLE ORIFICE (EVO) CONTROL
F7816-C
Pin
1 418
( DG / Y)
Ba t t e r y P o s i t i v e Vo l t a ge ( B + )
2 No t Us e d
3 42 8
( O / B K )
I nput ( L o w I n d i c a t o r )
4 844
( G Y/ R)
Da t a Li n k Co n n e c t o r ( DL C) I nput
( To wn Ca r On l y )
5 344
( B K / Y)
Co u r t e s y L a mp S wi t c h I nput
7 67 9
( G Y/ B K )
Ve h i c l e S p e e d Se n s o r ( VSS) I nput
B +
15 418
( DG / Y)
B +
16 2 95
( L B / P K )
' 2 98 ( P / O )
I gn i t i o n RUN I nput
17 42 7
( P K / B K )
I nput ( Hi gh I n d i c a t o r )
18 6 3 3 ( R ) St e e r i n g Wh e e l Ro t a t i o n Ra t e
I nput
19 634 ( BR) St e e r i n g Wh e e l Ro t a t i o n Ra t e
I nput
2 0 67 6
( P K / O )
Ve h i c l e S p e e d Se n s o r ( VSS) I nput
B-
VARIABLE ORIFICE (EVO) CONTROL
F7815-C
Pi n
8 432
( BK / P K )
Re a r Ai r Su s p e n s i o n He i ght Se n s o r
Gr o un d An d Di a g n o s t i c Gr o un d
9 844
( G Y/ R)
I nput )
10 No t Us e d
11 419
( DG / L G )
Wa r n i n g I n d i c a t o r Out put
12 6 3 5 ( Y) St e e r i n g Mo d e Se l e c t ( To wn Ca r )
13 1071
( BR/ P K)
LH Ai r Spr i n g So l e n o i d Co n t r o l
14 86 ( G Y/ O) EVO A c t u a t o r Co n t r o l Out put
2 1 Not Us e d
2 2 4 2 9 ( P / L G ) Re a r Ai r Su s p e n s i o n He i ght Se n s o r
P o we r Out put
2 3 42 0
( DB/ Y)
Co mp r e s s o r Re l a y Co n t r o l
2 4 42 1 ( PK) Ve nt So l e n o i d Co n t r o l
2 5 1072
( T / W)
RH Ai r Spr i n g So l e n o i d Co n t r o l
2 6 87 ( T / Y) EVO A c t u a t o r Fe e d b a c k
1. Verify t he vehicle owner' s original concerns by
operati ng the steering syst em t o dupl i cate the
condi ti on.
2. Inspect t o determine if any of t he fol l owi ng
mechani cal or electrical concerns appl y:
Mechanical Electrical
Ti r e p r e s s u r e , l o o s e

Op e n f u s e s .
wh e e l s .

Ci r c ui t r y ,
L o o s e t i e r o d e n d s , i nner c o n n e c t i o n s o p e n ,
ba l l j o i n t s . gr o u n d i n g o r s h o r t i n g .
L o o s e s u s p e n s i o n s t r u t s o r

St e e r i n g wh e e l r o t a t i o n
ba l l j o i n t s . se n so r .
L o o s e un i v e r s a l j o i n t s .

Ve h i c l e S p e e d Se n s o r .
L o o s e c o n n e c t i n g b o l t s on

P o we r s t e e r i n g pu mp
c o l u mn i n t e r me d i a t e s h a f t . a c t u a t o r v a l v e .
L o o s e s t e e r i n g ge a r

EVO c o n t r o l
a s s e mb l y . m o d u l e L S / L X .
I mp r o p e r d r i v e be l t t e n s i o n .

Co mp u t e r c o n t r o l a i r
Bi n d i n g o r mi s a l i gn e d s u s p e n s i o n .
s t e e r i n g c o l u mn .
P o we r s t e e r i n g p u mp , f l ui d
l e v e l , h o s e l e a k o r l i ne
r e s t r i c t i o n s .
3. If t he concer n(s) remai n af t er t he i nspect i on,
pe r f or m t he Di agnost i cs usi ng t he Super St ar II a s
out l i ned. Ret ri eve Di agnost i c Troubl e Codes
(DTCs) and go t o t he Sy mpt om Chart .
Use Rot unda Di gi t al Vol t -Ohmmet er 014- 00407 or
equi val ent t o per f or m t he f ol l owi ng pi npoi nt t e st s.
EVO DIAGNOSIS
Steering Very Di ffi cult/ Very Easy Power steering pump actuator
valve.
Steering wheel rotation sensor.
EVO control module.
Computer controlled suspension.
GO to EVO Steering Diagnosis.
PERFORM Actuator Output Circuit
Test, Steering Wheel Sensor Test
and Vehicle Speed Sensor Test.
(Pinpoint Test J for EVO Computer
Controlled Suspension System.)
Engine Stalls with High Wheel
Rotation
Inoperative idle speed control
circuit.
REFER to Powertrain
Emi ssi ons/Control Diagnosis
Manual.
1
Steering Does Not Vary with
Increased Wheel Rotation
Steering wheel rotation sensor
inoperative.
Open/short ed circuitry.
PERFORM Steering Wheel Sensor
Test. (Pinpoint Test J for EVO
Computer Controlled Suspension
System.)
Steering Does Not Vary With
Vehicle Speed
EVO control module.
Automatic shock control module.
PERFORM vehicle Speed Sensor
Test. (Pinpoint Test K for EVO
Computer Controlled Suspension
System.)
GO t o Section 04-05.
Steering Diagnostics Can Not Be
Entered
"EVO" control module.
Automatic shock control module.
GO to Pinpoint Test H. (Pinpoint
Test L for EVO Computer
Controlled Suspension System.)
I
i,
i
STEERING SYSTEM DIAGNOSIS
NOTE: Evaluation should be
conducted on a level road (little road
crown)
Steering Drift / Wander
Condition Where t he Vehicle
Wanders Side-To-Side on the
Roadway When it is Driven Straight
Ahead While the Steering Wheel is
Held in a Firm Position
Check ti re size and pressure.
Check if vehi cle is unevenly loaded
or overloaded.
Loose/worn front wheel spindle tie
rods or ball socket .
Steering gear mounting insulators
and/ or retaining bolts loose or
damaged.
Loose front suspension lower arm
struts or ball j oi nt(s).
Steering column gear input shaft
coupling connecting bolts loose.
coupling j oints l oose/worn.
Improper wheel alignment.
Excessive friction between
components.
Excessive toe-i n.
Be sure t i re si zes are correct and
ADJUST ti re pressures. REFER to
Section 04-04.
ADJUST load.
REPLACE front wheel spindle ti e
rod or tie rod end assembly as
necessary.
REPLACE bol t s. REFER to Secti on
11-02.
REPLACE arm and ball j oint
assembly. REFER to Secti on
04-01.
TIGHTEN at gear and at column.
REFER t o Secti on 11-04.
REPLACE steeri ng column gear
input shaft coupling assembly.
REFER t o Section 11-04.
ADJUST as requi red. REFER t o
Section 04-01.
REFER t o Sensitive Steering
Dignostic and Servi ce Procedure.
CHECK alignment. REFER to
Section 04-00.
Pulls to One Side A Condition
Where the Vehicle Tends to Pull t o
One Side When Driven on a Level
Surface
Improper tire size or different type.
Vehicle is unevenly or excessi vely
loaded.
Damaged front suspension
components.
Damaged rear suspension
components.
Steering gear valve effort out of
balance.
Check front and rear brakes for
proper operation.
Check for bent rear axle housing
and for damaged or sagging front
coi l springs in the front and/ or rear
suspension.
Check for damaged air spring in
the front and / or rear suspension.
Check rear suspension for
l oose/worn rear shock absorber
struts, suspension arm retaining
fasteners.
ADJUST ti re pressure.
REPLACE as requi red. REFER t o
Section 04-04.
ADJUST load.
ADJUST as required.
REFER t o Section 04-01 for front
suspension replacement.
REFER t o Section 04-02 for rear
suspension replacement.
PLACE transmission in NEUTRAL
while driving and TURN engine off
(coasti ng). If vehicle does not pull
with the engine off, REPLACE the
steering gear valve assembly.
REFER t o Section 11 -02. If vehicle
does drift with engine off:
CROSS swi t ch front
t i re/wheel assembli es.
I f vehicle pulls t o opposi te
si de, CROSS swi tch t i r e/ wheel
assemblies that were on the rear
to same side on the front.
I f vehicle pull direction is not
changed, CHECK front suspension
components and wheel alignment.
ADJUST if necessary. REFER t o
Section 06-00.
REPLACE if necessary. REFER t o
Section 04-01 for front suspension
or Section 04-02 for rear
suspension.
REPLACE if necessary. REFER to
Section 04-02.
TIGHTEN all retaining fasteners.
STEERING SYSTEM DIAGNOSIS (Cont i nued)
Feedback (Rattle, Chuckle,
Knocking Noises in Steering Gear)
Condition Where Roughness is
Felt in the Steering Wheel by the
Driver When the Vehicle is Driven
Over Rough Pavement.
coupling j oints l oose/worn.
Loose front wheel spindle tie rods.
Steering gear retaining bolts loose
or damaged.
coupling connecting bolts loose.
Loose suspension bushi ngs/
fasteners or ball j oi nts.
Check steering gear adj ustments.
Check steering column conditions.
REPLACE steering column gear
REPLACE front wheel spindle tie
rods.
REPLACE retaining bolts and
ti ghten. REFER to Section 11-02.
TIGHTEN bolts to speci fi cati on at
steering gear and at steering
column gear input shaft coupling.
REFER to Section 11-02 or 11 -04.
TIGHTEN suspension fasteners,
REPLACE worn bushings, or
REPLACE ball j oi nts. REFER to
Section 04-01.
REFER to Section 11 -04.
Poor Returnability, Sticky Feel
Condition Noti ced When the
Steering Fails to Return to Center
Following a Turn Without Manual
Effort From the Driver. In Addi ti on,
When the Driver Returns the
Steering Wheel to Center, it May
Have a Sti cky or Catchy Feel
Improper ti re size or incorrect t ype.
Misaligned steering column or
column flange rubbing steering
wheel and/ or flange.
coupling universal j oints binding.
Check for steering column tube
boot tears and / or evidence of
binding or damage to front wheel
spindle tie rods.
Damaged/worn front suspension
components.
Column bearing binding.
Contamination in system.
ADJUST tire pressures.
REPLACE as required. REFER to
Section 04-04.
ALIGN steering column. REFER to
Section 11-04.
REPLACE steering column gear
REPLACE as necessary. REFER to
Section 11-04.
INSPECT control arm ball j oi nts.
REFER to Section 04-01 for
replacement.
ADJUST toe as required. REFER to
Section 04-00.
REPLACE bearing. REFER to
Section 11-04.
FLUSH power steering syst em.
REFER to Service procedure.
Light Steering Efforts at All Vehicle
Speeds
Electronic variable orifice (EVO). Vehicles with air suspension, GO
to Pinpoint Test B.
Vehicles without air suspension,
Excessi ve Steering Effort While
Making Quick Maneuvers at High
Speed
Electronic variable orifice (EVO). Vehicles with air suspension, GO
to Pinpoint Test B.
STEERING SYSTEM DIAGNOSIS (Cont i nued)
Heavy Steering Efforts, Poor
Assist or Loss of Assi st
Condition Recognized by the
Driver While Turning Corners and
During Parking Maneuvers
Low power steering pump fluid.
Steering gear assembly external
or internal leak.
Power steeri ng pump external
leak.
Improper drive belt tensi on.
Hose or cooler external leak.
Improper engine idle speed.
Power steeri ng pump pulley loose
or warped.
Power steeri ng pump
f l ow/pressure not to
Hose or cooler line rest ri ct i on.
System contamination.
EVO power steering control valve
actuator sti cki ng.
FILL as required and CHECK for
system leaks.
REPLACE power steeri ng pump.
ADJUST drive belt tensi on. REFER
t o Section 03-05.
SERVICE/REPLACE as
necessary. REFER t o Section
11-02.
ADJUST idle. REFER to Powertrain
Cont rol/Emi ssi ons Diagnosis
Manual
2
.
REPLACE power steeri ng pump
pulley. REFER to Section 11-02.
CLEAN or REPLACE as necessary.
INSPECT system for foreign
obj ect s, kinked hose, etc.
FLUSH syst em.
Vehicles with air suspension, GO
to Pinpoint Test B.
Fluid Leakage Overfilled system.
Component leak.
CORRECT fluid level as required.
LOCATE suspect component, and
REFER to Section 11-02 for
service.
Drive Belt Squeal Check drive belt for proper tension
or glazing.
TIGHTEN or REPLACE drive belt as
required. REFER to Section 03-05.
Power Steering Pump Noisy Low fluid level and possible leak. REFILL to speci fi ed level. PURGE
air from system. CHECK for leaks.
Swish Type Noise Fluid flow into the bypass valve of
the pump valve housing with fluid
temperature below 54C (130F).
Normal noise.
Whine Type Noise Aerated fluid, vacuum leak in
syst em.
Check valve cover O-ring seal.
PURGE system of air. REFER t o
Service Procedures.
REPLACE power steering pump.
Clicking Type Noise Excessi ve power steering pump
wear.
11- 00- 12
St e e r i n g S y s t e mS e r v i c e 11- 00- 12
STEERING SYSTEM DIAGNOSIS (Continued)
Power Steering Pump /Remot e
Power Steering Pump Auxiliary
Reservoir Leaks
Excessive fluid fi ll.
Fluid cap missing, loose, damaged
or missing O-ring.
Loose or damaged hose fi tti ngs.
Leakage at shaft seal:
1. Seal damage.
2. Rotor shaft damage, such as
helical grooving or the OD has
an axi al scrat ch.
3. Shaft bushing worn.
Rear cover seal damaged.
Damaged inlet tube.
Housing porosity.
Loose outlet fi tti ng, nut, plug valve.
Outlet fi tti ng, nut, plug damaged.
ADJUST fluid to proper level.
SERVICE or REPLACE, if required.
SERVICE or REPLACE.
TIGHTEN as required. REFER to
Section 11-02.
Power Steering Pump Leaks, EVO
Power Steering Control Valve
Actuator
Damaged EVO power steering
control valve actuator ring.
actuator electri cal connector
damaged.
actuator damaged.
Vehicles with air suspension, GO
to Pinpoint Test B.
POWER STEERING PUMP NOISE DIAGNOSIS
Drive Belt Squeal (Particularly at
Full Steering Wheel Travel and
Stand Still Parking)
Loose drive belt. ADJUST drive belt tension t o
speci fi cati on. REFER to Section
03-05.
Chirp Noise in Steering Pump Loose or worn drive belt. ADJUST drive belt tension to
speci fi cati on or REPLACE drive
belt. REFER to Section 03-05.
Swish Type Noise A noise created by the flow of
excessi ve fluid into the bypass
port of the pump valve housing
(with temperature below 130).
The shearing effect of the cooler
(heavier) fluid is not detrimental to
power steering pump operati on.
A normal condition. Noise will
diminish with fluid temperature
increase.
Power Steering PumpNo or
Poor Assi st
Contamination can be caused by
foreign obj ects in the power
steering oil reservoir or power
steering pump or metallic parti cles
being generated by cam pack
di screpanci es.
System must be flushed thoroughly
when installing a serviced or new
power steering pump. REFER to
Service Procedures.
Moan or Whine Type Noise Fluid aeration.
Power steering pump loose or
misaligned on engine.
Low flui d.
Hose grounded.
Steering column grounded.
Damaged internal components.
PURGE the power steering system
to reduce aeration noise. REFER t o
TIGHTEN or ALIGN as required.
CHECK fluid level.
CHECK for hose being grounded.
CHECK steering column tube
alignment. REFER to Section
11-04.
E VO Steeri ng Diagnosis
Using the Super Star (I
The Cr o wn Vi c t o r i a / Gr a n d Marqui s wi t hout ai r
suspensi on is equi pped wi t h a st and al one EVO
st eer i ng cont r ol modul e. Thi s cont rol modul e is
di a gnose d usi ng t he Super St ar II, par t number
007 - 0041B or equi val ent .
The Da t a Li nk Connect or (DLC) used t o communi cat e
wi t h t he EVO cont r ol modul e is l ocat ed on t he ri ght
hand si de of t he l uggage compar t ment .
E n t e r i n g E VO Di a g n o s t i c s
When t he St ar Test er is connect ed, t he engi ne is
st a r t e d and t he HOL D/ TEST but t on i s l a t c he d d o wn ,
t he EVO cont rol l er wi ll respond by sendi ng a c o d e 20
t o t he St ar Test er whi c h represent s "Di a gnost i c s
mode e n t e r e d ". If t he DTC 2 0 is not di spl a y e d, go t o
Pi npoi nt Test H.
Once t hi s mode is ent er ed, t he EVO cont rol l er wi ll
cont i nuousl y c y c l e t hr ough a menu of f i ve t e st s. The
EVO cont rol l er wi l l scrol l t hr ough t hese t e st s wai t i ng
ei ght se c onds bef or e proceedi ng t o t he ne xt t est . If at
any t i me in t he ei ght -second peri od t he St ar Test er line
is t oggl e d hi gh by unl at chi ng t he HOL D/ TE ST but t on
f or at l east one se c ond but l ess t han ei ght , t hen
t oggl e d ba c k l ow by rel at chi ng t he HOLD / TEST
but t on, t he EVO cont rol l er wi ll ent er and run t hat
sel ect ed t e st . If t he HOL D/ TEST but t on i s unl at ched
f or t he ent i re ei ght se c onds in bet ween any of t he
t e st s, t he EVO cont rol l er wi ll exi t di agnost i c mode and
resume oper at i on in i t s normal operat i ng st a t e .
If powe r is r emoved at any t i me whi l e t he EVO
cont rol l er i s in di agnost i c mode, t he EVO cont rol l er wi ll
exi t di agnost i c mode and resume oper at i on in i t s
normal oper at i ng st a t e when power is r eappl i ed.
The sequence and def i ni t i on of t he f i ve t e st s t hat t he
ser vi ce t echni ci an can per f or m are a s f ol l ows:
1. Re a d i n g t h e Fa ul t Co d e s
The f i rst i t em on t he menu t hat t he EVO cont rol l er
wi l l out put t o t he St ar Test er is DTC 2 1 . Thi s
r epr esent s aski ng t he servi ce t echni ci an whet her
h e / s h e woul d li ke t o "Re a d f ault c o d e s ?" st or e d
in memor y. If t he servi ce t echni ci an r el eases t he
HOL D/ TE ST but t on f or one se c ond, t hen l at ches
t he HOL D/ TEST down agai n wi t hi n ei ght
se c onds af t er recei vi ng DTC 2 1 , t he EVO
cont rol l er wi ll ent er t hi s t est , out put t he f aul t
DTCs st or e d in memor y and compl et e t hi s t est by
out put t i ng DTC 22 t o t he St ar Test er whi c h
r epr esent s "End of fault c o d e s".
2. Cl e a r i n g t h e Fa ul t C o d e s
The second i t em on t h e menu t hat t he EVO
cont rol l er wi ll out put t o t he St ar Test er is DTC 23.
Thi s represent s a ski n g t he servi ce t echni ci an
whet her h e / s h e wo ul d li ke t o "Cl ear f aul t
c o d e s?" st or e d in me mor y . If t he servi ce
t echni ci an r e l e a se s t h e HOLD/ TEST but t on f or
one second, t hen l a t c he s t he HOLD/ TEST but t on
down agai n wi t hi n e i ght seconds af t er recei vi ng
DTC 23, t he EVO cont r ol l er wi ll ent er t hi s t est ,
cl ear t he f ault DTCs a n d compl et e t hi s t e st by
out put t i ng DTC 2 4 t o t he St ar Test er whi ch
represent s "Faul t c o d e s c l e a r e d ".
3. A c t u a t o r Ou t p u t Ci r c u i t Te st
The t hi rd i t em on t he menu t hat t he EVO
cont rol l er wi ll out put t o t he St ar Test er i s DTC 25.
Thi s represent s a ski n g t he servi ce t echni ci an
whet her h e / s h e wo ul d li ke t o "Per f or m act uat or
t e s t ?". If t he se r vi c e t echni ci an rel eases t he
HOLD/ TEST but t on f o r one second, t hen l at ches
t he HOL D/ TEST but t on down agai n wi t hi n ei ght
seconds af t er r ecei vi ng DTC 25, t he EVO
cont rol l er wi ll ent er t hi s sel f -t est and
aut omat i cal l y t e st f or t he act uat or f aul t s li st ed
bel ow. If f aul t s exi st , t he cont rol l er wi ll st or e t he
appr opr i at e c o d e s in memor y , out put t hese
c ode s t o t he St ar Test er and compl et e t hi s t est
by out put t i ng DTC 22 t o t he St ar Test er whi ch
represent s "End of f aul t c o d e s". If no f aul t s exi st ,
t he cont rol l er wi ll c ompl e t e t hi s t est by out put t i ng
DTC 26 t o t he St ar Test er whi ch represent s
"Test pa sse d ".
DT C DE SCRI P T I ON A CT I ON
2 7 A c t u a t o r Ci r c ui t Op e n GO t o Pi n po i n t Te st A.
2 8 A c t u a t o r Ci r c ui t S h o r t e d GO t o Pi n po i n t Te st B.
25 A c t u a t o r Ci r c ui t Hi gh
Si d e Sh o r t e d t o Gr o u n d
GO t o Pi n po i n t Te st C.
30 A c t u a t o r Ci r c ui t S h o r t e d
t o Ba t t e r y
GO t o Pi n po i n t Te st D.
31 A c t u a t o r Ci r c ui t L o w
Si d e Sh o r t e d t o Gr o u n d
GO t o Pi n po i n t Te st E.
4. St e e r i n g Wh e e l Se n s o r Te st
The fourth i tem on the menu that the EVO
control l er wi l l output t o the Star Tester is DTC 32.
This represents aski ng the servi ce techni ci an
whet her h e / she woul d like t o "Per f or m steeri ng
wheel sensor t est ?" . If the servi ce techni ci an
rel eases the HOLD/ TEST button for one second,
then l atches t he HOLD / TEST button down again
within eight seconds after receiving DTC 32, t he
EVO control l er will enter this t est . Once thi s t est
has been ent ered and wi th vehicle speed = 0, t he
control l er will wai t 30 seconds for the servi ce
techni ci an t o rot at e t he steeri ng wheel at least 40
degrees in one di recti on only. If the steeri ng
wheel rotati on is not det ect ed within thi s ti me, t he
control l er will st ore DTC 33 in memory and
compl et e thi s t est by outputting DTC 33 t o the
Star Tester whi ch represents "St eeri ng wheel
rotati on not det ect ed" . If the steeri ng wheel
sensor hardware is operati ng properl y, the
control l er will compl et e this t est by outputting
DTC 26 t o t he St ar Tester whi ch represents
" Test passed" . If DTC 33 is recei ved, go t o
Pinpoint Test F.
5. Ve hi c l e Sp e e d Se n s o r Te st
NOTE: Before entering this t est , the vehicle dri ve
wheel s must be rai sed off the floor. Refer t o Secti on
00- 02 for proper procedure.
The final item on t he menu that the EVO controller will
output t o the Star Tester is DTC 34. This represents
aski ng the servi ce technician whether he/ she woul d
like to "Per f or m vehi cl e speed sensor t est ?" . If the
servi ce techni ci an rel eases the HOLD/ TEST button
for one second, then l atches the HOLD/ TEST button
down agai n within eight seconds after receiving DTC
34, the EVO controller will enter thi s test. Once this
t est has been entered and wi th steering wheel rotati on
rat e = 0, the controller will wai t 30 seconds for t he
servi ce techni ci an t o make the vehicle speed go
above 24 km / h (15 mph). If a vehicle speed of great er
than 24 k m/ h ( 1 5 mph) is not det ect ed within this
ti me, the controller will st ore DTC 35 in memory and
compl et e thi s test by outputting DTC 35 t o t he Star
Tester whi ch represents "Vehi cl e speed > 15 mph not
det ect ed" . If the vehicle speed sensor hardware is
operati ng properl y, the controller will compl ete thi s
t est by outputting DTC 26 t o the Star Tester whi ch
represent s " Test passed" . If DTC 35 is recei ved, GO
t o Pinpoint Test G.
After compl eti on of this test, the EVO controller will go
back t o t est No. 1 and continuously cycl e through the
menu of t est s until t he servi ce technician either
unl atches the HOLD/ TEST button until t he control l er
exi t s thi s mode or removes power t o the EVO
control l er by turning the ignition swi t ch OFF.
The fol l owi ng Pinpoint Test s appl y t o vehi cl es NOT
equi pped wi t h air suspensi on.
PINPOINT TEST A: DTC 27 ACTUATOR CIRCUIT OPEN
A1 CHECK EVO ACTUATOR CONNECTION
Yes
No
GO to A2.
INSTALL actuator
harness connector
correctly. REPEAT
Actuator Output Circuit
Test.
Ignition OFF.
Access EVO actuator.
Check actuator harness connector.
Is act uat or harness c onne c t or f i rml y pl ugged
i nt o a c t ua t or ?
Yes
No
GO to A2.
INSTALL actuator
harness connector
correctly. REPEAT
Actuator Output Circuit
Test.
A2 CHECK HIGH SIDE CIRCUIT CONTINUITY
Yes
No >
GO to A3.
SERVICE open high side
circuit. GOt o A3.
Access EVO control module.
Disconnect control module 14-pin connector.
Disconnect actuator connector.
Measure resi stance between Pin 13 Circuit 330
(Y/ LG) of control module and Circuit 86 (GY/O) at
actuator.
Is r esi st ance l ess t han 5 ohms?
Yes
No >
GO to A3.
SERVICE open high side
circuit. GOt o A3.
PINPOINT TEST A: DTC 27ACTUATOR CIRCUIT OPEN (Cont i nued)
A3 CHECK LOW SIDE CIRCUIT CONTINUITY
Yes
No
REPLACE EVO actuator.
RESTORE vehicle.
REPEAT Actuator Output
Test.
SERVICE open low side
circuit. RESTORE
vehicle. REPEAT
Actuator Output Test.
Measure resistance between Pin 14 Circuit 353 (LB)
of control module and Circuit 87 (T/Y) at actuator.
Yes
No
RESTORE vehicle.
Test.
SERVICE open low side
circuit. RESTORE
vehicle. REPEAT
PINPOINT TEST B: DTC 28ACTUATOR CIRCUIT SHORTED
B1 CHECK CIRCUIT RESISTANCE
Yes
No
SERVICE short between
Circuit 330 (Y/LG) and
Circuit 353 (LB) or
between Circuit 86
(GY/O) and Circuit 87
(T/Y). RESTORE vehicle.
Test.
GOt o B2.
Ignition OFF.
Disconnect 14-pin harness connector.
Disconnect actuator connector.
Measure resi stance between Pin 13, Circuit 330
(Y/LG) and Pin 14, Circuit 353 (LB) of control
module connector.
Is resi st ance less t han 100K ohms?
Yes
No
SERVICE short between
Circuit 330 (Y/LG) and
Circuit 353 (LB) or
between Circuit 86
(GY/O) and Circuit 87
(T/Y). RESTORE vehicle.
Test.
GOt o B2.
B2 CHECK ACTUATOR RESISTANCE
Yes
No
RESTORE vehi cle.
Test.
REPLACE control
module. RESTORE
vehicle. REPEAT
Measure resi stance of EVO actuator.
Yes
No
RESTORE vehi cle.
Test.
REPLACE control
module. RESTORE
vehicle. REPEAT
PINPOINT TEST C: DTC 29ACTUATOR HIGH SIDE SHORTED TO GROUND
C1 CHECK CIRCUIT 330 (Y / LG)
Yes
No
SERVICE Circuit 330 "
(Y/LG) and/ or Circuit 86
(GY/O) for short to
ground. RESTORE
vehi cle. REPEAT
GOt o C2.
Ignition OFF.
Access EVO actuator and disconnect harness
connector.
Access EVO control module and disconnect
harness connector.
(Y/ LG) and Pin 5, Circuit 57 (BK).
Is resi st ance l ess t han 100K ohms?
Yes
No
SERVICE Circuit 330 "
(Y/LG) and/ or Circuit 86
(GY/O) for short to
ground. RESTORE
vehi cle. REPEAT
GOt o C2.
C2 CHECK ACTUATOR
Yes
No
RESTORE vehi cle.
Test.
REPLACE EVO control
module. RESTORE
vehi cle. REPEAT
Reconnect EVO actuator.
(Y/ LG) and Pin 5, Circuit 57 (BK).
Is resi st ance l ess t han 100K ohms?
Yes
No
RESTORE vehi cle.
Test.
REPLACE EVO control
module. RESTORE
vehi cle. REPEAT
PINPOINT TEST D: DTC 30ACTUATOR CIRCUIT SHORTED TO BATTERY
D1 CHECK ACTUATOR CIRCUIT 330 (Y / LG)
Yes
No
SERVICE Circuit 330
( Y/ LG) / 86 (GY/O) for
short to battery.
RESTORE vehi cle.
Test.
GO t o D2.
ignition OFF.
Disconnect 14-pin harness connector.
Disconnect EVO actuator.
Measure voltage between Pin 13, Circuit 330
(Y/LG) and Pin 5, Circuit 57 (BK).
Yes
No
SERVICE Circuit 330
( Y/ LG) / 86 (GY/O) for
short to battery.
RESTORE vehi cle.
Test.
GO t o D2.
D2 CHECK ACTUATOR CIRCUIT 353 (LB)
Yes
No
SERVICE Circuit 353
(LB)/87 (T/Y) for short to
battery. RESTORE
vehicle. REPEAT
REPLACE EVO control
module. RESTORE
vehicle. REPEAT
Measure voltage between Pin 14, Circuit 353 (LB)
and Pin 5, Circuit 57 (BK).
Yes
No
SERVICE Circuit 353
(LB)/87 (T/Y) for short to
battery. RESTORE
vehicle. REPEAT
REPLACE EVO control
module. RESTORE
vehicle. REPEAT
PINPOINT TEST E: DTC 31 ACTUATOR CIRCUIT LOW SIDE SHORTED TO GROUND
TEST STEP RESULT - ACTION TO TAKE
E1 CHECK CIRCUIT 353 (LB)
Yes
No
SERVICE Circuit 353 (LB)
and/or Circuit 87 (T/Y)
RESTORE vehi cle.
Test.
GOt o E2.
Ignition OFF.
Access EVO actuator and disconnect harness
connector.
harness connector.
(LB) and Pin 5, Circuit 57 (BK).
Yes
No
SERVICE Circuit 353 (LB)
and/or Circuit 87 (T/Y)
RESTORE vehi cle.
Test.
GOt o E2.
E2 CHECK ACTUATOR
Yes
No -
RESTORE vehicle.
Test.
REPLACE control
module. RESTORE
vehicle. REPEAT
Reconnect EVO actuator.
(LB) and Pin 5, Circuit 57 (BK).
Yes
No -
RESTORE vehicle.
Test.
REPLACE control
module. RESTORE
vehicle. REPEAT
PINPOINT TEST F: DTC 33STEERING WHEEL ROTATION NOT DETECTED
F1 CHECK CIRCUIT CONTINUITY
Yes
No
GOt o F2.
SERVICE open or high
resistance ci rcui ts.
RESTORE vehi cle.
REPEAT Steering Wheel
Sensor Test.
Ignition OFF.
harness connector.
Access Steering Wheel Rotation Sensor and
disconnect harness connector.
Measure resi stance of Circuit 633 (R/ Y), 634 (BR)
and 837 (Y/ BK) between Steering Wheel Rotation
Sensor connector and EVO control module
connector.
Yes
No
GOt o F2.
resistance ci rcui ts.
RESTORE vehi cle.
Sensor Test.
11- 00- 17
PINPOINT TEST F: DTC 33STEERI NG WHEEL ROTATION NOT DETECTED (Cont i nued)
F2 CHECK STEERING WHEEL ROTATION SENSOR
SUPPLY
Yes
No IN-
REPLACE sensor.
RESTORE vehi cle.
Sensor Test.
SERVICE Circuit 298
(P/ O) between Fuse 17
of fuse j unction panel and
sensor. RESTORE
vehi cle. REPEAT Steering
Wheel /Sensor Test.
Turn ignition ON.
Measure voltage at Steering Wheel Rotation Sensor
Circuit 298 (P/ O).
Yes
No IN-
REPLACE sensor.
RESTORE vehi cle.
Sensor Test.
SERVICE Circuit 298
(P/ O) between Fuse 17
of fuse j unction panel and
sensor. RESTORE
vehi cle. REPEAT Steering
Wheel /Sensor Test.
PINPOINT TEST G: DTC 35 VEHICLE SPEED ABOVE 24 KM/ H (15 MPH) NOT DETECTED
G1 CHECK SPEEDOMETER OPERATION
Yes
No
GO to 62.
(GY/BK) and/or 676
(PK/O) or vehicle speed
sensor. REFER to Section
13-01B.
Check for proper speedometer operati on.
Does speedomet er I ndi cat e vehi cl e speeds
above 24 k m/ h (15 mph)?
Yes
No
GO to 62.
(GY/BK) and/or 676
(PK/O) or vehicle speed
sensor. REFER to Section
13-01B.
G2 CHECK CIRCUIT 679 (GY/BK)
Yes
No
GOt o G3.
679 (GY/BK) between
cluster and EVO control
module. RESTORE
vehicle. REPEAT Vehicle
Speed Sensor Test.
Ignition OFF.
Access Instrument Cluster Connector C2 and
disconnect harness connector.
Access EVO control module and di sconnect
harness connector
Measure resistance between instrument cluster Pin
C2-14 and EVO control module Pin 9.
Yes
No
GOt o G3.
679 (GY/BK) between
cluster and EVO control
module. RESTORE
Speed Sensor Test.
G3 CHECK CIRCUIT 676 (PK/O)
Yes >
No
REPLACE EVO control
module. RESTORE
Speed Sensor Test.
676 (PK/O). RESTORE
vehi cle. REPEAT Vehicle
Speed Sensor Test.
Measure resistance between EVO control module
Pin 8 and Pin 5.
Yes >
No
REPLACE EVO control
module. RESTORE
Speed Sensor Test.
676 (PK/O). RESTORE
vehi cle. REPEAT Vehicle
Speed Sensor Test.
PINPOINT TEST H: STEERING DIAGNOSTICS CAN NOT BE ENTERED
H1 DIAGNOSTIC LAMP CHECK
Yes
No
REPLACE tester.
GOt o H2.
Test the Super Star II in another vehicle to see if the
devi ce is functional.
Check connection of tool to DLC.
Are c onc e r ns f ound?
Yes
No
REPLACE tester.
GOt o H2.
H2 RETEST CONTROL MODULE
Yes
No
GO to Entering EVO
Diagnostics.
GO to H3.
Connect Super Star II to DLC.
Start engine.
Latch HOLD/TEST button down.
Does DTC 20 appear?
Yes
No
GO to Entering EVO
Diagnostics.
GO to H3.
H3 EVO CONTROL MODULE CHECK
Yes
No I
GO to I N-
SECURE connection. GO
to Entering EVO
Diagnostics.
Turn ignition switch to OFF posi ti on.
Ensure 14-pin connector is properly connected to
module.
Is c onne c t i on properl y secur ed?
Yes
No I
GO to I N-
SECURE connection. GO
to Entering EVO
Diagnostics.
PINPOINT TE ST H: STEERI NG DIAGNOSTICS CAN NOT BE ENTERED (Cont i nued)
H4 CHECK POWER FEED
Yes
No
REPLACE EVO control
module. RESTORE
GOt o H5.
Disconnect EVO control module 14-pin connector.
Turn ignition swi tch to RUN posi ti on.
Using a DVOM, measure voltage from Pin 7
(ignition-run only) to Pin 5 (ground) at 14-pin
connector.
Are t here 12 vol t s?
Yes
No
REPLACE EVO control
module. RESTORE
GOt o H5.
H5 CHECK GROUND
Yes
No
SERVICE Circuit 298
(P/ O) for open.
RESTORE vehicle.
REPEAT Entering EVO
Diagnostics.
for open. RESTORE
vehicle. REPEAT Entering
EVO Di agnosti cs.
Measure resi stance from Pin 5, Circuit 57 (BK) to a
known good ground.
Yes
No
SERVICE Circuit 298
(P/ O) for open.
RESTORE vehicle.
REPEAT Entering EVO
Diagnostics.
for open. RESTORE
vehicle. REPEAT Entering
EVO Di agnosti cs.
PINPOINT TEST J: DTC 16, 17 OR 18STEERING VERY DIFFICULT/VERY EASY
J1 DETERMINE REQUIRED TEST STEP (DTC 16, 17 AND
18)
Yes
No
GOt o J6.
GOt o J2.
Perform Service Bay Diagnostics. Refer to Section
18-04.
Read and record displayed code(s).
Each code must be addressed individually. If more
than one error code is det ect ed, perform the test
step required for each code.
Is c ode 16, 17o r 18 di spl ayed?
Yes
No
GOt o J6.
GOt o J2.
J2 DETERMINE REQUIRED TEST STEP (DTC 74)
Yes
No
GOt o J22.
GOt o J3.
Read and record di splayed code(s).
Is c ode 74 di spl ayed?
Yes
No
GOt o J22.
GOt o J3.
Yes
No
GO to J4.
NOTE: Code 55 is only generated in drive cycle t est .
Yes
No
GO to J4.
Yes
No
REFER to Pump Flow and
Pressure Tests in Service
Procedures.
GO to J5.
Yes
No
REFER to Pump Flow and
Pressure Tests in Service
Procedures.
GO to J5.
J5 DETERMINE REQUIRED TEST STEP (OTHER CODES)
Yes
No
for air suspension
di agnosti cs.
GOt o J6.
Are c ode s ot her t han 11, 16, 17, 18, 55 or 74
de t e c t e d?
Yes
No
for air suspension
di agnosti cs.
GOt o J6.
PINPOINT TEST J : DTC 16, 17 OR 18STEERING VERY DIFFICULT/VERY EASY (Cont i nued)
J6 EVO ACTUATOR VALVE CHECK (SHORT TO GROUND
OR AN OPEN CIRCUIT) (DTC 16, 17 AND 18 CONCERN)
Yes
No
GO to J7.
MAKE proper connection.
GO to J 1 .
Verify harness connection on the EVO power
steeri ng control valve actuator on power steering
pump is properly seat ed.
Is c onne c t or pr oper l y seat ed?
Yes
No
GO to J7.
GO to J 1 .
J7 DTC 16: EVO ACTUATOR VALVE CHECK (SHORT TO
GROUND OR AN OPEN CIRCUIT)
Yes
No
GO to J12.
GO to J8.
Read all codes.
Is code 16 di spl ayed?
Yes
No
GO to J12.
GO to J8.
Yes
No
GO to J10.
GO to J9.
Turn ignition swi t ch t o the OFF posi t i on.
Read all codes.
Yes
No
GO to J10.
GO to J9.
Yes
No
GO to J 11.
GO to J10.
Turn ignition swi t ch t o OFF posi ti on.
Read all codes.
Yes
No
GO to J 11.
GO to J10.
J10 CHECK RESISTANCE ACROSS ACTUATOR VALVE
Yes
No
GOt o J 11.
GO to J12.
Ignition swi tch in OFF posi ti on.
Locate the control module behind glove box.
Harness connector can be di sconnected from
module without removing module.
Using an ohmmeter, measure resi stance across Pin
14 and Pin 13 of harness connector. Resistance
should be 7-18 ohms. If the resi stance is greater
than 1000 ohms, the circuit is open.
Is resi st ance bet ween 7-18 ohms?
Yes
No
GOt o J 11.
GO to J12.
J11 CHECK CONTINUITY OF WIRING
Yes
No
GO t o J12.
SERVICE wires as
necessary. GO to J 1 .
Disconnect EVO harness connector from EVO
actuator valve l ocat ed on power steeri ng pump.
Test continuity of Circuits 86 (GY/O) and 87 (T/Y)
from the actuator connector t o the 14-pin EVO
Refer to Component Locati on Schemati c and
System Schematic.
Yes
No
GO t o J12.
SERVICE wires as
J12 CHECK EVO ACTUATOR VALVE
Yes
No
REPLACE EVO valve.
RESTORE vehicle.
RETEST system.
GO to J13.
power steering control valve actuator locat ed on
power steering pump.
Using an ohmmeter, measure resi stance across the
two actuator valve connector pins.
Is resi st ance great er t han 20 ohms or less t han 5
ohms?
Yes
No
REPLACE EVO valve.
RESTORE vehicle.
RETEST system.
GO to J13.
J13 CHECK EVO ACTUATOR VALVE RESISTANCE
Yes
No
GO to J14.
GO to J15.
power steering cont rol valve actuator locat ed on
power steering pump.
Using an ohmmeter, measure resi stance across the
two actuator valve connector pins.
Is resi st ance be t we e n 5-20 ohms?
Yes
No
GO to J14.
GO to J15.
11- 00- 20 St e e r i n g S y s t e m :
Se r v i c e 11- 00- 20
PINPOINT TEST J : DTC 16, 17 OR 18STEERING VERY DIFFICULT/VERY EASY (Cont i nued)
J14 CHECK WIRE HARNESS
Yes
No
RESTORE vehicle.
RETEST system.
GOt o J15.
Ignition swi tch in OFF position.
EVO harness disconnected from EVO power
steering control valve actuator.
Disconnect EVO control module from the 14-pin
connector behind glove box. (Refer to removal.)
Is modul e di sconnect ed?
Yes
No
RESTORE vehicle.
RETEST system.
GOt o J15.
J15 CHECK WIRE HARNESS FOR SHORT TO GROUND (PIN
14 RESISTANCE OVER 1000 OHMS)
Yes
No
GOt o J17.
GO to J16.
Using an ohmmeter, measure resistance between
Pin No. 6 (ground) and Pin 14 of harness connector.
Is resi st ance over 1000 ohms?
Yes
No
GOt o J17.
GO to J16.
14 RESISTANCE LESS THAN 10 OHMS)
Yes
No
SERVICE harness.
RESTORE vehicle.
RETEST system.
GOt o J19.
Using an ohmmeter, measure resistance between
Pin 6 (ground) and Pin 14 of harness connector.
Yes
No
SERVICE harness.
RESTORE vehicle.
RETEST system.
GOt o J19.
26 RESISTANCE LESS THAN 10 OHMS)
Yes
No
SERVICE harness.
RESTORE vehicle.
RETEST system.
GO to J18.
Using an ohmmeter measure resistance between
Pin No. 6 (ground) and Pin 26 of harness connector.
Yes
No
SERVICE harness.
RESTORE vehicle.
RETEST system.
GO to J18.
26 RESISTANCE OVER 1000 OHMS)
Yes
No
GOt o J19.
GO to J20.
Using an ohmmeter, measure resi stance between
Pin 6 (ground) and Pin 26 of harness connector.
Yes
No
GOt o J19.
GO to J20.
J19 CHECK HARNESS FOR SHORT TO B+
Yes
No
SERVICE wires. GOt o
J 1 .
GO to J20.
Ignition swi tch in RUN posi ti on.
EVO harness di sconnected from EVO power
steering control valve actuator on power steering
pump.
Using a voltmeter, measure the voltage across
Pin No. 14 and Pin 6
Pin No. 26 and Pin 6
Yes
No
J 1 .
GO to J20.
J20 CHECK FOR SHORT ACROSS CIRCUITS 86 (GY/O)
AND 87 (T/Y) (RESISTANCE LESS THAN 10 OHMS)
Yes
No
SERVICE wires. GO to
J 1 .
GO to J 2 1.
pump.
Using an ohmmeter, measure resistance across Pin
14 and Pin 26 on harness connector.
Yes
No
SERVICE wires. GO to
J 1 .
GO to J 2 1.
J21 CHECK FOR SHORT ACROSS CIRCUITS 86 (GY/O)
AND 87 (T/Y) (RESISTANCE OVER 1000 OHMS)
Yes
No
REPLACE EVO control
module. RESTORE
K5.
Ignition swi tch in OFF position.
pump.
Using an ohmmeter, measure resistance across Pin
14 and Pin 26 on harness connector.
Yes
No
REPLACE EVO control
module. RESTORE
K5.
11- 00- 2 1 St e e r i n g S y s t e mS e r v i c e 11- 00- 2 1
PINPOINT TEST J: DTC 16, 17 OR 18STEERING VERY DIFFICULT/VERY EASY (Cont i nued)
J22 CHECK STEERING WHEEL SENSOR CONNECTION
(DTC 74 CONCERN)
Yes
No
GO to J23.
GOt o J 1 .
Verify harness connection on steering wheel
rotation sensor (locat ed on lower portion of steeri ng
column) is properly seat ed.
Is c onne c t or properl y seat ed?
Yes
No
GO to J23.
GOt o J 1 .
J23 STEERING WHEEL ROTATION SENSOR CHECK
Yes
No
SERVICE wires as
GOt o J24.
Disconnect EVO control module and leave
connectors mated. Refer to Section 04-05.
Examine wiring harness, verify that there is no
damage and:
Cr own Vi ct ori a, Grand Marqui s
Circuit 633 (R) is in Pin 18
Circuit 634 (BR) is in Pin 19
Circuit 837 (Y/ BK) is connected to Circuit 57
(BK).
Circuit 57 (BK) is in Pin 6 (ground)
Circuit 298 (P / 0) is connected t o steering
sensor, supplying ignition power 12 volts wi th
ignition on
Town Car
Circuit 633 (R) is in Pin 18
Circuit 634 (BR) is in Pin 19
Circuit 57 (BK) is in Pin 6 (ground)
Circuit 295 (LB / PK) is connected to steering
sensor, supplying ignition power 12 volts wi th
ignition on
Are wi res damaged or cr ossed?
Yes
No
SERVICE wires as
GOt o J24.
J24 TEST STEERING WHEEL ROTATION SENSOR SIGNALS
Yes
No
SHUT OFF engine.
REPLACE EVO control
module. RESTORE
GOt o J25.
Start engine.
NOTE: The resi stance values will vary between
meters, but the needle on all meters should swing
from a low to a higher resi stance and back
approximately every nine degrees of steering wheel
rotati on.
While rotating the steering wheel slowly, and using
an analog ohmmeter such as, Inductive
Dwell-Tach-Volt Ohmmeter 059-00010 or
equivalent, set to the 1K scale, measure the
resi stance from:
Pin 18t o Pi n 6
Pin 19t o Pi n 6
Does met er needl e swi ng f o r bot h ci r cui t s?
Yes
No
SHUT OFF engine.
REPLACE EVO control
module. RESTORE
GOt o J25.
J25 STEERING WHEEL ROTATION SENSOR WIRE CHECK
Yes !
No l >
GOt o J26.
SERVICE wires as
Disconnect EVO control module from 26-pin
connectors locat ed in luggage compartment.
Ignition swi tch in the OFF posi t i on.
Unplug steering sensor (locat ed on lower steering
column).
Check wires at steering sensor connector for
damage and/ or incorrect locati on.
Test continuity of Circuits 633 (R), 634 (BR) and 57
(BK) from steering sensor to EVO control module
connector. (Refer to Electri cal Schemati c).
Test continuity from Circuit 837 (Y / BK) to 57 (BK)
(Crown Vi ct ori a, Grand Marquis).
Yes !
No l >
GOt o J26.
SERVICE wires as
PINPOINT TEST J: DTC 16, 17 OR 18STEERING VERY DIFFICULT/VERY EASY (Continued)
J26 CHECK FOR SHORT ACROSS CIRCUITS 834 (R/ Y)
AND 835 (R/W) (RESISTANCE OVER 1000 OHMS)
Yes
No
GOt o J28.
GO to J27.
Steering sensor di sconnected.
Disconnect pin connectors. Measure resi stance
between:
Pin 18 and Pin 19
Pin 18 and Pin 6
Pin 19 and Pin 6 of the pin connectors (in
luggage compartment).
Yes
No
GOt o J28.
GO to J27.
J27 CHECK FOR SHORT ACROSS CIRCUITS 834 (R/ Y)
AND 835 (R / W) (RESISTANCE LESS THAN 10 OHMS)
Yes
No
SERVICE wires as
GOt o J28.
Steering sensor di sconnected.
Disconnect pin connectors.
Measure resi stance between:
Pin 18 and Pin 19
Pin 18 and Pin 6
Pin 19 and Pin 6 of the pin connectors (in
luggage compartment).
Yes
No
SERVICE wires as
GOt o J28.
J28 TEST STEERING SENSOR POWER CIRCUIT
Yes
No
REPLACE Steering
Sensor. RESTORE
SERVICE Circuit 295
(LB/PK) (Town Car),
Circuit 298 (P/O) (Crown
Vi ct ori a/Grand Marquis).
CHECK/REPLACE fuse.
GO to J 1 .
Using a voltmeter, measure the voltage between
Circuits 296 (LB/PK) and 57 (BK) (Town Car) and
298 (P/O) and 837 (Y/ BK) (Crown Vi ct ori a/Grand
Marquis) at the steering sensor connector.
Are t here 12 vol t s?
Yes
No
REPLACE Steering
Sensor. RESTORE
SERVICE Circuit 295
(LB/PK) (Town Car),
Circuit 298 (P/O) (Crown
Vi ct ori a/Grand Marquis).
CHECK/REPLACE fuse.
GO to J 1 .
PINPOINT TEST K: DTC 55 STEERING DOES NOT VARY WITH VEHICLE SPEED
K1 CHECK SPEED SENSOR CONNECTION (DTC 55
CONCERN)
Yes
No
GO to K2.
GOt o J 1 .
Ensure harness connection on vehicle speed
sensor, (located on the transmission) is properly
seat ed.
Is c onne c t or properl y seat ed?
Yes
No
GO to K2.
GOt o J 1 .
K2 SPEED SENSOR CHECK
Yes
No
J 1 .
GO to K3.
Disconnect electri cal connectors from the EVO
module (located in luggage compartment).
Ensure there is no damage to harness and that:
Circuit 679 (GY/BK) is in Pin 7
Circuit 676 (PK/O) is in Pin 20
Are wi res damaged or cr ossed?
Yes
No
J 1 .
GO to K3.
K3 TEST SPEED SENSOR GROUND CIRCUIT
Yes
No
GOt o K4.
SERVICE wire or ground
eyelet as necessary. GO
to J 1 .
Test continuity of speed sensor ground Circuit 676
(PK/ 0) , from Pin 20 to Pin 6 of 26-pin connectors.
Yes
No
GOt o K4.
SERVICE wire or ground
eyelet as necessary. GO
to J 1 .
K4 TEST SPEED SENSOR
Yes
No >
Section 13-01. GO to J 1 .
GOt o K5.
Perform "Speedomet er/Odomet er Reads
Inaccurately Test". Refer to Section 13-01A
(electroni c cluster) or 13-01B (conventional
cluster).
Are concer ns f ound?
Yes
No >
Section 13-01. GO to J 1 .
GOt o K5.
PINPOINT TEST K: DTC 55STEERING DOES NOT VARY WITH VEHICLE SPEED (Cont i nued)
K5 EVO CONTROL MODULE CHECK
Yes
No
GOt o K6.
SECURE connecti on. GO
t o K6.
Turn ignition s w i t c h t o O F F p o s i t i o n .
Ensure pin c o n n e c t o r s a r e p r o p e r l y c o n n e c t e d t o
module (locat ed under dash).
Check air suspension swi tch connecti on.
Check if the air suspension swi t ch is turned on.
Is c onne c t or pr oper l y seat ed?
Yes
No
GOt o K6.
SECURE connecti on. GO
t o K6.
K6 CHECK POWER FEED
Yes
No
REPLACE EVO cont rol
module. RESTORE
SERVICE short t o ground,
high resi st ance or open in
Circuit 418, 296 or 1053
as necessary. GO to J 1 .
Turn ignition swi tch to the OFF posi t i on.
Disconnect EVO control module 26-pin connectors
(locat ed under dash).
Turn ignition switch to RUN posi ti on.
Using DVOM, measure voltage from Pin 16
(ignition-run only) to Pin 6 (ground) at pin
connectors.
Measure voltage from Pin 1 to Pin 6.
If 12 volt s from Pin 1 t o Pin 6 connect, t est light
between Pins 1 and 6.
Are t here 12 vol t s wi t h bri ght l i ght ?
Yes
No
REPLACE EVO cont rol
module. RESTORE
SERVICE short t o ground,
high resi st ance or open in
Circuit 418, 296 or 1053
as necessary. GO to J 1 .
PINPOINT TEST L: STEERING DIAGNOSTICS CAN NOT BE ENTERED
L1 PERFORM SERVICE BAY DIAGNOSTICS
Yes
No
GO to J 1 .
Set up service bay di agnost i cs.
Can servi ce by di agnost i cs be st a r t e d?
Yes
No
GO to J 1 .
SERVICE PROCEDURES
P r e l i mi n a r y P r o c e d u r e s
Make the fol l owi ng preliminary checks bef ore
replacing or servi ci ng power steeri ng:
A i r Bl e e d i n g
If bubbles are present in t he power steeri ng fl ui d, bl eed
the syst em as f ol l ows:
1. Fill the power steeri ng pump auxi l i ary reservoi r
(3E764).
2. Run the engine until the fluid reaches normal
operati ng temperature of 74- 79C
( 165- 175F) .
3. CAUTI ON: Do n o t h o l d t h e s t e e r i n g wh e e l
( 3600) i n t h e f a r l e f t o r r i gh t p o s i t i o n o r
d a ma g e t o p o w e r s t e e r i n g p u mp ( 3A 67 4)
ma y r e s u l t .
Turn t he steeri ng wheel all t he way t o the left and
right several ti mes.
4. Check the fluid level.
5. If air is still t rapped in the syst em, refer t o Purging
Power Steeri ng Syst em of Air.
Fl u i d L e v e l
1. Run t he engine until the fluid reaches normal
operati ng t emperat ure of 74- 79C
( 165- 175F) .
2. Turn the steeri ng wheel all t he way t o t he left and
right several ti mes. Turn the engine off.
3. CAUTI ON: Do n o t o v e r f i l l t h e p o w e r s t e e r i n g
o i l r e s e r v o i r ( 3A 697 ) .
Check the fluid level in the power steeri ng oil
reservoi r. If the level is low, add fluid such as Ford
Premium Power Steering Fluid E6AZ- 19582- AA
ESW-M2C33-F.
P u mp Be l t
Repl ace and adj ust broken, gl azed or worn dri ve belt
pump bel ts. Refer t o Secti on 03- 05 for adjustment
procedure.
T u r n i n g E f f o r t C h e c k
P o w e r S t e e r i n g
Ensure front wheel s are properl y aligned and ti re
pressure is correct before checki ng turning effort.
1. Park vehi cl e on dry concret e and set the parki ng
brake.
2. Idle the engine for t wo or t hree minutes. Turn the
steering wheel ( 3600) t o the left and right several
ti mes to war m the fluid t o 43- 49C
( 110- 120F) .
11 - 00- 24 St eer i ng Sy s t e mSe r v i c e
11- 00- 24
3. Wi t h the engine running, at t ach a pull scal e t o the
rim of the steeri ng wheel . Starti ng wi th t he road
wheel s in strai ght-ahead posi ti on, measure the
pull requi red t o turn the steeri ng wheel one
compl ete revolution in each di recti on. Stati c
steeri ng wheel turning effort should measure no
more than 3.4 kg (7. 5 l bs).
Sensi t i ve St eeri ng Di agnosti c and Servi ce
Procedure
Confi rm t he concern wi th a test dri ve. Be awar e that:
Higher than usual fri cti on makes minor steeri ng
adj ustments more frequent.
The fri cti on may mask the aligning torque provi ded
by suspensi on and ti res.
The steeri ng center fri cti on may cause memory
steer and for slight steeri ng adj ustments, the
steeri ng wheel center may have a small range of
l ocati ons.
Verify that the vehi cl e has proper ride hei ghts and
right atti tude.
FENDER OPENING HEIGHTS (RIDE ATTITUDE)
Vehicle F r o n t Re a r
Cr o wn Vi c . / G d . Ma r q u i s - Ba s e 2 8 3 / 4 " 2 8 1/ 4"
Cr o wn Vi c . / G d . Ma r q u i s - Ha n d l i n g 2 8 1 / 2 " 2 8 "
P kg .
Cr o wn Vi c . / G d . Ma r q u i s - P o l i c e 2 9 1 / 4 " 2 8 1/ 2 "
To wn Ca r - Ba s e 2 8 3 / 4 " 2 8 1/ 2 "
To wn Ca r - Ha n d l i n g P kg . 2 9 " 2 8 3 / 4 "
1. Check ti re pressure and reset t o speci fi cati on.
o 30 psi Front / 34 psi Rear - Base wi th Michelin
XW-4 and XGT-4.
o 32 psi Fr ont / 35 psi Rear - Handling Package
wi t h Goodyear Eagle GA.
35 psi Fr ont / 35 psi Rear - Police wi th
Goodyear GT + 4.
2. Check front and rear alignment paramet ers.
Reset cast er and camber t o nominal speci fi ed
val ues. I MPORTANT: SET FRONT TOE TO 1/ 8"
( or - . 125) . TOE OUT-TOTAL (correspondi ng
val ues in i nches are .06 or 1 / 16" ) .
3. Adjust t he steeri ng gear meshl oad t o 8.0 in-lb (or
2.0 in-lb great er than prel oad).
4. Loosen idler t o f rame bol ts and gear bol ts.
Reti ghten idler and gear bol ts while pushing up on
the centerlink wi th about 75 lbs. of f orce t o t ake
up any sl ack in the bolt hol es.
5. Measure t he gap bet ween t he front suspension
l ower control arm front bushing and the inner
surf ace of the f rame as shown. The gap will be at
the front of t he headed end of the bushing.
G7812-A
Pa r t
1
Frame
2

Shim Washer
3

Inner Sleeve
4

Hard Rubber Washer
5

Bushing
6

Rubber
6. Add a shi m washer(s) ( 391112- S2) as required
t o fill this gap if it is greater than 1 / 1 6 " ( 1. 558
mm), Figure 1. Washer dimensions are:
Inside di ameter: 22. 5-23. 25 mm ( 0. 886- 0. 915
i n.)
Outsi de diameter: 50-51 mm ( 1. 969- 2. 008 in.)
a. Wi t h the car on a pit or hoist, look at t he front
of the front bushing on the front suspension
l ower control arm.
b. If the rubber head on the bushing touches the
flange on the frame, the shim is not needed
and probabl y cannot be installed.
c. If the gap between the rubber and t he f rame
is wi de enough that the inner sl eeve of the
bushing shows, shim washers may help.
d. Look at the size of the gap t o determi ne if one
(1) or t wo (2) washers will be needed.
CAUTI ON: DO NOT USE MORE THAN T WO
WASHERS.
e. Wi t h a j ack under the front bushing, remove
the bolt.
f. Lower and pry to get the bushing down far
enough t o slip the washer(s) over the bushing
inner sl eeve.
g. Jack and pry the bushing back into position
and slip the bolt into the hole.
11- 00- 2 5 St e e r i n g S y s t e mS e r v i c e 11- 00- 2 5
h. Vi sually i nspect t o ma ke sure t he pl ast i c
wa she r s ar e sti ll in posi t i on.
i. Install t he nut a nd t i ght en t o maxi mum
speci f i cat i on.
CAUTI ON: THE PL ASTI C WASHER MUST NOT BE
PI NCHED BETWEEN THE BUSHI NG INNER
SLEEVE AND THE FRAME.
7. Measure t he rot at i ng t or que of t he Pi t man a r m
st ud by pl aci ng t he Pi t man a r m in a vi se, doubl e
nutti ng t he st ud and measuri ng t he rot at i ng t or que
wi t h an i nch pound t or que wr e n c h. Rot at i ng
t or que shoul d be l ess t han 60 in-lb ( br e a ka wa y
t orque wi ll be sl i ght l y hi gher).
8. Repl ace Pi t man ar m if ne c e ssa r y wi t h a known
l ow f ri ct i on Pi t man a r m ( F3AC- 3B153- AA) .
P ART NUMBE R P A RT N A ME C L A S S
391112 - S2 Shi m Wa s h e r S
F3A C- 3B153- A A P i t ma n A r m L
E x t e r n a l L e a k a g e
When l ooki ng f or l eaks, use t hi s pr ocedur e t o pi npoi nt
t he e xa c t cause and l ocat i on t o avoi d mi sdi agnosi s:
1. Check f or overf i l l ed powe r st eeri ng oil reservoi r
( 3A697 ) .
2. Wi pe suspe c t e d a r e a dr y.
3. Check f or powe r st eer i ng pump over f l ow and
aerat i on.
4. Check f or e x a c t sour ce. Exampl e: Oil may be
running down f r om anot her a r e a (engi ne, e t c . ) and
dri p may not be leak poi nt .
5. CAUTI ON: Do n o t h o l d t h e s t e e r i n g wh e e l
( 3600) a ga i n s t a s t o p f o r mo r e t h a n f i v e
s e c o n d s a t a t i me , a s d a ma g e t o p o w e r
s t e e r i n g p u mp ( 3A 67 4) ma y r e sul t .
Cycl e t he st eeri ng wheel f r om st op-t o-st op 10
t i mes and c he c k f or l eaks.
6. Some l eaks are hi gh-pressure l eaks and may
requi re hol di ng st eer i ng wheel agai nst st o ps (no
more t han f i ve se c onds at a t i me) bef ore f lui d will
seep out .
P u m p F l o w a n d P r e s s u r e T e s t s
Bef or e perf ormi ng t he pump f l ow and pr essur e t e st s,
compl et e t he f ol l owi ng c he c ks f or condi t i ons whi c h
coul d cause l oss of powe r assi st . Take c or r e c t i ve
act i on if necessar y .
1. Check po we r st eeri ng oil reservoi r ( 3A697 ) f or
pr oper f lui d l evel .
2. Check t i r es f or c o r r e c t ai r pressure.
3. Che c k dr i ve bel t (8620) f or proper t ensi on.
4. Che c k po we r st eeri ng pump ( 3A67 4) f or c o r r e c t
model a nd vehi cl e appl i cat i on.
5. Che c k f or cor r ect -si ze power st eer i ng pump
pul l eys ( 3A7 33) on power st eeri ng pump and
engi ne.
6. Che c k ent i re sy st em f or da ma ge . Repl ace par t s
a s ne c e ssa r y .
If t he a bo ve i t ems ar e c or r e c t , and t he l oss of assi st
sti ll e xi st s, t e st t he power st eeri ng pump f l ow and
pr essur e t o det ermi ne whet her t he t roubl e is in t he
powe r st eer i ng pump, power st eeri ng gear ( 3504) or
cont r ol val ve.
T e s t E q u i p m e n t
1. Engi ne t achomet er .
2. The r mo me t e r : - 17 . 8C t o 148. 9C( 0Ft o
300F) .
3. Rot unda Power St eeri ng Sy st e m Anal yzer
014- 002 07 or equi valent.
4. Set of a da pt e r f i t t i ngs (part of 014- 00207) .
The t e st pr oc e dur e used in conj unct i on wi t h t he
Rot unda Powe r St eeri ng Syst em Anal yzer 014- 00207
or equi val ent , pr ovi des a met hod f or checki ng t he
compl et e po we r st eeri ng sy st e m. Thi s anal yzer can
be used on i nt egral or non-i ntegral power st eeri ng
sy st e ms t o det er mi ne t he cause of hard st eeri ng
a n d / o r l ack of assi st concerns.
The anal yzer pr ovi des readout s f or t he f ol l owi ng:
Sy st e m ba c k pressure.
Power st eer i ng pump f l ow.
St eeri ng / ge a r i nternal l eakage.
Power st eer i ng pump relief pressure.
The i nt erpret at i on of t he above readout s wi ll det ermi ne
whi ch of t he f ol l owi ng condi t i ons or component s ar e
t he cause of t he concer n:
Rest ri ct i on in hoses or f i t t i ngs.
St i cki ng gear val ve.
Ineffi ci ent pump cam pack.
St i cki ng reli ef val ve.
Bi ndi ng in suspensi on.
T e s t P r o c e d u r e
1. To connect t he analyzer into t he st eeri ng sy st e m,
r emove t he pressure f i t t i ng f r om t he power
st eeri ng pump and connect it into t he appr opr i at e
adapt er of t he analyzer.
2. Thr ead t he ot her adapt er of t he analyzer i nto t he
power st eeri ng pump.
3. Connect t he anal yzer t o t he adapt ers. Ti ghten
bot h connect i ons t o 20 N-m (15 Ib-ft) maxi mum.
Power St eer i ng Syst em Test i ng
G5869-B
Par t
1 Power Steering Reservoir
2 Power Steering Gear
3 Existing High Pressure Hose
Pa r t
4 Gate Valve
5 014-00207 Rotunda Power Steering
Analyzer
6 3A674 Clll Power Steering Pump
4. Ad d powe r st eeri ng f l ui d, if requi red. St ar t t he
engi ne, ensure t ransmi ssi on is in PARK and t he
par ki ng br ake is engaged and run engi ne f or
appr oxi mat el y t wo mi nut es at i dle.
NOTE: The vehi cl e must not be movi ng duri ng t he
f ol l owi ng c he c ks.
5. Re c or d t he f ol l owi ng:
a. Fl ow, l i t e r s/ mi n . (ga l l ons/ mi n. ) at 7 8 2 C
( 17 2 5 F ) .
b. Pressure, kP a ( ps i ) a t 7 8 2 C ( 1 7 2
5F) at idle wi t h t he ga t e val ve fully open.
If f l ow is bel ow 7.5 l i t e r s/ mi n . (2. 0
ga l l ons/ mi n. ), t he powe r st eeri ng pump
may requi re ser vi ce. However, at t hi s poi nt
cont i nue t he di agnosi s. Check f or f l ow and
relief pr essur e agai nst t he vehi cl e and
engi ne bei ng t e st e d .
If pr essur e is above 1034 kPa ( 150 psi ),
c he c k hoses f or r est r i ct i ons.
6. Part i al l y cl ose t he gat e val ve t o build up 5100
kPa ( 7 40 psi ). Obser ve and r e c o r d f l ow
( l i t e r s / mi n . ) ( ga l l o n s / mi n . ) a t 7 8 2 C ( 1 7 2
5 F) .
If f l ow d r o ps bel ow 5. 3 l i t e r s/ mi n . (1. 4
ga l l o n s/ mi n . ) , repl ace powe r st eeri ng pump.
7. Compl et el y cl ose and part i al l y open t he ga t e
val ve t hree t i mes. (Do not al l ow t he val ve t o
remai n cl osed f or more t han f i ve seconds. )
Obser ve and r e c or d pr essur e, kPa (psi ).
Pressure speci f i cat i on shoul d mai ntai n a current
pressure bet ween 827 5- 9653 kPa ( 1200- 1400
psi ) minimum t o maxi mum. If t he pressure
r e c or de d is l ower t han t he minimum speci f i cat i on
l i st ed, repl ace t he power st eeri ng pump.
If t he pr essur e r e c or de d is above t he maxi mum
speci f i cat i on l i st ed, repl ace power st eeri ng
pump.
8. I ncrease t he engi ne speed f r om idle t o
appr oxi mat el y 1500 r pm. Observe and r e c or d
f l ow, l i t e r s/ mi n . (gal l ons/ mi n. ).
If f l ow e xc e e ds t he maxi mum f r ee f l ow
speci f i cat i on, repl ace t he power st eeri ng pump.
9. Check idle spe e d, and set if necessary. Wi t h t he
engi ne at i dle, t urn (or have an assi st ant t urn) t he
st eeri ng wheel ( 3600) t o t he ri ght and left st ops.
Record t he pressure and f l ow at st ops.
Pressure devel oped at bot h st ops shoul d be
nearl y t he same as t he maxi mum pump out put
pressure.
11- 00- 2 7 St eer i ng Sy s t e mSe r v i c e 11- 00- 2 7
At t he sa me t i me, f l ow shoul d dr op bel ow 1.9
l i t e r s/ mi n . (0. 5 ga l l on/ mi n. ). If pr essur e doe s not
r e a c h maxi mum out put or f l ow doe s not d r o p
bel ow 1.9L (0. 5 ga l l on/ mi n. ), e xc e ssi ve i nt ernal
l eakage i s occur r i ng. Remove and di sassembl e
t he st eeri ng gear. Repl ace da ma ge d or br oken
pa r t s. Pay part i cul ar at t ent i on t o t he pi st on and
val ve seal s f or damage.
NOTE: If condi t i on sti ll e xi st s, c he c k f ront suspensi on
l ower a r m ball j oi nt s, l i nkage, et c. Ref er t o Di agnosi s.
10. Turn (or have an assi st ant t urn) st eer i ng wheel
sl i ght l y in bot h di rect i ons, and rel ease qui ckl y
whi l e wat chi ng t he pr essur e gauge. The needle
shoul d move f r om t he normal ba c k pr e ssur e
readi ng and snap ba c k as t he st eeri ng wheel is
r el eased. If it c ome s back sl owl y or st i c ks, ei t her
t he r ot a r y val ve in t he st eeri ng gear is st i cki ng or
st eeri ng col umn is bi ndi ng. Check t he st eeri ng
col umn bef or e repl aci ng t he st eeri ng gear val ve.
11. Di sconnect and r emove anal yzer and connect
li nes.
S y s t e m Ba c k - P r e s s u r e
Thi s t est is out l i ned as par t of t est pr ocedur e.
Mi n i mu m P u mp Fl o w
Thi s t e st is out l i ned as par t of t est pr ocedur e.
Re l i e f P r e s s u r e T e s t
I n t e r n a l L e a k a g e T e s t
Ti e R o d A r t i c u l a t i o n T o r q u e
Thi s c he c k may be done wi t h t he st eeri ng gear ( 3504)
on or of f t he vehi cl e.
Spr i n g S c a l e T 7 4P - 3504- Y
1. Di sconnect t i e r od end ( 3A130) f r o m f r ont wheel
knuckl e ( 3K186) (LH) / f ront wheel knuckl e
( 3K185) (RH) usi ng Tie Rod End Remover
TOOL-3290-D or equi val ent .
2. Hook Spri ng Scal e T74P-3504-Y over t i e r od end
and measure f or c e requi red t o move t i e r od end.
3. If f o r c e requi red t o move t i e r od end i s not
be t we e n 8. 9 N-m and 45 N-m (2 lb and 10 l b),
r epl ace t i e r od end.
Fl u i d L e a k
1. Wi t h engi ne i dli ng, t urn st eeri ng whe e l ( 3600) left
t o ri ght several t i mes. Che c k all possi bl e l eakage
poi nt s.
2. Ti ght en al l l oose f i t t i ngs. Repl ace d a ma ge d lines
and se a l s.
3. Che c k hose s f o r cut O-ri ngs.
S t e e r i n g Wh e e l F r e e P l a y
Wi t h t he whe e l s in t he st r ai ght ahead posi t i on, gent l y
t urn t he st eer i ng wheel ( 3600) t o t he l ef t and ri ght t o
c he c k f r e e pl ay. Fr ee pl ay shoul d be be t we e n 0 and
30 mm ( 0 and 1.18 i nches). If t he f r ee pl ay e x c e e d s
t hi s limit ei t her t he st eer i ng j oi nt s are wo r n o r t he
ba c kl a sh of t he st eeri ng gear ( 3504) i s e xc e ssi ve .
Ba c kl a sh can be adj ust ed af t er removi ng t he st eeri ng
gear . Ref er t o Sect i on 11-02. Gr asp t he st eeri ng gear
f i rml y a nd move it up and down and t o t he l ef t and ri ght
t o c he c k f or col umn beari ng wear, st eer i ng shaf t j oi nt
pl ay, st eer i ng gear l ooseness, or col umn l ooseness.
S t e e r i n g C o l u m n B e a r i n g
When c he c ki n g st eeri ng wheel f ree pl ay, al so c he c k
f or radi al pl ay or wobbl e bet ween t he st eeri ng wheel
( 3600) and st eer i ng col umn. Any f r ee pl ay d e t e c t e d
r ef l ect s we a r in t he st eeri ng col umn t ube beari ngs
( 3517 ) and c a n a dd t o apparent f ree pl ay. Ref er t o
Sect i on 11-04 f or st eeri ng col umn t ube repai r
pr ocedur es.
P u r g i n g P o w e r S t e e r i n g S y s t e m o f A i r
A whi ne noi se heard f r om t he power st eer i ng pump
may be c a use d by ai r in t he sy st e m.
The f ol l owi ng servi ce pr ocedur e must be pe r f or me d
whenever any of t he f ol l owi ng ser vi ce is per f or med:
All powe r st eeri ng noi se compl ai nt s wi t h evi dence of
aer at ed f l ui d on pre-del i very vehi cl es onl y, pri or t o
any component servi ce.
Any powe r st eeri ng sy st e m component (gear, hose,
et c. ).
NOTE: If t he air is not purged f r om t he powe r st eeri ng
sy st e m cor r ect l y, a second cust omer concer n or pump
fai lure coul d resul t . Thi s condi t i on can only occur on
pre-del i very vehi cl es wi t h evi dence of aer at ed flui d or
vehi cl es t hat have had st eeri ng component ser vi ce.
Fl u i d L e v e l T o p - O f f P r o c e d u r e
1. Check and fill pump reservoi r t o di pst i ck FULL
COLD or remot e reservoi r cent er mark.
2. Di sabl e ignition by di sconnect i ng EDI S/ DI S/ TFI
modul e or remove TFI di sconnect CMP / HA L L
EFFECT/PI P sensor.
11- 00- 2 8 St eer i ng Sy s t e mSe r v i c e 11- 00- 2 8
NOTE: Shut of f sol enoi d (on t he i nj ect i on pump) must
be di sconnect ed t o prevent st ar t i ng.
3. Crank engi ne 30 seconds, c he c k flui d level and
a dd if requi red.
4. NOTE: Do not hol d st eeri ng wheel on st ops.
Crank engi ne 30 seconds whi l e cycl i ng l ock t o
l ock.
5. Check flui d level and a dd Premi um Power
St eeri ng Fluid E6AZ-19582-AA or equi valent
meet i ng For d speci f i cat i on ESW-M2C33-F if
requi red.
A i r P u r g e w i t h V a c u u m E x t e r n a l S o u r c e
P r o c e d u r e
1. Ti ght ly i nsert t he rubber st opper of t he air
evacuat or assembl y i nto pump reservoi r.
2. Reconnect connect i on used t o di sabl e i gni t i on.
St ar t vehi cl e.
3. Appl y 20-25 i n-Hg (68-85 kPa) maxi mum vacuum
f or mi ni mum of t hr ee mi nut es at i dle; mai ntai n
maxi mum vacuum wi t h vacuum sour ce.
4. Rel ease vacuum and remove vacuum sour ce.
5. Ad d Premi um Power St eeri ng Flui d
E6AZ-19582-AA or equi val ent meet i ng For d
speci f i cat i on ESW-M2C33-F t o full wa r m or
reservoi r cent er mark.
6. Rei nstall vacuum sour ce and appl y 20-25 in-Hg
(68-85 kPa) vacuum.
Vacuum So ur c e Co n n e c t i o n
Cy cl e st eeri ng wheel f r om l ock-t o-l ock every 30
se c onds f or appr oxi mat el y f i ve mi nut es.
8. Shut engi ne of f , rel ease vacuum, remove vacuum
sour ce and l ower f ront end.
9. Ad d flui d if necessar y, install di pst i ck or reservoi r
cap.
St ar t engi ne and c y c l e st eeri ng wheel f r om
l ock-t o-l ock every 30 seconds f or appr oxi mat el y
f i ve mi nut es.
11. Check f or oil l eaks at all connect i ons.
12. In sever e c a se s it may be necessar y t o repeat ai r
purge wi t h vacuum sour ce pr ocedur e as shown in
t he f ol l owi ng i l l ust rat i on.
G2877-K
Pa r t
1 021-00014 Rotunda Vacuum Tester
(Recommended) Distributor
Machine (Alternate) A/ C
Recovery Machine
(Alternate)
2 Vacuum Hose
3

6.35-7.93 mm ( 1/ 4- 5/ 16
Inch)
I t e m
Pa r t
4

Hold Back at Least 3.175
mm (1/ 8 Inch)
5 Rubber Stopper Cap No. 7
6 Ensure Tight Seal in Stopper
7

6.35-7.93 mm ( 1/ 4- 5/ 16
Inch) Tubing Plexiglass,
Steel or Copper
8 Vacuum Gauge
Start-Up P r o c e d u r e , Af t e r P o we r St e e r i n g
P u mp o r Ge a r Se r v i c e
Af t er engi ne st art -up, f ol l ow t hese st e ps t o el i mi nat e
e xc e ssi ve st eeri ng sy st e m noi se due t o air t r a ppe d in
t he sy st e m duri ng ser vi ce:
1. Di sconnect t he i gni ti on coi l wi r e .
2. Fill t he power st eeri ng oil reservoi r ( 3A697 ) wi t h
Premi um Power St eeri ng Fluid E6AZ- 19582- AA
or equi val ent meet i ng For d speci f i cat i on
ESW-M2C33-F. Rai se vehi cl e on hoi st . Ref er t o
Sect i on 00- 02.
3. Crank t he engi ne wi t h t he st ar t er mot or ( 11002)
and add flui d until t he level remai ns const ant .
4. NOTE: Front wheel s must be of f t he f l oor duri ng
l ock-t o-l ock rot at i on of t he st eeri ng wheel ( 3600) .
Whi l e cranki ng t he engi ne, r ot at e t he st eeri ng
wheel f r om l ock-t o-l ock.
5. Che c k t he flui d l evel and a dd f l ui d if necessar y .
6. Connect t he i gni ti on coi l wi re.
7. St ar t t he engi ne and al l ow it t o run f or several
mi nut es.
9. Rot at e st eeri ng wheel f r o m l ock-t o-l ock.
10. Turn off t he engi ne and c he c k t he f l ui d l evel . Ad d
f lui d if necessar y.
11. Purge t he sy st e m of ai r as out l i ned, if ai r is sti ll
present .
Fi l l P r o c e d u r e
Thi s pr ocedur e i s r ecommended whenever t he powe r
st eeri ng pump ( 3A67 4) , st eeri ng gear ( 3504) or hy dr o
(if equi pped), is r e move d, ser vi ced and i nst alled i nt o
t he powe r st eeri ng hydraul i c sy st e m.
Ma t e r i a l s Re q u i r e d
1. A vacuum pump wi t h gauge, capabl e of pulling 84
kPa (25 i n-Hg). The vacuum sour ce shoul d be one
of t he f ol l owi ng:
Di st ri but or t e st machi ne vacuum pump.
Vacuum mot or f r om an ai r condi t i oni ng
char gi ng sy st e m.
Po we r St e e r i n g Sy st e m Fi l l Pr o c e d ur e
2. A No. 7 st opper c a p, or a speci al powe r st eeri ng
pump c a p assembl y wi t h a t ee connect i on,
shut of f val ves and a powe r st eeri ng pump
auxi l i ary reservoi r (3E764). The de va c t ool can
be used.
G2887-F
Pa r t
1 Remote Fill Reservoir
2

Hose
3
_
Valve No. 1
4

Tee
I t e m
Pa r t
5

Valve No. 2
6 0 to 30 Inch Vacuum Gauge
7 Valve No. 3
8 No. 7 Stopper
9 Hose
P r e p a r a t i o n
1. Assembl e t he vacuum fill sy st e m.
2. Install t he vacuum fill sy st e m on t he vehi cl e. If t he
st eeri ng gear or power st eeri ng pump has been
changed or f l ushed, al l ow old flui d t o drai n f r om
t he sy st e m.
3. Ti ght en all st eeri ng sy st e m and vacuum fill
connect i ons.
i n i t i a l Fi l l
1. Install t he c a p on t he power st eeri ng pump fill
neck or rubber st opper on power st eeri ng oil
2. Open Valve No. 1 and al l ow t he powe r st eeri ng
f lui d t o bl eed t hrough t he t ee f i t t i ng. Cl ose Valve
No. 1 af t er bl eedi ng.
3. Pour enough Premi um Power St eeri ng Flui d
E6AZ- 19582- AA or equi val ent meet i ng For d
speci f i cat i on ESW-M2C33-F in t he powe r
st eeri ng pump auxi l i ary reservoi r t o e xc e e d t he
amount requi red f or filling t he sy st e m.
4. Cl ose all val ves.
5. Open Val ves No. 2 and No. 3. St ar t t he vacuum
pump. Oper at e t he pump until a gauge readi ng of
84- 101 kPa (25-30 i n-Hg) is obt ai ned.
6. Cl ose Val ve No. 3, and shut off t he vacuum pump.
Wa t c h t he gauge f or appr oxi mat el y 30 se c onds.
If t he vacuum readi ng dr ops more t han 1 in-Hg (3
kPa), t her e is a leak in t he power st eeri ng or filling
sy st e m t hat must be c o r r e c t e d .
7. St ar t t he vacuum pump. Open Val ve No. 3.
Ope r a t e t he pump until a gauge readi ng of 84- 101
kPa (25-30 in-Hg) is obt ai ned.
8. Cl ose Val ve No. 2, and shut off t he pump. Open
Val ve No. 1 t o fill t he st eeri ng sy st e m wi t h f l ui d.
The powe r st eeri ng pump auxi l i ary reservoi r
shoul d be el evat ed hi gher t han t he power
st eeri ng pump and powe r st eeri ng oil reservoi r.
9. When flui d st ops drai ni ng f r om powe r st eeri ng
pump auxi l i ary reservoi r, cl ose Val ve No. 1 and
r emove c a p or rubber st opper.
Fi nal Fi l l
1. Adj ust flui d level in powe r st eeri ng pump t o
c o r r e c t l evel . There wi ll be a sl i ght dr op in t he
level when t he engi ne is f i rst st a r t e d and t he
st eeri ng wheel ( 3600) is c y c l e d .
2. Ope r a t e t he engi ne at an idle f or 15 mi nut es, t hen
i nspect f or l eaks. It wi l l not be necessar y t o
de va c t he sy st e m unl ess t her e is evi dence of ai r
in t he powe r st eeri ng pump t hat coul d c a use
noi se or af f ect per f or mance.
S t e e r i n g P u m p , P o w e r
P r o c e d u r e No . 1
If repl aci ng t he power st eeri ng pump ( 3A674) , it must
be pri med wi t h t he speci f i ed power st eeri ng flui d pri or
t o i nst al l at i on. Remove t he f i t t i ng f r om t he pr essur e
port and pour Premi um Power St eeri ng Fluid
E6AZ-19582-AA or equi valent meet i ng Ford
speci f i cat i on ESW-M2C33-F into t he pressure por t
wi t h t he port f aci ng upwar d t o maxi mi ze t he amount of
flui d a dde d t o t he power st eeri ng pump. Turn t he
powe r st eeri ng pump dri veshaf t sl owl y duri ng t hi s
pr ocedur e t o al l ow more fluid t o ent er t he power
st eeri ng pump. Mount t he power st eeri ng pump t o t he
vehi cl e in a manner t hat does not al l ow t he flui d t o
e sc a pe f r om t he powe r st eeri ng pump. Connect t he
plumbi ng lines t o t he power st eeri ng pump and power
st eeri ng oil reservoi r ( 3A697 ) . Fill t he reservoi r t o t he
pr oper l evel . St ar t t he vehi cl e and sl owl y make
st op-t o-st op t urns t o purge ai r f r om t he sy st e m. St op
t he engi ne, c he c k t he flui d level. Add addi t i onal flui d t o
t he powe r st eeri ng oil reservoi r (if necessar y) t o t he
proper l evel .
P r o c e d u r e No . 2
When t he unpri med repl acement power st eeri ng pump
has been mount ed t o t he engi ne, a t t a c h t he plumbi ng
lines t o t he power st eeri ng pump and power st eeri ng
oil reservoi r and fill t he power st eeri ng oil reservoi r t o
t he pr oper l evel . Rai se t he f ront of t he vehi cl e until
bot h f ront wheel s are off t he gr ound. St art t he vehi cl e
and sl owl y make st op-t o-st op t urns t o purge air f r om
t he sy st e m. St op t he engi ne and a dd addi t i onal flui d t o
t he powe r st eeri ng oil reservoi r (if necessar y) t o t he
proper l evel . Lower f ront of vehi cl e and check power
st eeri ng sy st e m f or proper oper at i on.
S t e e r i n g P u m p , P o w e r
Fl u s h i n g
If cont ami nat i on is f ound in t he power st eeri ng gear
( 3504) , f lush t he power st eeri ng sy st e m as f ol l ows:
1. Ma ke sure all ot her hoses ar e connect ed, t hen
di sconnect t he power st eeri ng pressure hose
( 3A7 19) at t he st eeri ng gear.
2. Pl ace t he power st eeri ng pressure hose in a
cont ai ner.
3. Fill t he power st eeri ng oil reservoi r ( 3A697 ) wi t h
For d Premi um Power St eeri ng Flui d
E6AZ-19582-AA (in Canada, Mot or cr af t
XT-1-QF) or equi valent meet i ng For d
Speci f i cat i on ESW-M2C33-F.
4. Di sconnect t he ignition coi l wi r e.
5. Whi l e addi ng appr oxi mat el y 1.9 liter (0. 5 gal ) of
f l ui d, t urn i gni ti on swi t ch ( 1157 2) t o t he START
posi t i on, and cr ank t he engi ne wi t h t he st ar t er
mot or ( 11002) . As soon as all flui d has been
a dde d, t urn t he ignition swi t c h t o t he OFF
posi t i on.
11- 00- 31 St eer i ng S y s t e mS e r v i c e 11- 00- 31
6 .
7.
8.
9.
10.
Connect the power steeri ng pressure hose at the
steeri ng gear.
Check the fluid level.
Crank the engine wi t h the st art er motor and add
fluid until the level remai ns const ant .
Lower vehicle and connect the ignition coil wi re.
Start the engine and turn t he steeri ng wheel
( 3600) f rom l ock-to-l ock t o expel any air t rapped
in the syst em. This will rest ore normal steeri ng
acti on.
Cl e a n i n g
Wash all part s, except seal s, in a chl ori nated sol vent
and dry wi th compressed air.
I n s p e c t i o n
NOTE: The only servi ceabl e component s on the
steeri ng pump are the EVO power steeri ng control
val ve actuator ( 3783) and the pressure hose t ube nut
(connector assembl y). If t he power steeri ng pump
( 3A674) needs repair, repl ace power steeri ng pump
assembl y wi th servi ce power steeri ng pump.
S t e e r i n g G e a r
Cl e a n i n g
1. Use a clean wor k bench and tool s.
2. Clean the exteri or of the steeri ng gear ( 3504)
wi th solvent. If necessary, drain off excess
hydraulic fluid.
3. Handle the part s careful l y t o avoi d ni cks, burrs,
scrat ches and dirt. Do not use sol vent on seal s.
I n s p e c t i o n
1. Inspect the sect or shaft bushing in the cover. If
damaged or l oose, repl ace sect or shaft cover
assembl y.
2. Inspect the input shaft beari ng. Check the fit of
the bearing on the input shaf t . Repl ace the
beari ng, if necessary. Slight l ateral play is
accept abl e, 0. 127- 0. 254 mm ( 0. 005- 0. 010
inch).
3. Inspect the val ve housing f or wear, scori ng or
burrs.
4. Inspect the tube seat s and the pressure and
return ports for ni cks. Repl ace them if necessary.
5. Inspect the sect or shaft beari ng in the housi ng.
Ensure that rollers are in pl ace and move freel y. If
bearing is damaged, repl ace housing assembl y.
The bearing cannot be servi ced separatel y.
6. Check the fluid passages f or obstructi on or
l eakage.
7. Inspect the gear housing f or cr acks and st ri pped
t hreads and the mati ng surf aces for burrs.
Inspect the piston bore for scori ng or wear. If
necessary, repl ace the housi ng. Surface
burnishing is accept abl e if no significant st ep can
be felt.
8. Ensure input shaf t bearing rot at es freel y.
9. Check t he input shaft for f reedom of movement in
the sl eeve. If movement is i mpai red, repl ace val ve
assembl y.
F l u s h i n g
Al ways fl ush t he power steering gear ( 3504) when
repl aci ng the power steeri ng pump ( 3A674) due t o
fluid contami nati on.
1.
5.
Remove t he power steering pump and power
steeri ng pump pulley ( 3A733) and servi ce the
power steeri ng pump as outlined.
NOTE: Connect only t he power steeri ng pressure
hose ( 3A719) .
Install t he power steering pump pulley on the
servi ced power steeri ng pump. Install t he power
steeri ng pump. Flush the power steeri ng pump
before installing.
Pl ace t he power steering pressure hose from t he
steeri ng gear in a container, and plug t he power
steeri ng reservoi r pump hose (3691).
Fill t he power steeri ng oil reservoi r ( 3A697) wi t h
Ford Premium Power Steering Fluid
E6AZ- 19582- AA (in Canada, Mot orcraf t
XT-1-QF) or equivalent meeting Ford
Speci fi cati on ESW-M2C33-F.
Di sconnect ignition coil wire and raise the front
wheel s off the ground. Refer t o Section 00- 02.
Whi l e addi ng approxi matel y 1.9 liters (0. 5
gallons) of Premium Power Steering Fluid
speci fi cati on ESW-M2C33-F, turn the ignition
swi t ch ( 11572) t o the START position and crank
the engine wi t h t he starter motor ( 11002) while
turning the steeri ng wheel ( 3600) from left to
right.
When all the fluid has been added, turn ignition
swi t ch to the OFF position and connect ignition
coil wi re.
Remove t he plug from the power steering
reservoi r pump hose and connect the power
steering reservoi r pump hose t o the power
steeri ng oil reservoir.
9 Check the fluid level. Add fluid if necessary. Do
not overfill the power steering oil reservoir.
10. Lower the vehi cl e.
11. Turn the steeri ng wheel from lock-to-lock wi thout
hitting the st ops to expel any trapped air.
SPECIFICATIONS
STATIC STEERING WHEEL TURNING EFFORT (LBS)
Co u ga r
Vehi cle Power
To wn Ca r , Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s 2 . 7 2 KG ( 6. 0
L b s )
TA1000B
BELT TENSION
Appl i c a t i on Mi ni mum Torque
4. 6L 40 N-m ( 30 L b - Ft )
POWER STEERING PUMP SPECIFICATIONS
Mi ni mum Fl ow
8
Mi ni mum Reli ef
P r e s s u r e
Maxi mum Reli ef
Pressure
Pump
Model
Maxi mum Free Fl ow
@1500 RPM
Li t e r s/ Mi n . Ga l . / Mi n .
b
kPa psi kPa psi
Pump
Model Li t e r s/ Mi n . Ga l . / Mi n .
b
5. 7 1.4 82 7 0 12 00 9 5 2 0 1380 HBD- AA 12. 9 3. 4
s
a At ze r o s p e e d ( v e h i c l e not mo v i n g) .
b 'IMPORTANT: Fl o w d e p e n d s o n p o we r s t e e r i n g p u mp mo d e l , e n gi n e r p m, a n d pul l e y r a t i o . En gi n e i d l e r p m must b e s e t t o s p e c i f i c a t i o n
wh e n c h e c k i n g p o we r s t e e r i n g p u mp mi n i mum f l o w c a p a c i t y .
POWER STEERING GEAR OPERATIONAL
SPECIFICATIONS
Descr i pt i on Spe c i f i c a t i on
Ty pe Re c i r c . Ba l l To r s i o n Bar
Ra t i o 14:1
Tur n s o f St e e r i n g Wh e e l ( L o c k
t o L o c k L i n k a g e
Di s c o n n e c t e d )
3. 4
Fl ui d Ca p a c i t y ( i n c l u d e d in
Pump Re s e r v o i r Fi l l )
1.6 Pi n t s ( A p p r o x i ma t e )
Fl ui d S p e c i f i c a t i o n E SW- M2 C33- F Pr e mi um
P o we r St e e r i n g Fl ui d ( Pa r t No .
E 6A Z - 19582 - A A )
Wo r m Be a r i n g P r e l o a d . 45- 1 N-m ( 409 L b- l n )
To t a l Me s h l o a d Ov e r Wo r m
Be a r i n g P r e l o a d
1.2 N-m ( 14- 18 Lb- l n )
POWER STEERING RELIEF PRESSURE
P r e s s u r e kP a ( ps i ) 8 3 4 0 - 8 8 2 0 ( 1 2 1 0 - 1 2 7 0 )
St e e r i n g P ump A d a p t e r s 2 0 15
Tool Numbe r /
T 7 4P - 3504- Y
Sp r i n g Sc a l e
T 7 4 P - 3 5 0 4 - Y
T OOL - 32 90- D Ti e Ro d End Re mo v e r
ROTUNDA EQUIPMENT
014- 002 07 P o we r St e e r i n g S y s t e m An a l y ze r
02 1- 00014 Va c u u m Te s t e r
059- 00010 I n d uc t i v e Dwe l l - Ta c h - Vo l t - Oh mme t e r
11- 02 - 1 11- 02 - 1
SECTION 11-02 Steering System, Power
SUBJECT PAGE
Hoses, Pressure and Return 11-02-6
Hydraulic Operation 11-02-6
Mechanical Operation ...11-02-6
Pressure Relief Valve Operation 11-02-6
Pump Connecti on 11-02-3
Steeri ng Gear . . . 11-02-2
Steeri ng Pump 11-02-1
Steeri ng, PowerVari abl e Assi st 11-02-1
Syst em Components 11-02-4
Steeri ng Syst em, Power 11-02-6
EVO Actuator Assembly 11-02-12
EVO Control Module 11-02-12
Hoses, Pressure and Return 11-02-15
Power Steeri ng Pressure (PSP) Swi t ch 11-02-11
Pump and Pulley ...11-02-6
Quick Connect Power Steeri ng Fitting 11-02-14
Reservoir, Power Steeri ng Pump
Auxiliary 11-02-11
SUBJECT PAGE
Steeri ng Sensor ..11-02-13
Steeri ng Sensor Ring 11-02-13
Vehicle Speed Sensor 11-02-13
DI SASSEMBLY AND ASSEMBLY
Hose Fittings, Pressure and Return 11-02-23
Steeri ng Gear Housi ng... 11-02-18
Valve Housing 11-02-19
Worm and Valve Sl eeve 11-02-21
Pump Flushi ng 11-02-24
Syst em Flushi ng 11-02-24
ADJUSTMENTS
Meshload 11-02-24
SPECI FI CATI ONS 11-02-25
SPECI AL SERVI CE TOOLS/EQUI PMENT 11-02-26
VEHICLE APPLICATION
St eeri ng, PowerVari abl e Assi st
The el ect roni c vari abl e ori f i ce (EVO) sy st e m i s
desi gned t o var y f l ow f r o m t he power st eer i ng pump
( 3A67 4) a s a f unct i on of vehi cl e spe e d and st eeri ng
wheel r at e of r ot at i on, gi vi ng a f o r m of vari abl e assi st .
The sy st e m pr ovi des:
Full powe r st eeri ng assi st at low vehi cl e spe e d f or
light par ki ng ef f ort .
Mi ni mum assi st at hi gh speed f or go o d "r o a d f e e l "
and di rect i onal st abi l i t y.
Full assi st is ret urned duri ng evasi ve maneuvers.
St eeri ng Pump
The CHI powe r st eeri ng pump ( 3A67 4) has t he
f ol l owi ng f eat ur es:
It is a bel t dri ven, vane-t y pe, powe r st eeri ng pump.
It is mount ed di r ect l y t o t he engi ne bl ock by f our
The EVO powe r st eer i ng cont r ol val ve a c t ua t or
( 37 83) is c onne c t e d t o t he pump body t o pr ovi de
vari abl e powe r st eer i ng assi st .
The el ect ri cal c onne c t or and casi ng ar e abl e t o
swi vel . Thi s is normal a nd doe s not i ndi cat e a l oose
power st eeri ng cont r ol val ve act uat or assembl y.
The powe r st eeri ng oil r eser voi r ( 3A697 ) f or t he
power st eeri ng flui d is mount ed on t he LH a pr on.
An i dent i f i cat i on t a g a t t a c he d t o t he po we r st eeri ng
pump i ndi cat es t he model number and bar c o d e .
Ref er t o t he se whe n se r vi c e pa r t s ar e r equi r ed.
POWER STEERING
CONTROL VALVE
ACTUATOR
3783
POWER STEERING
PUMP
3A674 G5874-D
11- 02- 2 St eer i ng Sy s t em, Power 11-02-2
NOTE: The power steering pump is serviced as an
assembly. If any service is required, the entire power
steering pump assembly must be replaced. The only
exception is if the EVO power steering control valve
actuator or connector on the power steering pump
assembly is found to be damaged; then replace the
power steering control valve actuator only.
On Town Car, a power steering sensitivity switch on
the LH side of the instrument panel allows the driver to
select the rate at which power steering assist is
reduced with vehicle speed. The switch has selections
for low, normal or high rate of decrease.
There are two types of EVO systems available:
BaseThe EVO system is stand alone and the
vehicle has steel rear springs (5560).
Optional Rear Air SuspensionThe EVO circuit is
combined in the Air Suspension Control Module.
(Refer to Section 04-05 for Description and Service
of the electronic air suspension system.)
Steering Gear
The steering gear (3504) has the following features:
It is a torsion-bar type of hydraulic assisted system.
The system furnishes power to reduce the amount
of effort required to turn the steering wheel (3600).
It also reduces road shock and vibration.
It includes a worm and one-piece rack piston which
is meshed to the gear teeth on the steering sector
shaft.
It includes a rotary-style hydraulic valve consisting
of:
an input shaft.
control valve sleeve.
torsion bar.
The valve is pinned to the worm, and the input shaft
is connected to the worm through the torsion bar.
The hydraulic action is generated by a relative
rotary position between the power steering gear
input shaft and control (3D517) and the
worm/sleeve assembly.
The steering gear is designed with the one-piece rack
piston, worm and sector shaft in one housing and the
rotary valve sleeve assembly in an attached housing.
This makes possible internal fluid passages between
the rotary valve sleeve and power cylinder, eliminating
all external lines and hoses, except the power steering
pressure hose (3A719) and power steering return
hose (3A713) between the power steering pump
(3A674) and steering gear assembly.
The power cylinder piston is an integral part of the
steering gear housing (3548).
The piston is double acting.
Fluid pressure may be applied to either side of the
piston.
The steering gear ratio is 14:1.
The steering gear allows 3.3 turns from steering
stop to steering stop.
The control valve is a unique rotary design that uses
relative rotational position of the power steering gear
input shaft and control and valve sleeve to direct fluid
flow.
In a neutral (straight-ahead) position, where power
assist is not required:
The power steering gear input shaft and control
valve and sleeve are held in a central position by the
torsion bar.
The fluid flows from the inlet port through the valve
to the outlet port and back to the power steering
pump.
No area of the steering gear is under high pressure.
The valve and housing cylinder are always full of
power steering fluid, which dampens road shock that
otherwise would be transmitted to the driver through
the steering wheel.
Power steering assist is provided as follows:
One end of the power steering gear input shaft and
control valve is attached to the steering column tube
(3514) and steering wheel.
The other end, providing the link to the wheel side of
the steering system, is connected to the worm
through the torsion bar.
As a steering maneuver is initiated, the rotation
force, applied through the steering wheel / steering
column to the power steering gear input shaft and
control, is transmitted to the worm where it meets
the resisting forces of the road wheels.
When the steering forces are great enough, the
rotational deflection (twisting) of the torsion bar
occurs.
This deflection changes the relative position of the
power steering gear input shaft and control and
control sleeve to cause a throttling of the hydraulic
flow and directs the high-pressure fluid to the
appropriate end of the piston in the steering gear
housing.
The difference in pressure forces on the piston
helps move the steering gear sector shaft (3575),
thus assisting in the turning effort.
The oil in the opposite end of the steering gear
housing is forced out through the return outlet of the
control valve and back to the power steering oil
reservoir (3A697).
With higher steering efforts, increased valve
displacement gives the driver proportionately higher
assisting pressure.
The driver will have a smooth hydraulic assist at all
times.
When the driver stops applying steering effort, the
following actions occur:
11- 02 - 3 St eeri ng Sy st em, Power 1 1 - 02- 3
The val ve sl eeve and power st eeri ng gear input
shaf t and cont r ol ar e ret urned t o a cent er ed posi t i on
by t he t or si on bar.
Thi s equal i zes pr essur e on bot h si des of t he pi st on.
The st eeri ng geomet r y wi ll t end t o ret urn t he f ront
wheel s t o t he st r ai ght -ahead posi t i on.
NOTE: A hi ssi ng noi se is a normal char act er i st i c of
r ot ar y val ve st eeri ng gear and in no wa y af f ect s
st eer i ng. A repl acement val ve wi l l al so exhi bi t sli ght
noi se, so it is not a l wa y s a cure f or t he condi t i on. Any
met al -t o-met al c o n t a c t s at t he f l exi bl e st eeri ng shaf t
coupl i ng (due t o col umn mi sal i gnment ) wi ll t ransmi t a
se ve r e val ve hi ssi ng noi se into t he passenger
c ompa r t me nt t hat shoul d be c o r r e c t e d .
The onl y ser vi ce t hat can be per f or med on t he cont r ol
val ve assembl y is t he repl acement of t he f our Teflon
seal s on t he cont r ol val ve sl eeve.
Pump Connect i on
The f ol l owi ng di agr am i l l ust rat es hydraul i c
connect i ons t o t he powe r st eeri ng pump ( 3A67 4) and
possi bl e l eakage poi nt s.
NOTE:
IF LEAK OCCURS
HERE, REPLACE
HOSE ASSY
NOTE: IF LEAK OCCURS
HERE, TIGHTEN NUT TO
SPECIFICATION. REPLACE
TEFLON SEAL IF
NECESSARY.
ALWAYS REPLACE
THIS SEAL WHEN A
LINE IS REMOVED.
G5788-B
I t em
Part
Number Descri pt i on
3 388898-S Teflon Seal
4 3D654 Power Steering Pump Valve
Outlet Fitting
5

O-Ring (Part of 3B584 Kit)
A

Tighten t o 34-46 N-m (26-34
Lb-Ft)
Cont i nued oper at i on under suc h condi t i ons may cause
e xc e ssi ve hi gh po we r st eer i ng flui d t emper at ur e and
da ma ge t he st eer i ng c ompone nt s.
Part
It em Number Descri pt i on
1 3A719 Power Steering Pressure
Hose
Outlet Fitting (Gold)
11- 0 2- 4 St e e r i n g S y s t e m, P o we r 11- 02- 4
EVO Component Lo c a t i o n
G7814-A
S y s t e m C o mp o n e n t s
EVO Power Steeri ng Control Val ve Act uat or ( 3783)
Assembl y: At t ached to the Cill power steeri ng pump
( 3A674) .
Shock absorber electronic steeri ng sensor
( 18B015) : At t ached to l ower steeri ng col umn.
Vehicle Speed Sensor (VSS)(9E731): At t ached t o
transmi ssi on.
Dat a Link Connector: Locat ed in l uggage
compart ment behind RH si de quarter-panel carpet .
Syst em Component s
Control Modul e: Locat ed between the dash panel
and instrument panel on the air conditioning plenum
on the passenger si de behind the glove
compartment.
The base vehicle control module is a 14-pin connector
wi th a bl ack pl asti c case, while the air suspension
vehi cl e has a 26-pin connector wi th a metal case.
SPEED
SENSOR
X
SPEED
SENSOR
/
CONTROL MODULE
ACTUATOR VALVE
(POWER STEERING
PUMP)
STEERING WHEEL
N
PUMP)
ROTATION SENSOR
G7708-B
In the event of an el ectri cal circuit mal functi on, such as
circuit open, short ed, or control modul e failure, t he
act uat or will provi de full power steeri ng assi st.
E VO A c t u a t o r A s s e m b l y
The power steeri ng control valve actuator generates a
di f f erent i al pressure, dependent on fl ow and current
input.
11- 02 - 5
Thi s differential pressure is used t o control t he
spool val ve in the Ford CHI power steeri ng pump.
The actuator / spool valve regul ates t he hydraul i c
f l ow and when combined wi t h a current control l i ng
devi ce, yi el ds a variable assi st power steeri ng
pump.
G5883-B
S t e e r i n g Wh e e l Ro t a t i o n S e n s o r
An opti cal shock absorber el ectroni c steeri ng sensor
(photocel l ), mounted on the l ower steeri ng col umn, is
used t o establ i sh t he rate of the st eeri ng wheel
rotati on.
When the steeri ng wheel rotati on rat e reaches 30
rpm (15 rpm f or air suspensi on model ), t he output
current t o the power steeri ng cont rol val ve act uat or
begi ns t o reduce, thereby provi di ng additional
power steeri ng assi st.
Once the steeri ng wheel rotati on rat e reaches 60
rpm ( 83 rpm for air suspensi on model ) and greater,
t he output current t o the power steeri ng control
val ve actuator reaches zero, and full power steeri ng
assi st is provi ded.
After the steeri ng wheel rotati on rat e drops bel ow
30 rpm (15 rpm for air suspensi on), the output
current returns t o the amount of current regul ated
by the vehi cl e speed sensor input, wi thi n one
second.
S H O C K A B S O R B E R
E L E C T R O N I C S T E E R I N G
S E N S O R 1 8 B 0 1 5
T O E L E C T R I C A L
C O N N E C T O R
G 5191- B
The vehi cl e speed sensor, al so used for air
suspensi on, is l ocat ed on t he transmi ssi on and is used
t o establ i sh vehi cl e speed.
The output current t o t he power steeri ng control
val ve act uat or is a functi on of vehi cl e speed and the
steeri ng wheel rotati on rat e.
When vehi cl e speed is less t han 1 6 k m/ h ( 1 0 mph),
the power steeri ng cont r ol val ve act uat or output
current is l ess than 60 mA, and full power steeri ng
assi st is provi ded.
As vehi cl e speed i ncreases t o 40 k m/ h (25 mph),
the current i ncreases linearly t o 300 mA.
As vehi cl e speed conti nues t o i ncrease up t o 142
k m/ h ( 88 mph), the current i ncreases linearly t o
590 mA. The current then remai ns constant at 590
mA for vehicle speeds great er than 142 k m/ h ( 88
mph).
Conversel y, as vehi cl e speeds decrease, t he
current decreases at t he linear rat e.
VEHI CLE SPEED
SENSOR 9E731 K6267-D
Da t a L i n k C o n n e c t o r
The dat a link connector is used f or di agnosti cs. Refer
t o Secti on 11-00 for EVO stand alone syst em, or
Secti on 04- 05 for air suspension syst em.
C o n t r o l Mo d u l e
The control module contai ns a mi croprocessor whi ch
anal yzes the vehicle speed sensor input and t he shock
absorber electronic steeri ng sensor input
continuously. Wi th thi s i nformati on, t he
mi croprocessor control s the power steeri ng control
valve actuator, t hereby regulating t he fluid fl ow f rom
the power steeri ng pump.
At low vehicle speeds, the power steeri ng control
val ve actuator is control l ed t o provi de full pump fl ow
for full power steeri ng assi st.
At higher vehicle speeds, t he power steering
control val ve act uat or is control l ed t o reduce power
steering pump fl ow and reduce t he power steeri ng
assi st.
For evasi ve maneuvering at high speeds, the power
steering control valve actuator is control l ed t o
increase the power steeri ng pump fl ow, t hereby
increasing power steeri ng assi st .
In the Crown Vi ctori a and Grand Marqui s, the base
vehicle syst em has a stand al one EVO syst em.
Wi th the addition of computer control l ed air
suspension, the air suspension control module is a
dual-function module whi ch cont rol s both the rear
air suspension and EVO syst ems.
1995 To wn Ca r , Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s J u l y 1 9 9 4
11- 02 - 6
St e e r i n g S y s t e m, P o we r 11- 02 - 6
Ho s e s , Pr e s s u r e a n d Re t u r n
The power st eeri ng hose at t he power st eeri ng pump
uses O-ri ng seal s at t he qui ck connect f i t t i ngs. Not e
t hat t her e ar e t wo possi bl e l eak poi nt s at t he st eeri ng
gear f i t t i ngs:
Bet ween t he power st eeri ng pr essur e hose
( 3A7 19) or powe r st eeri ng ret urn hose ( 3A7 13) and
t he hose nut.
Bet ween t he hose nut and t he c a st iron st eeri ng
gear housi ng ( 3548) or powe r st eeri ng pr essur e,
ret urn and pump out let line connect or.
Me c h a n i c a l O p e r a t i o n
The st eeri ng gear ( 3504) uses an i nt egral pi st on
desi gn t o pr ovi de powe r -a ssi st e d vehi cl e st eeri ng
c ont r ol .
H y d r a u l i c O p e r a t i o n
Thest eeri ng gear ( 3504) uses an i nt egral val vi ng t hat
di r ect s pump f l ow and cont r ol s pressure as requi red t o
reduce st eer i ng ef f ort duri ng oper at i on. The st eer i ng
gear cont ai ns:
A r ot a r y hydraul i c flui d cont rol val ve i nt egrat ed t o
t he powe r st eeri ng gear i nput shaf t and cont r ol
( 3D517 ) .
A boost cyl i nder i nt egrat ed wi t h t he st eeri ng gear
sect or shaf t ( 3575) .
P r e s s u r e Re l i e f Va l v e O p e r a t i o n
Lo c a t e d in t he power st eeri ng pump val ve body , t he
pr essur e reli ef val ve li mi ts hydraul i c pr essur e wi t hi n
t he powe r st eeri ng gear ( 3504) t o a preset maxi mum.
S t e e r i n g S y s t e m , P o w e r
P u m p a n d P u l l e y
St e e r i n g Pump Pul l e y Re mo v e r
P o we r St e e r i n g P u mp Pul l e y Re p l a c e r
T69L- 10300- B
T 91P - 3A 7 33- A
Re mo v a l
1. Loosen t he t ensi oner t o reli eve t ensi on of dri ve
belt ( 862 0) , r emove power st eeri ng pump
( 3A67 4) and power st eeri ng pump pulley
( 3A7 33) assembl y f r om t he engi ne a s out l i ned.
2. Pl ace power st eeri ng pump and power st eeri ng
pump pulley assembl y into vi se agai nst t he t wo
rear pump mount i ng hol es.
3. CAUTI ON: Do n o t a p p l y i n - a n d - o u t p r e s s u r e
o n t h e p o we r s t e e r i n g p u mp s h a f t . P r e s s ur e
wi l l d a ma g e t h e i n t e r n a l t h r u s t a r e a s .
Install St eeri ng Pump Pulley Remover
T69L- 10300- B on t he pulley hub.
4. Hol d t he small hex-head, and r ot at e t he t ool nut
count er cl ockwi se t o remove t he pulley.
POWER STEERING PUMP PULLEY
REPLACER T91P-3A733-A
8 m m
STEERING PUMP PULLEY
REMOVER T69L-10300-B
1. CAUTI ON: Do n o t a p p l y i n - a n d - o u t p r e s s u r e
o n t h e s h a f t . P r e ssur e wi l l d a ma g e t h e
i n t e r n a l t h r u s t a r e a s.
Pl ace t he power st eeri ng pump pulley on t he
power st eeri ng pump shaf t , and i nstall Power
St eeri ng Pump Pulley Repl acer T91P-3A733-A.
The small di amet er t hr eads on t he t ool shoul d be
engaged in t he power st eeri ng pump shaf t .
2. CAUTI ON: Do n o t a ppl y i n a n d o u t p r e s s u r e
o n t h e s h a f t . Pr e ssur e wi l l d a ma g e t h e
i n t e r n a l r o t a t i n g gr o u p .
NOTE: The power st eeri ng pump pulley f a c e must
be f l ush wi t hi n 0. 25 mm ( 0. 010 i nch) of t he end of
t he pump shaf t .
Hol d t he small hex-head, and r ot at e t he t ool nut
c l oc kwi se t o i nstall t he power st eeri ng pump
pulley on t he shaf t .
3. Remove t he t ool .
NOTE: If belt noi se is present af t er pump i nst al l at i on,
vi sually c he c k power st eeri ng pulley ali gnment wi t h
adj acent pul l eys. Adj ust pulley by posi t i oni ng t he
pulley a wa y f r om t he pump or push it t o t he pump t o
adj ust . A washer wi t h an i nsi de di amet er l arger t han
t he shaf t can be used as a spacer on t he pump shaf t .
Thi s adj ust ment is made by movi ng t he f an shroud
asi de.
11- 02- 7 11- 02 - 7
St e e r i n g P u mp , P o we r
Bel t Dr i ve
Re mo v a l
1. To r emove t he power st eeri ng f lui d f r o m t he
power st eeri ng pump auxi l i ary reservoi r (3E764),
di sconnect t he fluid powe r st eer i ng ret urn hose
( 3A7 13) at t he power st eeri ng pump inlet and
drai n t he f l ui d i nto a cont ai ner.
2. Remove t he power st eer i ng pressure hose
( 3A7 19) f r o m t he power st eer i ng pump out l et ,
and drai n t he flui d i nt o a cont ai ner.
3. Di sconnect t he dri ve bel t ( 862 0) f r om t he power
st eeri ng pump pulley ( 3A7 33) r emove f our
ret ai ni ng bol t s and r emove t he power st eeri ng
pump ( 3A67 4) and powe r st eer i ng pump pulley
assembl y.
4. Remove po we r st eeri ng pump pulley f r om powe r
st eeri ng pump assembl y.
1. Remove t he shi ppi ng t ube nut f r om powe r
st eeri ng pump housi ng pri or t o i nst al l at i on.
2. Install powe r st eeri ng pump pulley t o powe r
st eeri ng pump.
3. Pl ace t he power st eeri ng pump on t he mounti ng
bosse s of engi ne bl ock and i nstall t he bol t s at t he
si de of t he powe r st eeri ng pump. Ti ght en t o 20-30
N-m (15-22 Ib-f t ).
4. Pl ace t he dr i ve bel t on t he powe r st eer i ng pump
pulley a n d t i ght en bel t .
5. Install t he po we r st eer i ng pr essur e hose t o t he
power st e e r i ng pump f i t t i ng. Ti ght en t he t ube nut
wi t h a t ube nut wr e n c h r at her t han wi t h an
open-end wr e n c h. Ti ght en t o 34- 46 Nm ( 26- 34
Ib-f t ).
Swi vel a n d / or end pl ay of t he powe r st eeri ng
pr e ssur e hose end i s normal and does not
i ndi cat e a l oose f i t t i ng.
6. Connect t he powe r st eeri ng reservoi r pump hose
( 3691) t o t he powe r st eer i ng pump and reposi t i on
t he hose c l a mp t o powe r st eeri ng pump inlet
f i t t i ng.
7. Fill t he po we r st eeri ng oil reservoi r ( 3A697 ) wi t h
f l ui d t ha t me e t s Fo r d speci f i cat i on ESW-M2C33-F
such a s Fo r d Premi um Power St eeri ng Flui d
E6AZ- 19582- AA (in Canada, Mot or c r a f t
XT-1-QF).
Use st ar t -up pr oc e dur e af t er powe r st eeri ng
pump se r vi c e or st eeri ng gear overhaul . Ref er t o
Sect i on 11-00.
8. Check f o r l eaks, and c he c k t he flui d l evel . Ad d
f l ui d if necessar y .
11- 02 - 8 St e e r i n g S y s t e m, P o we r 11- 02 - 8
REMOVAL AND I N S T A L L A T I O N ( C o n t i n u e d )
Po we r St e e r i n g Co mpo n e n t s (Wi t hout Cool e r )
G7805-A
11 - 02 - 9 St e e r i n g S y s t e m, P o we r
11- 02 - 9
Pa r t
1 3691 Power Steering Reservoir
Pump Hose
2 3C510 Power Steering Hose
Bracket
3 3A713 Power Steering Return Hose
Hose
5 3504 Steering Gear
6 3A674 Power Steering Pump
Pa r t
7 N605888-S426 Bolt
8 391321 Clip
9

5/ 8 Inch Tube Nut
10 3E764 Power Steering Pump
Auxiliary Reservoir
11 N621905-S301 Nut (2 Req'd)
Lb-ln) !
B

Tighten t o 22-34 N-m (16-25
Lb-Ft)
11- 02- 10 St e e r i n g S y s t e m, P o we r
11- 02- 10
Power St eeri ng Component s (With Cool er)
VIEWT
VIEW U, V
AND W
4
) \Z
VIEWW
VIEWX
VIEWZ
G7806-A
11- 02 - 11 St e e r i n g S y s t e m, P o we r 11- 02 - 11
Pa r t Pa r t
1 3691 Power Steering Reservoir 11 5/ 8 Inch Tube Nut (2 Req'd)
Pump Hose 12 N605888-S426 Bolt
2 3C510 Power Steering Hose 13 3E764 Power Steering Pump
Bracket Auxiliary Reservoir
3 3A713 Power Steering Return Hose 14 N621905-S301 Nut (2 Req'd)
4 3A719 Power Steering Pressure 15 W611633 Bolt
Hose
16 W611635 Bolt
5 3504 Steering Gear
A

6 3A713 Oil Cooler Hoses Lb-Ft)
7 3D746 Power Steering Oil Cooler B

8 3A674 Power Steering Pump Lb-Ft)
9 N808355-S428 Bolt (2 Req'd)
c Tighten to 9-12 N-m (84-108
10 N623332-S Clip (2 Req'd)
Lb-ln)
(Continu ed)
Re s e r v o i r , P o w e r S t e e r i n g P u m p A u x i l i a r y
The power st eer i ng pump auxi l i ary reservoi r (3E764)
is mount ed wi t h t wo ret ai ni ng nut s on t he LH f ront
f ender apr on.
Re mo v a l
1. Di sconnect t he powe r st eeri ng reservoi r pump
hose ( 3691) and po we r st eeri ng ret urn hose
( 3A7 13) .
2. Drai n flui d f r o m powe r st eeri ng pump auxi l i ary
reservoi r.
3. Remove t wo ret ai ni ng nut s f r om power st eeri ng
pump auxi l i ary r eser voi r and remove power
st eeri ng pump auxi l i ary reservoi r.
NOTE: I nspect f i l t er sc r e e n in powe r st eeri ng pump
auxi l i ary reservoi r f or cont ami nant s, cl ean and f l ush
power st eeri ng pump auxi l i ary reservoi r. Repl ace
power st eeri ng pump auxi l i ary reservoi r if requi red.
1. Connect t he po we r st eeri ng reservoi r pump hose
and powe r st eer i ng r et ur n hose.
2. Posi t i on powe r st eer i ng pump auxi l i ary reservoi r
st uds i nt o hol es on LH f r ont f ender apr on.
3. Install t wo ret ai ni ng nut s. Ti ght en t he nuts t o
2. 7-4. 5 N-m ( 24- 40 lb-i n).
P o w e r S t e e r i n g P r e s s u r e ( P SP ) S w i t c h
The powe r st eeri ng pr e ssur e swi t c h (PSP
swi t c h) ( 3N824) uses an O-ri ng seal . If a leak oc c ur s,
ensure t he powe r st eer i ng pr essur e swi t c h is
t i ght ened t o 7-14 N-m (5-10 Ib-f t ). If t he leak cont i nues,
repl ace t he O-ri ngs, t hen t he powe r st eeri ng pressure
hose ( 3A7 19) , and f i nal l y t he powe r st eeri ng pressure
swi t c h.
Check operat i on of t he powe r st eeri ng pr essur e
swi t c h if ei t her or bot h of t he f ol l owi ng c onc e r ns a r e
not ed:
Engine st al l s duri ng par ki ng maneuvers.
Engi ne i dles t oo f ast .
The powe r st eeri ng pr essur e swi t c h i s normal l y
c l ose d. As power st eeri ng l oad i ncr eases, t he power
st eeri ng pr essur e swi t c h opens and i ncr eases t he idle
spe e d. Check PSP swi t c h operat i on a s f ol l ows:
1. Di sconnect el ect ri cal connect or at powe r
st eeri ng pr essur e swi t c h.
2. Connect a cont i nui t y t est er, Rot unda Di gi t al
Vol t -Ohmmet er 014- 00407 or equi val ent , a c r o ss
PSP swi t c h t ermi nal s.
3. St art engi ne and let i dl e.
4. Power st eeri ng pr essur e swi t c h shoul d be
normally cl osed (zero ohms) wi t h st eeri ng wheel
( 3600) st rai ght a he a d.
5. Turn st eeri ng wheel t o wa r d ei t her st op whi l e
wat chi ng cont i nui t y t est er. Power st eeri ng
pressure swi t c h shoul d open near t he st ops (no
cont i nui t y or infinite readi ng on ohmmet er ).
6. If power st eeri ng pr essur e swi t c h f ai l s ei t her t est ,
repl ace powe r st eeri ng pr essur e swi t c h. If power
st eeri ng pr essur e swi t c h i s OK, ref er t o t he
Powert rai n Cont r ol / Emi ssi ons Di agnosi s
Manual
1
.
1 P u r c h a s e d s e p a r a t e l y , r e f e r t o t h e e n d of t h i s Se c t i o n f o r v e h i c l e a ppl i c a t i o n .
11- 02- 12 St e e r i n g S y s t e m, P o we r 11- 02- 12
EVO Co n t r o l Mo d u l e
Remov al
WARNI NG: TURN AI R SUSPENSI ON SWI TCH
( LOCATED IN LUGGAGE COMPARTMENT) OFF TO
INJURY.
1. Remove gl ove compar t ment ( 06010) . Ref er t o
Sect i on 01- 12.
2. Det ach cont rol modul e ( 5A919) f r om snap-i n
f i ngers on br a c ke t behi nd gl ove compar t ment .
3. Pull cont r ol modul e out t o gai n a c c e ss t o cont rol
modul e c onne c t or s.
4. Di sconnect each cont r ol modul e connect or by
pushi ng cont rol modul e connect or rel ease but t on
and pulling connect or s f r om cont rol modul e.
1. Connect cont rol modul e el ect ri cal c onne c t or s t o
cont rol modul e.
2. Install cont rol modul e t o snap-i n f i ngers on
br a c ke t behi nd gl ove compar t ment .
3. Install gl ove c ompa r t me nt . Ref er t o Sect i on
01- 12.
4. Turn ai r suspensi on swi t c h ON.
CONT ROL
MODUL E
FRONT OF
VEHICLE _
F8462-A
EVO A c t u a t o r A s s e m b l y
Re mo v a l
1. Di sconnect EVO wi ri ng harness connect or f r om
EVO power st eeri ng cont rol val ve act uat or
( 37 83) .
2. Di sconnect power st eeri ng ret urn hose ( 3A7 13)
and power st eeri ng pressure hose ( 3A7 19) f r om
t he powe r st eeri ng pump ( 3A67 4) , and plug
openi ngs.
Di sconnect dri ve belt ( 8620) f r om power st eeri ng
pump pulley ( 3A7 33) . Remove f our ret ai ni ng bol t s
and remove power st eeri ng pump and power
st eeri ng pump pulley assembl y.
Pl ace power st eeri ng pump in vi se. Remove EVO
powe r st eeri ng cont rol val ve act uat or assembl y
f r om power st eeri ng pump using a 6 mm Allen hex
f r om t he back of t he power st eeri ng cont rol val ve
act uat or .
3.
4.
E VO P OWE R
S T E E RI NG CONT ROL
VA L VE A C T UA T OR
A S S Y
TO REMOVE
TURN
COUNTERCLOCKWISE
VIEW A
EVO POWER STEERING
CONTROL VALVE ACTUATOR
G5871-B
1. Install EVO power st eeri ng cont rol val ve act uat or
assembl y t o power st eeri ng pump. Ti ght en t o
14-20 N-m (10-15 Ib-ft).
2. Install power st eeri ng pump and power st eeri ng
pump pulley assembl y t o engi ne. Ti ght en f our
ret ai ni ng bol t s t o 20-30 N-m (15-22 Ib-ft)
3. Remove pl ugs and connect power st eeri ng ret urn
hose and power st eeri ng pr essur e hose t o power
st eeri ng pump.
4. Connect EVO wi ri ng harness t o EVO power
st eeri ng cont rol val ve act uat or assembl y.
5. Perf orm t he Purgi ng Power St eeri ng Sy st e m of
Ai r pr ocedur e. Refer t o Sect i on 11-00.
St e e r i n g S e n s o r
The shock a bsor be r el ect roni c st eeri ng sensor
( 18B015) i s l oc a t e d at t he l ower end of t he st eeri ng
col umn. It may be r emoved wi t h t he st eer i ng col umn in
or out of t he vehi cl e. The shoc k a bsor be r el ect roni c
st eeri ng sensor and sensor ri ng ar e se pa r a t e i t ems.
TO E L E CTRI CAL
CONNECTOR
SHUTTER
SLI T
ST E E RI NG
SHAFT
E L E CTRONI C ST E E RI NG
SE NSOR 18B015
F7689-B
1. Di sconnect sho c k absor ber el ect r oni c st eeri ng
sensor el ect ri cal connect or f r o m wi ri ng har ness.
2. Remove sensor el ect ri cal connect or f r o m br a c ke t
under i nst rument panel .
3. Remove t wo ret ai ni ng sc r e ws.
4. Remove sho c k absor ber el ect roni c st eeri ng
sensor.
5. To i nst al l , r ever se Removal pr oc e dur e s. Ti ght en
ret ai ni ng sc r e ws t o 2-3 Nm( 18-27 lb-i n).
E L E CT RONI C ST E E RI NG
SE NSOR RING
E L E CTRONI C ST E E RI NG
SE NSOR 18B015
RETAI NI NG
S C R E WS
F5146-C
S t e e r i n g S e n s o r R i n g
1. Remove st eeri ng col umn. Ref er t o Sect i on 11-04.
2. Remove st eer i ng shaf t f r o m st eeri ng col umn t o
3.
r emove sensor ri ng. Ref er t o Sect i on 11-04.
To i nst al l , r ever se Removal pr ocedur es.
R e mo v a l
Remove bol t ret ai ni ng vehi cl e spe e d sensor
mount i ng cl i p t o t r ansmi ssi on.
2. Remove vehi cl e spe e d sensor (VSS)(9E731) and
dri ven gear f r om t r ansmi ssi on.
3. Di sconnect el ect ri cal connect or f r om vehi cl e
spe e d sensor.
4. Remove dri ven gear ret ai ner and r emove dri ven
gear f r om vehi cl e spe e d sensor .
1.
2.
3.
4.
Posi t i on dri ven gear t o vehi cl e spe e d sensor.
Install gear ret ai ner.
Connect el ect ri cal connect or .
Ensure t hat i nternal O-ri ng i s properl y se a t e d in
t he sensor housi ng.
Insert vehi cl e spe e d sensor assembl y i nto
t ransmi ssi on housi ng. Install ret ai ni ng bol t and
t i ght en t o 7-10 N-m (60-84 lb-i n).
Lowe r vehi cl e.
VEHICLE SPEED
SENSOR 9E731
VE HI CL E S P E E D
SE NSOR
|gj CONNECTOR
K6267-D
S t e e r i n g G e a r
P i t ma n A r m Pul l e r T 64P - 3590- F
Re mo v a l
1. Remove st eeri ng shaf t u-joint shi eld ( 3F540) .
2. Tag power st eeri ng pressure hose ( 3A7 19) and
powe r st eeri ng ret urn hose ( 3A7 13) f or f ut ure
i dent i f i cat i on.
11- 02 - 14 St e e r i n g S y s t e m, P o we r
11-02-14
3. Di sconnect t he power st eeri ng pressure hose
and power st eeri ng ret urn hose f r om t he st eeri ng
gear ( 3504) . Plug t he li nes and por t s in t he
st eeri ng gear t o prevent ent ry of di rt .
4. Remove t he cl amp bol t s ret ai ni ng t he f l exi bl e
coupl i ng t o t he st eeri ng gear.
Remove t he se c t or shaf t ret ai ni ng nut.
6. CAUTI ON: Do n o t d a ma g e t h e se a l s a n d / o r
s t e e r i n g ge a r h o u s i n g ( 3548) . Do n o t use a
n o n - a p p r o v e d t o o l s u c h a s a p i c kl e f o r k .
Remove t he st eeri ng gear se c t or shaf t ar m
( 3590) f r om t he st eeri ng gear se c t or shaf t
( 3575) wi t h Pi t man Ar m Puller T64P-3590-F.
Remove t he t ool f r om t he st eeri ng gear sect or
shaf t a r m.
7. Support t he st eeri ng gear. Remove t he st eeri ng
gear ret ai ni ng bol t s.
8. Wor k t he st eeri ng gear f r ee of t he f l ex coupl i ng
and remove t he st eeri ng gear.
9. If t he f l ex coupl i ng di d not c ome of f wi t h t he
st eeri ng gear, lift it off t he shaf t .
I nst al l at i on
1. Turn t he st eeri ng wheel ( 3600) t o t he
st rai ght -ahead posi t i on.
2. Cent er t he power st eeri ng gear input shaf t and
cont rol ( 3D517 ) wi t h t he cent erl i ne of t he t wo
i ndexi ng f l at s at f our o' c l oc k as sho wn .
3. Sli de t he power st eeri ng gear input shaf t and
cont rol i nto t he f l ex coupl i ng and i nt o pl ace on t he
f r ame si de rai l . Install ret ai ni ng bol t s. Ti ght en t o
66-90 N-m (50-67 Ib-f t ).
4. Ensure t he wheel s are in t he st rai ght -ahead
posi t i on. Install t he st eeri ng gear se c t or shaf t ar m
on t he st eeri ng gear se c t or shaf t . Install t he
l ockwasher and nut. Ti ght en nut t o 270- 340 N*m
( 200- 250 Ib-f t ). Install and t i ght en t he st eeri ng
gear se c t or shaf t and ret ai ni ng bol t s.
5. Move t he f l ex coupl i ng i nt o pl ace on t he power
st eeri ng gear input shaf t and cont r ol . Install
ret ai ni ng bol t . Ti ght en t o 27-41 N-m (20-30 Ib-f t ).
6. Connect t he powe r st eeri ng pr essur e hose and
power st eeri ng ret urn hose t o t he st eeri ng gear.
Ti ght en t he li nes.
7. Fill t he powe r st eeri ng oil reservoi r ( 3A697 ) .
Ref er t o Sect i on 11-00. Turn st eeri ng wheel f r om
st op-t o-st op t o di st ri but e f l ui d.
8. Che c k t he flui d level and a dd flui d if necessar y.
9. St ar t t he engi ne and t urn t he st eeri ng wheel f r om
left t o ri ght . Inspect f or flui d l eaks.
10. Install st eeri ng shaf t u-joint shi el d.
Qu i c k C o n n e c t P o w e r S t e e r i n g F i t t i n g
Se a l Re p l a c e me n t
If a l eak oc c ur s bet ween t he t ubi ng and t ube nut,
r epl ace t he power st eeri ng pressure hose ( 3A7 19)
assembl y and t ube nut. If a leak occur s bet ween t he
t ube nut and t he pump housi ng out l et , repl ace t he
Teflon seal .
NOTE: IF LEAK OCCURS
HERE, TIGHTEN NUT TO
SPECIFICATION. REPLACE
TEFLON SEAL IF
NECESSARY.
ALWAYS REPLACE
THIS SEAL WHEN A
LINE IS REMOVED.
Pa r t
Hose
Outlet Fitting (Gold)
3 388898-S Teflon Seal
Outlet Fitting
5

O-Ring (Part of 3B584 Ki t)
A

Lb-Ft)
The f ol l owi ng pr ocedur e shoul d be used:
1. Check f i t t i ng t o det ermi ne whet her leak is
bet ween t ube and t ube nut or bet ween t ube nut
and power st eeri ng pump out l et .
2. If leak is bet ween t ube nut and power st eeri ng
pump out l et , c he c k t o ensure nut is t i ght ened t o
34-46 N-m (26-34 Ib-f t ).
3. If leak cont i nues or if leak is bet ween t ube and
t ube nut, remove power st eeri ng pr essur e hose.
11- 02- 15 St e e r i n g S y s t e m, P o we r
11- 02 - 15
4. Unscr ew t ube nut, and i nspect pl ast i c seal
washer. Al wa y s repl ace pl ast i c seal wa she r
when powe r st eeri ng pr essur e hose is r e move d.
To f aci l i t at e assembl y of new pl ast i c seal washer ,
a t a pe r e d shaf t such a s a Teflon Seal Repl acer
Set (D90P-3517-A) or equi val ent may be
requi red t o st r e t c h washer, so it ma y be sl i pped
over t ube nut t hr e a ds.
STRETCH PLASTIC SEAL OVER A TEFLON SEAL
INSTALLER TOOL (D90P-3517-A3) OR A TAPERED
TOOL, SUCH AS A CENTER PUNCH, UNTIL IT IS
LARGE ENOUGH TO SLIP OVER THE FITTING
THREADS. THE SEAL WILL SLOWLY RETURN
TO ITS ORIGINAL DIAMETER.
G5888-B
5. The rubber O-ri ng cannot be ser vi ced wi t h t hi s
desi gn. If l eak is due t o t he O-ri ng, r epl ace t he
power st eeri ng pr essur e hose assembl y.
6. Connect t ube nut and t i ght en t o 34-46 N-m ( 26- 34
Ib-ft).
The qui ck connect f i t t i ng may di sengage if not fully
assembl ed, if t he snap ri ng is mi ssi ng, or if t he t ube nut
or t he hose end is not machi ned properl y.
If t he f i t t i ng di sengages, r epl ace t he powe r st eeri ng
pressure hose assembl y. The f i t t i ng is fully engaged
only when t he power st eeri ng pr essur e hose wi ll not
pull out . To t e st f or posi t i ve engagement , t he sy st e m
shoul d be pr oper l y f i l l ed, t he engi ne st a r t e d, and t he
st eeri ng wheel ( 3600) c y c l e d f r o m l ock-t o-l ock.
Servi ce hose assembl i es have t ube nut s, snap ri ngs
and O-ri ngs al ready a t t a c he d .
H o s e s , P r e s s u r e a n d R e t u r n
Re mo v a l
1. Di sconnect bat t er y ground cabl e ( 14301) .
2. Remove powe r st eeri ng pr essur e hose f i t t i ng at
power st eeri ng pump auxi l i ary reservoi r ( 3E764)
or t ransmi ssi on cool er.
3. Remove powe r st eeri ng ret urn hose ( 3A7 13) at
power st eeri ng pump ( 3A67 4) .
4. Remove powe r st eeri ng ret urn hose f i t t i ng at
st eeri ng gear ( 3504) .
5. Remove powe r st eeri ng pr essur e hose f i t t i ng at
st eeri ng gear.
6. Remove powe r st eeri ng pr essur e hose ( 3A7 19)
and powe r st eeri ng ret urn hose.
1. Posi t i on po we r st eeri ng pr essur e hose and powe r
st eeri ng ret urn hose in vehi cl e.
2. Connect po we r st eeri ng pr essur e hose f i t t i ng t o
st eer i ng gear . Ti ght en t o 22- 34 N-m (16-25 Ib-f t ).
3. Connect po we r st eeri ng ret urn hose f i t t i ng t o
st eer i ng gear . Ti ght en t o 22- 34 N-m (16-25 Ib-f t ).
4. Connect po we r st eeri ng pr essur e hose f i t t i ng t o
powe r st eeri ng pump. Ti ght en t o 34- 46 Nm
( 26- 34 Ib-f t ).
5. Conne c t powe r st eeri ng ret urn hose t o powe r
st eeri ng pump auxi l i ary reservoi r or t ransmi ssi on
cool er.
6. Connect ba t t e r y ground cabl e.
H o s e Fi t t i n g s , P r e s s u r e a n d Re t u r n L i n e s a t
S t e e r i n g G e a r a n d P u mp
If a l eak oc c ur s be t we e n t he t ubi ng and t ube nut,
r epl ace powe r st eer i ng pr essur e h o s e / power
st eeri ng ret urn hose assembl y. If a l eak oc c ur s
bet ween t he power st eeri ng pr essur e hose nut and t he
Tef l onpower st eer i ng pump val ve out l et f i t t i ng
( 3D654) , r epl ace t he Teflon seal .
The f ol l owi ng pr oc e dur e shoul d be used:
1. CAUTI ON; DO NOT o v e r - t i g h t e n .
Check st eeri ng gear housi ng ( 3548) f i t t i ng and
powe r st eeri ng pump val ve out l et f i t t i ng t o
det ermi ne whi c h f i t t i ng is l eaki ng and whet her
leak is bet ween power st eeri ng pr essur e hose nut
and powe r st eeri ng pump val ve.
2. If l eak is be t we e n power st eeri ng pressure hose
nut and st eeri ng gear housi ng, or power st eeri ng
pump val ve out l et f i t t i ng c he c k t o ensure nuts are
t i ght ened t o 34-46 N-m ( 26- 34 Ib-ft) at powe r
st eeri ng pump and 22-34 N-m (16-25 Ib-ft) at
st eeri ng gear.
3. If l eak cont i nues or if l eak i s bet ween power
st eeri ng pr essur e hose and powe r st eeri ng
pressure hose nut, r emove powe r st eeri ng
pressure hose.
4. Unscrew powe r st eeri ng pr essur e hose nut, and
i nspect Teflon seal . Al wa y s repl ace Teflon seal
(power st eeri ng pressure hose pump out l et
Teflon seal , 388898-S) when powe r st eeri ng
pressure hose is r emoved. To f aci l i t at e assembl y
of new Teflon seal , a t a pe r e d shaf t may be
requi red t o st r et ch washer, so it may be sl i pped
over powe r st eeri ng pr essur e hose.
5. The rubber O-ri ng cannot be ser vi ced wi t h t hi s
desi gn. If l eak is due t o O-ri ng, repl ace powe r
st eeri ng pr essur e hose.
The qui ck connect f i t t i ngs may di sengage in t he
f ol l owi ng c a se s:
If not fully assembl ed.
If snap ring is mi ssi ng.
The powe r st eeri ng pump val ve out l et f i t t i ng is fully
engaged onl y when t he powe r st eeri ng pr essur e hose
bot t oms in t he port and wi l l not pull out . To t est f or
posi t i ve engagement , t he sy st e m shoul d be pr oper l y
f i l l ed, t he engi ne st a r t e d , and t he st eeri ng wheel
( 3600) c y c l e d f r o m l ock-t o-l ock. If power st eeri ng
pr essur e hose sti ll does not engage, repl ace t he
powe r st eeri ng pr essur e hose. Servi ce powe r st eeri ng
pr essur e hoses have t ube nut s, snap ri ngs and O-ri ng
al ready a t t a c he d .
Steering Gear
A d j u s t e r a n d L o c kn u t Wr e n c h
Sp a c e r - Va l v e Ho us i n g t o P i s t o n
T 57 L - 500- B
T 66P - 3553- B
T 66P - 3553- C
Di s a s s e mb l y
1. Hol d t he st eeri ng gear ( 3504) upsi de down over a
drai n pan, and c y c l e t he powe r st eeri ng gear
input shaf t and cont r ol ( 3D517 ) f r om st op-t o-st op
several t i mes t o drai n t he f lui d f r om t he st eeri ng
gear.
2. Usi ng mount i ng pads f or suppor t , secur e t he
st eeri ng gear in Bench Mount ed Holdi ng Fi xt ure
T57L- 500- B.
3. Remove t he l ocknut f r om t he adj ust i ng sc r e w.
4. NOTE: Cent erl i ne of t he t wo i ndexi ng f l at s shoul d
be f aci ng in t he f our o' c l oc k posi t i on.
Turn t he powe r st eeri ng gear input shaf t and
cont r ol t o ei t her st op, t hen ba c k appr oxi mat el y
1- 5/ 8 t urns t o cent er t he st eer i ng gear.
5. Remove t he sect or shaf t c ove r bol t s.
6. Tap t he l ower end of t he se c t or shaf t wi t h a
sof t -f aced hammer t o l oosen i t. Lift t he cover and
shaf t a s an assembl y f r om t he st eeri ng gear
housi ng ( 3548) . Di scar d t he O-ri ng.
7. Turn t he se c t or shaf t cover c ount e r c l oc kwi se t o
r emove t he c ove r f r o m t he se c t or shaf t adj ust er
sc r e w. Hol d sc r e w wi t h sc r e wdr i ve r if necessar y.
8. NOTE: If val ve housi ng seal s ar e t o be r epl aced,
pr o c e e d t o St ep 11. If t he se c t or shaf t seal s ar e
t o be r e pl a c e d, ref er t o St eeri ng Gear Housi ng.
The bal l s onl y need t o be r emoved if t he val ve
sl eeve ri ngs are r epl aced.
Remove val ve housi ng ret ai ni ng bol t s and
i dent i f i cat i on t a g. Separ at e val ve housi ng f r o m
st eer i ng gear housi ng whi l e hol di ng t he pi st on,
keepi ng it f r o m spi nni ng of f t he shaf t . Remove t he
val ve housi ng-t o-st eeri ng gear housi ng O-ri ng.
Di sc a r d O-ri ngs.
9. Wi t h t he pi st on held so t hat t he ball gui de f a c e s
up, remove t he ball gui de cl amp sc r e ws and t he
ball gui de cl amp. Wi t h a f i nger over t he openi ng in
t he ball gui de, t urn t he pi st on so t hat t he ball
gui de f aces down over a cl ean cont ai ner, and let
t he gui de t ubes dr op i nto t he cont ai ner.
10. Rot at e t he power st eeri ng gear input shaf t and
cont rol f rom st op-t o-st op, until all t he balls fall
f r om t he pi st on i nto t he cont ai ner. The val ve
assembl y can t hen be r emoved f r om t he pi st on.
I nspect t he pi st on bor e t o ensure all t he balls
have been r emoved.
11. NOTE: The wo r m cannot be unscr ewed f r om t he
pi st on.
Install t he val ve body assembl y in Bench Mount ed
Hol di ng Fi xt ure T57L-500-B and l oosen t he Allen
head r ace nut se t sc r e w in t he val ve housi ng.
Remove t he wo r m beari ng r ace nut usi ng Adj ust er
and Locknut Wr ench T66P-3553-B and
Spacer-Val ve Housi ng t o Pi st on T66P-3553-C.
12. Caref ul l y sli de t he power st eeri ng gear input shaf t
and cont r ol , wo r m and val ve assembl y out of t he
val ve housi ng.
SPACER-VALVE
HOUSING TO PISTON
T66P-3553-C
G4060-B
A s s e mb l y
1. Mount t he val ve housi ng in Bench Mount ed
Holdi ng Fi xt ure T57L-500-B wi t h t he f l anged end
up.
2. NOTE: Bef ore assembl i ng component s into t he
val ve housi ng, li berally coat seal li ps wi t h
Mul t i -Purpose Grease D0AZ- 19584- AA or
equi valent meet i ng For d speci f i cat i on
ESB-M 1C93-A.
Appl y a light coat of For d Premi um Power
St eeri ng Fluid E6AZ-19582-B (in Canada,
Mot or cr af t XT-1-QF) or equi valent meet i ng For d
speci f i cat i on ESW-M2C33-F l ubri cant t o t he
val ve sl eeve ri ngs on t he val ve sl eeve.
11- 02- 17 St e e r i n g f
* o we r
3. Carefully install the val ve / wor m assembl y in t he
steeri ng gear housing.
4. Refer t o speci al t orque procedure outlined in
Speci fi cati ons. Install t he race nut in the steeri ng
gear housi ng. Tighten nut t o 75- 120 N-m (55-90
Ib-ft) using Adj uster and Locknut Wr ench
T66P- 3553- B and Val ve Housing t o Piston
T66P-3553-C.
SPACER-VALVE HOUSING
TO PISTON
T66P-3553-C
ADJUSTER AND
LOCKNUT WRENCH
T66P-3553-B
REFER TO SPECIAL
TORQUE PROCEDURE
IN SPECIFICATIONS G1700-D
5. Install the Allen head race nut set scr ew through
the val ve housi ng. Tighten t o 1.7-2.8 N-m (15-25
lb-in).
6. Pl ace the piston on t he bench wi th t he ball guide
holes up. Insert t he wor m shaft into the pi ston so
the fi rst groove is in-line wi th the hole nearest the
center of t he pi ston.
7. Place the steeri ng gear ball return gui de ( 3523) in
the pi ston. Turning the wor m c l oc kwi se , as
vi ewed f rom the input end of the shaft, pl ace t he
same balls as removed in St ep 9 in the steeri ng
gear ball return gui de. A minimum of 27 balls is
requi red. If all the balls have not been i nserted
upon reachi ng the right st op, rot at e t he power
steeri ng gear input shaft and control in one
di recti on then t he ot her whi l e inserting t he
remaining balls.
BALL GUIDE
FIRST GROOVE OF WORM SHOULD BE
IN ALIGNMENT WITH THIS HOLE
BALL GUIDE CLAMP G1554-D
8. Secure t he steeri ng gear ball return gui des in t he
ball nut wi t h t he steeri ng gear ball ret urn guide
cl amp ( 3544) . Ti ghten scr ews t o 4. 8-7. 9 N-m
( 42- 70 lb-in).
9. Appl y petrol eum jelly t o the seal on t he pi ston.
10. Pl ace a new O-ring on the valve housing.
11. CAUTI ON: Take car e n o t t o d a ma g e t h e s e a l .
Slide t he pi ston and val ve into the steeri ng gear
housing.
12. Align t he fluid passage in the valve housing wi th
the passage in t he steeri ng gear housing. Place a
new O-ring onto t he fluid passage hole of t he
steeri ng gear housi ng. Install the identification t ag
onto bolt. Install, but do not ti ghten, the retaining
bol ts. The bolt wi t h t he identification t a g is t o be
installed on the upper RH si de of the val ve
housing.
13. Rotate t he ball nut so the t eet h are in the same
plane as the sect or t eet h. Tighten t he val ve
housing bolts t o 40- 60 N-m (30-45 Ib-ft).
14. Install the sect or shaft cover O-ring in the steeri ng
gear housing. Turn t he power steering gear input
shaft and control t o center the pi st on.
15. Appl y petroleum jelly t o the sector shaft j ournal .
Position the sector shaft and cover assembl y in
the steeri ng gear housing. Rotate the power
steeri ng gear input shaft and control one turn
either si de of center. Install t he sector shaft cover
bol ts. Tighten bol ts t o 75-95 N-m (55-70 Ib-ft).
16. Using a N-m (lb-in) t orque wrench, adjust t he gear
meshl oad t o 1.47-2.49 N-m (13-22 lb-in).
11-02-18 St e e r i n g S y s t e m, P o we r 11-02-18
DISASSEMBLY A N D ASSEMBLY ( Co n t i n u e d )
St e e r i n g Gear Co mpo n e n t s
,11
G2123-E
I t e m
Pa r t
d u mb e r De s c r i p t i o n I t e m
Pa r t
1 3D522 Worm Bearing Race Nut 7 388889-S Screw (2 Req'd)
2 382095-S Race Nut Set Screw 8 3544 Steering Gear Ball Return
3 Valve Housing
Guide Clamp
(Part of 3A587) 9 366973-S Power Steering Gear Piston
4 389512-S Power Steering Gear Control Seal
Valve Housing O-Ring 10 382743-S Piston Ring
5 3F586 Valve Sleeve Rings 11 372454-S94 O-Ring
6 3F628 Worm and Valve Assy 12 3A544 Piston
P i s t o n
1. Remove t he pl ast i c ri ng and t he O-ri ng f r om t he
pi st on and ball nut.
2. Di p a new O-ri ng in Premi um Power St eeri ng Flui d
E6AZ- 19582- AA or equi valent meet i ng For d
speci f i cat i on ESW-M2C33-F (in Canada XT-1-QF)
and i nstall it on t he pi st on and ball nut.
3. Install a new pl ast i c ri ng on t he pi st on and ball nut.
Be caref ul not t o st r e t c h it any more t han
necessar y.
S t e e r i n g Ge a r Ho u s i n g
Pul l e r
S e c t o r Sha f t Se a l Re p l a c e r
Be n c h Mo u n t e d Ho l d i n g Fi x t ur e
T 58L - 101- B
T 7 7 L - 357 6- A
T 59L - 100- B
T 57 L - 500- B
1. Remove snap ri ng f r om l ower end of st eeri ng gear
housi ng ( 3548) .
2. Remove power st eeri ng gear se c t or shaf t seal
usi ng Puller T58L-101-B. Di scar d t he seal .
IMPACT SLIDE
HAMMER
T59L-100-B
BENCH MOUNTED
HOLDING FIXTURE
T57L-500-B
PULLER
T58L-101-B
G3083-F
3. NOTE: The beari ng is not a separ at el y
servi ceabl e i t em; it i s part of t he st eeri ng gear
housi ng assembl y.
Remove power st eeri ng gear se c t or shaf t
pr essur e seal in t he same manner. Di sc a r d t he
powe r st eeri ng gear se c t or shaf t pr essur e seal .
4. Lubr i cat e t he new powe r st eeri ng gear se c t or
shaf t pressure seal and power st eeri ng gear
se c t or shaf t dust seal wi t h cl ean Mul t i -Purpose
Gr ease D0AZ- 19584- AA or equi val ent meet i ng
For d speci f i cat i on ESB-M1C93-A.
5. Appl y Mul t i -Purpose Gr ease D0AZ- 19584- AA or
equi valent meet i ng Fo r d speci f i cat i on
ESB-M1C93-A t o t he se c t or shaf t seal bor e .
6. Pl ace t he powe r st eeri ng gear se c t or shaf t dust
seal on Sect or Shaf t Seal Repl acer T77L- 3576- A
so t he rai sed lip of t he powe r st eeri ng gear se c t or
shaf t dust seal i s t o wa r d t he t ool .
Pl ace t he powe r st eeri ng gear se c t or shaf t
pr essur e seal on t he t ool wi t h lip a wa y f r om t he
t ool . The f l at back si de of t he power st eer i ng gear
se c t or shaf t pr essur e seal shoul d be agai nst t he
f l at si de of t he powe r st eeri ng gear se c t o r shaf t
dust seal .
7. CAUTI ON: Do n o t b o t t o m p o we r s t e e r i n g
ge a r s e c t o r s h a f t p r e s s u r e se a l a n d p o w e r
s t e e r i n g ge a r s e c t o r s h a f t d u s t s e a l a ga i n s t
b e a r i n g. T h e se a l wi l l n o t f u n c t i o n p r o p e r l y
w h e n b o t t o me d a ga i n s t t h e b e a r i n g .
Insert t he Sect or Shaf t Seal Repl acer
T77L-3576-A i nto t he se c t o r shaf t bor e and dri ve
t he t ool until t he powe r st eeri ng gear se c t o r shaf t
pressure seal and powe r st eeri ng gear se c t o r
shaf t dust seal cl ear t he snap ri ng gr o o ve .
8. Install snap ri ng in t he gr oove in t he st eer i ng gear
housi ng.
POWER STEERING GEAR
SECTOR SHAFT PRESSURE
SEAL 3591
POWER STEERING GEAR
SECTOR SHAFT DUST
SEAL 3586
SNAP
RING
352109-S
SECTOR SHAFT
SEAL REPLACER
T77L-3576-A
G3092-D
Va l v e Ho u s i n g
Pul l e r
I nput Sh a f t B e a r i n g / S e a l T o o l
Br a s s Tube Se a t Re mo v e r
Br a s s Tube Se a t Re p l a c e r
T 58L - 101- B
T 65P - 352 4- A
T 7 4P - 3504- L
T 7 4P - 3504- M
T 57 L - 500- B
1.
2.
Remove t he powe r st e e r i ng gear input shaf t seal
( 3D52 6) f r om t he r e a r of t he val ve housi ng usi ng
Puller T58L- 101- B. Di sc a r d t he powe r st eeri ng
gear input shaf t seal .
Remove t he snap ri ng f r om t he val ve housi ng.
G4059-B
Pa r t
1 3D525 Power Steering Gear Input
Shaft Bearing
Shaft Pressure Seal
3 352109-S Snap Ring
Shaft Dust Seal
5 374480-S Outlet Tube Seat
6 374309-S Inlet Tube Seat
7 3A587 Valve Housing
Turn t he f i xt ure so t he val ve housi ng is upsi de
d o wn .
4. CAUTI ON: Do n o t d a ma g e t h e wai ve b o r e i n
t h e h o u s i n g w h e n i n s e r t i n g a n d r e mo v i n g t h e
tool.
Insert Input Shaf t Be a r i n g/ Se a l Tool
T65P-3524-A in t he val ve body assembl y
opposi t e t he power st eeri ng gear input shaf t seal
and gent l y t a p t he power st eeri ng gear input shaf t
beari ng ( 3D525) and power st eeri ng gear input
shaf t seal out of t he housi ng. Di scar d t he powe r
st eeri ng gear input shaf t seal .
REMOVING BEARING AND OIL SEAL
HOLDING FIXTURE BEARING/SEAL TOOL
T57L-500-B T65P-3524-A2 G3114-D
5. Remove t he flui d inlet and out l et t ube seat s if t hey
are da ma ge d usi ng Br a ss Tube Seat Remover
T74P-3504-L.
6. Coat t he flui d inlet and out l et t ube seat s wi t h
pet rol eum j el l y and i nstall in t he housi ng wi t h
Br a ss Tube Seat Repl acer T74P- 3504- M.
7. Coat t he powe r st eeri ng gear input shaf t beari ng
and powe r st eeri ng gear input shaf t seal sur f ace
of t he housi ng wi t h pet rol eum j el l y.
8. Install t he powe r st eeri ng gear input shaf t beari ng
wi t h t he met al si de t hat c o ve r s t he rol l ers f aci ng
o ut wa r d . Seat t he power st eeri ng gear input shaf t
beari ng usi ng Input Shaf t Be a r i n g/ Se a l Tool
T65P-3524-A. Ensure powe r st eeri ng gear input
shaf t beari ng r ot a t e s f reel y.
G1363-F
9. Di p a new powe r st eeri ng gear input shaf t seal in
Premi um Power St eeri ng Fluid E6AZ-19582-AA
ESW-M2C33-F l ubri cant , and pl ace it in t he
housi ng wi t h t he met al si de f aci ng out wa r d. Dri ve
t he powe r st eeri ng gear input shaf t seal i nto t he
housi ng until t he out er edge doe s not qui t e cl ear
t he snap ri ng gr oove.
10. Pl ace t he snap ring in t he housi ng and dri ve t he
snap ri ng until ri ng seat s in i ts gr oove.
G1362-F
11. Appl y a li beral coat i ng of Mul t i -Purpose Grease
D0AZ- 19584- AA or equi valent meet i ng For d
speci f i cat i on ESB-M1C93-A t o t he ar ea bet ween
t he t wo seal s.
12. Pl ace t he power st eeri ng gear input shaf t seal in
t he housi ng wi t h t he rubber si de f aci ng out . Dri ve
t he power st eeri ng gear input shaf t seal so it si t s
behi nd t he undercut in t he power st eeri ng gear
input shaf t and cont rol ( 3D517) .
Wo r m a n d Valve Sl e e v e
SPECI A L SERVICE T OOL( S) REQUIRED
Se a l Re p l a c e me n t Se t T 7 5L - 3517 - A
Di s as s embl y a n d As s e mb l y
1. Remove val ve sl eeve ri ngs f r o m sl eeve by
i nsert i ng t he bl ade of a smal l po c ke t kni fe under
t he m and cut t i ng t he m of f .
PUSH ON BACK SIDE OF VALVE
SLEEVE RINGS. INSERT KNIFE
BLADE CAREFULLY AND CUT
RING WITHOUT SCRATCHING
VALVE SLEEVE.
G4061-B
2. Mount t he wo r m end of t he wo r m and val ve
sl eeve assembl y i nto a sof t -j awed vi se.
3.
G2966-C
Inst all Mandrel T7 5L- 3517 - A1 over t he sl eeve;
sl i de one val ve sl eeve ri ng over t he t ool .
MANDREL
T75L-3517-A1
G4062-D
Sli de Ri ng Pusher T7 5L- 3517 - A2 over t he
mandrel ; rapi dl y push down on t he pusher t ool ,
f or ci ng t he ri ng d o wn t he ramp i nto t he f our t h
gr oove of t he val ve sl eeve. Repeat t hi s st e p t hr ee
more t i mes, a nd e a c h t i me add one of t he
spa c e r s, usi ng Spacer Repl acer T7 5L- 3517 - A3
under t he mandrel t o o l . By addi ng t he spa c e r
e a c h t i me, t he mandrel t ool will line up wi t h t he
next gr oove of t he val ve sl eeve.
SLIDE PUSHER
T75L-3517-A2
G4063-D
11- 02- 22
St e e r i n g S y s t e m, P o we r 11- 02- 22
Spa c e r I nst a l l a t i on
SPACER INSTALLER
T75L-3517-A3
G4064-C
5. After installing the four val ve sl eeve rings, appl y a
light coat of Premium Power Steeri ng Fluid
E6AZ-19582-AA or equivalent meeti ng Ford
speci fi cati on ESW-M2C33-F t o the sl eeve and
rings.
6. Install one spacer over power steeri ng gear input
shaft and control ( 3D517) as a pilot for installing
t he sizing tube. Sl owl y install Sizing Tube
T75L- 3517- A4 over t he sl eeve val ve end of t he
wor m shaft onto the val ve sl eeve ri ngs. Make
sure t hat the rings are not being bent over as tube
is slid over t hem.
G4065-C
7. Remove the sizing tube, and check t he condition
of the rings. Ensure t he rings turn freel y in the
grooves.
11- 02 - 2 3 11- 02 - 2 3
8. NOTE: No further servi ce or di sassembl y of the
wor m and val ve assembl y is possi bl e.
The illustration shows the compl ete set of tool s
needed t o perform t he above operati ons. The
Tool Ki t Number for the compl et e Seal
Repl acement Set is T75L-3517-A.
SPACER REPLACERS
T75L-3517-A3
G2742-E
H o s e F i t t i n g s , P r e s s u r e a n d R e t u r n
If a leak occurs between the tubi ng and the t ube nut,
repl ace t he power steeri ng pressure hose ( 3A719) ,
power steeri ng return hose ( 3A713) assembl y. If a
leak occur s bet ween t he tube nut and t he cast iron
housi ng, repl ace the val ve. The fol l owi ng procedure
should be used.
1. Check t o make sure that t he nuts are ti ghtened t o
22- 34 N-m ( 16- 25 Ib-ft). Do not overti ghten.
2. If l eak conti nues, remove and repl ace Outl et Tube
Seat 374480- S, and Inlet Tube Seat 374309- S
and re-assembl e gear.
3. If l eak persi sts, repl ace power steeri ng return
hose and power steeri ng pressure hose as
requi red.
4. Unscrew the t ube nut, and i nspect t he pl asti c seal
washer. Al ways repl ace pl asti c seal washer
when power steeri ng pressure hose/ power
steeri ng return hose is removed. To faci l i tate
installation of t he new Teflon seal , a t aper ed
shaft such as a Teflon Seal Repl acer Set
D90P 3517 -A or equivalent may be requi red t o
st ret ch t he washer, so it may be sl i pped over t he
t ube nut t hread.
5. The rubber O-ring cannot be servi ced wi t h t hi s
desi gn. If leak is due t o O-ring, repl ace power
steeri ng pressure hose or power steeri ng return
hose assembl y.
6. Connect the tube nuts and ti ghten t o 22- 34 N-m
( 16- 25 Ib-ft).
Steering Gear
Cl eani ng
1. Use a cl ean wor k bench and t ool s.
2. Clean t he exteri or of the steeri ng gear ( 3504)
wi t h solvent. If necessary, drai n off excess
hydraul i c f l ui d.
3. Handle t he part s carefully t o avoi d ni cks, burrs,
scrat ches and dirt. Do not use solvent on seal s.
I ns pec t i on
1. Inspect t he sect or shaft bushing in the cover. If
damaged or l oose, repl ace steeri ng gear sect or
shaft housing cover ( 3580) assembl y.
2. Inspect the input shaft beari ng. Check the fit of
t he bearing on the power steeri ng gear input shaf t
and control ( 3D517) . Repl ace the beari ng, if
necessary. Slight lateral play is accept abl e,
0. 127- 0. 254 mm ( 0. 005- 0. 010 inch).
3. Inspect the val ve housing for wear, scori ng or
burrs.
4. Inspect the tube seat s and the pressure and
return port s f or ni cks. Repl ace t hem if necessary.
5. Inspect the sect or shaft beari ng in the housi ng.
Ensure that rollers are in pl ace and move freel y. If
bearing is damaged, repl ace housing assembl y.
The bearing cannot be servi ced separatel y.
6. Check the fluid passages for obstructi on or
l eakage.
7. Inspect the steeri ng gear housing ( 3548) for
cr acks and stri pped t hreads and the mating
surfaces for burrs. Inspect t he pi ston bore for
scori ng or wear. If necessary, repl ace the
steeri ng gear housing. Surface burnishing is
acceptabl e if no significant st ep can be felt.
8. Ensure power steeri ng gear input shaft and
control bearing rotates freel y.
9. Check the power steering gear input shaft and
control for f reedom of movement in the sl eeve. If
movement is i mpai red, repl ace val ve assembl y.
11- 02 - 2 4 St e e r i n g S y s t e m, P o we r 11- 02 - 2 4
CLEANING A N D INSPECTION (Conti nued)
10. Inspect t he pi st on r a c k and se c t or shaf t t eet h f or
ni cks and bur r s. St one-of f a s requi red.
S y s t e m Fl u s h i n g
Al wa y s f l ush st eeri ng gear ( 3504) when repl aci ng t he
powe r st eeri ng pump ( 3A67 4) due t o flui d
cont ami nat i on.
NOTE: The Clll power st eeri ng pump has a f i lt er built
i nt o t he f lui d reservoi r. Check f or cont ami nat i on and
cl ean or r epl ace t he reservoi r assembl y a s requi red.
1. Remove t he power st eeri ng pump and power
st eeri ng pump pulley ( 3A7 33) , and servi ce t he
pump a s out l i ned.
2. NOTE: Fl ush t he pr essur e line bef ore i nst al l i ng.
Connect only t he pr essur e hose.
Install t he powe r st eeri ng pump pulley on t he
powe r st eeri ng pump. Install t he power st eeri ng
pump.
3. Pl ace t he flui d ret urn line f r om t he gear in a
cont ai ner and plug t he flui d ret urn line f i t t i ng.
4. Fill powe r st eeri ng oil reservoi r ( 3A697 ) wi t h flui d
t hat meet s For d speci f i cat i on ESW-M2C33-F
such as For d Premi um Power St eeri ng Flui d
E6AZ- 19582- B (in Canada, Mot or c r a f t XT-1-QF).
5. Di sconnect i gni ti on coi l wi r e and rai se f ront
whe e l s off f l oor. Ref er t o Sect i on 00- 02.
6. Whi l e addi ng appr oxi mat el y 1.9 l i t ers (112 gal ) of
f l ui d, t urn i gni ti on swi t c h ( 1157 2 ) t o START
posi t i on (usi ng t he i gni ti on ke y ) and cr ank engi ne
wi t h st ar t er mot or ( 11002 ) whi l e t urni ng st eeri ng
wheel ( 3600) f r om l ock t o l ock.
7. When all flui d has been a dde d, t urn i gni ti on swi t c h
t o OFF posi t i on and connect ignition coi l wi r e.
8. Remove pl ug f r om t he powe r st eeri ng pump
reservoi r ret urn hose ni ppl e. At t a c h power
st eeri ng ret urn hose ( 3A7 13) t o ni ppl e. Ti ght en
hose cl amp t o 1-3 N-m (9-27 lb-i n).
9. CAUTI ON: Do n o t over f al l p o we r s t e e r i n g o i l
r e s e r v o i r -
Che c k flui d l evel . Ad d f lui d if necessar y.
11. St ar t engi ne and t urn st eeri ng wheel sl owl y f r om
l ock t o l ock several t i mes. Che c k flui d level and
adj ust a s r equi r ed.
P u mp F l u s h i n g
If di rt is f ound in t he power st eeri ng gear ( 3504) , f l ush
t he powe r st eeri ng pump ( 3A67 4) a s f ol l ows.
1. Ensure all ot her hoses ar e c onne c t e d, t hen
di sconnect t he powe r st eeri ng pr essur e hose
( 3A7 19) at t he st eeri ng gear .
2. Fill t he power st eeri ng pump auxi l i ary r eser voi r
( 3E764) wi t h For d Premi um Power St eeri ng Flui d
E6AZ-19582-B (in Canada, Mot or c r a f t XT-1-QF)
ESW-M2C33-F.
3. Di sconnect t he i gni ti on coi l wi r e .
4. Whi l e addi ng appr oxi mat el y 1.9 l i t ers (112
gal l on) of f l ui d, t urn i gni ti on swi t c h ( 1157 2) t o t he
RUN posi t i on and cr ank t he engi ne wi t h t he
st ar t er mot or ( 11002) . As soon as all flui d has
been a dde d, t urn i gni ti on swi t c h t o t he OFF
posi t i on.
5. Connect t he powe r st eeri ng pressure hose at t he
st eeri ng gear.
6. Check t he fluid l evel .
7. Crank t he engi ne wi t h t he st ar t er mot or and a dd
f lui d until t he level remai ns const ant .
8. Lowe r t he vehi cl e and connect t he ignition coi l
wi r e.
9. St ar t t he engi ne and t urn t he st eeri ng wheel
( 3600) f r om l ock t o l ock t o expel any ai r t r a ppe d
in t he sy st e m. Thi s wi ll r est or e normal st eeri ng
act i on.
ADJUSTMENTS
Me s h l o a d
Duri ng t he vehi cl e break-i n peri od, some f a c t or y
adj ust ment s may change. These changes wi ll not
necessari l y af f ect operat i on of t he st eeri ng gear
( 3504) assembl y, but shoul d excessi ve st eeri ng l ash
be encount ered, t hen a meshl oad adj ust ment may be
requi red.
Adj ust t he t ot al -over-cent er posi t i on l oad t o eli mi nate
e xc e ssi ve l ash bet ween t he sect or and r ack t eet h a s
f ol l ows:
1. Di sconnect t he st eeri ng gear se c t or shaf t a r m
( 3590) f r om t he st eeri ng gear sect or shaf t
( 3575) .
2. Di sconnect t he flui d power st eeri ng ret urn hose
( 3A7 13) at t he powe r st eeri ng pump auxi l i ary
reservoi r (3E764). Cap t he reservoi r powe r
st eeri ng ret urn hose pi pe.
3. Pl ace t he end of t he power st eeri ng ret urn hose in
a cl ean cont ai ner, and t urn t he st eeri ng wheel
( 3600) f r om left st op t o ri ght st op several t i mes
t o di schar ge t he flui d f r om t he st eeri ng gear.
4. Turn t he st eeri ng wheel t o 45 degr ees f r om t he
left st op.
5. Usi ng a N-m (lb-in) t or que wr e nc h on t he st eeri ng
wheel nut, det ermi ne t he t orque requi red t o r ot at e
t he st eeri ng gear sect or shaf t sl owl y
appr oxi mat el y one-quart er t urn f r om t he 45
degr ee posi t i on. Ref er t o Meshl oad Checki ng and
Set t i ng under Speci f i cat i ons. If vehi cl e is
equi pped wi t h ti lt col umn, pl ace t he st eeri ng
wheel in t he cent er ti lt posi t i on.
11- 02 - 2 5
7.
8.
Turn the steeri ng wheel back t o center and
determi ne the torque requi red t o rot at e t he
steeri ng gear sect or shaft back and f ort h acr oss
t he center posi ti on. If the readi ng is not correct
loosen t he nut and turn t he adj uster scr ew until
t he readi ng is correct . Tighten the nut whi l e
holding t he scr ew in pl ace.
Check t he readi ngs and repl ace the steeri ng gear
sect or shaft arm and steeri ng wheel hub cover.
Connect t he power steeri ng return hose t o t he
power steeri ng pump auxiliary reservoi r and fill
t he power steeri ng pump auxiliary reservoi r.
9. CAUTI ON: Do n o t p r y a ga i n s t t h e p o w e r
s t e e r i n g p u mp a u x i l i a r y r e s e r v o i r t o o b t a i n
p r o p e r b e l t toad. P r e s s u r e ma y d e f o r m t h e
p o w e r s t e e r i n g p u mp a u x i l i a r y r e s e r v o i r
c a u s i n g i t t o l e a k.
IDENTIFICATION TAG
SECTOR SHAFT
ADJUSTI NG SCREW
LOCK NUT
INPUT
SHAFT
CONTROL
VALVE
HOUSI NG
SECTOR
SHAFT
SECTOR SHAFT
COVER
G2965-C
SPECIFICATIONS
LUBRICANT SPECIFICATIONS STEERING GEAR SPECIFICATIONS (Cont 'd)
Fl ui d Ca p a c i t y
( i n c l u d e d i n
Pump Re s e r v o i r Fi l l )
0. 38 l i t e r ( 1. 6 P i n t s ) ( A p p r o x i ma t e )
Fl ui d Sp e c i f i c a t i o n Fo r d P r e mi u m P o we r St e e r i n g Fl ui d
E 6A Z - 19582 - A A (i n Ca n a d a XT- 1- QF)
STEERING GEAR SPECIFICATIONS
Tur n s of St e e r i n g Wh e e l
( L o c k t o L o c k L i n k a g e
Di s c o n n e c t e d )
3. 4
Wo r m Be a r i n g P r e l o a d 0. 45- 1. 2 4 N-m ( 4- 11 L b- l n )
To t a l Me s h l o a d Ov e r Wo r m
Be a r i n g P r e l o a d
5 L b- l n No mi n a l Ov e r P r e l o a d
Ty pe Re c i r c . Ba l l T o r s i o n Ba r
Ra t i o 14:1
(Continued)
MESHLOAD CHECKING AND SETTING
Ve h i c l e s Wi t h 0 - 8 0 4 5 k m ( 0 - 5 0 0 0 mi l e s )
Ch e c ki n g :
Re s e t if t o t a l me s h l o a d o v e r me c h a n i c a l c e n t e r i s e q u a l t o p r e l o a d
Re se t :
Se t t o r q u e me a s u r e d r o c ki n g a c r o s s c e n t e r t o a v a l ue 0. 90- 1. 36 N-m
(5 L b- l n No mi n a l ) gr e a t e r t h a n t h a t me a s u r e d 45 d e g r e e s f r o m t h e
r i ght s t o p .
Ve h i c l e s Wi t h Mo r e T h a n 8 0 4 5 k m ( 5 0 0 0 mi l e s ) Or Wh e r e T h e S e c t o r Shaf t Ha s B e e n Re p l a c e d
Ch e c ki n g :
Re s e t if me s h l o a d me a s u r e d wh i l e r o c ki n g i nput s h a f t o v e r c e n t e r i s
e q ua l t o t h e t o r q u e 45 d e g r e e s f r o m t h e r i ght s t o p .
Re s e t :
Se t t o r q u e me a s u r e d r o c ki n g a c r o s s c e n t e r t o a v a l ue 0. 56- 1. 02 N-m
( 5- 9 L b- l n ) gr e a t e r t ha n t h a t me a s u r e d 45 d e g r e e s f r o m t h e r i ght
s t o p .
11- 02- 26
St e e r i n g S y s t e m, P o we r 11- 02- 26
E VO A c t u a t o r A s s y - t o - Ho u s i n g 14- 20 10- 15
P ump- t o - E n gi n e Bo l t s 2 0- 30 15- 22
P r e s s u r e Ho s e Fi t t i n g ( At Pump) 34- 46 2 6- 34
Pump Aux i l i a r y Re s e r v o i r Nut s 9- 12 84- 108
( Lb- l n )
S h o c k A b s o r b e r E l e c t r o n i c
St e e r i n g Se n s o r S c r e ws
2- 3 18- 27
( Lb- l n )
P o we r St e e r i n g P r e s s u r e ( PSP)
Swi t c h
7 - 14 5- 10
Pi t ma n A r m t o S e c t o r Sha f t
Re t a i n i n g Nut
2 7 0- 340 2 00- 2 50
Ge a r t o Si d e Ra i l Mo un t i n g Bo l t s 66- 90 50 67
Fl e x Co u p l i n g t o Ge a r I nput Sha f t
Bo l t
2 7 - 41 2 0- 30
S e c t o r Sh a f t Co v e r Bo l t s 7 5- 95 55- 7 0
St e e r i n g Ge a r Ba l l Re t ur n Gui d e
Cl a mp S c r e w
4. 8- 7 . 9 42 - 7 0
( Lb- l n )
Va l v e Ho u s i n g Bo l t s 40- 60 30- 45
Wo r m Be a r i n g Ra c e Re t a i n i n g Nut 7 5- 12 0 55 90
Va l v e Ho us i n g Se t S c r e w Ra c e Nut 1. 7-2. 8 15- 25
( Lb- l n )
P r e s s u r e Ho s e t o Ge a r 2 2 - 34 16- 25
Re t ur n Ho s e t o Ge a r 2 2 - 34 16- 25
Me s h l o a d A d j u s t i n g S c r e w L o c k
Nut
47 - 61 35- 45
Ge a r Me s h l o a d 1. 47- 2. 49 13- 22
( L b- l n )
Ho s e Su p p o r t Br a c ke t - t o - Fr a me
Bo l t s
19- 26 14- 19
P r e s s u r e Li n e Su p p o r t
Br a c ke t - t o - P u mp Bo l t
9- 12 84- 108
( Lb- l n )
Ve h i c l e S p e e d S e n s o r Re t a i n i n g
Bo l t
7- 10 60- 84
( L b- l n )
P o we r St e e r i n g Re t ur n Ho s e t o
Au x i l i a r y Re s e r v o i r Cl a mp
1-3 9- 27
( L b- l n )
' Speci f i ed t or que because t he l engt h of t he t ool
requi red t o t or que t he nut wi ll af f ect t he obse r ve d
t or que readi ng on t he readi ng on t he t or que wr e n c h.
The t or que readi ng shoul d be c omput e d usi ng t he
l engt h of t he t or que wr e nc h and t he nomi nal speci f i ed
t or que a s f ol l ows:
Torque (usi ng t ool ) = Lengt h of Torque Wr e nc h x 98
(Met r i c) ( 72 Engl i sh)
T66P- 3553- B = Lengt h of Torque Wr e nc h + 5. 5
i nches
Exampl e: Wi t h 13-i nch t or que wr e nc h
13 i n. x 98 ( 72) = 13x98 ( 7 2 ) =67 ( 50)
13 i n. + 5. 5 = In. 18. 5
T 57 L - 500- B
Be n c h Mo u n t e d Ho l d i n g Fi x t ur e
T 58L - 101- B
Pul l e r
T 64P - 3590- F
Pi t ma n Ar m Pul l e r
T64P-3590-F
T 65P - 352 4- A
I nput Sha f t Be a r i n g / S e a l To o l
T65P-3524 A
T 66P - 3553- B
A d j u s t e r a n d L o c kn u t Wr e n c h
^ ^ ^ ^ ^ ^ ^
T66P-3553-8
T 66P - 3553- C
Sp a c e r - Va l v e Ho us i n g t o P i s t o n
^^^66P-3553-C
T 69L - 10300- B
St e e r i n g Pump Pul l e y Re mo v e r
T69L-1030O-B
T 7 4P - 3504- L
Br a s s Tube Se a t Re mo v e r
T74F-3SM-L
T 7 4P - 3504- M
Br a s s Tube Se a t Re p l a c e r
T74P-3504-M
( Co n t i n ue d )
11- 02 - 2 7 S t e e r i n g S y s t e m , P o we r 11- 02 - 2 7
(Conti nued)
T 7 5L - 3517 - A Se a l
Re p l a c e me n t Se t
Se t Co n s i s t s of :
T 7 5L - 3517 - A 1 - Ma n d r e l
T 7 5 L - 3 5 1 7 - A 2 - R i n g Pushe r
T 7 5 L - 3 5 1 7 - A 3 - S p a c e r
Re p l a c e r
T 7 5L - 3517 - A 4 - Si zi n g Tube
A3 ( ^~\
T75L-3S17-A
T 7 7 L - 357 6- A
S e c t o r Sh a f t Se a l Re p l a c e r
T77L-3576-A
T 7 8P - 37 33- A
P o we r St e e r i n g Pump To o l s
Se t Co n s i s t s of :
T 7 8P - 37 33- A 1 - Up p e r
Su p p o r t P l a t e
T 7 8P - 37 33- A 2 - L o we r
Su p p o r t P l a t e
T 7 8P - 37 33- A 3 - Se a l Dr i v e r
T78P-3733-A
T 91P - 3A 7 33- A
P o we r St e e r i n g Pump Pul l e y
Re p l a c e r
T91P-3A733-A
T o o l N u mb e r De s c r i p t i o n
D90P - 3517 - A Te f l o n Se a l Re p l a c e r Se t
ROTUNDA EQUIPMENT
007 - 0041B
SUPER STAR I I Te s t e r
11- 03- 1
St e e r i n g L i n ka ge 11- 03- 1
SECTION 11-03 Steering Linkage
SUBJECT PAGE
Steeri ng Linkage 11-03-1
Steering Li nkage . . . . . . . 11-03-3
Adj usti ng Sl eeve 11-03-3
SUBJECT PAGE
REMOVAL AND INSTALLATION (Cont' d.)
Idler Arm and Bracket Assembl y 11-03-5
Steeri ng Gear Sector Shaft Arm 11-03-4
Steeri ng Sector Shaft Arm Idler and Rod 11-03-3
Tie Rod End .....11-03-3
VEHICLE APPLICATION
St eeri ng Li nkage
P a r a l l e l S y s t e m
CAUTI ON: Ne v e r s t r a i g h t e n b e n t l i n ka ge , use n e w
p a r t s .
The st eeri ng l i nkage consi st s of t he f ol l owi ng
component s:
St eeri ng gear sect or shaf t ar m ( 3590) .
St eeri ng sect or shaf t a r m dr a g link ( 3304) .
St eeri ng idler ar m and br a c ke t ( 3355) assembl y.
Tie r od end ( 3A130) assembl i es (t i e r ods).
11- 03- 2 St e e r i n g L i n ka ge 11- 03- 2
St eer i ng Li nkage Co mpo n e n t s
FRONT OF VEHICLE
HORIZONTAL
VERTICAL
AFTER TOE SETTING, THE TWO CLAMP
BOLTS ON EACH SIDE OF VEHICLE MUST
BE POSITIONED WITHIN LIMITS SHOWN
WITH THREADED END OF BOLTS POINTING
TOWARD REAR OF VEHICLE
SECTION A
SECTION A
VIEWY
G3351-J
Pa r t
1 N805991-S428 Bolt (2 Req'd)
2 N800937-S60 Nut (2 Req'd)
3 386034-S60 Castle Nut
4 385002-S60 Castle Nut
5 3504 Steering Gear Assembly
6 5C145 Front Sub-Frame
7 391007-S190 Bolt (3 Req'd)
8 N806631-S36 Cotter Pin
9 3590 Steering Gear Sect or Shaft
Arm
10 380771-S101 Nut
11 34814-S2 Washer
12 3304 Steering Sector Shaft Arm
Drag Link
13 70244-S36 Cotter Pin
Pa r t
15 3A035 RH Link RH Yellow
3B161LH Link LH White
16 3355 Steering Idler Arm and
Bracket
17 383071-S2 Washer
18 391599-S428 Nut
A

Tighten to 98-132 N-m (73-97
Lb-Ft)
Lb-Ft)
Lb-Ft)
D Tighten to 69.5-80.5 N-m
(51-60 Lb-Ft)
E Tighten to 271-339 N-m
(200-250 Lb-Ft:
11- 03- 3 St eer i ng Li nkage 11- 03- 3
S t e e r i n g L i n k a g e
T i e R o d E n d
Re mo v a l
1. Rai se vehi cl e. Ref er t o Sect i on 00- 02. Remove
t he c ot t e r pin and nut f r om t he f ront wheel spi ndl e
connect i ng r od or end ball st ud. Di scar d c ot t e r
pi n.
2. Loosen t he t i e r od adj ust i ng sl eeve cl amp bol t s,
and r emove t he t i e r od end ( 3A130) f r om t he
spi ndl e ar m or cent er link using Tie Rod End
Remover TOOL-3290-D or equi val ent .
3. NOTE: Di scar d all pa r t s r emoved f r om t he
sl eeve.
Remove t he t i e r od end assembl y f r om t he
sl eeve, count i ng t he number of t urns requi red t o
do so .
Installation
1. Thr ead a new t i e r od end i nto t he sl eeve, usi ng
t he sa me number of t urns requi red f or removal
not ed in St ep 3, Removal . Do not t i ght en t he
sl eeve cl amp bol t s until af t er set t i ng t oe.
2. Install t he t i e r od end st ud t o t he spi ndl e a r m or
cent er link. Install t he ret ai ni ng nut and t i ght en t o
47- 63 N-m (35-47 Ib-f t ), t hen cont i nue t i ght eni ng
nut t o ali gn i t s next cast el l at i on wi t h t he c ot t e r pin
hol e in t he st ud. Install a new c ot t e r pi n.
3. Check t oe and adj ust if necessary. Ref er t o
Sect i on 04- 00. Loosen t he cl amps f r om t he
sl eeve, and oil t he sl eeve, cl amps, bol t s, and
nut s. Posi t i on t he adj ust i ng sl eeve c l a mps.
Ti ght en t he cl amp nut s t o 27-29 N-m (20-22 Ib-f t ).
HORI ZONTAL^
K M
L VERTICAL
G5175-B
Adj ust i ng Sleeve
Removal
Use t he f ol l owi ng pr ocedur e t o repl ace a wor n or
da ma ge d adj ust i ng sl eeve.
NOTE: Do not t i ght en t he cl amp bol t s until af t er set t i ng
t oe.
1. Remove t he spi ndle t i e rod end ( 3A130)
assembl i es.
2. Remove t he t i e r od end f r om t he sl eeve, count i ng
t he number of t urns requi red t o do so .
3. Sc r e w t he t i e r od end assembl y i nto t he new
sl eeve using t he same number of t urns requi red
f or removal . Bot h t he inner and out er t i e r od end
shoul d be t hr eaded equal l y i nto t he sl eeve.
Installation
1. Posi t i on t he t i e r od end assembl y on t he st eeri ng
se c t or shaf t ar m dr a g link ( 3304) and spi ndl e
a r m. Install t he ret ai ni ng nut. Ti ght en t o 47-63 N-m
(35-47 Ib-ft). Conti nue t o t i ght en nut t o ali gn i t s
next cast el l at i on wi t h t he c ot t e r pin hole in t he
st ud. Install a new c ot t e r pi n.
2. Check t oe and adj ust if necessary. Refer t o
Sect i on 04-00. Loosen t he cl amps f r om t he
sl eeve, and oil t he sl eeve, c l a mps, bol t s, and
nut s. Posi t i on t he cl amps. Ti ght en t he cl amp nut s
t o 27-29 N-m (20-22 Ib-f t ).
St eeri ng Sect or Shaft Arm Idler and Rod
Repl ace t he st eeri ng se c t or shaf t ar m dr a g link
( 3304) , connect i ng t he st eeri ng gear se c t or shaf t a r m
( 3590) and t he st eeri ng idler a r m and br a c ke t ( 3355) ,
when it is damaged or wor n at t he ball st uds.
Removal
1. Rai se t he vehi cl e on a hoi st , and i nstall saf et y
st ands. Ref er t o Sect i on 00- 02.
2. Remove t he c ot t e r pi ns and nut s t hat a t t a c h inner
t i e r od ends ( 3A130) t o t he st eeri ng sect or shaf t
a r m dr ag link. Di scar d c ot t e r pi n.
11- 03- 4 St e e r i n g L i n ka g e 11- 03- 4
3. Di sconnect the inner ti e rod end f rom t he steeri ng
sect or shaft arm drag link using Tie Rod End
Remover TOOL-3290-D or equivalent.
4. Remove the nut t hat retai ns t he steeri ng gear
sect or shaft arm t o t he steeri ng sect or shaft arm
drag link. Di sconnect t he steeri ng gear sect or
shaft arm f rom the steeri ng sect or shaft arm drag
link using Tie Rod End Remover TOOL-3290-D or
equivalent and remove t he steeri ng sect or shaft
ar m dr ag l i nk.
5. Remove the cot t er pin and nut retai ni ng the
steeri ng idler arm and br acket t o t he steeri ng
sect or shaft arm drag link, and remove the
steeri ng sect or shaft ar m drag link. Di scard
cot t er pin.
1. Position the steeri ng sect or shaft arm drag link t o
t he steeri ng gear sect or shaft arm and steeri ng
idler arm and bracket , and loosely install the
retaining nuts. Place t he steeri ng idler arm and
bracket and t he front wheel s in the
strai ght-ahead position t o maintain steeri ng
alignment and prevent bushing damage. Tighten
t he nuts t o 47-63 N-m ( 35- 47 Ib-ft). Continue t o
ti ghten the nuts until t he sl ots in t he nuts align wi th
t he holes in t he st ud. Install new cot t er pins.
2. Pl ace t he ti e rod ends on the steeri ng sect or shaft
arm dr ag link, and install t he retaining nuts.
Tighten the nuts t o 69. 5- 80. 5 N-m ( 51- 60 Ib-ft).
Continue t o tighten t he nuts until t he sl ots in t he
nuts align wi t h the hol es in t he st ud. Install a new
cot t er pin.
3. Remove t he safety st ands, and l ower t he vehi cl e.
Check t oe, adjust if necessary. Refer t o Secti on
04- 00.
Loosen t he cl amps f r om t he sl eeve, and oil t he
sl eeve, cl amps, bol ts, and nuts. Posi ti on t he
cl amps. Tighten the cl amp nuts t o 27- 29 N-m
( 20- 22 Ib-ft).
HORI ZONTAL^
L_ VERTICAL
G5175-B
Steering Gear Sector Shaft Arm
Pi t ma n Ar m Pul l e r T 64P - 3590- F
Re mo v a l
1. Remove and di scard t he nut that retai ns t he
steeri ng sect or shaft arm dr ag link ( 3304) t o the
steeri ng gear sect or shaft arm ( 3590) .
2. Di sconnect the steeri ng sect or shaft arm dr ag
link f rom the steeri ng gear sect or shaft arm using
Tie Rod End Remover TOOL-3290-D or
equivalent.
3. Remove t he steeri ng gear sect or shaft arm
retaining nut and l ock washer.
4. Position t he front wheel s in t he strai ght-ahead
posi ti on, and remove t he steeri ng gear sect or
shaft arm using Pitman Ar m Puller T64P-3590-F.
1. Wi t h t he front wheel s in t he strai ght-ahead
posi ti on, pl ace the steeri ng gear sect or shaft
arm, pointing it r ear war d, on the sect or shaf t .
Align t he blind t oot h on t he steeri ng gear sect or
shaft arm wi t h t he blind t oot h on t he sect or shaft
of t he steeri ng gear ( 3504) .
2. Install t he nut and l ockwasher. Tighten t o
271- 339 N-m ( 200- 250 Ib-ft).
11- 03- 5 St e e r i n g L i n ka g e 11- 03- 5
3. Install t he nut t hat ret ai ns t he st eeri ng se c t or
shaf t a r m dr a g link t o t he st eeri ng gear se c t or
shaf t a r m. Ti ghten t o 69. 5-80. 5 N-m (51-60 Ib-f t ).
STEERING GEAR
G1663-D
I dl er A r m a n d B r a c k e t A s s e m b l y
Re mo v a l
If t he st eer i ng i dler a r m and br a c ke t bushi ngs a r e
wo r n , r epl ace t he st eeri ng idler ar m and br a c ke t
( 3355) a sse mbl y as f ol l ows:
1. Remove t he c ot t e r pi n, nut, and washer ret ai ni ng
t he st eeri ng se c t or shaf t a r m dr a g link ( 3304) t o
t he st eeri ng idler ar m and br a c ke t . Di scar d c o t t e r
pi n.
2. Remove t he st eeri ng se c t or shaf t ar m d r a g link
f r om t he st eeri ng i dler ar m and br a c ke t .
3. Remove t he bol t s and nut s t hat ret ai n t he st eer i ng
i dler ar m and br a c ke t assembl y t o t he f r ont
sub-f rame ( 5C145) .
1. Install t he bol t s and nut s t hat ret ai n t he st eer i ng
i dler ar m and br a c ke t assembl y t o t he f r ont
sub-f rame. Ti ght en t o 98- 132 N-m (73-97 Ib-f t ).
2. Pl ace t he st eeri ng i dler a r m and br a c ke t and f r ont
whe e l s in t he st r ai ght -ahead posi t i on t o mai nt ai n
wheel al i gnment and prevent bushi ng da ma ge .
3. Install t he st eeri ng sect or shaf t a r m dr a g link nut
and washer . Ti ght en t o 47- 63 N-m (35-47 Ib-f t );
cont i nue t i ght eni ng nut t o ali gn i t s next
cast el l at i on wi t h t he c ot t e r pin hol e in t he st ud.
Install a new c ot t e r pi n.
SPECIFICATIONS
Steering Gear Sector Shaft Armto
Sector Shaft Retaining Nut and
Lock Washer
271- 339 200- 25 0
Steering Gear to Front Sub- Frame
Mounting Bol ts
66- 90 5 0- 65
Tie Rod End (Outer) to Spindl e Arm 47- 63 35 - 47
a
Steering Sector Shaft Arm Idl er
Arm Rod to Steering Idl erArm and
Bracket Nut
68- 92 5 0- 67
a
Sector Shaft ArmDrag Link Nut
69.5 - 80.5 5 1- 60
Idl er Arm Rod Nuts
47- 63 35 - 47
a
Tie Rod End Retaining Nut 47- 63 35 - 47
a
Steering Idl erArmand Bracket to
Front Sub- Frame Bol t
98- 132 73- 97
Tie Rod Cl amp to Adjusting Sl eeve 27- 29 20- 22
a Tighten to l ow l imit of specification, then tighten the nut to
the nearest cotter pin sl ot and insert the cotter pin.
Tool Numbe r /
T64P- 35 90- F
Pitman ArmPul l er
T64P-3S90-F
TOOL- 3290- D Tie Rod End Remover
11- 04- 1 St eer i ng Col umn 11- 04- 1
SECTION 11-04 Steering Column
SUBJECT PAGE
Fi xed and Tilt Col umns 11-04-1
St eeri ng Column .11-04-1
St eeri ng Column Lock 11-04-2
Steeri ng Col umn with Air Bag .11-04-2
Steeri ng Column 11-04-5
Air Bag Sliding Cont act 11-04-14
Bearing Retainer 11-04-13
Col umn Shi f t Cont r ol Sel ect or Lever and
Housi ng. . . . 11-04-9
I gni t i on Swi t ch 11-04-15
I gni t i on Swi t c h Lock Cyl i nder 11-04-14
Mul t i -Funct i on Swi t ch ...11-04-9
Parki ng Brake Vacuum Release Swi t ch 11-04-15
St eeri ng Col umn 11-04-7
St eeri ng Col umn Lock Housi ng Beari ng 11-04-10
SUBJECT PAGE
St e e r i ng Col umn Lower Yoke 11-04-13
St e e r i ng Col umn Shroud 11-04-15
St e e r i ng Shaf t 11-04-10
St e e r i ng Wheel Wi t h Ai r Ba gCr o wn Vi ct or i a,
Grand Marqui s. 11-04-6
St e e r i ng Wheel wi t h Ai r Ba gTo wn Car 11-04-5
St eer i ng Wheel wi t h Ai r Ba gTo wn Car 11-04-7
Ti l t Wheel Handl e and Shank ....11-04-13
St eer i ng Col umn. . 11-04-15
St e e r i ng Col umn 11-04-23
ADJUSTMENTS
Al i gnment f o r Clear Vi si on. . . 11-04-23
I gni t i on Swi t ch Adj ust ment .11-04-23
SPECIFICATIONS . 11-04-24
VEHICLE APPLICATION
Town Car, Cr own Vi c t or i a , Gr and Mar qui s
S t e e r i n g C o l u m n
NOTE: All f ast ener s ar e i mport ant in t hat t he y coul d
af f ect t he per f or mance of vi t al pa r t s and sy st e ms,
a n d / o r coul d resul t in maj or ser vi ce e xpe nse s. They
must be r epl aced wi t h f a st e ne r s of t he sa me par t
number if repl acement be c ome s necessar y . Do not
use a repl acement pa r t of l esser qual i t y or subst i t ut e
desi gn. Torque val ues must be used a s speci f i ed
duri ng a sse mbl y t o ensure pr oper f unct i oni ng of t hese
pa r t s.
The st eer i ng col umn has t he f ol l owi ng c ha r a c t e r i st i c s:
The st r uct ur al par t i s made of magnesi um di e
cast i ngs.
It is a t t a c he d t o a suppor t t hat i s an i nt egral par t of
t he i nst rument panel ( 04320) .
The l ower at t achment s a r e t hr ough a br a c ke t t ha t
bends duri ng st eeri ng col umn col l apse.
The upper at t achment s ar e t hr ough pl ast i c shear
modul es t hat separ at e f r o m t he mai n cast i ng duri ng
st eer i ng col umn col l apse. A cl i p and washer are
a t t a c he d t o t he shear modul es t o r educe st eeri ng
col umn sha ke and t o assi st in st eeri ng col umn
i nst al l at i on t o t he beam.
A uni que gearshi f t lever ( 7 210) mechani sm has
been i nst al l ed on t he st eeri ng act uat or housi ng
( 3F7 23) . It has t he i nsert pl at e l ocat ed a wa y f r om
t he gearshi f t lever and i nt er act s wi t h t he gearshi f t
l ever t hr ough a li nkage sy st e m. Thi s sy st e m
pr ovi des a posi t i ve i nt erl ock wi t h no adj ust ment s
r equi r ed.
F i x e d a n d T i l t C o l u m n s
Fi xed st eer i ng col umns d o not al l ow t he st eeri ng wheel
angl e t o be adj ust ed.
Vehi cl es equi pped wi t h t i l t st eeri ng col umns ar e:
Fi t t ed wi t h a ti lt mechani sm t ha t al l ows t he st eeri ng
whe e l angl e t o be adj ust ed t o sui t t he dri ver.
A ti lt l ever is l oc a t e d underneat h t he st eer i ng col umn
on vehi cl es.
Whe n t he ti lt lever is pul l ed t o wa r d s t he dri ver, t he
st eeri ng wheel ( 3600) can be adj ust ed t o one of f i ve
angl es t o suit t he dri ver.
When t he ti lt lever is r e l e a se d, t he st eeri ng wheel is
l oc ke d i nto posi t i on.
11- 04- 2 St e e r i n g Co l u mn 11- 04- 2
St eeri ng Column wi t h Ai r B a g
Bot h f i xed and tilt steeri ng col umns have steeri ng
wheel s ( 3600) whi ch are bol ted t o the t op of t he
steeri ng column and are fi tted wi t h a suppl emental
restrai nt syst em (SRS). Before performi ng wor k on or
around an SRS component, observe all SRS condi ti ons
and warni ngs t o avoi d unnecessary air bag
depl oyment and possi bl e injury.
Functi ons t o prevent inadvertent l ocki ng of the
steeri ng wheel ( 3600) .
Is l ocat ed on the l ower LH of the steeri ng column
bel ow the turn signal lever.
Must be pushed in order for the ignition swi t ch l ock
cyl i nder ( 11582) t o be rot at ed t o the LOCK
posi ti on.
St eeri ng Column Lock
The key rel ease button:
1
1

-
0
4
-
3

S
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11- 04- 4 St eer i ng Col umn 11- 04- 4
I t e m
Pa r t
1 043B13 Driver Side Air Bag Module
2 N804385-S100 Steering Wheel Bolt
3 3600 Steering Wheel
4 N805572-S36 Air Bag Module Retaining
Nuts
5 14A664 Air Bag Sliding Contact
6 3530 Upper Steering Column
Shroud
6 3513 Steering Column Opening
Weather Seal
7 3530 Lower Steering Column
Shroud
8 55929 Shroud Retaining Screws
9 11582 Ignition Switch Lock Cylinder
10 3C610 Steering Column Upper
Bearing Retainer
11 3E700 Steering Column Lock
Housing Bearing
12 3E717 Steering Column Lock Gear
13 13318 Turn Indicator Cancel Cam
14 3C610 Steering Column Upper
Bearing Retainer
15 3520 Steering Column Upper
Bearing Spring
Bearing Sleeve
16 3L539 Steering Column Upper
Bearing Tolerance Ring
Beari ng Upper (Small)
Flange
20 390345-S36 Screws
21 3D655 Spring
22 3F527 Tilt Steering Column Lock
Lever
23 3D544 Steering Column Release
Lever
24 3F530 Steering Column Lock
Actuator Lever Pin
25 3E695 Steering Column Lock Cam
26 14A163 Wiring Harness Ret ai ner
Upper
27 3524 Steering Gear Input Worm
Gear and Rack
28 3B664 Steering Column Locki ng
Lever Spring
29 3B661(RH) Steering Column Locki ng
3D653(LH) Lever
30 3E715 Steering Column Lock Lever
Act uat orUpper
31 3E715 Steering Column Lock Lever
Act uat orLower
32 3E691 Steering Column Lock Pawl
(Shaft)
33 3E696 Steering Column Lock Spring
(Shaft)
34 7361 Column Shift Selector Lever
Plunger
I t e m
Pa r t
35 7379 Gearshift Selector Tube
Spring
36 7210 Gearshift Lever
37 7G357 Gear Shift Lever Pin
38 7212 Transmission Column Shift
Selector Tube
39 7E400 Gearshift Tube Bushing
Clamp
40 7335 Gearshift Lever Socket
Bushing
41 N805858 Screws
42 14A099 Wiring Shield
43 7A216 Transmission Shift Selector
Position Insert
44 N805858 Screws
45 390345-S36 Screws
46

Part of 3F723
47 N805865 Tilt Pivot Screws
48 3D655 Steering Column Position
Spring
49 3F723 Steering Actuator Housing
51 N805858 Screws
52 3F530 Pin Pivot Lever
53 3E691 Steering Column Lock Pawl
54 3B663 Steering Column Lock Lever
Pin
55 3668 Steering Column Instrument
Panel Clamp
56

Shift Control Selector Lever
(Part of 7210)
57 805858 Screws
58 3D681 Steering Column Lower
Bearing Retainer
59 N806423-S56 Lower Column Mounting Nuts
60 14A206 Wire Connector Bracket
61 N804409 Screw
62 805859 Lower Bearing Housing
Retaining Screws
Bearing Sleeve
Bearing
65 3L539 Steering Column Upper
Bearing Tolerance Ring
66 3C131 Suspension Height Sensor
Control Ring
Bearing Spring
68 N808349-S100 Screw Flange Yoke
69 3N725 Steering Column Lower Yoke
70 N808349-S100 Bolt
71 7E364 Control Selector Cable
Bracket
72 805858 Shift Cable Bracket
Mounting Screws
73 Part of Wire Harness
74 7E395 Shift Cable and Bracket
11- 04- 5 St e e r i n g Co l u mn
+ " W
11- 04- 5
Pa r t Pa r t
i t e m Nu mb e r De s c r i p t i o n I t e m Nu mb e r De s c r i p t i o n
75 3517 Upper Steering Column Tube
Bearing (Large)
84 19A438 Ignition Lock Anti-Theft
Switch
76 14A163 Wiring Harness Retainer 85 3F719 ' Igni t i on/Shi f t er Interlock
77 3A525 Steering Column Gear Input Cable
Shaft Coupling 86 7H178 Bracket
78 3F540 Steering Shaft U-Joint Shield 87 N806038-S2 Screw
79 N803942-S100 Flange Bolt 88 043B13 Driver Side Air Bag Module
80 3B676 Lower Steering Column 89 N807493-S100 Bolt
Shaft Ext ensi on Assy
90 3600 Steering Wheel
. 81 7C464 Clip
91

Screw (2 Req'd)
82
-
Solenoid and Bracket
92 3L518 Plug
Vacuum Hose Extension
93 390345-S36 Screw (3 Req'd)
Parking Brake Release
Vacuum Hose Extension
( Co n t i n ue d )
Steering Column
Steering Wheel wi th Air BagTown Car
St e e r i n g Wh e e l Pul l e r T 67 L - 3600- A
Re mo v a l
1. Cent er f r ont wheel s t o t he st r ai ght -ahead
posi t i on.
2. WARNI NG: THE BACKUP POWER SUPPLY
BAG COMPONENT IS SERVI CED. FAI LURE TO
DO SO MAY RESULT IN PERSONAL I NJURY.
Di sconnect ba t t e r y ground cabl e ( 14801) t o
depl et e ai r bag backup powe r suppl y. Ref er t o
Sect i on 01- 20B.
3. Remove t wo ba c k cover pl ugs f r om t he st eeri ng
wheel ( 3600) .
4. Remove t he t wo sc r e w and wa she r assembl i es
ret ai ni ng t he dri ver si de ai r ba g modul e ( 043B13)
t o t he st eer i ng wheel .
5. Li ft t he dri ver si de air bag modul e off t he st eeri ng
whe e l .
6. Di sconnect ai r bag wi re har ness and r ed horn
c onne c t or f r o m dri ver si de ai r ba g modul e.
Remove modul e f r om st eeri ng whe e l .
7. Di sconnect spe e d cont rol wi r e har ness f r o m
st eeri ng whe e l .
8. CAUTI ON: Be s ur e c o n t a c t a s s e mb l y wi r e
h a r n e s s d o e s n o t g e t c a u gh t o n s t e e r i n g
wh e e l a s s e mb l y w h e n l i f t i n g o f f s h a f t .
Remove and di scar d st eeri ng wheel ret ai ni ng
bol t .
Install St eeri ng Wheel Puller T67L-3600-A and
remove st eeri ng wheel . Rout e c ont a c t assembl y
wi re harness t hrough st eeri ng wheel as st eeri ng
wheel is l i f t ed off t he st eeri ng gear input wo r m
gear and r a c k ( 3524) .
STEERING WHEEL
PULLER T67L-3600-A
G7816-A
Installation
1. Make sure t hat vehi cl e's f r ont wheel s are in t he
st rai ght -ahead posi t i on.
11- 04- 6 St eer i ng Col umn 11- 04- 6
2. CAUTI ON: Be sur e wi r i ng does not get
t r apped bet ween st eer i ng wheel and ai r bag
sl i di ng cont act .
Rout e c ont a c t assembl y wi r e harness t hr ough
st eeri ng wheel openi ng at t he t hr ee O' c l oc k
posi t i on and posi t i on st eeri ng wheel on st eeri ng
gear input wo r m gear and r a c k. The st eeri ng
wheel and st eeri ng gear input wo r m gear and
r a c k ali gnment mar ks shoul d be al i gned. Be sure
ai r bag c ont a c t wi r e is not pi nched.
3. Install new st eeri ng wheel ret ai ni ng bol t and
t i ght en t o 34-46 N-m ( 22- 33 Ib-f t ).
4. Connect spe e d cont rol wi r e har ness t o st eeri ng
wheel connect or.
5. Connect ai r bag wi r e har ness and r ed horn
connect or t o dri ver si de ai r bag modul e and i nstall
modul e t o st eeri ng wheel . Ti ght en dri ver si de ai r
ba g modul e ret ai ni ng sc r e ws t o 2-3 N-m (18-26
Ib-in).
6. Connect ai r bag ba c kup powe r suppl y and
ba t t e r y ground cabl e. Veri f y ai r ba g warni ng
i ndi cat or.
S t e e r i n g Wh e e l Wi t h A i r B a g C r o w n
V i c t o r i a , G r a n d Ma r q u i s
Re mo v a l
1. Cent er f ront wheel s t o t he st r ai ght -ahead
posi t i on.
2. WARNI NG: THE BACKUP POWER SUPPLY
BAG COMPONENT I S SERVI CED. FAI LURE TO
DO SO MAY RESULT IN PERSONAL I NJURY.
Di sconnect ba t t e r y ground cabl e ( 14301) t o
depl et e ai r bag ba c kup powe r suppl y. Ref er t o
Sect i on 01- 20B.
3. Remove f our air bag modul e ret ai ni ng nuts and lift
modul e off st eeri ng wheel ( 3600) .
4. Di sconnect ai r bag wi r e har ness f r om ai r ba g
modul e, and r emove modul e f r o m st eeri ng wheel .
CONNECTOR
DRIVER SIDE AIR BAG
MODULE 043B13
G5783-C
5.
6.
Di sconnect speed cont rol wi r e harness f r om
st eeri ng wheel .
CAUTI ON: Be s u r e c o n t a c t a s s e mb l y wi r e
h a r n e s s d o e s n o t ge t c a u g h t o n s t e e r i n g
wh e e l a s s e mb l y wh e n l i f t i n g o f f s h a f t .
Remove and di sc a r d st eeri ng wheel ret ai ni ng
bol t .
Install St eeri ng Wheel Puller T67L-3600-A and
remove st eeri ng wheel . Rout e cont act assembl y
wi r e harness t hr ough st eeri ng wheel as st eeri ng
wheel is li fted of f t he st eeri ng gear input wo r m
gear and r ack ( 3524) .
STEERING WHEEL
PULLER T67L-3600-A
G5554-C
11- 04- 7 St e e r i n g Co l u mn
11- 04- 7
Steering Wheel w i t h Air BagTown C a r
1. Ma ke sure t hat vehi cl e' s f ront wheel s ( 1007 ) ar e
in t he st rai ght -ahead posi t i on.
2. CAUTI ON: Be s u r e wi r i n g d o e s n o t ge t
t r a p p e d b e t w e e n s t e e r i n g wh e e l ( 3600) a n d
ai r b a g s l i d i n g c o n t a c t ( 14A 664) .
Rout e cont act assembl y wi r e harness t hr ough
st eeri ng wheel openi ng at t he t hr ee o' c l oc k
posi t i on and posi t i on st eeri ng wheel on st eeri ng
gear input wo r m gear and r a c k ( 3524) . The
st eeri ng wheel and st eer i ng gear input wo r m gear
and r ack ali gnment ma r ks shoul d be al i gned. Be
sur e air ba g c ont a c t wi r e i s not pi nched.
3. Install new st eeri ng wheel ret ai ni ng bol t and
t i ght en t o 34- 46 N-m (25-34 Ib-f t ).
4. Connect speed cont r ol wi r e harness t o st eeri ng
wheel and snap connect or i nto st eeri ng wheel
cl i p.
5. Connect ai r bag wi r e harness t o ai r ba g modul e
and i nstall modul e t o st eeri ng wheel . Ti ght en
modul e ret ai ni ng nut s t o 4-6 Nm (36-47 lb-i n).
6. Connect ai r ba g ba c kup power suppl y and
bat t er y ground cabl e ( 14301) . Veri f y ai r ba g
warni ng i ndi cat or.
S t e e r i n g C o l u m n
Re mo v a l
1. NOTE: All st eeri ng col umn component s are
assembl ed wi t h f a st e ne r s. They are desi gned
wi t h a t hr ead l ocki ng sy st e m t o prevent l ooseni ng
due t o vi brat i ons a ssoc i a t e d wi t h normal vehi cl e
oper at i on.
CAUTI ON: Do n o t r e mo v e t h e s t e e r i n g
c o l u mn t u b e ( 3514) , s t e e r i n g wh e e l ( 3600)
a n d ai r b a g mo d u l e a s a n a s s e mb l y f r o m t h e
v e h i c l e un l e s s t h e s t e e r i n g c o l u mn i s l o c k e d
t o p r e v e n t r o t a t i o n , o r l o we r e n d o f s t e e r i n g
s h a f t s h o u l d b e w i r e d i n s u c h a w a y t o
p r e v e n t t h e s t e e r i n g wh e e l f r o m b e i n g
r o t a t e d .
Ma ke sure t hat vehi cl e' s f ront wheel s ( 1007 ) ar e
in t he st r ai ght -ahead posi t i on. Di sconnect ba t t e r y
ground cabl e ( 14301) and air bag ba c kup power
suppl y.
2. Remove st eeri ng whe e l as out l i ned.
3. Remove RH and LH l ower moul di ngs f r o m
i nst rument panel ( 0432 0) by pulling up and
snappi ng out of r et ai ner s.
4. Remove i nst rument panel l ower t r i m cover .
5. Remove ai r bag sl i di ng c ont a c t ( 14A664) a s
out l i ned.
6. Remove ti lt st eeri ng col umn l ock lever ( 3F52 7 ) by
* r ^'
v
r ?wi n g it f r om st eer i ng col umn t ube .
Rot at e i gni t i on swi t c h ( 1157 2) t o RUN posi t i on.
Usi ng a 1 / 8-i nch dri f t , depr ess i gni ti on swi t c h
ret ai ni ng pin t hr ough a c c e ss hol e and r e mo ve
i gni ti on s wi t c h.
Remove f our ret ai ni ng sc r e ws f r o m l ower
st eer i ng col umn shr oud ( 3530) and r e move l ower
st eer i ng col umn shr oud and upper st eer i ng
col umn shr o ud .
UPPER STEERING
COLUMN SHROUD
3530 SHOWN
TRANSMISSION SELECTOR
LEVER ARM AND SUPPORT
COLUMN SHIFT ONLY) 7302
RETAINING SCREW
LOCATIONS
G5813-D
9.
10.
Remove t wo i nst rument panel rei nf orcement
br a c e bol t s. Remove rei nf orcement .
Remove st eeri ng col umn t o parki ng br a ke cont r ol
sha ke br a c e .
REINFORCEMENT
G5557-B
11- 04- 8 St e e r i n g Co l u mn 11- 04- 8
11. Di sconnect shi f t cabl e and br a c ke t ( 7E395) f r om
st eeri ng act uat or housi ng ( 3F7 23) by removi ng
one sc r e w.
TRANSMISSION RANGE
12. Remove t wo mult i -f unct i on swi t c h ret ai ni ng
sc r e ws and set mult i -f unct i on swi t c h ( 13K359)
asi de.
G5809-B
13. Remove pi nch bol t f r om st eeri ng col umn l ower
y o ke ( 3N7 25) t o l ower st eeri ng col umn shaf t
( 3B67 6) . Compr e ss l ower st eeri ng col umn shaf t
t o wa r d engi ne and se pa r a t e it f r om t he st eeri ng
col umn l ower y o ke .
14. Di sconnect shi f t cabl e and br a c ke t f r o m
t ransmi ssi on col umn shi f t sel ect or t ube lever
pi vot .
15. Remove shi f t cabl e and br a c ke t f r om l ower
col umn mount i ng.
16. Remove har ness f or shi f t l ock act uat or sol enoi d.
Whi l e support i ng st eeri ng col umn, remove f our
st eeri ng col umn t ube ret ai ni ng nut s. Lower
st eeri ng col umn and di sconnect vacuum hoses at
parki ng br a ke rel ease swi t c h ( 2B623) or remove
vacuum rel ease assembl y.
17. Remove st eeri ng col umn f r om vehi cl e.
Pa r t
1 N808349-S200 Screw
2 3B139 Steering Column Support
Bracket
Flange
4 3Z719 Shift Lock Actuator Solenoid
5 N806423-S56 Nut (4 Req'd)
A

Lb-Ft)
B

Lb-Ft)
1. Ali gn t he st eeri ng col umn l ower y oke t o l ower
st eeri ng col umn shaf t . Install one bolt and t i ght en
t o 26-35 N-m (18-26 Ib-ft).
2. Connect parki ng br ake rel ease swi t c h vacuum
hoses.
3. Support t he st eeri ng col umn t o st eeri ng col umn
support br a c ke t ( 3B139) . Install f our ret ai ni ng
nut s and t i ght en t o 13-19 N-m (9-14 Ib-f t ).
4. Posi t i on shi f t cabl e and br a c ke t t o l ower t wo
sc r e ws of st eeri ng act uat or housi ng. Ti ght en t o
7-11 N-m (5-8 Ib-ft).
5. Snap shi f t cabl e and br a c ke t ont o shi f t sel ect or
pi vot bal l .
6. Posi t i on mult i -f unct i on swi t c h and install t wo
ret ai ni ng sc r e ws. Ti ght en t o 2-3 N-m (18-26 Ib-in).
11- 04- 9 St e e r i n g Co l u mn 11- 04- 9
7. Connect all el ect ri cal c onne c t or s.
8. Install t ransmi ssi on shi f t cabl e and br a c ke t l oop
on shi ft sel ect or hook, and i nst all t ransmi ssi on
range sel ect or cabl e br a c ke t t o st eeri ng act uat or
housi ng. Install ret ai ni ng sc r e w.
9. Install i nst rument panel rei nf orcement br ace and
secur e wi t h t wo ret ai ni ng bol t s.
10. Install l ower i nst rument panel cover .
11. Snap RH and LH l ower i nst rument panel
mouldi ngs i nto pl ace.
12. Install upper st eer i ng col umn shr oud and l ower
st eeri ng col umn shr oud.
13. Install i gni ti on swi t c h l ock cyl i nder ( 11582)
assembl y.
14. Install ti lt st eeri ng col umn l ock l ever ont o st eeri ng
column t ube f l ange ( 3511) .
15. Install ai r bag sli di ng c o n t a c t sc r e w. Ti ght en t o
2-3 N-m (18-26 lb-i n).
16. Install st eeri ng wheel ont o st eeri ng gear input
wo r m gear and r a c k ( 352 4) . Install a new bol t and
t i ght en t o 34- 46 N-m ( 25- 34 Ib-f t ).
17. Posi t i on ai r bag modul e t o st eeri ng wheel . Install
f our ret ai ni ng nut s. Ti ght en t o 4-6 N-m (36-47
lb-i n).
18. Conneci ba t t e r y gr ound cabl e and air bag ba c kup
power suppl y.
19. Proveout ai r bag sy st e m. Ref er t o Sect i on
01- 20B.
Mult i -Funct i on Swi t ch
Removal
1. Di sconnect ba t t e r y gr ound cabl e ( 14301) .
2. Tilt st eeri ng col umn t o l owest posi t i on and remove
ti lt st eeri ng col umn l ock l ever ( 3F527 ) .
3. Remove i gni ti on swi t c h l ock cyl i nder ( 11582) .
4. Remove shr oud sc r e ws and r emove upper
st eeri ng col umn shr oud ( 3530) and Sower
5. Remove t wo sel f -t appi ng sc r e ws ret ai ni ng
multi -functi on swi t c h ( 13K359) t o st eeri ng col umn
t ube f l ange ( 3511) . Di sengage mult i -f unct i on
swi t c h f r om st eer i ng col umn t ube f l ange.
6. Di sconnect t he t wo el ect ri cal c onne c t or s.
Installation
1. Install t wo el ect ri cal c onne c t or s t o full
engagement .
2. Ali gn mult i -f unct i on swi t c h mount i ng hol es wi t h
cor r espondi ng hol es in st eeri ng col umn t ube
f l ange. Install t wo sel f -t appi ng sc r e ws, maki ng
sure t o st a r t s c r e ws in t he previ ousl y t a ppe d
hol es. Ti ght en t o 2-3 N-m (18-26 lb-i n).
3. Install upper st eer i ng col umn shr oud and l ower
st eeri ng col umn shr oud wi t h sc r e ws. Ti ght en t o
0. 6-1. 13 N-m (6-10 lb-i n).
4. Install i gni ti on swi t c h l ock cyl i nder.
5. Install ti lt st eer i ng col umn l ock l ever.
7. Che c k st eeri ng column a nd mul t i -f unct i on swi t c h
f or pr oper oper at i on.
Col umn Shi ft Cont rol Selector Lever and
Housi ng
Column Shift
Re mo v a l
1. Remove t i lt st eeri ng col umn l ock l ever ( 3F527 ) by
unscr ewi ng it f r om t he st eeri ng col umn rel ease
l ever ( 3D544) .
2. Turn i gni ti on swi t c h l ock cyl i nder ( 11582) t o RUN
posi t i on. Usi ng a 1 / 8- i nc h dri f t , pr e ss i gni ti on
swi t c h ret ai ni ng pi n t hr ough a c c e ss hol e and
r e move i gni ti on swi t c h l ock cyl i nder.
3. Remove l ower i nst rument panel cover ret ai ni ng
sc r e ws and r emove cover.
4. Remove f our ret ai ni ng sc r e ws f r o m l ower
st eer i ng col umn shroud ( 3530) . Remove upper
st eer i ng col umn shroud and l ower st eeri ng
col umn shr oud.
5. Remove shi f t l ever cover, gear shi f t lever pin
( 7 G357 ) and gearshi f t lever ( 7210) .
6. If necessar y , r emove shi ft lever cl i p.
1. If r e move d, i nstall shi f t lever cli p i nt o openi ng in
gear shi f t lever as shown.
2. Insert gearshi f t lever t hrough hol e in st eeri ng
col umn openi ng weat her seal ( 3513) . Posi t i on
cover on gearshi f t lever.
3. Insert gear shi f t l ever into openi ng in cont rol
sel ect or upper shaf t .
4. Install a new gear shi f t lever pin i nt o posi t i on and
t a p in pl ace until t he head seat s agai nst st eeri ng
col umn openi ng seal and t he Ti nnerman nut i s
vi si bl e on bot t om of shi f t er housi ng.
5. Posi t i on shi f t l ever seal assembl y on t he st eeri ng
col umn t ube f l ange (3511). Insert l ower
at t achment i nto t he sl ot on si de of st eeri ng
col umn t ube f l ange.
6. Posi t i on upper at t achment on mounti ng pin and
pr e ss i nt o pl ace. Install a Ti nnerman nut t o secur e
cover t o pedest al on st eeri ng col umn t ube f l ange.
7. Install upper st eer i ng column shroud and l ower
st eeri ng col umn shr oud wi t h f our sc r e ws.
8. Install l ower i nst rument panel cover and ret ai ni ng
sc r e ws.
9. Install i gni ti on swi t c h l ock cyli nder into st eeri ng
col umn t ube f l ange.
10. Install ti lt st eeri ng col umn l ock lever ont o st eeri ng
col umn rel ease l ever.
11- 04- 10 St e e r i n g Co l u mn 11- 04- 10
11. Check f or pr oper st ar t in PARK and NEUTRAL.
Ensure st ar t ci rcui t cannot be a c t ua t e d in DRIVE
or REVERSE posi t i ons and t he st eeri ng col umn is
l oc ke d in t he LOCK posi t i on.
2. Remove t hr ee nuts ret ai ni ng pri mary st eeri ng
col umn t ube boot (3C611) and remove st eeri ng
col umn t ube boot .
3. CAUTI ON: Be s ur e t h e s t e e r i n g c o l u mn i s i n
t h e l o c k e d p o s i t i o n . T h e l o we r e n d o f t h e
s t e e r i n g c o l u mn ma y be wi r e d i n s u c h a wa y
t o p r e v e n t t h e s t e e r i n g wh e e l ( 3600) f r o m
b e i n g t u r n e d a s ai r b a g s l i d i n g c o n t a c t
( 14A 664) a s s e mb l y d a ma g e d .
Remove bol t retai ni ng l ower st eeri ng col umn
shaf t ( 3B676) t o st eeri ng gear ( 3604) input shaf t .
4. Fr om i nsi de of vehi cl e, remove l ower st eeri ng
col umn shaf t .
5. Remove secondar y st eeri ng col umn t ube boot ,
1. Turn secondar y st eeri ng col umn t ube boot i nsi de
out and posi t i on over t hr ee mount i ng st uds t hen
mount t o gear.
2. Install l ower st eeri ng col umn shaf t t hr ough
st eeri ng col umn t ube boot f r om engi ne
compar t ment . Install new bol t and t i ght en t o
25-35 N-m (18-26 Ib-ft).
3. Install pri mary st eeri ng col umn t ube boot over
l ower st eeri ng column shaf t and down ont o t hr ee
st uds in dash panel .
4. Install t hr ee boot retai ni ng nut s. Ti ght en t o 5-7
N-m (44-61 i b-i n).
5. Ext end st eeri ng col umn gear input shaf t coupl i ng
and i nsert i nto st eeri ng column gear input shaf t
coupl i ng at end of st eeri ng col umn. Ti ght en bol t t o
25-35 N-m (18-26 Ib-ft).
6. Check st eeri ng column f or pr oper oper at i on.
S t e e r i n g C o l u m n L o c k H o u s i n g B e a r i n g
Up p e r
Re mo v a l
1. Remove st eeri ng column t ube f l ange ( 3511) f r om
st eeri ng col umn.
S t e e r i n g S h a f t
I n t e r me d i a t e
Re mo v a l
1. Remove bol t f r om upper st eeri ng col umn gear
i nput shaf t coupl i ng ( 3A525) . Col l apse st eeri ng
col umn gear input shaf t coupl i ng.
11- 04- 11 St e e r i n g Co l u mn 11- 04- 11
2. Sui t abl y suppor t st eeri ng col umn t ube f l ange and
t a p out smal l st eeri ng col umn t ube beari ng ( 3517 )
wi t h an appr opr i at e dri f t and a pl ast i c hammer.
1. Sui t abl y suppor t st eeri ng col umn t ube f l ange.
2. Posi t i on new st eeri ng col umn t ube beari ng i nto
st eeri ng col umn t ube f l ange a s shown in t he
f ol l owi ng i l l ust rat i on. Tap i nto pl ace wi t h a pl ast i c
hammer and a bushi ng dri ver i nst aller or so c ke t
t he sa me si ze as out er r a c e of bear i ng.
CROSS SECTION
OF BEARING
TUBE BEARING
POCKET AREA
PLASTIC HAMMER
G5544-D
I nt er medi at e
Removal
1. Remove st eeri ng col umn t ube f l ange.
2. Set st eeri ng col umn t ube f l ange f l at on
wo r kbe n c h a nd t a p l arge st eeri ng col umn t ube
beari ng l oose wi t h sui t abl e dri f t and a hammer.
1. Support st eeri ng column t ube f l ange on
wo r kbe n c h.
11- 04- 12 St e e r i n g Co l u mn 11- 04- 12
2. Position new l arge steeri ng column tube beari ng
into steeri ng column tube flange as shown.
CROSS SECTION
OF BEARING
GS546-C
3. Using a socket or bushing dri ver the same si ze a s
outer race of steeri ng column tube beari ng, t ap
beari ng into steeri ng col umn tube fl ange wi t h a
hammer until fully seat ed.
G5547-C
L o w e r
Re mo v a l
1. Remove power steeri ng cool er inlet filter ( 3F738)
as outlined.
3 REQ'D G5541-D
2. Suitably support steeri ng actuator housing
( 3F723) and t ap out steeri ng column tube bearing
wi th a hammer and a drift.
11- 04- 13 St e e r i n g Co l u mn 11- 04- 13
1. I nspect st eeri ng col umn t ube beari ng sl eeve
( 3518) . Repl ace if d a ma ge d .
3518 G5548-C
2. Posi t i on st eeri ng col umn t ube beari ng sl eeve in
st eeri ng act uat or housi ng.
G5549-C
3. Press in t he new st eer i ng col umn t ube beari ng
wi t h t humb pr essur e until se a t e d. Sl ot bet ween
inner and out er r a c e s shoul d f a c e out f r om t he
st eeri ng col umn l ower beari ng ret ai ner ( 3D681) .
4. Install st eeri ng col umn l ower beari ng ret ai ner on
st eeri ng act uat or housi ng assembl y a s out l i ned.
3 REQ'D G5541-D
B e a r i n g R e t a i n e r
L o w e r
1. Remove st eeri ng wheel ( 3600) a s out l i ned.
2. Remove st eeri ng col umn a s out l i ned.
3. Remove st eeri ng act uat or housi ng ret ai ni ng
sc r e ws.
4. Remove st eeri ng col umn l ower beari ng ret ai ner
( 3D681) .
5. To i nst al l , reverse Removal pr ocedur e.
S t e e r i n g C o l u m n L o w e r Y o k e
1. Remove t wo st eeri ng col umn l ower y o ke bol t s
and sl i de st eeri ng col umn l ower y o ke ( 3N7 25)
down l ower st eeri ng col umn shaf t ( 3B67 6) t o
cl ear st eeri ng column l ower beari ng ret ai ner
( 3D681) .
2. Remove st eeri ng col umn l ower y o ke f r om l ower
st eeri ng col umn shaf t .
3. To i nst al l , reverse Removal pr oc e dur e .
T i l t Wh e e l H a n d l e a n d S h a n k
1. To remove ti lt st eeri ng col umn l ock lever ( 3F527) ,
r ot at e t i lt st eeri ng col umn l ock lever
count er cl ockwi se.
2. To i nst al l , posi t i on ti lt st eeri ng col umn l ock l ever
and r ot at e c l oc kwi se until t i ght .
11- 04- 14 St e e r i n g Co l u mn 11- 04- 14
Ai r B a g Sl i d i n g Co n t a c t
Remov al
1. Ma ke sure t hat vehi cl e' s f r ont wheel s ( 1007 ) ar e
in t he st rai ght -ahead posi t i on and st eeri ng col umn
shaf t ali gnment mark is at t he 12 o' c l oc k posi t i on.
2. Di sconnect bat t er y ground cabl e ( 14301) t o
depl et e air bag ba c kup powe r suppl y.
3. Remove st eeri ng wheel ( 3600) a s out l i ned.
4. Remove l ower RH and LH moul di ngs f r om
i nst rument panel ( 04320) by pulling up and
snappi ng out of ret ai ner.
5. Remove i nst rument panel st eeri ng col umn cover
( 04459) and l ower st eeri ng col umn shr oud
( 3530) .
6. Di sconnect ai r bag sli di ng c ont a c t assembl y wi r e
harness.
7. Appl y t wo st r i ps of t a pe a c r o ss air bag sli di ng
c ont a c t st at or and r ot or t o prevent acci dent al
r ot at i on.
8. Remove i gni ti on swi t c h l ock cyl i nder ( 11582) and
r emove i gni ti on key warni ng swi t c h t ermi nal and
wi r e ( 11A12 8) .
9. De t a c h mai n wi ri ng mat i ng c onne c t or s d o wn
st eeri ng col umn t ube si de.
10. Remove t hr ee ai r ba g sl i di ng c ont a c t ret ai ni ng
sc r e ws and pull air ba g sl i di ng c ont a c t ( 14A664)
of f st eeri ng gear input wo r m gear and r a c k
( 3524) .
1. Ma ke sure t hat vehi cl e' s f ront wheel s are in t he
st r ai ght -ahead posi t i on and st eeri ng gear input
wo r m gear and r a c k al i gnment mar k is at t he 12
o' c l oc k posi t i on.
2. NOTE: If a new ai r ba g sl i di ng c ont a c t is bei ng
i nst al l ed, r emove t he pl ast i c l ock mechani sm
af t er ai r bag sli di ng c ont a c t is se c ur e d t o st eeri ng
gear i nput wo r m gear and r a c k.
Ali gn ai r bag sli di ng c ont a c t t o st eeri ng gear input
wo r m gear and r a c k and mount i ng bosse s and
sl i de ai r bag sli di ng c ont a c t on t o t he st eeri ng
gear i nput wo r m gear and r a c k.
3. Install t hr ee ret ai ni ng sc r e ws. Ti ght en sc r e ws t o
2-3 N-m (18-26 Ib-in). Remove t a pe st r i ps.
4. Rout e ai r bag sli di ng c ont a c t wi r es down st eeri ng
col umn and connect t o wi r e harness.
5. Install ignition key warni ng swi t c h t ermi nal and
wi r e i nto st eeri ng column t ube f l ange ( 3511) .
6. Connect main wi ri ng connect or s down st eeri ng
col umn.
7. Install l ower st eeri ng column shroud and
i nst rument panel st eeri ng col umn cover .
8. Install i gni ti on swi t ch l ock cyl i nder.
9. Install st eeri ng wheel as out l i ned.
11. Veri f y ai r bag warni ng i ndi cat or.
I g n i t i o n S w i t c h L o c k C y l i n d e r
L o c k Cy l i n d e r , Fu n c t i o n a l
Re mo v a l
1. The f ol l owi ng procedure appl i es t o vehi cl es t hat
have a f unct i onal ignition swi t c h l ock cyl i nder
( 11582) . Lock cyl i nder ke y s are avai l abl e f or
t hese vehi cl es, or t he l ock cyl i nder key numbers
ar e known and t he proper key can be made.
Di sconnect bat t er y ground cabl e ( 14301) .
2. Turn ignition swi t ch l ock cyl i nder t o RUN posi t i on.
3. Pl ace a 3. 17 mm ( 1 / 8 i nch) di amet er wi r e pin or
smal l dri f t punch in hole in upper st eeri ng col umn
shr oud ( 3530) under ignition swi t c h l ock cyl i nder.
Depr ess ret ai ni ng pin whi l e pulling out on i gni ti on
swi t c h l ock cyl i nder t o remove it f r om st eeri ng
col umn t ube f l ange ( 3511) .
1. Install ignition swi t c h l ock cyl i nder by t urni ng it t o
RUN posi t i on and depressi ng ret ai ni ng pi n. Insert
i gni ti on swi t c h l ock cyl i nder i nto st eeri ng col umn
t ube f l ange. Ensure ignition swi t c h l ock cyl i nder is
fully seat ed and ali gned in i nt erl ocki ng washer
bef ore turni ng key t o OFF posi t i on. Thi s wi ll
permi t cyl i nder retai ni ng pin t o ext end i nto ignition
swi t c h l ock cyl i nder housi ng hol e.
2. Rot at e ignition swi t ch l ock cyl i nder, using l ock
cyl i nder key, t o ensure c or r e c t mechani cal
operat i on in all posi t i ons.
11- 04- 15 S t e e r i n g Co l u mn 11- 04- 15
L o c k Cy l i n d e r , N o n - Fu n c t i o n a l
Re mo v a l
1. The f ol l owi ng pr ocedur e appl i es t o vehi cl es in
whi c h t he i gni ti on l ock is i noperat i ve and t he
i gni ti on swi t c h l ock cyl i nder cannot be r ot a t e d
due t o a lost or br oken ke y , unknown key number,
or an ignition swi t c h c a p t hat has been da ma ge d
a n d / o r br oken t o t he ext ent t hat t he key cannot
be r ot a t e d.
2. Remove st eeri ng wheel ( 3600) as out l i ned.
3. Usi ng channel -l ock pl i ers or vi se-gri p-t ype pl i ers,
t wi st i gni ti on swi t c h c a p until it se pa r a t e s f r om
i gni ti on swi t c h l ock cyl i nder.
4. Usi ng a 3/ 8- i n c h di amet er dri l l , drill down mi ddl e
of key sl ot appr oxi mat el y 44mm ( 1- 3/ 4 i nch) until
i gni ti on swi t c h l ock cyl i nder br eaks l oose f r om
br e a ka wa y base of i gni ti on swi t c h l ock cyl i nder.
Remove l ock cyl i nder and dri ll shavi ngs f r om
st eeri ng col umn t ube f l ange.
5. Remove st eeri ng col umn upper beari ng ret ai ner
( 3C610) , washer, i gni ti on swi t c h l ock cyl i nder
and st eeri ng col umn l ock gear ( 3E717) .
Thoroughl y cl ean all dri ll shavi ngs and ot her
f orei gn mat eri al s f r om c a st i ng.
6. Caref ul l y i nspect st eer i ng col umn t ube f l ange f or
da ma ge f r om t he a bove oper at i on. If damage i s
appar ent , st eeri ng col umn t ube f l ange must be
r epl aced.
1. Repl ace st eeri ng col umn t ube f l ange, if d a ma ge d .
2. Install st eeri ng col umn l ock gear and i gni ti on
swi t c h l ock cyl i nder a s out l i ned.
3. Install t ri m and el ect ri cal pa r t s.
4. Install new i gni ti on swi t c h l ock cyl i nder a s
out l i ned.
5. Install st eeri ng wheel a s out l i ned.
6. Che c k ignition swi t c h l ock cyl i nder oper at i on.
Igni ti on Swi t ch
St eeri ng Column Shroud
1. Remove f our sc r e ws ret ai ni ng upper st eer i ng
col umn shr oud ( 3530) and l ower st e e r i ng col umn
shr oud.
2. Remove upper st eeri ng col umn shr o ud a nd l ower
Parki ng Brake Vacuum Release Swi t ch
Ref er t o Sect i on 11-05 f or Removal and Inst al l at i on of
Rel ease Swi t c h, Aut o ma t i c Pa r ki n g Br a ke .
St eeri ng Column
Disassembly
1. Di sconnect bat t er y ground cabl e ( 14301) and air
bag ba c kup power suppl y.
2. Remove st eeri ng wheel ( 3600) assembl y a s
out l i ned.
3. Remove st eeri ng col umn f r om vehi cl e a s out l i ned.
4. Remove st eeri ng col umn l ower y o ke (3N725),
st eeri ng col umn upper beari ng spri ng ( 3520) ,
suspensi on hei ght sensor cont rol ri ng ( 3C131)
and st eeri ng col umn upper beari ng t ol er ance ri ng
( 3L539) .
11- 04- 16 St e e r i n g Co l u mn 11- 04- 16
St e e r i n g Co l umn
G5449-C
Pa r t Pa r t
1 3C131 Suspension Height Sensor 7 3D544 Steering Column Release
Control Ring Lever
2 7A216 Transmission Shift Selector 8 3517 Steering Column Tube
Position Insert Bearing (In Lock Housing)
3 7212 Shift Position Indicator 9 3Z719 Shift Lock Actuator
Attachi ng Point Solenoid
4 3511 Steering Column Tube 10 3517 Steering Column Tube
Flange Bearing
5 7212 Transmission Column Shift 11 7E364 Control Selector Cable
Selector Tube Bracket
6 3517 Upper Steering Column Tube 12 3N725 Steering Column Lower Yoke
Bearing (In Lock Housing)
5. Remove t urn i ndi cat or cancel c a m ( 13318) by
pushi ng up wi t h f l at -bl aded scr ewdr i ver . Not e
di rect i on of f l ush sur f ace.
LARGE SCREW
DRIVER
TURN INDICATOR
CANCEL CAM
13318
NOTE POSITION OF
FLUSH SURFACE
11- 04- 17 St eer i ng Col umn 11- 04- 17
6. Remove i gni ti on swi t c h ( 1157 2 ) assembl y.
IGNITION SWITCH
G5538-B
7. Remove st eeri ng col umn upper beari ng ret ai ner
( 3C610) and st eeri ng col umn upper beari ng
spri ng.
STEERING COLUMN
8. Remove st eel st eeri ng col umn t ube beari ng
sl eeve ( 3518) and st eeri ng col umn upper beari ng
t ol erance ri ng.
9. Remove gear shi f t lever ( 7 2 10) .
10. Remove shi f t l ock act uat or sol enoi d.
11. Remove shi f t cabl e and br a c ke t ( 7 E395) .
'G5540-D
Pa r t
1 7A216 Shift Control Selector
Bracket
2 N805858 Screws (6 Req'd)
3 7212 Transmission Column Shift
Selector Tube
4 7L278 Bushings
5 3Z719 Shift Lock Actuator
A

Lb-Ft)
12. Usi ng a dri f t , t a p st eeri ng col umn l ock act uat or
lever pin ( 3F530) l oose. Remove wi t h di agonal
pl i ers.
STEERING COLUMN
LOCK ACTUATOR
LEVER PIN 3F530
11- 04- 18 St e e r i n g Co l u mn 11- 04- 18
13. Remove pl ast i c st eeri ng col umn upper beari ng
ret ai ner f r om ignition swi t c h l ock cyl i nder bor e.
PLASTIC STEERING
COLUMN UPPER
BEARING RETAINER
3C610
14. Remove met al st eeri ng col umn l ock housi ng
beari ng ( 3E700) f r om i gni ti on swi t c h l ock cyl i nder
bor e.
G5448-B
15. Remove st eeri ng col umn l ock gear ( 3E717) .
16. Remove t wo ti lt pi vot bol t s. Use caut i on a s
st eeri ng col umn posi t i on spri ng ( 3D655) wi ll
rel ease when bol t s are r e move d. Remove
st eeri ng col umn t ube f l ange ( 3511) .
STEERING COLUMN
POSITION SPRING
3D655
PIVOT BOLTS
G5539-B
17 Remove st eeri ng gear input wo r m gear and r ack
( 3524) f r om st eeri ng col umn.
18. Remove st eeri ng col umn l ock lever act uat or
(3E715).
STEERING COLUMN
LOCK LEVER
ACTUATOR
3E715
STEERING ACTUATOR
HOUSING 3F723
G5562-B
19. Remove l ower st eeri ng col umn t ube beari ng
( 3517 ) and st eeri ng col umn l ower beari ng
ret ai ner ( 3D681) .
COLUMN LOWER
MOUNTING
BRACKET 3E660
SCREW
N806583-S36
3 REQ'D
STEERING COLUMN
LOWER BEARING
RETAINER 3F738
G5541-D
11- 04- 19 St eer i ng Col umn 11- 04- 19
20. Remove st eeri ng col umn l ock act uat or l ever pi n
usi ng a dri f t . Remove st eer i ng col umn l ocki ng
l ever ( 3B661) (RH) or st eer i ng col umn l ock left
hand lever ( 3D653) and st eeri ng col umn l ocki ng
l ever spri ngs ( 3B664) .
STEERING COLUMN
LOCKING LEVER
3B661 RH
3D653 LH G5560-C
2.
A s s e m b l y
1. Install st eeri ng gear i nput wo r m gear and r a c k
i nto st eeri ng act uat or housi ng ( 3F7 23) .
Install l ower st eer i ng col umn i nst rument panel
cl amp ( 3668) and st eer i ng col umn l ower beari ng
ret ai ner. Ti ght en sc r e ws t o 7-11 N-m (5-8 Ib-f t ).
COLUMN LOWER
MOUNTING
BRACKET3E660
SCREW
N806583-S36
3 REQ'D
STEERING COLUMN
LOWER BEARING
RETAINER 3F738
G5541-D
G5542-E
Pa r t
1 3C131 Suspension Height Sensor
Control Ring
2 3C664 Steering Column Shaft
Sleeve
Bearing Spring
4 3N725 Steering Column Lower Yoke
5 N808349-S100 Bolt
A
.
Lb-Ft)
Posi t i on st eeri ng col umn l ock lever act uat or , in
st eer i ng act uat or housi ng. Spr a y upper st eer i ng
col umn l ock lever act uat or and l ower st eeri ng
col umn l ock lever act uat or wi t h Mul t i -Purpose
Gr ease D7AZ- 19584- AA or D0AZ- 19584- AA
(ESR-M 1C159-A, ESB-M1C93-A) or equi val ent .
STEERING COLUMN
LOCK LEVER
ACTUATOR
3E715
STEERING ACTUATOR
HOUSING 3F723
GS562-B
3. Install suspensi on hei ght sensor cont r ol ri ng,
bushi ng, st eeri ng col umn upper beari ng spri ng
and st eeri ng col umn l ower y o ke t o st eeri ng gear
i nput wo r m gear and r a c k. Ti ght en pi nch bol t t o
25-35 N-m (18-26 Ib-f t ).
11- 05- 17 St e e r i n g Co l u mn S wi t c h e s 11- 05- 17
PINPOINT TEST B: NO POWER IN ACC POSITION
B1 CHECK IGNITION SWITCH
Yes
No
GO to B2 .
REPLACE the ignition
switch. RESTORE
Perform the Ignition Switch Component Test a s
outlined.
Is the i gni ti on swi t ch OK?
Yes
No
GO to B2 .
switch. RESTORE
B2 CHECK CIRCUIT
Yes
No
REPLACE the affected
fuse. RESTORE vehicle.
RETEST system.
SERVICE the affected
circuit for open /short
circuit. RESTORE
Key off.
Locate and disconnect the fuse junction panel
connector.
Key ON.
Measure the voltage of Circuit 454 (R / LG) for Town
Car or Circuit 297 (BK / LG) for Crown Victoria,
Grand Marquis at the fuse junction panel connector.
Is the vol tage greater than 10 vol t s?
Yes
No
REPLACE the affected
fuse. RESTORE vehicle.
RETEST system.
SERVICE the affected
circuit for open /short
circuit. RESTORE
PINPOINT TEST C: NO POWER IN ON POSITION
CI CHECK IGNITION SWITCH
Yes
No
GO to C2 .
swi t ch. RESTORE
Perform the Ignition Switch Component Test as
outlined.
Is t he i gni t i on swi t c h OK?
Yes
No
GO to C2 .
swi t ch. RESTORE
C2 CHECK CIRCUIT
Yes
No
REPLACE the af f ect ed
RETEST system.
SERVICE the circuit (s) in
question. RESTORE
Key off.
Locat e and disconnect the fuse j unction panel
connector.
Key ON.
Measure the voltage of the following ci rcui ts at the
fuse j unction panel connector.
Town Car
Yes
No
RETEST system.
question. RESTORE
F r o m I GN S w i t c h P i n C i r c u i t
Yes
No
RETEST system.
question. RESTORE
A4 489 ( P K / B K )
Yes
No
RETEST system.
question. RESTORE
A 1 454 ( R / L G )
Yes
No
RETEST system.
question. RESTORE
11 2 62 ( B R / P K )
Yes
No
RETEST system.
question. RESTORE
A 2 , A3 2 9 7 ( B K / L G )
Yes
No
RETEST system.
question. RESTORE
Yes
No
RETEST system.
question. RESTORE
F r o m I GN S w i t c h Pin C i r c u i t
Yes
No
RETEST system.
question. RESTORE
A 4 489 ( P K / B K )
Yes
No
RETEST system.
question. RESTORE
A 1 2 9 7 ( B K / L G )
Yes
No
RETEST system.
question. RESTORE
11 2 6 2 ( B R / P K )
Yes
No
RETEST system.
question. RESTORE
A 3 687 ( G Y/ Y)
Yes
No
RETEST system.
question. RESTORE
Are t he vol t ages great er t han 10 vol t s?
Yes
No
RETEST system.
question. RESTORE
PINPOINT TEST D: NO POWER IN START POSITION
D1 CHECK IGNITION SWITCH
CHECK Circuit 33
(W/PK) for open/short
circuit. REFER to Secti on
03-06.
swi t ch. RESTORE
Perform the Ignition Swi tch Component Test as
outlined.
Is t he i gni t i on swi t c h OK?
Yes
No
CHECK Circuit 33
(W/PK) for open/short
circuit. REFER to Secti on
03-06.
swi t ch. RESTORE
PINPOINT TEST E: MULTI-FUNCTION SWITCH DOES NOT OPERATE
E1 CHECK TURN SIGNAL LEVER POSITIONS
Yes
No
GO t o E2 .
If lever will not cancel,
check steering wheel
cancel cam for damage.
If lever is worn or
damaged, REPLACE
Prior to t est i ng, make sure hazard knob is pushed in
fully t o the OFF posi ti on. If the suspect circuit is
sati sfactory, the concern is elsewhere in the
system.
Check turn signal lever in the RH and LH turn
positions with steeri ng wheel locked in the straight
ahead posi ti on. Lock the lever in position for each.
Check lever by slightly holding it in the RH and LH
turn posi ti ons. When releasing, observe the lever
springs back to normal posi ti on.
Road test vehicle and observe turn signals for RH
and LH turn posi ti ons while manually turning steering
wheel for each posi ti on. Verify lever cancels when
steering returns from desi red turn posi ti on.
Does t ur n si gnal lever oper at e pr oper l y ?
Yes
No
GO t o E2 .
If lever will not cancel,
check steering wheel
cancel cam for damage.
If lever is worn or
damaged, REPLACE
E2 CHECK HAZARD SWITCH
Yes
No
GOt o E3.
If knob is worn or
damaged, REPLACE.
Fully press hazard swi tch and release to turn on
warning lamps. Verify swi tch operati on.
Fully press swi tch and release to turn off warning
lamps. Verify swi tch operati on.
Does hazard knob oper at e pr oper l y ?
Yes
No
GOt o E3.
If knob is worn or
damaged, REPLACE.
E3 CHECK HIGH BEAM AND FLASH-TO-PASS
Yes
No
GO to E4.
If lever is worn or
damaged, REPLACE
Turn on headlamp bulbs.
Press turn signal lever toward instrument panel to
STOP posi ti on. Release lever. Verify high beams.
Move lever back toward seat. Release lever. Verify
low beams.
Pull lever t oward driver seat gently to flash-to-pass.
Hold posi ti on. Verify both high and low beams are
on. Release lever. Verify low beams.
Turn off headlamp bulbs.
Pull lever to f lash-t o-pass again and hold. Verify
high beams come on. Release lever. Verify no high
beams.
Does hi gh beam, l ow beam and f l ash-t o-pass
oper at e?
Yes
No
GO to E4.
If lever is worn or
damaged, REPLACE
E4 CHECK WINDSHIELD WIPER AND WASH
Yes
No
Multi-function switch
operates.
If knob or lever is worn or
damaged, REPLACE
Rotate windshield wiper swi tch to LOW, HIGH and
INTERMITTENT posi ti ons. Verify rotation of switch
and wiper operati on. Turn switch t o OFF position.
Verify swi tch rot at es to OFF and wi pers stop
operati on.
Push the end of the swi tch in t oward center of
steeri ng column to WASH posi ti on. Release wash
posi t i on. Verify wi pers operate for a few wipes and
return to OFF.
Operate WASH in all speeds of wiper swi tch. Verify
wi pers return to sel ect ed speed after releasing from
WASH posi ti on.
Does t he wi ndshi el d wi per swi t c h and WASH
oper at e pr oper l y ?
Yes
No
Multi-function switch
operates.
If knob or lever is worn or
damaged, REPLACE
11- 05- 19 St eer i ng Col umn Swi t c hes
mm âac zr ~~ZWSBL
11- 05- 19
s w 1 9
PINPOINT TEST F: RELEASE SWITCH, AUTOMATICPARKING BRAKE DOES NOT OPERATE
F1 CHECK VACUUM HOSE
Yes
No
GO to F2.
CONTINUE to t race
vacuum hoses back to
engine vacuum source.
GO to F3.
Apply parking brake and place gearshift lever in
DRIVE range.
Check vacuum hose line for leaks, di sconnect s or
improper connecti ons.
Disconnect hose assembly from the vacuum swi t ch.
Attach a gauge, such as the Rotunda Vacuum Tester
021-00014 or equivalent, to the source hose. Check
for a minimum pressure of 34 kPa (5 psi ).
Is pressure more t han 34 kPa (5 psi )?
Yes
No
GO to F2.
CONTINUE to t race
vacuum hoses back to
engine vacuum source.
GO to F3.
F2 CHECK PARK BRAKE RELEASE ASSEMBLY
Yes
No
SERVICE or REPLACE
damaged components as
required.
REPLACE automatic
parking brake release
swi t ch.
Check park brake release swi tch and motor
assembly for damage, burrs or foreign materials
binding the function of system.
Is damage, burrs or f or ei gn mat eri al causi ng t he
par ki ng br ake rel ease swi t c h not t o oper at e?
Yes
No
SERVICE or REPLACE
damaged components as
required.
REPLACE automatic
parking brake release
swi t ch.
F3 CHECK PARK BRAKE RELEASE SWITCH ADJUSTMENT
Yes ^
No
Park brake release
swi tch operates
correctly.
ADJUST parking brake
release swi tch as
outlined.
Apply parking brake and place gearshift lever in
DRIVE range.
Does par ki ng brake rel ease?
Apply parking brake and place gearshi ft lever in
Does par ki ng br ake remai n appl i ed?
NOTE: If the parking brake hol d/rel ease function
occurs between any other shifter posi ti ons, the
adj ustment of the parking brake release
switch-to-column is i ncorrect.
Yes ^
No
Park brake release
swi tch operates
correctly.
ADJUST parking brake
release swi tch as
outlined.
I g n i t i o n S w i t c h C o n t i n u i t y T e s t
Di sconnect t he connect or f r o m t he ignition swi t c h
( 1157 2) . Test t he i gni ti on swi t c h cont i nui t y as
de sc r i be d in t he f ol l owi ng i l l ust rat i on. Connect a
sel f -power ed t e st l amp or ohmmet er bet ween t he
bl ade t ermi nal s i ndi cat ed on t he c ha r t in t he
i l l ust rat i on. No cont i nui t y be t we e n any bl ade and t he
ground t ermi nal shoul d exi st in any i gni ti on swi t c h
posi t i on e xc e pt t he proof and gr ound pi ns ( P 1, P2 and
GND) in t he START posi t i on onl y.
For an "engi ne won' t c r a n k" condi t i on, det ermi ne if
t he condi t i on exi st s wi t h t he shi f t cont rol sel ect or l ever
in bot h t he PARK and NEUTRAL posi t i ons bef ore
perf ormi ng t he i gni ti on swi t c h cont i nui t y t est . If t he
"n o - c r a n k" condi t i on oc c ur s in one shi f t lever posi t i on
but not t he ot her, a more pr obabl e cause is t he
t ransmi ssi on range (TR) sensor l ocat ed on t he
t ransaxl e. Ref er t o Sect i on 07-14 f or Di agnosi s and
Test i ng.
Ignition Swi t c h Conti nui ty Te st
ACC LOCK OFF RUN START
K14670-D
TOWN CAR
Pin
B1 5 6 8 ( L G) Suppl y
12 No t Us e d
A1 45 4
( R / L G )
I gn i t i o n Ou t pu t
B2 5 68 ( L G) Suppl y
A2 2 97
( B K / L G )
Fu s e d R u n / A c c e s s o r y Fe e d
B3 5 6 8 ( L G ) Suppl y
A 3 2 97
( B K / L G )
Fu s e d Run / A c c e s s o r y Fe e d
B4 32 5
( DB / O )
Cr a n k E n a bl e
STA 33 ( W/ P K ) St a r t e r I n t e r l o c k
A 4 489
( P K / B K )
I gn i t i o n Run Fe e d t o Cl u s t e r
B5 2 7 6 ( BR) S wi t c h Fe e d
11 2 62
( B R / P K )
St a r t e r Re l a y
GND 57 ( BK) Gr o un d
P 1 409 ( T / BK) St a r t e r I n t e r l o c k f r o m Br a ke
P2

No t Us e d
Pi n
B1 2 7 6 ( B R ) S wi t c h Fe e d
I 2 No t Us e d
Pin
A 1 2 97
( B K / L G )
Fu s e d R u n / A c c e s s o r y Fe e d
B2 568 ( LG) Suppl y
A2 687
( G Y/ Y)
A c c e s s o r y Fe e d
B3 568 ( L G) Suppl y
A 3 687
( G Y/ Y)
B4 37 ( Y) Ba t t e r y Su ppl y
STA 33 ( W/ P K ) St a r t e r I n t e r l o c k
A 4 489
( P K / B K )
I gn i t i o n Run Fe e d t o Cl ust e r
B5 2 7 6 ( BR) Swi t c h Fe e d
11 2 62
( B R / P K )
St a r t e r Re l a y
P1

Not Us e d
P2 97 7 ( P / W) St a r t e r I n t e r l o c k f r o m Br a ke
I g n i t i o n S w i t c h Me c h a n i c a l T e s t
Test t he mechani cal operati on of the ignition swi t ch by
rotati ng the ignition swi t ch through ail positions. The
movement should feel smooth wi th no sti cki ng or
binding. The ignition swi t ch should return f rom the
START position back to the RUN position wi thout
assi stance (spri ng return). If sti cki ng or binding is
encountered, check the fol l owi ng:
Burrs on the key.
Binding ignition swi t ch lock cylinder ( 11582) .
11 - 05- 2 1 St e e r i n g Co l u mn S wi t c h e s
i7 *>feaisiigr 7" _: ":wm& -_ z r~ ~ r_
-
: z s n z z : _ " " _
St eeri ng column shroud ( 3530) rubbi ng agai nst
i gni ti on swi t ch l ock cyl i nder.
Burrs or f orei gn mat eri al around rack-and-pi ni on
act uat or in st eeri ng col umn t ube f l ange ( 3511) .
Insufficient lubri cant on act uat or.
NOTE: Do not appl y l ubri cant t o i nsi de of t he i gni ti on
swi t c h.
Bi ndi ng ignition swi t c h.
Mu l t i - Fu n c t i o n S w i t c h C o n t i n u i t y T e s t
Test i ng f or el ect ri cal mal f unct i ons can be
accompl i shed using a cont i nui t y t est er and an
ohmmet er, such as Rot unda Di gi t al Vol t -Ohmmet er
014- 00407 or equi valent .
Refer t o t he di agnost i c c ha r t s and t he i l l ust rat i on t o
resol ve concerns wi t h t he mult i -f unct i on swi t c h
( 13K359) .
G7821-A
MULTI-FUNCTION SWITCH CONTINUITY TEST
SWI T CH A CT UA T OR P OSI T I ON CONT I NUI T Y BY CI RCUI T NUMBE R
T u r n S i g n a l L e v e r i n N e u t r a l
Ha za r d OFF
T u r n S i g n a l L e v e r i n L e f t T u r n
Ha za r d OFF
Turn S i g n a l L e v e r i n Ri g h t T u r n
Ha za r d OFF.
Turn Signal:
Cl o s e d : C1- 9 t o C1- 2 a n d C1- 10: C1- 1 t o C1- 11.
Ope n ; C1- 9 t o C1- 5, C1- 6 a n d C1- 4; C1- 6 t o C1- 5, C1- 8, C1- 2 a n d
C 1 - 1 0 ; C 1 - 4 t o C 1 - 1 1 .
C o r n e r i n g L a m p :
C1 - 2 t o C1 - 3 and C 1 -3; C 1 -3 t o C1 - 7 .
T u r n S i g n a l :
Cl o s e d : C1 - 9 t o C1 - 2 . C1 - 6 t o C 1 - 8 a n d C1- 10; C1- 1 t o C 1 - 1 1 .
Op e n : C1- 9 t o C1- 8, C1- 10, C1- 6; C1- 6 t o C1- 5 a n d C1- 2 ; C 1 - 4 t o
C 1- 11.
C o r n e r i n g L a m p :
Cl o s e d : C1- 2 t o C1- 7
Ope n : C2 - 2 t o C1- 3; C1- 3 t o C1- 7 .
T u r n S i g n a l :
Cl o s e d C 1 - 9 t o C 1 - 0 ; C 1 - 6 t o C1- 5 a n d C1- 2; C M t o C l - 1 1 .
Ope n : C1- 9 t o C1- 5. C1- 2 a n d C1- 6; C1- 6 t o C1- 8. C1- 10 and C1-4;
C 1 - 4 t o C 1 - 1 1 .
C o r n e r i n g L a mp :
Cl o s e d : C2 - 2 t o C1- 7
Ope n : C2- 2 t o C1- 3; C1- 3 t o C1- 7 .
Ha z a r d ON
Ha z a r d OFF
Turn Si gn a l Le ve r , Ri ght Turn
Cl o s e d : C 1 - 6 t o C 1 - 5 , C1- 8, C1- 2 a n d C M O ; C 1 - 4 t o C 1 - 1 1 .
Op e n : C1- 9 t o C1- 2 , C1- 10, C1- 6, C1- 5 a n d C108; C1- 1 t o C 1 - 1 1 .
Cl o s e d : C1- 9 t o C 1 - 2 a n d C1- 10; C1- 1 t o C 1 - 1 1 .
Ope n : C1- 9 t o C1- 5, C1- 8, C1- 6 and C1-4; C1- 6 t o C 1 - 5 , C1- 8, C1- 2
a n d C 1 - 1 0 ; C 1 - 4 t o C 1 - 1 1 .
H e a d l a mp B e a m S w i t c h i n g :
L e v e r at Hi g h B e a m
L e v e r at L o w B e a m
L e v e r at FL A SH- TO- P A SS
Cl o s e d C 2 - 2 t o C 2 - 5 .
Ope n C2- 2 t o C2 - 3 a n d C2 - 7 ; C2 - 7 t o C2 - 5.
Cl o s e d C 2 - 2 t o C 2 - 3 .
Ope n C2- 2 t o C2 - 5 a n d C2 - 7 ; C2 - 7 t o C2 - 3.
Cl o s e d C2- 2 t o C2- 3; C2 - 7 t o C2 - 5.
Ope n C2- 2 t o C2 - 5; C2- 7 t o C2- 3.
Wi p e r / Wa s h e r S w i t c h i n g :
Wa s h OFF a n d Wi p e r OFF
Wa s h ON a n d Wi pe r OFF
Re s i s t a n c e C2 - 4 t o C2- 6, 92 . 9 t o 113. 6k o h ms .
Re s i s t a n c e C2 - 4 t o C2 - 1, 42 . 84 t o 52 . 36K o h ms .
Re s i s t a n c e C2 - 4 t o C2- 6, Cl o s e d Ci r c ui t ( 5 o h ms o r l e s s ) .
Re s i s t a n c e C2 - 4 t o 0 2 - 1 , 42 . 84 t o 52 . 36K o h ms .
( Co n t i n ue d )
11- 05- 2 1
11- 05- 2 2 St e e r i n g Co l u mn S wi t c h e s 11- 05- 2 2
MULTI-FUNCTION SWITCH CONTINUITY TEST (Cont 'd)
SWI TCH ACTUATOR POSI TI ON CONTI NUI TY BY CI RCUI T NUMBE R
Wi p e r OFF a n d Wa s h OFF
Wi p e r L O o r L o w S p e e d a n d Wa s h OFF
Wi p e r HI or Hi gh S p e e d a n d Wa s h OFF
Re s i s t a n c e C2 - 4 t o C2 - 6, 2. 97 t o 3. 63K o h ms .
Re s i s t a n c e C2 - 4 t o C 2 - 1 , 3. 67 t o 4. 48K o h ms .
Re s i s t a n c e C2 - 4 t o C2 - 6, 2. 97 t o 3. 63K o h ms .
Re s i s t a n c e C2 - 4 t o C 2 - 1 , Cl o s e d Ci r c ui t (5 o h ms o r l e s s ) .
Re s i s t a n c e C 2 - 4 t o C 2 - 1 , 10. 19 t o 12. 46K o h ms .
Re s i s t a n c e C1- 4 t o C1- 6, Ma x i mu m De l a y 103. 3K o h ms t o Mi n i mum
De l a y 3. 3K o h ms . A c t i o n must b e gr a d u a l wi t h n o s ki p s high a n d l o w
r e s i s t a n c e r e a d i n gs wh i l e r o t a t i n g wi p e r kn o b .
Mu l t i - F u n c t i o n S w i t c h
Re mo v a l
2. Tilt col umn t o l owest posi t i on and r emove t i lt
st eeri ng col umn l ock lever ( 3F527 ) .
3. Remove i gni ti on swi t c h l ock cyl i nder ( 11582) .
4. Remove shr oud sc r e ws and remove upper
st eeri ng col umn shr oud ( 3530) and l ower
STANDARD COLUMN SHOWN
TILT COLUMN SIMILAR
5.
6.
Remove t wo sel f -t appi ng sc r e ws ret ai ni ng
multi -functi on swi t c h ( 13K359) t o st eeri ng col umn
t ube cast i ng. Di sengage mult i -f unct i on swi t c h
f r om cast i ng.
Di sconnect t wo el ect ri cal c onne c t or s.
K14710-C
Pa r t
1

Ha za r d Fl a she r But t o n
2 13K359 Mul t i - Fun c t i o n Swi t c h
3 390345- S36 Sc r e w (2 Re q' d )
4

To Mul t i - Fun c t i o n Swi t c h
5 3514 St e e r i n g Col umn A s s y
i nst al l at i on
1. Install t wo el ectri cal c onne c t or s t o full
engagement .
2. Ali gn multi -functi on swi t c h mount i ng hol es wi t h
cor r espondi ng hol es in st eeri ng col umn t ube
c a st i ng. Install t wo sel f -t appi ng sc r e ws, maki ng
sure t o st ar t sc r e ws in t he previ ousl y t a ppe d
hol es. Ti ght en t o 2-3 N-m (18-26 Ib-in).
3. Install upper st eeri ng col umn shr oud and l ower
4. Install i gni ti on swi t c h l ock cyl i nder.
5. Install t i lt st eeri ng col umn l ock l ever.
7. Check st eeri ng col umn t ube ( 3514) and
mult i -f unct i on swi t c h f or pr oper oper at i on.
I g n i t i o n S w i t c h
Re mo v a l
Remove t he upper st eeri ng col umn shr oud ( 3530)
by removi ng t he f our or f i ve sel f -t appi ng sc r e ws.
Remove ti lt st eeri ng col umn l ock lever ( 3F527 ) (if
equi pped).
2. Remove l ower st eeri ng col umn shr oud.
3. Di sconnect t he i gni ti on swi t c h el ect ri cal
connect or.
4. Rot at e i gni ti on swi t c h l ock cyl i nder ( 11582) t o
t he RUN posi t i on.
5. Remove t he t wo sc r e ws ret ai ni ng i gni ti on swi t c h
( 1157 2) .
6. Di sengage t he i gni ti on swi t c h f r o m t he act uat or .
NOTE: A new r epl acement i gni ti on swi t c h assembl y
wi ll be set in t he RUN posi t i on a s r ecei ved.
1. Adj ust t he i gni ti on swi t c h by sl i di ng t he carri er t o
t he i gni ti on swi t c h RUN posi t i on.
2. Check t o ensure t hat t he i gni ti on swi t c h l ock
cyl i nder is in t he RUN posi t i on. The RUN posi t i on
i s achi eved by r ot at i ng t he i gni ti on swi t c h l ock
cyl i nder a ppr oxi ma t e l y 90 de gr e e s f r om t he
LOCK posi t i on.
3. Install t he i gni t i on swi t c h i nto t he act uat or. It may
be necessar y t o move t he i gni t i on swi t c h sl i ght l y
ba c k and f o r t h t o ali gn t he i gni ti on swi t c h
mount i ng hol es wi t h t he l ock cyl i nder housi ng
t hr e a de d hol es.
4. Install ret ai ni ng sc r e ws. Ti ght en t o 5. 6-7. 9 N-m
(50-69 Ib-in).
5. Connect el ect ri cal connect or t o i gni ti on swi t c h.
6. Connect ba t t e r y ground cabl e. Check i gni ti on
swi t c h f or pr oper f unct i on, i ncludi ng START and
ACC posi t i ons. Al so, make cer t ai n t hat t he
col umn is in t he LOCK posi t i on.
7. Install upper st eer i ng col umn shr oud.
8. Install t he l ower st eeri ng col umn shr oud and ti lt
st eeri ng col umn l ock lever (if equi pped).
Fl a s h e r , I n d i c a t o r
T u r n Si g n a l Fl a s h e r
The t urn si gnal i ndi cat or f l asher ( 13350) is mount ed t o
t he f ront si de of t he f use j unct i on panel ( 14A067 ) . To
r emove, pull i ndi cat or f l asher st r ai ght out . To i nst al l ,
ali gn t he t ermi nal s of t he i ndi cat or f l asher wi t h sl ot s in
t he f use j unct i on panel and pr ess i ndi cat or f l asher i nt o
pl ace.
Ha z a r d Fl a s h e r
The hazard i ndi cat or f l asher is mount ed t o t he rear
si de of t he f use j unct i on panel , di rect l y behi nd t he t urn
si gnal i ndi cat or f l asher. To r emove, pull i ndi cat or
f l asher st rai ght out . To i nst al l , ali gn t he t ermi nal s of t he
i ndi cat or f l asher wi t h t he sl ot s in t he f use j unct i on
panel and pr e ss i ndi cat or f l asher i nto pl ace.
R e l e a s e S w i t c h , A u t o m a t i c P a r k i n g B r a k e
Re mo v a l
1. Di sconnect ba t t e r y ground cabl e ( 14301) and ai r
bag back-up powe r suppl y.
2. Remove l ower RH and LH moul di ngs f r om
i nst rument panel ( 04320) by pulling up and
snappi ng out ret ai ner.
3. Remove f i ve ret ai ni ng sc r e ws f r om i nst rument
panel st eeri ng col umn cover ( 04459) and r emove
i nst rument panel st eeri ng col umn cover .
4. Remove i nst rument panel rei nf orcement .
5. Di sconnect t ransmi ssi on shi f t cabl e f r om a c t ua t or
housi ng by removi ng one sc r e w.
6. Remove f our col umn ret ai ni ng nut s and l ower
st eeri ng col umn t ube ( 3514) assembl y.
7. Di sconnect vacuum hose ext ensi on assembl y
f r om parki ng br a ke rel ease swi t c h ( 2B623) .
Remove t wo sc r e ws ret ai ni ng parki ng br a ke
rel ease swi t c h t o st eeri ng col umn t ube assembl y
and r emove parki ng br a ke rel ease swi t c h.
SETTING PIN
SWITCH INSTALLATION
HOSE ASSY
2B654
PARKING BRAKE RELEASE
SWITCH ASSY
2B623
SCREW-VACUUM SWITCH
390345-S36
2 REQ'D
TI GHTEN TO
2.1-2.9 N-m
(18.6-25.74 LB-IN}
G7134-A
1
2
Put gear shi f t lever in NEUTRAL.
Pl ace parki ng br ake rel ease swi t c h over col umn
mount i ng bosse s and push par ki ng br a ke rel ease
swi t c h agai nst t urn i ndi cat or cancel c a m ( 13318) .
Secur e parki ng br a ke rel ease swi t c h wi t h t wo
sc r e ws.
Remove and di sc a r d t he plunger ret ai ner f r om
par ki ng br a ke rel ease swi t c h.
5. Connect vacuum hose ext ensi on assembl y t o
parki ng br ake rel ease swi t c h.
6. At t a c h st eeri ng column t ube assembl y t o half car
beam wi t h f our nut s.
7. Connect t ransmi ssi on shi f t cabl e t o st eeri ng
col umn t ube assembl y wi t h one scr ew.
8. Install i nst rument panel rei nf orcement br a c e wi t h
t hr e e bol t s.
9. Install i nst rument panel l ower t ri m cover wi t h f i ve
bol t s.
10. Install RH and LH mouldi ngs on i nst rument panel .
11. Connect ai r bag back-up power suppl y and
ba t t e r y ground cabl e.
SPECIFICATIONS
Tur n Si gn a l a n d Wi n d s h i e l d Wi p e r
S wi t c h
2- 3 18- 26
I gn i t i o n Swi t c h S c r e ws 5. 6- 7. 9 50- 69
P a r ki n g Br a ke Re l e a s e Swi t c h
Re t a i n i n g S c r e w
2. 1- 2. 9 18. 6- 2 5. 7 4
ROTUNDA EQUIPMENT
02 1- 00014 Va c uum Te s t e r
12 - 00- 1
CLIMATE CONT ROL
k# ML JL h ^ f
SECTION TITLE PAGE SECTION TITLE
G R O U P
, AGE
AIR CONDITIONING SYSTEMELECTRONIC
AUTOMATIC TEMPERATURE CONTROL 12-03B-1
AIR CONDITIONING SYSTEMMANUAL
A/C-HEATER ...12-03A-1
CLIMATE CONTROL SYSTEM SERVICE.. 12-00-1
COMPRESSOR AND CLUTCHFS-10 12-03C-1
SECTION 12-00 Climate Control SystemService
SUBJECT PAGE
BASIC PRINCIPLES
Ef f ect of Pressure on Boi l i ng or
Condensat i on 12-00-2
Heat Transf er 12-00-2
Lat ent Heat of Vapori zat i on 12-00-2
A / C Cl ut ch Cont r ol Relay 12-00-13
A / C Compressor and A / C Cl ut ch
Assembl i es 12-00-7
A / C Condenser Core 12-00-8
A / C Cycl i ng Swi t ch 12-00-12
A / C Ref ri gerant Syst em Oper at i on 12-00-4
Ref ri gerant Syst em Pr ot e c t i on. . . . . . . 12-00-8
Saf et y Pr ecaut i ons. . . . . 12-00-3
Servi ce Gauge Port Valves 12-00-13
Servi ce Precaut i ons. , . .........12-00-3
Speci al Servi ce Equi pment 12-00-12
Suct i on Ac c umul a t or / Dr i e r . ........12-00-11
Heater Bl ower Mot or Swi t ch 12-00-40
Heater Core 12-00-41
I nspect i on and Veri f i cat i on ....12-00-27
SUBJECT PAGE
SERVICE PROCEDURES
A / C Compressor 12-00-48
A / C Evaporat or Core a n d / o r A / C Condenser
Core. . . . ....12-00-47
A / C Mani f ol d Gauge Set Connect i on ..............12-00-51
I nspect i on and Assembl y Requi rement s ....12-00-58
Ref ri gerant Oil Addi ti on 12-00-57
Ref ri gerant Re c l a i mi ng/ Re c ove r y / Re c y c l i ng
Equi pment 12-00-51
Ref ri gerant Recovery 12-00-51
Ref ri gerant Syst em. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-00-50
Ref ri gerant Syst em Fi l t eri ng Af t er A / C
Compressor Repl acement 12-00-54
Ref ri gerant Syst em Test s ...12-00-42
Spr i ng Lock Coupl i ng ........12-00-54
Suct i on Ac c umul a t or / Dr i e r Repl acement
Gui del i nes ....12-00-56
Syst em Chargi ng ..................12-00-53
Syst em Chargi ng Se t -Up. . . . . . 12-00-53
Syst em Di schar gi ng. . 12-00-52
Syst em Evacuat i ng ............12-00-53
SPECIFICATIONS
Ref ri gerant Syst em Specifications.......................12-00-58
SPECIAL SERVICE TOOLS/ EQUI PMENT ....12-00-58
i
VEHICLE APPLICATION
12- 00- 2
BASIC PRINCIPLES
Cl i ma t e Co n t r o l S y s t e m S e r v i c e 12- 00- 2
He a t Tr a n s f e r
Vehi cl e ai r condi t i oni ng is t he cool i ng or ref ri gerat i on of
t he ai r in t he passenger compar t ment . Ref ri gerat i on is
accompl i shed by maki ng pr act i cal use of t hr ee l aws of
nat ure. These l aws and t hei r pr act i cal appl i cat i on ar e
out l i ned.
If t wo subst ances of di f f erent t emper at ur es are pl aced
near each ot her, t he heat in t he wa r me r subst ance wi ll
a l wa y s t ravel t o t he col der subst ance until bot h ar e of
equal t emper at ur e. For exampl e, a bl ock of i ce in an
i ce box doe s not t ransf er i t s col dness t o t he bot t l e of
mi lk st andi ng nearby. Rat her, t he heat in t he wa r m milk
aut omat i cal l y f l o ws i nto t he i ce whi c h has a l esser
degr ee of heat . In or der t o det ermi ne t he amount of
heat t hat t r ansf er s f r om one subst ance t o anot her,
sci ent i st s have est abl i shed a def i ni t e st andar d of
measurement cal l ed t he Bri t i sh Thermal Unit or BTU.
One BTU is t he amount of heat requi red t o rai se t he
t emper at ur e of 0. 45 ki l ogram (one pound) of wat er
0. 55C (1 F) . For exampl e, t o rai se t he t emper at ur e
of one pound of wa t e r f r o m 0 C ( 3 2 F ) t o 100C
( 2 12 F) , one BTU of heat must be a dde d f or each
0. 55C (1 F) ri se in t emper at ur e or a t ot al of 180
BTUs of heat . Conversel y, in order t o l ower t he
t emper at ur e of one pound of wa t e r f r om 100C
( 2 1 2 F) t o 0 C ( 3 2 F) , 180 BTUs of heat must be
r emoved f r om t he wat er .
L a t e n t He a t o f Va p o r i z a t i o n
When a liquid boi l s (changes t o a ga s), it a bsor bs heat
wi t hout rai si ng t he t emper at ur e of t he resul t i ng ga s.
When t he gas condenses (changes ba c k t o a li qui d), it
gi ves off heat wi t hout l oweri ng t he t emper at ur e of t he
resul t i ng li qui d.
For exampl e, pl ace one pound of wa t e r at 0C ( 32 F)
in a cont ai ner over a f l ame. Wi t h e a c h BTU of heat t hat
t he wat er a bsor bs f r om t he f l ame, i t s t emper at ur e
ri ses 0. 55C( 1F) . Af t er it has a bsor be d 180 BTUs
of heat , t he wa t e r r e a c he s a t emper at ur e of 100C
( 2 12 F) . Even t hough t he f l ame cont i nues t o gi ve i t s
heat t o t he wat er , t he t emper at ur e of t he wa t e r
remai ns at 100C ( 2 12 F) . The wat er , however,
st a r t s t o boi l or change f r om t he liquid t o t he gaseous
st a t e , and it cont i nues t o boi l until t he wa t e r has
pa sse d off i nt o t he at mospher e as vapor. If t hi s vapor
we r e col l ect ed in a cont ai ner and c he c ke d wi t h a
t hermomet er, it al so woul d sho w a t emper at ur e of
100C ( 212 F). In ot her wo r d s, t her e wa s a ri se of
onl y 100 C (180 F), f r om 0 t o 100 C ( 32 - 2 12 F) in
t he wa t e r and vapor t emper at ur e even t hough t he
f l ame appl i ed many more t han 180 BTUs of heat . The
heat is a bso r be d by t he li qui d in t he pr oc e ss of boi li ng
and di sappear s in t he vapor. If t he vapor wa s brought
in cont act wi t h cool air, t he hi dden heat woul d
r eappear and f l ow into t he cool er ai r as t he vapor
condensed ba c k t o wat er. Sci ent i st s ref er t o t hi s as
t he latent (hi dden) heat of vapor i zat i on.
Wat er has a l at ent heat of vapori zat i on of 97 0 BTUs
and a boi li ng poi nt of 100C ( 2 12 F) . Thi s means t hat
one pound of wat er at 100 C ( 212 F) wi ll a bsor b 97 0
BTUs of heat in changi ng t o vapor at 100C ( 2 12 F) .
Conversel y, t he vapor wi ll gi ve off 97 0 BTUs of heat in
condensi ng back t o wat er.
Thi s t r emendous heat t ransf er t hat o c c ur s when a
li qui d boi l s or a vapor condenses f or ms t he basi c
pri nci pl e of all convent i onal ref ri gerat i on sy st e ms.
For a liquid t o be a good ref ri gerant , t he amount of
heat t hat it a bsor bs when vapori zi ng is not t he only
f act or . If must al so have a l ow boi li ng poi nt . That i s, t he
t emper at ur e at whi ch it boi l s must be l ower t han t he
subst ance t o be c ool e d. To i l l ust rat e wi t h wat er , pl ace
a bot t l e of mi lk at r oom t emper at ur e 2 1. 6C( 7 0F)
next t o boi li ng wa t e r 100C( 2 12 F) . The heat woul d
f l ow f r o m t he (hi gher t emper at ur e) wa t e r t o t he (l ower
t emper at ur e) mi lk. The milk woul d be heat ed rat her
t han c ool e d, because t he boi li ng poi nt of wa t e r i s t o o
hi gh.
To ma ke pr act i cal use of t he heat t ransf er t hat t a ke s
pl ace when a liquid boi l s, c ho o se a liquid wi t h a l ow
boi li ng poi nt . Ref r i ger ant -134a is t he liquid most
commonl y used a s a repl acement f or R-12 in
aut omot i ve ai r condi t i oni ng sy st e ms because it boi l s at
- 2 6C ( - 15F) i n an open cont ai ner. R-134a is a liquid
t hat boi l s or vapor i zes wel l bel ow passenger
compar t ment t emper at ur es and, in vapori zi ng, wi ll
a bso r b t remendous amount s of heat wi t hout get t i ng
any wa r me r i t self .
E f f e c t o f P r e s s u r e o n B o i l i n g o r
C o n d e n s a t i o n
The sat urat i on t emper at ur e (t he t emper at ur e whe r e
boi li ng or condensat i on oc c ur s) of a liquid or vapor
i ncr eases or de c r e a se s, accor di ng t o t he pressure
e xe r t e d on i t.
In t he ai r condi t i oni ng sy st e m, hi gh-pressure liquid
Ref ri gerant R-134a f r om t he A / C condenser c or e
( 197 12 ) ent ers t he A / C evapor at or c or e ori f i ce
( 19D990) in t he liquid line. When t he liquid Ref ri gerant
R-134a is rel eased into t he A / C evapor at or c or e
( 19860) by t he A / C evapor at or c or e ori f i ce, t he
de c r e a se in pr essur e l ower s i t s t emper at ur e. As t he
Ref ri gerant R-134a f l ows t hrough t he A / C evapor at or
c or e , passenger compar t ment air passes over t he
out si de surf ace of t he A / C e va por a t or c or e . As
Ref ri gerant R-134a boi l s, it a bsor bs heat f r om t he air
and c ool s t he passenger compar t ment . The heat f r om
t he passenger compar t ment is a bsor be d by t he boiling
ref ri gerant and hi dden in t he vapor. The ref ri gerat i on
c y c l e is now under wa y . To compl et e t he c y c l e , t he
f ol l owi ng remai ns t o be done:
1. Di spose of t he heat in t he vapor.
2. Convert t he vapor ba c k t o li qui d f or reuse.
12 - 00- 3 Cl i mat e Cont r ol S y s t e mS e r v i c e 12 - 00- 3
BASIC PRINCIPLES (Continued)
3. Ret urn t he liquid t o t he st art i ng poi nt in t he
ref ri gerat i on c y c l e .
The A / C c ompr e ssor ( 197 03) and A / C condenser
c o r e pe r f or m t hese f unct i ons. The c ompr e ssor pulls
t he ref ri gerant vapor (cont ai ni ng t he hi dden heat ) out
of t he A / C e va por a t or c or e and suct i on
accumul at or / dri er ( 19C836) and f o r c e s it under hi gh
pr essur e i nt o t he A / C condenser c or e whi c h is
l ocat ed in t he out si de ai r st r eam at t he f r ont of t he
vehi cl e. The i ncreased pr essur e in t he A / C condenser
c or e rai ses t he Ref r i ger ant -R134a condensat i on or
sat urat i on t emper at ur e t o a poi nt hi gher t han t hat of
t he out si de air. As t he heat t r ansf er s f r om t he hot
vapor t o t he cool er air, t he Ref r i ger ant -R134a
c onde nse s ba c k t o a hi gh pr essur e l i qui d. The liquid
under hi gh-pressure now ret urns t hr ough t he
condenser t o e va por a t or t ube ( 19835) t o t he A / C
e va por a t or c o r e ori f i ce f or reuse.
It may seem di f f i cult t o underst and how heat can be
t r a nsf e r r e d f r o m a compar at i vel y cool er vehi cl e
passenger compar t ment t o t he hot out si de air. The
answer li es in t he di f f erence bet ween t he ref ri gerant
pr essur e t hat e xi st s in t he A / C evapor at or c or e and
t he pr essur e t hat exi st s in t he A / C condenser c or e . In
t he A / C e va por a t or c or e , t he A / C c ompr e ssor
suct i on r educes t he pr essur e and t he boi li ng poi nt
bel ow t he t emper at ur e of t he passenger
c ompa r t me nt . Heat t r ansf er s f r om t he passenger
c ompa r t me nt t o t he boi li ng ref ri gerant . In t he A / C
condenser c or e , t he A / C c ompr e ssor r ai ses t he
condensat i on poi nt a bove t he t emper at ur e of t he
out si de air. The heat t r a nsf e r s f r om t he condensi ng
ref ri gerant t o t he out si de air. The A / C e va por a t or c or e
ori f i ce and t he A / C c ompr e ssor si mpl y c r e a t e
pr essur e condi t i ons t hat permi t t he l aws of nat ure t o
f unct i on.
Safety Precautions
The ref ri gerant used in t hi s ref ri gerant sy st e m is
HFC-134a whi c h is a hy dr of l uor ocar bon ref ri gerant .
HFC-134a , al so known as R-134a, is non-corrosi ve,
non-expl osi ve, non-f l ammabl e and has a sl i ght
et her-l i ke odor.
HFC-134a is heavi er t han air.
Al t hough it is cl assi f i ed as a saf e ref ri gerant , cert ai n
precaut i ons must be obse r ve d t o pr ot e c t t he
sy st e m component and t he t echni ci an.
Use onl y HFC-134a ref ri gerant . Due t o envi ronment al
concer ns, when t he ai r condi t i oni ng sy st e m is drai ned,
t he ref ri gerant shoul d be col l ect ed usi ng ref ri gerant
r ecover y / recycl i ng equi pment meet i ng Soci et y of
Aut omot i ve Engi neers (SAE) requi rement s J1990 and
J2210.
Use of a r e c ove r y machi ne dedi cat ed f or R-134a i s
necessar y t o r educe t he possi bi l i t y of oil and
ref ri gerant i ncompat i bi l i t y / cont ami nat i on concer ns.
Ref er t o t he i nst ruct i ons pr ovi de d by t he equi pment
manuf act urer whe n ref ri gerant or char gi ng t he ai r
condi t i oni ng sy st e ms.
Avoi d breat hi ng A / C ref ri gerant a nd l ubri cant vapor
or mi st .
If acci dent al sy st e m di sc ha r ge o c c ur s, vent i l at e t he
wo r k a r e a bef or e resumi ng ser vi ce.
Li qui d HFC-134a at normal at mospher i c pr essur es
and t emper at ur es e va por a t e s so qui ckl y t hat it has t he
t endency t o f reeze anyt hi ng it c o n t a c t s.
Ext r e me care must be t aken t o prevent any liquid
ref ri gerant f r om comi ng in c ont a c t wi t h t he ski n and
especi al l y t he e y e s.
Wear non-penet rabl e gl oves a nd saf et y goggl es at
all t i mes when handl i ng liquid ref ri gerant .
If any li qui d ref ri gerant ge t s i nt o t he e y e s or on t he
ski n, i mmedi at el y f l ush e y e s a nd ski n wi t h pl ent y of
wa t e r f or at l east 15 mi nut es.
Remove cont ami nat ed cl ot hi ng and shoe s.
Call a physi ci an.
Ref ri gerant HFC-134a is a l wa y s under pr essur e.
Because t he sy st e m i s t i ght l y seal ed, heat appl i ed
t o any par t coul d cause e xc e ssi ve pr essur e
bui ld-up.
To avoi d an expl osi on, ke e p a wa y f r om open
f l ames, gl owi ng met al sur f a c e s, bl ow t o r c h, st eam
cl eani ng and wel di ng.
HFC-134a will de c ompose at hi gh t emper at ur es.
Ma ke sure t hat cont ai ners ar e never heat ed t o over
52 C( 12 5F) . Cont ai ners shoul d be st or e d and
i nst alled in a c c or da nc e wi t h all st a t e and l ocal
ordi nances.
When put t i ng HFC-134a i nt o t he ref ri gerant sy st e m,
a l wa y s c ha r ge f r om t he gas phase. If t he li qui d phase
is used f or char gi ng, liquid HFC-134a wi ll ent er t he
sy st e m and may damage t he A / C c ompr e ssor
( 19703) .
CAUTI ON: Re f r i ge r a n t HFC- 134a s h o u l d n o t b e
mi x e d wi t h ai r f o r l e a k- t e s t i n g o r f o r a n y o t h e r
p u r p o s e a b o v e a t mo s p h e r i c p r e s s u r e . HFC- 134a
i s c o mb u s t i b l e wh e n mi x e d w i t h h i gh
c o n c e n t r a t i o n s o f ai r a n d h i gh e r p r e s s u r e s .
Service Precautions
Never open or l oosen a connect i on bef or e removi ng
t he ref ri gerant f r om t he sy st e m wi t h a recycl i ng
machi ne such as t he Rot unda Mobi l e Recycl i ng
Cent er 176-0001 or equi val ent .
When looseni ng a connect i on af t er r e c ove r y , al l ow it
t o l eak off bef ore openi ng t he f i t t i ng if any resi dual
pressure i s evi dent .
A sy st e m whi ch has been opened t o r epl ace a
component or one whi ch has di schar ged t hr ough
l eakage must be empt i ed bef or e char gi ng.
12 - 00- 4 Cl i ma t e Co n t r o l S y s t e mS e r v i c e 12 - 00- 4
Immediately after di sconnecti ng a component f rom
t he sy st e m, seal t he open f i t t i ngs wi t h a c a p or pl ug.
Bef ore di sconnecti ng a component f rom t he
syst em, thoroughl y clean the outsi de of the fi tti ngs.
Do not remove sealing caps f rom a repl acement
component until ready t o install.
Refri gerant oil absorbs moi sture rapi dl y f rom t he
at mosphere if left uncapped. Do not open an oil
contai ner until ready t o use and install cap
immediately after use. Store oil only in a cl ean,
moi sture-free container.
o Bef ore connecti ng an open fitting, al ways install a
new O-ri ng seal . Coat fitting and O-ring seal wi t h
speci fi ed refri gerant oil before connecti ng.
When installing a refri gerant line, avoi d sharp
bends. Position line away f rom exhaust or any sharp
edges whi ch may damage the line.
Tighten t hreaded fittings only t o speci fi ed t orque.
Do not overti ghten.
When di sconnecti ng a t hreaded fi tti ng, use a
wrench on bot h hal ves of the fitting t o prevent
twi sti ng of refri gerant lines or t ubes.
o Do not open a refri gerant syst em or uncap a
repl acement component unless it is as cl ose as
possi bl e t o room temperature. This will prevent
condensati on f rom formi ng inside a component
whi ch is cool er than surrounding air.
o Keep servi ce tool s and work area cl ean. Avoi d
contami nati on of a refri gerant syst em through
carel ess wor k habi ts must be avoi ded.
Whenever component s in the engine compart ment
or instrument panel areas are being servi ced, t he
bat t ery ground cabl e ( 14301) must be
di sconnected t o eliminate the possibility of el ectri cal
short s, burned wiring and fi res. Ext reme care must
be exerci sed when performi ng el ectri cal t est s
where t he bat t ery must be connect ed t o operat e t he
syst em.
A/ C Refrigerant S y s t e m O p e r a t i o n
Refrigerant Fl o w
During stabi l i zed ( A/ C syst em shutdown) condi ti ons,
refri gerant syst em pressures are equalized on bot h
the high and l ow si des of t he refri gerant syst em.
When t he function control knob ( 18519) is moved t o
an A/ C, mix or def rost posi ti on, the syst em operat es
as f ol l ows:
The magneti c A / C cl utch field coil ( 2987) is
energi zed and the A / C cl utch ( 2884) is pulled into
cont act wi t h t he belt-driven A / C cl utch pulley
( 2E884) .
The A / C cl utch assembl y then rot at es the
compressor shaft.
When t he A / C compressor shaft is rot at ed, t he
pi stons are al ternatel y pulled out and f orced into
thei r respect i ve cylinder bores.
As each pi ston is pulled f rom its cyl i nder bore, the
pressure in t he cylinder suddenly drops far bel ow
t he refri gerant vapor pressure on t he sucti on si de of
the refri gerant syst em.
The higher refri gerant syst em vapor pressure
overcomes the suction reed valve spri ng pressure,
forci ng gas through the reed val ve and into the
l ower-pressure (or vacuum) area inside the A / C
compressor cylinder.
The spri ng pressure on the reed val ve cl oses t he
val ve when t he refri gerant syst em suction vapor
pressure and the compressor cylinder vapor
pressure are equal i zed.
As each piston is f orced into its respecti ve cylinder
bore, the refri gerant vapors f rom t he suction si de of
the refri gerant syst em are compressed into a
decreasi ngl y smaller ar ea, increasing t he
refri gerant vapor pressure and al so raising the
refri gerant vapor temperature.
The higher refri gerant vapor pressure now assi st s
in sealing t he suction reed valve cl osed and al so
opens the di scharge (hi gh-pressure) reed val ve as
the cylinder pressure exceeds the higher-pressure
si de of t he refri gerant syst em.
When the compressed hi gher-pressure and
temperature refri gerant vapor is di scharged into the
high-pressure si de of t he refri gerant syst em, the
di scharge reed val ve spri ng pressure and t he high
si de refri gerant pressure cl oses and seal s the reed
val ve.
Closing t he reed valve prevents the di scharge
pressure f rom re-entering the compressor cylinder.
The A / C compressor refri gerant vapor
compressi on cycl e begins as t he pi stons are again
pulled f rom their respecti ve compressor cylinder
bores by rotati ng the A / C compressor shaft.
The high-pressure and hi gh-temperature A / C
compressor di scharge refri gerant vapor is rel eased
into the t op of the A / C condenser core ( 19712)
assembl y, through the A / C compressor t o
condenser di scharge line ( 19972) .
In the A / C condenser cor e, refri gerant vapor
condenses into a liquid when heat is removed f rom
t he refri gerant vapor by ambient air passi ng over
A / C condenser core fins and tubing.
Liquid refri gerant f rom the bot t om of the A / C
condenser core enters t he high-pressure condenser
t o evaporat or tube ( 19835) and then the inlet side
of the A / C evaporat or core ori fi ce ( 19D990) .
The inlet filter screen of the A / C evaporator core
ori fi ce assembl y removes coarse contaminant
parti cl es. These parti cl es may be present in the
liquid refrigerant before t he liquid refrigerant enters
the cal i brated opening of the A / C evaporat or core
ori fi ce.
The outlet end of the A / C evaporat or core orifice
assembl y has a fine mesh filter wi t h four open side
sl ots.
The si de sl ots and filter a c t as a refri gerant fl ow
noise suppressor.
12 - 00- 5 Cl i ma t e Co n t r o l S y s t e m S e r v i c e 12-00=5
Refri gerant pressure is reduced in t he A/ C
evaporat or core ( 19860) as a result of the A / C
evaporat or cor e ori fi ce and the A / C compressor
sucti on.
As t he A / C evaporat or core pressure drops and t he
condenser t o evaporat or tube pressure i ncreases,
the liquid refri gerant passes t hrough the A / C
evaporat or core ori fi ce and enters t he A / C
evaporat or cor e at a l ow pressure and as a col d
liquid.
As ai rfl ow passes over t he pl at e/ f i n secti ons of the
A / C evaporat or core, t he refri gerant inside absorbs
the heat and changes into a vapor.
A / C compressor sucti on dr aws t he vapori zed
refri gerant and oil mi xture into the sucti on
accumul ator / dri er ( 19C836) where the heavi er oil
laden vapor s fall t o t he bot t om and the lighter
vapor s and oil mi xture continue their pat h to the
A / C compressor ( 19703) through the evaporat or
t o compressor sucti on line ( 19867) .
Two desi ccant bags, l ocat ed inside the suction
accumul at or/ dri er, absorb and retain moi sture
whi ch may be ci rcul ati ng in t he refri gerant syst em.
The heavi er oil laden refri gerant al so returns t o the
A / C compressor through a small liquid bl eed hole
near the bot t om of the aspi rator tube.
The liquid bl eed hole provi des a control l ed second
opportuni ty for the accumul ated refri gerant and oil
mi xture t o vapori ze as it passes through the
opening t o re-enter into the main vapor fl ow path t o
t he sucti on si de of the A / C compressor.
A / C Ev a po r a t o r Co r e O r i f i c e Cy c l i n g A / C Cl ut c h Re f r i ge r a n t Sy st e m
HIGH PRESSURE GAS
HIGH PRESSURE LIQUID
LOW PRESSURE LIQUID
LOW PRESSURE GAS
FRESH OR
RECI RCULATED
AIR L
OUTSIDE
AIR
L9033-A
1 19703 A / C Co mp r e s s o r
2 Lo w Pr e ssur e Se r v i c e Por t
3 19E561 A / C Cy c l i n g Swi t c h
4 19C836 Suc t i o n A c c u mu l a t o r / Dr i e r
I t e m
Pa r t
5 18527 Bl o we r Mo t o r
6 19860 A / C Ev a po r a t o r Co r e
7 19D990 A / C Ev a po r a t o r Co r e Or i f i c e
8 19712 A / C Co n d e n se r Cor .
12 - 00- 6
Cl i ma t e Co n t r o l S y s t e mS e r v i c e 12 - 00- 6
Par t
9

High Pressure Service Port
10 19D644 A / C Compressor Pressure
Relief Valve
( Co n t i n ue d )
i t em
Pa r t
11 19D594 A / C Pressure Cut -Of f Switch
Ref r i ger ant Sy s t e ms
Town Car, Crown Vi ctori a and t he Grand Marqui s
vehi cl es of f er the R-134a A / C syst em.
The R-134a sy st e m uses a non-chl orof l uorocarbon
(non-CFC)-based ref ri gerant R-134a.
R-134a is a hydr of l uor ocar bon (HFC)-based
ref ri gerant .
The A / C ref ri gerant sy st e m is an A / C e va por a t or
c or e o r i f i c e c y c l i n g A / C cl ut ch t y pe . The sy st e m
component s are:
A / C c ompr e ssor .
A / C c l ut c h.
A / C condenser c or e .
A / C evapor at or c or e .
Suct i on a c c umul a t o r / d r i e r .
The necessar y connect i ng ref ri gerant li nes.
Sy st e m oper at i on is cont rol l ed by:
A / C e va por a t or c o r e ori f i ce.
A / C cy cl i ng swi t c h ( 19E561) .
A / C c ompr e ssor pr essur e reli ef val ve ( 19D644) .
A / C pr essur e cut -of f swi t c h ( 19D594) .
The ref ri gerant sy st e m i ncor por at es a 10-cyl i nder
A / C c ompr e ssor cont rol l ed by an A / C cycl i ng swi t c h
connect ed in seri es wi t h t he A / C c l ut c h. The A / C
cycl i ng swi t c h:
Senses A / C evapor at or c o r e pr essur e t o cont rol
A / C c ompr e ssor oper at i on.
Uses t hi s met hod of A / C c ompr e ssor cont rol t o
st op A / C c ompr e ssor operat i on duri ng surroundi ng
t emper at ur es bel ow appr oxi mat el y 10C ( 50F)
and t o al so prevent A / C e va por a t or c or e i ci ng
duri ng normal sy st e m oper at i on.
A / C c ompr e ssor pressure reli ef val ve is i nst alled in
t he A / C c ompr e ssor ' s hi gh-pressure (di schar ge) A / C
mani f ol d and t ube ( 19D7 34) t o pr ot ect t he ref ri gerant
sy st e m agai nst excessi ve ref ri gerant pr essur es.
Engi ne compar t ment aeroshi el d and hood seal s are
uti li zed t o di rect ai rf l ow into t he A / C condenser c or e
and prevent reci rcul at i on of hot air. I mproperl y
i nst al l ed, mi ssi ng or damaged seal s and def l ect or s
can reduce sy st e m per f or mance.
Operat i on of t he A / C cl ut ch depends on si gnal s f r om
t he power t r ai n cont rol modul e (PCM)(12A650). The
sy st e m is pr ogr ammed t o i nt errupt A / C c ompr e ssor
operat i on when cert ai n condi t i ons exi st . The A / C
cl ut ch can be shut off (or kept of f ) f or several seconds:
At engi ne st ar t -up.
At hi gh engi ne speeds.
Duri ng accel er at i on.
When t he engi ne cool ant t emper at ur e e xc e e ds a
predet ermi ned t emper at ur e.
Duri ng l ow engi ne idle condi t i ons (appr oxi mat el y
2 00 r pm bel ow l ow idle speci f i cat i ons).
An A / C evapor at or c or e ori f i ce is used t o met er t he
liquid ref ri gerant into t he A / C evapor at or c or e f or
A / C evapor at or c o r e cool i ng.
12 - 00- 7
zmz
Cl i ma t e Co n t r o l S y s t e mS e r v i c e _
a r e _:- ~zzz. ~^r zzizzz. ^zzzzzzz:zzz~ Z3z
12 - 00- 7
ms: ;i
A / C Evaporat or Cor e Ori f i ce Ty pe S y s t e m4. 6L Engi ne
M4625-A
Par t Par t
Stem Number De sc r i pt i o n I t e m Numbe r De s c r i p t i o n
1 19A559 A / C Ev a po r a t o r Co r e
Ho usi n g
8 19972 A / C Co mpr e s s o r t o
Co n d e n se r Di s c ha r ge Li ne
2

L o w Pressure Service Port
9 19712 A / C Co n d e n se r Co r e
3 19E561 A / C Cy c l i n g Swi t c h 10 19703 A / C Co mpr e s s o r
4 19867 E v a po r a t o r t o Co mp r e s s o r
Suc t i o n Li ne
11 19D644 A / C Co mp r e s s o r P r e s s ur e
Rel i ef Va l ve
5 19D594 A / C Pr e ssur e Cut -Of f Swi t c h
12 19D734 A / C Ma n i f o l d a n d Tube
6

Hi gh Pr e ssur e Se r v i c e Por t
13 19835 Co n d e n se r t o E v a po r a t o r
7 19E746 A / C Tube L o c k Co upl i n g Cl i p
14 19C836
Tube
Suc t i o n A c c u mu l a t o r / Dr i e r
(Continued)
14 19C836
Tube
Suc t i o n A c c u mu l a t o r / Dr i e r
A / C C o m p r e s s o r a n d A / C C l u t c h
A s s e m b l i e s
The A / C c ompr e ssor ( 197 03) has t he f ol l owi ng
The FS-10 is a swa shpl a t e desi gn, 10-cyl i nder
alumi num A / C c ompr e ssor uti li zi ng t he t angent i al
desi gn mount .
Di spl acement of 170 c c ( 10. 4 cubi c i nches).
Lubr i cat ed by a c ha r ge of Mot or c r a f t YN- 12b
ref ri gerant oil or equi valent meet i ng Fo r d
speci f i cat i on WSH-M1C231-B in t he r ef r i ger ant
sy st e m.
The compr essor mai nshaf t i s dri ven by a dr i ve bel t
( 8620) f r om t he engi ne c r a nksha f t vi br at i on d a mpe r
( 6316) .
A one-pi ece, l i p-t ype seal (r epl aceabl e f r o m t he
f ront of t he A / C c ompr e ssor ) i s used t o se a l it at t he
shaf t openi ng in t he assembl y.
S y s t e mS e r v i c e 12 - 00- 8 12 - 00- 8 Cl i ma t e Co n t r o l
R e f r i g e r a n t S y s t e m P r o t e c t i o n
A / C C o m p r e s s o r P r e s s u r e Re l i e f Va l v e
An A / C c ompr e ssor pr essur e relief val ve ( 19D644)
has been i ncor por at ed in t he c ompr e ssor ' s A / C
mani f ol d and t ube ( 19D734) :
To rel i eve unusually hi gh ref ri gerant sy st e m
di schar ge pr essur e bui l dups, 3103 kPa ( 450 psi )
and a bove .
To prevent damage t o t he A / C c ompr e ssor
( 197 03) and ot her A / C sy st e m component s.
The val ve cl oses t o prevent t ot al ref ri gerant l oss
af t er t he excessi ve pr essur e has been rel i eved,
cl osi ng t he val ve.
A / C P r e s s u r e Cu t - Of f S w i t c h
An A / C pressure cut -of f swi t c h ( 19D594) i s used on
all vehi cl es t o i nt errupt A / C c ompr e ssor operat i on in
t he event of hi gh sy st e m di schar ge pr essur es.
Si n gl e Fu n c t i o n
The A / C pressure cut -of f swi t c h is l ocat ed in t he
di schar ge line bet ween t he A / C c ompr e ssor and
A / C condenser c or e ( 197 12) .
The A / C pressure cut -of f swi t c h is sensi t i ve t o
di schar ge pressure.
The A / C pressure cut -of f swi t c h opens t he ci rcui t t o
t he A / C cycl i ng swi t ch if di schar ge pr essur es
e xc e e d 27 51- 3068 kPa ( 399- 445 psi ).
A / C Pr essur e Cut -Of f Swi t c h
M4865-A
A / C C o n d e n s e r C o r e
NOTE: Whenever an A / C condenser c or e ( 197 12) i s
r epl aced, al so repl ace t he suct i on a c c umul a t or / dr i e r
( 19C836) .
The A / C condenser cor e has t he f ol l owi ng
char act er i st i cs:
It is an aluminum fin and t ube desi gn heat exchanger
l ocat ed in f ront of t he radi at or ( 8005) .
It cool s c ompr e sse d ref ri gerant gas by al l owi ng ai r
t o pa ss over fi ns and t ubes t o e xt r a c t heat . It
condenses ga s t o liquid ref ri gerant a s it is c ool e d.
Fi ve doubl e-act i ng pi st ons, posi t i oned axi al l y
around t he compr essor shaf t , oper at e wi t hi n t he
cyl i nder assembl y. The pi st ons are st a r t e d by a
swa shpl a t e t hat is pr essed on t he c ompr e ssor
shaf t .
w The swashpl at e changes t he rot at i ng act i on of t he
shaf t t o provi de a reci procat i ng dri vi ng f o r c e t o
each of t he f i ve pi st ons. Thi s f or c e is appl i ed,
t hr ough shoes, t o t he mi dpoi nt of each of t he
doubl e-end pi st ons.
Reed-t ype di schar ge val ves ar e assembl ed on t he
val ve pl at e.
The val ve pl at e is l ocat ed wi t h t he suct i on reed
val ve bet ween t he cyl i nder assembl y and t he head
at each end of t he A / C compr essor .
The heads ar e connect ed t o each ot her by gas-t i ght
pa ssa ge wa y s t hr ough t he cyl i nder assembl y whi ch
di r ect t he ref ri gerant gas t o t he suct i on and
di schar ge por t s l ocat ed in t he rear head.
The magnet i c A / C cl ut ch ( 2884) has t he f ol l owi ng
It dri ves t he c ompr e ssor shaf t . When vol t age is
appl i ed t o t he A / C cl ut ch f i el d coi l ( 2987) , t he
cl ut ch pl at e and hub assembl y (whi ch is sol i dl y
coupl ed t o t he c ompr e ssor shaf t ) is dr a wn r e a r wa r d
by magnet i c f o r c e t o wa r d t he A / C cl ut ch pulley
(2E884). The A / C cl ut ch pulley r ot at es f reel y on
t he c ompr e ssor f ront head cast i ng.
The magnet i c f or c e l ocks t he cl ut ch pl at e and hub
assembl y and t he A / C cl ut ch pulley t oget her as one
unit.
The cl ut ch pl at e and hub assembl y t hen t urns wi t h
t he A / C cl ut ch pul l ey, causi ng t he c ompr e ssor
shaf t t o r ot a t e .
When vol t age is r emoved f r om t he A / C cl ut ch f i el d
coi l , spr i ngs in t he cl ut ch pl at e and hub assembl y
move t he cl ut ch pl at e a wa y f r om t he A / C cl ut ch
pul l ey.
The cl ut ch pl at e and hub assembl y and c ompr e ssor
shaf t st o p r ot at i ng.
A / C Co mpr e sso r a n d A / C Cl ut c h Asse mbl y
M4860-A
12 - 00- 9 Cl i mat e Cont r ol S y s t e m Se r v i c e 12 - 00- 9
The A / C condenser c or e inlet and out l et
connect i ons ar e t he male part of a spri ng l ock
coupl i ng.
A speci al ser vi ce t ool is requi red t o di sconnect t he
ref ri gerant lines f r om t he A / C condenser c or e .
A / C Co n d e n se r Cor e
L9035-A
S p r i n g L o c k C o u p l i n g
The spri ng l ock coupl i ng i s a ref ri gerant line coupl i ng
held t oge t he r by a gar t er spri ng i nsi de a ci rcul ar c a ge .
When t he coupl i ng is connect ed t oget her , t he f l ar ed
end of t he f emal e f i t t i ng sl i ps behi nd t he gar t er
spri ng i nsi de t he c a ge of t he mal e f i t t i ng.
The ga r t e r spri ng and c a ge t hen prevent t he f l ared
end of t he f emal e f i t t i ng f r o m pulling out of t he cage.
Two O-ri ngs a r e used t o seal bet ween t he t wo
hal ves of t he coupl i ng.
The se O-ri ngs a r e green in col or and a r e made of
spe c i a l mat er i al .
Use onl y t he gr een O-ri ngs l i st ed in t he For d Mast er
Par t s Cat al og f or t he spri ng l ock coupl i ng.
A pl ast i c i ndi cat or ri ng is used on spri ng l ock
coupl i ngs t o i ndi cat e, duri ng vehi cl e assembl y, t hat
t he coupl i ng is c onne c t e d. Once t he coupl i ng is
c o n n e c t e d , t he i ndi cat or ri ng i s no l onger necessar y
but wi l l remai n capt i ve by t he coupl i ng near t he c a ge
openi ng.
The i ndi cat or ri ng may al so be used duri ng servi ce
oper at i ons t o i ndi cat e connect i on of t he coupl i ng.
Af t er t he coupl i ng has been cl eaned and new O-ri ng
seal s i nst al l ed and l ubri cat ed wi t h cl ean ref ri gerant
oi l , i nsert t he t a bs of t he i ndi cat or ri ng i nto t he c a ge
openi ng.
Connect t he coupl i ng t oget her by pushi ng wi t h a
sl i ght t wi st i ng mot i on. When t he coupl i ng is
c onne c t e d, t he i ndi cat or ri ng wi ll snap out of t he
c a ge openi ng but will remai n c a pt ur e d on or near t he
coupl i ng by t he ref ri gerant line.
12- 00- 10
Spr i n g Lo c k Coupl i ng
*ALSO SUPPLIED IN
KIT E35Y-19D690-A
FEMALE
FITTING
MALE
FITTING
3/8"-391396-Sl00*
1/2"-391397-S100*
5/8"-391304-Sl00*
3/4"-391307-S100
GARTER
SPRING
CAUTION DISCHARGE SYSTEM BEFORE >
DISCONNECTING COUPLING
CAGE
REPLACEMENT
O-RINGS
SEALS
SPRI NG LOCK COUPLING DISCONNECTED
TO CONNECT COUPLING
CAGE
OPENI NG
DISCONNECT TOOL
T81P-19623-G1 - 3/8 INCH
T81P-19623-G2-1/2 INCH
T83P-19623-C - 5/8 INCH
T85L-19623-A - 3/4 INCH
FIT TOOL TO COUPLING SO THAT TOOL CAN
ENTER CAGE OPENING TO RELEASE THE
GARTER SPRING.
GARTER SPRING
REPLACEMENT GARTER SPRINGS
3/8--E1ZZ-19E576-A*
1/2"-E1ZZ-19E576-B*
5/8-E35Y-19E576-A*
3/4"- E69Z-19E576-A*
*ALSO AVAILABLE IN
E35Y-19D690-A KIT WITH O-RINGS
CHECK FOR MISSING OR DAMAGED GARTER
SPRING REMOVE DAMAGED SPRING WITH
SMALL HOOKED WIREINSTALL NEW SPRING
IF DAMAGED OR MISSING.
PUSH TOOL INTO
CAGE OPENI NG
OPENING TO RELEASE THE FEMALE FITTING
FROM THE GARTER SPRI NG.
ACLEAN FITTINGS
I NSTALL NEW
O-RING SEALS
USE ONLY SPECIFIED
O-RING SEALS
C LUBRI CATE WI TH
CLEAN REFRI GERANT
OI L
D
ASSEMBLE FITTING
TOGETHER BY PUSHING
WI TH A SLI GHT TWI STI NG
MOTI ON
FITTINGS APART.
GARTER SPRI NG
TO ENSURE COUPLING ENGAGEMENT, VISUALLY
CHECK TO BE SURE GARTER SPRING IS OVER
DISCONNECTED SPRI NG LOCK COUPLING.
M4011-E
12- 00- 11 Cl i ma t e C o n t r o l S y s t e m S e r v i c e 12 - 00- 11
A / C E v a p o r a t o r C o r e Or i f i c e
The A / C evapor at or c or e ori f i ce ( 19D990) has t he
f ol l owi ng char act er i st i cs:
A di amet er of 1.46 mm ( 0. 058 i nch).
It is l ocat ed in t he evapor at or c o r e inlet t ube and ha s
f i lt er scr eens l ocat ed on t he inlet and out l et ends of
t he t ube body .
The A / C evapor at or c o r e ori f i ce assembl y i s t he
r est r i ct i on in t he ref ri gerant ci rcui t t hat c r e a t e s t he
pr essur e d r o p necessar y f or cool i ng by met eri ng t he
f l o w of li qui d ref ri gerant i nto t he A / C e va por a t or c o r e
( 19860) , whi ch reduces t he pr essur e.
Oper at i on i s as f ol l ows:
A / C evapor at or c or e t emper at ur e is cont rol l ed by
sensi ng t he pressure wi t hi n t he A / C evapor at or
c or e wi t h t he A / C cycl i ng swi t c h.
The A / C cycl i ng swi t c h cont r ol s A / C c ompr e ssor
operat i on as necessar y t o mai nt ai n t he A / C
evapor at or c or e pr essur e wi t hi n speci f i ed l i mi t s.
The inlet f i lt er screen a c t s as a st rai ner f or t he li qui d
ref ri gerant f l owi ng t hr ough t he A / C evapor at or c o r e
ori f i ce.
O-ri ngs on t he A / C evapor at or c o r e ori f i ce prevent
t he hi gh-pressure liquid ref ri gerant f r o m by passi ng
t he A / C evapor at or c o r e ori f i ce.
Adj ust ment or ser vi ces cannot be ma de t o t he A / C
evapor at or c or e ori f i ce assembl y and it must be
r epl aced a s a unit.
The A / C evapor at or c o r e ori f i ce shoul d be r e pl a c e d
whenever an A / C c ompr e ssor ( 197 03) is r epl aced.
A / C Ev a po r a t o r Co r e Or i f i c e
FLOW DI RECTI ON
M3101-D
A / C E v a p o r a t o r C o r e
NOTE: Whenever an A / C evapor at or c o r e i s
r e pl a c e d, al so repl ace t he suct i on a c c umul a t o r / d r i e r
( 19C836) .
The A / C evapor at or c o r e is t he pl a t e / f i n - t y pe wi t h a
uni que ref ri gerant f l ow pa t h.
A mi xt ur e of ref ri gerant and oil ent ers t he bot t om of
t he A / C e va por a t or c o r e t hr ough t he A / C
e va por a t or c o r e inlet t ube and is r out ed so t hat it
f l o ws t hr ough t he par t i t i oned f i rst f i ve and one half
pl a t e / f i n se c t i ons.
The next f i ve pl a t e / f i n sect i ons ar e part i t i oned t o
f o r c e t he ref ri gerant t o f l ow t o wa r d t he ot her end of
t he A / C e va por a t or c o r e .
The ref ri gerant t hen cont i nues over t o t he remai ni ng
si x and one half pl a t e / f i n sect i ons and t hen moves
out of t he A / C e va por a t or c o r e t hr ough t he A / C
e va por a t or c o r e out l et t ube.
Thi s S-pass f l ow pat t er n a c c e l e r a t e s t he f l ow of
ref ri gerant and oi l t hr ough t he A / C evapor at or c o r e .
A / C Evapor at or Co r e
M3777-C
S u c t i o n A c c u m u l a t o r / D r i e r
CAUTI ON: Re p l a c e me n t o f t h e s u c t i o n
a c c u mu l a t o r / d r i e r ( 19C836) i s n e c e s s a r y a n y
t i me a ma j o r c o mp o n e n t o f t h e r e f r i ge r a n t s y s t e m
i s r e p l a c e d . A ma j o r c o mp o n e n t i n c l u d e s A / C
c o n d e n s e r c o r e ( 197 12 ) , A / C c o mp r e s s o r
( 197 03) , A / C e v a p o r a t o r c o r e ( 19860) o r a
r e f r i ge r a n t h o s e / l i n e . A n A / C e v a p o r a t o r c o r e
o r i f i c e ( 19D990) o r O- r i n g se a l i s n o t c o n s i d e r e d
a ma j o r c o mp o n e n t , b u t t h e A / C e v a p o r a t o r c o r e
o r i f i c e s h o u l d b e r e p l a c e d wh e n e v e r t h e A / C
c o mp r e s s o r i s r e p l a c e d f o r l a c k o f p e r f o r ma n c e .
The suct i on a c c umul a t or / dr i e r is mount ed on t he f r ont
of t he A / C evapor at or c o r e housi ng ( 19A559) and
a t t a c he s di rect l y t o t he A / C e va por a t or c or e out l et
t ube.
A l ow-pressure servi ce a c c e ss gauge por t val ve i s
mount ed on t he si de of t he suct i on a c c umul a t o r / d r i e r .
It pr ovi des servi ce a c c e ss t o t he suct i on si de of t he
ref ri gerant sy st e m f or pr essur e readi ngs and
sy st e m di agnosi s.
It al so may be used f or l i qui d-chargi ng t he sy st e m
when requi red.
After entering the inlet of the sucti on
accumul at or/dri er, heavier oil-laden refri gerant
cont act s an i nf ernal l y-mount ed dome, whi ch serves
a s an umbrel l a. The oil t hen dri ps down onto t he
bot t om of t he cani st er.
A smal l di amet er oil bl eed hol e, in t he bot t om of t he
vapor ret urn t ube al l ows t he accumul at ed heavi er
liquid ref ri gerant and oil mi xt ure t o re-ent er t he
c ompr e ssor suct i on line at a cont rol l ed r at e.
As t he heavi er liquid refri gerant and oil mi xt ure
passes t hr ough t he smal l di amet er liquid bl eed hol e,
it has a se c ond opportuni ty to vapori ze and
reci rcul at e t hr ough t he A / C c ompr e ssor wi t hout
causi ng c ompr e ssor damage due t o sl uggi ng.
A f i ne-mesh scr eened filter f i t s t i ght l y around t he
bot t om of t he vapor return t ube t o filter out
ref ri gerant sy st e m cont ami nant parti cl es.
A desi ccant bag is mount ed i nsi de t he cani st er t o
a bso r b any moi st ure whi ch may be in t he ref ri gerant
sy st e m.
In addi t i on t o t he precedi ng condi t i on, t he suct i on
a c c umul a t o r / d r i e r shoul d al so be r epl aced if one of
t he f ol l owi ng condi t i ons exi st :
The suct i on a c c umul a t or / dr i e r is pe r f or a t e d.
The ref ri gerant sy st e m has been opened t o t he
a t mosphe r e f or a per i od of t i me longer t han requi red
t o ma ke a mi nor repai r.
Ther e is evi dence of moi st ure in t he sy st e m such as
i nt ernal cor r osi on of met al ref ri gerant lines or t he
ref ri gerant oil is t hi ck and dar k.
Suc t i o n A c c u mu l a t o r / Dri er
FROM A/C
EVAPORATOR CORE
LOW-PRESSURE V
SERVI CE ACCESS
GAUGE PORT VALVE
WI4461-B
A/ C Cycling Swi tch
The A / C cy cl i ng swi t c h ( 19E561) is mount ed on a
Sc hr a de r val ve-t ype f i t t i ng on t he si de of t he
e va por a t or t o c ompr e ssor suct i on line ( 19867 ) .
A val ve depr essor , l ocat ed i nsi de t he t hr e a de d end
of t he A / C cy cl i ng swi t c h, pr e sse s in on t he
Sc hr a de r val ve st e m.
Thi s al l ows t he suct i on pr essur e i nsi de t he
e va por a t or t o c ompr e ssor suct i on line t o cont r ol t he
operat i on of t he A / C cycl i ng swi t c h.
The el ect ri cal swi t c h c ont a c t s open when t he
suct i on pr essur e d r o ps t o 152-193 kPa ( 22 t o 28
psi ).
The c ont a c t s cl ose when t he suct i on pr essur e ri ses
t o 27 6- 324 kPa (40-47 psi ).
Ambi ent t emper at ur e bel ow appr oxi mat el y 7-10 C
( 45- 50F) , pr event s t he A / C cy cl i ng swi t c h
c o n t a c t s f r om cl osi ng.
Thi s i s due t o t he pressure / t emper at ur e
rel at i onshi p of t he ref ri gerant and t he requi rement of
t he sy st e m pr essur e t o r each 27 6- 324 kPa (40-47
psi ) t o cl ose t he A / C cycl i ng swi t c h c ont a c t s.
These c o n t a c t s cont rol t he el ect ri cal ci rcui t t o t he
A / C cl ut ch f i el d coi l (2987).
When t he A / C cycl i ng swi t c h c o n t a c t s cl ose, t he
A / C cl ut ch ( 2 884) is energi zed f or A / C
c ompr e ssor oper at i on.
When t he A / C cycl i ng swi t c h c ont a c t s open, t he
A / C cl ut ch is de-energi zed and A / C c ompr e ssor
operat i on st o ps.
The A / C cy cl i ng swi t c h wi ll cont r ol t he A / C
evapor at or c o r e pressure at a poi nt whe r e t he
pl a t e / f i n sur f ace t emper at ur e wi ll be mai nt ai ned
sl i ght l y a bove f reezi ng.
Thi s pr event s A / C evapor at or c o r e i ci ng and t he
bl ockage of ai rf l ow.
A / C Cy c l i n g Swi t c h
L9036-A
Special Service Equipment
CAUTI ON: Do n o t u s e R-12 s p e c i a l t o o l s a n d
e q u i p me n t w h e n s e r v i c i n g a R134a s y s t e m. Th i s
ma y c a u s e d a ma g e t o t h e R134a A / C s y s t e m.
R134a sy st e ms requi re speci al servi ci ng equi pment
desi gned speci f i cal l y f or sy st e ms. R-12 servi ci ng
equi pment cannot be used when servi ci ng R134a A / C
sy st e ms. R134a speci al servi ce equi pment i ncludes:
Rot unda R-134a A / C Servi ce Cent er 07 8- 00850 or
equi val ent .
Rot unda Mobi l e Recycl i ng Cent er 176-00001 or
equi val ent .
Rot unda R-134a Aut omat i c Cal i brat i on Hal ogen
Leak Det ect or 161-R0010 or equi val ent .
12 - 00- 13 S e r v V 12 - 00 "
Rot unda R-134a Mani f ol d Gauge Set 176-R032A or
equi val ent .
Rot unda R-134a Low-Si de Qui ck Di sconnect
176-R0036 or equi val ent .
Rot unda R-134a Hi gh-Si de Qui ck Di sconnect
Rot unda R-134a Vacuum Pump (1. 5 CFM)
176-00033 or equi val ent .
Service Gauge Port Valves
NOTE: The A / C ser vi ce por t f i t t i ngs ar e t he t wo-pi e c e
desi gn. The t op por t i on of t he f i t t i ng is alumi num and is
t hr eaded t o t he bo t t o m part and seal ed wi t h an O-ri ng
seal . The val ve seal i s an i nt egral par t of t he alumi num
f i t t i ng pi ece whi c h must be r epl aced if t he seal l eaks.
The Sc hr a de r -t y pe val ve c or e used on R-12
ref ri gerant sy st e ms IS NOT USED wi t h R-134a
ref ri gerant sy st e ms.
The hi gh-si de f i t t i ng i s t he l argest and speci al
coupl i ngs are requi red t o connect ser vi ce equi pment
t o bot h t he hi gh-si de and l ow-si de ser vi ce por t s. Ref er
t o t he R-134a equi pment li st.
Qui ck di sc onne c t s must be used t o connect a
mani f ol d ga uge set t o t he sy st e m.
Rot unda 176-R0036 i s t he l ow-si de qui ck
di sconnect and Rot unda 176-R0037 is t he hi gh-si de
qui ck di sconnect .
Al wa y s r e pl a c e t he A / C char gi ng val ve c a ps
( 19D7 02 ) on t he ser vi ce a c c e ss gauge por t val ves
af t er servi ci ng t he ref ri gerant sy st e m.
A/ C Clutch Control Relay
The A / C c l ut c h cont r ol rel ay de a c t i va t e s t he A / C
cl ut ch ( 2884) whe n it r ecei ves a si gnal f r om t he
power t r ai n cont r ol modul e ( PCM) ( 12A650) .
The A / C cl ut ch c a n be de a c t i va t e d in t hi s manner
under t he f ol l owi ng condi t i ons:
Engi ne st ar t -up.
Wi de-open t hr ot t l e .
Lo w engi ne i dle condi t i ons.
Excessi vel y hi gh engi ne t emper at ur e.
Manual A/ C- He a t e r Sy st e m
I
TEMPERATURE ADJUSTMENT
POTENTIOMETER
"T ,FUSE
p
9 I JUNCTION
- PANEL
I
30A J
BR/O
P/O
1
298 I P/O
VENTl
NORM,
A/C
~ E ;
I OFF I r OFF
ENTL, ^ LjFLOOR VENT I j r"**
-
**^*
H
^ k
M I X
NORM A/CJp
436
^ 298 j P / O 437| Y/ LG T
X 1111
I
L 9 | [
1
MAX A/C
249 I DB/LG
A/C
ELECTRONIC
DOOR
ACTUATOR
MOTOR
208 I GY
0
HEATER
BLOWER
MOTOR
SWITCH
T
1
A/C
BLOWER
MOTOR
\ LO
1 ,
BK 754
Y/R
A/C
BLOWER
MOTOR
SWITCH
RESISTOR
of thi s circuit
J L
M4629-A
12- 00- 15 Cl i mat e Cont r ol Sy s t e mSe r v i c e 12- 00- 15
Manual A/ C- He a t e r Sy st e m (Cont i nued)
FROM A/C
PRESSURE
#
198
CUT-OFF mmmmmm
SWITCH DG/O
TO
POWERTRAIN
CONTROL
MODULE (PCM)
POWER
RELAY
of this circuit
TO POWERTRAIN
CONTROL
MODULE
(PCM)
f 347jj^BK/Y
A/C
CLUTCH
DIODE
57^BK
A/C
CLUTCH
M4630-A
TO ^ BLACK
VACUUM ^mi^^mm^mmw^mummm^
DISTRIBUTION
AC-HEATER
CONTROL ASSEMBLY
VACUUM VALVE
CO
CD
Ol
I
o

o
to
<
o*
o

o
-%
&
3
Q.
2
BLOWER MOTOR
OUTSIDE-
RECIRCULATE
DOOR
VACUUM
MOTOR
\ HEATER CORE
\
TO DEFROSTERS \
A
FLOOR-DEFROST DOOR
f ^
P V
/ A V
V - VACUUM
NV - NO VACUUM
PV - PARTIAL VACUUM
OUTSIDE AIR
OUTSIDE-RECIRCULATE
DOOR
TEMPERATURE BLEND DOOR
(ELECTRICALLY CONTROLLED)
M4626-A
CO
CO
12- 00- 17 Cl i ma t e Co n t r o l S y s t e m S e r v i c e 12- 00- 17
T) (7) (7) (7)
u i n i
MANUAL A/C HEATER
FUNCTION SELECTOR SWITCH CONNECTOR
M4844-A
Pi n
Number Circuit Ci rcui t Func t i on
1 181
( B R / O )
Ho t i n RUN
2 3 4 8 ( P ) A / C Cy c l i n g S wi t c h Si gn a l
3 2 49
( DB / L G )
He a t e r Bl o we r Mo t o r Si gn a l
4 2 9 8 ( P / O ) Ho t in RUN
POTENTIOMETER
M4846-A
Pi n
1 436
( R / L G )
Gr o un d
2 437
( Y/ L G )
Co n t r o l P o t e n t i o me t e r Wi p e r
3 600 ( DB) Co n t r o l P o t e n t i o me t e r B +
HEATER BLOWER MOTOR SWITCH
M4847-A
Pin
1 5 7 ( B K ) He a t e r Bl o we r Mo t o r HI ( Gr o u n d )
2 7 54
( L G / W)
He a t e r Bl o we r Mo t o r Me d i u m L O
3 7 5 2 ( Y / R ) He a t e r Bl o we r Mo t o r Me d i u m HI
4 2 61
( O / B K )
He a t e r Bl o we r Mo t o r L O
a
0 n* a
(B7A
1
A/C CLUTCH CONTROL RELAY CONNECTOR
M4632-A
Pin
30 198
( DG / O )
Re l a y Co n t a c t Co mmo n Te r mi n a l
85 7 3 ( O / L B ) Re l a y Co i l Ne ga t i v e Te r mi n a l
86 361 ( R) Re l a y Co i l P o s i t i v e Te r mi n a l
87 No t Us e d
87 A 347
( B K / Y )
Re l a y Co n t a c t No r ma l l y Cl o s e d
Te r mi n a l
NOTE: A / C Cut -Out Relay c o n n e c t o r pa r t of rel ay bo x .
A/ C ELECTRONI C DOOR
ACTUATOR MOTOR CONNECTOR L8720-B
Pin
1
_
No t Us e d
2
_
No t Us e d
3 437
( Y/ L G )
Co n t r o l P o t e n t i o me t e r Wi pe r
4 436
( R/ L G )
Co n t r o l P o t e n t i o me t e r Gr o un d
( Co n t i n ue d )
12 - 00- 18 12 - 00- 18
Pin
Number Ci rcui t C i r c u i t F u n c t i o n
5 No t Us e d
6 6 0 0 ( DB ) Co n t r o l P o t e n t i o me t e r B+
Pin
7 2 9 8 ( P / O ) A c t u a t o r B + ( Ho t i n RUN)
8 2 08 ( GY) A c t u a t o r Gr o un d
El e c t r o n i c Aut o ma t i c Te mpe r a t ur e Co n t r o l ( EATC) Cr o wn Vi c t o r i a , Gr a nd Mar qui s
"""J*"" ~ T FUSE
I t 9 I JUNCTION
1
S "PANEL
K I
181 I~BR/0
n
i
5 1
K ' 1
j]
-
, 5
J L _ I
208 I GY
208 I GY
FUSE
JUNCTIC
PANEL
A/C
ELECTRONIC
DOOR
ACTUATOR
MOTOR
5^L G/ 0 J 43sJ^R/W ^
X
4 3 7
X
Y/ LG
X
2 4 5
X
MOTOR DRIVE
. CIRCUIT
3T* "
132
ELECTRONIC
2461 P AUTOMATIC
TEMPERATURE
CONTROL
BR/LG 1 (EATC)
MODULE
"I '
X
02-15 C2-5 C2-6 01-21 C1-22
ACTUATOR
CONTROL
ILLUMf- > ILLUMI-
NATI ON 1 ^ NATION
INPUT T
w
INPUT
' C2-4 4>C2-18
A/C
AMBIENT
AIR
TEMPERATURE
SENSOR
O/BK
LB/R
TO INSTRUMENT
ILLUMINATION
of thi s circuit
M46$4A
12 - 00- 19 Cl i ma t e Co n t r o l S y s t e m S e r v i c e 12 - 00- 19
El e c t r o n i c Aut o ma t i c Te mpe r a t ur e Co n t r o l ( E ATC) Cr o wn Vi c t o r i a , Gr a n d Ma r qui s ( Co n t i n ue d )
HOT AT ALL TIMES
TO MODULE DATA LINK
AND PCM PINS 15 AND 16
15 I PK/LB I
1 i
W"
i L
1
_
"! F U S E
| J UNCT I ON
. P ANE L
T/O
C1-13 C1-14
TO PIN 69
OF PCM
J Ct 12
8ATT
TO POWERTRAIN
CONTROL MODULE
(PCM) POWER
A/ C
C L U T C H
Si t
DI ODE
i l l
i
DI ODE
P
571 BK

A/ C
C L U T C H
INSTRUMENT
CLUSTER
02-20
ENGLISH/
METRIC
OUTPUT
01-25
E L E C T R O N I C
AUT OMAT I C
T E M P E R AT U R E
C ON T ROL
( E AT C)
MODUL E
of this circuit
M4635-A
12- 00- 20 Cl i ma t e Co n t r o l S y s t e mS e r v i c e 12- 00- 20
Ma r qui s
ELECTRONIC AUTOMATIC
TEMPERATURE CONTROL (EATC) ASSY
CONNECTOR C1 M4636-A
Pi n
8 2 69
( L B / O )
Bl o we r Co n t r o l l e r Fe e d b a c k
9 7 54
( L G / W)
Re l a y Si gn a l
10 No t Us e d
11 2 98 ( P / O ) Run P o we r - Ho t in RUN
12 54 ( L G / Y) B + Ba t t e r y
13 915
( P K / L B )
Mo d u l e Da t a Li n k ( SCP- ) f r o m
P o we r t r a i n Co n t r o l Mo d u l e
14 9 1 4 ( T / O) Mo d u l e Da t a Li n k ( S C P + ) f r o m
2 1 2 45
( B R / L G )
Bl e n d Do o r Dr i v e 1-CCW
2 2 2 4 6 ( P ) Bl e n d Do o r Dr i ve 2 - CW
2 3
__
No t Us e d
2 4 57 ( BK) Ve h i c l e Gr o u n d
2 5 3 4 8 ( P ) A / C Cy c l i n g Swi t c h
2 6 2 98 ( P / O ) B+ I gn i t i o n Run
Pin
1 7 67
( L B / O )
Amb i e n t Te mp e r a t u r e Se n s o r
2 47 0
( P K / B K )
Su n l o a d , A mb i e n t & I n - Ve hi c l e
Te mp e r a t u r e Se n s o r Gr o un d
3

No t Us e d
4 484
( O / B K )
I n st r ume n t Pa n e l I l l umi n a t i o n
5 437
( Y/ L G )
Te mpe r a t u r e Bl e n d Do o r
P o t e n t i o me t e r Wi p e r
6 438 ( R / W) Te mp e r a t u r e Bl e n d Do o r
P o t e n t i o me t e r - CW
7 7 5 2 ( Y / R ) Bl o we r Co n t r o l Si gn a l
15 436
( R/ L G )
Te mp e r a t u r e Bl e n d Do o r
P o t e n t i o me t e r - CCW
16 468 ( BR) Sun l o a d Se n s o r
17 7 90 ( W/ O ) I n - c a r Te mpe r a t u r e Se n s o r
18 1 9 ( L B / R ) I n st r ume n t Cl us t e r L i g h t s -
Va r i a bl e Vo l t a ge Di mme r
19 No t Us e d
2 0 5 0 6 ( R ) E n gl i s h - Me t r i c
A/C BLOWER MOTOR SPEED
CONTROL CONNECTOR
M4640-A
Pi n
1 2 69
( L B / O )
Bl o we r Co n t r o l Fe e d b a c k
3 7 54
( L G / W)
Re l a y Si gn a l
4 515 ( O / R ) A / C Bl o we r Mo t o r P o we r Ci r c ui t
12 - 00- 2 1 Cl i ma t e Co n t r o l S y s t e m S e r v i c e 12 - 00- 2 1
M4632-A
Pin
N u mb e r Ci rcui t C i r c u i t Func t i on
30 198
( DG / O )
85 ( 7 3 ( O / L B ) Re l a y Co i l Ne ga t i v e Te r mi n a l
86 361( R) Re l a y Co i l P o s i t i v e Te r mi n a l
87 No t Us e d
87 A 347
( BK/ Y)
Ci r c ui t
NOTE: A / C c ut -out rel ay c o n n e c t o r s par t of rel ay box.
A/ C ELECTRONI C DOOR
Pin
1 2 45
( B R / L G )
T e mp e r a t u r e Bl e n d Do o r Dr i v e
2 - CCW
2 438 ( R / W) T e mp e r a t u r e Bl e n d Do o r
3 437
( Y/ L G )
T e mp e r a t u r e Bl e n d Do o r
4 436
( L G / O )
P o t e n t i o me t e r - C C W
5 2 4 6 ( P ) T e mp e r a t u r e Bl e n d Do o r Dr i v e
1-CW
6 57 ( BK) Gr o u n d
7

No t Us e d
8 2 08 ( GY) B + = Ho t i n RUN
12-00-22 Cl i ma t e Co n t r o l S y s t e mS e r v i c e 12-00-22
El e c t r o n i c Aut o ma t i c Te mpe r a t ur e Co n t r o l Sy st e m ( EATC) To wn Car
m F U S E
I JUNCTION
PANEL
A/C
ELECTRONIC
DOOR
ACTUATOR
MOTOR
ELECTRONIC
p AUTOMATIC
TEMPERATURE
CONTROL
(EATC)
MODULE
M4645-A
El e c t r o n i c Aut o ma t i c Temper at ur e Cont r ol Syst em ( EATC) Town Car ( Cont i nued)
FUSE
JUNCTION
PANEL
L 1 . _ I
LG/P
FUSE
JUNCTION
PANEL
5061 R
INSTRUMENT
CLUSTER
f
CV12
BATT
-Jo
PWR
C2-2Q
ENGLISH/
METRIC
OUTPUT
STEERING WHEEL
SWITCHES INPUT
C^3
C1-10
ENGINE TEMP
VEHICLE SPEED
INPUT
C1-13 C1-14
JÂfC CONTROL
C1-25'X
ELECTRONIC
AUTOMATIC
TEMPERATURE
CONTROL
(EATC)
MODULE
1070 BR/LB
O/LB
See EVTM f o r mo r e de t a i l s
12 - 00- 2 4 Cl i mat e Cont r ol Sy s t e mSe r v i c e 12 - 00- 2 4
El ect r oni c Aut o ma t i c Temper at ur e Cont r ol Sy st e m ( EATC) To wn Car ( Cont i nue d)
LH
STEERI NG
WHEEL
CONTROL
SWITCH:
SPEED
CONTROL
RH
STEERI NG
WHEEL
CONTROL
SWITCH:
CLIMATE
CONTROLS
AND AUDIO
CONTROLS
HOT IN A C C OR RUN
[.hi
TO
AIR BAG
DIAGNOSTIC
MONITOR
296 W/P
4
10
15 12 14 13 4
STEERING
WHEEL
SWITCH
CONTROL
MODULE
SHIELD
832
LB/PK 833
484 T
-P, TO FRONT
! CONTROL
3 ? UNIT
1068
LG/BK
O/BK
848
BK
TO
SPEED
CONTROL
M48SS-A
Pin
8 7 57 ( R / W) Bl o we r Co n t r o l Fe e d b a c k
9 7 58 ( P / W) Re l a y Si gn a l
10 1069
( O / L B )
Cl i ma t e Co n t r o l Si gn a l f r o m
St e e r i n g Wh e e l S wi t c h Co n t r o l
Mo d u l e

No t Us e d '
11 2 95
( L B / P K )
Run P o we r - Ho t i n RUN
12 7 97 ( L G / P ) B + Ba t t e r y
13 915
( P K / L B )
Mo d u l e Da t a L i n k ( SCP- ) f r o m
P o we r t r a i n Co n t r o l Mo d u l e ( P CM)
14 9 1 4 ( T / O) Mo d u l e Da t a L i n k ( S C P + ) f r o m
2 1 2 45
( B R / L G )
2 2 2 4 6 ( P ) Bl e n d Do o r Dr i v e 2 - CW
2 3
_
No t Us e d
2 5 883
( P K / L B )
A / C Cy c l i n g S wi t c h
2 6 2 98 ( P / O ) B+ I gn i t i o n Run
Ba s e Mo d e l To wn Ca r
Pin
Number Ci r cui t Ci r cui t Funct i on
1 7 67
( L B / O )
A mb i e n t T e mp e r a t u r e Se n s o r
2 47 0
( P K / B K )
359
( G Y/ R )
Th e r ma l S wi t c h t o Co n t r o l Mo d u l e
Su n l o a d , A mb i e n t a n d I n - c a r
Se n s o r Gr o u n d
3 107 0
( B R / L B )
Cl i ma t e Co n t r o l Si gn a l f r o m
St e e r i n g Wh e e l S wi t c h Co n t r o l
Mo d u l e
No t Use d *
4 484
( O / B K )
I n st r ume n t I l l umi n a t i o n
5 437
( Y/ L G )
7 7 56
( R / P K )
Bl o we r Co n t r o l Si gn a l
15 436
( R / L G )
16 468 ( BR) A / C Su n l o a d Se n s o r
17 7 90 ( W/ O ) I n - c a r T e mp e r a t u r e Se n s o r
18 1 9 ( L B / R ) I n st r ume n t Cl u s t e r L i gh t s -
Va r i a bl e Vo l t a g e Di mme r
19 No t Us e d
2 0 506 ( R) En gl i sh - Me t r i c
Ba s e Mo d e l To wn Ca r
12- 00- 26 Cl i mat e Cont r ol Sy s t emSer v i c e 12- 00- 26
CONTROL CONNECTOR
M4 6 4 0 - A
Pin
2 7 56
( R / P K )
3 7 58 ( P / W) Re l a y Si gn a l
4 5 1 5 ( 0 / R ) A / C Bl o we r Mo t o r P o we r Ci r c ui t
A / C C L U T C H C O N T R O L R E L A Y C O N N E C T O R
M4 6 3 2 - A
P i n
30 347
( B K / Y )
85 331
( P K / Y)
Re l a y Co i l Ne ga t i v e Te r mi n a l
86 3 6 1 ( R ) Re l a y Co i l P o s i t i v e Te r mi n a l
87 No t Us e d
87 A 3 4 8 ( P ) Re l a y Co n t a c t No r ma l l y Cl o s e d
Te r mi n a l
N OT E : A / C c u t - o u t r e l a y c o n n e c t o r p a r t o f r e l a y b o x
A / C E L E C T R O N I C DO O R
A C T U A T O R MO T O R C O N N E C T O R L 8 7 2 0 - B
Pi n
1 2 45
( B R / L G )
Te mp e r a t u r e Bl e n d Do o r Dr i v e
1-CCW
3 437
( Y/ L G )
4 436
( R/ L G )
5 2 4 6 ( P ) Te mp e r a t u r e Bl e n d Do o r Dr i v e
2- CW
7

No t Us e d
8 2 9 8 ( P / O ) B+ Ho t in RUN
S T E E R I N G W H E E L S WI T C H E S
C O N T R O L MO D U L E C 2 K 2 2 7 6 1 - A
Pi n
1 595 ( L B / R ) Co mmu n i c a t i o n t o St e e r i n g Wh e e l
Co n t r o l S wi t c h e s
? No t Us e d
...
No t Us e d
4 832
( L B / P K )
Co mmu n i c a t i o n t o Ra d i o
5 57 ( BK) Co mmu n i c a t i o n Sh i e l d t o Ra d i o
( Co n t i n ue d )
P i n
6 1069
( O / L B )
Cl i ma t e Co n t r o l Si gn a l t o
E l e c t r o n i c A u t o ma t i c T e mp e r a t u r e
Co n t r o l
7 107 0
( B R / L B )
Co n t r o l
8 No t Us e d
9 2 96 ( W/ P ) Ba t t e r y
10 5 8 3 ( Y) P o we r t o St e e r i n g Wh e e l Co n t r o l
S wi t c h e s
Pi n
Number Ci r c ui t Ci r c ui t Func t i on
11

No t Us e d
12 1068
( L G . BK)
Co mmu n i c a t i o n f r o m Ra d i o
13 8 3 3 ( T) Co mmu n i c a t i o n t o Ra d i o
14 484
( O / B K )
P WM f r o m L i gh t i n g Co n t r o l Mo d u l e
15 848 ( BK) Gr o un d
16

No t Us e d
1. Veri f y t he vehi cl e o wn e r ' s ori gi nal c onc e r n by
oper at i ng t he cl i mat e cont r ol sy st e m t o dupl i cat e
t he c onc e r n.
mechani cal or el ect r i cal c onc e r ns appl y:
L o o s e , mi s s i n g o r d a ma g e d
A / C c o mp r e s s o r d r i v e b e l t .
L o o s e o r d i s c o n n e c t e d A / C
c l u t c h .
L o o s e , mi s r o u t e d o r
d a ma g e d v a c u u m l i n e s .
Di s c h a r g e d A / C s y s t e m.
Br o ke n o r l e a ki n g
r e f r i ge r a n t l i n e s.
Br o ke n o r l e a ki n g v a c u u m
c o n t r o l mo t o r .
Bl o wn f u s e .
Bl o we r mo t o r i n o p e r a t i v e .
A / C c o mp r e s s o r
i n o pe r a t i v e .
Co o l i n g f a n i n o p e r a t i v e .
Ci r c u i t r y o p e n / s h o r t e d .
EATC A / C c o n t r o l
Di s c o n n e c t e d e l e c t r i c a l
If t he c onc e r n(s) remai ns af t er t he i nspect i on,
det ermi ne t he sy mpt o m( s) and go t o t he
Sy mpt o m Cha r t .
Use Rot unda 7 3 Di gi t al Mul t i Met er 105- 00051 or
equi val ent f or di agnosi s of t he Pi npoi nt Test s.
CLIMATE CONTROL SYSTEM
I mp r o p e r / E r r a t i c Di r e c t i o n of
Ai r f l o w f r o m Out l e t ( s)
No v a c uum t o A / C c o n t r o l .
A / C d a mpe r d o o r s wi t c h .
A / C v a c uum c h e c k va l ve
d a ma g e d / l e a ks .
Da ma g e d / k i n k e d / p i n c h e d
v a c uum ho se .
L e a ki n g / d a ma g e d A / C v a c uum
r e se r v o i r t a n k a n d b r a c ke t .
Va c uum c o n t r o l mo t o r l e a ks
v a c uum.
Va c uum a c t ua t o r a r m not
c o n n e c t o r t o d o o r c r a n k.
GO t o Pi npoi nt Test A.
I nsuf f i c i e nt , Er r a t i c , or No He a t L o w r a d i a t o r c o o l a n t due t o l e a ks .
Engi ne o v e r he a t i n g.
The r mo s t a t .
Pl ugge d or pa r t i a l l y pl ugge d
he a t e r c o r e .
I n o pe r a t i ve A / C e l e c t r o n i c d o o r
a c t u a t o r mo t o r .
REFER t o e ngi ne c o o l i n g s e c t i o n .
GO t o Co mpo n e n t Test - he a t e r
c o r e .
REFER t o Se c t i o n 12-03A.
12 - 00- 2 8 Cl i ma t e Co n t r o l S y s t e mS e r v i c e 12 - 00- 2 8
CLIMATE CONTROL SYSTEM (Cont i nued)
A / C Does Not Operate / Does Not
Operate Properly
Bl o wn f use .
Ma l f un c t i o n i n g A / C c l u t c h c o n t r o l
r e l a y .
Ci r c ui t r y sho r t / o p e n .
Ma l f un c t i o n i n g A / C c y c l i n g s wi t c h .
A / C s y s t e m d i s c h a r ge d .
A / C c o n t r o l d a ma ge d .
GO t o Pi npoi nt Te st C.
A / C Al wa y s On Ci r c ui t r y sho r t / o p e n .
Da ma ge d A / C c o n t r o l .
Da ma ge d po we r t r a i n c o n t r o l
mo d ul e .
I mpr o pe r A / C c l ut c h ai r ga p.
GO t o Po we r t r a i n
Co n t r o l / E mi s s i o n Di a gn o si s
Ma n ua l
1
.
GO t o Se c t i o n 12-03C.
I nsuf f i c i e nt A / C Co o l i n g Re s t r i c t e d A / C e v a p o r a t o r c o r e
o r i f i c e .
L o w r e f r i ge r a n t L e v e l .
I n o pe r a t i v e A / C c y c l i n g s wi t c h .
Mi s s i n g, d a ma ge d or
mi s po s i t i o n e d r a d i a t o r ai r s e a l s
a n d a e r o s h i e l d s .
GO t o Re f r i ge r a n t Sy st e m t e s t s .
Cl i ma t e Co n t r o l Do e s Not Ho l d
Te mpe r a t ur e
Ma l f un c t i o n i n g A / C c o n t r o l . GO t o EATC Di a gn o st i c s in Se c t i o n
12-03B.
No Ope r a t i o n In Al l Te mpe r a t ur e
Se t t i n gs
No Ope r a t i o n In Al l Fun c t i o n
Se t t i n gs
I mpr o pe r Ope r a t i o n In Fun c t i o n
Se t t i n gs
No v a c uum t o A / C c o n t r o l .
Da ma ge d v a c uum c o n t r o l mo t o r .
Da ma g e d / ki n ke d v a c uum h o s e .
Ma l f un c t i o n i n g EATC A / C c o n t r o l .
GO t o Pi npoi nt Te st D.
GO t o Pi npoi nt Te st A.
GO t o EATC Di a gn o st i c s in Se c t i o n
12-03B.
No Ope r a t i o n In Al l Bl o we r Se t t i n gs
Bl o we r Mo t o r Do e s Not Ope r a t e
Bl o wn f us e .
Ci r c ui t r y o pe n / s h o r t e d .
He a t e r bl o we r mo t o r s wi t c h
d a ma ge d .
r e s i s t o r d a ma ge d .
Bl o we r mo t o r .
GO t o Pi npoi nt Te st E.
No Ope r a t i o n in Hi gh Bl o we r
Se t t i n g
r e si st o r .
He a t e r bl o we r mo t o r s wi t c h .
GO t o Pi npoi nt Te st F.
Bl o we r Mo t o r Op e r a t e s in Hi gh
Spe e d Onl y
r e si st o r . He a t e r bl o we r mo t o r
s wi t c h .
GO t o Pi npoi nt Test G.
A / C Cl ut c h Cy c l e s Ra pi d l y o L o w r e f r i ge r a n t c h a r ge . GO t o Re f r i ge r a n t Sy st e m Te st s.
No Swi t c hi n g In Ope r a t i o n b e t we e n
Out si d e Ai r a n d Re c i r c ul a t e d Ai r
Al l ai r f r o m d e f r o s t .
Da ma ge d v a c uum c o n t r o l mo t o r .
Da ma g e d / ki n ke d v a c uum h o s e .
Da ma ge d A / C c o n t r o l .
No i se Whi l e Ope r a t i n g Cl i ma t e
Co n t r o l Sy s t e m
A / C c o mp r e s s o r .
A / C c l u t c h .
Da ma ge d d r i ve be l t .
GO t o A / C Co mpr e sso r or A / C
Cl ut c h in De sc r i pt i o n a nd
Ope r a t i o n .
REFER t o Se c t i o n 03- 05.
No i se Whi l e Not Ope r a t i n g Cl i ma t e
Co n t r o l Sy s t e m
A / C c l u t c h .
Da ma ge d d r i ve be l t .
GO t o A / C Cl ut c h De sc r i pt i o n a n d
Ope r a t i o n .
Engi ne Co o l i n g Fan Mo t o r Do e s
Not Ope r a t e Wh e n A / C i s
Ac t i v a t e d
Po we r t r a i n c o n t r o l mo d ul e
d a ma ge d .
Fan c o n t r o l ( FC) c i r c ui t r y
d a ma ge d .
Co o l i n g f a n mo t o r d a ma ge d .
GO t o Pi npoi nt Te st H.
PINPOINT TEST A: IMPROPER/ERRATIC DIRECTION OF AIRFLOW FROM OUTLETS
A1 CHECK SYSTEM AI RFLOW
NOTE: The ai r ha n d l i n g s y s t e m i s d e s i gn e d t o pr o v i d e
De f r o st whe n no v a c uum i s a p p l i e d t o any of t h e t h r e e
v a c uum c o n t r o l mo t o r s . Thi s i s d o n e t o pr e v e n t a
si t ua t i o n wh e r e De f r o st c a n n o t be o bt a i n e d d ue t o a
s y s t e m v a c uum l e a k. I n st e a d , a l e a k in t he v a c uum
c o n t r o l c i r c ui t wi l l se n d al l ai r f l o w t o t he d e f r o s t e r
o ut l e t s. Thi s c o n d i t i o n ma y o c c u r dur i ng a c c e l e r a t i o n
( sl o w l e a k) , ma y e x i st at al l t i me s ( l a r ge l e a k) a n d ma y
ha ppe n onl y whe n c e r t a i n s pe c i f i c f un c t i o n s a r e
s e l e c t e d , i n d i c a t i n g a l e a k in t ha t po r t i o n of t h e c i r c ui t .
Wi t h e n gi n e runni ng and he a t e r bl o we r mo t o r s wi t c h
on hi gh, c h e c k s y s t e m a i r f l o w in e a c h A / C d a mp e r
d o o r s wi t c h po si t i o n t o d e t e r mi n e wh i c h po s i t i o n ( s )
ha v e i n c o r r e c t ai r f l o w. Re f e r t o v a c uum a ppl i c a t i o n
c ha r t f or c o r r e c t s y s t e m ai r f l ow.
Is ai r f l ow f r o m t he def r ost er out l et s f or al l
posi t i ons?
Ye s
No

G O t o A 2 .
G O t o A 1 3 .
A2 CHECK VACUUM SUPPLY HOSE
Ch e c k v a c uum suppl y ho se t o be sur e i t i s
c o n n e c t e d t o bo t h t he e n gi n e ma n i f o l d a n d v a c uum
c h e c k v a l v e .
Is hose di sc onne c t e d?
Ye s
No

RECONNECT h o s e . GO t o
A 1 .
GO t o A 3.
A 3 LEAK CHECK VACUUM SUPPLY HOSE
NOTE: The v a c uum h o s e s use d in t he pa s s e n ge r
c o mpa r t me n t c o n t r o l c i r c ui t a r e c o n s t r u c t e d f r o m PVC
pl a st i c ma t e r i a l . The v a c uum h o s e s use d in t he e ngi ne
c o mpa r t me n t a r e c o n s t r u c t e d of Hy t r e l . Be c a u s e of t he
ma t e r i a l s use d , t he v a c uum h o s e s sho ul d n e ve r be
pi n c he d of f dur i ng d i a gn o s i s t o l o c a t e a l e a k. Use
Ro t un d a Va c uum Te st e r 02 1 - 00014 or e qui va l e n t t o
l o c a t e v a c uum l e a ks. A wo o d gol f t e e c a n be use d a s a
pl ug whe n if is n e c e s s a r y t o pl ug o n e e n d of a v a c uum
ho se f o r l e a k t e s t pu r po s e s .
Di sc o n n e c t v a c uum suppl y ho se f r o m e n gi n e
ma n i f o l d f i t t i n g a nd f r o m c h e c k va l ve . Pl ug o n e e nd
of ho s e a n d l e a k t e s t wi t h v a c uum pump.
Does hose l eak?
Ye s
No

SERVI CE or REPLACE
v a c uum ho se . GO t o A 1.
CONNECT ho se t o
ma n i f o l d f i t t i n g. GO t o A4.
A4 CHECK VACUUM CHECK VALVE
Ch e c k A / C v a c uum c h e c k va l ve f o r c o r r e c t
i n st a l l a t i o n by r e mo vi n g t he r e se r v o i r ho se a n d t he
c o n t r o l a s s e mbl y so ur c e ho s e (one at a t i me ) f r o m
A / C v a c uum c h e c k va l ve a n d c h e c k f or v a c uum.
Engi ne must be runni ng f o r t hi s t e s t .
Ye s
No

RECONNECT bo t h h o s e s .
GO t o AS.
GO t o A5.
VACUUM HOSE FROM ENGI NE
CONNECTED TO THIS FITTING
M4631-A
Is vacuum avai lable at bo t h check val ve por t s?
PINPOINT TEST A: IMPROPER/ERRATIC DIRECTION OF AIRFLOW FROM OUTLETS (Cont i nued)
TE ST STE P RESULT ACTI ON TO TAKE
A5 I NSPECT VACUUM CHECK VALVE
Ye s
No
REPLACE A / C v a c uum
c h e c k v a l v e . GO t o A 1.
GO t o A6.
Inspect A / C vacuum check valve for an o b s t r u c t i o n
a n d / o r pr o pe r o pe r a t i o n . Ai r f l o w t hr o ugh t he A / C
v a c uum c h e c k va l ve sho ul d be in t he d i r e c t i o n
t o wa r d e n gi n e (Engi ne c o n n e c t i o n si d e i s ma r ke d
" VA C" ) .
I s c he c k val ve pl ugged or obst r uc t e d?
Ye s
No
c h e c k v a l v e . GO t o A 1.
GO t o A6.
A6 LEAK TEST VACUUM CHECK VALVE
Ye s
No
c h e c k va l ve . GO t o A 1.
REI NSTALL A / C v a c uum
c h e c k va l ve a n d GO t o
A7.
Re mo v e A / C v a c uum c h e c k va l ve f r o m v e hi c l e .
Co n n e c t t wo h o s e s a nd a Tee f i t t i n g t o o ut l e t p o r t s
of A / C v a c uum c h e c k v a l v e . Co n n e c t Ro t un d a
Va c uum Te st e r 02 1 - 00014 or e qui va l e n t t o Tee
f i t t i n g.
M4633-A
Pump 11. 34 kPa ( 15 i n c he s) v a c uum on A / C v a c uum
c h e c k v a l v e a nd o b s e r v e ga uge r e a d i n g. If v a c uum
l o ss e x c e e d s 3. 37 kPa ( 1 i nc h) pe r mi nut e , r e mo v e
A / C v a c uum c h e c k v a l v e f r o m t e s t e r a n d pl ug
v a c uum h o s e s . Pul l a v a c uum wi t h t he t e s t e r t o be
c e r t a i n h o s e s a n d t e s t e r a r e not c a u s e of l e a k.
PLUGS / / ^ \ \
VJf \ L j rJl
\ ^ ~ ^ i t - ^ ^ 021- 00014 m i
M4637-A
If t e s t e r a n d h o s e s d o not l e a k, c h e c k v a l v e f o r
c a us e of l e a k.
Does check valve l ose more t han 3.37 kPa (1
i nch) vacuum i n one mi nut e?
Ye s
No
c h e c k va l ve . GO t o A 1.
REI NSTALL A / C v a c uum
c h e c k va l ve a n d GO t o
A7.
A7 CHECK VACUUM RESERVOI R
Ye s ^
No t >
r e se r v o i r t a n k a n d
b r a c ke t . GO t o A 1.
CONNECT ho se t o A / C
v a c uum r e se r vo i r t a n k
a n d br a c ke t . GO t o A8.
Co n n e c t Va c uum Te st e r t o A / C v a c uum r e se r v o i r
t a n k a n d b r a c ke t a nd l e a k t e s t r e se r vo i r . Re se r v o i r
must ho l d v a c uum.
Does reservoi r l eak?
Ye s ^
No t >
r e se r v o i r t a n k a n d
b r a c ke t . GO t o A 1.
v a c uum r e se r vo i r t a n k
a n d br a c ke t . GO t o A8.
A8 CHECK SUPPLY HOSE
Ye s
No E>
SERVI CE or REPLACE
h o s e . GO t o A 1.
REMOVE pl ug a n d
RECONNECT v a c uum
h o s e s . GO t o A9.
Di sc o n n e c t a n d pl ug BL ACK suppl y h o s e a t A / C
c o n t r o l . Di sc o n n e c t o t he r e n d of suppl y h o s e f r o m
A / C c o n t r o l a n d l e a k t e s t h o s e wi t h v a c uum t e st e r .
Does suppl y hose l eak?
Ye s
No E>
SERVI CE or REPLACE
h o s e . GO t o A 1.
REMOVE pl ug a n d
RECONNECT v a c uum
h o s e s . GO t o A9.
A9 CHECK CONTROL ASSEMBLY
Ye s
No
NOTE Fun c t i o n po s i t i o n s
wh e r e v a c uum d r o p s . GO
t o A 1 0 .
GO t o A 1 1 .
Di sc o n n e c t v a c uum ha r n e s s at i n-l i ne mul t i pl e
c o n n e c t o r near A / C c o n t r o l . Pl ug al l v a c uum h o s e s
e x c e p t BLACK. Co n n e c t v a c uum t e s t e r t o BL ACK
h o s e . Se l e c t e a c h f un c t i o n po s i t i o n , a ppl y 11. 34
kPa ( 15 i n c he s) v a c uum a n d c h e c k f o r v a c uum d r o p.
Dr o p sho ul d not e x c e e d 3. 37 kPa ( 1 i n c h) v a c uum
pe r mi nut e f or a ny f un c t i o n po s i t i o n .
Does dr op exceed 3. 37 kPa ( 1 i nch) vacuum per
mi nut e?
Ye s
No
NOTE Fun c t i o n po s i t i o n s
wh e r e v a c uum d r o p s . GO
t o A 1 0 .
GO t o A 1 1 .
A 10 LEAK TEST CONTROL ASSEMBLY
Ye s
No
REPLACE A / C d a mpe r
d o o r s wi t c h . GO t o A 1 .
GO t o A 12 .
Re mo v e v a c uum ha r n e s s f r o m A / C c o n t r o l . Co n n e c t
v a c uum t e s t e r t o c o n t r o l suppl y po r t a n d pl ug
c o n t r o l por t t ha t i n d i c a t e d a l e a k in st e p A9. Se l e c t
f un c t i o n po si t i o n s n o t e d in St e p A9 a nd a ppl y 11. 34
kPa (15 i n c he s) v a c uum a f t e r s e l e c t i n g e a c h
po s i t i o n . Va c uum d r o p sho ul d not e x c e e d 1.68 kPa
( 1 / 2 i nc h) pe r mi n ut e .
Does vacuum dr op e xc e e d 1. 68 kPa (1 / 2 i nch) i n
one mi nut e?
Ye s
No
d o o r s wi t c h . GO t o A 1 .
GO t o A 12 .
A 1 1 CHECK SUPPLY HOSE FOR BL OCKAGE
Ye s
No
REPLACE suppl y h o s e .
GO t o A 1 .
GO t o A 15.
Di sc o n n e c t BL ACK suppl y ho s e f r o m A / C v a c uum
c h e c k v a l v e . Co n n e c t v a c uum t e s t e r t o suppl y ho se
a nd o pe r a t e t e s t e r a s if pul l i ng a v a c uum. If t e s t e r
c a n pul l a v a c uum, h o s e i s pl u gge d . If t e s t e r pul l s a
pa r t i a l v a c uum, ho s e i s r e s t r i c t e d .
Is hose pl ugged or r e st r i c t e d?
Ye s
No
REPLACE suppl y h o s e .
GO t o A 1 .
GO t o A 15.
A 12 LEAK TEST JUMPER VACUUM HARNESS
Ye s
No
SERVI CE or REPLACE
v a c uum j umpe r ha r n e s s .
GO t o A 1 .
CHECK c o n n e c t i o n of
v a c uum ha r n e ss t o A / C
d a mpe r d o o r s wi t c h f o r
l e a k. REPAI R or
REPLACE v a c uum j umpe r
ha r n e s s . GO t o A 1 .
Pl ug one e nd of v a c uum ho s e t ha t i n d i c a t e d a l e a k in
s t e p A9. Appl y 11. 34 kP a (15 i n c he s) v a c uum t o
h o s e a n d o bs e r v e v a c uum ga uge . Va c uum sho ul d
not d r o p.
Does vacuum d r o p?
Ye s
No
SERVI CE or REPLACE
v a c uum j umpe r ha r n e s s .
GO t o A 1 .
d a mpe r d o o r s wi t c h f o r
l e a k. REPAI R or
A 13 EVALUATE SYSTEM AIR FL OW
Ye s
No
GO t o A 1 4 .
GO t o A 1 5 .
Is t he ai rf l ow in st ep A1 c or r e c t f or each f unc t i on
posi t i on?
Ye s
No
GO t o A 1 4 .
GO t o A 1 5 .
A 1 4 I SOLATE LEAKI NG VACUUM CI RCUI T
Ye s
No
GO t o A 1 9 .
GO t o A 1 5 .
Re pe a t st e p A1 a n d a c c e l e r a t e e n gi n e s pe e d f or
e a c h f un c t i o n po s i t i o n .
Does ai r f l ow go t o de f r ost dur i ng accel er at i on?
Ye s
No
GO t o A 1 9 .
GO t o A 1 5 .
A 1 5 REVI EW VEHI CLE HI STORY
Ye s
No
GO t o A 1 8 .
GO t o A 1 6 .
Di d syst em f un c t i o n pr oper l y pri or t o t hi s
compl ai nt ?
Ye s
No
GO t o A 1 8 .
GO t o A 1 6 .
A 1 6 CHECK VACUUM HOSES
Ye s
No
REPLACE v a c uum h o s e .
GO t o A 1 .
GO t o A 1 7 .
Ch e c k e a c h v a c uum h o s e t o be sur e it is not
pl u gge d .
Is a hose pl ugged?
Ye s
No
REPLACE v a c uum h o s e .
GO t o A 1 .
GO t o A 1 7 .
A 17 CHECK VACUUM HARNESS
G O t o A 1 8 .
REPLACE v a c uum
Co mpa r e v a c uum h o s e c o l o r s in e a c h v a c uum
ha r n e s s t o t he v a c uum s c h e ma t i c .
Do t he hose c ol or s agree wi t h t he schemat i cs?
Ye s
No
G O t o A 1 8 .
REPLACE v a c uum
TEST STEP RESULT ACTI ON TO TA KE
A18 CHECK VACUUM CI RCUI T
Ye s t >
No [ >
UNKI NK or REPLACE
v a c uum ho se . GO t o A1.
GO t o A 1 9 .
Ch e c k v a c uum c i r c ui t f o r pi n c he d or ki n ke d v a c uum
ho s e .
Is hose pi nched or ki nke d?
Ye s t >
No [ >
UNKI NK or REPLACE
v a c uum ho se . GO t o A1.
GO t o A 1 9 .
A 1 9 CHECK VACUUM CI RCUI T CONNECTI ONS
Ye s
No
RECONNECT ho s e . GO t o
A 1 .
GO t o A 2 0.
Ch e c k e a c h v a c uum h o s e c o n n e c t i o n t o d e t e r mi n e if
i t i s pa r t i a l l y c o n n e c t e d or d i s c o n n e c t e d .
Is a vacuum hose c onne c t i on di sc onne c t e d or
part i al l y c onne c t e d?
Ye s
No
A 1 .
GO t o A 2 0.
A 2 0 CHECK VACUUM HOSE
Ye s E>
No >
SERVI CE or REPLACE
ho s e . GO t o A 1.
GO t o A 2 1 .
Di sc o n n e c t bo t h e n d s of v a c uum ho se in s u s p e c t e d
c i r c ui t . Pl ug one e n d a n d l e a k t e s t wi t h v a c uum
t e st e r .
Does vacuum hose l eak?
Ye s E>
No >
SERVI CE or REPLACE
ho s e . GO t o A 1.
GO t o A 2 1 .
A 2 1 CHECK VACUUM CONTROL MOTOR
Ye s
No >
G O t o A 2 2 .
REPLACE v a c uum c o n t r o l
mo t o r . GO t o A 1.
Ch e c k v a c uum mo t o r f o r l e a ks wi t h v a c uum t e st e r .
Does mot or hol d vacuum?
Ye s
No >
G O t o A 2 2 .
mo t o r . GO t o A 1.
A 2 2 CHECK VACUUM CONTROL MOTOR I NSTALLATI ON
Ye s
No
CHECK f or bi n d i n g or
d a ma ge d d a mpe r door .
SERVI CE or REPLACE
d a mpe r door . GO t o A 1.
CONNECT v a c uum
c o n t r o l mo t o r a r m t o d o o r
a n d / o r c r a n k a r m a n d
c h e c k o pe r a t i o n . GO t o
A 1 .
Ch e c k a t t a c hme n t of v a c uum mo t o r a r m t o d a mpe r
d o o r .
Is vacuum c ont r ol mot or arm at t ached t o door or
door cr ank arm?
Ye s
No
d a ma ge d d a mpe r door .
SERVI CE or REPLACE
d a mpe r door . GO t o A 1.
CONNECT v a c uum
A 1 .
PINPOINT TEST B: INSUFFICIENT, ERRATIC OR NO HEAT
T E ST STE P RESULT ACTI ON TO TA KE
B1 CHECK FOR PROPER ENGI NE COOL ANT LEVEL
Ye s
No
GO t o B2.
GO t o B3.
Is engi ne c ool a nt at pr oper l evel ( ho t / c o l d ) on
radi at or cool ant r ecover y reservoi r
Ye s
No
GO t o B2.
GO t o B3.
B2 CHECK FOR HOT WATER TO HEATER CORE I NLET
HOSE
Ye s
No
GO t o B4.
St a r t e n gi n e a n d a l l o w t o r e a c h nor ma l o pe r a t i n g
t e mpe r a t ur e .
Fe e l he a t e r c o r e i nl et h o s e .
Is t he heat er i nl et hose t o o hot t o handl e?
Ye s
No
GO t o B4.
B3 CHECK COOL ANT SYSTEM I NCLUDI NG RADI ATOR
CAP FOR L E AKS
Ye s
No
GO t o B4.
SERVI CE e ngi ne s y s t e m.
RETEST s y s t e m.
Fi l l c o o l a n t s y s t e m t o s p e c i f i e d l e v e l .
Pr e ssur e c h e c k c o o l a n t s y s t e m usi ng Ro t un d a
Ra d i a t o r / He a t e r c o r e pr e s s ur e t e s t e r 02 1 - 00012 or
e qui v a l e n t . It i s not n e c e s s a r y t o c h e c k c o mpo n e n t s
s e pa r a t e l y a t t hi s t i me .
Does c ool a nt sy st em i ncl udi ng radi at or cap hol d
pressure?
Ye s
No
GO t o B4.
SERVI CE e ngi ne s y s t e m.
RETEST s y s t e m.
B4 CHECK HEATER CORE OUTLET HOSE FOR HOT
WATER
Ye s
No
SERVI CE he a t e r c o r e f o r
pl ug or pa r t i a l pl ug.
REFER t o Se c t i o n 12-03A
( Ma n ua l ) or 12- 03B
( El e c t r o n i c ) f o r
t e mpe r a t ur e bl e n d d o o r
a c t ua t o r
d i a gn o s i s / s e r v i c e .
Engi ne o pe r a t i n g a n d a t n o r ma l o pe r a t i n g
t e mpe r a t u r e .
Fe e l he a t e r c o r e o ut l e t h o s e .
Is heat er cor e out l et hose c o o l or c ol d?
Ye s
No
SERVI CE he a t e r c o r e f o r
pl ug or pa r t i a l pl ug.
REFER t o Se c t i o n 12-03A
( Ma n ua l ) or 12- 03B
( El e c t r o n i c ) f o r
t e mpe r a t ur e bl e n d d o o r
a c t ua t o r
d i a gn o s i s / s e r v i c e .
PINPOINT TEST C: A / C DOES NOT OPERATE/DOES NOT OPERATE PROPERLY
C1 CHECK A / C CLUTCH OPERATI ON
Ye s
No
A / C c l ut c h c i r c ui t
f un c t i o n i n g pr o pe r l y .
G O t o C2.
NOTE: Outside temperature must be above 10C
( 50F) for A/ C compressor o pe r a t i o n .
Start engine.
Set A/ C control at MAX A/ C.
Check battery voltage. If not 12.5 volts refer to
Section 14-00 for charging system diagnosis.
Rotate blower speed switch to HI.
Does A / C clut ch engage?
Ye s
No
A / C c l ut c h c i r c ui t
G O t o C2.
C2 CHECK A / C CYCLI NG SWI TCH
Ye s
No
GO t o C3.
GO t o C4.
Disconnect electrical connector from A/ C c y c l i n g
s wi t c h .
Jumper harness connector pins.
Engi ne must be r unni ng, A/ C on, and blower switch
on HI .
Does A / C clutch engage?
Ye s
No
GO t o C3.
GO t o C4.
C3 CHECK REFRI GERANT SYSTEM PRESSURE
Ye s
No
REPLACE A / C c y c l i n g
s wi t c h . GO t oC1.
CHECK s y s t e m f o r
r e f r i ge r a n t s y s t e m l e a ks
or l o w c h a r ge . SERVI CE
a n d CHARGE s y s t e m a s
r e qui r e d . GO t o C1.
Turn e ngi ne off if engine is o pe r a t i n g.
Connect gauge set to service ports.
Re a d i n g must be above 345 kP a ( 50 psi).
Is pressure above 345 kPa (50 psi )?
Ye s
No
REPLACE A / C c y c l i n g
s wi t c h . GO t oC1.
CHECK s y s t e m f o r
r e f r i ge r a n t s y s t e m l e a ks
or l o w c h a r ge . SERVI CE
a n d CHARGE s y s t e m a s
r e qui r e d . GO t o C1.
C4 CHECK INPUT VOLTAGE AT A / C CYCLI NG SWI TCH
Ye s
No
GO t o C5.
GO t o C 1 5 .
Engi ne of f a n d i gni t i on s wi t c h i n RUN po s i t i o n .
Se t A / C c o n t r o l a t MAX A / C .
Che c k f o r b a t t e r y v o l t a ge at A / C c y c l i n g s wi t c h
ha r n e ss c o n n e c t o r , Ci r c ui t 348 (P) t o gr o un d .
Ye s
No
GO t o C5.
GO t o C 1 5 .
C5 CHECK I NPUT VOLTAGE A T A / C PRESSURE CUT-OFF
SWI TCH
Ye s
No
GO t o C6.
( P K/ L B) f o r o pe n .
RETEST s y s t e m.
Engi ne of f a n d i gni t i on s wi t c h i n RUN po si t i o n .
Set A / C c o n t r o l a t MAX A / C .
Che c k f or b a t t e r y v o l t a ge at A / C pr e s s ur e c ut - o f f
s wi t c h ha r n e ss c o n n e c t o r , Ci r c ui t 883 ( P K/ L B) t o
gr o un d .
Ye s
No
GO t o C6.
( P K/ L B) f o r o pe n .
RETEST s y s t e m.
C6 CHECK A / C PRESSURE CUT-OFF SWI TCH CONTACT
CONTI NUI TY
Ye s
No
G Ot o C7.
REPLACE A / C pr e s s ur e
c ut - o f f s wi t c h . RESTORE
Engi ne of f a n d i gni t i on s wi t c h in RUN po s i t i o n .
Che c k c o n t i n ui t y be t we e n A / C pr e s s ur e c ut - o f f
s wi t c h c o n t a c t s .
Does cont i nui t y exi st ?
Ye s
No
G Ot o C7.
REPLACE A / C pr e s s ur e
c ut - o f f s wi t c h . RESTORE
C7 CHECK FOR I NPUT VOLTAGE TO A / C COMPRESSOR
CLUTCH CONTROL RELAY AT RELAY CENTER
Ye s
No
GO t o C8.
SERVI CE o pe n Ci r c ui t
198( DG / O) . RETEST
s y s t e m.
Turn e ngi ne OFF, l e a ve i gni t i on s wi t c h in RUN
po si t i o n .
Ch e c k f or ba t t e r y v o l t a ge at Pi n 30, Ci r c ui t 198
( DG / O) of A / C c o mp r e s s o r c l ut c h c o n t r o l r e l a y
ha r n e ss c o n n e c t o r t o gr o un d .
Ye s
No
GO t o C8.
s y s t e m.
C8 CHECK PCM I NPUT VOLTAGE FROM A / C PRESSURE
CUT- OFF SWI TCH
Ye s >
No >
GO t o C9.
s y s t e m.
Engi ne of f a nd i gni t i on s wi t c h in RUN po si t i o n .
A / C c o n t r o l a t MAX A / C .
Usi n g a t e s t l a mp c h e c k f o r v o l t a ge a t PCM Ci r c ui t
198 ( DG / O) .
Ye s >
No >
GO t o C9.
s y s t e m.
PINPOINT TEST C: A / C DOES NOT OPERATE/DOES NOT OPERATE PROPERLY (Cont i nued)
C9 CHECK PCM PIN 85 CI RCUI T 73 (O / LB) OUTPUT TO
A / C COMPRESSOR CLUTCH CONTROL RELAY
Ye s
No
REFER t o t he Po we r t r a i n
Co n t r o l Emi ssi o n s
Di a gn o si s Ma n u a l
2
f o r
WOT c ut o ut a n d ECT.
SERVI CE a s r e qui r e d .
RETEST.
GO t o C 1 0 .
Disconnect Pin 85, Circuit 73 (O / LB) at A / C
c o mp r e s s o r c l ut c h c o n t r o l r e l a y .
Does A / C cl ut ch e n g a g e ?
Ye s
No
Co n t r o l Emi ssi o n s
2
f o r
WOT c ut o ut a n d ECT.
RETEST.
GO t o C 1 0 .
C10 CHECK A / C COMPRESSOR CLUTCH CONTROL
RELAY OUTPUT TO A / C CLUTCH
Ye s
No
GO t o C 1 1 .
REPLACE A / C
c o mp r e s s o r c l ut c h
c o n t r o l r e l a y .
Engi ne off a nd i gni t i on s wi t c h in RUN po s i t i o n .
A / C c o n t r o l at MAX A / C .
Using t e s t l a mp, c h e c k A / C c o mp r e s s o r c l ut c h
c o n t r o l r e l a y Pi n 87A Ci r c ui t 347 ( BK/ Y) f o r v o l t a ge .
Ye s
No
GO t o C 1 1 .
REPLACE A / C
c o mp r e s s o r c l ut c h
c o n t r o l r e l a y .
C 1 1 CHECK VOLTAGE SUPPLY TO A / C CLUTCH
Ye s
No
G O t o C 1 2 .
( BK / Y) f o r o pe n c i r c ui t .
RETEST s y s t e m.
Engi ne of f a nd i gni t i on s wi t c h in RUN po s i t i o n .
Di sc o n n e c t A / C c l ut c h e l e c t r i c a l c o n n e c t o r .
Usi n g a t e s t l a mp, c h e c k Ci r c ui t 347 ( BK / Y) at A / C
c l u t c h c o n n e c t o r .
Ye s
No
G O t o C 1 2 .
( BK / Y) f o r o pe n c i r c ui t .
RETEST s y s t e m.
C12 CHECK A / C CLUTCH GROUND CI RCUI T
Ye s P>
No
GO t o C 1 3 .
SERVI CE Ci r c ui t 57 ( BK) .
RETEST s y s t e m.
Usi n g an o hmme t e r c o n n e c t e d t o gr o un d , c o n n e c t
s e c o n d l e a d t o Ci r c ui t 57 ( BK) at A / C c l ut c h
c o n n e c t o r .
Me a s ur e r e s i s t a n c e .
Is resi st ance one ohm or l ess?
Ye s P>
No
GO t o C 1 3 .
SERVI CE Ci r c ui t 57 ( BK) .
RETEST s y s t e m.
C13 CHECK A / C CLUTCH COI L RESI STANCE
Ye s
No
REPLACE A / C c l ut c h
f i e l d c o i l . RESTORE
GO t o C 1 4 .
Engi ne of f a nd i gni t i on s wi t c h in RUN po s i t i o n .
Usi n g an o hmme t e r , c h e c k t h e r e s i s t a n c e b e t we e n
t he t wo t e r mi n a l s of t h e A / C c l ut c h f i e l d c o i l .
Is t he resi st ance 6 ohms or l ess?
Ye s
No
GO t o C 1 4 .
C 1 4 CHECK A / C COI L CURRENT DRAW
Ye s
No
SERVI CE A / C c l ut c h ai r
ga p. RESTORE v e hi c l e .
RETEST s y s t e m.
Usi n g an a mme t e r , c h e c k c ur r e n t d r a w of A / C c l ut c h
f i e l d c o i l .
Is cur r ent draw be t we e n 2 . 5 - 4. 5A ?
Ye s
No
SERVI CE A / C c l ut c h ai r
ga p. RESTORE v e hi c l e .
RETEST s y s t e m.
C15 CHECK VOLTAGE SUPPLY A T A / C DAMPER DOOR
SWI TCH
Ye s l >
No
GO t o C 1 8 .
GO t o C 1 6 .
Turn e n gi n e of f a n d i gni t i on s wi t c h in RUN po s i t i o n .
Usi n g a t e s t l a mp, c h e c k f o r v o l t a ge at Pi n 2 Ci r c ui t
348 (P) at A / C d a mpe r d o o r s wi t c h .
Ye s l >
No
GO t o C 1 8 .
GO t o C 1 6 .
C 1 6 CHECK VOLTAGE SUPPLY TO A / C DAMPER DOOR
SWI TCH
Ye s
No
SERVI CE Ci r c ui t 2 98
( P / O) f or o pe n c i r c ui t .
RETEST s y s t e m.
GO t o C 1 7 .
Usi n g t e s t l a mp c h e c k f o r v o l t a ge at o ut put si d e of
Fu s e 5 ( 1 5 A ) .
Ye s
No
( P / O) f or o pe n c i r c ui t .
RETEST s y s t e m.
GO t o C 1 7 .
PINPOINT TEST C: A/ C DOES NOT OPERATE/DOES NOT OPERATE PROPERLY (Conti nued)
TEST STEP RESULT A CT I ON TO TAKE
C17 CHECK CI RCUI T 2 98 (P / 0 ) FOR SHORT
Ye s
No
( P / O) f o r sho r t t o gr o un d .
REPLACE Fuse 5 ( 15A) .
RETEST s y s t e m.
G O t o C 1 8 .
Using an ohmmeter, connect one lead to output side
of Fuse 5 ( 15A) . Co n n e c t s e c o n d l e a d t o a kn o wn
go o d gr o un d .
Di sc o n n e c t e l e c t r i c a l c o n n e c t o r t o A / C d a mpe r
d o o r s wi t c h .
Ye s
No
( P / O) f o r sho r t t o gr o un d .
REPLACE Fuse 5 ( 15A) .
RETEST s y s t e m.
G O t o C 1 8 .
C18 CHECK A / C DAMPER DOOR SWI TCH MAX A / C
POSI TI ON
Ye s
No
G O t o C 1 9 .
REPLACE A / C d a mp e r
d o o r s wi t c h . RESTORE
Engi ne of f a n d i gni t i on s wi t c h in RUN po s i t i o n .
Re c o n n e c t A / C d a mpe r d o o r s wi t c h e l e c t r i c a l
c o n n e c t o r .
Ro t a t e A / C d a mpe r d o o r s wi t c h t o MAX A / C
po si t i o n .
Usi ng a t e s t l a mp c h e c k v o l t a ge at Pi n 4 Ci r c ui t 348
(P).
Ye s
No
G O t o C 1 9 .
REPLACE A / C d a mp e r
C 1 9 CHECK A / C DAMPER DOOR SWI TCH A / C POSI TI ON
Ye s
No
GO t o C5.
Engi ne of f a nd i gn i t i o n s wi t c h in RUN po s i t i o n .
Re c o n n e c t A / C d a mpe r d o o r s wi t c h e l e c t r i c a l
c o n n e c t o r .
Ro t a t e A / C d a mpe r d o o r s wi t c h t o A / C po s i t i o n .
Usi ng a t e s t l a mp c h e c k v o l t a ge at Pi n 4 Ci r c ui t 348
(P).
Ye s
No
GO t o C5.
PINPOINT TEST D: NO OPERATI ON IN ALL TEMPERATURE SETTI NGS
TEST STEP RESULT A CTI ON TO TAKE
D1 MANUAL A / C ELECTRI C BLEND DOOR ACTUATOR
SYSTEM CHECK ( CROWN VI CTORI A, GRAND
MARQUI S)
Ye s
No
Sy s t e m i s f ul l y f un c t i o n a l .
GO t o D2.
St a r t v e hi c l e a n d run e n gi n e unt i l i t r e a c h e s nor ma l
o pe r a t i n g t e mpe r a t ur e .
Turn on MAX A / C mo d e .
Ad j ust A / C c o n t r o l t o f ul l - COOL ( LEFT) a n d c h e c k
f o r c o o l d i sc ha r ge ai r.
Ad j ust A / C c o n t r o l t o f ul l - WARM (RI GHT) a n d c h e c k
f o r wa r m d i s c h a r ge ai r.
Va r y A / C c o n t r o l f r o m f ul l - WARM t o f ul l - COOL.
Di d air t emper at ur e change?
Ye s
No
GO t o D2.
SYSTEM FUSE CHECK ( CROWN VI CTORI A, GRAND
MARQUI S)
Ye s
No
GO t o D3.
REPLACE f use a n d GO t o
D1. If f use bl o ws a ga i n ,
c h e c k f o r sho r t s t o
gr o un d in Ci r c ui t 2 98 a n d
SERVI CE a s n e e d e d .
Ch e c k Fuse 5 at t he f use j un c t i o n pa n e l .
Is f use good?
Ye s
No
GO t o D3.
REPLACE f use a n d GO t o
D1. If f use bl o ws a ga i n ,
c h e c k f o r sho r t s t o
gr o un d in Ci r c ui t 2 98 a n d
SERVI CE a s n e e d e d .
SUPPLY VOLTAGE CHECK ( CROWN VI CTORI A,
GRAND MARQUI S)
G O t o D4.
CHECK Ci r c ui t s 2 47 a nd
246 f o r o p e n s / s h o r t s .
Di sc o n n e c t bl e n d d o o r a c t u a t o r c o n n e c t o r l o c a t e d
on t h e he a t e r ai r pl e num c h a mb e r a nd a c c e s s e d
t hr o ugh t he gl o v e c o mpa r t me n t o pe n i n g.
Usi ng a t e s t l i ght , c h e c k f o r ba t t e r y v o l t a ge be t we e n
Ci r c ui t 2 98 ( P / O) a n d Ci r c ui t 2 08 ( GY) .
Di d t he t est lamp l i ght ?
Ye s
No
G O t o D4.
CHECK Ci r c ui t s 2 47 a nd
246 f o r o p e n s / s h o r t s .
12 - 00- 36 Cl i ma t e Co n t r o l S y s t e mS e r v i c e 12- 00- 3
PINPOINT TE ST D: NO OPERATION IN ALL TEMPERATURE SETTI NGS (Continued)
D4 A / C CONTROL SUPPLY VOLTAGE CHECK ( CROWN
VI CTORI A/ GRAND MARQUI S)
Ye s
No
GO t o D5.
CHECK wi r i n g f o r
o pe n s / s h o r t s . If wi r i n g t o
po t e n t i o me t e r i s go o d ,
REPLACE t he A / C
c o n t r o l .
Re c o n n e c t bl e n d d o o r a c t u a t o r c o n n e c t o r at t he
A / C e v a po r a t o r c o r e ho usi n g.
Di sc o n n e c t he a t e r c o n t r o l c o n n e c t o r f r o m t he b a c k
of t he A / C c o n t r o l .
CAUTION: Never short across Ci rcui t s 436
(R/LG) and 600 (DB). Thi s coul d cause
dest r uct i ve damage.
Usi ng a t e s t l i ght , c h e c k f or r e f e r e n c e v o l t a ge .
Ye s
No
GO t o D5.
CHECK wi r i n g f o r
o pe n s / s h o r t s . If wi r i n g t o
po t e n t i o me t e r i s go o d ,
REPLACE t he A / C
c o n t r o l .
D5 A / C CONTROL POTENTI OMETER CHECK ( CROWN
VI CTORI A, GRAND MARQUI S)
Ye s
No
REPLACE A / C e l e c t r o n i c
d o o r a c t ua t o r mo t o r on
he a t e r ai r pl e n um
c ha mbe r .
REPLACE A / C c o n t r o l .
Di sc o n n e c t a nd r e mo v e c o n t r o l h e a d po t e n t i o me t e r .
Usi ng a mul t i met er , c h e c k r e s i s t a n c e b e t we e n
t e r mi n a l s 2 a nd 3.
Wi t h po t e n t i o me t e r at f ul l COOL ( r e s i s t a n c e
sho ul d be 3000 OHMS) .
Wi t h po t e n t i o me t e r at f ul l WARM ( r e s i s t a n c e
sho ul d be 15 OHMS) .
Is resi st ance l i nearl y vari abl e i n be t we e n c o o l
and war m?
Ye s
No
d o o r a c t ua t o r mo t o r on
he a t e r ai r pl e n um
c ha mbe r .
REPLACE A / C c o n t r o l .
PINPOINT TEST E: BLOWER MOTOR DOES NOT OPERATE
E1 CHECK BLOWER MOTOR OPERATI ON
Ye s
No
G O t o E 2 .
GO t o E4.
Turn i gni t i on s wi t c h t o RUN, A / C d a mpe r d o o r
s wi t c h t o FLOOR a n d he a t e r bl o we r mo t o r s wi t c h t o
HI.
Does heat er bl ower mot or swi t c h ope r a t e ?
Ye s
No
G O t o E 2 .
GO t o E4.
E2 CHECK BLOWER LO SPEED
Ye s
No
WI GGLE wi r e s a n d
CHECK f o r i n t e r mi t t e n t
o pe r a t i o n . SERVI CE if
n e c e ssa r y .
G Ot o E3.
Ro t a t e he a t e r bl o we r mo t o r s wi t c h t o L O.
Does heat er bl ower mot or swi t c h ope r a t e ?
Ye s
No
WI GGLE wi r e s a n d
CHECK f o r i n t e r mi t t e n t
o pe r a t i o n . SERVI CE if
n e c e ssa r y .
G Ot o E3.
E3 CHECK BLOWER MOTOR RESI STOR
Ye s
No
CHECK Ci r c ui t 2 61
( O/ BK) f r o m bl o we r
mo t o r t o he a t e r bl o we r
mo t o r s wi t c h r e si st o r a n d
Ci r c ui t 57 ( BK) f r o m
r e si st o r t o gr o un d .
SERVI CE a s n e c e ssa r y .
REPLACE he a t e r bl o we r
CHECK bl o we r mo t o r
o pe r a t i o n .
Ch e c k he a t e r bl o we r mo t o r s wi t c h r e si st o r f o r
c o n t i n ui t y of c o i l s a n d t he r ma l l i mi t er .
Is heat er bl ower mot or swi t c h resi st or good?
Ye s
No
( O/ BK) f r o m bl o we r
mo t o r t o he a t e r bl o we r
Ci r c ui t 57 ( BK) f r o m
r e si st o r t o gr o un d .
CHECK bl o we r mo t o r
o pe r a t i o n .
E4 CHECK BL OWER MOTOR
Ye s E>
No
( O/ BK) be t we e n bl o we r
mo t o r a n d t h e s pl i c e t o
he a t e r bl o we r mo t o r
swi t c h r e si st o r f o r an
o pe n . SERVI CE a s
n e c e ssa r y .
G Ot o E 5.
Turn i gni t i on s wi t c h OFF. Gr o un d Ci r c ui t 2 61 ( 0 / B K )
at t he bl o we r mo t o r . Po si t i o n A / C d a mpe r d o o r
s wi t c h at FLOOR a n d t ur n ke y t o RUN l o n g e n o ugh
t o c h e c k f o r bl o we r mo t o r o pe r a t i o n .
Does bl ower mot or ope r a t e ?
Ye s E>
No
( O/ BK) be t we e n bl o we r
mo t o r a n d t h e s pl i c e t o
swi t c h r e si st o r f o r an
o pe n . SERVI CE a s
n e c e ssa r y .
G Ot o E 5.
PINPOINT T E ST E: BLOWER MOTOR DOES NOT OPERATE (Conti nued)
E 5 CHECK FUSE
Ye s
No
GO t o E6.
GO t o E9.
Ch e c k bl o we r mo t o r f use .
Is f use good?
Ye s
No
GO t o E6.
GO t o E9.
E6 CHECK FUNCTI ON SELECTOR SWI TCH
Ye s
No
GO t o E8.
GO t o E7.
Pul l A / C c o n t r o l f r o m i n st r ume n t pa n e l e n o ugh t o
ga i n a c c e s s t o t h e e l e c t r i c a l c o n n e c t o r s . Wi t h A / C
d a mpe r d o o r s wi t c h se t at FLOOR a n d i gni t i on
s wi t c h i n RUN, c h e c k b a t t e r y v o l t a ge at f un c t i o n
s e l e c t o r s wi t c h Pi n 3 Ci r c ui t 2 49 ( DB/ L G ) .
Are 12 or more vol t s avai l abl e?
Ye s
No
GO t o E8.
GO t o E7.
E7 CHECK VOLTAGE SUPPLY
Ye s
No
TEST A / C d a mpe r d o o r
s wi t c h f o r c o n t i n ui t y in al l
s wi t c h po si t i o n s e x c e p t
OFF. REPLACE A / C
d a mpe r d o o r s wi t c h if not
continuous in al l po s i t i o n s
e x c e p t OFF.
( BR/ O) be t we e n f use
pa n e l and A / C c o n t r o l .
Wi t h sa me c o n d i t i o n s a s in St e p 6, c h e c k f o r v o l t a ge
at Pi n 4 of f un c t i o n s e l e c t o r s wi t c h Ci r c ui t 181
( BR/ O) .
Are 12 or more vol t s pr esent ?
Ye s
No
TEST A / C d a mpe r d o o r
s wi t c h f o r c o n t i n ui t y in al l
s wi t c h po si t i o n s e x c e p t
OFF. REPLACE A / C
d a mpe r d o o r s wi t c h if not
continuous in al l po s i t i o n s
e x c e p t OFF.
( BR/ O) be t we e n f use
pa n e l and A / C c o n t r o l .
E8 CHECK VOLTAGE
Ye s
No
REPLACE bl o we r mo t o r .
( DB/ L G ) be t we e n A / C
c o n t r o l a nd bl o we r mo t o r .
Re i n st a l l t he A / C c o n t r o l . Wi t h i gni t i on swi t c h in
RUN a nd A / C d a mpe r d o o r s wi t c h se t at FL OOR,
c h e c k ba t t e r y v o l t a ge at bl o we r mo t o r Ci r c ui t 2 49
( DB/ L G ) .
Are 12 or more vol t s pr esent ?
Ye s
No
( DB/ L G ) be t we e n A / C
c o n t r o l a nd bl o we r mo t o r .
E9 CHECK CI RCUI T
Ye s
No
GO t o E 1 0 .
Turn i gni t i on s wi t c h OFF. Di sc o n n e c t bl o we r mo t o r
c o n n e c t o r a n d i nst a l l a ne w f use . Turn i gni t i on s wi t c h
t o RUN wi t h A / C d a mpe r d o o r s wi t c h se t at FL OOR.
Does f use bl ow?
Ye s
No
GO t o E 1 0 .
E10 CHECK CI RCUI T FOR SHORT
Ye s
No
CHECK Ci r cui t 181
( BR/ O) f or sho r t .
CHECK Ci r c ui t 249
( DB/ L G ) f or sho r t .
Pul l A / C c o n t r o l f r o m i n st r ume n t pa n e l e n o ugh t o
ga i n a c c e s s t o t he e l e c t r i c a l c o n n e c t o r s .
Di sc o n n e c t t he ha r n e ss c o n n e c t o r f r o m t he A / C
d a mp e r d o o r s wi t c h . I nst al l a ne w f use a n d t ur n
i gn i t i o n s wi t c h t o RUN.
Does t he f use bl ow?
Ye s
No
CHECK Ci r cui t 181
( BR/ O) f or sho r t .
( DB/ L G ) f or sho r t .
PINPOINT TEST F: NO OPERATION IN HIGH BLOWER SETTING
F1 | CHECK BL OWER MOTOR OPERATI ON
Ye s
No
G O t o F 2 ,
GO t o F4.
s wi t c h t o FLOOR a n d he a t e r bl o we r mo t o r s wi t c h t o
f i r st po si t i o n f r o m HI .
Does bl ower mot or oper at e?
Ye s
No
G O t o F 2 ,
GO t o F4.
F2 CHECK BL OWE R SPEED
Ye s >
No
CYCLE he a t e r bl o we r
mo t o r s wi t c h f r om HI t o
LO se v e r a l t i me s. If
bl o we r o pe r a t e s e a c h
t i me , ADVI SE c us t o me r of
s y s t e m o pe r a t i o n . If
bl o we r d o e s not o pe r a t e
in HI e a c h t i me , REPLACE
swi t c h
GO t o F3.
Turn he a t e r bl o we r mo t o r s wi t c h t o HI .
Does bl ower mot or oper at e on HI?
Ye s >
No
CYCLE he a t e r bl o we r
mo t o r s wi t c h f r om HI t o
LO se v e r a l t i me s. If
bl o we r o pe r a t e s e a c h
t i me , ADVI SE c us t o me r of
s y s t e m o pe r a t i o n . If
bl o we r d o e s not o pe r a t e
in HI e a c h t i me , REPLACE
swi t c h
GO t o F3.
PINPOINT TEST F: NO OPERATION I N HI GH BLOWER SETTING (Cont i nued)
TEST STEP RESULT ACTI ON TO TAKE
F3 CHECK BL OWER SWI TCH
Ch e c k c o n t i n ui t y of he a t e r bl o we r mo t o r s wi t c h . Ye s
No
SWITCH TERMINALS
BLOWER SWITCH CONTINUITY
M4851-A
Switch Position Continuity between Terminals
Low 2
Me d i u m 1 2 a n d 3
Me d i u m 2 2, 4 a n d 3
Hi gh 2, 1 a n d 4
Is swi t c h cont i nuous in all posi t i ons?
SERVI CE Ci r c ui t 57 ( BK)
be t we e n he a t e r bl o we r
mo t o r s wi t c h a n d gr o un d
a s n e c e ssa r y .
mo t o r s wi t c h .
F4 CHECK BL OWER SPEEDS
Wi t h i gni t i on s wi t c h in RUN a nd A / C d a mpe r d o o r
s wi t c h at FL OOR, r o t a t e he a t e r bl o we r mo t o r s wi t c h
t o LO a n d t he n o n e po si t i o n t o wa r d HI .
Does bl ower mot or operat e i n bot h posi t i ons?
Ye s
No
I NSPECT ha r n e ss
c o n n e c t o r at he a t e r
bl o we r mo t o r s wi t c h .
REPLACE ha r n e ss
c o n n e c t o r if d a ma ge d . If
OK, REPLACE he a t e r
bl o we r mo t o r s wi t c h .
G O t o F 5 .
F5 CHECK L O BLOWER MOTOR SPEED
Re f e r e n c e bl o we r mo t o r s p e e d s in St e p F4.
Does bl ower mot or operat e i n LO?
Ye s
No

GO t o F6.
mo t o r swi t c h r e si st o r .
F6 CHECK BL OWER SWI TCH CONNECTOR
Ch e c k t o ma ke sur e c o n n e c t o r i s c o r r e c t l y a n d
s e c ur e l y c o n n e c t e d t o he a t e r bl o we r mo t o r s wi t c h .
Is c onne c t or pr ope r l y c onne c t e d t o heat er
bl ower mot or swi t c h?
Ye s
No

REPLACE c l ut c h
pr e ssur e pl a t e .
RECONNECT a nd CHECK
bl o we r mo t o r o pe r a t i o n .
PINPOINT TEST G: BLOWER MOTOR DOES NOT OPERATE PROPERLY
T E ST STEP RESULT ACTI ON TO TAKE
G 1 CHECK BL OWER OPERATI ON
Ye s
No
GO t o G5.
GO t o G2 .
s wi t c h t o FL OOR a n d he a t e r bl o we r mo t o r s wi t c h at
L O.
m Do e s b l o w e r m o t o r o p e r a t e ?
Ye s
No
GO t o G5.
GO t o G2 .
G2 CHECK BLOWER SWI TCH OPERATI ON
Ye s
No
GO t o G4.
GO t o G3.
Sl o wl y mo v e he a t e r bl o we r mo t o r s wi t c h f r o m L O t o
HI . St o p at e a c h d e t e n t a n d c h e c k f or bl o we r mo t o r
o pe r a t i o n .
Do e s b l o w e r m o t o r o p e r a t e i n any s p e e d e x c e p t
HI?
Ye s
No
GO t o G4.
GO t o G3.
PINPOINT TEST G: BLOWER MOTOR DOES NOT OPERATE PROPERLY (Cont i nued)
G3 CHECK GROUND CIRCUIT
Check Circuit 57 (BK) from heater blower motor
swi tch resi stor t o ground for an open.
Is gr ound wi r e open?
Yes
No

SERVICE and / o r
REPLACE as requi red.
REPLACE heater blower
motor swi t ch resi st or.
G4 CHECK CIRCUIT
Check Circuit 2 61 (O / BK) between blower motor
and heater blower motor swi tch resi st or for open.
Is ci r cui t open?
Yes
No

SERVICE as necessary
and CHECK blower motor
operati on.
REPLACE resi st or
assembly.
G5 CHECK BLOWER SWITCH
Check blower motor operation several ti mes in each
blower knob posi t i on.
Does bl ower mot or oper at e i n al l kn o b posi t i ons
wi t hout i nt er r upt i on?
Yes
No
CHECK system operation
in all function posi ti ons
and blower speeds. If OK,
INSTRUCT customer on
correct operation of
syst em.
GO t o G6.
G6 CHECK BLOWER SWITCH CONTINUITY
Remove harness connector from heater blower
motor switch and check continuity through heater
blower motor swi tch in each posi t i on.
Yes
No
SWITCH TERMINALS
BLOWER SWITCH CONTINUITY
M4851-A
Switch Position Continuity between Terminals
L o w 2
Me d i u m 1 2 a n d 3
Me d i u m 2 2 , 4 a n d 3
Hi gh 2, 1 a n d 4
Is swi t c h cont i nuous i n al l posi t i ons?
CHECK continuity of
Circuit 7 54 (LG/ W) and
Circuit 7 52 (Y/ R)
between heater blower
motor swi tch and heater
blower motor swi t ch
resi stor. SERVICE as
required.
REPLACE heater blower
motor swi t ch.
PINPOINT TEST H: ENGINE COOLING FAN DOES NOT OPERATE WHEN A / C IS ACTIVATED
GOt o H2.
GOt o H3.
H1 ] CHECK VOLTAGE SUPPLY TO COOLING FAN
Yes
No
ACTION TO TAKE
GOt o H2.
GOt o H3.
Start engine and run until normal operati ng
temperature is achi eved.
Turn engine OFF, leave ignition swi t ch in RUN
posi ti on.
Actuate A/ C damper door swi t ch t o MAX A / C
posi ti on.
Using a t est lamp, back probe Pin 1 Circuit 229
(R / O) and Pin 2 Circuit 2 2 9 (R / O) for voltage.
Yes
No
ACTION TO TAKE
GOt o H2.
GOt o H3.
1995 To wn Gar, Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s Jul y 1994
PINPOINT TEST H: ENGINE COOLING FAN DOES NOT OPERATE WHEN A / C IS ACTIVATED (Cont i nued)
TE ST STEP RESULT A CTI ON TO TAKE
H2 CHECK COOLI NG FAN GROUND
Ye s
No
GO t o H5.
SERVI CE f an mo t o r
gr o un d c i r c ui t f o r o pe n
c i r c ui t . RESTORE
Usi n g an o hmme t e r c o n n e c t e d to a kn o wn go o d
ground, connect second lead Circuit 57 (BK) at
c o o l i n g f a n mo t o r c o n n e c t o r .
Ye s
No
GO t o H5.
SERVI CE f an mo t o r
gr o un d c i r c ui t f o r o pe n
H3 BACK- PROBE FOR VOLTAGE SUPPLY
Ye s
No
GO t o H5.
GO t o H4.
Usi n g a t e s t l a mp, b a c k- p r o b e Pi n 3 Ci r c ui t 38
( B K / O ) f o r v o l t a ge .
Ye s
No
GO t o H5.
GO t o H4.
H4 CHECK FUSE ( 60A)
Ye s
No E>
( BK / O) f o r o pe n c i r c ui t .
RETEST s y s t e m.
( BK / O) f o r sho r t c i r c ui t .
RETEST s y s t e m.
Usi n g t e s t l a mp, c h e c k bo t h s i d e s of Fuse ( 60A) .
Is f use OK ?
Ye s
No E>
( BK / O) f o r o pe n c i r c ui t .
RETEST s y s t e m.
( BK / O) f o r sho r t c i r c ui t .
RETEST s y s t e m.
H5 CHECK COOLI NG FAN MOTOR
Ye s
No
(R / 0 ) f o r o pe n c i r c ui t .
RETEST s y s t e m.
REPLACE c o o l i n g f a n
mo t o r . RESTORE v e hi c l e .
RETEST s y s t e m.
Di sc o n n e c t c o o l i n g f a n mo t o r .
Usi n g a No . 10 ga uge j umpe r wi r e , c o n n e c t one e n d
t o b a t t e r y po si t i v e . Co n n e c t o t h e r e n d t o c o o l i n g
f a n , l o w t e r mi n a l a t f a n mo t o r .
Usi n g a s e c o n d j umpe r wi r e , c o n n e c t one e nd t o a
kn o wn go o d gr o un d . Co n n e c t t he o t he r e n d t o t h e
gr o un d t e r mi n a l on t he fan mo t o r .
Di d c ool i ng f an run?
Ye s
No
(R / 0 ) f o r o pe n c i r c ui t .
RETEST s y s t e m.
REPLACE c o o l i n g f a n
mo t o r . RESTORE v e hi c l e .
RETEST s y s t e m.
He a t e r B l o w e r Mo t o r S w i t c h
For t he swi t c h cont i nui t y t e st , ref er t o t he El ect ri cal
Schemat i c and Heat er Bl ower Mot or Current Dr a w
Test sc he ma t i c . Check f or cont i nui t y be t we e n
c onne c t or t ermi nal s a s shown on t he wi r i ng di agr am.
Use a sel f -power ed t est l amp and c he c k t ermi nal
cont i nui t y at ever y lever posi t i on. The l amp shoul d go
on f or e a c h c onne c t e d pai r of t ermi nal s.
The current d r a w t est is an i n-vehi cle t e st t ha t wi ll
det ermi ne if t he bl ower mot or ( 18527 ) i s oper at i ng
pr oper l y. Connect a 0-30 ammet er. Ground negat i ve
si de of A / C bl ower mot or connect or wi t h a 10-gauge
or l arger j umper wi r e , and measure t he A / C bl ower
mot or current dr a w.
On all el ect ri cal ci r cui t s, cont i nui t y must exi st f r om t he
sour c e of powe r (ba t t e r y ) t o t he unit whe r e t he power
is used and ba c k t o t he sour c e of powe r t hr ough t he
gr ound t ermi nal . A c he c k at e a c h connect i on in a
ci r cui t , st ar t i ng at t he bat t er y , wi ll l ocat e an open
ci r cui t or wi l l sho w t ha t t he ci rcui t is c ompl e t e .
Rot unda 7 3 Di gi t al Mult i Met er 105-00051 or
equi val ent , or a sel f -power ed t e st l amp connect ed at
any t wo poi nt s of a ci rcui t wi t h t he power r emoved
f r om t he ci rcui t , wi ll show if t he ci rcui t bet ween t he t wo
connect i ons i s open or cont i nuous.
If t he met er does not move or has a light movement
(hi gh resi st ance), t he ci rcui t may have a poor
connect i on or broken wi r e. If t he bulb does not li ght ,
t he ci rcui t is open.
If t he met er movement i s gr eat or full (l ow r esi st ance),
t he ci rcui t is compl et e. If t he bulb l i ght s, t he ci rcui t is
cont i nuous.
12- 00- 41 Cl i mat e Cont r ol Sy s t e m S e r v i c e 12- 00- 41
He a t e r Bl o we r Mo t o r Cur r e n t Dr a w Te st
DVOM
BATTERY
Heat er Co r e
POSI TI VE LEAD
NOTE: CONNECT AMMETER
NEGATI VE LEAD TO
ORANGE WIRE TERMINAL
IN CONNECTOR
L360S-G
Pl ugged Heat er Cor e
CAUTI ON: Car bon monox i de i s col or l ess,
o d o r l e s s and danger ous. If i t i s necessar y t o
o p e r a t e t he engi ne wi t h t he vehi cl e i n a c l os ed
a r e a such as a gar age, al ways use an exhaust
c o l l e c t o r to vent t he exhaust gas es out si de t he
c l o s e d area,, The heat er c or e ( 18476) i s an ai l
a l u mi n u m c or e whi c h has t wo r ows of f l at t ubes
t o ma x i mi z e engi ne cool ant f l ow. It i s l ocat ed i n
t h e h e a t e r ai r pl enum c hamber ( 18471) assembl y
i n t he passenger c ompar t ment under t he
i nst r ument panel ( 04320) .
He a t e r Co r e
HEATER
CORE
18476
M3450-B
Che c k t he heat er sy st e m t horoughl y a s f ol l ows:
1. I nspect f or vi si bl e evi dence of cool ant l eakage at
t he heat er wa t e r hose ( 1847 2) t o heat er c o r e
a t t a c hme nt s. A cool ant l eak at t he heat er wa t e r
hose coul d f ol l ow t he heat er c or e t ube t o t he
heat er c o r e a nd appear a s a l eak in t he heat er
c or e .
2. Che c k t he sy st e m f or l oose or over t i ght ened
hose c l a mps ( 8287 ) . The hose cl amps shoul d be
t i ght ened t o 1.7-2.4 N-m (15-21 lb-i n).
3. If l e a ka ge is f ound and t he hose cl amps ar e
over -t i ght ened, r epl ace t he hose cl amp and
t i ght en t o t he pr oper l evel . An over-t i ght ened
hose cl amp can c a use l eakage at t he heat er
wa t e r hose connect i on and da ma ge t he heat er
c o r e t ube.
4. Che c k t o see t hat t he engi ne cool ant is at t he
pr ope r l evel . St ar t t he engi ne and t urn on t he
heat er. When t he engi ne cool ant r eaches
oper at i ng t emper at ur e, f eel t he heat er c o r e out l et
hose t o see if it i s hot . If t he inlet hose i s hot and
t he out l et hose i s not hot , t he heat er c or e may
have an ai r po c ke t or may be pl ugged.
P r e s s u r e Te s t
NOTE: Due t o spa c e l i mi t at i ons, a bench t est is
r e c omme nde d f or heat er pr essur e t est i ng.
1. Drai n t he cool ant f r o m t he cool i ng sy st e m.
2. Di sconnect t he heat er wat er hoses f r om t he
heat er c or e t ube s.
3. Install a shor t pi ece of heat er wa t e r hose
(appr oxi mat el y 101. 6 mm (4 i nches) long) on
e a c h heat er c o r e t ube.
4. Fill t he heat er c o r e and heat er wa t e r hoses wi t h
wat er , i nstall pl ug BT-7422-B and adapt er
BT-7422-A f r o m Rot unda Ra d i a t o r / He a t e r Cor e
Pressure Test er 02 1 - 00012 or equi valent in t he
heat er wa t e r hose ends. Secure t he heat er wa t e r
hose s, pl ug and adapt er wi t h hose cl amps.
5. At t a c h t he pump and gauge assembl y Rot unda
Ra d i a t o r / He a t e r Cor e Pressure Test er
02 1- 00012 or equi val ent t o t he adapt er. Cl ose
t he bl eed val ve at t he base of t he gauge and
pump 207 kPa ( 30 psi ) of ai r pressure i nto t he
heat er c or e .
6. Obser ve t he pr essur e gauge f or a minimum of
t hr e e mi nut es. The pr essur e shoul d not dr op.
7. If t he pressure doe s not dr op, no l eaks are
i ndi cat ed.
8. If t he pressure d r o ps, c he c k t he heat er wat er
hose connect i ons t o t he heat er c or e t ubes f or
l eaks. If t he heat er wa t e r hoses do not l eak,
remove t he heat er c o r e f r om t he vehi cl e and
per f or m t he bench t e st as out l i ned.
Remove heat er c o r e f r om heat er ai r plenum
chamber.
Drai n all cool ant f r o m t he heat er c or e .
Connect t he 101. 6 mm (4 i nch) t est hoses wi t h
plug and adapt er t o t he heat er c or e t ubes.
Connect t he ai r pump and gauge assembl y t o
t he adapt er.
Appl y 2 07 kPa ( 30 psi ) of ai r pr essur e t o t he
heat er c o r e wi t h Rot unda Ra d i a t o r / He a t e r
Cor e Pressure Test er 02 1- 00012 or
equi val ent . Submer ge t he heat er c or e in wat er .
If a l eak is o bse r ve d , ser vi ce or repl ace t he
heat er c or e a s necessar y .
SERVICE PROCEDURES
Refrigerant System Tests
Test equi pment must be connect ed t o t he ref ri gerant
sy st e m in or der t o ma ke sy st e m t e st s. If a chargi ng
st at i on is used, f ol l ow t he i nst ruct i ons of t he st at i on
manuf act urer.
The best wa y t o di agnose a condi t i on in t he ref ri gerant
sy st e m i s t o not e t he sy st e m pr essur es (shown by t he
mani f ol d gauges), and t he A / C cl ut ch c y c l e rat e and
t i mes. Then c ompa r e t he f i ndi ngs t o t he f ol l owi ng
c ha r t s.
The sy st e m pr essur es ar e l ow-si de (compr essor
suct i on) and hi gh-si de (c ompr e ssor di schar ge).
An A / C cl ut ch c y c l e i s t he t i me t he A / C cl ut ch
( 2 884) is engaged pl us t he t i me it i s di sengaged
(t i me on plus t i me of f ).
A / C cl ut ch c y c l e t i mes ar e t he l engt hs of t i me (in
se c onds) t hat t he A / C cl ut ch is ON and OFF.
The f ol l owi ng t est condi t i ons must be est abl i shed t o
obt ai n a c c ur a t e pr essur e readi ngs:
Run engi ne at 1500 r pm f or 10 mi nut es.
NOTE: When ambi ent t emper at ur es e xc e e d 38C
( 100F) , engi ne shoul d be run at normal idle speed
onl y. For t e st s in ambi ent t emper at ur es bet ween 38C
( 100F) and 43C ( 110F) , sy st e m perf ormance
pr essur es wi ll be t he same as t hose f or ambi ent
t emper at ur es shown on t he char t in t he 32 C- 38C
( 90F- 100F) range. Cent er A / C regi st er di schar ge
t emper at ur es wi ll al so be si mi lar t o t hose shown in t he
c ha r t in t he 32 C- 38C ( 90F- 100F) range.
Ope r a t e A / C sy st e m on max A / C (reci rcul at i ng
ai r).
Run bl ower mot or ( 18527 ) at maxi mum spe e d.
St abi l i ze i n-vehi cle t emper at ur e at 21 C t o 2 7 C
( 7 0 Ft o 80F) .
Nor ma l P r e s s ur e / Te mpe r a t ur e Re l a t i o n shi ps-
Sy st e m
NORMAL CENTER A/C REGISTER
DISCHARGE TEMPERATURES
c
10
8
6
4 -
2-
0 -
5
45
40
30,
c ITE
Al
R A
RT
JC
EM
RE(
PE
SIS
RLA"
TE
TUI
3D ISC r HA
fC
RG E ITE
Al
R A
RT
JC
EM
RE(
PE
SIS
RLA"
TE
TUI
3D ISC r HA
fC
RG
- A / C Eva po r a t o r Co r e Or i f i c e / A / C Cy c l i c Swi t c h Re f r i ge r a nt
NORMAL A/C EVAPORATOR CORE
ORIFICE CYCLING A/C CLUTCH
^ REFRIGERANT SYSTEM PRESSURES
2000
1800
1800
1400
1 1 0
1000
7 0 80 0
1 5 20 25 SO
AMBIENT TEMPERATURES
1 00 F
800
500
400
300
200
100
I I I I I
-OW PRESSURES
SUCTION) PSI/kPa
I
(
I I I I I
-OW PRESSURES
SUCTION) PSI/kPa

I
0 7 0 90
1 5 20 25 30
35
100 F
C
M2840-E
12-00- 43 Cl i mat e Cont r ol S y s t e m S e r v i c e 12-00-43
Nor mal A / C Cl ut ch Cycl i ng Pressure Swi t ch Rat es and Ti mesEvapor at or Cor e Ori f i ce Type Syst em
NORMAL A/C CLUTCH CYCLE RATE PER MINUTE
CYCLES/MINUTE
SECONDS
100
TOTAL A/C CLUTCH
CYCLE TIME S E C O N D S
80
60
40
20
60 70 80
s
90 100F
'' i ' 1 i
1 1
|
1
15 20 25 30
NORMAL A/C CLUTCH
r
35
60
T -
15
SECONDS
100
70 80 90 100F
20 25 30
NORMAL A/C CLUTCH
ON TIME SECONDS
35
SECONDS
-
OFF TIME SECONDS
25
20
15
10
5
25
20
15
10
5
25
20
15
10
5
25
20
15
10
5
25
20
15
10
5
0
60 70 80 90 100F
100F
i
1S
I
20
25
i
30
35 15
i
20
25
i
30
t
35
AMBIENT TEMPERATURES AMBIENT TEMPERATURES
C
M2841-C
The f ol l owi ng pr oc e dur e is r e c omme nde d f or
achi evi ng a c c ur a t e di agnosi s resul t s in t he l east
amount of t i me.
1. Connect a mani f ol d gauge set , Rot unda R-134a
Mani f ol d Gauge Set 176-R032A or equi val ent , t o
t he sy st e m.
NOTE: The t e st condi t i ons, speci f i ed at t he t o p
of e a c h c ha r t , must be met t o obt ai n a c c ur a t e
t e st resul t s:
Run engi ne at 1500 r pm f or 10 mi nut es.
Ope r a t e A / C sy st e m on max A / C
(reci rcul at i ng ai r).
Run bl ower mot or at maxi mum spe e d .
St abi l i ze i n-vehi cle t emper at ur e at 21 C t o
2 7 C ( 7 0 F t o 80 F) .
NOTE: The di schar ge (hi gh) pr essur e shoul d
oper at e t he r ever se of t he suct i on pr essur e.
When t he suct i on pressure is dr oppi ng, t he
di schar ge pressure shoul d i ncrease. When t he
suct i on pressure is i ncreasi ng, t he di schar ge
pressure shoul d decr ease.
As soon as t he sy st e m i s st abi l i zed, r e c or d t he
hi gh and low pressures as shown by t he mani f ol d
gauges. Normal l y t he suct i on pr essur e shoul d
de c r e a se t o a range bet ween 152-193 kPa
(22-28 psi ) and t he A / C cycl i ng swi t c h shoul d
open. When t he A / C cycl i ng swi t c h opens, t he
suct i on pressure shoul d st ar t t o ri se t o a range
bet ween 276- 324 kPa (40-47 psi ). Somewher e
bet ween 276- 324 kPa (40-47 psi ), t he A / C
cycl i ng swi t c h shoul d cl ose and t he suct i on
pressure shoul d st ar t t o dr op.
12- 00- 44 Cl i mat e Co n t r o l S y s t e mS e r v i c 12- 00- 44
3. NOTE: When t he ambient t emperat ure is above
26C ( 80F) , the A / C cl utch may not cycl e.
Determi ne the A / C cl utch cycl e rat e per minute
( A/ C cl utch on ti me plus off ti me is a cycl e).
4. Record A / C cl utch off-time in seconds.
5. Record A / C cl utch on-time in seconds.
6. Record center A / C regi ster ( 19893) di scharge
t emperat ure.
7. Determi ne and record ambi ent t emperat ures.
8. Compare t est readi ngs wi t h previ ous appl i cabl e
chart s.
Plot a verti cal line for recorded ambient
t emperat ure f rom scal e at bot t om of each
chart t o t op of each chart .
REFRIGERANT SYSTEM PRESSURE AND A / C CLUTCH CYCLE TIMING EVALUATION CHART
NOTE: Syst em t est requi rement s must be met t o obt ai n accur at e t est readi ngs f or eval uat i on. Refer t o t he normal
ref ri gerant syst em pr e ssur e / t e mpe r a t ur e and t he normal A / C cl ut ch cy cl e rat e and t i mes char t s.
HI GH
( DI SCHA RGE )
P RE SSURE
L OW
( SUCT I ON)
P RE SSURE
A / C COMP RE S S OR C L UT C H CYCL E
T I ME
C O MP O N E N T C A U S E S
HI GH
( DI SCHA RGE )
P RE SSURE
L OW
( SUCT I ON)
P RE SSURE RATE ON OFF C O MP O N E N T C A U S E S
Hi gh Hi gh Co n t i n u o u s Run A / C Co n d e n s e r C o r e I n a d e q u a t e
Ai r f l o w
Hi gh No r ma l t o
Hi gh
Co n t i n u o u s Run En gi n e Ov e r h e a t i n g
No r ma l t o Hi gh No r ma l Co n t i n u o u s Run Ai r Re f r i ge r a n t
Re f r i ge r a n t Ov e r c h a r g e
( a ,
Hu mi d i t y or
Amb i e n t Te mp Ve r y H i g h
( b )
No r ma l Hi gh Co n t i n u o u s Run A / C E v a p o r a t o r Co r e
Or i f i c e O- Ri n g
S e a l L e a k i n g / Mi s s i n g
No r ma l No r ma l Sl o w o r No
Cy c l e
L o n g o r
Co n t i n uo us
No r ma l o r
No Cy c l e
Mo i s t u r e i n Re f r i ge r a n t S y s t e m,
E x c e s s i v e Re f r i ge r a n t Oi l
No r ma l L o w Sl o w L o n g L o n g A / C Cy c l i n g S w i t c h L o w Cut - Out
No r ma l t o L o w Hi gh Co n t i n u o u s Run A / C c o m p r e s s o r L o w P e r f o r ma n c e
No r ma l t o L o w No r ma l t o
Hi gh
Co n t i n u o u s Run E v a p o r a t o r t o Co mp r e s s o r Su c t i o n
L i n e P a r t i a l l y Re s t r i c t e d o r
P l u g g e d
( c )
No r ma l t o L o w No r ma l Fa s t Sho r t No r ma l A / C E v a p o r a t o r C o r e L o w o r
Re s t r i c t e d Ai r f l o w
No r ma l t o L o w No r ma l Fa st Sh o r t t o
Ve r y Sh o r t
No r ma l t o
L o n g
A / C Co n d e n s e r Co r e , A / C
E v a p o r a t o r Co r e Or i f i c e o r Condenser
t o E v a p o r a t o r T u b e P a r t i a l l y
Re s t r i c t e d o r P l u gge d
Ve r y Sh o r t
Sho r t t o
Ve r y Sh o r t
L o w Re f r i ge r a n t Ch a r ge
Ve r y Sh o r t
L o n g A / C E v a p o r a t o r Co r e P a r t i a l l y
Re s t r i c t e d o r P l u gge d
No r ma l t o L o w L o w Co n t i n u o u s Run E v a p o r a t o r t o Co mp r e s s o r Su c t i o n
L i n e P a r t i a l l y Re s t r i c t e d o r P l u gge d
A / C Cy c l i n g S w i t c h S t i c k i n g
Cl o s e d
Plot a horizontal line for each of t he other t est
readi ngs f rom scal e at LH si de of appropri ate
chart.
If t he point where t he t wo lines cr oss on each of the
chart s falls within t he dark band, the syst em is
operati ng normally. If the lines cr oss outsi de the dark
band on one or more of the chart s, t here is a concern
and t he speci fi c cause must be determi ned. This is
easi l y done by using the Refri gerant Syst em Pressure
and A / C Clutch Cycl e Timing Evaluation chart .
At the bot t om of t he chart , additional cause
components are listed for poor A / C compressor
operati on or a damaged A / C compressor ( 19703)
condi ti on.
1995 To wn Ca r , Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s Jul y 1 9 9 4
12 - 00- 45 Cl i mat e Cont r ol Sy s t e mSe r v i c e 12 - 00- 45
REFRI GERANT SYSTEM P R E S S U R E AND A / C CLUTCH CYCL E TIMING E V A L U A T I O N CHART
NOTE: Syst em test requirements must be met to obtain accurat e t est readi ngs for evaluation. Refer to the normal
refrigerant syst em pressure/t emperat ure and the normal A / C clutch cycl e rate and times chart s. (Cont'd)
HIGH
(DI SCHARGE)
PRESSU RE
LOW
(SUCTION)
PRESSURE
A / C COMPRESSOR CLUTCH CYCLE
TIME
COMPONENTCAUSES
HIGH
(DI SCHARGE)
PRESSU RE
LOW
(SUCTION)
PRESSURE RATE ON OFF COMPONENTCAUSES
Er r at i c Oper at i on or A / C Compr es s or Not Runni ng A / C Cycl i ng Swi t c h Di r t y Cont act s
or St i cki ng Open.
Poor Connect i on at A / C Cl ut ch
Connect or or A / C Cycl i ng Swi t ch
Connect or
A / C El ect r i cal Ci r cui t Er r at i c See
A / C C u t Out by Power t r ai n Cont r ol
Modul e
ADDITIONAL POSSIBLE CAUSE COMPONENTS ASSOCIATED WITH POOR A / C COMPRESSOR OPERATION
Dr i ve Bel t

A / C Compr es s or Dr i ve Bel t Loos e
A / C Cl ut ch

A / C Cl ut ch Sl i p p i n g / L o w Vol t age
A / C Cl ut ch Fi el d Coi l

A / C Cl ut ch Fi el d Coi l
Op e n Sh o r t e d , or Loos e Mount i ng
Cont r ol Assembl y Swi t ch

Cont r ol Assembl y Swi t c hDi r t y
Cont ac t s or St i cki ng Open
A / C Cl ut ch Wi r i ng Ci r cui t
-
A / C Cl ut ch Wi r i ng Ci r cui t Hi gh
Resi st ance, Open or Bl own Fuse
A / C Compr essor Not Oper at i ng

A / C Compr es s or Oper at i on
I nt er r upt ed by PCM
ADDITIONAL POSSIBLE CAUSE COMPONENTS ASSOCIATED WITH A DAMAGED A / C COMPRESSOR
A / C Cycl i ng Swi t ch

A / C Cycl i ng Swi t c hSt i c k i ng
Cl osed or A / C Cl ut ch Sei zed
Suct i on Ac c umul at or / Dr i er Suct i on
Ac c umul at or / Dr i er Ref r i ger ant Oi l
Bl eed Hol e Pl ugged
Ref r i ger ant L o w

Ref r i ger ant Leak s
( a) A / C c ompr es s or may mak e noi se on i ni t i al r un. Thi s sl uggi ng condi t i on i s c aus ed by ex c es s i v e l i qui d r ef r i ger ant .
( b) A / C cl ut ch may not cycl e in ambi ent t emper at ur es above 2 6 C ( 8 0 F) dependi ng on humi di t y condi t i ons.
( c) Low pr essur e r eadi ng wi l l be nor mal t o hi gh if pr essur e i s t aken at l ow si de ser vi ce por t and if r est r i ct i on i s downst r eam of A / C char gi ng
val ve c or e.
The di agnosi s c ha r t s pr ovi de t he most di r ect and sure
wa y t o det ermi ne t he c a use of any condi t i on in a
poorl y perf ormi ng ref ri gerant sy st e m.
Af t er servi ci ng and c or r e c t i ng a ref ri gerant sy st e m
concer n, t a ke addi t i onal pr essur e readi ngs and
obser ve t he A / C cl ut ch c y c l e rat e whi l e meet i ng t he
condi t i onal requi rement s in t he previ ous c ha r t s t o
ensure t he concer n has been c o r r e c t e d .
In ambi ent t emper at ur es a bo ve 27C ( 81 F ) , t he A / C
cl ut ch wi ll not normal l y c y c l e of f . Thi s wi ll de pe nd on
l ocal condi t i ons and engi ne r pm/ v e hi c l e spe e d . A / C
cl ut ch cycl i ng wi l l normal l y not occur when t he engi ne
is operat i ng at cur b idle spe e d .
If t he sy st e m cont ai ns no ref ri gerant or is ext r emel y
l ow on ref ri gerant , t he A / C cl ut ch wi ll not e nga ge f or
A / C c ompr e ssor oper at i on. A rapi d cycl i ng A / C
cl ut ch is usually an i ndi cat i on t ha t t he sy st e m i s l ow on
ref ri gerant .
S e r v i c e A c c e s s G a u g e P o r t Va l v e s
The f ol l owi ng Rot unda equi pment or equi valent i s
avai l abl e f or pressure-t est i ng t he ref ri gerant sy st e m:
equi val ent .
equi valent .
Leak Det ect or 161-R0010 or equi valent .
equi valent .
176-R0036 or equi valent .
1995 Town Car, Cr own Vi ct or i a, Gr and Mar qui s Jul y 1 9 9 4
12 - 00- 46 Climate Control SystemService
12-00-46
Rotunda R-134a Vacuum Pump (1.5 CFM)
Rotunda R-134a Vacuum Pump (3.0 CFM)
The low-pressure service access gauge port valve is
located on the side of the suction accumulator/drier
(19C836).
The high-pressure service access gauge port valve is
located on the A / C compressor to condenser
discharge line (19972).
C h e c k i n g f o r A / C L e a k s
WARNI NG: GOOD VENTI LATI ON I S NECESSARY
IN THE AREA WHERE A / C L E AK TESTI NG I S TO
BE DONE. IF THE SURROUNDI NG AI R I S
CONTAMI NATED WI TH REFRI GERANT GAS, THE
L E AK DETECTOR WI L L I NDI CATE THI S GAS A L L
THE TI ME. ODORS FROM OTHER CHEMI CALS
SUCH AS ANTI FREEZE, DI ESEL FUEL, DI SC
BRAKE CLEANER OR OTHER CLEANI NG
SOLVENTS WI L L CAUSE THE SAME CONCERN. A
FAN, EVEN IN A WE L L VENTI LATED AREA, IS
VERY HELPFUL IN REMOVI NG SMA L L TRACES OF
AI R CONTAMI NATI ON THAT MI GHT AFFE CT THE
L EAK DETECTOR.
1. Attach high- and low-side quick disconnects to
the manifold gauge set.
2. Adjust both manifold gauge valves to the
maximum clockwise (closed) position.
3. Adjust both quick disconnect valves to the
maximum counterclockwise (closed) position.
4. Remove A / C charging valve cap (19D702) from
the A / C service port fittings and install quick
disconnects.
5. Adjust both quick disconnect valves to the
maximum clockwise (open) position.
6. Both gauges should show approximately
413-551 kPa (60-80 psi) at 24C (75 F) with
engine not running.
7. If very little or no pressure is indicated, connect a
Refrigerant-R134a cylinder to the manifold gauge
set and adjust the low-pressure manifold gauge
valve to the counterclockwise (open) position.
This opens the system to cylinder pressure.
8. Check all system connections, the A / C
compressor center seal and shaft seal for leaks,
using a good leak detector. Pass the leak
detector along the underside of all points being
checked. Refrigerant is heavier than air and will
show most readily in those locations.
9. When performing leak tests of the A / C
evaporator core (19860) with an electronic leak
detector, test only at the evaporator drain tube
and the evaporator core refrigerant line
connections. Do not attempt to leak test at the
instrument panel registers or inside the
passenger compartment. Airflow from the blower
and/or chemical odors inside the vehicle may
cause false readings. This is especially important
after the vehicle has been in the sun and the
vehicle interior temperatures have risen above
the ambient level.
R-134a Manifold Gauge Set
LOW-PRESSURE HI GH-PRESSURE
GAUGE AND GAUGE AND
PUMP VALVE M3827-C
L e a k De t e c t o r , E l e c t r o n i c
Use Rotunda R-134a Automatic Calibration Halogen
Leak Detector 161-00010 or equivalent.
The electronic leak detector is operated by moving
the control switch to the ON position. The detector
automatically calibrates itself when it is turned on.
Move the probe at approximately 25 mm (1 inch)
per second in the suspected area. When escaping
refrigerant gas is located, the ticking/beeping
signal will increase in ticks/beeps per second. If the
gas is relatively concentrated, the signal will be
increasingly shrill.
Follow the instructions included with the detector to
improve handling and operating techniques.
1995 To wn Ca r , Cr o wn Vi c t o r i a , Gr a n d Marquis Jul y 1994
12 - 00- 47 Cl i ma t e Co n t r o l S y s t e m- S e r v i c e 12 - 00- 47
Ro t un d a R-134a Aut o ma t i c Cal i brat i on Ha l oge n
Leak De t e c t o r
M3 8 5 8 - B
A/ C Evaporator Core a n d / o r A / C
Condenser Core
On - Ve h i c l e Leak Tes t
If an A / C e va por a t or c or e ( 19860) or A / C condenser
cor e ( 197 12 ) i s suspe c t e d of l eaki ng, t he leak must be
veri f i ed pri or t o removi ng t he component f r om t he
vehi cl e. Thi s leak t e st shoul d be per f or med as out l i ned
bel ow. DO NOT rel y sol el y on t he resul t s of an
el ect roni c l eak de t e c t or as chemi cal s ot her t han
R-134a wi ll act i vat e t he leak det ect or .
1. Veri f y t hat t he mani f ol d gauge set is capabl e of
hol di ng vacuum.
a. Connect t he red and blue hoses t oget her
usi ng a 1 / 4-i nch f l are coupl i ng.
Ma n i f o l d Ga uge Se t Leak Test
B L U E H O S E .
\
R E D H O S E
E N D
1/4 F L A R E /
/ C O U P L I N G
VI EW A
c.
d.
e.
f.
M387 4- B
Connect t he gauge set yel l ow hose t o a
known good vacuum pump.
Turn t he vacuum pump on and open bot h
gauge set val ves.
Oper at e t he vacuum pump f or one minute and
cl ose bot h gauge set val ves. The l ow-si de
gauge shoul d i ndi cat e approxi mat el y 101
kPa (30 i n-Hg) of vacuum.
Al l ow t he gauge set , wi t h vacuum appl i ed, t o
set f or at l east 30 mi nut es.
2.
If t he gauge readi ng dr ops duri ng t hat t i me,
t he gauge set hose connect i ons, gauges or
val ves are l eaki ng and shoul d be repai red
bef ore proceedi ng wi t h t he leak t est .
Di scharge t he A / C sy st e m, ref er t o Sy st em
Di schargi ng.
1 9 9 5 To wn Car, Cr o wn Vi c t o r i a , Gr a n d Ma r q ui s Jul y 1 9 9 4
12 - 00- 48 Cl i mat e Cont r ol Sy s t e mSe r v i c e 12 - 00- 48
3. Di sconnect t he suspect A/C evapor at or c o r e or
A / C condenser c o r e f r om t he A / C sy st e m. DO
NOT l eak t est an A / C e va por a t or c o r e wi t h t he
suct i on a c c umul a t o r / d r i e r ( 19C836) a t t a c he d t o
t he c o r e t ubes, ref ri gerant out gassi ng f r o m oil
and desi ccant in t he suct i on a c c umul a t o r / d r i e r
wi ll i ndi cat e a f al se l eak condi t i on.
4. Cl ean t he e va por a t or and / or condenser c or e
t ube f i t t i ngs.
If t he c o r e t ube f i t t i ngs ar e t he f emal e spri ng l ock
desi gn, c he c k t he i nsi de of e a c h f i t t i ng f or sc r a t c he s,
c or r osi on, or debri s f r om det er i or at ed O-ri ngs. If
sc r a t c he s, cor r osi on or debr i s ar e f ound, t he l eak t e st
resul t s may not be a c c ur a t e unl ess t he f i t t i ng i s
pr oper l y cl eaned as f ol l ows.
a. Remove any sur f ace resi due f r om t he i nsi de
of t he f emal e spri ng l ock coupl i ng by
pol i shi ng wi t h 400-gr i t emer y cl ot h (or
equi val ent ). Poli sh t he f emal e sur f ace by
usi ng a t wi st i ng mot i on so t hat any sc r a t c he s
made wi ll not c r o ss t he O-ri ng seal i ng
sur f ace.
b. Per f or m addi t i onal pol i shi ng of sur f ace usi ng
600-gr i t emer y c l ot h or equi val ent .
c. All resi due f r om t he pol i shi ng oper at i on
shoul d be r e move d f r o m t he f i t t i ng by wi pi ng
wi t h a li nt-free c l ot h.
Fe ma l e Co r e Tube Fi t t i n g
POLISH OR SAND IN A
CIRCULAR MOTION ONLY,
ON THE INSIDE DIAMETER
OF THE TUBE IW0A
5. Connect t he a ppr opr i a t e t e st f i t t i ngs f r om Leak
Test Ada pt e r Set D93L- 197 03- B t o t he
e va por a t or or condenser t ube connect i ons.
6. NOTE: The aut omat i c shut -of f val ves on some
gauge set hose s do not open whe n connect ed t o
t he t e st f i t t i ngs. If avai l abl e, use hoses wi t hout
shut -of f val ves. If hose s wi t h shut -of f val ves are
used, ma ke sure t he val ve opens when a t t a c he d
t o t he t e st f i t t i ngs or i nstall an a da pt or whi c h wi ll
a c t i va t e t he val ve. The t e st i s not val i d if t he
shut -of f val ve doe s not ope n.
Connect t he r ed and blue hoses f r om t he mani f ol d
gauge set t o t he t e st f i t t i ngs on t he evapor at or or
condenser c o r e . Connect t he yel l ow hose t o a
known go o d vacuum pump.
7. Open bot h gauge set val ves and st ar t t he vacuum
pump. Turn t he A / C sy st e m bl ower on l ow and
al l ow t he vacuum pump t o oper at e f or a mi ni mum
of 30 mi nut es af t er t he gauge set l ow pr essur e
gauge i ndi cat es 101 kPa ( 30 i n-Hg). The one-half
hour evacuat i on is necessar y t o r emove any
ref ri gerant f r om oil left in t he evapor at or or
condenser c o r e . If t he ref ri gerant i s not
compl et el y r emoved f r om t he oi l , out gassi ng wi ll
oc c ur and degr ade t he vacuum and appear as a
ref ri gerant l eak.
8. If t he l ow pressure gauge readi ng wi ll not dr op t o
101 kPa ( 30 in-Hg) when t he val ves on t he gauge
and mani f ol d set ar e open and t he vacuum pump
i s oper at i ng, cl ose t he gauge set val ves and
obse r ve t he l ow-pressure gauge. If t he pressure
ri ses rapi dl y t o zer o, a l arge leak is i ndi cat ed.
Recheck t he t est bef or e repl aci ng t he evapor at or
or condenser c or e .
9. NOTE: Al wa y s remember t hat a l eaki ng f i t t i ng,
gauge set or hose connect i on wi ll appear as a
l eaki ng evapor at or a n d / o r condenser c or e .
If t he l ow pressure gauge readi ng ri ses 34 or
more kPa ( 10 or more i n-Hg) of vacuum f r om t he
101 kPa ( 30 in-Hg) posi t i on in 10 mi nut es, a l eak
is i ndi cat ed. If a ver y smal l leak is suspe c t e d, wai t
30 mi nut es and obser ve t he vacuum gauge. If a
smal l amount of vacuum is l ost , oper at e t he
vacuum pump wi t h gauge val ves open or an
addi t i onal 30 mi nutes wi t h t he sy st e m bl ower on
l ow t o r emove any remai ni ng ref ri gerant f r om t he
oi l in t he evapor at or or condenser c or e . Then
r e c he c k f or l oss of vacuum as out l i ned. If a very
smal l leak is suspe c t e d, al l ow t he sy st e m t o si t
overni ght wi t h vacuum appl i ed and c he c k f or
vacuum l oss.
10. If t he A / C evapor at or c or e a n d / o r A / C
condenser c or e does l eak, as veri f i ed by t he
a bove pr ocedur e, i nstall a new A / C evapor at or
c or e a n d / o r A / C condenser cor e c or e a s
out l i ned.
A / C C o m p r e s s o r
A / C Ma n i f o l d a n d T u b e L e a k T e s t
1. Ti ght en t he mani f old ret ai ni ng bolt t o 18-23 Nm
(13-17 Ib-f t ).
2. Ad d ref ri gerant t o t he sy st e m if necessar y.
3. Leak t est t he mani f ol d O-ri ng seal s usi ng Rot unda
R-134a Aut omat i c Cal i brat i on Hal ogen Leak
Det ect or 161-R0010 or equi valent .
4. If no l eaks are f ound, t he mani fold O-ri ng seal s
ar e go o d .
5. If a leak i s f ound at t he A / C mani fold and t ube
( 19D7 34) and t he mani f ol d ret ai ni ng bol t i s
t i ght ened t o 18-23 N-m (13-17 Ib-ft), i nstall new
mani f ol d O-ring seal s as out l i ned. Repeat t he l eak
t est .
E x t e r n a l L e a k T e s t
A / C Pressure Test Adapter T94P-19623-E
1. If t he A / C c ompr e ssor ( 197 03) i s on t he vehi cl e,
di schar ge t he A / C sy st e m usi ng t he pr ocedur e
outli ned in SYSTEM DI SCHARGI NG. Remove t he
A / C c ompr e ssor f r o m t he vehi cl e. Obse r ve all
saf et y pr ecaut i ons.
2. Remove t he mani f ol d ret ai ni ng bol t and r emove
t he A / C mani f ol d a nd t ube f r o m t he r ear he a d of
t he A / C c ompr e ssor . Install A / C Pr essur e Test
Adapt er T94P-19623-E on t he rear head of t he
A / C c ompr e ssor usi ng t he exi st i ng mani f ol d
ret ai ni ng bol t .
3. Connect t he hi gh- and l ow-pr essur e li nes of a
mani f ol d gauge set t o t he cor r espondi ng f i t t i ngs
on t he A / C Pr essur e Test Adapt er .
4. At t a c h t he cent er hose of t he mani f ol d gauge set
t o a ref ri gerant cont ai ner st andi ng in an upri ght
posi t i on.
A / C Compr essor Leak Te st
8.
9.
10.
11.
12.
Hand-rotate t he compressor shaf t 10 compl et e
revol ut i ons t o di st ri but e oi l wi t hi n t he A / C
c ompr e ssor .
Open t he l ow-pr essur e ga uge val ve, t he
hi gh-pressure gauge val ve and t he val ve on t he
ref ri gerant cont ai ner t o al l ow t he ref ri gerant
vapor t o f l ow i nto t he A / C c o mpr e sso r .
Usi ng Rot unda R-134a Aut oma t i c Cal i brat i on
Hal ogen Le a k Det ect or 161- R0010 o r equi val ent ,
c he c k f or l eaks at t he c o mpr e sso r shaf t seal and
t he c o mpr e sso r cent er se a l .
If a shaf t seal leak i s f ound, i nst al l a ne w sha f t
seal . Ref er t o Sect i on 12-03C. If an ext er nal l eak
is f ound at t he cent er j oi nt of t he A / C
c ompr e ssor , i nstall a new A / C c o mpr e sso r .
When t he l eak t est i s c ompl e t e d, c l ose t he
mani f ol d gauge val ves (bot h hi gh and l ow) a s wel l
a s t he val ve on t he ref ri gerant cont ai ner.
Sl owl y r e move t he gauge set hose s f r o m t he
pr essur e t e st pl at e. (Al l ow t he ref ri gerant t o
e sc a pe f r om t he A / C c o mpr e sso r . )
Install t he A / C c ompr e ssor on t he vehi cl e.
Leak t e st , e va c ua t e and c ha r ge t he sy st e m a s
out l i ned. Obser ve all saf et y pr ecaut i ons.
A/ C P R E S S U R E T E S T ADAPTER
T94P-19623-E
LOW SI DE QUI CK
DI SCONNECT
176-R0036
M4434-B
12-00-50 Cl i ma t e Co n t r o l S y s t e mS e r v i c e
12 - 00- 50
Ro t a t i n g T o r q u e C h e c k
The rot at i onal t or que of a used A / C c ompr e ssor
shoul d be c he c ke d if e xc e ssi ve c ompr e ssor dr a g is
suspe c t e d.
1. Di schar ge ref ri gerant sy st e m as out l i ned.
Obse r ve all saf et y pr ecaut i ons.
2. Remove t he A / C mani f ol d and t ube assembl y
f r o m t he A / C c ompr e ssor . Use c a r e not t o al l ow
di rt t o ent er t he A / C c ompr e ssor .
3. Wi t h t he A / C cl ut ch ( 2 884) di sengaged, r ot at e
t he c ompr e ssor shaf t and not e t he t or que
requi red t o r ot a t e t he shaf t one compl et e
revol ut i on. Do not measure t he st art i ng t or que.
4. If t he rot at i onal t or que e x c e e d s 9 N*m (7 Ib-ft)
repl ace t he A / C c ompr e ssor .
5. If t he rot at i onal t or que i s l ess t han speci f i ed,
e xc e ssi ve dr a g does not exi st in t he A / C
c ompr e ssor . Install t he A / C mani f ol d and t ube
assembl y and l eak t e st , evacuat e and c ha r ge t he
sy st e m as out l i ned.
6. Check t he sy st e m f or pr oper oper at i on.
Refrigerant System
NOTE: R-12 ref ri gerant and ref ri gerant oil is not
compat i bl e wi t h R-134a ref ri gerant and R-134a
ref ri gerant oi l .
CAUTI ON: Ne v e r mi x t h e t w o r e f r i ge r a n t s o r t h e
o i l s . Do i n g s o ma y c a u s e d a ma g e t o t h e A / C
s y s t e m.
In an ef f ort t o avoi d t he use of chl or of l uor ocar bon
(CFC) ref ri gerant s t hat may harm t he ozone l ayer of
t he a t mosphe r e , For d Mot or Company has i nt roduced
a new ref ri gerant sy st e m t hat requi res t he use of a
non-CFC ba se d ref ri gerant known a s R-134a. Thi s
new t y pe of ref ri gerant has many of t he same
pr oper t i es as R-12 and is si mi lar in f or m and f unct i on.
However, R-134a is a hy dr of l uor ocar bon (HFC)-based
ref ri gerant whi l e R-12 is a CFC-based ref ri gerant .
Because of t he absence of chl ori ne in i t s mol ecul ar
st r uct ur e, R-134a ref ri gerant wi ll not har m t he ozone
layer.
CAUTI ON: Do n o t a d d R-12 r e f r i ge r a n t t o a n A / C
s y s t e m t h a t r e q u i r e s t h e us e o f R- 134a
r e f r i ge r a n t . A l s o , d o n o t a d d R- 134a r e f r i ge r a n t
t o a n A / C s y s t e m t h a t r e q u i r e s t h e u s e o f R-12
r e f r i ge r a n t . T h e s e t w o t y p e s o f r e f r i ge r a n t s h o u l d
n e v e r b e mi x e d . Do i n g s o ma y c a u s e d a ma g e t o
t h e A / C s y s t e m.
Re f r i g e r a n t S y s t e m I d e n t i f i c a t i o n
The ref ri gerant used in t hi s ref ri gerant sy st e m i s
R-134a. R-134a ref ri gerant is t he onl y t y pe of
ref ri gerant t hat can be used in t he A / C sy st e m.
NOTE: R-134a requi res use of Mot or c r a f t YN-12b
ref ri gerant oil or equi val ent meet i ng For d speci f i cat i on
WSH- M1C231- B R-134a. Sy st e ms can be i dent i f i ed
by exami ni ng t he f ol l owi ng ar eas;
Vehi cl e's ref ri gerant c ha r ge t a g i ndi cat es R-134a
servi ce.
The A / C cycl i ng swi t c h ( 19E561) has a yel l ow
base.
An A / C pressure cut -of f swi t c h ( 19D594) has been
added t o t he di schar ge line. Thi s swi t c h i s not in
R-12 sy st e ms.
Hi gh- and l ow-servi ce c ha r ge por t s requi re "qui c k
c onne c t " a da pt e r s t o precl ude use of R-12 servi ce
equi pment .
Non-CFC I d e n t i f i c a t i o n Tag
R-134a
NON-CFC
R~134a
NON-CFC
R-134a
NON-CFC
R-134a
NON-CFC
L9037-A
S p e c i a l S e r v i c e E q u i p me n t
CAUTI ON: Do n o t u s e R-12 Spe c i a l To o l s a n d
E q u i p me n t w h e n s e r v i c i n g a R- 134a s y s t e m.
A l s o , d o n o t us e R- 134a Spe c i a l To o l s a n d
E q u i p me n t wh e n s e r v i c i n g a R-12 s y s t e m. Do i n g
s o ma y c a u s e d a ma g e t o t h e A / C s y s t e m. Re f e r
t o t h e Ro t u n d a E q u i p me n t Ca t a l o g f o r mo r e
i n f o r ma t i o n o n R- 134a Spe c i a l Se r v i c i n g
E q u i pme n t .
equi valent .
equi valent .
Leak Det ect or 161-F0010 or equi val ent .
equi val ent .
Test equi pment must be connect ed t o t he ref ri gerant
sy st e m in or der t o make sy st e m t e st s. If a chargi ng
st at i on is used, f ol l ow t he i nst ruct i ons of t he st at i on
manuf act urer.
Refri gerant R e c o v e r y
CAUTI ON: Use ex t r eme c ar e and obs er v e al l
saf et y and ser vi ce pr ecaut i ons r el at ed t o t he use
of r ef r i ger ant s. Fai l ur e t o d o so c oul d cont r i but e
t o e n v i r o n me n t a l pol l ut i on.
If a Rot unda R-134a A / C Ser vi ce Cent er 07 8- 00850
or equi valent recycl i ng st at i on i s used, t he f ol l owi ng
general pr ocedur es shoul d be obse r ve d a s wel l a s t he
operat i ng i nst ruct i ons pr ovi ded by t he manuf act urer.
1. Connect ref ri gerant r ecycl i ng st at i on hoses t o
vehi cl e A / C ser vi ce po r t s and r e c ove r y st at i on
inlet f i t t i ng.
2. Turn power t o t he r ecy cl i ng st at i on on t o st ar t
r ecover y pr oc e ss. Al l ow r ecycl i ng st at i on t o
pump ref ri gerant f r o m t he sy st e m until t he sy st e m
pressure is r educed t o a vacuum. On some
sy st e ms, t he pump wi ll be shut of f aut omat i cal l y
by a l ow-pr essur e swi t c h in t he el ect ri cal sy st e m.
On ot her uni t s, it may be necessar y t o manually
t urn off t he pump.
3. Once t he recycl i ng st at i on has e va c ua t e d vehi cl e
A / C sy st e m, cl ose t he st at i on inlet val ve (if
equi pped). Then swi t c h of f el ect ri cal power.
4. Al l ow vehi cl e A / C sy st e m t o remai n c l ose d f or
about t wo mi nut es. Obse r ve sy st e m
pr e ssur e / va c uum l evel s as shown on t he gauge.
If pr essur e doe s not ri se, di sconnect r ecycl i ng
st at i on hoses.
5. If sy st e m pr essur e r i ses, repeat St e ps 2 , 3 and 4
until t he vacuum level remai ns st abl e f or t wo
mi nut es.
6. Perf orm requi red ser vi ce oper at i ons. Evacuat e
and r echar ge t he A / C sy st e m.
R e f r i g e r a n t R e c l a i m i n g / R e c o v e r y / R e c y c l i n g
E q u i p m e n t
Ref ri gerant r e c ove r y sy st e ms and r ecycl i ng st at i ons
ar e in use in most aut omot i ve A / C servi ce f aci l i t i es.
Thi s equi pment al l ows t he r ecover y and reuse of
R-134a sy st e m ref ri gerant af t er cont ami nant s and
moi st ure have been r e move d.
For d Mo t o r Compa ny recommends t he use of a
Under wr i t er La bo r a t o r y (U. L. )-approved
r e c o v e r y / r e c y c l i n g devi ce such as Rot unda R-134a
A / C Se r vi c e Cent er 07 8- 00850 or equi val ent (whi ch
meet s SAE St a n d a r d J 1991) duri ng any A / C sy st e m
servi ce a n d r e c ha r ge procedure.
Hoses shoul d have shut -of f devi ces or c he c k val ves
wi t hi n 30. 5 c m (12 i nches) of t he hose end. Thi s wi ll
mi ni mi ze t he i nt roduct i on of non-condensi ble ai r
ent eri ng i nt o t he r ecy cl i ng st at i on. Thi s wi ll al so
mi ni mi ze t he amount of ref ri gerant rel eased when t he
hose(s) a r e di sc onne c t e d.
A / C Ma n i f o l d G a u g e S e t C o n n e c t i o n
If a mani f ol d gauge set is used, connect it a s f ol l ows:
1. Turn bo t h mani f ol d gauge set val ves all t he wa y t o
t he r i ght , t o c l ose t he hi gh- and l ow-pressure
hose s t o t he cent er mani fold and hose. A Rot unda
Qui ck Di sconnect (176-R0036 or 176-R0037) or
equi val ent must be used t o connect t he mani f ol d
ga uge set or chargi ng st at i on t o bot h t he
hi gh-pr essur e and l ow-pressure servi ce gauge
por t .
2. Remove t he A / C chargi ng valve c a p ( 19D7 02)
f r om t he hi gh- and l ow-pressure servi ce gauge
por t va l ve s.
3. Connect t he hi gh- and l ow-pressure hose, t o t he
r e spe c t i ve hi gh- and l ow-pressure servi ce gauge
por t s.
A / C Ev a po r a t o r Cor e Or i f i c e Syst em4. 6L Engi ne
M4625-A
Par t Pa r t
i t em Number Descr i pt i on I t e m Nu mb e r De s c r i p t i o n
Ho usi n g
8 19972 A / C Co mpr e s s o r t o
Co n d e n se r Di sc ha r ge Li ne
2

L o w Pr e ssur e Se r v i c e Por t 9 19712 A / C Co n d e n se r Co r e
3 19E561 A / C Cy c l i n g Swi t c h 10 19703 A / C Co mpr e s s o r
4 19867 Ev a po r a t o r t o Co mpr e s s o r
Suc t i o n Li ne
11 19D644 A / C Co mpr e s s o r Pr e ssur e
Rel i ef Va l ve
5 19D594 A / C Pr e ssur e Cut -Of f Swi t c h 12 19D734 A / C Ma n i f o l d a n d Tube
6 Hi gh Pr e ssur e Se r v i c e Por t 13 19835 Co n d e n se r t o Ev a po r a t o r
14 19C836
Tube
Suc t i o n Ac c u mu l a t o r / Dr i e r
14 19C836
Tube
Suc t i o n Ac c u mu l a t o r / Dr i e r
S y s t e m Di s c h a r g i n g
In or der t o mi ni mi ze t he di schar ge of r ef r i ger ant s i nto
t he a t mosphe r e , For d Mot or Company suppor t s t he
ef f i ci ent use, r e c ove r y and r ecy cl i ng of t he R-134a
used in passenger car, c o mpa c t t r uc k, and li ght t r uck
air condi t i oner s.
Di schar ge t he ref ri gerant f r om t he sy st e m bef ore
repl aci ng any ref ri gerant sy st e m component e xc e pt
t he A / C cycl i ng swi t c h ( 19E561) and t he A / C cl ut ch
( 2884) . Usi ng Rot unda R-134a A / C Servi ce Cent er
07 8- 00850 or equi val ent , f ol l ow manuf act urer' s
i nst ruct i ons t o di schar ge t he A / C sy st e m.
Syst em Evacuati ng
1. Connect mani f ol d gauge set a s out l i ned, (if not
c onne c t e d).
2. Leak-t est t he sy st e m a s out l i ned.
3. Recover t he ref ri gerant f r o m t he ref ri gerant
sy st e m a s out l i ned.
4. Ma ke sure bot h mani f ol d gauge val ves a r e t urned
all t he wa y t o t he ri ght (cl osed).
5. Ma ke sure t he cent er hose connect i on at t he
mani f ol d gauge i s t i ght .
6. Connect mani f ol d gauge set cent er hose t o a
vacuum pump.
7. Open mani f ol d gauge set val ves and st a r t t he
vacuum pump.
8. Evacuat e t he sy st e m wi t h t he vacuum pump until
l ow-pr essur e gauge r eads at l east 99. 4 kPa
( 29. 5 i n-Hg) (vacuum) and a s cl ose t o 101. 1 kPa
( 30 i n-Hg) a s possi bl e. Cont i nue t o ope r a t e t he
vacuum pump f or a mi ni mum of 45 mi nut es.
9. Whe n evacuat i on of sy st e m i s c ompl e t e , cl ose
t he mani f ol d gauge set val ves and t urn of f t he
vacuum pump.
10. Obse r ve l ow pr essur e gauge f or f i ve mi nut es t o
ensure sy st e m vacuum is hel d. If vacuum is hel d,
c ha r ge t he sy st e m. If vacuum is not hel d f or f i ve
mi nut es, l eak-t est t he sy st e m, servi ce t he l eaks
and e va c ua t e t he sy st e m agai n.
Syst em Chargi ng Set-Up
For d Mot or Company r ecommends usi ng a char gi ng
st at i on t o pe r f or m evacuat i on and char gi ng of t he
ref ri gerant sy st e m. Fol l ow t he i nst ruct i ons pr ovi ded
wi t h t he char gi ng st at i on.
If a char gi ng st at i on is not avai l abl e, sy st e m char gi ng
may be a c c ompl i she d usi ng a separ at e vacuum pump,
chargi ng cyl i nder and mani f ol d gauge set . The use of
small c a ns of R-134a is NOT r e c omme nde d.
If t he char gi ng cyl i nder met hod is used, t he cent er port
of t he mani f ol d gauge set shoul d have t wo ref ri gerant
hoses wi t h i nt egral shut -of f val ves built i nt o t he
mani f ol d gauge set . If t he gauge set doe s not have
shut -of f val ves and t wo hoses at t he cent er por t , a t ee
f i t t i ng and t wo hoses shoul d be i nst alled at t he cent er
port . In addi t i on, t he hoses a t t a c he d t o t he cent er port
shoul d have shut -of f val ves at t he ot her e nds of t he
t wo cent er hoses t o prevent ai r f r om ent eri ng t he
hoses whe n not connect ed t o t he vacuum pump and
chargi ng cyl i nder.
Syst em Chargi ng
C h a r g i n g f r o m Sma l l C o n t a i n e r s
The ref ri gerant c ha r ge l evel of A / C sy st e ms is cri t i cal
t o opt i mum per f or mance. Ei t her an uri der-charge or an
ove r -c ha r ge wi l l adver sel y af f ect per f or mance. Usi ng
smal l cans t o c ha r ge t hese sy st e ms is not
r e c omme nde d because t he c ha r ge level cannot be
accur at el y cont r ol l ed. A char gi ng cyl i nder or a
char gi ng st at i on is t he only r ecommended me t hod.
Chargi ng wi t h a chargi ng cyl i nder.
1. CAUTI ON: L i q u i d - c h a r ge i n t o t h e v e h i c l e
s u c t i o n a c c u mu l a t o r / d r i e r ( 19C836) o n l y . To
p r e v e n t a / c c o mp r e s s o r s l u g g i n g , d o n o t
l i q u i d - c h a r ge i n t o a r e f r i ge r a n t h o s e wh i l e
t h e e n gi n e i s o p e r a t i n g . Su ggi n g c a n d a ma g e
A / C c o mp r e s s o r ( 197 03) .
If t he vehi cl e suct i on (l ow) si de servi ce por t i s
l ocat ed on t he suct i on a c c umul a t or / dr i e r ,
connect t he gauge set center hose t o t he liquid
por t of t he chargi ng cyl i nder. If t he suct i on (l ow)
si de ser vi ce por t is NOT on t he suct i on
a c c umul a t o r / d r i e r (l ocat ed on t he suct i on hose),
connect t he cent er hose t o t he GAS port of t he
char gi ng cyl i nder.
2. When evacuat i ng t he sy st e m wi t h t he vacuum
pump, t he gauge set se c ond center hose shoul d
be connect ed t o t he char gi ng cyl i nder and
opened t o t he gauge set so t hat t he hose wi ll
evacuat e wi t h t he sy st e m.
3. When sy st e m evacuat i on i s compl et e, cl ose t he
cent er hose val ve t o t he vacuum pump and t urn
off t he pump.
4. Open t he chargi ng cyl i nder val ve and t he gauge
set l ow-si de val ve t o al l ow ref ri gerant t o ent er t he
sy st e m.
5. When no more ref ri gerant i s bei ng dr a wn i nto t he
sy st e m, cl ose gauge set hi gh si de val ve and st ar t
t he engi ne and sel ect an A / C f unct i on on t he
cont r ol assembl y. Then move t he heat er bl ower
mot or swi t c h ( 1857 8) t o HI t o al l ow t he remai ni ng
ref ri gerant t o be dr awn i nto t he sy st e m. Cont i nue
t o a dd ref ri gerant until t he speci f i ed wei ght of
ref ri gerant has been added Then cl ose t he
chargi ng cyl i nder val ve and al l ow t he sy st e m t o
pull any remai ni ng ref ri gerant f r om t he hose
When t he suct i on pressure drops t o
approxi mat el y 207 kPa ( 30 psi ), cl ose t he gauge
set center hose val ve.
6. Oper at e t he sy st e m until t he pr essur es st abi l i ze
t o veri f y normal operat i on and sy st e m pr essur es.
7. In hi gh ambi ent t emper at ur es, it may be
necessar y t o ope r a t e a hi gh-vol ume f an
posi t i oned t o bl ow ait t hr ough t he A / C condenser
c or e ( 197 12) and radi at or ( 8005) t o ai d in cool i ng
t he engi ne and prevent i ng excessi ve ref ri gerant
sy st e m pr essur es.
8. When chargi ng is compl et e, c l ose t he val ves at
t he ends of t he l ow and hi gh hose s if not equi pped
wi t h aut omat i c cl osi ng val ves. Then di sconnect
t he mani f ol d gauge set hoses f r o m t he vehi cl e
and i nstall t he A / C chargi ng val ve c a ps
( 19D7 02) on t he ser vi ce gauge por t f i t t i ngs.
Sp r i n g L o c k Co u pl i n g Di s c o n n e c t To o l T 81P - 1962 3- G1
( 3 / 8 i n c h)
Sp r i n g L o c k Co u pl i n g Di s c o n n e c t To o l T 81P - 1962 3- G2
( 1 / 2 i n c h)
Sp r i n g L o c k Co u p l i n g Di s c o n n e c t To o l T 83P - 1962 3- C
( 5 / 8 i n c h)
Sp r i n g L o c k Co u p l i n g Di s c o n n e c t To o l T 85L - 1962 3- A
( 3 / 4 i n c h)
C o u p l i n g Di s c o n n e c t
1. Remove ref ri gerant f r om sy st e m a s out l i ned. Fi t
Spri ng Lo c k Coupl i ng Di sconnect Tool
T81P-19623-G1 ( 3/ 8- i n c h) , T81P-19623-G2
( 1 / 2-i nch), T83P-19623-C (5 / 8-i nch) or
T85L- 19623- A ( 3/ 4- i n c h) t o t he coupl i ng.
2. NOTE: The gar t er spri ng may not rel ease if t he
t ool is c o c ke d whi l e pushi ng it i nt o t he c a ge
openi ng.
Cl ose t ool and push i nt o open si de of c a ge t o
e xpa nd gar t er spri ng and rel ease f emal e f i t t i ng.
3. Af t er gar t er spri ng i s e xpa nde d, pull f i t t i ng apar t .
4. Remove t ool f r om di sconnect ed coupl i ng.
C o u p l i n g C o n n e c t
1. Check t o ensure t hat gar t er spr i ng is in c a ge of
mal e f i t t i ng. If gar t er spri ng i s mi ssi ng, i nstall a
new spri ng by pushi ng it i nt o c a ge openi ng. If
gar t er spri ng is da ma ge d, r emove it f r om c a ge
wi t h a smal l wi r e hook (do not use a sc r e wdr i ve r )
and i nstall new spr i ng.
2. Cl ean all di rt or f orei gn mat eri al f r o m bot h pi eces
of coupl i ng.
3. Lubr i cat e and i nstall new green O-ri ng seal s on
mal e f i t t i ng.
Use only t he speci f i ed green O-ri ng seal s
because t hey ar e made of a speci al mat eri al . The
use of any O-ri ng seal ot her t han t he speci f i ed
green O-ri ng seal may al l ow t he connect i on t o
l eak i nt ermi t t ent l y duri ng vehi cl e oper at i on. Ref er
t o Servi ce Par t s Li st .
4. Lubr i cat e mal e f i t t i ng and green O-ri ng seal s and
i nsi de of f emal e f i t t i ng wi t h cl ean ref ri gerant oi l .
5. Install pl ast i c i ndi cat or ri ng i nto c a ge openi ng if
i ndi cat or ri ng is t o be used.
6. Fi t f emal e f i t t i ng t o male f i t t i ng and push wi t h a
t wi st i ng mot i on until gar t er spri ng snaps over
f l ar ed end of f emal e f i t t i ng.
If pl ast i c i ndi cat or ri ng is used, it wi ll snap out of
c a ge openi ng when coupl i ng is connect ed t o
i ndi cat e engagement .
7. If i ndi cat or ri ng is not used, c he c k coupl i ng
engagement by maki ng sure t he gar t er spri ng is
over f l ar ed end of f emal e f i t t i ng.
S e r v i c e P a r t s L i s t
Spri ng Lock Coupl i ng Servi ce Parts Li st
P a r t N u mb e r De s c r i p t i o n
E 35Y- 19D690- D O- r i n g Se a l Ki t - A / C Spr i n g
L o c k Co upl i n g
( Ki t c o n t a i n s 3 / 8 , 1/ 2 a n d 5 / 8
i n c h c o u pl i n g O- r i n g Se a l s a n d
3 / 8 , 1/ 2 a n d 5 / 8 i n c h
Co upl i n g Ga r t e r Sp r i n gs . )
R e f r i g e r a n t S y s t e m Fi l t e r i n g A f t e r A / C
C o m p r e s s o r R e p l a c e m e n t
Vehi cl es t hat have an i noperat i ve A / C c ompr e ssor
( 197 03) due t o i nternal causes shoul d have t he
ref ri gerant sy st e m cl eaned t o remove any debri s or
cont ami nant s t hat may be present t o prevent damage
t o t he repl acement A / C compr essor .
A f i lt er ki t shoul d be i nstalled in t he ref ri gerant sy st e m
bef or e repl aci ng t he A / C compr essor . The pancake
f i l t er suppl i ed wi t h each ki t shoul d be t emporari l y
i nst al l ed in t he liquid line bet ween t he A / C condenser
c o r e ( 197 12) and t he A / C evapor at or c or e ori f i ce
( 19D990) . The suct i on f i lt er suppl i ed wi t h each ki t
shoul d be permanent l y i nst alled in t he suct i on line
bet ween t he suct i on a c c umul a t or / dr i e r ( 19C836) and
t he A / C compr essor . Install t he repl acement A / C
c ompr e ssor and t he f i l t ers as out li ned in t he f ol l owi ng
pr ocedur e:
Af f e c t e d ki t is F2VY-19E773-C Fi lter Ki t f or sy st e ms
wi t h nylon-li ned suct i on hose.
1. Bef ore removi ng any ref ri gerant sy st e m
component s, di scharge t he sy st e m ref ri gerant
f ol l owi ng t he appr oved recycl i ng met hods.
2. NOTE: Due t o t he i nternal desi gn of t he suct i on
a c c umul a t or / dr i e r , it wi ll be necessary t o dri ll t wo
13 mm ( 1/ 2- i n c h) hol es in t he suct i on
a c c umul a t or / dr i e r cyl i nder t o drai n t he oil f r om
t he suct i on a c c umul a t or / dr i e r .
Remove t he suct i on a c c umul a t or / dr i e r assembl y
and drai n t he oil into a cal i brat ed cont ai ner.
3. Install a new suct i on accumul at or / d r i e r and a dd
new Mot or c r a f t YN-12b ref ri gerant oil or
equi val ent meet i ng For d speci f i cat i on
WSH-M1C231-B t o repl ace t he ol d oi l . The
quant i t y of new oil t o be added is t he amount t o
ma t c h t hat drai ned f r om t he ol d suct i on
a c c umul a t o r / d r i e r plus 60 ml (2 ounces).
12 - 00- 85 Cl i mat e Cont r ol S y s t e mS e r v i c e 12 - 00- 55
4. Install a new A / C e va por a t or c o r e ori f i ce. If t he
A / C e va por a t or cor e or i f i ce is l ocat ed in t he
li qui d line bet ween t he A / C condenser c or e and
t he A / C e va por a t or c o r e ( 19860) , repl ace t he
li qui d line assembl y.
5. Temporari l y i nstall t he pa nc a ke f i l t er in t he li qui d
line be t we e n t he A / C condenser c o r e and t he
A / C e va por a t or c or e or i f i ce. Be sur e t he f i lt er
inlet is t o wa r d t he A / C condenser c o r e .
Connect i ons can be made usi ng Test Ada pt e r Set
D93L- 197 03- B or equi val ent , and f l exi bl e
ref ri gerant hose of 17, 238 kPa ( 2 500 psi ) burst
rat i ng. Indi vi dual f i t t i ngs ar e al so avai l abl e.
6. Remove t he ol d A / C c o mpr e sso r f ol l owi ng t he
ser vi ce manual pr oc e dur e s and drai n t he oil i nt o a
cal i br at ed cont ai ner.
7. Ne w ser vi ce repl acement A / C c o mpr e sso r s ar e
shi pped wi t hout c o mpr e sso r oi l . If t he amount of
oil drai ned f r om t he r e move d A / C c ompr e ssor is
bet ween 85- 142 ml (3-5 ounces), pour t he sa me
amount pl us 30 ml (1 ounce) of cl ean ref ri gerant
oil i nt o t he new A / C c ompr e ssor . If t he amount of
oil drai ned f r om t he ol d A / C c o mpr e sso r is
gr eat er t han 142 ml (5 ounces), pour t he sa me
amount drai ned of cl ean ref ri gerant oil into t he
new A / C c ompr e ssor . If t he amount of ref ri gerant
oil drai ned f r om t he ol d A / C c o mpr e sso r is l ess
t han 85 ml (3 ounces), pour 85 ml ( 3 ounces) of
cl ean ref ri gerant oil i nt o t he new A / C
c ompr e ssor . Use Mo t o r c r a f t YN- 12b Ref ri gerant
Oil or equi val ent meet i ng Fo r d speci f i cat i on
WSH-M1C231-B.
8. NOTE: It wi ll be ne c e ssa r y t o t r ansf er t he
magnet i c A / C cl ut ch ( 2 884) f r om t he ol d A / C
c ompr e ssor t o t he repl acement A / C
c ompr e ssor . Fol l ow t he r e c omme nde d shop
manual pr oc e dur e s.
Install t he new A / C c ompr e ssor , f ol l owi ng shop
manual pr ocedur es. Be sure all mount i ng bol t s
ar e t i ght ened pr oper l y. Che c k t he t ensi on of t he
c ompr e ssor dri ve bel t ( 8620) . Ref er t o Sect i on
03-05.
9. Install t he suct i on f i l t er in t he suct i on hose cl ose
t o t he c ompr e ssor . Suct i on f i l t er sho wn in t he
i l l ust rat i on i s f or nylon-li ned c o r e hose . These
f i l t ers have t wo gr oove s in t he end t ubes t o
a c c o mmo d a t e O-ri ng seal s.
10. On t he f i l t er f or nylon-li ned hose, i nstall O-ri ng
seal s Part No. 19E772, ( t wo on e a c h f i l t er t ube).
11. Remove a l engt h of suct i on hose (cl ose t o t he
c ompr e ssor end) t o a c c o mmo d a t e t he suct i on
f i l t er and i nstall t he f i lt er, usi ng A / C hose cl amps
(Part No. D2AZ- 19B679- A) . Be sure f i l t er i s
c o r r e c t l y ori ent ed f or ref ri gerant sy st e m f l ow.
Che c k t he label on t he f i lt er. The si ze 12 cl amps
must be posi t i oned over t he O-ri ng seal s on t he
end t ube s and t i ght ened t o 6.2 N-m ( 55 Ib-in).
12. Evacuat e and c ha r ge t he sy st e m as out l i ned.
13. Che c k all ref ri gerant sy st e m hoses, lines and t he
posi t i oni ng of t he newl y i nst al l ed f i l t ers t o be sure
t he y do not i nt erf ere wi t h ot her engi ne
c ompa r t me nt component s. Use t i e st r a ps t o
ma ke adj ust ment s (if ne c e ssa r y ).
14. Set t he A / C cont r ol on MAX A / C , hi gh bl ower
and t emper at ur e cont rol at f ul l -col d. St ar t t he
engi ne and let it idle bri ef l y. Ma ke sure t he A / C
sy st e m i s operat i ng properl y.
15. Gradual l y bri ng t he engi ne up t o 1200 r pm by
runni ng it at l ower r pms f or shor t per i ods (f i rst at
800 r pm, t hen at 1000 r pm). Set t he engi ne at
1200 r pm and run it f or an hour wi t h t he A / C
sy st e m oper at i ng.
16. St op t he engi ne.
17. Remove t he ref ri gerant f r om t he sy st e m usi ng a
r e c ove r y machi ne.
18. Al l ow t he engi ne t o cool suf f i ci ent l y t o r emove t he
f i t t i ngs, f l exi bl e hoses and pa nc a ke f i l t er f r om t he
li qui d li ne.
19. Di sc a r d t he pancake fi lter. It can be used only
once.
20. Reconnect t he liquid line ba c k i nt o t he sy st e m.
2 1 . Evacuat e, c ha r ge and l eak t e st t he sy st e m. Ma ke
any necessar y adj ust ment s.
22. Check t he operat i on of t he sy st e m in all cont rol
f unct i on sel ect or lever posi t i ons.
12 - 00- 56 Cl i mat e Cont r ol Sy s t emSer v i c e 12 - 00- 56
Pa n c a ke a n d Suc t i o n Fi l t e r s
VIEW A VI EW B
O-RING
GROOVES
I
I
> FLOW %
USi WTM NVION
I .'" ' '.ir.Mr!:,.
11
jn
SUCTION FILTER FOR NYLON LI NED HOSE
M3879-B
Su c t i o n Accumul at or / Dr i er Replacement
Gu i d e l i n e s
Repl ace t he suct i on a c c umul a t o r / d r i e r ( 19C836) any
ti me a major component of t he ref ri gerant syst em is
r e pl a c e d. A maj or component i ncl udes A / C condenser
c o r e ( 197 12) , A / C c ompr e ssor ( 197 03) , A / C
e va por a t or c o r e ( 19860) or a ref ri gerant ho se / l i n e .
An A / C e va por a t or c o r e ori f i ce ( 19D990) or O-ri ng
seal i s not c onsi de r e d a maj or component but t he A / C
e va por a t or c o r e ori f i ce shoul d be r epl aced whenever
t he A / C c o mpr e sso r is r epl aced.
a c c umul a t or / dr i e r shoul d al so be r epl aced if one of
The suct i on a c c umul a t or / dr i e r is pe r f or a t e d.
at mospher e f or a peri od of t i me longer t han requi red
t o make a minor repai r.
There i s evi dence of moi st ure in t he sy st e m such as
i nternal cor r osi on of met al ref ri gerant li nes, or t he
ref ri gerant oil is t hi ck and dar k.
12 - 00- 57 Cl i ma t e Co n t r o l S y s t e m S e r v i c e 1 2 - 0 0 - 5 /
SERVICE PROCE
NOTE: The c o mpr e sso r oil f r om vehi cl es equi pped
wi t h an FS-10 A / C c ompr e ssor may have a da r k col or
whi l e mai nt ai ni ng a normal oil vi scosi t y. Thi s is normal
f or t hi s A / C c o mpr e sso r because c a r bon f r om t he
A / C c ompr e ssor pi st on ri ngs wi ll di scol or t he oi l .
When repl aci ng t he suct i on a c c umul a t o r / d r i e r , t he
pr ocedur e gi ven here must be f ol l owed t o ensure t ha t
t he t ot al oil c ha r ge in t he sy st e m is c or r e c t af t er t he
new suct i on a c c umul a t o r / d r i e r is i nst al l ed.
1. Drai n t he oil f r o m t he r emoved suct i on
a c c umul a t o r / d r i e r i nto a sui t abl e measuri ng
cont ai ner. It may be necessar y t o drill one or t wo
13 mm (1 / 2-i nch) hol es in t he bot t om of t he ol d
suct i on a c c umul a t o r / d r i e r t o ensure t hat all t he
oil has dr ai ned out .
2. Ad d t he sa me amount of ref ri gerant oil pl us 59 ml
(2 ounces) t o t he new suct i on a c c umul a t o r / d r i e r .
Use only t he oi l speci f i ed f or t he speci f i c vehi cl e
bei ng se r vi c e d (Mot or c r a f t YN-12b or equi val ent
oil cont ai ni ng t he same addi t i ves).
Refrigerant Oil Addi ti on
The A / C c ompr e ssor ( 197 03) uses a speci al
ref ri gerant oil Mo t o r c r a f t YN-12b or equi val ent
meet i ng For d speci f i cat i on WSH-M1C231-B. Thi s oil
cont ai ns speci al addi t i ves requi red f or t he A / C
c ompr e ssor . Use onl y t he speci f i ed t y pe and quant i t y
of ref ri gerant oil in t he A / C c ompr e ssor . If t her e is
surpl us oil in t he sy st e m, t oo much oil wi ll ci rcul at e wi t h
t he ref ri gerant , reduci ng t he cool i ng c a pa c i t y of t he
sy st e m. Too li ttle oi l wi ll result in poor l ubri cat i on of t he
A / C compr essor .
During A/ C Compressor Replacement
1. NOTE: The suct i on accumul at or / d r i e r ( 19C836)
and t he A / C e va por a t or c o r e ori f i ce ( 19D990)
must be r e pl a c e d and a f i l t er ki t i nst al l ed
whenever t he A / C c ompr e ssor is r e pl a c e d.
When rei nst al l i ng t he exi st i ng A / C c ompr e ssor or
i nstalli ng a new A / C c ompr e ssor , r emove as
much oil a s possi bl e. The A / C c o mpr e sso r s,
shaf t shoul d be r ot a t e d about si x t o ei ght
revol ut i ons whi l e pouri ng t he oil f r om t he po r t s.
Thi s ef f ect i vel y empt i es t he A / C c ompr e ssor of
oi l .
2. Obt ai n a cl ean cont ai ner t hat can al so be used a s
a measuri ng devi ce.
3. Pl ace t he A / C cl ut ch ( 2884) assembl y on t he
A / C c ompr e ssor shaf t so t he shaf t can be
r ot a t e d.
4. NOTE: Ser vi ce A / C c ompr e ssor s ar e shi pped
wi t hout c o mpr e sso r oi l .
Rot at e t he shaf t by hand si x t o ei ght revol ut i ons,
col l ect i ng t he oi l in a cl ean measuri ng devi ce.
5. If t he amount of oil drai ned f r om t he r e mo v e d A / C
c o mpr e sso r wa s bet ween 85 and 142 ml (3 and 5
ounces), pour t he same amount plus 30 ml ( 1
ounce) of cl ean Mot or c r a f t ref ri gerant oi l YN- 12b
WSH- M1C231- B i nt o t he new A / C c o mpr e sso r .
6. If t he amount of oil t hat wa s r emoved f r o m t he ol d
A / C c o mpr e sso r is gr eat er t han 142 ml (5
ounces), pour t he same amount drai ned of cl ean
Mot or c r a f t ref ri gerant oil YN-12b or equi val ent
meet i ng For d speci f i cat i on WSH- M1C231- B i nto
t he new A / C c ompr e ssor .
7. If t he amount of ref ri gerant oil t hat wa s r e move d
f r o m t he old A / C c ompr e ssor is l ess t han 85 ml
(3 ounces), pour 85 ml (3 ounces) of cl ean
meet i ng For d speci f i cat i on WSH- M1C231- B i nto
R- 134a Re f r i g e r a n t Oi l
CAUTI ON: Do n o t a d d R~134a r e f r i ge r a n t o i l t o a n
R- 12 s y s t e m. A l s o , d o n o t a d d R-12 r e f r i ge r a n t o i l
YN- 9 t o a n R- 134a s y s t e m. Mi x i n g t h e s e t w o
t y p e s o f r e f r i ge r a n t o i l s ma y c a u s e p o o r l u b r i c a n t
c i r c u l a t i o n r e s u l t i n g i n c o mp o n e n t f a i l ur e a n d
d a ma g e t o t h e A / C s y s t e ms .
The ref ri gerant oil requi red f or R-134a A / C sy st e ms is
a pol yal kal yl ene gl y col (PAG) oil (Mot or c r a f t YN-12b)
WSH- M1C231- B. Thi s t y pe of ref ri gerant oil wa s ma de
speci f i cal l y f or R-134a sy st e ms and is not sui t abl e f or
use in R-12 sy st e ms. Never use an R-134a ref ri gerant
oil in R-12 sy st e ms.
Du r i n g C o m p o n e n t Re p l a c e me n t
Whe n repl aci ng a component of t he ref ri gerant
sy st e m, f ol l ow t he c or r e c t pr ocedur es t o make sur e
t he t ot al oil c ha r ge i s c or r e c t af t er t he new component
is i nst al l ed. Duri ng normal A / C oper at i on, oil i s
ci r cul at ed t hr ough t he sy st e m wi t h t he ref ri gerant and
onl y a smal l amount is ret ai ned in t he A / C
c ompr e ssor . If cert ai n component s of t he sy st e m ar e
r e move d, some of t he ref ri gerant oil wi ll go wi t h t he
component . To mai ntai n t he ori gi nal t ot al oil c ha r ge ,
c ompe nsa t e f or t he oil lost by addi ng oi l t o t he sy st e m
wi t h t he repl acement part .
For t he A / C evapor at or c o r e ( 19860) , add 89 ml (3
ounces) of cl ean ref ri gerant oil t o t he suct i on
a c c umul a t o r / d r i e r inlet t ube whenever t he A / C
evapor at or c or e is r epl aced. Thi s wi ll compensat e f or
t he ref ri gerant oil l ost in t he r epl aced A / C evapor at or
c or e .
For t he A / C condenser c or e ( 197 12) , add 30 ml ( 1
ounce) of cl ean ref ri gerant oil t o t he A / C condenser
c or e or t he suct i on a c c umul a t or / dr i e r if t he A / C
condenser c or e is r epl aced.
When repl aci ng t he suct i on a c c umul a t or / dr i e r in
conj uct i on wi t h anot her component of t he ref ri gerat i on
sy st e m, measure t he amount of oil drai ned f r om t he
r emoved suct i on a c c umul a t or / dr i e r i nt o a sui t abl e
cont ai ner.
Drill t wo 13 mm (1 / 2 i nch) hol es in t he bot t om of t he
suct i on a c c umul a t or / dr i e r t o drai n oi l .
1 9 9 5 To wn Ca r , Cr o wn Vi c t o r i a , G r a n d Ma r q u i s Jul y 1 9 9 4
Ad d t he sa me amount of cl ean Mot or c r a f t YN- 12b
ref ri gerant oil or equi valent meet i ng For d
speci f i cat i on WSH-M1C231-B plus 60 ml (2
ounces).
Ot h e r Re f r i g e r a n t S y s t e m C o m p o n e n t s
Repl acement of hoses, c ompr e ssor val ves, A / C
cycl i ng swi t c h or ot her sy st e m component s doe s not
requi re t he addi t i on of ref ri gerant oi l .
Inspection a n d A s s e m b l y Requirements
NOTE: Any t i me a hose or component connect i on l eak
is o bse r ve d , t he connect or f i t t i ng must be se pa r a t e d,
cl eaned and a new O-ri ng seal i nst al l ed. The O-ri ng
seal s and connect or sur f aces shoul d be l ubri cat ed
wi t h cl ean Mo t o r c r a f t ref ri gerant oil YN-12b or
WSH- M1C231 -B pri or t o assembl y.
O-ri ng seal sur f a c e s must be f r ee of di rt , lint, bur r s and
sc r a t c he s.
All O-ri ng seal s must be l ubri cat ed wi t h cl ean
ref ri gerant oil YN-12b Mot or c r a f t or equi val ent
meet i ng For d speci f i cat i on WSH-M 1C231-B
i mmedi at el y pri or t o i nst al l at i on.
SPECIFICATIONS
Refrigerant System Specifications
Ref er t o Sect i on 12-03A (Manual A/ C- He a t e r
Sy st e m), 12-03B (EATC Sy st e m) f or ref ri gerant
sy st e m capaci t i es and el ect ri cal speci f i cat i ons.
Co u ga r
TA1000B
Ma n i f o l d Re t a i n i n g Bo l t 18- 23 13-17
He a t e r Ho s e Cl a mp s 1. 7-2. 4 15- 21
( Lb- l n )
A / C C o mp r e s s o r Ro t a t i o n a l
To r q u e ( MA X )
9 7
A / C Ho s e Cl a mp s 6. 2 55 ( L b- l n )
Tool Numbe r /
T 81P - 1962 3- G 1
T81P-19623-G1
T 81P - 1962 3- G 2
T81P-19623-G2
T 83P - 1962 3- C
T83P-1S623-C
T 85L - 1962 3- A
T85L-19623-A
T 94P - 1962 3- E
A / C P r e s s u r e Te st A d a p t e r
o
!

i
P-19623-E
D93L - 197 03- B Te st A d a p t e r Se t
ROTUNDA EQUIPMENT
02 1- 00012 Ra d i a t o r / He a t e r Co r e P r e s s u r e Te s t e r
02 1- 00014 Va c uum Te st e r
17 6- 00034 R- 134a Va c uum Pump ( 3. 0 CFM)
07 8- 00850 R- 134a A / C Se r v i c e Ce n t e r
105- 00051 7 3 Di gi t a l Mul t i Me t e r
161- R0010 R- 134a A u t o ma t i c Ca l i b r a t i o n Ha l o ge n
L e a k De t e c t o r
17 6- 00001 Mo b i l e Re c y c l i n g Ce n t e r
17 6- R032 A R- 134a Ma n i f o l d Ga uge Se t
17 6- R0036 R- 134a L o w- Si d e Qu i c k Di s c o n n e c t
17 6- R0037 R- 134a Hi gh- Si d e Qu i c k Di s c o n n e c t
17 6- 00033 R- 134a Va c uum Pump ( 1. 5 CFM)
12 - 03A - 1 Ai r Co n d i t i o n i n g S y s t e mMa n u a l A / C - H e a t e r 12 - 03A- 1
SECTION 12-03A Air Conditioning SystemManual
A/C-Heater
SUBJECT PAGE
VEHICLE AP P L I CATI ON 12 - 03A- 1
DESCRIPTION A ND OPERATI ON
A / C E v a p o r a t o r Co r e Housing 12-03A-6
A / C - H e a t e r System, Manual 12-03A-1
Air Fl ow Cont r ol 12- 03A- 4
Bl ower Mot or Swi t ch Resi st or 12-03A-5
Cl i ma t e C o n t r o l A s s e mb l y 12 - 03A- 4
Defroster, Demi st er and Regi ster Ducts 12-03A-7
El ectri cal System 12-03A-9
Heating System 12-03A-3
Instrument Panel Registers............. 12 - 03A- 5
R-134a Re f r i g e r a n t Syst em 12-03A-1
Refri gerant Syst em 12-03A-16
Rel ays. . . . . 12-03 A-10
Syst em Ai r f l ow Descri pt i on 12-03A-10
Vacuum Cont r ol Mot ors ..12-03A-8
Vent i l at i on Syst em 12-03A-4
El ectri cal Schemat i cs 12-03A-20
I nspect i on and Veri f i cat i on . 12-03A-24
Pi npoi nt Test s 12-03A-25
Sympt om Chart 12-03A-24
A / C Compressor 12-03A-65
A / C Compressor Relief Valve 12-03A-69
A / C Condenser Core 12-03A-59
A / C Cycl i ng Swi t ch 12-03A-56
A / C El ect r oni c Door Act uat or Mot or 12-03A-35
A / C Evaporat or Core 12-03A-39
A / C Evaporat or Core Housi ng 12-03A-36
A / C Evaporat or Core Ori f i ce 12-03A-57
SUBJECT PAGE
A / C Mani f ol d and Tube. . . . 12-03A-68
A / C Pressure Cut -Of f Swi t c h 12-03A-58
A / C Syst em Fi l t eri ng 12-03A-66
A / C Vacuum Reservoi r Tank and
Br acket 12-03A-69
Bl ower Mot or Swi t ch Resi st or 12-03A-42
Cl i mat e Cont r ol Assembl y ...12-03A-34
Doors 12-03A-50
Wi ndshi el d Def r ost er .12-03A-50
Duct s 12-03A-46
Heat er Air Plenum Chamber 12-03A-44
Heat er Bl ower Mot or and Bl ower Mot or Wheel
Assembl y 12-03 A-41
Heat er Bl ower Mot or Wheel ......... 12-03A-42
Heat er Core 12-03A-41
Heater Water Hoses ...12-03A-65
I nst rument Panel 12-03A-35
I nst rument Panel Regi st er Assembl i es 12-03A-43
Ref ri gerant Li nes 12-03A-61
Ref ri gerant Oil Addi t i on 12-03A-31
Relays 12-03A-35
Spri ng Lock Coupl i ng 12-03A-31
Suct i on Ac c umul a t or / Dr i e r 12-03A-55
Vacuum Cont r ol Mot ors .12-03A-53
ADJUSTMENTS
A / C Compressor Dri ve Bel t Tensi on 12-03A-69
Mini-Tube Vacuum Hoses 12-03A-69
VEHICLE APPLICATION
Cr own Vi c t or i a , Grand Mar qui s
R-134a Refri gerant Syst em
Cr own Vi ct or i a and Grand Mar qui s vehi cl es of f er t he
R-134a A / C sy st e m.
The R-134a sy st e m uses a non-chl orof l uorocarbon
(non-CFC) based ref ri gerant R-134a.
R-134a i s a hy dr of l uor ocar bon (HFC) ba se d
ref ri gerant .
R-134a requi res use of Mot or c r a f t YN-12b
ref ri gerant oil or equi val ent meet i ng For d
speci f i cat i on WSH- M1C231 -B.
Do not use R-12 Ser vi ce Tool s and Equi pment when
servi ci ng an R-134a sy st e m.
Never mi x R-12 and R-134a ref ri gerant s or oi l s.
They are not compat i bl e.
A/C-Heat er Syst em, Manual
The manual A/ C- he a t e r sy st e m has t he f ol l owi ng
f eat ures:
Sy st e m has a spl i t -case desi gn, wi t h i nt egral A / C
bl ower.
Cont rol s t he t emper at ur e a nd, duri ng A / C
operat i on, r educes t he rel at i ve humi di t y of air i nsi de
t he vehi cl e.
Cont rol knobs ( 18519) are provi ded t o adj ust t he
desi red t emper at ur e and sy st e m f unct i ons.
12 - 03A - 2 Ai r Co n d i t i o n i n g S y s t e mMa n u a l A / C - H e a t e r 12 - 03A - 2
Del i vers heat ed or cool ed ai r t o mai ntai n t he vehi cl e
i nt eri or t emper at ur e and c omf or t l evel .
A / C bl ower mot or speeds can be adj ust ed f or
desi red ai rf l ow.
Manual t emper at ur e cont rol can be mai nt ai ned in all
cont r ol set t i ngs e xc e pt when sy st e m i s t urned OFF.
In hot weat her, t he sy st e m wi ll cool t he vehi cl e t o a
comf or t abl e l evel .
Cool i ng or heat i ng can t hen be adj ust ed t o mai ntai n
desi red t emper at ur e.
The f unct i on sel ect or knob can be t urned on at any
t i me. The sy st e m wi ll heat vehi cl e t o desi red
t emper at ur e.
Out si de ai r is d r a wn f r om t he c o wl ai r inlet j ust
bel ow t he wi ndshi el d duri ng all sy st e m operat i ons
e x c e pt f or MAX A / C cool i ng (when reci rcul at ed ai r
is used).
12 - 03A - 3 Ai r Condi t i oni ng S y s t e mMa n u a l A/ C- Heat er 12 - 03A- 3
Sy st e m Bl o c k Di a gr a m
VEHICLE
O P E R A T O R
INPUTS
<
TEMPERATURE
CONTROL
POTENTIO-
METER
FEEDBACK
A/C A I R
TEMPERATURE
CONTROL DOOR
E L E C T R I C
A C T U A T O R
A/C AIR TEMPERATURE
CWTRCX. POOH ^
A/C BLOWER
HOTOR ^
A/C BLOWER
MOTOR
RESISTOR
A/C BLOWER
HOTOR ^
P
A/C BLOWER
MOTOR
RESISTOR
~-w
BLOWER
SWITCH
FUN C T I ON
S E L E C T O R
SWITCH
VACUUM
CONTROL
MOTOR
H E A T E R AIR
DAMPER DOOR
VACUUM
CONTROL
MOTOR
WI N DS H I E L D
DEFROSTER
DOOR
O U T P U T S
VACUUM
CONTROL
MOTOR
HEATER AND A/C
AIR INLET DUCT
DOOR ^
ENGINE
S E N S O R S
POWERTRAIN
CONTROL
MODULE
(PCM)
I
A/C
PRES-
SURE
CUT-OFF
SWITCH
A/C
CLUTCH
A/C
COMPRESSOR
A / C
COMPRESSOR
CLUTCH
CONTROL
RELAY
H4682-A
H e a t i n g S y s t e m
In t he manual A/ C- he a t e r sy st e m:
Heat can be a dde d t o sy st e m ai rf l ow in any of t he
f unct i on sel ect or knob posi t i ons, e xc e pt OFF.
Ai r di rect i on t hrough t he sy st e m is det ermi ned by
t he A / C damper door swi t c h posi t i on.
Quant i t y of air f l owi ng t hr ough t he sy st e m is
det ermi ned by t he posi t i on of t he heat er bl ower
mot or swi t c h (18578).
12 - 03A - 4 Ai r Condi t i oni ng Sy s t e mMa n u a l A / C - He a t e r 12 - 03A - 4
DESCRIPTION AND OPERATION ( C o n t i n u e d )
Ve n t i l a t i o n S y s t e m
In t he manual A/ C- he a t e r sy st e m:
Out si de air is dr a wn f r o m t he c owl in all f unct i on
sel ect or knob posi t i ons e xc e pt OFF and MAX A / C .
Vent i lat i on air can be heat ed, but not c ool e d, and
can be obt ai ned by sel ect i ng VENT.
C l i m a t e C o n t r o l A s s e m b l y
The cl i mat e cont r ol assembl y has t hr ee cont rol knobs
( 18519) :
The ai rf l ow cont r ol or f unct i on sel ect or knob, a
f unct i on sel ect or swi t c h cont ai ni ng a vacuum val ve
and el ect ri cal c o n t a c t s f or bl ower mot or and A / C
cl ut ch oper at i on.
The t emper at ur e cont r ol knob, whi c h cont r ol s t he
posi t i on of t he A / C el ect roni c door act uat or mot or
( 19E616) mount ed on heat er ai r plenum chamber
( 1847 1) .
The bl ower mot or cont r ol knob, an el ect ri cal swi t c h
t hat pr ovi des f our spe e d s of bl ower mot or
oper at i on.
Cl i ma t e Co n t r o l Asse mbl y
COOL WARM
M4S77-A
A i r F l o w C o n t r o l
Ai r f l ow cont rol is a c c ompl i she d in t he f ol l owi ng
manner:
Pri mary cont r ol i s t hr ough t he f unct i on sel ect or
knob ( 18519) mount ed on t he A / C damper door
swi t c h ( 19B888) whi c h i s part of t he A / C cont r ol
( 19980) .
The f unct i on sel ect or knob has t he se posi t i ons:
OFF, MAX A / C , NORM A / C , VENT, FLOOR, MIX
and DEFROST.
The A / C damper door swi t c h combi nes a vacuum
sel ect or val ve wi t h an i nt ernal el ect ri cal swi t c h.
The A / C damper door swi t c h di r e c t s sour ce
vacuum t o vari ous vacuum cont r ol mot or s
( 18A318) . Ref er t o t he Vacuum Cont rol Di agr am,
Sy st e m Ai rf l ow Sc he ma t i c and Vacuum Cont rol
Di agr am.
Two i nternal si ngl e-pol e el ect ri cal swi t ches ar e al so
cont r ol l ed by t he A / C damper door swi t c h. The
combi nat i on of t hese el ect ri cal swi t c he s cont r ol s
t he el ect ri cal suppl y t o t he A / C cl ut ch ( 2884) and
heat er bl ower mot or swi t c h ( 18578) .
The posi t i on of t he f unct i on sel ect or knob
det ermi nes t he manner in whi ch t he sy st e m wi ll
oper at e.
Each posi t i on of t he sel ect or knob is det ent ed f or
posi t i ve engagement .
T e mp e r a t u r e C o n t r o l
The t emper at ur e cont rol oper at es in t he f ol l owi ng
manner:
Temperat ure cont rol of t he manual A/ C- he a t e r
sy st e m is det ermi ned by t he posi t i on of t he
t emper at ur e cont r ol knob (bet ween COOL and
WARM) on t he A / C cont r ol .
Thi s cont rol knob is at t ached t o t he shaf t of a
pot ent i omet er mount ed in t he A / C cont r ol . Thi s
pot ent i omet er is el ect roni cal l y connect ed t o t he
A / C el ect roni c door act uat or mot or ( 19E616) t hat
ope r a t e s t he A / C air t emperat ure cont rol door.
The A / C el ect roni c door act uat or mot or cont ai ns a
reversi bl e el ect ri c mot or, anot her pot ent i omet er and
a pri nt ed ci rcui t boa r d. The wi per of t he
pot ent i omet er is connect ed t o t he act uat or out put
shaf t and moves wi t h t he out put shaf t t o i ndi cat e t he
posi t i on of t he A / C ai r t emper at ur e cont rol door.
Ba t t e r y vol t age is appl i ed t o t he ends of each
pot ent i omet er. The vol t age avai l abl e at e a c h wi per
i ndi cat es t he posi t i on of t he pot ent i omet er. The
pri nt ed ci rcui t boa r d dri ves t he act uat or in
whi chever di rect i on is necessary t o make t he
act uat or wi per vol t age agree wi t h t he cont rol wi per
vol t age.
Sy st e m uses a reheat met hod t o provi de condi t i oned
ai r t o t he passenger compar t ment .
All ai rf l ow f r om t he bl ower mot or ( 18527 ) passes
t hr ough t he A / C evapor at or c or e housi ng
( 19A559) , whe r e it can be cool ed and dehumi di f i ed.
Temperat ure is t hen regul at ed by reheat i ng a
port i on of t he cool ed dr y air and blendi ng it wi t h t he
remai ni ng cool ai r t o t he desi red t emperat ure.
Temperat ure blendi ng is vari ed by t he A / C ai r
t emper at ur e cont r ol door, whi ch regul at es t he
amount of cool ed air t hat f l ows t hrough a n d / o r
around t he heat er c or e ( 18476) , whe r e it is t hen
mi xed and di r ect ed into t he di st ri but i on heat er air
plenum chamber ( 1847 1) .
Ai r is fi nally di r ect ed t o t he heat er out let f l oor duct
( 18C433) , demi st er nozzle and duct ( 18D453) or
t he i nst rument panel A / C regi st ers ( 19893) ,
accor di ng t o t he f unct i on sel ect or posi t i on.
12 - 03A - 5 Ai r Conditioning SystemManual A/C-Heater 12-03A-5
Blower Motor Control
On t he manual sy st e m, bl ower mot or oper at i on is
cont rol l ed by t he heat er bl ower mot or swi t c h whi c h i s
par t of t he A / C c o n t r o l .
The heat er bl ower mot or swi t c h pr ovi de s f our
manual l y-sel ect ed bl ower spe e d s and may be
ope r a t e d in any posi t i on t o se l e c t t he desi r ed
amount of ai rf l ow.
The heat er bl ower mot or swi t c h and t he heat er
bl ower mot or swi t c h resi st or ( 18591) assembl y are
el ect ri cal l y l oc a t e d in t he gr ound ci rcui t of t he
bl ower mot or.
Vacuum Hoses
A vacuum hose har ness ( 19C82 7 ) , whi c h i s a t t a c he d
t o t he back of t he A / C damper d o o r swi t c h i s
c onst r uc t e d of a pol y vi nyl chl or i de (PVC) mat eri al and
di r ect s vacuum t o t hr e e vacuum c ont r ol mot or
oper at ed door s in t he manual sy st e m:
A heat er ai r damper door.
A wi ndshi el d def r ost er door.
A heat er and A / C ai r inlet duc t d o o r
The speed cont r ol vacuum r eser voi r ( 9E7 99) is used
t o st or e engi ne pr oduc e d vacuum needed t o ope r a t e
t he vacuum cont r ol mot or s.
It i s l ocat ed on t he LH wheel housi ng.
An A / C vacuum c he c k val ve ( 19A563) pr event s
accumul at ed vacuum f r om ret urni ng t o t he engi ne.
The vacuum hose s shoul d never be pi nched of f
duri ng di agnosi s.
Blower Motor Swi t ch Resi stor
The heat er bl ower mot or swi t c h r esi st or ( 18591)
assembl y oper at es in t he f ol l owi ng manner:
The assembl y i s l ocat ed in t he engi ne c ompa r t me nt
on t he A / C e va por a t or c or e housi ng ( 19A559) .
Thr ee resi st ance el ement s are mount ed on t he
resi st or boar d t o pr ovi de f our A / C bl ower mot or
spe e ds.
Dependi ng on t he heat er bl ower mot or swi t c h
posi t i on, seri es r esi st ance is a d d e d or by pa sse d in
t he A / C bl ower mot or ground ci rcui t t o de c r e a se or
i ncrease A / C bl ower mot or spe e d .
An overheat i ng pr ot ect i ve devi ce (t her mal l i mi t er)
has been a dde d t o prevent heat d a ma ge t o t he A / C
evapor at or c o r e housi ng.
Overheat i ng of t he resi st or coi l s can occur when t he
sy st e m ai rf l ow i s st oppe d or r e duc e d a s a resul t of
t he A / C bl ower wheel ( 19834) becomi ng l oc ke d
and / o r i s unable t o t urn f reel y.
Do not subst i t ut e t he t hermal l i mi t ed resi st or wi t h a
heat er bl ower mot or swi t c h r esi st or whi c h doe s not
i nclude t he t hermal limiter devi ce
He a t e r Bl o we r Mo t o r Swi t c h Re si st or Asse mbl y
HEATER BLOWER
MOTOR THERMAL
Blower Motor Thermal Limiter
The t her mal li mi t er, used in t he heat er bl ower mot or
swi t c h r esi st or , pe r f or ms t he f ol l owi ng f unct i ons:
Ser ves a s a t e mpe r a t ur e pr ot ect i ng f use.
Is l ocat ed a pr edet er mi ned di st ance a wa y f r om t he
resi st or coi l s and in seri es wi t h t he coi l ci rcui t .
e Will open t he r esi st or coi l ci rcui t when t emper at ur e
of t he t her mal li mi t er r e a c he s 121 C ( 2 50 F)
i nt errupt i ng bl owe r mot or operat i on in all speeds
e x c e pt HI.
Spri ng c o n t a c t s se pa r a t e when t he wa x sof t ens,
openi ng t he heat er bl ower mot or swi t c h resi st or
ci rcui t .
Repl ace ent i re heat er bl ower mot or swi t c h r esi st or
because spr i ng c o n t a c t s cannot be cl osed agai n.
Inst rument Panel Regi sters
The A / C regi st er ( 19893) assembl i es cont ai n t he
f ol l owi ng f eat ur es:
Ret ai ni ng t a bs t ha t l ock t he assembl i es into t he A / C
regi st er housi ngs of t he i nst rument t r i m panel s.
Hori zont al panel s swi vel and di rect t he outlet ai r up
or d o wn whi l e t he l ouvers permi t si de-t o-si de ai r
di st ri but i on.
The t humbwheel at t he LH si de of t he A / C regi st er
cont r ol s t he damper door t o al l ow full vol ume of ai r
or posi t i ve shut -of f .
If t he t humbwheel be c ome s di sengaged f r om t he
da mpe r door act uat i ng a r m, it can be qui ckl y
re-engaged by cycl i ng t he t humbwheel ei t her full up
or full d o wn .
The act uat i ng a r m is ramped al ong e a c h si de so
t hat t he t humbwheel t ang wi ll ri de up t he ramp and
snap i nto t he sl ot in t he a r m.
12- 03A - 6 Ai r Co n d i t i o n i n g S y s t e mMa n u a l A / C- He a t e r 12 - 03A - 6
i n st r ume n t Panel Re gi st e r
RAMP
M3776-C
The A / C evaporat or cor e ( 19860) .
The heater bl ower motor swi t ch resi stor ( 18591) .
The bl ower mot or ( 18527 ) .
The heat er ai r plenum chamber ( 1847 1) i s l ocat ed on
t he passenger si de of t he da sh panel under t he
i nst rument panel ( 04320) . Sy st e m ai r pa sse s t hr ough
t he da sh panel f r om t he A / C evapor at or c or e housi ng
t o t he heat er ai r plenum chamber. The heat er ai r
plenum chamber is responsi bl e f or t he di st ri but i on of
sy st e m ai r wi t hi n t he passenger compar t ment . It
cont ai ns t he f ol l owi ng component s:
The heat er c or e ( 1847 6) .
The A / C ai r t emper at ur e cont rol door.
The heat er air damper door.
The wi ndshi el d def r ost er door.
Two vacuum cont rol mot or s ( 18A318) .
A / C E v a p o r a t o r C o r e H o u s i n g
The A / C evapor at or c or e housi ng ( 19A559) is l ocat ed
on t he engi ne si de of t he dash panel . It cont ai ns t he
f ol l owi ng component s:
12 - 03A - 7 Ai r Condi t i oni ng S y s t e mMa n u a l A/ C- He a t e r
A / C Ev a po r a t o r Cor e Ho usi n g
H4S83-A
Pa r t
Pa r t
I t e m Nu mb e r Descr i pt i on I t e m Numbe r De s c r i p t i o n
1 18527 He a t e r Bl o we r Mo t o r
5 19C590
A / C Re c i r c ul a t i n g Ai r Duct
2 19A559 A / C E v a po r a t o r Co r e
6 1847 1
He a t e r Ai r Pl e num Cha mbe r
Ho usi n g 7 18591
He a t e r Bl o we r Mo t o r Swi t c h
3 Dash Panel
Re si st o r
4 19C92 8 A / C Re c i r c ul a t i n g Ai r Duct TM4683A
Sc r e e n
De f r o s t e r , De m i s t e r a n d R e g i s t e r Du c t s
The def r ost er , demi st er and regi st er d uc t s c a r r y
cl i mat e cont r ol ai r f r om t he heat er ai r plenum chamber
( 1847 1) t o t he vari ous i nst rument panel out l et s.
12 - 03A - 8 Ai r Co n d i t i o n i n g S y s t e mMa n u a l A / C- He a t e r 12 - 03A - 8
De f r o st e r , De mi st e r a n d Re gi st e r Duc t
M4684-A
Pa r t
1 18C515 Wi n d o w De f o gge r Nozzl e
2 19E630 A / C Si de Wi n d o w De mi st e r and Ho se , LH
3 19B680 A / C Ev a po r a t o r Re gi st e r Duc t , LH
4 18D453 De mi st e r Nozzl e a nd Duc t
5 19B680 A / C Ev a po r a t o r Re gi st e r Duc t , RH
6 0432 0 I nst r ume nt Panel
7 19E630 A / C Si d e Wi n d o w De mi st e r a nd Ho se , RH
TM4684A
V a c u u m C o n t r o l Mo t o r s
The vacuum cont r ol mot or s ( 18A318) ar e l ocat ed on
t he heat er ai r pl enum chamber ( 1847 1) and di rect
sy st e m ai rf l ow t o t he di f f erent out l et s.
12 - 03A - 9 Ai r Condi t i oni ng S y s t e mMa n u a l A / C - H e a t e r 12 - 03A - 9
Va c uum Co n t r o l Mo t o r s
M4685-A
Pa r t
1 1847 1 He a t e r Ai r Pl enum Cha mbe r
2 19C590 A / C Re c i r c ul a t i n g Ai r Duct
3 18A318 He a t e r a n d A / C Ai r I nl et Duc t Do o r Va c uum Co n t r o l Motor
4 18A318 He a t e r Ai r Da mpe r Do o r Va c uum Co n t r o l Mo t o r
5 19C827 Va c uum Ho se Ha r n e ss
6 18A318 Wi n d shi e l d De f r o s t e r Do o r Va c uum Co n t r o l Mo t o r
TM4685A
Va c u u m Ho s e s
Mi ni -t ube vacuum hoses are used in t he va c uum hose
harness ( 19C827 ) .
They provi de gr eat er f l exi bi l i t y wi t h l ess t endency t o
col l apse and ar e l ess suscept i bl e t o pi nchi ng.
Do not pi nch t he mi ni -tube vacuum hoses duri ng
di agnosi s.
Ser vi ce i s easi l y per f or med usi ng a shor t pi ece of
st a nda r d 3 mm ( 1 / 8-i nch) ID vacuum hose and
i nsert i ng t he cut ends of t he mi ni -tube i nt o t he ends
of t he st a nda r d 3 mm (1 / 8-i nch) ID vacuum hose.
Ref er t o Adj ust ment s, Mini-Tube Vacuum Hose s.
E l e c t r i c a l S y s t e m
The manual A/ C- he a t e r el ect ri cal sy st e m c onsi st s of
t he f ol l owi ng component s:
Bl ower mot or ( 18527 ) .
Bl ower spe e d heat er bl ower mot or swi t c h ( 1857 8) .
A / C da mpe r door swi t c h ( 19B888) .
A / C el ect roni c door act uat or mot or (19E616).
Heat er bl ower mot or swi t c h resi st or ( 18591) wi t h a
t hermal limiter.
A / C cycl i ng swi t c h ( 19E561) .
A / C cl ut ch (2884).
A / C c ompr e ssor cl ut ch cont r ol rel ay (19D572).
Power t r ai n cont rol modul e (PCM)(12A650).
Fuses and wi ri ng t o compl et e t he ci rcui t .
The bl ower mot or is i nst alled in t he A / C evapor at or
cor e housi ng ( 19A559) .
The heat er bl ower mot or swi t c h:
Is mount ed on t he A / C cont rol ( 19980) assembl y.
Wi t h t he heat er bl ower mot or swi t c h resi st or,
al l ows t he sel ect i on of f our A / C bl ower mot or
speeds.
The heat er bl ower mot or swi t c h resi st or:
Is i nst alled in t he A / C evapor at or cor e housi ng.
Cont ai ns t hr ee resi st ance coi l s and a t hermal limiter
whi ch is used a s a t emper at ur e prot ect i ng f use.
Re l a y s
The manual A/ C- heat er el ect ri cal sy st e m uses a rel ay
and t wo pressure sensi t i ve swi t c he s t o control syst em
functi ons. These component s are:
The A / C compressor cl utch control rel ay
( 19D572) .
The A / C pressure cut -of f swi t ch ( 19D594) .
The A / C cycl i ng swi t c h ( 19E561) .
A / C Co mp r e s s o r Cl ut c h Co n t r o l Rel ay
The A / C c ompr e ssor cl ut ch control rel ay cont r ol s
A / C cl ut ch operat i on ba se d on i nf ormat i on r ecei ved
f rom t he power t r ai n cont rol modul e ( PCM) ( 12A650) .
The A / C c ompr e ssor cl ut ch cont rol rel ay de a c t i va t e s
t he A / C cl ut ch when c omma nde d t o do so by the
power t r ai n cont rol modul e. The A / C cl ut ch coul d be
de a c t i va t e d in t hi s manner under t he f ol l owi ng
condi t i ons:
/ C- He a t e r 12 - 03A - 10
Engi ne st art -up.
Wi de open t hr ot t l e (WOT).
Duri ng l ow engi ne idle condi t i ons.
Excessi vel y hi gh engi ne t emper at ur es.
The A / C c ompr e ssor cl ut ch cont rol rel ay is a normal l y
c l ose d rel ay connect ed in t he A / C cl ut ch ci rcui t . When
t he rel ay is energi zed by t he power t r ai n cont rol
modul e, it st ops A / C cl ut ch oper at i on.
S y s t e m A i r f l o w De s c r i p t i o n
The f ol l owi ng i l l ust rat i ons cont ai n sy st e m vacuum
sc he ma t i c s and vacuum mot or c ha r t s whi c h show
vacuum rout i ngs and ai rf l ow when t he cont r ol s ar e set
at t hei r vari ous posi t i ons.
-^MH A L ; j >7t e ^ Ma n u a l A / C - H e a t e r 12 - 03 A - 1 1
YELLOW
M4686-A
I t e m Nu mb e r De s c r i p t i o n I t e m
Par t
1 18591 He a t e r Bl o we r Mo t o r Swi t c h 7 18476 He a t e r Co r e
Re si st o r
8

A / C Ai r Te mpe r a t ur e Co n t r o l
2 19860 A / C Evaporator Co r e
Door (Pa r t of 18471)
3 18627 He a t e r Bl o we r Mo t o r 9 18A361 He a t e r Ai r Da mpe r Do o r
4 So ur c e Vacuum
10 18A318 He a t e r Ai r Da mpe r Do o r
5 18731 He a t e r a nd A / C Ai r i nl et Duct
Va c uum Co n t r o l Mo t o r
Door 11 18A318 Wi n d shi e l d De f r o st e r Do o r
6 18A318 He a t e r a n d A / C Ai r I nl et Duct
Va c uum Co n t r o l Mo t o r
Door Va c uum Co n t r o l Mo t o r 12 18A478 Wi n d shi e l d De f r o st e r Do o r
( Co n t i n u e d ) TM4686A
12 - 03A - 12 Ai r Co n d i t i o n i n g S y s t e mMa n u a l A / C - He a t e r 12 - 03A - 12
VACUUM CONT ROL CHART
FUN C T I ON S E L E CT OR K N OB P OSI TI ON
FUNCT I ON M A X A / C
NORM
A / C VE NT OFF FL OOR MI X DE FROS T
HOSE
COL OR
He a t e r a n d A / C Ai r I nl et Duc t
Do o r
V NV NV V NV NV NV Wh i t e
He a t e r Ai r Da mp e r Do o r V V V NV NV NV NV Bl ue
Wi n d s h i e l d V V V V V NV NV Re d
De f r o s t e r Do o r V V V V V V NV Ye l l o w
A / C Bl o we r Mo t o r On On On Of f On On On
V = Va c u u m, NV = No Va c u u m
DESCRIPTION AND OPERATION ( C o n t i n y e d )
Sy st e m Ai r f l o w Sc he ma t i c VENT, FLOOR, MIX, DEFROST
(COOL) (WARM)
FAN TEMP FUNCTION
M4687-A
12 - 03A - 14 Ai r Condi t i oni ng Sy s t emManual A/ C- Heat er 12 - 03A - 14
Syst em Ai r f l o w Sc he ma t i c OFF, MA X A / C , NORM A / C
O U T S I DE
A I R
VENT POSITION (COOL)
O U T S I DE
AI R
FLOOR POSITION (WARM)
D E F R O S T DE F R O S T
O U T S I DE
AIR
OUTSI DE
AI R
FLOOR
MIX POSITION ( WARM) DEFROST POSITION (WARM)
Pa r t
1

A / C Ai r Te mpe r a t ur e Co n t r o l
Do o r ( Pa r t of 1847 1)
2 19860 A / C Ev a po r a t o r Co r e
3 18527 Bl o we r Mo t o r
M4SS8-A
Pa r t
4 19834 A / C Bl o we r Whe e l
5 18731 He a t e r a nd A / C Ai r I nl et Duc t
Door
6 18476 He a t e r Co r e
( Co n t i n ue d )
I t e m
Pa r t
7 18A361 He a t e r Ai r Da mpe r Door
I t e m
Pa r t
8 18A47 8 Wi n d shi e l d De f r o st e r Door
OFF
When t he f unct i on se l e c t or knob ( 18519) is in t he OFF
posi t i on:
The heat er and A / C ai r inlet duct door i s at full
vacuum. As a resul t , out si de ai r is c l ose d of f .
The wi ndshi el d def r ost er door i s at full vacuum and
t he heat er air damper door i s at no va c uum, cl osi ng
off t he pa ssa ge s t o t he demi st er nozzl e and duct
( 18D453) .
The bl ower mot or ( 1852 7 ) and A / C c ompr e ssor
( 197 03) are off.
MAX A / C
When t he f unct i on sel ect or knob is in t he MAX A / C
posi t i on:
The heat er and A / C ai r inlet duct door i s at full
vacuum, cl osi ng of f out si de ai r.
The heat er air damper door i s at full va c uum,
bl ocki ng ai rf l ow t o t he heat er out l et f l oor duct
( 18C433) .
The wi ndshi el d def r ost er door is at full va c uum,
cl osi ng off ai rf l ow t o t he demi st er nozzl e and duct .
Temper at ur e cont rol i s usually set f or maxi mum
c o l d , but may be heat ed if desi r ed.
Ai r wi ll be pi cked up at t he reci rc openi ng by t he
bl ower mot or. Wi t h t he t emper at ur e cont r ol set f or
maxi mum c o l d , ai rf l ow a c r o ss t he A / C e va por a t or
c or e ( 19860) wi ll be di ve r t e d past t he heat er c o r e
( 1847 6) and t hen di r e c t e d i nto t he passenger
c ompa r t me nt t hr ough t he i nst rument panel A / C
r egi st er s ( 19893) .
The A / C c ompr e ssor wi ll be oper at i ng whe n MAX
A / C i s sel ect ed.
The bl ower mot or i s on.
NORM A / C
When t he f unct i on sel ect or knob is in t he NORM A / C
posi t on:
The heat er and A / C ai r inlet duc t door is set at no
vacuum, bl ocki ng t he r eci r c pa ssa ge and admi t t i ng
out si de air.
All ot her door posi t i ons a r e t he same a s t ho se
previ ousl y descr i bed f or t he MAX A / C set t i ng.
Temper at ur e set t i ng can be changed manual l y a s
desi r ed.
The A / C c ompr e ssor wi l l be operat i ng whe n NORM
A / C i s se l e c t e d.
The bl ower mot or i s on.
VE NT
When t he f unct i on sel ect or knob is in t he VENT
posi t i on:
The heat er and A / C a i r inlet duct door, wi t h no
vacuum bei ng appl i ed, wi l l bl ock r eci r cul at ed air and
admi t out si de air. From t her e, ai r f l o ws t hrough t he
sy st e m t o t he i nst rument panel A / C r egi st er s.
The heat er air damper door is at full vacuum t o
bl ock ai rf l ow t o t he heat er out l et f l oor duct .
The wi ndshi el d de f r ost e r door is at full vacuum,
cl osi ng off ai rf l ow t o t he demi st er nozzle and duct .
The t emper at ur e set t i ng can be changed manually
t o heat t he air, but air cannot be cool ed bel ow
out si de t emper at ur e.
The bl ower mot or is on.
FLOOR
When t he f unct i on sel ect or knob i s in t he FLOOR
posi t i on:
The heat er and A / C air inlet duct door is in t he no
vacuum posi t i on, bl ocki ng reci rc ai r and admi t t i ng
out si de air.
The heat er ai r damper door is in t he no vacuum
posi t i on, cl osi ng of f ai rf l ow t o t he i nst rument panel
A / C r egi st er s.
The A / C ai r t emper at ur e cont rol door can be
posi t i oned t o mix ai r f l owi ng t hr ough and around t he
heat er c o r e t o achi eve t he desi r ed t emper at ur e
l evel .
The wi ndshi el d def rost er door is in t he full vacuum
posi t i on, bl ocki ng air ci rcul at i on t o t he demi st er
nozzle and duct .
MI X
When t he f unct i on sel ect or knob is in t he MIX posi t i on:
The heat er and A / C a i r inlet duct door is in t he no
vacuum posi t i on.
The heat er air damper door i s in t he no vacuum
posi t i on, bl ocki ng ai rf l ow t o t he i nst rument panel
A / C r egi st er s.
The wi ndshi el d def rost er door is in t he part i al
vacuum posi t i on, al l owi ng ai rf l ow t o bot h heat er
out l et f l oor duct and demi st er nozzle and duct .
DEFROST
When t he f unct i on sel ect or knob is in t he DEFROST
posi t i on:
12 - 03A - 16 Ai r Condi t i oni ng Sy s t e m Ma n u a l A/ C- Heat er 12 - 03 A - 16
The heat er and A / C air inlet duct door is in t he no
vacuum posi t i on, admi t t i ng out si de air.
Bot h t he heat er air damper door and t he wi ndshi el d
damper door are in t he no vacuum posi t i on, so t hat
most of t he i ncomi ng ai r is di r ect ed t o t he demi st er
nozzle and duct . There is al so ai rf l ow t o t he A / C
si de wi ndow demi st er and hose ( 19E630) .
The t emper at ur e cont rol knob set t i ng wi ll det ermi ne
t he amount of air t hat is di r e c t e d t hr ough t he heat er
c or e and t he amount t hat by pa sse s t he heat er c or e .
The A / C c ompr e ssor ope r a t e s t o dehumi di f y t he ai r
and r educe wi ndshi el d f oggi ng.
R e f r i g e r a n t S y s t e m
The A / C ref ri gerant sy st e m i s a A / C evapor at or c or e
ori f i ce ( 19D990) - - c y c l i n g A / C cl ut ch t y pe . The
sy st e m component s are:
A / C c ompr e ssor ( 197 03) .
A / C cl ut ch ( 2884) .
A / C condenser c or e ( 197 12) ,
A / C e va por a t or c o r e ( 19860) .
Suct i on accumul at or / d r i e r ( 19C836) .
And t he necessar y connect i ng ref ri gerant li nes.
Sy st e m operat i on is cont rol l ed by t he f ol l owi ng:
A / C damper door swi t c h ( 19R888)
A / C e va por a t or c o r e ori f i ce.
A / C cycl i ng swi t c h ( 19E561) .
Power t r ai n cont r ol modul e ( PCM) ( 12A650) t hr ough
t he A / C c ompr e ssor cl ut ch cont rol rel ay ( 19D57 2) .
The ref ri gerant sy st e m i nc or por a t e s a 10 cyl i nder
A / C c ompr e ssor cont rol l ed by an A / C cycl i ng swi t c h
connect ed in seri es wi t h t he A / C c l ut c h. The A / C
cycl i ng swi t c h:
Senses pr essur e t o cont r ol A / C c ompr e ssor
oper at i on.
Uses t hi s met hod of A / C c ompr e ssor cont rol t o
st o p A / C c ompr e ssor oper at i on duri ng ambi ent
t emper at ur es bel ow appr oxi mat el y 10C ( 50F)
and al so prevent A / C c ompr e ssor i ci ng duri ng
normal sy st e m oper at i on.
An A / C c ompr e ssor pr essur e relief val ve ( 19D644) is
i nst al l ed in t he hi gh-pressure (di schar ge) A / C
mani f ol d and t ube ( 19D7 34) t o pr ot e c t t he ref ri gerant
sy st e m agai nst excessi vel y hi gh ref ri gerant
pr e ssur e s.
Operat i on of t he A / C cl ut ch is dependent on si gnal s
f r om t he power t r ai n cont r ol modul e. The sy st e m is
pr ogr a mme d t o i nt errupt A / C c ompr e ssor operat i on
when cer t ai n condi t i ons exi st . The A / C cl ut ch can be
shut of f (or kept of f ) f or several se c onds:
At engi ne st art -up.
At hi gh engine speeds.
Duri ng accel erat i on.
When t he engi ne cool ant t emper at ur e e xc e e ds a
predet ermi ned t emper at ur e duri ng l ow engi ne idle
condi t i ons (approxi mat el y 200 r pm bel ow l ow idle
speci f i cat i ons).
An A / C evapor at or core ori f i ce is used t o met er t he
liquid ref ri gerant into t he A / C evapor at or cor e f or A / C
e va por a t or cor e cool i ng.
S e r v i c e A c c e s s G a u g e Por t Va l v e s
NOTE: The A / C servi ce port f i t t i ngs ar e t he t wo-pi ece
desi gn. The t op port i on of t he f i t t i ng is aluminum and is
t hr e a de d t o the bot t om part and seal ed wi t h an O-ri ng
seal . The val ve seal is an i nt egral part of t he aluminum
f i t t i ng pi ece whi ch must be repl aced if t he seal l eaks.
The Schrader t y pe valve cor e used on R-12
ref ri gerant sy st e ms is not used.
The hi gh side f i t t i ng is the l argest and speci al adapt er s
ar e requi red t o a t t a c h servi ce equi pment t o bot h t he
hi gh si de and l ow si de servi ce por t s. Ref er t o Speci al
Ser vi ce Equi pment list in Sect i on 12-00.
Rot unda R~134a Low Si de Qui ck Di sconnect
176-R0036 or equi valent
Rot unda R-134a Hi gh Si de Qui ck Di sconnect
176-R0037 or equi valent .
Al wa y s repl ace t he A / C chargi ng val ve c a ps
( 19D7 02) on t he servi ce a c c e ss gauge port val ves
af t er servi ci ng t he ref ri gerant sy st e m.
NOTE. Whenever an A / C evapor at or c or e is
r e pl a c e d, it is al so necessar y t o r epl ace t he suct i on
a c c umul a t or / dri er
The A / C evapor at or cor e is t he pl a t e / f i n- t y pe wi t h a
unique ref ri gerant f l ow pat h,
A mi xture of refriger ant aod oil enters the bot t om of
t he A / C evaporator core through t he A / C
evapor at or c or e inlet t ube and is rout ed so t hat it
f l ows t hrough t he first 5 5 pl a t e / f i n sect i ons.
The next f i ve pl a t e / f i n sect i ons ar e part i t i oned t o
f or c e t he ref ri gerant t o f l ow t o wa r d t he ot her end of
the A / C evaporator core
The ref ri gerant then continues over t o t he remai ni ng
6.5 pl a t e / f i n secti ons and t hen moves out of t he
A / C evapor at or c or e vi a t he A / C evapor at or c or e
out l et t ube.
Thi s S-pass f l ow pattern accel er at es t he f l ow of t he
ref ri gerant and oil through the A / C evapor at or c or e .
A / C Ev apor at or C o r e Or i f i c e
The A / C evapor at or cor e ori f i ce has t he f ol l owi ng
char act er i st i cs i
A di amet er of 1.46 mm (0. 058 i nch).
It i s l ocat ed in t he evapor at or c or e inlet t ube and has
filter screens l ocated on the inlet and out l et ends of
the tube body.
12 - 03A - 17 Ai r Condi t i oni ng Sy s t e mMa n u a l A/ C- He a t e r 12 - 03A - 17
The A / C e va por a t or cor e ori f i ce assembl y is t he
rest ri ct i on in t he ref ri gerant ci rcui t t hat c r e a t e s t he
pr essur e d r o p necessar y f or cool i ng by met eri ng t he
f l ow of li qui d ref ri gerant into t he A / C evapor at or c or e ,
t her eby reduci ng t he pressure. Operat i on is as
f ol l ows:
A / C e va por a t or cor e t emper at ur e is cont rol l ed by
sensi ng t he pr essur e wi t hi n t he A / C evapor at or
c o r e wi t h t he A / C cycl i ng swi t c h.
The A / C cy cl i ng swi t ch cont r ol s A / C c ompr e ssor
oper at i on a s necessary t o mai ntai n t he A / C
e va por a t or c o r e pressure wi t hi n speci f i ed l i mi t s.
The inlet f i l t er scr een a c t s as a st rai ner f or t he liquid
ref ri gerant f l owi ng t hrough t he A / C evapor at or c o r e
ori f i ce.
O-ri ngs on t he A / C evapor at or c o r e ori f i ce prevent
t he hi gh-pressure liquid ref ri gerant f r om by passi ng
t he A / C e va por a t or cor e ori f i ce.
Adj ust ment or servi ces cannot be made t o t he A / C
e va por a t or c or e ori f i ce assembl y and it must be
r epl aced a s a unit.
The A / C evapor at or cor e ori f i ce shoul d be r epl aced
whenever an A / C compr essor is r epl aced.
S u c t i o n A c c u m u l a t o r / Dr i e r
a c c u mu l a t o r / d r i e r i s n e c e s s a r y a n y t i me a ma j o r
c o mp o n e n t o f t h e r e f r i ge r a n t s y s t e m i s r e p l a c e d .
Fa i l ur e t o r e p l a c e t h e s u c t i o n a c c u mu l a t o r / d r i e r
wi l l e x p o s e t h e r e f r i ge r a n t s y s t e m t o e x c e s s i v e
mo i s t u r e a c c u mu l a t i o n . A ma j o r c o mp o n e n t
i n c l u d e s A / C c o n d e n s e r c o r e , A / C c o mp r e s s o r ,
A / C e v a p o r a t o r c o r e o r a r e f r i ge r a n t h o s e / l i n e .
A n A / C e v a p o r a t o r c o r e o r i f i c e o r O- r i n g i s n o t
c o n s i d e r e d a ma j o r c o mp o n e n t b u t t h e A / C
e v a p o r a t o r c o r e o r i f i c e s h o u l d b e r e p l a c e d
wh e n e v e r t h e A / C c o mp r e s s o r i s r e p l a c e d f o r
l a c k o f p e r f o r ma n c e .
The suct i on a c c umul a t or / dr i e r cont ai ns t he f ol l owi ng
f eat ur es:
The suct i on a c c umul a t or / dr i e r is mount ed on t he f r ont
of t he A / C e va por a t or c or e housi ng ( 19A559) and
a t t a c he s di r ect l y t o t he A / C evapor at or c or e out l et
t ube.
A l ow pr e ssur e ser vi ce a c c e ss gauge por t val ve i s
mount ed on t he si de of t he suct i on a c c umul a t or / dr i e r .
Its pur pose i s t o provi de servi ce a c c e ss t o t he
suct i on si de of t he ref ri gerant sy st e m f or pr essur e
readi ngs a nd sy st e m di agnosi s.
It al so ma y be used f or liquid char gi ng t he sy st e m
whe n r equi r ed.
Upon ent eri ng t he inlet of t he suct i on
a c c umul a t o r / d r i e r , heavi er oil laden ref ri gerant
c o n t a c t s an i nt ernal l y mount ed dome whi c h ser ves
a s an umbr el l a, and dri ps down ont o t he bot t om of
t he cani st er.
A smal l di amet er oil bl eed hol e al l ows t he
a c c umul a t e d heavi er liquid ref ri gerant and oil
mi xt ure t o re-ent er t he compr essor suct i on line at a
cont r ol l ed r a t e .
As t he heavi er li qui d ref ri gerant and oi l mi xt ur e
pa sse s t hr ough t he smal l di amet er li qui d bl eed hol e,
it ha s a se c o n d oppor t uni t y t o va por i ze and
r eci r cul at e t hr ough t he A / C c o mpr e sso r wi t hout
causi ng da ma ge due t o sl uggi ng.
A f i ne mesh scr eened f i l t er f i t s t i ght l y a r ound t he
bo t t o m of t he va por ret urn t ube t o f i l t er out
ref ri gerant sy st e m cont ami nant par t i cl es.
A desi ccant ba g i s mount ed i nsi de t he cani st er t o
a bso r b any moi st ur e whi ch may be in t he r ef r i ger ant
sy st e m.
a c c umul a t o r / d r i e r shoul d al so be r e pl a c e d if one of
The suct i on a c c umul a t o r / d r i e r i s pe r f o r a t e d .
a t mosphe r e f or a peri od of t i me l onger t han requi red
t o ma ke a mi nor repai r.
The r e is evi dence of moi st ure in t he sy st e m suc h a s
i nt ernal cor r osi on of met al ref ri gerant li nes or t he
ref ri gerant oil i s t hi ck and da r k.
Suc t i o n Ac c umul a t o r Dri er
FROM A/ C
EVAPORATOR CORE
LOW-PRESSURE V
SERVI CE ACCESS
GAUGE PORT VALVE
M446t"B
A / C C y c l i n g S w i t c h
The A / C cycl i ng swi t c h is mount ed on a Schr ader
val ve-t ype f i t t i ng on t he e va por a t or t o c ompr e ssor
suct i on line ( 19867 ) near t he suct i on
accumul at or / dri er.
A val ve depressor, l ocat ed i nsi de t he t hr e a de d end
of t he A / C cycl i ng swi t c h, pr e sse s in on t he
Schr ader val ve st e m.
Thi s al l ows t he suct i on pr essur e i nsi de t he suct i on
a c c umul a t or / dr i e r t o cont r ol t he oper at i on of t he
A / C cycl i ng swi t c h.
The el ect ri cal swi t c h c o n t a c t s wi ll ope n when t he
suct i on pressure is bet ween 152-193 kPa (22-28
psi ).
The c ont a c t s wi ll cl ose when t he suct i on pressure
ri ses t o 276- 324 kPa (40-47 psi ).
12 - 03A - 18
Ai r Condi t i oni ng S y s t e mMa n u a l A / C - He a t e r 12 - 03A - 18
Ambi ent t emper at ur e bel ow appr oxi mat el y 7-10 C
( 45- 50F) prevents t he A / C cycl i ng swi t c h
c ont a c t s f r om cl osi ng.
This is due t o t he pressure/ t e mpe r a t ur e
rel at i onshi p of t he ref ri gerant and t he requi rement of
t he sy st e m pressure t o r each 276- 324 kPa (40-47
psi ) t o cl ose t he A / C cycl i ng swi t c h c o n t a c t s.
These c o n t a c t s cont rol t he el ect ri cal ci rcui t t o t he
A / C cl ut ch f i el d coi l ( 2987) .
When t he A / C cycl i ng swi t c h c ont a c t s cl ose, t he
A / C cl ut ch i s energi zed f or A / C c ompr e ssor
oper at i on.
When t he A / C cycl i ng swi t c h c ont a c t s open, t he
A / C cl ut ch is de-energi zed and A / C c ompr e ssor
operat i on st o ps.
The A / C cycl i ng swi t c h wi ll cont rol t he A / C
evapor at or c or e pr essur e at a poi nt whe r e t he
pl a t e / f i n sur f ace t emper at ur e will be mai nt ai ned
sl i ght l y a bove f reezi ng.
Thi s pr event s A / C evapor at or cor e i ci ng and t he
bl oc ka ge of ai rf l ow.
NOTE: Whenever an A / C condenser c or e is r epl aced,
it is al so necessar y t o repl ace t he suct i on
a c c umul a t o r / d r i e r .
The A / C condenser c or e has t he f ol l owi ng
It is an alumi num fin and t ube desi gn heat exchanger
l ocat ed in f ront of t he radi at or ( 8005) .
It c ool s c o mpr e sse d ref ri gerant gas by al l owi ng air
t o pa ss over f i ns and t ubes t o e xt r a c t heat , and
condenses ga s t o liquid ref ri gerant a s it is c ool e d.
The A / C condensor c o r e inlet and out l et
connect i ons ar e t he mal e part of a spri ng l ock
coupl i ng.
A speci al ser vi ce t ool is requi red t o di sconnect t he
ref ri gerant lines f r om t he A / C condenser c o r e .
The A / C c ompr e ssor has t he f ol l owi ng
The FS-10 is a swashpl at e desi gn, 10-cyl i nder
alumi num A / C c ompr e ssor utilizing t he t angent i al
desi gn mount .
Di spl acement of 170 c c ( 10. 4 cubi c i nches).
Lubr i cat ed by a c ha r ge of Mot or c r a f t YN-12 or
equi val ent ref ri gerant oil meet i ng For d speci f i cat i on
WSH- M1C231- B.
The c ompr e ssor mai nshaf t is dri ven by a dri ve belt
( 8620) f r o m t he engi ne cr ankshaf t vi brat i on damper
( 6316) .
A one-pi ece, l i p-t ype seal (repl aceabl e f r o m t he
f r ont of t he A / C c o mpr e sso r ) is used t o seal it at t he
around t he c ompr e ssor shaf t , ope r a t e wi t hi n t he
cyl i nder assembl y. The pi st ons are a c t ua t e d by a
swa shpl a t e t hat is pr essed on t he c ompr e ssor
shaf t .
The swashpl at e changes t he rot at i ng act i on of t he
shaf t t o provi de a reci procat i ng dri vi ng f or c e t o
e a c h of t he f i ve pi st ons. Thi s dri vi ng f o r c e is
appl i ed, t hrough shoes, t o t he mi dpoi nt of each of
t he doubl e end pi st ons.
Reed-t ype di schar ge val ves ar e assembl ed on t he
val ve pl at e.
The val ve pl at e is l ocat ed wi t h t he suct i on reed
at e a c h end of t he A / C compr essor .
The heads are connect ed t o e a c h ot her by gas-t i ght
pa ssa ge wa y s t hrough t he cyl i nder assembl y whi c h
di rect t he ref ri gerant gas t o t he suct i on and
di schar ge por t s l ocat ed in t he rear head.
FS-10 A / C Co mpr e sso r
M4860-A
The spri ng l ock coupl i ng is a ref ri gerant line coupl i ng
held t oget her by a gar t er spri ng i nsi de a ci rcul ar c a ge .
When t he coupl i ng is connect ed t oget her, t he f l ared
end of t he f emal e f i t t i ng sli ps behi nd t he gar t er
spri ng i nsi de t he c a ge of t he male f i t t i ng.
The gart er spri ng and cage t hen prevent t he f l ared
end of t he f emal e f i t t i ng f r om pulling out of t he c a ge .
Two O-ri ngs are used t o seal bet ween t he t wo
hal ves of t he coupl i ng.
These O-ri ngs are green in col or and ar e made of
speci al mat eri al .
Use only t he green O-ri ngs l i st ed in t he For d Mast er
Par t s Cat al og f or t he spri ng l ock coupl i ng.
12 - 03A - 19 Ai r Condi t i oni ng Sy s t e mMa n u a l A/ C- Heat er 12 - 03A - 19
A pl ast i c i ndi cat or ri ng is used on spri ng l ock
coupl i ngs t o i ndi cat e, duri ng vehi cl e assembl y, t hat
t he coupl i ng i s c o n n e c t e d . Once t he coupl i ng is
c onne c t e d, t he i ndi cat or ri ng is no longer necessar y
but will remai n c a pt i ve by t he coupl i ng near t he c a ge
openi ng.
The i ndi cat or ri ng may al so be used duri ng ser vi ce
oper at i ons t o i ndi cat e connect i on of t he coupl i ng.
Af t er t he coupl i ng ha s been cl eaned and new O-ri ng
seal s i nst al l ed and l ubri cat ed wi t h cl ean ref ri gerant
oi l , i nsert t he t a bs of t he i ndi cat or ri ng into t he c a ge
openi ng.
Connect t he coupl i ng t oget her by pushi ng wi t h a
sl i ght t wi st i ng mot i on. Whe n t he coupl i ng i s
c onne c t e d, t he i ndi cat or ri ng wi l l snap out of t he
c a ge openi ng but wi ll remai n c a pt ur e d on or near t he
coupl i ng by t he ref ri gerant line.
An A / C c ompr e ssor pr essur e reli ef val ve has been
i ncor por at ed in t he c ompr e ssor ' s A / C mani f ol d and
t ube:
di sc ha r ge pr e ssur e bui l dups, 3103 kPa ( 450 psi )
and a bove .
Prevent damage t o t he A / C c ompr e ssor and ot her
A / C sy st e m c ompone nt s.
Af t er t he e xc e ssi ve pressure has been rel i eved, t he
val ve cl oses t o prevent t ot al ref ri gerant l oss.
A / C P r e s s u r e C u t - Of f S w i t c h
An A / C pr essur e cut -of f swi t c h i s used on all vehi cl es
t o i nt errupt A / C c ompr e ssor oper at i on in t he event of
hi gh sy st e m di sc ha r ge pr essur es.
S i n g l e
The A / C pr essur e cut -of f swi t c h i s l ocat ed in t he
di schar ge line be t we e n t he A / C c ompr e ssor and A / C
condenser c or e .
It i s sensi t i ve t o di sc ha r ge pr essur e.
The A / C pr essur e cut -of f swi t c h opens t he ci rcui t t o
t he A / C cycl i ng swi t c h if di schar ge pr essur es
e x c e e d 2 7 51- 3068 kPa ( 399- 445 psi ).
12 - 03A - 2 0 Ai r Co n d i t i o n i n g S y s t e mMa n u a l A / C - He a t e r 12 - 03A - 2 0
A/ C- He a t e r Sy s t e mMa n u a l
12 - 03A - 2 1 Ai r Condi t i oni ng S y s t e mMa n u a l A/ C- He a t e r
12 - 03A - 2 1
A/ C- He a t e r Sy st e mMa n ua l (Cont i nued)
FROM A/C
PRESSURE , 198
CUT-OFF I B M H H M H
SWITCH DG/O
DG/O
1 RELAY
CENTER
TO POWERTRAIN
CONTROL
MODULE
(PCM)
A/C
CLUTCH
TO
POWERTRAIN
CONTROL
MODULE (PCM)
POWER
RELAY
TO
VACUUM
DISTRIBUTION
BLACK
A/C-HEATER
CONTROL ASSEMBLY
VACUUM VALVE
NORM A/C
FLOOR
O DEF/FLR
%
O DEFROST
NORM A/C
V E N T
MAX FLOOR
OFF
0 DEF/FLR
\
O DEFROST
RED
YELLOW
FLOOR-
DEFROST
| DOOR
1
VACUUM
MOTOR
BLUE
PANEL
DOOR
VACUUM
MOTOR
DASH PANEL
\ HEATER CORE
\
TO DEFROSTERS \
^
FLOOR-DEFROST DOOR
V-VACUUM
NV- NO VACUUM
PV - PARTIAL VACUUM
WHITE
OUTSIDE-
RECIRCULATE
I DOOR
1
VACUUM
MOTOR
OUTSIDE AIR
OUTSI DE-RECIRCULATE
DOOR
PANEL
DOOR
TEMPERATURE BLEND DOOR
(ELECTRICALLY CONTROLLED)
M4S26-A
12 - 03A - 2 3 Ai r Co n d i t i o n i n g S y s t e mMa n u a l A / C - H e a t e r 12 - 03A - 2 3
A / C C L U T C H C O N T R O L R E L A Y CONNECTOR
M4632-A
Pin
30 198
( DG / O )
85 7 3 ( O / L B ) Re l a y Co i l Ne g a t i v e Te r mi n a l
86 361 ( R) Re l a y Co i l P o s i t i v e Te r mi n a l
87 No t Us e d
87 A 347
( B K / Y )
Te r mi n a l
NOTE: A / C cut -out rel ay connect or part of rel ay box.
A/C ELECTRONIC DOOR
Pi n
Number C i r c u i t Ci r cui t Func t i on
1

No t Us e d
2

No t Us e d
3 437
( Y/ L G )
4 436
( R / L G )
Co n t r o l P o t e n t i o me t e r Gr o un d
5

No t Us e d
Pin
6 600 ( DB) Co n t r o l P o t e n t i o me t e r B +
7 2 98 ( P / O ) A c t u a t o r B +
8 2 08 ( G Y) A c t u a t o r Gr o un d
MANUAL A/C HEATER
FUNCTION SELECTOR SWITCH CONNECTOR
M4844-A
Pin
1 181
( B R / O )
Ho t in RUN
2 3 4 8 ( P ) A / C Cy c l i n g Swi t c h Si gn a l
3 2 49
( DB / L G )
He a t e r Bl o we r Mo t o r Si gn a l
4 2 98 ( P / O ) Ho t in RUN
?
a
n
POTENTIOMETER
M4846-A
Pin
1 436
( R/ L G )
Gr o un d
2 437
( Y/ L G )
3 600 ( DB) Co n t r o l P o t e n t i o me t e r B+
12- 03A - 24 Ai r Condi t i oni ng Sy s t e mMa n u a l A/ C- Heat er 12- 03A- 24
HEATER BLOWER MOTOR SWITCH
M4847-A
1. Verify the vehi cl e owner' s original concern by
operati ng t he manual A/ C- heat er control s t o
dupl i cate t he condi ti on.
mechani cal or el ect ri cal c onc e r ns appl y:
P i n
1 57 ( BK) He a t e r Bl o we r Mo t o r HI ( Gr o un d )
2 7 54
( L G / W)
He a t e r Bl o we r Mo t o r MEDI UM L O
3 7 5 2 ( Y / R ) He a t e r Bl o we r Mo t o r MEDI UM HI
4 2 61
( O / B K )
He a t e r Bl o we r Mo t o r L O
ME CHA NI CA L E L E CT RI CA L
Br o ke n or l e a ki n g v a c u u m
c o n t r o l mo t o r .
Br o ke n A / C d a mp e r d o o r
s wi t c h .
Bl o wn f u s e .
He a t e r b l o we r mo t o r s wi t c h
A / C c o n t r o l i n o pe r a t i v e .
A / C e l e c t r o n i c d o o r
a c t u a t o r mo t o r i n o p e r a t i v e .
3. If t he concern(s) remai n af t er t he i nspect i on,
Sy mpt om Chart .
Use Rot unda 7 3 Di gi t al Mult i Met er 105- 00051 or
equi val ent f or di agnosi s.
MANUAL A / C HEATER SYSTEM
I mpr o pe r Ai r f l o w Fr o m Out l e t s Da ma ge d v a c uum c o n t r o l mo t o r or GO t o Pi npoi nt Te st A.
A / C d a mpe r d o o r s wi t c h .
Va c uum l e a k.
A / C El e c t r o n i c Do o r Ac t u a t o r
Mo t o r I n o pe r a t i v e , I n t e r mi t t e n t or
I mpr o pe r Ope r a t i o n
Ma l f un c t i o n i n g A / C e l e c t r o n i c
d o o r a c t u a t o r mo t o r .
GO t o Pi npoi nt Te st B.
12 - 03A - 2 5
12 - 03A - 2 5
PI NPOI NT TEST A: IMPROPER AIRFLOW FROM OUTLETS
A1 CHECK SYSTEM AI RFLOW
Ye s
No
GO t o A2.
GO t o A13.
NOTE: The ai r ha n d l i n g s y s t e m i s d e s i gn e d t o pr o v i d e
De f r o st whe n no v a c uum i s a ppl i e d t o any of t he t h r e e
v a c uum c o n t r o l mo t o r s . Thi s is d o n e t o pr e v e n t a
si t ua t i o n whe r e De f r o st c a n n o t be o bt a i n e d due t o a
s y s t e m v a c uum l e a k. I n st e a d , a l e a k in t h e v a c uum
c o n t r o l c i r c ui t wi l l se n d al l ai r f l o w t o t he d e f r o s t e r
o ut l e t s. Thi s c o n d i t i o n ma y o c c ur d ur i n g a c c e l e r a t i o n
( sl o w v a c uum l e a k) , ma y e x i st at al l t i me s ( l a r ge
v a c uum l e a k) a n d ma y ha ppe n onl y whe n c e r t a i n
spe c i f i c f un c t i o n s a r e s e l e c t e d , i n d i c a t i n g a l e a k in t ha t
po r t i o n of t he c i r c ui t .
Wi t h e n gi n e r unni ng a nd he a t e r bl o we r mo t o r s wi t c h
on hi gh, c h e c k s y s t e m a i r f l o w in e a c h A / C d a mpe r
d o o r s wi t c h po si t i o n t o d e t e r mi n e whi c h po s i t i o n ( s )
ha ve i n c o r r e c t ai r f l o w. Re f e r t o v a c uum a ppl i c a t i o n
c ha r t f or c o r r e c t s y s t e m a i r f l o w.
Is ai rf l ow f r o m t he de f r ost e r out l et s f or all
posi t i ons?
Ye s
No
GO t o A2.
GO t o A13.
A2 CHECK VACUUM SUPPLY HOSE
Ye s
No E>
A1.
GO t o A3.
Che c k v a c uum suppl y ho s e t o be sur e it i s
c o n n e c t e d t o bo t h t he e ngi ne ma n i f o l d a nd v a c uum
c he c k v a l v e .
Is hose di sc onne c t e d?
Ye s
No E>
A1.
GO t o A3.
A3 LEAK CHECK VACUUM SUPPLY HOSE
Ye s
No
SERVI CE or REPLACE
va c uum h o s e . GO t o A 1.
CONNECT ho se t o
NOTE: The v a c uum h o s e s use d in t h e pa s s e n ge r
c o mpa r t me n t c o n t r o l c i r c ui t a r e c o n s t r u c t e d f r o m PVC
pl a st i c ma t e r i a l . The v a c uum h o s e s use d in t he e n gi n e
c o mpa r t me n t a r e c o n s t r u c t e d of Hy t r e l . Be c a u s e of t h e
ma t e r i a l s u s e d , t he v a c uum h o s e s sho ul d never be
pi n c he d of f d ur i n g d i a gn o si s t o l o c a t e a l e a k. Use
Ro t un d a Va c uum Te st e r 02 1- 00014 or e qui va l e n t t o
l o c a t e v a c uum l e a ks . A w o o d gol f t e e c a n be use d a s a
pl ug whe n i t i s n e c e s s a r y t o pl ug one e nd of a v a c uum
ho se f or l e a k t e s t pu r po s e s .
Di sc o n n e c t v a c uum suppl y ho s e f r o m e ngi ne
ma ni f ol d f i t t i n g a n d f r o m A / C v a c uum c h e c k v a l v e .
Pl ug one e n d of ho s e a n d l eak t e s t wi t h v a c uum
pump.
Does hose l eak?
Ye s
No
SERVI CE or REPLACE
va c uum h o s e . GO t o A 1.
CONNECT ho se t o
12 - 03A - 2 6 Ai r Co n d i t i o n i n g S y s t e mMa n u a l A / C - H e a t e r 12 - 03A - 2 6
PINPOINT TEST A: IMPROPER AIRFLOW FROM OUTLETS (Cont i nued)
TEST STEP
A 4 CHECK VACUUM CHECK VALVE
NOTE: Engi ne must be r unni ng f o r t hi s t e s t .
Che c k A / C v a c uum c h e c k v a l v e f o r c o r r e c t
i n st a l l a t i o n by r e mo v i n g t h e r e se r v o i r h o s e a nd t h e
c o n t r o l a s s e mbl y s o u r c e ho se ( o n e a t a t i me ) f r o m
A / C v a c uum c h e c k v a l v e a nd c h e c k f o r v a c uum.
VACUUM HOSE FROM ENGI NE
CONNECTED TO THI S FITTING
M4631-A
Is vacuum avai lable at bot h check valve por t s?
RESULT
Ye s
No

ACTION TO TAKE
RECONNECT bo t h ho se s.
G O t o A 6.
G O t o A5.
AS I NSPECT VACUUM CHECK VALVE
I n spe c t A / C v a c uum c h e c k v a l v e f o r an o bs t r uc t i o n
a nd / or pr o pe r o pe r a t i o n . Ai r f l o w t hr o ugh t he A / C
v a c uum c h e c k v a l v e sho ul d be in t he d i r e c t i o n
t o wa r d e ngi ne (Engi ne c o n n e c t i o n si d e i s ma r ke d
" VA C" ) .
Is A / C vacuum check val ve pl ugged or
obst r uc t e d?
Ye s
No

c h e c k v a l v e . GO t o A 1 .
GO t o A 6.
12 - 03A - 2 7 Ai r Co n d i t i o n i n g S y s t e m Ma n y a l A / C - H e a t e r 12 - 03A - 2 7
PINPOINT TEST A: IMPROPER AIRFLOW FROM O U T LE T S (Continued)
T E S T STEP RESU LT A CT I O N T O T A KE
A 6 LEAK TEST VACUUM CHECK VALVE
Ye s
No
REPLACE A / C va c uum
REI NSTALL A / C va c uum
c h e c k v a l v e a n d GO t o
A 7 .
Re mo v e A / C v a c uum c h e c k va l ve f r o m v e hi c l e .
Co n n e c t t wo h o s e s a n d a Tee f i t t i n g t o o ut l e t po r t s
of A / C v a c uum c h e c k v a l v e . Co n n e c t Ro t un d a
Va c uum Te st e r 02 1 - 00014 or e qui va l e n t t o Tee
f i t t i n g.
J\^
=
S J j * C ^ ^ ^ 021-00014 (cj=j |
M4633-A
Pump 11. 34 kPa ( 15 i n c he s) va c uum on A / C va c uum
c h e c k va l ve a nd o b s e r v e ga uge r e a d i n g. If v a c uum
l o ss e x c e e d s 3. 37 kP a ( 1 i n c h) per mi nut e , r e mo v e
A / C v a c uum c h e c k v a l v e f r o m t e s t e r a n d pl ug
v a c uum h o s e s . Pul l a v a c uum wi t h t he t e s t e r t o be
c e r t a i n h o s e s a n d t e s t e r a r e not c a us e of l e a k.
M4637-A
If t e s t e r a n d h o s e s d o not l e a k, c h e c k A / C v a c uum
c h e c k v a l v e f o r c a u s e of l e a k.
Does A / C vacuum check val ve l ose more t han 1
i nch vacuum i n one mi nut e?
Ye s
No
REPLACE A / C va c uum
REI NSTALL A / C va c uum
c h e c k v a l v e a n d GO t o
A 7 .
A 7 CHECK VACUUM RESERVOI R
Ye s
No
r e se r vo i r t a n k a nd
br a c ke t . GO t o A 1 .
va c uum r e se r v o i r t a n k
a nd b r a c ke t . GO t o A 8 .
Co n n e c t Va c uum Te st e r t o A / C v a c uum r e se r v o i r
t a n k a n d b r a c ke t a nd l e a k t e s t r e se r vo i r . Re se r v o i r
must ho l d v a c uum.
Does reservoi r l eak?
Ye s
No
r e se r vo i r t a n k a nd
br a c ke t . GO t o A 1 .
va c uum r e se r v o i r t a n k
a nd b r a c ke t . GO t o A 8 .
A 8 CHECK SUPPLY HOSE
Ye s
No
SERVI CE or REPLACE
ho se . G O t o A 1 .
REMOVE pl ug a nd
RECONNECT v a c uum
h o s e s . GO t o A 9.
Di s c o n n e c t a n d pl ug BL ACK suppl y ho se at A / C
c o n t r o l . Di s c o n n e c t o t he r e n d of suppl y h o s e f r o m
A / C v a c uum c h e c k va l ve a n d l e a k t e s t ho se wi t h
v a c uum t e st e r .
Does suppl y hose l eak?
Ye s
No
SERVI CE or REPLACE
ho se . G O t o A 1 .
REMOVE pl ug a nd
RECONNECT v a c uum
h o s e s . GO t o A 9.
A 9 CHECK CONTROL ASSEMBLY
Ye s
No
NOTE f un c t i o n po si t i o n s
whe r e v a c uum d r o ps . GO
t o A 1 0 .
G O t o A 1 1 .
Di s c o n n e c t v a c uum ha r n e ss a t i n-l i ne mul t i pl e
c o n n e c t o r ne a r c o n t r o l . Pl ug al l v a c uum h o s e s
e x c e p t BL ACK. Co n n e c t v a c uum t e s t e r t o BL ACK
h o s e . Se l e c t e a c h f un c t i o n po s i t i o n , a ppl y 11. 34
kP a ( 15 i n c he s ) v a c uum a n d c h e c k f or v a c uum d r o p.
Dr o p sho ul d not e x c e e d 3. 37 kP a ( 1 i nc h) v a c uum
pe r mi nut e f o r a ny f un c t i o n p o s i t i o n .
Does d r o p e xc e e d 3. 37 kPa (1 i nch) vacuum per
mi nut e?
Ye s
No
NOTE f un c t i o n po si t i o n s
whe r e v a c uum d r o ps . GO
t o A 1 0 .
G O t o A 1 1 .
1995 To wn Ca r , Crown Vi c t o r i a , Gr a n d Ma r q u i s Jul y 1994
12 - 03A - 2 8 Ai r Co n d i t i o n i n g Sy s t emManual A/ C- Heat er 12 - 03A - 2 8
PINPOINT TE ST A: IMPROPER AIRFLOW FROM OUTLETS (Cont i nued)
A 1 0 LEAK TEST CONTROL ASSEMBLY
Ye s
No
d o o r s wi t c h . GO t o A 1.
GO t o A 1 2 .
Re mo v e v a c uum ha r n e ss f r o m A / C c o n t r o l . Co n n e c t
v a c uum t e s t e r t o c o n t r o l suppl y po r t a nd pl ug
c o n t r o l po r t t ha t i n d i c a t e d a l e a k in St e p A9. Se l e c t
f un c t i o n po si t i o n s n o t e d in St e p A9 a nd a ppl y 11. 34
kPa ( 15 i n c he s) v a c uum a f t e r se l e c t i n g e a c h
po s i t i o n . Va c uum d r o p sho ul d not e x c e e d 1.68 kPa
( 1 / 2 i nc h) pe r mi nut e .
Does vacuum dr op exceed 1. 68 kPa ( 1/ 2 i nch) i n
one mi nut e?
Ye s
No
d o o r s wi t c h . GO t o A 1.
GO t o A 1 2 .
A11 CHECK SUPPLY HOSE FOR BLOCKAGE
Ye s
No
REPLACE suppl y ho s e .
GO t o A 1 .
G O t o A 1 5 .
Di sc o n n e c t BL ACK suppl y ho se f r o m A / C v a c uum
c h e c k v a l v e . Co n n e c t v a c uum t e s t e r t o suppl y h o s e
a nd o pe r a t e t e s t e r a s if pul l i ng a v a c uum. If t e s t e r
c a n pul l a v a c u u m, ho s e i s pl ugge d . If t e s t e r pul l s a
pa r t i a l v a c uum, ho s e i s r e s t r i c t e d .
Is hose pl ugged or r est r i ct ed?
Ye s
No
REPLACE suppl y ho s e .
GO t o A 1 .
G O t o A 1 5 .
A 12 LEAK TEST JUMPER VACUUM HARNESS
Ye s
No
REPAI R or REPLACE
v a c uum j umpe r ha r n e ss.
GO t o A 1 .
d a mpe r d o o r swi t c h f o r
l e a k. REPAI R or
ha r n e ss. GO t o A1.
e Pl ug one e nd of v a c uum ho s e t ha t i n d i c a t e d a l e a k in
St e p A9. Appl y 11. 34 kPa ( 15 i n c he s) v a c uum t o
h o s e a n d o b s e r v e v a c uum ga uge . Va c uum sho ul d
not d r o p.
Does vacuum d r o p?
Ye s
No
REPAI R or REPLACE
v a c uum j umpe r ha r n e ss.
GO t o A 1 .
d a mpe r d o o r swi t c h f o r
l e a k. REPAI R or
A 1 3 EVALUATE SYSTEM AI R FL OW
Ye s
No
G O t o A 1 4 .
G O t o A 1 5 .
Is t he air f l ow i n St ep A1 c or r e c t f or each f unc t i on
posi t i on?
Ye s
No
G O t o A 1 4 .
G O t o A 1 5 .
A 1 4 I SOLATE LEAKI NG VACUUM CI RCUI T
Ye s >
No
GO t o A 1 9 .
GO t o A 1 5 .
Re pe a t St e p A1 a n d a c c e l e r a t e e ngi ne s p e e d f or
e a c h f un c t i o n po s i t i o n .
Does air f l ow go t o de f r ost dur i ng accel er at i on?
Ye s >
No
GO t o A 1 9 .
GO t o A 1 5 .
A 1 5 REVI EW VEHI CLE HI STORY
Ye s
No
GO t o A 1 8 .
GO t o A 1 6 .
Di d syst em f unc t i on pr oper l y pri or t o t hi s
compl ai nt ?
Ye s
No
GO t o A 1 8 .
GO t o A 1 6 .
A 1 6 CHECK VACUUM HOSES
Ye s
No
REPLACE v a c uum ho s e .
GO t o A 1 .
G O t o A 1 7 .
Ch e c k e a c h v a c uum ho se t o be sur e it i s not
pl ugge d .
Is a hose pl ugged?
Ye s
No
REPLACE v a c uum ho s e .
GO t o A 1 .
G O t o A 1 7 .
A 17 CHECK VACUUM HARNESS
Ye s
No
GO t o A 1 8 .
REPLACE v a c uum
Co mpa r e v a c uum ho s e c o l o r s in e a c h v a c uum
ha r n e ss t o t h e v a c uum s c h e ma t i c .
Do t he hose col or s agree wi t h t he schemat i cs?
Ye s
No
GO t o A 1 8 .
REPLACE v a c uum
A 1 8 CHECK VACUUM CI RCUI T
Ye s
No
UNKI NK or REPLACE
v a c uum ho s e . GO t o A1.
G O t o A 1 9 .
Che c k v a c uum c i r c ui t f or pi n c he d or ki n ke d v a c uum
ho se .
Is hose pi nched or ki nke d?
Ye s
No
UNKI NK or REPLACE
v a c uum ho s e . GO t o A1.
G O t o A 1 9 .
A19 CHECK VACUUM CI RCUI T CONNECTI ONS
Ye s
No
A1.
G Ot o A20.
Ch e c k e a c h v a c uum ho se c o n n e c t i o n t o d e t e r mi n e i f
i t i s pa r t i a l l y c o n n e c t e d or d i s c o n n e c t e d .
Is a vacuum hose c onne c t i on di sc onne c t e d or
part i al l y c onne c t e d?
Ye s
No
A1.
G Ot o A20.
1995 Town Ca r , Cr o wn Vi c t o r i a , Grand Ma r q u i s Jul y 1994
12 - 03A - 2 9 Ai r Condi t i oni ng Sy s t e mMa n u a l A/ C- Heat er 12 - 03A - 2 9
PINPOINT T E ST A: IMPROPER AI RFL OW FROM OUTLETS (Continued)
TE ST STEP RESULT ACTI ON TO T A KE
A 2 0 CHECK VACUUM HOSE
Ye s
No
REPAI R or REPLACE
ho se . GO t o A 1 .
G O t o A 2 1 .
Di sc o n n e c t bo t h e n d s of v a c uum ho se in s u s p e c t e d
c i r c ui t . Pl ug one e n d a n d l e a k t e s t wi t h v a c uum
t e st e r .
Does vacuum hose l eak?
Ye s
No
REPAI R or REPLACE
ho se . GO t o A 1 .
G O t o A 2 1 .
A 2 1 CHECK VACUUM CONTROL MOTOR
Ye s
No
G Ot o A 2 2 .
mo t o r . G Ot o A 1 .
Ch e c k v a c uum c o n t r o l mo t o r f o r l e a ks wi t h v a c uum
t e st e r .
Does vacuum c o n t r o l mot or hol d vacuum?
Ye s
No
G Ot o A 2 2 .
mo t o r . G Ot o A 1 .
A 2 2 CHECK VACUUM CONTROL MOTOR I NSTALLATI ON
Ye s
No
d a ma ge d d a mpe r d o o r .
REPAI R or REPLACE
d a mpe r door . GO t o A 1 .
CONNECT v a c uum
A 1 .
Ch e c k a t t a c hme n t of v a c uum c o n t r o l mo t o r a r m t o
d a mpe r door .
Is vacuum c o n t r o l mot or ar m at t ached t o door or
door crank arm?
Ye s
No
d a ma ge d d a mpe r d o o r .
REPAI R or REPLACE
d a mpe r door . GO t o A 1 .
CONNECT v a c uum
A 1 .
PINPOINT TEST B: A / C ELECTRONIC DOOR ACTUATOR MOTOR INOPERATIVE, INTERMITTENT OR IMPROPER
OPERATION
T E ST STE P RESULT ACTI ON TO TAKE
B1 CHECK SYSTEM FOR TEMPERATURE CONTROL
Ye s
No
G O t o B 2 .
St a r t v e hi c l e a nd run e n gi n e unt i l i t r e a c h e s nor ma l
o pe r a t i n g t e mpe r a t ur e .
Turn on MAX A / C mo d e .
Turn t e mpe r a t ur e c o n t r o l kn o b t o f ul l COOL ( l e f t )
a n d c h e c k f or c o o l d i s c h a r ge ai r.
Turn t e mpe r a t ur e c o n t r o l kn o b t o f ul l WARM ( r i ght )
a nd c h e c k f o r wa r m d i s c h a r ge ai r.
Va r y t e mpe r a t ur e c o n t r o l kn o b f r o m f ul l WARM t o f ul l
COOL .
Di d ai r t emper at ur e change?
Ye s
No
G O t o B 2 .
B2 CHECK FUSE
Ye s
No
GO t o B3.
REPLACE f use . GO t o B 1 .
If f use bl o ws a ga i n ,
CHECK f or s ho r t s t o
gr o un d in Ci r cui t 2 98
( P / O) a nd SERVI CE a s
n e e d e d .
Ch e c k Fuse F5 at t h e f use j un c t i o n pa n e l .
Is f use good?
Ye s
No
GO t o B3.
REPLACE f use . GO t o B 1 .
If f use bl o ws a ga i n ,
CHECK f or s ho r t s t o
gr o un d in Ci r cui t 2 98
( P / O) a nd SERVI CE a s
n e e d e d .
B3 MANUAL A / C ELECTRONI C DOOR ACTUATOR MOTOR
SUPPLY VOLTAGE CHECK
Ye s
No
GO t o B4.
CHECK Ci r c ui t s 2 08 ( GY)
a n d 2 98 ( P / O) .
RETEST s y s t e m.
Di sc o n n e c t A / C e l e c t r o n i c d o o r a c t u a t o r mo t o r
c o n n e c t o r l o c a t e d on t he he a t e r ai r pl e n um c h a mb e r
a c c e s s e d t hr o ugh t he gl o v e c o mpa r t me n t o pe n i n g.
Usi n g a t e s t l a mp, c h e c k f o r ba t t e r y v o l t a ge
b e t we e n Ci r c ui t 2 98 ( P / O) a nd Ci r c ui t 2 08 ( GY) .
Ye s
No
GO t o B4.
CHECK Ci r c ui t s 2 08 ( GY)
a n d 2 98 ( P / O) .
RETEST s y s t e m.
OPERATION (Cont i nued)
B4 CONTROL HEAD POTENTI OMETER SUPPLY VOLTAGE
CHECK
Ye s
No
GO t o B5.
CHECK Ci r c ui t s 436
( R/ L G ) a n d 600 ( DB) f o r
o p e n s / s h o r t s . RESTORE
CAUTION: Never j umper Ci rcui t 4 3 6 ( R/ L G ) t o
Ci rcui t 6 0 0 ( DB) (coul d dest roy A/ C el ectroni c door
actuator el ectroni cs).
NOTE: The A / C e l e c t r o n i c d o o r a c t u a t o r mo t o r use d on
ma nua l (non-EATC) s y s t e ms c a n be t e s t e d t o d e t e r mi n e
if t he a c t u a t o r a n d c i r c ui t f r o m t he A / C c o n t r o l i s
o pe r a t i n g pr o pe r l y usi ng t he f o l l o wi n g pr o c e d u r e .
I n-Ve hi c l e Ac t ua t o r a n d Ci r c ui t Te st
Re mo v e t he A / C c o n t r o l a n d d i s c o n n e c t t he
ha r n e ss c o n n e c t o r f r o m t h e t e mpe r a t ur e
c o n t r o l po t e n t i o me t e r .
Wi t h i gni t i on s wi t c h t ur n e d t o RUN a nd t he
s y s t e m in any po si t i o n e x c e p t OFF, j ump f r o m
t he po t e n t i o me t e r ha r n e ss c o n n e c t o r c e n t e r pi n
t o o n e of t h e si d e pi n s. The a c t u a t o r ( a n d
t e mpe r a t ur e bl e n d d o o r ) s ho ul d o pe r a t e in o n e
d i r e c t i o n . The n , j ump f r o m t h e c e n t e r pi n t o t h e
o t he r si d e pi n . The a c t u a t o r s ho ul d d r i ve in t he
o p p o s i t e d i r e c t i o n .
If t he a c t ua t o r a n d t e mpe r a t ur e bl e n d d o o r d o
not o pe r a t e in b o t h d i r e c t i o n s , e i t he r t he c i r c ui t
f r o m t he c o n t r o l po t e n t i o me t e r t o t he a c t u a t o r
or t h e a c t u a t o r i s at f a ul t . Te st t h e c i r c ui t a n d
a c t ua t o r s e pa r a t e l y t o i so l a t e t h e c o n d i t i o n .
A c t u a t o r Onl y Te st
Appl y po si t i v e ( + ) ba t t e r y p o we r t o Pi n 7 of t h e
a c t u a t o r a n d c o n n e c t t h e n e ga t i v e (-) l e a d t o
Pi n 8.
Jumpe r f r o m Pi n 3 t o Pi n 4 of t h e a c t ua t o r . The
a c t u a t o r sha f t sho ul d r o t a t e in o n e d i r e c t i o n t o
t he s t o p. The n , j umpe r f r o m Pi n 3 t o Pi n 6. The
a c t u a t o r sha f t sho ul d r o t a t e in t he o ppo s i t e
d i r e c t i o n . DO NOT j umpe r Pin 4 a n d 6 t o ge t he r ,
t h i s wi l l c r e a t e a sho r t .
Re c o n n e c t A / C e l e c t r o n i c d o o r a c t ua t o r mo t o r
c o n n e c t o r at t h e he a t e r ai r pl e n um c ha mbe r .
Di sc o n n e c t he a t e r c o n t r o l c o n n e c t o r f r o m t he
b a c k of t he A / C c o n t r o l .
CAUTION: Never shor t acr oss Ci rcui t s 436
(R/LG) and 600 (DB) as t hi s coul d cause
dest r uct i ve damage.
Usi n g a v o l t me t e r , c h e c k f o r r e f e r e n c e v o l t a ge
( a ppr o x i ma t e l y o n e t o t wo v o l t s l e ss t ha n
ba t t e r y v o l t a ge ) be t we e n Ci r c ui t s 436 ( R/ L G )
a n d 600 ( DB) .
Is t he vol t met er r egi st er i ng one t o t wo vol t s
l ess t han bat t er y vol t age?
Ye s
No
GO t o B5.
( R/ L G ) a n d 600 ( DB) f o r
o p e n s / s h o r t s . RESTORE
B5 CONTROL HEAD POTENTI OMETER CHECK
Ye s
No
d o o r a c t ua t o r mo t o r .
RETEST s y s t e m.
REPLACE po t e n t i o me t e r .
RETEST s y s t e m.
Di sc o n n e c t a n d r e mo v e c o n t r o l h e a d po t e n t i o me t e r .
Ch e c k r e s i s t a n c e be t we e n t e r mi n a l s 3 a n d 2.
Wi t h po t e n t i o me t e r a t f ul l COOL , r e si st a n c e
sho ul d be 3000 o hms.
Wi t h po t e n t i o me t e r a t f ul l WARM, r e s i s t a n c e
sho ul d be at 15 o h ms .
Is resi st ance l i nearl y vari abl e f r o m COOL t o
WARM?
Ye s
No
d o o r a c t ua t o r mo t o r .
RETEST s y s t e m.
REPLACE po t e n t i o me t e r .
RETEST s y s t e m.
12 - 03 Ai r Condi t i oni ng S y s t e mMa n u a l A/ C- He a t e r 12 - 03 A - 31
Re f r i g e r a n t Oi l A d d i t i o n
The A / C c ompr e ssor ( 197 03) uses a speci al
ref ri gerant oil Mot or c r a f t YN-12b or equi val ent
meet i ng For d speci f i cat i on WSH- M 1C231-B. Thi s oil
cont ai ns speci al addi t i ves requi red f or t he A / C
c ompr e ssor .
It is i mport ant t hat onl y t he speci f i ed t y pe and quant i t y
of ref ri gerant oil be used in t he A / C c ompr e ssor . If
t her e i s surpl us oi l in t he sy st e m, t o o much oil wi l l
ci rcul at e wi t h t he ref ri gerant , reduci ng t he cool i ng
c a pa c i t y of t he sy st e m. Too li ttle oil will result in poor
l ubri cat i on of t he A / C c ompr e ssor .
Du r i n g A / C C o m p r e s s o r Re p l a c e me n t
NOTE: The suct i on accumul at or / dri er ( 19C836) and
A / C evapor at or c or e ori f i ce ( 19D990) must be
r epl aced and a f i l t er ki t i nst al l ed whenever t he A / C
c ompr e ssor is r epl aced.
NOTE: Servi ce A / C c o mpr e sso r s are shi pped wi t hout
c ompr e ssor oi l .
Pri or t o rei nst alli ng t he exi st i ng A / C c ompr e ssor or
i nstalli ng a new A / C c ompr e ssor , t he A / C
c ompr e ssor must be ser vi ced wi t h t he c o r r e c t amount
of oil a s f ol l ows:
1. Obt ai n a cl ean cont ai ner t hat can al so be used a s
a measuri ng devi ce.
2. Pl ace t he A / C cl ut ch ( 2 884) on t he A / C
compr essor shaf t so t he shaf t can be r o t a t e d .
3. Rot at e t he shaf t by hand si x t o ei ght revol ut i ons,
col l ect i ng t he oil in a cl ean measuri ng devi ce.
4. If t he amount of oil drai ned f r om t he ol d A / C
c ompr e ssor is bet ween 85- 142 ml (3-5 ounces),
pour t he same amount pl us 30 ml ( 1 ounce) of
cl ean Mot or c r a f t YN-12b ref ri gerant oil or
WSH-M 1C231-B i nto t he new A / C c ompr e ssor .
f r om t he ol d A / C c ompr e ssor is great er t han 142
ml (5 ounces), pour t he sa me amount dr ai ned of
WSH-M 1C231-B i nto t he new A / C c ompr e ssor .
f r om t he ol d A / C c ompr e ssor is l ess t han 85 ml
(3 ounces), pour 85 ml ( 3 ounces) of cl ean
Mot or c r a f t YN-12b ref ri gerant oil or equi val ent
meet i ng For d speci f i cat i on WSH-M 1C231-B i nto
Du r i n g C o m p o n e n t Re p l a c e me n t
When it is ne c e ssa r y t o r epl ace a component of t he
ref ri gerat i on sy st e m, per f or m pr ocedur es a s out l i ned
t o ensure t he t ot al oil c ha r ge on t he sy st e m i s c o r r e c t
af t er t he new component is i nst al l ed. Duri ng normal
A / C oper at i on, some ref ri gerant oil is ci r cul at ed
t hr ough t he sy st e m wi t h t he ref ri gerant and so me is
ret ai ned in t he A / C c ompr e ssor . If cert ai n c ompone nt s
of t he sy st e m ar e r emoved f or repl acement , some of
t he ref ri gerant oil wi ll go wi t h t he component . To
mai ntai n t he ori gi nal t ot al oil c ha r ge , it is ne c e ssa r y t o
c ompe nsa t e f or t he oil l ost by addi ng oil t o t he sy st e m
wi t h t he repl acement component .
For t he A / C e va por a t or c o r e ( 19860) , a dd 89 ml ( 3
ounces) of cl ean Mo t o r c r a f t YN- 12b ref ri gerant oi l or
WSH-M 1C231-B t o t he suct i on a c c umul a t o r / d r i e r inlet
t ube whenever t he A / C e va por a t or c o r e is r e pl a c e d.
Thi s will c o mpe n sa t e for t he r ef r i ger ant oil l ost in t he
r epl aced A / C e va por a t or c o r e . For t he A / C
condenser c o r e ( 197 12) , a d d 30 ml ( 1 ounce) of cl ean
Mo t o r c r a f t YN-12b ref ri gerant oil or equi val ent
meet i ng Fo r d speci f i cat i on WSH-M 1C231-B t o t he
A / C condenser c o r e or t he suct i on a c c umul a t o r / d r i e r
if t he A / C condenser c or e is r e pl a c e d.
Whe n repl aci ng t he suct i on a c c umul a t o r / d r i e r in
conj unct i on wi t h anot her component of t he
ref ri gerat i on sy st e m, measure t he amount of oil
drai ned f r o m t he r emoved suct i on a c c umul a t o r / d r i e r
i nto a sui t abl e cont ai ner.
Dri ll t wo 13 mm ( 1 / 2 i nch) hol es in t he bot t om of t he
suct i on a c c umul a t o r / d r i e r t o drai n oi l .
Ad d t he sa me amount of cl ean Mot or c r a f t YN-12b
ref ri gerant oi l or equi val ent meet i ng For d
speci f i cat i on WSH- M2C231- B pl us 60 ml (2
ounces).
SP E CI AL SERVI CE TOOL( S) REQUI RED
Spr i n g L o c k Co u pl i n g Di s c o n n e c t To o l T 81P - 1962 3- G1
( 3 / 8 i n c h)
Spr i n g L o c k Co u pl i n g Di s c o n n e c t To o l T 81P - 1962 3- G2
( 1 / 2 i n c h)
Spr i n g L o c k Co upl i n g Di s c o n n e c t To o l T 83P - 1962 3- C
( 5 / 8 i n c h)
Spr i n g L o c k Co upl i n g Di s c o n n e c t To o l T 85L - 1962 3- A
( 3 / 4 i n c h)
C o u p l i n g Di s c o n n e c t
1. Remove ref ri gerant f r om sy st e m. Refer t o
Sect i on 12-00. Fit Spri ng Loc k Coupli ng
Di sconnect Tool T81P-19623-G1 ( 3 / 8 i nch),
T81P-19623-G2 ( 1 / 2 i nch), T83P-19623-C ( 5 / 8
i nch) or T85L-19623-A ( 3 / 4 i nch) t o t he coupl i ng.
2. NOTE: The gart er spri ng may not rel ease if t he
t ool is c o c ke d whi l e pushi ng it i nto t he c a ge
openi ng.
Cl ose t ool and push i nto open si de of c a ge t o
expand gar t er spri ng and rel ease f emal e f i t t i ng.
3. Af t er gart er spri ng is expanded, pull f i t t i ng apar t .
4. Remove t ool f r om di sconnect ed coupl i ng.
Co u p l i n g Co n n e c t
1. Check t o ensure t hat gart er spri ng is in c a ge of
male f i t t i ng. If gart er spri ng is mi ssi ng, install a
new spri ng by pushi ng it i nto c a ge openi ng. If
gart er spri ng i s damaged, remove it f r om c a ge .
wi t h a small wi r e hook (do not use a sc r e wdr i ve r )
and i nstall a new spri ng.
12 - 03A - 32 Ai r Condi t i oni ng Syst em' Ma n u a l A/ C- Heat er 12 - 03A - 32
2. Clean all di rt or f orei gn mat eri al f r om bot h pi eces
of coupl i ng.
3. Lubr i cat e and i nstall new green O-ring seal s on
male f i t t i ng.
Use onl y t he speci f i ed green O-ri ng seal s
because t hey ar e made of a speci al mat eri al . The
use of any O-ri ng seal ot her t han t he speci f i ed
green O-ri ng seal may al l ow t he connect i on t o
leak i nt ermi t t ent l y duri ng vehi cl e oper at i on. Ref er
t o Ser vi ce Par t s Li st .
4. Lubr i cat e male f i t t i ng, green O-ri ng seal s and
i nsi de of f emal e f i t t i ng wi t h cl ean ref ri gerant oi l .
5. Install pl ast i c i ndi cat or ri ng i nto c a ge openi ng if
i ndi cat or ri ng is t o be used.
6. Fi t f emal e f i t t i ng t o mal e f i t t i ng and push until
gar t er spri ng snaps over f l ar ed end of f emal e
f i t t i ng.
If pl ast i c i ndi cat or ri ng is used, it wi ll snap out of
c a ge openi ng when coupl i ng i s connect ed t o
i ndi cat e engagement .
7. If i ndi cat or ri ng is not used, ensure coupl i ng
engagement by vi sual l y checki ng t o veri f y gar t er
spri ng i s over f l ared end of f emal e f i t t i ng.
SERVI CE PARTS LI ST
P a r t N u m b e r De s c r i p t i o n
E 35Y- 19D690- D O- r i n g Se a l K i t - A / C Spr i n g L o c k Co upl i n g ( Ki t
c o n t a i n s 3 / 8 , 1 / 2 a n d 5 / 8 c o u p l i n g O- r i n gs
a n d 3 / 8 , 1/ 2 a n d 5 / 8 i n c h c o u p l i n g ga r t e r
s p r i n gs ) .
12- 03A- 33
Ai r Condi t i oni ng S y s t e mMa n u a l A/ C- H e a t e r 12- 03A- 33
Spri ng Lo c k Coupl i ng
*ALSO SUPPLI ED IN
KIT E35Y-19D690-A
F E MA L E
FI T T I N G
MALE
FI TTI NG
3/8*-391396-3100*
1/2"-391397-S100*
5/8"-391304-S100*
3/4"-391307-S100
G A R T E R
SPRI NG
C A G E
R E P L A C E ME N T
O - R I N G S
' S E A L S
SPRING LOCK COUPLING DISCONNECTED
CAUTION DISCHARGE SYSTEM BEFORE -
DISCONNECTING COUPLING
TO CONNECT COUPLING
CAGE
OPENI NG
DISCONNECT TOOL
T81P-19623-G1 - 3/8 INCH
T81P-19623-G2 - 1/2 INCH
T83P-19623-C - 5/8 INCH
T85L-19623-A - 3/4 INCH
FIT TOOL TO COUPUNG SO THAT TOOL CAN
ENTER CAGE OPENING TO RELEASE THE
GARTER SPRING.
GARTER SPRI NG
REPLACEMENT GARTER SPRINGS
3/8
H
-E1ZZ-19E576-A*
1/2"-E1ZZ-19E576-B*
5/8"-E35Y-19E576-A*
3/4"- E692-19E576-A*
'ALSO AVAILABLE IN
E35Y-19D690-A KIT WITH O-RINGS
CHECK FOR MISSING OR DAMAGED GARTER
SPRING REMOVE DAMAGED SPRING WITH
SMALL HOOKED WIREINSTALL NEW SPRING
IF DAMAGED OR MISSING.
PUSH TOOL I NTO
CAGE OPENI NG
OPENING TO RELEASE THE FEMALE FITTING
FROM THE GARTER SPRING.
ACLEAN FI TTI NGS
B I NSTALL NEW
O-RI NG SEALS
USE ONLY SPECI FI ED
O-RI NG SEALS
C LUBRI CATE WI TH
CLEAN REFRI GERANT
O I L
ASSEMBLE FI TTI NG
TOGETHER BY PUSHI NG
WI TH A SLI GHT TWI STI NG
MOTI ON
FITTINGS APART.
GARTER SPRI NG
TO ENSURE COUPUNG ENGAGEMENT, VISUALLY
CHECK TO BE SURE GARTER SPRING IS OVER
DISCONNECTED SPRING LOCK COUPLING.
M4011-E
C l i m a t e Co n t r o l Assembly
Re mo v a l
1. Remove ba t t e r y ground cabl e ( 14301) .
2. NOTE: The i nst rument panel upper mouldi ng
( 042 68) i s ret ai ned by snap-i n t a bs.
Remove t he i nst rument panel upper moul di ng.
Cl i ma t e Co n t r o l Asse mbl y
3. Remove f our sc r e ws f r om t he A / C cont rol
( 19980) and pull t he cont rol out of t he i nst rument
panel ( 04320) .
4. Remove t he t hr ee el ect ri cal connect or s and t he
vacuum hose harness ( 19C827 ) f r om t he A / C
c ont r ol .
M4692-A
Pa r t
1 0432 0 I nst r ume nt Pa ne l
2

Snap-I n Ta bs
3 042 68 I nst r ume nt Pa ne l Uppe r Mo ul d i n g
4 N80387 6- S2 Sc r e w ( 4 Re q ' d )
5 19980 A / C Co n t r o l
TM4692A
1. Connect t he t hr e e el ect ri cal c onne c t or s and t he
vacuum connect or t o t he A / C c ont r ol .
2. Posi t i on t he A / C cont r ol in t he i nst rument panel
and se c ur e wi t h f our sc r e ws.
3. Install t he i nst rument panel upper mouldi ng by
snappi ng in t he bo t t o m.
4. Connect ba t t e r y gr ound cabl e.
I l l u mi n a t i o n Bu l b s
1. Remove A / C cont rol as out l i ned.
2. Fr om t he ba c k of t he A / C cont r ol , remove t he
illumination bul bs by t wi st i ng count er cl ockwi se.
12 - 03A- 35 Ai r Condi t i oni ng Sy s t em'
i
Swi t c h Kn o b s
1. NOTE: Do not pr y t he knob ( 18519) off i t s shaf t
as damage t o t he sur f a c e of t he air condi t i oner
cont rol a sse mbl y bezel may result .
To r emove a ny of t he t hr ee cont rol knobs on t he
A / C c ont r ol , gr a sp a n d pull r ear war d.
2. If t he D-shaped spr i ng cl i p whi c h si t s inside t he
back end of t he kn o b remai ns on shaf t when knob
is pulled of f , r e move it wi t h needlenose pli ers and
install on kn o b.
3. To i nstall knob, al i gn i t s ke y e d surf ace wi t h
mat i ng sur f a c e on sha f t . Press knob f or war d until
fully seat ed in A / C c o n t r o l .
Bl o w e r Mo t o r S w i t c h
Re mo v a l a n d i n s t a l l a t i o n
1. Remove A / C c ont r ol a s out l i ned.
2. Remove knob.
3. Di sconnect el ect r i cal connect or.
4. Remove ret ai ni ng sc r e w.
5. Remove heat er bl ower mot or swi t ch (18578).
6. To i nst all, r e ve r se Removal procedure.
A / C Da mp e r Do o r S w i t c h
1. Remove A / C cont r ol a s out l i ned.
2. Remove knob.
3. Di sconnect va c uum bundl e and el ect ri cal
connect or.
4. Remove ret ai ni ng sc r e w.
5. Remove A / C da mpe r door swi t c h (19B888).
6. To i nst all, r ever se Removal pr ocedur e.
Rel ay Ce n t e r L o c a t i o n
RELAY CENTER (PART OF 12A581)
A/ C COMPRESSOR CLUTCH CONTROL
RELAY 19D572
PCM POWER RELAY 14B192
FUEL PUMP RELAY 14B192
FRONT OF
VEHI CLE
M4693-A
Re l a y s
A / C C o mp r e s s o r C l u t c h C o n t r o l Re l a y
1. Rai se hood ( 16612 ) t o gai n a c c e ss t o relay
center.
2. Di sl odge rel ay cent er f r o m vacuum t ank on LH
wheel housi ng.
3. Remove cover f r om rel ay cent er and remove A / C
compr essor cl ut ch cont r ol rel ay (19D572).
4. To i nstall, r ever se Removal pr ocedur e.
A / C E l e c t r o n i c Do o r A c t u a t o r Mo t o r
Re mo v a l
2. Remove i nstrument panel ( 04320) . Refer t o
Sect i on 01-12.
3. Remove four A / C el ect roni c door act uat or mot or
4. Remove A / C el ect roni c door act uat or mot or
(19E616).
A / C El e c t r o n i c Door Ac t ua t o r Mo t o r
M4694-A
Pa r t
1 1847 1 He a t e r Ai r Pl e num Cha mbe r
2 42 141- S8 Sc r e w (4 Re q' d )
3 19E616 A / C El e c t r o n i c Do o r Ac t u a t o r Mo t o r
4

A / C Ai r Te mpe r a t ur e Co n t r o l Do o r Sha f t ( Pa r t of 18471)
5

A / C Ai r Te mpe r a t ur e Co n t r o l Do o r ( Pa r t of 18471)
1
3.
4.
Insert A / C el ect roni c door act uat or mot or i nt o
A / C air t emper at ur e c ont r ol door ( 19D842 )
(manual l y movi ng A / C a i r t emper at ur e cont r ol
door wi ll hel p engage sha f t ).
At t a c h A / C el ect roni c door act uat or mot or wi t h
f our ret ai ni ng sc r e ws.
Install i nst rument panel . Ref er t o Sect i on 01- 12.
Connect bat t er y gr ound cabl e.
A / C E v a p o r a t o r C o r e H o u s i n g
Sp r i n g L o c k Co upl i n g Di s c o n n e c t To o l
( 3 / 8 i n c h)
Sp r i n g L o c k Co upl i n g Di s c o n n e c t To o l
( 1 / 2 i n c h)
T 81P - 1962 3- G 1
T 81P - 1962 3- G2
Re mo v a l
2. Di schar ge t he ref ri gerant f r om t he A / C sy st e m
whi l e observi ng all saf et y precaut i ons in Sect i on
12-00.
3. NOTE: Whenever t he A / C evapor at or c or e
housi ng ( 19A559) is r e move d, it wi ll be
necessar y t o repl ace t he suct i on
accumul at or / dri er ( 19C836) .
Di sconnect t he evapor at or t o c ompr e ssor
suct i on line ( 19867 ) f r om t he suct i on
a c c umul a t or / dr i e r usi ng Spri ng Lo c k Coupli ng
Di sconnect Tool T81P-19623-G1 or G2 and plug
t he openi ngs t o prevent di rt and e xc e ssi ve
moi st ure f r om ent eri ng. Posi t i on t he hose a wa y
f r om suct i on a c c umul a t or / dr i e r assembl y.
4. Di sconnect t he condenser t o e va por a t or t ube
( 19835) f r om t he A / C evapor at or c o r e inlet t ube
usi ng Spri ng Lo c k Coupl i ng Di sconnect Tool
T81P- 19623- G1 and G2 and pl ug t he openi ngs.
Posi t i on t he condenser t o e va por a t or t ube a wa y
f r om t he A / C e va por a t or cor e housi ng assembl y.
Heat er Wat er Hose s
5. Drai n cool ant f r om r adi at or ( 8005) . Sa ve cool ant
f or reuse.
6. Loosen t he hose c l a mps ( 82 87 ) and di sconnect
t he heat er wa t e r hoses ( 1847 2 ) f r om t he heat er
c o r e t ubes.
FRONT OF VEHI CLE
M4695-A
Pa r t
1 18472 Out l e t He a t e r Wa t e r Hose
2 18472 I nl et He a t e r Wa t e r Ho se
4 19867 Ev a po r a t o r t o Co mpr e s s o r
Suc t i o n Li ne
5 19836 Co n d e n se r t o Ev a po r a t o r
Tube
( Co n t i n ue d )
7. Remove t he t wo nut s ret ai ni ng purge val ve
mount i ng br a c ke t t o t he c o wl t o p ext ensi on
( 02 1A36) . Posi t i on purge val ve and br a c ke t
a wa y f r o m A / C evapor at or c o r e housi ng.
8. Remove radi at or cool ant r ecover y reservoi r
( 8A080) as out l i ned in Sect i on 03- 03. Posi t i on
radi at or cool ant r e c ove r y reservoi r f o r wa r d ,
a wa y f r o m A / C evapor at or c o r e housi ng.
I t e m
Pa r t
6 19C917 A / C Co n d e n se r Tube
Suppo r t Br a c ke t
7

A / C Ev a po r a t o r Co r e I nl et
Tube (Par t of 19860)
Housi ng
9. Di sconnect A / C bl ower mot or l ead assembl y
f r om t he main wi ri ng harness and r emove t he
hard-shel l connect or f r om t he heat er bl ower
mot or swi t c h resi st or ( 18591) .
10. Di sconnect t he l arge wi r e harness (whi ch
c r osse s t he A / C evapor at or cor e housi ng) at t he
hard shell connect i ng poi nt and posi t i on it a wa y
f r om t he A / C evapor at or c or e housi ng.
12 - 03A - 38 Ai r Co n d i t i o n i n g S y s t e mMa n u a l A / C- He a t e r 12 - 03A - 38
Mai n Wi r e Ha r ne ss
Pa r t
3 18591 He a t e r Bl o we r Mo t o r Switch
Re si st o r
4 14A163 Wi r i ng Ha r n e ss Re t a i n e r
5

A / C Bl o we r Mo t o r L e a d
As s e mbl y (Pa r t of 14401)
FRONT OF VEHI CLE
/
M4696-A
Pa r t
1 Ma i n Wi r i n g As s e mb l y t o
He a d l a mp Da sh Pa ne l
Jun c t i o n Wi r i n g As s e mb l y
I n t e r c o n n e c t
Housi ng
TM4696A
11. Fr om passenger si de of da sh panel ( 01610) , f ol d
car pet i ng ba c k on t he RH si de of t he f l oor.
Remove t he bot t om LH sc r e w of t he t wo sc r e ws
t hat support t he A / C reci rcul at i ng ai r duct
( 19C590) .
12. Fr om t he engi ne si de of t he dash panel , r emove
t he t hr ee nuts (one upper and t wo l ower ) f r om t he
t hr ee evapor at or assembl y mounti ng st uds. Al so
remove t he t wo sc r e ws (one drill poi nt and one
sheet met al ) f r om t he bl ower mot or ( 1852 7 ) and
bl ower mot or wheel ( 18504) assembl y port i on of
t he c a se A / C evapor at or c or e housi ng.
13. Pull t he bot t om of t he A / C evapor at or c o r e
housi ng assembl y a wa y f r om t he da sh panel t o
di sengage t he t wo bot t om st uds. Move t he t o p of
t he A / C evapor at or c or e housi ng assembl y a wa y
f r om t he dash panel di sengagi ng it f r om t he t op
st ud and maneuver t he c a se up and over t he
wheel wel l spl ash panel .
A / C Ev a po r a t o r Co r e Ho usi n g Re mova l
0
M4697-A
Pa r t
1 01610 Dash Panel
2 18471 He a t e r Ai r Pl e num Cha mbe r
3 56956-S2 Screw (2 Req'd)
4 19850 A / C Evaporator Housing
( Co n t i n ue d )
Part
5 45332 - S2 Nut ( 4 Re q ' d )
6 38687 7 - S36 Sc r e w ( 1 Re q ' d )
A

Ti ght e n t o 2. 5- 3. 2 N-m ( 2 2 - 2 8
Lb- l n )
1. Posi t i on t he A / C e va por a t or c o r e housi ng
assembl y next t o t he da sh panel by maneuveri ng
it down past t he wheel wel l spl ash panel .
2. Engage t he t wo bot t om da sh panel st uds into t he
A / C e va por a t or c o r e housi ng assembl y st ud
hol es. Move t he t o p of t he A / C e va por a t or c o r e
housi ng assembl y t o wa r d t he dash panel whi l e
engagi ng t he t o p da sh panel st ud i nto t he A / C
e va por a t or c o r e housi ng assembl y st ud hol e.
3. Repl ace, but do not t i ght en, t he t hr ee st ud nut s.
4. Repl ace t he t wo sc r e ws (one dri ll poi nt and one
sheet met al ) and t i ght en t o 2. 5-3. 2 N-m (22-28
lb-i n). Be caref ul t o ret urn t he dri ll poi nt sc r e w t o
t he c or r e c t hol e whi c h i s l ocat ed on t o p of t he
A / C e va por a t or c o r e housi ng and t o t he ri ght of
t he A / C bl ower mot or and bl ower mot or wheel
assembl y. Ti ght en t he t hr ee st ud nut s previ ousl y
i nst al l ed t o 2. 5-3. 2 N-m (22-28 lb-i n).
5. Posi t i on t he wi r e har ness connect or a c r o ss t he
A / C e va por a t or c o r e housi ng ( 19A553)
assembl y and connect t he vari ous connect or s.
6. Connect l ead assembl y t o t he bl ower mot or and
heat er bl ower mot or swi t c h resi st or.
7. Install radi at or cool ant r ecover y reservoi r t o
wheel wel l spl ash panel wi t h t wo ret ai ni ng nut s.
8. Install purge val ve mount i ng br a c ke t t o t he c o wl
t o p ext ensi on wi t h t wo ret ai ni ng nut s.
9. Pl ace t he hose c l a mps ont o t he heat er wa t e r
hoses and caref ul l y connect t he hoses t o t he inlet
and out l et heat er c or e t ubes. Posi t i on t he hose
c l a mps and t i ght en t o speci f i cat i on. Refill cool ant
sy st e m.
10. CAUTI ON: Ma ke s u r e c o r r e c t O- r i n g se a l s a r e
i n s t a l l e d wh e n e v e r a n A / C f i t t i n g i s s e r v i c e d .
L e a ks a n d r e f r i ge r a n t l o s s ma y r e s u l t .
Remove t he pl ugs f r o m t he evapor at or inlet t ube
and t he condenser t o evapor at or t ube and i nstall
new O-ri ng seal s di pped in cl ean ref ri gerant oi l .
Connect t he condenser t o evapor at or t ube t o t he
e va por a t or inlet t ube.
11. Remove t he pl ugs f r o m t he suct i on
a c c umul a t o r / d r i e r out l et and t he evapor at or t o
c o mpr e sso r suct i on line and i nstall new O-ri ng
se a l s di pped in cl ean ref ri gerant oi l . Connect t he
e va por a t or t o c ompr e ssor suct i on line t o t he
suct i on a c c umul a t o r / d r i e r .
12. Le a k-t e st , evacuat e and c ha r ge t he ref ri gerat i on
sy st e m f ol l owi ng t he r ecommended pr oc e dur e s
a nd sa f e t y precaut i ons. Ref er t o Sect i on 12-00.
13. Fr o m t he passenger compar t ment , i nstall t he
A / C reci rcul at i ng ai r duct sc r e w.
14. Che c k t he A / C sy st e m f or pr oper oper at i on.
NOTE: If an A / C evapor at or c o r e l eak i s suspe c t e d,
t he A / C evapor at or c or e ( 19860) must be l eak-t est ed
bef or e it is r emoved f r om t he vehi cl e. Ref er t o Sect i on
12-00 f or l eak-t est pr ocedur es.
NOTE: Whenever t he A / C evapor at or c o r e i s
r e pl a c e d, it wi ll be necessar y t o r epl ace t he suct i on
Re mo v a l
1. Remove t he A / C evapor at or c o r e housi ng
( 19A559) f r om t he vehi cl e a s out l i ned.
2. Remove A / C evapor at or c a se da sh panel seal
( 19C593) .
3. Remove t he A / C evapor at or c a se c ove r i nsul at or
( 19B666) f r om t he bot t om of t he A / C e va por a t or
c o r e housi ng.
4. Remove si x sc r e ws ret ai ni ng t he t wo hal ves of
t he A / C evapor at or c or e housi ng ( 19A553)
t oget her.
5. Separ at e t he t wo hal ves of t he A / C evapor at or
c or e housi ng and r emove t he A / C evapor at or
c or e and suct i on a c c umul a t or / dr i e r assembl y.
6. Di sconnect t he suct i on accumul at or / d r i e r inlet
f r om t he evapor at or c or e out l et t ube.
7. Remove t he ret ai ni ng sc r e w f r om t he suct i on
a c c umul a t or / dr i e r and evapor at or c or e mount i ng
br a c ke t s and remove t he suct i on
a c c umul a t or / dr i e r f r om t he A / C evapor at or
c o r e .
A / C Eva po r a t o r Cor e Re mova l
M3448-E
I t em
Par t
Number Descr i pt i on I t em
Par t
1 19C836 Suction Accumulator/Drier 5 19860 A / C Ev a po r a t o r Co r e
2 387977-S2 Spr i n g Nut (4 Re q' d ) 6 19A706 A / C Bl o we r Mo t o r Swi t c h
3 19A559 A/ C Evaporator Core
Re si st o r
Housi ng 7 42 152 - S2 Sc r e w (7 Re q' d )
4 19C593 A/ C Evaporator Case Dash 8 19A663 A / C Ev a po r a t o r Co r e
Panel Seal Ho usi n g (LH)
( Co n t i n ue d )
12 - 03 A - 41 Ai r Co n d i t i o n i n g S y s t e mMa n u a l A / C - H e a t e r 12 - 03A- 41
I nst al l at i on
1. NOTE: Whe n repl aci ng an A / C evapor at or corei n
a refrigerant sy st em, Motorcraft YN-12b
speci f i cat i on WSH-M 1C231-B shoul d be a d d e d
t o t he A / C evapor at or c or e t o ensure t hat t he
t ot al oil c ha r ge in t he sy st e m is c or r e c t bef or e t he
sy st e m i s ope r a t e d.
Pour 90 ml (3 ounces) of cl ean Mot or c r a f t
YN-12b ref ri gerant oil meet i ng For d speci f i cat i on
WSH-M 1C231-B di r ect l y i nt o t he inlet pi pe of t he
repl acement A / C e va por a t or c or e wi t h t he pi pe
hel d ver t i cal l y so t he oil wi ll drai n into t he A / C
e va por a t or c or e .
2. At t a c h t he suct i on accumul at or / d r i e r t o t he
e va por a t or c o r e mount i ng br a c ke t wi t h a
3. Install a ne w O-ri ng seal l ubri cat ed wi t h cl ean
Mot or c r a f t YN-12b ref ri gerant oil or equi val ent
meet i ng Fo r d speci f i cat i on WSH-M 1C231-B and
connect t he suct i on accumul at i on dri er inlet
connect i on t o t he out l et t ube of t he e va por a t or
c or e . Ti ght en usi ng a ba c kup wr e nc h t o pr event
component damage.
4. Posi t i on t he A / C evapor at or c o r e assembl y t o
t he RH half of t he A / C e va por a t or c o r e housi ng.
5. Appl y Caul ki ng Cor d D6AZ- 19560- A or
ESB-M4G32-A t o t he A / C e va por a t or c or e
housi ng f l ange and around t he evapor at or c o r e
t ubes.
6. Posi t i on t he A / C evapor at or c or e housi ng LH half
and da sh panel gasket t o t he c a se RH half.
7. Install suppor t st r a p on evapor at or inlet t ube.
8. Install seven sc r e ws t o a t t a c h t he t wo hal ves of
t he housi ngs t oget her. The cent er sc r e w on t he
f ront of t he housi ng al so ret ai ns t he suppor t
st r ap.
9. Install A / C evapor at or c a se da sh panel seal .
10. Install a new heat shi el d on t he bo t t o m of t he A / C
evapor at or c o r e housi ng wi t h st apl es.
11. Install t he A / C evapor at or c o r e housi ng in t he
vehi cl e as out l i ned.
12. Leak-t est , evacuat e and c ha r ge t he ref ri gerat i on
and saf et y precaut i ons. Ref er t o Sect i on 12-00.
He a t e r Co r e Re mova l
Pa r t
1 390092 - S2 Sc r e w ( 4 Re q ' d )
2 18658 He a t e r Co r e Ca se Se a l
3 18476 He a t e r Co r e
4 18570 He a t e r Da s h Ga ske t
5 18471 He a t e r Ai r Pl enum Cha mbe r
6 18B300 He a t e r Co r e Co v e r
TM3463C
3. Pull t he heat er cor e ( 1847 6) assembl y f r om t he
heat er ai r plenum chamber assembl y.
1. Caref ully install heat er c or e assembl y i nto t he
heat er ai r plenum chamber assembl y. Vi sually
check t o ensure t hat heat er c o r e c a se seal
( 18658) is properl y posi t i oned.
2. Posi ti on t he heat er cor e cover and install t he f our
retai ni ng sc r e ws.
3. Install t he heat er air plenum chamber assembl y
as out li ned.
H e a t e r C o r e
Re mo v a l
1. Remove t he heat er ai r plenum chamber ( 1847 1)
assembl y a s out l i ned.
2. Remove t he f our ret ai ni ng sc r e ws f r om t he heat er
c or e cover ( 18B300) and r emove t he heat er c o r e
cover f r om t he heat er air plenum chamber
assembl y.
H e a t e r B l o w e r Mo t o r a n d B l o w e r Mo t o r
Re mo v a l
1. Remove t wo nut s securi ng radi at or cool ant
recovery reservoi r ( 8A080) t o f ender spl ash
panel and move radi at or cool ant r ecover y
reservoi r a wa y f r om bl ower mot or ( 18527) .
12 - 03A - 42 Ai r Condi t i oni ng Sy s t emManual A/ C- Heat er 12 - 03A - 42
2. Di sconnect bl ower mot or f r om main wi ri ng
harness at t he snap-l ock connect or.
3. Remove t he bl ower mot or housi ng t ube ( 19A7 86)
f r o m t he bl ower mot or .
4. Remove t he f our ret ai ni ng sc r e ws ( t wo upper and
t wo l ower ) f r om t he bl ower mot or mount i ng pl at e.
5. Turn t he bl ower mot or and A / C bl ower wheel
( 19834) assembl y sl i ght l y t o t he ri ght so t ha t t he
bot t om edge of t he mount i ng pl at e f ol l ows t he
cont our of t he f r ont f ender spl ash panel . Whi l e
sti ll in t he A / C evapor at or c o r e housi ng
( 19A559) , lift t he bl ower mot or and A / C bl ower
wheel assembl y up and maneuver it out of t he
A / C evapor at or c or e housi ng.
Heat er Bl o we r Mo t o r a n d Bl o we r Mo t o r Whe e l
Asse mbl y Re mova l
FRONT OF
VEHI CLE 9
M1508-E
Pa r t
I t em d u mb e r De s c r i p t i o n
1 19834 A / C Bl o we r Whe e l
2 389915- 52 Sc r e w ( 4 Re q' d )
3 19805 A / C Bl o we r Mo t o r
4 19A786 Bl o we r Mo t o r Ho usi n g Tube
Ho usi n g
TM1508E
Installation
1. Posi t i on t he bl ower mot or and A / C bl ower wheel
assembl y i nto t he A / C e va por a t or c o r e housi ng
by t i lt i ng it t o t he ri ght so t hat t he bot t om edge of
t he mount i ng pl at e f ol l ows t he cont our of t he f ront
f ender spl ash panel . Maneuver t he assembl y past
t he f ront f ender spl ash panel and into t he t o p
port i on of t he housi ng openi ng, t hen down i nto
., posi t i on.
2. Install t he f our ret ai ni ng sc r e ws ( t wo upper and
t wo l ower ).
3. At t a c h t he bl ower mot or housi ng t ube t o t he
bl ower mot or.
4. Connect bl ower mot or l ead assembl y t o mai n
wi ri ng har ness.
5. Install radi at or cool ant r ecover y reservoi r on
f ender spl ash panel and secure wi t h t wo retai ni ng
nut s.
6. Che c k t he sy st e m f or proper A / C bl ower mot or
oper at i on.
Heater Blower Motor Wheel
Removal
1. Remove bl ower mot or ( 18527 ) and A / C bl ower
wheel ( 19834) assembl y as out li ned under
Heat er Bl ower Mot or and Bl ower Mot or Wheel
Assembl y.
2. Remove t he bl ower mot or wheel ret ai ner
( 18A2 87 ) f r om t he mot or shaf t .
3. Sli de t he A / C bl ower wheel f r om t he mot or shaf t .
He a t e r Bl o we r Mo t o r a n d Bl o we r Mo t o r Whe e l
Asse mbl y
A/C BLOWER
MOTOR 18527
A/C BLOWER WHEEL
19834
BLOWER MOTOR WHEEL
RETAI NER 18A287
M3590-C
Installation
1. Ali gn t he f l at sur f aces on t he i nsi de di amet er of
t he bl ower wheel hub wi t h t he f l at sur f ace of t he
mot or shaf t .
2. Sli de t he A / C bl ower wheel ont o t he mot or shaf t .
3. Install a new bl ower mot or wheel ret ai ner on t he
bl ower shaf t t o ret ai n t he wheel .
4. Install t he bl ower mot or and A / C bl ower wheel
assembl y as out li ned under Heat er Bl ower Mot or
and Bl ower Mot or Wheel Assembl y.
Blower Motor Switch Resistor
1. Di sconnect t he wi r e harness snap l ock connect or
f r om t he heat er bl ower mot or swi t c h resi st or
( 18591) .
2. Remove t he t wo resi st or assembl y ret ai ni ng
sc r e ws securi ng t he heat er bl ower mot or swi t c h
r esi st or t o t he A / C evapor at or c o r e housi ng
( 19A559) assembl y.
3. Remove t he heat er bl ower mot or swi t c h resi st or.
Bl o we r Mo t o r Swi t c h Resi st or I n st a l l a t i o n
SCREW
2 REQ' D M3447-C
I n s t r u m e n t P a n e l R e g i s t e r A s s e m b l i e s
NOTE: The i nst rument panel r egi st er s ar e ser vi ced as
assembl i es onl y.
RH
1. NOTE: The i nst rument panel upper mouldi ng
( 042 68) is ret ai ned by snap-i n t a bs.
Remove t he i nst rument panel upper mouldi ng t o
gai n a c c e ss t o A / C regi st er ret ai ni ng sc r e ws.
2. Remove t he A / C regi st er ret ai ni ng sc r e ws.
3. The A / C regi st er ( 19893) assembl y is secur ed in
t he i nst rument panel ( 04320) wi t h snap t a bs.
Remove t he A / C regi st er f r om t he i nst rument
panel .
RH I n st r ume n t Panel Regi st er Asse mbl y
RAMP
M3776-C
C e n t e r
The cent er and left A / C regi st er assembl i es are
a t t a c he d t o t he i nst rument panel fi ni sh panel ( 044D7 0)
by snap t a bs at t op and bo t t o m.
2. NOTE: The i nst rument panel upper mouldi ng is
ret ai ned by snap-i n t a bs.
Remove t he i nst rument panel upper mouldi ng t o
gai n a c c e ss t o t he i nst rument panel fi ni sh panel
3. NOTE: The i nst rument panel mouldi ng ( 04389) is
ret ai ned by snap in t a bs.
Remove t he i nst rument panel mouldi ng t o gai n
a c c e ss t o t he remai ni ng i nst rument panel f i ni sh
panel ret ai ni ng sc r e ws.
4. Remove ei ght ret ai ni ng sc r e ws f r om i nst rument
panel f i ni sh panel . Remove i nst rument panel fi ni sh
panel f r om i nst rument panel .
5. Di sengage snap t a bs and remove A / C regi st er.
12 - 03A - 44 Ai r Condi t i oni ng S y s t e mMa n u a l A / C- He a t e r 12 - 03A - 44
Ce n t e r I n st r ume n t Panel Re gi st e r Asse mbl y
1
M4S98-A
Pa r t
1 0432 0 I nst r ume nt Pa ne l
2 042 68 I nst r ume nt Pa ne l Uppe r Mo ul d i n g
3 04389 I nst r ume nt Pa ne l Mo ul d i n g
4 N807 12 2 - S411 Sc r e w (8 Re q' d )
5 044D7 0 I nst r ume nt Pa ne l Fi ni sh Panel
A

Ti ght e n t o 2. 1-2. 9 N-m ( 19- 26 Lb-l n)
H e a t e r A i r P l e n u m C h a m b e r
Re mo v a l
2. Di sconnect t he heat er wa t e r hoses ( 1847 2 ) f r om
t he heat er c o r e t ubes. Plug t he ends of t he heat er
wa t e r hose s t o prevent cool ant l oss.
3. Plug heat er c or e t ubes securel y t o prevent
cool ant l eakage f r om heat er c or e ( 1847 6) duri ng
heat er ai r plenum chamber r emoval .
4. Remove t hr ee nut s l ocat ed bel ow t he wi ndshi el d
wi per mot or ( 17 508) ret ai ni ng t he LH end of t he
heat er ai r plenum chamber ( 1847 1) t o t he da sh
panel ( 01610) .
5. Remove one nut ret ai ni ng t he upper LH cor ner of
t he A / C e va por a t or c o r e housi ng ( 19A559) t o
t he da sh panel .
6. Remove LH and RH l ower i nst rument panel
i nsul at ors.
7. Di sconnect t wo vacuum suppl y hoses f rom
vacuum sour ce. Push gr ommet and vacuum
suppl y hose into passenger compart ment .
8. Remove all i nst rument panel ret ai ni ng sc r e ws and
pull t he i nst rument panel ( 04320) back as f ar as
possi bl e wi t hout di sconnect i ng any wi re
harnesses.
9. Loosen t he RH door sill pl at e and remove t he RH
si de c o wl t ri m panel .
10. Remove c r oss body br ace and di sconnect wi ri ng
harness f r om A / C el ect roni c door act uat or mot or
( 19E616) and di sconnect t he sensor t ube f r om
t he evapor at or case connect or.
11. Di sconnect t he vacuum j umper harness at t he
multi ple vacuum connect or near t he heat er out l et
f l oor d uc t ( 18C433) .
12. Di sconnect t he whi t e vacuum hose f r om t he
heat er and A / C ai r inlet duct door vacuum cont rol
mot or ( 18A318) .
13. Remove t wo hush panel s.
14. Remove one pl ast i c push f ast ener ret ai ni ng t he
heat er out l et f l oor duct t o t he LH end of t he
heat er air pl enum chamber . Remove LH sc r e w
and l oosen RH sc r e w on t he rear f a c e of t he
heat er ai r pl enum c ha mbe r and r emove t he
heat er out l et f l oor duct .
15. Remove t wo nut s f r om t he t wo st uds al ong t he
l ower f l ange of t he heat er ai r plenum chamber .
Heat er Ai r Pl enum Cha mbe r a n d Ai r I nl et Duc t
) 0
16. Caref ul l y move heat er ai r pl enum chamber
r e a r wa r d t o al l ow heat er c o r e t ube s and t he st ud
at t he t o p of t he heat er air pl enum chamber t o
cl ear hol es in t he da sh panel . Remove heat er ai r
plenum chamber f r om vehi cl e by r ot at i ng t he t o p
of t he heat er ai r pl enum chamber f o r wa r d , down
and out f r om under t he i nst rument panel . Caref ul l y
pull l ower edge of i nst rument panel r e a r wa r d a s
necessar y whi l e rolli ng t he heat er ai r plenum
chamber f r om behi nd t he i nst rument panel .
M3438-C
Pa r t
2 56956- S2 Sc r e w (2 Re q' d )
3 38687 7 - S36 Sc r e w
4 45445- S36 Nut a nd Wa s he r As s y
5 19C928 A / C Re c i r c ul a t i n g Ai r Duc t
Sc r e e n
6 38687 7 - S36M Sc r e w (2 Re q' d )
7 45332 - S12 Nut a nd Wa she r
8 19B762 A / C Ai r I nl et Do o r Inner Se a l
Par t
1 1 18C433 He a t e r Out l e t Fl o o r Duct
12 557 34- S2 Nut
Housi ng
14 45332 - S2 Nut a n d Wa she r
A
Ti ght e n t o 2. 5-3. 2 N-m ( 2 2 - 2 8
Lb-l n)
(Continued)
TM3438C
1 Rout e t he vacuum suppl y hose t hr ough t he da sh
panel and seat t he gr ommet in t he openi ng.
12 - 03A - 46 Ai r Condi t i oni ng S y s t e mMa n u a l A / C - He a t e r 12 - 03A - 46
2. Posi t i on t he heat er ai r plenum chamber under t he
i nst rument panel wi t h t he A / C regi st er duct
openi ng up and t he heat er c o r e t ubes d o wn .
Rot a t e t he heat er ai r plenum chamber up behi nd
t he i nst rument panel and posi t i on t he heat er ai r
pl enum chamber t o t he dash panel . Insert t he
heat er c o r e t ubes and mount i ng st uds t hr ough
t hei r r espect i ve hol es in t he da sh panel and t he
A / C evapor at or c or e housi ng.
3. Install t hr ee nut s on t he st uds al ong t he l ower
f l ange and one on t he upper f l ange of t he heat er
ai r plenum chamber .
4. Install t hr ee nut s bel ow t he wi ndshi el d wi per
mot or t o ret ai n t he LH end of t he heat er ai r
pl enum chamber t o t he dash panel .
5. Install one nut t o ret ai n t he upper LH cor ner of t he
A / C evapor at or c o r e housi ng t o t he da sh panel .
6. Posi t i on heat er out l et f l oor duct on heat er ai r
pl enum chamber . Install t wo sc r e ws and pl ast i c
push f ast ener.
7. If r e move d, posi t i on heat er ai r damper door
vacuum cont rol mot or t o t he mount i ng br a c ke t .
Install t wo ret ai ni ng sc r e ws.
8. Connect t he whi t e vacuum hose t o t he heat er and
A / C a i r inlet duct door vacuum cont r ol mot or .
9. Connect t he vacuum j umper harness t o t he
pl enum harness at t he multi ple vacuum connect or
near t he heat er out l et f l oor duct . Install heat er
out l et f l oor duct .
10. Connect t he sensor t ube t o t he e va por a t or c a se
connect or on EATC-equi pped vehi cl es.
11. Install t he c r o ss body br a c e and connect wi ri ng
har ness t o t he A / C el ect roni c door act uat or
mot or .
12. Install t he bol t t o ret ai n t he l ower RH end of t he
i nst rument panel t o t he si de c o wl .
13. Install t he RH si de c owl t ri m panel and t i ght en t he
RH door sill pl at e ret ai ni ng sc r e ws.
14. Install gl ove compar t ment door ( 06024) and
c he c k ar ms.
15. Connect vacuum suppl y hose t o vacuum suppl y.
16. Install RH and LH l ower i nst rument panel
i nsul at ors.
17. Install t wo hush panel s.
18. Unplug t he heat er c o r e t ubes and connect t he
heat er wa t e r hoses t o t he heat er c or e t ubes.
19. Fill t he cool i ng sy st e m wi t h cool ant t o repl ace
cool ant lost duri ng removal of t he heat er ai r
plenum chamber.
20. Connect t he bat t er y ground cabl e. Check t he
sy st e m f or proper oper at i on.
Du c t s
De mi s t e r No zzl e a n d Du c t
Re mo v a l
1. Remove t he i nst rument panel ( 04320) . Ref er t o
Sect i on 01-12.
2. Wi t h t he i nst rument panel lyi ng on t he f ront seat ,
r emove f our sc r e ws ret ai ni ng t he demi st er nozzle
and duct ( 18D453) t o t he t op of t he i nst rument
panel and t wo sc r e ws ret ai ni ng t he demi st er
nozzl e and duct t o t he i nst rument panel
rei nf orcement ( 04545) .
3. Remove demi st er nozzle and duct f r om
i nst rument panel .
12- 03A- 47 Ai r Condi t i oni ng Sy st e mManual A/ C- He a t e r 12- 03A- 47
Demi st er Nozzl e and Duct Re mo v a l Cr own Vi ct or i a/ Gr and Marqui s
I NSTRU MENT
P A N E L A S S Y
0 4 3 2 0
DE MI S T E R
N O Z Z L E
A ND DU CT
1 8 D4 5 3
M343S-C
A / C S i d e Wi n d o w De mi s t e r a n d Hos e
1. Remove t he instrument panel . Refer t o Secti on
01- 12.
2. Wi t h t he i nst rument panel l yi ng on t he f ront seat ,
pull off bot h RH A / C si de wi n d o w demi st er and
hose ( 19E630) and LH A / C si de wi ndow
demi st er and hose f r om demi st er nozzle and duct
and wi ndow def ogger nozzl e ( 18C515) .
A / C Si de Wi n d o w De mi st e r a n d Hose
M4699-A
Pa r t
1 18C515 Wi n d o w De f o gge r Nozzl e
2 19E630 A / C Si d e Wi n d o w De mi st e r a n d Ho se , LH
3 18D453 De mi st e r Nozzl e a nd Duct
4 0432 0 I nst r ume nt Panel
5 19E630 A / C Si d e Wi n d o w De mi st e r a n d Ho se , RH
TM4699A
A / C E v a p o r a t o r Re g i s t e r Du c t s
1. Remove the instrument panel. Refer to Section
01-12.
2. With the instrument panel lying on the front seat,
remove two screws retaining either the RH A / C
evaporator register duct (19B680) or LH A / C
evaporator register duct to the top of the
instrument panel.
3. Remove one screw retaining the A / C evaporator
register duct to the demister nozzle and duct and
two screws to the instrument panel
reinforcement.
4. Remove the A / C evaporator register ducts from
12 - 03A - 49 Ai r Condi t i oni ng S y s t e mMa n u a l A/ C- He a t e r 12 - 03A- 49
A / C Evapor at or Regi st er Duct Removal Town Car
INSTRUMENT PANEL
ASSY 04320
RH A/C
EVAPORATOR
REGISTER DUCT
19B680
LH A/C EVAPORATOR
REGISTER DUCT
19B680
M3437-C
He a t e r Ou t l e t Fl o o r
Re mo v a l
1. Remove t wo sc r e ws ret ai ni ng passenger (r ear )
si de of heat er out l et f l oor duct ( 18C433) t o t he
heat er air pl enum chamber ( 1847 1) assembl y. It
may be ne c e ssa r y t o r emove t he t wo nut s
ret ai ni ng heat er ai r damper door vacuum cont r ol
mot or ( 18A318) t o t he mount i ng br a c ke t t o gai n
a c c e ss t o t he RH duct sc r e w.
2. Remove one pl ast i c push pin f ast ener ret ai ni ng
t he heat er out l et f l oor duct t o t he LH end of t he
heat er air pl enum chamber and r emove t he
heat er out l et f l oor duct .
He a t e r Out l e t Fl oor Duc t Re mova l
PUSH PIN
FASTENER
HEATER OUTLET
FLOOR DUCT
18C433
SCREW
2 REQ'D M3462-B
1. Posi t i on heat er out l et f l oor duct t o t he plenum ai r
duct openi ng. Install pl ast i c push pin f ast ener t o
t he LH end of heat er air plenum chamber and
heat er out let f l oor duct .
2. Install t he t wo sc r e ws t hat retai n t he passenger
(r ear ) si de of t he heat er out l et f l oor duct t o t he
heat er air plenum chamber assembl y.
1 2 - 0 3 A - 5 0 Air Conditioning SystemManual A/ C- Heat er 12- 03A- 5 0
3. Posi t i on t he heat er air damper door vacuum
cont r ol mot or. Install t he two retaining nuts.
A / C Rec i r c ul at i ng A i r
Removal
1. Remove t he heat er ai r plenum chamber assembl y
a s out l i ned.
2. Turn t he st eeri ng wheel ( 3600) t o t he ri ght t o
posi t i on t he RH f ront wheel so t hat t he RH f ront
f ender spl ash shi el d support br a c ke t is
accessi bl e. If necessar y, r emove t he RH f ront
wheel and t i re assembl y f r om vehi cl e.
3. Remove t he spl ash shi el d suppor t br a c ke t (one
sc r e w) and t he pl ast i c push r i vet s f r om around
t he wheel wel l openi ng on t he RH f r ont f ender.
4. Pull t he rear of t he spl ash shi el d a wa y f r om t he
wheel wel l and r emove t he nut f r om t he bo t t o m
st ud of t he A / C reci rcul at i ng ai r duct ( 19C590) .
6. Remove t he nut f r om t he st ud t hat ret ai ns t he
A / C reci rcul at i ng ai r duct t o t he c o wl t o p at t he
out si de ai r inlet openi ng.
6. Remove t he upper sc r e w f r o m t he out boa r d si de
of t he A / C reci rcul at i ng ai r duct assembl y.
7. Fr om t he passenger compar t ment , r emove t he
sc r e w f r om t he bot t om LH si de of t he A / C
reci rcul at i ng ai r duct assembl y.
8. Pull t he bot t om of t he A / C reci rcul at i ng ai r duct
assembl y r e a r wa r d di sengagi ng t he bot t om st ud
f r o m t he da sh panel ( 01610) . Whi l e movi ng it t o
t he lef t , di sengage t he t o p st ud and r emove t he
assembl y f r om t he vehi cl e.
1. Maneuver t he A / C reci rcul at i ng ai r duct
assembl y i nto posi t i on. Ensure t hat t he t o p and
bo t t o m st uds pr ot r ude t hr ough t he st ud hol es in
t he c o wl t o p and da sh panel .
2. Install t he sc r e w i nto t he bot t om LH si de of t he
A / C reci rcul at i ng ai r duct assembl y but do not
t i ght en.
3. Install t he nut t o ret ai n t he A / C reci rcul at i ng ai r
duct t o t he c owl t o p at t he out si de ai r inlet
openi ng.
4. Fr om t he engi ne compar t ment , i nstall t he upper
sc r e w on t he out boar d si de of t he A / C
reci rcul at i ng air duct assembl y.
6. Install t he nut on t he st ud l ocat ed behi nd t he RH
f ront f ender spl ash shi el d.
6. Install t he spl ash shi el d support br a c ke t and
sc r e w. Ti ght en t o speci f i cat i on. Al so secur e t he
out er edge of t he spl ash shi eld t o t he inner a r e a
of t he wheel wel l openi ng wi t h t he pl ast i c ri vet s. If
r emoved, repl ace t he RH f ront wheel and t i re
assembl y. Refer t o Sect i on 04-04.
7. Fr om t he passenger compar t ment , t i ght en t he
previ ousl y i nst al l ed sc r e w at t he bot t om LH si de
of t he A / C reci rcul at i ng air duct assembl y.
8. Install t he heat er air plenum chamber assembl y
a s out l i ned.
9. Check t he sy st e m f or proper oper at i on.
Doors
Wi n d s h i e l d De f r o s t e r
Re mo v a l
1. Remove t he heat er air plenum chamber ( 1847 1)
f r om vehi cl e a s out l i ned.
2. Through t he f l oor air di st ri but i on openi ng, pull t he
wi ndshi el d def r ost er door ( 18A47 8) f r om t he
cr ank ar m and remove t he wi ndshi el d def r ost er
door f r om t he heat er air plenum chamber .
Wi n d shi e l d De f r o st e r Door
M4700-A
Pa r t
It em Number De s c r i p t i o n
2 18A318 Va c uum Co n t r o l Mo t o r
3 18C433 He a t e r Out l e t Fl o o r Duct
4 38997 5- S2 Sc r e w
5 18A47 8 Wi n d shi e l d De f r o s t e r Do o r
6 Wi n d s hi e l d De f r o s t e r Do o r Cr a nk Ar m (Pa r t of 18471)
TM4700A
1. Posi t i on t he wi ndshi el d def r ost er door in t he
heat er air plenum chamber and posi t i on t he
wi ndshi el d def r ost er door t o t he cr ank a r m.
2. Through t he f l oor air di st ri but i on openi ng, i nstall
one sc r e w t o ret ai n t he wi ndshi el d def r ost er door
t o t he crank a r m.
j 3. Check t he wi ndshi el d def r ost er door f or f r e e dom
of movement . Cor r ect any exi st i ng st i cki ng,
bi ndi ng or gr abbi ng condi t i on.
4. Install t he heat er air plenum chamber in t he
He a t e r Ai r Da mp e r
Re mo v a l
1. Remove t he heat er air plenum chamber f r om t he
2 . Remove t he sl eeve nut ret ai ni ng t he vacuum
mot or a r m t o t he heat er air damper door
(18A361).
3. Remove t wo sc r e ws ret ai ni ng door hi nge t o
heat er ai r plenum chamber upper half.
12-^03 A - 62 Ai r Co n d i t i o n i n g S y s t e mMa n u a l A/ C- Heat er 12- 03A- 52
4. Drill and r emove t wo ri vet s ret ai ni ng t he heat er ai r
damper door hi nge t o t he heat er ai r plenum
chamber l ower half.
He a t e r Ai r Da mpe r Do o r
5. Remove t he heat er air damper door f r om t he
heat er ai r plenum chamber t hrough t he dash
panel inlet openi ng.
M4 7 0 1 - A
Pa r t
3 18A361 He a t e r Ai r Da mpe r Do o r
4

Sc r e w (2 Re q' d )
5

Ri vet (2 Re q' d )
TM4701A
1. Posi t i on t he heat er ai r damper door into t he
heat er ai r plenum c ha mbe r t hr ough t he da sh
panel inlet openi ngs.
2. Install t wo sc r e ws t o ret ai n heat er air damper
door hi nge t o heat er ai r plenum chamber upper
half.
3. Ei t her pop-ri vet or i nstall t wo sc r e ws and nut s t o
ret ai n t he panel door hi nge t o t he heat er air
plenum c ha mbe r l ower half.
4. Che c k t he door f or al i gnment and f r e e dom of
movement . Cor r ect any exi st i ng st i cki ng, bi ndi ng
or gr abbi ng condi t i on.
5. Connect t he vacuum mot or arm t o t he heat er ai r
damper door wi t h a new sl eeve nut.
6. Install t he heat er ai r plenum chamber in t he
vehi cl e.
7. Che c k t he sy st e m f or proper oper at i on.
He a t e r a n d A / C I n l e t Du c t
Re mo v a l
1. Remove t he A / C reci rcul at i ng ai r duct (19C590)
a s out l i ned.
2. Remove one sc r e w ret ai ni ng t he heat er and A / C
ai r inlet duct door ( 187 31) t o t he door cr ank a r m.
3. Pull t he heat er and A / C air inlet duct door f r om
t he cr ank a r m and remove t he heat er and A / C ai r
inlet duct door f r om t he A / C reci rcul at i ng ai r duct .
12 - 03A - 53 Ai r Co n d i t i o n i n g Sy s t e mMa n u a S A / C - H e a t e r 12 - 03A - 53
Heat er a nd A / C I nl et Duc t Do o r
Pa r t
1 187 31 He a t e r a n d A / C Ai r I nl et Duct
Do o r
3

He a t e r a nd A / C I nl et Duct
Do o r Cr a n k Ar m (Pa r t of
19C590)
5 42 12 7 - S2 Sc r e w
T M4 7 0 2 A
1. Posi t i on t he heat er and A / C a i r inlet duc t door in
t he A / C reci rcul at i ng ai r duct t hr ough t he da sh
panel inlet openi ng.
2. Install one sc r e w t o ret ai n t he heat er and A / C a i r
inlet duct door t o t he c r a nk a r m.
3. Che c k t he heat er and A / C a i r inlet duct door f or
f r e e dom of movement . Cor r e c t any exi st i ng
st i cki ng, bi ndi ng or gr abbi ng condi t i on.
4. Install t he A / C reci rcul at i ng air duct in t he vehi cl e
a s out l i ned.
5. Che c k t he sy st e m f or pr oper oper at i on.
V a c u u m C o n t r o l Mo t o r s
Wi n d s h i e l d De f r o s t e r Do o r
Re mo v a l
1. Remove t he heat er out l et f l oor duct ( 18C433) a s
out l i ned.
2. Remove t he pushnut ret ai ni ng t he vacuum mot or
a r m t o t he f l oor -def r ost door c r a nk a r m.
3. Remove t wo nuts ret ai ni ng t he vacuum cont r ol
mot or ( 18A318) t o t he mot or br a c ke t .
4. Di sengage t he vacuum cont r ol mot or f r o m t he
mount i ng br a c ke t and t he mot or a r m f r om t he
door c r a nk a r m.
5. Remove t he vacuum cont r ol mot or f r om t he
heat er air plenum chamber ( 1847 1) . Di sconnect
t he vacuum hoses f r om t he vacuum cont r ol
mot or.
Fl o o r - De f r o st Door Vacuum Mo t o r Re mova l
M3440- C
Pa r t
1 Wi n d shi e l d De f r o st e r Door
Cr ank Ar m (Par t of 18471)
2 18A318 Wi n d shi e l d De f r o st e r Door
Va c uum Cont r ol Mo t o r
3 18C433 He a t e r Out l et Fl oor Duct
4 38502 4- S2 Push Nut
5 452 46- S2 Nut (2 Re q' d )
1. Connect t he yel l ow vacuum hose t o t he vacuum
mot or end nipple and t he red vacuum hose t o t he
vacuum mot or si de ni pple. Posi t i on vacuum
cont rol mot or t o t he f l oor-def rost door crank ar m
and t he mot or mounti ng br a c ke t .
2 . Install t wo nuts t o ret ai n t he vacuum cont rol mot or
t o t he mounti ng br acket .
3. Install a new pushnut t o ret ai n vacuum cont rol
mot or ar m on t he door crank a r m.
4. Install t he heat er outlet f l oor duct assembl y.
1995 To wn Car, Cr own Vi c t o r i a , Gr a n d Ma r q u i s Jul y 1 9 9 4
He a t e r A i r Da mp e r Do o r
Re mo v a l
1. Remove t he heat er air plenum chamber f r om t he
vehi cl e a s out l i ned.
2. Reach t hr ough t he demi st er nozzle and duct
openi ng and remove t he sl eeve nut ret ai ni ng t he
vacuum mot or ar m t o t he heat er ai r damper door
( 18A361) .
3. Remove t wo sc r e ws ret ai ni ng t he vacuum cont rol
mot or t o t he mount i ng br a c ke t .
4. Di sengage t he vacuum cont rol mot or f r om t he
heat er ai r plenum chamber and di sconnect t he
vacuum hose f r om t he vacuum cont rol mot or .
He a t e r Ai r Da mpe r Door Va c uum Co n t r o l
1. Posi t i on t he vacuum cont r ol mot or t o t he
mount i ng br a c ke t and t he heat er air damper door
br a c ke t .
2. Install t wo sc r e ws t o ret ai n t he vacuum cont r ol
mot or t o t he mount i ng br a c ke t .
3. Connect t he vacuum mot or ar m t o t he heat er air
damper door wi t h a new sl eeve nut.
4. Connect t he vacuum hose t o t he vacuum cont rol
mot or.
5. Install t he heat er air plenum chamber in t he
vehi cl e a s out l i ned.
He a t e r a n d A / C Ai r I n l e t Du c t Do o r
Re mo v a l
1. Remove t he spri ng nut retai ni ng t he heat er and
A / C ai r inlet duct door vacuum cont rol mot or ar m
t o t he heat er and A / C air inlet duct door cr ank .
a r m.
2. Di sengage t he vacuum cont rol mot or a r m and
wa she r f r om t he cr ank a r m.
3. Di sengage t he assi st spri ng and t he second
wa she r f r om t he cr ank a r m.
4. Di sconnect t he whi t e vacuum hose connect or
f r o m t he vacuum cont rol mot or.
5. Remove t wo nut s retai ni ng t he vacuum cont rol
mot or and t he assi st spri ng br acket t o t he ai r inlet
duct mount i ng br a c ke t . Remove t he vacuum
cont rol mot or and t he assi st spri ng mounti ng
br a c ke t .
Heat er a n d A / C Ai r I nl et Duct Door Vacuum Co n t r o l
Mo t o r Removal
Pa r t
2 18B283 He a t e r Ai r Vent Door Spr i n g
3 He a t e r a n d A / C Ai r I nl et Duct
Door Cr a nk Ar m (Pa r t of
19C590)
4 452 7 0- S36 Nut (2 Re q' d )
6 447 11- S2 Wa she r
7 37 2 92 7 - S2 Pushnut
8 18A318 Va c uum Cont r ol Mo t o r
TM3446C
12 - 03A- S5 Ai r Conditioning S y s t e m Ma n u a l A/C-Heater 12 - 03A - 55
I nst al l at i on
1. Position t he vacuum cont r ol mot or and t he assi st
spri ng br a c ke t t o t he ai r inlet duct mount i ng
bracket . Install t he ret ai ni ng nuts.
2. Install one of the washer s on t he crank a r m.
Install the l oop end of t he assi st spri ng.
3. Install t he se c ond wa she r and t he vacuum cont r ol
mot or a r m on t he cr ank a r m. Secur e t he t wo
wa she r s, t he assi st spri ng and t he vacuum
cont rol mot or a r m on t he c r a nk ar m wi t h a new
spri ng nut .
4. Connect t he whi t e va c uum hose connect or ont o
t he vacuum cont rol mot or .
5. Check f or pr oper sy st e m oper at i on.
S u c t i o n A c c u m u l a t o r / D r i e r
a c c u mu l a t o r / d r i e r ( 19C836) i s n e c e s s a r y a n y
t i me a ma j o r c o mp o n e n t o f t h e r e f r i ge r a n t s y s t e m
i s r e p l a c e d . Fa i l ur e t o r e p l a c e t h e s u c t i o n
a c c u mu l a t o r / d r i e r wi l l e x p o s e t h e r e f r i ge r a n t
s y s t e m t o e x c e s s i v e mo i s t u r e a c c u mu l a t i o n . A
ma j o r c o mp o n e n t i n c l u d e s A / C c o n d e n s e r c o r e
( 197 12 ) , A / C c o mp r e s s o r ( 197 03) , A / C
e v a p o r a t o r c o r e ( 19860) o r a r e f r i ge r a n t
h o s e / l i n e . A n A / C e v a p o r a t o r c o r e o r i f i c e
( 19D990) o r O- r i n g se a l i s n o t c o n s i d e r e d a ma j o r
c o mp o n e n t b u t t h e A / C e v a p o r a t o r c o r e o r i f i c e
s h o u l d b e r e p l a c e d wh e n e v e r t h e A / C
c o mp r e s s o r i s r e p l a c e d f o r l a c k o f p e r f o r ma n c e .
In addi t i on t o t he pr ecedi ng condi t i on, t he suct i on
a c c umul a t o r / d r i e r shoul d al so be r epl aced if one of
The suct i on a c c umul a t o r / d r i e r i s pe r f or a t e d.
at mospher e f or a per i od of t i me longer t han requi red
t o make a mi nor repai r.
There is evi dence of moi st ure in t he sy st e m such as
i nt ernal c or r osi on of met al ref ri gerant lines or t he
ref ri gerant oil i s t hi ck and da r k.
NOTE: The c ompr e ssor oil f r o m vehi cl es equi pped
wi t h an FS-10 A / C c ompr e ssor may have a da r k col or
whi l e mai ntai ni ng a normal oil vi scosi t y . Thi s i s normal
f or t hi s A / C c o mpr e sso r be c a use c a r bon f r o m t he
A / C c ompr e ssor pi st on ri ngs wi ll di scol or t he oi l .
Repl ace t he suct i on a c c umul a t o r / d r i e r a s out l i ned t o
ensure t hat t he t ot al oil c ha r ge in t he sy st e m i s c or r e c t
af t er t he new suct i on a c c umul a t o r / d r i e r is i nst al l ed.
Drai n t he oi l f r o m t he r e move d suct i on
a c c umul a t o r / d r i e r i nto a sui t abl e measuri ng
cont ai ner. Drill one or t wo 1 / 2- i n c h hol es in t he
bo t t o m of t he ol d suct i on a c c umul a t o r / d r i e r t o
ensur e t ha t all t he oil has drai ned out .
A d d t he sa me amount of cl ean, new Mo t o r c r a f t
YN- 12b ref ri gerant oil meet i ng For d speci f i cat i on
WSH- M 1C231-B plus 60 ml (2 ounces) t o t he new
suct i on a c c umul a t o r / d r i e r . Use onl y t he oil
speci f i ed f or t he speci f i c vehi cl e bei ng se r vi c e d.
Re mo v a l
Sp r i n g L o c k Co u p l i n g Di s c o n n e c t To o l
( 3 / 8 i n c h)
( 1 / 2 i n c h)
T 81P - 1962 3- G 1
T 81P - 1962 3- G2
1. Di schar ge t he ref ri gerant f r o m t he A / C sy st e m
f ol l owi ng t he r ecommended ser vi ce pr oc e dur e s.
Obse r ve all sa f e t y precaut i ons. Ref er t o Sect i on
12-00.
2. Di sconnect t he evapor at or t o c ompr e ssor
suct i on line ( 19867 ) f r om t he suct i on
a c c umul a t or / dr i e r using Spri ng Lo c k Coupl i ng
Di sconnect Tool T81P-19623-G1 and G2.
3. Loosen t he f i t t i ng connect i ng t he suct i on
a c c umul a t or / dr i e r t o t he A / C evapor at or c o r e .
Use t wo wr e nc he s t o prevent component
damage.
4. Remove t he bol t ret ai ni ng t he A / C accumul at or
br acket ( 19D607 ) t o t he mount i ng br a c ke t .
5. Di sconnect t he suct i on a c c umul a t or / dr i e r f r om
t he A / C evapor at or cor e. Remove t he A / C
accumul at or br a c ke t s f r om t he suct i on
a c c umul a t or / dr i e r .
Pa r t
1

A / C Ev a po r a t o r Co r e Out l e t Tube ( Pa r t of 19860)
3 19867 Ev a po r a t o r t o Co mpr e s s o r Suc t i o n Li ne
5 19D607 A / C Ac c umul a t o r Br a c ke t
6 N8087 19- S2 Bol t
TM4703A
1. Usi ng a new O-ri ng seal l ubri cat ed wi t h cl ean
Mot or c r a f t YN-12b ref ri gerant oil meet i ng For d
speci f i cat i on WSH-M1C231-B, connect t he
suct i on a c c umul a t o r / d r i e r t o t he A / C evapor at or
c o r e out l et t ube. Ti ght en connect i on f i nger-t i ght
onl y.
2. Posi t i on t he A / C accumul at or br a c ke t on t he
suct i on a c c umul a t o r / d r i e r . Ali gn t he A / C
accumul at or br a c ke t wi t h t he mount i ng br acket
and i nstall t he ret ai ni ng bol t . Loosen t he
connect i on of t he suct i on a c c umul a t o r / d r i e r t o
t he A / C e va por a t or c o r e if it is necessar y t o
reposi t i on t he suct i on a c c umul a t o r / d r i e r t o install
t he br a c ke t ret ai ni ng sc r e w.
3. Ti ght en t he suct i on accumul at or / d r i e r t o A / C
e va por a t or c or e f i t t i ng usi ng t wo wr e nc he s.
4. Usi ng a new O-ri ng seal l ubri cat ed wi t h cl ean
Mot or c r a f t YN-12b ref ri gerant oil meet i ng For d
speci f i cat i on WSH-M1C231-B, connect t he
e va por a t or t o c ompr e ssor suct i on line t o t he
suct i on a c c umul a t or / dr i e r .
5. Leak-t est , evacuat e and c ha r ge t he sy st e m
f ol l owi ng t he r ecommended ser vi ce pr ocedur es.
Obse r ve all saf et y precaut i ons. Ref er t o Sect i on
12-00.
Re mo v a l
1. Di sconnect t he wi r e connect or f r om t he A / C
cycl i ng swi t c h ( 19E561) .
12- 03A-67 Ai r Co n d i t i o n i n g S y s t e mMa n u a l A / C - H e a t e r 12 - 03A - 57
2. Unscr ew t he A / C cy cl i ng swi t c h f r om t he
evapor at or t o c ompr e ssor suct i on line ( 19867 ) .
Pa r t
1 Wi r e Co n n e c t o r (Pa r t of
14401)
2 14A163 Wi r i n g Ha r n e ss Re t a i n e r
3

L o w Pr e ssur e Se r v i c e Por t
Fi t t i n g (Pa r t of 19c 836)
5 19867 Ev a po r a t o r t o Co mp r e s s o r
Suc t i o n Li ne
TM4704A
1. Install a new O-ri ng seal , l ubri cat ed wi t h cl ean
Mot or c r a f t YN-12 ref ri gerant oil or equi val ent
meet i ng Ford speci f i cat i on WSH-M 1C231-B, on
t he suct i on line f i t t i ng.
2. Sc r e w t he A / C cycl i ng swi t c h on t he suct i on line
f i t t i ng. Ti ght en t he A / C cycl i ng swi t c h f i nger-t i ght
only.
3. Connect t he wi re connect or t o t he A / C cy cl i ng
swi t c h.
4. Check t he sy st e m f or proper operat i on.
A / C E v a p o r a t o r C o r e O r i f i c e
The A / C evapor at or c or e ori f i ce ( 19D990) i s
c onst r uc t e d wi t h a pl ast i c body , t wo scr eens and a
smal l br a ss t ube down t he cent er of t he A / C
e va por a t or cor e ori f i ce body. Two O-ri ng seal s ar e
around t he A / C evapor at or c or e ori f i ce body t o seal
agai nst l eakage around t he body .
CAUTI ON: Do n o t a t t e mp t t o r e mo v e t h e A / C
e v a p o r a t o r c o r e o r i f i c e w i t h pl i e r s o r t o t w i s t o r
r o t a t e t h e A / C e v a p o r a t o r c o r e o r i f i c e i n t h e A / C
e v a p o r a t o r c o r e t u b e . To d o s o wi l l b r e a k t h e
f i x e d o r i f i c e t u b e b o d y i n t h e e v a p o r a t o r c o r e
t u b e . Use o n l y t h e r e c o mme n d e d t o o l a s o u t l i n e d .
Spr i n g L o c k Co u p l i n g Di s c o n n e c t To o l
( 3 / 8 i n c h )
Spr i n g L o c k Co u pl i n g Di s c o n n e c t To o l
( 1 / 2 i n c h)
Br o ke n Or i f i c e Tube E x t r a c t o r
T 81P - 1962 3- G 1
T 81P - 1962 3- G2
T 80L - 19990- B
Re mo v a l
f ol l owi ng t he r e c omme nde d ser vi ce pr oc e dur e s.
Obse r ve all saf et y precaut i ons. Ref er t o Sect i on
12-00.
2. Di sconnect t he condenser t o evapor at or t ube
( 19835) f r om t he A / C e va por a t or c or e ( 19860)
usi ng Spri ng Lo c k Coupl i ng Di sconnect Tool
T81P-19623-G1 and G2. Cap t he condenser t o
evapor at or t ube t o prevent t he ent rance of di rt
and e xc e ssi ve moi st ure.
3. Pour a smal l amount of cl ean Mot or c r a f t YN-12
speci f i cat i on WSH-M 1C231-B i nto t he
evapor at or c or e inlet t ube t o l ubri cat e t he t ube
and O-ri ng seal s duri ng removal of t he A / C
evapor at or c or e ori f i ce f r om t he evapor at or c o r e
t ube.
4. Engage t he Fi xed Ori f i ce Tube Tool
D80L- 19990- A or equi valent wi t h t wo t angs on
t he A / C evapor at or c or e ori f i ce. Do not t wi st or
r ot at e t he A / C evapor at or c or e ori f i ce in t he A / C
evapor at or c or e t ube as it may break off.
5. Hol d t he T-handle of t he Fi xed Ori f i ce Tube Tool
D80L- 19990- A or equi valent t o keep it f r om
turni ng and run t he nut on t he t ool down agai nst
t he A / C evapor at or c or e t ube until t he A / C
evapor at or c or e ori f i ce i s pulled f r om t he t ube.
NOTE: If t he A / C evapor at or c or e ori f i ce br e a ks in t he
A / C evapor at or c or e t ube, r emove it f r om t he t ube
wi t h Broken Ori f i ce Tube Ext r a c t or D80L- 19990- B or
equi valent a s f ol l ows.
a. To remove a broken A / C evapor at or c or e
ori f i ce, i nsert t he sc r e w end of t he Br oken Ori f i ce
Tube Ext r a c t or D80L- 19990- B i nto t he A / C
evapor at or c or e t ube and t hr ead t he sc r e w end
of t he t ool i nt o t he br ass t ube in t he cent er of t he
A / C evapor at or cor e ori f i ce. Pull t he A / C
evapor at or cor e ori f i ce f r om t he A / C evapor at or
cor e t ube.
12 - 03A- 5S Ai r Co n d i t i o n i n g S y s t e mMa n u a l A / C - He a t e r 12 - 03A - 58
b. If onl y t he br a ss cent er t ube is r emoved duri ng
St ep a, i nsert t he sc r e w end of Br oken Ori f i ce
Tube Ext r a c t or D80L- 19990- B i nto t he A / C
evapor at or c or e t ube and sc r e w t he end of t he
t ool i nto t he A / C evapor at or c or e ori f i ce body .
Pull t he A / C e va por a t or c o r e ori f i ce body f r om
t he A / C e va por a t or c o r e t ube.
A / C Ev a po r a t o r Cor e Or i f i c e
BROKE N ORI FI CE
T UBE E XTRACTOR
D80L-19990-B
NOTCH
A/ C EVAPORATOR
C O R E ORI FI CE
19D990
M1S07-E
1. Lubr i cat e t he O-ri ng seal s on t he A / C e va por a t or
c o r e ori f i ce l i beral l y wi t h cl ean Mot or c r a f t
YN-12b ref ri gerant oil or equi val ent meet i ng For d
speci f i cat i on WSH-M1C231-B.
2. Pl ace t he A / C e va por a t or c or e ori f i ce in t he
Fi xe d Ori f i ce Tube Tool D80L- 19990- A or
equi val ent and i nsert t he A / C evapor at or c o r e
ori f i ce i nto t he A / C evapor at or c or e t ube until t he
A / C evapor at or c o r e ori f i ce is seat ed at t he st op.
3. Remove t he r e mo v e r / r e pl a c e r t ool f r om t he A / C
e va por a t or c o r e ori f i ce.
4. Usi ng a new O-ri ng l ubri cat ed wi t h cl ean
meet i ng Fo r d speci f i cat i on WSH-M1C231-B,
connect t he condenser t o evapor at or t ube t o t he
O-ri ng seal s.
5. Leak-t est , evacuat e and c ha r ge t he sy st e m
f ol l owi ng t he r ecommended ser vi ce pr oc e dur e s.
Obse r ve all sa f e t y pr ecaut i ons. Ref er t o Sect i on
12-00.
A / C P r e s s u r e C u t - O f f S w i t c h
1. Loc a t e t he A / C pressure cut -of f swi t c h
( 19D594) on t he A / C c ompr e ssor t o condenser
di schar ge line ( 19972) .
2. Remove t he el ect ri cal connect or.
3. Remove t he A / C pressure cut -of f swi t c h.
12 - 03A - 59 Ai r Co n d i t i o n i n g S y s t e m Ma n u a l A / C - H e a t e r 12 - 03A - 59
MMMMMMBIIIIIIIIHl^'t'H IIH I"
11
11
1
I'll l>l I'HiHill'll'l'fflW ' I l l HU' l Umi l l l !
A / C Pr essur e Cut -Of f Swi t c h
A / C C O MP R E S S O R T O
C O N DE N S E R DI S CHA RG E
TUBE 19972
/
A / C P RE S S URE
C UT - OFF S WI T C H
19D594
FRON T O F
VEHI CL E fc
A / C COMPRESSOR
19703
M 4 7 0 5 - A
Re mo v a l
NOTE: Whenever t he A / C condenser c or e ( 197 12) is
r epl aced, it will be ne c e ssa r y t o r epl ace t he suct i on
accumul at or / dri er ( 190836) .
CAUTI ON: If a n A / C c o n d e n s e r c o r e l e a k i s
s u s p e c t e d , t h e A / C c o n d e n s e r c o r e mu s t b e
l e a k t e s t e d b e f o r e i t i s r e mo v e d f r o m t h e v e h i c l e .
Re f e r t o S e c t i o n 12 - 00 f o r l e a k- t e s t p r o c e d u r e .
S P E C I A L S E R V I C E T O O L ( S ) R E Q U I R E D
Spring Look Co u pl i n g Di s c o n n e c t To o l T 81F- 1962 3 G I
( 3 / 8 i n c h)
Sp r i n g tocM Cour.fmcj Di s c o n n e c t Too! T81F- 19623- G2
( 1 / 2 inch)
1. Di sconnect t he t ransmi ssi on oil cool er inlet and
out l et l i nes. Loose n t ransmi ssi on oil cool er lines
whi l e hol di ng r adi at or f i t t i ng wi t h a ba c k- up
wr e n c h.
2. Drai n engi ne cool i ng sy st e m, al l owi ng t he engi ne
cool ant t o drai n f r o m t he cool i ng sy st e m i nt o a
cl ean cont ai ner f or reuse. Di sconnect upper
r adi at or hose ( 82 60) , l ower r adi at or hose ( 8286)
a nd de-aerat i on hose f r om t he r adi at or ( 8005)
3. Di sc ha r ge t he ref ri gerant f r om t he A / C sy st e m at
t he ser vi ce a c c e ss val ve l ocat ed on t he suction
a c c umul a t o r / d r i e r . Observe all saf et y
pr ecaut i ons in Secti on 12-00,
4. Di sconnect t he t wo ref ri gerant lines a t t he f i t t i ngs
near t he radi at or on t he RH si de of t he vehi cl e
usi ng Spri ng Lo c k Coupli ng Di sconnect Tool
T81P- 19623- G1 and G2. Plug t he li nes t o prevent
di rt and excessi ve moisture f r om enteri ng.
5. Loosen engi ne air cl eaner t ube cl amp (9C632) at
air cl eaner out l et t ube ( 9B659) t o ma ss air f l ow
sensor ( MAF se nsor ) ( 12B579) and r emove air
cleaner out l et t ube f r om mass air f l ow sensor.
6. Unf ast en ret ai ni ng cl i ps t o r emove t he air cl eaner
cover and posi t i on it a wa y f r o m t he r a d i a t o r / A / C
condenser cor e a r e a .
7. If equi pped wi t h f an shroud ( 8146) , remove t wo
upper shr oud ret ai ni ng bolts at radi ator support
( 16138) . Lift f an shr oud sufficiently t o di sengage
l ower ret ai ni ng cl i ps and lay f an shr oud back over
f an bl ade ( 8600) /
Remove radi at or upper support retaining bol t s
and r emove radi at or support s. Lift radi ator and
A / C condenser c or e f r om vehi cl e as an
assembl y,
8. Remove upper condenser mounti ng br a c ke t boi t s
and separ at e A / C condenser c or e f r o m radi at or.
12 - 03A - 60 Ai r Co n d i t i o n i n g Sy s t e mMa n u a l A / C - Heat er 12 - 03A - 60
A / C Co n d e n se r Cor e Removal
FRONT OF
VEHI CLE
VI E W B
VI E W A
V I E W B
M4S56-A
I t e m
Pa r t
1 19712 A / C Co n d e n se r Co r e
2

To A / C Co mp r e s s o r
3

To A / C E v a po r a t o r Co r e
4

Ra d i a t o r Gr i l l e Ope n i n g
5

Sc r e w
I t e m
Pa r t
6 16138 Ra d i a t o r Suppo r t
7 8005 Ra d i a t o r
8 N602 7 2 8- S56 Sc r e w (2 Re q' d )
A

Ti ght e n t o 8-11 N-m ( 70- 97
Lb-l n)
1
3.
If t he A / C condenser c or e i s t o be r e pl a c e d, add
2. 9 ml (1 ounce) of cl ean Mot or c r a f t YN-12b
speci f i cat i on WSH-M 1C231 -B t o t he A / C
condenser c o r e .
Install A / C condenser c or e ont o radi at or and
secur e upper condenser mount i ng br a c ke t s t o
t he radi at or wi t h t wo ret ai ni ng bol t s.
Posi t i on t he radi at or and A / C condenser c o r e
i nto t he vehi cl e as an assembl y. Install upper
suppor t s and secur e wi t h bol t s.
Connect t he t ransmi ssi on oil cool er li nes whi l e
usi ng a back-up wr e n c h t o hol d f i t t i ng.
5. Pl ace f an shr oud i nto cl i ps on l ower radi at or
support of radi at or. Secure t o upper support wi t h
t wo bol t s. Posi t i on f an shroud t o mai ntai n a
uni f orm cl ear ance of approxi mat el y 25 mm (1
i nch) t o f an bl ades.
6. Posi t i on air cl eaner cover on t he ai r cl eaner body
and secur e retai ni ng cl i ps.
7. Install ai r cl eaner out l et t ube t o mass air f l ow
sensor and t i ght en engi ne air cl eaner t ube cl amp.
Ti ght en t o 3. 4-4. 6 N-m (30-41 lb-in).
8. Remove t he pl ugs f r om t he t wo ref ri gerant li nes
and i nstall new O-ring seal s af t er di ppi ng into
cl ean ref ri gerant oi l.
9. Connect t he condenser inlet t ube t o t he A / C
c ompr e ssor t o condenser di schar ge line ( 1997 2)
and t he condenser out l et t ube t o t he condenser t o
e va por a t or t ube ( 19835) .
10. Connect t he upper r adi at or hose, l ower radi at or
hose and de-aerat i on hose s. Ma ke sure l ower
radi at or hose is posi t i oned in support t hat is part
of t he f an shr oud. Cl ose t he radi at or dr ai ncock
( 8115) . Fill t he cool i ng sy st e m wi t h t he previ ousl y
drai ned radi at or cool ant .
11. Repl ace and t i ght en t he radi at or c a p ( 8100) .
FAN BL ADE HAS BEEN FI RST EXAMI NED FOR
CRACKS AND SEPARATI ON.
Ope r a t e t he engi ne a nd c he c k f or l eaks at t he
hose connect i ons and t he t ransmi ssi on oi l cool er
li nes. Che c k t he aut omat i c t r ansmi ssi on, radi at or
and f lui d l evel s.
13. Leak-t est , evacuat e and c ha r ge t he ref ri gerant
sy st e m. Obser ve all sa f e t y precaut i ons. Refer t o
Sect i on 12-00.
14. Check t he A / C sy st e m f or proper oper at i on.
Refrigerant Lines
NOTE: Whenever a ref ri gerant line is r e pl a c e d, it wi ll
be ne c e ssa r y t o r epl ace t he suct i on
( 3 / 8 i n c h)
( 1/ 2 i n c h)
T 81P - 1962 3- G1
T 81P - 1962 3- G2
S u c t i o n L i n e s
Re mo v a l
1. Di sc ha r ge t he ref ri gerant f r om t he A / C sy st e m
f ol l owi ng t he r ecommended pr ocedur e and
obser vi ng all sa f e t y precaut i ons. Ref er t o Sect i on
12-00.
2. Remove t he A / C cycl i ng swi t c h ( 19E561) a s
out l i ned.
3. Di sconnect and r emove t he evapor at or t o
c ompr e ssor suct i on line ( 19867 ) usi ng Spri ng
Lo c k Coupl i ng Di sconnect Tool T81P-19623-G1
and G2 as out l i ned.
Suc t i o n Li ne Removal
VIEW A VIEWB
FRONT OF VEHICLE
M4706-A
Pa r t
2 19867 Evaporator to Compressor Suction Line
3 19D734 A / C Ma n i f o l d a nd Tube
4 19C836 Suction Accumulator/Drier
5 19E746 A/ C Tube Lock Coupling Clip
TM4706A
I nst al l at i on
1. Wi t h t he pr ot e c t i ve c a ps i nst al l ed, rout e t he new
ref ri gerant li ne.
2. Connect t he e va por a t or t o c ompr e ssor suct i on
line i nto t he sy st e m usi ng new O-ri ng seal s
l ubri cat ed wi t h cl ean Mot or c r a f t YN-12b
ref ri gerant oi l or equi val ent meet i ng For d
speci f i cat i on WSH-M 1C231-B (ref er t o Spri ng
Lo c k Coupl i ng i l l ust rat i on).
3. Install t he A / C cycl i ng swi t c h as out l i ned.
4. Leak-t est , evacuat e and c ha r ge t he ref ri gerant
sy st e m f ol l owi ng t he r e c omme nde d pr oc e dur e s
5. Che c k t he A / C sy st e m f or pr oper oper at i on.
Li qui d Li ne Removal
L i q u i d L i n e s
Re mo v a l
1. Di sc ha r ge t he r ef r i ger ant f r o m t he A / C sy st e m
f ol l owi ng t he r e c omme nde d pr oc e dur e and
obser vi ng all sa f e t y pr ecaut i ons. Ref er t o Sect i on
12-00.
2. Di sconnect and r e move t he condenser t o
e va por a t or t ube ( 19835) usi ng Spri ng Lo c k
Coupl i ng Di sconnect Tool T81P- 19623- G1 and
G2 a s out l i ned.
VIEWB
VIEW A VIEWB
M4707-A
Pa r t
1 A / C Co n d e n se r Co r e Out l e t Tube (Pa r t of 19712)
2 19835 Co n d e n se r t o Ev a po r a t o r Tube
3

A / C Ev a po r a t o r Co r e I nl et Tube (Pa r t of 19860)
4 19C917 A / C Co n d e n se r Tube Suppo r t Br a c ke t
TM4707A
1. Wi t h t he pr ot ect i ve c a ps i nst al l ed, rout e t he new
ref ri gerant line.
Connect t he condenser t o evapor at or t ube into
t he sy st e m usi ng new O-ri ng seal s l ubri cat ed wi t h
cl ean Mot or c r a f t YN-12b ref ri gerant oil meet i ng
For d speci f i cat i on WSH- M1C231- B (ref er t o
Spri ng Loc k Coupl i ng i l l ust rat i on).
Leak-t est , evacuat e and c ha r ge t he ref ri gerant
Check t he A / C sy st e m f or proper oper at i on.
Di sc ha r ge Li ne Removal
Di s c h a r g e L i n e s
Re mo v a l
f ol l owi ng t he recommended pr ocedur e and
observi ng all saf et y precaut i ons. Refer t o Sect i on
12-00.
2. Remove A / C pr essur e cut -of f swi t ch ( 19D594)
as out l i ned.
3. Di sconnect and remove t he A / C compr essor t o
condenser di schar ge line ( 1997 2) usi ng Spri ng
Lock Coupli ng Di sconnect Tool T81P-19623-G1
and G2 a s out l i ned.
VI EW A VI E WB
M4708-A
Pa r t
1 19972 A/ C Compressor to Condenser Discharge Line
2 19972 A/ C Compressor to Condenser Discharge Line
3

A / C Condenser Core Inlet Tube (Part of 19712)
4 19D734 A/ C Manifold and Tube
5 19E746 A/ C Tube Lock Coupling Clip
TM4708A
1. Wi t h the pr ot ect i ve caps i nst al l ed, rout e t he new
ref ri gerant line.
Connect the A / C c o mpr e sso r t o condenser
di schar ge line into t he sy st e m using new O-ring
seal s l ubri cat ed wi t h cl ean Mo t o r c r a f t YN- 12b
speci f i cat i on WSH- M1C231- B (ref er t o Spri ng
Loc k Coupl i ng i l l ust rat i on).
Install t he A / C pr essur e cut -of f swi t c h a s
out l i ned.
Leak-t est , evacuat e and c ha r ge t he ref ri gerant
sy st e m f ol l owi ng t he r e c omme nde d pr ocedur e
and saf et y pr ecaut i ons. Ref er t o Sect i on 12-00.
Check t he A / C sy st e m f or pr oper oper at i on.
H e a t e r Wa t e r H o s e s
Re mo v a l
1. Part i al l y drai n cool i ng sy st e m. Ref er t o Sect i on
03-03.
2. Di sconnect heat er wa t e r hose s ( 1847 2 ) .
1. Appl y cool i ng sy st e m f l ui d E2FZ- 19549- AA or
equi val ent meet i ng Fo r d speci f i cat i on
ESE-M97B44-A t o t he i nsi de of t he heat er wa t e r
hoses.
2. Install new heat er wa t e r ho se s and hose cl amps
(8287).
3. Fill cool i ng sy st e m. Ref er t o Sect i on 03- 03.
He a t e r Wat er Hoses
OUTLET HEATER
WATER HOSE
18472
I NLET HEATER
WATER HOSE
18472
HOSE CLAMP
8287
4 REQ' D
FRONT OF VEHI CLE
M4709-A
If A / C compr essor ( 197 03) is i noperat i ve, due t o
i nternal causes, cl ean t he ref ri gerant sy st e m t o
r emove any debri s or cont ami nant s t o prevent da ma ge
t o t he repl acement A / C c ompr e ssor .
Repl acement of t he suct i on a c c umul a t or / dr i e r
( 19C836) is necessar y when t he A / C c ompr e ssor is
r epl aced.
The A / C evapor at or c or e ori f i ce ( 19D990) shoul d be
r epl aced whenever t he A / C c ompr e ssor is r epl aced
f or l ack of per f or mance, or when t here is debri s in t he
sy st e m.
Re mo v a l
1. Di scharge t he ref ri gerant f r om t he sy st e m
f ol l owi ng t he r ecommended servi ce pr ocedur es.
Obser ve all saf et y precaut i ons. Refer t o Sect i on
12-00.
2. Loosen t he idler pulley t o remove t he t ensi on f r om
t he A / C c ompr e ssor dri ve belt ( 8620) . Remove
t he dri ve belt f r om t he A / C cl ut ch pulley ( 2E884) .
3. Remove t he A / C mani f ol d and t ube ( 19D7 34)
f r om t he A / C c ompr e ssor as out l i ned.
4. Di sconnect t he A / C cl ut ch wi r es at t he wi r e
connect or.
5. Remove t hr ee A / C c ompr e ssor l ower ret ai ni ng
bol t s and r emove t he A / C compr essor .
6. Remove br a c ke t f r om A / C c ompr e ssor ,
1. Servi ce t he repl acement A / C c ompr e ssor wi t h
t he c o r r e c t amount of cl ean Mot or c r a f t YN-12b
speci f i cat i on WSH-M 1C231-B as out l i ned.
2. Install br a c ke t on A / C c ompr e ssor .
3. Posi t i on t he A / C c ompr e ssor t o t he engi ne.
4. Install t hr ee bol t s t o ret ai n t he A / C c ompr e ssor
t o t he engi ne.
5. Lubr i cat e new O-ri ng seal s wi t h cl ean Mot or c r a f t
speci f i cat i on WSH-M 1C231-B and posi t i on t hen
in O-ri ng seal gr oove s of A / C mani f ol d and t ube.
6. Appl y Pi pe Seal ant wi t h Teflon D8AZ- 19554- A
or equi val ent meet i ng Fo r d speci f i cat i ons
WSK- M2G350- A2 t o t hr e a ds of mani f ol d
ret ai ni ng bol t .
7. NOTE: When repl aci ng an A / C c ompr e ssor , use
ori gi nal mani f ol d bol t f r o m r emoved A / C
c ompr e ssor t o ret ai n A / C mani f ol d and t ube t o
new A / C c ompr e ssor . Do not use t he shi ppi ng
c a p bol t s.
Posi t i on A / C mani f ol d and t ube wi t h O-ri ng seal s
t o A / C c ompr e ssor . Install ret ai ni ng bolt and
t i ght en t o 17-23 N-m (12. 5-17 Ib-ft).
8. Connect t he A / C cl ut ch wi r es at t he harness
connect or and a t t a c h t he connect or t o t he A / C
c ompr e ssor f ront br a c ke t .
9. Install t he dri ve belt on t he A / C cl ut ch pulley and
adj ust t he dri ve belt t ensi on t o speci f i cat i on.
10. Leak-t est , e va c ua t e and c ha r ge t he sy st e m.
A/ C System Filtering
CAUTI ON: Fo l l o w a l l r e f r i ge r a n t s y s t e m s a f e t y
a n d s e r v i c e p r e c a u t i o n s o u t l i n e d i n Se c t i o n
12 - 00.
A f i l t er ki t shoul d be i nst al l ed in t he ref ri gerant sy st e m
bef or e repl aci ng t he A / C c ompr e ssor ( 197 03) . The
pa nc a ke f i lt er suppl i ed wi t h e a c h ki t shoul d be
t empor ar i l y i nst al l ed in t he li qui d line bet ween t he A / C
condenser c o r e ( 197 12 ) and t he A / C e va por a t or c or e
ori f i ce ( 19D990) . The suct i on f i l t er suppl i ed wi t h e a c h
ki t shoul d be permanent l y i nst al l ed in t he suct i on line
be t we e n t he suct i on accumul at or / dri er ( 19C836) and
t he A / C c ompr e ssor . Install t he f i l t ers as out li ned in
t he f ol l owi ng pr ocedur e:
Af f e c t e d ki t is F2VY-19E773-C Fi lt er Ki t f or sy st e ms
wi t h nylon-li ned suct i on hose.
1. Bef ore removi ng any ref ri gerant sy st e m
component s, di schar ge t he sy st e m ref ri gerant
f ol l owi ng t he appr oved recycl i ng met hods. Ref er
t o Sect i on 12-00.
2. Remove t he suct i on a c c umul a t or / dr i e r assembl y
and drai n t he oil into a cal i br at ed cont ai ner as
out l i ned.
3. Install a new suct i on accumul at or / d r i e r and add
new Mot or c r a f t YN-12 ref ri gerant oil or
WSH-M 1C231-B t o r epl ace t he ol d oil a s out l i ned.
4. Install a new A / C evapor at or c or e ori f i ce a s
out l i ned.
5. Temporari l y install t he pancake f i lt er in t he liquid
line bet ween t he A / C condenser c o r e and t he
A / C evapor at or cor e ori f i ce. Be sure t he f i lt er
inlet is t o wa r d t he A / C condenser c or e .
Connect i ons can be made usi ng Test Adapt er Set
D93L-19703-B or equi val ent , and f l exi bl e
ref ri gerant hose of 17, 238 kPa ( 2500 psi ) burst
rat i ng. Individual f i t t i ngs are al so avai l abl e.
6. Remove t he ol d A / C c ompr e ssor as out l i ned.
7. Drai n t he oil f r om t he repl acement A / C
c ompr e ssor into a cl ean cal i br at ed cont ai ner.
8. A new servi ce repl acement A / C c ompr e ssor is
shi pped wi t hout ref ri gerant oi l . If t he amount of oil
drai ned f r om t he r emoved A / C c ompr e ssor is
bet ween 85-142 ml (3-5 ounces), pour t he same
amount plus 30 ml ( 1 ounce) of cl ean Mot or c r a f t
speci f i cat i on WSH-M 1C231-B i nto t he new A / C
compr essor . If t he amount of oil drai ned f r om t he
old A / C compr essor is gr eat er t han 142 ml (5
ounces), t he same amount drai ned of cl ean
Mot or cr af t YN-12b ref ri gerant oil or equi valent
meet i ng For d speci f i cat i on WSH-M 1C231-B into
t he new A / C compr essor . If t he amount of
ref ri gerant oil drai ned f r om t he ol d A / C
c ompr e ssor is less t han 85 ml (3 ounces), pour
85 ml (3 ounces) of cl ean Mot or c r a f t YN-12b
speci f i cat i on WSH-M 1C231-B into t he new A / C
compr essor .
9. NOTE: It will be necessar y t o t ransf er t he A / C
cl ut ch ( 2884) f r om t he ol d A / C c ompr e ssor t o
t he repl acement A / C c ompr e ssor . Ref er t o
Sect i on 12-03Cf or FS-10 A / C compr essor .
Install t he new A / C c ompr e ssor as out l i ned.
10. Install t he suct i on f i lt er in t he suct i on hose cl ose t o
t he A / C compr essor . Thi s f i lt er has t wo gr ooves
in t he end t ubes t o a c c ommoda t e O-ri ng seal s.
11. On t he fi lter f or nylon-li ned hose, i nstall O-ri ng
seal s, Part No. 19E772, ( t wo on each f i lt er t ube).
12 - 03A - 67 Ai r Condi t i oni ng S y s t e m- - Ma n ua l A / C - H e a t e r 12 - 03A - 67
12. Remove a l engt h of suct i on hose (cl ose t o t he
A / C c ompr e ssor end) t o a c c o mmo d a t e t he
suct i on f i l t er and i nstall t he f i lt er, usi ng A / C hose
c l a mps (Part No. D2AZ- 19B679- A) . Be sure f i l t er
is c o r r e c t l y or i ent ed f or ref ri gerant sy st e m f l ow.
Che c k t he l abel on t he f i l t er. The si ze 12 cl amps
must be posi t i oned over t he O-ri ng seal s on t he
end t ubes and t i ght ened t o 6. 2 N-m ( 55 Ib-in).
13. Evacuat e and c ha r ge t he sy st e m. Ref er t o
Sect i on 12-00.
14. Che c k all ref ri gerant sy st e m hoses, li nes and t he
posi t i oni ng of t he newl y i nst al l ed f i l t ers t o be sure
t he y do not i nt erf ere wi t h ot her engi ne
c ompa r t me nt component s. Use t i e st r a ps t o
ma ke adj ust ment s (if ne c e ssa r y ).
15. Set t he A / C cont r ol on MAX A / C , hi gh bl ower
and t e mpe r a t ur e cont r ol at full COOL. St ar t t he
engi ne and let it idle bri ef l y. Ma ke sur e t he A / C
sy st e m is oper at i ng pr oper l y.
16. Gradual l y bri ng t he engi ne up t o 1200 r pm by
runni ng it at l ower r pms f or shor t per i ods (f i rst at
800 r pm, t hen at 1000 r pm). Set t he engi ne at
1200 r pm and run it f or an hour wi t h t he A / C
sy st e m oper at i ng.
17. St op t he engi ne.
18. Remove t he ref ri gerant f r om t he sy st e m usi ng a
r ecover y machi ne. Ref er t o Sect i on 12-00.
19. Al l ow t he engi ne t o c ool suf f i ci ent l y t o r emove t he
f i t t i ngs, f l exi bl e hoses and pancake f i l t er f r om t he
liquid line.
20. Di scar d t he pancake f i lt er. If can be used only
once.
2 1 . Reconnect t he liquid line back i nto t he sy st e m.
2 2 . Evacuat e, char ge and l eak t est t he sy st e m. Refer
t o Sect i on 12-00. Ma ke any necessar y
adj ust ment s.
23. Check t he operat i on of t he sy st e m in all cont rol
f unct i on sel ect or knob posi t i ons.
12 - 03A - 68 Ai r Condi t i oni ng Sy s t e mMa n u a l A / C - He a t e r 12 - 03A - 68
Pa n c a ke a n d Suc t i o n Fi l t e r s
VI EW A VIEW B
O-RING
GROOVES
(ERUHEOMOSE
TuZ
SUCTI ON FI LTER FOR NYLON LINED HOSE
M3879-B
A / C Ma n i f o l d a n d T u b e
Remov al
1. Di schar ge t he ref ri gerant f r o m t he sy st e m. Ref er
t o Sect i on 12-00. Remove bol t ret ai ni ng A / C
mani f ol d and t ube ( 19D7 34) assembl y t o t he rear
head of t he A / C c ompr e ssor ( 197 03) .
2. Di sconnect ot her ends of suct i on and di schar ge
li nes. Remove any br a c ke t a t t a c hme nt s and
r emove A / C mani f ol d and t ube assembl y f r om
vehi cl e.
1. Lubr i cat e new O-ri ng seal s wi t h cl ean ref ri gerant
oil and posi t i on t he m in t he O-ri ng seal gr oove s of
t he A / C c o mpr e sso r rear he a d.
2. Posi t i on A / C mani f ol d and t ube assembl y t o rear
head of A / C c ompr e ssor , maki ng sure A / C
mani f ol d and t ube pi l ot s are posi t i oned in A / C
c ompr e ssor port openi ngs. Install A / C mani f ol d
and t ube ret ai ni ng bol t and t i ght en bol t t o 17-23
N-m (12. 5-17. 0 Ib-ft).
3. Connect ot her ends of suct i on and di schar ge lines
usi ng new l ubri cat ed O-ring seal s. Install br a c ke t
at t achment s t hat we r e r emoved.
4. Leak-t est , evacuat e and char ge t he sy st e m.
Obser ve all saf et y precaut i ons. Ref er t o Sect i on
12-00.
12 - 03A - 69 Ai r Condi t i oni ng Sy s t emManual A / C - H e a t e r 12 - 03A - 69
A / C V a c u u m R e s e r v o i r T a n k a n d B r a c k e t
Remov al a n d I nst al l at i on
1. Remove rel ay modul e.
2. Remove t wo nut s.
3. Di sconnect vacuum hose and r emove spe e d
cont r ol vacuum reservoi r (9E799).
A / C Compressor Relief Valve
1. Di schar ge ref ri gerant f r om sy st e m. Obse r ve all
saf et y pr ecaut i ons. Ref er t o Sect i on 12-00.
2. Remove A / C pr essur e relief val ve def l ect or
( 19E592) f r o m A / C c ompr e ssor pr e ssur e relief
val ve ( 19D644) .
3. Remove A / C c ompr e ssor pr essur e relief val ve
f r om A / C mani f ol d and t ube ( 19D7 34) .
ADJUSTMENTS
Mini-Tube Vacuum Hoses
1. Measur e t he l engt h of t he da ma ge d a r e a of t he
mi ni -tube vacuum hose.
2. Cut a pi ece of st a nda r d 3 mm (1 / 8- i n c h) ID
vacuum hose appr oxi mat el y 25. 4 mm (1 i nch)
longer t han t he da ma ge d ar ea of t he mi ni -tube
vacuum hose.
3. Cut off t he mi ni -tube vacuum hose on e a c h si de of
t he damaged a r e a .
4. Di p t he mi ni -tube hose ends in Tet r a Hy dr o Furan
(THF) or Met hyl Et hyl Ket one (MEK). Thi s sol vent
wi ll act as a sol vent and seal t he mi ni -t ube in t he
vacuum hose.
5. Insert t he ends of t he mi ni -tube vacuum hose
appr oxi mat el y 9 mm ( 3 / 8 i nch) i nto t he ends of
t he st andar d 3 mm (1 / 8-i nch) ser vi ce vacuum
hose sect i on.
6. Shake ser vi ce j oi nt af t er assembl y t o ma ke sure
sol vent is di sper sed and vacuum line is not
pl ugged.
7. Test sy st e m f or a vacuum leak in ser vi ce a r e a .
-0. 010 I NCH MAXI MUM
\
CLEAR VI NYL CONNECTOR MI NI -TUBE
' VACUUM HOSE
CLEAR VI NYL
A/C VACUUM
HOSE TEE
19C904
M1435-E
A / C Compressor Drive Belt Tension
SPECIFICATIONS
REFRI GERANT SYSTE M COMP ONE NTS AND
CAPACI TI ES
I t em Spe c i f i c a t i on
A / C Co mp r e s s o r 197 03
A / C E v a p o r a t o r Co r e Or i f i c e 19D990
A / C Cy c l i n g Swi t c h 19E561
Su c t i o n A c c u mu l a t o r / Dr i e r 19C836
A / C E v a p o r a t o r Co r e 19860
A / C Co n d e n s e r Co r e 197 12
A / C Ma n i f o l d a n d Tube 19D7 34
A / C Co mp r e s s o r P r e s s u r e Re l i e f Va l v e 19D644
A / C P r e s s u r e Cut - Of f Swi t c h 19D594
Re f r i ge r a n t Ca p a c i t y 0. 964 kg ( 34. 0
o z)
Oi l Ca p a c i t y 2 07 ml ( 7 . 0 o z)
REFRI GERANT SYSTE M
A / C Compr e ssor FS- 10
Di s p l a c e me n t
Cy l i n d e r Bo r e
Cy l i n d e r St r o ke
Ro t a t i o n
Ro t a t i o n a l To r que ( Ope n P o r t s )
170 c c ( 1 0 . 4 C I D)
2 9. 0 mm ( 1. 14 i n)
2 5. 7 mm ( 1. 0 i n)
Cl o c kwi s e
10 N-m ( 7 I b-f t )
ma x i mu m
12 - 03A - 7 0 Ai r Co n d i t i o n i n g S y s t e mMa n u a l A / C - He a t e r 12 - 03A - 7 0
REFRIGERANT SYSTEM (Cont' d)
De s c r i p t i o n Speci f i cat i on
A / C E v a p o r a t o r C o r e Or i f i c e
Co l o r Co d e
Or i f i c e Di a me t e r
Or a n ge
1.46 mm ( 0. 057 5 i n)
A / C Cy cl i ng Swi t c h
Cl o s e
Op e n
2 7 6- 32 5 kP a ( 40- 47
ps i )
152 - 193 kP a ( 2 2 - 2 8
ps i )
Op e n 3103 kP a ( 450 p s i )
mi n i mum
A / C Pressure Cut -of f Swi t c h Compr essor Cont r ol
Op e n
Cl o s e
2 896 kP a ( 42 0 p s i )
mi n i mum
17 2 4 kP a ( 2 50 p s i )
ma x i mu m
Ref ri gerant
Ty pe
R- 134a Hy d r o f l u o r o c a r b o n ( HFC) WSH- M17 B19- A
Mo t o r c r a f t YN- 11
Ref ri gerant Oi l
Ty pe
P o l y a l ka l y l e n e Gl y c o l ( PAG) WS H- M1C2 31- B
Mo t o r c r a f t YN- 12 b
ELECTRICAL SYSTEM
Fuse No.
Fuse
Amps
Rat i ng Sy st em Pr ot e c t i on
1 30 A mp A / C Bl o we r Mo t o r
10 15 A mp A / C Cl ut c h
17 15 Amp A / C E l e c t r o n i c Do o r A c t u a t o r
Mo t o r
11 5 A mp I n st r ume n t I l l umi n a t i o n
SPRING LOCK COUPLING COMPONENTS
O- Ri n g
3 / 8 i n c h 3 9 1 3 9 6 - S 1 0 0
112 i n c h 3 9 1 3 9 7 - S 1 0 0
5 / 8 i n c h 3 9 1 3 0 4 - S 1 0 0
3 / 4 i n c h 3 9 1 3 0 7 - S 1 0 0
Ga r t e r Sp r i n gs
3 / 8 i n c h E 1Z Z - 19 E 5 7 6- A ( YF- 990)
112 i n c h E 1Z Z - 19 E 5 7 6- B ( YF- 991)
5 / 8 i n c h E 35 Y- 19 E 5 7 6- A ( YF- 1134)
3 / 4 i n c h E 69 Z - 19 E 5 7 6- A
Servi ce Ki t s
E 35Y- 19D690- D
Co n t a i n s 391396, 391397 , 391304, 391307
O- Ri n gs.
E 1Z Z - 19E 57 6- A & B a n d E 35Y- 19E 57 6- A
Spr i n gs
Descr i pt i on N*m Lb-Ft
Ra d i a t o r Co o l a n t Re c o v e r y
Re s e r v o i r t o Wh e e l Sp l a s h Pa n e l
( Nut )
5. 5- 7 . 0 4-5
A / C E v a p o r a t o r Co r e Ho us i n g t o
Da s h Pa n e l ( S c r e w a n d Nut )
2. 5- 3. 2 2 2 - 2 8
( Lb- l n )
I n st r ume n t Pa n e l Fi n i sh Pa n e l t o
I n st r ume n t Pa n e l ( Sc r e w)
2. 1- 2. 9 19- 25
( Lb- l n )
A / C Co n d e n s e r Co r e t o Ra d i a t o r
Su p p o r t ( Sc r e w)
9- 13 6- 10
En gi n e Ai r Cl e a n e r Tube Cl a mp 3. 4- 4. 6 30- 41
( Lb- l n )
A / C Ma n i f o l d a n d Tube Re t a i n i n g
Bo l t
17- 23 12. 5- 17
Tool Numbe r /
T 81P - 1962 3- G1
Sp r i n g - L o c k Co upl i n g
T81P-19623-G1
T 81P - 1962 3- G2
TB1P-19623-G2
T 83P - 1962 3- C
T83P-19S23-C
T 85L - 1962 3- A
Sp r i n g- L o c k Co upl i n g
T85L-19623-A
D80L - 19990- A Fi x e d Or i f i c e Tube To o l
D80L - 19990- B Br o ke n Or i f i c e Tube E x t r a c t o r
D81L - 197 03- A Hi gh Si d e A d a p t e r Se t
D93L - 197 03- B Te st A d a p t e r Se t
12 - 03A - 7 1 A i r Co n d i t i o n i n g S y s t e mMa n u a l A / C - H e a t e r 12 - 03A - 7 1
(Cont i nued)
ROTUNDA E QUI P ME NT
02 1- 00014 Va c u u m T e s t e r
105- 00051 7 3 Di gi t a l Mu l t i - Me t e r
17 6- R0036 R- 134a L o w Si d e Qu i c k Di s c o n n e c t
17 6- R0037 R- 134a Hi gh Si d e Qu i c k Di s c o n n e c t
12 - 03B- 1 Ai r Co n d i t i o n i n g S y s t e mE l e c t r o n i c A u t o ma t i c T e mp e r a t u r e Co n t r o l 12 - 03B- 1
SECTION 12-03B Air Conditioning SystemElectronic
Automatic Temperature Control
SUBJE CT PAGE
VEHI CLE APPLICATION 12-03B-1
A / C Pressure Cut-Off Swi t ch 12-03B-9
Control Assembly 12-03B-4
El ect roni c Automatic Temperature Control
Syst em 12-03B-1
Input Sensor s 12-03B-5
Syst em Operation 12-03B-9
Vacuum Control Motors 12-03B-9
El ect ri cal Schemat i cs 12-03B-12
Inspecti on and Verification 12-03B-21
Pinpoint Test s 12-03B-23
Symptom Chart 12-03B-22
A / C Compressor 12-03B-40
A / C Compressor Pressure Relief Valve 12-03B-39
A / C Condenser Core Assembly 12-03B-39
A / C Cycl i ng Swi tch 12-03B-39
A / C Evaporator Core 12-03B-39
A / C Evaporator Core Housing 12-03B-39
A / C Evaporator Core Orifice 12-03B-39
A / C Manifold and Tube 12-03B-40
A / C Pressure Cut-Off Swi t ch 12-03B-39
A / C Si de Window Demister and Hoses 12-03B-39
SUBJE CT PAGE
A / C Syst em Filtering 12-03B-40
Adding Refrigerant Oil 12-03B-36
Control Assembly 12-03B-37
Doors 12-03B-39
Heater Air Plenum Chamber 12-03B-39
Heater Blower Motor and Blower Motor Wheel
Assembly 12-03B-39
Heater Core 12-03B-39
Heater Water Hoses 12-03B-40
Instrument Panel 12-03B-37
Instrument Panel A / C Evaporator Register
Ducts 12-03B-39
Instrument Panel A / C Register
Assembl i es 12-03B-39
Refrigerant 134a (R-134a) Syst ems 12-03B-36
Refrigerant Li nes 12-03B-40
Sensor s 12-03B-37
Spring Lock Coupling 12-03B-36
Sucti on Accumulator/Dri er 12-03B-39
Vacuum Control Motors 12-03B-39
Windshield Defroster Hose Nozzle
Assembly 12-03B-39
SPECI FI CATI ONS 12-03B-40
SPECI AL SERVI CE TOOLS/EQUI PMENT 12-03B-41
VEHICLE APPLICATION
El ect roni c Aut omat i c Temperat ure Cont rol
Syst em
The El ect roni c Aut omat i c Temper at ur e Cont rol (EATC)
sy st e m is st andar d equi pment on Town Car and
avai l abl e a s an opt i on on Cr o wn Vi ct or i a and Gr and
Mar qui s vehi cl es.
Wi t h t he use of a mi cr ocomput er , t he cont r ol assembl y
anal yzes i nput f r o m t he f ol l owi ng maj or sour c e s:
Temperat ure, f unct i on, and bl ower sel ect i ons (made
by t he vehi cl e occupant s).
In-vehi cle t emper at ur e.
Ambi ent t emper at ur e.
A / C sunl oad sensor ( 19E663) .
Powert rai n cont r ol modul e (PCM)( 12A650).
EATC Sy st e m Di a gr a m
VEMCLE STEERING
OPERATOR
WHEEL
CONTROL
WHEEL
CONTROL
STEERING
WHEEL SWITCH
CONTROL
MODULE
JUC SUNLOAD
SENSOR
AUTOMATIC
TEMPERATURE
CONTROL SENSOR
A/C AMBIENT AIR
TEMPERATURE
SENSOR i
INPUTS
VEHTCLE
O P E R A T O R
I
TOWN CAR
ELECTRONS
CONTROL
ASSEMBLY
V E M C L E
SPEED
ENGINE COOLANT
TEMPERATURE ^
OTHER ENGINE
SENSORS
V
I
A/C BLOWER
MO T O R S P E E D
CONTROL
>
A C
BLOWER
MOTOR
A C AIR
TEMPERATURE
CONTROL DOOR
ELECTRONCDOOft
ACTUATOR MOTOR
AC AIR
TEl PBt Al Uf t E
CONTROL DOOR,,
FEEDBACK
HEATER AIR
DAMPER
DOOR VACUUM
CONTROL MOTOR
WATER AIR
DASIPERDOOW
WI N DS ME L D
D E F R O S T E R
DO O R VACUUM
C O N T R O L MOTOR
WINDSMELD
DEFROSTER
DOOR
mwum
POWERTRAIN
CONTROL
MODULE
I
HEATER AND A C
AIR INLET DUCT
DOOR VACUUM
CONTROL MOTOR
MEATERANDAC ^
AIR INLET DUCT
222
A C
PRESS-
URE
CUT-OFF
SWITCH
A C
A C CLUTCH
COMPRESSOR
A C CLUTCH
A C
COMPRESSOR
CLUTCH
CONTROL
RELAY
M4713-A
Usi ng t hese i nput s, t he mi cr ocomput er det er mi nes t he
c o r r e c t condi t i ons f or t he f ol l owi ng si x sour c e s of
out put :
A / C cl ut ch engagement .
Bl ower spe e d.
A / C a i r t emper at ur e cont rol door posi t i on.
Heat er ai r damper door posi t i on.
Wi ndshi el d def rost er door posi t i on.
Heat er and A / C a i r inlet duct door posi t i on.
A smal l DC el ect ri c mot or is used t o oper at e t he A / C
ai r t emper at ur e cont r ol door.
# Vacuum cont r ol mot or s ( 18A318) are used t o
cont rol each of t he t hr ee remai ni ng air di st ri but i on
door s.
A f e e dba c k ci rcui t is used in t he A / C el ect roni c
door act uat or mot or ( 19E616) t o suppl y t he cont rol
assembl y wi t h A / C air t emper at ur e cont rol door
posi t i on i nf ormat i on.
SYSTEM RESPONSE
Cont r ol
Assembl y
Sel ect i on
A / C
Temper at ur e
Cont r ol Door
R e s p o n s e
Heat er Air
Damper Door
Response
Wi ndshi el d
De f r ost e r Door
Response
Heat er and A / C
Air Inl et Duct
Door Response
A / C Bl ower
Mot or Response
(Unless
Manually
Overri dden)
A / C Cl ut ch
Response
8
OFF Re ma i n s f i x e d Do o r o p e n t o
wi n d s h i e l d
d e f r o s t e r d o o r .
No a i r f l o w.
Op e n t o f l o o r
o u t l e t s . No ai r
f l o w.
Ope n t o r e c i r c .
ai r ( c l o s e d t o
o u t s i d e a i r ) . No
ai r f l o w. ^
He a t e r b l o we r
mo t o r of f .
, v
A / C c l u t c h of f .
AUTOMATI C P o s i t i o n v a r i e s
a c c o r d i n g t o
s e n s o r i n put s a n d
o c c u p a n t
t e mp e r a t u r e
s e l e c t i o n . Do o r
t r a v e l i s f r o m ma x
he a t p o s i t i o n ( a l l
ai r f l ow t h r o u gh
h e a t e r c o r e ) t o
ma x c o o l p o s i t i o n
( a l l a i r f l o w
b y - p a s s e s
h e a t e r c o r e ) .
Ope n t o
wi n d s h i e l d
d e f r o s t e r d o o r
d ur i n g h e a t i n g.
Cl o s e d t o
wi n d s h i e l d
d e f r o s t e r d o o r
a n d o p e n t o
i n st r ume n t
pa n e l r e gi s t e r s
d ur i n g c o o l i n g.
Dur i n g h e a t i n g:
ENGI NE
COOL A NT
a b o v e 5 0 C
( 1 2 0 F) a i r
f l o w t o f l o o r .
b e l o w 50 C
( 1 2 0 F) ai r
f l o w t o
d e f r o s t e r .
b
Dur i n g c o o l i n g:
Do o r in t h e
f l o o r p o s i t i o n .
Op e r a t i o n n e a r
s e t
t e mp e r a t u r e :
Do o r
p o s i t i o n e d f o r
ai r f l o w t o f l o o r
o r spl i t
b e t we e n f l o o r
a n d d e f r o s t .
Fi x e d i n r e c i r c .
wh e n ma x
c o o l i n g i s
r e q u i r e d .
Ot h e r wi s e i s i n
o u t s i d e ai r
p o s i t i o n f o r
n o r ma l o p e r a t i o n .
v Vi a b l e h e a t e r
b l o we r mo t o r
s p e e d s wh e n
e n gi n e c o o l a n t
t e mp , i s a b o v e
50 C ( 1 2 0 F ) o r
c o o l i n g i s
r e q u i r e d .
Heat er bl ower
mo t o r i s f i x e d
a t l o w s p e e d
wh e n e n gi n e
c o o l a n t t e mp ,
i s b e l o w 50 C
( 1 2 0 F ) a n d
h e a t i n g i s
r equi r ed.
b
A / C c l u t c h c i r c ui t
i s e n e r gi ze d by
c o n t r o l a s s e mb l y
f o r c l u t c h
e n ga ge me n t if
o u t s i d e
t e mp e r a t u r e i s
a p p r o x i ma t e l y
1 0 C ( 5 0 F ) , o r
a b o v e .
8
MA X A / C A i r f l o w i s
d i r e c t e d t o
i n st r ume n t pa n e l
r e g i s t e r s .
Do o r i s i n t h e
f l o o r p o s i t i o n .
Ai r f l ow i nt o
s y s t e m f r o m
i n si d e t h e v e h i c l e
( r e c i r c . p o s i t i o n ) .
Va r i a bl e heat er
b l o we r mo t o r
s p e e d s un l e ss
ma n ua l l y
c o n t r o l l e d .
NORM A / C Sa me a s d ur i n g
M A X A / C
o p e r a t i o n .
Sa me a s d ur i n g
M A X A / C
o p e r a t i o n .
M A X A / C
o p e r a t i o n .
Ai r f l o w i nt o
s y s t e m f r o m
o u t s i d e t h e
v e h i c l e ( o u t s i d e
ai r p o s i t i o n ) .
MAX A / C
o p e r a t i o n .
AUTOMATI C
o p e r a t i o n .
VENT A / C c l u t c h of f .
| FL OOR
_ .
Ai r f l o w i s
d i r e c t e d t o t he
wi n d s h i e l d
FL R- DEF A i r f l o w i s
d i r e c t e d t o t he
wi n d s h i e l d
Ai r f l o w i s spl i t
b e t we e n t h e f l o o r
a n d d e f r o s t e r
o u t l e t s .
A / C c l u t c h c i r c ui t
e n e r gi ze d by
c o n t r o l a s s e mb l y
if a mbi e n t
t e mp e r a t u r e i s
a p p r o x i ma t e l y
10 C( 50 F) or
a b o v e .
8
The bl ower mot or ( 18627 ) is cont rol l ed by t he
cont rol assembl y t hr ough t he A / C bl ower mot or
speed cont rol ( 19E624) .
The A / C bl ower mot or speed cont rol i s necessar y
t o r eact t o t he l ow power si gnal f r om t he cont r ol
assembl y t o provi de hi gh power si gnal requi red t o
dri ve t he bl ower mot or. The f ol l owi ng sy st e m
r esponse c ha r t sho ws t he cont rol assembl y
r esponse t o t he f unct i on sel ect i ons.
12 - 03B- 4 Ai r Condi t i oni ng Sy s t e mEl e c t r o n i c A u t o ma t i c T e mp e r a t u r e Cont r ol 12 - 03B- 4
SYSTEM RESPONSE (Cont ' d)
Cont r ol
A ssembl y
Sel ecti on
A / C
Temper a tur e
Cont r ol Door
Response
Heater A i r
Da mper Door
Response
Wi nd shi el d
Defr oster Door
Response
H e a t e r a n d A / C
Ai r I n l e t Duc t
Do o r R e s p o n s e
A / C Bl o we r
Mo t o r Response
(Unl ess
Manual l y
Ove r r i dde n)
A / C Cl ut ch
Sni^spons
8
De f r o s t A i r f l o w i s
di r ected t o t h e
defroster o u t l e t s .
T h e A / C c o m p r e s s o r c l u t c h c i r c u i t e n e r g i z e d b y t h e E ATC c o n t r o l a s s e mb l y , b u t t h e f i n a l c o n t r o l o f c l u t c h o p e r a t i o n i s d e t e r mi n e d b y
t h e P o we r t r a i n Co n t r o l Mo d u l e (PCAA) t h r o u g h t h e us a o f a n o r ma l l y c l o s e d A / C c l u t c h c o n t r o l r e l a y . T h e A / C c l u t c h c a n b e s h u t o f f ( o r
k e p t o f f ) f o r s e v e r a l s e c o n d s at e n g n e start-up, during h i gh e n gi n e s p e e d s , d u r i n g a c c e l e r a t i o n , d u r i n g l o w e n gi n e i d l e c o n d i t i o n s
( a p p r o x i ma t e l y 2 0 0 r p m b e l o w i d l e s p e c s ) and w h e n t h e e n gi n e c o o l a n t t e mp e r a t u r e s e n s o r r e a d i n g e x c e e d s a p p r o x i ma t e l y 12 0C
( 2 4 5 F) .
If e n gi n e c o o l a n t t e mp e r a t u r e f a i l s t o r e a c h 500 ( 120F) a f t e r 3 1 / 2 mi n u t e s o f o p e r a t i o n , t h e h e a t e r b l o w e r mo t o r s p e e d wi l l i n c r e a s e
a n d t h e w i n d s h i e l d d e f r o s t e r d o o r wi l l shift f ro o i d e f r o s t p o s i t i o n t o f l o o r p o s i t i o n .
A Self Test f e a t ur e ha s been I ncl uded in t he c ont r ol
a sse mbl y t o suppl y t he t e c hni c i a n wi t h ai r di st ri but i on
e r r or c o d e s. The se c o d e s d i r e c t t h e t echni ci an t o t he
i noper at i ve c ompone nt . T h e SA T C Sy st e m Self Test
pr o c e d ur e i s d e sc r i be d and out l i ned in I nspect i on a nd
Ver i f i cat i on.
Control Assembl y
The EATC a sse mbl y i s l o c a t e d in t he i nst rument panel
and c o n si st s of :
El even push but t ons.
A var i abl e bl owe r spe e d c ont r ol whe e l f or manual
i nput .
A va c uum f l uor escent di spl ay ( VFD) f or di spl ay i ng
se t t e mpe r a t ur e , ambi ent t e mpe r a t ur e , f unct i on,
and di a gnost i c c o d e s.
EATC Co n t r o l As s e mbl y
ELECTRONI C
AUTOMATI C
TEMPERATURE
CONTROL ASSY
M3112-C
Whe n t he s y s t e m i s ope r a t i ng under AUTOMATI C
c o n t r o l , t he VFD wi l l sho w AUTO and t he pr e f e r r e d or
t a r ge t t e mpe r a t ur e t o whi c h t he el ement s of t he
a ut oma t i c c o n t r o l sy st e m r e spo n d .
A / C bl owe r mo t o r spe e d , under a ut oma t i c c o n t r o l ,
va r i e s in r e spo n se t o ambi ent t e mpe r a t ur e c ha n ge s
and a pr e de t e r mi ne d de l a y f a c t or .
Te mpe r a t ur e sel ect i on ma y be i nc r e a se d or
d e c r e a se d in one d e gr e e i nc r e me nt s be t we e n 18C
( 65F) and 2 9 C ( 85F) by pr e ssi ng t he r e d but t on
t o i nc r e a se or t he bl ue but t on t o d e c r e a se t he
d e si r e d t e mpe r a t ur e . The sy st e m wi l l r e spo n d - \
a c c or di ngl y .
Ot he r c ont r ol a sse mbl y f e a t ur e s i ncl ude:
A 16C ( 60F) set t i ng f or ma xi mum c o o l ari d a
3 2 C ( 90F) se t t i ng f or ma xi mum heat .
An OUTSI DE TEMP but t on whi c h, whe n pr e sse d ,
wi l l di spl ay t he ai r t e mpe r a t ur e out si de t he ve hi c l e .
An OFF but t on whi c h, if pr e sse d , wi l l a ppl y va c uum
t o c l o se t he A / C a i r inlet duc t door , shut of f A / C
bl owe r mot or ope r a t i on a n d di scont i nue c l i ma t e
c ont r ol f unct i ons e x c e pt OUTSI DE TEMP.
Whe n t he t humbwhe e l c ont r ol f or t he bl owe r mot or
( 1852 7 ) i s r o t a t e d out of t he posi t i on it o c c upi e d under
a ut oma t i c c o n t r o l , it wi l l remai n under manual c ont r ol
until t he a ut oma t i c but t on i s pr e sse d .
Under a ut oma t i c c o n t r o l , A / C bl owe r mot or spe e d
va r i e s a s r equi r ed t o a c c o mmo d a t e t he t ot a l
a ut oma t i c f unct i ons in t he sy st e m.
Under manual c o n t r o l , A / C bl owe r mot or spe e d i s
c onst a nt ba se d on t he t humbwhe e l se t t i ng.
An i llumi nat i on bul b in t he c ont r ol a sse mbl y pr ovi de s
backl i ght i ng f or t he va c uum f l uor e sc e nt di spl ay
wi n d o w. Whe n t he r he ost a t on t he he a d l a mp/ pa r ki n g
l amp swi t c h is r o t a t e d , t he i nt ensi t y of t he l i ght f r o m
t hi s bul b wi l l i nc r e a se or d e c r e a se dependi ng upon t he
di r ect i on of r ot a t i on. (The backl i ght i ng on t he c ont r ol
a sse mbl y , a s wel l a s in ot he r i nst rument panel
l oc a t i ons, wi l l di m whe ne ve r t he l i ght swi t c h i s
e nga ge d. )
The To wn Car al so has a pai r of opt i onal r e mo t e
c ont r ol but t ons l o c a t e d on t he st eer i ng whe e l ri ght
spo ke .
12 - 03B- 5 Ai r C o n d i t i o n i n g S y s t e m E l e c t r o n i c A u t o ma t i c T e mp e r a t u r e C o n t r o l 12 - 03B- 5
The se but t ons, ma r ke d TEMP a nd FAN, c a n be
use d in addi t i on t o t he c ont r ol a sse mbl y but t ons t o
c ha n ge sy st e m se t t i ngs duri ng s y s t e m o pe r a t i o n .
The lef t but t on ma r ke d TEMP c a n be use d t o
i nc r e a se or d e c r e a se t he set t e mpe r a t ur e .
De pr e ssi ng t he but t on " A " si de wi l l i nc r e a se t he
se t t e mpe r a t ur e a nd de pr e ssi ng t h e ' V si de wi l l
l ower t he set t e mpe r a t ur e .
The ri ght but t on, ma r ke d FAN, o pe r a t e s t o ove r r i de
a ut oma t i c bl owe r spe e d c ont r ol ope r a t i on or t o
i nc r e a se or d e c r e a se t he manual l y c ont r ol l e d
bl owe r spe e d . De pr e ssi ng t he but t on " A " si de and
rel easi ng wi l l i ncr ease t he bl owe r spe e d .
De pr e ssi ng t he but t on " v " si de wi l l l owe r t he bl owe r
spe e d .
To ret urn t o a ut oma t i c bl owe r spe e d c o n t r o l
o pe r a t i o n , push t he AUTOMATI C but t on on t he
EATC Cont r ol Asse mbl y .
Re mo t e Co n t r o l Bu t t o n s
M4714-A
I n p u t S e n s o r s
A / C A m b i e n t A i r T e m p e r a t u r e S e n s o r
The A / C ambi ent ai r t e mpe r a t ur e se nsor a nd br a c ke t
( 19E7 02 ) :
Is l o c a t e d in f r ont of t he A / C c onde nse r c o r e
( 197 12 ) near t he c e nt e r of vehi cl e.
Cont ai ns a t he r mi st or w>
5
c h me a sur e s t he
t e mpe r a t ur e of out si de ai r.
Se nds t he t e mpe r a t ur e r eadi ng t o t he c ont r ol
a sse mbl y .
A / C A mb i e n t Ai r Te mpe r a t ur e Se n so r
WI RI NG SHI ELD
14A099
RADI ATOR GRI LL OPENI NG
PANEL REI NFORCEMENT 8A284
FRONT OF
VEHICLE
A/ C AMBI ENT AI R
TEMPERATURE SENSOR
19E702
M485S-A
12 - 03B- 6 Ai r Condi t i oni ng Sy s t e mE l e c t r o n i c A u t o ma t i c T e mp e r a t u r e Cont r ol 12 - 03B- 6
Au t o ma t i c T e mp e r a t u r e Co n t r o l Se n s o r
Is l o c a t e d behi nd t he i nst rument panel ( 0432 0) t o
t he ri ght of t he EATC c ont r ol a sse mbl y .
Au t o ma t i c Te mpe r a t u r e Co n t r o l Se n so r
Cont ai ns a t he r mi st or whi c h me a sur e s t he
t e mpe r a t ur e of t he ai r i nsi de t he pa sse nge r
c o mpa r t me n t .
AUTOMATI C TEMPERATURE
CONTROL SENSOR ASSY
19C734
I NSTRUMENT PANEL 04320
I NSTRUMENT PANEL
UPPER MOLDI NG 04268
M4639-A
A / C S u n l o a d S e n s o r
The A / C sunl oad se nsor ( 19E663) :
Is l o c a t e d on t o p of t he i nst rument panel on t he
pa sse nge r si de.
Cont ai ns a phot ovol t a i c cel l t ha t is sensi t i ve t o l i ght .
A / C Sun l o a d Se n so r
M3779-A
The A / C c y c l i ng swi t c h i s mount ed on a Sc hr a d e r
va l ve - t y pe f i t t i ng on t he si de of t he suc t i on
a c c umul a t or / d r i e r ( 19C836) .
A va l ve d e pr e sso r , l o c a t e d i nsi de t he t hr e a d e d e nd
of t he A / C c y c l i n g s wi t c h, pr e sse s in on t he
Sc hr a d e r va l ve st e m.
Thi s a l l ows t he suc t i on pr e ssur e i nsi de t he suct i on
a c c umul a t o r / d r i e r t o c ont r ol t he o pe r a t i o n of t he
A / C c y c l i n g s wi t c h.
The A / C c y c l i ng swi t c h c o n t a c t s ope n whe n t he
suc t i on pr e ssur e d r o ps t o 152- 193 kPa ( 2 2 t o 2 8
psi ).
The A / C c y c l i n g swi t c h c o n t a c t s c l o se whe n t he
suc t i on pr e ssur e r i se s t o 2 7 6- 32 4 kPa ( 40- 47 psi ).
Ambi e nt t e mpe r a t ur e be l o w a ppr o x i ma t e l y 7 - 10C
( 45- 50F) , pr e ve n t s t he A / C c y c l i n g swi t c h
c o n t a c t s f r o m c l o si n g. Thi s i s due t o t he
pr e ssur e / t e mpe r a t ur e r el at i onshi p of t he
r e f r i ge r a nt a n d t he r equi r ement of t he s y s t e m
pr e ssur e t o r e a c h 2 7 6- 32 4 kPa ( 40- 47 psi ) t o c l o se
t he A / C c y c l i ng swi t c h c o n t a c t s.
The A / C c y c l i n g swi t c h c o n t a c t s c ont r ol t he
el ect r i cal ci r cui t t o t he A / C c l ut c h f i el d coi l ( 2 987 ) .
Whe n t he A / C c y c l i n g swi t c h c o n t a c t s c l o se , t he
A / C c l ut c h ( 2 884) i s ener gi zed f or A / C
c o mpr e sso r o pe r a t i o n .
Whe n t he A / C c y c l i n g swi t c h c o n t a c t s o pe n , t he
A / C c l ut c h i s de-ener gi zed a n d A / C c o mpr e sso r
ope r a t i on st o ps.
The A / C c y c l i n g swi t c h ( 19E561) wi l l c ont r ol t he
A / C e va po r a t o r c o r e pr e ssur e a t a poi nt whe r e t he
pl a t e / f i n sur f a c e t e mpe r a t ur e wi l l be mai nt ai ned
sl i ght l y a bo v e f r e e zi n g. Thi s pr e ve nt s A / C
e va po r a t o r c o r e i c i ng and t he bl o c ka ge of ai r f l ow.
A / C B l o w e r Mo t o r S p e e d C o n t r o l
CAUTI ON: fie s y s t e m s h o u l d n o t b e o p e r a t e d
w i t h t h e A / C Sl o we r m o t o r d i s c o n n e c t e d .
Da ma g e ma y oicurt o t h e A / C b l o w e r m o t o r
s p e e d c o n t r o l ( 19 E 62 4) i f c o o l i n g a i r i s n o t
p r o v i d e d b y t h e bi f cwer <mot or.
The f unct i on of t he A A*sc i o w e r mo t o r spe e d c ont r ol
i s t o c o n ve r t l ow po we r ^ wa l s f r o m t he EATC
c ont r ol a sse mbl y t o a hi gh c ur r e nt , var i abl e gr ound
f e e d f or t he bl owe r mo t o r ( 1852 7 ) .
A / C bl owe r mot or spe e d i s i nf i ni t el y var i abl e a n d i s
c ont r ol l e d by t he e l e c t r oni c c ont r ol a sse mbl y
so f t wa r e a nd A / C e l e c t r oni c d o o r a c t ua t o r mo t o r
posi t i on.
A de l a y f unct i on pr o vi d e s a gr a dua l i ncr ease or
d e c r e a se in A / C bl owe r mot or spe e d under all
c ondi t i ons.
The A / C bl o we r mot or spe e d c ont r ol i s l o c a t e d in t he
A / C e va po r a t o r c o r e housi ng ( 19A553) and i s
a c c e ssi bl e t hr o ugh t he engi ne c o mpa r t me n t .
A / C Bl o we r Mo t o r Spe e d Co n t r o l a n d As pi r a t o r As s e mbl y
CONTROL SENSOR
HOSE AND ELBOW
19D888
COVER
A/ C BLOWER MOTOR
SPEED CONTROL 19E624
SCREW
2 REQ' D
M2644- B
A / C E l e c t r o n i c Do o r A c t u a t o r Mo t o r
The A / C e l e c t r oni c d o o r a c t ua t o r mo t o r ( 19E616) i s
l o c a t e d on t o p of t he A / C e va po r a t o r c o r e housi ng
a sse mbl y .
It s f unct i on i s t o move t he A / C ai r t e mpe r a t ur e
c ont r ol d o o r on c o mma n d f r o m t he c ont r ol
a sse mbl y .
The A / C e l e c t r oni c door a c t ua t o r mot or c ont a i ns a
r ever si bl e e l e c t r i c mot or a nd a pot ent i omet er . The
pot e nt i ome t e r wi pe r i s c o n n e c t e d t o t he a c t ua t o r
out put sha f t and mo ve s wi t h t he out put shaf t t o
i ndi cat e t he posi t i on of t he A / C a i r t e mpe r a t ur e
c ont r ol door .
Ba t t e r y vo l t a ge i s appl i ed t o t he e nds of t he
pot ent i omet er . The vol t a ge avai l abl e at t he wi pe r
i ndi cat es t he posi t i on of t he pot ent i omet er . The
a c t ua t o r wi pe r vol t a ge i s sent t o t he c ont r ol modul e
and ma t c he d wi t h t he wi pe r vol t a ge of t he modul e
pot ent i omet er . The pr i nt ed ci r cui t bo a r d t hen dr i ve s
t he a c t ua t o r mot or in t he di r ect i on n e c e ssa r y t o
ma ke t he a c t ua t o r wi pe r vol t a ge a gr e e wi t h t he
c ont r ol modul e wi pe r vol t a ge .
A/ C ELECTRONI C
DOOR ACTUATOR
A/ C AI R TEMPERATURE MOTOR 19E616
CONTROL DOOR
CRANK A RM
~ ^ SCRE W
4 REQ' D
M3461- B
12 - 03B- 9 Ai r Condi t i oni ng Sy s t emEl ec t r oni c Aut omat i c Temper at ur e Cont r ol 12 - 03B- 9
A / C Co mp r e s s o r Pr es s ur e Rel i ef Val ve
An A / C c ompr e ssor pr essur e reli ef val ve ( 19D644)
has been i ncor por at ed in t he c ompr e ssor ' s hi gh
pr essur e di schar ge mani f ol d:
di schar ge pressure bui l dups, 3103 kPa ( 450 psi )
and above.
To prevent damage t o t he A / C c ompr e ssor
( 197 03) and ot her A / C sy st e m component s.
Af t er t he e xc e ssi ve pressure has been rel i eved, t he
val ve c l ose s t o prevent t ot al ref ri gerant l oss.
The A / C c ompr e ssor pr essur e relief val ve is
l ocat ed in t he A / C mani f ol d and t ube ( 19D7 34) .
A/ C Pressure Cut-Off Swi tch
An A / C pr essur e cut -of f swi t c h ( 19D594) i s used on
all vehi cl es t o i nt errupt A / C c ompr e ssor oper at i on in
t he event of hi gh sy st e m di schar ge pr essur es.
The A / C pr essur e cut -of f swi t c h is l ocat ed in t he
di schar ge line bet ween t he A / C c ompr e ssor
( 197 03) and A / C condenser c o r e ( 197 12) .
It i s sensi t i ve t o di schar ge pr essur e.
Vacuum Control Motors
The vacuum cont r ol mot or s ( 18A318) :
Ar e l ocat ed on t he A / C reci rcul at i ng ai r duct
( 19C590) and t he heat er ai r plenum chamber
( 1847 1) .
They di r ect sy st e m ai rf l ow t o t he di f f erent out l et s.
System Operation
The sy st e m aut omat i cal l y mai nt ai ns t he t emper at ur e
sel ect ed f or dri vi ng c omf or t and regul at es t he ai rf l ow
bet ween t he:
A / C regi st er ( 19893) .
Heat er out l et f l oor duct ( 18C433) .
Wi ndshi el d def r ost er hose nozzle ( 18490) .
A / C si de wi ndow demi st er and hose ( 19E630) .
The sy st e m al so provi des t he opt i on of manual l y
overri di ng t he bl ower speed and / or ai rf l ow di rect i on
a s desi r ed.
Addi t i onal l y, t he syst em has an A / C sunl oad sensor
( I 9E 663) f or aut omat i c sol ar sensi t i vi t y, resul t i ng in
t emper at ur e compensat i on duri ng hi gh sunl oad
condi t i ons. { -
The outside t emperat ure can al so be di spl ayed at
any tirr.e by moment ar i l y pressi ng t he OUTSIDE
TEMP but t on. The oi j t si de t emper at ur e wi ll t hen be
di spl ay ed until t he but t o n is pr essed agai n.
For opt i mum sut o ma t i c operat i on, t he sy st e m
shoul d be in AUTO anqi set t o t he desi red
temperature se t i ng. I
If t he passenger cu^fArtment t emperat ure i s
wa r me r or cool er thaMfe set t emperat ure, t he
cl i mat e cont r ol syst em^ka ut o ma t i c a l l y provi de
heat (when t he engi ne is wl r m) or ai r condi t i oni ng,
a s requi red, t o r each t he c omf or t set t i ng as f a st as
possi bl e.
If it is necessar y t o adj ust t he comf or t set t i ng, t he
set t i ng shoul d be changed only in small i ncrement s
(1-2 degr ees) t o mai ntai n comf or t and t o avoi d l arge
vari at i ons of t he passenger compar t ment
t emper at ur e. Rai si ng or l oweri ng t he set
t emper at ur e in l arge i ncrement s f r om t he c omf or t
set t i ng wi ll not reduce t he t i me requi red t o r each
st abi l i zed c omf or t .
Ref er t o t he f ol l owi ng i l l ust rat i on.
Co n t r o l Asse mbl y
VFD
VACUUM FLUORESCENT
DISPLAY WINDOW
j [mElfrjEini VFD
VACUUM FLUORESCENT
DISPLAY WINDOW
i off |
VFD
VACUUM FLUORESCENT
DISPLAY WINDOW
ÔUTSI DE T E MP ^
VFD
VACUUM FLUORESCENT
DISPLAY WINDOW
^ AUTOMATIC jj
VFD
VACUUM FLUORESCENT
DISPLAY WINDOW
^ A X A / C i NORM A / C ~ | VENT \ FLOOR \ FLR & DEF f DEF ^ j
%
M4641-A
A UT OMA T I C
Pr ess t he AUTOMATI C but t on t o t urn t he sy st e m ON
f or fully aut omat i c oper at i on. When f unct i oni ng
aut omat i cal l y, t he di gi t al di spl ay wi ndow wi l l sho w
AUTO and t he set t emper at ur e. The sy st e m wi ll
mai nt ai n t hi s t e mpe r a t ur e by cont rol l i ng ai r f l ow
di rect i on (f unct i onal set t i ng), ai rf l ow quant i t y (f an
spe e d), and di schar ge t e mpe r a t ur e requi red f or
c omf or t .
When heat i ng i s r equi r ed, ai rf l ow wi ll aut omat i cal l y
be di r ect ed t hr ough heat er out l et f l oor d uc t s and
A / C si de wi ndow demi st er and hoses wi t h a smal l
amount of ai r t hr ough wi ndshi el d de f r ost e r hose
nozzl e.
Duri ng cool we a t he r whe n t he engi ne cool ant i s
bel ow appr oxi mat el y 50 0 ( 1 2 0 F) and heat is
r equi r ed, t he ai rf l ow wi l l be di r ect ed t o t he def r ost er
out l et s at l ow bl ower spe e d . When engi ne cool ant
t emper at ur e r eaches 50 0 ( 1 2 0 F) o r af t er 3 1/ 2
mi nut es (whi chever o c c ur s f i r st ), t he bl ower spe e d
wi ll i ncrease and ai rf l ow wi ll shi f t t o t he f l oor.
When cool i ng i s r equi r ed, ai rf l ow wi ll be di r ect ed
t hr ough i nst rument panel r egi st er s. A / C r egi st er s
can be adj ust ed f or opt i mum c omf or t . When
maxi mum cool i ng i s r equi r ed, t he sy st e m wi ll
aut omat i cal l y ope r a t e wi t h r eci r cul at ed ai r f or rapi d
cool -down and aut omat i cal l y change t o out si de ai r
as t he passenger c ompa r t me nt i nt eri or a ppr oa c he s
t he sel ect ed t emper at ur e.
In moder at e condi t i ons, t he sy st e m wi l l
aut omat i cal l y ope r a t e , wi t h ai rf l ow di r e c t e d t hr ough
heat er out l et f l oor duct and t hr ough wi ndshi el d
def r ost er hose nozzle at a mode r a t e t emper at ur e
and f an spe e d.
OFF
Pr ess t he OFF but t on t o t urn t he sy st e m OFF
compl et el y; t he di gi t al di spl ay wi ndow wi ll be bl ank
(da r k) unless OUTSIDE TEMP has been se l e c t e d.
Di gi t a l Di s p l a y Wi n d o w
The di gi t al di spl ay wi n d o w wi ll i ndi cat e one of t hr ee
di spl ay s dependi ng upon t he manual sel ect i on:
Sel ect ed c omf or t t emper at ur e.
Out si de t emper at ur e.
Funct i on sel ect ed.
Wa r me r ( Re d ) B u t t o n
Pr ess t he red but t on t o rai se t he t emper at ur e set t i ng.
Pr ess t he but t on once t o rai se t he t emper at ur e one
degr ee.
Hol di ng t he but t on in wi ll cont i nuousl y rai se t he
t emper at ur e set t i ng in one-degree i ncrement s t o
2 9C ( 85F) , and t hen wi ll j ump t o 32 C ( 90F) in
one st ep f or cont i nuous maxi mum heat i ng.
C o o l e r ( Bl u e ) B u t t o n
Pr ess t he blue but t on t o l ower t he t emper at ur e set t i ng.
Press t he but t on once t o l ower t he t emper at ur e one
degr ee.
Hol di ng t he but t on in wi ll cont i nuousl y reduce t he
t emper at ur e set t i ng in one-degree i ncrement s t o
18C( 65F) and t hen wi ll j ump t o 15C ( 60F) in
one st e p f or cont i nuous maxi mum cool i ng.
OUTSI DE T E MP
Press t hi s but t on t o di spl ay t he out si de t emperat ure.
The out si de t emper at ur e wi ll be di spl ayed until t he
but t on is pr essed agai n.
If t he set t emper at ur e i s changed whi l e t he out si de
t emper at ur e is se l e c t e d, t he set t emper at ur e wi ll be
di spl ayed f or f our seconds and t hen revert back t o
t he out si de t emper at ur e.
If t he sy st e m is t urned OFF wi t h t he out si de
t emper at ur e sel ect ed or if t he OUTSIDE TEMP
but t on is de pr e sse d af t er t he sy st e m is of f , t he
out si de t emper at ur e wi ll be di spl ayed in t he di gi t al
di spl ay wi ndow. Depressi ng t he OUTSIDE TEMP
but t on wi ll t urn t he out si de t emper at ur e f eat ure OFF
and t he di gi t al di spl ay wi ndow wi ll become blank
(da r k).
12 - 03B- 11 Ai r Condi t i oni ng Sy s t e mE l e c t r o n i c Aut omat i c Temper at ur e Cont r ol 12 - 03B- 11
DESCRIPTIONS AMD OPERATIONS (Conti nued)
Ma n u a l Ov e r r i d e s
There are si x manual overri de but t ons al ong t he l ower
edge of t he cont rol assembl y . Each af f ect s sy st e m
operat i on as f ol l ows:
MA X A / C
Depressi ng t he MAX A / C but t on wi ll show MAX A / C
and t he set t emper at ur e in t he di spl ay wi ndow.
A / C a i r inlet duct door wi ll c l ose t o out si de air
al l owi ng ai r f r om i nsi de t he vehi cl e t o be dr a wn i nt o
t he sy st e m.
The A / C cl ut ch ( 2884) wi ll oper at e if t he ambi ent
t emper at ur e is appr oxi mat el y 10 C ( 50 F) or
above.
NORM A / C
Depressi ng t he NORM A / C but t on wi ll sho w A / C and
t he set t emper at ur e in t he di spl ay wi ndow.
The sy st e m will d r a w ai r f r o m out si de t he vehi cl e.
The A / C cl ut ch wi ll o pe r a t e if t he ambi ent
t emper at ur e is appr oxi mat el y 10 C ( 5 0 F).
VE NT
Pressi ng t he VENT but t on wi l l sho w VENT and t he set
t emper at ur e in t he di spl ay wi ndow.
The sy st e m will ope r a t e wi t h out si de ai r in t he panel
f unct i on.
The A / C cl ut ch wi ll be t urned OFF.
FL OOR
Pressi ng t he FLOOR but t on wi ll sho w FLOOR and t he
set t emper at ur e in t he di spl ay wi ndow.
The sy st e m will di st r i but e out si de ai r t hr ough t he
heat er out l et f l oor duct wi t h a smal l bl eed t o t he
A / C si de wi ndow demi st er and hoses and t he
wi ndshi el d def r ost er hose nozzl e.
e The A / C cl ut ch wi ll be t ur ned OFF.
F L R & D E F
Pressi ng t he FLR & DEF but t on will show FLOOR, t he
def r ost sy mbol and set t emper at ur e in t he di spl ay
wi ndow.
The sy st e m di st ri but es out si de ai r equally bet ween
t he wi ndshi el d def r ost er hose nozzle and t he heat er
out l et f l oor duct wi t h a smal l bl eed out t he A / C si de
wi ndow demi st er and hoses.
The A / C cl ut ch wi ll oper at e if t he ambi ent
t emper at ur e is appr oxi mat el y 10 C ( 50 F) and
above.
DE FROST /
Pressi ng t he DEFROST but t on wi ll sho w t he def r ost
sy mbol and set t emper at ur e in t he di spl ay wi ndow.
The sy st e m di st ri but es out si de ai r t o t he wi ndshi el d
def r ost er hose nozzle and t he A / C si de wi ndow
demi st er and hose wi t h a smal l bl eed t o t he heat er
out l et f l oor duct s.
The A / C cl ut ch wi ll oper at e if t he ambi ent
t emper at ur e is appr oxi mat el y 10 C ( 50 F) and
above.
B l o w e r S p e e d Ov e r r i d e T h u m b w h e e l
Rot at e t he bl ower spe e d over r i de t humbwheel more
t han 10 de gr e e s t o t urn OFF t he AUTOMATI C bl ower
i ndi cat or and provi de manual cont rol of t he A / C
bl ower mot or speed.
The di spl ay wi ll sho w FAN and a f an i con.
Rot at i ng t he wheel fully down agai nst i t s l ower st op
l ocks t he A / C bl ower mot or at i t s l owest speed.
Rot at i ng t he wheel fully up agai nst t he st op, l ocks
t he bl ower at i t s hi ghest spe e d.
Pr ess t he AUTOMATI C but t on t o resume aut omat i c
A / C bl ower mot or cont r ol and remove t he FAN and
i con f r om t he di spl ay wi ndow.
12 - 03B- 12
Ai r Condi t i oni ng Sy s t emEl ec t r oni c A u t o ma t i c Temper at ur e Cont r ol
12 - 03B- 12
El e c t r i c a l S c h e ma t i c s
El ect r oni c Aut omat i c Temper at ur e Cont r ol ( EATC) Cr own Vi c t o r i a , Gr and Marqui s
. T FUSE
I f 9 J JUNCTION
1
\ j PANEL
181 JTBR/O
A/C
BL OWE R
MOTOR
57
A/C
BLOWER
MOTOR
SPEED
CONTROL
1
2 6 9 | L B / 0 T
Y/ R 1 7 5 4 1 L(
GY
F U S E
JUNCTION
P A NE L
A/C
E L E C T R O N I C
DOOR
ACTUATOR
MOTOR
MOTOB DRIVE
E E
> 8 | G Y |
1 2081 G Y
JSYLG/O T 438YR/W Y 24SWF
A A A A
X
4 3 7
X
Y / L G
X
2 4 5
X
B R / l g
x
E L E C T R O N I C
2461
P
AUTOMATI C
T E MP E R A T U R E
CONTROL
( E A T C)
MODULE
C2 7 1 B 01 9 o i 11 c i
C2-15 - Cm C2-6 C1-21 01-22
0 1 2 4
C2 16
C?-2 C2 i /
02 1
BK 11 57 BK
57 , BK
o ~> ^
;l 11
- A C T U A T O R
. CONTROL
mum- > - fLtuMi-
NATION NATION
.INPUT ' f "^ ,
N P U T
' C
2
-
4
^ C2 - * 8
W
484 " O/ BK
A / C
AMBIENT
AIR
T E MP E R A T U R E
S E N S O R
T O I NST RUME NT
I L L UMI NATI ON
of this c i r c ui t
12 - 03B- 13
Ai r Co n d i t i o n i n g S y s t e mE l e c t r o n i c A u t o ma t i c T e mp e r a t u r e Co n t r o l 12 - 03B- 13
El e c t r o n i c Aut o ma t i c Te mpe r a t ur e Co n t r o l ( EATC) Cr o wn Vi c t o r i a , Gr a n d Ma r qui s (Cont i nue d)
HOT AT A L L TI MES
TO MODULE DATA LI NK
AND PCM PI NS 15 AND 16
PK/ LB
; FUSE
JUNCTI ON
P ANE L
10A^ |
54
T/ O
01-14
TO PI N 69
OF PCM
8ATT
TO POWERTRAI N
CONTROL MODULE
(PCM) POWER
RELAY
I NSTRUMENT
CLUSTER
02-20
ENGLISH/
METRIC
OUTPUT
ELECTRONIC
AUTOMATIC
TEMPERATURE
CONTROL
(EATC)
MODULE
A/C CYCLING
SWITCH
of this circuit
M4635-A
E ATCCr o wn Vi c t o r i a a nd Gr a nd Ma r qui s
Co n n e c t o r En d Vi e ws
Pin
Number Circuit Ci rcui t Funct i on
8 2 69
( L B / O )
9 7 54
( L G / W)
Re l a y Si gn a l
10
_
No t Us e d
11 2 98 ( P / O ) Run P o we r - Hot in RUN
12 5 4 ( L G / Y) B+ Ba t t e r y
13 915
( P K / L B )
Mo d u l e Da t a Li n k (SCP-) f r o m
14 9 14 ( T / O) Mo d u l e Da t a Li n k ( S C P + ) f r o m
2 1 2 45
( B R / L G )
Bl e n d Do o r Dr i ve 1-CCW
22 2 4 6 ( P ) Bl e n d Do o r Dr i ve 2 - CCW
2 3
_
No t Us e d
2 4 57 ( BK) Ve h i c l e Gr o un d
25 3 4 8 ( P ) A / C Cy c l i n g S wi t c h
26 2 9 8 ( P / O ) B + I gn i t i o n Run
Pin
1 7 67
( L B / O )
A mb i e n t T e mp e r a t u r e Se n s o r
2 47 0
( P K / B K )
Su n l o a d , Amb i e n t & I n - Ve hi c l e
T e mp e r a t u r e S e n s o r Gr o u n d
3 No t Us e d
4 484
( O / B K )
I n st r ume n t Pa n e l I l l umi n a t i o n
5 437
( Y/ L G )
P o t e n t i o me t e r - CW Gr o un d
15 436
( R / L G )
P o t e n t i o me t e r - CCW P o we r
16 468 ( BR) Su n l o a d Se n s o r
17 7 90 ( W/ O ) A u t o ma t i c T e mp e r a t u r e Co n t r o l
Se n s o r
18 19 0- B/ R) I n st r ume n t Cl u s t e r L i g h t s -
Va r i a b l e Vo l t a ge Di mme r
19 No t Us e d
2 0 506 ( R) E n g l i s h Me t r i c
CONTROL CONNECTOR
M4640-A
Pin
1 2 69
( L B / O )
3 7 54
( L G / W)
Re l a y Si gn a l
4 5 1 5 ( 0 / R ) A / C Bl o we r Mo t o r Po we r Ci r c ui t
0 -
fj rr
{87A}
M4632-A
P i n
30 198
( DG / O )
85 7 3 ( O / L B ) Re l a y Co i l Ne ga t i v e Te r mi n a l
86 3 6 1 ( R ) Re l a y Co i l P o s i t i v e Te r mi n a l
87 No t Us e d
87 A 347
( B K / Y )
Te r mi n a l
NOTE: A / C cut -out rel ay connect or s part of relay box.
A/C ELECTRONIC DOOR
P i n
1 2 45
( BR/ L G )
Te mp e r a t u r e Bl e n d Do o r Dr i ve
2 - CCW
3 437
( Y/ L G )
4 436
( L G / O )
5 2 4 6 ( P ) Te mp e r a t u r e Bl e n d Do o r Dr i ve
1-CW
7 No t Us e d
8 2 08 ( GY) B + Ho t In RUN
12 - 03B- 16 Ai r Condi t i oni ng Sy s t emEl ec t r oni c Aut omat i c Temper at ur e Cont r ol 12 - 03B- 16
El e c t r o n i c Aut o ma t i c Te mpe r a t ur e Co n t r o l (EATC) S y s t e mT o wn Car
. . . * FUSE
I f a I JUNCTION
J
:
"PANEL
iC i
181JTBR/0
A/C
BLOWER
MOTOR
5
A/C
BLOWER
MOTOR
SPEED
CONTROL
A/C
ELECTRONIC
DOOR
ACTUATOR
MOTOR
36^R/LG J 438^R/ W ^
J 437^Y/ LG J 245Ê
ELECTRONIC
9 d f i T P AUTOMATIC
JL TEMPERATURE
r~f CONTROL
.BR/LG T MODULE
M4645-A
12 - 03B- 17 Ai r Co n d i t i o n i n g S y s t e mEl ec t r oni c Aut omat i c Temper at ur e Cont r ol 12 - 03B- 17
El e c t r oni c Aut omat i c Temperat ure Cont rol (EATC) Sy st e m- To wn Car (Cont i nue d)
HOT AT ALL TIMES
T"
" FUSE
I JUNCTION
. PANEL
797 LG/P
m
FUSE
I JUNCTION
1
DA K I P I
F
INSTRUMENT
CLUSTER
Ct-12
BATT p"wR
01*11
STEERI NG WHEEL
SWI TCHES INPUT
C2*3 CI-10
ENGINE Ti MP
VEHICLE SPEED
INPUT
C1-13 01*14
IGN
ENGLISH/
OUTPUT
A/CCONTROL
C1-25s
BR/LB
1069 O/LB
ELECTRONIC
AUTOMATIC
TEMPERATURE
CONTROL
(EATC)
MODULE
883 I PK/LB
STEERING
WHEEL
SWITCH
CONTROL
MODULE
T/O
TO PCM VIA
MODULE DATA LINK
TO POWERTRAIN
CONTROL
MODULE (PCM)
POWER RELAY
361 I R
A/C PRESSURE
CUT-OFF
SWITCH
TO PIN 41
OF PCM
TO PIN 69
OF PCM
J
A/C
CLUTCH
DIODE
BK
See EVTM f o r mo r e det ai l s
A/C
CLUTCH
M4646-A
12 - 03B- 18 Ai r Condi t i oni ng S y s t e mE l e c t r o n i c A u t o ma t i c T e mp e r a t u r e Cont r ol 12 - 03B- 18
D1AQNOS8S AND TESTING (Conti nued)
El e c t r o n i c Aut o ma t i c Te mpe r a t ur e Cont r ol (EATC) S y s t e mT o wn Car ( Co n t i n ut e d )
LH
STEERI NG
WHEEL
CONTROL
SWI TCH:
SPEED
CONTROL
RH
STEERI NG
WHEEL
CONTROL
SWI TCH:
CLI MATE
CONTROLS
AND AUDI O
CONTROLS
HOT IN A C C OR RUN
TO
AIR BAG
DI AGNOSTI C
MONI TOR
4
10
15 12 14 13 4
STEERI NG
WHEEL
SWI TCH
CONTROL
MODULE
SHI ELD
832
LB/PK 833
\ TO FRONT
i CONTROL
484
T
UNI T
1088
LG/BK
O/BK
848
BK
TO
SPEED
CONTROL
it460~A
12 - 03B- 19 Ai r Co n d i t i o n i n g S y s t e mE l e c t r o n i c A u t o ma t i c T e mp e r a t u r e Co n t r o l
12 - 03B- 19
Pi n
9 7 58 ( P / W) Re l a y Si gn a l
10 1069
( O / L B )
Re mo t e Co n t r o l Mo d u l e t o
E l e c t r o n i c Cl i ma t e Co n t r o l Uni t ( + )
No t Use d *
11 2 95
( L B / P K )
Run P o we r - Ho t i n RUN
12 7 97 ( L G / P ) B + Ba t t e r y
13 915
( P K / L B )
Mo d u l e Da t a Li n k ( SCP- ) f r o m
14 9 1 4 ( T / O) Mo d u l e Da t a Li n k ( S C P + ) f r o m
2 1 2 45
( B R / L G )
2 2 2 4 6 ( P ) Bl e n d Do o r Dr i v e 2 - CW
2 3

No t Us e d
2 5 8 8 3
( P K / L B )
2 8 2 98 ( P / O ) B + I gn i t i o n Run
* Ba s e mo d e l T o wn Ca r .
CONNECTOR 02 M463S A
Pin
1 7 67
( L B / O )
Amb i e n t Te mp e r a t u r e Se n s o r
2 47 0
( P K / B K )
359
( G Y/ R )
Th e r ma l Swi t c h t o Co n t r o l Mo d u l e
Su n l o a d , A mb i e n t a n d A u t o ma t i c
Te mp e r a t u r e Co n t r o l Se n s o r
Gr o un d
3 107 0
( B R / L B )
Re mo t e Co n t r o l Mo d u l e t o
E l e c t r o n i c Cl i ma t e Co n t r o l Uni t (-)
No t Us e d '
4 484
( O / B K )
I n st r ume n t I l l umi n a t i o n
5 437
( Y/ L G )
P o t e n t i o me t e r - CW Gr o un d
7 7 56
( R / P K )
15 436
( R / L G )
P o t e n t i o me t e r - CCW P o we r
16 468 ( BR) Su n l o a d Se n s o r
17 7 90 ( W/ O ) I n-Ca r Te mp e r a t u r e Se n s o r
18 1 9 ( L B / R ) I n st r ume n t Cl ust e r L i g h t s -
Va r i a bl e Vo l t a ge Di mme r
19 No t Us e d
2 0 506 ( R) En gl i sh - Me t r i c
* Ba s e mo d e l To wn Car .
12 - 03B- 2 0 A i r Co n d i t i o n i n g S y s t e mE l e c t r o n i c A u t o ma t i c T e mp e r a t u r e Co n t r o l 12 - 03B 2 0
CONTROL CONNECTOR
M4640-A
P i n
Nu mb e r Ci r c u i t Ci r c u i t Fu n c t i o n
2 7 5 6
( R / P K )
3 7 5 8 ( P / W) Re l a y Si gn a l
4 515 ( O / R ) A / C Bl o we r Mo t o r P o we r Ci r c u i t
5 5 7 ( BK) Gr o u n d
(87A
M4632-A
Pi n
30 3 4 7
( B K / Y )
8 5 3 3 1
( P K / Y )
Re l a y Co i l Ne g a t i v e Te r mi n a l
86 3 6 1 ( R) Re l a y Co i l P o s i t i v e Te r mi n a l
87

No t Us e d
87 A 3 4 8 ( P ) Re l a y Co n t a c t No r ma l l y C l o s e d
Te r mi n a l
NOTE: A / C Cut -Out Relay connect or part of Rel ay Box.
A/C ELECTRONIC DOOR
Pi n
1 2 45
( B R / L G )
T e mp e r a t u r e Bl e n d Do o r Dr i v e
1-CCW
2 4 3 8 ( R / W) T e mp e r a t u r e Bl e n d Do o r
3 437
( Y/ L G )
4 436
( R / L G )
5 2 4 6 ( P ) T e mp e r a t u r e Bl e n d Do o r Dr i v e
2 - CW
6 57 ( BK) Gr o u n d
7

No t Us e d
8 2 9 8 ( P / O ) B + Ho t i n RUN
STEERING WHEEL SWITCHES
CONTROL MODULE C2
K22761-A
Pi n
1 595 ( L B / R ) Co mmu n i c a t i o n t o St e e r i n g Wh e e l
Co n t r o l S w i t c h e s
2

No t Us e d
3

No t Us e d
4 832
( L B / P K )
Co mmu n i c a t i o n t o Ra d i o
5 57 ( BK) Co mmu n i c a t i o n Sh i e l d t o Ra d i o
6 1069
( O / L B )
Co n t r o l
12 - 03B- 2 1 Ai r Co n d i t i o n i n g S y s t e mE l e c t r o n i c A u t o ma t i c T e mp e r a t u r e Co n t r o l 12 - 03B- 2 1
Pin
7 107 0
( B R / L B )
Co n t r o l
8
_
No t Us e d
9 2 96 ( W/ P ) Ba t t e r y
10 683 ( Y) P o we r t o St e e r i n g Wh e e l Co n t r o l
S wi t c h e s
11

No t Us e d
Pin
12 1068
( L G / B K )
Co mmu n i c a t i o n f r o m Ra d i o
13 833 ( T) Co mmu n i c a t i o n t o Ra d i o
14 484
( O / B K )
Fr o m L i gh t i n g Co n t r o l Mo d u l e
15 848 ( BK) Gr o un d
16 No t Us e d
1. Veri f y t he c ust ome r ' s ori gi nal concer n by
oper at i ng t he el ect roni c aut omat i c t emper at ur e
cont rol t o dupl i cat e t he condi t i on.
Va c u u m h o s e d a ma g e d .
A / C s y s t e m r e f r i ge r a n t .
Da ma g e d d r i v e be l t .
Bl o wn f u s e ( s ) .
Ci r c u i t r y
mi s r o u t e d / d a ma g e d .
Co n n e c t o r s
d a ma g e d / d i s c o n n e c t e d .
3. If t he concer n(s) remai ns af t er t he i nspect i on,
pe r f or m t he f ol l owi ng EATC Sy st e m Self Test :
The EATC Self Test wi ll de t e c t c onc e r ns in t he
sy st e m cont r ol f unct i ons f ound duri ng t he Self
Test and wi ll di spl ay t hese er r or c o d e s in
addi t i on t o i nt ermi t t ent er r or c o d e s f or
c onc e r ns t ha t oc c ur duri ng sy st e m oper at i on.
The vehi cl e i nt eri or t emper at ur e shoul d be
be t we e n 60 F and 80 F when per f or mi ng t he
Self Test . If t he t e mpe r a t ur e s a r e not wi t hi n t he
speci f i ed r anges, f al se i n-car t emper at ur e
sensor er r or c o d e s wi ll be di spl a y e d. Re c or d
all e r r or c o d e s di spl ay ed duri ng t he t e st .
If any er r or c o d e s appear duri ng t he Self Test ,
f ol l ow t he di agnost i cs pr oc e dur e gi ven under
' ' ACTI ON" f or e a c h er r or c o d e gi ven.
If a condi t i on e xi st s but no er r or c o d e s appear
duri ng t he Self Test , ref er t o t he Sy mpt om
Chart Condi t i on: EATC Sy st e m I noperat i ve,
Int ermi t t ent or I mproper Oper at i on.
The Self Test can be i ni t i at ed at any t i me wi t h
any result i ng er r or c ode s di spl ay ed. Normal
operat i on of t he sy st e m st ops when t he Self
Test is act i vat ed.
To ent er t he Self Test , pr e ss t he OFF and
FLOOR but t ons si mul t aneousl y and t hen pr ess
' t he AUTOMATI C but t on wi t hi n t wo seconds.
The di spl ay wi ll show a pul se t r a c e r goi ng
around t he cent er of t he di spl ay wi ndow. The
t e st may run as long as 30 se c onds.
To exi t Self Test and ret ai n er r or c o d e s, push
t he blue (cool er) but t on. The cont r ol wi ll exi t
Self Test , ret ai n all error c o d e s and t hen t urn
OFF (di spl ay bl ank).
To exi t Self Test and cl ear all er r or c o d e s,
pr ess Def r ost but t on. The VFD wi ndow wi ll
show 000 and all f unct i on sy mbol s f or one
se c ond. Then, t he EATC Cont rol Assembl y wi ll
t urn OFF (di spl ay bl ank) and all c o d e s wi ll be
cl ear ed.
The Self Test shoul d be deact i vat ed bef or e poweri ng
t he sy st e m down (sy st e m t urned OFF). Int ermi t t ent
er r or c o d e s wi ll be del et ed af t er 80 i gni ti on swi t c h ON
c y c l e s af t er t he i nt ermi t t ent condi t i on oc c ur s.
EATC SYSTEM SELF TEST ERROR CODE CHART
ERROR CODE DETECTED CONDITION ACTION
0 2 4 Fa ul t i n b l e n d d o o r c a l i b r a t i o n d ur i n g se l f t e s t GO t o Pi n po i n t Te st B
0 2 5 I n t e r mi t t e n t f a ul t i n b l e n d d o o r c a l i b r a t i o n GO t o Pi n po i n t Te st B
0 3 0 Se l f t e s t i n d i c a t e s a u t o ma t i c t e mp e r a t u r e c o n t r o l s e n s o r
s h o r t e d
GO t o Pi n po i n t Te st P
0 3 1 Se l f t e s t i n d i c a t e s a u t o ma t i c t e mp e r a t u r e c o n t r o l s e n s o r
o p e n
GO t o Pi n po i n t Te st P
0 4 0 Se l f t e s t i n d i c a t e s a mb i e n t s e n s o r s h o r t GO t o Pi n po i n t Te st J
0 4 1 Se l f t e s t i n d i c a t e s a mb i e n t s e n s o r o p e n GO t o Pi n po i n t Te st J
042 A mb i e n t s e n s o r i n t e r mi t t e n t s h o r t GO t o Pi n po i n t Te st J
0 4 3 A mb i e n t sensor i n t e r mi t t e n t o p e n GO t o Pi n po i n t Te st J
12 - 03B- 2 2 Ai r Condi t i oni ng Sy s t e mE l e c t r o n i c A u t o ma t i c T e mp e r a t u r e C o n t r o l 12 - 03B- 2 2
EATC SYSTEM S E L F T E S T ERROR CODE CHART (Cont'd)
ERROR CODE DETECTED CONDI TI ON ACTI ON
0 5 0 Sel f t es t i ndi c at es s unl oad s ens or shor t GO t o P i n p o i n t T e s t K
0 5 2 S u n l o a d S e n s o r i n t e r mi t t e n t s h o r t GO t o P i n p o i n t Te s t K
115 I n t e r mi t t e n t e n gi n e c o o l a n t t e mp e r a t u r e s i gn a l GO t o P i n po i n t Te s t G o r P i n p o i n t Te s t H
125 I n t e r mi t t e n t v ehi c l e s p e e d s i gn a l GO t o P i n p o i n t T e s t G o r P i n p o i n t T e s t H
NOTE: The ai r handl i ng s y s t e m i s de si gne d t o pr ovi de
d e f r o st whe n no va c uum i s a ppl i e d t o a ny of t he t hr e e
va c uum c o n t r o l mo t o r s { 18A318) . Thi s i s done t o
pr event a si t uat i on whe r e d e f r o st c a nnot be obt a i ne d
due t o a s y s t e m va c uum l eak. I nst ead, a l eak in t he
va c uum c o n t r o l ci r cui t wi l l se n d all ai r f l o w t o t he
d e f r o st e r out l e t s. Thi s condi t i on ma y o c c ur duri ng
a c c e l e r a t i on ( sl o w va c uum l e a k), ma y e xi st at all t i me s
(l ar ge va c uum l eak) a nd ma y ha ppe n onl y whe n
cer t ai n spe c i f i c f unct i ons a r e se l e c t e d , i ndi cat i ng a
l eak in t ha t por t i on of t he ci r cui t .
NOTE: The va c uum ho se s use d in t he pa sse n ge r
c o mpa r t me n t c ont r ol ci r cui t a r e c o n st r uc t e d f r o m PVC
pl ast i c mat er i al . The va c uum ho se s use d in t he engi ne
c o mpa r t me n t a r e c o n st r uc t e d of Hy t r e l . Be c a use of
t he mat er i al s use d, t he va c uum ho se s shoul d never be
pi nched of f duri ng di agnosi s t o l oc a t e a l eak. Use
Rot unda Vacuum Test er 02 1- 00014 or equi val ent t o
l oc a t e va c uum l e a ks. A wo o d gol f t e e c a n be used a s
a pl ug whe n it i s n e c e ssa r y t o pl ug one end of a
va c uum ho se f or l eak t e st pur po se s.
Use Rot unda 7 3 Di gi t al Mul t i met er 105- 00051 or
equi val ent f o r di a gnosi s.
EATC SYSTEM
EATC S y s t e m I n o pe r a t i v e ,
I n t e r mi t t e n t o r I mpr o pe r Op e r a t i o n
Da ma g e d o r i n o pe r a t i v e c h a r gi n g
s y s t e m.
Da ma g e d i nput s e n s o r ( s ) / e r r a t i c
i nput s i gn a l ( s ) .
Ch a r gi n g s y s t e m d a ma g e d .
Da ma g e d a u t o ma t i c t e mp e r a t u r e
c o n t r o l s e n s o r h o s e a n d e l b o w.
GO t o Pi n po i n t Te st A.
A / C E l e c t r o n i c Do o r A c t u a t o r
Mo t o r I n o pe r a t i v e , I n t e r mi t t e n t o r
I mpr o pe r Op e r a t i o n
Da ma g e d A / C e l e c t r o n i c d o o r
a c t u a t o r mo t o r .
Da ma g e d EATC mo d ul e . .-
GO t o Pi n po i n t Te st B.
EATC He a t e r Bl o we r Mo t o r Do e s
No t Run
Da ma g e d b l o we r mo t o r .
Da ma g e d A / C b l o we r mo t o r s p e e d
c o n t r o l .
GO t o Pi n po i n t Te st C.
EATC He a t e r Bl o we r Mo t o r
Op e r a t e s i n Hi gh i n Al l Bl o we r
Wh e e l P o s i t i o n s
c o n t r o l .
Da ma g e d EATC mo d u l e .
GO t o Pi n po i n t Te st D.
No t Op e r a t e a t L o we r S p e e d s
c o n t r o l .
Da ma g e d EATC mo d ul e .
GO t o Pi n po i n t Te st E.
hoi Of Mate a t Hi gh Sp e e d
c o n t r o l
Da ma g e d EATC mo d ul e .
GO t o Pi n po i n t Te st F.
EATC SYSTEM (Cont i nued)
CONDI TI ON POSSI BL E SOURCE ACTI ON
I n t e r mi t t e n t Ve hi c l e Mo d ul e Da t a
Link SignalDiagnostic Error
Code 115 or 125
Da ma ge d v e hi c l e s pe e d se n so r .
Da ma ge d e n gi n e c o o l a n t
t e mpe r a t ur e se n so r .
GO t o Pi npoi nt Te st G.
I n t e r mi t t e n t Ve hi c l e Mo d ul e Da t a
Li nk Si gn a l Di a gn o s t i c Er r or
Co d e s 115 a nd 125
Si mul t a n e o usl y
Da ma ge d po we r t r a i n c o mpo n e n t s .
Wa r m Di sc ha r ge Ai r In AUTOMATI C
a n d 60 F
A / C c l ut c h ma l f un c t i o n .
L o w r e f r i ge r a n t .
Da ma ge d EATC mo d ul e .
A/ Cai r t e mpe r a t ur e c o n t r o l d o o r
not in ma x A / C po si t i o n .
A / C Ambi e n t Ai r Te mpe r a t ur e
Se n so r I n o pe r a t i v e
Da ma ge d A / C a mbi e n t ai r
t e mpe r a t ur e se n so r a nd b r a c ke t .
GO t o Pi npoi nt Te st J .
A / C Sun l o a d Se n so r I n o pe r a t i v e Da ma ge d A / C sun l o a d se n so r .
GO t o Pi npoi nt Te st K.
Co n t r o l A s s e mb l y / VFD Do e s Not
Li ght Up He a t e r Bl o we r Mo t o r
OFF
GO t o Pi npoi nt Test L.
Co l d Engi ne Bl o we r Co n t r o l
Di a g n o s i s No Di a gn o st i c Er r or
Co d e
Da ma ge d mo d ul e d a t a l i nk wi r i n g
a n d / o r i n o pe r a t i v e e ngi ne c o o l a n t
t e mpe r a t ur e se n so r .
Da ma ge d EATC c o n t r o l a sse mbl y .
GO t o Pi npoi nt Te st M.
Te mpe r a t ur e Di spl a y Wo n ' t Swi t c h
Be t we e n Ce l si us a n d Fa hr e n he i t
GO t o Pi npoi nt Test N.
Sy s t e m Do e s Not Co n t r o l
Te mpe r a t ur e
Da ma ge d a ut o ma t i c t e mpe r a t ur e
c o n t r o l se n so r ho se a nd e l bo w.
I n-c a r se n so r s e a l s mi ssi n g or
d a ma ge d .
GO t o Pi npoi nt Te st P.
Co n t r o l As s e mb l y Tur ns On a n d
OFF E r r a t i c a l l y No Co n t r o l of
Sy s t e m
Cha r gi n g s y s t e m d a ma ge d .
GO t o Pi npoi nt Te st A, t he n GO t o
Pi npoi nt Te st P.
Te mpe r a t ur e Se t Poi nt Do e s Not
Re pe a t Af t e r Turni ng I gni t i on
Swi t c h OFF
Bl o wn f use .
GO t o Pi npoi nt Te st Q.
Pinpoint T e s t s
PI NPOI NT T E ST A: EATC SYSTE M I NOPERATI VE, I NTERMI TTENT OR I MPROPER OPERATI ON
A 1 PERFORM EATC SELF TEST
Ye s
No
REFER t o I n spe c t i o n a n d
Ve r i f i c a t i o n f o r
Di a gn o st i c Error Co d e s
t o f i n d t he " De t e c t e d
Co n d i t i o n . " PERFORM
t he n e c e s s a r y d i a gn o si s
a n d ma ke r e pa i r s.
GO t o A 2 .
Turn EATC Sy s t e m ON. Pr e ss t h e OFF a n d FLOOR
but t o n s si mul t a n e o usl y a n d t he n pr e s s t h e
AUTOMATI C but t o n wi t hi n t wo s e c o n d s . The t e s t
ma y t a ke a s l o n g a s 30 s e c o n d s . A pul se t r a c e r wi l l
c i r c l e a r o un d t h e c e n t e r of t he VFD wi n d o w dur i ng
t h e t e s t . Wh e n t h e se l f t e s t i s c o mp l e t e d , e r r o r
c o d e s wi l l be d i s p l a y e d in t he VFD wi n d o w t o l i st
f a ul t s f o un d d ur i n g t h e se l f t e s t . Er r or c o d e s wi l l a l so
be gi ve n f o r i n t e r mi t t e n t f a ul t s e n c o un t e r e d dur i ng
s y s t e m o pe r a t i o n . Re c o r d t h e s e e r r o r c o d e s .
Were error c ode s ot her t han 888 di spl ayed in t he
VFD wi ndow?
Ye s
No
REFER t o I n spe c t i o n a n d
Ve r i f i c a t i o n f o r
Di a gn o st i c Error Co d e s
t o f i n d t he " De t e c t e d
Co n d i t i o n . " PERFORM
t he n e c e s s a r y d i a gn o si s
a n d ma ke r e pa i r s.
GO t o A 2 .
12 - 03B- 2 4 Ai r Co n d i t i o n i n g S y s t e mE l e c t r o n i c A u t o ma t i c T e mp e r a t u r e C o n t r o l 12 - 03B- 2 4
PINPOINT TEST A: EATC SYSTEM INOPERATIVE, INTERMITTENT OR IMPROPER OPERATION (Cont i nued)
A2 CHECK BLOWER MANUAL OVERRI DE L OW SPEED
OPERATI ON
Ye s
No L>
GO t o A3.
REFER t o Pi npoi nt Te st E.
Ro t a t e t h e bl o we r t h u mb wh e e l d o wn t o t he s t o p.
Do e s the bl ower mot or go to l ow speed?
Ye s
No L>
GO t o A3.
REFER t o Pi npoi nt Te st E.
A3 CHECK BL OWER MANUAL OVERRI DE HI GH SPEED
OPERATI ON
Ye s
No >
GO t o A4.
REFER t o Pi npoi nt Te st F.
Ro t a t e t he bl o we r t h u mb wh e e l up t o t he s t o p.
Does the bl ower mot or go to high speed?
Ye s
No >
GO t o A4.
REFER t o Pi npoi nt Te st F.
A4 VERI FY DEFROST OVERRI DE OPERATI ON
Ye s
No
GO t o A5.
REFER t o "Va c uum L e a k
Di a gn o s i s " in Se c t i o n
12-00.
P r e s s t he De f r o st but t o n a nd c h e c k s y s t e m
d i s c h a r ge a i r f l o w. Ai r f l o w sho ul d be f r o m t h e
d e mi s t e r nozzl e a n d d uc t a nd t h e A / C si d e wi n d o w
d e mi st e r a n d h o s e . Al s o c h e c k t o be sur e t he he a t e r
a n d A / C ai r i nl et d uc t d o o r i s i n t he o ut s i d e po si t i o n .
A r e t hese t wo c ondi t i ons me t ?
Ye s
No
GO t o A5.
12-00.
A5 VERI FY FL OOR OVERRI DE OPERATI ON
Ye s
No
GO t o A6.
12-00.
P r e s s t he FL OOR but t o n a nd c h e c k s y s t e m
d i s c h a r ge a i r f l o w. Di sc ha r ge a i r f l o w sho ul d be f r o m
t he he a t e r o ut l e t f l o o r d uc t .
Is ai rf l ow di schar ged f r o m t he heat er out l et f l oor
duc t ?
Ye s
No
GO t o A6.
12-00.
A6 VERI FY VENT OVERRI DE OPERATI ON
Ye s
No
G Ot o A7.
12-00.
Pr e ss t he VENT but t o n a nd c h e c k s y s t e m d i s c ha r ge
a i r f l o w. Ai r f l o w sho ul d be f r o m t he A / C r e gi st e r s.
Is t hi s condi t i on met ?
Ye s
No
G Ot o A7.
12-00.
A7 VERI FY MAX A / C OVERRI DE OPERATI ON
Ye s
No
GO t o A8.
Di a gn o s i s " i n Se c t i o n
12-00.
Wi t h t he a mbi e n t t e mpe r a t ur e a b o v e 5C ( 40F) ,
pr e s s t he MAX A / C but t o n . Ch e c k t ha t t h e he a t e r
a nd A / C ai r i nl et d uc t d o o r i s in t he r e c i r c . ai r
po si t i o n ( c l o s e d t o o ut si d e a i r ) .
Is t he out si de-reci rc door cl osed t o out si de ai r?
Ye s
No
GO t o A8.
Di a gn o s i s " i n Se c t i o n
12-00.
A8 VERI FY A / C CLUTCH DOES NOT ENGAGE IN VENT
Ye s
No
G Ot o A9.
G Ot o Se c t i o n 12-03C.
P r e s s t he VENT but t o n . VENT sho ul d be d i spl a y e d
a n d t he A / C c l ut c h sho ul d not e n ga ge .
A r e t hese t wo c ondi t i ons met ?
Ye s
No
G Ot o A9.
G Ot o Se c t i o n 12-03C.
A9 VERI FY MAX A / C OPERATI ON
Ye s
No
G Ot o A10.
G Ot o Se c t i o n 12-00.
P r e s s t he MAX A / C but t o n a ga i n . MAX A / C sho ul d
be d i s pl a y e d a n d t h e A / C c l ut c h sho ul d e n ga ge f o r
A / C c o mp r e s s o r o pe r a t i o n .
A r e t h e s e t wo c ondi t i ons met ?
Ye s
No
G Ot o A10.
G Ot o Se c t i o n 12-00.
A10 VERI FY AUTOMATI C OPERATI ON
Ye s
No EN-
GO t o A11 if e qui ppe d
wi t h o pt i o n a l st e e r i n g
whe e l r e mo t e c o n t r o l
but t o n s. Te st c o mpl e t e
on v e hi c l e s wi t ho ut
r e mo t e c o n t r o l but t o n s.
REFER t o " E A T C Sel f
Te s t " in Pi npoi nt Te st
St e p A1 a nd " Di a gn o s t i c
Er r or Co d e s " in
I n spe c t i o n a nd
Ve r i f i c a t i o n .
P r e s s t he AUTOMATI C but t o n . The s e l e c t e d
t e mpe r a t ur e a n d AUTOMATI C sho ul d be sho wn in
t h e VFD d i spl a y wi n d o w.
Is t he VFD c or r e c t and compl et e?
Ye s
No EN-
GO t o A11 if e qui ppe d
wi t h o pt i o n a l st e e r i n g
whe e l r e mo t e c o n t r o l
but t o n s. Te st c o mpl e t e
on v e hi c l e s wi t ho ut
r e mo t e c o n t r o l but t o n s.
REFER t o " E A T C Sel f
Te s t " in Pi npoi nt Te st
St e p A1 a nd " Di a gn o s t i c
Er r or Co d e s " in
I n spe c t i o n a nd
Ve r i f i c a t i o n .
PINPOINT TEST A: EATC SYSTEM INOPERATIVE, INTERMITTENT OR IMPROPER OPERATION (Cont i nued)
A11 VERI FY STEERI NG WHEEL TEMP BUTTON OPERATI ON
Ye s
No
GO t o A 1 2 .
REFER t o Se c t i o n
13-01A.
Operate the s t e e r i n g w h e e l r e m o t e c o n t r o l TEMP
button to verify t h a t the s e t t e m p e r a t u r e i n c r e a s e s
when the " A " ( i n c r e a s e ) s i d e o f t h e b u t t o n i s
pushed and d e c r e a s e s w h e n t h e " v " ( l o w e r ) s i d e o f
the button is d e p r e s s e d .
Does the TEMP swi tch i ncrease and decr ease t he
set temperature as descri bed?
Ye s
No
GO t o A 1 2 .
13-01A.
A12 VERI FY STEERI NG WHEEL FAN SWI TCH OPERATI ON
Ye s
No
Te st c o mpl e t e . RESTORE
v e hi c l e .
13-01A.
Operate the s t e e r i n g w h e e l r e m o t e c o n t r o l F A N
button to verify that t h e blower s p e e d i n c r e a s e s
when FAN " A " ( i n c r e a se ) i s d e p r e s s e d a n d t ha t
t he bl o we r s p e e d d e c r e a s e s whe n FAN " v " ( l o we r )
i s d e p r e s s e d .
Do e s t h e FAN b u t t o n i n c r e a s e a n d d e c r e a s e t h e
b l o w e r m o t o r s p e e d a s d e s c r i b e d ?
Ye s
No
Te st c o mpl e t e . RESTORE
v e hi c l e .
13-01A.
PI NPOI NT TE ST B: A / C E L E CTRONI C DOOR ACTUATOR MOTOR I NOPERATI VE, I NTERMI TTENT OR I MPROPER
OPERATI ON
* TE ST STEP RESULT ACTI ON TO TAKE
B1 CHECK CODES
Ye s
No
G O t o B2.
REVI EW Er r or Co d e Cha r t
if o t he r e r r or c o d e s a r e
d i s pl a y e d . If no Er r or
Co d e s , PERFORM
Pi npoi nt Te st A.
NOTE: L e t t e r s in pa r e n t he s e s i n d i c a t e ( wi r e c o l o r ,
c i r c ui t n umbe r ) . GO t o EATC wi r i n g d i a gr a m a n d
c o n n e c t o r pi n d i a gr a ms .
Pe r f o r m Sel f Te st and c h e c k e r r o r c o d e s .
I s e r r o r c o d e 020 o r 021 d i s p l a y e d ?
Ye s
No
G O t o B2.
REVI EW Er r or Co d e Cha r t
if o t he r e r r or c o d e s a r e
d i s pl a y e d . If no Er r or
Co d e s , PERFORM
Pi npoi nt Te st A.
B2 CHECK ACTUATOR DRI VE
Ye s
No
GO t o B3.
GO t o B6.
Di sc o n n e c t b o t h e l e c t r i c a l c o n n e c t o r s f r o m r e a r of
EATC c o n t r o l a sse mbl y . Ope r a t e t he A / C e l e c t r o n i c
d o o r a c t u a t o r mo t o r in bo t h d i r e c t i o n s usi ng a ny
12-vol t ba t t e r y . The f o l l o wi n g pi ns c a n be j u mpe d t o
use t he v e hi c l e ba t t e r y . Ma ke sur e t h e i gni t i on
s wi t c h i s in t he RUN po s i t i o n . Al l pi n s a r e l o c a t e d in
t h e C1 (LH) ha r n e ss c o n n e c t o r .
Tri al 1: Pi n 2 4 ( BK, 57 ) t o Pi n 22 (P, 2 46) .
Tri al 2: Pi n 2 4 ( BKf 57 ) t o Pi n 2 1 ( BR/ L G , 2 45) .
Do e s the A / C e l e c t r o n i c d o o r a c t u a t o r mo t o r
d r i v e in b o t h d i r e c t i o n s ?
Ye s
No
GO t o B3.
GO t o B6.
B3 PERFORM EATC FUNCTI ONAL TEST
Ye s
No
Sy s t e m OK. RESTORE
v e hi c l e .
GO t o B4.
Re c o n n e c t wi r e ha r n e ss c o n n e c t o r s a nd pe r f o r m
EATC Fun c t i o n a l Te st t o c h e c k s y s t e m o pe r a t i o n .
Is t e s t s u c c e s s f u l ?
Ye s
No
v e hi c l e .
GO t o B4.
B4 CHECK RESI STANCES
Ye s
No
GO t o B5.
GO t o B6.
Dr i ve t he bl e n d d o o r a c t ua t o r t o t h e f ul l CCW
po si t i o n ( MAX he a t ) .
Di sc o n n e c t b o t h ha r n e ss c o n n e c t o r s f r o m r e a r of
EATC Co n t r o l As s e mbl y . Me a s ur e r e s i s t a n c e
be t we e n t he pi ns s ho wn b e l o w a t t h e c o n t r o l
a s s e mbl y C2 (RH) ha r n e ss c o n n e c t o r .
Pi n 15 ( R/ L G , 436) t o Pi n 6 ( R/ W, 438) - 5000- 7 000
o hms
Pi n 5 ( Y/ L G , 437 ) t o Pi n 6 ( R/ W, 438) - 3500- 6000
o hms
Pi n 5 ( Y/ L G , 437 ) t o Pi n 15 ( R/ L G , 436) - 2 50- 1500
o h ms
A r e all r e s i s t a n c e s w i t h i n v a l u e g i v e n ?
Ye s
No
GO t o B5.
GO t o B6.
B5 RETEST EATC SYSTEM
Ye s \ >
No
Sy st e m OK. RESTORE
v e hi c l e .
G Ot o B1.
Re c o n n e c t ha r n e s s c o n n e c t o r s a n d pe r f o r m EATC
Se l f Te st , Pi npoi nt Te st St e p A 1 .
is test s u c c e s s f u l ?
Ye s \ >
No
Sy st e m OK. RESTORE
v e hi c l e .
G Ot o B1.
12 - 03B- 2 6 Ai r Condi t i oni ng Sy s t e mE l e c t r o n i c A u t o ma t i c T e mp e r a t u r e Cont r ol
12 - 03B- 2 6
OPERATI ON ( Co n t i n u e d )
B6 CHECK CONTI NUI TY
Che c k v e hi c l e wi r i n g ha r n e s s a nd c o n n e c t o r
c o n t i n ui t y a s sho wn be l o w. Di sc o n n e c t b o t h h a r n e s s
c o n n e c t o r s f r o m r e a r of c o n t r o l a s s e mb l y a n d t h e
A / C e l e c t r o n i c d o o r a c t u a t o r mo t o r . The a c t u a t o r
c o n n e c t o r i s a c c e s s i b l e t hr o ugh t he gl o ve
c o mpa r t me n t .
Ye s
No
Cont r ol Assembl y
Conne c t or
Temper at ur e Bl end Door
Act uat or
C2
Pi n 5 ( Y / L G , 437 ) t o Pi n 3 ( Y / L G , 437 )
Pin 6 ( R / W, 438) t o Pin 2 ( R / W, 438)
Pi n 15 ( R / L G , 436) t o Pi n 4 ( R / L G , 436- T o wn Ca r )
( L G / O , 436- Cr o wn Vi c t o r i a ,
en
Pi n 2 1 ( B R / L G , 2 45) t o Pi n 1 ( B R / L G )
Pi n 2 2 (P, 2 46) t o Pi n 5 (P, 2 46)
P i n 2 4 ( B K , 57 ) t o Pi n 6 ( BK, 57 )
Re c o n n e c t al l t hr e e ha r n e s s c o n n e c t o r s at end of
t hi s t e st .
Is t here c ont i nui t y on all si x wi r es?
d o o r a c t ua t o r mot or . GO
t o B7.
GO t o B8.
B7 RETEST AFTER CHANGI NG BLEND DOOR ACTUATOR
Af t e r r e pl a c i n g A / C e l e c t r o n i c d o o r a c t u a t o r mo t o r ,
pe r f o r m Pi npoi nt Te st St e p A 1 .
Is t est successf ul ?
Ye s
No

Test c o mpl e t e .
G Ot o B 1 .
B8 RETEST AFTER SERVI CI NG WI RI NG HARNESS
Se r v i c e / r e p l a c e wi r i n g ha r n e s s . Re c o n n e c t a n d
pe r f o r m Pi npoi nt Te st St e p A 1.
Is t est successf ul ?
Ye s
No

Test c o mpl e t e .
G Ot o B1.
PINPOINT TEST C: EATC HEATER BLOWER MOTOR DOES NOT RUN
C1 CHECK BLOWER MOTOR OPERATI ON
Ye s
No
PERFORM Pi npoi nt Te st
St e p A 1.
GO t o C2.
St a r t e ngi ne a n d s e l e c t MAX A / C .
Does bl ower mot or oper at e?
Ye s
No
St e p A 1.
GO t o C2.
C2 CHECK VOLTAGE BETWEEN PI NS 4 AND 5
Ye s
No >
CHECK Fuse 9, a nd
bl o we r mo t o r Ci r c ui t s 181
( BR/ O) a n d 515 ( O/ R) .
GO t o C3.
Di sc o n n e c t t h e ha r n e s s c o n n e c t o r f r o m t h e A / C
bl o we r mo t o r s p e e d c o n t r o l .
St a r t e ngi ne a n d se t A / C c o n t r o l t o MAX A / C .
Me a sur e v o l t a ge b e t we e n Pi ns 4 a n d 5 of bl o we r
mo t o r s p e e d c o n t r o l ha r n e ss c o n n e c t o r . Sho ul d
ha ve ba t t e r y v o l t a ge .
Is vol t age l ess t han 10 vol t s?
Ye s
No >
CHECK Fuse 9, a nd
bl o we r mo t o r Ci r c ui t s 181
( BR/ O) a n d 515 ( O/ R) .
GO t o C3.
C3 VOLTAGE CHECK TO A / C BL OWE R MOTOR
Ye s
No ^
GO t o C4.
Re c o n n e c t h a r n e s s t o A / C bl o we r mo t o r s p e e d
c o n t r o l . Di s c o n n e c t bl o we r mo t o r f r o m ha r n e ss.
Che c k f o r v o l t a ge a c r o s s ha r n e ss c o n n e c t o r
Ci r c ui t s 515 ( O / R ) a nd 181 ( BR/ O) wi t h bl o we r
mo t o r on HI .
Is vol t age measurement 10 vol t s or more?
Ye s
No ^
GO t o C4.
PINPOINT TEST C: EATC HEATER BLOWER MOTOR DOES NOT RUN (Cont i nued)
TE ST STEP RESULT ACTI ON TO TAKE
C4 VOLTAGE CHECK BETWEEN PI NS 3 AND 5
Ye s
No
REPLACE A / C bl o we r
mo t o r s p e e d c o n t r o l .
GO t o C5.
Di sc o n n e c t ha r n e ss c o n n e c t o r f r o m A / C bl o we r
mo t o r s p e e d c o n t r o l . Che c k v o l t a ge b e t we e n Pi ns 3
a n d 5 of ha r n e ss c o n n e c t o r . Vo l t a ge r e a d i n g s ho ul d
be 10 or mo r e v o l t s wi t h bl o we r mo t o r on HI .
Is vol t age 10 vol t s or great er?
Ye s
No
GO t o C5.
C5 VOLTAGE CHECK AT EATC
Ye s
No
SERVI CE Ci r c ui t 7 7 6
( O / BK) f o r Town Ca r or
Ci r c ui t 758 ( L G / W) f or
Cr o wn Vi c t o r i a , Gr a nd
Ma r qui s be t we e n c o n t r o l
a s s e mb l y (Pi n 9) a n d A / C
bl o we r mo t o r s p e e d
c o n t r o l l e r (Pi n 3) f o r
o pe n . RESTORE v e hi c l e .
RETEST s y s t e m.
REPLACE EATC c o n t r o l
a sse mbl y . RESTORE
Re c o n n e c t A / C bl o we r mo t o r s pe e d c o n t r o l
c o n n e c t o r . Wi t h e ngi ne runni ng a n d c o n t r o l se t f o r
MAX A / C a n d HI bl o we r , c h e c k v o l t a ge a t EATC
c o n t r o l a s s e mbl y Pi n 9 and gr o un d . Vo l t a ge sho ul d
be 10 or mo r e v o l t s.
Is vol t age 10 vol t s or great er?
Ye s
No
( O / BK) f o r Town Ca r or
Ci r c ui t 758 ( L G / W) f or
Ma r qui s be t we e n c o n t r o l
a s s e mb l y (Pi n 9) a n d A / C
bl o we r mo t o r s p e e d
c o n t r o l l e r (Pi n 3) f o r
o pe n . RESTORE v e hi c l e .
RETEST s y s t e m.
PINPOINT TEST D: EATC HEATER BLOWER MOTOR OPERATES IN HIGH IN ALL BLOWER WHEEL POSITIONS
TE ST STEP RESULT A CTI ON TO TA KE
D1 CHECK BLOWER MOTOR MEDI UM SPEED OPERATI ON
Ye s
No
A.
GO t o 02 .
St a r t e n gi n e , se l e c t MAX A / C a nd po si t i o n t he
bl o we r t humbwhe e l mi d wa y be t we e n HI a n d L O. The
bl o we r mo t o r sho ul d o pe r a t e at a ppr o x i ma t e l y
me d i um s p e e d .
Is t he A / C bl ower mot or speed r educed f r om
hi gh speed?
Ye s
No
A.
GO t o 02 .
D2 CHECK VOLTAGE AT BL OWER SPEED CONTROLLER
Ye s
No
GO t o D5.
GO t o D3.
Di sc o n n e c t t he ha r n e ss c o n n e c t o r f r o m t h e A / C
bl o we r mo t o r s p e e d c o n t r o l . St a r t e n gi n e , se t
c o n t r o l a t MAX A / C a n d bl o we r t h u mb wh e e l a t LO.
Ch e c k f o r v o l t a ge be t we e n Pi ns 2 a n d 5 of t he
ha r n e s s c o n n e c t o r whi l e r o t a t i n g t h e bl o we r mo t o r
t h u mb wh e e l . The v o l t a ge r e a d i n g sho ul d be
b e t we e n 1 a nd 2 v o l t s f o r al l t humbwhe e l se t t i n gs
e x c e p t HI; sho ul d ha v e ze r o v o l t s at HI .
Is vol t age measurement bet ween 1 and 2 vol t s
e xc e pt in HI?
Ye s
No
GO t o D5.
GO t o D3.
D3 REVERI FY VOLTAGE IN D2
Ye s
No
GO t o D4.
Ve r i f y t he v o l t a ge me a sur e me n t in St e p D2.
Is t he vol t age measurement above 2 vol t s i n all
t humbwheel se t t i ngs?
Ye s
No
GO t o D4.
D4 ZERO VOLTAGE CHECK
Ye s
No
GO t o D6.
RETEST a nd GO t o D1.
Re f e r t o v o l t a ge me a sur e me n t t a ke n in St e p D2.
Is t he vol t age measurement zero vol t s f or al l
t humbwheel posi t i ons?
Ye s
No
GO t o D6.
RETEST a nd GO t o D1.
D5 VOLTAGE CHECK AT ANY POSI TI ON EXCEPT HI
Ye s
No
REPLACE t h e A / C bl o we r
RETEST s y s t e m.
REPLACE t h e E A T C
c o n t r o l a sse mbl y .
RETEST s y s t e m.
Ch e c k v o l t a ge be t we e n Pi ns 3 a n d 5 of A / C bl o we r
mo t o r s p e e d c o n t r o l wi t h t he bl o we r s p e e d
t humbwhe e l at a ny po si t i o n e x c e p t HI . Sho ul d be
ze r o v o l t s .
Is t he vol t age measurement zero?
Ye s
No
REPLACE t h e A / C bl o we r
RETEST s y s t e m.
REPLACE t h e E A T C
c o n t r o l a sse mbl y .
RETEST s y s t e m.
12 - 03B- 2 8 A i r Co n d i t i o n i n g S y s t e mE l e c t r o n i c A u t o ma t i c T e mp e r a t u r e Co n t r o l 12 - 03B- 2 8
PINPOINT TEST D: EATC HEATER BLOWER MOTOR OPERATES IN HIGH IN ALL BLOWER WHEEL POSITIONS (Cont i nued)
D6 VOLTAGE CHECK AT EATC PI N 7
Ye s
No
(R / PK) f o r Town Ca r o r
Ci r c ui t 7 52 ( Y/ R) f o r
Cr o wn Vi c t o r i a , Gr a n d
Ma r qui s b e t we e n EATC
c o n t r o l a s s e mb l y Pi n 7
a n d t he A / C bl o we r mo t o r
s p e e d c o n t r o l l e r Pi n 2.
RETEST s y s t e m.
GO t o D7 .
Re c o n n e c t ha r n e s s c o n n e c t o r t o A / C bl o we r mo t o r
s p e e d c o n t r o l . Wi t h t he e n gi n e r unni ng, se l e c t MA X
A / C a nd s e t t he bl o we r t h u mb wh e e l f or a me d i um
s p e e d . Ch e c k t h e v o l t a ge at Pi n 7 o f t he EATC
c o n t r o l a s s e mb l y .
Is t he vol t age measurement bet ween 1 and 2
vol t s?
Ye s
No
(R / PK) f o r Town Ca r o r
Ma r qui s b e t we e n EATC
c o n t r o l a s s e mb l y Pi n 7
a n d t he A / C bl o we r mo t o r
s p e e d c o n t r o l l e r Pi n 2.
RETEST s y s t e m.
GO t o D7 .
D7 VERI FY ZERO VOLTAGE
Ye s
No
RETEST v o l t a ge . GO t o
D1.
Ve r i f y t h e v o l t a ge me a sur e me n t t a ke n in St e p D6.
Is t he vol t age measurement zero vol t s?
Ye s
No
RETEST v o l t a ge . GO t o
D1.
PINPOINT TEST E: EATC HEATER BLOWER MOTOR DOES NOT OPERATE AT LOWER SPEEDS
E 1 CHECK BL OWE R MOTOR L O SPEED OPERATI ON
Ye s
No
St e p A 1 .
GO t o E 2 .
St a r t e n gi n e , s e l e c t MAX A / C a nd po si t i o n t he
bl o we r t h u mb wh e e l t o L O. The bl o we r mo t o r sho ul d
o pe r a t e at l ow s p e e d .
Sl o wl y r o t a t e t he bl o we r t h u mb wh e e l t o HI . The A / C
bl o we r mo t o r s p e e d s ho ul d i n c r e a se unt i l hi gh
bl o we r s p e e d i s o b t a i n e d .
Does t he A / C bl ower spe e d i ncrease t o hi gh
speed?
Ye s
No
St e p A 1 .
GO t o E 2 .
E 2 CHECK VOLTAGE BETWEEN BL OWE R MOTOR SPEED
CONTROL PI NS 2 AND 5
Ye s
No
REPLACE t he A / C bl o we r
RETEST s y s t e m.
G Ot o E 3.
Turn i gn i t i o n s wi t c h t o of f .
Di sc o n n e c t t h e ha r n e ss c o n n e c t o r f r o m t he A / C
bl o we r mo t o r s p e e d c o n t r o l . St a r t e n gi n e , s e l e c t
MAX A / C a n d r o t a t e t h e bl o we r t humbwhe e l t o LO.
Ch e c k v o l t a ge be t we e n Pi ns 2 a n d 5 of t he bl o we r
mo t o r s p e e d c o n t r o l l e r ha r n e ss c o n n e c t o r . Vo l t a ge
r e a d i n g s ho ul d be b e t we e n 1 a nd 2 v o l t s.
vol t s?
Ye s
No
REPLACE t he A / C bl o we r
RETEST s y s t e m.
G Ot o E 3.
E3 VERI FY VOLTAGE MEASUREMENT
Ye s
No
G Ot o E 4.
RETEST. G Ot o E 1 .
Ve r i f y t he v o l t a ge r e a d i n g o b t a i n e d in St e p E2.
Does t he vol t age measure zero vol t s?
Ye s
No
G Ot o E 4.
RETEST. G Ot o E 1 .
E 4 VOLTAGE CHECK AT EATC PIN 7
Ye s
No
(R / PK) f or Town Ca r or
Ma r qui s be t we e n Pi n 7 of
EATC c o n t r o l a sse mbl y
a n d Pi n 2 of A / C bl o we r
mo t o r s p e e d c o n t r o l l e r
f o r o pe n . RESTORE
GO t o E 5.
Re c o n n e c t ha r n e ss c o n n e c t o r t o A / C bl o we r mo t o r
s p e e d c o n t r o l . St a r t e n gi n e , se l e c t MAX A / C a nd
r o t a t e t h e bl o we r t humbwhe e l t o LO.
Ch e c k v o l t a ge be t we e n Pi n 7 of EATC c o n t r o l
a s s e mb l y a n d gr o un d . Sho ul d i n d i c a t e 1 t o 2 v o l t s .
vol t s?
Ye s
No
(R / PK) f or Town Ca r or
EATC c o n t r o l a sse mbl y
a n d Pi n 2 of A / C bl o we r
mo t o r s p e e d c o n t r o l l e r
GO t o E 5.
PINPOINT TEST E: EATC HEATER BLOWER MOTOR DOES NOT OPERATE AT LOWER SPEEDS (Cont i nued)
E5 ZERO VOLTAGE CHECK AT PIN 7
Yes
No
REPLACE the EATC
control assembly.
RESTORE vehicle.
RETEST system.
RETEST. GO t oE1.
Verify the voltage recorded in Step E4.
Does the voltage between Pin 7 and ground
measure zero vol t s?
Yes
No
REPLACE the EATC
control assembly.
RESTORE vehicle.
RETEST system.
RETEST. GO t oE1.
PINPOINT T E ST F: EATC HEATER BLOWER MOTOR DOES NOT OPERATE AT HIGH SPEED
F1 CHECK BLOWER MOTOR HI SPEED OPERATI ON
Ye s
No
A.
GO t o F 2 .
Start engine, select MAX A / C and position the
blower thumbwheel to a position midway between
LO and HI. Verify that the blower motor operates.
The n , r o t a t e t he bl o we r t humbwhe e l t o HI a n d c h e c k
t o s e e if t he b l o we r s p e e d r e s po n d s t o t he
t humbwhe e l mo v e me n t .
Does t he bl ower speed i ncrease wi t h movement
of t he t humbwheel t o wa r d HI?
Ye s
No
A.
GO t o F 2 .
F2 CHECK FOR 10 VOLTS OR MORE
Ye s
No >
RETEST s y s t e m.
GO t o F3.
Wi t h i gni t i on s wi t c h OFF, d i s c o n n e c t t he ha r n e ss
c o n n e c t o r f r o m t h e A / C bl o we r mo t o r s p e e d
c o n t r o l .
St a r t e n gi n e , s e l e c t MAX A / C a n d r o t a t e t he bl o we r
t h u mb wh e e l t o HI . Ch e c k v o l t a ge be t we e n Pi ns 3
a n d 5 of d i s c o n n e c t e d ha r n e ss c o n n e c t o r . Vo l t a ge
r e a d i n g sho ul d be 10 or mo r e v o l t s .
Is vol t age 10 vol t s or mor e?
Ye s
No >
RETEST s y s t e m.
GO t o F3.
F3 VOLTAGE CHECK AT PIN 9 OF EATC
Ye s
No
(P / W) f o r Town Ca r or
Ci r c ui t 7 54 ( L G / W) f o r
Cr own Vi c t o r i a , Gr a n d
EATC c o n t r o l a s s e mbl y
a nd Pi n 3 of A / C bl o we r
mo t o r s p e e d c o n t r o l l e r .
RETEST s y s t e m.
Re c o n n e c t ha r n e ss c o n n e c t o r t o A / C bl o we r mo t o r
s p e e d c o n t r o l .
St a r t e n gi n e , s e l e c t MAX A / C a n d r o t a t e bl o we r
t h u mb wh e e l t o HI . Me a s ur e v o l t a ge be t we e n Pi n 9 of
t he EATC c o n t r o l a s s e mb l y a nd gr o un d . Must
i n d i c a t e 10 or mo r e v o l t s whe n t h e bl o we r
t h u mb wh e e l i s r o t a t e d t o t he s t o p a t HI.
Is vol t age 10 vol t s or gr eat er ?
Ye s
No
(P / W) f o r Town Ca r or
Ci r c ui t 7 54 ( L G / W) f o r
Cr own Vi c t o r i a , Gr a n d
EATC c o n t r o l a s s e mbl y
a nd Pi n 3 of A / C bl o we r
mo t o r s p e e d c o n t r o l l e r .
RETEST s y s t e m.
PINPOINT TEST G: INTERMITTENT VEHICLE MODULE DATA LINK SIGNALDIAGNOSTIC ERROR CODE 115 OR 125
G1 CHECK POWERTRAI N CONTROL MODULE
DI AGNOSTI CS
Ye s
No
SERVI CE a s d i r e c t e d a nd
a ga i n PERFORM Pi npoi nt
Test St e p A 1 .
PERFORM a c o n t i n ui t y
t e st on t he mo d ul e d a t a
l i nk c i r c ui t s whi l e wi ggl i n g
t he wi r e s (Circuits 914
( T / 0 ) wi r e a nd 915
( P K/ L B) wi r e ) . SERVI CE
Pe r f o r m Di a gn o st i c Ro ut i n e s f o r Po we r t r a i n Co n t r o l
Mo d ul e . Re f e r t o Po we r t r a i n Co n t r o l / E mi s s i o n s
1
.
Do t he PCM di agnost i cs i ndi cat e a mal f unct i on of
a powe r t r a i n c ompone nt or si gnal ?
Ye s
No
SERVI CE a s d i r e c t e d a nd
a ga i n PERFORM Pi npoi nt
Test St e p A 1 .
PERFORM a c o n t i n ui t y
t e st on t he mo d ul e d a t a
l i nk c i r c ui t s whi l e wi ggl i n g
t he wi r e s (Circuits 914
( T / 0 ) wi r e a nd 915
( P K/ L B) wi r e ) . SERVI CE
12 - 03B- 30 Ai r Condi t i oni ng Sy s t emEl ec t r oni c Aut omat i c Temper at ur e Cont r ol 12- 038- 30
PINPOINT TEST H: INTERMITTENT VEHICLE MODULE DATA LINK SIGNALDIAGNOSTIC ERROR CODES 115 AND 125
SIMULTANEOUSLY
TEST STEP RESULT A CT I ON TO TAKE
H1 CHECK POWERTRAI N CONTROL MODULE ( PCM)
DI AGNOSTI CS
Ye s
No
GO t o H2.
SERVI CE or REPLACE a s
i n d i c a t e d .
Pe r f o r m Di a gn o st i c Ro ut i n e s f o r Po we r t r a i n Co n t r o l
Mo d ul e . Re f e r t o Po we r t r a i n Co n t r o l / Emi ssi o n s
2
.
A r e all t h e p o w e r t r a i n c o m p o n e n t s f u n c t i o n i n g
properl y?
Ye s
No
GO t o H2.
SERVI CE or REPLACE a s
i n d i c a t e d .
H2 CHECK CONTI NUI TY OF VEHI CLE DATA LI NK WI RES
Ye s
No
GO t o H 1 .
GO t o H3.
Ch e c k Ci r c ui t s 914 ( T/ O) and 915 ( P K / L B) f o r an
o pe n c i r c ui t b e t we e n t he EATC c o n t r o l mo d ul e a n d
t h e po we r t r a i n c o n t r o l mo d ul e .
A r e e i t h e r o r b o t h c i r c u i t s o p e n ?
Ye s
No
GO t o H 1 .
GO t o H3.
H3 CHECK CI RCUI TS FOR AN I NTERMI TTENT OPEN
Ye s
No
GO t o H 1 .
CHECK e a c h ha r n e ss
e l e c t r i c a l c o n n e c t o r f o r a
t i gh t c o n n e c t i o n ; t he n
A.
Ch e c k Ci r c ui t s 914 ( T/ O) and 915 ( P K / L B) f or an
i n t e r mi t t e n t o pe n c i r c ui t by wi ggl i n g e a c h wi r e a t
e a c h c o n n e c t o r whi l e c h e c ki n g f o r c o n t i n ui t y .
Do e s a n i n t e r mi t t e n t o p e n c o n d i t i o n e x i s t ?
Ye s
No
GO t o H 1 .
CHECK e a c h ha r n e ss
e l e c t r i c a l c o n n e c t o r f o r a
t i gh t c o n n e c t i o n ; t he n
A.
PI NPOI NT TE ST J : A / C A MBI E NT AI R TEMPERATURE SENSOR I NOPERATI VE
T E ST STEP RESULT A CTI ON TO TAKE
J 1 PERFORM EATC SELF DI AGNOSTI CS TEST
Turn t he i gni t i on s wi t c h t o RUN.
P r e s s OFF a n d FLOOR but t o n s si mul t a n e o usl y a nd
t he n pr e s s AUTOMATI C but t o n wi t hi n t wo s e c o n d s .
Se l f t e s t ma y run a s l ong a s 30 s e c o n d s .
Af t e r se l f t e s t , r e c o r d al l e r r o r c o d e s a nd a n y
t e mpe r a t ur e d i spl a y r e a d i n gs.
Pr e ss t he bl ue ( c o o l e r ) but t o n t o e xi t se l f t e s t .
A r e e r r o r c o d e s 0 4 0 , 0 4 1 , 0 4 2 o r 0 4 3 d i s p l a y e d
a n d i s t e mp e r a t u r e d i s p l a y r e a d i n g - 40F (-40C)
o r 12 8F?
Ye s
No

GO t o J 2 .
GO t o J 3 .
J 2 CHECK SENSOR RESI STANCE
NOTE: An o pe n s e n s o r wi l l c a use t he o ut s i d e
t e mpe r a t ur e d i spl a y t o r e a d - 40F or - 40C. A s h o r t e d
se n so r wi l l c a use t he o ut s i d e t e mpe r a t ur e d i spl a y t o
r e a d 128F.
Di sc o n n e c t t h e ba t t e r y gr o un d c a bl e f r o m t h e
ba t t e r y ( t hi s wi l l r e se t t h e o ut si d e t e mpe r a t u r e
d i spl a y me mo r y ) .
Di sc o n n e c t t h e A / C a mbi e n t ai r t e mpe r a t u r e se n so r
a n d b r a c ke t .
Usi n g a DVOM, me a sur e t he r e si st a n c e a c r o s s t he
t wo se n so r t e r mi n a l s a n d c o mpa r e t h e r e a d i n g wi t h
t h e f o l l o wi n g se n so r r e si st a n c e t a bl e :
Ye s
No

GO t o J 3 .
REPLACE A / C a mbi e n t
ai r t e mpe r a t ur e se n so r
a n d br a c ke t . RESTORE
Appr oxi ma t e Temper at ur e
Sensor R e s i s t a n c e Acceptance
5 0 F ( 1 0 C ) t o 6 8 F ( 2 0 C ) 3 7 K t o 5 8 K o b . n o
68F ( 2 0 C ) t o 8 6 F ( 3 0 C ) 2 4K t o 37Kohms
8 6 F ( 3 0 C ) t o 1 0 4 F ( 4 0 C ) 1 6 K t o 2 4 K o h m s
A r e r e s i s t a n c e v a l u e s wi t h i n t he spe c i f i e d l i mi t s?
PINPOINT TEST J : A / C AMBIENT AIR TEMPERATURE SENSOR INOPERATIVE (Cont i nued)
J 3 CHECK CI RCUI T 7 67 ( L B/ O) AT A / C AMBI ENT AIR
TEMPERATURE SENSOR
Ye s
No
GO t o J 6 .
GO t o J 4 .
Turn i gni t i on s wi t c h t o t he RUN po si t i o n .
Turn EATC mo d ul e t o NORM A / C po si t i o n .
Di sc o n n e c t A / C a mbi e n t ai r t e mpe r a t ur e se n so r a n d
b r a c ke t .
Usi ng v o l t me t e r , c h e c k Ci r c ui t 7 67 ( L B/ O) f o r
v o l t a ge at s e n s o r c o n n e c t o r .
Ye s
No
GO t o J 6 .
GO t o J 4 .
J 4 CHECK CI RCUI T 7 67 ( LB / O) AT EATC MODULE
Ye s
No
GO t o J 5 .
REPLACE EATC mo d ul e .
RETEST s y s t e m.
Usi ng v o l t me t e r , c h e c k Ci r c ui t 7 67 ( L B/ O) at EATC
mo d ul e Pi n 1 f o r v o l t a ge .
Ye s
No
GO t o J 5 .
RETEST s y s t e m.
J 5 CHECK CI RCUI T 7 67 ( L B / O ) FOR OPEN
Ye s
No
GO t o J 6 .
( L B/ O) f or o pe n .
RETEST s y s t e m.
Turn i gni t i on s wi t c h t o t he OFF po s i t i o n .
Usi ng a j umpe r c o n n e c t e d t o a kn o wn go o d gr o un d ,
c o n n e c t o t he r e n d t o Ci r c ui t 7 67 ( L B/ O) at s e n s o r
c o n n e c t o r .
gr o un d , c o n n e c t s e c o n d l e a d t o Ci r c ui t 7 67 ( L B / O )
at EATC mo d ul e c o n n e c t o r Pi n 1.
Ye s
No
GO t o J 6 .
( L B/ O) f or o pe n .
RETEST s y s t e m.
J 6 CHECK CI RCUI T 359 (GY / R)
Ye s
No
REPLACE A / C a mbi e nt
a nd br a c ke t . RESTORE
( G Y/ R) f or o pe n .
RETEST s y s t e m.
Co n n e c t j umpe r t o Ci r c ui t 359 ( G Y/ R) at se n so r
c o n n e c t o r .
gr o un d , c o n n e c t s e c o n d l e a d t o Ci r c ui t 359 ( G Y/ R)
at mo d ul e c o n n e c t o r Pi n 2.
Me a sur e r e s i s t a n c e .
Ye s
No
REPLACE A / C a mbi e nt
a nd br a c ke t . RESTORE
( G Y/ R) f or o pe n .
RETEST s y s t e m.
PINPOINT TEST K: A / C SUNLOAD SENSOR INOPERATIVE
K1 PERFORM EATC SELF DI AGNOSTI CS TEST
Ye s
No
GO t o K3.
GO t o K2 .
Pr e ss OFF a n d FL OOR but t o n s si mul t a n e o usl y a n d
t he n p r e s s AUTOMATI C but t o n wi t hi n t wo s e c o n d s .
Se l f t e s t ma y run a s l o n g a s 30 s e c o n d s .
Af t e r se l f t e s t , r e c o r d al l e r r o r c o d e s .
Pr e ss t h e bl ue ( c o o l e r ) but t o n t o e x i t se l f t e s t .
Is error c ode 0 5 0 , sunl oad sensor shor t e d,
di spl ayed?
Ye s
No
GO t o K3.
GO t o K2 .
K2 CHECK FOR I NTERMI TTENT SHORT CI RCUI T
Ye s
No
G Ot o K6.
G O t o K4.
Upon c ompl e t i on of sel f t est i n H 1 , was error
code 0 5 2 di spl ay ed?
Ye s
No
G Ot o K6.
G O t o K4.
PINPOINT TEST K: A / C SUNLOAD SENSOR INOPERATIVE (Cont i nued)
T E ST STEP RESUL T ACTI ON TO TAKE
K3 CHECK SUNLOAD SENSOR RESI STANCE
Ye s
No
REPLACE s h o r t e d A / C
sun l o a d se n so r .
RESTORE v e hi c l e . GO t o
K1.
G O t o K4.
Di sc o n n e c t ba t t e r y gr o un d c a bl e .
Di sc o n n e c t sunload sensor wi r e harness connector.
Usi n g a DVOM, c h e c k t he r e s i s t a n c e a c r o s s t h e t wo
se n so r c o n n e c t o r s .
NOTE: The A / C sun l o a d se n so r i s a ph o t o v o l t a i c
c e l l a nd sho ul d ha ve s o me un spe c i f i e d r e s i s t a n c e
a c r o s s t h e t e r mi n a l s d e pe n d i n g on t he l i ght
a v a i l a bl e t o t h e se n so r . The onl y t e s t t ha t c a n be
pe r f o r me d wi t ho ut s pe c i a l i ze d e qui pme n t i s f o r a
sho r t . If t h e r e s i s t a n c e a c r o s s t he se n so r t e r mi n a l s
i s ze r o o h ms , t h e se n so r i s s h o r t e d a n d s ho ul d be
r e p l a c e d .
Is t here zero resi st ance?
Ye s
No
REPLACE s h o r t e d A / C
sun l o a d se n so r .
RESTORE v e hi c l e . GO t o
K1.
G O t o K4.
K4 CHECK CI RCUI T 468 ( BR) AT SENSOR CONNECTOR
Ye s
No
G Ot o K7.
G O t o K5.
Turn i gni t i on s wi t c h t o t he RUN po s i t i o n .
Turn EATC mo d ul e t o NORM A / C po s i t i o n .
Pa r t i a l l y r e mo v e EATC mo d ul e a s o ut l i n e d .
Ga i n a c c e s s t o t he A / C sun l o a d se n so r a s o ut l i n e d .
Di sc o n n e c t A / C sun l o a d se n so r .
Usi ng v o l t me t e r , c h e c k Ci r c ui t 468 (BR) f o r v o l t a ge
at A / C sun l o a d se n so r c o n n e c t o r .
Ye s
No
G Ot o K7.
G O t o K5.
K5 CHECK CI RCUI T 468 ( BR) AT EATC MODULE
Ye s
No
GO t o K6.
RETEST s y s t e m.
Usi ng v o l t me t e r , c h e c k Ci r c ui t 468 ( BR) at EATC
mo d ul e Pi n 16 f o r v o l t a ge .
Ye s
No
GO t o K6.
RETEST s y s t e m.
K6 CHECK CI RCUI T 468 ( BR) FOR OPEN
Ye s
No
GO t o K7.
SERVI CE Ci r c ui t 468 ( BR)
Turn i gni t i on s wi t c h t o t he OFF po si t i o n .
Usi ng a j umpe r c o n n e c t e d t o a kn o wn go o d gr o un d ,
c o n n e c t o t h e r e n d t o Ci r c ui t 468 ( BR) at se n so r
c o n n e c t o r .
gr o un d , c o n n e c t s e c o n d l e a d t o Ci r c ui t 468 ( BR) at
EATC mo d ul e c o n n e c t o r Pi n 16.
NOTE: An o pe n c i r c ui t in t he wi r e ha r n e ss wi l l
a ppe a r t o t h e EATC c o n t r o l a s s e mbl y a s no sun .
Ye s
No
GO t o K7.
SERVI CE Ci r c ui t 468 ( BR)
K7 CHECK CI RCUI T 47 6 (BR / Y) RESI STANCE
Ye s
No
REPLACE A / C sun l o a d
se n so r . RESTORE
( BR/ Y) f o r o p e n .
RETEST s y s t e m.
Co n n e c t j umpe r t o Ci r c ui t 47 6 ( BR / Y) at se n so r
c o n n e c t o r .
gr o un d , c o n n e c t s e c o n d l e a d t o Ci r c ui t 47 6 ( BR/ Y)
at mo d ul e c o n n e c t o r Pi n 3.
NOTE: An o pe n c i r c ui t in t he wi r e ha r n e ss wi l l
a ppe a r t o t h e EATC c o n t r o l a s s e mb l y a s no sun.
Ye s
No
REPLACE A / C sun l o a d
se n so r . RESTORE
( BR/ Y) f o r o p e n .
RETEST s y s t e m.
PI NPOI NT TEST L: CONT ROL A S S E MBL Y/ VFD DOES NOT LI GHT UP HE A T E R BL OWE R MOTOR OFF
L1 CHECK I LLUMI NATI ON SUPPLY TO EATC MODULE
Ye s
No
G Ot o L 2 .
( LB / R) f o r o pe n c i r c ui t .
RETEST s y s t e m.
Turn he a d l a mp s wi t c h t o t h e PARK LAMP or
HEADLAMP po si t i o n .
Ro t a t e he a d l a mp d i mme r se n so r c o n t r o l t o f ul l -on
wi t ho ut t ur ni ng t he d o me l a mp o n .
Pa r t i a l l y r e mo ve EATC mo d ul e a s o ut l i n e d .
Usi ng a t e s t l a mp, c h e c k Ci r c ui t 19 ( L B/ R) f or
v o l t a ge .
Di d t e s t l a mp i l l u mi n a t e ?
Ye s
No
G Ot o L 2 .
( LB / R) f o r o pe n c i r c ui t .
RETEST s y s t e m.
L2 CHECK EATC SYSTEM GROUND
Ye s >
No
mo d ul e . RESTORE
f or o pe n c i r c ui t .
RETEST s y s t e m.
gr o un d , c o n n e c t s e c o n d l e a d t o Ci r c ui t 57 ( BK) , Pi n
2 4 at EATC mo d ul e c o n n e c t o r .
I s r e s i s t a n c e 5 o h ms o r l e s s ?
Ye s >
No
mo d ul e . RESTORE
RETEST s y s t e m.
PI NPOI NT TE ST M: COL D ENGI NE BL OWE R CONTROL DI A G NOS I S NO DI AGNOSTI C ERROR CODE
Mi CHECK COLD ENGINE BL OWER MOTOR OPERATI ON
Ye s
No
GO t o M2 .
GO t o M4.
Wi t h e ngi ne c o o l a n t be l o w 4 9 C ( 12 0F) ( c o l d
e n gi n e ) a n d c o n t r o l se t at " 3 2 C ( 90F)
AUTOMATI C, " c h e c k f or he a t e r bl o we r mo t o r
o pe r a t i o n . Bl o we r mo t o r sho ul d o pe r a t e a t l ow
bl o we r f or 3 1/ 2 mi n ut e s or unt i l e ngi ne c o o l a n t
t e mpe r a t ur e r e a c h e s 4 9 C ( 12 0F) , whi c he v e r
o c c u r s f i r st .
Do e s b l o w e r motor o p e r a t e a t l o w s p e e d w i t h
e n g i n e c o o l a n t t e mp e r a t u r e b e l o w 49C ( 12 0F)
a n d b e f o r e 3 1/ 2 mi nutes h a v e e l a p s e d s i n c e
e n g i n e s t a r t - u p ?
Ye s
No
GO t o M2 .
GO t o M4.
M2 CHECK WARM ENGI NE BL OWER MOTOR OPERATI ON
Ye s
N o [ >
Co l d e ngi ne l o c k out
St e p A 1 .
GO t o M3.
Al l o w e ngi ne t o o pe r a t e unt i l bl o we r mo t o r s p e e d
i n c r e a se s f r o m l o w bl o we r . Ch e c k amount of t i me
r e qui r e d f or bl o we r mo t o r s p e e d t o i n c r e a se .
Do e s b l o w e r mo t o r s p e e d i n c r e a s e b e f o r e 3 1/ 2
mi nutes ha v e e l a p s e d ?
Ye s
N o [ >
Co l d e ngi ne l o c k out
St e p A 1 .
GO t o M3.
M3 PERFORM EATC SELF DI AGNOSTI CS
Ye s
No [ >
G Ot o M5.
GO t o M4.
Pr e ss OFF a n d FLOOR but t o n s si mul t a n e o usl y a nd
Sel f t e s t ma y run a s l o n g a s 30 s e c o n d s . Af t e r se l f
t e s t , e r r o r c o d e s wi l l be d i s p l a y e d . Re c o r d al l e r r o r
c o d e s a n d pr e ss t he bl ue ( Co o l e r ) but t o n .
Wa s e r r o r c o d e 115 d i s p l a y e d ?
Ye s
No [ >
G Ot o M5.
GO t o M4.
M4 CHECK BLOWER MOTOR OPERATI ON
Ye s ! >
No
t o d i a gn o se bl o we r
mot or .
Se l e c t NORM A / C , t ur n i gni t i on ke y t o RUN a nd
r o t a t e bl o we r t humbwhe e l t o HI .
Do e s bl ower mo t o r o p e r a t e ?
Ye s ! >
No
t o d i a gn o se bl o we r
mot or .
MS CHECK ENGI NE COOL ANT LEVEL
Ye s
No
ADD r e c o mme n d e d
c o o l a n t mi xt ur e t o br i ng
c o o l a n t t o s pe c i f i e d l e ve l .
RETEST s y s t e m f o r
pr o pe r o pe r a t i o n .
GO t o M6.
Ch e c k e ngi ne c o o l a n t l e v e l .
I s e n g i n e c o o l a n t l e v e l l o w ?
Ye s
No
ADD r e c o mme n d e d
c o o l a n t mi xt ur e t o br i ng
c o o l a n t t o s pe c i f i e d l e ve l .
RETEST s y s t e m f o r
pr o pe r o pe r a t i o n .
GO t o M6.
12 - 03B- 34 Ai r Condi t i oni ng Syst emEl ect r oni c Aut omat i c Temper at ur e Cont r ol _ _ ^ 12- 031- 34
PI NPOI NT T E ST M: COL D ENGI NE BL OWE R CONT ROL DI A G NOS I S NO DI AGNOSTI C ERROR CODE ( Co n t i n u e d )
TE ST STEP RESULT A CT I ON TO T A KE
M6 CHECK ENGI NE COOLANT TEMPERATURE SI GNAL
Ye s
No
SERVI CE a s n e c e s s a r y .
GO t o M1 .
G O t o M7 .
Pe r f o r m po we r t r a i n c o n t r o l mo d ul e d i a gn o s t i c s t o
c h e c k f o r c o r r e c t o pe r a t i o n of e n gi n e c o o l a n t
t e mpe r a t u r e se n so r .
Do PCM d i a g n o s t i c s i ndi cate an e n g i n e cool ant
t e mp e r a t u r e s e n s o r f a u l t ?
Ye s
No
GO t o M1 .
G O t o M7 .
M7 CHECK CELO SI GNAL CI RCUI TS FOR OPEN WI RE
Ye s >
No
G Ot o M1 .
G O t o M8.
Ch e c k Wi r e Ci r c ui t s 914 ( T / O) a nd 915 (PK) f o r an
o pe n c i r c ui t be t we e n t h e EATC c o n t r o l a s s e mb l y
a n d t he po we r t r a i n c o n t r o l mo d ul e .
A r e e i t h e r o r b o t h c i r c u i t s o p e n ?
Ye s >
No
G Ot o M1 .
G O t o M8.
MS CHECK CELO CI RCUI TS FOR AN I NTERMI TTENT OPEN
Ye s
No
G O T O M1 .
Wi ggl e e a c h wi r e (110) a n d ( P K/ LB) at e a c h
c o n n e c t o r t o c h e c k f or an i n t e r mi t t e n t o pe n .
Do e s a n i n t e r mi t t e n t o p e n c o n d i t i o n e x i s t ?
Ye s
No
G O T O M1 .
PI NPOI NT TE ST N: TE MP E RATURE DI SPLAY WON' T SWI TCH BE TWE E N CEL SI US AND FAHRENHEI T
TE ST STEP RESULT A CT I ON TO TA KE
N1 CHECK EATC F TO C DI SPLAY
Ye s
No
G O t o N2 .
Wi t h EATC s y s t e m o n , d e p r e s s MAX A / C a nd
d e f r o s t but t o n s si mul t a n e o usl y f or at l e a st 3 / 4 of a
s e c o n d .
Di d d i s p l a y s w i t c h f r o m F to C?
Ye s
No
G O t o N2 .
N2 CHECK CI RCUI T 506 (R) FOR OPEN
Ye s >
No
GO t o N3,
SERVI CE Ci r c ui t 506 ( R)
f o r o pe n . REPLACE
d a ma ge d EATC mo d ul e .
RETEST s y s t e m.
CA UT I ON: A c c i d e n t a l s h o r t i n g o f t h e w r o n g p i n
c o u l d d e s t r o y t h e c o n t r o l a s s e mb l y .
Wi t h i gni t i on s wi t c h in t h e OFF po s i t i o n , pa r t i a l l y
r e mo v e EATC modul e a s o ut l i n e d .
Usi ng a j umpe r wi r e c o n n e c t e d t o a kn o wn g o o d
gr o un d , c o n n e c t o t he r e n d t o Ci r c ui t 506 ( R) , Pi n 20
at mo d ul e c o n n e c t o r .
Turn i gni t i on s wi t c h t o t h e RUN po si t i o n .
Di d d i s p l a y c h a n g e ?
Ye s >
No
GO t o N3,
f o r o pe n . REPLACE
d a ma ge d EATC mo d ul e .
RETEST s y s t e m.
N3 CHECK CI RCUI T 506 (R) FOR SHORT
Ye s
No
f o r sho r t . RESTORE
REPLACE d a ma ge d
EATC mo d ul e . RESTORE
CA UT I ON: A c c i d e n t a l s h o r t i n g o f t h e w r o n g pin
c o u l d d e s t r o y t h e c o n t r o l assembl y.
Le a v e j umpe r c o n n e c t e d .
gr o un d , c o n n e c t o t he r e n d t o Ci r c ui t 506 (R) at
EATC mo d ul e c o n n e c t o r Pi n 2 0.
I s resi stance 5 ohms o r l e s s ?
Ye s
No
f o r sho r t . RESTORE
REPLACE d a ma ge d
EATC mo d ul e . RESTORE
PINPOINT T E ST P: SYSTE M DOE S NOT CONTROL TEMPERATURE
P1 PERFORM EATC SELF TEST
Ye s
No
G O t o P 2 .
G Ot o P3.
Pr e ss OFF a nd FLOOR but t o n s si mul t a n e o usl y and
Sel f t e s t ma y run a s l o n g a s 30 s e c o n d s .
Af t e r se l f t e s t , r e c o r d al l e r r o r c o d e s a nd any
t e mpe r a t ur e d i spl a y r e a d i n gs .
Pr e ss t he bl ue ( Co o l e r ) but t o n t o e x i t se l f t e s t .
I s error c o d e 0 3 0 , 0 3 1 , 0 3 2 , or 0 3 3 di spl ayed?
Ye s
No
G O t o P 2 .
G Ot o P3.
PI NPOI NT T E ST P: SYSTE M DOES NOT CONTROL TEMPERATURE (Cont i nued)
P2 CHECK SENSOR RESI STANCE
NOTE: An o pe n se n so r wi l l c a us e t he wa r m a i r
d i s c h a r ge at 6 5 F ( 18C) s e t t i n g. A s h o r t e d s e n s o r wi l l
c a u s e c o o l d i s c h a r ge a i r a t 85 F ( 2 9C) s e t t i n g.
Di sc o n n e c t t he A / C a mbi e n t a i r t e mpe r a t ur e
se n so r .
Usi n g a DVOM, me a s ur e t he r e s i s t a n c e a c r o s s t he
se n so r t e r mi n a l s a nd c o mp a r e t he r e a d i n gs wi t h t h e
f o l l o wi n g s e n s o r r e s i s t a n c e t a bl e :
Ye s
No
Appr oxi ma t e Temper at ur e
Sensor Resistance Acceptance
Range
5 0 F ( 1 0 C ) t o 6 8 F ( 2 0 C ) 3 7 K t o 58K o h ms
6 8 F ( 2 0 C ) t o 8 6 F ( 3 0 C ) 2 4 K t o 3 7 K o h m s
8 6 F ( 3 0 C ) t o 104F ( 4 0 C ) 1 6 K t o 2 4K o h ms
A r e r e s i s t a n c e v a l u e s wi t hi n t h e speci f i ed l i mi t s?

G Ot o P 3.
REPLACE A / C a mbi e n t
a n d b r a c ke t . RESTORE
P 3 CHECK ASPI RATOR I NSTALLATI ON
Gai n a c c e s s t o a ut o ma t i c t e mpe r a t ur e c o n t r o l
se n so r h o s e a n d e l b o w a s o ut l i n e d .
Ch e c k f o r pr o pe r i n st a l l a t i o n o f a ut o ma t i c
t e mpe r a t ur e c o n t r o l se n so r ho s e a n d e l bo w,
i s a s p i r a t o r i n s t a l l e d pr oper l y and hose
c o n n e c t e d ?
Ye s
No

G Ot o P 4.
SERVI CE a ut o ma t i c
t e mpe r a t ur e c o n t r o l
se n so r h o s e a n d e l b o w
a s n e c e s s a r y . RESTORE
P 4 CHECK AUTOMATI C TEMPERATURE CONTROL
SENSOR OUTPUT AT EATC MODULE
Turn e ngi ne of f . L e a v e i gni t i on s wi t c h in RUN
po s i t i o n .
Di sc o n n e c t a ut o ma t i c t e mpe r a t ur e c o n t r o l se n so r .
Usi ng a v o l t me t e r , c h e c k Ci r c ui t 7 90 (W / O) a t Pi n
17 of c o n n e c t o r C1 f o r v o l t a ge .
I s v o l t a g e p r e s e n t ?
Ye s
No
PS CHECK AUTOMATI C TEMPERATURE CONTROL
CI RCUI T 7 90 ( W/ O )
Turn i gni t i on s wi t c h OFF.
Usi n g an o hmme t e r , c h e c k Ci r c ui t 7 90 ( W/ O ) f r o m
EATC mo d ul e t o a ut o ma t i c t e mpe r a t ur e c o n t r o l
se n so r c o n n e c t o r .
8s t h e r e c o n t i n u i t y ?
Ye s
No
P6 CHECK AUTOMATI C TEMPERATURE CONTROL
SENSOR RETURN CI RCUI T
Usi n g an o hmme t e r , c h e c k Ci r c ui t 47 0 ( P K/ BK) f or
c o n t i n ui t y f r o m EATC mo d ul e t o a s pi r a t o r c o n n e c t o r .
I s t h e r e c o n t i n u i t y ?
Ye s
No

G O t o P5.
RETEST s y s t e m.

G O t o P 6.
( W/ O ) f o r o pe n .
RETEST s y s t e m.
REPLACE a ut o ma t i c
t e mpe r a t ur e c o n t r o l
se n so r . RESTORE
( P K/ BK) f o r o pe n .
RETEST s y s t e m.
PI NPOI NT TEST Q: TEMPERATURE SET POINT DOES NOT REPEAT AFTER TURNING IGNITION SWITCH OFF
T E ST STEP RESULT A CTI ON TO T A KE
Q1 CHECK MEMORY SUPPLY TO EATC MODULE
Ye s
No
RETEST s y s t e m.
G O t o Q2 .
Wi t h i gni t i on s wi t c h in t he OFF po s i t i o n , pa r t i a l l y
r e mo v e EATC c o n t r o l mo d ul e a s o ut l i n e d .
Usi n g a v o l t me t e r , c h e c k Ci r c ui t 7 97 ( LG / P) o n
To wn Ca r or Ci r c ut i 54 ( L G / Y) on Cr o wn Vi c t o r i a ,
Gr a n d Ma r qui s f o r v o l t a ge a t EATC mo d ul e Pi n 12.
I s b a t t e r y v o l t a g e p r e s e n t ?
Ye s
No
RETEST s y s t e m.
G O t o Q2 .
12 0 3 3 6 Ai r Co n d i t i o n i n g S y s t e mE l e c t r o n i c A u t o ma t i c T e mp e r a t u r e Co n t r o l 12 - 03B- 36
PINPOINT TEST Q: TEMPERATURE SET POINT DOES NOT REPEAT AFTER TURNI NG I GNI TI ON SWI TCH OFF ( Co n t i n u e d )
TEST STEP RESULT A CT I ON TO T A KE
Q2 CHECK CI RCUI T 7 97 ( L G / P) SUPPLY
Ye s
No
RETEST s y s t e m.
( L G / P ) on To wn Ca r o r
Ci r c ui t 54 ( L G / Y) f o r
Cr o wn Vi c t o r i a f o r o pe n .
RETEST s y s t e m.
Re mo v e me mo r y f us e ( 5A) a t po we r d i st r i but i o n
bo x .
Usi n g an o hmme t e r , c h e c k Ci r c ui t 7 97 (LG / P) on
Town Ca r or Ci r c ui t 54 ( L G / Y) o n Cr o wn Vi c t o r i a ,
Gr a nd Ma r qui s f r o m EATC mo d ul e c o n n e c t o r Pi n 12
t o out put si d e o f me mo r y f us e ( 5A) c a v i t y f or
c ont i nui t y .
Ye s
No
RETEST s y s t e m.
( L G / P ) on To wn Ca r o r
Ci r c ui t 54 ( L G / Y) f o r
Cr o wn Vi c t o r i a f o r o pe n .
RETEST s y s t e m.
R e f r i g e r a n t 1 3 4 a ( R - 1 3 4 a ) S y s t e m s
In an ef f ort t o avoi d t he use of CFC r ef r i ger ant s t hat
ma y harm t he ozone l ayer of t he a t mo sphe r e , For d
Mot or Company ref ri gerant sy st e ms requi re t he use of
a Non-CFC ba se d ref ri gerant kn o wn a s R-134a. Thi s
new t y pe of ref ri gerant has many of t he sa me
pr oper t i es as R-12 and i s si mi l ar in f o r m and f unct i on.
However, R-134a i s a hy dr of l uor oc a r bon (HFC) based
ref ri gerant , whi l e R-12 i s a chl or of l uor ocar bon (CFC)
ba se d ref ri gerant . Because of t he a bse nc e of chl ori ne
in i t s mol ecul ar st r uct ur e, t he R-134a ref ri gerant wi ll
not have any harmf ul ef f ect s on t he ozone l ayer of t he
at mospher e.
R-134a A / C sy st e ms have speci al se r vi c e
requi rement s t ha t are out l i ned l at er. R-12 ref ri gerant
and component s can only be use d in R-12 sy st e ms,
whi l e t he R-134a ref ri gerant a nd c ompone nt s can only
be used in R-134a sy st e ms.
CAUTI ON: Do n o t a d d R-12 r e f r i g e r a n t t o a n A / C
s y s t e m t h a t r e q u i r e s t h e u s e o f R- 134a
r e f r i ge r a n t . Do n o t a d d R- 134a r e f r i ge r a n t t o a n
A / C s y s t e m t h a t r e q u i r e s t h e u s e o f R-12
r e f r i ge r a n t . T h e s e t w o t y p e s o f r e f r i ge r a n t s h o u l d
n e v e r b e mi x e d . Do i n g s o ma y c a u s e d a ma g e t o
t h e A / C s y s t e m.
NOTE: R-134a A / C sy st e ms c a n al so be i dent i f i ed by
gr een col or ed O-ri ng seal s used t hr oughout t he
sy st e m.
In order t o det ermi ne whi ch t y pe of A / C sy st e m a
part i cul ar vehi cl e has, i nspect t he A / C sy st e m maj or
component s and ref ri gerant l i nes. If t he sy st e m
component s have yel l ow R-134a NON-CFC t a gs as
i l l ust rat ed, it is an R-134a sy st e m requi ri ng t he use of
R-134a ref ri gerant .
R~134a
NON-CFC
R-134a
NON-CFC
R-134a NON-CFC
IDENTIFYING TAG
R-134a
NON-CFC
R-134a
NON-CFC
R-134a
NON-CFC-
R-134a
NON-CFC
L7713-A
If t he A / C sy st e m has any of t he R-134a i dent i f yi ng
c ha r a c t e r i st i c s out l i ned, R-134a ref ri gerant is t he onl y
t y pe of ref ri gerant t hat can be used in t he A / C sy st e m.
CAUTI ON: R- 12 a n d R- 134a c o mp o n e n t s a r e n o t
i n t e r c h a n ge a b l e . Do n o t repSace c o mp o n e n t s
f r o m a n R- 134a s y s t e m wi t h c o mp o n e n t s f o r a n
R-12 s y s t e m a n d v i c e v e r s a - f i x i n g c o mp o n e n t s
f r o m t h e s e t w o t y p e s o f s y s t e ms ma y c a u s e
c o mp o n e n t f a i l ur e a n d d a ma g e t o t he A / C
s y s t e m.
A d d i n g R e f r i g e r a n t Oi l
Ref er t o 12-03A f or Removal and Installati on
pr ocedur es.
pr ocedur es.
Co n t r o l A s s e mb l y
Ref er t o 12-03A f or Removal and Inst allat i on
pr ocedur es.
C o n t r o l A s s e m b l y I l l u mi n a t i o n L a mp s
pr oc e dur e s.
S e n s o r s
A u t o m a t i c T e mp e r a t u r e C o n t r o l S e n s o r
Re mo v a l
1. Remove ba t t e r y ground cabl e ( 14301) .
2. Remove t he i nst rument panel upper mouldi ng
( 04268) .
Aut o ma t i c Te mpe r a t ur e Co n t r o l Se nsor
3. NOTE: The i nst rument panel upper mouldi ng is
ret ai ned by snap-i n t a bs.
Remove sc r e w and sl i de aut omat i c t emper at ur e
cont r ol sensor ( 1907 34) up and out of t he
i nst rument panel ( 04320) .
4. Di sconnect t he el ect ri cal l ead and t he aut omat i c
t emper at ur e cont rol sensor hose and el bow
( 19D888) f r om t he aut omat i c t emper at ur e
cont rol sensor.
CONTROL SENSOR ASSY
19C734
I NSTRUMENT PANEL 04320
I NSTRUMENT PANEL
UPPER MOLDI NG 04268
M4639-A
12 - 03B- 38
M7 CondMomng s t o r m E l e c t r o n i c A u t o ma t i c T e m p e r a t u r e C o n t r o l
12- 038- 38
1. Connect t he el ect ri cal l ead and t he aut omat i c
t e mpe r a t ur e cont rol sensor hose and e l bow t o
t he aut omat i c t emper at ur e cont rol sensor .
2. Posi t i on t he aut omat i c t emper at ur e cont r ol
sensor on t he i nst rument panel and i nstall t he
3. Install t he i nst rument panel upper moul di ng by
snappi ng in t he bot t om and t op.
4. Connect bat t er y gr ound cabl e.
A / C A m b i e n t A i r T e m p e r a t u r e S e n s o r
Re mo v a l
1. Di sconnect ba t t e r y ground cabl e.
2. Di sconnect el ect ri cal connect or f r om A / C
ambi ent ai r t emper at ur e sensor and br a c ke t
( 19E7 02) .
3. Remove A / C ambi ent ai r t emper at ur e sensor and
br a c ke t f r o m i ts mount i ng l ocat i on on t he wi ri ng
shi el d ( 14A099) in f ront of t he A / C condenser
c or e ( 197 12) .
A / C Ambi e n t Ai r Te mpe r a t ur e Se nsor
WI RI NG SHI ELD
14A099
RADI ATOR GRI LL OPENI NG
PANEL REI NFORCEMENT 8A284
FRONT OF
VE HI C L E
A/C AMBI ENT AIR
TEMPERATURE SENSOR
19E702
M48S8-A
1 Install t he A / C ambi ent air t emper at ur e sensor
and br a c ke t i nto t he wi ri ng shi el d.
2. Connect el ect ri cal connect or t o A / C ambi ent air
t emper at ur e sensor and br acket .
4. Che c k sy st e m f or pr oper operat i on.
A / C S u n l o a d S e n s o r
1.
2.
4.
Remove i nst rument panel cover and pull A / C
sunl oad sensor ( 19E663) f r om mount i ng st uds.
Di sconnect el ect ri cal connect or f r om A / C
sunl oad sensor.
To install, reverse Removal pr ocedur es.
A / C B l o w e r Mo t o r S p e e d C o n t r o l
Re mo v a l
1. Di sconnect t he wi re harness connect or f r om t he
A / C bl ower mot or speed cont r ol ( 19E624)
assembl y.
2. Remove t he t wo bl ower cont rol l er assembl y
ret ai ni ng sc r e ws securi ng t he A / C bl ower mot or
speed cont rol boar d t o t he A / C evapor at or c or e
housi ng ( 19A553) assembl y.
3. Remove the A / C bl ower mot or speed cont rol
assembl y.
1. Posi t i on t he A / C bl ower mot or speed cont rol
assembl y in t he openi ng in t he A / C evapor at or
c or e housi ng assembl y.
2. Install the t wo bl ower control l er (VBSC) assembl y
i995 Town Car, Cr own Victoria, Grand Marquis Jul y 1994
12 - 03B- 39 Ai r Condi t i oni ng Sy s t emEl ec t r oni c A u t o ma t i c Temper at ur e Cont r ol 12 - 03B- 3g
3. Connect t he bl ower control l er (VBSC) wi re
harness and check A / C bl ower motor f or proper
operati on.
A / C Bl o we r Mo t o r Spe e d Co n t r o l (Vari abl e)
L 7 469- B
A / C Electronic Door Actuator Motor
Refer t o 12-03A f or Removal and Installation
procedures.
A / C Evaporat or Core Housi ng
A / C Evaporat or Core
Heater Core
Refer t o Secti on 12- 03A.
Heater Bl ower Mot or and Blower Mot or
Wheel Assembl y
Inst rument Panel A / C Regi ster Assembli es
A / C Side Wi ndow Demi ster and Hoses
Heater Air Plenum Chamber
Wi ndshi eld Def rost er Hose Nozzle Assembl y
Instrument Panel A / C Evaporator Register
Ducts
Doors
Vacuum Cont rol Mot ors
Refer to Secti on 12-03A.
Suct i on Accumul at or/Dri er
A / C Cycl i ng Swi t ch
A / C Pressure Cut-Off Swi t ch
A / C Compressor Pressure Relief Valve
A / C Evaporator Core Ori fi ce
A / C Condenser Core Assembly
Refrigerant Lines
Ref er t o Sect i on 12-03A.
Heater Water Hoses
A/ C Compressor
A/ C S y s t e m Filtering
A/ C Ma n i f o l d a n d Tube
SPECIFICATIONS
POWERTRAIN CONTROL/ EMI SSI ONS DIAGNOSIS
Co u ga r
T A 1 0 0 0 B
REFRI GERANT SYSTEM COMPONENTS AND CAPACI TI ES
Vehi cl e
FS-10 A / C
Compr e ssor
A / C
Evapor at o
Core
Ori f i ce
(Orange)
A / C
Cy cl i ng
Swi t c h
8
Muf f l er
Suct i on
Ac c umul a t o r /
Dri er
Ref ri gerant Capaci t y
Vehi cl e
FS-10 A / C
Compr e ssor
A / C
Evapor at o
Core
Ori f i ce
(Orange)
A / C
Cy cl i ng
Swi t c h
8
Di scharge Suct i on
Suct i on
Ac c umul a t o r /
Dri er Kg Oz.
Ma r q u i s , To wn Ca r
X X X X X X 0. 964 34
a P r e s s u r e t o o p e n a t 169 kP a ( 2 4. 5 p s i )
REFRI GERANT SYSTEM
Sy st e m Pr ot e c t i on
A / C Cy c l i n g S wi t c h Cl o s e ma x : 3 2 4 k P a ( 47 ps i )
Op e n ma x : 159 kP a ( 2 3 ps i )
A / C Co mp r e s s o r P r e s s u r e
Re l i e f Va l v e "
3103 kP a ( 450 p s i )
( Co n t i n ue d )
REFRI GERANT SYSTEM (Cont'd)
Type
Re f r i ge r a n t R- 134a WSH- M17 B19- A ( Mo t o r c r a f t
YN-11)
Re f r i ge r a n t Oi l WSH- M1C2 31- B ( Mo t o r c r a f t
YN- 12 b )
a L o c a t e d i n ma n i f o l d a t t a c h e d t o c o mp r e s s o r .
ELECTRICAL SYSTEM
S y s t e m Pr otecti on
A / C Bl o we r Mo t o r Ci r c ui t 30 A mp Mi n i - Fus e ( Lt . Gr e e n )
i n Pa n e l F-9
( D9Z B- 14A 094- G A )
A / C Cl u t c h Ci r c ui t 2 0 A mp Mi n i - Fus e ( Ye l l o w) i n
P a n e l F-6 ( D9Z B- 14A 094- E A )
A / C Bl ower Motor Cur r ent Draw
Low 4. 5- 5. 5 A mp s / 3 . 5 - 5 . 5 Vo l t s
Me d i u m L o w 7- 8 A m p s / 5 - 7 Vo l t s
Me d i u m Hi gh 1 4 - 1 8 A m p s / 8 - 1 0 Vo l t s
Hi gh 2 0- 2 5 A m p s / 1 2 - 1 3 Vo l t s
I l l umi n a t i o n Co n t r o l A s s y 1CP - 161 Bul b
a S y s t e m i n Ma x i mu m A / C P o s i t i o n .
SPRING-LOCK COUPLING COMPONENTS
O- Ri n g 3 / 8 i n c h 3 9 1 3 9 6 - S 1 0 0
1 / 2 i n c h 3 9 1 3 9 7 - S 1 0 0
5 / 8 i n c h 3 9 1 3 0 4 - S 1 0 0
3 / 4 i n c h 3 9 1 3 0 7 - S 1 0 0
Ga r t e r Sp r i n gs 3 / 8 i n c h E 1 Z Z - 1 9 E 5 7 6 - A ( YF- 990)
1 / 2 i n c h E 1ZZ- 19 E 5 7 6- A ( YF- 991)
5 / 8 i n c h E 3 5 Y- 1 9 E 5 7 6 - A ( YF- 1134)
3 / 4 i n c h E 69 Z - 19 E 5 7 6- A
SPRING-LOCK COUPLING COMPONENTS (Cont'd)
S e r v i c e Ki t s
E 35Y- 19D690- D Co n t a i n s 391396, 391397 , 391304, 391307
O- Ri n gs.
E 1Z Z - 19E 57 6- A a n d - B a n d E 35Y- 19E 57 6- A
Sp r i n gs .
A / C A mb i e n t Ai r Te mp e r a t u r e
S e n s o r a n d Br a c ke t ( Nut )
6. 2 - 7 . 3 55- 64
( Lb- l n )
ROTUNDA EQUIPMENT
0 2 1 - 0 0 0 1 4 Va c u u m Te s t e r
1 2 - 0 3 0 1 Co mp r e s s o r a n d C l u t c h F S - 1 0 12-03C- 1
SECTION 12-03C Compressor and ClutchFS-10
SUBJ E CT PAGE
VEHICLE APPLICATION 12-03C-1
A / C Compressor . . . . . 12-03C-1
DIAGNOSIS AND T E ST I N G
Compressor and Cl ut ch 12-03C-2
A / C Cl ut ch 12-03C-2
A / C Compressor . 12-03C-2
SUBJECT PAGE
A / C Mani f ol d and Tube Assembl y 12-03C-2
Shaf t Seal ... 12-03C-4
ADJUSTMENTS
A / C Cl ut ch Air Ga p. 12-03C-7
SPECIFICATIONS. 12-03C-7
SPECIAL SERVICE TOOLS/EQUIPMENT 12-03C-8
VEHICLE APPLICATION
A/ C Compressor
The FS-10 A / C c ompr e ssor ( 197 03) i s:
A swa shpl a t e desi gn.
Ten-cyli nder.
Al umi num.
Tangent i al desi gn mount .
M4860- A
Oper at i on and assembl y is as f ol l ows:
The c ompr e ssor mai nshaf t is dri ven by a dri ve bel t
( 862 0) f r o m t he cr ankshaf t pulley ( 6312) .
A one-pi ece, l i p-t ype seal (repl aceabl e f r om t he
f r ont of t he A / C c ompr e ssor ) i s used t o seal t he
ar ound t he c ompr e ssor shaf t , ope r a t e wi t hi n t he
cyl i nder assembl y.
The pi st ons are a c t ua t e d by a swa shpl a t e t hat is
pr e sse d on t he c ompr e ssor shaf t .
The swashpl at e changes t he r ot at i ng act i on of t he
shaf t t o provi de a r eci pr ocat i ng dri vi ng f o r c e t o
e a c h of t he f i ve pi st ons.
Thi s dri vi ng f o r c e is appl i ed, t hr ough shoes, t o t he
mi dpoi nt of each of t he doubl e-end pi st ons.
Reed-t ype di schar ge val ves are assembl ed on t he
val ve pl at e whi c h is l ocat ed wi t h t he suct i on r eed
at each end of t he A / C c ompr e ssor .
The heads have connect i ng gas-t i ght pa ssa ge wa y s
t hrough t he cyl i nder assembl y whi c h di r ect t he
ref ri gerant gas t o t he suct i on and di schar ge por t s
l ocat ed in t he rear head.
A magnet i c A / C cl ut ch ( 2884) is used t o dri ve t he
c ompr e ssor shaf t .
When vol t age is appl i ed t o t he A / C cl ut ch fi eld coi l
( 2987) , t he A / C cl ut ch (whi ch is sol i dl y coupl ed t o
t he c ompr e ssor sha f t ) is dr awn r e a r wa r d by
magnet i c f or c e t o wa r d t he A / C cl ut ch pulley
(2E884) whi ch is dri ven by t he engi ne dri ve bel t .
Magnet i c f or c e l oc ks t he A / C cl ut ch and t he A / C
cl ut ch pulley t oget her as one unit.
The c ompr e ssor shaf t t hen t urns wi t h t he A / C
cl ut ch. When vol t age i s removed f r om t he A / C
cl ut ch f i el d coi l , spri ngs in t he cl ut ch pl at e and hub
assembl y move t he A / C cl ut ch a wa y f r om t he A / C
cl ut ch pulley.
1 2- 03C- 2 Compressor a n d Cl u t c h FS - 1 0
1 2-03C- 2
C o m p r e s s o r a n d C l u t c h
A/ C Compressor
A/ C System Filtering
A/ C Manifold and Tube Assembly
A/ C Clutch
A/ C Clutch and A/ C Clutch Pulley
S P E C I A L S E R V I C E T O O L ( S ) R E QU I R E D
Compr es s or Cl ut ch Hol di ng Tool T94P- 19703- AH
Removal
1. Hol d A / C cl ut ch ( 2 884) wi t h Compr e ssor Cl ut ch
Hol di ng Tool T94P-19703-AH and r emove t he
A / C cl ut ch ret ai ni ng bol t .
A/C CLUTCH
2. Pull A / C cl ut ch and A / C c ompr e ssor cl ut ch hub
spa c e r s ( 19D648) f r om A / C c ompr e ssor shaf t . If
A / C cl ut ch cannot be pulled f r om A / C
c ompr e ssor shaf t , sc r e w an 8 mm x 1.25 mm bol t
into t he shaf t hole of t he A / C cl ut ch t o f or c e it
f r om t he shaf t .
8 x 1.25 mm
3. Remove A / C c ompr e ssor cl ut ch pulley retai ni ng
snap ri ng.
M3307 - B
4. Pull t he A / C cl ut ch pulley (2E884) assembl y f r om
A / C c ompr e ssor ( 197 03) .
12 - 03C- 3 Co mp r e s s o r a n d C l u t c h FS - 1 0 12 - 03C- 3
A / C Cl ut c h
M3304-F
Pa r t
1 N805338- S2 Pulley Snap Ring
2 2884 A / C Cl ut c h
3 N805332 - S2 Bol t (6 mm)
4 19D648 A / C Co mpr e s s o r Cl ut c h Hub
Spa c e r Shi m Ki t
I t e m
Pa r t
5 2E884 A / C Cl ut c h Pul l ey
6 2987 A / C Cl ut c h Fi e l d Coi l
A

Ti ght e n t o 11-13Nm ( 8- 10
Lb- Ft )
1 Cl ean pulley beari ng surf ace of A / C c ompr e ssor
head t o r emove any di rt or c or r osi on.
Install A / C cl ut ch pulley assembl y on A / C
c ompr e ssor . The beari ng is a sl i p-f i t on t he A / C
c ompr e ssor head and, if pr oper l y al i gned, shoul d
sl i p on easi l y.
Install A / C c ompr e ssor cl ut ch pulley ret ai ni ng
snap ri ng wi t h bevel si de of snap ri ng out .
Pl ace one medi um t hi ckness spacer shi m i nsi de
t he A / C cl ut ch hub spli ne openi ng and sl i de t he
A / C cl ut ch on t he end of t he A / C c ompr e ssor
shaf t .
Thr e a d a new 6 mm hub ret ai ni ng bol t into end of
A / C c ompr e ssor shaf t . Hol d A / C cl ut ch wi t h
Compr e ssor Cl ut ch Holdi ng Tool T94P- 19703- AH
and t i ght en A / C cl ut ch hub ret ai ni ng bolt t o 11-13
Norn (8-10 Ib-f t ). DO NOT USE A I R T OOL S .
Che c k and adj ust ai r gap as out l i ned.
Whe n i nstalli ng a new A / C cl ut ch, cy cl e it 10
t i mes at idle t o burni sh it and prevent sl i ppage.
A / C C l u t c h Fi e l d Co i l
NOTE: The A / C cl ut ch fi eld coi l ( 2 987 ) is pr essed on
t he f ront head of t he A / C cl ut ch f i el d coi l . Speci al
servi ce t ool s are requi red t o remove and i nstall t he
A / C cl ut ch f i eld coi l .
SPECI AL SERVI CE TOOL( S) REQUI RED
Sha f t P r o t e c t o r f o r Co i l Re mo v a l
Co i l P r e s s i n g To o l
Fi e l d Co i l Re p l a c e r
T 89P - 1962 3- FH
T89P - 1962 3- E H
T 91L - 1962 3- CH
Re mo v a l
CAUTI ON: Do n o t us e a i r t o o l s . A / C c l u t c h f i e l d
c o i l c a n b e e a si l y d a ma g e d .
1. Remove t he A / C compr essor f r om t he vehi cl e.
2. Remove t he A / C cl ut ch and A / C cl ut ch pulley as
out l i ned.
3. Not e l ocat i on of A / C cl ut ch f i eld coi l el ect ri cal
connect or on A / C compr essor housi ng pri or t o
removal so t hat it can be rei nst al l ed in t he same
l ocat i on.
4. CAUTI ON: Fa i l ur e t o use Sha f t P r o t e c t o r f o r
Co i l Re mo v a l T 89P - 1962 3- FH ma y r e sul t i n
d a ma g e t o t h e c o mp r e s s o r , ma ki n g t h e
c o mp r e s s o r u n u s a b l e .
Install Shaf t Seal Pr ot ect or T89P-19623-CH on
t he nose openi ng of t he A / C compr essor .
5. Install Pulley Puller D81P-19703-B or equi val ent
on t he A / C c ompr e ssor . Pl ace t he t i p of t he puller
f orci ng sc r e w in t he cent er pi lot of t he shaf t
pr ot e c t or and t he j a ws of t he puller around t he
back edge of t he A / C cl ut ch f i el d coi l .
A/ C CLUTCH FI ELD
COI L 2987
SHAFT PROTECTOR
FOR COI L REMOVAL
T89P-19623-FH
PULLEY PULLER
D81P-19703-B
M4 7 1 9 - A
6. Ti ght en t he puller f orci ng sc r e w t o pull t he A / C
cl ut ch f i el d coi l f r om t he A / C c ompr e ssor head.
CAUTI ON: Do n o t u s e a i r t o o l s . A / C c l u t c h f i e l d
c o i l c a n b e e a si l y d a ma g e d .
1. Cl ean t he coi l mount i ng sur f ace on t he f ront head
t o r emove any di rt or c or r osi on.
2. Wi t h t he A / C c ompr e ssor in a vert i cal posi t i on
(nose up), pl ace t he A / C cl ut ch f i el d coi l in
posi t i on on t he A / C c ompr e ssor f ront head.
Ma ke sure t he A / C c ompr e ssor cl ut ch f i el d coi l
el ect ri cal connect or is posi t i oned c or r e c t l y a s
not ed duri ng Removal .
3. Pl ace t he Coil Pressi ng Tool T89P-19623-EH wi t h
Fi el d Coil Repl acer T91P-19623-CH in posi t i on
over t he A / C c ompr e ssor nose and t o t he inner
radi us of t he A / C cl ut ch f i el d coi l .
4. Posi t i on 2-Jaw Puller D80L- 1002- L or equi val ent
on t he A / C c ompr e ssor and t he coi l pressi ng
t ool . The j a ws of t he puller shoul d be f i rml y
engaged wi t h t he rear si de of t he A / C
c o mpr e sso r f ront mount s. The f or ci ng sc r e w
must be pi l ot ed on t he cent er mar k of t he
pressi ng t ool .
5. Ti ght en t he f orci ng sc r e w wi t h a hand wr e nc h until
t he A / C cl ut ch f i el d coi l is pr e sse d on t he A / C
c o mpr e sso r f ront head. Check t o make sure t hat
t he A / C cl ut ch f i el d coi l bot t oms agai nst t he head
at all poi nt s around t he A / C c o mpr e sso r cl ut ch
f i el d coi l out er di amet er (OD).
COI L PRESSI NG TOOL
T89P-19623-EH
2-JAW PUu_ER
D80L-1002-L
FI ELD COI L
REPLACER
T91L-19623-CH
A/ C CLUTCH
FI ELD COI L
2987
L7716-C
Install t he A / C cl ut ch pulley and A / C cl ut ch on
t he A / C compr essor as out l i ned.
Check and adj ust ai r gap as out l i ned.
Install t he A / C c ompr e ssor on t he vehi cl e. Ref er
t o Sect i on 12-03A.
S h a f t S e a l
S P E C I A L S E R V I C E T O O L ( S ) R E QU I R E D
O- Ri n g To o l
Sn a p Ri ng Re mo v e r
Sha f t Se a l Re mo v e r
Sha f t Se a l P r o t e c t o r
Sha f t Se a l Re p l a c e r
T 7 1P - 197 03- C
T89P - 1962 3- DH
T 89P - 1962 3- BH
T 89P - 1962 3- CH
T 89P - 1962 3- A H
Re mo v a l
1 . Remove t he A / C compr essor ( 197 03) f r om t he
vehi cl e. Refer t o Sect i on 12-03A.
2. Remove A / C cl ut ch ( 2884) f r om A / C
c ompr e ssor as out l i ned.
3. Remove shaf t seal felt f r om nose of A / C
c ompr e ssor wi t h O-Ring Tool T71P-19703-C.
12 - 03C- 5 Co mp r e s s o r a n d C l u t c h F S - 1 0 12 - 03C- 5
Bl ow any debr i s f r o m i nsi de t he A / C c ompr e ssor
nose wi t h l ow-pr essur e c o mpr e sse d air. Then
cl ean t he i nsi de and out si de nose a r e a of t he A / C
c ompr e ssor wi t h a li nt -f ree c l ot h t o r emove any oil
and di rt .
Remove shaf t seal ret ai ni ng snap ri ng f r om i nsi de
A / C c ompr e ssor nose wi t h Snap Ri ng Remover
T89P-19623-DH a s de sc r i be d in t he f ol l owi ng
st e ps. Ref er t o t he i l l ust rat i ons.
Insert t he t i p of t he Snap Ri ng Remover
T89P-19623-DH i nt o one of t he snap ri ng e y e s
(Vi ew A).
Rot at e t he snap ri ng remover t o posi t i on t he t ool
t i p and t he snap ri ng eye cl osest t o t he A / C
c ompr e ssor shaf t (Vi ew B).
Pull t he snap ring remover up qui ckl y whi l e
keepi ng t he t ool shaf t agai nst t he si de of t he nose
openi ng and r emove t he snap ri ng (Vi ew C).
Snap Ri ng Removal
VI EW A VI E WB VIEWC M3412-B
1995 To wn Car , Cr o wn Vi c t o r i a , Gr a n d Marquis J u l y 1994
9. Position Shaft Seal Remover T89P-19623-BH
over A / C c ompr e ssor shaf t and push t ool into
nose of A / C compressor and down agai nst shaft
seal . Engage end of t ool wi t h i nsi de di amet er (ID)
of shaf t seal . Whi l e hol di ng t he hex part of t he
t ool , t urn t ool handl e c l oc kwi se t o expand t ool t i p
i nsi de seal inner radi us. Then pull shaf t seal f r om
t he A / C c ompr e ssor wi t h t he t ool .
1. CAUTI ON: Do n o t u s e p r o t e c t o r i f i t i s
d a ma g e d . Ob t a i n a n o t h e r s h a f t se a l ki t a n d
u s e p r o t e c t o r f r o m i t .
Obt ai n a new Shaf t Seal Ki t (Basi c Part No.
19D665). Caref ul l y r emove t he cont ent s of t he ki t
f r o m t he pa c ka ge . A pl ast i c shaf t seal pr ot ect or
is i ncl uded wi t h e a c h ki t . I nspect t he pr ot e c t or f or
any bur r s or ot her da ma ge . Shaf t Seal Pr ot ect or
T89P- 19623- CH can al so be used.
2. CAUTI ON: Do n o t a l l o w a n y d i r t o r f o r e i g n
ma t e r i a l s t o e n t e r t h e A / C c o mp r e s s o r .
Usi ng a cl ean li nt-free c l ot h, cl ean t he A / C
c ompr e ssor shaf t and t he seal poc ke t i nsi de t he
A / C c ompr e ssor nose.
3. Di p t he shaf t seal pr ot ect or and shaf t seal in
WSH-M 1C231-B. Posi t i on t he shaf t seal on t he
pr ot e c t or wi t h t he lip of t he seal poi nt i ng t o wa r d
t he l arge end of t he pr ot ect or as shown.
T89P-19623-CH M3413-B
4. Pl ace t he shaf t seal pr ot ect or wi t h shaf t seal
over t he end of t he A / C c ompr e ssor shaf t .
12 - 03C- 7 Co mp r e s s o r a r i d C l u t c h F S - 1 0 12 - 03C- 7
5. Usi ng Shaf t Sea! Repl acer T89P- 19623- AH,
sl owl y push seal d o wn shaf t pr ot e c t or ont o A / C
c o mpr e sso r shaf t until se a t e d.
SHAFT SEAL
REPLACER
T89P-19623-AH
7.
9.
10.
11.
M3312-C
Remove i nstaller t ool and shaf t pr ot e c t or f r om
A / C c ompr e ssor shaf t .
Pl ace a new shaf t seal ret ai ni ng snap ri ng into t he
A / C c ompr e ssor nose openi ng and seat t he snap
ri ng i nto t he gr oove.
Leak-t est t he shaf t seal i nst al l at i on af t er rot at i ng
t he A / C c ompr e ssor shaf t about 10 revol ut i ons
wi t h t he A / C cl ut ch. Ref er t o Sect i on 12-00, A / C
Compr e ssor Ext ernal Le a k Test .
Install a new shaf t seal f elt in nose of A / C
c ompr e ssor .
Install A / C cl ut ch on A / C c ompr e ssor a s
out l i ned.
Che c k and adj ust t he ai r gap as necessar y.
12. Install A / C c ompr e ssor on vehi cl e. Ref er t o
Sect i on 12-03A.
ADJUSTMENTS
A / C C l u t c h Air G a p
1. Measur e ai r ga p bet ween A / C cl ut ch and A / C
c l ut c h pulley mat i ng sur f aces in t hree equal l y
spa c e d l ocat i ons wi t h a f eel er gauge. Recor d t he
measur ement s.
FEELER
GAUGE
M3308-C
If t he smal l est air gap measurement is not wi t hi n
0. 35 t o 0. 85 mm ( 0. 014 t o 0. 033 i nch), r emove
t he A / C c l ut c h ( 2 884) a s out l i ned.
Remove and measure t he A / C cl ut ch shi m.
Sel ect t he appr opr i at e t hi ckness shi m f r om t he
A / C c ompr e ssor cl ut ch hub spacer ( 19D648) t o
pl ace t he ai r gap wi t hi n speci f i ed li mi t s.
Install A / C cl ut ch shi m and A / C cl ut ch a s
out l i ned. Che c k ai r gap measurement .
SPECIFICATIONS
A / C COMPRESSOR SPECIFICATIONS
De sc r i pt i on Spe c i f i c a t i on
TYPE: FS- 10 S wa s h p l a t e , 5 Do u b l e A c t i n g
P i s t o n s Ax i a l Ty pe
DI SP L ACE ME NT 170 c c ( 1 0 . 4 C I D)
CYLI NDER BORE ( Di a . ) 2 9. 0 mm ( 1. 16 i n c h)
STROKE 25. 7 mm ( 1. 03 i n c h)
ROTATI ON Cl o c kwi s e
ROTATI ONAL TORQUE
( Ma x i mu m, ma n i f o l d
r e mo v e d )
10 N-m (7 L b - Ft )
REFRI GERANT OI L
Fo r d Sp e c i f i c a t i o n
WSH- M1C2 31- B
Ca p a c i t y ( S y s t e m To t a l ) 2 07 ml (7 o z)
Pa r t Numbe r Mo t o r c r a f t YN- 1 ?o
A / C CLUTCH
Ai r Ga p Be t we e n A / C
Cl ut c h Pul l e y
a n d A / C Cl u t c h
0. 35 mm- 0. 85 mm
( 0. 014- 0. 033 I n c h)
Cur r e n t Dr a w 4. 36 A mp s @ 12. 8 v o l t s
Run-Out ( Ma x i mu m) 0. 50 mm ( 0. 02 I n c h) Ra d i a l o r
Ax i a l
A / C Co mp r e s s o r Sha f t Hub Bo l t 11- 13 8- 10
SPECIAL SERVICE TOOLS / EQUIPMENT
Tool Numbe r /
T 7 1P - 197 03- C
O- Ri n g To o l
T89P - 1962 3- AH
Shaft Seal Replacer
T89P-19623-AH
T 89P - 1962 3- BH
Sha f t Se a l Re mo v e r
T89P-19623- BH
T 89P - 1962 3- CH
Sha f t Se a l P r o t e c t o r
T89P-19623-CH
T 89P - 1962 3- DH
Sn a p Ri n g Re mo v e r
T89P-19623-DH
T 89P - 1962 3- E H
Co i l P r e s s i n g To o l
T89P-19623-EH
Tool Numbe r /
T 89P - 1962 3- FH
Sha f t P r o t e c t o r f o r Co i l
Re mo v a l
CD
T89P-19823-FH
T 91L - 1962 3- CH
Fi e l d Co i l Re p l a c e r
T91L-19623 CH
T 94P - 197 03- A H
Co mp r e s s o r Cl u t c h Ho l d i n g
To o l
T94P-19703-AH
D80L - 1002 - L 2 - Ja w Pul l e r
D81P - 197 03- B Pul l e y Pul l e r
13- 00- 1
I NSTRUMENTATI ON GROUP
AND WARNI NG J ^
SYSTEMS L O
SECTION TITLE PAGE
ANTI-THEFT ALARM SYSTEM 13-11-1
CLOCK 13-07-1
GAUGES, WARNING DEVICES CHIME
SYSTEM 13-09-1
HORN.. . 13-06-1
SUBJECT PAGE
VEHICLE APPL I CATI ON 13-00-1
I nst rument Cl ust er and Panel Li ghti ng 13-00-1
DIAGNOSIS AND TE STI NG
I nspect i on a n d Veri f i cat i on 13-00-18
P i n p o i n t Tests 13-00-19
SECTION TITLE PAGE
INSTRUMENT CLUSTER AND PANEL
L I GHTI NG 13-00-1
INSTRUMENT
CLUSTERCONVENTIONAL . 13-01B-1
INSTRUMENT CLUSTERELECTRONIC 13-01A-1
SUBJECT PAGE
Sy mpt om Chart . . . ...13-00-18
Audi o Syst em Lamps .... 13-00-23
Cl i mat e Cont r ol Lamps ....13-00-23
I nst rument Cl ust er Lamps 13-00-23
SPECIAL SERVICE TOOLS/EQUIPMENT ....13-00-23
SECTION 13-00 Instrument Cluster and Panel Lighting
VEHICLE APPLICATION
Town Car, Cr own Vi ct or i a, Grand Mar qui s
Instrument Cluster and Panel Lighting Heat ed back wi ndow swi t c h and light ( 18062 1) .
. The i nst rument cl ust er ( 10849) and panel l amps are
Instrument cl ust er.
powe r e d t hr ough t he i nst rument panel f use panel . Transmi ssi on cont rol sel ect or i ndi cat or ( 7 A110) .
Illumination power is suppl i ed t hr ough Ci rcui t 484 Radi o chassi s ( 18806) and di gi t al audi o c ompa c t
(O/BN).
di sc pl ayer ( 18D806) .
Ground is suppl i ed t hr ough Ci rcui t 57 ( BK) . Intensi ty of illumination is cont rol l ed by t he panel
The li ghti ng cont rol modul e and panel li ght i ng ci rcui t
di mmer swi t c h. !
pr ovi des illumination t o:
A / C i nst rument cl ust er.
El ect ri c cl ock ( 15000) .
13- 00- 2 I n s t r u me n t Cl us t e r a n d Pa n e l L i gh t i n g 13- 00- 2
El e c t r o n i c I n st r ume n t Cl ust e r - To wn Car
FRONT VI EW
fe |S-ft CHECK r r i
J L I I - ENGI NE Sfi
F a
cmmtss
sss

CH3L J E
<
k
SLOWLY
A c S5
<5>888988.8km
speeocamm o/oc
'88,
km/h
MPH
/G
LFR/mkm
CD
0
CONNECTOR C3
REAR VI EW
O D D D D D D D D ^ I D D f l f l D D D D
CONNECTOR C1
CONNECTOR C2
K22830-A
13- 00- 3 I n s t r u me n t Cl us t e r a n d Pa n e l L i gh t i n g
13- 00- 3
El e c t r o n i c I n st r ume n t Cl u s t e r Cr o wn Vi c t o r i a , Gr a nd Ma r qui s
FRONT VI EW
CHECK
ENGt t JE
3 = 8 8
LTR
GAL
TO
EMPTY
B8888&8t an
<p> OO
iam/li
MPH
CHECK AW agFBaow
TfSJNK AJt f i OH/ WO t i l l
C D
3
REAR VI EW
W* i f l f l D O D O D D ^
CONNECTOR C 1 .
K22831-A
1995 To wn Car, Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s July 1994
13- 00- 4 I n s t r u me n t Cl u s t e r a n d Pa n e l L i gh t i n g 13- 00- 4
I n st r ume n t Cl ust er, Convent i onal Cr own Vi ct or i a, Town Car, Gr a nd Mar qui s
Ci) GD (z) GD (J) GD (z) (^) (9) (10) (11) ^2) ^3)
ANTI- LOW CHECK
THEFT FUEL ENGINE
K22817-A
Pa r t
1

An t i - The f t I n d i c a t o r
2

L o w Fuel I n d i c a t o r (Pa r t of
10890)
3

Ma l f un c t i o n I n d i c a t o r L a mp
( MI L) (Pa r t of 10890)
4

Sa f e t y Be l t Wa r ni ng
I n d i c a t o r (Pa r t of 10890)
5

Cha r gi n g Sy s t e m Wa r ni ng
( Pa r t of 10890)
6

Turn Si gn a l I n d i c a t o r (Pa r t of
10890)
7

Ai r Suspe n si o n I n d i c a t o r
( Pa r t of 10890)
8

Tr a n smi ssi o n Co n t r o l
9

Turn Si gna l I n d i c a t o r (Pa r t of
10890)
10

An t i - L o c k I n d i c a t o r (Pa r t of
10890)
11

Hi gh Be a m I n d i c a t o r (Pa r t of
10890)
Pa r t
12 10849 Br a ke Sy st e m Wa r ni ng (Pa r t
of 10890)
13

Ai r Ba g Re a d i n e ss I n d i c a t o r
(Par t of 10883)
14

Oi l Pr e ssur e Ga uge (Pa r t of
10883)
15 10883 Engi ne Co o l a n t Te mpe r a t ur e
Ga uge
16 17K311 Tri p Od o me t e r Re se t Co n t r o l
Knob
17 7 A110 Tr a n smi ssi o n Co n t r o l
Se l e c t o r I n d i c a t o r
18 17255 Spe e d o me t e r
19 9305 Fuel Ga uge
20

Fuel Fi l l Door Aj ar I n d i c a t o r
(Par t Of 10883)
21

Ba t t e r y Vo l t a ge Ga uge (Pa r t
of 9305)
22

I nst r ument Cl ust e r Ma s k
E l e c t r i c a l S c h e m a t i c s
I n st r ume n t Cl ust e r a n d Panel L i gh t i n gT o wn Car
HOT AT ALL TIMES HOT AT ALL TIMES
FUSE
JUNCTION
PANEL
LG/Y
C3-11
VBATT
C3*6
VBATT
V/V0LTS PWM
OUT OUT
Oi -2 3*12
19 |T LB/R
I 484 I O/BK
195 I T/W
FUSE
JUNCTION
PANEL
of this circuit
1 9 5 | T/W
f LAMPS DC
1 * " '
DIM
DOWN
B 1
3
HEADLAMP
SWITCH
1032 I W/BK 1 1035 I O/R I
I 1033 I R/Y I 1036 I E BR/W
, mm ^ PP mm mm ^ LIGHTING
C1-13 C M0 C2-16 C2-15 , CONTROL
PARKING HEADLAMP PANEL PANEL "MODULE
LAMP SWITCH DIM UP DIM | (LCM)
SWITCH DOWN [
v
'
SOUD STATE j
K22845-A
I n st r ume n t Cl ust e r a n d Panel Li ght i n g T o wn T o wn Car ( Co n t i n ue d )
A
13- 00- 7 13- 00- 7
I n st r ume n t Cl ust e r a n d Panel Li ght i n g T o wn T o wn Car ( Co n t i n ue d )
y
K22847-A
13- 00- 8 I n s t r u me n t Cl u s t e r a n d Pa n e l L i gh t i n g
13- 00- 8
I n st r ume n t Cl ust e r a nd Panel Li ght i n g T o wn T o wn Car ( Co n t i n ue d )
WV REDUNDANT 4841 O/ BK
W/ O REDUNDANT
STEERI NG CONTROL
X
STEERI NG CONTROL
"1
, " REDUNDANT
I ,
1
I STEERING
I
L E D
i CONTROL
1
POWER RETURN I MODULE
I 10 15 |
1
AIRBAG
1 SLIDING
CONTACT
' SPEED
1 CONTROL
! SWITCH
I ASSEMBLY
T
484 1 O/BK
1 484 0
4841 O/ BK
LH FRONT
DOOR
LOCK/UNLOCK
SWITCH LAMP
LH FRONT
DOOR
INSIDE
HANDLE
LAMP
1 SWITCH
| ASSEMBLY (
- I n st r ume n t Cl ust e r a nd Panel L i g h t i n g Cr o wn Vi c t o r i a , Gr a nd Ma r qui s
I n st r ume n t Cl ust e r a n d Panel L i g h t i n g Cr o wn Vi c t o r i a , Gr a n d Ma r qui s ( Cont i nue d)
HOT AT ALL TIMES
of this circuit
W/ BK
HOT AT ALL TIMES
I OPfjf HEAD
1
1036 I I
1 HE A D-
" LAMP
1 SWI T CH
DIM ;
DOWN 1
FUSE
1 J UNCT I ON
C1-13
PARK LI GHT
SWI TCH I NPUT
01- 10
HEADLI GHT
SWI TCH
INPUT
03- 11
V B A T 1
" " l LI GHTI NG
11
C3- 6 I CONTROL
V BAT 3 | MODULE
PANEL DI M VARI ABLE VOLTAGE i
UP I NPUT DI MMI NG OUTPUT
L 02-18 03-2 |
PANEL DI M
DOWN I NPUT
1
1035 I O/R I
I 19 I LB/R
I /
W/ EATC
ONLY
1
W/ DI GI TAL
CLUSTER ONLY
INSTRUMENT
CLUSTER
( DI GI TAL )
13
LB/R
E L E CT RONI C 8 4 Q
A UT OMA T I C I
1 B
T E MP E RA T URE i
CONT ROL
8
( E A T C)
MODUL E
' | 676
I
ittet M* J
57 I BK
PK/O
I
676 I PK/O
13- 00- 11 Snsf r ume nt Cl u s t e r a n d Pa n e l L i g h t i n g 13- 00- 11
I nst r ume nt Cl yst er and Panel Li ght i ngCr own Vi c t o r i a , Gr and Ma r qui s (Cont i nued)
PUtSE WIDTH MODULATED
DIMMING OUTPUT
See EVTM f o r mor e de t a i l s
" LIGHTING
1 CONTROL
j MODULE
CONVENTI ONAL
I NSTRUMENT
CLUSTER
ELECTRONI C
I NSTRUMENT
CLUSTER
mm mm 1 R A R W I NDOW
*Y i DEFROST
1CONTROL
. J
A * 1 ELECTRONIC I INSTRUMENT f "
1
1
4
. AUTOMATIC i . CLUSTER |
c 8TEMPERATURE i
3
S g
1 CONTROL (EATC) I
i MESSAGE
ICENTER
I SWITCH
|ASSY
K22851-A
13-00-12
I n s t r u me n t Cl u s t e r a n d Pa n e l L i gh t i n g 13-00-12
I nst r ument Cl yst er and Panel L i gh t i n gCr own Vi ct or i a, Grand Marqui s (Cont i nued)
484
I 7 I LEFT
I
7
i REAR
I WINDOW
I CONTROL
| J SWITCH
mm* ^ J
0 * 1 MASTER
1 2
.WINDOW/
DOOR LOCK
|CONTROL
1
SWITCH
1 RIGHT FRONT
. WINDOW/DOOR
I LOCK CONTROL
| SWITCH
1
I RIGHT
.REAR
I WINDOW
: J
SWITCH
K22852-A
( Town Car)
K22562-A
Pin
1 5 0 6 ( R) E n g l i s h / Me t r i c I nput
2
_
No t Us e d
Pi n
3 143 ( L B / Y ) Swi t c h Mo d u l e I nput
4 39 ( R / W) En gi n e Co o l a n t T e mp e r a t u r e ( ECT
Se n s o r I nput )
5
_
No t Us e d
8 67 6 ( P K/ O) P o we r Gr o un d
9 2 95
( L B / P K )
S wi t c h e d P o we r ( Ho t i n Run)
11 2 05
( DB / L G )
Fue l Fl o w Ra t e I nput
12 67 9
( G Y/ B K )
Vo l t a ge I nput
14 911
( W/ L G )
L a mp
15 7 02
( W/ B K )
Co mp a s s Da t a B +
16 7 03 ( W/ O ) Co mp a s s Da t a B-
17 344
( B K / Y)
18 No t Us e d
Re q u e s t
2 0

Not Us e d
13- 00- 13 i n s t r u me n t Cl u s t e r a n d Pa n e l L i g h t i n g 13- 00- 13
ELECTRONI C I NSTRUMENT CLUSTER
CONNECTOR C2
K19973-B
Pin
2 1

No t Us e d
2 2 No t Us e d
2 3 152
( L B / W)
2 4

No t Us e d
2 5 419
( DG / L G )
Ai r Su s p e n d i n g I nput
2 6 2 03
( O / L B )
S p e e d Co n t r o l I nput
2 7 486
( B R / W)
De c kl i d Aj a r I nput
2 8

No t Us e d
2 9 No t Us e d
30

No t Us e d
31

No t Us e d
32

No t Us e d
33

No t Us e d
34

No t Us e d
35

No t Us e d
36

No t Us e d
Pin
1 67 6
( P K / O )
Ve h i c l e S p e e d S e n s o r ( VSS)
Gr o u n d
2 2 95
( L B / P K )
S w i t c h e d P o we r I nput ( Ho t i n Run)
3 484
( O / B K )
4 932
( G Y / W)
Hi gh Be a m I nput
5 No t Us e d
6
_
No t Us e d
7 489
( P K / B K )
I gn i t i o n S wi t c h
8 No t Us e d
!
9 67 6
( P K / O )
I nput
10 904
( L G / R )
Ch a r g e I n d i c a t o r I nput
11

No t Us e d j
12 No t Us e d
LI GHTI NG CONTROL
MODULE CONNECTOR C1
TOWN CAR
K22S87-A
Pin
1 2 94
( W/ L B )
P o we r
2 88 ( B K / Y ) I n st r ume n t Pa n e l L a mp S wi t c h e d
Fe e d
3 158
( B K / P K )
Ke y Wa r n i n g Swi t c h
4
__
No t Us e d
5 486
( B R / W)
De c kl i d Aj a r
( Co n t i n ue d )
TOWN CAR ( Co n t ' d )
Pin
6 2 02
( O / L G )
De c kl i d Pun c ho ut S wi t c h
7 2 5 ( DG / P ) An t i - The f t S wi t c h Di s a r m
8 7 0 ( L B / W) On Bo a r d Di a gn o s t i c Co n n e c t o r
9 1003
( G Y/ Y)
P o we r
11 62 7
( B K / O )
P a s s e n ge r ' s Do o r s Aj a r
12 465
( W/ L B )
I l l umi n a t e d En t r y
13 1032
( W/ B K )
P a r ki n g L a mp S wi t c h
14 2 4 ( DB / O ) An t i - The f t S wi t c h Ar m
15 2 3 07LG) An t i - t he f t S y s t e m S wi t c h Fe e d
16 2 2 2
( B R / L G )
Pin
1 2 96 ( W/ P ) R u n / A c e B + I nput
2 1034
( B K / W)
Do me L a mp Swi t c h
3 158
( B K / P K )
4 No t Us e d
5 486
( B R / W)
De c k L i d Aj a r
6 No t Us e d
7
_
No t Us e d
8 7 0 ( L B / W) Ke y l e s s En t r y , Me mo r y S e a t s , A BS
9 6 4 0 ( R / Y ) Run / St a r t B + I nput
10 1 0 3 3 ( R / Y ) He a d l a mp S wi t c h
11 62 7
( B K / O )
12 465
( W/ L B )
13 1032
( W/ B K )
14 3 4 0 ( R / L B ) Pa n i c Al a r m
15 No t Us e d
16 2 2 2
( B R / L G )
DRIVER SEAT CONTROL
MODULE CONNECTOR C2
TOWN CAR
K22688-A
Pin
1 342 ( L G / P ) St a r t e r I n t e r r upt Re l a x
2 No t Us e d
3

Not Us e d
4 1 ( DB) Ho r n S wi t c h Co n t r o l
5

Not Us e d
6 2 2 0 ( P / O ) A u t o l a mp On
8 2 17 ( DB/ O) A u t o l a mp
9 343
( DB/ L G )
10 344 ( B / Y ) Do o r Aj a r Out put L o w
11 867 ( DB) LF Do o r Aj a r
12

Not Us e d
13 194 ( PK) Wi n d o w Re g, Re l a y A c c y . Fe e d
14 183 ( T / Y) To n e Ge n e r a t o r
15 1036
( B R / W)
Pa n e l Di m Do wn
16 1035
( O / R )
Pa n e l Di m Up
17 85
( B R / L B )
Se a t Be l t Fa s t e n
18 688
( G Y/ L B )
He a t e d Ba c kl i gh t S wi t c h
19 936
( DG / W)
I gn i t i o n Ke y Cy l . Se n s o r
2 0 57 ( BK) Gr o un d
2 1

Not Us e d
2 2

Not Us e d
C R O W N V I C T O R I A , G R A N D M A R Q U I S
Pin
1

No t Us e d
2 932
( G Y/ W)
Hi gh Be a m S wi t c h
3

No t Us e d
4 6 ( Y/ L G ) Ho r n
5 No t Us e d
7 2 18 ( W/ P ) A u t o l a mp E n a bl e
8 2 17 ( DB/ O) A u t o l a mp De l a y
9 383 ( R / W) Ha z a r d I n d i c a t o r
10 344 ( B / Y ) Do o r Aj a r Wa r n i n g I n d i c a t o r
11 867 ( DB) Dr i v e r s Do o r Aj a r S w i t c h
12 688
( DB / O )
He a t e d Ba c kl i g h t Re l a y
13

No t Us e d
14 1 8 3 ( T / Y) E l e c t r o n i c I n st r ume n t Cl u s t e r To n e
Re q u e s t
15 1036
( B R / W)
16 1035
( O / R )
17 85
( B R / L B )
Se a t Be l t S wi t c h
18 1010
( DB / O )
Ba c kl i g h t S wi t c h
19

No t Us e d
2 0

No t Us e d
2 1

No t Us e d
2 2

No t Us e d
L I G H T I N G C O N T R O L
MO D U L E C O N N E C T O R C 3 K 2 2 6 8 9 - A
P i n
N u m b e r Ci r c u i t C i r c u i t F u n c t i o n
1 7 05
( L G / O )
De ma n d L i gh t i n g ( Ba t t e r y Sa v e r )
2 19 ( L B / R ) Va r i a b l e Vo l t a ge Di mmi n g
Ba c kl i g h t
3 117
( P K / B K )
Al l Do o r L o c k
5 53
( B K / L B )
P o we r Gr o u n d
6 195 ( T / W) V B a t 1
7

No t Us e d
8 450
( DG / L G )
Se a t Be l t I n d i c a t o r
9 67 6
( P K / O )
57 ( B K )
a
10 502 ( GY)
1 3 ( R / B K )
a
He a d l a mp s
11 54 ( L G / Y) V B a t 3
12 484
( O / B K )
P u mp Di mmi n g
13 44 ( L B) Fl a s h e r Ou t pu t
14 14 ( BR) P a r k L a mp s
15 385 ( W/ R ) Fl a s h e r P o we r Fe e d I nput
16 2 2 1 ( O / W) V B a t 4
H
L I G H T I N G C O N T R O L
MO D U L E C O N N E C T O R 04 K226S0A
T O W N C A R
P i n
N u mb e r Ci r c u i t C i r c u i t F u n c t i o n
1 186
( B R / L B )
2 175
( B K / Y )
V B a t 5
C R O W N V I C T O R I A , G R A N D M A R Q U I S
P i n
1 12
( L B / B K )
Hi gh Be a m He a d l a mp s
2 196
( DB / O )
Ba t t e r y Vo l t a g e I nput
13- 00- 16 I n s t r u me n t Cl ust e r a n d Pa n e l L i gh t i n g 13- 00- 16
Connect or End Vi e ws
Cr own Vi ct or i a, Gr a nd Marqui s
Pin
1 5 0 6 (R) E n g l i s h / Me t r i c I nput
2

No t Us e d
3 143 ( L B / Y ) Swi t c h Mo d u l e I nput
4 39 ( R / W) En gi n e Co o l a n t Te mp e r a t u r e ( ECT
Se n s o r I n p u t )
5 No t Us e d
7 54 ( L G / Y) Ba t t e r y P o we r I nput
8 67 6
( P K / O )
P o we r Gr o un d
9 964
( DB / L G )
B + In Run I nput
11 2 05
( DB / L G )
12 67 9
( G Y/ B K )
Vo l t a ge I nput
14 911
( W/ L G )
L a mp
15

No t Us e d
16 No t Us e d
17 344
( B K / Y )
Do o r Aj a r I nput
Pin
18 No t Us e d
Re q u e s t
2 0

No t Us e d
CONNECTOR C2 ft
Pin
21 _ No t Us e d
22 No t Us e d
23 152
( L B / W)
2 4

No t Us e d
25 419
( DG / L G )
Ai r Su s p e n d i n g I nput
2 6 2 03
( O / L B )
27 486
( B R / W)
2 8 No t Us e d
2 9 No t Us e d
30 No t Us e d
31 No t Us e d
32

No t Us e d
33

No t Us e d
34 No t Us e d
35 _ No t Us e d
36 No t Us e d
1995 To wn Ca r , Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s .July 1994
13- 00- 17
CONVENTIONAL INSTRUMENT CLUSTER
CONNECTOR 01
(CROWN VICTORIA, GRAND MARQUIS)
J5448-A
Pin
1 484
( O / B K )
Li qui d Cr y s t a l Di s pl a y Di mmi n g
I nput
3 6 4 0 ( R / Y ) P o we r I nput
4 67 8 ( Y) A BS I n d i c a t o r
5 39 ( R / W) En gi n e Co o l a n t Te mpe r a t u r e
I n d i c a t o r I nput
6 67 6
( P K / O )
Si gn a l Gr o un d
7

No t Us e d
8 No t Us e d
9 6 0 3 ( DG) A n t i - L o c k Br a ke I n d i c a t o r I nput
10 2 ( W/ L B ) Ri ght Turn I nput
11 911 Tr a n s mi s s i o n Co n t r o l I n d i c a t o r
L a mp
12 932 ( W/ G ) Hi gh Be a m I n d i c a t o r I nput
13 97 7 ( P / W) Br a ke I n d i c a t o r I nput
14 31 ( W/ R ) Oi l P r e s s u r e I nput
15 67 6
( P K / O )
Si gn a l Gr o un d
16 608
( P K / O )
Ai r Ba g I n d i c a t o r I nput
0 0 0 0 0 0 0
CONNECTOR C2
J5449-A
P i n
2 67 6
( P K / O )
Si gn a l Gr o un d
3 6 4 0 ( R / Y ) P o we r I nput
4

Not Us e d
5 658
( P K / L G )
Ma l f u n c t i o n I n d i c a t o r L a mp I nput
6 _
No t Us e d
7 No t Us e d
8 450
( DG / L G )
Se a t Be l t Wa r n i n g I n d i c a t o r I n put
9 67 6
( P K / O )
Si gn a l Gr o un d
10 3 (LG/ W) LH Tur n Si gn a l I n d i c a t o r I nput
11 88 ( B K / W) I l l umi n a t i o n Fe e d
12 904
( L G / R )
Ge n e r a t o r Ch a r g e I n d i c a t o r L a mp
I nput i
13

No t Us e d
14 67 9
( G Y/ B K )
Ve hi c l e S p e e d Se n s o r Si gn a l
15 419
( DG / L G )
Ai r Su s p e n s i o n I n d i c a t o r I nput (-)
16 1053
( L B / P K )
1995 To wn Ca r , Cr o wn Vi c t o r i a , G r a n d Ma r q u i s J u l y 1994
13- 00- 18 I nst r ument Cl ust er and Panel Li ght i ng 13- 00- 18
HEADLAMP SWI TCH
CONNECTOR C1
K22691-A
P i n
1 1036
( B R / W)
Pa n e l Di mme r ( Do wn ) Swi t c h
2 195 ( T / W) Ba t t e r y Vo l t a ge
3
___
No t Us e d
4 1035
( O / R )
Pa n e l Di mme r ( Up) S wi t c h
5 484
( O / B K )
2 96
( W/ P ) *
R u n / A C C B - f Vo l t a ge
6 No t Us e d
7 No t Us e d |
0 5 7 ( B ! 0 L o g i c Gr o un d
* Crown Vi ct or i a, Grand Marqui s
HEADLAMP SWI TCH
CONNECTOR C2 K22692-A
P i n
2 484
( O / B K )
2 96
( W/ P ) *
R u n / A C C B - f Vo l t a ge
Pin
3 1032
( W/ B K )
4 2 2 0 ( P / O ) Au t o l a mp De l a y
! 5
....
No t Us e d
6 8 8 ( B K / W )
1034
( B K / W) *
9 2 17
( DB / O )
10

No t Us e d
11 2 2 2
(BR/LG)
1 2
-
No t Us e d
Crown Vi ct ori a, Grand Marqui s
1. NOTE: El ect roni c cl ust er only wo r ks in run.
Veri fy t he vehi cl e owner ' s ori gi nal concer n by
operat i ng t he i nst rument cl ust er ( 10849) t o
dupl i cat e t he condi t i on and by observi ng t he
i ndi cat ors and gauges t o det ermi ne if t hey are
operat i ng properl y wi t h t he i gni ti on swi t c h
( 11572) :
Convent i onal cl ust er.
In RUN wi t hout t he engi ne runni ng.
In START bef ore t he i gni ti on swi t c h is rel eased.
In RUN wi t h t he engi ne runni ng.
2. Inspect t o det ermi ne if any of t he f ol l owi ng
Da ma g e d f uel t a n k.
En gi n e c o o l a n t l e v e l .
En gi n e oi l l e v e l .
A c c e s s o r y d r i v e be l t .
Fu s e .
Ci r c ui t wi r i n g.
S wi t c h e s o r s e n s o r s .
If t he concern(s) remai ns af t er t he i nspect i on,
det ermi ne t he sy mpt oms and go t o t he Sy mpt om
Chart .
S y m p t o m Ch a r t
Use Rot unda Di gi tal Vol t -Ohmmet er 014- 00407 or
equi valent t o perf orm el ect ri cal t e st s.
13- 00- 19 i n s t r u me n t Cl us t e r a n d Pa n e l L i gh t i n g 13- 00- 19
INSTRUMENT CLUSTER AND PANEL LIGHTING
Co n t r o l I l l umi na t i on I n o pe r a t i v e Fuse 13.
e He a d l a mp s wi t c h .
I nst r ume nt Cl ust e r I l l umi nat i on
I n o pe r a t i v e
Di mi ng l evel not ma x .
I l l umi nat i on bul bs c o n v e n t i o n a l
c l ust e r .
e I nst r ume nt c l ust e r pr i n t e d c i r c ui t .
Cl i ma t e Co n t r o l I l l umi nat i on
I l l umi nat i on bul bs.
Aud i o Sy s t e m I l l umi nat i on
Si ngl e I l l umi na t i on So ur c e
e Ci r c ui t wi r i n g.
Pi npoi nt Test s
PINPOINT TEST A: CONTROL ILLUMINATION INOPERATIVE
A1 CHECK PULSE WI DTH MODULATED DI MMI NG
Ye s
No
TURN of f pa r kl a mps , GO
t o A4.
G O t o A2.
Turn i gni t i on of f .
Turn h e a d l a mps s wi t c h t o pa r k l a mps po s i t i o n .
Do parkl amps t urn on and swi t ches on
i nst r ument panel l i ght ?
Ye s
No
TURN of f pa r kl a mps , GO
t o A4.
G O t o A2.
A2 CHECK PARKLAMPS
Ye s
No
G O t o A 3 .
Turn of f pa r kl a mps , t e s t
Fuse 4 or 15 Town Car . If
g o o d , GO t o A16.
e Turn i gni t i on of f .
Turn he a d l a mps s wi t c h t o pa r kl a mps po s i t i o n .
Do parkl amps t urn on?
Ye s
No
G O t o A 3 .
Turn of f pa r kl a mps , t e s t
Fuse 4 or 15 Town Car . If
g o o d , GO t o A16.
A3 CHECK PANEL LI GHTS
Ye s
No
TURN of f pa r kl a mps ,
TEST Fuse 4 or 15 To wn
Car. if g o o d , GO t o A16.
G O t o A4.
e Turn i gni t i on of f .
Turn he a d l a mps s wi t c h t o pa r kl a mps po s i t i o n .
Do parkl amps t urn o n , and p a n e l l i ght d o not ?
Ye s
No
TURN of f pa r kl a mps ,
TEST Fuse 4 or 15 To wn
Car. if g o o d , GO t o A16.
G O t o A4.
A4 CHECK VARI ABLE VOLTAGE DI MMI NG BACKLI GHT
Ye s
No
GO t o A7.
G O t o A5.
e Turn i gni t i on t o r un. Wa i t f o r d i s pl a y s t o i l l umi na t e .
Turn he a d l a mps s wi t c h t o pa r kl a mps po si t i o n .
Do di spl ays di m sl i ght l y when l i ght s t ur n on?
Ye s
No
GO t o A7.
G O t o A5.
A5 CHECK DI MMI NG BACKLI GHT, ONE DI MS OTHERS
DON' T
Ye s
No
TEST f o r v o l t a ge on
c i r c ui t 1 9 ( B / R ) i nt o
mo d ul e c o n t r o l l i n g
d i s pl a y whi ch d o e s not
d i m. If v o l t a ge r e a d s
gr e a t e r than 2 v o l t s ,
r e pl a c e d i spl a y mo d ul e , i f
v o l t a ge i s l e ss than 2
v o l t s , SERVI CE Ci r c ui t 19
( L B/ R) r e t e st s y s t e m.
G O t o A6.
e Turn i gni t i on t o r un. Wa i t f o r d i s pl a y s t o i l l umi na t e ,
e Turn he a d l a mps s wi t c h t o pa r kl a mps po s i t i o n .
Does at least one di spl ay d i m , a n d at l east o n e
di spl ay does not di m?
Ye s
No
TEST f o r v o l t a ge on
c i r c ui t 1 9 ( B / R ) i nt o
mo d ul e c o n t r o l l i n g
d i s pl a y whi ch d o e s not
d i m. If v o l t a ge r e a d s
gr e a t e r than 2 v o l t s ,
r e pl a c e d i spl a y mo d ul e , i f
v o l t a ge i s l e ss than 2
v o l t s , SERVI CE Ci r c ui t 19
( L B/ R) r e t e st s y s t e m.
G O t o A6.
A6 CHECK DI MMI NG BACKLI GHT, NO BACKLI GHT
DI MMI NG
Ye s
No
G O t o A I S .
G O t o A7.
e Turn i gni t i on t o r un. Wai t f or d i s pl a y s t o i l l umi nat e,
e Turn he a d l a mps s wi t c h t o pa r kl a mps po s i t i o n ,
e Do all di spl ays not d i m?
Ye s
No
G O t o A I S .
G O t o A7.
13- 00- 2 0 I n s t r u me n t Cl u s t e r a n d Pa n e l L i gh t i n g 13- 00- 2 0
PINPOINT TEST A: CONTROL ILLUMINATION INOPERATIVE (Cont i nued)
A 7 CHECK PANEL DI MMI NG SWI TCH
Ye s
No
Sy s t e m i s o pe r a t i n g
nor ma l l y .
G O t o A8.
Turn i gni t i on t o run. Wai t f or d i spl a y s t o i l l umi na t e .
Turn he a d l a mps swi t c h t o pa r kl a mps po si t i o n .
De pr e ss pa ne l di m i n c r e a se s wi t c h f or se v e r a l
s e c o n d s .
Do vi sual di spl ays and s w i t c h b a c k l i g h t s
i ncrease and decrease w i t h s w i t c h ?
Ye s
No
Sy s t e m i s o pe r a t i n g
nor ma l l y .
G O t o A8.
A8 CHECK PANEL DI MMER I NTENSI TY
Ye s
No
REPLACE l i ght i ng c o n t r o l
mo d ul e . RETEST s y s t e m.
GO t o A9.
Turn i gni t i on t o run, wa i t f or d i s pl a y s t o i l l umi na t e .
De pr e ss pa n e l . Di m i n c r e a se s wi t c h f or se v e r a l
s e c o n d s .
Does p a n e l s w i t c h e s i n t e n s i t y c h a n g e , di spl ays
st ay at maxi mum l i gh t on i n t e n s i t y ?
Ye s
No
GO t o A9.
A9 CHECK PANEL DI MMER SWI TCH I NTENSI TY
Ye s
No P >
CHECK c i r c ui t 484
( O/ BK ) f or sho r t t o B + . If
c i r c ui t i s go o d , REPLACE
l i ght i n g c o n t r o l mo d ul e .
RETEST s y s t e m.
GO t o A 1 0 .
Turn i gni t i on t o run. Wai t f or d i s pl a y s t o i l l umi na t e .
s e c o n d s .
Does di spl ays i n t e n s i t y c h a n g e , s w i t c h e s st ay at
maxi mum i n t e n s i t y .
Ye s
No P >
( O/ BK ) f or sho r t t o B + . If
c i r c ui t i s go o d , REPLACE
RETEST s y s t e m.
GO t o A 1 0 .
A 1 0 CHECK PANEL DI MMER AND I NCREASE OR
DECREASE
Ye s
No
G O t o A 1 1 .
REPLACE l i ght i n g c o n t r o l
Turn i gni t i on t o run. Wai t f or d i s pl a y s t o i l l umi na t e .
s e c o n d s .
Do e s s w i t c h e s a n d di spl ays i n c r e a s e but do not
d e c r e a s e , o r d e c r e a s e b u t d o n o t i n c r e a s e , or
st ay a t one i n t e n s i t y ?
Ye s
No
G O t o A 1 1 .
A11 CHECK PANEL DI M SWI TCH
Ye s
No
GO t o A 1 4 .
G O t o A 1 2 .
Co n n e c t new ge n e r a t i o n st a r t e s t e r t o d a t a l i nk
c o n n e c t o r .
Re que st pa ne l ba c kl i ght c o n t r o l i nput s wi t c h s t a t us .
Does d a t a i n d i c a t e b o t h s w i t c h e s n o t act i ve?
Ye s
No
GO t o A 1 4 .
G O t o A 1 2 .
A 1 2 CHECK PANEL DI M SWI TCH I NCREASE ACTI VE
Ye s
No
( O/ R) f o r sho r t t o ba t t e r y
or st uc k s wi t c h . RETEST
s y s t e m.
G O t o A 1 3 .
Usi ng t he new generation star tester, r e que st panel
ba c kl i ght c o n t r o l i nput s wi t c h s t a t us .
Does d a t a i n d i c a t e i n c r e a s e s w i t c h act i ve?
Ye s
No
( O/ R) f o r sho r t t o ba t t e r y
or st uc k s wi t c h . RETEST
s y s t e m.
G O t o A 1 3 .
A 1 3 CHECK PANEL DI M SWI TCH DECREASE ACTI VE
Ye s f >
No
( BR/ W) f or sho r t t o
ba t t e r y or st uc k s wi t c h .
RETEST s y s t e m.
GO t o A 1 4 .
Usi ng t he ne w ge n e r a t i o n st a r t e st e r , r e que st pa n e l
b a c k c o n t r o l i nput s wi t c h s t a t us .
Does d a t a i n d i c a t e d e c r e a s e s w i t c h act i ve?
Ye s f >
No
( BR/ W) f or sho r t t o
ba t t e r y or st uc k s wi t c h .
RETEST s y s t e m.
GO t o A 1 4 .
A 1 4 CHECK PANEL DI M DECREASE SWI TCH
Ye s
No
G O t o A 1 5 .
( BR/ W) f o r o pe n c i r c ui t
or ba d s wi t c h . RETEST
s y s t e m.
Whi l e ho l d i n g pa n e l di m d e c r e a s e s wi t c h , r e que st
pa n e l ba c kl i ght c o n t r o l i nput s wi t c h s t a t u s .
Does d a t a i n d i c a t e s w i t c h a c t i v e ?
Ye s
No
G O t o A 1 5 .
( BR/ W) f o r o pe n c i r c ui t
or ba d s wi t c h . RETEST
s y s t e m.
A 1 5 CHECK PANEL DI M I NCREASE SWI TCH
Ye s
No
G O t o A 1 6 .
( O/ R) f or o pe n c i r c ui t or
b a d s wi t c h . RETEST
s y s t e m.
Whi l e ho l d i n g pa n e l di m i n c r e a se s wi t c h , r e que st
pa n e l ba c kl i ght c o n t r o l i nput s wi t c h s t a t u s .
Does d a t a i n d i c a t e s w i t c h a c t i v e ?
Ye s
No
G O t o A 1 6 .
( O/ R) f or o pe n c i r c ui t or
b a d s wi t c h . RETEST
s y s t e m.
13- 00- 2 1 I n s t r u me n t Cl us t e r a n d Pa n e l L i gh t i n g 13- 00- 2 1
PI NPOI NT TE ST A: CONT ROL I L L UMI NATI ON I NOPERATI VE ( Co n t i n u e d )
T E ST STEP RESULT A CT I ON TO T A KE
A16 CHECK POWER FEED
Ye s
No
G Ot o A 1 7 .
CHECK c i r c ui t 195 ( T / W)
or 2 2 1 ( O / W) To wn c a r
f or o pe n c i r c ui t o r ba d
s wi t c h . RETEST s y s t e m.
Re mo v e connector C3 f r o m l i ght i n g c o n t r o l mo d ul e .
Re a d v o l t a ge at Pi n C3-6.
I s v o l t a g e readi ng B4-?
Ye s
No
G Ot o A 1 7 .
CHECK c i r c ui t 195 ( T / W)
or 2 2 1 ( O / W) To wn c a r
f or o pe n c i r c ui t o r ba d
s wi t c h . RETEST s y s t e m.
A 17 CHECK P WM OUTPUT
Ye s ^
No
RETEST s y s t e m.
Usi ng a j umpe r wi r e , sho r t Pi n C3- 6 t o Pi n 03- 12 .
Do s w i t c h b a c k l i g h t s t u r n o n ?
Ye s ^
No
RETEST s y s t e m.
A 18 CHECK POWER FEED
Ye s
No
GO t o A 1 9 .
CHECK Ci r c ui t 54 ( L G / Y)
or (195 ( T / W) Town Ca r )
f or o pe n c i r c ui t . RETEST
s y s t e m.
Re mo v e c o n n e c t o r C3 f r o m l i ght i n g c o n t r o l mo d ul e .
Re a d v o l t a ge at Pi n C3- 11.
Is v o l t a g e r e a d i n g B+ ?
Ye s
No
GO t o A 1 9 .
CHECK Ci r c ui t 54 ( L G / Y)
or (195 ( T / W) Town Ca r )
s y s t e m.
A 19 CHECK W D B OUTPUT
Ye s >
No
CHECK c i r c ui t 1 9 ( L B / R )
s y s t e m.
Usi ng a j umpe r wi r e , sho r t Pi n C3- 6 t o Pi n 03- 12 .
Do d i s p l a y s d i m?
Ye s >
No
CHECK c i r c ui t 1 9 ( L B / R )
s y s t e m.
PI NPOI NT TE ST B: I NSTRUMENT CL USTE R I LLUMI NATI ON I NOPERATI VE
T E ST STEP RESULT ACTION TO T A KE
B1 CHECK DI MMER SWI TCH OPERATI ON
Ye s
No
TURN he a d l a mp s wi t c h
of f . GO t o B5.
of f . GO t o B2 .
Turn he a d l a mp s wi t c h t o PARK po s i t i o n .
A c t u a t e pa n e l d i mme r s wi t c h t o ma x i mum wi t ho ut
t ur n i n g on d o me l a mps.
A r e a l l i n s t r u me n t c l u s t e r i l l u mi n a t i o n b u l b s o f f
( c o n v e n t i o n a l c l u s t e r ) ?
Ye s
No
of f . GO t o B5.
of f . GO t o B2 .
32 CHECK LH TURN SI GNAL I NDI CATOR
Ye s
No
GO t o 84.
G Ot o B3.
Turn i gni t i on s wi t c h t o RUN po s i t i o n .
@ Turn on LH t urn si gn a l .
Do e s LH t u r n i n d i c a t o r f l a s h ?
Ye s
No
GO t o 84.
G Ot o B3.
B3 CHECK GROUND CIRCUIT
Ye s
No >
REPLACE pr i n t e d c i r c ui t .
RESTORE s y s t e m.
RETEST s y s t e m.
SERVI CE o pe n in Ci r c ui t
1, Ci r c ui t 67 6 ( P K/ O)
Town Car Pi n 18, Ci r c ui t
57 ( BK) Cr o wn Vi c t o r i a
Pi n 7, Ci r cui t 57 ( BK)
Gr a n d Ma r qui s.
RETEST s y s t e m.
Turn i gni t i on s wi t c h t o OFF po si t i o n
Re mo v e i nst r ume nt c l ust e r . Re f e r t o Se c t i o n
13- 01B.
Ch e c k c o n t i n ui t y be t we e n Pi n 1, Ci r c ui t 67 6 ( P K/ O)
To wn Car, Pi n 18, Ci r c ui t 57 ( BK) Cr o wn Vi c t o r i a Pi n
7, Ci r c ui t 57 ( BK) Gr a nd Ma r qui s of i n st r ume n t
c l us t e r c o n n e c t o r J2 a nd gr o un d .
Is t h e r e c o n t i n u i t y ?
Ye s
No >
RETEST s y s t e m.
1, Ci r c ui t 67 6 ( P K/ O)
Town Car Pi n 18, Ci r c ui t
57 ( BK) Cr o wn Vi c t o r i a
Pi n 7, Ci r cui t 57 ( BK)
Gr a n d Ma r qui s.
RETEST s y s t e m.
B4 CHECK I LLUMI NATI ON BUL BS
Ye s .
No EN-
RETEST s y s t e m.
REPLACE bur n e d out
bul bs. RESTORE s y s t e m.
RETEST s y s t e m.
Re mo v e i l l umi nat i on bul bs f r o m i n st r ume n t c l ust e r .
Ch e c k c ont i nui t y of bul bs.
Do a l l b u l b s h a v e c o n t i n u i t y ?
Ye s .
No EN-
RETEST s y s t e m.
REPLACE bur n e d out
bul bs. RESTORE s y s t e m.
RETEST s y s t e m.
13- 00- 2 2 I n s t r u me n t Cl u s t e r a n d Pa n e l L i gh t i n g 13- 00- 2 2
PINPOINT TEST B: INSTRUMENT CLUSTER ILLUMINATION INOPERATIVE (Cont i nued)
T E ST STEP RESULT A CT I ON TO TA KE
B5 C H E C K C I R C U I T 19 ( L B / R )
Ye s
No
G O t o C L
19 ( L B/ R) . RESTORE
s y s t e m. RETEST s y s t e m.
Re mo v e i nst r ume nt c l ust e r . Re f e r t o Se c t i o n 13- 01A
( El e c t r o n i c ) 13-01B ( Co n v e n t i o n a l ) .
Pul l he a d l a mp s wi t c h t o PARK po si t i o n .
Me a sur e v o l t a ge at Pi n 29, Town Car, 15 Cr o wn
Vi c t o r i a , 1 Gr a n d Ma r qui s of i nst r ume nt c l ust e r
c o n n e c t o r J2 .
Ye s
No
G O t o C L
PINPOINT TEST C: CLIMATE CONTROL ILLUMINATION INOPERATIVE
C1 CHECK CI RCUI T 19 L B / R
Ye s
No
GO t o C2.
e Re mo v e A / C he a t e r c o n t r o l . Re f e r t o Se c t i o n
12-03A.
e Di sc o n n e c t c o n t r o l i l l umi nat i on bul b c o n n e c t o r .
Turn he a d l a mp s wi t c h t o PARK po si t i o n .
e Ac t u a t e pa n e l d i mme r s wi t c h t o ma x i mum wi t ho ut
t ur n i n g on d o me l a mps,
e Me a s ur e v o l t a ge be t we e n Ci r c ui t 19 ( LB / R) a n d
gr o un d .
e Is bat t er y vol t age pr esent ?
Ye s
No
GO t o C2.
C2 CHECK CI RCUI T 57 BK
Ye s
No
REPLACE i l l umi nat i on
bul b. RESTORE s y s t e m.
RETEST s y s t e m.
57 ( BK) . RESTORE
e Me a s ur e r e s i s t a n c e be t we e n Ci r c ui t 57 BK a n d
gr o un d .
Ye s
No
REPLACE i l l umi nat i on
RETEST s y s t e m.
57 ( BK) . RESTORE
PINPOINT TEST D: AUDIO SYSTEM ILLUMINATION INOPERATIVE
T E ST STEP RESULT A CTI ON TO TA KE
D1 CHECK CI RCUI T 19 ( L B / R)
Ye s
No
GO t o D2 .
Re mo v e r a d i o c h a s s i s or d i gi t a l a ud i o c o mp a c t d i sc
pl a y e r . Re f e r t o Se c t i o n 15- 01.
e Di sc o n n e c t c o n n e c t o r s ,
e Turn he a d l a mp s wi t c h t o PARK po si t i o n .
t ur n i n g on d o me l a mp.
Me a s ur e v o l t a ge be t we e n Ci r c ui t 19 ( LB / R) a n d
gr o un d .
e Is bat t er y vol t age pr esent ?
Ye s
No
GO t o D2 .
D2 CHECK CI RCUI T 57 ( BK)
Ye s
No
REMOVE r a d i o c h a s s i s
or d i gi t a l a ud i o c o mp a c t
d i s c pl a y e r f or s e r v i c e .
57 ( BK) . RESTORE
Me a s ur e r e s i s t a n c e be t we e n Ci r c ui t 57 ( BK) a n d
gr o un d .
Ye s
No
REMOVE r a d i o c h a s s i s
or d i gi t a l a ud i o c o mp a c t
d i s c pl a y e r f or s e r v i c e .
57 ( BK) . RESTORE
PINPOINT TEST E: SINGLE ILLUMINATION SOURCE INOPERATIVE
E 1 CHECK CI RCUI T 19 ( L B / R )
Ye s
No
G O t o E 2 .
Di sc o n n e c t c o n n e c t o r ( s ) t o i n o pe r a t i v e i l l umi na t i on
s o u r c e .
Turn he a d l a mp s wi t c h t o PARK po si t i o n .
t ur n i n g on d o me l a mps.
Me a s u r e v o l t a ge b e t we e n Ci r c ui t 19 ( LB / R) a n d
gr o un d .
Ye s
No
G O t o E 2 .
13- 00- 2 3 I n s t r u me n t Cl u s t e r a n d Pa n e l L i g h t i n g 13- 00- 2 3
PINPOINT TEST E: SINGLE ILLUMINATION SOURCE INOPERATIVE (Cont i nued)
E2 CHECK CI RCUI T 57 ( BK)
Ye s
No
GO t o E3.
57 ( BK) . RESTORE
Me a s ur e r e s i s t a n c e be t we e n Ci r c ui t 57 ( BK) a n d
gr o un d .
I s r e s i s t a n c e l e s s t h a n 5 o h ms ?
Ye s
No
GO t o E3.
57 ( BK) . RESTORE
E3 DETERMI NE SERVI CEABI LI TY OF BUL B
Ye s
No
REPLACE i l l umi na t i on
RETEST s y s t e m.
REPLACE c o mpo n e n t .
RETEST s y s t e m.
Che c k c o n t i n ui t y of bul b.
I s i l l umi nat i on b u l b s e r v i c e a b l e ?
Ye s
No
REPLACE i l l umi na t i on
RETEST s y s t e m.
REPLACE c o mpo n e n t .
RETEST s y s t e m.
Instrument Cluster Lamps
Bulbs, Miniature
Ref er t o Sect i on 13-01B.
Cli mat e Cont rol Lamps
Bulbs, Miniature
Audi o Syst em Lamps
Bulbs, Miniature
ROTUNDA EQUIPMENT
13- 01A - 1 I n s t r u me n t C l u s t e r E l e c t r o n i c 13- 01A - 1
SECTION 13-01A Instrument ClusterElectronic
SUBJECT PAGE
VEHI CLE APPLICATION . .......... 13-01A-1
Coolant Temperature Indication Syst em ...13-01A-5
El ect roni c I nst rument Cl ust er (EIC)... 13-01A-1
Fuel Indication Syst em . . . . . 13- 01A- 3
Message Cent er Cont r ol Assembl y (MCCA)
Swi t ch Module 13-01A-5
Message Cent er Di spl ays 13-01A-6
Odomet er. . . . 13-01A-5
Spe e dome t e r . . 13-01A-5
Warni ng I ndi cat ors 13-01 A-7
El ect ri cal Sc he ma t i c sTown Car 13-01A-9
I nspect i on and Veri f i cat i on ..13-01A-26
SUBJECT PAGE
Pi npoi nt Test s 13-01A-30
Sy mpt om Chart s ........ 13-01A-27
El ect roni c I nst rument Cl ust er (EIC) .... 13-01A-53
Message Cent er Cont r ol Assembl y (MCCA)
Swi t ch Modul e ...13-01A-54
I nst rument Panel Lamp Socket and
Bulb .. 13-01A-55
Transmi ssi on Range I ndi c a t or Col umn
Shi f t 13-01A-55
VEHICLE APPLICATION
Electronic Instrument Cluster (EIC)
The el ect roni c i nst rument sy st e m is made up of t wo
assembl i es. These assembl i es are:
An el ect roni c i nst rument cl ust er (10849)(EI C).
A message cent er cont rol assembl y (MCCA)
message cent er swi t c h modul e ( 10D996) modul e.
13- 01A - 2 I nst r ument Cl us t er El ec t r oni c 13- 01A - 2
The el ect roni c i nst rument cl ust er (EIC) consi st s of one
mi cr ocomput er -based modul e t ha t pr oc e sse s sensor
i nf ormat i on and cont r ol s t he t hr ee vacuum f l uorescent
(VF) di spl ay s. The di spl ays i ncl ude t he
speedomet er / odomet er, t he el ect roni c fuel and
engi ne cool ant t emper at ur e gauges, and t he message
cent er cont r ol assembl y (MCCA). The Town Car has a
c o mpa ss di spl ay f or t he c ompa ss opt i on. The
f ol l owi ng warni ng i ndi cat ors ar e al so i ncl uded in t he VF
di spl ays:
LH Di spl ay Warni ngs:
AIR BAG* (Cr own Vi c t or i a , Grand Mar qui s).
ANTI -LOCK* (Cr own Vi c t or i a , Grand Mar qui s).
Chargi ng Sy st em*.
Check Engine*.
Saf et y Belt* (Cr own Vi ct or i a, Grand Marqui s).
Oil Pressure* (Cr own Vi ct or i a, Grand Mar qui s).
Cent er Di spl ay War ni ngs:
Hi gh Beams*.
Lef t Turn Si gnal * (Cr own Vi ct or i a, Grand Mar qui s).
Ri ght Turn Si gnal * (Cr own Vi ct or i a, Grand Mar qui s).
RH Di spl ay Warni ngs:
CHECK AIR SUSPENSI ON.
OVERDRIVE OFF.
DOOR AJAR.
LUGGAGE COMPARTMENT (TRUNK) AJAR.
LOW WASHER FLUI D.
T h e s e warni ng i ndi cat or s cannot be di mme d.
1 3 - 01A - 3 I nst r ument Cl ust er El ect r oni c
13- 01A - 3
The el ect roni c i nst rument cl ust er is operat i onal only
when t he i gni ti on swi t c h ( 1157 2) is in RUN. The
el ect roni c vacuum f l uorescent di spl ays ar e powe r e d
by a nonservi ceabl e i nternal power suppl y. The only
illumination bulb used, whi ch is not servi ceabl e, is f or
backl i ght i ng of t he t ransmi ssi on range i ndi cat or
(PRND21). When t he headl amps ( 13008) ar e t urned
on, t he i nst rument cl ust er di ms accor di ng t o t he
i nteri or li ght i ng cont rol paddl e posi t i on (e xc e pt t hose
warni ngs i ndi cat ed above, whi c h do not di m).
MESSAGE CENTER
CONTROL ASSY
(MCCA)
"8"
CHBX AM SUSPBSON DOOR
OVBSflVECM? M M
mm AJAR LTR/lOOttnt
CD
TOWN CAR
TRANSMISSION
CONTROL SELECTOR
INDICATOR
MESSAGE CENTER
CONTROL ASSY
(MCCA)
5
H
F 5S
eamm
22
MM
emeu-
* i s
, SLOWLY J f 3
8888888km
SPEED comm. O/DOFF
km/h
MPH
Q j PRN( 6) 21
cmcKAmsusmmoN mm
mSHERFim DOOR AJAR AMR
^ 8 8 3 f t
m/mkm
l n
TRANSMISSION
CONTROL SELECTOR
INDICATOR
K22S36-A
EI C Di s p l a y P r o v e - Ou t
The EIC di spl ay pr ove out ope r a t e s in t he f ol l owi ng
manner:
Each t i me t he i gni ti on swi t c h is t urned f r om OFF t o
RUN, t he t hr ee el ect roni c di spl ay s wi ll pr ove out by
moment ari l y li ght i ng all of t he segment s and t hen
moment ari l y t urni ng all di spl ay segment s of f .
Af t er t he pr ove out , t he t hr ee di spl ays ret urn t o
normal oper at i on.
Prove out mode i ndi cat es t ha t all di spl ay segment s
are f unct i oni ng properl y.
Af t er initial prove-out peri od wi t h ignition swi t c h in
RUN, t hese warni ng i ndi cat ors are off wi t h t he
engi ne on (warni ngs wi ll be on if in RUN, engi ne
OFF).
When i nst rument cl ust er r ecei ves a si gnal f r om a
sensor, t he i nst rument cl ust er pr oc e sse s t hat si gnal
and t urns on t he r espect i ve i ndi cat or.
For exampl e, if t he AIR BAG i ndi cat or is on or
f l ashi ng, t he air ba g di agnost i c moni t or
( 14B056) has de t e c t e d a fault in t he
suppl ement al rest rai nt sy st e m.
It wa r ns t he dri ver by sendi ng a si gnal t o t he
i nst rument cl ust er.
Consequent l y t he i nst rument cl ust er t urns on
AIR BAG i ndi cat or.
When t he OVERDRI VE OFF i ndi cat or is on, t hat
i s because t he power t r ai n cont rol modul e
(PCM)( 12A650) (PCM) has sent a si gnal t o t he
i nst rument cl ust er i ndi cat i ng t hat t ransmi ssi on
OVERDRI VE range is l oc ke d out .
There ar e t hr e e except i ons t o proveout .
The t urn si gnal and hi gh beam i ndi cat ors wi l l not
light duri ng pr ove out .
In addi t i on, t he BRAKE, saf et y bel t , CHECK
ENGINE, AIR BAG, and oil pr essur e warni ng
i ndi cat ors wi ll remai n i llumi nated duri ng t he bl ank
port i on of pr ove out and t hen go blank at t he
begi nni ng of , or shor t l y af t er, normal i nst rument
cl ust er di spl ay.
The c ha r gi ng sy st e m war ni ng pr ove s out by l i ght i ng
when t he i gni ti on swi t c h i s in RUN, bef or e t he engi ne
is st a r t e d .
Fu e l I n d i c a t i o n S y s t e m
Fu e l G a u g e
The fuel gauge ope r a t e s in t he f ol l owi ng manner:
Fuel level i s di spl ay ed on a di gi t al bar gauge usi ng
14 ba r s f r o m t o p t o bot t om f or Town Car and 8 ba r s
f or Cr o wn Vi c t or i a , Grand Mar qui s.
An addi t i onal t wo-di gi t di spl ay (on t he me ssa ge
cent er ) sho ws t he a ppr oxi ma t e amount of f uel
remai ni ng in l i t ers or gal l ons f or Town Car.
Fuel remai ni ng i s di spl ayed in t he f ue l / t e mpe r a t ur e
gauge f or t he Cr own Vi c t or i a , Grand Mar qui s.
For f uel l evel s gr eat er t han 7 0 l i t ers ( 18 gal ),
t he l et t er F (full) i s di spl ay ed.
For f uel l evel s l ess t han 3 l i t ers (1 gal ), t he l et t er
E (e mpt y ) i s di spl ay ed.
Li t er or gal l on val ues ar e se l e c t e d by t he
Engl i sh/ Me t r i c but t on l ocat ed at t he l ower RH si de
of t he i nst rument cl ust er ( 10849) .
The di gi t al di spl ays are ba se d on a var yi ng current
f l ow f r om t he fuel sendi ng unit and fuel pump ( 9350) .
When t he fuel level is l ow, fuel sendi ng unit and
fuel pump resi st ance is l ow.
When t he fuel level is hi gh, fuel sendi ng unit and
fuel pump resi st ance is hi gh.
TOWN CAR
MESSAGE CENTER
CONTROL ASSY (MCCA)
CHECK
ENGI NE
H3
F
=
H\
COMPASS
EE SI
35 A\
MM
EE ^
S Q
CI RCL E
L SLOWLY J
SELECTED WI TH
MCCA I NSTRUMENT
I NDI CATOR SWI TCH
MODULE BUTTONS
CHECK AfB SUSPENSION TRUNK
WASHER FLUID DOOR AMR AMR
m/nokm
AVO
SPEED
TWP |
REMAIN]
COOLANT TEMPERATURE GAUGE,
FUEL GAUGE AND COMPASS
MESSAGE CENTER
CONTROL ASSY (MCCA)
B
CHECK
EM6INE
H = = F
Am
(8 =
88
* " -*.
Am
? =
LTR
GAL
* " -*.
E3
mm
TO
EMPTY C 5 5
TO
EMPTY
SS E
SELECTED WI TH
MCCA I NSTRUMENT
I NDI CATOR SWI TCH
MODULE BUTTONS
AVO 1
mm J
r INST 1
1 ECON J
1 T )|
T ) [ sib 1
K22837-A
The fuel pump sy mbol is a l wa y s on e xc e pt duri ng:
Check-out sequence - on / o f f / o n .
Lo w fuel level warni ng - t he fuel pump (ga s pump)
sy mbol f l ashes when appr oxi mat el y one-ei ght h of a
t ank of f uel remai ns.
Di a g n o s t i c Ba r s
Di agnost i c ba r s per f or m t he f ol l owi ng f unct i ons:
When onl y t he t o p and bo t t o m t wo ba r s appear on
t he fuel ga uge , t hi s i ndi cat es t hat t he r esi st ance of
t he fuel level sensor ( 927 5) i s a bove or bel ow t he
oper at i ng r esi st ance range (above 168 ohms or
bel ow 11 ohms).
Ei t her an open or shor t ci rcui t is present (ref er
t o Di agnosi s and Test i ng sect i on).
" CO" f or ci rcui t open or " CS" f or ci rcui t shor t
wi ll be di spl ay ed if Di gi t al Fuel Remai ni ng or
Di st ance t o Empt y f unct i on is sel ect ed (ref er t o
Di agnosi s and Test i ng).
Ther e is a built-in del ay of appr oxi mat el y 30
se c onds f r om t he t i me t he ci rcui t open or shor t
o c c ur s until t he di agnost i c ba r s appear, al so a 30
se c ond del ay f or di spl ay t o ret urn in CO or CS
condi t i on is el i mi nat ed.
Thi s is t o prevent moment ary sender i nt ermi t t ent
condi t i ons or ci rcui t noi se f r o m t ri ggeri ng t he
di agnost i c bar s.
L o w Fu e l L e v e l Wa r n i n g
A l ow fuel al ert is gi ven by a f l ashi ng fuel pump sy mbol
when t he fuel remai ni ng is appr oxi mat el y one-ei ght h of
t he t ank.
Fu e l S e n d e r Un i t
The f uel sender unit, whi ch is combi ned wi t h t he fuel
pump assembl y t o f or m t he fuel pump modul e,
ope r a t e s in t he f ol l owi ng manner:
13- 01A - 6 I nst r ument Cl us t er El ec t r oni c 13- 01A - 6
7-...JL -:n
The unit consi st s of a vari abl e resi st or cont rol l ed by
t he level of an a t t a c he d f l oat in t he fuel t ank ( 9002) .
When t he fuel l evel is l ow, resi st ance in t he fuel
pump modul e is l ow and number of lit bar s is
minimal (f rom EMPTY posi t i on).
When t he fuel level is hi gh, t he r esi st ance in t he
fuel pump modul e i s hi gh and number of lit bars
is gr eat er (f r om EMPTY posi t i on).
Coolant T e mp e r a t u r e Indication System
Coolant Temperature Gauge
The cool ant t emper at ur e gauge has t he f ol l owi ng
f eat ur es:
Thi s gauge is i dent i f i ed by a t her momet er sy mbol .
H means hi gh t emper at ur e.
C means l ow t emper at ur e, and NORMAL means
normal t emper at ur e.
Thi s gauge i ndi cat es t he engi ne cool ant
t emper at ur e based on an operat i ng resi st ance
range f r om t he engi ne cool ant t emper at ur e sensor
(ECT sensorX 12A648) ( 13, 000 ohms maxi mum t o
2 00 ohms mi ni mum, f r om l ow t o hi gh t emper at ur e,
whe r e resi st ances above 13, 000 ohms i ndi cat e
t emper at ur es bel ow t he range of t he gauge).
The number of bar s lit i ncreases a s t he engi ne
wa r ms up (f rom t he l owest bar i nto t he normal
oper at i ng regi on).
It is accept abl e under cert ai n dri vi ng condi t i ons,
such as heavy t raf f i c or st op and go dri vi ng in hot
weat her , f or t he bar t o poi nt t o t he t o p of t he normal
regi on.
Diagnostic Bars
Di agnost i c bar s on t hi s gauge i ndi cat e t hat t he
r esi st ance of engi ne cool ant t emper at ur e sensor is
l ower t han t he operat i ng resi st ance range (l ess t han
2 00 ohms).
When t he t op t wo and bot t om t wo ba r s appear on
t he cool ant t emper at ur e gauge, a shor t ci rcui t may
be present (ref er t o Di agnosi s and Test i ng).
When t he bot t om bar and t he t he r mome t e r and
TEMP di spl ays appear, an open ci rcui t may be
present .
High C o o l a n t Temperature Warning
When t he engi ne cool ant is overheat i ng:
The ba r s in t he cool ant t emper at ur e gauge ri se
a bove t he normal range.
The t emper at ur e sy mbol f l ashes.
A t one sounds ever y f i ve seconds t o al ert t he dri ver.
Engine Coolant Temperature (ECT) Sensor
Engi ne cool ant t emper at ur e sensor:
Is mount ed i nto t he engi ne i nt ake mani f ol d ( 9424) .
Sends a si gnal sent t o EIC whi c h var i es wi t h t he
r esi st ance of engi ne cool ant t e mpe r a t ur e sensor
rel at i ve t o t he engi ne cool ant t emper at ur e.
Speedometer
NOTE: The sy mbol K M/ H si gni f i es a met ri c spe e d
di spl ay and t he sy mbol MPH si gni f i es an Engli sh unit
speed di spl ay. Uni ts are cont r ol l ed by t h e E / M but t on.
The speedomet er di spl ay:
Provi des speed i nf ormat i on based on a
spe e d / d i st a n c e pulse si gnal (speci f i c number of
pul ses per mi le) f r om t he t ransmi ssi on-mount ed
vehi cl e speed sensor (VSS)(9E731).
Is li mi t ed t o a maxi mum of 193 k m/ h ( 120 mph).
Odometer
The odomet er ope r a t e s in t he f ol l owi ng manner:
Di spl ays ei t her mi les or ki l omet ers by pressi ng t he
E / M but t on.
Di spl ays seven di gi t s, wi t h t he last di gi t in t ent hs of
a unit.
The odomet er range is li mi t ed by t he i nst rument
cl ust er memory spa c e .
The English uni ts range f r om 000000. 5 t o
92 5691. 9 mi l es. (The di spl ay wi ll f r eeze at t hi s
val ue.)
The met ri c range is f r om 000000. 8 t o
858993. 4 km whe r e t he value wi ll roll over t o
000000. 0 and cont i nue accumul at i ng up t o
62 2 113. 6 km (t he equi val ent of 92 5691. 9 t ot al
mi les).
If t he mi l eage on t he ori gi nal odomet er is unknown,
t he repl acement odomet er wi ll show no mi l eage.
Then t he S sy mbol is a l wa y s di spl ayed when t he
EIC is t urned on (e xc e pt duri ng t he OFF port i on of
prove-out ).
If t he act ual vehi cl e mi leage can be veri f i ed, an
aut hori zed servi ce cent er can pr ogr am t he
repl acement odomet er t o ref l ect act ual mi l eage
(wi t hout t he S symbol ).
If a condi t i on exi st s wher e t he el ect roni c i nst rument
cl ust er ( 10849) cannot read a val i d odomet er
memor y f r om t he nonvolat i le el ect roni c memor y, t he
odomet er wi ll di spl ay t he wo r d ERROR.
Me s s a g e Center Control Assembly (MCCA)
Switch Module
The MCCA message cent er swi t c h modul e ( 10D996)
is l ocat ed i mmedi at el y t o t he ri ght of t he i nst rument
cl ust er ( 10849) . It consi st s of t hree but t ons:
13- 01A- 7 I n s t r u me n t C l u s t e r E l e c t r o n i c 13- 01A- 7
SELECT.
E / M,
RESET.
The EIC recei ves a resi st ance si gnal cor r espondi ng t o
t he but t on bei ng pr essed ( 17 , 600 ohms maxi mum,
range). A t one is sounded when t he but t on is pr essed.
S e l e c t
The SELECT but t ons di spl ay any of t he sel ect abl e
message cent er f unct i ons:
I nst ant aneous and aver age fuel economy (Town
Car ).
Tri p di st ance A (TRIP A) and B (TRIP B).
Di gi t al fuel remai ni ng (FUEL REMAI N)(Town Car).
I nst ant aneous fuel economy (INST ECONXCr own
Vi ct or i a, Grand Marqui s).
Ave r a ge fuel economy (AVG ECONXCr own
Vi ct or i a, Grand Marqui s).
Di st ance t o e mpt y (DIST TO EMPTY).
Aver age spe e d.
The hi ghl i ght ed box i ndi cat es t he f eat ure. The but t on
can be pr e sse d on t he ri ght ( f or wa r d) or left (r ever se)
si de t o move t he hi ghli ght box t o t he ri ght or t o t he left
menu sel ect i on.
E / M( E n g / Me t )
The E / M but t on di spl ays t he f unct i on in ei t her Engli sh
mode (MI LES PER GAL, GAL, MI LES) or met ri c mode
( LTR/ 100km, LTR, km). Thi s a f f e c t s bot h t he
el ect roni c i nst rument cl ust er (EIC) and el ect roni c
aut omat i c t emper at ur e cont rol sensor ( 19C734)
(EATC) if equi pped.
Re s e t
The RESET but t on r eset s t he cal l ed up message
cent er f unct i on a s f ol l ows:
Tri p di st ance reset t o zero.
Ave r a ge fuel economy is r eset t o t he i nst ant aneous
f uel e c onomy val ue.
Ave r a ge spe e d is reset t o i nst ant aneous.
Me s s a g e C e n t e r Di s p l a y s
The message cent er di spl ays cont ai n t he f ol l owi ng:
Ave r a ge spe e d (AVG SPEED).
Fuel remai ni ng (FUEL REMAI N)(Town Car ).
I nst ant aneous fuel e c onomy (INST ECONXCr own
Vi c t or i a , Gr and Marqui s).
w Ave r a ge fuel economy (AVG ECONXCr own
Vi c t or i a , Gr and Mar qui s).
Di st ance t o e mpt y (DIST TO EMPTY).
Tri p di st ance (TRIP A, TRIP B).
Ave r a ge and i nst ant aneousl y fuel economy (FUEL
ECONXTown Car ).
The me ssa ge cent er t a ke s in si gnal s f r o m t he
f ol l owi ng el ect roni c engi ne cont r ol s:
Vehi cl e speed sensor (VSSX9E731)
( spe e d / d i st a n c e ) .
Fuel pump module (fuel l evel ).
Power t r ai n cont rol modul e (PCM)( 12A650) (fuel
f l ow).
The me ssa ge cent er per f or ms cont i nuous cal cul at i ons
of a si gnal or si gnals t o suppl y t he i nf ormat i on f or each
me ssa ge cent er f unct i on.
Fu e l Re ma i n i n g
The fuel remai ni ng di spl ay:
I ndi cat es t he amount of fuel remai ni ng in t he fuel
t ank ( 9002) based on an operat i ng r esi st ance range
f r o m t he fuel pump ( 9350) ( 15 ohms mi ni mum t o
160 ohms maxi mum, empt y t o full t a nk).
Rounds t he val ues t o whol e numbers whi c h may
c a use t he gal l ons (U. S. )/ l i t e r s conversi on t o
di sagr ee sl i ght l y f r om dri ver cal cul at i on.
I n s t a n t a n e o u s Fu e l E c o n o m y
The i nst ant aneous fuel economy di spl ay:
Comput es i ts readi ng based on di st ance t r avel ed
(VSS si gnal) and fuel used (fuel f l ow si gnal f r om
PCM) i nf ormat i on.
Ma y i ndi cat e 0 t o 99 mi les per gallon or 1 t o 99
l i t ers / 100 ki l omet ers.
Di spl ays 0 miles per gallon or 99 l i t ers / 100
ki l omet er s.
Cannot be reset .
A v e r a g e Fu e l E c o n o m y
The aver age fuel economy di spl ay:
Comput es i t s readi ng f r om di st ance t r avel ed (VSS
si gnal ) and fuel used (fuel f l ow si gnal f r om PCM)
i nf ormat i on.
I ndi cat es t he value cal cul at ed si nce t he l ast reset .
Ma y be reset by pressi ng t he RESET but t on whi l e
t he aver age fuel economy f eat ure i s di spl ay ed.
Di s t a n c e t o E mp t y
The di st ance t o empt y di spl ay:
Is based on a cal cul at i on usi ng an aver age of t he
f uel economy over t he last 850 km ( 500 mi les) and
t he current fuel remai ni ng t o est i mat e t he di st ance
t hat can be dri ven wi t h remai ni ng f uel . Thi s di st ance
may i ncrease or decr ease dependi ng on t he most
recent dri vi ng condi t i ons.
Cannot be reset .
For pr oper di st ance t o empt y f unct i on, t he i gni ti on
swi t c h ( 1157 2) shoul d be t urned t o OFF when fuel is
bei ng a dde d t o t he fuel t ank
13- 01A - 8 I n s t r u me n t Cl u s t e r El ec t r oni c 13- 01A - 8
Whe n di st ance t o e mpt y dr ops t o 80 km ( 50 mi l es),
t he f uel comput er over r i des t he current di spl ayed
f unct i on, and f l ashes t he DIST TO EMPTY value f or
f i ve se c onds. The di spl ay r epeat s t hi s f unct i on at 40
and 16 km (25 and 10 mi l es).
T r i p Di s t a n c e
The t r i p di st ance f eat ur e:
Di spl ays t he el apsed di st ance si nce t he last reset
and can be used as a t r i p odomet er.
Can be r eset t o zer o by pressi ng t he RESET but t on
whi l e t he t r i p di st ance f eat ure is di spl ay ed.
Regi st ers up t o 999. 9 and changes t o 0. 0 when
999. 9 is e xc e e d e d .
TRIP A and TRIP B oper at e i ndependent l y.
Wa r n i n g I n d i c a t o r s
The warni ng i ndi cat or s i ncluded in t he el ect roni c
i nst rument cl ust er ( 10849) are di vi ded into t wo
cat egor i es as sho wn .
C a t e g o r y 1 ( Mi n o r Wa r n i n g )
All i ndi cat ors in t hi s c a t e gor y ope r a t e as f ol l ows
e x c e pt as not ed. Ca t e gor y 1 i ndi cat or s i nclude t he
f ol l owi ng:
MI NOR WARNI NG DEFINITION: Warni ng wi ll sound
one t one and f l ash on and off f or f i ve seconds.
Di mmi ng wi ll be overri dden whe n f l ashi ng if l ess t han
di scernabl e di mmi ng l evel .
CHECK AIR SUSPENSI ON.
DOOR AJAR.
m LUGGAGE COMPARTMENT (TRUNK) AJAR.
LOW WASHER FLUI D.
1. These i ndi cat ors cannot be di mmed whi l e
f l ashi ng.
2. Duri ng prove-out sequence, a one-second t one i s
sounded.
3. If a condi t i on is d e t e c t e d , t he i ndi cat or f l ashes f or
f i ve se c onds t hen remai ns lit.
4. The i ndi cat or go e s out when t he condi t i on is
r esol ved.
C a t e g o r y 2
Ca t e gor y 2 i ndi cat or s i nclude t he f ol l owi ng:
Seat Belt (no t one)*(Crown Vi c t or i a , Grand
Mar qui s).
AIR BAG (no t one is sounded)*(Crown Vi c t or i a ,
Gr and Mar qui s).
Chargi ng Sy st e m (no t one)*.
CHECK ENGINE (MI L) (no t one)*.
Oi l Pressure (no t one)(Cr own Vi c t or i a , Grand
Mar qui s).
1. These i ndi cat or s cannot be di mme d.
2. The i ndi cat ors remai n lit duri ng prove-out
sequence and possi bl y f or a shor t t i me af t er.
3. If a condi t i on is de t e c t e d, t he i ndi cat or l i ght s
cont i nuousl y.
4. The i ndi cat or goe s out when t he condi t i on i s
r esol ved.
5. No t one i s sounded.
I f t he AIR BAG i ndi cat or does not i llumi nate, a sa f e t y
bel t war ni ng chi me ( 10D840) modul e wi l l beep f i ve
t i mes. (Ref er t o Sect i on 01-20B f or Di agnosi ng and
Test i ng. )
In addi t i on t o t he warni ngs descr i bed above, t hr ee
i ndi cat ors are i ncl uded in t he cent er vacuum
f l uorescent (VF) t ube di spl ay. They ar e hi gh be a m,
ri ght t urn si gnal and left t urn si gnal i ndi cat ors, and ar e
all swi t c h-ope r a t e d. Turn si gnal s on Cr o wn Vi c t or i a ,
Gr and Marqui s only.
E x c e p t i o n :
The f ol l owi ng warni ng is present f or f our t o ei ght
se c onds onl y af t er t he i gni ti on swi t c h ( 1157 2 ) is
t urned t o RUN. (The t one t hat may a c c ompa ny t hi s
warni ng is i ndependent of i nst rument cl ust er cont r ol . )
Saf et y Belt* (Cr own Vi ct or i a, Grand Marqui s).
T h i s warni ng cannot be di mmed.
CHECK ENGI NE ( MI L)
The c he c k engi ne (MI L) warni ng i nf ormat i on i s sent by
t he power t r ai n cont rol modul e ( PCM) ( 12A650) on t he
d a t a communi cat i on link (DCL).
CHECK
ENGINE
K13906-B
CHARGI NG SYSTEM
Charge sy st e m warni ng (bat t er y sy mbol ) is di spl ayed
when t her e i s a concer n in t he char gi ng sy st e m.
The c ha r ge sy st e m warni ng (bat t er y symbol )
remai ns lit cont i nuousl y whi le t he concer n is
present .
. It goes out when t he concern is r e sol ve d.
Ref er t o Sect i on 14-00 f or addi t i onal i nf ormat i on.
L OW OI L PRESSURE ( C r o w n Vi c t o r i a , G r a n d
Ma r q u i s On l y )
If t he oil pressure dr ops bel ow t he normal range, t he
l ow oil pressure warni ng (oil can sy mbol ) l i ght s
cont i nuousl y. When t he oil pr essur e ret urns t o normal ,
t he warni ng goes out .
AI R S US P E NS I ON/ Ri DE CONT ROL
CHECK AIR SUSPENSI ON warni ng is di spl ayed when
t her e i s a concer n in t he air suspensi on cont r ol module
( 5A919) or ci rcui t ry.
CHECK AIR SUSPENSI ON warni ng f l ashes f or f i ve
se c onds, t hen remai ns lit.
When c onc e r n goe s a wa y t he warni ng st o ps.
Ref er t o Sect i on 04- 05 f or addi t i onal i nf ormat i on.
T RUNK A J A R
Thi s warni ng i ndi cat es t hat a l uggage compar t ment
door ( 40110) is aj ar or t her e is a concer n in t he
l uggage c ompa r t me nt door open warni ng l amp ci rcui t .
TRUNK AJAR warni ng f l ashes f or f i ve seconds,
t hen remai ns on.
When l uggage compar t ment door is cl osed or
concer n goe s a wa y , t he warni ng st ops.
DOOR A J A R
Thi s war ni ng i ndi cat es t hat a f ront or rear door is aj ar
or t her e is a concer n in t he door open warni ng l amp
ci rcui t .
DOOR AJAR warni ng f l ashes f or f i ve se c onds, t hen
remai ns on.
When t he f ront or rear door is cl osed or concer n
goe s a wa y , t he warni ng st ops.
L OW WA S HE R FLUI D
WASHER FLUI D warni ng is present when wi ndshi el d
wa she r flui d level is bel ow speci f i ed level or t her e is a
concer n in t he wi ndshi el d wa she r reservoi r flui d level
sensor.
WASHER FLUID warni ng f l ashes f or f i ve se c onds,
t hen remai ns on.
When t he wi ndshi el d washer flui d is r ai sed a bove
speci f i ed level or t he concer n goes a wa y , t he
warni ng st o ps.
Ref er t o Sect i on 01- 16 f or addi t i onal i nf ormat i on.
H e a d l a mp
HEADLAMP message oper at es as f ol l ows:
I ndi cat es a l ow-beam headl amp burn-out when t he
headl amp swi t c h ( 11654) is t urned t o t he headl amp
posi t i on.
The l amp out age i ndi cat or warni ng cont r ol modul e
pr ovi des t he ground t o li ght t hi s message.
Once t he message a ppe a r s, it wi ll remai n on t he
di spl ay until t he i gni ti on swi t c h is t urned t o OFF.
S A FE T Y B E L T C r o w n Vi c t o r i a , G r a n d Ma r q u i s
Saf et y belt warni ng oper at es a s f ol l ows:
If dri ver saf et y belt is not f ast ened wi t h i gni ti on
swi t c h t o RUN, t he SAFETY BELT warni ng wi ll
i llumi nate st eadi l y f or appr oxi mat el y one mi nut e.
The sa f e t y belt warni ng chi me wi ll al so sound f or
appr oxi mat el y 6 ( 2 ) se c onds.
If t he dri ver f ast ens t he saf et y belt whi l e t he saf et y
bel t warni ng is i llumi nated or saf et y belt warni ng
chi me sounds, t hey wi ll t urn off i mmedi at el y.
AI R B A G C r o w n Vi c t o r i a , G r a n d Ma r q u i s
AIR BAG warni ng is di spl ayed when t her e is a concer n
in t he air bag sy st e m. Refer t o Sect i on 01- 20B.
HI GH BE A M
Thi s i ndi cat or wi ll be di spl ayed when t he hi gh-beam
headl amps ( 13008) ar e on.
L H / R H T u r n C r o w n Vi c t o r i a , G r a n d Ma r q u i s
These i ndi cat ors wi ll be f l ashi ng when act i vat ed by t he
mult i -f unct i on swi t c h ( 13K359) . They al so oper at e in a
dual f l ashi ng mode a s a hazard i ndi cat or in t andem
wi t h t he EIC if ignition swi t c h is in RUN. If ignition
swi t c h i s in OFF, t he EIC is off and only t he hazard
i ndi cat ors in t he EIC f l ash.
OVERDRI VE OFF
NOTE: OVERDRIVE OFF warni ng will f l ash if t her e is a
probl em wi t h t he EEC or el ect roni c t ransmi ssi on
(si mi lar t o CHECK ENGINE). Ref er t o Engi ne Cont rol
Di agnost i cs sect i on is f l ashi ng O/ D OFF is shown.
OVERDRIVE OFF i ndi cat or l i ght s when t he
t ransmi ssi on is l ocked out of OVERDRI VE. Thi s is
done by pressi ng t he swi t c h but t on in t he end of t he
gear sel ect or lever.
SP E E D CONT ROL
SPEED CONTROL i ndi cat or l i ght s when t he speed
cont rol sy st e m is engaged. Ref er t o Sect i on 10-03 f or
addi t i onal i nf ormat i on.
T r a n s mi s s i o n Ra n ge
TRANSMI SSI ON RANGE i ndi cat or l amp (PRND21) is
lit wi t h i gni ti on swi t c h in RUN. A ci rcl e around t he
symbol i ndi cat es what gear t he t ransmi ssi on is i n.
13- 01A - 10 I n s t r u me n t C l u s t e r E l e c t r o n i c
13- 01A - 10
Electrical Schemati csTown Car
El e c t r o n i c Cl ust e r
HOT AT ALL TIMES
FUSE
1 JUNCTION
PANEL
""J ELECTRONIC
I INSTRUMENT
| CLUSTER
I
1
603 I DG
I
39j ^R/W
Y

ANTI-LOCK
BRAKE SYSTEM
ENGINE
COOLANT
TEMPERATURE
ii 4
(ECT) SENSOR
[!
PK' O
K17629-C
13- 01A - 11
El e c t r o n i c Cl ust er ( Cont i nue d)
I
t
LIGHTING
1
I CONTROL
| . MODULE
L _ _ i
FROM I NSTRUMENT
I LLUMI NATI ON
| TO REAR ILLUMINA l IUN
T
AIR - , ,
_ | SUSPENSI ON
i + f 4-
I G1 10
I SOUP STATE
cm
1 ELECTRONIC
J INSTRUMENT
I CLUSTER
I
FROM
I NSTRUMENT
I LLUMI NATI ON
I O J ^ _ J
152j ^LB/ W
a n
143
J
LB/ Y 152
J
L
" T 5150Q
i f f j L I f W SWI TCH
: I ^^^^ y ta uMi NA Ti oN
I - 1* 1 4 J "I gy L '
| 1750QO> I I
MESSAGE CENTER
MODULE
5 7 ^ B K
K17630-C
13- 01A- 12 i nst r ument Cl us t er El ec t r oni c 13- 01 A - 12
I El e c t r o n i c Cl ust er ( Co n t i n ue d )
1 POWERTRAIN
I CONTROL
I MODULE
I (PCM)
1995 Town Car, Crown Vi c t o r i a , Gr a n d Marquis July 1994
El e c t r o n i c Cl ust e r ( Cont i nue d)
HOT AT ALL TIMES
T r , FUSE
1
t
3
I JUNCTION
| 3 , PANEL
L i
S A :
f "
654 Y/ LG
See EVTM f o r mo r e details
of this c i r c ui t
C3-7
C3-10
CHARGE
INDICATOR INPUT
03- 4 C1-I6
I
I
I
| t ' | GENERATOR
VOL T A GE
RE GUL ATOR
i i
T T
932 I GY/ W 419 I DG/ LG
FROM
AUTOLAMPS
DELAYED
EXI T
TO REAR
AI R
SUSPENSI ON
702 W/ BK
I
1
703 I W/ O
I
T
W/ BK 703 1 V
W/ BK 703
C1 1
ELECTRONIC
INSTRUMENT
CLUSTER
I COMPASS I *Pg3
m
-\ ELECTRONIC
2
IMODULE
AUTOMATIC
l TEMPERATURE
I CONTROL
K17633-C
Co n n e c t o r En d Vi e ws T o wn Car
K22562-A
Pin
Number Ci r cui t C i r c u i t Funct i on
1 5 0 6 ( R ) E n g l i s h / Me t r i c I nput
2

No t Us e d
3 143 ( L B / Y) Swi t c h Mo d u l e I nput
Se n s o r I nput
5 No t Us e d
8 67 6
( P K / O )
P o we r Gr o un d
9 2 95
( L B / P K )
S wi t c h e d P o we r ( Ho t i n Run )
11 2 05
( DB / L G )
12 67 9
( G Y/ B K )
Vo l t a ge I nput
( Co n t i n ue d )
P i n
14 911
( W/ L G )
L a mp
15 7 02
( W/ B K )
C o mp a s s Da t a B +
16 7 03 ( W/ O ) C o mp a s s Da t a B-
17 344
( B K / Y )
18

No t Us e d
Re q u e s t
2 0

No t Us e d
CONNECTOR C2 |
Pi n
2 1 No t Us e d
2 2

No t Us e d
2 3 152
( L B / W)
2 4 No t Us e d
2 5 419
( DG / L G )
2 6 2 03
( O / L B )
2 7 486
( B R / W)
2 8
_
No t Us e d
2 9 No t Us e d
30

No t Us e d
31 No t Us e d
32

No t Us e d
33

No t Us e d
34 No t Us e d
35

No t Us e d
36

No t Us e d
CONNECTOR CS K19974-B
Pin
1 67 6
( P K / O )
Gr o u n d
2 2 95
( L B / P K )
S w i t c h e d P o we r I nput ( Ho t i n Run)
3 484
( O / B K )
4 932
( G Y / W)
Hi gh Be a m I nput
5

No t Us e d
6
_
No t Us e d
7 489
( P K / B K )
I gn i t i o n S wi t c h
8 No t Us e d
9 658
( P K / L G )
I nput
10 904
( L G / R )
Ch a r g e I n d i c a t o r I nput
11
_
No t Us e d
12

No t Us e d
LIGHTING CONTROL
MODULE CONNECTOR C I
fJ2S7A
Town Car
Pin
1 294
( W/ L B )
P o we r
2 88 ( B K / Y ) I n st r ume n t Pa n e l L a mp S wi t c h e d
Fe e d
3 158
( B K / P K )
Ke y Wa r n i n g S wi t c h
4 No t Us e d
5 486
( B R / W)
De c kl i d Aj a r
6 202
( O / L G )
De c kl i d P u n c h o u t S wi t c h
7 25 ( DG / P ) An t i - The f t S wi t c h Di s a r m
8 70 ( L B / W) On Bo a r d Di a gn o s t i c Co n n e c t o r
9 1003
( G Y/ Y)
P o we r
10 1033( R/ Y) He a d l a mp S wi t c h
11 627
( B K / O )
P a s s e n g e r ' s Do o r s Aj a r
12 465
( W/ L B )
I l l umi n a t e d Ent r y
13 1032
( W/ B K )
P a r ki n g L a mp S wi t c h
14 24 ( DB / O ) An t i - The f t S wi t c h A r m
15 23 ( T / L G ) An t i - The f t S y s t e m S wi t c h Fe e d
16 222
( B R / L G )
C r o w n Vi ct or i a, Grand Marqui s wi t h El ect roni c
I n s t r u me n t Cl u s t e r
Pin
1 296 ( W/ P ) R U N / A C C B+ I nput
2 1034
( B K / W)
3 158
( B K / P K )
4
_
No t Us e d
5 486
( B R / W)
De c kl i d Aj a r
6 No t Us e d
7

No t Us e d
8 70 ( L B / W) Ke y l e s s En t r y , Me mo r y Seat s, A BS
9 640 ( R / Y) Ru n / S t a r t B + I nput
10 1033 ( R / Y) He a d l a mp S wi t c h
11 627
( B K / O )
P a s s e n g e r Do o r Aj a r S w i t c h
12 465
( W/ L B )
13 1032
( W/ B K )
14 3 4 0 ( R/ L B) Pa n i c A l a r m
15

No t Us e d
16 222
(BR / L G)
LI GHTI NG CONTROL
MODULE CONNECTOR C2
K22688-A
Town Car
Pin
1 342 ( L G / P ) St a r t e r I n t e r r upt Re l a y
2 No t Us e d
3

No t Us e d
4 1 ( DB) Ho r n S wi t c h Co n t r o l
5

No t Us e d
6 2 2 0 ( P / O ) A u t o l a mp On
8 2 17 ( DB/ O) A u t o l a mp
9 343
( DB / L G )
10 344
( B K / Y)
Do o r Aj a r Out put L o w
11 8 6 7 ( DB ) L F Do o r Aj a r
12

No t Us e d
13 194 ( PK) Wi n d o w Re g. Re l a y A c c y . Fe e d
14 183 ( T / Y) To n e Ge n e r a t o r
15 1036
( B R / W)
Pa n e l Di m Do wn
16 1035
( O / R )
Pa n e l Di m Up
17 85
( B R / L B )
Se a t Be l t Fa s t e n
18 688
( G Y/ L B )
He a t e d Ba c kl i g h t S wi t c h
19 936
( DG / W)
I gn i t i o n Ke y Cy l i n d e r Se n s o r
2 0 57 ( BK) Gr o un d
2 1
_
No t Us e d
2 2 163 ( R / O ) Do o r L o c k Out put ( Dr i v e r )
13- 01A - 16 i n s t r u me n t
Pi n
1 No t Us e d
2 932
( G Y / W)
3

No t Us e d
4 6 ( Y/ L G ) Ho r n
5

No t Us e d
7 2 1 8 ( W / P ) A u t o l a mp En a bl e
8 2 17
( DB / O )
9 3 8 3 ( R / W) Ha za r d I n d i c a t o r
10 344
( B K / Y )
12 688
( DB / O )
He a t e d Ba c k L i gh t Re l a y
13

No t Us e d
14 183 ( T / Y) E l e c t r o n i c I n st r ume n t Cl u s t e r To n e
Re q u e s t
15 1036
( B R / W)
16 1035
( O / R )
17 85
( B R / L B )
18 1010
( DB / O )
Ba c k L i gh t S wi t c h
19

No t Us e d
2 0

No t Us e d
2 1

No t Us e d
2 2

No t Us e d
LIGHTING CONTROL
MODULE CONNECTOR 03 K22689-A
E l e c t r o n i c _ _ 13- 01A - 18
Pin
1 7 0 5
( L G / O )
De ma n d L i gh t i n g ( BAT S a v e r )
2 19 ( L B/ R) Va r i a bl e Vo l t a g e Di mmi n g B a c k
L i gh t
3 117
( P K / B K )
5 53
( B K / L B )
Co u r t e s y L a mp s ( BAT Sa v e r )
6 195 ( T / W) VB A T 1
7

No t Us e d
8 4 5 0
( DG / L G )
Se a t Be l t I n d i c a t o r
9 6 7 6
( P K / O )
57 ( BK) '
L o gi c Gr o un d
10 502 ( GY)
13 ( R / B K ) '
He a d l a mp s
11 54 ( L G / Y ) VBA T 3
12 4 8 4
( O / B K )
Pul se Wi d t h Mo d u l a t i o n ( P WM)
Di mmi n g
13 44 ( L B) Fl a s h e r Out put
15 385 ( W/ R ) Fl a s h e r P o we r Fe e d I nput
16 2 2 1 ( O / W) VB A T 4
LIGHTING CONTROL
Town Car
Pi n
1 186
( B R / L B )
He a t e d Ba c k L i ght S wi t c h t o Ba c k
Li ght
2 175
( B K / Y)
VBAT 5
C r o w n Vi ct ori a, G r a n d Marqui s
Pin
1 12
( L G / B K )
2 196
( DB / O )
13- 01A - 17
Ir " ~ " ~" 13- 01A - 17
HEADLAMP SWI TCH
CONNECTOR C1
K22691-A
Pin
1 1036
( B R / W)
Pa n e l Di mme r ( Do wn ) S wi t c h
3

No t Us e d
4 1035
( O / R )
5 484
( O / B K )
R U N / A C C B + V o l t a g e
6

No t Us e d
7
No t Us e d
j o o o o o o o o o o o o oi r
p o o o o o o o o o o o orSC^
~i yo o o o o o o o o o o o o
y fO O O O O O O O O O O O O n f f l
" O O O O O O O O O O O O OjPi
l o o o o o o o o o o o o oi nL
#JPTo o o o o o o o o o o o o l
I T O O O O O O O O O O O O onffl
(PCM) CONNECTOR
W928S-A
Pin
1 315 ( P / O ) Shi f t So l e n o i d 2
2 658
( P K / L G )
Ma l f u n c t i o n I n d i c a t o r L a mp
3

No t Us e d
4 2 2 8 ( DB) E l e c t r o - Dr i v e Co o l i n g Fa n
5 No t Us e d
6 No t Us e d
7

No t Us e d
8

No t Us e d
9

No t Us e d
10

No t Us e d
11 No t Us e d
12

No t Us e d
13 107 ( P) '
67 ( L G / Y)
Vo l t a ge P e a k t o P e a k
14

No t Us e d
15 915
( P K / L B )
Da t a Li n e t o OBD Te st Co n n e c t o r
(-)
16 914 ( T / O) Da t a L i n e t o OBD Te st Co n n e c t o r
( + )
17

No t Us e d
18

No t Us e d
19 No t Us e d
2 0 No t Us e d
P i n
2 1

No t Us e d
2 2

No t Us e d
2 3 2 59 ( O / R ) I gn i t i o n Gr o un d
2 4 57 0
( B K / W)
P o we r Gr o un d
25 57 ( BK) Ca s e Gr o un d
26

No t Us e d
27 2 37 ( O / Y) Shi f t So l e n o i d 1
2 8 2 2 8 (DB)'
2 2 9 ( R / O )
En a bl e Co o l i n g Fa n Out put
2 9 2 2 4 ( T / W) Tr a n s mi s s i o n Co n t r o l Swi t c h
30 2 42 ( DG) '
2 40 ( W/ R )
Oc t a n e Ad j u s t
31

No t Us e d
32

No t Us e d
33 67 6
( P K / O )
Ve h i c l e S p e e d Se n s o r (-)
34

No t Us e d
35 392
( R / L G )
He a t e d Ox y g e n Se n s o r - 12
( R- Ri ght )
36 968 ( T / L B) Ma s s Ai r Fl o w Se n s o r Re t ur n
37 92 3
( O / B K )
Se n s o r
38 354
( L G / R )
En gi n e Co o l a n t T e mp e r a t u r e ( ECT)
Se n s o r
Pin
39 7 4 3 ( GY) I n t a ke Ai r T e mp e r a t u r e (I AT)
Se n s o r
40 2 38
( DG / Y)
Fue l Pump Mo n i t o r
41 347
( B K / Y) '
198
( DG / O )
A / C Cl u t c h Si gn a l
42 No t Us e d
43 2 05
( DB / L G )
Fue l Fl o w Ra t e Out put
44 No t Us e d
45

No t Us e d
46

No t Us e d
47 360
( B R / P K )
EGR E l e c t r o n i c Va c u u m Re gu l a t o r
48 659 ( O / W) '
11 ( T / Y)
I gn i t i o n Di a g n o s t i c Mo n i t o r
49 395
( G Y/ O )
Pr o f i l e I gn i t i o n P i c ku p (PI P)
50 92 9 ( PK) Sp a r k Out put ( SP OUT)
51 57 0
( B K / W)
P o we r Gr o u n d
52
__
No t Us e d
53 No t Us e d
54 4 7 3 ( R / L B )
92 4
( B R / O ) '
Mo d u l a t e d L o c k u p ( ML )
55 554
( Y/ B K )
Ke e p Al i v e P o we r
56 191
( L G / B K )
Va p o r Ma n a g e me n t Va l v e Out put
57 No t Us e d
58 67 9
( G Y/ B K )
Ve h i c l e S p e e d Se n s o r ( VSS) (-)
59

No t Us e d
60 7 4
( G Y/ L B )
He a t e d Ox y g e n Se n s o r - 11
( F- Ri gh t )
61 3 9 3 ( P / L G ) He a t e d Ox y g e n Se n s o r - 2 2 ( R- L e f t )
62 No t Us e d
63

No t Us e d
64 1 9 9 ( L B / Y ) T r a n s mi s s i o n Ra n ge ( TR) Se n s o r
I nput
65 352
( B R / L G )
Di f f e r e n t i a l PFE EGR Se n s o r
66 No t Us e d
67 No t Us e d
68 No t Us e d
69 331
( P K / Y) '
7 3( O/ L B)
Wi d e Op e n T h r o t t l e A / C Cut o f f
7 0

No t Us e d
7 1 361 ( R) Ve h i c l e P o we r
Pin
7 2 561 ( T / R) l n j e c t o r - 7
7 3 559 ( T / BK) l n j e c t o r - 5
7 4 557
( B R / Y)
l n j e c t o r - 3
7 5 555 (T) I n j e c t o r - 1
7 6 57 0
( B K / W)
P o we r Gr o u n d
77 57 0
( B K / W)
P o we r Gr o u n d
7 8

No t Us e d
7 9 911
( W/ L G )
L a mp
80 92 6
( L B / O )
Fu e l Pump Co n t r o l
81 92 5 ( W/ Y ) E l e c t r o n i c P r e s s u r e Co n t r o l
82

No t Us e d
83 2 64
( W/ L B )
I d l e Ai r Co n t r o l So l e n o i d
84 97 0
( DG / W) '
6 8 3 ( P / L B )
Tr a n s mi s s i o n S p e e d Se n s o r
85 2 82
( DB/ O) '
7 95 ( DG)
Cy l i n d e r I d e n t i f i c a t i o n
86

No t Us e d
87 94 ( R / B K ) He a t e d Ox y g e n S e n s o r - 2 1 ( F- L e f t )
88 9 6 7 ( L B / R ) Ma s s Ai r Fl o w Se n s o r
89 355
( G Y/ W)
T h r o t t l e P o s i t i o n Se n s o r
90 351
( B R / W)
Ve h i c l e Re f e r e n c e Vo l t a ge
91 359
( G Y/ R)
Si gn a l Re t ur n
92 511 ( LG) Br a ke O n / O f f S wi t c h
93 387 ( R / W) He a t e r - 11 H 0 2 S ( F- Ri gh t )
94 3 8 8 ( Y / L B ) He a t e r - 2 1 H 0 2 S ( F- L e f t )
95 389
( W/ B K )
He a t e r - 12 H 0 2 S ( R- Ri gh t )
96 390 ( T / Y) He a t e r - 2 2 H 0 2 S ( R- L e f t )
98 562 ( BL ) l n j e c t o r - 8
99 560
( L G / O )
l n j e c t o r - 6
100 558
( B R / L B )
l n j e c t o r - 4
101 556 ( W) l n j e c t o r - 2
102

No t Us e d
103 57 0
( B K / W)
P o we r Gr o u n d
104

No t Us e d
* Town Car
13- 01A - 19
i n s t r u me n t C l u s t e r E l e c t r o n i c 13- 01A - 19
IGNITION SWI TCH CONNECTOR
SC22549-A
Town Car
Pin
B1 5 68 ( L G) Ba t t e r y I nput
A1 45 4
( R / L G )
Ho t i n RUN o r A CC Ou t p u t
B2 568 ( L G) Ba t t e r y I nput
A 2 2 97
( B K / L G )
Ho t i n RUN Ou t pu t
A 3 2 97
( B K / L G )
Ho t i n RUN Out put
B4 32 5
( DB / O )
Ba t t e r y I nput
STA 33 ( W/ P K ) Ho t i n START Ou t pu t
A 4 489
( P K / B K )
Ho t i n RUN Ou t pu t
B5 2 7 6 ( BR) Ba t t e r y I nput
1-1 2 62
( B R / P K )
Ho t i n START o r RUN Ou t p u t
P1 4 0 9 ( T / BK) Gr o u n d i n START Ou t pu t
P2

No t Us e d
12

No t Us e d
Pin
B1 2 7 6 ( BR) B +
12

No t Us e d
Cr own Vi ct or i a, Grand Marqui s (Cont ' d)
Pin
A1 2 97
( B K / L G )
Ho t in RUN or A CC
B2 568 ( LG) B +
A 2 687
( G Y/ Y)
Hot in RUN
B3 568 ( LG) B+
A 3 687
( G Y/ Y)
Ho t in RUN Out put
B4 37 ( Y) B+
STA 33 ( W/ P K ) Hot in START Out put
A 4 489
( P K / B K )
Ho t i n RUN
B5 2 7 6 ( BR) B +
11 2 62
( B R / P K )
Hot in START or RUN
P1
_
No t Us e d
P2 97 7 ( P / W) Gr o u n d e d i n St a r t Out put
HEADLAMP SWITCH
Pin
2 2 96 ( W/ P ) R U N / A C C B + V o l t a g e
3 1032
( W/ B K )
P a r kl a mp Swi t c h
4 2 2 0 ( P / O ) A u t o l a mp De l a y
5
_
No t Us e d
6 1034
( B K / W)
Do me l a mp S wi t c h
13- 01 A - 2 0 i n s t r u me n t C l u s t e r E l e c t r o n i c 13- 01A - 2 0
C r o w n Vi c t or i a , Grand Ma r q u i s (Cont 'd)
Pin
Number Ci r c ui t Ci r cui t Funct i on
9 2 17 (D/ O) A u t o l a mp De l a y
10
_
No t Us e d
11 2 2 2
(BR/ LG)
12 No t Us e d
Town Car
Pin
2 484
( O / B K )
3 1032
( W/ B K )
P a r kl a mp S wi t c h
4 2 2 0 (P/ O)
5 No t Us e d
6 88 ( B K / W)
9 2 17
( DB / O )
10 No t Us e d
11 2 2 2
( B R / L G )
12 No t Us e d
CD ( )
TO
HEADLAMP SWITCH
CONNECTOR C1
K22691-A
Pin
1 1036
( B R / W)
Pa n e l Di mme r ( DOWN) S wi t c h
Pin
3
_
No t Us e d
4 1035
( O / R )
Pa n e l Di mme r ( UP) S wi t c h
5 2 96 ( W/ P )
4 8 4
( O / B K ) '
R U N / A C C B + Vo l t a g e
6

No t Us e d
7

No t Us e d
* Town Car
SAFETY BELT WARNING
CHIME CONNECTOR
K14929-F
Pin
1 4 5 0
( DG / L G )
Fa s t e n Sa f e t y Be l t I n s t r u me n t
Cl ust e r
2 2 95
( L B / P K )
Ho t in RUN
3 2 94
( W/ L B )
Ho t in A CC a n d RUN
4 159
( R / P K )
Dr i v e r Do o r Op e n Wa r n i n g L a mp
Swi t c h
5

No t Us e d
6 158
( B K / P K )
I gn i t i o n Ke y Wa r n i n g S wi t c h
7 183 ( T / Y) To n e I n p u t I n s t r u me n t Cl u s t e r
8

No t Us e d
9 85
( B R / L B )
Dr i v e r Sa f e t y Be l t S wi t c h I nput
10 57 ( BK) Gr o un d
13- 01A - 2 1 I n s t r u me n t C l u s t e r E l e c t r o n i c 13- 01A - 2 1
El e c t r o n i c I n st r ume n t Cl u s t e r T o wn Car
F R O N T V I E W
nr
Q CHECK
555 H
1 = C
f
5
"
COMPASS
MM

t SLOWLY , 1? ?s
<5>888888km
spmocoMmi O/DOFF
I
I D / O O W
i L | P R N 2 1 U f J e
CHECH AM SUSPENSION TMtm
mSHBMim OmMAJM AM
ITR/KOkm
C^l frl Prl f
p
CONNECTOR C3
R E A R V I E W
1
innnni
TO
CONNECTOR C1 -
O
El e c t r o n i c I n st r ume n t Cl u s t e r Cr o wn Vi c t o r i a , Gr a nd Ma r qui s
FRONT VIEW
H S
l i
c ~ f
88
CHECK
ENGINE
S 3
LTR
GAL
TCI _
$ 888888. 81
10,
knt/h
MPH
CHECK SUSPSt St ON DOOR
OVBgtfBVSOFF AJAR
LOW
Hi 1
mm A M U R/noiui
nw l i Am
REAR VI EW
I k
CONNECTOR C1
<=>@g
K22831-
13- 01A - 2 3
I nst r ument Cl ust er El ect r oni c 13- 01A - 2 3
Electrical SchematicCrown Victoria, Grand
Marquis
El e c t r o n i c Cl ust e r
1 FUSE
J JUNCTION
( l i J & ^ V i PANEL
L 1 f i FUSE
f | JUNCTION
j PANEL
CI 7 C1-9
SOLID STATE
01-6 C1*8 C3-1 c w a
C3-2
C1*4
1 ELECTRONIC
INSTRUMENT
| CLUSTER (EIC)
1
I
FROM
POWERTRAIN 29 | Y/W
CONTROL
MODULE
(PCM)
NOT USED
of t hi s circuit
E3
K17637-C
El e c t r o n i c Cl ust e r (Cont i nue d)
13- 01A - 2 5
I n s t r u me n t C l y s t e r E l e c t r o n i c 13- 01A - 2 5
DIAGNOSIS AND TESTING (Conti nyed)
El e c t r o n i c Cl y st e r ( Cont i nue d)
450 DG/LG
C3-H
C2-25
I
I
" 1 LIGHTING
I CONTROL
MODULE
I
. J
' I MULTI- r *
, FUNCTION |
SWITCH
I
of t h i s c i r c ui t
I
e i I

432 |GY/W
* I LIGHTING
J CONTROL
I MODULE
i
?^|GY/W ^
1
X
0 3 4
SOLrD STATE
01-10 C1-10 02-26 C3-9
C1-11
ELECTRONIC
INSTRUMENT
CLUSTER
486
T I T T
I 205 DB/LG
2031 O/LB 201 I T/R 911 W/ LG
AIR SUSPENSION
TEST
CONNECTOR
I
1 1
' I AIR
. SUSPENSION/
I ELECTRONIC
1 VARIABLE
1
ORIFICE (EVO)
J STEERING
' CONTROL
MODULE
z
486 I BR/ W
WINDSHIELD
RESERVOIR
FLUID
LEVEL
SENSOR
57 |BK
m
' 1 LIGHTING
JCONTROL
J MODULE %
I SPEED
, CONTROL I
I SERVO !
79
1 POWERTRAIN
CONTROL
MODULE (PCM)
1
I
I ** mam nmt J
K17640-C
El e c t r o n i c Cl ust e r ( Co n t i n ue d )
I
I
LOW WASHER
FLUID INPUT
SO^R
C1-1
ENGLISH/
METRIC INPUT
| ELECTRONIC
i AUTOMATIC
I TEMPERATURE
1 CONTROL (EATC)
1
MODULE
INSTRUMENT
I CLUSTER
'452Q
CHARGE
_ I LIGHTING
I , CONTROL
I MODULE
PK/Y
z
WINDSHIELD
WASHER
LOW FLUID
SWITCH
57 ^BK
5 7 | BK
904 I LG/R
L J
K22853-A
Ma r qui s
K22562-A
Pin
1 506 (R) E n g l i s h / Me t r i c i nput
2 Not Us e d
3 1 4 3 ( L B / Y ) S wi t c h Mo d u l e I nput
4 3 9 ( R / W ) En gi n e Co o l a n t T e mp e r a t u r e ( ECT)
Se n s o r I nput
5

No t Us e d
6 29 ( Y / W) Fue l L e v e l I nput
7 54 ( L G / Y) Ba t t e r y P o we r I nput
8 67 6
(PK/O)
P o we r Gr o un d
9 964
( DB/ L G )
B + i n RUN I nput
10 8 2 ( P K / Y ) L o w Wa s h e r Fl ui d L e v e l I nput
11 2 05
( DB/ L G )
12 67 9
( G Y/ B K )
Vo l t a ge I nput
13 19 ( L B / R ) No n P WM Di mmi n g I nput
( Co n t i n ue d )
- 2 7 j s t e r E l e c t r o n i c 13- 01A - 2 7
Pin
14 911
( W/ L G )
L a mp
15

Not Us e d
16

Not Us e d
17 344
( B K / Y)
Do o r Aj a r I nput
18 No t Us e d
Re q ue s t
20 No t Us e d
Pin
1 67 6
( P K / O )
Gr o un d
2 GS4
( DB / L G )
S wi t c h e d P o we r I nput ( Ho t in RUN)
3 484
( O / B K )
4 932
( G Y/ W)
Hi gh Be a m I nput
6 3 ( L G / W) LH Tur n Si gn a l
7 88 ( B K / W) B + i n RUN I nput
9 658
( P K / L G )
P CM I nput
10 904
( L G / R )
Ch a r ge I n d i c a t o r B + I nput
11 450
( B K / L G )
12 608
( B K / Y)
Vi sual l y i nspect t he component s. Che c k f or da ma ge d
component s, bl own f uses, and l oose or c o r r o d e d
connect i ons. Check t he wi ri ng har ness f or obvi ous
si gns of shor t s, opens, bad connect i ons or da ma ge .
Veri f y speedomet er and odomet er oper at i on by r oa d
t est i ng t he vehi cl e.
NOTE: Per f or m EIC Self Test as out l i ned, pri or t o
perf ormi ng any Pi npoi nt Test s.
1. Press t h e E / M and SELECT (r ever se sel ect )
but t ons si mul t aneousl y whi l e t urni ng i gni ti on
swi t c h ( 1157 2) f r om OFF t o RUN. The EIC wi ll
ent er a speci al t est mode and di spl ay i nf ormat i on
in t he cent er di spl ay openi ng. Inf ormat i on
di spl ayed i ncludes a number in t he speedomet er
di spl ay and t wo numbers in t he odomet er di spl ay,
one on t he left and one on t he ri ght . Bot h t he left
and ri ght di spl ay openi ngs wi ll be dar k (of f ).
GO GO
no
1{?H P R N 2 1 [ F l B ~
BLANK BLANK
K22838-A
13- 01A - 2 8
I n s t r u m e n t C l u s t e r E l e c t r o n i c
13- 01A - 2 8
2. If any of t he di spl ay ed i nf ormat i on in t he cent er
openi ng f l ashes on and off cont i nuousl y, t he EIC is
i noperat i ve and shoul d be r epl aced. (Af t er
repl aci ng t he i nst rument cl ust er ( 10849) , veri f y
t ha t t he sy mpt o m is no l onger pr esent . If
sy mpt o ms persi st , begi n di agnosi s agai n. ) If t he
di spl ay doe s not f l ash, t urn t he i gni ti on swi t c h t o
OFF t o exi t t hi s speci al t e st mode. Then cont i nue
t hr ough t he di agnosi s sect i on (t he i nst rument
cl ust er may or may not be f aul t y at t hi s poi nt ).
FUNCTION DIAGNOSTIC MODE
TEMP GAUGE
Engi ne Cool ant Temperat ure Sensor
Input Short Ci rcui t ed Li ght s Top t wo
Bars a n d Bot t om t wo Bars and
Ext i ngui shes Temperat ure ISO
Symbol and Legend
r
N
0
R
M
A
1
L
Col d Engi ne Temperat ure i ndi cat i on
or Engi ne Cool ant Temperat ure
Sensor Input Open Ci rcui t ed Li ght s
Bot t om Bar and Te mp I SO Symbol
and Legend
JL
TEMP
FUEL GAUGE
Fuel Level Sensor Input Short
, Ci rcui t ed or Open Ci rcui t ed Li ght s
t Top t wo a nd Bot t om t wo Bars and
Ext i ngui shes Fuel Tank I SO Symbol
and Legend (After 30 second del ay)
Fuel Level Sensor Input Short
Ci rcui t ed or Open Ci rcui t ed Di splays
"CS" (Short ) or
u
CO" (Open) in
Message Cent er Di splay For "Fuel
Remai ni ng
1
' or "Distance t o Empty"
Selecti on (After 30 second del ay)
i i i
ODOMETER
Odomet er Mal f unct i on Di spl ays "Error" i n
Odomet er Di spl ay
8 I
MP H
, \) -M
c f r o r
CK14700-E
S y m p t o m C h a r t s
Use Rot unda 73 Di gi t al Mul t i met er 105-00051 or
equi valent t o per f or m el ect ri cal pi npoi nt t e st s.
EI C DI SPLAY DI AGNOSI S
CONDITION POSSI BLE SOURCE A CTI ON
Di spl a y Not I l l umi n a t e d , Too Di m or
Bl a n k But Ba c kl i gh t e d
Di mme d t o ba r e l y d i sc e r n a bl e ,
c o ul d be at MAX wi t h he a d l a mps
ON.
EI C.
Ci r c ui t r y .
Di spl a y Sc r a mb l e d , I n c o r r e c t Al l
t he Ti me or St uc k wi t h Al l
Se gme n t s On , Se gme n t s Hal f Li t ,
Bl i n ki n g or Mi ssi n g
EI C.
Ei C DISPLAY DI AGNOSI S (Conti nued)
CONDITION POSSI BLE SOURCE ACTION
Display Does Not Respond to
Buttons or No Be e p Whe n But t o n s
Pushed or Driver Alert Given
Circuitry.
Safety belt warning chi me.
EIC.
Message center swi t ch module.
Headlamp swi t ch.
FUEL GAUGE DI AGNOSI S
CO Displayed, Top Two and
Bottom Two Diagnostic Bars
Displayed
Fuel pump (FP) module.
EIC.
Circuitry.
CS Di splayed, Top Two and Bottom
Two Diagnostic Bars Displayed
o Fuel pump (FP) module.
Circuitry.
EIC.
Inaccurate Fuel Gauge Indication Fuel pump (FP) module.
Valve, tube or evaporati ve
emission canister.
Fuel t ank.
EIC.
TEMPERATURE GAUGE DIAGNOSIS
Temperature Gauge Displays Top
Two And Bottom Two Diagnostic
Bars
Engine coolant temperature (ETC)
sensor.
EIC.
Circuitry.
Temperature Gauge Always
Indicates Hot Or Cold Temperature
Engine coolant temperature (ETC)
sensor.
EIC.
Circuitry.
No Warning Tone When
Thermometer Symbol is Blinking
EIC.
SPEEDOMETER DIAGNOSIS
Speedometer Reads 0 km/ h (mph)
At All Speeds
EIC.
Circuitry.
Speedometer Constantly Reads
Too High Or Too Low
Drive gear.
EIC.
Circuitry.
GO to Pinpoint Test L.
Speed Indication Jumps Up And
Down Erratically
EIC.
Circuitry.
GO t o Pinpoint Test M.
Speed Control Indicator Always On Speed control servo.
Circuitry
EIC.
GO to Pinpoint Test N.
Speed Control Indicator Does Not
Come On When Speed Control
Engaged
EIC.
Circuitry.
GO to Pinpoint Test P.
ODOMETER DIAGNOSIS
Display Reads "Error" EIC. REPLACE EIC. AFFIX odometer
sti cker to door pillar.
Display Has "S" Illuminated EIC. GO to Pinpoint Test Q.
Mileage Constantly Reads Too
High Or Too Low
Drive gear.
EIC.
GO to Pinpoint Test R.
ODOMETER DIAGNOSIS (Continued)
Odometer Does Not Accumulate
Mileage or Counts 1.6 km ( 1. 0
mi l e) a n d Jumps Ba c k 1. 6 km ( 1 . 0
mi l e)
EIC.
GO to Pinpoint Test S.
MESSAGE CENTER DISPLAY DIAGNOSIS
Instantaneous or Average Fuel
Economy Always Reads 0
Miles / Gal Or 99 L /100 km or 99
Miles /Gal or OL/ 100 km
EI C.
Ci r c ui t r y .
Po we r t r a i n c o n t r o l mo d ul e .
GO t o Pi n po i n t Te st T.
Trip Distance Does Not
Ac c umul a t e
EI C. GO t o Pi npoi nt Te st S.
DTE Does Not Go Below 322 km
(200 Miles) With Fuel Tank Empty
or DTE Always Reads Zero
EI C.
Ci r c ui t r y .
Po we r t r a i n c o n t r o l mo d ul e .
GO t o Pi npoi nt Te st U.
W A R N I N G I N D I C A T O R D I A G N O S I S
DOOR AJAR Wa r ni ng
Ne v e r / A l wa y s Co me s On
Do o r o pe n wa r n i n g l a mp s wi t c h .
EI C.
Ci r c ui t r y .
Li ght i n g c o n t r o l mo d ul e .
GO t o Pi npoi nt Te st V.
TRUNK AJAR Wa r ni ng
Ne v e r / A l wa y s Co me s On
L u gga ge c o mpa r t me n t d o o r o pe n
wa r n i n g l a mp s wi t c h .
Ci r c ui t r y .
EI C.
Li ght i n g c o n t r o l mo d ul e .
GO t o Pi npoi nt Te st W.
CHARGE SYSTEM War ni ng
Al wa y s / Ne ve r Co me s On
EI C.
Ci r c ui t r y .
GO t o Pi npoi nt Te st X.
RIDE CONTROL / AI R
SUSPENSI ON War ni ng Al wa y s On
Ci r c ui t r y .
EI C.
GO t o Pi npoi nt Te st Y.
Lo w WASHER FLUI D Wa r ni ng
Ne v e r / A l wa y s On
Wi n d s hi e l d wa s h e r r e se r v o i r f l ui d
l e ve l se n so r .
Ci r c ui t r y .
EI C.
GO t o Pi npoi nt Te st AA.
CHECK ENGI NE (MI L) Wa r ni ng
Al wa y s On
EI C.
P CM.
GO t o Pi npoi nt Te st BB. REFER t o
Po we r t r a i n Co n t r o l / E mi s s i o n s
1
. PERFORM
Di a gn o st i c Sel f Te st .
LH Turn I n d i c a t o r Ne v e r / A l wa y s
ON ( Cr o wn Vi c t o r i a , Gr and
Ma r qui s)
Sh o r t e d or o pe n c i r c ui t r y .
Ma l f un c t i o n i n g t ur n si gn a l a n d
wi n d s hi e l d wi pe r s wi t c h .
GO t o Pi npoi nt Te st CC.
RH Turn I n d i c a t o r Ne v e r / A l wa y s
On
Sh o r t e d or o pe n c i r c ui t r y .
Ma l f un c t i o n i n g t urn si gn a l a n d
wi n d s hi e l d wi pe r s wi t c h .
GO t o Pi npoi nt Te st DD.
Hi gh Be a m Wa r n i n g Ne v e r / A l wa y s
On
EI C.
Ci r c ui t r y .
He a d l a mp s wi t c h .
GO t o Pi npoi nt Te st EE.
Sa f e t y Be l t Wa r ni ng Ne v e r / Al wa y s
On ( Cr own Vi c t o r i a , Gr a nd Ma r qui s
Onl y)
Bl o wn f use .
Ma l f un c t i o n i n g c hi me mo d ul e .
I n o pe r a t i v e sa f e t y be l t s wi t c h .
Ope n / s h o r t e d c i r c ui t r y .
GO t o Pi npoi nt Te st FF.
Lo w Oi l Pr e ssur e Wa r ni ng
Ne v e r / A l wa y s On (Cr own Vi c t o r i a ,
Gr a nd Ma r qui s)
EI C.
Oi l pr e ssur e se n so r .
Ci r c ui t r y .
GO t o Pi npoi nt Te st GG.
Ai r Ba g Wa r ni ng Ne v e r / Al wa y s On
(Cr own Vi c t o r i a , Gr and Ma r qui s)
EI C.
Ai r b a g d i a gn o st i c mo n i t o r .
Ci r c ui t r y .
GO t o Pi npoi nt Test HH.
1 Pur chased separ at el y, r ef er t o end of t hi s Sect i on f or vehi cl e appl i cat i ons.
1 9 9 5 Town Car , Cr own Vi ct or i a, Gr and Mar qui s Jul y 1994
13-01 A-31 I n s t r u me n t C l u s t e r E l e c t r o n i c 13-01 A-31
WARNING INDICATOR DIAGNOSIS (Cont i nued)
Overdrive OFF Indicator
EIC.
Circuitry.
GO to Pinpoint Test J J .
Transmission Control Selector
I n d i c a t o r Ne v e r / A l wa y s On
Bulb.
Ci r c ui t r y .
GO t o Pi npoi nt Te st KK.
PINPOINT TEST A: DISPLAY NOT ILLUMINATED, TOO DIM OR BLANK BUT BACKLIGHTED
A1 CHECK DI SPLAYS - HEADLAMPS OFF
Ye s
No
G O t o A2.
GO t o A3.
Turn i gni t i on s wi t c h t o RUN.
Turn h e a d l a mps OFF.
Ver i f y i l l umi na t i on of EI C, c l o c k a n d r a d i o .
Is el ect r oni c cl ust er di spl ay of f wi t h ot her
di spl ays on?
Ye s
No
G O t o A2.
GO t o A3.
A2 CHECK I NSTRUMENT CLUSTER POWER
Ye s
No
REPLACE e l e c t r i c
c l ust e r .
SERVI CE Ci r c ui t s 2 95
( L B/ P K) , 964 ( DB/ L G ) ,
7 97 ( L G / P ) a nd 54
( L G / Y) .
Ve r i f y po we r a t EIC Pi ns C1-7, C1- 9, C3- 2 wi t h
i gni t i on s wi t c h in RUN po si t i o n .
Is power pr esent ?
Ye s
No
REPLACE e l e c t r i c
c l ust e r .
SERVI CE Ci r c ui t s 2 95
( L B/ P K) , 964 ( DB/ L G ) ,
7 97 ( L G / P ) a nd 54
( L G / Y) .
A3 CHECK DI SPLAYS - HEADLAMPS ON
Ye s
No
GO t o A4.
GO t o A5.
Turn i gni t i on s wi t c h t o ON.
Turn pa r ki n g l a mps o n .
Whi l e v a r y i n g d i mmi n g l e ve l c h e c k o t he r d i s pl a y s :
r a d i o , c l o c k, t r a n s mi s s i o n c o n t r o l s e l e c t o r i n d i c a t o r .
Do ot her di spl ays i l l umi nat e pr ope r l y ?
Ye s
No
GO t o A4.
GO t o A5.
A4 CHECK FOR CI RCUI T 19 ( L B/ R) VOLTAGE
Ye s
No
REPLACE EI C. AFFI X
o d o me t e r s t i c ke r t o d o o r
pi l l ar . RESTORE v e hi c l e .
RETEST s y s t e m.
SERVI CE Ci r c ui t
19( L B/ R) . RESTORE
Turn pa r ki n g l a mp of f .
Di sc o n n e c t EI C.
Whi l e v a r y i n g d i mmi n g l e ve l , c h e c k v o l t a ge in Ci r c ui t
19 ( L B/ R) at Pi n 13 of e l e c t r o n i c i n st r ume n t c l ust e r .
Does vol t age vary bet ween 4 and 15V?
Ye s
No
RETEST s y s t e m.
19( L B/ R) . RESTORE
A S CHECK FOR LI GHTI NG CONTROL MODULE
Ye s
No
( L B/ R) . RESTORE
GO t o l i ght i n g c o n t r o l
mo d ul e d i a gn o si s.
Ch e c k l / P f use s 11 a nd 7 (Town Ca r ) 9 a n d 11
( Cr o wn Vi c t o r i a , Gr a n d Ma r qui s) . Re pl a c e if
n e c e ssa r y . P r o c e e d if d i s pl a y s st i l l d o not i l l umi na t e
pr o pe r l y .
Whi l e v a r y i n g d i mmi n g l e ve l , ve r i f y v o l t a ge o ut put at
Does di mmi ng i nput vol t age vary bet ween 4 and
15 V?
Ye s
No
( L B/ R) . RESTORE
GO t o l i ght i n g c o n t r o l
mo d ul e d i a gn o si s.
PINPOINT TEST B: DISPLAY SCRAMBLED, INCORRECT ALL THE TIME OR STUCK WITH ALL SEGMENTS ON, SEGMENTS
HALF LIT, BLINKING OR MISSING
B1 PERFORM SELF TEST
Ye s
No
REPLACE EI C, AFFI X
RETEST s y s t e m.
GO t o B2.
Turn i gni t i on t o OFF po si t i o n .
Push in t he E / M a n d s e l e c t ( l e f t ) but t o n s a n d h o l d .
Turn i gni t i on t o ON po s i t i o n whi l e ho l d i n g but t o n s.
Re l e a se but t o n s wh e n c l ust e r l i ght s .
Does odome t e r f l ash?
Ye s
No
REPLACE EI C, AFFI X
RETEST s y s t e m.
GO t o B2.
PINPOINT TEST B: DISPLAY SCRAMBLED, INCORRECT ALL THE TIME OR STUCK WITH ALL SEGMENTS ON, SEGMENTS
HALF LIT, BLINKING OR MISSING (Cont i nued)
B2 DISPLAY TEST
Yes
No
REPLACE EIC. AFFIX
odometer sticker to door
pillar. RESTORE vehicle.
RETEST system.
EIC OK. RESTORE
vehicle.
NOTE: There a r e 17 se gme n t d i s p l a y s .
Push SELECT> button once to e nt e r display t e s t .
Push E / M button to step through display test
inspection and verification.
Display test start with all blue / green segments off.
Test then cycles through following test to turn on
each segment or indicator ISO one time only, then
begins to full display after each segment has been
tested individually until all bl ue/green segments are
on. Next switch press start cycle all over again.
Do any segment s st ay on al ways or never come
on?

Yes
No
REPLACE EIC. AFFIX
odometer sticker to door
pillar. RESTORE vehicle.
RETEST system.
EIC OK. RESTORE
vehicle.
PINPOINT TEST C: DISPLAY DOES NOT RESPOND TO BUTTONS OR NO BEEP WHEN BUTTONS PUSHED OR DRIVER
ALERT GIVEN
C1 CHECK FOR WARNING CHIME
Yes
No
GO to C2 for Town Car.
GO to C4 for Crown
Victoria/Grand Marquis.
for safety belt warning
chime diagnosis.
NOTE: Buttons function only with ignition switch in RUN.
Check for fasten safety belt reminder chime or key
left in ignition reminder chime.
Does saf et y bel t warni ng chi me sound?
Yes
No
GO to C2 for Town Car.
GO to C4 for Crown
Victoria/Grand Marquis.
for safety belt warning
chime diagnosis.
C2 CHECK EATC METRIC MODE OUTPUT (TOWN CAR)
Yes
No
GOt oCI O.
GO to C3.
Check E/ M button operation.
Is EATC st uck at met ri c mode?
Yes
No
GOt oCI O.
GO to C3.
C3 CHECK EATC ENGLISH MODE OUTPUT (TOWN CAR)
Yes
No
GO to C8.
GO to C4.
Check E/ M button operation.
Is EATC st uc k at Engl i sh mode ?
Yes
No
GO to C8.
GO to C4.
C4 CHECK SWITCH WIRING CONNECTIONS
Yes
No
GO to C5.
Secure connections and
RECHECK.
Remove finish panel to expose instrument cluster.
Verify that connections at message center switch
module assembly are securely connected.
Are c onne c t i ons secure?
Yes
No
GO to C5.
Secure connections and
RECHECK.
C5 CHECK MCCA SWITCH ASSEMBLY (NO SWITCH
PRESSED)
Yes
No
GO to C6.
REPLACE message
center switch module.
RESTORE vehicle.
RETEST system.
Unplug message center module.
Measure the resistance between Pin 2 and Pin 8
(Circuit 572, O/BK and Circuit 676, PK/ O, Town
CarKCircuit 143, LB/ Y and Circuit 875 BK/ LB,
Crown Victoria / Grand Marquis) of the message
Resistance with no switch pressed should be
17,300 to 17,600 ohms.
Is r esi st ance wi t hi n r ange?
Yes
No
GO to C6.
REPLACE message
RESTORE vehicle.
RETEST system.
13- 01A- 33 I nst r ument Cl us t er El ec t r oni c 13- 01A - 33
ALERT GIVEN (Cont i nued)
C6 CHECK SWI TCH ASSEMBLY (BUTTONS PRESSED)
Unpl ug me s s a ge c e n t e r mo d ul e f r o m e l e c t r o n i c
i nst r ume nt c l ust e r .
Me a sur e t he r e s i s t a n c e be t we e n Pi n 1 (Ci r c ui t 57 2 ,
O/ BK , Town Ca r ) , (Ci r c ui t 143, L B/ Y, Cr o wn
Vi c t o r i a / G r a n d Ma r qui s) a n d Pi n 8 (Ci r c ui t 67 6,
P K / O , Town Ca r ) , (Ci r c ui t 87 5, B K / L B , Cr o wn
Vi c t o r i a / G r a n d Ma r qui s) (NOTE: Pr e ss onl y one
but t o n of t h e me s s a ge c e n t e r s wi t c h mo d ul e whi l e
pr e ssi n g t he pr o bl e m but t o n . )
The r e s i s t a n c e sho ul d be :
NOTE: Me a s ur e r e si st a n c e be t we e n Pi ns 1 and 8 f o r
SELECT f o r wa r d a nd REVERSE, be t we e n Pi ns 2 a nd
8 f o r E / ME Re se t .
Ye s
No

G O t o C7.
REPLACE me s s a ge
c e n t e r s wi t c h mo d ul e .
RETEST s y s t e m.
PINS BUTTON
RESISTANCE (i n
ohms)
2- 8 E M 5100- 52 00
1-8 SE L E CT ( f o r wa r d ) 5100- 52 00
1-8 SE L E CT ( r e v e r s e ) 2 2 50- 2 350
2- 8 RESET 2 2 50- 2 350
Is resi st ance wi t hi n range?
C7 VERI FY HARNESS CONTI NUI TY
Di sc o n n e c t ba t t e r y gr o un d c a b l e .
Re mo v e EI C.
Ch e c k c o n t i n ui t y in Ci r c ui t 143 a n d 152 (Town Ca r )
142 ( Cr o wn Vi c t o r i a , Gr a n d Ma r qui s) .
Ch e c k c o n t i n ui t y t o gr o un d in Ci r c ui t ( 67 6, P K / O a nd
Pi n 8 of s wi t c h mo d ul e C1-8 of EI C, Town Ca r ) , ( 87 5,
B K / L B , Cr o wn Vi c t o r i a / G r a n d Ma r qui s) .
Ye s
No
pi l l ar. RESTORE v e hi c l e .
RETEST s y s t e m.
SERVI CE r e s pe c t i v e
CS CHECK EATC I NPUT FROM EIC IN ENGLI SH MODE
Re mo v e t he c o n n e c t o r f r o m t he EATC.
Pr e ss t he E / M but t o n so t ha t t he i nst r ume nt c l ust e r
i s in ENGLI SH mo d e .
Ch e c k EATC c o n n e c t o r Pi n 2 0 (not on t he EATC).
Is Pin 20 at 5 vol t s DC?
Ye s
No

REFER t o Se c t i o n 12-03B
f o r EATC Di a gn o st i c s.
GO t o C9.
C9 CHECK EIC OUTPUT TO EATC IN ENGLI SH MODE
L e a v e i gni t i on s wi t c h at RUN.
Co n n e c t o r i s r e mo v e d f r o m t he EATC.
i s in ENGLI SH mo d e .
Re mo v e c o n n e c t o r C2 f r o m i nst r ume nt c l ust e r .
Ch e c k Pi n 32 of t h e i nst r ume nt c l ust e r (not t he
ha r n e s s c o n n e c t o r ) .
Is i nst r ument cl ust er Pin 32 at 5 vol t s DC?
Ye s
No
SERVI CE Ci r c ui t 506 (R)
f o r sho r t t o gr o un d or t o
a n o t he r wi r e . RESTORE
RETEST s y s t e m.
C10 CHECK EATC I NPUT FROM EIC IN METRI C MODE
Re mo v e t he c o n n e c t o r f r o m t h e EATC.
i s in METRI C mo d e .
Ch e c k EATC c o n n e c t o r Pi n 20 (not on t he EATC)
Is Pin 20 at 0 vol t s DC?
Ye s
No

REFER t o Se c t i o n 12-03B
f or EATC Di a gn o st i c s.
GO t o C 1 1 .
13- 01A - 34 i n s t r u me n t C l u s t e r E l e c t r o n i c 13- 01A - 34
ALERT GIVEN (Continued)
C11 CHECK EIC OUTPUT TO EATC IN METRI C MODE
Ye s
No
SERVI CE Ci r c ui t 506( R)
f o r o p e n . CHECK f or
i n t e r mi t t e n t c o n t a c t .
RETEST s y s t e m.
RETEST s y s t e m.
o L e a v e i gni t i on s wi t c h a t RUN.
Co n n e c t o r st i l l r e mo v e d f r o m t h e EATC.
P r e s s t he E / M but t o n so t ha t t he i nst r ume nt c l ust e r
i s in METRI C mo d e .
Re mo v e Co n n e c t o r C2 f r o m i nst r ume nt c l ust e r .
Ch e c k Pi n 32 of t h e i n st r ume n t c l ust e r (not t he
ha r n e s s c o n n e c t o r ) .
Is i nst r ument cl ust er Pin 32 at 0 vol t s DC?
Ye s
No
SERVI CE Ci r c ui t 506( R)
f o r o p e n . CHECK f or
i n t e r mi t t e n t c o n t a c t .
RETEST s y s t e m.
RETEST s y s t e m.
PINPOINT TEST D: CO DISPLAYED, TOP TWO AND BOTTOM TWO DIAGNOSTIC BARS DISPLAYED
D1 CHECK FUEL PUMP WI RI NG AT FUEL PUMP
Ye s
No
GO t o D3.
REMOVE j umpe r . GO t o
D2.
L o we r f ue l t a n k t o ga i n a c c e s s t o f uel pump ( FP)
mo d ul e c o n n e c t o r .
Unpl ug f ue l pump (FP) mo d ul e c o n n e c t o r .
Jumpe r v a r i a bl e r e s i s t a n c e t e r mi n a l Ci r c ui t 2 9
( Y/ W) a n d gr o un d t e r mi n a l Ci r c ui t 67 6 ( P K/ O)
(Town Ca r ) or Ci r c ui t 359 ( G Y/ R) ( Cr o wn Vi c t o r i a ,
Gr a n d Ma r qui s) of f uel pump ( FP) mo d ul e c o n n e c t o r .
Re c o n n e c t ba t t e r y .
Turn i gni t i on s wi t c h f r o m OFF t o RUN.
NOTE: It ma y t a ke se v e r a l mi n ut e s f or t he f ue l ga uge
t o r e s p o n d .
Ch e c k d i gi t a l f ue l r e ma i n i n g d i spl a y t o d e t e r mi n e
wh e t h e r i t s h o ws CO or CS.
Does f uel gauge di spl ay show CO?
Ye s
No
GO t o D3.
D2.
D2 CHECK FUEL PUMP RESI STANCE
Ye s
No
GO t o D4.
REPLACE f uel pump.
RETEST s y s t e m.
o Turn i gni t i on s wi t c h t o OFF.
Me a sur e t he r e s i s t a n c e of t h e f ue l pump ( FP)
mo d ul e a t Ci r c ui t s 7 87 ( P K/ BK) a nd 57 ( BK) .
Ver i f y t ha t t he r e s i s t a n c e i s l e ss t ha n 181 o hms
( n o r ma l l y be t we e n 15 a nd 160 o hms) .
Ye s
No
GO t o D4.
REPLACE f uel pump.
RETEST s y s t e m.
D3 CHECK FUEL PUMP WI RI NG AT EIC
Ye s
No
REPLACE EIC. AFFI X
RETEST s y s t e m.
SERVI CE f uel pump wi r i n g
RETEST s y s t e m.
Re mo v e c o n n e c t o r C1 f r o m EIC a nd se c ur e
c o n n e c t o r s f r o m sho r t i n g.
Jumpe r v a r i a bl e r e s i s t a n c e t e r mi n a l Ci r c ui t 2 9
( Y/ W) a n d gr o un d t e r mi n a l Ci r c ui t 67 6 ( P K/ O)
(Town Ca r ) or Ci r c ui t 359 ( G Y/ R) ( Cr o wn Vi c t o r i a ,
Gr a n d Ma r qui s) of ha r n e ss t o ge t h e r at f uel pump
( FP) mo d ul e .
Ve r i f y c o n t i n ui t y be t we e n Pi n C1 -2 a nd Pi n C1 -4
gr o un d of EIC c o n n e c t o r .
Is resi st ance cl ose t o zero ohms?
Ye s
No
REPLACE EIC. AFFI X
RETEST s y s t e m.
SERVI CE f uel pump wi r i n g
RETEST s y s t e m.
D4 VERI FY FUEL PUMP SENDER RESI STANCE OVER
RANGE
Ye s
No
REPLACE f uel pump.
I NSPECT f uel pump wi r i n g
c o n n e c t o r f e ma l e
t e r mi n a l s t o f l a sh or l o o s e
f i t . SERVI CE a s r e qui r e d .
RETEST s y s t e m.
Re mo v e f ue l pump (f uel l e ve l se n so r a n d pump) .
Re f e r t o Se c t i o n 10- 01.
Me a s ur e r e si st a n c e whi l e mo vi n g f l o a t r o d a r m
sl o wl y f r o m e mpt y t o f ul l .
Does resi st ance exceed 181 ohms at any t i me?
Ye s
No
REPLACE f uel pump.
I NSPECT f uel pump wi r i n g
c o n n e c t o r f e ma l e
t e r mi n a l s t o f l a sh or l o o s e
f i t . SERVI CE a s r e qui r e d .
RETEST s y s t e m.
PINPOINT TEST E: CS DISPLAYED, TOP TWO AND BOTTOM TWO DIAGNOSTIC BARS DISPLAYED
T E ST ST EP RESULT ACTION TO TAKE
E1 CHECK FUEL PUMP WI RI NG RESI STANCE AT EI C
Ye s
No
RETEST s y s t e m.
G O t o E 2 .
Re mo v e instrument cluster and secure connectors
f r o m s ho r t i n g.
Wi t h an o hmme t e r , measure resistance between Pin
C1 -6 a n d Pi n C1- 8 (SI G GND) of ha r n e ss.
Ver i f y t ha t t he r e s i s t a n c e is 14 o h ms or gr e a t e r
( n o r ma l l y 15 t o 160 o hms ) .
Is resi st ance at l east 14 ohms?
Ye s
No
RETEST s y s t e m.
G O t o E 2 .
E2 CHECK FUEL PUMP WI RI NG
Ye s
No
REPLACE f uel pump.
RETEST s y s t e m.
SERVI CE f ue l pump wi r i n g
f o r sho r t c i r c ui t .
RETEST s y s t e m.
L o we r f uel t a n k t o ga i n a c c e s s t o f ue l pump ( FP)
mo d ul e c o n n e c t o r .
Unpl ug c o n n e c t o r at f ue l pump ( FP) mo d ul e .
Me a sur e t he r e s i s t a n c e b e t we e n Pi n C1 -6 a n d Pi n
C1 -8 (GND) of ha r n e s s .
Ver i f y t ha t r e s i s t a n c e i s gr e a t e r t ha n 10 K o h ms .
Is resi st ance at l east 10 K ohms?
Ye s
No
REPLACE f uel pump.
RETEST s y s t e m.
SERVI CE f ue l pump wi r i n g
f o r sho r t c i r c ui t .
RETEST s y s t e m.
PINPOINT TEST F: INACCURATE FUEL GAUGE INDICATION
F1 CHECK FUEL GAUGE RESPONSE
Ye s
No
TURN i gni t i on s wi t c h t o
OFF. GO t o F3.
OFF. L e a v e 43 o hm
r e si st o r c o n n e c t e d . GO
t o F2.
L o we r f ue l t a n k a n d ga i n a c c e s s t o f uel pump ( FP)
mo d ul e c o n n e c t i o n s .
Co n n e c t a r e si st o r va l ue of b e t we e n 170- 100 o h ms .
Turn i gni t i on s wi t c h t o t he RUN po s i t i o n . Di spl a y 1 / 2
t a n k or a bo v e f ue l l e v e l .
Turn i gni t i on s wi t c h t o OFF. Di s c o n n e c t ba t t e r y .
Re mo v e 17 0- 100 o h ms r e si st o r .
Co n n e c t a 43 o hm ( 1 pe r c e n t ) r e si st o r in pl a c e of
f ue l pump ( FP) mo d ul e . Ve r i f y va l ue wi t h o hm me t e r .
NOTE: Al l o w at l e a st 30 s e c o n d s f o r c l ust e r t o r e a d
l e v e l .
FUEL REMAI N sho ul d r e a d 3 t o 4 G A L ( 1 3 t o 15
LTR).
Is f uel gauge c o r r e c t ?
Ye s
No
OFF. GO t o F3.
OFF. L e a v e 43 o hm
r e si st o r c o n n e c t e d . GO
t o F2.
F2 CHECK HARNESS RESI STANCE
Ye s
No
RETEST s y s t e m.
( Y/ W) . RESTORE
Re mo v e EIC a nd s e c u r e c o n n e c t o r s f r o m s ho r t i n g.
Me a s u r e r e s i s t a n c e b e t we e n Pi n C1 -6 a nd Pi n C1 -8
(GND) wi t h 43 o hm r e s i s t o r in p l a c e .
Is resi st ance wi t hi n range?
Ye s
No
RETEST s y s t e m.
( Y/ W) . RESTORE
F3 CHECK FUEL TANK SENDI NG UNI T AND PUMP
Ye s
No
GO t o F4.
SERVI CE or REPLACE
f uel pump ( FP) mo d ul e .
RETEST s y s t e m.
Ch e c k f uel pump ( FP) mo d ul e f o r bi n d i n g, s t i c ki n g,
mi sa l i gn me n t , e t c .
Ch e c k se n d e r r e s i s t a n c e not t o e x c e e d 181 o h ms
whi l e mo vi n g a r m sl o wl y f r o m fuel t o e mpt y .
Ch e c k f uel se n d e r r e s i s t a n c e . Re s i s t a n c e sho ul d be
135 t o 165 o hms of f ul l s t o p a n d 14t o 18 o hms a t
e mpt y s t o p.
Is f uel pump (FP) modul e r esi st ance wi t hi n l i mi t s
speci f i ed?
Ye s
No
GO t o F4.
SERVI CE or REPLACE
f uel pump ( FP) mo d ul e .
RETEST s y s t e m.
13- 01A - 36 ^ ^ i n s t r u me n t C l u s t e r E l e c t r o n i c 13- 01A - 36
PINPOINT TEST F: INACCURATE F UEL GAUGE I NDI CATI ON (Cont i nued)
F4 CHECK FUEL TANK
Ye s
No
S y s t e m OK. F a u l t c a u s e d
by o t he r v e hi c l e
s y s t e m( s ) . RESTORE
v e hi c l e .
REPLACE f uel t a n k or f ue l
t ube . Re f e r t o Se c t i o n
1 0 - 0 1 . RESTORE v e hi c l e .
RETEST s y s t e m.
Check f u e l tank f o r d e n t s , bul ge s or o t he r damage.
Ch e c k f o r pr o pe r i n st a l l a t i o n of f ue l t u b e .
I s f uel t ank OK?
Ye s
No
S y s t e m OK. F a u l t c a u s e d
by o t he r v e hi c l e
s y s t e m( s ) . RESTORE
v e hi c l e .
REPLACE f uel t a n k or f ue l
t ube . Re f e r t o Se c t i o n
RETEST s y s t e m.
PINPOINT TEST G: TEMPERATURE GAUGE DISPLAYS TOP TWO AND BOTTOM TWO DIAGNOSTIC BARS
T E ST STEP RESULT A CT I ON TO TA KE
G1 CHECK FOR TEMPERATURE SENDER SHORT
Ye s
No
REPLACE ECT se n so r .
REFER t o Se c t i o n 0 3 - 0 3 .
RETEST s y s t e m.
G O t o G 2 .
Unpl ug e n gi n e c o o l a n t t e mpe r a t ur e (ECT) se n so r
c o n n e c t o r . -
Do e s t e mp e r a t u r e g a u g e i n d i c a t e COL D w i t h
b o t t o m ba r l i t ?
Ye s
No
RETEST s y s t e m.
G O t o G 2 .
G2 CHECK FOR SHORT IN WI RI NG
Ye s
No
pi l l ar. RESTORE v e h i c l e .
RETEST s y s t e m.
SERVI CE bo t h Ci r c ui t 3 9
( R/ W) a nd 8 7 5 ( B K / L B ,
Ma r qui s) a s r e qui r e d .
RETEST s y s t e m.
Unpl ug e ngi ne c o o l a n t t e mpe r a t ur e (ECT) se n so r
c o n n e c t o r .
Di sc o n n e c t c o n n e c t o r C1 a n d c o n n e c t o r C2 f r o m
EIC.
Me a s ur e r e s i s t a n c e be t we e n c o n n e c t o r C 1 Pi n 4
a nd Pi n C 1 - 8 ( GND) .
o I s r e s i s t a n c e g r e a t e r t h a n 1 5 K o h m s ?
Ye s
No
pi l l ar. RESTORE v e h i c l e .
RETEST s y s t e m.
SERVI CE bo t h Ci r c ui t 3 9
( R/ W) a nd 8 7 5 ( B K / L B ,
Ma r qui s) a s r e qui r e d .
RETEST s y s t e m.
PINPOINT TEST H: TEMPERATURE GAUGE ALWAYS INDICATES HOT OR COLD TEMPERATURE
H1 CHECK TEMPERATURE GAUGE WI RI NG
Ye s
No
G Ot o H3. REMOVE
j umpe r . REPLACE ECT
se n so r . REFER t o Se c t i o n
RETEST s y s t e m.
G O t o H 2 .
Unpl ug c o n n e c t o r t o e n gi n e c o o l a n t t e mpe r a t u r e
(ECT) se n so r a n d c o n n e c t a j umpe r in pl a c e of ECT
se n so r .
Ga uge sho ul d gi ve a sho r t c i r c ui t i n d i c a t i o n .
( Bl i n ki n g t he r mo me t e r s y mb o l a n d t o p t wo a n d
b o t t o m t wo ba r s of ga uge l i t . )
Do e s g a u g e i n d i c a t e s h o r t c i r c u i t ?
Ye s
No
G Ot o H3. REMOVE
j umpe r . REPLACE ECT
RETEST s y s t e m.
G O t o H 2 .
H2 CHECK WI RI NG AT CLUSTER
Ye s
No
RETEST s y s t e m.
SERVI CE wi r i n g Ci r c ui t 3 9
( R/ W) a n d / o r 6 7 6 ( P K / 0 ,
Town Ca r ) , 8 7 5 ( B K / L B r
Ma r qui s) . RESTORE
Di sc o n n e c t C1 a nd C2 c o n n e c t o r s f r o m EI C.
Co n n e c t j umpe r in p l a c e of e ngi ne c o o l a n t
t e mpe r a t ur e (ECT) se n so r .
Ver i f y c o n t i n ui t y b e t we e n Pi n C2- 21 a n d Pi n C 1 - 4 of
ha r n e ss.
Is t h e r e c o n t i n u i t y ?
Ye s
No
RETEST s y s t e m.
SERVI CE wi r i n g Ci r c ui t 3 9
( R/ W) a n d / o r 6 7 6 ( P K / 0 ,
Town Ca r ) , 8 7 5 ( B K / L B r
Ma r qui s) . RESTORE
H3 CHECK ENGI NE COOL ANT TEMPERATURE (ECT)
SENSOR
Ye s
No
G O t o H4.
RETEST s y s t e m.
Wa r m up engi ne t o n o r ma l o pe r a t i n g t e mpe r a t u r e .
Me a sur e r e si st a n c e of e n gi n e c o o l a n t t e mpe r a t ur e
(ECT) se nsor .
Is r e s i s t a n c e g r e a t e r t h a n 8 K o h ms ?
Ye s
No
G O t o H4.
RETEST s y s t e m.
PINPOINT TEST H: TEMPERATURE GAUGE ALWAYS INDICATES HOT OR COLD TEMPERATURE (Cont i nued)
TE ST STEP RESULT ACTI ON TO TA KE
H4 CHECK COOLI NG SYSTEM
Ye s
No
RETEST s y s t e m.
SERVI CE c o o l i n g s y s t e m
a s r e qui r e d . REFER t o
Se c t i o n 03-03. RESTORE
Ch e c k t he r mo s t a t , c o o l a n t l e ve l , e t c . , f o r pr o pe r
o pe r a t i o n .
I s c o o l i n g system OK?
Ye s
No
RETEST s y s t e m.
SERVI CE c o o l i n g s y s t e m
a s r e qui r e d . REFER t o
PINPOINT TEST J: NO WARNING TONE WHEN THERMOMETER SYMBOL IS BLINKING
J1 REVI EW OPERATI ON / CONDI TI ON
Ye s
No
Sy s t e m OK.
NOTE: Sa f e t y be l t wa r n i n g c hi me wi l l not be e p if
a n o t he r so un d i s be i n g p r o d u c e d . Dr i ve r a l e r t onl y gi v e n
f o r t e mpe r a t ur e s a bo v e nor ma l ba n d .
Pr e ss any me s s a ge c e n t e r s wi t c h mo d ul e but t o n
a n d l i st e n f or be e p.
Does beep sound?
Ye s
No
Sy s t e m OK.
PINPOINT TEST K: SPEEDOMETER READS 0 KM/ H (MPH) AT ALL SPEEDS
K1 CHECK SPEEDOMETER READI NG
Ye s
No
RETEST s y s t e m.
GO t o K2.
Te st d r i v e v e hi c l e a b o v e 8 k m / h (5 mph) a n d l o o k
f or :
Spe e d o me t e r r e a d i n g
Od o me t e r c ha n gi n g
Ver i f y t ha t o d o me t e r a d v a n c e s whe n v e hi c l e i s
d r i ve n f o r wa r d .
Does odomet er advance wi t h no speed
i ndi cat i on?
Ye s
No
RETEST s y s t e m.
GO t o K2.
K2 CHECK SPEED CONTROL
Ye s
No
G O t o K3.
G O t o K4.
Te st d r i ve v e hi c l e a b o v e 30 MPH, c h e c k s p e e d
c o n t r o l o pe r a t i o n .
Di d speed c ont r ol oper at e pr oper l y ?
Ye s
No
G O t o K3.
G O t o K4.
K3 CHECK CONTI NUI TY
Ye s
No
RETEST s y s t e m.
Di sc o n n e c t c o n n e c t o r s C1 a n d C2 at EI C.
Di sc o n n e c t v e hi c l e s p e e d se n so r .
Ch e c k c o n t i n ui t y in Ci r c ui t 67 9 ( GY/ BK) a n d
c o n t i n ui t y t o gr o un d in Ci r c ui t 67 6 ( P K / O) .
Ye s
No
RETEST s y s t e m.
K4 CHE CKVSS
Ye s
No
CHECK Ci r c ui t s
67 9( G Y/ BK) a nd
6 7 6 ( P K / 0 ) f or c o n t i n ui t y .
If c i r c ui t s OK, CHECK
dr i ve n ge a r a n d r e t a i n e r
c l i p. REPLACE if
n e c e ssa r y . REFER t o
REPLACE v e hi c l e s p e e d
se n so r . REFER t o
Me a s ur e r e s i s t a n c e a c r o s s v e hi c l e s p e e d se n so r .
Is resi st ance be t we e n 200-300 ohms?
Ye s
No
CHECK Ci r c ui t s
67 9( G Y/ BK) a nd
6 7 6 ( P K / 0 ) f or c o n t i n ui t y .
If c i r c ui t s OK, CHECK
dr i ve n ge a r a n d r e t a i n e r
c l i p. REPLACE if
13- 01A - 38 ^ ^_ _ _ Jnstrument Cl y si ei r " o _^ _1*L^
A
38
PINPOINT TEST L: SPEEDOMETER CONSTANTL Y READS TOO HI GH OR TOO L O W
L1 CHECK VEHI CLE SPEED SENSOR DRI VE GEAR
Ye s -
No
GO t o L 2 .
I NSTALL c o r r e c t ge a r
wi t h r e t a i n i n g c l i p. REFER
t o Se c t i o n 0 7 - 0 1 .
RETEST s y s t e m.
Remove vehicle speed sensor from transmission
and verify that correct drive gear is installed for
v e hi c l e t r a n smi ssi o n / a x l e / t i r e c o mbi n a t i o n .
Is dri ve gear correct ?
Ye s -
No
GO t o L 2 .
I NSTALL c o r r e c t ge a r
wi t h r e t a i n i n g c l i p. REFER
t o Se c t i o n 0 7 - 0 1 .
RETEST s y s t e m.
L 2 CHECK DRI VE GEAR ON TRANSMI SSI ON OUTPUT
SHAFT
Ye s
No
GO t o L 3.
I NSTALL c o r r e c t o ut put
sha f t a n d / o r gear .
REFER t o Se c t i o n 07 - 01.
RETEST s y s t e m.
Check t ha t c o r r e c t d r i ve gear is installed on
t r a n smi ssi o n o ut put sha f t .
Is drive gear correct ?
Ye s
No
GO t o L 3.
I NSTALL c o r r e c t o ut put
sha f t a n d / o r gear .
RETEST s y s t e m.
L3 CHECK CONTI NUI TY
Ye s
No
GO t o L 4.
SERVI CE r e s p e c t i v e
Disconnect ba t t e r y ground cable.
Disconnect c o n n e c t o r s C1 and C2 at EI C.
Ch e c k c o n t i n ui t y in Ci r c ui t 67 9 ( G Y/ BK) a n d 67 9
(C1 -12, 136) c o n t i n ui t y t o gr o un d in Ci r c ui t 87 5
( C 1 - 8 K P K / 0 ) .
I s c o n t i n u i t y p r e s e n t ?
Ye s
No
GO t o L 4.
SERVI CE r e s p e c t i v e
L 4 CHECK VSS
Ye s
No
RETEST s y s t e m.
Me a sur e r e s i s t a n c e a c r o s s v e hi c l e s p e e d se n so r .
I s r e s i s t a n c e b e t w e e n 2 0 0 - 3 0 0 o h m s ?
Ye s
No
RETEST s y s t e m.
PI NPOI NT T E ST M: SPEED I NDI CATI ON J UMP S UP AND DOWN ERRATI CALLY
M1 CHECK SPEED SENSOR DRI VE GEAR
Ye s
No
GO t o L 3.
REPLACE d r i ve ge a r
a n d / o r r e t a i ni ng c l i p.
RETEST s y s t e m.
Re mo v e v e hi c l e s p e e d se n so r f r o m t r a n smi ssi o n .
Che c k t ha t al l ge a r t e e t h a r e in go o d c o n d i t i o n ,
r e t a i n e r c l i p i s i n st a l l e d a n d ge a r d o e s not sl i p on
sha f t .
I s v e h i c l e s p e e d s e n s o r i n g o o d c o n d i t i o n ?
Ye s
No
GO t o L 3.
REPLACE d r i ve ge a r
a n d / o r r e t a i ni ng c l i p.
RETEST s y s t e m.
PI NPOI NT T E ST N : SPEED CONTROL I NDI CATOR ALWAYS ON
N 1 CHECK SPEED CONTROL SERVO
Ye s
No
REPLACE s pe e d c o n t r o l
se r v o . VERI FY pr o pe r
o pe r a t i o n . REFER t o
GO t o N2*
Di sc o n n e c t c o n n e c t o r f r o m s pe e d c o n t r o l se r v o .
Do e s s p e e d c o n t r o l I n d i c a t o r g o o f f ?
Ye s
No
REPLACE s pe e d c o n t r o l
se r v o . VERI FY pr o pe r
o pe r a t i o n . REFER t o
GO t o N2*
13- 01 A - 39 I n s t r u me n t C l u s t e r E l e c t r o n i c 13- 01 A - 39
PINPOINT TEST N: SPEED CONTROL INDICATOR ALWAYS ON (Cont i nued)
N2 CHECK EIC
Di sc o n n e c t c l ust e r c o n n e c t o r C2.
Does speed c ont r ol i ndi cat or go of f ?
Ye s
No
CHECK Ci r c ui t
2 0 3 ( 0 / L B ) . SERVI CE a s
r e qui r e d . RESTORE
RETEST s y s t e m.
PINPOINT TE ST P: SPEED CONTROL INDICATOR DOES NOT COME ON WHEN SPEED CONTROL ENGAGED
P1 CHECK VOLTAGE AT SPEED CONTROL SERVO
Di sc o n n e c t c o n n e c t o r f r o m s p e e d c o n t r o l se r v o .
Me a s ur e v o l t a ge be t we e n Ci r c ui t 2 0 3 ( 0 / LB) a n d
Ci r c ui t 6 7 6 ( P K / 0 , Town Ca r ) , 57 ( BK, Cr o wn
Vi c t o r i a / G r a n d Ma r qui s) .
Is vol t age appr oxi mat el y 5V?
Ye s
No
GO t o P2.
G O t o P3.
P2 CHECK CONTI NUI TY
Ch e c k c o n t i n ui t y in Ci r c ui t 2 0 3 ( 0 / L B ) .
Ye s
No
RETEST s y s t e m.
2 0 3 ( 0 / L B ) . RESTORE
P3 VERI FY POWER AT SPEED CONTROL SERVO
Ch e c k f o r ba t t e r y v o l t a ge at t he s p e e d c o n t r o l se r v o
c o n n e c t o r in Ci r c ui t 2 95( L B/ P K, Town Ca r ) , 2 96
( W/ P , Cr o wn Vi c t o r i a / G r a n d Ma r q ui s ) .
Ye s
No
REPLACE s p e e d c o n t r o l
se r v o . REFER t o Se c t i o n
10-03. RESTORE v e hi c l e .
RETEST s y s t e m.
2 95( L B / PK) a n d / o r f use
4Town Car. SERVI CE
Ci r c ui t 2 96( L B/ P K)
a n d / or f use 6Cr o wn
Vi c t o r i a , Gr a nd Ma r qui s.
RETEST s y s t e m.
PINPOINT TEST Q: DISPLAY HAS " S" ILLUMINATED
Q1 DETERMI NE IF SPEEDOMETER / ODOMETER MODULE
IS ORI GI NAL
Ch e c k f o r mi l e a ge s t i c ke r on d o o r pi l l ar .
Is mi l eage st i c ke r ori gi nal ?
Ye s
No
REPLACE EI C. If
o d o me t e r r e a d i n g i s
kn o wn , pr o gr a m it i nt o
new EI C. If o d o me t e r
r e a d i n g i s un kn o wn ,
pr o gr a m in " S " 00000. 5
wi t h t he c i r c l e d S a nd
ze r o mi l e s in t he
o d o me t e r . RESTORE
v e hi c l e .
PINPOINT TEST R: MILEAGE CONSTANTLY READS TOO HIGH OR TOO LOW
R1 CHECK SPEEDOMETER
Ye s
No
REPLACE EI C. Af f i x
pi l l a r . RESTORE v e hi c l e .
RETEST s y s t e m.
GO t o Pi npoi nt Te st L.
Verify that speedometer is operating properly.
Does speedomet er operat e properl y?
Ye s
No
REPLACE EI C. Af f i x
RETEST s y s t e m.
PINPOINT TEST S: ODOMETER DOES NOT ACCUMULATE MILEAGE OR COUNTS 1.6 KM (1.0 MILE) AND JUMPS BACK
1.6 KM (1.0 MILE)
S1 CHECK ODOMETER OPERATI ON
Ye s
No
RETEST s y s t e m.
GO t o S2.
Ch e c k o d o me t e r t o d e t e r mi n e whe t he r it
a c c umul a t e s a nd t he n l o s e s 1.6 km (1. 0 mi l e ) or i t
wi l l not a c c umul a t e mi l e a ge at a l l .
Does odomet er accumul at e and t hen l ose 1.6 km
(1.0 mi le)?
Ye s
No
RETEST s y s t e m.
GO t o S2.
S2 VERI FY SPEEDOMETER
Ye s
No
RETEST s y s t e m.
Ver i f y t ha t s p e e d o me t e r wo r ks pr o pe r l y .
Does speedomet er oper at e pr oper l y ?
Ye s
No
RETEST s y s t e m.
PINPOINT TEST T: INSTANTANEOUS OR AVERAGE FUEL ECONOMY ALWAYS READS 0 MI LES/GAL OR 9 9 U100 KM OR
9 9 MI L E S / G A L OR 0 L / 1 0 0 KM
T1 CHECK MESSAGE CENTER DI SPLAY
Ye s
No
GO t o T2.
G O t o T3.
Ch e c k me s s a ge c e n t e r d i spl a y t o d e t e r mi n e
whe t he r i t i s s ho wi n g 0 MPG, 9 9 L / 1 0 0 KM or 99
MP G . OL / 100 KM.
Is message cent er di spl ay showi ng 0 MPG, 9 9
L/ 100 Km?
Ye s
No
GO t o T2.
G O t o T3.
T2 CHECK SPEEDOMETER OPERATI ON
Ye s
No
RETEST s y s t e m.
G O t o Pi npoi nt Te st K.
Ver i f y t ha t s p e e d o me t e r i s o pe r a t i n g pr o pe r l y .
Does speedomet er oper at e pr oper l y ?
Ye s
No
RETEST s y s t e m.
G O t o Pi npoi nt Te st K.
T3 OBSERVE O / D OFF I NDI CATOR
Ye s
No
REFER t o Po we r t r a i n
Co n t r o l / E mi s s i o n s
2
( f l o w
out put i n t e r r upt e d by EEC
s y s t e m f a i l ur e ) .
GO t o T4.
Te st d r i ve v e hi c l e wi t h 0 / D of f s e l e c t e d .
Does O/ D of f i ndi cat or f l ash?
Ye s
No
REFER t o Po we r t r a i n
2
( f l o w
out put i n t e r r upt e d by EEC
s y s t e m f a i l ur e ) .
GO t o T4.
T4 CHECK CONTI NUI TY OF CI RCUI T 2 05 (FUEL FL OW)
Ye s D>
No >
GO t o T4.
SERVI CE wi r i n g Ci r c ui t
2 05 ( DB/ L G ) a s r e qui r e d .
RETEST s y s t e m.
Ver i f y c o n t i n ui t y a n d a bs e n c e of s h o r t s in Ci r c ui t
2 06 ( DB/ L G ) .
I s wi r i ng OK?
Ye s D>
No >
GO t o T4.
SERVI CE wi r i n g Ci r c ui t
2 05 ( DB/ L G ) a s r e qui r e d .
RETEST s y s t e m.
PINPOINT TEST T: INSTANTANEOUS OR AVERAGE FUEL ECONOMY ALWAYS READS 0 MI LES/GAL OR 99 U100 KM OR
99 MI LES/GAL OR 0 L / 100 KM (Cont i nued)
T5 ENTER SELF TEST MODE
Ye s
No
o d o me t e r s t i c ke r t o door
RETEST s y s t e m.
GOt o T5.
Turn i gni t i on s wi t c h t o OFF.
Push a n d ho l d E / M a nd <SE L E CT (l e f t ) but t o n s
t o ge t he r .
Turn i gni t i on s wi t c h t o START whi l e ho l d i n g but t o n s.
Re l e a se but t o n s whe n c l ust e r l i ght s.
Al l o w e ngi ne t o run dur i ng r e ma i n d e r of t e s t .
Obs e r v e o d o me t e r .
Does odomet er f l ash?
Ye s
No
o d o me t e r s t i c ke r t o door
RETEST s y s t e m.
GOt o T5.
T6 ENTER DI SPLAY TEST MODE
Ye s
No
GO t o T7.
GO t o T5.
Push S e l e c t > ( r i ght ) but t o n o n c e a n d o b s e r v e
d i spl a y .
Is t he di spl ay t he same as i n St ep 1 of segment
di spl ays i n i nspect i on and ver i f i cat i on?
Ye s
No
GO t o T7.
GO t o T5.
T7 ENTER A / D, DI GI TAL PORT TEST MODE
Ye s
No
GO t o T8.
G O t o T S .
Push E / M and <SE L E CT ( l e f t ) but t o n s t o ge t h e r
o n c e . Ob s e r v e o d o me t e r d i spl a y , l ef t t wo d i gi t s .
m Does odomet er ' s l ef t t wo di gi t s read "OA"?
Ye s
No
GO t o T8.
G O t o T S .
T8 ENTER FUEL FL OW I NPUT TEST MODE
Ye s
No
OFF t o e xi t t e s t mo d e s .
Sy st e m OK.
RECHECK Ci r c ui t 205; if
OK t he n REPLACE
po we r t r a i n c o n t r o l
mo d ul e . REFER t o
Se c t i o n 03- 14. RESTORE
RETEST s y s t e m.
Push SE L E CT> ( r i ght ) but t o n t wi c e qui c kl y .
Obs e r v e l ef t t wo o d o me t e r d i gi t s c h a n ge t o " 1 b . "
Re pe a t t hi s st e p f our t i me s unt i l o d o me t e r l ef t t wo
d i gi t s r e a d " 5 F . " ( Le f t t wo d i gi t s of o d o me t e r wi l l
a d v a n c e : OA, 1B, 2C, 3D, 4E, 5F, 60, 7 1 , OA... e t c . )
Se l e c t 5F Obs e r v e t he r i ght f our d i gi t s of t he
o d o me t e r s e l e c t 5F t he n o bs e r v e d i spl a y . The
f r e que n c y of t he f uel f l o w pul se s f r o m t he PCM i s
s h o wn . ( St e p on a c c e l e r a t o r . )
" 0000" i n d i c a t e s no f ue l f l o w pul se s r e c e i v e d f r o m
t he P CM.
Any o t he r numbe r i n d i c a t e s f uel f l o w pul se s a r e
be i n g r e c e i v e d f r o m t h e PCM.
Do ri ght f our di gi t s read "0000" (no f uel pul ses)?
Ye s
No
OFF t o e xi t t e s t mo d e s .
Sy st e m OK.
RECHECK Ci r c ui t 205; if
OK t he n REPLACE
po we r t r a i n c o n t r o l
mo d ul e . REFER t o
RETEST s y s t e m.
PINPOINT TEST U: DTE DOES NOT GO BELOW 322 KM (200 MILES) WITH FUEL TANK EMPTY OR DTE ALWAYS READS
ZERO
U1 CHECK FUEL GAUGE
Ye s
No
GOt o U2.
REFER t o Fuel Ga uge
Di a gn o si s in Sy mpt o m
Cha r t .
Ver i f y t ha t f ue l ga uge i s o pe r a t i n g pr o pe r l y .
Does gauge operat e pr ope r l y ?
Ye s
No
GOt o U2.
REFER t o Fuel Ga uge
Cha r t .
U2 CHECK SPEEDOMETER
Ye s
No
GO t o Pi npoi nt Te st T.
REFER t o Spe e d o me t e r
Cha r t .
Ver i f y t ha t s p e e d o me t e r i s o pe r a t i n g pr o pe r l y .
Does speedomet er oper at e pr oper l y?
Ye s
No
REFER t o Spe e d o me t e r
Cha r t .
PINPOINT TEST V: DOOR AJAR WARNING NEVER/ALWAYS COMES ON
V1 CHECK EIC FOR WARNI NGS
Ye s
No
GO t o V2 .
G O t o V 4 .
Wa i t pa st pr o v e - o ut t i me .
Ch e c k EI C f o r DOOR AJAR wa r n i n g t o d e t e r mi n e
wh e t h e r wa r n i n g i s a l wa y s on or ne ve r o n .
Is door aj ar war ni ng al ways on?
Ye s
No
GO t o V2 .
G O t o V 4 .
PINPOINT TE ST V: DOOR AJAR WARNING NE VE R/ A L WA YS COMES ON (Cont i nued)
V2 CHECK DOOR OPEN WARNI NG LAMP SWI TCHES
The f o l l o wi n g s t e p s a r e t o be r e pe a t e d f or e a c h
d o o r o pe n wa r n i n g l a mp s wi t c h . St a r t wi t h t h e
d r i v e r ' s door , t he n f r ont pa s s e n ge r ' s , t he n r e a r
pa s s e n ge r ' s door .
Turn i gni t i on s wi t c h t o OFF. Thi s r e s e t s t he wa r n i n g.
Di sc o n n e c t d o o r o pe n wa r n i n g l a mp s wi t c h
c o n n e c t o r at d o o r o pe n wa r n i n g l a mp s wi t c h .
Turn i gn i t i o n s wi t c h t o RUN.
Ch e c k me s s a ge c e n t e r f o r wa r n i n g.
Re pe a t unt i l no wa r n i n g i s d i s pl a y e d or al l d o o r o pe n
wa r n i n g l a mp s wi t c h e s a r e d i s c o n n e c t e d .
Is war ni ng st i l l di spl ay ed?
Ye s
No

GO t o V4.
GO t o V3.
V3 LI GHTI NG CONTROL MODUL E CHECK
Unpl ug l i ght i n g c o n t r o l mo d ul e .
Is war ni ng st i l l pr esent ?
Ye s
No

GO t o V4.
SERVI CE l i ght i ng c o n t r o l
mo d ul e .
V4 CHECK CI RCUI T 62 7 ( BK / O)
Di sc o n n e c t e l e c t r o n i c i n st r ume n t c l ust e r .
Ch e c k c o n t i n ui t y t o gr o un d in Ci r c ui t 62 7 ( BK / O) .
Is cont i nui t y t o gr ound pr esent ?
Ye s
No
( BK / O) f o r shor t t o
gr o un d . RESTORE
GO t o V5.
V5 CHECK POWER AND GROUNDS
Che c k v o l t a ge on t he f o l l o wi n g pi n s:
Pi n
Ci r c u i t
Nu mb e r Vo l t a ge
C1- 7 2 96 ( W/ P ) 12V ( Ho t At Al l Ti me s )
C1- 9 2 95 ( L B / P K ) 12V ( Ho t In RUN)
C3- 7 489
( P K / B K )
12V ( Ho t In RUN)
C3- 2 2 95 ( L B / P K ) 12V ( Ho t In RUN)
C1- 8 8 7 5 ( P K / O ) OV
C3- 1 8 7 5 ( P K / O ) OV
Ye s
No
Are all vol t ages as spe c i f i e d?

GO t o V6.
RETEST s y s t e m.
V6 CHECK DOOR OPEN WARNI NG L AMP SWI TCH
Pul l c o n n e c t o r of f of t he pr o bl e m d o o r o pe n wa r n i n g
l a mp s wi t c h .
Co n n e c t a j umpe r wi r e f r o m Ci r c ui t 627 (BK / O) at
t h e ha r n e ss c o n n e c t o r t o gr o un d .
Is war ni ng di spl ayed?
Ye s
No
SERVI CE d o o r o pe n
RETEST s y s t e m.
V7 . RESTORE v e hi c l e .
RETEST s y s t e m.
V7 CHECK WI RI NG
Di sc o n n e c t e l e c t r o n i c i nst r ume nt c l ust e r
Ch e c k c o n t i n ui t y in Ci r c ui t 62 7 ( B K / O ) .
Ye s
No
REPLACE EI C. AFFI X .
RETEST s y s t e m.
( BK / O) f o r o pe n .
RETEST s y s t e m.
13- 01A - 43
i n s t r u me n t C l u s t e r E l e c t r o n i c
13- 01A - 43
PINPOINT TE ST W: TRUNK AJAR WARNI NG NE VE R/ A L WA YS COME S ON
W1 CHECK EIC FOR WARNI NGS
Wai t pa st pr o v e - o ut t i me .
Che c k EIC f or TRUNK AJAR wa r n i n g t o d e t e r mi n e
whe t he r t he wa r n i n g i s a l wa y s on or never o n .
Is t r unk aj ar war ni ng al ways on?
Ye s
No

GO t o W2 .
GO t o W5.
W2 CHECK LUGGAGE COMPARTMENT DOOR OPEN
WARNI NG LAMP SWI TCH
Pull c o n n e c t o r of f of l ugga ge c o mpa r t me n t d o o r
o pe n wa r n i n g l a mp s wi t c h .
Che c k EIC f or wa r n i n g.
Is warni ng di spl ayed?
Ye s
No

GO t o W3.
SERVI CE l ugga ge
c o mpa r t me n t d o o r o pe n
RETEST s y s t e m.
W3 LI GHTI NG CONTROL MODULE CHECK
NOTE: LCM pr o v i d e s pul l -up t o ba t t e r y f or EIC t o ke e p
wa r n i n g of f . If L CM i s i n o pe r a t i v e or r e mo v e d , EIC t r unk
a j a r wa r n i n g s t a y s o n .
Di sc o n n e c t t r unk aj ar s wi t c h .
Re mo v e EIC.
Wi t h i gni t i on s wi t c h in RUN po s i t i o n , c h e c k f o r
ba t t e r y v o l t a ge at Pi n C2 - 2 7 , Ci r c ui t 486.
Ye s
No

GO t o W4.
SERVI CE L CM.
W4 CHECK CI RCUI T 486 (BR / W)
Di sc o n n e c t e l e c t r o n i c i n st r ume n t c l u s t e r .
Che c k c o n t i n ui t y t o gr o un d in Ci r c ui t 486 ( BR/ W) .
Ye s
No
( BR/ W) f or sho r t .
RETEST s y s t e m.
RETEST s y s t e m.
W5 CHECK POWER AND GROUNDS
Che c k v o l t a ge on t he f o l l o wi n g pi ns:
Pin
Ci rcui t
Number Vol t age
C1- 7 7 9 7 / 5 4
( W/ P )
12V ( Ho t At Al l Ti me s)
C1- 9 2 95 ( L B / P K ) 12V ( Ho t In RUN)
C3- 7 489
( P K / B K )
12V ( Ho t In RUN)
C3- 2 2 95 ( L B / P K ) 12V ( Ho t In RUN)
C1- 8 87 5 ( P K / O ) ov
C3- 1 87 5 ( P K / O ) OV
Ye s
No

GO t o W6 .
RETEST s y s t e m.
W6 CHECK LUGGAGE COMPARTMENT DOOR OPEN
WARNI NG L AMP SWI TCH
Pul l c o n n e c t o r of f of t h e l ugga ge c o mpa r t me n t d o o r
o pe n wa r n i n g l a mp s wi t c h .
Co n n e c t a j umpe r wi r e f r o m Ci r c ui t 486 ( BR/ W) at
t h e ha r n e ss c o n n e c t o r t o gr o un d .
Ch e c k EIC f or wa r n i n g.
I s war ni ng di spl ayed?
Ye s
No
SERVI CE l ugga ge
c o mpa r t me n t d o o r o pe n
RETEST s y s t e m.
REMOVE j umper . GO t o
W7 .
PI NPOI NT TE ST W: TRUNK AJAR WARNING NEVER/ALWAYS COMES ON (Cont i nued)
W 7 CHECK WI RI NG
Ye s
No
RETEST s y s t e m.
( BR/ W) f o r o pe n .
RETEST s y s t e m.
Di sc o n n e c t e l e c t r o n i c i nst r ume nt c l u s t e r .
Ch e c k c o n t i n ui t y in Ci r c ui t 486 ( BR/ W) .
Is t here cont i nui t y pr esent ?
Ye s
No
RETEST s y s t e m.
( BR/ W) f o r o pe n .
RETEST s y s t e m.
PINPOINT TE ST X: CHARGE SYSTEM WARNING NEVER/ALWAYS ON
X 1 CHECK CHARGI NG SYSTEM VOLTAGE
Ye s
No
G O t o X2 .
SERVI CE ge n e r a t o r .
RETEST s y s t e m.
St a r t e ngi ne a nd c h e c k f o r wa r n i n g. Wa t c h f or
se v e r a l mi n ut e s.
Che c k ba t t e r y v o l t a ge .
I s t he vol t age normal (above 14 vol t s) f or engi ne
at f ast i dl e?
Ye s
No
G O t o X2 .
SERVI CE ge n e r a t o r .
RETEST s y s t e m.
X2 CHECK HARNESS TO GENERATOR
Ye s
No
SERVI CE t he ge n e r a t o r .
RETEST s y s t e m.
G O t o X S .
Di sc o n n e c t ge n e r a t o r .
Co n n e c t a j umpe r t o gr o un d f r o m Ci r c ui t 904 (LG / R)
near t he ge n e r a t o r .
Does charge warni ng go away?
Ye s
No
SERVI CE t he ge n e r a t o r .
RETEST s y s t e m.
G O t o X S .
X3 CHECK HARNESS TO EIC
Ye s
No
G O t o X5.
G O t o X4.
Turn i gni t i on s wi t c h t o RUN but d o not st a r t e ngi ne .
Re mo v e j umpe r .
Me a sur e v o l t a ge at ge n e r a t o r f r o m Ci r c ui t 904
( L G / R) t o gr o un d .
Is it great er t han 4 v o l t s ?
Ye s
No
G O t o X5.
G O t o X4.
X4 CHECK EIC I NTEGRAL ALTERNATOR REGULATOR
RESI STOR AND HARNESS
Ye s
No
SERVI CE a s r e qui r e d t o
o bt a i n ove r 4 v o l t s.
RETEST s y s t e m.
( P K/ BK, Town Ca r ) , 88
( BK/ W, Cr o wn
Vi c t o r i a / Gr a n d Ma r qui s)
of c o n n e c t o r C3.
RETEST s y s t e m.
~ X 5 ~
Re mo v e EIC.
Che c k f or l o o se or c o r r o d e d s c r e ws on ge n e r a t o r
wa r n i n g l a mp shunt r e si st o r on r e a r of EI C.
Che c k t ha t r e si st o r i s 400- 600 o h ms .
Ch e c k c ont i nui t y f r o m r e si st o r s c r e ws t o Ci r c ui t 904
( L G / R) at c o n n e c t o r .
Ch e c k f or sho r t t o gr o un d on Ci r c ui t 904.
Has any check f ai l ed?
Ye s
No
SERVI CE a s r e qui r e d t o
o bt a i n ove r 4 v o l t s.
RETEST s y s t e m.
( P K/ BK, Town Ca r ) , 88
( BK/ W, Cr o wn
of c o n n e c t o r C3.
RETEST s y s t e m.
~ X 5 ~ [ C H E C K EIC WI RI NG FOR OPEN CI RCUI T
Ye s
No
REPLACE EIC. AFFI X
o d o me t e r st i c ke r t o d o o r
RETEST s y s t e m.
( L G / R) . RESTORE
Di sc o n n e c t i nst r ume nt c l u s t e r .
Ch e c k f or c o n t i n ui t y in Ci r cui t 904, ( LG / R).
Ye s
No
REPLACE EIC. AFFI X
RETEST s y s t e m.
( L G / R) . RESTORE
16
i nst r ument Cl y s t er El ec t r oni c 13- 01A - 45
PINPOINT TE ST Y: RIDE CONTROL/AI R SUSPENSION WARNING ALWAYS ON
Y1 CHECK EIC FOR WARNI NGS
Turn I gni t i on swi t c h t o RUN.
Wait pa st pr o ve - o ut t i me .
Che c k EIC f or AI R SUSPENSI ON wa r n i n g to
d e t e r mi n e whe t he r t he wa r n i n g i s a l wa y s on or ne ve r
o n .
Is AIR SUSPENSION war ni ng al ways on?
Ye s
No

GO t o Y2 .
GO t o Y4.
Y2 CHECK AI R SUSPENSI ON CONTROL MODULE
Di sc o n n e c t ai r suspe n si o n c o n t r o l mo d ul e .
Ye s
No

GO t o Y3.
SERVI CE ai r suspe n si o n
c o n t r o l mo d ul e . REFER t o
Y3 CHECK CONTI NUI TY
_ Ch e c k c o n t i n ui t y in Ci r c ui t 4 1 9 ( DG / L G ) .
Ye s
No
RETEST s y s t e m.
( DG / L G ) . RESTORE
Y4 CHECK FOR POWER AND GROUNDS
Ch e c k v o l t a ge on t he f o l l o wi n g pi n s:
Pin
Circuit
N u mb e r Vo l t a g e
C1- 9 2 95 ( L B / P K ) 12V ( Ho t In RUN)
C3- 7 489
( P K / B K )
12V ( Ho t In RUN)
C3- 2 2 95 ( L B / P K ) 12V ( Ho t In RUN)
C1- 8 87 5 ( P K / O ) OV
C3- 1 87 5 ( P K / O ) OV
Ye s
No

GO t o Y5.
RETEST s y s t e m.
Y5 CHECK AIR SUSPENSI ON MODULE
Di sc o n n e c t c o n n e c t o r at ai r s us pe n s i o n c o n t r o l
mo d ul e .
Co n n e c t a j umpe r wi r e f r o m Ci r c ui t 4 1 9 (DG / LG) at
ha r n e s s c o n n e c t o r t o gr o un d .
Ch e c k EIC f o r wa r n i n g.
Is war ni ng di spl ayed?
Ye s
No
SERVI CE ai r suspe n si o n
GO t o Y6.
Y6 CHECK CONTI NUI TY
Di sc o n n e c t EIC.
Ch e c k c o n t i n ui t y in Ci r c ui t 419 ( DG / L G ) .
Ye s
No
REPLACE EIC. AFFI X
RETEST s y s t e m.
SERVI CE Ci r cui t 419
( DG/ L G) . RESTORE
PI NPOI NT T E ST A A : L OW WASHER FL UI D WARNI NG NEVER/ALWAYS ON
AA1 CHECK SYSTEM AND WARNI NG
Dr ai n f l ui d f r o m wi n d s hi e l d wa s h e r r e se r v o i r f or
"wa r n i n g ne ve r o n . "
Add f l ui d t o wi n d s hi e l d wa s h e r r e se r v o i r f o r
"wa r n i n g a l wa y s o n . "
Wai t pa st pr o v e - o ut t i me .
Ch e c k me s s a ge c e n t e r f o r l o w WASHER FLUI D
wa r n i n gs t o d e t e r mi n e wh e t h e r t he wa r n i n g i s
a l wa y s on or ne ve r o n .
Is warni ng al ways on?
Ye s
No

GO t o AA2.
GO t o AA4.
AA2 CHECK WI NDSHI ELD WASHER RESERVOI R FLUI D
LEVEL SENSOR
Di sc o n n e c t ha r n e s s c o n n e c t o r f r o m wi n d shi e l d
wa s h e r r e se r v o i r f l ui d l e ve l se n so r .
Che c k EIC f or wi n d s h i e l d wa s h e r f l ui d wa r n i n g.
Ye s
No

GO t o AA3.
SERVI CE wi n d shi e l d
wa s h e r r e se r v o i r f l ui d
l e ve l se n so r . REFER t o
Se c t i o n 0 1 - 1 6 . RESTORE
AA3 CHECK CONTI NUI TY
Che c k c o n t i n ui t y in Ci r c ui t 82 ( P K/ Y) .
I s cont i nui t y pr esent ?
Ye s
No
RETEST s y s t e m.
( P K/ Y) f o r sho r t t o
gr o un d . RESTORE
AA4 CHECK FOR POWER AND GROUNDS
Pin
Ci rcui t
Number Vol t age
C1- 9 2 95 ( L B / P K ) 12V ( Ho t In RUN)
C3- 7 489
( P K / B K )
12V ( Ho t In RUN)
C3- 2 2 95 ( L B / P K ) 12V ( Ho t In RUN)
C1- 8 87 5 ( P K / 0 ) OV
C3- 1 87 5 ( P K / 0 ) OV
Ye s
No
Are all vol t ages as speci f i ed?

G Ot o AA5.
RETEST s y s t e m.
AA5 CHECK WI NDSHI ELD WASHER RESERVOI R FLUI D
LEVEL SENSOR
Unpl ug ha r n e ss c o n n e c t o r f r o m wi n d s hi e l d wa s h e r
r e se r vo i r f l ui d l e ve l se n so r .
Co n n e c t a j umpe r wi r e a c r o s s t he 2 pi ns of ha r n e ss
c o n n e c t o r .
Che c k me s s a ge s f or l ow WASHER FLUI D wa r n i n g.
Ye s
No
SERVI CE wi n d shi e l d
wa s h e r r e se r v o i r f l ui d
l e ve l se n so r . REFER t o
G O t o AA6.
AA6 CHECK CONTI NUI TY
Che c k c o n t i n ui t y in Ci r c ui t 82 ( P K / Y) a n d c o n t i n ui t y
t o gr o un d in Ci r c ui t 87 5 ( P K/ O) Cr o wn Vi c t o r i a ,
Gr a nd Ma r qui s.
Ye s
No
RETEST s y s t e m.
13- 01A - 47 I n s t r u me n t Cl u s t e r I
E l e c t r o n i c 13- 01A - 47
PINPOINT TEST B B : CHECK ENGINE (MIL) WARNING ALWAYS ON
B B 1 CHECK EIC FOR MI L WARNI NG
Ye s
No >
Di a gn o si s Ma n u a l s
3
t o
PERFORM Di a gn o st i c
Sel f Te st .
Sy s t e m OK.
Che c k f or wa r n i n g me s s a ge s .
I s CHECK ENGI NE w a r n i n g d i s p l a y e d ?
Ye s
No >
Di a gn o si s Ma n u a l s
3
t o
PERFORM Di a gn o st i c
Sel f Te st .
Sy s t e m OK.
PI NPOI NT T E ST CC: LH TURN I NDI CATOR NE VE R/ A L WA YS ON ( CROWN VI CTORI A, GRAND MARQUI S ONLY)
CC1 CHECK EIC FOR WARNI NG
Ye s
No
GO t o CC2 .
G O t o C C 3 .
Che c k EIC f or LH t ur n i n d i c a t o r t o d e t e r mi n e if t h e
LH t ur n i n d i c a t o r i s a l wa y s on or never o n .
I s LH t u r n i n d i c a t o r a l w a y s o n ?
Ye s
No
GO t o CC2 .
G O t o C C 3 .
CC2 I SOLATE LH TURN I NDI CATOR SOURCE
Ye s
No
REPLACE e l e c t r o n i c
RETEST s y s t e m.
( L G / W) . REFER t o
Se c t i o n 11-05 f or
St e e r i n g Col umn
Swi t c h e s d i a gn o si s.
Re mo v e EIC a s o ut l i n e d .
Di sc o n n e c t c o n n e c t o r C3 f r o m EI C.
Me a sur e v o l t a ge Ci r c ui t 3 wi t ho ut t ur n si gna l
a c t i v a t e d .
I s v o l t a g e OV?
Ye s
No
RETEST s y s t e m.
( L G / W) . REFER t o
Se c t i o n 11-05 f or
St e e r i n g Col umn
Swi t c h e s d i a gn o si s.
CC3 CHECK FOR TURN SI GNAL SWI TCH POWER I NPUT
Ye s
No
REPLACE EI C.
( L G / W) f o r o pe n c i r c ui t .
f or t urn si gna l a n d
wi n d shi e l d wi pe r s wi t c h
c o n t i n ui t y t e st . RESTORE
Re mo v e EIC a s o ut l i n e d .
Usi ng t h e t ur n si gn a l l ever , si gn a l f o r a LH t ur n .
Usi ng a mul t i me t e r , me a sur e v o l t a ge at c o n n e c t o r
Pi n C3- 6, Ci r c ui t 3 ( L G / W) .
I s v o l t a g e g r e a t e r t h a n 9 v o l t s ?
Ye s
No
REPLACE EI C.
( L G / W) f o r o pe n c i r c ui t .
f or t urn si gna l a n d
PI NPOI NT TE ST DD: RH TURN I NDI CATOR NE VE R/ A L WA YS ON
DD1 CHECK EIC FOR WARNI NG
Ye s
No
G O t o DD2 .
G O t o DD3.
Ch e c k EIC f or RH t ur n i n d i c a t o r t o d e t e r mi n e if t he
RH t ur n i n d i c a t o r i s a l wa y s on or ne ve r o n .
I s RH t u r n i n d i c a t o r a l w a y s on?
Ye s
No
G O t o DD2 .
G O t o DD3.
DD2 I SOLATE RH TURN I NDI CATOR SOURCE
Ye s
No
RETEST s y s t e m.
SERVI CE Ci r c ui t 3.
Re mo v e EIC as o ut l i n e d .
e Di sc o n n e c t c o n n e c t o r C3 f r o m EI C.
Me a sur e v o l t a ge at Ci r c ui t 3 wi t ho ut t urn si gna l
a c t i v a t e d .
I s vol t age OV?
Ye s
No
RETEST s y s t e m.
SERVI CE Ci r c ui t 3.
DD3 CHECK FOR TURN SI GNAL SWI TCH POWER I NPUT
Ye s
No
REPLACE EI C.
( W/ L B ) f or o pe n c i r c ui t .
f or t ur n si gna l a n d
Re mo v e EI C a s o ut l i n e d .
Usi ng t he t ur n si gn a l l ever , si gn a l f o r a RH t ur n .
Usi ng a mul t i me t e r , me a sur e v o l t a ge at c o n n e c t o r
Pi n C3- 5, Ci r c ui t 2 ( W/ L B ) .
I s vol t age g r e a t e r t h a n 9 v o l t s ?
Ye s
No
REPLACE EI C.
( W/ L B ) f or o pe n c i r c ui t .
f or t ur n si gna l a n d
PINPOINT TEST EE: HIGH BEAM WARNING NEVER/ALWAYS ON
E E 1 VERI FY CONDI TI ON
Ye s
No
GO t o EE2.
GO t o EE4.
NOTE: Ma ke sur e t he l i ght s wi t c h e s a r e in pr o pe r
po s i t i o n s whe n c h e c ki n g c i r c ui t o pe r a t i o n .
Wa i t pa s t pr o v e - o ut t i me .
Ch e c k EIC d i s pl a y s t o d e t e r mi n e whe t he r t he
i n d i c a t o r i s a l wa y s on or ne ve r on.
Is HIGH BEAM i ndi cat or al ways on?
Ye s
No
GO t o EE2.
GO t o EE4.
EE2 CHECK EI C FOR SHORT CI RCUI T
Ye s
No
RETEST s y s t e m.
GO t o EE3.
Di s c o n n e c t c o n n e c t o r C3 at EI C.
Me a s u r e v o l t a ge at C3- 4.
Is vol t age OV wi t h i gni t i on ON, headl amps ON,
hi ghbeams OFF?
Ye s
No
RETEST s y s t e m.
GO t o EE3.
EES CHECK FOR SHORT TO BATTERY
Ye s
No
SERVI CE sho r t t o ba t t e r y
i n Ci r c ui t 12 ( L G / BK)
a n d / o r Ci r c ui t 932
( G Y/ W) . CHECK d a y t i me
runni ng l a mps c o n t r o l
mo d ul e (i f e q ui ppe d ) f or
sho r t t o ba t t e r y .
RETEST s y s t e m.
REPLACE HI -LO be a m
r e l a y T o wn Car,
mul t i - f un c t i o n
s w i t c h C r o w n
Vi c t o r i a / G r a n d Ma r qui s.
RETEST s y s t e m.
Re c o n n e c t EIC.
Di s c o n n e c t HI -LO Be a m Re l a y T o wn Car,
mul t i - f un c t i o n s w i t c h C r o w n Vi c t o r i a / Gr a n d
Ma r qui s.
Is HIGH BEAM i ndi cat or i l l umi nat ed?
Ye s
No
SERVI CE sho r t t o ba t t e r y
i n Ci r c ui t 12 ( L G / BK)
a n d / o r Ci r c ui t 932
( G Y/ W) . CHECK d a y t i me
runni ng l a mps c o n t r o l
mo d ul e (i f e q ui ppe d ) f or
RETEST s y s t e m.
REPLACE HI -LO be a m
r e l a y T o wn Car,
mul t i - f un c t i o n
s w i t c h C r o w n
Vi c t o r i a / G r a n d Ma r qui s.
RETEST s y s t e m.
EE4 CHECK EIC FOR OPEN CI RCUI T
Ye s
No
GO t o EE5.
RETEST s y s t e m.
Di s c o n n e c t EI C.
Co n n e c t a j umpe r wi r e f r o m hi gh be a m i nput pi n of
EI C (Pi n 4 of C3 c o n n e c t o r ) t o po si t i v e ba t t e r y
t e r mi n a l . Suppl y gr o un d t o gr o un d pi n of EI C (Pi n 1 of
C3 c o n n e c t o r ) .
Me a s u r e v o l t a ge at C4.
Ye s
No
GO t o EE5.
RETEST s y s t e m.
EES CHECK CI RCUI TRY
Ye s
No
GO t o EE6.
( L G / BK ) , Ci r c ui t 932
( G Y/ W) , d a y t i me runni ng
l a mps c o n t r o l mo d ul e (i f
e q ui ppe d ) a s r e qui r e d .
RETEST s y s t e m.
Re c o n n e c t EIC.
Di s c o n n e c t HI -LO be a m r e p l a y T o wn Car,
mul t i - f un c t i o n s w i t c h C r o w n Vi c t o r i a / Gr a n d
Ma r qui s.
Jump Ci r c ui t 1 2 ( LG / BK) at t h e HI -LO b e a m r e l a y
(Town Ca r ) mul t i - f un c t i o n s wi t c h ( Cr o wn
Vi c t o r i a / G r a n d Ma r qui s) c o n n e c t o r t o po si t i v e
ba t t e r y t e r mi n a l .
Is HIGH BEAM i ndi cat or i l l umi nat ed?
Ye s
No
GO t o EE6.
( L G / BK ) , Ci r c ui t 932
( G Y/ W) , d a y t i me runni ng
l a mps c o n t r o l mo d ul e (i f
e q ui ppe d ) a s r e qui r e d .
RETEST s y s t e m.
EE6 CHECK CONTI NUI TY
Ye s
No
REPLACE he a d l a mp
Di sc o n n e c t he a d l a mp s wi t c h .
Ch e c k c ont i nui t y in Ci r c ui t 502 (GY, Town Ca r ) ( 1 5
R/ Y, Cr o wn Vi c t o r i a / Gr a n d Ma r qui s) .
Ch e c k c o n t i n ui t y t o po we r in Ci r c ui t 38 ( BK / O) .
Ye s
No
REPLACE he a d l a mp
PINPOINT TEST FF: SAFETY BELT WARNING NEVER/ALWAYS ON
FF1 CHECK FOR VOLTAGE AT SAFETY BELT WARNI NG
CHI ME
Ye s
No
GO t o FF2.
( L B/ P K, Town Ca r ) , 640
( R/ Y, Cr o wn
b a c k t o i gni t i on s wi t c h .
RETEST s y s t e m.
Di sc o n n e c t safety belt warning chime.
Co n n e c t a 12-vol t t e s t l a mp be t we e n Ci r c ui t 2 95
( L B/ P K, Town Car), 640 (R/ Y, Crown
Vi c t o r i a / Gr and Ma r qui s) in warning chime
c o n n e c t o r a nd gr o un d .
Does t est lamp l i ght ?
Ye s
No
GO t o FF2.
( L B/ P K, Town Ca r ) , 640
( R/ Y, Cr o wn
RETEST s y s t e m.
FF2 CHECK FOR GROUND
Ye s
No
GO t o FF3.
CHECK Ci r c ui t 57 ( BK)
b a c k t o bo d y gr o un d .
RETEST s y s t e m.
( L B/ BK, Town Ca r ) , 640 ( R/ Y, Cr o wn
Vi c t o r i a / Gr a n d Ma r qui s) a n d 57 ( BK) in wa r n i n g
c hi me c o n n e c t o r .
Does t est l amp l i ght ?
Ye s
No
GO t o FF3.
CHECK Ci r c ui t 57 ( BK)
b a c k t o bo d y gr o un d .
RETEST s y s t e m.
FF3 CHECK CI RCUI T 450 (DG / LG) AND SAFETY BELT
WARNI NG I NDI CATOR BULB
Ye s
No
GO t o FF4.
(DG / LG) b a c k t o sa f e t y
be l t wa r n i n g i n d i c a t o r
bul b. CHECK bul b.
RETEST s y s t e m.
Co n n e c t j umpe r be t we e n Ci r c ui t 450 (DG / LG) a n d
Ci r c ui t 2 95 ( L B/ P K, Town Ca r ) , 640 ( R/ Y, Cr o wn
Vi c t o r i a / G r a n d Ma r qui s) in wa r n i n g c hi me
c o n n e c t o r .
Does saf et y bel t warni ng i ndi cat or l i ght ?
Ye s
No
GO t o FF4.
(DG / LG) b a c k t o sa f e t y
be l t wa r n i n g i n d i c a t o r
bul b. CHECK bul b.
RETEST s y s t e m.
FF4 CHECK FOR GROUND AT CI RCUI T 85 (BR / LB)
Ye s
No
GO t o FF5.
(BR / LB) b a c k t o sa f e t y
be l t s wi t c h . SERVI CE a s
Un buc kl e d r i ve r si d e sa f e t y be l t .
Co n n e c t a 12-vol t t e s t l a mp b e t we e n Ci r c ui t 85
(BR / L B) a n d Ci r c ui t 295 ( L B / PK, Town Ca r ) , 640
( R/ Y, Cr o wn Vi c t o r i a / G r a n d Ma r qui s) in wa r n i n g
Does t e st l amp l i ght ?
Ye s
No
GO t o FF5.
(BR / LB) b a c k t o sa f e t y
be l t s wi t c h . SERVI CE a s
FF5 CHECK FOR GROUND AT CI RCUI T 158 ( BK/ P K)
Ye s
No
GO t o FF6
( BK/ P K) b a c k t o i gni t i on
s wi t c h . SERVI CE a s
( BK/ P K) a n d Ci r c ui t 2 95 ( L B/ P K , Town Ca r ) , 640
( R/ Y, Cr o wn Vi c t o r i a / G r a n d Ma r qui s) in wa r n i n g
Ye s
No
GO t o FF6
( BK/ P K) b a c k t o i gni t i on
FF6 CHECK FOR VOLTAGE AT CI RCUI T 159 ( R/ P K)
Ye s
No
GO t o FF7.
( R/ P K) b a c k t o d o o r
o pe n wa r n i n g l a mp
( R/ P K) in wa r n i n g c hi me c o n n e c t o r a nd gr o un d .
Ope n d r i v e r door .
Ye s
No
GO t o FF7.
( R/ P K) b a c k t o d o o r
o pe n wa r n i n g l a mp
FF7 CHECK FOR GROUND BETWEEN CI RCUI T 158
( BK/ P K) AND 159 ( R/ P K)
Ye s
No
GO t o FF8.
( BK/ P K) , 112 ( BK / Y)
b a c k t o he a d l a mp s wi t c h .
RETEST s y s t e m.
Ope n d r i v e r d o o r .
( BK / P K ) a n d 159 ( R/ P K) in wa r n i n g c hi me
c o n n e c t o r .
Turn h e a d l a mp s wi t c h ON.
Ye s
No
GO t o FF8.
( BK/ P K) , 112 ( BK / Y)
b a c k t o he a d l a mp s wi t c h .
RETEST s y s t e m.
PINPOINT TEST FF: SAFETY BELT WARNING NEVER/ALWAYS ON (Cont i nued)
FF8 CHECK FOR VOLTAGE
Ye s
No
GO t o FF9, if e q u i ppe d
wi t h e l e c t r o n i c i nst r ume nt
c l ust e r . GO t o FF 10, If
e q u i ppe d wi t h a n a l o g
( W/ L B , Town Ca r ) , 2 96
( W/ P , Cr o wn
Vi c t o r i a / G r a n d Ma r qui s)
SERVI CE as r e qui r e d .
RETEST s y s t e m.
( W/ L B , Town Ca r ) , 296 ( W/ P , Cr o wn
Vi c t o r i a / G r a n d Ma r qui s) in wa r n i n g c hi me
c o n n e c t o r a n d gr o un d .
Turn i gni t i on s wi t c h t o ACC.
Ye s
No
GO t o FF9, if e q u i ppe d
wi t h e l e c t r o n i c i nst r ume nt
c l ust e r . GO t o FF 10, If
e q u i ppe d wi t h a n a l o g
( W/ L B , Town Ca r ) , 2 96
( W/ P , Cr o wn
Vi c t o r i a / G r a n d Ma r qui s)
SERVI CE as r e qui r e d .
RETEST s y s t e m.
FF9 CHECK FOR GROUND AT CI RCUI T 183 ( T / Y)
Ye s
No
GO t o F F I O .
REFER t o Me s s a ge
Ce n t e r d i a gn o s t i c s in
Se c t i o n 13-01 A.
RETEST s y s t e m.
Co n n e c t a 12-vol t t e s t l a mp be t we e n Ci r c ui t 183
( T/ Y) and Ci r c ui t 2 94 ( W/ L B , Town Ca r ) , 296 ( W/ P ,
Cr o wn Vi c t o r i a / G r a n d Ma r qui s) of wa r n i n g c hi me
c o n n e c t o r .
Turn i gni t i on s wi t c h t o RUN po si t i o n a n d pr e s s a
but t o n on t he e l e c t r o n i c i nst r ume nt c l ust e r .
Does t est l amp l i ght moment ari l y?
Ye s
No
GO t o F F I O .
REFER t o Me s s a ge
Ce n t e r d i a gn o s t i c s in
Se c t i o n 13-01 A.
RETEST s y s t e m.
FF10 CHECK WARNI NG CHI ME MODULE OPERATI ON
Ye s
No
Sy s t e m o pe r a t i n g
pr o pe r l y . RESTORE
v e hi c l e .
REPLACE sa f e t y be l t
wa r n i n g c hi me . RESTORE
Co n n e c t wa r ni ng c hi me mo d ul e .
Ch e c k f or pr o pe r o pe r a t i o n of :
S a f e t y be l t wa r n i n g
Ke y - i n - i gn i t i o n wa r n i n g
He a d l a mp s wi t c h on wa r n i n g
A u d i b l e be e p t o n e
Do all warni ngs oper at e pr oper l y?
Ye s
No
Sy s t e m o pe r a t i n g
v e hi c l e .
REPLACE sa f e t y be l t
wa r n i n g c hi me . RESTORE
PINPOINT TEST GG: LOW OIL PRESSURE WARNING NEVER/ALWAYS ON
T E ST STE P RESULT A CTI ON TO TA KE
GG1 CHECK EI C FOR WARNI NGS
Ye s
No
G Ot o GG2.
G O t o GG4.
Ch e c k EIC d i spl a y t o d e t e r mi n e wh e t h e r t he wa r n i n g
i s a l wa y s on or ne ve r o n .
Is LOW OIL PRESSURE war ni ng al ways on?
Ye s
No
G Ot o GG2.
G O t o GG4.
GG2 CHECK EIC FOR SHORT CI RCUI T
Ye s
No
GO t o GG3.
REPLACE oi l pr e ssur e
03- 00. RESTORE v e hi c l e .
RETEST s y s t e m.
Di sc o n n e c t oi l pr e ssur e se n so r .
Is LOW OIL PRESSURE war ni ng i l l umi nat ed?
Ye s
No
GO t o GG3.
RETEST s y s t e m.
GG3 CHECK CONTI NUI TY IN CI RCUI T 31 ( W/ R )
Ye s
No
REPLACE EIC. AFFI X
RETEST s y s t e m.
( W/ R) . RESTORE
Che c k c o n t i n ui t y in Ci r c ui t 31 ( W/ R) .
Ye s
No
REPLACE EIC. AFFI X
RETEST s y s t e m.
( W/ R) . RESTORE
PINPOINT TEST GG: LOW OIL PRESSURE WARNING NEVER/ALWAYS ON (Cont i nued)
GG4 CHECK FOR POWER AND GROUNDS
Pin
Circuit
N u mb e r Vo l t a g e
C1- 7 7 97 ( W/ P ) 12V ( Ho t At Al l Ti me s)
C1- 9 2 95 ( L B / P K ) 12V ( Ho t In RUN)
C3- 7 489
( P K / B K )
12V ( Ho t In RUN)
C3- 2 2 95 ( L B / P K ) 12V ( Ho t In RUN)
C1- 8 87 5 ( P K / O ) OV
C3- 1 87 5 ( P K / O ) OV
Ye s
No
>
>
GO t o GG5.
RETEST s y s t e m.
GG5
CHECK EIC FOR OPEN CI RCUI T
Di sc o n n e c t c o n n e c t o r at oi l pr e ssur e se n so r .
Co n n e c t a j umpe r wi r e f r om Ci r c ui t 31 ( W/ R) at
Is LOW OIL PRESSURE warni ng i l l umi nat ed?
Ye s
No
RETEST s y s t e m.
GO t o GG6.
GG6 CHECK CONTI NUI TY
Re mo v e j umper .
Ch e c k c o n t i n ui t y in Ci r c ui t 31 ( W/ R) .
Ye s
No
RETEST s y s t e m.
SERVI CE Ci r c ui t 3 ( W/ R) .
RETEST s y s t e m.
PINPOINT TEST HH: AIR BAG WARNING NEVER/ALWAYS ON
HH1 CHECK EIC FOR WARNI NGS
Ye s
No
GO t o HH2.
GO t o HH4.
o T u r n i gni t i on s wi t c h t o RUN.
Ch e c k EIC d i s pl a y t o d e t e r mi n e wh e t h e r t he wa r n i n g
i s a l wa y s on or n e ve r o n .
Is AIR BAG war ni ng al ways on?
Ye s
No
GO t o HH2.
GO t o HH4.
HH2 CHECK AIR BAG DI AGNOSTI C MONI TOR
Ye s
No
G Ot o HH3.
REPLACE ai r b a g
d i a gn o st i c mo n i t o r .
01- 2 0B. RESTORE
NOTE: If t h e ai r b a g wa r n i n g i n d i c a t o r f l a she s on a nd of f
c o n t i n uo usl y it me a n s t ha t it i s s ho wi n g a d i a gn o s t i c
c o d e . It d o e s not me a n t ha t t he ai r b a g wa r n i n g
i n d i c a t o r n e e d s t o be s e r v i c e d . Re f e r t o Se c t i o n
01- 2 0B.
WARNING: THE BACKUP POWER SUPPLY ENERGY
MUST BE DEPLETED BEFORE ANY AIR BAG
COMPONENT SERVICE IS PERFORMED AS
PERSONAL INJURY MAY RESULT. TO DEPLETE
BACKUP POWER SUPPLY ENERGY, DISCONNECT
THE POSITIVE BATTERY CABLE AND WAIT ONE
MI NUTE .
Di sc o n n e c t b a t t e r y gr o un d c a bl e .
Di sc o n n e c t po s i t i v e ba t t e r y c a bl e a nd wa i t one
mi nut e .
Di sc o n n e c t ai r b a g d i a gn o s t i c mo n i t o r .
Ch e c k EIC f o r wa r n i n g.
Is AI R BAG w a r n i n g i l l u mi n a t e d ?
Ye s
No
G Ot o HH3.
REPLACE ai r b a g
d i a gn o st i c mo n i t o r .
01- 2 0B. RESTORE
PINPOINT TEST HH: AIR BAG WARNING NE VE R/ A L WA YS ON (Conti nued)
HH3
CHECK CONTI NUI TY OF CI RCUI T 608 ( B K / Y)
Turn ignition switch to OFF.
Disconnect EIC.
Check continuity in Circuit 608 (BK/ Y).
Is c ont i nui t y present ?
Yes
No
RETEST s y s t e m.
( B K / Y) . RESTORE
v e h i c l e . RETEST s y s t e m.
HH4
CHECK FOR POWER AND GROUNDS
Ch e c k v o l t a ge on t h e f o l l o wi n g pi n s:
Pin
Ci rcui t
Number Vol t age
C1- 9 2 95 ( L B / P K ) 12V ( Ho t In RUN)
C3- 7 489
( P K / B K )
12V ( Ho t In RUN)
C3- 2 2 95 ( L B / P K ) 12V ( Ho t In RUN)
C1-8 87 5 ( P K / O ) OV
C3- 1 87 5 ( P K / O ) OV
Ye s
No
GO t o HH5.
RETEST s y s t e m.
HH5
CHECK AI R BAG DI AGNOSTI C MONI TOR
WARNING: THE BACKUP POWER SUPPLY ENERGY
MUST BE DEPLETED BEFORE ANY AIR BAG
COMPONENT SERVICE IS PERFORMED AS
PERSONAL INJURY MAY RESULT. TO DEPLETE
BACKUP POWER SUPPLY ENERGY, DISCONNECT
THE POSITIVE BATTERY CABLE AND WAIT ONE
MINUTE.
Ye s
No
Di sc o n n e c t po si t i v e ba t t e r y c a b l e a n d wa i t one
mi nut e .
Di sc o n n e c t c o n n e c t o r at ai r ba g d i a gn o s t i c moni t or .
Co n n e c t a j umpe r wi r e f r o m Ci r c ui t 608 ( BK / Y) at
Re c o n n e c t po si t i v e ba t t e r y c a bl e .
Is AIR BAG war ni ng i l l umi nat ed?
REPLACE ai r ba g
d i a gn o s t i c mo n i t o r .
G1-20B. RESTORE
GO t o HH6.
HH6 CHECK AI R BAG I NPUT CI RCUI T CONTI NUI TY
Di s c o n n e c t EI C.
Ch e c k c o n t i n ui t y in Ci r c ui t 608 ( BK / Y) .
Ye s
No
RETEST s y s t e m.
( BK / Y) . RESTORE
PINPOINT TEST JJ: OVERDRIVE OFF INDICATOR NEVER/ALWAYS ON
JJ 1 CHECK EIC FOR I NDI CATOR
Ye s
No
G O t o JJ2.
GO t o JJ4.
Ch e c k EIC d i spl a y t o d e t e r mi n e wh e t h e r t h e
i n d i c a t o r i s a l wa y s on or ne ve r on.
Is OVERDRI VE OFF i ndi cat or al ways on?
Ye s
No
G O t o JJ2.
GO t o JJ4.
13- 01A - 53
PINPOINT TEST JJ: OVERDRIVE OFF INDICATOR NEVER/ALWAYS ON (Cont i nued)
T E ST STEP RESULT A CTI ON TO TA KE
JJ2 CHECK PCM FOR SHORTED CI RCUI T
Di sc o n n e c t po we r t r a i n c o n t r o l mo d ul e .
Che c k EIC f o r i n d i c a t o r .
Is OVERDRIVE OFF i ndi cat or i l l umi nat ed?
Ye s
No

GO t o JJ3.
REPLACE po we r t r a i n
t he Po we r t r a i n
Di a gn o si s Ma n ua l
4
.
JJ3 CHECK CONTI NUI TY OF CI RCUI T 911 ( W/ L G )
Che c k c o n t i n ui t y in Ci r c ui t 911 ( W/ L G ) .
Ye s
No

REPLACE EIC. RESTORE
( W/ L G ) . RESTORE
JJ4 CHECK FOR POWER AND GROUNDS
Che c k v o l t a ge on t he f o l l o wi n g pi n s:
P i n
C i r c u i t
N u m b e r Vo l t a g e
C1- 7 7 97 ( W/ P ) 12V (Hot At Al l Ti me s )
C1- 9 2 95 ( L B / P K ) 12V (Hot In RUN)
C3- 7 489
( P K / B K )
12V ( Ho t In RUN)
C3- 2 2 95 ( L B / P K ) 12V ( Ho t In RUN)
C1- 8 87 5 ( P K / O ) OV
C3- 1 87 5 ( P K / O ) OV
Ye s
No

GO t o JJ5.
RETEST s y s t e m.
JJ5 CHECK PCM FOR OPEN CI RCUI T
Di sc o n n e c t c o n n e c t o r at po we r t r a i n c o n t r o l mo d ul e .
Co n n e c t a j umpe r wi r e f r o m Ci r c ui t 911 (W / LG) at
Is OVERDRIVE OFF i ndi cat or i l l umi nat ed?
Ye s
No
REPLACE po we r t r a i n
c o n t r o l modul e . REFER t o
t he Po we r t r a i n Co n t r o l
Emi ssi o n s Di a gn o si s
Ma n ua l
4
.
G O t o JJ6.
JJ6 CHECK I NDI CATOR SUPPLY CI RCUI T CONTI NUI TY
Ch e c k c o n t i n ui t y in Ci r c ui t 911 ( W/ L G ) .
Ye s
No

REPLACE bul b in EI C.
RETEST s y s t e m.
( W/ L G ) . RESTORE
PINPOINT TEST KK: TRANSMISSION CONTROL INDICATOR NEVER/ALWAYS ON
KK1 CHECK DI SPLAYS
Ye s
No
GO t o KK2.
GO t o Pi npoi nt Test St e p
A3.
Ch e c k o t he r d i s pl a y s : r a d i o , me s s a ge c e n t e r s wi t c h
mo d ul e .
Do ot her di spl ays i l l umi nat e pr oper l y ?
Ye s
No
GO t o KK2.
GO t o Pi npoi nt Test St e p
A3.
PI NPOI NT TEST KK: TRANSMI SSI ON CONTROL I NDI CATOR NE VE R/ A L WA YS ON ( Co n t i n u e d )
TEST STEP RESUL T ACTI ON TO T A KE
KK2 CHECK EIC BULB
Ye s
No
( L B/ R) . RESTORE
REPLACE bul b.
RETEST s y s t e m.
Ch e c k t he bul b in t he EIC.
I s bulb OK?
Ye s
No
( L B/ R) . RESTORE
REPLACE bul b.
RETEST s y s t e m.
Electronic Instrument Cluster (EIC)
NOTE: The el ect r oni cs wi thi n t he i nst rument cl ust er
( 10849) a r e NOT servi ceabl e. For a conf i rmed
el ect roni c f ai l ure, ret urn t he enti re assembl y t o t he
manuf act urer (pa c ka ge d caref ully t o avoi d damage t o
t he VF di spl a y s and ot her el ect roni c component s).
Instrument cl ust er shoul d be di sassembl ed only t o
servi ce pl ast i c de f e c t s (ref er t o servi ce par t di agram).
Federal l a w requi res t hat t he odomet er in any
repl acement speedomet er / odomet er must regi st er
t he sa me mi l eage as t hat regi st ered on t he removed
speedomet er / odomet er. Servi ce repl acement
speedomet er / odome t e r s and odomet er modul es wi t h
t he mi l eage pr eset t o act ual vehi cle mi l eage are
avai l abl e t hr ough For d El ect roni c Servi ce Cent ers. In
nearl y all i nst ances, t he mi leage cont i nues t o
accumul at e in t he odomet er memory even if t he
odomet er d o e s not di spl ay mi leage. Thi s mi l eage can
usually be veri f i ed by t he el ect roni c servi ce cent er s.
Cont act t he ser vi ce cent er f or i nst ruct i ons t o recei ve a
repl acement speedomet er / odomet er or odomet er
modul e wi t h t he mi l eage preset t o act ual mi l eage.
If t he act ual vehi cl e mi l eage cannot be veri f i ed, t he
ser vi ce cent er wi ll suppl y a speedomet er / odomet er or
odomet er modul e wi t h t he odomet er di spl ay preset t o
zero ( "0") mi les and t he servi ce odomet er segment
( "s") i llumi nat ed in t he vi ci ni ty of t he odomet er di spl ay.
In addi t i on, an odomet er mi leage st i cker is suppl i ed
wi t h t he r epl acement odomet er. Thi s st i cker must
di spl ay t he est i mat ed vehi cl e mi leage and is t o be
af f i xed t o t he dri ver' s door.
1. Di sconnect bat t er y ground cabl e ( 14301) and set
par ki ng br ake.
2. Unsnap left i nst rument panel mouldi ng ( 04389)
and ri ght i nst rument panel mouldi ng ( 04388) off
i nst rument panel f i ni sh panel ( 044D7 0) .
3. Pull cent er panel swi t c he s (if equi pped) f o r wa r d ,
di sconnect el ect ri cal connect or s and remove t he
cent er swi t c he s.
4. Remove i nst rument panel st eeri ng col umn cover
( 04459) .
5. Remove f our nut s ret ai ni ng t he st eeri ng col umn
and l ower t he st eeri ng col umn.
6. Remove knob f r om headl amp swi t c h ( 11654) .
7. Remove 13 sc r e ws ret ai ni ng i nst rument panel
fi ni sh panel and pull i nst rument panel f i ni sh panel
out .
8. Move t ransmi ssi on range sel ect or lever t o l ow
gear (1) posi t i on if requi red f or easi er a c c e ss.
9. Di sconnect el ect ri cal connect or s f r o m me ssa ge
cent er cont rol assembl y (MCCA) me ssa ge cent er
swi t c h modul e ( 10D996) .
10. Remove i nst rument panel fi ni sh panel caref ul l y so
not t o sc r a t c h t he i nst rument cl ust er l ens.
11. Di sconnect el ect ri cal connect or f r om f r ont of
i nst rument cl ust er.
12. Di sconnect t ransmi ssi on cont rol sel ect or
i ndi cat or ( 7 A110) f r om i nst rument cl ust er by
caref ul l y bendi ng bot t om t a b down and pulling
t ransmi ssi on cont rol sel ect or i ndi cat or assembl y
f o r wa r d .
13. Remove f our sc r e ws ret ai ni ng i nst rument cl ust er.
Pull i nst rument cl ust er out and di sconnect
el ect ri cal connect or s on rear of i nst rument
cl ust er.
14. Remove i nst rument cl ust er.
15. To i nst al l , reverse Removal pr ocedur e. Ti ght en
t he i nst rument panel fi ni sh panel ret ai ni ng sc r e ws
t o 2. 7-4. 0 Norn (24-35 Ib-in).
13- 01A - 55 i nst r ument Cl ust er El ect r oni c 13- 01A - 55
IEMOVAL A N D INSTALLATION ( C o n t i n u e d )
Town Car Shown, Cr own Vi c t o r i a , Grand Marqui s Si mi l ar
I t e m
Pa r t
1 04320 I nst r ument Pa ne l
2 044D70 I nst r ument Pa ne l Fi n i sh
Pa ne l
3 N80387 6- S36B Sc r e w ( 13 Re q' d )
4 04388 I nst r ument Pa ne l Mo ul d i n g
RH
5 04389 I nst r ume nt Pa ne l Mo ul d i n g
LH
I t e m
Pa r t
6

Ce n t e r Swi t c h e s (Fue l Door ,
Re a r De f r o st ) Ope n i n gs
7 04459 I nst r ume nt Pa ne l St e e r i n g
Col umn Co v e r
A

Ti ght e n t o 2. 7-4. 0 N-m ( 2 4- 35
Lb-l n)
Message Center Control Assembly (WICCA)
Swi tch Mo d u l e
R e mo v a l a n d I nst al l at i on
1. Per f or m St eps 1 t hrough 9 of El ect roni c
Inst rument Cl ust er (EIC) Removal pr ocedur e.
2. Remove t wo sc r e ws on ei t her si de of MCCA
message cent er swi t c h modul e ( 10D996) .
3. Remove MCCA message cent er swi t c h modul e
f r om rear of t he i nst rument panel f i ni sh panel
( 044D70) and repl ace.
4. Install t wo sc r e ws ret ai ni ng t he MCCA message
cent er swi t c h modul e.
1995 To wn Car , Crown Vi c t o r i a , Gr a n d Ma r q u i s Jul y 1994
13- 01A- S6 ^ I n s t r u me n t C l u s t e r E l e c t r o n i c
5. Install i nst rument panel f i ni sh panel by reversi ng
St e ps 1 t hr ough 9 of EIC removal pr ocedur e.
T r a n s m i s s i o n R a n g e I n d i c a t o r C o l u m n S h i f t
Di s a s s e mb l y
1. Di sassembl e i nst rument panel by perf ormi ng
St e ps 1 t hr ough 9 of El ect roni c Inst rument
Cl ust er Removal pr ocedur e.
2. Di sconnect t ransmi ssi on cont r ol sel ect or
i ndi cat or ( 7 A110) f r om i nst rument cl ust er
( 10849) by caref ul l y bendi ng bot t om t a b d o wn
and pulling t ransmi ssi on cont r ol sel ect or i ndi cat or
f o r wa r d .
3. Remove sc r e w ret ai ni ng cont r ol sel ect or br a c ke t
and cabl e ( 7 E363) t o st eeri ng col umn.
4. Di sconnect c a bl e l oop f r om gearshi f t lever pin
( 7 W441) on t he t ransmi ssi on sel ect or l ever a r m
and suppor t ( 7 302 ) of st eeri ng col umn and
r emove t ransmi ssi on cont r ol sel ect or i n d i c a t o r .
A s s e m b l y
1. Reverse St eps 2 , 3 and 4 of Di sassembl y
pr ocedur e.
2. Pl ace t ransmi ssi on range sel ect or lever in
OVERDRI VE ( ) posi t i on.
3. Adj ust cabl e t ensi on wheel at st eeri ng col umn
until r ed i ndi cat or f l ag i s cent er ed bet ween t he
cal i brat i on d o t s bel ow t he .
4. Move t ransmi ssi on range sel ect or lever t hr ough
all posi t i ons and c he c k t hat t he f l ag compl et el y
c o ve r s e a c h gr aphi c wi t h no overl ap i nto
adj oi ni ng gr a phi c s. Coveri ng t he cal i brat i on d o t s
in t he NEUTRAL or DRIVE (N or posi t i ons i s
accept abl e.
5. Reverse St eps 1 t hr ough 7 of EIC Removal
pr ocedur e t o assembl e i nst rument panel .
I n s t r u m e n t P a n e l L a m p S o c k e t a n d B u l b
1. Remove i nst rument cl ust er ( 10849) as out l i ned.
2. Remove si x sc r e ws ret ai ni ng f r ont of i nst rument
cl ust er.
3. Remove i nst rument cl ust er ma sk ( 10890) . Take
c a r e not t o sc r a t c h f i l t er in left di spl ay wi n d o w or
VF t ube di spl ay sur f a c e s. (If cl eani ng is r equi r ed,
use onl y a nonabrasi ve cl eaner. )
4. Pull mi ni at ure bulb ( 13466) f r om i nst rument panel
l amp so c ke t in l ower cent er of i nst rument cl ust er
and repl ace wi t h No. 37 mi ni at ure bulb l amp.
5. Install i nst rument cl ust er mask and i nstall si x
6. Install i nst rument cl ust er a s out l i ned.
SPECIFICATIONS
Co u ga r
TA1000B
De sc r i pt i on Lb-l n
I n st r ume n t Pa n e l Fi n i sh P a n e l
2 . 7 - 4. 0 2 4- 35
ROTUNDA EQUIPMENT
13- 01B- 1 Instrument ClusterConventional 13- 01B- 1
SECTION 13-01B Instrument ClusterConventional
SUBJECT PAGE
VEHI CLE APPLICATION 13-01B-1
DESCRIPTION AND OPERATI ON
Charge Indication Syst em 13-01B-4
Engi ne Coolant Temperat ure Indication
Syst em 13-01B-3
Fuel Level indication Syst em 13-01B-2
I nst rument Cl ust er (IC) 13-01B-1
Odomet er 13-01B-5
Oil Pressure I ndi cat i on Syst em 13-01B-4
Speedomet er 13-01B-5
Transmi ssi on Range I ndi cat or 13-01B-5
Tri p Odomet er 13-01 B-5
Warni ng I ndi cat ors 13-01 B-5
El ect i i cal Schemat i cs .... 13-01B-7
I n s p e c t i o n a n d Ve r i f i c a t i o n . ... 13-01B-19
Pi npoi nt T e s t s . , , 13-01B-21
Sy mpt om Chart . . . . . . . . 13-01B-19
SUBJECT PAGE
Bat t er y Vol t age Gauge 13-01B-41
Engi ne Cool ant Temperat ure Gauge 13-01B-41
Fuel Gauge 13-01B-40
I ndi c a t or s/ Wa r ni ng Bul bs 13-01B-42
I nst rument Cl ust er 13-01B-40
I nst rument Cl ust er Pri nt ed Ci rcui t 13-01B-40
Low Fuel Level Warni ng Swi t c h ..13-01B-40
Spe e dome t e r / Odome t e r 13-01B-41
Transmi ssi on Range I ndi cat or. . ...13-01B-41
I nst rument Cl ust er 13-01B-42
I nst rument Cl ust er Lenses 13-01B-43
SPECIFICATIONS 13-01 B-43
SPECIAL SERVICE TOOLS/EQUIPMENT 13-01 B-43
VEHICLE APPLICATION
Cr o wn Vi c t or i a , Grand Marqui s
Inst rument Cluster (IC)
The convent i onal i nst rument cl ust er ( 10849) c onsi st s
of t he f ol l owi ng assembl i es:
1 ) ( 2 ) i 3 J 14 J (T)
Speedomet er ( 17 255) .
Inst rument cl ust er t emper at ur e gauge ( 10883) and
oil pressure gauge assembl y.
Fuel gauge ( 9305) .
Transmi ssi on range i ndi cat or.
( 2 2 ) ^
tC2284@-A
13- 01B- 2 I n s t r u me n t C l u s t e r C o n v e n t i o n a l
13- 01B- 2
Pa r t
I t e m d u mb e r De s c r i p t i o n
1
L o w Fue l I n d i c a t o r (Pa r t of
10890)
2
.
( MI L XP a r t of 10890)
3

Sa f e t y Be l t Wa r n i n g
4

L H Turn Si gna l I n d i c a t o r
( Pa r t of 10890)
5

Cha r gi n g Sy st e m Wa r n i n g
( Pa r t of 10890)
6

Ai r Suspe n si o n I n d i c a t o r
( Pa r t of 10890)
7

Tr a n smi ssi o n Co n t r o l
8

A n t i - L o c k Br a ke Sy s t e m
Wa r n i n g ( Pa r t of 10890)
9

RH Turn Si gna l I n d i c a t o r
(Part of 10890)
10

Hi gh Be a m I n d i c a t o r ( Pa r t of
10890)
Pa r t
I t e m Nu mb e r De s c r i p t i o n |
11

Br a ke Sy s t e m Wa r ni ng
I n d i c a t o r ( Pa r t of 10890)
12

Ai r Ba g Re a d i n e ss I n d i c a t o r
( Pa r t of 10890)
13 10849 I nst r ume nt Cl ust e r
14

Oi l Pr e ssur e Ga uge ( Pa r t of
10883)
15 17 K311 Tr i p Od o me t e r Re se t ( Pa r t of
10890)
16 10883 Engi ne Coolant Te mpe r a t ur e
Ga uge
17 7 A110 Tr a n smi ssi o n Co n t r o l
Se l e c t o r I n d i c a t o r
18 17255 Spe e d o me t e r
19 9305 Fuel Ga uge
2 0

Fue l Fi l l Do o r Aj ar I n d i c a t o r
( Pa r t of 10883)
2 1

Ba t t e r y Vo l t a ge Ga uge ( Pa r t
of 9305)
22 10890 I nst r ume nt Cl ust e r Ma sk
I n s t r u me n t C l u s t e r Di s p l a y P r o v e o u t
When t he i gni ti on swi t c h ( 1157 2 ) i s t urned t o RUN,
t he f ol l owi ng warni ng l amps wi l l pr ove out by
moment ari l y l i ght i ng:
Charge war ni ng.
Saf et y bel t .
Ai r ba g.
Ant i -l ock br a ke .
Mal f unct i on Indi cat or La mp (MI L) (CHECK ENGINE).
O/ DOFF.
P r i n t e d Ci r c u i t
The i nst rument cl ust er pri nt ed ci rcui t ( 10K843) :
Suppl i es current t o t he i nst rument panel l amps and
warni ng i ndi cat ors.
Is made of copper f oi l whi c h is bonded t o t he
pol y est er -base f i lm (usual l y r ef er r ed t o as My l ar ).
Is mount ed t o t he i nst rument cl ust er housi ng and,
due t o i ts l ocat i on, cannot be easi l y i nspect ed
a n d / o r t e st e d in t he vehi cl e.
Is vul nerabl e t o damage whe n a pr obe is used f or
i n-vehi cle t est i ng because t he pr obe can pi er ce t he
pri nt ed ci rcui t or, in some c a se s, burn t he c oppe r
c onduc t or s.
F u e l L e v e l I n d i c a t i o n S y s t e m
The f uel level i ndi cat i on sy st e m consi st s of:
Fuel pump ( 9350) (l ocat ed in fuel t ank ( 9002) ) .
Lo w fuel warni ng swi t c h (l ocat ed on t he ba c k of
i nst rument cl ust er ( 10849) ) .
Fuel gauge ( 9305) (l ocat ed in i nst rument cl ust er )
Necessar y ci rcui t ry.
Fu e l G a u g e
The magnet i c fuel gauge has t he f ol l owi ng f eat ur es:
The coi l s f or m a magnet i c f i el d whi c h vari es in
di rect i on accor di ng t o t he vari abl e resi st ance of t he
f uel pump connect ed bet ween t wo of t hem.
A pri mary magnet , t o whi c h a shaf t and poi nt er a r e
a t t a c he d , r ot a t e s t o ali gn t o t hi s pri mary f i el d,
resul t i ng in poi nt er posi t i on.
The bo bbi n / c o i l assembl y is pr e sse d into a met al
housi ng whi ch has t wo hol es f or di al mount i ng.
The fuel pump changes r esi st ance accor di ng t o t he
level of fuel in t he f uel t ank.
CAUTI ON: Do n o t r e mo v e ma g n e t i c g a u g e
p o i n t e r s ; t h e g a u g e c a n n o t b e r e c a l i b r a t e d .
The poi nt er posi t i on vari es proport i onat el y t o t he
current f l ow. Ther e is no adj ust ment , cal i brat i on or
mai nt enance requi red f or t hi s gauge.
L o w Fu e l L e v e l Wa r n i n g
L o w Fue l L e v e l Wa r n i n g S wi t c h
The l ow fuel level warni ng swi t c h ( 9F326) :
1995 To wn Ca r , Cr o wn Vi c t o r i a , Grand Ma r q u i s Jul y 1994
13 n-p; >3
r
I n s t r u me n f Cf ust e H3-01
Is desi gned t o r educe fuel gauge needle f l uct uat i on
caused by fuel mot i on in t he fuel t ank.
Provi des a l ow fuel warni ng when fuel gauge r eads
appr oxi mat el y one-ei ght h f ul l .
LOW FUEL
LEVEL WARNI NG
SWI TCH 9F326 K16221-D
Fu e l P u mp Mo d u l e
The fuel pump consi st s of t he f ol l owi ng f eat ur es:
A vari abl e r esi st or is cont rol l ed by t he level of an
a t t a c he d f l oat in t he fuel t ank.
When f uel level i s l ow, r esi st ance in t he fuel t ank f uel
pump i s l ow a nd movement of t he gauge i ndi cat or
di al is mi ni mal (f r om t he EMPTY posi t i on).
When f uel level i s hi gh, t he r esi st ance in t he f uel
pump i s hi gh and movement of t he gauge i ndi cat or
(f r om t he EMPTY posi t i on) is great er.
E n g i n e C o o l a n t T e m p e r a t u r e I n d i c a t i o n
S y s t e m
The engi ne cool ant t emper at ur e i ndi cat i on sy st e m i s a
magnet i c t y pe sy st e m t hat consi st s of:
Inst rument cl ust er t emper at ur e gauge ( 10883)
(l ocat ed in i nst rument cl ust er ( 10849) ) .
Engi ne cool ant t emper at ur e sensor (ECT
se n so r ) ( 12A648) (l ocat ed in i nt ake mani f ol d
( 9424) ) .
Ne c e ssa r y ci r cui t r y.
E n g i n e C o o l a n t T e mp e r a t u r e G a u g e
The i nst rument cl ust er engi ne cool ant t emper at ur e
gauge has t he f ol l owi ng f eat ur es:
It consi st s of t hr ee pri mary coi l s of wi r e cal l ed t he
bobbi n, one coi l is wound at a 90 degr ee angl e t o
t he ot her t wo .
When power is appl i ed, c or r e c t f l owi ng t hr ough t he
bobbi n and sendi ng unit f or ms a magnet i c f i el d
whi c h vari es in st r engt h accor di ng t o t he vari abl e
resi st ance of t he engi ne cool ant t emper at ur e
sensor.
A pri mary magnet , t o whi ch a shaf t and poi nt er are
a t t a c he d , r ot a t e s t o ali gn at t hi s pri mary f i el d,
The bo bbi n / c o i l assembl y is pr essed i nto a met al
housi ng whi ch has t wo hol es f or di al mount i ng.
The gauge poi nt er remai ns in posi t i on when t he
i gni ti on swi t c h is t urned t o OFF
The gauge poi nt er moves t o t he c or r e c t posi t i on
whenever t he ignition swi t c h is t urned t o RUN.
An i nst rument vol t age regul at or as used on previ ous
model s, is not used.
RESISTANCE OF ENGINE COOLANT
TEMPERATURE SENSOR 12A648
COLD = 74 OHMS
HOT = 9.7 OHMS K22765-A
Pa r t
1

Poi nt e r
2 10883 I nst r ument Cl ust e r
Te mpe r a t ur e Ga uge
3 Coi l s
4 12A648 Engi ne Co o l a n t Te mpe r a t ur e
Se nsor
The i nst rument cl ust er t emper at ur e gauge is
l ocat ed in t he l ower ri ght port i on of t he i nst rument
cl ust er.
1995 Town Car, Crown Vi ct ori a, Grand Marqui s July 1994
13- 01B- 4 I nst r ument C l y s t e r C o n v e n t i o n a l 13- 01B- 4
Cr o wn Vi c t o r i a , Gr and Mar qui s
I NSTRUMENT CLUSTER
TEMPERATURE GAUGE
10883
OI L PRESSURE GAUGE
(PART OF 10883)
22841A
E n g i n e Co o l a n t T e mp e r a t u r e ( E CT ) S e n s o r
The engi ne cool ant t emper at ur e sensor i s mount ed
i nt o t he engi ne i nt ake mani f ol d. The si gnal sent t o
i nst rument cl ust er t emper at ur e gauge var i es wi t h t he
r esi st ance of engi ne cool ant t e mpe r a t ur e sensor at
c ol d cool ant t emper at ur es t he engi ne cool ant
t emper at ur e sensor resi st ance is hi gh, and at hi gh
cool ant t emper at ur es t he engi ne cool ant t emper at ur e
sensor r esi st ance i s l ow.
Oi l P r e s s u r e I n d i c a t i o n S y s t e m
Oil pr essur e i ndi cat i on sy st e m c onsi st s of :
Oil pr essur e gauge.
Oi l pr essur e sensor ( 927 8) (l oc a t e d in t he engi ne
bl oc k).
Ne c e ssa r y ci rcui t ry.
Oi l P r e s s u r e G a u g e
The oil pr essur e gauge i s a part of i nst rument
cl ust er t emper at ur e gauge ( 10883) assembl y.
The magnet i c gauge has t he f ol l owi ng f eat ur es.
If c onsi st s of three primary coi l s, one of whi c h is
wound at a 90 degree angle t o t he ot he r t wo .
The coi l s f o r m a magnet i c f i el d whi c h var i es in
di r ect i on a c c or di ng to the vari abl e r esi st ance of t he
oil pr essur e sensor c onne c t e d bet ween t wo of
t he m.
A pr i mar y magnet , t o whi c h a shaf t and poi nt er are
a t t a c he d , r ot at es to align t o t hi s pr i mar y f i el d,
The bobbi n / coi l assembl y is pr e sse d i nt o a met al
housi ng whi ch has two hol es f or dial mount i ng.
CAUTI ON: Bo. n o t r e mo v e ma g n e t i c ga u ge
p o i n t e r s ; t h e gauge cannot b e r e c a l i b r a t e d .
The r e i s no adj ust ment , cal i brat i on or mai nt enance
requi red f or t hese gauges.
I NSTRUMENT CLUSTER OI L PRESSURE. GAUGE
TEMPERATURE GAUGE (PART OF 10883)
1 0 8 8 3
K22841-A
C h a r g e I n d i c a t i o n S y s t e m
Char ge i ndi cat i on sy st e m consi st s of :
Bat t er y vol t age gauge.
Gener at or (GEN)( 10300).
Chargi ng sy st e m warni ng i ndi cat or.
B a t t e r y Vo l t a g e G a u g e
Ba t t e r y vol t age gauge is a part of fuel gauge ( 9305)
assembl y.
The ba t t e r y vol t age gauge:
I ndi cat es bat t er y vol t age when t he i gni ti on swi t c h
( 1157 2) i s in RUN (engi ne of f ).
Regi st ers wi t hi n t he band duri ng vehi cl e oper at i on.
Is not adj ust abl e and shoul d be r epl aced if
i noperat i ve.
LOW FUEL LEVEL
WARNING INDICATOR
(PART OF 10890)
CHARGE SYSTEM
WARNING INDICATOR
(PART OF 10890)
BATTERY VOLTAGE
GAUGE
(PART OF 9305)
FUEL GAUGE
9305
K22842-A
13- 01 B-5 I n s t r u me n t C l u s t e r C o n v e n t i o n a l 13- 01B- 5
C h a r g i n g System Wa r n i n g
A r ed c ha r ge sy st e m warni ng i ndi cat or is l ocat ed in
t he i nst rument cl ust er ( 10849) . Thi s i ndi cat or gl ows
when t her e i s no generat or out put or when t he
gener at or vol t age is excessi vel y hi gh.
If t he sy st e m is wor ki ng normal l y, t he f ol l owi ng
condi t i ons wi ll be present :
Wi t h ignition swi t c h OFF, ba t t e r y char ge i ndi cat or
sy mbol i s of f .
Wi t h ignition swi t c h in RUN (engi ne not runni ng),
c ha r ge i ndi cat or (gener at or ) i s on.
Wi t h i gni ti on swi t c h in RUN (engi ne runni ng), c ha r ge
i ndi cat or is of f .
S p e e d o m e t e r
The i nst rument cl ust er ( 10849) cont ai ns an el ect ri c
speedomet er ( 17 255) .
The el ect ri c speedomet er r e c e i ve s speed i nf ormat i on
f r o m t he t ransmi ssi on-mount ed vehi cl e speed sensor
( VSSX9E731) .
The ci rcui t el ect roni cs ar e cal i br at ed t o dri ve t he
speedomet er poi nt er t o a l ocat i on in proport i on t o t he
f r equency of t he input si gnal f r o m vehi cl e spe e d
sensor.
O d o m e t e r
The odomet er :
Is i nt egral t o t he spe e dome t e r ( 17 255) .
Is dri ven by t he vehi cl e spe e d sensor ( VSSX9E731)
input si gnal .
Regi st ers up t o 99, 999. 9 and t hen r eset s t o
00000. 0.
O d o m e t e r Replacement
The mi l eage on repl acement speedomet er / odome t e r s
cannot be r eset . If a r epl acement
speedomet er / odomet er i s i nst al l ed, a label r ecor di ng
t he vehi cl e' s mi l eage and da t e at t he t i me of t he
speedomet er / odomet er r epl acement must be
a t t a c he d t o t he dr i ver ' s door j a mb.
Tri p Odomet er
Tri p odomet er i s housed wi t hi n speedomet er ( 17 255)
be l ow t he pri mary odomet er.
The t r i p odomet er can be r eset by pushi ng t he reset
shaf t t hat e xt e nds f r om speedomet er .
Transmi ssi on Range Indi cator
Transmi ssi on range i ndi cat or i s l ocat ed in i nst rument
cl ust er ( 10849) , bel ow speedomet er ( 17 255) .
Warni ng Indi cat ors
Brake System
Thi s warni ng i s di spl ayed when par ki ng br ake i s not
f ul l y rel eased or t here is a concer n in t he braki ng
sy st e m. Ref er t o Sect i on 06- 00 f or addi t i onal
i nf ormat i on.
Anti -Lock Brakes
ABS warni ng i ndi cat es t hat t he ant i -l ock f eat ure is
di sabl ed. The warni ng goe s out whe n t he concer n i s
r esol ved. Ref er t o Sect i on 06- 09.
Check Engine (MIL)
The CHECK ENGINE (MI L) warni ng i nf ormat i on i s sent
by t he power t r ai n cont rol modul e (PCM)(12A650) on
t he d a t a link connect or (DLC).
CHECK
ENGINE
K13906-B
Anyt i me a CHECK ENGINE (MI L) warni ng oc c ur s,
ref er t o Powert rai n Cont r ol / Emi ssi ons Di agnosi s
Ma nua l .
1
13- 011- 6 I n s t r u me n t C l u s t e r C o n v e n t i o n a l 13- 011- 6
C h a r g i n g S y s t e m
Chargi ng sy st e m war ni ng (ba t t e r y sy mbol ) i s
di spl ay ed when t he r e i s a concer n in t he char gi ng
sy st e m. The c ha r ge sy st e m war ni ng (ba t t e r y symbol )
remai ns lit cont i nuousl y whi l e t he c onc e r n is present . It
goe s out when t he concer n i s r e sol ve d.
A i r B a g
AIR BAG warni ng i s di spl a y e d whe n t he r e is a concer n
in t he ai r ba g sy st e m. Ref er t o Sect i on 01- 20B f or
addi t i onal i nf ormat i on.
S a f e t y Be l t
If dr i ver ' s saf et y bel t is not f ast ened wi t h i gni ti on
swi t c h ( 1157 2 ) t urned t o RUN, t he SAFETY BELT
war ni ng wi ll i llumi nate st eadi l y f or appr oxi mat el y one
mi nut e. The l i ght i ng cont r ol modul e wi l l al so sound f or
appr oxi mat el y 6( 2) se c onds. If t he dri ver f ast ens
t he sa f e t y belt whi l e t he saf et y bel t warni ng is
i llumi nat ed or l i ght i ng cont rol modul e sounds t hey wi ll
t urn of f i mmedi at el y. Ref er t o Sect i on 01- 20A.
L o w Fu e l
Thi s li ght c ome s on whe n f uel gauge ( 9305) i ndi cat es
appr oxi mat el y 11B of a t ank. Igni ti on swi t c h must be
t ur ned t o RUN f or t hi s li ght t o c o me on.
A i r S u s p e n s i o n S y s t e m
If equi pped wi t h opt i onal comput er -cont r ol l ed ai r
suspensi on, t hi s li ght t el l s y ou if t he ai r suspensi on
sy st e m needs ser vi ce, or if t he ai r suspensi on swi t c h
(i n t he l uggage compar t ment on t he RH si de) is OFF.
Normal l y, t he AIR SUSP i ndi cat or li ght wi ll gl ow
moment ari l y as y ou t urn t he i gni ti on swi t c h t o RUN.
Hi g h B e a m
Thi s i ndi cat or wi ll be di spl a y e d when t he hi gh beam
headl amps are on or whe n t he hi gh beam headl amps
are f l a she d.
L H / R H T u r n
The se i ndi cat ors wi l l be f l ashi ng when act i vat ed by t he
mul t i -f unct i on swi t c h. The y al so oper at e in a dual
f l ashi ng mode a s a ha za r d i ndi cat or.
O v e r d r i v e Of f
Thi s li ght i ndi cat es t ha t t he t ransmi ssi on cont rol swi t c h
(TCS) on t he gearshi f t l ever has been pr e sse d. Whe n
t he li ght is on, t he aut omat i c t ransmi ssi on wi ll l ock out
OVERDRI VE, al l owi ng oper at i on in f i rst t hr ough t hi r d
ge a r s only. Pressi ng t he TCS agai n wi l l re-enabl e
OVERDRI VE. The aut omat i c t ransmi ssi on wi ll be in t he
O / DO N mode whe n t he engi ne is st a r t e d even if t he
O / D OFF mode wa s se l e c t e d when t he engi ne wa s
l ast runni ng. Ref er t o Sect i on 07-05.
13- 01B- 7
I nst r ument Cl us t er Conv ent i onal 13- 01B- 7
I n st r ume n t Cl ust e r
13- 01B- 8
I n st r ume n t Cl ust e r ( Co n t i n ue d )
INSTRUMENT
CLUSTER
1 INDICATOR LAMP
feieMef#Wf}/:--|
TO POWERTRAI N
CONTROL
MODULE
(PCM)
S e e E VT M f o r m o r e d e t a i l s
o f t hi s c i r c u i t
NOT
USED
ENGINE
COOLANT
TEMPERATURE
(ECT) SENSOR
A20384-B
13- 01B- 9
DIAGNOSIS A N D TESTING ( C o n t i n u e d )
I n st r ume n t Cl ust er ( Co n t i n ue d )
INSTRUMENT
CLUSTER
See EVTM f o r
mo r e det ai l s
TO ANTI - LOCK
BRAKE
CONTROL
MODULE
TO POWERTRAI N
CONTROL
MODULE (PCM)
TO AI R BAG
DI AGNOSTI C
MONI TOR
A20385-B
i . A A. : " i ' a. A . A
13- 01B- 10
Z Z J L JEHZ3
I nst r ument Cl ust er (Cont i nued)
* "1 INSTRUMENT
I CLUSTER
BRAKE
INDICATOR
LAMP
See EVTM f or more details
of this circuit
01-13
97 7 I P/W
FT
P/W
Y
NORMAL LOW
BRAKE
FLUID
LEVEL
SWITCH WITH WITHOUT
DRL DRL
I P 1
P2
I START
I
ACC
RUN ^ LOCK
1 IGNITION
| SWITCH
GNDI
I
977 I P/W
4 ' 1 DAYTIME
I . RUNNING
i I LAMPS
BK LJ ---J
512JT/LG
I (DRL)
* MODULE
1
i"
I
PARK
BRAKE
SWITCH
13- 01B- 11
I n s t r u me n t C l u s t e r C o n v e n t i o n a l 13- 01B- 11
j I n st r ume n t Cl ust e r (Cont i nue d)
mm. nam era mmm mmm m a f %
AI R SUSPENSI ON/
TEST CONNECTOR
TO AI R SUSPENSI ON/
ELECTRONI C
VARI ABLE ORI FI CE
(EVO) STEERI NG
MODULE
TO
GENERATOR
13- 018- 12 I n s t r u me n t C l u s t e r C o n v e n t i o n a l 13- 01B- 12
I n st r ume n t Cl ust e r ( Cont i nue d)
of this circuit
FROM
I NSTRUMENT
I LLUMI NATI ON
INSTRUMENT
CLUSTER
A20388-B
LIGHTING CONTROL
MODULE CONNECTOR C1
K22SS7-A
P i n
N u m b e r Circuit C i r c u i t Function
1 2 9 6 ( W/ P ) R U N / A C C B + i nput
2 1034
( B K / W)
3 158
( B K / P K )
Ke y in i gn i t i o n
4 No t Us e d
5 486
( B R / W)
De c k L i d Aj a r
6 No t Us e d
7

Hoi Ua e d
8 7 0 ( L B / W) Ke y l e s s Ent r y , Me mo r y S e a t s , A BS
:
9 640 ( R / Y) RUN/ S T A RT B + I nput
11 62 7
( B K / O )
12 465
( W/ L B )
13 1032
( W/ B K )
Pa r k L a mp
13- 01B- 13 I n s t r u me n t C l u s t e r C o n v e n t i o n a l 13- 01B- 13
Pi n
14 3 4 0 ( R / L B ) Pa n i c A l a r m
15 No t Us e d
16 2 2 2
( BR/ L G )
LI GHTI NG CONTROL
MODULE CONNECTOR C2
K22688-A
Pin
1 No t Us e d
2 932
( G Y/ W)
3 No t Us e d
4 6 ( Y/ L G ) Ho r n
5

No t Us e d
6 2 2 0 ( P / O ) A u t o l a mp O N / O F F
7 2 1 8 ( W / P ) A u t o l a mp E NA BL E
8 2 17
( DB / O )
9 3 8 3 ( R / W) Ha z a r d I n d i c a t o r
10 344
( B K / Y)
11 867 ( DB) Dr i v e r s Do o r Aj a r S wi t c h
12 688
( DB / O )
13

No t Us e d
14 183 ( T / Y) I n st r ume n t Cl u s t e r To n e Re q u e s t
15 1036
( B R / W)
16 1035
( O / R )
17 85
( B R / L B )
Sa f e t y Be l t S wi t c h
Pin
18 1010
( DB / O )
He a t e d Ba c k Wi n d o w S wi t c h
19 No t Us e d
2 0 No t Us e d
2 1 No t Us e d
2 2 No t Us e d
LIGHTING CONTROL
Pin
1 7 05
( L G / O )
2 19 ( L B / R ) Va r i a b l e Di mmi n g Out put t o
3 117
( P K / B K )
5 53
( B K / L B )
6 195 ( T / W) Ba t t e r y Vo l t a ge I nput t o L C M a n d
7

No t Us e d
8 450
( B K / L G )
Sa f e t y Be l t Wa r n i n g I n d i c a t o r
12 484
( O / B K )
Pul se Wi d t h Mo d u l a t o r I l l umi n a t i o n
Out put
13 44 ( L B) T u r n / Ha z a r d
14 14 ( BR) P a r k L a mp s
15 385 ( W/ R ) Fl a s h e r P o we r
LIGHTING CONTROL
MODULE CONNECTOR C4
K2269Q-A
Pin
1 12
( L G / B K )
Hi gh Be a m He a d l a mp s
2 196
( DB/ O)
INSTRUMENT CLUSTER
CONNECTOR C1
R10942-A
Pin
Number Circuit Ci r cui t Func t i on
2 67 6
( P K / O )
Gr o un d
3 6 4 0 ( R / Y ) I gn i t i o n ( Ho t in ST A RT / RUN)
4 No t Us e d
5 658
( P K / L G )
I nput
6 No t Us e d
7 No t Us e d
8 450
( DG / L G )
Fa s t e n Be l t s I n d i c a t o r I nput
9 67 6
( P K / O )
Gr o un d
10 3 ( L G / W) Le f t Turn I n d i c a t o r
11 88 ( B K / W) Ch a r ge I n d i c a t o r I nput ( + )
12 904
( L G / R )
Ch a r ge I n d i c a t o r I nput (-)
Pin
13

No t Us e d
14 6 7 9
( G Y/ B K )
Si gn a l I nput ( + )
15 4 1 9
( DG / L G )
16 1053
( L B / P K )
Ai r Su s p e n s i o n I n d i c a t o r I nput ( + ) |
INSTRUMENT CLUSTER
CONNECTOR C2
R10943-A
Pin
1 484
( O / B K )
Cl us t e r I l l umi n a t i o n
3 6 4 0 ( R / Y ) I gn i t i o n ( Ho t i n ST A RT / RUN)
4 67 6
( P K / O )
Gr o un d
5 39 ( R / W) En gi n e Co o l a n t T e mp e r a t u r e I nput
6 67 6
( P K / O )
Gr o un d
7 No t Us e d
8 No t Us e d
9 603 ( DG) A n t i - L o c k Br a ke I n d i c a t o r I nput
10 2 ( W/ L B ) Ri ght Tur n I n d i c a t o r I nput
11 911
( W/ L G )
L a mp ( TCI L) I nput
12 932
( G Y/ W)
Hi gh Be a m I n d i c a t o r I nput
13 97 7 ( P / W) Br a ke I n d i c a t o r I nput
M.
31 ( W/ R ) Oi l P r e s s u r e I Npi ".
(5 67 6
( P K / O )
Gr o un d
16
~ 6 0 8
1
( B K / Y)
Ai r Ba g I n d i c a t o r I nput
13- 01B- 15
IGNITION SWITCH CONNECTOR A20399-A
P i n
12

No t Us e d
A1 2 97
( B K / L G )
Ho t i n RUN o r A CC Out put
A 2 687
( G Y/ Y)
Ho t i n Run Ou t pu t
A3 687
( G Y/ Y)
Ho t i n Run Ou t pu t
STA 33 ( W/ P K ) Ho t i n St a r t Ou t pu t
A 4 489
( P K / B K )
Ho t i n Run Out put
B5 2 7 6 ( B R ) Ba t t e r y I nput
11 2 62
( B K / P K )
Ho t i n St a r t o r Run Ou t pu t
GND 57 ( BK) Gr o u n d I nput
P1

No t Us e d
P2 97 7 ( P / W) Gr o u n d e d i n St a r t Out put
HEADLAMP SWITCH
CONNECTOR C1
K22691-A
Pin
1 1036
( B R / W)
3

Not Us e d
4 1035
( O / R )
5 484
( O / B K )
RUN / A CC B + V o l t a g e
6
_
No t Us e d
7

No t Us e d
HEADLAMP SWITCH
CONNECTOR C2
K22692-A
Pin
1 57 ( BK) L o gi c Gr o un d
2 484
( O / B K )
R U N / A C C B + V o l t a g e
3 1032
( W/ B K )
P a r kl a mp s
5 No t Us e d
6 88 ( BK) Do me L a mp Swi t c h
Pin
9 2 17
( DB / O )
10 2 2 0 ( P / O ) A u t o l a mp S wi t c h t o Ampl i f i e r
11 2 2 2
( B R / L G )
12 No t Us e d
He a t e d Ba c k Wi n d o w Swi t c h a n d Li ght -
Vi c t o r i a , Gr a n d Ma r qui s
- Cr o wn
REAR
6
""" 1
WI N DO W 1
DEFROSTER!
40A I
POWER
DISTRIBUTION
BOX
See EVTM for
more details
of thi s ci rcui t
N9495-C
i^P2| \B2J Â2} IJt
IGNITION SWI TCH CONNECTOR
K22549-A
Pin
12
_
No t Us e d
A1 2 97
( B K / L G )
Ho t i n RUN o r A CC Ou t pu t
B2 5 6 8 ( L G) Ba t t e r y I nput
A2 687
( G Y/ Y)
B3 5 6 8 ( L G) Ba t t e r y I nput
A3 687
( G Y/ Y)
STA 3 3 ( W/ P K ) Ho t i n St a r t Ou t pu t
A 4 489
( P K / B K )
11 2 62
( B K / P K )
Ho t i n St a r t o r Run Out put
GND 57 ( BK) Gr o u n d I nput
P1

No t Us e d
P2 97 7 ( P / W) G r o u n d e d in St a r t Ou t pu t
13- 01B- 17
HEADLAMP SWI TCH
CONNECTOR C1
K22691-A
P i n
1 1036
( B R / W)
3 No t Us e d
4 1035
( O / R )
Pa n e l Di mme r ( Up) Swi t c h
5 2 96 ( W/ P ) R U N / A C C B + V o l t a g e
6
_
No t Us e d
7 No t Us e d
8 57 ( BK) L o g i c Gr o u n d
0
HEADLAMP SWI TCH
Pin
1 57 ( BK) L o gi c Gr o u n d
2 2 96 ( W/ P ) R U N / A C C B + Vo l t a ge
3 1032
( W/ B K )
P a r kl a mp S wi t c h
5

No t Us e d
6 1034
( B K / W)
7 195 ( T / W) Ba t t e r y Vo l t a g e
9 2 1 7 ( D / O 0 A u t o l a mp De l a y
10

No t Us e d
11 2 2 2
( BR/ L G )
12

No t Us e d
13- 01B- 18 I n s t r u me n t C l y s t e r C o n v e n t i o n a l 13- 011- 18
HOT IN START OR RUN HOT AT ALL TIMES
5
13
, FUSE
I JUNCTION
. PANEL
I f 16A |
POWER
DISTRIBUTION
BOX
C18
RUN/START AUTO LAMP
INPUT ENABLE
A9 B7
LOW BEAM
HEADLAMPS
AND CORNERING
LAMPS INPUT
C10
D2
LOGIC POWER
GROUND GROUND
C0 C4
I j 6401 R/Y I
g e y ; jj i ' J W L " - I 218 I W
2 2 1JO/ W J[
HI BEAM HI BEAM |
SWITCH HEADLAMPS'
INPUT INPUT 1
B2 D1 J
* T LIGHTING
I CONTROL
8
MODULE
I (LCM)
932
TO FUSE JUNCTION
PANEL AND DAYTIME
RUNNING LAMPS
(DRL) MODULE
~ AUTO-
| LAMP
I SENSOR
o/w
5 7 ^ BK
57 I BK
FLASH- G
TO-PASS
SWITCH
HI
HI I PASS
MULTI-
DIMMER FUNCTION
SWITCH | SWITCH
PASS I
EC
INSTRUMENT
PANEL
HI BEAU J
INDiCATdRj
GY/W
LG/BK
12j^LG/BK 12 ^L (
X
re:
T
13 R/BK
LH HIGH
BEAM
HEADLAMP
f
RH HIGH
BEAM
HEADLAMP
LH LOW
BEAM
HEADLAMP
RH LOW
BEAM
HEADLAMP
1-^1
57 BK
P i n
1 4 4 ( L G ) Tur n Si gn a l Fl a s h e r I nput
2 5 ( O / L B ) Ri ght Ma r k e r / S t o p / T u r n a n d P a r k
L a mp s
P i n
3 37 9
( B R / W)
Ri ght Co r n e r i n g L a mp s
4 385 ( W/ R ) Ha z a r d Fl a s h e r I nput
6 No t Usscj
Pin
5 2 ( W/ L B ) Ri gh t Turn I n d i c a t o r a n d L a mp s
7 3 8 0 ( P / Y ) L e f t Co r n e r i n g I nput
8 3 ( L G / W) L e f t Tur n I n d i c a t o r a n d L a mp s
9 5 1 1 ( L G ) S t o p l a mp I nput
10 9 ( L G / Q) L e f t Ma r k e r / S t o p / T u r n a n d Pa r k
L a mp s
MULTI-FUNCTION
SWITCH 7-PIN CONNECTOR C2
K19923-B
Pin
1 589 ( O) Wi p e r S p e e d Se l e c t
2 13 ( R/ BK ) L o Be a m
3 No t Us e d
4 993
( B R / W)
Co mmo n
5 12
( L G / B K )
Hi Be a m
6 590
( DB / W)
Wi p e r I n t e r v a l De l a y S wi t c h
7 2 2 1 ( O / W) P o we r Fe e d
r z i cn
0 0 0
HEATED BACK WINDOW
SWITCH AND LIGHT CONNECTOR
K19692-A
Pin
1 7 2 7
( Y / B K )
P o we r Out t o Gr i d
2 175
( B K / Y)
P o we r In f r o m Gr i d
3 2 98
( P / O )
P o we r
5 19
( L B / R )
I l l umi n a t i o n P o we r
1. Veri f y t he vehi cl e owner ' s ori gi nal concer n by
oper at i ng t he i nst rument cl ust er ( 10849) t o
dupl i cat e t he condi t i on and by observi ng t he
i ndi cat ors and gauges t o det ermi ne if t hey ar e
oper at i ng pr oper l y wi t h t he i gni ti on swi t c h
( 1157 2) :
In RUN wi t h t he engi ne OFF.
In START bef or e t he ignition swi t c h is rel eased.
In RUN wi t h t he engi ne runni ng.
2. I nspect t o det ermi ne if any of t he f ol l owi ng
Da ma g e d f ue l t a n k.
En gi n e c o o l a n t l e v e l .
En gi n e o i l l e v e l .
A c c e s s o r y d r i v e be l t .
Fuse .
S wi t c h e s or s e n s o r s .
det ermi ne t he sy mpt o ms and go t o t he Sy mpt om
Chart .
Use Rot unda 7 3 Di gi t al Mul t i met er 105-00057 or
equi val ent t o pe r f or m t he f ol l owi ng el ect ri cal pi npoi nt
t e st s.
13- 01B- 2 0 I n s t r u me n t C l u s t e r C o n v e n t i o n a l 13- 01B- 2 0
I n t e gr a t e d Ci r c ui t Di splay(s)
I n o pe r a t i ve or Er r a t i c
Fuse .
I nst r ume nt c l ust e r pr i n t e d c i r c ui t .
Fuel Le v e l Re a d s I n a c c ur a t e l y Ci r c ui t wi r i n g.
Fue l ga uge .
Fue l pump.
Engi ne Co o l a n t Te mpe r a t ur e
Re a d s I n a c c ur a t e l y
Engi ne c o o l a n t t e mpe r a t ur e ( ECT)
se n so r .
Ci r c ui t r y o pe n / s ho r t e d .
Te mpe r a t ur e ga uge .
Oi l Pr e ssur e Re a d s I n a c c ur a t e l y Oi l pr e ssur e se n so r .
Ci r c ui t r y o p e n / s ho r t e d .
Ga uge .
Cha r ge I n d i c a t o r Re a d s
I n a c c ur a t e l y
Da ma ge d bul b.
S p e e d o me t e r / Od o me t e r Re a d s
I n a c c ur a t e l y
Ve hi c l e s p e e d se n so r ( VSS) .
Sp e e d o me t e r / o d o me t e r .
Br a ke Wa r ni ng Ne v e r / Al wa y s On Sh o r t e d / o pe n wi r i n g / c i r c ui t r y .
DRL c o n t r o l mo d ul e .
Bl o wn i n d i c a t o r bul b.
Pa r ki n g b r a ke s wi t c h c i r c ui t
ma l f un c t i o n .
L o w Oi l Pr e ssur e Wa r n i n g
S h o r t e d / o pe n wi r i n g.
L o w oi l pr e ssur e se n so r
o p e n / s h o r t e d .
Ai r Ba g Wa r ni ng Ne v e r / Al wa y s On Ci r c ui t r y ma l f un c t i o n .
Se n so r ma l f un c t i o n .
REFER t o Se c t i o n 01- 2 0B.
An t i - L o c k Wa r n i n g Ne v e r / A l wa y s
On
Ci r c ui t r y ma l f un c t i o n .
Se n so r ma l f un c t i o n .
LH Turn I n d i c a t o r Ne ve r / Al wa y s
On
Op e n / s h o r t e d c i r c u i t r y / wi r i n g.
Mul t i - f un c t i o n swi t c h ma l f un c t i o n .
GO t o Pi npoi nt Te st J .
RH Turn I n d i c a t o r Ne ve r / Al wa y s
On
Hi gh Be a m Wa r n i n g Ne ve r / Al wa y s
On
DRL Co n t r o l Mo d ul e .
Emi ssi o n s y s t e m c o n c e r n .
Co n t r o l / E mi s s i o n s Di a gn o si s
Ma n ua l
2
.
He a t e d Ba c k Wi n d o w I n d i c a t o r
Ma l f un c t i o n i n g s wi t c h .
Bl o wn f u s e ( s ) .
Sa f e t y Bel t Wa r n i n g Ne v e r / Al wa y s
On
Li ght i n g Co n t r o l Mo d ul e .
GO t o Pi npoi nt Te st N.
2 P u r c h a s e d s e p a r a t e l y , r e f e r t o t h e e n d o f t h i s Se c t i o n f o r v e h i c l e a p p l i c a t i o n .
CONVENTIONAL INSTRUMENT CLUSTER (Cont i nued)
Do o r Aj ar Wa r ni ng Ne v e r / Al wa y s
On
Li ght i n g Co n t r o l Mo d ul e
Ma l f un c t i o n i n g d o o r o pe n wa r n i n g
l a mp s wi t c h e s .
Op e n / s h o r t e d wi r i n g.
Bl own i n d i c a t o r bul b.
PINPOINT TEST A: INTEGRATED CIRCUIT DISPLAY(S) INOPERATIVE OR ERRATIC
A1 CHECK CI RCUI T 640 (R / Y)
Re mo v e i n st r ume n t c l ust e r a s o ut l i n e d .
Di sc o n n e c t i nst r ume nt c l ust e r c o n n e c t i o n s C1 a n d
C2 ( Cr o wn Vi c t o r i a ) , C2 ( Gr a n d Ma r qui s) .
Re mo v e Fuse 13 ( 10A) f r o m i n st r ume n t pa n e l f use
j un c t i o n pa n e l .
Ch e c k c o n t i n ui t y b e t we e n l o a d si d e of Fuse 13
( 10A) a n d gr o un d .
Ye s
No
SERVI CE sho r t t o gr o un d
in Ci r c ui t 640 ( R/ Y) .
RETEST s y s t e m.
GO t o A2.
A2 CHECK PRI NTED CI RCUI T SUPPLY CI RCUI TS
Me a sur e r e s i s t a n c e of Ci r c ui t 640 ( R/ Y) b e t we e n
l o a d si d e of Fuse 13 ( 10A) a n d e a c h of t he f o l l o wi n g
pi ns of i n st r ume n t c l ust e r c o n n e c t o r s :
CROWN VICTORIA
C1 Pi n 4
C2 Pi n 8
GRAND MARQUIS
C2 Pi n 12
Ye s
No
Is resi st ance less t han 1 ohm f or all ci r cui t s?
REPLACE i nst r ume nt
c l ust e r pr i n t e d c i r c ui t .
RETEST s y s t e m.
SERVI CE o pe n in c i r c ui t s
a s r e qui r e d . RESTORE
PINPOINT TEST B: FUEL LEVEL READS INACCURATELY
B1 VERI FY POWER AT FUSE
Ye s
No
GO t o B3.
G Ot o B2.
Use v o l t me t e r t o ve r i f y s y s t e m v o l t a ge at l o a d si d e
of wa r n i n g i n d i c a t o r Fuse 13 ( 10A) .
Is vol t age pr esent at l oad si de of f use?
Ye s
No
GO t o B3.
G Ot o B2.
B2 VERI FY POWER AT FUSE PANEL
Ye s
No
REPLACE f use .
SERVI CE wi r i n g t o f use
pa n e l . RETEST s y s t e m.
Use v o l t me t e r t o ve r i f y s y s t e m v o l t a ge at f e e d si d e
of wa r n i n g i n d i c a t o r Fuse 13 ( 10A) .
Is vol t age pr esent at f e e d si de of f use?
Ye s
No
REPLACE f use .
SERVI CE wi r i n g t o f use
pa n e l . RETEST s y s t e m.
B3 VERI FY POWER AT CLUSTER
Ye s
No
GO t o B4.
(R / Y) f o r o pe n c i r c ui t .
RETEST s y s t e m.
I nst r ume nt c l ust e r c o n n e c t o r s i n st a l l e d .
Pa r t i a l l y r e mo v e i nst r ume nt c l ust e r .
Usi n g a mul t i me t e r , c h e c k f or v o l t a ge a t i nst r ume nt
c l ust e r c o n n e c t o r a n d ga uge t e r mi n a l .
Is vol t age at i nst r ument cl ust er c onne c t or and
gauge t er mi nal ?
Ye s
No
GO t o B4.
RETEST s y s t e m.
P I NP OI NT TEST B: FUEL LEVEL READS INACCURATELY (Cont i nued)
TEST STEP RE SUL T A CT I ON TO TAKE
B4 VERI FY GROUND CI RCUI T AT CLUSTER
Ye s
No
G O t o B 5 .
( O / Y ) Cr o wn Vi c t o r i a ,
359 ( G Y/ R ) Gr a n d
Ma r q u i s f o r o p e n c i r c u i t .
RETEST s y s t e m.
Us e a v o l t - o h mme t e r t o c h e c k c o n t i n ui t y of
i n st r ume n t c l u s t e r a n d ga u ge gr o u n d c i r c u i t s .
Is t he r e c o n t i n ui t y ?
Ye s
No
G O t o B 5 .
( O / Y ) Cr o wn Vi c t o r i a ,
359 ( G Y/ R ) Gr a n d
Ma r q u i s f o r o p e n c i r c u i t .
RETEST s y s t e m.
B5 CHECK TEST BOX ( L OW)
Ye s
No
GO t o B8 .
GO t o B6 .
Turn i gn i t i o n s wi t c h t o OFF p o s i t i o n .
I n se r t Ro t u n d a I n st r ume n t Ga u ge S y s t e m Te s t e r
02 1- 00055 or e q ui v a l e n t i n f ue l pump c i r c u i t .
Di s c o n n e c t 14405 c o n n e c t o r un d e r i n st r ume n t pa n e l
a n d c o n n e c t t e s t e r t o c l u s t e r s i d e o f c o n n e c t o r .
Se t t e s t e r t o 2 2 o h ms .
Turn i gn i t i o n s wi t c h t o RUN p o s i t i o n , wa i t 60
s e c o n d s a n d r e a d f ue l ga u ge .
Does f ue l gauge r ead EMPTY?
Ye s
No
GO t o B8 .
GO t o B6 .
B6 CHECK TEST BOX ( RETEST)
Ye s
No
GO t o B8 .
G O t o B7 .
Tur n i gn i t i o n s wi t c h t o OFF p o s i t i o n .
Turn i gn i t i o n s wi t c h t o RUN p o s i t i o n .
Ta p l i ght l y on i n st r ume n t c l ust e r , wa i t 60 s e c o n d s
a n d r e a d f ue l ga u ge .
Ye s
No
GO t o B8 .
G O t o B7 .
B7 L OW FUEL LEVEL WARNI NG SWI TCH BYP A SS TEST
Ye s
No
REPL ACE l o w f ue l l e v e l
wa r n i n g s wi t c h .
RETEST s y s t e m.
REPL ACE f ue l ga u ge .
I NSTALL l o w f ue l l e v e l
RETEST s y s t e m.
Re mo v e i n st r ume n t c l u s t e r a n d i n s p e c t i n st r ume n t
c l u s t e r pr i n t e d c i r c ui t .
Re mo v e l o w f ue l l e v e l wa r n i n g s wi t c h a n d c o n n e c t a
j u mpe r wi r e f r o m Ga u ge Te s t e r d i r e c t l y t o f ue l ga u ge
'SIG' t e r mi n a l .
I n st a l l i n st r ume n t c l us t e r .
Tur n i gn i t i o n s wi t c h t o RUN p o s i t i o n a n d r e a d f ue l
ga u ge .
Ye s
No
RETEST s y s t e m.
I NSTALL l o w f ue l l e v e l
RETEST s y s t e m.
B8 CHECK TEST BOX (HI GH)
Ye s
No
GO t o B 1 0 .
G O t o B9.
Wi t h Ro t u n d a I n st r ume n t Ga u ge Sy s t e m Te s t e r
02 1 - 00055 or e qui v a l e n t c o n n e c t e d a s in St e p B5,
s e t t e s t e r t o 145 o h ms .
Turn i gn i t i o n s wi t c h t o RUN p o s i t i o n .
Wa i t 60 s e c o n d s a n d r e a d f ue l ga u ge .
Does f ue l gauge r ead FUL L ?
Ye s
No
GO t o B 1 0 .
G O t o B9.
B9 ANTI - SL OSH MODUL E BYP A SS TEST
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
Re mo v e i n st r ume n t c l u s t e r a n d i n s pe c t i n st r ume n t
c l u s t e r pr i n t e d c i r c ui t .
Re mo v e l o w f ue l l e v e l wa r n i n g s wi t c h .
Co n n e c t a j umpe r wi r e f r o m t e s t e r t o f ue l ga u ge
' SI G' t e r mi n a l .
Turn i gn i t i o n s wi t c h t o RUN p o s i t i o n a n d r e a d f ue l
ga u ge .
Does f ue l gauge r ead FUL L ?
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
B 1 0 I NSPECT FUEL TANK
Ye s
No
REPL ACE f ue l t a n k.
RETEST s y s t e m.
GO t o B 1 1 .
I n s pe c t f ue l t a n k f o r d a ma g e or d i s t o r t i o n .
Is t he r e da ma ge ?
Ye s
No
REPL ACE f ue l t a n k.
RETEST s y s t e m.
GO t o B 1 1 .
PINPOINT TEST B: FUEL LEVEL READS INACCURATELY (Cont i nued)
B11 CHECK TEST BOX - EMPTY STOP
Ye s
No
GO t o B 1 2 .
REPLACE f ue l pump.
RETEST s y s t e m.
Co n n e c t one l e a d of mul t i me t e r t o t he f ue l pump
mo d ul e si gna l l e a d a nd t he o t he r l e a d t o gr o un d .
NOTE: Fl o a t r o d i s a ga i n st e mpt y s t o p ( c l o s e s t t o
f i l t e r ) .
Does mul t i met er read bet ween 14- 18 ohms?
Ye s
No
GO t o B 1 2 .
RETEST s y s t e m.
B12 CHECK TEST BOX - FULL STOP
Ye s
No
GO t o B 1 3 .
RETEST s y s t e m.
Co n n e c t one l e a d of mul t i me t e r t o t he f ue l pump
si gn a l l e a d a nd t h e o t he r l e a d t o f ue l pump mo d ul e
gr o un d .
NOTE: Fl o a t r o d i s a ga i n st f ul l s t o p .
Does mul t i met er read be t we e n 155- 165 ohms?
Ye s
No
GO t o B 1 3 .
RETEST s y s t e m.
B13 CHECK FLOAT ROD LEVEL
Ye s
No
GO to 114.
RETEST s y s t e m.
Co n n e c t one l e a d t o mul t i me t e r t o t he f ue l pump
si gn a l l e a d a n d t h e o t he r l e a d t o f ue l pump mo d ul e
gr o un d .
Sl o wl y mo ve f l o a t r o d f r o m f ul l s t o p t o e mpt y s t o p .
Does ohmmet er readi ng sl owl y decr ease?
Ye s
No
GO to 114.
RETEST s y s t e m.
B1 4 CHECK FUEL LEVEL WARNI NG SWI TCH
Ye s
No
REPLACE l o w f uel l e ve l
RETEST s y s t e m.
GO t o B 1 5 .
Co n n e c t Ro t un d a I nst r ume nt Ga uge Sy s t e m Te st e r
02 1- 00055 or e qui va l e n t i n f ue l pump c i r c ui t .
Di sc o n n e c t Ci r c ui t 14405 c o n n e c t o r under
i n st r ume n t pa n e l a n d c o n n e c t t e s t e r t o c l ust e r si d e
of c o n n e c t o r .
Se t t e s t e r t o 56 o hms .
Turn i gni t i on s wi t c h t o t h e RUN po s i t i o n , wa i t 60
s e c o n d s .
Is l ow f uel i ndi cat or on?
Ye s
No
REPLACE l o w f uel l e ve l
RETEST s y s t e m.
GO t o B 1 5 .
B15 CHECK GAUGE AND I NDI CATOR
Ye s
No
L o w f ue l l e ve l wa r n i n g
s wi t c h o pe r a t i n g
GO t o B 1 6 .
Turn i gn i t i o n s wi t c h t o t h e OFF po s i t i o n .
Re se t t e s t e r t o 33 o h ms .
Turn i gn i t i o n s wi t c h t o t h e RUN po s i t i o n .
Wa i t 60 s e c o n d s .
Is i ndi cat or on and gauge showi ng 1 / 8 t a n k?
Ye s
No
L o w f ue l l e ve l wa r n i n g
s wi t c h o pe r a t i n g
GO t o B 1 6 .
B16 CHECK I NDI CATOR
Ye s
No
REPLACE l ow f ue l l e ve l
RETEST s y s t e m.
GO t o B 1 7 .
Wi t h i gni t i on s wi t c h in t h e RUN po s i t i o n , gr o un d
i n d i c a t o r c i r c ui t be t we e n i n d i c a t o r a n d l o w f ue l l e ve l
Is i ndi cat or on?
Ye s
No
REPLACE l ow f ue l l e ve l
RETEST s y s t e m.
GO t o B 1 7 .
B17 CHECK I NDI CATOR BUL B
Ye s
No
RETEST s y s t e m.
REPLACE d a ma ge d
i n d i c a t o r bul b. RESTORE
Turn i gn i t i o n s wi t c h OFF.
Re mo v e i n st r ume n t c l ust e r a s o ut l i n e d .
Re mo v e i n d i c a t o r bul b a n d c h e c k bul b c o n t i n ui t y
usi n g an o hmme t e r .
Does bul b t e st OK?
Ye s
No
RETEST s y s t e m.
REPLACE d a ma ge d
i n d i c a t o r bul b. RESTORE
= X . l
PINPOINT TE ST C: ENGINE COOLANT TEMPERATURE READS INACCURATELY
TE ST STEP RESULT A CT I ON T O TAKE
C1 CHECK POWER AT CLUSTER
Turn i gn i t i o n s wi t c h t o t he OFF po s i t i o n .
Turn i gn i t i o n s wi t c h t o RUN po si t i o n .
Usi n g a mul t i me t e r c h e c k f o r v o l t a ge a t c l ust e r
c o n n e c t o r pi n pe r c ha r t .
CROWN VICTORIA
Ye s
No
Conne c t or
Pin Ci rcui t Ci r cui t Func t i on
C2 8 640 ( R / Y) I gn i t i o n Vo l t a ge
C1 8 359 ( G Y / R ) Ga u ge Gr o u n d
C1 6 39 ( R/ W) En gi n e Co o l a n t T e mp e r a t u r e I nput
GRAND MARQUIS
Conne c t or
Pin Ci rcui t Ci r cui t Funct i on
C2 12 640 ( R / Y ) I gn i t i o n Vo l t a ge
C1 8 563 ( O / Y ) Ga u ge Gr o u n d
C1 3 39 ( R / W) En gi n e Co o l a n t T e mp e r a t u r e I nput
Is sy st e m vol t age pr esent ?

GO t o C2 .
(R / Y) f or o pe n c i r c ui t .
RETEST s y s t e m.
0 2 CHECK CLUSTER GROUND
Usi n g an mul t i me t e r c o n n e c t e d t o a kn o wn go o d
gr o un d , c o n n e c t o t he r e nd t o gr o un d c i r c ui t pe r
c ha r t a b o v e .
Ye s
No

GO t o 0 3 .
SERVI CE Cr o wn Vi c t o r i a
Ci r c ui t 359 ( G Y/ R) o r
Gr a nd Ma r qui s Ci r c ui t
563 ( O/ Y) f o r o pe n
0 3 CHECK ENGI NE COOL ANT TEMPERATURE ( ECT)
SENSOR CI RCUI T AT L OW
I nser t Ro t un d a I nst r ument Ga uge Sy s t e m Te st e r
02 1 - 00055 or e qui va l e n t . Di s c o n n e c t c o n n e c t o r at
ECT se n so r a n d c o n n e c t t e s t e r t o i nst r ume nt c l ust e r
si d e of c o n n e c t o r . Se t t o 7 4 o h ms .
Turn i gn i t i o n s wi t c h t o RUN po si t i o n .
Does gauge read col d?
Ye s
No

G O t o C 4 .
GO t o 0 5 .
C4 CHECK ENGI NE COOLANT TEMPERATURE (ECT)
SENSOR CI RCUI T AT HIGH
Se t Ga uge Sy s t e m Te st e r t o 10 o h ms .
Does gauge read hot ?
Ye s
No
REPLACE e n gi n e c o o l a n t
t e mpe r a t ur e ( ECT)
se nsor . RESTORE
GO t o C5.
0 5 CHECK ENGI NE COOLANT TEMPERATURE I NPUT
CI RCUI T
Wi t h i gn i t i o n s wi t c h in t he RUN po si t i o n a nd usi ng a
t e s t l a mp c o n n e c t e d t o kn o wn go o d gr o un d , c o n n e c t
pr o be t o ECT se n so r c o n n e c t o r .
Ye s
No

GO t o 0 7 .
GO t o 0 6 .
PINPOINT TEST C: ENGINE COOLANT TEMPERATURE READS INACCURATELY (Cont i nued)
C6 CHECK CI RCUI T 39 ( R / W)
Ye s
No
(R / W) f o r o pe n c i r c ui t .
RETEST s y s t e m.
GO t o C7.
Turn ignition switch to OFF position. Remove
instrument cluster as outlined.
Turn i gni t i on s wi t c h t o RUN po si t i o n . Usi ng t e s t
l a mp, c h e c k Ci r c ui t 39 ( R/ W) at i nst r ume nt c l ust e r
c o n n e c t o r pe r c ha r t .
CROWN VICTORIA
Ye s
No
RETEST s y s t e m.
GO t o C7.
Conne c t or
Pin Ci rcui t Ci rcui t Func t i on
Ye s
No
RETEST s y s t e m.
GO t o C7.
C2 8 6 4 0 ( R / Y ) I gn i t i o n Vo l t a ge
Ye s
No
RETEST s y s t e m.
GO t o C7.
C1 8 359 ( G Y/ R ) Ga u ge Gr o u n d
Ye s
No
RETEST s y s t e m.
GO t o C7.
C1 6 39 ( R/ W) En gi n e Co o l a n t Te mp e r a t u r e I nput
Ye s
No
RETEST s y s t e m.
GO t o C7.
GRAND MARQUIS
Ye s
No
RETEST s y s t e m.
GO t o C7.
Conne c t or
Pin Ci rcui t Circuit Funct i on
Ye s
No
RETEST s y s t e m.
GO t o C7.
Ye s
No
RETEST s y s t e m.
GO t o C7.
C1 8 563 ( O/ Y) Ga u ge Gr o un d
Ye s
No
RETEST s y s t e m.
GO t o C7.
Ye s
No
RETEST s y s t e m.
GO t o C7.
Ye s
No
RETEST s y s t e m.
GO t o C7.
C7 CHECK ENGI NE COOL ANT TEMPERATURE GAUGE
GO t o C8.
REPLACE e ngi ne c o o l a n t
t e mpe r a t ur e ga uge .
RETEST s y s t e m.
Turn i gni t i on s wi t c h t o OFF po s i t i o n .
Di sc o n n e c t c l ust e r c o n n e c t o r s .
Usi ng an mul t i me t e r , c h e c k ga uge f o r c o n t i n ui t y at
c o n t a c t c l i ps .
Is t here cont i nui t y at all cl i ps?
Ye s
No
GO t o C8.
RETEST s y s t e m.
C8 CHECK PRI NTED CI RCUI T
RETEST s y s t e m.
RETEST s y s t e m.
Re c o n n e c t c l ust e r c o n n e c t o r s .
Usi ng an mul t i me t e r , c h e c k f o r c o n t i n ui t y f r o m ga uge
c o n t a c t c l i ps t o c l ust e r c o n n e c t o r s pe r c ha r t .
CROWN VICTORIA
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
Conne c t or
Pin Ci rcui t Ci r cui t Func t i on
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
GRAND MARQUIS
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
Conne c t or
Pin Ci rcui t Circuit Func t i on
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
C1 8 563 ( O/ Y) Ga u ge Gr o u n d
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
Is t here c ont i nui t y at all c i r c ui t s?
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
PINPOINT TEST D: OIL PRESSURE READS INACCURATELY
D1 DETERMI NE SYSTEM APPLI CABI LI TY
Ye s
No
GO t o D2 .
GO t o D8.
The r e a r e t wo s y s t e ms f o r i n d i c a t i n g oi l pr e ssur e ,
t h e r e b y r e qui r i n g t wo d i f f e r e n t t e s t pr o c e d u r e s .
Does vehi cl e have an oi l pressure gauge?
Ye s
No
GO t o D2 .
GO t o D8.
PINPOINT TEST D: OIL PRESSURE READS INACCURATELY (Cont i nued)
T E ST STEP RESULT . ACTION TO TAKE
D2 CHECK POWER AT CLUSTER
Ye s
No
GO t o D3.
( R / Y ) f o r o pe n c i r c ui t .
RETEST s y s t e m.
Usi n g a mul t i me t e r c h e c k f o r v o l t a ge at c l u s t e r
CROWN VICTORIA
Ye s
No
GO t o D3.
RETEST s y s t e m.
Conne c t or
Pin Ci r cui t Ci r cui t Fun c t i o n
Ye s
No
GO t o D3.
RETEST s y s t e m.
Ye s
No
GO t o D3.
RETEST s y s t e m.
Ye s
No
GO t o D3.
RETEST s y s t e m.
C1 14 31 ( W/ R ) Oi l P r e s s u r e I nput
Ye s
No
GO t o D3.
RETEST s y s t e m.
GRAND MARQUIS
Ye s
No
GO t o D3.
RETEST s y s t e m.
Conne c t or
P i n Ci r cui t Ci rcui t Func t i on
Ye s
No
GO t o D3.
RETEST s y s t e m.
Ye s
No
GO t o D3.
RETEST s y s t e m.
C2 8 31 ( W/ R ) Oi l P r e s s u r e I nput
Ye s
No
GO t o D3.
RETEST s y s t e m.
Is sy st em vol t age pr esent ?
Ye s
No
GO t o D3.
RETEST s y s t e m.
D3 TEST OI L PRESSURE SENSOR CI RCUI T AT L OW
Ye s
No
GO t o D4.
GO t o OS-
Pl a c e i gn i t i o n s wi t c h i n t he RUN po si t i o n wi t h e n gi n e
OFF. Obs e r v e ga uge pe r f o r ma n c e .
Does gauge read " L " or bel ow?
Ye s
No
GO t o D4.
GO t o OS-
D4 CHECK GAUGE RESPONSE
Ye s
No
se n so r . RESTORE
GO t o D5.
Di sc o n n e c t oi l pr e s s ur e se n so r a n d sho r t t he l e a d t o
e ngi ne gr o un d .
Does gauge i ndi cat e mi d-scal e or sl i ght l y above
mi d-scal e?
Ye s
No
se n so r . RESTORE
GO t o D5.
D5 CHECK CI RCUI T 3 1 ( W/ R )
Ye s
No
GO t o D6.
( W/ R ) f o r o pe n c i r c ui t .
RETEST s y s t e m.
Le a v e oi l pr e s s ur e i nput c i r c ui t s h o r t e d t o gr o un d .
Turn i gni t i on s wi t c h t o t he OFF po s i t i o n . Re mo v e
i nst r ume nt c l ust e r a s o ut l i n e d .
Usi ng an mul t i me t e r c o n n e c t e d t o a kn o wn g o o d
gr o un d , c o n n e c t s e c o n d l e a d t o Co n n e c t o r C 1 , Pi n
14. Me a s ur e r e s i s t a n c e .
Ye s
No
GO t o D6.
RETEST s y s t e m.
D6 CHECK OI L PRESSURE GAUGE
GO t o D7 .
ga u ge . RESTORE
Di sc o n n e c t i nst r ume nt c l ust e r c o n n e c t o r s .
Usi ng an mul t i me t e r c h e c k ga uge f o r c o n t i n ui t y at
c o n t a c t c l i p s .
Is t here cont i nui t y at all cl i ps?
Ye s
No
GO t o D7 .
ga u ge . RESTORE
D7 CHECK PRI NTED CI RCUI T
ga u ge . RESTORE
RETEST s y s t e m.
Usi ng an mul t i me t e r c h e c k f o r c o n t i n ui t y f r o m ga uge
c o n t a c t c l i ps t o c l ust e r c o n n e c t o r s pe r c ha r t .
CROWN VICTORIA
Ye s
No
ga u ge . RESTORE
RETEST s y s t e m.
Conne c t or
Pin Ci r cui t Ci r cui t Func t i on
Ye s
No
ga u ge . RESTORE
RETEST s y s t e m.
Ye s
No
ga u ge . RESTORE
RETEST s y s t e m.
Ye s
No
ga u ge . RESTORE
RETEST s y s t e m.
C 1 14 31 ( W/ R ) Oi l P r e s s u r e I nput
Ye s
No
ga u ge . RESTORE
RETEST s y s t e m.
Is t here cont i nui t y at all ci r cui t s?
Ye s
No
ga u ge . RESTORE
RETEST s y s t e m.
13- 01B- 2 7 i n s t r u me n t C l u s t e r C o n v e n t i o n a l 13- 018- 2 7
PINPOINT TEST D: OIL PRESSURE READS INACCURATELY (Cont i nued)
T E ST STE P RESULT ACTION TO TA KE
DS CHECK POWER AT CLUSTER
Turn i gni t i on s wi t c h t o RUN po si t i o n .
Usi ng a mul t i me t e r c h e c k f or v o l t a ge at c l ust e r
GRAND MARQUIS
Ye s
No
GO t o D9.
RETEST s y s t e m.
Conne c t or
Pi n Ci rcui t Ci r cui t Func t i on
C2 12 640 ( R / Y) I gn i t i o n Vo l t a ge
C2 8 31 ( W/ R ) Oi l P r e s s ur e I nput
Is sy st e m vol t age present ?
D9 CHECK CI RCUI T 31 ( W/ R)
Di sc o n n e c t oi l pr e ssur e se nsor . Co n n e c t Ci r c ui t 31
( W/ R ) t o kn o wn g o o d gr o un d .
Di d i ndi cat or l amp i l l umi nat e?
Ye s
No
se n so r . RESTORE
GO t o D1 0 .
D10 CHECK CI RCUI T31 ( W/ R) AT CLUSTER
Usi ng a t e st l a mp c o n n e c t e d t o a kn o wn g o o d
gr o un d , c o n n e c t pr o be t o c l ust e r c o n n e c t o r C2 , Pi n
8.
Ye s
No
RETEST s y s t e m.
GO t o D 1 1 .
D11 CHECK OI L PRESSURE I NDI CATOR L AMP
Re mo v e oi l pr e ssur e i n d i c a t o r l a mp a s o ut l i n e d .
Usi n g an mul t i me t e r c h e c k bul b f o r c o n t i n ui t y .
Does oi l i ndi cat or bul b t est OK?
Ye s
No
RETEST s y s t e m.
REPLACE bul b.
RETEST s y s t e m.
PINPOINT TEST E: CHARGE INDICATION READS INACCURATELY
T E ST STEP RESULT ACTI ON TO T A KE
E1 L AMP CHECK NO. 1
Ye s
No
GO t o E 2 .
Engi ne OFF.
I gni t i on s wi t c h in OFF po si t i o n .
Is char ge i ndi cat or on?
Ye s
No
GO t o E 2 .
E2 L AMP CHECK NO. 2
Ye s
No
G Ot o E 3.
GO t o E 4.
Engi ne OFF.
I gni t i on s wi t c h i n RUN po si t i o n .
Ye s
No
G Ot o E 3.
GO t o E 4.
E 3 L AMP CHECK NO. 3
Ye s
No
G O t o E 6.
La mp t e s t c o mp l e t e a n d
o pe r a t i o n a l .
I gni t i on s wi t c h in RUN po si t i o n .
Engi ne r unni ng.
Ye s
No
G O t o E 6.
La mp t e s t c o mp l e t e a n d
o pe r a t i o n a l .
13- 01B- 2 8 i n s t r u me n t Cl u s t e r ' Co n v e n t i o n a l 13- 01B- 2 8
PINPOINT TEST E: CHARGE INDICATION READS INACCURATELY (Cont i nued)
E4 I NOPERATI VE I NDI CATOR L AMP
Engi ne OFF.
Ignition switch in RUN position.
Di s c o n n e c t r e gul a t o r c o n n e c t o r a n d gr o un d T
t e r mi n a l .
Is charge i ndi cat or on?
Ye s
No

G O t o E5.
A TERMI NAL
I TERMI NAL
GENERATOR
REGULATOR
WI RI NG PLUG
JUMPER WI RE
NEGATI VE BATTERY
CABLE CLAMP
J3333-C
E5 CHECK CI RCUI T 904 ( LG / R) FOR OPEN
Turn i gn i t i o n s wi t c h t o t h e OFF po s i t i o n .
Re mo v e i nst r ume nt c l us t e r a s o ut l i n e d .
Usi n g an o hmme t e r c o n n e c t e d t o a kn o wn g o o d
gr o un d , c o n n e c t s e c o n d l e a d t o pi n pe r c h a r t .
CROWN VICTORIA
Ye s
No

REMOVE j umpe r wi r e . GO
t o E6.
(LG / R) f or sho r t c i r c ui t .
RETEST s y s t e m.
Conne c t or
Pin Ci rcui t Ci r cui t Fun c t i o n
C2 18 9 04 ( L G / R ) Ch a r g e I n d i c a t o r I n put
GRAND MARQUIS
Conne c t or
Pin Ci rcui t Ci rcui t Fun c t i o n
C2 5 9 04 ( L G / R ) C h a r g e I n d i c a t o r I nput
PINPOINT TEST E: CHARGE INDICATION READS INACCURATELY (Cont i nued)
E6 CHECK CI RCUI T 904 ( L G / R) FOR SHORT
Ye s >
No
( LG / R) f o r o pe n c i r c ui t .
RETEST s y s t e m.
G O t o E 7 .
Di sc o n n e c t v o l t a ge r e gul a t o r c o n n e c t o r .
gr o un d , c o n n e c t s e c o n d l e a d t o pi n pe r c ha r t .
CROWN VICTORIA
Ye s >
No
RETEST s y s t e m.
G O t o E 7 .
Co n n e c t o r
P i n Ci rcui t Ci rcui t Func t i on
Ye s >
No
RETEST s y s t e m.
G O t o E 7 .
C2 18 904 (LG/ R) Charge Indi cator Input
Ye s >
No
RETEST s y s t e m.
G O t o E 7 .
GRAND MARQUIS
Ye s >
No
RETEST s y s t e m.
G O t o E 7 .
C o n n e c t o r
Pi n Ci r cui t Ci r cui t Funct i on
Ye s >
No
RETEST s y s t e m.
G O t o E 7 .
C2 5 904 (LG/ R) Charge Indicator Input
Ye s >
No
RETEST s y s t e m.
G O t o E 7 .
Ye s >
No
RETEST s y s t e m.
G O t o E 7 .
E7 CHECK CI RCUI T 88 ( B K / W) FOR VOLTAGE
GO t o E 8.
(BK / W) f o r o pe n c i r c ui t .
RETEST s y s t e m.
Turn i gni t i on s wi t c h t o t he RUN po si t i o n .
Usi ng a t e s t l a mp c o n n e c t e d t o a kn o wn g o o d
gr o un d , c o n n e c t o t he r e n d t o pi n pe r c ha r t .
CROWN VICTORIA
Ye s
No
GO t o E 8.
RETEST s y s t e m.
C o n n e c t o r
Ye s
No
GO t o E 8.
RETEST s y s t e m.
C2 17 88 ( BK/ W) Charge Indicator Input
Ye s
No
GO t o E 8.
RETEST s y s t e m.
GRAND MARQUIS
Ye s
No
GO t o E 8.
RETEST s y s t e m.
C o n n e c t o r
Ye s
No
GO t o E 8.
RETEST s y s t e m.
C2 4 88 ( BK/ W) Charge Indicator Input
Ye s
No
GO t o E 8.
RETEST s y s t e m.
Ye s
No
GO t o E 8.
RETEST s y s t e m.
E8 CHECK CHARGE I NDI CATOR L AMP
REPLACE i n st r ume n t
c l ust e r pr i n t e d c i r c ui t
RETEST s y s t e m.
REPLACE d a ma ge d bul b.
RETEST s y s t e m.
Re mo v e c ha r ge i n d i c a t o r l a mp bul b.
Usi n g an o hmme t e r , c h e c k c o n t i n ui t y of bul b.
Is b u l b c o n t i n u i t y OK?
Ye s &
No
REPLACE i n st r ume n t
c l ust e r pr i n t e d c i r c ui t
RETEST s y s t e m.
RETEST s y s t e m.
PINPOINT TEST F: SPEEDOMETER/ODOMETER READS INACCURATELY
F1 CHECK SPEED SI GNAL
Ye s F>
No l >
GO t o F2.
se n so r . RESTORE
Ra i se d r i ve wh e e l s of f t h e gr o un d .
Co n n e c t an AC v o l t me t e r be t we e n t he t wo o ut put
wi r e s on t he t r a n smi ssi o n mo un t e d v e hi c l e s p e e d
se n so r .
Engi ne r unni ng.
Is vol t age bet ween 1.3-6.1 vol t s AC?
Ye s F>
No l >
GO t o F2.
se n so r . RESTORE
PINPOINT TEST F: SPEEDOMETER/ ODOMETER READS INACCURATELY (Conti nued)
F2 CHECK DRI VEN GEAR
Di sc o n n e c t v e hi c l e s p e e d se n so r f r o m
t r a n s mi s s i o n . Ver i f y pr e se n c e of dr i ve n ge a r wi t h al l
t e e t h in g o o d c o n d i t i o n a n d p r e s e n c e of r e t a i n e r
c l i p.
Are dri ven gear t e e t h O K and is cl i p pr esent ?
Ye s
No

GO t o F3.
REPLACE wi t h pr o pe r
ge a r a n d / o r c l i p. REFER
t o Se c t i o n 07 - 01.
RETEST s y s t e m.
F3 CHECK DRI VE GEAR
Ve r i f y pr e s e n c e of dr i ve ge a r on o ut put sha f t .
Is dri ve gear pr esent ?
Ye s
No

GO t o F4.
SERVI CE t r a n s mi s s i o n a s
F4 CHECK CI RCUI T 67 9 ( G Y/ BK)
Re mo v e i nst r ume nt c l ust e r a s o ut l i n e d .
Usi ng an o hmme t e r c o n n e c t e d t o a kn o wn g o o d
gr o un d , c o n n e c t s e c o n d l e a d t o Ci r c ui t 67 9
( G Y/ BK) pe r c ha r t .
R O W N V I C T O R I A
Ye s
No
C o n n e c t o r
P i n C i r c u i t C i r c u i t F u n c t i o n
C 1 4 6 4 0 ( R / Y ) P o we r I nput
C1 12 359 ( G Y/ R ) Ve hi c l e S p e e d I nput (B-)
C2 14 67 9
( G Y/ B K )
Ve h i c l e S p e e d I nput ( B + )
G R A N D M A R Q U I S
C o n n e c t o r
P i n C i r c u i t C i r c u i t F u n c t i o n
C2 10 67 9
( G Y/ B K )
Ve h i c l e S p e e d I nput ( B+ )
C2 11 359 ( G Y/ R ) Ve hi c l e S p e e d I nput ( B- )
C2 12 6 4 0 ( R / Y ) P o we r I nput
( G Y/ BK) f o r sho r t .
RETEST s y s t e m.
Le a v e o hmme t e r
c o n n e c t e d t o Ci r c ui t 67 9
( G Y/ BK) . GO t o F 5 .
F5 CHECK CI RCUI T 67 9 ( G Y/ BK) FOR OPEN
Usi ng a j umpe r wi r e c o n n e c t e d t o a kn o wn g o o d
gr o un d , c o n n e c t o t he r e n d t o Ci r c ui t 67 9 (GY / BK) at
v e hi c l e s p e e d se n so r c o n n e c t o r .
Ye s
No

GO t o F6.
(GY / BK) f o r o pe n c i r c ui t .
RETEST s y s t e m.
PINPOINT TEST F: SPEEDOMETER/ODOMETER READS INACCURATELY (Cont i nued)
F6 CHECK CI RCUI T 359 (GY / R)
G O t o F 7 .
( G Y/ R) f o r o pe n c i r c ui t .
RETEST s y s t e m.
Di sc o n n e c t o hmme t e r f r o m Ci r c ui t 67 9 ( G Y/ BK) ,
c o n n e c t o hmme t e r t o Ci r c ui t 359 ( G Y/ R) pe r c ha r t .
CROWN VICTORIA
Ye s
No
G O t o F 7 .
RETEST s y s t e m.
Conn: Pin Ci rcui t Func t i on
Ye s
No
G O t o F 7 .
RETEST s y s t e m.
C1 4 640 ( R/ Y) P o we r I nput
Ye s
No
G O t o F 7 .
RETEST s y s t e m.
C1 12 359
(GY/R)
Ve h i c l e S p e e d I n put (-)
Ye s
No
G O t o F 7 .
RETEST s y s t e m.
C2 14 67 9
(GY/ BK)
Ye s
No
G O t o F 7 .
RETEST s y s t e m.
GRAND MARQUIS
Ye s
No
G O t o F 7 .
RETEST s y s t e m.
Conn: Pin Ci rcui t Func t i on
Ye s
No
G O t o F 7 .
RETEST s y s t e m.
C2 10 67 9
(GY/ BK)
Ye s
No
G O t o F 7 .
RETEST s y s t e m.
C2 11 359
(GY/R)
Ye s
No
G O t o F 7 .
RETEST s y s t e m.
C2 12 640 ( R/ Y) P o we r I nput
Ye s
No
G O t o F 7 .
RETEST s y s t e m.
Ye s
No
G O t o F 7 .
RETEST s y s t e m.
F7 CHECK SPEEDOMETER
G O t o F8.
REPLACE s pe e d o me t e r .
RETEST s y s t e m.
Usi n g o hmme t e r , c h e c k s p e e d o me t e r f o r c o n t i n ui t y
at c o n t a c t c l i ps.
Is t her e cont i nui t y at all cl i ps?
Ye s
No
G O t o F8.
RETEST s y s t e m.
F8 CHECK PRI NTED CI RCUI T
RETEST s y s t e m.
RETEST s y s t e m.
Usi n g an o hmme t e r c h e c k f o r c o n t i n ui t y f r o m
s p e e d o me t e r c o n t a c t c l i ps t o c l ust e r c o n n e c t o r s
pe r c ha r t .
CROWN VICTORIA
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
Conn: Pin Ci r cui t Func t i on
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
C1 4 640 ( R/ Y) P o we r I nput
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
C1 12 359
(GY/R)
Ve h i c l e S p e e d I n put (-)
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
C2 14 67 9
(GY/ BK)
Ve h i c l e S p e e d I n put ( + )
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
GRAND MARQUIS
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
Conn: Pi n Ci r cui t Func t i on
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
C2 10 67 9
(GY/ BK)
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
C2 11 359
(GY/R)
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
C2 12 640 ( R/ Y) P o we r I nput
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
Is t her e cont i nui t y at all c i r c ui t s?
Ye s
No
RETEST s y s t e m.
RETEST s y s t e m.
PINPOINT TEST G: BRAKE WARNING NEVER/ALWAYS ON
TE ST STE P RESULT A CT I ON TO T A KE
G1 CHECK IC FOR WARNI NG
Ye s
No
G O t o G S .
G O t o G 2 .
NOTE: Make sure brake fluid is at specified level.
Che c k wa r n i n gs t o d e t e r mi n e if t he wa r n i n g i s
a l wa y s on or ne ve r o n .
Is war ni ng al ways on?
Ye s
No
G O t o G S .
G O t o G 2 .
G2 CHECK BRAKE FLUI D LEVEL SWI TCH VOLTAGE
SUPPLY
Ye s
No
G O t o G3.
GO t o G4.
Turn i gn i t i o n s wi t c h t o OFF.
Di sc o n n e c t c o n n e c t o r a t br a ke f l ui d l e ve l s wi t c h .
Co n n e c t a j umpe r wi r e f r o m Ci r c ui t 97 7 ( P / W) a t t he
br a ke f l ui d l e v e l s wi t c h c o n n e c t o r t o gr o un d .
Is brake wa r ni ng l amp i l l umi nat ed?
Ye s
No
G O t o G3.
GO t o G4.
G3 CHECK FOR OPEN CI RCUI T
Ye s
No
REPLACE b r a ke f l ui d
l e ve l s wi t c h . RESTORE
97 7 ( P / W) , 57 ( BK) or
512 ( T / L B) . RESTORE
Usi ng a mul t i me t e r , c h e c k c o n t i n ui t y in Ci r c ui t 57
( BK) f r o m b r a ke f l ui d l e ve l s wi t c h t o gr o un d a n d
Ci r cui t 97 7 ( P / W) t o i gni t i on s wi t c h a n d Ci r c ui t 512
11 LB) t o pa r ki n g b r a ke .
Ye s
No
REPLACE b r a ke f l ui d
97 7 ( P / W) , 57 ( BK) or
512 ( T / L B) . RESTORE
G4 CHECK FOR OPEN CI RCUI T/ OPEN BUL B
Ye s
No
CHECK v o l t a ge at 18-pi n
c o n n e c t o r ( C1) Pi n 2 in
RUN. CHECK br a ke
wa r n i n g bul b in I C.
RETEST s y s t e m.
( P / W) f o r o pe n .
RETEST s y s t e m.
Di sc o n n e c t j umpe r wi r e .
Di sc o n n e c t i n st r ume n t c l ust e r .
Usi ng a mul t i me t e r , c h e c k c o n t i n ui t y i n Ci r c ui t 97 7
( P / W) be t we e n 01 c o n n e c t o r Pi n 10 ( Cr o wn
Vi c t o r i a ) , Pi n 9 ( Gr a n d Ma r qui s) a n d b r a ke f l ui d l e ve l
s wi t c h .
Ye s
No
CHECK v o l t a ge at 18-pi n
c o n n e c t o r ( C1) Pi n 2 in
RUN. CHECK br a ke
wa r n i n g bul b in I C.
RETEST s y s t e m.
( P / W) f o r o pe n .
RETEST s y s t e m.
G5 CHECK HARNESS FOR SHORT CI RCUI T
Ye s
No
CHECK Ci r c ui t 97 7 ( P / W)
f or s h o r t s . RESTORE
GO t o G6.
Put t r a n smi ssi o n in PARK.
Re l e a se pa r ki n g b r a ke .
Di sc o n n e c t c o n n e c t o r a t t he br a ke f l ui d l e ve l s wi t c h .
Is brake war ni ng l amp i l l umi nat ed?
Ye s
No
CHECK Ci r c ui t 97 7 ( P / W)
f or s h o r t s . RESTORE
GO t o G6.
G6 CHECK BRAKE FLUI D LEVEL SWI TCH GROUND
Ye s
No
REPLACE br a ke f l ui d
f o r s h o r t s or d a ma ge d
s wi t c h e s . RESTORE
Ma ke sur e t ha t :
Pa r ki n g b r a ke i s OFF, DRL mo d ul e i s g o o d , i gn i t i o n
s wi t c h i s in OFF, b r a ke f l ui d l e ve l i s pr o pe r .
Usi ng a mul t i me t e r , c h e c k f o r gr o un d o n Ci r c ui t 57
( BK) in f l ui d l e ve l s wi t c h c o n n e c t o r .
Is t here an open c i r c ui t ?
Ye s
No
REPLACE br a ke f l ui d
f o r s h o r t s or d a ma ge d
s wi t c h e s . RESTORE
PI NPOI NT TEST H: LOW OIL PRESSURE WARNI NG NE VE R/ A L WA YS ON
TEST STE P RESULT t > A CT I ON TO TAKE
H1 CHECK WARNI NG L A MP I LLUMI NATI ON
Ye s
No
GO t o H4.
GO t o H2 .
Che c k i nst r ume nt c l u s t e r l o w oi l pr e s s u r e i n d i c a t o r
t o d e t e r mi n e if i n d i c a t o r l a mp i s a l wa y s o n or n e ve r
on.
Is l ow oi l pressure i ndi c a t or al ways o n ?
Ye s
No
GO t o H4.
GO t o H2 .
PINPOINT T E ST H: LOW OIL PRESSURE WARNING NEVER/ALWAYS ON (Continued)
T E ST STEP RESULT A CT I ON TO TAKE
H2 CHECK L OW OI L PRESSURE I NDI CATOR LAMP BULB
Ye s B>
No ii>
GO t o H3.
REPLACE d a ma ge d
mi ni a t ur e bul b. RESTORE
Re mo v e mi ni a t ur e bul b.
Using an ohmmeter, check continuity of mi ni a t ur e
bul b.
Ye s B>
No ii>
GO t o H3.
REPLACE d a ma ge d
H3 CHECK SENSOR RESI STANCE FOR OPEN CI RCUI T
Ye s
No
RETEST s y s t e m.
REPLACE l o w oi l
pr e ssur e se n so r .
RETEST s y s t e m.
Ch e c k l ow oi l pr e ssur e se n so r r e s i s t a n c e be t we e n
t he t wo se n so r t e r mi n a l s.
Is resi st ance great er t han 100 K ohms?
Ye s
No
RETEST s y s t e m.
REPLACE l o w oi l
RETEST s y s t e m.
H4 CHECK CI RCUI T 31 ( W/ R ) FOR SHORT CI RCUI T
Ye s
No
REPLACE s h o r t e d l o w oi l
RETEST s y s t e m.
( W/ R) f o r s h o r t e d c i r c ui t .
RETEST s y s t e m.
Di sc o n n e c t t h e wi r i n g ha r n e ss c o n n e c t o r f r o m t h e
i nst r ume nt c l ust e r a n d l o w oi l pr e ssur e se n so r .
Usi ng a nd o hmme t e r , c o n n e c t o n e t e s t l e a d t o
Ci r c ui t 31 ( W/ R) Pi n 8 at t he IC c o n n e c t o r , a n d t h e
o t he r l e a d t o a kn o wn go o d gr o un d .
Is resi st ance 0 K ohms?
Ye s
No
REPLACE s h o r t e d l o w oi l
RETEST s y s t e m.
( W/ R) f o r s h o r t e d c i r c ui t .
RETEST s y s t e m.
PINPOINT TEST J: LH TURN INDICATOR NEVER/ALWAYS ON
J 1 CHECK I NDI CATOR L AMP
Ch e c k i nst r ume nt c l ust e r LH t ur n i n d i c a t o r t o
d e t e r mi n e if i n d i c a t o r l a mp i s a l wa y s on or never o n .
I s LH t urn i ndi cat or al ways on?
Ye s
No

GO t o J7.
GO t o J 2 .
J2 CHECK MULTI -FUNCTI ON SWI TCH OUTPUT
Gai n a c c e s s t o mul t i - f un c t i o n s wi t c h c o n n e c t o r .
Turn i gni t i on s wi t c h t o RUN po si t i o n .
Ac t u a t e mul t i - f un c t i o n s wi t c h in l ef t t ur n po si t i o n .
Co n n e c t one e n d of a t e s t l a mp t o a kn o wn go o d
gr o un d , c o n n e c t o t he r e n d t o s u s pe c t l a mp c i r c ui t
pe r c ha r t :
Ye s
No

Le a v e s wi t c h a c t u a t e d .
GO t o J3.
REPLACE d a ma ge d
RETEST s y s t e m.
C1- 8 3 ( L G / W) L e f t Fr o n t Turn Si gn a l
C1- 10 9 ( L G / 0 ) L e f t Re a r Tur n Si gn a l
J3 CHECK SUSPECT L A MP SUPPLY
Gai n a c c e s s t o s u s p e c t l a mp c o n n e c t o r a s o ut l i n e d .
Di sc o n n e c t s u s p e c t l a mp.
Usi ng a t e s t l a mp c o n n e c t e d t o a kn o wn go o d
gr o un d , c o n n e c t o t he r e n d t o t he s u s p e c t c i r c ui t pe r
c ha r t .
Ye s
No

GO t o J4.
GO t o J6.
C1- 8 3 ( L G / W) L e f t Fr o n t Turn Si gn a l
13- 01B- 34 I n s t r u me n t Cl ust erConvent i onal 13- 01B- 34
PINPOINT TEST J: LH TURN INDICATOR NEVER/ALWAYS ON (Conti nued)
TEST STEP RESULT A C T I O N TO TAKE
J4 C H E C K S U S P E C T LAMP GROUND
Usi n g an o hmme t e r c o n n e c t e d t o a kn o wn go o d
gr o un d , c o n n e c t se c o n d l ead t o Ci r cui t 57 ( BK) at
s u s p e c t l a mp c o n n e c t o r .
Is r esi st ance 5 ohms or less?
Ye s
No
>

GO t o J5.
RETEST s y s t e m.
J5 CHECK SUSPECT BULB
Usi n g an o hmme t e r c h e c k c ont i nui t y of s u s p e c t
bul b.
Ye s
No

SERVI CE d a ma g e d l a mp
s o c ke t . RESTORE
RETEST s y s t e m.
J6 CHECK SUSPECT LAMP CIRCUIT
Turn i gn i t i o n s wi t c h t o OFF po si t i o n .
Di s c o n n e c t t he mul t i -f unc t i on s wi t c h .
Usi n g an o hmme t e r c o n n e c t e d t o a kn o wn g o o d
gr o un d , c o n n e c t s e c o n d l e a d t o suspe c t c i r c ui t pe r
c h a r t .
Me a s u r e r e s i s t a n c e .
Ye s
No
Pi n Number Ci r cui t Ci rcui t Func t i on
C1- 8 3 ( L G / W) Le f t Fr o n t Turn Si gn a l
SERVI CE s u s p e c t c i r c ui t
f or sho r t t o gr o un d .
RETEST s y s t e m.
SERVI CE s u s p e c t c i r c ui t
RETEST s y s t e m.
Is r esi st ance 5 ohms or less?
J7 CHECK MULTI -FUNCTI ON SWI TCH
Re f e r t o Se c t i o n 11-05 a nd r e mo ve mul t i - f un c t i o n
s wi t c h a s o ut l i n e d .
Te st mul t i - f un c t i o n s wi t c h per c o mpo n e n t t e st . Re f e r
t o Se c t i o n 11-05.
Di d mul t i -f unct i on swi t ch t est OK?
Ye s
No

GO t o J8.
REPLACE mul t i - f un c t i o n
J8 CHECK I NDI CATOR FLASHER
Re c o n n e c t mul t i - f un c t i o n s wi t c h .
Ga i n a c c e s s t o t he i n d i c a t o r f l a she r a s o ut l i n e d .
Re f e r t o Se c t i o n 17 - 01.
Di s c o n n e c t i n d i c a t o r f l a she r .
Di d l amps t ur n of f ?
Ye s
No
REPLACE d a ma ge d
RETEST s y s t e m.
SERVI CE Ci r c ui t 44 ( L B)
f or sho r t t o B + v o l t a ge .
RETEST s y s t e m.
PINPOINT TEST K: RH TURN INDICATOR NEVER/ALWAYS ON
K1 CHECK I NDI CATOR L AMP
Ye s
No
GO t o K7.
GO t o K2.
Ch e c k i n st r ume n t c l ust e r RH t ur n i n d i c a t o r t o
d e t e r mi n e if i n d i c a t o r l a mp i s a l wa y s on or never o n .
Is RH t ur n i ndi cat or al ways on?
Ye s
No
GO t o K7.
GO t o K2.
~ . f i w i M" ~
B
* Co n v e n t i o n a l 13- 01B- 35
PINPOINT TEST K: RH TURN INDICATOR NEVER/ALWAYS ON (Cont i nued)
K2 CHECK MULTI-FUNCTION SWITCH OUTPUT
Yes
No
Leave swi tch act uat ed.
GOt o K3.
REPLACE damaged
RESTORE vehicle.
RETEST system.
Gain access t o multi-function swi tch connector.
Turn ignition swi tch t o RUN position.
Actuate multi-function swi tch in right turn posi ti on.
Connect one end of a t est lamp to a known good
ground, connect other end to suspect lamp circuit
per chart:
Yes
No
GOt o K3.
REPLACE damaged
RESTORE vehicle.
RETEST system.
Pin Number Circuit Circuit Function
Yes
No
GOt o K3.
REPLACE damaged
RESTORE vehicle.
RETEST system.
C1- 5 2 ( W/ L B ) Right Fr o n t Tur n Signal
Yes
No
GOt o K3.
REPLACE damaged
RESTORE vehicle.
RETEST system.
C1- 2 5 ( O/ LB) Right Re a r Tur n Signal
Yes
No
GOt o K3.
REPLACE damaged
RESTORE vehicle.
RETEST system.
Yes
No
GOt o K3.
REPLACE damaged
RESTORE vehicle.
RETEST system.
K3 CHECK SUSPECT LAMP SUPPLY
Yes
No
GO to K4.
GO to K6.
Gain access to suspect lamp connector as outlined.
Disconnect suspect lamp.
ground, connect other end to the suspect circuit per
chart.
Yes
No
GO to K4.
GO to K6.
Yes
No
GO to K4.
GO to K6.
C1-5 2 ( W/ L B ) Right Fr o n t Tur n Signal
Yes
No
GO to K4.
GO to K6.
C1-2 5 ( O/ LB) Right Re a r Turn Signal
Yes
No
GO to K4.
GO to K6.
Yes
No
GO to K4.
GO to K6.
K4 CHECK SUSPECT LAMP GROUND
Yes
No
GO to K5.
for open circuit.
RESTORE vehicle.
RETEST system.
suspect lamp connector.
Yes
No
GO to K5.
for open circuit.
RESTORE vehicle.
RETEST system.
K5 CHECK SUSPECT BULB
Yes
No
SERVICE damaged lamp
socket. RESTORE
REPLACE damaged bulb.
RESTORE vehicle.
RETEST system.
Using an ohmmeter check continuity of suspect
bulb.
Yes
No
SERVICE damaged lamp
socket. RESTORE
REPLACE damaged bulb.
RESTORE vehicle.
RETEST system.
K6 CHECK SUSPECT LAMP CIRCUIT
Yes
No
RESTORE vehicle.
RETEST system.
for open circuit.
RESTORE vehicle.
RETEST system.
Disconnect the multi-function swi t ch.
ground, connect second lead to suspect circuit per
chart.
Yes
No
RESTORE vehicle.
RETEST system.
for open circuit.
RESTORE vehicle.
RETEST system.
Yes
No
RESTORE vehicle.
RETEST system.
for open circuit.
RESTORE vehicle.
RETEST system.
C1- 5 2 ( W/ L B ) Right Fr o n t Tur n Signal
Yes
No
RESTORE vehicle.
RETEST system.
for open circuit.
RESTORE vehicle.
RETEST system.
C1- 9 5 ( O/ LB) Right Re a r Tur n Signal
Yes
No
RESTORE vehicle.
RETEST system.
for open circuit.
RESTORE vehicle.
RETEST system.
Yes
No
RESTORE vehicle.
RETEST system.
for open circuit.
RESTORE vehicle.
RETEST system.
K7 CHECK MULTI-FUNCTION SWITCH
Yes
No
GO to K8.
swi t ch. RESTORE
Remove multi-function swi t ch. Refer to Section
11-05.
Test multi-function swi tch per component t est . Refer
to Section 11-05.
Di d mul t i -f unct i on swi t c h t e st OK?
Yes
No
GO to K8.
swi t ch. RESTORE
13- 01B- 36_
I n s t r u me n t C l u s t e r C o n v e n t i o n a l 13-01B-36
PI NPOI NT TE ST K: RH TURN I NDI CATOR NE VE R/ A L WA YS ON ( Co n t i n u e d )
KB CHECK I NDI CATOR FLASHER
Ye s
No
REPLACE d a ma ge d
RETEST s y s t e m.
SERVI CE Ci r c ui t 44 ( LB)
f or s ho r t t o B+ v o l t a ge .
RETEST s y s t e m.
Re c o n n e c t mul t i - f un c t i o n s wi t c h .
Gai n a c c e s s t o t he i n d i c a t o r f l a she r . Re f e r t o
Se c t i o n 17 - 01.
Di sc o n n e c t i n d i c a t o r f l a she r .
Di d l a m p s t u r n o f f ?
Ye s
No
REPLACE d a ma ge d
RETEST s y s t e m.
SERVI CE Ci r c ui t 44 ( LB)
f or s ho r t t o B+ v o l t a ge .
RETEST s y s t e m.
PI NPOI NT TE ST L: HI GH BE A M WARNI NG NE VE R/ A L WA YS ON
L 1 CHECK HIGH BE AM I NDI CATOR L AMP
Ch e c k i n st r ume n t c l ust e r hi gh be a m i n d i c a t o r t o
d e t e r mi n e if i n d i c a t o r l a mp i s a l wa y s on or ne ve r o n .
I s h i g h b e a m i n d i c a t o r a l w a y s o n ?
Ye s
No

GO t o L 8.
GO t o L 2 .
L 2 CHECK HIGH BEAM I NDI CATOR BUL B
Re mo v e hi gh be a m i n d i c a t o r l a mp at i nst r ume nt
c l ust e r . Ca r e f ul l y i n spe c t t he mi ni a t ur e bul b.
I s m i n i a t u r e bulb b u r n e d o u t o r d a m a g e d ?
Ye s
No
REPLACE i n d i c a t o r l amp
GO t o L 3 .
L 3 CHECK CI RCUI T 9 3 2 (GY / W) FOR VOLTAGE
Re i n st a l l hi gh be a m i n d i c a t o r l a mp.
Turn i gni t i on s wi t c h t o RUN, a c t ua t e he a d l a mps t o
hi gh b e a m.
Usi n g a t e st l a mp c h e c k f o r v o l t a ge at Pi n 1 Ci r c ui t
9 3 2 ( G Y/ W) of DRL mo d ul e c o n n e c t o r .
Di d t e s t l a m p i l l u m i n a t e ?
Ye s
No
( G Y/ W) for o pe n c i r c ui t .
RETEST s y s t e m.
GO to L 4.
L 4
L 5
CHECK DRL CONTROL MODULE
Usi n g a j umpe r wi r e , c o n n e c t one e n d t o Pi n 8 Ci r c ui t
1 2 (LG / BK) , c o n n e c t o t he r e nd t o Pi n 1 Ci r c ui t 9 3 2
( G Y/ W) of DRL mo d ul e c o n n e c t o r .
Di d h i g h b e a m i n d i c a t o r i l l u m i n a t e ?
Ye s
No
CHECK CI RCUI T 1 2 ( L G / B L ) CONTI NUI TY
Di sc o n n e c t t he DRL c o n t r o l mo d ul e wi r e ha r n e ss
c o n n e c t o r .
Di sc o n n e c t t he mul t i - f un c t i o n s wi t c h 7-pi n
c o n n e c t o r .
Usi ng an o hmme t e r , c h e c k c o n t i n ui t y of Ci r c ui t 12
( L G / BK) f r o m DRL c o n n e c t o r Pi n 8 t o mul t i - f un c t i o n
s wi t c h c o n n e c t o r Pi n F.
D o e s C i r c u i t 12 ( L G / B K ) h a v e c o n t i n u i t y ?
Ye s
No
REPLACE DRL c o n t r o l
mo d ul e . RESTORE
G Ot o L 5.
G Ot o L 6.
( LG/ BK) f or o pe n c i r c ui t .
L 6 CHECK MULTI -FUNCTI ON SWI TCH VOLTAGE SUPPLY
I NPUT
Gai n a c c e s s t o mul t i - f un c t i o n s wi t c h c o n n e c t o r .
Ac t ua t e mul t i - f un c t i o n s wi t c h in hi gh be a m po si t i o n .
Co n n e c t one e nd of a t e s t l a mp t o a kn o wn go o d
gr o un d , c o n n e c t o t he r e nd t o s u s p e c t l amp c i r c ui t
per c ha r t :
Yes
No
Pi n Number Ci rcui t Ci r cui t Funct i on
C2- 7 221 ( O/ W) Power Feed
Le a v e s wi t c h a c t u a t e d .
G Ot o L 7 .
( R/ Y) a n d / o r he a d l a mp
swi t c h f or an o pe n c i r c ui t .
REFER t o Se c t i o n 1 7 - 0 1
for l i ght i ng d i a gn o si s.
RETEST s y s t e m.
Di d t e s t l a m p i l l u m i n a t e ?
13- 01B- 37 Inst rument Cl us t er Conv ent i onal 13- 01B- 37
PINPOINT TEST L: H I G H B E A M W A R N I N G N E VE R / AL WAYS ON (Cont i nued)
L7 CHECK MULTI-FUNCTION SWITCH OUTPUT
Gain access to multi-function switch connector.
Turn ignition switch to RUN position.
Actuate multi-function switch in high beam position.
Connect one end of a test lamp to a known good
ground, connect other end to suspect lamp circuit
per chart:
Yes
No
P i n N u m b e r C i r c u i t C i r c u i t F u n c t i o n
C2 - 5 12 ( L G / B K ) Hi Be a m
System OK. CHECK and
SERVICE connectors and
pins for intermittent
conditions. RESTORE
REPLACE damaged
multi-function switch.
RESTORE vehicle.
RETEST system.
Did test lamp illuminate?
L8 CHECK CIRCUIT 1 2 (LG/ BK) FOR SHORT CIRCUIT
Using an ohmmeter, connect one test lead to a
known good ground, and the remaining test lead to
Pin 8 at the DRL control module.
Yes
No
GO to L9.
SERVICE Circuit 12
(LG/BK) for short to
ground. RESTORE
L9 CHECK DRL CONTROL MODULE FOR SHORT CIRCUIT
ground, check voltage output at Pin 1, Circuit 9 32
(GY/W).
Did the t est lamp illuminate?
Yes
No
REPLACE shorted DRL
control module. REFER to
Section 17-04. RESTORE
for daytime running lamps
diagnosis.
PINPOINT TEST M: HEATED BACK WINDOW INDICATOR NEVER/ALWAYS ON
Mi CHECK INDICATOR STATUS
Yes
No
REPLACE heated back
window switch. RESTORE
GO t oM2.
Determine if the heated back window indicator lamp
is never on or always on.
Is indicator lamp al ways on?
Yes
No
REPLACE heated back
GO t oM2.
M2 CHECK POWER SUPPLY
Yes
No
GO to M3.
REPLACE blown fuse(s).
RESTORE vehicle.
RETEST system.
ground, check for voltage on the output side of:
F17 (15A) fuse in the fuse junction panel.
DEF fuse (40A) fuse in the power distribution
box.
Does the t est lamp illuminate at both f use s?
Yes
No
GO to M3.
REPLACE blown fuse(s).
RESTORE vehicle.
RETEST system.
M3 CHECK POWER SUPPLY FOR OPEN CIRCUIT
Yes
No
GOto M4.
SERVICE affected circuit
for open circuit.
RESTORE vehicle.
RETEST system.
Using an ohmmeter, check the resistance of power
Circuits 29 8 (P/ O) and 175 (BK/ Y).
Yes
No
GOto M4.
SERVICE affected circuit
for open circuit.
RESTORE vehicle.
RETEST system.
M4 CHECK GROUND CIRCUIT
Yes
No
REPLACE heated back
SERVICE ground Circuit
57 (BK) for open circuit.
RESTORE vehicle.
RETEST system.
ground, check the resistance of Circuit 57 (BK), Pin
4 of the heated back window switch.
Is resi stance 5 K ohms or less?
Yes
No
REPLACE heated back
SERVICE ground Circuit
57 (BK) for open circuit.
RESTORE vehicle.
RETEST system.
13- 01B- 38
Instrument ClusterConventional
13- 01B- 38

PINPOINT TEST N: SAFETY BELT WARNING NEVER/ALWAYS ON
N i CHECK SAFETY BELT SWI TCH I NPUT
Ye s
No
GO t o N4.
GO t o N 2 .
Di sc o n n e c t b a t t e r y n e ga t i v e c a bl e .
Di sc o n n e c t l i ght i n g c o n t r o l mo d ul e c o n n e c t o r C2.
Me a sur e r e s i s t a n c e b e t we e n Pi n C2- 17 , Ci r c ui t 85
( BR/ L B) a n d a kn o wn go o d gr o un d wi t h s a f e t y be l t
not i n st a l l e d i nt o be l t c o n n e c t o r .
Ye s
No
GO t o N4.
GO t o N 2 .
N2 CHECK SAFETY BELT SWI TCH
Ye s
No
GO t o N3.
REPLACE s a f e t y bel t
wa r n i n g s wi t c h . GO t o N3
t o c h e c k c i r c ui t .
A c c e s s a n d d i s c o n n e c t s a f e t y be l t s wi t c h .
Me a sur e r e s i s t a n c e b e t we e n s wi t c h t e r mi n a l s wi t h
sa f e t y be l t not i n st a l l e d i nt o be l t c o n n e c t o r .
Ye s
No
GO t o N3.
REPLACE s a f e t y bel t
wa r n i n g s wi t c h . GO t o N3
t o c h e c k c i r c ui t .
N3 CHECK SAFETY BELT WARNI NG SWI TCH GROUND
Ye s
No
SERVI CE o pe n Ci r c ui t 85
( BR/ L B) b e t we e n s a f e t y
be l t wa r n i n g s wi t c h a n d
( BK) . RESTORE v e hi c l e .
RETEST s y s t e m.
Me a sur e Ci r c ui t 57 ( BK) , r e s i s t a n c e t o gr o un d
be t we e n t he s a f e t y be l t wa r n i n g s wi t c h a n d a kn o wn
go o d gr o un d .
Ye s
No
( BR/ L B) b e t we e n s a f e t y
be l t wa r n i n g s wi t c h a n d
( BK) . RESTORE v e hi c l e .
RETEST s y s t e m.
N4 CHECK LI GHTI NG CONTROL MODULE POWER I NPUTS
Ye s
No
GO t o N5.
SERVI CE o pe n c i r c ui t or
o pe n suppl y f us e . GO t o
N5 t o c h e c k gr o un d s.
Di sc o n n e c t al l l i ght i n g c o n t r o l mo d ul e c o n n e c t o r s .
Re c o n n e c t t he ba t t e r y n e ga t i v e c a bl e .
Me a sur e v o l t a ge b e t we e n t h e f o l l o wi n g c o n n e c t o r
pi ns a nd a kn o wn go o d gr o un d :
C1- 1 Ci r c ui t 2 96 ( W/ P )
C1- 9 Ci r c ui t 640 ( R/ Y)
C3- 6 Ci r c ui t 195 ( T / W)
C3- 16 Ci r c ui t 2 2 1 ( O / W)
C4- 2 Ci r c ui t 196 ( DB/ O)
Is bat t ery vol t age pr esent ?
Ye s
No
GO t o N5.
SERVI CE o pe n c i r c ui t or
o pe n suppl y f us e . GO t o
N5 t o c h e c k gr o un d s.
N5 CHECK LI GHTI NG CONTROL MODULE GROUND
CI RCUI TS
Ye s
v
No t >
GO t o N6.
SERVI CE o pe n gr o un d
c i r c ui t ( s ) . RESTORE
Me a sur e t h e r e s i s t a n c e b e t we e n t he f o l l o wi n g
c o n n e c t o r pi ns a n d a kn o wn go o d gr o un d :
C3- 4 Ci r c ui t 57 ( BK)
C3- 9 Ci r c ui t 57 ( BK)
Ye s
v
No t >
GO t o N6.
c i r c ui t ( s ) . RESTORE
N6 CHECK SAFETY BELT WARNI NG I NDI CATOR
Ye s
No
GO t o N 7 .
mo d ul e . RESTORE
Me a sur e r e s i s t a n c e b e t we e n Pi n C3- 8, Ci r c ui t 450
( BK/ L G ) a n d a kn o wn go o d gr o un d .
Is ci rcui t open (i nf i ni t e resi st ance) t o gr ound?
Ye s
No
GO t o N 7 .
mo d ul e . RESTORE
N7 CHECK I NDI CATOR BULB
Ye s
No
GO t o N8.
REPLACE i n d i c a t o r bul b.
RETEST s y s t e m.
A c c e s s a nd r e mo v e i n d i c a t o r bul b.
Ch e c k c o n t i n ui t y of bul b f i l i me n t .
Is bulb OK?
Ye s
No
GO t o N8.
REPLACE i n d i c a t o r bul b.
RETEST s y s t e m.
N8 CHECK CI RCUI T 450
Ye s
No
GO t o N9.
450 ( DG / L G ) / ( B K / L G )
be t we e n l i ght i n g c o n t r o l
mo d ul e a n d c l ust e r .
Me a sur e r e s i s t a n c e b e t we e n Pi n C3- 8 of l i ght i n g
c o n t r o l mo d ul e a n d Pi n C1- 8 of i nst r ume nt c l ust e r .
Ye s
No
GO t o N9.
450 ( DG / L G ) / ( B K / L G )
be t we e n l i ght i n g c o n t r o l
mo d ul e a n d c l ust e r .
13- 01B- 39 I n s t r u me n t Cl u s t e r
Co n v e n t i o n a l 13- 01B- 39
PINPOINT TE ST N: SAFETY BELT WARNING NEVER/ALWAYS ON (Cont i nued)
N9 CHECK I NDI CATOR GROUND
Ye s
No
SERVI CE o pe n f l e x c i r c ui t
of i nst r ume nt c l ust e r .
RETEST s y s t e m.
c i r c ui t ( s) . RESTORE
Measure resistance Circuit 679 (GY / BK) to a known
good ground, Pins C1-2, C1- 9, C2-4, C2-6 and C2-16
Ye s
No
SERVI CE o pe n f l e x c i r c ui t
RETEST s y s t e m.
c i r c ui t ( s) . RESTORE
PINPOINT TEST P: DOOR AJAR WARNING NEVER/ALWAYS COMES ON
P1 CHECK IC FOR WARNI NG
Ye s
No
G O t o P2.
G O t o P4.
Ch e c k IC t o d e t e r mi n e if t he wa r n i n g i s a l wa y s on or
ne ve r o n .
Is war ni ng al ways on?
Ye s
No
G O t o P2.
G O t o P4.
P2 CHECK DOOR AJAR WARNI NG LAMP SWI TCHES
Ye s
No
G O t o P3.
SERVI CE t he l a st d o o r
o pe n wa r n i n g l a mp s wi t c h
t e s t e d . RESTORE
The f o l l o wi n g s t e p s a r e t o be r e p e a t e d f o r e a c h
d o o r o pe n wa r n i n g l a mp s wi t c h . St a r t wi t h t he
d r i v e r ' s d o o r , t he n f r o n t pa sse n ge r , t he n r e a r
p a s s e n ge r s .
Pul l c o n n e c t o r of f of t h e d o o r o pe n wa r n i n g l a mp
s wi t c h .
Re pe a t unt i l no wa r n i n g i s d i s p l a y e d or al l d o o r o pe n
wa r n i n g l a mp s wi t c h e s a r e d i s c o n n e c t e d .
Is wa r ni ng st i l l di spl ayed?
Ye s
No
G O t o P3.
SERVI CE t he l a st d o o r
o pe n wa r n i n g l a mp s wi t c h
t e s t e d . RESTORE
P3 CHECK CONTI NUI TY OF CI RCUI T 62 7 ( B K / O )
Ye s I5>
No
( BK / O) or 867 ( DB) f o r
sho r t c i r c ui t . RESTORE
mo d ul e . RESTORE
Re mo v e l i ght i n g c o n t r o l mo d ul e c o n n e c t o r s .
Ch e c k c o n t i n ui t y b e t we e n Pi ns C1- 11, C2 - 11 a n d a
kn o wn go o d gr o un d .
Ye s I5>
No
( BK / O) or 867 ( DB) f o r
sho r t c i r c ui t . RESTORE
mo d ul e . RESTORE
P4 I SOLATE CAUSE OF DOOR AJAR WARNI NG L AMP
CONCERN
Ye s
No
RETEST s y s t e m.
G O t o PS.
Pul l c o n n e c t o r of f of t h e pr o bl e m d o o r o pe n wa r n i n g
l a mp s wi t c h .
Co n n e c t a j umpe r wi r e f r o m Ci r c ui t 62 7 ( B K / O ) ,
Ci r c ui t 867 ( DB) f o r d r i v e r d o o r at t h e ha r n e s s
c o n n e c t o r t o gr o un d .
Ch e c k c l ust e r f o r wa r n i n g,
o 0s warning di spl ayed?
Ye s
No
RETEST s y s t e m.
G O t o PS.
P5 CHECK CONTROL CI RCUI T CONTI NUI TY
Ye s
No
mo d ul e . RESTORE
( BK / O) Ci r c ui t 867 ( DB)
f o r d r i ve r d o o r f or o pe n
L e a v e j umpe r wi r e c o n n e c t e d a s i n Te st St e p P4.
Re mo v e l i ght i n g c o n t r o l mo d ul e .
Ch e c k c o n t i n ui t y of c i r c ui t wi r i n g f o r Ci r c ui t 62 7
( BK / O), Ci r c ui t 867 ( DB) f o r d r i v e r d o o r t o l i ght i n g
c o n t r o l mo d ul e C1 a n d C2 c o n n e c t o r .
Ye s
No
mo d ul e . RESTORE
( BK / O) Ci r c ui t 867 ( DB)
f o r d r i ve r d o o r f or o pe n
13- 018- 40 I n s t r u me n t C l u s t e r C o n v e n t i o n a l 13- 01B- 40
R E MO V A L AND INSTALLATION
Re mo v a l
1. Di sconnect ba t t e r y ground cable ( 14301) .
2. Remove LH i nst rument panel moul di ng ( 04389)
and RH i nst rument panel mouldi ng ( 04388) .
3. Remove t he si x ret ai ni ng sc r e ws and r emove t he
loweri nst rument panel st eer i ng col umn c ove r
( 04459) ( Cr own Vi ct ori a). Remove t he f i ve
ret ai ni ng sc r e ws and r emove i nst rument panel
st eer i ng col umn cover (Grand Marqui s).
4. Remove sc r e w f ast eni ng t ransmi ssi on range
i ndi cat or col umn br a c ke t t o t he st eeri ng col umn.
De t a c h t he cabl e l oop f r om t he pin and cane shi f t
lever. Remove t he col umn br a c ke t f r om t he
col umn.
5. Remove t he f our cl ust er ret ai ni ng sc r e ws.
6. Di sconnect t he cl ust er c onne c t or s f r om t he
i nst rument cl ust er ba c k pl at e ( 10848) and
r emove t he i nst rument cl ust er ( 10849) .
1. Posi t i on t he i nst rument cl ust er t o t he i nst rument
panel ( 0432 0) , connect i ng t he cl ust er f e e d pl ug,
and ensuri ng t he t ransmi ssi on range cabl e is
r out ed pr oper l y. Install t he f our cl ust er ret ai ni ng
sc r e ws.
2. Posi t i on t he t ransmi ssi on r ange i ndi cat or col umn
br a c ke t t o t he st eeri ng col umn t ube ( 3514)
(l ocat e pi n in col umn sl ot ) and adj ust t he
t ransmi ssi on cont r ol sel ect or i ndi cat or ( 7 A110)
a s f ol l ows:
a. Pl ace t he t ransmi ssi on sel ect or l ever a r m
and suppor t ( 7 302) on t he st eeri ng col umn
t ube in t he 1 posi t i on.
b. Pl ace t he l oop on t he i ndi cat or cabl e
assembl y over t he ret ai ner pi n on t he shi f t
lever.
c. Secur e c a bl e br a c ke t wi t h sc r e w.
d. Shi f t t he t ransmi ssi on sel ect or lever a r m and
suppor t i nt o t he posi t i on. Adj ust t he t humb
wheel on t he st eeri ng col umn t ube so t he
ent i re wi dt h of t he poi nt er f al l s wi t hi n t he
l et t er .
e. When pr oper l y a dj ust e d, t he ent i re wi dt h of
t he poi nt er must fall wi t hi n t he wi dt h of t he
l et t er a n d must t ouc h t he remai ni ng l et t er s
or numeral s when vi e we d paral l el t o t he
cent er line of t he st eer i ng col umn t ube f r om
t he dr i ver ' s posi t i on.
3. Posi t i on t he l ower st eeri ng col umn shr oud ( 3530)
and i nstall t he ret ai ni ng sc r e ws.
4. Connect ba t t e r y ground cabl e cabl e and c he c k
t he oper at i on of t he i nst rument s.
I n s t r u m e n t C l u s t e r P r i n t e d C i r c u i t
Re mo v a l
1. Di sconnect ba t t e r y gr ound c a bl e ( 14301) .
2. Remove i nst rument cl ust er ( 10849) assembl y a s
out l i ned.
3. Remove i llumi nat i on a nd i ndi cat or mi ni at ure bul bs
( 13466) .
4. Remove gauge cl i ps.
5. Remove i nst rument cl ust er pri nt ed ci rcui t
( 10K843) f r om t he i nst rument cl ust er.
1. Pl ace t he pr i nt ed ci rcui t on t he i nst rument cl ust er
and i nstall t he i ndi cat or and t he illumination
mi ni at ure bul bs.
2. Install t he 9-gauge cl i ps (Grand Mar qui s),
14-gauge cl i ps (Cr own Vi ct or i a).
3. Install t he i nst rument cl ust er assembl y a s
out l i ned.
4. Connect ba t t e r y gr ound cabl e.
L o w Fu e l L e v e l Wa r n i n g S w i t c h
1. Remove i nst rument cl ust er ( 10849) a s out l i ned.
2. Gr a sp i nst rument cl ust er pri nt ed ci rcui t ( 10K843)
on out si de f ar e dge s. Avoi d t ouchi ng ci rcui t
component s.
3. Push out c onne c t or t a b and sl i de l ow fuel level
warni ng swi t c h ( 9F32 6) out .
4. To i nst al l , posi t i on l ow f uel level warni ng swi t c h in
gui des, line up t ermi nal s over cent er of i nst rument
cl ust er pri nt ed ci rcui t connect i ons, and push until
l ow f uel level warni ng swi t c h cl i cks in pl ace.
5. Install i nst rument cl ust er as out l i ned.
Fu e l G a u g e
2. CAUTI ON: T h e g a u g e s a r e c a l i b r a t e d a t t h e
f a c t o r y . E x c e s s i v e r o u g h h a n d l i n g c o u l d
d i s t u r b t h e c a l i b r a t i o n . Do n o t r e mo v e
p o i n t e r s .
Remove i nst rument cl ust er ( 10849) a s out l i ned.
3. Remove sc r e ws ret ai ni ng i nst rument cl ust er ba c k
pl at e ( 10848) and r emove i nst rument cl ust er
main lens ( 10887 ) and i nst rument cl ust er ma sk
( 10890) .
4. Remove fuel gauge ( 9305) assembl y.
5. To Install, r ever se Removal pr ocedur e.
13- 01B- 41 I nst r ument Cl ust er '
C o n v e n t i o n a l
13- 01B- 41
Engine Coolant Temperature Gauge
Removal
2. Remove instrument cluster (10849) as outlined.
3. Remove screws retaining instrument cluster main
lens (10887) and instrument cluster mask
(10890) assembly to instrument cluster back
plate (10848) and remove.
4. Pull engine coolant temperature gauge out of
instrument cluster clips.
1. Position gauge terminals to clips on instrument
cluster back plate and press engine coolant
temperature gauge into clips.
2. Position instrument cluster main lens and
instrument cluster mask assembly to instrument
cluster back plate and install retaining screws.
3. Install instrument cluster as outlined.
4. Connect battery ground cable. Check instrument
cluster engine coolant temperature gauge
operation.
Oi l P r e s s u r e G a u g e
Oil pressure gauge is integral with engine coolant
temperature gauge. Refer to Engine Coolant
Temperature Gauge Removal and Installation as
outlined.
B a t t e r y V o l t a g e G a u g e
Battery voltage gauge is integral with fuel gauge
(9305). Refer to Fuel Gauge Removal and Installation
procedures.
S p e e d o m e t e r / O d o m e t e r
CAUTI ON: Dur i n g s e r v i c e , i t i s i mp o r t a n t t o k e e p
t h e s p e e d o me t e r ( 17 2 55) f a c e - u p a s
s p e e d o me t e r f u n c t i o n wi l l b e a f f e c t e d b y s t o r a g e
i n t h e f a c e - d o w n p o s i t i o n .
Fe d e r a l l a w r e q u i r e s t h a t t h e o d o me t e r i n a n y
r e p l a c e me n t s p e e d o me t e r mu s t r e gi s t e r t h e
s a me mi l e a ge a s t h a t r e g i s t e r e d i n t h e r e mo v e d
s p e e d o me t e r .
Re mo v a l
2. Remove the instrument cluster (10849) as
outlined.
3. Remove seven screws retaining the instrument
cluster mask (10890) and instrument cluster main
lens (10887) assembly.
4. Remove speedometer assembly.
1. Position the speedometer assembly to the
instrument cluster back plate (10848) and install.
2. Position the instrument cluster mask and
instrument cluster main lens assembly to the
instrument cluster back plate and install the seven
retaining screws.
3. Install the instrument cluster as outlined.
4. Connect battery ground cable and check the
operation of the speedometer.
T r a n s m i s s i o n R a n g e I n d i c a t o r
Re mo v a l
1. Remove instrument cluster (10849) as outlined.
2. Remove eight screws from instrument cluster
main lens (10887) and instrument cluster mask
(10890).
3. Remove engine coolant temperature gauge and
fuel gauge (9305) from instrument cluster.
4. Remove transmission range indicator from
speedometer (17255) releasing snaps.
5. Remove transmission range indicator.
1. Install the control selector bracket and cable
(7E363) to the speedometer and secure snaps.
2. Install the speedometer assembly into the
instrument cluster.
3. Install engine coolant temperature gauge and fuel
gauge in instrument cluster.
4. Install eight screws retaining instrument cluster
main lens and instrument cluster mask assembly.
5. Position the instrument cluster to the instrument
panel (04304), connecting the cluster feed plug,
and ensuring the transmission range cable is
routed properly. Install the four cluster retaining
screws.
6. Position the transmission range indicator column
bracket to the steering column tube (3514)
(locate pin in column slot) and adjust the
transmission range indicator as follows:
a. Place the transmission selector lever arm
and support (7302) on the steering column
tube in the 1 position.
b. Place the loop on the indicator cable
assembly over the retainer pin on the shift
lever.
c. Secure cable bracket with screw.
d. Shift the transmission selector lever arm and
support into the position. Adjust the thumb
wheel on the steering column tube so the
entire width of the pointer falls within the
letter .
13- 01B- 42 I n s t r u me n t Cl us t er Conv ent i onal
13- 011- 42
When pr oper l y adj ust ed, t he ent i re wi dt h of
t he poi nt er must f al l wi t hi n t he wi dt h of t he
l et t er a n d must t ouc h t he remai ni ng l et t er s
or numeral s when vi e we d paral l el t o t he
cent er line of t he st eer i ng col umn t ube f r o m
t he dr i ver ' s posi t i on.
7. Posi t i on t he l ower st eeri ng c ol umn shr oud ( 3530)
and i nst all t he ret ai ni ng sc r e ws.
8. Connect ba t t e r y gr o un d c a bl e ( 1 4 3 0 1 ) and c he c k
t he oper at i on of t he i nst r ument s.
I n d i c a t o r s / W a r n i n g B u l b s
WARNI NG: I LLUMI NATI ON BULBS ARE
PRESSURI ZED AND MAY SHATTER IF
IMPROPERLY HANDLED. WEAR EYE PROTECTI ON
WHEN SERVI CI NG I LLUMI NATI ON BUL BS.
1 . Di sconnect ba t t e r y gr ound cabl e ( 1 4 3 0 1 ) .
I n st r ume n t Cl ust e r Bul b Re pl a c e me n t L o c a t i o n s
2. Remove i nst rument cl ust er ( 10849) a s out l i ned.
3. Remove i ndi cat or / warni ng bul bs.
4. To i nst al l , r e ve r se Removal pr oc e dur e .
1. Remove f i ve ret ai ni ng sc r e ws f r o m f ront of
i nst rument cl ust er ma sk ( 10890) .
2. Gent l y pry i nst rument cl ust er ma sk f r om '
i nst rument cl ust er ba c k pl at e ( 10848) and
r emove.
3. Remove f our ret ai ni ng sc r e ws f r om i nst rument
cl ust er ( 10849) .
4. Gent l y remove i nst rument cl ust er f r om i nst rument
cl ust er mask.
5. To assembl e, r ever se St eps 1 t hrough 4.
Instrument Cluster Lenses
CAUTI ON: The u s e of v i n y l c l e a n e r s a n d si mi l a r
ot her cl eani ng agent s t o cl ean t he v e h i c l e i n t e r i o r
a n d / o r i ndi cat or l amp l e n s h a s r esul t ed i n
damage t o t he i ndi cat or l amp l ens. The chemi cal
c ont ent of t hese cl eani ng agent s
( O- di chl or obenzene, et hyl al cohol a n d / o r
Cel l osol ve) , has pr oduc ed f oggi ng, s pot t i ng,
st ai n, or spl ot ches of t he l enses, ei t her t hr ough
over - spr ay or di r ect use on t he l enses. Ther ef or e,
e x t r e me caut i on shoul d be t ak en dur i ng i nt er i or
cl eanup t o pr event over - spr ay of cl eani ng agent s
whi c h cont ai n t he chemi cal c ont ent s ment i oned
f r o m c ont ac t i ng t he i ndi cat or l amp l ens.
The i ndi cat or l amp lens shoul d be cl eaned wi t h
Ul t ra-Cl ear Spr a y Gl ass Cl eaner E4AZ- 19C507- AA or
equi val ent commer ci al cl eani ng pr oduc t meet i ng Fo r d
speci f i cat i on ESR-M14P5-A, usi ng a cl ean, sof t ,
l i nt -f ree c l o t h. The For d Gl ass Cl eaner has been
speci al l y f or mul at ed f or cl eani ng wi n d o ws in
aut omot i ve vehi cl es and i s a ppr o ve d f or use in
cl eani ng t he pl ast i c i ndi cat or l amp l ens. Read and
caref ul l y f ol l ow t he di r ect i ons on t he cont ai ner f or best
r esul t s.
SPECIFICATIONS
POWERTRAI N CONTROL/EMI SSI ONS DI AGNOSI S
MA NUA L VE HI CL E AP P L I CATI ONS
OBDI I 3. 8L Mu s t a n g , 4. 6L T o wn Ca r , Cr o wn Vi c t o r i a ,
Co u g a r
TA1000B
SPEEDOMETER CALI BRATI ON TOLERANCE SPECI FI CATI ONS
Ac t ua l
Spe e d o me t e r / Od o me t e r
Value I ndi cat ed
48 k m/ h (30 mph)
Ac t ua l Speed
97 k m / h (60 mph)
Ac t ua l Speed
Odomet er Measures Over
Act ual 16 km (10 mi l es)
Di st ance
A l l o wa b l e Ra n ge 45- 56 k m / h
( 2 8- 35 mp h )
93- 104 k m / h
( 58- 65 mp h )
15. 4- 16. 6 km
( 9. 6- 10. 3 Mi l e s )
I n st r ume n t Cl u s t e r Re t a i n i n g
S c r e w s
0. 8- 1. 4 8- 12
ROTUNDA EQUI PMENT
02 1- 00055 I n st r ume n t Ga u ge S y s t e m T e s t e r
13- 06- 1 Ho r n 13- 06- 1
SECTION 13-06 Horn
SUBJECT PAGE
Horn Mounti ng Locati on . 13-06-1
Horn Swi t ch, Steeri ng Wheel Mount ed 13-06-1
Horn Sy st em . . 13-06-1
SUBJECT PAGE
Horn Assembl y 13-06-6
Horn Rel ay. . . 13-06-6
Horn Swi t c h 13-06-6
VEHICLE APPLICATION
Town Car, Cr own Vi ct or i a, Gr and Mar qui s
Horn System Horn bl ow swi t c h.
The horn sy st e m consi st s of : Horn rel ay ( 14N089) .
Horn ( 13832 ) assembl y wi t h dual horns (one
hi gh-pi t ched, one l ow-pi t ched).
Horn Switch, Steering Wheel Mounted
The horn bl ow swi t c h:
Is mount ed in t he dri ver si de ai r ba g modul e
( 043813) .
Is ope r a t e d by pressi ng t he dri ver si de ai r ba g
modul e.
Cl oses t he ci rcui t t o t he hor ns ( 13832) wi t h t he use
of a horn rel ay ( 14N089) .
When t he horn bl ow swi t c h i s pr e sse d, el ect ri cal
c ont a c t is made whi c h compl et es t he ci rcui t and t he
horns bl ow.
If horn swi t c h repl acement be c ome s necessar y,
repl ace t he dri ver si de ai r ba g modul e assembl y. Ref er
t o Sect i on 01- 20B.
Horn Mounting Location
The horns ( 13832 ) are mount ed a s f ol l ows:
On Town Car, t he horns ar e mount ed t o t he hor n
mount i ng br a c ke t ( 13830) t ha t i s a t t a c he d t o t he LH
si de of t he radi at or suppor t ( 16138) .
On Cr own Vi c t or i a , Grand Mar qui s, t he hor ns ar e
mount ed on t he f ront cr ossmember .
13- 08- 2 He r n
13- 06- 2
El e c t r i c a l Schematics
To wn Car
6
C ON T A C T
TO SPEED
CONTROL
Se e EVTM for more det ai l s
of t hi s ci rcui t
K20014-B
13- 06- 3 Ho r n 13- 06- 3
DIAGNOSIS AND TESTING (Cont i nue
HOT AT ALL TIMES
m^^mm.-mm.mmf p Q W E R
I f HRN J DI STRI BUTI ON
AI R B AG
I SL I DI NG
1
C O N T A C T
SWITCHES
See EVTM for mor e d eta i l s
of t h i s c i r c ui t
1. Veri f y t he c ust ome r ' s ori gi nal concer n by
oper at i ng t he horn sy st e m t o dupl i cat e t he
condi t i on.
2. I nspect t o det er mi ne if one of t he f ol l owi ng
mechani cal or el ect r i cal concer ns appl y:
Ve r i f y t h a t ho r n r e t a i n i n g
s c r e w i s t i gh t .
Ve r i f y t h a t t h e gr o u n d o f t h e
ho r n i s g o o d by i n s p e c t i n g
c o n n e c t i o n f o r c o r r o s i o n .
Ve r i f y t h a t ho r n s a r e n o t
t o u c h i n g sur r o un d i n g s h e e t
me t a l o r o t h e r c o mp o n e n t s .
Ch e c k s y s t e m f u s e .
Ch e c k wi r i n g f o r o b v i o u s
s h o r t or o p e n s .
Ch e c k c o n n e c t o r s f o r
o b v i o u s d a ma g e .
3. If t he concerns remai n af t er t he i nspect i on,
det ermi ne t he sy mpt oms and go t o t he Sy mpt om
Chart .
13- 06- 4 Ho r n 13- 06- 4
Symptom Chart
equi val ent t o per f or m el ect ri cal Pi npoi nt Test s.
HORN SYSTEM
Hor n s y s t e m Al wa y s On Hor n bl o w s wi t c h .
Swi t c h c i r c ui t r y .
Hor n Sy s t e m I n o pe r a t i v e Ci r c ui t r y o pe n / s h o r t e d .
Hor n r e l a y .
Hor n bl o w s wi t c h .
Ho r n s.
PINPOINT TEST A: HORN SYSTEM ALWAYS ON
A1 CHECK HORN SWI TCH CI RCUI T FOR SHORT
Ye s
No
G O t o A 2 .
REPLACE s h o r t e d hor n
r e l a y a nd br a c ke t .
RETEST s y s t e m.
Re mo v e hor n r e l a y a n d b r a c ke t a s o ut l i n e d .
Di sc o n n e c t po si t i v e ba t t e r y c a b l e a n d wa i t o n e
mi n ut e .
Usi n g o hmme t e r c o n n e c t e d t o a kn o wn go o d
gr o un d , c o n n e c t o t he r l e a d t o Pi n 85, Ci r c ui t 6
( Y/ L G ) a t r e l a y c o n n e c t o r .
Ye s
No
G O t o A 2 .
REPLACE s h o r t e d hor n
r e l a y a nd br a c ke t .
RETEST s y s t e m.
A2 CHECK HORN SWI TCH FOR SHORT
Ye s
No
GO t o A 3.
REPLACE d r i ve r si d e ai r
b a g mo d ul e .
RETEST s y s t e m.
Di s c o n n e c t d r i ve r si d e ai r b a g mo d ul e . Re f e r t o
Se c t i o n 01- 2 0B.
Wi t h o hmme t e r st i l l c o n n e c t e d t o r e l a y c o n n e c t o r
a n d gr o un d , r e a d r e s i s t a n c e .
Ye s
No
GO t o A 3.
REPLACE d r i ve r si d e ai r
b a g mo d ul e .
RETEST s y s t e m.
A3 CHECK FOR SHORTED AI R BAG SLI DI NG CONTACT
Ye s
No
REPLACE s h o r t e d ai r ba g
sl i d i n g c o n t a c t .
RETEST s y s t e m.
Ci r c ui t 6 ( Y/ L G ) .
RETEST s y s t e m.
Di s c o n n e c t o hmme t e r f r o m r e l a y c o n n e c t o r .
Ca r e f ul l y c h e c k r e s i s t a n c e of e a c h c o n t a c t a t ai r
b a g sl i d i n g c o n t a c t .
Ye s
No
REPLACE s h o r t e d ai r ba g
sl i d i n g c o n t a c t .
RETEST s y s t e m.
Ci r c ui t 6 ( Y/ L G ) .
RETEST s y s t e m.
PINPOINT TEST B: HORN SYSTEM INOPERATIVE
B1 CHECK HORN OPERATI ON
Ye s
No
G O t o B2.
REPLACE hor n or ho r n s
t ha t d i d not so un d .
RETEST s y s t e m.
Di sc o n n e c t bo t h ho r n s a s o ut l i n e d .
Co n n e c t one e n d of a j umpe r wi r e t o ba t t e r y
po s i t i v e .
To uc h o t he r e nd t o c o n n e c t o r at e a c h ho r n .
Di d each horn sound?
Ye s
No
G O t o B2.
REPLACE hor n or ho r n s
t ha t d i d not so un d .
RETEST s y s t e m.
B2 CHECK HORN CI RCUI TRY
Ye s
No
Sy s t e m OK.
RETEST s y s t e m.
GO t o B3.
Usi n g a t e s t l a mp, c o n n e c t l e a d t o a kn o wn g o o d
gr o un d .
Co n n e c t o t he r e n d t o hor n ha r n e s s c o n n e c t o r .
Po si t i o n t e s t l a mp in v i si bl e po s i t i o n .
A c t u a t e ho r n bl o w s wi t c h .
Ye s
No
Sy s t e m OK.
RETEST s y s t e m.
GO t o B3.
13-06-5 Ho r n 13-06-5
T"
PINPOINT TEST B: HORN SYSTEM INOPERATIVE (Cont i nued)
TE ST STE P RESUL T A CT I ON TO TAKE
B3 CHECK HORN FEED AT RELAY
Ye s
No
GO t o B4.
GO t o B5.
Remove hor n relay and b r a c ke t a s outli ned.
Co n n e c t t e s t l a mp t o kn o wn g o o d gr o un d .
Co n n e c t t e s t l a mp pr o be t o Pi n 87 , Ci r c ui t 1 ( DB) a t
r e l a y .
Ac t u a t e hor n bl o w s wi t c h .
Ye s
No
GO t o B4.
GO t o B5.
B4 CHECK HORN CI RCUI T CONTI NUI TY
Ye s
No
GO t o B5.
SERVI CE o pe n i n Ci r c ui t 1
( DB) . RESTORE v e hi c l e .
RETEST s y s t e m.
Usi n g o hmme t e r , c o n n e c t o n e l e a d t o ho r n ha r n e s s
c o n n e c t o r . Co n n e c t o t h e r l e a d t o Pi n 87 , Ci r c ui t 1
(DB) a t r e l a y c o n n e c t o r . Re a d r e s i s t a n c e .
I s resi st ance 5 ohms or l ess?
Ye s
No
GO t o B5.
SERVI CE o pe n i n Ci r c ui t 1
( DB) . RESTORE v e hi c l e .
RETEST s y s t e m.
B5 CHECK HORN SYSTEM SUPPLY
Ye s
No
GO t o B8.
GO t o B6.
Usi n g t e s t l a mp c o n n e c t e d t o a kn o wn go o d gr o un d ,
c o n n e c t t e s t l a mp pr o b e t o Pi n 30, Ci r c ui t 460
( Y/ L B ) a t r e l a y c o n n e c t o r .
Ye s
No
GO t o B8.
GO t o B6.
B6 CHECK SUPPLY CI RCUI T
Ye s
No
SERVI CE o pe n i n Ci r c ui t
40 ( L B / W) .
RETEST s y s t e m.
GO t o B7.
Wi t h t e s t l a mp, c h e c k Fuse 16 ( 2 0A) a t i n st r ume n t
pa n e l .
I s f use OK?
Ye s
No
SERVI CE o pe n i n Ci r c ui t
40 ( L B / W) .
RETEST s y s t e m.
GO t o B7.
B7 CHECK FOR SUPPLY SHORT TO GROUND
Ye s
No
Ci r c ui t 40 ( L B/ W) .
RETEST s y s t e m.
GO t o B8.
Usi n g o hmme t e r , c h e c k c o n t i n ui t y f r o m Pi n 30,
Ci r c ui t 460 ( Y / LB) a t r e l a y c o n n e c t o r t o a kn o wn
go o d gr o un d .
Is resi st ance 5 ohms or Bess?
Ye s
No
Ci r c ui t 40 ( L B/ W) .
RETEST s y s t e m.
GO t o B8.
03 CHECK HORN RELAY
Ye s
No
GO t o B9.
REPLACE hor n r e l a y a n d
b r a c ke t .
RETEST s y s t e m.
Re c o n n e c t ho r n r e l a y a n d b r a c ke t .
Usi n g t e s t l a mp c o n n e c t e d t o a kn o wn g o o d gr o un d ,
c o n n e c t p r o b e of t e s t l a mp t o Pi n 85, Ci r c ui t 6
( Y/ L G ) .
Ye s
No
GO t o B9.
REPLACE hor n r e l a y a n d
b r a c ke t .
RETEST s y s t e m.
B9 CHECK HORN SWI TCH FEED FOR OPEN
Ye s
No
REPLACE dr i ve r si d e a i r
b a g mo d ul e .
RETEST s y s t e m.
SERVI CE o pe n in Ci r c ui t 6
( Y/ L G ) .
RETEST s y s t e m.
Di sc o n n e c t ba t t e r y po si t i v e c a b l e a s o ut l i n e d . Wa i t
one mi n ut e .
Di sc o n n e c t d r i ve r si d e ai r b a g mo d ul e .
Wi t h t e s t l a mp c o n n e c t e d t o kn o wn go o d gr o un d ,
c h e c k Ci r c ui t 6 ( Y/ L G ) a t ho r n s wi t c h c o n n e c t o r .
Ye s
No
REPLACE dr i ve r si d e a i r
b a g mo d ul e .
RETEST s y s t e m.
SERVI CE o pe n in Ci r c ui t 6
( Y/ L G ) .
RETEST s y s t e m.
13- 06- 6 Ho r n 13- 06- 6
NOTE: For Cr own Vi ct or i a, Gr and Marqui s vehi cl es
wi t hout spe e d cont r ol , a c a p cont ai ni ng a short i ng bar
is pl aced over t he 10-pin ser vo connect or . The
short i ng bar c onne c t s pi ns 6 and 10, provi di ng a ret urn
t o ground f or t he horn si gnal . If t hi s short i ng bar i s not
present , t he horn wi ll not f unct i on. Ref er t o Sect i on
10-03 f or El ect ri cal Schemat i c and Wi r e Harness
Connect or i nf ormat i on.
H o r n A s s e m b l y
1. Di sconnect horn ( 13832) .
2. Remove ret ai ni ng sc r e w and r emove horn and
horn mount i ng br a c ke t ( 13830) assembl y.
3. To i nst al l , r ever se t he Removal pr ocedur e.
Ti ght en ret ai ni ng sc r e w t o 10-12 N-m (7-9 Ib-ft) on
Town Car. Ti ght en ret ai ni ng sc r e w t o 8-12 Nm
(6-9 Ib-ft) on Cr own Vi ct or i a, Grand Marqui s.
To wn Car
K18652 - A
I t e m
Pa r t
1 N801939- S36 Sc r e w
2 16138 Ra d i a t o r Suppo r t
3 13830 Horn Mo un t i n g Br a c ke t
4 13833 Horn
5 13832 Hi gh Pi t c h Hor n
A Ti ght e n t o 10-12 N-m (7-9
Lb- Ft )
Cr o wn Vi c t o r i a , Gr a n d Mar qui s
SCREW
TI GHTEN TO
8-12 N-m
(6-9 LB-FT)
CROSSMEMBER
WI RI NG ASSY
14290
K16126-B
H o r n S w i t c h
If horn swi t c h repl acement becomes necessar y,
repl ace t he dri ver si de ai r bag modul e a s an assembl y.
Ref er t o Sect i on 01- 20B.
H o r n Re l a y
1. Open t he hood ( 16612) .
Open power di st ri but i on box l ocat ed on t he RH 2.
3.
4.
si de.
Pull out horn rel ay ( 14N089) .
To i nst al l , r ever se Removal pr ocedur e.
SPECIFICATIONS
De s c r i p t i o n N- m L b - Ft
Ho r n Re t a i n i n g Sc r e w ( To wn Ca r ) 10-12 7-9
Ho r n Re t a i n i n g Sc r e w ( Cr o wn
8- 12 6-9
R O T U N D A E Q U I P M E N T
13- 07 - 1 Cl o c k 13- 07 - 1
SECTION 13-07 Clock
SUBJECT PAGE
Cl ock 13- 07 - 1
DIAGNOSIS A ND TE STI NG
El ect ri cal Schemat i c 13- 07 - 3
I nspect i on and Veri fi cati on . 13- 07 - 7
SUBJECT PAGE
Pi npoi nt Test s 13- 07 - 8
Sy mpt om Chart 13- 07 - 8
Cl ock ... 13- 07 - 10
SPECIAL SERVICE TOOLS/EQUIPMENT 13- 07 - 10
VEHICLE APPLICATION
Town Car, Cr o wn Vi ct or i a, Gr and Marqui s
C l o c k
The el ect ri c c l o c k ( 15000) :
Di spl ays t i me in a 12-hour f or ma t .
Illumi nates wi t h i gni ti on swi t c h ( 1157 2) in ACC or
RUN.
To wn Car
INSTRUMENT
CLUSTER
10849
Di ms when headl amps ( 13008) a r e on.
Is l ocat ed in i nst rument panel ( 04320) t o t he ri ght of
t he i nst rument cl ust er ( 10849) .
ELECTRIC
CLOCK 15000
INSTRUMENT
PANEL 04320
K20021-A
13- 07 - 2
Cl o c k 13- 07 - 2
Cr o wn Vi c t o r i a (Gr and Ma r qui s Si mi l ar )
I NSTRUMENT
CLUSTER
10849
I
ELECTRIC
CLOCK 15000
I NSTRUMENT
PANEL 04320
K20022-B
S e t t i n g T i me
1. Pr ess and hol d H but t on until desi r ed hour i s
di spl ay ed.
2 . Pr ess and hol d M but t on until desi r ed mi nute i s
di spl ay ed.
T I M E
D I S P L A Y
SET HOURS MI NUTES
K22668-A
13- 07 - 3
Electrical Schematic
El e c t r i c Cl o c k
HOT AT ALL TIMES HOT IN ACC OR RUN HOT AT ALL TIMES
1 F U S E
J UN C T I ON
1 P A N E L
LG/W
LG/W
8
1 F U S E
I J UN C T I ON
1 P A N E L
jm j
ELECTRI C
CL OCK

' I FUS E
i J UN C T I ON
1 P A N E L
4
B+
INPUT
5
IGN
INPUT
PARK
LAMPS
INPUT
2

-3
I LLUf /
JNATiON
INPUT
w
w 0
1
14 BR
57 BK
VARI ABLE LOGI C
* I DI M DOWN VOLTAGE GND
_ Z Z ^ i G2-15 C3-2
:
--C3-
I
L I G HT I NG
C ON T ROL
MODUL E
( L CM)
-PARK PWR a
LAMPS GND 1
cs-i-r - J $S M j
' V" ^ """"
! BK
See EVTM for mor e det ai l s
K2 2 686- A
13- 07 - 4 C l o c k 13- 07 - 4
LIGHTING CONTROL
MODULE CONNECTOR C 1
K22SS7-A
Pi n
1 2 94
( W/ L B )
R u n / A c e B + I nput
2 88 ( B K / W) Do me L a mp Swi t c h
3 158
( B K / P K )
4 No t Us e d
5 486
( B R / W)
L u g g a g e Co mp a r t me n t Do o r Aj a r
6 2 0 2 ( B / L G ) De c kl i d P u n c h o u t
7 2 5 ( DG / P ) A / T Di s a r m
8 7 0 ( L B / W) I S 0 9 1 4 1 Da t a Co m Li n k
9 1003
( G Y/ Y)
Ru n / S t a r t B + I nput
11 62 7
( B K / O )
12 465
( W/ L B )
13 1032
( W/ B K )
14 2 4 ( D B / B ) Pa n i c Al a r m
15 2 3 ( T / L G ) Ho o d Op e n Swi t c h
16 2 2 2
( B R / L G )
DRIVER SEAT CONTROL
MODULE CONNECTOR C 2
K22688-A
Pin
Number Ci rcui t C i r c u i t Funct i on
1 342 ( L G / P ) St a r t I n t e r r upt Re l a y I nput
2 932
( G Y/ W)
3

Not Us e d
4 1 ( DB) Hor n Re l a y
5

Not Us e d
8 2 17
( DB / O )
9 343
( DB / L G )
Ha za r d I n d i c a t o r ( EN) A / T
I n d i c a t o r ( FN)
10 344
( B K / Y)
11 867 ( DB) Dr i ve r Do o r Aj a r Swi t c h
12 688
( DB / O )
He a t e d Ba c kl i t e Re l a y ( Cr o wn
Vi c t o r i a , Gr a n d Ma r q u i s o n l y )
13 194 ( PK) De l a y e d A CC
Re q u e s t / P o l i c e Da r k Ca r
15 1036
( B R / W)
Do wn
16 1035
( O / R )
He a d l a mp Di mme r S wi t c h I nput Up
17 85
( B R / L B )
Se a t Be l t Swi t c h
18 688
( G Y/ L B )
Re a r De f r o s t Swi t c h
19 936
( DG / W)
Ke y Cy l i n d e r Se n s o r
2 0 57 ( BK) Ke y Cy l i n d e r Se n s o r
2 1

Not Us e d
2 2 344
( B K / Y)
Gr o un d
13- 07 - 5 C l o c k 13- 07 - 5
LI GHTI NG CONTROL
MODULE CONNECTOR C3 K226B9-A
Pi n
N u m b e r C i r c u i t Ci rcui t Func t i on
1 7 05
( L G / O )
2 19 ( L B / R ) Va r i a bl e Di mmi n g Ou t pu t t o
3 117
( P K / B K )
5 53
( B K / L B )
6 195 ( T / W) Ba t t e r y Vo l t a ge I nput t o L C M a n d
7 No t Us e d
8 450
( B K / L G )
9 57 ( P K / O ) L o gi c Gr o un d
10 502 ( GY) L o w Be a m He a d l a mp s a n d
11 54 ( L G / Y ) Ba t t e r y Vo l t a ge I nput
12 484
( O / B K )
Pul se Wi d t h Mo d u l a t e I l l umi n a t i o n
Out put
13 44 ( L B) T u r n / Ha z a r d
15 385 ( W/ R ) Fl a s h e r P o we r
LIGHTING CONTROL
MODULE CONNECTOR C4
K22690-A
Pin
1 17 5
( B K / Y )
2 186
( B R / L B )
Ba t t e r y Vo l t a ge I n put
Ma r qui s
LIGHTING CONTROL
MODULE CONNECTOR C1
K22617-A
Pi n
1 2 96 ( W/ P ) R u n / A c e B+ I nput
2 1034
( B K / W)
3 158
( B K / P K )
Ke y i n I gn i t i o n
4 No t Us e d
5 486
( B R / W)
De c k L i d Aj a r
6

No t Us e d
7 No t Us e d
8 7 0 ( L B / W) Ke y l e s s En t r y , Me mo r y Se a t s , A BS
9 6 4 0 ( R / Y ) Ru n / S t a r t B + I nput
11 62 7
( B K / O )
12 465
( W/ L B )
13 1032
( W/ B K )
14 3 4 0 ( R / L B ) Pa n i c Al a r m
15

No t Us e d
16 2 2 2
( B R / L G )
13- 07 - 6 Cl o c k 13- 07 - 6
DRIVER SEAT CONTROL
MODULE CONNECTOR C2
K22688-A
Pi n
1 No t Us e d
2 932
( G Y / W)
3 No t Us e d
4 6 ( Y/ L G ) Ho r n
5 No t Us e d
7 2 1 8 ( W / P ) A u t o l a mp En a bl e
8 2 17
( DB / O )
9 383 ( R / W) Ha z a r d I n d i c a t o r
10 344
( B K / Y )
11 8 6 7 ( DB) Dr i v e r s Do o r Aj a r S wi t c h
12 688
( DB / O )
He a t e d Ba c kl i t e Re l a y
13 No t Us e d
Re q u e s t
15 1036
( B R / W)
16 1035
( O / R )
17 85
( B R / L B )
18 1010
( DB / O )
Ba c kl i t e S wi t c h
19 No t Us e d
2 0 No t Us e d
2 1 No t Us e d
2 2 No t Us e d
LIGHTING CONTROL
MODULE CONNECTOR C3 8C22SSS-A
Pin
1 7 05
( L G / O )
2 19 ( L B / R ) Va r i a bl e Di mmi n g Out put t o
3 117
( P K / B K )
5 53
( B K / L B )
He a d l a mp Di mme r Swi t c h
7

Not Us e d
8 450
( B K / L G )
9 57 ( BK) L o gi c Gr o un d
10 13 ( R / B K ) L o w Be a m He a d l a mp s a n d
12 484
( O / B K )
Pul se Wi d t h Mo d u l a t e d I l l umi n a t i o n
Out put
13 44 ( L B) T u r n / Ha z a r d
15 385 ( W/ R ) Fl a s h e r P o we r
LIGHTING CONTROL
MODULE CONNECTOR C4
K22690-A
13-11-13 A n t i - T h e f t A l a r m S y s t e m 13-11-13
GLOVE/LUGGAGE
COMPARTMENT
LOCK CYLI NDER
43507
SLEEVE AND
COVER ASSY
43320
RI VET
388524-S '
2 REQ'D N8517-B
Door Lock Switches, Theft Warning
Ignition Lock Anti-Theft Swi tch
Removal a n d Installation
1. Di sconnect bat t er y ground c a bl e ( 14301) .
2. Remove t he i gni ti on key l ock cyl i nder f r om
st eeri ng col umn t ube (3514)Ref er t o Sect i on
11-04.
3. Lo c a t e i gni ti on l ock ant i -t hef t swi t c h ( 19A438)
a t t a c he d t o st eeri ng col umn t ube next t o i gni ti on
ke y warni ng swi t c h t ermi nal and wi r e swi t c h.
4. Sli de t he i gni ti on l ock ant i -t hef t swi t c h of f st eeri ng
col umn t ube.
5. Remove t he c l oc k spri ng assembl y t o a c c e ss t he
ground l ocat i on of t he i gni ti on l ock ant i -t hef t
swi t c h.
6. Di sconnect ground t ermi nal .
7. Di sconnect t he i gni ti on l ock ant i -t hef t swi t c h f r o m
wi ri ng harness.
I gn i t i o n L o c k An t i - The f t Swi t c h
LOCK CYLI NDER HOUSI NG
22074
I GNI TI ON SWI TCH
LOCK CYLI NDER
11582
I GNI TI ON CYLI NDER
SENSOR CONNECTOR
I GNI TI ON LOCK
ANTI -THEFT
SWI TCH 19A438
N12473-A
SPECIFICATIONS
9- 14 7- 10
St r i ke r
2 6-8
Cy l i n d e r P l a t e Bo l t
5-8 3-5
S c r e w
8- 12 6-8
Do o r L a t c h St r i ke r S c r e w 8- 14 7- 10
ROTUNDA EQUI PMENT
Mo d e l Descr i pt i on
007 - 00500 Ne w Ge n e r a t i o n STAR Te s t e r
14- 00- 1
BATTERY A ND
CHARGI NG SYSTEM
GROUP
14
SE CTI ON TI TL E PAGE SE CTI ON TI TL E PAGE
BATTERY AND CHARGING BATTERY 14-01-1
SYSTEMSERVI CE. . . . ...14-00-1
GENERATOR, INTEGRAL REAR MOUNT
REGULATOR INTERNAL FAN TYPE 14-02-1
y ~w & w w T"
SECTION 14-00 Battery and Charging
SystemService
SUBJECT PAGE
Chargi ng Sy st em 14-00-1
IGR Generat or Wi t h I nt egral Rear Mount
Re gul a t or I nt e r na l Fan Type 14-00-2
Bat t ery 14-00-15
Drai n Test i ng ..14-00-15
Generat or Bench Test s 14-00-18
SUBJECT PAGE
Generat or On-Vehi cle Test s 14-00-17
ADJUSTMENTS
Dri ve Bel t , Ac c e ssor y 14-00-18
SPECIAL SERVICE TOOLS/EQUIPMENT ....14-00-18
VEHICLE APPLICATION
Charging S y s t e m
The chargi ng sy st e m consi st s of a:
Generat or (GEN)( 10346) wi t h i nt egral rear mount
vol t age regul at or (VR)(10316).
Thi s sect i on cont ai ns general i nf ormat i on appl i cabl e t o
all chargi ng sy st e ms and gener at or s. For i nf ormat i on
on bat t er i es, ref er t o Sect i on 14- 01. For i nf ormat i on
speci f i c t o t he gener at or / chargi ng sy st e m, ref er t o
Sect i on 14-02.
Char ge i ndi cat or.
Ba t t e r y ( 10655) .
Vol t age gauge in i nst rument cl ust er.
Asso c i a t e d wi r i ng.
14- 00- 2 Ba t t e r y a n d Ch a r gi n g S y s t e mS e r v i c e 14- 00- 2
I GR Ge n e r a t o r Wi t h i n t e g r a l Rear Mo u n t
Re g u l a t o r I n t e r n a l Fan T y p e
Thi s vehi cl e uses t he IGR gener at or (GEN)( 10346)
wi t h i nternal f an and i nt egral rear mount ed vol t age
regul at or (VR)(10316).
E l e c t r i c a l S c h e m a t i c
Cha r gi n g S y s t e mT o wn Car
J4476-C
14- 00- 3 Ba t t e r y a n d Ch a r g i n g S y s t e m S e r v i c e 14- 00- 3
3 WITH
CLUSTER
J5470-A
1995 Town Car, Cr own Vi ct or i a, Gr and Marquis July 1994
14- 00- 4 Ba t t e r y a n d Ch a r g i n g S y s t e mS e r v i c e 14- 00- 4
An a l o g I n st r ume n t Cl u s t e r Cr o wn Vi c t o r i a
HOT IN START OR RUN
I FUSE
J | * | JUNCTION
S e e EVTM f or mo r e de t a i l s
f t hi s c i r c ui t
ANTi-SLOSH
MODULE
VOLTMETER
; E i C T f ^ 0 l ^ v . ; |
i r v F SPEED- >
4 c I y IOMETER/ /
l B
* 0 / 85 jfODOMETER /
O/Y
563
679
359
GY/ BK
O/Y
VEHICLE
SPEED
SENSOR
(VSS)
I
676 i P K / O
GY/ R
359 | GY/ R
TO OI L
PRESSURE
GAUGE
> TO
TEMPERATURE
GAUGE
J544S-A
14- 00- 5 Ba t t e r y a n d Ch a r g i n g S y s t e m S e r v i c e
14- 00- 5
of this circuit
POWERTRAI N 7
CONTROL I
MODULE (PCM) |
"FUSE
| JUNCTION
PANEL
CHARGE
INDICATOR |
41S I DG/LG 419
AI R
SUSPENSI ON
TEST
CONNECTOR
I GENERATOR
J547 1- A
HOT AT ALL TIMES
START
RUN
I
m mm^ | G N m 0 N
| SWITCH
ACC I
LOCK
" ^ j OFF |
4891
P K / B K
INSTRUMENT
CLUSTER
See EVTM f o r
mo r e de t a i l s
| GENERATOR
INSTRUMENT
CLUSTER
T T
82 I PK/Y 904 I LG/R
A
I
DOOR "
AJAR S
INPUT
T
627 I BK/O
TO
RKE
MODULE
' | GENERATOR
1
WINDSHIELD
WASHER LOW
FLUID SWITCH See EVTM f o r
mo r e det ai l s
5 7 ^ B K
I
CONNECTOR C 2
J5449-A
Pi ll
2 67 6
( P K / O )
Si gn a l Gr o u n d
3 640 ( R / Y ) P o we r I nput
4

No t Us e d
5 658
( P K / L G )
6

No t Us e d
7

No t Us e d
8 450
( DG / L G )
Se a t Be l t Wa r n i n g I n d i c a t o r I nput
9 67 6
( P K / O )
Si gn a l Gr o un d
10 3 ( L G / W) L H Tur n Si gn a l I n d i c a t o r I nput
11 88 ( B K / W) I l l umi n a t i o n Fe e d
12 904
( L G / R )
Ge n e r a t o r Ch a r g e I n d i c a t o r L a mp
I nput
13

No t Us e d
14 67 9
( G Y/ B K )
Ve h i c l e S p e e d Se n s o r Si gn a l
15 419
( DG / L G )
16 1053
( L B / P K )
Ai r Su s p e n s i o n I n d i c a t o r I nput ( + )
Pin
1 67 6
( P K / O )
Si gn a l Re t u r n Ve h i c l e S p e e d
Se n s o r
2 2 95
( L B / P K )
E l e c t r o n i c I n st r ume n t Cl us t e r
3 484
( O / B K )
L i q u i d Cr y s t a l Di s p l a y i l l umi n a t i o n
Fe e d
4 932
( G Y / W)
Hi gh Be a m I n d i c a t o r I nput
Pin
Number Ci rcui t Ci rcui t Fun c t i o n
5 Not Us e d
6 Not Us e d
7 489
( P K / B K )
E l e c t r o n i c I n st r ume n t Cl u s t e r
I gn i t i o n Run Si gn a l
8

Not Us e d
9 658
( P K / L G )
10 904
( L G / R )
Ch a r g e I n d i c a t o r L a mp Fe e d
11 No t Us e d
12 Not Us e d
112 J ( 11 ) ( 10) f 9 I I S ) ( 7
Pin
1 87 5
( B K / L B )
P o we r Gr o un d
2 9 64
( DB / L G )
3 484
( O / B K )
L i qui d Cr y s t a l Di spl a y
4 932
( G Y/ W)
Hi gh Be a m I nput
6 3 ( L G / W) LH Tur n Si gn a l ;
7 88 ( B K / W) I n st r ume n t Pa n e l L a mp S w i t c h e d
Fe e d
9 658
( P K / L G )
Ma l f un c t i o n I n d i c a t o r L a mp ( MI L )
I nput ( Ch e c k En gi n e )
10 9 0 4
( L G / R )
11 450
( DG / L G )
12 608
( B K / Y)
BATTERI ES ( 10655) CONTAI N SULFURI C ACID*
AVOI D CONTACT WI TH SKI N, EYES, OR
CLOTHI NG. ALSO, SHI ELD YOUR EYES WHEN
WORKI NG NEAR THE BATTERY TO PROTECT
AGAI NST POSSI BLE SPLASHI NG OF THE ACI D
SOLUTI ON. IN CASE OF ACI D CONTACT WI TH
SKI N OR EYES, FLUSH I MMEDI ATELY WI TH
WATER FOR A MI NI MUM OF 15 MI NUTES AND
GET PROMPT MEDI CAL ATTENTI ON. IF ACI D IS
SWALLOWED, CALL A PHYSI CI AN IMMEDIATELY.
WARNI NG: BATTERI ES NORMALLY PRODUCE
EXPLOSI VE GASES WHI CH CAN CAUSE
PERSONAL INJURY. THEREFORE, DO NOT
ALLOW FLAMES, SPARKS OR LI GHTED
SUBSTANCES TO COME NEAR THE BATTERY.
WHEN CHARGI NG OR WORKI NG NEAR A
BATTERY, ALWAYS SHI ELD YOUR FACE AND
PROTECT YOUR EYES. ALWAYS PROVI DE
VENTI LATI ON.
WARNI NG: WHEN LI FTI NG A PLASTI C- CASED
BATTERY, EXCESSI VE PRESSURE ON THE END
WALLS COULD CAUSE ACI D TO SPEW THROUGH
THE VENT CAPS, RESULTI NG IN PERSONAL
INJURY, DAMAGE TO THE VEHI CLE OR BATTERY.
LI FT WI TH A BATTERY CARRI ER OR WI TH YOUR
HANDS ON OPPOSI TE CORNERS.
1.
2.
oper at i ng t he engi ne t o dupl i cat e t he condi t i on.
I nspect t o det ermi ne if one of t he f ol l owi ng
Be f o r e a t t e mp t i n g t o t e s t a
b a t t e r y , i t i s i mpo r t a n t t o gi v e
i t a t h o r o u g h e x a mi n a t i o n t o
d e t e r mi n e if i t h a s b e e n
d a ma g e d .
Ba t t e r i e s a r e t e s t e d t o
d e t e r mi n e t h e s t a t e o f c h a r g e
a n d a bi l i t y t o c r a n k a n e n gi n e .
The r e sul t o f t h e s e t e s t s i s t o
s h o w t h a t t h e b a t t e r y i s e i t h e r
g o o d , n e e d s r e c h a r g i n g , o r
mus t b e r e p l a c e d .
Pr e l i mi n a r y c h e c k s t o t h e
c h a r g i n g s y s t e m s h o u l d be
ma d e r e g a r d l e s s of t h e f a ul t
c o n d i t i o n . T h e s e c h e c k s
i n c l ud e :
Ch e c k t h e f u s e s / f u s e l i n ks
t o t h e ge n e r a t o r t o e n s ur e
t h a t t h e y a r e not bur n e d o r
d a ma g e d . Th i s c o n d i t i o n ,
r e s u l t i n g i n a n o p e n c i r c u i t
o r h i gh r e s i s t a n c e , c a n
c a u s e e r r a t i c o r i n t e r mi t t e n t
c h a r g i n g s y s t e m c o n c e r n s .
C h e c k b a t t e r y p o s t s a n d
c a b l e t e r mi n a l s f o r c l e a n
a n d t i gh t c o n n e c t i o n s .
Cl e a n t h e p o s t s a n d t h e
c a b l e s t o e n s u r e g o o d
e l e c t r i c a l c o n t a c t .
Ch e c k f o r s e c u r e
c o n n e c t i o n s a t t h e
ge n e r a t o r o u t pu t , v o l t a ge
r e gu l a t o r a n d e n gi n e
gr o u n d . A l s o c h e c k t h e
c o n n e c t i o n a t t h e l o a d
d i s t r i b u t i o n po i n t .
Ch e c k t h e ge n e r a t o r d r i v e
be l t t o e n s ur e p r o p e r
t e n s i o n a n d n o sl i p b e t we e n
t h e ge n e r a t o r pul l e y a n d t h e
d r i v e b e l t . Re f e r t o Se c t i o n
03- 05.
Ch e c k b a t t e r y f o r f ul l
c h a r g e a s o u t l i n e d .
Be f o r e p e r f o r mi n g c h a r g i n g
s y s t e m t e s t s o n t h e v e h i c l e ,
n o t e c o n d i t i o n s s u c h a s : s l o w
c r a n ki n g, d i s c h a r g e d b a t t e r y ,
c h a r g e i n d i c a t o r l a mp s t a y s
ON wi t h e n gi n e r un n i n g,
c h a r g e i n d i c a t o r l a mp d o e s
n o t i l l umi n a t e wi t h i gn i t i o n
s wi t c h in RUN a n d e n gi n e n o t
r un n i n g, e t c . Thi s i n f o r ma t i o n
wi l l a i d in i s o l a t i n g t h e p a r t o f
t h e s y s t e m c a u s i n g t h e
s y mp t o m.
Wh e n a r e l a t i v e l y n e w
b a t t e r y i s d i s c h a r g e d , t e s t
f o r c ur r e n t d r a i n . The
f o l l o wi n g a r e s o me o f t h e
mo s t c o mmo n c u r r e n t d r a i n
c o n c e r n s :
Gl o v e c o mp a r t me n t
l a mp s t a y s o n wi t h t h e
d o o r c l o s e d .
En gi n e c o mp a r t me n t
l a mp s t a y s o n
c o n s t a n t l y .
L i c e n s e p l a t e l a mp o r
i n t e r i o r l a mp s t a y s o n
c o n s t a n t l y .
Ot h e r e l e c t r o n i c
c o mp o n e n t
ma l f u n c t i o n s .
3. If t he i nspect i on reveal s obvi ous concer n(s) t hat
can be readi l y i dent i f i ed, servi ce a s requi red.
4. If t he concern(s) remai ns af t er t he i nspect i on,
det ermi ne t he sy mpt om(s) and go t o t he f ol l owi ng
Sy mpt om Chart .
BATTERY AND CHARGING SYSTEM DIAGNOSIS
Ba t t e r y Wi l l Not St a y Ch a r ge d
De a d b a t t e r y
Sl o w Cr a n k
L o w Ba t t e r y Vo l t a ge
No Ge n e r a t o r Out put
Vo l t me t e r Re a d s L o w
I gni t i on s wi t c h OFF ba t t e r y d r a i n .
Op e n / v o l t a g e d r o p in ' B + \ Ci r c ui t
38 ( BK / O) .
Op e n / v o l t a g e d r o p in 'A', Ci r c ui t
36 ( Y/ W) .
Ope n / hi gh r e s i s t a n c e in T, Ci r c ui t
904 ( L G / R) .
Vo l t a ge r e gul a t o r .
Ge n e r a t o r .
Ba t t e r y .
Ba t t e r y c o n n e c t i o n s .
Dr i ve be l t .
BATTERY AND CHARGING SYSTEM DIAGNOSIS (Cont i nued)
CONDITION POSSI BLE SOURCE ACTI ON
Generator Warning Lamp Stays
ON, Engi ne Runni ng
Ope n 'A', Ci r c ui t 36 ( Y/ W) .
Sh o r t e d ' I ' , Ci r c ui t 904 ( L G / R) .
Op e n / h i g h r e s i s t a n c e i n ' S \ Ci r c ui t
4 ( W/ BK ) .
Vo l t a ge r e gul a t or .
Ge n e r a t o r .
Ge n e r a t o r Wa r n i n g La mp Fl i c ke r s /
I nt e r mi t t e nt
L o o s e c o n n e c t i o n t o ge n e r a t o r ,
v o l t a ge r e gul a t or , or p o we r
d i st r i but i o n bo x .
L o o s e f use or po o r c o n n e c t i o n in
Ci r c ui t 36 ( Y/ W) .
L o o s e br ush ho l d e r s c r e w.
Ge n e r a t o r .
GO t o Pi npoi nt Test C.
Vo l t me t e r Re a d s Hi gh ( Ba t t e r y
Vo l t a ge Gr e a t e r Tha n 15.5 V)
Ba t t e r y Bo i l s Ov e r
Vo l t a ge d r o p in *A\ Ci r c ui t 36
( Y/ W) .
Vo l t a ge d r o p in T, Ci r c ui t 904
( L G / R) .
Po o r gr o un d .
Ge n e r a t o r .
GO t o Pi npoi nt Test D.
Ge n e r a t o r Wa r n i n g L a mp Do e s Not
Co me On
Ope n / h i g h r e s i s t a n c e i n T, Ci r c ui t
904 ( L G / R) .
Bur n e d out l a mp.
Po o r gr o un d .
' S' , Ci r c ui t 4 ( W/ B K ) s h o r t e d to
B + .
Ge n e r a t o r .
GO t o Pi npoi nt Test E.
No i sy Ge n e r a t o r A c c e s s o r y d r i ve be l t .
A c c e s s o r y b r a c ke t s .
Be nt pul l ey .
Ge n e r a t o r .
Ot he r a c c e s s o r i e s .
G Ot o Pi npoi nt Test F.
Ra d i o I n t e r f e r e n c e Vo l t a ge r e gul a t o r .
Ge n e r a t o r .
Ot he r c o mpo n e n t s .
GO t o Pi npoi nt Test G.
Ge n e r a t o r Wa r n i n g La mp St a y s
ON, I gni t i on Swi t c h OFF
L a mp Ci r c ui t 904 ( L G / R) s h o r t e d
t o B + .
I mpr o pe r l a mp c i r c ui t wi r i n g,
I nst r ume nt c l ust e r .
GO t o Pi npoi nt Test H.
Pi npoi nt Test s
Use Rot unda 7 3 Di gi t al Mul t i met er 105-00051 or
equi val ent f or t he f ol l owi ng El ect ri cal Test s.
PI NPOI NT T E ST A: BATTERY WI L L NOT STAY CHARGED
TE ST STEP RESULT A CT I ON TO TAKE
A1 CHECK BATTERY CONNECTI ONS
Ye s \
No
GO t o A2.
CLEAN a nd TI GHTEN t he
ba t t e r y c a b l e s .
I n spe c t t he ba t t e r y c a b l e s f or l o o se or c o r r o d e d
Are t he bat t er y cabl es cl ean and t i ght ?
Ye s \
No
GO t o A2.
CLEAN a nd TI GHTEN t he
ba t t e r y c a b l e s .
A2 CHECK DRI VE BELT TENSI ON
Ye s
No
GO t o A 3.
ADJUST or REPLACE t he
d r i v e be l t .
Pe r f o r m t he dr i ve be l t a d j ust me n t p r o c e d u r e . Re f e r
t o Se c t i o n 03- 05.
Is t he dri ve bel t adj ust ed pr oper l y ?
Ye s
No
GO t o A 3.
ADJUST or REPLACE t he
d r i v e be l t .
PINPOINT TEST A: BATTERY WILL NOT STAY CHARGED (Cont i nued)
T E S T S T E P RESULT E> ACTION TO TAKE
A 3 LOOSE BATTERY POST
Yes
No
GO to A4.
REPLACE battery.
C h e c k f o r l o o s e battery p o s t s .
Are p o s t s OK?
Yes
No
GO to A4.
REPLACE battery.
A4 CRACKED BATTERY COVER
Yes
No
GO to A5.
REPLACE battery.
Remove battery hold down clamps and shi elds.
Check for broken / cracked case o r battery cover.
A r e c a s e a r i d c o v e r O K ?
Yes
No
GO to A5.
REPLACE battery.
A S CHECK BATTERY
Yes
No
GO to A6.
REPLACE the battery.
Perform the Battery Capaci ty Test. Refer to
Component Tests.
I s t h e b a t t e r y O K ?
Yes
No
GO to A6.
REPLACE the battery.
A 6 CHECK FOR KEY-OFF DRAIN
Yes
No
GO to A7.
GO to Component Tests
to find the cause of
ignition switch-OFF
battery drain.
Perform Battery Drain Test. Refer to Component
T e s t s .
I s c u r r e n t d r a i n l e s s t h a n 3 0 mA ( o r t e s t lamp
of f )?
Yes
No
GO to A7.
GO to Component Tests
to find the cause of
ignition switch-OFF
battery drain.
A7 CHECK FOR OPEN ' B+ ' CIRCUIT
Yes
No
GO to A8.
38 (BK/ O).
Measure voltage at ' B+ ' terminal on the back of t he
generator, Circuit 38 (BK/ O).
Is vol t age at ' B+ ' t er mi nal equal t o bat t er y
vol t age?
Yes
No
GO to A8.
38 (BK/ O).
A8 CHECK FOR OPEN ' A ' CIRCUIT
Yes
No
GO to A9.
CHECK fuse in Circuit 36
(Y/ W) and REPLACE if
required. If OK, SERVICE
open in Circuit 36 (Y/ W).
Measure voltage at t est point 'A' on the voltage
regulator.
Is vol t age at t est poi nt 'A' equal t o bat t er y
vol t age?
Yes
No
GO to A9.
(Y/ W) and REPLACE if
open in Circuit 36 (Y/ W).
A9 CHECK FOR OPEN FIELD CIRCUIT
Yes
No
GO to A10.
GO t o A16.
Measure voltage at t est point 'F' on the voltage
regulator.
Is vol t age at t est poi nt ' F' equal t o bat t er y
vol t age?
Yes
No
GO to A10.
GO t o A16.
A10 CHECK FOR OPEN T CIRCUIT
Yes
No
GO t o A 11.
(LG/R).
NOTE: Voltage regulator must be connected to wiring
harness for t hi s t est .
Turn ignition swi t ch to RUN posi t i on.
Measure voltage at wiring harness T terminal,
Circuit 904 (LG/R).
Is vol t age great er t han 1 V?
Yes
No
GO t o A 11.
(LG/R).
A11 CHECK VOLTAGE DROP IN 'A' CIRCUIT
Yes
No
GO to A12.
SERVICE excess voltage
drop in Circuit 36 (Y/ W).
CHECK fuse and
connectors in Circuit 36
and SERVICE as
required.
Measure voltage drop between t est point 'A' on the
voltage regulator and the posi ti ve ( + ) battery post.
Is vol t age dr op less t han 0. 25 V?
Yes
No
GO to A12.
drop in Circuit 36 (Y/ W).
CHECK fuse and
connectors in Circuit 36
and SERVICE as
required.
A12 CHECK FIELD TURN-ON
Yes P>
No
GO t o A13.
GO to A16.
Measure voltage at t est point 'F' on the voltage
regulator.
Is vol t age at t e st poi nt ' F' l ess t han 2 V?
Yes P>
No
GO t o A13.
GO to A16.
PINPOINT TEST A: BATTERY WILL NOT STAY CHARGED (Cont i nued)
A13 CHECK FOR SHORTED RECTIFIER
Yes
No
REPLACE generator.
GOt oA14.
Remove one-pin *S' connector from generator.
Measure voltage between the *S' terminal on the
back of the generator and ground.
Measure voltage between the positive ( + ) battery
terminal and the ' S' terminal on the back of the
generator.
Is ei ther vol tage readi ng great er t han 1 ?
Yes
No
REPLACE generator.
GOt oA14.
A14 CHECK VOLTAGE DROP IN ' B+ ' CIRCUIT
Yes
No
GO to At 5.
drop in Circuit 38 (BK/ O).
CHECK fuse link in Circuit
38 and the connections
between the battery and
Instal l ' S' connector.
Start engine.
Turn headlights ON and set blower on HIGH.
With engine running at 2 000 rpm, measure voltage
drop between the ' B+ ' terminal on the back of the
generator and the positive ( + ) battery post.
Is vol tage drop less than 0.5 V?
Yes
No
GO to At 5.
drop in Circuit 38 (BK/ O).
CHECK fuse link in Circuit
38 and the connections
between the battery and
A15 CHECK FOR OPEN STATOR PHASE
Yes
No
REPLACE voltage
regulator.
REPLACE generator.
Connect test point ' F' on the voltage regulator to
the negative (-) battery post using a jumper wire.
Perform Generator Load Test. Refer to Component
Tests.
Is generator out put current greater than the
mi ni mum out put speci f i ed?
Yes
No
REPLACE voltage
regulator.
REPLACE generator.
A16 CHECK FOR OPEN/SHORTED FIELD
Yes
No
REPLACE generator.
CHECK for worn brushes
(less than 8 mm long) or
open brush leads and
REPLACE if required. If
OK, REPLACE voltage
regulator.
Remove generator from vehicle.
Remove voltage regulator.
Measure resistance between the generator slip
rings.
Is resi stance greater than 10 ohms OR less than 1
ohm?
Yes
No
REPLACE generator.
CHECK for worn brushes
(less than 8 mm long) or
open brush leads and
REPLACE if required. If
OK, REPLACE voltage
regulator.
PINPOINT TEST B: GENERATOR WARNING LAMP STAYS ON, ENGINE RUNNING
B1 CHECK FOR OPEN ' A ' CIRCUIT
Yes
No
GO to B2.
( Y/ W) and REPLACE if
open in Circuit 36 ( Y/ W) .
Measure voltage at test point 'A' on the voltage
regulator.
Is vol t age at t est poi nt ' A' equal t o bat t er y
vol t a ge ?
Yes
No
GO to B2.
( Y/ W) and REPLACE if
open in Circuit 36 ( Y/ W) .
B2 CHECK FOR SHORTED ' I ' CIRCUIT
Yes
No
in Circuit 904 (LG/ R).
GO to B3.
Remove three-pin voltage regulator connector.
Turn ignition switch to RUN position.
Is i ndi cat or l amp on?
Yes
No
in Circuit 904 (LG/ R).
GO to B3.
B3 CHECK ' S' CIRCUIT FUNCTION
Yes
No
REMOVE jumper wire. GO
to B4.
to B5.
Install voltage regulator connector.
Remove one-pin ' S ' connector.
Connect wiring harness ' S' terminal, Circuit 4
(W/ BK) to the positive ( + ) battery post using a
jumper wire.
Is i ndi cat or l amp on?
Yes
No
to B4.
to B5.
B4 CHECK FOR OPEN ' S' CIRCUIT
Yes
No
SERVICE open or excess
(W/ BK).
CHECK for loose or bent
pin in voltage regulator or
connector. If OK,
REPLACE voltage
regulator.
Remove three-pin voltage regulator connector.
Measure wiring resistance between the one-pin ' S'
connector and t he' S' (center) pin of the voltage
regulator connector.
Is resi st ance gr eat er t han 1 ohm?
Yes
No
SERVICE open or excess
(W/ BK).
CHECK for loose or bent
pin in voltage regulator or
connector. If OK,
REPLACE voltage
regulator.
PINPOINT TEST B: GENERATOR WARNING LAMP STAYS ON, ENGINE RUNNING (Cont i nued)
B5 CHECK STATOR OUTPUT VOLTAGE
Ye s I >
No U>
GO t o B6.
GO t o Pi npoi nt Te st A t o
f i n d t he c a use of l o w
ge n e r a t o r out put .
Start engine.
Measure voltage at the ' S' terminal on the back of
the generator.
i s voltage at least 1/ 2 of b a t t e r y v o l t a g e ?
Ye s I >
No U>
GO t o B6.
GO t o Pi npoi nt Te st A t o
f i n d t he c a use of l o w
ge n e r a t o r out put .
B6 CHECK GENERATOR OUTPUT VOLTAGE
Ye s
No
GO t o Pi npoi nt Te st D t o
f i n d t he c a use of hi gh
o ut put v o l t a ge .
REPLACE v o l t a ge
r e gul a t o r .
Measure voltage at the B+ terminal on the back of
t he ge n e r a t o r wi t h t he e n gi n e runni ng at 2 000 r pm
a n d al l a c c e s s o r i e s t ur n e d OFF.
I s vol t age great er t han 15.5 V?
Ye s
No
GO t o Pi npoi nt Te st D t o
f i n d t he c a use of hi gh
o ut put v o l t a ge .
r e gul a t o r .
PINPOINT TEST C: GENERATOR WARNING LAMP FLICKERS/INTERMITTENT
C1 CHECK FOR LOOSE CONNECTI ONS
Ye s
No
G Ot o 02.
CLEAN or SERVI CE
c o n n e c t i o n s a s r e qui r e d .
Ch e c k t h e s e c o n n e c t i o n s f o r c o r r o s i o n , l o o se or
be n t pi n s, or l o o se e y e l e t s:
Thr e e - pi n v o l t a ge r e gul a t o r c o n n e c t o r .
One -pi n ' S' c o n n e c t o r .
Ge n e r a t o r ' B- F e y e l e t .
Po we r d i st r i but i o n bo x e y e l e t s .
Ba t t e r y c a b l e s .
A r e a l l connect i ons cl ean and t i ght ?
Ye s
No
G Ot o 02.
CLEAN or SERVI CE
c o n n e c t i o n s a s r e qui r e d .
C2 CHECK FOR FI ELD CI RCUI T DRAI N
Ye s U>
No ^
GO t o C3.
GO t o C5.
Turn i gni t i on s wi t c h t o OFF po s i t i o n .
Me a sur e v o l t a ge at t e s t poi nt *F' on t he v o l t a ge
r e gul a t or .
Is v o l t a g e at t e st poi nt ' F' equal t o bat t er y
v o l t a g e ?
Ye s U>
No ^
GO t o C3.
GO t o C5.
C3 CHECK FOR LOOSE 'A' CI RCUI T FUSE
Ye s
No
SERVI CE l o o se f use
c o n n e c t i o n .
GO t o C4.
Start e n gi n e .
Ch e c k t he ge n e r a t o r f use in the po we r d i st r i but i o n
bo x f o r a l o o se c o n n e c t i o n by wi ggl i n g t he f use wi t h
t h e e ngi ne r unni ng.
Do e s i ndi cat or l amp f l i c ke r ?
Ye s
No
SERVI CE l o o se f use
GO t o C4.
C4 CHECK 'A' CI RCUI T CONNECTI ONS
Ye s
No
r e gul a t or . If c o n c e r n st i l l
e x i s t s , REPLACE
ge n e r a t o r .
SERVI CE po o r
c o n n e c t i o n in Ci r c ui t 36
( Y/ W) .
Wi t h e ngi ne r unni ng, c o n n e c t t e s t po i n t 'A' on t he
v o l t a ge r e gul a t o r t o t he po si t i v e ( + ) ba t t e r y po s t
usi ng a j umpe r wi r e .
Does i ndi cat or lamp f l i c ke r ?
Ye s
No
r e gul a t or . If c o n c e r n st i l l
e x i s t s , REPLACE
ge n e r a t o r .
SERVI CE po o r
c o n n e c t i o n in Ci r c ui t 36
( Y/ W) .
05 CHECK BRUSH HOLDER SCREWS
Ye s
No
GO t o C6.
TI GHTEN s c r e ws t o
s pe c i f i c a t i o n . REFER t o
Se c t i o n 14-02.
Re mo v e ge n e r a t o r f r o m v e hi c l e .
Ch e c k t he br ush ho l d e r s c r e ws , l o c a t e d on t he
v o l t a ge r e gul a t o r ( t e st po i n t s ' F' and ' A' ) .
Are t he brush hol der scr ews t i ght ?
Ye s
No
GO t o C6.
TI GHTEN s c r e ws t o
s pe c i f i c a t i o n . REFER t o
Se c t i o n 14-02.
C6 CHECK FOR GROUNDED SLI P RI NG
Ye s t >
No
If gr e a s e or di r t ha s
a c c umul a t e d near t he sl i p
r i n gs, CLEAN t he sl i p
r i n gs a nd RECHECK
r e s i s t a n c e . If st i l l l e ss
t ha n 200 o hms, REPLACE
ge n e r a t o r .
r e gul a t or .
Re mo v e v o l t a ge r e gul a t o r .
Me a s ur e r e s i s t a n c e f r o m e a c h ge n e r a t o r sl i p r i ng t o
t he ge n e r a t o r ho usi n g.
Is resi st ance f r om ei t her s l i p ri ng t o housi ng less
t han 200 ohms?
Ye s t >
No
If gr e a s e or di r t ha s
r i n gs, CLEAN t he sl i p
r i n gs a nd RECHECK
r e s i s t a n c e . If st i l l l e ss
t ha n 200 o hms, REPLACE
ge n e r a t o r .
r e gul a t or .
1995 Town Car , Cr own Vi ct or i a, Gr and Mar qui s Jul y 1994
P I N P O I N T T E S T D: V O L T M E T E R R E A D S H I G H ( B A T T E R Y V O L T A G E G R E A T E R T H E N 15. 5V)
D 1 CHECK VOLTAGE DROP IN 'A' CI RCUI T
Ye s
No
GO t o D 2 .
SERVI CE e x c e s s v o l t a ge
d r o p in Ci r c ui t 36 ( Y/ W) .
CHECK f use a n d
c o n n e c t o r s in Ci r c ui t 36
a nd SERVI CE a s
r e qui r e d .
Turn i gn i t i o n s wi t c h t o ON po s i t i o n .
Me a s ur e v o l t a ge be t we e n t e s t poi nt 'A' on t h e
v o l t a ge r e gul a t o r a n d t he po s i t i v e ( + ) ba t t e r y p o s t .
is v o l t a g e d r o p l e s s t h a n 0 . 2 5 V?
Ye s
No
GO t o D 2 .
SERVI CE e x c e s s v o l t a ge
d r o p in Ci r c ui t 36 ( Y/ W) .
CHECK f use a n d
c o n n e c t o r s in Ci r c ui t 36
a nd SERVI CE a s
r e qui r e d .
D 2 CHECK VOLTAGE DROP IN 1' CI RCUI T
Ye s
No
G Ot o D3.
SERVI CE hi gh r e s i s t a n c e
in Ci r c ui t 904 ( L G / R) .
NOTE: Vo l t a ge r e gul a t o r must be c o n n e c t e d t o wi r i n g
ha r n e ss f o r t hi s t e s t .
Me a s ur e v o l t a ge at wi r i n g ha r n e s s T t e r mi n a l ,
Ci r c ui t 904 ( L G / R) .
I s v o l t a g e g r e a t e r t h a n 1 V ?
Ye s
No
G Ot o D3.
in Ci r c ui t 904 ( L G / R) .
D 3 CHECK FOR POOR GROUNDS
Ye s
No
GO t o D4.
CLEAN or SERVI CE
gr o un d s a s r e qui r e d .
Ch e c k f o r po o r gr o un d c o n n e c t i o n s b e t we e n v o l t a ge
r e gul a t o r a n d ge n e r a t o r , ge n e r a t o r a n d e n gi n e , or
e n gi n e a n d ba t t e r y .
A r e a l l g r o u n d c o n n e c t i o n s c l e a n a n d t i g h t ?
Ye s
No
GO t o D4.
CLEAN or SERVI CE
gr o un d s a s r e qui r e d .
D 4 CHECK FOR FI ELD CI RCUI T DRAI N
Ye s
No
Ge n e r a t o r i s OK.
r e gul a t or .
GO t o D 5 .
Turn i gn i t i o n s wi t c h t o OFF po s i t i o n .
Me a sur e v o l t a ge at t e s t poi nt ' F' on t he v o l t a ge
r e gul a t o r .
I s v o l t a g e a t t e s t p o i n t ' F' e q u a l t o b a t t e r y
v o l t a g e ?
Ye s
No
r e gul a t or .
GO t o D 5 .
D 5 CHECK FOR GROUNDED SLI P RI NG
Ye s
No
If gr e a se or di r t ha s
r i ngs, CLEAN t he sl i p
r i ngs a nd RECHECK
r e si st a n c e . If st i l l l e ss
t ha n 2 0 0 o h ms , REPLACE
ge n e r a t o r .
r e gul a t or .
Re mo v e ge n e r a t o r f r o m v e hi c l e .
Re mo v e v o l t a ge r e gul a t or .
Me a s ur e r e s i s t a n c e f r o m e a c h ge n e r a t o r sl i p r i ng t o
t he ge n e r a t o r ho usi n g.
I s r e s i s t a n c e f r o m e i t h e r s l i p r i n g t o h o u s i n g l e s s
t h a n 2 0 0 o h m s ?
Ye s
No
If gr e a se or di r t ha s
r i ngs, CLEAN t he sl i p
r i ngs a nd RECHECK
r e si st a n c e . If st i l l l e ss
t ha n 2 0 0 o h ms , REPLACE
ge n e r a t o r .
r e gul a t or .
PI NPOI NT T E ST E: GENERATOR WARNI NG L A MP DOE S NOT COME ON
E1 CHECK FOR OPEN T CI RCUI T
Ye s
No
G O t o E 2
904 ( L G / R) .
Re mo v e t hr e e - pi n v o l t a ge r e gul a t o r c o n n e c t o r .
Turn i gni t i on s wi t c h t o ON po s i t i o n .
Me a sur e v o l t a ge at wi r i n g ha r n e s s T t e r mi n a l ,
Ci r c ui t 904 ( L G / R) .
I s v o l t a g e g r e a t e r t h a n 0 V?
Ye s
No
G O t o E 2
904 ( L G / R) .
E 2 CHECK FOR BURNED OUT BULB
Ye s
No
t o E 3 .
REPLACE l a mp or
in l amp s o c ke t or Ci r c ui t
904 ( L G / R) .
Co n n e c t wi r i n g ha r n e ss T t e r mi n a l , Ci r c ui t 904
( L G / R) t o gr o un d wi t h a j umpe r wi r e .
Is i n d i c a t o r l a mp o n ?
Ye s
No
t o E 3 .
REPLACE l a mp or
in l amp s o c ke t or Ci r c ui t
904 ( L G / R) .
E 3 CHECK FOR POOR GROUNDS
Ye s
No
GO t o E 4.
CLEAN or SERVI CE
grounds a s required
Che c k f o r po o r gr ound c o n n e c t i o n s b e t we e n v o l t a ge
r e gul a t o r a nd ge n e r a t o r , ge n e r a t o r a n d e n gi n e , or
e ngi ne a n d ba t t e r y .
A r e a l l g r o u n d c o n n e c t i o n s c l e a n a n d t i g h t ?
Ye s
No
GO t o E 4.
CLEAN or SERVI CE
grounds a s required
14- 00- 14
Battery and Charging SystemService
14- 00- 14
PINPOINT TEST E: GENERATOR WARNING LAMP DOES NOT COME ON (Cont i nued)
E 4 CHECK ' S' CI RCUI T WI RI NG
Ye s
No
( W/ BK ) . Ci r cui t sho ul d
be "HOT" onl y whe n
e ngi ne i s r unni ng. CHECK
f o r s wa p p e d wi r e s in
v o l t a ge r e gul a t o r
c o n n e c t o r .
GO t o E5.
Re mo v e o n e - pi n ' S' c o n n e c t o r f r o m ge n e r a t o r .
Me a s ur e v o l t a ge at wi r i n g h a r n e s s ' S ' t e r mi n a l .
Ci r c ui t 4 ( W/ B K ) .
I s vol t age great er t han 0 V ?
Ye s
No
( W/ BK ) . Ci r cui t sho ul d
be "HOT" onl y whe n
e ngi ne i s r unni ng. CHECK
f o r s wa p p e d wi r e s in
v o l t a ge r e gul a t o r
c o n n e c t o r .
GO t o E5.
E5 CHECK FOR SHORTED RECTI FI ER
Ye s
No >
If l a mp i s on wi t h o n e - pi n
' S' c o n n e c t o r r e mo v e d ,
REPLACE ge n e r a t o r .
r e gul a t or .
Me a s ur e v o l t a ge at t h e ' S ' t e r mi n a l on t h e b a c k of
t he ge n e r a t o r .
I s vol t age great er t han 1 ?
Ye s
No >
If l a mp i s on wi t h o n e - pi n
' S' c o n n e c t o r r e mo v e d ,
r e gul a t or .
PINPOINT TEST F: NOISY GENERATOR
F1 CHECK FOR ACCESSORY DRI VE NOI SE
Ye s
No
G Ot o F2.
GO t o Se c t i o n 03- 05 a n d
SERVI CE a c c e s s o r y
d r i ve be l t a s r e qui r e d .
Ch e c k t he d r i v e be l t t o ma ke sur e t ha t i t i s i n st a l l e d
pr o pe r l y a nd i s not d a ma ge d . Re f e r t o Se c t i o n
03- 05.
Is dri ve bel t OK?
Ye s
No
G Ot o F2.
GO t o Se c t i o n 03- 05 a n d
SERVI CE a c c e s s o r y
d r i ve be l t a s r e qui r e d .
F2 CHECK GENERATOR MOUNTI NG
Ye s
No
GO t o F3.
I NSTALL ge n e r a t o r t o
s pe c i f i c a t i o n s . REFER t o
Se c t i o n 14-02.
Ch e c k t he ge n e r a t o r a n d ge n e r a t o r mount i ng
b r a c ke t f o r l o o s e bo l t s or mi sa l i gn me n t c o n d i t i o n .
Is gener at or mount ed c o r r e c t l y ?
Ye s
No
GO t o F3.
I NSTALL ge n e r a t o r t o
s pe c i f i c a t i o n s . REFER t o
Se c t i o n 14-02.
F3 CHECK GENERATOR PULLEY
Ye s
No
G O t o F4.
REPLACE ge n e r a t o r
pul l ey.
Ch e c k t he ge n e r a t o r pul l e y f o r d a ma ge ( be n t ) or a
mi sa l i gn me n t c o n d i t i o n .
Is pul l ey OK?
Ye s
No
G O t o F4.
REPLACE ge n e r a t o r
pul l ey.
F4 SUBSTI TUTE KNOWN GOOD GENERATOR
Ye s
No
I NSTALL or i gi na l
ge n e r a t o r . CHECK o t he r
a c c e s s o r i e s t o f i nd t he
c a use of t he n o i se .
Re mo v e ge n e r a t o r a nd r e pl a c e wi t h a kn o wn go o d
ge n e r a t o r .
Is noi se pr esent wi t h a kn o wn go o d gener at or ?
Ye s
No
I NSTALL or i gi na l
ge n e r a t o r . CHECK o t he r
a c c e s s o r i e s t o f i nd t he
c a use of t he n o i se .
PINPOINT TEST G: RADIO INTERFERENCE
G1 VERI FY RADI O I NTERFERENCE
Ye s
No
Ge n e r a t o r i s OK. REFER
t o Se c t i o n 15-00 t o f i nd
t he c a us e of t he r a d i o
i n t e r f e r e n c e .
GO t o G2.
St a r t e n gi n e .
Tune r a d i o t o a st a t i o n wh e r e i n t e r f e r e n c e i s
pr e se n t .
i s i nt er f er ence pr esent wi t h c o n n e c t o r r emoved?
Ye s
No
t he c a us e of t he r a d i o
GO t o G2.
G2 SUBSTI TUTE KNOWN GOOD GENERATOR
Ye s f >
No I "
t he c a use of t he r a d i o
Re mo v e ge n e r a t o r a nd r e pl a c e wi t h a kn o wn go o d
ge n e r a t o r .
Is i nt e r f e r e nc e pr esent wi t h kn o wn good
gener at or ?
Ye s f >
No I "
t he c a use of t he r a d i o
PINPOINT TEST H: GENERATOR WARNING LAMP STAYS ON, IGNITION SWITCH OFF
H1 CHECK L AMP CI RCUI T WI RI NG
Ye s
No
( L G / R) . Ci r c ui t sho ul d be
hot i n RUN po s i t i o n onl y .
SERVI CE i n st r ume n t
c l ust e r . REFER t o Se c t i o n
13-00.
Turn I gni t i on s wi t c h t o OFF po s i t i o n .
Me a s ur e v o l t a ge a t wi r i n g ha r n e ss ' I ' t e r mi n a l ,
Ci r c ui t 904 ( L G / R) .
Is vol t age gr eat er t han zero V?
Ye s
No
( L G / R) . Ci r c ui t sho ul d be
hot i n RUN po s i t i o n onl y .
SERVI CE i n st r ume n t
c l ust e r . REFER t o Se c t i o n
13-00.
B a t t e r y
NOTE: Whenever possi bl e, t est and charge bat t ery
( 10655) at or near room t emperat ure.
Read t he bat t ery open ci rcui t termi nal vol t age wi th a
digital vol tmeter such as Rotunda 73 Digital Mul ti meter
105- 00051 or equivalent, capabl e of readi ng 0. 01
vol t. If open circuit vol tage of bat t ery is bel ow 12.4
vol ts and t he bat t ery has passed t he capaci t y test,
charge t he bat t ery.
Ca p a c i t y T e s t i n g
1. Use a high rat e di scharge t est er wi t h a vari abl e
rat e control or a fused r at e tester wi t h meter
compensati on for di fferent bat t ery el ectri cal
si zes. Fol l ow i nstructi ons suppl i ed wi t h t est er f or
t he bat t ery capaci t y t est .
2. Di scharge rat es at 2 7 C ( 80F) shoul d equal
one-half of t he col d cranki ng amps as shown in
t he fol l owi ng.
C o l d Cr a n k i n g A mp s Di s c h a r g e Ra t e A mp s
650 3 2 5
540 2 7 0
3. Vol tage readi ngs at 15 seconds for good bat t ery
( 10653) (Bat t ery Capaci t y Test) are shown in t he
fol l owi ng tabl e:
A p p r o x i ma t e Ba t t e r y T e mp e r a t u r e
Mi n i mum
L o a d Vo l t a ge
2 7 C ( 8 0 F ) a n d a b o v e 9. 6
2 1 C ( 7 0 F ) 9. 6
1 6 C ( 6 0 F) 9. 5
1 0 C ( 5 0 F) 9. 4
4 C ( 4 0 F ) 9. 3
- 1 C ( 3 0 F) 9. 1
- 7 C ( 2 0 F) 8. 9
-12C(10F) 8. 7
-18C(0F) 8. 5
4. Wai t t wo minutes and measure Open Circuit
Vol tage (OCV) wi th a digital vol t met er capabl e of
readi ng 0. 01 vol t.
5. Charge bat t ery for 20 minutes at 35 amps.
6. Repeat t est st ep procedures.
A l t e r n a t e Te s t Me t h o d
Use Rotunda Power Sensor Plus El ectroni c Bat t ery
Tester 162- 00002. Fol l ow t he manufacturer' s defi ned
test procedure.
Dr a i n T e s t i n g
NOTE: A vol tmeter is someti mes used f or thi s t est but
it will react t o a very small normal drain caused by
" al ways- on" el ectroni c syst ems such as st art er
i nterl ock, anti-theft al arm, illuminated entry, et c, whi ch
cause no concern. The t est l amp shows only drai ns
whi ch are l arge enough t o cause a concern.
NOTE: For vehi cl es wi t h el ectroni c instrument cl uster
( 10849) or message center, when t he Message
Center is initially power ed up (after a bat t ery
di sconnect), t he Message Center " comput er " may be
energi zed f or as long as one minute causi ng a 0. 25
amp current dr aw before returning t o the normal
0. 010. 0. 012 amp current draw. Therefore, it is
i mportant t o allow at l east one minute t o pass (after
ammeter hookup) before observi ng any current
measurements.
Check for current drai ns on t he battery in excess of
100 milliamps wi t h all t he el ectri cal accessori es off
and t he vehi cl e at rest. Current drains can be t est ed
one of three ways:
1. Connect a 12-volt t est lamp in seri es wi th bat t ery
positive termi nal . If lamp gl ows, then a drain
exi sts.
2. Use an in-line ammeter between the bat t ery
positive or negative post and its respecti ve cabl e.
B a t t e r y a n d C h a r g i n g S y s t e m S e r v i c e
14- 00- 16
3. Use a clamp-on current probe to the battery
positive or negative cable. Make sure that the
probe is properly calibrated to prevent false
readings.
J 2 819- B
Typically, a drain of approximately one amp can be
attributed to an engine compartment lamp, glove
compartment lamp, or luggage compartment lamp
staying on continually. Other component failures or
wiring shorts may be located by selectively pulling
fuses or disconnecting fuse links to pinpoint the
location of the current drain. When the current drain is
found, the test lamp will go out or the meter reading will
fall to an acceptable level. If the short is still not
located, after checking all the fuses and fuse links, the
drain may be due to the generator
(GENX10346)/ voltage regulator (VR)( 10316).
Disconnect the generator output wire from the output
stud and the generator regulator connector. If this
eliminates the drain, check the charging system to
locate the concern.
W i t h Clamp O n D C Ammeter Test Procedure .
1. Turn the ignition switch (11572) to the OFF
position and make sure there are no electrical
loads. After determining that the engine
compartment lamp is turning off properly,
disconnect the Samp.
2. NOTE: Do not start vehicle with clip on cable.
Clamp the meter clip securely around positive or
negative battery cable (all cables if two or more
lead to post).
Test Co n c l u s i o n
The current reading (current drain) should be less than
0.05 amp. If it exceeds 0.05 it indicates a constant
current drain which could cause a discharged battery.
Possible sources of current drain are vehicle lamps
(engine compartment, glove compartment, luggage
compartment, etc.) that do not shut off properly.
If the drain is not caused by a vehicle lamp, remove
fuses from the fuse panel, one at a time, until the cause
of the drain is located. If drain is still undetermined,
remove fusible links one at a time at the power
distribution box contained within the headlamp dash
panel junction wire (14290) to find the problem circuit.
Wi t h Vo l t me t e r T e s t P r o c e d u r e
This test requires a digital volt-ohmmeter with an
appropriate low voltage scale such as Rotunda 73
Digital Multimeter 105-00051 or equivalent. The meter
must read within 0.01 millivolt. Also required is a shunt
assembly similar to that shown in the illustration.
T e s t P r o c e d u r e
1. Turn ignition switch to the OFF position and make
sure there are no electrical loads. After
determining the engine compartment lamp is
turning off properly, disconnect the lamp.
2. Check battery voltage. If voltage is under 11.5
volts, charge the battery to above 11.5 volts.
3. NOTE: When the battery is disconnected and
reconnected, some abnormal drive symptoms
may occur while the powertrain control module
(PCM)(12A650) relearns its adaptive strategy.
The vehicle may need to be driven 10 miles or
more to relearn the strategy.
Disconnect battery ground cable (14301).
4. CAUTION: Do n o t c r a n k t he e n gi n e , i t c o u l d
d e s t r o y t h e s h u n t . A l s o do n o t u s e t h e s h u n t
to measure s t a r t i n g c u r r e n t s .
Connect shunt assembly as shown.
5. Set volt-ohmmeter to 200 or 300 mv scale for an
accurate reading (must be within 0.01 millivolt).
6. Connect meter leads to shunt as shown. With this
size shunt (50 mv = 50 amps) and meter, a direct
current drain measurement can be made.
Pa r t
1 Ne ga t i v e Ba t t e r y Ter mi nal
(Pa r t of 10653)
2 14301 Ba t t e r y Gr ound Ca bl e
( Co n t i n ue d )
14- 00- 18 l a t t e r y a n d Ch a r g i n g S y s t e mS e r v i c e 14- 00- 18
4. Wi t h t he engi ne running at 2 000 r pm, adj ust t he
Rot unda Al t ernat or, Regul at or, Bat t er y and
St art er Test er (ARBST) 010- 007 2 5 or equi val ent
l oad bank t o det ermi ne t he out put of t he
gener at or . Generat or out put shoul d be gr eat er
t han t he gr a ph shown bel ow. If not , ref er t o t he
Sy mpt o m Chart f or di agnost i c pr ocedur es.
100
80
6 0
9 5 A MP G E NE RA T OR
A MP S
4 0
2 0
76 AMPS
MIN 2000
RPM
/
AMPS
100
5 0 0 1000 1S00 2 0 0 0 2500
ENGI NE SP E E D
J4621-A
130 AMP GENERATOR
80
40
20
87 AMPS MIN
2000 RPM
0 500 1000 1500 2000 2500
ENGI NE SPEED J4617-A
N o - L o a d T e s t
1. Swi t c h t he Rot unda Al t ernat or, Regulat or,
Bat t er y and St art er Test er (ARBST) 010- 007 25
or equi valent t o t he vol t met er f unct i on.
2. Connect t he vol t met er posi t i ve l ead t o t he
generat or B+ t ermi nal and t he negat i ve l ead t o
ground.
3. Turn all el ect ri cal accessor i es OFF.
4. Wi t h t he engi ne running at 2 000 r pm, c he c k t he
generat or out put vol t age. The vol t age shoul d be
bet ween 13. 0 and 15.0 vol t s. If not , ref er t o t he
Sy mpt om Chart f or di agnost i c pr ocedur es.
G e n e r a t o r B e n c h T e s t s
NOTE: The i nt egral rear mount r egul at or i nt er nal f an
t y pe generat or (GEN)( 10300) is ser vi ced a s an
assembl y only.
Repl ace generat or as requi red af t er perf ormi ng
Generat or On-Vehi cle Test s. Ref er t o Sect i on 14-02
f or Removal and Installati on pr ocedur es.
ADJUSTMENTS
Drive Belt, Accessory
Ref er t o Sect i on 03- 05 f or dri ve belt t ensi oni ng
pr ocedur e.
ROTUNDA EQUI PMENT
010- 007 2 5 Al t e r n a t o r , Re gul a t o r , Ba t t e r y a n d
St a r t e r Te s t e r ( ARBST)
105- 00051 7 3 Di gi t a l Mul t i me t e r
162 - 00002 P o we r Se n s o r Pl us E l e c t r o n i c Ba t t e r y
Te st e r
14- 01- 1 Ba t t e r y 14- 01- 1
SECTION 14-01 Battery
SUBJECT PAGE
VE HI CL E APPLICATION . 14-01-1
Bat t er y . 14-01-1
Bat t er y. 14-01-1
Bat t er y 14-01-2
Bat t ery Tray 14-01-3
Envi r onment al Prot ect i on 14-01-1
SUBJECT PAGE
SERVICE PROCEDURES
Bat t ery Chargi ng 14-01-4
Jump St ar t i ng 14-01-5
Bat t ery Cl eani ng. 14-01-5
To o l s. . . . 14-01-5
Wat er Addi t i on 14-01-6
VEHICLE APPLICATION
Town Car, Cr own Vi ct ori a, Grand Mar qui s
B a t t e r y
Vehi cl es a r e equi pped wi t h a hi gh c ol d c r a nki ng
a mpe r a ge , 12 vol t , di rect current (DC) ba t t e r y
( 10653) .
B a t t e r y
E n v i r o n m e n t a l P r o t e c t i o n
For d Mot or Company st rongl y r e c omme nds t ha t
l ead-aci d bat t er i es ( 10653) be ret urned t o an
aut hori zed r ecycl i ng f aci l i t y f or di sposal .
1 ^
L E
J4961-A
14- 01- 2 Ba t t e r y 14- 01- 2
B a t t e r y
WARNI NG: BATTERI ES ( 10653) NORMALLY
PRODUCE EXPLOSI VE GASES WHI CH CA N
CAUSE PERSONAL INJURY. THEREFORE, DO NOT
A L L OW FL AMES, SPARKS OR LI GHTED
WHE N CHARGI NG OR WORKI NG NEAR A
BATTERY, AL WAYS SHI ELD YOUR FACE AND
PROTECT YOUR EYES. AL WAYS PROVI DE
VENTI LATI ON.
R e mo v a l
1. Remove ba t t e r y cabl es f r om ba t t e r y t ermi nal s
(ba t t e r y gr ound cabl e ( 14301) f i r st ).
J4392-D
Pa r t
1 10653 Ba t t e r y
2 14300 Po si t i v e Ba t t e r y Ca bl e
3 14301 Ba t t e r y Gr o un d Ca bl e
4

To Po we r Di st r i but i o n Bo x
( Pa r t of 14300)
5 16005 RH Fr ont Fe n d e r
2. Cl ean ba t t e r y cabl e t ermi nal s usi ng an a c i d
neut rali zi ng sol ut i on and t ermi nal cl eani ng br ush.
J2847-B
3. Remove bat t er y hol d down cl amps ( 107 18) .
Pa r t
1 N62 3333- S2 U-Nut
2 N606690- S2 Bol t (1 Req'd)
3 N80152 1- S2 Nu t ( 1 Re q' d )
4 10718 Ba t t e r y Hol d Down Cl a mp
5 10756 Ba t t e r y Mo un t i n g Cl a mp Bo l t
6 10653 Ba t t e r y
A

Ti ght e n t o 7-10 N-m ( 62 - 88
Lb-l n)
B

Ti ght e n t o 3-5 N-m ( 2 7 - 44
Lb-l n)
14- 01- 3 Ba t t e r y 14- 01- 3
4. WARNI NG: BATTERI ES NORMALLY PRODUCE
EXPLOSI VE GASES WHI CH CA N CAUSE
PERSONAL INJURY. THEREFORE, DO MOT
A L L OW FL AME S, SPARKS OR LI GHTED
SUBSTANCES TO COME NEAR THE
BATTERY. WHEN CHARGI NG OR WORKI NG
NEAR A BATTERY, A L WA YS SHI ELD YOUR
FACE AND PROTECT YOUR EYES. AL WAYS
PROVI DE VENTI LATI ON.
WHE N LI FTI NG A PL ASTI C- CASED BATTERY,
EXCESSI VE PRESSURE ON THE END WA L L S
COUL D CAUSE ACI D TO SPEW THROUGH
THE VENT CAP S, RESULTI NG IN PERSONAL
I NJURY. LI FT WI TH A BATTERY CARRI ER OR
WI TH YOUR HANDS ON OPPOSI TE
CORNERS.
Remove bat t er y f r om vehi cl e.
1. Clean cabl e t ermi nal s a nd ba t t e r y hol d down
c l a mp wi t h a wi r e br ush. Repl ace all cabl es or
pa r t s t hat are wor n or f r a y e d .
2. Cl ean ba t t e r y t r a y ( 107 32 ) wi t h a wi r e br ush and
scr aper .
3. Pl ace ba t t e r y in ba t t e r y t r a y wi t h posi t i ve and
negat i ve t ermi nal s in sa me posi t i on a s previ ous
ba t t e r y . Assembl e and t i ght en hol d-down
ha r d wa r e so bat t er y is secur e. Do not
over -t i ght en.
4. NOTE: When t he ba t t e r y is di sc onne c t e d and
r e c onne c t e d, some abnor mal dri vi ng sy mpt o ms
may oc c ur whi l e t he power t r ai n cont r ol modul e
( PCM) ( 12A650) rel earns i t s adapt i ve st r a t e gy .
The vehi cl e may need t o be dri ven 10 mi l es or
mor e t o rel earn t he st r a t e gy .
Secur e cabl es (posi t i ve f i r st ) t o pr ope r t ermi nal s.
Ti ght en ba t t e r y t ermi nal bo l t s/ n ut s t o 7-10 Nm
( 62- 88 Ib-i n). Do not over -t i ght en. Appl y
pet r ol eum j elly t o t ermi nal s.
B a t t e r y T r a y
Re mo v a l
1. Remove ba t t e r y ( 10653) f r om vehi cl e as out l i ned.
2. Remove ret ai ni ng bol t s, sc r e ws and wa she r s
f r om ba t t e r y t r a y ( 107 32) .
3. Remove ba t t e r y t r ay f r om vehi cl e.
1. Posi t i on ba t t e r y t r a y t o f ront f ender apr on
( 16055) in engi ne compar t ment .
2. Install ret ai ni ng bol t s and wa she r s. Ti ght en e a c h
t o 8-12 N-m (6-8 Ib-f t ).
3. Install ba t t e r y in engi ne compar t ment a s out l i ned.
4. Ti ght en hol d-down br a c ke t bolt t o 7-10 N-m
(62-88 Ib-in) and nut t o 3-5 N-m (27-44 Ib-in).
14- 01- 4 14- 01- 4
SERVICE PROCEDURES
ALLOW FLAMES, SPARKS OR LI GHTED
VENTI LATI ON.
WI TH YOUR HANDS ON OPPOSI TE CORNERS.
BATTERI ES CONTAI N SULFURI C ACI D. AVOI D
CONTACT WI TH SKI N, EYES OR CLOTHI NG.
ALSO. SHI ELD YOUR EYES WHEN WORKI NG
NEAR THE BATTERY TO PROTECT AGAI NST
POSSI BLE SPLASHI NG OF THE ACI D SOLUTI ON.
IN CASE OF ACI D CONTACT WI TH SKI N OR EYES,
FLUSH IMMEDIATELY WI TH WATER FOR A
MI NI MUM OF 15 MI NUTES AND GET PROMPT
MEDI CAL ATTENTI ON. IF ACI D IS SWALLOWED,
CALL A PHYSI CI AN IMMEDIATELY.
B a t t e r y C h a r g i n g
Bef or e r echar gi ng a di sc ha r ge d ba t t e r y ( 10653) ,
i nspect and ser vi ce t he f ol l owi ng condi t i ons, if t he y
exi st :
1. Loose gener at or dri ve belt ( 8620) .
2. Pi nched or grounded gener at or / vol t age regul at or
wi ri ng har ness.
3. Loose har ness connect i ons at t he gener at or
(GEN)( 10346) a n d / o r vol t age regul at or.
4. Loose or c o r r o d e d connect i ons at ba t t e r y and / o r
engi ne gr ound.
5. Excessi ve bat t er y drai n due t o:
a. Engine compar t ment , l uggage c ompa r t me nt ,
gl ove compar t ment and c our t e sy l amps
remai ni ng energi zed (damaged or
mi sadj ust ed swi t c h, gl ove compar t ment left
open, e t c ) .
b. Luggage compar t ment sol enoi d cont i nuousl y
energi zed on vehi cl es equi pped wi t h
el ect roni c door l ock cont r ol sy st e m.
c. I noperat i ve aut ol amp modul e causi ng
appr oxi mat el y 2 a mp drai n wi t h i gni ti on
swi t c h ( 1157 2 ) in t he OFF posi t i on and
aut ol amp of f .
Mai nt enanc e- Fr ee Bat t er i es
NOTE: Lo w mai nt enance bat t er i es ar e c ha r ge d in t he
sa me manner.
WARNI NG: WEAR SAFETY GLASSES. BATTERY
CHARGI NG CAN BE DANGEROUS. WHI LE BEI NG
CHARGED, THE BATTERY PRODUCES A
POTENTI ALLY EXPLOSI VE MI XTURE OF
HYDROGEN AND OXYGEN GASSES. KEEP
SPARKS, FLAMES AND LI GHTED CI GARETTES
AWAY FROM BATTERI ES. REMEMBER, IN CASE
OF ACI D CONTACT WI TH SKI N, EYES OR
CLOTHI NG, FLUSH IMMEDIATELY WI TH LARGE
AMOUNTS OF WATER. GET MEDI CAL
ATTENTI ON.
Col d bat t er i es wi ll not readi l y a c c e pt a c ha r ge .
Ther ef or e, bat t er i es shoul d be al l owed t o wa r m up t o
appr oxi mat el y 5 C ( 4 1 F) bef or e char gi ng. Thi s may
requi re f our t o ei ght hours at r oom t emper at ur e
dependi ng on t he initial t emper at ur e and ba t t e r y si ze.
A ba t t e r y whi c h has been compl et el y di schar ged may
be sl ow t o a c c e pt a c ha r ge initially, and in some c a se s
may not a c c e pt a c ha r ge at t he normal char ger
set t i ng. When bat t er i es ar e in t hi s condi t i on, chargi ng
can be st a r t e d by use of t he de a d ba t t e r y swi t c h on
c ha r ge r s so equi pped.
To det ermi ne whet her a ba t t e r y is accept i ng a c ha r ge ,
f ol l ow char ger manuf act urer' s i nst ruct i ons f or use of
de a d ba t t e r y swi t c h. If swi t c h is t he spri ng-l oaded
t y pe , it shoul d be hel d in t he ON posi t i on f or up t o t hr ee
mi nut es.
Af t er rel easi ng swi t c h and wi t h char ger sti ll on,
measure bat t er y vol t age. If it sho ws 12 vol t s or hi gher,
t he bat t er y is accept i ng a c ha r ge and is capabl e of
bei ng r e c ha r ge d. However, it may requi re up t o t wo
hours of char gi ng wi t h bat t er i es col der t han 5 C
( 41 F) bef ore t he c ha r ge rat e i s hi gh enough t o show
on t he char ger ammet er. It has been f ound t hat all
non-damaged bat t eri es can be c ha r ge d by t hi s
pr ocedur e. If a bat t er y cannot be c ha r ge d by t hi s
pr ocedur e, it shoul d be r epl aced.
A rapi d r echar ge pr ocedur e has been devel oped f or
rechargi ng bat t eri es t hat have pa sse d t he Lo a d Test
and onl y need a r echar ge. Thi s can be due t o:
i n-servi ce no-st art bat t er y f ai l ures (vehi cl e wi ll not
cr ank due t o l ow bat t er y st a t e of c ha r ge ), or bat t er y
di schar ged in vehi cl e due t o key-of f l oads. Ref er t o
Lo a d Test pr ocedur e in Sect i on 14-00.
NOTE: If excessi ve gassi ng or el ect r ol y t e spewi ng
o c c ur s duri ng t he char ge, di scont i nue char gi ng. The
ba t t e r y has r eached servi ceabl e c ha r ge . If t he bat t er y
wi ll not a c c e pt at l east 5A af t er 20 mi nut es of
char gi ng, repl ace t he bat t er y.
The bat t er y can be rapi dl y r e c ha r ge d by usi ng ei t her
of t he f ol l owi ng met hods:
Perf orm a 2-hour char ge usi ng 20A const ant current
(manual set t i ng on char ger ).
Perf orm a 2-hour c ha r ge usi ng a const ant pot ent i al
(aut omat i c set t i ng on c ha r ge r ).
14- 01- 5 Ba t t e r y 14- 01- 5
If t he ba t t e r y has f ai l ed, or is l ow in c ha r ge , it may be
necessar y t o ref er t o Di agnosi s and Test i ng, Sect i on
14-00.
Jump Starting
Battery Cleaning
Keepi ng t he ba t t e r y t o p cl ean and dry r e duc e s t he
need f or ser vi ce and ext ends bat t er y l i f e. Al so, make
cert ai n t he cabl e c l a mps ar e t i ght l y f a st e ne d t o t he
bat t er y po st s. If cor r osi on is f ound, di sconnect t he
cabl es and cl ean c l a mps and post s wi t h a wi r e br ush.
Neut ral i ze t he c or r osi on wi t h a sol ut i on of baki ng so d a
and wat er. Af t er i nstalli ng cabl es, appl y a smal l
quant i t y of Premi um Long-Li f e Gr ease XG-1-C or -K or
equi val ent meet i ng Fo r d speci f i cat i on ESA-M1C75-B
t o e a c h ba t t e r y post t o help prevent c or r osi on.
J 2 8 4 7 - B
Tools
Any one wor ki ng wi t h a ba t t e r y ( 10653) needs t he
pr oper t ool s. Usi ng t he ri ght t ool s wi ll prevent damage
t o t he ba t t e r y , ba t t e r y cabl es and bat t er y hol d down
cl amp ( 107 18) .
Tool s and equi pment manuf act ur ed f or servi ci ng
bat t er i es have pa r t s i nsul at ed t o help prevent ar ci ng
shoul d t he t ool be d r o ppe d or pl aced acci dent al l y
be t we e n a t ermi nal a nd so me ot her c ont a c t sur f a c e .
Fi l l i n g De v i c e s
For ba t t e r i e s wi t h r emovabl e vent c a ps, one of t he
most i mport ant on-vehi cl e se r vi c e s is t o mai nt ai n t he
c o r r e c t el ect r ol y t e l evel . Two devi ces are avai l abl e f or
t hi s pur pose : a sel f -l evel i ng fi ller whi c h al l ows t he
ba t t e r y t o be f i lled t o a pr edet er mi ned level
aut omat i cal l y, and a sy r i nge -t y pe filler.
J 2 8 4 9 - B
Pliers
Bat t er y pl i ers have j a ws speci f i cal l y desi gned f or
gri ppi ng cabl e cl amp bol t s securel y. Care shoul d be
t aken whe n removi ng or repl aci ng t he cabl e cl amp
bol t s so t hat t he bat t er y t ermi nal is not subj ect ed t o
any e xc e ssi ve l at eral or t wi st i ng f o r c e s. Such f o r c e s
coul d cause maj or damage t o t he i nternal component s
of t he ba t t e r y , and l eakage at t he t ermi nal s.
BATTERY
CLAMP PULLER
J2850-1
14- 01- 6 Ba t t e r y 14- 01- 6
C l a mp P ul l e r
Use a cl amp puller t o r emove a cabl e cl amp f r om t he
ba t t e r y t ermi nal . Wi t h t he j a ws gri ppi ng t he undersi de
of t he cabl e cl amp, pull t he cl amp up by means of
pr essur e e xe r t e d agai nst t he t o p of t he ba t t e r y
t ermi nal . Pr oper use of t hi s t ool avoi ds t he damagi ng
l at eral or t wi st i ng f o r c e s t hat resul t when usi ng a pry
bar or pl i ers.
C l a m p S p r e a d e r
The spr e a de r is used t o e xpa nd t he cabl e cl amp af t er
it has been r emoved f r om t he t ermi nal and t he cl amp
bol t has been l oosened. The cabl e cl amp can t hen be
easi l y pl aced in i t s c or r e c t posi t i on compl et el y on t he
t ermi nal .
T e r mi n a l C l e a n i n g Br u s h
The t ermi nal cl eani ng brush is desi gned wi t h uni ts t o
cl ean bot h t he t a pe r e d ba t t e r y t ermi nal and t he mat i ng
sur f ace of t he cabl e cl amp. Ref er t o i l l ust rat i on under
Ba t t e r y Inst al l at i on, St ep 1.
Ca r r i e r
A L L OW FL AME S, SPARKS OR LI GHTED
VENTI LATI ON.
WA L L S COULD CAUSE ACI D TO SPEW THROUGH
THE VENT CAP S, RESULTI NG IN PERSONAL
Use a sui t abl e bat t er y carri er f or lifting and
t r anspor t i ng t he ba t t e r y . The i llust rat i on sho ws a
cl amp-t y pe carri er used t o gri p t he si dewal l s of t he
cont ai ner j ust bel ow t he lip of t he cover. The carri er is
used on t he si dewal l s, rat her t han t he endwal l s, si nce
t he si dewal l s have addi t i onal st r engt h f r om t he inner
cel l part i t i ons. Thi s is part i cul arl y i mport ant wi t h t he
pl ast i c-cased bat t er y whi ch has endwal l s t hat ar e
f l exi bl e.
BATTERY
CARRIER
J 2 9 2 8 - B
Wa t e r A d d i t i o n
Some bat t er i es ( 10653) have removabl e vent c a ps
and may occasi onal l y requi re t he addi t i on of wat er . If
t he el ect r ol yt e level is bel ow t he level i ndi cat or in any
cel l , a dd enough pure wat er t o bri ng t he level up t o t he
i ndi cat or. In bat t eri es wi t hout a level i ndi cat or, mai ntai n
el ect r ol y t e level at 6. 3 t o 12. 7mm (1 / 4 t o 1/ 2 i nch)
a bove t he pl at es. Never a dd el ect r ol yt e ("ba t t e r y
a c i d ") t o t he bat t er y. Thi s coul d short en t he life of t he
ba t t e r y .
Ba t t e r y 14- 01- 7
SPECIFICATIONS
BATTE RY SP E CI FI CATI ONS
De sc r i pt i on 4 . 6 L S F I
Ma n u f a c t u r e r Mo t o r c r a f t
Mo d e l ( s t d . , o p t . ) St a n d a r d
Vo l t a ge 12 Vo l t
A mp s a t - 1 7 . 7 C ( 0 F ) c o l d
c r a n k
650
Mi n u t e s - r e s e r v e c a p a c i t y 130
A mp s / hr s . - 2 0 hr. r a t e 7 2
L o c a t i o n Ri gh t Fr o n t o f En gi n e
Co mp a r t me n t
TORQUE SP E CI FI CATI ONS
De s c r i p t i o n N- m L b - l n
Ba t t e r y Te r mi n a l B o l t s / N u t s 7 - 10 62 - 88
Ho l d - Do wn Br a c k e t Bo l t 7 - 10 6 2 8 8
Ho l d - Do wn Br a c k e t Nut 3- 5 2 7 - 44
Ba t t e r y Tr a y Re t a i n i n g Bo l t s 8- 12 6- 8 ( L b - Ft )
14- 02 - 1 Ge n e r a t o r , I n t e gr a l Rear Mo u n t Re g u l a t o r I n t e r n a l Fan T y p e 14- 02 - 1
SECTION 14-02 Generator, Integral Rear Mount
RegulatorInternal Fan Type
SUBJECT PAGE
VEHI CLE APPLICATION ....14-02-1
Chargi ng Syst em 14-02-1
Generator 14-02-1
Generator Ci rcui t ....14-02-2
Voltage Regulator ..... 14-02-1
Generator and Regulator 14-02-2
Generator .14-02-2
SUBJ E CT PAGE
Vol t age Regul at or 14-02-3
Vol t age Regul at or 14-02-4
Generat or 14-02-4
ADJUSTMENTS
Generat or Dri ve Bel t . . . . 14-02-4
VEHICLE APPLICATION
Generat or (GEN)( 10346) / Vol t age regul at or.
Generat or warni ng l amp.
Assoc i a t e d wi ri ng.
Ref er t o t he El ect ri cal and Vacuum Troubl eshoot i ng
Manual f or wi ri ng schemat i cs and l ocat i ons of
component s.
G e n e r a t o r
The gener at or (GEN)( 10346):
Suppl i es current t o t he vehi cl e' s el ect ri cal sy st e m
Char ges t he ba t t e r y ( 10653) .
Wi t h t he i gni ti on swi t c h ( 1157 2) in t he RUN posi t i on:
Vol t age is suppl i ed t hr ough t he " I " ci rcui t t o t he
vol t age regul at or.
The generat or warni ng l amp t urns on (l amp
prove-out ).
The vol t age regul at or t urns on, al l owi ng current t o
f l ow t hr ough t he " A " ci rcui t t o t he gener at or f i el d
coi l .
Vo l t a g e R e g u l a t o r
The vol t age regul at or:
Adj ust s t he gener at or f i el d current t o i ncrease or
de c r e a se gener at or out put current .
Set s t he gener at or out put vol t age.
C h a r g i n g S y s t e m
The el ect ri cal char gi ng sy st e m is a negat i ve ground
sy st e m consi st i ng of:
Wi t h t he engi ne runni ng:
The generat or pr oduces al t ernat i ng current (AC),
whi c h is changed t o di r ect current (DC) by t he
rect i f i er di odes.
Current is suppl i ed t o t he vehi cl e t hr ough t he
generat or B + t ermi nal (st ud).
The generat or warni ng l amp t urns of f .
Generat or out put is cont rol l ed by t he vol t age
regul at or.
Turns t he generat or warni ng lamp on when a
probl em is det ect ed in t he chargi ng sy st e m or
a ssoc i a t e d wi ri ng.
The generat or out put vol t age wi ll var y wi t h
t emper at ur e. The out put vol t age is t ypi cal l y hi gher in
t he wi nt er (col d) and l ower in t he summer (hot ).
The vol t age regul at or wi ll t urn t he generat or warni ng
l amp on f or t he f ol l owi ng condi t i ons:
14- 02 - 2 Gener at or , I nt egr al Rear Mount Re g u l a t o r I n f e r n a l Fan T y p e 14- 02 - 2
Ignition swi t c h ( 1157 2) in t he RUN posi t i on wi t h t he
engi ne not runni ng. Thi s is t he l amp prove-out (does
not i ndi cat e a probl em wi t h t he char gi ng sy st e m) .
Open in t he " A " ci orcui t or " S " ci rcui t .
I noperat i ve generat or (GEN)( 10346).
Generat or out put vol t age t o o hi gh.
Ref er t o Sect i on 14-00 f or di agnost i c pr ocedur es if t he
generat or war ni ng l amp st a y s on wi t h engi ne runni ng.
GENERATOR PULLEY
10344
A
S B+
S '
VOLTAGE
REGULATOR
10316
GENERATOR
10346
J4619-B
G e n e r a t o r C i r c u i t
Ci r c u i t De s c r i p t i o n
Ba t t e r y P o s i t i v e Vo l t a ge ( B+ ) Ou t p u t
The B + ci rcui t (Ci rcui t 38):
Suppl i es t he generat or out put current t o t he power
di st ri but i on bo x.
Is a l wa y s hot .
6
T ( I gni t i on) Ci r cui t
The " I " ci rcui t (Ci rcui t 904) :
Turns t he vol t age regul at or on when t he i gni ti on
swi t c h ( 1157 2 ) i s in t he RUN posi t i on.
Turns t he gener at or warni ng l amp on if t her e is a
probl em in t he chargi ng sy st e m or a ssoc i a t e d
wi ri ng.
" A " ( Ba t t e r y Se n se ) Ci r c u i t
The " A" ci rcui t (Ci rcui t 36):
Is used by t he vol t age regul at or t o sense ba t t e r y
vol t age.
Suppl i es cur r ent t o t he gener at or f i el d coi l .
Is a l wa y s hot .
Is pr o t e c t e d by a f use in t he power di st ri but i on box.
" S " ( St a t o r ) Ci r c u i t
The " S " ci rcui t (Ci rcui t 4):
Is used by t he vol t age regul at or t o sense t he
gener at or ( st a t o r ) out put .
Vol t age is t y pi cal l y one-half of ba t t e r y vol t age when
t he gener at or (GEN)( 10346) i s ope r a t i ng.
The gener at or warni ng l amp wi ll t urn on if t he " S "
ci rcui t vol t age is zer o. The warni ng l amp wi l l t urn off if
t he " S " ci rcui t vol t age is gr eat er t han 5 vol t s.
NOTE: If t he " S " ci rcui t is open or di sc onne c t e d, t he
gener at or warni ng l amp wi ll t urn on, even if t he
gener at or is oper at i ng normal l y.
G e n e r a t o r a n d R e g u l a t o r
Ref er t o Sect i on 14-00 f or Di agnosi s and Test i ng
pr ocedur es of t he i nt egral rear mount
r e gul a t or i nt e r na l f an t y pe gener at or (GEN)( 10346).
WARNI NG: BATTERI ES ( 10653) NORMALLY
PRODUCE EXPLOSI VE GASES WHI CH CAN
CAUSE PERSONAL INJURY. DO NOT ALLOW
FLAMES, SPARKS OR LI GHTED TOBACCO TO
COME NEAR THE BATTERY. WHEN CHARGI NG
OR WORKI NG NEAR A BATTERY, ALWAYS SHI ELD
YOUR FACE AND PROTECT YOUR EYES. ALWAYS
PROVIDE VENTI LATI ON.
WARNI NG: WHEN LI FTI NG A PLASTI C- CASED,
INJURY. LI FT WI TH A BATTERY CARRIER OR
WARNI NG: KEEP BATTERI ES OUT OF REACH OF
CHI LDREN. BATTERI ES, CONTAI N SULFURI C
ACI D. AVOI D CONTACT WI TH SKI N, EYES OR
CLOTHI NG. ALSO, SHI ELD YOUR EYES WHEN
WORKI NG NEAR THE BATTERY TO PROTECT
AGAI NST POSSI BLE SPLASHI NG OF THE ACI D
SOLUTI ON. IN CASE OF ACI D CONTACT WI TH
THE SKI N, EYES OR CLOTHI NG, FLUSH
IMMEDIATELY WI TH WATER FOR A MI NI MUM OF
15 MI NUTES. IF ACI D IS SWALLOWED, DRINK
LARGE QUANTI TI ES OF MI LK OR WATER,
FOLLOWED BY MI LK OF MAGNESI A, A BEATEN
EGG OR VEGETABLE OI L. CALL A PHYSI CI AN
IMMEDIATELY.
G e n e r a t o r
Re mo v a l
14- 02 - 3 Ge n e r a t o r , I n t e gr a l Re a r Mo u n t Re g u l a t o r I n t e r n a l Fa n T y p e 14- 02 - 3
4.
5.
Di sconnect t he wi r e harness at t achment s t o t he
generat or (GEN)( 10346) and vol t age regul at or.
Di sengage t he generat or dri ve belt ( 8620) f r om
t he generat or pulley ( 10344) . Ref er t o Sect i on
03- 05.
Remove ret ai ni ng bol t s and generat or mount i ng
br a c ke t ( 10153) .
Remove t he mount i ng bol t s and t he generat or.
Installation
1. Posi t i on t he generat or on t he engi ne.
2. Install t he generat or mount i ng bol t s. Ti ght en bol t s
t o 20- 30 N-m (15-22 I b-f t ).
3. Install generat or mount i ng br a c ke t and ret ai ni ng
bol t s. Ti ght en bol t s t o 8-12 N-m (70-106 Ib-in).
4. Install t he dri ve belt over t he generat or pulley.
5. Connect t he vol t age regul at or wi ri ng and out put
wi r e t o t he ge n e r a t o r / vo l t a ge regul at or. Ti ght en
out put t ermi nal nut t o 9-11 Nm (80-97 Ib-in).
Ge n e r a t o r Asse mbl y
FRONT OF ENGINE
J4477-A
Pa r t
1 N60667 6- S36 Ge n e r a t o r Mo un t i n g Br a c ke t
Bo l t ( 3 Re q' d )
2 10153 Ge n e r a t o r Mo un t i n g Br a c ke t
Pa r t
3 N8062 00- S2 Ge n e r a t o r Mo un t i n g Bo l t (2
Re q' d )
4 10346 Ge n e r a t o r
5 6010 Cy l i nde r Bl o c k
6 942 4 I nt a ke Ma n i f o l d
A Ti ght e n t o 8-12 N-m ( 7 0- 106
Lb- l n )
B
Ti ght e n t o 2 0- 30 N-m ( 15- 22
Lb- Ft )
Volt age Regulator
Removal
Remove t he f our sc r e ws ( T20 TORX-t ype head),
at t achi ng t he vol t age regul at or t o t he generat or
(GEN)(10346). Remove t he vol t age regul at or, wi t h
gener at or brush and t ermi nal hol der ( 10320)
a t t a c he d , f r om t he generat or.
Installation
At t a c h t he vol t age regul at or and generat or brush and
t ermi nal hol der t o t he generat or wi t h at t achi ng
sc r e ws. Ti ght en t o 2. 3-3. 4 N*m (20-30 Ib-in).
GENERATOR
10346
VOLTAGE REGULATOR 10316
AND GENERATOR BRUSH AND
TERMI NAL HOLDER 10320
SCREW
4 REQ'D
TI GHTEN TO
2.3-3.4 N-m
(20-30 LB-IN)
J4620-B
14- 02 - 4
irssEw
Ge n e r a t o r , I n t e gr a l Rear Mo u n t Re gu l a t o r -
T .J* r - - 'i'^tijH-' ^ ^ ^ ^ ^ J i y ^ | i p ^ | ^ B j t y
- I n t e r n a l Fa n T y p e 14- 02 - *
DISASSEMBLY AND ASSEMBLY CLEANING AND INSPECTION
Vo l t a g e R e g u l a t o r
NOTE: If t he generat or (GEN)( 10346) a sse mbl y
needs f urt her servi ce, repl ace as an assembl y .
Di s a s s e mb l y
1. Hol d t he vol t age regul at or in one hand and pr y off
t he c a p coveri ng t he 'A' sc r e w head wi t h a
scr ewdr i ver .
2. Remove t wo sc r e ws ( T20 TORX-t ype head)
at t achi ng t he vol t age regul at or t o t he gener at or
brush and t ermi nal hol der ( 10320) . Separ at e t he
vol t age regul at or f r om generat or br ush and
t ermi nal hol der.
A s s e mb l y
1. At t a c h generat or brush and t ermi nal hol der t o
vol t age regul at or wi t h t wo sc r e ws.
2. Repl ace c a p on t he head of t he 'A' t ermi nal
sc r e w.
3. Depr ess t he generat or brushes ( 10347 ) into t he
generat or brush and t ermi nal hol der and hol d t he
generat or brushes in posi t i on by i nsert i ng a
st andard-si ze paper cl i p or equi val ent t hr ough
bot h t he l ocat i on hole in t he vol t age regul at or and
t hr ough t he hol es in t he generat or br ushes.
VOLTAGE
REGULATOR
0316
SCREW
2 REQ'D
TI GHTEN TO
2.8-4.0 N-m
(25-35 LB-IN)
GENERATOR
BRUSH
A N D TERMI NAL
HOLDER 10320
J2950-F
G e n e r a t o r
1. Che c k t he generat or pul l ey ( 10344) f or
l ooseness on t he gener at or r ot or shaf t and f or
c r a c ks or ot her da ma ge . Repl ace any generat or
pulley t hat is l oose, c r a c ke d or bent .
2. Che c k t he f ront and r e a r housi ngs f or c r a c ks,
part i cul arl y in t he we bbe d ar eas at t he mounti ng
ear. Repl ace a d a ma ge d or c r a c ke d housi ng.
ADJUSTMENTS
G e n e r a t o r Dr i v e B e l t
SPECIFICATIONS
GENERATOR SPECI FI CATI ONS
I t e m c i f i c a t i o n s
Ge n e r a t o r ( 10346) F6Z U
Ra t i n g ( ge n . c r a n k / r e v ) 130 A mp
Ge n e r a t o r Ra t i o ( ge n . 2. 8: 1
c r a n k / r e v . )
Re gu l a t o r Ty pe ( 10316) E l e c t r o n i c I n t e gr a l wi t h
Ge n e r a t o r
Vo l t a ge Re gu l a t o r S c r e ws 2 . 3- 3. 4 2 0- 30
Br u s h a n d Te r mi n a l
Ho l d e r - t o - Ge n e r a t o r Re gu l a t o r
S c r e ws
2. 8- 4. 0 2 5- 35
Ge n e r a t o r Mo u n t i n g Br a c ke t Bo l t s 8- 12 7 0- 106
Ge n e r a t o r Mo u n t i n g Bo l t s 20 30 15- 22
( L b - Ft )
Out put Te r mi n a l Nut 9- 11 80- 97
15- 00- 1
SECTI ON TI TLE PAGE SECTION TI TLE
ANTENNA . 15-02-1 RADIO AMD TAPE CHASSI S.
AUDIO SYSTEMSSERVI CE 15-00-1 SPEAKERS .
PHONE, MOBILE ....................15-04-1
PAGE
.15-01-1
.15-03-1
SECTION 15-00 Audio Syste
S '
SUBJ E CT PAGE
VEHI CLE APPLICATION ................15-00-1
DESCRIPTION AND OPERATI ON
Radio Recept i on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 00- 1
A n t e n n a s a n d Mo b i l i t y 1 5 - 0 0 - 1
DI AGNOSI S AND TE STI NG
El ect ri cal Schemat i c. . . 15-00-18
SUBJECT PAGE
Sy mpt om Chart s 15-00-47
VEHICLE APPLICATION
Town Car, Cr own Vi c t or i a , Grand Marqui s
Radio Recept i on
FM st er eo has a range of about 32 km ( 20 mi les)
bef or e i nt erf erence noi ses are he a r d. Thi s means
t hat in concer n a r e a s wi t h tall bui ldi ngs or hi lls, it i s
necessar y t o sel ect t he st r ongest possi bl e st at i on.
The r adi o chassi s ( 18806) or rear chassi s unit
(RCU) aut omat i cal l y t unes t o t he cent er of any gi ven
st at i on, eli mi nat i ng t he need f or manual fi ne t uni ng.
A n t e n n a s a n d Mo b i l i t y
Al t hough an aut omobi l e radi o chassi s wi ll gi ve
out st andi ng mobi l e r ecept i on, it cannot provi de t he
cont i nuous r ecept i on of home audi o component s.
The home recei ver is not li mi t ed by t he vehi cl e
oper at i ng c ha r a c t e r i st i c s and cert ai n geogr aphi cal
e f f e c t s a s i s t he mobi l e unit.
For e xa mpl e , f or t he best FM r ecept i on, t he
aut omobi l e ant enna shoul d be desi gned li ke a TV
ant enna and poi nt ed in t he di rect i on of t he st at i on.
The best AM ant enna is a long pi ece of wi r e , t he
hi gher t he wi r e t he bet t er t he r ecept i on.
However, because of desi gn necessi t y, t he
aut omobi l e ant enna is r est r i ct ed in si ze, hei ght and
di rect i on and must recei ve bot h A M and FM
st at i ons. Thi s means t hat a li mi t ed amount of t he
st at i on' s si gnal r eaches t he vehi cl e r adi o c ha ssi s.
T u n i n g
Tuning t he radi o chassi s into a st at i on can be done in
one of f our wa y s. Fi rst t he memory but t ons c a n be
used. Second, t he seek up or seek d o wn but t on can be
used t o tune t o t he next st at i on. Thi r d, t he Tune Up and
Tune Down but t ons may be used. Four t h, t he Scan
but t ons may be used.
FM Fl u t t e r
Fl ut t er can be char act er i zed as f ol l ows:
Repeat ed pops and hi ssi ng bur st s hear d in t he radi o
spe a ke r s, duri ng an ot her wi se go o d br o a d c a st .
15- 00- 2 Audio Sy st e msSe r vi c e 15- 00- 2
Condi t i on usual l y e xi st s whi l e t ravel i ng in t he f ri nge
a r e a of t he st at i on and it wi l l be c ome mor e sever e
be y ond an a ppr oxi ma t e 40 km ( 25 mi l es) f r om t he
st at i on. The si gnal l oss be c ome s gr eat er a wa y f r o m
t he st a t i on, until fi nally noi se t a ke s over and
r ecept i on be c o me s i mpossi bl e.
Fl ut t er ma y al so be not i ced near t he st at i on
be c a use of t he li ne-of -si ght c ha r a c t e r i st i c s of FM
r adi o wa v e s. Thi s condi t i on can happen when a
bui ldi ng or l arge st r uct ur e i s bet ween t he radi o
c ha ssi s and t he st at i on bei ng r ecei ved.
So me of t he FM si gnal bends around t he bui ldi ng,
but cer t ai n spo t s have al most no si gnal .
So me of t he se si gnal l osses are onl y a f e w i nches
wi d e and if t he vehi cl e i s pa r ke d in one of t hese
d e a d spo t s, y ou wi ll only hear noi se f r o m t he radi o
c ha ssi s. Af t er movi ng out of t he sha d o w of t he
st r uc t ur e , t he st at i on wi ll ret urn t o normal .
Fl ut t er wi l l not oc c ur on A M because t he A M radi o
wa v e s a r e much l onger t han FM wa v e s.
FM Multi-Path Cancellation
Cancel l at i on can be def i ned as f ol l ows:
It i s c a use d by t he li ne-of -si ght c ha r a c t e r i st i c and it
e xi st s whe n t he radi o wa v e s ar e r ef l ect ed f r o m
obj e c t s or st r uc t ur e s.
The noi se pr oduc e d by cancel l at i on i s si mi lar t o
f l ut t er, wi t h t he addi t i on of di st ort i on in t he pr o gr a m.
A mor e f ami l i ar descr i pt i on of cancel l at i on i s i t s
si mi l ari t y t o t he multi ple gho st s and pi ct ur e j umpi ng
t ha t o c c ur s on t el evi si on when a l ow f l yi ng pl ane
pa sse s. The sa me condi t i on e xi st s in t he vehi cl e,
e x c e pt t ha t t he vehi cl e i s movi ng and t he ref l ect i ng
st r uc t ur e i s st at i onar y. The r ef l ect ed si gnal cancel s
t he normal si gnal , causi ng t he ant enna t o pi ck up
noi se and di st or t i on.
Cancel l at i on e f f e c t s ar e most promi nent in
met r opol i t an a r e a s, but c a n al so be c ome qui t e
se ve r e in hilly t errai n and de pr e sse d r o a d wa y s.
FM Strong Signal Capture and AM Overloading
FM c a pt ur e i s an unusual condi t i on t hat o c c ur s whe n
t ravel i ng in t he vi ci ni t y of a br o a d c a st t owe r .
If l i st eni ng t o a we a k FM st at i on, whe n passi ng t he
br o a d c a st t owe r , a st r onger st at i on ma y i nt erf ere
wi t hout changi ng t he t uni ng c ont r ol . When passi ng
t he t o we r , t he st at i on may swi t c h ba c k and f or t h a
f e w t i me s be f or e ret urni ng t o t he st at i on ori gi nal l y
t une d.
A l ocal i zed condi t i on whi c h wi l l not har m t he recei ver
i s known a s over l oadi ng.
Whe n sever al br o a d c a st t o we r s ar e present
(c ommon in met r opol i t an a r e a s), sever al st at i ons
ma y ove r l oa d t he recei ver, resul t i ng in consi der abl e
st at i on changi ng, mi xi ng and di st or t i on.
Some over l oadi ng may al so be not i ced on A M, but
usual l y t o a l esser degr ee.
Receiving FM Stereo
Be c a use mor e d a t a i s car r i ed in t he FM st er eo wa ve s
t ha n in t he monaural FM br o a d c a st s, f l ut t er,
cancel l at i on and c a pt ur e ar e even mor e not i ceabl e.
The FM st e r e o noi se-f ree br o a d c a st range i s
appr oxi mat el y 32 km ( 20 mi l es). Thi s i s 8 km (5
mi l es) l ess t han t hat recei ved wi t h t he monaural FM
r adi o.
The radi o chassi s may never encount er any of
t he se t r oubl esome condi t i ons a s t he y ar e mor e
promi nent in met ropol i t an a r e a s, hilly t errai n and
de pr e sse d r o a d wa y s.
However , when di agnosi ng FM st e r e o c onc e r ns, it
i s r ecommended t o accur at el y t une t o t he st r ongest
FM st e r e o st at i on.
Stereo Indicator Inoperative o r Fl i c k e r i n g ( A M
and FM Reception are OK)
Veri f y t hat cust omer is li steni ng t o st e r e o st at i ons.
A we a k or di st ant si gnal may c a use t he st e r e o
i ndi cat or t o f l i cker. Tune radi o t o a nearby FM
st e r e o st at i on. If recept i on i s go o d , but st e r e o
i ndi cat or i s sti ll i nt ermi t t ent , r emove radi o chassi s
f or ser vi ce.
Interfering Noise
The r e ar e many possi bl e sour c e s of radi o
i nt erf erence:
One such sour ce i s t he vehi cl e i gni ti on sy st e m. Thi s
hi gh-vol t age swi t chi ng sy st e m pr oduces a radi o
f r equency el ect romagnet i c f i el d t hat radi at es at AM,
FM and CB f requenci es. Al t hough component s have
been desi gned i nt o t he vehi cl e t o mi ni mi ze t hi s
c onc e r n, t he noi se is more not i ceabl e if t he radi o
c ha ssi s i s t uned sl i ght l y of f channel when li steni ng
t o FM pr ogr a ms.
Vehi cl e el ect ri cal a c c e ssor i e s and owner add-on
a c c e ssor i e s may al so cont ri but e t o radi o
i nt erf erence.
Ther e are al so many noi se sour c e s whi c h ar e
ext ernal t o t he vehi cl e such as powe r li nes,
communi cat i on sy st e ms, i gni ti on sy st e ms of ot her
vehi cl es and neon si gns.
Noi se or st at i c may result f r o m many causes. Two of
t he most common sour c e s of radi o chassi s noi se ar e
l i st ed bel ow:
Ignition Noise
The most ef f ect i ve met hod of eval uat i ng i gni ti on noi se
i s t o c ompa r e t he radi o per f or mance wi t h t he engi ne
on, ver sus engi ne of f . if ignition noi se i s present wi t h
engi ne runni ng:
Check t o see t hat t he spar k plug wi r e s ar e t he
suppr essor t y pe and t hat t he spar k pl ugs ( 12405)
ar e t he c or r e c t resi st or t y pe .
Check t o see t hat spar k plug wi r es ar e fully se a t e d
in ignition coi l t o we r s.
15- 00- 3 A u d i o S y s t e ms S e r v i c e 15- 00- 3
Check t o see t hat spark plug wi res are fully seat ed
on spa r k pl ugs.
Check t o see t hat spar k pl ugs a r e pr oper l y ga ppe d
and se a t e d in cyl i nder heads.
Mi s s i n g o r Da ma g e d No i s e S u p p r e s s i o n
C o m p o n e n t s
Noi se suppressi on component s may be da ma ge d or
mi ssi ng.
Check groundi ng ef f ect i veness of t he radi o
f r equency i nt erf erence suppr essi on bond. We dge a
l arge fi le be t we e n met al pa r t s t o ensure pr oper
gr ound, suc h a s bet ween t he t ai l pi pe and body , or
bet ween t he f ender and f r ame, whi l e radi o speaker
( 18808) i s pl ayi ng and engi ne i s runni ng. Li st en f or a
de c r e a se in t he obj ect i onabl e radi o spe a ke r noi se.
If a reduct i on in noi se i s not ed, f i r st t r y t i ght eni ng
body and exhaust sy st e m c l a mps and br a c ke t s.
Then, if necessar y , i nstall a new radi o f r equency
i nt erf erence suppressi on bond ( 19A095) bet ween
t he t wo met al pa r t s t o ensure pr oper gr ound.
S y s t e m L a y o u t
The f ol l owi ng pa ge s i l l ust rat e To wn Car and Cr o wn
Vi c t or i a , Grand Mar qui s audi o sy st e m equi pment
l a y out s.
15- 00- 4 A u d i o S y s t e ms S e r v i c e
15- 00- 4
Luxur y Aud i o Sy st e m Di gi t al wi t h JBL wi t h Di gi t a l Aud i o Co mpa c t Di sc P l a y e r To wn Car
Pa r t
1 1157 2 Ignition Switch
2 Fuse Junction Pa n e l Circuit
P r o t e c t i o n Fus e s
3 19A383 Ce l l ul a r Pho n e Ha n d se t
4 19A391 Ha n d s Fr e e Ce l l ul a r Pho n e
Mi c r o ph o n e
5 18812 Di v e r si t y Wi n d s h i e l d
An t e n n a a n d Co a x i a l Ca bl e
( Ra d i o An t e n n a L e a d i n
Ca bl e )
6 18C852 Fr o n t Co n t r o l Uni t ( FCU)
7 14588 Bo d y Ca bl e ACP a n d Aud i o
Si gn a l Ra d i o
Re c e i v e r / Tu n e r Wi r e s
8 14588 Sub Wo o f e r Ca bl e En a bl e
a n d Aud i o Si gn a l Ra d i o
Re c e i v e r / Tu n e r Wi r e s
9 18D806 Di gi t a l Aud i o Co mp a c t Di sc
Pl a y e r
10 18C851 Re mo t e Ch a s s i s Uni t (Al l
Lux ur y Sy s t e ms )
11 18B849 Sub- Wo o f e r Ampl i f i e r (JBL
-DSP Sy s t e m Onl y )
12 18812 RCU t o An t e n n a I so l a t o r
Co a x i a l Ca bl e ( Ra d i o
An t e n n a L e a d in Ca b l e )
Pa r t
13 18808 Sub- Wo o f e r Sp e a ke r (JBL
-DSP Sy s t e m On l y )
14 18K891 Ra d i o An t e n n a I so l a t o r
15 Re a r Wi n d o w He a t e r
G r i d / A M An t e n n a
16 18812 Re a r Wi n d o w FM An t e n n a
a n d Co a x i a l Ca bl e t o I so l a t o r
Mo d ul e ( Ra d i o An t e n n a L e a d
i n Ca bl e )
17 18A886 Ce l l ul a r Te l e pho n e An t e n n a
18 18808 Sp e a ke r s J BL
19 19A387 Ce l l ul a r Te l e pho n e
Ampl i f i e r / Tr a n s c e i v e r
20 Po we r Di st r i but i o n Bo x
Ci r c ui t Pr o t e c t i o n Fuse s
2 1 14588 CD Aud i o a n d ACP Ca bl e
( Ra d i o Re c e i v e r / Tun e r
Wi r e s )
22

I n-Li ne Fu s e Ce l l u l a r
Pho n e
2 3

L i ght i n g Co n t r o l Mo d ul e
( L CM)
2 4

Pho n e Aud i o
25 St e e r i n g Whe e l Co n t r o l
Mo d ul e
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15- 00- 7 A u d i o S y s t e ms - S e r v i c e
Pa r t
1 18812 Di v e r si t y Wi n d shi e l d
t o RCU ( Ra d i o L e a d In
Ca b l e )
4 18808 Sub- Wo o f e r Spe a ke r (JBL
5 19A391 Ha n d s Fr e e Ce l l ul a r Pho n e
Mi c r o pho n e As s e mb l y
6 19A383 Ce l l ul a r Pho n e Ha n d se t
7 18C851 Re mo t e Cha s s i s Uni t (Al l
9

Re a r Wi n d o w He a t e r
10 Re a r Wi n d o w FM An t e n n a
a nd Co a x i a l Ca bl e t o I so l a t o r
Mo d ul e ( Ra d i o L e a d In
Ca bl e )
11

( LCM)
Pa r t
12 18808 Sp e a ke r s J BL
13 11572 Ignition Swi t c h
14 Fuse Jun c t i o n Pa ne l Ci r c ui t
Pr o t e c t i o n Fu s e s
Ci r c ui t P r o t e c t i o n Fuse s
16 I n-Li ne Fu s e Ce l l u l a r
Phone
17 19A387 Cel l ul ar Te l e pho n e
Ampl i f i e r / Tr a n sc e i v e r
18 18A886 Cel l ul ar Te l e pho n e An t e n n a
Si gnal
20 14588 Sub Wo o f e r Ca bl e En a bl e
a nd Aud i o Si gn a l
Co a x i a l Ca bl e
22 Phone Aud i o Ca bl e
23 St e e r i n g Wh e e l Co n t r o l
Mo d ul e
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Pa r t Pa r t
I t e m Number De s c r i p t i o n I t e m d u mb e r De s c r i p t i o n
1 18812 Di ve r si t y Wi n d shi e l d
10 18808 S p e a ke r s P r e mi u m
11
11572 I gni t i on Swi t c h
t o RCU ( Ra d i o L e a d In
Ca bl e ) P r o t e c t i o n Fu s e s
2 18C852 Fr ont Co n t r o l Unit ( FCU)
3 19A391 Ha n d s Fr e e Ce l l ul a r Pho n e Ci r c ui t P r o t e c t i o n Fus e s
Mi c r o pho n e As s e mbl y
14 I n-Li ne Fu s e Ce l l u l a r
4 19A383 Ce l l ul a r Pho n e Ha n d se t Pho n e
Luxur y Sy s t e ms )
15 19A387 Ce l l ul a r Te l e pho n e
Ampl i f i e r / Tr a n s c e i v e r
6 18K891 Ra d i o An t e n n a I so l a t o r 16 19A886 Ce l l ul a r Te l e pho n e An t e n n a
Mo d ul e
7

Si gna l ( Ra d i o
Re c e i v e r / Tu n e r Wi r e )
8 18812 Rear Wi n d o w FM An t e n n a
a nd Co a x i a l Ca bl e t o I so l a t o r
Mo d ul e ( Ra d i o L e a d In
Co a x i a l Ca bl e ( Ra d i o L e a d
In Ca bl e )
Ca bl e )
19 Pho n e Aud i o Ca bl e
9 Li ght i n g Co n t r o l Mo d ul e
( LCM)
2 0

St e e r i n g Wh e e l Co n t r o l
Mo d ul e
1
5
-
0
0
-
1
0

A
u
d
i
o

S
y
s
t
e
m
s
S
e
r
v
i
c
e

1
5
-
0
0
-
1
0

1
9
9
5

T
o
w
n

C
a
r
,

C
r
o
w
n

V
i
c
t
o
r
i
a
,

G
r
a
n
d

M
a
r
q
u
i
s

J
u
l
y

1
9
9
4

Pa r t Pa r t
I t e m Nu mb e r De s c r i p t i o n i t e m Nu mb e r De s c r i p t i o n
1 18C852 Fr ont Co n t r o l Uni t ( FCU) 9 18D806 Di gi t a l Aud i o Co mpa c t Di sc
Pl a y e r ( CD/ DJ )
-DSP Sy s t e m Onl y ) 10 18808 S p e a ke r s J BL
11
12
Fu s e Jun c t i o n Pa ne l Ci r c ui t
4 18C851 Re mo t e Ch a s s i s Uni t (Al l P r o t e c t i o n Fuse s
13

Po we r Di st r i but i o n Bo x
5 18K891 Ra d i o An t e n n a I so l a t o r Ci r c ui t Pr o t e c t i o n Fuse s
Mo d ul e 14 14588 Bo d y Ca bl e ACP a nd Aud i o
6

Si gn a l ( Ra d i o
a n d Co a x i a l Ca bl e t o I so l a t o r
Mo d ul e
15 14588 Sub- Wo o f e r Ca bl e a n d Aud i o
Si gn a l ( Ra d i o
8

( L CM)
( Ra d i o L e a d in Ca bl e )
1
5
-
0
0
-
1
2

A
u
d
i
o

S
y
s
t
e
m
s
S
e
r
v
i
c
e

1
5
-
0
0
-
1
2

D
E
S
C
R
I
P
T
I
O
N

A
N
D

O
P
E
R
A
T
I
O
N

(
C
o
n
t
i
n
u
e
d
)

L
u
x
u
r
y

A
u
d
i
o

S
y
s
t
e
m

D
i
g
i
t
a
l

w
i
t
h
o
u
t

D
i
g
i
t
a
l

A
u
d
i
o

C
o
m
p
a
c
t

D
i
s
c

P
l
a
y
e
r
C
r
o
w
n

V
i
c
t
o
r
i
a
,

G
r
a
n
d

M
a
r
q
u
i
s

1
9
9
5

T
o
w
n

C
a
r
,

C
r
o
w
n

V
i
c
t
o
r
i
a
,

G
r
a
n
d

M
a
r
q
u
i
s

J
u
l
y

1
9
9
4

masrzz7T^fmr~.TPW -gassr I M B S " ' a - j a r -moor-mssr^- . s a a K ~ _ . 3 aray_ ~ r : ^ s : mm?
r
zzii^
f
!^Fi
Pa r t Pa r t
i t e m Nu mb e r De s c r i p t i o n i t e m Nu mb e r De s c r i p t i o n
1 18C852 Fr o n t Co n t r o l Uni t ( FCU) 9 No t Us e d
2 18B849 Sub- Wo o f e r Ampl i f i e r (JBL 10 18808 Sp e a ke r s J BL
-DSP Sy s t e m On l y ) 11 11572 I gni t i on Swi t c h
P r o t e c t i o n Fus e s
Ci r c ui t P r o t e c t i o n Fuse s
Mo d ul e
14 14588 Bo d y Ca bl e ACP a nd Aud i o
Si gna l ( Ra d i o
6 Re a r Wi n d o w He a t e r
Re c e i v e r / E n a b l e )
G r i d / A M An t e n n a 15 14588 Sub- Wo o f e r Ca bl e a n d Aud i o
( Ra d i o L e a d In Ca bl e )
Si gna l ( Ra d i o
8
( LCM)
1
5
-
0
0
-
1
4

A
u
d
i
o

S
y
s
t
e
m
s
S
e
r
v
i
c
e

1
5
-
0
0
-
1
4

Pa r t Pa r t
7 18808 Sp e a ke r s P r e mi u m
Luxury Systems)
8
9
Fuse Jun c t i o n Panel Ci r c ui t
P r o t e c t i o n Fuse s
4

10

Ci r c ui t Pr o t e c t i o n Fuse s
11 14588 Bo d y Ca bl e ACP a nd Aud i o
Si gn a l
6

( L CM)
( Ra d i o L e a d in Ca bl e )
1
5
-
0
0
-
1
6

A
u
d
i
o

S
y
s
t
e
m
s
S
e
r
v
i
c
e

1
5
-
0
0
-
1
6

D
E
S
C
R
I
P
T
I
O
N

A
N
D

O
P
E
R
A
T
I
O
N

(
C
o
n
t
i
n
u
e
d
)

E
S
R
/
E
S
C

A
u
d
i
o

S
y
s
t
e
m
C
r
o
w
n

V
i
c
t
o
r
i
a
,

G
r
a
n
d

M
a
r
q
u
i
s

1
9
9
5

T
o
w
n

C
a
r
,

C
r
o
w
n

V
i
c
t
o
r
i
a
,

G
r
a
n
d

M
a
r
q
u
i
s

J
u
l
y

1
9
9
4

Pa r t Pa r t
Stem Nu mb e r De s c r i p t i o n I t e m d u mb e r De s c r i p t i o n
1
2
18806
18K891
E SC/ E SR Ra d i o Ch a s s i s
Ra d i o An t e n n a I sol a t or
Mo d ul e
6
7
18808
1157 2
Sp e a ke r s P r e mi u m or
JBL
I gni t i on Swi t c h
3
_
8

Fuse Jun c t i o n Pa ne l Ci r c ui t
Pr o t e c t i o n Fuse s
Ra d i o Re c e i v e r / Tu n e r Wi r e
9

Ci r c ui t Pr o t e c t i o n Fus e s
t o I so l a t o r Mo d ul e 10
_
Spe a ke r Ha r n e ss
5

( L CM)
I sol a t e d Radi o An t e n n a
(C AAAAAAAAAAAA
_
HEATED REAR WI NDOW
WINDSHIELD
DIVERSITY ANTENNA
(TOWN CAR ONLY)
FM ANT. GRI D
COAX
TO ANTENNA I NPUTS .
ON REAR CONTROL UNIT
(LUX)
BR/LB
ISOLATOR
RADIO
ANTENNA
TO HEATED
BACK
WI NDOW SWI TCH
AND LIGHT
K22546-A
16- 00- 18 A u d i o S y s t e m s S e r v i c e 15- 00- 18
Luxury Audi o Sy st e m Digital (JBL with Digital Audi o Co mpa c t Di sc Pl a y e r )Town Ca r
HOT AT A L L TI MES
HOT IN RUN I HOT IN ACC
OR START I OR RUN
1
i POWER
, DIST
I BOX
. DISTRIBUTION I
1 P
v
*
828
GY/R
C2-11
C2-7
G2-8
C M 6
02-15
594
593
GY
DB/W
503
504
BR/LG
See EVTM for
more details
of this circuit
LG/ BK
Lux ur y Audi o Sy st e m Di gi t a l (JBL wi t h Di gi t a l Aud i o Co mpa c t Di sc P l a y e r ) To wn Car ( Co n t i n ue d )
HOT IN START
r~ l POWER
fc
IDISTRI-
IBUTION
JBOX
40Aj
R/LB
K22510-A
FRONT CONTROL UNIT
GRAY CONNECTOR C1
Pin
1 1003
( G Y/ Y)
P o we r ( St a r t a n d Run)
2 No t Us e d
3 694
( B K / L G )
Gr o un d
4 7 2 3
( G Y/ R )
Pho n e T r a n s c e i v e r A c t i v e ( PTA)
( P h o n e Mo d e )
5 19 ( L B / R ) ( L CM) I l l umi n a t i o n
6 2 94
( W/ L B )
P o we r ( A CC a n d Run)
7 57 ( BK) Gr o un d ( I l l umi n a t i o n )
8 7 97 ( L G / P ) 12- Vo l t Ba t t e r y Fe e d
FRONT CONTROL UNIT
BLACK CONNECTOR C2 K21912-A
Pi n
1 No t Us e d
2 No t Us e d
3 194 ( P K) De l a y e d A CCY I nput
4 1068
( L G / B K )
Au d i o S y s t e m ON ( A S YS ON)
5 833 ( T) Au d i o Co mmu n i c a t i o n s P r o t o c o l B
( ACP B)
Pin
6 Ba r e Sh i e l d
7 5 9 4 ( GY) Ta pe Au d i o RH -
8 593
( DB / W)
Ta pe Au d i o RH +
9

No t Us e d
10 No t Us e d
11 Ba r e Shi e l d
12

No t Us e d
13 832
( L B / P K )
Au d i o Co mmu n i c a t i o n s P r o t o c o l A
( ACP A)
14

No t Us e d
15 504
( W/ P K )
Ta pe Au d i o L H -
16 503
( B R / L G )
Ta pe Au d i o LH +
REMOTE CHASSIS UNIT
BLACK CONNECTOR CI K21913-A
Pin
1 8 2 8 ( P / L B ) 12 Vo l t s Ba t t e r y Fe e d
2 694
( B K / L G )
Gr o un d
3 694
( B K / L G )
Gr o un d
4

No t Us e d
5

A n t e n n a Up
6 No t Us e d
7 804
( O / L G )
L H Fr o n t S p e a ke r ( + )
8 813
( L B / W)
L H Fr o n t S p e a ke r (-)
9 800
( G Y/ L B )
L H Re a r Speaker ( + )
10 801 ( T / Y) L H Re a r S p e a ke r (-)
11 805
( W/ L G )
RH Fr o n t S p e a ke r ( + )
12 811
( DG / O )
RH Fr o n t S p e a ke r (-)
15- 00- 2 1 A u d i o S y s t e ms S e r v i c e 15- 00- 2 1
Pin
13 802 ( O / R ) RH Re a r S p e a k e r ( + )
14 803
( B R / P K )
RHRe a r S p e a k e r (-)
REMOTE CHASSIS UNIT
GRAY CONNECTOR C2
K21914-A
Pin
1 Ba r e Sh i e l d
2 167
( B R / O )
Ra d i o Su b - Wo o f e r Hi gh Au d i o ( + )
3

No t Us e d
5 168
( R / B K )
Ra d i o S u b - Wo o f e r Hi gh Au d i o (-)
6 17 3
( DG / P )
Su b - Wo o f e r E n a bl e
9) 0 ( l 7 ) M6) Ms )
REMOTE CHASSIS UNIT
GRAY CONNECTOR C3
K21915-A
Pin
1 832
( L B / P K )
( ACP A)
2 1068
( L G / B K )
Au d i o S y s t e m ON ( A S YS ON)
3

No t Us e d
Pin
Number Ci rcui t Circuit Funct i on
4 No t Us e d
5

No t Us e d
6 503
( B R / L G )
Ca s s e t t e I nput LH ( + )
7 593
( DB / W)
Ca s s e t t e I nput RH ( + )
15 8 3 3 ( T) A u d i o Co mmu n i c a t i o n s P r o t o c o l B
( A CP B)
16 Ba r e Sh i e l d ( ACP )
17 32 ( R / L B ) St a r t Li n e
18 Ba r e Sh i e l d ( Ta pe )
19 504
( W/ P K )
Ca s s e t t e i n put L H (-)
2 0 5 9 4 ( GY) Ca s s e t t e I nput RH (-)
REMOTE CHASSIS UNIT
BLACK CONNECTOR C4
K21916-A
Pin
8 1068
( L G / B K )
A u d i o S y s t e m ON ( A S YS ON)
9 7 98
( L G / R )
CD I nput L H (-)
10 7 99
( O / B K )
CD I nput RH (-)
11 7 2 4 ( L B / Y ) P h o n e Au d i o I nput (-)
12 7 2 5 ( P K) P h o n e A u d i o I nput ( + )
13 No t U s e d DS P ( NAV- )
14 832
( L B / P K )
A u d i o Co mmu n i c a t i o n s P r o t o c o l A
( A CP A)
2 1 856 ( P) CD I nput RH ( + )
2 2 6 9 0 ( GY) CD I nput L H (-)
2 3 Ba r e Sh i e l d
2 4 No t U s e d DS P ( N A V+ )
( A CP B)
26 Ba r e ( A CP ) Sh i e l d
15- 00- 2 2
A u d i o S y s t e ms S e r v i c e 15- 00- 2 2
SUB-WOOFER AMPLIFIER
GRAY CONNECTOR C1
K21917-A
Pin
1
__
No t Us e d
2 No t Us e d
3 2 87
( B K / W)
S p e a ke r Vo i c e Co i l Re t ur n
4 82 2
( B K / L G )
S p e a ke r Vo i c e Co i l Fe e d
5

No t Us e d
6 No t Us e d
7

No t Us e d
8

No t Us e d
9

No t Us e d
10 No t Us e d
MM C 3J (T) M j
BLACK CONNECTOR C2
K21918-A
Pin
1

No t Us e d
2 173
( DG / P )
Ra d i o Su b - Wo o f e r Hi gh Au d i o Mu t e
3 No t Us e d
4 No t Us e d
5 167
( B R / O )
Ra d i o Su b - Wo o f e r Hi gh A u d i o ( + )
6 168
( R / B K )
Ra d i o Su b - Wo o f e r Hi gh Au d i o (-)
9 J ( 10) 111J ( 12) (13
COMPACT DISC CHANGER
14)
K21919-A
Pin
1

No t Us e d
2 8 5 6 ( P ) L H Au d i o Out put ( + )
3 Ba r e Sh i e l d
4 69 4
( B K / L G )
Gr o un d
5 Ba r e Sh i e l d
6 832
( L B / B K )
( ACP A)
7

No t Us e d
8 690 ( GY) RH Au d i o Out put ( + )
9 7 99
( O / B K )
RH Au d i o Out put (-)
10

No t Us e d
11 7 98
( L G / R )
L H Au d i o Out put (-)
12 2 96 ( W/ P ) 12 Vo l t s Ba t t e r y Fe e d
13 1068
( L G / B K )
A u d i o Sy s t e m ON ( A SYSON)
14 833 ( TN) A u d i o Co mmu n i c a t i o n s P r o t o c o l B
( ACP B)
CONTROL MODULE C2 K22761-A
15- 00- 2 3 A u d i o S y s t e ms S e r v i c e
mm "imr-
15- 00- 2 3
Pi n
N u mb e r Ci r cui t C i r c u i t F u n c t i o n
1 5 9 5 ( L B / R ) Co mmu n i c a t i o n t o S WC
2

No t Us e d J
3

No t Us e d
4 832
( L B / P K )
A CP A To Ra d i o
5 57 ( BK) A CP Sh i e l d t o Ra d i o
6 1069 Cl i ma t e Ct r l . Si g. t o EATC
7 107 0 Cl i ma t e Ct r l . Si g. t o EATC
8 ( Op t i o n a l
Gr o un d )
( Op t i o n a l Gr o u n d )
( Co n t i n ue d )
Pi n
Number Ci r c ui t Ci r cui t Fun c t i o n
9 2 96 ( W/ P ) Ba t t e r y
10 5 8 3 ( Y) P o we r t o S WC
11 No t Us e d
12 1068
( L G / B K )
A S YS ON Fr o m Ra d i o
13 8 3 3 ( T) A CP B To Ra d i o
14 4 8 4
( O / B K )
P WM Fr o m L CM
15 8 4 8 ( BK) Gr o un d
16 No t Us e d
Lux ur y Aud i o Sy st e m Di gi t a l (JBL wi t ho ut Di gi t a l Aud i o Di sc P l a y e r ) To wn Car
HOT AT A L L TI MES
HOT AT I HOT IN ACC I HOT AT
A L L TI MES I OR RUN I A L L TI MES
7"!
j
POWER
DISTRIBUTION
BOX
828
1003
See EVTM for
mo r e de t a i l s
TO CELLULAR PHONE
K22710-A
Luxur y Audi o Sy st e m Di gi t al (JBL wi t ho ut Di gi t al Aud i o Di sc P l a y e r ) T o wn Car ( Cont i nue d)
694
HOT IN START
BK/ LG
LB/ PK I ,
T U -
w
r.
1068
4*
I 1
I 1 GY
DB/ W
503
I | BR/ LG
828
PK/ LB
1 \ 167
I 1
I BR/ O
I 173
a.----.-----.*/ DG/ P
C3-16 C3 1 5 C3- 1
C3- 2
C1 - 1 3
C3- 18
C3- 20
C3-7
C3- 6
C3-19
C3 - 1 4
C2- 5
C2- 2
C2-1
G2-6
C M 2
C1-6
C1-5
" 01 -8
C 1 . 7
SOLI D-
STATE
03-17
REMOTE
CHASSIS
UNIT
BK/ LG
>
J
BK/ LG
800
GY/ LB
_ 804
O/ LG
REAR
LH
FRONT
DOOR
SPEAKER
RH
REAR
SPEAKER
RH
FRONT
DOOR
SPEAKER
J
R/ LB
725 - - - -
See EVTM f o r
mo r e de t a i l s
04*23
, t i >
LG/ BK
TO
CELLULAR
PHONE
K22509-A
15- 00- 2 6
A u d i o S y s t e ms S e r v i c e 15- 00- 2
1
FRONT CONTROL UNIT
GRAY CONNECTOR C1
K21911-A
P i n
N u m b e r C i r c u i t Ci rcui t Func t i on
1 1003
( G Y/ Y)
2
_
No t Us e d
3 6 9 4
( B K / L G )
Gr o un d
4 7 2 3
( G Y/ R )
P h o n e T r a n s c e i v e r A c t i v e ( PTA)
6 2 9 4
( W/ L B )
7 57 ( BK) Gr o u n d ( I l l umi n a t i o n )
8 7 97 ( L G / P ) 12 Vo l t Ba t t e r y Fe e d
FRONT CONTROL UNIT
BLACK CONNECTOR C2
K21912-A
Pi n
1 No t Us e d
2

No t Us e d
3 194 ( P K) De l a y e d A c c y I nput
4 1068
( L G / B K )
A u d i o S y s t e m ON ( A S YS ON) ( A CP
Wa k e Up )
( A CP B)
Pin
6 Ba r e Shi e l d
7 594 ( GY) Ta pe A u d i o RH -
8 593
( DB / W)
Ta pe A u d i o RH +
9
_
No t Us e d
10

No t Us e d
11 Ba r e Sh i e l d
12

No t Us e d
13 832
( L B / P K )
( ACP A)
14

No t Us e d
15 584
( W/ P K )
Ta pe Au d i o L H -
16 583
( BR/ L G )
Ta pe A u d i o L H +
REMOTE CHASSIS UNIT
BLACK CONNECTOR C1
K21913-A
Pi n
1 803
( B R / P K )
RH Re a r S p e a ke r (-)
2 802 ( O / R ) RH Re a r Sp e a ke r ( + )
3 811
( DG / O)
4 805
( W/ L G )
5 801 ( T / Y) L H Re a r S p e a ke r (-)
6 800
( G Y/ L B )
L H Re a r Sp e a ke r ( + )
7 813
( L B / W)
L H Fr o n t S p e a ke r (-)
3 804
( O / L G )
L H Fr o n t S p e a ke r ( + )
9

No t Us e d
10

No t Us e d
11
_
No t Us e d
12 694
( B K / L G )
Gr o un d
REMOTE CHASSIS UNIT
GRAY CONNECTOR C2
K21914-A
Pin
N u m b e r C i r c u i t Ci r cui t Funct i on
1 173
( DG / P )
2 168
( R / B K )
Ra d i o Su b - Wo o f e r Hi gh A u d i o (-)
3 57 ( BK) Gr o u n d
4

No t Us e d
5 167
( B R / O )
6 Ba r e Sh i e l d
REMOTE CHASSIS UNI T
GRAY CONNECTOR C3
K21915-A
Pin |
N u mb e r | C i r c u i t Circuit Function
1 I 832
': a:"J/PK)
{ ACP A)
1068
J ( L G / B K )
Au d i o S y s t e m On ( A S YS ON)
3 ) No t Us e d
( Co n t i n ue d )
Pi n
Number Ci rcui t Ci r cui t Fun c t i o n
4 No ! Us e d ,
5
_
No t Us e d
6 5 0 3
( B R / L G )
Ca s s e t t e I nput L H ( + )
7 5 9 3
( DB / W)
15 833 ( T) A u d i o Co mmu n i c a t i o n s P r o t o c o l B
( A CP B)
16 Ba r e Sh i e l d ( A CP )
17 3 2 ( R / L B ) St a r t Li n e
19 5 04
( W/ P K )
Ca s s e t t e I nput L H (-)
2 0 594 ( GY) Ca s s e t t e I nput RH (-)
REMOTE CHASSIS UNIT
BLACK CONNECTOR C4
K21916-A
Pi n
8 1068
( L G / B K )
A u d i o S y s t e m ON ( A SYSON)
9 7 98
( L G / R )
CD I nput L H (-)
10 7 99
( O / B K )
CD I nput RH (-)
11 7 2 4 ( L B / Y ) Pho n e Au d i o I nput (-)
12 7 2 5 ( PK) Pho n e Au d i o I nput ( + )
13 Not U s e d DS P ( NAV- ) ,
14 832
( L B / P K )
( ACP A)
2 1 8 5 6 ( P ) CD I nput L H ( + )
2 2 6 9 0 ( GY) CD I nput RH ( + )
2 3 Ba r e Shi e l d
2 4 Not U s e d DS P ( NAV- J)
2 5 833 ( T) Aud i o Co mmu n i c a t i o n s P r o t o c o l B
( ACP B)
2 6 Ba r e ( ACP) Sh i e l d
15- 00- 2 8
GRAY CONNECTOR C1
K21917-A
P i n
Number Ci rcui t C i r c u i t F u n c t i o n
1 No t Us e d
2 No t Us e d
3 2 87
( B K / W)
4 82 2
( B K / L G )
5
_
No t Us e d
6 No t Us e d
7 No t Us e d
8 No t Us e d
9 No t Us e d
10 No t Us e d
SUB- WOOFER AMPLI FI ER
BL A CK CONNECTOR 0 2
K21918-A
P i n
1 No t Us e d
2 173
( DG / P )
P i n
3

No t Us e d
4

No t Us e d
5 167
( B R / O )
6 168
( R / B K )
STEERI NG WHEEL SWI TCHES
P i n
1 595
( L B / R S )
Co mmu n i c a t i o n t o S WC
2 No t Us e d
3
_
No t Us e d
4 832
( L B / P K )
A CP A To Ra d i o
5 57 ( BK) ACP Sh i e l d t o Ra d i o
8 ( Opt i o n a l
Gr o un d )
( Opt i o n a l Gr o un d )
9 2 96 ( W/ P ) Ba t t e r y
10 5 8 3 ( Y) P o we r t o SWC
11

No t Us e d
12 1068
( L G / B K )
13 833 (T) ACP B To Ra d i o
14 484
( O / B K )
P WM Fr o m L CM
15 848 ( BK) Gr o un d
16

No t Us e d
15- 00- 2 9 A u d i o S y s t e ms S e r v i c e
15- 00- 2 9
Luxur y Aud i o Sy st e m A n a l o g T o wn Car
HOT AT
ALL TIMES
HOT IN ACC I HOT AT
OR RUN I ALL TIMES
m I FUSE
1 8
, JUNCTION
I PANEL
BK/LG
TO CELLULAR PHONE
C1-3
C1-5
C2- 3 C1-7
SOLID
STATE
C I - 8
C2- 6
C1-1
C2 7
C2-8
C2 16
ct-e C2-15
G1-4 C2-4
11
< ? 5
5
{ 2 n
LB/PK egg I i
1068
LG/BK
K22701-A
LB/PK
1995 Town Car, Cr own Vi ct or i a, Gr and Ma r q u i s Jul y 1994
1
FRONT CONTROL UNIT
GRAY CONNECTOR C1
K21911-A
Pi n
1 1003
( G Y/ Y)
2 No t Us e d
3 694
( B K / L G )
Gr o un d
4 7 2 3
( G Y/ R )
P ho n e Tr a n s c e i v e r A c t i v e ( PTA)
6 2 94
( W/ L B )
7 67 ( BK) Gr o u n d ( I l l umi n a t i o n )
8 7 97 ( L G / P ) 12 Vo l t Ba t t e r y Fe e d
FRONT CONTROL UNIT
BLACK CONNECTOR C2
K21912-A
P i n
N u mb e r C i r c u i t Co r c ui t F u n c t i o n
1 No t Us e d
2
--
No t Us e d
' 3 194 ( P K) De l a y e d A c c y lnpt
4 1068
( L G / B K )
Au d i o S y s t e m On ( A SYSON)
5 8 3 3 ( T) Au d i o Co mmu n i c a t i o n s P r o t o c o l B
( ACP B)
6 Ba r e Sh i e l d
I 7 6 9 4 (c Ta pe A u d i o RH -
Pi n
N u mb e r Ci r c u i t C i r c u i t F u n c t i o n
8 593
( DB / W)
Ta pe A u d i o RH +
9

No t Us e d
10

No t Us e d
11 Ba r e Shi e l d
12 Not Us e d
13 832
( L B / P K )
Aud i o Co mmu n i c a t i o n s P r o t o c o l A
( ACP A)
14 Not Us e d
15 504
( W/ P K )
Ta pe Au d i o LH -
16 583
( BR/ L G )
Ta pe A u d i o L H +
REMOTE CHASSI S UNIT
BL ACK CONNECTOR CI
K21913-A
Pi n
N u mb e r Circuit cult F u n c t i o n
1 803
( B R / P K )
RH Re a r Sp e a ke r (-)
3 811
( DG / O)
RH Fr o n t Sp e a ke r (-)
4 805
( W/ L G )
RH Fr o n t Sp e a ke r ( + )
5 801 ( T / Y) LH Re a r Sp e a ke r (-)
6 800
( G Y/ L B )
7 813
( L B / W)
LH Fr o n t Sp e a ke r (-)
8 804
( O / L G )
L H Fr o n t Sp e a ke r ( + )
9 Not Us e d
10

No t Us e d
11

Not Us e d
12 694
( B K / L G )
Gr o un d
13 694
( B K / L G )
Gr o un d
14 8 2 8 ( P / L B ) 12 Vo l t s Ba t t e r y Fe e d
REMOTE CHASSIS UNIT
GRAY CONNECTOR C3
K21915-A
Pin
1 832
( L B / P K )
( ACP A)
2 1068
( L G / B K )
Au d i o S y s t e m On ( A SYSON)
3

No t Us e d
4

No t Us e d
5 No t Us e d
6 583
( B R / L G )
Ca s s e t t e I nput LH ( + )
7 593
( DB / W)
15 833 (T) A u d i o Co mmu n i c a t i o n s P r o t o c o l B
( ACP B)
16 Ba r e Sh i e l d ( ACP)
17 3 2 ( R / L B ) 12 Vo l t s in St a r t
19 604
( W/ P K )
Ca s s e t t e I nput LH (-)
2 0 594 ( GY) C a s s e t t e I nput RH (-)
REMOTE CHASSIS UNIT
BLACK CONNECTOR C4
P i n
Number C i r c u i t c i r c u i t F u n c t i o n
8 1068
( L G / B K )
A u d i o S y s t e m ON ( A S YS ON)
9 7 98
( L G / R )
CD I nput L H ( + )
10 7 99
( O / B K )
CD I nput RH (-)
11 7 2 4 ( L B / Y) P h o n e Au d i o I nput (-)
12 7 2 5 ( PK) P h o n e Au d i o I nput ( + )
13 No t Us e d
14 832
( L B / P K )
( ACP A)
2 1 8 5 6 ( P ) CD I nput LH ( + )
2 2 6 9 0 ( GY) CD I nput RH ( + )
2 3 Ba r e Sh i e l d
2 4
_
No t Us e d
2 5 833 (T) A u d i o Co mmu n i c a t i o n s P r o t o c o l B
( ACP B)
2 6 Ba r e ( A CP ) Sh i e l d
CONTROL MODULE C2 K227S1 -A
Pin
Number Ci r cui t Ci r cui t Funct i on |
1 5 9 5 ( L B / R ) Co mmu n i c a t i o n t o S WC ;
2 No t Us e d
3 No t Us e d
4 832
( L B / P K )
A CP A To Ra d i o
5 57 ( BK) A CP Sh i e l d t o Ra d i o
8 ( Opt i o n a l
Gr o un d )
( Op t i o n a l Gr o un d )
9 2 96 ( W/ P ) Ba t t e r y j
10 583 ( Y) P o we r t o SWC
11 Wot Usee!
12 1068
( L G / B K )
13 833 (T) ACP B To Ra d i o !
( Co n t i n ue d )
P i n
14 484
( O / B K )
P WM Fr o m L C M
15 848 ( BK) Gr o u n d
P i n
16

No t Us e d
1
5
-
0
0
-
3
3

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d
i
o

S
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s
t
e
m
s
S
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1
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-
0
0
-
3
3

D
I
A
G
N
O
S
I
S

A
N
D

T
E
S
T
I
N
G

(
C
o
n
t
i
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L
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A
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i
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S
y
s
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m

D
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(
J
B
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w
i
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D
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i
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A
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C
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p
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D
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V
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G
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M
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15- 00- 34 Audi S y s t e ms S e r v i c e 15- 00- 34
1
FRONT CONTROL UNIT
GRA Y C O N N E C T O R C 1
K21911-A
Pin
Nu mb e r Ci r c ui t r c u i t Functi on
1 6 4 0 ( R/ Y) 12 Vo l t I gn i t i o n Fe e d ( Ru n / S t a r t )
2

No t Us e d
3 69 4
( B K / L G )
Gr o un d
4 __ No t Us^ci
5 19 (LB/ R) I l l umi n a t i o n
6 137
( Y / B K )
12 Vo l t Run / A c c y Fe e d
7 57 ( BK) I l l umi n a t i o n Gr o un d
8 54 ( L G / Y ) 12 Vo l t Ba t t e r y Fe e d
FRONT CONTROL UNIT
BLACK C O N N E C T O R C 2
Pi n
N u m b e r C i r c u i t r c u i t F u n c t i o n
1 No t U sed
2 No t Us e d
3 No t Us e d
4 1068
( L G / B K )
A S YS ON ( ACP Wa ke Up)
5 8 3 3 ( T ) A u d i o Co mmu n i c a t i o n s P r o t o c o l B
( ACP B)
6 Ba r e Sh i e l d
7 5 9 4 Co"'} Ta pe Au d i o RH -
Pen
8 593
( DB / W)
Ta pe Aud i o RH +
9

No t Us e d
10

No t Us e d
11 Ba r e Shi e l d
12

No t Us e d
13 832
( L B / P K )
( ACP A)
14

No t Us e d
15 584
( W/ P K )
Ta pe Aud i o LH -
16 583
( B R / L G )
Ta pe Au d i o LH +
REMOTE CHASSIS U NI T
BL ACK CONNECTOR C 1
K21913-A
Pin
N u mb e r Ci r cui t C i r c u i t Functi on |
2 82 4 ( W/ P ) RH Re a r Sp e a ke r (-) j
3 805
( W/ L G )
RH Fr o n t Sp e a ke r (-1) I
4 811
( DG / O)
RH Fr o n t S p e a ke r (-) I
'
5 800
( G Y/ L B )
LH Re a r Sp e a ke r ( + )
6 801 ( T / Y) LH Re a r S p e a ke r { }
7 804
( O / L G )
LH Fr o n t S p e a ke r ( + )
8 813
( L B / W)
LH Fr o n t S p e a ke r (-)
9 Not Us e d
10 Not Us e d
11 No t U sed
12 694
( B K / L G )
Gr o un d \
I
13 694
( B K / L G )
Gr o un d
14 37 ( Y) ,
12 Vo l t s Ba t t e r y Feed
1995 To wn Car , Cr o wn Vi c t o r i a , Gr and Ma r q u i s Jul y 1994
15- 00- 35 A u d i o S y s t e m s S e r v i c e 15 - 00- 35
REMOTE CHASSIS UNIT
GRAY CONNECTOR C2
K21914-A
P i n
1 17 3
( DG / P )
S u b - Wo o f e r E n a b l e
2 168
( R / B K )
Ra d i o S u b - Wo o f e r Hi gh A u d i o (-)
3 No t Us e d
4 No t Us e d
5 167
( B R / O )
Ra d i o S u b - Wo o f e r Hi gh A u d i o ( + )
6 Ba r e S h i e l d
REMOTE CHASSIS UNIT
GRAY CONNECTOR 03
K21915-A
Pin
1 8 3 2
( L B / P K )
A u d i o C o mmu n i c a t i o n s P r o t o c o l A
( A CP A )
2 1068
( L G / B K )
A u d i o S y s t e m On ( A S YS ON )
3 No t Us e d
4 No t Us e d
6 No t U s e d
6 6 0 3
( B R / L G )
C a s s e t t e I n put L H ( + )
Pin
7 5 9 3
( D B / W )
C a s s e t t e I n put RH ( + )
15 8 3 3 ( T) A u d i o C o mmu n i c a t i o n s P r o t o c o l B
( A CP B)
16 Ba r e S h i e l d ( A CP )
17 3 2 ( R / L B ) S t a r t L i n e
18 Ba r e S h i e l d ( T a p e )
19 5 0 4
( W / P K )
C a s s e t t e I n put L H (-)
2 0 5 9 4 ( GY) C a s s e t t e I n put RH (-)
REMOTE CHASSIS UNIT
BLACK CONNECTOR C4
K21916-A
Pin
8 1068
( L G / B K )
A u d i o S y s t e m ON ( A S YS ON )
9 7 9 8
( L G / R )
CD I n put L H (-)
10 7 9 9
( O / B K )
CD I n put RH ( + )
11 7 2 4 ( L B / Y ) P h o n e A u d i o I n put (-)
12 7 2 5 ( P K) P h o n e A u d i o I n put ( + )
13 No t U s e d DS P ( NA V- )
14 832
( L B / P K )
A u d i o C o mmu n i c a t i o n s P r o t o c o l A
( A CP A )
2 1 8 5 6 ( P ) CD I n put L H ( + )
2 2 6 9 0 ( GY) CD I n put RH ( + )
2 3 Ba r e S h i e l d
2 4 No t U s e d DS P ( N A V+ )
2 5 8 3 3 ( T) A u d i o C o mmu n i c a t i o n s P r o t o c o l B
( A CP B)
2 6 Ba r e ( A CP ) Sh i e l d
15- 00- 36
A u d i o S y s t e ms S e r v i c e 15- 00- 36
GRAY CONNECTOR C1
K21917-A
Pin
1
No t Us e d
2

No t Us e d
3 2 87
( B K / W)
4 82 2
( B K / L G )
5

No t Us e d
6

No t Us e d
7

No t Us e d
8

No t Us e d
9 No t Us e d
10 No t Us e d
BL A CK CONNECTOR C2
K21918-A
P i n
1 No t Us e d
2 173
( DG / P )
P i n
N u mb e r C i r c u i t r c u i t F u n c t i o n
3
......
No t Us e d
4

Not Us e d
5 167
( B R / O )
Ra d i o Su b - Wo o f e r Hi gh Aud i o ( + )
6 168
( R / B K )
COMPACT DISC CHANGER
K21919-A
P i n
1

Not Us e d
2 8 5 6 ( P ) LH Au d i o Out put ( + )
3 Ba r e
( B K / L G )
Sh i e l d
4
Ba r e
( B K / L G )
Gr o un d
5 Ba r e Shi e l d
6 832
( L B / B K )
( ACP A)
7
.......
N o t i c e '
8 GY) RH Au d i o O u t p u t : Vf
9 7 99
( O / B K )
RH Au d i o Out put (-)
10

No t Us e d
11 7 98
( L G / R)
LH Au d i o Out put (-)
12 2 96 ( W/ P ) 12 Vo l t s Ba ' l i c - y :
:
o s d
13 1038
( L G / B K )
Au d i o S y s t e ms ON ( A SYSON)
14 833 (TN) Aud i o Co mmu n i c a t i o n s P r o t o c o l B
( ACP B)
Lux ur y Aud i o Sy st e m Di gi t a l Cr o wn Vi c t o r i a , Gr a n d Ma r qui s
HOT AT ALL TIMES
1 POWER
DISTRIBUTION
1 BOX
HOT IN START I HOT IN ACC
OR RUN I OR RUN
HOT AT
ALL TIMES
FUSE
JUNCTION
PANEL
HOT IN START
See EVTM f o r
mo r e de t a i l s
o f t hi s c i r c ui t
15- 00- 38
1 ) ( 2 ) 1 3 ) ( 4
FRONT CONTROL UNIT
GRAY CONNECTOR C1
K21911-A
Pin
1 6 4 0 ( R / Y ) 12 Vo l t I gn i t i o n Fe e d ( Ru n / S t a r t )
2 No t Us e d
3 694
( B K / L G )
Gr o un d
4 No t Us e d
5 19 ( L B / R ) I l l umi n a t i o n
6 137
( Y / B K )
12 Vo l t Run / A c c y Fe e d
8 54 ( L G / Y) 12 Vol t Ba t t e r y Fe e d
FRONT CONTROL UNIT
BLACK CONNECTOR C2
Pin
1 No t Us e d
2 No t Us e d
3 No t Us e d
4 1068
( L G / B K )
A u d i o S y s t e ms ON ( A SYSON)
5 833 ( T) A u d i o Co mmu n i c a t i o n s P r o t o c o l B
( ACP B)
6 Ba r e Sh i e l d
7 5 9 4 ( GY) Ta p e Au d i o RH -
Pin
8 593
( DB / W)
Ta pe Aud i o RH +
9 No t Us e d
10 No t Used
11 Ba r e Sh i e l d
12 No t Used
13 832
( L B / P K )
( ACP A)
14 No t Us e d
15 584
( W/ P K )
Ta p e Au d i o L H -
16 583
( BR/ L G )
Ta p e Au d i o L H +
REMOTE CHASSIS UNI T
BL ACK CONNECTOR C1
13J H 4 J
K21913-A
Pin
1 803
( BR/ P K )
2 802 ( O / R ) RHRe a r S p e a ke r ( + )
3 811
( DG / O)
4 805
( W/ L G )
5 801 ( T / Y) LH Re a r Sp e a ke r (-)
6 800
( G Y/ L B )
LH Re a r S p e a ke r ( + )
7 313
( L B / W)
L H Fr o n t S p e a ke r ()
8 804
( O / L G )
LH Fr o n t Sp e a ke r ( + )
9
_
No t Us e d
10 No t Used
11

No t U s e *
12 694
( B K / L G )
Gr o un d
13 694
( B K / L G )
Gr o un d
14 37 ( Y) 12 Vo l t s Ba t t e r y Fe e d
REMOTE CHASSIS UNIT
GRAY CONNECTOR C2
K21914-A
Pin
1 173
( DG / P )
2 168
( R / B K )
3 No t Us e d
4 No t Us e d
5 167
( B R / O )
Ra d i o Su b - Wo o f e r Hi gh Au d i o ( + )
6 Ba r e Sh i e l d
REMOTE CHASSIS UNIT
GRAY CONNECTOR C3
Pin
1 832
( L B / P K )
( ACP A)
2 1068
( L G / B K )
Au d i o S y s t e ms ON ( A S YS ON)
3 No t Us e d
4 No t Us e d
5 No t Us e d
6 583
( B R / L G )
Ca s s e t t e I nput L H ( + )
Pin
7 593
( DB / W)
C a s s e t t e I nput RH ( + )
15 833 ( T) Au d i o Co mmu n i c a t i o n s P r o t o c o l B
( ACP B)
16 Ba r e Sh i e l d ( ACP )
17 32 ( R / L B ) St a r t L i n e
19 584
( W/ P K )
Ca s s e t t e I nput L H (-)
2 0 594 ( GY) C a s s e t t e I nput RH (-)
REMOTE CHASSIS UNIT
BLACK CONNECTOR C4
Pin
8 1068
( L G / B K )
Aud i o S y s t e m ON ( A SYSON)
9 7 98
( L G / R )
CD I nput L H ( - )
10 7 99
( O / B K )
CD I nput RH (-)
11
_
Not Us e d
12 No t Us e d
13
_
Not U s e d DS P ( NAV- )
14 832
( L B / P K )
( ACP A)
2 1 8 5 6 ( P ) CD I nput L H ( + )
2 2 690 ( GY) CD I nput RH ( + )
2 3 Ba r e Shi e l d
2 4
_
No t U s e d DS P ( N A V+ )
2 5 833 (T) Au d i o Co mmu n i c a t i o n s P r o t o c o l B
( ACP B)
2 6 Ba r e ( ACP ) Sh i e l d
GRAY CONNECTOR C1
8C21917-A
P i n
1

No t Us e d
2

No t Us e d
3 2 87
( B K / W)
4
82 2
( B K / L G )
5

No t Us e d
6

No t Us e d
7

No t Us e d
8 No t Us e d
9

No t Us e d
Pin
10

No t Us e d
BLACK CONNECTOR C2
K21918-A
Pin
1

No t Us e d
2 173
( DG / P )
Ra d i o Su b - Wo o f e r Hi gh A u d i o Mu t e
3

No t Us e d
4

No t Us e d
5 167
( B R / O )
6 168
( R / B K )
15- 00- 41 A u d i o S y s t e ms S e r v i c e
Luxur y Aud i o Sy st e m A n a l o g Cr o wn Vi c t o r i a , Gr a nd Ma r qui s
HOT AT A L L TI MES
HOT IN
START OR RUN
HOT IN ACC I HOT AT
OR RUN I A L L TI MES
POWER f
DISTRIBUTION s
c I
I FUSE
JUNCTION
I PANEL
See EVTM for
more details
of this circuit
K22713-A
1995 Town Car, Crown Vi ctori a, Grand Ma r q u i s Jul y 1994
1
FRONT CONTROL UNIT
GRAY CONNECTOR C1
K21911-A
P i n
1 640 ( R / Y) 12 Vo l t I gn i t i o n Fe e d Ru n / S t a r t
2

No t Us e d
3 6 9 4
( B K / L G )
Gr o un d
4

No t Us e d
5 19 ( L B / R ) I l l umi n a t i o n
6 137
( Y / B K )
12 Vo l t R u n / A c c y Fe e d
8 54 ( L G / Y) 12 Vo l t Ba t t e r y Fe e d
FRONT CONTROL UNIT
BLACK CONNECTOR C2
K21912-A
Pi n
1
No t Us e d
2 No t Us e d
3 No t Us e d
4 1068
( L G / B K )
A u d i o S y s t e ms ON ( A SYSON)
( ACP B)
6 Ba r e Sh i e l d
7 5 9 4 ( GY) T a p e A u d i o RH
( Co n t i n ue d )
Pin
8 593
( DB / W)
Ta pe Au d i o RH +
9

No t Us e d
10

No t Us e d
11 Ba r e Shi e l d
12 No t Us e d
13 832
( L B / P K )
( ACP A)
14 No t Us e d
15 584
( W/ P K )
Ta p e Au d i o L H -
16 583
( BR/ L G )
Ta pe Au d i o L H +
REMOTE CHASSIS UNIT
BLACK CONNECTOR C1
K21913-A
Pin
1 802 ( O / R ) RH Re a r S p e a ke r ( + )
2 803
( B R / P K )
3 805
( W/ L G )
RH Fr o n t Sp e a ke r ( + )
4 811
( DG / O )
RH Fr o n t Sp e a ke r (-)
5 800
( G Y/ L B )
6 801 ( T / Y) LH Re a r S p e a ke r (-)
7 813
( L B / W)
LH Fr o n t Sp e a ke r (-)
8 804
( O / L G )
LH Fr o n t Sp e a ke r ( + )
9
_
No t Us e d
10 Not Us e d
11 No t Us e d
12 694
( B K / L G )
Gr o un d
13 694
( B K / L G )
Gr o un d
14 37 ( Y) 12 Vo l t s Ba t t e r y Fe e d
15- 00- 43 ' x d i o S
-
REMOTE CHASSIS UNIT
GRAY CONNECTOR 0 3
K21915-A
Pin
N u m b e r C i r c u i t C i r c u i t Function
1 832
CLB/ PK)
( ACP A)
2 1068
( L G / BK)
Au d i o S y s t e m On ( A S YS ON)
3^
m
15- 00- 43
msc ~ z z z SUSP* JMT ~ aME. i~~ 1
Pi n
Number Ci rcui t Ci r cui t Fun c t i o n
3 No t Us e d
4 No t Us e d
5 No t Us e d i
6 5 8 3
( B R / L G )
Ca s s e t t e I n put LH ( + )
7 593
( DB / W)
15 833 ( T ) A u d i o Co mmu n i c a t i o n s P r o t o c o l B
( ACP B)
16 Ba r e Sh i e l d ( A CP )
17 3 2 ( R / L B ) 12 Vo l t s in St a r t
19 5 84
( W/ P K )
Ca s s e t t e I nput LH (-)
2 0 594 ( GY) Ca s s e t t e I nput RH (-)
ESR/ ESC Aud i o S y s t e mCr o wn Vi c t o r i a , Gr a nd Mar qui s
HOT IN ACC OR RUN
TO
ILLUMINATION
19 | LB/R
I
' F U S E
I J UNCT I ON
P A N E L
HOT AT ALL TIMES
" T FU S E
I J UNCT I ON
| } . P A N E L
of this circuit
01- 5 C t - 6
SOLI D STATE
C1 8
G2S 02 - 7 C2-4 C2-3 02 * 6 C2- 5 C2-2 C2*1
C1-3
C1-7
RA DI O
CHA S S I S
O/LG
LB/ W
*X| f l
x l l j
L H
FRONT
S P E A K E R
W/ LG
DG/O
GY/LB
801
*X
X
L H
RE AR
S P E A KE R
C I ]
RH
FRONT
S P E A K E R
802 O/R
T
BK/LG
BR/PK
X
RH
RE A R
S P E A K E R
K2 2 52 6- A
Co n n e c t o r End Vi ew
1 ) ( 2 J ( 3
ELECTRONIC SEARCH RADIO/ELECTRONIC
SEARCH CASSETTE RADIO CHASSIS
CONNECTOR C1
K22757-A
Pin
1 No t Us e d
2 No t Us e d
3 694
( B K / L G )
Gr o un d
4 No t Us e d
5 19 ( L B / R ) I l l umi n a t i o n Fe e d
6 137
( Y/ B K )
I gn i t i o n Fe e d
8 7 97 ( L G / P ) Ba t t e r y Fe e d
15- 00- 45 A u d i o S y s t e ms S e r v i c e 15-00-45
ELECTRONI C SEARCH RADI O/ELECTRONI C
SEARCH CASSETTE RADI O CHASSI S
CONNECTOR C2
Pi n
Number Ci r c u i t Ci r c u i t Fu n c t i o n
1 803
( B R / P K )
RH Re a r S p e a k e r Gr o un d
2 802 ( O / R ) RH Re a r S p e a ke r Su p p l y
3 811
( DG / O )
RH Fr o n t S p e a ke r Gr o un d
4 805
( W/ L G )
RH Fr o n t S p e a ke r Su p p l y
5 801 ( T / Y) LH Re a r S p e a ke r Gr o u n d
6 800
( G Y/ L B )
LH Re a r S p e a k e r Su p p l y
7 813
( L B / W)
LH Fr o n t S p e a ke r Gr o un d
8 804
( 0 / L G )
LH Fr o n t S p e a ke r Su ppl y
NOTE: Many c ust ome r s do not underst and t he
l i mi t at i ons of FM r ecept i on. Ref er t he cust omer t o t he
Owner Gui de f or i nf ormat i on about t he li mi t at i ons of
FM radi o per f or mance.
Internal di agnost i c exami nat i on of t he Front Cont rol
Unit (FCU), Rear Chassi s Unit (RCU), sub-woof er
ampli fi er, audi o c ompa c t di sc pl ayer, St eeri ng Wheel
Cont rol (SWC) modul e and radi o chassi s shoul d be left
t o t he aut hori zed radi o ser vi ce cent er. However, t he
aut omot i ve t echni ci an shoul d be abl e t o anal yze and
i sol at e radi o recept i on condi t i ons t o t he proper ar ea or
component causi ng t he condi t i on. All radi o condi t i ons
can be i sol at ed t o one of f i ve general ar eas:
Ant enna sy st e m.
Radi o chassi s ( 18806) .
Radi o speaker sy st e m.
Radi o noi se suppressi on equi pment .
Premi um sound sy st e m.
Audi o Communi cat i ons Prot ocol (ACP) net wor k.
Re t r i e v i n g Di a g n o s t i c T r o u b l e C o d e s ( DT Cs )
The Luxur y Audi o Sy st e m has on-boar d di agnost i c
capabi l i t i es and is equi pped t o c he c k f or e ve r y
component avai l abl e in t he Luxur y sy st e m even if t hi s
speci f i c vehi cl e is not equi pped wi t h all c ompone nt s.
Thi s wi ll se t a DTC f or t he mi ssi ng component s. These
DTCs can be i gnor ed if a Sy st e m Conf i gurat i on
Sel f -t est i s pe r f or me d f i rst and det ermi ned t hat t he
vehi cl e is not equi pped.
The ba t t e r y must be fully c ha r ge d f or pr oper audi o
sy st e m oper at i on. The i gni ti on swi t c h ( 1157 2 ) must be
in t he ON or ACCY. posi t i on. Turn t he sy st e m on and
t une in a st r ong AM st at i on and veri f y go o d r ecept i on.
Af t er an A M st at i on is c he c ke d , t une in a st r ong FM
st at i on. The sy st e m is now r eady t o ent er t he
di agnost i c mode.
Di a gn o s t i c Mo d e :
NOTE: Ba t t e r y must be fully c ha r ge d f or pr oper audi o
sy st e m oper at i on and sel f -t est .
Ent er Di agnost i cs mode by pressi ng pre-set but t on
"3" and t he "SEEK DOWN" but t on si mul t aneousl y f or
t hr ee se c onds. Thi s wi ll suspend all normal radi o
f unct i ons and di spl ay "DI AG".
1. NOTE: To per f or m di agnost i cs, pr ess t he
appr opr i at e but t ons a s i nst ruct ed.
SYSTEM CONFIGURATION SELF-TEST:
Pr ess pre-set but t on " 1". Thi s wi ll c he c k f or
connect i on of all possi bl e devi ces and l og t he
f aul t c ode s f or any devi ce t hat does not r espond.
The di spl ay wi ll f l ash "SELF" whi l e gat heri ng t he
f aul t c o d e s, t hen st op f l ashi ng when compl et e. To
exi t Sy st e m Conf i gurat i on Sel f -t est , pr e ss pre-set
but t on " 1 " agai n. To ret ri eve f ault c o d e s, pr e ss
t he "TUNE UP" but t on. Thi s wi ll di spl ay t he f ault
c o d e s if any exi st . Cont i nued pressi ng of t he
"TUNE UP" but t on wi ll di spl ay t he next f aul t
c o d e . Recor d c ode s and c ompa r e wi t h c ode I.D.
in t abl e bel ow. To exi t t he Ret ri eval Mode , pr e ss
pre-set but t on " 1 " .
CONFI GURATI ON SELF-TEST CODES
C o d e De s c r i p t i o n
0 No f a ul t c o d e s l o g g e d
1 No r e s p o n s e f r o m RCU
2 No r e s p o n s e f r o m t a p e d e c k
3 No r e s p o n s e f r o m b e ze l mi c r o
4 No r e s p o n s e f r o m C D/ DJ
5 No r e s p o n s e f r o m St e e r i n g Wh l Cn t
6 No r e s p o n s e f r o m RI CP
7 No r e s p o n s e f r o m Re mo t e Cl i ma t e Cnt
8 No r e s p o n s e f r o m Na v i ga t i o n Uni t
9 ROM c h e c k s u m v e r i f i c a t i o n f a i l e d
Remember, sy st e m conf i gurat i on wi ll t e st f or all
possi bl e equi pment connect i ons. I nspect t he vehi cl e t o
det ermi ne act ual equi pment i nst al l ed.
3.
2. FRONT CONTROL UNIT (FCU) DISPLAY TEST:
To ent er t he FCU di spl ay t est , pr ess pre-set
but t on " 5" . Thi s c he c k wi ll light all segment s in
t he FRONT CONTROL UNIT (FCU). The sy st e m
wi l l aut omat i cal l y exi t t hi s t est af t er f i ve se c onds.
FRONT CONTROL UNIT (FCU) and REAR
CHASSIS UNIT (RCU) I.D.
To ent er t hi s t est , pr e ss pre-set but t on " 3 " . Thi s
t e st i dent i f i es t he so f t wa r e level of t he FCU and
RCU. The FCU is t e st e d f i r st , f ol l owed by t he
RCU. The compl et ed t e st wi ll exi t aut omat i cal l y.
For c o d e i dent i f i cat i on, see t abl e bel ow. The
di spl ay wi ll have t wo sequences of f i ve c o d e s
e a c h. The f i rst sequence is f or t he f ront cont r ol
unit, t he se c ond sequence is f or t he Remot e
Chassi s Unit.
SOFTWARE IDENTIFICATION CODES
Pr oducl Producl
Type Vari ant
Code Descr i pt i on Code Descr i pt i on
11 FCU 1 Ba s e A n a l o g
2 A n a l o g w / C D- DJ
3 JBL/DSP
4 J BL / DS P w / C D- DJ
5 J BL / DS P w / C D- DJ
& Cl o c k
J B L / DS P & Cl o c k
31 RCU 1 A n a l o g
2 Di gi t a l
3 Mi d l i n e
REAR CHASSI S UNIT SELF-TEST:
To ent er t hi s t e st , pr e ss pre-set but t on " 4 " . Thi s
t e st wi ll c he c k t he RCU "Re a d Only Me mo r y "
(ROM), and EEPROM memor y chi ps. The
c ompl e t e d t e st wi ll exi t aut omat i cal l y. For c o d e
I.D., see t abl e bel ow.
RCU SELF-TEST CODES
E E P ROM Checksums
Code ROM E Q Seek Var.
St er eo
Var.
0 FAI L FAI L FAI L FAI L
1 PASS FAI L FAI L FAI L
2 FAI L PASS FAI L FAI L
3 PASS PASS FAI L FAI L
4 FAI L FAI L PASS FAI L
5 PASS FAI L P ASS FAI L
6 FAI L PASS PASS FAI L
7 PASS PASS PASS FAI L
8 FAI L FAI L FAI L PASS
y PASS FAI L FAI L PASS
A FAI L P ASS FAI L P ASS
B PASS P ASS FAI L P ASS
C FAI L FAI L PASS PASS
D
a
PASS FAI L PASS P ASS
RCU SELF-TEST CODES (Cont 'd)
EEPROM Checksums
C o d e ROM EQ Seek Var.
St er eo
Va i .
E FAI L PASS P ASS PASS
PASS PASS P ASS PASS
a A n a l o g uni t wh i c h i s OK
b Di gi t a l uni t wh i c h i s OK
5. COMPACT DISC CHANGER:
The Compact Di sc Changer wi ll aut omat i cal l y
di spl ay error c ode s f or unaccept abl e operat i ng
condi t i ons t hat hi nder normal per f or mance. For
c ode I.D. see t abl e bel ow.
The sy st e m wi ll aut omat i cal l y exi t t he t est upon
compl et i on of t he t est .
LUXURY CD CODES
Di spl ay Operat i ng Condi t i ons
CD- E1 Me c h a n i s m Er r o r
CD- E2 Fo c u s Er r o r
CD- E3 Di s c Un r e a d a b l e
To o Ho t Th e r ma l Sh u t d o wn
No CD E mpt y Sl o t o r Ma g . not i n s e r t e d
S p e a k e r Wa l k - A r o u n d T e s t
To ent er t hi s t est , pr ess pre-set but t on " 2 " .
Included in t he Luxury Audi o Sy st em on-board
di agnost i c capabi l i t i es is t he SPEAKER
WALK-AROUND t est . Thi s t est wi ll aut omat i cal l y
adj ust t he vol ume t o mi d-level and di spl ay "SPKR" on
t he FRONT CONTROL UNIT (FCU). The Fade and
Bal ance wi ll t hen sel ect each speaker a s f ol l ows:
Ri ght Front (RF), Lef t Front (LF), Ri ght Rear (RR), Lef t
Rear (LR). A c ode char ge at Job 1 + 9 0 wi ll change
order t o RF, LF, LR and RR.
If a di versi t y ant enna sy st e m is de t e c t e d, t he
SPEAKER WALK-AROUND wi ll be per f or med t wi c e -
f i rst wi t h t he sub-ant enna only and t hen wi t h t he main
ant enna only.
Af t er t he ant enna t est is compl et e, t he sy st e m wi ll t hen
send a si gnal t o t he sub-woof er speaker (JBL onl y).
The sy st e m wi ll t hen exi t t he t est aut omat i cal l y upon
compl et i on of t he t est .
The di agnosi s c ha r t s and t e st s shoul d be used wi t h
encl osed schemat i cs, t he El ect ri cal and Vacuum
Troubl eshoot i ng Manual and appr opr i at e t est
equi pment t o accur at el y di agnose and qui ckl y ser vi ce
most radi o sy st e m concer ns.
1.
2.
operat i ng t he el ect roni c audi o sy st e m t o
dupl i cat e t he condi t i on.
I nspect t o det ermi ne if one of t he f ol l owi ng
1 9 9 5 To wn Ca r , Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s Jul y 1 9 9 4
DIAGNOSIS AMD TESTING (Cont i nued)
Me c h a n i c a l
Radi o c has s i s wi t h o r
wi t hout t ape pl ayer
physi cal l y d a ma g e d ,
mi sal i gned, any cont r ol s
i noper at i ve.
Di gi t al audi o c o mp a c t d i s c
pl ayer physi cal l y d a ma g e d ,
mi sal i gned, any cont r ol s
i noper at i ve.
Ant enna, t wo- pi ece ant enna
c abl e or on- gl ass FM
ant enna ( f r ont a n d / o r r ear )
a n d o n - gl ass AM ant enna
( def r ost er gr i d on r ear
wi n d o w) p h y s i c a l l y
d a ma g e d , mi s a l i gn e d
Radi o s peak er s
mount i ng / s p e a k e r c ones
physi cal l y d a ma g e d ,
mi sal i gned.
Ra d i o i gn i t i o n i n t e r f e r e n c e
c a p a c i t o r , r a d i o f r e q u e n c y
i n t e r f e r e n c e s u p p r e s s i o n
b o n d a n d r a d i o r e c e i v e r
h o o d b o n d i n g s t r a p
mi s a l i gn e d , d a ma g e d o r
p o o r me t a l - t o - me t a l
c o n t a c t .
Mo b i l e t e l e p h o n e h a n d s e t ,
mo b i l e t e l e p h o n e
mi c r o p h o n e , mo b i l e
t e l e p h o n e t r a n s c e i v e r
h o l d e r c r a d l e p h y s i c a l l y
d a ma g e d , mi s a l i gn e d .
E l e c t r i c a l
Op e n f u s e s .
Op e n c o n n e c t o r s .
I gn i t i o n s wi t c h .
3. If t he i nspect i on reveal s obvi ous concer n(s) t hat
c a n be readi l y i dent i f i ed, ser vi ce as requi red.
det er mi ne t he sy mpt om(s) and pr o c e e d t o t he
Sy mpt o m Chart .
Ref er t o t he el ect ri cal sc he ma t i c s, and t o t he
di agnosi s c ha r t s t o i sol at e radi o chassi s concer ns.
equi val ent t o pe r f or m el ect ri cal Pi npoi nt Test s.
S y m p t o m C h a r t s
AUDIO SYSTEM LUX
CONDITION POSSIBLE SOURCE ACTI ON
Luxur y Aud i o Sy s t e m Do e s Not
Po we r Up Whi l e I gni t i on Swi t c h i s
in ACCESSORY or RUNNo
Di spl a y a n d No Aud i o
Ope n FCU or A 1 f use s or
p o we r / g r o u n d c o n n e c t i o n s.
Ope n RCU f use s or p o we r / g r o u n d
ASYSON wi r e .
ACP l i ne A be t we e n Fr ont Co n t r o l
Uni t a n d Re mo t e Cha s s i s Uni t .
ACP l i ne B be t we e n Fr ont Co n t r o l
Uni t a n d Re mo t e Ch a s s i s Uni t .
GO t o Pi npoi nt Test A.
Whe n St e e r i n g Whe e l Co n t r o l
Aud i o But t o n s (Vol ume , ME M a nd
BAND) a r e P r e s s e d , No t hi n g
Ha p p e n s FCU a n d Di spl a y
Fun c t i o n No r ma l l y
Ope n SWC f use or p o we r / g r o u n d
Ope n ASYSON l i ne.
Ope n ACP l i ne A.
o Ope n ACP l i ne B.
o Ope n c o mmun i c a t i o n wi r e be t we e n
push but t o n s unit a nd SWC
mod ul e.
o De f e c t i v e push but t o n s or
d e f e c t i v e SWC mo d ul e .
GO t o Pi npoi nt Test D.
FCU Di spl a y s "NO DJ " Whe n
CDDJ Is Pr e se n t arid FCU CD
But t o n i s P r e s s e d A M, enrj
Ta pe Ar e No r ma l
o Ope n CDDJ f use or p o we r / g r o u n d
connections.
'
s
Open ASYSON l i ne,
o Ope n ACP l i ne A.
o Ope n ACP l i ne B.
De f e c t i v e CDDJ.
GO t o Pi npoi nt Test E.
15- 00- 48 . A u d i o S y s t e ms S e r v i c e
AUDIO SYSTEMLUX (Cont i nued)
Dur i ng CD Mo d e , The FCU Di spl a y
Sh o ws " C DE 1 "
CDDJ me c h a n i s m e r r or . NOTE: A me c ha n i c a l f a i l ur e ha s
o c c u r r e d . TRY t o e j e c t ma ga zi n e ,
t hi s ma y c l e a r t he e r r o r c o n d i t i o n .
If t he ma ga zi n e wi l l not e j e c t ,
SWAP t h e CD c ha n ge r .
Po we r d i s c o n n e c t / r e c o n n e c t ma y
c l e a r CDE1 er r or .
Sh o ws "CDE2"
L a se r f o c u s e r r or . FOCUS e r r or pr o ba bl y b a d , d i r t y or
s c r a t c h e d d i s c . TRY a kn o wn go o d
d i sc . If e r r or p e r s i s t s wi t h go o d
d i s c , REPLACE c ha n ge r .
Sh o ws "To o Ho t "
The r ma l s h u t d o wn . CD c ha n ge r t he r ma l shut d o wn
pr o t e c t i o n mo d e , if t e mpe r a t ur e
e x c e e d s 60C ( 140F) , t he
c ha n ge r wi l l shut d o wn t o pr e se r v e
l a se r l i f e.
S h o w s "Bad CD"
Un r e a d a bl e CD. CHECK al l d i s c s , if pr o bl e m o c c u r s
on one d i s c , CHECK t ha t d i sc . If
pr o bl e m o c c u r s on al l d i s c s , MAKE
SURE t ha t d i s c s a r e l a be l e d si d e
up in a ma ga zi n e . If d i s c s a r e not
s c r a t c h e d , d i r t y or i n se r t e d upsi d e
d o wn , REPLACE CD c ha n ge r .
Sh o ws "No CD"
No CD f o un d .
NOTE: Af t e r a CD e r r o r o c c u r s , t he
a c t ua l e r r o r c o d e wi l l be d i s pl a y e d
f o r a c o upl e mi n ut e s, t he n t h e r a d i o
wi l l s t o p c o mmun i c a t i n g t o t h e CD
c ha n ge r on ACP. Af t e r
c o mmun i c a t i o n be t we e n r a d i o a n d
CD s t o p s , " No CD" wi l l be
d i s pl a y e d on t h e Luxur y Fr o n t
Co n t r o l Uni t whe n e v e r t h e CD
mo d e i s s e l e c t e d , unt i l t he
ma ga zi n e i s e j e c t e d or i gni t i on i s
c y c l e d ( o n / o f f / o n ) . " No CD" wi l l
be d i s pl a y e d f o r e mpt y sl o t s whe n
t he ma ga zi n e i s f i r st l o a d e d a n d
t he s l o t s / d i s c s a r e i ni t i al l y
c h e c ke d / l o a d e d by t h e c ha n ge r .
Af t e r al l s l o t s a r e i ni t i al l y c h e c ke d ,
t he CD c ha n ge r wi l l me mo r i ze t he
e mpt y s l o t s , t he ne xt t i me t hr o ugh
t he ma ga zi n e , whe n i n c r e me n t i n g
or d e c r e me n t i n g d i s c s , t he
c ha n ge r wi l l ski p t he e mpt y s l o t s
a n d p r o c e e d t o t h e ne xt a v a i l a bl e
d i s c . If t he ma ga zi n e i s e j e c t e d a nd
l o a d e d a ga i n , t h e c ha n ge r wi l l
r e pe a t t hi s c y c l e t o f i gur e wh i c h
d i s c s a r e pr e se n t . If v e hi c l e ha s
be e n in an a c c i d e n t , t h e CD
c ha n ge r sho ul d be f un c t i o n a l l y
c h e c ke d b e c a u s e d i s c s ma y be
j a mme d in t he c ha n ge r .
"NO CD" i s d i s pl a y e d whe n a CD
i s not f ound in a sl o t .
FCU Is In Ta pe Mo d e , Di spl a y
Sh o wi n g " T A P E " No Aud i o at
S p e a k e r s A M, FM a n d CDDJ
Mo d e s a r e No r ma l
Ta pe a ud i o wi r e s.
Ta pe a ud i o wi r e s b e t we e n FCU
a nd RCU.
Da ma ge d FCU.
Da ma ge d RCU.
G O t o P i n p o i n t Test F.
15- 00- 48
In Ta pe Mo d e , Aud i o Vo l ume Hal f
a s Lo ud a s No r ma l
Ta pe a ud i o wi r e s .
Ta pe a ud i o wi r e s b e t we e n FCU
a n d RCU.
Da ma ge d FCU.
Da ma ge d RCU.
GO t o Pi npoi nt Test F.
FCU i s in Ta pe Mo d e , t he Di spl a y
Sho ws " T DE 1 "
Thr e e si d e c h a n ge s in 10 s e c o n d s .
De f e c t i v e t a p e .
REPLACE d a ma ge d FCU, SEND
t h e FCU t o a s e r v i c e c e n t e r t o
REPLACE d a ma ge d t a p e d e c k
i n si d e t he FCU.
FCU i s in Ta pe Mo d e , t he Di spl a y
Sho ws " TDE 2 "
Ca n ' t e j e c t t h e t a p e .
De f e c t i v e t a p e .
REPLACE d a ma ge d FCU, SEND
t h e FCU t o a s e r v i c e c e n t e r t o
FCU i s i n Ta pe Mo d e , t he Di spl a y
Sho ws " TDE 3"
Ca n ' t l o a d t h e t a p e . REPLACE d a ma ge d FCU, SEND
t he FCU t o a s e r v i c e c e n t e r t o
Whe n I gni t i on i s Cy c l e d Fr o m OFF
t o START or OFF t o ACCESSORY,
FCU P o we r s Up No r ma l l y , Di spl a y
i s On N o Aud i o i n Al l Mo d e s of
Ope r a t i o n
RCU St a r t (STA) l i ne.
Da ma ge d RCU.
Da ma ge d FCU.
The FCU Di spl a y Sh o ws CDDJ, But
The r e i s No CDDJ A u d i o A M, FM
a n d Ta pe Mo d e s a r e No r ma l
CDDJ a ud i o wi r e s .
Da ma ge d CDDJ.
Da ma ge d RCU.
In CDDJ Mo d e , Aud i o Vol ume Hal f
a s Lo ud a s No r ma l
CDDJ a udi o wi r e s be t we e n CCDJ
a n d RCU.
Da ma ge d CDDJ.
L o ud " P OP S " He a r d Whe n I gni t i on
Swi t c h i s Cy c l e d Be t we e n OFF a n d
ACCESSORY or OFF a n d RUN
Sub- wo o f e r Ampl i f i e r e n a bl e l i ne i s
s h o r t e d t o ba t t e r y .
RCU st a r t l i ne (STA) i s
s h o r t e d / o p e n e d .
Da ma ge d subwo o f e r .
Da ma ge d RCU.
GO t o Pi npoi nt Test K.
De l a y A c c e s s o r y i s Not Fun c t i o n a l .
Aud i o Sy s t e m Do e s Not Shut Of f
Wh e n An y of t he Do o r s a r e Ope n
a n d I gni t i on Swi t c h i s OFF. Aud i o
Sy s t e m Shut s OFF Be f o r e 10
Mi n ut e De l a y or a ny of t h e Do o r s
a r e Ope n a nd I gni t i on Swi t c h i s
OFF.
De l a y a c c e s s o r y s h o r t e d t o
gr o un d .
A SYSON i s s h o r t e d t o ba t t e r y .
Dr i ve r d o o r a j a r s wi t c h .
Ope n d e l a y a c c e s s o r y l i ne
b e t we e n L CM a nd FCU.
Da ma ge d L CM.
Da ma ge d FCU.
On e or Mo r e of The Aud i o Co n t r o l
But t o n s, Suc h a s Vo l ume , Se e k,
Tune a nd Sc a n i s Not Fun c t i o n a l in
Ei t he r Ra d i o , Ta pe or CDDJ Mo d e
or Al l Mo d e s
Da ma ge d RCU f o r A M / FM mo d e .
Da ma ge d t a pe f or TAPE mo d e .
Da ma ge d CDDJ f o r CDDJ mo d e .
Da ma ge d FCU f or any one or al l
mo d e s .
REPLACE d a ma ge d RCU.
REPLACE d a ma ge d t a p e d e c k.
REPLACE d a ma ge d CDDJ.
REPLACE d a ma ge d FCU.
Wh e n He a d l a mp Swi t c h i s in PARK
or HEAD Po si t i o n , No FCU Ba c k
L i g h t i n g A l l Ot he r I nst r ume nt
Pa ne l Li ght i n g i s No r ma l
Ope n suppl y wi r e .
Ope n gr o un d .
Da ma ge d FCU.
Da ma ge d L CM.
The FCU Di spl a y Ca n Be Di mme d
But Not Co n t r o l But t o n s or Co n t r o l
But t o n s Ca n Be Di mme d But No t
FCU Di spl a y
Da ma ge d FCU. REPLACE FCU.
I r r e gul a r Ope r a t i o n of FCU Di spl a y
a n d I n d i c a t o r LEDS
Da ma ge d FCU. REPLACE FCU.
No St e e r i n g Whe e l Co n t r o l But t o n s
Ba c kl i gh t i n g, Bo t h LH a n d RH Si d e
I l l umi nat i on suppl y wi r e .
Da ma ge d L CM.
Da ma ge d SWC mo d ul e .
Da ma ge d r i ght ha n d si d e push
but t o n s.
GO t o Pi npoi nt Te st N.
1995 Town Ca r , Cr o wn Vi c t o r i a , G r a n d Ma r q u i s J u l y 1994
CONDITION P O S S I B L E S O U R C E A C T I O N
Le f t Ha n d Si d e ( LHS) Push But t ons
Co n t r o l l e r Uni t Ba c kl i gh t i n g i s
Mi s s i n g, Whe n t h e He a d l i ght
Swi t c h in PARK or He a d l i ght
P o s i t i o n S WC Ba c kl i gh t i n g i s
OK, No LH Ba c kl i ght i n g
Da ma ge d RHS pus h but t o n uni t .
Da ma ge d LHS pus h but t o n uni t .
De gr a d e d A M Re c e pt i o n or
Co n t i n uo us Se e k in A M
Po o r c o n n e c t i o n s t o r e a r d e f r o st
gr i d .
RCU t o AI M c o a x i a l c a b l e d e f e c t .
Sho r t t o ur e t ha n e on r e a r gl a s s .
Da ma ge d gr i d l i n e s.
Po o r d e f r o s t e r gr i d gr o un d .
Po o r AI M gr o un d .
Po o r AI M po we r c i r c ui t c o n n e c t i o n .
AI M po we r c i r c ui t sho r t t o gr o un d .
Da ma ge d RCU.
GO t o Pi npoi nt Te st R.
De gr a d e d FM Re c e pt i o n or
Co n t i n uo us Se e k in FM
Po o r c o n n e c t i o n t o r e a r gl a s s FM
a n t e n n a .
De f e c t i v e AI M t o r e a r gl a s s FM
a n t e n n a c o a x i a l c a b l e .
Sho r t t o ur e t ha n e on r e a r gl a s s .
Da ma ge d d e f r o s t e r gr i d l i ne s.
Da ma ge d r e a r gl a s s FM a n t e n n a
pa t t e r n .
Da ma ge d RCU t o AI M c o a x i a l
c a bl e c o n n e c t i o n .
Poor c o n n e c t i o n t o f r ont gl a ss FM
d i v e r si t y a n t e n n a .
Da ma ge d c a b l e b e t we e n f r ont
gl a s s FM d i v e r si t y a n t e n n a a n d
RCU.
Da ma ge d f r o n t gl a s s FM d i v e r si t y
pa t t e r n .
Da ma ge d RCU.
GO t o Pi npoi nt Test S.
One or Mo r e Sp e a ke r s Ha ve No
S o u n d A l l Mo d e s
Da ma ge d + s p e a ke r wi r e .
Da ma ge d - s p e a ke r wi r e .
Da ma ge d spe a ke r .
On e or Mo r e Sp e a ke r s Ha ve
Di s t o r t e d S o u n d A l l Mo d e s
G Ot o Pi npoi nt Test U.
On e or Mo r e Sp e a ke r s Ha ve L o w
Vo l u me A l l Mo d e s ( AM , FM,
TAPE a n d CDDJ)
GO t o Pi npoi nt Te st V.
On e or Mo r e Sp e a ke r s Po p or
Cr a c kl e Whe n Ve hi c l e Dr i ven Ove r
Bu mp s A l l Mo d e s
L o o s e c o n n e c t i o n .
GO t o Pi npoi nt Te st W.
On e or Mo r e Sp e a ke r s Exhi bi t Hum
on Al l Mo d e s
I nsuf f i c i e nt n o i se s u ppr e s s i o n . GO t o Pi npoi nt Test Y.
The Re s po n s e Ti me Be t we e n
Pr e ssi n g Any of t h e Aud i o Co n t r o l
But t o n s a nd Aud i o Sy s t e m
Re s po n s e i s Mo r e Tha n Two
Se c o n d s
St e e r i n g whe e l c o n t r o l mo d ul e .
CDDJ.
RCU.
FCU.
GO t o Pi npoi nt Test Z.
A U D I O SYSTEMESR/ESC
Ra d i o i s I n o pe r a t i v e or I nt e r mi t t e nt Bl o wn f u s e ( s ) .
Ope n o r s h o r t e d po we r f e e d s .
Ba d gr o un d f e e d .
Da ma ge d r a d i o c h a s s i s .
GO t o Pi npoi nt Te st AA.
One o r Mo r e Ra d i o Sp e a ke r s i s
I n o pe r a t i v e or Di s t o r t e d
Spe a ke r ( s ) b a d .
Wi r i n g t o s p e a ke r ( s ) o pe n or
s h o r t i n g.
Ba d a n t e n n a s y s t e m.
GO t o Pi npoi nt Te st BB.
Ra d i o Cha ssi s Ha s We a k or No i sy
Re c e pt i o n
I mpr o pe r or d a ma ge d n o i se
s uppr e s s i o n e qui pme n t .
GO t o Pi npoi nt Te st CC.
Ra d i o Cha s s i s Fun c t i o n Test Not
Wo r ki n g Pr o pe r l y ( Di spl a y
Ope r a t i o n a l )
Wi r i n g or b a d s p e a ke r s .
GO t o Pi npoi nt Te st DD.
Gr a phi c s Do Not Li ght Up Wi t h
L i gh t s Tur ne d On
I l l umi nat i on f e e d .
I l l umi nat i on gr o un d .
GO t o Pi npoi nt Te st EE.
Ra d i o Cha s s i s Op e r a t e s , No
Di spl a y
Cl ust e r l i ght s a r e on at l ow
i nt e nsi t y .
I l l umi nat i on pr o b l e m.
GO t o Pi npoi nt Te st FF.
Ra d i o Do e s Not Fun c t i o n In Ta pe
Mo d e
Fo r e i gn ma t e r i a l in t a pe
me c ha n i sm.
Ta pe me c ha n i sm n e e d s c l e a n i n g.
GO t o Pi npoi nt Te st GG.
PINPOINT TEST A: LUXURY AUDIO SYSTEM DOES NOT POWER UP WHILE IGNITION SWITCH IS IN ACCESSORY OR RUN:
NO FCU DISPLAY AND NO AUDIO
A 1 CHECK FCU SUPPLY
Ye s
No
GO t o A4.
GO t o A2.
Me a sur e v o l t a ge be t we e n Ci r c ui t 797 ( LG / P) (Town
Ca r ) or Ci r c ui t 54 ( L G / Y) ( Cr o wn Vi c t o r i a , Gr a nd
Ma r qui s) , Pi n 8 of 0 1 c o n n e c t o r ( ha r n e ss si d e ) a nd
a kn o wn go o d gr o un d .
Does vol t met er read more t han 10 vol t s?
Ye s
No
GO t o A4.
GO t o A2.
A2 CHECK FUSE 18 OUTPUT (TOWN CAR) FUSE 8
OUTPUT ( CROWN VI CTORI A, GRAND MARQUI S)
Ye s
No
( L G / P ) o pe n be t we e n
f use a nd Pi n 8 of C1 FCU
c o n n e c t o r . RESTORE
v e hi c l e a nd VERI FY
s y s t e m o pe r a t i o n .
GO t o A3.
Me a sur e v o l t a ge be t we e Ci r c ui t 7 97 ( LG / P) (Town
Ca r ) or Ci r c ui t 54 ( L G / Y) ( Cr o wn Vi c t o r i a , Gr a nd
Ma r qui s) , c a v i t y No. 18, l o c a t e d in t he i nst r ume nt
pa n e l f use pa n e l and a known g o o d gr o un d .
Does vol t met er need more t han 10 vol t s?
Ye s
No
( L G / P ) o pe n be t we e n
GO t o A3.
A3 CHECK FUSE 18 ( TOWN CAR) OR FUSE 8 ( CROWN
VI CTORI A, GRAND MARQUI S) CONTI NUI TY
Ye s
No
SERVI CE Fuse 18 suppl y ,
CHECK f or p o s s i b l e
Ci r c ui t 797 ( L G / P ) sho r t
t o gr o un d . REPLACE
bl o wn f use . RESTORE
Re mo v e 10A f use , c a vi t y No. 18 (Town Ca r ) or
c a v i t y No . 8 ( Cr o wn Vi c t o r i a , Gr a n d Ma r qui s) a nd
pe r f o r m a c o n t i n ui t y c h e c k on t h e f use by me a sur i n g
r e s i s t a n c e a c r o s s t he f use t e r mi n a l s.
Ye s
No
CHECK f or p o s s i b l e
Ci r c ui t 797 ( L G / P ) sho r t
NO FCU DISPLAY AND NO AUDIO (Cont i nued)
A 4 CHECK A1 SWI TCHED SUPPLY
Ye s
No
GO t o A7.
G Ot o A5.
Cy c l e t he i gni t i on s wi t c h t o RUN.
Me a s ur e v o l t a ge be t we e n Ci r c ui t 2 94 (Y / BK) (Town
Ca r ) or Ci r c ui t 137 ( Y/ BK ) ( Cr o wn Vi c t o r i a , Gr a n d
Ma r q ui s) , Pi n 6 of C1 FCU c o n n e c t o r ( ha r n e ss si d e )
a n d a kn o wn go o d gr o un d .
Ye s
No
GO t o A7.
G Ot o A5.
A5 CHECK FUSE 6 ( TOWN CAR) OR FUSE 11 ( CROWN
VI CTORI A, GRAND MARQUI S) OUTPUT
Ye s
No
2 94 ( W/ L B ) be t we e n
v e hi c l e a n d VERI FY
G Ot o A6.
Me a s ur e v o l t a ge b e t we e n Ci r c ui t 294 (Y / BK) (Town
Ca r ) or 137 ( Y/ BK ) ( Cr o wn Vi c t o r i a , Gr a n d
Ma r q ui s) , c a v i t y No. 6 (Town Ca r ) or c a v i t y No. 11
( Cr o wn Vi c t o r i a , Gr a n d Ma r qui s) , l o c a t e d in t h e
i nst r ume nt pa n e l f use pa n e l a n d a kn o wn go o d
gr o un d .
Ye s
No
2 94 ( W/ L B ) be t we e n
G Ot o A6.
A6 CHECK FUSE 6 (TOWN CAR) OR FUSE 11 ( CROWN
Ye s
No
CHECK f o r po s s i b l e
Ci r c ui t 2 94 ( W/ L B ) sho r t
Re mo v e 10A f use , c a v i t y No. 6 (Town Ca r ) or No. 11
( Cr o wn Vi c t o r i a , Gr a n d Ma r qui s) a nd pe r f o r m a
c o n t i n ui t y c h e c ko n t he f use by me a sur i n g
Ye s
No
Ci r c ui t 2 94 ( W/ L B ) sho r t
A7 CHECK CI RCUI T 1003 ( G Y/ Y) (TOWN CAR) OR
CI RCUI T 640 ( R/ Y) ( CROWN VI CTORI A, GRAND
MARQUI S) SUPPLY
Ye s
No
GO t o A10.
GO t o A8.
Ensur e t ha t i gni t i on s wi t c h i s st i l l in RUN.
me a sur e v o l t a ge be t we e n Ci r c ui t 296 ( W/ P ) , Pi n 6
of C1 c o n n e c t o r ( ha r n e ss si d e ) a nd a kn o wn go o d
gr o un d .
Ye s
No
GO t o A10.
GO t o A8.
A 8 CHECK FUSE 8 ( TOWN CAR) OR FUSE 13 ( CROWN
VI CTORI A, GRAND MARQUI S) OUTPUT
Ye s
No
( W/ P ) o pe n be t we e n f use
a nd Pi n 6 of C1 FCU
GO t o A9.
Me a s ur e v o l t a ge be t we e n Ci r c ui t 1003 ( GY/ Y)
(Town Ca r ) or Ci r c ui t 640 ( R/ Y) ( Cr o wn Vi c t o r i a ,
Gr a n d Ma r qui s) , c a v i t y No. 8, l o c a t e d in t he
i n st r ume n t pa n e l f use pa n e l a nd a kn o wn go o d
gr o un d .
Does vol t met er r e a d more t han 10 vol t s?
Ye s
No
a nd Pi n 6 of C1 FCU
GO t o A9.
A 9 CHECK FUSE 8 ( TOWN CAR) OR FUSE 13 ( CROWN
Ye s
No
SERVI CE Fuse 8 suppl y .
SERVI CE po s s i bl e Ci r c ui t
296 ( W/ P ) sho r t t o
gr o un d . REPLACE bl o wn
f use . VERI FY s y s t e m
o pe r a t i o n .
Re mo v e 15A f use , c a v i t y No. 8 a nd pe r f o r m a
c o n t i n ui t y c h e c k on t he f use by me a sur i n g
Ye s
No
SERVI CE po s s i bl e Ci r c ui t
296 ( W/ P ) sho r t t o
f use . VERI FY s y s t e m
o pe r a t i o n .
A10 CHECK CI RCUI T 57 ( BK) CONTI NUI TY
Ye s
No
G Ot o A11.
FCU gr o un d o pe n .
RESTORE v e hi c l e a nd
VERI FY s y s t e m
o pe r a t i o n .
Ensur e t ha t t he i gni t i on s wi t c h i s OFF a nd me a sur e
r e s i s t a n c e be t we e n 57 ( BK) , Pi n 7 of FCU C1
( ha r n e ss e n d ) a nd a kn o wn go o d gr o un d .
Ye s
No
G Ot o A11.
FCU gr o un d o pe n .
VERI FY s y s t e m
o pe r a t i o n .
T E ST STEP RESULT A CTI ON TO T A KE
A 1 1 A L L CHECK CI RCUI T 6 9 4 ( BK/ L G ) CONTI NUI TY
Ye s
No
G O t o A 1 2 .
( BK/ L G ) FCU gr o un d
o pe n . RESTORE v e hi c l e
a n d VERI FY s y s t e m
o pe r a t i o n .
Ensur e t ha t t h e i gni t i on s wi t c h i s OFF a nd
d i s c o n n e c t FCU C1 a nd RC UC 1 c o n n e c t o r s .
Me a sur e r e s i s t a n c e b e t we e n 6 9 4 ( BK/ LG) , Pi n 3 of
FCU C1 ( ha r n e ss e n d ) a n d Pi n 2 of RCU C1 ( ha r n e s s
e n d ) c o n n e c t o r s .
Ye s
No
G O t o A 1 2 .
( BK/ L G ) FCU gr o un d
o pe r a t i o n .
A 1 2 CHECK RCU SUPPLY
Ye s
No
G O t o A 1 5 .
G O t o A 1 3 .
Me a s ur e v o l t a ge b e t we e n Ci r c ui t 8 2 8 (P / L B) , Pi n 1
of RCU C 1 c o n n e c t o r ( ha r n e ss si d e ) a n d a kn o wn
go o d gr o un d .
Ye s
No
G O t o A 1 5 .
G O t o A 1 3 .
A 1 3 CHECK FUSE R OUTPUT
Ye s
No
8 2 8 ( P / L B) b e t we e n f use
a n d Pi n t of C 1 RCU
G O t o A 1 4 .
Me a sur e v o l t a ge b e t we e n Ci r c ui t 8 2 8 (P / L B) , c a v i t y
No. R, l o c a t e d in t he po we r d i st r i but i o n f use bo x
( e n gi n e c o mpa r t me n t ) a n d a kn o wn go o d gr o un d .
Ye s
No
8 2 8 ( P / L B) b e t we e n f use
a n d Pi n t of C 1 RCU
G O t o A 1 4 .
A 1 4 CHECK FUSE R CONTI NUI TY
Ye s
No
SERVI CE Fuse R suppl y .
(P / LB) po s s i b l e sho r t t o
f use . RESTORE v e hi c l e
o pe r a t i o n .
Re mo v e 2 6 A f use , c a v i t y No. R a n d pe r f o r m a
Ye s
No
SERVI CE Fuse R suppl y .
(P / LB) po s s i b l e sho r t t o
o pe r a t i o n .
A 15 CHECK CI RCUI T 6 9 4 ( BK/ L G ) , PIN 2 OF RCU C 1 ,
GROUND FOR OPEN
Ye s
No
G O t o A 1 6 .
( BK/ L G ) RCU o pe n
gr o un d . RESTORE
Whi l e t he i gni t i on s wi t c h i s OFF, me a sur e r e s i s t a n c e
b e t we e n 6 9 4 ( BK/ L G ) , Pi n 2 of C 1 ( ha r n e ss e n d )
Ye s
No
G O t o A 1 6 .
gr o un d . RESTORE
A 1 6 CHECK CI RCUI T 6 9 4 ( BK/ LG) , PIN 3 OF RCU C1,
GROUND FOR OPEN
Ye s
No
G O t o A 1 7 .
gr o un d . RESTORE
Me a sur e r e s i s t a n c e b e t we e n 6 9 4 ( BK/ L G ) , Pi n 3 of
C 1 ( ha r n e s s e n d ) a nd kn o wn go o d gr o un d .
Ye s
No
G O t o A 1 7 .
gr o un d . RESTORE
A 1 7 CHECK FCU A N D RCU COMMUNI CATI ON LI NK
Ye s
No
GO to A18.
GO t o Pi npoi nt Test B t o
CHECK Co mmun i c a t i o n
Li nk.
Di sc o n n e c t SWC mo d ul e c o n n e c t o r .
Di sc o n n e c t CDDJ c o n n e c t o r .
Co n n e c t FCU C1 a nd C 2 c o n n e c t o r s .
Co n n e c t RCU C1 a nd C 3 c o n n e c t o r s .
Ope n a n d c l o s e dr i ve r door .
Turn FCU ON a nd r o t a t e v o l ume kn o b.
Does t he FCU di spl ay cont ai n dat a and show
di f f e r e nt val ues f or vol ume when vol ume knob is
r ot a t e d?
Ye s
No
GO to A18.
GO t o Pi npoi nt Test B t o
CHECK Co mmun i c a t i o n
Li nk.
PINPOINT TE ST A; LUXURY AUDIO SYSTEM DOES NOT POWER UP WHILE IGNITION SWITCH IS IN ACCESSORY OR RUN:
A18 CHECK SWC MODULE FOR I NTERNAL SHORT
Ye s D>
No
GO to A1t B
REPLACE d a ma ge d SWC
mo d ul e . VERI FY s y s t e m
o pe r a t i o n .
Connect SWC module connector.
Di sc o n n e c t CDDJ c o n n e c t o r s .
Co n n e c t FCU C1 and C2 c o n n e c t o r s .
Co n n e c t RCU G1 and C3 c o n n e c t o r s .
Open and close driver door.
Turn FCU ON a n d r o t a t e vo l ume kn o b.
Does t he FCU cont ai n dat a and show di f f e r e nt
val ues f or vol ume when vol ume knob i s r ot a t e d?
Ye s D>
No
GO to A1t B
REPLACE d a ma ge d SWC
o pe r a t i o n .
A19 CHECK CDDJ FOR I NTERNAL SHORT
Ye s
No
VERI FY s y s t e m
o pe r a t i o n .
REPLACE d a ma ge d
CDDJ. VERI FY s y s t e m
o pe r a t i o n .
Co n n e c t SWC mo d ul e c o n n e c t o r .
Co n n e c t CDDJ c o n n e c t o r .
Co n n e c t FCU C1 a n d C2 c o n n e c t o r s .
Co n n e c t RCU C1 a nd C3 c o n n e c t o r s .
Ope n a n d c l o s e d r i ve r door .
Turn FCU ON a n d r o t a t e vo l ume kn o b.
Does t he FCU cont ai n dat a and show di f f e r e nt
val ues f or vol ume when vol ume kn o b Is r ot a t e d?
Ye s
No
VERI FY s y s t e m
o pe r a t i o n .
REPLACE d a ma ge d
o pe r a t i o n .
PINPOINT TEST B: NETWORK (ASYSON) TEST
B1 CHECK CI RCUI T 1068 ( L G / BK) ASYSON FOR OPEN
BETWEEN FCU AND RCU
Ye s
No
GO t o B2.
SERVI CE ASYSON o pe n
be t we e n FCU a nd RCU.
VERI FY s y s t e m
o pe r a t i o n .
Di s c o n n e c t FCU c o n n e c t o r C2, RCU c o n n e c t o r C3,
SWC a n d CDDJ c o n n e c t o r s .
Me a s u r e r e s i s t a n c e be t we e n FCU c o n n e c t o r C2,
Pi n 4 ( ha r n e ss s i d e ) a n d RCU c o n n e c t o r C3, Pi n 2
( ha r n e s s e n d ) .
Ye s
No
GO t o B2.
SERVI CE ASYSON o pe n
be t we e n FCU a nd RCU.
VERI FY s y s t e m
o pe r a t i o n .
B2 CHECK CI RCUI T 1068 ( L G / BK) ASYSON FOR SHORT
TO GROUND BETWEEN FCU AND RCU
Ye s
No
GO t o B3.
(LG / BK) sho r t t o gr o un d
be t we e n FCU & RCU.
VERI FY s y s t e m
o pe r a t i o n .
Di sc o n n e c t FCU c o n n e c t o r C2, RCU c o n n e c t o r C3,
Me a s u r e t he r e s i s t a n c e be t we e n Ci r c ui t 1068
(LG / BK ) FCU c o n n e c t o r C2, Pi n 4 ( ha r n e s s e n d )
a nd a kn o wn go o d gr o un d .
Is r esi st ance gr eat er t han 1 M ohm?
Ye s
No
GO t o B3.
VERI FY s y s t e m
o pe r a t i o n .
B3 CHECK CI RCUI T 1068 ( L G / BK ) ASYSON FOR SHORT
TO GROUND BETWEEN RCU AND CDDJ
Ye s
No
G Ot o B4.
be t we e n RCU & CDDJ.
VERI FY s y s t e m
o pe r a t i o n .
Me a s u r e t he r e s i s t a n c e be t we e n Ci r c ui t 1068
( L G / BK ) RCU c o n n e c t o r C4, Pi n 8 ( ha r n e ss e n d )
Is r esi st ance gr eat er t han 1 M ohm?
Ye s
No
G Ot o B4.
VERI FY s y s t e m
o pe r a t i o n .
B4 CHECK CI RCUI T 1068 ( L G / BK ) ASYSON FOR SHORT
TO BATTERY BETWEEN FCU AND RCU
Ye s
No
Go t o B5.
( L G / BK) sho r t t o ba t t e r y
VERI FY s y s t e m
o pe r a t i o n .
Di s c o n n e c t FCU c o n n e c t o r C2, RCU c o n n e c t o r C3,
Me a s u r e t h e v o l t a ge be t we e n Ci r c ui t 1068 ( LG / BK)
FCU c o n n e c t o r C2, Pi n 4 ( ha r n e ss e n d ) a n d a kn o wn
g o o d gr o un d .
Does vol t met er r ead zero vol t s?
Ye s
No
Go t o B5.
( L G / BK) sho r t t o ba t t e r y
VERI FY s y s t e m
o pe r a t i o n .
15- 00- 55 _ _ A u d i o S y s t e m s S e r v i c e 15- 00- 55
D I A G N O S I S AND TESTING (Conti nued)
PINPOINT TEST B: NETWORK (ASYSON) TEST (Cont i nued)
B5 CHECK CI RCUI T 1068 ( LG / BK) ASYSON FOR SHORT
TO BATTERY BETWEEN RCU AND CDDJ
Ye s
No
GO t o B6.
( L G / BK ) sho r t t o b a t t e r y
b e t we e n RCU a n d CDDJ.
RESTORE v e hi c l e a n d
VERI FY s y s t e m
o pe r a t i o n .
Me a s ur e t h e v o l t a ge b e t we e n Ci r c ui t 1068 ( LG / BK)
RCU c o n n e c t o r C4, Pi n 8 ( ha r n e ss e nd) a n d a kn o wn
go o d gr o un d .
Do e s vol tmeter read zero vol ts?
Ye s
No
GO t o B6.
( L G / BK ) sho r t t o b a t t e r y
b e t we e n RCU a n d CDDJ.
VERI FY s y s t e m
o pe r a t i o n .
B6 CHECK CI RCUI T 1068 ( L G / BK) ASYSON VOLTAGE
LEVEL
Ye s
No
ACP A & ACP B Ne t wo r k
Te st .
VERI FY s y s t e m
o pe r a t i o n .
o Ensur e t ha t t he i gn i t i o n s wi t c h i s in RUN a n d FCU
p o we r but t o n i s o n .
Co n n e c t onl y FCU C1 a n d C2 c o n n e c t o r s a n d
me a sur e t h e v o l t a ge of Ci r c ui t 1068 ( L G / BK)
ASYSON b e t we e n Pi n 2 of RCU C3 a n d a kn o wn
go o d gr o un d .
I s v o l t a g e g r e a t e r t h a n 10 v o l t s ?
Ye s
No
ACP A & ACP B Ne t wo r k
Te st .
VERI FY s y s t e m
o pe r a t i o n .
PI NPOI NT TEST C: NETWORK (ACP A & ACP B) TEST
C1 CHECK CI RCUI T 832 ( LB / PK) ACP A FOR OPEN
Ye s
No
GO t o C2.
( L B/ P K) o pe n b e t we e n
FCU a n d RCU. RESTORE
Di sc o n n e c t FCU c o n n e c t o r C 2 , RCU c o n n e c t o r C3,
Me a s ur e r e si st a n c e be t we e n FCU c o n n e c t o r C2,
Pi n 13 ( ha r n e ss si d e ) a n d RCU c o n n e c t o r C3, Pi n 1
( ha r n e ss e n d ) .
Is r e s i s t a n c e 5 o h ms o r l e s s ?
Ye s
No
GO t o C2.
( L B/ P K) o pe n b e t we e n
FCU a n d RCU. RESTORE
C2 CHECK CI RCUI T 832 ( LB / PK) ACP A FOR SHORT TO
GROUND BETWEEN FCU AND RCU
Ye s ^
No l >
GO t o C3.
( LB / PK) sho r t t o gr o un d
VERI FY s y s t e m
o pe r a t i o n .
o Di sc o n n e c t FCU c o n n e c t o r C2, RCU c o n n e c t o r C3,
SWC a nd CDDJ c o n n e c t o r s .
Me a sur e t he r e s i s t a n c e be t we e n Ci r c ui t 832
( L B/ P K ) FCU c o n n e c t o r C2, Pi n 13 ( ha r n e ss e n d )
Is resi stance g r e a t e r t h a n 1 M ohm?
Ye s ^
No l >
GO t o C3.
( LB / PK) sho r t t o gr o un d
VERI FY s y s t e m
o pe r a t i o n .
C3 CHECK CI RCUI T 832 (LB / PK) ACP A FOR SHORT TO
GROUND BETWEEN RCU AND CDDJ
Ye s
No
GO t o C4.
( LB / P K) sho r t t o gr o un d
VERI FY s y s t e m
o pe r a t i o n .
Di sc o n n e c t Re mo t e Ch a s s i s Uni t C4 a nd CDDJ
( L B/ P K ) RCU c o n n e c t o r C4, Pi n 14 ( ha r n e ss e nd)
a nd a kn o wn go o d gr o un d .
Is r e s i s t a n c e g r e a t e r t h a n 1 M ohm?
Ye s
No
GO t o C4.
( LB / P K) sho r t t o gr o un d
VERI FY s y s t e m
o pe r a t i o n .
C4 CHECK CI RCUI T 832 ( L B/ P K) ACP A FOR SHORT TO
SHI ELD
Ye s
No -
GO t o C5.
( L B/ P K) sho r t t o shi e l d
VERI FY s y s t e m
o pe r a t i o n .
( L B/ P K ) FCU c o n n e c t o r C2, Pi n 13 ( ha r n e s s e nd)
a nd Pi n 6, shi e l d , ( Ba r e ) of t he sa me c o n n e c t o r .
I s r e s i s t a n c e g r e a t e r t h a n 1 M ohm?
Ye s
No -
GO t o C5.
VERI FY s y s t e m
o pe r a t i o n .
PINPOINT TEST C: NETWORK (ACP A & ACP B) TEST (Cont i nued)
SHI ELD BETWEEN RCU AND CDDJ
Ye s
No
G o t o 0 6 .
VERI FY s y s t e m
o pe r a t i o n .
Di sc o n n e c t Re mo t e Ch a s s i s Uni t C4 a n d CDDJ
Me a sur e t h e r e s i s t a n c e b e t we e n Ci r c ui t 832
( LB / PK) RCU c o n n e c t o r C4t Pi n 14 ( ha r n e ss e n d )
a n d Pi n 23, s hi e l d , ( Ba r e ) of t h e sa me c o n n e c t o r .
Is resi st ance great er t han 1 M ohm?
Ye s
No
G o t o 0 6 .
VERI FY s y s t e m
o pe r a t i o n .
BATTERY BETWEEN FCU AND RCU
Ye s
No
GO t o 07 .
( L B/ P K) sho r t t o ba t t e r y
VERI FY s y s t e m
o pe r a t i o n .
Me a sur e t he v o l t a ge be t we e n Ci r c ui t 832 ( LB / PK)
FCU c o n n e c t o r C2, Pi n 13 ( ha r n e ss e n d ) a n d a
Does vol t met er read zero vol t s?
Ye s
No
GO t o 07 .
VERI FY s y s t e m
o pe r a t i o n .
BATTERY BETWEEN RCU AND CDDJ
Ye s
No
Go t o 0 8.
VERI FY s y s t e m
o pe r a t i o n .
Me a sur e t h e v o l t a ge b e t we e n Ci r c ui t 832 ( LB / PK)
RCU c o n n e c t o r C4, Pi n 14 ( ha r n e ss si d e ) a n d a
Ye s
No
Go t o 0 8.
VERI FY s y s t e m
o pe r a t i o n .
C8 CHECK CI RCUI T 832 ( LB / PK) ACP A VOLTAGE LEVEL
Ye s
No
SERVI CE sho r t be t we e n
Ci r c ui t 832 ( L B/ P K) a n d
833 (T). RESTORE
GO t o C9.
Ensur e t ha t t he i gni t i on s wi t c h i s OFF a nd t he FCU
po we r but t o n i s ON. Ope n a n d shut t he d r i ve r d o o r t o
r e se t De l a y A c c e s s o r y .
Co n n e c t onl y FCU C1 a n d C2 c o n n e c t o r s . Whi l e
c y c l i n g t he i gni t i on s wi t c h f r o m OFF t o RUN,
me a sur e t h e v o l t a ge of ACP A b e t we e n RCU Pi n 1 of
C3 c o n n e c t o r a nd a kn o wn go o d gr o un d .
Is ACP A vol t age const ant 2.5 vol t s
appr oxi mat el y?
Ye s
No
SERVI CE sho r t be t we e n
Ci r c ui t 832 ( L B/ P K) a n d
833 (T). RESTORE
GO t o C9.
0 9 CHECK CI RCUI T 832 ( LB / PK) ACP A VOLTAGE LEVEL
CHANGE
Ye s
No
G O t o C I O .
VERI FY s y s t e m
o pe r a t i o n .
Wi t h s y s t e m se t up a s in 08, me a sur e v o l t a ge ACP
C3- 1 t o gr o un d .
Does ACP A vol t age change f or t he f i r st second
and set t l e at appr oxi mat el y 4.7 VDC and
t her eaf t er t he ACP A vol t age change once every
10 seconds?
NOTE: If ACP A v o l t a ge c h a n ge s al l t he t i me ,
r e pl a c e d a ma ge d FCU.
Ye s
No
G O t o C I O .
VERI FY s y s t e m
o pe r a t i o n .
C 1 0 CHECK CI RCUI T 833 (T) ACP B FOR OPEN BETWEEN
FCU AND RCU
Ye s
No
G O t o C 1 1 .
SERVI CE Ci r c ui t 833 (T)
o pe n be t we e n FCU a n d
RCU. RESTORE v e hi c l e
and VERI FY s y s t e m
o pe r a t i o n .
o Di sc o n n e c t FCU c o n n e c t o r C2, RCU c o n n e c t o r C3,
Me a sur e r e s i s t a n c e b e t we e n FCU c o n n e c t o r C2,
Pi n 5 ( ha r n e ss si d e ) a nd RCU c o n n e c t o r 03, Pi n 15
Ye s
No
G O t o C 1 1 .
o pe n be t we e n FCU a n d
RCU. RESTORE v e hi c l e
and VERI FY s y s t e m
o pe r a t i o n .
T E S T STEP RESULT A CT I ON TO T A KE
C 1 1 CHECK CI RCUI T 833 (T) ACP B FOR SHORT TO
GROUND BETWEEN FCU AND RCU
Ye s
No
G O t o C 1 2 .
sho r t t o gr o un d b e t we e n
FCU & RCU. RESTORE
Me a sur e t h e r e s i s t a n c e be t we e n Ci r c ui t 833 (T),
FCU c o n n e c t o r C2 , Pi n 5 ( ha r n e s s e n d ) a nd a kn o wn
go o d gr o un d .
Ye s
No
G O t o C 1 2 .
FCU & RCU. RESTORE
C12 CHECK CI RCUI T 833 (T) ACP B FOR SHORT TO
GROUND BETWEEN RCU AND CDDJ
Ye s
No
G O t o C 1 3 .
RCU & CDDJ. RESTORE
Di sc o n n e c t Re mo t e Cha s s i s Uni t C4 a n d CDDJ
Me a sur e t h e r e s i s t a n c e be t we e n Ci r c ui t 833 (T),
RCU c o n n e c t o r C4, Pi n 25 ( ha r n e ss e n d ) a nd a
Ye s
No
G O t o C 1 3 .
RCU & CDDJ. RESTORE
C 13 CHECK CI RCUI T 833 (T) ACP B FOR SHORT TO SHI ELD
BETWEEN FCU AND RCU
Ye s
No
G O t o C 1 4 .
sho r t t o shi e l d b e t we e n
FCU & RCU. RESTORE
Me a sur e t h e r e s i s t a n c e be t we e n Ci r c ui t 833 (T)
FCU c o n n e c t o r C2 , Pi n 5 ( ha r n e ss e n d ) a n d Pi n 6,
shi e l d , ( Ba r e ) of t he s a me c o n n e c t o r .
I s r e s i s t a n c e g r e a t e r t h a n 1 M o h m ?
Ye s
No
G O t o C 1 4 .
FCU & RCU. RESTORE
C14 CHECK CI RCUI T 833 (T) ACP B FOR SHORT TO SHI ELD
BETWEEN RCU AND CDDJ
Ye s
No
G O t o C 1 5 .
RCU & CDDJ. RESTORE
Me a sur e t he r e s i s t a n c e be t we e n Ci r c ui t 833 (T)
RCU c o n n e c t o r C4, Pi n 2 5 ( ha r n e s s e n d ) a nd Pi n 2 3,
shi e l d , ( Ba r e ) of t h e s a me c o n n e c t o r .
Ye s
No
G O t o C 1 5 .
RCU & CDDJ. RESTORE
C15 CHECK CI RCUI T 833 (T) ACP B FOR SHORT TO
BATTERY BETWEEN FCU AND RCU
Ye s
No
GO t o C 1 6 .
sho r t t o ba t t e r y b e t we e n
FCU & RCU. RESTORE
Me a sur e t he v o l t a ge be t we e n Ci r c ui t 833 (T) FCU
c o n n e c t o r C2, Pi n 5 ( ha r n e ss e n d ) a n d a kn o wn
go o d gr o un d .
Do e s v o l t me t e r r e a d z e r o v o l t s ?
Ye s
No
GO t o C 1 6 .
FCU & RCU. RESTORE
C 16 CHECK CI RCUI T 833 (T) ACP B FOR SHORT TO
BATTERY BETWEEN RCU AND CDDJ
Ye s
No
G O t o C 1 7 .
RCU & CDDJ. RESTORE
Di sc o n n e c t Re mo t e Ch a s s i s Uni t C4 a nd CDDJ
Me a sur e t he v o l t a ge b e t we e n Ci r c ui t 833 (T) RCU
c o n n e c t o r C4, Pi n 2 5 ( ha r n e ss e n d ) a n d a kn o wn
go o d gr o un d .
Ye s
No
G O t o C 1 7 .
RCU & CDDJ. RESTORE
C17 CHECK CI RCUI T 833 (T), ACP B VOLTAGE LEVEL
Ye s
No
SERVI CE sho r t b e t we e n
Ci r cui t 832 ( L B/ P K ) a nd
833 (T). RESTORE
G O t o C 1 8 .
Ensur e t ha t t h e i gn i t i o n s wi t c h i s OFF a n d t he FCU
po we r but t o n in ON. Ope n a nd shut t he d r i ve r d o o r t o
r e se t De l a y A c c e s s o r y .
Co n n e c t onl y FCU C1 a n d C2 c o n n e c t o r s . Whi l e
c y c l i n g t he i gn i t i o n s wi t c h f r o m OFF t o RUN,
me a sur e t he v o l t a ge of ACP B b e t we e n RCU Pi n 1 5
of C3 c o n n e c t o r a n d a kn o wn go o d gr o un d .
I s Ci r c u i t 8 3 3 (T) ( ACP B) v o l t a g e c o n s t a n t 2 . 5
v o l t s a p p r o x i ma t e l y ?
Ye s
No
SERVI CE sho r t b e t we e n
Ci r cui t 832 ( L B/ P K ) a nd
833 (T). RESTORE
G O t o C 1 8 .
C18 CHECK CI RCUI T 833 ( T ) , ACP B VOLTAGE LEVEL
CHANGE
Ye s
No
VERI FY s y s t e m
o pe r a t i o n .
VERI FY s y s t e m
o pe r a t i o n .
Wi t h s y s t e m se t up a s in C17 , me a sur e v o l t a ge RCU
Pi n C3- 15 t o gr o un d .
Does Ci rcui t 833 (T) (ACP B) vol t age change f or
t he f i r st second and set t l e at appr oxi mat el y 0. 4
vol t s and t hereaf t er t he ACP B vol t age change
once every 10 seconds?
Ye s
No
VERI FY s y s t e m
o pe r a t i o n .
VERI FY s y s t e m
o pe r a t i o n .
Audio S y s t e m s S e r v i c e
15- 00- 59
PINPOINT TEST D: WHEN STEERING WHEEL CONTROL A UDI O BUTTONS (VOLUME, MEM AND BAND) ARE PRESSED,
NOTHING HAPPENSFCU AND ITS DISPLAY FUNCTION NORMALLY
D 1 CHECK CONNECTIONS
Yes
No '
GO t o D2.
_ SERVI CE dirty, loose or
c o r r o d e d pi n s . I NSTALL
c i r c ui t pi n s i n p r o p e r
l o c a t i o n s .
Re f e r t o t h e following diagram to check SWC circuit
connections at the module, at the top of the steering
column and to the LH steering wheel control switch.
Are all connect i ons cl ean, t i ght and are all
c i r c u i t s in proper pi ns?
Yes
No '
GO t o D2.
_ SERVI CE dirty, loose or
c o r r o d e d pi n s . I NSTALL
c i r c ui t pi n s i n p r o p e r
l o c a t i o n s .
1995 T o wn Car, Cr o wn Vi c t o r i a , Grand Ma r q u i s J u l y 1994
15-00-60 A u d i o S y s t e ms S e r v i c e
15- 00- 60
PINPOINT TEST D: WHEN STEERING WHEEL CONTROL AUDIO BUTTONS (VOLUME, MEM AND BAND) ARE PRESSED,
NOTHING HAPPENSFCU AND ITS DISPLAY FUNCTION NORMALLY (Cont i nued)
D2 CHECK SWC MODULE BY USI NG SELF DI AGNOSTI C
Ye s
No
Faul t c o d e 5 me a n s SWC
i s una bl e t o c o mmun i c a t e
wi t h t he FCU. GO t o D3.
GO t o D1 0 .
Reset a ud i o system by turning i gni t i on s wi t c h to
OFF. Ope n a n d shut t he door a n d recycle t he
i gni t i on swi t c h t o RUN.
Ent e r d i a gn o st i c mo d e by pr e ssi n g pr e - se t but t o n
" 3 " a n d "Se e k Do wn " si mul t a n e o usl y a nd ho l d bo t h
but t o n s unt i l t he FCU d i spl a y s h o ws " DI A G" . Thi s
wi l l suspe n d al l n o r ma l a ud i o f un c t i o n s.
P r e s s pr e - se t but t o n " I " . Whe n t he FCU s t o p s
f l a shi n g "Se l f ", p r e s s "Tune UP " but t o n t o d i spl a y
e r r o r c o d e s . Pr e ssi n g "Tune UP " mo r e t ha n o n c e
wi l l s h o w o t he r f a ul t c o d e s .
Does t he FCU di spl ay show 5?
Ye s
No
Faul t c o d e 5 me a n s SWC
i s una bl e t o c o mmun i c a t e
wi t h t he FCU. GO t o D3.
GO t o D1 0 .
D3 CHECK SWC FUSE
Ye s
No
GO t o D4.
GO t o D5.
Me a s ur e v o l t a ge b e t we e n Ci r c ui t 2 96 ( W/ P ) , Pi n 9
of SWC c o n n e c t o r ( ha r n e s s si d e ) a nd a kn o wn go o d
gr o un d .
Is vol t age more t han 10 vol t s?
Ye s
No
GO t o D4.
GO t o D5.
15- 00- 61 Audi o S y s t e ms S e r v i c e 15- 00- 61
PINPOINT TE ST D: WHEN STEERI NG WHEEL CONTROL AUDIO BUTTONS (VOLUME, MEM AND BAND) ARE PRESSED,
NOTHING HAPPENSFCU AND I TS DISPLAY FUNCTION NORMALLY (Continued)
D4 CHECK FUSE 8 OUTPUT
Me a sur e v o l t a ge be t we e n Ci r c ui t 296 ( W/ P ) , c a v i t y
No . 8 l o c a t e d in t h e i n st r ume n t pa n e l f use pa n e l a n d
a kn o wn g o o d gr o un d .
Ye s
No
Is vol t age more t han 10 vol t s?
1 595 ( L B / R ) Co mmu n i c a t i o n t o S WC
2 No t Us e d
3

No t Us e d
4 832 ( L B / P K ) ACP A
5 57 ( BK) A CP Sh i e l d
8 ( Opt i o n a l
Gr n d . )
( Op t i o n a l Gr n d . )
9 2 96 ( W/ P ) Ba t t e r y
1 0 5 8 3 ( Y) P o we r t o S WC
11
_
No t Us e d
12 1068
( L G / B K )
A S YS ON Fr o m Fr o n t Co n t r o l Uni t
13 8 3 3 ( T ) A C P B
14 4 8 4 ( O / B K ) P WM Fr o m L C M
15 848 ( BK) Gr o un d
16 No t Us e d
a n d Pi n 9 of SWC mo d ul e .
GO t o D6.
GO t o D5.
D5 CHECK FUSE 8 CONTI NUI TY
Re mo v e 15A f use , c a v i t y No. 8 a nd pe r f o r m a
Ye s
No

SERVI CE f use suppl y . GO
t o Se c t i o n 18- 01.
CHECK f or po s s i b l e
ba t t e r y li ne sho r t t o
gr o un d REPLACE bl o wn
o pe r a t i o n .
15- 00 62 A u d i o S y s t e ms S e r v i c e 15- 00- 62
PI NPOI NT T E ST D: WHE N STEERI NG WHE E L CONTROL AUDIO BUTTONS (VOLUME, MEM AND BAND) ARE PRESSED,
NOTHING HAPPENSFCU AND ITS DISPLAY FUNCTION NORMALLY (Continued)
D6 CHECK CI RCUI T 848 ( BK) GROUND FOR OPEN
Ye s
No
GO t o D7 .
a nd VERI FY s y s t e m
o pe r a t i o n .
Di sc o n n e c t the SWC and speed c o n t r o l 10-pin
connectors.
Measure the resistance between circuit be t we e n
848 ( G N/ O) SWC mo d ul e c o n n e c t o r , Pi n 15 a nd Pi n
6 of t he 10-pi n s p e e d c o n t r o l mo d ul e c o n n e c t o r .
Ye s
No
GO t o D7 .
o pe r a t i o n .
D7 CHECK CI RCUI T 1068 (LG / BK) ASYSON FOR OPEN
Ye s
No
GO t o D8.
( L G / BK) o pe n be t we e n
FCU a nd SWC mo d ul e .
VERI FY s y s t e m
o pe r a t i o n .
Di sc o n n e c t FCU C2, RCU C3 a n d C4, CDDJ a n d
SWC c o n n e c t o r s .
Me a sur e r e s i s t a n c e be t we e n FCU c o n n e c t o r C2,
Pi n 4 ( ha r n e ss si d e ) a nd SWC mo d ul e c o n n e c t o r ,
Pi n 12 ( ha r n e ss e n d ) .
Ye s
No
GO t o D8.
( L G / BK) o pe n be t we e n
FCU a nd SWC mo d ul e .
VERI FY s y s t e m
o pe r a t i o n .
D8 CHECK CI RCUI T 832 ( LB / PK) ACP A FOR OPEN
Ye s
No
GO t o D9.
( L B/ P K) ACP A o pe n
be t we e n FCU a nd SWC.
VERI FY s y s t e m
o pe r a t i o n .
o Di sc o n n e c t FCU C2, RCU C3 a nd C4, CDDJ a n d
Pi n 13 ( ha r n e ss si d e ) a nd SWC c o n n e c t o r , Pi n 4
Ye s
No
GO t o D9.
be t we e n FCU a nd SWC.
VERI FY s y s t e m
o pe r a t i o n .
D9 CHECK CI RCUI T 833 (T) ACP B FOR OPEN
Ye s
No
G Ot o D10.
ACP B o pe n be t we e n
FCU a nd SWC. RESTORE
Di sc o n n e c t FCU C2, RCU C3 a n d C4, CDDJ a nd
Pi n 5 ( ha r n e ss si d e ) a nd SWC c o n n e c t o r , Pi n 13
Ye s
No
G Ot o D10.
FCU a nd SWC. RESTORE
D1 0 CI RCUI T 583 (Y) POWER TO AUDI O BUTTONS UNIT
FOR OPEN
Ye s
No
G O t o D 1 1 .
SERVI CE Ci r c ui t 583 (Y)
o pe n be t we e n C1 a nd
SWC. RESTORE v e hi c l e
o pe r a t i o n .
Di sc o n n e c t SWC a n d B1 c o n n e c t o r s .
Me a sur e r e s i s t a n c e be t we e n Ci r c ui t 583 ( Y) , Pi n 10
of SWC c o n n e c t o r ( ha r n e ss si d e ) a nd Pi n 2 of B1
c o n n e c t o r .
Ye s
No
G O t o D 1 1 .
o pe n be t we e n C1 a nd
SWC. RESTORE v e hi c l e
o pe r a t i o n .
D11 CI RCUI T 583 ( Y) POWER TO AUDI O BUTTONS UNI T
FOR SHORT TO GROUND
Di sc o n n e c t t h e SWC a nd B1 c o n n e c t o r s .
Me a sur e Ci r c ui t 583 (Y) r e s i s t a n c e be t we e n Pi n 10
of SWC c o n n e c t o r a n d a kn o wn go o d gr o un d .
Ye s
No
B1 CONNECTOR
Is resi st ance more t han 1 M ohm?
K22763-A
P i n N u m b e r C i r c u i t C i r c u i t F u n c t i o n
1 595 ( L B / R ) Co mmu n i c a t i o n
2 5 8 3 ( Y) Al t . P o we r to Co n t r o l Mo d u l e
3

No t Us e d
5 4 6 0 ( Y / L B ) Ho r n SW Fe e d
6 151 ( L B / B K ) S p e e d Ct r l . ON/ OFF t o Amp

GO t o D 1 2 .
sho r t t o gr o u n d .
VERI FY s y s t e m
o pe r a t i o n .
D12 CI RCUI T 583 (Y) POWER TO AUDI O BUTTONS UNIT
VOLTAGE LEVEL
Co n n e c t t he SWC c o n n e c t o r .
Me a sur e Ci r c ui t 583 (Y) v o l t a ge be t we e n Pi n 2 of B1
c o n n e c t o r a n d a kn o wn g o o d gr o un d .
Do e s v o l t me t e r r e a d a p p r o x i ma t e l y 12 v o l t s ?
Ye s
No

G O t o D1 3 .
REPLACE t he SWC
o pe r a t i o n .
D13 CHECK CI RCUI T 848 (BK) GROUND FOR OPEN
Di sc o n n e c t SWC a nd B1 c o n n e c t o r s .
Me a sur e t he r e si st a n c e b e t we e n Ci r c ui t 848
( GN/ O) SWC mo d ul e c o n n e c t o r 15 a n d Pi n 4 of B 1 .
Is resi st ance 5 ohms or l e s s ?
Ye s
No
GO t o D14.
848 ( BK) . RESTORE
D1 4 CI RCUI T 595 ( LB / R) COMMUNI CATI ON TO AUDI O
BUTTON UNIT VOLTAGE LEVEL
Ensure t ha t t h e SWC a nd B1 c o n n e c t o r s a r e bo t h
c o n n e c t e d a n d i gni t i on s wi t c h i s in RUN.
Whi l e pr e s s i n g SWC a ud i o v o l ume up but t o n ,
me a sur e c i r c ui t 595 ( L B/ R) v o l t a ge b e t we e n Pi n 1
of SWC c o n n e c t o r a nd a kn o wn go o d gr o un d .
Does vol t age change a n d vary bet ween 0 a n d 5
vol t s?
Yes
No
REPLACE t he SWC
mo d ul e . RESTORE
v e hi c l e and VERI FY
G O t o D1 5 .
D15 CHECK CI RCUI T 595 ( L B/ R) COMMUNI CATI ON TO
AUDI O BUTTONS UNIT FOR OPEN
Di sc o n n e c t t he SWC a n d C1 c o n n e c t o r s .
Me a s ur e r e si st a n c e b e t we e n Ci r c ui t 595 ( L B/ R) ,
Pi n 1 of SWC c o n n e c t o r ( ha r n e ss si d e ) a n d Pi n 1 of
B1 c o n n e c t o r .
Ye s
No
GO t o D1 6 .
( L B/ R) o pe n be t we e n B1
a n d SWC. RESTORE
[L_m_Ji
B3 CONNECTOR
K22764-A
P i n N u m b e r Circuit C i r c u i t F u n c t i o n
1 151 ( L B / B K ) S p e e d Ct r l ON / OFF To A mp
3 1 0 8 9 ( R / P K ) Aux . P WM L i gh t i n g Fo r S C M Fe e d
4 5 8 3 ( Y) Al t . P o we r t o Co n t r o l Mo d u l e
D16 CI RCUI T 595 ( LB / R) COMMUNI CATI ON TO AUDI O
BUTTONS UNIT FOR SHORT TO GROUND
Di sc o n n e c t the SWC a nd C1 c o n n e c t o r s .
Me a sur e Ci r c ui t 595 ( L B / R) be t we e n Pi n 1 of SWC
c o n n e c t o r and a kn o wn go o d gr o un d .
Is resi st ance more t han 1 M ohm?
Ye s
No
REPLACE a ud i o but t o n s
uni t . RESTORE v e hi c l e
o pe r a t i o n .
( L B/ R) sho r t t o gr o un d .
VERI FY s y s t e m
o pe r a t i o n .
PINPOINT TEST E: FCU DISPLAYS "NO DJ" WHEN CDDJ IS PRESENT AND FCU "CD" BUTTON IS PRESSED, AM, FM
AND TAPE MODES ARE NORMAL
E1 CHECK CDDJ FUSE
Ye s r>
No
GO t o E4.
GO t o E 2 .
NOTE: Be f o r e c he c ki n g CDDJ f use e n sur e t ha t t he CD
ma ga zi n e i s i n se r t e d a nd t he r e i s at l e a st one CD in
ma ga zi n e .
Me a sur e v o l t a ge be t we e n Ci r c ui t 2 96 ( W/ P ) , Pi n 12
of CDDJ c o n n e c t o r ( ha r n e ss si d e ) a nd a kn o wn
go o d gr o un d .
Ye s r>
No
GO t o E4.
GO t o E 2 .
E2 CHECK FUSE 8 OUTPUT
Yes
No
SERVI CE o pe n be t we e n
f use a nd Pi n 12 of CDDJ
G Ot o E3.
Me a sur e v o l t a ge be t we e n Ci r c ui t 296 ( W/ P) c a v i t y
No. 8, l o c a t e d in t he i nst r ume nt pa n e l f use pa n e l a nd
Yes
No
SERVI CE o pe n be t we e n
f use a nd Pi n 12 of CDDJ
G Ot o E3.
15- 00- 65
PI NPOI NT TEST E: FCU DISPLAYS " NO DJ" WHE N CDDJ IS PRESENT AND FCU " C D" B U I T ON IS PRESSED, ,*ML FM
A ND TAPE MODE S ARE NORMA L ( Co n t i n u e d )
E3 CHECK FUSE 8 CONTI NUI TY
Ye s
No
GO t o Se c t i o n 18- 01.
ba t t e r y l i ne sho r t t o
o pe r a t i o n .
# Re mo v e 15A f use , c a v i t y No. 8 a nd pe r f o r m a
r e si st a n c e a c r o s s t he f use t e r mi n a l s.
i s resi st ance 5 ohms or l ess?
Ye s
No
GO t o Se c t i o n 18- 01.
ba t t e r y l i ne sho r t t o
o pe r a t i o n .
E4 CHECK CI RCUI T 694 (BK / LG) GROUND FOR OPEN
Ye s t >
No
GO t o E5.
Ci r c ui t 694 ( BK/ L G ) .
VERI FY s y s t e m
o pe r a t i o n .
Di sc o n n e c t CDDJ c o n n e c t o r .
Me a s ur e t h e r e s i s t a n c e b e t we e n Ci r c ui t 694
( BK/ L G ) CDDJ c o n n e c t o r , Pi n 4 and kn o wn go o d
gr o un d .
Ye s t >
No
GO t o E5.
Ci r c ui t 694 ( BK/ L G ) .
VERI FY s y s t e m
o pe r a t i o n .
E5 CHECK CI RCUI T 1068 ( LG / BK) ASYSON FOR OPEN
Ye s
No
G O t o E0
( L G / BK) ASYSON o pe n
be t we e n RCU a n d CDDJ.
VERI FY s y s t e m
o pe r a t i o n .
Di sc o n n e c t FCU C2 , RCU C3 a n d 0 4 , CDDJ a n d
Me a sur e r e s i s t a n c e be t we e n RCU c o n n e c t o r 0 4 ,
Pi n 8 ( ha r n e ss si d e ) a nd CDDJ c o n n e c t o r , Pi n 13
Ye s
No
G O t o E0
( L G / BK) ASYSON o pe n
be t we e n RCU a n d CDDJ.
VERI FY s y s t e m
o pe r a t i o n .
E6 CHECK CI RCUI T 832 ( LG / PK) ACP A FOR OPEN
Ye s
No
GO t o E 7
VERI FY s y s t e m
o pe r a t i o n .
Di sc o n n e c t FCU C2 , RCU C3 a n d C4, CDDJ a n d
Me a s ur e r e s i s t a n c e be t we e n RCU c o n n e c t o r C4,
Pi n 14 ( ha r n e ss si d e ) a n d CDDJ c o n n e c t o r , Pi n 6
i s resi st ance 5 ohms or l ess?
Ye s
No
GO t o E 7
VERI FY s y s t e m
o pe r a t i o n .
E7 CHECK CI RCUI T 833 (T) ACP B FOR OPEN
Ye s
No
REPLACE d a ma ge d
CDDJ. RESTORE v e hi c l e
o pe r a t i o n .
SERVI CE Ci r cui t 833 (T)
RCU a n d CDDJ.
VERI FY s y s t e m
o pe r a t i o n .
Di sc o n n e c t FCU C2, RCU C3 a n d C4, CDDJ a nd
Me a s ur e r e s i s t a n c e b e t we e n RCU c o n n e c t o r C4,
Pi n 25 ( ha r n e ss si d e ) a n d CDDJ c o n n e c t o r , Pi n 14
Ye s
No
REPLACE d a ma ge d
CDDJ. RESTORE v e hi c l e
o pe r a t i o n .
SERVI CE Ci r cui t 833 (T)
RCU a n d CDDJ.
VERI FY s y s t e m
o pe r a t i o n .
PINPOINT TEST F: FCU IS IN TAPE MODE, DISPLAY SHOWING "TAPE" NO AUDIO AT S P E A K E RS A M, FM AND CDDJ
MODES ARE NORMAL
TEST STEP RESULT > A CTI ON TO T A KE
F1 CHECK FCU TAPE DECK RH (-) AUDI O
Ye s
No
GOt o FI .
G O t o P 3 .
I nser t a n o n - bl a n k t a pe i nt o FCU c a s s e t t e l o a d i n g
po r t . Se l e c t t a pe mo d e by pr e ssi n g t a pe on t he FCU
be ze l .
Wi t ho ut d i sc o n n e c t i n g C3 or Fr ont Co n t r o l Uni t C2,
me a sur e t h e v o l t a ge be t we e n RCU C3 c o n n e c t o r ,
Pi n 2 0, Ci r c ui t 594 (GY) a n d a kn o wn go o d gr o un d .
Does t he vol t age vary and range approxi mat el y
be t we e n 30 and 200 Mi l l i vol t AC?
Ye s
No
GOt o FI .
G O t o P 3 .
1995 To wn Ga r , Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s Jul y 1994
15- 00- 66 A u d i o S y s t e ms S e r v i c e 15 - C~ T
PINPOINT TE ST F: FCU IS IN TAPE MODE, DISPLAY SHOWI NG " T A P E " NO AUDIO AT S P E A K E RS A M, FM AND CDDJ
MODES ARE NORMA L (Cont i nued)
F2 CHECK FCU TAPE DECK RH ( + ) AUDI O
Ye s
No l>
VERI FY s y s t e m
o pe r a t i o n .
G Ot o F3.
Without disconnecting Re mo t e Cha s s i s uni t C3 or
Front Control Unit C2, me a sur e t he v o l t a ge b e t we e n
RCU C3 connector, Pin 7, Ci r c ui t 593 ( DB/ W) a n d a
Does the vol tage wary and range appr oxi mat el y
be t we e n 30 and 200 Mi l l i vol t A C?
Ye s
No l>
VERI FY s y s t e m
o pe r a t i o n .
G Ot o F3.
F3 CHECK CI RCUI T 594 ( GY) , CASSETTE RH (-) AUDI O
FOR OPEN
Ye s
No
GO t o F4.
(GY) o pe n . RESTORE
o Di sc o n n e c t FCU C2 a n d RCU C3.
Me a sur e Ci r c ui t 594 (GY) r e s i s t a n c e be t we e n FCU
c o n n e c t o r C2, Pi n 7 ( ha r n e ss e nd) a nd RCU C3
c o n n e c t o r , Pi n 2 0.
Ye s
No
GO t o F4.
FOR SHORT TO GROUND
Ye s
No
G Ot o F5.
(GY) sho r t t o gr o un d .
VERI FY s y s t e m
o pe r a t i o n .
Di sc o n n e c t FCU C2 a n d RCU C3.
c o n n e c t o r C2, Pi n 7 ( ha r n e ss e nd) a nd a kn o wn
go o d gr o un d .
Ye s
No
G Ot o F5.
VERI FY s y s t e m
o pe r a t i o n .
FOR SHORT TO SHI ELD
Ye s
No P>
GO t o F6.
(GY) sho r t t o shi e l d .
RESTORE v e hi c l e and
VERI FY s y s t e m
o pe r a t i o n .
c o n n e c t o r C2, Pi n 7 ( ha r n e ss e n d ) a nd Pi n 11,
( Ba r e ) , shi e l d of t h e sa me c o n n e c t o r .
Is r e s i s t a n c e g r e a t e r t h a n 1 M ohm?
Ye s
No P>
GO t o F6.
VERI FY s y s t e m
o pe r a t i o n .
FOR SHORT TO RH ( + )
Ye s
No
GO t o F 7 .
(GY) sho r t t o Ta pe R H + .
VERI FY s y s t e m
operation.
Di sc o n n e c t Fr ont Co n t r o l Uni t C2 a nd Re mo t e
Ch a s s i s Uni t C3.
Me a s ur e Ci r c ui t 594 (GY) r e s i s t a n c e b e t we e n FCU
c o n n e c t o r C2, Pi n 7 ( ha r n e ss si d e ) a n d Pi n 8, Ci r c ui t
593 ( DB/ W) , Ta pe Aud i o RH ( + ) of t he sa me
c o n n e c t o r .
Ye s
No
GO t o F 7 .
(GY) sho r t t o Ta pe R H + .
VERI FY s y s t e m
operation.
FOR SHORT TO LH (-)
Ye s
No ^
GO t o F8.
( GY) sho r t t o Tape LH- .
VERI FY sy st e m
o pe r a t i o n .
Di sc o n n e c t Fr ont Co n t r o l Uni t C2 a n d Re mo t e
Me a s ur e Ci r c ui t 594 (GY) r e s i s t a n c e be t we e n FCU
c o n n e c t o r C2, Pi n 7 ( ha r n e ss e n d ) a n d Pi n 15,
Ci r c ui t 584 ( W/ PK) , Ta pe Aud i o LH (-) of t he s a me
c o n n e c t o r .
Ye s
No ^
GO t o F8.
( GY) sho r t t o Tape LH- .
VERI FY sy st e m
o pe r a t i o n .
FOR SHORT TO LH ( + )
Ye s ! >
No >
Go t o F9-
(GY) sho r t t o Ta pe LH+.
VERI FY sy st e m
o pe r a t i o n .
Me a s ur e Ci r c ui t 594 ( GY) r e s i s t a n c e be t we e n FCU
c o n n e c t o r C2, Pi n 7 ( ha r n e ss e n d ) a n d Pi n 16,
Ci r c ui t 583 ( BR/ L G ) , Ta pe Aud i o LH ( + ) of t he sa me
c o n n e c t o r .
Ye s ! >
No >
Go t o F9-
(GY) sho r t t o Ta pe LH+.
VERI FY sy st e m
o pe r a t i o n .
PINPOINT TEST F: FCU IS IN TAPE MODE, DISPLAY SHOWING "TAPE"NO AUDIO AT SPEAKERSAM, FM AND CDDJ
MODES ARE NORMAL (Cont i nued)
TEST STEP RESUL T A CTI ON TO TAKE
FOR SHORT TO BATTERY
Ye s U>
No >
G O t o F10.
( GY) sho r t t o ba t t e r y .
VERI FY s y s t e m
o pe r a t i o n .
Me a sur e Ci r c ui t 5 9 4 ( GY) v o l t a ge b e t we e n FCU
go o d gr o un d .
Ye s U>
No >
G O t o F10.
( GY) sho r t t o ba t t e r y .
VERI FY s y s t e m
o pe r a t i o n .
F1 0 CHECK CI RCUI T 593 ( DB/ W) , CASSETTE RH ( + )
AUDI O FOR OPEN
Ye s
No
G O t o F 1 1 .
( DB / W) o pe n . RESTORE
Di sc o n n e c t FCU C2 a nd RCU C3.
Me a s ur e Ci r c ui t 593 ( DB/ W) r e s i s t a n c e be t we e n
FCU c o n n e c t o r C2 Pi n 8 ( ha r n e ss e n d ) a n d RCU C3
c o n n e c t o r , Pi n 7.
Ye s
No
G O t o F 1 1 .
( DB / W) o pe n . RESTORE
F11 CHECK CI RCUI T 593 ( DB/ W) , CASSETTE RH ( + )
AUDI O FOR SHORT TO GROUND
Ye s
No
GO t o F 1 2 .
( DB / W) sho r t t o gr o un d .
VERI FY s y s t e m
o pe r a t i o n .
Me a sur e Ci r c ui t 593 ( DB/ W) r e s i s t a n c e be t we e n
FCU c o n n e c t o r C2, Pi n 8 ( ha r n e ss e n d ) a n d a kn o wn
go o d gr o un d .
Ye s
No
GO t o F 1 2 .
( DB / W) sho r t t o gr o un d .
VERI FY s y s t e m
o pe r a t i o n .
AUDI O FOR SHORT TO SHI ELD
Ye s
No
G O t o F 1 3 .
( DB / W) sho r t t o shi e l d .
VERI FY s y s t e m
o pe r a t i o n .
Me a sur e Ci r c ui t 593 ( DB/ W) r e s i s t a n c e be t we e n
FCU c o n n e c t o r C2, Pi n 8 ( ha r n e ss e n d ) a n d Pi n 1 1 ,
Ye s
No
G O t o F 1 3 .
( DB / W) sho r t t o shi e l d .
VERI FY s y s t e m
o pe r a t i o n .
AUDI O FOR SHORT TO LH (-)
Ye s L>
No
G O t o F 1 4 .
( DB/ W) sho r t t o LH (-).
VERI FY s y s t e m
o pe r a t i o n .
Me a sur e Ci r c ui t 593 ( DB / W) r e s i s t a n c e be t we e n
FCU c o n n e c t o r C2, Pi n 8 ( ha r n e ss e n d ) a n d Pi n 15,
Ci r c ui t 584 ( W/ P K) , Ta pe Aud i o LH (-) of t h e sa me
c o n n e c t o r .
Is resi t ance great er t han 1 M ohm?
Ye s L>
No
G O t o F 1 4 .
( DB/ W) sho r t t o LH (-).
VERI FY s y s t e m
o pe r a t i o n .
AUDI O FOR SHORT TO LH ( + )
Ye s U>
No >
G O t o F 1 5 .
( DB/ W) sho r t t o LH ( + ) .
VERI FY sy st e m
o pe r a t i o n .
Me a sur e Ci r c ui t 593 (DB / W) r e s i s t a n c e be t we e n
FCU c o n n e c t o r C2, Pi n 8 ( ha r n e ss e n d ) a n d Pi n 16,
Ci r c ui t 583 (BR / L G ) , Ta pe Aud i o LH ( + ) of t he sa me
c o n n e c t o r .
Ye s U>
No >
G O t o F 1 5 .
( DB/ W) sho r t t o LH ( + ) .
VERI FY sy st e m
o pe r a t i o n .
AUDI O FOR SHORT TO BATTERY
Ye s >
No
GO t o F 1 6 .
( DB/ W) shor t t o ba t t e r y .
VERI FY sy st e m
o pe r a t i o n .
Me a sur e Ci r c ui t 594 ( GY) v o l t a ge b e t we e n FCU
c o n n e c t o r C2, Pi n 8 ( ha r n e ss e nd) a n d a kn o wn
go o d gr o un d .
Do e s vol t met er read zero vol t s?
Ye s >
No
GO t o F 1 6 .
( DB/ W) shor t t o ba t t e r y .
VERI FY sy st e m
o pe r a t i o n .
16- 00- 68 A u d i o S y s t e ms S e r v i c e 1 5 - 0 0 - 68
PINPOINT TEST F: FCU IS IN TAPE MODE, DISPLAY SHOWING " TAPE" NO AUDIO AT SPEAKERSAM, FM AND CDDJ
MODES ARE NORMAL (Continued)
VEST STEP RESULT ACTI ON TO TAKE
F 1 i CHECK CI RCUI T 584 ( W/ P K ) , CASSETTE LH (-) AUDI O
FOR OPEN
Ye s
No
GO t o F 1 7 .
( W/ P K) o pe n . RESTORE
Disconnect FCU C2 and RCU C3.
Measure Circuit 584 (DB / W) resi stance between
FCU connector C2, Pin 15 (harness end) and RCU
C3 c o n n e c t o r , Pi n 19.
Is resi stance 5 ohms or less?
Ye s
No
GO t o F 1 7 .
( W/ P K) o pe n . RESTORE
F1? CHECK CI RCUI T 584 ( W/ P K ) , CASSETTE LH (-) AUDI O
FOR SHORT TO GROUND
Ye s
No
G O t o F 1 8 .
( W/ P K) sho r t t o gr o un d .
VERI FY s y s t e m
o pe r a t i o n .
Measure Circuit 584 (W / PK) resi stance between
FCU connector C2, Pi n 15 (harness end) and a
Is resi stance greater than 1 M ohm?
Ye s
No
G O t o F 1 8 .
( W/ P K) sho r t t o gr o un d .
VERI FY s y s t e m
o pe r a t i o n .
F18 CHECK CI RCUI T 584 ( W/ P K ) , CASSETTE LH (-) AUDI O
FOR SHORT TO SHI ELD
Ye s
No
G O t o F 1 9 .
sho r t t o shi e l d . RESTORE
Measure Circuit 584 (W / PK) resi stance between
FCU connector C2, Pin 15 (harness end) and Pin 11,
(Bare), shield of the same connector.
Is resi stance greater than 1 M o h m ?
Ye s
No
G O t o F 1 9 .
F19 CHECK CI RCUI T 584 ( W/ PK) , CASSETTE LH (-) AUDI O
FOR SHORT TO LH ( + ) , TAPE AUDI O WI RES
Ye s
No r
GO t o F2 0.
( W/ P K) sho r t . RESTORE
Di sc o n n e c t Fr ont Co n t r o l Uni t C2 a nd Re mo t e
Cha s s i s Uni t C3.
Me a sur e Ci r c ui t 584 ( W/ P K) r e s i s t a n c e be t we e n
FCU c o n n e c t o r C2, Pi n 15 ( ha r n e ss e n d ) a nd Pi n 16,
Ci r c ui t 583 ( BR/ L G ) , Ta pe Aud i o LH ( + ) of t he sa me
c o n n e c t o r .
Is r e s i s t a n c e g r e a t e r t h a n 1 M o h m ?
Ye s
No r
GO t o F2 0.
( W/ P K) sho r t . RESTORE
F2 0 CHECK CI RCUI T 584 ( W/ P K ) , CASSETTE LH (-) AUDI O
FOR SHORT TO BATTERY
Ye s
No
G Ot o F 2 1 .
( W/ P K) sho r t t o ba t t e r y .
VERI FY s y s t e m
o pe r a t i o n .
o Di sc o n n e c t FCU C2 a nd RCU C3.
Me a s ur e Ci r c ui t 584 ( W/ PK) v o l t a ge be t we e n FCU
c o n n e c t o r C2, Pi n 15 ( ha r n e ss e n d ) a nd a kn o wn
go o d gr o un d .
m Do e s v o l t me t e r r e a d z e r o v o l t s ?
Ye s
No
G Ot o F 2 1 .
( W/ P K) sho r t t o ba t t e r y .
VERI FY s y s t e m
o pe r a t i o n .
F2 1 CHECK CI RCUI T 583 ( BR/ L G ) , CASSETTE LH ( + )
AUDI O FOR OPEN
Ye s
No .
GO t o F 2 2 .
( BR/ L G ) o pe n . VERI FY
Me a s ur e Ci r c ui t 583 (BR / L G ) r e s i s t a n c e be t we e n
FCU c o n n e c t o r C2, Pi n 16 ( ha r n e s s e n d ) a nd RCU
C3 c o n n e c t o r , Pi n 6.

Ye s
No .
GO t o F 2 2 .
( BR/ L G ) o pe n . VERI FY
F2 2 CHECK CI RCUI T 583 ( BR/ LG) , CASSETTE LH ( + )
AUDI O FOR SHORT TO GROUND
Ye s '
NO
GO t o F2 3.
( BR/ L G ) sho r t t o gr o un d .
VERI FY s y s t e m
o pe r a t i o n .
Me a s ur e Ci r c ui t 583 (BR / L G ) r e s i s t a n c e be t we e n
FCU c o n n e c t o r C2, Pi n 16 ( ha r n e s s e n d ) a n d a
Ye s '
NO
GO t o F2 3.
( BR/ L G ) sho r t t o gr o un d .
VERI FY s y s t e m
o pe r a t i o n .
PINPOINT TEST F: FCU IS IN TAPE MODE, DISPLAY SHOWING "TAPE"NO AUDIO AT SPEAKERSAM, FM AND CDDJ
MODES ARE NORMAL (Cont i nued)
F23 CHECK CI RCUI T 583 (BR / L G ) , CASSETTE LH ( + )
AUDI O FOR SHORT TO SHI ELD
Ye s
No
G O t o F 2 4 .
( BR/ L G ) sho r t t o s hi e l d .
VERI FY s y s t e m
o pe r a t i o n .
Di sc o n n e c t FCU C2 and RCU C3.
Me a sur e Ci r c ui t 583 (BR / LG) r e s i s t a n c e b e t we e n
FCU c o n n e c t o r C2 , Pi n 16 ( ha r n e ss end) a n d Pi n 1 1 ,
Ye s
No
G O t o F 2 4 .
( BR/ L G ) sho r t t o s hi e l d .
VERI FY s y s t e m
o pe r a t i o n .
F24 CHECK CI RCUI T 583 ( BR/ L G ) , CASSETTE LH ( + )
AUDI O FOR SHORT TO BATTERY
Ye s
No
REPLACE d a ma g e d FCU.
VERI FY s y s t e m
o pe r a t i o n .
( BR/ L G ) sho r t t o ba t t e r y .
VERI FY s y s t e m
o pe r a t i o n .
Me a sur e Ci r c ui t 583 ( BR/ LG) v o l t a ge be t we e n FCU
c o n n e c t o r C2 , Pi n 16 ( ha r n e ss e nd) and a kn o wn
go o d gr o un d .
Ye s
No
REPLACE d a ma g e d FCU.
VERI FY s y s t e m
o pe r a t i o n .
( BR/ L G ) sho r t t o ba t t e r y .
VERI FY s y s t e m
o pe r a t i o n .
PINPOINT TEST G: WHEN IGNITION IS CYCLED FROM OFF TO START, OR OFF TO ACCESSORY, FCU POWERS UP
NORMALLY, DISPLAY IS ON NO AUDIO IN ALL MODES OF OPERATION
G1 CHECK CI RCUI T 32 ( R/ L B) , RCU START VOLTAGE
LEVEL
Ye s
No
GO t o G4.
G O t o G 2 .
Ensur e t ha t t he i gni t i on s wi t c h i s OFF. Di sc o n n e c t
RCU C 3 c o n n e c t o r a n d me a sur e v o l t a ge b e t we e n
Ci r c ui t 32 ( R/ L B) , Pin 17 of RCU C3 c o n n e c t o r a nd a
Does t he st art li ne vol t age vary bet ween
approxi mat el y zero and 12 VDC when swi t chi ng
t he i gni t i on swi t ch bet ween OFF and START?
Ye s
No
GO t o G4.
G O t o G 2 .
G2 CHECK CI RCUI T 32 (R / LB) RCU START FOR OPEN
Ye s
No
G O t o G 3.
SERVI CE o pe n b e t we e n
RCU C3 a n d i gni t i on
s wi t c h . VERI FY s y s t e m
o pe r a t i o n .
Di sc o n n e c t i gni t i on s wi t c h c o n n e c t o r , me a sur e
r e s i s t a n c e be t we e n STA ( St a r t ) ( ha r n e ss e n d ) and
Pi n 17 of RCU C3 ( ha r n e ss e n d ) .
Ye s
No
G O t o G 3.
SERVI CE o pe n b e t we e n
RCU C3 a n d i gni t i on
o pe r a t i o n .
G3 CHECK CI RCUI T 32 (R / L B ) , RCU START FOR SHORT
TO BATTERY
Ye s
No
GO t o G4.
SERVI CE Ci r c ui t 32 sho r t
t o ba t t e r y . VERI FY
Whi l e b o t h RCU C3 and i gn i t i o n s wi t c h a r e
d i s c o n n e c t e d , me a sur e t he v o l t a ge be t we e n RCU
C3, Pi n 17 a n d a kn o wn g o o d gr o un d .
Ye s
No
GO t o G4.
SERVI CE Ci r c ui t 32 sho r t
t o ba t t e r y . VERI FY
G4 CHECK FCU AND RCU COMMUNI CATI ON
Ye s
No
VERI FY s y s t e m
o pe r a t i o n .
VERI FY s y s t e m
o pe r a t i o n .
Re se t a ud i o s y s t e m by c y c l i n g t he i gni t i on s wi t c h t o
OFF. Ope n a nd shut t h e d o o r a n d r e c y c l e t he
i gni t i on s wi t c h t o RUN.
ENt er d i a gn o s t i c mo d e by pr e s s i n g pr e - se t but t o n
" 3 " and "SEEK DOWN" si mul t a n e o usl y a nd ho l d
bo t h but t o n s unt i l t he FCU d i s pl a y s h o ws "DSAG".
Thi s wi l l s u s pe n d al l nor ma l a ud i o f un c t i o n s.
Af t er hol di ng bot h but t ons (SEEK DOWN AND
PRE-SET 3) f or 2 0 se c onds, does t he FCU di spl ay
show "DI AG"?
Ye s
No
VERI FY s y s t e m
o pe r a t i o n .
VERI FY s y s t e m
o pe r a t i o n .
16- 00- 70 - ~ - - * - - - . . . 16- 00- 70
D I A G N O S I S A N D T E S T I N G ( C o n t i n u e d )
PINPOINT TEST H: THE FCU DISPLAY SHOWS CDDJ, BUT THERE IS NO CDDJ AUDIOAM, FM AND TAPE MODES ARE
NORMAL
TEST STEP RESULT L-
;
ACTION TO TAKE
H1 CHECK CDDJ AUDI O LI NE CI RCUI T 7 98 ( L G / R)
VOLTAGE LEVEL
Ye s L >
No
G O t o H2.
GO t o H3.
I nsert a kn o wn go o d CD i nt o CD ma ga zi n e a n d i nse r t
t he CD ma ga zi n e i nt o t he CDDJ. Se l e c t CDDJ mo d e
by pr e ssi n g CD on t he FCU be ze l .
Wi t ho ut d i sc o n n e c t i n g RCU C4, me a sur e t he
v o l t a ge be t we e n RCU C4 c o n n e c t o r , Pi n 9, Ci r c ui t
798 ( L G / R) a n d a kn o wn go o d gr o un d .
Do e s the v o l t a g e v a r y a n d r a n g e a p p r o x i ma t e l y
b e t w e e n 150 a n d 3 0 0 Mi l l i v o l t A C ?
Ye s L >
No
G O t o H2.
GO t o H3.
H2 CHECK FCU CDDJ RH ( + ) AUDI O
Ye s
No
VERI FY s y s t e m
o pe r a t i o n .
GO t o H3.
Wi t ho ut d i sc o n n e c t i n g RCU C4, me a sur e t he
v o l t a ge be t we e n RCU C4 c o n n e c t o r , Pi n 2 1 , Ci r c ui t
856 (P) a n d a kn o wn go o d gr o un d .
Do e s t h e v o l t a g e v a r y a n d r a n g e a p p r o x i ma t e l y
b e t w e e n 3 0 and 2 0 0 Mi l l i v o l t A C ?
Ye s
No
VERI FY s y s t e m
o pe r a t i o n .
GO t o H3.
H3 CHECK CI RCUI T 7 98 ( L G / R) , CDDJ LH (-) AUDI O FOR
OPEN
Ye s l >
No t>
GO t o H4.
( L G / R) o pe n . RESTORE
Di sc o n n e c t CDDJ a n d RCU C4 c o n n e c t o r s .
Me a sur e Ci r c ui t 7 98 ( L G / R) r e s i s t a n c e be t we e n
CDDJ c o n n e c t o r , Pi n 11 ( ha r n e ss e nd) a n d RCU C4
Is resi stance 5 o h ms o r l e s s ?
Ye s l >
No t>
GO t o H4.
( L G / R) o pe n . RESTORE
SHORT TO GROUND
Ye s &>
No S>
G O t o MS-
( L G / R) sho r t t o gr o un d .
VERI FY s y s t e m
o pe r a t i o n .
Me a s ur e Ci r c ui t 7 98 ( LG / R) r e s i s t a n c e be t we e n
CDDJ c o n n e c t o r , Pi n 11 ( ha r n e ss e n d ) a nd a kn o wn
go o d gr o un d .
I s r e s i s t a n c e g r e a t e r t h a n 1 M o h m?
Ye s &>
No S>
G O t o MS-
( L G / R) sho r t t o gr o un d .
VERI FY s y s t e m
o pe r a t i o n .
SHORT TO SHI ELD
Ye s
No
G O t o H6.
( L G / R) sho r t t o shi e l d .
VERI FY s y s t e m
o pe r a t i o n .
Di sc o n n e c t FCU a nd RCU C4 c o n n e c t o r s .
Me a s ur e Ci r c ui t 7 98 ( L G / R) r e s i s t a n c e be t we e n
CDDJ c o n n e c t o r , Pi n 1 ( ha r n e ss e nd) a n d Pi n 3,
( Ba r e ) , shi e l d of t he s a me c o n n e c t o r .
Is resi stance greater t h a n 1 M o h m ?
Ye s
No
G O t o H6.
( L G / R) sho r t t o shi e l d .
VERI FY s y s t e m
o pe r a t i o n .
H6 CHECK CI RCUI T 7 98 ( L G / R) , CDDJ RH (-) AUDI O FOR
SHORT TO RH ( + )
Ye s i >
No l>
GO t o H7
( L G / R) sho r t t o CDDJ
L H+ . RESTORE v e hi c l e
o pe r a t i o n .
Di sc o n n e c t Re mo t e Co n t r o l Uni t C4 a nd CDDJ
Me a s ur e Ci r c ui t 7 98 ( L G / R) r e s i s t a n c e be t we e n
CDDJ c o n n e c t o r , Pi n 11 ( ha r n e ss si d e ) a n d Pi n 2,
Ci r c ui t 856 (P), CDDJ Aud i o RH ( + ) of t he sa me
c o n n e c t o r .
is r e s i s t a n c e g r e a t e r t h a n 1 M o h m?
Ye s i >
No l>
GO t o H7
( L G / R) sho r t t o CDDJ
L H+ . RESTORE v e hi c l e
o pe r a t i o n .
H7 CHECK CI RCUI T 7 98 ( L G / R) , CDDJ RH (-) AUDI O FOR
SHORT TO LH (-)
Ye s >
No ! >
GO t o H8.
sho r t t o CDDJ LH (-).
VERI FY s y s t e m
o pe r a t i o n .
v c o n n e c t Re mo t e Co n t r o l Uni t C4 a n d CDDJ
Me a s u r e Ci r c ui t 7 98 ( L G / R) r e s i s t a n c e be t we e n
CDDJ c o n n e c t o r , Pi n 11 ( ha r n e ss e nd) a nd Pi n 8,
Ci r c ui t 690 ( GY) , CDDJ Aud i o RH ( + ) of t he sa me
c o n n e c t o r .
Ye s >
No ! >
GO t o H8.
sho r t t o CDDJ LH (-).
VERI FY s y s t e m
o pe r a t i o n .
15- 00- 7 1 15- 00- 7 1
PI NPOI NT TE ST H: THE FCU DI SPLAY SHOWS CDDJ , BUT THERE I S NO C DDJ A UDI OA M, FM A ND TAPE MODE S ARE
NORMA L (Cont i nued)
H8 CHECK CI RCUI T 7 98 ( L G / R) , CDDJ LH(-) AUDI O FOR
SHORT TO RH (-)
Ye s >
No >
GO t o H9
sho r t t o CDDJ RH (-).
VERI FY s y s t e m
o pe r a t i o n .
Di sc o n n e c t Re mo t e Co n t r o l Uni t C4 and CDDJ
Me a sur e Ci r c ui t 7 98 ( LG / R) r e s i s t a n c e b e t we e n
CDDJ c o n n e c t o r , Pi n 11 ( ha r n e ss e n d ) and Pi n 9,
Ci r c ui t 7 99 ( O/ BK) , CDDJ Aud i o RH (-) of t h e s a me
c o n n e c t o r .
Is resi st ance g r e a t e r t han 1 M o h m ?
Ye s >
No >
GO t o H9
sho r t t o CDDJ RH (-).
VERI FY s y s t e m
o pe r a t i o n .
H9 CHECK CI RCUI T 7 98 ( L G / R) , CDDJ LH(-) AUDI O FOR
SHORT TO BATTERY
Ye s
No
GO t o HI O.
VERI FY s y s t e m
o pe r a t i o n .
Di sc o n n e c t CDDJ a nd RCU C4 c o n n e c t o r .
Me a sur e Ci r c ui t 7 98 ( LG / R) v o l t a ge be t we e n CDDJ
c o n n e c t o r , Pi n 1 1 ( ha r n e s s e n d ) a n d a kn o wn go o d
gr o un d .
Ye s
No
GO t o HI O.
VERI FY s y s t e m
o pe r a t i o n .
H10 CHECK CI RCUI T 856 (P), CDDJ L H( + ) AUDI O FOR
OPEN
Ye s ! >
No &
GO t o H 1 1 .
SERVI CE Ci r c ui t 856 (P)
o pe r a t i o n .
Di sc o n n e c t CCDJ a nd RCU C4 c o n n e c t o r .
Me a s ur e c i r c ui t 856 (P) r e s i s t a n c e be t we e n CDDJ
c o n n e c t o r , Pi n 2 ( ha r n e ss e n d ) a nd RCU C4
c o n n e c t o r , Pi n 2 1 .
Ye s ! >
No &
GO t o H 1 1 .
o pe r a t i o n .
SHORT TO GROUND
Ye s
No
GO t o H12.
SERVI CE Ci r cui t 856 (P)
VERI FY s y s t e m
o pe r a t i o n .
Me a sur e Ci r c ui t 856 (P) r e s i s t a n c e be t we e n CDDJ
c o n n e c t o r , Pi n 2 ( ha r n e s s e n d ) a n d a kn o wn go o d
gr o un d .
Ye s
No
GO t o H12.
VERI FY s y s t e m
o pe r a t i o n .
SHORT TO SHI ELD
Ye s
No
GO t o H13
Di sc o n n e c t CDDJ a nd RCU C4 c o n n e c t o r s .
Me a s ur e Ci r c ui t 856 (P) r e s i s t a n c e be t we e n CDDJ
c o n n e c t o r , Pi n 2 ( ha r n e s s e n d ) a nd Pi n 3, ( Ba r e ) ,
shi e l d of sa me c o n n e c t o r .
i s resi st ance great er t han 1 M ohm?
Ye s
No
GO t o H13
SHORT TO RH( + )
Ye s
No
GO t o H 1 4 .
sho r t t o RH ( + ) .
VERI FY sy st e m
o pe r a t i o n .
Me a s ur e Ci r c ui t 856 (P) r e s i s t a n c e be t we e n CDDJ
c o n n e c t o r , Pi n 2 ( ha r n e s s e n d ) a nd Pi n 8, Ci r c ui t 690
( GY) , CDDJ Aud i o RH( + ) of t h e sa me c o n n e c t o r .
Is resi st ance g r e a t e r t han 1 M ohm?
Ye s
No
GO t o H 1 4 .
sho r t t o RH ( + ) .
VERI FY sy st e m
o pe r a t i o n .
H1 4 CHECK CI RCUI T 856 ( P) , CDDJ L H( + ) AUDI O FOR
SHORT TO RH(-)
Ye s
No
GO t o H 1 5 .
sho r t t o RH(-). RESTORE
sy st e m o pe r a t i o n .
Me a s u r e Ci r c ui t 856 (P) r e s i s t a n c e be t we e n CDDJ
c o n n e c t o r , Pi n 2 ( ha r n e s s e n d ) a nd Pi n 9, Ci r c ui t 7 99
( O / B K ) , CDDJ Aud i o RH(-) of t he sa me c o n n e c t o r .
Is resi st ance gr eat er t h a n 1 M ohm?
Ye s
No
GO t o H 1 5 .
sho r t t o RH(-). RESTORE
sy st e m o pe r a t i o n .
PI NPOI NT TEST H: THE FCU DISPLAY SHOWS CDDJ, BUT THERE IS NO CDDJ AUDI OAM, FM AND TAPE MODES ARE
NORMAL (Cont i nued)
H15 CHECK CIRCUIT 856 (P) CDDJ L H( + ) AUDI O FOR
SHORT TO BATTERY
Ye s
No
G O t o H 1 6 .
VERI FY s y s t e m
o pe r a t i o n .
Me a sur e Ci r c ui t 856 (P) v o l t a ge be t we e n CDDJ
c o n n e c t o r , Pi n 2 a nd a kn o wn go o d gr o un d .
# Do e s vol t met er r e a d zero v o l t s ?
Ye s
No
G O t o H 1 6 .
VERI FY s y s t e m
o pe r a t i o n .
H16 CHECK CI RCUI T 690 ( GY) , L H( + ) AUDI O FOR OPEN
Ye s
No
GO t o H 1 7 .
Di sc o n n e c t CDDJ a nd RCU C 4 c o n n e c t o r s .
Me a sur e Ci r c ui t 690 ( GY) r e s i s t a n c e b e t we e n CDDJ
c o n n e c t o r , Pi n 8 ( ha r n e ss e n d ) a nd RCU C4
c o n n e c t o r , Pi n 2 2 .
Is r e s i s t a n c e 5 ohms or l ess?
Ye s
No
GO t o H 1 7 .
HI ? CHECK CIRCUIT 690 (GY), CDDJ RH( + ) AUDI O FOR
SHORT TO GROUND
Ye s
No
GO t o H 1 8 .
VERI FY s y s t e m
o pe r a t i o n .
m Me a s ur e Ci r c ui t 690 (GY) r e s i s t a n c e b e t we e n CDDJ
c o n n e c t o r , Pi n 8 ( ha r n e ss e n d ) a n d a kn o wn go o d
gr o un d .
m Is resi stance great er t han 1 M ohm?
Ye s
No
GO t o H 1 8 .
VERI FY s y s t e m
o pe r a t i o n .
H18 CHECK CI RCUI T 690 ( GY) , CDDJ RH( + ) AUDI O FOR
SHORT TO SHI ELD
Ye s
No
G O t o H 1 9 .
VERI FY s y s t e m
o pe r a t i o n .
Me a sur e Ci r c ui t 690 (GY) r e s i s t a n c e b e t we e n CDDJ
c o n n e c t o r , Pi n 8 ( ha r n e ss e n d ) a n d Pi n 3, ( Ba r e ) ,
shi e l d of t he sa me c o n n e c t o r .
is resi stance great er t han 1 M ohm?
Ye s
No
G O t o H 1 9 .
VERI FY s y s t e m
o pe r a t i o n .
H19 CHECK CI RCUI T 690 ( GY) , CDDJ RH( + ) AUDI O FOR
SHORT TO CI RCUI T 7 99 ( O/ BK ) RH(-)
Ye s
No
GO t o H2 0.
(GY) sho r t t o RH(-).
VERI FY s y s t e m
o pe r a t i o n .
^ c o n n e c t Re mo t e Co n t r o l Uni t C4 a n d CDDJ
# Me a s ur e Ci r c ui t 690 (GY) r e s i s t a n c e be t we e n CDDJ
c o n n e c t o r , Pi n 8 ( ha r n e ss e n d ) a n d Pi n 9, Ci r c ui t 7 99
( O/ BK) , CDDJ Aud i o RH(-) of t he s a me c o n n e c t o r .
I s r e s i s t a n c e great er t han M ohm?
Ye s
No
GO t o H2 0.
(GY) sho r t t o RH(-).
VERI FY s y s t e m
o pe r a t i o n .
H2 0 CHECK CI RCUI T 690 ( GY) , CDDJ RH( + ) AUDI O FOR
SHORT TO BATTERY
Ye s
No
G Ot o H 2 1 .
(GY) sho r t t o ba t t e r y .
VERI FY s y s t e m
o pe r a t i o n .
# Me a s ur e Ci r c ui t 690 (GY) v o l t a ge be t we e n CDDJ
c o n n e c t o r , Pi n 8 ( ha r n e ss e n d ) a n d a kn o wn go o d
gr o un d .
Does v o l t me t e r r e a d zero vol t s?
Ye s
No
G Ot o H 2 1 .
(GY) sho r t t o ba t t e r y .
VERI FY s y s t e m
o pe r a t i o n .
H2 1 CHECK CI RCUI T 7 99 ( 0 / BK) , CDDJ RH (-) AUDI O FOR
OPEN
Ye s
No
GO t o H2 2 .
( O/ BK ) o pe n . VERI FY
# Di sc o n n e c t CDDJ a n d RCU C4 c o n n e c t o r s .
Me a s ur e Ci r cui t 7 99 ( 0 / BK) r e s i s t a n c e be t we e n
CDDJ c o n n e c t o r , Pi n 9 ( ha r n e ss e n d ) a n d RCU C4
Is r e s i s t a n c e 5 ohms or l ess?
Ye s
No
GO t o H2 2 .
( O/ BK ) o pe n . VERI FY
PI NPOI NT TE ST H: THE FCU DI SPLAY SHOWS CDDJ , BUT THERE I S NO CDDJ A U DI O A M, FM A ND TAPE MODE S ARE
NORMAL ( C o n t i n u e d )
H22 CHECK CI RCUI T 799 ( O/ BK ) , CDDJ RH(-) AUDI O FOR
SHORT TO GROUND
Ye s
No
GO to H23.
( O / B K ) sho r t t o gr o un d .
VERI FY s y s t e m
o pe r a t i o n .
Di sc o n n e c t CDDJ a nd RCU 04 connectors.
Me a sur e Ci r c ui t 7 99 (O / BK) resistance b e t we e n
CDDJ c o n n e c t o r , Pi n 9 ( ha r n e ss e n d ) and a kn o wn
go o d gr o un d .
Ye s
No
GO to H23.
( O / B K ) sho r t t o gr o un d .
VERI FY s y s t e m
o pe r a t i o n .
H23 CHECK CI RCUI T 799 ( O/ BK ) , CDDJ RH(-) AUDI O FOR
SHORT TO SHI ELD
Ye s
No
GO t o H2 4.
( O / B K ) sho r t t o s h i e l d .
VERI FY s y s t e m
o pe r a t i o n .
Me a sur e Ci r c ui t 7 99 ( 0 / BK) r e s i s t a n c e b e t we e n
CDDJ c o n n e c t o r , Pi n 9 ( ha r n e ss e n d ) and Pi n 3,
( Ba r e ) , shi e l d of t he sa me c o n n e c t o r .
Ye s
No
GO t o H2 4.
( O / B K ) sho r t t o s h i e l d .
VERI FY s y s t e m
o pe r a t i o n .
H24 CHECK CI RCUI T 799 ( O / B K ) , CDDJ AUDI O RH(-) FOR
SHORT TO BATTERY
Ye s
No
REPLACE d a ma ge d
o pe r a t i o n .
SERVI CE Ci r cui t 7 99
( O/ BK ) shor t ba t t e r y .
VERI FY s y s t e m
o pe r a t i o n .
Me a sur e Ci r c ui t 7 99 ( 0 / BK) v o l t a ge be t we e n CDDJ
c o n n e c t o r , Pi n 2 ( ha r n e s s e nd) and a kn o wn go o d
gr o un d .
Ye s
No
REPLACE d a ma ge d
o pe r a t i o n .
SERVI CE Ci r cui t 7 99
( O/ BK ) shor t ba t t e r y .
VERI FY s y s t e m
o pe r a t i o n .
PI NPOI NT TE ST K: L OUD " P OP S " WHE N I GNI TI ON SWI TCH I S CYCL E D BE TWE E N OFF AND ACCE SSORY OR OFF A ND
RUN
K1 DETERMI NE THE CAUSE OF THE LOUD " P OP S"
Ye s
No
GO t o K3.
G O t o K 2 .
Di sc o n n e c t t he s ub- wo o f e r a mpl i f i e r 2-pi n po we r
c o n n e c t o r .
Cy c l e t he i gni t i on s wi t c h f r o m OFF t o START or
RUN.
I s t h e r e a n y P OP S?
Ye s
No
GO t o K3.
G O t o K 2 .
K2 CHECK SUB- WOOFER AMPLI FI ER ENABLE LI NE
VOLTAGE LEVEL, CI RCUI T 173 (DG/ P)
Ye s i >
No
sho r t t o ba t t e r y . If sho r t i s
not f o un d , GO t o K 3 .
REPLACE d a ma ge d
subwo o f e r a mpl i f i e r .
Re c o n n e c t t h e Sub- wo o f e r a mpl i f i e r , 2-pi n po we r
c o n n e c t o r , d i s c o n n e c t Sub- wo o f e r bl a c k c o n n e c t o r .
I nsur e t ha t t h e FCU po we r but t o n i s OFF, r e c y c l e t h e
i gn i t i o n s wi t c h t o OFF a n d o pe n a nd shut t he d r i ve r
d o o r ,
Me a s ur e Ci r c ui t 173 ( DG / P ) , Sub- wo o f e r e n a bl e
v o l t a ge l i ne, Pi n 2 of t he subwo o f e r bl a c k c o n n e c t o r
( ha r n e ss e n d ) a n d a kn o wn go o d gr o un d .
I s v o l t a g e a p p r o x i ma t e l y 1 2 v o l t s ?
Ye s i >
No
sho r t t o ba t t e r y . If sho r t i s
not f o un d , GO t o K 3 .
REPLACE d a ma ge d
subwo o f e r a mpl i f i e r .
K3 CHECK CI RCUI T 32 ( R/ L B) , RCU START VOLTAGE
LEVEL
Ye s
No
SERVI CE Circuit 32 sho r t
t o ba t t e r y .
REPLACE RCU.
I nsur e t ha t t h e i gni t i on s wi t c h i s OFF a n d o pe n a n d
shut t h e d r i ve r d o o r . Di sc o n n e c t RCU C3 c o n n e c t o r
a n d me a sur e v o l t a ge b e t we e n Ci r c ui t 32 ( R/ L B) , Pi n
17 of RCU C3 c o n n e c t o r a nd a kn o wn go o d gr o un d .
I s t h e v o l t a g e a p p r o x i ma t e l y 12 v o l t s ?
Ye s
No
SERVI CE Circuit 32 sho r t
t o ba t t e r y .
REPLACE RCU.
PI NPOI NT T E ST L: DELAY ACCESSORY I S NOT FUNCTI ONAL ( TOWN CAR)
L1 CHECK L CM OUTPUT AND DRI VER AJ AR SWI TCH
Ye s
No
REPLACE dr i ve r d o o r a j a r
o pe r a t i o n .
GO t o L 2 .
Turn t he FCU ON, t ur n ignition s wi t c h f r o m OFF t o
RUN t o START t o RUN. Turn t h e i gni t i on s wi t c h t o
OFF.
Do e s t h e A u d i o s y s t e m s h u t o f f ?
Ye s
No
REPLACE dr i ve r d o o r a j a r
o pe r a t i o n .
GO t o L 2 .
15- 00- 7 4 A u d i o S y s t e ms S e r v i c e ^ ^ 15- 00- 7 4
PINPOINT TEST L: DELAY ACCESSORY IS NOT FUNCTIONAL (TOWN CAR) ( Co n t i n u e d )
L2 CHECK DELAY ACCESSORY VOLTAGE LEVEL
Ye s >
No
VERI FY s y s t e m
o pe r a t i o n .
GO t o L 3.
Measure the voltage of Delay A c c e s s o r y , Pin 3 of
FCU C2 connector, Circuit 194 (P).
i s v o l t a g e appr oxi mat el y 12 vol t s?
Ye s >
No
VERI FY s y s t e m
o pe r a t i o n .
GO t o L 3.
L 3 CHECK CI RCUI T 194 (P) FOR SHORT TO GROUND
Ye s
No
GO t o L 4.
VERI FY s y s t e m
o pe r a t i o n .
m Disconnect LCM connector C2 and FCU connector
C2 and Delay Accessory Relay.
Measure Circuit 194 (P) resi stance be t we e n FCU
go o d gr o un d .
is r e s i s t a n c e g r e a t e r than 1 M ohm?
Ye s
No
GO t o L 4.
VERI FY s y s t e m
o pe r a t i o n .
L 4 CHECK CI RCUI T 194 (P) FOR OPEN
Ye s P>
No [ >
GO t o L 5.
194 (P). RESTORE
v e hi c l e . VERI FY s y s t e m
o pe r a t i o n .
m Disconnect L CM connector C2 and FCU connector
C 2 and Delay Accessory Relay.
Measure Circuit 194 (P) resistance between FCU
c o n n e c t o r C 2 , Pin 3 (harness end) and LCM,
connectorB, Pin 13.
Is resi stance 5 ohms or l e s s ?
Ye s P>
No [ >
GO t o L 5.
194 (P). RESTORE
o pe r a t i o n .
L5 CHECK CI RCUI T 1068 ( L G / BK) ASYSON FOR SHORT
TO BATTERY BETWEEN FCU AND RCU
Ye s
No
GO t o L 6.
( L G / BK) ASYSON sho r t
t o ba t t e r y be t we e n FCU &
RCU. RESTORE v e hi c l e .
VERI FY s y s t e m
o pe r a t i o n .
Me a sur e t he v o l t a ge be t we e n Ci r c ui t 1068 ( L G / BK)
FCU c o n n e c t o r C2, Pi n 4 ( ha r n e ss e n d ) a nd a kn o wn
go o d gr o un d .
Do e s vol t met er read zero vol t s?
Ye s
No
GO t o L 6.
t o ba t t e r y be t we e n FCU &
RCU. RESTORE v e hi c l e .
VERI FY s y s t e m
o pe r a t i o n .
L 6 CHECK CI RCUI T 1068 ( L G / BK) A SYSON FOR SHORT
TO BATTERY BETWEEN RCU AND CDDJ
Ye s
No
REPLACE d a ma ge d L CM.
t o ba t t e r y be t we e n RCU
& CDDJ. RESTORE
o pe r a t i o n .
Me a sur e t he v o l t a ge be t we e n Ci r c ui t 1068 ( L G / BK)
RCU c o n n e c t o r C4, Pi n 8 ( ha r n e ss e n d ) a nd a kn o wn
go o d gr o un d .
Ye s
No
REPLACE d a ma ge d L CM.
t o ba t t e r y be t we e n RCU
& CDDJ. RESTORE
o pe r a t i o n .
PI NPOI NT TE ST M: WHE N HE A DL A MP SWI TCH I N PARK OR HEAD POSI TI ON, NO FCU BA CKL I G HT I NG A L L OTHER
I NSTRUME NT PANEL LI GHTI NG I S NORMAL
M1 CHECK L CM OUTPUT
Ye s
No
VERI FY s y s t e m
o pe r a t i o n .
GO t o M2 .
Di sc o n n e c t FCU C1 c o n n e c t o r .
Ensur e t ha t t he he a d l i ght s wi t c h i s in PARK po si t i o n .
Whi l e a d j ust i n g i nst r ume nt pa n e l d i mme r f r o m
mi ni mum t o ma x i mum, me a sur e v o l t a ge be t we e n
FCU c o n n e c t o r C 1 , Pi n 4 ( ha r n e ss e n d ) a nd a kn o wn
go o d gr o un d .
Does vol t age vary and range appr oxi mat el y
be t we e n 3. 5 and 1 2 vol t s?
Ye s
No
VERI FY s y s t e m
o pe r a t i o n .
GO t o M2 .
M2 CHECK CI RCUI T 19 ( L B/ R) FOR SHORT TO GROUND
Ye s
No
GO t o M3.
VERI FY s y s t e m
o pe r a t i o n .
Di sc o n n e c t L CM c o n n e c t o r C3 a n d FCU c o n n e c t o r
C 1 .
Me a s ur e t he r e s i s t a n c e be t we e n Ci r c ui t 19 ( LB / R)
be t we e n FCU c o n n e c t o r C 1, Pi n 4 ( ha r n e ss e nd) a nd
I s resi st ance great er t han 1 M ohm?
Ye s
No
GO t o M3.
VERI FY s y s t e m
o pe r a t i o n .
15- 00- 7 5 A u d i o S y s t e m s S e r v i c e
PINPOINT TEST M: WHEN HEADLAMP SWITCH IN PARK OR HEAD POSITION, NO FCU BACKLIGHTINGALL OTHER
INSTRUMENT PANEL LIGHTING IS NORMAL (Cont i nued)
M3 CHECK CI RCUI T 19 ( L B/ R) FOR OPEN
Ye s
No
GO to M4.
SERVICE Circuit 19
(LB/R) open. RESTORE
vehicle. VERIFY system
operation.
C1.
Me a sur e t he r e s i s t a n c e be t we e n Ci r c ui t 1 9 ( L B / R)
FCU c o n n e c t o r C 1 , Pi n 4 a n d L CM c o n n e c t o r C3 Pi n
2 ( ha r n e ss e n d s ) .
Ye s
No
GO to M4.
SERVICE Circuit 19
(LB/R) open. RESTORE
operation.
M4 CHECK CI RCUI T 19 ( L B/ R) FOR SHORT TO BATTERY
(+)
Ye s
No
GO to MS .
SERVICE Circuit 19
(LB/R) short to battery.
RESTORE vehicle.
VERIFY system
operation.
C1.
Me a sur e t he v o l t a ge be t we e n Ci r c ui t 19 ( L B/ R),
FCU c o n n e c t o r C 1 , Pi n 4 ( ha r n e ss e nd) and a kn o wn
go o d gr o un d .
Ye s
No
GO to MS .
SERVICE Circuit 19
(LB/R) short to battery.
RESTORE vehicle.
VERIFY system
operation.
M5 CHECK CI RCUI T 57 ( BK) , FCU I LLUMI NATI ON GROUND
FOR OPEN
Ye s
No
REPLACE damaged LCM.
RESTORE vehicle.
VERIFY system
operation.
SERVICE open Circuit 6 7
(BK).
C1.
Me a sur e t he r e s i s t a n c e b e t we e n Ci r c ui t 57 ( BK)
FCU c o n n e c t o r C 1, Pi n 2 ( ha r n e ss e n d ) and a kn o wn
go o d gr o un d .
Ye s
No
REPLACE damaged LCM.
RESTORE vehicle.
VERIFY system
operation.
SERVICE open Circuit 6 7
(BK).
PINPOINT TEST N: NO STEERING WHEEL CONTROL BUTTONS BACKLIGHTING, BOTH LH AND RH SIDE
TEST STEP RESULT TIONTOTA'-C
N1 CHECK L CM OUTPUT
Ye s
No
REPLACE SWC module.
RESTORE vehicle.
VERIFY system
operation. If backlighting
i s still not functioning,
REPLACE RHS push
button unit. RESTORE
operation.
GO to N2-
NOTE: N1 i s not r e qui r e d if i nst r ume nt pa ne l d i mmi n g
i s f un c t i o n a l .
Di sc o n n e c t SWC mo d ul e c o n n e c t o r .
Ensur e t ha t t he he a d l i ght s wi t c h i s in PARK po s i t i o n .
Whi l e a d j ust i n g i nst r ume nt pa n e l d i mme r f r o m
mi ni mum t o ma x i mum, me a sur e v o l t a ge be t we e n
SWC c o n n e c t o r Pi n 14 ( ha r n e ss e nd) a n d a kn o wn
go o d gr o un d .
Does t he vol t age vary and range appr oxi mat el y
bet ween 0.9 and 12 vol t s?
Ye s
No
REPLACE SWC module.
RESTORE vehicle.
VERIFY system
operation. If backlighting
i s still not functioning,
REPLACE RHS push
button unit. RESTORE
operation.
GO to N2-
N2 CHECK CI RCUI T 484 ( O/ BK ) FOR SHORT TO BATTERY
Yes
No ^
GO to N3.
SERVICE Circuit 484
(O/BK) short to battery.
RESTORE vehicle.
VERIFY s y s t e m
operation.
Di sc o n n e c t L CM c o n n e c t o r C3 a n d SWC connect o?
Me a sur e t he v o l t a ge be t we e n Ci r c ui t 484 ( O/ BK) ,
SWC c o n n e c t o r Pi n 14 ( ha r n e ss e n d ) a n d a kn o wn
go o d gr o un d .
Yes
No ^
GO to N3.
SERVICE Circuit 484
(O/BK) short to battery.
RESTORE vehicle.
VERIFY s y s t e m
operation.
N3 CHECK CI RCUI T 484 (O / BK) FOR OPEN
Ye s
No
SERVICE Circuit 484
(O/ BK) open. RESTORE
operation.
Di sc o n n e c t L CM c o n n e c t o r C3 a n d SWC c o n n e c t o r .
Me a sur e r e s i s t a n c e be t we e n Ci r c ui t 484 ( 0 / BK)
be t we e n SWC c o n n e c t o r , Pi n 15 ( ha r n e ss e n d ) a n d
L CM c o n n e c t o r C3 Pi n 12 ( ha r n e s s e n d ) .
Ye s
No
SERVICE Circuit 484
(O/ BK) open. RESTORE
operation.
1 9 9 5 To wn Car , Cr o wn Vi c t o r i a , Gr a n d Ma r q u i s Jul y 1994
PINPOINT TEST P: SWC BACKLIGHTING OR NO LHS BACKLIGHTING
TE ST STEP RESULT ACTI ON TO T A KE
P 1 REPLACE LHS OR RES PUSH BUTTONS UNI TS TEST
Ye s
No
REPLACE LHS push
but t o n s uni t . RESTORE
o pe r a t i o n .
REPLACE RHS push
o pe r a t i o n .
Re mo v e LHS push but t o n s uni t by pl a c i n g a s c r e w
d r i v e r b e t we e n t he st e e r i n g whe e l a pe r t ur e a n d t h e
b o t t o m o f t h e pl a s t i c be ze l . Fi r ml y but c a r e f ul l y pr y
t he LHS but t o n c o n t r o l l e r u pwa r d .
Ensur e t h a t t h e he a d l i ght s wi t c h i s in PARK p o s i t i o n .
Se t i n st r ume n t pa ne ! d i mme r t o ma x i mum.
Di sc o n n e c t t h e 4-Pi n c o n n e c t o r f r o m B3. Me a s u r e
t h e v o l t a ge b e t we e n Ci r c ui t 1089 ( Re d wi t h Pi nk
s t r i pe ) , Pi n 3 of 4-Pi n c o n n e c t o r ( ha r n e ss s i d e ) a n d
Does vol t me t e r read more t han 1 vol t ?
Ye s
No
REPLACE LHS push
o pe r a t i o n .
REPLACE RHS push
o pe r a t i o n .
PINPOINT TEST R: DEGRADED A M RECEPTI ON OR CONTI NUOUS SEEK I N A M
R1 CHECK CONNECTI ONS ON REAR WI NDOW
DEFROSTER GRI D
Ye s >
No
GO t o R2 .
CLEAN wi r e t e r mi n a l s
a n d gl a s s mo un t e d
c o n n e c t o r t a b s . RETEST
A M r e c e pt i o n .
Ch e c k wi r e c o n n e c t i o n s f r o m t he An t e n n a I so l a t o r
Mo d ul e ( AI M) t o t he r e a r wi n d o w d e f r o s t e r gr i d a t
t h e r i ght a n d l ef t si d e of t h e r e a r gl a s s .
Are t he c onne c t i ons t i ght and f r ee of di r t or
c or r osi on?
Ye s >
No
GO t o R2 .
c o n n e c t o r t a b s . RETEST
A M r e c e pt i o n .
R2 CHECK RCU TO AI M COAXI AL CABLE CENTER
CONDUCTOR
Ye s
No
G Ot o R4
G O t o R3.
A c c e s s a n d d i s c o n n e c t RCU t o AI M c o a x i a l c a b l e
c o n n e c t o r f r o m RCU.
Me a s u r e r e s i s t a n c e b e t we e n c a b l e c o n n e c t o r
c e n t e r c o n d u c t o r a n d a kn o wn go o d gr o un d .
Is r esi st ance 3 0 0 - 3 6 0 ohms?
Ye s
No
G Ot o R4
G O t o R3.
R3 CHECK CENTER CONDUCTOR CONTI NUI TY
Ye s
No
REPLACE AI M. RESTORE
v e hi c l e . RETEST A M
r e c e pt i o n .
REPLACE AI M t o RCU
c a b l e . RESTORE v e hi c l e .
RETEST A M r e c e pt i o n .
f r o m AI M.
Me a s u r e r e s i s t a n c e f r o m c e n t e r c o n d u c t o r of c a b l e
a t RCU e n d t o c e n t e r c o n d u c t o r of c a b l e a t AI M e n d .
Is r esi st ance 3 ohms o r l e s s ?
Ye s
No
r e c e pt i o n .
c a b l e . RESTORE v e hi c l e .
R4 CHECK RCU TO AI M COAXI AL CABLE OUTER
CONDUCTOR
Ye s
No
G O t o R6.
GO t o R5.
* Me a s u r e r e s i s t a n c e b e t we e n o ut l e t c o n n e c t o r of
c o a x i a l c a b l e at Re mo t e Co n t r o l Uni t e n d a n d a
kn o wn g o o d gr o un d .
Ye s
No
G O t o R6.
GO t o R5.
R5 CHECK OUTER CONDUCTOR CONTI NUI TY
Ye s
No
r e c e pt i o n .
REPLACE RCU t o AI M
c a bl e . RESTORE v e hi c l e .
f r o m AI M.
Me a s u r e r e s i s t a n c e f r o m o ut e r c o n d u c t o r of c o a x i a l
c a b l e a t RCU e nd t o o ut e r c o n d u c t o r of c o a x i a l
c a b l e at AI M e n d .
Ye s
No
r e c e pt i o n .
R6 CHECK FOR SHORT TO URETHANE
Ye s
No
G O t o R7 .
LOCATE a nd SERVI CE
sho r t t o r e a r wi n d o w
mount i ng ur e t ha n e .
RETEST AM r e c e pt i o n .
Di s c o n n e c t AI M t o d e f r o s t e r c o n n e c t i o n s on t he
r i ght a n d l ef t of t he r e a r gl a s s .
Me a s u r e t he r e s i s t a n c e b e t we e n b o t h t h e d e f r o s t e r
gr i d c o n n e c t i o n s a n d t he ur e t ha n e r e t a i n i n g t he r e a r
wi n d o w gl a s s of t he v e hi c l e .
* I s t h e resi st ance g r e a t e r t han 100 K-Ohms?
Ye s
No
G O t o R7 .
LOCATE a nd SERVI CE
sho r t t o r e a r wi n d o w
mount i ng ur e t ha n e .
RETEST AM r e c e pt i o n .
1 9 9 * To wn C?r , Cr c w- i V t r j . e r k . f*?^?-* Kf eraj , :!* J u l y 1S94
15- 00- 7 7 A u d i o S y s t e m s S e r v i c e 1S- 00- 7 7
PINPOINT T E ST R: DEGRADED AM RECEPTI ON OR CONTINUOUS SE E K I N A M ( Co n t i n u e d )
T E ST STEP RESULT ACTION TO T A KE
R7 CHECK FOR DAMAGED DEFROSTER GRI D LI NES
Ye s
No ^
GO t o R8.
SERVI CE any s u s p e c t e d
o pe n gr i d l i n e s.
RETEST A M r e c e p t i o n .
P l a c e a br i ght l a mp i nsi de v e hi c l e c l o s e t o t h e
d e f r o s t e r gr i d l i n e s.
I n spe c t t he d e f r o s t e r gr i d l i ne s c l o s e l y f r o m t h e
o u t s i d e of t he v e h i c l e .
A c l e a r s po t of l i ght sho wi n g t hr o ugh a gr i d l i ne
i n d i c a t e s an o pe n or d a ma ge d l i ne on t h e gl a s s .
Are all the defroster grid lines in pl ace and
cont i nuous?
Ye s
No ^
GO t o R8.
o pe n gr i d l i n e s.
R8 CHECK AI M GROUND CI RCUI T TO DEFROSTER GRID
Ye s
No
GO t o R9.
r e c e pt i o n .
A c c e s s t h e AI M a n d d i s c o n n e c t t h e r e a r wi n d o w
d e f r o s t e r suppl y l i ne.
Me a s u r e t h e r e s i s t a n c e b e t we e n t h e r i ght r e a r
d e f r o s t e r suppl y wi r e a nd t he AI M c a s e .
Is the resi st ance l ess than 3 ohms?
Ye s
No
GO t o R9.
r e c e pt i o n .
R9 CHECK AI M GROUND CI RCUI T TO VEHI CLE
Ye s
No
GO t o R 1 0 .
SERVI CE o pe n gr o u n d .
I NSTALL ba n d s t r a p if
n e c e s s a r y . RESTORE
r e c e pt i o n .
Me a s u r e r e s i s t a n c e be t we e n AI M c a s e a n d a kn o wn
g o o d gr o un d .
Is the resi st ance 3 ohms or l e ss?
Ye s
No
GO t o R 1 0 .
SERVI CE o pe n gr o u n d .
I NSTALL ba n d s t r a p if
n e c e s s a r y . RESTORE
r e c e pt i o n .
R10 CHECK AI M POWER CI RCUI T TO DEFROSTER GRI D
Ye s
No
GO t o R 1 1 .
r e c e pt i o n .
Me a s u r e r e s i s t a n c e b e t we e n l ef t d e f r o s t e r gr i d
suppl y wi r e a nd AI M d e f r o s t e r suppl y t a b .
Ye s
No
GO t o R 1 1 .
r e c e pt i o n .
R11 CHECK AI M POWER CI RCUI T FOR SHORT TO GROUND
Ye s ^
No
REPLACE RCU.
r e c e pt i o n .
Me a s u r e r e s i s t a n c e be t we e n AI M d e f r o s t e r suppl y
t a b a n d kn o wn g o o d gr o un d .
Is resi st ance greater than 20 K-ohms?
Ye s ^
No
REPLACE RCU.
r e c e pt i o n .
PINPOINT TE ST S: DEGRADED FM RECEPTI ON OR CONTI NUOUS SEEK I N FM
TE ST STEP RESULT A CT I ON TO T A KE
S1 CHECK CENTER CONDUCTOR CONNECTI ON ON REAR
WI NDOW FM ANTENNA PATTERN
Ye s
No
GO t o 82.
c o n n e c t o r t a b . RESTORE
c o n n e c t i o n . RETEST FM
r e c e pt i o n .
Ch e c k c o a x i a l c a b l e c o n n e c t i o n t o t h e FM pa t t e r n
a t t h e t o p of t he r e a r gl a s s .
Are the connect i ons tight and free of dirt or
corrosi on?
Ye s
No
GO t o 82.
c o n n e c t o r t a b . RESTORE
r e c e pt i o n .
S2 CHECK GROUND CONNECTI ON ON REAR WI NDOW
FM ANTENNA PATTERN
Ye s >
No
G O t o S 3.
DI SCONNECT
c o n n e c t i o n . CLEAN s t u d
a n d i ug. RESTORE
r e c e p t i o n .
A c c e s s t he gr o un d c o n n e c t i o n l o c a t e d in t he
he a d l i n e r a bo v e t h e FM a n t e n n a pa t t e r n .
Are the connect i ons tight and free of dirt or
corrosi on?
Ye s >
No
G O t o S 3.
DI SCONNECT
c o n n e c t i o n . CLEAN s t u d
a n d i ug. RESTORE
r e c e p t i o n .
S 3 CHECK FM ANTENNA TO AI M COAXI AL CABLE
CENTER CONDUCTOR
Ye s
No
G O t o S5.
G O t o 8 4 .
A c c e s s a n d d i sc o n n e c t FM t o AI M c o a x i a l c a b l e
c o n n e c t o r f r o m FM a n t e n n a on r e a r gl a s s .
Me a s u r e r e s i s t a n c e be t we e n c o n n e c t o r c e n t e r
c o n d u c t o r t a b a n d a kn o wn go o d gr o un d .
Is resi st ance 3 0 0 - 3 6 0 K-ohms?
Ye s
No
G O t o S5.
G O t o 8 4 .
1995 To wn Ca r , Cr o wn Vi c t o r i a , 3 r a n d Ma r q u i s J u l y 1394
PINPOINT TEST S: DEGRADED FM RECEPTION OR CONTINUOUS SEEK IN FM (Cont i nued)
S4 CHECK CENTER CONDUCTOR CONTI NUI TY
Ye s
No
v e hi c l e . RETEST FM
r e c e pt i o n .
REPLACE AI M t o FM
a n t e n n a c a bl e . RESTORE
r e c e pt i o n .
A c c e s s a n d d i s c o n n e c t FM t o AIM c o a x i a l c a b l e
f r o m AI M.
Me a sur e r e s i s t a n c e f r o m c e n t e r c o n d u c t o r of c a b l e
at FM a n t e n n a t o c e n t e r c o n d uc t o r of c a bl e at AI M
e n d .
Ye s
No
r e c e pt i o n .
REPLACE AI M t o FM
a n t e n n a c a bl e . RESTORE
r e c e pt i o n .
S5 CHECK FM ANTENNA TO AI M COAXI AL CABLE OUTER
CONDUCTOR
Ye s
No
GO t o S7 .
GO t o S6.
A c c e s s a nd d i s c o n n e c t gr o un d c o n n e c t i o n l o c a t e d
in t h e he a d l i n e r a b o v e t he FM a n t e n n a .
Me a sur e r e s i s t a n c e be t we e n FM a n t e n n a gr o un d
t a b a n d a kn o wn go o d gr o un d .
Is r e s i s t a n c e 3 ohms o r l e s s ?
Ye s
No
GO t o S7 .
GO t o S6.
S6 CHECK OUTER CONDUCTOR CONTI NUI TY
Ye s l >
No
r e c e pt i o n .
REPLACE a n t e n n a t o AI M
RETEST FM r e c e pt i o n .
A c c e s s a n d d i s c o n n e c t FM a n t e n n a t o AI M c o a x i a l
c a b l e f r o m AI M.
Me a sur e r e s i s t a n c e f r o m o ut e r c o n d u c t o r of c o a x i a l
c a b l e a t FM a n t e n n a t o o ut e r c o n d u c t o r of c o a x i a l
c a b l e a t AI M e n d .
Ye s l >
No
r e c e pt i o n .
REPLACE a n t e n n a t o AI M
S7 CHECK FOR SHORT TO URETHANE
Ye s
No
GO t o S8.
FI ND a nd SERVI CE sho r t
t o r e a r gl a ss ur e t ha n e .
Di sc o n n e c t AI M t o FM a n t e n n a c o n n e c t i o n at t h e t o p
of t he r e a r gl a s s .
Me a sur e t he r e s i s t a n c e b e t we e n b o t h t h e FM
a n t e n n a c o n n e c t i o n a nd t he ur e t ha n e r e t a i n i n g t h e
r e a r gl a s s of t h e v e hi c l e .
Is t he resi st ance great er t han 100 K-ohms?
Ye s
No
GO t o S8.
FI ND a nd SERVI CE sho r t
t o r e a r gl a ss ur e t ha n e .
SS CHECK FOR DAMAGED FM ANTENNA PATTERN LI NES
Ye s
No
GO t o S9.
o pe n gr i d l i ne. RESTORE
v e hi c l e . CONFI RM t ha t al l
he a t e r gr i d l i nes a r e
c o n t i n uo us wi t h a
v o l t me t e r whi l e he a t e r
gr i d i s under po we r .
Pl a c e a br i ght l a mp i n si d e v e hi c l e c l o s e t o t he
a n t e n n a pa t t e r n l i ne s.
I n spe c t t he FM a n t e n n a pa t t e r n a n d he a t e r l i ne s
c l o s e l y f r o m t h e o ut s i d e of t he v e hi c l e .
A c l e a r spo t of l i ght s ho wi n g t hr o ugh a l i ne i n d i c a t e s
an o pe n or d a ma ge d l i ne on t h e wi n d o w.
Are all t he FM ant enna pat t er n gri dl i nes in pl ace
and cont i nuous?
Ye s
No
GO t o S9.
o pe n gr i d l i ne. RESTORE
v e hi c l e . CONFI RM t ha t al l
he a t e r gr i d l i nes a r e
c o n t i n uo us wi t h a
v o l t me t e r whi l e he a t e r
gr i d i s under po we r .
S9 CHECK FOR HIGH RESI STANCE FM ANTENNA
PATTERN
Ye s
No
GO t o S 1 8 . For Town Car,
G O t o S I O .
Usi ng met er , MOVE t e s t
poi nt in unt i l o pe n i s
f o un d . SERVI CE o pe n FM
a n t e n n a pa t t e r n .
Di sc o n n e c t AI M t o FM a n t e n n a c o n n e c t i o n at t he t o p
of t he r e a r gl a s s .
Me a s ur e t he r e s i s t a n c e f r o m t h e c o p p e r c o n n e c t o r
s o l d e r e d t o t he gl a s s t o e a c h e n d of t he FM a n t e n n a
pa t t e r n .
Is each resi st ance 3 ohms or l ess?
Ye s
No
GO t o S 1 8 . For Town Car,
G O t o S I O .
f o un d . SERVI CE o pe n FM
a n t e n n a pa t t e r n .
S 10 CHECK CENTER CONDUCTOR CONNECTI ON ON
FRONT WI NDOW FM ANTENNA PATTERN
Ye s
No
G O t o S 1 1 .
a nd gl a s s mo un t e d
c o n n e c t o r t a b. RESTORE
r e c e pt i o n .
Che c k c o a x i a l c a b l e c o n n e c t i o n t o t he FM pa t t e r n
at t he t o p of t he f r o n t gl a s s .
# A r e t h e c o n n e c t i o n s t i g h t a n d f r e e o f d i r t and
c or r osi on?
Ye s
No
G O t o S 1 1 .
a nd gl a s s mo un t e d
c o n n e c t o r t a b. RESTORE
r e c e pt i o n .
15- 00- 7 9 A u d i o S y s t e m s S e r v i c e 15- 00- 7 9
PINPOINT T E ST S: DEGRADED FM RECEPTI ON OR CONTINUOUS SE E K IN FM (Cont i nued)
S 11 CHECK GROUND CONNECTI ON OF FRONT WI NDOW
FM ANTENNA PATTERN
Ye s
No
GO t o S 1 2 .
DI SCONNECT
c o n n e c t i o n . CLEAN st ud
and l ug. RESTORE
r e c e pt i o n .
Access the ground connection located in the
he a d l i n e r under t h e p a s s e n ge r si d e visor r e t a i n i n g
screw.
A r e t h e c o n n e c t i o n s t i g h t a n d f r e e o f d i r t a n d
c o r r o s i o n ?
Ye s
No
GO t o S 1 2 .
DI SCONNECT
c o n n e c t i o n . CLEAN st ud
and l ug. RESTORE
r e c e pt i o n .
S 12 CHECK FM ANTENNA TO RCU COAXI AL CABLE
CENTER CONDUCTOR
Ye s
No
GO t o S 1 4 .
G O t o S 1 3 .
A c c e s s a nd d i s c o n n e c t FM t o RCU c o a x i a l c a b l e
c o n n e c t i o n f r o m FM a n t e n n a on f r ont gl a s s .
Me a sur e r e s i s t a n c e b e t we e n c o n n e c t o r c e n t e r
c o n d uc t o r t a b a n d a kn o wn go o d gr o un d .
Ye s
No
GO t o S 1 4 .
G O t o S 1 3 .
S 13 CHECK CENTER CONDUCTOR CONTI NUI TY
Ye s
No
REPLACE RCU.
REPLACE RCU- FM
ant enna c a bl e . RESTORE
ve hi c l e . RETEST FM
r e c e pt i o n .
A c c e s s a n d d i s c o n n e c t FM t o RCU c o a x i a l c a b l e
f r o m RCU.
Me a sur e r e s i s t a n c e b e t we e n c e n t e r c o n d uc t o r of
c a bl e at FM a n t e n n a t o c e n t e r c o n d u c t o r of c a b l e at
RCU e n d .
Ye s
No
REPLACE RCU.
REPLACE RCU- FM
ant enna c a bl e . RESTORE
ve hi c l e . RETEST FM
r e c e pt i o n .
S 14 CHECK OUTER CONDUCTOR CONTI NUI TY
Ye s
No
GO t o S 1 5 .
REPLACE FM
a nt e nna -RCU c a bl e .
A c c e s s a nd d i s c o n n e c t FM a n t e n n a t o RCU c o a x i a l
c a bl e f r o m RCU.
Me a sur e r e s i s t a n c e f r o m o ut e r c o n d uc t o r of c o a x i a l
c a bl e at Re mo t e Co n t r o l Uni t e n d t o a kn o wn go o d
gr o un d .
Ye s
No
GO t o S 1 5 .
REPLACE FM
a nt e nna -RCU c a bl e .
S 15 CHECK FOR SHORT TO URETHANE
Ye s
No
G O t o S 1 6 .
SERVI CE sho r t t o f r ont
wi n d o w ur e t ha n e .
Di sc o n n e c t RCU t o FM a n t e n n a c o n n e c t i o n at t h e
t o p of t he f r o n t gl a s s .
Me a sur e t h e r e s i s t a n c e b e t we e n b o t h t he FM
a n t e n n a c o n n e c t i o n a n d t h e ur e t ha n e r e t a i n i n g t he
f r ont gl a s s of t h e v e h i c l e .
Is t he resi st ance great er t han 100 K-ohms?
Ye s
No
G O t o S 1 6 .
SERVI CE sho r t t o f r ont
wi n d o w ur e t ha n e .
S 16 CHECK FOR DAMAGED FM ANTENNA PATTERN
Ye s
No
GOt oS17.
f ound. SERVI CE o pe n FM
ant enna pa t t e r n .
RETEST FM r e c e p t i o n .
Di sc o n n e c t RCU t o FM a n t e n n a c o n n e c t i o n at t h e
t o p of t he f r o n t gl a s s .
Me a sur e t he r e s i s t a n c e f r o m t h e c o p p e r c o n n e c t o r
so l d e r e d t o t h e gl a s s t o e a c h e n d of t he FM a n t e n n a
pa t t e r n .
is each resi st ance 3 ohms or l ess?
Ye s
No
GOt oS17.
f ound. SERVI CE o pe n FM
ant enna pa t t e r n .
S17 CHECK RCU TO AI M COAXI AL CABL E CENTER
CONDUCTOR
Yes
No
G O t o S 1 9 .
GO t o S 1 8 .
A c c e s s a nd d i s c o n n e c t RCU t o AI M c o a x i a l c a b l e
c o n n e c t o r f r o m RCU.
Me a sur e r e s i s t a n c e b e t we e n c o n n e c t o r c e n t e r
c o n d uc t o r a n d a kn o wn g o o d gr o un d .
Is resi st ance 3 0 0 - 3 6 0 ohms?
Yes
No
G O t o S 1 9 .
GO t o S 1 8 .
S18 CHECK CENTER CONDUCTOR CONTI NUI TY
Ye s
No
r e c e pt i o n .
A c c e s s a nd d i s c o n n e c t RCU t o AI M c o a x i a l c a b l e
f r o m AI M.
Me a sur e r e s i s t a n c e f r o m c e n t e r c o n d u c t o r of c a b l e
at RCU end t o c e n t e r c o n d u c t o r of c a b l e a t AI M e n d .
Ye s
No
r e c e pt i o n .
1 5 0 0 - 8 0 A u d i o S y s t e ms S e r v i c e 15- 00- 80
PI NPOI NT T E ST S: DE GRADE D FM RECEPTI ON OR CONTI NUOUS SEEK I N F M ( Co n t i n u e d )
T E ST STE P RESULT A CTI ON TO T A KE
S 19 CHECK RCU TO AI M COAXI AL CABLE OUTER
CONDUCTOR
Ye s
No
REPLACE RCU.
G O t o S 2 0.
@ Me a sur e r e s i s t a n c e b e t we e n o ut l e t c o n d u c t o r of
c o a x i a l c a bl e at Re mo t e Co n t r o l Uni t e n d a nd a
i s r e s i s t a n c e 3 o h ms o r Bess?
Ye s
No
REPLACE RCU.
G O t o S 2 0.
S 2 0 CHECK OUTER CONDUCTOR CONTI NUI TY
Ye s
No
r e c e pt i o n .
A c c e s s a nd d i s c o n n e c t RCU t o AI M c o a x i a l c a bl e
f r o m AI M.
Me a sur e r e s i s t a n c e f r o m o ut e r c o n d u c t o r of c o a x i a l
c a bl e at RCU e n d t o o ut e r c o n d u c t o r of c o a x i a l
c a bl e a t AI M e n d .
I s r e s i s t a n c e 3 o h ms o r l e s s ?
Ye s
No
r e c e pt i o n .
PI NPOI NT T E ST T: ONE OR MORE SP E A KE RS HAVE NO S O U N DA L L MODE S
T E ST STE P RESULT A CTI ON TO TAKE
T 1 VERI FY A M/ F M CASSETTE
Ye s
No
G O t o T 2 .
If no so un d in t a p e mo d e ,
If no so un d in CDDJ mo d e ,
If no so un d on A M a n d / o r
FM, GO t o Pi npoi nt Te st
S.
Ver i f y t ha t t h e no so un d pr o bl e m e x i s t s on al l mo d e s
by ve r i f y i n g o pe r a t i o n of FM, A M, CASSETTE a n d or
CD.
@ Do e s t h e n o s o u n d p r o b l e m e x i s t o n a l l me d i a
mo d e s ?
Ye s
No
G O t o T 2 .
If no so un d in t a p e mo d e ,
If no so un d in CDDJ mo d e ,
If no so un d on A M a n d / o r
FM, GO t o Pi npoi nt Te st
S.
T 2 VERI FY SPEAKERS
Ye s
No
G Ot o T 3.
e Ver i f y wh i c h s p e a ke r s e x hi bi t no so un d c o n d i t i o n by
usi ng f a d e a n d ba l a n c e a n d l i st e n i n g t o e a c h
spe a ke r .
Do a l l s p e a k e r s e x h i b i t n o s o u n d c o n d i t i o n ?
Ye s
No
G Ot o T 3.
T 3 CHECK FOR VOLTAGE SUPPLY TO SPEAKER
Ye s
No
G O t o T 4 .
G O t o T 5.
Wi t h t he a ud i o s y s t e m of f , c h e c k t he v o l t a ge at o n e
c i r c ui t on t h e ha r n e ss si d e of t h e s p e a ke r c o n n e c t o r
t o a kn o wn g o o d gr o un d .
Ch e c k t he s e c o n d c i r c ui t on t h e ha r n e ss si d e of t he
s pe a ke r c o n n e c t o r t o a kn o wn go o d gr o un d .
Use t he f o l l o wi n g c i r c ui t n umbe r s f o r To wn Car.
LH r ear : 800 ( G Y/ L B) a n d 801 ( T / Y)
LH f r ont : 804 ( 0 / LG) a n d 813 ( L B / W)
RH r ear : 802 ( O/ R) a n d 803 ( BR/ P K)
RH f r o n t : 805 (W / LG) a n d 811 (DG / O)
Sub- wo o f e r (JBL o n l y ) : 287 ( B K / W) a n d 82 2
( BK/ L G )
Fo r Cr o wn Vi c t o r i a , Gr a n d Ma r qui s s a me a s a b o v e
e x c e pt :
RH r e a r : 802 ( O/ R) a n d 82 4 ( W/ P )
Do e s v o l t me t e r r e a d mo r e t h a n 5 v o l t s ?
Ye s
No
G O t o T 4 .
G O t o T 5.
PINPOINT TEST T: ONE OR MORE SPEAKERS HAVE NO SOUND-ALL MODES (Cont i nued)
T4 CHECK WI RE HARNESS FOR SHORT
Ye s
No
REPAI R s h o r t in wi r e
ha r n e ss.
REPLACE RCU.
Wi t h t he a ud i o s y s t e m of f , c h e c k t h e wi r e ha r n e s s
f o r a sho r t t o a DC v o l t a ge by d i s c o n n e c t i n g ha r n e ss
a t t he s p e a ke r a n d RCU c o n n e c t o r C1 or ESC
c o n n e c t o r C2 a n d c h e c k t he v o l t a ge at e a c h c i r c ui t
on t he h a r n e s s si d e of s p e a ke r c o n n e c t o r t o a
kn o wn g o o d gr o un d .
Use t h e f o l l o wi n g c i r c ui t n umbe r s f o r Town Car.
LH r e a r : 800 (GY / LB) a n d 801 (TV Y)
LH f r o n t : 804 ( 0 / LG) a n d 813 ( L B / W)
RH r e a r : 802 ( O / R) a nd 803 ( BR / PK)
RH f r o n t : 805 (W / LG) a n d 811 (DG / 0)
( BK/ L G )
Fo r Cr o wn Vi c t o r i a , Gr a n d Ma r qui s sa me a s a b o v e
e x c e p t :
RH r e a r : 802 ( 0 / R) a nd 82 4 ( W / P)
Does v o l t me t e r r e a d more t h a n 5 vol t s?
Ye s
No
REPAI R s h o r t in wi r e
ha r n e ss.
REPLACE RCU.
T5 CHECK HARNESS SI DE CI RCUI T
Ye s
No
REPLACE spe a ke r .
GO t o T 6 .
Wi t h t h e a ud i o s y s t e m OFF, c h e c k t he r e s i s t a n c e
b e t we e n o n e c i r c ui t on t h e ha r n e ss si d e of t he
s p e a ke r c o n n e c t o r a nd a kn o wn g o o d gr o un d .
Al s o c h e c k t he s e c o n d c i r c ui t on t h e ha r n e ss s i d e of
t h e s p e a ke r c o n n e c t o r t o a kn o wn go o d gr o un d .
Use t h e f o l l o wi n g c i r c ui t n umbe r s f o r Town Car.
LH r e a r : 800 ( G Y/ L B) a n d 801 ( T / Y)
LH f r o n t : 804 (O / LG) a n d 813 ( LB / W)
RH r e a r : 802 ( O / R) a nd 803 ( BR / PK)
RH f r o n t : 805 ( W/ L G ) a n d 811 ( DG / O)
( BK/ L G )
Fo r Cr o wn Vi c t o r i a / G r a n d Ma r qui s sa me a s a b o v e
e x c e p t :
RH r e a r : 802 ( 0 / R) a nd 82 4 ( W / P)
Is t h e r e s i s t a n c e g r e a t e r t h a n 100 K-ohms?
Ye s
No
GO t o T 6 .
T6 CHECK WI RI NG HARNESS FOR A SHORT TO GROUND
Ye s
No
REPAI R sho r t in wi r e
ha r n e ss.
REPLACE RCU.
Wi t h t h e a ud i o s y s t e m OFF, c h e c k t h e wi r e ha r n e s s
f o r a sho r t t o gr o un d by d i s c o n n e c t i n g t he ha r n e ss
at t he s p e a ke r a nd RCU c o n n e c t o r C1 or ESC
c o n n e c t o r C2 a n d c h e c k t he r e s i s t a n c e at e a c h
c i r c ui t on t h e ha r n e ss si d e of s p e a ke r c o n n e c t o r t o
Use t he f o l l o wi n g c i r c ui t n umbe r s f o r Town Car.
LH r ear : 800 ( G Y/ L B) a n d 801 ( T / Y)
LH f r ont : 804 ( O/ L G ) a nd 813 ( L B / W)
RH r e a r : 802 ( O/ R) a nd 803 ( BR/ P K)
RH f r o n t : 805 ( W/ L G ) a n d 811 ( DG / O)
Sub- wo o f e r (JBL onl y ) : 287 ( B K / W) a nd 82 2
( BK/ L G )
Fo r Cr o wn Vi c t o r i a / Gr a n d Ma r qui s sa me a s a b o v e
e x c e p t :
RH r ear : 802 ( O / R) a nd 82 4 ( W / P)
Ye s
No
REPAI R sho r t in wi r e
ha r n e ss.
REPLACE RCU.
DIAGNOSIS A N D TESTING ( C o n t i n u e d )
PINPOINT TEST U: ONE OR MORE SPEAKERS HAVE DISTORTED SOUNDALL MODES
U1 VERI FY DI STORTI ON
Ye s
No
G O t o U 2 .
If d i st o r t i o n on AM/ FM
onl y, GO t o Pi npoi nt Te st
S.
If d i st o r t i o n on CDDJ onl y ,
G Ot o Pi npoi nt Te st H.
If d i st o r t i o n in TAPE onl y,
Verify that t he distortion problem exists on all
modes by verifying operat i on of FM, AM, CASSETTE
a n d / o r CD.
Does the di st ort i on probl em exist on ail medi a
modes?
Ye s
No
G O t o U 2 .
If d i st o r t i o n on AM/ FM
onl y, GO t o Pi npoi nt Te st
S.
If d i st o r t i o n on CDDJ onl y ,
G Ot o Pi npoi nt Te st H.
If d i st o r t i o n in TAPE onl y,
02 VERI FY SPEAKER DI STORTI ON
Ye s
No
G Ot o U3.
G Ot o U4.
Verify which speakers have distorted sound by
using the fade and bal ance controls and listening to
each speaker.
Do all speakers have distorted sound?
Ye s
No
G Ot o U3.
G Ot o U4.
U3 CHECK VOLUME RANGE
Ye s
No
Sy s t e m OK.
GO t o U4.
o Check volume range for distorted sound.
Does the di st ort ed sound onl y happen at hi gh
vol ume?
Ye s
No
Sy s t e m OK.
GO t o U4.
04 CHECK TRIM PANELS
Ye s
No
G Ot o US-
REPAIR l o o se t r i m pa n e l
a n d / o r t r i m.
Check for loose t ri m panel s and / or loose trim near
the speaker(s) wi t h distorted sound.
o Are the tri m panels and/or t ri m fast ened
securel y?
Ye s
No
G Ot o US-
REPAIR l o o se t r i m pa n e l
a n d / o r t r i m.
0 5 CHECK CONNECTI ON
Ye s
No
REPAIR d a ma ge d
c o n n e c t i o n s.
With the audio syst em OFF, check the connections
at e a c h c o mpo n e n t f or l o o s e a n d / o r d i r t y
Are the connect i ons cl ean and seat ed properl y?
Ye s
No
REPAIR d a ma ge d
PINPOINT TEST V: ONE OR MORE SPEAKERS HAVE LOW VOLUMEALL MODES
TEST STEP RESULT ACTI ON TO T A KE
V1 VERI FY L OW VOL UME PROBL EM
Ye s
No
GO t o V2 .
If on CDDJ mo d e onl y, GO
t o Pi npoi nt T e s t H.
If on Ta pe mo d e onl y , GO
t o Pi npoi nt Te st F.
If on AM a n d / or FM onl y,
GO t o Pi npoi nt Te st S.
# Verify that the low vol ume problem exists on all
modes by verifying operat i on of FM, AM, CASSETTE
a n d / o r CD.
Does the low vol ume probl em exist on all medi a
modes?
Ye s
No
GO t o V2 .
If on CDDJ mo d e onl y, GO
t o Pi npoi nt T e s t H.
If on Ta pe mo d e onl y , GO
If on AM a n d / or FM onl y,
GO t o Pi npoi nt Te st S.
V2 VERI FY L OW VOL UME ON SPEAKERS
Ye s
No
G Ot o V3.
Verify low vol ume concern on one or more speakers
by using t he fade and bal ance controls and listening
to each speaker.
i s low v o l u me concern exist on all speakers?
Ye s
No
G Ot o V3.
V3 CHECK SPEAKER CI RCUI TS
Ye s
No
REPAI R sho r t be t we e n
t he t wo c i r c ui t s.
REPLACE s p e a ke r s .
With the audio syst em off, for each speaker
exhibiting low vol ume, measur e t he resistance
between both circuits in t he harness side of the
speaker connect or.
Use t he f o l l o wi n g c i r c ui t n umbe r s f o r To wn Car.
LH rear: 800 (GY/LB) and 801 ( T/ Y)
LH front: 804 ( 0 / LG) and 813 (LB / W)
RH rear: 802 (O/ R) and 803 (BR/PK)
RH f r o n t : 805 ( W / LG) a nd 811 ( DG / O)
Sub-woof er (JBL o n l y ) : 2 87 ( B K / W) a n d 82 2
( BK/ L G )
For Cr o wn Vi c t o r i a / Gr a n d Ma r qui s s a me a s a bo v e
e x c e pt :
RH rear: 802 ( 0 / R) a n d 82 4 ( W/ P)
l e resi stance 5 0 ohms or less?
Ye s
No
REPAI R sho r t be t we e n
t he t wo c i r c ui t s.
REPLACE s p e a ke r s .
A u d i o S y s t e ms S e r v i c e
_ i r _ J J F i ] E r " Z T T " :
PI NPOI NT TE ST W: ONE OR MORE SPEAKERS POP OR CRA CKL E WHE N VEHI CLE IS DRI VEN OVER BUMP SA L L
MODE S
T E ST STEP RESULT > A CT I ON TO TAKE
W1 VERI FY A M/ F M CASSETTE OPERATI ON
Ye s
No
G O t o W 2 .
If on CDDJ mo d e onl y , GO
t o Pi npoi nt Te st H.
If on TAPE mo d e onl y , GO
If on A M a n d / o r FM onl y ,
GO t o Pi npoi nt T e s t S .
Veri f y t ha t t he po p or c r a c kl e pr o bl e m e x i s t s on al l
mo d e s by ve r i f y i n g o pe r a t i o n of FM, A M, CASSETTE
a n d / o r CD.
Do e s t h e p o p o r c r a c k l e s o u n d e x i s t o n a l l
mo d e s ?
Ye s
No
G O t o W 2 .
If on CDDJ mo d e onl y , GO
t o Pi npoi nt Te st H.
If on TAPE mo d e onl y , GO
If on A M a n d / o r FM onl y ,
GO t o Pi npoi nt T e s t S .
W 2 CHECK SUB- WOOFER
Ye s
No >
G O t o W 3 .
Do e s t h e p o p a n d / o r c r a c k l e h a p p e n o n t h e
s u b - w o o f e r s p e a k e r o n l y ?
Ye s
No >
G O t o W 3 .
W3 CHECK AUDI O SYSTEM COMPONENT CONNECTI ONS
Ye s
No \
GO t o W 4
REPAI R c o n n e c t i o n s .
# Wi t h t he a ud i o s y s t e m of f , c h e c k al l c o n n e c t i o n s at
e a c h a ud i o s y s t e m c o mpo n e n t f or c l e a n l i n e ss a nd
pr o pe r s e a t i n g.
A r e a l l c o n n e c t i o n s cl ean a n d p r o p e r l y s e a t e d ?
Ye s
No \
GO t o W 4
REPAI R c o n n e c t i o n s .
W4 CHECK AUDI O SYSTEM WI RI NG
Ye s >
No
REPAI R wi r i n g.
Wi t h t he a ud i o s y s t e m of f , c h e c k f or br o ke n ,
c r a c ke d or s h o r t e d wi r e s in t he a ud i o s y s t e m.
Use t he c i r c ui t c a l l o ut s in a ud i o s y s t e m s c h e ma t i c s
t o c h e c k e a c h c i r c ui t .
A r e w i r e s b r o k e n , c r a c k e d o r s h o r t e d ?
Ye s >
No
REPAI R wi r i n g.
PI NPOI NT T E ST X: ONE OR MORE SP E AKE RS EXHI BI T HUM ON A L L MODE S
TE ST STEP RESULT ^ ACTI ON TO TA

95 Ford Lincoln Mercury SM

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95 Ford Lincoln Mercury SM

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1995 Town Car ,

0.050 Undersize add 0.025 to standard thickness.

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